OWNER

EIL JOB No.: 6987

ONGC PETRO PACKAGE CONTROL PHILOSOPHY
additions LTD EIL /OWNER ID. CODE
(OPaL) P.O.: 7500029319 EPCC2-GP-VD-
3670-GP-MR-003 003_9319_ZSG_251060
PMC
[Fima Maschinenbau GmbH] CONTRACTOR IDENTIFICATION. CODE
Job-EC-T-N°
ENGINEERS
INDIA LIMITED 3670-GP-VD-
003_9319_ZSG_251060
CONTRACTOR
PROJECT: DAHEJ
UNIT: PP UNIT (340 LOCATION: DAHEJ,
PETROCHEMICAL
KTPA) INDIA Sheet 1 of 10 REV 02
COMPLEX

2nd REACTOR RECYCLE GAS COMPRESSOR 33-KC-251A/B

PACKAGE CONTROL PHILOSOPHY

C H E C K CHECKED
ED DATE DATE
INITIALS SIGNATURE

NO T ACCEPTED
NOT ACCEPTED
A C CACCEPTED
EPTED AS
AS NO TED
NOTED
A C CACCEPTED
EPTED SMP 15.12.12
7(&1,0217¶6$&&(37$1&(2)7+,6
DOCUMENT DOES IN NO WAY RELIEVE THE
SUPPLIER OF HIS CONTRACTUAL
OBLIGATIONS. (TM 061)

General Note:

Instrument tag numbers for compressor 33-KC-251A are with suffix “A”.
Same tag number with suffix “B” to be considered for compressor 33-KC-251B.

02 FOR APPROVAL LR RD RD 05-12-2012

01 FOR APPROVAL LR RD RD 11-09-2012
Rev. Description Prepared Checked Approved Date

This document is Maire Tecnimont Group’s property and cannot be used by others for any purpose, without prior written consent
 Start Up Conditions

Checked

Main Motor
Assure that the motors will run with correct power …
Check the rotation direction of the main motor …

Auxiliary Motor:
Assure that the motors will run with correct power …
Check the rotation direction of the main motor …

Oil Heater:
Assure that the oil heater will run with the correct power. …

Process:
Make sure that process conditions / instruments / valves are ready for start up …

Check the suction-/ and pressure side pipelines

Connections of the flanges, compensators …
Ensure that the pipelines are free of any foreign substances/ parts …
Make sure that suction strainer is installed …
Check that casing is completely drained and drain valve is closed …

Oil System:
Check connections and pipes and instruments to damage …
Check oil level in the tank …
Check function of oil heater …
Check function of aux. oil pump …
Check connections and pressure of water supply for oil cooler …
Make sure that all valves inline are open/close acc. P&ID and document: …
"Package Control Philosophy"

Seal Gas System

Check connections and tubings and instruments to damage …
Check connections and pressure of separation seal gas …
Check connections and pressure of secondary seal gas …
Check connections and pressure of primary seal gas …
Check connections and pressure of instrument air …
Make sure that all valves inline are open/close acc. P&ID and document: …
"Package Control Philosophy"
 Alarm Situations

The alarms are displayed at the local panel.

The instruments that send alarm signals are marked in the P&IDs the range of the alarms
are descriped in the IO list / instrument list.

Shutting down compressor in case of emergency

The EMERGENCY-STOP switch serves to switch off the compressor HZS 25507-A
in case of danger. Actuation of the EMERGENCY-STOP switch will
bring the compressor to a standstill immediately.
Stop operation of the compressor in the normal way if there is no
emergency.

Procedure:
Press the EMERGENCY-STOP button HZS 25507-A
The main motor will be switched off.
The aux. oil pump motor will be switched off
The oil heater will be switched off.

Switching on again after EMERGENCY-STOP situation:

Remove the danger or the reason for actuating the EMERGENCY-
STOP
Remove any faults at the machine.
Acknowledge alarms using the RESET button on the local panel HZS 25508-A
Check whether starting conditions are ok
Switching on the compressor HS 25504-AST
 Adjusting Purge Gas System before compressor start

Ensure, that all interconnecting piping are connected correctly to the purge gas panel and the dry gas
seal according to the P&ID and the GA drawing.

As soon as the purge gas panel is pressurized other components could be pressurized too. Ensure that
all interconnected components downstream the purge gas panel are ready for commissioning.

Primary seal gas leakage line (Flare Line)

check valve downstream / upstream of is open PCV 25596-A

check if bypass valve is closed
check valve downstream / upstream of is open FT 25534-A
check if bypass valve is closed
Adjust valve (would be just available after opening seal gas)
F= XX Nm³/h
FAL: < XX Nm³/h
FAH:> XX Nm³/h

ckeck that valve at PI 25534-A

is open and shows a pressure of 2,5 kg/cm² g

Seperation Gas Line

check Nitrogen supply (by client),

a present pressure of 5 kg/cm² g

check valve downstream / upstream of is open PCV 25586-A

check if bypass valve is closed

check valve downstream / upstream of is open FT 25585-A

check if bypass valve is closed
Adjust valve
F= XX Nm³/h
FAL: < XX Nm³/h
FAH:> XX Nm³/h

Secondary Seal Gas Line

check Nitrogen supply (by client),

a present pressure of 5 kg/cm² g

check valve downstream / upstream of is open PCV 25589-A

check if bypass valve is closed
check valve downstream / upstream of is open FT 25586-A
check if bypass valve is closed
Adjust valve
F= XX Nm³/h
FAL: < XX Nm³/h
FAH:> XX Nm³/h

ckeck that valve at PI 25542-A

is open and shows a pressure of 5 kg/cm² g
 Primary Seal Gas Line

check Nitrogen/Propylene supply (by client),

a present pressure of ~34/28 kg/cm² g

check valve downstream / upstream of is open FT 25531-A

check if bypass valve is closed

check valve downstream / upstream of is open PDCV 25540-A

check if bypass valve is closed

after compressor has been started:

check valve shows a differential pressure of 1 kg/cm²

Adjust valve FT 25531-A

F= XX Nm³/h
FAL: < XX Nm³/h
FAH:> XX Nm³/h
 Adjusting Oil System before compressor start

Assure that all valves to measuring devices are open

Assure that valve upstream / downstream aux. Oil Pump is opened 33-PC-256-A
Assure that valve upstream / downstream main Oil Pump is opened 33-PC-257-A

Pressure in front of aux. oil pump: approx. atmosphere PI 25565-A

Supply pressure of aux. oil pump 6-8 kg/cm² g
if aux. oil pump is switched on PI 25564-A

Assure that bypass valves of safety valve are closed (main oil pump) PSV 25514-A
Assure that bypass valves of safety valve are closed (aux. oil pump) PSV 25542-A
check valve downstream / upstream of is open PCV 25575-A
check if bypass valve is closed

Assure that all oil drains and vents of Filter are closed 33-EE-250 A/B
Assure that cooling water supply is open TP4
Assure that cooling water return is open TP5

Assure that valve upstream / downstream is opened TCV 25533-A

Assure that all oil drains and vents are closed 33-GN-251 A/B

check valve downstream / upstream of is open PCV 25517-A

 Oil Heater Control

The oil heater includes a thermo control switch. The Heater works in the remote mode if the oil is too
cold and in the local mode if a START signal is present

The following conditions have to be fulfilled to start the oil heater.

The oil heater stops if one of the conditions is not fulfilled.

Oil Level is between min and max 1 LG 25531-A

Oil Level is between min and max 1 LT 25552-A
Protective switch for main motor signals no fault 0 XA 25504-F-AL

Switching on the oil heater

Local:
Turn the switch to change the mode in position LOCAL 1 HS 25516-A
Press the oil heater START button 1 HS 25506-AST
The oil heater starts
The indicator lamp at the local panel lights up 1 XL 25506-R-AL
Oil Heater can not be started if the temperature limiter was
activated. (must be reseted after clarification of the
malfunction)

Via DCS:
Turn the switch to change the mode in position REMOTE 0 HS 25516-A
If the conditions are fulfilled and the oil temperature is too
low the oil heater starts via DCS
The indicator lamp at the local panel lights up 1 XL 25506-R-AL
Oil heater can not be started if the temperature limiter was
activated. (must be reseted after clarification of the
malfunction)

Switching off the oil heater

Local:
Turn the switch to change the mode in position LOCAL 1 HS 25516-A
Press the oil heater STOP button 1 HS 25506-ASP
The oil heater stops.
The indicator lamp at the local panel switched off 0 XL 25506-R-AL

Turn the switch to change the mode in position REMOTE 0 HS 25516-A

If the conditions are not fulfilled or the oil temperature is high
enough the oil heater stops via DCS
The indicator lamp at the local panel switched off 0 XL 25506-R-AL

To make sure that the oil and the bearings becomes not too
cold when the outside temperature is too low turn the switch
to change the mode in position REMOTE 0 HS 25516-A
 Switching on the compressor

Assure that the start conditions are fulfilled.

The values are listet in the instrument list.

Switching on the auxiliary oil pump:

The auxiliary oil pump must be switched on first by compressor main motor start sequence
before the compressor might be switched on to ensure an adequate supply of oil to the bearings
during the compressor start.
The following conditions have to be fulfilled to start the auxiliary oil pump.

The oil pump stops if one of the conditions is not fulfilled.

Oil level is between min and max. LT 25552-A
Auxiliary oil pump FAULT lamp at local panel is not
illuminated 0 XA 25505-F-AL

Switching on via local panel:

Turn the switch to change the mode in position LOCAL 1 HS 25515-A
Press the auxiliary oil pump START button 1 HS 25505-AST
The auxiliary oil pump starts
auxiliary oil pump RUN lamp at local panel lights up 1 XL 25505-R-AL

Switching on via DCS:

Turn the switch to change the mode in position REMOTE 0 HS 25515-A
If the conditions are fulfilled the oil pump starts via DCS

Automatically start of aux. oil pump:

If the compressor is running (lamp lights up) 1 XL 25504-R-AL
The oil pressure before gearbox is too low 1 PZT 25562 AA/BA/CA
The auxiliary oil pump will start automatically
auxiliary oil pump RUN lamp at local panel lights up 1 XL 25505-R-AL

Switching on the main motor

The auxiliary oil pump must be switched on before the main motor is switched on by
compressor main motor start sequence.
Assure that the start conditions are fulfilled.

Switching on is only possible if the following conditions are fulfilled:

(The values for normal running conditions are listed in the IO alarm list)

General:
The following lamps on local panel
TRIP MACHINE do not light up 0 XZA 25508-AL
TRIP PROCESS do not light up 0 XZA 25507-AL
COMMON ALARM MACHINE do not light up 0 XA 25508-AL
COMMON ALARM PROCESS do not light up 0 XA 25507-AL
Main motor RUN do not light up 0 XL 25504-R-AL
READY TO START light up 1 XL 25510-AL

Oil System:
The auxiliary oil pump is running 1 XL 25505-R-AL
The oil temperature is within tolerance TT 25554-A
The oil pressure upstream of the gearbox is within tolerance PZT 25562 AA/BA/CA
Oil level is between min and max LT 25552-A

Seal Gas:
Pressure difference of filters is within tolerance
Primary seal gas supply PDT 25543-A
Secondary seal gas supply PDT 25539-A
Pressure at flare line is within tolerance PZT 25595 AA/BA/CA
Pressure at secondary seal gas line is within tolerance PT 25598 AA/BA/CA
Pressure difference between primary seal gas line and PZDT 25585 AA/BA/CA
casing is within tolerance

Gear Box:
No vibration fault VT 25551-XA
VT 25551-YA
VT 25552-XA
VT 25552-YA
VT 25553-XA
VT 25553-YA
VT 25554-XA
VT 25554-YA
VT 25555-A
No high bearing temperature TE 25555 XA/YA
TE 25556 XA/YA
TE 25557 XA/YA
TE 25558 XA/YA
TE 25559 XA/YA
TE 25560 XA/YA
TE 25561 XA/YA
TE 25562 XA/YA
TE 25563 XA/YA
TE 25564 XA/YA
TE 25565 XA/YA
TE 25566 XA/YA

Main Motor
No high bearing temperature TE 25537 AA/BA
TE 25538 AA/AB
TE 25575 BA/AA
TE 25576 AA/AB
No high winding temperature TE 25534-AA/BA/CA/DA
TE 25535-AA/BA/CA/DA
TE 25536-AA/BA/CA/DA

Manual start via local panel:

Turn the switch to change the mode in position LOCAL 1 HS 25509-A
Main motor LOCAL lamp at local panel light up 1 XL 25509-AAL
Push button main driver START 1 HS 25504-AST
The main motor starts
Main motor RUN lamp at local panel light up 1 XL 25504-R-AL

Start via DCS:

Turn the switch to change the mode in position REMOTE 0 HS 25509-A
Main motor REMOTE lamp at local panel light up 1 XL 25509-BAL
Main motor starts via DCS
Main motor RUN lamp at local panel light up 1 XL 25504-R-AL
 Switching off the compressor

The auxiliary oil pump must be switched on before the main motor can be switched off.

Switching off via local panel:

Turn the switch to change the mode in position LOCAL 1 HS 25515-A
Press the aux. oil pump START button 1 HS 25505-AST
The auxiliary oil pump starts
Turn the switch to change the mode in position LOCAL 1 HS 25509-A
Push button main motor STOP to shut down the main motor 1 HS 25504-ASP
Wait until the main motor has stopped!
Press the aux. oil pump STOP button 1 HS 25505-ASP

Switching off via DCS:

Turn the switch to change the mode in position REMOTE 0 HS 25509-A
Push button main motor STOP in DCS to shut down the main
motor 0 HS 25504-ASP
The auxiliary oil pump starts
The main motor has stopped
The post lubrication timer starts and after the time has
passed the aux. pump stops.

The compressor must remain switched off for about one hour before it can be switched
on again.