HCDP

By Mahesh Vora
BASIC PROCESSES OF
REFRIGERATION
 Mechanical Refrigeration
Compression
Absorption
 Expansion
Valve expansion
Turbine expansion
 BASICS STEPS
 Expansion  Compression

 Evaporation  Condensation
Refrigerant Classification
Desirable Characteristics
of Refrigerants
 Thermally stable
 Safe (toxicity and flammability)
 Low cost and widely available
 Compatible with materials of construction
 High performance
 High latent heat
 Low compression superheat
 Low throttling losses
 High heat transfer properties
 Environmentally benign
• ODP (Ozone Depletion Potential)
• GWP (Greenhouse Warming Potential)
Refrigerant Comparison
Refrigerant Pressure-
Capacity Relationship
 Propane as a refrigerant
 Molecular Weight : 44.097
 Boiling Point : -43.67°F ( -42.04°C) @ 1 atm
 Freezing Point : -305.84F (-187.69C) at 1 atm
 Specific Gravity : 1.5223 At 70°F (21.1°C) @ 1 atm, Air = 1
 Vapor Pressure :109.73 psig, (756.56 kPa) at 70°F (21.2°)
 Vapor Density :1.1.77kg/CuM), At 70°F (21.1°C) @ 1 atm
 Compressibility factor Z : 0.9824 @ 15°C @ 1 atm
 Critical pressure : 4249 kPa (abs.)
 Critical temp. : 96.7 °C
 Critical volume : 0.00454 m3/kg
 Sp. heat ratio k : 1.14
 Sp. heat Cp : for ideal gas = 1.6242 @ 15°C @ 1 atm
for liquid = 2.5918 @ 15°C @ 1 atm
 ABOUT HCDP
 HCDP means hydrocarbon dewpoint project, part of the
Cambay Onshore Facility modification project - COFMP.
 The earlier sales gas hcdp was 10 deg C. As per the
provisions of the contract this stands revised at -3 deg C
with effect from August 2004.
 Effectively it means we are competing with LNG
suppliers.
 The total capital cost of the project is 18 MM USD
including the ALHF section.
 M/S Toyo Engg. Ltd, was awarded the lump sum turnkey
contract (LSTK), M/S Technip has done the engineering,
and the refrigeration package has been provided by
Kirloskar Pneumatics. The screw compressors are of
HOWDEN mfg. (UK)
 HCDP
 The entire package consists of the
following units:
• Propane storage
• Refrigeration compressor package.
• Methanol Injection package.
• Corrosion inhibition package.
 REFRIGERATION PACKAGE
 SALIENT FEATURES:
 3 Main compressors, 3 booster compressors with associated
equipments.
 1st gas chiller heat duty: 2.2 MM Kcal/hr
 2nd gas chiller heat duty: 0.55 MM Kcal/hr.
 Economizer u/s of 2nd gas chiller provides sub cooling which
has downsized the booster compressors
 Temperature drop across first gas chiller is from 55 to 35 deg C.
 The process gas from compressors is taken through the tube
side, and goes to the TEG contactor.
 Temp drop in second gas chiller is from -3 to -8 deg C, the
process gas from G/G exch. passes through the tube side and
goes to the LTS. Earlier we were utilizing the JT valve for cooling
the gas to attain dew point.
 REFRIGERATION PACKAGE
EQUIPMENTS
 3 MAIN COMP. { 360 KW-  Economizer and surge drum
FLC 39 amps.}
 3 BOOSTER COMP. { 160
 Propane recovery pumps
KW-FLC 259 amps}  Oil charging cum rectification
 Ref main comp suction KOD vessel
 Booster comp suction KOD  Flare and closed drain
 Air cooled condensers-8 system
fans{4 variable pitch, 4 fixed  Methanol injection package
speed} for hydrate control
 Propane receiver  Corrosion inhibition package
 Thermo siphon vessel  Utilities like PA, IA, service
 Secondary oil separator water
 2 chillers
 PROPANE STORAGE
 The propane storage tank/bullet is of 27.88 cubic meter capacity.
 Liquid propane will be unloaded from tankers using the two vane
type unloading/transfer pumps of 4.6 cubic meter /hr capacity.
 Propane storage area complies with the CCOE regulations.
 ESD for this area is integrated with our FSC philosophy of shutdown
and blow down depending on ESD levels.
 Propane has to be handled carefully. It can give cold burns if it
comes in contact with skin.
 It is heavier than air so tends to settle down. The cloud formed can
propagate and can cause fire by flashback.
 Explosive Limit: 2.1 to 9.5%
 Auto ignition temp: 470 deg C.
 High vapor pressure. 6840 mm Hg @20 deg C.
Screw Compressor
 Screw Compressor
 Design for low pressure :
 suction : vacuum to 100 psig
 discharge : up to 350 psig
 Features:
 Reduced Maintenance
 Turn Down
 High Compression Ratios
 Wide Operating Ranges
 Smaller Package Sizes
 Lower Vibration
 REFRIGERATION PACKAGE
COMPRESSORS
 Compressors are screw compressors, with
provision for oil-propane separation on
compressor discharge side.
 Loading unloading of compressors and hence
the extent of refrigeration is controlled by the
tube side outlet temperatures of gas chillers, and
is done by 4 hydraulically operated solenoid
valves in each compressor
 Compressor controls PLC based, PLC housed in
LER.
 COMPRESSOR OPERATION
CAPACITY CONTROL
 MANUAL MODE:
 Compressor can be started from field station,
and can be loaded/unloaded by push buttons.
One push button for loading one for unloading.
 AUTO MODE:
 The TIT 40009/40004 on tube side outlet of
1st/2nd gas chillers will give output pulse at
regular time intervals. Depending on temp. being
higher or lower than set point, the
loading/unloading will occur.
 COMPRESSOR OPERATION
CAPACITY CONTROL
 There is a hysteresis band which means on either side
of the set point till a certain value is reached no control
action is initiated. For e.g., if set point is -8 degC, and
the hysteresis band is 0.5 degC, than no unloading or
loading will occur till temp is maintained between -7.5
and -8.5 deg c.
 Compressor loads till 100% limit switch ZSH actuates,
and will unloads till 10% limit switch ZSL actuates
whether in manual or auto mode.
 The PT on the suction header will open the PV
40001/40005 when compressors are running at min
capacity and suction pressure is below set point to avoid
tripping of compressors. With increase in suction
pressure this PV will close.
COMPRESSOR LOAD SHARING
 For the compressors to be in load sharing mode,
two trains have to be running and in auto as far as
the temperature control is concerned.
 The compressor which has started first is the
master (lead) comp. while the one starting second
is the slave (lag) comp.
 If the master comp. is say at 100% and the
second one is at 80%, then under load sharing,
the master comp would unload by 10% and come
to 90%, while the slave comp. would load up by
10% and come to 90%, thereby achieving equal
loading.
 COMPRESSOR TRIPS/ESD
 Suction pressure low/high
 Discharge pressure high/low
 Discharge temp high
 Lube oil outlet temp high, diff pr low
 Ref comp suction KOD high/low level
 Ref receiver high/low level
 ESD from local.
 F & G system ESD initiation
 ESD initiation in process area will trip the
package depending on the ESD levels
 Compressors Start permissive
 Compressor minimum capacity feedback should available.
 Hot gas bypass valve (40010A/B/C, 40005A/B/C) open feedback
should available.
 Oil pump running feedback (from propane receiver to first gas
chiller), 60 sec time to start comp.
otherwise oil pump will stop.
 SDV 40002 open feedback, any lube oil pump start this valve will
open.
 All condenser fans running feedback. Provided bypass switch which
allow to start even if any fans not available.
 Oil temp. of OTS should be above 35 deg C. Oil heater provided with
auto switch in LER UCP.
 All trip/ESD conditions are healthy.

* For any booster compressor to start , above this & the main
compressor running feedback is a permissive to start.
 COMPRESSOR OPERATION
 PRESTART CHECKS:

• No alarms active in UCP.

• Two GTGs are running and on load.
• Suction and discharge valves are lined up.
• Lube oil ckt is lined up.
• All instrumentation is in line.
• Air cooled condensers are switched on.
• Propane levels in all vessels are normal.
 COMPRESSOR OPERATION
 START UP:
• Put the selector switch on local mode from field panel. Start
the main compressor.
• Note down the amps drawn. It should not be more than 39
amps.
• If there is no process gas load, then ensure that the suction
pressure control valve is open to maintain minimum suction
pressure to avoid low suction trip.
• Load the compressor using the push buttons on the panel.
The loading pulse will actuate the loading solenoid (2 nos)
and the sliding piston operates, which increases the gas
flow from inlet to outlet.
• Monitor motor amps while loading.
• Increase the process load gradually so that suction pressure
increases. Once sufficient load is available close suction
pressure control PV.
COMPRESSOR OPERATION
• Continue loading till suction pressure is at it’s
normal value.
• Once the process gas temperatures are attained at
chiller outlets, put the TICs on auto.
• The compressor which starts first is the lead
compressor and the compressor which starts
second is the lag compressor.
 Refrigeration Circuit
 The refrigeration circuit is closed loop cycle.
 One stream of liquid propane refrigerant from Receiver is sent to the 1st
gas chiller via control valve (LCV-40007). The level of liquid refrigerant is
maintained inside 1st gas chiller by (LT-40007), the process gas passes
through the tubes of the 1st gas chiller, where it is cooled by boiling the
refrigerant liquid and vaporized refrigerant come back to the main
compressor SKOD. Then the refrigerant main compressor sucks the gas
from main comp. SKOD. The process gas is cooled from 50 deg C to 29
deg C.
 The other stream of liquid refrigerant from receiver is fed to main comp.
SKOD. The liquid level is maintained in main comp. SKOD by (LT-40008).
The liquid stream from main comp. SKOD is fed to 2nd gas chiller through
Economizer where it get subcooled at tube side by boiling the refrigerant
liquid at shell side and vaporized refrigerant comes back to main comp.
economizer port through economizer surge drum. The level of liquid
propane is maintained shell side by LT-40004.
 Refrigeration Circuit
 The level of liquid refrigerant is maintained inside 2 nd gas chiller by LT-
40002, the process gas passes through the tubes of the 2 nd gas chiller,
where it is cooled by boiling the refrigerant liquid and vaporized
refrigerant comes back to the booster comp. SKOD. Then the refrigerant
booster comp. sucks the gas from booster gas comp. SKOD. The
process gas cooled from 2 to -6 deg C.

 The booster comp. discharge refrigerant is bubbled through the liquid

pool inside the main comp. SKOD, where it gets desuperheated & sucked
by the main comp.

 Within the compressor, refrigerant vapors come in contact with the

circulating synthetic lubrication oil, which aids compression while
lubricating and keeping the discharge temp. of refrigerant low. The
compressed gas/oil mixture discharges from the compressor to the Oil
Tank Separator (OTS).

 In OTS the refrigerant passes through an SS mesh blanket where

entrained oil is removed. The oil is recycled to the comp. through the
Lube oil ckt. Refrigerant is then passes through Secondary oil separator
where oil carryover is limited to 5 ppm.
 Refrigeration Circuit

 Oil build up in the Secondary oil separator is

sent back into the comp. suction. Remaining
entrained oil will settle in the 1st gas chiller & 2nd
gas chiller and is recovered in the oil
rectification ckt.

 The refrigerant passed through secondary oil

separator and enters the air cooled condenser
where it exchanges heat with air and
condenses. The condensed liquid from
condenser goes to receiver via Thermosyphon
vessel. It completes the refrigeration cycle.
Compressor Application Range
Typical Screw Compressor
Performance
 What is Hydrate ?
 A hydrate is a physical combination of
water and other small molecules which
produces a solid that has an ‘ice-like’
appearance but possesses a different
structure than ice. Their formation in gas
and/or condensate handling systems can
plug piping, pipe fittings, equipment and
instruments, restricting or interrupting flow.
Hydrate