Training Manual Copressor House

CONTENTS
Part 1: CENTRIFUGAL COMPRESSORS GENERAL: 1

1. Compressors construction and parts 2
2. Centrifugal compressor surging 6
3. Monitoring and protective devices 8
Part 2: STEAM TURBINES GENERAL: 10

1. Steam turbines ‐ principles & operation 11
2. Multi‐stage turbines 13
3. Steam control to a turbine 15
4. Types of steam turbines 16
5. Removal of non condensable gases 18
6. Turbine leak steam and seal steam systems 20
Part 3: NATURAL GAS COMPRESSOR & TURBINE 23

1. Introduction 24
2. N.G. Compressor Start‐Up 25
3. Normal Shut down 38
4. Start after Emergency shut down 40
5. Normal Operation 41
Part 4: PROCESS AIR COMPRESSOR & TURBINE 43

1. Introduction 44
2. P.A. Compressor Start‐Up 46
Part 5: SYNTHESIS GAS COMPRESSOR & TURBINE 62

1. Introduction 63
2. Syn. Gas Compressor Start‐Up 64
6. Special operation‐ Drying unit 82
7. Start up check lest 85
Part 5: REFRIGERATION COMPRESSOR & TURBINE 88

1. Introduction 89
2. Syn. Gas Compressor Start‐Up 92
Maaden Phosphate Company Ammonia Plant
Compressor House Area Page 1

COMPRESSORS CONSTRUCTION AND PARTS
A centrifugal compressors is built of two main parts:
a. Rotor.
b. Casing.
a. Rotor:
1. The shaft, which is coupled to the driver as it rotate, the wheels (impellers)
also do.
2. Impellers used to increase the kinetic energy of gas in the form of velocity
with a minor increase in pressure.
b. Casing:
The casing houses the rotor and is made-up of the following:
1. Diaphragms: These used to separate the stages in multistage compressors
2. Diffusers: Used to change the velocity of the gas into pressure.
3. Guide vanes and return passages: Used to direct (guide) the gas leaving
the diffuser of a stage into the eye of the next impeller.
4. Balancing drum: Used to minimize axial thrust.
5. Labyrinth seals: Fitted in the diaphragm to minimize the internal leakage

between the stages
6. Bearings and Seals

Maaden Phosphate Company A
Ammonia Plant
DETA
AILED PA
ARTS OF CENTRIIFUGAL COMPRE
C ESSORS:
1. Imppellers:
This consists ofo a wheell shaped element

e coontaining 'Curved Vanes'
V at the
t
centree of which is the gass inlet calleed the 'EY
YE' of the impeller.
i T wheell is
The
mounnted on the shaft. Ass the wheell is rotatedd at high sppeed, the gas
g is throw wn
off thhe outer ed
dge of the vanes, annd more gaas flows innto the eyye to take its
place.. The speeed of rotattion of the wheel impparts kinettic energy to the gas in
the foorm of velo
ocity, whichh will be converted
c t pressuree (potentiall) energy.
to
2. Shaaft:
The shhaft due to

o the high speed
s of rootation, willl tend to move:
m -
Radiaally: mo
ovement accross the shhaft (Vibraation) and.
Axiallly: ovement allong the shhaft (Thrust). Thrusst is a tenddency of the

mo t
rotor to move horizontaally in a direction away froom the HP P end off a
comprressor.
In ordder to minim
mize and control
c these movements, bearings are fittted.
(Fig. 1)
Compreessor House Area

A Pagge 3
3. Diffusers:
Following its exit from the blade tips, the partly pressurised gas enters the
diffusion stage of the compressor.
The function of the diffuser is to reduce the velocity of the gas in a carefully
controlled fashion in order to obtain efficient energy conversion. The diffuser
achieves this velocity reduction by controlling the volume of gas during its
passage from the compressor impeller to the delivery outlet.
4. Diaphragms:
As mentioned earlier multistage compressors contain diaphragms, which

separate between the impellers (stages), the diaphragm are usually made of cast
iron or other hard metal such as steel. Some of diaphragms are liquid cooled,
the inside of the diaphragm has a passage way through which cooling water
can circulate.
Fig. (9) Diaphragm

(Fig. 2)

5. Guide Vanes:
Guide vanes are designed to guide the flow of gas efficiently into the eye of the
impeller and placed at the end of return passage of the diaphragm. Inlet guide
vanes can be adjustable either manually or automatically to control the
compressor capacity by changing the angle of gas flow into the eye of the
impeller.
6. Seals:
Seals are used in machines to prevent leakage of fluids to the

atmosphere. Leakage to atmosphere is undesirable, especially
when toxic or other dangerous fluids are concerned.
7. Bearing:
Bearings are very important parts of rotating machinery. They are installed
around the shaft of the rotating element and serve a number of purposes
1. In conjunction with oil, bearings help to minimize friction.

2. They support the weight of the rotor.
3. Bearings control shaft movement.
8. Balancing drum:
Balancing drum, shown in Figure (3) is attached to the shaft at the discharge
end of the compressor to equalize the thrust caused by the imbalance of
pressure, which causes an axial force, or thrust that pushes the rotor toward the
suction end. One end of the drum is vented to the suction end of the
compressor while the non-vented side of the drum is exposed to the gas at
discharge pressure. The discharge gas pushes on the balancing drum exerting a
force in the direction of the discharge end of the compressor.

(Fig.
Fig. (10) 3)
Balancing Drum
CENTRIFUGAL COMPRESSOR SURGING
Surging is the rapid back and forth flow of gas in the compressor; surging
occurs when the compressor is operated below minimum capacity
A centrifugal compressor operates within certain limits of speed, suction

pressure, suction gas volume and discharge pressure.
When the suction gas volume flow is below the capacity of the machine at
operating speed and its discharge pressure is high, a high differential pressure
exists across the compressor. This condition can cause a momentary back-flow
of discharge gas through the machine into the suction side. The back-flow

tends to slow down the compressor while the governor control system tries to
maintain the operating speed.
This rapid back-and-forth flow of gas within the compressor plus the action of
the governor in trying to maintain a steady speed causes 'Surging'.
Surging can be very damaging in compressors in that high vibrations are set up
which will damage bearings, seals,, rotor and to associated piping and
equipment.
Surging is normally prevented by a ‘Recycle Control System’, which at some

preset, suction low-flow condition, will operate to allow discharge gas to
recycle back to the suction side. The recycle gas is taken from downstream of
the discharge gas cooling system to prevent heat build up. Many compressor
systems simply rely upon a suction flow element and control system operating
a recycle valve before the suction flow drops to the surge point.
Process
7A10-V03
88,566
50 160
MPS
22.8
FCV
Antisurge
Valve
Turbine
7A10-K01-TS01 NG compressor
7A10-K01
To Ejectors
WSR Condenser
7A10-E01 7A10-E01
WS Antisurge cooler
WCR
WC
(Fig. 4)

Large powerful machines incorporate a 'Computerized Suction Flow

Controller' which takes into account - suction gas pressure, temperature,
volume and molecular weight and computes the point at which the recycle
valve will open to prevent surging.
The 'Compression Ratio' of a compressor is the ratio between the discharge
and suction pressures in Absolute Units - (psia or bara).This is also called
“Compressor pressure ratio”. For example, if a compressor discharge pressure
is 600 psia and its suction pressure is 50 psia, the pressure ratio is 12 : 1.
Operating conditions, which lead to surge, are:
Drop in suction pressure.

Rise in discharge pressure.
Drop in machine speed (energy input).
Alteration of gas specific gravity.
Low flow rate.
MONITORING AND PROTECTIVE DEVICES
Control systems for compressor application are passing through different

levels, such levels currently available range from the basic manual type to
remote logic decision making microprocessor systems.
All control systems, within manual or automatic, contain fundamental elements

for:
Sensing.
Monitoring.
Protection devices.
For compressors in general the following parameters are monitored, controlled

and safety devices are provided to:
Warn the operator to take a corrective action, start a stand by

device or stop the machine.

Lube oil pressure (low pressure will start the stand by pump, warn
the operator trip the machine).
Bearings temperature (warn the operator to stop the machine if

temperature increases).
Discharge temperature / pressure (warn the operator to stop the

machine if high).
Seal oil level (start the standby pump, warn the operator to trip the
machine).
Vibration and axial displacement (warn the operator / trip the

machine if exceeds the preset values).
Compressor speed (trip the machine in case of over speed).
In addition to the above, other parameters related to the compressor drive will
trip the compressor.


STEAM TURBINES - PRINCIPLES & OPERATION
A turbine is driven by the flow of a high-energy fluid - liquid, gas (or air). The
kinetic energy of the fluid is converted into mechanical energy.
In steam turbines, the thermal energy contained in steam is used to drive the
shaft of the turbine. Steam turbines are generally used where there is a
plentiful supply of water. The water must first be treated to remove impurities,
which will cause problems in the turbine - chlorides, other salts, Oxygen and
solid particles. This is done to prevent corrosion, erosion and scale deposits in
the system.
When the water has been purified, it is then passed into a Steam Generation
Plant where it is heated to produce steam.
Steam at normal atmospheric conditions is Saturated (Wet) steam - i.e. 212°F

(100°C) and is of no use for driving turbines.
The use of this steam in a turbine will cause erosion of the turbine internals due
to droplets of water contained in the steam. The boilers are therefore
constructed with a 'Super-heater' section, which takes the wet steam and adds
more heat energy to it, up to a high temperature. At this temperature, the steam
cannot contain any water. When steam is super-heated, it contains much more
heat energy than wet steam and can be piped long distances with little loss of
energy or condensation taking place.
In any turbine, the rotor is mounted on a shaft and consists of the ' sails ' or '
paddles which we will now refer to as 'Buckets' or 'Blades'. The blades are
fitted into a wheel at an angle and are called' Rotor Blades'.
The wheel is then mounted on to the shaft. This arrangement of a single wheel
is called lone stage' or a 'Single Stage Rotor' and does not produce much
power. (Figure. 5)
As stated earlier, the energy needed to drive our turbines, comes from high-
pressure, superheated steam. In order to get the steam to pass to the rotor
blades, we need a means of directing the steam on to the blades. The piece of

Ammonia Plant
equipmment usedd for this iss called a NOZZLE.

N As the steeam leaves a nozzle, its
pressuure decreasses and its 'VELOCIT TY' increaases.
This high
h veloccity steam jet is direected at the rotor blaades and the
t rotor and
a
shaft begin
b to ro
otate. As more
m and more
m steam
m is releaseed on to thhe blades, the
t
speedd of rotation
n increasess.
(Fig. 5)
5

A Pagee 12
Ammonia Plant
MUL
LTI-STAG
GE STEAM
M TURBIN
NES
A muulti-stage tu urbine is one,

o whichh has two or more wheels. The T steam is
directted on to the
t blades of the firsst stage whheel and, as
a it strikees the anglled
bladess they mov ve away inn an oppossite direction to the flow
f of steeam, causiing
rotatioon of the wheel
w and shaft.
s
As thhe steam gives up energy too move thhe rotor blades, b its pressure is
decreaased, its vo
olume incrreases and it leaves thhe blades in
i an oppossite directiion
to that taken by the wheel.. (Figure. 6)
6
(Figg. 6)

A Pagee 13
Ammonia Plant
To acchieve thiss, a row of

o fixed, unmoving,
u , angled blades
b is, fitted intoo a
“DIAPPHRAGM M”, which is mountedd in the “CA
ASING” ofo the turbine.
Thesee stationary
y blades are called “S
STATOR BLADES”
B ”.
The sttator bladees act like further

f nozzzles and re-direct
r thhe steam onn to the rottor
bladess of the seccond stagee wheel. Because
B thee steam preessure has dropped anda
its volume is grreater, to get
g the sam me amount of energy out of it, the t blades of
the seecond stagee are largerr (greater area)
a than those
t of the first stagge.
Due to t the decrrease in prressure and increasee in volum me, this arrrangement of
alternnating rotorr and statorr blades, annd increasiing blade size,
s is
continnued throuugh the turbbine in ordder to obtaain the requuired amouunt of powwer
from thet steam for
f operational needss.
Whenn the steamm leaves a turbine,

t it may still contain
c a lot
l of energgy - pressuure
and heat.
h m be dirrected for use in annother proccess system.
Thiss steam may
(Figurre. 7)
(Fig. 7)

A Pagee 14
Ammonia Plant
STEA
AM CONT
TROL TO
O A TURB
BINE
In ordder to contrrol a turbinne speed, a method ofo controlliing the steam supplyy is
needeed. To do thhis, the turrbine steam
m inlet firstt enters a 'S
STEAM CH HEST'.
The stteam chestt contains a series off steam vallves. whichh can be oppened onee at
a timee as requirred. As eaach valve opens
o the flow of steeam to thee nozzle(s)) is
increaased thus in
ncreasing the
t turbinee speed. (Fiigure. 8)
The opening
o off the steam OVERNOR', which in
m valves iss controlleed by a' GO
turn iss controlled by the tuurbine speeed control system.
s
(Fig.
( 8)

A Pagee 15
TYPES OF STEAM TURBINE
For any steam turbine to operate, a pressure difference must exist between the
steam supply and the exhaust. Where the exhaust steam is above atmospheric
pressure, the turbine is classed as a ' Back Pressure Steam Turbine ' or 'Non-
Condensing Steam Turbine '.
1. BACK-PRESSURE STEAM TURBINES
As an example, taking our 600 Psi steam supply to a turbine, the turbine speed
will still be controlled by the steam input. If we have an exhaust pressure of
say 125 Psi (a D.P. of 475 Psi), this exhaust steam will still contain a lot of heat
and pressure energy and may be used to drive other smaller turbines and for
heating purposes in re-boilers, heaters, vaporizers ... etc.
In this type of turbine, the exhaust pressure must be maintained at a constant

level by a PCV control system downstream of the turbine exhaust. Any
changes in the exhaust pressure will affect the turbine speed by changing the
pressure drop across it. The governor would be fighting against these pressure
fluctuations and speed control would be erratic.
2. CONDENSING STEAM TURBINES
In a condensing steam turbine, the maximum amount of energy is extracted

from the steam. This is achieved by passing the exhaust steam into a
condenser (called a Surface Condenser). The steam is condensed by surface
contact with bundles of tubes through which cooling water is passing. As the
steam condenses, its volume, on changing to water, decrease by about 1800
times.
This great decrease in volume causes a vacuum to form in the condenser. Due
to this, the pressure drop across the turbine and therefore the turbine power, is
maximized. The steam condensate (water) is level controlled in the condenser
and pumped back to the steam generation plant.

(Fig.. 9)

A Pagee 17
However, although the water for the steam generation is purified and treated,
the steam will still contain some Non-condensable gases. These non-
condensable will build up in the surface condenser and gradually destroy the
vacuum, thereby decreasing the P.D. across the turbine and thus decreasing its
efficiency and power.
In order to maintain the vacuum, the non-condensable gases must be removed

from the surface condenser. This is carried out by a system of ' STEAM
EJECTORS and ' Ejector Condensers ', which pull the gases from the surface
condenser and eject them to the atmosphere.
REMOVAL OF NON-CONDENSABLE GASES
As stated, the gases are removed from the surface condenser by a system of 1st
and 2nd stage ejectors and condensers. An ejector consists of a 'Venturi Tube '
through which a jet of high velocity steam is passed. This high velocity steam
creates a 'suction' (vacuum) in the venturi tube. Condensing the steam as it
leaves the ejector increases vacuum.
The non-condensable gases are piped into the low-pressure area of the 1st stage
ejector and are carried with the steam into the Ist stage ejector condenser. The
water produced from the steam is piped back to the surface condenser.
Again, these gases, as they build up in the 1st stage ejector condenser, will tend
to destroy the vacuum. To prevent this, the gases are pulled from the 1st stage
system into the 2nd stage by another ejector. Again the steam is condensed and
piped back to the surface condenser.
In the 2nd stage condenser, the gases are allowed to build up pressure until, at
just above atmospheric pressure, a check (non-return) valve will open and pass
them to atmosphere. As they escape, the pressure drop causes the check valve
to close again. This is a continuous process.
A water level is maintained in the ejector condensers by a 'Loop' seal tube to

prevent the gases also returning to the surface condenser.

(Fig.. 10‐

A Pagee 19
TURBINE SEAL-STEAM SYSTEM (Figure. 11)
When a condensing steam turbine is first started up and in a low-load

condition, steam from the inlet (H.P.) end will leak from the outboard gland -
even though carbon-ring seals and labyrinth seals are installed to minimize the
leakage. Superheated steam is invisible and, due to its high temperature, is
very dangerous. Leakage of steam is also a waste and is not desirable.
Conversely, under the same low-load conditions, the L.P end of the turbine will
be under the vacuum of the surface condenser.
The vacuum will tend to pull in cold atmospheric air through the seals along
the shaft. Cold air will have a detrimental effect on the hot metal of the shaft,
which can lead to damage.
In order to minimize these problems, a manually controlled supply of low

pressure SEAL steam (about 2 Psi), is piped to a common line feeding the
glands of the machine. This pressure will prevent the ingress of air at the L.P.
end and ensure a positive pressure at the H.P. end during start-up. (The ejector
units are started and vacuum pulled before starting the turbine).
When the turbine load is increased, the leakage of steam into the Seal-steam
header will cause greater pressure than the Seal steam supply and will begin to
flow to the L.P. end seal. At this point, the Seal steam supply can be shut
down and the Seal-steam taken from the H.P. end and manually maintained at
2 Psi by venting excess into the surface condenser.
Even when the seal pressures are maintained at 2 Psi, some leakage occurs
from both seals. This is taken care of by the LEAK steam recovery system.

Ammonia Plant
(Fig. 11)
TURB
BINE LEA
AK-STEA
AM SYSTE
EM (Figurre. 12)
Leakaage of steamm from turrbine glandds to atmoosphere (in both typess of turbinne),
as alreeady menttioned, is dangerous
d and a wastte of steamm. The turrbine inboaard
and ouutboard glands are fiitted with carbon
c ringg seals andd labyrinth seals to heelp
prevennt leakage.

A Pagee 21
Ammonia Plant
Thesee seals do not

n compleetely stop the t escape of steam. In order too completeely
prevennt it, a turb
bine will also be fitteed with a LEAK-stea
L am system, which pippes
the leeakage into o a water-ccooled leaak-steam coondenser. The conddensate froom
the coondenser iss drained away
a to a 'Hot-well' from wheere it is retturned to the
t
steam
m generation n plant.
The leak
l steam
m condenseer is fittedd with an ejector syystem to remove
r noon-
condeensable fro
om the steaam and disccharge them to atmoosphere witth the ejecttor
exhauust steam. This, in thhe case off the condeensing turbbine, is to prevent
p noon-
condeensable from re-enterring the surrface condenser.
(Fig. 12)

A Pagee 22

1. Introduction
Natural gas process feed stream is passing natural gas compressor suction
separator 7A10-V03 and entering natural gas compressor 7A10-K01 which is
compressing it to 5.28 MPa g. The compressor is a MP steam turbine driven
single shaft type. A bypass around the natural gas compressor is installed for
start-up operations when gas is fed to the reformer without prior compression.
The compressor is equipped with dry gas seals. Lube oil for compressor and
turbine is supplied by the lube oil system for natural gas compressor/turbine
7A10-K01-TS01.
The natural gas compressor serves also as nitrogen circulator for heating up
purposes of the reforming section, for the low temperature CO shift catalyst
reduction and Methanator heating..
(Fig. 13)

2. NG Compressor Start Up
a. Startup of Lube Oil Circulation

No. Actions Resp.
1 Ensure all drains and vents are closed in Lube oil, Control oil lines, Lube oil
FO
coolers, accumulators and Control oil filters.
2 Ensure lube oil over head tank non return valve bypass valve is in closed FO
condition.
3 Open suction valves of 7A10‐U01‐P01 / 02 / 03 Lube oil Pumps. FO
4 Open discharge valves of 7A10‐U01‐P01 / 02 / 03 Lube oil Pumps. FO
5 Ensure Lube oil and Control oil accumulators valves are lined up. FO
6 Stroke checks 7A10‐PV1030, 7A10‐7A10‐TV1040,7A10‐TV1042 and line up FO

isolation valves. CO
7 Ensure N2 to 7A10‐U01‐T01 on 25‐GNN‐0417 is in open condition. FO
8 Ensure Lube oil console is having 70% level and check moisture content FO
with Lab. Centrifuge if necessary.
9 Ensure both the Lube oil Pumps 7A10‐U01‐P01 /P02/03 Motors are SS
energized.
10 Start 7A10‐U01‐P01 or P02 Motor driven Lube oil Pump check for any oil FO
leaks and get it fixed.
11. Open lube oil cooler and Filters vents to bleed off air till continuous flow FO
of oil is noticed through sight glasses.
12 FO
Ensure Lube oil header pressure is maintained at 0.3 MPa through 7A10‐
PIC1033 and pump discharge pressure through 7A10‐PIC1030 at 1.0 MPa
13 Check ∆p across Lube oil filters 7A10‐U01‐F01/02 and if it is more than CO

0.15 MPa change over to standby filter.

14 If Lube oil temperature is less than 40˚C line up SL Steam to console FO

through 7A10‐TV1040 and raise oil temperature.
15 If Lube oil temperature is more than 40˚C open cooling water return valve FO
and adjust flow by throttling supply valve. CO
16 Check for oil leaks both at floor level, Compressor Platform and fix them. FO
17 Check oil flow through sight glasses in oil return lines of bearings of FO
Turbine and Compressor.
18 Fill up lube oil over head tank through NRV bypass line till continuous FO
overflow through sight glass noticed.
19 Keep the other Lube oil Pump 7A10‐U01‐P01/02 and Emergency Lube Oil FO
Pump 7A10‐U01‐P03 Motor switches on Remote mode.
20 Check Auto start of 7A10‐U01‐ P01/P02 Motor at 0.85 MPa in PI1031. FO
21 After checking Auto start of 7A10‐U01‐P01/02 and keep its motor Switch FO
on Remote.
22 Check Auto start of 7A10‐U01‐P03 in same way which should come at FO

0.052 MPa in 7A10‐PI1035. Keep its switch on Remote. CO
b. Startup of Dry Gas Seal Unit
No. Actions Resp.
1 Ensure all drains and vents are closed in Dry Gas seal unit are closed. FO
2 Ensure N2 is available for Buffer gas and instrument air is available for FO
driving Dry Gas seal Unit Booster Compressor.
3 Ensure N2 is lined up for Buffer Gas through filters 7A10‐U11‐F03/04 and FO

7A10‐PRV1557 is set at 0.1Mpa for secondary seals.

4 Check oil level in Filter of Booster Compressor and make up if necessary. FO

Line up inlet and outlet valves of Booster Compressor.
5 Line up primary seal gas to the Compressor and to the Seal gas Booster FO
unit through filters 7A10‐U11‐F01/02.
6 Set 7A10‐PDIC1041 at 0.056 MPa on Auto mode. CO
7 Establish a flow of 5.0 Nm3/hr of Secondary seal gas through 7A10‐FI1045 FO

and 7A10‐FI1046 by adjusting valves manually.
8 Pressurize the Compressor casing with N2 or NG depending on the service FO

for which Compressor has to be started.
9 Initiate 7A10‐HS1041 to start the seal gas Booster unit as the casing FO
begins to pressurize.
10 Establish a flow of 58 Nm3/hr of Primary Seal Gas through 7A10‐FI1005 FO

and 7A10‐FI1006 by adjusting valves manually.
c. Purging of NG Compressor Loop

No. Actions Resp.
1 Ensure 7A10XV1001 and 7A10PXV1003 are in closed condition and in

FO
between bleed off is kept open to avoid NG entry.
2 Ensure 7A10‐HXV1005 and its downstream isolation valve is in closed FO

condition and in between bleed off is kept open.
3 Ensure spectacle blind in between 100mm double block valves in N2 FO

make up line of NG Compressor is reversed to open.
4 Open 100mm N2 make up double block valves gradually and feed N2 to FO

Compressor.
5 Pressurize the loop up to 0.5Mpa FO
6 Depressurize the loop up to 0.02 MPa through HXV1003. FO

7 Repeat the above steps till O2 less than 2 vol. %. FO
8 Keep the loop under Nitrogen positive pressure of 0.5MPa. FO
9 Check for leaks if any with soap solution and get them fixed. FO
10 If Compressor has to be started on NG mode continues pressurizing with FO

NG through 7A10‐XV1001 and 50mm bypass across 7A10‐PXV1003 up to
CO
2.0 MPa and do leak testing.
d. Lining up of Turbine Condenser 7A10-E05

No. Actions Resp.
1 Inform Utilities about lining up of Sea cooling water from 7A60‐E01A/B to

FO
7A10‐E05.
2 Open 7A10‐E05 Sea Water Return valve fully and open Sea Water Supply FO
valve by 20% or slightly more as required.
3 Establish level in 7A10‐E05 through service water hose. FO
4 Stroke check 7A10‐LV1021A and B. FO

CO
5 Ensure 7A10‐LV1021A and B upstream and downstream isolation valves FO

are lined up. Set 7A10‐LIC1021 at 50% on Auto.
6 Check condensate Pumps 7A10‐P01A and B Motors are energized. SS
7 Open 7A10‐P01A/B suction and discharge valves. FO
8 Line up cooling water to Ejector condenser 7A10‐U04‐E01 FO
9 Drain condensate from LP steam lines to Ejectors. FO
10 Start one of the condensate pumps 7A10‐P01A/B on recycle through FO

7A10‐LV1021B.
11 Raise 7A10‐E05 level above 60% and check for standby Pump Auto start. FO
Keep both the Pumps on Remote. CO

12 Open sealing condensate to 7A10‐PSV151 on 7A10‐E05. FO
13 Gradually line up SL Steam to Hogging ejector. Open valve on non FO

condensable vapor line.
14 Gradually line up one set of ejectors for 1st and 2nd stage each. FO
15 Establish vacuum at ‐0.08 MPa in 7A10‐E05. FO
16 Discard the initial condensate collected to dump out. FO
17 Check for possible air ingression and arrest it. FO
e. NG Compressor Trip Check
Note
Ensure Lube oil system, Dry Gas seal Unit, Turbine condenser in line and Compressor
casing is under pressure. After ensuring no Lube oil, Dry Gas seal alarm conditions are
not existing reset 01X1.01 NG Compressor/Turbine Trip. If Compressor has to be
started on N2 mode, Override 7A10‐HS1004. Finally Reset trip X_A, NG Compressor
No. Actions Resp.
1 Ensure SM Steam inlet isolation valve of 7A10‐K01‐TS01 is in closed

FO
condition.
2 Set the Idle/Rated Switch in NG Compressor Operator Panel (DCS) 7A10‐

CO
HS1035 to Idle.
3 Ensure the manual trip button (Red) is pulled out. FO
4 Ensure the TTV test lever is in vertical (Neutral) position. FO
5 Initiate Start Turbine switch 7A10‐HS1033 which will energize Control oil FO
Trip solenoid valves 7A10‐XVY1030A/B.
6 Latch each solenoid valve by pushing down on the handle which opens FO
the solenoids and pressurizes Emergency Trip Cylinder with Control oil.

7 Ensure TTV is latched in the field. FO
8 FO
Ensure 01X1.04 is healthy and Dry Gas Seal Unit is lined up.
CO
9 Ensure Lube oil low pressure Trip is in line. CO
10 Ensure High Axial Displacement trip of both Turbine and Compressor are CO
in line.
11 Ensure High Exhaust Steam Pressure Trip of 7A10‐K01‐TS01 is in line. CO
12 Ensure Control oil low pressure Trip is in line. CO
13 Ensure NG Compressor High Suction Pressure Trip is in line. CO
14 Ensure Turbine over speed Trip is in line. CO
15 Actuate 7A10‐HS1001 (Emergency Off) from DCS and confirm Trip alarm FO
appears in DCS/ Field and delatching of TTV. CO
16 Reset 01X1.01, repeat same for 7A10‐HS1002 (Emergency Off) from Field FO
and confirm Trip alarm /Delatching of TTV. CO
17 Reset 7A10‐X_1.01 and actuate 01X1.04 Dry Gas Seal Trip from DCS and FO
confirm Trip alarm /Delatching of TTV. CO
18 Repeat for Low Lube oil, Low Control oil pressure Trips by reducing the FO
Lube oil turbine speed keeping Motor on Local. CO
19 Check Auto Start of 7A10‐U01‐P02 and 7A10‐U01‐P03 by keeping the FO

Motors switches on Remote. CO
20 After completing Trip checking restore back all, keep lube oil Turbine FO
pump running and secure Motor switches on Remote.

f. Warming up of Main Turbine 7A10-K01-TS01
Note
The conditions to be checked and ensured before Startup of NG Compressor/Turbine

are given in the Check List under 7.5.1 Special Operations. During each and every
Startup of the machine it should be updated, signed by concerned all to ensure safe
No. Actions Resp.
1 Ensure SM Steam inlet isolation valve of 7A10‐K01‐TS01 is in closed FO

condition.
2 Open SM Steam inlet valve downstream trap u/s drain i/v for condensate FO
removal & ensure trap is isolated .
3 Warm up through SM inlet upstream 25mm double block vent valves and FO
through 25mm bypass up to Turbine TTV.
4 Ensure all the line condensate is removed & turbine is in heated up FO

condition
8 Ensure TTV is latched in the field and in closed condition. FO
9 FO
CO
10 Watch for SM Steam inlet temperature of 7A10‐K01‐TS01 is 350˚C. FO
11 Throttle warm up valves and once SM Steam Pressure has risen to 5.3 FO
MPa open 150mm SM isolation valve fully.

g. Startup of 7A10-K01 on N2 Mode
NOTE
Selector Switch 7A10‐HS1011 enables the operation of machine either on Speed or

Suction Pressure. Compressor is protected from surging by the Anti surge Controller
7A10‐FIC1003 via Recycle Cooler 7A10‐E01 and Selector Switch 7A10‐FHS1003
f l d
No. Actions Resp.
1 Set 7A10‐PIC1040 at 0.02 MPa on auto and line up 7A10‐PV1040 sealing steam FO/CO
to 7A10‐K01‐TS01
2 Adjust gland leakage block valve of 7A10‐K01‐TS01 and keep slightly negative FO
pressure of ‐0.0005 MPa.
3 Override HS1004 to start Compressor on N2 mode. Set the Idle/Rated switch CO

7A10‐HS1035 to Idle.
4 Override 7A10‐FHS 1154 low Feed Gas to Reformer. CO
5 Override 7A10‐FFHS1155 Low Steam/Carbon ratio to Reformer. CO
6 Set 7A10‐FHS1003 Selector Switch on N2 mode for Anti surge Controller 7A10‐ CO
FIC1003.
7 Ensure 7A10‐HXV1003 and its bypass valves are in closed condition if opened CO
for purging.
8 Ensure 7A10‐XV1001, 7A10‐PXV1003 are closed and in between 25mm bleed FO

off kept opened. (Ensure spectacle blind is closed). CO
9 Ensure 7A10‐HXV1005, discharge manual valve are closed and in between FO

25mm bleed off kept opened. (Ensure spectacle blind is closed).
10 Ensure spectacle blind and double block valves in 250‐NAG‐7A10‐0404 at FO

Compressor discharge are opened if circulation is for Reformer N2 loop.

Compressor discharge are opened if circulation is for LTS N2 loop.

12 Finally ensure Compressor casing is under pressure and Anti surge valve 7A10‐ FO
FXV1003 is in full open condition.
13 Reset Trip X_A and 01X1.01 from DCS. Watch for local “Turbine Ready to Start” FO
lamp glowing. CO
14 Ensure the manual Trip button (Red) is pulled out and locking lever is in place. FO
15 Ensure TTV Test lever is in vertical (neutral) position. FO
16 Initiate Start Turbine switch 7A10‐HS1033 from DCS. CO
17 Latch solenoid valves 7A10‐XVY1030A/B by turning the handles down and FO

watch for Control oil pressure rise.
18 Push up the Reset button on TTV to latch it. FO
19 Inform DCS and slowly open TTV until the Rotor starts to turn. Increase the FO
speed to 1000 RPM and hold for 30 minutes.
20 After 30 minutes open TTV to speed up to 2000 RPM, watch for Governor FO
control and full open TTV. Hold for 30 minutes.
21 Ensure SM Steam availability co‐ordinate with Utilities for raising 7A10‐K01 FO

speed to Minimum Governor Speed.
22 Close the drains on TTV and casing. Watch for abnormal sound and vibration if SS
any.
23 Change switch 7A10‐HS1035 to Rated, watch for speed raise and crossing CO
critical speed band quickly. (4905‐6160 RPM).
24 Ensure 7A10‐K01 speed holding at Minimum Governor Speed of 9231 RPM. CO

Monitor axial movement / radial vibrations.
25 Maintain 7A10‐E05 level through 7A10‐LIC1021. CO
26 Adjust 7A10‐FIC1003 to route N2 to Reformer / LTS loop and accordingly FO

increase make up N2 to 7A10‐K01 suction. CO
27 Once Compressor operation is stabilized and vacuum is steady cut off Hogging FO
ejector closely watching vacuum.

h. Startup of NG Compressor on NG Mode

No. Actions Resp.
1 Set 7A10‐PIC1040 at 0.02 MPa on auto and line up 7A10‐PV1040 sealing FO

steam to 7A10‐K01‐TS01. CO
2 Adjust gland leakage block valve of 7A10‐TS01 and keep slightly negative FO
pressure of ‐0.0005 MPa.
3 Override 7A10‐HS1004 to start Compressor on NG mode. Set the CO

Idle/Rated switch 7A10‐HS1035 to Idle.
4 Override 7A10‐FHS1154 low Feed Gas to Reformer. CO
5 Override 7A10‐FFHS1155 Low Steam/Carbon ratio to Reformer. CO
6 Set 7A10‐FHS1003 Selector Switch on NG mode for Anti surge Controller CO

FIC1003.
7 Ensure 7A10‐HXV1003 and its bypass valves are in closed condition if FO

opened for purging. CO
8 Ensure 7A10‐XV1001, 7A10‐PXV1003 are opened and in between 25mm FO

bleed off kept closed. (Ensure spectacle blind is opened).
9 Ensure 7A10‐HXV1005, discharge manual valve are opened and in FO

between 25mm bleed off kept closed. (Ensure spectacle blind is closed).
10 Ensure spectacle blind and double block valves in 25mm at Compressor FO

discharge are closed.

Compressor discharge are closed.
12 Finally ensure Compressor casing is under pressure and Anti surge valve FO
7A10‐FXV1003 is in full open condition.
13 Reset Trip X_A and 01X1.01 from DCS. Watch for local “Turbine Ready to FO
Start” lamp glowing. CO

14 Ensure the manual Trip button (Red) is pulled out and locking lever is in FO
place.
15 Ensure TTV Test lever is in vertical (neutral) position. FO
17 Latch solenoid valves 7A10‐XVY1030A/B by turning the handles down FO

and watch for Control oil pressure rise.
19 Inform DCS and slowly open TTV until the Rotor starts to turn. Increase FO
the speed to 1000RPM and hold for 30 min.
20 Close the drains on TTV and casing. Watch for abnormal sound and FO
vibration if any.
21 After 30 minutes open TTV to speed up to 2000 RPM, watch for FO

Governor control and full open TTV. Hold for 30 minutes.
22 Ensure SM Steam availability co‐ordinate with Utilities for raising 7A10‐ SS

K01 speed to Minimum Governor Speed.
23 Change switch 7A10‐HS1035 to Rated, watch for speed raise and crossing CO
critical speed band quickly. (4905‐6160 RPM).
24 Ensure7A10‐K101 speed holding at Minimum Governor Speed of 9231 CO

RPM. Monitor axial movement/radial vibrations.
26 Adjust 7A10‐FIC1003 to route NG to Reformer / LTS loop and accordingly FO

increase NG flow to 7A10‐K01 suction. CO
27 Once Compressor operation is stabilized and vacuum is steady cutoff FO

Hogging ejector closely watching vacuum.

i. Following guidelines to be followed for Cold Start, Warm Start, Hot Start and
Very Hot Start of NG Compressor:
Hold Time at Hold Time at

Type of Start Restart attempt after
1000 RPM 2000 RPM
Cold Start More than 24 Hours 30 Minutes 30 Minutes
Warm start 03 to 24 Hours 20 Minutes 20 Minutes
Hot Start 0.5 to 03 Hours 10 Minutes 10 Minutes
Very Hot start Less than 0.5 Hours 10 Minutes 05 Minutes
Following guidelines to be followed for bearing vibration and temperature:
Vibration Normal Maximum Trip
Journal Bearings < 30 Microns 38 Microns 57 Microns
Bearing Metal
Normal Maximum Trip
Temperature
Journal/Thrust
< 100˚C 120˚C 125˚C
Bearings
Maximum – Alarm only. Can be operated at this value indefinitely.
Trip – Alarm only. The DCS Operator should take the action to shutdown the machine.
Note
Machine will shut down by the Trip System on Compressor or Turbine Axial Displacement
at a value of +/‐ 0.75 mm.

ABBREVIATION
L: LOCAL
DCS : DISTRIBUTED CONTROL SYSTEM
CCR : CENTER CONTROL ROOM
LGB : LOCAL GAUGE BOARD
GSP : GAS SEAL PANEL
OSTM : OVERSPEED TRIP MODULE
GOV : GOVERNOR
SW : SWITCH
PB : PUSH BUTTON
CUST : CUSTOMER
MHI : MITSUBISHI HEAVY INDUSTRIES, LTD.
TRANS : TRANSMITTER
INST : INSTRUMENT
MPU : MAGNETIC PICK‐UP
ANA : ANALOG SIGNAL
SOV : SOLENOID VALVE
COS : CHANGE OVER SWITCH
*: APPLICABLE
IS : INTRINSICALLY SAFETY INSTRUMENT
ESD : EMERGENCY SHUT DOWN SYSTEM
CCR : CENTRAL CONTROL ROOM
ITCC : INTEGRATED TURBINE & COMPRESSOR CONTROL SYSTEM

3. Normal Shutdown of NG Compressor
Note
When Ammonia Plant had proposal for planned shutdown, the plant Front End Load
will be gradually reduced, Back End will be shutdown and once Feeds had cutoff to
Reformer followed by N2 cooling with NG Compressor had completed, NG
Compressor will be stopped as follows:
No. Actions Resp.
1 Ensure Feed Gas to Primary Reformer reduced gradually in steps

and 7A10-PIC1003 is controlling Compressor Discharge pressure CO
by reducing speed.
2 Ensure 7A10-FIC1003 antisurge controller of NG Compressor CO

maintains the discharge flow by recycling. (Unloading)
3 When speed reaches Minimum Governor take 7A10-PIC1003 on CO

Manual mode.
4 When Feed Gas is completely cutoff to Primary Reformer and CO

cooling of Feed preheater coils is no longer required unload the
Compressor fully by opening 7A10-FXV1003.
5 FO
Isolate 7A10-HXV1005 and manual discharge valve.
CO
6 Inform Utilities about stopping of NG Compressor and stop the FO

machine through 7A10-HS1001. CO
7 Close Turbine TTV from field and also main SM Steam inlet FO
isolation valve.
8 Take steam ejectors out of service by closing non condensable FO

valves followed by steam valves.
9 Break the vacuum inside Turbine condenser and stop the FO

condensate pump 7A10-P01A/B.
10 When vacuum falls below 0.02 MPa isolate sealing steam to FO

Turbine.

11. Continue Lube oil circulation and throttle Lube oil cooler return FO
valve to maintain oil temperature 40-45˚C.
12. Isolate 7A10-XV1001 and 7A10-PXV1003 suction valves. CO
13 Depressurize Compressor casing through 7A10-HXV1003 to FO

Synthesis Gas Flare.
14 Purge the NG Compressor loop with N2 through 50mm GNN-7A10- FO

0303 line.
15 Pressurize up to 0.5 MPa and depressurize through 7A10-HXV1003 FO

up to 0.05 MPa.
CO
16 Repeat this until Combustibles is less than 1% volume. FO
17 Check for explosives at possible drain locations and continue FO

purging if any explosives noticed.
18 When Compressor casing pressure is less than 0.05 MPa Dry Gas FO
Seal Booster Compressor can be stopped.
19 When Turbine and Compressor bearing temperatures are less than FO

40˚C Lube oil circulation can be stopped.
20 Inform Utilities and isolate Cooling water to 7A10-E01 and Sea FO

Cooling Water to 7A10-E05.

4. Startup after Emergency Shutdown of NG Compressor
After identifying the cause of tripping of NG Compressor start the Compressor as described
under Normal Startup Procedure (7.1.1).
Follow the guidelines given below for Hot Restart Slow roll times for restarting the
Compressor:
Restart attempt Hold Time at 2000

Type of Start Hold Time at 1000 RPM
after RPM
Warm start 03 to 24 Hours 20 Minutes 20 Minutes
Hot Start 0.5 to 03 Hours 10 Minutes 10 Minutes
Very Hot start Less than 0.5 Hours 10 Minutes 05 Minutes
Journal Bearings < 30 Microns 38 Microns 57 Microns
Bearing Metal
Normal Maximum Trip
Temperature
Journal / Thrust
< 100˚C 120˚C 125˚C
Bearings

Note
Machine will shut down by the Trip System on Compressor or Turbine Axial Displacement at
a value of +/‐ 0.75 mm.

5. Normal Operations of NG Compressor
Machine Monitoring
Parameter Operating Value Controlled By Resp.
Suction Pressure 1.9 MPa 7A10‐PIC1003 CO
Discharge Pressure 5.39 MPa 7A10‐PIC1003 CO
Discharge / Antisurge Flow 73,000 Kg/Hr 7A10‐FIC1003 CO
Lube Oil Pressure 0.15 MPa 7A10‐PIC1033 CO
Lube Oil Temperature 45˚C 7A10‐TIC1042 CO
Control Oil pressure 1.0 MPa 7A10‐PIC1030 CO
∆P of Dry gas seal 0.057 MPa 7A10‐PDIC1041 CO
Primary Seal Gas Flow 58 Nm3/Hr 7A10‐FI1005/1006 FO
Secondary Seal Gas flow 5 Nm3/Hr 7A10‐FI1045/1046 FO
Turbine Condenser Level 50% 7A10‐LIC1021 CO

No. Actions Resp.
1 Watch for any abnormal sound, vibration, leak etc. in Compressor,

Turbine, Lube oil Pump, Turbine, Condensate Pump and report to Shift FO
Supervisor on top priority.
2 Observe any deviation in Process Parameters and follow up with

FO
Instrument Maintenance for corrective action.
3 Coordinate with Maintenance Supervisors for cleaning of Dry Gas seal FO

filters, Lube oil makeup to console, cleaning of strainers etc.
4 Periodical monitoring of oil flow through sight glasses of oil return lines FO
of bearings and report any abnormality like moisture etc.
5 Watch for any Steam, Gas, and Oil leaks and fix them on top priority. FO
6 Closely monitor Exhaust pressure and changeover Ejectors if necessary. FO
7 Watch for level build up in Suction separator. FO
8 Check Stand‐by Lube Oil Pumps / Condensate Pumps motors switches FO

on Remote position.
9 Maintain Primary and secondary Seal Gas flows at specified values by FO

vendor.
10 Adjust Sea Cooling water to7A10‐E05, cooling water to 7A10‐E01 / Lube FO

oil cooler.
11 Check Dry gas seal for any Oil by opening drain. FO


1. Introduction
The process air compressor is a single shaft two casings, four stages
compressor. Interstage coolers are located downstream the first three
process stages.
The process air compressor turbine 7A10‐K02‐TS01 is powered by MP steam

(5.1 MPa g, 424°C). LP steam is injected into the turbine in order to balance
the LP steam system. The turbine exhaust steam is condensed in process air
compressor turbine condenser 7A10‐E09. The turbine condensate is sent to
unit 7110 for polishing.
The lube oil will be supplied by the lube oil system 7A10‐U05 for the process
air compressor/turbine.
Control and Safety
The process air flow is controlled by the turbine speed and/or by the flow
control valve. In case the process air requirements of the plant are below the
surge limit of the compressor, safe operation is maintained by means of a
surge controller.
Control is achieved by blowing off a portion of the discharge air to

atmosphere via air vent silencer 7A10‐A02 thus ensuring a minimum flow
through the compressor. In the event of a process air compressor failure the
process air preheaters 7A10‐H02‐E51/ E52 in the convection section are
protected against overheating by automatic injection of boiler feed water by
process air desuperheater 7A10H02‐E04.

(Fig. 14)

2.NG Compressor Start Up
a. Startup of Lube Oil Circulation

No. Actions Resp
1 Ensure all drains and vents are closed in Lube oil, Control oil lines, Lube oil
FO
coolers, accumulators and Control oil filters.
condition.
3 Open suction valves of 7A10‐U05‐P01/02/03 Lube oil Pumps. FO
4 Open discharge valves of 7A10‐U05‐P01/02/03 Lube oil Pumps. FO
6 Stroke checks 7A10‐PV1230, 7A10‐TV1339, 7A10‐TV1341 and line up FO

isolation valves. CO
7 Ensure N2 to 7A10‐U05‐T01 on 25mm GNN‐7A10‐0412 is in open condition. FO
9 Ensure both the Lube oil Pumps 7A10‐U05‐P02/03 Motors are energized. SS
10 Start 7A10‐U05‐P02 Motor driven Lube oil Pump check for any oil leaks and FO
get it fixed.
11. Open lube oil cooler and Filters vents to bleed off air till continuous flow of FO
oil is noticed through sight glasses.
12 Ensure Lube oil header pressure is maintained at 0.25 MPa through 7A10‐ CO
PIC1233 and pump discharge pressure through 7A10‐PIC1230 at 1.0 MPa g.
13 Check ∆p across Lube oil filters 7A10‐U05‐F01/02 and if it is more than FO


14 If Lube oil temperature is less than 40˚C line up SL Steam to console CO

through 7A10‐TV1339 and raise oil temperature.
15 If Lube oil temperature is more than 40˚C open cooling water return valve FO
and adjust flow by throttling supply valve.
16 Check for oil leaks both at floor level, Compressor Platform and fix them on FO
top priority. CO
17 Check oil flow through sight glasses in oil return lines of LP, HP casings of FO
Compressor, Turbine bearings and Gear Box.
19 Keep the other Lube oil Pump 7A10‐U05‐P01/02 and Emergency Lube Oil FO
Pump 7A10‐U05‐P03 Motor switches on Remote mode.
20 Check Auto start of 7A10‐U05‐P02 Motor at 0.85 MPa in PI1231. FO
on Remote.

0.052 MPa in 7A10‐PI1231. Keep its switch on Remote. CO
b. Lining up of Turbine Condenser 7A10-E09

No. Actions Resp
1 Inform Utilities about lining up of Sea cooling water from 7A60‐E01A/B to FO

7A10‐E09.
4 Stroke check 7A10‐1201A and B. FO

CO

6 Check condensate Pumps 7A10‐P02A and B Motors are energized. SS
8 Line up cooling water to Ejector condenser 7A10‐U06‐E01. FO
10 Start one of the condensate pumps 7A10‐P02A/B on recycle through 7A10‐ FO

LV1201B.

17 Check for possible air ingression and arrest on top priority. FO
c. Initial Condition
No. Actions Resp
1 Stroke checks 7A10‐FXV1201, 7A10‐HXV1205, 7A10‐HV1211, 7A10‐ FO

HV1212, 7A10‐HV1213, 7A10‐LV1205, and 7A10‐PV1254. CO

2 Ensure 7A10‐E11, 7A10‐E12, 7A10‐E13 condensate collectors have no FO

level and their traps isolation valves are opened.
3 Ensure spectacle blinds in 7A10‐K02‐TS01 SM and SL inlet valves and their FO

25mm bypass valves downstream are reversed to open.
4 Ensure 7A10‐F01 Primary and Secondary Filters Elements installation and FO

start Dust Evacuation Fan through 7A10‐U05‐K01 CO
5 Ensure 7A10‐K02 final discharge 7A10‐MV1203 is in closed condition. FO
6 Line up Cooling water to 7A10‐E06, 7A10‐E07, and 7A10‐E08. FO
d. Trip Check
Note
Ensure Lube oil system, Turbine condenser in line and Compressor casing is under air.
After ensuring no Lube oil alarm conditions are existing Reset 02X2.01 Process Air
Compressor / Turbine Trip.
No. Actions Resp
1 Ensure SM, SL Steam inlet isolation valves and their 25mm bypass valves of
FO
7A10‐K02‐TS01 are in closed condition.
2 Set the Idle/Rated Switch in Process Air Compressor Operator Panel (DCS) CO
7A10‐HS1235 to Idle.
6 Latch each solenoid valve by pushing down on the handle which opens the FO
solenoids and pressurizes Emergency Trip Cylinder with Control oil.

9 Ensure High Axial Displacement trip of Turbine, Compressor LP, HP and CO

Gear Box are in line.
11 Ensure NG Compressor High Suction Pressure Trip is in line. CO
13 Actuate 7A10‐HS1201 (Emergency Off) from DCS and confirm Trip alarm CO
appears in DCS / Field and delatching of TTV. FO
14 Reset 01X1.01, repeat same for 7A10‐HS1202 (Emergency Off) from Field CO
and confirm Trip alarm / Delatching of TTV. FO
15 Repeat for Low Lube oil, Low Control oil pressure Trips by reducing the CO
Lube oil turbine speed keeping Motor on Local. FO
16 Check Auto Start of 7A10‐U05‐P02 and 7A10‐U05‐P03 by keeping the CO

Motors switches on Remote. FO
17 After completing Trip checking restore back all, keep lube oil Turbine pump FO
running and secure Motor switches on Remote.
18 After ensuring Lube oil lined up to Turning Gear start the Turning Device as FO
follows:
19 Remove the spindle cover; install the ratchet spanner at the end of the FO
worm shaft of Turning gear Device.
20 Pull the lever to reset the stopper for the worm Gear and turn down the FO
lever.
21 Turn the ratchet spanner clockwise to engage the worm with the worm FO
wheel.
22 Remove the ratchet spanner and install the spindle cover after FO
engagement.
23 Start the Turning Motor. Watch for the Rotor turning. FO

24 Run the Turning Gear for at least 2 hours prior to Slow Roll of the machine. FO
e. Warming up of Main Turbine 7A10-K02-TS01

Note
The conditions to be checked and ensured before Startup of Air Compressor/Turbine

are given in the Check List under 7.5.2 Special Operations. During each and every
Startup of the machine it should be updated, signed by concerned all to ensure safe
startup of the machine.
No. Actions Resp.
1 Ensure SM Steam inlet isolation valve of 7A10‐K02‐TS01 is in closed

FO
condition.
2 Open SM Steam inlet valve downstream drain and ensure trap lined up. FO
3 Warm up through SM inlet upstream 25mm double block vent valves and FO
8 Ensure SL Steam isolation valve remains closed. FO
9 Watch for SM Steam inlet temperature of 7A10‐K02‐TS01 is 400˚C. FO
No. Actions Resp.
10 Throttle warm up valves and once SM Steam Pressure has risen to 5.3 FO
MPa open 250mm SM isolation valve fully.

f. Startup of 7A10-K02
Note
Selector Switch 7A10‐SHS1201 enables the operation of machine either on Discharge
flow or pressure. Compressor is protected from surging by the Anti surge Controller
7A10FIC1201 by venting air to Silencer7A10‐A02 and blow off valve 7A10HV1205
circulating 3rd stage suction air to 1st stage suction.
No. Actions Resp.

1 Set 7A10‐PIC1240 at 0.02 MPa on Auto and line up 7A10‐PV1240 sealing FO
2 Adjust gland leakage block valve of 7A10‐K02‐TS01 and keep slightly FO
negative pressure of ‐0.005 Kg/cm2g.
3 Set the Idle/Rated switch 7A10‐HS1235 to Idle. FO
4 Reset Trip 02X2.01 from DCS. Watch for local “Turbine Ready to Start” FO
lamp 7A10‐UL1231 glowing. CO
5 Ensure the manual Trip button (Red) is pulled out and locking lever is in FO
place.
6 FO
Ensure TTV Test lever is in vertical (neutral) position.

8 Latch solenoid valves 7A10‐XVY1230A/B by turning the handles down FO
and watch for Control oil pressure rise.
10 Inform DCS and slowly open TTV until the Rotor starts to turn. Increase FO
the speed to 500 RPM and hold for 60 minutes.
11 Watch for automatic stopping of Turning Gear and ensure it got FO
disengaged.
12 Close the drains on TTV and casing. Watch for abnormal sound and FO
vibration if any.
13 After 60 minutes open TTV to speed up to 1000 RPM, watch for FO
Governor control and full open TTV.
14 Watch for the remaining time at ideal speed in 7A10‐K02 DCS Operator CO
Panel. For Cold start 30 Minutes.

15 Ensure SM Steam availability, co‐ordinate with Utilities for raising 7A10‐ SS

K02 speed to Minimum Governor Speed.
16 When idle speed timer reaches zero, press the “Continue” button on CO
Operator panel.
17 Watch for Operator Panel goes to Step 4 – “accelerate to Minimum CO
Governor”.
18 Watch for crossing of critical speed band (1890‐2670 RPM) quickly. CO
19 Ensure 7A10‐K02 speed holding at Minimum Governor Speed of 4172 CO

RPM. Monitor axial movement / radial vibrations.
20 Watch for Operator Panel goes to Step 6 – “At Minimum Governor”. CO
21 Press the “Continue” button to go to Step 8 ‐ “Turbine Online”. CO

22 Maintain 7A10‐E09 level through 41LIC2001. CO
23 Adjust 7A10‐FIC1201 to gradually raise the discharge pressure CO
maintaining the flow. FO
25 Closely watch 7A10‐E06, 7A10‐E07, 7A10‐E08 condensate separators CO
level and maintain by 7A10‐HIC1211, 1212, 1213.
26 Watch individual stage suction temperatures and adjust cooling water to FO
Inter stage coolers accordingly.
27 Isolate lube oil to Turning Gear, once operation of Compressor is FO
stabilized.
28 Compressor can be speed up over Minimum Governor Speed according CO
to requirements and ensure closing of 7A10‐HXV1205.
29 Once SL Steam is available prepare for introduction of SL Steam warming FO
up, up to 7A10‐XV1231 through upstream drain.
30 Gradually open PV8172B and pressurize up to 7A10‐XV1231 and open in CO
co‐ordination with DCS. Maintain SL Pressure. FO

Following guidelines to be followed for Cold Start, Warm Start, Hot Start and Very Hot Start
of Process Air Compressor:
Turning Gear Restart attempt Hold Time at Hold Time at
Type of Start
Operation after 500 RPM 1000 RPM
Cold Start 120 Minutes More than 48 Hours 60 Minutes 30 Minutes
Warm start 90 Minutes 08 to 48 Hours 45 Minutes 15Minutes
Hot Start 60 Minutes 0.5 to 08 Hours 30 Minutes 10 Minutes
Very Hot start 30 Minutes Less than 0.5 Hours 10 Minutes 05 Minutes
Following guidelines to be followed for bearing vibration and temperature;

Turbine Journal Bearings < 40 Microns 56 Microns 84 Microns
LP Compressor Journal Bearings < 40 Microns 56 Microns 84 Microns
HP Compressor Journal Bearings < 30 Microns 43 Microns 64 Microns
Gear Box Low Speed shaft
< 70 Microns 93 Microns 137 Microns
Journal Bearings
Gear Box High Speed shaft
Journal Bearings
Bearing Metal Temperature Normal Maximum Trip

Turbine and Compressor Journal
< 100˚C 120˚C 125˚C
/ Thrust Bearings
Gear Box Journal/Thrust Bearings < 100˚C 110˚C 120˚C

Note
Machine will shut down by the Trip System on Compressor or Turbine Axial Displacement
at a value of +/‐ 0.75 mm.

3. Normal Shutdown of Process Air Compressor
Note
Once Process Air had been cutoff to Secondary Reformer during planned shutdown and
Instrument Air backup from Utilities made available, Process Air Compressor will be
shutdown as follows:
No Actions Resp.
.
1 Ensure Process Air to Secondary Reformer reduced gradually in steps and

7A10‐PIC1201 is controlling Compressor Discharge pressure by reducing CO
speed.
2 Ensure Process Air Preheater coils 7A10‐H02‐E51/52 cooling is taken care CO

by 7A10‐FXV1161 and 7A10‐FXV1162.
3 Inform Utilities, Urea Plants about stopping of Process Air Compressor SS

and ensure back up for Instrument Air.
4 Once Minimum Governor Speed is reached ensure opening of CO

41HXV2005 and discharge flow is vented through 7A10‐PV1201.
5 Watch for raise in SL Header pressure and maintain through PIC8172A. CO
6 Gradually reduce SL Steam admission in steps and close fully maintaining FO

SL Header Pressure. CO
7 Isolate SL admission valve from field and also isolate PV8172B upstream FO
isolation valve.
8 Ensure Turbine Condenser level is maintained through 7A10‐LIC1201. CO
9 Trip Process Air Compressor from DCS by 7A10‐HS1201 and stop the CO
machine.
10 Close Turbine TTV and SM Steam inlet isolation valve from field. FO

11 Once after stopping compressor start Turning Gear Device after ensuring FO
Lube oil lined up to Device.
12 Take steam ejectors out of service by closing non condensable valves FO

followed by steam valves.
13 Break the vacuum inside Turbine condenser and stop the condensate FO
pump 7A10‐P02A/B.
14 FO
When vacuum falls below 0.02 MPa isolate sealing steam to Turbine.
CO
15 Continue Lube oil circulation and throttle Lube oil cooler return valve to FO
maintain oil temperature 40‐45˚C.
16 Inform Utilities and isolate Cooling water to all the three Inter stage FO
coolers.
17 Inform Utilities and isolate Sea Cooling Water to 7A10‐E09. FO
18 Ensure Turbine casing is cooled and stop Turning Gear device. FO
19 Ensure Turbine and Compressor bearings temperatures are below 40˚C FO

and stop Lube oil circulation.
20 Keep the Standby Auxiliary Lube oil Pumps Motor switches on Local FO
mode.

4. Startup after Emergency Shutdown of Process Air

Compressor
After identifying the cause of tripping of Process Air Compressor start the Compressor
as described under Normal Startup Procedure (7.1.2).
Compressor:
Turning Hold Time
Type of Restart Hold Time
gear at 1000
Start attempt after at 500 RPM
Operation RPM
Warm start 08 to 48 Hours 90 minutes 45 Minutes 15 Minutes
Hot Start 0.5 to 08 Hours 60 minutes 30 Minutes 10 Minutes
Very Hot start Less than 0.5 Hours 30 minutes 10 Minutes 05 Minutes

84
Turbine Journal Bearings < 40 Microns 56 Microns
Microns
84
LP Compressor Journal Bearings < 40 Microns 56 Microns
Microns
64
HP Compressor Journal Bearings < 30 Microns 43 Microns
Microns
137
Gear Box Low Speed shaft Journal Bearings < 70 Microns 93 Microns
Microns
106
Gear Box High Speed shaft Journal Bearings < 50 Microns 72 Microns
Microns

Turbine and Compressor Journal/Thrust Bearings < 100˚C 120˚C 125˚C
Gear Box Journal / Thrust Bearings < 100˚C 110˚C 120˚C

Trip – Alarm only. The DCS Operator should take the action to shutdown the
machine.
Note
Machine will shut down by the Trip System on Compressor or Turbine Axial
Displacement at a value of +/- 0.75 mm.

5. Normal Operations of Process Air Compressor
Machine Monitoring
Parameter Operating Value Controlled By Resp.
Suction Pressure 0 MPa 7A10‐PIC1211 CO
Discharge Pressure 4.58 MPa 7A10‐PIC1201 CO
Discharge / Antisurge Flow 155,000 Kg/Hr 7A10‐FIC1201 CO
Lube Oil Temperature 45˚C 7A10‐TIC1241 CO
Control Oil pressure 1.03 MPa 7A10‐PIC21230 CO
Turbine Condenser Level 50% 7A10‐LIC1201 CO
No. Actions Resp.

1 Watch for any abnormal sound, vibration, leak etc. in Compressor, FO
Turbine, Lube oil Pump, Turbine, Condensate Pump and report to Shift
2 FO
Observe any deviation in Process Parameters and follow up with
3 FO
Coordinate with Maintenance Supervisors for cleaning of Lube oil filters,
Lube oil makeup to console, cleaning of strainers etc.
4 FO
Periodical monitoring of oil flow through sight glasses of oil return lines
of bearings and report any abnormality like moisture etc.

5 FO
Watch for any Steam, Oil leaks and fix them on top priority.
6 FO
Closely monitor Exhaust pressure and changeover Ejectors if necessary.
7 Watch for level buildup in Inter stage Coolers Condensate Collectors. FO
8 FO
Check Stand‐by Lube Oil Pumps/Condensate Pumps Motors switches on
Remote position.
9 FO
Adjust Sea Cooling water to 7A10‐E09, cooling water to7A10‐E06 / 07 /
08 / Lube oil cooler.
10 FO
Check Compressor Suction Filter Primary and Secondary Filter Elements
for blockage / Dust Evacuation Fan Operation.
Startup Check List For Process Air Compressor/Turbine
S.No. Description Condition Yes No Remarks

GENERAL
1 All maintenance Jobs Completed
2 Line flanges Boxed up
3 Covers and PSVs Boxed up
Clearance from Maintenance
4 Obtained
Supervisor.
All Instrumentation, transmitters
Restored and
5 switches, PI, TI vibration and Axial
lined up
thrust probes etc.
Clearance from Instrument
6 Obtained
Supervisor.
7 Drains & bleeds Closed

Ensure All Anti Surge Valves are

8 Confirmed
Lined up/Open
7A10‐LV‐21201A/B to be Stroke
9 Confirmed
checked / Lined up.
UTILITIES
1 Electric power source Available
2 Breaker for all motors On
3 Instrument Air Available & lined up Confirmed
Sea cooling water to surface
4 Lined Up
condenser 7A10‐E09
Ensure CW lined up to Inter / After
5 Lined Up
Condenser
6 Cooling water to lube oil coolers Lined Up
LP Nitrogen to lube oil console and
7 Lined Up
bearing housing
8 SM/SL steam available Confirmed
9 Compressor Casing purged with N2 Confirmed
10 Lube oil console level Normal
11 Lube oil/control Oil cooler filter On line
12 Control oil accumulator Lined Up
MAIN OIL PUMP
1 Warming of SM/SL lines Completed
3 Bearing Oil level Normal
4 SL exhaust I/V Opened
5 Turbine L.O. pump Started
Pumps discharge pressure (1.10
6 Normal
MPa)
7 L.O. Header Pressure (0.24 MPa) Normal
Visually
8 Oil flow to bearings in sight glass
checked
Check for Oil leak, if any attend and
9 Confirmed
rectify.
10 Ensure Oil temperature (42 ‐ 45˚C) Confirmed
11 Lube oil run down tank over flow in Visually

sight glass checked

12 Start Turning Gear for 2 Hours Confirmed
13 Motor pump position Remote
SURFACE CONDENSER
1 Build up condenser Level Opened

2 Ejector condenser traps Lined Up
Priming valve of Cond. Pumps
3 Opened
Suction
4 Condensate circulation Started
5 Seal water to PSV of condenser Opened
6 Stand by condensate pump Remote
PULL VACUUM
Line up start up ejector Maintain
1 Confirmed
steam pressure 0.4O~0.42 MPa
Check vacuum & line up sealing
2 Confirmed
steam to turbine.
Sealing steam control valve 7A10‐‐
3 Confirmed
PV‐1240A/B in service.
4 Seal steam pressure 0.025 MPa. Normal
If vacuum more than ‐0.07 MPa
5 line up one set of Primary & Lined Up
Secondary ejectors.
Do Main turbines warm up by
6 opening MP Steam I/V, Traps & Started
Drains.
COMPRESSOR
Both 7A10—HV1205 and 7A10‐‐FV
1 Opened
1201 to be opened.


1. Introduction
The synthesis gas compressor is directly driven by the synthesis gas

compressor turbine 7A50‐K01‐TS01 which is arranged in‐between the two
compressor casings. Live steam of 11.1 MPa g and 530°C is fed to the turbine.
Medium pressure steam is extracted to satisfy together with the extraction

flow of the refrigeration compressor turbine the demand of the plant (header
conditions: 5.1 MPa g, 424°C).
The remaining steam is condensed by synthesis gas compressor turbine

condenser 7A50‐E05 at a pressure of ‐ 0.0833 MPa g. For lubrication, the
synthesis gas compressor turbine 7A50‐K01‐TS01 and the compressor 7A50‐
K01 are connected to the lube oil system 7A50‐U01. Compressor shaft sealing
is done by dry gas seals.
(Fig. 15)

2. Syn Gas Compressor & Turbine Start Up
Caution
Before starting Lube oil circulation Separation Gas must be lined up to compressor which
protects carryover of oil from bearings along shaft through seals and further to
Compressor Barrel. Lineup N2 through Buffer Gas filters 7A50‐U11‐F03/04 and ensure
7A50‐PRV5539 is controlling at 0.1 MPa. For LP case. Line up N2 through Buffer Gas
filters 7A50‐U11‐F07/08 and ensure 7A50‐PRV5563 is controlling at 0.1 MPa. for HP case.
a) Startup of Lube Oil Circulation

No. Actions Resp.
1 Ensure all drains and vents are closed in Lube oil, Control oil lines, Lube
FO
oil coolers, accumulators and Control oil filters.
condition.
3 Open suction valves of 7A50‐U01‐P01/02/03 Lube oil Pumps. FO
4 Open discharge valves of 7A50‐U01‐P01/02/03 Lube oil Pumps. FO
6 Stroke check 7A50‐PV5195, 7A50‐PV5198, 7A50‐TV5045, 7A50‐5047 and FO

line up isolation valves. CO
7 Ensure N2 to 7A50‐U01‐T01 on 25 GNN‐7A50‐0414 is in open condition. FO
9 Ensure the Lube oil Pumps 7A50‐U01‐P01/P02/03 Motors are energized. SS
10 Start 7A50‐U01‐P01 Motor driven Lube oil Pump check for any oil leaks FO
and get it fixed.
11. Open lube oil cooler and Filters vents to bleed off air till continuous flow FO

12 Ensure Lube oil header pressure is maintained at 0.24Mpa. through CO

7A50‐PIC5198 and pump discharge pressure through 7A50‐PIC5195 at
1.0 MPa.
13 Check ∆p across Lube oil filters 7A50‐U01‐F01/02 and if it is more than FO

14 If Lube oil temperature is less than 40˚C line up SL Steam to console FO

through 7A50‐TV5045 and raise oil temperature. CO
15 If Lube oil temp. is more than 40˚C open cooling water return valve and FO
adjust flow by throttling supply valve.
17 Check for oil leaks both at floor level, Compressor Platform and fix them FO
on top priority.
18 Check oil flow through sight glasses in oil return lines of bearings of FO
20 Ensure oil level in Turbine inboard and outboard bearings oil sumps and FO
line up cooling water to both bearings housing.
21 Keep Motor driven Lube oil Pump 7A50‐U01‐P01/P02 and Emergency FO

Lube Oil Pump 7A50‐U01‐P03 Motor switches on Remote mode.
22 Check Auto start of 7A50‐U01‐P02 Motor at 0.9MPa. CO
on Remote.

0.04 MPa .Keep its switch on Remote.

b) Startup of Dry Gas Seal Unit
No. Actions Resp.
1 Stroke checks 7A50‐PDV5026A/B, 7A50‐PDV5041 and line up all

instruments impulse lines of Transmitters and switches. Ensure all drains FO
and vents are closed in Dry Gas seal unit are closed.
2 Ensure all drains and vents are closed in LP case and HP case Dry Gas seal FO
units.
3 Ensure N2 is available for Buffer gas and instrument air is available for FO
driving Dry Gas seal Unit Booster Compressors.

7A50‐PRV5539 is set at 0.1 MPa for secondary seals of LP case.

7A50‐PRV5563 is set at 0.1 MPa for secondary seals of HP case.
6 Check oil level in Filter of Booster Compressors and make up if necessary. FO

Line up inlet and outlet valves of Booster Comp.
unit through filters 7A50‐U11‐F01/02. (LP case)
unit through filters 7A50‐U11‐F05/06. (HP case)
9 Set 7A50‐PDIC5026A at 0.055 MPa on Auto mode. (LP case‐ Drive End FO
Side).
10 Set 7A50‐PDIC5026B at 0.024 MPa on Auto mode. (LP case‐ Non Drive FO
End Side).
11 Set 7A50‐PDIC5041 at 0.22 MPa on Auto mode. (HP case both Drive and FO
Non Drive Ends).

12 Establish a flow of 6.0Nm3/hr on secondary seal gas through 41FI6030 FO

and 7A50‐FI5031 by adjusting valves manually. (LP)
13 Establish a flow of 6.0Nm3/hr on secondary seal gas through 41FI6045 FO

and 7A50‐FI5046 by adjusting valves manually. (HP)
14 Pressurize the Compressor casing with N2 or Synthesis Gas based on FO

purging or startup of Compressor.
Initiate 7A50‐HS5041 to start the seal gas Booster unit as the LP casing FO
16 Initiate 7A50‐HS5042 to start the seal gas Booster unit as the HP casing FO
17 Establish a flow of 250 Nm3/Hr of Primary Seal Gas through 7A50‐FI5015 FO

to LP Drive End by adjusting valves manually.

to LP Non Drive End by adjusting valves manually.

to HP Drive End by adjusting valves manually.
20 Establish a flow of 600 Nm3/Hr of Primary Seal Gas through 7A50‐FI5018 FO/CO
to HP Non Drive End by adjusting valves manually
c) Pre Startup Activities of Synthesis Gas Compressor
No. Actions Resp.
1 Stroke checks 7A50‐FXV5012, 7A50‐FXV5013, 7A50‐FXV5014, 7A50‐ FO

HV5007, 7A50‐HV5008, 7A50‐LXV5010, 7A50‐PXV5163, 7A50‐LV5014,
7A50‐HXV5058, 7A50‐PV5075, 7A50‐HXV5005 and 7A50‐FV5059A,B. CO
2 Ensure 7A50‐V01, 7A50‐V02, 7A50‐V03 and 7A50‐V04 have no level and FO

isolation valves are closed.

3 Build up level in 7A50‐V01 through condensate from 7A30‐E11 and open FO

7A50‐P02A/B suction, discharge valves.
4 Energize 7A50‐P02A/B Motors and start one pump on closed circulation. FO
5 Line up Cooling water to 7A50‐E01, 7A50‐E04, 7A50‐E10, 7A50‐E14 and FO

7A50‐E21.
6 Ensure spectacle blinds in 7A50‐K01‐TS01 SH and SM outlet valves and FO

their 25mm bypass valves downstream are reversed to open.
7 Ensure 7A50‐K01‐TS01 SH Steam inlet and Extraction Steam outlet valves FO

7A50‐MV5001 and 7A50‐MV5002 are closed.
8 Ensure 7A50‐PV5003B upstream valve is lined up and SM Steam is being FO

Letdown to maintain SM Header Pressure. CO
9 Ensure Cooling water is circulating through Turbine casing support of FO

7A50‐K01‐TS01.
10 Open LP and HP case Compressor drains and check for any liquid like oil FO
or water and remove completely.
d) Purging of Synthesis Gas Compressor Loop

No. Actions Resp.
1 Ensure 7A50‐MV5004 and 7A50‐XV5003 are in closed condition and in

FO
between bleed off is kept closed.
2 Ensure 50mm bypass double block bypass valves of 7A50‐MV5004 and

CO
7A50‐XV5003 are in closed condition.
3 Ensure spectacle blind in between 7A50‐MV5004 and 7A50‐XV5003 and FO

its bypass valves are reversed to open.
4 Ensure 7A50‐XV5001 and its bypass 7A50‐HXV5005 is in closed condition. FO

5 Ensure 7A50‐HXV6152, 7A50‐HXV6154 to OT Synthesis are in closed FO

condition and 7A50‐HXV5153 is in open condition.
6 Ensure 7A50‐XV5002A and 7A50‐XV5002B are in closed condition. FO
7 Ensure 7A50‐HV5007, 7A50‐HV5008, 7A50‐HV5155, 7A50‐HV5164 and FO

7A50‐FXV5166 are in closed condition.
8 Ensure the Synthesis Gas Drying unit is isolated and bypass valve 7A50‐ FO
HXV5058 is in open condition.
9 Ensure 50mm double block valves on 50‐GSY24 (Recycle H2 to 7A50‐K01) FO

are in closed condition.
10 Pressurize the Synthesis Gas Compressor loop with 2 N2 hoses hooked up FO

one at LP 1st Suction and 2nd at Recycle Suction.
11 Purge by depressurizing and pressurizing through 7A50‐HV6007, 7A50‐ FO

HV5008 and Compressor casing drains till O2 is less by 2%. CO
12 Keep the loop under Nitrogen positive pressure of 0.5 MPa and close all FO
vents, drains.
13 Check for leaks if any with soap solution and get them fixed at the FO
earliest possible.
14 Once purging is completed Synthesis Gas can be introduced through FO

50mm bypass across 7A50‐MV5004 and 7A50‐XV5003.
15 Gradually raise the pressure up to 3.5 MPa ensuring Dry Gas Seal Unit is FO
in line. Open 7A50‐MV5004 and 7A50‐XV5003.
e) Lining up of Turbine Condenser 7A50‐E05

No. Actions Resp.
1 Inform Utilities about lining up of Sea cooling water from 7A60‐E01A/B to FO

7A50‐E05.

4 FO
Stroke check 7A50‐LV5001A and B.
CO

6 Check condensate Pumps7A50‐P01A and B Motors are energized. SS
8 Line up cooling water to Ejector condenser 7A50‐U02‐E01. FO
10 Start one of the condensate pumps 7A50‐P01A/B on recycle through FO

7A50‐LV5001B.

18 Stroke checks 7A50‐HV5007, 7A50‐HV5008, 7A50‐HV5155, 7A50‐ FO

HV5164, 7A50‐FXV5166 and 7A50‐TV5030. CO

f) Trip Check
Note
casing is under pressure. After ensuring no Lube oil, Dry Gas seal alarm conditions do
not exists Reset 07X6.01 Synthesis Gas Compressor/Turbine Trip. Finally Reset trip
X_G, Synthesis Gas Compressor Recycle Operation.
No. Actions Resp.
1 Ensure SH Steam inlet isolation valve of 7A50‐K01‐TS01 is in closed FO

condition.
2. Set the Idle/Rated Switch in Synthesis Gas Compressor Operator Panel CO

(DCS) 7A50‐HS5035 to Idle.
8 FO
CO
10 Ensure High Axial Displacement trip of both Turbine and Compressor CO

(Both LP, HP) are in line.
13 Ensure Synthesis Gas Compressor Low Suction Pressure Trip is in line. CO

15 FO
Actuate 7A50‐HS5001 (Emergency Off) from DCS and confirm Trip alarm
appears in DCS / Field and delatching of TTV. CO
No. Actions Resp.
16 FO
Reset 07X6.01, repeat same for 7A50‐HS5002 (Emergency Off) from Field
and confirm Trip alarm / Delatching of TTV. CO
17 FO
Reset 07X6.01 and actuate 07X6.04 Dry Gas Seal Trip from DCS and
confirm Trip alarm / Delatching of TTV. CO
18 FO
Repeat for Low Lube oil, Low Control oil pressure Trips by reducing the
Lube oil turbine speed keeping Motor on Local. CO
19 FO
Check Auto Start of 7A50‐U01‐P02 and 7A50‐U01‐P03 by keeping the
Motors switches on Remote. CO
20 After completing Trip checking restore back all, keep lube oil Turbine FO
pump running and secure Motor switches on Remote.
21 After ensuring Lube oil lined up to Turning Gear start the Turning Device FO
as follows.
22 Remove the spindle cover; install the ratchet spanner at the end of the FO
23 Pull the lever to reset the stopper for the worm Gear and turn down the FO
lever.
24 Turn the ratchet spanner clockwise to engage the worm with the worm FO
wheel.
25 Remove the ratchet spanner and install the spindle cover after FO
engagement.
27 Run the Turning Gear for at least 2 hours prior to Slow Roll of the FO
machine.

g) Warming up of Main Turbine 7A50‐K01‐TS01

Note
The conditions to be checked and ensured before Startup of Synthesis Gas

Compressor / Turbine are given in the Check List under 7.5.3 Special Operations.
During each and every Startup of the machine it should be updated, signed by
concerned all to ensure safe startup of the machine.
No. Actions Resp.
1 Ensure SH Steam inlet and SM Extraction valves of 7A50‐K01‐TS01 are in FO

closed condition. CO
2 Open SH Steam inlet valve downstream drain and ensure trap lined up. FO
3 Warm up through SH inlet upstream 25mm double block vent valves and CO
4 Warm up SM Extraction line through bypass valve and vent. When CO

pressure is equalized open MV6002.
5 Watch for any leaks and get them fixed at the earliest possible. CO
6 While warming up watch for any oil smoke from Turbine casing and CO
insulation and get it fixed by all means.
7 FO
Ensure TTV is latched in the field and in closed condition.
CO
8 Ensure 07X6.04 is healthy and Dry Gas Seal Unit is lined up. FO
9 Watch for SH Steam inlet temperature of 7A50‐K01‐TS01 is 500˚C. FO
10 Throttle warm up valves and once SH Steam Pressure has raised to 113
Kg/cm2 open 7A50‐MV5001 fully.

h) Startup of 7A50‐K01
No. Actions Resp.
1 FO
Set 7A50‐PIC5040 at 0.014 MPa on auto and line up 41PV6040 sealing
2 Adjust gland leakage block valve of 7A50‐TS01 and keep slightly negative FO
pressure of ‐0.0005 MPa
3 Ensure one set of ejectors are in line and Exhaust Pressure is maintained FO
at ‐0.08 MPa
4 Reset any ITCC failures and alarms in Operator Panel of Synthesis Gas CO
Compressor in DCS.
5 Ensure TTV test lever is in “Neutral” position. FO
6 Reset 07X‐6.01.The local “Ready to Start” light 7A50‐UL5031 should CO

glow.
7 FO
Initiate the Start turbine switch in Operator Panel of Synthesis Gas
Compressor to energize 7A50‐XVY5030A/B solenoids. CO
8 Latch each solenoid valve by pushing down the handle. Pull out the Reset FO
button on the side of Turbine pedestal.
9 Watch for Operator panel goes to “Step 1‐accelerate”. FO
10 Ensure all Anti surge valves are in open condition and 7A50‐MV5004, FO
7A50‐XV5003 are opened fully.
11 Slowly open the TTV until the rotor starts to turn. Raise the speed to 500 FO
RPM. Hold for 60 minutes.
12 Watch for any abnormal sound or vibration from Turbine and FO

Compressor casings.
13 Watch for automatic stopping of Turning Gear motor and confirm it has FO
disengaged.
14 After 60 minutes open TTV further to raise the speed to 1000 RPM and FO
open TTV fully ensuring Governor control.

15 Watch for the operator panel goes to “Step 3‐At Idle Speed”. CO
16 Close the drains on TTV, Governor valve and casing. FO
17 Watch for the remaining time at ideal speed in 7A50‐‐K01 DCS Operator FO
18 Ensure availability of 60 MT/Hr of SH Steam to raise to Minimum SS

Governor Speed. Co‐ordinate with Utilities.
19 When the idle speed timer reaches zero, press the “Continue” button on FO
Operator Panel and watch for going to Step 4‐accelerate to Minimum
Governor.
20 FO
Closely monitor quick crossing of critical speed band (2460‐ 4620 RPM).
Watch for abnormal sound and vibration if any. CO
21 Watch for the Minimum Governor Speed holding at 7828 RPM and CO
record Radial/axial vibration readings.
22 Watch for the operator panel goes to “Step 6‐At Minimum Governor”. CO
23 Press “Continue” button further to go to Step 8‐Turbine on line. CO
24 If necessary select the suction pressure control of Turbine speed. CO
26 FO
Once operation has stabilized prepare for lining up SM Steam Extraction
by 7A50‐HS5037. CO
27 While lining up Extraction, ensure 7A50‐PIC5003B set point is lower than CO

7A50‐PIC5003. Otherwise Extraction will not start.
28 Watch for level raise in 7A50‐V01suction separator and start 7A50‐ FO

P02A/B Pump.

30 Isolate lube oil to Turning Gear, once operation of Compressor is FO

stabilized.

Following guidelines to be followed for Cold Start, Warm Start, Hot Start and Very Hot Start
of Synthesis Gas Compressor:
Turning Gear Hold Time at Hold Time
Type of Start Restart attempt after
Operation 500RPM at 1000RPM
Cold Start More than 36 Hours 120 Minutes 60 Minutes 30 Minutes
Warm start 06 to 36 Hours 90 Minutes 45 Minutes 20 Minutes
Hot Start 0.5 to 06 Hours 60 Minutes 30 Minutes 10 Minutes
Journal Bearings of
Turbine, LP, HP casings
Bearing Metal
Normal Maximum Trip
Temperature
Journal/Thrust Bearings
< 100˚C 120˚C 125˚C
of Turbine, LP, HP casings
Note

3. Normal Shutdown of Synthesis Gas Compressor
Note
When Ammonia Plant Front End Load has been reduced for any planned shutdown
and once Reaction in Ammonia Synthesis Loop Converters, Once Through ammonia
converters had been killed Synthesis Gas Compressor can be shutdown as follows:
No. Actions Resp.

1 Reduce Ammonia Plant Load to 80% and take shutdown of OT Synthesis
CO
through 7A50‐HS5004.
2 Ensure 7A50‐HXV5152, 7A50‐HXV5154 are closed and 7A50‐HXV5153 got FO
opened in field. CO
3 Watch for Synthesis Gas Compressor Makeup gas and Recycle Gas flows FO
are taken care through Anti surge valves. CO
4 Monitor Compressor Discharge pressure and maintain through purge valve CO

7A50‐FXV5166 or by 7A50‐HV5164.
5 Closely monitor both Dry Gas Seal units for LP and HP casings and maintain CO
primary, secondary seal gas flows.
6 Gradually reduce Plant load up to 50%. Ensure Purge Gas FO
recovery/Hydrogen recovery Unit had been stopped CO
7 Ensure Reaction in converters had been killed. Partially vent the gas at FO
7A30‐PV3182.
8 Inform Utilities about Synthesis Gas Compressor Shutdown for maintaining FO
SM Header pressure through Package Boilers.
9 Gradually reduce Extraction SM Steam from 7A50‐K01‐TS01 and letdown CO
through7A50‐PV5003B accordingly.
10 Maintain SM Header pressure in co‐ordination with Utilities. SS
11 Once SM Header pressure is stable Extraction can be completely cutoff. CO
12 Close 7A50‐MV5002 from field and ensure trap is lined up. FO
13 Gradually reduce Turbine speed up to Minimum Governor. CO

14 After ensuring all the three Antisurge valves in full open condition, actuate CO
X_G (Synthesis Gas Compressor recycle operation) FO
15 Watch for closing of 7A50‐XV5001, 7A50‐HXV5005, 7A50‐XV5002A/B in FO
field and opening of 7A50‐XV5004, 7A50‐HXV5006.

16 If Recycle H2 to NG Compressor is lined up from 7A50‐K01 Stop it. SS

17 Inform Utilities and trip 07X6.01 from DCS. CO
18 Maintain SH Header pressure through PIC1170. CO
19 Monitor 7A50‐E07 level and if required 7A50‐LXV5010 can be closed to CO
avoid tripping of 7A60‐K01 on high level.
20 After ensuring stopping of 7A50‐K01 start Turning Gear after lining up Lube FO
oil to device.
21 Close 7A50‐MV5004 from field. Ensure bypass 50mm double block valves FO
are in closed condition.
22 Depressurize Compressor loop slowly through 7A50‐HXV5007 and 7A50‐ FO
HXV5008 to Flare up to 0.05 MPa.
23 Hookup N2 hoses at LP suction, Recycle suction and start pressurizing up to FO
0.5 MPa.
24 Repeat depressurizing and pressurizing through 7A50‐HXV5007 and 7A50‐ FO
HXV5008 until Combustible is less than 1%.
25 Block Synthesis Gas Compressor loop with N2 at 0.05 MPa FO
26 Check for explosives at possible drain locations and continue purging if any FO
explosives noticed.
27 When Compressor casing pressure is less than 0.05 MPa Dry Gas Seal FO
Booster Compressor can be stopped.
28 When Turbine casing got cooled down Turning Gear can be stopped. FO
Isolate Lube oil to device.
29 When Turbine and Compressor bearing temperatures are less than 40˚C FO
Lube oil circulation can be stopped.
30 Inform Utilities and isolate Cooling water to 7A50‐E01, 7A50‐E04, 7A50‐ FO
E10 and Sea Cooling Water to 7A50‐E05.

4. Startup after Emergency Shutdown of Synthesis Gas Compressor

After identifying the cause of tripping of Synthesis Gas Compressor start the Compressor as
described under Normal Startup Procedure.
Compressor:
Hold Time
Type of Restart Turning gear Hold Time
at 1000
Start attempt after Operation at 500 RPM
RPM
Warm start 06 to 36 Hours 90 minutes 45 Minutes 20 Minutes
Hot Start 0.5 to 06 Hours 60 minutes 30 Minutes 10 Minutes
Journal Bearings of Turbine LP, HP casings < 30 Microns 41 Microns 62 Microns
125˚
Journal / Thrust Bearings of Turbine, LP, HP casings < 100˚C 120˚C
C

Note

5. Normal Operation of Synthesis Gas Compressor

Machine Monitoring
Parameter Operating Value Monitored By Resp.

st
1 Stage Suction Pressure 3.5 MPa 7A50‐SIC5001 CO
1st Stage Discharge Pressure 6.31 MPa 7A50‐PI5012 CO
2nd Stage Suction Pressure 6.21 MPa 7A50‐PI5013 CO
2nd Stage Discharge Pressure 11..2 MPa 7A50‐PI5014 CO
3rd Stage Suction Pressure 10.42 MPa 7A50‐PI5015 CO
3rd Stage Discharge Pressure 20.0 MPa 7A50‐PI5016 CO
Recycle Stage Suction Pressure 20.0 MPa 7A50‐PI5017 CO
Recycle Stage Discharge Pressure 21.24 MPa 7A50‐PI5018 CO
2nd Stage Discharge/Antisurge Flow 154000 kg/Hr 7A50‐FIC5012 CO
3rd Stage Discharge/Antisurge Flow 118000 kg/Hr 7A50‐FIC5013 CO
Recycle Stage Discharge/Antisurge CO

362000 kg/Hr 7A50‐FIC5014
Flow
Lube Oil Temperature 45˚C 41TIC5047 CO
Control Oil pressure 1.0 MPa 41PIC5195 CO
∆P of LP Dry gas seal 0.24 MPa 7A50‐PDIC5026A/B CO
∆P of HP Dry gas seal 0.22 MPa 7A50‐PDIC5041 CO

LP Primary Seal Gas Flow 180 Nm3/Hr 7A50‐FI5015/5016 CO
LP Secondary Seal Gas flow 6 Nm3/Hr 7A50‐FI5030/15031 CO

HP Primary Seal Gas Flow 600 Nm3/Hr 7A50‐FI5017/5018 CO
CO
HP Secondary Seal Gas flow 6 Nm3/Hr 7A50‐FI5045/5046
CO
Turbine Condenser Level 50% 7A50‐LIC5001

No. Actions Resp.
1 FO
Watch for any abnormal sound, vibration, leak etc. in Compressor, Turbine,
Lube oil Pump, Turbine, Condensate Pump and report to Shift Supervisor
on top priority.
2 Observe any deviation in Process Parameters and follow up with FO

3 Coordinate with Maintenance Supervisors for cleaning of Dry Gas seal FO

4 Periodical monitoring of oil flow through sight glasses of oil return lines of FO
bearings and report any abnormality like moisture etc.
5 Watch for any Steam, Gas, and Oil leaks and fix them on top priority. FO
6 Closely monitor Exhaust pressure and changeover Ejectors if necessary. FO
7 Watch for level buildup in Suction separator and Inter Stage separator. FO
8 Check Standby Lube Oil Pumps / Condensate Pumps motors switches on FO

Remote position.
9 Maintain Primary and secondary Seal Gas flows at specified values by FO

vendor.
10 Adjust Sea Cooling water to 7A50‐E05, Cooling water to 7A50‐E01 / 04 / FO

10, Lube oil cooler.

6. Special Operation Synthesis Gas Drying Unit
Note
Once Synthesis Gas Compressor operation is stabilized Synthesis Gas Drying unit can
be taken in line. Moreover it is mandatory that Drying Unit should be pressed into
service to avoid moisture entering Ammonia Synthesis Converters and Once through
Ammonia Converter Catalysts thereby reducing activity permanently resulting
Production loss.
a. Initial Conditions
No. Actions Resp.
1 Ensure both Adsorber vessel inlet and outlet spectacle blinds are
FO
reversed to open.
2
Ensure all drains and vents in Drying Unit are closed and inlet valve
FO
downstream spectacle blind is reversed to open.
3 Ensure Drying Unit main isolation valve is closed and Filters outlet
FO
individual isolation valves are in closed condition.
4 FO
Ensure 7A50-HXV5058 is in full open condition for SGC stable
operation. CO
5 Stroke check 7A50-FV5059A/B, 7A70-PXV7151A/B and soundness of FO

all sequence operated UVs in regeneration, cooling, pressurizing and
depressurizing lines. CO
6 Ensure spectacle blinds in SM steam inlet to 7A50-U03-E01 and

FO
condensate outlet are reversed to open.
7 Ensure Drying Unit Filters inlet and outlet spectacle blinds are reversed FO
to open and keep 2 filters in service.
8 Hook up N2 hose at inlet valve downstream and start purging the unit FO
free of O2.
9 Pressurize the unit up to 0.5 MPa and depressurize through Filters PSV FO
25mm bypass valves up to 0.02 MPa.
10 Repeat purging till sample is free of O2 and block the unit at 0.5 MPa. FO
Check for leaks and fix them on top priority.

b. Regeneration of Adsorbers
No. Actions Resp.
1 After ensuring purging, start heating of Absorbers by selecting Step

CO
number 1 under sequence control.
2 Drain Condensate in SM Steam inlet line to 7A50-U03-E01 and line up

FO
Steam to it.
3 FO
Line up regeneration gas through 7A50-FV5059B for heating the both
Adsorbers. Put 7A50-HS1059 in DCS on 7A50-FV5059B. CO
4 Set 7A70-PIC7151A or B (preferably initially) at 3.5 Kg/cm2g and

CO
ensure 7A70-PXV7151B is lined up to Flare. (7A90-A02)
5 Open SM Steam to Regeneration Gas Heater and ensure functioning of

FO
trap and rise in gas temp.
6 Gradually raise the temperature at the rate of 50˚C/Hr to 150˚C at

FO
41TI6060/6063.
7 CO
Ensure the heated regeneration gas through both Adsorbers is routed
to Reformer or 7A90-A02 through 7A70-PXV7151B. FO
8
If both Adsorbers are not heated to desired temperature set value,
CO
advance the step through 7A50-HS5056. (Step advance)
9
Once both Adsorbers are heated up and regenerated from possible
CO
moisture, start cooling sequence through program.
10 Watch for completion of cooling sequence and mobilize for lining up

CO
Synthesis Gas Drying Unit.
c. Startup Procedure
No. Actions Resp.
1 Start gradually pressurizing by crack opening inlet valve up to

FO
Adsorbers inlet ensuring UVs are closed.
2 Once pressure is equalized with SGC 1st stage Discharge, open 7A50- FO
U03-V01 inlet valve fully.

3 Now open 25mm bypass I/V across 7A50-UV5051/5053 depending on FO

the Adsorber to be lined up and gradually pressurize the unit.
4 Once pressure is equalized with pressure upstream of inlet UVs open FO

Filters outlet valves. Close the 25mm bypass fully.
5 Set 7A50-HS5055 either on Auto/Manual from DCS and start sequence

control 07S6.24 and check for corresponding opening and closing of CO/FO
UVs of both Adsorbers.
6 Ensure 7A50-HXV5058 is in full open condition for SGC stable

FO
operation.
7 Continuously monitor the moisture content at online Analyzer 7A50-

CO
AP5002. Request Lab to check Dew Point /Moisture.
8 Gradually load the drying unit by slowly closing 7A50-HXV5058 and

CO
keep close watch on SGC flows.
9 Route the entire SGC 1st Stage Discharge gas through Drying Unit by
CO
closing 7A50-HXV5058 fully.
10 Watch for any possible gas leaks and get them fixed on top priority. FO
11 Keep the Standby Adsorber on Regeneration mode to use it in case of

CO
possible moisture slip from the one in line.
Note
The Operation of Drying Unit should be always at Normal operating pressure otherwise
at very low pressures Molecular Sieves are less efficient due to increased gas velocity
resulting moisture slip in Synthesis Gas to Ammonia Converters.
Note
Shutting down of Synthesis Gas Drying Unit doesn’t need any special attention as it is
protected by Control Logic X_G, 07X6.01 which isolates the unit through 07S6.24. Field
Operator has to ensure the closing of UVs in field for securing the unit safely.

7. Startup Check List For Synthesis Gas Compressor/Turbine
Date:
S.No. Description Condition Yes No Remarks
GENERAL
1 All maintenance Jobs Completed
2 Line flanges Boxed up
3 Covers and PSVs Boxed up
4 Clearance from Maintenance Supervisor. Obtained
All Instrumentation, transmitters Restored

5 switches, PI, TI vibration and Axial and lined
thrust probes etc. up
6 Clearance from Instrument Supervisor. Obtained
7 Drains & bleeds Closed
Ensure All Anti Surge Valves are Lined

8 Confirmed
up/Open
7A50-LV-5001A/B to be Stroke checked

9 Confirmed
/ Lined up.
UTILITIES
1 Electric power source Available
2 Breaker for all motors On
3 Instrument Air Available & lined up Confirmed
Sea cooling water to surface condenser

4 Lined Up
7A50-E05
5 Ensure CW lined up to Inter/After Cond. Lined Up
6 Cooling water to lube oil coolers Lined Up
LP Nitrogen to lube oil console and

7 Lined Up
bearing housing
8 SH/SL steam available Confirmed

Compressor Casing purged with N2

9 Confirmed
Casing under Synthesis Gas pressure
10 Lube oil console level Normal
11 Lube oil/control Oil cooler filter On line
12 Control oil accumulator Lined Up
MAIN OIL PUMP
1 Warming of SM/SL lines Completed
3 Bearing Oil level Normal
4 SL exhaust I/V Opened
5 Turbine L.O. pump Started
6 Pumps discharge pressure (1.10 MPa) Normal
7 L.O. Header Pressure (0.24 MPa) Normal
Visually
8 Oil flow to bearings in sight glass
checked
Check for Oil leak, if any attend and

9 Confirmed
rectify.
10 Ensure Oil temperature (42 - 45˚C) Confirmed
Lube oil run down tank over flow in sight Visually

11
glass checked
12 Start Turning Gear for 2 Hours Confirmed
13 Motor pump position Remote
SURFACE CONDENSER
1 Build up condenser Level Opened
2 Ejector condenser traps Lined Up
3 Priming valve of Cond. Pumps Suction Opened
4 Condensate circulation Started
5 Seal water to PSV of condenser Opened
6 Stand by condensate pump Remote

PULL VACUUM
Line up startup ejector Maintain steam

1 Confirmed
pressure 0.4O~0.42 MPa
Check vacuum & line up sealing steam to

2 Confirmed
turbine.
Sealing steam control valve 7A50-PV-

3 Confirmed
5040A/B in service.
4 Seal steam pressure 0.025 MPa. Normal
If vacuum more than -0.07 MPa lineup

5 Lined Up
one set of Primary & Secondary ejectors.
Do Main turbines warm up by opening HP

6 Steam I/L & Extraction SM Steam line, Started
Traps & Drains.
COMPRESSOR
1 Ensure 7A50-E01, E04, E10 are lined up. Lined Up
Ensure OT Synthesis loop Isolated & B/P B/P

2
opened Opened
Ensure Synthesis Gas Drying unit in line

3 Confirmed
7A50-HV-5058 Opened
SEAL GAS CIRCUIT
N2 supply pressure D/S of Regulators

1 (7A50-PRV-5536, 7A50-PRV-5563 at 0.1 Normal
MPa
2 Filters DP of N2 supply is normal Confirmed
PDCV 5026A/B (set at 0.035 MPa / 0.073

3 MPa) & PDCV-5041 (set at 0.035 MPa) Confirmed
are on line and pressure is normal.
DP of seal gas I/B & O/B are normal for

4 Confirmed
LP/HP
DGS BOOSTER COMPRESSOR
1 Check oil level in filter Normal
2 Ensure I/L & O/L I/V s opened. Opened


1. Introduction
The ammonia refrigeration compressor 7A60‐K01 is a steam turbine driven

single shaft compressor consisting of two casings with two stages each. In the
low pressure casing gas from NH3‐f1ash drum 7A60‐V03 is compressed to
aboutO;346 MPag and discharged into NH3‐f1ash drum 7A60‐V02 where it is
cooled down to O°C (boiling temperature) by passing a submerged sparger.
Ammonia vapor from the O'T final chiller 7A50‐E22 is injected into the low
pressure casing as an intermediate injection stream at a pressure of approx.
0.072 MPag. Vapors from NH3‐flash drum 7A60‐V02, make up gas / interstage
chiller 7A50‐E07, loop chiller 117A50‐E17 and reflux cooler 7A50‐E18 enter
the high pressure casing at about 0.315 MPag and are compressed to the final
pressure of 1.814 MPag. Vapors from loop chiller I 7A50‐E16, wash water
chiller 7A50‐E05 and ammonia product cooler 7A60‐E10 are injected into the
HP casing at approx. 0.456 MPag.
The compressor is driven by the refrigeration compressor turbine 7A60‐K01‐

TS01, a HP steam consuming turbine with an extraction of MP steam. Exhaust
steam is discharged into refrigeration compressor turbine condenser 7A60‐
E07. The obtained steam condensate is returned to the demineralization unit
90 by the condensate pumps 7A60‐P01A1B.
Control and Safety

The quantity of ammonia gas handled by the refrigeration compressor 7A60‐
K01 is adjusted to the refrigeration demand of the plant by variation of the
compressor speed. In cases when the refrigeration requirements of the plant
are below the surge limit of the compressor, safe operation is maintained by
means of a anti‐surge controller. Control is achieved by opening anti‐surge
valves in the outlet lines of the two compressor casings which ensure a
minimum flow through the compressor by throttling the gas and allowing it to
return to the suction side of the compressor after cooling.
Gas from the outlet of the low pressure casing is flashed into 7A60‐V02; gas
from the outlet of the high pressure casing is fed to ammonia condenser
7A60‐E01. In the first case, the gas is entering the vessel below the liquid level

in order to cool down the gas and to ensure only saturated vapor is leaving
the vessel towards the compressor.
The anti‐surge circuits are realized as follows:

o 1st stage (primary suction of low pressure casing): gas from the outlet
of the low pressure casing is routed via a submerged sparger in NH3‐
f1ash drum 7A60‐V03 back to 1st stage suction.
o 2nd stage (intermediate stage of the low pressure casing): gas from the
suction line of the 3rd stage is let down to the suction line of 2nd
stage.
o 3rd stage (primary suction of high pressure casing): gas from the outlet
of the high pressure casing is routed via a submerged sparger in NH3‐
f1ash drum 7A60‐V02 back to 3rd stage suction.
o 4th stage (intermediate stage of the high pressure casing): gas from
the outlet of the high pressure casing is routed via a submerged
sparger in loop chiller I 7A50‐E16 back to 4th stage suction.
In case of a synthesis gas drying unit 7A50‐U03 shutdown and during start‐up
of the ammonia plant, water rich gas is passing through the tubes of the OT
final chiller 7A50‐E22.
To avoid freezing of water and subsequent blocking of the tubes under these
conditions, refrigerant flow to the O'I final chiller is interrupted. The shell side
operating temperature will rise accordingly from ‐21°C to approx. O°C. When
refrigerant flow to OT final chiller 7A50E22 is interrupted, accumulation of
water on loop chiller II 7A50‐E17 shell side is prevented by a constant small
liquid ammonia draw‐off to NH3‐f1ash drum 7A60‐V03.

(Fig. 16)

2. REFRIGERATION UNIT NORMAL STARTUP
a. Startup of Lube oil circulation

Note
Before starting Lube oil circulation Separation Gas must be lined up to compressor
which protects carryover of oil from bearings along shaft through seals and further to
Compressor Casing. Line up N2 through Buffer Gas filters 7A60-K01-U11-F03/04 and
ensure 7A60-PRV6541 is controlling at 0.1 MPa g.
N0 Action Resp.
1
Ensure all drains and vents are closed in Lube oil, Control oil lines, Lube
FO
oil coolers, accumulators and Control oil filters.
Ensure lube oil over head tank non return valve bypass valve is in closed
2 FO
condition.
3 Open suction valves of 7A60-U01-P01/02/03 Lube oil Pumps. FO
4 Open discharge valves of 7A60-U01-P01/02/03 Lube oil Pumps. FO
Stroke checks 7A60-PV6150, 7A60-TV6150, 7A60-TV6152 and 7A60- CO

6
PV6153 line up isolation valves.
FO
7 Ensure N2 to 7A60-U01-T01 on 25mm line is in open condition. FO
Ensure Lube oil console is having 70% level and check moisture content
8 FO
Ensure all the Lube oil Pumps 7A60-U01-P01/02/03 Motors are

9 S.S.
energized.
Start 7A60-U01-P01 or P02 Motor driven Lube oil Pump check for any oil
10 FO
leaks and get it fixed.
Open lube oil cooler and Filters vents to bleed off air till continuous flow
11 FO

Ensure Lube oil header pressure is maintained at 0.3 MPa g through

12 7A60-PIC6153 and pump discharge pressure through 7A60-PIC6150 at CO
1.0 MPa g.
Check ∆p across Lube oil filters 7A60-U01-F01/02 and if it is more than

13 FO
0.15 MPa g change over to standby filter.
If Lube oil temperature is less than 40˚C line up SL Steam to console CO

14
through 7A60-TV6150 and raise oil temperature.
FO
If Lube oil temperature is more than 40˚C open cooling water return
15 FO
valve and adjust flow by throttling supply valve.
Check for oil leaks both at floor level, Compressor Platform and fix them
16 FO
on top priority.
Check oil flow through sight glasses in oil return lines of bearings of
17 FO
Fill up lube oil over head tank through NRV bypass line till continuous
18 FO
Keep Motor driven Lube oil Pump 7A60-U01-P01 or P02 and Emergency
27 FO
Lube Oil Pump 7A60-U01-P03 Motor switches on Remote mode.
Watch for Auto start of 7A60-U01-P01 or P02 Motor at 0.85 MPa g in CO

28
7A60-PI6151.
FO
After checking Auto start of 7A60-U01-P01 or P02 standby motor Switch

29 FO
on Remote.
CO
Check Auto start of 7A60-U01-P03 in same way which should come at
30
0.052 MPa in 7A60-PI6035. Keep its switch on Remote. FO

b. Startup of Dry Gas Seal Unit
N0 Action Resp.
1 Ensure all drains and vents are closed in Dry Gas seal unit. FO
Ensure N2 is available for Buffer gas and instrument air is available for
2 FO
driving Dry Gas seal Unit Booster Compressor.
Ensure N2 is lined up for Buffer Gas through filters 7A60-K01-U11-F03/04

3 FO
and 7A60-PRV6541 is set at 0.1 MPa g for secondary seals. (LP Case)
Ensure N2 is lined up for Buffer Gas through filters 7A60-U11-F07/08 and

4 FO
7a60-PRV6562 is set at 0.1 MPa g for secondary seals. (HP Case)
Check oil level in Filter of Booster Compressor and make up if necessary.

5 FO
Line up inlet and outlet valves of Booster Comp.
Line up primary seal gas to the Compressor and to the Seal gas Booster
6 FO
unit through filters 7A60-U11-F01/02. (LP case)
Line up primary seal gas to the Compressor and to the Seal gas Booster
7 FO
unit through filters 7A60-U11-F05/06. (HP case)
Set 7A60-PDIC6026A at 0.035 MPa g on Auto mode. (LP case- Drive End
8 CO
Side).
Set 7A60-PDIC6026B at 0.073 MPa g on Auto mode. (LP case- Non Drive
9 CO
End Side).
Set 7A60-PDIC6041 at 0.22 MPa g on Auto mode. (HP case both Drive
10 CO
and Non Drive Ends).
Establish a flow of 8.0 Nm3/hr of Secondary seal gas through 7A60-

11 FO
FI6030 and 7A60-FI6031 by adjusting valves manually. (LP)
Establish a flow of 8.0 Nm3/hr of Secondary seal gas through 7A60-

12 FO
FI6045 and 7A60-FI6046 by adjusting valves manually. (HP)
Pressurize the Compressor casing with N2 or Ammonia vapor based on

13 FO
purging or startup of Compressor.
Initiate 7A60-HS6041 to start the seal gas Booster unit as the LP casing
14 FO
15 Initiate 7A60-HS6042 to start the seal gas Booster unit as the HP casing FO

Establish a flow of 50 Nm3/Hr of Primary Seal Gas through 7A60-FI6013

16 FO
to LP Drive End by adjusting valves manually.

17 FO
to LP Non Drive End by adjusting valves manually.

18 FO
to HP Drive End by adjusting valves manually.

19 FO
to HP Non Drive End by adjusting valves manually.
c. Pre Startup Activities Of Refrigeration Compressor
Note
The conditions to be checked and ensured before Startup of Refrigeration

Compressor/Turbine are given in the Check List Special Operations.
N0 Action Resp.
Stroke checks 7A60-PXV6001, 7A60-FXV6002, 7A60-FXV6003, 7A60- CO

1 FXV6004, 7A60-FXV6005, 7A60-FXV6006, 7A60-FXV6009, 7A70-
FXV7004B and 7A50-FXV5170. FO
Stroke checks 7A60-LXV6002, 7A60-LXV6004, 7A60-LXV6006A/B, 7A60- CO

2
LV6008, 7A60-LXV6010, 7A60-HXV6007 and 7A60-PV6011. FO
Stroke checks 7A50-LXV5010, 7A50-LXV5150, 7A50-LXV5152A/B, 7A50-

LXV5161, 7A50-LXV5163, 7A50-LXV5165A/B, 7A50-LXV5167A/B, 7A50- CO
3
LXV5169, 7A50-LXV5172, 7A50-PXV5163, 7A50-PV5172 and 7A50- FO
FXV5170.
After stroke checking close upstream and downstream block valves of all
4 FO
except for all antisurge valves.
Ensure all drains and vents in Refrigeration Unit are closed. Ensure
5 FO
7A60-XV6010 and 7A60-XV6011 are lined up to flare.
Cordon off the area and keep all unauthorized people away from Plant
6 FO
informing about charging of Ammonia.

Keep the loop under Nitrogen positive pressure of 0.5 MPa g Ensure
8 Spectacle Blinds in DAP Product Ammonia line are reversed to open FO
condition.
Check for leaks if any with soap solution and get them fixed at the
9 earliest possible. Ensure LP and HP discharge XVs of 7A60-K01 are in FO
closed condition.
Ensure all the four suction XVs of Refrigeration Compressor are closed CO
10
and spectacle blinds are reversed to open. FO
Gradually open Ammonia Product line to DAP Plant and back charge CO
11 Ammonia to Receiver through 7A60-HV6007 and 200mm block valves of
7A60-E10. FO
From Ammonia Receiver charge Ammonia to 7A60-V02 through 7A60- CO

12
LXV6002. FO
From Ammonia Receiver charge Ammonia to 7A50-E16 through 7A50- CO

13
LXV5161. FO
From Ammonia Receiver charge Ammonia to 7A50-E07 through 7A50- CO

14
LXV5010. FO
CO
15 From 7A50-E16 charge Ammonia to 7A50-E17 through 7A50-LXV5163.
FO
CO
From 7A60-V02 transfer Ammonia to 7A60-V03 through 7A60-
16
LXV6006A. FO
Increase Ammonia make up from Utilities to meet the required levels of CO

17
filling in all chillers. FO
Maintain levels in Loop chillers I, II and 7A50-E07 around 30%. If level CO

18
raises drain through manual drains to 7A60-V03. FO
Ensure around 20% to 30% level build up in 7A60-V01, 7A60-V02, CO

19
7A60-V03, 7A50-E07, 7A50-E16 and 7A50-E17.
FO
CO
Avoid taking level in 7A50-E22, 7A60-E10 and 7A70-E05. For three of
20
these Ammonia can be filled up on need basis.
FO

CO
Open 7A60-PSV626, 7A60-PSV633, 7A60-PSV634, 7A60-PSV601 and
21
7A60-PSV602 - 25mm bypass valves to remove N2/air from system.
FO
After having enough levels makeup from Utilities can be throttled to CO

22
7A60-E10. FO
Ensure Dry Gas Seal Units of both LP and HP casings of 7A60-K01 are CO
23
functioning OK and drain out any oil/moisture. FO
Inform Utilities and gradually charge Sea cooling water to both 7A60-
24 E01A/B. (Already charged as soon as Sea Water Pumps are started at CO
Utilities).
CO
Ensure 7A60-V01 bypass vapor valve to 7A60-E01A/B is in 90% closed
25
condition to direct 7A60-K01 discharge for precooling in 7A60-V01.
FO
26 Ensure 7A60-E02 shell side is filled up with Ammonia from 7A60-V02. FO
Ensure 450mm vapors inlet valves of 7A60-E01A/B are in full open

27 FO
condition and spectacle Blinds are reversed to open.
Ensure 250mm liquid Ammonia outlet valves (4 Nos.) of 7A60-E01A/B

28 FO
are opened fully and spectacle blinds are reversed to open condition.
Open Suction and Discharge valves of 7A60-P02A/B pumps and ensure

29 spectacle blinds in suction, discharge and minimum flow lines are FO
reversed to open condition.
Ensure 250mm liquid Ammonia outlet valves (4 Nos.) of 7A60-E01A/B

28 FO
are opened fully and spectacle blinds are reversed to open condition.
Open Suction and Discharge valves of 7A60-P02A/B pumps and ensure

29 spectacle blinds in suction, discharge and minimum flow lines are FO
reversed to open condition.
Prime well 7A60-P02A/B Pumps through Cooling lines to 7A90-V02. After

30 FO
cooling close 25mm lines to 7A90-V02.
Check drains on each Compressor stage suction strainers and ensure no

31 FO
liquid is present.

d. Lining up of Turbine Condenser 7A60-E07
N0 Action Resp.
Inform Utilities about lining up of Sea cooling water from 7A60-E01A/B

1 FO
to 7A60-E07.
Open 7A60-E07 Sea Water Supply Valve fully and open Sea Water
2 FO
Return Valve by 20% or more as per required.
3 Establish level in 7A60-E07 through service water hose. FO
CO
4 Stroke check 7A60-LV6021A and B.
FO
Ensure 7A60-LV6021A and B upstream and downstream isolation valves

5 FO
are lined up. Set 7A60-LIC6021 at 50% on Auto.
6 Check condensate Pumps 7A60-P01A and B Motors are energized. S.S.
7 Open 7A60-P01A /B suction and discharge valves. FO
8 Line up cooling water to Ejector condenser 7A60-U02-E01. FO
Start one of the condensate pumps 7A60-P01A /B on recycle through

10 FO
7A60-LV6021B.
Raise 7A60-E07 level above 60% and check for standby Pump Auto start. CO
11
Keep both the Pumps on Remote.
FO
12 Open sealing condensate to 7A60-PSV651 on 7A60-E07. FO
Gradually line up SL Steam to Hogging ejector. Open valve on non

13 FO
15 Establish vacuum at -0.08 MPa in 7A60-E07. FO

Trip Check
Note
casing is under pressure. After ensuring no Lube oil, Dry Gas seal alarm conditions are
not existing, reset 7A60-XVHS6001 and check for opening of all suction and discharge
XVs of Refrigeration Compressor. Ensure all the four Antisurge valves are open.
N0 Action Resp.
Ensure SH Steam inlet isolation valve of 7A60-K01-TS01 is in closed

1 FO
condition.
Set the Idle/Rated Switch in Refrigeration Compressor Operator Panel

2 CO
(DCS) 7A60-HS6035 to Idle.
Initiate Start Turbine switch 7A60-HS6033 which will energize Control oil
5 FO
Trip solenoid valves 7A60-XVY6030A/B.
Latch each solenoid valve by pushing down on the handle which opens
6 FO
CO
8 Ensure 09X7.04 is healthy and Dry Gas Seal Unit is lined up.
FO
Ensure High Axial Displacement trip of both Turbine and Compressor

10 CO
(Both LP, HP) are in line.
11 Ensure High Exhaust Steam Pressure Trip of 7A60-K01-TS01 is in line. CO
Ensure Refrigeration Compressor Low Suction Pressure Trip for all the
13 CO
four stages are in line.
Ensure Refrigeration Compressor LP and HP Discharge Pressure High,

14 CO
trips are in line.

Ensure 7A50-E07, 7A50-E16, 7A50-E17, 7A50-E22, 7A60-V02, 7A60-

15 CO
V03, 7A60-E10, 7A70-E05 High Level trips are in line.
Actuate 7A60-HS6001 (Emergency Off) from DCS and confirm Trip alarm CO
17
appears in DCS / Field and de-latching of TTV.
FO
Reset 09X7.01, repeat same for 7A60-HS6002 (Emergency Off) from CO

18
Field and confirm Trip alarm / de-latching of TTV. FO
CO
Reset 09X7.01 and actuate 09X7.04 Dry Gas Seal Trip from DCS and
19
confirm Trip alarm / de-latching of TTV. FO
Repeat for Low Lube oil, Low Control oil pressure Trips by reducing the CO
20
Lube oil turbine speed keeping Motor on Local. FO
CO
Check Auto Start of 7A60-U01-P02 or PO2 and 7A60-U01-P03 by keeping
21
the Motors switches on Remote. FO
After completing Trip checking restore back all, keep standby lube oil
22 FO
pump Motor switches on Remote.
After ensuring Lube oil lined up to Turning Gear start the Turning Device
23 FO
as follows.
Remove the spindle cover; install the ratchet spanner at the end of the
24 FO
Pull the lever to reset the stopper for the worm Gear and turn down the
25 FO
lever.
Turn the ratchet spanner clockwise to engage the worm with the worm
26 FO
wheel.
Remove the ratchet spanner and install the spindle cover after
27 FO
engagement.
Run the Turning Gear for at least 2 hours prior to Slow Roll of the
29 FO
machine.

e. Warming up of Main turbine 7A60-K01-TS01
N0 Action Resp.
Ensure SH Steam inlet and SM Extraction isolation valves of 7A60-K01-

1 FO
TS01 are in closed condition.
2 Open SH Steam inlet valve downstream drain and ensure trap lined up. FO
Warm up through SH inlet upstream 25mm double block vent valves and
3 FO
Warm up SM Extraction line through bypass valve and vent. When

4 FO
Pressure is equalized open 7A60-MV6002.
5 Watch for any leaks and get them fixed at the earliest possible. FO
While warming up watch for any oil smoke from Turbine casing and
6 FO
insulation and get it fixed by all means.
8 Ensure 09X7.04 is healthy and Dry Gas Seal Unit is lined up. FO
9 Watch for SH Steam inlet temperature of 7A60-K01-TS01 is 500˚C. FO
Throttle warm up valves and once SH Steam Pressure has risen to 11.3
10 FO
MPa open 7A60-MV6001 fully.
f. Startup of 7A60-K01
N0 Action Resp.
Set 7A60-PIC6040 at 0.02 MPa g on auto and line up 7A60-PV6040 CO

1
sealing steam to 7A60-K01-TS01. FO
Adjust gland leakage block valve of 7A60-K01-TS01 and keep slightly

2 FO
negative pressure of -0.0005 MPa g.
Ensure one set of ejectors are in line and Exhaust Pressure is maintained
3 FO
at -0.08 MPa g.
4 Reset any ITCC failures and alarms in Operator Panel of Synthesis Gas CO

Compressor in DCS.
5 Ensure TTV test lever is in “Neutral” position. FO
Reset 09X7.01. The local “Ready to Start” light 7A60-UL6031 should

6 CO
glow.
Initiate the Start turbine switch in Operator Panel of Synthesis Gas CO

7
Compressor to energize 7A60-XVY6030A/B solenoids.
FO
Latch each solenoid valve by pushing down the handle. Pull out the Reset
8 FO
button on the side of Turbine pedestal.
9 Watch for Operator panel goes to “Step 1-accelerate”. FO
Ensure all antisurge valves are in open condition and 7A60-XV6001 to

10 FO
7A60-XV6006 are opened fully.
Slowly open the TTV until the rotor starts to turn. Raise the speed to 500
11 FO
RPM. Hold for 60 minutes.
Watch for any abnormal sound or vibration from Turbine and Compressor
12 FO
casings
Watch for automatic stopping of Turning Gear motor and confirm it has
13 FO
disengaged.
After 60 minutes open TTV further to raise the speed to 1000 RPM and
14 FO
open TTV fully ensuring Governor control.
15 Watch for the operator panel goes to “Step 3 - At Idle Speed”. CO
16 Close the drains on TTV, Governor valve and casing. FO
Watch for the remaining time at ideal speed in 7A60-K01 DCS Operator
17 FO
Ensure availability of 50 MT/Hr of SH Steam to raise to Minimum

18 S.S.
Governor Speed. Co-ordinate with Utilities.
When the idle speed timer reaches zero, press the “Continue” button on
19 Operator Panel and watch for going to “Step 4-accelerate to Minimum FO
Governor”.
Closely monitor quick crossing of critical speed band (2466- 4620 RPM).
20 CO
Watch for abnormal sound and vibration if any.

FO
Watch for the Minimum Governor Speed holding at 3575 RPM and record
21 CO
Radial / axial vibration readings.
22 Watch for the operator panel goes to “Step 6 - At Minimum Governor”. CO
23 Press “Continue” button further to go to “Step 8 - Turbine on line”. CO
24 If necessary select the suction pressure control of Turbine speed. CO
25 Maintain 7A60-E07 level through 7A60-LIC6021. CO
Once operation has stabilized prepare for lining up SM Steam Extraction CO

26
by 7A60-HS6037.
FO
While lining up Extraction, slowly close HIC1160 to go to full Extraction.

27 CO
Otherwise Extraction will not start.
Watch Compressor each stage flow and adjust antisurges for stable
28 CO
operation of Refrigeration Compressor.
Once Compressor operation is stabilized and vacuum is steady cutoff

29 F0
Isolate lube oil to Turning Gear, once operation of Compressor is

30 F0
stabilized.
Following guidelines to be followed for Cold Start, Warm Start, Hot Start and Very Hot
Start of Refrigeration Compressor:
Turning Gear Hold Time at Hold Time at

Restart attempt
Type of Start
after Operation 500RPM 1000RPM
Cold Start More than 48 Hours 120 Minutes 60 Minutes 30 Minutes
Very Hot start Less than 0.5 Hours 30 Minutes 10 Minutes 05 Minutes

Journal Bearings of Turbine, LP,

HP casings
Bearing Metal
Normal Maximum Trip
Temperature
Journal / Thrust Bearings of

< 100˚C 120˚C 125˚C
Turbine, LP, HP casings
machine.
Note

3. Startup after Emergency Shutdown of Refrigeration Compressor
After identifying the cause of tripping of Refrigeration Compressor start the Compressor
as described under Normal Startup Procedure (CHAPTER 9.1).
Compressor:
Restart attempt Turning gear Hold Time Hold Time

Type of Start
after Operation at 500RPM at 1000RPM
Very Hot start Less than 0.5 Hours 30 Minutes 10 Minutes 05 Minutes
Journal Bearings of Turbine,

LP, HP casings
Bearing Metal
Normal Maximum Trip
Temperature
Journal / Thrust
Bearings of Turbine, < 100˚C 120˚C 125˚C
LP, HP, Casings
machine.

Note
Startup of Chillers and Inert Gas Cooler after ESD
N0 Action Resp.
Charge Ammonia from Ammonia Storage through Ammonia Process S.S.

1
Pumps 7210-P01A/B.
Gradually charge Ammonia through bypass of NRV in Product Ammonia FO

2
line to DAP Plant.
Build up levels in Ammonia Receiver, Loop Chillers, Ammonia Flash CO

3
Drums and Makeup Gas Chiller.
FO
Once vapour load is generated start Refrigeration Compressor as CO

4
described under Normal Startup Procedure. FO
CO
5 Line up Inert Gas cooler to remove the non-condensable.
FO

4. REFRIGERATION COMPRESSOR NORMAL SHUT DOWN
Note
When Ammonia Plant had proposal for planned shutdown, the plant Front End Load
will be gradually reduced, Back End will be shutdown and once Synthesis Unit had
taken Shutdown already and draining of Ammonia Flash drums, All Chillers,
Separators had been completed Refrigeration Compressor will be stopped as
follows:
N0 Action Resp.
1 Ensure Hydrogen recovery Unit has been shutdown and off gas is being
CO
vented through 7A70‐PV7013 and 7A70‐PXV7151B.
While off loading Synthesis Gas Compressor ensure Chiller levels are
2 CO
maintained to avoid tripping of 7A60‐K01.
Gradually off load Refrigeration Compressor by reducing the speed and

3 CO
opening antisurge valves.
Ensure Ammonia supply to DAP Trains is swapped from Ammonia Plant

4 CO
to Ammonia Storage.
Gradually reduce levels in Chillers and immediately after shutting down CO

5
OT Synthesis isolate NH3 to 7A50‐E22. FO
Gradually Extraction from 7A60‐K01‐TS01 and changeover to HIC1160 CO

6
and fully cutoff Extraction. FO
7 Close 7A60‐MV6002 from field. FO
Ensure Dry Gas Seal Unit is in line and prepare for lining up Booster
8 FO
Compressor.
Gradually reduce the speed of the machine taking care of stage pressures
9 CO
and Compressor discharge flows.
Once Minimum Governor speed is reached hold for a short while for
10 CO
stable operation of Compressor and vibration level.

Inform Utilities about stopping of 7A60‐K01 to adjust firing in Package

11 S.S.
Boilers.
Ensure all the four antisurges are full open and actuate 09X7.01. After CO
12 ensuring stopping of Compressor and lining up of Lube oil, start Turning
Gear device. FO
Maintain SH Header pressure through PIC1170. Close 7A60‐MV6001 CO

13
locally from field. FO
If any shutdown activity is there depressurize Compressor casing through

14 FO
7A60‐XV6010 and 7A60‐XV6011.
CO
15 Ensure all the four suction XVs got closed.
FO
When Compressor casings arte less than 0.05 MPa Booster Compressors
16 FO
can be stopped.
Isolate sealing steam to 7A60‐K01‐TS01 and cutoff Steam Ejectors. Break

17 FO
the vacuum in 7A60‐E07.
Stop Condensate Pumps 7A60‐P01A/B and keep the Motors switches on

18 FO
local mode.
Once Turbine Casing is cooled Turning Gear can be stopped. Isolate Lube
19 FO
oil to device.
When Turbine and Compressor bearing temperatures are less than 40˚C
20 FO
Lube oil circulation can be stopped.

5. Normal Operation of Refrigeration Compressor
Machine Monitoring
Parameter Operating Value Monitored by Resp.
1st Stage Suction Pressure 0 MPa g 7A60-PIC6001 CO
1st Stage Suction Flow 12,870 Kg/Hr 7A60-FIC6001 CO
2nd Stage Suction Pressure 0.08 MPa g 7A60-PI6005 CO
LP Discharge Pressure 0.33 MPa g 7A60-PI6058 CO
LP Discharge Temperature 76˚C 7A60-TI6004 CO
3rd Stage Suction Pressure 0.276 MPa g 7A60-PI6007 CO
3rd Stage Suction Flow 101,075 kg/Hr 7A60-FIC6004 CO
4th Stage Suction Pressure 0.41 MPa g 7A60-PI6060 CO
HP Discharge Pressure 1.83 MPa g 7A60-PI6010 CO
HP Discharge Temperature 129˚C 7A60-TI6009 CO
LP Discharge/Antisurge Flow 25,000 kg/Hr 7A60-FIC6002 CO
HP Discharge/Antisurge Flow 208,395 kg/Hr 7A60-FIC6003 CO
Lube Oil Pressure 0.15 MPa g 7A60-PIC6153 CO
Lube Oil Temperature 45˚C 7A60-TIC6152 CO
Control Oil Pressure 1.0 MPa g 7A60-PIC6150 CO
∆P of LP Dry Gas Seal 0.035/0.073 MPa g 7A60-PDIC6026A/B CO

∆P of HP Dry Gas Seal 0.035 MPa g 7A60-PDIC6041 CO
3
LP Primary Seal Gas Flow 50/96 Nm /Hr 7A60-FI6013/6014 CO
LP Secondary Seal Gas Flow 8/8 Nm3/Hr 7A60-FI6030/6031 CO
HP Primary Seal Gas Flow 71/71 Nm3/Hr 7A60-FI6015/6016 CO
3
HP Secondary Seal Gas flow 8/8 Nm /Hr 7A60-FI6045/6046 CO
Turbine Condenser Level 50% 7A60-LIC6021 CO

N0 Action Resp.
1 Watch for any abnormal sound, vibration, leak etc. in Compressor,

Turbine, Lube oil Pump, Turbine, Condensate Pump and report to Shift FO
Observe any deviation in Process Parameters and follow up with

2 FO
Coordinate with Maintenance Supervisors for cleaning of Dry Gas seal

3 FO
Periodical monitoring of oil flow through sight glasses of oil return

4 FO
lines of bearings and report any abnormality like moisture etc.
Watch for any Steam, Ammonia, and Oil leaks and fix them on top
5 FO
priority.
Closely monitor Exhaust pressure and changeover Ejectors if

6 FO
necessary.
Watch for level buildup in Suction separator and Inter Stage

7 FO
separator.
Check Standby Lube Oil Pumps / Condensate Pumps motors switches

8 FO
on Remote position.
Maintain Primary and secondary Seal Gas flows at specified values by

9 FO
vendor.
Adjust Sea Cooling water to 7A60-E07, 7A60-E01A/B, Cooling water to

10 FO
Lube oil cooler.

Training Manual Copressor House

Uploaded by

Document Information

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

Training Manual Copressor House

Uploaded by

Copyright:

Available Formats

CONTENTS

Part 1: CENTRIFUGAL COMPRESSORS­ GENERAL: 1

Part 2: STEAM TURBINES­ GENERAL: 10

Part 3: NATURAL GAS COMPRESSOR & TURBINE 23

Part 4: PROCESS AIR COMPRESSOR & TURBINE 43

Part 5: SYNTHESIS GAS COMPRESSOR & TURBINE 62

Part 5: REFRIGERATION COMPRESSOR & TURBINE 88

Compressor House Area Page 1

COMPRESSORS CONSTRUCTION AND PARTS

A centrifugal compressors is built of two main parts:

The casing houses the rotor and is made-up of the following:

1. Diaphragms: These used to separate the stages in multistage compressors

2. Diffusers: Used to change the velocity of the gas into pressure.

4. Balancing drum: Used to minimize axial thrust.

5. Labyrinth seals: Fitted in the diaphragm to minimize the internal leakage

6. Bearings and Seals

Compressor House Area Page 2

This consists ofo a wheell shaped element

The shhaft due to

Axiallly: ovement allong the shhaft (Thrust). Thrusst is a tenddency of the

Compreessor House Area

As mentioned earlier multistage compressors contain diaphragms, which

Fig. (9) Diaphragm

Compressor House Area Page 4

Seals are used in machines to prevent leakage of fluids to the

1. In conjunction with oil, bearings help to minimize friction.

Compressor House Area Page 5

CENTRIFUGAL COMPRESSOR SURGING

A centrifugal compressor operates within certain limits of speed, suction

Compressor House Area Page 6

Surging is normally prevented by a ‘Recycle Control System’, which at some

Compressor House Area Page 7

Large powerful machines incorporate a 'Computerized Suction Flow

Operating conditions, which lead to surge, are:

 Drop in suction pressure.

MONITORING AND PROTECTIVE DEVICES

Control systems for compressor application are passing through different

All control systems, within manual or automatic, contain fundamental elements

For compressors in general the following parameters are monitored, controlled

 Warn the operator to take a corrective action, start a stand by

Compressor House Area Page 8

 Bearings temperature (warn the operator to stop the machine if

 Discharge temperature / pressure (warn the operator to stop the

 Vibration and axial displacement (warn the operator / trip the

 Compressor speed (trip the machine in case of over speed).

Compressor House Area Page 9

Compressor House Area Page 10

STEAM TURBINES - PRINCIPLES & OPERATION

Steam at normal atmospheric conditions is Saturated (Wet) steam - i.e. 212°F

Compressor House Area Page 11

equipmment usedd for this iss called a NOZZLE.

Compreessor House Area

A muulti-stage tu urbine is one,

Compreessor House Area

To acchieve thiss, a row of

The sttator bladees act like further

Whenn the steamm leaves a turbine,

Compreessor House Area

Compreessor House Area

TYPES OF STEAM TURBINE

1. BACK-PRESSURE STEAM TURBINES

In this type of turbine, the exhaust pressure must be maintained at a constant

2. CONDENSING STEAM TURBINES

In a condensing steam turbine, the maximum amount of energy is extracted

Part 1: CENTRIFUGAL COMPRESSORS GENERAL: 1

Part 2: STEAM TURBINES GENERAL: 10

Drop in suction pressure.

Warn the operator to take a corrective action, start a stand by

Bearings temperature (warn the operator to stop the machine if

Discharge temperature / pressure (warn the operator to stop the

Vibration and axial displacement (warn the operator / trip the

Compressor speed (trip the machine in case of over speed).