technical specification for mechanical integration of
TRANSCRIPT
Technical specification for mechanical integration of chiller loop and skid
for sCO2 rig components
I. Scope of work
The tender broadly includes the following:
1. Fabrication and supply of a portable skid for mounting the components of the CO2 loop in
accordance with ASME B 31 standards.
2. The complete mechanical integration of the chiller system with the CO2 loop in accordance with
ASME 31.3 standards
II. Technical specifications
This document provides the technical specification required for successful integration of the
components present in the chiller loop, the CO2 cylinder of the sCO2 loop and skid for sCO2 pump,
precooler, condenser& pressure vessel. Below tables provide the detail requirements of this tender
which need to be quoted/provided by the bidders/vendors.
Sr. No. Spec Remark
1
All the hardware to be procured/fabricated by vendor should be
capable of sustaining high pressure of 3100 psi and operating
temperature of min -100 C and max of 50
0 C
2
All the components should meet the ASME standard for design,
material, assembly, operation and integration, specifically piping
(including pipe bends), valves, fittings, joints, etc. should meet ASME B31 standard
3
All the integration hardware when assembled with the rig components
should provide leak-proof working and vendor should demonstrate the leak test as per ASME 31.3
4 The skid should be capable of taking 2 times the weight of all the
components and the transient loading due to operation
5
The skid should be designed to withstand the vibrations coming from
rotating component (sCO2 pump) without failure for continuous daylong
operation of the plant
6
The skid should be portable and should have leveling casters with
required locking mechanism so that it should not vibrate or move during the operation
7
Skid should have sufficient extra space (minimum of 300 mm) between
all the components to provide accessibility for connection, inspection and repair
8
Skid should have space to put test coupon of 600 mm by 600 mm and
other accessories like sensors, back pressure relief valves, electrical circuits, etc. Refer to the CO2 loop schematic
9
The skid is expected to have slotted holes to assemble the components
tightly. And it should have necessary connections/connectors/hooks for
packaging, transportation and lifting to avoid damage to components and to the skid itself
10 The skid components should be painted to have corrosion resistance properties
11
All the components should be tested before integration. Perform
calibration & provide test certificate for thermal sensors. Comply with
ASME B31 standard wherever applicable
12 Vendor should demonstrate the working of all the components by
working electrical connection through DAQ and control panel
13
Vendor is also expected to demonstrate emergency shutdown of the
circuit and its effect on the mechanical integration components and skid
14 All the components should at least have 1 year warranty
15 All the components (wherever possible) should be made of Stainless Steel only
16 Vendor shall have the manufacturing facility (steel cutting, welding,
testing etc) required for the execution of the project. (Proof of having
the manufacturing facility to be attached)
17
Vendor must have experience and must provide the proof of executing
super critical CO2 system with the operating pressure of 3100 psi and
operating temperature of min -100 C and max of 50
0 C
18 All the components should be well insulated to avoid any heat transfer
between the system and the surrounding.
III. Material/components Provided by IITM:
SR. No. Items Quantity
1 Precooler 1
2 Condensor 1
3 Chiller 1
4 CO2 cylinder 2
5 sCO2 pump with motor 1
6 Test coupon 1
7 Pressure vessel 1
Technical Specifications for materials supplied by IIT Madras
1. Precooler: Heat Exchanger of 10KW
The heat exchanger unit should be capable of handling the hot fluid of the pressure up to 200 bar and at a
maximum flow rate of 0.1 kg/s and at a maximum inlet temperature of 100o C. The heat exchanger
is expected to behave like an unit to cool of super critical CO2. The heat exchanger shall accept water /
Refrigerant / MEG as one of the cold fluids. The cold fluid operating pressure shall not exceed 4 bar and
maximum operating temperature of 400 C. The heat exchanger unit can be made of SS316L meeting
ASME standards of 200 bar pressure application on the side while 4 bar maximum pressure on the cold
side. The unit can be diffusion bonded multiple channel type compact heat exchanger type specially built
for super critical CO2 application purpose. The Unit shall be specifically meant for handling gaseous CO2 or
liquid CO2 or super critical CO2 as hot fluid. The cold and hot fluid ports must meet standard BSP flange
connections to be able connect a 1-inch pipeline in the layout. The heat exchanger is expected to have an
outer insulation to minimize the ambient temperature effects in the closed operation. The construction of
the HX should comply the ASME design code for meeting the maximum operating pressure and
temperature requirements. The units should have been pretested for any leak using the standard water
leak test procedures.
Thermal requirements
Parameter Hot Side Cold Side
Heat load 10 KW @
max flow
10 KW @
max flow
Inlet Temperature ( C ) 100 10
Outlet Temperature ( C ) 50 46.8
Design Temperature Max 2000C 50
0 C
Flow Requirements
Parameter Hot Side Cold Side
Pressure Drop < 0.5 bar < 0.5
Inlet Pressure 200 bar Max 4 bar Max
Inlet Flow (kg/s) 0.2 0.5
Mechanical requirements
Parameter Hot Side Cold Side
Material (Nozzle, Flange, Header &
Pipe)
SS316L SS316L
Welding No No
Bonding Diffusion Diffusion
Inlet Flange Size
Requirement
To connect to a 1- inch SS
pipeline
To connect to a 1-inch SS pipeline
Outlet Flange Size
Requirement
To connect to a 1- inch SS
pipeline
To connect to a 1-inch SS pipeline
Additional Requirements
Parameter
Insulation Yes for outside surface of the HX
Inbuilt Strainer for
both fluids Yes
Fouling Allowance Not needed
Fluid
Properties for Sizing
the HX
Use Refprop of NIST database (https://www.nist.gov/srd/refprop)
2. Cooling Heat Exchanger of 10 KW Rated / Condenser
The heat exchanger unit should be capable of handling the hot fluid of the pressure up to 200 bar and at a
maximum flow rate of 0.1 kg/s and at a maximum inlet temperature of 40o C.The heat exchanger is
expected to behave like a condenser unit to cool of liquid/gaseous CO2 so that it turns in to complete
liquid state before being pressurized to super critical state. The working hot fluid is CO2from the standard
gas bottle. The heat exchanger shall accept MEG as one of the cold fluids. The cold fluid operating
pressure shall not exceed 4 bar and maximum operating temperature of 400 C. The heat exchanger unit
can be made of SS316L meeting ASME standards of 200 bar pressure application on the side while 4 bar
maximum pressure on the cold side. The unit can be diffusion bonded multiple channel type compact
heat exchanger type specially built for super critical CO2 application purpose. The Unit shall be
specifically meant for handling gaseous CO2 or liquid CO2 or super critical CO2 as hot fluid. The cold and
hot fluid ports must meet standard BSP flange connections to be able connect a 1-inchpipeline in the
layout. The heat exchanger is expected to have an outer insulation to minimize the ambient temperature
effects in the closed operation. The construction of the HX should comply the ASME design code for
meeting the maximum operating pressure and temperature requirements. The units should have been
pretested for any leak using the standard water leak test procedures.
Thermal requirements
Parameter Hot Side Cold Side
Heat load ~10 KW @
max flow
~10 KW @ max
flow
Inlet Temperature ( C ) 40 5
Outlet Temperature ( C ) <10 xx
Design TemperatureMax 2000C 50
0 C
Flow Requirements
Parameter Hot Side Cold Side
Pressure Drop < 0.25 bar < 0.3
Inlet Pressure 200 bar Max 4 bar Max
Inlet Flow (kg/s) 0.33 0.5
Mechanical Requirements
Mecha Parameter Hot Side Cold Side
Material (Nozzle, Flange, Header &
Pipe)
SS316L SS316L
Welding No No
Bonding Diffusion Diffusion
Inlet Flange Size
Requirement
To connect to a 1- inch SS
pipeline
To connect to a 1-inch SS
pipeline
Outlet Flange Size
Requirement
To connect to a 1- inch SS
pipeline
To connect to a 1-inch SS
pipeline
Additional Requirements
Parameter
Insulation Yes for outside surface of the HX
Inbuilt
Strainer for
both fluids
Yes
Fouling Allowance Not needed
Fluid Properties for
Sizing the HX
Use Refprop of NIST database (https://www.nist.gov/srd/refprop)
3. Chiller Unit of 20KW
The chiller unit shall be expected to provide coolant at a minimum temperature of -100 C and to a
maximum temperature of 400 C. The Chiller should be a closed loop integrated system that works
automatically on a digitally controlled set point temperature at a required mass flow of the coolant.
The chiller unit is expected to have easily accessible digital panel to control the flow and temperature
requirement. There should be additional options to be able control the unit operation through a PC as
well. The coolant ports should meet up with BSP piping standards. The chiller unit shall be a quiet unit
adhering to the sound level up to 60 DBA. The unit shall be expected to have zero leakage of the coolant
and if happens should have an automatic tripping system.
Operational Specifications
S.No. Description
1. Cooling Capacity at a minimum coolant temperature 20 KW
2. Minimum Temperature -10oC
3. Maximum Temperature 400 C
4. Coolant Flow 0 to 40 GPM at a pressure of 4 bar
5. Temperature Stability Within + 0.10 C
6. Control Automatic
7. Condenser Type Air or Water Cooled
8. Coolant Type MEG
9. Nominal Coolant Connection Ports Inlet 1 inch BSP standard connection port
10. Nominal Coolant Connection Ports Outlet 1 inch BSP standard connection port
11. Automatic Tripping Yes
12. Control System Integrated with digital display
13. Communication RS232/RS485
14. Operation Mode Through PC as well as on the Panel
15. Coolant Refilling Automatic
16. Tripping system Automatic tripping for coolant leakage
Electrical Specifications
S.No. Description
1. Voltage 3 Phase – 220- 240 V
2. Power Up to 20 KW
3. Current 10 - 15 A
4. Frequency 50-60 Hz
4. CO2 cylinder
CO2 Gas (HSN CODE – 2811 2190) – 2.0 Grade in 47ltr W.C
Carbon Steel cylinder confirms to IS 7285 fitted with RH threaded Valve confirms to IS 3224. Filling
pressure – 60 kg/cm2
Gas capacity – 31 kg, Gas Purity – 99%
5. High Pressure sCO2 Pump with motor
The pump is expected to deliver super critical CO2 at a pressure of 200 bar with no pulsation in the flow.
The expected maximum mass flow outlet from the pump is 0.05 kg/s at a maximum discharge pressure of
200 bar. The pump should have the in-built cooling system to protect from overheating issues. The pump
needs to have full protections against burst protection with appropriate burst protection disc and
pressure regulating valves. The motor associated with the pump needs to be electrically driven with the
capacity of up to 30 KW rating. The electrical motor shall have a small fan to electrically cool it.
The pump should have noise levels less than 60 DB, if exceeds, the system needs to have an appropriate
noise protection cabinet. The pump shall have required protection for handling back pressures and
Cavitation. The inlet and exit ports of the pump shall meet the standard BSP norms. The pump shall be
quoted along with the back-pressure regulator to regulate the feed pressure to the pump.The pump shall
be associated with adequate control systems to be built as auxiliary units and shall be quoted along with
the quotation. The expectation is to deliver the flow at a given set point flow and discharge pressure
without any flow fluctuations using Feedback loop control system that uses PID controller along with the
Coriolis flow meter. The motor VFD unit should be coupled with the PID controller as well to control the
flow appropriately. The motor shall be controlled from the location outside the lab through a personal
computer. Hence the final system shall encompass required software interface to be used from a lab PC.
Detailed technical specifications for the requirements are listed below.
Operational Specifications
Description
Mass flow 0 – 0.05 kg/s or 0 to 180 kg/h
Discharge Pressure Max 200 bar
Discharge Temp (C) 70 degree C
Power Rating 30 KW
Operating Mode Set Pressure and Mass Flow Control Modes
Control System Yes. Include accessories for a fully automated PID control system to achieve steady mass
flow at a set pressure
Pump Cooling In built lubricant cooling system
Electrical Motor 30 KW
Electrical Motor Cooling Fan 2 HP blower fan for cooling the
motor
Inlet Pressure Up to 60 bar
Communication RS232/RS485
Mode of Operation Continuous & Closed Loop System
VFD Suitable for CO2 pump at the specified power rating of 30
KW
Fluid Condition at the Pump Inlet Liquid CO2 at 100 C and 50 to 60 bar pressure
Back Pressure Regulation Valve Rated up to 400 bar
Pump Base Frame Made of Mild Steel
Motor to Pump Shaft Coupling Yes
Burst Protection Disc (Explosion protection) Yes
Pulsation Damper Yes
Controller (Mass flow and Discharge pressure based set point)
PID controller unit for feed
back from the flow meter to the VFD of the motor
Software Interface Software to be installed in the PC to control the pump
Back pressure regulator One unit at the inlet of the pump to regulate the back
pressure with range of 300 bar
Electrical Specifications
Description
Voltage 3 Phase – 220- 240 V
Power Up to 30 KW
Current 10 - 15 A
Frequency 50 – 60 Hz
6. Test coupon
As per the size provide in the tender specifications sheet.
7. Pressure vessel
The pressure vessel is expected to store liquid CO2 at a maximum pressure of 100 bar and at a minimum
temperature of 50 C. The purpose of this vessel is expected to act a phase separator to be able to supply
liquid CO2 to the downstream pump. it can expect a maximum withdrawal liquid flowrate of 0.05kg/s
while there might be a 30% volume fraction of uncondensed vapour of CO2 might exist in the feed line.
The unit is intended to supply only liquid CO2 to the downstream high pressure pump while the input to
the unit is coming from a condenser. The output line shall be from the bottom of the vessel. The unit
is expected to have a rupture disc for burst protection and a self-regulating valve for maintaining the
pressure within 100bar. It should have the provision for venting CO2 out during the restart operation for
depressurizing the system. The unit shall have digital level sensor whose output should be monitored
through the system. The vessel should also have the pressure and temperature sensors embedded in it
whose output also must be data logged. The vessel should have proper insulation to minimize the losses
to ambient. The maximum ambient temperature expected is 420 C. The make shall be of SS316L material
complying with ASME codes of standard pressure vessel manufacturing.
System Operational specifications
Parameter
Pressure 100 bar
Temperature Min of5 deg C
Equipment Make SS316 L
Pressure Sensor In-built range 150 bar
Pressure Safety Valve 100 bar capacity
Temperature RTD + 0.1 deg C accuracy
Liquid Level Digital with RS232/485 connection
Self- Regulating Valve Made of SS316Lbody for maximum of 300 bar pressure
Vapour volume Maximum 30% of
volume
the liquid
Total Vessel
Capacity
To be designed as
separator by Vendor
a phase
Inlet line Feed 1” inch BSP (above
level)
the liquid
Output Line 1” inch BSP (from the bottom)
Drain Line 1” inch BSP
Insulation Outer walls to be covered to
maintain temperature 5 deg C
Sight Glass No
Wall Thickness Meeting ASME codes
Liquid Residence Time 15 mins
Withdrawal liquid
rate
0.05 kg/s
Fluid Properties Use Refprop of NIST database
(https://www.nist.gov/srd/refprop)
Electrical Requirement
Voltage 220 to 240 V
Current 15 amps / 3 Phase supply
IV. Material/components to be procured by fabricator/vendor:
SR. No. Items Quantity
1 Manual needle type valve for CO2 cylinder discharge (50-70 bar) 1
2 Pneumatic operated on-off automated valve (fail-open type) 1
3 Manual needle type Valves 2
4 Thermocouple temparature sensor (RTD temperature range-100 C to50
0 C) 4
5 3/8'' tube 20m
6 Male connecter 3/8'' for HX 4
7 Tee connector 3/8" 4
8 3/8'' union 20
9 3/8'' Nut and ferrule 15
10
Skid for Pump (minimum size: LXBXH (height from ground) : 2000 mm X 900 mm X 200 mm)
1 unit
11
Noise Arrester for Pump to restrict noise level to less than 60 dbs
(perforated acoustic cover; galvanized sheet metal with adequate foam
packing; minimum size: 2100 mm (L) x 1000 mm (B) x 700 mm (H)
1 unit
12
Skid for assembling pressure vessel, condenser and precooler (minimum size: 2000 mm (L) x 2400 mm (B) x 1000 mm (height from ground)
1 unit
V. Mechanical Integration Schematic:
1. sCO2 test loop with only key components:
2. Chiller Loop:
1. Chiller Circuit(MEG fluid)
a. 21-24 line
i. Pipe connecting chiller exit to condenser inlet
ii. Pipe connecting condenser exit to chiller inlet
iii. Both the pipes require a temperature sensor (T5&T6)each.
b. 21-18 line
i. Pipe connecting chiller to pre-cooler inlet with temp sensor (T7) in b/w
ii. Pipe connecting precooler exit to chiller with temp sensor (T5) in b/w
Use engineering judgments and calculations whenever required such that the components withstand
the operating condition of 3100 psi pressure and temperature of min -100 C and max of 50
0 C.
VI. Training:
Vendor shall demonstrate to the IIT M staff the operation of the complete system via a
working DAQ and control system. The vendor shall also provide a complete operating manual
outlining the steps in operation and procedures for emergency shutdown.
For technical clarifications, contact
Dr. Anandu Surendran
Mob: 7550160214
Technical compliance sheet Vendors are required to submit their bids along with this duly filled technical compliance sheet
Sr.No. Specification/requirements Complied/Not Complied
Catalogue Page No /reference
Remarks (if any)
1
All the hardware to be procured/fabricated by vendor should be capable of sustaining high pressure of 3100psi and operating temperature of min-10
0C and max of 50
0C
2
All the components should meet the ASME
standard for design, material, assembly,
operation and integration, specifically
piping(including pipe bends), valves, fittings,
joints, etc. should meet ASMEB31 standard
3
All the integration hardware when assembled
with the rig components should provide leak-
proof working and vendor should demonstrate
the leak test as per ASME31.3
4 The skid should be capable of taking 2 times the
weight of all the components and the transient
loading due to operation
5
The skid should be designed to withstand the vibrations coming from
Rotating component(sCO2pump)without failure
for continuous day long operation of the plant
6
The skid should be portable and should have
leveling casters with required locking mechanism
so that it should not vibrate or move during the
operation
7
Skid should have sufficient extra space (minimum
of 300mm) between all the components to
provide accessibility for connection, inspection And repair
8
Skid should haves pace to put test coupon of
600mm by 600mm and other accessories like
sensors, back pressure relief valves, electrical circuits, etc. Refer to the CO2 loop schematic
9
The skid is expected to have slotted holes to
assemble the components tightly. And it should
have necessary connections/connectors/hooks for
packaging, transportation and lifting to avoid
damage to Components and to the skid itself
10 The skid components should be painted to have corrosion resistance properties
11
All the components should be tested before integration. Perform
Calibration & provide test certificate for thermal
sensors. Comply with ASMEB31 standard
wherever applicable
12 Vendor should demonstrate the working of all the
components by working electrical connection
through DAQ and control panel
13
Vendor is also expected to demonstrate emergency shutdown of the
Circuit and its effect on the mechanical
integration of components and skid
14 All the components should at least have 1 year warranty
15 All the components(wherever possible) should be made of Stainless Steel only
16 Vendor shall have the manufacturing facility (steel
cutting, welding, testing etc)required for the
execution of the project. (Proof of having the
manufacturing facility to be attached)
17
Vendor must have experience and must provide the proof of executing
Supercritical CO2 system with the operating
pressure of 3100 psi and operating temperature
of min-100C and maxof50
0C
18 All the components should be well insulated to
avoid any heat transfer between the system and
the surrounding.