Scribd
Upload
277 views51 pages

Air Compressor

The document describes an air compressor used to produce air at high pressure for an ammonia synthesis reaction. It discusses the four stage centrifugal compressor process, protection systems like antisurge loops, start-up and shutdown procedures, potential problems, and implemented improvements.

Uploaded by

Inaam Ur Rehman
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PPT, PDF, TXT or read online on Scribd
277 views51 pages

Air Compressor

The document describes an air compressor used to produce air at high pressure for an ammonia synthesis reaction. It discusses the four stage centrifugal compressor process, protection systems like antisurge loops, start-up and shutdown procedures, potential problems, and implemented improvements.

Uploaded by

Inaam Ur Rehman
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PPT, PDF, TXT or read online on Scribd
You are on page 1/ 51

Air Compressor

Contents
 Introduction
 PID Description
 Trip securities
 Start-up Procedure
 Antisurge loop
 Shutdown
 Problems
 Improvements
Introduction
 Nitrogen for ammonia synthesis reaction is
taken from air.

 Air is introduced in SECONDARY REFORMER


at 34 Kg/cm2.

 Air compressor is installed to produce air at


such high pressure.
Introduction (cont …)
 Air compressor is four stage centrifugal
compressor.

 Pressure is increases up to 34 Kg/cm2 through


a four stage process.

 Air compressor is made by NOVA PIGNONE.


Data sheet
Data sheets
Air Compressor Schematics on
DCS
 Air Compressor is represented in form of
schematics.

 Any value could be changed from a specified


group of that particular group or through
schematic.
Air Compressor Schematic
Turbine Schematic
Lube Oil Schematics
PID Description
 Air enters in first stage of compressor through
filters.

 Filters comprises of inertial, primary and


secondary filters to ensure the dust removal
from air.

 Dust removed due to inertia by inertial filters,


are sent back to atmosphere through a blower.
Primary Filter replacement
 Primary filter are basically sacrificial filters,

 when these filters are choked with dust and ∆P


increases these are replaced.

 Secondary filters are also replaced but their life


is longer than primary filters.
PID Description (cont …)
 Air leaves from first stage of compressor at 2
Kg/cm, and then enters into a Interstage cooler
and knock out vessel .

 After knock out vessel air enters into the


second stage of compressor.

 Air leaves at 8 Kg/cm2, then enter into knock


out vessel and Interstage cooler.
PID Description (cont …)
 After second stage knock out vessel air
enter into 3rd stage.

 Air leaves at 16 Kg/cm2, then after passing


Interstage cooler air enters into 4th stage.

 Air leaves 4th stage at 34 Kg/cm2, and sent


to SECONDARY REFORMER.
Instrument Air
 Instrument air is also supplied from air
compressor.

 IA is taken from compressor third stage


discharge after Interstage cooler.

 This air is passed from a cooler and knockout


vessel, then supplies for IA preparation.
Lube oil
 Lube is used for two basic purposes, i.e.
heat and friction removal.

 Lube oil is pumped from a console and after


cooling and filtering sent to compressor.

 After lubrication and heat removal it returns


back in lube oil console.
Lube oil System
Lube oil System
Condensing and vacuum System
 Condenser is installed for condensing the low
pressure steam at compressor discharge.

 This condensed steam is sent to water


treatment and used for BFW preparation.

 Vacuum is maintained inside the condenser to


get the maximum output from turbine while
giving maximum pressure difference.
Condensing and vacuum System
Steam Circuit
Trip securities
Start-up Procedure
Main steps of Start-up are given below
 Fill check list of K-4421 start-up.
 Online lube oil circulation.
 Start condensing and vacuum system.
 Take sealing steam into service
 Carry out heating and pressurization of
steam lines
 Compressor start-up
DSTK-4421 Start-up check list
Lube oil circulation (check list)
Lube oil circulation (start-up Procedure)
Vacuum And Condensing System (check list)
Condensing System (Start-up)
Ejector and Vacuum System (Start-up)
Ejector and Vacuum System (Start-up)
Sealing steam (Start-up)
Heating And pressurization of Steam lines
Compressor (Check list)
Compressor (Start-up)
Compressor (Start-up) Cont…
Surging
 Surge is an unstable, pulsating condition
that occurs due to low flow and high head
across compressor.

 Reversal of flow occur in cyclic order during


surging and its frequency could be high as
high as 150 cycles per second.
Consequences of Surging
 Causes instability of flow and pressure.
 Damage the compressor shaft and seal.
 Damage to compressor bearing.
 Cause impellers to rub against stationary
diaphragm.
 Cause shaft coupling failure.
 Possible shearing of drive shaft.
Surge Prevention
 Maintaining operating point below the surge
limit through the compressor by increasing the
speed of prime mover

 Relieves resistance in compressor discharge


network, allowing flow to increase.
Antisurge Loop
 Surging of a compressor is very
dangerous. . . As compressor could damage
due to surging

 So antisurge loops are installed for the


compressor safety.

 Centrifugal Compressor could surge if


suction pressure/Flow is low or discharge
pressure is high.
Antisurge Loop For Air Compressor
Shutdown Procedure
 Shutdown is required in case of turnaround
or in case of emergency.

 Steps used in shutdown procedure are given


below
Shutdown Procedure
Problems
 At high plant load discharge temperature of air
increased.

 Strainer at LS induction line had flown into the


inlet nozzle, and flow was reduced.

 Interstage knockout vessels high level security


malfunctioned and compressor tripped.
Problems ( cont … )
 Compressor tripped at low lube oil pressure
during lube oil pump change over.

 A cloth was not removed from compressor by


maintenance, and came to know when
compressor rolled and flow of lube oil blocked.

 Once compressor started rotating reverse and


as consequence rotor replaced.
Improvements
 Material of cooler is changed from CS to
SS.

 Barring improvement. . . Barring will not


start if lube oil pressure is not running.

 Tripping of air compressor is provided if


boiler and primary reformer trips.
Improvements
 Additional SOV is installed at main control
valve of air to secondary reformer.

 Load was reduced due to high Rpm limit of


air compressor. Its alarm limits are changed
as per available margin.

You might also like

pFad - Phonifier reborn

Pfad - The Proxy pFad of © 2024 Garber Painting. All rights reserved.

Note: This service is not intended for secure transactions such as banking, social media, email, or purchasing. Use at your own risk. We assume no liability whatsoever for broken pages.


Alternative Proxies:

Alternative Proxy

pFad Proxy

pFad v3 Proxy

pFad v4 Proxy