Air Compr

ENGRO CHEMICAL PAKISTAN LIMITED
Manufacturing Division, Daharki

Document Type:
Air Compressor Post Manual
Document No.:
PR-UT1-M7
Document Status:
Final
Posts Manuals
AIR
COMPRESSORS
POST MANUAL
Department : Production
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SF
AIH
ARQ
MAL
Burero/KRm
ARH
JP
Unit : Utility-1
in : June, 1996
in : June, 1998
in : June, 1999
in : June, 2003
in : June, 2006
in : July , 2009
in : July , 2009
in : July , 2009
in : July , 2012
Code: PR-UT1
TABLE OF CONTENTS
CHAPTER
SECTION DESCRIPTION
01
02
03
04
05
06
07
PROCESS FLOW DESCRIPTION

FUNDAMENTALS OF AIR ADSORPTION
FUNDAMENTALS OF AIR COMPRESSION
FUNDAMENTALS OF AIR COMPRESSOR
SAFETY & HAZARDS OF THE AREA
HAZARDS OF INADVERTENT MIXING
STANDARD OPERATING CONDITIONS
01
02
03
EQUIPMENT DETAIL AND SPECIFICATION

RECIPROCATING COMPRESSORS C-701A/B
CENTRIFUGAL AIR COMPRESSOR C-702
EQUIPMENT SPECIFICATION
01
AIR DRYERS FOR INSTRUMENTS AIR

AIR DRYERS FOR INSTRUMENTS AIR
01
02
03
04
INSTRUMENTATION & CONTROL

01
02
03
CONTROL & INSTRUMENTATION FOR C-701 A/B

CONTROL & INSTRUMENTATION FOR C-702
CONTROL & INSTRUMENTATION FOR AD-712
01
PROCEDURES
START-UP , SHUTDOWN AND HANDOVER PROCEDURES
01
02
TROUBLE SHOOTING GUIDE LINES

C-702 TROUBLE SHOOTING GUIDE LINES
AD-712 TROUBLE SHOOTING GUIDE LINES
05
06

Document Type:
Document No.:
PR-UT1-M7
Document Status:
Final
Posts Manuals
07
01
02
03
04
05
06
07
08
09
10
11
12
13
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AIR
COMPRESSORS
POST MANUAL
Originated by :
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Burero/KRm
ARH
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Unit : Utility-1
in : June, 1996
in : June, 1998
in : June, 1999
in : June, 2003
in : June, 2006
in : July , 2009
in : July , 2009
in : July , 2009
in : July , 2012
Code: PR-UT1
APPENDIX
POWER SUPPLY TO THE UNIT
EMERGENCY HEALTH INFORMATION
LIST OF PSV`S
LIST OF FLOW ORIFICES
LIST OF CARSEAL VALVES
LIST OF SAFETY EQUIPMENTS
CONTROL VALVES & FAIL SAFE POSITION
EQUIPMENT LIST
SAFETY CRITICAL SECURITIES
PREDETERMINED INVENTORY LIMITS OF HAZARDOUS
MATERIALS
CHEMICAL COST DATA
LESSON LEARNT FROM PAST INCIDENTS
AREA P&ID`S
____________________
Rehman Hanif
URUT-1 Section Head
August, 2009
_____________________
Jahangir Piracha
Production Manager
August, 2009

Document Type:
Document No.:
PR-UT1-M7
Document Status:
Final
Posts Manuals
CHAPTER-1
PROCESS FLOW
DESCRIPTION
Originated by :
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Issue No. 3 by :
Issue No. 4 by :
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Burero/KRm
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Unit : Utility-1
in : June, 1996
in : June, 1998
in : June, 1999
in : June, 2003
in : June, 2006
in : July , 2009
in : July , 2009
in : July , 2009
in : July , 2012
Code: PR-UT1
TABLE OF CONTENTS
SECTION
DESCRIPTION
01
PAGE
1.1
1.2

PLANT AIR
INSTRUMENT AIR
1
1
2.1
2.2
2.3

REMOVAL OF MOISTURE FROM AIR
ADSORPTION
3
4
5
3.1
3.2
3.3
3.4
3.5
3.6
3.7
FUNDAMENTALS OF AIR COMPRESSION

AIR COMPRESSION
THE IDEAL GAS LAW
COMPRESSION RATIO
VOLUMETRIC EFFICIENCY
MECHANICAL EFFICIENCY
HEAT OF COMPRESSION
TYPES OF COMPRESSION
7
8
9
9
9
10
10
02
03
04
4.1
4.2
4.3
4.4
4.5
4.6

CLASSIFICATION OF COMPRESSORS
CONSTRUCTION OF RECIPROCATING
COMPRESSOR
CATEGORIES OF RECIPROCATING COMPRESSOR
PERFORMANCE OF RECIPROCATING
COMPRESSOR
CONTROLLING COMPRESSOR OUTPUT
UNLOADING THE COMPRESSOR
13
15
17
17
19
21

Document Type:
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Posts Manuals
CHAPTER-1
PROCESS FLOW
DESCRIPTION
4.7
4.8
4.9
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Code: PR-UT1
4.10
4.11
4.12
4.13
4.14
4.15
4.16
LUBRICATION
PRIMING THE SYSTEM FOR OPERATION
SEPARATION OF WATER & OIL FROM
COMPRESSED GAS
PULSATION & VIBRATION CONTROL
ACCESSORIES
CHOKE
SURGE
TURNDOWN
DESIGN POINT
TERMINOLOGY
5.1
5.2
5.3
5.4
SAFETY AND HAZARDS OF THE AREA

INTRODUCTION
SAFETY AND FIRE FIGHTING EQUIPMENT
HAZARDS
PERSONAL PROTECTION
29
29
29
30
6.1

31
7.1

32
05
06
07
21
22
23
23
24
25
25
25
26
28
Engro Chemical Pakistan Ltd

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SECTION-1 PROCESS FLOW DESCRIPTION

There are two types of air systems in our plant:
1.1
PLANT AIR
Plant air is supplied to Uty-1 through KGT-2501 at a pressure of around 500 psig. This air is
let down at Uty-1 at a pressure of 8.44 kg/cm2 (120 psig) through PIC-704V. C-702 and
C-701 A/B discharge headers also combine at down stream of PIC-704 to supplement plant
air and instrument air pressure. This 8.44 kg/cm2 (120 psig) air goes into a knock out drum
D-711, where moisture coming along with air is knock out. Air from D-711 goes into the
dryers AD-711 & AD-712 through a filter FIL-711. Air at outlet of air dryers is instrument
air.
PIC-703V is installed at D-711 outlet to provide plant air. This valve normally remains full
open. This valve basically controls the pressure of instrument air and cuts plant air in case
of low pressure in instrument air header i.e 8.08 kg/cm2 (115 psig)
Plant air is used for the passivation in CO2 stripper C-2515 at Amm-2, HPD and LPD at
urea-1 and for passivation in C-2E at urea-2. It is also used at bagging machines and
diverting gates, for the operation of pneumatic equipment like grinders, and has been
provided at Utility stations.
1.2
INSTRUMENT AIR
This dry and oil free air is used throughout the plant for pneumatic instruments.
Instrument air is produced by removing moisture in AD-711 & AD- 712 from plant air.
Both instrument and plant air are supplied by two Ingeresoll Rand 24 NMCM (900 SCFM),
2 stage reciprocating air compressors C-701A/B, a centrifugal compressor C-702 & KGT air
from Ammonia-2 C-701A is driven electrically by a 201.42 KW (270 HP), 1450 rpm motor,
while C-701B is equipped with an elliot steam driven turbine. In normal operation
instrument air header is kept pressurized through KGT air from ammonia-2 and C-702.
C-701 A/B remain stand by. If for any reason air pressure decreases, then C-701A/B cuts in
thru PLCI-702A/B which are set at 8.15~8.08 kg/cm2 (116~115 psig). The air compressors
discharge hot air at a pressure of 8.44~8.79 kg/cm2 (120-125 psig). This air is then cooled in
after coolers (E-702A/B). The entrained oil droplets are removed by injecting boiler feed
water through P-513 at the outlet of C-701 A/B. This injection also provides a quenching
effect thereby cooling the discharge air.
The compressed air is then stored in an air-receiver D-711. From D-711 air is bifurcated to
plant air and instrument air systems. The air used for instrumentation passes through Fil-711

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where oil is seperated. Then air is dried in drying towers AD-711 A / B & AD-712 A / B.
The pressure of instrument air is controlled by PIC- 704 & PIC- 703.
In case the air pressure in D-711 drops below 8.08 kg/cm2 (115 psig), PIC-703 which is on
the plant air header closes allowing the instrument air header to stay pressurized for a longer
period
UREA-2
- For passivation Air in
C-2E
- Utility Stations
PLANT AIR
UREA-1
- LP Decomposer
- HP Decomposer
- P-103
- Vibrating Screen Switch
- For Blowers
PM&S
- Bagging Lines
- Utility Stations
- Clamping Machines
- Sewing Machines
AMMONIA
WORK SHOPS
- To supplement Process Air
- Grinders
- C -2515 ( Passivation air)
- Drills
- Utility Station
- Motors & Bearings Cooling
UTILITIES
- Motor Pool
- Boiler Stack
- F.D Fan (SG-641)
- Utility Station

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ADSORPTION
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SECTION - 2
2.1
2.1.1
EARTH AND ITS ATMOSPHERE
Thermo Sphere
Meso Sphere
Strato Sphere
Tropo Sphere
2.1.2
First blanket
: Tropo Sphere
Second blanket
: Strato Sphere
Third blanket
: Meso Sphere
Fourth blanket
: Thermo Sphere
Normal composition of air is available in Tropo Sphere only.
PHYSICAL PROPERTIES AND COMPOSITION OF AIR.

Air becomes light with the increase of temp. and lifts upwards leaving a low pressure zone at
ground level. Sorrounding air moves horizontally to fill up the low pressure zone. Temp.
Variations are more on land as compared to the sea. Thats why air mostly blows from sea to
the land. Sea breeze brings moisture to the land.
Air contains 78% Nitrogen, 21% Oxygen and rest of 1% contains CO2, Argon, Krypton,
Neon, Xenon etc. CO2 and Nitrogen have variable % on account of their natural cycle.
2.1.3
EVAPORATION AND MOISTURE FORMATION:

The phenomenon in which liquid converts into vapors without applying external heat.
Evaporation increases with the increase in temp. decrease of pressure, decrease in humidity,
increase in wind velocity. Evaporation decrease with the increase in pressure, increase in
humidity, decrease in temp. decrease in wind velocity.
2.1.4
CONDENSATION

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Condensation principles are reverse of the evaporation principles. Product of condensation is

water droplets that do not have sufficient kinetic energy to suspend in the air against
gravitational pull.
2.1.5
DEW POINT
This is the temp. below which the moisture in the air condenses and forms droplets of water.
2.1.6
FACTORS AFFECTING DEW POINT

dew point is affected by pressure, temperature & Concentration of water vapors increase in
moisture vapors concentration increases the dew point & vice versa. Decrease in temp.
Increases the dew point & vice versa.
2.1.7
WET BULB TEMP. :

This the minimum possible temp. obtained by the evaporation under a certain pressure. Wet
Bulb Temp. Increases with the increase in pressure. Wet Bulb Temp. Increases with the
increase in humidity.
2.1.8
PLANT AIR :
It is compressed air which is used at plant for cleaning , purging, ventilation, driving
pneumatic equipments, passivation & cooling purposes.
2.1.9
INSTRUMENT AIR :
Clean and moisture free air is called instrument air. It is produced by air dryers.
2.1.10 AFFECT OF MOISTURE IN INST. AIR :

Water is incompressible fluid thats why enhances hunting of control valves. Water causes
corrosion in the equipments.
2.2
REMOVAL OF MOISTURE FROM AIR
I.
KNOCK OUT METHOD.
II.
Knock Out drums are used for this purpose. Expansion of gas causes its cooling thus the
moisture vapors with relatively low energy are condensed. The vapors with relatively higher
energy are not removed during K.O and carried over.
LIQUID ABSORPTION :

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Moisture in the air is absorbed in liquid like TEG (Try Ethylene Glycol) in absorber. The rich
TEG solution is heated to remove water and recycled in absorber. This method is used to
remove moisture from a huge amount of gas like on N.G wells.
III.
SOLID ADSORPTION:
This method is used to remove moisture from lesser amount of gas. Solid adsorbents like
Alumina Balls, Silica Gel and activated carbon are used. Solid adsorbents can be regenerated
with the application of heat and variation in pressure.
Adsorbent has an unlimited life if protected from dust and oil. Activated carbon like charcoal,
anthracite are not used for air because they are combustible. A solid adsorbent should have
high crush strength and larger surface area (Porosity).
This method of air drying is applicable in our system.
2.3
ADSORPTION
2.3.1
INTRODUCTION
Adsorption is the process by which molecules of a liquid or gas contact and adhere to a solid
surface. In this course we focus exclusively on gas adsorption.
The most common configuration for industrial adsorbers involves the use of fixed bed
adsorption system.
At least two identical packed beds are used in a fixed bed system: one for adsorption and the
second for regeneration. A variety of adsorption system have been developed that permits
both adsorption and regeneration to occur in the same unit.
2.3.2
ADSORPTION MECHANISMS
Adsorption processes are classified as either physical or chemical. The dominant mechanism
depends on the adsorbent and the adsorbate(s).
PHYSICAL ADSORPTION
Occurs when London-van der Walls forces bind the adsorbing molecule to the solid substrate;
these intermolecular forces are the same ones that bond molecules to the surface of a liquid. It
follows that heats of adsorption are comparable in magnitude to latent heats (10 to 70
KJ/mole). Species that are physically adsorbed to a solid can be released by applying heat
(much the same as a liquid can be readily volatilized by heating); the process is reversible. An

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increase in temperature causes a decrease in adsorption efficiency and capacity. Almost all
adsorption process pertinent to air pollution control valve physical adsorption.
CHEMICAL ADSORPTION
Occurs when covalent or ionic bonds are formed between the adsorbing molecules and the
solid substrate. This bonding leads to a change in the chemical form of the adsorbed
compounds, and is therefore not reversible. An example of a chemical adsorption process is
the formation of CO2 when O2 gas adsorbs to a carbon substrate. The bonding forces for
chemical adsorption are much greater than for physical adsorption. Thus, more heat is
liberated. For many applications the adsorbent is chemical impregnated with a substance that
encourages chemical reactions with particular adsorbates. With chemical adsorption, higher
temperatures can improve performance.
Note that the heats of adsorption for oxygen and nitrogen are typically small relative to those
for the organics. It follows that the organics tend to be more tightly bound than are the oxygen
and nitrogen, and can therefore displace adsorbed oxygen or nitrogen. This explains why
VOCs (volatile organic compounds) are effectively removed by activated carbon despite the
relative abundance of oxygen and nitrogen in typical carrier gases.
2.3.3
ADSORBENTS
There are several adsorbents commonly used. The most common is activated carbon. While
activated carbon can be made from nutshells, wood, and petroleum, most of the activated
carbon that is used for pollution control is manufactured from bituminous coal. Activation
is the process that produces the porous structure essential for effective adsorption. It involves
heating in the absence of oxygen to dehydrate and carbonize, followed by heating in the
presence of oxygen to obtain the porous structure. Activated carbon attracts non-polar
molecules such as hydrocarbons. Typical surface areas are 300 to 1500 m2 / g.
Other materials are activated alumina made from hydrated alumina, silica, and zeolities.
Activated alumina is commonly used to remove oxygenates and mercaptans from
hydrocarbons and fluorides from water. It is used to support catalysts and as a desiccant.
Typical surface areas are 300 to 900 m2 / g. Zeolites are generally aluminosilicates. They are
crystalline and have micro pores that are uniform in dimension. They are called molecular
sieves because they can discriminate between nearly identically sized molecules.
Factors that effect the capacity of an adsorbent include its surface area, its pore size, and its
polarity.

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SECTION-3 FUNDAMENTALS OF AIR COMPRESSION

3.1
AIR COMPRESSION
"When a gas is forced to occupy a smaller volume, its pressure is increased". All the positive
displacement compressors operate on this principle of volume reduction.
Compressed air is air that has been squeezed together, or forced into less space. When air is
compressed, its pressure and temperature increase. Pneumatic systems use compressed air to
transmit energy in order to perform work. Compressed air can be used as a power medium to
operate machines and drive power tools.
3.1.1
POSITIVE DISPLACEMENT COMPRESSION

Air can be compressed through displacement. This process displaces the air by decreasing the
volume in which it is contained. A reciprocating air compressor, for example, uses a piston to
compress air. As the piston is withdrawn from the cylinder, pressure decreases in the cylinder.
Due to this pressure differential, the suction valve opens, allowing air to fill the cylinder. At
the end of the downward stroke, pressure equalizes and the suction valve closes. When the
piston strokes upward, the pressure inside the cylinder begins to increase. When cylinder
pressure exceeds pressure on the discharge side, the discharge valve opens, allowing the air at
increased pressure to exit.
3.1.2
DYNAMIC COMPRESSION
Dynamic type compressors are machines in which air is compressed by the action of rotating
impellers imparting velocity and pressure to the air.
The Cooper turbo compressors discussed in this text are of the radial flow centrifugal type of
dynamic compressor.
In a centrifugal compressor, the velocity of the incoming air is increased by the rotating
impeller. The velocity is increased by centrifugal force.
The air enters the center, or eye, of the impeller. As the impeller rapidly rotates the air,
centrifugal force causes the air to move away from the center of motion. As a result, the
rotation of the impeller throws the air outward at a very high velocity. As this high velocity
air leaves the impeller, it enters the diffuser where its velocity decreases. The diffuser
surrounds the impeller and serves to gradually reduce the velocity of the air leaving the
impeller and to convert the velocity energy to a higher pressure.
A scroll or volute casing surrounds the diffuser and serves to collect the gas to further reduce
the velocity of the gas and recover additional velocity energy.

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THE IDEAL GAS LAW

All gases follow certain gas laws which are the starting point of any gas behavior. These laws
are:
a).
b).
c).
Boyles Law
Charless Law
Combined Law
A) BOYLES LAW
The volume of any definite quantity of gas at constant temperature varies inversely as the
pressure on the gas.
V
V =
P =
V =
K1 =
1/P at constant temperature

Volume
Pressure
K1 / P, PV=K1
Proportionality constant
It follows from the above:

P1V1 = K = P2V2 at constant temperature
B) CHARLES'S LAW OR GAY LUSSAC'S LAW
Volume of a definite quantity of gas at constant pressure is directly proportional to the
absolute temperature
V
V
T
K2
=
=
=
T
K2 T
Absolute temperature
Proportionality constant
C) THE COMBINED LAW

The simultaneous variation of volume, temperature and pressure of gas is obtained by
combining Boyless and Charless Laws.
P1 V1 =
T1
P2 V2 =
T2
Constant

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COMPRESSION RATIO
A compressor is a machine that by doing work on a gas, increase gas pressure. The gas
normally enters a compressor at one pressure and leave it at higher pressure.
The difference between the suction and discharge pressure represent the work done on a gas
by a compressor less losses due to heat and Friction.
The compression Ratio R is relationship between absolute discharge pressure (P2) and
absolute suction pressure (P1)
Compression Ratio = Absolute Discharge Pressure
Absolute Suction Pressure
Ratio is determined in absolute pressure. Because Gauges are usually calibrated to read zero
point at atmospheric condition .That's why atmospheric pressure i,e. 14.7 is added.
Absolute value is taken as to express the graph in somewhat linear which is understandable
and evaluation of compression ratio is easier.
3.4
VOLUMETRIC EFFICIENCY
It is the ratio of actual capacity to its theoretical capacity.
Volumetric Efficiency =
Actual Capacity
Theoretical Capacity
In dynamic compressor when it operates near its capacity limit, its efficiency falls off. So for
maximum efficiency it should be operated at less then its capacity limit.
3.5
MECHANICAL EFFICIENCY
It is the ratio of Horse Power applied to the gas to its apparent power.
Mechanical Efficiency =
Horse Power out put

Horse Power in put
Out put means power applied at the gas and input mean power given to motor. Mechanical
and volumetric efficiencies are not directly proportional to each other, because with the
decrease of volumetric efficiency mechanical efficiency do not have significant change.
It is that Horse Power which is Required by the shaft of a compressor.

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HEAT OF COMPRESSION
When gases are compressed, their temperature increases. The amount of temperature increase
depends on,
1
2
3
Nature of gas
Temperature of gas
Compression ratio
As compared with heavy gases light gases show more temperature rise for the same ratio of
compression.
3.7
TYPES OF COMPRESSION
There are four main types of compression. These are the application of four laws of
thermodynamics.
a.
b.
c.
d.
3.7.1
Isobaric process
Isochoric process
Isothermal process
Adiabatic process
ISOBARIC PROCESS :
Isobaric process is that in which the pressure of the system remains constant.
For example a certain amount of gas is filled in a cylindrical vessel provided with friction less
piston, which is free to move. When certain amount of heat ---Q is given to system, the gas
expand such as pressure remain constant. The work done by the gas in a moving piston of
Area (A) to a small distance. The volume change from V1 to V2 and temperature will also
P1, V1, T1
change T1 to T2.
P1,V2,T2

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ISOCHORIC PROCESS :
The process in which the volume of the system remains constant.
Consider some gas is filled in a cylinder and its piston is tightly fixed. Certain amount of heat
Q is supplied to the system, due to which pressure increase from P1 to P2 and temperature
also increase from T1 to T2, no change in volume takes place due to piston at constant
position.
W = P V = O
According to first law of thermodynamics Q = U + W
W = O
So Q = U
So heat is used to increase only the internal energy of the system.
P2,V1,T2
P1,V1,T1
V
3.7.3
ISOTHERMAL PROCESS :
The process in which temperature of the system remains constant is Isothermal process.
Consider a gas is filled in a cylinder having non-conducting walls and conducting base. when
it is placed over a hot body, the heat flows from hot body to gas, the gas will expand on
heating. It will move the piston upward, so tend to remain constant. If pressure of cylinder is
increased by increasing weight on piston there should be increase in temperature. But as base
is conductor, temperature remains same.
Q = U + W
AS U = O (because internal energy remains same)
So Q = W (Temperature)
It means energy supplied to the system is equal to work done (W).
P1,V1,T1
P
P2,V2,T1
V

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ADIABATIC PROCESS :
A process in which no heat enter or leaves the system is called adiabatic process.
During an adiabatic process, the working substance is perfectly insulated from the
surrounding such that it does not exchange heat energy from the surroundings. However if a
process such as compression or expansion of a gas is done very quickly, it will be nearly
adiabatic because the flow of heat into or out of the system requires finite item.
If the pressure is suddenly reduce on the piston the gas expands pushing the piston up and the
temperature falls. As no heat exchange can take place
U = W
A curve between pressure and volume during the adiabatic process is called an adiabatic
curve as shown
P1,V1,T1
P
P2,V2,T1
V

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4.1
CLASSIFICATION OF COMPRESSORS
4.1.1
ROTARY COMPRESSORS AND BLOWERS
4.1.2
These are used to move large volume of gas but with smaller compression ratio. These are of
two types:
LOBED BLOWERS
The gas is trapped between the two rotating lobes of impellers inside a casing. With the
opposite rotation of impellers on two independent shafts, the gas is displaced from the suction
port to the discharge port. The pressure of the gas is thus increased.
As there is some clearance between the casing and rotating lobes, internal gas leakage from
high-pressure side to low pressure side prevents the building up high discharge pressure. In
this compressor no internal lubrication is required.
4.2.3
SLIDING - VANE COMPRESSOR

A set of vanes, mounted on the slots of a rotor which is off the center in casing, move the gas
out against the wall of casing through centrifugal action. The gas trapped in the pockets of
each pair of vanes is compressed to smaller volume and moves out into discharge port. The
vanes, loaded on spring make a gas-tight seal against the wall casing. Hence internal
lubrication is required.

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CENTRIFUGAL COMPRESSOR
It resembles with a multistage centrifugal pump with in built gas cooling stages and suction
port. Large volume of gas can be compressed but not to very high pressure as compared with
reciprocating compressor. Because of their lesser maintenance frequency, they are replacing
the reciprocating compressor in modern plants.
4.1.5
SCREW COMPRESSORS
The gas is displaced by a helically lobed rotors which resemble a set of screws. These
opposite moving rotors are driven by gears and do not have any metal to metal contact in the
casing. These also do not require internal lubrication. These are normally used for extruding
work.
4.1.6
LIQUID PISTON COMPRESSOR

In a liquid compressor, cupped blades are mounted on a rotor and the casing is partially filled
with a liquid. The casing is elliptical in shape and liquid settles at its bottom. As the rotor
moves, the liquid settles at its bottom. As the rotor moves, the liquid is thrown out in a
whirling motion due to centrifugal action and adopts the shape of the casing. Near the center
of rotor, there are two suction and discharge ports. As the rotor turns, gas is trapped between
the blade rings and the whirling liquid. This liquid helps to compress the gas and discharges it
into outlet. Since liquid acts as a piston, some liquid is carried away with gas. Liquid make up
system is built with the compressor to keep the quantity of liquid constant.
4.1.7
RECIPROCATING COMPRESSORS
In this compressor a fixed volume of gas is drawn thru a suction valve into a cylinder. This
gas, trapped between suction and discharge valves, is forced by a moving piston to occupy a
smaller volume. The compressed gas then leaves thru discharge valve into discharge jacket
and finally into discharge line.

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One complete revolution of a reciprocating compressor constitutes one forward and one
backward stroke. The compressor is further classified into single-acting or double-acting
depending whether the gas is being compressed on single end or both ends of the compressor
piston.
Reciprocating compressors are used for high compression ratio (i.e. for providing high
pressure). These compressors also require tremendous amounts of lubricants for lubrication.
The suction and discharge valves of the compressor are basically two uni-directional check
valves which operate with gas pressure. There are two types of the valves commonly used,
single deck & double deck valves.
4.2
CONSTRUCTION OF RECIPROCATING COMPRESSOR

PISTONS:
Piston is a device which is used to compress the gas. Large pistons are oftenly made of
hollow fabrication but small pistons are usually made of solid material. Piston is engaged with
piston rod and locked with a lock nut. The hollow construction decreases weight of piston.
The piston rod extends through the piston and drawn up tight against the shoulder by the lock
nut.

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PISTON RINGS
Piston rings provide a seal that prevent or minimizes leakage between the piston and the liner.
They also carry heat from the piston to the cylinder wall. The compressor's cooling system
carries most of the heat away from the cylinder. The ring material is chosen to provide an
initial rapid wear and therefore a quick seal of the ring to the wall. Piston rings are made of
material that wears more rapidly than the cylinder or liner. Compressor piston rings are made
of bronze, cast iron, back lite, teflon, carbon, or other similar material.
These materials cause low friction and wear slightly faster than the cylinder liner or bore. The
rings seal by a close fit against the cylinder and against sides of the grooves.
Metal piston rings are made either in one piece, with a gap or in several pieces. The piston
rings spread the oil over the length of the stroke.
METALLIC ROD PACKING
Packing prevents compressed gas from leaking along the piston rod. In compressors that
operate below atmosphere pressure, packing prevents air from being drawn into the cylinder.
Most modern compressors use metallic rings as the packing. The rings are arranged in pairs
in each cup. The operating pressure usually determines the number of cups that are used. The
cups are held together for assembly by long studs. Packing rings are made in segments. :
The segments form the rings are held against the piston rod garter springs.
WIPER RINGS
The wiper crapes the oil into the distance piece. From the distance piece, the oil is drained to
a sump line. Many compressors have a set of scraper rings near the crosshead. Where
necessary, there are passages through the walls of the packing cups to permit the circulation
of cooling water. The much of the heat generated in the packing is removed by the water.
RODS, CROSSHEAD AND BEARINGS
Piston rods are usually made of high quality steel alloy that is usually surface hardened. The
piston rod screws into is secured in place by a locking device. The crosshead shoes or slippers
are removable and adjustable. The crosshead guides are usually integral with the frame. The
oil is supplied under pressure through holes in the bearing surface. The bearings may be made
of habit, bronze, or aluminium. Since aluminium scores easily, the oil must be particularly
clean when aluminium bearings are used. The rod load is the maximum force that the

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compressor piston rods can safely stand. Breakage within a piston may be due to
misalignment caused by a piston that is too loose.
4.3
CATEGORIES OF RECIPROCATING COMPRESSOR

Reciprocating compressors are categorized according to three different factors.
1.
2.
3.
No. of cylinders
No. of stages
Action
Reciprocating compressors typically have one to four cylinders. Each cylinder has its own
piston, rings and valves. If each cylinder draws air directly from the atmosphere and
discharges it directly into the storage tank or receiver, the compressor is called single stage.
Single stage compressors can have any number of cylinders as long as each cylinder
discharges into the receiver
In multistage compressors, the discharge of one cylinder is directed to the inlet of another.
Higher discharge pressure can be obtained in this manner; the air is compressed once in the
1st stage and it is compressed even more in the 2nd stage. Figure 2 shows a two cylinder
two-stage reciprocating compressor.
Reciprocating compressors can also be either single-acting or double-acting. A single acting
compressor compresses the air on one side of the piston.(fig.3). A double acting compressor
compresses the air on both sides of the piston (which divides the cylinder into two separate air
chambers). Since the double acting compressor compresses air on both sides of the piston, it
has another set of valves as shown in figure 4.
On an upstroke the double acting cylinder discharges air from discharge valve-1 and at the
same time draws air in thru inlet valve-2. On a down stroke air is discharged from discharge
valve-2 and drawn in thru inlet valve-1. At any given speed a double acting compressor has
twice the flow rate of a single acting compressor of the same size.
4.4
PERFORMANCE OF RECIPROCATING COMPRESSOR

The performance of Reciprocating Compressor is represented by pressure volume (P.V)
diagram.

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The diagram indicates the pressure in the cylinder of the compressor in relation to cylinder
volume .As the piston of the compressor moves back and forth in the cylinder, the volume of
the cylinder changes .The horizontal line in a p-v diagram, shown above as A to C, represents
the change in volume produced by the movement of the piston in the cylinder, a vertical line
on the diagram represents pressure in the cylinder. This piston has displaced all the gas it can
and is as far toward one end of the cylinder as it can go.
The pressure in the clearance space is equal to the discharged pressure. This is what the p-v
diagram looks like at the start of a stroke cycle in a positive displacement compressor.
The pressure in the cylinder and the position of the piston as shown by points A. As the piston
begins to move back in the cylinder, the gas in the clearance space expands. As the gas
expands, pressure in cylinder decreases. When the pressure in the cylinder drops slightly
below the suction line pressure, the suction valve opens. Curve AB on this p-v diagram shows
the movements of the piston and the pressure decrease.
The opening of the suction valve is represented on the p-v diagram by point B. As the piston
moves further back into the cylinder, gas flows in. The pressure in the cylinder remains
relatively constant. Here, the p-v diagram shows the point at the piston has moved as far in
one direction as it can go.

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The end of the pistons suction or intake stroke is represented by point C. As soon as the
piston begins to move in the opposite direction, the gas begins to be compressed.
Compression of the gas causes the pressure of the gas in the cylinder to increase. The gas
pressure increases until it is slightly above discharge pressure. Heres pressure in the cylinder
is slightly above discharge pressure.
This condition is represented on the p-v diagram by point D. As the piston continues its
stroke, the gas is discharged through the proper valve. During the discharged stroke, the gas
pressure in the cylinder remains relatively constant. This p-v diagram shows one or more
complete cycle of compressor.
4.5
CONTROLLING COMPRESSOR OUTPUT

The performance of a reciprocating compressor is represented below by a conventional P-V
diagram. As the piston of a compressor moves back and forth, the volume of gas in the
cylinder changes. These conditions are represented on the diagram by point A, B, C & D for
one complete cycle.
During the suction stroke the suction valve opens as the pressure decreases and lets the gas
into cylinder. During discharge stroke, the discharge valve opens and lets the gas into the
outlet line. The horse power required by a compressor depends on the work done in given
time and compressor mechanical efficiency.
Mechanical efficiency is defined as ratio of HP applied to the gas to HP received from the
driver. The ratio of distances BC/AD is called volumetric efficiency which is essentially the
ratio of compressor's actual capacity to its theoretical capacity.
With the decrease of volumetric efficiency, the work done by a compressor decreases and the
HP requirements are also reduced. But this does not significantly affect the mechanical
efficiency.

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CONTROL BY THROTTLING
Sometimes it is necessary to change capacity or rate of flow through compressor. A valve
installed on the suction line is throttled & this reduces the suction pressure. The discharge
pressure of compressor remains the same but due to increase in compression ratio HP
requirement of compressor rises up. (Fig. 5)
Throttling also increases discharge temperature and can create partial vacuum that permits the
atmospheric air into compressor. If some flammable gas is present, an explosion can result.
Hence throttling is used as temporary method of rate control.
4.5.2
CONTROL BY CLEARANCE
Clearance is the space left between cylinder and piston head plus valve recesses at the end of
discharge stroke. The capacity of a reciprocating compressor is controlled by varying the
amount of clearance in the cylinder. This additional space allotted to cylinder volume is
known as clearance pocket. (Fig. 6)
At start of suction stroke the gas in the clearance space expands and energy of gas expansion
adds to the force of return of the stroke. On compression part of the cycle, the compressor
spends energy to compress additional gas and not the clearance gas and hence does less work.
In a way clearance gas work as reciprocating compressor. The phenomenon can be clearly
understood considering a P.V. Diagram. (Fig. 7)
On a P.V diagram when a clearance pocket is closed, piston travels from point C to point
E and gas intake is represented by CE and when this gas is compressed, piston travels from
point E to B to give required discharge pressure to the gas.
Now when the clearance pocket is opened the gas in the clearance pocket expands and
opening of suction valve is delayed up to point D.
The gas intake is represented by DE with clearance pocket open, only additional gas is to be
compressed but to raise large volume of gas to discharge pressure the piston travels a longer
distance from E to A. The shaded area of diagram represents the work done in case of
open clearance pocket. Since this area is lesser than the area represented by closed clearance
pocket operation, the HP requirements are accordingly reduced.
So with the addition of clearance pocket a reduction in volumetric efficiency is achieved.
Also as clearance is increased the load on the prime mover or driver is decreased. Thus if the
compressor is overloaded, the overload can be reduced by increasing (opening) the amount of
clearance.
The clearance pockets are of various designs and can be operated by hand or instrument.
a). FIXED VOLUME CLEARANCE POCKET

It cannot be adjusted by an operator. (Fig. 8)

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b). HAND -OPERATED FIXED VOLUME CLEARANCE POCKET

The addition of a valve makes it possible to add a fixed volume of clearance when needed.
(Fig. 9)
c). VARIABLE CLEARANCE POCKET
The hand wheel is designed to vary the clearance as needed. (Fig. 10)
4.6
UNLOADING THE COMPRESSOR

In normal compression cycle of reciprocating compressor both suction and discharge valves
are closed. In some compressors, hand wheel operated or pneumatic or hydraulic pressure
operated diaphragm suction valves known as unloader valves are incorporated for capacity
control. The disc of suction valve is lifted off its seat. The gas entering the cylinder returns
back into suction gas jacket and hence no gas is discharged from compressor. When an
unloader is used, there is a slight power loss as gas is forced back into suction jacket, but in
general unloading on end of cylinder removes the power requirement at that end. Unloading
both ends of cylinder (if it has) causes cylinder to overheat and hence should not be practiced.
To reduce the pressure and temperature at the packing of the cylinder, unload the head-end of
the cylinder. To reduce the power loss unload all head-end suction valves at one end of
multi-cylinder compressor. Capacity controlled by unloading the suction valves results in a
step wise change often denoted by percentage
4.7
LUBRICATION
Lubrication provides a film that reduces the friction and hence also decreases wear between
the moving compressor parts. It also provides cooling by carrying away frictional heat from
the system. The grade of oil selected for lubrication should not break down or decompose.
Otherwise it will foul and plug valves and other compressor parts. Highly stable oils are
required for cylinder & packing lubrication. Lubrication in a reciprocating compressor is
applied thru various systems discussed below.
4.7.1
SPLASH LUBRICATION
Oil from crank case reservoir is splashed with movement of crank shaft & counter weights.
Centrifugal force throws oil outward from rotating crank shaft to oil passage which leads it to
bearings etc.
4.7.2
PRESSURE LUBRICATION
Oil is first filtered thru a strainer and then pumped into a cooler. Cooled oil is again filtered
and distributed into different channels for lubrication. Pressure of oil is regulated constantly.
Low pressure alarm and shutdown devices are often installed to safeguard the equipment
against loss of lubrication.

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FORCE-FEED LUBRICATION
Cylinder and packing lubrication is done by means of high quality oil. One or more force feed
lubricators are used to supply the oil. Each lubricator is equipped with one or more small
plunger pumps. The oil is pumped thru a sight glass, tubing and check valves on to lubrication
points. Typical force-feed lubricator is shown on the given sketch. (Fig.11)
Lubricator pump is driven by compressors crank shaft, but before the compressor is started,
lubricator must be operated by hand. The compressor cylinders and packings are lubricated by
mechanical force feed lubricators. The lubricator is located on the free end of the frame and is
direct driven off the frame.
Separate feeds are provided to each compressor cylinder for lubricating the piston and
packing and the piston and liner.
Figure-8 illustrates a McCord Model 55 lubricator pump, one of several types that are used.
The cut on the left illustrates operation on suction stroke and one on the right, the discharge
stroke.
For the suction stroke, oil is drawn thru sight glass, past the suction valve and into plunger
bore by means of two small ducts that straddle the suction valve seat. On the upward or
discharge stroke (right hand view), the suction valve seats and oil is forced from the plunger
bore back thru two small ducts and on past the discharge valve. High pressure feed back to
the sight feed shown by the letter V shows the manner in which plunger wear is
compensated for any slippage is immediately drawn back into the sight feed glass by vacuum.
The amount of oil taken, in on the next plunger stroke is automatically reduced by the amount
of slippage.
4.8
PRIMING THE SYSTEM FOR OPERATION

When starting a compressor for the first time or after a line has been disconnected for service
work, proceed as follows:
a).
Besure that all air is removed from each pump. This can be done by operating each
pump manually with the discharge connection loosened.
b).
Disconnect each lubricator line at the delivery end (ahead of the check valve) and
operate the lubricator pump until oil appears. This can be done by using the hand
crank and operating pump manually. Long lines can be quickly filled using grease gun
filled with oil.
Should the lubricator reservoir run dry, it will be necessary to prime each pump again. If
this occurs, serious damage to the cylinders is probable in a short period of time.
Lubricator operation can be checked by observing sight feeds at regular intervals & making
sure that the reservoir is kept filled.

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SEPARATION OF WATER & OIL FROM COMPRESSED GAS

Oil and moisture must be removed from the system as they are a source of trouble for
efficient operation of compressor, gaskets, exchangers and other process equipment. Moisture
is always present in the gas as it is difficult to obtain a dry gas. The amount of moisture varies
with type of gas manufacturing steps. As this gas passes thru a compressor, it also pick up oil
vapors. When this gas cools, these vapors condense on the piping surface. Heat transfer
equipment and instrument tubing are fouled by this oil. Sometimes oil and moisture are
poisons for the process.
Oil and moisture separation from the compressed gas is carried out by two methods.
1.
2.
Absorption and sieving on a chemical compound to get extra dry gas

Mechanical separation techniques.
Method No. 2 is normally used for oil and moisture separation in reciprocating compressors.
It involves:
4.10
a).
Cooling of compressed gas where oil and water vapors also condense. Compressors
are equipped with inter stage or after stage heat exchangers called coolers.
b).
Separators are installed downstream of coolers to knock down suspended droplets of

oil and water. These separators or knock out drums contain internal baffles or some
other complex mechanical design. These are often equipped with level devices and
auto drainers.
c).
Lastly traps are installed to discharge the condensed liquid from the system with
minimum gas loss
PULSATION & VIBRATION CONTROL

Because of cyclic mode of operations, reciprocating compressors produce pressure and flow
rate pulsation in their inlet and outlet piping. These pulsation's are reduced by specially
designed vessels (pulsation bottles) placed immediately at the inlet and discharge nozzles of
each cylinder.
The reciprocating parts of compressors such as pistons, rods, cross heads and connecting rods
have inertia forces (momentum) which are never perfectly balanced. Under part load
conditions the unbalanced reciprocating forces become severe. Massive precise foundations
are built to keep the vibration minimum. Counter weights are also designed to balance the
opposing forces.
Vibration can also be caused by failure of some mechanical part. Hence constant measuring
devices and excess vibration cutout instruments are often installed to save the machines.

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ACCESSORIES
In order to do their jobs efficiently most air compressors are equipped with a number of
accessories. Figure 9 shows a two cylinder, two stage, double acting L shape reciprocating
compressor with 4 common pieces of accessory equipment; an intake air filter, an inter-cooler
with a moisture separator, an after-cooler with a moisture separator and a receiver.
Almost every compressor has an intake air filter. These filters are usually made of a porous,
fibrous material; they remove dust, dirt and other contaminants from air before it enters the
cylinders. This prevents premature wear to the cylinders, pistons and rings due to the abrasive
properties of the contaminants.
Most multistage compressors are equipped with inter coolers. Inter cooler, usually coupled
with a moisture separator, cools & removes moisture from air being discharged from one
stage before it enters next stage. The after cooler and its moisture separator repeat this
function for the air discharged from last stage before it enters the receiver. (Single-stage
compressors can only have after coolers).
A receiver is nothing more than a storage tank for compressed air. Discharge piping transfers
compressed air from compressor to the receiver. Additional pipes or hoses transfer
compressed air from the receiver to the rest of the air system. Air can be drawn from the
receiver in a steady stream, as opposed to pulsing discharge from the compressor. Also, the
reservoir of compressed air can satisfy momentary high demands above the capacity of
compressor. Receivers are typically equipped with drain plugs to remove additional moisture
that settles in the tank as the air cools and the water vapor in it condenses.
Since moisture separators are never 100% effective, additional dryers may be installed when
extremely dry air is required. Air dryers, usually installed downstream of the receiver, work
on either of two principles; they may be either refrigeration dryers or desiccant dryers.
Refrigeration dryers work by passing air over a series of cold refrigeration coils similar to
those in a home refrigerator. Air from the receiver enters a precooler / preheater, where it is
cooled by outgoing cool air. From the precooler /preheater, the air flows to a heat exchanger,
which contains the refrigeration coils. as air passes over the coils, it is further cooled and
moisture (oil or water ) condenses into droplets. The droplets-laden air then passes thru a
conventional moisture separator to remove the liquid. Next, the cool dry air flows back thru
precooler / preheater to be warmed by incoming air and then discharged to the system that
uses it.
Desiccant dryers have tanks filled with a moisture absorbing chemical called a desiccant
which can be regenerated when it becomes saturated with moisture. Air flows thru an inlet &
down thru desiccant bed of the left-hand tank where airs moisture is absorbed. They dry air
then exits thru a central tube. At the same time tank on the right is being regenerated.
Regeneration restores desiccants moisture absorbing capability after it has been saturated. As
dry air leaves the desiccant dryer, a small portion of the air is directed to the central tube of
the tank being regenerated. This air is heated by heating coils in the central tube until it is

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capable of absorbing additional moisture. The heated air then moves up thru the desiccant
material, absorbing moisture and thus regenerating the tank. When the left-hand tank has been
saturated, the air flow switches to the right-hand tank while the tank on the left is regenerated.
This allows the drying process to continue without interruption.
4.12
CHOKE
When the compressed air system pressure decreases, a centrifugal compressor delivers an
increased volume of air. As the system pressure continues to decrease, the volume of air
delivered from the compressor continues to increase until the air velocity somewhere in the
compressor reaches the speed of sound. At this point, the flow is said to be CHOKED
because further reduction in system pressure does not result in additional air volume delivered
from the compressor. Choke is the maximum flow that can be passed through the compressor.
4.13
SURGE Surge is a momentary reversal of flow in the compressor. As the compressor discharge
pressure increases, the discharge flow decreases. Increasing the discharge pressure eventually
leads to a point where the pressure developed by the compressor cannot over come the system
resistance. When this occurs, the compressor can support no higher discharge pressure and
flow abruptly reverses, going back from discharge to inlet. The discharge pressure drops
rapidly due to the lack of air delivery into the discharge piping, and, forward flow is resumed.
If the conditions causing surge persist, the reverse-then-forward flow cycle continues. This is
characterized by repeated slamming of the discharge check valve and audible whumping.
Continuous operation in surge can cause high vibration and high interstage air temperatures,
resulting in compressor shutdown. For this reason, Cooper Turbo compressors are typically
equipped with control systems to prevent surging.
4.14
TURNDOWN Turndown is the ability of the centrifugal compressor to maintain its discharge pressure set
point at reduced discharge flows. With the control system set to deliver a constant discharge
pressure, the inlet throttle valve will throttle inlet flow to maintain discharge pressure in the
event that the compressor is producing more than the system requires. As the inlet throttle
valve moves in the closed direction, the flow through the compressor decreases. As the flow
decreases, the compressor moves closer to surge. Surge is eventually reached, at that pressure
set point, establishing the turndown range.
True turndown is the amount of flow (measured in % of full flow) that the compressor can
throttle back, while maintaining a constant discharge pressure, until reaching the surge point.
Usable turndown is defined as true turndown minus a control margin. Typically, an anti-surge
control set point is established 5% above the minimum flow surge point. This allows stable
compressor operation during periods of large demand swings.

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FUNDAMENTALS
OF AIR
COMPRESSOR
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DESIGN POINT
Each compressor is designed for a specified set of operating conditions that correspond to a
point on the performance curve. At this design point the compressor operates at its best
efficiency. If the compressor is operated off the design point, the efficiency will be lower.
Therefore, the objective is to operate the compressor as close to an optimum level of
efficiency as possible.
The design point is based on several conditions.
Inlet Temperature
Inlet Pressure
Relative Humidity
Input Speed
Cooling Water Temperature/ Interstage Temperature.
Changes in these conditions will effect the performance characteristics of the compressor.
INLET TEMPERATURE.
Lower Temperature:
Increases the surge pressure.
Increases the maximum capacity (weight flow) at a given discharge pressure
Increases power consumption (horsepower)
Higher Temperature
Decreases the surge pressure
Decreases the maximum capacity (weight flow) at a given discharge pressure.
Decreases power consumption (horsepower)
INLET PRESSURE
Changes can be caused by fouled inlet filters or changing barometric pressure.
LOWER INLET PRESSURE:
Decreases the discharge pressure along the entire curve.
Decreases the maximum capacity (weight flow)
Decreases the consumption or horsepower (due to reduced weight flow)

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COMPRESSOR
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INPUT SPEED
Speed has a strong influence on compressor performance A 3% change in speed can affect
maximum capacity by 12%
LOWER SPEED
Decreases the discharge pressure along the entire curve.
Decreases the maximum capacity (weight flow)
Decreases power consumption (horsepower)
HIGHER SPEED
Increases the discharge pressure along the entire curve.
Increases the maximum capacity (weight flow)
COOLING WATER TEMPERATURE / INTERSTAGE TEMPERATURE
Cooling water temperature will affect the performance of the compressor stage after the first
stage. The effect in performance is similar to that of inlet air temperature. This of course is
true because cooling water temperature variations will directly effect the temperature of the
air entering the second, third and subsequent stages where there are inter coolers located
between stages.
LOWER COOLING WATER TEMPERATURE.
Increases discharge pressure.
Increases maximum capacity (weight flow)
HIGHER COOLING WATER TEMPERATURE.
Decreases discharge pressure.
Decreases maximum capacity (weight flow)
Decreases power consumption (horsepower
TWO OTHER CAUSES CAN ALSO HAVE AN AFFECT ON COMPRESSOR
PERFORMANCE
1.
Fouled Inter coolers -- After long service and particularly where poor cooling water is used
deposits form inside the inter cooler tubes and reduce their ability to remove the heat added
during compression. When inter cooler tubes become fouled, more cooling water will be
required to maintain the desired inter stage air temperatures. If fouling is sever or if the water
supply is inadequate, inter stage temperatures will increase, resulting in a decreases in
performance.

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COMPRESSOR
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Impeller Erosion - Damage to an impeller that has caused blade tip wear, will cause
performance changes similar to a reduction in speed. An eroded impeller means a reduction in
discharge pressure and power consumption.
CONCLUSIONS
From the basic principles covered in this section, a worst case scenario would consist of high
inlet and inter stage temperatures, low inlet pressure, high humidity, and low input speed.
These factors tend to lower the pressure making capabilities and decrease the usable operating
range. The fact that these conditions also tend to decrease the power consumption is little
compensation if the compressor cannot make the required discharge pressure. The final
defense against running out of capacity on a hot, humid day, is to design the compressor for
sever base conditions and include a large pressure rise to surge.
4.16
TERMINOLOGY
SURGE The maximum pressure of a centrifugal compressor before a reversal in flow occurs.
This flow reversal is usually accompanied by a whumping noise, high vibration and high
inter stage air temperatures. Surge is a characteristic of all centrifugal compressors. As the
surge point is reached, the air flow abruptly reverses, going back from discharge to inlet. The
discharge pressure drops rapidly due to the lack of air delivery into the discharge piping, and
forward air flow is resumed. If the conditions causing surge persist, the reverse -then- forward
air flow cycle will continue. This is characterized by a repeated slamming of the discharge
check valve and audible whumping
CHOKE Frequently called stonewall also. Choke is at the opposite end of the performance curve from
surge. Choke is the maximum flow at which the compressor can operate.
TURNDOWN The maximum amount (expressed in percent) that flow can be reduced while still maintaining
design discharge pressure. If flow is reduced further, the compressor will surge.
RISE TO SURGE This is the amount of pressure that the compressor can produce in excess of the design
pressure.

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SAFETY
AND HAZARDS OF
THE AREA
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SECTION-5 SAFETY AND HAZARDS OF THE AREA

5.1
INTRODUCTION
PHILOSOPHY
The purpose of this section is to familiarize the operator with some potential hazards in the air
compressor post and the equipment provided to control the hazards.
There is no job so important that it cannot be done safely. The use of safe procedures and the
proper safety equipment is a help in conducting our business, not a hindrance It is essential
that the operator develop positive safety attitude. This will occur only when he firmly believe
that the safe way is the only way he can properly do his job.
The operator is not only responsible for his own safety but also he has a responsibility to
conduct himself in such a manner so as not to jeopardize the safety of his fellow employees.
The operator is the proprietor of the plant. He is operating and as such has the prime
responsibility for the safety of all who enter his work area.
5.2
SAFETY AND FIRE FIGHTING EQUIPMENT

All safety equipment should be in place and in proper working order, refer to Chapter-7,
Appendix Section 6.1.
5.3
HAZARDS
5.3.1
STEAM.
Area comprises 12 kg/cm2 (175 psig) super heated , 12 kg/cm2 (175 psig) saturated and
2 kg/cm2 (25 psig steam). Steam is used for the operation of air compressor C-701B, heating
of regeneration air in AD-711/712 and heating of coating oil.Steam system operates at very
high temperatures. There is a risk of burns if exposed to high temperature and high pressure
steam. Area operators are advised to use special precautions and protectives against the this
hazard Do not touch the naked steam piping Use PPE while taking samples and operating or
attending maintenance activities at steam.
5.3.2
LUBE OILS
Various lube oils are being used at utility unit. Oil leaks can occur which are health, fire
material.Use appropriate protective equipment during clean up.
Warn all employees in the area in which the leaks occur and in the surrounding area which
may be affected. Remove or control the possible sources of ignition.
5.3.3
ELECTRIC SHOCK
Gas turbine and compressor area contains a big electrical net work comprising of generator ,
Main Switch gear room, urea switch gear room, 6.6 KV, 440V, 120V AC and 125V DC
circuits.While working at the electrical systems proper procedures to be used. An electrical
work permit to be obtained before any work is to be performed on any electrical circuit.

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The electrical power source should be turned off and lock out tag out procedure to be strictly
followed Stay in contact with your shift supervisor and Shift Co-ordinator to ensure that
correct power source or breaker has been turned off / disconnected / locked an properly
tagged.
Work permit procedure and lock out tag out procedures to be followed strictly. An incident
will be recorded if electrical job found in progress with out wok permit, proper authorization
and proper isolation.
5.4
PERSONAL PROTECTION
No amount of personal protective equipment is an adequate substitute for safe working
conditions carefulness in following instructions, or using good judgment Further protective
equipment is of little valve if not used properly.
5.4.1
MANDATORY PERSONAL PROTECTION

Use of following personal protectives is mandatory in the area.
1.
2.
3.
4.
5.
6.
7.
Approved Safety goggles.

Approved gloves.
Approves Safety Shoes.
Approves Hard Hat
The collar must be kept buttoned , sleeves must not be rolled and trouser legs should
be let outside boots .
Approved dust Masks, While working with filters of GT.
Approved face shield while washing CWMs.
5.4.2
OTHER SAFETY EQUIPMENT
A)
SCOTT AIR PACK

For exposure to any concentration of over 50 ppm of ammonia gas Scott air packs must be
worn. Scott Air-Packs are strategically located throughout the plant.
B)
SAFETY SHOWER
To facilitate the quick removal of chemicals form the body safety showers and eye washing
facilities have been provide at strategic locations throughout the plant. The safety showers
have quick-Acting valves capable of supplying large quantities of water.

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HAZARDS OF
INADVERTENT
MIXING
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SECTION- 06 HAZARDS OF INADVERTENT MIXING

6.1
The scenarios of inadvertent mixing which may occur at Air Compressor post along
with their Hazards and Prevention Measures have been discussed as under:
Sr #
1
Description
Hazards
Oil emulsification Oil emulsification could
in C-701A/B and
result into improper oil
C-702 due to lube
lubrication resulting into
oil cooler leakage
bearing damage.
Excessive
Water
ingress into Steam
System
Excessive water
ingress into air
system.
Prevention Measures
Regular monitoring of Lube
oil level in oil reservoirs.
Lab analysis of Oil samples
Drain moisture from reservoir
by opening drain valve.
Centrifuge operation in case
water appears in the above
two tests.
Steam hammering can Closely monitor 12kg/cm2g

occur which may result (175psig) steam lines during
into piping and supports
startup of C-701B.
damage
Check operation of steam
Excessive
water
in traps .
steam can damage steam Completely drain condensate
turbine.
from steam lines before start
up.
Dew point of instrument
air will increase.
Potential of control
valve failure .
Check C-702 1st stage after

cooler for internal leakage.
Check operation of auto
drainers.
Crack open auto drainer
bypass valve.
Open D-711 auto drainer
bypass valve.

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SECTION-07
STANDARD OPERATING
CONDITIONS
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STANDARD OPERATING CONDITIONS.
Followings are the Standards Operating Conditions of Air Compressor post.
1)
Tag No: VT-1/2/3/4/5/6 C-702 Vibration
Deviati Display
ons
range
High
Alarm/
trip
1.5/2.0
Normal
Operating
Range
(Guidelin
es)
0.7
Unit = Mills
Possible causes
Effects / Hazards
/ Consequences
Oil temperature
OIL pressure
Surging
Mechanical
Operation of
compressor at high
vibration could
damage
equipment.
failure
Instrumentation
failure
Inter lock = Yes

Set point=2.0
Determine Causes
Corrective
Actions
Oil temperature high
Control oil temperature
Maintain oil temperature
by increasing CW flow
Oil temperature low
within range
Oil pressure high/low Maintain oil pressure

within normal range
Oil type incorrect

Contaminated oil
Use recommended oil

Sent oil sample for
Surging
Check minimum amps
analysis
set point, inlet filters dp
and air pressure set point
Misalignment
Drive coupling
damaged or worn
Impellers dirty or
damaged
Vibration probes
faulty
Normal
Low
0.2- 0.5
0.1
Instrumentation
fault
2)
Tag No: TE-3/5 C-702 Inter stage temperature
Check alignment
Check coupling
Check ampellers
Calibrate vibration
probes
Vibration probe
Calibrate vibration
faulty
Termination loose in
PLC
probes
Check termination in
PLC and rectify fault
Unit = oC (oF)
Inter lock = Yes

Set point=60 (140)

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Deviati Display
ons
range
Alarm/
trip
Normal
Operating
Range
(Guidelin
es)
High
54.4/60
(130/140)
51.6
(125)
STANDARD OPERATING
CONDITIONS
Possible causes
CWS insufficient Reduction in

compressor
Inter stage/ after
cooler low
efficiency
Instrumentation
faulty
Normal
32.2-48.8
(90-120)
26.6
(80)
Low
Effects / Hazards
/ Consequences
efficiency
Reduction in air
dryer efficiency
High
Normal
Low
Alarm/
trip
2.81/3.52(
40/50)
Normal Possible causes

Operating
Range
(Guidelin
es)
1.05
(15)
0.42-0.7
(6-10)
0.35
(5)
Determine Causes
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Corrective
Actions
CW flow to coolers
Increase cooling water
insufficient
Coolant temperature
too high
Inter cooler and after
cooler fouled
Sensor reading faulty
Surging
flow
Reduce CWS
temperature
Back wash / clean inter
stage/after coolers
Check sensor calibration
Check surging conditions
No issue
3) Tag No: PDT-1 C-702 Lube oil filter pressure drop

Deviati Display
ons
range
Document No.
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Issue No
Chapter No
Section No
Page
Unit = kg/cm2g (Psig)
Effects / Hazards
/ Consequences
Determine Causes
Inter lock =Yes

Set point=3.52 (50)
Corrective
Actions
Lube oil filter

Sensor
Compressor
Oil filters element
Change over lube oil
operation at low
lube oil pressure
could damage
machine
Compressor
tripping on low oil
pressure security
dirty or clogged
Sensor faulty
Calibrate sensor
Lube oil filters

Sensor
High oil pressure
Oil filter element
Replace oil filter
worn out
Sensor faulty
Calibrate sensor
could cause
leakage in oil
circuit
filters. Replace filter.
4) Tag No: PT-3/4 C-702 Lube oil pressure Unit = kg/cm2g (Psig) Inter lock = Yes
Set point Low/ High=4.92/1055 (70/150)

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Deviati Display
ons
range
High
Alarm/
trip
8.94/10.55
(140/150)
Normal
Low
5.62/4.92
80/70
STANDARD OPERATING
CONDITIONS

Operating
Range
(Guidelin
es)
8.44
(120)
7.03-8.08
(100-115)
6.68
(95)
Effects / Hazards
/ Consequences
Document No.
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Issue No
Chapter No
Section No
Page
Determine Causes
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Corrective
Actions
Regulator
High oil pressure
Lube oil pressure
failure
Oil temperature
Sensor
could result in oil

leakages and
tubing failure
Compressor
tripping
regulator set
improperly or
malfunctioning
Low oil temperature
Increase oil temperature

Calibrate sensor
Oil level
Machine
operation at low
Pump failure
oil pressure could
Oil filter
result into
Oil temperature
equipment
damage
Sensor
Tripping of
Oil level in reservoir
Maintain lube oil level
compressor
too low
Pressure regulator
set improperly or
malfunction
Oil filter element
dirty or clogged
High oil temperature
Leakage within oil

circuit
Sensor reading
faulty
Pump coupling
failure
Check setting of
regulator.check health of
regulator
in reservoir
Check and adjust

pressure regulator
Replace oil filter

Maintain oil
temperature
Check oil leakages and
remove them
Calibrate sensor
Replace coupling.

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STANDARD OPERATING
CONDITIONS
5) Tag No: TE-1 C-702 Lube oil temperature

Deviati Display
ons
range
Alarm/
trip
High
57.262.7
(135/145)

Operating
Range
(Guidelin
es)
56.6
(134)
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Unit = oC (oF) Inter lock = Yes

Set point Low/ High =15.5/62.7 (60/145)
Effects / Hazards
/ Consequences
CWS
Could result into
insufficient
CWS
temperature
Oil cooler
Sensor
Thermal mixing
valve
bearing over
heating and gear
box damage.
Compressor
tripping
Determine Causes
Corrective
Actions
Water flow to lube oil Increase CWS to lube oil

cooler insufficient
cooler
Coolant temperature
Reduce cooling water
too high
Oil cooler fouled
Thermal mixing
valve faulty or
missing
temperature
Back flush / clean cooler
Calibrate sensor
Check thermal mixing
valve presence and
operation
Check thermostat
presence and calibration
Oil heater thermostat

faulty or missing
Normal
Low
21.1/15.5
(70/60)
43.3-54.4
(110-130)
40.5
(105)
CWS excessive Could result into CWS pressure high

oil circuit leakage Sensor reading
Sensor
Could result into

faulty
Thermal
machine
tripping
Thermal mixing
mixing valve
and thermostat
valve faulty or
missing
Oil heater thermostat
faulty or missing
Maintain CWS pressure

Check calibration of
sensor
Check thermal mixing
valve operation and also
verify its presence
Check thermostat
operation and also
verify its presence

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STANDARD OPERATING
CONDITIONS
6) Tag No: TE-8/9/10 C-702 Motor stator temperature

Deviati Display
ons
range
High
Alarm/
trip
165.4/170.9
(330/340)

Operating
Range
121
(250)
problem
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Unit = oC (oF) Inter lock = Yes

Set point=170.9 (340)
Effects / Hazards
/ Consequences
Ambient too high Could result into

motor winding
Voltage improper
failure
Load too high
Could result into
Electrical problem machine tripping
Mechanical
Document No.
Revision No
Issue No
Chapter No
Section No
Page
Determine Causes
Voltage low
Motor overload
Wiring improper
Winding shorted
Motor seized
Compressor shaft seized
Compressor set point
improper
Sensor faulty
Dirt in air gaps
Corrective
Actions
Check and control voltage

Reduce load
Check wiring
Rectify winding fault
Check motor shaft rotation
Check compressor rotation
Verify set points and give
correct value
Replace faulty sensor

Clean air gaps and check
canopy fan
Normal
82.1-112.7
(180-235)
76.6
(170)
Sensor faulty
Sensor faulty
Ambient too low
Replace faulty sensor

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STANDARD OPERATING
CONDITIONS
7) Tag No: AI-001 AD-712 instrument air Dew point analyzer

Deviati Display
ons
range
High
Alarm/
trip

Operating
Range
(Guidelin
es)
-6
(-10)
Effects / Hazards
/ Consequences
Improper
Could results into
regeneration
Humid inlet air
Analyzer faulty
Change over
valves failure
Desiccant
performance
poor
control valve
failure
Could results into
transmitters failure
Document No.
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Section No
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Unit = oC (oF) Inter lock = No

Determine Causes
Poor or no
regeneration
Excessive free water

in air to the dryer
Dew point analyzer
Corrective
Actions
Check dryer valve

sequence operation and
sequence times.Check
regeneration flow is
satisfactory,
depressurization is
satisfactory
Check upstream system
drains and pre filter
drains. Reduce
quenching water flow
into C-701A/B.
Calibrate analyzer
faulty
Dryer sequence
valves failed to
change over.
Desiccant
performance
poor.(desiccant
powdered or
contaminated by oil
etc.)
Inlet air low pressure
or high temperature.
Regeneration cooler
or heater fault
Normal
Low
-17--56
(-30--100)
-56
(-110)
Analyzer faulty
Analyzer faulty
Check dryer logic and

controls
Check condition of
desiccant and change if
necessory.Check pre
filter operation for oil
removing.
Check process operating

conditions and normalize
it.
Check cooling water
flow and steam flow.
Calibrate analyzer.

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STANDARD OPERATING
CONDITIONS
8) Tag No: PT-1/2 C-702 discharge air pressure

Deviati Display
ons
range
Alarm/
trip

Operating
Range
(Guidelin
es)
9.49
(135)
Demand low
Instruments
fault
Normal
Low
8.93-9.28
(127-132)
8.72
(124)
Control failure
High load
Mechanical
fault
Document No.
Revision No
Issue No
Chapter No
Section No
Page
Unit = kg/cm2g (Psig)

Effects / Hazards
/ Consequences
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Inter lock = No
Determine Causes
Corrective
Actions
Machine surging Low air demand at

Check air demand and
adjust load
Mechanical failure plant
Air pressure set point Check air pressure set
may occur
too high
Sensor faulty
Control valve faulty
Compressor
discharge non return
valve malfunction
points
Calibrate sensor
Check block valve
Check non return valve
operation
Surging could
Air pressure set
Check and correct air
happen
Compressor over
loading could
results into
machine failure
point incorrect
Maximum amps set
point incorrect
Air demand above
compressor rating
Sensor reading
faulty
Inlet air filters dirty
or restricted
Impellers dirty
Control valve faulty
pressure set point

Check and correct
maximum amp set point
Keep compressor
loading below rating
Check and calibrate
sensor
Clean or replace inlet
air filters
Clean impellers
Rectify control valve
fault

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Tag No: PI-704
Deviati Display
ons
range
High
Alarm/
trip
7.38
(105)
STANDARD OPERATING
CONDITIONS
Instrument air pressure

Operating
Range
(Guidelin
es)
8.72
(124)
Low demand
Control failure
Document No.
Revision No
Issue No
Chapter No
Section No
Page
Unit = kg/cm2g Psig

Effects / Hazards
/ Consequences
Low
8.23-8.52
(117-122)
8.08
(115)
High demand
Control failure
Dryer fault
Compressor
tripping
PR-UT1-M7
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1
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39 of 39
Inter lock = No
Determine Causes
Corrective
Actions
Pressure relief
Low instrument air
Adjust load at
valve may pop

Instrumentation
failure could occur
Compressor may
surge
consumption at plant
Incorrect pressure set
point to compressors
Check and correct
compressors
Sensor faulty
pressure set poin of

compressors
Check set point of
PIC-704 and control
valve opening
Check set point of
PIC-703 and control
valve opening
Calibrate sensor
Control valves on
Leakage in
Check and remove
fail safe position

resulting into
plant tripping.
Over loading of
compressors
instrument air
header
Controller failure
PIC-704 malfunction
PIC-703 malfunction
Normal
:
:
:
:
:
:
Dryer desiccant
broken resulting into
high differential
pressure across
dryers
Sensor failure
KGT-2501or C-702
tripping
instrument air leakages
Check PIC-704 out put

and take control valve
on bypass if needed
Replace desiccant if dp
across dryer is high
Calibrate sensor
Start C-701A/B and
close PIC-703V if not
closed on auto

Document Type:
Document No.:
PR-UT1-M7
Document Status:
Final
Posts Manuals
CHAPTER-2
EQUIPMENT
DETAIL AND
SPECIFICATION
Originated by :
Issue No. 1 by :
Issue No. 2 by :
Issue No. 3 by :
Issue No. 4 by :
Revision 1
:
Reviewed by :
Approved By :
Update due :
AAd
SF
AIH
ARQ
MAL
Burero/KRm
ARH
JP
Unit : Utility-1
in : June, 1996
in : June, 1998
in : June, 1999
in : June, 2003
in : June, 2006
in : July , 2009
in : July , 2009
in : July , 2009
in : July , 2012
Code: PR-UT1
TABLE OF CONTENTS
SECTION
DESCRIPTION
01
1.1
1.2
1.3
1.4
1.5
1.6
1.7
02
2.1
2.2
2.3
2.4
2.5
2.6
2.7
2.8
03
3.1
3.2
3.3
3.4
3.5
3.6
3.7
3.8
PAGE
RECIPROCATING COMPRESSORS C-701 A/B

AIR COMPRESSORS
C-701A/B AIR COMPRESSORS
IMPORTANT DETAILS
ELLIOT STEAM TURBINE
TURBINE OIL SYSTEM
GOVERNOR
OILS USED IN LUBRICATION
1
1
2
3
3
3
4
CENTRIFUGAL AIR COMPRESSOR C-702

NEW C-702 INSTALLATION BACKGROUND
AIR FLOW DESCRIPTION
THE COMPRESSOR LUBRICATION SYSTEM
GEARBOX AND RESERVOIR VENTING
MODULATED BLOW OFF VALVE
INLET GUIDE VANES
LIQUIDATOR CONDENSATE DRAIN TRAP
COMPRESSOR CONTROL THEORY OF
OPERATION
5
5
6
7
8
8
8
9
EQUIPMENT SPECIFICATIONS
AIR COMPRESSORS CO-701 A/B
C-701A MOTOR
C-701B TURBINE
C-701 A/B DUST BLOWER MOTOR
C-701 A/B INLET AIR FILTER FIL-701
C-701 A/B INTER COOLER E-702 A/B
C-701 A/B AFTER COOLER
KNOCK OUT DRUM D-711
12
12
12
13
13
13
13
14

Document Type:
Document No.:
PR-UT1-M7
Document Status:
Final
Posts Manuals
CHAPTER-2
EQUIPMENT
DETAIL AND
SPECIFICATION
SECTION
3.9
3.10
3.11
3.12
3.13
3.14
3.15
3.16
3.17
Originated by :
Issue No. 1 by :
Issue No. 2 by :
Issue No. 3 by :
Issue No. 4 by :
Revision 1
:
Reviewed by :
Approved By :
Update due :
AAd
SF
AIH
ARQ
MAL
Burero/KRm
ARH
JP
in : June, 1996
in : June, 1998
in : June, 1999
in : June, 2003
in : June, 2006
in : July , 2009
in : July , 2009
in : July , 2009
in : July , 2012
Unit : Utility-1
Code: PR-UT1
DESCRIPTION
AIR DRYER AD-711
AIR DRYER AD-712
REGENERATION COOLER E-713
REGENERATION STEAM HEATER E-712
MOISTURE SEPARATOR D-712
CENTRIFUGAL AIR COMPRESSOR (C-702
C-702 MOTOR
LUBE OIL PUMP MOTOR
CANOPY FAN MOTOR
PAGE
14
14
15
15
15
15
16
16
16

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SECTION-01
RECIPROCATING
COMPRESSORS
C-701 A/B
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EQUIPMENT DETAILS AND SPECIFICATION
RECIPROCATING COMPRESSORS C-701 A/B

1.1
AIR COMPRESSORS
We have two reciprocating, two-stage double acting, Ingeresoll Rand air compressors C-701
A/B and a centrifugal compressor C-702 to supply compressed air. Each reciprocating
compressor is designed to produce 1596 NMCH (980 SCFM) of compressed air (at 100%
load) at 8.79~9.49 kg/cm2g (125-135 psig) on continuous basis and C-702 is designed to
produce 2647 NMCH (1625 SCFM) air capacity. During normal operations air is supplied
from NH3-2 KGT and C-702. C-701A/B remains standby.
1.2
C-701A/B AIR COMPRESSORS

Air compressors C-701A/B provide instrument air for all pneumatic instrumentation in three
major sections of the plant ie. Ammonia, Urea and Utilities. They also supply Plant air for
process needs to the above mentioned three major sections as well as to the workshop and
PM&S.
C-701A is driven by an AEG electric motor while C-701B is driven by an Elliot steam turbine
powered by 12 kg/cm2g (175 psig) super heated steam.
Air flows thru two independent suction air filters to provide dust free air to the suction of air
compressors. It consists of a louver pocket in which dust is separated on the principle of
inertia, followed by a screen type filters (PL-24). The filters are self cleaned by means of a
motor driven traveling screen. Air goes to first stage of compressor after passing inlet filter.
Air is compressed to 2.11 kg/cm2g (30 psig) in the low pressure (first stage) stage.
An inter cooler is provided between the low pressure 1st stage and the high pressure 2nd stage
with ordinary plant cooling water as the cooling medium. It cools the heated compressed air
being discharged from the 1st stage, hence increasing the density and reducing load on the
2nd stage. Air is send to 2nd stage of compressor from inter cooler where it is compressed to
8.79~9.14 kg/cm2g (125-130 psig) pressure.
The air from 2nd stage discharge at a temperature of around 148.7oF (300F) flows thru a
double pipe heat exchanger E-702 where it is cooled to around 46oF (115F). Condensing
water in the air is separated by means of a moisture trap water knockout bottle.
The air after passing thru exchanger is led to the air receiver D-711.
Both the stages are also water jacketed in order to prevent the valves from over heating.

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C-701 A/B
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IMPORTANT DETAILS
w
Both compressors are double acting in function.
Each compressor has two stages (angle configuration) with there being one cylinder
per stage.
Each compressor has a capacity of 1596 NMCH (980 SCFM).
Number of inlet / outlet valves are 6/6 for 1st stage and 4/4 for 2nd stage. They are of
channel type.
A fly wheel is provided at both compressors to provide inertia.
Both the cylinders are protected by safety valves. PSV-702A/B at the 1st stage
discharge is set at 2.6 kg/cm2g (37 psig) while PSV-701A/B at 2nd stage discharge is
set at 10.55 kg/cm2g (150 psig).
Maximum allowable discharge temperature for both compressors is 176.5oC (350F).

When this temperature is reached, alarm is sounded in control room indicating need
for immediate corrective action i.e. unloading of compressor.
C-701A is driven by an AEG electric motor with a rated HP of 270 running at 1450
rpm. The gear ratio is 2.82:1.
C-701B is driven by an Elliot steam turbine with a rated HP of 240 running at 3600
rpm. The turbine is equipped with a Wood Ward governor and runs on 12 kg/cm2g
175 psig superheated steam. The gear ratio is 7:1.
For cylinder lubrication a force feed lubricator is used, while for crank case
lubrication purposes an oil pump is installed which is driven by the compressor shaft.
In case the pump fails to maintain pressure and the oil pressure goes below 0.84
kg/cm2g 12 psig, the compressor trips on an PLCO security.
Gear box lubrication is carried out through shaft driven lube oil pump. In case of
C-701B, turbine bearings are also lubricated through same lube oil pump.
Figure-2 shows the various valve locations for the 1st and 2nd stage in a simple machine
sketch, while figure-1 shows the orientation of the major sub-units comprising the air
compressor.
Both the stages are also water jacketed in order to prevent the valves from overheating.

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C-701 A/B
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ELLIOT STEAM TURBINE

The driver of air compressor C-701B is an 240 HP two stage steam turbine. Super heated 12
kg/cm2g (175 psig) steam is used to rotate the buckets and rotor of turbine. The exhaust is 2
kg/cm2g (25 psig) steam which is led to the main 2 kg/cm2g (25 psig) steam header.
The rated maximum speed of turbine is 3600 rpm and over speed trip setting is 3950 rpm. The
turbine is normally run at 2900-3100 rpm. The speed of the turbine is regulated by a Wood
ward PG governor
The Elliot steam turbine is a rugged machine requiring a minimum of operating attention.
Providing adequate lubrication is the one really essential and important operating
requirement. However any routine system of inspection which anticipates possible operating
difficulties before they reach serious proportions is desirable and some points which should
be part of a regular inspection routine are mentioned below:
1.
2.
3.
4.
1.5
Check oil in sump and add oil if needed

Fill governor oil and maintain level as needed
Check smoothness of operation and note any change
Check governor for hunting
TURBINE OIL SYSTEM

It is a pressure circulation system in which an oil pump forces oil thru cooler, filter etc. to
bearings, gear reducer and governor, returning the warm oil by gravity to an oil reservoir.
Figure-3 shows the turbine oil distribution for C-701B.
1.6
GOVERNOR
Wood ward PG governor controls speed of steam turbine in C-701B. The governor is
mounted on a housing which is fastened to the bearing case. It is driven at reduced speed from
turbine shaft by means of a worm and worm wheel and is connected to the governor valve
thru suitable linkage.
The following elements found in the PG governor are sufficient to enable the governor to
maintain a constant engine speed as long as the load does not exceed capacity.
1.
An oil pump, storage area for oil under pressure and a relief valve by which maximum
oil pressure may be limited.
2.
A centrifugal flyweight-head pilot valve assembly which control flow of oil to and
from the governor power cylinder assembly.

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3.
A power cylinder assembly - sometimes referred to as a servo motor - which

repositions the steam valve of the turbine.
4.
A compensating system which gives stability to the governed system.
5.
A means of adjusting the governor and thus the turbine speed setting.
The governor has its own-self-contained oiling system and the main turbine lubrication
system provides for oiling the worm and worm wheel drive. The oiling system consists of an
oil pump and oil filter. The governor drive shaft driven at a speed proportional to turbine
speed by mechanical connection to the turbine, rotates the pump drive gear and governor pilot
valve bushing. As the rotating drive gear turns the idler gear, oil is drawn from the oil sump
and is carried in the space between the gear teeth and the walls of the gear pocket to the
discharge side of the pump.
The operation of the governor is such that increased speed results in outward movement of
governor rod end, this movement is transmitted thru linkage to close the governor valve.
Decrease in turbine speed results in inward movement of rod end and opening of governor
valve until equilibrium conditions are obtained.
When turbine is shutdown, the governor valve will move to open position and turbine will
thus be ready for immediate startup with no manual resetting of governor valve being
required. However, resetting of the over speed trip lever will be necessary if the lever was
tripped to shutdown the turbine.
The governor linkage should be kept well lubricated at all times.
1.7
OILS USED IN LUBRICATION

EQUIPMENT
OIL
Cylinders (FFL)
Crank case
Gear reducer & turbine bearings
Governor oil
Viterea -150
T -68
Omalla -220
Turbine oil-32

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AIR COMPRESSOR
C-702
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SECTION-2 CENTRIFUGAL AIR COMPRESSOR C-702

2.1
NEW C-702 INSTALLATION BACKGROUND

As per 850 KT balances, approx. 2769 NMCH (1700 SCFM) of supplemental air was needed
from UTY compressors (C-701 A/B, C-702) on continuos basis during summer months to
sustain 850 KT load. Our actual operating experience at 850 KT load also verified these
balances, as 1222~2444 NMCM (750~1500 SCFM) of air had to be obtained from C-701 A/B
and C-702 during summer months. This mode of operation, obviously, requires UTY
compressors to be fully healthy and operational. However, the situation was not so favor able
due to the non-availability of C-702 (Damaged 2nd stage screws and casing) and unhealthy
condition of C-701 A/B. (High final discharge temperature problem). That made our
operation highly vulnerable, especially during summers, as outage of any of C-701 A/B
would lead to process air shortage, hence, direct production loss. Moreover, reliability of
these oil lubricated compressors cannot be ensured with full confidence due to inherent design
problems. Ultimately, a brand new, fully reliable and healthy compressor was needed to
ensure availability of installation / plant air on long term basis. Based on that philosophy a
new centrifugal air compressor C-702 of capacity 2647NMCH (1625 SCFM) installed
instead of old C-702.
2.2
AIR FLOW DESCRIPTION.

Air enters the system through the inlet filter/ silencer. It travels through the intake pipe to the
inlet valve. The inlet valve directs the flow of air to the first stage. Air is compressed by the
first stage and directed to the first stage intercooler. Air is cooled in the intercooler and
directed to the second stage where it is compressed further and directed to the second stage
intercooler. Air is cooled in the second stage intercooler and directed to the third stage where
it is compressed to design pressure and discharged to the plant system.
The air enters the compressor through the inlet connection, which is proportioned to minimize
shock or turbulence as the air enters the impeller. The impeller imparts the velocity to the air
and delivers it to the diffuser where the flow is decelerated and the velocity energy is
gradually converted to pressure energy. The diffuser portion of the compressor is formed by
the back flat section of the inlet piece.
The diffuser is a narrow passage channeling the air as it leaves the impeller into the volute
section of the scroll where the air is collected. A shaft seal must be provided where the shaft
passes through the scroll to prevent the air from escaping out of the scroll. When the pressure
ratio exceeds the limit of a single stage compressor, a multistage must be used. This
construction requires a return passage for the air leaving each scroll and to deliver it to the
inlet of each succeeding stage. Keep in mind that the impeller is the only means of adding
energy to the air and all the work is done in this element. The flow passages, as opposed to a

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reciprocating unit are open throughout. There are no mechanical means of preventing back
flow in the design of the unit, and it can occur when the compressor is shut down unless a
check valve is used externally downstream of the compressor discharge.
Condensate drains are included as a part of each intercooler to remove condensate that has
resulted from cooling the compressed air.
A bypass valve is used for unloaded operation.
A check valve is provided in the discharge line to prevent reverse flow of the compressed air
in the plant air system.
A block valves is used to isolate the compressor from the plant air system during compressor
shutdown.
NOTE:
AN AUTOMATIC BLOCK VALVE IS STRONGLY RECOMMENDED AS ADDED
PROTECTION IN THE EVENT OF DISCHARGE CHECK VALVE LEAKAGE OR
FAILURE.
Centrifugal air compressor performance can be represented by a characteristic curve of
discharge pressure versus flow. This is a continuously rising curve from right to left. See fig.
01 for C-702 components.
2.3
THE COMPRESSOR LUBRICATION SYSTEM

1
The main oil pump mounted on the compressor gearbox and driven off of an extension
of the bull gear shaft, draws oil from the reservoir and cycles it through the lubrication
system and the compressor gearbox. Oil is prevented from being pumped back into the
reservoir through the auxiliary oil pump by a check valve
The oil passes through the oil cooler where excess heat is removed with the standard
package, oil temperature is maintained by regulating the flow of cooling water through
the oil cooler. This method, though effective, may require seasonal adjustments.
Including the Thermostatic Mixing valve option will automatically control oil
temperature by regulating the oil flow around the oil cooler, thus keeping the
temperature of the oil entering the compressor constant.
The oil continues on to the oil filter where impurities are removed. Cooper Turbo
Compressor offer the Duplex Oil Filter option. The duplex oil filter eliminates the
necessity for compressor shutdown during filter maintenance.

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The oil next flows to the gearbox where it flows through a manifold and is thereafter
distributed to the bullgear bearings the pinion bearings and the two gear-mesh spray
nozzles.
The oil returns to the oil reservoir, where it passes around a baffle arrangement that
breaks down any foam before it is allowed to continue to recycle through the
compressor lubrication system.
The pressure regulator valve maintains the correct operating pressure throughout the
lubrication cycle and returns any excess oil to the reservoir.
The oil pressure sensor and oil temperature sensor ensure that all critical mechanical
components are being properly lubricated and cooled by the oil. These sensors allow
the Quad 2000 Control Panel to inform the operator of present lubrication system
conditions.
It should be noted that during normal operation the auxiliary pump does not operate.
The main oil pump provides full compressor oil flow and pressure requirement. See P
& ID of C-702 for lube oil system.
2.4
GEARBOX AND RESERVOIR VENTING

During multi-geared, centrifugal compressor operation, the action of meshing gears and the
rotation of the bullgear cause air to become entrapped in the lubricating oil. As this air is
released from the oil, it forms an oil-laden mist in the gearbox and the oil reservoir. It is very
important that both the gearbox and oil reservoir are properly vented so that this oil mist is
not allowed to escape.
The Turbo Air 3000 Compressor utilizes a simple venturi-type ejector/ filter system to create
a slight vacuum inside the gearbox and oil reservoir. This vacuum prevents oil or oil mist
from migrating out into the atmosphere and / or creating other oil leaks.
WARNING:
INTRODUCING WATER INTO THE OIL RESERVOIR WILL HAVE ADVERSE
EFFECTS ON THE LUBRICATING OIL AND WILL CAUSE SEVERE DAMAGE
TO THE COMPRESSOR. BE SURE THE EJECTORS SUPPLY AIR IS CLEAN
AND DRY AND THE FILTER IS PROPERLY MAINTAINED.
Under normal operating conditions, the Ejector/Filter Arrangement operates as
follows:
1
Dry, filtered, compressed air enters the ejector inlet and is transformed into a high
velocity stream in the ejector nozzle.

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Air from the main oil reservoir becomes entrained in this high velocity stream
The resulting pumping action draws the oil-laden air from the reservoir and gearbox
and delivers it to the filter where droplets of oil accumulate and are then returned to
the main oil reservoir
2
The oil return line includes a mist trap before the oil reservoir. This mist trap serves as
a vapor lock to prevent the oil mist from bypassing the filter and escaping to the
surrounding area. See fig. 2
CAUTION:
ALWAYS MAINTAIN THE PROPER AIR SUPPLY PRESSURE TO THE
RESERVOIR VENT EJECTOR/FILTER SYSTEM WHENEVER THE OIL PUMP
IS IN OPERATION. FAILURE TO DO SO MAY CAUSE OIL LEAKS.
2.5
MODULATED BLOW OFF VALVE

The basic objective of the MBOV is to prevent surging by venting air thus maintaining
sufficient air flow through the compressor during low load operation or sudden load rejection.
2.6
INLET GUIDE VANES:

The basic objective of the IGV is to prevent motor from overloading by controlling inlet air
flow
2.7
LIQUIDATOR CONDENSATE DRAIN TRAP

The Liquidator is a demand operated condensate trap. Its purpose is to automatically drain
condensae from a compressed air system at natural collection points, without loss of
compressed air.
When the reservoir reaches the trigger point (approximately 52 ounces) a single acting, air
operated actuator opens the discharge ball valve and the condensate drains from the reservoir.
For proper operation of the Liquidator, venting or pressure relief is required. Trapped air
inside the reservoir can form an air lock and prevent the drain trap from operating. To
minimize air loss, a vent air pressure equalization line is utilized. The air is returned to the air
piping of the compressor at a tapped hole downstream of the vessel drain.

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The actuator requires a minimum of 3.87 kg/cm2g (55 psig) to open the valve and discharge
the condensate.See fig. 3.
CAUTION:
AIR / WATER UNDER PRESSURE WILL CAUSE SEVER INJURY OR DEATH.
BEFORE ANY DISASSEMBLY,
Shut down the compressor and relieve all pressure
Tag out and lock out the compressor starter
2.8
COMPRESSOR CONTROL THEORY OF OPERATION
2.8.1
AUXILIARY OIL PUMP CONTROL:

Prior to running the compressor the PLC signals the Auxiliary Oil Pump contactor to close
(XS-118). This assures that the Auxiliary Oil Pump is always running prior to starting the
compressor. Once the compressor is running the Auxiliary Oil Pump will turnoff and the
compressor will run on the man (shaft driven) oil pump. If at any time during the compressor
operation, the oil pressure drops below the alarm point the Auxiliary Oil Pump will
automatically start and return normal oil pressure. Pressing Reset will clear the alarm if the
alarm condition no longer exists. Cycling the Auxiliary Oil Pump switch (HS-130) off after
clearing the alarm will reset the oil pump circuit and shut off the oil pump. The auxiliary Oil
Pump turns on when ever the main motor is signaled to shutdown and on a loss of a motor
current signal to the LC. The LC will override the Auxiliary Oil Pump switch (HS-130) when
in the off position in the event of a low oil pressure alarm while the compressor is running or
shutting down.
2.8.2
RESET SEQUENCE
The reset push-button (HS-133) is pressed either to obtain a permissive start prior to running
or to reset an alarm while the compressor is running. If an alarm condition occurs while the
compressor is running, the alarm light (XL-104) flashes signaling an unacknowledged alarm.
Pressing the acknowledge push-button (HS-132) changed the light to steady on. The light can
be turned-off by pressing the Reset push-button, provided the alarm condition is no longer
present. If Reset is pressed and the alarm condition still exists, the alarm light will flash.
Prior to running, pressing the reset will start a 5-second period to check oil pressure, oil
temperature, and allow time for the Inlet Guide Vane (IGV) to close and the Blow-off valve
(BOV) to open. During this time, Reset will also clear any alarm or trip indications that were
present after the last shutdown (provided those conditions no longer exists). Note that the
compressor will be allowed to start in an alarm condition, but not in a trip condition. Alarm
conditions will continue to be displayed until the alarm condition is eliminated and the Reset

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Push-button turns-off the light. At the end of the Reset period the Ready-to-Start light
(XL-100) indicates that the compressor is ready to start.
2.8.3
START-UP SEQUENCE
Once the trips have been cleared and the control is reset (ready to start), pressing the Start
Push-Button (HS-134) will energize the main motor starter. If the PLC controller does not see
motor current after 5-seconds the PLC will indicate a trip and signal the motor to stop,
sensing a motor starter problem. During the first 15 seconds of start-up the compressor
remains unloaded and monitors vibration using alarm and trip levels 2xs the normal
operating levels and ignores inlet air temperatures. This prevent tripping due to higher than
normal inter-stage temperatures if the compressor was recently shut down and allows for the
normally higher vibration levels at start-up
.
After the 15 seconds delay the auxiliary oil pump will turn off (if oil pressure above the low
alarm limit), begin monitoring inlet temperatures and use the normal vibration alarm and trip
levels.
2.8.4
AUTOMATIC START
The PLC will automatically start the compressor if; a) System pressure (PT2) is less than a
user set able start pressure, b) HS-138 is in Automatic and HS-139 is in the local or remote
positions.
2.8.5
UNLOAD/AUTO-DUAL/MODULATE SWITCH (HS-137)

In the Unload position the Inlet Guide Vane (IGV) are closed (4ma signals, fail closed) or will
ramp closed over a 10 second period, and the Blow Off Valve (BOV) is/will open (4ma
signal, fail open). This condition generates minimal flow and discharge pressure. In the
Auto-Dual and Modulate positions the compressor remains unloaded until after the l5-second
time delay at startup, then the compressor will automatically load. Loading the compressor
activates the IGV and BOV control loops causing the IGV to open and the BOV to close and
regulate to design discharge pressure.
2.8.6
AUTO-DUAL
control loads the compressor when the system pressure falls below the reload pressure
(reload pressure = pressure set point -reload pressure drop set point). The load sequence
opens the inlet valve until the motor load is greater than the minimum load for the set
pressure. The blow-off valve is then closed, and the inlet valve controls to system pressure,
while limiting the motor current draw to the maximum amps. If the inlet valve throttles the
compressor to the minimum load (surge control line) for the given discharge pressure the

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AIR COMPRESSOR
C-702
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compressor unloads, waiting for system pressure to fall. The compressor is unloaded by,
opening the blow-off valve and closing the inlet valve (with a 10 second ramp).
2.8.7
MODULATE
provides a continuous gas delivery at a constant-pressure, while providing automatic surge
control to protect against periods of low process demand. The compressor loads by opening
the inlet valve until the motor load is equal to the minimum load for the set pressure. At this
point both the inlet and the blow-off valve are placed in' automatic control, The blow-off
valve provides both surge control ( see surge control below) and maximum discharge pressure
control (PTl) (maximum discharge pressure set point), The inlet valve controls to the system
pressure (PT2) (pressure set point) while limiting the motor load (ITl) (maximum amp set
point), The compressor remains loaded until signaled to unload.
2.8.8
SHUTDOWN SEQUENCE:
Pressing the Stop push-button (HS-135) signals the PLC to unload the compressor and
de-energize the motor run relay (XS-119). The motor run relay contact de-energizes the main
motor starter stopping the motor. Also, the Auxiliary Oil Pump starter is energized so that the
auxiliary oil pump can provide oil during the coast down period. The E-Stop sequence is
different. The E-Stop (HS-136) push-button de-energizes the main motor starter directly. The
PLC senses the loss of motor current, opens the BOV, and starts the auxiliary oil pump.
2.8.9
MAINTENANCE/MANUAL/ AUTOMATIC SWITCH (HS-138):

Selects the PLC operation mode. In the maintenance mode all power to the PLC digital output
card(s) is removed preventing the operation of the compressor. The manual position will be
overridden while the compressor is in operation. The manual position signals the PLC that the
compressor is to start/stop from the local push buttons (HS-134, 135) (compressor protection
is still active in the manual position). In the automatic position, the Manual/Local/Remote
switch (HS-139) determines the source of control signals (Start/Stop/Unload/
Auto-Dual/Modulate) ..
2.8.10 MANUAL/LOCAL/REMOTE (HS-139):

Determines the source of control signals. In manual control only the local push buttons and
selector switches are active. In local mode both the Local switches and the PLC automatic
control is active, but the PLC will not receive commands through Mod Bus from the DCS. In
remote mode the PLC will accept control commands from the DCS.
2.8.11 DCS/MOD BUS INTERFACE:
The DCS through the Mod bus port is able to reset the control system to achieve a ready to
start, start the compressor, stop the compress, unload, select Auto-Dual and Modulate control.
The DCS will also have access to all monitoring points and compressor status

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EQUIPMENT
SPECIFICATIONS
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AIR COMPRESSORS C-701 A/B :

Inger soll Rand
Reciprocating, two stage, double acting
1596 NMCH (980 SCFM) (at 100% load)
8.78~9.49 kg/cm2g (125~135 psig).
6/6
4/4
4/4
176.5 oC (350 oF).
Moter / Steam Turbine
C-701A MOTOR :
Make
KW (HP)
RPM
Gear Ratio
Voltage / Frequency
Power Supply
3.3
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EQUIPMENT SPECIFICATIONS
Make
Type
Capacity
Discharge pressure
Number of suction/ discharge valves
for 1st stage
Number of suction/ discharge valves
for 2nd stage
Number of Clearance valves (1st/2nd stage)
Maximum allowable discharge temp.
Driver
3.2
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Page
AEG
201.5 (270)
1450
2.82 : 1
440 / 50
EE-630 bus - II
C-701B TURBINE :
Make
KW (HP)
Stages
Inlet Steam
Exh. Steam
Rated speed
Operating speed
Trip speed
Governor
Gear Ratio
Elliot
179 (240)
02
12 kg/cm2g (175 psig SH. steam)
2 kg/cm2g (25 psig)
3600 rpm.
2900 - 3100 rpm.
3950 rpm.
wood ward PG
7:1

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EQUIPMENT
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1 Inertial and 1 felt

1873.33 kg/hrs (4130 Pounds per hour).
Atmospheric
Amb.
6.4 cm of WC (2.5 inches of H2O)
Dust
50 Micron & Larger (98% removal)
1.03 kg/cm2g (14.7 psig)
C.S
1.6 cm of WC (0.62 H2O)
Single finned tube

24.34 m3 (262 Sq. Ft.)
Air shell side, Cooling water tube side.
Air 148.7 oC (300 oF), CW 33.9oC (93oF).
Air 46.1oC (115 oF), CW 45oC (113 oF).
0.21 kg/cm2g (3 psig)
C-701 A/B AFTER COOLER :

Type
Heating surface
Fluid
Inlet temperature
Outlet temperature
Pressure drop
Duty
No. of fins
3.8
373 ()
250
50 cycle
2900
EE-614 (In C-702 PLC room)
C-701 A/B INTER COOLER E-702 A/B:

Type
Heating surface
Fluid
Inlet temperature
Outlet temperature
Pressure drop
3.7
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C-701 A/B INLET AIR FILTER FIL - 701 A/B:

No. of elements
Quantity of air filtered
Operating pressure
Operating temperature
Allowable dirty pressure drop
Nature of particles removed
Size of particles removed
Design pressure
Material of construction
Clean pressure drop
3.6
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C-701A/B DUST BLOWER MOTOR :

KW (HP)
Voltage
Frequency
RPM
Power supply
3.5
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KNOCK OUT DRUM D-711 :
Single finned tube

24.34 m3 (262 Sq. Ft.)
Air shell side, Cooling water tube side.
Air 148.7 oC (300 oF), CW 33.9oC (93oF).
Air 46.1oC (115 oF), CW 45oC (113 oF).
0.21 kg/cm2g (3 psig)
56736KCal per hour (225,000 BTU per hour.
26.

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Size
Operating temp.
Operating pressure
Design temp.
Design pressure
Material
Retention time
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76 ID x 192 L.
37.7 oC (100 oF).
8.79 kg/cm2g (125 psig)
73.8oC (165 oF).
10.55 kg/cm2g (150 psig)
CS
2 minutes.
AIR DRYER AD-711 :

Capacity
Operating pressure
Inlet temp.
Design pressure
Design temp.
Corrosion allowance
Due point
Regeneration time
Cooling water required
Saturated Steam required
Desiccant
3.10
Document No.
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1466 NMCH (900 SCFM)

8.44 kg/cm2g (120 psig)
46.1 oC (115 oF).
10.55 kg/cm2g (150 psig)
204.2 oC (400 oF).
1/16
0.6 oC (33 oF). Max.at 8.79 kg/cm2g (125psig)
4 hrs. (03 hrs. Heating & 01 hr. Cooling)
2.73 m3/hr (12 gpm).
62.56 kg/hr (138 lb/hr.12 kg/cm2g (175 psig)
Mobil Sorbead R
AIR DRYER AD-712

Type
Application
Capacity
Inlet pressure
Inlet temp. Into package
Exit dew-point
Maximum pressure drop across package
Adsorption period
Regeneration period
Design code
Desiccant type
Desiccant charge
Design pressure
Design temperature
DSR 5 MK II
Drying compressed air
1629 NMCH (1000 SCFM)
8.44 kg/cm2g (120 psig)
46.1oC (115oF).
Lower than 0oC (32F) at working pressure
0.51 kg/cm2g (7.25 psig)
4 Hours
4 Hours
ASME VIII (Not U stamped)
Activated Alumina
(Refer to Filling Details)
11.25 kg/cm2g (160 psig).
204 oC (400 oF)

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EQUIPMENT
SPECIFICATIONS
Design temperature
836 Nm3/hour
174 oC max. (345 oF)
46 oC max. (345 oF)
32 oC (89.6 oF)
41 oC max (106 oF)
11.25 kg/cm2g (160 psig) Air side
11.25 kg/cm2g (160 psig) Water side
205 oC (400 oF) Air side
65 oC (150 oF) Water side
836 Nm3 / hour

46 oC (115 oF)
182 oC (360 oF)
14.0 kg/cm2g / 11.25 kg/cm2g
205 oC / 205 oC
MOISTURE SEPARATOR D-712

Type
Efficiency
3.14
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REGEN STEAM HEATER E-712

Regeneration flow
Regen inlet temperature
Regen exit temperature
Design pressure Shell / Tube
Design temp. Shell / Tube
3.13
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REGENERATION COOLER E-713

Regeneration flow
Gas Inlet temperature
Gas exit temperature
Gas exit temperature
Water outlet temperature
Design pressure
3.12
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Mesh pad
99%
CENTRIFUGAL AIR COMPRESSOR (C-702)

Manufacturer
Capacity
Rated Speed 1st Stage

Rated Speed 2nd Stage
Rated Speed 3rd Stage
Lubricating Oil
Cooper Turbo Compressor

3014 NMCH (1850 SCFM) at 46.1oC (115F) &
1.02 kg/cm2a (14.5 psia)
2647 NMCH (1625 SCFM) at 15.5oC (60F) &
1.03 kg/cm2a (14.7 psia)
40000 RPM
60000 RPM
60000 RPM
Turbo Blend Oil

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C-702 MOTOR
Speed
Voltage / Frequency
KW (HP)
FLA
Insulation Class
Power Factor
Starting Ampers
Starting Time
Instantaneous Over Current
Thermal Over Load
2979 RPM
6.6 KV / 50 Cycle
450 (603)
46A
F
0.9
298
8 Sec.
495A
45 A (1875 Sec.)
LUBE OIL PUMP MOTOR

Voltage / Frequency
KW (HP)
Speed
FLA
3.17
EQUIPMENT
SPECIFICATIONS
440V / 50 Hz
3.73 (5)
1435 RPM
6.1 A
CANOPY FAN MOTOR

Voltage / Frequency
KW (HP)
FLA
440V / 50 Hz
0.746 (1)
1.5 A @ 400 V
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Document Type:
Document No.:
PR-UT1-M7
Document Status:
Final
Posts Manuals
CHAPTER-3
AIR DRYERS FOR
INSTRUMENT AIR
Originated by :
Issue No. 1 by :
Issue No. 2 by :
Issue No. 3 by :
Issue No. 4 by :
Revision 1
:
Reviewed by :
Approved By :
Update due :
AAd
SF
AIH
ARQ
MAL
Burero/KRm
ARH
JP
Unit : Utility-1
in : June, 1996
in : June, 1998
in : June, 1999
in : June, 2003
in : June, 2006
in : July , 2009
in : July , 2009
in : July , 2009
in : July , 2012
Code: PR-UT1
TABLE OF CONTENTS
SECTION
DESCRIPTION
01
1.1
1.2
1.3
1.4
AIR DRYERS FOR INSTRUMENT AIR

OIL FILTER FILL-711
AIR DRYERS AD-711 A/B
PAGE
1
1
2
3

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1.1
AIR DRYERS FOR

INSTRUMENT AIR
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AIR DRYERS FOR INSTRUMENT AIR

The air after compression is sent to air receiver D-711 which serves a three fold purpose.
First, it acts as a pulsation dampener to eliminate vibrations in air lines due to pressure
variations. Secondly, it serves as a reservoir for instrument air system with a residence time of
two minutes. Lastly, entrained water vapors are knocked down and flow to sewer thru a trap
assembly. The trap is an automatic drain type which maintains a liquid seal to minimize air
losses. A safety valve PSV-711 discharges air to atmosphere if pressure increases to 10.55
kg/cm2g (150 psig). A high level switch is installed at D-711.
The air from D-711 is discharged into plant air and instrument air headers. Pressure in
instrument air header is maintained by PIC-703 installed on plant air header. In case
instrument air header pressure drops to 8.08 kg/cm2g (115 psig), PIC-703V close to maintain
pressure in the instrument air header.
1.2
OIL FILTER FIL - 711

The purpose of the pre-filter FIL - 711 is to remove oil mist and droplets from air before the
air reaches the Humidryer AD - 711 & AD - 712. Hence it prevents any reduction in the
moisture adsorption capacity at the desiccant.
The filter unit comprises a welded steel chamber with inlet, outlet and drain connections and
integral legs. It is fitted with a filter pad composed of a highly resilient mineral fiber, treated
and prepared for removal of oil mist and droplets. The condensate thus removed is collected
and drained off, once in every shift.
The separator operates at a temperature of 46oC (115oF) and a pressure of 8.79 kg/cm2g (125
psig) with a maximum pressure drop of 0.35 kg/cm2g (5 psig) across the filters.
The pre-filter operates on a continuous 24 hours cycle. A bypass piping arrangement is
provided to facilitate cartridge replacement without interrupting process air flow. Cartridge
replacement is carried out after every six weeks. A safety valve PSV - 714 set at 11.25
kg/cm2g (160 psig), is provided to protect Filter - 711.

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PROCESS DESCRIPTION
The air dryer (Humidryer) AD-711 is a fully automatic complete plant, designed to dry
compressed air in volumes sufficient for plant requirements with no gas losses occurring in
regeneration system.
It employs a solid granular desiccant which adsorbs water vapor at normal temperatures and
is then regenerated to restore fully adsorption capacity by heating and cooling with a flow of
process gas to release the moisture adsorbed. The cycle of adsorption and regeneration does
not change the mechanical or physical properties of the desiccant. It does not wear out and is
virtually everlasting, provided contamination by oil or dust is avoided.
Designed for 24 hours operation, the Humidryer incorporates dual adsorber towers, one
adsorber being regenerated and cooled while the other is in use. The adsorber off-stream is
regenerated at full working pressure by raising the temperature of the desiccant with a steam
of process gas taken from incoming manifold. The air is preheated by passing thru a steam
heater. The moisture evolved in the adsorber being regenerated is conveyer with the
regeneration gas to a water cooled heat exchanger where it is condensed and removed by an
automatic trap. The regeneration gas is the end of heating is automatically switched out of
circuit and the desiccant is rapidly cooled down by the cold regeneration flow thru the hot bed
and water cooled heat exchanger unit full drying efficiency is restored.
In Humidryer the cooling flow is arranged to flow in the opposite direction to heating flow, to
avoid a wet desiccant face at the outlet of the bed when this goes on drying duty. This
arrangement allows consistently low dew points to be achieved.
The automatic operation of Humidryers is achieved by an electric control panel operating a
system of pneumatic solenoids and valve to effect the operations required. The program of
operations is determined by a preset electrically operated timer, making the operation of
Humidryer fully automatic. Various sequences can be included to meet process requirements.
The regeneration gas is obtained by directing a constant flow from inlet manifold by the use
of a proportioning valve. This valve automatically regulates the gas for regeneration
regardless of fluctuations in the process flow.
This proportioning valve can be balanced by adding or subtracting weights on to the heating
cap to enable in regeneration flow to be obtained.
The control panel for AD-711 is equipped with a timer which regulates time for heating and
cooling cycles during regeneration. At present the timer is so set so as to give 3 hours of

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heating and 01 hours of cooling time. The control panel has an override function which will
prolong either heating period or the cooling period by interrupting the sequence of time,
should either of these functions be effected however, at present override system is faulty.
12 kg/cm2g (175 psig) saturated steam is used for heating purposes during regeneration, while
for cooling purposes plant cooling water is employed.
Both the towers of the air dryer are protected by safety valves PSV-705 A/B which are set at
10.19 kg/cm2g (145 psig). (See fig.01)
1.4
1.4.1
BACKGROUND OF INSTALLATION
AD-711 is designed for 1466 NMCH (900 SCFM) but it was handling almost double flow.
Excessive load on AD-711 caused slippage of moisture to the Instrument air and increased
Dew Point. So the chances of moisture condensation were high. Due to excessive load, the
adsorbent become over saturated with the water during service. Regeneration cycle could no
remove all water from adsorbent. Due to excessive flow the dryer was subjected to higher
exposure of dust and oil. Due to above limitations of AD-711 a new air dryer AD-712 was
installed in 2002. The new air dryer is of almost similar to the old one.
1.4.2
PROCESS DESCRIPTION
The type DSR humidyer is a self-contained packaged air or gas-drying unit designed for
continuous 24 hour per day service.
The humidryer incorporates twin vertical adsorber towers to permit continuous operation, one
adsorber being reactivated and cooled whilst the other is on drying duty. The towers are
connected by air operated 4-way diversion valves, which automatically direct operation at
regular intervals.
1.4.3
REACTIVATION PROCESS:
After its period of dryer duty, saturated bed is reactivated by the controlled application of heat
conveyed from and exchanger by a fix proportion of process flow.
Reactivation is carried out of full line pressure thus avoiding possible contamination of the
process fluid and elimination pressure buildup and blow down which are usually responsible
for premature desiccant break down.
The required reactivation flow is maintained at a constant level regardless of fluctuation in the
process throughput by means of an automatic control valve.

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The reactivation flow heated in an external exchanger and passed the saturated bed where the
previously adsorbed water vapor is released and coveyed to the reactivation inter-cool in
which it is condensed and ejected via a separator and automatic discharge trap. The heating
flow passes upwards through the bed (countercurrent to the process stream).
On completion of the heating period the heater is de-energised or bypass and the cold
reactivation flow is directed in a downward direction (co-current with the drying system)
through the freshly reactivated bed until complete cooling is effected.
When the reactivation heating and cooling periods are completed, the process flow diversion
valves automatically reverse to bring the freshly reactivated adsorber on stream and initiate
regeneration of the saturated bed.
1.4.4
ADSORBENT MATERIAL:
The adsorber towers are charged with activated alumina. The desiccant is supported by steel
frame screens.
The desiccant can be reactivated repeatedly, without any loss of efficiency over very long
periods provided it is protected from contamination by dust, oil or other foreign matter.
1.4.5
MAIN ITEMS DESCRIPTION & OPERATING SEQUENCE

Humidryers incorporate dual Adsorber tower so that drying is continuous, one tower being
regenerated and cooled while the other is on stream. The towers are interconnected by
diversion valves which enable the process gas to flow through one or the other at specified
intervals.
Each Adsorber is regenerated in turn by raising the temperature of the desiccant with an
external steam heater, suitably arranged for the proper distribution of heat.
The regeneration gas supply is obtained from the process inlet manifold and eventually
returns to the inlet manifold after cooling through an external heat exchanger. This enables no
losses to be occurred in the process gas stream.
On DSR models, changeover takes place by the operation of the main diversion valves and
the heating/cooling diversion valves move into the heating position routing the regen flow in
an upward direction through the bed. At the end of heating, the two heating/cooling valves are
both diverted into cooling position by-passing the heater and routing the cooling regen flow
downward through the bed. Subsequently, at the next changeover these move back into the
heating position when the main division valves are operated.

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The reduction of water vapor at very low quantities is achieved in humidryers by the use of
desiccants which are highly porous granular substances and have a strong affinity for water.
Water vapor carried in the gas passing through the bed 0 desiccant is therefore retained and
the air emerges dry.the humidryer is of robust design, the only moving parts except for the
control system, being the main diversion and control valve.
After initially starting up, the humidryer control system operates the changeover and
regeneration periods, the correct sequence of which is preset in the works before dispatch.
REGEN. CONTROL VALVE (FIC-712) OPERATING CONDITIONS
The function of the control valve is to maintain a constant flow of air through the regeneration
circuit regardless of fluctuation in the process flow. Normally the regeneration is
approximately 30% of the maximum design flow and this is the minimum flow necessary to
regenerate the dryer satisfactory. The control valve enables the dryer to work with an
infinitely variable flow between the minimum (regen flow) and the maximum (design flow).
SEQUENCE OF OPERATIONS
The following sequence of operation is on a fixed 4 hour time cycle initiated by a PLC in
the control panel, which operates solenoid valves etc.
The sequence of operation is.
STEP
OPERATION
STATUS
1.
Changeover valves XV001A/B

Tower B Regen
Tower A Drying.
2.
Port valve XV002 & 003

Start heating
Tower A Drying
Tower B Heating
3.
Port valves XV002 & 003

Start cooling
Tower A Drying
Tower B Cooling
4.
Changeover valves XV001A/B

Tower A Regen
Tower B Drying
5.

Start heating
Tower B Drying
Tower A Heating
6.

Start cooling
Tower B Drying
Tower A Cooling

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INSTRUMENT AIR
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MODE OF OPERATION
There are two modes of operation Auto & Manual Advance, which are selected via a key
operated selector switch:
AUTO:
In this mode the sequence will continuously cycle through the 8 sequence steps described
previously automatically on an 8 hour NEMA cycle.
This mode of operation is the normal mode of operation.
MANUAL ADVANCE:
When selected in this mode the sequence can be advance one step at a time by operating the
Manual Advance pushbutton once for each step. The sequence will remain in the step until
the push button is operated again or ht selector switch is returned to the Auto mode.
This mode of operation is used for testing & commissioning only since the alarms are not
interlocked with the sequence.
Currently only Auto mode of operation is enable.

Document Type:
Document No.:
PR-UT1-M7
Document Status:
Final
Posts Manuals
CHAPTER-4
INSTRUMENTAS
AND CONTROL
Originated by :
Issue No. 1 by :
Issue No. 2 by :
Issue No. 3 by :
Issue No. 4 by :
Revision 1
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AAd
SF
AIH
ARQ
MAL
Burero/KRm
ARH
JP
Unit : Utility-1
in : June, 1996
in : June, 1998
in : June, 1999
in : June, 2003
in : June, 2006
in : July , 2009
in : July , 2009
in : July , 2009
in : July , 2012
Code: PR-UT1
TABLE OF CONTENTS
SECTION
DESCRIPTION
01
1.1
1.2
1.3
1.4
1.5
02
2.1
2.2
2.3
2.4
2.5
03
3.1
3.2
3.3
3.4
CONTROLS & INSTRUMENTATION FOR

C-701 A/B
LOADING SYSTEM OF C-701 A/B
LOW PRESSURE LUBE OIL SECURITY
TIME METERING VALVE
HIGH TEMPERATURE ALARM & PRESSURE
SAFETY VALVES
PLCI-702 B & LOW LUBE OIL PRESSURE
SECURITY LOOP
C-702
ALARM / TRIP SECURITIES
CONTROL LOGIC OF MODULATED BLOW
OFF VALVE
CONTROL LOGIC OF INLET GUIDE VANES
ANTI SURGE CONTROL / SURGE
PREVENTION
CONTROL LOGIC OF AUXI. LUBE OIL PUMP
AD-712
GENERAL
SEQUENCE
MOISTURE ANALYZER
REGENERATION FLOW CONTROLLER
(FIC-712)
PAGE
1
3
3
4
4
6
7
7
8
9
10
10
12
12

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CONTROLS & INSTRUMENTATION FOR C-701A/B
PIC-703
Located on plant air header; it closes if the air pressure in D-711 drops below 8.08 kg/cm2g
(115 psig) to maintain instrument air pressure.
PLCI-702A/B
Allows the standby air compressors C -701 A/B to cut-in if the air pressure drops below their
set point.
PIC-701A/B
Controls pressure in air system by loading / unloading the compressors C- 701 A/B.
PIC-704V
Controls instrument air header pressure at 8.58~8.79 kg/cm2g (122~125 psig).
1.1
LOADING SYSTEM OF C-701A/B

Both air compressors have provision for fully automatic loading / unloading operation and for
complete unloaded condition at the time of startup. This is accomplished thru use of
instruments explained below. Please refer to fig 1.
BYPASS VALVE
This automatic bypass valve is mounted on top of the low pressure cylinder and its function
when in open position is to vent the air to atmosphere for complete unload position during
startup. After compressor startup and motor reaching peack speed an air signal from the
UL-48 element will act to close the valve.
UL-48 ELEMENT
The UL-48 element is a three way valve which when open allows instrument air pressure to
reach the air loader and the auto bypass valve. The UL-48 valve opens when the air pressure
on its diaphragm is exhausted via the solenoid valve. Its internal ball lifts thus linking
instrument air with the loader.
THE 3-WAY SOLENOID VALVE
Its function is to prevent compressor loading before motor has reached peak speed. A time
delay signal to the 3-way solenoid valve will switch it to an energized state so that air signal
to the UL-48 element can be exhausted.
UL-31C CLEARANCE VALVE
In addition to the 6/6 1st stage valves 4/4 2nd stage valves there are 4 UL-31C type clearance
valves on each stage.
The function of these valve is to provide capacity control thru clearance unloading. Thru
clearance unloading, air in the cylinder is compressed into a clearance pocket when the piston
travels in one direction and the air is returned to the cylinder on the on the return stroke. The
automatic operation of the clearance valve is governed by the loader described below.

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UL-32 HIGH PRESSURE CYLINDER RELIEF VALVE

The high pressure cylinder (on both C-701A/B) is furnished with two UL-32 cylinder relief
valves, one at each end of the cylinder.
These valves open after all the clearance valves have been opened and after the inter cooler
has been vented to atmosphere.
The following table gives the effect of capacity control:
CFM
Discharge Pressure
BHP
Discharge Temperature
75%
50%
25%
802
140
168
310
535
140
121
310
245
140
71
310
LOADER AND LOADING

The regulation of C-701A/B is accomplished thru clearance unloading. With clearance
unloading the air in the cylinder is compressed into a clearance pocket when the piston travels
in one direction and the air returns to the cylinders on return stroke. The purpose of the
regulator is to control the air output of the compressor in 5 steps between full load and no
load according to the demand for air.
The output pressure range of PIC-701A/B (pressure control instruments for C-701A/B
respectively) is 0.21~1.05 kg/cm2g (3~15psig), and is piped to the top of loader. Supply
pressure is piped to orifice to the regulator valve body. Please refer to figure
.
Assume that compressor running at FULL LOAD and such being the case, the output pressure
from the instrument will be approx. 1.05 kg/cm2g (15 psig). All of the regulating valves will
be on their upper seats, thus pressure will be applied to unloading devices.
Assume now that discharge pressure starts to increase above the setting of pressure control
instrument. The output pressure of PIC-701A/B decrease to 0.84 kg/cm2g (12 psig) and
compressor will be thus unloaded to load.
If discharge pressure continues to increase, the action of the PIC-701A/B will cause output
pressure to continue to decrease and compressor will be unload to 1/2, & 0 load. A
decrease in discharge pressure will cause compressor to be reloaded.

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Before startup the bypass valve at top of 1st stage cylinder is in open position therefore
compressor is fully unloaded. When the necessary motor speed is reached 3-way solenoid
valve is energized thereby exhausting air from diaphragm of UL-48 element. From the UL-48
element the instrument air pressure is transmitted to the loader where it is balanced with the
0.21~1.05 kg/cm2g (3-15 psig). Signal coming from controller PIC-701 and a resultant signal
for loading / unloading the capacities is sent to the clearance valves.
The instrument air pressure is also transmitted via the UL-48 element to bypass control valve
at top of 1st stage resulting in closing of the bypass valve.
A plant air line is also connected with instrument air supply line for loading. In normal plant
operation plant air line remains isolated. See fig 01.
1.2
LOW PRESSURE LUBE OIL SECURITY

Both air compressors are equipped with a security which trips the compressor whose crank
case lubrication oil pressure goes below a critical level. This pressure is set at 0.84 kg/cm2g
(12 psig). This is the only security on both the compressors which can trip the machine.
Study a condition when C-701B had run on auto and stopped due to loss of lubricating oil
pressure. Low oil pressure signal will actuate a lock up device called 77-8 which will close
the steam control valve and will not open unless reset.
In case compressor trips on actuation of PLCO security, condition would be:
Air bleeding from reset device indicates running condition of C-701B on auto. But if the air is
bleeding and the compressor is at stand still, such a situation is created only when the low oil
pressure has actuated. Investigate, rectify problem, check oil pump and reset the system for a
fresh start.
1.2.1
HOW TO RESET / ACTION

Reduce PLCI-702 set point to zero, reset the venting air observe 1.41 kg/cm2g (20 psig) signal
on the output gauge. Compressor will be stand still. Raise PLCI-702 set point. Observe 3 psig
signal on the output gauge compressor out-in air bleeds from the device compressor continues
to run. If problem of low oil continues to exit, the lock up device called 77-8 will again stop
the unit.
1.3
TIME METERING VALVE

Function of time metering valve is very important, without this the compressor C-701B would
not start. It is similar to a time delay relay which is used in the motor control circuit of
C-701A.

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In C-701A this time delay relay bypass lube oil pressure switch till such time that compressor
comes up to speed and pump develops enough lube oil pressure to actuate its oil pressure
switch. (If by any chance lube oil pressure does not develop the compressor would trip).
Similarly in C-701B the time metering valve would hold the 4-way (PNEUMATIC) pilot
valve in its last position so as to allow the compressor to come up to speed and develop
enough lube oil pressure to actuate lube oil transfer valve 77-8.
The above arrangement also takes care of the requirement that compressor loading should
take place only when it has come up to speed.
1.4
HIGH TEMPERATURE ALARM & PRESSURE SAFETY VALVES

Low pressure cylinder is protected by a safety valve PSV-702 set at 2.6 kg/cm2g (37 psig).
Compressor discharge is fitted with PSV-701 set at 10.55 kg/cm2g (150 psig). Receiver drum
D-711 is also equipped with PSV-711 set at 10.55 kg/cm2g (150 psig).
A high temperature alarm is located on the discharge of each compressor. This is et at 350F.
In the event the alarm is sounded, load on the compressor should be reduced.
1.5
PLCI-702B & LOW LUBE OIL PRESSURE SECURITY LOOP

PLCI-702 B performs the function of C-701B start and stop. Suppose compressor is stop and
out put at PLCI-702 as 1.41 (20 psig).
kg/cm
2 g
This 1.41 (20 psig) signals goes to HPS and a three way valve 77-8A. When pressure acts on
77-8A port C to B as open while port A is close. This allows a 7.03 (100 psig) signal to act at
Null Matic Device. When pressure act on Null Matic Device port 4 and 3 are connecting
allowing 1.41 (20psig) signal at 3 way valve of loader which is insufficient for loading. Also
port 2 & 1 are connecting releasing pressure at upstream of 77-8. As there is no oil pressure at
that time because compressor is stand still, there is not pressure at the top of 77-8B. When
there is not pressure at top of 77-8B port C & A is open allowing 0 signal HPS. A 1.41 (20
psig) signal is coming of PLCI-702 B and 0 signal is coming from 77-8 B to H.P.S. It selects
high pressure signal i.e 1.41 (20psig) and sends to steam control valve which closes the
steam valve thus stopping the air compressor.
k g / c m
2 g
k g / c m
k g / c m
2 g
2 g
k g / c m
k g / c m
2 g
2 g
On other hand when it has to start C-701 B reduce PLCI-702B output to zero.This zero signal
goes to HPS and 77-8A. HPS selects zero signal and sends to steam control valve allowing it
open. Compressor starts and sufficient oil pressure acts at 77-8B to close port A.

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When zero pressure act on 77-8A port C and A are opened releasing pressure at Null Matic
Device. When pressure is zero at Null Matic Device, port 4 and 5 are connected allowing 7.03
(100psig) signal for loading. Also port 2 and 3 are connected causing 1.41 (20psig) signal at
77-8B.
k g / c m
2 g
k g / c m
2 g
If during normal operation oil pressure drops, it will open port A & C of 77-8B allowing 1.41
(20psig) signal to HPS, which will close steam valve and stop the compressor.
For normal shut down bleed valve 77-1 has to reset to build up 1.41 (20psig) signal to HPS
which in response will stop the compressor. (see fig. 02)
k g / c m
2 g
k g / c m
2 g

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SECTION-2 CONTROLS & INSTRUMENTATION FOR C-702

2.1
ALARM / TRIP SECURITIES:

Security
Alarm
Description
PDT2
Inlet Filter Differntial Pressure
TE-3
TE-5
VT-1
VT-2
VT-3
VT-4
VT-5
VT-6
2nd Stage Suction Temperature

3rd Stage Suction Temperature
1st Stage Vibration x axis (E)
1st Stage Vibration y axis (W)
2nd Stage Vibration x axis (E)
2nd Stage Vibration y axis (W)
3rd Stage Vibration x axis (E)
3rd Stage Vibration y axis (W)
PDT1
Oil Filter Pressure Drop
PT3
Main Oil Pressure Alarm
PT4
Main Oil Pressure Alarm
TE1
TE6
TE7
TE8
TE9
TE10
Oil Temperature
Oil Return Drain Temperature
Oil Return Drain Temperature
Motor Stator 1 Temperature
Low
5.62 kg/cm2
(80 psig)
-
High
25.4cm WC
(10 Inch. WC)
54.4oC (130F)
54.4oC (130F)
1.5 mils
1.5 mils
1.5 mils
1.5 mils
1.5 mils
1.5 mils
2.81 kg/cm2
(40 psig)
9.84 kg/cm2
(140 psig)
-
Trip
Low
High
59.9oC (140F)
59.9oC (140F)
2.0 mils
2.0 mils
2.0 mils
2.0 mils
2.0 mils
2.0 mils
3.52 kg/cm2
(50 psig)
-
4.92 kg/cm2
(70 psig)
21oC (70F) 57.2oC (135F) 15.5oC (60F)
165.4oC (330F)
165.4oC (330F)
165.4oC (330F)
-
10.55 kg/cm2
(150 psig)
62.7oC (145F)
93.2oC (200F)
93.2oC (200F)
170.9oC (340F)
170.9oC (340F)
170.9oC (340F)
During an FMEA exercise carried out in December, 2008, it was observed that there was no
tripping of C 702 in case of the PLC power failure which had the potential of compressor
damage. Following modifications in logic has been carried out to take care of this situation.
Software changes include the usage of a new tripping inverter contact (B3:4/3) in rung
no.0006 of the program and the addition of a new rung (0007) including Normally-Closed
(NC) contact of (B3:4/3) going to Trip contact to MCC (O:3/4).
Hardware Changes are explained below:
a) Current Scenario:
1. During normal motor running condition, the motor does not trip because relay KA1.5 is
De-Energized and gives open contact to Tripping contact MCC (XS-114) which is
Normally-open (NO)
2. During normal condition if SLC power fails, since relay KA1.5 is De-Energized and gives
open contact to Tripping contact MCC (XS-114) which is Normally-open (NO), so the
motor does not trip.

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3. During normal condition if any security actuates, relay KA1.5 is energized, gives close
contact to XS-114 and the motor trips.

b) Proposed Scenario:
1. During normal motor running condition, the motor does not trip because relay KA1.5 will
be Energized (due to addition of tripping inverter contact in logic) ,will give open contact
to XS-114 which now will be Normally-Closed (NC) .
2. During normal condition if SLC power fails, relay KA1.5 will be De-Energized and gives
close contact to Tripping contact MCC (XS-114) which is Normally close (NC), so the
motor will trip.
3. During normal condition if any security actuates, relay KA1.5 will be De-Energized (due
to addition of tripping inverter contact in logic), will give Close contact to XS-114 and the
motor trips.
2.2
CONTROL LOGIC OF MODULATED BLOW OFF VALVE:

MBOV control signal is generated from PT-1 (Compressor discharge pressure) & main motor
current.
PID-3 Block (Proportional Integral Derivative Controller) receives error signal from the
comparator, which compares the motor current with the surge control line BIAS set point
(33.4 Amps).
PID-4 Block (Proportional Integral Derivative Controller) receives error signal from the
comparator, which compares compressor discharge pressure with the discharge pressure set
point 8.93~9.0 kg/cm2 (127~128psig).
The two output signals of flow controller BOV signal and Pressure Cap controller BOV
signal are sent to the comparitive low selector switch, which forwards the lower signal to the
MBOV. (see fig.01)
2.3
CONTROL LOGIC OF INLET GUIDE VANES:

IGV control signal is generated from PT-2 (System pressure) & main motor current
PID-1 block receives error signal from comparator, which compares the max. Motor current
set point (45 Amps.) with the main motor current.
PID-2 block receives error signal from comparator, which compares the system pressure set
point 8.93~9.0 kg/cm2 (127~28psig) with the system pressure(PT-2)
The two controller output from PID-1 block & PID-2 block are sent to the comparative low
selector switch , which forwards the lower value to the IGV.(see fig.02)
2.4
ANTI SURGE CONTROL / SURGE PREVENTION:

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Surge prevention is accomplished by modulating the blow-off valve (BOV). If demand (flow)
is reduced to the point of surge, the BOV will open to maintain a minimum flow through the
compressor. BOV control is determined by comparing the operating point to a "pressure vs.
amps" surge control line. The slope and position of this line is determined at start-up and
entered into the PLC (minimum amps = surge slope * discharge pressure + current offset).
The compressor operates to the area to the right of the surge line. As flow is reduced the
operating point moves to the surge control line. At this point, a PI control loop begins to
regulate the opening of the BOV. This action prevents the compressor operating point from
crossing the line into the surge region.
In the figure 03 the surge limit line, Anti surge control sensitive area, surge control line and
normal operating area are shown.
The basic objective of the surge control is to keep the operating point to the right side of the
surge control line. In case of low load operation, sudden load rejection or sudden increase in
the system pressure, the operating point moves towards left side. When the operating point
crosses the surge control line , the anti surge control takes sudden action and opens the
MBOV accordingly
Surge Control Line Equation = Y = mx + C
Minimum Amps. = Surge Slope * Discharge Pressure + Current Offset
= 0.171 * PT-1 +12
Distance between surge limit line and surge control line is maintained at an optimum value as
large distance result in power wastage, and lesser distance provides lesser margin for the anti
surge control system to prevent compressor from surging. (see fig.04 for detail)
Surge Limit Line
Surge Control Line

Operating Point
Surge Area
Surge Control Sensitive

Region
Normal Operating Region
Motor Current (Amps.)
2.5
CONTROL LOGIC OF AUXILIARY LUBE OIL PUMP (ALOP)
Choke Flow Line

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When comperassor is OFF shutdown turning selector switch to ON will turn the ALOP ON
and turning selector switch to OFF will shut it down.
When comperassor is ON running turning selector switch to OFF will turn the ALOP ON
and turning selector switch to ON position will cause the ALOP to cut-in if pressure is bellow
5.62kg/cm2 (80 psig).
As per procedure, before starting the comperassor, ALOP is turned ON. When the
comperassor is started, the ALOP will turn OFF automatically after 15 Seconds.
How ever if lube oil pressure is bellow 5.62kg/cm2 (80 psig), the ALOP keeps running. Or
whenever there is low pressure of lube oil less then 5.62kg/cm2 (80 psig) the ALOP cuts in
and does not cutout automatically. (Switch has to be cycled back to ON position to turn it
OFF, and will stop only if the alarm condition has been reset)
When the comperassor is shutdown and selector switch is in ON position and pressure of the
lube oil is not LOW. The ALOP turns ON once the comperssor is shutdown. In this case it has
to be turned OFF manually.
When the comperassor is shutdown and selector switch is in OFF position, the ALOP rurns
for 30 minutes after comperassor has shutdown and then turns OFF. How ever during this
time cycling the switch will turn the ALOP OFF.

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SECTION-3 CONTROLS & INSTRUMENTATION FOR AD-712

3.1
GENERAL
The sequence of operation is controlled by an Allen Bradley PLC type 1747-130A on a
fixed 8 Hour NEMA cycle.
The sequence valves are monitored for correct operation via limit switches.
Indication lamps are provided for dryer status, and various alarm conditions which are self
explanatory from the Electrical Schematic Diagram.
3.2
SEQUENCE
Assume valves XV-001A / 001B are ported to Regen. On tower B with tower A Drying,
and valves XV-002 / 003 are ported to Cooling.
STEP 1: SELECT TWR. B DRYING & A REGEN.
Time: 0.00 hrs.
PLC output O/0 becomes energized and output O/1 Becomes De-energized, via travel, when
the valves reach the correct position PLC inputs 1/0 &1/3 are detected to confirm the correct
valve travel.
If however the valve fails to reach the correct position after 15 seconds delay period the
Valves XV-001A / 001B Failure indication lamps becomes energized, also the common alarm
relay AR on output O/8 will become de-energized to initiate the clients remote alarm. The
alarm fault must be detected and rectified then the Alarm Reset pushbutton operated before
the sequence can continue.
STEP 2: SELECT TWR. A HEATING
Time : Approx. 10 seconds.
PLC output O/2 becomes energized and output O/3 becomes de-energized, via output O/2
SOLENOID VALVES XY-002H & XY-003H are energized to provide the pneumatic signals
to select valves XV-002 & 003 for tower A Heating
The valves are monitored via limit switches ZSH-002H & XY-003H after 15 seconds for
correct travel, when the valves reach their correct positions PLC inputs 1/4 &1/6 are detected
to confirm the correct valve travel.
The alarm circuitry is initiated in a similar manner described previously via the associated
limit switches.

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The common alarm circuitry is initiated in the same manner as previously described.
STEP 3 : SELECT TWR. A COOLING
Time : 3 hrs. 0 mins
solenoid valves XY-002C & XY-003C are energized to provide the pneumatic signals to
select valves XV-002 & 003 for tower A Cooling.
The valves are monitored via limit switches ZSC-002 & ZSC-003 after 15 seconds for correct
travel, when the valve reach their correct positions PLC inputs 1/5 & 1/7 are detected to
confirm the correct valve travel.
limit switches.
STEP 4 : SELECT TWR. ADRYING & B REGEN.
Time : 4.00 hrs.
solenoid valve XY-001B is energized to provide the pneumatic signal to select valves
XV-001A & 001B for tower A Drying and B for Regeneration
The valves are monitored via limit switches ZSB-001A & ZSA-001B after 15 seconds delay
period the Valves XV-001A/001B Failure indication lamps becomes energized, also the
common alarm relay AR on output O/8 will become de-energised to initiate the clients remote
alarm.
The alarm fault must be detected and rectified then the Alarm Reset pushbutton operated
before the sequence can continue.
STEP 5 : SELECT TWR. B HEATING
Time : 4 hrs. 10 seconds
PLC output O/2 becomes energized and output O/3 becomes de-energized, via to select
valves XV-002 & 003 for tower B Heating
The valves are monitored via limit switches ZSH-002 & ZSH-003 after 15 seconds for correct
travel, when the valves reach their correct positions PLC inputs 1/4 & 1/6 are detected to

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limit switches
The common alarm circuitry is initiated in the same manner as previously described.
STEP 6 : SELECT TWR. B COOLING
Time : 7 hrs. 0 mins
solenoid valves XY-002 & 003C are energized to provide the pneumatic signals to select
valves XV-002 & 003 for tower B Cooling.
The valves are monitored via limit switches ZSC-002 & ZSC-003 after 15 seconds for correct
travel, when the valve reach their correct positions PLC inputs 1/5 & 1/7 are detected to
limit switches.
At 8:00 hrs. The cycle returns to step 1 and continues throughout the steps described
automatically.
3.3
MOISTURE ANALYZER
The moisture content of the process outlet is monitored continually via a moisture analyzer
A1-001, a 4-20 Ma signal is provided for remote monitoring if required.
3.4
REGENERATION FLOW CONTROLLER (FIC- 712)

The regeneration flow is controlled via a flow indicating controller FIC-712, the monitor the
flow in the regeneration line via a flow transmitter FT-712 and produces an output to position
the control valve FIC-712V, hence maintaining the regeneration flow within the set-point of
FIC-712.

Document Type:
Document No.:
PR-UT1-M7
Document Status:
Final
Posts Manuals
CHAPTER-5
OPERATION
PROCEDURES
Originated by :
Issue No. 1 by :
Issue No. 2 by :
Issue No. 3 by :
Issue No. 4 by :
Revision 1
:
Reviewed by :
Approved By :
Update due :
AAd
SF
AIH
ARQ
MAL
Burero/KRm
ARH
JP
Unit : Utility-1
in : June, 1996
in : June, 1998
in : June, 1999
in : June, 2003
in : June, 2006
in : July , 2009
in : July , 2009
in : July , 2009
in : July , 2012
Code: PR-UT1
TABLE OF CONTENTS
SECTION
DESCRIPTION
01
1.1
1.2
1.3
1.4
1.5
1.6
1.7
1.8
1.9
1.10
1.11
START UP / SHUT DOWN PROCEDURES

C-701 A/B STARTUP & LINE UP PROCEDURE
C-702 START UP / LINE UP PROCEDURE
SHUTDOWN PROCEDURE
C-701 A/B SHUT DOWN PROCEDURE
C-701A HAND OVER PROCEDURE
C-701B HAND OVER PROCEDURE
BYPASSING PROCEDURE OF D-711
PUTTING BACK IN SERVICE PROCEDURE
FOR D-711
AD-711 START UP AND LINE UP PROCEDURE
AD-712 START UP AND LINE UP PROCEDURE
ROLE STATEMENT IN GRAVE EMERGENCY
SHUT DOWN
PAGE
1
2
4
5
5
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6
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OPERATION PROCEDURES
SECTION-01
1.1
START UP / SHUT DOWN PROCEDURES
C-701 A/B STARTUP & LINE UP PROCEDURE

1.
Make sure all work permits have been returned and all mechanical work on
compressor & its connected equipment is complete.
2.
Check oil levels of lube oil, force feed lubricator gear box, crankcase and governor
C-701B.
3.
Make sure cooling water valves of after cooler, inter cooler, jacket water cooler and
gear box oil cooler are all open.
4.
Make sure outlet air valves of after cooler are open and all necessary downstream
valves are in correct position.
5.
Open inlet valves to moisture traps at inter cooler and at outlet of after cooler. Valves
of pulsation bottle drain and capacity bleeders have been cracked. Open water drain
bleeders wherever present.
6.
Start blower of air filter
7.
All securities and instruments are in service.
8.
Crank the flywheel manually to check for free rotation. Hand press force feed
lubrication pistons several times to provide initial lubrication to the cylinders.
9.
Open quenching water isolating valve also verify that P-513 is running.
10.
Put PIC-701A / B set point to zero for whichever compressor is being started to avoid
sudden loading the compressor.
11.
Put PLCI-701 AB Set Point to zero.
12.
Inform Ammonia-2 unit prior to starting any instrument air compressor
FOR C-701 A STARTUP

13 a). Check local switch of C-701A. It should be at auto position. Raise breaker of C-701A.
Start the compressor from PLCI-702A by raising its set point.
FOR C-701 B STARTUP
13 b). Ensure that 12 kg/cm2g (175 psig) steam to be C-701B and 2 kg/cm2g (25 psig) valves
are open & steam is available.
13 c). Inform boiler operator before startup.
13 d). Open drain valves to remove condensate from steam line.

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13 e). Reset trip lever of T & T valve.

13 f). Check that PLCI-702BV is on Auto.
13 g). Start C-701B by raising PLCI-702B set point.
1.2
14.
Check inter cooler pressure. It should be below 2.6 kg/cm2g (37 psig).
15.
Check for any abnormal noise and vibration shutdown if necessary.
16.
Check for any oil, water, air or steam leakage
17.
Check delta P of suction filter.
18.
Check crank case oil pressure, gear box oil pressure is normal.
19.
Check for any abnormal sound, vibration etc.
20.
If all parameters are normal, then load compressor by increasing set point of PIC-701
A/B.
C-702 START UP / LINE UP PROCEDURE

After the after the completion of Pre-Startup Checks, the Instrument Air Compressor (C-702)
will be started as follows:
1.
2.
3.
4.
5.
6.
7.
8.
9.
Rack-in the main motor breaker in MSGR (Panel # 18 on EE-620 Bus-1)

Get the terminal connections verified by Electrician
Turn On the Air Supply to Oil Reservoir Vent Ejector and the pressure so that no oil
is carried over from the vent
Switch On the Control Power Supply of PLC panel from EE-84 A in MSGR .
Cabinet Supply from UPS ON (XL-11) indication will appear on PLC Panel
Switch On PLC Panel Auxiliary Supply from the panel (HS-10). Auxiliary Supply
On (XL-10) indication will appear on PLC Panel.
Switch On the accessories Power Supply of PLC panel from EE-614. Service
Supply ON indication will appear on PLC Panel
Turn On the Compressor Canopy Fan from EE-614
Switch On the Auxiliary Lube Oil Pump Supply from EE-614.
Turn ON the Auxiliary Lube Oil Pump from PLC Panel (HS-130). Auxiliary Lube
Oil Pump ON indication will appear on PLC panel
NOTE:
AUXILIARY LUBE OIL PUMP MUST ALWAYS BE STARTED PRIOR TO
COMPRESSOR STARTUP TO ENSURE THROUGH LUBRICATION OF THE
SYSTEM

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Verify that no water or oil leaking at any point

Close the manual condensate drain bypass valve (Condensate in Inter / After Coolers
will now be removed through automatic drainers)
Turn Hs-137 switch to UNLOAD Mode
Press Control Reset button on PLC panel. READY TO START indication will
appear on PLC panel
CAUTION:
ENSURE THAT EMERGENCY STOP BUTTON IS PULLED. PRESSING THE
BUTTON TRIPS THE COMPRESSOR DURING NORMAL OPERATION
14
15
Inform Boiler boardman about compressor startup

Turn Maintenance / Manual / Auto Key Switch (HS-138) on PLC Panel to Manual
mode
NOTE:
IF HS-138 IN MANUAL MODE THE COMPRESSOR WILL START / STOP
FROM LOCAL PUSH BUTTON HS-134/135- COMPRESSOR PROTECTION
WILL BE ACTIVE. INMAINTENANCE MODE, ALL POWER TO PLC DIGITAL
OUTPUT CARDS WILL BE DEMERGISED PREVENITING THE COMPRESSOR
FROM STARTUP OR TRIPPING THE COMPRESSOR IF IT IS RUNNING. IN
AUTO MODE HS-139 DETERMINES THE CONTROL SIGNAL SOURCE. ONLY
MANUAL MODE IS IN SERVICE
16
Turn Manual / Local / Remote Switch (HS-139) on PLC Panel to Manual mode
NOTE:
IF HS-139 IS IN MANUAL MODE ONLY THE LOCAL PUSH BUTTONS AND
SELECTOR SWITCHES ARE ACTIVE. IN REMOTE MODE THE PLC WILL
ACCEPT CONTROL COMMAND FROM DCS (SUBJECT TO AVAILABILITY
OF DCS / MOD BUS INTERFACING - DISABLED). ONLY MANUAL MODE IS
IN SERVICE.
17
Prior to startup ensure that:

i
ii
iii
18
IGV is closed
MBOV is full open
Automatic Shut-off Valve is full closed
Slowly open C-702 outlet valve near D-711 while monitoring IA system Pressure.

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CAUTION:
AIR SYSTEM AUTOMATIC BLOCK VALVE OPENS ON AUTO WHEN THE
COMPRESSOR RECEIVES START COMMAND AND CLOSES ON RECEIVING
STOP COMMAND.
IN CASE THE CHECK VALVE AT UPSTREAM OF BLOCK VALVE IS LEAK
THROUGH, THE SYSTEM PRESSURE MIGHT GET RELEASED THROUGH
OPEN MBOV. A DECREASE IN PRESSURE WHILE OPENING THE C-702
OUTLET VALVE WILL INDICATE POSSIBILITY OF LEAK THROUGH
CHECK VALVE. CLOSE THE VALVE AND HAVE THE CHECK VALVE
CHECKED BY MAINTENANCE.
19
20
21
22
23
1.3
Press START button on PLC panel. Compressor will accelerate to full speed.
Log / monitor the compressor vibrations, process temperatures, process pressures and
motor stator temperatures
If compressor operation is found to be satisfactory, the compressor may be loaded
Switch over HS-137 from Unload to Module position.(The compressor will be
loaded by opening IGV and BOV opening will change for surge prevention and
controlling 3rd stage discharge pressure (PT1). IGV will control system pressure (PTA)
while limiting motor load - below max. Amps set point)
Log / monitor the compressor vibrations, process temperatures, process pressures and
motor stator temperatures.
SHUTDOWN PROCEDURE
The compressor will be shutdown as per following sequence:
1
2
Inform Ammonia-2 and Utility-1 Board man about Compressor shutdown

Reduce load on the compressor slowly by starting & loading C-701 A/B or increasing
air import from Ammonia-2
When the flow has reduced to 543 NMCH (20 KSCFH), turn HS-137 to Unload
position. IGV will close (ramp close to minimum opening in 10 seconds) and MBOV
will fully open.
CAUTION:
DURING MANUAL SHUTDOWNS, ENSURE THAT IGVs HAVE FULLY CLOSED
AFTER UNLOAD COMMAND BEFORE STOPPING THE COMPRESSOR
4
5
Shutdown the compressor from Stop button (HS-135)

After shutdown keep cooling water and lube oil circulating for at least 30 minutes to
remove heat from the system.

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Open the condensate drainers bypass valve.

Close C-702 isolating valve near D-711.
Put off and rack out the main breaker if required.
C-701 A/B SHUT DOWN PROCEDURE

1.
2.
3.
Inform SS / SIC , NH3-2 & boiler operator.

Un load C-701 A/B gradually through PIC-701 A/B keeping close eye on instrument
air pressure.
After unloading compressor decrease set point of PLCI-702 A/B. Air bleeding will be
started through PCV-702 A/B. Reset bleeding air, ensure 20 psig signal at PLCI-702
guage. Compressor will stop.
NOTE:
IN CASE OF C-701A AFTER RESETTING BLEEDING AIR, MOTOR SHOULD
BE STOP BY PRESSING LOCAL ON / OFF SWITCH TO OFF POSITION.
4
5
6
1.5
C-701A HAND OVER PROCEDURE

1.
2.
3.
4.
5.
6.
7.
1.6
Follow C-701A Shut down procedure

Put PLCI-702A set point zero.
Put PIC-701A set point zero.
Put motor local selector switch at off position.
Rack out motor breaker, lock out and tag out.
Hand over C-701A .
Close discharge air outlet valve.
C-701B HAND OVER PROCEDURE

1.
2.
3.
4.
5.
6.
7.
1.7
Close quenching water valve.

Stop dust blower.
Crack open drain valves of clearance valves.
Follow C-701B Shut down procedure

Put PLCI-702B set point zero.
Put PIC-701B set point zero.
Drop trip lever of steam turbine.
Close 12 kg/cm2g (175 psig) steam and 2 kg/cm2g (25 psig) steam isolating valves.
Close discharge air outlet valve
Hand over C-701B.
BYPASSING PROCEDURE OF D-711

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Inform SS / SIC & NH3-2

Shift impulse of PIC-701 A/B , PLCI-702 A/B, PT-703 and PT-704 on new impulse
header. Close impulse from D-711.
Start C-701 A/B and line up through their by pass lines. Close isolating valve of their
original discharge lines.
Start C-702 (If not running)
Open V-1
Close V-2 , V-3, V-4 & V-5. Keep close eye on instrument air pressure.
NOTE:
DURING STEP 6 D-711 WILL BE BY PASSED BUT PLANT AIR HEADER WILL
ALSO BE ISOLATED TILL THE D-711 IS DEPRESSURIZED AND BLIND -1 IS
INSTALLED.
7.
8.
9.
10.
11.
12.
13.
14.
15.
1.8
Depressurize D-711 from its GLG drain or auto drainer upstream drain valve.
Get the blind-1 installed.
Open V-4 so that plant air could be lined up.
Install blind-2 .
Debox up D-711.
Check that explosivity in D-711 is nil.
Check O2 is 21%
Provide 24 V light in the vessel.
D-711 is ready for vessel entry and inspection. (See fig. 1 for detail)
PUTTING BACK IN SERVICE PROCEDURE FOR D-711

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Get the box up certificate .

Get the vessel boxed up.
Close V-4. Keep an eye on inst. Air pressure.
Remove blind-1 & blind-2
Slightly open V4 and pressurize the vessel very slowly up to the system pressure
Have a thorough check up for any leakage.
Open V-2 & V-3 to put vessel in service.
Close V-1. Keeping eye on inst. Air pressure.
Open isolating valve of C-701A/B Original discharge lines and isolate there by pass
lines
Shift the impulse of PIC-701 A/B, PLCI-702 A/B and PT-3/4 back to D-711.

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Inform SS / SIC and NH3-2.

Open CWS / CWR valve to Reg. Cooler .
Switch ON control power Supply to PLC from EE-08.
Open slowly AD-711 service inlet valve. Keep monitoring the Inst. Air header
pressure
Check that manual drain valve of moisture separator is crack open & steam trap is in
service.
Check that regeneration air flow is normal.(3.5 division).
Take regeneration heater into service after draining condensate.
Now slowly open the AD-711 A/B service outlet valve. Keep monitoring instrument
air pressure.
AD -712 START UP AND LINE UP PROCEDURE

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
1.11
July, 2009
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AD -711 START UP AND LINE UP PROCEDURE

1.
2.
3.
4.
1.10
:
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:
Inform SS / SIC and NH3-2.

Open CWS / CWR valve to Reg. Cooler E-713.
Switch ON control power Supply to PLC from EE-84 A.
Install fuses inside PLC cabinet & put ON breaker (Inside PLC cabinet).
Open slowly AD-712 service inlet valve. Keep monitoring the Inst. Air header
pressure
Check that auto drainer & steam trap are in service.
Adjust regeneration air flow at FIC-712 at 489 NMCH (300 SCFM)
Ensure due point analyzer is in service. Its discharge bleeder should be crack open
Take regeneration heater E-712 into service after draining condensate.
Now slowly open the AD-712 A/B service outlet valve. Keep monitoring instrument
air pressure.
ROLE STATEMENT IN GRAVE EMERGENCY SHUT DOWN

1.
2.
3.
4.
Put on Scott air pack.

Leave GTs, C-701 A/B and C-702 as such.
Drop trip levers of P-601B & C.
Switch off P-601 A & D.
Inform control room and rush to plant gate or new air port gate depending on wind direction
equipped with Scott air pack.

Document Type:
Document No.:
PR-UT1-M7
Document Status:
Final
Posts Manuals
CHAPTER-6
TURBLE
SHOOTING
GUIDE LINES
Originated by :
Issue No. 1 by :
Issue No. 2 by :
Issue No. 3 by :
Issue No. 4 by :
Revision 1
:
Reviewed by :
Approved By :
Update due :
AAd
SF
AIH
ARQ
MAL
Burero/KRm
ARH
JP
Unit : Utility-1
in : June, 1996
in : June, 1998
in : June, 1999
in : June, 2003
in : June, 2006
in : July , 2009
in : July , 2009
in : July , 2009
in : July , 2012
Code: PR-UT1
TABLE OF CONTENTS
SECTION
DESCRIPTION
01
PAGE
1.1
1.2
1.3
1.4
1.5

DRIVE TRAIN TROUBLE SHOOTING
CONTROL SYSTEM TROUBLE SHOOTING
AIR SYSTEM TROUBLE SHOOTING
LUBRICATION SYSTEM TROUBLE SHOOTING
TROUBLE SHOOTING OF AUTO DRAINER
1
3
5
6
7
2.1
TROUBLE SHOOTING GUIDE LINE FOR

AD-712
FAULT FINDING AND CORRECTION
02

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TROUBLE SHOOTING GUIDE LINES

SECTION-01
1.1
DRIVE TRAIN TROUBLESHOOTING
Condition:
Possible Causes:
Motor Vibration/Unusaual Sounds
Starter malfunction
Foundation bolts loose
Other mechanical part (s) loose
Excessive or unbalanced voltage
Lubrication inadequate or excessive
Dirt on fan
Dirt in air gap
Bearings worn
Misalignment
Drive coupling worn
Motor Overheating
Ambient temperature too high
Ventilation inadequate voltage
Voltage low, high, or unbalanced
Motor Overload
Control settings improper
Ground inadequate
Connections improper
Ground inadequate
Connections improper
Wiring improper
Starter malfunction
Dirt in air gap
Windings shorted
Single phasing
Motor seized
Compressor set points improper
Gearbox Oil Leak(s)
Ejector trap not filled
Ejector pressure incorrect
Reservoir vent filter clogged
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DRIVE TRAIN TROUBLESHOOTING

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POSSIBLE CAUSES:
COMPRESSOR VIBRATION
Split line seal faulty
Oil seal malfunction
Seal damaged
Sensor Reading faulty
Wiring in control panel incorrect
High oil temperature
Low oil temperature
Low oil pressure
Oil type incorrect
Oil contaminated
Surging
Motor vibration
Misalignment
Drive coupling damaged and / or worn
Impellers dirty or damaged
Rotor cartridge malfunction
1.2
CONTROL SYSTEM TROUBLE SHOOTING

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POSSIBLE CAUSES:
CONTROL PANEL INOPERATIVE

Power switch not on
Improper grounding
Power to panel interrupted
Fuse defective or blown (FU 1)
Control panel power supply voltage (s)
incorrect
Wiring connection error
Quad control board faulty
CONTROL PANEL DISPLAY
INOPERATIVE
Control panel inoperative
Electrical connections faulty
Power supply voltage incorrect
Contrast potentiometer set incorrectly
Display backlight failed
CONTROL PANEL KEYPAD
INOPERATIVE
Keypad failed
CONTROL PANEL POWER SUPPLY
VOLTAGE (S) INCORRECT
Control panel inoperative
Output potentiometer set incorrectly
Fuses blown or faulty (FU 2, 3)
Line filter failed
Power supply failed
MOTOR OVERLOAD
Maximum Amp set point too high
Inlet guide vane assembly inoperative
Inlet guide vane assembly out of adjustment
ONTROL SYSTEM TROUBLE SHOOTING

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POSSIBLE CAUSES:
CONTROL VALVE (S) FAULTY

Thermal overload relay set improperly
Current transducer faulty
Starter problem
Motor problem
Wiring from control panel faulty
Metering valve setting incorrect
____ Bypass valve
(AUTO-DUAL Control only)
Instrument air supply interrupted
_____ By pass valve
(AUTO-DUAL Control only)
_____ Below - off valve
(CONSTANT PRESSURE Control only
Valve or inlet guide vane assembly adjusted
improperly
Mechanical linkage malfunction
(inlet guide vane assembly only)
Control solenoid valve malfunction
_____ Blow - off valve
(AUTO-DUAL Control only
Inlet guide vane assembly motor or coupling
malfunction
(inlet guide vane assembly only)
Optical coupler malfunction
Valve failure
COMPRESSOR CONTROL
PERFORMANCE ABNORMAL
Set points incorrect
Air demand too high or low
Air system constraints
(from demand swings, volume shifts,
pressure drops, etc.)
Control valve (s) faulty
1.3
AIR SYSTEM TROUBLE SHOOTING
CONDITION:
POSSIBLE CAUSES:

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HIGH AIR PRESSURE

Low demand
Air pressure set point too high
Sensor Reading Faulty
Control Valve (s) Faulty
LOW AIR PRESSURE
Air pressure set point incorrect
Maximum Amp set point incorrect
Air demand above compressor rating
Inlet air filter dirty or restricted
Ambient air temperature excessive
Impellers dirty
HIGH AIR TEMPERATURE
Water flow to cooler (s) insufficient
Coolant temperature too high
Inter cooler (s) after cooler fouled
Hot air bypassing inter coolers / after cooler
Coolant bypassing inter coolers / after cooler
Surging
SURGING
Air pressure set point too high
Inlet air filter dirty or restricted
Minimum Amp set point too low
High Air Temperature
CHECK VALVE MALFUNCTION
Valve oversized
Seat or disc worn or dirty
Disc movement impaired
1.4
CONDITION:
OIL LEAK (S)
POSSIBLE CAUSES:

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Connection loose
Filter cartridge loose
Gearbox Oil Leak (s)
Pump shaft seal worn or damaged
OIL MIST
Ejector vent filter clogged
Filter trap not filled
Ejector pressure incorrect
HIGH OIL TEMPERATURE
Water flow to cooler insufficient
Coolant temperature too high
Oil cooler fouled
Thermal mixing valve faulty
Oil heater thermostat faulty
LOW OIL TEMPERATURE
Water flow through cooler excessive
Thermal mixing valve faulty or missing
Oil heater thermostat faulty or missing
HIGH OIL FILTER DIFFERENTIAL
PRESSURE
Oil filter element dirty or clogged
HIGH OIL PRESSURE
Pressure regulator set improperly or
malfunctioning
Low oil temperature

CONDITION:
POSSIBLE CAUSES:
LOW OIL PRESSURE
Oil level too low

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malfunctioning
Fuses in pump motor starter blown or faulty
High Oil Temperature
Leakage within gearbox
Pump motor starter over loads tripped
Wiring or pump motor or starter incorrect
Pump rotation incorrect
Pump seized
Pump coupling damaged
Pump suction line restriction
MAIN OIL PUMP MALFUNCTION
Pump suction line restricted
Pump coupling damaged
Pump damaged
malfunctioning
Oil level too low
1.5
TROUBLE SHOOTING OF AUTO DRAINER
Condensate will not flow into reservoir
Excessive bubbling in reservoir
Drain will not open when trigger point is

reached.
Check for blockage in bottom of vessel or

piping
Check to see that the vent (needle valve) in
the top of the drain is not closed.
Vent (needle valve) in the top of the drain is
open too much. Adjust (close) until
bubbling slows to 1 or 2 small bubbles
every few seconds.
Check pilot air to be sure it is not plugged
Check pressure on pilot air line, should be at
least 3.87 kg/cm2g (55 psig). Actuator may
open slowly (or not at all) at lower pressure.

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SECTION-02
2.1
TROUBLE SHOOTING
GUIDE LINES
FOR AD-712
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TROUBLE SHOOTING GUIDE LINE FOR AD-712
FAULT FINDING AND CORRECTION

The following table contains details of the most probable causes of dryer faults.
Fault
Wet product air.
Sequence Valve
Failure
Non-return valve
failure.
Cause
Poor or no regeneration.
Excessive free water in air

to the dryer.
Moisture analyzer out of
calibration.
Dryer sequence valves
failed to changeover.
Process or regeneration
non return valves stuck or
leaking.
Desiccant performance
poor. (desiccant powdered
or contaminated by oil
etc.)
Low instrument air
pressure
Valve / actuator seizure.
Limit switch fault (if
fitted).
Solenoid or air valve
failure.
Lack or air feed to
actuator.
Logic fault.
Valve guides worn.
Contamination on seats.
Damage to seats.
Corrective Action
Check : Dryer valve sequence operation
and sequence times.
Check : Purge flow is satisfactory and
purge silencers are clear.
Check : Depressurisation is satisfactory.
Check : Process operating conditions.
(Flow rate / Pressure / Temperature)
Check : Upstream system drains.
Check : Pre-filter drains (if fitted)
Re-calibrate analyzer.
Check : Dryer logic and controls
Check : Condition of non-return valves.
Check : condition of desiccant and

change if necessary.
Check : Air pressure

Service valve / actuator.
Service switch.
Service solenoid or air valve.
Check : Solenoid or air valves and
pneumatic circuit components.
Check : Sequence logic / timer.
Service valves.
Service valves.
Service valves.

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Regenerating
Tower not
depressurising.
Regenerating
tower not
pressurising.
High pressure
loss across dryer.
Excessive
regeneration
purge flow.
TROUBLE SHOOTING
GUIDE LINES
FOR AD-712
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Main inlet valves or

exhaust valves fail to
operate.
Non-return valve fault.
Purge exhaust silencers
blocked (if filled).
Repressurising valve fault.
(Failure to close).
See Sequence valve failure
Exhaust valve sticking

open.
Purge orifice blocked.
Desiccant broken down
Regenerating tower not

depressurising.
See Regenerating Tower not

depressurising.
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See Non-return valve failure

Service silencers.
Clean orifice.
Change desiccant.
NOTE
IF THE AIR DRYER IS TO BE SHUT DOWN, THE FLOW THROUGH THE
DRYER MUST BE ISOLATED.

Document Type:
Document No.:
PR-UT1-M7
Document Status:
Final
Posts Manuals
CHAPTER-7
APPENDIX
Originated by :
Issue No. 1 by :
Issue No. 2 by :
Issue No. 3 by :
Issue No. 4 by :
Revision 1
:
Reviewed by :
Approved By :
Update due :
AAd
SF
AIH
ARQ
MAL
Burero/KRm
ARH
JP
Unit : Utility-1
in : June, 1996
in : June, 1998
in : June, 1999
in : June, 2003
in : June, 2006
in : July , 2009
in : July , 2009
in : July , 2009
in : July , 2012
Code: PR-UT1
TABLE OF CONTENTS
CHAPTER-07
SECTION
01
02
APPENDIX
PAGE
1.1
DESCRIPTION
2.1
2.2
2.3
2.4
EMERGENCY HEALTH INFORMATION

TURBINE OIL
MAGNA-320
ALUMINA BALLS
MSDS LINK
2
3
4
5
3.1
LIST OF PSVs
LIST OF PSVs
4.1

FLOW ORIFICES
5.1
LIST OF CARSEAL VALVES

CARSEAL VALVES
6.1

03
04
05
06
07
7.1
08
8.1
8.2
8.3
8.4
CONTROL VALVES AND THEIR FAIL SAFE

POSITION
FAIL SAFE POSITION OF CONTROL VALVES AT
AIR COMPRESSOR POST IN CASE OF
INSTRUMENT AIR FAILURE
EQUIPMENT LIST
DRUMS
EXCHANGER
DRIVER MOTORS
MISCELLANEOUS EQUIPMENT
11
12
12
12
12

Document Type:
Document No.:
PR-UT1-M7
Document Status:
Final
Posts Manuals
09
9.1
10
10.1
11
12
CHAPTER-7
APPENDIX
11.1
11.2
12.1
Originated by :
Issue No. 1 by :
Issue No. 2 by :
Issue No. 3 by :
Issue No. 4 by :
Revision 1
:
Reviewed by :
Approved By :
Update due :
AAd
SF
AIH
ARQ
MAL
Burero/KRm
ARH
JP
Unit : Utility-1
in : June, 1996
in : June, 1998
in : June, 1999
in : June, 2003
in : June, 2006
in : July , 2009
in : July , 2009
in : July , 2009
in : July , 2012
Code: PR-UT1

13
PREDETERMINED INVENTORY LIMITS OF

HAZARDOUS MATERIALS
PREDETERMINED INVENTORY LIMITS OF
HAZARDOUS MATERIALS
14
CHEMICAL COST DATA

CHEMICAL COST DATA
SAMPLING SCHEDULE AT AIR COMPRESSOR
POST
15
15
16

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POWER SUPPLY
TO THE UNIT
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APPENDIX
SECTION-1 POWER SUPPLY TO THE UNIT:
S#
1
2
3
4
5
6
7
8
9
10
Equipment
C-702 Main Motor
C-701 A Motor
C-702 Lube Oil Pump Motor
C-702 Canaopy Fan Motor
C-702 PLC Power
C-702 Accessories Power
C-701 A/B Dust Blowers
C-701 A/B Quenching Water Solenoid
AD-711 Control Power
AD-712 Control Power
See fig. 1 for detail.
Voltage
6.6KV
440 V
440 V
440 V
120 V
220 V
440 V
110 V
110 V
110 V
Power Source
EE-620 BUS-1
EE-630 BUS-2
EE-614
EE-614
EE-84A
EE-614
EE-614
EE-08
EE-08
EE-84 B

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EMERGENCY
HEALTH
INFORMATION
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SECTION 02. EMERGENCY HEALTH INFORMATION

2.1
TURBINE OIL
PRODUCT NAME (S): TURBINE OIL
HAZARDS IDENTIFICATION
POTENTIAL HEALTH EFFECTS:
PRIMARY ROUTE OF ENTRY :
SKIN: The product,as with many petroleum product ,may cause minor skin, eye and lung
irritation,but good hygienic practices can minimize these effects.Normal use of this product
does not result in generation of oil mist. However if an oil mist is generated, overexposure
can cause minor and reversible irritation to the eyes ,skin ,and especially the lungs.Proper
personal protective equipment and sufficient ventilation can provide adequate
Protection
CARCINOGINICITY INFORMATION : none of the components present in this material

at concentrations equal to or greater than 0.1% are listed by IARC, OSHA or ACGIH as
a carcinogen .
FIRST AID MEASURES
INHALATION:If inhaled,remove to fresh air.If not breathing, give artificial respiration. If
breathing is difficult,give oxygen.Call a physician.
SKIN CONTACT:Wash skin thoroughly with soap and water. If irritation develops and
persists,consult a physician.If injected under the skin, necrosis could occur.See physician.
EYE CONTACT:In case of contact,immediately flush eyes with plenty of water for at least
15 minutes.Call a physician.
INGESTION:Material poses an aspiration hazard.If swallowed , do not induce
Vomiting. Immediately give 2 glasses of water.Never give anything by mouth to an
unconscious person.Call a physician.If vomiting occurs naturally,hava victim lean
forward to reduce the risk of aspiration.
PERSONAL PROTECTION
RESPIRATORY PROTECTION: None normally required except in emergencies or
when conditions cause excessive air borne levels of mists or vapors.
PROTECTIVE GLOVES:Should be worn when the potential exists for prolonged or
repeated skin contact. NBR or neoprene recommended.

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EYE PROTECTION: Safety glasses with side shields.

OTHER PROTECTIVE EQUIPMENTS: Coverall with long sleeves if splashing is
probable.
2.2
MAGNA - 320
IDENTIFICATION
PRODUCT NAME :
Magna 320.
APPLICATION :
Lubrication.
HAZARD IDENTIFICATION
This product is not classified as hazardous
HEALTH EFFECTS
ON EYES: May cause transient irritation.
ON SKIN: Unlikely to cause harm on brief or occasional contact.
BY INHALATION :Low volatility makes inhalation unlikely at ambient temperatures.
BY INGESTION: May cause nausea, vomiting and diarrhea.
CHRONIC: Repeated and prolonged skin contact may lead to skin disorders.
OTHER: None known.
FIRST AID MEASURES
EYES CONTACT: irrigate immediately with copious quantities of water for several
minutes.
SKIN CONTACT:Wash thoroughly with soap and water or suitable skin cleanser as
soon as possible .
INHALATION : Remove from exposure .
INGESTION :Obtain medical attention . Do not induce vomiting
SPECIAL EXPOSURES HAZARDS : None
EXPOSURE CONTROLS /PERSONAL PROTECTION
ENGINEERING CONTROL MEASURE : None
PERSONAL PROTECTIVE EQUIPMENTS :

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Avoid skin and eye contact

Wear impervious (eg of PVC), in case of repeated or prolonged contact .
Change contaminated clothing and clean before reuse.
2.3
ALUMINA BALLS
MOST IMPORTANT HAZARDS
ADVERSE HUMAN HEALTH EFFECTS :
respiratory system.
Slightly irritating to eyes and
FIRE OR EXPLOSION: No particular fire or explosion hazard.

CLASSIFICATION/SPECIFIC HAZARDS : According to EEC criteria this
product is not classified as hazardous substance.
TRIPPING HAZARD : If spilled may cause the floor to be very slippery.
FIRST AID MEASURES
INHALATION : Move to fresh air. If necessary seek medical attention.
SKIN CONTACT : Rinse with water.
EYE CONTACT : Immediately rinse with plenty of water for 15 minutes.Seek
medical attention.
INGESTION : Rinse out mouth with water. Consult with doctor.
ACCIDENTAL RELEASE MEASURES
PERSONAL PRECAUTIONS : Avoid contact with the eyes. Don't breath
dust.Use Dust Mask.
ENVIRONMENTAL PRECAUTIONS : No risk of environment.
TRIPPING HAZARD : Balls are slippery.
METHODS FOR CLEANING UP : Sweep up or vacuum up the product.
2.4
MSDS LINKS
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References for details of MSDS of the chemicals of utilities-1 are given below:
CHEMICAL NAME
Acti-Brom-3434
Anthracite
Chorine
IRA-96
IRA-120
IRA-402
NALCO-73204
NALCO-7348
NALCO-7356 plus
NALCO-8506
Sodium Hexametaphosphate
Sodium Hydroxide
SodiumHypochlorite14-15%
Sulphuric Acid
Trisodium Phosphate
OMALA-150
OMALA-220
Turbine Oil
Aluminia activated balls
Vitrea Oil
Alum
Calcium hydroxide
Magna -320
Methane gas
MSDS VOLUME
1 (a)
1 (a)
1 (a)
1 (a)
1 (a)
1 (a)
1 (a)
1 (a)
1 (a)
1 (a)
1 (a)
1 (a)
1 (a)
1 (a)
1 (a)
1 (b)
1 (b)
1 (b)
1(a)
1(b)
1(a)
1(a)
1(b)
1(a)
REFERENCE #
OP/CHEM/2
OP/CHEM/6
OP/CHEM/18
OP/CHEM/38
OP/CHEM/39
OP/CHEM/40
OP/CHEM/48
OP/CHEM/50
OP/CHEM/51
OP/CHEM/55
OP/CHEM/67
OP/CHEM/68
OP/CHEM/69
OP/CHEM/71
OP/CHEM/74
OP/OIL/24
OP/OIL/220
OP/OIL/44
OP/CHEM/04
OP/OIL/75
OP/CHEM/03
OP/CHEM/11
OP/OIL/
OP/CHEM/44
MSDS can be seen in MSDS Volume 1a & 1b, placed in the control room

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SECTION-03
3.1
Document No.
Revision No
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Chapter No
Section No
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LIST OF PSVs
:
:
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LIST OF PSVs
LIST OF PSVs:
S.No PSV
LOCATION
1.
99A
Portable air compressor discharge
SET PRESSURE
Kg/cm2g
Psig
8.79
125
2.
99B
Portable air compressor discharge
8.79
125
3.
701A
E-702A C-701A discharge line
10.55
150
4.
701B
E-702B C-701B discharge line
10.55
150
5.
702A
C-701A interstage (1 spare available)
6.
702B
C-701B interstage (1 spare available)
2.6
37
7.
705A
AD-711 instrument air dryer (Tower-A)
10.19
145
8.
705B
AD-711 instrument air dryer (Tower-B)
10.19
145
9.
711
D-711 Air receiver drum outlet
10.55
150
10.
713
C-701B turbine discharge line
2.46
35
11.
714
FIL-711 instrument air oil separator
11.25
160
C-701B air comp. turbine sentional
3.87
55
2.6
37
12.
806
13.
706A AD-712 istrument air dryer (Tower-A)
11.25
160
14.
706B AD-712 instrument air dryer (Tower-B)
11.25
160

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SECTION-04
4.1
LIST OF FLOW
ORIFICES
FLOW ORIFICES
Tag No
Description
FI-702
FI-712
FI-118
C-702 air flow

Regeneration air flow to AD-712
Air flow to UTY-1 from Ammonia-2.
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SECTION-05
5.1
LIST OF CAR SEAL

VALVES
Document No.
Revision No
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Chapter No
Section No
Page
LIST OF CAR SEAL VALVES
CAR SEAL VALVES

LOCATION
CAR SEAL
PSV-705A Isolation valve located at AD-711 tower-A

PSV-705B Isolation valve located at AD-711 tower-B
PSV-711 Isolation valve located at D-711
25# Steam line valve from C-701BT
Open
Open
Open
Open
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SECTION-06
LIST OF SAFETY
EQUIPMENTS
6.1
6.1.1
FULL FACE MASK

1.
2.
6.1.2
Near C-701B
IN MSGR near INERGEN PLC
FIRE EXTINGUISHERS
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
6.1.4
At C-701A in between C-701 A/B

At MSGR
SCOTT AIR PACKS

1.
2.
6.1.3
Document No.
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Page
3.52 kg (50 pound) Dry chemical trolley mounted in front of GT-603

12 kg Dry chemical in front of GT-603.
10.55 kg (150pound) Dry chemical at GT-601
10.55 kg (150pound) Dry chemical at GT-602
10.55 kg (150pound) Dry chemical at P-601D
3.52 kg (50 pound) Dry chemical at GT-601 (PS-406)
3.52 kg (50 pound) Dry chemical at GT-602 (PS-404 )
3.52 kg (50 pound) Dry chemical at C-701 A
CO2 fire extinguisher No-1 MSGR
CO2 fire extinguisher No-2 MSGR
30 kg CO2 Fire ext. No- 1 MSGR
30 kg CO2 Fire ext. No- 2 MSGR
CO2 Fire ext. In front of GT-603
C02 LANCES
1.
2.
3.
4.
5.
GT-601 (WEST)
GT-601 (EAST)
GT-602 (WEST)
GT-603 (EAST)
GT-603 (WEST)
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At GT-601 ( 01 EACH)
At GT-602 ( 01 EACH)
At GT-603 MCC ( 01 EACH)
At MSGR (01 EACH)
Near C-7018 (04 EACH)
At PS-1003
FIRE HYDRANT HOSES

1.
2.
6.1.9
12 kg/cm2g (175 psig) at GT-601

2 kg/cm2g (25 psig) in between C-701 A/B
FIVE MINUTES PACKS

1.
6.1.8
LIST OF SAFETY
EQUIPMENTS
BOX CONTAINING COMFO MASK

1.
2.
3.
4.
5.
6.1.7
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STEAM LANCES
1.
2.
3.
4.
6.1.6
:
:
:
:
South / East of GT-602

TK-200 North, near Deluge valve
RESUSCITATOR
1.
At MSGR (01)
6.1.10 LADDERS
1.
At west of MSGR (01)
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SECTION-07
7.1
CONTROL VALVES
AND THEIR
FAIL SAFE POSITIONS
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CONTROL VALVES AND THEIR FAIL SAFE

POSITION
FAIL SAFE POSITION OF CONTROL VALVES AT AIR COMPRESSOR

POST IN CASE OF INSTRUMENT AIR FAILURE.
S.No Tag No.

1
2
3
4
5
6
7
8
9
10
PIC-703V
PIC-704V
FIC-712V
PLCI-702V
MBOV-702
IGV-702
XV-001A
XV-001B
XV-002
XV-003
Description
Instrument air pressure control valve
Plant air from Ammonia-2 pressure control valve
AD-712 regeneration air flow control valve
C-701B 12 kg/cm2g (175 psig) steam inlet valve
C-702 modulating blow off valve
C-702 inlet guide vanes
AD-712 tower -A change over valve
AD-712 tower -B change over valve
Regeneration air to heater
Regeneration air to cooler
Fail Safe Position

Close
Open
Close
Open
Open
Close
Last position
Last position
Last position
Last position

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EQIPMENT
LIST
Document No.
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Chapter No
Section No
Page
SECTION-08 EQUIPMENT LIST

8.1
DRUMS
D-702
D-711
D-712
8.2
.
EXCHANGERS
E-701A/B
E-702A/B
E-713
E-712
E-711
8.3
C-701A/B inter stage coolers

C-701A/B after stage coolers
Regeneration air cooler of AD-712
Regeneration air steam heater of AD-712
AD-711 regeneration heater (Process air cooler at Urea-1)
DRIVER MOTORS
MC-701A
MC-702
8.4
C-702 air knock out drum

Air knock out drum
Moisture separator at AD-712
Auxiliary lube oil pump motor

Emergency lube oil pump motor
MISCELLANEOUS EQUIPMENT
C-701A
C-701B
C-702
FIL-701A/B
FIL-711
AD-711
AD-712
TC-701B
Instrument air compressor 701A

Instrument air compressor 701B
Instrument air compressor 702
C-701A/B inlet air filters
Oil separator /filter upstream of AD-711/712.
Air dryer 711
Air dryer 712
Turbine C-701B compressor
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SECTION-09
9.1
SAFETY CRITICAL
SECURITIES
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LIST OF SAFETY CRITICAL SECURITIES

Following securities are provided at Air compressor Post to protect the area from the
different hazardous situations leading to severe damage to equipment and human.
1)
2)
3)
4)
5)
6)
Smoke detectors installed in C-702 PLC room.

OST of C-701B steam turbine.
Emergency stop push button of C-702.
All PSVs of compressor post.(list of PSVs at compressor post is provided in
appendix section-03 )
C-702 Anti surge system
C-702 PLC
Please refer to Safety Critical Manual PR-UR1-P3 for philosophy, function, by passing
procedure and back in service procedures of all above safety critical devices.

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POWER SUPPLY
TO THE UNIT
Document No.
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SECTION-10 PREDETERMINED INVENTORY LIMITS OF

HAZARDOUS MATERIALS
S.No.
1
2
3
4
5
6
7
HAZARDOUS SUBSTANCES
Turbine oil-32
Hygrol-100
Omala-220
Hygrol-32
Turbine T-68
Vitrea-150
Magna-320
MAXIMUM LIMIT
02 Drum
01 Drum
01 Drum
01 Drum
01 Drum
01Drum
01Drum
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PR-UT1-M7
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4
7
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Effective
Prepared.
Reviewed
Approved
:
:
:
:
July, 2009
ARH
JP
SECTION-11
11.1
POWER SUPPLY
TO THE UNIT
Document No.
Revision No
Issue No
Chapter No
Section No
Page
:
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PR-UT1-M7
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11
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CHEMICAL COST DATA
POST CHEMICALS , LUBES AND POWER COST DATA

DESCRIPTION
HYGROL - 100
OMALLA-220
TURBINE-68
TURBO-46
TURBINE - 32
VITREA- 150
POWER
MAGNA-320
FLUSHING OIL
PRICE (Rs)
13,901
17,257
17,454
26,859
16,664
9,072
2.5
13,887
12,819
UNIT
DRUM
DRUM
DRUM
DRUM
DRUM
DRUM
KW
DRUM
CANE
Note:- All Costs data have been taken from Budget 2006 F&O
11.2
SAMPLING SCHEDULE AT AIR COMPRESSOR POST POST

2nd SATURDAY OF THE MONTH
TIME
1500 Hrs
1500 Hrs
SAMPLE & ANALYSIS

C-701A Lube oil for Appearance , BS & W , Viscosity & neutralization no.
C-701B Lube oil for Appearance , BS & W , Viscosity & neutralization no.
3rd SATURDAY OF THE MONTH

TIME
1500 Hrs
SAMPLE & ANALYSIS

C-702 Lube oil for Appearance , BS & W , Viscosity & neutralization no.

Effective
Prepared.
Reviewed
Approved
:
:
:
:
July, 2009
ARH
JP
SECTION : 12
12.1
LESSON LEARNT
FROM PAST
INCIDENTS
Document No.
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Issue No
Chapter No
Section No
Page
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LESSONS LEARNT FROM PAST INCIDENTS
LESSONS LEARNT FROM PAST INCIDENTS

1.
Regularly monitor C-701A / B gear box oil pressure as there is no alarm or trip
security on gear box oil pressure. ( Gear box lube oil pump failure incident )
2.
Always keep PIC-704 on auto mode to cater C-702 tripping emergency.(C-702

nuisance tripping incident )
3.
Keep C-701 A / B cut-in set point 0.35 kg/cm2 (5 psig) and loading pressure 0.42
kg/cm2 (6psig) less than running pressure to quick start and loading of compressors in
case of C-702 or KGT-2501 tripping emergency.
4.
Be careful in opening PT-1/2 set point change window from PLC panel of C-702The
pop up window for changing set point is currently showing `zero ` as default. In case
any one pressed the enter button inadvertently , the compressor discharge pressure will
become zero having great potential of surging
5.
Regularly drain instrument air regulators during night shift to remove moisture from
instrument air .

Air Compr

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ENGRO CHEMICAL PAKISTAN LIMITED

Manufacturing Division, Daharki

Air Compressor Post Manual

PROCESS FLOW DESCRIPTION

EQUIPMENT DETAIL AND SPECIFICATION

AIR DRYERS FOR INSTRUMENTS AIR

INSTRUMENTATION & CONTROL

CONTROL & INSTRUMENTATION FOR C-701 A/B

TROUBLE SHOOTING GUIDE LINES

ENGRO CHEMICAL PAKISTAN LIMITED

Air Compressor Post Manual

ENGRO CHEMICAL PAKISTAN LIMITED

Air Compressor Post Manual

PROCESS FLOW DESCRIPTION

FUNDAMENTALS OF AIR ADSORPTION

FUNDAMENTALS OF AIR COMPRESSION

FUNDAMENTALS OF AIR COMPRESSOR

ENGRO CHEMICAL PAKISTAN LIMITED

Air Compressor Post Manual

SAFETY AND HAZARDS OF THE AREA

HAZARDS OF INADVERTENT MIXING

STANDARD OPERATING CONDITIONS

Air Compressor Post Manual

Engro Chemical Pakistan Ltd

SECTION-1 PROCESS FLOW DESCRIPTION

Air Compressor Post Manual

Engro Chemical Pakistan Ltd

- To supplement Process Air

- C -2515 ( Passivation air)

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Engro Chemical Pakistan Ltd

FUNDAMENTALS OF AIR ADSORPTION

EARTH AND ITS ATMOSPHERE

PHYSICAL PROPERTIES AND COMPOSITION OF AIR.

EVAPORATION AND MOISTURE FORMATION:

Air Compressor Post Manual

Engro Chemical Pakistan Ltd

Condensation principles are reverse of the evaporation principles. Product of condensation is

FACTORS AFFECTING DEW POINT

WET BULB TEMP. :

2.1.10 AFFECT OF MOISTURE IN INST. AIR :

REMOVAL OF MOISTURE FROM AIR

KNOCK OUT METHOD.

Air Compressor Post Manual

Engro Chemical Pakistan Ltd

Air Compressor Post Manual

Engro Chemical Pakistan Ltd

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Engro Chemical Pakistan Ltd

SECTION-3 FUNDAMENTALS OF AIR COMPRESSION

POSITIVE DISPLACEMENT COMPRESSION

Air Compressor Post Manual

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THE IDEAL GAS LAW

1/P at constant temperature

It follows from the above:

C) THE COMBINED LAW

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Horse Power out put

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