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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 DMPNC! DMPNC! Prepared by Prepared by Pro"uctionC! Pro"uctionC!  T  Tea#ea#

(2)

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

(3)

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

(4)

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)

(5)

COMPRESSOR COMPONENTS

 T $      T      $  J $  J $

(6)

COMPRESSOR COMPONENTS

• Compressor • Turbine 'rive • .overnor

• Antisur"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 

(7)

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

(8)

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)

(9)

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" %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)

(10)

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

(11)

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"

(12)

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" • Conrm t$e o% o* nitro"en

(13)

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

(14)

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

(15)

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$e torue capability o* t$e Turnin" .ear) T$is %ill be done by Maintenance)

• Start turnin" "ear system +appro() one $our prior to startup *or cold start up

• 'isable lock out *unction o* turnin" "ear by selectin" $andle position on turnin" "ear be*ore turnin" motor start)

• Conrm 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

(16)

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 8oC

•  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" %armup)

• 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")

(17)

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

(18)

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 antisur"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 liuid)

(19)

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:74 SP I8;

'P /ETEEN F1!S& N7 AN' PRIMARG /!FFER

P'T:78 SP I8;

ES0 C1OSE FEE' /AC3

S1:87 SP I8;

O0ER&EA' TAN3 1E0E1 &I.&

1IA:7 SP CONTRO1 OI1 &'R PRESS!RE NOT 1O

(20)

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  4rpm#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$e T9T valve +78TO0:4-)And conrm t$at t$e all mec$anical conditions are satis*actory)

• Conrm 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$an"es, And conrm t$at all t$e mec$anical conditions are satis*actory)

(21)

STEAM T!R/INE  START!P

Start t$e Turbine +Typical o* FCC .C by Elliot

Ebara-• Conrm 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$an"es, And conrm t$at all t$e mec$anical conditions are satis*actory)

• /rin" t$e RPM to lo% Idle speed7 o* 4;rpm  4

rpm#sec by t$rottlin" 78TO0:4 manually %it$ "overnor valves +S0:87- %ide open *or eualiBed casin" %armin" and keep at t$at RPM *or ? min

• Conrm t$at t$e 'eep casin" metal temp +TI:87

TI:8:- K ? QC and s$allo% casin" metal temp +TI:88TI:8;- K ? QC and Temp di< +TI:8=TI:8>-K 47; QC)

• Rise t$e deep casin" metal temperatures to 4; QC at

(22)

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 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

(23)

STEAM T!R/INE  START!P

1oadin" t$e Turbine +Typical o* FCC .C by Elliot

Ebara-• 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

(24)

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

• 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%

(25)

TRIP # EMER.ENCG S&!T'ON

• 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* FCCIN'MA .C

I87

1O TO /EARIN.S &'R PRESS!RE TO TRIP .C 7#8

PT:7A#/#C TRIP

I8:

.C SEA1 NITRO.EN PRESS!RE 1O

PT:7@;A#/#C TRIP

I8=

'P /ETEEN F1!S& N7 AN' PRIMARG /!FFER TO TRIP .C

P'T:77A#/#C TRIP

I844 RPM IN'ICATION TO TRIP CONFIRM SO!RCE +SA:87- TRIP

I847

SPEE' SI.NA1 FROM .O0ERNOR O0ERSPEE' TRIP

+7#8- TRIP

I848

O0ERSPEE' PROTEC&TION PROTEC&78

SS&&:8;4 +7#8- TRIP

I84:

EMER.ENCG STOP P!S& /!TTON

+&S:8=- TRIP

I874 S:7;A#/#C 7#8 TRIP

I877 0:7;#:7;4 4#7 TRIP

I878 0:7;7#:7;8 4#7 TRIP

I87: 0:8;#:8;4 4#7 TRIP

I87; 0:8;7#:8;8 4#7 TRIP

I87= S:8;A#/#C 7#8 TRIP

I87> T:7;#:7;4 4#7 TRIP I87? T:7;7#:7;8 4#7 TRIP I87@ T:7;:#:7;; 4#7 TRIP I88 T:7;=#:7;> 4#7 TRIP I884 T:8;#:8;4 4#7 TRIP I887 T:8;7#:8;8 4#7 TRIP I888 T:8;:#:8;; 4#7 TRIP I88: T:8;=#:8;> 4#7 TRIP

(26)

TRIP # EMER.ENCG S&!T'ON

!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

(27)

TRIP # EMER.ENCG S&!T'ON

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

(28)

&OT # CO1' START!P

(29)

S&!T'ON 9 &AN'O0ER TO MAINTENANCE

• S%itc$ t$e Speed control and t$e Antisur"e valves to

manual)

• .radually reduce load by reducin" t$e turbine speed

to minimum "overnin" speed and open t$e antisur"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

(30)

S&!T'ON 9 &AN'O0ER TO MAINTENANCE

• Close t$e e($aust block valve and release t$e casin"

internal pressure as uickly as possible) Conrm Bero speed *or a %$ile and conrm t$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 blockedin

(31)

S&!T'ON 9 &AN'O0ER TO MAINTENANCE

• Open t$e compressor drains and drain o< any liuid) • 'epressurise and pur"e %it$ 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* liuid is drained *rom t$e

compressor, it s$ould be analyBed to determine t$e source) Steps s$ould be taken immediately to prevent liuid *rom enterin" into t$e compressor)

• &andover to maintenance *or blindin")

• A*ter blindin" pur"e t$e system and $andover to

(32)

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 /1OER-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 :34 +N&T RECGC1E .AS COMPRESSOR &ITAC&I &G'ROCAR /ON MOTOR 'RI0EN !NIT:7 CCR :734 +CCR RECGC1E .AS COMPRESSOR-'RESSOR RAN' &G'ROCAR /ON STEAM T!R/INE 'RI0EN !NIT:7 CCR :737 + NET .AS COMPRESSOR4- &ITAC&I &G'ROCAR /ON MOTOR 'RI0EN !NIT:7 CCR :738 + NET .AS COMPRESSOR7- &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 !NIT7: REFRIE.ERATION .AS MOTOR

(33)

&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"

(34)

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

(35)

References

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