HOW TO MANAGE COMPRESSOR

EFFECTIVELY ?

INDRAPRASTHA
GAS
LIMITED By: Jatin Mogha
(Manager-O&M)

1
 WHAT IS A COMPRESSOR?

A natural gas compressor increases the pressure of

a gas by reducing its volume. The natural gas enters
the cylinder through the intake valves, where it is
compressed and forced out through discharge
valves

IND RAPRASTHA GAS LIMITE D, A JOINT VE NTURE OF GAIL ( IND IA) LTD ., BPCL & GOVT. OF NCT OF D E LHI 2
 TYPES OF COMPRESSOR PACKAGES IN IGL

Presently IGL has 75.6 lakhs kg of compression capacity with

527 no. of gas compressors. Type of compressor packages in
IGL are:
▪ Dresser Rand (400 SCMH & 1200 SCMH)
▪ Burckhardt (400 SCMH, 600 SCMH & 1200 SCMH)
▪ Delta (600 SCMH, 1200 SCMH & 2400 SCMH)
▪ Galileo (1150 SCMH)
▪ Chicago Pneumatics (600 SCMH, 1200 SCMH & 2400 SCMH)
▪ Kirloskar (600 SCMH, 1200 SCMH & 2400 SCMH)
▪ Tulip (600 SCMH &1200 SCMH)

IND RAPRASTHA GAS LIMITE D, A JOINT VE NTURE OF GAIL ( IND IA) LTD ., BPCL & GOVT. OF NCT OF D E LHI 3
 CONTRIBUTING FACTORS FOR
COMPRESSOR EFFECTIVENESS

Compressor
Effectiveness

Reliability Efficiency Gas loss Safety

IND RAPRASTHA GAS LIMITE D, A JOINT VE NTURE OF GAIL ( IND IA) LTD ., BPCL & GOVT. OF NCT OF D E LHI 4
 INCREASING COMPRESSOR RELIABILITY

In IGL we maintain the availability of compressor packages of more than 98.5%.

Through Preventive Maintenance

a) Time Based Maintenance
▪ We have made ISO formats as per OEM guidelines for each type of compressor
in IGL

IND RAPRASTHA GAS LIMITE D, A JOINT VE NTURE OF GAIL ( IND IA) LTD ., BPCL & GOVT. OF NCT OF D E LHI 5
 SAMPLE ISO FORMAT (NOT ACTUAL)
INDRAPRASTHA GAS LIMITED
SCHEDULE MAINTENANCE FORMAT
BURCKHARDT 400/600/1200 COMPRESSOR PACKAGE
TIME: CNG STATION: DATE:

SR. NO. OF COMP PACKAGE: RUNNING HOURS:

18000

36000
1500

3000

4500

9000
TYPE OF MAINTENANCE:(Tick in respective maintenance)

S.no. REMARKS

18000

36000
1500

3000

4500

9000
ACTIVITIES TO BE CARRIED OUT

1 WALK AROUND INSPECTION:COMPRESSOR

1.2 Check for any oil,gas and coolant leakages,if found any abnormality then
√ √ √ √ √ √
rectify the same.
2 LUBRICATION SYSTEM:
2.1 Change compressor oil. √ √ √ √ √ √
2.4 Change con rod big end bearings of all stages √ √ √
2.6 Change crankshaft main bearings √ √
3 GAS SYSTEM:
3.1 Check all stages compressor valves for passing and replace valve
internals.Replace valve in every 18000 hrs maint if found any √ √ √ √
abnormality.
3.2 Change all stages piston rings √ √ √
3.6 Conduct visual & DP check of pilot cylinder studs of all stages.Replace if
√ √
found damaged.
4 TRANSMISSION SYSTEM :
4.1 Inspect/Replace/Rebuild main drive coupling & bolts. √ √ √ √ √ √
5 OTHER ASSEMBLIES:
5.1 Inspect coalescent and package suction filter. If diiferantial pressure
√ √ √ √ √
reached to 0.55 bar change the filter element
6 DETAIL PARAMETERS
Before After
Description
Maintenance Maintenance
6.1 Compressor oil pressure (DPT)
7 ADDITIONAL JOBS DONE
7.1
8 SPARES CONSUMED:
SPARES QTY ITEM CODE REMARKS

Signature of Maintenance Engineer Signature of Maintenance Technician

Name : Name :
6
Designation: Designation:
 INCREASING COMPRESSOR RELIABILITY
▪ Elimination of human Error
To eliminate the human error in planning and execution of schedule maintenance,
notification is generated in SAP based on the cumulative running hours uploaded in
SAP on 25th of every month and same is closed in SAP within defined timeline.
▪ Inspection Before Maintenance
IBM (Inspection before Maintenance) is also carried out before 7 days of planned
date of schedule maintenance for proper planning of spares, manpower and
third party services.
▪ Defined time duration of every maintenance
In IGL we have defined the time duration of every type of maintenance for the
compressors like shown below
Burckhardt-600 SCMH Maintenances allowed time
S.No Type of Maintenance Time Duration
1 1500 / 3000 hours maintenance 5 hours
2 4500 hours maintenance 8 hours
3 9000 hours maintenance 48 hours
4 18000 hours maintenance 72 hours
5 36000 hours maintenance 72 hours
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 INCREASING COMPRESSOR RELIABILITY

b) Through Condition based Maintenance:

▪ Condition Monitoring is planned between two consecutive time based
maintenances for checking the overall health of the Compressor.
▪ Condition monitoring majorly involves checking of parameters like
vibration, temperature, flow etc. and thereby analyzing the checked
parameters for any abnormality.
▪ Periodicity of condition monitoring is as per following frequency
750 hrs or 4 months whichever is earlier for engine driven packages.
1250 hrs or 4 months whichever is earlier for motor driven packages.
▪ CBM is carried out after condition monitoring for compliance.

IND RAPRASTHA GAS LIMITE D, A JOINT VE NTURE OF GAIL ( IND IA) LTD ., BPCL & GOVT. OF NCT OF D E LHI 8
 COMPRESSOR EFFICIENCY

In IGL we maintain the efficiency of compressor packages of

more than 90%.
HOW?
a) Through calculation of gas flow rate: In each control room, daily gas
flow rate of compressor package is calculated and monitored based
on the previous day compressor output, running hours etc. and
corrective action is taken for each package below 90%.
b) Through running the compressor at OEM defined suction pressure
▪ Quarterly Gas filter cleaning is carried out.
▪ Gas filter cleaning above 0.3 bar differential pressure.
▪ Yearly Gas filter replacement.

IND RAPRASTHA GAS LIMITE D, A JOINT VE NTURE OF GAIL ( IND IA) LTD ., BPCL & GOVT. OF NCT OF D E LHI 9
 COMPRESSOR EFFICIENCY
c) Through Secondary lube audit on quarterly basis as per format
shown.
SECONDARY LUBRICATION AUDIT
COMPRESSOR NAME :
CONTROL ROOM :
CNG STATION : DATE : TIME:
SR. NO. OF COMPRESSOR : RUNNING HOURS :

S.NO. ACTIVITIES MEASURED VALUES REMARKS

DNFT timing and tripping
1
check
2 lubrication pump
Divider block and pressure
3
gauges
Non return valves (NRV) and
4
check valve protector
5 Oil tubing and fittings
6 Oil viewer
7 Secondary lube drop count
Lube oil tank, pump and
8
internals inspection
9 Spider coupling check
10 Filter
OTHER OBSERVATION
1

NAME OF ENGINEER INCHARGE AND

SIGNATURE 10
 GAS LOSS
In IGL we target to achieve and maintain the Gas loss below 0.4%.
HOW?

a) Through Quarterly gas leak test .

b) Through daily calculation and monitoring of gas loss based on the
previous day readings, corrective steps are taken at stations for gas
loss above 0.4% .
c) Through inlet flow meter calibration with master flow meter once in a
two years.
d) Through checking of the packing passing of compressors using
permanently installed Rota meters.

IND RAPRASTHA GAS LIMITE D, A JOINT VE NTURE OF GAIL ( IND IA) LTD ., BPCL & GOVT. OF NCT OF D E LHI 11
 SAFETY

Safety is ensured through

a) Calibration/checking of safety equipment's
▪ Pressure safety valves are calibrated yearly.
▪ Pressure Vessels are checked half year/yearly basis.
▪ GD/FD calibration is carried out half yearly.
b) Providing on site and class room trainings to the Compressor
operators/technicians regarding safe operation of compressor at
control room level.
c) Mock drills are conducted once in a year at the stations by F&S
department.

IND RAPRASTHA GAS LIMITE D, A JOINT VE NTURE OF GAIL ( IND IA) LTD ., BPCL & GOVT. OF NCT OF D E LHI 12
 REGULAR TRAINING IS GIVEN IN IGL
TO STATION STAFF

ON SITE TRAINING
PROVIDED TO STATION
STAFF

CLASS ROOM TRAINING

PROVIDED TO STATION
STAFF

IND RAPRASTHA GAS LIMITE D, A JOINT VE NTURE OF GAIL ( IND IA) LTD ., BPCL & GOVT. OF NCT OF D E LHI 13
THANK YOU

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