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1
Azzour South OCGT-9 Project
2012
Serial N.:
UCV1003286
UCV1003287
4960SN03
UCV1003288
UCV1003289
4960SN04
Sinergia Srl
Onore . Bg . Italy
Ph +39 034673515
www.sinergia-it.com
August 8, 2014
Operation & Maintenance Manual i
INDEX
INDEX
INDEX i
LIST OF FIGURES vii
LIST OF TABLES ix
1 PREFACE 1
2 GENERAL INFORMATION 3
2.1 MANUFACTURER 3
2.2 W ARRANTY 3
2.2.1 Controversies 4
2.3 NOTES ABOUT THE PRESENT MANUAL 4
2.3.1 Characters and symbols 4
2.3.2 Target group 5
3 PRODUCT DESCRIPTION 7
3.1 3COMPRESSING UNITS 8
3.1.1 Inlet air filter 10
3.1.2 Main motor 10
3.1.3 Screw air compressor modules 12
3.1.4 Lubricating system 19
3.1.5 Cooling system 20
3.1.6 Air/water separator 22
3.1.1 Control panel 23
3.1.2 Conditions of guaranteed performance 25
3.2 DRYING SYSTEM 25
3.2.1 Baseplate 27
3.2.2 Upstream filters 28
3.2.3 Heatless dryer DH400 29
3.2.4 Downstream filters 32
3.2.5 Control panel 33
3.2.6 Conditions of guaranteed performance 35
3.3 RISKS DUE TO DESIGN LIMITS 35
4 OPERATING PRINCIPLES 37
4.1 COMPRESSING UNITS 37
4.1.1 Inlet filtration 37
ii Operation & Maintenance Manual
Pulse air system
4.1.2 Compression 37
4.1.3 Condensate separation 40
4.1.4 Lubrication 40
4.1.5 Cooling 42
4.2 DRYING UNITS 42
4.2.1 Inlet filtration 42
4.2.2 Drying 43
4.2.3 Phases duration 50
4.2.4 Outlet filtration 50
5 CONTROL SYSTEM 53
5.1 COMPRESSING UNITS 53
5.1.1 Capacity control 53
5.1.2 Automatic start/stop control 53
5.1.3 Remote start/stop 54
5.1.4 Remote load/unload 54
5.1.5 Power outage restart 55
5.1.6 Sequencer control and timed lead/lag 55
5.1.7 HMI screen pages 55
5.1.8 Alarms 63
5.1.9 Start and stop 65
5.1.10 Load/unload 66
5.1.11 Remote signals 66
5.2 DRYING UNITS 67
5.2.1 HMI screen pages 68
5.2.2 Setting operating mode and parameters 70
5.2.3 Start and stop 71
5.2.4 Remote signals 72
6 STAFF SAFETY 73
6.1 SAFETY SYMBOLS 73
6.2 W ARNING SYMBOLS ON THE SKIDS 80
6.3 SAFETY DEVICES 81
6.4 CORRECT AND IMPROPER USE 81
6.5 RESIDUAL RISKS 82
6.6 AUTHORIZED PERSONNEL LOCATION 83
7 LOADING AND TRANSPORT 85
Operation & Maintenance Manual iii
INDEX
7.1 LOADING/UNLOADING 85
7.2 TRANSPORT 87
7.3 DAMAGE DUE TO TRANSPORT 88
8 PACKAGING 89
9 DELIVERY TO SITE 91
9.1 UNLOADING AND LAYDOWN 91
9.2 RECEIVING INSPECTION 91
9.3 PRESERVATION 91
10 STORAGE 93
10.1.1 Temporary storage (less than 6 months) 93
10.1.2 Long term storage (longer than 6 months) 94
11 INSTALLATION 97
11.1 REQUIREMENTS FOR INSTALLATION SITE 97
11.2 RISKS TO BE REMOVED AT THE INSTALLATION AREA 98
11.3 MECHANICAL INSTALLATION 99
11.3.1 Foundation 99
11.3.2 Anchoring to foundation 101
11.3.3 Assembling and connections 101
11.4 ELECTRICAL INSTALLATION 104
12 COMPLETION ACTIVITIES 109
12.1 PRE-COMMISSIONING 109
12.2 COMMISSIONING 110
13 START-UP 113
13.1 DOCUMENT COMPILATION 113
13.2 PRELIMINARY ACTIVITIES 113
13.3 PRELIMINARY CHECKS OF THE MACHINERIES 114
13.4 READY FOR PRESSURIZATION ACTIVITIES 115
13.5 PRESSURIZATION AND TURN ON 115
13.6 INTEGRATION IN THE COMPRESSED AIR SYSTEM 117
13.7 CHECKS AFTER FIRST START-UP 118
13.8 TESTS 118
14 MONITORING 119
15 SHUTDOWN AND RESTART 121
15.1 SUBSEQUENT STARTS 123
16 ANOMALIES AND TROUBLESHOOTING 125
iv Operation & Maintenance Manual
Pulse air system
LIST OF FIGURES
Figure 3.1: General arrangement of one train of the pulse air compressing plant at the installation site.
Orange dashed rectangles indicate the compressors, while the green dashed rectangle indicate
the drying skid. Tags “11SCAxxx-xxxxx” and “12SCAxxx-xxxxx” indicate a component of the first
and second train respectively. 7
Figure 3.2: Sierra SH75WC (INGERSOLL RAND) compressing units: front (up) and back (down) sides. 9
st nd
Figure 3.3: Double stage compressor block, with indication of the 1 and 2 stages and gear box details. 14
Figure 3.4: Compressing stages: low pressure first stage (right), high pressure second stage (left). 14
Figure 3.5: First compressor stage: low pressure stage. 15
Figure 3.6: Second compressor stage: high pressure stage. Detail of the profile shape. 15
Figure 3.7: Gear box components. 16
Figure 3.8: Bearing system of the high-pressure compressor. 17
Figure 3.9: Sealing system of the high pressure compressor. 18
Figure 3.10: Inlet/blow down valve of the double stage compressor. 19
Figure 3.11: Watercooled heat exchangers integrated into the compressor package. 21
Figure 3.12: Unit control panel. 24
Figure 3.13 Drying skid with two drying lines. Main components are indicated: A pre-filters; B vessel; C post-
filter; D control panel; E baseplate; F lifting lug; G safety valve. 26
Figure 3.14: Plan view of the drying skid with indication of the fundamental components: A baseplate; B pre-
filter; C dryer column; D post-filter; E-F piping, G control panel. Main connections are indicated:
TP106A dryer A air inlet; TP106B dryer B air inlet; TP107A dryer A air outlet; TP107B dryer B air
outlet; TP108 condensate drain of the drying package. Anchor holes for lifting (located at
baseplate corners), earth lugs and hazard pictograms are indicated. 27
Figure 3.15: Baseplate drawing of the drying skid with indication of main dimensions, earth and lifting lugs. 28
Figure 3.16: Dryer tower drawing with indication of main connections: air inlet N1; air outlet N2; connection to
pressure gauge N5; spare nozzle N6; connection to safety valve N7. Each vessel is equipped
with flanged openings for desiccant material loading N3 and unloading N4; nameplate NP; lifting
lugs, supporting brackets BS and earth pales EP. 31
Figure 3.17: Dryer local control panel. 34
Figure 4.1: Principle of operation of the inlet/blowdown valve during compressor load and unload phases. 38
Figure 4.2: Air path during the adsorption phase of left tower (4960SN04B) of the dryer 11SCA01-AT001.
The inlet valve AA007 and the outlet valve AA011 are open, while the inlet valve AA008 and the
outlet valve AA012 of the other column (4960SN04A), which is regenerating, are closed. 45
Figure 4.3: Air path (blue line) during the expansion and dehumidification phases of the right tower
(4960SN04A) of the dryer 11SCA01-AT001. The inlet valve AA008 and the outlet valve AA012
are closed, while the exhaust valve AA010 is open. The inlet valve AA007 and the outlet valve
AA011 of the other column (4960SN04B) which is in adsorption (red line), are open. 47
viii Operation & Maintenance Manual
Pulse air system
Figure 4.4: Air path (blue line) during the pressurization phase of the right tower (4960SN04A) of the dryer
11SCA01-AT001. The inlet valve AA008, the outlet valve AA012 and the exhaust valve AA010
are closed. The inlet valve AA007 and the outlet valve AA011 of the other column (4960SN04B)
which is in adsorption (red line), are open. 49
Figure 5.1: LAYOUT screen page. 55
Figure 5.2: Keyboard for value insertion. 57
Figure 5.3: First HOME page. 58
Figure 5.4: Second HOME page. 59
Figure 5.5: List of monitored parameters. 59
Figure ;.6: SETTING-BASIC screen page. 60
Figure 5.7: SETTING-ADVANCE screen page. 61
Figure 5.8: SETTING- ALARMS screen pages. 61
Figure 5.9:SETTING-TRANSMITTERS screen pages. 62
Figure 5.10: ACTIVE - ALARMS screen page, showing the last activated alarm. 63
Figure 5.11: HISTORY- ALARMS screen page with memorized past alarms. 63
Figure 5.12: Screen page indicating dryer status and main controlling parameters: dew point values and past
time from last column switch. 68
Figure 5.13: Screen page indicating dryer operating modality: local or remote, under dew point control or
foxed time. 68
Figure 5.14: Screen page indicating dryer operation under dew point control. 69
Figure 5.15: Screen page indicating the operating time interval of each dryer before switching. 69
Figure 5.16: Screen pages indicating alarm states, particularly warning due to: probe transmission error of
dew point value (a); bad dew point value (b); pre-filter clogging (c); post-filter clogging (d). 70
Figure 7.1: Lifting schemes of the compressing skids: by crane (up) or by forklift (down). The total weight of
each compressor is 2800 kg. 86
Figure 7.2: Hoisting scheme of the drying skids. The total weight of the skid is ~3100 kg. The center of
gravity is specified. See Figure 3.14 for the letter legend. 87
Figure 11.1: Foundation detail for the compressors. 100
Figure 11.2: Foundation detail of the drying skids. 100
Figure 11.3: Fixing system of the compressors (left) and drying skids (right). 101
Operation & Maintenance Manual ix
LIST OF TABLES
LIST OF TABLES
Table 2.1 Special meaning of characters and symbols used in the Manual 5
Table 3.1: Technical features of the main motor. 11
Table 3.2: Technical features of air screw compressor module. 13
Table 3.3: Screw compressor parameters. 16
Table 3.4: Cooling data. 22
Table 3.5: Technical features of upstream pre-filters. 29
Table 3.6: Technical features of dryer vessels 30
Table 3.7: Technical features of downstream post-filters. 32
Table 4.1: Actuated valve position during drying phases. 44
Table 6.1: Safety symbols used in the present manual. 74
Table 6.2: Continuation of Table 6.1. 75
Table 6.3: Decals associated to the compressors. 76
Table 6.4: Decals associated to the compressors. 77
Table 6.5: Decals associated to the compressors. 78
Table 6.6: Decals associated to the compressors. 79
Table 6.7: Decals associated to the compressors. 80
Table 6.8: Forbidden situations. 82
Table 11.1: Electrical data of the compressing units. 105
Table 11.2:Continuation of Table 11.1. 106
Table 16.1: Main potential anomalies of compressing skids. 125
Table 16.2: Continuation of Table 16.1. 126
Table 16.3: Continuation of Table 16.1. 127
Table 16.4: Continuation of Table 16.1. 128
Table 16.5: Continuation of Table 16.1. 129
Table 16.6: Main potential anomalies of drying skids. 130
Table 16.7: General anomalies. 131
Table 17.1: Maintenance schedule for 4-year operation prescribed by Sinergia for the main components of
the compressing skids. 137
Table 17.2: Continuation of Table 17.1. 138
Table 17.3: Continuation of Table 17.1. 139
Table 17.4: Maintenance schedule for 2-years operation prescribed by Sinergia for the main components of
the dryers. 143
x Operation & Maintenance Manual
Pulse air system
1 PREFACE
The present Operation and Maintenance Manual edited by Sinergia Srl. is an important tool for a better
understanding of the functionality of the air compressing plant, correct application and maintenance in
compliance with its end use.
This Manual must be always available at the plant location and permanently well kept on the plant to which it
is associated.
The personnel in charge of installation, use, maintenance and repair of plant components must consult this
Manual before the start of any activity, and scrupulously follow all the included instructions in order to avoid
any danger, damage to equipment and injuries to personnel.
This Manual is compliant with the Machine Directive 2006/42/CE and does not take into account local
regulations that, in any case, have to be strictly observed by the personnel.
NOTE:
The Customer must be ensure that the staff in charge of any activity on the air compressor plant
is adequately trained, has read and understand all the instructions.
Operation & Maintenance Manual 3
PRODUCT DESCRIPTION
2 GENERAL INFORMATION
2.1Manufacturer
2.2Warranty
The warranty conditions included into the contract countersigned by Hyundai Engineering & Construction
Co., LTD and Sinergia Compression S.R.L, in the Art. 29 are reported in the following.
All the Goods furnished pursuant to the Contract and/or the Work performed are guaranteed to be new,
unused and of the best quality obtainable (unless otherwise authorized by the Purchaser), to conform in all
respects to the Contract, to be free from faulty design, workmanship or Goods and/or Work, to comply with
all applicable legal requirements or other regulations commonly accepted in the industry, and to be of
sufficient size and capacity so as to fulfil in all respects any operating conditions specified in the Contract.
The warranty period shall be 12 months from the date of issue of the Provisional Acceptance Certificate
issued by the Company or 18 months after Delivery whichever comes earlier. (Expected PAC: 30 June
2014).
The Warranty is valid only in case of a strict observation of Vendor’s (Sinergia) maintenance schedule with
any assistance done by specialized staff and with obligation to use only original spare parts.
Vendor shall not be responsible for repair, replacement, or making good of any defect or damage to the
goods arising out of or resulting from any of the following causes: misuse or improper operation of the goods
by the Purchaser, operation outside of the specifications stipulated in the supply contract’s technical
conditions and normal wear and tear of parts.
Vendor is willing to replace any parts proven to be defective during the said warranty period, provided that
the contractor gives a prompt written notice and satisfactory proof of such defect by sending the part to
Vendor. If after examination (shall be completed within 2 (two) weeks after receiving Purchaser’s written
notice) this part is proved to be defective, it will be replaced free of charge. Otherwise, it will be regularly
invoiced. In case the contractor is not able to send back the defective part, Vendor ask for a regular order
and will subsequently refund the given cost only if it can be proven that the defect falls within the warranty.
If any trouble or defect in the design, Goods, Work, workmanship, operating characteristics or performance
of any part of the Goods and/or Work arises or is in danger of arising, at any time up to twelve (12) months
from the effective date of the Performance Acceptance Certificate issued by Company, and the Vendor is
4 Operation & Maintenance Manual
Pulse air system
notified thereof, the Vendor shall, at its own cost and expense and as promptly as possible thereafter, make
all alterations, repairs and replacements as may be necessary to permit the Goods and/or Work to function
in accordance with the Contract and to fulfil the foregoing warranties.
Should the Vendor fail to correct or to commence and diligently proceed with taking appropriate actions to
correct the defective Goods and/or Work within a reasonable time of being called upon to do so, the
Purchaser may, at its option, remove and correct (whether by repair or replacement) such defective Goods
and/or Work at the Vendor's expense. The Purchaser may, however, at its option, elect to accept the
defective Goods and/or Work with an adjustment in the Contract Price. If, pursuant to the above warranties,
the Vendor alters, repairs or replaces any defective Goods and/or Work, the provisions of this Article shall
then apply to such altered, repaired or replaced Goods and/or Work for a period of one (1) year from the
date on such alterations, repairs or replacements were completed.
Notwithstanding the above, in case of an emergency or any HSE related issue, the Purchaser shall have the
right to remedy the defect by itself or have it remedied by third party(ies) at the Vendor’s expense , but only
after receiving the vendor’s written consent. (at least by email) The foregoing provisions of this Article.
If Vendor fails his guarantee obligations within reasonable time from Purchaser’s notice, Purchaser reserves
the right to take directly all corrective actions to make-good the supply according to the Contract
requirements. All relevant costs will be on Vendor’s account and Vendor will be back charged for them.
2.2.1 Controversies
Court of competent jurisdiction the court of competent jurisdiction for the settlement of any disputes that
might arise shall be the court of Bergamo (Italy). Any issues not explicitly clarified in these general warranty
terms shall be solved as per the Italian Civil Code.
The present manual includes information about the assembled air compressor plant and its components
designed and constructed by Sinergia. Concerning the equipment supplied by external providers, it is
fundamental to refer to their associated manuals.
Table 2.1 Special meaning of characters and symbols used in the Manual
Character/Symbol Definition
3 PRODUCT DESCRIPTION
The air compressing plant for pulse air supply is intended to compress and dry air. It includes two trains,
each one constituted by:
couple of compressing skids, which include a two stages, screw, oil free and water cooled
compressor coupled with inlet air filter, main motor, coolers, air/water separators and lubricating
system;
couple of heatless dryers assembled on the same skid;
Figure 3.1 shows the general arrangement of each train at the final installation site with the interconnecting
piping between compressors and dryers.
Dryers:
Compressor: Compressor:
11/12SCA01-AT001
11/12SCA01-AN001 11/12SCA02-AN001
11/12SCA02-AT001
Figure 3.1: General arrangement of one train of the pulse air compressing plant at the installation site.
Orange dashed rectangles indicate the compressors, while the green dashed rectangle
indicate the drying skid. Tags “11SCAxxx-xxxxx” and “12SCAxxx-xxxxx” indicate a
component of the first and second train respectively.
NOTE:
Note that, all the interconnecting piping between are supplied by Sinergia.
In the following, the compressing and drying packages are described separately. Note that the
components/equipment are mentioned with the associated tags as per the P&ID drawings (APPENDIX A) in
different colors: orange for the compressors, green for the dryers. The following prefixes will be omitted for
brevity;
8 Operation & Maintenance Manual
Pulse air system
11SCA70 and 11SCA71 for the first 11SCA01-AN001 and second 11SCA02-AN001 compressors
respectively of the first train (Serial n.UCV1003286, UCV1003287);
12SCA70 and 12SCA71 for the first 12SCA01-AN001 and second 12SCA02-AN001 compressors
respectively of the second train (Serial n.UCV1003288, UCV1003289);
11SCA72 for the dryers 11SCA01-AT001 and 11SCA02-AT001 of the first train (Serial n. 4960SN04);
12SCA72 for the dryers 12SCA01-AT001 and 12SCA02-AT001 of the second train (Serial n.
4960SN03).
3.13Compressing units
Each train includes two compressors model Sierra SH75WC (Figure 3.2), manufactured and supplied by
INGERSOLL RAND. The Sierra compressor is an electric motor driven, two stage, and dry screw
compressor complete with accessories piped, wired and baseplate mounted. It is a totally self–contained oil
free and water-cooled compressing package .A standard compressor is composed of the following:
Each compressing package (see Figure 3.2) includes:
baseplate;
sound attenuating canopy with quick-latch panels for easy accessibility and motor driven fan for air
cooling;
inlet air filter;
main motor;
two compressing stages;
lubricating system, which includes:
- gear case/sump;
- oil filter;
- oil pumps;
- oil cooler;
first stage intercooler;
inter stage condensate separator with automatic condensate drains;
second stage after cooler;
final stage condensate separator with automatic condensate drains;
control instruments;
control panel;
valves;
interconnecting piping for air, oil, water, condensate;
electrical system;
safety provisions.
Operation & Maintenance Manual 9
PRODUCT DESCRIPTION
The motor and airend are integrally mounted. This assembly is isolated from the base by rubber isolation
mounts. Flexible pipe connections are used where necessary to isolate the main base and customer
connections.
Figure 3.2: Sierra SH75WC (INGERSOLL RAND) compressing units: front (up) and back (down) sides.
10 Operation & Maintenance Manual
Pulse air system
Mounting: B35;
Insulation class: F;
Temperature class: B;
Drive: direct;
Rotation: Counter clockwise (from drive end);
Bearings:
- DE/ N-DE: 6314C3 / 6216C3;
- Grease: CPN 92844729;
- Grease amount: 20 g
Vacuum degassed ball bearings for the non-drive end and roller bearings for the drive end provide
dependable and reliable service. The motor shaft has the largest available standard diameter. This
means that larger bearings are fitted. These oversized bearings have an average applied life of
135,000 hours, which is approximately eight times greater than a standard bearing life. Both
bearings are grease lubricated with bearing housings having grease nipples and relief plug fittings to
simplify the lubrication procedures.
The main technical features: are listed in Table 3.1.
Table 3.1: Technical features of the main motor.
Installed power kW 90
Adsorbed power kW 78
N. of poles - 2
Voltage V 415
Frequency Hz 50
Phase number - 3
Weight kg ~410
12 Operation & Maintenance Manual
Pulse air system
The screw compressing modules are twin-shafted rotating displacement machines. The compression
principle is based on a purely rotational action. Each screw compressing stage includes male and female
rotors, which are the only moving parts of the module. Both rotors are equipped with screw-shaped lobes
(teeth), with very little clearance between them, and flutes. They run into the rotor housing, generating a
positive displacement. The inlet and outlet of the compressor medium takes place via special profiled
opening contours in the compressor stage housing.
The rotors are manufactured from high quality forged steel and stainless steel. First-stage rotors are
machined from E35 steel and second-stage rotors from X20CR13 stainless steel (400 series). Rotor
housings are in cast iron: GG20 (DIN 1691) material no. 0.6020. Components are machined and assembled
to ensure that tolerances are kept within the designed specifications. This is essential to producing airends
and compression modules with required performance and durability.
The suction side drive shaft is on the male rotor, in carbon steel, with cylindrical end.
The compressor stages are completely dry, namely lubrication is not used. Due to the absence of
lubrication, male and female rotor profiles must mesh in a contact-free manner, but with the smallest possible
gaps in between. To this aim, the high quality precision AGMA 12 class gearing is installed on the rotor
shafts.
The temperature immediately downstream each compressing stage is monitored by a temperature element
and a temperature indicator transmitter: TE-CT001 and TIT-CT001 for the first stage, TE-CT003 and TIT-
CT003 for the second stage.
0 0
The compressors are designed to operate at ambient temperature ranging from 2 C to 46 C. When
conditions other than the design levels described are encountered, contact the Manufacturer for additional
information.
The technical and performance features of the compressor modules are listed in Table 3.2.
Operation & Maintenance Manual 13
PRODUCT DESCRIPTION
GENERAL DATA
3
Capacity FAD ISO 1217 2009 Anne C at 10 bar(g) m /min 10.7
Unloaded kW 16
COMPRESSION MODULES
st nd
Rotor diameter (1 -2 stage) mm 108-72.9
st nd
Male motor speed (1 -2 stage) RPM 16133-19120
st nd
Tip speed (1 -2 stage) m/s 91-73
LUBRICATION DATA
Sump capacity lt 34
In the following, the features of the compressor module components are briefly illustrated.
st nd
Figure 3.3: Double stage compressor block, with indication of the 1 and 2 stages and gear box details.
Figure 3.4: Compressing stages: low pressure first stage (right), high pressure second stage (left).
st
The 1 low pressure compressing stage shown in Figure 3.5 is mainly characterized by:
air-cooled rotor housing with exterior cooling fins;
rotors arranged one upon the other.
nd
The 2 high pressure compressing stage shown in Figure 3.6 is mainly characterized by:
liquid-cooled rotor housing with cooling jacked (by poached oil);
rotor arranged side by side.
Operation & Maintenance Manual 15
PRODUCT DESCRIPTION
Figure 3.6: Second compressor stage: high pressure stage. Detail of the profile shape.
16 Operation & Maintenance Manual
Pulse air system
The module is equipped with an inter–stage safety valve (PSV-AA003) set at 3,1 bar(g), and a second stage
safety valve (PSV-AA002) set at max. 11,3 bar(g). The design of the pressurized system is well above the
safety valve settings.
The gearcase is vented by a mounted breather. The breather prevents oil vapor from escaping the sump
area. The breather exhaust is piped outside the airend canopy.
If minor leaks occur in the rotary single lip seal, they can collect in the exterior area of the sealing cover and
they are drained from there through a small connection pipe. Eventual leakages are returned directly to the
gear box’s oil tank through a re-feeding. To this aim, it is necessary to attach the pre-assembled tube to the
dedicated hose.
escapes through all sealing vents, except from the suction side sealing vents of the low-
pressure compressor stages. This leakage can be up to 2% of the suction volumetric flow rate;
however, it is already calculated out of the guaranteed delivery quantity of the compressor
module.
3.1.3.5 Coating
Both the rotors and the internal surfaces of the cast iron chambers are treated with a special Ultracoat™
coating to preserve them from corrosion. Ultracoat™ is a patented process that robotically applies a micro
coating of organic, high temperature resins with PTFE and Molybdenumdisulfide to specially prepared
surfaces. This process creates a mechanical bond of coating to metal. Furthermore, it increases the
efficiency limiting the clearances with the air end (rotor to rotor / rotor to housing). Since the rotors are pinion
gear driven, no rotor contact can occur; consequently, this precisely applied coating should last the life of the
airend.
NOTE:
The compressors are supplied already filled with ULTRACOOLANT oil.
The intercooler and after cooler are “water in the shell” design. Consequently, the compressed air that must
be cooled flows into the tube bundle, while the cooling water runs into the shell, over the outside surfaces of
the tubes, so that it can adsorb the required heat.
The oil cooler employs “water in the tube”, thus the cooling water flows into the tube bundle, while the oil
flows into the shell.
Furthermore, the exchangers are of countercurrent type namely, the fluids flow in opposite directions,
improving the cooling efficiency. The heat exchangers are capable of cooling the compressor under
continuous full load conditions 24 hours/day. The cooling technical data are listed in Table 3.4.
Figure 3.11: Watercooled heat exchangers integrated into the compressor package.
The tube bundle of the coolers is secured at the extremities to the tube sheets and single segmental
baffles are used to support the tubes and to enable a desirable velocity to be maintained for the shell side
fluid. They are responsible for obstructing and redirecting the flow of fluid in the shell side. In fact, they direct
the water through the shell so that the water does not take a short cut through the shell side leaving
ineffective low water volumes. Baffles are fixed to the tube bundle in order that the bundle is still removable
for maintenance, and they are normal to the walls of the shell and force the water to flow at right angles to
the axis of the tubes. The increased turbulence results in greater heat transfer. Moreover, the baffles help in
keeping the tubes from sagging and increase the strength of the tubes by preventing their failure by flow-
induced vibration.
The Ingersoll Rand watercooled heat exchangers are completely design according the lastest version of
T.E.M.A. class “C”. These standards include: pressure classification, design of floating head, gasket, tube
sheet, channel and bonnet, nozzle, flange, tube, shell, baffle and temperatures, testing procedures,
Corrosion allowances and service limitations.
22 Operation & Maintenance Manual
Pulse air system
Inside the LCP are installed: power distribution, PLC system and marshaling terminal strips with interposing
relays mounted on the front mounting plate.
Fuses, relays and terminal strip are installed to protect and exchange all necessary signals between PLC,
and DCS.
The PLC is provided already configured and programmed to perform the logic sequence and functionality.
Application software has been developed with Development Application Tools provided by PLC system
supplier.
For detailed information about control refer to the wiring and schematic diagram (APPENDIX L).
Operation & Maintenance Manual 25
PRODUCT DESCRIPTION
WARNING!
Presence of electrical supply!
Risk of electrical shock.
Each compressing module produce a sound level in “free field conditions” (per CAGI/PNEUROP, ±3 db(A))
of 76 db(A).
3.2Drying system
Each train includes ta couple of heatless dryers installed in parallel on the same skid (see Figure 3.13).
26 Operation & Maintenance Manual
Pulse air system
G G
D
B B B B
D
A AA A CC C C
F E F
Figure 3.13 Drying skid with two drying lines. Main components are indicated: A pre-filters; B vessel; C
post-filter; D control panel; E baseplate; F lifting lug; G safety valve.
Figure 3.14 shows the plan view of the drying skid with indication of the fundamental components.
Operation & Maintenance Manual 27
PRODUCT DESCRIPTION
Figure 3.14: Plan view of the drying skid with indication of the fundamental components: A baseplate; B
pre-filter; C dryer column; D post-filter; E-F piping, G control panel. Main connections are
indicated: TP106A dryer A air inlet; TP106B dryer B air inlet; TP107A dryer A air outlet; TP107B
dryer B air outlet; TP108 condensate drain of the drying package. Anchor holes for lifting
(located at baseplate corners), earth lugs and hazard pictograms are indicated.
The two dryers are identical and they can operate in parallel or one as the alternative to the other, namely
one works while the other is in standby. Each dryer is independent from the other; consequently, each dryer
is supplied with its wet air inlet and dry air outlet connection and its own control panel as shown in Figure
3.14.
In the following, the main dryer components are illustrated. For details of the equipment position mentioned
by green characters see APPENDIX A.
3.2.1 Baseplate
The baseplate is 3.95 m long, 1.6 m wide, 0.97 m high (including supports of skid components) and it is
constituted by painted, carbon steel beams S275J2 (painting in agreement with the Client painting
specification). It is equipped with lifting lugs for skid loading, unloading and placement, and stainless steel
plaque soldered with the basement on all the skid edges for ground connection (see ).
On the bottom flanges of the external baseplate beams there are the holes to anchor the baseplate to the
foundation (18).
28 Operation & Maintenance Manual
Pulse air system
Figure 3.15: Baseplate drawing of the drying skid with indication of main dimensions, earth and lifting
lugs.
Weight kg 4.4
Corrosion allowance mm 0
Corrosion allowances mm 2
Figure 3.16: Dryer tower drawing with indication of main connections: air inlet N1; air outlet N2;
connection to pressure gauge N5; spare nozzle N6; connection to safety valve N7. Each vessel
is equipped with flanged openings for desiccant material loading N3 and unloading N4;
nameplate NP; lifting lugs, supporting brackets BS and earth pales EP.
A dew-point transmitter (AT-CM102 for dryer SCA01, AT-CM101 for dryer SCA02) is installed on the outlet
line of each dryer for the control of the efficiency of the desiccant process.
Weight kg 4.4
Corrosion allowance mm 0
differential pressure switch (PDIS-CP082 for pre-filters of the dryer SCA01, PDIS-CP084 for pre-
filters of the dryer SCA02) with interception valves and 5 ways stainless steel manifold equipped with
needle valves for drain, compensation and interception;
drain manual valve (normally closed);
downstream intercepting manual valve.
On the front side the following components are mounted (see Figure 3.17):
Siemens LOGO! TD Text Display;
indicating lamps:
o green lamp to indicate power supply;
o white lamp to indicate dryer operation;
o red lamps to indicate alarm state.
The PLC is provided already configured and programmed to perform the logic sequence and functionality.
The micro Programmable Logic Controller (PLC) controls all automatic operations:
automatic valves of dryers;
Operation & Maintenance Manual 35
PRODUCT DESCRIPTION
WARNING!
Presence of electrical supply!
Risk of electrical shock.
NOTE:
Sinergia does not supply cable glands for Customer side.
Under previous conditions, the following values of main parameters are guaranteed:
dew point: -25°C @ outlet conditions;
particle size: 0.01 micron;
noise limit: 85 dB pondered at 1 m of distance.
In agreement with the Client’s requirements, the skids are not designed and constructed to withstand the
below conditions, which could cause both material damages and personnel injuries.
Accidental loads:
the skids are not designed in order to support the additional stresses due to:
o further loads located above the dryer;
o snow;
o rain;
36 Operation & Maintenance Manual
Pulse air system
o wind;
o seismic hazard.
Fire:
the skids are equipped with safety valves, which could discharge overpressure due to temperature
increase. They are not equipped with further fire prevention systems (see Section 11.2).
Accidental impacts:
the skids are not protected against accidental impacts, that must be taken into account depending on
the installation site.
The Client must provide to remove the associated risks at the installation site (see Section 11.2).
Operation & Maintenance Manual 37
OPERATING PRINCIPLES
4 OPERATING PRINCIPLES
Each compressing and drying train includes a couple of compressing units and a couple of heatless dryers
designed to work one as the alternative to the other.
In fact each compressor can be set to follow an automatic lead/lag sequence and changeover every a set
time interval, as described in Section 5.1.6, while the dryers can be set to switch every a set time interval, as
described in Section 5.2.1.
In the present section, the operating principles of the compressing and the drying systems are illustrated
separately.
4.1Compressing units
In this section, the operating principles of the compressing unit is described. Particularly, the following main
phases are described:
inlet air filtration;
air compression;
condensate separation;
lubrication;
cooling.
4.1.2 Compression
From the filter outlet, .via a round flexible hose, the air passes through the inlet/blow down valve BV-001
into the first compressing stage. This valve id described in Section 3.1.3.6. The suction pressure is
monitored by the pressure transmitter PIT-CP103; if the pressure is lower than the limit set according to the
load/unload status, an alarm or a shutdown (if negative) signal is transmitted.
38 Operation & Maintenance Manual
Pulse air system
In the following, the function of this valve during the load and unload operation is illustrated, referring to the
Figure 4.1.
When the compressor is under full load operation, the inlet valve BV-001 (included into the blow down
valve) is open and suctions the ambient air. The control cylinder activates the inlet valve opening. In fact,
under load, the oil is loaded from the lube oil header into the cylinder due to the open position of the solenoid
valve AA007 in the direction from the oil header to the compressor. Consequently, due to the compression of
the internal spring, the inlet valve mechanically opens. Simultaneously, the relief valve (GV-001), whose
position is induced by the cylinder too, is closed and the relief line, both from the first and the second stages
is under pressure (this is the meaning of the “compressed medium” direction in the full load scheme of the
figure).
RELIEF VALVE
INLET VALVE
RELIEF VALVE
INLET VALVE
Figure 4.1: Principle of operation of the inlet/blowdown valve during compressor load and unload phases.
When the compressor is in unload operation, the solenoid valve is closed in the direction from the lube oil
header, while is open in the direction from the compressor to the lube oil header. Consequently, the
pressurized oil is discharged and the spring of the cylinder relaxes inducing the closure of the inlet air valve
and, via mechanical linkage, the opening of the relief valve. Thus, the air included in the relief line is
discharged to the atmosphere thought the silencer installed downstream the relief valve.
Note that:
all the air line up to the second stage aftercooler, prior to the non-return valve CV-002, is
depressurized;
the inlet valve is not completely closed, but a small amount of air is admitted to cool the first
compressing stage.
Operation & Maintenance Manual 39
OPERATING PRINCIPLES
Under full load operation the first compressing stage compress the air from the atmospheric pressure to a
pressure between 1.7 to 2.6 bar(g).
The operating process of the screw compressing stage includes three main phases:
Suction
In the meshing profile of the rotor couple, as the male rotor lobe exits from a flute in the female rotor
at the intake side, a chamber is formed (namely between the locking pair of lobes and the forward-
moving lobes). The chamber into which the gas flows has a closed V-shape. As rotation continues,
the filled flute leaves the intake port and migrates to the discharge end. The space on the inlet side is
continually expanded by the rotation of the rotors and reaches its maximum when the lobe profiles
cut off the inlet opening.
Compression
Moving to the opposite side of the rotor pair, the male rotor lobe enters the flute of the female rotor
reducing the size of the previously formed chamber. Consequently, the gas is shifted to the still-
closed outlet and it is continuously compressed through the steady reduced working chamber.
The compression, which is determined by the geometry of the outlet contours (the “built in pressure
ratio”), is thereby reached.
Exhaust
Before the male rotor lobe completely fills the flute of the female rotor thus, the chamber size
decreases approaching to zero, the gas reaches the outlet opening through which it is discharged.
The size of this aperture determines the length of time during which the gas remains in the flute, and
the pressure at which the gas is discharged.
These phases repeat various times (according to the number of lobes in the male rotor) at every rotation of
the male rotor, resulting in a quasi-continuous, low pulsation flow,
Then, the air is discharged through a Venturi nozzle, which dampens any pressure pulsation that may be
present and delivered to the intercooler.
The inter-stage is equipped with the pressure safety valve PSV-AA003, a safety device against abnormally
overpressures (higher than 3.1 bar.g).
Then the inter-stage separator removes any condensation that may be included into the air under certain
conditions of ambient humidity and temperature.
The temperature at the inter-stage separator (second stage inlet temperature) is controlled by the
temperature transmitters TIT-CT002, while the pressure (second stage inlet pressure) by the pressure
transmitter PIT-CP104. In case of excessive values of temperature or pressure, the compressor shutdown is
activated.
See the Sections 4.1.5 and 4.1.3 for the operating principles of the cooling and separation processes.
After the moisture separation the air is delivered to the second compressing stage, to reach a compressing
pressure of 10 bar.(g). The operating principle of the second stage is similar to that of the first stage except
that in the first stage the rotor housing is air cooled by exterior cooling fins, while in the second stage, it is
liquid cooled by a cooling jacked.
Note that, expansion joints prevent vibrations transmission. The compressed outlet air is dampened by the
Venturi nozzle and delivered firstly to the after cooler, which reduces the air temperature from a
40 Operation & Maintenance Manual
Pulse air system
o o
temperature of 180 C to 46.3 C and then to the final stage separator for removal of moisture included into
the air.
Upstream the after cooler it is installed a check valve to prevent any air backflow into the compressor.
Consequently, as previously noted, during the compressor unload operation, the air piping up to this valve
becomes depressurized, while downstream it remains under pressure.
The final stage is equipped with the pressure safety valve PSV-AA002, a safety device against abnormally
overpressures (higher than 11.3 bar.g).
The discharge temperature at the final-stage separator (second stage inlet temperature) is controlled by the
temperature transmitters TIT-CT004, while the discharge pressure by the pressure transmitter PIT-CP105. In
case of high values of temperature, an alarm triggers, while if the pressure is excessive the compressor
shutdowns.
4.1.4 Lubrication
The lubricating circuit is necessary to treat the lube oil, which lubricates gears and bearings, cools the
second compressing stage and activates the inlet/blowdown valve.
The oil circuit is equipped with a overpressure valve PSV-AA001, which prevents overpressures,
discharging the oil into the sump if the circuit pressure overcomes 6.1 bar(g). It also regulates the oil
pressure and may divert some oil flow back to sump.
The gear case is vented to a mounted breather. The breather prevents oil vapor from escaping the sump
area.
The oil pressure downstream the oil pumps is about 2.8 – 3.6 bar(g), at normal operating temperature (54 –
0
63 C), while along the lubrication lines, downstream the distributing manifolds the pressure required for gear
and bearing lubrication is about 1.5÷2 bar(g).
Before the oil injection into the second stage, the temperature transmitter TIT-CT005 monitors the oil
temperature and gives a shutdown signal for excessive temperatures.
4.1.5 Cooling
The air/oil cooling is achieved using water. The purpose of the coolers is to cool the air coming from the
o
compressing stages to a final outlet temperature of 46.3 C, related to a maximum inlet water temperature of
o o
38 C and a Cold Temperature Difference (CTD) of 8.3 C.
The cooling is achieved using the simple principle that if a hot fluid and a cold fluid are separated by a heat-
conducting surface, heat can be transferred from the hot fluid to the cold one.
The air cooler receives the air in the tube bundle and the cooling water at the shell side. The two fluids enter
into close contact through the tube bundle and the baffles. While the cooling water runs into the shell, over
the outside surfaces of the tubes, the hot air flows into the tube bundle countercurrent. The heat content is
exchanged from one fluid to the other and vice versa, consequently the air, which flows in the tubes, cools,
while the water adsorbs heat.
The operating principle of the oil cooler is the same, except that the oil flows at the shell side, while the
cooling water in the tube bundle.
4.2Drying units
Each train includes a couple of completely independent heatless dryers, as shown in Figure 3.1. The two
dryers can work one as the alternative to the other, namely, when the duty dryer operates, the other one is in
stand-by.
The operating principles of the two heatless dryers are identical, thus in the following they are described
referring to a single unit, particularly the dryer SCA01.
The fundamental phases of each heatless dryer operation are:
inlet filtration;
heatless drying;
outlet filtration.
See APPENDIX A for details of equipment position mentioned in the following paragraphs by green
characters.
controlled by the actuated valves installed upstream (AA017/AA018), one for each filter. Each pre-filter can
be totally intercepted for maintenance thanks to the manual valve installed downstream. The pre-filters
protects the adsorbent material by removing liquids and reducing the contamination level of compressed air;
in fact they are able to remove solid particulate larger or equal to 0,01 μm.
Furthermore, condensate, which accumulates at the bottom of the filter casing, is delivered to the drain main
collector through the floating drain trap. A manual valve (normally open) is installed upstream each drain trap
to intercept it and a bypass manual valve (normally closed) is installed to bypass it in case of maintenance or
emergency.
At the filter outlet the air is delivered to the dryer, in particular to the column that is in the adsorption phase
through the inlet actuated valve (AA007 or AA008).
A differential pressure switch (PDIS-CP081), common to both the pre-filters, allows monitoring the pressure
drop across the duty filter. If the differential pressure is over the set alarm threshold (300 mbar) an alarm
triggers, meaning that the filter is clogged and needs to be substituted. Consequently the two filters switch,
namely the actuated valve upstream the duty pre-filter closes (blocking the filter operation), while the
actuated valve upstream the other pre-filter opens, making it operative.
A five ways manifold with needle valves is installed upstream the differential pressure switch to allow
isolating it in case of maintenance, draining and compensation. Furthermore, a couple of manual valves is
installed to ensure the pressure switch isolation.
Each filter is also equipped with a differential pressure indicator (PDI-CP501/CP502) which allows local
monitoring of the pressure drop.
4.2.2 Drying
Dryer operating includes two main phases:
adsorption;
regeneration.
4.2.2.1 Adsorption
Filtered and saturated air enters at the bottom side of the column in adsorption phase through the associated
inlet actuated valve (AA007 or AA008) and crosses the adsorption material bed (molecular sieve). As air
flows up through this “on line” tower, its moisture content adheres to the desiccant surface and it is retained
within the required dew point value. Dry compressed air is then discharged from the tower to post-filtration.
Thanks to inlet air entering at the bottom of the “on line” tower and flowing up through the desiccant bed,
liquid condensate caused by system upset is kept away from the desiccant and remains at the bottom of the
tower from where it can be easily exhausted during the regeneration cycle.
A solid-state controller automatically cycles the flow of compressed air between the two towers, while the “on
line” tower is drying, the “off line” tower is regenerating.
At the column outlet, a percentage of desiccated air (10 %) is delivered to the regenerating column through
the purge valve, while the remaining amount is conveyed to the after-filters for further purification. The non-
return valves installed on the purge lines allow the air flux in the correct direction.
Figure 4.2 shows the path of compressed air from the inlet point to the outlet one during the adsorption
phase of column B (4960SN04B for dryer 11SCA01-AT001, 4960SN03B for dryer 12SCA01-AT001). During
this step, the inlet valve AA007 and the outlet valve AA011 are open, while the exhaust valve AA009 is
44 Operation & Maintenance Manual
Pulse air system
closed. In the same time, the parallel line is in regeneration phase, thus the inlet valve AA008 and the outlet
valve AA012 of the column B are closed.
In the represented case the duty pre-filter is that activated by the valve AA018, consequently, the valve
AA017 is closed. Concerning the after filtration, the duty post-filter is that activated by the valve AA021,
consequently, the valve AA022 is closed.
Note that, if the dryer in stand-by, the valve AA021 remains open, while the valve AA022 is closed.
On the other hand, during the adsorption phase of column A (4960SN04A for dryer 11SCA01-AT001,
4960SN03A for dryer 12SCA01-AT001), the inlet valve AA008 and the outlet valve AA012 are open, while
the exhaust valve AA010 is closed. In the same time, the parallel line is in regeneration phase, thus the inlet
valve AA007 and the outlet valve AA011 of the column B are closed.
Table 4.1 lists the valve position during all the drying phases.
Column A Column B
Column A
Column B
End phase Inlet Outlet Blow off Inlet Outlet Blow off
Regeneration
condition valve valve valve valve valve valve
Dehumidification Cycle time> 6 min open open closed closed closed open
Adsorption
Column switch
Dehumidification Cycle time> 6 min closed closed open open open closed
Adsorption
Column switch
Figure 4.2: Air path during the adsorption phase of left tower (4960SN04B) of the dryer 11SCA01-AT001.
The inlet valve AA007 and the outlet valve AA011 are open, while the inlet valve AA008 and the
outlet valve AA012 of the other column (4960SN04A), which is regenerating, are closed.
46 Operation & Maintenance Manual
Pulse air system
4.2.2.2 Regeneration
One column is in the regeneration phase while the other one is in adsorption.
Regeneration (purging or “offline” cycle), is the process by which moisture accumulated during the “on line”
cycle (adsorption) is stripped away.
This phase includes three steps:
expansion;
dehumidification;
pressurization.
Expansion
During the expansion the column is depressurized, namely the pressure inside the tank is discharged into
the atmosphere, dragging outside part of the moisture entrapped into the adsorbing material.
When column B (4960SN04B for dryer 11SCA01-AT001, 4960SN03B for dryer 12SCA01-AT001) is in
expansion the actuated inlet valve AA007 and outlet valve AA011 are closed. The pressurized air flows from
the top to the bottom of the tower and is discharged through the actuated valve AA009 and the silencer.
On the other hand, when column A (4960SN04A for dryer 11SCA01-AT001, 4960SN03A for dryer 12SCA01-
AT001) is in expansion the actuated inlet valve AA008 and outlet valve AA012 are closed. The pressurized
air flows from the top to the bottom of the tower and is discharged through the actuated valve AA010 and the
silencer.
Figure 4.3 shows the air path during expansion in column A.
Operation & Maintenance Manual 47
OPERATING PRINCIPLES
Figure 4.3: Air path (blue line) during the expansion and dehumidification phases of the right tower
(4960SN04A) of the dryer 11SCA01-AT001. The inlet valve AA008 and the outlet valve AA012
are closed, while the exhaust valve AA010 is open. The inlet valve AA007 and the outlet valve
AA011 of the other column (4960SN04B) which is in adsorption (red line), are open.
48 Operation & Maintenance Manual
Pulse air system
Expansion phase ends when the vessel pressure equals the atmospheric one.
Dehumidification
During the dehumidification, a percentage of dry air taken from the dryer outlet is delivered to the column
that is in the regeneration phase. As low-pressure and dry purge air flows gently through the regenerating
bed, from the top to the bottom of the tower, it attracts the moisture accumulated on the surface of the
desiccant during the adsorption phase, and exhausts it to the atmosphere.
In the present case, about the 10% of dry air (purge air) is delivered through the purge valve and the purge
line to the top of the column in regeneration (A or B). The check valves installed along the purge lines,
upstream the towers, prevent the air flux in the wrong direction. The moisture evaporates tanks to the dried
airstream and it is discharged to the atmosphere through the actuated valve (AA009 after column B or
AA0010 after column A) and the silencer.
Air path during dehumidification in columns A is the same shown in Figure 4.3.
Pressurization
After dehumidification, the column in regeneration is bringing back to the working pressure to avoid pressure
oscillations on the network when it is switched to the adsorption phase. To this aim, the actuated valve
(AA009 for column B or AA010 for column A) closes.
Air path during pressurization in columns A is shown in Figure 4.4.
Operation & Maintenance Manual 49
OPERATING PRINCIPLES
Figure 4.4: Air path (blue line) during the pressurization phase of the right tower (4960SN04A) of the dryer
11SCA01-AT001. The inlet valve AA008, the outlet valve AA012 and the exhaust valve AA010
are closed. The inlet valve AA007 and the outlet valve AA011 of the other column (4960SN04B)
which is in adsorption (red line), are open.
50 Operation & Maintenance Manual
Pulse air system
When pressure reaches the working value, the regenerated column is ready to start a new adsorption cycle.
The column that was in the adsorption process is automatically switched to regeneration and vice versa.
The moisture loading is affected by inlet temperature, pressure, relative humidity and flow. These conditions
vary throughout the day and rarely combine perfectly to produce maximum moisture loads. An inlet
temperature drop can significantly reduce the moisture load. Dryers are sized for “worst case scenario”
operation, with the fixed time control mode to accommodate maximum moisture loads, but since a fixed
duration cycle does not compensate for fluctuating loads, energy is wasted by regenerating more often than
necessary.
The dew point control mode is designed to adjust the energy use necessary to actual moisture load. Dew
point control eliminates the unnecessary use of energy by delaying regeneration until the total design
moisture load is achieved. Under dew point control, adsorption and regeneration cycles switch based on the
dew point value. If the dew point value transmitted by the transmitter AT CM102 is worse than the set point
equal to +5 °C, the adsorption time must increase at most up to the set maximum cycle time (60 min);
otherwise, the adsorption time must decrease at most up to the minimum set cycle time (6 min).
Due to less frequent cycling, switching valves and desiccant will last longer and require less maintenance.
Note that, if the dryer in stand-by, the inlet valve of the post filter, which was the duty one remains open (e.g.
AA022), while the inlet valve of the post filter, which was in stand-by (e.g. AA022) is closed.
Each filter is also equipped with a differential pressure indicator (PDI-CP503/CP504) which allows local
monitoring of the pressure drop.
Operation & Maintenance Manual 53
CONTROL SYSTEM
5 CONTROL SYSTEM
Each compressor and each dryer is equipped with its own local control panel, which includes a
Programmable Logic Controller (PLC), as described in Section 3.1.1 and 3.2.4. The control system is
equipped with a Human Machine Interface (HMI) device, which allows setting and controlling the operation
of the compressor. The control system displays the values of the parameters in proper engineering units and
indicates the associated condition: alarm, trip, fault, etc…The installed instrumentation and the relative
signals are indicated as on the P&I (APPENDIX A).
In the following section, the control system of the units is described.
5.1Compressing units
WARNING!
Remote start/stop machine!
Disconnect power before servicing.
May start or stop at any time.
Lock and tag out.
Can cause severe injury or death.
The lateral bar includes the main buttons, which allows navigating into the HMI pages. The pages are
gathered into three groups:
HOME: page with the graphical representation of the plant with indication of the state of the
dryer, the process phases, the main control parameters and the pushbuttons for local start and stop
of the dryer.
SETTING: pages for basic and advance setting of parameters for process control and alarm
management.
ALARMS: pages with information about the last triggered alarm and the history of past
activated alarms.
To move from one page to another press the associated tactile zone over the desired symbol previously
illustrated. The selected, active group lights up orange.
To page through in the selected group, press the pushbutton, which represents the arrow:
- load:
- unload
Operation & Maintenance Manual 57
CONTROL SYSTEM
control modality:
- local lead;
- local lag;
- remote hardware;
- remote Modbus.
To insert the setting values, touch the white fields and the keyboard shown in Figure 5.2.
5.1.7.1 HOME
The home pages are shown in Figure 5.3-Figure 5.5.
The first HOME page shown in Figure 5.3 indicates
o online pressure, namely the pressure below which the compressor starts to work in load
condition;
o offline pressure, namely the pressure over which the compressor enters in unload condition;
o the measured actual pressure, which is indicated also on the colored bar;
o Time to autorestart: time measured (in min. and sec.) from which the compressor operates in
unload condition. In auto-restart modality, once a set time interval is reached the compressor
stops;This time interval is set in the “BASIC SETTING” page;
o operating hours;
o measured actual temperature.
o
The third and fourth HOME pages shown in Figure 5.5 list the measured parameters by control
instruments installed on the machine, which are monitored for a complete control of the compressor
operation. The instruments of measure are indicated by their associated tag, as per P&Id
(APPENDIX A).
Operation & Maintenance Manual 59
CONTROL SYSTEM
5.1.7.2 SETTING
Under the SETTING menu, three pages are available for parameter setting:
SETTING-BASIC: to set the basic parameters. This page has free access to everyone.
SETTING-ADVANCE: to set and enable control modalities and set alarm thresholds. This page is
protected by password (set password at delivery: 1111).
SETTING-TRANSMITTERS: to set the range of measure of the installed transmitters. This page is
protected by password (set password at delivery: 7858).
The SETTING-BASIC page is shown in Figure ;.6. It includes the setting of the following parameters:
o Off line pressure of the lead (9 bar) and the lag (8 bar) compressor: pressure over which the
compressor enters in unload condition;
o Delta pressure of the lead (0.7 bar) and the lag (0.7 bar) compressor: subtracting this delta
value from the “off line pressure” the on line pressure is calculated, namely the pressure below
which the compressor start to work in load condition.
o Unload auto stop time: once the compressor reaches this set time from the unload condition
it automatically stops;
60 Operation & Maintenance Manual
Pulse air system
o Purge filter Close/Open: the air filter cleaning system is activated for a time interval equal to
the set open time (1 sec.) every the set Close time (10 sec);
o Drain discharge: the drain valves of the condensate separators air filter opens for a time
interval equal to the set open time (1 sec.) every the set Close time (180 sec);
SETTING-ADVANCE pages.
The first page shown in Figure 5.7 allows enabling the following control modalities:
o Automatic lead/lag sequence: the automatic switch of lead/lag condition between the two
compressors every the set lead/lag exchange time. This control modality must be enabled in
the present plant under local control;
o Hardware control: remote control commands from the Client (option) namely:
- remote control enable;
- remote tart/stop;
- remote load/unload enabled;
- remote load/unload switch.
o Modbus control: control commands from Modbus (via Ethernet). This control modality must
be disabled in the present plant;
o Poro (Power Auto Restart Option): if enabled, this option allows the compressor to
automatically restart after a blackout.
Operation & Maintenance Manual 61
CONTROL SYSTEM
NOTE:
The lead/lag off-line and delta pressure, and the lead/lag exchange time must be the same on both the
control panels of the train.
The other pages shown in Figure 5.8 allow setting the alarm thresholds set for the compressor
control.
The SETTING-TRANSMITTERS pages are shown in Figure 5.9. They allows setting the measuring
range of the installed transmitters: minimum and maximum limits corresponding to the 4mA and
20mA signals. These values are set following the calibration values stated by the transmitter
manufacturer or ad hoc different calibrations and they can be selected to adjust the probe reading
errors. Nearby the setting columns, the page shows the actual values read by the probes.
Regarding the measuring ranges, see the instrument schedule in APPENDIX M.
5.1.7.3 ALARMS
The active alarm page automatically opens in case of a new triggered alarm and the alarm pushbutton
remains highlighted until the alarm is not reset.
As Figure 5.10 shows, for an activated alarm there is indication of:
type: warning or trip (see Section 5.1.8);
hour;
date;
status: in, namely activated alarm;
description.
Operation & Maintenance Manual 63
CONTROL SYSTEM
Each alarm must be recognized by the operator and reset pushing the RESET pushbutton (at the bottom of
the screen page).
All occurred alarms are memorized in the HISTORY-ALARMS page (Figure 5.11). In this page the input (in)
and output (out) status are memorized This is useful for future verifies analyses.
Figure 5.10: ACTIVE - ALARMS screen page, showing the last activated alarm.
Figure 5.11: HISTORY- ALARMS screen page with memorized past alarms.
5.1.8 Alarms
The control of each compressor includes various alarm signals, which can be of two types: warning or trip:
warning indicates a not urgent alarm or notify anticipate if the temperature or pressure is in order to
exceed the normal operating limits. The warnings does not stop the compressor;
trip stops the compressor immediately.
In case of trip, to restart the compressor it will be necessary to push the reset pushbutton.
Some alarms trigger due to the excess of an upper or lower admissible threshold that must be set in the
setting pages illustrated above. These alarms can be of four types:
HH: very high alarm;
H: high alarm;
L: low alarm;
64 Operation & Maintenance Manual
Pulse air system
In the following, all the potential alarms are listed, distinguishing warning and trip type.
Warning alarms:
o Error pressure transmitter CP-103
o Error pressure transmitter CP-104
o Error temperature transmitter CT-005
o Error pressure transmitter CP-101
o Error pressure transmitter CP-102
o Oil pump overload 3M
o Oil pump starter fault 3M
o Air Filter Clogged DPAH CP-081
o Oil filter clogged PDAH (CP-101 - CP-102)
o Low 2 stage inlet pressure at load PAL- CP-104
o High discharge temperature TAHH- CT-004
o High filter differential pressure PDAH- CP-081
Trip alarms
o Error temperature transmitter CT-001
o Error temperature transmitter CT-003
o Error temperature transmitter CT-002
o Error pressure transmitter CP-105
o Error temperature transmitter CT-004
o Error differential pressure transmitter CP-081
o Emergency stop
o Main motor overload 1M
o Fan motor overload 2M
o Main motor starter fault 1M
o Low oil pressure PALL CP-102
o High oil temperature TAHH- CT-005
o Low vacuum pressure at load PALL- CP-103
o Low vacuum pressure at unload PALL- CP-103
o High 2 stage inlet pressure at load PAHH- CP-104
o High 2 stage inlet pressure at unload PAHH- CP-104
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CONTROL SYSTEM
if the stop is pressed while unit is running unloaded, the compressor stops immediately, otherwise:
the compressor immediately unloads;
the compressor continue to run unloaded for 10 seconds;
the compressor stops.
5.1.9.3 Emergency stop
If the machine has to be stopped in emergency, press the emergency stop button located on the
instrument panel. This will over–ride the normal unload/stop button and will immediately stop the machine
without the 10 second delay.
WARNING!
Never allow the machine to stand idle with pressure in the system.
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In the case of emergency due to the activation of the shutdown button on the control panel or to the ESD
signal, the automatic shutdown procedure is activated:
5.1.10 Load/unload
The compressor can be load or unload from the local control panel using the key pushbuttons:
F3-Compressor load: pressing this button will cause the unit load if the unit is running and the
discharge pressure is less than the online pressure. This also return the machine to the operating
mode that is specified by the mode of operation set point.
F4-Compressor unload: if the unit is running loaded, pressing this button will cause the unit to
unload. The unload indicator light will be on.
5.2Drying units
The dryers are equipped with their own Local Control Panel (LCP). Furthermore, start and stop can be
performed locally or remotely from the Client Distributed Control System (DCS).
For more information about signal interface, refer to the dedicated wiring diagrams (APPENDIX L).
Each dryer is equipped with its own control panel and Programmable Logic Controller (PLC), as described in
Section 3.2.4. The control system is equipped with a Human Machine Interface (HMI) device (LOGO! TD
Text display), which allows setting and controlling the operation of the dryer.
The basic instructions of the LOGO! Display are:
change the page: use the up/down arrow pushbuttons;
insert the values in the pages:
o press ENTER until a cursor appears;
o use the left/right arrow to move the cursor;
o press the Ok pushbutton to insert the value;
o use the up/down arrow pushbuttons to increase/decrease the value;
o press the Ok pushbutton to definitively set the value.
set the control advanced parameters:
o press the down arrow until timer page;
o press “ESC”;
o select “SET PARAM” to go to the menu.
function keys: F1, F2, F3 and F4. Concerning the present machinery, they need to:
o F1: start the dryer under local control;
o F2: stop the dryer under local control;
o F3: change the control modality from local to remote pushing the associated button for at least
2 seconds;
o F4: change the control modality from dew point control to fixed time mode, pushing the
associated button for at least 5 seconds;
This pushbutton is used also to reset al alarm state.
In the following section, the screen pages of the HMI are described.
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Figure 5.12: Screen page indicating dryer status and main controlling parameters: dew point values and
past time from last column switch.
Figure 5.13: Screen page indicating dryer operating modality: local or remote, under dew point control or
foxed time.
o REGULATION: indicates that the dryer can operate under dew point control mode, being
equipped with a dew point probe;
o
o DP: Dew Point value in C;
o
o SP: dew point set point (-25 C);
o OUT: percentage of dryer cycle: at 0% the cycle time is 60 minutes, at 100% it is 6 minutes.
Figure 5.14: Screen page indicating dryer operation under dew point control.
DRYER SWITCH:
The dryers operate alternatively; this page allows setting the duration of the operating time
interval, after which the dryers switch.
Figure 5.15: Screen page indicating the operating time interval of each dryer before switching.
ALARMS:
In case of alarm, the alarm page automatically appears, indicating:
o WARNING: type of alarm;
o instrument of measure which signals the malfunction: dew point probe (CM102), differential
pressure indicator (CP501/CP502) across pre-filters; differential pressure indicator
(CP503/CP504) across post-filters.
o cause of alarm: bad signal, high value, filter clogged;
o parameter associated to the alarm (if necessary).
o bad transmission of the dew point probe (CM102), namely dew point probe signal in error
(<4mA or >20mA);
a) bad dew point value, over the set threshold;
b) clogged pre-filter, indicated by high differential pressure across the filter;
c) clogged post-filter, indicated by high differential pressure across the filter.
a) b)
c) d)
Figure 5.16: Screen pages indicating alarm states, particularly warning due to: probe transmission error
of dew point value (a); bad dew point value (b); pre-filter clogging (c); post-filter clogging (d).
The set points of the thresholds are listed in the alarm annunciator list attached in APPENDIX N.
To set the control advanced parameters, it is necessary to press the down arrow until timer page, then “ESC”
and “SET PARAM” to go to the menu.
Under dew point control, adsorption and regeneration cycles switch on the basis of the dew point value,
particularly the control is made by a PID (Proportional Integral Derivative) controller, which requires the
setting of proportional gain and integral time parameters. Thus, the following controlling parameters must be
set:
Dew point set point SP: -25 C;
o
Furthermore, the measuring range of the dew point probe is set, in order to identify the probe malfunction:
Dew point probe minimum value Min: -80 C;
o
NOTE:
All others accessible parameters should not be changed.
6 STAFF SAFETY
The skids are designed and constructed in compliance with the most recent safety regulations. Nevertheless,
the personnel in charge of any activity on/with the machineries have to pay attention and comply with the
safety instructions prescribed in the present manual.
DANGER!
Danger due to incorrect behaviour!
Minor or relevant components damage and personnel injuries could be due to:
not-observance of safety instructions;
activity carry out by non-qualified personnel;
machinery not use within design specifications;
product modifications not authorized by the Manufacturer;
incorrect maintenance.
Personnel must wear proper Personal Protective Equipment (PPE) depending on the performing activity.
In the manual, referring to the described activity, proper PPE are suggested. However, standard safety
regulations must be obeyed.
From a safety point of view, the units must be daily inspected, to ensure that operating conditions are safe
and eventually intervene to re-establish the dangerous ones.
Concerning the components which were provided by external suppliers, for further safety details consults the
associated handbooks in the appendixes.
WARNING!
Danger due Mobile Telephones!
The correct operation of this machine may be affected by the nearby use of a mobile
telephone. Ensure that such telephones, when in use, are kept at least 5 meters from the
perimeter of a machine which is operating or is being worked on whilst connected to its
power supply.
6.1Safety symbols
Table 6.1 lists symbols used in the present manual and/or attached on the units to indicate potential hazards
and prescription of Personal Protective Equipment (PPE). This table indicates also the activities during which
personnel must obey obligatory instructions and must pay attention to potential hazards.
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For the compressors, see also the decals illustrated in the following tables.
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On the equipment, hazard or relevant parts are indicated by proper symbols (see APPENDIX B). The
following indications are supplied.
Compressing skids:
electrical supply;
ground connections;;
high surface temperatures;
rotating parts;
draining points;
cooling water in and out;
oil leak;
pressurized vessels;
air filter;
guards to be maintained fitted;
lifting eyebolts.
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LOADING AND TRANSPORT
Drying skid
electrical supply;
ground connections;
lifting eyebolts.
6.3Safety devices
In addition to chamfer of all edges, the skids are equipped with the following safety devices.
Compressing units:
pressure safety valves PSV-AA003 and PSV-AA002 installed on the intercooling and aftercooling
lines respectively. They are set to 3.1 bar(g) and 11.3 bar(g) respectively;
oil safety valve PSV-AA001;
guards of rotating components to prevent any accidently touching;
canopy to prevent any accidently touching and to reduce noise level;
air silencer to exhaust air during the unload phase.
Drying units:
one safety valve installed on each column (PSV-AA013-PSV-AA016) with discharge to safe area (at
the Client’s charge). They are set to 12.1 bar(g).
silencer installed on the discharging lines to exhaust wet air during the depressurization phase.
The compressing and drying trains have been designed and supplied for use only in the following specified
conditions and applications:
compression and drying of normal ambient air free from unknown or undetectable additional gases,
vapors. or particles;
operation within the ambient temperature range specified in the Section 11.1.
The use of the units in any of the situation types listed in Table 6.8:
is forbidden;
is not approved by the Vendor;
may impair the safety of users and other persons;
may prejudice any claims made against the Vendor.
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Use of air for indirect human consumption, without suitable filtration and purity checks.
Use of the machine outside the ambient temperature range specified in the Section 11.1.
Use of the machine where there is any actual or foreseeable risk of hazardous levels of flammable
gases or vapors.
WARNING!
Presence of electrical supply!
The plant is not intended and must not be used in potentially explosive atmospheres,
including situations where flammable gases or vapors may be present.
Use of the machine fitted with components non approved by the Vendor.
All the machineries must operate in compliance with data reported in the contract conditions and in the
declaration of conformity.
Uses or conditions, which differ from previous points, imply improper uses.
Clear misuse is the use of components as climbing aid. Vessels, connections, pipes, valves and other
elements are not design to that aim; they could fracture or became damaged.
6.5Residual risks
Although risks have been reduced as far as possible with accurate design and construction, some residual
risks persist.
Concerning the dryers, the residual risks are:
discharge of air under pressure:
o the unit is equipped with pressure safety valves installed on the vessels against the risk of
blast due to too high overpressure. The vents must be in safe area (at the Client’s charge),
however the risk of safety valve discharge persist;
o although a silencer is installed, during the depressurization phase the discharge of air under
pressure generates a strong and sudden noise.
Sliding:
o spilled desiccant agent beads on the floor during desiccant material empting and filling
could cause sliding.
o the unit is equipped with pressure safety valves installed on inter and final stages against the
risk of blast due to too high overpressure. The risk of safety valve discharge persist.
sliding:
o oil leaks could cause sliding;
o cooling water leaks could cause sliding;
DANGER!
Danger due to material use!
The following substances are used in the manufacture the compressors and may be
hazardous to health if used incorrectly:
- preservative grease
- rust preventative
- compressor coolant
The safety prescriptions of the lubricant oil required for the compressing unit
operation are included in the data sheet in APPENDIX D.
AVOID INGESTION, SKIN CONTACT AND INHALATION OF FUMES
Maintenance of the dryers requires the replacement of the desiccant material,
whose safety datasheet is attached in APPENDIX E.
NOTE:
Note that, in case of fire, fire extinguishers suitable for devices under tension have to be used.
Do not use extinguishers intended for Class A or Class B fires on electrical fires. Use only extinguishers
suitable for class BC or class ABC fires.
Further residual risks which characterize the various life phases of the machinery are listed in the associated
following sections by “danger advises”.
Personnel are allowed staying in any position around both the compressing and drying units at the floor
level. For maintenance activity, which require elevated positions, a proper ladder or gangway must be
adopted.
The operator cannot use any components as support.
Attention must be paid to the discharges of safety valves. During inspections or maintenance activities of the
highest parts of the skids, personnel must never stay in front of them, except if the plant is depressurized.
Operation & Maintenance Manual 85
LOADING AND TRANSPORT
7.1Loading/unloading
The compressors can be moved by a fork lift truck (2.5 ton / 5500 lbs minimum), inserting the forks in the
slots incorporated within their base. Alternatively, a crane or hoist can be used, adopting a special lifting
frame. The dryers must be moved by a crane, using a suitable lifting beam.
Details for lifting are reported both on the packages and in the general arrangement drawings (APPENDIX
B). Figure 7.1 and Figure 7.2 show the proper hoisting scheme for the compressing and drying skids
respectively, with indication of the total skid weight and the load for each lifting lug.
DANGER!
Danger due to improper lifting/handling!
Figure 7.1: Lifting schemes of the compressing skids: by crane (up) or by forklift (down). The total weight
of each compressor is 2800 kg.
Operation & Maintenance Manual 87
LOADING AND TRANSPORT
Figure 7.2: Hoisting scheme of the drying skids. The total weight of the skid is ~3100 kg. The center of
gravity is specified. See Figure 3.14 for the letter legend.
7.2Transport
The transport is excluded from the Sinergia Supply (Ex works Sinergia).
Equipment must be protected with care during the transport in order to avoid falls and/or damages.
WARNING!
Danger due to incorrect transport!
Transport must be performed by qualified and authorized technicians. Incorrect
activity can cause material damages and personnel injuries.
Accurately ensure and safeguard the skids.
Do not place further loads over the packages: they can cause material damages.
The packages are not designed for mechanical loads.
Keep the skids always in upright position.
Obey safety precaution. In-observance can cause material and/or personnel
damages.
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NOTE:
Sinergia declines any responsibility for damages caused by not correct transportation beyond the scope
of supply.
In case the packing and/or the skids have been damaged during transportation, both the hauler and the
manufacturer must be urgently contacted and a written report of damages must be sent to the Manufacturer.
WARNING!
Danger due to damaged components!
Do not put in operation a damaged unit: damaged components can cause working
anomalies and/or other damages.
Operation & Maintenance Manual 89
PACKAGING
8 PACKAGING
According to the Customer requirements and specifics, the various supplied skids are packaged with a
seaworthy packaging, namely fumigated and marked wooden box coupled with sac barrier, coex cover
and dehydrating salts included.
To ensure a good protection during transportation, all flanged and threaded opening will be covered with
dedicated bolted and gasketed plugs.
This type of packing guarantees protection of the goods during both land/overseas transport and outside
storage for a period not longer than 6 months.
Separated boxes are provided, as listed in the packing list in APPENDIX Q.
NOTE:
Remove not damaged packing only at the final installation place, as it guarantees the protection against
atmospheric agents and corrosion.
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DELIVERY TO SITE
9 DELIVERY TO SITE
At the installation site, all the packages must be unloaded as close as possible to the dedicated area in order
to minimize any probability of equipment damage.
All the prescriptions described in 7 regarding the loading are valid also for the unloading, thus refer to that
section for details.
9.2Receiving Inspection
Upon arrival at the final destination site, goods, including preservation and packing, shall be inspected for
signs of transport damage. Accordance with the packing list (APPENDIX Q) must be verified. Any
discrepancy must be notified immediately to the site manager and a written report of the damages must be
sent to the Manufacturer.
WARNING!
Danger due to unpack!
Pay attention to not damage the unit with the instruments used to unpack it.
9.3Preservation
Packages should remain intact until the installation and the assembly of the plant. The adopted packing (see
Section 8) has been decided considering a protection period of at most 6 months including shipping and idle
times before installation. If this time is expected to be exceeded, long tern preservation is required. Long
term storage procedures are described in Section 10.1.2.
Operation & Maintenance Manual 93
STORAGE
10 STORAGE
In case it is necessary to store the packaged skids, the storage place must satisfy the following general
conditions:
indoor would be the best, otherwise in a protected place under a roof, not exposed to rain, hail, sea
water, blowing sand…;
flat surface, isolated from the ground (by a concrete cover to avoid moisture) and external vibrations;
dry;
dust-free;
minimum temperature of +1 °C to avoid ice formation;
NOTE:
The supplied packaging (see Section 8) guarantees protection of the goods for a period not longer
than 6 months from the packing, including land/oversea transport and outside storage.
NEVER place heavy packages on other packages and ensure to not exceed the load capacity of the
supporting floor.
b. In the case of temporary storage of the skids during the plant life, due to the disconnection from
the external plant, it is fundamental to:
o drain accumulated condensate from filters and separators, clean and dry drainage
systems;
o accurately clean and dry all the components and equipment, included internal surfaces of
piping, tanks and any shell subjected to pressure under operation;
o ensure that everything is in good condition and not damaged; in the contrary case,
substitute or repair following Sinergia’s prescriptions.
o plug all flanged and threaded opening with bolted plugs of blind flanges with gaskets.
o grease bearings, gears, mechanical seals and threated connections;
o protect the skids accurately wrapping them with a plastic sheet or a tarpaulin;
o ensure the skids against potential accidental impacts by protections and information signs.
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in a molecular layer. This type of protection can be adopted alone or integrated with
other packaging.
o if the previous processes cannot be performed, hang up enough sachets of
dehydrating salt at the upper parts of the skids to adsorb the humidity, avoiding the
contact with water (which could accumulate at the bottom of the skids), which could
induce corrosion. Then, protect the skids with a lorry tarpaulin accurately wrapped.
o ensure the skids against potential accidental impacts by protections and information
signs.
o concerning the single components installed on the skids, follow the long term storage
prescriptions listed below and suggested by the relative Manufacturers in the
associated handbooks attached in the appendixes.
b. In the case of long storage of the assembled skids during the plant life, due to the disconnection
from the external plant, it is necessary to:
o follow the prescriptions for the short-term storage (point b);
o inspect the skids to ensure component integrity and not corrosion evidence;
o fill the skids of nitrogen as described above at point a;
o apply a new long storage packing or protections as described above at point a;
o concerning the single components installed on the skids, follow the long term storage
prescriptions listed below and suggested by the relative Manufacturers in the associated
handbooks attached in the appendixes.
- store instruments and electronic equipment, which were disassembled or extracted by the
original packaging, indoor, in a closed and dry site, wrapped, protected by vapor corrosion
inhibitors devices, and placed in protective wooden boxes (inside the control panel is
possible) not in contact with the ground. Note that components sealed in plastic shrink-wrap
(i.e. spare parts) are not exempt from corrosion problems, since moisture will collect inside
the plastic, resulting in corrosion.
- store delicate instruments, as distribution components and programmable controllers, as
indicated at the previous point; in addition the storage place must be air conditioned.
Carbon steel wrought surfaces, nor painted, nor galvanized:
- perform a treatment for rust prevention, applying a corrosion preventive compound, e.g.
TECTYL products or alternative protective products in agreement with Client’s specifications
or Sinergia’s prescriptions. These products must be applied after 12 mounts from shipment
and afterwards, every 6 mounts. Prior new application, the “old” protection must be removed
with vapor degreasing, hot alkaline wash, or low-pressure steam by normal dry cleaning
procedures.
Small parts (threads, valve stems, flange mating faces, nuts and bolts, machined surfaces,…):
- clean all the parts;
- apply corrosion preventive compound;
- wrap with laminate craft papers or polyethylene sheets;
- store indoor, in a closed and dry site and placed in protective wooden boxes.
NOTE:
For any doubt, contact Sinergia.
Sinergia declines any responsibility for damages due to improper storage.
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INSTALLATION
11 INSTALLATION
WARNING!
Danger due incorrect installation!
The dryer installation must be performed by qualified and authorized technicians.
Incorrect installation could cause material damages and/or personnel injuries.
NEVER left tools or other objects on the units; they could fall and cause damages.
Site conditions have a high influence on the plant efficiency. In order to guarantee its operation as efficient
and continuous as possible, and with minimum maintenance, the installation site must respect the design
conditions, in agreement with the Customer’s requirements or, in any case, it must be characterized by
features less hazardous (to the operation) than the design ones:
indoor;
safe area;
maximum design ambient temperature: 50 °C;
minimum ambient temperature: 2 °C;
maximum ambient temperature: 46 °C;
maximum humidity for air inlet: 95 %;
design pressure: 0,99 bar (a);
maximum water cooling temperature: 38°C;
site adequately accessible for maintenance activity:
o free-space of at least 1 m above the skids;
o free-space of at least 1 m around the skids.
If headroom is restricted, then the exhaust should be ducted or deflected away from the
compressors.
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NOTE:
The units are not suitable for use in flammable gas risk areas.
If ducting is fitted, the sump breather needs to be piped outside the enclosure to avoid back
pressure into the compression module.
When the ambient conditions other than the design levels listed above are encountered, contact the Supplier
for additional information.
If necessary, the plant components must be preserved by suitable devices from pulsations of compressed
air and transmitted vibrations.
The units can be installed on any level floor with sufficient payload. A dry, well-ventilated area where the
atmosphere is as clean as possible is recommended.
Sufficient space all round and above the compressor must be allowed, to enable the effective removal of
the cooling air, which, in turn, will reduce the risk of re–circulating the cooling air back through the
compressor.
NOTE:
Hard surfaces may reflect noise with an apparent increase in the decibel level. When sound transmission
is important, a sheet of rubber or cork can be installed beneath the machine to reduce noise. It is
recommended that provision be made for lifting heavy components during major overhaul.
NOTE:
For any doubt, explanations and/or support concerning installation contact Sinergia Srl.
The Customer must provide for removal of some risks at the installation site:
Blast:
it is important to install the skids far from components/systems at risk of explosion, which could
compromise both machineries and personnel.
Fire:
it is important to install the skids far from components/systems at risk of fire, which could
compromise both machineries and personnel, and have a suitable fire prevention system.
NOTE:
Note that, in case of fire, fire extinguishers suitable for devices under tension have to be used.
Do not use extinguishers intended for Class A or Class B fires on electrical fires. Use only extinguishers
suitable for class BC or class ABC fires.
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INSTALLATION
Accidental impacts:
the units are not protected against accidental impacts, which could induce relevant damages.
Consequently, it is fundamental to safeguard them against moving means, which could operate at
the installation site, nearby the machinery, as for instance:
o trucks;
o fork lifts;
o cranes;
o etc…
NOTE:
Sinergia declines any responsibility for damages due to blast, fire or accidental impacts.
11.3Mechanical installation
WARNING!
Prescriptions for correct installation!
If more than one compressor is connected to one common downstream plant,
effective isolation valves must be fitted and controlled by work procedures, so
that one machine cannot accidentally be pressurized / over pressurized by
another.
Screw type compressors should not be installed in air systems with reciprocating
compressors without means of isolation such as a common receiver tank. It is
recommended that both types of compressor be piped to a common receiver
using individual air lines. Do not use a receiver tank or similar vessels that fail to
meet the design requirements of the compressor.
Installation must be in accordance with recognized electrical codes and any
local Health and Safety Codes.
The use of plastic bowls on line filters and other plastic air line components of the
compressing units without metal guards can be hazardous. From a safety stand-
point, metal bowl should be used on any pressurized system.
11.3.1 Foundation
The machines must be positioned securely and on a stable foundations. Any risk of movement should be
removed by suitable means, especially to avoid strain on any rigid discharge piping.
The foundations are at Customer’s charge. Sinergia provides the foundation detail drawing with all the
necessary indications for design and construction, namely the operating loads, the location of the anchor
points and the fixing systems, as shown in the following figures. The compressors and the dryer skids must
be anchored by the prescribed anchor bolts, as shown in Figure 11.3.
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.
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INSTALLATION
Figure 11.3: Fixing system of the compressors (left) and drying skids (right).
leveling of the skid. This step is critical and of fundamental importance. It must be performed by
qualified personnel using a machinist level, an industrial laser or an optical level located on the top
frame of the baseplates;
WARNING!
To prevent entry of dust, debris or water during assembling/connecting activities, maintain sealed the
plugs/enclosures installed prior the transport to cover all flanged and threaded openings, instrument
and electrical devices.
It is fundamental to ensure removing of plugs only at the realization of each connection. The original
plugs should be stored for potential future use.
Furthermore, prior to the installations/connections ensure that nothing is included into the connecting
piping.
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The installation must follow the installation layout (APPENDIX C), the P&IDs (APPENDIX A) and the general
arrangements (APPENDIX B).
NOTE:
All the interconnecting piping between the skids and the cooler are at Customer’s charge.
WARNING!
Compressor reciprocal damages due to incorrect installation!
Since more than one compressor is connected to the common downstream plant,
effective check valves and isolation valves must be fitted and controlled by work
procedures, so that one machine cannot accidently be pressurized / over pressurized
by another.
o condensate drain outlet (TP-105), located at the base of the compressor, to open drain, which
is at Client’s charge;
WARNING!
Compressor damage due to incorrect drain!
The drain line must slope downward from the base to work properly. Improper
condensate drain piping could cause compressor damage.
Condensate drain lines CANNOT be piped together in a common header.
o cooling water inlet (TP-103) and outlet (TP-104) piping to water supply and discharge
respectively.
Carefully inspect the water system before installing the compressor package. Ensure that the
piping is free of scale and deposits that may restrict water flow to the compressing package.
Proper operation of the compressor requires that a maximum water flow of 91 lpm is provided at a
0
maximum supply temperature of 38 C.
Water temperature and pressure gauges should be installed in the water piping for use in any
fault finding of the water system.
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INSTALLATION
Corrosivity (Hardness, pH, Total dissolved solids, Temperature at inlet and Alkalinity should be
analyzed monthly, or if stable for 3 to 4 months, analyzed quarterly. Acceptable concentration:
Langelier Index 0 to 1
Iron content should be analyzed monthly. Acceptable concentration: 2 mg/l (2 ppm)
Sulphate content should be analyzed monthly. Acceptable concentration: 50 mg/l (50 ppm)
Chloride content should be analyzed monthly. Acceptable concentration: 50 mg/l (50 ppm)
Nitrate content should be analyzed monthly. Acceptable concentration: 2 mg/l (2 ppm)
Silica content should be analyzed monthly. Acceptable concentration: 100 mg/l (100 ppm)
Dissolved Oxygen content should be analyzed daily, or if stable, analyzed weekly. Acceptable
concentration: 0 mg/l (0 ppm) (as low as possible)
Oil and Grease content should be analyzed monthly. Acceptable concentration: 5 mg/l (5 ppm)
Ammonia content should be analyzed monthly. Acceptable concentration: 1 mg/l (1 ppm)
11.4Electrical installation
DANGER!
Presence of electrical supply!
Electrical connections must be performed by qualified personnel and under the direct
responsibility of the Customer. Incorrect installation can cause material damages
and/or personnel injuries.
Risk of electrical shock.
Keep all parts of the body and any hand–held tools or other conductive objects,
away from exposed live parts of the compressor electrical system.
For details about the control system configuration and wiring see the following documents:
Control system configuration (APPENDIX J);
Logic control diagrams with tripping logic diagrams (APPENDIX K);
Wiring and schematic diagrams with fixing and installation detail for local control station (APPENDIX
L).
Table 11.1: Electrical data of the compressing units.
ELECTRICAL DATA
Adsorbed power kW 78
Number of poles - 2
Number of poles - 4
Current A 1.3
Current A 1.3
Current A 128
Current 3.3
Furthermore, earth cable (yellow-green cable) must be connected to the specific ground lugs, whose
location is indicated by the corresponding symbols in the particular drawings and on the equipment.
WARNING!
Danger due to ground connection!
Use indicated terminals for ground connections.
Lack of earth connection can cause material damages and/or personnel injuries.
NOTE:
Sinergia does not supply cable glands for Customer side.
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INSTALLATION
NOTE:
Sinergia declines any responsibility for damages due to incorrect installation.
Operation & Maintenance Manual 109
COMPLETION ACTIVITIES
12 COMPLETION ACTIVITIES
Pre-commissioning and commissioning include various tasks, which can be always attributed to activities of
quality control and coordination during different phases:
design;
work management;
delivery of the machinery.
These phases are planned by the Manufacturer, following a detailed procedure defined and agreed with the
Client.
In this framework, attention is focused on the last phase, which is carried out on site. In the following, main
aspects are reported.
12.1 Pre-commissioning
The main aim of the pre-commissioning phase is to guarantee the correct and adequate operation of all the
plant components, in compliance with the design.
NOTE:
Plant pre-commissioning must be performed by specialized staff, either technicians of Sinergia or third
parties authorized by it, otherwise, Sinergia’s warranty decays.
The pre-commissioning phase includes three main activities on site: conformity checks, static/de-energized
tests and piping test, as specified in the following.
\\
Conformity checks:
The skids must be totally checked to verify the conformity to contract and design specifications, by:
visual check of each package component to visually verify condition, installation quality,
compliance with technical drawings and design specifications, Sinergia’s instructions, safety rules,
codes, standards and good practice;
preliminary tests with equipment de-energized, including di-electric strength tests, loops and
circuits continuity tests, earth resistance measurements, insulation resistance measurements;
check continuity of transmission and identification of indication, control and alarm signals of
instrumentation;
continuity and insulation test for instrument cables;
continuity and tightness test for pneumatic tubing;
check fixing of pipe anchors, guides, spring hangers and supports;
alleviate with suitable devices any excess stress that may be imposed on pipes, compressors or
pump flanges;
110 Operation & Maintenance Manual
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ensure that the position of the emergency stop device is known and recognized by its
markings.
Static/de-energized tests.
Equipment must be tested to ensure the goodness of critical components. This "cold" testing includes:
verify calibration certificates of instruments;
verify setting certificate of safety valves;
check lubricating oil level; add lubricant if necessary (See Section 17.1.4);
inspection and closure of all openings/connections;
verify the installation of the interception valve downstream the compressor;
before making any part or conductor electrically live, verify that electric motor/control wiring are not
exposed or saturated with moisture/water deposits; in this case dry off.
Once the pre-commissioning is performed, the “ready for commissioning” certificate must be issued.
12.2 Commissioning
The main aim of the commissioning phase is to guarantee that the assembled plant correctly runs, in
compliance with the project objectives and Client requirements.
The specific purposes are:
to confirm that all components are correctly installed and activated in compliance with the design;
to confirm the expected plant performance by a series of tests and measurements;
to guarantee security conditions for personnel who will operate with/on the machinery;
to verify the necessary documentation for operation and maintenance of the plant.
NOTE:
Plant commissioning must be performed by specialized staff, either technicians of Sinergia or third
parties authorized by it, otherwise, Sinergia’s warranty decays.
In order to transfer smoothly the plant from Sinergia to the Client, final operators in charge of any activity
on/with the machinery should assist the Commissioning team.
The commissioning phase includes three main activities on site: conformity checks, dynamic verifications
and running-in and on-line operational and functional tests, as specified in the following.
Dynamic verifications
Elementary electrical and communication plants, and instrumental functions must be tested to verify the
correct performance, in agreement with the design criteria.
check of correct power supply and test;
Operation & Maintenance Manual 111
COMPLETION ACTIVITIES
WARNING!
Wrong compressor rotation!
If the compressor is operated in the opposite direction of rotation, airend damage may
result and is not warrantable.
This phase must follow the “ready for commissioning” certificate issue.
From a practical point of view, the preliminary checks before the start-up and the activities required for
pressurization are the same required in the phase of start-up, described in the following section.
Operation & Maintenance Manual 113
START-UP
13 START-UP
Start-up phase is planned by the Manufacturer, following a detailed procedure defined and agreed with the
Client. In the following, main aspects are reported.
This phase must follow the “ready for start-up” certificate issue.
NOTE:
Plant start-up must be performed by specialized staff, either technicians of Sinergia or third parties
authorized by it, otherwise, Sinergia’s warranty decays.
Initial compressor starting should be performed by an Ingersoll–Rand Qualified Service Technician.
In order to transfer smoothly the plant from Sinergia to the Client, final operators in charge of any activity
on/with the machinery should assist the Commissioning team.
13.1Document compilation
During Start-up, staff must note relevant aspects useful for the definition of the first start-up sequence and
procedure.
At the end of the start-up sequence, Start-up staff must issuance:
certificate of ready for operation;
punch list updated and closed.
Previous documents will be included in the start-up dossier.
regulation system, the unloader valve, the safety valve of the compressing units will be compromised.
Modifications are required for low ambient modifications; to this aim contact the Vendor.
Before the startup, the cooling water system must be vented as follows.
Open the vent cock and allow all air to escape from the system.
When water is observed at the vent cock, close it. The system is now properly vented.
Dryers:
upstream and downstream intercepting valves of the dryers (if installed by the Client) are closed;
purge valve is open;
drain valves are in correct position (pre- filters: intercepting open, bypass closed; post-filter:
closed);
manual intercepting valves of filters are open.
Compressing units:
WARNING!
Ensure that all protective covers/guards are in place before attempting to start the
machine.
check lubricating oil level; add lubricant if necessary (See Section 17.1.4).
Operation & Maintenance Manual 115
START-UP
Specific activities required to prepare pressurization and to bring the plant in operation must be performed:
establish the list of available equipment;
perform audit and technical reviews required for the issuance of the ’’ready for pressurization’’
certificate;
check that all punch list items are clarified and treated accordingly. Verify that the punch list is
updated and closed;
ensure safety equipment and critical utilities availability and reliability;
ensure that there is a safe working procedure which has been issued by supervisory personnel, and
that it is understood by all persons concerned with the operation of the plant;
ensure that the safety procedure to be applied is based on the appropriate national regulations;
ensure that the safety procedure is followed at all times;
carry out the final safety tests (Distributed Control System (DCS), Fire and Gas (F&G), deluge,
etc…);
replace the following components, as detailed in the ”Spare part list for commissioning and start-
up” in APPENDIX O:
o compressing skids:
- filtering elements of air filtering system;
- oil filters;
- lubricating oil;
o drying skids:
- filtering cartridge of pre-/post-filters;
issuance of the “ready for pressurization’’ document.
Once the “ready for pressurization’’ activities have been performed, pressurization, turn on and tests can
be performed.
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Each train can be started locally (from local control panels of compressors and dryers) or from remote
control, depending on the selected modality on the control panels.
DANGER!
Potential discharge of pressurized air!
Air under pressure could be discharged both from the compressing and drying
skids; particles included in the air could be violently ejected causing severe
injuries to eyes and/or skin! Avoid contact.
Plant operation generates a strong and sudden noise which could cause
damages to the auditory apparatus;
In emergency case, the safety valves could discharge air under pressure.
Do not point air nozzles or sprayers toward anyone.
Potential discharge of pressurized oil!
Lubricant could leak from the oil circuit.
Potential discharge of pressurized water!
Pressurized water squirts could be discharged from the cooling circuit causing
injuries to eyes and/or skin!
Risk of burn!
NEVER touch surfaces of the compressing units subjected to excessively high
o
temperatures, which can reach temperatures higher than 60 C.
Risk of electrical shock!
Presence of electrical supply.
Keep all parts of the body and any hand–held tools or other conductive
objects, away from exposed live parts of the compressor electrical system.
Risk of sliding!
Potential leakages of lubricant) or water (condensation or cooling circuit) could cause
sliding.
Never start-up the compressing units without all protective covers in place and
canopy/doors closed.
Obey safety precaution. Personnel in charge of start-up must be equipped with the
necessary Personal Protective Equipment (PPE), namely safeguard shoes, gloves
eye and hearing protections and instructed on their use in accordance with workplace
safety legislation. In-observance could cause personnel injuries.
The starting sequence of the compressors and the dryers is illustrated in in the Sections 5.1.9 and 5.2.3
respectively. In order to turn on one entire train follow the next steps:
Operation & Maintenance Manual 117
START-UP
switch on the main electrical isolation switch. The power on indicators on the panels will
illuminate, indicating that the line and control voltages are available;
set the required parameters and the operation modality on the control panels of the
compressors (as described in Section 5.1.7). Pay attention to select the same setting parameters
on both the panels. Enable the automatic lead/lag sequencer and, optionally the hardware control.
set the required parameters and the operation modality on the control panels of the dryers
(as described in Section 5.2.2). Pay attention to select the same setting parameters of both the
panels. Set the same time for the switch of the dryers.
verify that the compressors are ready to start: the writing appears on the bottom bar on the
HMI;
start both the compressors, one after the other (see Section5.1.9). Compressors will start and
load automatically if there is sufficient demand for air, otherwise they will run in unload condition.
keep closed the outlet valves, which intercepts the dryers downstream (if installed by the Client);
starts both the dryers, one after the other, as follows. Automatically one dryer will operate while
the other one will stay in stand-by.
slowly open the inlet valve, which intercepts the dryer upstream (if installed by the Client);
DANGER!
Danger due to rapid build-up of opressure!
Slowly open the compressed air inlet valve; a rapid build-up of pressure can cause dryer
damages, in particular life reduction of the molecular sieves. Furthermore, discharge of
pressure can cause severe personnel injuries.
To integrate the train in the external air system, after the previous steps, the following instructions must be
executed:
118 Operation & Maintenance Manual
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WARNING!
Danger due to abrupt drop in pressure!
Slowly open the compressed air outlet valve; a rapid drop in pressure can cause dryer
damages.
13.8Tests
Once the process is in operation, performance tests must be carried out on plant and equipment.
Finally, product design specification conformity must be proved.
Operation & Maintenance Manual 119
MONITORING
14 MONITORING
DANGER!
Potential discharge of pressurized air!
Air under pressure could be discharged both from the compressing and drying
skids; particles included in the air could be violently ejected causing severe
injuries to eyes and/or skin!
Plant operation generates a strong and sudden noise which could cause
damages to the auditory apparatus;
In emergency case, the safety valves installed on the condensate separators
could discharge air under pressure. Although the discharges are above the eye
level, attention must be paid.
Potential discharge of pressurized oil!
Lubricant could leak from the oil circuit.
Potential discharge of pressurized water!
Pressurized water squirts could be discharged from the cooling circuit causing
injuries to eyes and/or skin!
Risk of burn!
NEVER touch surfaces of the compressing units subjected to excessively high
o
temperatures, which can reach temperatures higher than 60 C.
Risk of electrical shock!
Presence of electrical supply.
Keep all parts of the body and any hand–held tools or other conductive
objects, away from exposed live parts of the compressor electrical system.
Risk of sliding!
Potential leakages of lubricant oil or water (condensation or cooling circuit) could
cause sliding
Make sure that all protective covers are in place and that while the compressing
module is left unattended (in operation or not) the canopy/access doors of the
protective canopy are closed and locked.
Obey safety precaution. All persons positioned near to operating machinery must be
equipped with the necessary Personal Protective Equipment (PPE), namely
safeguard shoes, gloves eye and hearing protections and instructed on their use in
accordance with workplace safety legislation. In-observance can cause personnel
injuries.
120 Operation & Maintenance Manual
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NOTE:
Ensure that the machines are operating at the rated pressure
Operation & Maintenance Manual 121
ANOMALIES AND TROUBLESHOOTING
DANGER!
Potential discharge of pressurized air!
Air under pressure could be discharged both from the compressing and drying
skids; particles included in the air could be violently ejected causing severe
injuries to eyes and/or skin! Avoid contact.
Plant operation generates a strong and sudden noise which could cause
damages to the auditory apparatus;
In emergency case, the safety valves could discharge air under pressure.
Do not point air nozzles or sprayers toward anyone.
Potential discharge of pressurized oil!
Lubricant could leak from the oil circuit.
Potential discharge of pressurized water!
Pressurized water squirts could be discharged from the cooling circuit causing
injuries to eyes and/or skin!
Risk of burn!
NEVER touch surfaces of the compressing units subjected to excessively high
o
temperatures, which can reach temperatures higher than 60 C.
Risk of electrical shock!
Presence of electrical supply.
Keep all parts of the body and any hand–held tools or other conductive
objects, away from exposed live parts of the compressor electrical system.
Risk of sliding!
Potential leakages of lubricant) or water (condensation or cooling circuit) could cause
sliding.
Never start-up the compressing units without all protective covers in place and
canopy/doors closed.
Obey safety precaution. Personnel in charge of start-up must be equipped with the
necessary Personal Protective Equipment (PPE), namely safeguard shoes, gloves
eye and hearing protections and instructed on their use in accordance with workplace
safety legislation. In-observance could cause personnel injuries.
122 Operation & Maintenance Manual
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The necessity to shut down the plant can occur in different cases:
maintenance;
emergency or breakdown;
disassembly.
Attention must be paid to the sequence of the required steps to avoid the unit damage and to preserve the
machinery efficiency.
Depending on the reason of shutdown, different procedures may be necessary:
stop of the process without complete depressurization;
complete depressurization.
Complete depressurization is strictly prescribed in case of disassembly and some maintenance activity (see
Section17).
NOTE:
To assure the proper valve positioning, the supply of compressed air to instruments (pilot air) must
NOT be removed prior to shut down the train.
intercept the dryers closing the manual valves downstream the post-filters, or the dryer
intercepting valves (if installed by the Client);
stop the dryers (see Section 5.2.3); note that all the actuated valves close, except at least one
inlet valve.
shut down the upstream compressors (see Section 5.1.9.2); automatically the compressors
depressurize upstream the discharge check valve CV-002 installed upstream the aftercooler. Allow
enough time for the automatic blowdown valve to complete the vent;
maintain open the manual valves installed downstream the pre-filters in order to ensure the
depressurization of the discharging line of the compressor, downstream the discharge check valve
CV-002.
NOTE:
Sinergia declines any responsibility for damages due to incorrect shutdown procedure.
15.1Subsequent starts
Table 16.1- Table 16.7 list the main anomalies, which could occur during the compressing and drying train
operation. Related potential causes and troubleshooting are also reported.
Concerning the components which were provided by external suppliers, for further details consults the
associated handbooks in the appendixes.
Table 16.1: Main potential anomalies of compressing skids.
Display panel and power on light does Check wiring. Verify 24VDC is within voltage
not highlight tolerance
shuts down
Manually reset motor overload relay, and press reset
button.
($) Auxiliary oil pump failure See the associated manual in APPENDIX R
Auxiliary oil pump Fault of the pump driven motor See the associated manual in APPENDIX R
does not operate when
required
Compressor operating over pressure - Check and adjust controller set points
Pressure relief valve
opens Defective valve Replace valve
Operation & Maintenance Manual 129
ANOMALIES AND TROUBLESHOOTING
Too low outlet air flow rate Too low flow rate supplied by operating Check compressor operation
compressor/s Repair to increase inlet flow rate
Dew point deterioration Inlet air temperature higher than - Excessive increase of temperature due
design conditions to compressor operation:
Check compressor operation
Repair to reduce air temperature
Drain from upstream filter does not - Incorrect operation of actuated drain
run correctly valves; check, replace or reactivate
- See (*) in
- Table 16.7
Operation & Maintenance Manual 131
ANOMALIES AND TROUBLESHOOTING
(*) Lack or not sufficient pilot air supply Check supply of pilot air; restore the
Faulty Actuated valve minimum pressure of 5 bar(g)
Display panel showing ### Communication error between panel Check cable connections between HMI and
instead of process value and PLC PLC
DANGER!
Danger due to incorrect activities!
Machinery maintenance must be performed by qualified and authorized technicians.
Attempt repairs only in clean, dry, well lighted and ventilated areas.
Danger due to rotating machineries!
NEVER perform maintenance activity on working machineries.
NEVER remove protective guards while the machinery is operating.
Potential discharge of pressurized air!
NEVER perform maintenance activity on pressurized components as long as the units
are pressurized; discharge of pressurized air, oil or water could cause severe
injuries. Avoid contact.
NEVER open any drain valve or remove components without first ensuring that the
compressor is FULLY SHUT– DOWN, power isolated and all air pressure relieved
from the system.
Air under pressure could be discharged both from the compressing and drying skids;
particles included in the air could be violently ejected causing severe injuries to eyes
and/or skin!
Plant operation generates a strong and sudden noise which could cause damages to
the auditory apparatus;
In emergency case, the safety valves could discharge air under pressure.
Do not point air nozzles or sprayers toward anyone.
Potential discharge of pressurized oil!
Lubricant could leak from the oil circuit.
Potential discharge of pressurized water!
Pressurized water squirts could be discharged from the cooling circuit causing injuries to
eyes and/or skin!
Risk of burn!
External surfaces are subjected to high temperatures (>60 C). NEVER perform
o
NEVER leave tools or other object (such as cleaning rags) on the units; potential
falls could cause damages of other components and/or personnel injuries.
Make sure that all protective covers are in place and that while the compressing
module is left unattended (in operation or not) the canopy/access doors of the
protective canopy are closed and locked.
It is recommended a preventive maintenance activity of the plant in order to ensure efficient operation and
high performance for a elevate number of years. The following sections illustrate the main maintenance
activity prescribed for the compressors and the dryers. Maintenance of the equipment installed on the skids
must be performed in agreement with the relative manuals (see, APPENDIX R).
The list of the spare parts prescribed by the Vendor are attached in APPENDIX O and APPENDIX P.
NOTE:
Use of spare parts in compliance with the Manufacturer requirements and guidelines is recommended.
Original spare-parts guarantee these aspects; non-original parts could damage or cause not correct
operation of the plant.
WARNING!
Danger due to incorrect activities!
Once required maintenance activity is performed, prior to put again the plant into
service, ensure that:
the skids are suitably tested;
all removed guards and safety devices are restored;
the compressor canopy is replaced and the doors are closed;
hazardous materials are effectively contained and disposed of.
17.1Compressing units
Disconnect the inlet and discharge water lines from the connections located at the rear of the unit.
Locate the oil cooler by removing the left and center rear panels. Remove the two drain plugs
located at the end of the cooler.
136 Operation & Maintenance Manual
Pulse air system
To remain efficient the compressor components require a routine maintenance, as scheduled in Table 17.1
Operation & Maintenance Manual 137
MAINTENANCE AND REPAIRS
Table 17.1: Maintenance schedule for 4-year operation prescribed by Sinergia for the main components of
the compressing skids.
COMPRESSING UNIT
Maintenance schedule
DAILY
FIRST 150 HOURS
1 MONTH
3 MONTHS
2000 HOURS
4000 HOURS
6 MOUNTS
8000 HOURS
1 YEAR
16000 HOURS
4 YEARS
40000 HOURS
Assembled components Kind of maintenance
CONDENSATE SOLENOID
Rebuild using field kits. *
VALVES
Clean
GEARCASE BREATHER *
(every 4000 hours or 6 months).
*: checks; X: replacements
138 Operation & Maintenance Manual
Pulse air system
COMPRESSING UNIT
Maintenance schedule
DAILY
FIRST 150 HOURS
1 MONTH
3 MONTHS
2000 HOURS
4000 HOURS
6 MOUNTS
8000 HOURS
1 YEAR
16000 HOURS
4 YEARS
40000 HOURS
Assembled components Kind of maintenance
Replace:
- seals (kit seal);
- motor coupling; X
PRE-LUBE PUMP - flexible insert;
- pump coupling;
Gears X
Replace X
HYDRAULIC CYLINDER
Replace kit, retrofit valve, blowdown X
- Clean
* *
CONDENSATE STRAINER - Change the lubricating oil and filter
X X
element.
Operation & Maintenance Manual 139
MAINTENANCE AND REPAIRS
COMPRESSING UNIT
Maintenance schedule
DAILY
FIRST 150 HOURS
1 MONTH
3 MONTHS
2000 HOURS
4000 HOURS
6 MOUNTS
8000 HOURS
1 YEAR
16000 HOURS
4 YEARS
40000 HOURS
Assembled components Kind of maintenance
gasket
X
UNLOAD LINE
Element foam
X
Element metallic
Replace two ways valve
COOLING SYSTEM X
In the following sections, prescribed main maintenance activities on the compressing skids are reported.
Regarding the components supplied by external providers, refers to the associated ,manuals.
Remove the dirty filter. Clean all interior surfaces of the filter box as required. Install new filter element(s).
Replace cover and tighten wingnut. Reinstall enclosure panel. Start machine and run in load mode to verify
filter condition.
Parts required: two air filer elements.
Remove the main motor utilising appropriate lifting gear as recommended and following established
safe working practices.
Apply Loctite 620 to the sleeve and shaft journal. Install the sleeve ensuring that the face of the
sleeve is 4mm from the shoulder on the shaft. Wipe excess Loctite.
Apply Loctite 524 to the seal outer diameter and install into the seal housing with lip facing towards
the compressor.
Using the seal installation tool, slide the seal housing into place on the bearing housing, being
careful not to tilt the housing and seal. Apply axial pressure to the end of the installation tool while
the seal leaves the tool and enters the wear sleeve. The seal will slip between the tool and the
sleeve if pressure is not applied.
Apply Loctite 242 to the 4 seal housing bolt threads and tighten.
Refit the coupling flush with the end of the input shaft. Apply Loctite 242 to the grub screws and
tighten.
When refitting the motor, ensure that there is a 4mm gap between the two coupling half faces. If
necessary, loosen the grub screws and slide the motor coupling forwards or backwards to achieve
this (Loctite and retighten the grub screws).
Allow 24 hours for all Loctite applications to cure before restarting the machine.
17.1.11Motor bearing greasing
To grease the motor bearings follow the next steps:
Clean the area around the inlet and outlet plugs before removing the plugs.
Add the specified quantity of recommended grease using a hand lever gun.
Replace the inlet plug.
Run the machine for 10 minutes.
Replace the outlet plug.
NOTE:
Use High Temperature Grease UNIREX N 6 (CPN:92844729) grease (for cartridge of 400 g) or
equivalent.
WARNING!
Do not over pack the motor bearings with grease as this may lead to motor failure.
Ensure dirt and/or other contaminants are not introduced into the bearing during the
greasing process.
Disconnect the inlet and discharge water lines from the connections located at the rear of the unit.
Locate the oil cooler by removing the left and center rear panels. Remove the two drain plugs
located at the end of the cooler.
Operation & Maintenance Manual 143
MAINTENANCE AND REPAIRS
17.2Drying units
To remain efficient the dryer components require a routine maintenance, as scheduled in Table 17.4.
Table 17.4: Maintenance schedule for 2-years operation prescribed by Sinergia for the main components of
the dryers.
DRYER
Maintenance schedule
DAILY
WEEKLY
6 MONTHS
1 YEAR
2 YEAR
Assembled components Kind of maintenance
SPIRAL GASKETS
- #150 2" (dryer inlet and outlet valves, pre- Replacement X
and post-filter valves)
- #150 1" (dryer exhaust valves)
*: checks; X: replacements
144 Operation & Maintenance Manual
Pulse air system
DRYER
Maintenance schedule
DAILY
WEEKLY
6 MONTHS
1 YEAR
2 YEAR
Assembled components Kind of maintenance
SOLENOID VALVES
- Nabur bistable ¼” (dryer inlet and outlet) Replacement X
- Nabur monostable ¼” (dryer exhaust and
filter inlet)
Check *
MOLECULAR SIEVE
Replacement X
*: checks; X: replacements
In the following sections, main maintenance procedures on the dryers are reported. Regarding the
components supplied by external providers, refers to the associated ,manuals.
WARNING!
Danger due incorrect behaviour!
To reach the filling nozzle at columns top fix the safety harness to eyebolt lifting
located at columns top.
NEVER use pipes or valves as climbing support or holding points; there is the
risk of injuries due to slipping components, components breaks, damages of the
unit due to applied stresses and/or discharge of compress air.
Whenever it is necessary to use a rung ladder or a gangway, ensure that they are
appropriate to allow the operator to work in safe conditions.
In addition to PPE mentioned in Section 17, wear an anti-dust mask to handle the
molecular sieves.
WARNING!
Risk of sliding!
If the molecular sieve has been spilled on the floor, there is the risk of sliding on the agent
beads. Clean promptly the floor.
carefully clean the base of the vessel from impurities and/or incrustations, draw using an
industrial vacuum cleaner;
ensure that the emptying nozzle at the bottom of the column is closed;
slowly discharge the desiccant material in the vessel to prevent chipping and generate dust
resulting in premature clogging of the filters;
146 Operation & Maintenance Manual
Pulse air system
fill the desiccant material in layers. If necessary, use a proper funnel and a small rod to distribute
the desiccant by through the opening of the vessel.
NOTE:
It is important to insert slowly the desiccant material to prevent chipping and generate dust resulting in
premature clogging of the filters.
Ensure a high bulk density inside the vessel. To this purpose, during the filling, beat regularly with a
rubber hammer on the exterior wall of the tank or use a vibrator applied to the vessel; these methods help
the material compaction. The desiccant material must fill completely the columns and must never be
pressed with any mechanical equipment.
stop the dryer in which the filter which requires maintenance is included;
intercept the filter closing the inlet manual valve;
depressurize the filter casing opening the bypass drain valve for the pre-filters or the drain valve
for the post filters;
Operation & Maintenance Manual 147
MAINTENANCE AND REPAIRS
close the filter screwing the closing blind flange; change the gasket if damaged;
verify that the pointer of the differential pressure gauge is on 0 position;
dispose the cartridge as indicated in Section 18
open the inlet manual valve;
restart the dryer.
The procedure is the same also for the post-filters. Note that it is possible to intercept each post- filtering line
and not each single post-filter.
WARNING!
Danger due to obstructed silencer
Obstruction of silencer may generate the build-up of dangerous overpressure, with
consequent burst of the silencer. Fragments ejection may cause personnel injury and
material damage.
Dryer Manufacturer prescribes a daily check and a replacement of the silencer every six mounts. However,
replacement is always required in case of excessive pressure in the columns during regeneration.
The procedure for silencer replacement comprises:
DANGER!
Danger due to presence of electrical supply!
Risk of electrical shock!
Cables of electrical supply and of external lines are under power also after the train
shutdown. Before to start any activity on the electrical system, ensure that electrical
supply cables and external lines are voltage-free. Furthermore, ensure that electrical
supply cable to the skid components are secured against switch-on.
shutdown and depressurize the train under review (see Section 15);
make the electrical supply cables to the machineries voltage-free;
secure the electrical supply cable against switch on during checks;
check wirings and control panels for visible damage and corrosion.
Operation & Maintenance Manual 150
MATERIAL DISPOSAL
18 MATERIALS DISPOSAL
Sinergia is actively engaged in environmental protection in agreement with ISO 14001 standards, and it
always designs, manufactures and develops all its products as recyclable as possible.
Recycling is a source of wealth, which contributes to pollution reduction by the recovery of materials for
reuse.
Recycling prevents the waste of potentially useful materials and reduces the consumption of both raw
materials and energy, consequently the emission of greenhouse gases.
In case of disposal of the machineries of the plant to which the present manual is associated, or of some of
their components, refer to the drawing/manuals for the constitutive material identification and classification in
recyclable or not. For detailed information of constituting materials of the components which were provided
by external suppliers, consults the associated handbooks in the APPENDIX R.
Concerning the lubricant oil and the desiccant material disposal, see the associated safety datasheet in
APPENDIX D and APPENDIX E respectively.
Materials can be disposed in agreement with the European Waste Catalogue (EWC) prescribed by the
European legislation (Decision 2000/532/EC). For countries outside the EU, please check the applicable
legislation.
When the units are to be permanently decommissioned or dismantled, it is important to ensure that all
hazard risks are either eliminated or notified to the recipient of the machine. In particular:
do not destroy batteries or components containing asbestos without containing the materials
safely;
do not dispose of any pressure vessel that is not clearly marked with its relevant data plate
information or rendered unusable by drilling, cutting etc;
do not allow lubricants or coolants to be released into land surfaces or drains;
do not dispose of a complete machine without documentation relating to instructions for its use;
Concerning condensate disposal, as waste water regulations vary by country and region it is the
responsibility of the user to establish the limitations and regulations in their particular area. Ingersoll–Rand
and its associated distributors are happy to advise and assist in these matters.
Operation & Maintenance Manual 151
APPENDIXES
19 APPENDIXES
For brevity, the following appendixes are reported in the attached CD.
Operation & Maintenance Manual I
APPENDIXES
APPENDIX L: Wiring and schematic diagrams with fixing and installation detail for
local control station
Operation & Maintenance Manual XIII
MAINTENANCE AND REPAIRS
Sinergia Srl
Onore . Bg . Italy
Ph +39 034673515
www.sinergia-it.com