Air Compressor

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

at 34 Kg/cm2.
 Air compressor is installed to produce air at

such high pressure.
Introduction (cont …)
 Air compressor is four stage centrifugal
compressor.
 Pressure is increases up to 34 Kg/cm2 through

a four stage process.
 Air compressor is made by NOVA PIGNONE.

Data sheet
Data sheets
Air Compressor Schematics on
DCS
 Air Compressor is represented in form of
schematics.
 Any value could be changed from a specified

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

secondary filters to ensure the dust removal
from air.
 Dust removed due to inertia by inertial filters,

are sent back to atmosphere through a blower.
Primary Filter replacement
 Primary filter are basically sacrificial filters,
 when these filters are choked with dust and ∆P

increases these are replaced.
 Secondary filters are also replaced but their life

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

second stage of compressor.
 Air leaves at 8 Kg/cm2, then enter into knock

out vessel and Interstage cooler.
PID Description (cont …)
 After second stage knock out vessel air
enter into 3rd stage.
 Air leaves at 16 Kg/cm2, then after passing

Interstage cooler air enters into 4th stage.
 Air leaves 4th stage at 34 Kg/cm2, and sent

to SECONDARY REFORMER.
Instrument Air
 Instrument air is also supplied from air
compressor.
 IA is taken from compressor third stage

discharge after Interstage cooler.
 This air is passed from a cooler and knockout

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

cooling and filtering sent to compressor.
 After lubrication and heat removal it returns

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

treatment and used for BFW preparation.
 Vacuum is maintained inside the condenser to

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

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

network, allowing flow to increase.
Antisurge Loop
 Surging of a compressor is very
dangerous. . . As compressor could damage
due to surging
 So antisurge loops are installed for the

compressor safety.
 Centrifugal Compressor could surge if

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

below
Shutdown Procedure
Problems
 At high plant load discharge temperature of air
increased.
 Strainer at LS induction line had flown into the

inlet nozzle, and flow was reduced.
 Interstage knockout vessels high level security

malfunctioned and compressor tripped.
Problems ( cont … )
 Compressor tripped at low lube oil pressure
during lube oil pump change over.
 A cloth was not removed from compressor by

maintenance, and came to know when
compressor rolled and flow of lube oil blocked.
 Once compressor started rotating reverse and

as consequence rotor replaced.
Improvements
 Material of cooler is changed from CS to
SS.
 Barring improvement. . . Barring will not

start if lube oil pressure is not running.
 Tripping of air compressor is provided if

boiler and primary reformer trips.
Improvements
 Additional SOV is installed at main control
valve of air to secondary reformer.
 Load was reduced due to high Rpm limit of

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

Air Compressor

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Air Compressor

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Air Compressor

 Air is introduced in SECONDARY REFORMER

 Air compressor is installed to produce air at

 Pressure is increases up to 34 Kg/cm2 through

 Air compressor is made by NOVA PIGNONE.

 Any value could be changed from a specified

 Filters comprises of inertial, primary and

 Dust removed due to inertia by inertial filters,

 when these filters are choked with dust and ∆P

 Secondary filters are also replaced but their life

 After knock out vessel air enters into the

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

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

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

 IA is taken from compressor third stage

 This air is passed from a cooler and knockout

 Lube oil is pumped from a console and after

 After lubrication and heat removal it returns

 This condensed steam is sent to water

 Vacuum is maintained inside the condenser to

 Reversal of flow occur in cyclic order during

 Relieves resistance in compressor discharge

 So antisurge loops are installed for the

 Centrifugal Compressor could surge if

 Steps used in shutdown procedure are given

 Strainer at LS induction line had flown into the

 Interstage knockout vessels high level security

 A cloth was not removed from compressor by

 Once compressor started rotating reverse and

 Barring improvement. . . Barring will not

 Tripping of air compressor is provided if

 Load was reduced due to high Rpm limit of

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