CONTROL PHILOSOPHY WRITE UP CAS-1

CONTRACT NO:- LAC No. : HO(Contracts)/NISP/CAS/339, DATED 23.01.2015

DOC .NO.:NMDC/BS/011/08/27/DE/0252, R0
JOB NAME: Compressed Air Station (PKG NO.-011)
NMDC - NAGARNAR-C.G

Purpose:- The Centralized Compressed Air Station -1 ( CAS-1 ) shall provide

required industrial air as well as instrument air for industrial purpose for
different consumers of proposed RMHS, Coke Oven, By-product, Sinter
Plant,Lime- Dolomite plant.In this regard the Control philosophy write up has been
furnished as described below.
Plant Control Philosophy

Plant parameters during normal operation,referred to the Approved drawing of

INTEGRATED P & I DIAGRAM FOR AIR SUPPLY SYSTEM CAS-1 Drg/Doc
no -NMDC/BS/011/01/16/BE/0008,Rev4, , INTEGRATED P & I DIAGRAM FOR
WATER SUPPLY SYSTEM CAS-1 , Drg/Doc no- NMDC/BS/011/01/15/BE/0010,
Rev3 , P & I DIAGRAM FOR COMPRESSOR (AIR,LUBE OIL & WATER) CAS-
1 & 2 , Drg/Doc no- NMDC/BS/011/04/16/DE/0020, Rev 2.

Three nos 3 stage centrifugal compressors ( Capacity of each compressor

160 NM3/Min ) are suitable for parallel and Simultaneous operation
delivering air at required capacity and pressure at 9 Kg/cm2.

Brief description about equipment

Suction Air Filter With Silencer and Manometer : Each compressor unit is
provided with dry air intake filter and silencer unit (SF-1 /SF-2/SF-3).The
inlet air source should be as cool as possible. Filter should not be placed in
any area where the maximum ambient temperature exceeds the specified
maximum design compressor inlet air temperature that is listed on the
compressor data plate. Air temperature in excess of the specified maximum
will have negative effect on compressor aerodynamics performance.
The inlet air filter assembly and blown of silencer will be mounted outside
and away from the walls to prevent the reflection of the noise . The exhaust
from the silencer should be directed upward and equipped with a rain cap
for protection from weather. U Tube Manometer ( MM-1001 ) is fitted with
filter. The manometer is positioned where filter cleanliness can be easily
monitored. In built silencer is used to attenuate the traveling sound
waves to compressor suction.Differential pressure(DPT-A01/DPT-A02/DPT-
A03 ) across suction filter produces high alarm if the pressure crosses the
set point . It indicates that the filter has been choked and goes to the
maintenance mode to prevent back pressure and filter element needs to be
cleaned manually.
 Compressor :

1. Principle of operation :
Filtered air ( controlled by electric actuated inlet guide vane ,IGV-1001-
01/IGV-1001-02/IGV-1001-03 valve operated by 110V AC ,1phase which is
provided to it from control panel ) enters the the compressor's first stage and is
compressed. After inlet compression, the air travels through an intercooler
where heat and moisture are removed from the compressor air .
After the air is cooled and dried , it enters the compressor's second stage
and is further compressed. The air is then directed through a second
intercooler to once again remove heat and moisture .
Finally ,the air enters the compressor's third stage ,where it is compressed to
the design discharge pressure and supplied to the plant air system . Moisture
is condensed as the compressed air is cooled between compression stages .The
amount condensed depends upon humidity condition existing at site. The
condensate must be drained from the compressor.

CAUTION : Condensate collects in the bottom of the intercooler shells and

must be continuously drained. Failure to drain ,the shells may result in
damage to the compressor due to water carryover. Keep each inter cooler
condensate drain line separate from any other drain.
Each compressor is furnished with a drain valve for each inter cooler. The
outlet end of each drain is to be positioned so that each may be individually
observed during routine visual checks and adjusted if needed.
Air discharge check valve is provided to prevent reverse air flow through the
compressor while shut down.
The Shut off valve is installed on the compressor discharge air pipe line , down
stream side of the check valve , to isolate the compressor from the air system.

The compressor's integral lubrication system supplies oil to the compressor

bearings & gears , while the water system supplies cooling water to the
intercooler tube bundles and oil cooler.
The PLC control system automatically positions the inlet control device to
maintain the Motor load within acceptable limits. Also, the unloading valve is
automatically positioned to maintain the design pressure.Protective device are
implemented within control system to automatically shut down the compressor
in the event that any of the parameters reach unacceptable level.

Surge is a common characteristic of centrifugal compressors. Surge occurs

when the compressor is unable to overcome the pressure of the plant air
system.Surge may occur due to typical design conditions or abnormal control
operations. When the compressor experiences surge, the direction airflow
reverses as the compressor is attempting to produce flow against the back
pressure of the plant air system.In the event of a surge , the control system
automatically detects and the eliminates the surge condition by unloading the
compressor ( Unloading valve opens -UCVs )
 Caution : Continuous operations of the compressor in the surge condition will
cause severe mechanical damage .

The PLC control panel is responsible for positioning the inlet control valve
(IGVs ) , positioning the unloading control valve (UCVs ),
sequencing start - up and shut down events , governing different modes of
operation ,monitoring operation parameters , and providing alarm & trip
indications. The control panel utilizes PLC to perform these functions .
Communication takes place via the PLC operator interface located on front
of the control panel.

2. Safety Precautions

1) Ensure all piping and electrical connections are secure before operating
the compressor .
2) Ensure that all valves controls , and the trip and safety are functioning
correctly.
3) Review the operating precautions outlined in the Motor's instruction
manual before the Motor is operated
4) Verify that the compressor drive shaft can be rotated by hand before
starting the compressor.
5) If unusual noises , vibration are detected during operation , stop the
compressor immediately to determine and correct the cause

3. Preparing for final start - up.

a) Disconnect the coupling between the compressor and driver .

Note : Gear type coupling must have the coupling sleeve secured to the coupling
hub with an adapter during uncoupled operation
b) Start the driver and verify that the rotational direction of driver shaft is
Correct.
c) connect the coupling between the compressor and driver ( lubricate
coupling as necessary.)
d ) Inspect sight glass (1LG001/2LG001/3LG001 )on oil reservoir for proper
level If oil level drop below the bottom of the oil level sight gauge before
operating the pump , oil should be added until the level reaches the mid
point of the sight gauge.
4) Current Date and Time
The current date and time are maintained by 'the real time hardware clock'.
the date & time can be adjusted using following procedure .
a) Push the Main Menu function key to access Main Menu screen. Status
Screen is shown.
b) Under the Main menu, push the Set points function key to access Setpoint
Screen1.

c) Push the Setpoint function key to access Setpoint Screen5.

d) Setpoint screen 5 displays the date and time setpoint fields.

 Setpoint Screen 5 also displays the current date & time settings in the
white field located on the right side of the screen.
e) Push the 'HMI Date and time while field and a keypad will appear. Enter
the correct month, day and year on the keyboard.
f) After the 'date & time' have been entered into the selected area, Push the
SET Time key to update the HMI with the correct time setting.
g) Press the STATUS key to return to status screen.

5) Manual start - up vs Automatic Start - up :

Manual start-up requires an operator to physically push the necessary keys in

order to start the compressor and supply air to the plant air system.
Automatic start-up requires an operator to initiate the panel. The control
panel will then automatically start the compressor and supply air to the plant
when the plant air pressure decays to a low level.

6) Manually initiated start - up

a. Check the oil level and temperature. If necessary , add oil until the "Full"
mark is reached on the oil level sight gauge. Heat the oil if the temperature is
less than 74 deg F ( 23deg C). The oil heater (1OHR/2OHR/3OHR) should be
configured to maintain the oil temperature at approx. 100deg F ( 38 deg C )
b. Prime the main oil pump if the compressor is being started for the
first time,
Or the the main oil pump has currently been repaired or placed.
i) Remove the pipe plug from the suction side of the pump.
ii) Fill the pump and suction the line with oil.
iii) Replace and tighten the pipe plug.
c) Turn on the air supply to the pneumatic control components and the seal air
Piping harness ( if required)
Note : Temperature , pressure and vibration transmitters are monitored for
failure at all times. A fault with any of these transmitters will be
annunciated on the PLC interface and start -up will be prevented until
the fault is corrected.

d)Push the STATUS key on the PLC touch pad screen to access the status
Screen.
e) Push the Main Menu key on the touch screen to access the Main menu
Screen.
f ) Push MODE key to access the 'mode of operation ' screen.The 'mode of
operation' screen contain four individual mode selection menus.
i. Control Mode
ii. Start/ Stop Mode
iii. Inlet control device Mode
iv. Unloading valve Mode

g ) Select the desired operating mode by pressing the appropriate selection

h ) After the appropriate control mode selection has been made, push the
STATUS key on the touch screen to return to the Status screen
i) Open the cooling water supply valve ( 1BFV-001,2BFV -001) to the
intercooler tube bundles
j) Pull out the Emergency Stop key on the front of the control panel to enable
the start sequence.

Note : If the 'Emergency Stop key is in 'pushed -in' position,the following

message will appear in the upper left corner of the status screen :Pull
Emergency Stop to enable.. If the Emergency Stop key is in the pulled-Out
position ,the following message will appear in the left corner of the status -
screen: STOPPED
k) Push the START function key on the status screen to initiate the start
sequence .A screen will appear prompting the operator to either confirm or
cancel the start sequence . Press the Confirm key to continue the start-up
procedure
Note : If the start-up is successful , the following messages will appear in the
left corner of the status screen throughout the start sequence :
a) Start Sequence initiated
b) Motor starting
c) Compressor running........
d) Compressor running

l) The auxiliary oil pump (AOP) will start when the start-up procedure is
confirmed..Fifteen seconds after the AOP started , the low oil pressure alarm
and trip are enabled ( by 1PT001/ 2PT001/3PT001) and the oil temperature
( by 1TE001/2TE001/3TE001) is checked. If the oil temperature is 74 deg
F( 23deg C ) or greater, you are permitted to start. If the oil temperature does
not exceed the permissive setpoint , the following message will appear in the
upper left corner of status screen : AOP ON - wait ,Cold oil . If the oil
temperature does not exceed 74 deg F ( 23 deg C) within 15 minutes, the start-
up sequence will be aborted.
CAUTION : Operating personnel should stay clear of the coupling and rotating
shafts while the control system is waiting for the oil temperature to reach 74
deg F ( 23deg C). You will start automatically once the oil temperature reaches
23 deg C ( 74deg F)

m) Twenty- five seconds after the motor is energized, the oil pressure is checked,
the motor starter status is checked ( ie breaker of respective compressor
spring charged , switch gear selected remote, control supply healthy, trip coil
supervision healthy,protection relay not disturbed ) and the motor current
alarm is enabled. If the oil pressure is sufficient , the AOP automatically shuts
off.
If the oil pressure does not exceed the acceptable level within 60 seconds after
the motor starter status is checked, the PLC assumes a main oil pump (MOP)
failure and trips the compressor.
If the motor starter status indicates that the motor has not been started ,the
PLC assumes a motor overload condition ( etc ) exists, and the start sequence is
aborted
n) Five seconds later, the following events occur :
i) The inlet & unloading valves are placed under control of the PLC. The inlet
 control valve (1IGV / 2IGV /3IGV) modulates from its closed position. The
unloading valve (1UCV/ 2UCV/3UCV) waits an additional 8 seconds to begin
modulation to prevent a possible surge

ii) The interstage air temperature alarm and trip are enabled.

OPERATIONAL CHECKS
Although the Compressor is designed to operate autonomously , occasional
monitoring and minor adjustment is necessary for safe and efficient operation :
a) Adjust intercooler water valves ( 1BFV001/ 2BFV001/3BFV003) to maintain
the design interstage air temperature 15 deg F ( 8 deg C) higher than the
design cooling water inlet temperature is located on the compressor name
plate b) Check the oil reservoir oil level(1LG001/2LG001/3LG001) . Monitor the
oil temperature and pressure ( by 1TE001/2TE001 /3TE001,
1PT001/2PT001/3PT003 ).
If necessary, adjust water flow through the oil cooler to maintain an oil
temperature to the bearings of 115 - 125 deg F ( 46 - 52 deg C )
c) The moisture elimination section drain valve discs are notched to allow
constant moisture drainage. In some cases , it may be necessary to open the
valves to ensure adequate drainage .
Caution : Ensure that there is no moisture accumulation in the intercoolers
during the operation. Plugged or restricted drainage from the intercoolers
will result in a rising water level and eventual water carry - over into the
next stage of compression . Water in the air stream will damage impellers
resulting in a loss of performance and vibration
d) The operating personnel should record data approximately every 4 hours.
The operating data should be reviewed periodically. The data will alert the
operating personnel of a maintenance problem , such as dirty oil cooler, etc.
This will aid the operating personnel in scheduling maintenance shutdowns
and reduce unexpected shutdowns that may be detrimental to the plant.

Manual Start

PAP shut down

Oil in 0 P S I G
For 0 Min, Pull to enable

Pull enable button

PAP shut down

Oil in 0 P S I G
For 0 Min, Push start
 Push start button

CC
Auxiliary oil pump start

Next Page

Oil Temperature Oil Pressure

Start 20 min Timer Wait 15 seconds

Is oil Temp>74degF No Trip low oil

No Is oil pressure
?
? pressure
Yes > 15 PSIG

No Yes
Alarm
? No low oil Pr
PAP Starting, Oil in XX PSIG
Oil in XX deg F
Wait : Cold Oil
PAP starting Auxiliary oil
oil is XX PSIG pump stops
No Oil is xx deg F
? PAP Starting oil in xx PSIG
Has 20 min Oil in XX deg F
Timer started ABORT
? START
UP
Yes
Is oil Temp. & pressure
Satisfied
Yes Is seal air pr. Yes
? Satisfied ?

Compressor Drive
Motor Status
Alarm on
Low oil temp

PAD Starting; Oil in xx PSIG

Auxiliary oil pump
RS Vib x.xx micro m
LS Vib x.xx micro m
 stops

Wait 25 seconds

ABORT No
Start - Up
Trip motor
?
starter status

Is Motor Starter
Yes Coil Energized

Shut down Enable Motor

sequence Alarm

Start 35 sec timer

No

Yes No
Shut off auxiliary ?
oil pump ?
Has 35 second
Is oil pressure timer elapsed
> 37 PSIG Yes

Wait 5 sec enable

alarm position ICV Trip Main oil
pump failure

Wait 8 sec position

unloading valve Shut down sequence

PAP running
Oil in xx deg F
Air out xx PSIG
RS Vib xx micro m
AUTOMATICALLY INITIATED START - UP
Note : Temperature, pressure and vibration transmitters are monitored for failure
at all times. A fault with any of these transmitters will be annunciated on the PLC
operator interface and prevent start - up until the fault is corrected.

1) Check the oil reservoir level and temperature . If necessary , add oil until the Full
mark is reached on the oil level sight gauge. Heat the oil if the temperature is less
than 74degF (24deg C). The optional oil heater should be configured to maintain the
oil temperature at 100 deg F (38 deg C)
2) Prime the main main oil pump if the compressor is being started for the first time,
or the main oil pump has currently been repaired or replaced
a) Remove pipe plug from suction side of the pump.
b) Fill pump and suction line with oil .
c) Replace and tighten pipe-plug.
3)Turn on the air supply to the pneumatic control components and the seal air
piping harness ( if required)
4)Push the STATUS key on the PLC touch pad screen to access the status screen.
5)Push the MAIN MENU key on the touch screen to access the Main Menu Screen.
6)Push the MODE key to access the 'mode of operation' screen.
7)Access the drop-down menu titled START/STOP MODE. Select the desired operating
mode ( AUTO /MANUAL or AUTO/ AUTO) by pressing the appropriate selection in the
START/STOP drop down menu. Also, select the control mode ( Base,Suction
Throttle, Intermittent or Auto /dual ).

Note :
The ( AUTO/MAN) start/stop mode can be selected with any of the control
modes ( Suction Throttle, Base Mode, Intermittent Mode , or Auto/Dual). The
( AUTO/AUTO ) start/stop mode can only be utilized when the intermittent or
Auto/dual control modes are selected

8) After the appropriate control mode selections have been made, push the STATUS
Key on the PLC touch pad screen to return to the Status screen.
9) Open the cooling water supply valves to the intercooler tube bundles.

10) Open the manual block valve ( 1NRV001/2NRV )to the plant air system.

11) Pull out the EMERGENCY Stop key on front of the control panel to enable the
start seq unce.

Note : If the 'Emergency Stop key is in pushed -in position,the following

message will appear in the upper left corner of the status screen.:Pull
Emergency Stop to enable . If the Emergency Stop key is in the
pulled - Out position ,the following message will appear in the left
corner of the status screen: STOPPED
12) Push the START function key on the status screen to initiate the start
sequence .A screen will appear prompting the operator to either confirm or
cancel the start sequence . Press the Confirm key to continue the start-up
Procedure.

13) If the system pressure is above the low system pressure setpoint , the unit will
be placed in stand -by mode and the following message will be displayed in the
upper left corner of the Status screen: WAITING TO AUTO-START .

CAUTION

Operating personnel should stay clear of the coupling and rotating shafts while
the control system is waiting for the plant air pressure to decrease. Motor will
start automatically once the plant air pressure decreases to the low system
Pressure setpoint.
14) When the system pressure falls below the automatic start setpoint , the
Auxiliary oil pump ( AOP) will start.
15) Fifteen seconds after the AOP is started ,the low oil pressure alarm and trip
are enabled and the oil temperature is checked. If the oil temperature is
74 deg F (23 deg C) or greater , the driver is permitted to start. If the
Oil temperature does not exceed the permissive set point ,the following
message will appear in the left corner of the Status screen : AOP ON - Wait ,
Cold oil . If the oil temperature does not exceed 74deg F ( 23 deg C) within
15 minutes ,the start up sequence will be aborted.
Note : The compressor will not auto start if the start- up sequence has been
aborted due to the cold oil condition . The operator will have to manually launch
the start-up sequence , at which time , the auto start feature will re- initiate.
16) Twenty -five seconds after the motor starter is energized, the oil pressure is
checked , and the motor current alarm is enabled. If the oil pressure is
sufficient , the AOP automatically shuts off..
If the oil pressure does not exceed the acceptable level within 60 seconds
after the motor starter energized ,PLC assumes a main oil pump ( MOP )
failure and trips the compressor.
If the motor starter status indicates that the driver has not started , the
PLC assumes a motor overload condition (etc.) exists, and the start sequence
is aborted.
17) Five seconds later , the following events occur :
a) The inlet and unloading valves are placed under control of the PLC. The
inlet control valve (1IGV/ 2IGV) modulates from its closed position .The
unloading valve (1UCV/2UCV) waits an additional 8 seconds to begin
modulation to prevent a possible surge
b) The interstage air temperature alarm and trip are enabled
Automatic Start

PAP shut down oil in O PSIG for 0 min; Pull to enable

Pull enable button

PAP shut down oil is O PSIG for 0 min; Push start

Push start button

Yes No PAP shut down oil in

CC ? xx PSIG ; Ready auto
start Air system xx
PSIG
Is system pressure below
Low pressure set point?
 SEAL AIR SYSTEM

The seal air system provides pressurized air to the pinion seals. The
pressurized air provides a barrier so that oil cannot leak into the compressed
air system. The seal air system consists of a seal air blow -off regulator and an
optional seal air supply regulator.

During normal operation of the air compressor unit.the last stage of compress -
ion provides a small amount of pressurized air into the seal air system. This air
is provided to the pinion seals. The seal air blow-off regulator vents any excess
air. The seal air blow-off regulator should be adjusted to 6-7 psig ( 0.41 to 0.48
bars).

EMERGENCY SHUTDOWN

1, The compressor will automatically shutdown should any of the following

circumstances occur.
High final interstage Air Temp {1TE002( IAT) / 2 TE 002(IAT)/3 TE 002(IAT)}
Low oil pressure (1PT001/2PT001/3PT001)
High Vibration low speed pinion ( 1VT 001/ 2VT001/3VT001)
PLC fault
Manual emergency Trip
Motor current Transmitter failure ( 1IT001/2IT001/3IT001)
Oil pressure Transmitter failure ( 1PT001/2PT001/3PT001)
Oil temp.RTD failure ( 1TE001/2TE001/3TE001)
Interstage air temp. RTD failure.{ 1TE002( IAT) / 2 TE 002(IAT)/ 3 TE 002(IAT)}
High speed pinion vibration transmitter failure ( 1VT002/2VT002/3VT002)
Low speed pinion vibration transmitter failure (1VT 001/ 2VT001/3VT001)
Discharge air pressure transmitter failure ( 1PT003/2PT003/3PT003)

2. When a shutdown command is received the following steps are automatically

taken :
a) Motor is shut down
b) The red trip light will flash and the horn will sound
c) The auxiliary oil pump will start
d) The unloading valve will open
e) The condition that cause d the shut down will be displayed in the upper left
corner of the Status screen .

3. Push the ACK key on the lower right corner of the trips & alarm screen.
Then hide the alarm screen followed by the RESET key located on the upper
 left corner of the status screen. These actions will clear the trip status.

Note : The compressor coast down timer is set for 120 seconds to prevent
attempted start - up while the driver is coasting down. A
(COASTDOWN) message will appear on the upper left corner of the
Status screen during the coast down period.

4. Two minutes after the shutdown command is received, a compressor restart

is permitted.
5. If the restart is not attempted, the AOP will remain on for an additional
thirteen minutes for cooling purposes and then automatically shut down.

CAUTION
In cold weather climates it may be necessary to continue running the cooling
water to prevent freeze-up of the oil cooler.

Note : The compressor will not auto start if it is shutdown manually or by an

emergency shutdown . The automatic start sequence must be re-initiated
for this mode of operation.

6. Close the Motorized Shut-off valve if the unit is not going to be

restarted.

MANUAL SHUTDOWN

1.Slowly close the manual shut-off valve to isolate the compressor from plant
air system

CAUTION

Failure to close the manual shut -off valve may lead to reverse rotation of the
Compressor ( if the check valve were to fail )

2. Push the STATUS key on the PLC touch pad screen to access the Status
screen .
3. Push the STOP key located on the Status screen. A screen will appear
prompting the operator to CONFIRM or IGNORE the stop command .Press
the CONFIRM key to continue .

The following actions will take place :

a) The unloading valve slowly opens and the inlet control device slowly closes
unloading the compressor
b) Approximately 30 seconds later, the motor is shut down
c) All alarm and trips disabled
d) The compressor coast down timer initiates.The timer is set for 120 seconds to
 prevent an attempted start-up while the motor is coasting down
e) If the shutdown sequence is successful , the following message will appear in
the upper left corner of the status screen throughout the shutdown sequence :
Stopping
Coast down
Cool down
Compressor shutdown

Note
If the operator encounters an emergency, pushing the EMERGENCY STOP
push key on the front of the control panel will immediately unload the
compressor and shut down the driver.

4) Two minutes after the shutdown command is received , the message

'Cooldown' appears in the upper left corner of the Status screen.,at which time
a compressor restart is permitted.
5) If a restart is not attempted , the AOP will remain operating for 15 minutes
for cooling purposes and automatically shut down. The automatic start
sequence must be re-initiated for this mode of operation,

Manual Stop

PAP running
Oil in xx deg F
Air out xx PSIG
RS Vib xx micro m

Push Stop button

Drive motor shuts down

Alarm & trips

Dis enabled

Un loading valve opens

 Start timer

Coast down; Restart delayed until

PAP stops for xx sec.

Has two minutes ? No

Timer elapsed

Yes

Re start is permitted

PAP Shut down

Oil in xx PSIG
Pull to Enable

No
Has 15 Minute Timer Elapsed ?

Yes

Aux. Oil pump stops

Water solenoid shuts off

PAP shut down oil is O PSIG for 0 min; Pull to enable

AUTOMATIC SHUTDOWN

The automatic stop feature is optional.

1) Push the STATUS key on the PLC touch pad screen to access the status screen.
2) Push the Mode key to access the mode of operation screen.
3) Access the drop down menu titled START/STOP Mode. Select the desired
operating mode ( AUTO/AUTO) by pressing the appropriate selection in the
START/SOP MODE drop-down menu. Also , select the desired control
mode( intermittent or AUTO DUAL)

Note : Steps 1 - 3 are only require for initial start-up.

4) The compressor will now receive an automatic stop command once the plant air
system demand is satisfied.
5) Once the automatic stop command is received, the compressor ' s inlet control
valve will close and the unloading valve will open.
6) The compressor will continue running in this manner until the system pressure
drops below the low system pressure setpoint at which time the compressor will
reload. If the system pressure does not drop below the low system pressure setpoint
within 30 minutes of the compressor unloading , the compressor receives a shutdown
command.
7) When the shutdown command is received the following steps are automatically
taken
a) The motor starter is de-energized to stop the motor
b) The auxiliary oil pump will start
c) The compressor coast down timer initiates. The timer is set for 120 sec to prevent
an attempted start -up while the driver is coasting down
d) If the shutdown sequence is successful, the following message will appear in the
Upper left corner of the status screen during the shutdown-screen.
Stopping
Coast down
Cool down
Compressor shutdown
8) Two minutes after the shutdown command is received , the message 'Cooldown'
appears in the upper left corner of the Status screen.,at which time a compressor
restart is permitted. If the system pressure has fallen below the low system
pressure setpoint , the compressor will automatically restart.
9) If a restart is not attempted, the AOP will remain on for an additional thirteen
minutes for cooling and then shut down automatically.
10) After coast down the unit will await an auto start command.
11) When the system pressure drops below the low system pressure setpoint,the
compressor will automatically start.
 Automatic Stop

PAP running
Oil is xx deg F
Air out xx PSIG
RS Vib xx micro m

Is unloading valve open above

Set point No
?

Yes

Start xx sec timer

Yes
? Start 30 min
Unl. Valves
Has Timer open ln valve Timer
Elapsed closes
No

PAP unloaded ; Stop in xx min ;

oil in xx deg F; RS Vib. Xx micro m

No
Ln valve opens Yes
?
Unl Valve closes ?
Is system Pr. No
Below set pt
Has
30 min Timer
elapsed

Alarm & Trips Drive motor shuts

disenabled down

Aux. Oil
pump start
EE
 EE

Unl Valves opens

Start timer

Coast down; Re-store delayed

until PAP stop for xx sec.

No
? Yes
Re start is permitted
Has 2 min timer elapsed

PAP shut down; Oil in xx PSIG;

Ready Auto start; Air System Is
xx PSIG

Is system Pr.
Below pr, set
point
Has 15 min timer elapsed ?
No ?

Yes Yes

Aux. Oil pump stops

CC

PAP shut down; Oil in 0 PSIG;

Ready Auto start; Air System Is
xx PSIG
SURGE DETECTION
Surge is a performance characteristic of a compressor that arises when the
compressor can not overcome the system resistance. When this happen , a flow
reversal occurs until the compressor can again overcome the system resistance.
Surge is usually associated with an excessive discharge pressure , however
excessive suction throttling can also cause surge.

CAUTION
Operating the unit in a surge condition can cause extensive damage to the
compressor . It is recommended that the unit not be operated in a continuous
surge condition.

If surge occurs while the unit is operated in the suction throttling or control
modes ,the control system will automatically change the compressor's operating set
point in an attempt to prevent future surge occurrences . The control system will
also automatically reload the compressor into the plant air system after making a
change to the operating set point.If compressor surge occurs again, the control
system will continue to change the operating setpoint away from surge until a max
operating set point is achieved . At this point , the unloading valve will remain
fully open until an operator investigates the problem and pushes the
ACKNOWLEDGE and RESET function keys.

Surge Detection Check

After the unit is operating , check to see that the surge detection circuitry is
functional. The following procedure may be used :
1. If the block valve to the plant air system is not closed, slowly close it.
2. Push the STATUS key on the PLC touch pad screen to access the status screen.
3. Push MODE key to access the mode of operation screen .
4. Access the "CONTROL MODE " drop- down menu.
5. Push BASE to configure the compressor to operate in base mode.
6. Access the "UNLOADING VALVE" drop-down menu.
7. Push MANUAL to place the unloading valve under manual control.
8. Slowly close the unloading control valve by pushing the key. The % open valve
on the screen will decrease and the compressor discharge pressure will increase. As
the discharge pressure increases, the compressor approaches surge.When surge
occurs, the PLC should recognize it and open the unloading control valve ,flash the
Common alarm light, sound the horn, and display the surge condition on the
operator interface screen.

CAUTION : If the control panel does not recognize surge , push the key on the
operator interface until the surge condition is eliminated . Contact an Eliott service
office.

9. To clear the surge recognition circuit , push the ACK and RESET keys.
Following are the details of each compressor in brief :

1) Discharge air pressure - 9 kg/cm2

2) Auxiliary power consumption - 22 KW
3) Mode of operation : Manual / Automatic
4) Interstage pressure : 2.94, 4.98, 9.03 kg/cm2
5) Speed of main gear : 2970 r.p.m
6) Inter stage air temperature before inter cooler at rated capacity and
pressure :
141.7 and 135.9 deg C
7) Outlet air temperature before after cooler at rated capacity : 111.3deg C
8) Air temp.at delivery after after cooler at rated capacity and pressure : 37 to
48
degC .
9) Noise level when the compressor running at rated capacity : 85 db
10) Cooling water requirement for each compressor :
- For inter cooler : 110 M3 /hr
- For after cooler : 66 M3 / hr
- For oil cooler : 15M3/hr
Total requirement of water for each Compressor - 191M3/hr
Pressure of the cooling water required at compressor inlet - 2.5 Kg/Cm2
Temperature rise of cooling water - 10 deg C

Each compressor has individual control panel in which auxiliary drive

systems like
AOP motor, Oil heater ,Power supply to valves , PLC etc & Siemens make S7 -
200 model PLC have installed to operate the compressor locally in Auto/
Manual mode. The control cabinet including transformer for 110 V AC supply
mounted on the base .
Pneumatically operated Isolating valves ( MOV-037, MOV-038 & MOV-039 for
compressor 1, 2 & 3) are installed on outlet line of Compressor which will be
operated from common PLC as per plant requirement.

Lube system : Lubrication system has two positive displacement rotary

pumps. These pumps provide a constant oil flow to the compressor
bearings , gears and other moving parts . The main oil pump is driven by the
gear shaft . The motor driven auxiliary oil pump , located in the oil
reservoir ,operates automatically when the oil pressure is low. Other major
components in this systems are oil cooler ,duplex filter, Thermostatic control
valve ,Pressure Transmitter , Pressure gauge , Temperature element , level
gauge, Pressure safety valve , fittings etc.

Oil Cooler ( OC -101A,101B/ OC -102A,102B/ OC -103A,103B) is a shell and

finned tube type heat exchanger . Cooling flows through the tubes .Oil flows
through the shell and around the tubes. Buffers inside the shell control the oil
flow through the cooler.

Oil filter (OF-101 /102/ 103 ) : Cartridge type duplex filter is used for oil
filtration purpose.
Thermostatic Control valve (1TCV 1001/ 2TCV1001/3TCV1001) is furnished to
regulate the oil temperature to the compressor .When the oil temperature to
the compressor is below 110degF ( 43 deg C), the control valve causes the oil
by pass the cooler . When the oil temperature exceeds the 120degF (49 deg C),
the valve routes all the oil through the cooler. At oil temperatures between 110
deg F and 120degF (43degC & 49 deg C) , the valve regulates the oil flow
between the oil cooler and the bypass to maintain this temperature range.

Oil heater (1OHR/ 2OHR /3OHR) : An oil heater is installed in the side of the oil
reservoir . An integral thermostat can be adjusted to obtain the desired oil
Temperature.

Relief valve ( 1PSV001/2PSV001/3PSV001) : This valve is used to maintain oil

pressure in the Gear Cage header . The oil pressure can be adjusted while
the unit is running by removing the cap and turning the adjusting screw.

Safety , Control & monitoring device of the lubrication system : The system is
equipped with an oil pressure transmitter (1PT001 / 2PT001/3PT001)
and oil temperature element (1TE001/ 2TE001/3TE001 ,connected with PLC)
on the oil feed line to the compressor. The oil pressor transmitter trips the
compressor if a low oil pressor condition should occur. The oil temperature
alarms and trips the compressor if a hot oil condition should occur.

During normal compressor operation ,the main oil pump supplies oil to fulfill
the unit's oil requirements ( bearings , gears). The auxiliary oil pump remains
on stand by until the performance of the main oil pump deteriorates. The relief
valve is to be adjusted to maintain a system oil press within the range (1.7 bar
to 2.0 bar )

When the unit shuts down (manually or due to or safety trip device ) the
auxiliary oil pump automatically starts. The auxiliary oil pump continues to
operate and cool the compressor bearings. After 15 minutes ,the auxiliary oil
pump automatically shuts off.
Lubrication system operating data :
1) Low oil temperature alarm - 21 deg C
2) Minimum oil temperature for permissive start - 23deg C
3) System oil pressure - 1.7 bar to 2.1 bar differential
4) Max.Pressure drop across oil filter - 0.7 bar
5) Low oil pressure trip - 1.0 bar
6) Low oil pressure permissive - 1.4 bar
7) Auxiliary oil pump start pressure - 1.4 bar
8) Auxiliary oil pump stop pressure - 2.2 bar
9) Oil temperature from oil cooler - 46deg C to 52 deg C
10) High temperature alarm oil from cooler - 57deg C
11) High temperature trip oil from cooler - 60 deg C
12) Reservoir Capacity - 245 lt.
 Each Compressor is driven by HT Motor ( 1400 Kw, 6.6 KV Volt) which is
Started through FCMA soft starter connected with HT switch board. ( Client
scope )

Cooling water supply & System: Existing pump house ,Cooling Tower ,Cooling
water supply and Return pipe lines will be utilized for these new
Compressors. Motorized Butterfly valves ( MOV-013/ MOV-015/MOV-017
for Compressor (1 ,2 & 3 ) are installed in water Inlet line of the
Compressor. Motorized Butterfly valves ( MOV-014/ MOV-016/MOV-018 ) are
installed on water outlet line of compressor ( 1, 2 & 3 ).
Cooling water maintains air & lubrication oil temperature within design limits.
The coolers are shell and fined tube type. Cooling water passes through the
tubes and cooled medium through the shell and around tubes.
Cooling water supply is to be limited to maximum pressure of 8.6 bar for the
intercoolers and 10.3 bar for the standard oil coolers.
Note : An insufficient pressure drop across the cooler connections or
insufficient water flow will result in inadequate cooling .
Water inlet temperature exceeding the design value will have a negative effect
on compressor aerodynamic performance may result in alarms or trips due
to high lube oil or inter stage air temperature.
Excessive water velocity will lead to erosion problems, noise or insufficient
heat transfer .Lower velocities will result in increased cooling water
discharge temperature .

TE-W03 / TE-W05/TE-W07 Temperature element is used to get inlet water

temperature of compressor.
TE-W02 / TE-W04/TE-W06 Temperature element has been provided to get
outlet water temperature of compressor.
TE A01 / TE A02 /TE A03 has been provided to get outlet water temperature
from after cooler.

N2 supply (customer scope) as control air is to be supplied during operation of the

compressor. Self operated pressure control valve, pressure switch and pressure safety
valve are incorpsed in the system. Operation pressure is approx. 0.9 kg/cm2.

Compressor are furnished with electric actuated inlet guide vane (1 IGV / 2 IGV/3 IGV).
The valve will need to have 110 v Ac / 1 phase provided to it from control Panel. The 4-
20 mA signal is wired from the control Panel to the valve.

The Seal air Pressure switch (SAPS) senses the buffer pressure in the compressor seals.
The seal air pressure (SAPS) is used in conjunction with intermittent mode or dual mode
control. The SAPS is ignored during base mode and suction throttle mode control. A low
seal air pressure condition also prevents. The inlet valve/guide vanes from closing ( un
load compressor) and prevents the auxiliary oil pump from continuously running during
start up. The switch is set so that the contacts close at (0.27 bar) and open at (0.13 bar).
A blow off regulator is installed on the sal air harness to vent air should the air pressure
exceeds 0.45 bar.
Control and instrumentation :
Individual Compressor will be communicated to BSL PLC through RS 485 Modbus
protocol.

The PAP PLC control system regulates the inlet and unloading valves, monitors the
operating Parameters (temperatures, pressure etc), provides alarm and trip indication,
sequence start - up and shut down of the unit, governs the different modes of operation,
stores pertinent data and provides hard copy output information via serial printer interface
and communicate with common PLC.

The control panel utilizes a PLC to perform these functions. Integral with PLC is the
HMI LC Touch panel display.

Primary communication with the PLC is through the integral HMI Touch screen display
on the front of the control panel. Commands for starting compressor, selecting control
modes, entering set points, acknowledge alarms, etc are entered on the Touch screen, the
display informs the operator of the unit's operating status, set points, data, control modes,
and alarm and trip conditions.

The inlet inlet control valve / guide vanes are positioned to maintain a deserved motor
amperage. The unloading valve opens to exhaust compressed air to atmosphere when the
compressor output flow exceeds the system demand. The valves (or guide vanes) may be
positioned manually or automatically through the PLC interface.

Per-massive Condition :
1) Breaker of respective compressor spring charged
2) Switch gear selected remote
3) Control supply healthy
4) Trip coil supervision healthy
5) Switchgear is not disturbed ( protection relays of motor are not actuated )
6) Lubrication oil pressure archived
7) Lubrication oil temperature achieved

Following set points found on the PLC set screen :

1. Discharge air Pressure set : Utilizes the unloading valve to maintain this pressure at
the discharge of the air compressor.

2. System air Pressure Low : This set point determines the plant air pressure at which
the unit loads and /or automatically starts.

3. Minimum Motor Amps : This set point (along with max motor Amps set
point)determines the operating amperage range of the motor.The min amps set point
corresponds to the suction throttling horse power of the unit.
4. Max Motor Amps : This set point (along with minimum motor Amps set
point)determines the operating amperage range of the motor. The max. amps set point
corresponds to the suction throttling horse power of the unit.

5. Inlet valve prop band and Reset : These set points control the responsiveness of the
inlet control valve / guide vanes.
Note : The proportional band and reset settings determine the responsiveness of the
control valve ( Inlet valve and unloading valve)

6. Unloading valve Prop. Band and Reset : These set points control the responsiveness
of the unloading control valve.

7. Valve times (Inlet or unloading): These set points determine the closing speed of the
inlet valve (in seconds) and the opening speed of the unloading valve in order to obtain a
smooth unloading of the compressor during intermittent and dual mode operation.

8. Valve position to Auto unload : These set points determine the unloading valve
position, at which a timer in the PLC software is limited before unloading the compressor
on intermittent and dual mode control.

9. Aux. Oil pump shut off Pressure : This set point determines the oil pressure during
start - up of the compressor at which auxiliary oil pump is permitted to shut off.

10. Oil temp. Start permissive : The permissive start set point determines the oil
temperature at which the compressor can be started.

11. Surge DP/DT : These set point determine the sensitivity of the surge detection
system. Surge is detected when a certain pressure drop (DP) occurs within a certain time
period (DT).

12. Adaptive control increment : If the compressor surge occur, this set point
determines the amount of incremental adjustment, which the controls will move away
from surge. Every time the compressor surges, the controls make an incremental change
until compressor surge no longer exists or the maximum motor amperage is reached.

13. Suction throttle prop band and reset : These set points control the responsiveness
of the inlet control valve / guide vanes during the throttling action.

Control System:

The control system regulates the air flow through the compressor by positioning the air
inlet control value and discharge air unloading value. The controls also unload the
compressor when occurs.
The control system performs the following functions :
1) Start/Stops the air compressor unit.
2) Motor amperage control.
3) Discharge pressure control.
4) Suction throttling control.
5) Intermittent mode control.
6) Auto dual mode control.
7) Auto start stop control.

A) Start/Stop mode - manual/manual

An operator required to physically push the necessary keys in order to start and stop the
air compressor unit. Any of the control modes (base mode, suction throttling,
Intermittent or dual) can be used with manual/manual. Select by pressing start/stop
Mode in drop down menu.

B) Start/Stop mode - Auto manual

Automatic start/stop requires an operator to only initiate the panel. The control panel
then automatically starts the compressor when the plant air pressure decreases to the
low system air pressure setpoint. An operator is still required to physically stop the air
Compressor. Any of the control modes (base mode, suction throttling, intermittent or
Dual) can be used with auto/manual control. This can be selected by pressing the
start/stop mode drop down menu and select Auto manual.

C) Automatic Start/Automatic Stop

The Automatic start/stop requires an operator to only initiate the panel.The control
Panel automatically starts the compressor when the plant air pressure decreases to
the low system air pressure setpoint. When the plant air system does not require the
units compressed air for a period of time, the control panel unloads the compressor
(unloading control valve fully opens and inlet valve/guide vanes fully closed).If the
compressor is not required to re load within 30 minutes, the control panel will shut down
the compressor unit select by pressing the start/stop dropdown menu and A

Various Controls

Inlet control valve/guide vane control :

A) Manual operation of the inlet control valve/guide valves allows the operator to
manually adjust the compressor inlet air flow, which in turn, affects the Motor current.
Manul control can be obtained by selecting the inlet valve drop down menu.

Note : Manually closing the inlet control valve/guide valve too far during compressor
operation may result in compressor surge.
B) Automatic operation of the inlet control valve/guide valves allows the control panel to
automatically adjust the Motor current.
The control panel will automatically maintain the Motor current at the set point. This can
be obtained by selecting the Inlet valve drop down Menu.

Unloading valve operation

A) Manual operation of the unloading control valve allows the operator to manually
adjust the compressor discharge pressure.

Note :Manually closing the unloading control valve too far during compressor operation
may result in compressor surge.

B) Automatic operation of the unloading control valve allows the control panel to
automatically adjust the compressor discharge pressure.
The control panel will automatically maintain the compressor discharge pressure at the
set point.

Base Mode control

The base mode control maintains the design discharge pressure of the compressor by
modulating the control valve. As the plant air demand decreases, the unloading control
valve will modulate (open) and blow off excess air to atmosphere.

The inlet control valve/guide vanes modulate to maintain the design motor current
(amperage).
The set point required for base mode operation are listed below:
1. Discharge air pressure
2. Maximum motor current

To operate the compressor air in base mode, access the control mode drop-down menu
and select base mode.

Suction throttle mode control

The suction throttle control mode is a method of reducing the motor power consumption
by throttling the inlet air flow when the plant air system demand is satisfied. When the
plant air pressure (compressor discharge pressure) is satisfied, the inlet control
valve/guide vanes throttle the inlet air flow. The inlet control valve/guide vanes throttle
the air flow until a minimum amperage set point is released. If the plant continues to
decrease, the unloading control valve will modulate to maintain design discharge pressure.
The set points require for suction throttle mode operation are listed below

1. Discharge air pressure

2. Maximum Motor current
3. Minimum Motor current
To operate the compressor in suction throttle mode, access the control mode drop down
menu and select suction throttle mode.

Note: If the minimum amps set point valve is too low while operating in suction throttle
mode, the compressor may surge.

Intermittent Mode control

Intermittent mode is basically on ON-OFF type of control. The compressor loads and
unloads based on the plant air system demand. When the system air pressure is below the
low system air pressure set point, the inlet control valve/guide vanes open to maintain
design motor amperage and the unloading control valve closes to deliver all of the
compressed air to the plant air system. As the plant air system demand decreases, the
compressor discharge pressure increases and unloading valve maintains design discharge
pressure by venting excess air to atmosphere. As the plant air system demand further
decreases, the unloading valve opens further to maintain design pressure once the valve
position has exceeded the Auto unload set point (% open), a timer is initiated. If the %
open set point is exceeded for 3 mins, the compressor unloads (unloading control valve
fully opens and the inlet vane/guide vane fully close.) The compressor remains unloaded
until the plant air pressure decreases to the system pressure set point at which time the
cycle will begin again. The set points required for intermittent mode of operation are
listed below.

1. Low system air pressure

2. Final discharge air pressure
3. Maximum motor current
4. Valve position to Auto unload

To operate the compressor in intermittent mode, access the control mode drop down
menu and select intermittent.

Auto dual mode control

Auto dual mode control is the same as intermittent mode with the exception that once the
compressor discharge pressure rises to the design discharge pressure, the inlet control
valve/guide vanes throttle the inlet air flow to reduce the drive horse power. The inlet
control valve/guide vanes throttle air flow until the minimum amperage set point is
reached. If the system pressure (compressor discharge pressure) continuous to increase,
the unloading valve opens to maintain decrease pressure if the unloading valve opens
beyond the % open setpoint for the set point amount of time, the compressor unloads
(unloading valve fully opens and inlet valve guide vanes fully close.). The compressor
will continue to run this unloaded state until the plant air system pressure falls below the
low system pressure setpoint. The compressor will then re load and the cycle will repeat.
The setpoints required for auto dual mode operation are listed below.
1) Low system air pressure
2) Final discharge air pressure
3) Maximum Motor current
4) Minimum Motor current
5) Valve position to Auto unload

To operate the compressor in auto dual mode, access the control mode drop down menu
and select Auto dual.

Status Screen - Compressor running

1) Inlet valve position

2) Unloading valve position
3) Discharge air pressure
4) Oil Temperature
5) Oil Pressure
6) Low speed vibration
7) Hi speed vibration
8) Final Air Temperature
9) System air pressure

Set Point Screen

1) Discharge air pressure set point.

2) System air pressure low set point.
3) Minimum Motor Amps. Set point.
4) Maximum Motor Amps. Set point.

Following various operating/information messages will be appeared in the PLC.

1. Starts screen in compressor running condition.

2. Various operating status at pull out emergency stop to enable condition.
3. Various operating status at waiting to Auto start condition.
4. Various operating status at compressor shut down condition.
5. Various operating status at compressor unloaded condition.
6. Various operating status at coast down condition.
7. Various set points.
8. History (line number of starts, no. Of surges, compressor run time, power on.)
9. Inlet oil temperature trip and alarm adjustment screen.
10. Mode selection screen.

Various Graphic data screen will be appeared line :

1. Compressor discharge pressure.
2. System air pressure.
3. Inlet oil.
4. Motor current.
5. Final inter stage air temps.
6. Low speed Rotor vibration.
7. High speed Rotor vibration.
8. Inlet Oil temperature.
9. First inter stage air temps.
10. After cooler air temp.
11. Bearing temperature.
12. Statar temp.
13. First stage discharge pressure.
14. 2nd stage discharge pressure.

Following information will be available in the PLC .

Sr Description Signa From To Range Cal. range Remark

no l type
1 Motor Bearing AI TE-012 Com.P PT100 0-200 deg Motor
Temp. LC C DE
2 Motor stator AI TE-008 Com PT100 0-200 deg
wind.Temp ( R ph) PLC C
3 Motor stator wind AI TE-009 Com PT100 0-200 deg
Temp ( Y - ph) PLC C
4 Motor stator wind AI TE - 010 Com PT100 0-200 deg
Temp ( B - ph) PLC C
5 Motor Bearing Temp AI TE- 011 Com PT100 0-200 deg Motor
PLC C NDE
6 Water outlet from oil AI TE- 006 Com PT100 -28.9 to
cooler temp PLC 104 DegC
7 Moisture sep. Outlet AI TE-007 Com PT 100 -28.9 to
air temp. PLC 104 Deg C
8 Water outlet from AI TE005 Com PT100 -28.9 to
after cooler temp PLC 104 Deg C
9 Water inlet to after AI TE004 Com PT100 -28.9 to
cooler temp PLC 104 Deg C
10 After cooler outlet AI TE003 Com PT100 -28.9 to
air temp PLC 104 Deg C
11 After cooler inlet air AI TE002 Com PT100 -28.9 to
temp PLC 104 Deg C
12 Final inter stage AI TE002 CICB PT100 -28.9 to
discharge temp. (IAT) PLC 104 Deg C
13 Lube oil inlet temp. AI TE001 CICB PT100 -28.9 to
PLC 104 Deg C
14 Comp. 1 stage AI PT -004 Com 4-20 0- 14
 Discharge pressure PLC ma kg/cm2
15 Comp. 2nd stage AI PT -005 4-20 0- 14
Discharge pressure ma kg/cm2
16 System Air Pressure AI PT-003 CICB 4-20 0- 15
PLC ma kg/cm2
15 Lube oil inlet AI PT-001 CICB 4-20 0- 07
Pressure PLC ma kg/cm2
16 Comp.disc.Pressure AI PT-002 CICB 4-20 0- 15
PLC ma kg/cm2
17 Seal air pressure DI PS-001 CICB Dry -
PLC contact
18 Air filter Diff. AI PDT-001 Com 4-20 0-635
Pressure PLC ma mmWC
19 Low speed pinion AI VT-001 CICB 4-20 0- 102
vibration PLC ma
20 Low speed pinion AI VT-002 CICB 4-20 0- 102
vibration PLC ma
21 Inlet guide vane AO CICB PV 4-20 0.2- 1
Transducer PLC 001 ma kg/cm2
22 Unloading valve AO CICB PV 4-20 0.2- 1
Transducer PLC 002 ma kg/cm2
23 Motor AMPs AI CICB IT-001 4-20 0- 100
Transducer PLC ma AMPs
24 Main Drive Status DI SWGR CICB Dry
PLC contact
25 EM STOP PB DI UMP CICB Dry
PLC contact
26 HORN DO CICB UMP Dry
PLC contact
27 Alarm light DO CICB UMP Dry
PLC contact
28 Trip light DO CICB UMP Dry
PLC contact
29 Main Drive Start DO CICB SWGR Dry
command PLC contact
30 Main Drive Stop DO CICB SWGR Dry
command PLC contact
31 Common Alarm DO CICB Com Dry
Contact PLC PLC contact
32 Common Trip DO CICB Com Dry
Contact PLC PLC contact
33 Air discharge flow AI FT Com 4-20ma 0-7kg/cm2
PLC diff. press

Note : UMP - Unit Panel ( Local Panel)

 Following Indication /Alarm will be available in the common PLC :

1) Differential Pressure across suction filter high at 20mmWC

2) Air pressure before inlet of 2nd stage of compressor high / low at 3.94 / 1.94
kg/cm2

3) Air pressure before inlet of 3rd stage of compressor high /low at 5.98/3.98
kg/cm2

4) Air pressure Discharge air pressure of Compressor high at 9.6/6.4 kg/cm2

5) Water inlet pressure low for compressor at 1.75 kg/cm2

6) Common discharge water header pressure low at as per site requirement

7) Discharged air flow low

8) Discharge air temperature high
9) Air temp before entering to moist .separator high

10) Outlet temperature of water from after cooler high

11) Motor Stator winding Temperature high at 120 deg C

12) Temperature for Motor NDE bearing high at 90 deg C

13) Temperature for Motor NDE bearing high at 90 deg C

14) Outlet temperature of water from oil cooler low at 35 degC

15) Inlet water temperature to After Cooler high at 36 deg C

16) Inlet air Temperature to After Cooler of Compressor high at 115 deg C
17) Final inter stage air discharge temp. High at 52..12 deg C
18) Lube oil inlet temp. High/low at 57.22/21.22 deg C

19) Outlet water temp. High at 48 deg C

20) Inlet water temp High at 35 deg C

21)Low speed pinion Vibration of Compressor high at 22.86 m

22) High speed pinion vibration of Compressor high at 22.86 m

23) Current Transducer high for Motor of Compressor at 98.8

24) Seal air pressure of compressor low at 0.14 kg/cm2

25) Vibration Monitor for Motor (X & Y ) at DE direction high at 12 mm/sec

 Following Trip signal will be available in PLC :

1) Final inter stage discharge air temperature high high at 55 deg C

2) Lube oil inlet temperature for compressor high high at 60 deg C
3) Lube oil inlet pressure of compressor low low at 1.055 kg/cm2
4) Low speed pinion vibration high high at 30.48 m
5) High speed pinion vibration for compressor high high at 30.48 m
6) Discharged air temperature high high at 52 deg C

7) Motor Driving end bearing temperature high high at 100 deg C

8) Motor Non Driving end bearing temperature high high at 100 deg C

9) Vibration Monitor of Motor : no tripping till 2 min after initial start.

at 14 mm/sec

10) Motor Ampere of compressor low low at 18A

11) Average Temperature of Stator winding of Motor is high- high ,beyond 122
deg C.

12) Discharge valve of Compressor line does not open within certain time
( approx 1 min ) of switching on the compressor .

13) Differential pressure of air across suction filter high - high

As soon as the compressor trips, discharge valve will be closed.,

after Certain time by using timer in logic , water supply valve
will be closed.

Major Preparation for restart after an extended shut down

1) Disconnect nitrogen system and re-installed seal relief valve.

2) Re-install oil mist elimination.
3) Reconnect water piping and inter cooler drain piping. Remove plugs from the inter
cooler drains.
4) Remove desiccant and re-connect inlet and discharge lines.
5) As a precaution, remove casing drain and check for any liquid.
6) Re-grease coupling (if required), change oil filters and check oil levels of compressor.
Stroke the inlet and unloading control valves (open & closed) assure proper operation.
7) Take an oil sample and check the content. Change oil if necessary.
8) Guide lines on the preparation for service of the motor provided in the manual.
 SYSTEM OPERATION AND CONTROL PHILOSOPHY
(FOR HOC AIR DRYER UNIT )
Ref : Approved P & I DIAGRAM FOR AIR DRYER UNIT (HOC) CAS-1, Drg/Doc
no-NMDC/BS/011/04/16/DE/0034

BOTH HOC AIR DRYER UNITS COMPRISE OF THE FOLLOWING COMPONENTS.

1. ELECTRIC HEATER-1 NO.

2. INTER COOLER WITH MOISTURE SEPARATOR-1 NO.

3. ACTIVATED CARBON FILTERS- 2 NO. (1W + 1S)

4. PRE FILTERS-2 NO. (1W + 1S)

5. ADSORBER TOWERS- 2 NO. (1 TOWER UNDER DRYING & OTHER TOWER

UNDER REGENERATION CYCLE)

6. AFTER COOLER-1 NO.

7. AFTER FILTERS-2 NO. (1W + 1S)

THE SYSTEM COMPROMISES OF ABOVE SL NO-1 TO SL NO-7 AND A POWER AND

CONTROL PANEL OF FOLLOWING DETAILS.

THE 415V AC POWER SUPPLY (THE SOURCE TO BE DECIDED BY BSL) WILL BE

PROVIDED TO OUR ELECTRICAL PANEL. THE 3-PHASE R,Y,B POWER SUPPLY WILL

BE TERMINATED ON TERMINAL U,V,W AND THROUGH MCCB. 415VAC POWER

SUPPLY WILL BE PROVIDED TO ELECTRIC HEATER THROUGH MCCB AND

COTRACTOR ON TERMIAL U1,V1,W1. 220 VAC POWER SUPPLY (THE SOURCE TO BE

DECIDED BY BSL) PROVIDED FOR PANEL LIGHT AND EXHAUST FAN.THE

FOLLOWING INTERLOCKS HAVE BEEN PROVIDED IN HOC AIR DRYER UNIT.

 1. ANALOGUE INPUTS ARE AVAILABLE IN HOC AIR DRYER 1 (PT01,PT02,DPM01)

AND ALSO IN HOC AIR DRYER 2 (PT03,PT04,DPM02).

PROVISION OF ALARM FOR FOLLOWING ABNORMAL CONDITIONS :-

1. AIR INLET TEMPERATURE LOW IN HOC AIR DRYER 1. ( TE01 85 DEG C )

2. HEATER TEMPERATURE HIGH IN HOC AIR DRYER 1. ( TE02 160 DEG C )

3. INTER COOLER INLET TEMPERATURE HIGH IN HOC AIR DRYER 1. ( TE03

160 DEG C )

4. INTER COOLER OUTLET TEMPERATURE HIGH IN HOC AIR DRYER 1. ( TE04

40 DEG C )

5. AFTER COOLER INLET TEMPERATURE HIGH IN HOC AIR DRYER 1. ( TE05

160 DEG C )

6. AFTER COOLER OUTLET TEMPERATURE HIGH IN HOC AIR DRYER 1. ( TE06

40 DEG C )

7. AIR OUTLET TEMPERATURE HIGH IN HOC AIR DRYER 1. ( TE07 40 DEG C )

8. DEW POIT HIGH IN HOC AIR DRYER 1. ( DPM01 MINUS 39 DEG C )

THE AIR DRYER WILL START, THE PLC OUTOUTS FROM Q-1 TO Q-7 ARE TAKEN

FOR THE OPERATION OF THE CHANGE OVER VALVES AND ELECTRIC HEATER AS

PER PROGRAMMED CYCLE TIMES MENTIONED IN LOGIC DIAGRAM.

THE LOGIC FED IN THE PLC WILL BE LIKE THAT,OUTPUTS FROM Q-1 TO Q-7 WILL

ALSO ON AND THE CHANGEOVER VALVE WILL ON AND ELECTRIC HEATER WILL ON

OR OFF ACCORDING TO HEATER TEMPERATURE SET POINT AND HEATER MANUAL

SWITCH ON.
DEW POINT METER OF MITCHELL UK SESOR AND RADIX MAKE HAS BEEN

PROVIDED FOR THE MONITORING OF MOISTURE CONTENT IN THE PRODUCT DRY

AIR.

INTERLOCK DETAILS

WHEN THE HEATER TEMPERATURE GOES BEYOND THE SET POINT OF THE

TEMPERATURE COTROLLER I.E. 160 DEG C, THE ELECTRIC HEATER WILL BE

SWITCHED OFF AND IT WILL BE SWITCHED ON AT 150 DEG C,AVAILBILITY OF PLC

OUTPUT Q-5 AND MANUAL SWITCH SW-3 SHOULD BE ON.

PROCESS DESCRIPTION:

HOC AIR DRYER ARE BASED ON WELL PROVEN ADSORPTION

TECHNOLOGY USING ACTIVATED ALUMINA IS AN ADSORBENT HAVING

AFFINITY OF ADSORPTION OF MOISTURE FROM COMPRESSED AIR.

THEREFORE, THE DRY AIR IS RECOVERED TO A HIGH DEGREE WHILST

ALMOST ALL THE MOISTURE IS ADSORBED.

HEATING CYCLE-

THIS COMPRESSED AIR AT 9 Kg/cmg IS PASSED THROUGH AN ELECTRIC

HEATER WHICH IS ON AND ENTERS ADSORBER-1 TOWER THROUGH TOP

4-WAY VALVE, HEATED UP ACTIVATED ALUMINA BED TO 160 DEG C MAX.

AND COOLED DOWN AT INTERCOOLER,MOISTURE WILL BE REMOVED AT

MOISTURE SEPARATOR, THEN PASSED THROUGH ACTIVATED CARBON

FILTER FOR REMOVAL OF OIL PARTICLES IF ANY. IT WILL THEN BE

PASSED THROUGH A PREFILTER FOR REMOVAL OF DUST PARTICLES

UPTO 3 MICRON. NOW THIS COMPRESSED AIR WILL BE FED TO

ADSORBER-2 FROM BOTTOM 4-WAY VALVE FOR REMOVAL OF MOISTURE

AND COOLED DOWN THROUGH AFTER COOLER,THEN PASSED THROUGH

AFTER FILTER FOR REMOVAL OF DUST PARTICLE UPTO 1 MICRON.DEW

POINT OF DRY AIR MEASURED AT THIS POINT WHICH WOULD BE MINUS 40

DEG C.

COOLING CYCLE-

COMPRESSED AIR AT 9 KG/CM2G CONTINUES PASSING THROUGH THE

ELECTRIC HEATER (WHICH WILL NOW BE IN OFF MODE) AND ENTERS

ADSORER-2 THROUGH BOTH 3-WAY VALVE AND COOLED DOWN AT

INTERCOOLER, MOISTURE WILL BE REMOVED AT MOISTURE SEPARATOR,

THEN PASSED THROUGH ACTIVATED CARBON FILTER FOR REMOVAL OF

OIL PARTICLES IF ANY.THEN IT WILL BE PASSED THROUGH PREFILTER

FOR REMOVAL OF DUST PARTICLES UPTO 3 MICRON. NOW COMPRESSED

AIR WILL BE FED TO ADSORBER-2 FROM BOTTOM 4-WAY VALVE FOR

REMOVAL OF VAPOUR MOISTURE,THE DRY AIR FROM TOP OF ADSORER-2

WILL BE PASSED THROUGH ADSORBER-1 BOTTOM TO TOP FOR COOLING

OF ACTIVATED ALUMINA BED THROUGH 2-WAY VALVE AND BOTTOM 4-

WAY VALVE.THIS DRY AIR WILL COOL DOWN ACTIVATED ALUMINA AT

ADSORER-1 AND THE OUTGOING HOT DRIED AIR WILL BE COOLED DOWN

THROUGH AFTER COOLER AND PASSED THROUGH AFTER FILTER FOR

REMOVAL OF DUST PARTCLE UPTO 1 MICRON. DEW POINT OF DRIED AIR

AT THIS POINT WHICH WOULD BE MINUS 40 DEG C..

THE ADSORBERS KEEP SWITCHING AUTOMATICALLY AND DRY AIR WITH

DEW POINT OF MINUS 40 DEG C IS CONTINUOUSLY PRODUCED. THE

ADSORPTION PROCESS IS RUN WITH FIXED CYCLE TIMES. TOTAL CYCLE

TIME FOR ONE COMPLETE CYCLE OF ADSORPTION AND REGENERATION

IS : 8 HOURS (4 HOURS + 4 HOURS).