Development of CNG Compressor

Model: 3W815
to

Presentation on

3rd International Foundry Congress & Exhibition 2010

Presenter December 01, 2010 Muhammad Asim

Development Engineer

1 2 3 4

Introduction Salient Features After sales & Service Plan Future Targets

Introduction
For 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

Introduction
For 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 2005 Started R&D for manufacturing of complete CNG compressor through Reverse Engineering Finalizing the design in accordance with International applicable codes & standards

Introduction
For 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 2005 Started R&D for manufacturing of complete CNG compressor through Reverse Engineering Finalizing the design in accordance with International applicable codes & standards

2006-07 Parts & vendors development and completion of prototype CNG Compressor

Introduction
For 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 2005 Started R&D for manufacturing of complete CNG compressor through Reverse Engineering 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, OGRAs TEC given approval for manufacturing of CNG Compressor Model:3W815

Engineering & Quality Assurance

1 2 3 Standards Followed Design Specifications Materials

4
5 6

Consultant & Vendors

Local & Imported Parts 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 Data
Make & Model Compressor configuration Compressor design No. of cylinders No. of stages Gas inlet pressure (min-max) Gas discharge pressure Gas discharge capacity at 15 Psig Gas discharge capacity at 08 Psig Hypercomp, 3W815 W-120 Cross head design, Atmospheric crankcase 03 03 08-15 Psig 3625 Psig 270 m3/hr 225 m3/hr

Tolerance on discharge capacity 5% at 30C ambient temperature Compressor speed Electric motor size 795-900 Rpm 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
Ambient temperature range Overall dimensions Overall weight

Clockwise if viewed from drive end

Up to 50C L = 2135mm, W = 1190mm, H = 1730mm 2.4 ton

Technical Data
Piston stroke Piston speed 127 mm 3.36m/s @ 795 Rpm

3.81m/s @ 900 Rpm

Cylinder bores 1st stage 2nd stage 3rd stage 206.375 mm 88.9 mm 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 Through force feed lubricator 12 liter

Cylinder Lubrication (Optional) Oil capacity (crankcase)

Oil capacity (lubricator)

Recommended oil for ambient temperature ranges

1.5 liter
Above 60F : SAE 30 32 to 60 F : SAE 20 Below 32F : SAE 10W

Materials
Parts Description
Crankcase Crankshaft Connecting rods Crosshead pistons

Material
Gray cast iron SG iron SG iron Gray cast iron, Gr : 17

Form
Cast Cast Cast Cast

Crosshead pins
Distance piece Cylinders 1st stage 2nd stage 3rd stage Cylinder liners 2nd stage 3rd stage Compressor cylinder heads 1st stage 2nd stage 3rd stage

AISI 8620
Gray cast iron, Gr : 17

Forged
Cast

Cast iron alloy ASTM 1045 ASTM 1045

Cast Forged Forged

Cast iron alloy Cast iron alloy

Cast Cast

Cast iron, Gr : 17 ASTM 1045 ASTM 1045

Cast Forged Forged

Materials
Parts Description
Pistons 1st stage 2nd stage 3rd stage Piston rods Piston rods nuts Valve seats & guards Valve plates Valve springs Packing Cases (Stuffing boxes) Piston rings, rider rings & packing rings Heat exchanger Shell Tubes Tube sheet ASTM 106, Gr : B Stainless steel 316L Stainless steel 304L Extruded Extruded Bar Stock Aluminium 6082 Aluminium 7075 AISI 4140 AISI 4140 ASTM 1045 Carbon steel Stainless steel Stainless steel ASTM 1045 PTFE, PEEK Extruded Extruded Bar stock Bar stock Bar stock Plate Plate plate Forged Bar stock

Material

Form

Consultants
Materials 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 Excel Engineering Lhr Prototype Casting of crankcase Casting of crankcases, crosshead cylinders and 1st stage head

Vendors
Rastgar Engineering Excel Engineering Lhr Qadri Brothers Prototype Casting of crankcase Casting of crankcases, crosshead cylinders and 1st stage head Casting of crankshafts, flywheels

Vendors
Rastgar Engineering Excel Engineering Lhr Qadri Brothers KSB Prototype Casting of crankcase Casting of crankcases, crosshead cylinders and 1st stage head Casting of crankshafts, flywheels Materials testing & dynamic balancing

Vendors
Rastgar Engineering Excel Engineering Lhr Qadri Brothers KSB Prototype Casting of crankcase Casting of crankcases, crosshead cylinders and 1st stage head Casting of crankshafts, flywheels Materials testing & dynamic balancing

PSQCA

Selection/testing of materials and critical casting development like Connecting Rods

Vendors
Rastgar Engineering Excel Engineering Lhr Qadri Brothers KSB Prototype Casting of crankcase Casting of crankcases, crosshead cylinders and 1st stage head Casting of crankshafts, flywheels Materials testing & dynamic balancing

PSQCA

Selection/testing of materials and critical casting development like Connecting Rods

For manufacturing of Liners For smaller parts casting

ShahSons Multan GM Engineering Lhr

Vendors
Rastgar Engineering Excel Engineering Lhr Qadri Brothers KSB Prototype Casting of crankcase Casting of crankcases, crosshead cylinders and 1st stage head Casting of crankshafts, flywheels Materials testing & dynamic balancing

PSQCA

Selection/testing of materials and critical casting development like Connecting Rods

For manufacturing of Liners For smaller parts casting

ShahSons Multan GM Engineering Lhr

Hercules Engineering Lhr

For special coatings and pistons anodizing

Vendors
Rastgar Engineering Excel Engineering Lhr Qadri Brothers KSB Prototype Casting of crankcase Casting of crankcases, crosshead cylinders and 1st stage head Casting of crankshafts, flywheels Materials testing & dynamic balancing

PSQCA

Selection/testing of materials and critical casting development like Connecting Rods

For manufacturing of Liners For smaller parts casting

ShahSons Multan GM Engineering Lhr

Hercules Engineering Lhr

PMO

For special coatings and pistons anodizing

Critical CNC machining

Vendors
Rastgar Engineering Excel Engineering Lhr Qadri Brothers KSB Prototype Casting of crankcase Casting of crankcases, crosshead cylinders and 1st stage head Casting of crankshafts, flywheels Materials testing & dynamic balancing

PSQCA

Selection/testing of materials and critical casting development like Connecting Rods

For manufacturing of Liners For smaller parts casting

ShahSons Multan GM Engineering Lhr

Hercules Engineering Lhr

PMO Precision Engineered Parts (USA)

For special coatings and pistons anodizing

Critical CNC machining Manufacturing of piston rings, rods and seals

Vendors
Rastgar Engineering Excel Engineering Lhr Qadri Brothers KSB Prototype Casting of crankcase Casting of crankcases, crosshead cylinders and 1st stage head Casting of crankshafts, flywheels Materials testing & dynamic balancing

PSQCA

Selection/testing of materials and critical casting development like Connecting Rods

For manufacturing of Liners For smaller parts casting

ShahSons Multan GM Engineering Lhr

Hercules Engineering Lhr

PMO Precision Engineered Parts (USA) Petrocon Engineering (Pvt) Ltd.

For special coatings and pistons anodizing

Critical CNC machining Manufacturing of piston rings, rods and seals Fabrication of heat exchangers, piping and structure

Vendors
Rastgar Engineering Excel Engineering Lhr Qadri Brothers KSB Prototype Casting of crankcase Casting of crankcases, crosshead cylinders and 1st stage head Casting of crankshafts, flywheels Materials testing & dynamic balancing

PSQCA

Selection/testing of materials and critical casting development like Connecting Rods

For manufacturing of Liners For smaller parts casting

ShahSons Multan GM Engineering Lhr

Hercules Engineering Lhr

PMO Precision Engineered Parts (USA) Petrocon Engineering (Pvt) Ltd. Jiacco Pakistan (Pvt) Ltd.

For special coatings and pistons anodizing

Critical CNC machining Manufacturing of piston rings, rods and seals Fabrication of heat exchangers, piping and structure Radiography of welded joints

Vendors
Rastgar Engineering Excel Engineering Lhr Qadri Brothers KSB Prototype Casting of crankcase Casting of crankcases, crosshead cylinders and 1st stage head Casting of crankshafts, flywheels Materials testing & dynamic balancing

PSQCA

Selection/testing of materials and critical casting development like Connecting Rods

For manufacturing of Liners For smaller parts casting

ShahSons Multan GM Engineering Lhr

Hercules Engineering Lhr

PMO Precision Engineered Parts (USA) Petrocon Engineering (Pvt) Ltd. Jiacco Pakistan (Pvt) Ltd. Hamid Traders

For special coatings and pistons anodizing

Critical CNC machining Manufacturing of piston rings, rods and seals Fabrication of heat exchangers, piping and structure Radiography of welded joints Special painting

Introduction
For 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 2005 Started R&D for manufacturing of complete CNG compressor through Reverse Engineering 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

Introduction
For 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 2005 Started R&D for manufacturing of complete CNG compressor through Reverse Engineering 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, OGRAs 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 No special tool is required for any maintenance operation Minimum maintenance cost due to 03 stages & low RPM

Accessible hence easily maintainable

Salient Features
High quality safety relief valves are used Full flow filtered pressurized lubrication Specifically designed heat exchangers for high ambient conditions No additional motor is required for water & oil pumps

Low vibration requiring no specific foundations

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 Material : Excel Eng. Lhr : Gray Cast Iron, Gr:17

Crank case
Vendor Material : Rastgar Engineering : 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 NRVs 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.

Process Vendor

: :

Fabrication & Welding Petrocon Engineering

Skid Fabrication

Heat Exchangers & Piping Fabrication

Hiring of level 3 inspector Welding procedure qualification Hiring of qualified welders Materials certification

Process Vendor

: :

Radiography & DPT Jiaco Pakistan

100% Radiography & DPT of all Butt & Fillet welded joints (160 No.)

Calibration
Each & every measuring instrument is calibrated from reputable source

Hydrostatic Testing
All compression cylinders are hydrostatically tested at 1.5 times of design pressure for 24 hours

Hydrostatic Testing
All 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

OGRAs TEC (Technical Evaluation Committee) Inspection & Performance Test

Engineering Development Board (EDB)s CEO & EDB Team Visit

Liners
Vendor Material : Shahsons Eng. Multan : Gray Cast Iron Alloy

Vendors
Rastgar Engineering Excel Engineering Lhr Qadri Brothers KSB Casting of crankcase Casting of crankcases, st stage head cylinders and 1 crosshead Casting of crankshafts, flywheels Materials testing & dynamic balancing

PSQCA

Selection/testing of materials and critical casting development like Connecting Rods

For manufacturing of Liners For smaller parts casting

ShahSons Multan GM Engineering Lhr

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