Overview of ASG Rotating Equipment - PPT PDF

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Mechanical Training

TOPICS: 1.

Definition of Rotating Equipment

2.

Different Types of rotating equipment

3.

Definition of compressor and its classification

4.

Centrifugal compressor-Definition, working principle, major components and application at ADNOC Sour Gas

5.

Reciprocating compressor- Definition, working principle, major components and application at ADNOC Sour Gas

6.

Definition of pump and its classifications

7.

Centrifugal pump-Definition, working principle, major components and application at ADNOC Sour Gas

8.

Difference between compressor and pump

9.

Turbo expander – definition, working principle and application at ADNOC Sour Gas

10.

Steam turbine – definition, working principle, components and application at ADNOC Sour Gas

At the end of the module the trainees are able to : • Understand the purpose and functions of Rotating equipment in ADNOC Sour Gas. • Familiarize the rotating equipment in ADNOC Sour Gas. • Identify at site the different type of Rotating Equipment in ADNOC Sour Gas.

A device consisting of fixed and moving parts that converts/modifies the input energy into useful work. • The input energy may be electricity, Chemical ( fuel), pneumatic or hydraulic. • Rotating equipment moves products such as solids, liquids and gases Examples: • Compressor, Pump, Turbo expander, Turbine, Fin Fan Cooler • Rotating equipment in ADNO Sour Gas (Main Plant) (4- Steam Turbines, 24- Compressors, 301- Pumps, 1569- Motors)

Compressor

Pumps

Turbo expander Compressor

Steam Turbine Generator

Fin Fan Cooler

• Compressor is a machine which increase the pressure energy of a compressible fluid, either gas or vapor. • A device that transfers energy from the prime mover to a gas fluid for the purpose of raising the pressure energy of the gaseous fluid. • Applications of Centrifugal Compressors in ADNOC Sour gas are; • • • • •

721/22-C-201 AB: Vapor Recovery Compressors 730-C-201 ABC: Refrigerant Compressors 740-C-201 ABC: Residue Gas Compressors 741/42-C-101: Regeneration Gas Compressor 741/42-C-302: Recycle Gas Compressors

• A compressor that operates by volumetric displacement is called a positive displacement compressor. • A positive displacement compressor first traps a volume of gas in a cylinder or casing. Then the gas is displaced into a smaller volume, or space. The greater the reduction in volume, the greater the increase in pressure.

• Most positive displacement compressors operate with reciprocating motion, but some use rotary motion. Screw Rotary Type

Lobe - Rotary Type

Piston - Reciprocating Type

• Reciprocating compressors are machines which raises the gas pressure by using reciprocating motion • The reciprocating compressor is probably the best known and the most widely used of all compressors. • Gas is displaced with back-and-forth or up-and-down motion in a reciprocating compressor.

1) 0726-C-101A/B Recycle gas compressor Recycle Gas Compressor is equipped with valves un-loaders in order to be operated at 0%, 50%, 75% and 100% of maximum capacity.

2) 0726-C-102A/B Make-Up Hydrogen Compressor Two stage reciprocating compressors of make SAID M/C impianti, Italy ; type;2HD2, one operating and one spare. Hydrogen from the make-up header enters. Make-up Hydrogen Compressor 1st Stage Suction Drum and is compressed in the 1st stage of Make-Up Hydrogen Compressor from 21 barg to approximately 32 barg. The discharge gas from the compressor 1st stage is air cooled in Make-Up Hydrogen Compressor 1st Stage Discharge Cooler and the cooled make-up hydrogen enters Make-Up Hydrogen Compressor 2nd Stage Suction Drum and is compressed to approximately 56 barg in the second stage of the compression.

3) 0726-C-201 Recycle H2 Compressor It is an electric motor driven reciprocating compressor. It compresses the slipstream of hydrogen produced from the PSA Unit, which is added as recycle hydrogen to the unit feedstock upstream of feed preheating train. Recycle Hydrogen is compressed in recycle hydrogen compressor 0726-C-201 from 21 barg to 31.8 barg and mixed with Natural gas feed before being sent into Hydrodesulphuriser (0726-R-201). Recycle Hydrogen Compressor is equipped with valves unloaders in order to be operated at 0%, 50%, 75% and 100% of maximum

• Dynamic compressors are machines which raises the pressure energy of the compressible fluids by using the acceleration force. • The dynamic compressors are further subdivided into three categories, based primarily on the direction of flow through the machine. These are radial, axial, and mixed flow. • The radial-flow, or centrifugal compressor is a widely used compressor and is probably second only to the reciprocating compressor in usage in the process industries.

• In dynamic compressors, energy is transferred from a moving set of blades to the gas. The energy takes the form of velocity and pressure in the rotating element, with further pressure conversion taking place in the stationary elements. • Because of the dynamic nature of these compressors, the density and molecular weight have an influence on the amount of pressure the compressor can generate.

• A compressor that uses centrifugal tendency to impart velocity and pressure to a gas is called Centrifugal Compressor. • In a centrifugal compressor, energy is transferred from a set of rotating impeller blades to the gas. The designation “centrifugal” implies that the gas flow is radial, and the energy transfer is caused from a change in the centrifugal forces acting on the gas

Horizontally split compressor:

Vertically split Compressor:

1) 0721-C-201 Vapour Recovery Compressor The Vapour Recovery Compressor (0721-C-201) is a two process stage centrifugal machine and these gases are compressed: from 6 barg to 28.5 barg in the 1ststage from 27.7 barg to 70.0 barg in the 2ndstage

2) 0730-C-201A/B

Refrigerant Compressors

Each compressor is a two stage centrifugal compressor driven by a variable speed motor (VSD). Each compressor is rated at approximately 18 MW with a 1 MW first stage and a 17MW second stage. The speed of the compressor motor driver is controlled by the refrigerant demand of the high and low pressure level users. The normal compressor operating pressures are: first stage suction at 8.6 barg, and second stage suction at 12.0 barg. The discharge of the second stage is approximately 26 barg, this is dictated by the condensing temperature in the Refrigerant Condensers (0730-E-203A/B) which are set at 69°C.

3) 0740-C-201A/B/C

Residue Gas Compressors

This Compressor is a BCL 505 model Centrifugal compressor Made by GE-NP. It is a vertically split casing compressor, having a 500 mm impeller nominal size and 5 impellers on common shaft. Velocity range is from 5660rpm (JT Case) to 6700rpm (Normal Case). Driver is a Variable speed Electro motor with dry air purged and pressurized enclosure system, and air cooling facilities. To reach said velocity a Gear Box (multiplier) is installed between the Compressor and the Driver.

FUNCTIONS 1.

To move fluids from lower level to higher level.

2.

To move fluids from lower pressure areas to higher pressure areas.

3.

To increase the flow rate of the fluid.

1. Rotodynamic pumps  Operate by imposing acceleration on a liquid.  Velocity increases gives an increase in kinetic energy of the liquid.  The kinetic energy is converted to pressure energy by reducing the speed of motion of the liquid.

2. Positive displacement pumps  It works by taking in liquid at suction pressure, trapping it and pushing it out at the higher delivery pressure.  They are constant displacement machines  Deliver an approximately constant flow rate whatever the differential pressure.

Centrifugal pump is a machine which uses the centrifugal force to add the pressure energy to the incompressible fluid. A centrifugal pump is one of the simplest pieces of equipment in any process plant. Its purpose is to convert energy of a prime mover (an electric motor or turbine) first into velocity or kinetic energy and then into pressure energy of a fluid that is being pumped.

In Shah gas plant the pumps are used to move the various fluids such as water, Condensate, NGL, liquid Sulphur and other Hydrocarbon liquids through the different stages of gas processing. And also pumps are used to transfer the end products such as condensate and NGL to GASCO Habsan. The pumps which are used in our plants are listed below with name and tag no.

Unit: 721 0721-P-202A/B Inlet Separation Steam Condensate Pumps 0721-P-203A/B Stabilizer Reflux Pumps 0721-P-204A/B Light Condensate Pumps 0721-P-206 Methanol Portable Drum Pump 0721-P-201A/B Methanol Transfer Pump 0721-P-361A/B Absorber Water Wash Make-Up Pumps 0721-P-354A/B Sweet Gas Water Wash Pumps 0721-P-359A/B/C Absorber Side Cooler Pumps

Unit: 725  725-P-101A/B/C Condensate Booster Pump  725-P-102A/B/C Condensate Shipping Pump

Unit: 726 0726-P-101A/B Reactor Feed Pumps  0726-P-105A/B Wash Water Injection Pumps 0726-P-103/Z Closed Drain Pump 0726-P-201A/B BFW Feed Pumps 0726-P-203 Condensate Pump

Unit: 730 0730-P-201A/B Refrigerant Transfer Pumps 0730-P-202A/B Oily Water Sump Pumps

Unit:731 0731-P-101A/B/C Lean Solvent Circulating Pumps 0731-P-103A/B Solvent Reflux Pumps  0731-P-106A/B/C Lean Solvent Pumps 0731-P-112A/B Lean Solvent Filter Pumps 0731-P-102A/B Oily Water Sump Pumps 0731-P-105 Hydrocarbon Sump Drum Pump 0731-P-107A/B Steam Condensate Pumps 0731-P-108 Solvent Sump Drum Pump 0731- P1A/B Anti-foam Injection Pumps

The Condensate Booster Pumps are horizontal pumps that take suction from the storage tanks and raise the pressure to approximately 5.7 bar-g.

The discharge from the Booster Pumps is routed to the suction of the Condensate Shipping Pumps, which are multistage barrel type pumps operating at approximately 86 bar-g discharge pressure.

• • • •

Both pump and compressor moves fluids from one energy level to another Pump moves an incompressible fluid – liquids Compressor moves compressible fluids - gases The principles of dynamic machines apply to both pumps and compressors. However , since gases are compressible, the volume flow rate and hence the gas velocity in a passage is affected.

Turbo-expander is a centrifugal or axial flow turbine through which a high pressure gas is expanded to produce work that is used to drive a compressor or other machines. Turbo expanders remove energy from a gas stream, thereby cooling the gas and producing power.

Turbo expanders are used to refrigerate a gas stream, removing work directly from the gas. By expanding the gas in a nearly isentropic process, energy in the high-pressure gas entering the expander is removed, and the gas exits at lower pressure and temperature.

The gas flows radially inward and is accelerated through inlet guide vanes, then enters the outside of expander impeller at approximately the same velocity as the blade tip. Work is extracted from the gas by removing this momentum as the gas moves inward through the impeller blades. The gas is forced to slow down due to the decrease of blade rotational velocity with decreasing radius.

Some of the remaining energy can be recovered with a conical diffuser, to convert the velocity into pressure, thus reducing the static pressure at the turbine wheel discharge, resulting in additional refrigeration. This type of turbine is commonly a 50% reaction-type turbine, with half of enthalpy change occurring in the rotary part (impeller), and the other half taking place in the stationary components.

In ADNOC Sour Gas, turbo expanders are used for the NGL separation process in the two identical Units 0741 and 0742, for inlet gas sub cooling by means of its isentropic expansion. The mechanical energy which is also produced in this process is transferred through the shaft to a residual gas booster compressor. A portion of the gas coming from Expander Separator (0741-V-303) is sent to the expander side of the Turbo expander/Recompressor (0741-EC301), where the gas is expanded from approximately 59 barg down to 29 barg, thus chilling it as follows:

Ethane Recovery: from -45°C to -75°C. Ethane Rejection: from -41°C to -72°C. The expanded gas is then fed to the De-methaniser (0741-V-304) column, above CT4.The expander is coupled with a single stage centrifugal compressor, which recovers the work produced by the gas expansion by compressing the De-methaniser (0741-V-304) overhead gas.

•A steam turbine is a device that extracts thermal energy from pressurized steam and uses it to do mechanical work on a rotating output shaft.

There are two basic types of turbine designs. One is called the "impulse" design in which the rotor turns due to the force of steam on the blades. The other is called a "reaction" design, and it works on the principle that the rotor derives its rotational force from the steam as it leaves the blades.

Steam turbines may be condensing or non-condensing, depending on how the steam exiting the turbine is used. In the condensing turbine, the steam exiting the turbine enters a condenser to convert the steam back to water. This creates a vacuum, which helps force, the steam through the turbine. The water is then pumped back to the boiler to be converted into steam again.

A single-flow turbine design has steam entering at one end. The steam then travels in one direction toward the other end of the section and exits the casing to be reheated, or passes on to the next section. A double-flow section, however, has steam entering in the middle and flowing in both directions toward the ends of the section.

Non-condensing turbine is not converted into water but is sent to another unit or system in the plant operating at a lower pressure. In a non-condensing turbine, steam can be extracted from the turbine at extraction points to obtain desired pressure rates. Back Pressure Turbine: In this type of turbine all the steam is exhausted at a pressure above atmospheric for use in process plants

The function of the steam turbine is to convert the heat energy in compressed steam directly to rotating power. In a turbine, steam expands in stationary or moving nozzles from which it discharges at high velocity. The force of the highvelocity jets of steam causes the moving parts to rotate, thus making the energy in the steam available to do useful mechanical work, to drive a pump or compressor.

Backpressure steam turbine generators (0780-G-101A/B/C/D) producing LP steam and MP steam from HP superheated steam are used to generate power, to fulfill the fast control of the MP and LP steam necessities of the Plant. MP steam is produced by extraction and LP steam is produced from the STG exhaust. The requirement for LP steam and MP steam will vary with the process requirements. The steam balance requires four (4) 30 MW STGs for Unit 0780 during normal operation backpressure steam turbine generator turndown capability per unit is approximately 20-25%.

The steam conditions at the inlet and outlet of the STGs are as follows: • • •

Turbine Inlet Condition: 390°C @ 40.0 barg MP Steam Extraction Condition: 325°C @ 22.5 barg LP Steam Exhaust Condition: 197°C @ 5.5 barg

The Fin Fan Air Cooler Heat Exchangers are tubular heat transfer equipment in which ambient air, passing over the outside of the tubes, acts as the cooling medium to condense and/or cool a fluid inside the tube.

Practical demonstration on the following equipment at site: 1. 0741-EC-301

Turbo Expander

2. 0740-C-201A

Residue Gas Compressor ( Centrifugal )

3. 0726-C-201

Recycle H2 Compressor ( Reciprocating )

4. 0726-P-203

Condensate Pump ( Centrifugal )

5. 0780-G-101A

Steam Turbine Generators

6. 0773-P-101B

Fire water pump ( Diesel engine driven )

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