DHDT Compressor

Mangalore Refinery and Petrochemicals Ltd, Mangalore Doc No.
DHDT Unit – Phase-3 - Operating Manual F … ….

Section-1- Chapter IX –Description of Major Equipments 25-09-2012
Lube Oil System

Main reservoir:
The main reservoir has a charge capacity of about 8.2 m3. The reservoir is equipped with the
following control safety and instruments:
 Level gauge (LG 701A/B)
 Low oil level alarm switch (LT 702)
 Local thermometer (TI 745)
The reservoir is fitted with a electric heater to give the oil correct viscosity during start-up (or
after prolonged periods of non-operation). The reservoir is provided with necessary
appurtenances for charging, draining, venting and inspecting.
The complete list of the instruments, their tag nos. and set values are shown in the “Instrument
Data Sheet” enclosed in the “drawings” volume. The constructional and operational features of
the instrument and auxiliary equipment are available in the relevant volume of this manual.
Oil Pumps:
Two identical screw pumps are provided for required oil circulation. MP Steam Turbine drives
the main oil pump whereas the A.O.P (stand-by oil pump) is driven by AC-Motor. Each of these
pumps is capable of supplying total oil requirement of the unit (i.e., Drive turbine + compressor),
and can be operated on a continuous basis.
The stand-by pump is started automatically based on the low-pressure signal from the pressure
transmitter (PT 775) located in the unit’s Lube oil header.
The Emergency Oil Pump (E.O.P) is driven by AC-Motor. In the event that the header pressure
falls below the set pressure of PALL 776, the compressor is tripped. The E.O.P starts on
receipt of the compressor trip signal.
The suction line of each pump is provided with a strainer, an isolation valve and pressure gauge.
Indication of operation of Pump is obtained by pressure gauges (PI 761A/B, 763A/B & 765A/B
for MOP, AOP & EOP respectively.) installed in the discharge line of each pump. The drain lines of
the unit (i.e., from Drive turbine + from compressor) are joined to the reservoir through the
drain header of the unit.
Emergency Lube Oil System:
In the event of fall in the pressure level in the lube oil header (which could be caused by the
tripping of main lube oil pump), the pressure transmitter (PT 775) in the header starts the
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standby pump. The L.O (Lube Oil) accumulators (3 X 55lts) supply pressurized L.O to the header
during the period of L.O.P changeover from Main to Auxiliary. If the A.O.P cannot arrest the drop
in the header pressure even after the oil in the accumulators is consumed, the pressure
transmitter (PT 776 A, B & C) will trip the compressor drive turbine with a 2-out-of-3 logic.
Some time is required for the compressor and drive turbine rotors to stop completely, owing to
the high inertia of the rotating masses. Therefore, sufficient oil quantity should be supplied to
the bearings until the machines come to a standstill.
An overhead rundown tank (GB-33301-FB 52) (common to both turbine & compressor) with a
normal level capacity of about 2000lt, (placed about ~6.50 meters above the machine
centreline) is provided for this purpose. It supplies the oil quantity required to the bearings
during coasting down in case none of the pumps work. The E.O.P will supply oil to turbine
bearings during barring of turbine. This tank is filled with oil during the start-up preparation
of the lube oil system. While the main oil pump is running, the oil inlet valve (LO 64) to the
overhead rundown tank is kept open until the oil circulates through the flow glass piece (SG
703) in the overflow line to the main reservoir. Then oil
inlet valve is closed. A permissive to compressor driver start-up interlock from level
transmitter (LT 704) is provided on the overhead rundown tank. While the units are
running, the overhead rundown tank level is maintained by continuous oil flow through a fixed
orifice (RO 709). In the event of failure of the pumped oil supply, the non-return valve opens,
allowing the oil to reach the lube oil header and thereby ensuring lubrication of bearings during
coast down.
Lube Oil Coolers:
The oil is cooled by a TWIN OIL COOLER (GB-33301-EA 51 A/B) (one as stand-by to the other).
Each cooler is designed to cool the total oil requirement of the unit. During normal operation,
the oil flow is directed to only one of the coolers, leaving the other as a standby. This is realized
by means of two numbers of 3-way, trans flow valves. A hand lever simultaneously controls the
valves. By opening the bypass valve in the line across one of the trans flow valves, the oil
pressure in the two 3-way Trans flow valves gets equalized. This facilitates a smooth change
over operation.
Cooler Change Over:
When it is required to maintain a cooler and subsequently bring it into operation without
interrupting the plant, proceed as follows:
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� Check that the by-pass valve is open. Slightly open the standby cooler vent and check that the
cooler is full.
� Direct the oil flow to the stand-by cooler. As the oil pressure is equal in both the coolers this
operation is quite simple.
� Now the oil flow through the working cooler is zero.
� Close the by-pass valve and open the draining valve and vent of the cooler to be taken for
maintenance.
� Clean and check the condition of the cooler and close the drains.
� Open the by-pass valve to fill the cleaned cooler and close the vent as soon as the oil starts
flowing in the pipe.
� The cleaned cooler will then be full of oil at the working pressure, the by pass valve being
open.
Filters:
The oil reaches the 5-μ duplex oil filters (GB-33301-FD 51A/B) (2x100%), which are arranged
side-by-side. One is in operation and the other is the stand-by. Each filter provides a continuous
filtration of the total oil supplied by the oil system.
Only One filter at a time is put to service so that the cleaning, inspection and maintenance of the
second filter can be performed without interrupting oil flow or shutting down the machines. The
oil flow is directed to one of the filters leaving the other free for maintenance. This is realized by
means of two 3-way Trans flow valves, which the hand lever simultaneously controls. To
equalize the oil pressure and facilitate the change over operation, a bypass valve connects the
two filters. The pressure drop in the filter units is measured by means of a differential pressure
indicator (PDI 771). To annunciate a high differential pressure across filter, a Differential
pressure transmitter, PDT 770 is connected to an alarm in DCS. When the differential pressure
exceeds 1.5 kg/cm2, take the filter for cleaning by switching the oil flow to the standby filter. be
ready for use. The transfer of operation from one filter to the other should be accomplished in
the same way as that of the twin oil coolers. After checking that the filter to be used is full (i.e.,
the by-pass valve is open) transfer the oil flow with the help of the 3-way Trans flow valve. Then
clean and fill the other following the procedure described for the coolers.
Lube oil lines:
The filtered oil at the required temperature arrives to a header from which the lube oil bearing
lines are tapped. The oil pressure in the lube oil header is maintained at a constant value of 2 ~
2.5-barg (28 to 35 psig) with the help of the bypass control valve PCV 702, placed in the L.O
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header. Each oil feed pipe is fitted with a flow regulator, which reduces the oil pressure to the
required level. A local gauge indicates the pressure value. Flow glasses and local thermometers
are installed on the oil outlet lines that are leaving each of the lubrication points. The oil drains
are collected to a common header and joined to the L.O. Reservoir .
Governing oil line:
The Governing oil line is taken from pump discharge header and through a filter before it’s
connected to Governor.
Adjustment of the lube oil pressure to bearings:

The lube oil pressure to the bearings is adjusted by means of the flow
regulator provided in each oil inlet line to bearings.
I. Lube Oil Header: 2.0 to 2.5 Kg/cm2g (28 to 36 psig)
II. Lube Oil pressure to thrust bearings: 0.3 to 1.3 Kg/cm 2g (4 to 19 psig)
III. Lube Oil pressure to radial bearings: 0.9 to 1.3 Kg/cm 2g (13 to 19 psig)
Check the regular lube oil flow through the bearings by means of flow glasses.
Adjustment of the governing oil pressure:
The pressure in the Governing Oil line is maintained at ~ 8.0 Kg/cm 2g, which is controlled with
the help of the bypass control valve PCV701.
Pressure Control Valves:
Pump Discharge Header Pr Control Valve PCV 701

The pump discharge pressure control valve PCV 701 maintains a constant (desired) pressure (of
~8.0 kg/cm2 (g) – as required by the turbine governing system) in the header, by bypassing the
excess oil that is being pumped, back to the reservoir.
Lube Oil Header Pr Control Valve PCV 702.
The pressure control valve PCV 702 maintains a constant (desired) pressure (of ~2.5 kg/cm 2 (g)
– as required by the Lube oil header).
Valve setting:
Keep the oil pump in operation with the stop valves (LO 01/05 & 02/07) in open condition and
bypass valves (LO 20 & 21) in closed condition, watching the pressure transmitter (PT 768)
placed in the pump discharge header line set the bypass control valve (PCV 701) so that the
pressure in the discharge header reaches the required value. Repeat the same procedure to set
the bypass control valve (PCV 702) in the L.O header by checking the gauge pressure shown in
PI 772.
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Lube oil instruments:
The Lube oil system is protected by the safety and control instrument.
The complete list of the instruments, the tags and the setting values
of these instruments are shown in the following documents
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Governing System
Introduction:
The turbo-compressor is provided with Electro-hydraulic governing system. The electronic

governor is Woodward microprocessor based digital governor. The governing system is
designed to control the speed corresponding to speed reference signal provided by manual
loader. Additionally the system incorporates protective devices like emergency trip device,
emergency stop valve, remote trip solenoid valve and a dedicated electronic over speed
protection.
Electronic governor:
The Electro-hydraulic speed control circuit comprises of speed transmitter (SE 701A ,B&C),
controller 5009, Electro-hydraulic converter (1800), control valve actuator (1910) and control
valves (0801). The speed controller in the Woodward electronic governor feeds a signal based
on the actual speed/load to Electro-hydraulic converter (1800). The Electro-hydraulic converter
converts the electrical signal into proportional hydraulic signal called as secondary oil pressure.
Electronic over speed protection:
A dedicated electronic over speed protection system is provided apart from the protection given
in the electronic governor which receives signals from proximity probe transducers or magnetic
pickups (SE 702 A,B&C).
Electro-hydraulic converter (1800):
The Electro-hydraulic converter is connecting link between electronic and hydraulic parts of
Electro-hydraulic governing system. The output signal of electronic governor is fed to the torque
motor of Electro hydraulic converter (I/H). Torque motor positions the control slide, which in
turn builds up the secondary oil pressure proportional to the signal. This secondary oil pressure
is transmitted to the control valve actuator.
Control valve actuator (servomotor) (1910):
Control valve actuator (1910) positions the control valves (0801) corresponding to the
secondary oil pressures generated by Electro-hydraulic converter Control valve actuator
(Servomotor) mainly consists of a pilot valve; a power cylinder and a feed back system. Upon
change in secondary oil pressure, pilot valve provides oil passages to and from power cylinder.
The movement of power piston is transmitted to the control valves through levers. The feed
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back lever resets the pilot valve to its neutral position once the power piston occupies new
position corresponding to changed secondary oil pressure. The system is such that the increase
in secondary oil pressure causes the control valves to open.
Hence interruption of secondary oil pressure caused the control valves to close.
Damping device (5620):
Damping device (5620) damps out the quick oscillations in secondary oil pressure generated by
Electro-hydraulic converter. This helps in improving the stability of the governing system.
Emergency stop valve (2301) and starting device (1841):
The emergency stop valve (2301) is of quick closing type. The valve is actuated by means of a
starting device (1841). The emergency stop valve consists of a spring-loaded piston and piston
disc, which is connected to the valve cone through a spindle. For opening the emergency stop
valve, start-up oil from starting device (1841) is admitted to the space above the spring-loaded
piston, by operating the starting device. Due to start-up oil pressure, the piston moves towards
the piston disc and they form a tight seal against each other. Oil from trip oil circuit is then
admitted to the space under the piston disc and the space above the piston is connected to oil
drain. The trip oil now forces both the piston disc and piston to the outer position thereby
opening the stop valve. As long as the trip oil pressure is maintained the piston and the piston
disc, cannot be separated by spring force. The stop valve is closed only when the trip oil pressure
drop substantially. On a loss of trip oil pressure, the pressure of secondary oil tapped from trip oil
circuit drops to zero, thus causing the control valves to close. This arrangement provides a two-
fold protection against steam entering the turbine.
Tester (2309) for emergency stop valve:
Testing device (2309) is provided to check the proper functioning of emergency stop valve
(2301) during normal operation of turbine. If the testing device is operated, it will admit the
pressure oil to the space behind the test piston of emergency stop valve, which will then be
pushed against the piston and move the piston and valve spindle towards the closed position
(partial closing).
Trip solenoid valve (2222):
Trip solenoid valve facilitates the tripping of turbine from remote place such as control room
through push button. Whenever the solenoid valve is de-energized, interrupts the oil supply to trip
oil circuit and simultaneously depressurizes the trip oil circuit. Solenoid valve is also de-
energized by any one of the signals initiated by limit value monitoring devices.
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Hand trip valve (2250):
Whenever the turbine is to be tripped, the governing oil pressure (trip oil line after hand operated
valve) is drained by hand trip valve. Thus pressure in front of stop valve piston disc and
secondary oil pressure falls, resulting in closure of stop valve and control valves. The hand
trip valve (2250) is operated either manually or by loss of source oil pressure.
Duplex filter (4520):
The Duplex filter with 225 LPM 10 micron filtration consists of filter head with change over
valve and two filter bowls which are removable for maintenance. The change over mechanism
facilitates redirection of fluid stream from the dirty to clean filter housing without reduction in
flow. The arrangement also provided with a maintenance indicator, which monitors the degree
of clogging of the filter elements. Arrows indicate which filter bowl is in operation. Closing of
both filter bowls simultaneously is not possible. Inbuilt PD Optical–Electrical indicator switch
with connecting plug is available in the duplex filter.
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Unit Start-Up:
Initially the compressor loop is to be purged with nitrogen as mentioned below:
The isolation valves in suction, discharge, vent (in discharge) and Anti surge lines shall be in
closed condition.
 The Anti-surge valve FV 034 shall be in open condition (in manual mode).
 Admit the N2 for purging in to the loop from upstream of the seal gas duplex filters till
the loop pressure reaches ~ 2 Kg/cm2 (g).
 Open and then close the compressor casing drains. Close the N 2 purge valve and reduce
the pressure by venting the N2 to the atmosphere through the vent valve (in the
discharge line) to reach a pressure of ~ 0.2 Kg/cm2 (g).
Repeat this operation a few times until the amount of oxygen present in the gas of
the compressor circuit is below 5 ppm. The inlet valve for purging N 2 shall be
closed.
Before the compressor is started, it shall be ensured that the entire recycle
loop is similarly purged with N2.
 Open the compressor casing drains and remove any liquid accumulation.
 Ensure that the Dry Gas Seal is kept operational.
 Verify that the equipment permissive to start circuit is completed.
 Check visually that the valves are in startup position as indicated below.
 Suction isolation valve OPEN
 Anti surge valve OPEN (Manual-mode)
 Discharge isolation valve OPEN
 Discharge vent valve CLOSE
 N2 bottle/Make up line inlet valve (If present) OPEN
 After purging of gas circuit is completed the compressor is started in the following
sequence.
 Admit start-up N2 dry gas seal duplex filters and through the ends in to the compressor)
with the help of in to the loop till the pressure reaches ~6 kg/cm 2. This pressure is decided
such that the compressor is able to develop ΔP sufficient to overcome the loop resistance at
the min governing speed of ~ 6000 rpm
Note:During this start-up period, there is a possibility of condensation taking place in
the clean gas line. Coalescent type duplex-filters remove any condensate that is formed
in the gas.
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Before starting the drive turbine, ensure that the valve P11 is open and N 2 is available at the
sealing zone of the dry gas seal to provide the requisite ΔP. OPEN the suction isolation valve.
Start the drive turbine as per the start-up procedure and take the train to a speed of 6000 rpm.
During this period it is required to continue injecting make-up N 2 in to the loop to sustain the
suction pressure. However, from this point onwards, the injection can be carried out from the
discharge line.
 On attaining a stable operating condition, H 2 shall be injected in to the loop (which is
initially filled with N2) while ramping the speed so that the compressor is still able to
raise the pressure to overcome the loop resistance.
 At a stage where the discharge pressure in the compressor is capable of
providing the clean gas for the dry gas seal, start up connection can be closed.
 Continue to inject make-up H 2, which is available at a higher pressure, in to the loop.
This simultaneously results in altering the gas composition gradually so that it
eventually matches with the design composition while raising the loop pressure from
24.97 kg/cm2 to the design pressure of 65.4 kg/cm 2. At each step of this transition the
compressor speed is to be ramped-up so as to ensure that the compressor develops
discharge pressure, adequate to overcome the system resistance, despite the fall in the
gas molecular weight due to addition of H2.
 After the compressor discharge parameters are stabilized, take the compressor on line by
closing the anti surge valve.
 For every speed rise, the following checks should be carried out during initial start up (or)
starting after prolonged shutdown:
• Machine vibrations.
• Ensure that the Seal gas lines are free from condensate liquid.
• Bearing oil pressure and temperatures.
• Bearing temperatures.
• Radial Vibrations.
• Axial displacements.
 Gas composition shall be periodically analyzed.
Preparation of Dry Gas Seal System
The primary seal injection is provided with clean gas (during normal operation it is taken from
compressor discharge) through filter and control valve. This clean gas injection shall be always
provided with a positive ΔP (with respect to the equalizing line pressure) to prevent the unclean
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process gas from entering into the Dry Gas Seal area through compressor ends. The startup
procedure is as follows.
Starting Of Seal Gas from Standstill
 It is assumed that the compressor loop is already purged with N 2.

Prior to preparing the gas seal system for start-up, ensure that the Nitrogen feed valve (IG 11)
and clean gas feed valve P 11 (taken from discharge line) are kept OPEN. Also ensure that the
suction isolation valve and process gas vent valve are in CLOSED condition. Discharge isolation
valve shall be in OPEN condition. Anti Surge Valve shall be in OPEN condition (in manual mode).
 Fill the loop with N2 (from N2 bottles) through duplex filters till the pressure in the loop
becomes 15 kg/cm2.
 Ensure the connection of plant N 2, which is normally at 5 kg/cm 2, to secondary dry gas seal
and separation seal.
 Keep the suction isolation valve in OPEN condition and start the drive turbine as per start
up procedure. Provide N2 (from N2 bottles / MUG) to primary dry gas seal – through duplex
filters - during the start-up until the compressor develops adequate ΔP to overcome the
resistance of seal gas circuit.
 Once the compressor develops pressure, adequate to provide requisite ΔP, the bottled N 2
can be disconnected. The clean gas is supplied from discharge line (through P 11).
 After attaining stable operating conditions, a suitable ΔP (as recommended by the seal
manufacturer) shall be maintained between clean gas and seal balance line with the help
of control valve PDIC 715. The supply of N 2 to secondary seals also shall be fine tuned by
opening the Needle valves IG 16 & 17 located in each of the lines, in dynamic condition, by
referring the ΔP (between the N2 inlets to secondary dry gas seal and vent-to-flare) in the
respective pressure gauges.
 Healthiness of the system variables viz., flow rates of primary, secondary and separation
seals; ΔP etc shall be compared to test protocol parameters.
Starting of Seal Gas after Brief Shutdown
For every other startup subsequent to initial startup, the condition of the gas seal system is to be
checked and the N2 supply pressure and differential pressure are to be ensured. Healthiness of
the system variables viz., flow rates of primary, secondary and separation seals; ΔP etc shall be
compared to initial start-up parameters. To start the machine again, ensure readiness of sub-
systems such as lube oil system before starting. During Standstill at settle out, clean gas from N 2
bottles shall be provided. When the machine is restarted, supply of clean gas (from N 2 bottles) to
the seals must be ensured until the compressor reaches to a speed where it is capable of
providing the requisite ΔP to the seals.
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Oil System Preparation:
The system is shown in B.H.E.L. drg 0-336-00-32082.

 Be sure that the main oil reservoir is filled with the recommended grade of oil (refer
Sec.4 for the grade of recommended lube oil).
 Check the oil level in the main reservoir (LG 701 A/B).
 Switch on the electrical heater for heating the oil so that the oil temperature in the
reservoir reaches 40° - 50°C. The start-permission is inter-locked to the min. level of oil
in the tank & the other inter-lock is for cut-off, based on high temperature of oil. The oil
temp should not be less than 25°C.
 Admit the Nitrogen to reservoir by opening the AFR valve (PCV 703). Adjust the valve IG-
03, observing the pressure in the gauge (PI 786), to maintain the N 2 pressure at 100 -
200 mm-of-WC in the tank.
 Check that the isolating valves of the oil pumps (LO 01 & 02) are open.
 Ensure that, for the Lube oil pump discharge header pressure control valve (PCV 701),
the by-pass valves (LO 16) are closed and the isolating valves LO 13 & LO15A are open.
 Check that all oil drain valves of coolers, filters, level indicators and pipes are Closed.
 Check that the water inlet and outlet valves of oil coolers are closed.
 Check that the isolating valves of pressure switches, pressure gauges, pressure
transmitters, level gauge, switches and valve actuators are open.
Lube oil system starting:
Start permissive (IS 75, 74 for M.O.P & A.O.P) are taken from PAL 728, which is located in the N 2
line. This is to ensure that N2 supply to separation (Barrier) seal is ON before the lube oil is
pumped in to the circuit and lube oil does not enter the seals. In addition to this, N 2 supply to the
compressor bearing chambers is also to be ensured.
However, these supplies are to be given only after opening the drains in these pipes and
thoroughly ensuring that there is no liquid present.
 Filtered N2 is admitted to the barrier seals through needle valve IG 20/21.
 To supply the filtered Nitrogen to the Secondary Dry Gas Seal at a constant desired
pressure, open the control valve PCV 711 A / B. Maintain the recommended ΔP between
the N2 inlets to secondary dry gas seal by opening the Needle valves IG 16/17 located in
each of the lines. (The ΔP is shown in the respective differential-pressure-indicators PDI
725 / 727).
 Admit the N2 through AFR (PCV 703) and the individual feed valves to bearing chambers
of the compressor.
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 Start the main lube oil pump according to manufacturer’s instructions.

 Open the by-pass valves of twin coolers and twin filters (refer to para. “Coolers” and
“Filters” in section 4).
 Open the vent valves of oil cooler and filters in service. Bleed off the air and close the
valves again.
 Crack opens the vent valves of oil cooler and oil filters not in service and closes it again
as soon as they are full.
 Check the oil pressure to the various points, bearing in mind that the oil pressure should
be:
o Lube Oil Header: 2.0 to 2.5 Kg/cm2 g (28 to 36 psig)
o Lube Oil pressure to thrust bearings: 0.3 to 1.3 Kg/ cm2g (4 to 19 psig)
o Lube Oil pressure to radial bearings: 0.9 to 1.3 Kg/ cm2g (13 to 19 psig)
 Check the normal flow of oil coming out from radial and thrust bearing by the flow Sight
glasses devices. Check the Lube Oil pressure drop across the filters.
 Keep the stand-by oil pump driver ready to start on auto.
 Stop the main pump driver and check the stand-by pump automatic start-up.
 Then stop manually the stand-by pump and check the pressure point at which the trip
switch (PALL 776 with a 2-out-of-3 voting) installed in the lube oil header operates.
 Restart the main oil pump.
 Put the stand-by pump in automatic mode.
 The system is provided with a control valve (TV 735) to regulate the temperature of oil
going to the bearings. A temperature element TE 735 positioned downstream of the
cooler communicates with the controller TIC 735. This controller operates the
temperature-control-valve and regulates the quantity of oil going through the coolers.
Turbine Start Up
The starting operations may have an important influence on the possible curtailment of turbine
life because major thermal and mechanical stresses will be experienced in the course of starting.
This hazard will be particularly enhanced with starts from the cold. The most favourable
conditions can therefore be expected when the temperature of the live steam during the starting
period can be matched as closely as possible to the actual temperature of the turbine casing. For
starting a cold turbine or one which has cooled down to below 230°C, it is recommended to use
a live-steam temperature to the casing temperature as the limits set by the requirements of the
boiler or of the elements of the entire turbine plant will permit. However, the temperature of the
live steam must always exceed by at least 30° C the saturation temperature of the steam at the
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chosen live-steam pressure. The permissible rate of the temperature change for the live steam as
a function of steam flow may be gathered from the Test Report of First Commissioning. Abrupt
temperature changes can be tolerated only on condition that they are keeping within the limits
set by the permissible rates of change.
Oil Supply:
The oil pump employed for starting should have been switched on some time before in order to
carry out the preparatory starting operations that can be performed during standstill, the
checks for proper functioning of the governor system, and also to achieve a certain pre-warning
of the oil.. Check, whether the ensuring journal pressures correspond to the values listed in the
Test Report.
 The hydraulic turning gear will be started by opening the associated pressure-oil
valve. If necessary, help with a few strokes of the manual turning gear. As soon as the
turbine has attained a speed of 80 to 120 rpm, the jacking oil pump can be switched
off again, since it will now be safe to presume that an adequate bearing oil film has
formed at that speed.
Condensing System:
The cooling-water supply for the condenser should be taken into operation. Start a condensate
pump. Make sure that the bearing on the suction side is adequately lubricated with water that
the glands receiving water to the extent that a small stream of seal water keeps flowing from the
gland into the open. In addition, enough condensate to prime the condensate pump should be
available in the condenser hot well. The shut-off valve in the equalizing line to the condenser
should be open and may remain open at all times. Open the delivery valve fully. Open the
minimum flow valve to the condenser to the extent permitting a steady and adequate circulation
of condensate, but without causing major Collapse in pressure in the condensate pressure line.
Start the water-Level regulating system of the condenser consists of an outflow of level
regulator. Also make sure that the collected amount of condensate is returned to surface
condensate header.
Start the air extraction system (Ejector System) in order to ensure the proper evacuation of the
condenser.
Opening the Live-Steam Valve:
After a thorough draining on the line ahead of the live-steam valve, open that valve so that the
live steam line to the turbine will gradually be pressurized and warmed up. If the live-steam
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valve is equipped with a bypass, this should be opened first in order to relieve the pressure on
the valve. In order to achieve satisfactory evacuation of the condensing system, steam must be
admitted to the shaft seals at a pressure exceeding the atmospheric by about 6 milli bars. This
prevents air from entering into the turbine casing along the rotor shaft. Open the suction valve 1
to 2 turns and the seal- steam valve to the point where light wisps of steam emerge at the steam
vents. Engage the emergency trip gear.
Opening of Emergency Stop Valve and Control Valve:
After having sufficiently drained the live steam line, turn the hand wheel of the starting device in
the opening direction.
 This will cause trip-oil pressure to build up behind the piston disc of the emergency
stop valve. Check the oil pressure prevailing in the space behind the piston, the
condition at which the emergency stop valve begins to open. The movement, the
emergency stop valve, starts with its opening movement, pause with further turning
the starting-device hand wheel until the "oil pressure behind the piston has definitely
collapsed. Only after having made sure that this has been the case, open the starting
device to maximum position to open the emergency stop valve fully.
 Next, through electronic governor speed raise push button, build secondary oil
pressure and speed starts increasing. Adjust the speed reference to minimum speed
as per start up curves.
The live-steam drains may now gradually be throttled and will be closed on condition that a
lasting flow of steam exists and may be expected to continue, and provided a superheat
temperature of about 50°C has been attained at the admission side of the turbine. With turbines
driving a compressor, the speed increases are intricately connected with the load increase and
cannot be controlled independently.
Bringing the turbine up to speed:
Further loading of the turbine can be done thru speed setting in DCS as per loading
requirements in the process side.
Automatic oil pump control:
When the auxiliary oil pump is not operating, make sure that the "Automatic Oil Pump Control"
continues to be switched on. In the event of failure the main oil pump, it will ensure that
following a major drop in the system oil pressure, the existing auxiliary oil pump will take over
the supply immediately and maintain it at the required level.
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Oil Cooling:
If the temperature at the oil cooler outlet exceeds 40°C, the cooling water inlet valve has to be
opened to the point at which a constant oil temperature of 45°C (bearing-oil inlet temperature)
will be maintained. The oil outlet temperature at the individual turbine bearings are not
identical and may vary within a range from 50°C to 65°C for an inlet temperature of 45°C. Be
sure not to exceed' these values, especially not at the time of loading the turbine. Electric
thermocouples or resistance thermometers will be installed on request for measuring the
temperature inside the babit lining. These temperatures are subject to appreciable variation, If
the temperatures attaining during the starting period of exceeding the limit values listed in the
Test Report, the respective bearings have to be observed with particular care. If a temperature of
120°C is reached, the turbine must be shut down immediately.
Unit shutdown:
Trip on Seal Failure:
Whenever the compressor trips the Anti surge valve gets fully opened. If the trip is due to seal
failure, the compressor loop needs to be depressurized so that the process gas doesn’t leak to
the environment through the compressor ends. This is achieved by venting the process gas
followed by isolating the compressor (after it comes to rest) from the loop by closing suction
and discharge valves.
Trip on any other reason:
In case the compressor trips on reason other than seal failure, the loop reaches to a settle out
condition where the entire loop settles to a uniform pressure. In the Standstill at settle out, clean
16
gas shall be provided. When the machine is restarted, supply of clean gas (from N 2 bottles) to the
seals must be ensured until the compressor reaches to a speed where it is capable of providing
the requisite ΔP to the seals.
Special Instructions:
a) Never run the machine with any of the alarms or trips bypassed.
b) Never run the machine with anti surge control in the manual mode (except during start-up).
c) Check and keep the compressor gas interlocking and trip system in normal startup condition
before startup.
d) Record all-important parameters periodically. Initiate corrective actions wherever
parameters are abnormal.
e) Trip the unit if any trouble or abnormality is noticed during loaded run of the unit such as:
• Quick and sudden rise of vibrations.
• Gas leakage from compressor or from any other part of the gas system.
• Abnormal noise from the rotating equipment.
Routine Checks (during normal operation):
The following checks shall be performed on a regular basis on the machines that are
continuously under operation.
Oil level in the main reservoir.

Oil temperature in the main reservoir.
Oil pressure in the lube oil header.
Oil pressure in the journal and thrust bearings.
Bearings metal temperature.
Oil flow in the discharge lines.
Oil temperature in the discharges from bearings.
Periodical analysis of oil sample from main reservoir.
Removal of accumulated condensate/liquids from the duplex filter.
Differential pressure across the clean gas & equalizing line at the dry gas seal.
The primary leakage flowing through vent-to-flare.
Nitrogen pressure and flow through secondary dry gas seal inlet line.
Rotors axial displacements
Radial vibrations
Temperature and pressure of the gas at the suction and discharge.
Pressure drop across suction strainer.
Analysis of gas composition.
17
During normal operation any operating value, which is not automatically recorded, must be
entered in a logbook at regular intervals.
Operating Oil Pressures and Temperatures:
L.O.P discharge 9.0 Kg/cm2 (g)

Lube oil header 2 to 2.5 Kg/ cm2 (g)
Journal bearing 0.9 to 1.3 Kg/ cm2 (g)
Thrust bearing 0.3 to 1.3 Kg/ cm 2 (g)
 Minimum Bearing oil inlet 35 deg C

 Maximum Bearing oil inlet 50 deg C
18

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Mangalore Refinery and Petrochemicals Ltd, Mangalore Doc No.

DHDT Unit – Phase-3 - Operating Manual F … ….

Lube Oil System

Emergency Lube Oil System:

Lube Oil Coolers:

Lube oil lines:

Governing oil line:

Adjustment of the lube oil pressure to bearings:

Pressure Control Valves:

Pump Discharge Header Pr Control Valve PCV 701

Lube oil instruments:

The turbo-compressor is provided with Electro-hydraulic governing system. The electronic

Electronic over speed protection:

Electro-hydraulic converter (1800):

Control valve actuator (servomotor) (1910):

Damping device (5620):

Emergency stop valve (2301) and starting device (1841):

Tester (2309) for emergency stop valve:

Trip solenoid valve (2222):

Hand trip valve (2250):

Duplex filter (4520):

Preparation of Dry Gas Seal System

Starting Of Seal Gas from Standstill

 It is assumed that the compressor loop is already purged with N 2.

Starting of Seal Gas after Brief Shutdown

Oil System Preparation:

The system is shown in B.H.E.L. drg 0-336-00-32082.

Lube oil system starting:

 Start the main lube oil pump according to manufacturer’s instructions.

Opening the Live-Steam Valve:

Opening of Emergency Stop Valve and Control Valve:

Bringing the turbine up to speed:

Automatic oil pump control:

Trip on any other reason:

Routine Checks (during normal operation):

Oil level in the main reservoir.

Operating Oil Pressures and Temperatures:

L.O.P discharge 9.0 Kg/cm2 (g)

 Minimum Bearing oil inlet 35 deg C

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