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All praise and thanks for Almighty Allah, Who has given me the opportunity to work in a
professional field and gave me the ability to complete this report successfully.
We fully acknowledge the assistance provided to us in understanding of different processes
during our stay at MAKORI. We would like to thank Mr. Hashim Raza and Mr.Saif-ulIslam(Company Men), Mr. Irshad ali,Mr.Ali Arslan, Mr. Aslam Hameed, Mr. Azeem Baig, Mr.
Arsalan and Mr.Kashif Hafeez Shift In-Charge, Makori) for guiding us all the way, without their
support and appreciation this learning could have not been possible. We would also like to thank
every person that has helped and made our stay comfortable.
We would also like to thank Mr. Hedayat Ullah, Mr. Haleem, Mr. Sajid and Mr. Junaid (Trainee
Process Engineers), Mr. Naveed Lodhi, Mr. M Irfan, Mr A.Mutlb, Mr.Ikram and Mr.Haneef
Ullah (Senior Process Operators), Mr. Munir and Mr. Wajid(Senior Technicians) , Mr. Rizwan,
Mr. Wajid and Mr. Waheed( Process operator), Mr. Tahir, Mr. Faheem and Mr. Basit
(Technicians) for their co-operation with us.
CONTENTS
INTRODUCTION14
ABOUT MOL ........................................................................................................................... 15
SAFETY ORIENTATION ..................................................................................................... 16
PERSONAL PROTECTIVE EQUIPMENTS (PPE) ............................................................. 17
FIRE HAZARDS ................................................................................................................... 17
FIRE PROTECTION SYSTEMS .......................................................................................... 18
FIRE PUMPS ......................................................................................................................... 18
SPRINKLER SYSTEM ......................................................................................................... 18
FOAM PROTECTION .......................................................................................................... 18
USING ADDITIVES AND INHIBITORS ............................................................................ 19
NON VERBAL SAFETY SIGN ............................................................................................ 20
4.5.2.7
13
This report is in the pretext of the activities that we performed during our internship at Makori
Gas plant (EPF).
This report highlights all the events that occurred during my stay at EPF. It also briefly discusses
the processes that are going on in this facility.
The report deals with the processing of condensate, gas and handling of produced water. It is also
provided with the illustrations and flow charts where ever needed so that reader can be able to
fully understand the basics of any process.
Similarly there is also detail description about Maintenance department.
14
ABOUT MOL
MOL has been working in Pakistan through its subsidiary MOL Pakistan Oil & Gas Co. since
1999.Makori Gas Plant is situated in a Dist. Karak, Khyber Pakhtunkhwa. It is mainly a gas
production and processing facility but condensate is also produced along with the gas. Currently
the plant is producing around 30 MMSCFD of Gas and 8000bbl of condensate. The gas is sold to
the companys client Sui northern gas pipeline (SNGPL). Whereas the condensate produced is
transported to Attock Refinery and NRL for further processing. The Gas Plant receives its raw
gas from three wells, Makori East-1 and 2 and Makori-3.
As per sales agreement with SNGPL, the following specifications of the sales gas are needed to
be satisfied:
In order to achieve the above mentioned objectives, Propane based refrigeration unit is installed
at Makori Oil Field.
CONDENSATE SPECIFICATIONS
Water content
Carbon content
Nitrogen
Oxygen
Reid Vapor Pressure
8000 BPD
600-650 BPD
30 MMSCFD
GAS SPECIFICATIONS
Approximate Flow weighted average gas composition
COMPONENT
MOLE %
0.5270
1.0104
90.1990
5.2201
1.9288
0.4647
0.3832
0.0754
0.1281
0.0001
0.0605
0.0024
0.0000
Nitrogen
Carbon dioxide
Methane
Ethane
Propane
n-butane
I-butane
n-pentane
I-pentane
NeoPentane
C6+
Water
Hydrogen sulfide
SAFETY ORIENTATION
On our arrival at EFP, we were inducted into the Health, Safety and Environment Department.
This orientation included safety requirements at plant. The presentation shown to us consisted of
various safety policies and equipment. We were familiarized with PPE policy, smoking policy,
fire hazards, drugs policy etc. The explanations of these are as follows:
16
17
FIRE PUMPS
For moderate- to large-sized facilities, fire pumps with a higher capacity rating or the installation
of multiple fire pumps may be required. The fuel supply for these engines should be arranged so
it will not be interrupted during plant emergencies.
SPRINKLER SYSTEM
Buildings are often protected by automatic sprinkler systems. These sprinkler systems are
designed to distribute enough water to either extinguish a fire or to control it until additional
firefighting equipment and personnel arrive. A piping system supplies water to sprinkler heads.
Sprinkler systems must be regularly inspected, tested and maintained.
FOAM PROTECTION
Fixed foam protection should be provided for all atmospheric storage tanks containing
flammable or combustible liquids. The foam lateral control valve or point of connection to a
portable generator should be located outside the wall of the dyke surrounding the tank.
18
`
Typically, a fire extinguisher consists of a hand-held cylindrical pressure vessel containing an
agent which can be discharged to extinguish a fire. At MPF we have following agents for fire
extinguishers:
Dry chemical Powder
Aqueous foam forming liquids
There are following types of extinguishers in MGP:
Portable
CO2
Trolley
To operate a fire extinguisher a rule of PASS is used it is as below:
PPull the pin.
AAim the nozzle at the base of fire.
SSqueeze the handle.
SSweep on the base of fire.
USING ADDITIVES AND INHIBITORS
The following prompt action must be taken if the inhibitor or additive comes in contact with
eyes, skin, or clothing:
Eyeswash them out immediately with the solution provided and report to the Medical
Department.
Skinwash off thoroughly with soap and water, again report to the Medical Department.
19
Clothingremove all contaminated clothing and treat any areas of affected skin. If
clothing (including safety boots) cannot be laundered, it must be destroyed.
Combined emergency water showers and eye baths must be located in areas where dangerous
corrosive substances are used. All persons working on equipment in this area must know the
location and the correct operation of these showers.
NON VERBAL SAFETY SIGN
Some non-verbal safety sign are also present at different location which help the workers.
20
21
PROCESS OVERVIEW
The Makori gas plant facility processes raw gas into marketable gas and condensate oil, the
following processes are used:
Pressure Regulation
Phase separation
Condensate Stabilization
Water Dew point control
Hydrocarbon Dew point control
Gas metering
Water Evaporation
The gas coming from the well is subjected to pressure control for downstream section by choke
manifold. Raw gas after the pressure regulation is subjected to phase separation where it passes
through stage separators, heat exchanger and degasser. In separator the raw gas is divided into
gas, liquid hydrocarbons and produced water. The separated gas is directed inlet coalescers,
gas/gas exchanger and gas/liquid exchanger for further separation and where MEG is also
sprayed for dehydration of gas. The MEG is sent to regeneration unit and gas is sent to HCDP
control process to meet the sale gas specifications. After HCDP process the gas is metered and is
transferred to SNGPL system. The separated hydrocarbon condensate oil from all the separators,
heads to the stabilization unit from where it is sent to storage tanks. The produced water heads to
produce water handling system.
22
WELL
2.1 WELL CASING
Casing is a large-diameter pipe that serves as the structural retainer for the walls of oil and gas
wells, or well bore. It is inserted into a well bore and cemented in place to protect both
subsurface formations and the well bore from collapsing and to allow drilling fluid to circulate
and extraction to take place.
Installing well casing is an important part of the drilling and completion process. Well casing
consists of a series of metal tubes installed in the freshly drilled hole.
There are four types of well casing.
Conductor Casing
Surface Casing
Intermediate Casing
Production Casing
23
The first three casings are installed for the protection of the production tubing while Production
casing a conduit from the surface of the well to the petroleum producing formation.
24
2.3.1 FUNCTIONS
A wellhead serves numerous functions; some of these are:
Provide a means of casing suspension. (Casing is the permanently installed pipe used to
line the well hole for pressure containment, collapse prevention during the drilling phase)
Provides a means of tubing suspension (Tubing is removable pipe installed in the well
through which well fluids pass)
Provides a means of pressure sealing and isolation between casings at surface when many
casing strings are used.
Provides a means of attaching a blowout preventer during drilling
Provides a means of attaching a Christmas tree for well control during production,
injection, or other operations
Provides a reliable means of well access
Provides a means of attaching a well pump
The primary components of a wellhead system are:
Casing Head
Casing Spools
The primary components of a wellhead system are:
Hangers
Packoffs (Isolation) Seals
Bowl Protectors / Wear Bushings
Mudline Suspension Systems
Tubing Heads
Tubing Hangers
Master valves
Kill wing valve
Swab valve
Production valve
25
Swab
Valve
Production
Valves
Kill wing
valve
Surface safety
valve (SSV)
Master valve
GUAGES AT MAKORI-3
2.5 MAKORI 1
The well was commissioned on January 8, 2006.Well Depth is 4307m.But now it has been
killed,givig no production.
2.6 MAKORI 3
The formation used at Makori 3 is Lockhart. Average pressure and temperature is 3700 psi and
98 oF respectively. The daily gas production is 22.6 MMSCF whereas the daily condensate
production is 204 BBL per day.
.
27
28
29
which gives false level indications to the level controllers. Corrosion Inhibitor, this is injected to
reduce corrosion rate in the pipelines and the system equipment.
30
TYPES OF CHOKES
There are two main types of chokes;
1. Fixed choke
2. Adjustable choke
The adjustable choke installed at Makori 3 well has an opening of 16/64 inches. The pressure
and temperature value at upstream is 3500psi and 130 oF respectively whereas the pressure and
temperature values at downstream are 1024 psi and 96 oF.
CHOKE MANIFOLD
31
STABILIZATION OF
CONDENSATE
3.1 CONDENSATE STABILIZATION
Hydrocarbon condensate recovered from natural gas may be shipped without further processing.
The process of increasing the amount of intermediates (C 3 to C 5) and heavy (C + 6)
components in the condensate is called "condensate stabilization." This process is performed
primarily in order to reduce the Ried vapor pressure of the condensate liquids below 7 so that a
vapor phase is not produced upon flashing the liquid to atmospheric storage tanks.
PROCEDURE OF TEST
1. Remove the sample from chiller, and insert chilled transfer tubes into the sample.
2. Remove the liquid chamber from chiller and place it in an inverted position over the top
of the transfer tube.
3. Invert the entire system rapidly so that liquid chamber is now in upright position with end
of transfer tube. Fill the chamber to overflowing and keep withdrawing transfer tube from
the chamber.
4. Now remove the Vapor chamber from the water bath and couple it with liquid chamber
within 10 seconds without spillage.
5. Shake the apparatus vigorously upside down.
6. Keep the apparatus in the water bath for 1hr.
7. Take the apparatus out of the water bath and shake it.
8. After some fixed intervals, observe the reading.
9. The final reading will be the one, when two consecutive observed readings are same.
33
The gas is very much lighter, separates within few seconds. Crude oil requires 40 to 70 seconds
to separate from water.
As pressure lowers the density of gas further decreases, makes separation easier.
Gas bubbles in the liquid will break out in most oilfield applications in 30 to 60 seconds;
consequently, the separator is designed so that the liquid remains in the vessel for 30 to
60 seconds.
The length of time that a liquid remains in the vessel is called its residence time.
The fluid produced from a well is usually a mixture of oil, gas, water, and sediment in varying
amounts and at elevated temperatures and pressures. The oil alone is a complex mixture of many
hydrocarbon compounds, including compounds which enter the gas phase during the production
process.
3.3.2 SEPARATORS
Vessel used for separation process is called separator,may be vertical or horizantal.
3.3.2.1 TWO PHASE & THREE PHASE SEPARATORS
These vessels are manufactured in three forms: Spherical, Vertical and Horizontal. Horizontal
and vertical separators are installed at
different location of BPP.
TWO-PHASE SEPARATORS
In both horizontal and vertical two-phase
separators, the well stream enters at the
side or end of the vessel. The lighter
fluid (usually gas) passes out at the top,
and the heavier fluids allowed settling
and being withdrawn from the bottom of
the vessel.
THREE-PHASE SEPARATORS
Flow in a three-phase separator is, that
fluids entering at one end of the vessel
and the liquids being allowed to settle
out in the inlet and outside of the weir in
the vessel.
34
Diameter
Length
Design Capacity
Design Pressure
Test pressure
Max Allowable Pressure
Pressure HI alarm
Pressure LO alarm
SPECIFICATION
42 inches
10 feet
5000 BPD 20 MMSCFD Gas
1440 Psig at 100 0F
2160 psi
1315 Psig at 300 0F
1275 psi
700 PSI
Impingement of the dispersed oil droplets upon a surface, which facilitates their
coalescence;
Centrifugal force, which takes advantage of the density differences of the oil and gas.
Deflector plate
Weir plate
Mist eliminator
Vortex breaker
Coalescing/Dixon plates
Two safety valves
Blow down valve
Pressure control valve
Level controllers
37
LEVEL GAUGE
Two Level gauges are installed which monitor the water and condensate levels, when water level
reaches 60%, the water is drained so that no water can come in the condensate line. Similarly
when the level of condensate reaches a certain point are drained out in their respectively line.
39
Condensate is discharged from the 1st stage separator under level control to the Second Stage
Separator A level controller installed on the separator is connected to a level control valve. A setpoint is given to the level controller which maintains the condensate level in that tank according
to the desired set-point.
When the condensate level falls below the set-point, the level controller sends a signal to the
level control valve to close it and vice versa, thereby maintaining a constant level in the vessel.
At the exit point of the condensate a vortex breaker is present to prevent swirling of the
condensate.
1. Produced Gas is sent directly to Inlet Coalescer Filter (MRU).
2. Produced water is diverted to Closed Drain System.
3. Condensate passes to 2nd stage separator.
3.5.1 SPECIFICATION
Length
OD
Design pressure
Test pressure
MAWP
SPECIFICATION
10 ft
42
1440psi
2160 psi
1345 PSI
41
42
The basic purpose of heating the crude is to reduce the viscosity. The cold condensate after
leaving the cold outlet of the heat exchanger will enter into the crude heater and enters into the
heat medium.
43
3.8.1 DUTIES
New heater= 6MMBtu/hr
Old heater= 2MMBtu/hr
44
Well Heads
Adjustable
Chokes
Exchanger
Degassing
Unit
Condensate
Heaters
2nd Stage
Separator
Exchanger
Storage Banks
The storage tank locality is classified into four banks A, B, C and D. Each bank is comprised of 5
storage tanks, connected in series with individual capacity of 500 barrels making one bank to
store 2500 barrels.
A new storage tank is installed having capacity of 10000 barrels. Thus totel capacity is increased
to 25000 bbl.
The pressure & vacuum relief valves (PVRV) are installed on top of storage tanks through which
volatile products escapes out.
Each bank is provided with the level transmitter which sends signal to HMI apart from it level of
each tank is monitored by glass level gauge. The tanks are filled to maximum of 80% of their
total depth. Condensate from the storage tanks supplied to ARL and NRL by bowsers daily.
tend to settle on the bottom of the pipeline, while the gasses occupy the top section of the
pipeline. Under certain operating conditions gas and liquid are not evenly distributed throughout
the pipeline, but travel as large plugs with mostly liquids or mostly gasses through the pipeline.
These large plugs are called slugs.
Slugs can be generated by different mechanisms in a pipeline:
Terrain slugging is caused by the elevations in the pipeline, which follows the ground elevation
or the sea bed. Liquid can accumulate at a low point of the pipeline until sufficient pressure
builds up behind it. Once the liquid is pushed out of the low point, it can form a slug.
Hydrodynamic slugging is caused by gas flowing at a fast rate over a slower flowing liquid
phase. The gas will form waves on the liquid surface, which may grow to bridge the whole crosssection of the line. This creates a blockage on the gas flow, which travels as a slug through the
line.
Riser-based slugging, also known as severe slugging, is associated with the pipeline risers often
found in offshore oil production facilities. Liquids accumulate at the bottom of the riser until
sufficient pressure is generated behind it to push the liquids over the top of the riser, overcoming
the static head. Behind this slug of liquid follows a slug of gas, until sufficient liquids have
accumulated at the bottom to form a new liquid slug.
Pigging slugs are caused by pigging operations in the pipeline. The pig is designed to push all or
most of the liquids contents of the pipeline to the outlet. This intentionally creates a liquid slug.
Slugs formed by terrain slugging, hydrodynamic slugging or riser-based slugging are periodical
in nature. Whether a slug is able to reach the outlet of the pipeline depends on the rate at which
liquids are added to the slug at the front (i.e. in the direction of flow) and the rate at which
liquids leave the slug at the back. Some slugs will grow as they travel the pipeline, while others
are dampened and disappear before reaching the outlet of the pipeline.
SLUGCATCHER DESIGN
Slugcatchers are designed in different forms:
1. Vessel Type Slugcatcher
2. Finger Type Slugcatcher
3. Parking Loop Slugcatcher
A vessel type slugcatcher is essentially a conventional vessel. This type is simple in design and
maintenance.
A finger type slugcatcher consists of several long pieces of pipe ('fingers'), which together form
the buffer volume. The advantage of this type of slugcatcher is that pipe segments are simpler to
design for high pressures, which are often encountered in pipeline systems, than a large vessel. A
47
disadvantage is that its footprint can become excessively large. An example of a large fingertype slugcatcher can be seen in Den Helder, The Netherlands, using Google Maps.
A Parking Loop slugcatcher combines features of the vessel and finger types. The Gas/Liquid
Separation occurs in the Vessel, while the Liquid is stored in the parking loop shaped fingers.
Loading arm A is operated by solenoid operating valve (SOV) 1 and 3. While load arm B is
operated by solenoid operating valve (SOV) 2 and 4 are used to fill the condensate from storage
tanks into the bowsers by means of pumps which are given below:
Vertical centrifugal pumps (2)
Horizontal centrifugal pumps (2)
3.13.1 CENTRIGUGAL PUMPS AT LOADING AREA
These pumps are electively driven and produce a power of 15 HP. The discharge pressure is 20
psi and the speed is 1760 rpm.
48
3.13.2 BOWSERS
Before filling the bowsers safety checklist is necessary to made to ensure the safety of bowsers.
After filling bowsers their specific gravity and temperatures are determined.
By using APIVCF software the base volume, correction factor (K-factor) and specific gravity at
60F is determined. It is ensured that the API remains within the range of 52-55. Payments are
made against this corrected volume and specific gravity.
49
GAS CYCLE
1st stage &
inlet
separators
2nd stage
separator +
De-ethanizer
MRU
Ariel
Compressor
3rd stage
degasser
Sales Gas
metering
In gas cycle we mainly concentrate on hydrocarbon dew point. The hydrocarbon dew point is the
temperature (at a given pressure) at which the hydrocarbon components of any hydrocarbon-rich
gas mixture, such as natural gas, will start to condense out of the gaseous phase. It is also
referred as the HCDP. The hydrocarbon dew point is a function of the gas composition as well as
the pressure.
The significance of HCDP is:
1. The gas has better burning capacity if HCDP is controlled.
2. Gas will not produce liquid in pipelines
3. Corrosion rate is reduced
The heavier hydrocarbons must be removed to control the HCDP; this is done at Makori in
mechanical refrigeration unit (MRU). The SNGPL requirement for HCDP is 32degF while dew
point at Makori is <24F.
50
The mechanical refrigeration unit is installed to control the hydrocarbon dew point and to
dehydrate natural gas. The hydrocarbon dew point is achieved by cooling the gas to a
temperature of -15 oC whereas for dehydration of gas, Mono Ethylene Glycol is injected.
extract the condensate droplets from the gas. This removed condensate is also drained. The gas
moves out of the top of the vessel to MRU unit.
52
4.1.3 REFRIGERATION
Refrigeration is a process in which work is done to move heat from one location to another. This
work is traditionally done by mechanical work.
Types of refrigeration can be classified as:
Cyclic Refrigeration
Non cyclic refrigeration
CYCLIC REFRIGERATION
This consists of a refrigeration cycle, where heat is removed from a low-temperature space or
source and rejected to a high-temperature sink with the help of external work, and its inverse, the
thermodynamic power cycle
NON CYCLIC REFRIGERATION
In non-cyclic refrigeration, cooling is accomplished by melting ice or by subliming dry ice.
These methods are used for small-scale refrigeration such as in laboratories and work shops
Cyclic refrigeration can be classified as:
1. Vapor cycle, and
2. Gas cycle
Vapor cycle refrigeration can further be classified as:
a) Vapor-compression refrigeration
b) Vapor-absorption refrigeration
53
: 37oC
: -1oC
54
4.1.6 CHILLER
The gas coming from gas/gas exchanger and gas/liquid exchanger join together and enter the
tube side of the chiller. On the shell side of chiller propane is added. Propane evaporates due to
the heat of tube side and the vapors accumulate in the suction scrubber. This evaporation causes
a cooling effect and the temperature of gas is further reduced to -15 oC. At this temperature the
heavier hydrocarbons present in gas start condensing. The operating pressure of chiller is 20 psi
or 120-150 KPa. MEG is added to prevent hydrate formation.
55
4.1.8 DE-ETHANIZER
It is employed to remove lighters from the condensate in order to get required value of Reid
vapor pressure. It contains packers that are made up of Paul rings. The packers basically hinder
the flow of the heavier hydrocarbon liquids due to which the lighter parts are removed from the
liquid in the form of vaporized product. After passing through the Paul rings, the NGL maintains
its level on the chimney tray from where it is directed to the re-boiler of the deethanizer. In reboiler, the NGL is heated to give out any gases. The heating in the re-boiler is done through
TEG.
Re-boiler is of tube/shell type with TEG passing through tubes and NGL on shell side. The gas is
removed from the top. The condensate after leaving the deethanizer is entered into the line that
head towards the heat exchanger for pre heating and then towards condensate heater after which
condensate stabilization process continues as explained earlier. The overhead vapors from the
deethanizer first enter into the u-tube exchanger on the tube side and then directed into the line
heading towards the Ariel compressor.
56
DE-ETHANIZER
57
2nd stage
separator
(Ariel
Compress
or)
Degasser
Inlet
cooler
Deethanizer
rrer
Gas/Gas
exchanger
1st stage+
inlet
separator
Gas/Liquid
exchanger
LTS
Chiller
58
4.4.2.1
HEAT EXCHANGER
When the lean MEG passes through heat exchanger from accumulator, it exchanges heat with the
external atmosphere to cool hot glycol.
4.4.2.2 PD-PUMP
After passing through the heat exchanger the lean MEG is pumped to LTS boot with the help of
plunger type positive displacement pump.
4.4.2.3 LTS-BOOT
The MEG passes through tubes present inside LTS boot. A heating medium is provided at the
boot of LTS to separate the condensate from the MEG. Here MEG exchanges heat with cold
MEG present in boot. Then it is injected into gas/gas exchangers, gas/liquid exchanger, and the
chiller. The MEG while passes through these phases absorbs any water vapors in the exchanger.
After absorption the glycol is said to rich glycol. The gas from 2 gas/gas, and gas/liquid
exchanger come to chiller along with MEG. After it sent to LTS, which is three phase separator
so here separation of condensate, MEG and gas occurs.
60
61
62
Vapor
out
Reboiler
stack
Gas/Gas exchanger
MEG Reboiler
Heat
Accumulator
Flash Tank
chiller
L.T.S
PD
pump
MEG CYCLE
Formula (C3H8)
State (colourless gaseous hydrocarbon)
Boiling Point (42C)
Melting Point (190C)
At EPF Propane is used as a Refrigerant.
4.5.2 DETAIL DESCRIPTION
The refrigerant goes through following equipment in the MRU
4.5.2.1 CHILLER
As explained earlier that Propane is used as the refrigerant in chiller. Gasses from the gas/gas
and gas/liquid enter into the chiller where they are passed through the tubes while propane is on
shell side. Excessive drop in temperature occurs here causing heavier hydrocarbons to condense
out as propane after exchanging heat vaporizes.
4.5.2.2 MYCOM COMPRESSOR
After cooling raw gas in chiller, vaporize propane from suction scrubber enters into the
MYCOM compressor, which is reciprocating economized screw compressor. The suction
pressure remains around 300 kPa and discharge pressure is around 1250 kPa, which is controlled
by pressure control valve (PCV). With gaseous propane lube oil also enters into the vaporize
propane which act as a lubricant as well as coolant.
This mixture enters into the refrigerant/oil separator, in which lube oil is separated from gaseous
propane. After this propane enters into the propane accumulator and then into the FIN fan
condenser.
4.5.2.3 FAN CONDENSER
The gaseous propane from the
accumulator is entered into the fan
condenser. In this condenser Gaseous
propane is in tubes which contain the fins
with it, to increase the surface area for
cooling. In this condenser cool air is
forced to pass on to the network of fin
tubes. Most of the propane recovered in
liquid form in this stage but some
propane still remains in gaseous form,
depending upon ambient temperature.
64
65
LCV
Econo
mizer
MyCom
Compressor
Lube
oil
filter
Propane vapors
LCV
Chiller
Coolant line
Desicant
filter
separator
Refrigerant
/oil
pump
Coolant
TCV
Lube oil
pump
Refrigerant
accumulator
Condenser
PROPANE CYCLE
4.5.2.6 ECONOMIZER
After exchanger liquid propane enters into the economizer in which it pressure further drops,
sudden drop in pressure cause cooling which is called Joule Thomson Effect. The pressure in the
economizer is dropped by the liquid expansion valve. The pressure in economizer is around
370Kpa. In this stage temperature of liquid propane further drops to- 4oC. The gaseous propane
escapes out and enters again into the MYCOM compressor.
JOULE-THOMSON EFFECT
It is named after James Prescott Joule and William Thomson . Experimented in 1852 on Joule
expansion, which is an,
Adiabatic expansion (Throttling) of gas
66
Isenthalpic Process
Temperature of the gas is increased or decreased depending upon initial state
JOULE THOMSON COEFFICIENT
The change of temperature (T) with respect to change in pressure (P) i.e.
= T/ P
The sign of the coefficient may be either positive or
negative.
Depends upon Relative magnitudes of the attractive
and repulsive intermolecular forces due to initial
Pressure and Temperature.
J-T COEFFICIENT MEASUREMENT
A schematic diagram of the apparatus used for
measuring the isothermal Joule-Thomson
coefficient (JT) is shown. The electrical heating
required to offset the cooling arising from
expansion is interpreted as H and used to calculate
(H/p)T, which is then converted to .
For ideal gases
= 0,
No change in temperature of ideal gases with reduction in pressure.
For real gases
If > 0, (+ve)
cooling occurs on expansion
If < 0, (-ve)
Heating occurs on expansion
INVERSION TEMPERATURE
The Joule-Thomson inversion temperature is the temperature where Joule-Thomson coefficient
changes sign.
Below Inversion Temperature, the J-T Coefficient is +ve, But it is ve above this temperature.
67
4.5.2.7
Lower is the boiling point of the gas, lesser will be its inversion temperature
Molecular gases have higher boiling point, so their inversion temperature will be higher.
Non ideal behavior is dominant, when the gases are closer to their boiling point
Hence their Joule Thomson Coefficient is positive
HEAT MEDIUM
Tri-ethylene glycol is used as a heat medium in the third stage processing area. TEG has good
thermal conductivity and heat capacity and is also a cheaper source of heating as compared to
coiled tube heaters. Heat medium heater contains TEG which is heated through combustion of fuel
gas inside a U-tube which passes through the heat medium and heats up TEG. The gases produced
as a result of combustion exit the U-tube via the other end and to the external atmosphere through
the chimney. A temperature controller is present on the heater (TC-485) to which operates a
temperature control valve (TCV-485) to regulate fuel gas supply to the heater for combustion and
therefore control its temperature. Heat medium is supplied to:
Chiller
Suction Snubber
Lube Oil/Refrigerant Separator
De-ethanizer Reboiler
Glycol Reboiler
Chiller boot
68
MEG
REGENERATOR
DEETAHNIZER
REBOILER
SUCTION
SCREBBER
TEG Heater
CHILLER
BOOT
REF.OIL
SEPARATER
69
71
Water from 1st stage, 2nd stage, and 3rd stage degasser is drained to close header i.e. to HP flare
KO drum that serves as collection vessel. The HP flare knock out drum is used for liquid storage
which is then pumped to the oil water separator using the diaphragm pumps. Water from
oil/water separator is plunged into the evaporation pond while condensate recovered from it is
pumped to 3rd stage degasser.
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1st Stage
&inlet
Separators
2nd Stage
Separator
3rd stage
De-gasser
KO-HP
Drum
Oil Water
Separator
E-Pond
FLOW DIAGRAM
74
GAS METERING
75
6.5 SDV-1110
This is a solenoid operated piton type valve which can be used to discontinue gas supply to
SNGPL. It is connected with the PLC and can also be manually operated.
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PLANT UTILITIES
7.1 INSTRUMENT AIR SUPPLY
Air supply is needed in the plant to operate various instruments such as PCV, LCV, TCV, SDV1110, Diaphragm pumps etc and also in heat medium heater and crude heater. These instruments
require that the air be supplied in dried form. However air from air compressor can be used
directly without drying in plant utilities.
Air is sucked into the compressor from external atmosphere and made to pass through filters to
remove solid particles. The Screw type rotary compressor compresses the air and discharged at a
pressure of 120 Psig into the oil separator. Oil is pumped into the compressor for lubrication and
heat removal. Oil separator separates the oil from air and after being passed through a cooler it is
recycled back to the compressor. Air is also cooled and made to pass through a water separator to
separate moisture from air. This air is received by the air receiver which separates condensed
liquids from the air stream. Air from air receiver is supplied directly to:
Gas Generator (start air)
Chemical injection pumps
LP Gas Compressor (start air)
To skim oil pumps
LP K.O. drum recycle pumps
HP K.O. drum recycle pumps
Instruments however require that the air be dry and free from solid particles in order to prevent
corrosion and degradation and for their effective operation. Air from air receiver is passed
through pre-filters which remove solid particles before the air is passed on to instrument air
dryers. Dried air is further made to pass through instrument air after filters and is ready to be
supplied to:
Wellhead area
First stage separator
Second stage separator
Crude/Crude heat exchanger
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Crude heater
Third stage degasser
Storage tank area
Gas dehydration skid
Glycol regeneration package
Gas compressor package
Gas metering skid
HP Flare package
LP Flare package
Fusible loop
Inlet filter coalescer
HDCP Skid
7.3 ELECTRICITY
Electricity is being utilized in the plant operation, produced operations. It is produced by one of
two types of engine driven generators in the plant: Gas generator and Diesel generator. These
generators are driven by four-stroke combustion engines that utilize fuel (gas/diesel) for
combustion. An internal combustion engine (diesel or gas fired) turns a power shaft which is in
turn connected to an electrical generator. As the electrical generator spins it generates electricity.
Depending on the application this may be alternating current (AC) or direct current (DC). This
electricity is then fed to a power distribution system for use.
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CONTROL
DEVICES
A power operated device that modulates the fluid flow rate in a process control system.
A control valve is actually an assembly that includes minimum:
Valve Body
Actuator
Types of Control Valves
Linear Motion Valve
Rotary Motion Valve
79
Diaphragm
Spring
Yoke
Coupling
Body
Bonnet
Packing Box
Plug
Seat Ring
Cage
DIAPHRAGM ACTUATOR
80
A fluid powered device in which the fluid acts upon a flexible component, the diaphragm.
There are two types
Direct Actuator
Reveres Actuator
DIRECT ACTUATOR: A diaphragm actuator in which the actuator stem extends with
increasing diaphragm pressure.
REVERSE ACTUATOR: A diaphragm actuator in which the actuator stem retracts with
increasing diaphragm pressure.
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82
VENT HOLE
Depending upon the service there is a hole called weep hole in orifice plate. Top Hole (Vent
Hole) used for liquid services and this hole allows the trapped gas / air to escape.
BOTTOM HOLE (DRAIN HOLE)
Used for gas services and this hole allow the moisture / liquid accumulated in the bottom of
Orifice Plate to drain.
83
84
Pitot tube does not cause a pressure loss and is least accurate.
85
8.2.5 ANNUBAR
Advanced shape of Pitot tube.
Annubar has number of impact holes and
static holes.
It Measure the average flow.
Usually, used in lines of larger diameter.
8.2.6 ROTAMETER
Actually, it is a Variable area flow meter (Orifice plate is the fixed area
flow meter). It is used for
Clean liquid
Low temperature
Low pressure
Differential pressure flow measuring instrument
Two types
1) Glass rotameter
2) Metal tube
Vacuum Pressure
Gauge Pressure
Atmospheric Pressure
ATMOSPHERIC PRESSURE
Atmospheric pressure is the pressure exerted by the air on the earth surface. It varies with
altitude.
At sea level the average pressure of the atmosphere is sufficient to hold a column of mercury at
the height of 760 mm or 29.92 inches of Hg. The amount of pressure exerted by air is
approximately 14.7 psia at sea level.
ABSOLUTE PRESSURE
Actual atmospheric pressure is the pressure that exists at any given moment.
VACUUM PRESSURE
Absence of atmospheric pressure is called Vacuum.
The space in which the pressure is less than atmospheric pressure is said to be under partial
vacuum. When a vacuum gauge reads zero, the pressure in the space is the same as atmospheric
pressure.
GAUGE PRESSURE
The pressure that actually shown on the dial of a gauge that registers pressure at or above
atmospheric pressure.
Diaphragm
Borden Tube CType
1) Borden Tube Spiral Type
2) Borden Tube Helical Type
3) Borden Tube (Guage)
8.3.4 TYPES OF PRESSURE TRANSMITTERS
1) Delta Pressure Transmitter
2) Gauge Pressure Transmitter
3) Absolute Pressure Transmitter
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Thermometer
Bimetallic Thermometer
Thermocouple (TC)
Resistance Temperature Detector (RTD)
Pyrometer
8.4.1 THERMOMETERS
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8.4.3 THERMOCOUPLE
Thermocouple produce electric current when subjected
to temperature changes. They are made by connecting
two different metals to form a closed circuit. If one of
the two connections or junctions is heated, current will
flow through the circuit, the amount of current
produced depends on the difference in temperature
between the two junctions and on the characteristics of
the two metals.
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Pure
Uniform quality
Stable with given temperature rage
Able to reproduce resistance temp. Reading
8.4.5 PYROMETER
Technique for determine a bodys
temperature by measuring its
electromagnetic radiations.
Pyrometer is based on two principles:
1) Intensity of electromagnetic
radiation emitted by the body,
depends on the body emittance.
2) Intensity of electromagnetic
radiation emitted by the body,
depends on the body temperature.
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94
TOOLS
1.1
A hammer with two ends on the head, one that is round and the other flat. Sometimes called a
machinist's hammer, a ball peen is a good choice for working
with metal. Its steel head is harder than that of a claw hammer, so
is less likely to chip on impact. Ball peen hammers are commonly
used to drive cold chisels, set rivets, and bend and shape metal.
They range in weight from 4 ounces (used, for example, in model
boat making) to 32 ounces and have wooden, steel, or graphite
handles.
Before the advent of pneumatic rivet guns, ball peen hammers
were commonly used for riveting. First the flat head drove the
nail through, then the round ball was used to "peen over" the
other side of the rivet. The biggest danger while peening rivets is
to strike the nail shaft straight on on as this can make the nail bend inside the hole. Then if the
boards are stressed the bend might straighten and the boards separate making for a structure
that falls apart or leaks. The ball of the ball peen hammer tends to produce glancing blows that
mash some of the metal away from the sides of the hole. This also hardens the metal so that it
becomes as elastic as the surrounding material.
In tool box of Mechanical Workshop we have different sizes of ball pien hammers. Their head is
made up of Carbon Steel. Not used for hammering because it can cause sparking.
1.2
COMBINATION SPANNER
A spanner is a tool used to provide grip and mechanical advantage in applying torque to turn
objectsusually rotary fasteners, such
as nuts and boltsor keep them from
turning.
A double-ended tool with one end like
an open-ended spanner and the other
end like a ring spanner. Both ends
generally fit the same size of bolt.
95
Here at Makori, we have combination spanners ranging from 6mm-32mm. The rating on
spanner defines the outer diameter of the nut it can open. Combination spanners can be used to
open nuts of a particular diameter only defined by its rating. To apply more torque the open end
of another spanner can be fitted inside the ring of the spanner whose open end is being applied to
the nut to increase the moment arm and vice versa.
Manufacturer of Combination Spanners being used at Makori includes ELORA, ENIUS.
They are made up of Chrome Vanadium Steel(Chromium-vanadium steel refers to steel alloys
incorporating carbon, manganese, phosphorus, sulfur, silicon, chromium, and vanadium. Some
forms can be used as high speed steel. Chromium and vanadium both make the steel more harden
able. Chromium also helps resist abrasion, oxidation, and corrosion. Chromium and carbon can
both improve elasticity) and some of them have Drop Forged (Drop forging is a process used to
shape metal into complex shapes by dropping a heavy hammer with a die on its face onto the
work piece) stamped on them.
1.3 FILES
A file is a metalworking, woodworking and plastic working tool used to cut fine amounts of
material from a workpiece. It most commonly refers to the hand tool style, which takes the form
of a steel bar with a case hardened surface and a series of sharp, parallel teeth. Most files have a
narrow, pointed tang at one end to which a handle can be fitted.
In Makori we have flat, triangular, rectangular, circular/round, half-round files.
They are made up of material harder than the one on which they are supposed to be used.
There Manufacturers include ELORA.
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97
Here at MPF, we have pipe wrenches ranging in length from 8 inch-36 inch.
Most of these are made from Steel but some are of Aluminum too.
Drop Forged pipe wrenches are also available.
Manufactures include STANLEY, RIDGID.
1.8 PLIERS
Pliers are a hand tool used to hold objects firmly, possibly
developed from tongs used to handle hot metal in Bronze
Age Europe they are also useful for bending and
compressing a wide range of materials. Generally, pliers
consist of a pair of metal first-class levers joined at a
fulcrum positioned closer to one end of the levers, creating
short jaws on one side of the fulcrum, and longer handles
98
on the other side. This arrangement creates a mechanical advantage, allowing the force of the
hand's grip to be amplified and focused on an object with precision. The jaws can also be used to
manipulate objects too small or unwieldy to be manipulated with the fingers.
99
Here at MPF, we have L-keys for opening nuts with internal diameter of 1mm-12mm.
These are made up of Chromium Vanadium Steel.
There Manufacturers include ELORA, STANLEY.
1.12 PUNCH
A punch is a hard metal rod with a shaped tip at one end and
a blunt butt end at the other, which is usually struck by a
hammer. Most woodworkers prefer to use a ball-peen
hammer for using punches. Punches are used to drive objects,
such as nails, or to form an impression of the tip on a work
piece. Decorative punches may also be used to create a
pattern or even form an image.
Here at MPF, we have Brass Punch And is stroked using
ball peen to loosen tightly fitted objects to get them out for
maintenance.
1.13 SCRAPPER
A hand scraper is a single-edged tool used to scrape metal
from a surface. This may be required where a surface needs to
be trued, corrected for fit to a mating part, needs to retain oil
(usually on a freshly ground surface), or even to give a
decorative finish.
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101
1.17 C-SPANNER
A sickle-shaped spanner having a projection at the end of the
curve, used for turning large narrow nuts that have an indentation into which the projection on
the spanner fits.
in tapered pipe threads performs a lubricating function, which more easily allows the threads to
be screwed together, to the point of deformation, which is what creates the seal.
WHITE-Single density- should only be used on NPT threads up to 3/8 inch and can ordinarily
be used for low-pressure home/residential water (lawn/garden hose/sprinkler), LPG/cooking-gas
fittings/connections.
YELLOW- Double Density- yellow double density is often labeled as "Gas type": When
working with natural gas fittings or propane/butane fittings, use yellow Teflon tape because you
can screw and unscrew fittings several times and it stays sealed.
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FITTINGS
Fittings are used in pipe and plumbing systems to connect straight pipe or tubing sections, to
adapt to different sizes or shapes, and for other purposes, such as regulating or measuring fluid
flow. The term plumbing is generally used to describe conveyance of water, gas, or liquid waste
in ordinary domestic or commercial environments, whereas piping is often used to describe highperformance (e.g. high pressure, high flow, high temperature, hazardous materials) conveyance
of fluids in specialized applications. The term tubing is sometimes used for lighter-weight
piping, especially types that are flexible enough to be supplied in coiled form.
Fittings (especially uncommon types) require money, time, materials, and tools to install, so they
are a non-trivial part of piping and plumbing systems. Valves are technically fittings, but are
usually discussed separately.
2.1 MATERIALS
The bodies of fittings for pipe and tubing are most often of the same base material as the pipe or
tubing being connected, for example, copper, steel, polyvinyl chloride (PVC), chlorinated
polyvinyl chloride (CPVC), or acrylonitrile butadiene styrene (ABS). However, any material that
is allowed by the plumbing, health, or building code (as applicable) may be used, but must be
compatible with the other materials in the system, the fluids being transported, and the
temperatures and pressures inside and outside of the system. For example, brass- or bronzebodied fittings are common in otherwise copper piping and plumbing systems. Fire hazards,
earthquake resistance, and other factors also influence choice of fitting materials.
104
2.3.1 ELBOW
105
2.3.2 COUPLING
2.3.3 UNION
106
2.3.4 REDUCER
2.3.5 TEE
107
2.3.6 CAP
2.3.7 PLUG
A plug closes off the end of a pipe. It is similar to a cap but it fits inside the fitting it is mated to.
In a threaded iron pipe plumbing system, plugs have male threads.
2.3.8 NIPPLE
A short stub of pipe, usually threaded iron, brass, chlorinated
polyvinyl chloride (CPVC) or copper; occasionally just bare
copper. A nipple is defined as being a short stub of pipe which
has two male ends. Nipples are commonly used for plumbing and
hoses, and second as valves for funnels and pipes.
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2.3.9 FLANGES
Flanges are generally used when there is a connection to valves, in-line instruments and/or
connection to equipment nozzles is required. Flange fittings generally involve pressing two
surfaces to be joined tightly together, by means of threaded bolts, wedges, clamps, or other
means of applying high compressive forces. Often, a gasket, packing, or an O-ring is installed
between the flanges to prevent leakage, but it is sometimes possible to use only a special grease,
or nothing at all, if the mating surfaces are precisely formed. Flanges are designed to the
following pressure ratings: 150 lb, 300 lb, 400 lb, 600 lb, 900 lb, 1500 lb and 2500 lb or 10Bar,
15Bar, 25Bar, 40Bar, 64Bar, 100Bar and 150Bar. Various types of flanges are available
depending upon the type of their constructional features. The following are types of flanges
generally used in piping. These flanges are available with different facing like raised face, flat
face, ring joint face etc. Typically they are made from forged materials and have machined
surfaces.
tighter tolerances and clean joints. It also can be used to connect very dissimilar materials such
as metals and metalized ceramics.
THREADING- is applied to flanges and pipes to allow the connections to be screwed together
in a manner similar to nuts or bolts.
While the method of attachment can be a distinguishing feature, there are other considerations
more important to pipe flange selection. Factors an industrial buyer should consider first are the
flange's physical specifications, type, material, and performance features most suitable for the
application.
O-RING GROOVE
1. BLIND
Flanges are round plates with no center hold used to close the ends of pipes, valves, or
equipment. They assist in allowing easy access to a line once it has been sealed. They can
also be used for flow pressure testing. Blind flanges are made to fit standard pipes in all
sizes at higher pressure ratings than other flange types.
BLIND FLANGE
2. LAP JOINT
Flanges are used on piping fitted with lapped pipe or with lap joint stub ends. They can
rotate around the pipe to allow for an easy alignment and assembly of bolt holes even
after the welds have been completed. Because of this advantage, lap joint flanges are used
in systems requiring frequent disassembly of the flanges and pipe. They are similar to
slip-on flanges, but have a curved radius at the bore and face to accommodate a lap joint
stub end. The pressure ratings for lap joint flanges are low, but are higher than for slip-on
flanges.
3. SLIP-ON
Flanges are designed to slide over the end of piping and then be welded in place. They
provide easy and low-cost installation and are ideal for lower pressure applications.
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Pressure
Capacity
Very high
Low
Pipe
Sizes
All
All
Slip-on
Low
All
Socket weld
Threaded
Welding
neck
High
Low
High
Small
Small
All
Applications / Advantages
Closing pipes, flow pressure testing
Systems requiring frequent
disassembly
Low installation cost, simple
assembly
Smooth bore for better fluid flow
Attachment without welding
High pressures and extreme
temperatures
CARBON STEEL is steel alloyed primarily with carbon. It has a high hardness and strength
which increases with carbon content, but lowers ductility and melting point. For more
information on carbon and alloy steels, please visit the Carbon Steels and Alloy Steels area on
GlobalSpec.
ALLOY STEEL is steel alloyed with one or more elements which enhance or change the steel's
properties. Common alloys include manganese, vanadium, nickel, molybdenum, and chromium.
Alloy steels are differentiated based on standard grades. For specific information on individual
types of alloying elements, please visit the Metals and Alloys section on GlobalSpec.
STAINLESS STEEL is steel alloyed with chromium in amounts above 10%. Chromium
enables stainless steel to have a much higher corrosion resistance than carbon steel, which rusts
readily from air and moisture exposure. This makes stainless steel better suited for corrosive
applications that also require high strength. For more information on stainless steel alloys, please
visit the Stainless Steel Alloys area on GlobalSpec.
CAST IRON is iron alloyed with carbon, silicon, and a number of other alloyants. Silicon forces
carbon out of the iron, forming a black graphite layer on the exterior of the metal. Cast irons
have good fluidity, castability, machinability, and wear resistance but tend to be somewhat brittle
with low melting points. For more information on cast irons, please visit the Cast Irons area on
GlobalSpec.
ALUMINUM is a malleable, ductile, low density metal with medium strength. It has better
corrosion resistance than typical carbon and alloy steels. It is most useful in constructing flanges
requiring both strength and low weight. For more information on aluminum, please visit the
Aluminum and Aluminum Alloys area on GlobalSpec.
BRASS is an alloy of copper and zinc, often with additional elements such as lead or tin. It is
characterized by good strength, excellent high temperature ductility,reasonable cold ductility,
good conductivity, excellent corrosion resistance, and good bearing properties. For more
information on brass and other copper alloys, please visit the Copper, Brass, and Bronze Alloys
area on GlobalSpec.
PVC or polyvinyl chloride is a thermoplastic polymer that is inexpensive, durable, and easy to
assemble. It is resistant to both chemical and biological corrosion. By adding plasticizers it can
be made softer and more flexible.
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ASME/ANSI B16.5 provides dimensions and tolerances for flanges in pipe sizes from 1/2"
through 24" and in classes ranging 150 through 2500.
Class chart for class 150 looks like this.
Nominal
Pipe Size
NPS
(inches)
Class 150
Diameter of
Flange
(inches)
No.
of
Bolts
Diameter of
Bolts
(inches)
Bolt
Circle
(inches)
1/4
3-3/8
1/2
2-1/4
1/2
3-1/2
1/2
2-3/8
3/4
3-7/8
1/2
2-3/4
4-1/4
1/2
3-1/8
1-1/4
4-5/8
1/2
3-1/2
1-1/2
1/2
3-7/8
5/8
4-3/4
2-1/2
5/8
5-1/2
7-1/2
5/8
3-1/2
8-1/2
5/8
5/8
7-1/2
10
3/4
8-1/2
11
3/4
9-1/2
13-1/2
3/4
11-3/4
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10
16
12
7/8
14-1/4
12
19
12
7/8
17
14
21
12
18-3/4
16
23-1/2
16
21-1/4
18
25
16
1-1/8
22-3/4
20
27-1/2
20
1-1/8
25
24
32
20
1-1/4
29-1/2
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GASKETS
A gasket (correct terminology is a "joint" made from "jointing material") is a mechanical seal
which fills the space between two or more mating surfaces, generally to prevent leakage from or
into the joined objects while under compression.
3. ASBESTOS GASKET
Sheet packing was a common
asbestos - containing product
used to make gaskets for
commercial and industrial
settings. Asbestos fibers are
mixed with a binding material
and compressed to form the
product , which can then be cut
into various shapes and sizes to
form gaskets and heat seals.
These products were used on
pipes and boilers and in between
joints on ships. When used in
between pipe joints as a gasket,
sheet packing prevents the
contents of the pipe from leaking
out.
Asbestos was commonly used as a component of this product because it provided
resistance to high temperatures, as well as excellent durability and flexibility. Its cost
effective nature also made asbestos an appealing material to produce gaskets and heat
seals cheaply.
4. HEAD GASKET
A head gasket is a gasket that sits between the engine block and cylinder head(s) in an internal
combustion engine.
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Its purpose is to seal the cylinders to ensure maximum compression and avoid leakage of coolant
or engine oil into the cylinders; as such, it is the most critical sealing application in any engine,
and, as part of the combustion chamber, it shares the same strength requirements as other
combustion chamber components.
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SEALS
Seals are usually defined as components or assemblies which prevent the passage of fluids
between the moving parts of a machine. Note that "fluid" may refer to liquid, vapour or gas.
O-rings are one of the most common seals used in machine design because they are
inexpensive, easy to make, reliable, and have simple mounting requirements. They can
seal tens of megapascals (thousands of psi) of pressure.
2. PISTON RINGS
The piston ring is a between the moving piston and its cylinder. The engine produces
useful power by burning the mixture of petrol and air in the space above the piston, using
the increased pressure resulting from combustion to force the piston down, thereby
turning the crankshaft. In the case of the piston, there is no rotation about its own axis
and the seal is required to slide up and down the cylinder.
The seals in this particular case are known as PISTON RINGS. They must operate under
very severe conditions of temperature and pressure, with very poor lubrication. They are
very often made of good quality CAST IRON which, due to its high carbon content,
possesses good self-lubricating properties.
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RING TYPES
Each of the 3 rings in a set is a specialist and will use a distinct combination of shapes, materials,
heat treatment and/or surface coatings in order to perform its assigned function in an optimal
way.
There are two types of piston rings:
Compression Rings (Top and Second ring)
Oil Control Rings
There are different combinations of numbers of these rings with respect to the designs of
engines. Some engines require 2, 3, 4, 5 or 6 piston rings per piston.
FUNCTIONS
Piston Rings must complete 3 principle functions in engines.
Seal off the combustion chamber from the crankcase
Limit and control oil consumption
Transfer the heat absorbed by the piston in the combustion process to the cooled cylinder
walls.
TOP RING
This is referred to as the upper compression ring. This ring operates under the harshest
conditions with respect to thermal and mechanical loading. Its job is to form a gas-tight barrier
between the piston and cylinder wall in order to seal the combustion chamber. They also transfer
the heat to the cooled cylinder walls like a bridge.
SECOND RING
This is referred as the lower compression ring. One of its job is to work together with the top ring
in order to seal the combustion chamber and transfer the heat to the cylinder walls. They also
control oil consumption.
The scrapper or second compression ring behaves as both a compression ring and oil control
ring.
122
123
4. PACKING
They are designed to enhance and extend service life of your valves and pumps. Packings are
available in many different styles and materials. It is made up of relatively soft material.
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Applications that involve ball valves, gate, globe, and valve cocks also go in favour of packing
since seals need rotary motion to be able to seal off anything. It is exactly this reason that gland
packings are integrated in reciprocating pumps.
Mechanical Seals - What Makes Them Any Good?
When it comes to popularity, seals win. They are implemented in a lot more applications partly
because they cause very few leak problems, and they are practically maintenance free.
Sticklers for power consumption may also be inclined to use seals more because they have
considerably low energy consumption. Thanks to the few leakages, seals hardly ever experience
interruptions, thereby saving time and effort.
Other factors of a seal's durability are the duration of the sealing operation, ambient
temperatures, and the liquid being pumped. Pressure and temperatures cause gradual damage for
both seals and packings, especially with mechanical seals. If seals are your choice for sealing
equipment, remember that accidental dry running may make seals deteriorate faster.
The price of seals may also discourage you because they are a lot more expensive than packings.
Which to Choose
At the end of the day, the best way to approach this is choosing the sealing equipment that can
get the job done with very few hassles. Whether you choose gland packing or mechanical seals,
make an informed decision so that you can prevent snags in your budget and productivity.
4.4 WASHER
A washer is a thin plate (typically disk-shaped) with a hole (typically in the middle) that is
normally used to distribute the load of a threaded fastener, such as a screw or nut. Other uses are
as a spacer, spring (belleville washer, wave washer),
wear pad, preload indicating device, locking device, and
to reduce vibration (rubber washer). Washers usually
have an outer diameter (OD) about twice the width of
their inner diameter (ID).
Washers are usually metal or plastic. High quality bolted
joints require hardened steel washers to prevent the loss
of pre-load due to Brinelling after the torque is applied.
Washers are also important for preventing galvanic
corrosion, particularly by insulating steel screws from
aluminium surfaces.
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VALVES
A valve is a device that regulates, directs or controls the flow of a fluid (gases, liquids, fluidized
solids, or slurries) by opening, closing, or partially obstructing various passageways. Valves are
technically valves fittings, but are usually discussed as a separate category. In an open valve,
fluid flows in a direction from higher pressure to lower pressure.
Valves may be operated manually, either by a handle, lever, pedal or wheel. Valves may also be
automatic, driven by changes in pressure, temperature, or flow. These changes may act upon a
diaphragm or a piston which in turn activates the valve, examples of this type of valve found
commonly are safety valves fitted to hot water systems or boilers.
More complex control systems using valves requiring automatic control based on an external
input (i.e., regulating flow through a pipe to a changing set point) require an actuator. An
actuator will stroke the valve depending on its input and set-up, allowing the valve to be
positioned accurately, and allowing control over a variety of requirements.
by a spreader, after the disc has been fully lowered into its seated position. When the
valve is opened, pressure on the disc is relieved before it is raised, eliminating friction
and scoring of the body seats and the disc itself.
3. FLEXIBLE WEDGE DISCS
Flexible wedge discs of gate valves are solid only at the center and are flexible at the
outer edge and seating surface. This design enables the disc face to overcome the
tendency to stick in high temperature services where wide swings in temperature occur.
Flexible wedge discs are generally found only in steel valves.
GATE VALVE STEM CONSTRUCTION
There are three types of stem features which can be found in gate valve construction: (1) rising
stem/outside screw and yoke, (2) rising stem/inside screw, and (3) nonrising stem/inside screw.
1. RISING STEM/OUTSIDE SCREW AND YOKE
Rising stem/outside screw and yoke construction retains stem threads outside the valve.
Rising stem/outside screw and yoke construction is recommended where high
temperatures, corrosives, and solids in the line might damage stem threads inside the
valve. When the handwheel is turned, the stem rises as the yoke bushing engages the
stem threads. The external threads enable easy lubrication; however, care must be taken
to protect the exposed stem threads from damage. And advantage of rising stem valves is
the ability to determine valve position by observing the position of the stem.
2. RISING STEM/INSIDE SCREW
The rising stem/inside screw is the most common stem design in bronze gate valve
construction. Because the hand wheel and stem both rise, adequate clearance must be
provided for operation. The stem and handwheel positions indicate the position of the
disc inside the valve. In the open position, the backseat helps protect the stem threads;
but, care must be taken to protect the stem externally.
3. NONRISING STEM/INSIDE SCREW
Nonrising stem/inside screw design has the chief advantage of requiring minimum
headroom for operation. Since the stem does not travel vertically, packing wear is
reduced. Heat, corrosion, erosion, and solids may damage the stem threads inside the
valve and cause excessive wear. In addition, it is impossible to determine the disc
position since the handwheel and stem do not rise.
GATE VALVE BONNET CONSTRUCTION
There are three types of gate valve bonnet construction: bolted, threaded, and welded designs.
1. BOLTED AND UNION BONNETS
The bolted and union bonnet designs, featuring three piece construction, are preferred for
rugged service. Bolted construction and union construction are stronger and safer than
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threaded body bonnet design. Industrial valve users generally select union bonnet bronze
or bolted bonnet, iron body gate valves.
2. TWO PIECE THREADED BONNET
The two piece threaded bonnet is the least expensive design and should be used for lower
pressures or where shock and vibration are not encountered. A union bonnet valve would
be more suitable than a threaded bonnet valve, if frequent disassembly of the valve is
required.
3. WELDED BONNET
The welded bonnet construction provides the most leak free, body to bonnet joint. This
design is usually found in 2 inch and smaller forged steel valves. The disadvantage of the
welded bonnet is that it provides no access to the trim parts if repairs are necessary.
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plugs are solid and are used with smaller valves or with low pressure drops across the valve. The
advantages are simpler design, with one possible leak path at the seat and usually lower cost. The
disadvantages are the limited size; with a large unbalanced plug the forces needed to seat and
hold the flow often becomes impractical. Balanced plugs have holes through the plug.
Advantages include easier shut off as the plug does not have to overcome static forces. However,
a second leak path is created between the plug and the cage, and cost is generally higher.
STEM
The stem serves as a connector from the actuator to the inside of the valve and transmits this
actuation force. Stems are either smooth for actuator controlled valves or threaded for manual
valves. The smooth stems are surrounded by packing material to prevent leaking material from
the valve. This packing is a wearable material and will have to be replaced during maintenance.
With a smooth stem the ends are threaded to allow connection to the plug and the actuator. The
stem must not only withstand a large amount of compression force during valve closure, but also
have high tensile strength during valve opening. In addition, the stem must be very straight, or
have low run out, in order to ensure good valve closure. This minimum run out also minimizes
wear of the packing contained in the bonnet, which provides the seal against leakage. The stem
may be provided with a shroud over the packing nut to prevent foreign bodies entering the
packing material, which would accelerate wear.
CAGE
The cage is part of the valve that surrounds the plug and is located inside the body of the valve.
Typically, the cage is one of the greatest determiners of flow within the valve. As the plug is
moved more of the openings in the cage are exposed and flow is increased and vice versa. The
design and layout of the openings can have a large effect on flow of material (the flow
characteristics of different materials at temperatures, pressures that are in a range). Cages are
also used to guide the plug to the seat of the valve for a good shutoff, substituting the guiding
from the bonnet.
SEAT RING
The seat ring provides a stable, uniform and replaceable shut off surface. Seat rings are usually
held in place by pressure from the fastening of the bonnet to the top of the body. This pushes the
cage down on the lip of the seat ring and holds it firmly to the body of the valve. Seat rings may
also be threaded and screwed into a thread cut in the same area of the body. However this
method makes removal of the seat ring during maintenance difficult if not impossible. Seat rings
are also typically beveled at the seating surface to allow for some guiding during the final stages
of closing the valve.
Economical globe valves or stop valves with a similar mechanism used in plumbing often have a
rubberwasher at the bottom of the disc for the seating surface, so that rubber can be compressed
against the seat to form a leak-tight seal when shut.
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131
RESILIENT BUTTERFLY VALVE - These types of valves are generally used for low
pressure applications. They use a flexible rubber seat and therefore doesn't have high sealing
ability. They can operate under working pressure up to 232 Psi.
HIGH PERFORMANCE BUTTERFLY VALVE - This valves are used in systems requiring
higher pressure resistance. The disc though positioned in the center of the pipe is arranged in a
peculiar way in order to increase sealing ability and robustness.They can work up to 725 working
pressure.
TRI-CENTRIC BUTTERFLY VALVE -This valve uses a metal seat instead of a rubber one
therefore can withstand high pressure conditions. They can work up to 1450 Psi working
pressure.
One more type of butterfly valve known as the Diverter butterfly valve, is used to bypass
coolers in order to attain fine control of cooling water temperature. This valve has two legs or
pipes connecting to it. A pneumatic actuator controls the opening and closing of the valve on the
basis of a signal provided by a temperature sensor. This valve delivers precise control of flow
rate in both the branches. A provision of manual control is also provided in case of failure of the
pneumatic system.
WORKING & USES OF BUTTERFLY VALVES
The Working of butterfly valves is very much similar to that of ball valves. Rotating of the
handle, manually or with the help of a pneumatic system, turns the plate either perpendicular or
parallel to the flow of the fluid. Butterfly valves can also be used for regulating the flow by
adjusting the lever and by keeping a close watch on the desired output flow.
Butterfly valves are used on all types of ships and firefighting apparatus. They are also widely
used for domestic piping purposes. On ships they are used for large capacity lines such as
forward and aft sea water suction lines or lines from various tanks to their respective pumps.
Lube oil pipelines also preferably have butterfly valves fitted in them due to obvious reasons as
discussed above.
valve has a relatively small orifice with a long, tapered seat, and a needle-shaped plunger, on the
end of a screw, which exactly fits this seat.
As the screw is turned and the plunger retracted, flow between the seat and the plunger is
possible; however, until the plunger is completely retracted the fluid flow is significantly
impeded. Since it takes many turns of the fine-threaded screw to retract the plunger, precise
regulation of the flow rate is possible.
The virtue of the needle valve is from the vernier effect of the ratio between the needle's length
and its diameter, or the difference in diameter between needle and seat. A long travel axially (the
control input) makes for a very small and precise change radially (affecting the resultant flow).
Needle valves may also be used in vacuum systems, when a precise control of gas flow is
required, at low pressure,[1] such as when filling gas-filled vacuum tubes, gas lasers and similar
devices.
USES
Needle valves are usually used in flow metering applications, especially when a constant,
calibrated, low flow rate must be
maintained for some time, such as the
idle fuel flow in a carburetor.
Note that the float valve of a carburetor
(controlling the fuel level within the
carburetor) is not a needle valve,
although it is commonly described as
one. It uses a bluntly conical needle, but
it seats against a square-edged seat rather
than a matching cone. The intention here
is to obtain a well-defined seat between
two narrow mating surfaces, giving firm
shutoff of the flow from only a light
float pressure.
Since flow rates are low and many turns of the valve stem are required to completely open or
close, needle valves are not used for simple shutoff applications.
Since the orifice is small and the force advantage of the fine-threaded stem is high, needle valves
are usually easy to shut off completely, with merely "finger tight" pressure. The spindle and/or
seat of a needle valve, especially one made from brass, are easily damaged by excessive turning
force when shutting off the flow.
Small, simple needle valves are often used as bleed valves in hot water heating applications.
133
Unlike a ball valve, or valves with a rising stem, it is not easy to tell from examining the handle
position whether the valve is open or closed
There are similar check valves where the disc is not a ball, but some other shape, such as a
poppet energized by a spring. Ball check valves should not be confused with ball valves, which
is a different type of valve in which a ball acts as a controllable rotor to stop or direct flow.
Check valves are often used with some types of pumps. Piston-driven and diaphragm pumps
such as metering pumps and pumps for chromatography commonly use inlet and outlet ball
check valves. These valves often look like small cylinders attached to the pump head on the inlet
and outlet lines. Many similar pump-like mechanisms for moving volumes of fluids around use
check valves such as ball check valves. The feed pumps or injectors which supply water to steam
boilers are fitted with check valves to prevent back-flow.
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ENGINES &
COMPRESSORS
6.1 COMPRESSOR
6.1.1 RECIPROCATING COMPRESSORS
typically larger, and more costly than comparable rotary units. Another type of reciprocating
compressor is the swash plate compressor, which uses pistons which are moved by a swash plate
mounted on a shaft - see Axial Piston Pump.
Reciprocating compressors are often some of the most critical and expensive systems at a
production facility, and deserve special attention. Gas transmission pipelines, petrochemical
plants, refineries and many other industries all depend on this type of equipment. Due to many
factors, including but not limited to the quality of the initial specification/design, adequacy of
maintenance practices and operational factors, industrial facilities can expect widely varying
lifecycle costs and reliability from their own installations.
Various compressors are found in almost every industrial facility. Types of gases compressed
include the following:
Other applications
There are two primary classifications of industrial compressors: intermittent flow (positive
displacement), including reciprocating and rotary types; and continuous flow, including
centrifugal and axial flow types.
Reciprocating compressors are typically used where high compression ratios (ratio of discharge
to suction pressures) are required per stage without high flow rates, and the process fluid is
relatively dry. Wet gas compressors tend to be centrifugal types. High flow, low compression
ratio applications are best served by axial flow compressors. Rotary types are primarily specified
in compressed air applications, though other types of compressors are also found in air service.
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BASIC DESIGN:
The compression cylinders, also known as stages, of which a particular design may have from
one to six or more, provide confinement for the process gas during compression. A piston is
driven in a reciprocating action to compress the gas. Arrangements may be of single-or dualacting design. (In the dual-acting design, compression occurs on both sides of the piston during
both the advancing and retreating stroke.) Some dual-acting cylinders in high-pressure
applications will have a piston rod on both sides of the piston to provide equal surface area and
balance loads. Tandem cylinders arrangements help minimize dynamic loads by locating
cylinders in pairs, connected to a common crankshaft, so that the movements of the pistons
oppose each other. Gas pressure is sealed and wear of expensive components is minimized
through the use of disposable piston rings and rider bands respectively. These are formed from
comparatively soft metals relative to piston and cylinder/liner metallurgy or materials such as
polytetrafluoroethylene (PTFE).
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INTAKE
At the conclusion of a prior cycle, the piston is fully retreated within the cylinder at V1, the
volume of which is filled with process gas at suction conditions (pressure, P1 and temperature,
T1), and the suction and discharge valves are all closed. This is represented by point 1 (zero) in
the P-V diagram. As the piston advances, the volume within the cylinder is reduced. This causes
the pressure and temperature of the gas to rise until the pressure within the cylinder reaches the
pressure of the discharge header. At this time, the discharge valves begin to open, noted on the
diagram by point 2.
With the discharge valves opening, pressure remains fixed at P2 for the remainder of the
advancing stroke as volume continues to decrease for the discharge portion of the cycle. The
piston comes to a momentary stop at V2 before reversing direction. Note that some minimal
volume remains, known as the clearance volume. It is the space remaining within the cylinder
when the piston is at the most advanced position in its travel. Some minimum clearance volume
is necessary to prevent piston/head contact, and the manipulation of this volume is a major
compressor performance parameter. The cycle is now at point 3.
Expansion occurs next as the small volume of gas in the clearance pocket is expanded to slightly
below suction pressure, facilitated by the closing of the discharge valves and the retreat of the
piston. This is point 4.
When P1 is reached, the intake valves open allowing fresh charge to enter the cylinder for the
intake and last stage of the cycle. Once again, pressure is held constant as the volume is changed.
This marks the return to point 1.
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2. COMPRESSION STROKE
In this stroke, both valves are closed and the piston starts its movement to the minimum volume
position (upward direction in the cylinder) and compresses the fuel mixture. During the
compression process, pressure, temperature and the density of the fuel mixture increases.
3. POWER STROKE
When the piston reaches the minimum volume position, the spark plug ignites the fuel mixture
and burns. The fuel produces power that is transmitted to the crank shaft mechanism.
4. EXHAUST STROKE
In the end of the power stroke, the exhaust valve opens. During this stroke, the piston starts its
movement in the minimum volume position. The open exhaust valve allows the exhaust gases to
escape the cylinder. At the end of this stroke, the exhaust valve closes, the inlet valve opens, and
the sequence repeats in the next cycle. Four stroke engines require two revolutions.
Many engines overlap these steps in time; jet engines do all steps simultaneously at different
parts of the engines.
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COMBUSTION
All internal combustion engines depend on the combustion of a chemical fuel, typically with
oxygen from the air (though it is possible to inject nitrous oxide in order to do more of the same
thing and gain a power boost). The combustion process typically results in the production of a
great quantity of heat, as well as the production of steam and carbon dioxide and other chemicals
at very high temperature; the temperature reached is determined by the chemical make up of the
fuel and oxidisers (see stoichiometry), as well as by the compression and other factors.
The most common modern fuels are made up of hydrocarbons and are derived mostly from fossil
fuels (petroleum). Fossil fuels include diesel fuel, gasoline and petroleum gas, and the rarer use
of propane. Except for the fuel delivery components, most internal combustion engines that are
designed for gasoline use can run on natural gas or liquefied petroleum gases without major
modifications. Large diesels can run with air mixed with gases and a pilot diesel fuel ignition
injection. Liquid and gaseous biofuels, such as ethanol and biodiesel (a form of diesel fuel that is
produced from crops that yield triglycerides such as soybean oil), can also be used. Engines with
appropriate modifications can also run on hydrogen gas, wood gas, or charcoal gas, as well as
from so-called producer gas made from other convenient biomass. Recently, experiments have
been made with using powdered solid fuels, such as the magnesium injection cycle.
Internal combustion engines require ignition of the mixture, either by spark ignition (SI) or
compression ignition (CI). Before the invention of reliable electrical methods, hot tube and flame
methods were used. Experimental engines with laser ignition have been built.
GASOLINE IGNITION PROCESS:
Gasoline engine ignition systems generally rely on a combination of a lead-acid battery and an
induction coil to provide a high-voltage electric spark to ignite the air-fuel mix in the engine's
cylinders. This battery is recharged during operation using an electricity-generating device such
as an alternator or generator driven by the engine. Gasoline engines take in a mixture of air and
gasoline and compress it to not more than 12.8 bar (1.28 MPa), then use a spark plug to ignite the
mixture when it is compressed by the piston head in each cylinder.
DIESEL IGNITION PROCESS:
Diesel engines and HCCI (Homogeneous charge compression ignition) engines, rely solely on
heat and pressure created by the engine in its compression process for ignition. The compression
level that occurs is usually twice or more than a gasoline engine. Diesel engines will take in air
only, and shortly before peak compression, a small quantity of diesel fuel is sprayed into the
cylinder via a fuel injector that allows the fuel to instantly ignite. HCCI type engines will take in
both air and fuel but continue to rely on an unaided auto-combustion process, due to higher
pressures and heat. This is also why diesel and HCCI engines are more susceptible to coldstarting issues, although they will run just as well in cold weather once started. Light duty diesel
engines with indirect injection in automobiles and light trucks employ glowplugs that pre-heat
the combustion chamber just before starting to reduce no-start conditions in cold weather. Most
diesels also have a battery and charging system; nevertheless, this system is secondary and is
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added by manufacturers as a luxury for the ease of starting, turning fuel on and off (which can
also be done via a switch or mechanical apparatus), and for running auxiliary electrical
components and accessories. Most new engines rely on electrical and electronic engine control
units (ECU) that also adjust the combustion process to increase efficiency and reduce emissions.
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INTRODUCTION
Waukesha engine which is the driver of the Ariel Compressor and the Cooler is a 4 Stroke V
type Engine. Basically this engine has four strokes i.e. Intake, Compression, Power, Exhaust to
complete its cycle. A Stroke is length between TDC (Top Dead Center) and BDC (Bottom Dead
Center) of the cylinder.
FLYWHEEL
Flywheel is basically a Mechanical Storage Device used during starting and balancing of
crankshaft of the engine during its operations. Initially it is driven by the pneumatic starter motor
to give drive to crankshaft at starting of the engine. It has 36 reference points and two pick up
coils which send signals to the ESM which in turn controls the Electronic governor which
controls the speed of the engine.
CRANKSHAFT
Crankshaft which is the main driver converts the reciprocating motion of connecting rod of the
piston into rotary motion. In each stroke the crankshaft rotates 180 degrees; hence it completes
two revolutions in the four strokes
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CAMSHAFT
Camshaft which is driven by crankshaft is used to operate the inlet and exhaust valves of the
Engine cylinder through push rods and rocker arms.
CROSS HEAD
A crosshead is a mechanism used in large reciprocating engines and reciprocating compressors
to eliminate sideways pressure on the piston. It is generally used for smooth transfer of motion
between connecting rod and crankshaft.
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CARBURETOR
Carburetor is basically a mechanical device which is used to deliver an exact air fuel ratio to the
engine cylinders through intake manifold. A butterfly valve is installed in the carburetor which
performs this function.
GOVERNOR
Waukesha engine has an electronic governor which controls the flow of the air fuel mixture
delivered to the cylinders hence controlling the speed of the crankshaft.
SPARK PLUGS
Spark plug is used to produce spark during the power stroke of the engine. The spark plugs get
current from the extension assembly of theIgnition Coils which are energized by the 24 volts
batteries of the ignition system.
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ACTUATOR
149
FUEL SYSTEM
Fuel system comprises of three components i.e.
1. Pressure regulator (both on left and right side) one for each carburetor
2. Carburetor on both sides
3. Air Fuel Ratio Control (ESM)
Pressure regulator ensures steady fuel supply to the carburetor. All engines have one main fuel
gas pressure regulator and it reduces the incoming fuel supply pressure to the carburetor.
CARBURETOR
PRESSURE REGULATOR
IGNITION SYSTEM
Ignition system comprises of the following components
1. ESM Ignition System
2. Spark Plugs
3. Ignition Coils
4. ESM Knock Detection Control
5. Wiring
150
The ESM controls spark plugs timing. ESM system detects detonation by monitoring vibrations
at each cylinder with engine mounted knock sensors. When a signal exceeds a detonation
threshold the ESM system retards timing incrementally on an individual cylinder to keep
cylinders safe from knocking.
151
INTAKE MANIFOLD
TURBOHARGER
INLET FILTER
152
EXHAUST SYSTEM
Exhaust system consists of following components
1. Exhaust Manifold
Exhaust gases resulting from combustion of each cylinder enters the exhaust manifold through
exhaust valves.
2. Exhaust Waste gates
A water cooled exhaust waste gate is mounted at the outlet of each exhaust manifold. It controls
the flow of exhaust gases to turbocharger..
3. Turbocharger
The exhaust gases from the cylinders turn the turbine side of the turbocharger which drives the
compressor and compresses the air.
EXHASUT MANIFOLD
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LUBRICATION SYSTEM
Main Lubrication System comprises of the following parts
1. Oil Pan and Pickup Screen
The bottom of crankcase is enclosed by oil pan. The oil pickup screen prevents the entry of
foreign material into the oil circuit.
2. Oil Pump
The gear driven oil pump is externally mounted in front of the engine below the crankshaft. It
draws oil from the oil pan and delivers it to the oil cooler.
3. Oil Cooler
It is type of small shell and tube heat exchanger in which the coolant flows through the tubes to
cool down the lube oil which is in the shell side.
OIL COOLER
4. Temperature Control Valve
It controls the temperature of the lube oil. If its temperature is low it is sent back to the oil pan
for further lubrication or it is sent to cooler for cooling.
1. JACKET WATER CIRCUIT
a) Jacket Water Header
There are special passages in crankcase and cylinder for the flow of the coolant to keep their
temperature low and this system is known as jacket water system.
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b) Exhaust Manifold
Exhaust manifold assembly is composed of individual water cooled segments which cools the
exhaust gases from the cylinder.
c) Jacket Water Pump
A belt driven centrifugal pump is mounted at the front of the engine which is used to pump water
from the cooler into the water jackets in the engine.
d) Water Manifold
Water manifold receives cooling water from each system of exhaust manifold and routes it to the
thermostat housing for temperature sensing for routing it to cooler or back to engine.
e) Jacket Water Control Valve
During the startup of engine parts are cool and the desired temperature in the cylinders is not
achieved yet. As the temperature is achieved this valve turns on the cooling system.
2. AUXILIARY COOLING WATER CIRCUIT
Auxiliary water pump is also belt driven and is located on the lower left front side of the engine
which pumps the coolant of auxiliary system.
a) Intercoolers
It cools the inlet air to the turbocharger to provide denser air to the turbocharger.
b) Oil Coolers
It is type of small shell and tube heat exchanger in which the coolant flows through the tubes to
cool down the lube oil which is in the shell side.
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TECHNICAL DATA
Cylinders
Piston displacement
Compression ratio
Bore & stroke
Jacket water system capacity
Lube oil capacity
Starting system
Dimensions l x w x h inch (mm)
Weights lb (kg)
TECHNICAL DATA
V12
7040 cu. in. (115 L)
8:1
9.375 x 8.5 (238 x 216)
100 gal. (379 L)
190 gal. (719 L)
125 - 150 psi air/gas 24V electric
147 (3734) x 85 (2159) x 97.83 (2485)
21000 (9525)
PERFORMANCE DATA
PERFORMANCE DATA
1200 RPM
1680 (1253)
Power bhp (kWb)
BSFC (LHV) Btu/bhp-hr (kJ/kWh)
7881 (11149)
Fuel Consumption Btu/hr x 1000 (kW)
13240 (3881)
EMISSIONS
NOx g/bhp-hr (mg/Nm3 @ 5% O2)
13.30 (4922)
CO g/bhp-hr (mg/Nm3 @ 5% O2)
11.20 (4140)
3
NMHC g/bhp-hr (mg/Nm @ 5% 02)
0.35 (131)
3
THC g/bhp-hr (mg/Nm @ 5% O2)
2.40 (873)
HEAT BALANCE
Heat to Jacket Water Btu/hr x 1000 (kW)
3849 (1128)
Heat to Lube Oil Btu/hr x 1000 (kW)
567 (166)
Heat to Intercooler Btu/hr x 1000 (kW)
179 (53)
Heat to Radiation Btu/hr x 1000 (kW)
724 (212)
Total Exhaust Heat Btu/hr x 1000 (kW)
3900 (1143)
INTAKE/ EXHAUST SYSTEM
Induction Air Flow scfm (Nm3/hr)
2424 (3651)
Exhaust Flow lb/hr (kg/hr)
11273 (5113)
Exhaust Temperature F (C)
1179 (637)
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1000 RPM
1400 (1044)
7693 (10882)
10781 (3156)
12.90 (4782)
9.40 (3477)
0.34 (127)
2.30 (844)
3227 (946)
462 (135)
122 (36)
642 (188)
2962 (868)
1972 (2970)
9171 (4160)
1112 (600)
6.3.1.2 COOLER
INTRODUCTION
The cooler or heat exchanger used for the cooling of flash gases and the coolant of engine and
compressor has six stages which is manufactured by ACE (One stage for the cooling of engine
and compressor and the other five are for the cooling of the flash gases). The cooling is carried
out by two forced draft fans which are used to exchange the heat of coolant with the atmosphere
through finned tubes. These fans are driven by the crankshaft of the engine through belt and
pulley mechanism. It is an air cooled heat exchanger. A special coolant is used for the cooling of
engine which is demin water. This coolant is also cooled down by this heat exchanger. Weight of
the cooler is 27 tones.
FAN DATA
Number of Fans: 02
RPM: 343
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Diameter: 156
Number of Blades: 06
AIR DATA
T (0F)
Pre-Cooler
110
55
55
135
45
90
146
50
96
200
105
95
After Intercooler
210
124
86
160
90
70
Cooler Stages
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TECHNICAL DATA
Frame is the main housing of compressor in which all the components of the compressor are
arranged like crank shaft, pulsation dampeners, vibration switches etc. Ariel Corporation has two
types of frames JGK, JGT. Frame of the Compressor installed at Makori Production Facility is
JGK/6. 6 shows number of throws or cylinders.
COMPRESSOR DETAILS
MANUFACTURER:
ARIEL CO.
FRAME MODEL
JGK/6
STROKE
5.5"
SERIAL NUMBER
F-37892
NO. OF STAGES
1200 RPM
600 RPM
DIRECTION OF ROTATION
37,000 LBS
40,000 LBS
METHANE, ETHANE
SERVICE (GASES)
CYLINDER DETAILS
CYLINDER NO.1
SERIAL NUMBER
C-131445
CLASS
BORE
15.875"
1 EACH
1 EACH
STROKE
5.50"
HEAD END
0.080"~0.140"
CRANK END
0.04"
HEAD END
17.2
CRANK END
17.8
MAWP (PSIG)
635 PSIG
CYLINDER NO.2
SERIAL NUMBER
C-131446
CLASS
BORE
11"
1 EACH
1 EACH
STROKE
5.50"
HEAD END
0.080"~0.140"
CRANK END
0.04"
HEAD END
18.1
CRANK END
16.8
MAWP (PSIG)
845 PSIG
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CYLINDER NO.3
SERIAL NUMBER
C-131447
CLASS
BORE
12.5"
2 EACH
2 EACH
STROKE
5.50"
HEAD END
0.080"~0.140"
CRANK END
0.04"
HEAD END
18.4
CRANK END
19.5
MAWP (PSIG)
635 PSIG
CYLINDER NO.4
SERIAL NUMBER
C-131448
CLASS
BORE
6.25"
2 EACH
2 EACH
STROKE
5.50"
HEAD END
0.080"~0.140"
CRANK END
0.04"
HEAD END
17.5
CRANK END
21.1
MAWP (PSIG)
2050 PSIG
STAGES
Ariel compressor installed at MPF has 4 stages and 6 throws. The suction pressure of compressor
is 7 PSIG and Discharge is 990 PSIG. 1st and 2ndstage has single throw whereas 3rdand 4thstage
has double throws.
PULSATION DAMPENERS
Pulsation dampeners are installed to remove gas pulsation and provide steady continuous flow.
OPPOSED THROW RECIPROCATING WEIGHT BALANCING
To balance the weight across the crankshaft, the piston motion in opposing cylinders must be
same i.e. if we have compression stroke in the 1st stage cylinder then the strokein 2nd stage
cylinder must also be a compression stroke.
PRESSURE TRANSMITTERS INSTALLED AT THE COMPRESSOR
Pressure transmitters are installed at compressor oil, 1st stage suction line and discharge line, 2nd
stage suction line and discharge line, 3rd stage suction line and discharge line, 4th stage suction
line and discharge line and side stream line.
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COMPRESSION PRINCIPLE
Compression is accomplished
by the main and secondary
rotors synchronously meshing
in a one-piece cylinder. The
main rotor has four (4) helical
lobes 90 degree apart.
The secondary rotor has six
(6) matching helical grooves
60 degree apart to allow
meshing with main
rotorlobes.
The air inlet port is located on
top of the compressor
cylinder near the drive shaft end. The discharge port is near the bottom at the opposite end of the
compressor cylinder. Figure is an inverted view to show inlet and discharge ports. The
compression cycle begins as rotors unmesh at the inlet port and air is drawn into the cavity
between the main rotor lobes and secondary rotor grooves (A). When the rotors pass the inlet
port cutoff, air is trapped in the interlobe cavity and flows axially with the meshing rotors (B).
As meshing continues, more of the main rotor lobe enters the secondary rotor groove, normal
volume is reduced and pressure increases.
Oil is injected into the cylinder to remove the heat of compression and seal internal clearances.
Volume reduction and pressure increase continues until the air/oil mixture trapped in the
interlobe cavity by the rotors passes the discharge port and is released to the oil reservoir (C).
Each rotor cavity follows the same fill-compress-discharge cycle in rapid succession to
produce a discharge air flow that is continuous, smooth and shock free.
165
COMPRESSOR PARTS
COMPRESSOR
166
167
AIR FILTER
DRIVE MOTOR
168
169
AIR-COOLED UNITS
A combination oil/aftercooler is supplied as standard equipment on all air-cooled
units. The air-cooled unit with the standard enclosure requires sufficient flow for the
compressor oil/aftercooling system and for electric motor cooling. Air is drawn into the unit at
the motor side of the enclosure and is exhausted at the oil cooler side. For continuous efficiency,
oil cooler cores must be periodically cleaned with either vacuum or compressed air.
170
CONTROL DEVICES
CONTROLLER
This compressor unit features the AUTOSENTRY controller, which integrates all the control
functions under microprocessor control. Its functions include safety and shutdown, compressor
171
regulation, operator control, and advisory/maintenance indicators. The keypad and display
provide the operator with a logical and easily operated control of the compressor and indication
of its condition. The controller is factory adjusted for the compressor package, but allows tuning
for specific applications.
RELIEF VALVE
A pressure relief valve(s) is (are) installed in the final discharge line and set to approximately
120-125% of the units full load operating pressure for protection against over pressure.
BLOWDOWN VALVE
This valve normally is used for control functions, but also serves to
relieve reservoir pressure following a shutdown. The blow down
valve is a two-way solenoid valve which is piped into the oil
reservoir outlet ahead of the minimum pressure valve. When the
solenoid is deenergized, the valve opens and the coolant system is
blown down. When the solenoid is energized, the valve closes to
allow the coolant system to pressurize. A control air check valve is
provided to ensure that the inlet valve is closed during blow down.
MINIMUM DISCHARGE PRESSURE/CHECK VALVE
An internal spring-loaded minimum pressure valve is used in the final discharge line to provide
a positive pressure on the coolant system of the compressor even if the air service valve is fully
open to atmospheric pressure. This valve also functions as a check valve to prevent back flow of
air from the shop air line when the unit stops, unloads, or is shut down. The valve incorporates a
spring-loaded piston which maintains approximately 65 psig in the oil reservoir. When the air
pressure on the upstream (reservoir) side of the valve rises above 65 psig, the spring is
overridden and the valve opens to full porting.
INLET VALVE
The Inlet valve restricts the inlet to control delivery and closes to unload the compressor. At
shutdown, the inlet valve closes to prevent the back flow of air. The inlet valve position is
controlled by air pressure in its piston cylinder, which is controlled by the AutoSentry
172
Controller through solenoid valves IVC and IVO. As Pressure to the piston is increased, the
valve closes to restrict air flow and compressor delivery.
173
SHUTTLE VALVE
Also known as a double check valve, the shuttle valve is a device
which will take two (2) supply signals and allow the one with the
highest pressure to pass through. The shuttle valve is used to provide
control air pressure from either the reservoir or plant air system, as
required during different operating conditions.
PURGE AIR VALVE
The purge valve is a normally closed two-way air actuated valve that admits purge air from the
final discharge manifold to the compressor to counteract the oil knock that occurs in oil-flooded
rotary screw compressors when they are completely unloaded with pressure in the oil reservoir.
This valve is controlled by the same control pressure which controls the inlet valve.
SYSTEM PRESSURE TRANSDUCER
This transducer is connected after the minimum pressure valve. It converts the pressure in the
plant air system into an electrical signal for use by the AutoSentry controller for modulation
and control.
RESERVOIR PRESSURE TRANSDUCER
This transducer is connected to the coolant system. Its signal is used to prevent loaded starts,
monitor reservoir pressure, and monitor the condition of the air/oil separator.
AIR FILTER VACUUM SWITCH
This switch is used to monitor air filter condition and alert the user if the filter requires service or
replacement.
DISCHARGE THERMISTOR
This sensor is located directly in the compressor discharge. Its signal is used
to monitor compressor temperature and shut down the compressor if a coolant problem is
detected.
RESERVOIR THERMISTOR
This sensor is located near the separator and is used to monitor temperature and shut down the
compressor if high temperatures are detected.
EMERGENCY STOP PUSH-BUTTON
This is a maintained push-button, and removes power from the controller outputs regardless of
controller status. It is located on the upper section of the panel, next to the keypad. This should
be used for emergency purposes only - use the keypad [STOP/RESET] for normal controlled
stopping.
CONTROL TRANSFORMER
This control device changes the incoming power voltage to 110-120 volts for use by all unit
control devices. The transformers employed are usually connectable for several input voltages,
refer to the transformer label for connection prior to energizing. Two primaries and one
secondary fuse are provided. Refer to adjacent labelling for replacement information.
174
TERMINAL STRIP
This provides connections for all 110-120 volt devices not contained within the enclosure.
FAN STARTER
The starter is used to provide control and overload protection for the cooling fan or the
ventilation fan of water-cooled units with enclosure. Overload heaters should be selected and
adjusted based on the motor nameplate amps and the instructions located inside the cover of the
electrical enclosure. Three fuses are provided. Refer to adjacent labelling for replacement
information.
MAIN STARTER
This starter is used to provide control and overload protection for the main drive motor.
Full voltage starters employ a single contactor, overload heaters should be selected and adjusted
based on the motor nameplate amps and the instructions located inside the cover of the
enclosure. Wye-delta starters employ three contactors which are controlled sequentially to
provide low current starting. For wye-delta starters, the motor nameplate amps must be first
multiplied by 0.577 before using the heater
175
MAINTENANCE
TROUBLESHOOTING
SYMPTOM POSSIBLE
Compressor fails to start
CAUSE
1. Wrong lead connections.
2. Blown fuses in control box.
3. Motor starter overload
heaters tripped.
4. Pressure in reservoir.
5. Read error message on
control panel
6. Remote Contact is open.
1. High discharge temperature.
2. High discharge temperature
switch malfunction.
3. Blown fuse in starter/
control box.
4. Motor starter overload
heaters trip.
1. Improperly adjusted
control.
2. Air leak in control lines.
3. Restricted control line.
4. Blowdown valve
malfunction.
1. Insufficient receiver
176
REMEDY
1. Change leads.
2. Replace fuse.
3. Reset and investigate cause
of overload.
4. Inspect blow down valve.
5. Take appropriate action.
6. Replace switch or jumper.
1. See High Discharge Air
Temperature this section.
2. Replace switch
3. Replace fuse (investigate if
fuses continue to blow).
4. Reset and investigate cause
of overload.
1. Refer to Manual 13-9-653
and adjust control.
2. Determine source of leak
and correct.
3. Clean control lines.
4 Repair clean or replace
valve.
1. Increase receiver size.
capacity.
2. Restriction in service piping 2. Inspect and clean service
piping.
3. Restriction in control
3. Inspect and clean control
tubing.
tubing.
4. Plugged aftercooler.
4. Inspect and clean
aftercooler.
1. Contact your champion
Compressor starts too slowly 1. Wye Delta switch time set
too long.
distributor.
2. Minimum Pressure/Check
2. Repair or replace.
Valve is faulty.
3. Supply voltage is too low.
3. Check the supply voltage.
1. Restricted air filter.
1. Clean or replace filter.
Compressor is low on
delivery and pressure
2. Sticking inlet valve.
2. Inspect and clean inlet
valve.
3. Minimum pressure valve
3. Replace valve.
stuck closed.
4. Leaks in the compressed air 4. Check for leaks fix any
system.
leaks found.
5. Aftercooler is frozen
5. Thaw out. This machine
cannot operate in temperatures
below 320 F (00 C).
6. Unload pressure adjusted
6. Adjust the unload pressure.
too low.
See Manual 13-9-653.
1.
Oil
carryover
through
lines.
1. See Oil Carryover in this
Excessive oil consumption
section.
2. Oil leaks at all fittings and
2. Tighten or replace fittings
gaskets.
or gaskets.
3. Shaft seal leaking.
3. Replace shaft seal.
High discharge air
1. Thermostatic mixing valve 1. Repair or replace valve.
temperature
stuck open.
2. Dirty or clogged cooler
2. Clean cooler.
face.
3. Insufficient cooling air flow 3. Provide unrestricted supply
of cooling air.
4. Clogged oil filter or cooler
4. Replace filter or clear
(interior)
cooler.
5.Low compressor oil.
5. Add oil to proper level.
Oil carryover
1. Overfilling the reservoir.
1. Drain excess oil from
system.
2. Clogged
2. Tighten or replace faulty
lines.
3. Ruptured oil separator
3. Replace element.
element.
4. Loose assembly.
4. Tighten all fittings and
load to unload excessively
177
178
gaskets.
5. Use Gardner Denver AEON
4000 or 9000 SP lubricating
coolant.
6. Replace seals in valve.
7. Reduce temperature. See
High Discharge Air
Temperature this section.
8. Replace check valve.
9. Check oil reservoir
temperature and if low change
thermal mixing valve element
to higher temperature.
179
STANDARD FEATURES
Ajax integral engine-compressors are gas compressors with built-in two cycle natural gas engine.
The slow speed (440 rpm max), simplistic design make this compressor highly reliable, low
maintenance and easy to operate. Ajax is the compressor of choice in its power range (105-600
KW) and it is common to see several Ajax machines in one compressor station. Standard features
include:
1. Hydraulic fuel control system: for optimum fuel efficiency.
2. Babbitt sleeve and/or Double-row tapered roller bearings: for maximum loading in
extreme application conditions.
3. Power cylinders: two-cycle, low-BMEP, chrome-plated, with fewer parts for less
maintenance. Require no gas control valves.
4. Crosshead guides: absorb (relieve) crank stresses on the cylinder and prevent
contamination of lube oil in crankcase.
5. Splash lubrication system: no oil pump, filter or cooler required for main and
connecting rod bearings. Oil-bath lubrication system is sealed from combustion process
in the cylinders.
6. Reliable ignition: solid-state, time-based ignition system without distributor.
7. Efficient lubrication: force-fed lubrication system for power and compression cylinders,
with lube point injection and divider block.
8. Crosshead structure with Babbitt facing at both the power and the compressor ends.
9. Crankshaft and Connecting rods: closed-die forged in precision dies.
10. Crankcase: ribbed, cast iron construction for durability.
11. Distant piece (intermediate casing): API-Type II extra-length design for easy rod
packing maintenance.
12. High rod load and cylinder working pressure: full-load operation through a variety of
compression ratios up to 6:1 per stage.
13. Compressor cylinders: large gas passages and valve flow areas for high efficiency.
14. High-quality differential poppet valves.
15. Cylinder clearance/loading regulation: manual, hand-wheel type, variable-volume
extra clearance pocket with indicator allows the cylinder unloading without depressurizing.
The model line of Ajax compressors includes four basic models (according to the number of
power cylinders: DPC 2801, DPC 2802, DPC 2803, DPC 2804). Maximum shaft power for the
largest compressor DPC 2804 is about 600 kW.
180
ENGINE CYLINDERS
2. Integral compressor frame mount (skid). The steel skid is mounted and secured on a
foundation plate fabricated according to the manufacturers drawings. The steel skid is
built for heavy-duty service and designed to carry reciprocating compressor with gas
engine drive including auxiliary systems and process equipment.
3. Separators (scrubbers) one set at the inlet to compression stage and another set at the
outlet from aftercooler section provide 95% efficiency for separation of liquid droplets
larger than 5 m. Each separator is equipped with a pressure-relief valve which is
181
mounted directly on the separator or on the connecting piping, automatic drain valve, and
condensate level gauges for the automatic high-level emergency tripping system.
4. Suction and discharge surge tanks are provided at the inlet and discharge connections.
Gas flow pulsations occurring during the operation of reciprocating compressor are
dampened in surge tanks and supply pipelines which are designed and intended to
suppress pressure fluctuations up to +\-5% of the peak ratio 2.5:1 under standard gas
conditions. Discharge surge tanks are fitted with suitable connections for drain lines,
pressure and temperature gauges.
182
5. Oil lubrication system for compressor and engine crankcase and power and compression
cylinders comprising the following:
o Lube oil crankcase for lubrication of crankshaft, bearings and crossheads
o Lube oil storage tank for lubrication of cylinder faces and gland seals of
compressor and drive rods
o Main lubricator driven by crankshaft for oil supply to the cylinders
o Instrumentation for lube oil system performance monitoring
o Lube oil piping set
o Hand pump for pre-lubrication of main bearings, connecting rod bearings and
crossheads
o Pre-lubrication and lube oil pre-heating system with oil supply to crankshaft,
bearings and crossheads
o Thermostatic valve
o Oil level regulator and low-level switch
o Pressure-relief device (safety valve)
183
ALTERNATOR
o
o
o
o
o
o
o
o
o
185
COOLING PUMP
10. Gas air cooler of prefabricated, modular design comprising the following:
o Liquid cooler section for compressor and engine cylinders cooling system
o Compressed gas cooling section (according to the number of compression stages)
o Fan with V-belt motor drive
o Set of piping and flange connections to the main lines
o Casing with skid (frame) for housing all equipment above listed
o Air cooler located outside the main compressor skid on a separate foundation.
186
FAN COOLER
11. Fuel gas injection system. Patented, cam gear-actuated hydraulic fuel injection system
provides optimum fuel efficiency. Fuel preparation technology based on "internal
carburation system" makes it completely unnecessary to employ any additional devices
for reduction of hazardous emissions. Dual ignition (with antechamber) is designed to
ensure complete fuel combustion resulting in less generation of NOx.
SPARK PLUG
12. Drive exhaust system comprising the following:
o One silencer for power drive exhaust system (vertically mounted on the common
skid) with pipe connections to cylinder exhaust manifolds.
13. Compressor piping system comprising the following:
o Complete set of interstage piping for connection of compressor gas path elements
from the suction drum inlet flange to the discharge stage outlet flanges
187
o
o
o
o
ENGINE
COMPRESSOR
MODEL
Serial No.
Bore(in)
Stroke(in)
Rating at 100F ambient & 1500
FASL (KW)
Rating at 100F ambient & 1500
FASL (BHP)
Rod Load(lbs)
Rated RPM
Speed range(Minimum)
Speed range(Maximum)
Deration for each 1000 over 1500
elevation
Number of power cylinders
Model Cylinder(1)
Model Cylinder(2)
Serial No. Cylinder (1)
Serial No. Cylinder (2)
Throws
Stroke(in)
Stroke(cm)
Rod diameter (in)
Rod diameter (cm)
Rod load (lbs)
Rod load (KN)
Suction pressure
Discharge pressure:
188
DPC-2802 LE
85047
15
16
298.3
384
30000
440
300
440
3
2
13 YK11F
6 YKCD
14015
13976
2
11
27.94
2.5
6.35
33000
147
26-28 psi
1220 psi
TEMPERATURES
TEMPERATURES
st
352 F
367 F
855 F
855 F
192 F
200 F
189
SPECIFICATIONS
Model
Serial No.
Leak(psig)
HYD(psig)
Suction pressure (kPa)
Discharge Pressure (kPa)
Starting Current (A)
SPECIFICATIONS
P250VSD
2555898
313
470
175
1100
2200
for inspection. Read this instruction manual carefully before undertaking any work on the
system.
This screw compressor is classified as a positive displacement rotary type. It compresses the
refrigerant gas continuously using the volume change between two rotating screw profile rotors.
Refrigerant gas is trapped in the clearance between the two mated rotors and pressure increased
by decreasing the volume. The refrigerant is then discharged as a high-pressure gas.
COMPRESSOR STRUCTURE
191
COMPRESSION PHASE
As the rotors further rotate, the suction side of the
clearance is sealed by the mating of the lobes and the
volume between the lobes decreases while the sealing
line moves toward the discharge side.
COMPRESSION PHASE
193
DISCHARGE PHASE
When the volume is decreased to the designated Vi, the clearance between the discharge port and
the rotors is linked and the refrigerant is pushed to the discharge side.
DISCHARGE PHASE
194
In other words, Vi is the ratio of the groove volume after competition of suction to the volume
when the discharge port opens. Conventional screw compressors have three fixed Vi values, that
is 2.63, 3.65 and 5.80, termed L port, M port and H port, respectively. The relationships
are:
Vi = (Pd/Ps)1/k or Vik = Pd/Ps
Consequently, the Vi corresponding to the compression ratio changes according to the refrigerant
used.. The new V-Series, Maximizer Series Screw Compressors, are designed so that the Vi can
Be adjusted on site according to operating conditions.
195
VARIABLE Vi MECHANISM
The Vi of a conventional screw compressor is determined by the combination of the axial
discharge port of the rotors on the bearing head and the radial discharge port of the shaft (radial
discharge port on the unloader slide valve). In the case of a conventional model, the axial and
radial elements are combined to exhibit particular characteristics at partial load. In the case of VSeries compressors, the Vi can be changed by altering the size of the radial port while
196
maintaining the axial port at Vi 5.10. As shown, the radial port of a conventional model becomes
larger as Vi becomes smaller. In the case of V-Series compressors, the stop position of the
variable Vi unloader slide valve moves to the discharge side and changes Vi by reducing the size
of the radial port at full load operation. The refrigeration capacity changes only slightly under
various Vi and other conditions. Refrigeration capacity is influenced considerably by shaft power
but changes little inresponse to slight changes in operating conditions, as the diagram shows,
consequently, once Vi is adjusted to the operating conditions, it is not necessary to alter it in
response to slight changes in operating conditions. The Vi must be adjusted only when there are
major changes in operating conditions such as a change in the application of the compressor. For
instance, when the operating conditions of the compressor are changed from cooling at approx.
0C evaporative temperature to refrigeration at -400 C evaporative temperatures with the
compressor Vi set to the L port configuration, shaft power must be double. In such a case it is
advisable to change the Vi to the H port configuration. Similarly, if the compressor is to be used
for refrigeration at an evaporative temperature of 00C-300C, it is advisable to set the Vi to the M
port configuration. Temperature drops and the compression ratio Vi increases as refrigeration
progresses but Vi should not be changed according to the varying conditions. The Vi should be
fixed during operation (when Vi must be changed according to operating conditions, a
Maximizer Screw Compressor, namely a new V-Series unit, should be used).
197
OIL FLOW
198
199
GENERATORS
7.1 GAS GENRATOR
The gas generator is the main source of electrical energy at the plant. It is operated by fuel gas
and responsible for running the following instruments
Condenser
Glycol circulation pumps
Loading pumps
Mycom compressor
Lube oil pump
Coolant pump
Lights
Instrument air compressor
CCR/MCC room
200
SR-4B
Serial No.
5YA01192
Arrangement No.
6I-4848
Volts
480 V
Frequency
60 Hz
Power
765KW/956 KVA
Amperes
1503A
RPM
1200
G3516
16
Vee Type- 4 stroke
Spark Ignition
170 mm (6.7 in.)
190 mm (7.5 in.)
69 L (4210 cu. in.)
Turbocharged-Aftercooled
Electronic (ADEM A3)
Low Emission (Lean Burn)
8015 kg (17670 lb)
8 kg/kW (13.2 lb/bhp)
19.3 bhp/L
217.7 L (57.5 gal)
200.6 L (53 gal)
17 L (4.5 gal)
424 L (112 gal)
1000 hours
Counterclockwise
SAE No. 00
183
1200
56499
201
137 F
62 psi
190 F
7.5psi
9 psid
132.51 in
Width
67.05 in
Height
67.7 in
The total running load of the plant is 450KW. The gas generator is operated at the 45-50% load.
202
AIR INLET
TURBOCHARGER
CONTROL SYSTEM
Governor, RH, 3161 with self contained synthetic oil sump.
Air-fuel ratio control, mechanical speed control, without torque control.
Governor control, positive locking
203
COOLING SYSTEM
Thermostats and housing for conventional core radiator
Jacket water pump, gear driven, centrifugal
RADIATOR
EXHAUST SYSTEM
Exhaust manifold, dry
EXHAUST PIPE
204
FLYWHEEL
FUEL SYSTEM
Fuel filter, with service indicators, cartridge type with RH service
Fuel transfer pump
INSTRUMENTATION
Instrument Panel, RH
Engine oil pressure gauge
Fuel pressure gauge
Oil filter differential gauge
Jacket water temperature gauge
Service meter, electric
Tachometer
CONROL PANEL
205
LUBE SYSTEM
Crankcase breather, top mounted
Oil cooler
Oil filler and dipstick, RH
Oil pump
Oil filter, cartridge type with RH service
Shallow oil pan
CRANKCASE BREATHER
MOUNTING SYSTEM
Rails, mounting, engine length, 254 mm (10 in), industrial-type, C-channel.
POWER TAKE-OFFS
Accessory drive, upper RH
Front housing, single sided
PROTECTION SYSTEM
Junction box
Manual shutoff, RH
Safety shutoff protection, energized to shutdown
Low oil pressure, low idle 69 kPa (10 psi); high idle
207 kPa (30 psi)
Water temperature
Overspeed
3161 governor solenoid energized to shutdown
STARTING SYSTEM
Starting switch
206
GENERAL
Paint, Caterpillar Yellow,
Vibration damper and guard,
Lifting eyes
60 Hz
Power
1000KW/1200KVA
Amperes
1503A
RPM
1800
207
PUMPS
8.1 DEFINITION
Pumps are the devices that take the suction at low pressure and discharge the liquid at high
pressure.
8.2 TYPES
They are classified into two main categories
1. Centrifugal pumps
2. Positive displacement pumps
The pumps that are installed at the facility belong to both categories. The centrifugal type pumps
are installed at loading area, third stage degasser and refrigerant accumulator. The pump that is
used to pump lube oil is gear pump, the pump used with glycol is plunger pump and the pump
installed with the HP and LP knock out drums are diaphragm pumps that all fall into the category
of PD pumps.
The faster the impeller rotates, higher is the discharge pressure and flow rate of the pump. The
centrifugal pump have higher flow rate as compared to PD pumps. The type of pump to be used
for specific application depends upon:
Type of liquid
Viscosity of liquid
Flow rate required
Distance and elevation which liquid has to travel.
PARTS OF CENTRIFUGAL PUMP
SUCTION PORT: this is where liquid enters the pump from the pipeline.
CASING: The outside cover of the pump body is called casing. The outer rim of the casing is
known as volute.
IMPELLER: It is the main working part of the pump, which directs the liquid and increases its
velocity.
WEAR RINGS: These rings protect the pump casing and impeller from wear caused by
vibration. Pumps fluids lubricate the rings.
SHAFT: One end of shaft is connected to prime mover or driver while the other end with the
impeller.
SHAFT SLEEVE: It is a metal tube that slips over the shaft to form a very close fit. It protects
the shaft from damage caused by too tight packing.
BEARING: Bearings are fitted around the pump shaft at the part of pump body where the shaft
enters. Bearings are housed inside an extension to pump casing, the lower part of which act as a
reservoir to contain oil. This oil is used to lubricate the bearings.
LUBRICATION OF PUMP PARTS
The bearings are lubricated by the oil present in the bearing housing. The shaft is surrounded by
the loose fitted steel rings called slinger rings which hang down into the lubricating oil. As the
shaft rotate, the rings are rotated with shaft causing the lubrication of shaft. Wear rings are fitted
between the impeller collar and pump casing. The small gap is maintained between these faces
209
so minimizing the frictional wear of the wear rings. During the operation of pump, fluid
continuously flows through these spaces causing the lubrication of wear rings. As result of
vibration the wear rings would be damaged first.
SHAFT SEALS
Seals are used to prevent the leakage of the liquid to be pumped. They are fitted around the pump
shaft and inside the body casing extension. The compartment which holds the seal is known as
stuffing box. Two types of seals are commonly used:
Soft Seal
Mechanical Seal
The pumps that are being used at Makori contain the Mechanical Seals.
PLUNGER PUMP
diaphragm moving up), the pressure decreases, and fluid is drawn into the chamber. When the
chamber pressure later increases from decreased volume (the diaphragm moving down), the fluid
previously drawn in is forced out. Finally, the diaphragm moving up once again draws fluid into
the chamber, completing the cycle. Diaphragm pumps have good suction lift characteristics,
some are low pressure pumps with low flow rates; others are capable of higher flows rates,
dependent on the effective working diameter of the diaphragm and its stroke length. The pumps
are operated by the instrument air and hence they are known as pneumatically driven pumps.
Pneumatic Air
DIAPHRAGM PUMP
212
213
FLOWSERVE PUMPS
Three Vertical Single Stage Motor Driven Centrifugal Pumps are installed near Degaser.
Siemens Motor is used to drive them.
There purpose is to transport condensate from degaser to Heat Exchanger to Storage Tanks.
TAG DATA
Serial No.
Equipment No.
Purchase Order
Model
Size
MDP
Material
Date
FLOW SERVE(1)
0106-1197 B
21-P-02B
0260061
MK3 Vertical In-Line
2K4X3V-10/10.00RV
275 psi @ 100 F
D4/CF8M
08/FEB/2006
214
Serial No.
Equipment No.
Purchase Order
Model
Size
MDP
Material
Date
FLOW SERVE(2)
0106-1196 A
21-P-01A
0260061
MK3 Vertical In-Line
2K3X1.5V-13/9.69RV
230 psi @ 100 F
D4/CF8M
07/FEB/2006
Serial No.
Equipment No.
Purchase Order
Model
Size
MDP
Material
Date
FLOW SERVE(3)
0106-1196 B
21-P-01B
0260061
MK3 Vertical In-Line
2K3X1.5V-13/9.69RV
230 psi @ 100 F
D4/CF8M
07/FEB/2006
215
TAG DATA
Serial No.
Part No.
Max Disc.
Max Supply
WILDEN PUMPS
2 Instrument Air Driven Diaphragm Pumps have been installed with High Pressure Knockout
Drum to pump condensate to Oil Water Separator (OWS).
216
TAG DATA
Desc.
Serial No.
Date
Item No.
M/O No.
WILDEN PUMP
PX1500/AAAAA/WFS/WF/WF
0021150601
11/08/10
15-11577
M829470
1 Instrument Air Driven Diaphragm Pump has been installed with Low Pressure Knockout
Drum.
217
TAG DATA
Desc.
Serial No.
Date
Item No.
M/O No.
WILDEN PUMP
T20/WWWAB/WFS/TF/PF
0021150598
11/08/10
20-10020
M829450
DEAN PUMPS
2 Horizontal Single Stage Motor Driven Centrifugal Pumps are installed with Heating Medium
for pumping TEG. WEG Motors are used here. These pumps are also provided with cooling fins.
COOLING FINS
218
TAG DATA
Serial No.
Size & Model
GPM
Head (feet)
Impeller Dia
Max. Pressure
Max. Temperature
RPM
DEAN PUMP
181532
1x3x8 RA-3146
100
253
8 - 3/8
350 psig. at 650 deg.F.
650 deg.F. at 350 psig.
3500
BEAR PUMPS
2 Duplex Motor Driven Plunger Pumps are used for pumping TEG with TEG Regenerator. WEG
Motors are used here.
219
TAG DATA
SERIAL NO.
MODEL
RATED GPM
RATED RPM
RATED HP
GALS/REV.
SIZE & STROKE
RATED DISCHARGE PRESSURE
DATE
BEAR PUMP
C60161D
CX-5
5
340
5
0.0153
1.00 x 2.25
1350 psi
08/FEB/2008
2 KSB Horizontal Single Stage Motor Driven Centrifugal Pumps have been installed in
this area for loading condensate from storage tanks into boozers. However they are not in
use nowadays.
220
TAG DATA
Type
W. No.
Q
H
N
B.H.P.
KSB PUMPS
RPK 80-250
9972170971/100/2
65 M3/H
20 M
1750 r.p.m
4 KW
TAG DATA
Type
W. No.
Q
H
N
B.H.P.
KSB PUMPS
RPK 80-250
9972170971/100/3
65 M3/H
20 M
1750 r.p.m
4 KW
221
2 Vertical Single Stage Motor Driven GOULDS pumps are installed with one loading
arm for condensate loading. SIEMENS Motors are being used to provide the drive.
TAG DATA
Serial No.
Equipment No.
Purchase Order
Model
Size
MDP
Material
Date
FLOW SERVE(1)
0106-1197 C
21-P-02C
0260061
MK3 Vertical In-Line
2K4X3V-10/10.00RV
275 psi @ 100 F
D4/CF8M
08/FEB/2006
Serial No.
Equipment No.
Purchase Order
FLOW SERVE(2)
0106-1197 A
21-P-02A
0260061
222
Model
Size
MDP
Material
Date
2 Horizontal Single Stage Motor Driven pumps are installed with second loading arm for
condensate loading.
2 Vertical Single Stage Motor Driven BERKELY Pumps are installed. Baldor Reliance
Motors are being used to provide the drive.
223
1 Motor Driven Horizontal Single Stage KSB Centrifugal pump has been installed near
Large Condensate Tank to pump condensate. SIEMENS Motor is used to drive the pump.
224
TAG DATA
Type
W. No.
Q
H
N
B.H.P.
KSB PUMPS
RPK 80-250
9972170971/100/1
65 M3/H
20 M
1750 r.p.m
4 KW
1 Wilden Diaphragm Pump Driven by Instrument Air is also installed here. It transfers
drained water-condensate to OWS.
2 HESKEL Diaphragm Pumps are installed to pump oil for operating SSV and SSSV.
They are operated by Instrument Air and convert 125 psi to 3500 psi for SSV and to 9000
psi for SSSV.
225
TAG DATA
Pump Model
Serial No.
HYD. Pressure
HASKEL INTERNATIONAL
MHP-110
M310-1076
13500 psi max.
1 Williams Singlex Plunger Pump has been installed here to pump Methanol into the line.
226
TAG DATA
Model No.
Serial No.
Max. Pump Pressure
Max. Flow Rate
WILLIAMS PUMP
P500V300
3108771-02
3250 psi 224 BAR
2.3 GPH or 2.71 LPH
2 Motor Driven Horizontal KSB Centrifugal Pumps are used in this area for filling large
water tank or discharging water from the large storage tank to fire monitors in the plant.
They are Driven by Siemens Motor.
TAG DATA
Type
W. No.
Q
H
N
B.H.P.
227
TAG DATA
Client No.
Type
W. No.
Q
H
n
B.H.P.
KSB PUMPS
0430291001
ETANORM G 100-200 G1
18- 8304
300.01 M3/H
76.20 M
3575 r.p.m
76.63 KW
228
TAG DATA
KSB PUMPS
ETA 80/20 AR
21-7-10-6973
Type
W. No.
TAG DATA
Model No.
Serial No.
Max. Pressure
Max. Temperature
Mfg. Date
AURORA PUMPS
PVM4-90 Flange 1-1/4 300# 4-bolt EPDM
1854426-10
360 psi
250 F
04/11/2008
229
1 Instrument Air Driven Wilden Diaphragm Pump is used to fill MEG in the MEG
Accumulator.
2 UNION Motor Driven Singlex Plunger Pumps are used for the circulation of MEG. 1
pump operates at a time. TECO Motors are used.
230
TAG DATA
UNION PUMP
P-695A
R105252AX
1-1/8 X 2-1/4 SX3
2.5 GPM
1770 LBS.
1200 PSIG @ 800 F
0.0 PSIG @ 200 F
N/A
A Vertical Single Stage Motor Driven Centrifugal Union Pump is used to recirculate
Propane in the circuit. Reliance Electric Motor is used here.
231
TAG DATA
Item No.
Serial No.
Pump Size
Capacity
Head
R.P.M
MAWP
Casting Hydrotest
UNION PUMP
P-860
C0060280A-1
2-1/2/2/10A VLK
35 GPM
250 ft
3550
690 PSIG @ 110F
1100 PSIG
1 MYCOM Motor Driven Gear Pump is used to pump lube oil from Oil Separator to
Compressor. It is an external Gear Pump. Siemens Motor is used to provide the drive.
232
TAG DATA
Model
Serial No.
DP(kg/cm3)
TP(kg/cm3)
AP(kg/cm3)
DP(MPa)
TP(MPa)
AP(MPa)
Ref.
Date
1 Instrument Air Driven Wilden Diaphragm Pump is used to pump condensate from
OWS to Degaser.
233
2 GOULDS Vertical Multi-Stage Motor Driven Centrifugal Pumps are installed here to
pump water from Evaporation pond to Boozers.
234
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236