- Axial Compressors
The ensemble of the rotoric and statoric blading and their inlet and compressor discharge casings define turbine’s axial compressor.
The stator blades, assembled on the air inlet casing and compressor discharge casing is made up of 19 stages.
First 5 are variable guide vanes while the last one acts as flow straighteners.
The rotoric blading is made up of 17 stages. The 1st 3 are made in aluminum.
Air compression is carried out across a set of passages in the annular chambers, the sections of which, defined by the dimensions of the stator and rotor vanes once the stage number increases.
The performance is distinguished by a nearly constant high compression ratio and an efficiency that remains almost constant when the air flows range between 70 and 100 percent.
Engines are the machines which produces power by using chemical energy of the fuel. The power produced can be utilized in many ways. At Qadirpur gas field there are total 28 engines which are running for different purpose and from different companies.
Engines differentiation w.r.t Manufacturers.
- 20 Waukesha Engine’s. 28 Engines
- 08 CATERPILLAR Engine’s.
Engines differentiation w.r.t Fuel
- 27 Engines run on gas as the fuel (Gas Engines)
- 1 Engine run on diesel (Diesel Engine)
Waukesha engines are installed at various places at the field but as we have divided our field in to two zones so I will discuss engines with respect to those zones.
- Front End Compression Plant (FECP)
- Mother Plant
Front End Compression Plant (Waukesha Engines)
At front end compression plant there are 14 positive displacement compressors which needs some power to be driven. Waukesha engines are there to run those 14 compressors to initially compress the gas right after the gas leaves slug catcher. Waukesha engines are basically gas engines. They produce mechanical energy by using gas as a fuel (by Converting Chemical energy to Mechanical energy). Waukesha engines suck the gas from the line of slug catcher (Intake stroke). Engines are of 12 cylinders, V-shaped design. The whole cylinder assembly is attached to damper in series. The damper is then attached to the shaft of the coolers and flywheel. Waukesha engines are horizontal positioned so it is the sump tank. Following is a table which leads us to more specifications of Waukesha engines.
Various utility systems are operated in Qadirpur gas processing plant. Some important systems are
Fuel Gas: In normal operation, the fuel gas is supplied from the recycle membrane, with a small quantity flowing into the LP system directly from the condensate / water separation. When the permeate compression is not in operation, fuel gas is supplied from the export gas heater.
Compressed Air: Instrument air is critical to the operation of the plant. Therefore 2 x 100 % compressor units are provided as well as 2 x 100 % instrument air driers. The air compression system is designed for a throughput of 620 scfm and an air delivering pressure of 110 psig.
Produced Water Treatment and Injection: This system consists mainly of a Corrugated Plated Interceptor (CPI) and a sand filter designed to achieve a free oil contents in the treated water, less than 5 ppm. The treated p/water is disposed of by injection into a shallow aquifer. The p/water from the CPI is sent to the p/water filter to reduce the TSS up to 1 ppm and 5 mm of size. Liquids produced by the backwash cycle are stored in a filter backwash tank for several hours to allow any solids to settle out. The liquids are then transferred to the inlet of the CPI unit for treatment. The slurry is pumped to one of the two settling pits, where further separation of water and solids taken place. Decant water can be returned to the CPI by a sump pump. The filtered water from sand filter is collected in the p/water tank. The pumps then foreseen to feed the treated water to the guard filters and to inject it into the well.
Effluent / Oily Water Disposal: The oily water treatment system receives the contaminated water from the open drains system and from the various sump pumps. The oily water collected in the Slug Catcher is pumped into the oily sewer by means of the Slug Catcher sump pump. The oily water collected in the flare KO drum is also sent to the oily sewer. The oily water through the oily sewer is collected into the oily water drains CPI located in a concrete pit, where the oil removal takes place. The separated oil is conveyed by the oil skimmers into the recovered oil pit. This oil is then transferred to the condensate storage tank, while the treated water is discharged by gravity to the river channel
Flare System: Hydrocarbon vapors from relief valves, pressure control dumps and de pressuring systems are collected into a 32″ flare header and routed to the flare KO drum to remove any liquids in the streams. The gas from the KO drum is fed to the flare where its combustion takes place. The liquid collected in the KO drum is sent to the p/water CPI by the pumps. A flare tip is equipped with 3 pilots, which are fed with fuel gas during normal operation. F. Inert Gas System The inert gas system comprises a membrane type inert gas generator, A-5804, which is design to produce 40 scfm of 97.5 % N2 from dry air provided by the compressed air system. Inert gas is delivered to approximately 90 psig to the inert gas receiver, which provides a surge volume of 5 minutes.
Valves: Valves are basically the devices which are used for controlling and regulating a flow/process on a plant. There are so many valves positioned and installed at Qadirpur gas field. Some of them are below :
|FCV||Flow Control Valve|
|ESDV||Emergency Shutdown Valve|
|PCV||Pressure Control Valve|
|PSV||Pressure Safety Valve|
|TCV||Temperature Control Valve|
|BDV||Break down Valve|
|LCV||Level Control Valve|
|RCV||Ratio & Control Valve|
|ABV||Air Bleed Valve|
|GCV||Gas Control Valve|
|SRV||Speed Ratio Valve|
JOBS I witnessed at Qadirpur Gas Field
- PM of Waukesha Engine K-1304.
(Bridge mounted on valves and Valve springs got fractured, New head
installed in place of that after Boroscopy)
- PM of Waukesha Engine K-1311.
(Oil leakage from Damper and Gas Kit)
- PM of Waukesha Engine K-1306.
(Leakage in Centrifugal Pump)
- PM of Gas Blower PT-2 Train.
(Leakage in Mechanical Seals and producing undetermined sound during
- Change of Air Filters and Oil of the Refrigeration Package Waukesha Engine
(Air filters got packed with dust particles & Oil change via Pneumatic
- Change of Khus Pads of Solar Turbine C
(Pads got packed with dust particles)
- Dismantling & Mantling of Waukesha Engine K-1307
(Waukesha engine goes under an over haul at Orient Lahore)
- PM of Centrifugal Pump Underneath the ground at Mother Plant.
(Impeller got fractured at high RPM )
- Report on Oil Leakage Status of Waukesha Engines(K-1301-K1314)
(Compiled a report on the oil leakage of engines from Gas kits & Damper)
- PM of the Condensate Pump (Centrifugal Pump)
(Leakage in Mechanical Seal)
- PM of Gas Turbine (Nuovo Pignone PG-10)
(Oil leakage from Bearing Housing)
- PM of Gas Turbine (Nuovo Pignone PG-10)
(Change of insulation because the older one got burnt)
- Dismantling of Gas Turbine Nuovo Pignone PG-10
(Dismantled HP and LP module of Turbine due to series of mishaps)
- Formulated a data sheet regarding the Rotary machines installed at Qadirpur
Gas field for Vibrational Analysis by PAEC).
- Formulated a data sheet on MS excel for Tool Inventory of Qadirpur gas field
- PM of Air Cooler of Solar Turbine
(Change of belt for the pulleys of 1 fan, Dismantled motor of 1 Fan,
Change of Bearings (Journal) of 1 Fan).
- PM of Condensate Tank (8500 BBL)
(Sand Blasting of condensate tank)
- PM of the Orifice of Metering Section.
- Change of Air Filters of Gas Turbine Nuovo Pignone (PG-10).
(112 Air filters were changed )