Installation and Commissioning of Screw Type Compressor

Career Episode 1

Your Full Name: Mohammad Bahalul AlamYour Date of Birth: 12/06/1981Your Email: Mohammad.bahalul@gmailcomYour Address:Your Phone No:

A. Introduction:

CE 2.1: This career episode is based on the project of installation and commissioning of 1000 CFM screw type air compressor. The project was held on in British American Tobacco Bangladesh Company Limited. The duration of the installation & commissioning of the compressor was from 8th – 26th August, 2010. The Dhaka Factory of BATB is situated in Mohakhali DOHS, Dhaka. My position was Manufacturing Services Engineer in BATB Dhaka Factory.

B. Background:

CE 2.2: Engineering project background:

BATB has gone through a phase of phenomenal growth over the last few years. Long term forecasts show further potential for growth in demand. In order to cater to the market demand, production facilities have been enhanced at regular intervals; however, corresponding infrastructure expansions have not been adequate to support the production facilities. Compressed air is used in the following areas:-

pneumatic machinery parts of both cigarette makers and packers humidifying sprays inside factory lamina and stem cutters in Primary Manufacturing Department Machine cleaning nozzles etc.

In the beginning of 2009, the Dhaka factory was equipped with 6 air compressors with different levels of capacity for each compressor (400, 400, 800, 1000, 1000, 1000 CFM respectively). A summary of these are listed below:

Compressor Identification

CFM Brand Model Asset capitalization Date

Compressor-1 400 MotivAir ERC450MV/A 01/01/1990Compressor-2 400 MotivAir 450PUA 12/01/1994Compressor-3 800 CompAir 6180N08A 12/01/1997Compressor-4 1000 CompAir L160 - 7.5A 31/03/2003Compressor-5 1000 CompAir L160 - 7.5A 31/12/2008Compressor-6 1000 CompAir L160 RS - 7.5A 31/12/2008

The factory requirement was to provide 2800-3000 CFM. Compressor # 1 & # 2 are over 20 years old, obsolete & inefficient. In 2008 compressor #2 was irreparably damaged from a break down. Compressor # 1 was also stopped in order to avoid any accident in the future resulting from a breakdown. Thus the installed capacity of compressor available for factory was reduced to 3800 CFM.

In order to meet the production requirement, 3 compressors run round the clock and fourth one (800 CFM) is on stand-by as back-up at that time. These compressors are maintained as per manufacturer’s recommendations. Based on total number of running hours, maintenance activities can take up to 3 days. If one of the compressors is taken under maintenance and at the same time if there is a breakdown in another,

there will be a shortage of capacity. In addition to the new production lines and other infrastructure expansion (air-conditioning) the requirement for compressed air will increase to approx. 3200 CFM.

Project objectiveThe project objective was to install a new compressor of 1000 CFM with dryer, replacing the two existing old compressors. This replacement would increase the net capacity which would also cater for the increased compressed air requirement on the production floor next 10 years.

CE2.3: My duties and responsibilities in this project

I was assigned by the Project Manager to lead the project. My responsibility was to draw the lay out of the compressor room, then study where it should be feasible to install, then made a costing for the whole project, raise LC for the compressor, assigned the contractors for the particular job, then commissioning of it and finally take over from the local agent. I was the key person who was all in all for the supervision, monitoring and control of the project.

The organizational structure for the particular project was as follows:

C. Personal Engineering Activities:

Technical Services Manager

Project Manager

Manufacturing Services Engineer (My Position)

Electrical Contractor

Mechanical Contractor

Civil Contractor

Head of Supply Chain

Managing Director

CE 2.4: Reason of project initiating:As I say before, Compressor # 1 and #2 are not fit for further operation. Thus the total capacity of the compressor plant became 3800 CFM where the factory requirement was 2800-3000 CFM. Furthermore more machines will be added on the production floor. Then the requirements will become increase against the production capacity. Any breakdown of the compressor at that time will be disaster for the production. Moreover if one compressor goes for maintenance and at that time another one was in breakdown, then production will be hampered. So considering these things, I feel the importance to install a new compressor immediately and convey the same feelings to my higher authority.

CE 2.5: Visiting similar project / review previous similar work: I was in charge of all the utilities of Dhaka Factory, so I knew the condition of the compressors very well. When I took charges of the compressor plant, I observed the oldest two compressors are in idle condition and they were not fit for operation. Among the other four compressors, number 6 was new and belong the latest technology at that time. It was compacted, inverter operated and user friendly. So I decided to install that type of another compressor in the plant. My project manager also agreed with me.

CE 2.6: Project proposal submission, tendering or meeting with higher authority: After review the previous job of compressor # 6, I thought the same model would be advantageous for us. I shared my view with my top team and they suggested preparing a business proposal (Business Case) with rationale, costing, benefits, risk, project time table etc. For a rough costing I got some idea from Trident Agency (local agent of COMPAIR). Then with help of my Project Manager I had prepared the Business Case for purchasing a new compressor which would then be submitted to the CAPEX meeting (A meeting where all the top team members endorse a project). When the CAPEX (capital expenditure) was approved with budget, then I asked Trident Agency to give Proforma Invoice on behalf of CompAir mentioning the following things:

Pos. Description Qty. unitPrice/unit

(Euro)Total

(Euro)1 CompAir L160RS-7.5A

Frequency Inverter Regulated Speed, Air Cooled, oil injected high performance rotary screw compressor, Capacity 9.88 – 27.55 m3/min 7.5 bar g, 160 KW motor, Delcos 3100RS enhanced microprocessor control and monitoring syste.

1

2 CompAir F678C+Refrigerant Air Dryer with zero loss drainStandard capacity 67.8 m3/min

1

3 CompAir CF0600 N4”BPre filter, capacity 60.0 m3/min

1

4 CompAir CF0600 N4”CSub micro filter, capacity 60.0 m3/min

1

5 CompAir V2000Compressed air receiver (2000 liters)

1

6 Bekomet-13, zero loss drain 17 Owamat 8 (Separate oil from drained water) 18 Spares:

Frequency converter 1Electronic Delcos 3100 1

9 Maintenance sparesService kit CK2290-3 (Oil & Air Filter)Separator kit CK4290-272 (Oil Separator)Major kit CK8290-1 (Minimum pressure valve, O-ring etc.)

111

Here one thing is noticeable that my plant belongs to four “COMPAIR” compressors and all were supplied by Trident Agency. They always give us quick maintenance and spare support. Furthermore our

operators are familiar with a same platform of operation. So I decided to take quotations from only “COMPAIR”. When we got the Proforma Invoice, it was approved by the top team according to the delegation of authority and the L/C was raised from our store department.

CE 2.8: Technical Details of the Work:I had divided the whole job in to three main stream; mechanical, electrical and civil. First I draw a layout of the compressor room. Then I took a look of the compressor and dryer specification. This drawing and specification gave me an idea to estimate the required materials and jobs to do. The drawings of the compressor plant in BATB:

The specification of the Compressor with Dryers was as follows:

Compressor UnitManufacturer “COMPAIR”Type L 160 RS-7.5AMotor rating KW 160Motor speed RPM 1500Full load current Amp 334Voltage/phase/frequency V/Ph/Hz 440/3/50Suction pressure Bar 1Delivery pressure Bar g 7.5Volume rate of flow M3/min 27.55Weight Kg 4900PLC DELCOS 3100Country of Origin GermanyDryer

Comp 3 Comp 2 Comp 1 Comp 6 Comp 4 Comp 5

Main Panel

Vacuum pumps

Dryer 1 in the ground floor and dryer 2 on the mezzanine floor

Manufacturer “COMPAIR”Type F678CS+Power KW 9.92Load Amp 19.3Voltage/phase/frequency V/Ph/Hz 440/3/50

By considering the drawing and the rated ampere of the compressor & the dryer I estimated the following electrical equipments. For wire selection I took a wire manufacturer (BRB Cables) guide and choose wires by adding 20% more amperes over the rated current as a safety factor. For example: I choose 4 X 240 sm NYY wire for main power cable from main DB to sub DB where as the wire manufacturer illustrated

4 X 240 means 4 no of wire having the nominal cross sectional area of conductor of 240 mm &sm means the conductor of multiple stranded wires of Sector shaped cross sectionNYY means PVC insulated and PVC sheathed cablesStandard BDS-901 and VDE-0271/3.69Voltage rating: 600/1000 voltsCurrent rating: Under ground at 30 deg C: 385 A

In the air at 35 deg C: 410 A

Sl No Description Specification Units Requirements

1 MCCB at Main DB (Siemens) 400A 12 MCCB at SDB (Siemens) 400A 13 Wire from main DB to SDB-------NYY 240sm X 4 core feet 804 Earth wire from main DB to SDB-------BYA 120rm X 1 core feet 805 MCCB for Dryer 63A 636 Wire for SDB to Inverter – 6 pieces 95rm X 1 core feet 237 Earth Wire for SDB to Inverter – 2pieces 95rm X 1 core feet 238 Wire for water discharge—4 pieces 23/076 X 3 core feet 80

By considering the drawing and the compressor # 6 I estimated the following mechanical equipments.

Sl No Description UnitRequiremen

t

1Installation & supply of 4" Dia Pipe (Made in Korea, 40

schedule)For

Ft 60

2 Installation & supply of 4" collar flange for pipe joint pcs 223 Installation & supply of 4" Bend pcs 164 Installation & supply of 4" Tee joint pcs 25 Installation & supply of 4" ball valve pcs 56 Installation & supply of 5/8 bolt pcs 887 Pipe joint welding pcs 508 Pipe cutting pcs 209 4" Dia Thread Pipe pcs 1010 4"×6" Reducer pcs 1

11 Profile sheet fitting at roof sft 16012 Gasket ( Heat proof) pound 513 16 Gauge MS sheet 32" Dia Duct making Ft 2414 16 Gauge MS sheet 24" Dia Duct making Ft 2616 1.5" Flat Bar for 32" Dia Flange Pair 817 1.5" Flat Bar for 24" Dia Flange Pair 918 Compressor & dryer exhaust duct top shed pcs 219 Pre/After Filter Fitting pcs 220 Painting all pipe & accessories L/s 1

According to the American Petroleum Institute (API), where pipes are categorized in schedule number, I choose Schedule 40 pipes (sometimes called ‘standard weight’) which are the lightest that would be specified for low compressed air application. The 100 mm Schedule 40 pipe has an outside diameter of 114.30 mm, a wall thickness of 6.02 mm, giving a bore of 102.26 mm.

Calculation of pressure loss in pipe

Normally the major cause of pressure loss in the straight pipe is friction. This is illustrated by the D’Arcy equation:

Where:L = Length of pipe (m)u = Flow velocity (m/s)g = Gravitational constant (9.81 m/s²)d = Pipe inside diameter (m)hf = Head loss to friction (m)f = Friction factor (dimensionless)

Before the calculation of pipe losses, at first the friction factor must be calculated. The friction factor will be dependant on the pipe size, inner roughness of the pipe, flow velocity and fluid viscosity.

A pipe of 4” (100 mm) diameter is carrying air (compressible fluid) flow of 27.55 m3 / min through a distance of 27 meters. So the velocity in pipe is

fLu²2gd

hf

According to the Reynolds number equation

Where:Re= Reynolds number = Density (kg/m3) = for air at 30º C, the value is 1.1644u = Mean velocity in the pipe (m/s) = 58.5d = Internal pipe diameter (mm) =100μ = Dynamic viscosity (Pa s). For air at 30º C, the value is 0.0000186 Pa-s

In general for a fluid when the Reynolds number is less than 2000 the flow is laminar and when the Reynolds number is above 4000 the flow is turbulent. So the air flow in the pipe line is turbulent following the Reynolds number 366,223.

For commercial steel pipe, absolute roughness K is 0.045 mm. So, relative roughness, k/d = 0.045/100= 0.00045

From Moody diagram (friction factor diagram), corresponding to Re = 366,223 and k/d of 0.0045, friction factor in the turbulent region is 0.0175

The floor condition was not so good. I proposed tiles fitting on the floor and the civil activities are as follows:

Floor dismantling Cement Concrete Tiles fitting

Flow ,m³ / min60 Pipe Cross Section Area, m²

Velocity, m / s

27.5560 × [3.14 × {(d/1000)²}/4]

27.5560 × [3.14 × {(100/1000)²}/4]

58.5 m/s

× u × (d/100)

Re

× u × (d/1000)

Re

0.0000186

× 58.5 × (100/1000)

fLu²2gd

Head loss, hf0.0175×18× (58.5)²2×9.81× (100/1000)

549 m per 27 m length

Room painting Double bubble insulation fitting at roof to prevent heat.

CE 2.9: Design and planning for the project:

At first I called all of my contractors and had a meeting with them. On that meeting I made them understand what they should do in the project. Then I asked for sealed quotation from them. These quotations are opened in a tender committee and then negotiation started with the contractors. After negotiation the committee selected one heavy gang contractor for goods loading and unloading, one for mechanical connection job, one for electrical job and the rest one for civil job. Then Purchase Order was made for the particular job.

After that I made a Gantt chart for the project and share it with the contractors in a pre project implementation meeting. Thus the contractors understood the serial number of jobs and who will do what and when after whom. The Gantt chart is as bellow:

Sl. No.

Description of work Resources

August

8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26

1Make arrangement for the compressor 3 electrical connection

Shahabuddin Electric & Co                                      

2Replacement of Compressor 3 to the place of Compressor 2

Almas Engg                                     

3Complete its piping connection to the Receiver 3 and make a provision to use the new Dryer

Happy Engg                                     

4Right off the Compressor 1 along with its Dryer, panel board, pre filter & after filter.

Almas Engg                                     

5Dismantle Dryer 2 along with its pre filter & after filter and box up as spares.

Almas Engg                                     

6 Dismantle Owamat as spares. Almas Engg                                      

7Make ready all electrical connections for the new compressor.

Shahabuddin Electric & Co                                      

8 Install the New Compressor to the right place. Almas Engg                                      

9 Install the Air Receiver Tank to the right place Almas Engg                                      

10 Install the Dryer to the right place. Almas Engg                                      

11 Fitting all the piping connection Happy Engg                                      

12 Install the Owamat Filter Happy Engg                                      

13 Commissioning & Hand OverTrident Agency, BATB                                      

CE 2.10: Project supervision / implementation and commissioning:

I started the job according to the Gantt chart and the proposed layout. The proposed layout is as follows:

First I engaged Electrical contractors to disconnect electrical connection of Compressor # 3 and made a new arrangement for its new position. In the same time Almas Engineering was instructed to remove compressor # 2 and shift Compressor # 3 to the position of Compressor # 2. After that Happy Engineering made all piping joint for Compressor # 3 and made another arrangement to use the new dryer. Then Compressor # 1 & # 2 along with their dryer was shifted to truck for Kushtia. Shahabuddin Electric & Co. then laid down all the new cables and made SDB for new compressor. By this time Almas Engineering installed the new Compressor in the free space with its receiver and dryer. After that Happy Engineering started the pipe fitting job of new compressor to receiver, pre filter, after filter and to the header. The exhaust duct of compressor and dryer was fitted at the same time. Then the owamat was installed and fitted. In the mean time the floor was furnished with tiles and the wall were painted. I also attached 12 no of turbine ventilator on the tin shed compressor room so that the hot trapped air in the compressor room can easily removed from the room. When all the electrical connections are completed then we ran the compressor in front of Trident Agency. In full load it took the following parameters:Current : 268 Amp in each phase (Average)Voltage : 405 V (Average)Load : 95 %Pressure : 7 Bar g (Average)Dryer due point temperature : 4 deg centigradeWe monitored the parameters for three consecutive days and finally took over it from Trident Agency.

CE 2.11: Project submission / presentation:

Comp. 3 Free space of Comp. 1 & 2

New Comp.

New dryer

When the project is done, Trident Agency and the contractors submitted their bill and I signed the bill for capitalized. After capitalization the compressor moved from Capex (Capital Expenditure) to Revex (Revenue Expenditure). After completion of civil work I made an inauguration ceremony for the first commercial start of the new compressor. Our Head of Supply Chain inaugurated this ceremony. Then I present the project completion update to our project update meeting.

CE 2.12: Complex Problem Identification and Solution:

When I initiated the project, I observed Dryer # 3 performed not so well. The problem of the dryer was sometimes its due point temperature reached 10 to 15 degree centigrade instead of four. I found the root cause of the problem. There was a leak in the evaporator coil and the refrigerant gas was leaked very slowly. So when the gas was recharged it was working well and after that it showed again the high temperature. To resolve this problem I need a set of new evaporators but I had not at that time. So I planned to make a Dryer # 3 bypass line so that I could use the new dryer for Compressor # 3 when New Compressor was off. I made another bypass line for New Dryer so that in the worst condition if the New Dryer was in problem, I could run the new compressor without the Dryer.

CE 2.13: Project outcome:

I was the first project where I do each and everything of the project to complete it within committed timeline. My Project Manager helped me a lot and everyday I gave an update of the project to him. He gave his valuable direction to me if necessary. The project gave me a confidence and it became easier to run the other projects on later. By this project I not only learn about the technical job, I also learnt about the project management: cost estimation, risk calculation, time management, team management, EHS consideration, logistic job etc. The project outcome was the a new compressor which

Helped in improved maintenance of the existing compressors. Increased the reliability by providing backup compressors during routine operations &

maintenances. 20 year old compressors which have exhausted their useful life and are a potential safety hazard as

well as inefficient in their operation will be disposed off.

CE 2.14: Risk Management:

The practical problem was the risk. When I shifted Compressor # 3, the factory was run on three compressors. If another compressor was gone to breakdown then production would suffer. To mitigate the risk I did the preventive maintenance of all the compressors when production was off. Further more by taking the calculative risk assessment, we shifted the compressor within six hours and no problem was happened. When the Compressor # 3 was back within six hours I was released from the stress. Another calculative risk was taken when I connected four inches compressor line with six inches header through reducer at weekly factory closure time (forty five minutes) for Jummah prayer. In this case I also do the job within target time.

CE 2.15: Team Management & Time Management:

I always prefer to take a decision by consulting with team. The advantages of this are some unknown things of me are come out in reality and I can take preparation for that. That’s why I called on several meetings with top teams and the contractors for this project. When I made the Gantt chart of the project I arranged a special meeting with the contractors and gave them the opportunity to share their views about the project. They shared some important things and I consolidated everyone’s views in the Gantt chart. Finally I got a Gantt chart where everyone was agreed with their job and timeline. The beauty of this thing I didn’t face any major problem on the project run time.

CE 2.16: Occupational Health and Safety Management:

According to the BATB policy and guideline I took the following safety initiatives and precautions:

The CompAir ensured that it has got the “CE” or equivalent certification from the manufacturer’s end as a conformance to environmental, health and safety requirements.

I ensured Work Permit for work at height, working with heavy objects, electrical work, and hot work etc. for the contractors.

I ensured that the Factory's Standing Instruction on Fire Safety is understood and followed by the contractors.

I ensured all necessary protective clothing as required by the nature of the job are used (safety spectacles, goggles, face shields to protect eye and face, ear muff and ear plugs to protect hearing, foot wear and hand gloves to protect foot and hand, safety helmets to protect head, safety belts/fall arrestor for high level job etc.)

I ensured the use of Adjustable Spanner (slide-wrench) is prohibited. All portable electrical equipment / tools like hand drill, hand grinding machine etc. must be double

insulated AC. Any electrical power tapping must be done through company's standard plug and sockets

extensions connected only through ELCB. Defective plugs, sockets, cables must not be used under any circumstances. Electrical Welding set must be insulated cable connectors of the locking joint type and capable of

being plugged into company's standard sockets connected only under ELCB. Earthing of welding set must be done properly with standard earthing clamp directly to the object

to be welded, and not through any other objects or machine body. Any person doing welding job must be accompanied by a ' Fire Watcher' equipped with necessary

Fire fighting equipment. All gas welding set must be equipped with all necessary safety accessories like flash back

protector, pressure regulator, meters, valve wrench/wheel, fire extinguisher etc. Ensure that all employees have adequate knowledge about company's colour coding system,

environmental, health and safety sign and symbols. Metal ladders must NOT be used while doing any electrical job. While using ladders one person must be at the bottom of it tightly pressing the feet of the ladder to

the ground. Ensure good housekeeping near working place all the time, providing proper barricade with

necessary sign board and safe access to all work areas free from any obstruction, projections and oily materials.

No dangling and/or trailing cables will be allowed in the work areas which may cause any entanglement.

Ensure that main switch, Local Isolators, Main isolating valves of compressed air, steam, vacuum, water etc. are in ‘OFF’ position and locked using a multi-locking device before starting of any job on the machine or any energy line.

Any equipment using electrical main supply must have appropriate earthing facility with a 3pin flat plug-socket arrangement covered by ELCB.

D. Summery:

CE 2.17: Summery:

This is my first project where I lead each and everything for the successful completion of the project. I do lot of things before as a part of a project but not as a project leader. So this project gave me a high level satisfaction and confidence. By this project I learnt a lot about the project management along with the best engineering and EHS practices.