1

2
3
4
5

DCS LOADING FOR SURGE IN STATION 1 AND RV716A OPEN LOADING IN STATION 2
VIBRATION TREND AND INTERLOCK ARE NOTHING IN DCS.
SURGE / CHOKE CALCULATION BY MHI
C-1711 TRIP THEN C-1714 TRIP - ELECTRICAL INTERLOCK
C-1714 TRIP / STOP - RV716A CLOSE (IN DCS)

- PCV715 OPEN
6 EMERGENCY STOP
- C-1714 STOP PB IN DCS
- C-1714 STOP PB IN LOCAL PANEL

C-1714 - Compressor & accessories - Total schedule

May-Jun-2004 24 25 26 27 28 29 ###### 1 2 3 4 5 6 7
Day -14 -13 -12 -11 -10 -9 -8 -7 -6 -5 -4 -3 -2 -1 0

Dept.

8
1

9 ### 11 ########################### 21 ############################## 1 2

2 3 4 5 6 7 8 9 ### 11 ###### 14 #################################
MHI S/V

ETA Haldia
Alignment checking

Setting up Packer
for adjustment

Testrun

Fixing of Air , LO , Drain piping of comp. assy

Oil flushing

COMPRESSOR

MECHANICAL

All Piping
connection

stair & operating

platform installation

stair & operating

platform fabrication
Base
Level
preperation
checking & C/LErection
marking & Structural
alignmentmember
Grouting
erection
& curing
ETA Haldia

FILTER

Baseframe
Assembly
Level
fabrication
check &
Erection
& c/l
fixing
marking
Ladder & maintenance Platform fabrication & installation

SILENCER

Civil structural job completion

Level
ETA
check
Haldia
& Template fixingErection

HV Panel installtion
Main Motor installation
HV Cable tray installation

Tray outside Comp Room

Tray inside Comp Room

HV Cable laying
HV Cable termination
HV test of cable & motor.
Statutory Inspection
LV Cable tray installation

Tray outside Comp Room

Tray inside Comp Room

ELECTRICAL

LV Cable laying
LV cable termination
Oil pump & Vapour fan cable
laying & connection.
Lighting cable laying.
Lighting cable termination &
fixture installation.
HV Starter Panel
Commissioning
Oil flushing
Motor solo run
Comp. Load run
Crane installation.
HV switch gear room lighting &
fixture installtion.
Note :

1.Motor solo run require oil flushing for bearing lubrication.

2. During HV test of motor no person is allowed nearby for approx. 4 hrs.

JB INSTALLATION
GI PIPE (AIR) FABRICATION

INSTRUMENTATION

CABLE TRAY INSTALLATION

CABLE LAYING
TERMINATION AT PANEL
INSTRUMENT INSTALLATION
LOCAL PANEL POWER UP
LOCAL PANEL TESTING
DCS CONFIGURATION
CV AIR PIPING/TUBING
LOOP CHECKING
INTERLOCK TESTING

HOT WORK NEAR PIPE

RACK

COMPRESSOR HOUSE STRUCTURE IS COMPLETED

Dear Sir,
Forwarded to you. Please refer to attachment.
And MHI is asking Some change of schedule as below.
Please consider the same.
Originalschedule
20thand21st/Jun:LOOPCHECKING
21stand22nd/Jun:INTERLOCKTESTING,OILFLUSHING
23rd/Jun :MOTORSOLORUN
24th/Jun:COPMLOADRUN
RevisedSchedule
20thto22nd:sameasabove
23rd :MOTORSOLORUN
COMP.MECHANICALTEST
SURGELINECONFIRMATION
24th:COMPCONTROLTEST
FULLLOADTEST
And we have decided to request MHI to provide one Instrumentation S/V for Test Run.
Duration is 22nd to 24th as same as Mechanical S/V.

Regards,
T Chiba

or Test Run.

C-1714 SAFETY ASSESSMENT

1

Operation procedure
Draw Process Flow Diagram
Control procedure
only C-1714 start up
C-1714 hook up to main line
Rate up

Safety analysis
job confirmation
piping job confirmation
Venting
Line flushing
Oil line
Air line
CW line
Valve operation position
Interlocks
SOP making

Quality analysis
Dust going into process, so Delta Y check

C-1714 AIR LINE FLOW DIAGRAM

AIR IN

AIR OUT

HV 715
1

3
2

INTERMEDIATE
VALVE
2

C-1711 OUTLET
1

EXISTING AIR LINE

RV 716

C-1714 OUTLET

PCV 715

SILENCER

AIR OUT

FLOW = 136 KNm 3/H

PRESS = 17.5 Kg/cm2G

C-1714 TEST RUN PLAN

COOLING WATER START

FINISHED

LUBE OIL FLUSHING

CONTINUE

MOTOR SOLO RUN

30 min

MECHANICAL TEST RUN

1 Hr

SURGE TEST

AS PER MHI PLAN

CONTROL TEST
AIR LINE FLUSHING

1 Hr

FULL LOAD TEST

AS PER REACTOR CONDITION

SAMPLING

M-1745 SAMPLING (DELTA Y) AFTER 3 HOURS OF C-1714 TAKEN IN LINE.

SAMPLING EVERY 2 HOURS

MOTOR
LUBE OIL

PRESS
TEMP

1ST STAGE INLET

PRESS
TEMP

1ST STAGE OUTLET

PRESS
TEMP

2ND STAGE INLET

PRESS
TEMP

2ND STAGE OUTLET PRESS

TEMP
3RD STAGE INLET

PRESS
TEMP

3RD STAGE OUTLET PRESS

TEMP
4TH STAGE INLET

PRESS
TEMP

4TH STAGE OUTLET PRESS

TEMP

MOTOR SOLO RUN

PRECONDITIONS
4 DEG IN OPERATION.
COUPLINGS BETWEEN COMPRESSOR AND MAIN MOTOR DECOUPLED
COOLING WATER IS RUNNING
LOCAL TRANSMITTERS VALVES ARE OPEN

METHOD
1

AUXILIARY OIL PUMP NFB ON

AUXILIARY OIL PUMP ( MANUAL) START

LUBE OIL PRESSURE ( LOCAL PANEL - PG1-6) NORMAL ( 0.1 ~ 0.15 MPaG)

VCB ON

INCHING
CONFIRM ROTATION DIRECTION - CLOCKWISE FROM COMPRESSOR SIDE

CONFIRM MOTOR STOPS ROTATING COMPLETELY.

MOTOR START

CHECK LUBE OIL PRESS, TEMP

CONFIRM TEST FINISH ( 2 HOURS )

###
11

VCB OFF
HAND OVER TO MECHANICAL FOR COUPLING

CHECK

MECHANICAL RUNNING TEST

PRECONDITIONS
ALL VALVE OPERATION FROM FIELD. NO VALVE OPERATION FROM DCS.
1 PERSON IN FIELD AND 1 IN DCS. BOTH HAVING WALKIE TALKIE.
4 DEG IN OPERATION.
HV 715 FULL CLOSE
PC 715 FULL OPEN
RV 716 FULL CLOSE
VCB ON
COOLING WATER IS RUNNING
LOCAL TRANSMITTERS VALVES ARE OPEN
READY FOR START SIGNAL IS GLOWING

METHOD
1

AUXILIARY OIL PUMP NFB ON

AUXILIARY OIL PUMP ( MANUAL) START

LUBE OIL PRESSURE ( LOCAL PANEL - PG1-6) NORMAL ( 0.1 ~ 0.15 MPaG)

START C-1714 MAIN MOTOR

HV715 SLOWLY OPEN FROM 0 TO 100%.

AIR FLOW ( FI 715 ) FROM DCS
AIR PRESSURE (PC715) FROM DCS
AIR TEMP ( TI 715 ) FROM DCS

HV 715 OPEN SLOWLY 0 TO 100% FROM FIELD.

PCV 715 OPENING ADJUST CAREFULLY TO ADJUST PRESS = 1.71MPaG

PCV 715, MV

PERFORM LEAK TEST AROUND C-1714 BY SOAP SOLUTION

RECORD DATA AS ATTACHED.

SURGING TEST
PRECONDITIONS
ALL VALVE OPERATION FROM FIELD. NO VALVE OPERATION FROM DCS.
1 PERSON IN FIELD AND 1 IN DCS. BOTH HAVING WALKIE TALKIE.
4 DEG IN OPERATION.
HV 715 FULL CLOSE
PC 715 FULL OPEN
RV 716 FULL CLOSE
C-1714 RUNNING
MANUAL VALVES 1, 2, 3 FULL CLOSE

METHOD
1

HV715 MV INCREASE FROM 0 TO MIN OPENING FROM FIELD.

SLOWLY CLOSE PCV 715 FROM FIELD AND RECORD DATA.

AT ONE STAGE, AIR FLOWRATE WILL FLUCTUATE, INCREASE PCV 715 MV.
THIS IS SURGE POINT AT A GIVEN HV 715

PCV 715 MV INCREASE SLOWLY TO 100%.

HV 715 MV INCREASE TO 50% FROM FIELD.

SLOWLY CLOSE PCV 715 FROM FIELD AND RECORD DATA.

AT ONE STAGE, AIR FLOWRATE WILL FLUCTUATE, INCREASE PCV 715 MV.
THIS IS SURGE POINT AT A GIVEN HV 715

PCV 715 MV INCREASE SLOWLY TO 100%.

HV 715 MV INCREASE TO 60% FROM FIELD.

###
11

SLOWLY CLOSE PCV 715 FROM FIELD AND RECORD DATA.

AT ONE STAGE, AIR FLOWRATE WILL FLUCTUATE, INCREASE PCV 715 MV.
THIS IS SURGE POINT AT A GIVEN HV 715

###

PCV 715 MV INCREASE SLOWLY TO 100%.

###

DECREASE HV 715 MV TO 0%.

###

STOP C-1714.

CHECK

SURGE LINE RECORD SHEET

POINTS

1
2
3

4
5
6

7
8
9

HV715

AIR FLOW

AIR TEMP

AIR PRESS

MV

FI 715

TI 715

PC 715 _ PV

SHAFT VIBRATION
LP PINION

HP PINION

CONTROL TEST
PRECONDITIONS
ALL VALVE OPERATION FROM FIELD. NO VALVE OPERATION FROM DCS.
1 PERSON IN FIELD AND 1 IN DCS. BOTH HAVING WALKIE TALKIE.
4 DEG IN OPERATION.
HV 715 FULL CLOSE
PC 715 FULL OPEN
RV 716 FULL CLOSE
MANUAL VALVES 1, 2, 3 FULL CLOSE
COOLING WATER IS RUNNING
LOCAL TRANSMITTERS VALVES ARE OPEN
READY FOR START SIGNAL IS GLOWING
METHOD

CHECK

AIR LINE FLUSHING

PRECONDITIONS
4 DEG IN OPERATION.
C-1714 RUNNING
HV 715 ~ 10% OPEN
PC 715, AUT SV = 1.71 MPaG
RV 716 FULL CLOSE
DISCHARGE PRESS = 1.71MPaG
MANUAL VALVES 1, 2, 3 FULL CLOSE

METHOD
1

VALVE 2 FULL OPEN

RV 716 OPEN

PC 715 MAN, AND MV DECREASE VERY SLOWLY.

OPEN VALVE 1 VERY SLOWLY ( 1/4 TURN INITIALLY )

IF PRESSURE DECREASE RATE IS FAST, DECREASE PCV MV.

WAIT FOR PRESSURE STABILIZATION.

REPEAT STEP 4 AND 5

VALVE 1 (4 ~ 5 TURNS) OPENING IS ENOUGH TO GET SUFFICIENT FLOW

IF FLOW IS LESS, DECREASE PCV MV MORE AND OPEN VALVE 1 MORE.

RECORD THE DATA

CONTINUE 1 HOUR FLUSHING

###

STOP AIR FLUSHING

PCV 715 PUT IN AUT, SV = 17.1K/G
SLOWLY CLOSE VALVE 1.
IN CASE PRESSURE FLUCTUATES, CONTROL PCV IN MANUAL ( OPEN SLOWLY ).
CONTINUE TO CLOSE VALVE 1 TILL FULL CLOSE.

CHECK

FULL LOAD TEST ( C-1714 IN LINE )

PRECONDITIONS
4 DEG IN OPERATION.
C-1714 RUNNING
HV 715 ~ FULL CLOSE
PC 715, FULL OPEN
RV 716 FULL CLOSE
DISCHARGE PRESS = 1.71MPaG
MANUAL VALVES 1, 2, 3 FULL CLOSE

METHOD
RECORD INITIAL VALUE OF N-1711 DELTA P
AS RATE UP WILL BE DONE, INCREASE CAT FLOWRATE.
1

VALVE 3 FULL OPEN

HV 715 MV INCREASE 0 TO 5% SLOWLY

PCV 715 AUT SV = 1.75 MPaG

RV 716 OPEN

OPEN VALVE 1 SLOWLY.

IN CASE PRESSURE DECREASE RATE IS HIGH, CONTROL PCV MANUALLY.

CONFIRM INCREASE IN FC731 PV.

WHEN XI738 INCREASE FROM 2.2 TO 2.4, INCREASE PX FLOW (MAX FC724 PV = 38T/H)

ADJUST XI738 TO TARGET BY ADJUSTING HV715, KEEPING FC724 PV = 38T/H

### HC711 WILL BE FULL OPEN.

11

AT SUDDEN DECREASE IN ATMOSPHERIC TEMP CAUSES XI738 INCREASE,

ADJUST AIR FLOW BY HV 715.

### M-1745 SAMPLING (DELTA Y) AFTER 3 HOURS OF C-1714 TAKEN IN LINE.

SAMPLING EVERY 2 HOURS

CHECK

### MONITOR N-1711 DELTA P

RATE DOWN

PRECONDITIONS
C-1714 RUNNING
HV 715 OPEN
PC715 SV = 1.75 MPaG
RV 716 FULL OPEN
MANUAL VALVE 2 FULL CLOSE
MANUAL VALVE 1, 3 FULL OPEN
METHOD
1
2
3
4
5
6
7
8
9
10
11

C-1714 TEST RUN CHECKLIST

ITEM
MAIN

LOCATION
SUB

FIELD

DCS

PARAMETER
NOR

1 CW line flush

2 CW start

flushing
venting

3 Oil flushing
4 Interlock test

list interlocks ( E + I )

5 Lube oil

Tank level OK
Oil cooler CW flow start
Auxiliary oil pump start

6 Control valves loop test

HV 715
PCV 715
RV 716

6 Motor solo run

a
b
c
d

lube oil
CW
VCB ON
Inching

Start ( confirm rotating direction

f
g
h

Fill the sheet 6

Confirm test finish
VCB OFF
Hand over to mechanical for
Coupling fixing.

i
7 Mechanical Run

Mechanical hand over confirm

Auxiliary oil pump start

c
d

Lube oil pressure OK

CW flow to intercoolers OK
CW flow to Oil cooler OK
CW flow to motor cooler OK
VCB ON
C-1714 air inlet valve (HV715)
full close
PC715 full open
Intermediate valve full open
C-1714 discharge RV716 full
close.
Valves 1, 2, 3 close
Ready for Start signal OK
C-1714 main motor start
Auxilliary oil pump stop (1 min
after main motor start)

e
f
g
h
i
j

1.02 K/G

ACT

REMARKS

Fill data sheet no 17.

C-1714 MAIN INTERLOCKS

Ready for start
1
2
3
4
5
6
7
8

LO supply pressure Normal

Suction valve (HV715) close
Blow OFF valve full open
Aux LO pump "AUT"
LO tank level normal
LO temp Normal
Intermediate valve full open
Main motor VCB ON

1.02 K/G

LO supply press low low

LP shaft vibration high high
HP shaft vibration high high
Main motor electrical fault
Emergency Stop
Main motor stator temp high high ( U phase )
Main motor stator temp high high ( V phase )

0.618 K/G
160 m
160 m

8 Main motor stator temp high high ( W phase )

155 degC

35 to 45 degC

C-1714 trip
1
2
3
4
5
6
7

Main motor cooling water leakage ( compressor

side)
Main motor cooling water leakage ( opposite
10
compressor side)
11 C-1711 trip
9

155 degC
155 degC