A TECHNICAL REPORT ON THE STUDENT INDUSTRIAL WORK EXPERIENCE SCHEME (S.I.W.E.

S) TIT 499

SUBMITTED TO THE INDUSTRIAL TRAINING COORDINATING CENTRE (ITCC) UNIVERSITY OF IBADAN

BY

UMUKORO GODSGIFT EZAINA

MATRIC NO. : 145594
2010/11 SESSION

JANUARY 2012

Umukoro G. E. 145594, Mechanical Engineering Dept., Faculty of Technology, University of Ibadan Ibadan, Oyo. January 20, 2012 The Director, Industrial Training Coordinating Centre (ITCC) University of Ibadan, Ibadan, Oyo. Dear Sir, SUBMISSION OF INDUSTRIAL TRAINING WORK REPORT I hereby write to notify you on the submission of my Industrial Training (S.I.W.E.S) Work Report (TIT 499). The report gives accounts of the experience I gained during the six (6) months Industrial training as required for 400 level students of the faculty of technology. My training commenced on the 6th of June 2011 and ended on the 5th of December 2011 at the Nigeria LNG Limited. Attach herewith, is a detailed copy of my report. Thank you sir for your approval Yours Faithfully,

Umukoro G. E. 145594

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ACKNOWLEDGEMENT
First of all, I salute my industrial Base supervisor, Engr. Nyakura Matthew, Mrs. Margret Beckley, Mr. Jude Esumobi, Mr. Ngozi Ogueji, Engr. Dare Laoye and all members of the following departments; HRP/2, NSML and PEI at the Nigeria LNG Limited who assisted tirelessly to see that my SIWES is completed with uttermost excellence. My profound gratitude goes to Dr. Grant Akata, my family and Princess my love, for their support during my training. Finally, this work would not have been possible without the special grace of God.

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ABSTRACT
The need for students in Nigerian universities to acquire Industrial skills and experience in their course of study and also to expose students to work methods and techniques in handling equipment and machinery that may not be available in the university has led to the SIWES program. In imparting the basic skills in engineering, there is a need to provide students the opportunity to apply the theoretical principles taught in class room to real job situation. Hence this work report gives in details my experience in the 2010/11 SIWES for 400 level Mechanical Engineering students. This report starts with a brief introduction and description of LNG, LPG and Natural gas liquids production from Wellhead (feed gas) to shipment. It gives an overview of the production processes of these products, however, focused in dept and details, on the application of industrial instrumentation and control systems for the processes described in the production of NLNG products. The first two chapters gives a precise overview of the processes while the remaining chapters reports the Instrumentation, control systems and equipment such as flowmeters, transmitters, wide range of valves, actuators etc. Each section is accompanied by case scenarios and Learning Activities carried out by the reporter during the 6 months SIWES. Hence, while this report is exhaustive, it also captures on the Job experience through Learning activities and where possible relation of practical experience with class room mechanical courses. Detailed Explanations have been given with adequate diagrams both within and at the appendix. Useful Recommendations to students, universities and on power generation haves also been presented at the end of this report. Materials have been source from text books, students log book, company manuals and learning resources. A list of reference has been well outlined at the end of this report.

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CONTENTS
Title Page Letter of Submission Acknowledgement Abstract Contents List of Tables and Figures List of Learning Activities Carried out in NLNG gas plant Chapter 1: 1.1 1.2 1.3 INTRODUCTION I II III IV V IX XII 1 1 3 4
5

Nigeria LNG Limited (NLNG) SIWES in Nigeria LNG Limited Production and Processing terminologies.

Chapter 2: NATURAL GAS PRODUCTION, FROM WELL HEAD TO PROCESSING PLANTS

2.1

Liquefaction Process of Natural Gas, the NLNG model

6 7 7 8 8 9 9 9 10 14 14

2.1.1 Trunkline Terminal 2.1.2 Plant Pressure Control Station (PPCS) 2.1.3 Acid Gas Removal Unit 2.1.4 Dehydration Unit 2.1.5 Mercury Removal Unit 2.1.6 Liquefaction Unit Propane Refrigerant System Mixed Component Refrigerant (MCR or MR) System 2.2 2.3 Utility Operations Preview of the Next Chapters INSTRUMENTATION EQUIPMENTS AND SAFETY INSTRUMENTED SYSTEMS IN LNG PRODUCTION 3.1 3.2 Key terms in Industrial Instrumentation and Process control Instrumentation Equipments

Chapter 3

15 15 16 17 18 19 20 21 22 24 25 V

3.2.1 Differential pressure transmitters 3.2.2 Inferring gas and liquid flow with DP Transmitter ACTIVITY 1: ACTIVITY 2: Calibrating a DP Transmitter Used as Flow Meter Corrective Maintenance on a Vortex Flowmeter 3.2.3 Vortex Flowmeters 3.2.4 Inferring liquid level (with the DP transmitter) 3.2.5 Pressure Sensor Accessories 3.2.6 Thermocouples

ACTIVITY 3: Replacing & Simulation of Thermocouple Transmitter on Hot Gas Bypass Line

26

3.3

Instruments and Equipment Maintenance

26 27 28 29 30 31 32 32 34 35 36 37 37 38 39 40 40 41 43 44 44 46 47 47 47 47 48 49 49 50 51
51 51 52

3.3.1 Instrument calibration 3.3.2 Calibration procedures ACTIVITY 4: ACTIVITY 5 3.4 3.5 3.6 3.7 Calibration of a Analog Linear Pressure Transmitter Calibration of a Smart Pressure Transmitter

Instrument connections Instrumentation Documents Instrument Identification Tags Safety Instrumented Systems (SIS)

3.7.1 Layers of Protection 3.7.2 Components of Safety Instrumented Systems (SIS) 3.8 Instrumented Protective Function (IPF) 3.8.1 Instruments Proof Test 3.8.2 Methods of Proof Testing 3.8.3 General Safety Records and Measures in the LNG Industry PROCESS CONTROL AND CONTROL VALVES IN LNG PRODUCTION

Chapter 4 4.1 4.2 4.3

Automatic Control Loops Process Control Loops Control Loop Equipments (Components of Control Loops)

4.3.1 Controllers 4.3.2 Distributed Control Systems in NLNG gas plant 4.4 4.5 Control Valves Valve types Maintenance Work Carried Out on Butterfly Valves in NLNG

4.5.1 Butterfly Valve ACTIVITY 6: 6.1 6.2 6.3. Disassembled and Replaced the Lining of a butterfly valves Stroke and Functionality Test carried out on a 72 inch butterfly valve Seat and Liner Replacement for a 32 inch butterfly valve

4.5.2 Ball Valve 4.5.3 Globe Valve ACTIVITY 7:

7.1 7.2 7.3

Globe Valve Repair jobs done during training in NLNG gas plant

Maintenance work carried out on 24 inch Globe valve IN NLNG gas plant Maintenance work carried out on 16 inch Globe valve IN NLNG gas plant Maintenance work carried out on a 2 inch Valtek Globe control valve

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4.6

Control Valve Accessories/Special Valves

54

4.6.1 Positioners ACTIVITY 8 ACTIVITY 9 Functionality Test for a Neles, Positioner in NLNG Workshop Repair of a BIFFI Actuator Limit switch on a Butterfly Valve

54 55 56 56 56 57 58 58 59 59 60 60 61 62 62 63 64 64 65 65 66 66 67 68 84 84 84 85 86 87 88 NLNG PLANT PICTURES, SYMBOLS AND DIAGRAMS VII 90

4.6.2 Limit Switch/Proximitors 4.6.3 Solenoid Valves (SOV) ACTIVITY 10: Overhauling Maxseal ICON4 3-way Solenoid valve 4.6.4 Supply Pressure Regulators ACTIVITY 11: Overhauling and Installing a Bellofram Type 51 Regulator 4.6.5 Relief Valves (RVs) and Pilot operated RVs ACTIVITY 12: Relief valve Set point adjusting and calibration in NLNG gas plant 4.6.6 Flow Boasters and Poppet Valves ACTIVITY 13 Adjusting Flow Booster Operation on an Anti-surge valve

ACTIVITY 14: Overhauling and Installation of a Ross Poppet valve 4.6.7 Quick Exhaust Valve ACTIVITY 15: Replacing a Quick Exhaust Valve on a Control Valve 4.6.8 Switching Valve Regulators 4.7 Valve Actuator 4.7.1 Pneumatic Diaphragm Actuators 4.7.2 Piston Actuators 4.7.3 Handwheel Actuator 4.8 4.9 4.10 Valve failure mode Control Process Alarm Monitoring Trip Systems CONCLUSION AND RECOMMENDATIONS 4.8.1 Fail Open and Fail Close (Air to Close and Air to Open Valve)

Chapter 5 5.1

Recommendations

5.1.2 Recommendations to Engineering Students 5.1.3 Recommendations to Engineering department 5.1.4 Recommendation for Power Generation in Nigeria 5.2 Conclusion

REFERENCE APPENDIX

LIST OF LEARNING ACTIVITIES These are practical maintenance, troubleshooting and repair activities done during training sited in words and photographs to buttress this report. ACTIVITY 1: ACTIVITY 2: ACTIVITY3: ACTIVITY 4 ACTIVITY 5 ACTIVITY 6: 6.1 6.2 6.3. ACTIVITY 7:
7.1 7.2 7.3

Calibrating a DP Transmitter Used as Flow Meter Corrective Maintenance on a Vortex Flowmeter

Replacing & Simulation of Thermocouple Transmitter on Hot Gas Bypass Line

19 21
26

Calibration of a Analog Linear Pressure Transmitter Calibration of a Smart Pressure Transmitter Maintenance Work Carried Out on Butterfly Valves in NLNG Disassembled and Replaced the Lining of a butterfly valves Stroke and Functionality Test carried out on a 72 inch butterfly valve Seat and Liner Replacement for a 32 inch butterfly valve Globe Valve Repair jobs carried during training in NLNG gas plant
Maintenance work carried out on 24 inch Globe valve IN NLNG gas plant Maintenance work carried out on 16 inch Globe valve IN NLNG gas plant Maintenance work carried out on a 2 inch Valtek Globe control valve Functionality Test for a Neles, Model ND9200H Positioner in NLNG Workshop

29 30 47 47 48 49 51
51 51 52

ACTIVITY 8 ACTIVITY 9

55 56 57 58 59 60 62 62

Repair of a BIFFI Actuator Limit switch on a Butterfly Valve

ACTIVITY 10: Overhauling Maxseal ICON4 3-way Solenoid valve. ACTIVITY 11: Overhauling and Installing a Bellofram Type 51 Regulator in NLNG gas plant ACTIVITY 12: Relief and Pilot valve Set point adjusting and calibration in NLNG gas plant ACTIVITY 13 Adjusting Flow Booster Operation on an Anti-surge valve ACTIVITY 14: Overhauling and Installation of a Ross Poppet valve ACTIVITY 15: Replacing a Quick Exhaust Valve on a Control Valve

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LIST OF TABLES AND FIGURES Fig. 2.1: Fig. 2.2: Fig. 2.3: Fig. 2.4: Fig 2.5: Fig. 2.6: Fig 2.7: Fig. 2.8: Fig. 2.9: Composition of Natural gas compare to Liquefied Natural gas Natural Gas Value Chain Constituents of LPG, NGLs and LNG Different sectors in Natural gas production LNG production Process flow chart NLNG Trunkline Terminal Unit NLNG Plant Pressure Control Station Acid Gas Removal Unit showing Absorber column and Incinerator Dehydration Unit 5 5 6 6 7 7 7 8 9 9 10 11 11 12 13 13 15 17 18 19 20 21 22 22 23 23 24 24 25 25 26 28 IX

Fig. 2.10: Mercury Removal Process Fig. 2.11: LNG Refrigeration Circuit Fig. 2.12: External and Internal view of the Main Cryogenic Heat Exchanger and Fig. 2.13: MCHE Flow Schematic Representation Fig. 2.14: Fractionation Unit showing series of distillation Columns Fig. 2.15: LNG Storage and Loading to LNG Carriers Fig. 2.16: One of the 24 dedicated NLNG ships Fig. 3.1: Fig. 3.2: Fig. 3.3: Fig. 3.4: Fig. 3.5: Fig. 3.6: Fig. 3.7: Fig. 3.8: Fig. 3.9: Fig. 3.10 Fig.3.11: Fig. 3.13: Fig.3.15: Fig. 3.17 Instrumentation Flow chart DP Transmitter Construction and the Rosemount Model used in NLNG Inferring Fluid flow with DP transmitter Connections for Calibration of DP transmitter on a Calibration Bench Vortex flowmeter with views showing the shedder bar and the Converter Maintenance Service carried out on a Yokogawa Vortex Flow transmitter Vortex flowmeter assembly Calibration Table for Vortex flowmeter DP Transmitter measuring positive difference between the vessel and atmosphere and Level on Liquid storage vessel (pressurized) DP transmitter measuring the height of colored water inside a plastic tube Valve manifold in operation and out-service Thermowell in use with a temperature gauge and a Thermowell Up-tests and Down-tests Fig. 3.12: Compensated wet leg and Remote seal Capillary leg type Transmitter Fig. 3.14: Thermocouple types and temperature ranges Fig. 3.16: Diagram to Illustrate Field Simulation on the Temperature Transmitters

Calibration Table for DP transmitter used for Flow Indication and Alarm (FIA) 25

Fig.3.18: Fig.3.19:

Bench Hookup for Calibrating Analog Pressure transmitter Calibration Table for Analog Pressure Transmitter

29 30 30 30 31 32 33 33 33 35 36 37 40 41 41 42 42 45 45 45 48 48 49 49 50 51 52 52 53 53 54 55 55 55 55

Fig. 3.20: Calibration Table for Smart Pressure Transmitter Fig. 3.21: Calibrating a Rosemount Smart Transmitter Fig. 3.22: A Rosemount magnetic flowmeter installed with 4-bolt flange fittings Fig. 3.23: Compression-style fitting of Impulse tube line Fig. 3.24: Process Flow Diagram Fig. 3.25: Process and Instrument Diagrams Fig. 3.26: Loop diagrams Fig. 3.27: Layers of Protection Fig. 3.28: Components of s Safety Instrumented System Fig. 3.29: Sensors and valves (left) and Programmable Logic Controller (Right) Fig. 4.1: Fig. 4.2: Fig. 4.3: Fig. 4.4: Fig. 4.5: Fig. 4.6: Fig. 4.7: Fig. 4.8: Fig. 4.9: Fig.4.10: Diagrammatic representation automatic control Open Loop Control System Closed Loop Control System Feedback control loop illustration Feedforward Control and Schematic diagram of feedforward control Typical Analog-based DCS Digital/PLC Controllers NLNG Central Control Room showing DCS Replaced Butterfly valve Lining 72 inch butterfly valve with disk stuck stroked and left open

Fig. 4.11: Replacing a 32 inch Butterfly valve rubber liner Fig. 4.12: Ball valve Fig. 4.13: A photograph of a cut-away and sectional view of Globe control valves Fig. 4.14: Assembled Globe valve (left) and new packings fitted in the valve Fig. 4.15 Actuator and Accessories connection for a globe valve Fig. 4.16: Body and Seat Test done on NLNG Test Unit for Shut-off valves Fig. 4.17: Photograph showing different stages of the 2 inch globe valve overhauling Fig. 4.18: Cross section view showing all parts of a valtek control valve used in NINLG Fig. 4.19: Exploded view of actuator assembly (air-to-close or open spring position) Fig. 4.20: A Simplified Valve Positioner Installation Fig. 4.21: Valtek Logix positioner Fig. 4.22: Calibration table for positioner Fig. 4.23: Functionality test done on a Positioner in NLNG Instrument workshop X

Fig. 4.24: Faulty Limit Switch disassembled and repaired in NLNG gas plant Fig. 4.25: Schematic of SOV in line with a control valve and pictorial illustration Fig. 4.26: Overhauling of a Maxseal spool type Solenoid valve in NLNG workshop Fig. 4.27: Sectioned and disassembled views of overhauled air-filter regulators Fig. 4.28: Schematic diagram of Pilot Operated relief valves Fig. 4.29: Schematic and Test set-up for Relief valves on Test bench Fig. 4.30: Valtek Flow Booster in use in NLNG gas plant Fig. 4.31: Flow Booster Installation Schematic on the Cylinder Actuator Fig. 4.32: Disassembled Ross poppet valve for overhauling and installation Fig. 4.33: New Quick exhaust valve re-installed on a Tight shut off valve Fig. 4.34: Sectional View and photograph of Fisher 164A Switching Valve worked on Fig. 4.35: Pressure Control valve with pneumatic actuator worked on in NLNG plant Fig.4.36: Schematic representation of double acting pneumatic piston actuators Fig. 4.37: Schematic of piston pneumatic actuator position for valve Failure Mode Fig. 4.38: DCS Display panel (Foxboro) Fig. 4.39: Schematic diagram of a compressor safeguarding system Fig. 4.40: Control Scheme for a Binary distillation Column Fig. 5.1: Relevance of SIWES in NLNG gas plant to Mechanical Engineering courses

56 57 57 59 60 60 60 61 62 63 63 65 66 67 68 69 69 71

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