AVU & SR-LPG Treatment Unit

Paradip Refinery
DATED:03.09.2023
Topic Covered: “SOP”: K3 A/B : OFF GAS COMPRESSOR START UP AFTER MAINTENANCE.

Faculty: MD ARIF
Training Session Attended By:
Sl. Sl.
No Name Signature/Date No. Name Signature/Date
.
MR. GYAN CHANDRA GUPTA GURUNADHA RAO KILLADA
1 8

MR. RAKESH Jagdish Singh Chauhan

2 9

MR. DHEERAJ PAL SINGH

3 MAKHLOGA 10
MR. AJEET PRATAP
4 11

MR. ARVIND YADAV

5 12

MR. DHARMENDRA KUMAR

6 13

7 14

Discussion Points:

1. COMPRESSOR START UP AFTER MAINTENANCE

Prior to start up the compressor; check again the installation thoroughly to likelihood of troubles. The
following items should be checked as a guide, but any other specific conditions in installation should
be taken in to consideration as well.

.
Action By
Sl.
Job Description
No EA/
SI PE
JEA

Confirm again that all mounting bolts, connection bolts and flanges are
1 √
tightened firmly.

2 Check lube oil level in the reservoir and its quality. √

AVU & SRLPG Treatment Unit - Skill DevelopmentPage 1 of 2

 3 Confirm instrument air supplied sufficiently in motor. √ √

4 Commission cooling water to lube oil cooler. √

5 Confirm the electrical power supply to all drives. √ √

6 Confirm total draining of the process piping and volume bottles. √

7 Keeping suction & discharge valve closed, purge compressor with N2. √

8 Pressurize with N2 to 1.5 kg & do leak test. Rectify if any. √

9 Commission nitrogen flow as the primary and secondary seal gas. √

10 Supply and adjust the primary and secondary seal gases to the shaft seal portion. √

Start Jacket CW pump. Maintain jacket CW pressure > 3.5 kg/. Keep stand by
11 √
pump in heathy mode.

12 Start Aux lube oil pump. √

After the oil pump has started, make air venting from the oil system and check
these items.

a. Oil pressures and temperatures (should be within the specified ranges.)

b. Oil levels of the oil reservoir.
13 √
c. Oil leakage of piping or equipment.
d. Oil flows through the sight glasses to confirm all of the equipments are
properly lubricated.
e. Maintain LO pressure > 3.5 kg.

Commission instrument air to motor, to keep it pressurize. Check for healthy

14 √ √
pressure, confirm with panel about Motor purge Healthiness.

15 Line up & Commission instrument air to local panel, to keep it pressurize. √ √

Line up suction drum (10V6) & drain out liquid from it. Also drain condensate
16 √
from V6 to compressor suction & compressor discharge header.

17 Confirm valve positions. √ √

a. Fully open the suction main valve.

b. Fully open the discharge valve(care should be taken if dis valve passing).
c. Confirm other valve positions according to the P & I diagrams.
d. Check a smooth action of the discharge check valve.
e. Line up one each of the pressure safety valves for both stages.
f. Take spill back is lined up. Check stroking of this valve.

AVU & SRLPG Treatment Unit - Skill DevelopmentPage 2 of 2

 g. Check & match compressor load position in field & panel.
h. Set compressor load to 0%

18 Make manual turning (Barring) to confirm the smooth rotation of the rotors. √

19 Prepare for starting of the main driver and check if it is ready to start. √

Start lubricator pump & maintain its pressure > 8 kg. Ensure LO drops from all
20 √ √
points & LO level in reservoir is maintained.

Bypass interlock for no load run. (Compressor will trip if load is not given within
21 √
20 minutes of switch-on.)

22 Confirm start up clearance is obtained. √ √

23 Open spill back 100%. √

Start the main motor in 0% load. Check for any abnormal noise, vibration and
24 √ √
gas and bearing temperatures.

After the compressor has reached a steady states, increase load to 17.9% and
close spill back. Run for about 1 hour under the specified conditions, and check
or confirm the followings.

a. No leakage from the process gas line.

b. Gas pressures
25 √ √
c. Gas temperatures
d. Vibration and noise of compressor.
e. Bearing temperatures of compressor, speed-up gear and main driver.
f. Cooling water inlet and outlet temperatures.
g. Oil system pressures, temperature and oil levels.

If no problems appear on the machines and the system, increase load as per
26 √ √
requirement.

27 Check the operating conditions. √

Continue to operate the compressor for about one hour under the normal
28 √ √
operating conditions and observe.

Check for noise, vibration and take a periodic reading on process gas, lube oil
29 and seal gas supply systems. Confirm from Panel about motor vibration/frame √ √ √
vibration to be healthy .

All readings should be reviewed and checked whether they are normal and
30 √ √ √
within allowable ranges.

AVU & SRLPG Treatment Unit - Skill DevelopmentPage 3 of 2

 During the first several days, make frequent checks to be sure that all conditions
and readings remain reasonably steady and within allowable ranges.
31 √ √
Suction/discharge volume bottles should be drained each shift, report if no gas
or liquid from drain is found and possible chokings in the drain lines.

Suggestions for Improvement of the Content:

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