technical specification for mechanical integration of sco2

Technical specification for mechanical integration of sCO2 loop

I. Scope of work

The tender broadly includes the following:

1. Mechanical integration of the components of the CO2 loop in accordance with ASME B 31

standards.

2. Integration of control systems and software for the CO2 test rig

Detailed specifications regarding the work are provided in the tender s specification sheet.

II. Technical Specifications

This section provides the technical specification required for successful integration of the

components present in the sCO2 loop (shown in schematic).Below tables provide the detail

requirements of this tender which need to be quoted/provided by the bidders/vendors.

Sr. No. Specifications

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 50 C and max of 1250 C along with sustaining vibrations of the pumps or other rotating parts of the circuit

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. Vendor should demonstrate the leak test as per ASME 31.3 with CO2 as working fluid and at a pressure of 4650 psi & 125 ˚C

4 All the components should be tested before integration. Perform calibration & provide test certificate for pressure transmitter, flow meter and thermal sensors. Comply with ASME B31 standard wherever applicable

5 Vendor should connect all the vent lines through manifold or some other means to provide a single port to connect to exhaust/atmosphere

6 Vendor should demonstrate the working of all the components in the loop by working electrical connection through DAQ and control panel

7 Vendor should demonstrate an emergency shutdown of the circuit and its effect on the mechanical integration components

8 All the components should at least have 1 year warranty

9 All the components (wherever applicable) should be made of Stainless Steel (grade 304) only for handling corrosive and oxidative nature of the plant operation

10 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)

11 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 50˚ C and max of 125˚ C

12 The components between sCO2 pump and test coupon should be well insulated to avoid any heat transfer between the system and the surrounding.

13

Tube connecting different components should be seamless. Tube schedule must be selected according to ASME Tube Schedule specification for the pressure of 4650 psi & 125 ˚C. Vendor should provide the rate of the tube for bulk quantity as mentioned in the table below and per meter rate for extra material

14 The accuracy of temperature and pressure sensors should be within 1% of the full scale value. Calibration certificates to be provided by the vendor for the sensors

III. Material/components provided by IITM

SR. No. Material/components Provided by IITM Quantity

1 Precooler 1

2 Condensor 1

3 Pressure vessel 1

4 CO2 cylinder 2

5 sCO2 pump with motor 1

6 Automated back pressure regulator (Pneumatic operated)

1

7 Coriolis flow meter 2

8 Test coupon 1

Detailed 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 500 C

Flow Requirements


Pressure Drop < 0.5 bar < 0.5

Inlet Pressure 200 bar Max 4 bar Max Inlet Flow (kg/s) 0.2 0.5

Mechanical Requirement


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



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


Heat load ~10 KW @ max flow

~10 KW @ max flow

Inlet Temperature ( C ) 40 5 Outlet Temperature ( C ) <10 xx

Design TemperatureMax 2000C 500 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 Requirement


Material (Nozzle, Flange, Header & Pipe)

SS316L SS316L

https://www.nist.gov/srd/refprop

Welding No No

Bonding Diffusion Diffusion

Inlet Flange Size Requirement



Outlet Flange Size Requirement



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. 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

flow rate of 0.05kg/s while there might be a 30% volume fraction of uncondensed vapor 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 Requirements

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 SS 316L body 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

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.

Operational Specifications

S.No. Description 17. Mass flow 0 – 0.05 kg/s or 0 to 180 kg/h 18. Discharge Pressure Max 200 bar

19. Discharge Temp (C) 70 degree C 20. Power Rating 30 KW

21. Operating Mode Set Pressure and Mass Flow Control Modes

22. Control System Yes. Include accessories for a fully automated PID control system to achieve steady mass flow at a set pressure

23. Pump Cooling In built lubricant cooling system

24. Electrical Motor 30 KW 25. Electrical Motor Cooling Fan 2 HP blower fan for cooling the

motor

26. Inlet Pressure Up to 60 bar

27. Communication RS232/RS485

28. Mode of Operation Continuous & Closed Loop System

29. VFD Suitable for CO2 pump at the specified power rating of 30 KW

30. Fluid Condition at the Pump Inlet Liquid CO2 at 100 C and 50 to 60 bar pressure

31. Back Pressure Regulation Valve Rated up to 400 bar

32. Pump Base Frame Made of Mild Steel

33. Motor to Pump Shaft Coupling Yes

34. Burst Protection Disc (Explosion protection) Yes

35. Pulsation Damper Yes

36. 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

37. Software Interface Software to be installed in the PC to control the pump

38. Back pressure regulator One unit at the inlet of the pump to regulate the back pressure with range of 300 bar

Electrical Specifications

S.No. Description

5. Voltage 3 Phase – 220- 240 V 6. Power Up to 30 KW 7. Current 10 - 15 A

8. Frequency 50 – 60 Hz

6. Automated back pressure regulator

System Requirements

Parameter

Maximum Set Point Pressure to be Maintained

300 bar

Temperature Min of5 deg C

Make SS316 L

Pressure Sensor In-built range 300 bar

ICE Protection Yes

Inbuilt Heater Yes for ICE protection

Maximum sCO2 0.2 kg/s

Maximum CO2 temperature 100 o deg C

Minimum CO2 temperature 5 0 deg C

Control Connection RS232/RS485 connection to PC

~ 30 litres

Inlet Port Preferred 1” inch BSP (above the liquid level)

Output Port Preferred 1” inch BSP (from the bottom)

Pilot Port Preferred 1” inch BSP

Fluid Properties Use Refprop of NIST database (https://www.nist.gov/srd/refprop)

Design Meeting ASME codes of design

Electrical Requirement

Voltage 220 to 240 V

Current 15 amps / 3 Phase supply

7. Coriolis Flow Meter for sCO2

The flow meter is expected to measure flow rate at a pressure of high pressure (~ 100 bar) of liquid

CO2 fluid. The unit shall be capable of measuring up to 0.05 kg/s of maximum flow of liquid CO2. The

unit shall be able to interface with the controlling device to be able to precisely control flow. The




unit shall be able withstand the maximum operating temperature of 1500 C. The unit shall comply

with ASME standards of high-pressure piping requirements. The unit shall be supplied with the

Transmitter device which can seamlessly work with PLC and associated HMI interface. Accordingly,

the electrical signal needs to be programmed to be able to precisely control the VFD of the pump for

a given set point flow rate. The set point of the Mode bus device shall be 0% at a current rating of 4

mA and 100% at a current rating of 20 mA. The transmitter should be associated with the noise filter

(electronic component / in built PLC) that attenuates unwanted fluctuations in the current signal to

be able to work with the PID controllers.

Detailed technical specifications for the requirements are listed below.

Operational Specifications

S.No. Description

1. Nominal Mass flow 0.0002 – 0.05 kg/s or 0 to 180 kg/h

2. Maximum Pressure in the Line 100 bar

3. Maximum Temp (C) 1500 C

4. Communication RS485Modebus

5. Mode of Operation Continuous

6. Type of Fluid sCO2 in liquid state

7. Data Transmission Milliamp / digital outputs

8. Mass Flow Accuracy Shall not exceed + 0.1 % of max flow

9. Temperature Accuracy + 1o C

10. Signal 4-20 mA

11. Signal Noise Reduction Transmitting device with Noise reduction features/PLCs

Mechanical Specifications

S.No. Description

1. Nominal Inlet Diameter BSP 3/8” inch

2. Nominal Outlet Diameter BSP 3/8” inch

3. Material Make 316L stainless steel

Electrical Specifications

S.No. Description

1. Voltage 3 Phase – 220- 240 V

2. Current 10 - 15 A


Control Integration

S.No. Description

1. Display Input digital display

2. Current 10 - 15 A


8. Test coupon

Test coupon is a 600 mm by 600 mm additively printed metal block with provisions for inserting

pressure and temperature sensors on the hot and cold sides. The coupon serves as a heat exchanger transferring heat from the hot oil to the cold sCO2 fluid.

IV. Material/components to be procured by fabricator/vendor:

SR. No. Material/components to be procured by fabricator/vendor Quantity

1 Manual Valves (Needle type) 5

2 3/8" check valve 2

3 Liquid CO2 filter having 5 micron filter made of SS316 (100 bar pressure) 1

4 Pressure gauge (pressure range 0 to 3046psi) 4

5 Thermocouple temparature sensor (RTD temperature range 10˚ C to 200˚ C)

3

6 Safety relief valve (spring operated) for 3046 psi pressure 3

7 Safety relief valve (spring operated) for 1450 psi pressure 2

8 Dampening vessel (4570 psi max pressure and 125˚ C, 2 lit hold up) 1

9 Manual vent valve (Needle type) 3

10 Manual vent back pressure regulator (spring operated fail open type for 1450 psi pressure)

1

11 3/8'' Nut and ferrule 40

12 Tee male 3/8'' 15

13 Union Cross3/8" 5

14 Male connecter 3/8'' to tube 20

15 3/8'' union 20

16 3/8'' tube 20 m

V. Mechanical Integration Schematic:

1. Main sCO2 loop (sCO2 fluid):

a. 1-2 line:

i. Pipe connection from CO2 cylinder to accumulator junction

ii. Regulated by manual needle valve(MV1),pneumatic control valve(AV1)

which is activated by accumulator level sensor, and control valve (CV1)

b. 2-3 line:

i. Pipe connection from accumulator junction to accumulator

c. 4-5 line:

i. Pipe connection from accumulator exit to pre cooler inlet through a liquid

CO2 filter

d. 6-7 line:

i. Pipe connecting pre cooler exit to sCO2 pump inlet

ii. This line contains manual needle valve (MV2), coriolis flow meter (M1),

temperature (T1) and pressure (P1) sensor as shown

e. 8-9 line:

i. Pipe connection from pump outlet to dampening vessel inlet

ii. This line contains pressure sensor (P2) and a bypass line connecting to vent

f. 10-11 line:

i. Dampening vessel exit to test coupon inletwith manual valve (MV3),

pressure (P3) and temperature (T2) sensors in b/w

g. 12-13 line:

i. Test coupon outlet to automated back pressure regulator inlet (operated

through pnematics)

ii. This line contains temperature sensor (T3), pressure sensor (P4), and manual

valve (MV4) as shown

h. 14-15-16-2 line:

i. Pipe connecting automated back pressure regulator exit to condenser inlet

ii. Pipe connecting condenser exit to accumulator junction through manual

valve (MV5)

2. Secondary sCO2 line (sCO2 fluid):

a. 17-19 line:

i. Pipe connection from accumulator to vent junction through safety relief

valve (SV1)

b. 18-19 line:

i. Pipe connection from accumulator to vent junction through manual vent

valve (VMV1)

c. 8-19 line:

i. Pipe connecting sCO2 pump outlet to vent junction through safety relief

valve (SV2)

d. 20-19 line:

i. Pipe connecting dampening vessel to vent junction through manual vent

valve (VMV2) and coriolis flow meter (M2)

e. 19 to vent:

i. Pipe connecting the vent junction to atmosphere

f. 12 to vent:

i. Pipe connecting test coupon outlet to atmosphere through manual vent

valve (VMV3)

Use engineering judgement and calculations whenever required such that the components

withstand the operating condition mentioned above without failure for continuous daylong

operation of the plant. Vendor should submit any such calculations performed to design the

component.

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

[email protected]

mailto:[email protected]

Technical compliance sheet

Vendors are required to submit their bids along with this duly filled technical compliance sheet

Sr. No. Specifications/ 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 3100 psi and operating temperature of min 50 C and max of 1250 C along with sustaining vibrations of the pumps or other rotating parts of the circuit

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. Vendor should demonstrate the leak test as per ASME 31.3 with CO2 as working fluid and at a pressure of 4650 psi & 125 ˚C

4

All the components should be tested before integration. Perform calibration & provide test certificate for pressure transmitter, flow meter and thermal sensors. Comply with ASME B31 standard wherever applicable

5 Vendor should connect all the vent lines through manifold or some other means to provide a single port to connect to exhaust/atmosphere

6 Vendor should demonstrate the working of all the components in the loop by working electrical connection through DAQ and control panel

7 Vendor should demonstrate an emergency shutdown of the circuit and its effect on the mechanical integration components

8 All the components should at least have 1 year warranty

9 All the components (wherever applicable) should be made of Stainless Steel (grade 304) only for

handling corrosive and oxidative nature of the plant operation

10

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)

11

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 50˚ C and max of 125˚ C

12 The components between sCO2 pump and test coupon should be well insulated to avoid any heat transfer between the system and the surrounding.

13

Tube connecting different components should be seamless. Tube schedule must be selected according to ASME Tube Schedule specification for the pressure of 4650 psi & 125 ˚C. Vendor should provide the rate of the tube for bulk quantity as mentioned in the table below and per meter rate for extra material

14

The accuracy of temperature and pressure sensors should be within 1% of the full scale value. Calibration certificates to be provided by the vendor for the sensors

technical specification for mechanical integration of sco2

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