S1 S1 SIRIKIT OIL FIELD OJT FIRST ROTATION REPORT REPORT

By

MR. PHYOE MAUNG MAUNG MAUN @NEON

MECHANICAL DEPARTMENT

Content

Article

Title

Preventive Maintenance of Gas Compressor

Turbo Charger Recondition

Heat Exchanger Installation

Crude Loading Pump Preventive Maintenance

Diaphragm Pump Corrective Maintenance

Gas Compressor Overhaul or Four Yearly PM

6.1

Engine removing from the compressor attachment

6.2

Compressor Overhaul Maintenance

6.3

Engine Overhaul Maintenance

6.4

Engine Relocation and Alignment of Engine and Compressor

1. Preventive Maintenance of Gas Compressor Identification : K 3900, K 3300, K 3700, K 3100 of Sirikit Oil Field Compressor Type Dresser Rand Reciprocation Compressor Engine Type Waukesha 12 Cylinder V Type

Date

: (3-May-2013), (4-May-2013), (7-May-2013), (10-May-2013)

Operation : K 3900, K 3300 and K 3100 are boost from IP, LLP,LP to be HP header line which compresses gas up to 275 psi from the HP line and LP line. K 3700 is used for gas lift of production well which compresses gas up to 1250 psi.

Maintenance : Procedure Remove Lube Oil from the Lube Oil Filter Drain Lube Oil from the Line Change Lube Oil Filter (7) Change Air Filter (2) Check the Cylinder Over Head Change the cylinder over head ( at K 3900 on 3 May 2013) Check each Cylinder pressure Test Engine Pilot Valve Change Spark Plugs Check Fan Belt

Condition

: at K 3900 on 3 May 2013 -Change the cylinder over head using by crane -Change Cylinder Over Head Gasket -Tight Cylinder Over Head Bolt by Torque 200, 400, 600 ft/ lb

At K 3300 on 4 May 2013 -Leak water ate the Water Host of Engine

JHA

: High Noise Level working in the area of running machines Working under too hot weather Hot Surface Hot Lube Oil Fire Working above of engine Changing Lube Oil Wet Floor Area

Figure: K 3300 Dresser Rand Compressor

2. Turbo Charger Recondition Identification : Used in Waukesha Engine Date : 4-May-2013

Operation : Turbo charger is driven by the turbine which is powered by exhaust gas of Engine. It can give pre-compression of inlet air.

Maintenance : Procedure Disassemble each part of turbo charger Clean the turbine blade by abrasive paper Change thrust bearing, thrust collar and piston ring Reassemble

JHA

: Cleaning of impeller by abrasive paper can get injuries to the hand.

Figure: Turbo Charger Part

3. Heat Exchanger Reinstallation Identification : E 2010 Shell and Tube Type Heat Exchanger Date Operation : 8-May-2013 : To heat transfer between steam and crude oil

Maintenance : Procedure Install Head Cover and Rear Cover of Heat Exchanger Install Steam Inlet Line and Outlet Line Install Crude Inlet Line and Outlet Line Tight torque of the cover bolt ( 350 ft-lb) Rotate the Swing Blind to the Open position Inspect before running Clean the working area

Condition - At test running, there is a leakage of water at the inlet steam line. Inspect the fault condition of inlet steam line.

JHA

: Working in Height Scaffolding Using Lifting by crane Process Crude Oil, hot steam Hot surface Pipe Line Working Under Very Hot Weather Swing Blind Rotation

4. Crude Loading Pump Preventive Maintenance (PM) Identification : Centrifugal Pump for crude Loading Date : (9-May-2013)

Operation : In crude loading, centrifugal pump is used to transfer crude from the oil tank to the road tanker.

Maintenance: Procedure Change Lube oil of the reduction gear box Refilling Grease into the Stiffing Box of Pump Clean the Pump area

JHA

: Fire Working Loading area Narrow Space for working Process Crude Line

5. Diaphragm Pump Corrective Maintenance Identification : Magnus Aodd Diaphragm Pump A-series Date : (11-May-2013)

Operation : This pump is driven by pneumatic air and transfers cool water from the water tank to the cooler tube line of K 3700 cooler system. The pump cannot run normally to pump.

Maintenance: Procedure Removes from the working line Disassemble each part of Pump Clean each part Search the fault of the pump Assemble the pump

Condition JHA

: Fault is found in the broken air-spring seat and cutting washer : Working in narrow space Wet Area Removing with high torque force Using Pneumatic Tool Air

Figure: Aodd Diaphragm Pump A Series

6. Compressor Overhaul (or) Four-Yearly Major Preventive Maintenance

Identification : K 3400 of Sirikit Oil Field Compressor Type Dresser Rand Reciprocation Compressor Engine Type Waukesha 12 Cylinder V Type Date : (14-May-2013) to ( 25-May-2013)

Operation: This K 3400 is used to boost the gas from the LLP gas header to HP header.

In this major maintenance, there have the following steps6.1 Engine removing from the compressor attachment 6.2 Compressor Overhaul Maintenance 6.3 Engine Overhaul Maintenance 6.4 Engine Relocation and Alignment of Engine and Compressor 6.1 Engine Removing from the compressor attachment Maintenance Procedure: Drain all Lubricant from the engine side Remove all peripheral equipments from the engine Lift the exhaust duct line by crane Lift the engine by crane Clean that area

JHA

-Lifting heavy load engine by crane - Draining hot Lubricant -Having many trainee in small area -Wet Floor from 3500

6.2 Compressor Overhaul Maintenance Maintenance Procedure: Change connecting rod packing Change compressor piston ring/rider ring of 1st/2nd stage compressor Recondition all suction and discharge valves Recheck alignment coupling and compressor cylinder to frame Inspect Main Bearing No.1 , No.2, No.3 and No.4 Inspect and record the following component Retake the torque Compressor Valve cover cylinder 23 Retake the torque Compressor Valve cover cylinder 20.5 Retake the torque Compressor Valve cover cylinder 13 Retake the torque all valve cover center bolts

Figure: Connecting Rod Linear Run out Data Recording

JHA: -Removing of Cylinder cover / cap -Work in narrow space which between two cylinders -Rotating of crank shaft by manually -Closing of swing blind -Removing of pistons -Working near wet area K 3500 -Taking high stress torque

Condition/Snag: Throw No.4 piston ring depth is higher than procedure allowance amount .Therefore, there have the modified for that piston.

6.3 Engine Overhaul Maintenance Maintenance Procedure: Recondition cylinder head assembly (12) Change hydraulic lifters 2 each and adjust valve clearance Change cylinder sleeves Change piston with piston ring. Change torsional vibration damper Change crank shaft main bearing Change connecting rod cap screw Change crankshaft thrust bearing Change camshaft bearing and thrust bearing Recondition both side turbochargers Clean lube oil engine crankcase and cooler Recondition Auxiliary pump and WJ ump Recondition engine pre-lube oil pump and motor starter Change W/j pump driven belt Change Auxiliary pump driven belt Change engine lube oil strainer Change all spark plugs and high tension lead Check carburetor or repair if required Check fuel gas regulator and change diaphragm if damaged Engine Compression before start up Retaking the torque of fan blade coupling bolt by 120 ft/lb Retaking the torque the tapper bush joint bolt by 30 ft/lb Regrease pillow block bearing both end Drain out water from cooler prior to remove engine Refill water in cooler/leak test prior to restart up JHA: -Communication -Lifting and rotating of engine block -Removing of crankshaft -Using Oxyacetylene Gas Flame for installation of Gear

Condition/Snag The new crankshaft is smaller connecting rod bearing side and is not compactable with the engine body. Therefore, the old crankshaft is used again.

Figure: Before Removing Waukesha Old Crankshaft

6.4 Engine Relocation and Alignment of Engine and Compressor Maintenance Procedure: JHA: -Lifting by crane -Installing of exhaust duct line in high place -Using Laser Lift the engine block from the workshop to the worksite Attach the engine and compressor by coupling Take the torque of coupling Make the laser alignment of engine and coupling Check with the dia-gauge alignment Check the crank shaft waving by dia-gauge Install all peripheral equipment of engine Fill the lubricant oil to the tank Test for the running compressor