A Sunrise Project for a Sunshine Future
A Sunrise Project for a Sunshine Future
PARADEEP REFINERY PROJECT
PARADEEP REFINERY PROJECT
COMPR
COMPR
ES
ES
SOR
SOR
OPERA
OPERA
TION
TION
Faculty Faculty Rajsekhar Patnala Rajsekhar Patnala DMPNC! DMPNC! Prepared by Prepared by Pro"uctionC! Pro"uctionC! T Tea#ea#
CONTENTS
CONTENTS
•
• IntroductionIntroduction
•
• CompresCompressor Tsor Takeover From Maintenaakeover From Maintenancence
•
• Start!pStart!p
•
• Normal Runnin" And Monitorin"Normal Runnin" And Monitorin"
•
• Trip#Emer"ency S$utdo%nTrip#Emer"ency S$utdo%n
•
• &ot#Cold Start !p&ot#Cold Start !p
•
CONTENTS
CONTENTS
•
• IntroductionIntroduction
•
• CompresCompressor Tsor Takeover From Maintenaakeover From Maintenancence
•
• Start!pStart!p
•
• Normal Runnin" And Monitorin"Normal Runnin" And Monitorin"
•
• Trip#Emer"ency S$utdo%nTrip#Emer"ency S$utdo%n
•
• &ot#Cold Start !p&ot#Cold Start !p
•
INTRO'!CTION
INTRO'!CTION
•
• Compressors are comple( mac$ines)Compressors are comple( mac$ines)
•
• Comple(ity lies in Comple(ity lies in t$e *orces+t$ermal, mec$anict$e *orces+t$ermal, mec$anical stressesal stresses
etc- t$at are actin" on
etc- t$at are actin" on t$e mac$ine components)t$e mac$ine components)
•
• Operatin" personnel s$ould understand t$e systems andOperatin" personnel s$ould understand t$e systems and
procedures t$orou"$ly)
procedures t$orou"$ly)
•
• SOPs on various operational procedures s$ould beSOPs on various operational procedures s$ould be
available
available $andy$andy))
•
• Operatin" personnel s$ould be very attentive and *ollo%Operatin" personnel s$ould be very attentive and *ollo%
all t$e sa*ety norms %$ile in t$e vicinity or %orkin" %it$
all t$e sa*ety norms %$ile in t$e vicinity or %orkin" %it$
compressor)
COMPRESSOR COMPONENTS
T $ T $ J $ J $COMPRESSOR COMPONENTS
• Compressor • Turbine 'rive • .overnor
• Antisur"e System
• /earin"s +Temp, 0ibration, a(ial displacement-• 1O System +cooler, Filter, accumulators, mist
eliminator-• /arrin" System • .land System
• Condensate System • Rundo%n Tank
COMPRESSOR 2 TA3EO0ER FROM MAINTENANCE
4) Ensure t$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$ere are any incomplete 5obs)
;) Ensure removal o* debris, tools and tackle, sca<oldin" in t$e compressor area)
=) Ensure area is cleaned properly and t$ere is no oil spilla"e
COMPRESSOR START!P
'ependin" on t$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<er) :) Startup oil system)
;) Establis$ seal system) =) Take turnin" "ear inline)
>) Start live steam pipin" %armup &P side and 1P side) ?) Steam turbine c$est valve Initial %armup)
@) 1ineup t$e "land steam condenser) 4)1ineup vacuum condenser in line) 44)Preparation o* compressor)
47)Startin" steam turbine)
STEPS '!RIN. START!P
PREPARATION• 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" $ouse
PrecautionsD
• Remove air pockets)
• Ensure TS0#PS0s are in line • Ensure T., P. are %orkin"
STEPS '!RIN. START!P
ESTA/1IS& SEPARATION SEA1 /!FFER
• 1ine up t$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 bu<er) • 1ine up separation seal bu<er valves
PrecautionsD
• Ensure TS0#PS0s are in line • Ensure T., P. are %orkin" • Conrm t$e o% o* nitro"en
STEPS '!RIN. START!P
ESTA/1IS& 1!/E OI1 SGSTEM
• Ensure t$at suHcient oil level is t$ere in t$e reservoir or else Top
up
• &eat oil i* necessary
• Prepare accumulators ready)
• Prepare t$e 1OP+T- and start t$e pump • Circulate oil t$rou"$ various circuits
• Remove air pockets *rom TS0, impulse lines, lters, accumulators
etc)
• Fill t$e rundo%n tank , commission it and c$eck t$rou"$ si"$t "lass • Ensure o% t$rou"$ all t$e Oil return lines)
• Run t$e mist eliminator • Run Centri*u"e
PrecautionsD
• Ensure t$at leaks are not t$ere,
• StabiliBe t$e pressure, temperature level readin"s • C$eck t$e auto start o* t$e standby pump
STEPS '!RIN. START!P
ESTA/1IS& SEA1 .AS SGSTEM
• 3eep t$e disc$ar"e PS0 bypass open) • 1ine up Flus$ "as supply to t$e seal)
• Set t$e o% o* us$ "as on bot$ 'E and N'E ) • Establis$ primary bu<er
PrecautionsD
• Ensure t$ere is not pressure buildup in t$e compressor
casin" t$at %ill dama"e t$e seal
• Ensure t$at t$e lter 'P is normal and t$ere is no
STEPS '!RIN. START!P
TA3IN. T!RNIN. .EAR IN 1INE
• Initial operation o* turnin" "ear s$ould be done manually to ensure t$at breaka%ay o* t$e turbine train is possible %it$out e(ceedin" t$e torue capability o* t$e Turnin" .ear) T$is %ill be done by Maintenance)
• Start turnin" "ear system +appro() one $our prior to startup *or cold start up
• 'isable lock out *unction o* turnin" "ear by selectin" $andle position on turnin" "ear be*ore turnin" motor start)
• Conrm t$at t$e turnin" "ear is in disen"a"e position and start t$e motor)
• C$eck *or s$a*t rotation and proper operation o* turnin" "ear) Ad5ust t$e Seal "as system o%s a*ter turnin" "ear is put in operation)
PrecautionsD
• Ensure s$a*t rotation p$ysically and *rom eld instruments • C$eck t$e a(ial displacement and vibration probe readin"s
STEPS '!RIN. START!P
START 1I0E STEAM PIPIN. 9 STEAM T!R/INE C&EST 0A10E INITIA1 ARM!P
• Admit 1P Steam+e($aust steam- *or appro(imately 8 $ours
by openin" bypass valve o* NR0 %it$ openin" casin" drain and ot$er drains to remove condensate)
• Ensure t$at SS& steam is super$eated by at least 8oC
• Open t$e b#vJs in t$e drain includin" TT0 drains and %arm
up lines to allo% t$e removal o* condensate arisin" durin" %armup)
• arm up inlet pipin" system simultaneously up to t$e
recommended super$eat condition as s$o%n in table) TT0 %arm up %ill be part o* Inlet pipin" system)
• TT0 drain line s$all be kept open durin" %arm up)
• Continue %armin"up casin" %it$ e($aust steam until
temperatures are climbin" very slo%ly) Increase casin" metal temperature to +S1 Temp 8- oC appro() at deep
temperature sensors + I* necessary open TT0 valves and admit steam into casin")
STEPS '!RIN. START!P
1INE!P T&E .1AN' STEAM CON'ENSER
• Ensure coolin" %ater is C$ar"ed
• C$eck t$e C pressures and temperatures on t$e
"land steam condenser)
• Ensure t$at t$e "oose neck sealed by llin" %it$
%ater Take inline t$e condensate trap in t$e SM line)
• C$ar"e steam slo%ly and establis$ vacuum)
• Ensure t$at no steam escapes at t$e rotor ends o* t$e
steam turbine,
• In case o* steam escape $ave t$e mal*unction
corrected) PrecautionsD
• I* steam turbine is in $ot condition durin" turbine trip
break t$e vacuum till t$e time steam is c$ar"ed, in"ress o* air into "land %ill cause s$a*t
STEPS '!RIN. START!P
PREPARATION OF COMPRESSOR
• Ensure /lindin"# 'eblindin" is done as per list)
• Pur"e t$e suction lines %it$ Nitro"en pur"e provided,
to remove air *rom t$e circuit Pressurise t$e casin" to );k"#cm7 and vent to atmosp$ere and 'epressurise usin" 1P's in suction, disc$ar"e and spill back line)
• Repeat t$is till sample *rom casin" reads o(y"en
K)7L)
• Open antisur"e valves to *ull open condition and *ree
*rom $and %$eel)
• Open Inventory isolation valves)
• 1ineup tracin" steam o* suction lines o* t$e
Compressor)
• Once Compressor is oatin" %it$ suction close t$e
PS0 bypass t$at are opened) 'rain compressor casin" *ree o* any liuid)
STEAM T!R/INE START!P
PERMISSI0ES FOR STARTIN. STEAM T!R/INE
• Normally unless certain conditions o* t$e compressor
are met as mentioned typical o* FCC .C belo%, t$e compressor start is not allo%ed by t$e ES' system
• .C Start PermissiveD
I8;
STARTPERMISSI0E FOR .C FROM 4ST AS 0A10E OPEN FEE'/AC3
FS&4?7 SP I8;
STARTPERMISSI0E FOR .C FROM 7N' AS 0A10E OPEN FEE'/AC3
FS&48; SP I8;
1O COO1ER O#1 TEMP NOT 1O
TT::7 SP I8;
1O S!PP1G &'R PRESS!RE COMP PERMISSI0E NOT1O
PT:74 SP I8;
'P /ETEEN F1!S& N7 AN' PRIMARG /!FFER
P'T:78 SP I8;
ES0 C1OSE FEE' /AC3
S1:87 SP I8;
O0ER&EA' TAN3 1E0E1 &I.&
1IA:7 SP CONTRO1 OI1 &'R PRESS!RE NOT 1O
STEAM T!R/INE START!P
Start t$e Turbine +Typical o* FCC .C by Elliot
Ebara-• C$eck i* Ready to start is ac$ieved) • 3eep t$e "overnor valve *ull open)
• Slo%ly open t$e TT0 valve manually to increase t$e
RPM 4rpm#sec
• /rin" t$e rpm to lo% idle speed o* =rpm)
• I* any noise is observed reduce speed to previous step
and %ait till noise "ets reduced
• Monitor +SI:8#7- and control speed at lo% Idle
speed 4 usin" t$e T9T valve +78TO0:4-)And conrm t$at t$e all mec$anical conditions are satis*actory)
• Conrm t$at t$e bearin" temperatures +T4
:8;#4#7#8#:#;#=#>- and vibration levels +0I:8;#7, 0IG:8;4#:- are stabiliBed be*ore makin" speed c$an"es, And conrm t$at all t$e mec$anical conditions are satis*actory)
STEAM T!R/INE START!P
Start t$e Turbine +Typical o* FCC .C by Elliot
Ebara-• Conrm t$at t$e bearin" temperatures +T4
:8;#4#7#8#:#;#=#>- and vibration levels +0I:8;#7, 0IG:8;4#:- are stabiliBed be*ore makin" speed c$an"es, And conrm t$at all t$e mec$anical conditions are satis*actory)
• /rin" t$e RPM to lo% Idle speed7 o* 4;rpm 4
rpm#sec by t$rottlin" 78TO0:4 manually %it$ "overnor valves +S0:87- %ide open *or eualiBed casin" %armin" and keep at t$at RPM *or ? min
• Conrm t$at t$e 'eep casin" metal temp +TI:87
TI:8:- K ? QC and s$allo% casin" metal temp +TI:88TI:8;- K ? QC and Temp di< +TI:8=TI:8>-K 47; QC)
• Rise t$e deep casin" metal temperatures to 4; QC at
STEAM T!R/INE START!P
Start t$e Turbine +Typical o* FCC .C by Elliot
Ebara-• .radually open T9T valve *ully) T$en "overnor %ill
control train speed a Iittle bit above lo% Idle speed7 o* 4;) Conrm t$at "overnor is controllin" speed +once t$e speed e(ceeds re*erence speed +SI:84#8- a
• No% press acceleration start +&S:874-, t$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$e deep casin" temperatures to rise above 4;
QC
STEAM T!R/INE START!P
1oadin" t$e Turbine +Typical o* FCC .C by Elliot
Ebara-• C$eck t$e process readiness
• Put antisur"e controllers in auto)
• Slo%ly increase t$e load and allo% t$e antisur"e to
close)
• Put t$e speed controller in auto cascade)
• $ile loadin" %atc$ *or level increase in compressor
NORMA1 R!NNIN. AN' MONITORIN.
• '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
• Antisur"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%
TRIP # EMER.ENCG S&!T'ON
• 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$utdo%n
• /elo% is t$e Typical o* FCCIN'MA .C
I87
1O TO /EARIN.S &'R PRESS!RE TO TRIP .C 7#8
PT:7A#/#C TRIP
I8:
.C SEA1 NITRO.EN PRESS!RE 1O
PT:7@;A#/#C TRIP
I8=
'P /ETEEN F1!S& N7 AN' PRIMARG /!FFER TO TRIP .C
P'T:77A#/#C TRIP
I844 RPM IN'ICATION TO TRIP CONFIRM SO!RCE +SA:87- TRIP
I847
SPEE' SI.NA1 FROM .O0ERNOR O0ERSPEE' TRIP
+7#8- TRIP
I848
O0ERSPEE' PROTEC&TION PROTEC&78
SS&&:8;4 +7#8- TRIP
I84:
EMER.ENCG STOP P!S& /!TTON
+&S:8=- TRIP
I874 S:7;A#/#C 7#8 TRIP
I877 0:7;#:7;4 4#7 TRIP
I878 0:7;7#:7;8 4#7 TRIP
I87: 0:8;#:8;4 4#7 TRIP
I87; 0:8;7#:8;8 4#7 TRIP
I87= S:8;A#/#C 7#8 TRIP
I87> T:7;#:7;4 4#7 TRIP I87? T:7;7#:7;8 4#7 TRIP I87@ T:7;:#:7;; 4#7 TRIP I88 T:7;=#:7;> 4#7 TRIP I884 T:8;#:8;4 4#7 TRIP I887 T:8;7#:8;8 4#7 TRIP I888 T:8;:#:8;; 4#7 TRIP I88: T:8;=#:8;> 4#7 TRIP
TRIP # EMER.ENCG S&!T'ON
!sual Trip conditions Process side
• &i"$ 3O' level
• &i"$ disc$ar"e temperature
• Inventory valve accidental closure
Mac$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
TRIP # EMER.ENCG S&!T'ON
AFTERMAT& OF TRIP 9 &OT CO1' START!P E<ects o* activation o* trip
• TT0 %ill close
• Control oil to "overnor %ill stop • Inventory valve %ill close
• Mac$ine train %ill coast do%n to barrin" condition • /arrin" %ill be activated
&OT # CO1' START!P
S&!T'ON 9 &AN'O0ER TO MAINTENANCE
• S%itc$ t$e Speed control and t$e Antisur"e valves to
manual)
• .radually reduce load by reducin" t$e turbine speed
to minimum "overnin" speed and open t$e antisur"e valve *ully)
• Press t$e Stop .ov stopD T$is %ill eventually close
t$e .overnor 0alve and t$e T 9 T 0alve)
• Monitor t$e vibration levels, particularly %$en
approac$in" t$e unit critical speeds) In t$e event t$at severe vibration is encountered %$en approac$in" t$e critical speed, decelerate as uickly as possible)
• S$ut do%n t$e "land condenser leak o< system be*ore
S&!T'ON 9 &AN'O0ER TO MAINTENANCE
• Close t$e e($aust block valve and release t$e casin"
internal pressure as uickly as possible) Conrm Bero speed *or a %$ile and conrm t$at t$ere is no possibility o* reverse rotation)
• T$en select ratc$etin" position +not lockout
position-o* t$e lever on t$e turnin" "earbo() And start t$e turnin" "ear)
• T$e recommended turnin" period is minimum 4: $rs
a*ter turbine s$ut do%n) $en turnin" period is over, stop t$e turnin" motor) And select lockout position +not ratc$etin" position- o* t$e lever on t$e turnin" "earbo( be*ore rotor complete stop)
• /e sure t$at no steam can enter t$e turbine *rom any
source %$en idle) Open t$e turbine casin" drains once unit is entirely blockedin
S&!T'ON 9 &AN'O0ER TO MAINTENANCE
• Open t$e compressor drains and drain o< any liuid) • 'epressurise and pur"e %it$ nitro"en and blind t$e
suction and disc$ar"e .eneral Precaution
• Allo% t$e au(iliary oil pump to operate until t$e
bearin"s $ave reac$ed temp) o* oil leavin" t$e cooler)
• S$utdo%n t$e "as seal system a*ter t$e compressor
$as been depressuriBed) S$ut do%n t$e separation seal bu<er a*ter oil system $as been s$utdo%n
• I* an unusual amount o* liuid is drained *rom t$e
compressor, it s$ould be analyBed to determine t$e source) Steps s$ould be taken immediately to prevent liuid *rom enterin" into t$e compressor)
• &andover to maintenance *or blindin")
• A*ter blindin" pur"e t$e system and $andover to
1IST OF MA6OR CENTRIF!.A1 COMPRESSORS
!NIT COMPRESSOR 0EN'OR SER0ICE 'RI0E
!NIT 78 FCC .C +ET.AS COMPRESSOR-E11IOT E/ARA &G'ROCAR /ON STEAM T!R/INE 'RI0EN !NIT 78 FCC
MA/ +MAIN AIR /1OER-MAN T!R/O AIR STEAM T!R/INE 'RI0EN !NIT > PR! 0RC +0APOR RECO0ERG COMPRESSOR-E11IOT E/ARA &G'ROCAR /ON MOTOR 'RI0EN !NIT: N&T :34 +N&T RECGC1E .AS COMPRESSOR &ITAC&I &G'ROCAR /ON MOTOR 'RI0EN !NIT:7 CCR :734 +CCR RECGC1E .AS COMPRESSOR-'RESSOR RAN' &G'ROCAR /ON STEAM T!R/INE 'RI0EN !NIT:7 CCR :737 + NET .AS COMPRESSOR4- &ITAC&I &G'ROCAR /ON MOTOR 'RI0EN !NIT:7 CCR :738 + NET .AS COMPRESSOR7- &ITAC&I &G'ROCAR /ON MOTOR 'RI0EN !NIT 7#74#77 0.O&'T RECGC1E .AS
COMPRESSOR /&E1 &G'RO.EN
STEAM T!R/INE 'RI0EN !NIT 48#4:#4; '&'T RECGC1E .AS
COMPRESSOR /&E1 &G'RO.EN
STEAM T!R/INE 'RI0EN !NIT7: REFRIE.ERATION .AS MOTOR
&AT CAN .O RON.
'urin" startup
• Not Properly dryin" t$e steam# *aulty Steam Traps • Not .ivin" suHcient time *or idlin"
• Not ensurin" 1O uality#uantity • Improper lineup o* process valves
• /ypassin" Sa*ety Interlocks • Improper Inertisation
• Restriction in disc$ar"e circuit • Improper 'rainin" o* 3O'#Casin"
SAFETG ASPECTS
• Strictly Avoid Assumptions
• Follo% SOPs provided
• Communication bet%een eld and panel
• 3een observation *or leaks %it$ "as monitors • Ear Mu<s alon" %it$ ot$er sa*ety "ear
• Ensure t$at all t$e online "as detectors in t$e vicinity
are *unctionin"
• C$eckin" o* t$e Sa*ety Interlock systems • Test Run#Sur"e Test s$ould be done be*ore