9.

Air Compressor House

Contents:
Introduction
LP Compressor
Specification
LP Compressor control
Compressor surge
LP Compressor start up procedure
Pre start check.
Start up.
Typical LP Compressor face plate readings.
Shutdown procedure of LP Compressor.
Lube oil used in Compressor House.
D!S and D"!TS.
Trouble shooting #LP Compressor$.
HP Compressor.
HP Compressor start%up procedure.
HP Compressor shut down.
"ormal check%up.
HP compressor alarm.
Trouble Shooting #HP Compressor$.
Instrument air dryer.
Details of air dryer thermoprobe.
Tips.
&uide book for 'tility operation( Section )* +ir Compressor Page , of ,-
Air Compressor House
Introduction:
Instrument and plant air re.uirement of whole refinery is met by two "os of LP #low pressure$
compressors with emergency back up of HP compressor which can be run with /0D& power.
LP compressors feed air to one number of LP recei1er #2.- 0
3
capacity$ at 4.5 kg6cm-. Plant air
and air for nitrogen generation is directly supplied from the LP recei1er through shut off 1al1es
#which got shut at low pr. 5.7 kg6cm-$. Instrument air is supplied from LP recei1er through two
numbers of air dryers. HP compressor feed air to HP recei1er #87.35 0
3
capacity$ at 3- kg6cm-.
In case LP recei1er air pressure drops( HP recei1er feeds air to instrument air header at outlet of
LP recei1er( through pressure reducer #controller$ and non return 1al1es and protected by safety
1al1e with set pressure of ).5 kg6cm-. Incase of power failure air recei1ers are capable to supply
instrument air for about ,5 minutes.
1. LP Compressor:
Specification:
Type* Centrifugal three stage modulated controls and unloading facilities.
0ake* 06S Ingersoll%rand( 0odel* C38 0 9 3. Capacity* 54)7 : - "m
3
6hr( discharge press
4.5 kg 6cm-a( rpm -);5( LP recei1er normal pressure 4.7 <g6cm-( safety 1al1e set pr* ,7.5
kg6cm-( cooling water flow and temp rise in oil cooler% -)7 LP0= 3.8
7
C
Inter cooler Stage ,%387 LP0 = 4.33
7
C. Stage -%327 LP0 =4.33
7
C( +fter cooler%)47LP065
7
C
+P motor* <>* -.-( +* 2.)( rpm* ,237(
LP Compressor control*
0onitoring( protection and control of LP compressor is performed by micro processor based
?0icro controller?.
It monitors the operating parameters and if re.uire generates audio6 1isual alarms and
e1en trips the compressor in abnormal condition. It has facilities to control the compressor by
any one of following three modes of control.
,. 0odulated Control. #+t "@L( LP Compressor is pro1ided with this control$.
-. Dual Control* This is the combination of modulated control and Two step Control( from
panel any one of these can to be selected.
3. +uto Dual Control* This is the combination of modulated control and #modulated A Two
step Control$. Brom panel any one of these can be selected.
&uide book for 'tility operation( Section )* +ir Compressor Page - of ,-
Status 0odulated
control
Two step control 0odulated ATwo step
control
Compressor
S6D
I6L 161 full closed
C6P 161 full open
I6L 161 full closed( C6P 161
full open
I6L 161 full closed( C6P
161 full open
Compressor
started
I6L 161 open to
unload position
#-;D$(
I6L 161 open to unload
position #-;D$(
I6L 161 open to unload
position #-;D$(
Discharge
pressure less
than set pr.
+ir demand is
more
Cypass 161 will
be modulated to
closed then( inlet
161 will modulate
open.
+t cut in pressure #min
allowed pressure$( bypass
161 will fully closed and
inlet 161 will fully open.
+t cut in pressure # min
allowed pressure$(
bypass 161 will fully
closed and inlet 161 will
fully open
Discharge
pressure
increases
abo1e set
pressure. +ir
demand is less
Inlet 161 will be
throttled upto
throttle range
#57D$( then
bypass 161 will
modulate open.
+t cut out pressure #ma:
allowed Pressure$( bypass
161 will fully open and
inlet 161 will throttle to a
position permitted by the
unload limit regulator
#-;D$.
Inlet 161 will be throttled
upto throttle range( if
still pressure is high
compressor will unload
#bypass 161 will fully
open and inlet 161 will
throttle to a position
permitted by the unload
limit regulator #-;D$.
Description:
,. >hen compressor started in unload( I6L 161 will remain open at -;D. >hen selector
changed o1er from unload to modulated control( I6L 161 will open 57D #CLL 1alue$ keeping
bypass 161 open at ,77D.
-. >hen compressor is started on modulated control I6L 161 will open -;D till Epre lube timeF
elapsed #,4sec$( after that I6L 161 will open to 57D.
3. Throttling @ange of inlet 1al1e* This is the minimum #flow$ opening of inlet 1al1e. If further
inlet 1al1e is throttled( compressor will run in surge range hence unstable and may get
surged on further flow reduction. So compressor air flow should always be more than surge
1alue( in other words inlet 161 should not be throttled more than throttle range #57D$.
Compressor surge:
when compressor could not de1elop pressure more than the system press( re1ersal of flow
takes place which may damage the compressor impeller. It is called surge.
The surge sensor is a differential pressure switch that senses the difference between normal
operation pressure and rapidly decreasing discharge pressure( which occur during surge
condition. n sensing surge( it unloads the compressor #I6L 161 open -;D( and bypass 161
fully open.
&uide book for 'tility operation( Section )* +ir Compressor Page 3 of ,-
LP Compressor start up procedure

Pre start check:

,. Check that( lube oil le1el and temp is normal.
-. pen the block 1al1e in discharge line.
3. Charge cooling water system.
2. Line up lube oil system.
5. 0aintain seal air pressure more than ,7 psig.
8. Drain condensate from air coolers( accumulators and piping etc by opening trap bypass 161.
;. If starting after long shut down( 1ent cooler!s waterside.
Start up:
,. Turn on the cooling water to the air coolers and ensure the water circulation. Cooling water
inlet pressure should be 3.5 <g6cm- appro:. and the outlet pressure should be -.-5 kgcm-.
-. /nsure that the instrument airline 1al1e and the control air 1al1es are open condition.
Instrument air gauge reading at filter should be 5 kg6cm-. Inlet and bypass pressure gauge
should read 85%;7 psi.
3. Seal air pr. gauge #from instrument airline$ should read G,7 psig( #ma: -5psig( min 8psig$.
2. Switch on IS%, #main supply to 0P%3 panel$H IS%3 #oil heater supply$ and IS%- #pre lube oil
pump motor supply$.
5. Pre lube pump should start automatically #pro1ided seal air pressure is abo1e 5.5 psi$.
Check that oil pressure at compressor casing should read --psi appro:. #pre adIustment
1alue$.
8. Check that P across oil filter is .<. #J 7.)8 <g6cm-$.
;. Let the oil temperature rise upto 34
7
C #appro:.$. Switch off IS%3 to isolate heater if the
temperature rise is much.
4. /nsure that the inlet 1al1e #CK%-$ is in closed position and the bypass 1al1e #CK%,$ is in
fully open condition.
). See that block 1al1e #gate 1al1e after 0S$ is in fully open condition.
,7. +dIust discharge of air pressure set point to the desired setting #; <g6cm-$.
,,. Set faceplate display #of 0P%3$ to E compressor not ready E. @elease stop push button and
wait for E compressor ready signal E.
,-. /nsure HT breaker at ser1ice position with remote facility.
,3. Set faceplate to display E motor current F.
,2. /nsure selector switch on EunloadF position.
,5. Start compressor. Check the starting and normal current drawn.
,8. Check all parameters displayed on the faceplate.
,;. +llow the compressor to run on unload mode for 3%2 minutes.
,4. Check oil temperature. +dIust the inlet 6outlet C> 1al1es so that oil temperature is in the
range of ,,7
7
B to ,,5
7
B.
,). Change the position of switch SS%- to modulate mode. The discharge air pressure will reach
the pre set 1alue within 37%sec. Check the 1al1e positions of inlet and bypass 1al1e.
-7. Check 1ibration le1el( motor current and other parameters. @ecord on hourly basis.
&uide book for 'tility operation( Section )* +ir Compressor Page 2 of ,-
!pical LP compressor face plate readings:
"unction Actual Alert Shut do#n
il temp. high
7
C 23 2) 5-
il temp. low 23 35 3-
Kibration stage , #mills$ 7.,; 7.42 ,.72
Kibration stage - #mills$ 7.-, 7.47 ,.77
Kibration stage 3 #mills$ 7.-, 7.47 ,.77
+ir temp. stage - -4 2) 5-
il pressure <P+ ,27 ,-8 ,,-
Kal1e opening D 5, 2) -5
#unload$ -2 -; ,77
0otor current 53.8
System pr.6 set point ;.77 ;.77
Surge " Les 7.2 <g6cm
-
Low water flow " Les
Low seal air " " Les
Dirty inlet filter " Les 8Fwcl 7.7-<g6cm
-
Dirty oil filter " Les 7.)8<g6cm
-
Low oil le1el " Les
Shutdo#n procedure of LP compressor:
,. Put selector switch in EunloadF position from modulate position.
-. Check motor current( the function window should display as MCompressor unload M( check
that bypass 1al1e is ,77D open = inlet 1al1e is in P, position #presently at -;D$.
3. +llow the compressor to run for 3 N 2 minutes.
2. Press M STP ! push button to stop the compressor.
5. Check that Pre lube pump has started automatically.
8. Check oil pressure on display window.
;. Drain out condensate from air coolers.
4. +llow the pre lube pump to run for 37 minutes = ensure oil temperature is constant #at
ambient 1alue$ for 5 minutes.
). Switch off control power = CKT supply( isolate IS%, #2,5 K. main supply to 0P%3$.
,7. Inform electrical to isolate HT motor supply.
Lu$e oil used in Compressor House*
Sl "o /.iupment Lubricant Part to be lubricated
, HP Compressor SP%,77 6 T'@CL%,77
r compressor oil ,77
Compressor Crank casing
3 LP Compressor SP%3- 6 T'@C%3- Compressor motor bearings
&uide book for 'tility operation( Section )* +ir Compressor Page 5 of ,-
Do%s and don%ts:
,. +uto Condensate trapes should always be in ser1ice. Periodically check its working by
opening bypass 161.
-. Periodically drain recei1er 1essels and drier moisture separator.
3. 0onitor dp across pre filter( adsorber( after filter if it is high than normal take correcti1e
action and inform shift incharge.
2. Don!t take heater in ser1ice without sufficient air flow.
5. Periodically monitor operating parameter( lube oil filter dp and suction filter dp.
8. 0aintain lube oil temp ,,7
7
B to ,,5
7
B.
rou$le shooting &LP Compressor':
,. Power failure.
-. Compressor discharge temp high.
3. Low system air pressure.
2. High 1ibration*
5. Low lube oil pressure.
8. High lube oil temperature.
;. Compressor is not taking start.
4. Compressor surge*
1. Po#er failure:
(ffects:
LP air compressor and hp air compressor will trip.
LP air compressor au:iliary lube oil pump cuts in auto after getting emdg power supply.
+ir drier heater will cut out.
Plant air and instrument air pressure will drop.
Plant air to nitrogen plant( shut off 1al1e will close.
Hp recei1er to instrument air control 1al1e will open to maintain instrument air pressure.
Cooling water supply may fail.
Seal air pressure may drop.
Actions:
Hp air compressor may be started after starting emdg.
pen hp recei1er outlet control 1al1e bypass 1al1e( if re.uire.
n resuming power( charge cooling water system.
pen lp cooler condensate drain and moisture separator drain 1al1es.
@estart compressors after resumption of power.
Check that seal air pressure is ok.
&uide book for 'tility operation( Section )* +ir Compressor Page 8 of ,-
). Compressor discharge temp high:
+ir flow may be 1ery less causing after cooler inlet temperature high.
Cooling water to compressor Iacket cooling is not effecti1e.
Check Iacket cooling line for choking.
Oacket may be dirty #hp compressor$.
Check inter stage coolers inlet 6 outlet temperature.
Cooling water flow 6 pr. Low or temp. High.
+fter cooler is not working.
Check cooling water pressure( flow and temperature.
Cooler tubes may be choked or dirty.
/:cessi1e number of tubes may be plugged to arrest tubes leakage.
Dirty or plugged air cooler on water side or air lock.
*. Lo# discharge +s!stem air pressure:
'nloading 1al1e is open or passing.
Inlet 1al1e is not open up to re.uirement.
Suction filter is choked.
+tmospheric temperature is 1ery high.
Inter stage cooler outlet temperature is high.
+ir consumption is 1ery high.
Compressor not loaded or low surge.
>orn out impeller.
,. High -i$ration:
Cearings damaged.
0oisture le1el high in air.
Low oil temperature.
0isalignment with dri1er.
@otor damaged due to damaged aero parts.
@otor unbalance due to buildup.
Induced 1ibration from dri1er due to worn coupling6spacer.
.. Lu$e oil pressure lo#:
Lube oil le1el low( lube oil pump fail or pressure gauge faulty
@elief 161 setting improper.
Suction 6discharge line or cooler leak.
Suction strainer 6 discharge filter dirty.
Standby pump nr1 passing.
Lube oil temperature may be high.
/. High lu$e oil temperature:
&uide book for 'tility operation( Section )* +ir Compressor Page ; of ,-
Cooling water flow 6 pr. Low or temp. High.
Cooler tube dirty or air lock.
0. "ail to start:
"o primary power to starter.
"o control panel power.
Defecti1e motor starter.
Seal air pressure low( lube oil temperature high( lube oil pressure low and cw flow low.
Bailure to clear shut down or interlocks de1ice.
1. Compressor surge:
Discharge block 1al1e closed.
Dirty inlet filter
Improper calibration of surge sensor.
High inter stage air temperature
>orn aerodynamics part.
Improper adIustment on llr or low current limit.

). HP Compressor*
Three stage reciprocating air compressor( third stage split into two part installed at both end of
compressor. Loading6 unloading pressure -4 <g6cm- and 3- <g6cm- respecti1ely. HP recei1er
safety 1al1e set pressure* 3-.82 kg6cm-.
0ake* <hosala Crepelle( "ew Delhi%55( S. ". 8232( type* 3H+- TC@T( P* 8.,; m36min(
pressure* 3,.82 kg6cm-( speed* ;,7rpm.
0otor* <irloskar( "o.-)578,74%,( <>* ;5( rpm*,242( +H ,-;( 2,5 K( +P* <>* ,.,( rpm* )-5
Inter stage cooler #heat e:changer$ in between stage I = II #horiQontal position$*
>orking pressssore* -.262.7 <g6cm-g #shell side6tube side$( Design pressure 2.768.7 <g6cm-g(
Hydraulic test pressureH 8.7 6 ,7.7 <g6 cm-g. flow capacity* 3,7., m36hr( S". )87,7,47(
supplied by* <& <hosala Compressors LTD( ,. Deshbandhu &upta @oad " Delhi%55.
Inter stage cooler #heat e:changer$ in between stage II = III #horiQontal position$*
>orking pressssore* ,7.862.7 <g6cm-g#shell side6tube side$( Design pressure ,3.768.7 <g6cm-g(
Hydraulic test pressureH -7.76 ,7.7 <g6 cm-g.
+fter stage cooler #heat e:changer$ in between stage III = HP recei1er #1ertical position$*
>orking pressssore* 3,.562.2 <g6cm-g #shell side6tube side$( Design pressure 38 68.7 <g6cm-g(
Hydraulic test pressureH 57 6 ).7 <g6 cm-g.
HP Compressor start2up procedure:
Check lube oil le1el.
,. Charge cooling water system.
-. pen all condensate drain 1al1es of moister separator.
3. Confirm that discharge and bypass 1al1es are fully open.
2. Check that MK! belt is in good condition.
5. Check the alarm panel for its healthyness.
&uide book for 'tility operation( Section )* +ir Compressor Page 4 of ,-
8. Start lube oil pump for ,7 to ,5 minutes in auto mode and note that lube oil pressure is
abo1e ,.4 kg6cm- and ELube oil pressure low E alarm got reset.
;. "ow start compressor and slowly close bypass 1al1e fully and also condensate drain 1al1es.
4. Check that au:. Lube oil pump stopped in auto.
HP Compressor Shut Do#n:
,. pen bypass 1al1e fully and close discharge 1al1e .
-. Stop the compressor.
3. pen all condensate drain 1al1es.
2. Check that pre Lube oil pump is started on auto.
5. Stop pre lube oil pump after half an hour.

3ormal Check2up:
,. Drain condensate from recei1er( moist. Separator and lines etc.
-. Check that all moisture traps are working.
3. Check lube oil filter differential pressure.
2. Check motor bearings temp and amps. It should not run with 1ibration or abnormal sound.
5. Check for any lube oil leakage.
8. Check that all parameters are normal.
HP compressor alarm:
S.". T+& " I"ST@'0/"T +L+@0 T@IP
, BSL%,33- Blow low after cooler
- B+L%,33, Blow low of c.w.r. header
3 P+L%,33, Lub oil pressure lo ,.4 kg6cm-
2 PSLL%,333 Lub oil pressure lo lo ,.8 kg6cm-
5 T+H%,33, Temp. Hi of ,ststg. Inter cooler ,85
7
C
8 T+HH%,33- Temp. Hi hi of ,ststg. Inter cooler ,;7
7
C
; T+H%,333 Temp. Hi of -nd stg. Inter cooler ,85
7
C
4 T++H%,332 Temp. Hi hi of -nd stg. Inter cooler ,;7
7
C
) T+H%,335 Temp. Hi at discharge ,85
7
C
,7 T++H%,338 Temp. Hi hi at discharge ,;7
7
C
rou$le Shooting &HP Compressor':
,$ Discharge pressure low
-$ Suction pressure high
3$ +ir flow low
2$ +ir temperature high
5$ Kal1e body hot.
8$ <nocking sound
&uide book for 'tility operation( Section )* +ir Compressor Page ) of ,-
1. Discharge pressure lo#
Suction 161( discharge 161 #mounted on cylinder$ passing.
Consumption high #recei1er pressure 1ery low$.
Inlet 6 outlet 1al1es passing. Check each stage inlet and outlet pressure and temperature.
Inlet pressure and suction 1al1e body temperature unusually high indicates inlet 1al1e of that
stage is passing. utlet pressure unusually low and discharge 1al1e body temperature high
indicates discharge 1al1e of that stage is passing.
Suction filter is choked.
+ir suction piping is plugged with moisture6condensate.
+ir coolers are leaking.
Compressor discharge relief 1al1e or moisture drain 1al1e may be passing.
). Suction pressure high: Suction 1al1e may be passing.
*. Air flo# lo#
Suction 6 discharge 1al1e passing.
Suction strainer dirty or piston ring worn out.
Compressor running unloaded.
,. Air temperature high
Cooling water flow or pressure low or cooler tube dirty.
5. 4al-e $od! hot: Kal1e may be passing.
/. 5nocking sound:
If knocking sound is coming from crankcase( bearing of the big end of connecting rod may
ha1e e:cessi1e play.
If sound is from cylinder( piston ring may be broken or piston rod on cross head may not be
tightened properly.
Symptom Possible cause6 correcti1e action
Lube oil
pressure low
Lube oil le1el low( lube oil pump fail or pressure gauge faulty
@elief 161 setting improper( suction 6discharge line or cooler leak.
Suction strainer 6 discharge filter dirty or standby pump nr1 passing.
High lube oil
temperature
Cooling water flow 6 pr low or temp high.
Cooler tube dirty or air lock.
High air
temperature
Dirty or plugged air cooler on water side or air lock.
Cooling water flow 6 pr low or temp high.
Low system
air pressure
Compressor not loaded or low surge.
Dirty inlet filter or greater demand than realiQed( worn out impeller.
High
1ibration
Low oil temperature. 0isalignment with dri1er.
>orn coupling6spacer. @otor damaged due to damaged aero parts.
@otor unbalance due to buildup. Induced 1ibration from dri1er.
&uide book for 'tility operation( Section )* +ir Compressor Page ,7 of
,-
Bail to start "o primary power to starter. "o control panel power. Defecti1e motor
starter. Trip 1al1e not reset.
Seal air pressure low. Bailure to clear shut down or interlock de1ice.
Continual
surge
Discharge block 1al1e closed. Dirty inlet filter
Improper calibration of surge sensor. High inter stage air temperature
>orn aerodynamics part improper adIustment on llr or low current limit.
Instrument Air dr!er:
Two "os of air drying unit Supplied by 06S Lloyds Steel Industries Limited # Prabhade1i(
0umbai.$ thru order "o% "@L63-226-,%L"%P%27),6744. Lear built% ,));. 0odel* "LP%+%
33-7.Design condition* Inlet air at 4.5 <g6Cm-a( at 34
7
C( outlet dew point #%27
7
C$. 0ode of
operation* fully automatic as well as manual.Power supply*2,5K +C. Control supply*,,7 K +C.
+dsorbers* It is 1ertical cylindrical 1essels two "os. +t a time one in regeneration and other in
reactication( filled with desiccant% +cti1ated +lumina(
@eacti1ation air heater* Cylindrical horiQontal mounted 1essels with E'F type heating
elements.@ating* 88 "os of heating elements of - <> capacity each( arranged in two banks of
)7 <> and 2- <>.
@eacti1ation air cooler* 8 pass shell and tube( horiQontal mounted heat e:changer. Cooling water
flow thru tubes at 2.7 <g6cm-g.
Pre filter6 after filter* these are filled with imported Schumacher ceramic candles. This retains
solid6dust impurities and moisture from air. Condensate water #in pre filter$ is drained
periodically by automatic drain trap.
0oisture Separator* This is demister pad type separator. Bitted at down stream of cooler remo1es
moisture of reacti1ated air.
2 >ay Kal1es* 0ake* Chemtrols. SiQe6rating* ,57 "C +S +( ,57R #-"os$.
,77 "C +s + ,57 R #,"os$.
Details of air dr!er thermopro$e:
Tag "o. Location Cut in 6Cut out temp. @emark
TSH%,357 n heater for skin temp. -,5.; 6 --7
7
C Coth heater will trip
TSH%,35, @eacti1ation air heater 6L ,45.2 6 ,)7
7
C Heater bank%, of )7 <>
TSH%,35- @+H 6L temp ,;8.5 6 ,47
7
C Heater bank%- of 2- <>
TSH%,353 @+H 6L temp ,)5.4 6 -77
7
C
TSH%,352 0oisture separater 6L 58., 6 87
7
C
ips:
Drier outlet air flow 333-0
3
6hr at ;.7 <g6cm- and dew point N85
7
C. There is an alarm at
dew point temperature of #%,7
7
C$
@eacti1ation air flow ,)77 "m
3
6hr( controlled by control 161 on main air to drier pipe line.
@eacti1ation heater cut in6 cut out for bank N,* ,;8.5 6 ,47
7
C and for bank%- ,45.2 6 ,)7
7
C.
@eacti1ation cycle 8 hr heating and - hr cooling.
&uide book for 'tility operation( Section )* +ir Compressor Page ,, of
,-
+dsorber Ced temp during reacti1ation at bottom ,85
7
C. and at top ,57
7
C.
Temperature of bed which is in ser1ice* at bottom -7
7
C. and at top 37
7
C.
@eacti1ation air flow in bed from bottom to top.
"ormal air for drying ( flow in bed from top to bottom.
Coth heater bank will trip( in case skin temperature goes to --7
7
C. or regeneration flow is
less than 5;7 "0
3
6 hr.
&uide book for 'tility operation( Section )* +ir Compressor Page ,- of
,-