Gop Uty 07 (A) (Ia, Pa, n2, Deg)

Job Qualification Program
GOP-UTY -07A
IA/PA/N2, DEG 415V

Document: GOP-UTY-07A
Rev. No. : 00
Issue No. : 01
GOP-UTY-07A Effective Date : OCT-2014
(IA/PA/N2,DEG PVC-II ) Page: : 2/53
Prepared by : JAZ/OSW
Prepared By: ___________________________________________

Jahanzaib Waqar Ahmed / Owen Wilfred
Reviewed By: ___________________________________________

Unit Manager, Operations/Unit Manager, Training
Approved By: ____________________________________________

Department Manager (Training & Technology)
Change Record
S No. Rev. No. Date Page No. Section Description of Change
Distribution List
1 LAN
2 Training Manager (Original Copy)
Rev. No. : 00
Issue No. : 01
Contents
1. Purpose ........................................................................................................................ 4
2. Abbreviation .................................................................................................................. 4
3. Technical Terms ........................................................................................................... 4
4. Compressors ................................................................................................................ 5
5. Screw Compressor ....................................................................................................... 7
6. Air Dryers ...................................................................................................................... 9
7. Instrument Air, Plant Air & Nitrogen Generation System ............................................ 13
8. Process Area Description ........................................................................................... 14
9. Tripping Securities (Compressors) ............................................................................. 20
10. Trouble Shooting (Compressors) ................................................................................ 22
11. Start Up and Shutdown Procedure For Compressor .................................................. 25
12. Equipment’s Specifications ......................................................................................... 26
13. Nitrogen Generation Units .......................................................................................... 30
14. Activated carbon ......................................................................................................... 33
15. Pressure Swing Adsorption ........................................................................................ 34
16. Nitrogen An Inert Gas ................................................................................................. 35
17. Blow off Device ........................................................................................................... 39
18. Trouble Shooting ........................................................................................................ 40
19. Specifications Of Nitrogen Unit and Vessel ................................................................ 41
20. Introduction to Diesel Engine Generator ..................................................................... 42
21. Generator Introduction ................................................................................................ 46
22. PVC-II DEG Specification & Basic Design Data ......................................................... 50
23. Control Panel Of DEG ................................................................................................ 52
24. Safety Critical Devices ................................................................................................ 53
25. Electrical System & MCC ............................................................................................ 55
26. P& ID’S (IA/PA/N2 ..................................................................................................... 58
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1. Purpose
The purpose of this document is to give introduction on the basic parts and operations of
UTILITIES/CCPP Area-IV and including basic theory of instrument air, plant air, nitrogen units, Diesel
engine generators of PVC-II 415V its operations, mechanical parts, maintenance, Startup and
troubleshooting.
2. Abbreviation
JQP Job Qualification Program

SOP Standard Operating Procedure
T/A Trade Apprentice
TAE Trainee Assistant Engineer
UM Unit Manager
VP Manu. Vice President Manufacturing
3. Technical Terms
CCR Central Control Room

UTY Utilities
CCPP Combined Cycle Power Plant
IA/PA/N2 Instrument Air/Plant Air/Nitrogen
VCM Vinyl Chloride monomer
PVC Poly vinyl Chloride
FLA Full load Ampere
KW Kilo Watt
MCC Motor Control Center
C.W Cooling water
DEG Diesel Engine Generator
P & ID Piping and instrumentation diagram
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4. Compressors
Compressor: A mechanical device that increases the pressure of a gas by reducing its volume.
Similar to a pump – Increases the pressure on a fluid and transport it through a pipe.
Types of compressor:
There are two basic types of compressors.
Positive Displacement
Dynamic
Positive Displacement Compressor: A compressor that confines successive volumes of

gas within a closed space in which the pressure of the gas is increased as the volume of the closed
space is decreased. PD compressors are further classified into two types as reciprocating
compressor and rotary compressor.
a) Reciprocating compressor: Reciprocating compressors compress gas by physically

reducing the volume of gas contained in a cylinder using a piston. As the gas volume is decreased,
there is a corresponding increase in pressure. This type of compressor is referred to as a positive
displacement type. Reciprocating compressors are typically a once-through process. That is, gas
compression and lubricant separation occur in a single pass.
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Reciprocating compressors may be further classified as single-acting or double-acting. Single-

acting compressors, also classified as automotive compressors or trunk piston units5, compress
gas on one side of the piston, in one direction. Double-acting compressors compress gas on both
sides of the piston.
b) Rotary compressor: Rotary compressors are classified as positive displacement or

dynamic compressors. A positive displacement compressor utilizes gas volume reduction to
increase gas pressure. Examples of this type of compressor include rotary screw, lobe and vane
compressors.
Screw Compressor
Vane Compressor Lobe Compressor

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5. Screw Compressor
The rotary screw compressor consists of two intermeshing screws or rotors which trap gas
between the rotors and the compressor case. The motor drives the male rotor which in turn drives
the female rotor. Both rotors are encased in a housing provided with gas inlet and outlet ports.
Gas is drawn through the inlet port into the voids between the rotors. As the rotors move, the
volume of trapped gas is successively reduced and compressed by the rotors coming into mesh.
These compressors are available as dry or wet (oil-flooded) screw types. In the dry-screw type, the
rotors run inside of a stator without a lubricant (or coolant). The heat of compression is removed
outside of the compressor, limiting it to a single-stage operation. In the oil-flooded screw type
compressor, the lubricant is injected into the gas, which is trapped inside of the stator. In this
case, the lubricant is used for cooling, sealing and lubrication. The gas is removed from the
compressed gas-lubricant mixture in a separator. Rotary compressors, such as the screw
compressor, continuously recirculate (1 to 8 times per minute) the lubricant-gas mixture to
facilitate gas cooling and separation as opposed to reciprocating compressors, which are once-
through processes.
Lubrication in a rotary compressor:
In a rotary screw compressor, the lubricant is injected into the compressor housing. The rotors are
exposed to a mixture of the gas and lubricant. In addition to providing a thin film on the rotors to
prevent metal-to-metal contact, the lubricant also provides a sealing function to prevent gas
recompression, which occurs when high-pressure, hot gas escapes across the seal between the
rotors or other meshing surfaces and is compressed again. Recompression causes gas discharge
temperatures to exceed the designed range for the unit. This often leads to loss of throughput and
poor reliability.
The lubricant also serves as a coolant by removing heat generated during gas compression. For
example, for rotary screw air compressors, the air discharge temperature may be 80 0C to 1100C
(1800F to 2300F), accelerating oxidation due to turbulent mixing of the hot air and lubricant.
In addition to these functions, the bearings at the inlet and outlet of the compressor must be
lubricated. With rotary screw compressors, the lubricant is in contact with the gas being
compressed at high temperatures and it experiences high shearing force between the
intermeshing rotors. These are demanding use-conditions for the lubricant.
A simplified diagram for lubricant flow in a typical rotary screw compressor is shown in Figure.
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Lubricant Flow in a Rotary Screw Compressor
The lubricant and gas mixture from the compressor discharge line goes into a gas/lubricant
separator where the compressed gas is separated from the lubricant. After separation, the
lubricant is cooled and filtered, then pumped back into the compressor housing and bearings.
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6. Air Dryers
A compressed air dryer is a device for removing water vapor from compressed air. Compressed air
dryers are commonly found in a wide range of industrial and commercial facilities. The process of
air compression concentrates atmospheric contaminants, including water vapor. This raises the
dew point of the compressed air relative to free atmospheric air and leads to condensation within
pipes as the compressed air cools downstream of the compressor.
Excessive water in compressed air, in either the liquid or vapor phase, can cause a variety of
operational problems for users of compressed air. These include freezing of outdoor air lines,
corrosion in piping and equipment, malfunctioning of pneumatic process control instruments,
fouling of processes and products, and more.
Types of dryers:
There are various types of compressed air dryers. Their performance characteristics are typically
defined by the dew point.
Regenerative desiccant dryers, often called "regens" or "twin tower" dryers

Refrigerated dryers
Deliquescent dryers
Membrane dryers
Regenerative Desiccant Dryers:
The term "desiccant dryer" refers to a broad class of dryers. Other terms commonly used are
regenerative dryer and twin tower dryer, and to a lesser extent adsorption dryer.The compressed
air is passed through a pressure vessel with two "towers" filled with a media such as activated
alumina, silica gel, molecular sieve or other desiccant material. This desiccant material attracts the
water from the compressed air via adsorption. As the water clings to the desiccant, the desiccant
"bed" becomes saturated. The dryer is timed to switch towers based on a standard NEMA cycle,
once this cycle completes some compressed air from the system is used to "purge" the saturated
desiccant bed by simply blowing the water that has adhered to the desiccant off.The duty of the
desiccant is to bring the pressure dew point of the compressed air to a level in Which the water
will no longer condense, or to remove as much water from the compressed air as Possible. A
standard dew point that is expected by a regenerative dryer is −400C (−400F), this
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Means that when the air leaves the dryer there is as much water in the air as if the air had been
"Cooled" to −40 °C (−40 °F). Required dew point is dependent on application and −70 0C is required in
some applications. Many newer dryers come equipped with dew dependent
Switching (DDS) which allows for the dryer to detect dew point and shorten or lengthen the drying
cycle to fulfill the required dew point. Often times this will save significant amounts of energy which
is one of the largest factors when determining the proper compressed air system.
The regeneration of the desiccant vessel can be during three different methods:
Heatless "pressure-swing" drying, which uses part of the dry compressed air coming from the
other vessel to dry the desiccant in the vessel being regenerated at lower pressure. 17-20%
purge rate.
Heated dryer, which uses a hot air blower, so there is no loss of compressed air. >7% Purge
Rate.
Heat of compression, which can only be used with an oil free compressor.
Refrigeration dryers: Employ two heat exchangers, one for air-to-air and one for air-to-
refrigeration. However, there is also a single TRISAB heat exchanger that combines both functions.
The compressors used in this type of dryer are usually of the hermetic type and the most common
gas used is R-134a. The goal of having two heat exchangers is that the cold outgoing air cools
down the hot incoming air and reduces the size of compressor required. At the same time the
increase in the temperature of outgoing air prevents re-condensation.
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Most manufacturers produce "cycling dryers". These store a cold mass that cools the air when the
compressor is OFF. When the refrigeration compressor runs, the large mass takes much longer to
cool, so the compressor runs longer, and stays OFF longer. These units operate at lower dew
points, typically in the 35–40 0F range. When selected with the optional "cold coalescing filter",
these units can deliver compressed air with lower dew points.
Some manufacturers are marketing compressors with built-in refrigeration dryers, but these have
had a mixed acceptance in the market.
Commonly a coalescing prefilter is installed immediately upstream of a refrigerated dryer to

remove lubricating oil and other contaminants that have the potential to foul the dryer's heat
exchangers.
Deliquescent Dryer: Typically consists of a pressure vessel filled with a hygroscopic media
that absorbs water vapor. The media gradually dissolves—or deliquesces—to form a solution at
the base of the pressure vessel. The liquid must be regularly drained from the vessel and new
media must be added. The media is usually in tablet or briquette form. Deliquescent dryers have
no moving parts and don't require electrical power for operation. Common applications therefore
often involve remote, hazardous, or mobile worksites. Deliquescent dryers are used for removing
water vapor from compressed air, natural gas, and waste gases such as landfill gas and digester
gas. The performance of a deliquescent dryer, as measured by outlet dew point, is highly
dependent on the temperature of the air or gas being processed, with cooler temperatures
resulting in better performance.
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Membrane Dryer: Refers to a dehumidification membrane that removes water vapor from
compressed air. Typically, the compressed air is first filtered with a high-quality coalescing filter.
This filter removes liquid water, oil and particulate from the compressed air. The water vapor–
laden air then passes through the center bore of hollow fibers in the membrane bundle. At the
same time, a small portion of the dry air product is redirected along the outside surface of the
fibers to sweep out the water vapor which has permeated the membrane. The moisture-laden
sweep gas is then vented to the atmosphere, and clean, dry air is supplied to the application. The
membrane air dryers are designed to operate continuously, 24 hours per day, 7 days per week.
Membrane air dryers are quiet, reliable and require no electricity to operate.
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7. Instrument Air, Plant Air & Nitrogen Generation System
At EPCL plant there are various instruments, which used compressed air for theirs operation e.g.
controls valves etc. Moreover compressor air is also used for cleaning, purging, operating some
mechanical machine etc.
Compressed air system includes six air compressors C-4201 , C-4202A/B/C/D and C-4203 two air
moisture separator N-4201 A/B, two Pre-filter F-4201A/B, two sets of air dryer M-4201A/B, two
after filter F4203A/B, two IA receiving vessel V-4201A/B and one PA vessel V-4202.
There are three separate distribution network for instrument air, plant air and nitrogen
generation. Plant air is the containing moisture. It is used for mixing, blowing and other purposes.
The instruments being very sensitive and delicate have to be fed with quality air, which must be
free from moisture, oil particles or any other undesirable material. For this purpose, air after
compression has to be filtered and dried before being used as instrument air and nitrogen
generation.
The Nitrogen generator produces Nitrogen gas from atmospheric air using Molecular Sieves
Separation technique. It uses Carbon Molecular Sieves which has ability to preferentially remove
oxygen from air. Nitrogen generator consists of 2-Beds filled with Carbon Molecular Sieves. When
pressurized air is passed through these adsorbers Nitrogen comes out as product gas.
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8. Process Area Description
Plant Air:
Plant air contains moisture. It is used for mixing, blowing, cleaning and other purposes.
Air Water Separator N-4201 A/B:

The discharged gas from the compressor enters the air-water separator in which it strikes the
knock out drum. The moisture present in air is condensed and drains out at the bottom. The air is
collected from the top of separator tank, some amount of which is stored in the plant air storage
vessel (V-4202) and rest of the amount is treated for getting instrument air.
Instrument Air:
The instrument air should be dust-free, oil-free and dry. To prevent condensation in the supply
piping or in the instruments, the dew point of the air at operating pressure after drier should
always be at least 10°C lower than the lowest ambient temperature.
Air Quality:
The quality of the air is important to ensure that instrumentation will function properly and
reliably. The most important parameters in specifying air quality are:
Dew Point, Oil Content, Particulate matter & Temperature.
Air Pre-filter (F- 4201 A/B):

An air pre filter with a drain trap installed at the entrance of the desiccant drums. For the
desiccant type dryer, the filter mesh is less than 3 micrometers (microns).
Air Dryer (M-4201 A/B):

The air is then passes through the drier where the desiccant Al2O3 is used which removes the
remaining moisture from the air. This equipment will dry compressed air having 100% relative
humidity to the stipulated dew point, and shall be durable for continuous operation under the
specified pressure, humidity and flow rate. The design dew point for instrument air should be
more than 10°C below the lowest recorded outside temperature under the line pressure.
The air drier is the twin-vessel adsorption type with regeneration works on pressure swing
adsorptions process via programed logic controller (PLC).
Air After-Filter (F-4203 A/B):

An air after filter with a drain trap installed at the outlet of the desiccant drums. For further
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precision or removal of drier desiccant contamination from air, the filter mesh is less than 3
micrometers (microns).
Air Compressors
INGERSOLL RAND ROTARY SCREW COMPRESSOR:
The SSR compressor is an electric motor driven, Single stage, oil injected screw compressor
complete with accessories piped, wired and baseplate mounted. It is a totally self-contained air
compressor package.
A standard compressor is composed of the following:-
Inlet air filtration

Compressor and motor assembly
Pressurized coolant system with cooler
Separation system
Capacity control system
Motor starting control system
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Instrumentation
Safety provisions
After cooler
Moisture separator and drain trap
Air enters the compressor passing through the inlet air filter and inlet valve. Compression in the
screw-type air compressor is created by the meshing of two helical rotors (male and female) on
parallel shafts, enclosed in heavy duty cast iron housing.
The air-coolant mixture discharges from the compressor into the separation system. This system
Self-contained in the receiver tank, removes all but a few PPM of the coolant from the discharge
air. The coolant is returned to the system and the air passes to the after cooler. The after cooling
system consists of a heat exchanger, a condensate separator, and a drain trap. By cooling the
discharge air, much of the water vapor naturally contained in the air is condensed and eliminated
from the downstream plant-piping and equipment.
The compressor is design for high temperature and high relative humidity ambient. It can operate
at max. 460C ambient temperature.
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Air compressor internal

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The following is a list of the set point. It’s Also included maximum and minimum limits, steps
size, and units of measure.
Description MIN MAX STEP UNIT

OFFLINE PRESSURE 75 RATED+3 1 PSI
OFFLINE-
ONLINE PRESSURE 65 1 PSI
10
CONTROLE MODE MOD/ACS-MODULATION-ON/OFF LINE
DISPLAY TIME 10 600 10 SEC
AUTO RESTART OFF ON - -
AUTO RESTART TIME 2 60 1 MIN
SEQUENCER OFF ON - -
REMOTE START/STOP* OFF ON - -
POWER OUT/RESTART* OFF ON - -
POWER OUT RESTART
10 120 1 SEC
TIME*
DISPLAY LOAD TIME 0 60 1 SEC
LEAD/LAG** - - - -
LAG OFFSET 0 45 1 PSI
LOW AMBIENT OFF ON - -
ALARMS (Compressors):-
When the warning occurs, the alarm indicator will flash and the display will alternate between the
current message and the warning message. If multiple warning exist, the messa
SCROLL FOR ALARM
Will be substituted for the warning message. The up and down arrows can be used to obtain the
warning. A warning needs to be reset by an operator. The warning will clear when the SET button
is pressed once. The following is list of the warning message.
1) CHG SEPR ELEMENT

This warning will occur if the pressure on the separator is 12 psig (0.8 bars) greater
than the pressure at the package discharge and the unit is fully loaded.
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2) HIGH AIR END TEMP

This will occur if the air end temperature exceed to 220 0F (105 0C).
3) HIGH AIR PRESSURE

This will occur if the unit is connected to an ISC (SEQUENCER) and the line pressure
exceed the maximum offline pressure for three seconds.
4) T2 SENSOR FAILURE
This will occur when the low ambient Option is turned on and either the low ambient
sensor is not installed or broken.
When the alarm occurs, the alarm indicator will light and display will show actual
alarm message. If alternately multiple alarms have occurred the display will show
scroll for alarm. In this situation the up and down will be used to view the alarms
messages, all alarms (with the exception of the emergency stop) will be reset by twice
pressing the SET button. Any exception to the above will be explained in the alarm
description.
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9. Tripping Securities (Compressors)
1) LOW SUMP PRESSURE

This will occur if the unit is running and sump pressure is too low.
2) HIGH AIR PRESSURE

This will occur if the unit is running and sump pressure is greater than unit rated operating
pressure plus 20 psig (1.4 bar), plus the separator pressure drop, or the line pressure is 15
psig (1.0 bar) above the rated pressure.
3) HIGH AIR END TEMPERATURE

This will occur if air end discharge temperature is greater than 228 0F (109 0C)
4) STARTER FAULT 1SL (2SL)

This alarm will occur if the starter contacts open while the unit is running. this alarm will
also occur if the unit is given the start command and the starter contacts do not open.1SL
refer to the auxiliary circuit on starter contactor 1M.2SL refer to auxiliary circuit on the
starter contacts 2M and 1S.
5) MAIN MOTOR OVERLOAD

This will occur if motor overload is sensed.
6) FAN MOTOR OVERLOAD

This will occur if the fan motor overload is sensed.
7) TEMPERATURE SENSOR FAIL.

This will occur when the sensor temperature is recognized as faulty.
8) REMOTE STOP FAIL

This will occur if the momentary remote STOP switch does not disengage.
9) REMOTE START FAIL.

This will occur if the momentary remote START switch does not disengaged.
10) CHECK MOTOR ROTAION

This will occur if a unit is started and compressor has incorrect rotation.
11) CALIBRATION FAIL This alarm will occur if the sensor calibration routine is executed and
the sensor reading exceeds 10% of scale.
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12) NO CONTROLE POWER

This alarm will occur when the controller senses a loss of control power.
13) PRESSURE SENSOR FAIL

Whenever the pressure sensor is recognized as faulty, a pressure sensor failure alarm will
occur.
14) LOW UNLOAD SUMP PRESSURE

This alarm will occur if the unit is running unloaded and sump pressure is less than 15 psig.
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10. Trouble Shooting (Compressors)
TROUBLE CAUSE &/OR DISPLAY ACTION

High coolant Excessive coolant level. - Check level lower if necessary
consumption/coolant in by draining,
air system Plugged separator - Check separator pressure drop.
element.
- Check separator pressure drop.
If low replace element
Separator element leak.
-Remove and inspect
orifice/screen. Clean if required
Plugged separator -Operate at rated pressure.
scavenges orifice/screen. -Reduce system load.
-Inspect and repair leaks.

Compressor operating at
low
Pressure (75 psig/5bar) or
below
Coolant system leak.
Water in air system Defective moisture - Inspect and clean if required.

separator /drain trap Replace separator/trap if
defective.
Trap drain or drain piping -Inspect and clean.
plugged
After cooler core dirty. - Inspect and clean
Enclosure panels not in -Install enclosure panels
placed. -Slope drains line away from
Drain line/drip leg trap. Install drip leg.
incorrectly installed. -Contact local Ingersoll-Rand
Distributor or Air centre.
No refrigerated or
desiccant dryer in air
system
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Excessive noise level Compressor -Contact authorized distributor

defective.(Bearing failure or air centre immediately, do not
or rotor contact) operate unit.
-Install enclosure panels, Inspect
& tighten.
Enclosure panel not in
place.
Loose component
mounting.
Excessive vibration Loose components - Inspect & tighten.
Motor or compressor -Contact authorized distributor
bearing failure or air centre immediately, do not
operate unit.
- Inspect area for other
External sources equipment
Pressure relief valve open Compressor operating -Adjust Intellisys set points.
over pressure
Defective valve. -Replace valve.
Compressor fails to start. 110/120v control voltage -Check fuses, Check transformers
not available. & wiring connections
-Inspect contactors.
“Starter fault 1SL (2SL)” -Rotate emergency stop button
“EMERGENCY STOP” to disengaged, & press” SET”
button twice.
-Manually reset main or fan
“MAIN MTR OVERLOAD” motor overload relay, and press”
or SET” button twice.
FAN MOTOR OVERLOAD” -Check for defective sensor, bad
sensor connection broken sensor
PRES SENSOR FAIL” or wires.
TEMPERATURE SENSOR
FAIL
Compressor shutdown “HIGH aired temperature” Ensure that installation area has
adequate ventilation.
-Ensure that cooling fan is
operating. If not reset circuit
breakage in side starter box.
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-Check coolant level. Add if

required.
-Cooler cores dirty. Clean coolers
-Check for restricted or
“HIGH air pressure” malfunctioning blow down valve
or minimum pressure check
valve.
-Check for air leak from tank or
“LOW sump pressure blow down piping
-Adjust sump pressure
-Check for defective sensor, bad
Pressure sensor fail or sensor connection, or broken
Temperature sensor fail sensor wires.
-Interchange any two-line
Check motor rotation connection (L1, L2, L3) at the
starter.
-Check for loose wires.
MAIN MTR OVERLD’’ -Check supply voltage.
-Check heater size.
-Check supply voltage.
“FAN MTR OVER LOAD” -Fan motor overload tripped.
-Check for dirty cooler cores.
-Inspect starter contactors.

‘’STARTER FAULT 1AL
(2AL)”
Low system air pressure. Compressor running in -Press “UNLOAD/LOAD” button.
“Unload”
Mode. -Press “UNLOAS/STOP” button’
set off-line set point at a higher
Controller off-line set value.
point too low.
-Check filter condition. Replace
Dirty air filter element. as required.
Air leak. -Check air system piping.
Moisture separator trap -Inspect and repair. Check
control system operation.
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11. Start Up and Shutdown Procedure For Compressor
Startup Procedure for Compressor
1. Ensure no maintenance job is going on equipment and its accessories.

2. Check compressor motor connection done and breaker is properly racked in.
3. Check electrical power is available.
4. Check cooling water supply is available.
5. Check Lube oil level is sufficient.
6. Fully open Compressor outlet valve.
7. Check compressor suction air filter is clean.
8. Drain all moisture from outlet line drain of compressor.
9. After complete draining, minimize drain valve of compressor.
Shut Down Procedure for Compressor

1. Inform Boardman/SIC about the activity.
2. Unload the compressor by pressing unload button.
3. Check IA/PA header pressure is normal.
4. Check other compressors are running normal.
5. Stop the compressor by pressing stop button.
6. Close the outlet valve of compressor.
7. Open the drain valve of compressor.
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12. Equipment’s Specifications
AIR COMPRESSORS- C4201;
TAG NO. C-4201

Type Screw
Mode Mm55w/c
Manufacturer Ingersoll rand
Capacity 10 m³/min
Pressure 0.85 Mpa
Power 55 Kw
Power Requirement 400 V / 50Hz / 3 Phase
Max .Design Temperature
46 ˚C
Design pressure 1.0 Mpa
Motor RPM 1485
Motor ampere 132 Amp
Noise level <75 dB
COMPRESSOR- C4203:
TAG NO. C-4203

Type SCREW
Manufacturer COMP AIR
Capacity 5 M³/MIN
Pressure 0.85
Power 30 KW
Power Requirement 400 V / 50HZ / 3 PHASE
Max .Design Temperature 46 ˚C
Design pressure 1.0 MPA
Motor RPM 1485
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COMPRESSOR- C4202 A/B/C/D
TAG NO. C-4202 A/B/C/D

Type Screw
Mode Mm250-25W/C (6.6kv,IP54)
Manufacturer Ingersoll rand
Capacity 43 m³/min
Pressure 0.85 Mpa
Power 250 kw
Power Requirement 6600 V / 50Hz / 3 Phase
Max .Design Temperature
46 ˚C
Motor RPM 1485
Motor ampere 33 Amp
Noise level <85 dB
EQUIPMENT SPECIFICATION OF PLANT AIR:
Air Moisture Separator N- 4201 A/B

TAG NO. N-4201 A/B
Capacity/Separator 60 m³/min
Operating pressure 0.85 Mpa
Operating temperature 40 ˚C
Design temperature 70
Size ID 1400,H 3750 mm
PLANT AIR VESSEL V-4202

TAG NO. V-4202
Capacity 118 m³/min vertical
Design temperature 60 ˚C
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Size DN 4000,H 8000mm

Material 16 MnR
SPECIFICATION OF INSTRUMENT AIR:
AIR PRE-FILTER -F4201 A/B

TAG NO. AIR PRE-FILTER (F-4201 A/B)
Capacity/filter 60 m³/min
Size ID250, H 1190 mm
Instrument Air Dryer M-4201 A/B):

TAG NO. M-4201 A/B
Capacity/Drier 60 m3/min
Operating temperature <40 0C
Operating Pressure 0.85 Mpa (g)
Design Pressure 1.0 Mpa (g)

Design Temperature 70 0C
Dew Point ≤ -40 0C at 0.8 Mpa
Electric Power 200W, 220V, 01 PH, 50Hz

Emergency Power Yes
Detail Specification of Dryer:

TAG NO. M-4201 A/B
Adsorbent (Desiccant) Al203 (Aluminum Oxide)
Desiccant Quantity 1336 Kg
Vessel Desiccant Pressure 0.6 ~ 1.0 MPa
Dryer Operating Cycle 5 Min
Type of Operation Fully automatic
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AIR AFTER -F4203 A/B;

TAG NO. F-4203 A/B
CAPACITY/FILTER 60 M3/MIN
OPERATING PRESSURE 0.85 MPA
OPERATING TEMPERATURE 40 ˚C
DESIGN PRESSURE 1.0 MPA
DESIGN TEMPERATURE YES 70 ˚C
OIL PRECISION ≤,0.01 PPM
DUST PRECISION ≤,0.01µM
SIZE ID250, H 1190 MM2.4
INSTRUMENT AIR VESSELS -V4201 A/B

TAG NO. V-4201 A/B
Size DN 4000,H 8000mm
Material 16 MnR
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13. Nitrogen Generation Units
.
ADSORPTION
Adsorption is the adhesion of atoms, ions, or molecules from a gas, liquid, or dissolved solid to a
surface. This process creates a film of the adsorbate on the surface of the adsorbent. This process
differs from absorption, in which a fluid (the absorb ate) permeates or is dissolved by a liquid or
solid (the absorbent) Adsorption is a surface-based process while absorption involves the whole
volume of the material. The term sorption encompasses both processes, while desorption is the
reverse of it. Adsorption is a surface phenomenon.
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Molecular Sieve
A molecular sieve is a material with very small holes of precise and uniform size. These holes are
small enough to block large molecules while allowing small molecules to pass. Many molecular
sieves are used as desiccants. Some examples include activated charcoal and silica gel.
The diameter of a molecular sieve is measured in Angstroms (Å) or nanometers (nm). The unit
conversion for 1 Å is 0.1 nm. According to IUPAC notation, micro porous materials have pore
diameters of less than 2 nm (20 Å) and macro porous materials have pore diameters of greater
than 50 nm (500 Å); the meso-porous category thus lies in the middle with pore diameters
between 2 and 50 nm (20-500 Å).
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14. Activated carbon
The term “activated carbon” defines a group of materials with highly developed internal surface
area and porosity and hence a large capacity for adsorbing chemicals from gases and liquids.
Activated carbons are extremely versatile adsorbents of major industrial significance and are used
in a wide range of applications concerned principally with the removal of species by adsorption
from the liquid or gas phase, in order to effect purification or the recovery of chemicals. They also
find use as catalysts or catalyst supports. The strong market position held by activated carbon
adsorbents relates to their unique properties and low cost compared with that of possible
competitive adsorbents.
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15. Pressure Swing Adsorption
Pressure Swing Adsorption (PSA) processes rely on the fact that under pressure gases tend to be
attracted to solid surfaces, or adsorbed. The higher the pressure, the more gas is adsorbed; when
the pressure is reduced, the gas is released, or desorbed. PSA processes can be used to separate
gases in a mixture because different gases tend to be attracted to different solid surfaces more or
less strongly.
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16. Nitrogen An Inert Gas
Nitrogen gas is a staple of chemical industry being inert in nature it is suitable for a wide range of
covering varies aspect of chemical manufacturing processing & handling due to its low reactivity
nitrogen is an excellent that can be used to protect valuable products from harmful contaminants
it also enables the safe storage and use of flammable compounds and can help prevent
combustible dust explosions nitrogen shipping due to its low reactivity nitrogen is an excellent
blanketing and pure gas that can be used of flammable compounds and can help prevent
combustible dust explosion nitrogen gas can be used to remove contaminants from process
streams through methods such stripping and sharping.in the 1980s alternative method of onsite
gaseous nitrogen generation such as PSA and membrane separation came into practice initially
these techniques were suitable only for small volume low purity applications today however PSA
and membrane system are an efficient supply mode of a variety of volumes purity requirement
and usage patterns PSA system operate on the principle on adsorption whereas membrane system
separate based on selective permeation pressure swing adsorption in the PSA process (Figure 1)
compressed air first passes through a combination of filters to remove entrained oil and water.
The purified air is then directed to one of two adsorption vessels that are packed with (CMS)
Carbon molecular sieve. The remaining impurities such as carbon dioxide and residual moisture
are adsorbed by the CMS at the entrance of the adsorbent bed at high pressure the CMS
selectivity adsorbs oxygen allowing nitrogen to pass through at the desired purity level while one
vessel producing nitrogen the second vessel is depressurized to remove the adsorbed oxygen
which is the vented to the atmosphere the automatic cylinder adsorption and desorption between
the two beds enables the continues production of nitrogen. A large range of flow and purity
combinations can be adjusting the size of the air compressor and adsorption vessel containing the
CMS.PSAs can economically produce nitrogen gas at flow rates from less 5000 sch to greater than
60,000 scfh and at purities ranging from 95% to 99.9995%.
Rev. No. : 00
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DESCRIPTION: (REF: P&ID NO T07B01-4200PS07-03)
A 4”dia off take for nitrogen generation unit is taken directly from 8” dia line of instrument air
discharge header. (Ref: P&ID No T07B01-4200PS07-01)
IA first passes through precision filter then enter activated carbon filter to remove odor.
After carbon filter air goes to air buffer tank followed by nitrogen generators. Nitrogen generator
is made up of two adsorption tanks which are filled by carbon molecular sieve, a set of valves and
a controller. Valves that are normally close are opened by electromagnetic valve which is
controlled by the controller.
When adsorption tank is working, air source enters from the open valve under the tank and flows
from the opened valve to the top of the tank. The wastage gas which is produced in regeneration
tower will flow out from the bottom of the tank. There are a set of valves in the middle of each
tank to balance pressure. Nitrogen flows from upside valve to nitrogen buffer tank via precision
filter and then to the nitrogen storage tank V- 4203.
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17. Blow off Device
While the purity of the outlet nitrogen could not reach the quality requirement, it is allowed to
blow off it, and can chose manual blowing off or auto blowing off.
Auto blow off
If chose auto blowing off mode, switch on the blow off button on the control panel first to adjust
the nitrogen gas pressure with regulator 2 and close valve 1, with valve 2 open and solenoid valve
closed. There is a micro-content nitrogen analyzer in parallel connection with solenoid valve. In
case the nitrogen purity doesn’t reach the set value, this instrument will send signals to solenoid
valve to open it and blow off the gas.
If chose manual blowing off mode, switch the blow off switch button on the control panel first,
then adjust the nitrogen gas pressure with regulator, and open valve 1 close valve 2.
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18. Trouble Shooting

TROUBLE CAUSE &/OR DISPLAY ACTION
Actual flow over nominal one Replace a filter off big flow
Actual pressure below nominal one Replace a filter off big flow
Filter element end set nut not Tighten the filter element
tightened and nut
Air flow in short circuit Check o-ring and rubber
Bad filtration
gasket
Bypass valve not closed completely Close Bypass valve
completely
Filter element is ageing Replace
Air is mixed with oil due to high Check whether drainer in

level of oil and water blocking or not
Lower pipeline dirty Clean pipeline timely
Input air full of foreign matter Improve quality of inlet air
Filter element blocked seriously Replace
Pressure difference
Too much water in filter container Check weather drainer is
increases suddenly
blocking
The end cover loose to leak Refix the end cover
Inlet pressure too low Increase inlet pressure
Flow decreases O-ring and flange gasket damaged Replace

suddenly or leaking
Leak of pipe Replace
Pipeline valve opened un Open valve

completely
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19. Specifications Of Nitrogen Unit and Vessel
TAG NO. M-4202 & M-4203

Capacity 600 Nm³/h
Design Pressure 1.0 Mpa
Design temperature 70 oC
Operating Pressure 0.6 Mpa
Operating Temperature ≤ 45 0C
Dew Point <-40 0C @ 0.8Mpa(g)
Purity Dew Point 99%
Oil content of inlet air ≤0.03 ppm
Power 100W, 220V, 50Hz (Emergency power supply)
Size L 2600, W 2200, H 3500 mm
Nitrogen Vessel -V4203
TAG NO. V-4203

size DN 4000,H 8000mm
Material MnR
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20. Introduction to Diesel Engine Generator
Introduction:
In fast track during PVC-II plant start up power is supplied by GTG at base plant & stand by DEG of
PVC-II. After the installation of power generation units the whole power is supplied by 02 GTs & 01
STG (Combine cycle Power Plant) and DEG acts as emergency stand by.
Diesel Engines:
The important areas for application of I.C engines are power generation. The devices or systems
used to produce a net power output are called engines, and the cycles they operate on, is called
power cycle. Engines where working fluid (fuel) is renewed at the end of each cycle is called open
cycle, as in automobile engines. The combustion gases are exhausted and replaced by fresh air
fuel mixture at the end of each cycle.
Engines are categorized as internal combustion or external combustion engines, depending on
how the heat is supplied to the working fluid. In external combustion engine (such as steam power
plants), energy is supplied to the working fluid from an external source such as furnace, nuclear
reaction etc. In internal combustion engines, this is done by burning the fuel within the engine
system.
Overview of I.C. engines

Despite its simplicity, the I.C engines employing piston-cylinder device is one of the rare
inventions that have proved to be very versatile and to have a wide range of applications. It
Rev. No. : 00
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is the powerhouse of the vast majority of automobiles, ships and electric power generators,
as well as many other devices.
Reciprocating engines are classified as spark-ignition (SI) engines or compression ignition (CI)
engine, depending on how the combustion process into the cylinder is initiated. In SI engines
the combustion of the air-fuel mixture is initiated by a spark plug. In CI engines, the air-fuel
mixture is self-ignited as a result of compressing the mixture above its self-ignition
temperature.
IC engine main parts are:
Lube oil pump and its filter

Crank shaft
Big ends
Engine block
Connecting rods
Pistons
Piston rings
Fuel pump and its filter
Cam shaft
Intake and exhaust valves
Gears of crank and cam shafts
Flywheel
Air-Fuel controlling devices (Governor)
Diesel cycle (I.C. engine):

In diesel engine the following sequence of event is continuously repeated at the time the engine is
running.
Induction Stroke
The induction stroke, during which only air is taken into the combustion chamber and cylinder, as a
result of the partial vacuum or depression created by piston downward movement.
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Compression Stroke
The compression stroke, in which the advancing piston compresses the air into the very small volume
of the combustion chamber and raises its temperature high enough to ensure self-ignition of the fuel
charge. This demands compression to operate at much higher compression ratios, typically between
12 and 24.
Power Stroke
In power stroke, fuel charge is injected into the combustion chamber and mixes in the very hot air,
and during which the gases of combustion expand and perform useful work on the retreating piston.
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Exhaust Stroke
The exhaust-stroke, during which the products of combustion are purged from the cylinder and
combustion chamber by advancing piston and discharged into the exhaust system.
Characteristics of Diesel Engine:

The diesel engine has better fuel economy than the petrol engine. This is because its thermal
efficiency is 30-36% compared with the 22-25% of petrol engine. The diesel engines have generally
proved to be more reliable to need less maintenance and also to have a longer life than an equivalent
petrol engine. The maximum tuning effort on torque exerted by the crankshaft of the diesel engine is
greater and also better maintained over a wider range of engine speeds.
A disadvantage of the diesel engine is that it tends to be heavy and bulky in relation to its power
output. This is explained by the greater operating pressures. A safety consideration is that the fuel oil
used in diesel engine is far less dangerously flammable than petrol, thus reducing the fire risk in the
event of an accident.
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21. Generator Introduction
The development of electrical technology on a commercial scale began when it was freed from its
former dependence on cells and batteries.
Michael faraday carried out a series of experiments, which after years of painstaking work, ended in
the discovery of electromagnetic induction. One of faraday’s basic experiments is very simple and
well worth repeating. A coil of wire is wound on an empty cardboard tube, and the ends of the wire
are connected to a galvanometer. As the permanent magnet is plunged into the coil the meter
registers a momentary current. When the magnet is pulled out of the coil the meter registers a
momentary current in the opposite direction. No current is registered while the magnet is at rest,
either in the coil or outside.
We might tempt to conclude that motion is an essential component of this experiment. As the
permanent magnet replaced by an electromagnet and placed inside the fixed coil. If the
electromagnet current is increased quickly, the meter again registers a momentary current. No
current is registered by the meter when the electromagnet current is steady. Once again the size of
current depends on the speed with which the electromagnet current is varied.
From these simple experiments it should be clear that the size of the current produced (induced) in
the coil depends on the strength of the magnetic field involved and on the speed with which the
magnetic field is changed and it cut the lines of magnetic field.
The generator principle

To induce an EMF or a current requires a magnetic field and a conductor moving at right angles to
the direction of the field. The simplest method of achieving this is to arrange for a coil of wire to be
rotated continuously in a magnetic field. Such an arrangement forms the basis of all types of
generators.
The magnitude of the EMF induced in the coil will depend on the strength of the magnetic field, the
speed of rotation, the number of turns on the coil. This simple machine converts mechanical energy
(i.e. the work done in turning the coil) into electrical energy. In each revolution the current induced
in the coil rises to a maximum value, falls to zero, reverses, rises to maximum, and falls to zero again.
It is in fact an alternating current.
The reason for the rise and fall of the current is that the magnitude of the induced EMF depends on
the rate at which lines of force are cut. When the coil is vertical it moves along the lines of force
without actually cutting them, no EMF is induced. When the coil is horizontal its movement is at right
angles to the field, and greatest possible number of lines of force is cut per second; the EMF induced
reaches its maximum value.
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Alternator Description
General
The alternator fitted on the generating set is of the brushless self-excitation type which eliminates
the maintenance associated with slip rings and brushes. The control system consists of an automatic
voltage regulator, protective circuits and the necessary instruments to allow monitoring of the
output of the generating set.
Major Components
The alternator unit is completely self-contained and is designed and constructed to provide trouble
free operation, ease of maintenance and long service life.
The Stator core is produced from insulated low loss electrical grade sheet steel laminations. These
are built and welded under a fixed pressure to give an extremely rigid core to withstand vibrations
and load impulses. The complete wound stator is, after impregnation, pressed into the frame and
pinned into position.
A high grade precision machined shaft carries the rotor assembly which comprises the alternator
rotating field systems, the exciter rotator/rotating diode system and the cooling fan. The rotor is
mechanically wedged and supported on the winding end to allow an over speed of up to 2250 RPM.
The complete rotor assembly is dynamically balanced to ensure vibration-free running.
At the drive end of the rotor assembly a cast-aluminum centrifugal fan draws cooling air through
screened/louvered covers at the non-drive end and discharges it through similar side mounted
covers at the drive end.
Method of Operation
The electrical power produced by the generating set is derived from a closed loop system consisting
principally of the exciter rotor, the main revolving field and the automatic voltage regulator.
The process begins when the engine starts to rotate the internal components of the alternator. The
residual magnetism in the main rotor produces a small alternating voltage (AC) in the main stator.
The automatic voltage regulator rectifies this voltage (converts it to DC) and applies it to the exciter
stator.
This DC current to the exciter stator creates a magnetic field which, in turn, induces an AC voltage in
the exciter rotor. This AC voltage is converted back to DC by the rotating diodes.
When this DC voltage appears at the main rotor, a stronger magnetic field than the original residual
field is
Created which induces a higher voltage in the main stator.
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This higher voltage circulates through the system inducing an even higher DC voltage back at the
main rotor. This cycle continues to build up the voltage until it approaches the proper output level of
the generating set. At this point the automatic voltage regulator begins to limit the voltage being
passed to the exciter stator which, in turn, limits the overall power output of the alternator.
This buildup process takes place in less than one second.
Automatic Voltage Regulator

The Automatic Voltage Regulator (AVR) maintains a no load to full load steady state voltage to tight
tolerances. The AVR has a volts/hertz characteristic which proportionally reduces the regulated
voltage at reduced speeds. This feature aids the engine during sudden large additions of load.
Synchronous AC generators
In AC generator development, high voltage at its terminals created the problems of insulation and
mechanical construction associated with rotating slip rings and stationary brushes and it is surprising
that the design of synchronous (practical) AC generator eliminates the need for the slip rings. This
was achieved by keeping the coil stationary and rotating the magnetic field. The figure shows a
magnet rotating between a pair of fixed coils and the magnetic field cutting each coil rises and falls as
the poles move past it and an alternating e.m.f. is induced.
In practice, the rotating permanent magnet is replaced by an electromagnet. Since there are two sets
of winding (one for electromagnet and other for stationary coil), we have to distinguish between
them by calling the rotating electromagnet the “rotor” and calling the stationary armature coil the
“stator”. The winding of the rotor, which provide the magnetic field, are supplied with direct current
called excitation. Stator slots are cut to carry copper windings. Heat is removed by air or water
circulating in tubes.
In actual practice power is generated commercially in the form of a 3-phase current rather them the
single-phase current of the domestic supply. The simple single-phase AC generator is modified to
produce 3-phase output by giving it three separate sets of stator windings. The three phase induced
e.m.f. are shown in figure and they are out of phase with one another by 120°. The rotor of 3-phase
generator has several pair of poles arranged symmetrically around its circumference, while the stator
has three times as many pairs of windings.
Engine cooling system
The engine cooling system is comprised of,

A radiator,
A high capacity radiator fan
Rev. No. : 00
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A thermostat valve.
The alternator has its own internal fan to cool the alternator components.
The air is pushed through the radiator so that the air is drawn past the alternator, then past the
engine and finally through the radiator.
For heating purpose two block electric heaters are provided to maintain the water temperature.
The cooling water is primarily used in lube oil coolers, then used in engine jackets cooling and finally
in after coolers to cool the combustion air. Return cooling water line has control panel temperature
indicator and high temperature switch. A thermostatic valve is installed on return line to direct return
cooling water either to the suction of cooling water pump or toward cooling water skid (radiator fan),
depending on temperature of cooling water.
Rev. No. : 00
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22. PVC-II DEG Specification & Basic Design Data
UTY-II DEG Basic Design Data

Manufacturer............................................................. MITSUBISHI
Model........................................................................ D 1600 65.4A50.
Engine Type............................................................. 4 Cycle, water Cooler.
Fuel system............................................................... Diesel
Nominal operation speed ................................. ...... 1500
High Engine speed trip.............................................. 1875 RPM
Compression Ratio ................................................... 15: 1
Type ....................................................................... 4 - Stroke
Cylinder & Arrangement........................................... V – 16 at 60˚
Bore........................................................................ 170mm (6.7 inch)
Stroke....................................................................... 180mm (8.46 inch)
Lubrication oil............................................................
Method of starting...................................................... Electric starting motor.
Aspiration.........................................Turbocharged, After Cooler (Jacket water to Cooler)
Method of fuel injection.............................................. Electronic fuel injector
Exhaust System
Exhaust manifold type................................................Dry
Exhaust flow at rated KW...........................................385 m3/min
Exhaust temperature at rated KW...............................519C.
Max allowable back pressure......................................5.9KPa
Lubrication System
Oil pressure at idle speed................................................2-3kg/cm2
Oil pressure at rated speed...........................................5-6.5kg/cm2
Maximum oil temperature...........................................1100C/2300F
Oil capacity of standard pan.........................................200 liters
Total system capacity (includes oil filters)...................230 liters
Cooling System
Coolant capacity (engine only)................................................170 liters
Radiator system capacity including Engine…………………..420 liters
Rev. No. : 00
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Maximum outlet pressure of engine water pump.............................2kg/cm 2

Maximum coolant temperature at engine outlet...............................98 0C/2080F
Fuel system
Recommended fuel…………………………………....Diesel
Fuel injector...................................................................Mitsubishi PS8x2
Maximum fuel flow……………………………………510 LPH
Maximum suction head of feed pump...........................75 mmHg
Maximum static head of return &leak pipe...............................150mmHg
Starting system
Battery charging alternator................................................24V-30AH
Starting Motor capacity V-KW.........................................24-7.5X 2
Recommended min. battery capacity (above 5 C).....................300 Ah
Air Requirements
Combustion air……………………………………146 m3 /min
Radiator-cooled cooling air………………………..2039 m3/min
Fuel Consumption
At 100 % Load……………………………………410 LPH
At 100 % Load……………………………………302 LPH
At 50 % Load……………………………………..208 LPH
At 25 % Load……………………………………..112 LPH
GENERATOR SPECIFICATION
Manufacturer............................................................. KOHLER
Model........................................................................ 1800REOZM
Power O/P...................................................................1580 KW
KVA............................................................................1975 KVA
Voltage........................................................................415 V
Power Factor................................................................0.8
Operation speed.......................................................... 1500 RPM
High Engine speed trip.............................................. 1875 RPM
Insulation Class............................................................NEMA class H
Generator Poles............................................................4
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23. Control Panel Of DEG

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Issue No. : 01
24. Safety Critical Devices
There are following safety critical devices in IA/PA/N2 Area
At IA/PA Compressors Set Point

C-4202A PSV-4238 A1 & A2 12.23 Kg/cm2
C-4202B PSV-4238 B1 & B2 12.23 Kg/cm2
C-4202C PSV-4238 C1 & C2 12.23 Kg/cm2
C-4202D PSV-4238 D1 & D2 12.23 Kg/cm2
C-4201 PSV-4237 12.23 Kg/cm2
C-4203 PSV-4239 12.23 Kg/cm2
At Gas Liquid Separator:
N-4201 A/B PSV-4240 A/B 0.98Mpa
At PA Storage Vessel
V-4202 PSV-4202 0.98Mpa
At IA Storage Vessel
V-4201 A/B PSV-4201 A/B) 0.98Mpa
At Nitrogen Units:
V-4231 (Air Tank) (PSV-4235) 0.98Mpa
V-4232 (N2 Buffer Tank) (PSV-4236) 0.98Mpa
V-4221 (Air Tank) (PSV-4231) 0.98Mpa
V-4222 (N2 Buffer Tank) (PSV-4232) 0.98Mpa
AIA-4201 & AIA-4203 (N2 Analyzers) 99%
V-4203 (N2 Storage Vessel) (PSV-4203) 0.98MPa
At PVC-II DEG 415V

5E (Emergency Stop) DEG 415 V PVC-II N/A
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Issue No. : 01
12 (Over Speed Trip switch at DEG 415 V PVC-II) 1800 RPM

26W1 (Coolant High Temperature) DEG 415 V PVC-II
48 (Fail To Start Device) DEG 415 V PVC-II
59 (Over Voltage) DEG 415 V PVC-II
63Q1 (Low Oil Pressure) DEG 415 V PVC-II
(Coolant Low Level Switch) DEG 415 V PVC-II
415 V DEG (PVC-II)
Rev. No. : 00
Issue No. : 01
25. Electrical System & MCC
PVC II Sub Station:

All breakers of IA/PA & N2 Unit in PVC-II Sub-station, Some breakers in E-BUS.
E-BUS:
M-4201 A/B (Air Dryers), M-4202/M-4203 (Nitrogen Units), C-4201 (Emergency Compressor)
remaining all breakers in Normal Buses.
General Sub Station:
All waste water breaker in (GSS) LV room.
E-BUS:
C-4202 A & C-4202 B on Emergency Bus 6.6 kV breaker room, and remaining all breakers on Normal
Buses.
PVC-II SUB-STATION MV & LV (6.6KV & 415V)

PVC-II sub-station is in two parts (rooms) MV & LV (MV is 6.6KV and LV is 415V).
The Purpose for providing 6.6 KV power to PVC-II is for operation of their dryer blower and exhaust
blower i.e. BL-2H and BL-3H.
In MV (6.6KV) room we have 01 6.6KV Bus powered by two incomer line breakers coming from GSS.
These line breakers IN MV room named “INCOMING LINE-I & INCOMING LINE-II” and a Tie breaker
between them named “BUS-TIE” for power line up in case of emergency or requirement. And at
down Stream of these INCOMING LINE breakers we have two transformer feeder breakers named
“TRANSFORMER-I & TRANSFORMER-II” and transformer for step down the voltages for LV room
power (i.e. 6.6KV to 415V). After transformers we have 03 415V buses in LV (415V) room.
1. Emergency Bus
2. Bus-I
3. Bus-II
In LV room 415V power from transformers is then go through two breakers named “QF1 and QF2”
and a tie breaker between them named QF3. An automatic transfer switch (ATS) interlock is also
there for mitigation of QF1 or QF2 breakers tripping, ATS will close the tie breaker QF3 and power
will supply via remaining breakers. From the startup of PVC-II, ATS interlock is not in service. QF1 is
for power up Bus-I and Qf2 is for power up Bus-II.
We also have extension of both buses. Bus-I extended via a local breaker for further powering up the
breakers of plant equipments and Bus-II extended via a breaker named QF4 for powering up
Emergency Bus.
Power from DEG 415V connected or isolated to Emergency Bus via a breaker QF5 which is also
named as circuit breaker (CB) in DEG generator control panel (GCP).
Rev. No. : 00
Issue No. : 01
We have an interlock between QF4 and QF5, as per this interlock one breaker will remain in opposite
condition as the other, for example if power failure occurred and DEG starts on auto mode and QF5
closes then QF4 will open automatically.
This interlock between Qf4 and QF5 can be bypass through selector switches on breakers in LV room.
There are two positions on selector switches LOCAL & GCP, both selector switches on LOCAL
indicates the interlock is bypass and both selector switches on GCP indicates interlock is in service
and operation of breaker will be performed via DEG GCP.
See the power line diagram below.
Rev. No. : 00
Issue No. : 01
FROM FROM
GSS GSS
DEG PVC-II
(415V)
Rev. No. : 00
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26. P& ID’S (IA/PA/N2

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Job Qualification Program

IA/PA/N2, DEG 415V

Prepared By: ___________________________________________

Reviewed By: ___________________________________________

Approved By: ____________________________________________

S No. Rev. No. Date Page No. Section Description of Change

JQP Job Qualification Program

CCR Central Control Room

There are two basic types of compressors.

Positive Displacement Compressor: A compressor that confines successive volumes of

a) Reciprocating compressor: Reciprocating compressors compress gas by physically

Reciprocating compressors may be further classified as single-acting or double-acting. Single-

b) Rotary compressor: Rotary compressors are classified as positive displacement or

Vane Compressor Lobe Compressor

Lubrication in a rotary compressor:

Lubricant Flow in a Rotary Screw Compressor

Regenerative desiccant dryers, often called "regens" or "twin tower" dryers

Regenerative Desiccant Dryers:

Commonly a coalescing prefilter is installed immediately upstream of a refrigerated dryer to

7. Instrument Air, Plant Air & Nitrogen Generation System

8. Process Area Description

Air Water Separator N-4201 A/B:

Air Pre-filter (F- 4201 A/B):

Air Dryer (M-4201 A/B):

Air After-Filter (F-4203 A/B):

A standard compressor is composed of the following:-

Inlet air filtration

Air compressor internal

Description MIN MAX STEP UNIT

1) CHG SEPR ELEMENT

2) HIGH AIR END TEMP

3) HIGH AIR PRESSURE

9. Tripping Securities (Compressors)

1) LOW SUMP PRESSURE

2) HIGH AIR PRESSURE

3) HIGH AIR END TEMPERATURE

4) STARTER FAULT 1SL (2SL)

5) MAIN MOTOR OVERLOAD

6) FAN MOTOR OVERLOAD

7) TEMPERATURE SENSOR FAIL.

8) REMOTE STOP FAIL

9) REMOTE START FAIL.

10) CHECK MOTOR ROTAION

12) NO CONTROLE POWER

13) PRESSURE SENSOR FAIL

14) LOW UNLOAD SUMP PRESSURE

10. Trouble Shooting (Compressors)

TROUBLE CAUSE &/OR DISPLAY ACTION

-Inspect and repair leaks.

Coolant system leak.

Water in air system Defective moisture - Inspect and clean if required.

Excessive noise level Compressor -Contact authorized distributor

-Check coolant level. Add if

-Inspect starter contactors.

11. Start Up and Shutdown Procedure For Compressor

Startup Procedure for Compressor

1. Ensure no maintenance job is going on equipment and its accessories.