BASIC of H2 Makeup Compressor - Startup

SAUDI ARAMCO BASE OIL COMPANY
LUBEREF II
HYDROGEN MAKEUP GAS COMPRESSOR

TRAINING MATERIAL (C-4002A/B)
INDEX
SECTIONS DESCRIPTION PAGE NO
I SAFETY 02
II INTRODUCTION 06
III HYDROGEN MAKEUP-GAS COMPRESSOR 09
IV STARTUP 25
Requested by: RASHID AL-GHAMDI
V MONITORING 30
Prepared by: Reviewed by: Design & Print First edition
2015
VI SHUTDOWN 33
CHANDRASEKARAN M.SENTHILKUMAR SAEED
ALGHAMDI
VII TROUBLE SHOOTING 36
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VIII MSDS 45
SAFETY
Section-I
PREPARED BY: CHANDRASEKARAN BASIC TRAINGING MANUAL FOR DATE: 20 /08/2015

REVIEWED BY: M.SENTHILKUMAR HYDROGEN MAKEUP-GAS COMPRESSOR REV: 00
APPROVED BY: RASHID ALGHAMDI (C-4002A/B) Page | 1
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Safety
In the safety point of view, the important factors in this unit is handling the hydrogen gas. Since the
flammability range is very high.(4-74% flammability range).
Safety involves the following general principles:

 Segregation - seeks to contain hydrogen in gas-tight systems with discharge of hydrogen only
through selected vent points.
 Ventilation - dilutes and sweeps away hydrogen which has leaked in close buildings.
 Ignition control - prevents ignition by outlawing potential ignition sources such as naked lights or
flames and gives attention to electrical devices to prevent sparks or overheating through an overload.
Hydrogen and air mixtures containing 4-74% hydrogen can be ignited readily. The most incendiary
composition is 27-30% hydrogen in air at normal temperatures and pressure; so a safety margin must be
allowed if these proportions are approached.
Hazard Present in Compressor unit:
The various hazard present in the compressor units are
1. Fire Hazard

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2. Mechanical Hazard
3. Explosion Hazard
Fire Hazard
Like any flammable fuel, hydrogen can combust. But hydrogen’s buoyancy, diffusivity and small
molecular size make it difficult to contain and create a combustible situation. In order for a hydrogen fire
to occur, an adequate concentration of hydrogen, the presence of an ignition source and the right
amount of oxidizer (like oxygen) must be present at the same time. Hydrogen has a wide flammability
range (4- 74% in air) and the energy required to ignite hydrogen (0.02mJ) can be very low . However, at
low concentrations (below 10%) the energy required to ignite hydrogen is high similar to the energy
required to ignite natural gas and gasoline in their respective flammability ranges making hydrogen
realistically more difficult to ignite near the lower flammability limit. On the other hand, if conditions exist
where the hydrogen concentration increased toward the stoichiometric (most easily ignited) mixture of
29% hydrogen (in air), the ignition energy drops to about one fifteenth of that required to ignite natural
gas (or one tenth for gasoline).
1. EXPLOSION HAZARDS
Hydrogen is a highly flammable gases. It is a nontoxic material, although hydrogen gas will cause
asphyxiation when present in the atmosphere in high concentrations, and nausea, dizziness and
unconsciousness when present in lower concentrations.
The operating personnel should consider the following three characteristics of hydrogen with respect to
their flammability and/or explosivity.

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Explosive limits: These indicate the minimum and maximum amounts of vapors in air at which an explosive
mixture is formed. For Hydrogen explosive limit is 18.3 to 59%
 Auto-ignition temperature (AIT): This indicates the temperature at which hydrogen present in the
air may ignite. For hydrogen auto ignition temperature is 500 0C.
Before introducing hydrocarbons inside equipment items, care should be taken that oxygen content is
below < 0.1 % vol. to avoid formation of an explosive mixture. Adequate purging or steaming is thus
essential. Additionally, ventilation is essential since leaks from equipment may form potentially hazardous
gas pockets.
When combustible gases are mixed with oxygen (air), an explosive mixture may be formed.
Whether such a mixture is explosive depends on the concentration of the gas in the gas-air mixture. The
concentrations below and above which the mixture is not explosive, are called the lower and higher
explosion limits respectively. Explosive limits and AIT of some light hydrocarbons and some of the most
important gases present in reforming plants are shown in Table 1.
MECHANICAL HAZARD
Insulation
Even though from a process point of view the insulation of some hot equipment and piping may not be
required or not economically justified, insulation of some equipment and piping must be considered for
personnel protection, especially in those areas with frequent travel of operating personnel.
Rotating Machinery
It is recommended that hazards present in certain rotating machinery be clearly identified. Examples
include: Critical speeds of compressors, guards around equipment and nitrogen purge to crank case.

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Electrical Hazards
Procedures for the lock-out of electrical equipment are recommended. Use of sparking equipment within
the battery limits shall be made subject to approval.
Introduction
Section-II

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COMPRESSOR INTRODUCTION:
A gas compressor is a mechanical device that increases the pressure of a gas by reducing its volume.
Compressors are similar to pumps: both increase the pressure on a fluid and both can transport the fluid through a
pipe
TYPES OF COMPRESSOR:
Compressors can be classified as follows

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SELECTION OF COMPRESSOR:
Selection of compressor is mainly based on capacity, service and many other parameters. Selection of
compressor Based on capacity and discharge pressure is depicted in the below diagram.

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RECIPROCATING COMPRESSOR:
In a reciprocating compressor, a volume of gas is drawn into a cylinder, it is trapped, and compressed
by piston and then discharged into the discharge line. The cylinder valves control the flow of gas through
the cylinder; these valves act as check valves.

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TYPES OF RECIPROCATING COMPRESSOR:
Single – Acting compressor
It is a compressor that has one discharge per revolution of crankshaft.
Double – Acting Compressor
It is a compressor that completes two discharge strokes per revolutions of crankshaft. Most heavy-duty
compressors are double acting.
Major Parts of reciprocating compressor
The various parts of reciprocating compressor are
 Suction valve.
 Piston.
 Cylinder & Liner
 Oil seal
 Discharge valve.
 Crank case
 Head

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SUCTION VALVE :
 The main body of valve that withstands the differential pressure when the valve is closed.
 Counter seat
The valve component that limits the lift and contains the springs
 Rings
The element that withstands the differential pressure, ensuring gas seal
 Spring
The element that acts on the rings, causing valve closing
 Shim
The element that determines the valve lift.
 Stud bolt, nut & pin

These elements fasten all the components together.

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PISTON :
The main part of the reciprocating compressor is Piston. By the movement of piston, in
reciprocating action the designed capacity of gases compressed to its designed discharge pressure.
PISTON ROD:
Generally, the piston rod is fastened to the piston by means of special nut that is prevented from
unscrewing. The surface of the rod has suitable degree of finish designed to minimize wear on the sealing
areas as much as possible. The piston is provided with grooves for piston rings and rider rings.

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Piston rod packing:
Piston rod packing ensures sealing of the compressed gas. The piston rod packing consists of
series of cups each containing several seal rings side by side. The rings are built of three sectors, held
together by a spring installed in the groove running around the outside of the ring.
The entire set of cups is held in place by stud bolts. Inside channels are there for cooling, gas
recovery and lubrication of the piston rod packing.
Piston rod Packing :

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Cylinder & Liner :
Piston reciprocates inside a cylinder. To provide for reduced reconditioning cost, the cylinder may
be fitted with a liner or sleeve. A cylinder or liner usually wears at the points where the piston rings rub
against it. Because of the weight of the piston, wear is usually greater at the bottom of a horizontal
cylinder. A cylinder liner is usually counter bored near the ends of the outer ring travel i.e. counter bores
are made just ahead of the points where the end piston rings stop and reverse direction. Shoulders may
form in the liner where the ring’s travel stops unless counter bores are provided.
Oil Seal :
An arrangement of scraper rings serves to keep the oil, entrained by piston rod, from leaking out of
the crankcase. The oil scraped is returned to the crankcase reservoir.

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Piston Rings:
Piston rings provide a seal that prevents or minimizes leakage through piston and liner. Metal
piston rings are made either in one piece, with a gap or in several segments. Gaps in the rings allow them to
move out or expand as the compressor reaches operating temperature. Rings of heavy piston are
sometimes given bronze, Babbitt or Teflon expanders or riders. Lubrication is a must for metallic rings.
Teflon rings with Teflon rider bands are sometimes used to support the piston when the gas do not permit
use of a lubricant.
Discharge Valves :
There are normally three types of valves, these are
1. Plate valve.
2. Channel valve.
3. Poppet valve.

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Plate Valve :
Heavy-duty compressors use a form of plate valve. The part that closes against a valve seat is a
flat metal plate. The plates are held tightly against the seat by a set of springs.
Channel Valve:
These valves use channel shaped plates instead of flat plates. Above each channel is a
bowed, steel tension spring. Spring pushes from the stop plate and channels cover the slots in the valve
seat.

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Poppet Valve:
These are shaped like the valves in an automobile engine. These are separate, round poppets to
seat against holes in the valve seats. Poppets are made of low friction material (e.g. Bakelite), they provide
a low-pressure drop and are often used when ratios of compression are low and also for high flow rates.

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Automatic valves:
The valves are of automatic type. They open due to the effect of the differential pressure
between cylinder and the suction or discharge chambers, and close due to the force of springs acting on the
plates plus the differential pressure across the valves.
Crank Case:
Crank case supports the crankshaft. All bearing supports are bored under setup condition to ensure
perfect alignment. Crankcase is provided with easy removable covers on the top for inspection and
maintenance. The bottom of the crankcase serves as the oil reservoir. A main pump for lubrication of the
crank mechanism is placed on the shield mounted on the side opposite the coupling and is driven by
compressor.

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Crankshaft:
The crankshaft is built in a single piece. On the inside of the shaft are holes for passage and
distribution of lube oil.
Main Bearings:
The main bearings are built in two halves, made of steel, with inner coating of antifriction metal.
Connecting Rods:
The connecting rod has two bearings. The big end bearing is built in two halves. It is made of
metal with inner coating of antifriction metal. The connecting rod small end bearing is build of steel, with
inner coating of antifriction metal. A hole runs through the connecting rod for it’s entire length, to allow
passage of oil from the big end to the small end bush.

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Head :
The ends of cylinder are equipped with removable heads, these heads may contain water/liquid
jacket for cooling. One end is called head-end head and other crank-end head. The crank-end contains
packing (a set of metallic packing rings) to prevent gas leakage around piston rod.
Trouble Shooting:
Trouble Possible cause Remedies

Restore correct tightening of flywheel
Check support bearings.

Misalignment and looseness.
Correct alignment.
Perform correct tightening of foundation.

Excessive press pulsation. Restore compressor design operating conditions.
Excessive noise or abnormal Restore the minimum condensate level in knock out
noise. drum.
Excessive entrainment of
Increase frequency of drawing clean separators.
condensate
Add drain valves at points where liquid
accumulates.
Incorrect assembly Repeat assembly, following the correct order.
Restore their fastening.
Loosening of cylinder valves Correct position of the valves.
Restore the surfaces on which the valve rests.
Increase cooling fluid rate.
Insufficient cooling Clean the cooling system.
Abnormal temperature gas Utilize a fluid that gives lower deposits
discharge Apply adequate tightening torque.
Leakage of gas from gaskets Replace damaged gaskets.
Restore sealing surface
Restore clearances between piston rings and their
grooves.
Gas flow rate not at required Inadequate piston ring seal. Replace worn out rings.
value. Correctly install packing seal.
Excessive leakage of gas from Restore proper clearance.
packing. Restore / replace piston rod.

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HYDROGEN MAKEUP-GAS
Compressor
Section-III
HYDROGEN MAKE UP GAS COMPRESSOR (C-4002 A/B) :

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The following PFDs should be used as aids in this section:
PFD – Make-Up Hydrogen Section = 40-G2-PF-012
This section presents the process requirements for the make-up hydrogen compression section. The purpose of
the compression section is to compress the make-up hydrogen from a supply pressure of 20.5 bar (g) to the Hydro
cracker and dewaxing reactor section pressure of 182.8 bar (g).
The make-up hydrogen compression facility consists of two identical parallel trains, each with four stages of
compression. The HCR suction drum (D-4020) is common to all trains (C-4002A/B), with one of the two trains
normally operating to supply 100% of the make-up hydrogen requirement, with an additional 10% spilling back to the
HCR suction drum.

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The make-up hydrogen entering the compression section will come from an off plot hydrogen plant and
hydrogen recovery unit. The make-up hydrogen from this unit is supplied at 45°C and 20.5 bar (g).
The total make-up hydrogen is combined with spillback gas before going to the common HCR suction drum (D-
4020) where any entrained liquid is separated from the gas. After leaving the KO drum, the gas is divided between
the parallel compressor trains. During normal operation, only one train will be used to supply the hydrogen required
by the HCR and DW Units. The second train is a spare.
In each train, gas is compressed in the first stage of the make-up hydrogen compressor (C-4002A/B) to about
42.9 bar (g) and then cooled to 40°C in the water-cooled HCR intercooler (E-4031A/B). Condensed liquid (if any) is
separated from the gas in the second-stage suction drum (D-4021A/B). The gas is then further compressed in a
similar fashion in the second and third stages to the desired reaction section pressure. The compressed gas is sent
either to the HCR reaction section or the DW reaction section. Excess hydrogen not required by the reaction section
flows back through a common spillback line and through the spillback cooler (E-4033).
Electric tracing and insulation are required between all suction KO drums and the respective compressor inlets to
guard against the possibility of liquid condensation in the compressor suction lines. Similarly, jacket cooling water
should be at a temperature at least as high as the compressor inlet temperature to prevent condensation.
Each compressor stage should be provided with removable suction filters to prevent damage caused by line scale
and miscellaneous objects that sometimes find their way into the piping and equipment.
It is important to minimize the additive content of compressor lubricants that may come in contact with process
streams so as to avoid possible catalyst poisoning in the reactors. These lubricants should also decompose easily at
the normal reactor operating conditions in order to prevent catalyst coking.
Some of the major details of hydrogen make up gas compressor are given below,
Equipment no C-4002 A/B

Equipment name Make up Hydrogen compressor
No of stage 4
Power rating 6600 KW @ rated RPM of 327
Type of Driver Syn. Motor
Cylinder Lubricating Type
Type of unloader Hydrocom.

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Separate cooling console One common to all units

Dual pumps (Auxiliary & Main)
Arranged for heating jacket as well as cooling.
Capacity control Hydraulic Programmable controller one for each unit
Free standing.
Heaters Frame lube oil
Cyl. Lubricators
Cooling water
Electric
Barring Device Electric
Flywheel locking device
Cooling water for cylinders

Temp in 0c Pressure in Bar(a)
supply 65 1.5
Return 70 1.0
Cooling water for coolers

Temp in 0c Pressure in Bar (a)
supply 35 4.9
Return 45 3.0
Cooling for Rod packing

Type Fluid: closed C.W supply pressure @ 2 BARG and 420C

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Pressure at various stage :
First stage Second stage Third stage Fourth stage

Pressure in BarA 20.5 38.7 66.7 116.5
Temp at suction
46 60 60 60
in 0C
Mass flow rate in 5791
5791 5791 5791
Kg/hr
Volumetric flow
3713 2070 1216 714
rate in m3/hr
Volumetric flow
rate @
63944 63944 63944 63944
Nm3/hr
Compressor Startup
Section-IV
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Precommissioning of Reciprocating compressor

After foundations, installations, piping and wiring have been completed.
1) Flushing the inside of crankcase and the lube oil piping.
2) Blow-off for cleaning the process piping, if necessary.
3) Mechanical running at site by air under no-load or low load.
4) Load-up operation by process gas up to 100% load.
5) All-round inspection.
The above work is carried out under the makers attendance or guidance, and then the operations
are left to Customer or End User.
In this chapter, necessary cares during this operation are described.
Startup of reciprocating compressor

PREPARATIONS FOR STARTING
On starting the compressor after completion of installation, overhauling, or long stoppage, the following
inspections and preparations should be carried out.
Operating a gas compressor unit shall not commence before and official ‘clearance for operation’ has been
received from the maintenance department. Depending on the nature of maintenance that has been
carried out, such clearance shall include in general the following checks or verifications there of;
a) In foundations, installations, piping, wiring, etc., such abnormality as mentioned below must not be
found.
(1) Crack of foundation

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(2) Slack of foundation bolts

(3) Slack of piping connections
(4) Breakage or earth of electric wire
b) Verify the validity of certificates for pressure vessels and safety relief valves. Verify calibration certificates
for pressure and temperature instruments and check switch settings.
Trip switch settings shall comply with values as per “ANN. AND INTERLOCK TABLE”.
Check logic for start/stop sequence and capacity control are functioning properly
c) Check wiring to motors, heaters and switches is correctly connected. Check covers on wiring boxes are
properly closed. Check motors and heaters are correctly fused.
d) Verify the extent of maintenance is covered and signed for acceptance in the field service report
compressors. Check all covers and guards, protection or otherwise, have been provided with correct
gaskets and have been secured with correct torque-wrench values as mentioned on the drawings in the
instruction manual, chapter Ⅳ.
e) Compressor proper and fittings shall be in good order. Confirm that the minor modifications have been
finished, if any.
f) No slack of bolts and nuts of all parts should be found.
g) Check the lube oil level in crankcase whether oil has been filled up to nearly center line of level gauge.
SAE 30# (ISO VG #100) oil, which is alkaloid, is used as standard for crankcase oil.
If cylinders are lubricated, fill the lubricator tank with oil. In that case, take care not to confound this oil
with the crankcase oil.
i) Inspect the lube oil filter and replace the new one.
j) Supply cooling water and check cooling water pressure. Remove trapped air from the cooling water
system by venting high point vent valves/plugs. Check cooling water system is operating free of leakage.
Supply cooling water to the lube oil cooler, compressor cylinder and stuffing box, if water-cooled.
In that case, the valves of pipe-line should be fully opened. As a general rule, these valves should not be
throttled. And make sure that cooling water is flowing through the equipment by sight-glass at the outlet.
k) Supply instrument air and check instrument air pressure. Check instrument air system is Operating free
of leakage.

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l) If suction valve unloaders and clearance pockets are equipped for the capacity control,
The former should be set under the no-load condition.
The hydraulic system should be filled up with defined hydraulic pressure of 100±10barg.
m) If it is winter season, raise the lube oil temperature above 20℃ (68 ﾟ F) as minimum by means of
heating the oil by electric heater, if necessary.
n) Start (auxiliary) lube oil pump and check oil pressure. Check oil system to be no leakage.
This pump should be driven continuously until starting of compressor.
o) Turn the crankshaft by a device.
The turning shall be limited max. 2 revolutions. Otherwise it may produce a possibility of bearing damage.
If cylinders are lubricated with motor-driven lubricator, push on start button of the motor.
And check whether oil is filled in the tubes up to cylinders. This can be confirmed by disconnecting the line
at the non-return valve on cylinder.
q) Open the drain valves and eliminate the drains. Then, shut the drain valves. (HydroCOM and bypass
control valves will be controlled by control loop in DCS.)
r) Drain liquid from gas lines, snubbers, gas coolers and other equipment, if any.
s) Check barring device is locked in OFF-position.
t) Remove all tools, check walkways are cleared and compressor platform has been sufficiently cleaned.
Remove warning-signs ‘maintenance work in progress’ and prohibition signs ‘Do not start’.
Provide warning signs ‘Unit is remotely controlled and may start with warning’, if remote start system is
provided.
u) Confirm that any tools do not remain around compressor or any people do not remain near the
compressor.
v) Confirm all safety devices to be in operating condition.
Startup
a) In no alarm conditions, confirm "Starting all right" and then, start the main driver (Electric motor).
If the shaft-driven main lube oil pump and the motor-driven oil pump are equipped, stop the motor-driven
oil pump after the main driver has reached the rated speed.

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In case that the motor-driven oil pump is supplied for the auxiliary, set the select switch in the position of
“Auto-start" after stopping it.
b) Check the lube oil pressure to confirm the feed condition of the crankcase oil to the main, crank-pin and
crosshead-pin bearings.
If cylinders are lubricated, confirm the oil feeds to cylinder and stuffing box by sight glasses of the
lubricator.
c) After main driver runs up to normal speed and all parts are confirmed in good order, enable HydroCOM
system by “LOAD ENABLE” push button. When the enable signal is set, the compressor delivers minimum
load. Since the bypass control valve is fully opened, no gas flow is delivered to the process. Then the start-
ramp function in DCS ramps up the compressor load smoothly.
d) When starting the compressor after long stoppage (more than a week) or overhauling, confirm whether
any abnormal conditions do not exist in any parts of compressor during no-load running, and then load up.
Especially attentions should be paid for lube oil pressure, bearing and lube oil pump temperatures, sound of
moving parts and the reading of ammeter.
In no-load running, suction gas temperature gradually increases, because of gas being blown back to
suction side through unloaded suction valves and heated by friction.
Accordingly, a period of no-load running by suction valve unloaders or bypass through no gas cooler should
be possibly shortened.

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Inspection
Section-V

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INSPECTIONS AND CARES DURING OPERATION
To check compressor performance while in operation, it is advised to keep records of the main operating
data. These data can either be automatically monitored (data recorder) or manually by means of log sheets.
A visual check of the compressor operation should be made at least every 8 hours.
It is User’s responsibility to keep the operating condition specified in data sheet and shall not operate the
compressor under the alarm condition.
DATA TO BE MONITORED
a) Suction and discharge pressures per stage.
b) Suction and discharge temperatures per stage.
In such case as the heating system of the gas being provided, attention should be paid for suction gas
temperature so that it is kept at a uniform temperature to protect the gas from condensing.
c) Lubricating oil pressures and temperatures, and differential pressure across oil filter
Adjust the lube oil temperature to keep it above 40℃(104 ﾟ F) even in winter by the bypass valve.
d) bearing temperature each main bearing.
e) Cooling water pressures and temperatures.
(1) As a rule, cylinder cooling water should be always full-flowed. In case of regulating the temperature by
throttling the valves, the temperature difference between inlet and outlet should not exceed 5℃(9 ﾟ F)as
standard.
(2) Valves of cooling water to stuffing box should be fully opened.
(3) In such cases as the temperature-controlled hot water being supplied to the cylinder jackets to prevent
the gas from condensing, care should be paid for the inlet temperature so that it is kept at a uniform
temperature.
f) Function of cylinder / stuffing box lubricator.
g) Current / voltage / power factor (if possible) / temperature of electric driver.
h) Leakage rate of stuffing boxes.
i) Stuffing box temperature each cylinder.

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VISUAL INSPECTION
j) Level of liquid separators.

k) Oil levels, such as crankcase, lubricator, gear box, motor bearing and auxiliaries.
(1) Check oil level in crankcase is keeping normal (not lower than minimum level and not higher than
maximum level) and fill up the lube oil, if necessary.
(2) If cylinders are lubricated, fill the lubricator tank with cylinder oil regularly. No feed of oil must cause
serious damages.
l) Local pressure and temperature indicators.
m) Sound and vibration of moving parts.
Abnormal sound and vibration are the first sign causing a serious damage. In such a case, the compressor
should be immediately stopped and inspected.
n) Temperature at suction discharge valve cover to determine eventual valve leakage. In case of
temperature rising of valve cover or gas, check whether the bolts of valve keeper have been tightened
sufficiently or not, as the insufficient tightening causes such troubles.
o) Check for possible gas / water / oil leakages.
p) Drain off frequently and regularly, and watch the amount and color of drain. Take care of black drain.
Black drain means the abnormal wear of cylinder liner and piston rings in most cases.
q) When the relief valve is blown, before re-starting of the compressor, check each part, and trace the
cause, if any.
r) Watch the amount and temperature of leakage gas from stuffing box (rod packing) and compartment
adjacent to the cylinder.
s) Inspect that all foundation bolts are tight, and there is no leakage from gaskets and pipe connections.

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Compressor Shutdown
Section-VI
COMPRESSOR SHUT DOWN

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Cares and procedures when compressors are stopped are as follows:

a) Disable HydroCOM by “LOAD DISABLE” push button. When the disable signal is set, the stop-ramp
function in DCS ramps down the compressor load smoothly.
After the compressor load reaches minimum load, enable signal will be reset automatically.
When stopped, the compressor shall be under the condition of no compressing in the cylinders.
b) Then stop the main driver.
c) Stop the motor-driven lubricator to prevent over lubrication during stoppage of compressor.
d) Close the main shut-off valves in the discharge gas line.
e) Close the main shut-off valves in the suction gas line.
f) Relieve the pressure in the cylinders, and replace gas by Nitrogen.
g) Shut and drain off the cooling water, if the freezing temperature is expected or the shutdown is expected
long.
h) Drain off all the drains in the same case as mentioned the above.
i) Abnormal points shall be checked and repaired during stoppage.
j) Management in case that the long stoppage is expected:
(1) After the cylinders have been cooled, all liquid in the cylinders should be drained off to prevent the
cylinder inside from corrosion during the stoppage. It is preferable to coat the rust preventive oil on the
cylinders.
(2) Run the compressor for about 5 minutes every week under an unloaded condition to prevent the parts
from being rusty or corrosive.
In such case as an unload running being impossible, the compressor to be turned at max. 2 revolutions by a
barring device, while the oil is supplied by the auxiliary lube oil pump.
If cylinders are lubricated, the lubricator shall be actuated.
Stand-by machine shall be turned at max. 2 revolutions by a barring device, while the oil is supplied by the
auxiliary lube oil pump.
(3) In such case that the process gas piping, in which corrosive gases are handled, is overhauled and left
open to atmosphere, the piping ends to be fitted with blind flanges and the inside of the piping to be filled
up with Nitrogen to prevent it from being rusty or corrosive.None of this work may cause a serious trouble.
(4) Close the main shut-off valve in suction and discharge gas lines, and take off or lock the handle.

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(5) Take off the instruments that are liable to damage.

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Trouble
shooting
Section-VII
TROUBLE SHOOTING GUIDE

In order to find the abnormal conditions during running, it is very important to be well aware of normal
conditions, to record the data regularly and to be familiar with every sound from compressor and the
auxiliaries.
Don't overlook even a small abnormal phenomenon, because it must result trouble.

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Generally, the trouble of compressor occurs hardly from single cause, but from several complicated causes.
The following are the abnormal phenomena that appear on ordinary compressors and must be watched
carefully.
1) ABNORMAL PRESSURE
1-a) Low suction pressure
Causes Remedies
Increased resistance in suction pipe line. Check the pipe line and fittings (Valve,
etc.).
Excessive capacity of compressor. Decrease the compressor capacity by the
Capacity control device.
Over cooling in the four stage gas cooler. Decrease the flow of cooling water.
(In case multi-stage compressor)
Leakage from suction pipe line. Check the pipe connection.

Low process gas pressure. Inspect process side.
High suction pressure
Causes Remedies
Faulty suction compressor valves. Check and renew valves.
Increased leakage from piston rings. Renew piston rings.
Leakage from the back of cylinder liner. Tighten cylinder liner correctly.
High pressure gas flow into suction pipe line. Close and check the bypass valves.
Insufficient cooling in the fore stage gas cooler. (In Increase the flow of cooling water, clean tubes.
case multi-stage compressor)
Shortage of compressor capacity. Increase the compressor capacity by the capacity
control device.
Low discharge pressure
Causes Remedies
Low suction pressure. See above 1-a).
Increased leakage from piston rings and Check piston rings and stuffing boxes.
stuffing boxes.
Leaky discharge pipe line. Check leakage from valves and other fittings.
Faulty suction and discharge compressor valve. Check and renew valves.

EXPANSION PROJECT
LUBEREF-II
Excessive capacity of next stage compressor. Check the next stage capacity control device.
Drain valves or bypass valves are not Close valves perfectly.
perfectly closed.
High discharge pressure
Causes Remedies
Increased resistance in discharge pipe line Check the pipe line and fittings (valve,
etc.).
Faulty suction compressor valves of the next stage. Check and renew valves.
High suction pressure. See above 1-b).
Insufficient cooling in the four stage gas cooler. Increase the flow of cooling water, clean tubes.
Low suction temperature. Care about overload.
Vibration of gas in suction and discharge Change the piping layout.
pipe lines.
Increased resistance at discharge Check the valve lift and the spring force.
compressor valve.
Abnormal Temperature
2-a) Low suction temperature
Causes Remedies
Low process temperature. Check the process side.
Over cooling in the gas cooler Decrease the flow of cooling water
Excessive capacity of compressor. Decrease the capacity by the capacity control
device.
2-b) High suction temperature
Causes Remedies
Faulty suction compressor valves. Check and renew valves.
Bypass valves are not perfectly closed. Close valves perfectly.
Heating of the suction pipe line. Remove the cause, cool the pipe, if
necessary.
2-c) Low discharge temperature

EXPANSION PROJECT
LUBEREF-II
Causes Remedies
Low suction temperature. See above 2-a).
Leaky discharge pipe line. Check leakage from valves or other fittings.
Low discharge pressure. See above 1-c).
2-d) High discharge temperature
Causes Remedies
High discharge pressure. See above 1-d).
High suction temperature. See above 2-b).
Low suction pressure. See above 1-a).
Increased resistance in the discharge pipe line. Check the pipe line and fittings (valve,etc.).
3) ABNORMAL SOUND
3-a) Knocking sound in crank case
Causes Remedies
Loose main bearing or crank-pin bearing. Check the bearing clearance, renew or
adjust the bearing.
Loose tightening bolt of bearings. Tightening the bolts correctly.
Faulty angle between piston center and Re-machining to get 90 deg.
crank-pin, crosshead-pin or crankshaft.
3-b) Knocking sound at crosshead guide
Causes Remedies
Loose crosshead pin bearings. Check the bearing clearance, renew if
necessary.
Loose nut for piston rod and crosshead. Tighten correctly and lock the nut surely.
Increase clearance between crosshead Check the clearance, adjust or renew if necessary.
and crosshead guide.
The uneven wear of crosshead guide or guide shoe. Adjust or renew guide shoes and re-boring
guide if necessary

EXPANSION PROJECT
LUBEREF-II
3-c) Knocking sound in cylinder
Causes Remedies
Dropping of pieces into cylinder. Take out the pieces and inspect the inside
of cylinder.
Piston touches the top or bottom of cylinder. Check and adjust the top clearance.
Loose tightening nut of the piston. Tighten correctly and lock the nut perfectly.
Loose tightening of cylinder liner. Renew a loose liner.
The valve is not fixed firmly. Check and fix the valve or the piston.
Increased clearance between piston rings Check the grooves and if necessary, renew
and the grooves. piston rings or piston.
Water hammer phenomenon. Drain off perfectly and check that discharge
valve is in good order.
Breakage of suction or discharge Renew broken parts.
compressor valves.
Improper working of suction valve Check and adjust it.
unloader.
4) ABNORMAL SOUND IN PIPE LINE

4-a) Knocking sound in pipe
Causes Remedies
Resonant vibration of gas at the sudden Remove the parts, change the layout.
change section of the piping.
Resonant vibration of gas at the branch or Make the flow smooth at the parts, change
junction parts of the pipe. the layout.
4-b) Abnormal sound by the vibration of the pipe
Causes Remedies
Vibration of the pipe. Strengthen the supports or change the
piping layout.
Worse piping support. Support pipes tightly.
4-c) Abnormal sound from non-return valves
Causes Remedies

EXPANSION PROJECT
LUBEREF-II
Non-return valves in poor order. Check and renew the valves, if necessary.
4-d) Abnormal sound in shell and tube type cooler
Causes Remedies
Baffle plates loosened. Make the baffle plates rigid.
Clattering sound from the tubes and baffle Strengthen the shell of the cooler and
plates. tighten anchor bolt firmly.
.4-e) Leakage sound from pipes and pipe connections
causes Remedies
Cracked pipe. Mend by welding or remove the parts.
Insufficient tightening of flange bolts. Tighten sufficiently.
Breakage of gaskets. Renew the gaskets.
Leakage form valves. Inspect and re-grind valves.
5) ABNORMAL VIBRATION
5-a) Vibration of the foundation
Causes Remedies
Resonance between the ground and Take measures to avoid the resonance.
foundation block.
5-b) Abnormal vibration of the compressor
Causes Remedies
Insufficient support of the foundation. Reinforce the foundation.
Loosen foundation bolts. Tighten correctly.
Loose connection studs of each part. Tighten correctly.
Eccentric center of flywheel shaft due to Check the clearance, modify correctly and
the excessive clearance of the bearings. renew the bearings if necessary.
6) ABNORMAL CONSUMPTION OF POWER

6-a) Much consumption since running-in period

EXPANSION PROJECT
LUBEREF-II
Causes Remedies
Too much capacity. Check operating conditions in comparison
with designed ones.
Too much resistance in pipe line. Inspect valves, check the piping.
High suction and discharge pressures. Inspect the process side.
Too high viscosity of lube oil. Feed the suitable oil.
6-b) Increased power consumption during running
Causes Remedies
High differential pressure between suction Inspect the pipe line and fittings (valves, etc.).
and discharge.
Higher pressure loss in gas passage. Inspect the pipe line and fittings (valves, etc.).
Higher pressure loss in compressor valves. Check and adjust the lift of valves.
Higher friction loss of the moving parts. Inspect the moving parts, i.e. bearings,
crosshead guides, check the lubricating oil
pressure.
Ⅱ-7 CAPACITY CONTROL
1) Suction Valve Unloader
The capacity of compressor can be controlled with following.
a) Suction valve unloader with HydroCOM system
Suction valve unloaders are fitted on both ends of the cylinders, control steps of which is 100 to 15, and 0%
Suction valve unloader:
Hydraulic operated by HydroCOM system:
Hydraulic pressure failure ■load type.
Capacity % 100～15, 0
Head End Under control of the HydroCOMM

Unloader of the cylinders
Crank End Under control of the HydroCOMM

2) Running with zero capacity should not be continued for longer hours. It should be limited only at
start/stop and for 5 minutes.

EXPANSION PROJECT
LUBEREF-II
COMPRESSOR SAFETY DEVICE

1) The following safety devices are equipped on the compressor.
a) Lube oil pressure relief at each LO pump
set: Approx. 5.5 barG
b) Regulating lube oil pressure at crankcase inlet
set : 2.5 barG
c) Other safety devices are listed in the "ANNUNCIATOR AND INTERLOCK TABLE".
2) Emergency Stop
The compressor is provided with some protective devices to prevent serious damages from any troubles.
When lube oil (crankcase) pressure drops to pre-determined value, the compressor is stopped
automatically.
As there may be erroneous operations of instrument itself in case of emergency stops, the cause should be
examined considering this.
The compressor must be immediately stopped and checked in case that the following running conditions
have been noticed:
a) abnormal knocking sound
b) abnormal vibration
c) crack or damage of pipe and violent gas blow
Immediately after stopping the compressor for checking troubles,
i) close the main shutoff valves in gas line and purge the process gas in the compressor
cylinder under the unloaded condition,
ii) operate the lube oil pump, and
iii) turn the compressor, at least three rounds.
Troubles and Checking
a) Low lube oil pressure

EXPANSION PROJECT
LUBEREF-II
Troubles Remedies
Clogged filters. Clean (check inside).
Troubles of lube oil pump. Repair.
Breakage of pipe. Repair.
Leakage of oil from joint. Repair.
b) High lube oil temperature
Trouble Remedies
Fouling of shell-side or tube-side of lube oil cooler clean
Clog or fouling of cooling water passage in the lube oil cooler clean
Seizure of any moving part in crankcase. Check bearings and crosshead shoes, repair
PREPARED BY: CHANDRASEKARAN

REVIEWED BY: M.SENTHILKUMAR
APPROVED BY: RASHID ALGHAMDI
MSDS
BASIC TRAINGING MANUAL FOR
HYDROGEN MAKEUP-GAS COMPRESSOR
(C-4002A/B)
DATE: 20 /08/2015
REV: 00
Page | 44
Section-VIII
EXPANSION PROJECT
LUBEREF-II
MATERIAL SAFETY DATA SHEET

SECTION 1. PRODUCT IDENTIFICATION
PRODUCT NAME: Hydrogen, compressed

CHEMICAL NAME: Hydrogen FORMULA: H2
SYNONYMS: None
MANUFACTURER: Air Products and Chemicals, Inc.
7201 Hamilton Boulevard
Allentown, PA 18195-1501
PRODUCT INFORMATION: 1-800-752-1597
SECTION 2. COMPOSITION/INFORMATION ON INGREDIENTS
Hydrogen is sold as pure product >99% CAS NUMBER: 1333-74-0
EXPOSURE LIMITS: OSHA: None ACGIH: Simple asphyxiant

EXPANSION PROJECT
LUBEREF-II
SECTION 3. HAZARD IDENTIFICATION
EMERGENCY OVERVIEW
Hydrogen is a flammable, colorless, odorless, compressed gas packaged in cylinders at high pressure.
It poses an immediate fire and explosive hazard when concentrations exceed 4%. It is much lighter
than air and burns with an invisible flame. High concentrations that will cause suffocation are within
the flammable range and must not be entered.
POTENTIAL HEALTH EFFECTS INFORMATION:

INHALATION: Asphyxiant. It should be noted that before suffocation could occur, the lower
flammability limit of hydrogen in air would be exceeded possibly causing both an oxygen-deficient and
explosive atmosphere. Exposure to moderate concentrations may cause dizziness, headache, nausea
and unconsciousness. Exposure to atmospheres containing 8-10% or less oxygen will quickly bring
about unconsciousness without warning leaving individuals unable to protect themselves. Lack of
sufficient oxygen may cause serious injury or death.
EYE CONTACT: None

SKIN CONTACT: None
CHRONIC EFFECTS: None
OTHER EFFECTS OF OVEREXPOSURE: None
EXPOSURE INFORMATION:
ROUTE OF ENTRY: Inhalation
TARGET ORGANS: None
EFFECT: Asphyxiation (suffocation)
SYMPTOMS: Exposure to an oxygen-deficient atmosphere (<19.5%) may cause dizziness, drowsiness,
nausea, vomiting, excess salivation, diminished mental alertness, loss of consciousness, and death.
MEDICAL CONDITIONS AGGRAVATED BY OVEREXPOSURE: None CARCINOGENIC
POTENTIAL: Hydrogen is not listed by NTP, OSHA or IARC.
SECTION 4. FIRST AID

INHALATION: Persons suffering from lack of oxygen should be removed to fresh air. If victim is not
breathing, administer artificial respiration. If breathing is difficult, administer oxygen. Obtain prompt
medical attention.
SKIN CONTACT: None
EYE CONTACT: None

EXPANSION PROJECT
LUBEREF-II
INGESTION: None
NOTES TO PHYSICIAN: None
SECTION 5. FIRE AND EXPLOSION

FLASH POINT: AUTOIGNITION: FLAMMABLE LIMITS:
Flammable gas 565.5_C (1050_F) LOWER: 4% UPPER:
74%
EXTINGUISHING MEDIA: CO2, dry chemical, water spray or fog for surrounding area. Do not
extinguish until hydrogen source is shut off.
HAZARDOUS COMBUSTION PRODUCTS: None
SPECIAL FIRE FIGHTING INSTRUCTIONS: Evacuate all personnel from danger area. Immediately cool
container with water spray from maximum distance, taking care not to extinguish flames. If flames are
accidentally extinguished, explosive re-ignition may occur. Stop flow of gas if without risk while
continuing cooling water spray.
UNUSUAL FIRE AND EXPLOSION HAZARDS: Burns with a pale blue, nearly invisible flame.
Hydrogen is easily ignited with low-ignition energy, including static electricity. Hydrogen is lighter than
air and can accumulate in the upper sections of enclosed spaces. Pressure in a container can build up
due to heat, and it may rupture if pressure relief devices should fail to function.
SECTION 6. ACCIDENTAL RELEASE MEASURES

Evacuate immediate area. Eliminate any possible sources of ignition, and provide maximum
explosionproof ventilation. Shut off source of hydrogen, if possible. If leaking from cylinder, or
valve, call the Air Products' emergency phone number. The presence of a hydrogen flame can be
detected by approaching cautiously with an outstretched straw broom to make the flame visible.
SECTION 7. HANDLING AND STORAGE

STORAGE: Specific requirements are listed in NFPA 50A. Cylinder storage locations should be
wellprotected, well-ventilated, dry, and separated from combustible materials. Cylinders should never
knowingly be allowed to reach a temperature exceeding 125 _F (52 _C). Cylinders of hydrogen should
be separated from oxygen cylinders or other oxidizers by a minimum distance of 20 ft., or by a barrier
of noncombustible material at least 5 ft. high having a fire resistance rating of at least _ hour.
Cylinders should be stored upright with valve protection cap in place and firmly secured to prevent
falling or being knocked over. Protect cylinders from physical damage; do not drag, roll, slide or drop.
Use a suitable hand truck for cylinder movement. Post "No Smoking or Open Flames" signs in the
storage areas. There should be no sources of ignition. All electrical equipment should be explosion
proof in the storage and use areas. Storage areas must meet national electric codes for class 1
hazardous areas.

EXPANSION PROJECT
LUBEREF-II
HANDLING: Do not "open" hydrogen cylinder valve before connecting it, since self-ignition may occur.
Hydrogen is the lightest gas known and may collect in the top of buildings with out proper ventilation.
It may leak out of a system which is gas-tight for air or other gases. Leak check system with leak
detection solution, never with flame. If user experiences difficulty operating cylinder valve,
discontinue use and contact supplier. Use only approved CGA connections. DO NOT USE ADAPTERS.
Never insert an object (e.g., wrench, screwdriver, pry bar, etc.) into valve cap openings. Doing so may
damage valve, causing a leak to occur. Use an adjustable strap wrench to remove over-tight or rusted
caps. Never strike an arc on a compressed gas cylinder or make a cylinder a part of an electrical circuit.
SPECIAL PRECAUTIONS: Use piping and equipment adequately designed to withstand pressures to be
encountered. Use a check valve or other protective apparatus in any line or piping from the cylinder to
prevent reverse flow.
SECTION 8. PERSONAL PROTECTION/EXPOSURE CONTROLS

ENGINEERING CONTROLS: Provide natural or explosion-proof ventilation adequate to ensure
hydrogen does not reach its lower explosive limit of 4%.
RESPIRATORY PROTECTION:
General Use: None
Emergency Use: Air supplied respirators are required in oxygen-deficient atmospheres. Before
entering area you must check for flammable or oxygen-deficient atmospheres.
PROTECTIVE GLOVES: Work gloves are recommended when handling cylinders.
EYE PROTECTION: Safety glasses are recommended when handling cylinders.
OTHER PROTECTIVE EQUIPMENT: Safety shoes are recommended when handling cylinders.
SECTION 9. PHYSICAL AND CHEMICAL PROPERTIES

APPEARANCE AND STATE: Colorless gas at normal temperature and pressure.
ODOR: Odorless
MOLECULAR WEIGHT: 2.016
BOILING POINT (1 atm): -423.0 _F (-252.8 _C)
SPECIFIC GRAVITY (Air =1): 0.06960
FREEZING POINT/MELTING POINT: -434.5 °F (-259.2 _C)
VAPOR PRESSURE (at 70 F): Not applicable
GAS DENSITY (At 70 F (21.1 C) and 1 atm): 0.00521 lb/ft3 (0.08342 kg/m3) SOLUBILITY
IN WATER (Vol/Vol at 60 F (15.6 C)): 0.019

EXPANSION PROJECT
LUBEREF-II
SPECIFIC VOLUME (At 70 F (21.1 C) and 1 atm): 192 ft3/lb (11.99m3/kg)
SECTION 10. REACTIVITY/STABILITY

CHEMICAL STABILITY: Stable
CONDITIONS TO AVOID: None
INCOMPATIBILITY (Materials to Avoid): Oxidizing agents. Some steels are susceptible to hydrogen
embrittlement at high pressures and temperatures.
REACTIVITY:
A) HAZARDOUS DECOMPOSITION PRODUCTS: None
B) HAZARDOUS POLYMERIZATION: Will not occur.
SECTION 11. TOXICOLOGICAL INFORMATION

Hydrogen is a simple asphyxiant.
SECTION 12. ECOLOGICAL INFORMATION

No adverse ecological effects are expected. Hydrogen does not contain any Class I or Class II ozone
depleting chemicals (40 CFR Part 82). Hydrogen is not listed as a marine pollutant by DOT (49 CFR
Part 171).
SECTION 13. DISPOSAL

WASTE DISPOSAL METHOD: Do not attempt to dispose of residual or unused product in the cylinder.
Return to supplier for safe disposal.
Residual product within process system may be vented at a controlled rate, to the atmosphere through
a vent stack that discharges to an elevated point. This stack should be in an isolated area away from
ignition sources.
SECTION 14. TRANSPORTATION

DOT/IMO SHIPPING NAME: Hydrogen, compressed
HAZARD CLASS: 2.1 (Flammable Gas )
IDENTIFICATION NUMBER: UN1049
PRODUCT RQ: None
SHIPPING LABEL(s): Flammable gas.
PLACARD (When required): Flammable gas.
SPECIAL SHIPPING INFORMATION: Cylinder should be transported in a secure upright position in a
well-ventilated truck. NEVER TRANSPORT IN PASSENGER COMPARTMENT OF A VEHICLE. Shipment of
compressed gas cylinders which have not been filled with the owner's consent is a violation of Federal
law (49 CFR Part 173.301 (b)).

EXPANSION PROJECT
LUBEREF-II
SECTION 15. REGULATORY INFORMATION

U.S. FEDERAL REGULATIONS:
EPA - ENVIRONMENTAL PROTECTION AGENCY
CERCLA: Comprehensive Environmental Response, Compensation, and Liability Act of 1980 (40 CFR
Parts 117 and 302):
Reportable Quantity (RQ): None
SARA: Superfund Amendment and Reauthorization Act
SECTION 302/304: Requires emergency planning on threshold planning quantities (TPQ) and release
reporting based on reportable quantities (RQ) of EPA's extremely hazardous substances (40 CFR Part
355).
Extremely Hazardous Substances: None
Threshold Planning Quantity (TPQ): None
SECTIONS 311/312: Require submission of material safety data sheets (MSDSs) and chemical
inventory reporting with identification of EPA defined hazard classes (40 CFR Part 370). The hazard
classes for this product are:
IMMEDIATE: No PRESSURE: Yes
DELAYED: No REACTIVITY: No
FLAMMABLE: Yes
SECTION 313: Requires submission of annual reports of release of toxic chemicals that appear in 40
CFR Part 372.
Hydrogen does not require reporting under Section 313
40 CFR PART 68: Risk Management for Chemical Accidental Release. Requires the development and
implementation of risk management programs at facilities that manufacture, use, store, or otherwise
handle regulated substances in quantities that exceed specified thresholds.
Hydrogen is not listed as a regulated substance. However, any process that involves a flammable gas
on site in one location, in quantities of 10,000 pounds (4,553 kg) or greater, is covered under this
regulation.
TSCA: Toxic Substance Control Act: Hydrogen is listed on the TSCA inventory.
OSHA - OCCUPATIONAL SAFETY AND HEALTH ADMINISTRATION:

EXPANSION PROJECT
LUBEREF-II
29 CFR 1910.119: Process Safety Management of Highly Hazardous Chemicals. Requires facilities to
develop a process safety management program based on Threshold Quantities (TQ) of highly
hazardous chemicals.
Hydrogen is not listed in Appendix A as a highly hazardous chemical. However, any process that involves
a flammable gas on site in one location, in quantities of 10,000 pounds (4,553 kg) or greater is covered
under this regulation unless it is used as fuel.
SECTION 16. OTHER INFORMATION:
OTHER INFORMATION:
NFPA RATINGS: HEALTH: =0 FLAMMABILITY: = 4 REACTIVITY: =0
SPECIAL: = SA (CGA recommends this to designate simple asphyxiant )


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SAUDI ARAMCO BASE OIL COMPANY

HYDROGEN MAKEUP GAS COMPRESSOR

SECTIONS DESCRIPTION PAGE NO

III HYDROGEN MAKEUP-GAS COMPRESSOR 09

PREPARED BY: CHANDRASEKARAN BASIC TRAINGING MANUAL FOR DATE: 20 /08/2015

Safety involves the following general principles:

Hazard Present in Compressor unit:

The various hazard present in the compressor units are

PREPARED BY: CHANDRASEKARAN BASIC TRAINGING MANUAL FOR DATE: 20 /08/2015

PREPARED BY: CHANDRASEKARAN BASIC TRAINGING MANUAL FOR DATE: 20 /08/2015

PREPARED BY: CHANDRASEKARAN BASIC TRAINGING MANUAL FOR DATE: 20 /08/2015

PREPARED BY: CHANDRASEKARAN BASIC TRAINGING MANUAL FOR DATE: 20 /08/2015

Compressors can be classified as follows

PREPARED BY: CHANDRASEKARAN BASIC TRAINGING MANUAL FOR DATE: 20 /08/2015

PREPARED BY: CHANDRASEKARAN BASIC TRAINGING MANUAL FOR DATE: 20 /08/2015

PREPARED BY: CHANDRASEKARAN BASIC TRAINGING MANUAL FOR DATE: 20 /08/2015

PREPARED BY: CHANDRASEKARAN BASIC TRAINGING MANUAL FOR DATE: 20 /08/2015

TYPES OF RECIPROCATING COMPRESSOR:

Single – Acting compressor

It is a compressor that has one discharge per revolution of crankshaft.

Double – Acting Compressor

compressors are double acting.

Major Parts of reciprocating compressor

The various parts of reciprocating compressor are

PREPARED BY: CHANDRASEKARAN BASIC TRAINGING MANUAL FOR DATE: 20 /08/2015

 Stud bolt, nut & pin

PREPARED BY: CHANDRASEKARAN BASIC TRAINGING MANUAL FOR DATE: 20 /08/2015

PREPARED BY: CHANDRASEKARAN BASIC TRAINGING MANUAL FOR DATE: 20 /08/2015

Piston rod packing:

Piston rod Packing :

PREPARED BY: CHANDRASEKARAN BASIC TRAINGING MANUAL FOR DATE: 20 /08/2015

Cylinder & Liner :

PREPARED BY: CHANDRASEKARAN BASIC TRAINGING MANUAL FOR DATE: 20 /08/2015

There are normally three types of valves, these are

PREPARED BY: CHANDRASEKARAN BASIC TRAINGING MANUAL FOR DATE: 20 /08/2015

PREPARED BY: CHANDRASEKARAN BASIC TRAINGING MANUAL FOR DATE: 20 /08/2015

PREPARED BY: CHANDRASEKARAN BASIC TRAINGING MANUAL FOR DATE: 20 /08/2015

PREPARED BY: CHANDRASEKARAN BASIC TRAINGING MANUAL FOR DATE: 20 /08/2015

PREPARED BY: CHANDRASEKARAN BASIC TRAINGING MANUAL FOR DATE: 20 /08/2015

Trouble Possible cause Remedies

Check support bearings.

Perform correct tightening of foundation.

PREPARED BY: CHANDRASEKARAN BASIC TRAINGING MANUAL FOR DATE: 20 /08/2015

HYDROGEN MAKE UP GAS COMPRESSOR (C-4002 A/B) :

PREPARED BY: CHANDRASEKARAN BASIC TRAINGING MANUAL FOR DATE: 20 /08/2015

The following PFDs should be used as aids in this section:

PFD – Make-Up Hydrogen Section = 40-G2-PF-012

PREPARED BY: CHANDRASEKARAN BASIC TRAINGING MANUAL FOR DATE: 20 /08/2015

Equipment no C-4002 A/B

PREPARED BY: CHANDRASEKARAN BASIC TRAINGING MANUAL FOR DATE: 20 /08/2015

Separate cooling console One common to all units

Cooling water for cylinders

Cooling water for coolers

Cooling for Rod packing

PREPARED BY: CHANDRASEKARAN BASIC TRAINGING MANUAL FOR DATE: 20 /08/2015

Pressure at various stage :

First stage Second stage Third stage Fourth stage

Precommissioning of Reciprocating compressor