INTRODUCTION

Gas lift unit has been installed at CPF – Gandhar to compress gas and sending it
to different GGS for lifting well fluid as a secondary oil recovery. Lean gas
coming from IPCL/GAIL is being used for this purpose.

Three number of single stage double acting Gas lift compressor has been installed
to increase the pressure from a pressure of 36 kg/cm2 to 122 kg/cm2. The
capacity of each compressor is 3.9 LCMD. Each has wide range of loading
option viz, 0%, 50%, 63%, 75%, 88% & 100%.

The compressor is being driven electrically by 6.6 KV motor.

 FEED GAS QUALITY

The gas which is being supplied by IPCL / GAIL has methane ( CH4 ) as main
constituents. The percentage of higher hydrocarbon is very less because of this it
is called Lean Gas. The average composition of lean gas is as follows:

CONSTITUENTS VOLUME %

Methane 99.05
Ethane 0.57
Propane 0.12
Iso-Butane 0.06
Normal-Butane 0.08
Iso-Pentane 0.05
Normal-Pentane Nil
Hexane Nil
Carbondioxide Nil
Nitrogen 0.07
Net Calorific Value 8256 Kcal / m3
Average Molecular Weight 16.26
Specific Gravity at 15 deg C 0.5637
 Process Description :

The Gas lift unit consists of the following :-

1) Suction KOD ( 86-V -101 )

2) Gas lift compressor ( 86-K-101 A/B/C )
3) Discharge KOD ( 86-V-103 )

The lean gas at a pressure around 36 kg/cm2 coming from GAIL is entering
into the Suction KOD ( 86 V 101 ) where any entrained liquid is separated out
and the gas coming out from the top of KOD is entering into the suction header.
The KOD is provided with LSH-1101 & LSHH-1101 to give alarm for high level
and to trip the compressor for high-high level. Suction KOD is also provided
PSV-1107 A/B to take care of very high pressure and release the excess gas to
the flare header. 86 TSH-1101 has been provided to give an alarm if the inlet gas
temperature goes beyond 60 deg C.
All the three compressors are taking suction through separate suction line
to individual compressor’s suction volume bottle ( 86-V-01 ). The volume bottle
is provided with PSL & PSLL to give alarm for low pressure and to trip the
compressor for low-low pressure . The volume bottle is also provided PSV-1107
A/B to take care of very high pressure and release the excess gas to the flare
header As it is a single stage double acting compressors gas from suction volume
bottle is entering into the compressor cylinder- 1 and cylinder-2 . The gas after
compression to a pressure of 123 kg/cm2 from cy-1 & cy-2 enters into the
discharge volume
bottle ( 86-V-02 & 86-V-03 ) and the gas from two volume bottles joins together
before entering into the after cooler. The volume bottles are provided with TSHH
& TSHH to give alarm for high temperature and to trip the compressor for high-
high temperature

This high pressure & high temperature discharge gas is entering to the after
cooler (86-E102 A/B/C ) where it is cooled by water in a shell & tube heat
exchanger ( gas in tube side and water in shell side ) from a temperature of 145
deg. C to a temperature of 50 deg. C and then joining to the common discharge
header for the three compressors. The PSHH is provided at the inlet of the cooler
which will trip the machine in case of very high pressure. The high temperature
common discharge line before the entry of the cooler is also provided PSV-1107
A/B to take care of very high pressure and release the excess gas to the flare
header.

The common discharge header is provided with PSH-1101 & PSHH-1101

to give alarm for high pressure and to trip the compressor for high-high pressure
and PSL-1107 & PSLL-1107 to give alarm for low pressure and to trip the
compressor for low-low pressure.

To take care of the high discharge pressure a recycle line has been
provided. The control valve ( PCV- 1104/1113/1114 ) has been provided in the
respective compressor A/B/C for this purpose. Two branch lines of the final
discharge gas (one from before the after cooler and other from after the after
cooler) is joining before the Recycle Valve. The down stream line of the recycle
valve is joining to the recycle header. The recycle gas of three compressors is
entering separately to this recycle header. The recycle header in turn is joining to
suction KOD inlet line from GAIL lean gas supply line before entering into
suction KOD (86-V-101 )

The compressed gas from the three compressors after joining in the
discharge header enters into the discharge KOD ( 86-V-103 ) Any liquid formed
during cooling of the compressed gas is knocked out and the gas coming out from
the top of the KOD is going to GGS through a 8” gas lift header. The KOD is
provided with LSH-1105 & LSHH-1105 to give alarm for high level and to trip
the compressor for high-high level. Discharge KOD is also provided PSV-1111
A/B to take care of very high pressure and release the excess gas to the flare
header.
Compressor Loading/Unloading:

The compressor can be operated at different capacity viz, 0, 50, 63, 75, 88
& 100 %. This can be done both in manual mode and auto mode. The auto mode
capacity control is related with the recycle valve output. Normally when the
compressor is running at 100% load the discharge pressure is within the limit
(123 kg/cm2 ) which is usually the set point of the recycle valve the recycle valve
will remain in closed condition. Now if the discharge pressure starts increasing
beyond the set point the recycle valve will start opening and the compressed gas
will go to recycle header through recycle valve to maintain the discharge
pressure.

But if the opening goes beyond 15% (approx.) the compressor load will be
one step down i.e from 100% to 88%. Due to this load reduction less gas will be
compressed and the discharge pressure will be within the limit and the recycle
valve will starts closing. But if the line pressure did not fall and opening of the
recycle valve remains same (i.e 15%) or starts further increasing, load (i.e
capacity) will be decreased to next stage i.e 75%. In the phenomenon load will go
on decreasing till the discharge pressure is not maintained in the required limit. In
this process compressor will go on un-loading sequence.

The reverse is true while loading, after the start of compressor at 0% load
the compressor will go on loading step wise when put auto mode up to 100% till
it achieved the desired pressure. In spite of being loaded at 100% if it cannot
build up the desired pressure it will continue to at 100% load continuously.
Compressor cylinder jacket cooling system :

Compressor cylinder jacket is being cooled by circulating the cold de-

mineralized (DM) water surrounding the jacket. The DM water circulation run in
closed loop system. The DM water circulating pump 86 P-103 A/B takes suction
from the reservoir ( V-1 ) and passes through the cooler where it gets cooled.
This cold DM water enters into the jackets of both the cylinder ( Cy-1 & Cy-2 )
of each compressor and after cooling the jacket it return to the reservoir.
Methanol is added to the DM water to enhance the performance and efficiency of
cooling. To maintain the desired temperature of the DM water a auto set three
way valve is provided in the line after the cooler connected with the inlet to the
cooler. If the temperature of the DM water is getting lower than the desired value
this control valve bypasses the cooler and maintain the temperature. The cooling
medium used in cooler is normal cooling water to cool the DM water. The DM
water tank is provided with a heater for maintaining the water temperature in a
desirable range. The heater acts on actuation of switch 86 TSHL-040491 which
cut-in ( ON ) below 20 deg C and cut out ( OFF ) above 45 deg C. If the flow rate
of DM water falls below 4 m3/hr it will give an alarm by 86 FSL -040001. If the
pressure of DM water falls below 2045 kg/cm2 it will give an alarm by 86 PSL
-040411. The 86 LSL-040471 will give an alarm if the level falls below 70 mm in
the DM water tank
Compressor lube oil system :

All the compressor is provided with individual lube oil system. Lube oil
from a small tank is pumped by lube oil pump 86- P-102 A/B and send to the
compressor for lubrication after getting cooled by lube oil cooler and after being
filter. Lube oil feed to compressor should maintain a temperature and hence it is
provided with a lube oil heater which cut-in ( ON ) below 40 deg C and cut out
( OFF ) above 50 deg C in actuation of the switch 86 TSHL- 530491. High lube
oil temperature is indicated by the switch 86 TSH-530001 if the temperature rises
beyond 65 deg C. The low lube oil pressure will be sensed by 86 PSL-1104 and
will give an alarm if the L/O pressure falls below 3.5 kg/cm2.

Compressor frame oil pressure and level is to be maintained in normal

limit for safe running of the machine. Low frame oil level will be indicated by 86
LSL- 500301 for a level below 70 mm. Low frame oil pressure will be indicated
by 86 PSL- 500001 for a pressure below 1084 kg/cm2 if the pressure goes
further low ( 1.53 kg/cm2 ) the PSLL-530001 will trip the compressor.

Purge Air Compressor :

The gas lift unit is provided with four purge air compressor (86 K-102 A/B/C/D)
for the purpose of purging its main motor and local control panel. Each
compressor is having a capacity of 1.29 m3/min and build up air pressure from
ambient to 7 kg/cm2 by reciprocating action. The compressor is run by electrical
motor. After compression and getting cooled by the in built finned tube cooler it
enters into a volume bottle. The outlet from the volume bottle form the purge air
header for GLC. This header is also connected with the main purge air header of
the whole plant.
Normal Start-up :

1. Line-up the compressor by opening suction / discharge valves up to battery

limit & line up recycling valve (86-PCV-1104/1113/1114)

2. Line up the motor purging system and start Purge air compressor (2 nos) –
one in MANUAL & one in AUTO mode.

3. Start the purging of motor and panel and ensure that the PURGE
COMPLETE LED glows .

4. Start the AOP in MANUAL mode.

5. Line-up Cooling water system & start cooling water pump.

6. Press Shut down RESET button on LCP.

7. Select operation mode through main key selection switch.

8. Obtain Control Room & Electrical Sub-Station clearance permission.

9. After getting unit “Ready to Start”, press start button.

10. Put AOP in AUTO mode.

11. Put the compressor on MANUAL mode (50%, 62%, 75%, 88%, 100%
load) or AUTO mode as per the requirement.

12. Check level of Lubricating oil in crankcase and Force Feed Lubricators.

13. Ensure No load running time does not exceed.

Normal Activity :

1. Log the parameters ( temperatures, pressures, levels and amperage ) hourly

in the Log-book.

2. Check & Drain the suction / Disch. Volume bottles & KODs hourly.

3. Check all parameters are within limits, any alarms on LCP.

4. Monitor oil level in frame sump and add oil as required to maintain the
proper level as indicated on sight glass in Force feed Lubricators.

5. Inform CR / Mech Section immediately in case of any abnormality.

6. Watch differential pressure across oil filter to check cleanliness. Change

over filter if necessary and arrange cleaning of choked filter.
7. Be vigilant for any unusual noise while the machine is operating. These
should be investigated immediately and periodically.

Normal Shut-down :

1. Unload the compressor in descending sequence of steps and bring it to 0%

capacity. SWITCH OFF from LCP.

2. SWITCH OFF the Main motor supply & Control supply.

3. Close suction & discharge valves.

4. If the compressor is to be given for maintenance, depressurize and purge

with inert gas to make the compressor free of hydrocarbon gas if handled.
Trouble Shooting :

1. Low Lube Oil Pressure

- Low oil level
- Plugged oil pump strainer
- Leaks in suction and discharge lines of the oil pump
- Worn out bearing of the oil pumps
- Defective oil pump
- Dirt in oil filter check valve
- Broken oil filter check valve spring
- Oil pressure by pass leaking
- Defective pressure gauge

2. High Oil Pressure

- Plugged oil pressure lines
- Defective oil filter mechanism
- Excessive spring tension in oil pressure adjusting mechanism.
- Defective Pressure gauge

3. Over heated Cylinders

- Insufficient cooling water, sourced pipe on or cylinder.
- Broken valve and valve springs.
- Insufficient lubrication.
- Packing too tight.
- Choked cooling water passage.
4. High Intercooler Pressure
- Broken or leaking valves.
- Defective gauge.
5. Low Intercooler Pressure
- Broken or leaking valves.
- Leak in Intercooler.
- Piston rod packing leaking.
- Defective pressure gauge.
6. Knocking Sound
- Scoured piston or cylinder
- Defective lubrication.
- Foreign material in cylinder.
- Piston hitting cylinder head.
- Loose piston or piston pin.
- Loose main bearing.
- Scoured cross heads or crossheads guides.

7. High suction temperature

- Broken or leaking suction valves.
 EQUIPMENT SPECIFICATION

Lift Gas Compressor

Tag No : 86 K-101 A/B/C

Type : Single stage double acting
Capacity : 17500 (max), 15300 (nor), 8750(min).
Suction Pr. : 36 kg/cm2
Discharge Pr. : 122 kg/cm2
Manufacturer : Nuovo Pignone, Italy.

Compressor Motor

Power : 1000 KW
Voltage : 6600 V
RPM : 370
Manufacturer : ANSALDO

After Cooler E-102A/B/C

SHELL TUBE
Design Pressure kg/cm2 130 88
Design Temperature deg C 200 99
Hydro-test Pressure kg/cm2 195 132
Fluid handled GAS WATER

Purge Air Compressor

Manufacturer : ING ENEA AATTEI SPA, ITALY

Capacity : 1.29 m3/min
Suction Pr. : Ambient
Discharge Pr. : 7.0 kg/cm2
 EMERGENCY, SAFETY AND FIRE FIGHTING

Safety of personnel and equipment is a very important consideration in

operation of the unit. Though design of the plant takes care of a number of
emergency conditions and makes the plant operationally safe, proper operating
procedures and use of safety equipment are a must for the safe running of plant
and a safe environment to work in.

Gas detection system :

5 Nos. of gas sensors are provided at strategic locations in the

compressor housing for monitoring the gas leakage and in the event of gas
leakage in the plant, the field sensor will extend the signal to the respective gas
monitor provided in the control room. The gas monitor will indicate the alarm
(20% of LEL) for required safety measures to be taken by the operator. If the
LEL increase beyond 60% then the compressor will trip.

Fire Fighting :

To meet the safety requirements of fire accidents, fire fighting facilities are
provided in the system. In case of fire, operating personnel should break the glass
of nearby manual call point (MCP) so that automatic fire alarm will be
enunciated at main control room as well as at the FIRE Station. Compressor to
be stopped. Attempt should be made to extinguish fire using sand, water, dry
chemical powder (DCP) or portable extinguisher available at site.
 DETAILS OF SAFETY SWITCHES

FLOW & LEVEL SWITCHES

SL SET CATE-
TAG UNIT SERVICE
NO POINT GORY
86 FSL Cooling
1 040001 GLC Medium 4 m3/hr B
           
86 LSH
1 011171A GLC GLC-A 70 mm B
86 LSH
2 011171B GLC GLC-B 70 mm B
86 LSH
3 011171C GLC GLC-C 70 mm B
Suc KOD ( 86-
4 86 LSH 1101 GLC V-101) 70 mm B
Disch KOD
5 86 LSH 1105 GLC ( 86-V-103) 70 mm B
Suc KOD ( 86-
6 86 LSHH 1101 GLC V-101) 70 mm A
Disch KOD
7 86 LSHH 1105 GLC ( 86-V-103) 70 mm A
86 LSL
040471 (LSL- Cooling
8 1133) GLC Medium tank 70 mm B
86 LSL
500301( LSL- Comp Frame
9 1132) GLC Oil 70 mm A
PRESSURE SWITCHES

SL SET CATE-
TAG UNIT SERVICE
NO POINT GORY
86 PDSH
530401(pdsh1136 Comp Lub oil 1.0
1 ) GLC filter kgscA B
Comm Disch 127
2 86 PSH 1101 GLC gas Outlet Hdr kgscg B
Comm Disch 131.5
3 86 PSHH 1101 GLC gas Outlet Hdr kgscg A
Inlet to Gas 130.5
4 86 PSHH 1102 GLC cooler E-102A kgscg A
Inlet to Gas 130.5
5 86 PSHH 1103 GLC cooler E-102B kgscg A
Inlet to Gas 130.5
6 86 PSHH 1104 GLC cooler E-102C kgscg A
Inst Air
capacity 4.6
7 86 PSL 020531 GLC control kgscg A
Cooling
medium pump 2.45
8 86 PSL 040411 GLC disch kgscg A
PRESSURE SWITCHES

SET CATE-
TAG UNIT SERVICE
POINT GORY
86 PSL
070002 ( psl 150
1131) GLC Nitrogen mBar C
34.15
86 PSL 1101 GLC GLC-A kgscg B
34.15
86 PSL 1102 GLC GLC-B kgscg B
34.15
86 PSL 1103 GLC GLC-C kgscg B
3.5
86 PSL 1104 GLC   kgscg B
Comm Disch 110.0
86 PSL 1107 GLC gas Outlet Hdr kgscg B
Inst. Air for 4.6
86 PSL 1130 GLC capacity control kgscg B
PA press
86 PSL 1137 GLC control unit   B
86 PSL 1.84
530001 GLC Comp Frame oil kgscg B
32.5
86 PSLL 1101 GLC GLC-A kgscg A
32.5
86 PSLL 1102 GLC GLC-B kgscg A
32.5
86 PSLL 1103 GLC GLC-C kgscg A
Comm Disch 105.2
86 PSLL 1107 GLC gas Outlet Hdr kgscg A
86 PSLL
530001( psll 1.53
1135) GLC Comp Frame oil kgscg A
TEMPERATURE SWITCHES

SL SET CATE-
TAG UNIT SERVICE
NO POINT GORY
Cooling
86 TSH medium to
1 040111 GLC compr 60 degC B
Common Inlet
2 86 TSH 1101 GLC to 86-V-103 52 degC B
86 TSH GLC-A Cyl 1 145
3 1111A/B GLC outlet degC B
86 TSH GLC-A Cyl 2 150
4 1112A/B GLC outlet degC B
86 TSH GLC-B Cyl 1 145
5 1114A/B GLC outlet degC B
86 TSH GLC-B Cyl 2 150
6 1115A/B GLC outlet degC B
86 TSH GLC-C Cyl 1 145
7 1117A/B GLC outlet degC B
86 TSH GLC-C Cyl 2 150
8 1118A/B GLC outlet degC B
Comm Disch
9 86 TSH 1119 GLC gas Outlet Hdr   B
86 TSH 120
10 1140/1/2/3/4/5 GLC   degC B
11 86 TSH 1146 GLC   85 degC B
TEMPERATURE SWITCHES

SL SET CATE-
TAG UNIT SERVICE
NO POINT GORY
max op
86 TSH temp+10
12 501391/2A GLC GLC-A Cyl 1/2 degC B
max op
86 TSH temp+10
13 501391/2B GLC GLC-B Cyl 1/2 degC B
max op
86 TSH temp+10
14 501391/2C GLC GLC-C Cyl 1/2 degC B
86 TSH Lub oil feed to
15 530001 GLC compr. 65 degC B
86 TSH Bearing 1/2
16 530341/2 GLC temp. 85 degC B
<20 cut-
86 TSHL Cooling med. in, >45
17 040491 GLC Htr temp control cut-off C
<40 cut-
86 TSHL Cyl /Packing lub in, >50
18 090491 GLC oil heater cut-off C
<40 cut-
86 TSHL Comp Lub oil in, >50
19 530491 GLC Heater cut-off C
20 86 USL 1132 GLC Mech Lubricator 1.4 barg A
21 86 USL 1133 GLC Mech Lubricator 1.4 barg A
86 USL
22 900001 GLC Mech Lubricator   A
86 XSH Dew point( PA (-) 30
23 000001 GLC Receiver) degC B
PSV

SET
SL NO TAG NO DESCRIPTION
POINT

1 PSV-1107 A/B Suction KOD 44 kg/cm2

st
2 PSV-011011 1 Stage volume bottle of 44 kg/cm2
A/B/C compressor A/B/C
3 PSV-1109 Discharge line before the 133 kg/cm2
After cooler
4 PSV-1110 - Do - 133 kg/cm2
5 PSV-1111 A/B Discharge KOD 133 kg/cm2
 PLANT UTILITIES

A. Cooling Water :

Cooling water is taken from the Main Cooling Water supply header at a
pressure of 4 kg/cm2 and temperature 20 – 27 deg C in winter and summer.. This
is used for the following purpose.
1) To cool the hot compressed discharge gas in after
cooler of the three compressor 86 E-102 A/B/C
2) To cool the jacket cooling DM water 86 E-104
A/B
3) To cool lube oil in the cooler 86 E-103 A/B

Cooling water after exchanging heat returns from all the cooler to the Main
Cooling Water Return header in a closed cycle.

B. Instrument Air & Plant Air :

Instrument air is taken from the instrument air supply header at a pressure
of 6.5 kg/cm2. This is used for functioning control valves, solenoid operated
valves and other control equipments.
Plant air is utilized for blowing & cleaning purpose.

C. Purge air :
Purge air at a pressure of 7 kg/cm2 is supplied from the Purge air
compressors (4 nos) dedicated for the gas lift compressor. Apart from this purge
air supply the unit is connected to the Mian Purge Air header. Purge air is utilized
for Motor purging and Local Control Panel (LCP) purging.
D. Inert Gas ( Nitrogen )
Nitrogen is required for inertization the compressor cylinders and/or the
hydrocarbon bearing pipe lines whenever a major maintenance is taken up. It is
supplied from the main nitrogen supply header.

E. Power Supply :
Different voltage bearing power supply line is entering into the gas lift unit
for the following purpose.
1) 6.6 KV AC : Main Motor Supply
2) 110 V DC : Control Supply ( Logic/Relay/Switch )
3) 110 V AC : Annunciation/ trip amplifier/Temperature monitor
4) 230 V AC : Small pump/compressor motor
5) 240 V AC : Lighting

F. Service water And Fire Water :

Service water at a pressure of 5 kg/cm2 is supplied from the supply header for
washing and floor cleaning purpose.
Fire water at a pressure of 10 kg/cm2 is supplied in the vicinity of the plant via
fire water hydrant for fire fighting and emergency handling.

G. Communication System :
Operator cabin is provided with telephone to communicate with the Control room
during normal condition. However, public address (PA) system is provided at
strategic location for communication during emergency as well as normal
operation.
 VENT & DRAIN SYSTEM

While taking up the major maintenance of the compressor, it is required to de-

pressurized the machine. During de-pressurization the hydrocarbon gas is vented
to flare header through the PSV bypass.
A cold vent line is coming out from each of the three compressor which vents out
the gas from the compressor cylinder 1 & 2 in case of packing leakage.

The liquid collected in the suction and discharge KODs are periodically drained
to OWS ( Oily Water Sump ). The spillage of lube oil etc. on the floor when
cleaned with service water also goes to the OWS .
 SPADE LIST

FOR TOTAL UNIT SHUTDWON.

Sl. NAME OF THE TYPE OF

LOCATION SIZE CLASS
No LINE BLIND
1 GLC suction line B/L Area 10” 300 Spectacle
2 GLC discharge line B/L Area 8” 900 Spectacle
Near Control
3 Flare Header 12” 150 Slip Blind
Room

FOR INDIVIDUAL COMPRESSOR

Sl. NAME OF THE TYPE OF

LOCATION SIZE CLASS
No LINE BLIND
Comp Suction line D/S of I/V 6” 300 Spectacle
Comp Discharge At suction I/V
line valve 1.5” 300 Spectacle
equalization
(1) Comp disch.
(2) Comp.
4” 900 Spectacle
recycle line D/S
Compr. Discharge 2” 1500 Spectacle
of control valve
line
(3) Recycle
3” 1500 Spectacle
control valve by-
pass.
Comp Suction line Next to D/S of
150 Slip Blind
PSV suc. I/V
(1) PSV U/S
Compr. Discharge flange 150 Slip Blind
line PSV (2) PSV by- 150 Spectacle
pass
 CONTENTS

ITEMS PAGE NO
Introduction 1
Feed Quality 2
Equipment Specification 3
Process Description 4–9
Start up / Normal activity /
10 – 13
Shutdown Procedure
Process safety trip interlock 14 - 19
Utilities 20 - 21
Vent and Drain system 22
Emergency, Safety & Fire 23
fighting
Spade List 24
Process flow diagram 25 - 26
OIL & NATURAL GAS CORPORATION LTD.
ANKLESHWAR ASSET

GAS LIFT COMPRESSOR UNIT

OPERATING MANUAL

PREPARED BY

C. K. DAS
SE(P), CPF-GANDHAR