Qadirpur Gas Plant

Internship Report (CCR-2)

8/119/2016
OGDCL

Prepared By:
Sohail Abbas (CSR Internee)
Shahid Zafar (CSR Internee)

Submitted To:
I/C Process

Front End Compression

General Description:
OGDCL Qadirpur Gas plant is basically gas separation plant. The raw gas, coming from wells,
contains impurities like Hydrogen Sulphide, CO2 and others. So to obtain methane as sweet gas
separation is needed. This plant was built at pressure conditions of 780psig, which was natural
pressure obtaining from the producing wells. Now the pressure of the wells is reduced to almost
305psig. That is why compression of the raw gas is needed to meet the requirement of the plant.
Central Control Room 2 (CCR-2) is responsible for the operation of compression facility and in
addition to this, it also provide the utilities like Instrument air, Plant air and Instrument Nitrogen
to the mother plant.
Raw gas from the wells is transferred to two main headers, named Eastern header and Northern
header. These both headers form a common Header, from which raw gas enters in the slug
catchers, which removes the liquid hydrocarbons forming the condensate and water. Then raw
gas goes to compression facility which includes reciprocating and centrifugal compressors.

1. Gas Gathering System

Raw gas from the different wells in eastern side of the plant meets in a common pipe called as
Eastern Header. And the raw gas from northern wells mixes in the Northern Header.

Header Pipe size (inches) Flow rate (MMSCFD)

Eastern
Northern

26
30

105
235

These two headers having valves to control the flow rate combines form a common header from
which gas is transferred to liquid separation unit to separate liquid droplets in the gas. This liquid
separation unit is called slug catchers.

2. Slug Catchers
The raw gas form the wells contain too much vapors of higher hydrocarbons and water which
can cause damage to compressors. So it is necessary to remove liquid drops before the gas
entering to compressors section. Two slug catchers are installed at the plant operating at same
principle, vessel type slug catcher and Finger type slug catcher. As the gases are of low density
then liquids, they go up direction leaving liquid at bottom. Raw gas leaving the slug catchers is
then routed to the compression section. The process flow diagram from gathering system to the
compressors is shown here.

Fig: PFD Slug Catchers

Reciprocating Compressors
(QICP)
1. Introduction:
Qadirpur Interim Compression Project (QICP) includes fourteen reciprocating compressors
acting on same principle. All of the compressors are engine driven. Each compressor has its own
gas engine. They are installed to meet the demand of main plant. This plant was built at pressure
conditions of 720-750psig, which was natural pressure obtaining from the producing wells. Now
the pressure of the wells is reduced to almost 320psig. That is why compression of the raw gas is
needed to meet the requirement of the plant. These all compressors are operating in parallel
having same suction header and the discharge header. Raw gas from suction header goes to the
inlet of each compressor and after compression; it is discharged into main discharge header, from
where it is transferred to main plant for separation.

2. Compressors Process Description:

Raw gas coming from well headers is introduced in slug catchers to remove liquid contained in
it. After slug catchers, vessel as well as finger type slug catchers, raw gas is transferred to
compression facility. Part of the gas comes in main suction header of reciprocating compressors
and other goes to centrifugal compressors. The properties of suction header line of reciprocating
compressors are illustrated below:
Header
Suction

Diameter
(inches)
26

Temperature
()
105-110

Pressure
(psig)
314-320

Flow rate
(MMSCFD)
150-160

Every reciprocating compressor is getting its suction from suction line in parallel. The suction
line of each compressor contains an emergency shutdown valve to control the flow rate to the
compressor. The raw gas then goes to the inlet of scrubber prior entering to compressor. After
slug catchers gas still contain some liquid droplets which can be dangerous for compressor that is
why the scrubbers are installed at the inlet of each compressor.

i.

Scrubber:

The function of scrubber is to prevent entering of liquid

droplets to the compressor cylinders. It works on the general
gravity separation principal. Gas enters at middle point of
the scrubber vessel. It then passes to demister pad which
removes liquid by settling then down. The scrubber vessel
contain liquid level controller, which controls the liquid
level at desired level. The liquid level is maintained so that
gas cannot escape through bottom drain of vessel. The raw
gas is then discharged from the top of the vessel as shown in
the diagram.
After the scrubber, raw gas enters to the suction bottle of the
compressor.

ii.

Suction Bottle:

Suction bottle gives smooth flow to the compressor. It removes the pulses in the gas which can
cause harm to compressor. It is also known as pulsation bottle.

iii.

Compressor:

The Ariel compressors are reciprocating compressors.

They are double acting balanced opposed two stage
compressors, having four cylinders. In double acting
compressor, gas is compressed on both side of the
piston and also has two discharge strokes per
revolution. Each two opposite cylinders are balanced
opposed shown in diagram. The cranks are arranged so
that the motion of each piston is balanced by the
motion of the piston opposite to it. Raw gas after suction bottle is introduced in the piston at
315psig & 103, which after 1st stage compression goes to the discharged bottle. As
compression causes in rise of temperature, gas is cooled in fan cooler prior entering to 2nd stage
compression. After cooling it is routed to other scrubber to remove moisture and then it goes for
2nd stage compression. After 2nd stage its discharge pressure is about 740psig. The specifications
of each compressor are listed below:

Specs

Designed

Operating

Alarm

RPM
Discharge
Pressure(psig)
Capacity(MMSCFD)

1500
1270

900-1150
720-780

1275
800

40

16-20

NA

iv.

Discharged bottle:

Its working principal and function is same as of suction bottle.

v.

Fin Fan cooler:

Gas after compression enters in cooler in the tubes having fins. Fan of the cooler is driven by
same prime mover (Waukesha engine) of compressor. As raw gas passes from the tubes, fan
blows ambient air on it. All the tubes have fins which increases the heat transfer rate.
The condition of raw gas before and after cooler is as follows:

Condition

Temperature

Entering
Discharge

180
110

Raw gas leaving the fan goes for 2nd stage compression in similar manner as it was in 1st stage
compression. Then raw gas goes to discharge header. The compressors log sheet is illustrated
below:
Compressor Suction
press
(psig)
A-1301
A-1302
A-1303
A-1304
A-1305
A-1306
A-1307
A-1308
A-1309
A-1310
A-1311
A-1312
A-1313
A-1314

Suction
temp()

314
312
315
314

115
112
114
113

Inter
stage
press.
(psig)
524
542
530
540

314

111

306
313
306
313
314

Discharged 1st stage

2nd stage
press.
Discharged Discharged
(psig)
temp()
temp()
750
760
740
752

182
191
188
192

141
166
170
167

532

758

193

153

117
115
116

528
568
455

745
759
750

182
199
109

153
159
180

113
114

536
540

763
768

190
179

166
169

vi.

Discharge Header:

All the gas discharging from each compressor is routed to main discharge header. The properties
of discharged header are as follows:
Header
Discharge

Diameter
(inches)
24

Diagram of whole system is shown below:

Temperature
()
105-110

Pressure
(psig)
740-750

Flow rate
(MMSCFD)
150-160

3. Engine (Waukesha)
There are fourteen numbers of Waukesha engines, one for each compressor, operating at same
principle. Fuel for engine is natural gas which is obtained from fuel gas system. Here some
description is provided.
The Waukesha engine has 12 cylinders, 6 from one side and 6 opposite to it (V type). All of
them are mounted on same crankshaft which rotates primary to reciprocating compressor. The
pistons in the cylinder are timed so that at least three power strokes are occurring at same time.
The main parts of the engine are listed below.

ESM Engine Control unit

Cylinders
pistons
Crankcase
Crankshaft
Camshaft
Intake manifold
Exhaust manifold
Carburetor
Regulator
Turbocharger
Auxiliary water pump
Jacket water pump
Starter motor
Oil pump
Push rod
Rocker arm
Magnetic pickup
Gear train
IPM-D
Flywheel
Oil cooler
Oil filter
Governor actuator
Waste gate

i.

Fuel gas System of engine:

Engine utilizes sale gas (Methane) coming from sale gas headers to fuel gas system. Each engine
gets its fuel from common fuel header having pressure of 180psig and flow rate of 1.9MMSCFD.
At the suction of each engine, fuel gas passes through fuel gas scrubber which restrict liquid
particle to engine carburetor. After scrubber fuel gas goes to gas regulator, which controls the
pressure of gas to 60psig for engine carburetors. Their also exist a line of fuel which goes to
engine starter motor to rotate crankshaft during startup of engine and to pre-lube pumps, which
then goes to vent line.

4. Lubrication System
Lube oil is used as lubricant of engine as well as for compressor. It provides lubrication, cooling
and cleaning to the parts of machine. It prevents wear and tear of equipments. Oil level, pressure
and temperature are maintained in the system. Lubrication system consist of following things

Day Tank: it is used to maintain oil level through the control valves at desired point. It is
simply a vessel for storing lube oil.
Pre lube Pumps: two pumps are only used (one for compressor and one for engine) to
lubricate whole system before starting of the engine and compressor. These both are
pneumatically driven by fuel gas.
Oil pumps: these pumps are shaft driven. They are used for lubrication while the machine
is running.
Oil cooler: it is used to dissipate heat of lube oil which was gained by lube oil during
lubrication, so that the oil can be used effectively again. Auxiliary water is used as
coolant.
Oil filter: it filters oil to remove contaminants carried by oil. Micro spin Filters are used
for filtering engine lube oil.

The conditions of lube oil for compressor as well as for engine are as follows:
Condition
Operating
High Alarm
Trip
Low Alarm
Trip

Compressor
Pressure (psig)
Temperature ()
59
105
250
190
300
195
37
N/A
35
N/A

Engine
Pressure (psig)
Temperature ()
53.6
180
95
190
110
195
37
N/A
35
N/A

During the startup of engine, it is started at offload till the temperature of lube oil reaches at
110 and the rotations reaches at 775rpm.

5. Cooling System
The cooling system provides cooling for compressor and engine. It includes:
Jacket Water Circuit:
Jacket water is provided as a jacket to the engine to cool the whole body of engine. The jacket
water pump rotates the flow of coolant (De-mineralized water) to exchange heat from engine
body. It gets its suction from surge tank. After exchanging heat, water goes to remote heat
transfer devise; here it is fin fan cooler. It has following components:

Jacket Water Header

Water manifold
Jacket Water pump
Fin fan cooler
Control valve

Auxiliary water circuit:

Auxiliary water is coolant for the compressor and engine auxiliaries. It is used as coolant in lube
oil cooler and intercooler. It also has separate pump to rotate the water. It includes

Auxiliary Water pump

Intercooler
Oil cooler
Fin fan cooler
Control valve

Centrifugal Compressors
Introduction
The gas coming from the slug catchers enters in the common suction line of the centrifugal
compressors, from where all three compressors get their suction. The suction pressure of the
compressors is around 305psig. As all three compressors are of same construction, operating
principle and operating conditions, we will discuss here as one compressor (Train-A).
Centrifugal compressors are two stage compressors; 1st stage is called Low Pressure (LP) and
other is High Pressure (HP). The prime mover for each compressor is Gas Turbine. Their tag
names are Turbine Train-A, Turbine Train-B and Turbine Train-C one for each compressor.
These all compressors are operating in parallel having common suction header and the discharge
header. Raw gas from suction header goes to the inlet of each compressor and after compression;
it is discharged into main discharge header, from where it is transferred to main plant for
separation.

Compressors Process Description

Raw gas coming from well headers is introduced in slug catchers to remove liquid contained in
it. After slug catchers (vessel as well as finger type) raw gas is transferred to compression
facility. Part of the gas comes in main suction header of reciprocating compressors and other
goes to common suction header of centrifugal compressors.

i.

Suction Header

The properties of main suction header are illustrated below:

Header
Suction

Diameter
(inches)
26

Temperature
()
105-110

Pressure
(psig)
305-310

Flow rate
(MMSCFD)
200-250

Each centrifugal compressor is getting its suction from common suction header in parallel. The
inlet line of each compressor contains an emergency shutdown valve (Pneumatically controlled)
and also a manual valve to control the flow rate to the compressor. The raw gas then goes to the
inlet of LP scrubber prior entering to compressor because after slug catchers gas still contain
some liquid droplets which can be dangerous for compressor.

ii.

LP Scrubber:

The function of scrubber is to prevent entering of liquid droplets to the compressor. It works on
the general gravity separation principal. Gas enters at bottom of the scrubber vessel. It then goes
upward to discharge side and liquid condensate settles down to bottom of the scrubber due to
gravity. It then passes to demister pad which removes further liquid by settling then down.
The scrubber vessel contain liquid level controller, which controls the liquid level at desired set
point. This mechanism contains three level transmitters (LT-0104A, LT-0105A and LT-0106A)
and a level control valve (LCV-0104A). LCV is mounted on bottom drained pipe and is signaled
from LT. This mechanism ensures that the vessel should not got flooded and also not to become
empty. If any of two above condition reaches, turbine will trip and compressor too. Thats why
the desired liquid level (usually 40%) is maintained in It. Level is maintained because gas
shouldnt escape through bottom drain of vessel. Following are the conditions adjusted for the
low pressure LP scrubber:

Set point
Liquid level (%)

40

Alarm
Low
High
15
80

Trip
Low
10

High
90

The raw gas is then discharged from the top of the vessel. It then goes to the suction of Low
Pressure Compressor (LP Compressor).

iii.

LP Compressor

It is multi-stage centrifugal compressor. This means it has more the one impeller and diffuser.
Each impeller and diffuser makes a stage. Raw gas at suction pressure of 300psig comes at the
eye of first impeller. As the gas leaves
the first impeller it gains some velocity
and pressure. The increased velocity
partially converted into pressure in the
diffuser. As the gas leaves the diffuser,
it enters the return passage, which
guides it into the eye of next impeller.
In this way each impeller adds to the
total energy of the gas. When gas leaves
LP compressor its pressure becomes
530-540psig. A typical diagram of
multi-stage centrifugal compressor is
shown.

LP Compressors suction and discharge gas properties are:

Compressor

Suction
Alarm

Operating

Trip

Discharge
Alarm

Operating

Trip

Pressure (psig)

300-305

Low
110

High Low High

496 100 584

530-570

Low
400

High Low High

950 390 1000

Temperature
()

110-120

N/A

140

190-240

N/A

265

N/A

N/A

N/A

As compression causes rise in temperature so after compression gas is transferred to fin fan
cooler to cool down the discharged gas prior to further compression.

iv.

Gas cooler (inter stage cooling)

Gas after compression enters in cooler in the tubes having fins. Two Fans of the cooler are motor
driven. As raw gas passes from the tubes, fan blows ambient air on it, which causes gas
temperature to reduce. All the tubes have fins which increases the heat transfer rate.
The temperature of raw gas before and after the 1st stage cooler is as follows:

Temperature

Condition
Entering

180-220
110-120
150
160

Operating
Alarm
Trip

Discharge

Cooling of gas causes the liquid vapors to condense, so we need to remove liquid droplets. To do
this gas goes to High Pressure Scrubber (HP Scrubber). It passes to the anti-surge valve prior to
HP scrubber. Anti-surge valve prevent the compressor from surging. It can be operated manual
or auto by control system of the machine.

v.

HP Scrubber

It works on the same principle as LP scrubber. The only difference is of pressure and Height (HP
is smaller to LP). It also contains three level transmitters (LT-0107A, LT-0108A and LT-0109A)
and a level control valve (LCV-0109A).
Its operating conditions are:

Set point
Liquid level (%)

40

Alarm
Low
High
15
80

Trip
Low
10

High
90

270

vi.

HP Compressor

It is also multi-stage centrifugal compressor. It is operating on same principle as described in LP

compressor. The discharge from LP compressor is suction to HP compressor, making them two
stage compressors. Its suction and discharge gas properties are:
Compressor
Operating

Suction
Alarm

Pressure (psig)

520-550

Low
400

Temperature
()

110-120

N/A

Trip

High Low High

584 370 600
132

N/A

N/A

Operating

Discharge
Alarm

Trip

720-800

Low
400

High Low High

950 390 1000

190-200

N/A

265

N/A

To cool gas leaving the compressor, it is transferred to after stage coolers.

vii.

After stage Cooler

After stage coolers are like inter stage coolers. Two fans are driven by electric motor. The gas is
subjected to enter the cooler in tubes having fins which helps to increase heat transfer area.
Process gas is cooled by ambient air.
Temperatures are given below:

Condition

Temperature

Entering

180-220
110-120
150
160

Discharge

viii.

Operating
Alarm
Trip

Discharge Header

After leaving the cooler, process gas passes to the anti-surge valve and then goes to discharge
header. Anti-surge valve prevent the compressor from surging. It can be operated manual or auto
by control system of the machine. Discharge header properties are
Header
Discharge

Diameter
(inches)
18

Temperature
()
110-115

Pressure
(psig)
750-780

Flow rate
(MMSCFD)
200-250

270

ix.

Seal Gas System

Compressor bearing uses lube oil for lubrication and cooling. The impellers of compressor and
bearing have nothing in between them which separate them apart. So it might be possible that
lube oil got mixed with the process gas.
To prevent mixing of lube oil to process gas, a seal of other gas is maintained in between them
with high pressure. Seal gas should be a gas which does not affect the concentration of process
gas. Usually Nitrogen and sale gas (methane) is used here.

Gas Turbine
(Prime mover)

Introduction:
As it stated earlier that each centrifugal compressor is driven by the gas turbine, so it is necessary
to mention description of gas turbine.
A gas turbine, also called a combustion turbine, is a type of internal combustion engine. It has an
upstream rotating compressor coupled to a downstream turbine, and a combustion chamber in
between. Three numbers of gas turbines are installed here in front end compression facility
having tag names as Train A, Train B and Train C. These all turbines are Solar Turbine by A
Caterpillar Company.

Description:
A gas turbine engine is a type of internal combustion engine. Essentially, the engine can be
viewed as an energy conversion device that converts energy stored in the fuel to useful
mechanical energy in the form of rotational power. The term gas refers to the ambient air that
is taken into the engine and used as the working medium in the energy conversion process.

This air is first drawn into the engine where it is compressed, mixed with fuel and ignited. The
resulting hot gas expands at high velocity through a series of airfoil-shaped blades transferring
energy created from combustion to turn an output shaft.

1. Basic Components and their Description

i.

Air Intake System

The air is drawn in the combustion chamber through filters. 80 filters are installed in the intake
system, which filters the air before entering to combustion chamber. The differential pressure of
air is maintained, which indicates the smooth working of filters. If DP is more than the desired
value, cleaning is carried out. Cleaning is usually carried out using Instrument air from utilities.
Cleaning of air filters is carried out using Huff and Puff system. If after cleaning, the DP is still
higher then filters are changed.

ii.

Compressor

The axial type compressor takes in outside air and then compacts and pressurizes the air
molecules through a series of rotating and stationary compressor blades. Flow of air is controlled
by inlet Guide Vanes (IGVs) at compressor. Compressor at startup is driven by using starter
motor and then by turbine itself. Starter motor is electrically driven and got de-latch to the
system when NGP (Nominal Gas Producer) speed reaches to 65%. Compressor discharge
pressure is about 130-160 psig.
NGP maximum range is set at 103.6% and is operated between 90 to 98%.

iii.

Combustor

In the combustor, fuel is added to the pressurized air molecules and ignited. The fuel to air ratio
is 1:14.7. The heated molecules expand and move at high velocity into the turbine section. The

temperature in combustion chamber is also adjusted, having set point of 1360 when the
turbine is in operation. This means that turbine will give alarm at that temperature at then get trip
at 1440 . Thirteen numbers of thermocouples are installed in the combustion chamber to sense
the temperature. Normal operating temperature in chamber is about 1200 to 1300 .

iv.

Turbine

The turbine converts the energy from the high velocity gas into useful rotational power though
expansion of the heated compressed gas over a series of turbine rotor blades. Two turbines are
placed in it. One is compressor turbine, whose shaft is coupled to compressor of turbine. 70 to
75% of energy is used by this turbine to run itself. Other is Power Turbine, whose shaft is
coupled to driven load (here it is a centrifugal compressor).

Minimum speed of Power Turbine when idle should be 44% , while when loaded is 56.75%.

v.

Output Shaft & Gearbox

Rotational power from the turbine section is delivered to Centrifugal Compressor through the
output shaft via a speed reduction gearbox.

vi.

Exhaust

The engines exhaust section directs the spent gas out of the turbine section and into the
atmosphere.

2. Lube Oil System:

The lubricating requirements for the gas turbine are furnished by a common forced-feed
lubrication system. Lubricating fluid is circulated to the three main turbine bearings, generator
bearings, reducing gear, accessory gear, as hydraulic oil in torque converter and also as control,
trip oil, high pressure hydraulic oil & generator seal oil. This lube is also goes to centrifugal
compressor bearings.
Such a system must supply cool, clean and pressurized oil to bearing. This lube oil system
includes the following:
i.
ii.
iii.
iv.
v.

Lube oil reservoir in the accessory base

Main lube oil pump
Auxiliary lube oil pump
Emergency lube oil pump
Lube oil heat exchangers (Cooler and Heater)

In this system of turbine cooler (fin fan) and heater are operated as follows:
Cooler
115
105

ON
OFF

Heater
95
100

Cooler contain an electric motor driven fan and tubes having fins. Oil comes inside the tube and
exchanges its heat with air.
vi.
vii.

Lube oil filters: ensure the circulation of clean oil.

Mist Eliminator: recovers the oil vapors leaving the reservoir.

Pressure and temperature in the turbine is maintained as follows:

Operating
Alarm
Trip

Temperature
130-140
175
180

Pressure (psig)
33-38
10
8

3. Cooling Air system

The cooling air system provides the necessary air flow from the blower to prevent excessive
temperature buildup in the parts during normal. Atmospheric air from external centrifugal
blowers is used cool the turbine exhaust frame. Air enters by passing from enclosure filters into
the enclosure and then goes to exhaust. Inside frame temperature limits are set as
Enclosure
Alarm
Trip

Temperature
150
160

4. Fire Protection System

Temperature sensor and smoke detectors are installed in the enclosure of turbine. Carbon dioxide
system is installed in enclosure which will become activated while smoke detectors give signal to
it. The carbon dioxide fire protection system extinguished fires by reducing the oxygen content
of the air in the compartment. While the turbine is running the enclosure doors should be closed
and fire system should be at auto position.

Plant Utilities
Plant utilities at CCR-2 include:

Ingersol Rand Instrument Air Compressor

Atlas Capco Air Compressor
Nitrogen Generation System
Power House 2

1. Ingersol Rand Instrument Air Compressor (A-4701A/B)

The air compression system is design for a supply of plant air and instrument air to the plant at a
pressure of 105psig. Instrument air is critical to the plant operations. Therefore 2 compressors
4701A/B (one operational and other standby) are installed with two instrument air drier to
provide instrument air and plant air to QICP. The Ingersoll is an electric motor driven, single
stage screw compressor, the motor power requirements is 132kw. The package is complete with
accessories piped, wired and base plate mounted in a close casing.
Compression in screw type air compressor is created by the meshing of two (male and female
screw) helical rotors. Coolant oil is added at the suction of compressor with air. We add coolant
to remove compression heat and for lubrication purpose. The air/coolant mixture then discharges
from the compressor into the element separator. The separator removes almost all the coolant
from the mixture and coolant returns after cooling and air is discharged and is pushed through
after cooler by passing through separator and cooling system. The coolant system consist of a
sump, cooler, thermostatic valve and a filter and again the coolant is pressurized and forced to
the bearings again. The compressor load control system is automatic on-off line. The
compressor will operate to maintain a set discharge line pressure and is provided with restart
system. The Off-load set point is 105psig and On-load is 94psig. The compressor is design to
provide a supply of 620scfm of air at pressure of 110psig. The compressed air then goes to plant
air receiver which removes the entertained liquids from the air. It provides one minute surge time
capacity at 620 scfm, which is the maximum plant air requirement.

Air Dryer:

The air to be dried is taken from outlet of the plant air receiver goes to two air dryers (one
operational and other standby). Air dryer contain silica gel which removes the liquid droplets.
Their exits to tower for one air dryer. While one is drying the air other will be on regeneration
process. Regeneration is done by part of the dried air. These air dryers reduces the dew point of

air to 50. This means first moisture vapor in air will condense only when air temperature
reduces to 50.
After driers instrument air goes to four air receivers as shown in figure. These vessels provide
surge capacity of 5 minute at flow of 320 scfm. The important things to check during operations
are coolant level; package pre filters checked for blockage, the coolant temperature discharge
pressure and discharge temperature.

2. Atlas Capco Air Compressor (0501A/B)

This system also contains two screw compressors 0501A/B (one operational and other standby)
with an air drier. The compressors load control system is automatic on-off line. The compressor
will operate to maintain a set discharge line pressure and is provided with restart system. The
Off-load set point of these compressor is 115psig and On-load is 94psig.
Its operating procedure is identical to 4701 compressors.

3. Nitrogen gas generation process

PSA NITROGEN GAS GENERTOR(X-0509) installed in QICP has a capacity of 230 Nm3/hr
of 99% pure nitrogen at 90psig. Plant air or instrument air is its feed stalk. The air supply system
should be capable of delivering an average of 372Nm3/hr. Carbon Molecular sieves are used
adsorbent. I is very porous materials chosen because of the large specific surface area. Carbon
molecular sieves (CMS) may utilize their molecular sieve characteristics to exclude some gas
molecules from their structure based on the size of the molecules, thereby restricting the ability
of the larger molecules to be adsorbed.
The PSA system consist of 2 vessels (adsorption beds) loaded with carbon molecular sieves. The
CMS adsorbs oxygen from the stream air, leaving a nitrogen stream which is collected in
nitrogen buffer tank. The CMS bed has an adsorption (production cycle of 80 seconds duration.
during this cycle the process valve allow the compressed air to enter the CMS bed and prevent
the loss of compressed air through the silencer and once the production cycle complete the
process valve allow to flow of nitrogen into buffer tank . During the adsorption cycle the CMS
bed becomes loaded with oxygen after each production cycle the system has desorption cycle
(blow down cycle) to regenerate the CMS bed. Desorption cycle is a few seconds in duration.
After desorption cycle the process repeats adsorption (production). The nitrogen buffer tank is
sized in such a way that it can store enough nitrogen to maintain the two bed specific desorption
cycle during which no nitrogen is being produced. The product control valve which is located
after the nitrogen buffer tank is used to establish and maintain flow rate and purity of two bed

system the system will produce higher purity nitrogen a lower flow rate and high purity nitrogen
at higher floe rates.
Excessive oil and moisture contamination in the inlet air is very detrimental to the adsorption
vessel carbon molecular sieve (CMS) material. If there is any indication of excessive oil level in
the feed air unit should be shut down and correct problem before restarting. High moisture
content also effect the performance of the CMS bed.

4. Power house 2
The power house 2 is responsible to provide power to QICP it has a capacity of almost 2950
KW. Three rental (smart power) engine driven generator of Caterpillar with capacity as follow
are installed:
Tag Name
G-3216
G-3212-1
G-3212-2

Capacity (KW)
1000
630
630

OGDCL owned Waukesha Engine (model-P486L) is also installed and attached with Marathon
electric Magna synchronous AC generator. It normally remains standby as the other generator
produce enough power to run the plant. All these generators can be synchronized.
Synchronization is the process of matching the speed and frequency of a Generator or other
source to a running network.
After 3000 running hours the engine maintenance is necessary. Engine lube oil, oil filter and air
filter should be replaced. Mostly shell mysella s5 n 40 is used for lubrication but other brands
can also be used. The oil temperature and pressure and Engine performance tells us when we
should have to replace filters and engine oil.
The plant uses almost 600kW power in routine hours but when we start the turbine it required
170 kW more power to run the starter motor. The plant house provides power to run main lube
oil pump of turbine, oil cooler (HX-901), inter and after cooler fans, the instrument air
compressor 0501/4701 and the air conditioner of CCR 2 and QICP lighting. The power house
also provides power to run pump 4101A/B and the sump pump 4102A/B of liquid knock out
vessel side of CCR 2.
The power house 2 is also equipped with battery system for emergency use. It has almost
285 batteries connected in parallel.