CO2 COMPRESSOR

11/21 K-01
Type : 2MCL527 + GB + 2BCL306a
Capacity : 27282 NM3/hr

Suction Conditions
Pressure : 1.6 kg/cm2 abs
Temp : 40°C
Molecular wt (dry) : 43.58

Discharge Conditions
Pressure : 160 kg/cm2 abs
Temp : 108°C

Normal Speed (MCL / BCL) 8029 / 11642 RPM

Rated Speed 8505 / 12332
First Critical Speed 3200 / 6090

At normal operating conditions

Stage 1 2 3 4
Suction Temp °C 40 44 45 50
Suction pr kg/cm2 1.6 6.2 24.1 87.8
Discharge pr kg/cm2 6.4 24.7 88.6 160
Discharge Temp °C 187 194 190 108

The centrifugal compressors are designated by a series of capital letters and

numbers. The capital letters describe the casing features. MCL indicates a
compressor with the casing in two halves horizontally split. BCL indicates a
compressor with the casing vertically split at end cover locations. The
numbers after the letters, describe the impeller nominal diameter in
millimeters and the impeller number.

FUNCTIONAL DESCRIPTION

The gas is compressed from 0.66 kg/cm2 to a final pressure of 160 kg/cm2 in
four compression stages by two centrifugal compressors driven by a single
steam turbine driver (EHNK 32/36/64-3)
The saturated wet gas from BL, before entering the compressor passes
through suction knockout drum MV 09.The condensate from the gas is
separated and drained through LV 61. The KO drum is provided with a very
high level switch LSXH 62 A/B/C that will trip the machine if actuated.
Three pressure switches PSXL 601A/B/C are provided down stream of the KO
drum on CO2 line, which will actuate if the suction pressure drops below the

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specified limit. A voting logic two out of three will trip the machine. Also near
the first stage suction inlet on suction pipe a liquid trap is provided.

Inter-stage coolers are provided for 1st, 2nd and 3rd stages to maintain the
gas at proper suction temperatures. After each cooler the gas flows through
inter-stage condensate separators.

The condensate formed during cooling in the inter-stage coolers is separated

and drained through level control valves (LIC-605, LIC-608 LIC- 611) All the
three separators are fitted with high level switches (LSXH 606 / 609 / 612) to
trip the machine on very high separators levels.

To avoid over cooling, the cooling water flow from the third stage intercooler
is controlled by a temperature controller TIC-619 that controls the temp of
4th stage suction. 4th stage suction temp is maintained at 50°C (The critical
properties of CO2 are Tc = 31.1°C; Pc 73.2 kg/cm2). Anti-surge line with
surge control valve FV602 bypasses the 4th stage discharge gas to first stage
suction. Anti-surge line u/s and d/s are steam jacketed.

Another bypass line with HV603 bypasses the third stage suction gas to the
first stage suction (Inter-stage spill back)

A vent line with inter-stage vent valve HV601 vents out gas from 3rd stage
suction to atmosphere. On the final discharge a vent valve PV03 maintains
the discharge pressure by venting the gas to atm.

Solenoid valves causes the anti-surge valve FV602 and inter-stage vent valve
HV601 open rapidly in response to the trip system.

Safety valves are provided in the discharge of each stage to prevent the
downstream from over pressurization.

SAFETY VALVES SET PRESSURES

First stage discharge PSV : 7 .5 kg/cm2

Second stage discharge PSV : 30 kg/cm2
Third stage discharge PSV : 105 kg/cm2
Final stage discharge PSV : 176.5 kg/cm2

SHAFT SEALING

In order to minimize the gas losses from the compressor, the shaft ends are
provided with shaft sealing systems.
On MCL, we have labyrinth seals on both 1st and 2nd suction ends. The first
leak off gas from the 2nd suction labyrinth is balanced with the 1st suction end
and second leak from both ends are connected to vent.

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On BCL, we have labyrinth seal with mechanical gas film type seals (dry gas
seals) on 3rd and 4th suction ends.
On 3rd suction end one hot gas injection for labyrinth seal and one seal gas
injection for dry gas seal are provided. A positive pressure difference across
hot gas injection and 3rd suction pressure, seal gas injection and hot gas
injection pressure is to be maintained. The leakage from mechanical seal is
vented to atmosphere. In the event of excessive leakage, pressure increases
and the pressure switch PSH632 will activate an alarm.

On 4th suction end labyrinths, after the hot gas injection, the leakage through
the balance drum is balanced with the 2nd discharge gas line. A positive
pressure difference across seal gas injection and balance leg is maintained.
The leakage from the mech. seal is vented to atmosphere and pressure
switch PSH633 will activate an alarm on excessive leakage.

The seal gas is from the 3rd discharge and filtered through 5-micron gas filter
and its flow is regulated through flow orifices.

TK 01 TURBINE

Normal power output 8400 KW

Maximum power output 8400 KW
Speed - normal 8029 rpm
Speed Min/ Max 7290 / 8505 rpm
First critical speed 3300 rpm
Steam pressure 104 kg/cm2
Temperature 504°C
Exhaust pressure 0.12 a
Extraction pressure 26.5 kg/cm2
HP Wheel chamber pressure 77 kg/cm2
Extraction steam temp 342°C
Turbine to governor speed 8.5 / 1.0
Ratio

FUNCTIONAL DESCRIPTION

Steam flow through the turbine is in the axial direction, before the turbine
casing is the emergency stop valve, the function of which is to shut off the
total steam supply from KS header to the turbine in the shortest possible
time. The live steam flows through the body of emergency stop valve to the
valve chest of the HP control valves. These control valves are actuated by a
lift bar and are so designed that their point of opening is determined by the
lift bar, which is raised and lowered by the relay cylinder through a system of
levers. The relay cylinder receives its control pulses from the hydraulic
governor. The hydraulic governing system is designed to control the speed of
turbo compressor. Simultaneously the extraction steam pressure in
extraction line is also maintained by the governing system. Additionally,
turbine governing system incorporates protective device to protect the

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turbine during adverse operating conditions, such as over speed, rotor axial
/radial shift and low control oil pressure.

The HP control valves admit the live steam to the nozzle groups of the single
row regulating stage. Turbines designed for regulating the steam flow
through nozzle groups are provided with regulating stage, which takes the
form of impulse blades permitting partial admission. After the part of energy
of the live steam has been utilized in the regulating stage which is of single
row impulse type, the steam is passed to drum blade for doing further work
and finally to LP blading section. In accordance with available heat drop,
work is done and finally the expanded steam is passed out through exhaust
hood to condenser.

STEAM EXTRACTION
For this type of turbine (partial condensation and extraction type), part of
steam is bled from the turbine at the extraction branch behind the wheel
blading and fed to the extraction steam. The control member here is the
extraction stop valve (QCNRV), which operates and is tripped out in the same
manner as the HP emergency stop valve. The purpose of the extraction stop
valve is to separate the turbine from the extraction steam on trip out in order
to prevent the turbine from over speeding due to reverse flow of medium
pressure steam when the machine is shut down.
The pressure at the extraction branch is controlled by the LP control valve.
The steam rate through the HP section is matched to the extraction rate in
such a way that the pressure at the extraction branch is kept constant within
the design data. Governing is by means of extraction pressure controller. The
LP section consists of a further length of drum blading.

TURBINE CASING

The turbine casing is split axially. It is mounted on and aligned at the front
end bearing pedestal, the front bearing pedestal serves both for supporting
the turbine shaft by a journal bearing and a thrust bearing and for strutting
the turbine casing by means of the casing side brackets and centering
guides. Particular importance is attached to proper alignment, because the
turbine shaft and the outer shell are supported independently of each other
in the bearing pedestals. Whilst the position of the shaft is fixed by the
bearings, the outer support of the casing must be so designed as to allow
thermal expansion at the front end-bearing pedestal as well. The vertical
position of the casing is governed by the bracket supports, whilst the small
clearance under the heads of the bolts (used to bolt down the casing side
brackets to the bearing pedestal) permits transverse thermal expansion of
the casing relative to the bearing pedestal. The upper and lower casing
guides fix the center position of the casing in the horizontal plane through
the axis. They are designed to permit the casing to expand freely upwards
and downwards. The rear end bearing pedestal is cast integral with the
exhaust branch which is fixed in the axial direction relative to the bed plate,
but which can freely expand radially in accordance with thermal expansion.

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Since the front end casing centering guide does not allow any axial
displacement of the casing relative to the bearing pedestal, the front end
bearing pedestal is moved towards the front end on thermal expansion of the
casing. The oil piping is therefore installed with sufficient flexibility.
Transverse displacement of the front end-bearing pedestal is precluded by an
axial feather key. Likewise, transverse displacement of the exhaust branch
relative to the bedplate is prevented by a centering guide. The exhaust
branch is flanged to the turbine casing.

The turbine shaft is machined from an alloy steel forging. The journal
bearings supporting the turbine shaft are arranged in two bearing pedestals.
The front end bearing pedestal also houses the thrust bearing which locates
the turbine shaft axially and takes up the axial forces.

The blading consists of an impulse stage, which permits partial admission

and consequent efficient governing, and of no. of reaction stages in the LP
drum part. The radial and axial clearances are liberally designed with a view
to combining high operational safety with an optimum utilization of available
heat drop.

The function of balance piston is to compensate the axial thrust to the

highest possible degrees. Since the axial thrust varies with the load, the
residual thrust is taken up by the thrust bearing mentioned above. At the
same time, the balance piston seals of the high pressure in the wheel
chamber against the pressure prevailing before the shaft glands.

The shaft glands seal off the casing at the points where the shaft passes
through .The sealing elements consists of packing strips in the gland rings
and of grooves machined in the shaft.

The packing gland shell (gland ring) carries on the periphery of its inner
surface caulked in sealing strips which together with the edges of
corresponding sealing strips or comb like projections on the rotor shaft, are
forming a seal without mechanical contact between the moving rotor and
stationary turbine casing. Such a series connection of consecutive sealing
edges constitutes a seal of labyrinth type which acts on the principle of
transforming potential energy (pressure) into kinetic energy (velocity of flow)
and subsequently dissipating the kinetic energy by the formation of eddies.
With sealing devices, which have no mechanical contact with the rotating
member, a slight flow of leakage steam has to be accepted.

The governing system of the turbine is of the oil hydraulic type. The pulses
are transmitted by governing members, located in the governing system
flanged to front end bearing pedestal.

The function of emergency governor is to interrupt the steam supply to the

turbine as soon as speed rises to an inadmissible value in the event of a
disturbance.

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DESCRIPTION OF TURBINE CONTROL SYSTEM

The turbo compressor set is equipped with hydraulic governing system. The
governing system is designed to control the speed of turbo compressor set
according to the signal issued by compressor capacity controller (SC-604).
Simultaneously the extraction steam pressure in extraction line is also
maintained by the governing system. Additionally turbine-governing system
incorporates protective devices to protect the turbine during adverse
operating conditions such as over speed, rotor axial shift.

GENERAL CONTROL PHILOSOPHY

For control purpose single casing condensing turbine with one controlled
extraction has been divided internally with steam glands in two parts ,
namely HP Part and LP Part.

In each part of the turbine steam flow is regulated by a set of steam control
valves. The amount of opening of each valve is controlled by the hydraulic
signal (secondary oil pressure) generated by speed governor and extraction
pressure controller.

Speed governor generates the secondary oil pressure for control valve
actuator (servomotors) in such a way that the change in amount of steam
flow through HP & LP parts of turbine is same. This does not affect the steam
flow through extraction.

Extraction pressure controller acts in such a way that upon decrease in

extraction pressure, HP control valves open more and LP control valves move
in close direction. Valve movements through changes in secondary oil
pressures are designed such that the increase in power in HP part of the
turbine is equal to the decrease in power in LP part of turbine. This
arrangement does not affect the total power developed by the turbine.
Similarly, upon increase in extraction pressure, HP control valves move in
close direction and LP control valves move in open direction.

Output of speed governor and extraction pressure controller is coordinated in

a hydraulic amplifier through simple lever system.

SPEED CONTROL

A Woodward PG-PL speed governor is employed to control the speed of turbo

compressor set. An auto-manual station (SC-604) provides air signal of 0.2
to 1.0 kg/cm2 to pneumatic speed setting mechanism for adjusting the
governor speed. Actual speed is acquired from turbine shaft through gear
drive by a centrifugal flyweight head pilot valve assembly. Depending upon
speed setting and actual speed, pilot valve controls the flow of oil to and

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from the governor power cylinder assembly. The power cylinder assembly in
turn positions a lever of hydraulic amplifier.

HYDRAULIC AMPLIFIER

Hydraulic amplifier consists mainly of 3 sets of control sleeve, hollow follow-

up piston, tension spring and a set of lever system for extraction pressure
control. Control sleeves and hollow follow-up pistons are provided with
control ports. The hollow follow-up pistons are held in their respective control
sleeves with the help of tension springs. The overlap of ports between control
sleeve and follow-up piston depends upon output from Woodward speed
governor power cylinder and tension in the tension springs.

Oil from trip oil circuit is admitted into the follow-up piston through an
orifice. The pressure inside follow-up piston depends on overlap of control
ports. This pressure is called as secondary oil pressure.

Any variation in the position of power cylinder output due to speed change,
or change in pneumatic speed setting signal causes the overlaps of port
between control sleeve and follow-up piston to readjust. This readjustment
results in either increase or decrease of HP secondary oil pressure or LP
secondary oil pressure. These pressures are transmitted to the HP and LP
control valve actuators respectively.

EXTRACTION PRESSURE CONTROL

Extraction pressure is sensed by a pressure transmitter and provides actual

value to a pressure controller PIC-647. Pressure controller depending on the
set pressure and actual pressure, generate 0.2 ~ 1.0 kg/cm2 pneumatic
signals. This signal is transmitted to a pneumatic actuator (positioning
device) which in turn position the tension springs in follow-up pistons
through levers. Upon decrease in extraction pressure HP follow-up piston
spring is pulled up and LP follow-up piston spring is released. These results in
increase in HP secondary oil pressure and decrease in LP secondary oil
pressure. Upon increase in extraction pressure, control action is reversed.
These pressures are transmitted to the HP and LP control valve actuators
respectively.

Thus the HP & LP secondary oil pressures are generated in hydraulic amplifier
through combined action of speed governor and extraction pressure
controller.

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CONTROL VALVE ACTUATORS

Control valve actuators position the control valve corresponding to the

secondary oil pressure generated by hydraulic amplifier.
Control valve actuator (servomotor) mainly consists of a pilot valve; a power
cylinder and a feed back system. Upon change in secondary oil pressure,
pilot valve provides oil passages to and from power cylinder. The movement
of power piston is transmitted to the control valves through levers. The feed
back lever resets the pilot valve to its neutral position once the power piston
occupies new position corresponding to changed secondary oil pressure. The
system is such that the increase in sec oil pr causes the control valves to
open. Hence interruption of sec oil pr causes the control valves to close.

EMERGENCY STOP VALVE AND STARTING DEVICE

The emergency stop valve provided in KS line is of quick closing type. The
valves are actuated by means of a starting device. Emergency stop valve
consists of spring-loaded piston and piston disc, which is connected to the
valve cone through a spindle. For opening the ESV, startup oil from starting
device is admitted to the space above the spring-loaded piston, by operating
the starting device. Due to start up oil pressure the piston moves towards
the piston disc and they form a tight seal against each other. Oil from trip oil
circuit is then admitted to the space under the piston disc, and the space
above the piston is connected to oil drain. The trip oil now forces both the
piston disc and piston to the outer position thereby opening the ESV. As long
as the trip oil pressure is maintained, the piston and piston disc cannot be
separated by spring force. The stop valve is closed only when trip oil
pressure drops substantially. On the loss of trip oil pressure, the pressure of
secondary oil tapped from trip oil circuit drops to zero, thus causing the
control valves to close. This arrangement provides a two-fold protection
against steam entering the turbine.

Once ESV is opened, further operation of starting device builds up sec oil
pressure. At a preset value of sec oil pressure, control valve actuator shall
open the control valves, thereby admitting the steam into turbine. Maximum
value of sec oil pressure can be limited at any point of operation by starting
device. At certain speed governor takes over the speed control. At this point
starting device can be released fully.

TESTER FOR ESV

Testing device is provided to check the proper functioning of ESV during

normal operation of turbine. If the testing device is operated, it will admit the
pressure oil to the space behind the test piston of ESV, which will then be
pushed against the piston and move the piston and valve spindle towards the
closed position (partial closing)

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TRIPPING DEVICE

Whenever the turbine is to be tripped, the governing oil pressure (trip oil line
after tripping device) is drained by tripping device. Thus pressure in front of
ESV piston disc and sec oil pressure fall, resulting in closure of ESV and
control valves.

The tripping device is operated on the occurrence of any of the following

- Manual operation
- Actuation of over speed governor
- Rotor axial movement
- Drop in trip oil pressure.

OVERSPEED GOVERNOR

Over speed governor protects the turbine against speeds higher than the
safe value for turbine operation. Over speed governor consists of an eccentric
pin located inside the turbine shaft and held in position with a spring. At a
preset speed (trip speed) centrifugal forces of eccentric pin will overcome the
spring force and the pin will move out of shaft. The outward movement of
the pin actuates a lever of tripping device and thereby tripping the turbine.

AXIAL SHIFT PROTECTION

Whenever the turbine rotor movement in axial direction is excessive, then a

projection on the rotor comes underneath the lever of tripping device and
actuates the lever and thereby tripping the turbine.

OVERSPEED GOVERNOR TESTER

Over speed governor tester facilitates the testing of overspend governor pin
when turbine is operating at maximum continuous speed. When overspend
governor tester is operated it will hydraulically bypass the tripping device
ensuring uninterrupted oil supply to governing system irrespective of the
position of tripping device. On further operation of overspend governor
tester, pressurised oil is injected below the overspend governor pin. The
pressurised oil causes the pin to move out of shaft and actuates the tripping
device lever, this ascertains the free movement of overspend governor pin.

NON RETURN EXTRACTION STEAM VALVE

In the extraction steam line, non-return quick closing flap valve has been
provided, which prevents reverse flow of steam into turbine. Also at turbine
trip, non-return valve is closed by its actuator, which in turn acts at the loss
of trip oil pressure. Drain speeder helps in quick draining of oil from QCNRV
actuator.

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TRIP SOLENOID VALVE (SSSV 2222)

Trip solenoid valve facilitates the tripping of turbine from remote place such
as control room through push button. Whenever the solenoid valve is de
energized, it interrupts the oil supply to trip oil circuit and simultaneously
depressurizes the trip oil circuit.

SURFACE CONDENSOR

The surface condenser is a shell and tube nest arrangement with water boxes
at either end. The steam side of the condenser is connected to the exhaust
hood of the turbine. The main functions of the condensor are,

- To condense the steam exhausted from the turbine.

- To maintain a vacuum such that the heat drops to be utilised in the
turbine is maximum.
- To maintain the temperature of the condensate always at the saturation
temperature so that all dissolved gases are liberated .
- To facilitate the extraction of air and other gases.

To operate the condenser at the optimum efficiency, the condenser is

designed such that the temperature of the exhaust steam and that of the
condensate are nearly equal. In other words, the cooling water will carry no
heat other than the latent heat of condensation.
High level switches LSXH 641 A/B/C are provided on hot well and will trip the
machine in case of high level.

EXTRACTION SYSTEM OF NON-CONDENSIBLES

Each system consists of two steam jet ejectors, one intercondensor and one
after condenser. There are two such systems along with a hogging ejector.
The primary ejectors by means of motive steam (LS) eject the gases and
vapors from the turbine condenser and condense them in the inter
condenser. The secondary ejectors further ejects the uncondensed gases
from inter condenser and condenses in the after condenser. The cooling
medium in these ejector condensers is cooling water. The after condenser
operates at atmospheric pressure and the uncondensed vapors are vent into
atmosphere. The condensate from inter-condensers flow to hot well by
means of loop line and the condensate from after condenser by means of
condensate traps.
The hogging ejector is a single stage ejector which by means of motive
steam ejects the air of turbine condenser to atmosphere. The hogging
ejector reduces the startup time and is also called as startup ejector.
The normal operating pr of the condenser is -0.92 ata and pressure switches
PXH 648 A/B/C, if activated on turbine exhaust pressure very high will trip
the machine.

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LUBE OIL SYSTEM

The lubrication system for turbine and compressor and for governing system
is common. The main reservoir has a capacity of 18.8 m3 and a electrical
heater for heating purpose so that the right viscosity for start up is obtained.

The overhead tank has a capacity of 5.0 m3 .The overhead run down tank is
placed about 7.5 m over the compressor center line. This tank shall cater
required oil quantity to the bearings during the time taken for the turbine to
reach zero speed after it is tripped in the event of all the lube oil pumps fail.
This tank caters compressor side lubrication for 5 min and turbine side for 10
minutes. Two identical centrifugal oil pumps P 24 A/B provide the oil
circulation, both pumps are motor driven. Each pump is capable of supplying
the capacity required by the whole system; therefore each pump can operate
as stand by pump for continuous service. The stand by pump starts
automatically by pressure switch PXL 677.

On the lube discharge header a hydro-pneumatic accumulator (holdup tank)

direct contact type (V13) with a retention time of 5 sec is installed, it is fitted
with level control valve for discharging into the system and level switches to
maintain proper level into the vessel. Nitrogen from pressurized cylinders is
used for maintaining the hold up tank pressure.

The lube oil from the pumps discharge is cooled in the oil cooler E38 A/B. The
twin oil coolers are designed for one in service at a time and the oil can be
diverted to one of the coolers by means of two three way valves which are
simultaneously operated by a hand lever, and leaving the other cooler as
standby.

From the lube oil pumps discharge header, hot oil at the discharge pressure
is fed to control / governing oil system. In the governing oil circuit there is a
duplex filter assembly whose filtration range is 5 micron.

The cooled lube oil then passes through a duplex filter system with one in
service at a time. The filtration range is 10 microns.

The filtered clean cool oil then flows to the lube oil header whose pressure is
maintained by PCV 670. The lube oil header is split into two separate headers
catering the requirements of compressor train and turbine separately.

The overhead lube oil tank is fed from this L.O. header and during normal
running a constant amount of oil is fed through a flow orifice and overflow of
the O.H. tank is diverted to main oil reservoir. The O.H. tank is fitted with
LSXL 653, which is connected to compressor start up interlock.
On lube oil header the pressure switch PSXL 674 shall alert low oil header
pressure and also give command to
- Start up interlock permissive
- Standby pump start interlock

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The emergency lube oil pump P25 is motor driven with emergency power
supply. In case of shut down of both oil pumps, the lube oil header pressure
switch PXL676 gives command for starting EOP. During such shut down
event, the lubrication requirement of turbine is met by this pump for cooling
down period.

THE LUBRICATING POINTS ON COMPRESSOR / TURBINE

- Turbine MCL coupling

- MCL thrust bearing
- MCL front journal bearings
- MCL rear journal bearings
- MCL gear box coupling
- Gear Box
- Gear box BCL coupling
- BCL front journal bearings
- BCL rear journal bearings
- BCL thrust bearings
- Turbine rear journal bearings
- Turbine front journal bearings
- Turbine thrust bearings
- Governor drive gears
- Barring device

The oil to individual bearings and other points is controlled with regulating
valves. The individual oil pressure, are in the following ranges:
Thrust bearings 0.3 ~ 1.3 kg/cm2 (adjust 0.7 kg/cm2)
Journal bearings 0.5 ~ 1.5 (adjust 1.5 kg/cm2)
Couplings 1.5 ~ 2.0
Gear box 1.8 ~ 2.0

The oil outlet from these points is collected to individual return headers and
flows to the main oil reservoir. All the return headers are provided with flow
glasses, and local temperature gauges.
The lube oil reservoir is also fitted with an oil clarifier which will separate
moisture and any foreign material from the oil. This unit operated in closed
circulation and its operation is intermittent or need based.

START UP PREPARATION

The compressor start up is divided into following activities:

- Cooling water system preparation
- Lube oil system preparation
- Steam network preparation
- Turbine condenser preparation
- Compressor gas circuit preparation
- Rolling the machine
- Loading the machine

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LUBE OIL SYSTEM PREPARATION

1. Be sure that main oil tank is filled with recommended grade of oil (T 46)
2. Check the oil level in main oil tank, if necessary make up.
3. Confirm that the suction strainers of P24 and P25 are clean and are in
position.
4. Check that the suction and discharge valves of all the pumps are open.
5. Lube oil header pressure control valve u/s & d/s i/v are open and bypass
is closed
6. Hold up tank level control valve is in line
7. All oil drain valves of coolers, filters and pipes are closed
8. Check that the isolation valves of pressure switches, pressure gauges,
pressure transmitters, level gauges, switches and valve actuators are
open.
9. Oil coolers CW inlet i/v are open and CW outlet i/v are crack open.
10.Start the lube oil pump P24 and check its discharge pressure.
11.Open the vent of the cooler in line to bleed off all the air. Once oil starts
coming through flow glass, close the vent. Open the bypass of the stand
by cooler and bleed off all the air. Thus the stand by cooler is also full of
oil and is at working pressure.
12.Bleed off all the air from the filter in line and isolate the vent. Open the
bypass of stand by filter and also bleed off all the air, thus the stand by is
full of oil and is at working pressure.
13.Fill the overhead tank by slightly opening the bypass of filling orifice.
Close once the overflow starts. During this operation care must be taken
not to overload the lube oil pump. Once overflow starts, there will be a
constant overflow from this tank.
14.Check L.O. temperature and if necessary adjust the cooler CW outlet i/v.
15.Check the oil pressure at various points and confirm they are OK
- Lube oil pump disch. pressure : 10.0 kg/cm2
- Lube oil header pressure : 2.5 kg/cm2
- Lube oil pr to journal bearings : 0.5 to 1.5 kg/cm2
- Lube oil pr to thrust bearings : 0.3 to 1.3 kg/cm2
- Lube oil pr to coupling or gear box : 1.5 to 2.0 kg/cm2
- Control oil pressure : 8 kg/cm2
16.Check the normal flow of oil coming from all the return headers. The temp
of all the outlets shall be same.
17.Check the L.O. filter diff pressure it should be normal.

STEAM NETWORK PREPARATION

Once the K.S. network is charged up to compressor battery limits, the K.S.
header up to turbine stop valve should be brought to the operating
temperature and pressure. The line heating should be carried out gradually in
order to maintain the stresses on turbine flanges uniform and to achieve a
uniform heating of turbine body and rotor, proceed as follows:
1. Start turbine the rotor by engaging barring device.

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2. Open the drains (2 nos) and 2 " start up vent on K.S. header.
3. Crack open the K.S. isolation valves bypass. Slowly the K.S. line
temperature starts increasing. Up to 300°C follow an approx. temperature
gradient of 50 to 60°C/hr, beyond 300°C open the bypass fully and start
throttling the start up vent. Once a temp of 400°C is obtained, close the
drains and the header can be pressurized and i/v be opened as and when
required.
4. During heating, 25-30°C more than the saturation temperature
(320°C+30°C=350°C) must be achieved to avoid possible condensation
during rolling the machine.
5. Keep the extraction line steam trap by pass crack open to drain out the
condensate. Also crack open the extraction line isolation valve bypass.
6. Now the auto changeover of P 24 A to B and vice versa may be checked
and the pressure dip should be minimum, so that it does not activate the
trip switches. A smooth change over indicates effective hydro-pneumatic
hold up system.

TURBINE CONDENSER PREPARATION

1. Ensure condenser CW inlet and outlet valves are open. Bleed off the air
from vents.
2. Ensure the air valves between condenser and ejectors are open.
3. Close the hot well drain
4. Ensure the i/v of level gauges, level switches, pressure switches are open
5. Ensure all the individual drain valves coming to drain collecting header are
open. These drains are:
- Turbine HP casing drain
- Extraction header drain
- Turbine LP casing drain
- Balance leg drains
6. Ensure that the condensate inlet and outlet valves of one of the ejector
condenser are open
7. Open the isolation valve of LV640 A/B. Ensure that the condensate inlet
and outlet valves of one of the ejector are open.
8. Crack open PW make up and once the level is made up, open the suction,
discharge and vent valves of both the condensate pump
9. Keep LC640 on manual and start P27. This is to avoid overloading of the
pump during startup. Now maintain the hot well level with LC 640 and
take it on auto mode. If necessary, now build up the hot well level till the
high level alarm appears. At this point the stand by condensate pump
should take a start automatically. If satisfactory, stop one of the pumps,
and normalize hot well level and leave the control on auto mode. Thus the
condensate circulation is established and vacuum can be pulled as and
when required.
10.Take clearance from shift engineer and proceed to pull the vacuum.
11.Open the motive steam LS isolation valves.
12.Ensure that the isolation valves of sealing condensate header are open
and check that for all the sealing points condensate injection is on.

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13.Open the turbine gland steam condenser cooling water inlet and outlet
isolation valves. Open the gland steam vent line isolation to the gland
steam condenser.
14.Keeping the gland steam header drains open, charge gland steam header
by opening PV653. Maintain the gland steam header at a positive pr
(approx. 0.2 kg/cm2)
15.Open the motive steam to the gland steam condenser ejector and
maintain the gland steam vent header pressure slightly positive.
16.Now line up the hogging ejector. Lineup first motive steam followed by
opening of the air valve. Once the air from the system is evacuated, line
up secondary and primary ejectors system. Open the air valve for this
system. Now we can cut the hogging ejector, first by cutting air valve
followed next cutting by motive steam. Now the vacuum level at no load
must be constant about 0.12 to 0.15 ata.

COMPRESSOR GAS CIRCUIT PREPARATION

1. Obtain clearance from the shift engineer to charge the gas.

2. Open the casing drain valves of MCL (5 drains) and BCL (1 drain)
3. Check that inter stage separators MV16, MV17, MV18 and KO drum MV09
's LCV bypass valves are in close position and LIC's are in auto mode set
at 40%.
4. Ensure that inter stage coolers E25, E26, E27 's CW inlet and outlet
valves are open and E27 CW outlet control valve is on auto with bypass
crack open.
5. Compressor discharge vent PV03 is on manual and is open approximately
by15- 30%. All the steam tracing and jackets are live.
6. Open CO2 valve on the inlet of KO drum
7. Now check in field and confirm that
- Anti-surge valve FV602 is fully open
- 2-1 kick back valve HV 602 is fully open
- Inter-stage vent HV 601 is fully open (because the turbine is yet
reset)
- Manual vent on 2nd suction is kept open.

ROLLING THE MACHINE

1. Ensure KS header temperature has reached a minimum of 400°C. Close

the start up vent and drains and pressurise KS header and open KS
motorized valve MHV3056.
2. Open the extraction line i/v. close the trap bypass and line up trap.
3. Obtain clearance from shift engineer for rolling.

CONFIRM THE FOLLOWING

- Speed signal is zero SC 604
- Extraction signal is zero PC 647
- Anti-surge control is on manual and valve is fully open
- 2 - 1 spill back valve is fully open

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4. Reset the turbine. Turbine reset is possible only when
- All the trip conditions are in reset condition
- Overhead tank level is normal
- Anti surge valve is open
- 2 - 1 spill back valve is open
- Barring device is disengaged
- L.O. header pressure is normal

5. On reset:
- The control oil solenoid valve (SSSV 2222) energizes and control oil
circuit shall be pressurized. However engage automatic trip gear for
permitting trip oil pressure to build up
- Inter stage vent valve closes.

Now the machine is ready for rolling

ROLLING

To roll the machine turns the starting device in the opening direction slowly.
Gradually the trip oil pressure above the piston disc of ESV will start building
up. As soon as the oil pressure above the piston disc exceeds the pressure
of the oil below the piston, the emergency stop valve begins to open. Stop
turning startup device until the ESV is fully open.
Once the ESV is fully open and the oil pressure below the piston has
collapsed to ZERO, proceed further by gradually turning the startup device in
opening direction. The secondary oil pressure will start building up. At the
secondary oil pressure value shown in governor adjustment report, (1.5
kg/cm2) the control valves are going to open. Very cautiously allow the
control valves to open and admit KS to turbine. The rotor will start rotating
and allow it to accelerate to the lowest speed shown on the starting and
loading chart.
Following the start up chart, increase the turbine speed through further
turning of the startup device in the opening direction and while paying
special attention to the prohibited speed ranges 3000-4500 RPM and to the
smooth running behavior of the entire machine set. Speed up and achieve
the minimum governing speed, from where the speed governor takes over.
Now the starting device can be further turned in the opening direction into its
ultimate position and lock it.

NB:
The first critical speed of MCL is 3200 rpm, Turbine- 3600 rpm, BCL -7000
rpm (equivalent compressor train speed is 3925 rpm) are all falling in the
range of 3000 - 4000 rpm. So the prohibited speed range for the entire
machine is 3200 ~ 4500 rpm should be crossed step less and as fast as
possible i.e. care should be taken not to hold the machine in prohibited speed
range.

109
During starting, before and after the prohibited speed range limits check the
following:
- Machine vibrations
- Bearing oil pressure and temperature
- Bearing metal temperature
All these parameters must be normal and well within the acceptable
limits.
6. Close the casing drains.
7. Cut off PW water make up to the condenser.
8. Slowly start closing vent valve in the 2nd suction, watching 1st /2nd suction,
watching 1st discharge/ 2nd suction pressure. If the machine surges, do
not close further, increase the speed by 30 ~ 50 rpm and then close.
9. Confirm the seal leak vent valves are open.
10.Confirm the hot seal gas injection to 4th suction side end seal is fully open
and crack open the same to 3rd suction side end seal and maintain a
positive pressure difference, i.e. the hot seal gas pressure must be 0.8 ~
1.0 kg/cm2 above the third suction pressure.
11.Check the pressure differential of clean seal gas to dry seals of both BCL
ends is positive.
12.Line up the extraction (MS header is already charged)
- Line up extraction at MGS
- If there is an isolation valve closed on trip oil supply to extraction
NRV, release the NRV flap by operating the oil relay by opening the
isolation valve slowly. While operating the oil relay ensure that the
trip oil pressure to ESV does not fall.
- Now start giving the extraction control signal PC647 watching the
extraction pressure. The extraction steam starts flowing into the
MS header, maintain normal header pressure, so that normal
extraction pressure is maintained. Maintain a minimum extraction
flow of about 25 t/hr. Depending on the requirement increase the
extraction flow 55 t/hr.

Machine expansion should be achieved before loading the machine. As a

result of thermal expansion of turbine casing an absolute displacement of
bearing pedestal can result. By knowing the rotor position and casing
position safe conclusion can be drawn with regard to the axial clearances
inside turbine.
13.Now close the turbine casing drains and extraction header drain.
14.Do not run the machine with low vacuum of turbine condenser as this will
increase the turbine exhaust temperature.

LOADING THE MACHINE

1. Using the speed controller SC 604, increase the speed in increments and
simultaneously start closing HV 603. Watch out not to increase first and
2nd discharge pressure beyond normal values. Closing HV603 will increase
the flow to 3rd suction.

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2. Check the 3rd suction flow and 4th suction temperature maintain TC 619 at
50°C.
3. By closing HV 603, MCL is loaded fully and any increase in speed shall
increase the capacity. Now start closing the main anti surge valve FV 602
slowly. On closing FV 602, the 3rd suction gas flow shall decrease and final
discharge pressure shall start building up. In order to maintain the
required suction flow, simultaneously raise the speed of the machine. At
any given speed, maintain a safe suction gas flow so as to operate the
machine away from surge limits.
4. Maintain the discharge pressure by either slowly closing PV 03 or by
closing FV 602. But the 3rd suction flows to be maintained above the surge
limit.
5. During loading maintain the individual suction temperature at near normal
values, and observe the thrust bearing temperature and pressure
differential across each stages of MCL and BCL. If the thrust loading is
high, immediately pressure differential to be adjusted accordingly to
maintain / minimize thrust load and bring down the bearing temperature.
Imbalance in pressure ratios will cause an increase in thrust and so
maintain the compressor ratios while loading.
6. Do not keep the machine running at low pr (100 ~ 120 kg/cm2) and at
low speeds for longer time. This causes an increase in thrust.
7. Now the machine is in fully loaded condition and CO2 is being discharged
to atmosphere through PV 03
8. Once the CO2 feed to reactor is started, slowly the PV 03 will close and
the CO2 flow to the reactor can be increased/ decreased by either varying
the speed of the machine or by varying the anti surge flow control valve.
However the safe limit is not to be crossed, as the machine may reach a
surge point.

Monitor the following while the machine is running:

a. Radial and axial vibrations of the turbine and compressor.

b. Bearing metal temperature.
c. Oil overflow in overhead tank
d. Behavior of hot well level controller
e. Inter stage separators and KO drum level controller
f. Liquid trap functioning in first stage suction drip leg
g. Check whether HV 601,HV 603, FV602, PV 03 are passing in full close
condition
h. Seal gas injection pressure for BCL and gland steam header pressure for
turbine
i. Lube oil pressure to each individual point
j. DP across LO and G O & dry gas filters
k. The intercoolers CW outlet temperature.
l. The compressor inter stage temperature and pressure
m. Woodward governor oil level
n. Lube oil temperature of reservoir, after cooler and temperature of LO
from discharging points

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o. Pressure and level in L.O. hold up tank
p. Secondary oil pressure of governing system and corresponding valve lift
vs. speed
q. Expansion of turbine casing
r. Periodically sample the main reservoir oil for moisture, sediments and
other quality checks
s. Regularly (every shift) run the oil clarifier for a period of 2 hrs. When the
oil clarifier is running precaution should be taken not to drain out the
reservoir.

UNLOADING THE MACHINE

Whenever there is a planned shut down, machine has to be gradually

unloaded and then stopped. Unnecessarily do not resort to Emergency Trip
for normal shutdowns. Follow the steps below:
Obtain clearance from the shift engineer; inform steam generation plant and
ammonia plant positively.

1. Assume that CO2 is being discharged through PV03 and PV03 is on auto
control mode.
2. Slowly start reducing the speed and simultaneously maintain 3rd suction
flow by opening anti surge valve.
3. Once the pressure drops to 100~110 kg/cm2, start opening 2-1 spill back
HV 603. Keeping a watch on the thrust-bearing temp, further open FV602
and HV 603.
4. Now reduce the speed to minimum governing speed.
5. Now stop the machine by activating any of the stop devices.

SHUT DOWN OPERATION

a. The machine must be kept turning on barring device for about 24 hrs (till
the casing expansion of turbine comes less than 1 mm) from the time of
shut down.
b. Ensure that the oil pump is running and emergency power availability for
barring device motor and emergency L.O. pump.
c. Keeps the condensate pump running for about eight hours after shut
down and keep PW make slightly open condition.
d. Cut off vacuum, gland steam and gland steam ejector.
e. Isolate KS, MS and LS headers.
f. Isolate the compressor suction valve. Open the inter stage manual vent
on 2nd suction.
g. Open the compressor casing drains on MCL & BCL.
h. Open the turbine casing drains and extraction header drains.
i. After approx., six hours, when the turbine exhaust temperature comes to
normal, isolate PW make up to hot well and stop the condensate pump.

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TURBINE DRAINS IDENTIFICATION

P- 27 SIDE

UREA PLANT AMMONIA

SIDE PLANT SIDE

E- 28 SIDE

4 5 6 7 9 10

To E 28

DRAINS COLLECTING HEADER

1 2 3 8

1. HP Wheel chamber drain

2. Extraction NRV u/s drain
3. Extraction PSV u/s drain
4. Extraction line (just outlet) drain
5. HP wheel chamber to LP side balancing line drain
6. HP wheel chamber to LP side balancing line drain
7. LP casing second drain
8. Turbine front end leakage to rear end line drain
9. PV653A d/s line drain
10. PV653B d/s line drain

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 DRY GAS SEAL DESCRIPTION

To minimize the CO2 losses from BCL, dry gas seal is used at both the ends.
Seal gas tapping is taken from 3rd discharge line after filtering it.
Its specifications are as follows:

SERVICE CONDITIONS
Make John Crane
Seal temp 45°C/175°C (normal)
Seal pressure 88-bar g max
25 bar g normal
Speed of rotation 12332 rpm (max continuous)
Process gas CO2

SEAL CAPABILITIES
Axial movement +/- 2.5 mm
Radial movement +/- 0.6 mm

LEAKAGE RATES
Estimated leakage at 12332 rpm (equal to 8500 turbine rpm) at 25 bar g
Process side seals 39 standard liters per minute.
Simply explained, the typically comprises of an 'O' ring sealed carbon FACE,
located in a stainless steal retainer, spring loaded against a rotating carbide
SEAT, fixed to the shaft.

ROTATING
TUNGSTEN
RING
STATIC
CARBON
RING

ROTATING
SHAFT

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Sealing of the fluid is achieved at the radial interface of rotating and
stationary rings by a unique and
ingenious method. The sealing
surfaces are lapped to a high
degree of flatness, but the SPIRAL
rotating carbide ring has a series GROOVE

of logarithmic spiral grooves SEALING

machined into its running face. DAM
The profile of these grooves is
shown below:

RIDGE

With rotation, fluid is drawn

inwards towards the root of the ROTATIONAL
groove, called the sealing dam. DIRECTION
The sealing dam provides
resistance to flow, increasing the pressure. The generated pressure lifts the
carbon ring surface out of contact with the tungsten carbide ring by a precise
amount, typically 3 microns. The gap between the radial faces is set when
the closing forces of hydrostatic pr and spring load equate to the opening
forces generated within the fluid film.
Under dynamic equilibrium conditions, the force acting upon the seals can be
graphically shown below

The closing force, Fc , is a result of the system pressure plus a very small
spring force. The opening force, Fo , is a result of the system pressure
breakdown between the face and seat, plus the pr generated by the spiral
grooves. At equilibrium, i.e., when Fc equals Fo , the operating clearance is,
as previously mentioned, approx. 3 microns for most commonly encountered
fluids. If a disturbance occurs which results in a reduced sealing gap, the
pressure generated by the spiral grooves considerably increases as shown
below
FC=FO
F P GAP=0.003MM FO
OPENING
FORCE

COMPRESSION

EXPANTION

NORMAL
SPRING LOAD+HYDROSTATIC RUNNING

Similarly, if an upset causes the gap to increase there is reduction in the pr

generated and the seal regains its equilibrium very quickly

115
 INCREASING
OPENING
REDUCED
CLOSING FORCE
GAP
FORCE

The result of this mechanism is highly stable yet very thin fluid interface
between the static face and the rotating seat. This results in the two surfaces
being kept apart and not touching under normal dynamic operating condition.
In turn this leads to a long life, reliable seal with no wear at the interface.

116