CO2 Compressor
CO2 Compressor
11/21 K-01
Type
Capacity
: 2MCL527 + GB + 2BCL306a
: 20700 NM3/hr
Suction Conditions
Pressure
Temp
Molecular wt (dry)
Discharge Conditions
Pressure
Temp
7976 / 11565
8100 / 11745
3200 / 6090
RPM
1
40
1.6
6.1
178
2
45
6.22
25
174
3
45
24.16
88
165
4
50
87.79
160
100
specified limit. A voting logic two out of three will set the trip memory to trip
the machine. Also near the first stage suction inlet on suction pipe a liquid
trap is provided.
Interstage coolers are provided for 1st, 2nd and 3rd stages to maintain the gas
at proper suction temperatures. After each cooler the gas flows through
interstage condensate separators.
The condensate formed during cooling in the interstage 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 4 th
stage suction. 4th stage suction temp is maintained at 50C (The critical
properties of CO2 are Tc = 31.1C; Pc 73.2 kg/cm2) An antisurge line with
surge control valve FV602 bypasses the 4th stage discharge gas to first stage
suction. Antisurge 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 ( Interstage spill back)
A vent line with interstage vent valve HV601 vents out gas from 3 rd 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 antisurge valve FV602 and interstage vent valve
HV601 open rapidly in response to the trip system.
Safety valves are provided in the discharge of each stages to prevent the
downstream from overpressurisation.
Safety Valves Set pressures
First stage disch. PSV
Second stage disch PSV
Third stage disch PSV
Final stage disch PSV
:
:
:
:
7
28
105
175
kg/cm2
kg/cm2
kg/cm2
kg/cm2
Shaft sealing
In order to minimise the gas losses from the compressor, the shaft ends are
provided with shaft sealing systems.
On MCL, we have labyrinth seals on both 1 st 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.
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 3 rd 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 2 nd disch gas line. A positive pressure
difference across seal gas injection and balance leg is maintained. The
leakage from the mech. seal is vented to atm and pressure switch PSH633
will activate an alarm on excessive leakage.
The seal gas is from the 3rd disch and filtered through 5-micron gas filter and
its flow is regulated through flow orifices.
TK 01 TURBINE
Normal power output
Maximum power output
Speed - normal
Speed Min/ Max
First critical speed
Steam pressure
Temperature
Exhaust pressure
Extraction pressure
Ext stm temp
Turbine to governor speed
Ratio
5552 KW
6365 KW
7976 rpm
7290 / 8505 rpm
3300 rpm
110 kg/cm2
510C
0.1 a
24.5 kg/cm2
326C
8.5 : 1
FUNCTIONAL DESCRIPTION
Steam flow through the turbine is in the axial direction. Arranged 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
SPEED CONTROL :A woodward PG-PL speed governor is employed to control the speed of turbo
compressor set. An automanual station (HIC-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
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 followup 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. These results in
either increase or decrease of HP secondary oil pressure and 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 PIC647. Pressure controller depending on the
set pressure and actual pressure, produces 0.2~1.0kg/cm 2 pneumatic signal.
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
extrn pr, 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.
against the piston and move the piston and valve spindle towards the closed
position ( partial closing)
TRIPPING DEVICE
Whenever the turbine is to be tripped, the governing oil pr (trip oil line after
tripping device) is drained by tripping device. Thus pr in front of ESV piston
disc and sec oil pr falls, 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 overspeed governor
- Rotor axial movement
- Drop in trip oil pressure.
OVERSPEED GOVERNOR
Overspeed governor protects the turbine against speeds higher than the safe
value for turbine operation. Overspeed 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
Overspeed governor tester facilitates the testing of overspeed governor pin
when turbine is operating at maximum continuous speed. When overspeed
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 overspeed governor tester,
pressurised oil is injected below the overspeed 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 overspeed 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 pr. Drain speeder helps in quick draining of oil from QCNRV
actuator.
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 pr switch
will trip the machine and as well as gives command for starting EOP. During
such shut down event , the lubrication requirement of turbine are met by this
pump for cooling down period.
THE LUBRICATING POINTS ON COMPRESSOR / TURBINE
-
The oil to individual bearings and other points is controlled with regulating
valves. The individual oil pressure, are in the following range:
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 a 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:
- Lube oil system preparation
- Steam network preparation
- Turbine condensor preparation
- Compressor gas circuit preparation
- Rolling the machine
- Loading the machine
3. Crack open the K.S. isolation valves bypass. Slowly the K.S. line temp
starts increasing. Up to 300C follow an approx. temp gradient of 50 to
60C/hr, beyond 300C open the bypass fully and start throttling the start
up vent. Once a temp of 400C is obtained, close the drains and the
header can be pressurized and i/v be opened as and when required.
4. During heating, 25-30C more than the saturation temperature
(320C+30C=350C) 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 pr dip should be minimum, so that it does not activate the trip
switches. A smooth change over indicates effective hydropnuematic hold
up system.
Turbine condensor Preparation
1. Ensure condensor CW inlet and outlet valves are open. Bleed off the air
from vents.
2. Ensure the air valves between condensor and ejectors are open.
3. Close the hot well drain
4. Ensure the i/v of level gauges, level switches, pr 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
condensor 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 i/v.
12.
Ensure that the i/v of sealing condensate header is open and check
that for all the sealing points condensate injection is on.
13.
Open the turbine gland steam condensor cooling water inlet and outlet
i/v. Open the gland steam vent line isolation to the gland steam
condensor.
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 condensor ejector and
maintain the gland steam vent header pr 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 interstage 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 interstage 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
by 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
- Antisurge valve FV602 is fully open
- 2-1 kick back valve HV 602 is fully open
- Interstage vent HV 601 is fully open (because the turbine is yet
reset)
- Manual vent on 2nd suction is kept open.
ROLLING THE MACHINE
1. By this time KS header temperature has reached a minimum of 400C.
close the start up vent and drains and pressurise KS header,open KS
motorized valve.
2. Open the extraction line i/v. close the trap bypass and line up trap.
3. Obtain clearance from shift engineer for rolling.
4. Reset
-
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
- Interstage vent valve closes.
Now the machine is ready for rolling
Rolling
To roll the machine turn 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 pr above the piston disc exceeds the pr 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 pr below the piston has collapsed to
ZERO, proceed further by gradually turning the startup device in opening
direction. The secondary oil pr will start building up. At the secondary oil pr
value shown in governor adjustment report, (1.5 kg/cm 2) 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 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 stepless and as fast as
possible i.e. care should be taken not to hold the machine in prohibited speed
range.
During starting, before and after the prohibited speed range limits check the
following:
- Machine vibrations
- Bearing oil pr and temp
- Bearing metal temp
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 condensor.
8. Slowly start closing vent valve in the 2nd suction, watching 1st /2nd suction,
watching 1st disch/ 2nd suction pr. 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 4 th suction side end seal is fully
open and crack open the same to 3 rd suction side end seal and maintain a
positive pr difference, i.e. the hot seal gas pr must be 0.8 ~ 1.0 kg/cm 2
above the third suction pr.
11.
Check the pr 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 pr to ESV does not fall.
- Now start giving the extraction control signal PIC647 watching the
extraction pr. The extraction steam starts flowing into the MS
header, maintain normal header pressure, so that normal extraction
pr is maintained. Maintain a minimum extraction flow of about 25
t/hr. Depending on the requirement increase the extraction flow
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 condensor as this
will increase the turbine exhaust temp.
Loading the machine
1. Using the speed controller HIC 604, increase the speed in increments and
simultaneously start closing HV 603. Watch out not to increase first and
2nd discharge pr beyond normal values. Closing HV603 will increase the
flow to 3rd suction.
2. Check the 3rd suction flow and 4th suction temperature maintain TIC 619
at 50C.
3. By closing HV 603, MCL is loaded fully and any increase in speed shall
increase the capacity. Now start closing closing the main antisurge valve
FV 602 slowly. On closing FV 602, the 3 rd suction gas flow shall decrease
and final discharge pr 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 disch pr 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 temp at near normal
values, and observe the thrust bearing temp and pr differential across
each stages of MCL and BCL. If the thrust loading is high, immediately pr
differential to be adjusted accordingly to maintain / minimize thrust load
and bring down the bearing temp. Imbalance in pr 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/cm 2) and at
low speeds for longer time. This causes an increase in thrust.
7. Now the machine is in fully loaded condition and CO 2 is being discharged
to atm through PV 03
8. Once the CO2 feed to reactor is started, slowly the vent 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 antisurge flow.
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.
b.
c.
d.
e.
f.
g.
h.
i.
j.
k.
l.
m.
n.
o.
p.
q.
r.
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 3 rd suction
flow by opening antisurge valve.
3. Once the pr drops to 100~110 kg/cm 2, start opening 2-1 spill back HV
601. Keeping a watch on the thrust-bearing temp, further open FV602
and HV 601.
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. Keep the machine 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. Keep the condensate pump running for about eight hours after shut down.
Keep PW make slightly open.
d. Cutoff vacuum cut off gland steam and gland steam ejector.
e. Isolate KS, MS.
f. Isolate the compressor suction valve. Open the interstage 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 temp comes to normal,
isolate PW make up to hot well and stop the condensate pump.
P- 27
SIDE
UREA PLANT
SIDE
AMMONIA
PLANT SIDE
E- 28 SIDE
10
To E 28
Make
Seal temp
Seal pressure
Speed of rotation
Process gas
John Crane
45C/175C (normal)
88-bar g
max
25 bar g
normal
12332 rpm (max continuous)
CO2
SEAL CAPABILITIES
Axial movement
Radial movement
+/- 2.5 mm
+/- 0.6 mm
LEAKAGE RATES
Estimated leakage at 11745 rpm (equal to 8100 turbine rpm) at 25 bar g
Process side seal 39
standard liter 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
RIDGE
ROTATIONA
L
DIRECTION
SPIRAL
GROOVE
With rotation, fluid is drawn inwards towards the root of the groove, called
the sealing dam. The sealing dam provides resistance to flow, increasing the
pr. The generated pr 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 pr plus a very small spring
force. The opening force, Fo , is a result of the system pr 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 pr
generated by the spiral grooves considerably increases as shown below
F
FC=FO
GAP=0.003MM
FO
OPENING
FORCE
COMPRESSIO
N
EXPANTION
SPRING
LOAD+HYDROSTATIC
NORMAL
RUNNING
CLOSING
FORCE
REDUCED
GAP
INCREASING
OPENING
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.
Inturn this leads to a long life, reliable seal with no wear at the interface.