Process Air Compressor Knockout Replacement Presented By: Saud Saleem Designation: App. Engineer(Mech)

Overview: Introduction Project Handling Cost estimation Problem Area

Introduction: Knockout? A knockout drum is used whenever a process requires droplets to be separated from a vapor stream. T1 Inter Cooler Condensate causing Corrosion Condensate Removed and Drained Out Main Suction T2 T3 Where T2 > T1 Where T3 < T2 Condensed Vapors Knockout Drum

Working Principle of Vane Pack: Flow Vane Pack

Introduction: Background: Existing knockouts were replaced in 1987. Upon inspection in TA-07, heavy corrosion and cracks was observed on impellers. PECO (Original Vendor) informed that knockouts are undersized

Project Handling: Steps taken sequentially Planning and Scheduling Engineering Procurement Execution

Project Handling: PLANNING & SCHEDULING:

Percentage scope of each section: Project Handling: Percentage scope of each section:

Cost Estimation: Rs. 60.4 MM Rs.17.0 MM Rs. 1.54 MM Rs. 1.39 MM Cost Basis 30-Sep-2007 Foreign Component Cost of Internals € 90,178 Cost of Instrumentation € 100,000 Local Component Cost of Vessels Rs. 60.4 MM Cost of piping+ Civil works Rs.17.0 MM Custom Duty @ 5% Rs. 1.54 MM Sales Tax Rs. 1.39 MM Cost of Construction Rs. 12.75 MM Total Local Component Rs. 93.1 MM (€ 1.1 MM) Contingency @ 10% € 0.13 MM Total Cost In Euro € 1.43 MM

Project Handling: Engineering: Process Design Mechanical Design Civil Design

Project Handling: Procurement: Mechanical equipments: Instrumentation: Knockout vessels Internals Glass Level Gauges Flexibility bellows Hanger supports Instrumentation: Level transmitter Level Controller Control valves

Mechanical Equipment: Upstream Gas Distribution Plate & YORKMESHTM Agglomerater FLEXICHEVRON Vane Pack Tower Attachements Knockout Vessel

Comparison of total procurement by each section:

Project Handling: Procurement Status: Material procured Internals Material under procurement Knockout vessels Pending materials Expansion bellows Control valves Glass Level Gauges Spring hanger support

Project Handling: Execution: Mechanical Installation of New Interconnecting Piping Re-routing of existing piping Erection of KO vessel Installation of Internals Installation Of Glass Level Gauges

C-111A C-109A AVAILABLE SPACE FOR C-111A NEW C-111A NEW C-108A NOZZLE SIZE INCREASED NEW PIPING Ø 12” C-109A

Project Handling: Execution: E&I Installation Of Control Valves Installation Of Level Transmitters Installation Of Switches

Project Handling: Execution: Civil Structure Foundation

Problem Areas: Procurement of knock out vessels. Procurement of control valves. Procurement of Flexible bellows. Project time line.

Thank You

Questions?