Method Statement For Urea Plant CO2 Compressor Revamping

CONTRACTOR
COMPANY
GUJARAT STATE FERTILIZERS & CHEMICALS LIMITED
REVAMPING OF UREA-II PLANT
VADODARA, GUJARAT, INDIA
DOCUMENT NO:
Document Tittle Method statement for revamping Urea plant CO2 compressors
ISSUED FOR APPROVAL CODE
 CODE A– NO COMMENTS. PROCEED WITH MANUFACTURE /

FABRICATION / CONSTRUCTION AS PER THE DOCUMENT.
 INFORMATION
 CODE B – PROCEED WITH MANUFACTURE / FABRICATION /
CONSTRUCTION AS PER COMMENTED DOCUMENT. REVISED
 REVIEW/APPROVAL
DOCUMENT REQUIRED FOR REVIEW.
 CODE C – DOCUMENT DOES NOT CONFORM TO BASIC
 CONSTRUCTION
REQUIREMENTS AS MARKED. RESUBMIT FOR REVIEW
 CODE D – DOCUMENT IS RETAINED FOR RECORDS. PROCEED
 AS BUILT
WITH MANUFACTURE /FABRICATION
 CODE E – DOCUMENT IS RETAINED FOR INFORMATION WITH
COMMENTS.
Issued for
00 JPP 17-07-2023
Review & Approval DTK CAT
Rev No. Description Prepared by Reviewed by Approved by Approved Date
METHOD STATEMENT- Urea Plant II CO2 Compressors

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 CONTENTS
1. Introduction................................................................................................................................................ 3
2. Safety......................................................................................................................................................... 4
3. CO2 Compressor Specification.................................................................................................................. 5
4. Compressor Parts...................................................................................................................................... 6
5. Why revamp of Compressors?................................................................................................................. 11
6. OEM-IHI recommendation....................................................................................................................... 11
7. Compressor wise scope of Work:............................................................................................................. 13
8. Execution methodology............................................................................................................................ 14
9. Reports:................................................................................................................................................... 21
10. Annexures................................................................................................................................................ 22

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1. Introduction
M/s. GUJARAT STATE FERTILIZERS & CHEMICALS LIMITED (GSFC) hereinafter

referred to as the “OWNER” has awarded the project “Revamping of Urea-II Plant” to M/s.
Larsen & Toubro Limited on EPC basis for Revamping of Urea Plant-II at its existing
Fertilizer Nagar complex, Vadodara, Gujarat.
M/s. GSFC is having two Urea plants at Vadodara unit producing fertilizer grade pilled Urea
having capacity of 323 and 800 MTPD each. Urea I & II plants were established way back in
year 1967 & 1969 respectively. GSFC is operating these plants for more than 50 years with
regular repair & Maintenance.
To improve the reliability and safety of very old plants along with reducing specific energy
consumption to meet the targeted energy norms stipulated by Government of India, GSFC
intends to revamp Urea-II plant with increased capacity of 1175 MTPD from existing Plant
capacity of 800 MTPD by using some of the equipment / machinery of Urea – I Plant like
use of One CO2 Compressor, Prilling Tower etc.
Total 4 nos CO2 compressors are installed in compressor house for urea-1 & urea-2 plant.
XUK101A & XUK101B are running for urea-2 plant.UK101A & UK101B are running for
Urea-1 plant. For urea-2 both compressors are running & for urea-1 one compressor is
running & 1 compressor is in standby, which can also use as a standby urea-2.
CO2 compressors XU-K101 A/B in Urea-II plant, and CO2 compressor U-K101 A in Urea-I
plant will be revamped, while CO2 Compressor U-K101B in Urea-I plant will not be
revamped.
IHI supplied CO2 compressor 4Units to GSFC Urea-I & II plant in 1965,1968 and 1980.

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2. Safety
A. General Safety Precautions
1. All JSA’s and Task risk assessments should be in approved form & all Work
Permits to be checked and ensured in place before the start of any work.
2. Conduct Toolbox talk before starting of any activity/shift with execution team to
ensure flawless and safe execution.
3. All required tools shall be prepared and brought into place when site conditions
allow.
4. All machine such as welding / grinding / cutting machines, lifting tools and tackles
and any other mechanical & machinery resources shall be checked before use if
any damages are visible.
5. When crane lifting/ Hydra (at new canteen location) is required to execute the
described job, then required documents for the lift shall be available.
B. Permit Issuing Methodology
“No Permit No Work”
1. All Job safety analysis (JSA) and risk assessment will be in approved state
before starting of any activities.
2. Prior to start of work all mandatory safety protocols shall be followed.
3. All hot work/ cold /height work permits, and permissions will be obtained in
advance from relevant authorities of client in accordance with client HSE
system and format.
4. Appropriate methodology statements shall be submitted on obtaining, handling
& closure of all permits by L&T HSE.
5. Single point responsibility shall be established for co-ordination of receipt of
permits from Client.

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3. CO2 Compressor Specification

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4. Compressor Parts
Compressors consist of below major parts.
1. Crank case / Frame

2. Cylinder
3. Distance piece
4. Crank shaft
5. Connecting rod
6. Cross head
7. Piston rod
8. Piston rod packing
9. Piston
10. Piston ring
11. Bearing
12. Suction & discharge valves
1. Crank case / Frame
The first thing you’ll notice in a compressor is its heavy and rugged frame which encloses all
the rotating components such as the crankshaft and crosshead assembly.
The frame is also called a crankcase and it has a square or rectangle shape. Its role is to
offer support to the crankshaft & cross head assembly.
2. Cylinder
The cylinder is a pressure vessel that contains the gas in the compression cycle. they are
one of the most important components of a reciprocating compressor. Double-acting
cylinders compress gas in both directions of piston travel. Most reciprocating compressors
use double-acting cylinders. Choice of cylinder material is determined by operating
pressure.
3. Distance piece
The distance piece provides separation between the compressor cylinder and the
compressor frame. t can either have a single, double or even an extra-long compartment
arrangement. the single design uses a structure where the distance between the diaphragm
and cylinder packing is extended in order to prevent any part of the rod entering the
crankcase and cylinder stuffing box.
4. Crank shaft
The crankshaft rotates around the frame axis and drives the connecting rod, piston rod, and
piston. Crankshafts as reciprocating compressor parts are either connected to the electric
motor directly or indirectly with the use of a belt and pulley system. As the motor shaft
rotates, the crankshaft also performs a rotary motion which gives the piston the ability to
carry out its reciprocating motion inside the cylinder. But first, a rod must be connected to
the crankshaft and rod to enable the piston to perform an upward and downward movement.

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5. Connecting rod
This component connects the crosshead and crankshaft, converting a rotary motion into a
motion that is reciprocating. Manufactured out of forged steel, the connecting rod also has a
drilled hole to allow for the passage of oil.
6. Cross head
A crosshead enables the piston to be inserted in the cylinder bore. The use of a crosshead
enables a compressor to use a narrow piston and it enables longer strokes and higher
efficiency.
7. Piston rod
Threaded through the piston, the piston rod is responsible for transmitting the reciprocating
crosshead into the piston. This component is traditionally manufactured out of alloy steel.
Where it is passed through the cylinder packing, the surface must be polished and
hardened.
8. Piston rod packing
Similar to the piston rod, rod packing is essential to preventing gas leakage as it is passed
through the cylinder and crank closure. Where a cooling pack is needed, stuffing boxes may
be jacketed for liquid coolant. Packing rings sit at the heard of the rod packing assembly.
9. Piston
The piston is often referred to as the heart of the reciprocating compressor. The piston
moves up and down in the cylinder. This movement knows as a reciprocating movement.
The piston sucks and compresses the air during its motion. The piston is located at the end
of the piston rod and acts as the movable barrier in the compressor cylinder. Selection of
material is based on strength, weight, and compatibility with the gas being compressed. The
piston is usually made of a lightweight material such as aluminium or from cast iron or steel
with a hollow centre for weight reduction.
10. Piston ring
During the piston movement within the cylinder, the coolant must not leak through the space
between the piston and the cylinder wall. So, this air compressor component covers with the
piston ring. The piston rings are wounded on the piston and as the piston moves up and
down the cylinder, the piston rings come in contact with the walls of the cylinder. Due to the
amount of friction created during this reciprocating motion, rings have to be replaced
frequently in order to maintain the seamless operation of the compressor. In some cases, a
wear band or rider ring is used as an additional piston ring.

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11. Bearing
Bearings located throughout the compressor frame assure proper radial and axial position-
ing of compressor components. Main bearings are fitted in the frame to properly position the
crankshaft. Crank pin bearings are located between the crankshaft and each connecting
rod. Wrist pin bearings are located between each connecting rod and crosshead pin.
Crosshead bearings are located at the top and bottom of each crosshead. Most of the bear-
ings in reciprocating compressors are hydrodynamic lubricated bearings. Pressurized oil is
supplied to each bearing through oil supply grooves on the bearing surface. The grooves
are sized to ensure adequate oil flow to prevent overheating.
12. Suction & Discharge valve
The essential function of compressor valves is to permit gas flow in the desired direction
and to block all flow in the opposite (undesired) direction. Each operating end of a
compressor cylinder must have two sets of valves. The set of inlets (suction) valves admits
gas into the cylinder. The set of discharge valves is used to evacuate compressed gas from
the cylinder.

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5. Why revamp of Compressors?

A. Compressor Performance
 Total absorbed power consumption of the three compressors running in parallel

shall not be higher than 4,550 kW at normal operation condition.
 Discharge pressure at normal condition is lower than the original design from 200
Kg/cm2 to 165 Kg/cm2.
B. Vibration issue
 Problem of high vibration has been observed mainly urea-2 compressors. GSFC
wants to reduce the vibration issue.
C. Oil carry problem in process gas
 GSFC wants to reduce the oil carry over to products. Oil contamination in C02 gas.
D. Overhauling of compressor /Inspection & replacement of Damaged parts.
6. OEM-IHI recommendation
A. Compressor Performance
 Cylinder Valve Changing cylinder valve to Non-metallic ring plate type a) Reason
In this compressor modification, it is required to reduce the power consumption
without existing cylinder replacement. Therefore, we recommend changing to non-
metallic ring plate valves. In general, poppet valves are easy to repair in the field,
due to their cartridge construction. However, since the effective passage area is
smaller than other type valves, the gas velocity and pressure loss are too high. As
a result, the compressor shaft power also.

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B. Vibration issue.
 Heavier Cross head replacement: Recently, almost cylinder vibration seems to be

lower and more stable than before, with GSFC's foundation modification. However,
there are some parts which the vibration is close to the allowable limited value.
Generally, the cause of compressor vibration is due to unbalanced forces. Therefore,
by changing to a heaver crosshead, IHI will adjust the reciprocating difference weight
between the left and right side and reduce compressor vibration. At the same time,
the crosshead will change to the latest design. it is necessary to change the piston
rod, if replacement crosshead. Therefore, IHI recommend to replace the piston rod
and piston where the crosshead is to be replaced.
 4th stage cylinder support modification: The existing 4th stage cylinder support
has low rigidity. In addition, recent 4th cylinder vertical vibration for XU-K101A/B is
higher than allowable limited value. So, IHI recommend to change to the latest
design.
Existing support

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7. Compressor wise scope of Work:

1) XU-K101 A (2000kW):
 Replacement of 1st~4th stage suction/discharge valve assembly.

 Replacement of 2nd & 4th stage Crosshead
 Replacement if 2nd stage Piston & Piston Rod
 Replacement of 4th stage Piston Rod
 Replacement of 4th stage Cylinder Support
 Pulsation Analysis for the Compressor Unit
 Cleaning and overhauling of the Compressor Unit Parts if deemed necessary.
 Replacement of any other parts or components as pre their perceived condition and
reusability
2) XU-K101 B (2000kW):

 Replacement of 2nd & 4th stage Crosshead
 Replacement if 2nd stage Piston & Piston Rod
 Replacement of 4th stage Piston Rod
 Replacement of 4th stage Cylinder Support
reusability
3) U-K101 A (1600kW):

reusability

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8. Execution methodology
A. Suction & discharge valve replacement:
 Removal of Jack bolt.

 Removal of valve cover Nut
 Removal of existing valve.
 Installation of new valve in reverse sequence of removal
Jack bolt
Valve cover Nut Valve

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B. Cross head assembly replacement:

Plan- A: Removal of cross head from cross head window
 Opening of cross head window/side covers side covers of cross head guides, distance
pieces.
Side cover window
 Opening and removal of cylinder jackets, cooling water pipelines, lube oil lines etc.
Cooling water & lube oil piping lines

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 Measurement of Piston rod run out, piston end clearance and cross head shoe
clearance.
Cross head shoe
Cross head Piston rod
 Opening, dismantling/removal of head end cover.
Head cover

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 Measure the clearance between piston and liner with the help of filler gauge.
 Opening of cross head lock nut, oil scrapper ring from diaphragm and removal of
diaphragm.
Cross head lock nut

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 Dismantling and removal of piston rod packing housings along with end flanges and
guide bushes.
Piston rod packing
 Removal of Piston-Piston Rod assembly from cylinder from head cover side.
Piston rod
Piston

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 Removal of Piston Ring, Rider Ring/Band from piston.
 Removal of cross head from cross head guide for replacement of cross head shoe.
Cross head
Plan -B: Removal of cross head by removal of cylinder & & distance piece.
 All step to be followed of plan A & than below steps to be followed.
 Cylinder assembly to be dismantled by disconnection of volume bottle & base supports.
Cylinder to
Distance piece
disconnection
.
Volume bottle disconnection Foundation anchor nut removal

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 Distance piece to be removed by disconnection with crank case/ Frame.

 Cross head to be removed after removal of distance piece.
Crank case/frame nut to be removed Distance piece
C. Mechanical cleaning & preassembly work:
 Thorough Cleaning of all the parts viz. Cylinder liner, piston-piston rod Assly, piston rings, Rider
Rings/Band, Cylinder Valves, Valve covers, Rod Packings, cross head, Guide Bushes, Support,
Fasteners etc.
 Measurement of piston, Piston rod, piston ring-rider ring, cylinder liner etc
 Replacement of piston ring/rider ring/cross head shoe with minor adjustment for required
clearances.
D. Mechanical cleaning & preassembly work:
 Assembly of cross head, Piston-piston rod in cylinder, piston rod packing with housing, Oil wiper
packing with rings etc.
 Measure clearance between piston and liner with filler gauge.
 Fasten the piston rod in cross head by tightening piston lock nut.
 Measure clearance between piston and liner by filler gauge.
 Assembly of head end cover.
 Boxing up of stage cooling water jacket, covers and cooling water inlet/outlet line, lube oil line
using new gaskets, "O"-Ring, etc.
 Measurement and adjustment if required of piston end clearance, piston rod run out.
 Overhauling & assembly of all suction and discharge cylinder valves with internals.
 Installation of Suction & Discharge Valves

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E. Measurement of various clearance & Dimensions:
 Piston rod run out.

 Piston end clearance
 Cross head shoe clearance
 Levelling (spirit level) readings of cylinder, distance piece and crank case
 Cylinder liner bore.
 Piston ring clearances
 Cross head pin to connecting rod bearing clearance and cross head pin to pin bushing clearance.
Please refer attached inspection format for details.
F. Pre-start trails & recommissioning of the compressor:
 Ensure the free run of machine by cranking/Barring the Compressor. Barring operation of compressor
shall be carried out as and when required.
 To test the joints & other components viz. cylinder valve assembly, cylinder outer head joint etc., after
pressurizing with CO2 Gas. If leak observed, the same shall be attended by you on priority basis.
 Contractor shall carry out all activities for re-commissioning of machine with CO2 Gas, running with
Gas in Unload Condition for Few Hours (i.e., @ 4-6 hours), on full load run & taking into Operation.
9. Reports:
 Preparation and submission of overhauling report indicating all the important activities, observations,
clearances, alignment readings, etc. to be prepared.

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10. Annexures
A. Inspection formats
B. IHI Operation & maintenance manual
C. OEM proposal for revamp
D. GSFC RFP document
E. CASALE datasheet
F. Revamp scope & 2 years spare list
G. Revamp parts list
H. Agreed deviation list.

Method Statement For Urea Plant CO2 Compressor Revamping

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CONTRACTOR

ISSUED FOR APPROVAL CODE

 CODE A– NO COMMENTS. PROCEED WITH MANUFACTURE /

Rev No. Description Prepared by Reviewed by Approved by Approved Date

METHOD STATEMENT- Urea Plant II CO2 Compressors

METHOD STATEMENT- Urea Plant II CO2 Compressors

M/s. GUJARAT STATE FERTILIZERS & CHEMICALS LIMITED (GSFC) hereinafter

METHOD STATEMENT- Urea Plant II CO2 Compressors

A. General Safety Precautions

“No Permit No Work”

METHOD STATEMENT- Urea Plant II CO2 Compressors

3. CO2 Compressor Specification

METHOD STATEMENT- Urea Plant II CO2 Compressors

1. Crank case / Frame

1. Crank case / Frame

METHOD STATEMENT- Urea Plant II CO2 Compressors

8. Piston rod packing

10. Piston ring

METHOD STATEMENT- Urea Plant II CO2 Compressors

12. Suction & Discharge valve

METHOD STATEMENT- Urea Plant II CO2 Compressors

METHOD STATEMENT- Urea Plant II CO2 Compressors

METHOD STATEMENT- Urea Plant II CO2 Compressors

5. Why revamp of Compressors?

 Total absorbed power consumption of the three compressors running in parallel

C. Oil carry problem in process gas

D. Overhauling of compressor /Inspection & replacement of Damaged parts.

METHOD STATEMENT- Urea Plant II CO2 Compressors

 Heavier Cross head replacement: Recently, almost cylinder vibration seems to be

METHOD STATEMENT- Urea Plant II CO2 Compressors

7. Compressor wise scope of Work:

 Replacement of 1st~4th stage suction/discharge valve assembly.

 Replacement of 1st~4th stage suction/discharge valve assembly.

 Replacement of 1st~4th stage suction/discharge valve assembly.

METHOD STATEMENT- Urea Plant II CO2 Compressors

 Removal of Jack bolt.

Valve cover Nut Valve

METHOD STATEMENT- Urea Plant II CO2 Compressors

B. Cross head assembly replacement:

Cooling water & lube oil piping lines

METHOD STATEMENT- Urea Plant II CO2 Compressors

Cross head shoe

Cross head Piston rod

 Opening, dismantling/removal of head end cover.

METHOD STATEMENT- Urea Plant II CO2 Compressors

Cross head lock nut

METHOD STATEMENT- Urea Plant II CO2 Compressors

Piston rod packing

METHOD STATEMENT- Urea Plant II CO2 Compressors

 Removal of Piston Ring, Rider Ring/Band from piston.

 All step to be followed of plan A & than below steps to be followed.

 Cylinder assembly to be dismantled by disconnection of volume bottle & base supports.

METHOD STATEMENT- Urea Plant II CO2 Compressors

 Distance piece to be removed by disconnection with crank case/ Frame.

Crank case/frame nut to be removed Distance piece

C. Mechanical cleaning & preassembly work:

D. Mechanical cleaning & preassembly work:

METHOD STATEMENT- Urea Plant II CO2 Compressors

E. Measurement of various clearance & Dimensions:

 Piston rod run out.

Please refer attached inspection format for details.

F. Pre-start trails & recommissioning of the compressor:

METHOD STATEMENT- Urea Plant II CO2 Compressors