KR-301 Control

OWNER
EIL JOB No.: 6987

ONGC PETRO Compressor control description EIL /OWNER ID. CODE
additions LTD Supplier P.O.: 7500028454
(OPaL) EPCC2- GP-VD-004-8454-
3670- GP-MR-004 ZSG-301514
PMC Burckhardt Compression CONTRACTOR IDENTIFICATION. CODE
ENGINEERS Job-EC-T-N°
INDIA LIMITED 3670-GP-VD-004-8454-
ZSG-301514
CONTRACTOR
PROJECT: DAHEJ
LOCATION:
PETROCHEMICAL UNIT: PP UNIT
DAHEJ, INDIA
Sheet 1 of 16 REV 02
COMPLEX (340 KTPA)
BCA Supplier Off Gas

Project No. Document No. Compressor
2001189 TSP 2030374 Tag No. 33-KR-301
Compressor control description
CHECKED DATE
CHECKED DATE
INITIALS SIGNATURE
NO T ACCEPTED
NOT ACCEPTED
AC CEPTED ACCEPTED AS
AS NO TED NOTED
AC CEPTED ACCEPTED SMP 06.11.12
7(&1,0217¶6$&&(37$1&(2)7+,6
DOCUMENT DOES IN NO WAY RELIEVE THE
SUPPLIER OF HIS CONTRACTUAL
OBLIGATIONS. (TM 061)
02 Issue for approval PATEL_D KUENZLER_S KUENZLER_S 18.10.12

01 Issue for approval DESAI_S DHOTRE_D KUENZLER_S 10.11.11
Rev. Description Prepared Checked Approved Date
This document is Maire Tecnimont Group’s property and cannot be used by others for any purpose, without prior written consent
VOLUME 5 OF 7, PAGE NO. 4165 of 5762

OWNER
EIL JOB No.: 6987
ONGC PETRO Compressor control description EIL /OWNER ID. CODE
additions LTD Supplier P.O.: 7500028454
(OPaL) EPCC2- GP-VD-004-8454-
3670- GP-MR-004 ZSG-301514
PMC Burckhardt Compression CONTRACTOR IDENTIFICATION. CODE
ENGINEERS Job-EC-T-N°
INDIA LIMITED 3670-GP-VD-004-8454-
ZSG-301514
CONTRACTOR
PROJECT: DAHEJ
LOCATION:
PETROCHEMICAL UNIT: PP UNIT
DAHEJ, INDIA
Sheet 2 of 16 REV 02
COMPLEX (340 KTPA)
BCA Supplier Off Gas

Project No. Document No. Compressor
2001189 TSP 2030374 Tag No. 33-KR-301
S.No Document Description Page No

A Compressor control description 3
This document is Maire Tecnimont Group’s property and cannot be used by others for any purpose, without prior wr itten consent

Kennwort
OPAL DAHEJ-02
Compressor Control philosophy
Projektauftrag_Nr.
2001189
Starting and stopping procedure given below shall be read as a general description only. For
detailed description of the control philosophy and operation of the reference is made to the
logic and functional diagram.
The compressor is controlled by the DCS (distributed control system). The compressor is provided
with a LIB (local instrument board). The LIB permits to observe various measurements etc. The
compressor can be operated in operation mode or maintenance mode. Visualisation and control of
the compressor operation is normally done from CCR (client's control room)
Table of content:
1 GENERAL OPERATION ................................................................................................................................................ 2
2 PREPARATION OF COMPRESSOR UNIT BEFORE STARTING........................................................................... 2
3 STARTING AND OPERATION WITH PROCESS GAS IN "OPERATION (AUTO)" MODE .............................. 4
3.1 STARTING AND OPERATION OF THE COMPRESSOR IN “OPERATION(AUTO)”- MODE. ........................................... 4
4 LOCAL STARTING AND OPERATION OF COMPRESSOR IN "MAINTENANCE (MANUAL)" MODE ....... 6
4.1 STARTING AND OPERATION OF COMPRESSOR IN MAINTENANCE (MANUAL) MODE. ........................................... 7
5 CONTINUOUS OPERATION ......................................................................................................................................... 9
5.1 CAPACITY CONTROL DURING NORMAL OPERATION ................................................................................................ 9
5.2 CAPACITY CONTROL DURING OPERATION WITH NITROGEN. .................................................................................. 9
6 COMPRESSOR STOP.................................................................................................................................................... 10
6.1 NORMAL STOP IN: "OPERATION(AUTO)" OR "MAINTENANCE(MANUAL)" MODE ............................................... 10
6.2 AUTOMATIC STOP BASED ON TRIP (SHUT DOWN I-312-S) ...................................................................................... 11
6.3 EMERGENCY STOP (ESD) ........................................................................................................................................... 12
7 LUBE OIL SYSTEM ....................................................................................................................................................... 12
8 COOLING WATER SYSTEM....................................................................................................................................... 13
9 DISTANCE PIECE PURGE SYSTEM ......................................................................................................................... 14
Reference documents:
Dwg. No. 3670-GP-VD-004-8454-KDR-301517 Interconnection Drawing

Doc. No. 3670-GP-VD-004-8454-KDS-301513 Logic diagram
Doc. No. 3670-GP-VD-004-8454-KLK-301526 Alarm & Set point list
Dwg. No. 3670-GP-VD-004-8454-ZDM-301302A P & I diagram Gas system
Dwg. No. 3670-GP-VD-004-8454-ZDM-301302B P & I diagram Capacity control
Dwg. No. 3670-GP-VD-004-8454-ZDM-301302C P & I diagram Lube oil system
Dwg. No. 3670-GP-VD-004-8454-ZDM-301302B P & I diagram Cooling water system
Dwg. No. 3670-GP-VD-004-8454-ZGB-301101 GA Gas system
Rev. Index A
erstellt / prepared 24.09.2012 KUENZLER_S
2030374
überprüft / reviewed 25.09.2012 REGEZ_R Seite 1
genehmigt / approved 25.09.2012 KUENZLER_S von 14

Kennwort
OPAL DAHEJ-02
Projektauftrag_Nr.
2001189
1 General operation
The compressor 4D300B-3W_1 described below is situated in a Propylene plant in Dahej, Gujarat
2 2
in India. It is used to compress propylene from a pressure of 1.24 kg/cm a and 1.53 kg/cm a to a
2
discharge pressure of 26.6 kg/cm a. The suction temperature is 59°C. Before and after the first
stage and after the second stage the gas is cooled. The capacity is regulated by valve unloaders
in steps of 100%, 50% and 0%, and by an overall bypass.
2 PREPARATION OF COMPRESSOR UNIT BEFORE STARTING

Before the compressor is allowed to run the following checks and start conditions have to be
fulfilled:
2.1 Check that the cooling water system is in operation (normal and closed cooling water
system).
2.2 Check the oil level in the crankcase (should be approximately in the middle of oil sight
glass).
2.3 Check that the lube oil system is ready for operation and the manual valves are in the
correct position, especially for lineup of the prelube oil pump.
2.4 Check that the pure propylene is available for purging the compressor distance piece.
2.5 Check that nitrogen is available for motor purge (if applicable) and valve control
2.6 The main drive motor can be started only after the pre-lube oil pump has successfully been
running for 2 minutes for prelubrication. This must be considered when the compressor will
be started.
2.7 Check that all manual valves are set to the right position acc. to the relevant operating case.
2.8 The compressor is provided with several safety instruments which check if the respective
operating parameters are within the acceptable limits. Below is the table giving the start-
interlocks of the compressor, that must be considered while starting the compressor –
Interlock table – (Interlock I-302-O)

-A
Switch Tag No. Compressor will not be allowed to start if -
PAL-30203 the suction pressure is lower than the setpoint (*)
PAH-30203 the suction pressure is higher than the setpoint (*)
LAH-30216 the level of liquid collected in the 1st stage suction separator is
higher than the set point (*), indicating requirement of drain
LAH-30217 the level of liquid collected in the 2nd stage suction separator is
rd
LAH-30220 the level of liquid collected in the 3 stage suction separator is
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Kennwort
OPAL DAHEJ-02
Projektauftrag_Nr.
2001189
ZI-30203 Overall By-Pass Valve PV 30203 is not in fully open position

st
ZI-30204 By-Pass Valve over 1 Stage PV 30204 is not in fully closed
position
PDAL-30268 the differential pressure across the compressor oil skid inlet and
outlet is lower than the set point (*), indicating lower oil flow
TAL-30261 the oil temperature at the inlet of the compressor is lower than
the set point (*), indicating requirement to heat up the oil by
activating the pre lube oil pump 33-PG-303
LAL-30222 the level of lube oil in the compressor crank case is lower than
the set point (*), indicating requirement of fresh filling in the
system.
ZAL-30250 the cover on the flywheel & the coupling guard is open.
TAL-30268 the temperature of coolant at the outlet of the Cylinders is lower

than the set point(*), indicating requirement of initial heat up
running to avoid condensation of gas in the cylinders.
FAL-30270 the flow of the coolant through the cooling circuit is lower than
the set point (*)
LAL-30252 the level of coolant in the expansion vessel is lower than the set
point (*), indicating requirement of fresh filling in the system.
HEAT TRACING The heat tracing for the propylene purge line, separators etc. is
not “ON”
SHUTDOWN Compressor shut down push button is pressed or Process trip or

Emergency shutdown is activated.
(*) For the set points of the individual instruments refer the ‚‘Instrument List‘ No. 3670-GP-
VD-004_8454_KLS_301505.
Important remarks
The mode- selector in LOP shall only be set to another position during compressor standstill.
The mode could be either “Operation(Auto)” or “Maintenance(Manual)”. In the
“Operation (Auto)” mode the compressor could be operated with process gas. In
“Maintenance (Manual)” mode the compressor could be operated locally from the field with
nitrogen.
In case that the mode will be changed during operation the function will be overriden.
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Kennwort
OPAL DAHEJ-02
Projektauftrag_Nr.
2001189
3 STARTING AND OPERATION WITH PROCESS GAS IN "OPERATION (AUTO)" MODE

Description of “Operation (Auto)" mode:
The “Operation (Auto)" mode is designed to operate the compressor with process gas
when controlling the overall by-pass valve and capacity control automatically.
- In this mode all functions will be carried out fully automatically through the DCS
- The overall bypass valve PV-30203 and the capacity control will be active after the
compressor start sequence is completed successfully.
- The suction pressure controller PIC-30203 (software type, part of the DCS-programme)
has to be adjusted at site during commissioning.
Note: After any stop of the compressor, the overall bypass valve will close. After a time of
5 minutes the control valve will be de-energised and move to its fail safe position --> Valve
Open.
- The compressor will be started locally from the LOP. In order to check for any exceptional
occurences, there must be an operator present at at the compressor for start-up until the
start-up sequence has concluded.
3.1 Starting and operation of the compressor in “Operation(Auto)”- mode.
3.1.1 Before starting the compressor make sure that the position of the manual valves
correspond to following list:
Gas suction isolating valve HV-HOLD (Client) Open
Gas discharge isolating valve HV-HOLD (Client) Open
Nitrogen supply valve HV-001 Closed
Vent valve to flare HV-HOLD (Client) Closed
Vent valve to atmosphere HV-HOLD (Client) Closed
Shut-off valve up- & downstream PV-30203 HV-031, HV-032 Open
Shut-off valve over by-pass PV-30203 HV-033 Closed
Shut-off valve up- & downstream PV-30204 HV-014, HV-015 Closed
Shut-off valve over by-pass PV-30204 HV-016 Closed
Vent valve over relief valves Various Closed
Propylene purge valve HV-HOLD (Client) Open
Nitrogen purge valve HV-049 Closed
Nitrogen suppy valve for valve unloaders HV-046 Open
Shut-off valve on separator drain various Closed
Shut-off valves on level indicator various Open
Shut-off valves for pressure instruments various Open
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OPAL DAHEJ-02
Projektauftrag_Nr.
2001189
3.1.2 The mode selector must be in "Operation (Auto)" position. The compressor can then be
started from the LOP.
- "Compressor On (Auto)"
Afterwards the following sequences will proceed fully automatically:

- Cooling water pump will be started along with the prelub oil pump, if not already running
indicated by "Cooling pump Run" status in DCS
- Pre-lube oil pump will be started for 2 min. (*1), if not already running
indicated by "El. oil pump run" status in DCS
- Capacity control will be switched to 0 % position, if not already
- Bypass valve PV-30203 will fully open if not already
3.1.3 After the pre-lube oil pump and the cooling water pump has been running for 2 minutes (*1)
and provided no faults and start interlocks (I-302-O) are registered in the DCS, the indication
of DCS sequence status "Compressor Run" will flash to show that the compressor is ready
to start.
3.1.4 The main motor can be started by confirming the start-up sequence " Compressor On " for
a second time. The feed back is shown by continuous illumination of the DCS status
"Compressor Run".
3.1.5 After approx. 30 seconds (*2) of running the pre-lube oil pump will be switched off and the
capacity control will switch to 50% position. After approximately 2 minutes (*3), the
capacity control will be switched automatically to the auto control by the pressure
controller PIC-30203 from DCS as described in section 5.0, Continuous operation.
3.1.6 Afterwards the control of by-pass valve PV-30203 will be switched to automatic control by
the pressure controller PIC-30203 as a function of suction pressure. Refer section 5.0
CONTINUOUS OPERATION.
Remarks:
The suction pressure alarm and interlock instruments will be overrided during the first 20 seconds
(*2) of running.
(*1) Time adjustable from 1 to 2 min., To be set during commissioning at site at DCS.
(*2) Time adjustable from 0 to 30 sec., To be set during commissioning at site at DCS.
Rev. Index A
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Kennwort
OPAL DAHEJ-02
Projektauftrag_Nr.
2001189
4 LOCAL STARTING AND OPERATION OF COMPRESSOR IN "MAINTENANCE (MANUAL)"

MODE
Description of local starting and operation for maintenance
- In general the starting and operation for maintenance is designed to operate the
compressor unit manually in following cases:
For “Maintenance (Manual)” mode with nitrogen for commissioning, service and
running-in the pistons (only to be carried out by the responsible Burckhardt
Compression service and commissioning engineer).
- When starting and operating the compressor with nitrogene for maintenance, the position
of capacity control must be selected in the DCS or LOP according to the process
requirements.
- When starting and operating for maintenance the different actions have to be carried out
manually. The by-pass valve PV-30203 is always fully open after compressor start. It shall
be openend and closed from the DCS/LOP manually as required. The DCS programme
shall allow parallel operation of the manual bypass valve.
- Additionally the operator shall control the manual bypass valve parallel to the automatic
bypass valve according to the requirements of the process.
- The bypass valve over the first stage (PV-30204) shall be fully opened from the DCS
if the pressure after the first stage increases more than 4.5 kg/cm2 a.
- Note:
After any stop of the compressor the bypass valve will close. After a time of five minutes
the control valve will be de-energized and fail to its safe position --> Valve Open.
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Kennwort
OPAL DAHEJ-02
Projektauftrag_Nr.
2001189
4.1 Starting and operation of compressor in maintenance (Manual) Mode.
4.1.1 Before starting the compressor make sure that the position of the manual valves
correspond to following list:
Gas suction isolating valve HV-HOLD (Client) Open
Gas discharge isolating valve HV-HOLD (Client) Open
Nitrogen supply valve HV-001 Closed
Vent valve to flare HV-HOLD (Client) Closed (*)
Vent valve to atmosphere HV-HOLD (Client) Closed (*)
Shut-off valve up- & downstream PV-30203 HV-031, HV-032 Open (*)
Shut-off valve over by-pass PV-30203 HV-033 Closed (*)
Shut-off valve up- & downstream PV-30204 HV-014, HV-015 Closed (*)
Shut-off valve over by-pass PV-30204 HV-016 Closed (*)
Vent valve over relief valves Various Closed
Propylene purge valve HV-HOLD (Client) Open (*)
Nitrogen purge valve HV-049 Closed (*)
Nitrogen suppy valve for valve unloaders HV-046 Open
Shut-off valve on separator drain various Closed
Shut-off valves on level indicator various Open
Shut-off valves for pressure instruments various Open
(*) or acc. to the responsible Burckhardt Compression service and commissioning engineer
4.1.2 As soon as all manual valves have been set to the right position, the complete piping
system and the compressor cylinders are filled with nitrogen to a max. pressure of 1.5
kg/cm2 a, close the vent valve HV-HOLD to atmosphere.
Remarks: In case that the compressor has not been run for a very long period of time it
might be necessary to open the vent valve HV-HOLD for approx. 1 minute
(during purging with nitrogen) in order to make sure that the complete pipe
system is properly purged and filled with nitrogen only.
4.1.3 As soon as the complete piping system and the compressor cylinders are filled with
nitrogen, close the nitrogen supply valve HV-001 and afterwards the vent valve HV-HOLD,
if not already closed.
4.1.4 The mode selector must be in "Maintenance (Manual) " position. The compressor can
then be started locally, provided that an operator is at the machine to check the start-up.
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OPAL DAHEJ-02
Projektauftrag_Nr.
2001189
The compressor shall be prepared for starting by initiating the start-up sequence on the LOP:
- " Compressor On (Manual)""
The sequenece of operataion is as below:

a. Capacity control will be switched to 0 % position automaticaly, if not already
b. Bypass valve PV-30203 will fully open automaticaly if not already
c. Cooling water pump will be started manually from LOP
d. Prelub oil pump will be started manually from LOP
4.1.5 After the pre-lube oil pump and the cooling water pump has been running for 2 minutes (*1)
and provided no faults and interlocks (I-302-O) are registered in the DCS, the indication of
DCS sequence status "Compressor Run" will flash to show that the compressor is ready to
start.
4.1.6 The main motor can be started by confirming the start-up sequence " Compressor On " for
a second time. The feed back is shown by continuous illumination of the indication lamp
"Compressor Run".
4.1.7 After approx. 30 seconds (*2) of running the pre-lube oil pump will be switched off and the
capacity control will be switched to 50% position. After approximately 2 minutes (*3), the
capacity control is released.
4.1.8 From here on, the required capacity step is controlled by the operator from the DCS or
LOP, when operating in "Maintenance" mode. In addition to the 50% position, the
capacity control 100% position could also be selected, this shall be selected only by the
responsible Burckhardt Compression service and commissioning engineer.
Special attention has to be given to the stage discharge temperatures.
4.1.9 The By-pass valve PV-30203 normally remains in open position. It can be controlled
manually as required by the operator in the DCS/ LOP. The manual by pass valves HV-
033 over PV 30203 shall be used for running in of pistons and control of the process.
4.1.10 The bypass valve over the first stage (PV-30204) shall be fully opened from the DCS/LOP
if the pressure after the first stage increases more than 4.5 kg/cm2 a.
Remarks:
The suction pressure alarm and interlock instruments will be overrided during the first 20 seconds
(*2) of running.
(*1) time adjustable from 1 to 2 min., To be set during commissioning at site at DCS.
(*2) time adjustable from 0 to 30 sec., To be set during commissioning at site at DCS.
(*3) time adjustable from 1 to 5 min., To be set during commissioning at site at DCS.
Rev. Index A
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Kennwort
OPAL DAHEJ-02
Projektauftrag_Nr.
2001189
5 CONTINUOUS OPERATION
The gas flow is controlled through the capacity control as stated below in point 5.1. The
capacity control (by actuating the valve unloaders on the compressor) will be controlled
through the position of the bypass valve.
The bypass valve is controlled through the suction pressure controller PIC-30203 acc. to
the process requirements.
5.1 Capacity control during normal operation

The overall bypass valve PCV-30203 is controlled by the suction pressure (measured by PT-
30203) and automatically set to the required position. From this point on, the DCS will control the
compressor unit based on suction pressure only as follows:
• Overall bypass valve (PV-30203) will open from 0% to approx. 55% to regulate the suction
pressure, according to the pressure setpoint given to the pressure controller PIC-30203.
Positioner PY-30203 will operate the bypass valve automatically.
• if at the point of overall bypass valve approx. 55% open and the valve unloaders are on 100%
and the suction pressure is still decreasing, the valve unloaders will switch to 50% load
(solenoid valve HYS 30260 & HYS 30261 de-energized) and simultaneously the overall
bypass valve will close to approx. 15% open position in order to control the setpoint pressure.
• Overall bypass valve (PV-30203) will now open from 0% to 100% as required to regulate the
suction pressure, according to the pressure setpoint given to the pressure controller PIC-
30203. Positioner PY-30203 will operate the bypass valve automatically.
• if at the point of fully closed overall bypass valve and 50% valve unloader position the suction
pressure is still increasing, the valve unloaders will switch to 100% solenoid valve and
simultaneously the overall bypass valve will open to approx. 50% to control the discharge
pressure.
• Overall bypass valve (PV-30203) will now again open and close from 0% to approx. 55% to
reach the suction pressure setpoint (pressure controller PIC-30203 will control the bypass
valve automatically)
Remark: For details regarding the arrangement of valve unloaders see P&I diagram capacity
control ZNG 122.831.410 (3670-GP-VD-004-8454-ZDM-301302D)
5.2 Capacity control during operation with nitrogen.
5.2.1 During operation with Nitrogen in "Maintenance (Manual)" mode, automatic capacity
control through bypass valve PV-30203 and valve unloaders is suspended.
5.2.2 Due to too high resulting discharge temperatures it is not allowed to run the compressor at
other valve unloader positions than "Maintenance (Manual)". The position remains locked.
Compressor operates only in Maintenance capacity control position.
Solenoid valve De-energized Capacity control
Item no. Energized LOP selector position
° HYS 30260 / 30261 De-energized Maintenance(Manual)

HYS 30262 Energized
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OPAL DAHEJ-02
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2001189
5.2.3 The process shall be controlled with the manual valves as described above in 4.1.9.
5.2.4 Unlocking of 50% and 100 % position for special maintenance purposes shall only be
done by the responsible Burckhardt Compression service and commissioning
engineer
6 COMPRESSOR STOP
The compressor shall be stopped from the DCS/LOP.
6.1 Normal stop in: "Operation(Auto)" or "Maintenance(Manual)" mode
6.1.1 Stop the motor by initiating the stop sequence in DCS.

"Compressor stop"
6.1.2 The following operations will proceed automatically:
a. By-pass valve PV-30203 will close in order to avoid pressure increase in the suction
line.
b. After 5 seconds from the instant the compressor is stopped, the capactiy control will be
switched to 0 % position.
c. The pre-lube oil pump 33-PG-303 will be started automatically for post lubrication and
will be switched off after 5 minutes
d. In order to release the discharge pressure in the pipe system by-pass valve PV-30203
opens after 5 minutes (*1)
6.1.3 After the main motor has stopped, the compressor start system will be locked in acc. to the
temperature set points of the motor windings.
(*1) Time adjustable from 2 to 10 min., To be set during commissioning at site
(*2) Time adjustable from 0 to 40 min., Time to be agreed with the motor manufacturer, high
voltage switch gear and local regulations
(*3) Final temperatures and number of starts according to motor manufacturers instructions.
In case that the compressor will not run for a long period of time (more than 24 hours),
proceed as follows:
6.1.4 Close the manual shut-off valve HV-HOLD (if not already closed) of the Propylene purge
line.
6.1.5 Close the manual suction and discharge isolating valve.
6.1.6 Open the manual vent valve to the relief line.
6.1.7 As soon as the discharge pressure is released to approx. 1.1 kg/cm2 g then close the
manual relief valve.
6.1.8 Open the manual vent valve to atmosphere.
6.1.9 Open the manual nitrogen purge valve to the suction line
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OPAL DAHEJ-02
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2001189
6.1.10 As soon as the complete piping system and the compressor cylinders are filled with
nitrogen close the vent valve to atmosphere.
6.1.11 Please proceed according to the operating and instruction manual chapter 04, operating
and trouble shooting
6.2 Automatic stop based on trip (shut down I-312-S)

6.2.1 The compressor will be tripped for the following reasons:
- High gas discharge temperature each stage (2oo3) TZAHH-30205,
TZAHH-30208, TZAHH-30225
- High gas pressure on suction side PZAHH-30204,
- High gas pressure on discharge side PZAHH-30248
- Low gas pressure on suction side PZALL-30204
- High level in separators (2oo3) LZAHH-30205
LZAHH-30218, LZAHH-30219
- High vibration on compressor (1oo8) VZAHH-30203 -A
- Low oil pressure upstream bearings (2oo3) PDZALL-30267
- Low cooling water pressure (2oo3) PZALL-30293
- Motor winding / bearing temperature TZAHH-30206 / 30207
6.2.2 The following operations will proceed automatically:
a. By-pass valve PV-30203 will close in order to avoid pressure increase in the suction
line.
b. After 5 seconds from the instant the compressor is stopped, the capacity control will be
switched to 0 % position
c. The pre-lube oil pump 33-PG-303 will be started automatically for post lubrication and
will be switched off after 5 minutes
d. In order to release the discharge pressure in the pipe system By-pass valves PV-30203
will open after 5 minutes (*1)
6.2.3 After the main motor has stopped, the compressor start system will be locked in acc. to the
temperature set points of the motor windings.
6.2.4 In case that the compressor will not be started again close the manual shut-off valve HV-
HOLD of the Propylene purge line.
(*2) Time adjustable from 0 to 40 min., Time to be agreed to the motor manufacturer, high
voltage switch gear and local regulations.
In case that the compressor will not run for a long period of time (more than 12 hours)
proceed acc. To point 6.1.5 - 6.1.11.
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OPAL DAHEJ-02
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2001189
6.3 Emergency stop (ESD)
Complete compressor can be stopped (KZMSS-30203/XZS-30204) with emergency stop

from SIS or from LOP.
The stop procedure shall be same as described in 6.2.2 with following excemptions
a. No Post lubrication of Pre lube oil pump 33-PG-303
b. No Cooling water pump operation 33-PC-302A/B
c. Capacity control will be switched to 0% without any delay

d. Bypass valves fall in their fail safe position
e. Cooling water heater shut off without any delay
7 LUBE OIL SYSTEM

7.1 The crank gear of the compressor is oil lubricated. The main lube oil pump is crank shaft
driven, therefore always in operation as long as the compressor is in operation. Before
starting and after stopping of the compressor, the individual bearings must be pre or post-
lubricated (see point 1.3). For this, an additional external pre-lube oil pump (item no 33-PG-
303) is mounted. Before the compressor is started, the oil is drawn by this external oil pump
from the sump in the crankcase of the compressor and pumped through the oil cooler (Item
no. 33-EE-310A/B) and filter (Item no. 33-GN-310A/B) to the individual bearings. The cooler
and filter are in duplex construction which allows change over from one cooler to another or
from one filter to another during operation without stopping the machine.
7.2 When starting the compressor, the external pre-lube oil pump 33-PG-303 will run in parallel
with the crankshaft driven main oil pump for approx. 30 seconds (*1). When the main oil
pump has reached full capacity the pre-lube oil pump will be switched off.
7.3 Considering the ambient temperatures, the compressor is not provided with an electrical
heater.
7.4 In case the oil temperature inside the external oil piping drops below 15 deg c (indicated
through TAL-30261) the external pre-lube oil pump 33-PG-303 will be switched on (I-303-O)
automatically (during compressor standstill only).
The external oil pump 33-PG-303 remains in operation

- until next compressor start
or
- until it will be switched off manually by the operator
7.5 If the differential pressure of oil (between outlet of filter & inlet of pump) falls below 2.5
kg/cm2, then the pre-lubrication oil pump is started due to the signal from PDAL-30268 (I-
303-O). This pump will continue operation until it is stopped by the operator or the
compressor is stopped (after post lubrication period). -A
Rev. Index A
2030374

Kennwort
OPAL DAHEJ-02
Projektauftrag_Nr.
2001189
2
7.6 If the differential pressure of the oil falls further to a value of 2.0 kg/cm , then the PDZALL-
30267 trips the compressor for safety reason.
7.7 If the compressor is tripped due to power failure or oil supply related fault or emergency
shut down (see point 6.2) there will be no post-lubrication.
7.8 The pre lube oil pump itself is provided with start interlocks in case of low oil level LAL-
30222 in the crank case (I-302-O). -A
Remarks:
(*1) time adjustable from 0 to 30 sec., To be set during commissioning at site.
8 COOLING WATER SYSTEM

8.1 The compressor, the lubricating system and compressed gas are water cooled. The cooling
water is led to the individual elements through a supply manifold. The return flow of the
cooling water from each cooling element is individually monitored for temperature.
8.2 There are two different cooling water systems:

A) Closed Coolant System for the compressor (cylinder block, guide bearings & cross
heads)
B) Open Coolant System for the process gascoolers, cooling water coolers and lube oil
coolers
8.4 The open coolant system has two individual connections at the battery limit, one directly to
the compressor foundation for the oil cooler and bypass cooler and one for the water skid.
The supply and return headers for the open cooling water are located on the foundation,
before getting split for the individual coolers. The return pipes from individual coolers are
brought separately to the return header where temperature indicators are located for the
return temperatures.
8.5 The closed cooling water system is completely located on the skid. The supply headers
start from the skid and continue up to an appropriate location near the compressor, from
where the individual lines to the compressor cylinders and cross head are distributed. The
return lines from the compressor are brought individually upto the return header where
temperature indicators are located for the return temperatures. The return sub-header from
the compressor on the skid is provided with a flow transmitter FT-30270 and a temperature
transmitter TT-30268.
8.6 The coolant system is also provided with a expansion vessel 33-VV-309, which
accomodates the expanded volume of the coolant when heated. The vessel is provided with
a level indication and a transmitter LG-30251 / LT-30252, which provides a start interlock
for the compressor (I-302-O) and for the heater (I-304A-O) with LAL-30252, if the level in
the tank is low. Included in the expansion vessel is the heater 33-EZ-313 in order to preheat
the coolant when the cooling water temperature is below the setpoint in order to avoid
condensation. During normal operation, the heater will not be necessary as the compressor
emits enough thermal energy to maintain the water on the required temperature. During
standstill the heater is controlled by the outlet temperature (I-304A-O). The aim is to
maintain the temperature of compressor return line above the setpoint of 35°C. This
Rev. Index A
2030374

Kennwort
OPAL DAHEJ-02
Projektauftrag_Nr.
2001189
temperature is controlled by the temperature transmitter TT-30268. The heater itself is

provided with the following start interlocks (I-304A-O).
• Sufficient Level in the cooling water tank (LAL-30252),to prevent overheating of the
device itself.
• Sufficient flow in the coolant return line (FAL-30270).Without flow, heating of the
compressor can not be maintained.
• Temperature limiter is active (TS-30266) to avoid overheating of the device.
• Sufficient coolant temperature TT-30268. As long as the compressor is heating up
the coolant, there is no need of additional heating by the heater.
8.7 The return flow from the compressor is pumped back into the system with the help of the
cooling water pumps 33-PC-302A or 33-PC-302B. During normal operation, only one pump
is in operation, the other one is standby. If the flow drops below the setpoint FAL-30270, the
standby pump will start (I-308-O) in order to maintain the required pressure in the coolant
system. Both pumps will remain in operation. If the flow is sufficient again, the standby
pump has to be switched off manually by the operator.
During standstill, one of the water pumps will start automatically (I-308-O) if the outlet
temperature drops below the set point TAL-30268 in order to heat up the coolant medium
by circulation. The pumps are provided with a start interlock in case of low level LAL-30252
in the cooling water tank (I-307-O).
8.8 At the down stream of the pumps, the cooler (33-EE-311A and 33-EE-311B) and a three-
way thermostatic control valve (TCV-30270) are located. The thermostatic valve TCV-30270
is set at 35°C at outlet of the valve (rated range 30°C - 41°C). Below the temperatue of
30°C, the valve keeps the passage from the pumps to the compressors (port B to port A)
open. Thus, the water flows into the compressor without being cooled. This helps raising
the temperature of the cooling water faster, so that the cooling water temperature is above
the required return temperature of 35°C (control through TT-30268). If the water
temperature rises above 30°C, the TCV starts opening the passage C to A. However, till the
coolant outlet temperature of 41°C, the water flows through the cooler as well as direct from
the pumps to compressors (mixed flow). If the temperature is above 41°C, the passage C to
A is completely opened and the passage B to A is closed. Thus, the complete flow of water
is now cooled through the coolers (33-EE-311A and 33-EE-311B). The maximum return
temperature of the teped water is limited through TAH-30268.
8.9 If the pressure of the cooling water falls to a value below the setpoint, then the PZALL-
30293 trips the compressor for safety reason.
9 Distance Piece Purge System

9.1 In order to avoid the powder contaminated process gas in the crankcase of the compressor,
the distance piece is purged with pure propylene. The pressure in the crankcase shall
2
always be maintained at 0.5 kg/cm higher than the suction pressure, this is ensured with a
PCV and a flow orifice at the inlet line of the distance piece. If the suction pressure exceeds
2
1.5 kg/cm g, the leakgas over the packing will be vented to the flare via PCV 30208.
Rev. Index A
2030374

KR-301 Control

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EIL JOB No.: 6987

BCA Supplier Off Gas

Compressor control description

02 Issue for approval PATEL_D KUENZLER_S KUENZLER_S 18.10.12

VOLUME 5 OF 7, PAGE NO. 4165 of 5762

BCA Supplier Off Gas

S.No Document Description Page No

VOLUME 5 OF 7, PAGE NO. 4166 of 5762

1 GENERAL OPERATION ................................................................................................................................................ 2

2 PREPARATION OF COMPRESSOR UNIT BEFORE STARTING........................................................................... 2

8 COOLING WATER SYSTEM....................................................................................................................................... 13

9 DISTANCE PIECE PURGE SYSTEM ......................................................................................................................... 14

Dwg. No. 3670-GP-VD-004-8454-KDR-301517 Interconnection Drawing

VOLUME 5 OF 7, PAGE NO. 4167 of 5762

2 PREPARATION OF COMPRESSOR UNIT BEFORE STARTING

Interlock table – (Interlock I-302-O)

PAL-30203 the suction pressure is lower than the setpoint (*)

PAH-30203 the suction pressure is higher than the setpoint (*)

VOLUME 5 OF 7, PAGE NO. 4168 of 5762

higher than the set point (*), indicating requirement of drain

ZI-30203 Overall By-Pass Valve PV 30203 is not in fully open position

TAL-30268 the temperature of coolant at the outlet of the Cylinders is lower

SHUTDOWN Compressor shut down push button is pressed or Process trip or

VOLUME 5 OF 7, PAGE NO. 4169 of 5762

3 STARTING AND OPERATION WITH PROCESS GAS IN "OPERATION (AUTO)" MODE

3.1 Starting and operation of the compressor in “Operation(Auto)”- mode.

VOLUME 5 OF 7, PAGE NO. 4170 of 5762

Afterwards the following sequences will proceed fully automatically:

VOLUME 5 OF 7, PAGE NO. 4171 of 5762

4 LOCAL STARTING AND OPERATION OF COMPRESSOR IN "MAINTENANCE (MANUAL)"

VOLUME 5 OF 7, PAGE NO. 4172 of 5762

4.1 Starting and operation of compressor in maintenance (Manual) Mode.

VOLUME 5 OF 7, PAGE NO. 4173 of 5762

- " Compressor On (Manual)""

The sequenece of operataion is as below:

VOLUME 5 OF 7, PAGE NO. 4174 of 5762

5.1 Capacity control during normal operation

5.2 Capacity control during operation with nitrogen.

° HYS 30260 / 30261 De-energized Maintenance(Manual)

VOLUME 5 OF 7, PAGE NO. 4175 of 5762

6.1 Normal stop in: "Operation(Auto)" or "Maintenance(Manual)" mode

6.1.1 Stop the motor by initiating the stop sequence in DCS.

VOLUME 5 OF 7, PAGE NO. 4176 of 5762

6.2 Automatic stop based on trip (shut down I-312-S)

6.2.2 The following operations will proceed automatically:

VOLUME 5 OF 7, PAGE NO. 4177 of 5762

6.3 Emergency stop (ESD)

Complete compressor can be stopped (KZMSS-30203/XZS-30204) with emergency stop

c. Capacity control will be switched to 0% without any delay

7 LUBE OIL SYSTEM

The external oil pump 33-PG-303 remains in operation

VOLUME 5 OF 7, PAGE NO. 4178 of 5762

8 COOLING WATER SYSTEM

8.2 There are two different cooling water systems:

VOLUME 5 OF 7, PAGE NO. 4179 of 5762

temperature is controlled by the temperature transmitter TT-30268. The heater itself is

9 Distance Piece Purge System

VOLUME 5 OF 7, PAGE NO. 4180 of 5762

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