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OIL AND GAS DEVELOPMENT COMPANY LIMITED

CHANDA OIL FEILD

INTERNSHIP REPORT

SUBMITTED TO:
I/C MECHANICAL

SUBMITTED BY:
MAZ-ULLAH (UET PESHAWAR)
M.FARHAN BABAR (UET PESHAWAR)
SYED HASSAAN ALI (COLLEGE OF EME,NUST)
SYED MAAZ HASSAN (COLLEGE OF EME,NUST)
DANISH ASDAQUE (COLLEGE OF EME,NUST)

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ACKNOWLEDGEMENTS

First of all we would thank Allah Almighty for audacity and courage. We are
grateful to the field manager, his excellency Mr. Abdul Majeed for his technical and
moral support in Chanda oil field. We are greatly obliged to all the workers and staff of
all the departments especially of the mechanical department for their co-operation and
support.

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TABLE OF CONTENTS

CHAPTER NO 1 ……………………………….
INTRODUCTION TO CHANDA OIL FIELD
CHAPTER NO 2 ………………………………
DEPARTMENT IN CHANDA OIL FIELD
CHAPTER NO 3 ………………………………
SEPARATOR SYSTEM OF CHANDA OIL FIELD
CHAPTR NO 4 ………………………………
DEHYDRATION SYSTEM OF CHANDA OIL FIELD
CHAPTER NO 5 ………………………………..
LPG RECOVERY UNIT OF CHANDA OIL FIELD
CHAPER NO 6 ………………………………
FACILITIES AT THE WELL AND SEPARATORS IMPORTANT PARAMETERS
CHAPTER NO 7 …………………………………..
VALVES INTRODUCTION AND TYPES
CHAPTER NO 8 ………………………………
FITTINGS
CHAPTER NO 9 ………………………………
PUMPS
CHAPTER NO 10 ……………………………..
AJAX COMPRESSORS
CHAPTER NO 11 ……………………………..
ENGINES
RECOMMENDATIONS

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CHAPTER NO 1

INTRODUCTION

CHANDA OIL FIELD

Chanda Oil field is located in Shakardara near district Kohat.


Exploration in the area started in 1936 while the drilling activity started in January 1989
when OGDCL drilled the first well namely SHAKARDARA 1 in Lumshiwaal
formation(4548m depth) and other 13 wells were drilled too. This well was abandoned as
dry hole with minor oil showings during testing.
In late 90’s the exploration took a new turn and OGDCL drilled Chanda 1
(spud in 1998) in the same concession (Block no.3370Shakkardara). Chanda deep
1 was drilled and completed in the following years (2000-2001).
Well Chanda No. 2 was drilled and completed in the year 2005-2006. This
well of TD 4990m.This well is slanted with MD = 4990 m and TVD = 4920 M Mela no.1
well of Mela Oilfield is one of the major discoveries of OGDCL.

MAJOR PROCESSES
There are three major processes carried out in an Oil field.
1. Gas Processing
2. Crude processing
3. Water processing
GAS PROCESSING:
In gas processing following proceedings are made:
1. Separation
2. Dehydration
3. Dew Point Reduction
4. LPG Recovery

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CRUDE PROCESSING:
In crude processing following actions are made:
1. Crude Stabilization
2. Crude Refining
WATER PROCESSING:
In crude processing following actions are made:
1. CPI (Corrugated Plate Interceptor)
2. TPI (Tilted Plate Interceptor)
3. OPV (Open Pond Evaporator)

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CHAPTER NO 2

DEPARTMENTS IN CHANDA

MAIN DEPARTMENTS OF CHANDA OIL FIELD: The following are main


departments in Chanda oil field

 Mechanical Department
 Process Department
 Instrument Department
 Storage and Dispatch Department
 Telemetry Department
 Electrical Department

MECHANICAL DEPARTMENT
Mechanical department is the core of Chanda Oil Field as it is responsible for repair,
maintenance and troubleshooting of all the mechanical equipment installed which
includes:
 Pumps
 Compressors
 Generators
 Heat Exchangers
 Storage Vessels
 Separators
 Storage Tanks
 Hot Oil Furnace
 Refrigeration Package
These equipments are the part and parcel of the Plant.

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PROCESS DEPARTMENT
The Process Department of Chanda Oil Field is accountable for operation and
proper working of the Plant. Its basic purpose is to keep an eye on the smooth running of
the Plant all the time. Keeping a record of operating conditions of all the equipment is
also a duty of the Process Department.

INSTRUMENT DEPARTMENT
Instrument department is responsible for governing all the control equipments installed
like
 Switches
 Control valves
 Panels
 Flow meters
 Pressure and temperature Gauges

STORAGE AND DISPATCH DEPARTMENT


At Chanda Oil Field the storage system comprises of four crude storage tanks of
the same storage capacity i.e.6000bbls.crude stream from Chanda no.1 and Chanda deep
no.1 is brought to H.P, M.P and L.P separators. The crude after separation is sent to tank
no. 1 and tank no.2.the crude from Chanda no.2 is brought to H.P and L.P separators and
finally to tank no. 3 or tank no.4. Tank no.1, 2 and 3 are connected directly to dispatch
line which is 8i.n spiral pipeline. Whereas tank no. 4 is connected to tank no. 3 and tank
no.2 through shifting valves. One tank at a time is put on dispatch line while others on
production from the wells. Regular dip of tanks is taken to ascertain the volume of the
tanks.
DISPATCH
The production from the tank is brought to the pumping station of the
Dispatch/filling gantry. The pumping station has three pumps for the transfer of crude to
the filling gantry outlets (the classification of the pumps is attached).at a time, three

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Browsers can be loaded. Prior to loading dip of each chamber is checked and verified
from ARL calibration charts.

TELEMETRY DEPARTMENT
Telemetry is basically combination of Instrumentation and Communication. In oil
and gas fields it is very necessary to monitor the well parameters in real time so that in
case of emergency the situation can be controlled with out any complication.
For this purpose a sophisticated system of electronics gauges is installed at the
wells of Chanda oilfield. The following parameters of the well are monitored in
real time.
 Well head pressure
 Well head temperature
 Flow line pressure
 Flow line temperature
 SSV Pressure
 SSSV Pressure
The system can shut down the well in case of emergency and can also change the
flow line pressure with special commands. All the parameters mentioned above
are continuously monitored at the control rooms that are being displayed on the
computer screen.
Similarly the storage tanks of crude oil are also equipped with the electronics
instruments which monitor the following parameters of the tanks
 Product level
 TOV (Total Observed Volume)
 Product temperature
 Water level (m)
 Water volume (bbls)
 Observed density
 GSV (General Standard Volume)
 Total mass (tons)
In case of any emergency alarm system alerts the crew to control the situation.

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ELECTRICAL DEPARTMENT
Electrical department is an essential element of Chanda Oil Field. They are mainly
accountable for:
 Power Generation
 Power Management
 Lighting system
 CCR
 Wirings and Cables
 Driving motors
 Starting motors
 Generators

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CHAPTER NO 3

SEPARATOR SYSTEM OF CHANDA OIL FIELD

Chanda oilfield has 3 wells on production. The crude oil from the wells comes to
the separation system where there are two separation systems installed. One for Chanda 1
and Chanda deep and other for Chanda 2.

SEPARATION SYSTEM FOR WELLS CHANDA 1 AND


CHANDA DEEP 1
There are three separators installed for Chanda1 and Chanda deep1. High
pressure separator (also called first stage separator). Medium pressure separator
(second stage separator), and Low pressure separator (third stage separator).
The crude oil line comes from the wells to the choke manifold system from
where it goes to the first stage separator. In the separator deflector plate is fitted
the crude oil strikes to the deflector late and according to the specific gravity the
gas and oil are separated. The oil settles down where as the gas moves upward
from where it goes to the dehydration unit. The oil then goes to the medium
pressure separator and then low pressure separator so that the maximum
amount of gas is separated. Then the oil goes to the storage tanks from where it is
dispatched through Bowsers.

Design Specifications of the Separators of Chanda 1 andChanda Deep 1


Design Parameters of High Pressure Separator
A system for separating fluids from each other. The mixture of fluids to be
separated is injected into a cylindrical tank so as to cause the fluids to rotate and thereby
accelerate their separation into strata. A float valve at the top of the tank allows lighter
fluids to be exhausted while a second float valve at the bottom of the tank provides for
the exhaust of heavier fluids. In the event of an oil spill on an open

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body of water, the present invention would provide for the clean up of the oil slick by
separating it from the water.

Types of separator:
The separator may be 2-phase, 3-phase etc

 High pressure separator


 Meduim pressure separator
 Low pressure separator

V-101
CLIENT: OIL & GAS DEVELOPMENT CORPORATION (PAKISTAN)
PROJECT ENGINEERS: PETROSIN
MANUFACTURER: PETROSIN CORPORATION PTE (LTD)
Unite name Flash separator-ii Size(FT) ID 4′ 3.2″ Design Pressure 126 PSIG
Design code ASME SECT VIII Min Head THK 0.375″ Design 2480F
DIV 1 1992 INCL Temperature
1993 ADDENDA
Manufacturer 167-01-3001 Shell THK 0.5″ Min D-Metal 320F
S.No Temperature
Country of Origin Singapore Hydro test date ---- M.A.W.P at D.T 126 PSIG
P.O No OGDC/LPG/001 T/T 12′ 9.5″ Test Pressure 189PSIG
New
Equipment No V-101 Radiography FULL RT-2 Corr allow 0.125 inch
Head/Int
Project No P-167 Stress Relief NO Capacity 5752 ltrs
Inspection PETROSIN Erection Weight 6400 lbs ---------
Authority

V-102
CLIENT: OIL & GAS DEVELOPMENT CORPORATION (PAKISTAN)

PROJECT ENGINEERS: PETROSIN


MANUFACTURER: PETROSIN CORPORATION PTE (Ltd)
Unite name Flash separator- Size(MM) ID 1296 Design 75 PSIG

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iii Pressure
Design code ASME SECT VIII Min Head 0.375″ Design 3200F
DIV 1 1992 ED INCL
1993 ADDENDA THK Temperature
Manufacturer 167-03-3001 Shell THK 0.375″ Min D-Metal 320F
S.No Temperature
Country of Singapore Hydro test 18051995 M.A.W.P at 75 PSIG
Origin date D.T
P.O No OGDC/LPG/001 T/T 3900 Test Pressure 112.5
New PSIG
Equipment No V-102 Radiography FULL Corr allow 0.125
Head/Int inch
Project No P-167 Stress Relief NO Capacity 5750 ltrs

V-109

Certified by PETROSIN Corporation PTE Ltd (SINGAPORE)


W M.A.W.P 276psig at 2480F T/T 10′4″
RT-2 Min Design 320F at 276 PSIG Design Pressure 276 psig
Metal Temperature
Manufacturer Petrosin corporation Design Temperature 2480F
PTE(Ltd)
Manufacturer SNo. 167-02-3001 Min D.Metal Temp 320F
Unit Name LPG column reflux M.A.W.P at D.Temp 276 psig
drum
Design Code ASME SECT VIII DIV 1 1992 Test Pressure New 414 psig
INCL 1993 ADDENDA
Country Origin Singapore Corr Allow Head 0.125 inch
/int
P.O No OGDC/LPG/001 Stress relief NO
Equipment No V-109 Radiography FULL RT-2
Project No P-167 Erection weight 5550 lbs
Inspection Authority PETROSIN Capacity 3030 Hrs
Size(Ft)I.D 3′ 3.5″ Min Head Thk 0.47″

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Year Built 1994 Shell THK 0.625″

V112

PROJECT ENGINEERS: PETROSIN


MANUFACTURER: PETROSIN CORPORATION PTE (Ltd)
Unit Name Water Flash Inspection ABS IV Design 85 PSIG
Vessel Authority Pressure
Design Code ASME SECT VIII Size(MM) 12″STD Design 2850F
DIV 1 1992 ED
INCL 1993 I.D Temperature
ADDENDA
Manufacturer 167-09-3001 Min Head 0.375″ Min Design 320F
S.No (sheel) THK Metal Temp
Capacity 110 ltrs Shell THK 12″STD M.A.W.P at 85 PSIG
D Temp
P.O No OGDC/LPG/001 Hydro Test 23-05-1995 Test Press 127.5 PSIG
Date New
Equip No. V-112 Stress Relief NO Corr allow 0.125 inch
Head/INT
Project No. P-167 Radiography FULL-RT2 Erection 660 lbs
Weight

V-115

Certified by PETROSIN RAVI INDUSTRIES (Ltd)


W. Maxi allowable working pressure 865 PSIG at 1500F
Maxi allowable external working pressure 374 PSIG at 1500F
Minimum design metal temperature 450F at 780 PSIG
HT Manufacturer S.No V-1087
YEAR BUILT 2006

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V-116-A
Certified by Heavy Mechanical Complex Pvt Ltd Texila Pakistan
Description 39.1/4″*15′-0″ 3 Phase Separator
Maximum working pressure 1440psi at 1300F
Minimum design metal temperature 100F at 1440psi
Design oil flow rate 3000 BBLs
Design gas flow rate 5-26 MMSCFD
Design water flow rate 50-400 BBLs
L.P.O No. IBA/A/10078
Manufacturer serial No. 70308-2
YEAR BUILT 2004

V-116-B
All the other data is same only serial No is changed.
Serial No. 70308-4

V-117

Manufec S.No 133-10 Test pressure 2175 PSIG


Design Code ASME SECT viii DIV 1 1989- Fabricated weight 1961 KG
ED-1989 ADDENDA
Design Pressure 1420 PSIG C.A 0.125″
Design Temp 1650F Stress relief No
Min Head THK 0.718″ (10″ CAP) Radiography Full
1.031″ (16″ CAP)
NOM shell THK 0.718″ (10″ CAP) Item No ---------
1.031″ (16″ CAP)
YEAR BUILT 1991

V-201

Unit Name Glycol Flash T/T 2480 Design 180 PSIG


Vessel Pressure
Design Code ASME SECT viii Equipment V-201 Design 2000F

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DIV 1 1992-ED- No Temperature
INCL-1993
ADDENDA
Manufacturer 167-13-3001 Pipe Cap size 20″*S Min Design 320F
S.No (SHELL) Metal Temp
Country Singapore Pipe Cap 0.5″ M.A.W.P at 180 PSIG
Origin THK D Temp
P-O No OGDC/LPG/001 Metal A 254 Test Press 270 PSIG
WPB New
Project No P-167 Shell THK 0.5″ Corr allow 0.125
Head/INT inch
Inspection Petrosin Stress Relief NO Erection 1550 lbs
Authority Weight
Metal A 106 B Radiography Spot RT2 Capacity 450 ltrs

V-500

CLIENT: OIL & GAS DEVELOPMENT CORPORATION (PAKISTAN)


PROJECT ENGINEERS: PETROSIN
MANUFECTURER: PETROSIN CORPORATION PTE (LTD)
Unit Name Flair T/T 4880 Design 50PSIG
Knockout Pressure
Drum
Design Code ASME SECT viii Equipment V-500 Design 4800F
DIV 1 1992-ED-
INCL-1993 No Temperature
ADDENDA
Manufacturer 167-12-3001 Size 1397 Min Design -500F
S.No (SHELL) (MM)I.D Metal Temp
Country Singapore M.A.W.P at 50 PSIG
Origin D Temp
P-O No OGDC/LPG/001 Hydro test 11-10-95 Test Press 75 PSIG
date New
Project No P-167 Shell THK ??? Corr allow 0.125 inch
Head/INT
Inspection ABS IV Stress Relief Yes Erection 7600 lbs

15
Authority Weight
Metal A 516 70 Radiography FULL Capacity 8550 ltrs

CHAPTER NO 4

DEHYDRATION SYSTEM OF CHANDA OIL FIELD

A dehydration unit is installed at Chanda oilfield for the recovery of the


refined gas. The gas is sent to SNGPL through the metering skid. The gas from the
separators come to the V101 inlet separator from where it goes to the glycol absorber
V100 in glycol absorber the gas comes from the bottom of the absorber and lean glycol is
showered from the top. In this way the moisture from the gas is absorbed and it is sent to
the scrubber V200 for further refinement. The gas is then sent to the SNGPL metering
skid. The lean glycol becomes rich glycol (as it carries the moisture from the gas). This
rich glycol then goes to the positive displacement pumps from where it goes to the flash
separators in order to remove any suspended particle. Charcoal filters are connected to
the flash separator. The glycol then goes to the reboiler and then to glycol surge tank after
passing through the heat exchangers. Now it has again become lean glycol and is ready to
be used again in the dehydration unit.

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CHAPTER NO 5

LPG RECOVERY UNIT OF CHANDA OIL FIELD

In order to extract the LPG from the crude oil at Chanda Oil Field an LPG
recovery unit is being installed and the work is in progress nowadays. The crude oil from
the well comes to the HP separator from where gas and oil is separated the crude goes to
the crude stabilizers and gas goes to the dehydration unit. Then the gas stream from the
crude stabilization unit goes to the compressors. From the compressors, one stream of gas
goes to the LPG recovery unit and other to the chilling unit. From the chilling unit the
light stream goes to the sale gas whereas the heavier stream (containing heavier
hydrocarbons) goes to the de-ethanizer column. Here ethane is removed. Then it goes to
the LPG recovery unit. After LPG unit the LPG goes to the LPG bullets for cooling and
storage. A propane regeneration unit is also attached with the LPG bullets. The LPG
bullets are four in number. They have the following stipulation Design pressure of
172psig. Design temperature is 320F 1490F. They have a capacity of 34899FT3
INTRODUCTION
LPG is an economical clean and environment friendly fuel. It is the most
popular domestic fuel in area where supply of natural gas is not available.
Government of Pakistan encouraged LPG as an alternative fuel, to project the
environment and to conserve the fuel wood resources. Number of LPG
companies has increased from 29 to 36 and LPG production has grown more
than 350,000 Metric Tons.
In this production of LPG, OGDCL holds the major shares of its
production. In this line up of LPG producing fields, Chanda Oil Field is merging
as a leading LPG producing field after Dakhni Oil Field established in 2004, near
Kohat. The credit of finding reservoirs of Oil and Gas in this area goes to
OGDCL.
PRODUCTION DATA
Chanda oil Field has started its production since July 1994. The crude
produced by the three wells is collected in Chanda Plant. Here oil and Gas are

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separated. The oil is stored in the four crude storage tanks and the gas is
dehydrated by a Dehydration Plant installed here.

LPG PLANT AT CHANDA OIL FIELD

The gas produced from the wells at Chanda, is a high BTU gas. Handsome
amount of Butane is present in it. Therefore it has been decided to install an LPG
Recovery Plant. The LPG Recovery Plant installed at Chanda oil Field has been
relocated from Fimkassar. The plant can recover approximately 56 tons of LPG in
a single day. Also 04 Bullets have been installed to store the LPG.The initial
analysis shows that approximately 20 tons of LPG can be recovered in a single
day from the production of three wells.

18
PFD of LPG Plant
INSTALLATION

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CHAPTER NO 6

FACILITIES AT THE WELL AND SEPARATORS


IMPORTANT PARAMETERS

CLASS:
Class is used to describe the pressure rating of the piping system. For example Class 150,
300, or API 3000, API 5000. This relates to the maximum allowable design pressure that
a flange of certain dimensions and made of a certain material can be used with in a piping
system.
DIFFERENTIAL PRESSURE:
The pressure difference between the upstream and downstream ports of a valve.
DOWNSTREAM:
The process stream after it has passed through the valves.
END CONNECTION:
The part of the valve that joins to the piping system.
ERROSION:
Material weight loss inside a piping system caused by the process flow.
HYDROSTATIC TEST:
A test using water under pressure to detect any leaks through the body,
sealing joint or closure elements.
LINE BLIND:
A pipeline shut off device, whereby a flat disc is forced between two
flanges.
PIPING SCHEDULE:
A method of noting the wall thickness of a pipe for example Sch 40, Sch
80, Sch 160. The larger the number the thicker the wall thickness of the pipe at a
given nominal diameter.
RADIOGRAPHY:
A method of examination that uses X-Rays to produce an internal image

20
of a test piece.
RAISED FACE FLANGE:
A flange face that has a raised section on the mating surface. This allows
greater loading to be applied to the gasket and creates a more efficient seal than a
flat face flange.
RING TYPE JOINT:
A flanged end connection with a circular groove on the metal face, where
a softer ring metal is placed before mating up to a similar flange face and bolting up.
Ring type joint connections are used on higher pressure piping system,
ASME 900 lb and above.
SEAL WELD:
The fillet type weld required for socket weld fittings to prevent leakage.
SEAT:
A circular ring into which the closure element of a globe valve enters.
TUBING:
Small bore piping used to supply air or hydraulic fluid to an actuator.
VENT:
An opening in a piping system that can be exposed to the atmosphere and
allows fluid to be released.

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CHAPTER NO 7
VALVES INTRODUCTION AND TYPES

Valve is a mechanical device which is used to control the flow of a fluid.


Valves are of various types each depending upon the condition and requirement of the
operation.
PARTS OF VALVES:
 Wheel
 Spindle
 Gland pusher
 Set
ACTUATOR:
A device used to open/close or control the valve. Key types include:
 Electrical
 Hydraulic
 Pneumatic
AIR FILTER:
An accessory added to an actuator to prevent oil, water or dirt in the air supply from
entering the pneumatic actuator.
GATE VALVE:
The gate valve is fully open fully closed valve usually used where high pressure fluid is
required to be controlled. The control mechanism is a gate like restriction which moves
up and down to open and close the flow. When handle rotated to open, its spindle comes
out to signify that the valve is being open.e.g.
Gate valve size 3” RF Class: 300
GLOBE VALVE:
The globe valve is like gate valve but its spindle does not come out when it is opened.
Another difference is that the flow before valve and after valve is not along the same line
but little up or down to the previous axis of flow. So it also incurs some pressure drop
across it.e.g.
Globe Valve size 4” Class 800

22
Globe Valve size 6 x 6 Class 600
BALL VALVE:
In ball valve, the mechanism to control the flow is a ball which has a hole
in it. The ball rotates along its axis to open or close. This valve is usually used in
low pressure lines. It has got quick opening and good shut off.
e.g.
Ball valve size 3 x 3 Class 600
Ball valve size 2 x 2 Class 600
Ball valve size 2” Class 600
Ball valve size 2x1/2” RF Class 300
Ball valve size 4” RF Class 150
NON RETURN VALVE:
A valve that allows the flow of a process fluid in only one direction. It will
not allow any flow reversal.e.g.
Non Return valve size 4” Class 1500
WATER CHECK VALVE:
This is a NRV type valve. This is like a flag and a plate fitted in it which
remains parallel to the flow as well as the required pressure of the fluid remains
on line. At the moment, the pressure drops the plate moves and becomes
perpendicular to the flow under the action of the spring and return flow is
checked at the same moment
BUTTERFLY VALVE:
Butterfly valve is a partially open partially close valve usually installed on
fire hydrants. Closing mechanism is a plate which opens or closes the valve with
the help of handle. A sprocket is attached with the handle.
BYPASS VALVE:
A valve smaller in diameter and is fitted in parallel to a larger valve.
SAFETY VALVE
A pressure relief valve that is designed to reduce over pressurization in a gas or stream
service.

23
PRESSURE SAFETY VALVE
A self operating valve used to reduce any excess pressure in a system. The valve opens if
the internal pressure exceeds that holding the closing element onto the seat.
ACTUATOR VALVE
Actuator valve or shut down valve is a pressure relief valve with it various names are
pneumatically operated valves and are operated (close or open) against a setting pressure.
NEEDLE VALVE
Needle valve is a smaller size valve. A needle is used to close or open mechanism which
sets in seat to close the flow and vice versa. Needle valves are installed at line having
pressure ranges from 3000 to 10000 psi.
SOLENOID VALVE
Solenoid valve is electrically operated and used in instrumentation. Such valves are often
deployed as pilot a valve that is, fitted to actuators that in turn control larger valves.
STRAINER
Its basics function is to remove impurities at suction. SSSV (Sub Surface Safety Valve):
It operates within a pressure range of 3300-7500 psi. If the pressure is out of the
mentioned range, a pressure plate closes the valve. It is installed a few hundred meters
below the surface as a supplementary safety feature.
SSV (Surface Safety Valve):
A SSV valve is located at the ground level. Both manual and automatic operations are
permitted. At preset, the valve is manually operated. It is the primary safety measure for
the well.
CHRISTMAS TREE:
It is a combination of safety valves and chokes.
CONTROL VALVES: A valve that regulates the flow or pressure of a fluid. Control
valves normally responds to signals generated by independent devices such flow meters
or temperature gauges. Control valves are normally fitted with actuators and positioners.
Features:
Proportioning Trim permits straight line increase in flow.
Adjustable Hand wheel calibrated in sixty fourths of an inch.
Available in Wide Range of bodies and trim.

24
Pressure Rating threaded 5000 psi; socket weld 3600 psi; butt
weld 5000 psi; flanged 5000 psi (maximum).
Teflon Packing for positive seal and minimum maintenance.
Construction affords simple, easy inspection or replacement.
Secure in any position to resist vibration.
Corrosive Service optional 316,410 or duplex stainless steel
bodies.
Control valves are
Pressure control valve:
Flow control valve:
Flow Control valve size 4 1/16” Class 5000
Level control valve:
Level Control Valve Size 0.50” Class 600
CHOKE
A valve usually used in well control operations to reduce the pressure of a
fluid from high pressure in the closed well bore to atmospheric pressure. It may
be adjusted (opened or closed) to closely control the pressure drop. Adjustable
choke valves are constructed to resist wear while high velocity, solids laden
fluids are flowing by the restricting or sealing elements.
GASKETS
A flange gasket is a type of gasket made to fit between two sections of
pipe that are flared to provide higher surface area.Flange gaskets come in a
variety of sizes and are categorized by their inside diameter and their outside
diameter.There are many standards in gasket for flanges of pipes.
The gaskets for flanges can be divided in major 3 different categories:
 Sheet gaskets
 Ring gaskets
 Spiral wound gaskets
DESCRIPTION SCHEDULE RATING MATERIAL
Gasket 6” RTJ 600 #
Gasket 4” RTJ 600 #

25
Gasket 3” RTJ 600 #
Gasket 2” RTJ 600 #
FLANGES
A flange can also be a plate or ring to form a rim at the end of a pipe when
fastened to the pipe (for example, a closet flange). A blind flange is a plate for
covering or closing the end of a pipe. A flange joint is a connection of pipes,
where the connecting pieces have flanges by which the parts are bolted together.
ASME/ANSI PIPE FLANGES:
Pipe flanges that are made to standards called out by ASME/ANSI B16.5
or ASME/ANSI B16.47 are typically made from forged materials and have
machined surfaces. They are typically in .Pressure Classes. such as 150#, 300#,
600#, 900# 1500#; however, ASME B16.47 still recognizes the 75# or .Class 75.
flange for certain low pressure and low temperature applications. These
.Pressure Classes. have both pressure and temperature ratings for specific
materials. The flanges are made to standardized dimensions and are
typically of
followin styles:
 Flat face
 Raised face
 Ring joint
FLANGE DIMENSION:
Flanges are used on equipment for the nozzles and in piping systems. The
flanges are bolted together with a gasket in between to prevent leakage.

26
CHAPTER NO 8

FITTINGS

The following are different component of fitting


 Concentric reducer
 Eccentric reducer
 Tee equal
 Tee reducing
 Elbow 90
 Elbow 45
 Weldolet
 Sockolet
 Thredolet
 Elbowlet
 Reducing bush
 Reducing coupling
 Full coupling
 Nipple
 Half coupling
 Union
 Plug

27
CHAPTER NO 9

PUMPS

Definition: A pump is a device that raises or transfers fluids. Pumps are selected
for processes not only to raise and transfer fluids, but also to meet some other criteria.
This other criteria may be constant flow rate or constant pressure.
The pumps are used for pressurizing the gas condensate to a high pressure of
250psi from a low pressure of 50psi. The pumps use the gas in condensate form which in
coming from the condenser.
PUMP DESCRIPTION
The shaft seal of WUC pump is subjected to the discharges pressure of the pump.
The can and the suction side of the discharge head are designed for maximum suction
pressure. Liquid is flowing through the suction connection of the discharge head and
through the CAN to the impellers. The last stage impeller is discharging the liquid
through the column pipe, following the shafts, to the discharge connection. The thrust is
balanced by back wearing ring and balancing holes. The sense of rotation of the pump is
CCW looking from the coupling to the shaft end of the pup, rotating left.

STARTING AND OPERATING OF PUMP


The bearing housing must be filled with the indicated oil. The pump must be
completely filled with liquid to avoid running. During the operation of the pump, the
temperature should be held constant. Check the sense of rotation of the pump. All the
pipe work must be connected properly. The pump rotor and shaft seal must be in correct
axial position.
Check the sealing system with all auxiliary piping system. The pump shall be operated
between 25 to 110 percent of rated capacity. Bearing temperature should not exceed 80
deg C. Observe the power consumption of the pump to deduct excessive power wear.

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MAINTENANCE
• Inspection
If the pump is working correctly, it is not recommended to dismantle the pump
completely and run a complete reliability check. However, if the wear is exceeding 0.4
mm in diameter, an overhaul is recommended.

TYPES OF PUMPS
There are two major types of fluid transfer pumps
1) Positive Displacement Pumps
2) Non Positive Displacement Pumps
1) POSITIVE DISPLACEMENT PUMPS:
Positive displacement pumps are a major type of pumps. Positive displacement
pumps operate by forcing a fixed volume of fluid from the inlet pressure section of the
pump into the discharge zone of the pump. These pumps generally tend to be larger than
equal capacity dynamic pumps. Positive displacement pumps frequently are used in
hydraulic systems at pressures ranging up to 5000 psi.
2) NON POSITIVE DISPLACEMENT PUMPS (Dynamic Pumps):
Dynamic pumps are one category of pumps under which there are several
classes, two of which are: centrifugal and axial. These pumps operate by
developing a high liquid velocity and converting the velocity to pressure in a
diffusing flow passage. Dynamic pumps usually have lower efficiencies than
positive displacement pumps, but also have lower maintenance requirements.
Dynamic pumps are also able to operate at fairly high speeds and high fluid flow
rates.

CENTRIFUGAL PUMPS:
A centrifugal Pump is a hydraulic machine consisting of a set of rotating vanes
enclosed within casing, to impart energy to a fluid through Centrifugal force. Centrifugal
pumps are a practical choice for fairly constant, large flows of over 100 gpm at moderate

29
pressures and low fluid viscosities. The first step in selecting a centrifugal pump is to
determine application requirements: quantity of flow, pressure rise (or change in head) in
ft of fluid, and other conditions such as high fluid viscosity or temperature.
A centrifugal pump consists of an impeller and an intake at its center. These are
arranged so that when the impeller rotates, liquid is discharged by centrifugal force into a
casing surrounding the impeller. The casing is there in order to gradually decrease the
velocity of the fluid which leaves the impeller at a high velocity. This velocity is
converted to pressure which is needed to discharge the fluid. Some of the advantages of
centrifugal pumps are, smooth flow through the pump and uniform pressure in the
discharge pipe, low cost, and an operating speed that allows for direct connection to
steam turbines and electric motors. The centrifugal pump accounts for not less then 80%
of the worlds pump production because it is more suitable for handling large capacities
of liquids than the positive displacement pump.

PRINCIPLE OF CENTRIFUGAL PUMP:


.

GENERAL COMPONENTS OF CENTRIFUGAL PUMPS


A centrifugal pump is constructed from about a dozen major components
1) Stationary components
2) Rotary components
3) Auxiliary Component

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IMPELLER:
DEFINITION:
The impeller is the main rotating part of the pump that
provide the centrifugal acceleration to the fluid.The impellor is classified on the
basis of following parameters.
1. Types of flows:-
Following are the types of the flows
 Radial flow
 Axial flow
 Mixed flow
2. Based on suction:-
Single suction: In single suction the liquid inlet is on one side.
Double suction: In double suction the liquid inlet to the impeller symmetrically from
both
sides.
3. Based on mechanical construction
Closed: Shrouds or sidewall enclosing the vanes.
Open: No shrouds or wall to enclose the vanes.
Semi open or vortex type:
SHAFT:
The basic purpose of a centrifugal pump shaft is to transmit the torques
encountered when started during operation while supporting the impeller and other
rotating parts.
Linear shafts are elongated, rod shaped devices that provide linear or rotary
motion for power transmission applications. They are used as axles, pistons, and rollers in
heavy machinery. Some linear shafts have axial and radial holes for mounting to support
structures. Most linear shafts are made of aluminum, alloy steel, carbon steel, stainless
steel, composite materials, or plastics. Alloy steel is harder than carbon steel and provides
superior durability. Stainless steel is well suited for applications in which corrosion
resistance is an important consideration. Aluminum linear shafts provide good electrical

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and thermal conductivity, high reflectivity, and resistance to oxidation. Composite
materials are often made of carbon fibers bonded together by resins. They are not as
strong as metal shafts, but are lightweight and help reduce energy requirements.
MECHANICAL SEAL
A mechanical seal is a device which helps join systems or mechanisms together
by preventing leakage (e.g., in a plumbing system), containing pressure, or excluding
contamination. Controlling of the pumped fluid desire to exit
through the stuffing box, the area where rotary positive
displacement pumps and centrifugal pumps require the pump
shaft enters the pump fluid end. When operating the pumped
fluid within the stuffing box sees a pressure higher than the
surrounding atmospheric pressure, and on static lift
applications; during the priming cycle, the stuffing

TYPES OF MECHANICAL SEAL:-


 MULTI SPRING SEAL:
Multiple spring type of seals are designed for rigorous service in high temperature
applications in a wide range of chemical industry. This is a compact design, precision
lapped faces, high flexibility and field reparability. Various seal face materials and
elastomer can be offered for a wide service application. Multiple spring ensures uniform
loading of seal face.
 SINGLE SPRING SEAL:
Single coil spring seals are available with a wide range of variety of elastomer for
handling practically any industrial fluid. This type of seals is non clogging. This Spring
Seals are designed for high velocity pumps and for brasive services where solid
accumulation is possible as they are cleaning. The compact design of this seals permits to
use in all types of rotating equipment's i.e. Centrifugal pumps, mixers, and agitators.

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CHAPTER NO 10

AJAX COMPRESSORS
A compressor is a mechanical device which is used to compress the incoming
fluid to a high set pressure. The compression of the gas is carried out in three phases i.e.
 Low pressure compression (5 -50PSI)
 Medium pressure compression (50 – 225 psi)
 High pressure compression (225 – 850 psi)
The compressors used here are AJAX compressors which are used to
compress the incoming gas in liquid form from 5 psi to 850 psi. Two DPC
600(HP & MP) and one DPC 140(LP) compressors are used. All the three
compressors are engine driven. The engine comes as an integral part of the
compressor.
OPERATING CONDITIONS

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HIGH PRESSURE AND MEDIUM PRESSURE COMPRESSOR
SPECIFICATIONS:
The general specifications of the AJAX DPC600 compressor are given below
Basic Specifications
Compressor Cylinders

Lubrication

Fuel Volume Tank

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Air Intake System

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CHAPTER NO 11

ENGINES
Engine is a mechanical device to convert heat energy into mechanical energy.

Types of engine: The following are different type of engine

1. Diesel engine:
It is also called as compression ignition engine. In this process heat addition take
place at constant pressure. This is effective in large vehicles such as trucks, diesel
locomotives

2. Petrol engine:
It is also called as spark ignition engine. In this process heat addition takes place
at constant volume.

3. Gas engine:
Jet engines take a large volume of hot gas from a combustion process (typically a
gas turbine, but rocket forms of jet propulsion often use solid or liquid propellants)
and feed it through a nozzle which accelerates the jet to high speed. As the jet
accelerates through the nozzle, this creates thrust and in turn does useful work.

Operations

Four stoke or Otto cycle


1. Intake
2. compression
3. power
4. exhaust

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Two stroke cycle

. Intake and compression

2. Power and exhaust

Common components
1. Ignition system
2. Spark plug
3. Compression rings
4. Combustion chambers
5. Timing belts and valves
6. Fuel systems
7. Oxidiser-Air inlet system
8. Valves
9. Piston engine valves
10. Control valves
11. Cooling and lubrication systems

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RECOMMENDATIONS

More emphasis should be there for the safety of workers,there should be provision
of personal protection kit which inclues safety helmets,safety boots,ear muffs and
gas masks.
Ear muphs should be use at noisy places especially in compressor side in the plant

There should be close circuit cameras (CCTV) in the plant


There should be proper availability accommodation to the trainees.
Sports activities must be provide for the officers as well as for the trainees
LPG fumes are being emitted from tank top at Mela gas processing facility, and
there is ample chance that it may catch fire due to static electricity, measures
should be taken to avoid this.
AJAX COMPRESSOR units are old and should be replaced because they are
prone to day to day mechanical failures which result in waste of revenue.
The mechanical seals of condensate pumps leak on weekly basis. Suitable
measures should be taken to replace and maintain the seals.
Some LPG is lost to flare on daily basis, it is advised that it should be use to run a
boiler and thus providing amperage to the plant.
There is no provision of fire lorry at Mela processing facility,it should be
remedied.
SCADA (supervisory control and data acquisition) should be properly
implemented on plant and well head facility, currently it is being used on at well
head facilities in controlling the solenoid valve at bypass
Telemetry department is currently undermanned and short of resources. It should
be made nerve centre of all operations.
Equipment in control room is obsolete and much of it is not in working
conditions.It should be replaced by new equipment.

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