development of cng compressor
TRANSCRIPT
Presentation on
Development of CNG Compressor
Model: 3W815to
3rd International Foundry Congress & Exhibition 2010
Presenter
Muhammad Asim
Development Engineer
December 01, 2010
1 Introduction
3 After sales & Service Plan
2 Salient Features
4 Future Targets
IntroductionFor the last 25 years dealing in the imports, refurbishment, sales & supply of Rotary, Screw, and Reciprocating compressors
1998 Started import, supply, services and parts manufacturing for CNG compressors
2002/03 Valuable Experience: refurbishment of 5000Psi Marine compressor (HPAC REAVEL TC 3-1/2 MK7) for Pakistan NAVY
IntroductionFor the last 25 years dealing in the imports, refurbishment, sales & supply of Rotary, Screw, and Reciprocating compressors
1998 Started import, supply, services and parts manufacturing for CNG compressors
2002/03 Valuable Experience: refurbishment of 5000Psi Marine compressor (HPAC REAVEL TC 3-1/2 MK7) for Pakistan NAVY
2004 Started R&D for manufacturing of complete CNG compressor through Reverse Engineering
2005 Finalizing the design in accordance with International applicable codes & standards
IntroductionFor the last 25 years dealing in the imports, refurbishment, sales & supply of Rotary, Screw, and Reciprocating compressors
1998 Started import, supply, services and parts manufacturing for CNG compressors
2002/03 Valuable Experience: refurbishment of 5000Psi Marine compressor (HPAC REAVEL TC 3-1/2 MK7) for Pakistan NAVY
2004 Started R&D for manufacturing of complete CNG compressor through Reverse Engineering
2005 Finalizing the design in accordance with International applicable codes & standards
2006-07 Parts & vendors development and completion of prototype CNG Compressor
IntroductionFor the last 25 years dealing in the imports, refurbishment, sales & supply of Rotary, Screw, and Reciprocating compressors
1998 Started import, supply, services and parts manufacturing for CNG compressors
2002/03 Valuable Experience: refurbishment of 5000Psi Marine compressor (HPAC REAVEL TC 3-1/2 MK7) for Pakistan NAVY
2004 Started R&D for manufacturing of complete CNG compressor through Reverse Engineering
2005 Finalizing the design in accordance with International applicable codes & standards
2006-07 Parts & vendors development and completion of prototype CNG Compressor
2007-08 Test Trials & The 3W815 CNG compressor
2010 After evaluation of 18- months, OGRA’s TEC given approval for manufacturing of CNG Compressor Model:3W815
Engineering & Quality Assurance
1 Standards Followed
2 Design Specifications
3 Materials
4 Consultant & Vendors
5 Local & Imported Parts
6 Quality assurance
Standards Followed
Reciprocating compressors for petroleum, chemical and gas industry services API (American Petroleum Institute) Standard 618, Fourth edition, June 1995
Pakistan CNG Rule 1992
ASME Section VIII, IX and B31.3
TEMA Class R, ASME Section VIII Div. I for heat exchangers designing
Design Specifications
General data
Technical data
Lubrication details
General DataMake & Model Hypercomp, 3W815
Compressor configuration W-120
Compressor design Cross head design, Atmospheric crankcase
No. of cylinders 03
No. of stages 03
Gas inlet pressure (min-max) 08-15 Psig
Gas discharge pressure 3625 Psig
Gas discharge capacity at 15 Psig 270 m3/hr
Gas discharge capacity at 08 Psig 225 m3/hr
Tolerance on discharge capacity ± 5% at 30˚C ambient temperature
Compressor speed 795-900 Rpm
Electric motor size 75Kw (100hp) for 270 m3/hr at 15 Psig
75Kw (100hp) for 225 m3/hr at 08 Psig
Cooling System Water cooled
Direction of rotation Clockwise if viewed from drive end
Ambient temperature range Up to 50˚C
Overall dimensions L = 2135mm, W = 1190mm, H = 1730mm
Overall weight 2.4 ton
Technical Data
Piston stroke 127 mm
Piston speed 3.36m/s @ 795 Rpm
3.81m/s @ 900 Rpm
Cylinder bores
1st stage 206.375 mm
2nd stage 88.9 mm
3rd stage 38.1 mm
Cylinder jacket cooling Water
Inter stage gas cooling Water
Lubrication Details
Crankcase Lubrication Big end bearings are pressure fed. Main bearings, small end bearings and crosshead cylinders are splash lubricated
Cylinder Lubrication (Optional) Through force feed lubricator
Oil capacity (crankcase) 12 liter
Oil capacity (lubricator) 1.5 liter
Recommended oil for Above 60˚F : SAE 30
ambient temperature ranges 32 to 60 ˚F : SAE 20
Below 32˚F : SAE 10W
MaterialsCrankcase Gray cast iron Cast
Crankshaft SG iron Cast
Connecting rods SG iron Cast
Crosshead pistons Gray cast iron, Gr : 17 Cast
Crosshead pins AISI 8620 Forged
Distance piece Gray cast iron, Gr : 17 Cast
Cylinders
1st stage Cast iron alloy Cast
2nd stage ASTM 1045 Forged
3rd stage ASTM 1045 Forged
Cylinder liners
2nd stage Cast iron alloy Cast
3rd stage Cast iron alloy Cast
Compressor cylinder heads
1st stage Cast iron, Gr : 17 Cast
2nd stage ASTM 1045 Forged
3rd stage ASTM 1045 Forged
Parts Description Material Form
MaterialsParts Description Material Form
Pistons
1st stage Aluminium 6082 Extruded
2nd stage Aluminium 7075 Extruded
3rd stage AISI 4140 Bar stock
Piston rods AISI 4140 Bar stock
Piston rods nuts ASTM 1045 Bar stock
Valve seats & guards Carbon steel Plate
Valve plates Stainless steel Plate
Valve springs Stainless steel plate
Packing Cases (Stuffing boxes) ASTM 1045 Forged
Piston rings, rider rings & packing rings PTFE, PEEK Bar stock
Heat exchanger
Shell ASTM 106, Gr : B Extruded
Tubes Stainless steel 316L Extruded
Tube sheet Stainless steel 304L Bar Stock
ConsultantsMaterials Mr. Munir Ahmad (Ex. Deputy Director
General)
PSQCA
Prototype castings Mr. Imtiaz Rastgar (Chairman)
Rastgar Engineering
Mr. Rick Tyma (Manager Technical)
Precision Engineered Parts (USA)
Welding Mr. Reza Ahmad Malik (Chief Executive)
Dynamic Inspection Services Company
Heat Exchanger Design Mr. Abdul Majid (Design Engineer)
Dar-ul-Riaz (Saudi Arabia)
Vendors Rastgar Engineering Prototype Casting of crankcase
Vendors Rastgar Engineering Prototype Casting of crankcase
Excel Engineering Lhr Casting of crankcases, crosshead cylinders and 1st stage head
Vendors Rastgar Engineering Prototype Casting of crankcase
Excel Engineering Lhr Casting of crankcases, crosshead cylinders and 1st stage head
Qadri Brothers Casting of crankshafts, flywheels
Vendors Rastgar Engineering Prototype Casting of crankcase
Excel Engineering Lhr Casting of crankcases, crosshead cylinders and 1st stage head
Qadri Brothers Casting of crankshafts, flywheels
KSB Materials testing & dynamic balancing
Vendors Rastgar Engineering Prototype Casting of crankcase
Excel Engineering Lhr Casting of crankcases, crosshead cylinders and 1st stage head
Qadri Brothers Casting of crankshafts, flywheels
KSB Materials testing & dynamic balancing
PSQCA Selection/testing of materials and critical casting development like Connecting Rods
Vendors Rastgar Engineering Prototype Casting of crankcase
Excel Engineering Lhr Casting of crankcases, crosshead cylinders and 1st stage head
Qadri Brothers Casting of crankshafts, flywheels
KSB Materials testing & dynamic balancing
PSQCA Selection/testing of materials and critical casting development like Connecting Rods
ShahSons Multan For manufacturing of Liners
GM Engineering Lhr For smaller parts casting
Vendors Rastgar Engineering Prototype Casting of crankcase
Excel Engineering Lhr Casting of crankcases, crosshead cylinders and 1st stage head
Qadri Brothers Casting of crankshafts, flywheels
KSB Materials testing & dynamic balancing
PSQCA Selection/testing of materials and critical casting development like Connecting Rods
ShahSons Multan For manufacturing of Liners
GM Engineering Lhr For smaller parts casting
Hercules Engineering Lhr For special coatings and pistons anodizing
Vendors Rastgar Engineering Prototype Casting of crankcase
Excel Engineering Lhr Casting of crankcases, crosshead cylinders and 1st stage head
Qadri Brothers Casting of crankshafts, flywheels
KSB Materials testing & dynamic balancing
PSQCA Selection/testing of materials and critical casting development like Connecting Rods
ShahSons Multan For manufacturing of Liners
GM Engineering Lhr For smaller parts casting
Hercules Engineering Lhr For special coatings and pistons anodizing
PMO Critical CNC machining
Vendors Rastgar Engineering Prototype Casting of crankcase
Excel Engineering Lhr Casting of crankcases, crosshead cylinders and 1st stage head
Qadri Brothers Casting of crankshafts, flywheels
KSB Materials testing & dynamic balancing
PSQCA Selection/testing of materials and critical casting development like Connecting Rods
ShahSons Multan For manufacturing of Liners
GM Engineering Lhr For smaller parts casting
Hercules Engineering Lhr For special coatings and pistons anodizing
PMO Critical CNC machining
Precision Engineered Parts (USA) Manufacturing of piston rings, rods and seals
Vendors Rastgar Engineering Prototype Casting of crankcase
Excel Engineering Lhr Casting of crankcases, crosshead cylinders and 1st stage head
Qadri Brothers Casting of crankshafts, flywheels
KSB Materials testing & dynamic balancing
PSQCA Selection/testing of materials and critical casting development like Connecting Rods
ShahSons Multan For manufacturing of Liners
GM Engineering Lhr For smaller parts casting
Hercules Engineering Lhr For special coatings and pistons anodizing
PMO Critical CNC machining
Precision Engineered Parts (USA) Manufacturing of piston rings, rods and seals
Petrocon Engineering (Pvt) Ltd. Fabrication of heat exchangers, piping and structure
Vendors Rastgar Engineering Prototype Casting of crankcase
Excel Engineering Lhr Casting of crankcases, crosshead cylinders and 1st stage head
Qadri Brothers Casting of crankshafts, flywheels
KSB Materials testing & dynamic balancing
PSQCA Selection/testing of materials and critical casting development like Connecting Rods
ShahSons Multan For manufacturing of Liners
GM Engineering Lhr For smaller parts casting
Hercules Engineering Lhr For special coatings and pistons anodizing
PMO Critical CNC machining
Precision Engineered Parts (USA) Manufacturing of piston rings, rods and seals
Petrocon Engineering (Pvt) Ltd. Fabrication of heat exchangers, piping and structure
Jiacco Pakistan (Pvt) Ltd. Radiography of welded joints
Vendors Rastgar Engineering Prototype Casting of crankcase
Excel Engineering Lhr Casting of crankcases, crosshead cylinders and 1st stage head
Qadri Brothers Casting of crankshafts, flywheels
KSB Materials testing & dynamic balancing
PSQCA Selection/testing of materials and critical casting development like Connecting Rods
ShahSons Multan For manufacturing of Liners
GM Engineering Lhr For smaller parts casting
Hercules Engineering Lhr For special coatings and pistons anodizing
PMO Critical CNC machining
Precision Engineered Parts (USA) Manufacturing of piston rings, rods and seals
Petrocon Engineering (Pvt) Ltd. Fabrication of heat exchangers, piping and structure
Jiacco Pakistan (Pvt) Ltd. Radiography of welded joints
Hamid Traders Special painting
IntroductionFor the last 25 years dealing in the imports, refurbishment, sales & supply of Rotary, Screw, and Reciprocating compressors
1998 Started import, supply, services and parts manufacturing for CNG compressors
2002/03 Valuable Experience: refurbishment of 5000Psi Marine compressor (HPAC REAVEL TC 3-1/2 MK7) for Pakistan NAVY
2004 Started R&D for manufacturing of complete CNG compressor through Reverse Engineering
2005 Finalizing the design in accordance with International applicable codes & standards
2006-07 Parts & vendors development and completion of prototype CNG Compressor
2007-08 The 3W815 CNG compressor & its Test Trials
Associated Manufacturing Activities
Manufacturing steps
Quality Assurance
Associated Manufacturing Activities
Manufacturing steps
Quality Assurance
Calibration
Associated Manufacturing Activities
Manufacturing steps
Quality Assurance
Calibration
Hydrostatic testing
Associated Manufacturing Activities
Manufacturing steps
Quality Assurance
Calibration
Hydrostatic testing
Assembling of Bare shaft compressor
Associated Manufacturing Activities
Manufacturing steps
Quality Assurance
Calibration
Hydrostatic testing
Assembling of Bare shaft compressor
Pump on skid with heat exchangers & other parts
Associated Manufacturing Activities
Manufacturing steps
Quality Assurance
Calibration
Hydrostatic testing
Assembling of Bare shaft compressor
Pump on skid with heat exchangers & other parts
Performance & endurance test before paint
Associated Manufacturing Activities
Manufacturing steps
Quality Assurance
Calibration
Hydrostatic testing
Assembling of Bare shaft compressor
Pump on skid with heat exchangers & other parts
Performance & endurance test before paint
Paint
Assembling after paint
Associated Manufacturing Activities
Manufacturing steps
Quality Assurance
Calibration
Hydrostatic testing
Assembling of Bare shaft compressor
Pump on skid with heat exchangers & other parts
Performance & endurance test before paint
Paint
Assembling after paint
3rd party inspection & performance test
Associated Manufacturing Activities
Manufacturing steps
Quality Assurance
Calibration
Hydrostatic testing
Assembling of Bare shaft compressor
Pump on skid with heat exchangers & other parts
Performance & endurance test before paint
Paint
Assembling after paint
3rd party inspection & performance test
IntroductionFor the last 25 years dealing in the imports, refurbishment, sales & supply of Rotary, Screw, and Reciprocating compressors
1998 Started import, supply, services and parts manufacturing for CNG compressors
2002/03 Valuable Experience: refurbishment of 5000Psi Marine compressor (HPAC REAVEL TC 3-1/2 MK7) for Pakistan NAVY
2004 Started R&D for manufacturing of complete CNG compressor through Reverse Engineering
2005 Finalizing the design in accordance with International applicable codes & standards
2006-07 Parts & vendors development and completion of prototype CNG Compressor
2007-08 Test Trials & The 3W815 CNG compressor
2010 After evaluation of 18- months, OGRA’s TEC given approval for manufacturing of CNG Compressor Model:3W815
Salient Features Dedicated natural gas
compressor design
W type proven 120˚ degree utilizing gas load balancing
Accessible hence easily maintainable
No special tool is required for any maintenance operation
Minimum maintenance cost due to 03 stages & low RPM
Salient Features High quality safety relief
valves are used
Full flow filtered pressurized lubrication
Low vibration requiring no specific foundations
Specifically designed heat exchangers for high ambient conditions
No additional motor is required for water & oil pumps
After Sales & Service Plan
100% parts availability round the clock
Fully equipped mobile workshop
Experienced technical staff
On site & in house training for operators
Future Targets
To develop & manufacture CNG compressors range from 200m3/hr to 1000m3/hr for local & international market
High pressure Air compressors for Defense forces
40 bar compressors for PET bottling industry
Oxygen, Nitrogen & CO2 compressor for industrial use
Q & A
THANK YOU FOR KIND ATTENTION
HPAC REAVEL TC 3-1/2 MK7 Compressor
Performance Test Witness by Navy Team
Material Testing Reports
Patterns
Parts Drawings
Crank case Cross Head Cylinders 1st Stage Head
Vendor : Excel Eng. Lhr
Material : Gray Cast Iron, Gr:17
Crank caseVendor : Rastgar Engineering
Material : Gray Cast iron
Crankshafts & Flywheels
Vendor : Qadri Brothers Lhr
Material : SG & Gray Cast Iron, Gr:17
Crankshafts & Flywheels
Vendor : KSB pumps Hasanabdal
Process : Dynamic Balancing
Connecting Rods
Vendor : PSQCA, Lhr
Material : SG Iron
Misc. Smaller Parts
Vendor : GM Eng., Lhr
Material : Gray Cast Iron, Gr: 17
Special Coatings & Anodizing
Vendor : Hercules Eng., Lhr
Coating : Teflon, Hard Anodizing
Valves Compression & Rider Rings Piston Rod & Rod Sales
Vendor : Precision Engineered Parts, USA
Parts Machining
Indigenously Developed Parts• Crankcase
• Crankshaft
• Bearing Covers
• Oil Pump Assembly
• Cross Head Cylinders
• Cross Head Pistons
• Seal Carrier Plates
• Stuffing Boxes
• Compression Cylinders
• Liners
• Compression Pistons
• Water Jackets
• Heads
• Fly Wheel
• Pulleys
• Skid
• Heat Exchangers
Imported Parts• Bearings (Main, Big &Small End) USA
• Piston Pins USA
• Piston Rods USA
• Rod Seals USA
• Compression Rings USA
• Compressor Valves USA
• Pressure Safety Valves USA
• Explosion Proof Pressure & Germany
• Temperature Switch Gauges
• Explosion Proof Electric Motor China
• Explosion Proof Terminal Box UK
• Explosion Proof Glands UK
• Forced Feed Lubricator USA
• Low & High Pressure NRV’s Japan & UK
• Oil Filters at Suction & Discharge UK
Quality Assurance In the final process of implementing ISO 9001 standard
to ensure our product quality.
An agreement with 3rd party Burea Veritas has been established
Quality procedures and instructions are made for on line inspection.
Skid Fabrication
Process : Fabrication & Welding Vendor : Petrocon Engineering
Heat Exchangers & Piping Fabrication
Hiring of level 3 inspector
Welding procedure qualification
Hiring of qualified welders
Materials certification
Process : Radiography & DPTVendor : Jiaco Pakistan
100% Radiography & DPT of all Butt & Fillet welded joints (160 No.)
CalibrationEach & every measuring instrument is calibrated from reputable source
Hydrostatic TestingAll compression cylinders are hydrostatically tested at 1.5 times
of design pressure for 24 hours
Hydrostatic TestingAll heat exchanger and welded joints are hydrostatically tested at
1.5 times of design pressure for 24 hours
Assembly of Bare shaft compressor
Pump On Skid With Heat Exchangers & Other Parts
Performance & Endurance Test Before Paint
Paint
Assembling After Paint
Paint Thickness Test
3rd Party Inspection & Performance Test
OGRA’s TEC (Technical Evaluation Committee) Inspection & Performance Test
Engineering Development Board (EDB)’s CEO & EDB Team Visit
Liners
Vendor : Shahsons Eng. Multan
Material : Gray Cast Iron Alloy
Vendors Rastgar Engineering Casting of crankcase
Excel Engineering Lhr Casting of crankcases, crosshead cylinders and 1st stage head
Qadri Brothers Casting of crankshafts, flywheels
KSB Materials testing & dynamic balancing
PSQCA Selection/testing of materials and critical casting development like Connecting Rods
ShahSons Multan For manufacturing of Liners
GM Engineering Lhr For smaller parts casting
Paint
Associated Manufacturing Activities
Manufacturing steps
Quality Assurance
Calibration
Hydrostatic testing
Assembling of Bare shaft compressor
Pump on skid with heat exchangers & other parts
Performance & endurance test before paint
Paint