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  • Start Up and Operation: Presented by Fs Engineer Sundyne

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    Naveedullah Awan
    70 views36 pages
    This document provides information on starting up and operating a compressor. It discusses preparing the compressor by filling it with the correct lubricating oil, performing an uncoupled motor run to check rotation, and pressurizing the casing. The start-up process involves opening valves, starting the compressor to reach the desired flow, and monitoring parameters like flow, pressure differentials, amperage, and vibrations. When running, the document outlines checking for leaks, monitoring process conditions, and verifying the oil system. It also covers compressor surge, the anti-surge control system, conditions that can cause surge, and shutting down the compressor.

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    11_Operation_logic

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    This document provides information on starting up and operating a compressor. It discusses preparing the compressor by filling it with the correct lubricating oil, performing an uncoupled motor run to check rotation, and pressurizing the casing. The start-up process involves opening valves, starting the compressor to reach the desired flow, and monitoring parameters like flow, pressure differentials, amperage, and vibrations. When running, the document outlines checking for leaks, monitoring process conditions, and verifying the oil system. It also covers compressor surge, the anti-surge control system, conditions that can cause surge, and shutting down the compressor.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Flag for inappropriate content
    Download as pdf or txt
    70 views36 pages

    Start Up and Operation: Presented by Fs Engineer Sundyne

    Uploaded by

    Naveedullah Awan
    This document provides information on starting up and operating a compressor. It discusses preparing the compressor by filling it with the correct lubricating oil, performing an uncoupled motor run to check rotation, and pressurizing the casing. The start-up process involves opening valves, starting the compressor to reach the desired flow, and monitoring parameters like flow, pressure differentials, amperage, and vibrations. When running, the document outlines checking for leaks, monitoring process conditions, and verifying the oil system. It also covers compressor surge, the anti-surge control system, conditions that can cause surge, and shutting down the compressor.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Flag for inappropriate content
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    of 36

    START UP and OPERATION

    Presented by Fs Engineer
    Sundyne
    INTRODUCTION

    •General, data sheet, compressor curve

    • Test results

    •Start up and compressor operation

    •Compressor control , Anti surge system

    •Shut down
    GENERAL DISCUSSION

    •Are recurring problems a responsibility of maintenance?

    •Controls/procedures may result in equipment failure

    •May need coordination with process group


    DATA SHEET
    TEST CURVE
    TEST CURVE

    Pressure
    (Pout-Pin)/Pin 7,00% 7,59% 7,36% 7,06% 6,73% 6,01% 5,05% 3,82% 2,37% 0,57%
    Ratio
    TEST RUN
    PREPARATION FOR START-UP

    Drain storage oil,

    Fill with correct lubricating oil (ISO VG 32) :


    • Adjust level according to the MIN/MAX marks on the sight
    glass.

    Fill filter and heat exchanger with oil :


    • Run auxiliary lube oil pump ,
    • Verify oil level again

    Perform uncoupled run of the motor :


    • Check rotation ( CCW ).
    • Check amperage.

    lundi 16 décembre 2013


    MOTOR Rotation
    PREPARATION FOR START-UP

    Verify opening of Port 1 connection, ( seal vent)

    Check presence of the fill and vent cap of the gearbox,

    Run Auxiliary oil pump

    Pressurize casing,( suction pressure)

    • Verify compressor casing of any liquid ( open compressor


    drain valve)

    • Jog start (2-3 sec.) until the oil pressure rise

    lundi 16 décembre 2013


    START-UP

    Open the suction valve at 100%,


    Open recycle valve at 100% ,

    NEVER START AGAINST CLOSED DISCHARGE VALVE

    START,

    Bring the compressor to the desired flow by throttling


    discharge valve,

    lundi 16 décembre 2013


    START-UP

    Check for any leakage on port 1,

    Check the level of oil,

    Check that ALOP has stopped

    Check all parameters according to the design :


    • Flow,
    • Differential pressure ( Head),
    • Amperage,
    • oil pressure…
    • Oil temperature
    • vibration

    lundi 16 décembre 2013


    Start UP
    Ready to Start
    Common Logic
    Process Loop

    With the process loop complete, DCS, and surge


    control system operational
    Trace process loop and recycle line, check for
    blockage and openings
    Check drain casing for liquids
    Process gas can be introduced to the loop
    Check that Nitrogen outlet seal port is opened to
    atmosphere (safe area)
    PROCESS LOOP

    CASING LOW
    POINT DRAIN
    VALVE SHOULD
    BE CHECKED FOR
    LIQUID PRIOR
    START UP
    Start-up Compressor

    With all permissive start set points satisfied (Within the


    Lube oil system, seal system, motor, and process
    conditions)
    Control valve set at operating position (flow per the
    specification sheet)
    Safety first, check overall condition of equipment (i.e.
    connections, coupling guards, etc.)
    Compressor motor is started
    Compressor up to speed in about 2-3 seconds
    Running Operation

    • Verify flow and Motor Amps


    • Compressor should run stable
    • Verify ALOP stops, 15 seconds after start up and oil
    heater off.
    • Check lube oil pressure, oil level
    • Verify Vibration, and motor power
    • Verify seal system leakage
    • Check process conditions (flow, pressures,
    temperatures) against specification sheet
    • Verify oil system for any oil leakage
    • Check working of the oil temperature TCV
    OPERATION

    Monitor very closing the suction in order to avoid clogging


    of suction strainer during the internal start up
    OPERATION
    Compressor Anti-Surge
    Control – What is ‘surge’ ?

    OK
    H Caution !

    Danger !!

    Q (Volume Flow)

    “Surge occurs when the peak head capability of a compressor is


    reached and flow is further reduced.”
    “When the compressor can no longer meet the head imposed by
    the suction and discharge conditions, flow reverses.”
    Major Process Parameters During Surge
    Compressor Anti-Surge Control –
    Surge can damage a compressor!

    Possible Results of Surge :


    High Vibration
    Damage to Bearings
    Damage to Impeller
    Damage to High Speed Shaft
    Process Upsets …...
    Compressor Anti-Surge Control – What
    can cause surge?
    Startup and Shutdown
    Operation at reduced throughput
    Operation at heavy throughput with:
    Trips
    Power loss
    Operator errors
    Process upsets
    Load changes
    Gas composition changes
    Cooler problems
    Filter or strainer problems
    Driver problems
    Surge is not limited to times of reduced throughput.
    Surge can occur at full operation
    SURGE
    SURGE TEST
    SURGE LINE
    SURGE LINE
    Shut Down Compressor

    Valve position set at normal operating point


    Process loop ready for shutdown

    lube oil can remain on until next start-up


    Or Circulate lube oil for 15 minutes after compressor stops
    LONG PERIOD STOP

    • RUN THE ALOP ON BI-MONTHLY BASIS FOR ONE DAY


    • KEEP NITROGEN INSIDE THE PROCESS LOOP (PURGE)
    • TURN INPUT SHAFT EVERY THREE MONTHS (BY HAND)
    • COOLING WATER SHOULD BE KEPT CLOSED
    NORMAL START UP

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