A Initial version J. Trigo P. Iturri V.

Recuenco 05-06-2015
DIBUJO / CONTROL / APROB. /
REV. DESCRIPCIÓN FECHA / DATE
DRAWN CHKD APPD

PROPIETARIO / EMPLOYER

CONTRATISTA/ CONTRACTORS FECHA / NOME /

DATE NAME
DIB. / DRAWN
CONTRL / CHKD
APROB. /APPD

QUITARACSA I

MANUAL DE OPERACIÓN Y MANTENIMIENTO PARA EL

SISTEMA DE AIRE COMPRIMIDO DE SERVICIO

OPERATION & MAINTENANCE MANUAL FOR THE

SERVICE COMPRESSED AIR SYSTEM
Rev. No.

Rainpower documento no. A

Rev. No. Página /

Sheet
ENERSUR DOCUMENTO NO. QUIT1-IEM-2318 A 1 of 12
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OPERATION & MAINTENANCE MANUAL
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SERVICE COMPRESSED AIR SYSTEM Sign. dato / Date
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Ordre nr. / Order No. Kunde / Customer Prosj. dok. nr. / Proj. Doc. No.
ENERSUR QUIT1-IEM-2318
Indeks / Index Anlegg / Site Filnavn / File Name
A QUITARACSA 1 QUIT1-IEM-2318-RevA

INDICE DE CONTENIDO / TABLE OF CONTENTS

1 INTRODUCTION
1.1 PURPOSE
1.2 SCOPE OF WORK
1.3 LIMITS
1.4 REFERENCES
2 GENERAL REQUIREMENTS
2.1 TECHNICAL REQUIREMENTS
2.2 ROLES AND RESPONSIBILITIES
2.3 HSE REQUIREMENTS
2.4 SYSTEM DESCRIPTION, SETTINGS, ALARMS AND SHUTDOWN
3 OPERATION
3.1 OPERATION CONTROL MODE
3.2 LEAD/LAG OPERATION CONFIGURATION
3.3 START/STOP COMMANDS
3.4 GUIDELINES FOR EMERGENCY OPERATIONS
4 MAINTENANCE
4.1 INSPECTION SCHEDULE
4.2 SYSTEM INSPECTION
4.3 AIR COMPRESSOR INSPECTION
4.4 AIR RECEIVER INSPECTION
4.5 PIPING AND VALVES INSPECTION
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1 INTRODUCTION
1.1 Purpose
This document establishes the guidelines to develop the Operation and Maintenance tasks and procedures, it is
applicable for the Service Compressed Air System of Quitaracsa I hydroelectric station.

This document is in line and is not the intended to repeat, nor supersede information and guidelines which are detailed
in the individual package manual, General Technical Specification (GTS) 6C120060-ES-05-008 and the Particular
Technical Specification (PTS) 6C120060-ES-05-0009. In case of any contradiction, the document that contains more
restrictive requirements shall prevail.

1.2 Scope of Work

The scope of work under this particular technical manual includes the Operation and Maintenance procedures for the
Service Compressed Air System, which involves the following scope:

General Requirements
Operation
Maintenance

The O&M procedure defines the roles and responsibilities of the operation staff and the required quality assurance
documentation that will be needed.

1.3 Limits
As shown as in the flow diagram and piping arrangement, the service compressed air system supplies specified quality
and condition air for the powerhouse and transformer cavern use. It drives the braking system for the generator,
powers pneumatic actuators and supports general maintenance activities.

The system flow diagram QUIT1-DEM-1426 describes and limits the compressed air system network, air receivers
and the installation of the compressor units.

1.4 References
This manual considers the follow documents as references:

QUIT1-DEM-1426, Service Compressed Air System Flow Diagram (2 pages)

QUIT1-DEM-1435, Service Compressed Air System Piping Arrangement (8 pages)
QUIT1-DEM-1504, Service Compressed Air System Isometric Diagram (14 pages)
QUIT1-IEM-2349, Service Compressed Air System Description
QUIT1-IEM-2454, Compressed Air System - Calculation Brief
QUIT1-IEM-2309, Service Compressed Air System, Test & Commissioning Manual
 Dokumenttype / Document
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QUITARACSA 1 E & M CONSORTIUM Dok. nr. / Doc. No. Rev.
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OPERATION & MAINTENANCE MANUAL
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SERVICE COMPRESSED AIR SYSTEM Sign. dato / Date
05-06-2015
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2 GENERAL REQUIREMENTS
2.1 Technical Requirements
Documents to prove the factory acceptance test, the as-built drawings, the site acceptance test including pre-
operational and operational test. Installation protocols, records and logs properly documented and kept up to date.

Package manufacturer Operation & Maintenance Manual and Spare Parts Manual

Air quality delivered according to ISO 8573-1 specification (0.1 m particles, water content 3 mg/m3, oil content 0.01
mg/m3).

2.2 Roles and Responsibilities

Once the equipment and system are ready to be operated, the Owner shall prepare a schedule and table (list or check
list) identifying and briefly describing the various tasks to develop and nominate the responsible for developing the
tasks, the competences needed, the tools, materials, spare parts and instrumentation required, the deliverables and the
HES requirements for the operation and maintenance of the system.

2.3 HSE Requirements

The HSE and safety procedures should comply with Owner codes, GTS and PTS, it minimum includes the quality
control and safety procedures, proper personal protective equipment, lock-out /tag-out procedures and other Owner
safety requirements.

The safety requirements in the air compressor manual must be taking into account during any cool start.

The main valves of compressor units, and the inlet and outlet valves of air receivers must be kept in open position.

2.4 System Description, settings, alarms and Shutdown

As described in document QUIT1-IEM-2349, two rotary screw type compressors are installed, in a lead/lag
configuration and supporting the scheduled maintenance program.
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The packages include electric motors and starters, air intake filters, oil separators, discharge water traps, refrigeration
air dryers with condensate line forwarded to drainage pit and the supervisory and control modules for monitoring and
alarm detection through a complete set of instruments associated to electric and mechanical operation parameters;
these units will report to the main distributed control system.

Air receiver or accumulator tanks, ASME standard code compliant, should be fitted with all the required instruments,
blow off safety valve, automatic condensate bleed, tap off points for instruments and flanged main line connections.
Main supply line should be fitted with all the instruments required, supply valves should be installed with standard
size quick couplings at all consumer points.

Each compressor unit will be equipped with an onboard LCP with automatic control (independent from SCADA). The
LCP control may be by relay logic or PLC. Each compressor unit will be fed from the Common Services MCC. In
normal operating conditions (mainly during first charging of air accumulator tanks), both compressors may operate
simultaneously. Each compressor unit will have different start/stop pressure settings in automatic control mode of
operation (own pressure switches). In emergency conditions when normal AC power is lost, the Diesel Generator
(DG) will not supply any compressor. The control power for each compressor unit must be tapped off from the power
feeder in the LCP. The SCADA system will only visualize (supervise) the status of the compressor units and no
command (control) is foreseen (except to close/open the contactor in MCC box).

Any compressor unit may be started/stopped at any time from its LCP by means of pushbuttons or touch screen. In
normal operating conditions both compressor units should be set up in standby mode and the running/stop commands
will be managed in each LCP by relay logic or PLC. Each compressor unit will have its own start/stop pressure
settings (different settings for each compressor). The lead compressor will have its start pressure setting adjusted
above (at a higher value than) the lag compressor (the lead unit starts first if available). In case the lead compressor is
running and the pressure lowers down and reaches the start pressure of the lag compressor, then the lag compressor
also starts. The lead compressor will have its stop pressure setting adjusted below (at a lower value than) the lag
compressor (the lead unit stops first). The lead and lag compressors may be exchanged by re-adjusting their start/stop
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pressure settings (e.g. based on operation time counters). During emergency conditions when the Diesel Generator is
running and connected to the Common Services MCC the SCADA system will open the contactors in the MCC box
for both compressor units. However, if needed during Diesel Generator operation, it should be possible to close the
contactor in the MCC box for one compressor unit, in order to recharge any air receiver. This operation should be
done through a soft button in the operator workstation only.

Table 2.-1 presents the main data of air compressor units and air receivers, and the Table 2-2 shows the air compressor
and receiver settings and alarms.

Table 2-1: Air compressor and receiver data

SERVICE AIR COMPRESSOR

Quantity 2
Type Oil injected rotary screw compressor, air cooled, single stage, driven
by electric motor and belt, enclosed in sound insulating bodywork,
floor mounted
Discharge 1.7 m3/min
Max./nominal pressure 9.1 / 8.6 bar
Rated motor power 11 kW / 15 HP
Oil capacity 3.2 l
Sound level 6.8 dB (A)
AIR RECEIVERS Common Air Receiver Unit Air Receiver
Quantity 1 2
Type vertical vertical
Max./nominal pressure 9.1 / 8.6 bar 9.1 / 8.6 bar
Capacity 2.0 m 3 0.5 m3
Code compliant ASME, CECT or DIN standard code compliant

Table 2-2: Air compressor settings and alarms

Pressure (bar) Pressure switches

Start-up of lead compressor 6.8 Compressor pressure switch
Start-up of lag compressor 6.5 Compressor pressure switch
Stop of compressors 8.0 Compressor pressure switch
Main air receiver low pressure alarm 6.0 QAB10-CP102
Main air receiver high pressure alarm 8.5 QAB10-CP101
Unit 1 air receiver low pressure alarm 5.0 QAB10-CP112
Unit 1 air receiver high pressure alarm 8.5 QAB10-CP111
Unit 2 air receiver low pressure alarm 5.0 QAB10-CP122
Unit 2 air receiver high pressure alarm 8.5 QAB10-CP121
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3 OPERATION
3.1 Operation Control Mode
The standby mode is available in both compressor units, automatically set from the LCP by touching the start button;
during normal operating condition both compressor units should be kept in standby mode and the run (load)/stop
commands will be managed in each LCP by input signals from pressure switches (start/stop pressure).

3.2 Lead/Lag operation configuration

The operation band, lead or lag configuration, shall be set on LCP by means of tuning software or adjusting the
pressure switches.

In concordance with scheduled maintenance program the compressors units shall be configured between lead and lag
condition.

3.3 Start/Stop commands

In concordance with the local service condition (normal or emergency situation) the MCC will feed or not the
compressors units, when local service failed the air compressed goes to unavailable condition opening the breaker at
MCC, once the local service returns to normal situation and the MCC will close the breaker (triggered from SCADA)
and energize the compressor units (main power led turn ON). Figure 3-1 presents a view of the LCP with device
designations.

Initial start is required from LCP by means of push button “on”; after internal unload and load fresh air process the
compressor will be available (compressor operating led turn ON) to supply compressed air to the network. Figure 3-2
presents the led designations.

As long as the pressure into the network is below the setting, the compressor will run fully loaded up to reaching the
maximum limit and the pressure switch detects it, then the compressor unit will stop and return to standby condition.

Any consumer points (braking system for both units, service air outlets, etc.) will be available with compressed air at
any moment.

During normal operation, the air receiver bypass line will be kept closed and it shall be open during receiver
inspection. The network purge points and receiver drainage are of the automatic purge system type. All air service
outlets include quick couplings.

In order to monitoring the service air compressed system, the SCADA will receive low and high pressure alarms from
the air receivers and status (available, running, in manual or automatic) from compressor units.

In order to stop any compressor unit, the button “OFF” needs to be touched from its LCP, after internal process the
unit turns off.
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Figure 3-1: LCP view with device designations

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Figure 3-2: LED designations

3.4 Guidelines for emergency operations

In case of emergency situation at any of the air compressor units (over pressure, oil leak, air leak, high vibration,
noise, etc,), those must be shut down by pushing the emergency button in the LCP. Afterwards, the incident must be
evaluated, the power supply must be removed by opening the AC breaker at the LCP and/or at the MCC. The air
compressor unit should not be run til solving the emergency situation.

In case of emergency situation at any air receiver (over pressure, safety valve stack, drainage defect, air leak, vessel
defect, etc.) it must be isolated by closing the inlet and outlet main valves, then bypass valve shall be opened to keep
the air flow to consumers. The pressure at the receiver should be released bygradually opening some tap off points or
ports (drainage, forcing safety valve, pressure switch ports, etc.) and decreasing the pressure. The problem must be
evaluated and the defect repaired. In order to restore into operation the air receiver after reparation, it must be flushed,
pressure tested and leak tested. The intake valve shall be gradually open up to reaching a pressure balance with the
network and then the outlet valve shall be gradually open. Finally, the bypass valve shall be gradually closed.

In case of emergency situation in any pipe section, it must be isolated by closing the nearest upstream and downstream
valves. The section shall be depressurized and the defect solved. Before restoring the section into operation, it shall be
flushed, pressure tested and leak tested. Afterwards the upstream valve should be opened until the pipe pressure is
balanced with the network pressure, and finally the downstream valve shall be opned

4 MAINTENANCE
4.1 Inspection Schedule
The following matrix presents the Inspection Schedule for the Service Compressed Air System. It takes into account
the O&M reccomendations from the compressor manufacturer, and the recommendations for testing and
commissioning from the IEEE 1248 standard.
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Service Compressed Air System Periods / elapsed time

EQUIPMENT/SYSTEM Daily Monthly Yearly 500h 1K 2K 4K
System routine inspection x
System detailed inspection x
Air compressor routine inspection x
Air compressor middle inspection x
Air compressor detailed inspection x
Air compressor test & commissioning x
Air receiver routine inspection x
Air receiver detailed inspection x
Piping & valves routine inspection x
Piping & valves detailed inspection x

4.2 System inspection

Routine Inspection Check Remark (special requirements)
The elements shall be free of visual defects and collisions
(corrosion, cracks, bends, shocks, blows, dents, scratches,
irregular welds, etc). The elements shall be tight and
fastened. Include air compressor, air receiver, piping and
valves.
Inspect automatic drainers, if necessary purge air
receivers
Compare local and remote pressure values from air
compressor and air receivers.
Functional checks: noise, vibration, start/stop limits

Detailed Inspection Check Remark (special requirements)

Leak testing NDT, using shock pulse or sniffer
or water soap
Pressure testing Hydrostatic pressure test

4.3 Air compressor inspection

Routine Inspection Check Remark (special requirements)
Check the oil level
Inspect operation of the condensate trap, clean filter
Inspect air filter, clean if necessary Stop condition, main valve close,
electric power off
Circuitry checkout, (clean & adjust control panel and Stop condition, main valve close,
power cables) electric power off
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Middle Inspection Check Remark (special requirements)

Check the tension and the condition of the belts, adjust if Stop condition, main valve close,
necessary electric power off
Inspect the oil cooler, clean if necessary
Inspect air cooler, clean if necessary
Inspect the condenser, clean if necessary

Detailed Inspection Check Remark (special requirements)

Change the oil and the oil filter Stop condition, main valve close,
Change the air filter electric power off. Roto inject oil is
recommended
Calibration of instrumentation (gauge pressure, pressure
switch, temperature switch)
Test and commissioning Check Remark (special requirements)
Perform the task detailed during Air compressor test and Stop condition, main valve close,
commissioning electric power off.

4.4 Air receiver Inspection

Routine Inspection Check Remark (special requirements)
Calibration of pressure switches Switch Isolating valve close,
pressure relieve
Check functionality of over pressure valve
Check functionality of drain device

Detail Inspection Check Remark (special requirements)

Hydrostatic test Inlet and oulet valve isolated,
Thickness and Corrosion test (Ultra sound test) receiver pressure relieve
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4.5 Piping and valves Inspection

Routine Inspection Check Remark (special requirements)
Valves functional check
Paint condition inspection
Quick coupling functional check

Detail Inspection Check Remark (special requirements)

Hydrostatic test Inlet and oulet valve isolated,
receiver pressure relieve