228037830-Compressors-Operation.pptx

COMPRES COMPR ESSOR SOR OPERA OPERATION TION

Faculty Rajsekhar Patnala

Prepared by Pro"uctionC!  Tea#  Tea#

DMPNC!

PARADEEP REFINERY PROJECT A Sunrise Project for a Sunshine Future

CONTENTS •

Introduction

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Compressor Compres sor Takeover Takeover From Maintenance Maintena nce

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Start!p

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Normal Runnin" And Monitorin"

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Trip#Emer"ency S$utdo%n

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&ot#Cold Start !p

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S$utdo%n And &andover To Maintenance

CONTENTS •

Introduction

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Compressor Compres sor Takeover Takeover From Maintenance Maintena nce

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Start!p

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Normal Runnin" And Monitorin"

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Trip#Emer"ency S$utdo%n

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&ot#Cold Start !p

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S$utdo%n And &andover To Maintenance

INTRO'!CTION •

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Compressors are comple( mac$ines) Comple(ity lies in t$e *orces+t$ermal, mec$anical mec$anical stresses etc- t$at are actin" on t$e mac$ine components) Operatin" personnel s$ould understand t$e systems and procedures t$orou"$ly) SOPs on various operational procedures s$ould be available $andy $andy)) Operatin" personnel s$ould be very attentive and *ollo% all t$e sa*ety norms %$ile in t$e vicinity or %orkin" %it$ compressor)

COMPRESSOR COMPONENTS

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COMPRESSOR COMPONENTS •

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Compressor Turbine 'rive .overnor Antisur"e System /earin"s +Temp, 0ibration, a(ial displacement1O System +cooler, Filter, accumulators, mist eliminator/arrin" System .land System Condensate System Rundo%n Tank 

COMPRESSOR 2 TA3EO0ER FROM MAINTENANCE 4) Ensure t$at all t$e 5obs are completed as per t$e 6ob list) 7) .et t$e clearance *rom maintenance departments +mec$anical # electrical # inst-) 8) Ensure t$at blindin" 9 deblindin" is done *or Normal Runnin" condition) :) P$ysically look around t$e compressor to c$eck i* t$ere are any incomplete 5obs) ;) Ensure removal o* debris, tools and tackle, sca) Ensure proper li"$tin")

COMPRESSOR START!P 'ependin" on t$e Compressor vendor and type t$ere %ill be minor variations in t$e compressor operatin" procedures) T$e procedure presented in t$e *ollo%in" slides "ives "eneral idea %$ic$ %ill be common *or all t$e centri*u"al steam driven compressors)

STEPS '!RIN. START!P 4) Preparation) 7) Establis$ coolin" %ater) 8) Establis$ separation seal bu) Start live steam pipin" %armup &P side and 1P side) ?) Steam turbine c$est valve Initial %armup) @) 1ineup t$e "land steam condenser) 4)1ineup vacuum condenser in line) 44)Preparation o* compressor) 47)Startin" steam turbine) 48)Compressor loadin" and stabiliBin")

STEPS '!RIN. START!P PREPARATION •

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Ensure all t$e utilities are commissioned namely Coolin" ater, Plant air, Nitro"en, &&P#&P#MP#1P Steam .et t$e clearance *rom maintenance departments+ mec$anical#electrical #instrumentation +i* maintenance  5ob is carried out Ensure t$at blindin" 9 deblindin" is done *or Normal Runnin" condition) Take Clearance *or Steam *rom TPS)  Ensure &&P steam main valves, bypass valves, control valve and trip valve are closed Ensure backpressure 1P Steam line main valves 9 bypass valves are closed) Open condensate drain valve in S&& line and dry t$e steam upto main /#0 Open condensate drain valve in S1 line and dry t$e steam upto main /#0

STEPS '!RIN. START!P ESTA/1IS& COO1IN. ATER Commission coolin" %ater in *ollo%in" systems E5ector condenser o* .land System 1O cooler) Turbine steam condenser 1O pump bearin" $ouse •

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PrecautionsD Remove air pockets) Ensure TS0#PS0s are in line Ensure T., P. are %orkin" •

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STEPS '!RIN. START!P ESTA/1IS& SEPARATION SEA1 /!FFER •

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1ine up t$e Nitro"en supply Filter) Ensure 'P across lter is in normal ran"e, Service t$e lter i* P'. s$o%s $i"$) Set pressure o* separation seal buK 47; QC) Rise t$e deep casin" metal temperatures to 4; QC at +TI:87#:- at end o* lo% idle7 4; rpm)

STEAM T!R/INE  START!P Start t$e Turbine +Typical o* FCC .C by Elliot Ebara•

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.radually open T9T valve *ully) T$en "overnor %ill control train speed a Iittle bit above lo% Idle speed7 o* 4;) Conrm t$at "overnor is controllin" speed +once t$e speed e(ceeds re*erence speed +SI:84#8- a No% press acceleration start +&S:874-, t$e train %ill be brou"$t to $i"$ Idle speed o* 7: rpm by Auto Acceleration 1o"ic) and t$en back to re*erence speed-) T$ere is a critical speed band +4=74-, in t$is band t$e acceleration %ill be 7 rpm#sec Allo% t$e deep casin" temperatures to rise above 4; QC Increase t$e speed to minimum "overnin" speed)

STEAM T!R/INE  START!P 1oadin" t$e Turbine +Typical o* FCC .C by Elliot Ebara•

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C$eck t$e process readiness Put antisur"e controllers in auto) Slo%ly increase t$e load and allo% t$e antisur"e to close) Put t$e speed controller in auto cascade) $ile loadin" %atc$ *or level increase in compressor 3O's and turbine condensate %ell)

NORMA1 R!NNIN. AN' MONITORIN. •

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'urin" normal runnin" condition t$e operatin" parameter o* bot$ process and mac$ine are to be monitored) T$e monitorin" inter*aces are 'CS panel, SRR, 1CP)

Parameters to monitor Process P#T#F Antisur"e controller deviation Compressor disc$ar"e pressure controller) Compressor 3O' levels and Auto Run o* condensate pumps) 1O system lter 'P# Temp, 1O uality level 0ibration#compressor temp# a(ial displacement readin"s) Seal system $ealt$+'P, Nitro"en pressure, seal "as leak o%)Coolin" %ater o% .land leak and .land system •

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TRIP # EMER.ENCG S&!T'ON •

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Trip is e(ecuted by ES' system %$en any o* t$e process# mac$ine parameters crosses $ealt$y values and brin" t$e mac$ine to sa*e s$utdo%n 1O TOis /EARIN.S &'R PRESS!RE TO TRIP .C 7#8.C /elo% t$e Typical o* FCCIN'MA

I87 I8: I8= I844 I847 I848 I84: I874 I877 I878 I87: I87; I87= I87> I87? I87@ I88 I884 I887 I888 I88:

PT:7A#/#C .C SEA1 NITRO.EN PRESS!RE 1O PT:7@;A#/#C 'P /ETEEN F1!S& N7 AN' PRIMARG /!FFER TO TRIP .C P'T:77A#/#C RPM IN'ICATION TO TRIP CONFIRM SO!RCE +SA:87SPEE' SI.NA1 FROM .O0ERNOR O0ERSPEE' TRIP +7#8O0ERSPEE' PROTEC&TION PROTEC&78 SS&&:8;4 +7#8EMER.ENCG STOP P!S& /!TTON +&S:8=S:7;A#/#C 7#8 0:7;#:7;4 4#7 0:7;7#:7;8 4#7 0:8;#:8;4 4#7 0:8;7#:8;8 4#7 S:8;A#/#C 7#8 T:7;#:7;4 4#7 T:7;7#:7;8 4#7 T:7;:#:7;; 4#7 T:7;=#:7;> 4#7 T:8;#:8;4 4#7 T:8;7#:8;8 4#7 T:8;:#:8;; 4#7 T:8;=#:8;> 4#7 CONTRO1 OI1 &EA'ER PRESS!RE 1O

TRIP TRIP

TRIP TRIP TRIP TRIP TRIP TRIP TRIP TRIP TRIP TRIP TRIP TRIP TRIP TRIP TRIP TRIP TRIP TRIP TRIP

TRIP # EMER.ENCG S&!T'ON !sual Trip conditions Process side &i"$ 3O' level &i"$ disc$ar"e temperature Inventory valve accidental closure •

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Mac$ine side &i"$ vibrations &i"$ a(ial displacement &i"$ temperature in bearin"s 1O pressure lo% 1o% control oil pressure E(cessive sur"e Seal *ailure detected by $i"$ seal "as o% Over speed trip Emer"ency stop •

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TRIP # EMER.ENCG S&!T'ON AFTERMAT& OF TRIP 9 &OT CO1' START!P E PR!

!NIT: N&T

!NIT:7 CCR

!NIT:7 CCR

!NIT:7 CCR !NIT 7#74#77 0.O&'T !NIT 48#4:#4; '&'T !NIT7:

RECGC1E .AS COMPRESSOR RECGC1E .AS COMPRESSOR REFRIE.ERATION .AS

MOTOR

&AT CAN .O RON. 'urin" startup •

Not Properly dryin" t$e steam# *aulty Steam Traps

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Not .ivin" suHcient time *or idlin"

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Not ensurin" 1O uality#uantity

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Improper lineup o* process valves

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/ypassin" Sa*ety Interlocks

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Improper Inertisation

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Restriction in disc$ar"e circuit

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Improper 'rainin" o* 3O'#Casin"

SAFETG ASPECTS •

Strictly Avoid Assumptions

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Follo% SOPs provided

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Communication bet%een eld and panel

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3een observation *or leaks %it$ "as monitors

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Ear Mu