IA to
Reservoir
Condensate
Drain system
Instrument Air (IA) compressor is
used to compress atmospheric air and deliver to
instruments like pneumatic valve operations and other
process requirement.
ADCO-RUMAITHA PHASE-III
project consists of 4 No’s of Air Compressor.
Rotary Screw
Membrane
Compressor
• Suction Filter • Dryer
• Air Package • Nitrogen
Compressor System
Self Cleaning Desiccant
Filter Fixed bed
Air compressor is an electric motor driven, Oil free, dry,
double stage screw compressor with Interstage coolers and
Auto condensate drain removal system.
2nd stage
1st stage discharge
discharge (~10
BDV& BFV for (1.7-2.4 barg) to
Atmospheric barg) to discharge
Load/Unload Interstage Air
through Inlet self air cooler and to
compressor at cooler and to
cleaning filter moisture
Inlet moisture
separator finally
separator
discharging
During sequence, Auto Drain: LO System: Safety PSV’s:
Load: BFV(Open), Running Time: Main pump (Connected 1st stage: 3.8 barg
BDV(Close) Open Interval (180 Sec) to shaft) Discharge: 11 barg
Unload: BFV(Close), Open timing (5 Sec) Standby (Motor driven)
BDV(Open) Auto Standby: for Bearing cooling
Open Interval (600 Sec)
Open timing (5 Sec)
Shut Down:
Always Open
Suction air filter is used to clean the incoming air to compressor.
Sequence will be activated,
1. Timer (Every 200 sec)
2. DP (High: 5.88 mbar) Type: Cartridge Filter
3. DP (Low: 2.94 mbar)
No of Cartridge: 2 No’s
Cleaning type: Air pulse Jet
Cleaning Interval: 200 Sec.
Air Pressure: 3 barg
Valve opening time: 1 sec
Vendor • Ingersoll Rand
Type • Rotary Double stage screw compressor
Driver • Electrical motor operated
Rated Capacity • 1825 Nm3/Hr
Motor load • 355 KW
Motor Speed • 1500 RPM
Discharge Pressure • 9.5 barg
No of compressor • Normal:2 No’s; Peak time: 3 No’s
In operation
To atm.
Suction Discharge
Filter Silencer Air
Blow
3.8 barg PSV 11 barg PSV down
1st 2nd
Cooler Cooler
stage stage
LO System
Suction
Load/Unload
valve Operated Condensate Auto Drain
by mechanical
linkage
Lube oil system is integral part of this package to provide
lubrication for Bearings, compressor 2nd stage housing for
cooling and for operation of Inlet butterfly valve.
Parts associated with LO system:
1. Lube oil sump
2. Primary oil pump driven by main shaft
3. Secondary oil pump driven by electric motor
4. Oil pressure control valve (PCV set pressure 2.7 barg)
5. Oil cooler (Air cooled type cooler)
6. Thermostatic control valve (Close-54.4 DegC and Open-60
DegC)
7. Oil filter (Cartridge)
1. Perform construction checks like, Installation, Tie in points
and Alignment etc.,
2. Perform Electrical checks like, Power source, Voltage and
Earthing
3. Confirm lube oil level (Top up if required)
4. Confirm all the valves status and keep discharge open
condition
5. Ensure normal pressure and temperature of the
compressor
6. Open and check manual condensate drain valves if any
water or residual pressure in the system
7. Confirm the power source to Auxiliary Lube oil pump,
Interstage/Discharge air coolers.
8. Confirm suction filter DP is normal and Auto cleaning
status
9. Confirm from MCC “Ready to Start” indication
Individual
LO level min 2/3 of Group Start LO level min 2/3 of
(Field) Start sight glass sight glass
Don’t select any Select any one
operation mode operation mode
Every 750 Hrs of
operation mode
Keep all the motors in has to be changed Keep all the motors in
LOCAL mode REMOTE mode
Keep only one
compressor in
Remote to avoid
Start all the air coolers All the LEAD Ensure all the motors
manually. compressors should “READY TO START”
all the be in REMOTE and
compressor start READY TO START
at same time on
No mode selection
Confirm LO pump Confirm Main motor&
operation due to NOT running LO pump NOT running
All the
compressors will Main motor Initiate GROUP
set Lead-1 Start from field PB starts after 3 sec
of all the coolers
START to com package
run indication
Individual compressor Lead-1,2,3 comp. will
will be started start in 2sec interval
Compressor will load Compressor will load
after 10 sec. on conditional basis.
Tag Description Trip Value Remarks
Trip will be initiated on
2nd stage inlet 2.96 barg (Load) 2nd stage discharge temp.>32 C,
pressure HH 0.33 barg (Unload) Main motor running for last 7
sec.
2nd stage discharge 11.0 barg (Load) 10 sec time delay after unload
pressure HH 3.4 barg (Unload) of the compressor to release the
residual pressure.
Bearing oil pressure 2.27 barg After starting the main motor 8
LL sec time delay for pressure rise.
DP reference to the atm. and
Inlet differential 0.2 bar (Load) inlet pressure. (Helps to
pressure HH 0.9 bar (Unload) determine if less flow through
compressor)
1st stage discharge 238 C ---
temperature HH
2nd stage inlet 15 sec time delay after main
temperature HH 65 C motor start (For Air coolers to
respond on load)
Tag Description Trip Value Remarks
2nd stage discharge 271 C ---
temperature HH
Pkg. discharge 65 C ---
temperature HH
Bearing oil 77 C ---
temperature HH
Range has given to avoid level
Interstage liquid level 15% to 17% switch malfunction (No level
HH indication on DCS, mandatory
to check by manual valve)
Range has given to avoid level
switch malfunction (No level
Discharge liquid level 15% to 17% indication on DCS, mandatory
HH to check by manual valve)
Main motor ready to Ready to start from ---
start MCC negative
Auto
Start
Receiver tank
pressure <8.3 barg
No STOP
Package discharge
initiation from
pressure <9.3 barg
Group/Auto/DCS
GROUP Start from
DCS START Individual START
from DCS
• Motor running for 10 sec
• System should be unloaded condition
Condition • DCS Unload button should be released position
to Load • Unload order should be negative
• Lead-1 compressor will load first
• Receiver tank pressure <8.3 barg
Lead-1 • Package discharge pressure <9.3 barg
Load • Lead-2 or Lead-3 is in loaded condition
• Receiver tank pressure <8.8 barg
• Package discharge pressure <9.8 barg
Lead-2 • Load order /Lead-1 loaded (10 sec time delay)
Load • Lead-1 and Lead-3 in Loaded
• Receiver tank pressure <8.8 barg
• Package discharge pressure <9.8 barg
Lead-3 • Load order/Lead-1&2 loaded (10 sec time delay)
Load
• Prior in loaded condition
• DCS Unload initiated
Condition • Trip/Emergency stop
to Unload • Any motor unavailable in Remote to enable start
• Receiver tank pressure >8.8 barg
• Package discharge pressure >9.8 barg
Lead-3 • Compressor switch to Auto Standby mode
Unload
• Receiver tank pressure >8.9 barg
• Package discharge pressure >9.9 barg
Lead-2 • Compressor switch to Auto Standby mode
Unload
• Receiver tank pressure >9.0 barg
• Package discharge pressure >10.0 barg
Lead-1 • Compressor switch to Auto Standby mode
Unload
Stop from
Lead-3,2,1
in 5 sec
interval
Running
continuously No START
on Unload order should
for 10 be initiated
minutes
Operation Air coolers
Mode will be
STANDBY stopped after
(Operation 3 sec of main
ID-4) motor stop
STOP from
DCS
(10 sec time
delay for
STOP IPS TRIP
Unload)
Condensate Auto drain system equipped with this Air
compressor package to drain the condensed moisture
from Interstage and Discharge moisture separator.
This is solenoid operated valve and solenoid is being
controlled from DCS logic system.
After start of the main motor the draining sequence will
be activated, Every 180 sec (60-360 sec) drain sequence
valve will be open for 5 sec (2-20 sec).
During Trip of the compressor Drain valve will be
remain in open position.
It’s mandatory to check intermittently by opening of
manual block valve to ensure the auto drain valve is
functioning properly. (No alarm or Analog value in DCS
to monitor level of the separator) >15% of level
compressor will be tripped.
Group and Auto start Inhibition:
1. More than one mode of operation selected
2. Any Lead compressor trips
3. Any motor unavailable to start and not in Remote
4. Motor oil pump running
5. If Group operation released from DCS
Receiver pressure transmitter fault:
• Tank receiver equipped with two transmitters for
redundancy
• Selector switch provided in the DCS to choose anyone
transmitter
• Incase of failure of selected transmitter automatically
follows the healthy redundant transmitter to control the
process.
• In failure of both receiver transmitter system will be
controlled based on package discharge pressure.
Heatless desiccant compressed air dryers removes moisture
from compressed air to achieve a standard pressure dew
point of -40 DegC at atmospheric pressure.
For, ADCO-RUMAITHA Phase-III project 4 No’s of Dryers
available. 1- Online; 2- Regeneration; 3,4- Standby
Desiccant Inlet Outlet Sequence
• Material: • Max: 5475 • Max: 4561 • Regen.
Activated Nm3/Hr Nm3/Hr Flow: 610
Alumina • Nor: 3650 • Nor: 3040 Nm3/Hr
Nm3/Hr Nm3/Hr • Regen
• Pres: 8.9- • DP: 0.8 time:
• Life time: 9.4 barg bar 4 Minutes
3 Years • Humidity: • Dew • Online
110% point: - time:
40C @atm 5 Minutes
Online
Regeneration
DRYER DRYER
-A -B
Time
Condition check Dryer-A Dryer-B Remarks
(Min)
0 (Start Dryer-A/B Dryer RUN
from STOP Release common valve --- indication to
DCS) open LCP/DCS
“B” inlet valve
Dryer-B inlet close initiate
valve close once “A” inlet
full open.
Any valve Dryer-A inlet
1 Dryer-A
discrepancy valve open
Dryer-B purge (Drying) Dryer-
outlet valve B (Regen.)
open after 3 sec indication to
DCS
Dryer-A/B
2 common purge
vent valve open
Dryer-A/B
common purge
vent valve close
4
Dryer-B purge
outlet valve
close
Dryer-A inlet Dryer-B inlet
5
valve close valve open
Any valve malfunction or Not fully opened/closed
both dryer’s will go to fail safe mode.
On fail safe mode both dryer’s will be move to
online mode. Operator has to take decision which
one to place in service and required maintenance to
be carried.
Unless fix the issue dryer can’t be operate in Auto
mode. It’s required to closely monitor the outlet dew
point temperature.
The Nitrogen generation package is designed to produce
the Nitrogen used as utility for ADCO-Rumaitha Phase-
III project units.
Vendor : Bellelli Engineering
Description Design Value
Air feed temperature 15 – 65 DegC
Air feed pressure 8.0 – 8.5 barg
Air flow rate 2625 Nm3/Hr
Air feed dew point -40 DegC
Output Nitrogen purity 98% (v/v)
Nitrogen outlet temperature 65 DegC
Nitrogen outlet flow 750 Nm3/Hr
Nitrogen outlet pressure 7 – 7.5 barg
No of membrane modules 13 (10-Service; 3-Standby)
Vent to
safe
location
Oxygen rich
Air to vent
Electric
Heater SP:
60 DegC
Nitrogen Module
(Membrane)
O2 Analyzer
Pressure
Control valve
to control
package inlet
pressure
Nitrogen to
Air Flow from Receiver (98%
purity)
IA Receiver
Upon sequence start from DCS,
1. Open Inlet shut down valve
2. Electric heater energizing (Package pressure >6.8 barg)
3. Production valve open (Once O2 content <2.0%)
4. Vent valve close (Once O2 content <2.0% and Production
valve full opens)
Upon sequence stop from DCS/IPS,
1. De-energize heater
2. Open vent valve
3. Close production valve
4. Close inlet valve (After 60 sec purging of the system)
It’s required to maintain minimum of 7.7 barg pressure in the
package and it’s being controlled by inlet pressure control valve.
It’s required to maintain inlet temperature of 15 – 65 DegC
(Optimum 60 DegC) for efficient membrane separation. (Membrane
max design temperature 70 DegC)
Equipped with Oxygen analyzer at the outlet and if O2 content is
more than 2% (v/v) DCS will close the production valve and all the
flow will routed to vent.
If O2 content High High concurrent with,
1. Low feed pressure
2. Low feed temperature
3. High Nitrogen Flow
In these above case package will not initiate trip only production
valve closes and vent valve opens until on spec product.
If O2 content High High non-concurrent
with the above conditions, Package will initiate trip and closes the
inlet valve. Root cause to find out, If necessary standby filters to be
taken in service.
