Oil and Gas Development Company Limited (OGDCL)

Training Report on Nandpur Gas Dehydration Plant

Submitted to:
Field Manager
Incharge Maintenance
OIST

Submitted by:
Name

: Sadaqat Ali Sukhera

Institution

: Comsats Institute of Information Technology

Department : Mechanical Engineering

7th, 4th year

Semester

Duration

: 07-07-14 to 07-08-14

Acknowledgement
In the name of ALLAH the most beneficent and the most merciful. It is indeed a matter of great
honor for me to do one month Internship with OGDCL Pakistan.
I would like to thank the Field Manager (FM Nandpur Gas Field) for giving me opportunity to
work at Nandpur Gas Field. I would like to express my heartiest thanks to I/C Maintenance Sir
Faran Arshed (J.E Maintenance), Sir Abdul Rehman (Asst. Engr.) , Sir Ghulam Murtaza,
Sir Shoukat Bhatti, Sir Waqar (J.E Production)

for guiding me and providing me

information about the Dehydration Plant.

I would like to thank Sir Muhammad Afzal ( process) , Sir Shahzad (Admin) for their help
and support .
I express my profound gratitude to OGDCL for providing me this opportunity to learn and get
Industrial experience of Oil and Gas sector at NandPur Gas field.
I express my gratitude to each and every member of NandPur Gas Field who helped me during
this period of Internship and Guided me.

Table of contents

Chapter
1
2
3
4
5

Description
HSE (Health and Safety Environment )
Field Introduction
Nomenclature
Departments at Nandpur Gas field
Maintenance Department
Pumps
o Rotodynamic Pump
o Positive Displacement Pump
Valves
o Flow Control Valve
o Pressure Control Valve
o Emergency Shutdown valve
o Level Control Valve
o Gate Valve
o Ball Valve
Generator
Corrosion protection
Production Department
Central Gathering System
Christmas Tree
Plant production
Total Wells
Environmental Conditions
Wells data
Design Capacity
Gas Composition
Process Department
Dehydration Plant
o Process overview
o Reasons of Dehydration
o Methods of Dehydration
o Absorption by Liquid desiccant
o Advantages
o Disadvantages
o Gas dehydration process
o Glycol Regeneration
o Pump working
Laboratory Analysis
Equipment Specifications
FKPCL
Combined Power Plant

CHAPTER#1
Health Safety and Environment (HSE) at NandPur Gas Field
I have visited many industries during my engineering
life as a student and my experience says that only those Industries prosper which prefer a
persons life who is getting 30K salary over a machine of worth 30 Million.
Life is the most precious thing and your life is very much important for your love ones. So keep
an eye on the disorders to identify the faults and obey the rules to get yourself safe and sound.
Keep all the factors in mind which can create the problems and damages.

Safety First
One should be alert and focus should be at work while on duty. Also one should estimate himself
in respect of working capacity and he should not over exert himself.

Hazards
Mechanical hazards
Chemical hazards

Mechanical Hazards
Use of defective tool e.g. ladder with weak or broken rung, improper use of tools, etc.

Chemical Hazards
As the producing gas is of low BTU, so the chance of fire is negligible. Working fluids like triethylene Glycol and Natural Gas are not too toxic to take some precautions.

Safety Precautions for Material handling

While loading and unloading or lifting the materials one should use proper belts or required
measures.

First Aid
Medical facility is available at the plant but one should know about the basics of the First Aid

CHAPTER#2
Field Introduction
Location:
Nandpur plant located about 22 kilometer from Kabirwala towards Jhang chopper hatta
stop and 07 kilometers from Nandpur Residential Colony.

Regular Production Date

25 December 2005

Manufacturer

PETROCIN Manufacturing LTD.

Plant Capacity

50 MMSCFD/day

Location

Nandpur located about 22 Km from

Kabirwala and 07 Km from Jhang road NP
Colony to SS # 01. At single road.

Nandpur/Punjpir Gas Field is situated in the northern irrigated plain of Pakistan. Its
physical feature consists of ravines and plains. The climate is dry hot in summer and cold
in winter. In summer, maximum temperature goes to 50 C. Rain are very rare.

Nandpur gas field is located near Saria Sidhu across Sidhnai canal about 22km from
Kabirwala, Distt. Khanewal, Province of Punjab. Punjpir is located about 45 km west of
Kabirwala and 28 Km from Nandpur colony. Wells of Nandpur Gas field are spread in 17
sq.miles, while Punjpir is located further north across the River Ravi and Koranga Canal
ofk f Multan Shorekot road.

OGDCL discovered this field in 1980. But due to low BTU value SNGPL refused to
purchase this Gas. After this no well was drilled.

About 50 to 55 mmscfd gas, having BTU 220.6 BTU/SCF is supplied to Fauji Kabirwala
Power Plant (FKPCL) through 16 Dia pipelines. OGDCL planed to drill more wells and
make agreement to supply 55- 60 MMSCFD to FKPCL. Regular supply of from
Nandpur/Pun jpir Gas field started since March 2000 to FKPCL.

CHAPTER#3
Nomenclature of Nandpur Gas Field
Nandpur gas field is comprised of the following skids mounted, modularized major
components.

SDV-100

Emergency shut down valve on inlet gas line after

inlet

V-100

Separator
Absorber (Glycol Contactor Column, with Glitsch

E-300
V-200
FE-200

Structure packing)
Gas Glycol Heat Exchanger.
Sale Gas Scrubber.
Sale Gas Flowing Meter and Flow Control
System.

H-500
T-600
P-400A/B/C/D
E-700
V- 1000
Fl-800A/B
Fl-900

Glycol regeneration with still column,

TEG accumulator
Glycol circulating pumps
Glycol heat exchanger
Flash separator Skimmer
Cartridge filter
Charcoal filter

V-1100

Inst. Gas scrubber

CHAPTER #4
Departments at Nandpur Gas Field

1.
2.
3.
4.
5.

Maintenance Department.
Health safety and Environment (HSE).
Production Department.
Process Department.
Equipments and Instrumentation (E&I).

Chapter #5
Maintenance Department
Pumps

A pump can be defined as a fluid machinery, which converts mechanical energy

into pressure energy or simply shaft power to fluid power.
Rotodynamic pumps (dynamic pumps)
Positive displacement pump

Rotodynamic Pumps
In rotodynamic pumps energy is increased by means of dynamic force imparted to the fluid
increasing the pressure through rotating and stationary parts.

These are of three types

Radial flow
Axial flow
Mixed flow

Positive displacement
A pump utilizing a plunger or cylinder to displace fluids, usually under pressure.

Valves
Flow Control valves
A valve is a device that regulates flow of fluid by opening closing or partially obstructing
passage ways .flow control valves are mostly used.
Types of FCV

Air to Open
In this type of FCV gas is supplied from the bottom of Diaphragm .this Valve is fully
closed before supply.

Air to Close

In this type of FCV gas is supplied from top of diaphragm. This valve is fully open before
supply.

Pressure Control Valve (PCV)

These valve control pressure of a fluid in a pipeline carrying gas.

Emergency Shutdown Valve (ESV)

These valves are preset at a specified pressure and prevent excessive pressure blasts in pipelines.

Level Control Valve (LCV)

These valves control the level of fluid being supplied in a container.

Corrosion Prevention
There are two types of monitoring for corrosion

Internal Corrosion
External Corrosion

Corrosion Inhibitor
For internal monitoring chemical packaging is used and in chemical packaging corrosion
inhibitor is used
Chemical package has a skid which has storage tank and dozing pump in it.
Dozing pump gives stroke and and injects corrosion inhibitor after short intervals .
The interval is 3-4strokes per minute.

ER probe and corrosion coupons.

These are installed at injection place injection points are upstream and downstream

Upstream
From exploration well to Head.

Down stream
From well head to plant distributor or customer.
Corrosion Data Collection Unit (CDCU)
Monitoring is done by Corrosion Data Collection Unit (CDCU)

CHAPTER #6
Production Department

Central Gathering System (CGS)

Gas Produced from all wells of Nandpur, Bahu and Punjpir wells gathers at CGS and through
production headers it is supplied to dehydration Plant and after treatment it is supplied to
FKPCL.
The plant has production capacity of 50 MMCFD /day, The field is producing low BTU
gas.Currently plant is producing 27 MMCFD of gas/day which is purchased by FKPCL and the
FKPCL plant generates 157MW of electricity from combined power cycle of 2 gas turbines and
1 steam turbine .

Dehydration Plant
It consists of a setup that uses Tri ethylene glycol (TEG) to absorb water content from gas
coming through production header. it is a kind of chemical separation.

Separators
It separates moisture from gas mechanically. Separators separate fluids on basis of two forces.
1. Gravity (heavy fluids settle down)
2. Whirling action (heavy particles are collected at walls of separator)

Types of separators
On basis of shape

Horizontal separators.
Vertical separators.
Cyclone separators.

On basis of separating Fluids

Two Phase (for gas and water)

Three Phase (for Oil , Gas and Water)

Christmas Tree
The combination of pipes and flanges is called Christmas tree . this is a point where gas is
extracted tubing and casing is installed within the well .The control valves ,pressuregauges and
chokes assembled at the top of well to control the flow of oil and gas after the wellhas been
drilled and the complete setup is called Christmas Tree. Piping is installed until gas reserviour is
found and then concrete base is developed for gas extraction .There are two parts of Christmas
tree flange valve / hanger and pipe work/tubular valve

Pipe Work
In pipe work casing is installed and then tubing is installed, in tubing packers and screen is put
inside well hole .There is annulus gauge that measures leakage of gas or oil from tubing .

Flange Valves
The Upper Part of Christmas is called Flange Valve that consists of two wing valves , master
valve and head/up valve.

Master valve
It is located at the bottom of X-Mas tree above the tubing hanger. It is used to control the flow of
oil and gas from well. During normal production is is kept opened.

Upper Master Valve (operational valve)

Lower Master Valve (Backup Valve)

Wing Valve
It is used to take production from well and for injection purposes e.g Corrosion Inhibitors

Swab Valve
It is located at the top of X-Mas tree and it is used for different work over jobs e.g. wire line or
slick line

Choke
It is used to control the flow rate it is divided in to 64 parts of an inch .
Pressure Gauge
It is used to measure both well head shut in pressure (WHSIP) and well head flowing pressure
(WHFP)

Plant Production :
Daily total Production
Punjpir Field production
Nandpur Field production
Daily Revenue generation
Monthly Revenue generation

30.009MMSCFD.
0.180MMSCFD.
8.388MMSCFD.
Million Rs. Approx.
Million Rs. Approx.

Total Wells:
Total Wells Drilled
Nandpur:

17
09

Punjpir:
Sarai Sidhu:

Single Completion)
07 (All Single Completion)
01 (single completion)

(05Dual

Environmental Conditions:
Maximum Ambient Temp.

50C

Minimum Ambient Temp.

1C

Maximum Wet Bulb Temp.

20.1C (Annual Mean)

27.3C (Monthly Mean)

Mean Max Temp. During summer [July].

40C

Mean Minimum Temp. During winter.

3C

Relative Humidity at 35C

69%

Average Monthly Rainfall.

56mm [January]
90mm [March]
310mm [August]

WELLS DATA

Completion,

03

Well
No.

String

Formation

Status

Ann.
Press.

Avg.

Qg

Cum. Gas

Avg. Qw

BTU
/SCF

Psig

BBLS
MMSCF

MMSCF
NP-1

Short

Samanasuk

Shut in

0.000

1853.600

Long

Shinwari

Shut in

0.000

23243.389

Short

Lumshiwal

Shut in

0.000

7146.462

Long

Samanasuk

Shut in

0.000

7162.345

Short

Lumshiwal

Shut in

0.000

21375.313

Long

Samanasuk

Shut in

0.000

22426.647

Short

Lumshiwal

Shut in

0.000

0.000

Long

Samanasuk

Shut in

0.000

5362.633

Short

Lumshiwal

Shut in

0.000

0.000

Long

Shinwari

Flowing

1935

6.430

70

25262.082

NP-6

Single

Lumshiwal

Shut in

0.000

1156.025

NP-9

Single

Lumshiwal

Flowing

1.881

290

11391.597

NP-10

Single

Samnasuk

Shut in

0.000

4512.662

NP-11

Single

Samnasuk

Flowing

0.104

218

870.091

SS-1

Single

Lumshiwal

Flowing

0.048

386

18592.113

300

Long

Samnasuk

Shut in

505

87.815

PP-1

Single

Samanasuk-X

Flowing

75

0.106

372

14701.861

PP-2

Single

Samanasuk

Shut in

590

0.000

8010.918

PP-3

Single

Samanasuk

Shut in

0.000

8338.640

PP-4

Single

Samanasuk

Shut in

0.000

9827.299

PP-5

Single

Samnsuk X

Shut in

0.074

367

14983.178

NP-2

NP-3

NP-4

NP-5

1795

1760

350

70

PP-6
PP-7

Single
Single

Samnasuk X
Samnasuk X

Shut in
Shut in

Design Capacity:

Inlet Capacity
Operating Pressure
Temperature

50MMSCFD
PSIG
130 F

Gas Composition
Nitrogen
Methane
Carbon dioxide
Ethene

61%
3.6%
2.6%
0.15%

CHAPTER #7

Process Department
Dehydration Plant
Gas that is being extracted from NandPur gas field is having high moisture content and low
BTU. To remove moisture content from gas Dehydration plant is installed .
Dehydration Process take place for the purification of gas water vapors and moisture that remain
in the gas even after passing through separator .Most of water is removed by separator
mechanically , rest is treated by glycol dehydration plant .
If this water vapor and moisture is not removed it will cause damage to turbine blades and If
supplied to domestic lines it will destroy these lines too .
Gas is processed to the dehydration plant to make it free from vapors. Gas is passed through
contact tower from the bottom and glycol is sprayed from top and in this way moisture is
absorbed then it is proceeded to glycol scrubber and the line is protected by PCV (pressure
Control Valve) and FCV (flow control Valve ) and then comes the output point of gas.

Process overview
A liquid desiccant dehydration system utilizes the water absorbing properties of a family of
liquid chemical called glycols. The process of dehydration via TEG (tri ethylene glycol)is
illustrated from fig below.

Dry gas
vapor

Glycol acts like a

sponge to remove water

Glycol

from produced gas.

Wet gas

Glycol is too expensive to be used once and then disposed. Wet glycol must be treated so it can
be reused. This explains the complexity of a liquid desiccant dehydration system.

Lean glycol is pumped into the top of the absorption tower. Bubble caps on each level allow the
gas to pass upward without allowing the glycol to pass through.. The glycol drains down to drive
the pump. The glycol, now a water-rich solution, is dumped from the bottom. After passing
through the wet-glycol filter, the glycol enters a three-phase gas /glycol/condensate separator.
The purpose of this system component is to remove the major portion of gas/condensate trapped
in the glycol before the l,lglycol enters the reboiler. From the gas/glycol/condensate separator,
the wet glycol flows into the reboiler. A burner fires a gas flame into the fire tube in the bottom
of the vessel. A wire mesh protective barrier called a flame arrestor allows air to flow into the

fire tube while confining the flame within the tube. The wet glycol is heated until the water
content boils and turns into steam. Water boils at around 212 F and glycol does not boil until it
reaches 549 F. If the wet glycol is heated to an appropriate temperature, the water separates
from the glycol in the form of vapor while the glycol remains a liquid. The water vapor is vented
upward through a column on the top of the reboiler called the stripper. Inside the stripper, the
rising vapor is stripped of any glycol content with the help of a coil called a reflux condenser.
This process of removing any glycol from the vapor is called fractionation. The vapor, now
almost pure water, is vented out the top.

Reasons for the Gas Dehydration.

Natural gas can combine with liquid or free water to form solid hydrates that can plug
valves, fittings, or even pipelines.

If not separated from the produced water, the natural gas is corrosive, especially when
CO2 and/or H2S are also present.

Water can condense in the pipeline causing slug flow and possible erosion and corrosion.

Water vapor increases the volume and decreases the heating value of the sales gas
contracts and/or pipeline specifications have maximum water content usually 7 lb H2o
per mmscf or dew point.

Sales gas contracts and/or pipeline specifications have maximum water content usually
7 lb per mmscf or dew point

Dehydration allows operation of cryogenic and refrigerated absorption plants without

freeze ups.

Methods of Dehydration
The most common methods of dehydration are:
1. Adsorption by solid desiccant (using Molecular Sieve, Silica Gel, Activated alumina). To
achieve very low water contents.
2. Absorption by liquid desiccant (using glycols).

3. Condensation by refrigeration with Glycol or methanol injection. Used for low flow rates

Absorption by liquid desicant

A liquid desiccant should posses following properties:
1. High affinity for water.
2. Low cost.
3. Non corrosiveness.
4. Stability towards gas components.
5. Stability during regeneration.
6. Ease of regeneration.
7. Low or moderate viscosity.
8. Low vapor pressure at contact temperature
9. Low solubility for natural gases and hydrocarbon liquids
10. Low foaming or emulsifying tendencies.
Tow organic compounds, which fulfill all these requirements to a satisfactory degree, are:

DEG;

HO(C2H4O)2H

TEG

HO(C2H4O)3H

Advantages.
Glycol absorption has the following advantages over solid desiccant:

1. Lower installed cost (solid desiccant plants cost 50% more at 10 MMSCFD and 33%more at
50 MMSCFD.).
2. Lower pressure drop (5 to 10 PSI vs.10 to50 PSI for solid desiccant units).
3. Glycol dehydration is continuous rather than batch.
4. Glycol makeup is easy.
5. Less heat required per pound of water removed. Thus lowering utility cost.

Disadvantages.
1. Water dew point below (25F requires striping gas and Still column.
2. Glycol is susceptible to contamination.
3. Glycol is corrosive when contaminated or decomposed.

Gas Dehydration Process

From main production header gas is directed to Gas Glycol
Contactor column, V-100. An ESDV-100 is also provided at upstream of PCV-200 to cut off
supply of feed gas to dehydration unit in case of emergency.
Process of gas dehydration using TEG is a simple absorption process involving contact of
incoming natural gas with water lean TEG through a contact section
The wet gas coming from different wells is fully saturated with water vapors undergoes
following two steps

Gas Dehydration.

Glycol regeneration.

In absorber gas enters from bottom and glycol enters from top to make countercurrent contact. At
first wet gas enters at 580 psig into integral separator at bottom of contactor column to separate
free water. The wet gas then flows upward through a demisting pad to separate out entrained
liquids and then flows upward through gas injection bubble cap tray to structured packing to
provide intimate contact between gas and glycol.
The accumulated liquids at bottom of integral separator are drained through LCV-100.
Because of large differences in concentration and strong affinity of TEG towards water, the water
transfers from vapor to liquid. In this counter flow operation, the dehydrated gas passes through
another demister pad at top of tower for removal of entrained glycol. It is then discharged from
top of contactor at almost 60 F and is routed to gas/glycol exchanger E-300 exchanging heat
with warm glycol feed to absorber. This provides cooling of glycol before direct contact with gas
stream on top of packing. The lean glycol at about 570 psig is sprayed at the top of packing
through a liquid distributor and then flows across column to the bottom of tower where it is
discharged to regenerator.
After passing through exchanger dehydrated gas at 60 F flows through sale gas scrubber V-200
to separate any water and entrained glycol. There is demister pad in scrubber for this separation.
Level of glycol in scrubber is controlled by LCV-200 and directed to flash separator V-1000. The
gas leaves scrubber at 550 Psig and passes through FCV-200 to control flow of sale gas. A blow
down valve PCV-201 is provided at down stream of sale gas scrubber for over pressure
protection. The sale gas is then passed to FKPCL through metering station at FKPCL to measure
flow rate, pressure and temperature.

Glycol Regeneration

The water rich glycol is discharged at 600 ~ 700 psig from tower
through drive side of Kimray Glycol powered Energy Exchange pumps P-400A/B/C/D at 50 F
and is routed at 80 psig to flash separator V-1000 where entrained gases are removed. These
gases, if combined with water vapors would cause severe corrosion, secondly to separate off

liquid hydrocarbon from glycol which could cause foaming. From V-1000 it is passed through
cartridge filters to remove pipe scales, rust and glycol degradation products. Next it is passed
through activated charcoal filter FL-900 that acts as an adsorbent for liquid hydrocarbon, treating
chemicals, which may have come through with glycol.
From charcoal filter discharge is sent to still column reflux coil exchanging heat with the hot dry
vapors from the reboiler. The rich TEG leaves the still column reflux coil at 100 F. From still
column rich TEG is passed through E-700 to preheat and then showered at the top of still
column.
Water vapor plus some glycol vapors rise from reboiler to the still column. The glycol vapors are
condensed by the cooler wet glycol. Any glycol vapor above feed point is retained by condensing
the small amount of water reflux in the top column.
The wide difference in the boiling points of water and glycol provides an easy and effective
separation of the two components by fractional distillation, which is accomplished in packed still
column at top of reboiler.
Water rich vapor rises in intimate contact with descending glycol rich liquid. The purpose of still
column is to vent water vapors and to recover glycol vapor generated by heat in reboiler. As long
as still column top temperature is maintained at 212.5 F, glycol losses from still column are
minimal. The reboiler is fire tube heater using LPG in tube side. Reboiler temperature depends
on degree of concentration required for lean glycol. For concentrations up to 98.5%, 385 F is
acceptable and for concentration higher than this, 400 F is required.
Although TEG begins to degrade at 405 F, it does not present a problem as long as air is
excluded from system. For very high purity concentration requirement, stripping gas is injected
into the glycol stream, which reduces partial pressure of water in solution and increases purity of
glycol.
Hot reconcentrated glycol then flows through reboiler H-500 through a down comer pipe into
accumulator via glycol/glycol exchanger E-700. The level of accumulator is kept not less than
50%. Glycol makeup is made to replace continuously lost glycol. The energy exchange pumps P400A/B/C/D takes suction from accumulator discharges back to absorber to complete the cycle.

Working of pump
The Glycol Energy Exchange pump, Pressure Volume or PV-series that
utilize the energy of the wet glycol at absorber pressure as a source of power. It transfers energy
available from the wet glycol at absorber pressure to an equivalent volume of dry glycol at
reboiler pressure. In order to circulate the glycol additional energy is required to overcome
friction losses within the pump and connecting piping. This additional energy is supplied by gas
at absorber pressure. The pump is designed within in maximum working pressure of 1500 psig
with a factor of safety of 10.
The pump contains two basic moving parts
o Piston rod assembly
o Pilot piston.

Equipment Specifications:

1. Glycol /Gas Contactor Column.

Tag # V-100
Design Pressure = 1500 psig
Design temperature = 150 F
Nominal Shell Thickness = 2.0
Corrosion Allowance = 0.125
Fabricated wt. = 19.25 mT
Gas throughput = 50mmscfd @ 850 psig

Packed with GemPak type packing

2. Sale Gas scrubber.

Tag # V-200
Description: 762mm OD * 2286mm
Design Temp. = 150 F
Design Pressure = 1500 psig
Test pressure

= 2250 psig

Nom. shell thickness = 1.5

Corrosion Allowance = 3.2mm
Fabricated weigh

= 2.18mT

3. Glycol Reboiler.
Tag # H-500
Normal heat duty = 625,000 BTU/ hr
Average heat flux = 8500

BTU/ hr

Burner Capacity = 1.2 mmBTU/hr (@ min. 25 psig)

Description = 1117.6mm OD * 6096mm
Shell thickness = .375

Design pressure = ATM

Test pressure

= leak test

Corrosion Allowance = 3.2mm

Fabricated weight

= 3.30 mT

4. Still Column.
OD = 14
Packing

7 ft bed of 1 SS Pall rings

2thick calcium silicate with smooth aluminum jacket insulation

5. Horizontal Accumulator
Size = 24 O.D * 14 S/S
2 internal fuel gas preheat coil

6. Lean/Rich Glycol Heat Exchanger

Tag # E-700
Type: shell and tube

Flow rate (lb/hr)

Inlet pressure (psig)

Lean Glycol, Process side

5960
<50

Rich Glycol ,Service side

6258
<50

Inlet temp. (0F)

Outlet temp. (0F)
Pressure drop(psi)
Heat exchanged (Btu/hr)

400
190
<1
800

132
335
<4.1
200

7. Flash Separator:

Tag # V-1000
Size = 508mm OD * 2286mm
Design Temp. = 300 F
Design Pressure = 120 psig
Test pressure

= 180

Fabricated weight = 1.8mT

Internals:
Inlet Distributor
Skimmer hydrocarbon bucket & weir
Demisting pad

3 thick, T- 304 SS

Oil weir & Vortex breaker

8. Cartridge Filter:
Tag # FL 800A/FL800B
Type : cartridge type unit
Fluid flowing =Rich TEG
Fluid capacity = 690 GPH

Closure type = lid lifting ring

Internals

= filter elements

Quantity

=2

Filter element:
Two, 10 micron filter element

100% stand by

Length = 40, ID = 1.5 , OD = 2.75

Flow direction : outside to inside
Dirt holding capacity = 2400 2800 gm/ element app.

9. Charcoal Filter:
Tag # FL-900
Type

: charcoal type filter utilizing granular activated

carbon media

Closure type = lid lifting david

Fluid flowing : TEG
Fluid capacity :
Internal

: charcoal filter element

Design pressure :
Temp: 140 0F

10.Instrument gas Scrubber:

Tag # V-1100

100GPH

Design pressure = 125 psig

Test pressure = 187.5
Temperature = 250 0F
Fabricated weight = 1.2mT

11.Glycol Energy Exchange Pump:

Tag # P-400 A/B/C/D

Model: Kimray 45015 PV
Type: Double acting, Piston pump
Capacity = 450 US gph, each
Strokes = 10~28 / min.
Design suction pressure = atmospheric
Design discharge pressure = 1100~850 psig
Design temperature = 240 F
Gas consumption = 2130 ~ 2745 SCFH @ full flow

Laboratory Analysis:

Two types of laboratory Analysis are carried out at NandPur Plant

Laboratory.

Glycol Analysis

Gas analysis

Glycol Analysis
In Glycol Analysis, Specific Gravity, PH & water content of Lean and Rich
Glycol are determined.
Specific gravity of Lean and Rich glycol is determined by Hydrometer
PH of Lean and Rich glycol is determined by PH meter
Water content of Glycol are determined by specific gravity-water content table as shown below.

Specific Gravity

Water content%

Glycol Purity%

1.1273

0.00

100

1.1269

1.00

99

1.1265

2.00

98

1.1261

3.00

97

1.1257

4.00

96

1.1253

5.00

95

Usually lean Glycol should be of light brown color, whereas Rich Glycol should be of
dark brown color. Rich glycol is also filtered in the laboratory on filter paper to check any solid
residue.

Gas Analysis
In Gas Analysis BTU, specific gravity and moisture contents of sale gas are
determined. Gas gravity and BTU are determined by Gas chromatography technique. The
apparatus used is called BTU Analyzer. Moisture content of sale gas is measured by Dew Point
Apparatus.
Moisture content measurement consists of two steps.

Dew point determination by dew point apparatus.

Moisture measurement by Temperature-Pressure Graph.

CHAPTER#8
FKPCL (Fauji KabirWala Power Company)

Background
FKPCL located at Kabirwala is one of the major producer of rtelectric energy in Pakistan. Major
supply of FKPCL goes to WAPDA grid station for further distribution. Around 157 MW is
produced and supplied to WAPDA gathering grid and rest is used in Fauji complex. FKPCL is
designed at combined cycle using natural gas as fuel.
Model W251-B11 NSD one westing house steam turbine model SC28lt is a unique power plant
that operates on two types of gaseous fuels of different heat Content .
i.e SNGPL gas =

940 BTU

Nandpur low BTU gas = 300-320 BTU

History
1997- Construction of project was started by EPC contractor NEPCO of USA.
1999- Construction of plant Completed on 24th July.
1999-Relaibility run was completed.
2000-First commercial dispatch achieved on 9th March

FKPCL Departments
Operations

Shift
Chemical section
Business Administration

Maintenance

Mechanical Section
Electrical Section
I&C Section
Store and Procrutement
Planning Section

IT Section

Administration

General Administration
Civil Engineering
Medical

Interconnection with WAPDA

Electrical output is connected to 132 KV grid station through a 24 km long double circuit
transmission to khanewal distt

OGDCL and SNGPL are the two main natural gas suppliers having different BTU, 300 BTU and
900 BTU are the approximate readings respectively. This low and high BTU supply is mixed at
gathering station because low BTU gas doesnt burn so this needs to be tackled by averaging the
BTU at around 550 which when ignited catches fire and burn. the ratio of high and low BTU is
considered according to the supply of both the suppliers. A ratio range is set around 60:40 to
65:35 high BTU to low BTU gas

In Power plant a widely used combination is a gas turbine operating at Brayton Cycle by burning
natural gas, whose hot exhaust powers a steam turbine operating at rankine cycle. This is

commonly called Combined Cycle gas turbine. The exhaust from gas turbine is at 1000C which
works on water to make it steam and temperature drops to 100C which is nonhazardous and
released to environment.

Low BTU is heated to increase temperature for efficient combustion.

This gas is then transported to scrubbers for removal of moisture. If

moisture is present and not removed it can damage turbine blades.

Then into gas skid to control pressure and flow of gas and designed to
protect natural gas turbine from slugs .

A filter house is installed in which 192 different types of AIR filters are
present in which there are metallic air filters conical and cylindrical air
filters.

This gas is transported then to separators. These separators give it a

swirling effect and the heavy particles of moisture drop down and light
gas goes into turbine inlet.

Evaporation cooler is installed which contains a zigzag pattern. Its

function is to remove water vapors from the gas. When the gas strike the
zigzag pattern the water particles collide with each other and drops down.

When gas enters into turbine this moves into fuel nozzles which gives
swirling effect to mix LOW and HIGH BTU gases for burning.

High BTU

A water storage tank is installed in which water is stored, this water is pumped from the ground.
A damming plant is installed to remove the minerals from water because minerals can damage
the system and can cause corrosion. This demineralization plant contain different chemicals for
example sulphuric acid which remove minerals.

Steam Turbines
A steam turbine is a device that extracts thermal energy from pressurized steam and uses it to do
mechanical work on a rotating output shaft. The turbine generates rotary motion, it is particularly
suited to be used to drive an electrical generator.

Gas Turbine
A gas turbine also called a combustion turbine, is a type of internal combustion engine. Energy is
added to the gas stream in the combustor where the fuel is mixed with air and ignited in the high

pressure environment of the combustor. Energy can be extracted in the form of shaft power
which is used to power the generators.

Power Station
A power station is an industrial facility for the generation of electric power. At the center of
nearly all power stations is a generator, a rotating machine that converts mechanical power into
electrical power by creating relative motion between a magnetic field and a conductor.

Mechanism
In Power plant a widely used combination is a gas turbine operating at Brayton Cycle by
burning natural gas, whose hot exhaust powers a steam turbine operating at rankine cycle. This is
commonly called Combined Cycle gas turbine. The exhaust from gas turbine is at 1000C which
works on water to make it steam and temperature drops to 100C which is nonhazardous and
released to environment.

Combined Cycle
In electric power generation a combined cycle is an assembly of heat engines that work off the
same source of heat, converging it into mechanical energy.

Principle
The principle is that the exhaust of one heat engine is used as the heat source for another thus
extracting more useful energy from the heat, increasing the systems overall efficiency.

How does A combined-cycle power plant works

Air inlet

The air is drawn through the large air inlet section where it is cleaned, cooled and controlled in
order to reduce noise.

Turbine-Generator
The air then enters the gas turbine where it is compressed, mixed with natural gas and ignited,
which causes it to expand. The pressure created from the expansion spins the turbines the blades
which are attached to the shaft and a generator creating electricity.

Heat exchanger
The hot exhaust gas exist the turbine at about 1100 degrees and enters the heat exchanger. In
heat exchanger there are 18 layers of tall tube bundles, filled with high purity water. The hot
exhaust gas coming from the turbines passes through these tube bundles, which act like a
radiator, boiling the water inside the tubes, and turning that water into steam. The gas then exists
the power plant through the exhaust at a much cooler 180 degrees, after having given up most of
its heat to the steam process.

Steam Turbine
The steam turbine is a Siemens Westinghouse turbine. Steam enters the turbine with temperature
as high as 1000 degree. The pressure of the steam is used to spin turbine blades that attached to a
rotor and a generator producing additional electricity of about 56 MW.
After the steam is spent in the turbine process, the residual steam leaves the turbine at low
pressure and low temperature of about 100 degrees. This exhaust steam passes into a condenser ,
to be turned back into water.

Transmission of Generated onto the Grid

The gas turbine and steam turbine generators produce power at 13,000volts. Transformers take
the generated volts and transform them to 230000 volts which is the required voltage needed for
transmission to the nearby tower that sends power to the substation of WAPDA.

Condenser And Cooling Tower

The purpose of the condenser is to turn low energy steam back into pure water for use in the heat
exchanger.
The purpose of the cooling tower is to cool the circulating water that passes through the
condenser. It consists of ten cells with large fans on the top, inside the cone like stacks, and a
basin of water underneath.

Water Tank
The largest tank is the service water tank. It contains 470,000 gallons of water to be used for
drinking , fire fighting and for the high purity water train. The water from tank is pumped to
water treatment building where it is de-mineralized.

Control Room
From the control room the plant operators monitor and operate the facility through plant
Distributed Control System.
The system gives operators both audible and visual signals to keep them informed of plant
conditions at all times and to determine when maintenance is required.