Innovative Technologies For The Planet: Andritz Group

ANDRITZ GROUP
INNOVATIVE TECHNOLOGIES
FOR THE PLANET
A GLOBAL PARTNER FOR KEY INDUSTRIES THAT SHAPE THE WORLD
NOVEMBER 2019
XAYABURI HYDRO POWER PROJECT
TRAINING
COMPRESSED AIR SYSTEM
CHAPTER OVERVIEW
01 INTRODUCTION
06 MAINTENANCE
02 SAFETY
07 SPARE PARTS
03 TECHNICAL DATA
08 DECOMMISSIONING
04 DESCRIPTION 09 DESCRIPTION OF INSTALLED

DEVICES
05 OPERATION
10 LIST OF DOCUMENTS
3 / ANDRITZ (HYDRO) / TRAINING CWS/ © COPYRIGHT (RUDOLF HAMMELMÜLLER)

INTRODUCTION
• The training contains essential information about the correct, safe and purposeful operation of the system
• The training is based on the operation and

maintenance manual XB-P3-PH-M-4160-9870

CHAPTER OVERVIEW
01 INTRODUCTION
06 MAINTENANCE
02 SAFETY
07 SPARE PARTS
03 TECHNICAL DATA
08 DECOMMISSIONING
DESCRIPTION OF INSTALLED
04 DESCRIPTION
09 DEVICES
05 OPERATION 10 LIST OF DOCUMENTS

SAFETY
• Common safety instruction are listed in point 2.1 to 2.4 of the O&M manual
• Important safety instructions for compressed air system are listed in point 2.5 with wording as follows:
After each dismantling / exchange of a component the system has to be checked regarding tightness and if the
pressures are within normal range.
• For doing maintenance work on the system it is necessary to be fully aware if part of the system need to be
isolated or not.
• Isolating valves, maintenance units, etc. may only be exchanged or repaired if the inlet itself is isolated from the
system and no pressure is applied to the device.

SAFETY
Further points
• Only personnel with special knowledge and experience are entitled to work on the system
• Regularly inspect all pipes, hoses and bolted connections for leakage and externally visible damages - Damages
must be repaired immediately.
• System sections and pressure pipes have to be de-pressurized before commencing repair work
• In case of changing, armatures, length and quality of hose lines must correspond to the requirements regarding
nominal pressure

CHAPTER OVERVIEW
01 INTRODUCTION
06 MAINTENANCE
02 SAFETY
07 SPARE PARTS
03 TECHNICAL DATA
08 DECOMMISSIONING
04 DESCRIPTION
09 DEVICES
05 OPERATION

TECHNICAL DATA

TECHNICAL DATA

CHAPTER OVERVIEW
01 INTRODUCTION
06 MAINTENANCE
02 SAFETY
07 SPARE PARTS
03 TECHNICAL DATA
08 DECOMMISSIONING
04 DESCRIPTION
09 DEVICES
05 OPERATION 10 LIST OF DOCUMENTS

DESCRIPTION
Components of compressed air system
Due to availability reasons and to keep the compressed air distribution pipes short, two (2) compressed air systems
are installed in the powerhouse.
Each compressor sets consists of :
Two (2) rotary screw compressor sets, complete with electric motors, control and protection accessories
Two (2) main pressure vessels, complete with all control and protection accessories
One (1) set of pipes, valves and accessories, complete for connecting the two pressure compressed air system,
pressure air vessels and all pressure air consumers in the powerhouse
One (1) set of condensate drains, including valves, pipes and accessories at every place where condensate is to
be drained
One (1) oil-condensate separator, including valves, pipes, instruments and control elements
One (1) set of sensor, transmitters and pressure gauges
One (1) power / control board, motor control centre (MCC) for each compressor
One (1) set of foundation material, in order to support and fix up the various components like, compressors, air
vessels, pipes, etc.
DESCRIPTION
Main function of the compressed air system
The compressors feed the compressed air into air vessels. A safety valve is installed in each compressor set to
protect the compressed air system against high air pressure. Each pressure air vessel is equipped with a safety
valve as well.
The pipe routing is ring feeder design. Compressed air from the low pressure air system can be taken off for the
pneumatic tools.
The two pressure air systems are connectable over interconnection pipes and manual operated shut-off valves.
The compressed air system is designed with functional reference to the

schematic diagram XB-P3-PH-C-4160-0004.

DESCRIPTION
Main function of the compressed air system
One pressure air system supplies compressed air to generating units 1 to 4 and
the other pressure air system to generating units 5 to 7and EdL unit.
The control system operates the compressed air system according to the air pressure in the vessels.
Transmitters provide the required information to the control system.
Normally one compressor refills the air vessels while the other compressor stands by.
From time to time the control system changes the function of the two compressors from normal operation to standby
operation.
If one compressed air system is out of operation due to a fault or maintenance work, the interconnection pipes allow
connecting the other compressed air systems to the consumers by opening of manual operated shut-off valves.

DESCRIPTION
Arrangement
The detailed arrangement is shown in the drawings XB-P3-PH-D-4160-3600.
One pressure air system is assembled in the compressor room between generating unit 2 and unit 3 and
the other compressed air set is installed in the compressor room between generating unit 6 and unit 7.
The compressed air systems are installed at the turbine floor, elevation 234.50 m a.s.l.

DESCRIPTION
Arrangement
The pressure air system deliver compressed air for the following purposes:
• Mechanical brakes of the generators
• Expansion tank installed in the closed cooling water loops,
• Pneumatic actuators at cooling water system
• Maintenance seal at turbine shaft seal
• Pneumatic tools for maintenance and repairs (general use)

DESCRIPTION
Schematic Drawing of one compressor set:
Connection pipe to
second compressor set

CHAPTER OVERVIEW
01 INTRODUCTION
06 MAINTENANCE
02 SAFETY
07 SPARE PARTS
03 TECHNICAL DATA
08 DECOMMISSIONING
04 DESCRIPTION 09 DESCRIPTION OF INSTALLED

DEVICES
05 OPERATION

OPERATION
Remote operation of the compressed air system
• During normal operation, the compressors are always in REMOTE operation from control system.
• The compressors are controlled via the system pressure in the compressed air system.
• One compressor should be leading and on standby which will be decided by the control system.

OPERATION
Remote operation of the compressed air system
The setting pressure values for remote operation are defined as follows :

OPERATION
Local operation of the compressed air system
• In normal operation the compressors should be operated in REMOTE operation.
• For maintenance purpose the compressor can be also changed to LOCAL operation according to the control
mode selection at compressor control panel.
Refer to instruction book of compressor section 4.9.
• For starting of the compressor in LOCAL operation

Refer to instruction book of compressor section 8.3.

OPERATION
De-pressurizing of the compressed air system
During maintenance at both compressors, or at both air tanks of the compressed air system 1, the unit
compressed air system can be supplied from compressed air system 2 (or converse).
• Open bypass valve =00QFB30AA501 to supply the unit with the compressed air from system 2.
• Switch-off and secure compressor 1 (=00QFA11AN001) and compressor 2 (=00QFA12AN001) against

restarting at the MCC.
• Close and lock the system supply valves =00QFB11AA502 and =00QFB12AA502.
• Open the air release valves =00QFB11AA601 and =00QFB12AA601 to de-pressurize the system.
• The air is released via a silencer.

OPERATION
De-pressurizing of the compressed air system
During maintenance at one air tank, the unit compressed air system can be supplied from the other air tank. Both
compressors can remain in REMOTE operation
• Close and lock the air tank inlet valve =00QFB11AA501. From the feedback of the position switch
=00QFB11CG301-S01 the pressure control of the compressors change to air tank 2 – refer to section 5.3
Remote operation of the system
• Close and lock the system supply valves =00QFB11AA502
• Open the air release valves =00QFB11AA601 to de-pressurize the system.
• The air is released via a silencer.

OPERATION
Limits of operation
The operating range of the compressed air system is limited to the compressor capacities.
The settings values regarding pressure can be found in the commissioning record sheets.
Basically the system is very reliable if the following points will be watched and maintained:
• Leakages
• Correct measurement of instruments
• Starts of compressors during one hour – if the number of starts per hour abnormal increase an overheating of
the compressor is possible which will lead to automatically shut down of the compressor

CHAPTER OVERVIEW
01 INTRODUCTION
06 MAINTENANCE
02 SAFETY
07 SPARE PARTS
03 TECHNICAL DATA
08 DECOMMISSIONING
04 DESCRIPTION
09 DEVICES
05 OPERATION

MAINTENANCE
GENERAL INSTRUCTION
Service inspections and maintenance operations carefully done according to the following instructions are of vital
importance for keeping the plant and all its components in a reliable operating condition.
Service inspections are intended to detect incipient defects and malfunctions early enough to ensure that by taking
immediate remedial action such as repair and replacement of defective components, etc. consequential damage
and hence extended periods of standstill of the machine unit will be avoided.
Maintenance operations contribute towards keeping the plant components in a reliable operating condition for an
extended period of time.
It is recommended to contact Andritz HYDRO in good time whenever major repairs or replacements of components
will be necessary.
Consider safety instructions in the operation and maintenance manual !

MAINTENANCE
REMARKS FOR DISASSEMBLY / REASSEMBLY OF SYSTEM
• After each dismantling tests and checks during assembly have to be executed and recorded as described in the
drawings and commissioning instruction XB-P3-PH-Q-4160-9700. It is recommended to contact Andritz Hydro so
that support during assembly and commissioning can be given.
• For maintenance work, it will be necessary to secure and depressurize the section in the system, where the
maintenance is planned.
During this stage of maintenance works these valves must be locked to avoid unintentional opening. Also the
interconnection between the systems must be taken in consideration and relevant valves must be closed to
avoid pressurizing during maintenance works.
• For doing maintenance work on the system the maintenance staff must be fully aware about relations of the
connections and interconnections to ensure that correct valves will be closed or opened. Schematic diagrams
XB-P3-PH-C-4160-0004 will provide help to get overview about the system.

MAINTENANCE
MAINTENANCE INFLUENCING FACTORS AND CLEANING
The normal operation includes influences like e.g.
• Period of operation
• Standstill period
• Pollution degree of air
Keep the system as clean as possible. This eases visual checks detected during inspections tours. Leakage of
liquids and visible wearing can be detected easier. Special care shall be taken to rotating parts like motors and
actuators, instruments and valves since clean system and atmosphere will increase lifetime of these parts.

MAINTENANCE
MAINTENANCE AND INSPECTION PLAN
Maintenance and inspection activities of compressors, instruments, valves, etc. are described in chapter 9
Brochures of operating and maintenance manual in detail.
The activities for the main components are listed in

chapter 6.6.2 of the operation and maintenance manual.

MAINTENANCE
CHECK LIST OF OPERATING VALUES
• The values in table 6.2 show acceptable ranges of parameters. If values are found out of these ranges corrective
actions shall be taken.

MAINTENANCE
TROUBLE SHOOTING
Malfunctions are either

• Detected during inspection tours by the operating personnel or
• Indicated by electrical monitoring units.
Possible causes of such malfunctions and the remedial action to be taken are described in chapter 6.9 “Trouble
shooting” of operating and maintenance manual

CHAPTER OVERVIEW
01 INTRODUCTION
06 MAINTENANCE
02 SAFETY
07 SPARE PARTS
03 TECHNICAL DATA
08 DECOMMISSIONING
04 DESCRIPTION
09 DEVICES
05 OPERATION

SPARE PARTS
• Check availability of spare parts before starting with maintenance works
• Spare parts according the spare part list XB-P3-PH-D-4160-8800 have been delivered at initial contract.
• Increased scope may arise out of experience during long term operation.

CHAPTER OVERVIEW
01 INTRODUCTION
06 MAINTENANCE
02 SAFETY
07 SPARE PARTS
03 TECHNICAL DATA
08 DECOMMISSIONING
04 DESCRIPTION
09 DEVICES
05 OPERATION

DECOMMISSIONING
INFORMATION FOR DISASSEMBLY
Prior to dismantling, the condition of the system shall be evaluated by an expert, meaning a person who has
gained experience in power plants and its auxiliary system.
This evaluation shall contain the design conditions, static conditions, type and condition of components as well as
type and position of pipes and other installations. On the basis of the determined findings an expert has to provide
a written disassembly plan. This plan shall include the following:
• Extent, sequence and type of disassembly work.
• Required tools and safety precautions.
• Dangers to health due to influence of possible hazardous ingredients.
Usually the disassembly takes place in reverse order from the assembly. Therefore loosen, saw off or thermally
separate the connections of the individual parts.
Remove all liquids from the plant before dismantling or scrapping.

DECOMMISSIONING
INFORMATION FOR DISASSEMBLY
Fixate the parts to be dismantled or secure with lifting tools on the slinging means in such a way that they cannot
fall down and crash or oscillate after loosening or separating the connections.
Working on parts, which may fall down, is only permitted if the working area is protected by suitable equipment to
ensure a safe operation.
Supporting and stiffening components may only be removed, if measures for stability are met.
Take the danger of fire and release of hazardous vapours and combustion products into account during thermal
separation.

DECOMMISSIONING
DISPOSAL
Comply to all national, regional and local legal requirements and regulations during the disposal or recycling of
parts and components of the machine/plant as well as for materials necessary for operation.
High-quality recyclable materials like steel or copper are integrated in the machine. These can be recovered via a
scrapping process with a high recycling ratio.
Substance, being hazardous for water and soil, like parts contaminated with oil, have to be stored in separated
areas or collecting trays. If necessary remove oil, grease and other contamination from the parts.
Separate the different materials (steel, copper, aluminium, casting, plastic, cables, etc.) as far as possible.
Remove electrical and electronic components from the machine and collect them separately. Disposal via the
normal domestic waste is not permitted.

CHAPTER OVERVIEW
01 INTRODUCTION
06 MAINTENANCE
02 SAFETY
07 SPARE PARTS
03 TECHNICAL DATA
08 DECOMMISSIONING
04 DESCRIPTION
09 DEVICES
05 OPERATION

DESCRIPTION OF INSTALLED DEVICES
Parts of the equipment under this group “Compressed Air System” are procured items from global market.
For all equipment brochures, data sheets and manuals are attached to the operation and maintenance manual of
the cooling water system.
In point 9 of the manual the listing follows the alphabetic order

of suppliers/manufacturers name.

CHAPTER OVERVIEW
01 INTRODUCTION
06 MAINTENANCE
02 SAFETY
07 SPARE PARTS
03 TECHNICAL DATA
08 DECOMMISSIONING
04 DESCRIPTION
09 DEVICES
05 OPERATION

LIST OF DOCUMENTS
In point 10 of the manual all documents (Drawings, Bill of material, commissioning record sheets, etc.) are listed.
Also the Revision index of each document is listed. So note that each change in the equipment done by the
operator shall be reflected in a new revision
of the related document incl. info to Andritz Hydro.

LEGAL DISCLAIMER
© ANDRITZ AG 2018
This presentation contains valuable, proprietary property belonging to ANDRITZ AG or its affiliates (“the ANDRITZ GROUP”), and no licenses
or other intellectual property rights are granted herein, nor shall the contents of this presentation form part of any sales contracts which may be
concluded between the ANDRITZ GROUP companies and purchasers of any equipment and/or systems referenced herein. Please be aware
that the ANDRITZ GROUP actively and aggressively enforces its intellectual property rights to the fullest extent of applicable law. Any
information contained herein (other than publically available information) shall not be disclosed or reproduced, in whole or in part, electronically
or in hard copy, to third parties. No information contained herein shall be used in any way either commercially or for any purpose other than
internal viewing, reading, or evaluation of its contents by recipient and the ANDRITZ GROUP disclaims all liability arising from recipient’s use or
reliance upon such information. Title in and to all intellectual property rights embodied in this presentation, and all information contained therein,
is and shall remain with the ANDRITZ GROUP. None of the information contained herein shall be construed as legal, tax, or investment advice,
and private counsel, accountants, or other professional advisers should be consulted and relied upon for any such advice.
All copyrightable text and graphics, the selection, arrangement, and presentation of all materials, and the overall design of this presentation are
© ANDRITZ GROUP 2018. All rights reserved. No part of this information or materials may be reproduced, retransmitted, displayed, distributed,
or modified without the prior written approval of Owner. All trademarks and other names, logos, and icons identifying Owner’s goods and
services are proprietary marks belonging to the ANDRITZ GROUP. If recipient is in doubt whether permission is needed for any type of use
of the contents of this presentation, please contact the ANDRITZ GROUP at welcome@andritz.com.

Innovative Technologies For The Planet: Andritz Group

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Innovative Technologies For The Planet: Andritz Group

Uploaded by

Copyright:

Available Formats

ANDRITZ GROUP

04 DESCRIPTION 09 DESCRIPTION OF INSTALLED

3 / ANDRITZ (HYDRO) / TRAINING CWS/ © COPYRIGHT (RUDOLF HAMMELMÜLLER)

• The training is based on the operation and

4 / ANDRITZ (HYDRO) / TRAINING CWS/ © COPYRIGHT (RUDOLF HAMMELMÜLLER)

05 OPERATION 10 LIST OF DOCUMENTS

5 / ANDRITZ (HYDRO) / TRAINING CWS/ © COPYRIGHT (RUDOLF HAMMELMÜLLER)

6 / ANDRITZ (HYDRO) / TRAINING CWS/ © COPYRIGHT (RUDOLF HAMMELMÜLLER)

7 / ANDRITZ (HYDRO) / TRAINING CWS/ © COPYRIGHT (RUDOLF HAMMELMÜLLER)

8 / ANDRITZ (HYDRO) / TRAINING CWS/ © COPYRIGHT (RUDOLF HAMMELMÜLLER)

9 / ANDRITZ (HYDRO) / TRAINING CWS/ © COPYRIGHT (RUDOLF HAMMELMÜLLER)

10 / ANDRITZ (HYDRO) / TRAINING CWS/ © COPYRIGHT (RUDOLF HAMMELMÜLLER)

05 OPERATION 10 LIST OF DOCUMENTS

11 / ANDRITZ (HYDRO) / TRAINING CWS/ © COPYRIGHT (RUDOLF HAMMELMÜLLER)

Components of compressed air system

Main function of the compressed air system

The compressed air system is designed with functional reference to the

13 / ANDRITZ (HYDRO) / TRAINING CWS/ © COPYRIGHT (RUDOLF HAMMELMÜLLER)

Main function of the compressed air system

14 / ANDRITZ (HYDRO) / TRAINING CWS/ © COPYRIGHT (RUDOLF HAMMELMÜLLER)

The detailed arrangement is shown in the drawings XB-P3-PH-D-4160-3600.

15 / ANDRITZ (HYDRO) / TRAINING CWS/ © COPYRIGHT (RUDOLF HAMMELMÜLLER)

• Mechanical brakes of the generators

• Expansion tank installed in the closed cooling water loops,

• Pneumatic actuators at cooling water system

• Maintenance seal at turbine shaft seal

• Pneumatic tools for maintenance and repairs (general use)

16 / ANDRITZ (HYDRO) / TRAINING CWS/ © COPYRIGHT (RUDOLF HAMMELMÜLLER)

Schematic Drawing of one compressor set:

17 / ANDRITZ (HYDRO) / TRAINING CWS/ © COPYRIGHT (RUDOLF HAMMELMÜLLER)

04 DESCRIPTION 09 DESCRIPTION OF INSTALLED

18 / ANDRITZ (HYDRO) / TRAINING CWS/ © COPYRIGHT (RUDOLF HAMMELMÜLLER)

Remote operation of the compressed air system

19 / ANDRITZ (HYDRO) / TRAINING CWS/ © COPYRIGHT (RUDOLF HAMMELMÜLLER)

Remote operation of the compressed air system

20 / ANDRITZ (HYDRO) / TRAINING CWS/ © COPYRIGHT (RUDOLF HAMMELMÜLLER)

Local operation of the compressed air system

• In normal operation the compressors should be operated in REMOTE operation.

• For starting of the compressor in LOCAL operation

21 / ANDRITZ (HYDRO) / TRAINING CWS/ © COPYRIGHT (RUDOLF HAMMELMÜLLER)

De-pressurizing of the compressed air system

• Switch-off and secure compressor 1 (=00QFA11AN001) and compressor 2 (=00QFA12AN001) against

• The air is released via a silencer.

22 / ANDRITZ (HYDRO) / TRAINING CWS/ © COPYRIGHT (RUDOLF HAMMELMÜLLER)

De-pressurizing of the compressed air system

• Close and lock the system supply valves =00QFB11AA502

• Open the air release valves =00QFB11AA601 to de-pressurize the system.

• The air is released via a silencer.

23 / ANDRITZ (HYDRO) / TRAINING CWS/ © COPYRIGHT (RUDOLF HAMMELMÜLLER)

24 / ANDRITZ (HYDRO) / TRAINING CWS/ © COPYRIGHT (RUDOLF HAMMELMÜLLER)

25 / ANDRITZ (HYDRO) / TRAINING CWS/ © COPYRIGHT (RUDOLF HAMMELMÜLLER)

Consider safety instructions in the operation and maintenance manual !

26 / ANDRITZ (HYDRO) / TRAINING CWS/ © COPYRIGHT (RUDOLF HAMMELMÜLLER)

REMARKS FOR DISASSEMBLY / REASSEMBLY OF SYSTEM

27 / ANDRITZ (HYDRO) / TRAINING CWS/ © COPYRIGHT (RUDOLF HAMMELMÜLLER)

MAINTENANCE INFLUENCING FACTORS AND CLEANING

The normal operation includes influences like e.g.

28 / ANDRITZ (HYDRO) / TRAINING CWS/ © COPYRIGHT (RUDOLF HAMMELMÜLLER)

MAINTENANCE AND INSPECTION PLAN

The activities for the main components are listed in

29 / ANDRITZ (HYDRO) / TRAINING CWS/ © COPYRIGHT (RUDOLF HAMMELMÜLLER)

CHECK LIST OF OPERATING VALUES

30 / ANDRITZ (HYDRO) / TRAINING CWS/ © COPYRIGHT (RUDOLF HAMMELMÜLLER)