Professional Documents
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Study Report
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On Refrigeration System
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Topic Index
Sl.
Topics Page No.
No.
1 Scope
2 Engineering
v Piping Layout
vi Isometric Drawing
3 Mechanical
i Compressor
ii Heat Exchanger
iii Valves
iv Flanges
v Fittings
vi Welding
i Carbon Steel
5 Instrumentation
i Pressure
ii Temperature
6 Knowledge Sharing
1. SCOPE
Scope
It serves as the basis for the design, erection and commissioning of the entire
skid. There are standard symbols and notations which denote various
components.
a. Piping Connections
b. Process Flow Directions
c. Equipments
d. Fittings like Valves
e. Piping sizes
f. Gauges and Switches
g. Mounting of switches (Field, control panel mounting, etc.)
h. Tie in Points
i. Items to be supplied loose
j. Insulation
k. Tag Nos.
l. Fittings like Nuts and Bolts, etc.
m. Materials
i. Compressor
It is one of the most important components of the package. Various type
of Compressors used are Screw, Reciprocating or Centrifugal.
The compressor id loaded or unloaded using an Oil circuit. The
Compressor has been dealt in detail in the subsequent Chapters.
v. Economizer
Economizer is used when the Temperature difference to be achieved is
large and cannot be achieved only with the use of a Chiller.
Here, the refrigerant received from the Condensor-Reciever, is split into
two parts. One goes into the tube side and other to the shell side. The
liquid going into the Shell side is flashed using an expansion device and
this in turn cools the liquid in the tube side.
The evaporated vapor is collected in the surge drum and is sent to the
superfeed of the Compressor. The pressure of the Superfeed line is higher
than the regular suction.
vi. Chiller and Condenser
Chillers and the Condenser are the heat exchanging units of the System.
They are generally Shell and Tube type Heat exchangers with the
respective fluids flowing in shell and tubes. Again, the Heat Exchangers
have been dealt with in detail in the further sections.
The PFD contains the Heat and Mass Balance Chart which gives all the process
parameters at various points in a system. It also contains information on the
various bypasses and system connections.
v. Piping Layout
As the name suggests, the piping layout gives the general layout of the piping
connections between various components. In case of multiple skids, the
interconnections between the skids are displayed in the Layout.
a. Screw Compressor
A screw Compressor uses 2 helical screw rotors to compress vapor when it
enters through the suction and moves through the screws.
The vapor enters the screw through the suction and moves along the threads.
There are two screws, one male and other female, the space between the two, as
they mesh, reduces and hence the vapor is compressed. In case of oil flooded
compressors, the oil serves as a cooling agent and as a mechanical seal.
The loading and unloading is done using injection of oil into the compressor
loading/unloading chamber. It consists of a double acting piston-cylinder
arrangement (single acting in case of Howden XRV) and the loading takes place
by inserting oil into one side of the piston and unloading by inserting oil into the
other side. This depends on the Pressure of the vapor at suction of the
compressor. The Pressure transmitters transmit signals to the controllers and
hence the solenoid valves load or unload the compressor.
The loading/unloading takes place with the help of a sliding spool which
operates with the loading piston. The length of the rotors which is engaged with
the spool is said to be loaded and the gas gets compressed only in that length of
rotors.
There is also a Superfeed Suction along with the regular suction. The refrigerant
which has evaporated from the Economizer will be fed to the superfeed. This
vapor is at a higher pressure than the compressor suction. So the superfeed will
be provided at a distance where the pressure of the suction gas inside the
compressor is equal to the vapor in the superfeed.
b. Reciprocating Compressor
A reciprocating compressor is a compressor which uses a Piston cylinder
arrangement for compression of vapor. The reciprocating compressors used for
refrigeration are generally in a V or W arrangement. It consists of solenoid
valves which take part in the loading and unloading of the compressor. Unlike a
screw compressor, this compressor cannot undergo step-less capacity control.
It is a double cylinder compressor (bore 85mm and stroke 110mm) with one of
the cylinder always under loaded condition and the second is loaded using a
solenoid operated valve. The Cylinder liners are cast iron material and fine
boring and honing is done for mirror finish surfaces. The compressors are belt
driven and give max. and min. speeds of 1450RPM and 600RPM.
Piston has 3 compression rings and one oil ring and they ensure ample
lubrication with minimum usage of oil. The crankshaft is made of aluminum
alloy.
ii. Heat Exchangers
Heat exchangers are of the following types:
a) Double Pipe
b) Shell and Tube Type
c) Plate Type
Depending on which side the Refrigerant flows, the Shell and tube type chillers
are classified into two types
The components of a typical Shell and Tube Type Heat Exchanges are,
1. Shell
2. Tubes
3. Tube Sheets
4. Baffles
5. Tie Rods
6. Head/Bonnet
7. Gasket
a. Shell
A shell is a cylindrical container which houses shell side fluid in the heat
exchanger. They are generally made by rolling metal plates and then
passing through the mandrel to check for out of roundness. The material
generally used is Low Carbon Steel.
The Above Figure gives the TEMA designations for the various types of Shells
and Channels (Heads).
b. Tubes
The tubes form as the medium between the shell fluid and the tube side
fluid. Materials used are copper, steel alloys, Alloys of Nickel, titanium,
aluminum. Finned tubes are used to increase the heat transfer area by
about 2 to 5 times.
d. Baffles
The baffles are plates in which holes are drilled and are inserted in
between the shell. They have the following functions:
a. Support the Tubes.
b. Maintain the tube spacing
c. Direct the flow of the fluid in the desired pattern.
The spacing between the baffles is called as Baffle Spacing. The Baffle
spacing must be 15% of the Diameter of the shell. Baffles are either
stamped/punched or drilled. For a gas or a vapor, baffles are placed such
that the gas moves horizontally. For a liquid, they are placed such that
liquid flows vertically.
f. Head/Bonnet
It is required to contain the tube side fluid and provide the desired
direction.
The various configurations of the channels according to TEMA standards
are given in the figure above.
g. Gasket
The gasket is a sealing element which provides the sealing between the
various mating surfaces. The gaskets contain sealing materials which
prevent the leakage within the members under compression.
A commonly used gasket is a Spiral wound gasket. It consists of an outer
ring of SS, a filler material which is generally softened graphite and an
outer ring. The filler material is wound spirally. The filler acts as a
sealing material and the metallic parts act as the rigid support.
iii. Valves
A valve is a device which does the regulation of flow of a particular fluid. The
regulation can be in terms of various fluid properties like flow rate, pressure,
direction, etc. This is done by opening or closing the obstruction to the flow,
partially or fully.
a. Gate Valve
A Gate Valve is a valve which is used primarily for allowing or
obstruction the flow of the fluid by using a rectangular wedge to do the
obstruction.
This valve should only be used to on or off the flow and not to regulate
the flow.
The valve consists of a body which has a rectangular wedge blocking the
path of the flow. The gate is operated with the help of a threaded Stem
which rises or lowers because of a handle.
The Gate tends to vibrate if the gate is partially open.
They have a rising or a non-rising stem where a rising stem gives an
indication of the status of the gate. They can have either a flanged end or
an end which needs to be welded.
b. Globe Valve
A Globe valve consists of a plug which sits on a seat to obstruct the flow.
The Globe valve is generally used for regulation the flow of liquid. The
plug is operated using a stem which can be operated using a handwheel.
Apart from the regular Body, stem, bonnet, the globe valve consists of a
cage which determines the flow of the fluid.
The Valves are generally made of Carbon Steel, LTCS or Stainless Steel.
c. Butterfly Valve
The Butterfly Valve is a valve used for regulating the flow using a disc.
This disc is mounted on a rod where the rod is turned using a handle and
it in turn turns the disc to open or close the path of flow.
d. Check Valve
A check valve, also called as a non-return valve, is a valve which allows
the flow of liquid only in one direction. It blocks the flow coming from
the other side. The various types of check valves are;
a. Ball Check Valve: It consists of a spring loaded ball which allows the
entry of fluid when the spring is compressed and blocks it from the
opposite side as the spring recoils.
b. Swing Check Valve: This consists of a disc which is hinged at one
end and allows flow as it swings off the seat and blocks it as it goes
back on to the seat.
c. Flapper Check Valve: It has a flapper which is hinged and is similar
to the swing check.
A flapper type Check valve should not be used in a vertical line when the
flow is from the top.
e. Needle Valve
A needle valve is a valve which obstructs and regulates the flow of the
fluid with the help of a needle shaped plunger. This is operated with the
help of a threaded stem and a handle. It is only used for relatively lower
flow rates. They are generally used for flow metering circuits.
a. Elbows
They are used when the direction of the piping is to be changed by 90deg
or 45deg. It consists of either Short Radius (Radius is 1.5 times the pipe
diameter) or Long Radius (Radius is equal to the size of the pipe).
b. Reducers
They are used if the size of the pipe is to be changed.
Length of the Reducer = Average of smaller and larger diameter of the
reducer
The reducer can be concentric or eccentric.
c. Union
It consists of a male and a female ends and a nut which allows for easy
fixation and removal as compared to a coupling.
d. Tee
A Tee is a fitting which is used when the piping has to be split divided
into two directions like 108deg. The Tee can be Equal Tee or an Unequal
Tee based on the sizes of the pipes on the branches. The Tee is generally
classified as Reducing Tee, Double Branch Tee, etc.
e. Coupling
A coupling is one which connects two pipes .If the pipes are of different
diameters then it is called as a reducer. The Coupling can be a socket
weld type or a threaded type. If the Threads are only on one of the sides,
then it is called as a half coupling; it is called a full coupling if the
threads are on both the sides.
f. Olets
Whenever a Tee is not advisable, then fittings like Olets are used. The
olets can be Socket Weld Olets, Butt Weld olets, Threaded Olets, etc.
g. Cap
A Cap is used where the end of the pipe is to be blinded or closed.
v. Flanges
Types of flanges are;
a. Slip-on Flange
Slip-on flanges are the ones where the inner diameter of the flange is
slightly larger than the diameter of the pipe. These are welded to the pipe
after the pipe is inserted in the flange.
b. Weld-neck Flange
These flanges give a reduction in the concentration of stresses. These
contain a neck at the end of the flange which can be welded to the pipe.
c. Threaded Flange
The flange has internal threads which fit on to the pipe which has threads
on its outside surface. The flanges has tapered threads which can be used
in highly combustible areas where welding is dangerous.
d. Blind Flange
This is a flange which is used to seal the ends of the pipes so that the fluid
cannot escape through the pipes.
The flanges are also further classified as Flat Face, Raised Face, Male-Female
Face, Tongue-grove face Flanges.
Generally, the weld at the root is made using TIG welding as it produces a
cleaner weld. And the rest of the weld is done using MAW.
Classification of Welding Electrodes is done as follows.
E7018-X
E - Indicates Electrode
70 - Indicates the strength of the joint made by the electrode when welded.
Measured in pounds per square inch.
8 - Indicates Coating
Welding Positions
Coating
0 – Cellulose, Sodium
1 – Cellulose, Potassium
2 – Rutile, Sodium
3 – Rutile, Potassium
4 – Rutile, Iron Powder
5 – Low Hydrogen, Sodium
6 – Low Hydrogen, Potassium
7 – Iron Powder, Iron Oxide
8 – Low Hydrogen, Iron Powder
9 – Iron Oxide, Rutile, Potassium
vii. Thermostatic Expansion Valve
The Thermostatic Expansion Valve is an expansion valve which opens or closes
based on the pressure changes on the diaphragm. It consists of a bulb which is
filled with the refrigerant used in the system. The bulb is attached to the chiller
outlet pipe and the pressure in the bulb varies as the temperature of the chiller
outlet changes.
The pressures acting on the diaphragm are Bulb pressure, Evaporator pressure
and spring pressure.
4. MATERIALS
The Materials used in Piping are:
b. Carbon Steel
It is a material which has a considerable percentage of carbon as unless a
minimum value is specified.
c. Stainless Steel
Austenitic Chromium Nickel Alloy Steel pipe for high temperature service has
excellent corrosion resistance except chlorides. Stress concentration cracking
can occur at temp above 60 deg C. It consists of two types viz. 304L and 316L.
304 is a versatile type of a material. The old name was 18/8 because of the 18%
Chromium and 8% Nickel. It undergoes Work Hardening so Annealing should
be done.
304L is the Low Carbon Version of the 304. It has improved weldability. Also
called as EN58E. It has high resistance to carbide precipitation.
Material Composition ASME Standards Description Properties
Forged Cast
Forged Carbon
A105 Steel Piping
Components
Carbon Steel C-Si Seamless -290C to
A216-WBC
Carbon Steel 4250C
A106 pipe for high
Temperature
Applications
Seamless and
welded Steel
A333
pipe for low-
Low Temperature
-460C to
Temperature C-Mn-Fe Low
A352-LCB 3400C
Carbon Steel Temperature
A350-LF2 Carbon Steel
A352-LCC for piping
Components
Seamless and
welded Steel
A333
pipe for low-
Low Temperature
-1010C to
Temperature 3.5 Ni Alloy Based
3400C
Alloy Steel (Nickel) Forged
A350-LF3 A352-LC3 Carbon Steel
for piping
Components
The above Table shows various types of materials and ASME standards
5. INSTRUMENTATION
The various types of Instruments used are:
i. Pressure
The pressure transmitters consist of pressure sensors which sense the pressure in
a system and the transmitter/transducer converts this signal to feed to the
controller.
The various types of pressure sensors are,
a) Capacitive : This type of sensor uses a diaphragm to form a variable
capacitor and then measures this displacement caused due to pressure.
b) Piezoelectric : The sensor employs piezoelectric strain gauges to measure
the strain caused due to the pressure.
c) Electromagnetic : The sensor uses electromagnetic principles to detect the
displacements in the diaphragm.
A Differential pressure sensor uses two pressures on the two sides of the
diaphragm in contrast to the simple pressure sensor which uses pressure on one
side and atmospheric pressure on the other side.
The Above figure shows the comparison between RTD and Thermocouple.
6. KNOWLEDGE
SHARING
i. Pressure Testing
a. Initially the PSVs are isolated and all connections are checked.
b. Pressure is raised upto 1.7 kg/cm2 g using a compressor and dry air or
nitrogen is let in through the Filter Drier core and major leaks are found out.
c. Now the pressure is increased to 13.97 kg/cm2g and held for 10 minutes.
d. Now for the leakage testing, Pressure is brought to 12.7 kg/cm2g.
Examination is done by putting soap solution over all the joints, flanges,
valves, glands, etc.
e. During inspections, each component is checked according to the P&ID.
v. Stand by pressure
At the start of the compressor, the gas of refrigerant at compressor suction has
an initial pressure at atm. temperature called as standby pressure.
viii. EPCG
Export promotion capital Goods license is given by the Govt. of India to
companies who export certain amount of their produce.
If the company requires certain imported machinery etc, then those imported
goods are exempted from import duty.
ix. Method to find flow of Pump if Flow Meter is not Available
If a direct flow meter is not available for a water pump, then take the Head (H)
vs Flow (Q) curve which is available for each pump. Convert the pressure
generated by pump into head and for that flow, note the corresponding Flow.