Operation Material 2016
Operation Material 2016
Operation Material 2016
:
BUSINESS SUPPORT DEPARTMENT Training Section
Operation Material
PLANT AREA
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1- What are products of ASU plants and how GAS as company is distributing it
products to customers?
9- What methodologies are used in GAS to utilize turbine power as get generated?
10- How cool down process of feed air in ASU process plant is vital important?
11- What type equipments are installed in GAS ASU plant for feed cool down?
16- How many type of GAS compressions are for industrial gases?
17- What type of liquid pump are available with GAS plants?
19- How GAS employee will report road tanker hazard from field?
20- How field operator will do his 1st visit to plant area?
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Plant Safety
Note. Plant safety notes are provided in progression level 1 for awareness.
Oxidation term very commonly used to explain oxygen reaction with metals and oxide of
metal get develop. Ferrous/ ferric oxide are 2 oxides of iron and common name is RUST.
Other oxidizers are:-
1-Flourine.
2-Chlorine.
3-Nitrous Oxides (N2O4 or NO2)
All these chemical reactions of elements is named as oxidation.
As ASU process is basically to produce oxygen. Nitrogen as gas /liquid is also available on
plant site. Plant area can have following atmospheric conditions:-
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Filtration
Why do we need filtration?
In ASU process filtration is needed to protect air compressors and working stream
pipeline from any foreign particles that lead to damage or blockage to the system.
If there is no filter installed on process pipeline, during long run of operation a lot of
unwanted impurities will move with the feed to the system causing damage the
equipment and blocked the system.
All type of air filters performance is effected by DUST and Moisture . Special
attention is recommended during stormy and humid conditions of atmosphare.
Vacuum
The down streamside of the air filter leads to the suction conditions of the air.
compressor operates at a slight vacuum head pressure. Operator will suffer from this
vacuum effect during doing internal inspection. All safety measures should be observed
when filter internal inspection in required.
Operating Conditions
Fuel Operated equipment should not be allowed near the air filter area to
avoid potential accumulation of organic compounds in the process leading to
potential explosion in clod box. All these areas must be marked clearly.
Change filters
If the standby filter is available than change over can be done such
as lube oil filters.
If There is NO standby filter than filter elements should only be changed when the plant or
equipment is shutdown.
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Environmental Aspect.
Filter elements is to be disposed in accordance with Environmental Management System
(GIMS).
1-Oil filter:
An oil filter is provided to remove impurities and contaminants from re-
circulating lube oil supply for rotating part of machines or an equipments
hydraulic oil (Jacking oil) as it get return back from gear box after lubrication.
Two oil filters are provided to kept one in operation and one in standby to run
the equipments continuously during filter cleaning.
Oil filter are provided with proper access to remove filter mesh for cleaning or
replacement.
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Differential pressure gauge always installed across the filter or strainer, if the
P increases to the required limit Process flow and pressure will change, in such
situation equipment must be change over and replace or clean the filter
cartridge / strainer by mechanical.
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Strainers can be classified into two main types according to their body
configuration named as Y-Type and the Basket Type but still there are some
other types such as Backwashing Type FILTER.
SW system at the inlet of Plate Heat Exchangers and DCACs water outlet
streams are some time provided with back flush or back wash type water
Filter / Strainers.
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D-Temporary strainers
Temporary strainers are designed for protection of equipment and
instrumentation during start-up periods. The strainer is usually installed
between a set of flanges for an initial period after a new plant has been
erected. Installation of a spool piece equal or more than the length of the
strainer is recommended for easy installation or removal of strainer.
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Compression
Compression term is simply increasing gas pressure. In molecular terms, increased
pressure will cause molecules hitting the sides of an enclosed space more frequently.
Many type of compressors are used in process industry. In ASU process only
Reciprocating or centrifugal compressors are used depending upon nature of process
and capacity of plant. In Tonnage plant centrifugal compressors are preferred.
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ASU process is based on free air as raw material and table below provide air features.
Table below will provide contaminants availability in free air AFTER FILTER.
PRODUCTS GROUP
oxygen O2 20.95 -218 -183 -118 51.3 32
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As air get free from dust and enter to compressor for process of compression, Different
type of compressors are used for compression. Common type of compressors are :-
1-Centrifugal compressor.
2-Reciprocating compressor.
1-Centrifugal compressor.
Centrifugal compressor are available in a no. of varieties. The selection of compressor
depends upon process requirement. As air is ASU feed, commonly compressor is
named as air compressor. Air compressors are commonly in multi stage construction .
In GAS for ASU process 3 stage, 4 stage and 5 stage air compressors are in service.
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2-Stage Impellor.
4-Stage Casing.
6-Gear Box.
8-Electric Motor.
10- Field information transfer instrument,(PTs, TTs, LTs, FTs, and PDTs)
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2-Impellor
Compressor impellor is mounted on shaft and housed in stage casing.
As impellor size goes bigger, Kinetic energy impart to air molecules get also high. In
other words discharge pressure of stage will be high.
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3-Casing diffuser:-
Diffuser is a stationary part of the Centrifugal compressor which is placed inside the
casing where it divert air to casing which is released from the impellor outlet.
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4-Casing:-
Stage casing is an important unit of
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get diverted to change kinetic energy of compressed air to potential energy. As a result
compressed air will get high pressure air before it get enter to heat exchanger.
In compressors stage casing is commonly made of good grade of steel to with stand
pressure, temperature and low erosion rate.
Compressor can have no. of stages depending upon process requirement. Normally
one impellor is housed in casing but some time more than one impellor can also be
housed in one stage casing.
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As air Leaves from impellor, it got high molecule velocity. In stage casing kinetic energy
get transfer:-
As air temperature get increase, Air gases molecule get apart from each other, Mass
flow of gases get low. To improve mass flow of gases it is essential to cool down air
gases to possible low temperature before it get enter to next compression stage.
Heat Exchanger in between the stages known as inter stage cooler and another heat
exchanger after final stage known as after cooler.
Commonly shell and tube type Heat Exchangers are arranged with compressors as
inter stage coolers.
Some time air is passing from shell side and some time cooling media is passing from
shell side. Assignment of flows depends upon duty of heat exchanger.
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As steam traces in compressed air after compression will pass through heat exchanger
and get change to water and will get collected in basement of heat exchanger. This
water formation is called as condensate. Condensate formation rate depends upon
Humidity level of atmosphere. It is very important to remove condensate from heat
exchanger on regular basis to have good performance of heat exchanger. High level of
condensate in heat exchanger will have adverse effect on heat exchanger in heat
transfer process.
High level of condensate in heat exchanger will reduce air passage for air and can lead
air compressor to operate in surge area.
As air will undergo compression process and moisture will continue to knock out in
heat exchangers. Very small amount of moisture in form of steam will be available in
compressor final discharge flow.
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Air compressor all inter stage coolers are provided moisture drain trap to remove
condensate on regular basis.
HEAT EXCHANGER
Moisture drain trap are arranges in GAS with air compressor Heat exchanger
(Intercoolers).
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6-Gear Box.
Gear box is an important structural part of an air compressor. It provides
support to all bearings, compressor seal system and casings of all stages. It
provide housing to speed up gear system as get arranged. (Bull Gear and Pinion
Gears)
BULL GEAR
Bull gear is a main driving gear that is bigger in size which is directly connected
with the driving motor shaft and used to increase the speed of the driven
Pinions gear.
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PINION GEARS
Pinion gears are a small gears mounted on a impellor shaft driven by Bull gear
to increase the RPM of each stage. They are different in size and RPM.
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shafts. AS there are 3 stages in MAC, one free end of shaft is provided with THRUST
BEARING to equalize axial thrust of 3rd stage. All bearings are lubricated with
recommended grade of oil. Bearing body is provided with temperature and vibration
measuring probes Vibration measuring probes are provided at X-AXIS and Y-AXIS
level.
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1-Main oil pump mostly screw oil pump coupled with main bull to
have a positive drive all time.
Oil get return back to oil reservoir with some seal gas as get leakage
to oil . oil in reservoir is make free of gas by extraction process of
gas. To extract this seal gas and oil vapors mist exhaust fan is
running on cont. bases. Oil demister is provided to minimize oil
droplets carry over to vent.
Main oil pump and Aux. oil pump outlets are joint in one header to
divert oil to oil cooler before returning it to machine for lubrication.
Required oil pressure for system is controlled a PCV valve placed on
this header.
Two oil filter elements are provided in parallel to each other so that
one stay in service all time and second element is kept in stand by
position for change over when ever DP of filter get increase to limit.
Electric heater will come in service if oil temperature get drop below
20Co.
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If one oil pump is driven by compressor main gear box, after power failure it takes
time to become in standstill position. Therefore oil supply to all parts continue without
any delay. Emergency lube. Oil reservoir is not provided in system.
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8-Primover.
Type of drivers.
1- Electric motor.
2- Steam Turbine.
3- Diesel engine.
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1-EXCITER
Excitation system is provided with motor to run it at synchronized speed.
Exciter is provided at Non drive end (NDE) of motor shaft. Its working helps to
improve power factor of motor. For such motors power factor is 1.0 .
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To run the compressor safely Anti Surge system has been provided.
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FIG NO.1
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FIG.NO.2
This controller is programmed to control operation of Anti Surge valve
at outlet of compressor to vent out gas to reduce outlet pressure. As a
result gas flow through compressor will increase and operation will be
in safe area. This controller is providing following information as guide
line to operator as under. All data information guide line are numbered
as under for easy understanding in fig 2.
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8-Analog display, Actual value by RED light / Set point value by GREEN light.
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9-Raise /lower keys for set points and parameter. These both keys
whenever pushed together will RESET controller ERROR function.
10-Set point selection (I/E Key) (can be disabled)
11-Status display.
12-AUTO/MAN transfer key.
13-Raise or lower key for output variable (MV). To close valve on MAN.
Quickly.
14-Lower legend plate.
15-Handle for removal.
16-Module locking screw (E).
17-Output variable display.
18-Multi function key(F-Key).
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The trickling cooler Or Direct Contact Air Cooler is a vertical, cylindrical vessel
containing trays or packing OR pall/Beta rings built up to various heights. process air
enters from the bottom. A demister is built in before the air outlet at the top. Cooling
down of process air after the air compressor prior to enter mole sieve. The air is
cooled down by contact with water over trays and packing rings in lower portion of
vessel. In upper zones of vessel the air is further cooled down by contact with chilled
water . The demister sieve serves to remove any drops of water still contained in the
cooled air stream. The warm water collects at the bottom of the vessel. The direct
cooler cools and washes air by direct contact with cooling water.
Differential Pressure
DCAC and EV. Cooler are provided with demister pads to hold water droplets carry
over to streams. It helps to minimize cooling water losses. As water carry over
generates scaling, demister pads will get chock and air passing will get channel
passages and water carry over with stream will increase.
Water carry over with stream will effect purification of Mol sieve and RHEs PHE.
PDI is provided to measure differential pressure across demister pads / packing in
DCAC and EV. Coolers.
Field operator is required to check PDIs regularly for preventive measures.
Level Control
For DCAC / Ev. Cooler Level control system (LIC) is provided to operate the equipment
safely. Alarms, Level switches and Interlocks system also provided with LOW/ LO
LO/HI/ HI HI to take action or shut down the equipments in safe mode.
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Paul rings are made of poly propylene and Beta rings are made of stainless
steel material.
The evaporating cooler cools the water against a flow of dry gas, normally pure
nitrogen and waste nitrogen but gas stream is replaced by wet air after DCAC
during plant start up. The water flows down wards through the packing from
top of the vessel and comes into contact with the rising dry gases. As a result
water is cooled down and collect at the bottom of vessel which is pumped to
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DCAC cooler. During the process humid gases leaving from the top of the
evaporating coolers
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Water treatment.
Cooling water supplies to DCAC /EV. Cooler are arranged on following basis:-
1- Chemically treated cooling water from cooling water header. (Sami close
circuit)
2- Process / potable water supply to EV. Cooler to maintain level (Close
circuit).
2.Biocide
2.HYDREX 7918 /7310
3.Caustic Soda 49%
3.Caustic Soda 49%
As chemical handlings are dangerous, Operator should read MSDS for material
Carefully and understand NFPA poster placed on chemicals storage container .
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As feed air is leaving DCAC / Trickling cooler after getting cool down with direct contact
with water. Air is carrying water vapours according to saturation point at gas
temperature. These vapours get change to water droplets during moving to next
purification unit. On Some plants DCAC outlet lines are provided with purge bottles
named as Catch Pot. Moisture drain traps are arranged with Catch Pot to remove water
condensate on regular basis. Drain traps bypass system is also provided to operate in
case malfunctioning of normal system .
Condensate level awareness to DCS operator is provided through level transmeter
reading.
Field operator have to check system functioning minimum twice in shift.
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A- DCAC cooler
As DCAC cooler is a confine space vessel as no direct cross ventilation of air is
possible. For isolation all confine space PTW requirements should get fulfilled.
B- EV. Cooler.
As EV. Cooler is a confine space vessel as no direct cross ventilation of air is possible.
For isolation all confine space PTW requirements should get fulfilled.
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Potential Hazards:
There are no major hazards associated with normal operation of the direct contact air
cooler and EV. cooler. The following potential hazards exist during maintenance.
1. Hazard caused by the fact that the direct cooler operates under pressure.
2. Asphyxiation.
Air Purification
Contents of blocking material in feed air get reduce to minimum but not get
completely remove. Presence of these elements in feed air will block main heat
exchanger in HRS. only. Therefore complete removal of blocking material is
essential for smooth continuous plant operation. Different methods are used to
remove these impurities as under:-
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Normally there are Two mole sieve vessels / Two banks of RHE are arranged with
every plant. One MS bed/ One bank of RHE stay in service for specified designed time
period and other under goes regeneration process.
FUNCTION OF UNIT
Compressed air after compressor is used as process feed. Process feed is
cooled down in process air cooler (PAC) with direct contact of water streams.
This feed air is enrich in unwanted impurities of the process these impurities
are:
1. Water Vapors
2. Carbon Dioxide
3. Oxides of Sulphar and Nitrogen.
4. Hydrocarbons
All these impurities are harmful for ASU operation as all these will get solidify
in heat exchanger and will block the feed air passage. To remove these
impurities and to keep ASU in continue operation. Two bed molsieve dryer is
arrange before heat exchanger. One bed stay in operation for specified time
while the other under goes the operation of regeneration so that it can be
switch to service at the end of cycle of operation.
These dryers or Mole Sieves are named as:
1. WEP Warn End Purifier
2. FEP Front End Purifier
3. PPU Pre-Purification Unit
4. MS-UNIT Mole sieve unit
NOTE: In GAS mol sieve term is used for all warm end purifiers/
driers.
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UNIT CONSTRUCTION
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The unit consists of two vessels made of mild steel and installed in horizontal
or vertical position. Inside the vessel a bed is arranged to support the
adsorbents layers those will be spread for the purposed of it function. Vessel is
provided with ports to allow the entry/exit of gases and for the entry of human
being for examination from top and bottom of grid. Also a port is provided to
remove the condensate during operation of service and regeneration. Air inlet
ports are provided with baffle plates to distribute the air gas uniformly. This
also avoids the direct hitting of air to bed from down side. Normal / Maple
butterfly types valves are provided in system to perform all necessary activities.
There are only three types of flows through the system are under:
1. Process Feed Air (wet air enters from
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bottom)
ADSORBANDS SPECIFICATION
There are no. of types of absorbent are arranged in layer wise over the bed.
These are:
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SILICA ALUMINA
This is compound of silica and aluminum oxide that have a great efficiency to
absorb and release water vapors. They are in size 2-5 mm in dia.
Silica Gel :-
Silica gel is also used for low temperature ( cryogenic temperature -150 C )
adsorption of hydrocarbons and carbon dioxide.
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It is used to adsorb the traces of carbon dioxide (CO) and some of other
hydrocarbon available in feed air. It is most commonly named with its grain
size a 13x or 16x. This is a compound of sodium aluminum silicate and also
known as ziolite. Sometimes it is also compound of different oxide bonded
together.
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exchanged X zeolite (CAX) to adsorb nitrous oxide and optionally ethylene, prior to
cryogenic separation of the purified air stream.
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Molsieve beds are laid in horizontal or vertical position as designed by plant supplier.
As purification process is continuous process and changeover of beds takes place after
specified time period. To do smooth changeover of beds, beds are equipped with
butterfly type valve to change flow direction.. Depressurizing and pressurizing valves are
control valves and operate as programmed.
In some plants operation, every step is delayed for specified time to confirm that bed
have acquired safe operational conditions before advancing to next step. This time
period is named as Prepare For Next Step.
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These absorbents provided have certain capacity of adsorption. Total air flow quantity
should not increased calculated design quantity.
NOTE: Flow verses pressure chart is provided by vendor for consideration.
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OPERATIONAL LIMITATION
As the absorbents have certain adsorption capacity, so the beds are regenerated after
specified time of operation. This is why two beds are required for continue smooth
operation. One bed stays in operational service while the second one undergoes
regeneration process to make the beads activated. Operation cycle can be varied not
to exceed the specified capacity of the beads. All plants have different duration of
time of bed in operation.
REGENERATION
Regeneration term is used to reactivate the beads after service. Thermal swing
process is used to reactivate the beads. Waste nitrogen or dry air is used in reverse
direction of process flow in hot condition (about 200~207C or as advised by vender)
for certain time to damp heat to remove all impurities adsorbed by adsorbent. The
adsorbents are then cooled down to certain temperature before taking in service to
the that bed.
BAKING
Baking is also regeneration process of adsorbents but in this case hot flow is
continuously passed through adsorbents till the inlet and outlet temperature become
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equal. Baking process carried out during initial commissioning of Mole Sieve or CO2 /
Moisture breakthrough .
Note: To facilitate during operational process all necessary areas are provided with
temperature, pressure and differential pressure indicator. These are listed below:
REGENERATION FACILITY
To provide the necessary heat energy to reactivate adsorbents regeneration heaters
are provided. To make the heating process more reliable more than one heaters
are arranged in heating system. Some time a heat accumulator is also associated
with heater that stores heat during cooling, pressurizing and depressurizing cycle of
operation and release heat during heating cycle with dry gas flow. Heater provided
work on following basis.
Electric heater can have only one heating element and heater is coming in service
during Heating cycle only.
Electric heater have 3 heating elements. 2 heating elements come in service on 100%
load fully or gradually and 3rd element can share heating to meet heat transfer
requirement. Heater element No. 2 and 3 are of same power to do inter change
whenever required.
Some time heaters are having 3 bundles of heating elements. All 3 will be in service
and Outlet temperature will be controlled by controller output by controlling heater
power.
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Some time heater outlet temperature is controlled by regulating flow through heater/
A flow controller is provided on heater inlet line.
Heater protection :-
For heater elements protection, all elements are provided with 2 sets of RTDs to
Provide temperature signal to DCS system and to electric supply breaker.
Electric heater can get trip from DCS signal which can be reset from DCS
Heater trip due to hardwire trip interlock then breaker will be Rest from substation.
Heater trips are also assigned to low gas flow through heater. As low flow will result
high element temperature can cause damage to element in long run.
In heaters gas outlet high temperature is also interlocked to trip heater power to safe
it. Temperature range assigned varies from one unit to another.
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Operators and maintenance staff should not enter a vessel containing molecular sieve
without the correct PPE, as the sieve will continue to "breathe" contaminants after
depressurization.
Fully depressurized
Fully ventilated
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Flow reversal between feed air and WN is necessary at 10 -12 minutes interval
of time to prevent build up of ice from water vapors and carbon dioxide
deposits on exchanger surface in the high pressure air stream. In reverse
process the deposits are evaporated by low pressure WN. Reverse process is
achieved by reversing (or changeover) valves piped into the warm end of the
exchanger.
R. Heat air flow will leave Heat exchanger from middle point at temperature of
-80 to -100oC for Expansion Turbine inlet flow. Plant will have 2 banks of RHEs
for continuous and smooth operation. Both banks will have equal no. of heat
exchangers. Nos. of heat exchangers depends upon capacity of the plant.
Process air will leave heat exchanger at temperature of -171 to -173oC with
dew point >-80oC and free off Hydrocarbons
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COLD END
Warm End
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Different types of manometers and DPI indicators are equipped with RHEs cold box
for monitoring purpose. At present pressure differential transmitters and indicators
are in service.
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Semi Auto: Any delay to switching valve open / close or feed back failure set the
switch to semi auto. Which be changeover back to auto position when situation is
normalize.
Manual: Sequence can be manage on manual regardless auto change over which
is prohibited.
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Before entering to switching valves room, Cross ventilate the area and use sniffer to
ensure presence of oxygen is 21%.
Hazards of Noise:
System generates heavy sound due to sudden depressurizing of air stream during
changeover. Ear protective MUFFs must be use prior to entering the area.
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PRODUCTS GROUP
oxygen O2 20.95 -218 -183 -118 51.3 32
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Air purification units provided with ASUs can remove a small portion of hydrocarbons
gases and remaining will get pass to MHE and distillation column . Finally hydrocarbon
will get accumulated in reboiler and condenser sump and can lead to Plant explosion.
HYDROCARBON ANALYSERS
Hydrogen carbons are main source of ignition/explosion if ignition Supporters are
available. Ignition support agent is OXYGEN. Therefore A mixture of Hydrocarbon and
oxygen can cause explosion if conditions Of explosion get achieved. These condition
are:-
1-Concentration of Hydrocarbon mixture with LEL range:
For example: 4% acetylene, 96% oxygen, Static charge Can develop
explosion.
2- Concentration of Hydrocarbon mixture with UEL range:
For Example: 96% acetylene, 4% oxygen, Static charge, Can develop
explosion.
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1- As all area pipeline are processing pressurized air. Check air leakage in area.
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RHEs Area
1- Check that both doors of switching room are open for cross ventilation of air.
2- Check sound level inside switching room after stream changeover .It will help
to analyze leakage from valves,
4- Check GAN/instrument air line to valves for leakage and damage of tubes.
Dry air booster compressor all construction is similar to main air compressor.
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4- In some booster compressor heat exchanger is provided at inlet stream for heat
exchange with final discharge flow of booster compressor from after cooler to
improve temperature of stream flow before entry to heat exchanger.
5- Balance gas is withdrawn from stage casing and routed back to inlet of
compressor.
NOTE:- Never ever try to start booster air compressor lube Oil system if
seal gas supply is not available.
Air or gas extracted from impellor back was processed before entry to booster,
extracted gas can be diverted to booster inlet for re-processing under control of
pressure because seal gas supply to labyrinth seal is also provided from balance gas.
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ASU process demands cooling to liquefy gases for fraction distillation of air.
Liquefaction temperatures of main air components are too low. Therefore intense
cooling is required to liquefy the Air.
EXPANSION TURBINE
Expansion turbine air or gas will enter to turbine impellor at medium or high pressure
and will leave impellor from center at low pressure and at low temperature. As a
result work force energy will be produced.
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As air or gas enters at outer edge of impellor and leaves from inner edge of impellor,
Turbine types:-
1-Blower/Booster Loaded Expander
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Impellor. Casing is that section which contains stationary nozzle and the
Impellor consist of blades mounted on it. When the air expands in a nozzle its
pressure decreases and velocity increases when this high-velocity air strikes on
the blade it runs the Impellor and produces mechanical power. Nozzles are
additionally equipped to vary the nozzle area and can expand air effectively .
Nozzle areas are selected to increase the cold generation.
Expansion Turbine work force energy can be utilize to run Generator to produce
power 4.16 KV which is connected to power bus bar in substation.
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As dry air is coming after molsieve. It get purified and get cool down to -115 to
-125oC before entering to expansion turbine. Some traces of blocking materials
like dust, CO2 , NH3 N2O and hydrocarbons can pass through molsieve. These
elements can get solidifies as air get cool down in main heat exchanger . If
these solidified tiny particles passed over high speed rotating impellor van , will
develop erosion in rotor vans and also these small particles (ice, CO2 or dust)
can cause severe erosion of the nozzles and wheel blade tips. This will reduce
life of rotor and IGV. A fine metallic Mesh filter is arranged at inlet of turbine to
minimize entry of solidified ice particles.
Nozzles are usually variable and used to control the throughput for the turbine.
Their function is to convert some of the pressure energy into kinetic energy or
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work force energy. There is a pressure drop across the nozzles which causes an
increase in the gas velocity and a decrease in the gas pressure, Because of the
high velocity.
Gas passage through nozzle and way it is diverted to Impellor blade at inlet of
Impellor blade. Number of IGV nozzles depends upon the number of blades on
Impellor. Nozzles position is controlled by an actuator to meet through put or
flow of turbine.
Figure indicates that no. of nozzles of guide van are equal to no. of blades on
rotor/impellor.
Deriming of turbine is carried out during plant shut down, or for plant cold standby
position or plant shutdown for more than 4 Hrs or
required to hand over to maintenance for some
job.
Turbine casings
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Turbine casing is main component to provide support to IGV, impellor housing and
IGV actuator.
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Impellor
Impellor is main part of turbine where expansion takes place and gas pressure energy
get change to kinetic energy and due to rotation of impellor kinetic energy get transfer
to shaft of turbine. As shaft of turbine will rotate and other couple equipment will
utilize energy.
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LABYRINTH SEAL
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Diffuser:
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In practice, the gas leaving the wheel still has some kinetic energy. The outlet
diffuser is designed to convert this energy kinetic energy to pressure head of
gas. There will be pressure increase between the wheel outlet and the outlet
of the turbine. Diffuser will help to minimize turbulence in air stream flow after
turbine casings.
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pump.
5- Oil cooler .
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If main oil pump is operated by main gear box Bull gear, oil pump will take enough
time to become stand still due to heavy mass rotation. As result oil supply to
equipment will drop gradually and stand by pump will be in operation on time.
Emergency oil tank is omitted from these equipment.
If oil reach to feed flow , it can reach to column will create operational hazards and can
lead to ASU explosion.
To have safe operation of expansion turbine, oil seal on shaft is provided to avoid oil
movement towards process feed flows.
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Gear Box
refer to air compressor
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ATTENTION:-Operator have to check dew point from turbine body drain and it
should be less than -40oC.
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3-Main oil pump and AUX. lube oil pumps get primed.
3- DFE get derimed and dew point of DFE machine is less than -40o C.
3- After cool down properly , commission DFE & close all drain, than inform DCS.
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Oxygen as liquid is produced from lower part of low pressure column in condenser.
Oxygen purity is 99.6 % to 99.8 % . Liquid oxygen production pressure outlet of
Column is 0.6 to 0.7 kg/cm2.. Liquid oxygen will get pressurize to customer header
pressure by internal compression pump. Compressed liquid will pass through fin type
Plate heat exchangers and will leave cold box from warm end of heat exchanger at
supply header pressure . pressure of oxygen gas is 30 to 32kg/cm 2 . As liquid oxygen
get compressed and vaporized in plate heat exchanger, compression is named as
internal compression. Liquid oxygen pump is named as internal compression pump.
Suction pressure of LOX I C Pump is 2.0 to 2.4 kg/cm2 base on condenser level.In order
to evaporate and warm up the compressed liquid a counter current stream of Air with
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higher pressure than the required liquid pressure is required due to thermodynamic
reasons. With this method a complex external Oxygen compression is no long
required, thus plant operation and maintenance has become considerably easier and
more reliable. Furthermore the risk of dangerous hydrocarbons enrichment in the
condenser is avoided because liquid oxygen is permanently withdrawn from
condenser. Pumped liquid and evaporated in the heat exchanger saves power and
reduce maintenance cost of oxygen compressors, Compared by external compression
system.
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Liquid pump term is used for pumps used to transfer liquid product under controlled
operating conditions. These operating conditions are:-
1-Working temperature
Structure of pump depends upon requirement of discharge pressure and flow. LOX I C
pump can be a single stage or multi stage pumps.
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In GAS liquid pumps are arranged with cryogenic liquid storage tanks and with
distillation column and are routed to meet ASU process requirements.
Types Of Pumps
Following types of cryogenic liquid pumps are used :-
Nitrogen as dry gas is recommended for sealing media. Nitrogen gas for seal gas is
normally drawn from nitrogen customer header and step down to required pressure
by pressure control valve. This is to ensure that seal gas will be available at required
pressure all time.
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Seal gas pressure is always maintained more than reference pressure. Additional
pressure valves are determined according to nature of leaking material.
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Seal gas flow control is based on reference pressure that operates pressure differential
controller to regulate seal gas flow.
Reference pressure and seal gas pressure are indicated on a pressure PDI gauge. Red
pointer indicates reference pressure and black pointer indicates actual seal gas
pressure. Seal gas streams are named as:-
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NOTE: Pumps running with slow roll, standstill seal is not require.
Labyrinth type seal gas system is provided with pump to minimize cold travel to
Liquid pumps motor power supply voltage are 460V and can vary depending upon
motor power and nature of motor duty.
Customer GOX supply varied time to time so that LOX I C pump discharge pressure
controller and down stream Flow controller will maintain pump discharge flow and
pressure accordingly.
As I.C pump smooth operation is required for proper functioning of main heat
exchanger.
2- LOX I.C pump outlet recycle valves HIC/ PIC are provided to control the load on
main heat exchanger and LOX I.C pump.
3- Stand by pump keep running on Slow roll, it can loaded up any time in case of
running pump trip. .
5- Motor over load protection provided to safe motor from over load operation.
8- Shaft and Seal temperature LO LO will trip motor to protect motor from cold
creep.
Solidified hydrocarbons in LOX will reach to LOX I.C. pump inlet strainer. As a result pump
inlet strainer will get chock after certain period of time. Strainer chockage will be
indicated by DP local gauge / transmitter OR by pump performance. To do cleaning of
strainer, deriming of Lox I.C pump is recommended.
For detail procedure follow to SOP of GAS for LOX I.C pumps deriming.
1- Check and confirm that all PTW get close and lock out/tag out get
removed.
2- Check area housekeeping get complete.
3- LOX I.C pump insulation packed properly and cold box closed and
cold box GAN purge commission.
4- Check dew point from LOX I.C pump casing blow. It must be less
than -40oC.
5- Follow LOX I.C pump cool down procedure as SOP of gas. cooling
rate should be slow so that all pump parts get cool down properly
6- Inform to DCS operator before Start LOX I.C pump from field
switch on slow roll.
7- Keep pump running condition on slow roll for hours to ensure all
pump parts get proper cool down and check pump for any
abnormality or leakage.
All these heat exchangers are made from aluminum metal due to good
heat transfer quality. A number of streams are pass through each block of
heat exchanger, Some streams are high pressure and some are low
pressure.
As feed air comes out from main heat exchanger cold end. It is in form of
mist very near to have state of change to get liquefied.
Special care should be taken during injecting LOX to heat exchanger after
taking I.C. pump in service. During deriming or start up of the plant warm
up or cool down rate should not be more than -30oC.
Process Technology
All element have three state as mention below:-
1-SOLID state.
2-LIQUID state.
3-GASEOUS state.
3-Critical Press. There are specific pressure points for all liquids/liquid
mixtures and gases to have change of state. If pressure is
increased above this specified point, change of state will
not take place even temperature is raised or reduced to
any level. This specific pressure is call CRITICAL PRESSURE
5-Flash Point. Flash point term is also used to indicate boiling point of a
element in liquid state.
Distillation
These gases are accepted for commercial use . For example steel mill and
petrochemicals plants uses high purity Oxygen purity for their process and Nitrogen
gas is used for plant purging and blanketing or sometime in the process and at GAS it is
used for emergency instrument gas supply.
Temperature.
Distillation of feed air starts as air get into distillation column. Mostly all feed air is
entering to lower column from lower portion of column. In some plants expansion
Turbine discharge flow is directed to low pressure column. Sieve trays arrangement
starts from upper level of air pipeline to pressure column. Sieve trays are arranged in
bundles ( As required to meet design requirements, bundle can have any numbers of
trays).
Feed air will start liquefaction if temperature and pressure conditions get satisfied.
Normally pressure column temperature in bottom is -173 to -174oC and pressure varies
from 4.0 to 5.5 kg/cm2. Temperature at upper part of pressure column is -177 to
o
-179 C and pressure varies as DP of pressure column.
Liquid rich in oxygen ( Rich Liquid RL ) will get collected in bottom of pressure column
or in sump and nitrogen gas vapors will evolve upward . Nitrogen vapors will change
to pure nitrogen gas or liquid after heat exchange with LOX in reboiler. Pure LIN or
GAN as product can be collected from upper part of pressure column.
ASU Column
Column is cylindrical in shape. There are three parts of air distillation column.
These are named as :-
1-Lower column or high pressure column.
2-Upper column or low pressure column.
3-Condenser.
1- Pressure Column. It is lower part of column and working pressure varies
from 4.0 to 5.4 kg/cm2. Gases and liquids temperatures
varies from -174 to -172oC at bottom of column .
Temperature at top end of pressure column varies from
Sieve Tray. A Type of tray with very small holes that holds liquid on it
in column for distillation.
Types of columns.
Distillation columns are named according to internal construction as under:-
A- Distillation methodology.
1- Sieve tray column.
As sieve trays are made of thin metal sheets . care will be required to avoid
followings:-
1- Sudden drop of pressure in column.
2- High cool down rate during plant start up.
3- High liquid holding on stay due to over design feed processing.
4- Rapid rate of loading and unloading of plant.
The packing used in cryogenic plants is like honeycombed sections having several light
sheets of stainless steel or aluminium rigid together.
The big advantage of packed columns is their low pressure drop and consequently a
low plant power consumption as compared to conventional sieve tray columns.
Because of advantage of low pressure drop is more critical at lower pressures.
In figure below left side view shows how streams inter act in pack column.
L iq u id in le t in to p r e - d is tr ib u to r
E le m e n t d is tr ib u to r
L o c a tin g g r id
S t r u c tu r e d p a c k in g
F e e d in le t in to r in g c h a n n e l
S u p p o r t g r id
V a n e c o lle c to r
E le m e n t d is tr ib u to r w ith
p r e - d is tr ib u to r
B e d lim ite r
R a n d o m p a c k in g
S u p p o r t p la te
G a s in le t s y s te m
Liquids Distributors.
Liquid distributors are used to give a uniform spread of liquid over the top surface of
the packed bed whilst permitting the passage of vapor through the distributor.
The quality of liquid distribution is of vital importance and any design and installation
should ensure equal distribution over the whole surface of the packing. A distributor is
required at every feed and product off take point and in argon columns between
sections of packing.
A liquid collection header is required for every liquid distributor to ensure uniform and
correctly distribution of liquid.
2- Packed coulmn .
Low
With developments of new technology low pressure columns are now a days are in
pack system arrangements.
Gases properties at 1
bar(Atms)
Freezing Gas density Liquid density
Boiling point (c) point (c) ( kg/m3) ( kg/m3)
As quality of liquid on every tray is different, therefore different quality products can be
withdrawn from column. These products are:-
Analysis Equipments
In GAS all analyzers are measuring oxygen in as product or as impurity with different
range of measurement. Every equipment is measuring with in specified range of
analysis.
Three type of analyzers are in service in gas as under:-
1- Paramagnetic analyzer for Oxygen concentration.(For Oxygen)
2- Zirconium Oxide analyzer for oxygen concentration.(For Waste Gas)
Oxygen analyzer.
In GAS all higher oxygen concentration analyzers are paramagnetic type analyzers.
These analyzers are working on paramagnetic properties of oxygen. This property
enables oxygen to get attracted toward magnetic field. See below self explained
working principle of instrument.
PRINCIPLE OF MEASUREMENT
In the cell, two glass spheres filled with nitrogen gas are suspended with strong metal.
At first, the spheres are kept in balance in an inhomogeneous magnetic field. When
oxygen molecules having a large magnetic susceptibility flow there, the molecules are
pulled toward the stronger magnetic field zone and the spheres are moved away
from the zone. The resulting deviation of the spheres is detected with the light source,
reflecting mirror and light receiving element, and a current is flowed through the
feedback loop to control so that the spheres can return to the initial balanced state.
The current flowing through the feedback loop is proportional to oxygen
concentration. Thus, oxygen concentration is converted into an electric signal. Electric
signal is converted to display for indication of results.
The sample gas diffuses through the Teflon membrane. Any oxygen in the sample gas is
reduced on the surface of the cathode by the following HALF REACTION:
(Four electrons combine with one oxygen moleculein the presence of water from
the electrolyteto produce four hydroxyl ions.)
When the oxygen is reduced at the cathode, lead is simultaneously oxidized at the
anode by the following HALF REACTION:
Therefore it takes two of the above anode reactions to balance one cathode
reaction and transfer four electrons.)
The electrons released at the surface of the anode flow to the cathode
surface when an external electrical path is provided. The
current is
proportional to the amount of oxygen reaching the cathode. It is
measured and used to determine the oxygen concentration in the gas mixture.
Reboiler
A tubular/fin plate heat exchanger placed at the bottom of low pressure distillation
column or stripper to supply necessary column vapors or heat. (Reboiler at the
bottom of upper column which is also a condenser for lower column
Condenser:
B a th C o n d e n s e r
GOX
- u s e d f o r o n e - s t o r ie d c o n d e n s e r s
GOX
LO X LO X
- lo n g o p e r a t io n e x p e r ie n c e
PGAN
- n a t u r a l L O X c ir c u la t io n
- n o o x y g e n p ip e w o r k o n t h e c o n d e n s e r
LO X LO X - f it f o r A S U 's w it h lo w p r e s s u r e G O X -
p ro d u c t
PGAN
Top of
P re s s u r e c o lu m n
L O X r in s in g lin e
D o w n F lo w C o n d e n s e r LOX
- u s e d in s te a d o f tw o -s to rie d o r
PGAN
m o r e -s to rie d b a th c o n d e n s e r s
- no condenser vessel
- L O X - r e c y c l e p u m p f o r r e f l u x is n e c e s s a r y
P L IN - o x y g e n p ip e w o r k is n e c e s s a r y
- f i t f o r A S U 's w i t h in t e r n a l L O X c o m p r e s s i o n
G O X+LO X
- f it f o r la r g e s iz e A S U 's
P L IN - e n e r g y s a v i n g s o lu t io n
PGAN Top of
P r e s s u r e c o lu m n
C) Combi Condenser:
C om bi C ondenser
L O X fr o m L o w p r e s s u r e c o lu m n
- C o m b in a t io n o f b a t h c o n d e n s e r p lu s
d o w n f lo w c o n d e n s e r
PGAN
- n o o x y g e n p ip e w o r k
- n o L O X - r e c y c le p u m p in c o n n e c t io n
P L IN
w it h K r /X e - p r o d u c t io n
G O X+LO X G O X+LO X
G O X +LO X G O X +LO X - L O X - r e c y c le p u m p f o r r e f lu x is n e c e s s a r y
PGAN
w it h o u t K r /X e - p r o d u c t io n
P L IN - f it f o r A S U 's w it h in t e r n a l L O X c o m p r e s s io n
P L IN - f it f o r la r g e s iz e A S U 's
PGAN Top of
LOX P r e s s u r e c u lu m n
L O X p r o d u c t f o r t h e in t e r n a l
c o m p r e s s io n
Condenser / Reboiler
Hazard Operation
As feed stock of ASU process plant is AIR and sucked from atmosphere. Atmospheric
conditions varies from location to location for contaminations of hydrocarbons.
Hydrocarbons are extremely dangerous for ASU operation as all will get accumulate in
low pressure column lower portion and finally will reach to condenser and reboiler.
All gaseous products are directed to compressors for gas compressor to meet customer
supply requirement. Nitrogen supply pressure is maintained at 11.5 kg/cm 2. And
gaseous oxygen pressure in maintained at 32 kg/cm2 (can vary as per customer
demand).
In GAS only centrifugal oxygen compressors are used for oxygen gas compression.
These oxygen compressors are operating with ASUs as under:-
The OG Compressor is probably main equipment and the most important equipment
on the site, Oxygen gas supply to customer will be impossible without this equipment
from these ASUs as product pressure is too low.
Construction:
The compressor unit consists of two casing namely low-pressure casing and high-
pressure casing.
Low /High -pressure casing is made of suit able material specifications and having 5
stages with built in / after stage intercooler. Low pressure casing is housing 3 stages
and further every stage is having more than one impellor. For example ASU 21 /22
oxygen compressor 1 /2 /3 stages have 2 impellors in each stage and High pressure
casing for 4 / 5 stages have 3 impellors in each stage.
All stage impellors are close impellors to minimise gas losses from stage outlet nozzles.
Low and High-pressure inter stage coolers are also made of suit able material
recommended for oxygen service. Interstage coolers are arranged in 2 constructional
way as under:-
1- Shell and tube type interstage cooler for every stage.
2- Parallel side build cooler for LP stage only and HP stage with shell and tube
type interstage coolers.
Oxygen compressor all stages are having same speed as both stage shafts are coupled
together.
Gas System:-
Oxygen as gas is produced from distillation column. Product gas pressure is about
0.65kg/cm2 and temperature of gas is -180oC. After heat exchange in cold box with air
streams, oxygen at pressure of 0.45 to 0.5 kg/cm2 and temperature about 20oC will
leave cold box. Oxygen product flow if measured by Restricted Orifice placed in
product line. Product line pressure is control by pressure control valve by venting of
gas. Manual valves are provided to isolate ASU unit if required.
Figure below for oxygen gas production layout ex. Cold box.
Low pressure oxygen as gas will enter to compressor suction. Compressor suction line
is provided with shut off valve. This valve is ON/OFF type valve and will get fully close
if any malfunction or unsafe operation detected by process control.
XV PV
Oxygen compressor will run on nitrogen cycle. Inlet shut off valve and discharge valve
to customer will get close and vent valve will get open.
As differential pressure across valve is high, valve operation creates lot of noise and it
makes unsafe entry to compressor housing without proper safety gears.
Oxygen compressor is housed in flame proof housing to minimise damage risk in case
compressor get fire. Secondly this housing also serve as acoustic housing to reduce
sound level of compressor area.
A fine mesh metallic filter is provided at inlet of compressor to avoid any hard particle
entry to impellor. As hard particle will generate friction in gas passage and atmosphere
is rich in oxygen will get fire immediately. Regular cleaning is recommended for this
filter. Dry Gas Fiter for compressors
Compressor Impellors
As suction pressure of
oxygen varies from 2500 to
3500 mmWc and discharge
pressure of compressors
varies from 28.0 to 32.0 kg / cm2.
Oxygen compression is
carried out in nos. of stages.
Oxygen compressors are
5 stage compressors
and further every stage is
having more than one
impellor as arranged internally. All these impellors are close impellor as shown in
figure below.
ASU 21 / 22 oxygen compressors are having 2 impellors in each stage in Low pressure
casing and 3 impellors in each stage of high pressure casing.
The main pump is driven through the low speed gear shaft, while the auxiliary one is
separate motor driven which can be start/stop on DCS.
Pumps draw oil from reservoir and pump to a pressure up to 2.5 kg/Cm2 cool down in
oil cooler than passes through the filter before entering to the bearing and gear box
for lubrication. A thermostatic mixing valve is also provided which mix the oil from the
pump and the cooler outlet to maintain an oil temperature as recommended by
venders. During cold operation this valve restricts the oil through the cooler to raise
the oil temperature quickly. As well as, an oil heater system is also provided in the
reservoir which maintain the reservoir temperature >20 oC . If the heater on Auto ON
position heater will be ON/OFF automatically according to the temperature set value.
Emergency oil supply tank is arranged with compressor having both oil pump on
electric motor drive. Oil tank is located at suitable height to maintain oil pressure to
compressor rotating shaft bearings for some time as Aux. lube oil pump will be in
operation as soon as low pressure alarm get activated.
The auxiliary pump provides the oil during start up till main pump discharge pressure
reached to required pressure than pump will stop automatically.
During operation if the oil pressure dropped due to any reason to pre set value. @nd
or Aux. oil pump will start automatically to avoid compressor train shutdown.
Auxiliary oil pump start automatically, and oil pressure is not controlled above preset
pressure value, compressor will trip.
The two notch type clean able filters are provided to clean the oil supply before going
to the bearings and gear box and motor bearings.
The notch filter is as type having a three-way cock valve. During normal operation One
filter is in service and other always in standby ready for service, If the D.P across the
filter reaches to max.1.0 kg/Cm2. changeover the filter to clean one. When switching
over one filter element to other care to be taken that the filter element taking in
operation is filled up with oil before Starting the handle switching over to stand by
element. Always do slowly transfer of handle simply in the opposite position.
Without having filled up the new one element, a pressure drop could be caused which
could lead to a shutdown of the compressor.
A three chamber are namely as Oxygen gas chamber, oxygen / nitrogen mixture
exhaust and equalizing chamber, and nitrogen gas as a seal /buffer gas chamber.
Nitrogen gas is injected into the seal gas feeding chamber through pressure control
system with reference to pressure extracted from the equalizing chamber.
The exhaust chamber is located in between the seal feeding and equalizing chamber,
from where the leakage of oxygen is concluded based on gas analysis. Regular analysis
of gas vent will help to monitor performance of gas seal system.
In the equalizing chamber leaked oxygen gas is collected. So the pressure of leakage
gas, which is collected in equalizing chamber, will be almost equal to suction pressure,
which works as a reference pressure to PCV for buffer gas.
Oil Seal:-
Another labyrinth seal also provided to stop oil traveling to the gas side, this labyrinth
is placed in between shaft seal and bearings housing. N2 gas from seal gas control
system is supplied to this seal to avoid oil to mix with oxygen gas.
Labyrinth seal are made of light alloy or material resistance to oxygen corrosion and
having less hardness than that of the shaft to avoid any change to the shaft in the
event of a any accidental contact.
Every centrifugal compressor has got a curved called Surge Curve whose shape
depends on a number of mechanical and aerodynamic factors. Surge curve is traces
out experimentally; it separates the machine-operating range into two areas.
Stable operating area
Unstable operating area where surge takes place leading to a heavy mechanical
damage. Possible damages caused by surging can be:
1-Thrust bearing failure.
2-Rubbing of labyrinth strips causing higher clearances and consequently
higher leakages/thrust forces.
3-Rubbing of impellers blades.
4-Failure of blading on axial compressor due to overstress / overheating.
5-Damage on suction filter, silencer, process armature etc.
To avoid surging anti surge system is provided which has been programmed in DCS
panel at control room.
Anti surge valve will be operated at low flow as calculated by programmed formula
and high discharge pressure to save the compressor from surging.
Flow Switch:
Vibrations:-
Bentley Nevada system 3300 is provided to indicate all the shaft vibration of the
compressors shaft. An electric Signal from Bently Nevada monitor comes to DCS for
vibration monitoring.
ALERT and DANGER alarms setting also provided which can be seen by pushing alert
and danger push button for each vibration indicator on monitor panel.
Oxygen gas is introduced to compressor gradually and finally compressor get fully inlet
flow media as oxygen gas.
Gas analysis will be conducted from compressor outlet before connecting to customer
supply header. At latest practice compressors are provided with discharge product
analysis confirmation to open discharge valve to header.
If both ASU 21 /22 are shutdown and oxygen compressor header tie in valve is closed,
oxygen compressor will be purged from respective unit to get product purity at
compressor discharge end after low and high pressure purging.
after motor get its normal running speed as motor is induction motor. Nitrogen
injection valve will get close gradually and oxygen inlet valve will open gradually. Vent
valve to atmosphere will remain open till product quality get confirm and main
discharge valve opening permitted by interlock reset.
Do not start any job in compressor housing before taking gas test of atmosphere in
oxygen compressor housing by gas sniffer. Do gas test on regular basis.
Personnel Safety.
Please follow this instruction, proceed with caution, especially in the described
situation, and follow to all work safety measures on to other users.
To be observed are not only the safety instruction included in this OM, but also the
General safety Measures for the prevention of accidents should be followed.
Caution Sign.
Some safe work practice signs are explained in operation manual of compressor OM,
those have to be especially considered, So that work instruction, safety measures and
Proper guideline are correctly followed, In order to avoid damages and destruction of
machines and / or other components.
1- In Gas Jubail area gaseous nitrogen purity is maintain at less than 10 ppm.
2-In Gas Yanbu area gaseous nitrogen purity is maintained at less than 5 ppm.
1-Compressor
casing and
stages.
Compressor Casing (Each stage) provide housing for impellor, diffuser, IGV and
inlet /outlet port of gas. commonly it is made of steel or alloy steel depending upon
nature of duty. In multi stage compressors stage casings are located in line of pinion
shaft as power to impellor will be provided by pinion shaft and are mounted on
gearbox frame structure.
As balance gas is collected from back side of impellor to minimize axial thrust on
impellor. This balance gas is also used as internal seal gas source. For external seal gas
source nitrogen supply from seal gas header is arranged to maintain all time seal gas to
nitrogen compressors.
Balance gas pressure helps to maintain shaft seal gas pressure for internally build seal
gas systems
9-
Storage Area
In GAS all ASUs products are being delivered to customers directly. No buffer storage
zoon is provided in system to supply gases to customer in case of plant shutdown for
some time.
As products liquids temperatures are too low, Specially designed storage vessels are
required to hold products in liquids form. GAS have storage for following products:-
All liquids storage tanks are double walled tanks and insulated to maintain inner tank
working temperature. Inner tanks working temperatures are in range of cryogenic
temperatures, Storage tanks are named as cryogenic storage.
In GAS both type of storage facilities are in service for following services:-
1-LOW PRESSURE
ATMOSPHERIC
TANKS:
Road tankers are filled through low / high pressure pumps to supply
LIN/LOX/LAR liquid to customers.
Storage product quality is continuously analyzed and maintain to avoid any risk of
contamination with LIN/LOX/LAR products while leaving plant to the storage.
In all plants low pressure cryogenic liquid storage tanks are provided to store liquid as
product.. Max. working pressure of tanks is 0.08 kg/cm2 or 800mmwc.
Tank test pressure is 0.1223kg/cm2 or 1223mmwc.
Tanks basements are made of concrete in two layers. About 2m space is provided for
cross ventilation to sweep out cooling from bottom of tanks if cold patch appeared on
bottom ring.
Liquid storage tanks are designed to withstand with high wind pressure.
Design Wind speed. 160km/Hrs.
These internal shut off valves can be RESET by Push button operation from field if shut
off valves are electro pneumatic type. System needs reset by key operation from field
cabin. Before resetting shut off valves operated emergency switch must be normalize
otherwise system will not be Reset.
In some LOX/LIN storage tanks emergency shut off valves resetting is performed by
MANNUAL operation. Electric supply to electromagnetic solenoid valve is normally
380V. Operator should observe extra care during valve resetting operation.
1- Field operator has to visit area immediately and confirm to DCS operator about area
situation.
2-Field operator to confirm from DCS operator about ES. Get operated.
3-DCS will confirm ES. Number get operated.
4-Field operator will visit ES in field and release it.
5-Field DCS operator confirm to Field operator that ES is normalized and then field
operator will open EM. Shut off valves by push buttons one by one.
6-Field operator will confirm from DCS operator about status of valves that all get
open or not.
7-Field operator will reset all the pumps from substation panel.
8-Field operator will reset LIN backup pumps A/B by putting the field switches to OFF
position then put on Ready position and some pumps needs to confirm that back up
pumps cooling fans are in operation.
9-Confirm with DCS operator that area get normalized.
GAN is supplies to the annular space of the tanks to keep Perlite powder always dry
with a local flow indicator to ensure always availability of purge gas to the tanks. GAN
supply to purge line is arranged from GAN main header.
Operator Safety:-
Tank storage area have bulk LIN/LOX storage, Area can have oxygen deficiency or
enrichment due to leakage /spillage of liquid . For employees safety areas are
provided with local area analysis equipments to warn out all concerns in area. A
siren will get activate and a area light will start blinking as soon as area get
deficiency or enrichment of oxygen in area.
All personnel those are in the area of the tank, as a minimum, should review the
following documents for awareness of personals physical hazard:
Before product is introduced into tank, the GAS should develop procedures to cover
spillage, traffic, visitors, maintenance, emergency evacuation and fire fighting, etc. if
emergency get develop in the storage area.
Construction Of Tank:
These tanks are normally double wall tanks. Internal tank is high pressure tank made
of alloy steel suitable for cryogenic temperature operation. Outer shell is made of
carbon steel and space between two shells is filled with insulation material and after
that insulation filling performance is further enhanced by vacuum as vacuum is also
non conductor of heat media.
Based on construction and duty performed these high pressure tanks are named as
Atmospheric Vaporizers
media. LOX / LIN supply to vapouriser are arranged from LOX /Lin high pressure tanks.
Both liquid flows are in counter directions. Sea water is distributed from top of
vapouriser and get collected in pit for further disposal to sea.
Liquid pumps
Liquid pumps used to transfer liquid product under controlled operating conditions to
LIN/LOX vaporizers and to fill LIN/LOX /LAR road tankers. These operating conditions
are:-
1-Working temperature
To prepare Liquid pump for operation, Follow following guideline and also follow
to standard operating procedure (SOP) of GAS for liquid pumps cool down.
1- Check and confirm that all PTW get close and lock out/tag out get
removed.
2- Check area housekeeping get complete.
3- Liquid pump cold box insulation packed properly and cold box
closed if provided. Cold box GAN purge must be open before cool
down.
4- Check dew point from liquid pump casing / pipeline blows, It must
be less than -45oC.
5- Follow to liquid pumps cool down procedure as SOP of gas, cooling
rate should be slow so that all pump parts get cool down properly,
wait till all pump casing and pipe lines get heavy ice coating.
6- Inform to DCS operator before Start liquid pump from field switch.
The storage tank which is double walled vacuum insulated vessel having little
evaporation loss and highly reliable for safe transportation of cryogenic liquids. These
tanker are used sometime for storing of liquefied argon/oxygen/nitrogen. As tanker
vessel is vacuum insulated , it is also named as VIT.
These tankers are of different capacities. Tanker are designed for low pressure
2.5kg/cm2 and high pressure from 18 to 25 kg/cm2.
High pressure tankers are used to do liquid decanting to customer VIEs without pump.
Low pressure inner tank vessel tankers are provided with liquid pumps to transfer
liquid from Tanker to customer VIEs. Tankers Liquid pumps are capable to deliver liquid
to customer VIEs up to 18 kg/cm2 pressure.
Jubail Area
1- ASU 31/41/51/71 Main air compressor drives 13.8KV
8- All other motors and heaters power supply varies from 380 to 560volts.
9- All chemical dozing pumps power supply varies from 110to 220 volts.
Yanbu Area
1- ASU 32/42/52 main air compressor drives 13.8KV
2- ASU 32/42/52 booster compressor drives 13.8KV
3- All Nitrogen compressor with capacity of 50000Nm3/Hr. 13.8KV.
4- All chilling units CW and SW pumps. 4.16KV
5- All other motors and heaters supply varies from 480 to 600 volts.
6- All chemical dozing pumps power supply varies from 110to 230 volts
Alternative current as it passes through stator winding produce EMF field in motor
rotor and stator . Magnetic field will force motor rotor to rotate as result of repulsion
and attraction of magnetic pools.
These motors are equipped with power factor correction mechanism known as excitation
system. As motor power factor is less than 1 due to Cos . Excitation system will improve
power factor and approach to 1.
In these days electric motors stator cooled with external draft of air are preferred as these
motors are treated as water proof as water will not enter in motor even it get in water.
Power is supplied under controlled monitoring system. Electric motor will start with
normal operating voltage and frequency of 15Hz.
Motor rotor will start rotation with slow rotation and rotor rotation will increase as
power supply frequency will increase. Normally it takes 2 min. to achieve normal
frequency of 60 Hz. M
Motor will achieve its max. speed called as synchronized speed. System will confirm all
informations before shifting power supply from main power supply breaker.
As power supply to motor will get consume very gradually, no power impact will be
observed on main power supply grid. This system will help to avoid limitations on nos.
of starts of motor in 24Hrs.
Process Instrumentation:-
To have a smooth plant process it is very important to maintain certain parameters of
processing raw material to acquire product on specification. These basic parameters
are:-
1- Level of liquids in different parts of plant equipment (L).
2- Pressure of processing media stream in different locations (P).
3- Temperature of processing media streams in different locations (T).
4- Flow of processing media in different streams of process in plant (F).
5- Differential pressure in streams across equipments (PD).
To measure all these parameters standard practice instrument are installed in plant
layout on stream as routed and as required basis.
1-LEVEL
Basically level is measured on differential measurement of head pressures as under:-
1- Total head pressure -----------HT
2- Vapor head pressure-------H
3- Net level head -------------HN
HN = HT - H
Level Gauge.
Level glass gauges are provided in field to indicate levels of pits and tanks. These glass
gauges are graduated with scale to measure levels.
With the development of digital display systems, in these days digital level indicator
are provided in plants on site. These helps to minimise error in data recording.
There are 2 types of transmitters available in field. One type is box type to send only
electric signal and 2nd is window type provide display of data in field and serves as
field gauge.
2-Pressure
Pressure is force to drive process media from one place to another place. It is
measured in different units of measurements as under:-
Basic measuring tool is pressure gauge. Pressure gauges are available to measure
pressure in all standards. Pressure is measured in 2 scales as positive or negative .
Negative pressure is measured in term of water column height and noted as WC with
measuring unit. For example 10mmWC .
Pressure gauges
Pressure gauges are used to measure wide range of Positive / Negative pressures.
Dial type gauge provided with needle to indicate pressure value of stream at any
location.
To have accurate values of data, Now digital display type pressure gauges are also
available on plant site. These are also equally used to measure Positive / Negative
pressures.
Pressure Transmitters
Pressure transmitters provides services to transfer pressure data equivalent electric
signal to control panel via field junction box.
Different type of transmitters are available for service. Window type transmeters
provide service of gauge also as data can be read in field.
3-Temperature
Degree of hotness or coldness of a fluid media is measured in terms of temperature.
Following measuring scales are used in normal practice:-
1- Degree centigrade. oC 0 o C as water freezing point.
2- Degree Fahrenheit oF 32o F as water freezing point.
o
3- Degree Absolute. A 273.2o C as water freezing point.
o
4- Degree Kelvin K 273.2o C as water freezing point.
o
5- Degree Rankin R 492oF as water freezing point.
All these temperature scales are transferable to each other by applying equivalent
scale conversion equations as under:-
o
C = (oF - 32) / 9/5.
o o
A/K = C + 273.2
o o
R = F + 460
To measure temperature following equipments are used in GAS.
1- Temperature gauge.
2- Thermocouple.
3- Resistance temperature detector (RTD)
1-Temperature Gauge
2-Thermocouple:-
It is used to measure temperature in a wide range. It is working on principle as under:
The junction between two metals generates a voltage which is a function of
temperature. Thermocouples depend on this feedback effect. Although almost any
two types of metal can be used to make a thermocouple, a number of standard types
are used because they possess predictable output voltages and large temperature
gradients. The diagram below shows a K type thermocouple, which is the most
popular:
4-Radiation Pyrometers:-
If working temperature of object is too high and human reach is unsafe, radiation
pyrometer type instruments are used to measure temperature. Pyrometer is working
on electric signal principle as under:-
4-Flow Of Stream.
Every process
demands specified
amount of feedstock
to produce specified
amounts of
products. To supply
specified amount of
feedstock, standard
measuring instruments and systems are applied. Flow of fluid through a pipe is
function of followings:-
F = PAV
There are several types of flow measurement devices. Commonly used devices in gas
are:-
Control Valves
Control valves are valves used to control conditions such as flow, pressure,
temperature, and liquid level by fully or partially opening or closing in response to
signals received from controllers that compare a the set point" to a "process
variable" and operate the control valve accordingly.
Dry instrument air or nitrogen is recommended for supply of air to control valves.
Supply pressure to valve is maintained in between 3.5 to 5.0 kg / cm 2. As observed
from control valve behavior, if supply pressure get drop below 3.5 kg/cm2 could be
malfunctioning.
Self control valves are provided in the plant to maintain the required stable upstream
or downstream pressure. These valves are usually used to maintain the pressure with
small flow rate.
These type of valves are diaphragm type operated valves. One side of diaphragm is
provided with spring force to move spindle and other side of diaphragm is provided
with a pressure force of fluid (gas or Liquid ) needs control of operating parameters.
As soon as pressure drops in upstream / downstream of valve, self controlled valve
will operate to compensate it. No control system required to assist valve functioning.
Control loop
Measuring data, processing the data from feedback information and finally making a
control action to operate the valve. These three functions make up what is known as a
control loop.
Kg 1.0 0.001 0.700 0.2315 0.8765 1.0 0.001 0.800 0.326 1.237
Ton 1000 1.0 700 232.4 879 1000 1.0 800 328.6 1,244.0
Nm3 1.4285 0.0014 1.0 0.3205 1.2558 1.2500 0.0013 1.0 0.4106 1.5552
Gallon 4.321 0.0043 3.120 1.0 3.78531 3.059 0.0030 2.435 1.0 3.7853
Liter 1.1416 0.00126 0.7963 0.2642 1.0 0.80829 0.00089 0.6430 0.26417 1.0
ARGON HYDROGEN
US US
Kg Ton Nm3 Liters Kg Ton Nm3 Liters
Gallon Gallon
1.0 0.001 0.5603 0.1896 0.7178 1.0 0.001 11.124 3.7236 14.0949
1000 1.0 560.3 189.8 718 1000 1.0 10,092 3,378 12,787
1.7847 0.0018 1.0 0.3387 1.2815 0.0898 0.000099 1.0 0.3346 1.2671
5.2743 0.0053 2.952 1.0 3.78531 0.26857 0.00029 2.9881 1.0 3.78531
1.393 0.0013 0.7803 0.26417 1.0 0.07094 0.000078 0.78919 0.26417 1.0
1 Nm3 = 3.940 Kg
1 Kg = 0.2538 Nm3
1 Kg = 253.8 Liter
1 Liter = 0.00394 Kg