GAS ENGINE DRIVEN MULTI STAGE COMPRESSOR CONTROL SYSTEM

PARAS TIWARI a , DEVRAT SAH b, ANIL KUMARC

Student of Mechanical Engineering of Dept., Delhi Technological University, Delhi 110 042, India

ABSTRACT
KEYWORDS
Natural gas compressors are essential for extracting, transporting, and distributing natural
Reciprocating Compressor
gas—a fossil fuel formed over millions of years. Various industries, such as natural gas
Compressors Components
processing, refineries, and chemical plants, use natural gas for diverse processes such as paper
Engine Components
and pulp manufacturing, metal refining, chemical production, and food processing.
Instrumentation
CO2 Flooding System This paper examines compression process and how natural gas compressors work. It focuses
Pressure and Temperature on the operation of reciprocating compressors and provides a detailed description of a gas
Variations in Compressor Stages. engine-driven multi-stage reciprocating Burckhardt compressor, powered by a Caterpillar
engine 3406. It also analyses the working parameters such as pressure, temperature, and
practical exposure of various components involved in the compression process, such as
blowdown vessels, gas inlet valves, strainers, separators, and discharge filters.
Furthermore, this paper explores the workings of the Caterpillar engine, illustrating its key
components, specifications. It also describes the instrumentation used in compressor systems,
including pressure transmitters, RTDs, vibration switches, and gas detectors etc. It emphasizes
the safety features such as flame detectors, CO2 systems, hooters, and pressure-regulating
valves that ensure operational safety controlled by programmable logical controlled system
(PLCs). Additionally, it discusses the lubrication systems and the factors affecting reliability
under different working conditions.
Finally, this paper presents the pressure and temperature variations across different stages of
compression, demonstrating the dynamic nature of the compression process. This
comprehensive overview serves as a valuable resource for engineers, researchers, and
professionals involved in the natural gas industry and compressor technology.

INTRODUCTION: -
Natural Gas Compressors
Compressed natural gas (CNG) and compressed hydrogen
gas (CHG) could be considered clean compared to petrol or
diesel. Natural gas primarily consists of methane, but also
contains other hydrocarbons such as butane, propane and
ethane. CNG is stored in high-pressure cylinder on the vehicle
(190–250 bar). Natural gas vehicles (NGVs) connect to the
high-pressure reservoir tanks (200–235 bar) at refueling
stations during filling process. Two main goals could be seen
for refueling stations, operating costs at the refueling stations
and the time to refuel a vehicle (filling time). The main
operating cost of any CNG refueling station belongs to the
compressor. So, a simulation to optimize the refueling
process is very important. Filling time less than 5 min is
referred as a fast fill. In these refueling stations, CNG is
stored in reservoir tanks. There are two systems for storing
CNG in reservoir tanks, cascade (multi-line) and buffer
(mono-line) storage systems. Reservoir tanks in a cascade
storage system are divided into three pressure levels, low,
medium and high pressures. In a buffer system, reservoir
tanks are only in one pressure level. A refueling station with
a cascade storage system uses the priority panel to control the
outlet flow of compressor to a series of cascade storage tanks.
Based on the algorithm in the dispenser the on-board NGV
cylinder is switched from lower pressure reservoir to a higher
one, when the mass flow rate drops to a certain limit. There
are many similarities between the CNG and CHG refueling
process which makes the present work as a useful research for
the CNG refueling stations..
Reciprocating compressors are utilized extensively in various
industries such as: power plants and refineries, refrigeration
systems and CNG stations (Compressed Natural Gas
stations). The key feature of these compressors is high
pressure ratio achievement. A reciprocating compressor is the
heart of any CNG station. In CNG station, natural gas must
be compressed from the distribution pipeline pressure (about
0.5 MPa) to a much higher value (20 MPa 25 MPa) [5]. This
pressure rise is done by employing a multi-stage compressor
(three or four stages). A major part of the initial and current
costs of CNG stations are dependent on reciprocating
compressor. Also, one of the greatest difficulties in CNG
stations is high work required for compressing natural gas [5].
Accurate modeling of CNG compressors could improve
P. Tiwari , D. Sah and A. Kumar
design parameters that lead to efficiency enhancement and
required work reduction.
Various modelling methods have been developed for
reciprocating compressors thermodynamic analysis. These
methods can be roughly classified in global models and in
differential models where the variables depend on time (or
crank angle) [6]. Stouffs et al. [6] presented a global method
for studying reciprocating compressors performance. This
model is based on five main and four secondary
dimensionless physically meaningful parameters. The set of
algebraic equations for Residual mass fraction, volumetric
effectiveness, the specific work and the indicated efficiency
presented in the previous subsections defines the global
model of reciprocating compressors.In another work,
Armaghani et al. [7] employ both the first and second laws of
thermodynamics to conduct exergy analysis on a
reciprocating air compressor, aiming to understand in-
cylinder properties at various crank angles. The paper
presents a simple global model to investigate the influence of
engine speed on the thermodynamic properties of a
reciprocating compressor. The model considers factors such
as volumetric effectiveness, specific work, and indicated
efficiency for different operating pressure ratios. The
significance of wall heat transfers and the negative impact of
the clearance volume are addressed in the mode. The authors
employ the first and second laws of thermodynamics for
energy and exergy analyses, respectively. The equations
derived include the gas equation of state, heat transfer
equation, mass flow rate equation, and piston movement
equation. The numerical solution is obtained using the
Runge-Kutta method. Farzaneh-Gord et al. [8] presented a
thermodynamic model to analyze reciprocating compressors.
In this study, they used AGA8 equation of state for computing
the thermodynamic properties of natural gas based on real gas
model. The continuity and first law of thermodynamics has
been used to present a mathematical model.Castaing et al. [9]
presented a comprehensive study on the dynamic simulation
of reciprocating refrigeration compressors, focusing on
efficiency calculations and experimental validation. They
discuss two main approaches to modeling reciprocating
compressors. One approach involves solving three-
dimensional fluid dynamic equations, he alternative
approach, followed by the authors, employs a set of ordinary
differential equations (ODEs) to capture the behavior of each
component, simplifying the model for better computational
efficiency. Efficiency definitions, including volumetric,
isentropic, and effective, are crucial for evaluating energy and
mass flows in compressors. The paper introduces two key
parameters, the dead volume ratio and friction factor, as
essential influencers of these efficiencies. The model aims to
calculate these efficiencies dynamically, avoiding the need
for estimation. This approach allows for meaningful
comparisons between compressors and refrigerants. Porkhial
et al. [10] investigates the transient characteristics of
reciprocating compressors in household refrigerators,
emphasizing their impact on energy consumption. They
-2-
highlight the significance of reducing energy consumption in
household appliances, with a particular focus on refrigerators,
which contribute significantly to energy usage. The research
employs the M7 model of a 1/5 hp Nicchi compressor,
commonly found in 12 ft3 refrigerators using refrigerant R12,
as a sample for experimentation. Experimental results are
compared with theoretical predictions, and they develop
governing equations and a simulation program to model the
transient behavior accurately. Pe'rez-Segarra et al. [11]
provide an in-depth analysis of various thermodynamic
efficiencies commonly used to characterize hermetic
reciprocating compressors. The focus is on volumetric
efficiency, isentropic efficiency, and combined mechanical–
electrical efficiency. The authors present a methodology to
break down these efficiencies into their main components,
offering a more profound understanding of the overall
behavior of hermetic compressors.
Filbert et al. [12] presented the increasing significance of
sensor integrity in critical systems, particularly in the oil and
gas industry. The proposed method involves using Genetic
Programming (GP) to generate a regression model for the
RPM sensor in a multistage compressor. The paper compares
this "white box" approach with Multiple Linear Regression
(MLR) and Neural Network Regression (ANN). The GP
algorithm is tested on a smaller sample set, and the results
indicate variations in performance across generations and
little difference between basic and extended function sets. It
discusses various types of faults, such as constant faults, bias
drift faults, and noise faults, and evaluates the effectiveness
of the proposed method using histograms of residuals. The
limitations of requiring user expertise to differentiate between
types of sensor faults are acknowledged.
Targhi et al. [1] presented thermodynamic analysis of a CNG
refueling station, focusing on the reciprocating compressor—
a critical component influencing the refueling process. The
study integrates reservoir tanks, on-board NGV cylinders,
connecting pipes, and reciprocating compressors, offering
insights into the dynamic performance of the entire system.
The research employs a detailed theoretical framework to
model the on-board NGV cylinder, reservoir tanks,
connecting pipes, and the reciprocating compressor. The
methodology ensures consideration of pressure variations in
the reservoir tanks during the filling process, crucial for
accurate compressor modeling.
Xinqian et al. [13] proposes a method that precisely identifies
critical geometric features affecting performance dispersion,
facilitating a synergistic optimization of performance and
cost. Researchers have employed two main strategies to
reduce the sample size required for uncertainty studies in
compressors. The first approach involves improving
sampling algorithms under a given dimensionality, such as
Latin Hypercube Sampling (LHS) and sparse grid sampling.
The second approach focuses on reducing dimensionality
through feature extraction or selection. Feature extraction
P. Tiwari , D. Sah and A. Kumar
methods like Principal Component Analysis (PCA) may be
limited when applied to multiblade rows. Feature selection,
on the other hand, involves selecting critical features based
on expert knowledge or mathematical methods, addressing
the correlation relationship with nonlinear multivariable
coupling effects.
Mohammad Omar Abdullah et al. [14] provided the review
on programmable logic controllers (PLCs) applications with
the help of providing similarities and differences between the
Personal Computer (PC) and PLC, PLC Hardware, PLC
Software, Other programmable devices. This paper discuss
the application of PLC in Water and wastewater management
control, Sun-tracking system, Wind energy, Photovoltaic
applications, Heating, ventilating and air-conditioning
(HVAC) control, Research, training and education,
Manufacturing, Control and monitoring of plants and other
applications.
C. Subramaniyan et al. [15] investigates the impact of
measurement and instrumentation errors on the performance
of a double stage reciprocating air compressor with an
intercooler. the paper addresses the role of intercooling in
enhancing performance. The authors highlight the need for
analyzing uncertainties in instrumentation, as minor errors
can lead to significant deviations in performance evaluation.
The uncertainty analysis is carried out using mathematical
modeling for both first law efficiency and second law
efficiency. Equations for uncertainty in electric power input,
air power output, compressor speed, and volumetric
efficiency are presented. The uncertainty on first and second
law efficiencies is discussed with respect to the pressure ratio.
Farzaneh-Gord et al. [5] also presented numerical
investigation of the effects of natural gas compositions on the
performance of reciprocating compressors used in
compressed natural gas (CNG) stations. The study uses a
numerical model based on the first law of thermodynamics,
mass balance, AGA8 equation of state, and thermodynamic
relationships to predict compressor parameters at various
crank angles and cylinder volumes.
Kagiri, C. et al. [2] the paper provides a comprehensive
overview of the optimization of CNG fueling station
operations, emphasizing the importance of efficient
compressor control strategies in minimizing energy costs.
The presented research addresses a critical aspect of CNG
infrastructure development and contributes valuable insights
to the growing body of literature on sustainable transportation
solutions. The study formulates a mathematical model
considering compressor on/off status, electricity pricing, and
storage constraints. Gas demand data from a CNG fueling
station in Johannesburg is utilized for optimization. The
results demonstrate a significant reduction (59.28%) in the
cost of electricity, validating the effectiveness of the proposed
open-loop optimization strategy.
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The above mentioned research papers does not provide the
comprehensive knowledge about the gas engine driven
multistage compressors along with their various components.
This is the gap area which we tried to fill in this paper. This
research paper aims to provide a comprehensive exploration
of natural gas compressors, with a specific focus on
reciprocating compressors, exemplified by the Burckhardt
compressor powered by a Caterpillar engine 3406. The paper
covers various key aspects related to the compression
process, reciprocating compressors, engine components,
instrumentation, CO2 flooding systems, and variations in
compressor stages.
3rd Stage 1st Stage
2nd Stage
FIG :- 1 MulƟstage ReciprocaƟng Compressor
Difference Between Natural Gas and Electric
Compressors
Natural gas-powered gas compressors and electric gas
compressors are two of the most popular types of gas
compressors on the market today, and both have different
uses and industries where they are most useful. The main
difference comes from the fuel source that powers the gas
compressor. Electric gas compressors are powered by
electricity and must be plugged into an electric outlet to work.
Natural gas compressors are powered by natural gas and can
be hooked up to a natural gas line or a portable natural gas
tank.
Both natural gas compressors and electric gas
compressors have some pros and cons, and the best gas
compressor for your industry or company depends on the type
of work you need it for and other factors. Natural gas
compressors are generally more versatile and portable and
boast higher energy efficiency and lower energy costs.
However, they can also run louder and give off exhaust that
requires proper ventilation.
Industries That Use Natural Gas
Natural gas has many industrial purposes, from providing an
energy source to power machinery to being a main ingredient
in manufacturing products like plastics, fertilizers, anti-
freeze, and fabrics. However, most natural gas is consumed
by a small number of industries, including the following:
 Paper and pulp
 Metals
P. Tiwari , D. Sah and A. Kumar
 Chemicals
 Petroleum refining
 Stone, clay, and glass
 Plastics
 Food processing
Among these industries, natural gas serves many purposes,
including heating, cooling, and cooking, just as in residential
and commercial uses. It’s also used for treating and
incinerating waste matter, preheating metals like steel and
iron, drying and dehumidifying, melting glass and fueling
industrial boilers. Natural gas can also be separated into
various other gases and chemicals for use in manufacturing.
Butane, ethane and propane all come from natural gas and can
be used for various purposes.
In addition, natural gas is used as a gas desiccant system in
which the natural gas serves as a dehumidifying product for
industries that manufacture pharmaceuticals, plastics and
even candy. The natural gas controls the moisture level in the
air and protects the integrity of the products.
Natural gas compression services are important to many
industrial uses, including:
 Gas lift
 Reinjection of gas to maintain pressure
 Gas gathering
 Gas processing operations
 Transmission and distribution systems
 Controlling gas volume for shipment and storage
How Does a Natural Gas Compressor Work?
There are two main types of natural gas compressors used for
industrial purposes — reciprocating and screw compressors.
These two types of natural gas compressors work in different
ways to compress the gas.
1. Reciprocating Compressors
A popular choice across many different industries that use
compressed natural gas, reciprocating compressors use
crankshaft-driven pistons and positive displacement to
compress the gas to the correct pressure. There are three main
stages in the functioning of the most common types of
reciprocating compressors:
Stage 1: In the first stage of gas compression, the natural gas
enters the machine through an inlet and passes through a
scrubber where any liquids fall out and can be drained away.
Then, the crankshaft-driven pistons push and compress the
natural gas, increasing the pressure and temperature of the
gas. The gas is then pushed through an intercooler, which
helps to cool down the gas again. The heating and cooling
processes allow for more condensate to fall out of the gas, so
it goes through another scrubber for the liquids to collect.
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Stage 2: In the next stage, the natural gas is again pushed
along with another piston to increase the pressure further.
This also raises the temperature again, so the gas then goes
through the intercooler to drop the temperature lower. And,
just as in the first stage, the heating and cooling of the gas
causes some more liquids and condensation to fall out in one
last scrubber.
Stage 3: The natural gas goes through one more stage before
the compression process is complete. In this stage, the piston
again pushes the natural gas to compress it even further and
increase the pressure even more. Again, the temperature rises
with the increase in pressure, so the gas is pushed through the
intercooler one last time. Some industries use an additional
scrubber to remove even more condensate, but this is less
common.
2. Screw Compressors
Another type of natural gas compressor is a screw
compressor. These compressors use a pair of helical screws
or rotors, aligned side by side, to spin and compress the gas.
The natural gas enters the inlet with suction and moves
around the threads of the screws, which compresses the gas
as it goes through the machine. The gas is discharged on the
other side of the unit at a higher pressure. Screw compressors
are generally used in industries and businesses that don’t
require as high of gas pressure or as high a volume of gas.
Lubrication System
The lubrication system has two basic functions: to lubricate
the compressor's moving components and to cool the system
by removing heat from the compressor's moving parts.
Although all compressors must have a lubrication system, the
actual design and function of these systems will vary
depending on compressor type.
Positive-Displacement Compressors Lubrication system
Positive-displacement compressors use their lubrication
system to provide additional functions. The lubrication
system must inject sufficient quantities of clean fluid to
provide lubrication for the compressor's internal parts, such
as pistons and lobes, and to provide a positive seal between
moving and stationary parts. The main components of a
positive-displacement compressor's lubrication system
consist of an oil pump, filter, and heat exchanger. The
crankcase of the compressor acts as the oil sump. A lockable
drain cock is installed at the lowest end of the crankcase to
permit removal of any water accumulation that has resulted
from sweating of the crankcase walls. The oil passes through
a strainer into the pump. It then flows through the heat
exchanger, where it is cooled. After the heat exchanger, the
cooled oil flows directly to the moving parts of the
compressor before returning to the crankcase sump. A small
portion is diverted to the oil injector, if one is installed. The
P. Tiwari , D. Sah and A. Kumar

oil that is injected into the cylinder seals the space between CONSIDERATIONS IN SELECTION
the cylinder wall and the piston tings. This prevents
Before choosing a specific type of compressor, consideration
compressed air from leaking past the pistons, and thus
must be given to a number of important factors.
improves the compressor's overall efficiency
1. Discharge pressure required.
Sizes of Natural Gas Compressors
2. Capacity required.
Natural gas compressors are available in a range of sizes to 3. Power supply characteristics.
fit different industrial jobs. Smaller, single-stage compressors
are used for lower volumes and pressures of natural gas and 4. Availability and cost of cooling water.
may be used to gather vapors and fugitive gases. Medium-
5. Space required for compressor.
sized compressors are often found at wellheads and gathering
systems, as well as many other industrial uses. The largest 6. Compressor weight.
natural gas compressors use several stages and are most often
used at compressor stations along a pipeline that transports 7. Type and size of foundation required.
large quantities of natural gas. 8. Type of control required.

MATERIALS AND METHODS: 9. Maintenance costs

Compressor Capacity
Gas Engine-driven reciprocating 3-stage gas compressor
a. 600 S.C.M.H. or 450 KG/h (600*0.75=450)
Compressor package contains b. 1200 S.C.M.H. or 900 KG/h (1200*0.75=900)
c. 2400 S.C.M.H. or 1800 KG/h (2400*0.75=1800)
1. 3-stage Burkhardt gas compressor
Density of gas = 0.75
2. A Caterpillar 3406 Engine.
3. Various instruments for the measurement. Components of Compressor

1. 3 stages of compressor
A. COMPRESSOR COMPONENTS:
2. Blow down vessel (BDV)
3. Gas Inlet Valve
A. COMPRESSOR 4. Strainer
5. Suction Filter
It is a device used to increase the pressure of air or a gas. The
6. Separator
pressure can be used in S.C.M.H. (Standard Cubic Meter per
7. Condensate Bottle
Hour). Compressors change mechanical energy into gas
8. Discharge Filter
energy. This is in accordance with the First Law of
9. Package drain valve
Thermodynamics, which states that energy cannot be created
10. Oil drain valve
or destroyed during a process (such as compression of a gas),
11. Belt guard
although the process may change mechanical energy into gas
12. Compression oil filter
energy. Some of the energy is also converted into non usable
13. Idler Pulley
forms such as heat losses.
14. Drain Pot
Reciprocating compressors are the best known and most 15. Plumber Block
widely used compressors of the positive displacement type. 16. Gear Box
They operate on the same principle as the old, familiar bicycle 17. Diaphragm Valve
pump, that is, by means of a piston in a cylinder. As the piston 18. Volume Bottle
moves forward in the cylinder, it compresses the air or gas 19. Compressor Oil Level Glass
into a smaller space, thus raising its pressure. 20. Priority Panel
21. Flow Indicating Transmitter (FIT)-3
For reciprocating compressors, multi-staging is used

1. To save power.
The components are described below:-
2. To limit gas discharge temperature.
1. 3 Stages of compressor
3. To limit pressure differential.
Multi-stage compressors feature two or more piston
In common with all positive displacement compressors, the cylinders, each of a different diameter. After the first
reciprocating compressor is classified as a "constant-volume compression stage, air passes through a heat exchanger,
variable pressure" machine. For most applications, they are where it is cooled before arriving at the second
the most efficient built today.
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P. Tiwari , D. Sah and A. Kumar

cylinder. Cooling the air reduces the work needed to

compress it during the second or third stages.
In a two-stage compressor, the air passes through two
chambers in total. In the second chamber, it is pressurized to
the required extent. In a three-stage compressor, an additional
cycle of compression and cooling occurs before this.

2. Blow Down Vessel

The blow-down tank is designed to collect compressor 5. Suction Filter
blowdown gas and safety valve vent gas and then flow it back
to the compressor again. After the shut off of the compressor
gas from all the stages comes and store into the B.D.V. and
pressure of all stage become equal.

PRV
BDV

FIG :- 2 Blow Down Vessel (BDV)

FIG :- 4 SucƟon Filter

The suction filter is used to filter out the dust particles

3. Gas Inlet Valve
available in the gas after it passes through the strainer of the
compressor.
Gas Inlet Valve is mounted on the main gas pipeline which is
There are two suction filters employed in the compressor.
located at outside the package. It controls the gas flow too.
Among the two suction Filters, one is an In-Line filter and the
other one is a Stand-by filter.

6. Separator
The separator is used in the package after every stage to
separate condensate from the gas. A separator is used after
the intercooler.

7. Condensate Bottle
A condensate bottle is employed after the separators.
Suction Valve Condensate from all the separators comes into the
Condensate Bottle through the diaphragm valves.

FIG :- 3 SucƟon Valve

4. Strainer
Suction strainer is used to filter the heavy dust particles
present inside the gas after it passes through the suction filter.
FIG :- 5 Condensate BoƩle
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P. Tiwari , D. Sah and A. Kumar

8. Diaphragm Valve
It allows the condensate to enter into the condensate bottle.
11. Oil Drain Valve
Diaphragm valve allows condensate to flow into the
condensate bottle only when the package is not running. But
in actual practice P.L.C is programmed in a special way so it
can automatically open the diaphragm valve in every 6-8
hours so condensate can enter into the condensate bottle.

FIG :- 8 Oil Drain Valve

FIG :- 6 Diaphragm Valve Oil drain valve is provided at the bottom of the compressor to
drain the oil available inside the compressor during
maintenance.
9. Discharge Filter
12. Belt Guard
Discharge Filter filters the gas after the compression process
Belt Guard is provided to avoid the danger caused by the
to remove condensate and oil form it.
slipping of the belt from the grooves provided for the smooth
There are two discharge filters available. Both are In-line
function of the belt.
filters

Volume Bottle

Belt Guard

FIG :- 9 Belt Guard and Volume boƩle

13. Compressor Oil filter

FIG :- 7 Discharge Filter

10. Package Drain Valve
Package Drain Valve is employed to drain the gas available
inside the package. During the maintenance of the
compressor, it is required to drain all the lines completely for
this purpose the drain valve is provided.
-7-
It is used to continuously filter the oil available inside the
compressor for the lubrication of the compressors part. Servo
press 220 is used in the compressor for the lubrication
purpose.
14. Drain Pot
Drain pot is provided to drain out the condensate from the
package. The condensate collected inside the compressors are
drained out of the compressors by using Drain pot.
P. Tiwari , D. Sah and A. Kumar
FIG :- 10 Drain Pot
15. Gear Box
Gear box spins the fan to cool down the gas of cooler.
Lubricating oil used in gear box is MOBIL GEAR 600XP.
Gear box
FIG :- 11 Gear Box
16. Compressor Oil Level Glass
Compressor oil level glasses are provided to check the oil
level present inside the compressor. There are three glasses
available to check the compressor oil level say low level
glass, medium level glass, high level glass.
17. Priority Panel
It is an electronic device used to decide the priority to send
the gas into the dispenser or cascade. Nine actuators are
provided on the priority panel to deliver the gas to various
dispenser or the cascade.
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FIG :- 12 Priority Panel
18. F.I.T
Flow Indicating Transmitter (F.I.T) is provided to measure
the flow of gas at the different sections. There are four F.I.T
used inside the package at the Gas suction (F.I.T-1), Gas
Discharge (F.I.T-2), Engine Suction (F.I.T-3) and Vent
(F.I.T-4) respectively.
FIT (flow indicating Transmitter)
FIG :- 13 Flow IndicaƟng TransmiƩer (FIT)
B. GAS ENGINE COMPONENTS
Engine
An engine is a device that changes the energy from a fuel into
mechanical energy, which in turn generates motion. In the
case of cars, gasoline and diesel are the most common fuels
used by engines, such as the ones that power them.
Alternative fuel types do exist though, including natural gas
and biofuels. Engines that generate macroscopic motion from
heat are commonly referred to as heat engines in
thermodynamics. In this instance, heat is produced as a result
of the engine's fuel burning, which drives the pistons.
P. Tiwari , D. Sah and A. Kumar

Four-Stroke cycle

The motor shaft, an exterior to the cylinder engine

component, is connected to the piston. The piston turns the
crankshaft as it moves. Other components that power the
machine are connected to the crankshaft.

The internal combustion engine diagram is given below

which explains the working and functions of the following
parts:

Two-stroke, diesel, rotary, and generator internal combustion

engines are additional varieties. Two-stroke engines use two
strokes as opposed to four. The fuel burns in diesel engines
due to hot air, not a spark. A rotating component serves as the
engine's piston in rotary engines. Air is continuously drawn
into the front of turbine engines, which are used in jet aircraft.
FIG :- 14 Caterpillar Engine At the rear of the engine, the exhaust exits.
How Engine Work?
Despite their strength, internal combustion engines lose most
A moving component called a piston slides up and down in a of the energy from burning fuel as heat. To prevent the
cylinder in many internal combustion engines. Four to eight engines from overheating, water or air cooling is required.
cylinders are the norm for car engines. A cylinder's top has This is how engine works.
valves that let air and fuel in and allow burned fuel to escape.
ENGINE
A spark plug is also located at the top of the cylinder. The fuel
is lit on fire by the spark plug. Make Caterpillar
The four strokes of the engine's cycle are Model 3306NA,3406TA
Cylinder 6
 Intake, Cylinders and Arrangement 6 cylinder in-line block
 Compression,
Bore 137 mm (5.4 inch)
 Combustion, and
Stroke 165 mm (6.5 inch)
 Exhaust
Displacement 14.6 L (893 in3)
A valve opens during the intake stroke, allowing fresh fuel Firing Order 1-5-3-6-2-4
and air to fill the cylinder. Rotation (flywheel end) Counterclockwise

The piston then advances toward the top of the cylinder Valve Lash (inlet) 0.38 mm (.015 inch)
during the compression stroke. By compressing the fuel and Valve Lash (exhaust) 0.76 mm (.030 inch)
air while keeping both valves closed, the piston produces Compression Ratio 16:25:1
pressure.
Table 1 Engine specificaƟons
When the piston reaches its maximum height, the fuel burns
by a spark from the spark plug. The piston is then forced back
down during the combustion stroke, also known as the power Intake Manifold EGC Turbocharger
stroke, by an explosion of fuel burning. A second valve opens
during the exhaust stroke, causing the piston to rise. After Cooler

It pushes the hot gases from the burned fuel out of the
cylinder.

Intake

Vibration Switch

FIG :- 16 Caterpillar Engine

Components of the Caterpillar Engine

FIG :- 15 4-Stroke Engine Working Cycle
1. Engine Gauge
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P. Tiwari , D. Sah and A. Kumar

2. Engine stator motor Radiator is provided to store the coolant used in the engine
3. Engine main pulley and radiator also cools down the hot coolant coming out of
4. Radiator the engine with the help of the radiator fan.
5. Engine oil Filter Two glasses glass1 and glass2 is provided on the top of the
6. Flywheel radiator to show the level of the coolant inside the radiator.
7. Engine Oil dip stick Demineralized Water with nalcool is used as coolant.
8. Intake Manifold
9. Exhaust Manifold
Flame Detector
10. Coupling
11. Air filter Coolant level Glass
12. Spark Plug
13. Stator motor lubricator
Radiator Cap
14. Engine After cooler
15. Ignition coil
16. Flow Indicating Transmitter (FIT)-3
17. Electronic Gas Carburetor (ECG)
18. Programmable Logical Control (PLC)

Components are described below

1. Engine Gauge

Service M. G.
FIG :- 18 Radiator Cap , Flame detector and Coolant level glass
Press. G. Temp. G.
5. Engine Oil Filter

Oil G. Engine oil filter is used to continuously clean the oil

circulating inside the engine.

Dipstick
FIG :- 17 Engine Gauge

Different gauges are mounted on the engine to measure the Engine oil filter
various parameters written below:-
a. RPM Meter
b. Pressure Gauge
c. Temperature Gauge
d. Oil Pressure Gauge

2. Engine Stator Motor FIG :- 19 Engine Oil Filter and dipsƟck

An air assisted engine stator motor is employed to provide the

starting aid to the engine. Engine starts smoothly with the 6. Flywheel
help of the stator motor.
Lubrication oil used is Shell Rimula R3 Low Flywheel is used to transfer the power coming out of the
engine towards the compressor through coupling or a shaft.
3. Engine main pulley
7. Lubrication System
This is engine main pulley which transmit the power coming
out of the engine to the compressors pulley with the help of Dip Stick is used to check the oil available inside the engine.
the drive belt. Purpose of the lubrication system:
a. To reduce the effect of friction
4. Radiator b. Provide cooling effect to the parts
c. Provide sealing effect
d. Provide cleaning effect

- 10 -
P. Tiwari , D. Sah and A. Kumar

8. Intake manifold
Stator Motor
Intake manifold delivers the air fuel mixture to every
cylinder.

9. Exhaust Manifold
Exhaust manifold exhausts the burned gases out of the
package.

10. Air Filter

This is the most important part of the air intake system. It Stator Motor Air Lubricator
consists of an air filter which cleans the air sucked from the
environment during the suction of suction stroke. Vacuum
indicator provided on the air filter shows the red band if the
filter is choked. FIG :- 22 Stator Motor Air Lubricator

12. After Cooler

AN after cooler is employed to bring down the temperature
of the air compressed by the turbocharger [Fig 12].

13. Ignition Coil

The ignition coil converts the low voltage current coming
from the magneto into the high voltage current and sends it to
the spark plug for the combustion purpose.

Ignition Coil

Air Filter

Exhaust Manifold
FIG :- 20 Air filter

Sparkplug is fitted inside the combustion chamber. It is used

to provide the spark to burn the air fuel mixture present inside
the combustion chamber.

FIG :- 23 IgniƟon Coil and Exhaust Manifold

14. Electronic Gas Carburetor (EGC)

The Electronic Gas Carburetor (EGC) offers an innovative
and state-of-the-art approach to gaseous fuel carburetion for
most gas engines in the range of 10 to 500 horsepower. It
precisely controls the air/fuel ratio using variable pressure
control combined with an advanced and improved mixing
FIG :- 21 Spark plug venturi. The EGC provides built in control for a wide-band
oxygen sensor that is located in the exhaust stream. This
11. Stator motor lubricator
improved control technique and enhanced fuel mixing
Stator motor lubricator lubricates the air which used to drive combine to provide the ultimate combination of reduced
the stator motor. emissions along with
improved engine fuel efficiency.

- 11 -
P. Tiwari , D. Sah and A. Kumar

C. INSTRUMENTATION PT-1201-Compressor lube oil differential pressure

transmitter
Instruments used for measuring different parameters

1. Pressure Transmitter
2. RTD
3. CO2 System
4. Vibration Switch Pressure Transmitter
5. Differential Pressure Transmitter (DPT)
6. Hooter
7. Safety Valve
8. Differential Pressure Switch
9. Gas Detector (GD)
10. Fire Detector (FD)
11. Pressure Regulating Valve (PRV)

The instruments are described below

FIG :- 25 Pressure TransmiƩer
1. Pressure Transmitter
2. RTD
The Resistance Temperature Detector (RTD)
This is known as the resistance thermometer and uses the
resistance of the RTD element with temperature to measure
the temperature. Different types of materials can be used to
make the metal.

FIG :- 26 Resistance Temperature Detector (RTD)

The materials include nickel, platinum, and copper. However,

platinum is the most accurate and therefore the most
expensive.

FIG :- 24 Pressure TransmiƩer(PT) Various RTD employed are written as follows:

TE-1101- Gas suction Temperature

It is used to measure the pressure of gas, oil and air.
TE-1110- 1st stage discharge Temperature
These work very similarly to a pressure transducer, but
TE-1111- 1st stage discharge Temperature after cooler
instead of a voltage reading, pressure transmitters output a
TE-1120- 2nd stage discharge Temperature
current signal across a low-impedance load.
TE-1121- 2nd stage discharge Temperature after cooler
TE-1130- 3rd stage discharge Temperature
Various PT employed are written as follows:
TE-1140- Final gas Temperature
TE-2201- Engine lube oil Temperature
PT-4101-Priority panel pressure transmitter
TE-2401- Engine Coolant Temperature
PT-4102- Priority panel pressure transmitter
TE-2411- Auxiliary jacket water Temperature
PT-4103- Priority panel pressure transmitter
TE-2001- Exhaust gas Temperature
PT-1101- Gas Suction pressure transmitter
PT-1103- B.D.V pressure transmitter
3. CO2 System
PT-1110- 1st stage discharge pressure
Carbon Dioxide CO2 Flooding System: The package shall
PT-1120- 2nd stage discharge pressure
be protected by automatically operated CO2 flooding system
PT-1130- 3rd stage discharge pressure
designed as per NFPA-12 which should have minimum
PT-2201- Engine lube oil pressure transmitter
following features: -
PT-2301- Starting air pressure transmitter

- 12 -
P. Tiwari , D. Sah and A. Kumar

a. CO2 flooding system should be installed for the distinguished hooter etc., shall be provided for CO2
protection of CNG compressor by automatic actuation flooding system.
system. The package should be protected by automatic h. CO2 Cylinders shall be provided outside the package at
operated CO2 flooding system designed as per NFPA-12. a safe place, minimum 4.5 meters away (aerial distance),
b. Gas Detection by installation of hydrocarbon gas where it is not exposed to fire in case of fire in the
detector (IR type) with self-check function and compressor. Facility shall be made to operate the system
transmitter with adjustable alarm levels (0-100% of both manually from remote with the help of a switch/
flammability range) with preset of 10%, 20% and 50%. call point and with help of pull-down lever on cylinders.
Each package should have at least 2 nos. gas detectors. i. Suitable online weight (CO2) loss monitoring/
In case there is separate compartment for Gas engine and indication device to be provided to ascertain the health
compressor, each compartment should have at least 2 of the CO2 flooding system.
nos. GD’s i.e., 4 nos. total Gas Detector for the package. j. All installation shall be compatible for hazardous area
c. Installation of flame detector (UV-IR type) with self- Class 1, Division 1, Group-D for Methane Gas.
check function and transmitter, alarm & shutdown on
detection of flame. Each enclosure should have at least
2 nos. flame detectors. In case there is separate
compartment for Gas engine and compressor, each
Weighing dial
compartment should have atleast 2 nos. FD’s i.e., 4 nos.
total Flame Detector for the package.
d. CO2 flooding system will consist of 2 nos. brand new
CO2 cylinders of 45 Kg capacity. One cylinder will act
as main & other as stand by, which shall have identical
arrangement and connected to the system. The cylinders
should be placed in a shed raised above ground level to
protect from weather and direct sunrays as per Gas
Cylinder Rules, 2016. Cylinders shall be fitted with
automatic actuated Valves, Solenoid valves. No extra
utility as air, inert Gas shall be made available by
OWNER/used by the supplier to operate the system
other than the UPS. Cylinder should be ISI marked as Solenoid Valve
per IS: 7285 and PESO approved.
e. The System shall be designed to operate on 24 V DC
supply. FRLS (Fire resistant low smoke) cables shall be
used for the wiring of the system.

f. Interlock of CO2 Flooding system with compressor as By-bass Cyl.

IN- Line Cyl.
per following sequence: -

i. Compressor shall trip on detection of gas at preset

level.
ii. Compressor shall trip on detection of flame at preset
level and automatic discharge of CO2 gas shall take
place from the main cylinder simultaneously.
iii. Compressor shall not start if the CO2 Flooding System
is faulty, not working, SWITCHED OFF etc. The
compressor shall be able to start only when the CO2
Flooding System is in healthy working condition FIG :- 27 Carbon Dioxide CO2 Flooding System
iv. Maintenance Override Switch shall be provided to
keep the system off during maintenance.
v. Selector switch shall be provided to put Main/Stand 4. Vibration Switch
by Cylinder in line at the turn of a switch as per
requirement. This package consists of 2 vibration switches. One is fitted on
g. Alarm panel for CO2 Flooding System shall be integral the engine’s body and the other is fitted on the compressor’s
with the main compressor panel. Necessary displays as body. If the vibration of the of the compressor or engine
system ON, OFF, FAULT, RESET, Gas/ Flame exceeds the predefine limit then it will provide the signal to
indication, Remote actuation of solenoid valve, the PLC and shut down the compressor after providing the
alarm.

- 13 -
P. Tiwari , D. Sah and A. Kumar

8. Gas Detector
Gas Detector consists of sensors which sense the gas leakage
inside the compressor and sends the signals to the PLC which
Viration Switch shuts off the compressor immediately after providing the
alarm. There are 4 gas detectors are employed inside the
package. 2 GD are employed inside the compressor and the 2
Gas detectors are employed inside the engine to detect the gas
leakage.

FIG :- 28 VibraƟon Switch

Gas Detector

5. Differential Pressure Transmitter

It is fitted in the bottom of the right-hand corner of the

compressor. It shows the pressure of lubricating oil before
and after the oil filter.so we can measure the effectiveness of
the oil pump.

FIG :- 30 Gas Detector

9. Flame Detector
Each package shall be provided with two nos. UV - IR flame
detectors to cover the enclosure effectively as already spelt in
the scope of supply. In case there is separate compartment for
Gas engine and compressor, each compartment should have
at least 2 nos. GD’s and 2 nos. FD’s i.e., 4 nos. total Gas
Detector and 4 nos. Flame Detector for the package. All
material used in the package shall be flame retardant.
If the Flame detector detects the possibility of fire, then it will
send the signal to the PLC which then provide the alarm and
start the co2 system.

FIG :- 29 DifferenƟal Pressure TransmiƩer

6. Hooters
If there will be any usual or unusual situation happens inside
the package then the package will provide the alarm through FIG :- 31 Flame Detector
the hooters. For example, door opening alarm, compressor
automatic cut off alarm etc. 10. Pressure Regulating Valve (PRV)

PRV is employed to provide the required amount of gas to the

7. Safety Valve
compressor. A diaphragm is provided inside the PRV to adjust
Safety Valve is mounted on the separator and sends the gas of the pressure of the gas automatically.
extra high pressure available between the stages into the
volume bottle.

- 14 -
P. Tiwari , D. Sah and A. Kumar
Press. Regulating Valve
Ball Valve
FIG :- 32 Pressure RegulaƟng valve and ball valve
EXPERIMENTAL SETUP:
Experimental procedure This setup comprises a complete
compressor package, which includes compressor
components, engine components, instruments, and a PLC. We
have taken readings of various parameters in every two hours
with the help of the PLC.
A. Boundary Conditions:
boundary conditions" are the defined limits or ranges within
which the compressor and engine are expected to operate.
These conditions are crucial for understanding and analyzing
the performance of the natural gas compressor system. The
specified pressure and temperature values at different stages
and for various components, such as gas suction, discharge,
and engine temperatures, serve as the boundaries or limits for
the experimental setup.
The experimental setup involves measuring the performance
parameters under these defined boundary conditions. The
pressure and temperature variations at each stage provide
insights into the efficiency and effectiveness of the natural gas
compressor. The results and discussion section would likely
present data and findings based on the experimental setup and
how well the compressor operates within the specified
boundaries.
A. Pressure
1st stage inlet Pressure: 16 to 19KG/CM ଶ
1st stage outlet Pressure: 48 to 57 KG/CM ଶ
2nd stage inlet Pressure: 48 to 57 KG/CM ଶ
2nd stage outlet Pressure: 96 to 114 KG/CM ଶ
3rd stage inlet Pressure: 96 to 114 KG/CM ଶ
3rd stage outlet Pressure: 250 KG/CM ଶ
Engine Fuel Pressure: 0.8-1.2
- 15 -
B. Temperature
Gas Suction Temperature: 10.5℃
1st stage Discharge Temperature: 110-140℃
2nd stage Discharge Temperature: 110-140℃
3rd stage Discharge Temperature: 110-140℃
Final stage Discharge Temperature: 40-50℃
Auxiliary jacket water Temperature: 60-70℃
Engine jacket water Temperature: 75-92℃
B. Control Systems:
Control systems implemented to regulate various parameters
during the experiments. This may include information about
automation, monitoring, and feedback mechanisms.
PLCs are used in CNG compressors to control compressor
speed, monitor gas temperature and pressure, and regulate gas
flow via the compressor. This enables precise management of
the compression process, ensuring that natural gas is
compressed to the correct pressure and temperature.
Compressed Natural Gas (CNG) distribution at filling
stations necessitates careful monitoring and control to ensure
the safe and effective supply of fuel to vehicles. PLCs
(Programmable Logic Controllers) are critical components of
CNG dispensing systems, providing the necessary control
and automation to ensure the dispensing process’s precision
and reliability.
PLCs can be configured to monitor and regulate many aspects
of CNG dispense, such as flow rate, pressure, and gas
temperature. They can also be set to control the dispenser
valve, ensuring that each vehicle receives the exact amount
of gas.
PLCs can also be used to integrate safety systems such as gas
detectors and emergency shutdown controls to guarantee that
the dispensing process is safe and in accordance with industry
norms.
Operators may guarantee that the process is efficient,
accurate, and safe for both employees and equipment by
employing PLCs to monitor and regulate CNG dispensing. In
addition, CNG dispensing may be done with confidence
thanks to the option to program the system for automated
shutdown in the case of a fault, reducing the risk of accidents
or equipment failure.
PLCs (Programmable Logic Controllers) have transformed
the way processes are regulated and automated in the CNG
(Compressed Natural Gas) business. PLCs provide:
P. Tiwari , D. Sah and A. Kumar
1. A dependable and efficient method of controlling
equipment and processes in a CNG plant.
2. Increasing production.
3. Decreasing downtime.
4. Maintaining constant product quality.
They have also contributed to increased safety and reduced
the likelihood of accidents by ensuring that important
processes are completed precisely and on time. In addition,
PLC integration with SCADA (Supervisory Control and Data
Acquisition) systems expands its capabilities even further,
allowing for centralized monitoring and control of the entire
facility. Overall, the usage of PLCs in the CNG industry has
been a game changer, enhancing efficiency, lowering costs,
and increasing profitability for CNG plant operators.
C. Safety Protocols:
Safe Handling Guidelines
Careful procedures are necessary for handling compressed
gases. This includes the cylinders containing the compressed
gases, regulators or valves used to control the gas flow, and
the piping used to confine the gases during flow.
Users and installers must know the type of gas contained in
cylinders before installation and use. The cylinder must be
returned to the supplier if its content is not identified, if the
hydrostatic test date is past due, or if it is damaged. An
inventory must be kept of all gas cylinders used and stored in
your shop. The inventory must be kept in the shop’s SDS
binder.
Never modify, tamper with, paint, deface, obstruct, remove,
or repair any part of the cylinder, including the pressure relief
device, the container valve, or the valve protection device.
This can turn a cylinder into a potential rocket or
fragmentation bomb and result in serious injury. Never strike
an electric arc on the cylinder. This can cause an explosion
and fire.
PPE Requirement
Steel-toed, slip-resistant shoes and gloves are required when
transporting cylinders. Eye-protection, face shields, and
protective aprons may be required when working with the
gas, depending on the gas in the cylinder.
Regulators and Caps requirement
Regulators and caps are always required. Never use a cylinder
without attaching the correct pressure regulator.
After attaching the regulator, check the adjusting screw of the
regulator to see that it is released before opening the cylinder.
Never permit the gas to enter the regulator suddenly.
Before using a cylinder, slowly “crack” the valve to clear dust
or dirt. Do not stand in front of the regulator gauge glass when
opening the valve and make sure that the opening is not
pointed toward anyone. Additional precautions must be taken
with toxic or flammable gas cylinders.
- 16 -
If there is a leak between the cylinder and regulator, always
close the valve before attempting to tighten the union nut.
Regulators must be removed from the cylinders when not in
use
and replaced with caps. Never force the regulator or cap when
removing or replacing them. In addition, the cap should only
be
hand tightened.
Handling leaking cylinders
If you discover a leaking cylinder, first evaluate the size of
the leak and hazards of the gas. For minor leaks, immediately
evacuate the room or area. If it is safe to do so, wear the
appropriate PPE to match the hazard, and move the cylinder
to a safe place such as a fume hood. Immediately contact both
Environment Health & Safety and the cylinder vendor to
inform them of the leaking cylinder.
If you find a major and uncontrollable leak, immediately
evacuate the room or area. Call 911 and initiate the
emergency response procedures outlined in your emergency
response/action plan or chemical release procedures.
Storage
Chaining
Compressed gas cylinders must be double chained to a stable
structure, such as a wall. Install one chain one-third from the
bottom of the cylinder and a second chain one-third from the
top of the cylinder. Do not use straps or bench clamps for
securing cylinders. If chains are needed, submit a request to
Facilities Management or contact EH&S for guidance on
having restraints installed.
A maximum of three cylinders may be clustered together.
Secure cylinders of equal sizes together to avoid chaining
problems.
Casings
Whenever feasible, use cylindrical “clam shell” casings or
frame casings to secure cylinders next to workbenches.
Clam shell casings are safer than chains for larger sized
cylinders, and frame casings can be used to secure cylinders
of various sizes. Both types of casings allow cylinders to be
securely bolted to the floor and secured adjacent to the
working area, away from walls and without the need for
chaining.
Storage of cylinders that contain different types of gases
You must store oxygen cylinders at least 20 feet away from
fuel-gas cylinders or combustible materials (especially oil or
grease). If this is not possible, you can separate them by a
noncombustible barrier that is at least five feet high with a
fire resistance rating of least one-half hour. The barrier must
P. Tiwari , D. Sah and A. Kumar

be at least 18 inches above the tallest cylinder. Some shops

have affixed five-foot sheet metal partitions between Press variation in different stages (Bar)
cylinders to meet regulations.

stage 3
Additional Storage Requirements Discharge 230.87

As a general rule, never store cylinders on transportation

stage 2
carts. The only exception to this rule involves the use of Discharge 112.05
welding cylinders (oxygen and fuel cylinders). When used for
portable service or for intermittent use, welding cylinders

Stage 1
may remain on carts. Discharge 52.18
Always store cylinders in upright positions on their base
unless they are designed for use in a horizontal position.
Suction 15.62
If used horizontally, they must be secured horizontally

Transporting Cylinders 0 50 100 150 200 250

Unless cylinders are secured on a special cart, remove the

regulators, close the valves, and replace with the protective
valve caps before moving them. Do not lift the cylinder by
the protective valve caps.
Transport cylinders weighing more than 40 pounds on a cart
and secure them with a chain.
(Suction): Pressure starts at 15.62 Bar.
Stage 1, Stage 2, and Final (Discharge): The pressure
gradually increases significantly at each stage, reaching 52.18
Bar, then 112.05 Bar, and finally 230.87 Bar.
Observations:

Always handle cylinders with care. Cylinders must never be
dragged, pushed, or pulled across the floor. Never drop a
cylinder, or permit cylinders to strike each other violently
when moving. Load cylinders to allow as little movement as
possible and secure them to prevent violent contact or
upsetting.
Disposal
When cylinders are empty or no longer needed, you must
dispose of them. Empty cylinders must be marked “Empty”
and stored apart from other cylinders. Whenever possible,
return empty cylinders to the supplier. If the supplier is
unknown, dispose of the cylinder as hazardous chemical
waste through EH&S.
Never discard pressurized cylinders in the trash.
RESULT AND DISCUSSION
Incremental Pressure: There's a noticeable and consistent
increase in pressure from one stage to another, especially
during the transition from Stage 1 to Stage Final. This could
indicate a process where pressure is being actively built up or
contained.
Significant Pressure Spike: The most substantial rise in
pressure occurs between Stage 2 Discharge and the Final
Stage, suggesting a concentrated effort to achieve a much
higher-pressure level, possibly for a specific purpose or
requirement.
Potential Process or System: The activity changing from
"suction" in Stage 1 to "dispatch" in subsequent stages
indicates a shift in the process or function being performed.
The rising pressure could be integral to this process, perhaps
indicating a pressurization or compression step.
Completion or Endpoint: The final pressure reading at
230.87 Bar in the Stage Final suggests the culmination of this
process, potentially achieving the desired pressure level for
completing the task.

Pressure variation in different stages (Bar) Temperature variation in different stages ( oC)

Stage 1 stage 2 stage 3 Suction Discharge Discharge Discharge Discharge

suction Discharge Discharge Discharge Stage 1 Stage1 stage 2 stage 3 Final

Stage
15.62 52.18 112.05 230.87
36.9 133.7 120.5 92.3 42.80

- 17 -
P. Tiwari , D. Sah and A. Kumar
Temp. variation in Diff. stages (Degree C)
Discharge
Final Stage 42.8
Discharge
stage 3 92.3
Discharge
stage 2 120.5
Discharge
Stage 2 133.7
Suction
Stage 1 36.9
0 50 100
(Suction) Temperature: The temperature starts at 36.9
degrees Celsius.
Stage 1, Stage 2, and Stage Final (Discharge): The
temperature fluctuates across these dispatch stages,
measuring 133.7, 120.5, and finally 92.3 degrees Celsius,
respectively. To lower down the temperature we employed
aftercoolers after every stage of compression so that we can
increase the pressure of the gas till the desired level without
increasing its temperature.
Observations:
Initial Temperature: The starting temperature at Stage 1
during the suction phase is notably lower compared to the
temperatures observed during the dispatch stages.
Temperature Variations: There's a fluctuation in
temperatures across the dispatch stages. The temperature
initially rises from Suction to Stage 1 (133.7 degrees Celsius),
then decreases at Stage 2 (120.5 degrees Celsius) before
dropping further to 92.3 degrees Celsius at the Final Stage.
Potential Heat Exchange or Transformation: The increase
and subsequent decrease in temperature suggest a
transformation or exchange of heat energy during these
dispatch stages. The gas gains the heat during the
compression process and looses the heat during the cooling
process. The reduction from Stage 1 to Stage Final might
indicate a cooling process or heat dissipation which is done
by the aftercooler.
Operational Changes: The change in temperature alongside
the transition from "suction" to "dispatch" could signify
different operational phases, each with its own temperature
requirements or thermal changes.
Engine RPM: There's minimal variation in the engine RPM
readings across the time intervals, staying within a narrow
range around 1375-1378. This consistency indicates stable
engine performance during the observed time frames. If there
is high variation available in the engine RPM and engine is
producing noise or we can say that engine is hunting then it
can be caused by the faulty spark plug in this situation we
should check the spark plugs one by one to know the reason
for the engine hunting.
Lube Oil Pressure: The lube oil pressure readings display
slight fluctuations, but they generally remain within a
relatively close range (4.28-4.34 Kg/cm³). These variations
are typical and might not signify any immediate concerns
regarding lubrication system performance.
Lube Oil Temperature: The lube oil temperature shows a
progressive increase over time, starting at 58.3°C and
reaching 66.3°C. While this temperature rise is observable, it
falls within a moderate range and doesn’t surpass critical
levels. However, continued monitoring is advisable to ensure
the temperature remains within optimal operating limits.
Auxiliary jacket water temperature: The auxiliary jacket
water temperature consistently rises from 37.2°C to 47.1°C
over the observed time periods. This gradual increase could
150
be attributed to the engine's continuous operation or
environmental factors affecting the cooling system. It's within
a reasonable range but warrants attention to prevent
overheating issues.
Engine Jacket Water Temperature: Similar to the auxiliary
jacket water temperature, the engine jacket water temperature
displays a gradual rise from 87°C to 90.2°C. This increase
indicates the engine's normal thermal behavior during
operation. However, close monitoring is essential to ensure it
remains within safe operational limits. Monitoring the Engine
jacket water temperature is essential for ensuring optimal
performance, prevention of overheating of engine, assessing
the cooling system efficiency, ensuring optimal combustion
conditions, increase engine’s longevity, safety of personnel
and equipments etc.
Engine gas flowmeter reading fit-3 (kg/hr)
191660
191640
191620
191600
191580
191560
191540
191520
191500
191480
191460
6:00- 8:00 8:00- 10:00 10:00- 12:00 12:00- 14:00
These readings from the Engine Gas Flowmeter (FIT-3) can
be used to find out the Engine consumption per hour by
evaluating the engine gas consumption and the engine total
running hours. If the engine consumption is too high or too
- 18 -
P. Tiwari , D. Sah and A. Kumar

low then we should find out the reason of the cause and take
the needful steps.

Engine Parameters

100

90.2
90 87.7 88
87

80

70
66.3

61.7 61.7
60 58.3
y- Axis

50 47.1
44.3
42.1

40 37.2

30

20

10
4.32 4.29 4.34 4.28

0
6:00- 8:00 8:00- 10:00 10:00- 12:00 12:00- 14:00
X -Axis(Time slots in 24 hrs Format)

Lube oil press (Kg/cm3)

Lube oil Temp (C)
Auxiliary Jacket Water Temp (C)
Engine Jacket Water Temp (C)
Linear (Lube oil press (Kg/cm3) )
Linear (Lube oil Temp (C) )
Linear (Auxiliary Jacket Water Temp (C))
Linear (Engine Jacket Water Temp (C))

- 19 -
P. Tiwari , D. Sah and A. Kumar

Differnce in pressure and temperature in different stage in different stages

250
6:00- 8:00 8:00- 10:00 10:00- 12:00 12:00- 14:00
(24 hrs)

200

150

100

50

0
1st Stage 1st Stage 2nd Stage 3rd Stage 1st Stage 1st Stage 2nd Stage 3rd Stage
Suction press. Discharge press. Discharge press. Discharge press. Suction temp. Discharge temp. Discharge temp. Discharge temp.
(kg / cm2) (kg / cm2) (kg / cm2) (kg / cm2) (Degree C) (Degree C) (Degree C) (Degree C)

First Stage Suction Pressures: The readings fluctuate across
time intervals, varying between approximately 15.35 and
52.18 kg/cm2. There seem to be variations but without a
consistent trend.
Second Stage Suction Pressures: These readings also
display fluctuations but with a wider range compared to the
first stage, varying between approximately 112.05 and 120.24
kg/cm2.
Third Stage Suction Pressures: There's a noticeable
increase in readings across the intervals, starting from around
200.49 and reaching 230.87 kg/cm2. The readings generally
show an upward trend.
Variability Between Stages: The third stage consistently
exhibits the highest pressure readings, followed by the second
stage, while the first stage displays relatively lower readings
overall.
Observation Across Time Intervals: While there are
fluctuations within each stage, there isn't a clear linear trend
observed across the time intervals for each stage. Some stages
show variations, while others have more consistent readings.
Potential Issues: The wide fluctuations in readings across
stages might indicate potential inconsistencies or variations
in the operational conditions or equipment performance.
effectiveness. For instance, fluctuations in discharge
pressures might suggest changes in load or system
demand.
 Temperature variations at different stages highlight the
heat generated during compression, with higher
temperatures observed at later stages.
2. Engine Operation:
 The engine RPM remains relatively stable across the
recorded time frames, indicating consistent operation.
 Consistent levels of engine oil pressure and temperature
within acceptable ranges suggest proper lubrication and
cooling.
3. Gas Flow and Other Parameters:
 Gas flow rates show minimal variance, suggesting a
consistent intake of gas into the system.
 Parameters like exhaust gas temperature, fuel gas
pressure, and various temperatures (jacket water, oil)
within acceptable limits indicate stable engine
performance and efficient combustion.
4. System Reliability and Maintenance:

 The recorded parameters such as oil levels, auxiliary

jacket water temperature, and engine running hours
CONCLUSION:
within normal ranges indicate proper maintenance and
1. Compressor Performance: system health.

 The varying suction and discharge pressures across 5. Potential Areas for Further Investigation:
different stages indicate the compression process's

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P. Tiwari , D. Sah and A. Kumar

 The variations observed in discharge pressures and

temperatures might warrant a closer examination of
individual compressor stages to optimize efficiency or
identify potential issues.
 Monitoring trends in engine parameters over more
extended periods could reveal patterns related to long-
term wear, facilitating predictive maintenance.

In conclusion, while the data reflects overall stable operation

and well-maintained systems, periodic monitoring and deeper
analysis of specific parameters can offer insights for
continuous improvement, efficiency enhancement, and
predictive maintenance strategies in both the compressor and
the engine systems.

Acknowledgment

The authors would like to express their sincere gratitude to

the staff at Centre for Energy and Environment, DTU-Delhi
for their assistance during the data collection phase. This
research was made possible through the collaboration and
support of many individuals, and we are deeply thankful for
their contributions.

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P. Tiwari , D. Sah and A. Kumar

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