The document provides details about a summer training report at the Dibiyapur Compressor Station owned by GAIL. It summarizes the key details about GAIL, the compressor station, and specifics about the 501-KC5 gas engine that was the topic of study. The compressor station boosts incoming natural gas to supply customers. It consists of gas turbines, compressors, transformers, and a battery room. Operational details of the 501-KC5 dec engine like parts, working cycles, startup process, and trip conditions of the Auraiya station are described.

1. SUMMERTRAINING REPORT
AT
GAIL COPMRESSOR STATION,DIBIYAPUR
SUBMITTED BY: RAHUL KUMAR
BRANCH: MECHANICAL
COLLAGE:-NOIDA INSTITUTE OF ENGG ANDTECH
TOPIC: - 501-KC5 DEC ENGINE

2. INTRODUCTION OF PLANT
• GAIL- Gas Authority of India Limited
• GAIL is one of the MAHARATNA enterprises and ranks among PSU public
sector unit in India.
• It was establish in 16th of August ,1984.
• GAIL is India’s flagship natural gas company, integrating all aspects of
natural gas value chain (including Exploration & Production, Processing,
transmission, distribution and Marketing) and its related services.
• GAIL covers its main portion in (HVJ) Hazira-Vijaypur-Jagdishpur line .In
between this three station there are 6 fertilizers companies and 6 power
plant.
• It is one of the largest cross –country natural gas pipeline projects in the
world.
• This 1800Km long pipeline was built at the cost of 17 billion
rupees(US$280 million)

3. DIBIYAPUR REGION
• Dibiyapur Compressor station is in Auraiya district spread in 1089Kms of
pipeline (from 2” TO 30”) of 18MMSCMD supply.
• It is a two stage booster station which boost the incoming gas from Vijaipur
up to 90Kg/cm2 for its consumers.
• Compressor station consist 2nos gas turbine generators(GTG), 3nos gas
turbine compressors(GTC) , 2nos of European gas turbine(EGT)
• Four Power transformers for the eminent operation of the power system.
• For Uninterrupted Power Supply (UPS), there is a battery room containing
Ni-Cd Batteries.
• Major customers- PATA, NTPC, IGFCL, IFFCO, BHEL, KSFL, CUGL, GGL AND
TCL.
• Sale of NG(natural gas) in DIBIYAPUR region is approx 18 MMSCMD.

4. PIPELINE INTRODUCTION
• At Pressure of 58Kg/cm2, received from GAIL Vijaipur, through 30” HVJ
Pipeline.
• This total rich natural gas (Feed gas ) is passed to GAIL Pata, where rich
gas is converted into lean gas, which has 98.5% of C1, is received back at
the compressor station from GAIL, Pata, at pressure of 48Kg/cm2.
• Approx. 3.2 MMSCMD of this lean gas is supplied through pressure reduction
skid to NTPC, Auraiya.
• However , remaining 6.6MMSCMD of lean gas is compressed in two stages
( Primary & Booster compressor) to get discharge pressure of 90Kg/cm2
• 5.5MMSCMD is transmitted through 18” Jagdishpur line to fulfill the
contractual requirement of end consumers . IFFCO, Phulpur, IGFCL
Jagdishpur & BHEL, besides city gas consumers at Kanpur and Lucknow. The
balance approx. 1.1 MMSCMD of compressed gas is dumped to 24” Aonla
line.

7. INTRODUCTION

8. AURAIYA STATION OPERATION
CONDITION
MODEL CDP-416
GAS HANDLED NATURAL GS
WEIGHT FLOW 142842(kg/hr)
INLET PRESSURE 46.7(KG/CM2A)
INLET TEMPRATURE 40 (oC)
INLET MOLECULAR WEIGHT 19.3
INLET (CONST PRESSURE/CONST VOL) 1.275(K AVG)
INLET COMPRESSIBILITY (Z1) 0.91
INLET VOLUME 3915(AM3/hr)
DISCHARGE PRESSURE 944.2(PSIA)
DISCHARGE TEMPRATURE 70(oC)
DISCHARGE(CONST PRESSU/CONST VOL) 1.275(K AVG)
DISCHARGE COMPRESSIBILITY (Z2) 0.930

9. PERFORMANCE
BHP REQIUIRED AT COMPR 2283(KW)
SPEED 13120(RPM) APPROX
MAX .CONTINUOUS SPEED 13776(RPM)
OVER SPEED TRIP 14465(RPM)
HEAD POLY 4717(M)
EFFICIENCY 81.6%
SUBJECT TO A TOLERANCE OF (+,-,4%)
COMPRESSURE IS GUARANTED FOR
HEAD AND INLET VOLUME

10. PARTS OF TURBINE
• COMPRESSOR
• STARTER DRIVE GEARBOX
• ACCESSORY DRIVE GEARBOX
• COMBUSTION CHAMBER
• DIFFUSER
• TURBINE

12. • Front of engine have air inlet bell, Drive
gearbox, Starter drive gear box
• The REAR of engine have POWER TURBINE
assembly.
• The TOP of engine have the BREATHER.
• The power turbine may be connected with
GENERATOR or COMPRESSER according to
requirement

13. KC5 GAS GENERATOR
DIMENSIONS

14. WORKINF LIMIT’S OF TURBINE

15. WORKING OF DIFFERENT
SECTIONS
COMPRESSOR CHAMBER
• It is a single entry , fourteen
stage , axial flow type.
• During operation air is
compressed up to 9.5 times
the intake PRESSURE
• Compressor diffuser ,
secured to the rear of
compressor casing , directs
the air from the compressor
rotor to combustion section
STARTER DRIVE GEARBOX
• It is mounted on the top of
the air inlet chamber.
• It transmits torque from the
STARTER to the
COMPRESSOR rotor.
• It provides means for
measuring GG speed
,separating oils from air and
oil mixture

16. WORKING OF DIFFERENT PARTS
ACCESSORY DRIVE GEAR BOX
• Mounted on the top of air
inlet.
• Receives its drive from the
compressor rotor via side
gear.
• The main and external
scavenge oil pump
assembly is mounted on
the front & on rear.
COMBUSTION SECTION
• It is attached to the diffuser
, incorporates , six
cylindrical shaped liners.
• Here combustion liners mix
AIR & FUEL , guide the hot
gases into turbine unit and
also , control combustion

17. SIMPLE CYCLE OF GAS TURBINE

18. THERMODYNAMIC CYCLE

19. PROCESS OF FUNCTIONING
• The gas turbine engine is essentially a heat
engine using air as working fluid.
• As air passes through engine ,the Kinetic
energy of air is increased.
• To obtain this the pressure energy first
increased and then Heat energy is added in
the combustion chamber.
• Heat is added at constant pressure and adding
fuel

20. • After compression the gases is expanded
through the turbine .
• And the kinetic energy is converted into the
mechanical work in the PT .
• And the available as Torque at the PT shaft
output spline.

21. WORKING PROCESS DIAGRAM

22. WORKING CYCLE (P-V) DIAGRAM

23. STARTING OF A ENGINE
• Starter begins to rotate the Gas generator(GG).
• The GG rpm & oil pressure begin to increase.
• Governor control the Fuel valve for starting .
• At 2200 GM rpm, the ignition occurs and opens the fuel shutoff
valve.
• Due to ignition the GG accelerate up to 100000rpm with in the
(30-40)sec after passing through 2200 GG rpm.
• At 2300-2400 GG rpm the measured temperature (MGT) should
increase rapidly to (1200-1400)degree F.
• At 8400 GG rpm ,the control system turn off ignition and starter
system.

24. • Now the GG should accelerate normally to ideal speed in 30-40
seconds from 2200 rpm.
• If the GG rpm is less then 48 per second for the 5 second time
period the system will shut down automatically.
• UP to 11,000 GG rpm the compressor bleed valves are fully open
to unload compressor , at this position they begin to move to the
closed position.
• APPROX at 12,600 GG rpm they are fully closed , this speed is for
59*F compressor inlet temprature (CIT).

25. NORMAL OPERATION
CONDITIONS
• GG operate between 10,000 & 14,500 rpm.
• Maximum CTIT is 1895*F
• Vibrations are 1.0mil GG turbine is normal,
above this is the warning condition.
• GG oil pressure is 50-60 psig .
• OIL temperature at the inlet to the GG should
be less than 160*F.

26. COMBUSTOR AIR SYSTEM
This system consists of 6 indivisible combustion linear , FUEL
(natural) GAS is continuously injected and mixed with AIR .
• The AIR is compressed which is flowing from the compressor.
• Once the ignition occurs , combustion is continuously go on
without igniter.
• About 25% of the air leaving the compressor is utilized for the
combustion.
• The remainder is used to cool the metal parts and dilute the
flame temperature to an acceptable turbine inlet
temperature .
• Now the high pressure and temperature gas is passes to the
TURBINE

27. FUEL SYSTEM
• The system is mounted in the pit one of the BASEPLATE ,
except filter .
• The fuel filter is mounted adjacent to the base plate.
• When the GG reaches 2200 rpm the fuel system stop valves
SOV-XX47X & SOV-XX46X opens .
• And fuel vent solenoid valve SOV-XX48X closes.
• Fuel flows through filter XXKTF-15 to the gas valve .
• The fuel flows to the combustion chamber by way of the fuel
manifold.
• The fuel is ignite by the spark igniter in the gas generator
combustion chamber.
• As the GG passes through 8400 rpm the starter solenoid
valve ,SOV-X43X ,SOV-XX44X , AND SOV-XX45X and the spark
igniters de-energise .

28. LUBE OIL SYSTEMS
• It is used for the lubrication of various
components of the units.
• It is provided with the 2 independent oil
system as given below :_____
• GAS GENERATOR lube oil system.
• POWER TURBINE AND COMPRESSSOR lube oil
system

29. GAS GENERATOR LUBE OIL SYSTEM
• Synthetic oil is used for lubrication in this system and is
stored in reservoir(XXKTV-16).
• This oil is also used to operate 5th and 10th stage compressor
bleed valve actuators.
• The reservoir having storage capacity of 144 liters of oil.
• Two level switches are provided in XXKTV-16 for electric
signals to main control panel to produce alarm and shutdown
on lowering oil level.
• The level transducer is mounted on XXKTV-16 which sends the
electronic signal to the unit control panel , which is used for
indication (TI-XX64X) and actuate the alarm , and shut down
switches

30. PROCESS OF OIL FLOW
• As GG COMPRESSOR rotates , oil draws from the reservoir (XXKTV-
16) by GG lube pump , on the accessory driving housing.
• Then oil passes through the foot valve (SFV-XX41XX) before enter
into the lube pump.
• SFV-XX41X in addition to straining the oil , has a check valve , which
holds oil in the line to keep the pump primed .
• The pressure control valve maintains the proper pressure to GG
bearing and gears .
• Now the drain oil from the bearing is removed by an external
scavenge pump on the accessory drive housing.
• Another oil pump in the accessory section pumps the drain oil from
the accessory drive housing off the gas generator .
• The oil from both pumps meets at a common connections and carried
by piping to an air eliminator and is piped to (AE-XX41X).

31. • Now air is removed form the oil by air eliminator and is piped toR-
XXKTV-16 .
• And the air free oil is piped to cooler.
• A motor driven fan mounted below the cooler cools the oil as it
passes through passages with XXKE-11-X.
• thermostatic control valve is mounted downstream of XXKE-11-X .
• A bypass line is installed across XXKE-11-X , if the scavenge oil
temperature is below140*F ,TCV-XX41X begins to close and the
must flow through cooler XXKE-11X.
• The scavenger oil flows from cooler to the one of two filters.
• Actuation of HV-XX41X allows transfer of oil from one filter to
another .
• From the filter a portion of oil returns to reservoir and a portion of
oil is placed to the hydraulic pump mounted on the accessory drive
box.
• The hydraulic pump discharge operates actuators of the
5th and 10th stage compressors bleed valve.
• A portion of oil from the main lube pump is piped to
lubricate the clutch in the staring pump.

32. • The pressure control valve down streams of the filters
provide the required suction pressure head for the
hydraulic pump .
• PCV-XX43X is set at 0.14kg/cm2 .
• Another relief valve is mounted in the hydraulic pump
housing , this valve will open and relief the hydraulic
pump discharge pressure ,if the pressure exceeds
28kg/cm2.
• And a magnetic chip detector is in the accessory drive
housing of the gas generator .
• The detectors is in the discharge side of the scavenge
pump.
• The detectors are electrically connected to the
annunciator on the main control valve

33. FIRE DETECTION SYSTEM
• Two U.V detectors in each enclosure .
• Two rate of rise thermal detectors in each
enclosure.
• Supervisory monitor with malfunction , function
annunciation , fire detection annunciation ,
contacts for unit and station shutdown .
• Contacts to trigger fire extinguishing system.
• There is also two high detectors in each
enclosure.

34. TRIPING OF AURAIYA STATION
• COMPRESSOR
• Minimum pressure :- 46.7kg/cm2A
• Maximum pressure :- 66.4kg/cm2A
• Minimum temp :- 40*C
• Maximum temp :- 70*C
• Mini/max compress:-0..930
• BHP required :- 2283KW
• Minimum Speed :-13120rpm
• Maximum speed :-14465

35. CONCLUSION
GAIL has setup a huge pipeline over India with its easy working condition
for the employees and also with their great safety. It has set-up at least
more than one back-up system so that system works with no hazardous
accident.
After summing up all I conclude this report with my utmost privilege in
doing summer training with very cooperative atmosphere.