Chapter-5 (shutdown Procedure(.doc
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PRODUCTION DEPARTMENT AMMONIA PLANT AREA SPECIFIC
Chapter No.
Rev.
5.0
0
Prepared by: SAK
1 of 3
Approved by:
Date:
NUR
01797
SYNTHESIS GAS COMPRESSORS SUBJECT / TITLE
5.0: SHUTDOWN PROCEDURE
Page:
5.0 SHUTDOWN PROCEDURE Note: Following procedure is specifically related to K / KT306B. 1
Reduce the compressor speed to minimum governor (3700 rpm). Maintain antisurge flow accordingly. Also open antisurge bypass valves.
2
Transfer speed control to outside control by the time speed is at minimum governor.
3
Trip the turbine by means of the hand or remote operated tripping mechanism.
4
Ensure closure of recycle suction MOV.
5
Vent the high pressure case below 100 Kg/cm2 (1,400 psig) within five (5) minutes after tripping and continue to vent down to suction pressure. Close the discharge block valve to prevent back flow through the check valve.
CAUTION: The 3rd case (HPC) on both K306 A & B must be vented within five minutes after a machine shutdown. If not done, compressor seals will be severely damaged by high pressure. 6
Adjust seal oil differential pressures.
7
Open surge control valve bypasses if not already open.
8
Set outside speed potentiometer to the zero speed setting (all the way CCW).
9
Reset turbine stop valve.
10 Slow roll turbine at 1,000 rpm for 45 minutes. 11 Trip the turbine after 45 minutes.
Note: The stop valve trip should never be reset until the unit is ready to be started again. PRODUCTION DEPARTMENT AMMONIA PLANT AREA SPECIFIC
SYNTHESIS GAS COMPRESSORS SUBJECT / TITLE
5.0: SHUTDOWN PROCEDURE
Chapter No.
Rev.
5.0
0
Prepared by: SAK
2 of 3
Approved by:
Date:
NUR
01797
Page:
12 Stop the slow roll and close the suction block valve and bypass. Cut off the KT306B turbine seal system. 13 Vent the compressor cases into the vent header being careful not to allow back flow from the vent header to enter then compressor. Close compressor vent to header. 14 Purge compressor with nitrogen. Open at least one case drain on each case & monitor explosivity. Stop nitrogen purging till explosivity is ‘Nil’. 15 Close block valve to steam turbine & open drains. 16 Turn off Turbine Lube Oil Pump after KT306B has been cooled down. 17 Shutdown compressor seal oil pump. i)
Take auxiliary pump off automatic start.
ii)
Take seal steam off seal oil turbine.
iii) Trip seal oil turbine. iv)
Open overhead tank drains.
18 Shutdown compressor lube oil pump. i)
Take auxiliary pump off automatic start.
ii)
Take seal steam off lube oil turbine.
iii) Trip lube oil turbine. iv)
Close steam inlet valve to emergency pump on gas turbine.
19 Shutdown surface condenser if not required. i)
Take auxiliary pump off automatic start.
ii)
Take seal steam off condensate pump turbine.
iii) Trip condensate turbine. iv)
Close off steam valve in steam ejector header.
PRODUCTION DEPARTMENT AMMONIA PLANT AREA SPECIFIC
Chapter No.
Rev.
5.0
0
Prepared by: SAK
3 of 3
Approved by:
Date:
NUR
01797
SYNTHESIS GAS COMPRESSORS SUBJECT / TITLE
5.0: SHUTDOWN PROCEDURE 5.1: SHUTDOWN SUMMARY
Page:
20 Cooling Water. i)
After shutdown, cooling water may be turned off of condenser, oil coolers, gas coolers and pump bearings as required.
ii)
Inform utilities (UCR) if cooling water of all interstage coolers is to be isolated.
21 Secure the train by putting off relevant motors breakers and placing relevant tags.
5.1
SHUTDOWN SUMMARY 1
Slow compressor to minimum speed maintaining antisurge flow.
2
Take compressor out of loop.
3
Trip compressor.
4
Slow roll compressor.
5
Block in compressor and depressurize.
6
Shutdown compressor seal oil system. Drain overhead seal oil tanks.
7
Purge compressor with Nitrogen.
8
Shutdown compressor lube oil system.
9
Shutdown turbine lube oil system after cooling.
10 Shutdown condenser E410 if not required. 11 Turn off cooling water if required.
Chapter No.
Rev.
5.0
0
Prepared by: SAK
1 of 3
Approved by:
Date:
NUR
01797
SYNTHESIS GAS COMPRESSORS SUBJECT / TITLE
5.0: SHUTDOWN PROCEDURE
Page:
5.0 SHUTDOWN PROCEDURE Note: Following procedure is specifically related to K / KT306B. 1
Reduce the compressor speed to minimum governor (3700 rpm). Maintain antisurge flow accordingly. Also open antisurge bypass valves.
2
Transfer speed control to outside control by the time speed is at minimum governor.
3
Trip the turbine by means of the hand or remote operated tripping mechanism.
4
Ensure closure of recycle suction MOV.
5
Vent the high pressure case below 100 Kg/cm2 (1,400 psig) within five (5) minutes after tripping and continue to vent down to suction pressure. Close the discharge block valve to prevent back flow through the check valve.
CAUTION: The 3rd case (HPC) on both K306 A & B must be vented within five minutes after a machine shutdown. If not done, compressor seals will be severely damaged by high pressure. 6
Adjust seal oil differential pressures.
7
Open surge control valve bypasses if not already open.
8
Set outside speed potentiometer to the zero speed setting (all the way CCW).
9
Reset turbine stop valve.
10 Slow roll turbine at 1,000 rpm for 45 minutes. 11 Trip the turbine after 45 minutes.
Note: The stop valve trip should never be reset until the unit is ready to be started again. PRODUCTION DEPARTMENT AMMONIA PLANT AREA SPECIFIC
SYNTHESIS GAS COMPRESSORS SUBJECT / TITLE
5.0: SHUTDOWN PROCEDURE
Chapter No.
Rev.
5.0
0
Prepared by: SAK
2 of 3
Approved by:
Date:
NUR
01797
Page:
12 Stop the slow roll and close the suction block valve and bypass. Cut off the KT306B turbine seal system. 13 Vent the compressor cases into the vent header being careful not to allow back flow from the vent header to enter then compressor. Close compressor vent to header. 14 Purge compressor with nitrogen. Open at least one case drain on each case & monitor explosivity. Stop nitrogen purging till explosivity is ‘Nil’. 15 Close block valve to steam turbine & open drains. 16 Turn off Turbine Lube Oil Pump after KT306B has been cooled down. 17 Shutdown compressor seal oil pump. i)
Take auxiliary pump off automatic start.
ii)
Take seal steam off seal oil turbine.
iii) Trip seal oil turbine. iv)
Open overhead tank drains.
18 Shutdown compressor lube oil pump. i)
Take auxiliary pump off automatic start.
ii)
Take seal steam off lube oil turbine.
iii) Trip lube oil turbine. iv)
Close steam inlet valve to emergency pump on gas turbine.
19 Shutdown surface condenser if not required. i)
Take auxiliary pump off automatic start.
ii)
Take seal steam off condensate pump turbine.
iii) Trip condensate turbine. iv)
Close off steam valve in steam ejector header.
PRODUCTION DEPARTMENT AMMONIA PLANT AREA SPECIFIC
Chapter No.
Rev.
5.0
0
Prepared by: SAK
3 of 3
Approved by:
Date:
NUR
01797
SYNTHESIS GAS COMPRESSORS SUBJECT / TITLE
5.0: SHUTDOWN PROCEDURE 5.1: SHUTDOWN SUMMARY
Page:
20 Cooling Water. i)
After shutdown, cooling water may be turned off of condenser, oil coolers, gas coolers and pump bearings as required.
ii)
Inform utilities (UCR) if cooling water of all interstage coolers is to be isolated.
21 Secure the train by putting off relevant motors breakers and placing relevant tags.
5.1
SHUTDOWN SUMMARY 1
Slow compressor to minimum speed maintaining antisurge flow.
2
Take compressor out of loop.
3
Trip compressor.
4
Slow roll compressor.
5
Block in compressor and depressurize.
6
Shutdown compressor seal oil system. Drain overhead seal oil tanks.
7
Purge compressor with Nitrogen.
8
Shutdown compressor lube oil system.
9
Shutdown turbine lube oil system after cooling.
10 Shutdown condenser E410 if not required. 11 Turn off cooling water if required.
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