WINTER TRAINING 2019-2020 AT ONGC (OIL AND NATURAL GAS CORPORATION LIMITED) HAZIRA PLANT, SURAT Re De it ey OnGC TRAINING REPORT (WINTER VOCATION TRAINING) Training Period : 10 December 2019 to 8 January 2020 SUBMITED BY CHANDAN KUMAR (SVNIT,SURAT) VAIBHAV SAXENA (SVNIT,SURAT) PREETI VERMA (SVNIT,SURAT) NINDOLIA ABHI RAMESHCHANDRA (SVNIT,SURAT)THAKKER SAVAIBHAI GHANSHYAMBHAI (SVNIT,SURAT) YUDHISTHER KUMAR (SVNIT,SURAT) CHAUDHARI HARSHAL RAKESHBHAI (SVNIT,SURAT) MECHANICAL ENGINEERING DEPARTMENT Sardar Vallabhbhai National Institute of Technology (SVNIT), Surat Page | 1ACKNOWLEDGEMEN' Industrial Training is an integral part of engineering curriculum Providing engineers with first hand and practical aspects of their studies. It Gives them the knowledge about the work and circumstances existing in The company. Main thing about the training is exposure to the industrial Environment and people over there. The preparation of this report would Not have been possible without valuable contribution of ONGC family Comprising of several experienced engineers in their respective field of work. It gives us great pleasure in completing our training at ONG Hazira and submitting training report for the same. We express our deepest gratitude to Shri GC Dhole, I/c KDM Trainings, for giving us a chance to come at Hazira plant for training. at the same time we would also like to thank Shri A K Singh, GM (IC Area Mechanical Maintenance) for giving us permission for orientation in operational area of plant. Our sincere thanks to our mentor Miss Sandhya Bhatt who guided Us throughout our project and explained us each and every thing, ina practical way. He guided us through aspect functioning and process of the given project. We would also like to thank all the experts who delivered a brilliant Lecture in their field of expertise, so that we could co-relate the theoretical and technical aspects of all the practical process that we see in the plant. To name a few we would like to thank Shri Manish Bhowmik, Shri Pratik Patel, Shri Harish Bhambani, Mr. Praveen sir, Shri Abhilash Patel and others. And at last but not the least we are also thankful to all staff members of plant for their kind cooperation and valuable guidance throughout the process of work. Page |2PREFACE Industrial Training refers to work experience that is relevant to professional developments an essential component in the development of the practical and professional skill required of manger and an aid to prospective employment. The winter training is an ideal opportunity for the student to have a firsthand experience with the different function of the industry/corporate sector. It is famous saying that the “person who has read 1000’s of pages is not worth than the person who has travelled for 100’s of meters”. Teaching gives the knowledge of theoretical aspects of management but implementation of theory gives practical knowledge of management field. The aim of this training is to introduce the fundamentals and the basic principles of financial management and business accounting in real life day to day application of business transition. Practical Knowledge of theory is of grater important for a finance student. This project report is an outline of what we have learnt during our training period at Oil& Natural Gas Corporation Limited (ONGC), one of the prestigious public sector companies running with strategy values and time management. We are thankful to Oil & Natural Gas Corporation Limited for giving us such a valuable opportunity to work with them. We are thankful to Oil & Natural Gas Corporation Limited for giving us such a valuable opportunity to work with them. Page | 3HAZIRA Energy Policy H = High level of energy performance be ensuring availability of information and resources. A =Adherence to all applicable legal and other requirement. ZL Zealous effort toward reduction of energy wastages. I = Initiate action to purchase efficient items, equipment, services and design. R = Review of objective, target, and action plans to ensure continual improvements. A = Adopt energy conservation measure to enhance energy efficiency. Page | 4CONTENTS SR. NO TITLE PAGE NO. 1 Introduction to ONGC Hazira Plant 6 2 Gas Processing Units in Hazira Plant i: 3 Co-generation Plant 13 4 Utilities 18 5 Brief Description of Mechanical Equipment in | 23 the processing units 6 Condition Monitoring 30 7. Mechanical Maintenance 33 8 Conclusion 34 Page | 5‘RODUCTION TO ONGC HAZIRA PLA! Natural gas is a substitute for coal, petrol and diesel as fuel in industrial boilers and furnaces and is much cleaner, hence leading to less pollution in the atmosphere. Natural gas being rich in Propane and Butane gives straight run LPG. Natural Gas is also liquefied and transported worldwide as LNG. Compressed Natural Gas (CNG) is used in automobiles in increasing numbers resulting in cleaner environment. Natural Gas produced in some gas fields in India containing toxic Hydrogen Sulphide Gas in varying amounts. This gas is called Sour Natural Gas and requires special treatment for the removal of the toxic gas. Hydrocarbon condensate, the liquid drop out from the gas during the production and transportation, associated with sour natural gas also is thus sour. This sour condensate has to be treated to make it sweet, marketable and safe for use as LPG and other Value Added Products (VAP). ONGC Hazira Plant receives sour natural gas from its South Bassein and other Satellite fields in Mumbai Offshore, which are sub-sea reservoirs. The gas is transported from these fields to Hazira Plant through a sub-sea pipeline, approximately 250 km long. The gas is received at Gas Terminal in a slug catcher where gas and slug containing hydrocarbon condensate, moisture and chemicals (like corrosion inhibitors) are separated. Gas and associated condensate are sent further in separate systems for processing. The sour gas processing system at Hazira Plant consists of the following: Gas Terminal Gas Sweetening Unit (GSU) - 9 trains (31-39) Gas Dehydration Unit (GDU) - 9 trains (41-49) Dew Point Depression Unit (DPD) - 9 trains (51-59) Sulphur Recovery Unit (SRU) Condensate Fractionation Unit (CFU) LPG Recovery Unit — 1 train dave Page | 6erg ee GAS PROCESSING UNITS IN HAZIRA PLANT 1. Gas Sweetening Unit (GSU): Sour gas from the slug catcher is sent to GSU for sweetening ie. bringing the H2S level to a permissible limit of 4 ppm. Methyl Di-ethanol Amine (MDEA) or lean amine is used for the absorption of H2S and it is then regenerated and reused. Accordingly, the two major processes taking place in the GSU are absorption and regeneration. Absorptio) The sour gas coming at atmospheric temperature is first heated to a temperature of 40-45°C. It is then passed through a Knock Out Drum (KOD) to remove water or condensate molecules if any. Next, it enters the bottom of a high pressure absorber column. Lean amine is pumped to the top of the absorber column using a lean amine pump, which is a multistage centrifugal pump. The absorber column includes 14 valve trays. Different liquid feed possibility to the column allows selecting adequate number of the trays to obtain the required results taking into account the feed gas quality and operating conditions. The selected feed position could be to the trays 1, 3, 5, 7, or 9 and the switching over from one to another is done manually. The MDEA feed nozzles are arranged such that the liquid feed is fed to the down comers of trays (1, 3, 5, 7 and 9) and not the trays themselves. The upper tray is dry and retains the major part of carry overs. The total lean MDEA solution flows to the column in a controlled way with the flow control valve. MDEA absorbs the H2S from the gas and the sweet gas is collected from the top of the absorber column, cooled and sent for further processing to the Gas Dehydration Unit (GDU). The MDEA that has absorbed the H2S, flows down to the bottom of the absorber from where, itis taken for further proces RNH, + HS = RNH*s + SH" Regeneration: Page | 7The rich amine ie. MDEA after absorbing H2S, passes through a series of cellulose, charcoal and cartridge filters for the removal of any undesirable chemical and biological particles and then enters a plate heat exchanger and regenerator at temperature of 40-45°C and is heated there to a temperature of about 120°C. At this temperature, the absorbed HS is given out and is sent to the Sulphur Recovery Unit (SRU) to obtain elemental sulphur. The lean amine collected at the bottom of the regenerator is routed through amine-amine exchanger and cooled to 45°C ina lean amine cooler and sent to a large amine storage tank. Lean amine is pumped from this tank and is reused in the absorption process. Gas Sweetening 2. Gas Dehydration Unit (GDU): Sweetened gas from GSU is sent to the Gas Dehydration Unit (GDU) to remove moisture. Tri- ethylene glycol (TEG) is used to absorb moisture from the gas and is regenerated and reused. Hence, absorption and regeneration processes take place in GDU as well. Absorption ‘The sweetened gas enters the inlet knock out drum of GDU at a pressure of 60 kg/cm? and a temperature of 45°C, where any entrained MDEA is knocked out. Next, it enters the bottom of a high pressure absorber column, Lean glycol or TEG is pumped to the top of the absorber column using a lean glycol reciprocating pump. The absorption process here is similar to that in GSU. The dehydrated sweet gas is collected from the top of the absorber column and is sent to the Dew Point Depression (DPD) unit for further processing. Regeneration The rich glycol i.e TEG afier absorbing moisture, passes through filters (similar to amine in GSU) and is heated up to a temperature of around 100°C using a heat exchanger. At this temperature, moisture is given out in the form of steam and is released in the atmosphere. The lean glycol collected at the bottom of the regenerator is cooled and stored in a lean glycol storage tank from where it is pumped and reused in the absorption process. Page | 8GAS DEHYDRATION UNIT 3. Dew Point Depression Unit (DPD): Dehydrated sweet gas enters the DPD unit to reduce the dew point of the gas to avoid solidification of molecules in the gas which may lead to choking of pipelines during transportation and to separate heavier hydrocarbons (C3, C4, etc.) from the lighter ones (Ci, ©). The dehydrated gas from GDU is first passed through a gas-gas exchanger and is cooled to about 15°C. This gas is further cooled to about 5°C in a chiller with the help of propane refrigerant in a closed circulation cycle (vapor-compression refrigeration cycle). Both the gas- gas exchanger and chiller are shell and tube type exchangers. The chilling temperature is controlled by a temperature control valve, which regulates the gas flow through chiller and operates at a preset temperature valve in automatic mode. The cooled gas condensate at 5°C {goes to a filter separator where the liquid and gas is separated. The condensate, which consists of heavier hydrocarbon, is pumped to LPG Plant surge drum for further processing. The cooled ‘2as ice. the lighter hydrocarbons, from the top is passed through the gas-gas exchanger where the chillness of this gas is exchanged with the incoming gas from GDU. The gas is then distributed to the Hazira ~ Vijaipur ~ Jagdishpur (HVJ) Pipeline. Vapor Compression Refrigeration or Propane Refrigeration Cycle used in DPD Propane refrigeration system has been provided in the DPD unit to supply refrigeration required in the gas chiller. Once the system is filled with liquid propane it operates in a closed cycle and very little makeup of propane from external source is required. Single stage refrigeration is provided. 1. Propane from accumulator at 45°C flows over to propane sub-cooler where it is sub cooled by cooling water to 40°C. 2. Then it flows over to gas chiller through level control. 3. Refrigerant propane after evaporation in the chiller flows over to propane compressor via suction knock out drum, Page | 94. Propane vapor is then compressed by reciprocating propane compressor driven by electric motor. This compressor is a double cylinder, double acting, single stage reciprocating, compressor specified as 2HD/1 5. The compressed propane vapor is condensed in the propane condenser and taken to the accumulator for reuse in the propane refrigeration cycle. The temperature of the bypassed propane vapor is maintained at 0°C by spraying liquid propane in a quench nozzle via a temperature control valve. In each train, two refrigerant propane compressors are provided. One compressor will be in operation and other will be stand- by. 4. Liquified Petroleum Gas (LPG) Recovery Unit: Sweet gas from GSU and condensate from DPD is processed in the LPG Recovery Unit to yield value added products (VAPs) such as LPG, Propane and Naphtha, Feed gas from gas sweetening unit flows to a knock out drum where any liquid present in the gas is knocked off. After this the gas flows through a molecular sieve drier where moisture level is reduced up to 1 ppm. From there the gas passes through a filter to separate any solid particles mingled with the gas. This dried gas is cooled to -30°C in a cold box and the condensed liquid is separated out in a separator. Vapour from this separator is expanded almost isentropically in an expander as a result of which the temperature further falls down to around -50°C. Liquid condensed on cooling is separated out in another separator. The refrigeration of the vapour stream from this separator is recovered to cool down the feed gas stream, Further, this lean gas stream is compressed by expander compressor to about 37kg/en? (from 30 kg/cm?) and finally to 46.5 kg/cm? by the Jean gas compressor and supplied to consumers as high pressure lean gas. Condensate from dew point depression unit, at high pressure is flashed into the surge drum afier heating to 25°C - 30°C to avoid hydrate formation, Condensate is passed through a coalester filter where most of the free water present in the condensate is separated, Hydrocarbon liquid from the coalester filter flows to liquid driers where the moisture content is brought down to 5 ppm. Page | 10Liquid from both the separators along with light drier outlet is routed to the Light End Fractionator (LEF) column. The light hydrocarbons (a part of propane and lighters) are removed from the top of the column, These light hydrocarbons are expanded in LEF O/H expander and the refrigeration recovered by cooling the feed gas stream in a cold box. LEF O/H gases from the cold box are compressed to supply to KRIBCHO as low pressure Jean gas also used for internal fuel gas consumption. Excess gas is compressed by residue gas compressor to high pressure lean gas header. Liquid from the bottom of LEF column is routed to LPG recover column. Liquefied petroleum gas LPG recover column, Liquefied petroleum gas (LPG) is withdrawn from this column as overhead product and sent to storage. The bottom product, aromatic rich naphtha is also sent to storage. Propane is used as refrigerant for LEF overhead condenser and is generated by fractionating small amount of LPG product in the propane column. 5, Condensate Fractionation Unit (CFU): Condensate fractionating unit is designed to remove HS and to recover LPG & NGL from slug catcher condensate. The condensate as it comes from the slug catcher is heated in a condensate preheater and received in surge drum. The preheater uses LP steam to heat the condensate up to 33°C to 36°C to avoid any hydrate formation. Hydrate formation is possible if there is high pressure drop across valves. The flash vapour from the surge drum is taken to gas sweetening unit directly (bypassing compressor) when condensate inlet pressure is at 80 kg/cm? or more. Below 80 kg/em?, the pressure is maintained 2 kg/cm®, below the inlet pressure in the surge drum to allow differential for incoming liquid and the vapour is routed through the compressor system. Free water droplets, if any, get separated in the surge drum and are collected in boot. Water level is drained through interface level control mechanism, The condensate in the surge drum is taken into condensate transfer pumps (one operating & one standby). This centrifugal pump is provided to generate sufficient head and flow to avoid any condensate flashing in the down steam filter coalester. Two units of cartridge type filter-coalester are provided. The filter is used to remove any scale/dust/debris/iron sulphides/black material which may entail during pre- commissioning/commissioning, pigging operation of the trunk lines. The coalester element is Page | 11used for removal of free water. The free water collected in the boot and is drained through interface level control mechanism. The condensate flows further through flow control valve into the stripper column top tray. This is designed to maintain a back pressure to ensure that no flashing occurs in the filter chamber. Dew point depression unit’s condensate can also be processed in CFU besides LPG plant as and when required so. At the top of stripper column lighter fractions come out. Itis the offset gas which further goes into knockout drum, where liquid is separated. From there it goes to GSU. LPG component moves into a re-boiler from where itis refluxed in the stripper column for purification, Some part of this liquid after purification goes to LPG line. Stripper column temperature is maintained by HP steam, LPG which comes out from re-boiler section further goes to the caustic wash unit (since it has H2S). From bottom of the stripper column Naphtha and NGL are produced. This NGL either goes to KRU or NGL line depending on the requirement. Page | 12COGENERATION PLANT ‘The co-generation plant at ONGC, Hazira is a CPP (captive power plant) specifically built to cater the needs of this particular industry. The electricity requirements of the Hazira plant are met through an in-house electricity generation system without depending upon an external source. Its role is to meet the energy requirement of the plant via production of steam and power. Since, steam is a primary input for processing of Natural Gas, the idea of Gas Turbines with Heat Recovery Steam Generators (HRSG) was implemented. For power generation, electricity from GEB (Gujarat Electricity Board) is taken at 66KV through two feeders. There are 3 gas turbines and 3 HRSGs in the Co-gen plant. Gas Turbines: A gas turbine, also called a combustion turbine, is a rotary engine that extracts energy from a flow of combustion gas. It has an upstream compressor coupled to a downstream turbine, and a combustion chamber in-between, Gas turbines run on the principle of Brayton cycle. Brayton Cycle- The Brayton cycle (or Joule cycle) represents the operation of a gas turbine engine, The cycle consists of four processes, as shown in figure: a—b: Adiabatic, quasi-static (or reversible) compression in the inlet and compressor; bc: Constant pressure fuel combustion (idealized as constant pressure heat addition); c~d: Adiabatic, quasi-static (or reversible) expansion in the turbine and exhaust nozzle, with which we take some work out of the air and use it to drive the compressor, and take the remaining work out and use it to accelerate fluid for jet propulsion, or to turn a generator for electrical power generation. d—a: Cool the air at constant pressure back to its initial condition. ‘Combustor Inlet Construction Details: + Compressor stages: 17 + Turbine stages: 2 - Number of combustors: 10 . Pressure ratio: 10.3 Page | 13Working- 1, An initial external source is required to start the GT. This initial start-up is called cranking, which can be accomplished via diesel engine, starter motor or turbo- expander. For this purpose diesel engines are used in GT at Co-Gen to bring turbine speed up to 20% of rated speed (when combustion takes place) and 60% (self-sustaining speed) until it disconnects. ‘The accessary gear couples turbine shaft at starting device to compressor end through hydraulic torque converter and jaw clutch. The accessory drive gear located at the compressor end of the gas turbine is a gearing assembly coupled directly through a flexible coupling to the turbine rotor. Its function is to drive each gas turbine accessory at its proper speed and to connect and disconnect the turbine from its starting device. 3. There is an axial 17 stage compressor, consisting of stator blades, rotor blades, variable inlet guide vanes and two exit guide vanes. This compressor increases air pressure from atmospheric pressure to around 8 kg/em?. 4. High pressure gas from compressor enters and oxidizes the fuel, in this case natural gas and makes it combustible. Combustion is initiated by two spark plugs. There are ten combustion chambers. The fuel is injected into the combustion chamber through fuel nozzles. In two of the combustion chambers spark plugs are provided to ignite the fuel mixture initially. ‘The flame then travels to other combustion chambers through cross fire tubes. There are two flame detectors to detect flame. 5. The hot gas then hits the turbine blades resulting in the conversion of heat into mechanical work. The turbine used is a two stage turbine. 6. The turbine is coupled with a generator using a load gear box. To generate electricity at the standard frequency of 50 Hz, the required speed is 3000 rpm. The turbine attains a speed of around 5100 rpm. The load gear box reduces the turbine speed to the required generator speed. 7. The generator is a two pole device operating at 3000 rpm. It is air cooled by open circuit filtered air sucked by rotor mounted fins. 8. The exhaust gas generated is at a temperature of 500°C. The energy of this exhaust is utilized in HRSGs. = | ae HRSG rem Block Diagram of Gas Turbine Generator Page | 14Heat Recovery Steam Generator (HRSG): A boiler or steam generator is used wherever a source of steam is required. A heat recovery steam generator or HRSG is an energy recovery heat exchanger that recovers heat from a hot gas stream. It produces steam that can be used in a process or used to drive a steam turbine. ‘The 3 HRSGs installed in the plant are horizontal, water tube type boilers. Working- 1, Exhaust from the gas turbine is sent to the burner floor of the HRSG, its flow being controlled by a diverter damper and Guillotine gate. The diverter damper controls exhaust flow to bypass chimney in case the gas turbine is not running or header to the HRSG. The Guillotine gate provides positive isolation when the D/D blocks the header to HRSG. 2. There are 4 burners in the burner floor. The number of burners working at a time depends on the steam requirement in the plant. The exhaust gas is burnt here to generate heat required for steam production. In case the gas turbine is not running, a centrifugal fan, called the FD (forced draught) fan, is provided to supply oxygen required for combustion. 3. The heated gas passes through the HP evaporator. It consists of a steam drum (top drum), a water drum or mud drum (bottom drum) and plain tubes along unheated down-comer on either side, Water flows through the tubes, gaining heat from the incoming exhaust. 4. Next is the LP evaporator. It consists of a LP steam drum (top drum), a mud drum (bottom drum) and spiral finned tubes along with unheated down comer on either side. The exhaust further loses heat in this section. 5. Water in the HP and LP mud drums is de- mineralized or DM water. DM water is first passed through a de-aerator for removal of oxygen and then sent to the mud drums. 6. Since the exhaust while entering the LP evaporator loses its energy, therefore to increase the efficiency of the steam generator, water from de- aerator is passed through an economizer or make up heater to pre- heat it, enabling better heat transfer with minimum energy consumption. 7. The exhaust temperature reduces to around 120°C from 500°C. It is let out using a chimney. ‘The HRSG can be operated in three modes: 1. GT mode: HRSG is connected with the gas turbine and only its exhaust is used as a heat source. No burners are used. 2. GT + Supplementary mode: HRSG is connected with the gas turbine and supplementary firing is achieved using the burners. 3. FD mode: Used when the gas turbine is not running. Page | 15Flam J = “oRoter fn & wom [pve || te tee Cee =) oo L 3 — here Other boilers: Boilers other than HRSG used for steam generation are as follows: KTI-— HP — 60t0ns, LP- 180tons and MP- 60tons © LP at 9kg/cm2, HP at 30kg/cm? and MP at 18kg/cm2 Thermax - © Water tube boiler MP boiler © Capacity 37.5tons/hr # Pressure at 37.5kg/em2, 223degrees C,feed water inlet temp 1 10degrees, boiler surface 648m2,capacity 45.3m3/hr * Contains economiser and air preheater for better efficiency (accessories) * De-aerator removes oxygen to prevent corrosion FD fan- 1500rpm, backward curved airfoil; rated power- 110MW Fire tube MP boilers (IAEC) - * 3pass (3times passes from tubes) 1 shell boiler © Boiler SA -671m2 © Maximum 45tons/hr © Hot gas +air +electrode sparking DM Plant: De-mineralization is the process of removing the mineral salts from water by ion-exchange. Impurities that remains dissolved in water dissociate to form positive and negative charged particles known as ions. Presence of salts in boiler feed water may lead to scaling, acidity or Page | 16alkalinity may cause corrosion and other suspended particles may result in erosion, all these problems ultimately leading to thinning and rupture of boiler tubes. Process- 1. Firstly the water passes through ACF (activated carbon filter) for the separation of organic matter and suspended solids. 2. Secondly, it passes through SACE (strong acid cation exchanger) where a resin is used to remove cations such as Na’, Mg"?, Ca", etc. This resin, once saturated, is treated with 28- 30% HCI for regeneration. 3. It then passes through WBAE (weak base anion exchanger) where another resin is used to remove anions of weak bases. This resin, once saturated, is treated with 40% NaOH for regeneration. 4. After ion exchange, water is sent to a degasser unit to remove CO2 present. 5. Water then passes through SBAE (strong base anion exchanger) where anions of strong bases are removed. 6. Lastly, water passes through a mixed bed exchanger where resins for both anion and cation exchange are present to remove any remaining ions. 7. Internal treatment is done by dozing hydrazine, sodium sulphite, tri-sodium phosphate, ammonia to remove oxygen and salts and maintain pH. Page | 17UTILITIES Utilities are the services which are essential for the operation of the plant, though these may not contribute directly towards the revenue generated. The major utility systems at Hazira Plant are: Locomotives Air compressors Cooling towers LPG Pumps ‘Waste water treatment plant yaepe Locomotives: Locomotives are used for the transportation of VAP’s such as LPG/ Naphtha etc. that are produced in the Plant. The locomotive in the plant is a diesel engine similar to that of the Indian Railways except that this locomotive has a spark arrestor and flame arrestor to avoid hazards due to gas leakage. ‘The modern diesel locomotive is a self- contained version of the electric locomotive. Like the electric locomotive, it has electric drive, in the form of traction motors driving the axles and controlled with electronic controls. It also has many of the same auxiliary systems for cooling, lighting, heating, braking for the train. It can operate over the same routes (usually) and can be operated by the same drivers. It differs principally in that it carries its own generating station around with it, instead of being connected to a remote generating station through overhead wires or a third rail. The generating station consists of a large diesel engine coupled to an alternator producing the necessary electricity. A fuel tank is also essential. ‘The ignition of diesel fuel pushes pistons connected to an electric generator. The resulting electricity powers motors connected to the wheels of the locomotive. A diesel internal combustion engine uses the heat generated from the compression of air during the upward cycles of the stroke to ignite the fuel 1. Diesel fuel is stored in a fuel tank and delivered to the engine by an electric fuel pump. Diesel fuel has become the preferred fuel for railroad locomotive use due to its lower volatility, lower cost, and common availability, 2. The diesel engine (A) is the main component of the diesel-electric locomotive. It is an internal combustion engine comprised of several cylinders connected to a common crankshaft. Fuel is ignited by the intense compression, pushing the piston down. The piston’s movement turns a crankshaft. 3. The diesel engine is connected to the main generator (B), which converts the engine's, mechanical power to electrical power. The electricity is then distributed to traction motors (C) through circuits established by various switchgear components. 4. Because it is always turning, whether the locomotive is moving or not, the main generator’s, output is controlled by the excitation field current to its windings. 5. The engineer controls the power output of the locomotive by using an electrically-controlled throttle. As it is opened, more fuel is injected into the engine’s cylinders, increasing its ‘mechanical power output. Main generator excitation increases, increasing its electrical output. 6. Each traction motor (C) is directly geared to a pair of driving wheels. The use of electricity as the “transmission” for the locomotive is far more reliable than using a mechanical Page | 18transmission and clutch, Starting a heavy train from a dead stop would burn out a clutch in a brief time, Air Compressors: ‘Air and Inert Gas requirement in the plant is met using these air compressors. Compressed air generated is of three types: 1. Plant air i.e. compressed atmospheric air 2. Instrument air ie. moisture free plant air 3. Inert Gas ie. oxygen free instrument air, mainly consists of nitrogen Instrument air is used for operation of instruments (control valves). Instrument air is utilized in automatic plants, for use by instruments, so it has to be free from any kind of moisture. Plant air is used for cleaning, blowing and operation of pneumatic tools etc. Plant air, which may have some moisture, is used in SRU plant. Plant air, instrument air and inert gas is produced using centrifugal, reciprocating and screw type air compressors. Inert gas (IG) Plant Air is used in many places within the plant, Inert gas systems are used for purging to ensure hydrocarbon’ air free condition during shutdown and start-up activities. Inert gas is prepared from the atmosphere at the inert gas plant through the PSA (pressure swing adsorption), in which the air is passed through carbon molecular sieves, which have the granules of a special compound which adsorbs N2 at the surface, and relieves ©2, when under pressure. The container is then depressurized so that the entrapped nitrogen escapes which is then delivered to appropriate location. Nitrogen is used for regular processes in KRO (as sealing medium in certain pumps). Two towers work in conjugation, one working under adsorption mode and the regeneration mode. Page | 19Cooling Towers: A cooling tower is a heat rejection device that rejects waste heat to the atmosphere through the cooling of a water stream to a lower temperature. Cooling towers may either use the evaporation of water to remove process heat and cool the working fluid to near the wet-bulb air temperature or, in the case of closed circuit dry cooling towers, rely solely on air to cool the working fluid to near the dry-bulb air temperature. The wet-bulb temperature (WBT) is the temperature read by a thermometer covered in water-soaked cloth (wet-bulb thermometer) over which air is passed. The dry-bulb temperature (DBT) is the temperature of ait measured by a thermometer freely exposed to the air, but shielded from radiation and moisture. Two types of cooling towers are used, cross flow induced draft and counter flow induced draft. Cross flow Towers have a design that allows the air to flow horizontally through the fill and the tower’s structure into an open plenum area. Hot water flows downward fiom distribution basins. There is less recirculation because the speed of exit air is higher than entering air. However, fans and motor drive require weather-proofing against moisture which can lead to freezing making it less efficient. Counter flow Towers have a design where the air is vertically upwards and the counter current with hot water is falling downwards to cool the air. This allows for maximum performance out of each plan area and helps minimize pump head requirements. Also, they are less likely to ice up in cold weather conditions and can save energy in the long run. Page | 20Induced Draft towers are typically mounted with a fan at the top of the cooling tower, known, as ID fan, which allows hot air out and pulls air throughout. The high exiting air velocities reduces the chance of re-circulation, To avoid the entrapment of water droplets in the leaving stream air, drift eliminators are used LPG Pumps: LPG produced in the LPG Recovery Unit is stored in large spheres. There are a total of 9 spheres in Hazira Plant divided in two phases (6 in phase 1 + 3 in phase 2). LPG is an odourless gas, hence ethyl mercaptan is dosed in LPG in the spheres which gives it a smell similar to rotten cabbages. This helps to identify LPG leakage if any, as LPG leakage into the atmosphere may lead to explosion. A reciprocating pump is used to dose ethyl mercaptan. LPG from the spheres are transported through pipelines using motor driven centrifugal pumps (One pump connected with each sphere). Double mechanical seals are used to join the system, A flushing line is provided to create an LPG layer to avoid metal to metal contact in the mechanical seal and prevent wear and tear in the same. A pressure gauge is provided between the two mechanical seals. Deflection in the gauge will indicate the failure of one seal Waste water treatment plant (WWTP): Wastewater treatment is the process of converting wastewater — water that is no longer needed. or is no longer suitable for use — into water that can be discharged back into the environment. ‘Wastewater is full of contaminants including bacteria, chemicals and other toxins. Its treatment aims at reducing the contaminants to acceptable levels to make the water safe for discharge back into the environment. There are two sections in the wastewater treatment plant namely chemical or physical treatment plant, and biological wastewater treatment plant. Biological waste treatment plants use biological matter and bacteria to break down waste matter. Physical waste treatment plants use chemical reactions as well as physical processes to treat wastewater. 1. Firstly, wastewater is drained to the WWTP by gravity through the main sewer system. 2. The first mechanical stage is called preliminary treatment or rather pre-treatment, Water flows through gravel chamber for settling out the grit from water. Afterwards, gravel is disposed of at the dump. Water further reaches the bar screens used to remove large objects from the wastewater. At first come the coarse screens and then the fine screens which remove smaller objects. Page | 2410. After the removal of large objects, grit is to be removed from the wastewater. Similar to the gravel chamber, grit chamber allows the settlement of grit. Then, grit is removed from the tank and disposed of at the dump. Neither gravel nor grit can be reused due to their high contamination. The next sedimentation stage is called primary treatment during which the wastewater flows to primary settling tanks. Water is driven towards the hopper in the base of the tank. Treated water heads toward edges and the particulates of higher sedimentation velocity than the flow velocity settle on the bottom of the tank. This is the point where primary pre-treatment ends and secondary wastewater treatment starts. The secondary treatment, also called biological stage, is based on natural processes. WWTPS use bacteria which consume the contaminants, in particular biodegradable organics, carbon and phosphorus. Dead bacteria and organic residues subsequently transform into sludge. During the biological stage, the excess sludge (ie. excess bacteria) is pumped out and moved before the settling tanks. Here, the sludge settles and is transported to digestion tanks for further treatment. In the digestion tanks, sludge pumped out of the settling tanks is heated and mixed. When sludge digestion reaches optimal level, the second digestion stage takes place in storage tanks. Here, the water is separated from the semi-solid sludge and transported back for further treatment, whereas the residual semi-solid undergoes mechanical dewatering. Sludge, digested and dewatered to the optimal degree, is finally disposed of at the dump. The final step of wastewater treatment is the deep inspection of service water. Aim of this inspection is to analyse the contamination level and ensure that the treated water complies with the highest standards, defining its release or reuse for domestic and/or industrial purposes. st Actes oot i tinction 4 SMG chienion CPePres ce ar Dap itenl eo Page | 22BRIEF _DESCRPTION OF MECHANIC. THE PROCESSING UNITS A. Static equipment 1. Heat exchanger (denoted by X in the plant) A heat exchanger is a system used to transfer heat between two or more fluids. Heat exchangers are used in both cooling and heating processes. The fluids may be separated by a solid wall to prevent mixing or they may be in direct contact. They are widely used in space heating, refrigeration, air conditioning, power stations, chemical plants, petrochemical plants, petroleum refineries, natural-gas processing, and sewage treatment. The classic example of a heat exchanger is found in an internal combustion engine in which a circulating fluid known as engine coolant flows through radiator coils and air flows past the coils, which cools the coolant and heats the incoming air. The essential principle of a heat exchanger is that it transfers the heat without transferring the fluid that carries the heat. EQUIPMENT_IN TYPES. a. Shell and tube type - Shell and tube heat exchangers consist of a series of tubes which contain fluid that must be either heated or cooled. A second fluid runs over the tubes that are being heated or cooled so that it can either provide the heat or absorb the heat required. A set of tubes is called the tube bundle and can be made up of several types of tubes: plain, longitudinally finned, etc. Shell and tube heat exchangers are typically used for high-pressure applications. This is because the shell and tube heat exchangers are robust due to their shape. Units in which shell and tube type exchanger is used are GSU, GDU, DPD, CFU. ‘Straight-tube heat exchanger =! (one pass tube-sie) tl b. Plate heat exchanger- These exchangers are composed of many thin, slightly separated plates that have very large surface areas and small fluid flow passages for heat transfer. ‘There are many types of permanently bonded plate heat exchangers, such as dip-brazed, vacuum-brazed, and welded plate varieties, and they are often specified for closed-loop applications such as refrigeration. Plate heat exchangers also differ in the types of plates that are used, and in the configurations of those plates. When compared to shell and tube exchangers, the stacked-plate arrangement typically has lower volume and cost. Another difference between the two is that plate exchangers typically serve low to medium pressure fluids, compared to medium and high pressures of shell and tube. A third and important difference is that plate exchangers employ more counter-current flow rather than cross current flow, which allows lower approach temperature differences, high temperature changes, and increased efficiencies. Plate heat exchanger is used in GSU. Page | 232. Pressure Vessel: A pressure vessel is a container designed to hold gases or liquids at a pressure substantially different from the ambient pressure. Pressure vessels can be dangerous, and fatal accidents have occurred in the history of their development and operation, Consequently, pressure vessel design, manufacture, and operation are regulated by engineering authorities backed by legislation. It is used in the plant for the storage of LPG, etc. B. Rotary Equipment 1, Pumps (denoted by P in the plant): ‘A pump is a device used to transfer and distribute liquids in various industries. Pumps convert mechanical energy into hydraulic energy while electrical energy is generally used to operate the various types of pumps. Pumps have two main purposes: to transfer of liquid from one place to another place (e.g. water from an underground into a water storage tank) and to circulate liquid around a system (e.g. cooling water or lubricants through machines and equipment). Components of a Pumping System: Pump casing and impellers Prime movers: electric motors, diesel engines or air system Piping used to carry the fluid . Valves, used to control the flow in the system Other fittings, controls and instrumentation End-use equipment, which have different requirements (e.g. pressure, flow) and therefore determine the pumping system components and configuration. Examples include heat exchangers, tanks and hydraulic machines. Types: . Reciprocating Pump - A reciprocating pump is a class of positive-displacement pumps which includes the piston pump, plunger pump and diaphragm pump. Piston pump is the commonly used type in the plant. The working of reciprocating pump is as follows: i, When the power source is connected to crank, the crank starts rotating and connecting rod is also displaced along with rank. ii, ‘The piston connected to the connecting rod moves in linear direction. If crank moves outwards then the piston moves towards its right and create vacuum in the cylinder. Page | 24b, i iii. ‘This vacuum causes suction valve to open and liquid from the source is forcibly sucked by the suction pipe into the cylinder. iv, When the crank moves inwards or towards the cylinder, the piston moves towards its, left and compresses the liquid in the cylinder. v. Now, the pressure makes the delivery valve to open and liquid is discharged through delivery pipe vi. When piston reaches its extreme left position whole liquid present in the cylinder is delivered through delivery valve. vii. ‘Then again the crank rotate outwards and piston moves right to create suction and the whole process is repeated. viii. Generally the above process can be observed in a single acting reciprocating pump where there is only one delivery stroke per one revolution of crank. But when it comes to double acting reciprocating pump, there will be two delivery strokes per revolution of crank. Reciprocating pumps are used in GDU in the Plant. It is also used for dosing chemicals at other units. T tonne f | Centrifugal Pump - Centrifugal pump is a hydraulic machine which converts mechanical energy into hydraulic energy (i.e. pressure energy) by the use of centrifugal force acting on the fluid. The flow of liquid takes place in radial outward direction. It works on the principle of forced vortex flow. The forced vortex flow means when a certain mass of fluid or liquid is allowed to rotate by an external torque than there is a rise in pressure head of the rotating, liquid takes place. This rise in pressure head is used to deliver the fluid from one location to. another. It is centrifugal force acting on the fluid that makes it to flow within the casing. ‘The rise in the pressure head of the rotating liquid at any point is directly proportional to the square of the tangential velocity of the rotating liquid. Working of a centrifugal pump is as follows: As the electric motor starts rotating, it also rotates the impeller. The rotation of the impeller creates suction at the suction pipe. Due to suction created the fluid from the sump starts coming to the casing through the eye of the impeller. i, From the eye of the impeller, due to the centrifugal force acting on the fluid, the fluid starts moving radially outward and towards the outer of casing, iii, Since the impeller is rotating at high velocity it also rotates the fluid around it in the casing, The area of the casing increasing gradually in the direction of rotation, so the velocity of the fluid keeps on decreasing and the pressure increases reaching its maximum at the outlet of the pump. Page | 25iv. Now from the outlet of the pump, the fluid goes to its desired location through delivery pipe Centrifugal pumps are used in almost all units of the Plant, 2. Compressor A compressor is a mechanical device that increases the pressure of air/ gas by reducing its volume. An air compressor is a specific type of gas compressor. Compressors are similar to pumps: both increase the pressure on a fluid and both can transport the fluid through a pipe. As gases are compressible, the compressor also reduces the volume of a gas. Liquids are relatively incompressible; while some can be compressed, the main action of a pump is to pressurize and transport liquids. Types: a. Reciprocating compressor- A reciprocating compressor uses pistons to compress the gas. There is a central crankshaft that drives anywhere from two to six pistons inside cylinders. The crankshaft is generally driven by an external motor. As the pistons draw back, gas is injected from an intake valve in the compressor. This gas is injected into the cylinders of the pistons, and is then compressed by the reciprocating action of the pistons. The gas is then discharged. The discharge from Air Compressors is usually stored in Air Vessels for use when needed and also as a buffer to supply air in times of pressure loss in system. However, the gas must be stored or used directly from the compressor to prevent it from losing its pressurization. The reciprocating compressor is single acting ‘when the compressing is accomplished using only one side of piston and double acting when both the sides of piston used. Reciprocating compressors are used in CFU and DPD. rennet ton Va yaar b. Centrifugal Compressor- The compression principle of centrifugal compressor is quite different from that of reciprocating or rotary type compressor. They achieve a pressure Page | 26rise by adding kinetic energy/ velocity to a continuous flow of fluid through the rotor or impeller. This kinetic energy is then converted to an increase in potential energy/static pressure by slowing the flow through a diffuser. The pressure rise in the impeller is in most cases almost equal to the rise in the diffuser. When the air passes through the rotating impeller it experiences force or work which is performed by centrifugal forces. The work input takes place as an increase in pressure and velocity or speed of the air flow through the impeller. The air flow loses its velocity after entering in the diffuser section. The diffuser is actually a fixed or static component that escorts the air flow when it leaves the impeller. This loss in velocity eventually results in an additional increase of pressure. The impeller and the diffuser contributes about 65% and 35% of the total pressure developed or produced in the compressor. ‘tse ie ing ‘Centtuga comeressor schemate diagram Bearings and mechanical seals Bearings: ‘The term "bearing" is derived from the verb "to bear"; a bearing being a machine ‘element that allows one part to bear (ie., to support) another. A bearing is a machine ‘element that constrains relative motion to only the desired motion, and reduces friction between moving parts. The design of the bearing may, for example, provide for free linear movement of the moving part or for free rotation around a fixed axis; or, it may prevent a motion by controlling the vectors of normal forces that bear on the moving parts. Most bearings facilitate the desired motion by minimizing friction. Types: a. Journal Bearing - A Journal Bearing is a shaft or journal rotating in a bearing. The shaft rotates in the bearing with a layer of lubricant separating the two parts. Since journal bearings are designed to reduce load friction, they are often used when the Joad is light and the motion is continuous. With a journal bearing, there is no rolling ‘element like in other bearings. This is why journal bearings are often called radial or sleeve bearings. Page | 27b. Thrust Bearing - A Thrust Bearing is a particular type of rotary bearing. Like other bearings they permit rotation between parts, but they are designed to support a predominantly axial load. It is to prevent the shaft from drifting in the axial direction and to transfer thrust loads applied on the shaft. Vertical thrust bearings also need to support the weight of the shaft and any components attached to it. The moving surface exerted against a thrust bearing may be the area of the end of the shaft or the area of a collar attached at any point to the shaft. cc. Ball Bearing - A Ball Bearing is a type of rolling-element bearing that uses balls to maintain the separation between the bearing races. The purpose of a ball bearing is to reduce rotational friction and support radial and axial loads. It achieves this by using at least three races to contain the balls and transmit the loads through the balls. In most applications, one race is stationary and the other is attached to the rotating assembly (e.g., a hub or shaft). As one of the bearing races rotates it causes the balls to rotate as well. Because the balls are rolling they have a much lower coefficient of friction than if two flat surfaces were sliding against each other. Ball bearings tend to have lower load capacity for their size than other kinds of rolling-element bearings due to the smaller contact area between the balls and races. However, they can tolerate some misalignment of the inner and outer races. Page | 28Sealing Systems: A Mechanical Seal is a device that helps join systems or mechanisms together by preventing leakage (e.g. in a plumbing system), containing pressure, or excluding contamination. The effectiveness of a seal is dependent on adhesion in the case of sealants and compression in the case of gaskets. A stationary seal may also be referred to as ‘packing’. The Packing could be of Graphite’ Asbestos) Rubber etc. The Seals are important components in pipelines, static equipment etc. Mechanical seals are used in Industrial Pumps, Compressors, and other applications where a spinning shaft protruding into a wetted process is likely to have continuous, rigorous duty. Mechanical seals move the point of the seal away from the shaft to specially designed sealing faces that gradually wear down. This provides a longer service life. Mechanical seals may be spring loaded or pneumatically operated. At Hazira Plant, the Mechanical Seals play a major role in preventing leakage of hazardous hydrocarbons into the atmosphere. 26e Page | 29CONDITION MONITORING Condition monitoring (or, colloquially, CM) is the process of monitoring a parameter of condition in machinery (vibration, temperature etc.), in order to identify a significant change which is indicative of a developing fault. It is a major component of Predictive Maintenance. The use of condition monitoring allows maintenance to be scheduled, or other actions to be taken to prevent consequential damages and avoid its consequences. Condition monitoring techniques are normally used on rotating equipment, auxiliary systems and other machinery (Compressors, Pumps, Electric Motors, Internal Combustion Engines, Press), while periodic inspection using non-destructive testing (NDT) techniques and fit for service (FFS) evaluation are used for static plant equipment such as steam boilers, piping and heat exchangers. Vibration Analysis: Vibration analysis refers to the process of measuring the vibration levels and frequencies of industrial machinery, and analysing that information to determine the health of the machine, and its components. Factors leading to vibrations in machines: Clearance or tolerance in machine parts Misalignment Unbalance Loose parts and joints Foundation related issues such as soft foot Turbulence in fluid flow ayaeye Vibrations are measured in the following terms: 1, Displacement (for rotation speed < 600 rpm) 2. Velocity (for rotation speed b/w 600-3000 rpm) 3. Acceleration (for rotation speed > 3000 rpm) Vibrations can be measured, using a device called an accelerometer. An accelerometer generates a voltage signal, proportional to the amount of vibration, as well as the frequency of vibration, or how many time per second or minutes the vibration takes place. This voltage signal from the accelerometer is fed into a data collector, which records this signal as either a time waveform (amplitude vs. time), as a Fast Fourier Transform (amplitude vs. frequency), or as both. The time waveform gives raw data and is difficult to analyse whereas the FFT diagram is easier to analyse. Phase analysis and orbit analysis confirm the results obtained using FFT analysis. The signals can then be analysed by a trained vibration analyst, or by the use of a computer program algorithm. The frequency of the signal helps identify the source of the problem while its amplitude helps to determine the criticality of the problem. The analysed data is then used to determine the health of the machine, and identify any impending problems in the machine. Page | 30Safety Valves: Safety Valve is a type of valve that automatically actuates when the pressure of inlet side of the valve increases to a predetermined pressure, to open the valve disc and discharge the fluid (steam or gas) and when the pressure decreases to the prescribed value, to close the valve disc again. Types: 1. Pressure Safety Valve (PSV) - A pressure safety is a safety device designed to protect a pressurized vessel or system during an overpressure event. An overpressure event refers to any condition which would cause pressure in a vessel or system to increase beyond the specified design pressure or maximum allowable working pressure. It is used in gas lines, steam lines and water lines. A pressure safety valve consists of a nozzle- disc and spring- bolt arrangement. The spring is adjusted using a bolt to give it stress/tension corresponding to the required pressure value. When pressure in the line increases beyond the allowable working pressure, the disc located above the nozzle is lifted up, releasing excess pressure A bellow is also given in the valve to control flare line pressure. PSVs are calibrated and tested using a test bench where air or water, depending on where it is used. Page | 31Thermal Safety Valve (TSV) ~ A thermal safety valve is similar to PSV, the difference being that it actuates at a pressure corresponding to the required temperature. It is generally smaller in size than a PSV and is used mostly in cooling water lines. Pressure Vacuum Relief Valve (PVRV) — A pressure vacuum relief valve is used when pressure decreases below the desired limit. In such conditions, vacuum is created inside the system due to pressure drop. PVRV relieves this vacuum by bringing in air from the atmosphere, preventing the system from collapsing, Page | 32MECHANICAL MAINTENANCE The continuous operation of machines and equipment is very critical for running any industry or plant. Therefore, the down time costs are enormous as compared to the running costs or maintenance costs. In order to keep the plant equipment and machinery in good shape and to achieve highest level of equipment and system availability, a stringent maintenance regime is adopted. Mechanical maintenance techniques are broadly classified as: 1, Preventive Maintenance - This is the type of maintenance which is carried out on a fixed schedule. It could be hour based where a machine is taken under maintenance after it has run for a specified number of hours or calendar based where a machine is taken under maintenance after a specified number of months or years. For example, boilers are taken under maintenance once in a year (Calendar Based). Reciprocating Compressors at the Plant undergo maintenance after 2000 hrs, 4000 hrs, 6000 hrs, $000 hrs, 10000 hrs and so on and are overhauled at 16000 hrs. Centrifugal Pumps are taken up for Maintenance every 4000 Hours and Overhaul at 12000 how The time period after which maintenance has to be carried out is decided by the manufacturer and is specified in the manual of the machine. 2. Predictive Maintenance - This type of maintenance is done while the equipment is in operation where any growing internal problem is detected by trouble shooting techniques called condition monitoring techniques. The recommendations made based on these observations such as vibrations, noise level, lube oil condition, ete. are immediately implemented by the concerned maintenance groups. This helps in preventing the unplanned shutdown/ breakdowns of the equipment and excessive damage to the parts. ‘The frequency of these checks depends on the criticality of the equipment. 3. Breakdown Maintenance - In spite of regular preventive and predictive maintenance, there are few cases of breakdown maintenance. These breakdowns of equipment are attended on war footing, sometimes even working overnight depending upon the criticality of the equipment. It is necessary to keep spare parts for the machines available at all times. Each breakdown case is thoroughly analysed using defect analysis techniques to avoid such occurrences in the future. 4, Planning for Resources — The Maintenance of the equipment can be properly carried out only if the material resources like spares, consumable and other miscellaneous items along with the requisite man power are available on time. In order to achieve this planning is an important activity that is done to ensure that the necessary resources are at hand. Also some spares and other regularly consumed material like gaskets, O Rings etc. are to be in hand to meet any untoward incident. Page | 33CONCLUSION Industrial Training is an integral part of engineering curriculum providing engineers with first- hand knowledge and practical aspects of the subjects studied at the undergraduate level. Moreover, it provides them with the knowledge about the work circumstances existing in the ‘company. The industrial training at ONGC, Hazira has been a great learning experience where my theoretical knowledge was put to practical use along with getting to know something new. The knowledge acquired here would help me approach further subjects in- depth with greater understanding. It also gave a lot of knowledge about the proce: equipment and their maintenance Page | 34PROJECT Different Types of valvesOutline > What is valve? > Classification of valves > Valve types. > Methods of controlling flow through a valve. > Basic Parts of the valve. > Valve types What is valve? A valve is a device that regulates, directs or controls the flow of a fluid by opening, closing, or partially obstructing various passageways. Valve Functions 1.Stopping and starting fluid flow. 2.Varying (throttling) the amount of fluid flow. 3.Controlling the direction of fluid flow. 4.Regulating downstream system or process pressure. 5.Relieving component or piping over pressure. anClassification of Valves The following are some of the commonly used valve classifications, based on mechanical motion: ¢Linear Motion Valves: The valves in which the closure member, as in gate, globe, diaphragm, pinch moves in a straight line to allow, stop, or throttle the flow. *Rotary Motion Valves: When the valve-closure member travels along an angular or circular path, as in butterfly, ball, plug valves. *Quarter Turn Valves: Some rotary motion valves require approximately a quarter turn, 0° through 90°, motion of the stem to go to fully open from a fully closed position or vice versa. Classification of valves based on motion Quarter Valve types Linear motion Rotary motion turn Gate Valve x Globe valve x Plug valve x x Ball valve x x Butterfly valve x = Diaphragm valve _ Pinch valve x a2Basic Parts of the valve 1.Body 2.Bonnet 3.Trim(Internal element) 4.Actuator 5.PackingBody It is called the shell, is the primary pressure boundary principal of a valve. It serves as the the framework that holds element of a valve assembly because it is everything together.Bonnet * The cover for the opening in the valve body. * Bonnet is the second principal pressure boundary of a valve. * It is cast or forged of the same material as the body and is connected to the body by a threaded, bolted, or welded joint. The attachment of the bonnet to the body is considered a pressure boundary. This means that the weld joint or bolts that connect the bonnet to the body are pressure-retaining parts. Valve bonnets, although a necessity for most valves, represent a cause for concern, Bonnets can complicate the manufacture. Increase valve size. Represent a significant cost portion of valve cost. Bonnets are a source for potential leakage. 49Valve Trim The internal elements of a valve are collectively referred to as a valve's trim. The trim typically includes a disk, seat, stem, and sleeves needed to guide the fluid. A valve's performance is determined by the disk and seat interface and the relation of the disk position to the seat. Because of the trim, basic motions and flow control are possible. Valve TrimInternal parts of the valve Disk: - Disk is the third primary principal pressure boundary. It provides the capability for allowing and stopping fluid flow. The disk is a pressure-retaining part. Disks are typically forged and, in some designs, hard-surfaced to provide good wear characteristics. Most valves are named, in part, according to the design of their disks. Seat or seal rings: - Provide the seating surface for the disk. To improve the wear- resistance of the seal rings, the surface is often hard-faced by welding and then machining the contact surface of the seal ring. Stem: - Connects the actuator (hand wheel) and disk, is responsible for positioning the disk. Stem designs fall into four basic categories: 1.Rising stem with outside screw 2.Rising stem with inside screw 3.Non rising stem with inside screw 4.Sliding stem Ss.Actuator (hand wheel) Operates the stem and disk assembly. An actuator may be operated manually or automatically. — v Actuator Packing It is used to prevent leakage from the space between the stem and the bonnet. Packing 53Valve Section Valve Selection Considerations 1.Pressure. 2.Temperature. 3.Type of fluid. A. Liquid. B. Gas, i.e., steam or air. C. Dirty or abrasive (erosive) D. Corrosive. 4. Flow Considerations A. On-off or Throttling. B. Is the valve needed to prevent backflow. C. Concern for pressure drop. D. Velocity. 5.Operating conditions A. Frequency of operation. B. Accessibility. C. Overall space/size available. D. Manual or automated control. E. Need for bubble-tight shut-off. F. Concerns about body joint leaks. G.Fire safe design. H. Speed of closureMaterial Selection There are factors govern the basic materials selection * Corrosion-resistance requirements. * Thermal shock. * Piping stress. + Fire hazard. Types of materials typically available include * Ductile iron. * Carbon steel. * Cast iron. * Stainless steels. * Brass. * Bronze. * Polyvinyl chloride (PVC) plastic. Body Materials * For small valves are usually brass, bronze, or forged steel. * For larger valves, cast iron, cast ductile iron or cast steel as required for the pressure and service. Seat and Valve Disk Materials * The valve seat and valve disk are sometimes referred to as the valve trim and are usually constructed of the same material selected to meet the service requirements. * Valve stem material should be selected to meet service conditions. Stainless steel is commonly used for most HVAC applications, and bronze is commonly used in ball valve construction. 55.Table 2.9 Temperature Limits for Body Materials Material Upper | Upper | Lower | Lower Limit} Limit | Limit | Limit ‘A (0) rc | Cast iron 410} 210 20 4 Ductile Iron 650 345 -20 5 *Carbon Stee! (Grade WCB) 1000 535 20 6 Carbon Steel (Grade LCB) 650 345 50 10 ‘Carbon Moly 850 455 -20 4 1-1/4 Cr- #2 Mo (Grade WCE) } 1000 535 -20 6 24/4 Cr- 172 Mo (Grade WCs) | 1050 565 -20 4 5.Cr- 1/2 Mo (Grade C5) 1100 595, 20 4 9.Cr- 1 Mo (Grade C12) 1100 | 595 20 6 ‘Type 304 (Grade CF 8) 1500 815 425, 220 ‘Type 347 (Grade CFEC) 1500 815 425 220 ‘Type 316 (Grade CFEM) 1500 815 425 220 34/2 Ni (Grade LC3) 650 M5 -150 5 ‘Aluminum 400 205 325 160 [Bowe + _s50 | 205 | ws | 00 | Inconel 600 1200 650 325 160 ‘Monel 400 900 480 “325 -160 Hasteloy B 700 370 325 | 160 | Hasteloy C 1000 535 325 160 Tranium 600 315 NA NA Nickel 500 | 260 | -325 | -160 ‘Aloy 20 300 150 50 10 ‘Courtesy of Vale ternational. ‘The carbon phase of carbon stel may be converted to graphite upon long exposure temperatures above 75°F (415°C). Check applicable codes for maximum temperature rat ing of various materials. Other specific data avaiable in ANSI B1634 56Body Typo Material Body Standard Bonnet Standard Castings Stainless Stee! A5I-CFBM AATO-316 Carbon Steel A2IG.WCB AGTE-70 Chrome-moly A2IT-WCB 4479-316 A2I7-WCS AMTO-316 A2N7-C5 AAT9-316 Forgings Stainless Stel ATA3.CFBM AATS-316 Carbon Steel A105 AGTE-70 Chrome-noly ANGI 4479-316 ANB2F22 AAT9-316 ANB2-5a AMTS-316 Bar Stainless Steel A1B2F316 AAT9.316 Carbon Steel AGTS-10 AGTE-70 Chromesmoly See Forgings See Forgings Valve and Connection Threaded ends + Used for small application up to 4 in. they are cheap but can be stripped and leak, for this reason they are used when leakage is not a problem. + Threaded ends should not be used with corrosive processes, since the threads can either fail or become inseparable. & oa Threaded end 57Welded ends When zero leakage is required for environmental, safety, or any efficiency reasons the piping can be welded to the valve, providing one piece construction. Many users insist that high-pressure application requires a permanent end especially if they involve high temperatures. Welded valve Welded ends Flanged ends The most expensive but are the best from an installation and removal standpoint. The main advantage of flanges is that the valve can be removed easily from the line. Flanged endsValve types Globe valve Gate valve Plug valve Ball valve Needle valve Butterfly valve Diaphragm valve Pinch valve Check valve Safety/relief valve Reducing valve Globe Valves A globe valve is a linear motion valve used to stop, start, and regulate fluid flow. The three primary body designs for globe valves are Z-body, Y-body, and Angle. Advantages @ Recommended for _ throttling applications. o Good for frequent operation. e Easy to repair. Disadvantages e Flow path causes a_ significant pressure drop. Globe valves are more costly than alternative valves. 59Gate Valves Flow is controlled by raising or lowering the valving element. Gate valves are not usually used to regulate flow because the valving element can be damaged when in the partially open position. Similarly, they also limit the pressure drop across the valve when fully open. Gate Fa valve Advantages Gate valves opens or closes slowly, which prevents fluid hammer and subsequent damage to the piping system. They need long operation time since setting the valve to the fully open or closed position requires the handle to be turned many times. Good choice for on-off service. Full flow, low pressure drop. Bidirectional. Disadvantages It is not suitable for throttling applications. It is prone to vibration in the partially open state. It is more subject to seat and disk wear. Repairs, such as lapping and grinding, are generally more difficult to accomplish.Ball Valves A ball valve is a rotational motion valve that uses a ball-shaped disk to stop or start fluid flow. Advantages * Maintains and regulates high volume, high pressure, and high temp flow. * Low purchase and maintenance costs. + No lubrication requirements. * Give tight sealing with low torque. * Time of valve operation is minimized. * Can be used for throttling service. * Can handle fluids with suspended solids. Disadvantages * Have relatively poor throttling characteristics. * Difficult to clean, leads to contamination. 61Diaphragm Valves: - A diaphragm valve is a linear motion valve that is used to start, regulate, and stop fluid flow. The name is derived from its flexible disk, which mates with a seat located in the open area at the top of the valve body to form a seal. Advantages * Valve components can be isolated from the process fluid. * Valve construction prevents leakage of the fluid without the use of a gland seal (packing) Disadvantages The diaphragm becomes worn more easily and regular maintenance is necessary. + These types of valves are generally not suited for very high temperature fluids and are mainly used on liquid systems. 63