TEC HNC/D

ELECTRICAL & ELECTRONIC

ENGINEERING

PROJECT

TITLE: Modifecatation of the pressure switch in station air

compressor

pg. 1
ACKNOWLEDGMENT:

First, I would like to thank my parents who helped me to grow up and helped me to
start my first studies at the primary and secondary school and who did encourage
me to be at this level of education.

I also want to thank my friend Salem sewed from Amal field Libya for his support
and help, and big thanks for the assessor Mr Ammar Irhoma for the technical
support he had given during the sessions.

Moreover, I would like to thank everyone in the company who gave me the chance
of this high academic study.

Thanks

pg. 2
 Contents
Criteria Title Page number

Acknowledgment 2

P1 Giving three ideas 4

P2 Decision matrix for the projects 5

P4 Project design specification 8

Aim of the project 11

Project objectives 11

P4 Project resources 12

P4 Risk assessment 12

P5 Implementation of the project 13

P6 Project risk assessment 21

P7 Project evaluation 23

P8 Justifying the results 25

P9 Testing records 26

P9 Project log book 28

Appendixes 29

P3 Discussion on project

Documents for the unit from the company

P10 Presentation

References

pg. 3
pg. 4
GIVING THREE IDEAS

Introduction:

In this project I will give solution for the problem that I have personally faced
when I have been told to fix the problem occurred in the station air compressor at
station 5, the problem was about the function of the pressure switch.

The main aim of the station air compressor is to feed the station by the needed air
to keep the operation of the compressors, which are used to feed the oil wells with
the gas

So in this project I will be giving first of all three possible ideas of different
projects which are:

 Modification the station air compressor pressure switch

 Install Pressure switch on Recycle pump

 Install stand by generator in oil station

I have to choose one of these and the decision will be taken depending on the
matrix on the next following pages

pg. 5
Project title: Modification the pressure switch on the station air compressor

Decision matrix for choosing project:

Category 1 2 3 4 5
Relevance 
Specific 
Measurable 
Achievable 
Realistic 
Time 
Challenging 
Total 28

Relevance: this project is very relative to my main job as an electrician in Amal oil
field.

Specific: this project is very specific because it will focus on how to find a better
solution for a certain problem

Measurable: it is easy to measure the success in this project.

Achievable: I might face some difficulties with doing this project but I think I will
take over them easily.

Realistic: This project is very realistic because it was a problem I have faced

Time: Actually, a project like this needs time to complete it due to the material
needed

Challenging: there are some problems on this point but I think I have some scope
which allow me giving a variety of solutions.

pg. 6
Project title; Install pressure switch on Recycle pump.

Decision matrix for choosing project:

Category 1 2 3 4 5
Relevance 
Specific 
Measurable 
Achievable 
Realistic 
Time 
Challenging 
Total 19

Relevance: this project is also relative to my job, but the instrument dept do most
of the job on it

Specific: this project is not really very specific because it will give an overview of
how to use the pressure switches on the pumps

Measurable: in this project it is not easy to measure the success.

Achievable: No I do not have enough resources to complete the project.

Realistic: this problem is a little bet not important because you still be able to
switch the recycle pumps by other ways.

Time: No I do not have enough time to finish the project.

Challenging: there is not more working to be included with this project.

pg. 7
 Project title; Install stand by generator in oil station

Decision matrix for choosing project:

Category 1 2 3 4 5
Relevance 
Specific 
Measurable 
Achievable 
Realistic 
Time 
Challenging 
Total 19

Relevance: this project is also relative to my main job as an electrician.

Specific: this project is not as specific as the first choice because it will focus on
how to make the generators ready in case of power failure

Measurable: this can be considered as measurable some how

Achievable: I might face some difficulties with doing this project

Realistic: this problem is not trivial but it is not as vital as the first problem.

Time: actually a project like this must be done with more time than the given

Challenging: there is not more working to be included with this project

pg. 8
P4: Project design specifications:

There are ten stations in Amal oil field, a certain process should be done in each
station in order to produce the oil and pump it to the main station

This process needs a certain amount of air to achieve the job in the complete way,
the only way to get the air is to have the station air compressor which can feed the
station with the required air

Project design specifications

1- Performance requirement

Function

The function of the project is to provide a better stability to the operation of the
station air compressor

Loading

This project will have only one primary function which is providing stability to the
operation of the station air compressor

Aesthetics

In this project a pleasing elegant design is very essential because the project should
be done to have a nice look as well as the project will provide the quality of
operation

Reliability

Although the equipment used in the project are electrical and the possibility of
failure is very low they need to be checked regularly to make sure they don’t go
out of calibration
pg. 9
Environment conditions

All the equipment used in this project will be exposed to the hot weather, dusty
weather, and highly corrosive gas so they should be designed to work under these
conditions

Human factors

It will be easy for the operators to monitor and control the process. All the meters
and indicators are on the location of the unit and they are easy to be observed.
Therefore, the operators will be exposed to the noise and the risk of the unit.

Quality

The quality of the project should meet the companies quality standards, all the
equipment used should be the same type and have the same quality of the
equipment used in the company in the other sites, all the equipment used should be
new and free of defects

2-Manufacture requirement

Material

All the materials for the project can be taken from the company’s warehouse
because such equipment is already used in some other application in the field.

Assembly

All the equipment should be assembled manually

Packing and shipment

pg. 10
All the equipment used in the project are electrical so they should be packed in a
way to prevent damage during transport, such equipment are expensive and fragile
so they have to be packed in protective boxes.

3-Acceptance standards

Inspection

The tolerance of the system should BE ±1 PSI

Testing

The project performance will be testing as soon as the project finishes and this
process is called commissioning, the commissioning will be observed by the
department supervisors to make sure that the project meets the standards that it has
been agreed for

Standards

The company standards as regards to maintenance stats that the equipment should
be checked once a month to insure reliability

4-Disposal

Standards

The company’s standards of disposal are to collect the disposal in the junk yard
until ready for the recycling company to come and collect it.

Legislation

The company’s legislation is to separate the material so that it will be easier for the
recycling companies to deal with it,

pg. 11
5- Operation requirement

Installation

All the technicians involved in this project should have a very good back ground
about electrical installation.

Use

The operators that will deal with this project will have to have a good experience
about the function of each project component as well as how to operate the unit.

Maintenance,

After the commissioning of the project the project will be passed to the planning
department to make a preventative maintenance schedule, and provide work scope
for each one of the equipment to insure that right procedures are being carried out
during the maintenance

Aim of the project

The main aim for this project is to improve the performance of the equipment,
make it more reliable, accurate and solve the problem that is usually happened
in the station air compressor which will negatively affect on the production of
oil.

Project objectives

 Re-design the pressure switch system by changing the location of the

pressure switch.
 Improve the cycle working of the compressor
 Adjust the operation time for the unit

pg. 12
P4: Project resources

1. internet

2. Harouge oil operation catalogues

3. information from the technicians in the company

4. some photos from the location of the project

P4: Risk assessment

To ensure that the project is going to be done in a safe manner, it is very important
to create a risk assessment that have mentioned all the hazards can be occurred
during the project

Hazard Action to be taken

Eyes Follow the computers using the

procedure

Use correct chair and table

Have a break for 5 minutes after an hour

of working

Don not sit close to the computer

Electrical chock Ensure all cables are insulated

Ensure that power socket equipped with

RCD breaks

pg. 13
P5 Implementation of the project: Introduction

It is very important to have the required air in the station to ensure that the process
is working properly. The air is needed for most of the stages that used in the
process of producing the oil. For instance, the big gas compressors that used to
inject a high gas pressure to the reservoir of the well that will then push the oil out
of the well, in that way the oil is obtained from the well, each compressor in the
station will be responsible for injecting the gas for more than ten wells. To ensure
that the gas compressor is working well the operators of the gas compressor will be
always ensure that the air is available in order of successful starting up. Many other
machines need the air for their operation. For example, transfer pump, chemical
pumps, and the high-pressure pumps that used in the water treatment plant. The
following figure illustrates all the loads that need the air.

Fig 1 the load distribution of the air

pg. 14
 Each station has at least two station air compressors that produce the air that
flows in the pipeline within 90 to 120 PSI. Therefore, the station air compressor
should have a pressure switch that measure the air pressure in the pipe line and
give the signal to the contactor to run the compressor. The station air compressor
that is placed and used in every station in the field should also has the other
important components for instance, the cooling fan, main motor, control valve,
control panel and the pressure switch. The following figure shows the whole unit.

Fig 2 the station air compressor

The pressure switch that should be used in the station air compressor should be
chosen to have the ability to sense two values of pressure; therefore, the chosen
pressure switch has two limits which can be adjusted with. The two limits will be
adjusted according to the required pressure; in this case, the air pressure needed in
the pipeline should be within 90 to 120 PSI.

pg. 15
The theory of the pressure switch

A switch is a component in electrical device that is used to add or remove power to

the device. Switches operate by breaking or establishing an electric circuit in order
to affect the power provided to an electrical device. They accomplish this by
establishing an electrical circuit in order to turn off the power, and establishing an
electrical circuit to turn on power to the device. The switch is passive, requiring no
manual operation by the operator. air pressure does it all. When the pressure drops
to the upper limit, the normally open contacts close, completing the electrical
circuit and activating the compressor. When the set pressure is reached, the
contacts open again, turning off the compressor.
Some switches in the airline work with a diaphragm pressing against a piston and
spring inside the unit. The spring pressure is set by an adjustment screw. Sufficient
pressure on the diaphragm keeps the switch "off." When the pressure drops, the
switch activates. Moreover, the pressure switch is used in the station air
compressor as a feedback to the controller which will work according to the
received signal from the pressure switch, this controller will control the
compressor accordingly, therefore this system is like a close loop system as it has
these three components and the feedback. The next diagram illustrates the system.

set point output

Controller/ Star – Delta Electrical Compressor
connection Diagram

Feedback Pressure Switch

fig3. block diagram of the station air compressor

pg. 16
Problem justifications

This type of compressor has been working in the stations for more than five years
without any problems; it has been adjusted to compress the air in the pipe line
process within 90 to 120 PSI. However, in the last few years it has been noticed
that the functioning of the compressor started to be unstable. Instead of
compressing the air within 90 to 120 PSI, the pressure gauges indicates that the air
pressure exceeded the desired value which made disturbance to the system.
However, it can be said that the pressure switch is not working properly and needs
calibration.

From the history analysis of the equipment it is clear that the cause of the problem
is the pressure switch as it is responsible for sensing the pressure in the pipe line of
the process. It has been adjusted and calibrated many times but the problem did not
exist.

After more analyses and investigation about the problem, the cause of the problem
was the location of the pressure switch as it is located near to the cooling fan and
the main motor that rotates with a high speed about 3540 RPM. However, this
speed of the motor is more than enough to cause the vibration that can affect to the
functioning of the pressure switch accordingly.

The following figure shows the old location of the pressure switch as it was beside
the main motor.

pg. 17
 Fig 4. the old location of the pressure switch

Problem solution

If this problem persists in this way, the operation of the station will be negatively
affected as a result of the that, because most of the devices used in the separation
process needs the air pressure to perform their jobs. Therefore, this problem should
be solved to reduce and stop the process disturbance. However, the best solution
for such a problem is to find appropriate location that ensures a good operation
conditions for the pressure switch. Moreover, the new location should be far away
from any source of vibration that can affect on the pressure switch operation.

The new location for the pressure switch will be outside the body of the unit, this
place will be away from the sources of vibration, in addition the pressure will be

pg. 18
allocated in a place that will give a comfortable position for maintenance and
calibration

Project specification

To implement the solution of the problem some materials will be needed, these
required materials will be listed below.

1. 4 core cable, 1.5 mm, 5 meter.

2. 20 mm gland cable
3. Explosion proof Pressure switch
4. 4 pieces bolts and nuts, size 8mm
5. 4 terminal lugs, size 1.5 mm

The job that will be done should not take long time as only the pressure switch will
be moved to another place. Therefore, moving the pressure switch to another place
that is away from its original place needs cable that is longer than the original
length.

Implementing the project

Before starting the job, a permit to work should be filled to ensure that the job will
be done in a safe circumstances, all the hazardous expected conditions will be
mentioned in the form. Moreover, the approval of safety officer and the manager
should be obtained in the permit to work, as the safety department will decide
whether the job needs to be done under safety staff observation or not.

Another procedure should be done before starting the job is to fill the shutdown
notification, the purpose of this form is to inform all the affected departments by

pg. 19
this shutdown, the reasons of the shutdown should be mentioned as well as the
time needed to do the job.

After doing all of the previous procedures, the station air compressor will be ready
for the shutdown and start implementing the project.

The design procedure

1- Prepare the new location of the pressure switch and drill 4 holes to be
suitable for 4mm size bolts.
2- Switch off the station air compressor.
3- Disconnect the pressure switch electrically by disconnecting the cable from
the pressure switch as well as removing the four bolts that hold the pressure
switch with it’s original base.
4- Mountain the pressure switch on the new place by four 8mm bolts and tight
them well
5- Connect the 4core, 1.5 mm cable from the controller to the pressure switch,
the gland should be well installed to ensure that the gas will not go inside the
pressure switch and cause a huge explosion accordingly.

After doing the previous steps, it can be said that the job is nearly finish, the
following figure shows the pressure switch mounted on it’s new place.

pg. 20
Fig.5 new location of the pressure switch

Figure 6 the pressure switch

pg. 21
Commissioning of the project

When the project is finished and become ready to be used and before switching on
the unit to be used in the process, an important procedure to ensure that the unit
will work properly should be done, these procedure steps will be as follows.

1. Calibrate the pressure switch as the required set point

2. Ensure that the connection of the pressure switch is right
3. Meger the cable and check the resistance of the circuit
4. Check the tightness of the bolts
5. Open the bypass valve and close the main valve
6. Switch on the unit and observe the operation
7. If the pressure exceeds the set point, switch off the unit and calibrate the
pressure switch until the pressure become within limits

P6: Risk assessment for moving the pressure switch

Hazard Action to be taken

Noise Ensure that the worker or technician is

wearing the ear plugs

Electrical chock hazard Main electrical breaker of the equipment

should be in off position while working
on the equipment, and all the damaged
equipment should be reported to the
supervisor.

pg. 22
Hazardous chemicals Ensure that the work place is completely
ventilated, if not the worker should wear
the mask

Slippery Ensure that the workplace is regularly

cleaned
Falling objects The worker should wear safety helmet
to protect from pumping or falling
objects

Manual handling hazard The worker should use cranes and

forklifts to carry heavy materials and
avoid carrying them as much as
possible.

Fire hazard The fire fighting equipment should be in

place, and the worker should be trained
to use them in case of emergency.

Mechanical equipment and moving Rotating equipment should not to be left

parts hazard running while working, and the tag
should be put on the main breaker. The
guarding should be provided. The
safety goggles should be provided and
worn.

Note: To avoid the hazards the worker should use P.P.E when he is at workplace.

pg. 23
P7 Project evaluation

By starting this project I have to choose one of the three chosen projects. At first, it
was very difficult to choose one of them, but I have chosen the ongoing project
mainly for two reasons, the first one because it is considered to be the most related
to my major. the second reason of choosing the project because I have personally
faced the problem of the pressure switch and I have to find a solution for the
disturbance of the unit operation.

Generally, it can be said that the station air compressor is very essential to be used
in the oil field stations to provide the required air. Therefore, any disturbance in the
unit will affect negatively on the oil separation process and the quantity of the oil
production.

As mentioned before, the station air compressor has a disturbance on it’s operation,
although the pressure switch was calibrated many times, it doesn’t work properly
because of the vibration. Due to that, a new location for the unit should be found,
but before that, I must bear in mind the cost and the time of doing the project.

The best solution was to change the location of the pressure switch. Therefore, I
have to prepare my new design that will not cost very much with enhancing the
good operation condition, applying and defining the health& safety regulations.
Moreover, the standard of the project must be accepted, for instance which type of
material will be used in the project and is the material that will be used meets the
requirement specifications.

Therefore, I have chosen a new place for the pressure switch that is away from any
source of vibration, the new place is not far away from it’s original one which

pg. 24
means the new design will not need very long cable and pipe, therefore the new
design will not be costly.

Moreover, the material that is used in the project is high standard material that can
meet the required specifications as well as the material is an explosion proof which
can be used in rainy weather, dusty weather, and even in the hazardous conditions.

Implementing safety regulations while doing the project will ensure that the job
will be done in a safe environment. Therefore, all the safety procedure has been
followed while doing the project, for example the permit to work has been filled
and approved from the competent authorities, the risk assessment is filled with
mentioning all the expected hazardous in it, and the workers have to follow the
safety procedure and wear all the PPE needed in the job.

Implementing the project should be under the supervision of the design engineer to
ensure the correct steps of implementation and the good quality job is obtained.
After implementing the project the test should take place before running the unit to
ensure that the unit will work as required and the test should be carried out under
the supervision of the project manager and the engineer design as well.

The test should be recorded for the future reference and a preventive maintenance
schedule should be applied for the unit to ensure the unit will last for longer time
without any operation inconvenience.

At last, by finishing this project the unit will work steadily without any
disturbance, which will lead in increasing the oil production.

pg. 25
P8: justify the results

It is well known that the performance of the station air compressor has not been as
expected for many years and each time the technicians have to recalibrate the
pressure switch of the unit to carry out the operation of compressing the air.

Implementing this project provide the stability of the unit operation and the unit
become more accurate than before as the air pressure is provided within limits
without any inconvenience.

The station air compressor become more reliable as the quality and the
specification of the material used in the project meet the standards. Moreover,
changing the location of the pressure switch solved the problem of unit’s
disturbance and guaranteed the reliability of the unit operation.

At last, implementing this project ensures that the needed air pressure will be
available at all times, that means the oil separation process will be done without
any disturbance, therefore, the oil production will be increased accordingly.

pg. 26
(P9)- Testing records

After the commissioning, the unit should be back on line, but the operators should
observe the operation of the unit. One of the important things that should be
monitored well is the pressure values to know whether the pressure switch is
working properly or not. Therefore, the records of the air pressure will be recorded
for a period of time. The air pressure records will be taken in the morning when all
the machines and employees are working and in the afternoon when some of the
machines are stopped.

The air pressure records are taken each ten minutes approximately as shown below.
The records show that the compressor needs only ten minutes to pump the air from
the lower limit to the upper limit, whereas the decreasing of the pressure takes
about 30 minutes to reach the lower limit. The chart below illustrates the operation
records.

Morning records:-

PSI
140

120

100

80

60 PSI
40

20

0
8:30 8:40 8:50 9:00 9:13 9:23 9:30 9:40

Chart 1 testing records

pg. 27
The records taken in the afternoon was not as the same as the morning records,
because the demand of the air is decreased as some of the machines that need the
air are switched off. It is clear from the chart below that the time of decreasing the
air pressure is more than it was in the morning.

PSI
140

120

100

80

60 PSI
40

20

0
5:00 5:10 5:20 5:30 5:40 5:50 6:00 6:10

Chart 2 testing records

pg. 28
(P9.M2)- Logbook

Identification of the work Time taken

Research of different projects from 08/02/2010 to 15/02/2010

different resources

Contact my company colleagues for an 15/02/2010 to 22/2/2010

advice to choose specific project

Evaluating the three projects ideas by 22/2/2010 to 08/03/2010

the given matrix to come up with the
suitable project

Discuss and agree aims and objectives 08/03/2010 to 22/03/2010

of the chosen project

Collecting the information and diagrams 22/03/2010 to 19/04/2010

about the chosen project mainly from
my company colleagues

Typing the collected information and 19/04/2010 to 24/05/2010

trying to put them in the right order to
achieve most of the criteria.

Making sure that all aspects of the 24/05/2010 to 31/05/2010

project are covered

Finding the best way and method to 07/05/2010 to 28/05/2010

present the project and presenting it as
required.

Typing the references which have been 28/05/2010 to 05/06/2010

used while doing the project.

pg. 29
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pg. 37
References

http://www.iqsdirectory.com/pressure-switches/

harouge oil operation documents

pg. 38