CONTENTS I. Description on the propane refrigerant compressor system 1. Specification of the propane refrigerant compressor K-101A. 2.

Gas flow diagram of the compressor (K-101A) II. III. Control philosophy Start up and loading 4 5 2

1. Pre-start operation 2. Charge propane into the refrigerant system (Propane make up) 3. Start up the propane refrigerant compressor K-101A 4. Loading IV. Shut down of the compressor 11

A. Normal shut down B. Shut down for overhaul or rest for long period. C. In electric power failure Attached drawing Gas flow diagram of the compressor How to handle valve to start up the compressor - ANNEXURE 1 - ANNEXURE 2

Reference drawing Compressor process data sheet 6972-010-50-45A-DS-0006 Compressor expected performance curve 6972-010-50-45A-MDX-0018 Lube oil system P&I Diagram 6972-010-50-45A-3-1002-1 Seal oil system P&I Diagram 6972-010-50-45A-3-1002-2 Vibration monitoring system diagram 6972-010-50-45A-3-1002-3 Operating & Maintenance Manual 6972-010-50-45A-SOI-0052 Loop Schematic 6972-010-50-51-1-1002 Logic Diagram Compressor 6972-010-50-51-2-1008 Process P&ID 6972-010-50-02-1-101111,1112,1113,1114 Evacuation Compressor MDS 6972-010-50-45B-DS-0027 Evacuation Compressor P&ID 6972-010-50-45B-1-1025

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I.

Description on the Propane Refrigerant Compressor System :

The propane refrigerant system is designed to provide refrigeration at 8 C, -7 C,-27 C and -40 C. The propane liquid from the accumulator (10-V-108-A) at 42.5 C and 15.1 kg/cm2A saturation pressure is passed through propane sub cooler (10-E-118).Part of this subcooled liquid flow through feed gas cooler II (10-E-122) under level control of the kettle with a feed gas temperature controller override. Feed gas outlet temperature of 10-E-122 is controlled by refrigerant side pressure in the kettle via a pressure control valve on the refrigerant vapor line. The pressure of liquid refrigerant is reduced to 6.2 kg/cm2A across the level controller of the kettle thereby 8C refrigeration is achieved in feed gas cooler II. The rest of liquid from propane sub cooler is flashed through a pressure controller, cascaded with level controller of the propane accumulator to 6.2 kg/cm2A. The vapor and liquid are separated in the Propane 4th stage suction drum (10V-109) of the propane refrigerant compressor (10-K-101). The flashed vapor flow to 4 th stage suction of the compressor. One stream of liquid from 4th stage suction drum (10V-109), under level control of kettle, flows of LEF condenser(10-E-105) .The pressure of this liquid is reduced to 3.9 kg/cm 2A across the level controller by virtue of which -7 C refrigerant is achieved in LEF condenser. The reflux temperature is controlled by varying refrigerant side pressure in the kettle via a pressure controller on the refrigerant vapor line. The rest of liquid is flashed to 3.9 kg/cm 2A and resultant vapor and liquid flow to propane 3rd stage suction drum (10-V-110). The flashed vapor along with vapor from LEF condenser flow to 3rd stage suction of compressor. The liquid from 3rd stage suction drum is split in three stream, one being used in feed gas chiller-1 (10E-101) and returned to 3rd stage suction drum. Another liquid stream flows to feed gas chiller -2 (10-E-102) under level control of kettle. The pressure of this liquid stream is reduced to 2 kg/cm2A across the level controller and thereby refrigerant of -27 C is achieved in feed gas chiller -2. The feed gas outlet temperature is controlled by varying refrigerant side pressure in the kettle via a pressure controller on the refrigerant vapor line. The rest of liquid is flashed is flashed to 2 kg/cm 2A and resultant vapor and liquid flows to 2nd stage suction drum (10-V-111). The flashed vapor along with vapor from feed gas chiller-2 flows to 2nd stage of the compressor. The liquid from 2nd stage suction drum flows to feed gas chiller-104 (10-E-104) under level control of the kettle. The pressure of this liquid is reduced to 1.1 kg/cm 2A across level controller of the kettle and thereby refrigeration of - 40 C is achieved in the feed gas chiller-4. The refrigerant side pressure in the feed gas chiller E-104 is maintained by the IGV of the compressor and feed gas outlet temperature is maintained by refrigerant level in the kettle. The vapor from feed gas chiller-E-104 flows to 1st stage suction via 1st stage suction drums (10-V-112). Quench lines, with temperature controller, are provided to 3 rd stage, 2nd stage and 1st stage suction drum. The quench liquid is drawn from 4th stage suction drum. A propane transfer pump (10-P-104 A/B) is provided to transfer liquid propane from all the four suction drums to propane storage.

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1. Specification of the refrigerant propane compressor K-101A. The propane compressor K-101A is a four compression stage centrifugal compressor driven by synchronous motor. Refrigerant (propane) gas to the each stage of compressor comes from four (4) suction drums at different levels of temperature and pressure respectively. See the table below. Normal Condition 2nd Stage 3rd Stage 29190 66040 1.78 3.48 22.8 0.8 3.48 5.69 6.9 23.1 Rated Condition 2nd Stage 3rd Stage

Weight Flow (dry) ( kg/h) Suction Press. (kg/cm2A) Suction Temp. (C) Discharge Press. (kg/cm2A) Discharge Temp. (C)

1st Stage 10750 1.05 40.8 1.78 -17.3 1st Stage 11300 1.05 -40.8 1.90 -14.9

4th Stage 85700 5.69 19.8 16.0 69.5 4th Stage

Weight Flow (dry) ( kg/h) 30668 72644 94244 Suction Press. (kg/cm2A) 1.90 3.73 6.0 -21.8 0.8 19.4 Suction Temp. (C) Discharge Press. (kg/cm2A) 3.73 6.0 16.0 8.0 22.7 68.3 Discharge Temp. (C) Gas Handled PROPANE GAS Speed ( rpm) 10904 Synchronous Motor 3350 kW x 6600V x 50Hz x 4P 1st stage of the compressor is equipped with inlet guide vane ( IGV ) to regulate suction flow. 2. Specification of Evacuation Compressor

EVACUATION COMPRESSOR
PRESSURE @ VENDORS B/L kg/cm2g PRESSURE @ CYLINDER FLANGE kg/cm2g TEMPERATURE @ VENDORS B/L 0 C

STAGE 1
15.0 to 2.0

STAGE 2
4.88 to 15.78

1.97 to 15.09

4.84 to 15.65

(-)10 TO 46

20 TO 77

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TEMPERATURE @ CYLINDER FLANGE 0 C

(-)10 TO 46

20 TO 77

3. Gas flow diagram of the compressor ( K-101-A). Refer Annexure 1 II. Control philosophy CONTROL PHILOSOPHY The compressor shall be controlled to prevent from entering surging during start up, normal operation and shut down. The shaft seal of the compressor shall prevent air from intruding into compressor during compressor running and stand still. By MEANS of Each compression stage shall be equipped with anti-surging controller.

The compressor is equipped with oil film seal. The seal oil system has an overhead tank. The seal oil pressure is controlled higher than the gas pressure by controlling oil level in the overhead tank. If the level goes down extremely low, the compressor shall be tripped. But the S.O system shall be kept in operation even if the compressor is shut down, except overhaul period. This compressor has additional seal chamber neighboring the seal oil chamber. In electric power failure, nitrogen gas shall be supplied in the additional seal chamber to prevent air intrude into compressor casing. Loading and quenching shall be carried out ( controlled ) so that the compressor is cooled down and loaded gradually to avoid abnormal deformation of the casing. The compressor shaft vibration shall be watched during loading and quenching, because abnormal deformation may cause high vibration amplitude.

Even if electric power fails and the oil pump stops, the shaft seal must be effective.

This compressor is of a cryogenic compressor. Then the compressor casing starts to shrink as gas temperature goes down after start up. But no abnormal deformation of the compressor casing shall occur during start up and loading.

Compressor Train Details :

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IHI make 7 impeller 4 stage compressor running at 10900 rpm driven by synchronous motor of Toshiba make 3350 kw , 6.6 kv and 1500 rpm. The gearbox IHI make with low speed / high speed are used for increasing the speed. The motor / compressor / gear box are having common lube oil system with standby lubricating and lube oil / seal oil tank. The compressor is provided with MMS of Bently Nevada make.

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III. Start-up and loading A Pre-start Operation Before starting the refrigerant propane compressor K-101A for the first time (after the installation), make certain that all steps in the preceding section of the plant "Initial Preparation" have been carried out, then proceed to the prestart operation instructed herein. 1. Confirm that no dangerous nor explosive gas is remaining in the compressor shelter. 2. Establish all the necessary utilities. i) ii) iii) iv) v) vi) Turn on instrument air supply Supply instrument air into local panel and driving motor, and purge the interior. Make sure that the power source for the driver is available. The same is checked for the auxiliary motors and degassing drum heater Establish current supply to the control and monitoring system. Check all other utilities such as sealing gas, buffer gas for the availability, if applied. When used, supply the sealing gas to the bearings and / or shaft seals, and adjust the pressure.

vii)

Note: It is important that the safety devices are all functioning during the startup. 3. Open all the compressor drains. Drain off all liquid, and then close the valves. i) ii) Drain all suction lines by opening the drain valves for liquid if any. Drain the compressor casing and ensure that no liquid is remaining in the casing.

This is to prevent compressor surging during start-up. 4. Charge Nitrogen Gas into the refrigerant system. Nitrogen gas shall be charged into the system in accordance with the plant manufacturers instruction manual.

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5. Put the lube and seal oil system in operation Instrument for TRIP in the L.O & S.O system is of 2 out of 3 system. They are : Lube oil supply pressure LL and Seal oil level in overhead tank LL a. Check valve positions in the system. i) ii) iii) Open all main line valve so that oil flow is not interrupted to the bearings, gear and seals. Open all the block valves for pressure sensing device. Open the bypass valves of pressure control valve, differential pressure control valve and level control valve, if furnished.

Note: The bypass valve is in normally closed, however, it should be fully opened at start up. Prior to starting pump the bypass valve is to be opened and then closed slowly to apply pressure to the system gradually. (This is to prevent any possibility of collapsing oil filter elements when system is empty). b. Check oil reservoir and degassing drum for proper level. c. The valve in cooling water supply line should be opened fully. So adjustment of water flow rate can be made by throttling the valve in return line. If the oil temperature is lower than 20C, close the return line valve until the oil temperature rise up to 25 by operating of compressor. d. Confirm that the level control valve actuates smoothly. e. Start the main oil pump. f. Fill the oil piping with lube and seal oil, then slowly close the bypass valve of pressure control valve and differential pressure control valve to apply pressure to the system. Note : Oil pressure is to be maintained at correct values. The pump discharge pressure must be stabilized. g. Never forget oil cooler and oil filter venting. h. Check the system for oil leak. Check all eight flow glasses to make sure that there is oil flow to each bearing gear and seal. FG 418, 421, 422, 423, 429, 430, 444 & 445. Warning: The compressor and driver must not be operated when oil flow is not supplied to the bearings, gear and seal rings. 6. Establish oil level in the S.O overhead tank and check the level control system for normal operation.

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a. Close the bypass valve of the level control valve slowly. b. Set the level control circuits into operation. c. Make sure that the level in the S.O overhead tank is controlled automatically at normal level. d. Check again the oil reservoir for proper level. 7. Establish cooling water flow through the cooler of driving motor by opening the valve.

2. Charge Propane into the refrigerant system. ( Propane make up ) Propane shall be charged into the system in accordance with the plant manufacturers instruction manual. 3. Start up the refrigerant propane compressor K-101A Operation philosophy. a) The compressor shall be controlled to prevent from entering surging. b) The shaft seal shall function so reliantly that air can not intrude in the compressor casing. Before starting the compressor, make certain that all the items in the preceding section "restart operation" have been completed. 1) Turning the rotor a. Remove the cover of the wheel shaft of speed increasing gear and set the turning lever on it. b. Turn the shaft with the manual turning lever. Listen sound with listening rod at the compressor casing, bearing and gear case, to check for rubbing . If there is unusual noise or if it is difficult to turn by hand, disassemble the compressor and/ or gear to check the bearings and seals including oil baffle plate. (It may be necessary to remove the top half of the compressor to check inter stage labyrinth clearances if the cause of trouble cannot be detected otherwise.) Warning: The compressor and driver shall not be turned when the oil is not supplied to the bearings and seals. Never leave the turning lever on the shaft - end- of gear, the cover shall be reassembled before start up. 2) Purge or evacuation of propane gas If necessary, purge via vent valve or evacuate from the compressor casing by evacuation system at the compressor discharge. After purging or evacuation, the compressor casing pressure should be kept between 2.1 kg/cm2g and 1.9 kg/cm2 g. 3) Position of each valve Tag nos. Set the position of each suction valve and minimum flow by pass valve. c) 1st stage suction valve (MOV501) :Fully closed d) 2nd stage suction valve (MOV502) :Fully closed

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e) f) g) h) i) j) k) l) m) n) o)

3rd stage suction valve (MOV503) :Fully closed 4th stage suction valve (MOV504) :Fully closed 5th stage suction valve (MOV505) :Fully open 1st stage suction valve (IGV) :Minimum position 30 2nd stage suction valve (HCV501) :Minimum opening 3rd stage suction valve (HCV502) :Minimum opening 4th stage suction valve (HCV503) :Fully close 1st stage minimum flow valve (FV-501) :Auto mode 2nd stage minimum flow valve (FV-502) :Auto mode 3rd stage minimum flow valve (FV-503) :Auto mode 4th stage minimum flow valve (FV-504) :Auto mode

Note : As for the valve position, refer to table in the attached drawing How to handle valve to start up the compressor . The valve position shall be in the table. 4) Start the driving motor after getting confirmation of preparation of the control room. In the case of an initial start following a corrective maintenance or long period standstill, energize momentarily a few times and allow compressor to coast stop in the following manner. Confirm that no abnormality exists. 1st: Switch off 3 sec after start 2nd: Switch off 10 sec after start Caution: The next start should be made after confirming complete stop of the rotor. During this operation check the following: a. Direction of rotation (to be checked at the first step). b. No unusual sounds in the compressor, gear and driver. Note: If any unusual sounds are heard, stop the equipment immediately and investigate. c. Rate of compressor deceleration. If the rotor takes unusual short time to stop, investigate and correct the cause. d. Vibration If the compressor, driver or gear vibrates excessively, stop the equipment and investigate. e. Bearing temperature In the case of any abnormal and sudden rise in temperature, stop the equipment and investigate. 5) First quenching, pressurizing. After the start up of compressor, following quench injections shall be taken in accordance with plant manufacturers instruction manual. a. 1st stage quench valve. b. 2nd stage quench valve. c. Simultaneously the 4th stage suction valve ( side flow ) shall be opened gradually. The 4th stage minimum flow valve mode shall be in Auto mode. d. Position of each suction valve and discharge valve shall be adjusted.

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6) Following operation ( quenching and pressurizing ) shall be taken subsequently. a. Gradually open the 1st stage, 2nd stage, 3rd stage and 4th stage quench valve. b. Adjust position of the 1st stage IGV, 2nd stage, 3rd stage and 4th stage suction valve.

7) Evacuation Compressor (EC): The compressor/driver can not be started with settle out pressure. Casing/system pressure to be reduced to 2kg/cm2 with following options a. Use of Evacuation compressor. b. Blow off propane gas from the system. Evacuation Compressor (EC) a motor driven reciprocating compressor is provided downstream of propane compressor K-101-A. The purpose of this compressor is to evacuate propane refrigerant from K-101-A system in order to bring down the system settling pressure for starting up the Refrigeration Compressor K-101-A. The discharge of EC is fed back to the system in the down stream of NRV thus avoiding the propane loss to atmosphere. EC is designed to start on manual mode and no interlocking is required with main compressor. 8) After the start-up mentioned above is accomplished, check the following a. b. c. d. e. f. g. h. i. j. k. Oil flow through the sight glass Oil cooler outlet temperature Oil pressure Vibration of bearings, compressor casing and driver. Gas flow rate, gas temperature and pressure. Voltage, ampere and power consumption of driving motor Gas leakage from the connections Oil level of S.O overhead tank Level of oil reservoir, degassing drum Vibration of auxiliary equipment and piping Thermal expansion of the compressor casing

Note: Check the bolts connecting the casing with base plate for clearance which allows the heat expansion of the compressor casing.

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l. Axial displacement of the wheel gear shaft. m. Thermal expansion of piping n. Monitoring and control systems (They should be functioning without any abnormality) o. Check that the drain trap, if furnished, normally works 4. Loading Prior to loading the compressor, all the items in the preceding section of the plant should be checked and confirmed that there is no abnormality. Loading the compressor should be done gradually by keeping an eye on the ampere meter. Loading is to be done through HIC 501/502/503 and PIC-504 by keeping an observation on the refrigerant level in all chillers and suction drums. Should "surging" of the compressor occur (surging" is a sudden, momentary back flow due to insufficient volume flow) the blow-off discharge valve and/ or bypass valve shall be immediately opened to compensate sufficient volume flow. This compressor is equipped with a surging preventing device which will open bypass valve automatically. However special care must be taken to avoid a sudden and excessive fluctuation of flow or operating pressure. Careful observation against the following should be kept during the loading. 1. Bearing return oil temperature 2. Vibrations -of the shaft of the compressor and speed increasing gear 3. Gas temperature 4. Gas pressure 5. Voltage ampere and power consumption of driving motor 6. Gas leakage from the connections 7. Vibration of auxiliary equipment and piping 8. Working conditions of monitoring and control system Daily Checks 1. 2. 3. 4. 5. 6. 7. 8. 9. Lube oil pressure Oil cooler oil outlet temperature Bearing metal temperature Process gas pressure and temperature Compressor flow rate Voltage, ampere and power consumption of driving motor Bearing return oil temperature Axial displacement Outer seal oil temperature

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IV. Shut down of the compressor. While shutting down the compressor, 1) 2) The anti-surging controller shall function properly. Care should be taken so that air does not intrude into the compressor system till all hydrocarbon gases have been removed

A) Normal Shut Down 1. Propane Refrigeration System 1) Stop the compressor motor in accordance with the manufacturers instruction manual. 2) After the compressor rotor stops to rotate, isolation valve shall be closed. The gas pressure in the compressor will be settled at a certain level which is called settle out pressure. 3) If the pressure in the compressor remains abnormally high, gas in the compressor shall be vent off through flare stack. 4) Bypass valve and quenching valve shall be closed. 2. Lube & seal oil system of the compressor. 1) Even after the compressor shut down, the L.O & S.O system shall be kept in operation in order to seal the gas in compressor and to cool down bearing / seal ring. B) Shut Down for overhaul or rest for long period 1. Propane Refrigerant Compressor. 1) Stop the compressor motor. 2) Isolation valve shall be closed. 3) Propane gas in the compressor shall be withdrawn by the evacuation system. 4) Residual propane gas shall be vent through flare.

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5) No dangerous gas shall remain in the compressor system. 2. Lube & seal oil system of the compressor. 1) The L.O & S.O system shall be kept in operation. 2) After the bearing and seal ring are cool down and residual propane gas in the compressor system is vent completely, the system shall be stopped . C) In electric power failure In case of Power Failure Stand by lub oil pump will start on emergency power.In case of no emergency power available Seal oil will be fed thru Seal Oil over head tanks for 20 minutes to avoid propane gas leak to atmosphere. There is also provision to feed Nitrogen to Seal to avoid propane leak in case of an extreme case of no seal oil available/failure to evacuate compressor. D) Requirement Of Nitrogen. 1. Compressor will continue to run even N2 is not available. 2. Compressor doesnt have any logic for N 2 supply in terms of rate, pressure, on/off as well. 3. In case of SO not available N2 will help to avoid propane leak to atmosphere. However it is advisable to have Nitrogen available at the pressure/rate as mentioned in MDS.

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