Compressor Shutdown

In this article, we will learn the instrumentation engineer duties during a
compressor shutdown job of a plant.

Before proceeding further, let us see all the instruments used for the safety of
the centrifugal compressor or the controlling/operation of the centrifugal-type
compressor.
Compressor Shutdown Job
The following instruments are installed in a centrifugal compressor:
1. Control valves and their accessories
2. Differential Pressure type flow meters
3. Pressure transmitters
4. Temperature transmitters and RTD/thermocouple
5. Level Transmitter
6. Vibration probes
7. Pressure gauges
8. Temperature gauges
9. Pressure switches
10. Flow switches
11. Level switches
12. Controller: PLC and its cards
Now let us discuss what jobs can be done during the shutdown on all the
above-mentioned instruments
Control Valves and their Accessories
Two types of control valves are used in a centrifugal air compressor. One is
Inlet Guide Vane (IGV) and the other is a Blow-Off Valve or Anti-Surge Valve.
So, we should do the stroke checking of both control valves. If any issue is
found in the control valve during the stroke-checking activity, then we can go
for calibration of the control valves.
Here one important thing to note is that the Blow-Off Valve or Anti-Surge
Valve is an equal percentage type of valve characteristics in many
compressors.
So, refer to any standard document before doing the job on Blow-Off Valve or
Anti-Surge Valve. Check the physical condition of the Air Filter Regulator.
Replace if necessary.
Replace the pressure gauges if needed. If any Solenoid Valve is present on
the control valve, check the solenoid valve as per the standard procedure.
If any other valve accessory is present, then check the same. If a volume tank
is present, then check the PSV of the volume tank.
The calibration of the PSV is very important. Make sure that the PSV is
calibrated.
Differential Pressure type Flow Meters
Differential pressure type flow meters are installed in the compressor to
measure the flow of the gas as well as one of the most important parameters
i.e. flow of the cooling water. Hence, during every opportunity, the differential
pressure type flow meters should be calibrated.
Also, whenever cooling water is isolated and again normalized there will be air
trapped in the DP-type flow meter’s tubing. Hence, after normalization of the
cooling water circuit, the DP-type flow meter of the cooling water should be
flushed.
The flow of the gas is also used for calculating the Surge value. This Surge
value is used in Surge Control System for the protection of the compressor.
Inspect the orifice plate if any opportunity is available.
Pressure Transmitters
Pressure transmitters are used to know the pressure of suction, individual
stage pressure as well as discharge pressure.
The values of the pressure are also used for calculating the surge value.
Check the response of the pressure transmitters and do calibration if needed.
Temperature Transmitters and RTD/Thermocouple Sensors
Temperature transmitters are installed for suction gas, intercooler inlet,
intercooler outlet, and discharge gas temperature measurement. The values
of suction gas temperature and/or discharge gas temperature are taken for
calculation of the Surge value.
The response of the RTD/thermocouple as well as the temperature transmitter
should be checked. One important thing to note here is to carry out the
inspection as well as the hydro test of the thermowell used for the
RTD/thermocouple.
In most cases, thermowells are neglected.
Level Transmitter
Level transmitters are used for measuring the level of lube oil in the lube oil
reservoir.
Generally, differential pressure level transmitters are used for the lube oil
reservoir level measurement. Calibration of the level transmitter should be
done after proper isolation of the lube oil system.
Vibration Probes
Characteristic checking, resistance checking, and response checking of
the vibration monitoring system should be done in every shutdown.
Pressure Gauges
Pressure gauges are used for viewing the pressure of the lines on which they
are installed.
Calibration of the pressure gauges is necessary because, during emergency
conditions like a blackout, pressure gauges can be used to know the pressure
in the system or the line on which they are installed.
Temperature Gauges
Temperature gauges also function like pressure gauges. Hence calibration of
the temperature gauge is also necessary.
Pressure Switches
Pressure switches are installed in seal gas pressure or some other important
pressure parameter on which the compressor should immediately trip.
Ensure that the contact used for the pressure switch remains closed when the
pressure is healthy.
Flow Switches
Flow switches are installed in the cooling water flow line. Cooling water is one
of the most important factors while the compressor is running. Because during
the compression of the gas, the temperature of the gas increases.
Due to increased temperature, the volume of the gas also increases, and
hence more energy is needed to compress the gas.
Hence intercoolers are given which have a cooling water flow to reduce the
temperature of the gas. When the flow is healthy, the contact should be
closed.
Level Switches
Level switches are required to monitor the amount of water in case of an air
compressor in the intercooler.
If there is a high level of condensation in the intercooler then the compressor
should trip. Here also, when the level switch is healthy, the contact should be
closed.
A Controller like PLC and its cards
All connection tightening, panel cleaning jobs, and power supply checking in
the PLC panel should be done during the shutdown of the compressor.
Also, Cause & Effect checking and Interlock checking should be done during
the shutdown of a plant.

Compressor Shutdown

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Compressor Shutdown

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In this article, we will learn the instrumentation engineer duties during a

compressor shutdown job of a plant.

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