SAFE OPERATING PROCEDURE

FOR RECIPROCATING GAS

COMPRESSOR PACKAGE

Document No: CP/GPP/CS/2020/0002

1.0 PURPOSE:

To provide guideline for the execution of the operation and maintenance of Chicago Pneumatic
make CNG compressor of inline the safety guideline of Atlas Copco (I) Ltd.

2.0 SCOPE:

This procedure is applicable to field service.

3.0 RESPONSIBILITY:

Site Engineer, Team Leader, representative of customer

DRN./ DSP REV IND. ALTERATION By DATE DRG. NO SH.

CHK. SPT 25.05.20 1 / 10
SK 07.06.20
DSP REV.
APPD
2
 CNG
Operation procedure Compressor

Before starting the compressor: -

1. Ensure that air pressure of starter is in the range of 8-10 Barg.

2. Check coolant level each shift.
3. Check oil level of starter motor.
4. Check engine oil level each shift.
5. Ensure that the gas suction valve is open and the suction pressure is in the range as
per design after the PRV (Pressure regulating Valve).
6. Ensure that the isolation valves of Gas vent lines are closed.
7. Ensure that the Gas discharge valve is open.
8. Check the oil level in crankcase & Lube oil.
9. Check the supply voltage in all three phases and ensure that it is in the range of 380 to
440 AC volts in each phase for air compressor.
10. Ensure that all the manual drain vales are closed.
11. Check the instrumentation gas pressure and ensure that it is in the range of 6 to 10
bar.
12. Check all the ESDs (Emergency switching device) are released.

DRN./ DSP REV IND. ALTERATION BY DATE DRG. NO SH.

CHK. SPT 25.05.20 2 / 10
SK 07.06.20
DSP REV.
APPD
2
 CNG
Operation procedure Compressor

START UP SEQUENCE

When 'POWER SUPPLY' is 'ON'

---> Drain valves (BDV1-High Dump Actuator & POV2-Low Dump Actuator) are open.

---> Compressor Suction Actuator (POV1 - Energize to open type) will be controlled
on suction gas pressure in load condition. If “HIGH SUCTION GAS
PRESSURE” condition is sensed by PT-01, then it will close Suction Actuator
POV1.

MANUAL MODE

Ensure that "Maintenance/Manual/Auto” selector switch is in Manual mode.

STEP- 0
---> Suction Actuator POV1 is OPEN,
Check low suction pressure (PT1) after some delay.
--->Opens High Bank Actuator POV54 of priority panel.

Message

If all Trip Parameters & CO2 system are healthy (Input =1) “COMPRESSOR READY TO
START “will be displayed.

STEP- 1

Start Compressor by pressing “Compressor Start PB”

---> Cooler fan command is given. If there is no feedback of ‘contactor on’ within 5
sec., “Compressor tripped due to cooler motor fault” is displayed. BDV1 &
POV2 are deenergized and cooler fan command is off. Else move to further
step.

---> After 6 second from cooler fan started, main motor command is given. If there is
no feedback of ‘Soft starter on’ within 5 sec. “Compressor tripped due to main
motor fault” is displayed. BDV1 & POV2 are deenergized and main motor
command is off. After 30 sec. Delay, cooler motor is off. Else move to further
step.

a) Activate No Flow Oil Switch (NF01)

b) Activate Low differential oil pressure after delay of 6 sec (settable).
c) Activate Vibration switch VS01

DRN./ DSP REV IND. ALTERATION BY DATE DRG. NO SH.

CHK. SPT 25.05.20 3 / 10
SK 07.06.20
DSP REV.
APPD
2
 CNG
Operation procedure Compressor

Message

If above conditions (a, b, c) are healthy "COMPRESSOR RUNNING" is displayed.

Else appropriate trip messages as per condition a, b & c will be displayed.
Drain valves BDV1& POV2 will be closed after settable time
(from HMI) Else appropriate trip messages for above
interlocks will be displayed. Message
Once drain valves are closed "COMPRESSOR ON LOAD SWITCH TO AUTO
MODE" command is displayed

AUTO MODE

STEP- 2
When compressor is running and system is healthy, put the selector switch in AUTO
MODE.
Load/Unload, auto stop & auto start functions will be active only in auto mode.
EMERGENCY STOP/TRIP OF COMPRESSOR

When any trip conditions occurs (refer the trip list for compressors) or emergency
stop push button is pressed.

---> Drain valves BDV1 & POV2 will be OPEN (De-energize).

---> Main motor command is deactivated
---> Cooler motor command is deactivated.
---> Compressor suction valve POV01 is closed.

STOP

When STOP push button is pressed

---> Drain valves BDV1 & POV2 will be opened after settable time.
---> Compressor suction valve POV01 is closed.
---> After some settable delay, main motor command is deactivated
---> After main motor command is deactivated, with some delay cooler motor command is deactivated

DRN./ DSP REV IND. ALTERATION BY DATE DRG. NO SH.

CHK. SPT 25.05.20 4 / 10
SK 07.06.20
DSP REV.
APPD
2
 CNG
Operation procedure Compressor

AUTO MODE SEQUENCE

In auto mode, when pressure sensed by compressor discharge pressure transmitter PT04 reaches
to its Auto Stop Set Point (Settable from HMI), auto-unloading condition will be established.
Auto Unloading

---> Suction Actuator (POV1) closes (De-energize).

---> After delay High Dump actuator (BDV1) opens (De-energizes).
---> After delay Low Dump actuator (POV2) opens (De-energizes).
In this condition compressor will run for 300 sec. (settable).

Auto Loading

After Compressor is stopped in Auto Stop condition within 300 sec. time duration, if
compressor discharge pressure is less than Auto start set point ,(Settable from HMI))

---> Suction Actuator (POV1) opens (Energize), Low dump actuator (POV2) closes
(Energize).
---> After delay of 30 sec., High dump actuator (BDV1) closes (Energize).
And compressor will be again in load condition.

Auto Stop

---> After settable time BDV1 & POV2 will be De-energized

---> After settable time main motor will be off.
---> And settable time, with some delay cooling fan will be off.

Auto Start
After Compressor stopped on Auto Stop condition, if auto start condition occurs (i.e.
Compressor Discharge Pressure is less than Auto Start Set point (Settable from HMI))
then,

---> After cool down time delay 5 - 30 sec. (settable). Cooler fan command is
given if there is no feedback of contactor on with in 5 sec. Compressor will
be tripped due to cooler motor fault. else move to further step.
---> After 6 second from cooler fan started "main motor on command" is given if there is no
feedback of Soft-starter on with in 5 sec. Compressor will be tripped due to main motor fault.

When any trip condition is triggered, appropriate trip messages will be displayed,
compressor will be tripped and it will be removed from Auto Operation. Now in this
condition, operator has to start the compressor in Manual mode only.

Similarly when Emergency stop is pressed emergency stop push button pressed
message would be displayed, compressor will be removed from Auto Operation. Now
in this condition operator has to start the compressor in Manual mode only.

DRN./ DSP REV IND. ALTERATION BY DATE DRG. NO SH.

CHK. SPT 25.05.20 5 / 10
SK 07.06.20
DSP REV.
APPD
2
 CNG
Operation procedure Compressor

EMERGENCY STOP SEQUENCE

Step 0

- When “Emergency stop” PB is pressed.

- Suction Actuator (POV1) will be closed.
- All priority Actuators will be closed.
- Drain valves BDV1, POV2 will be opened.
- Main motor will be OFF.
- Cooler motor will be OFF.

GAS DETECTION LOGIC

This compressor package is having two flame detector and two % LEL gas detector.

Gas detectors are connected to PLC with analog inputs & PLC will create fault
according to % level. If any gas detector senses gas level (10% alarm, 20% trip)
above high trip set point then machine will trip with audio visual indication.

While flame detector inputs are directly connected to CO2 system through main control
panel (These i/p’s are not connected to PLC).During starting of compressor PLC shall
check status feedback from CO2 system healthy contact (=1) is received.

DRN./ DSP REV IND. ALTERATION BY DATE DRG. NO SH.

CHK. SPT 25.05.20 6 / 10
SK 07.06.20
DSP REV.
APPD
2
 CNG
Operation procedure Compressor

ALARM CONDITIONS FOR COMPRESSOR

• COMPRESSOR SUCTION PRESSURE – PT01

Low alarm- if pressure goes below set point (settable from HMI) it will give
audiovisual alarm LOW INLET GAS PRESSURE.

High alarm- if pressure goes above set point (settable from HMI) it will give
audiovisual alarm HIGH INLETGAS PRESSURE.

• COMPRESSOR DISCHARGE GAS PRESSURE – PT04

High alarm- if pressure goes above set point (settable from HMI between) it will give audiovisual alarm

HIGH DISCHARGE COMPRESSOR PRESSURE.

• GAS DETECTOR FOR COMP CHAMBER-GD-1

High alarm- if gas level goes above set point (settable from HMI) it will give audiovisual alarm.

• GAS DETECTOR FOR COMP CHAMBER-GD-2

High alarm- if gas level goes above set point (settable from HMI) it will give audiovisual alarm.

• DISCHARGE GAS TEMPERATURE 1st STAGE – TE02

High alarm- if temperature goes beyond set point (settable from HMI) it will give audio visual alarm

DISCHARGE GAS 1ST STAGE TEMP HIGH.

• DISCHARGE GAS TEMPERATURE 2nd STAGE – TE03

High alarm- if temperature goes beyond set point (settable from HMI) it will give
audio visual alarm DISCHARGE GAS 2nd STAGE TEMP HIGH.

• DISCHARGE GAS TEMPERATURE 3rd STAGE – TE04

High alarm- if temperature goes beyond set point (settable from HMI) it will give
audio visual alarm DISCHARGE GAS 3rd STAGE TEMP HIGH.

• AFTER COOLER OUTLET TEMP – TE05

High alarm- if temperature goes beyond set point (settable from HMI) it will give audiovisual alarm

AFTER COOLER GAS OUTLET TEMP HIGH

DRN./ DSP REV IND. ALTERATION BY DATE DRG. NO SH.

CHK. SPT 25.05.20 7 / 10
SK 07.06.20
DSP REV.
APPD
2
 CNG
Operation procedure Compressor

TRIP CONDITIONS FOR COMPRESSOR

• COMPRESSOR SUCTION PRESSURE – PT01

Low trip- if pressure goes below trip set point (low alarm settable from
HMI) it will trip the compressor with audiovisual indication.

High trip- if pressure goes above trip set point (high alarm settable from
HMI) it will trip the compressor with audiovisual indication.

• COMPRESSOR DISCHARGE GAS PRESSURE 1st STAGE –PT02

High trip- if pressure goes above trip set point it will trip the compressor with audiovisual indication.

• COMPRESSOR DISCHARGE GAS PRESSURE 2nd STAGE – PT03

High trip- if pressure goes above trip set point it will trip the compressor with audiovisual indication.

• COMPRESSOR DISCHARGE GAS PRESSURE – PT04

High trip- if pressure goes above trip set point it will trip the compressor with audiovisual indication.

• COMPRESSOR LUBE OIL PRESSURE

Low trip- if the differential pressure is below 2.4Bar, it will trip the
compressor with audiovisual indication

• GAS DETECTOR FOR COMP CHAMBER – GD-01

High alarm- if gas level goes above trip set point (settable from HMI) it will trip
the compressor with audiovisual indication

• GAS DETECTOR FOR COMP CHAMBER – GD-02

High alarm- if gas level goes above trip set point (settable from HMI) it will trip
the compressor with audiovisual indication

• DISCHARGE GAS TEMPERATURE 1st STAGE – TE02

High trip- if temperature goes above trip set point (settable from HMI) it will trip
the compressor with audiovisual indication.

DRN./ DSP REV IND. ALTERATION BY DATE DRG. NO SH.

CHK. SPT 25.05.20 8 / 10
SK 07.06.20
DSP REV.
APPD
2
 CNG
Operation procedure Compressor

• DISCHARGE GAS TEMPERATURE 2nd STAGE – TE03

High trip- if temperature goes above trip set point (settable from HMI) it will trip the
compressor with audiovisual indication.

DISCHARGE GAS TEMPERATURE 3rd STAGE – TE04

High trip- if temperature goes above trip set point (settable from HMI) it will trip the
compressor with audiovisual indication

• AFTER COOLER OUTLET TEMP – TE05

High trip- if temperature goes above set point (settable from HMI) it will trip the
compressor with audiovisual indication

• COMPRESSOR VIBRATION S/W-VS01

In running condition if the contact opens it will trip the compressor with audiovisual indication.

• NO FLOW OIL SWITCH -NF01

if the contact opens it will trip the compressor with audio visual indication.

• CO2 SYSTEM HEALTHY

If the contact opens it will trip the compressor with audiovisual indication.

• EMERGENCY OFF

If this input operates externally it will trip the compressor with audio visual indication.

DRN./ DSP REV IND. ALTERATION BY DATE DRG. NO SH.

CHK. SPT 25.05.20 9 / 10
SK 07.06.20
DSP REV.
APPD
1
 CNG
Operation procedure Compressor

FLOWMETER DATA:

Suction, Discharge & LCV gas Mass Flow meter.

Suction gas Mass Flow Meter FM02, Discharge Mass Flow meter FM01
and LCV FM03 (Through MODBUS to PLC) MODBUS input for mass flow
of gas in kg/hr. These readings will be used to calculate the total Gas
used.

ENERGY METER DATA:

MODBUS input for Energy consume by motor in KWh.
These readings will be used to calculate the Energy consume by
motor.

“Chicago Pneumatic service representative or service engineer should be consulted

before carrying out any maintenance”.

Note: For the long term storage or preservation of CNG compressor, refer document:

CP/GPP/CS/2020/00202

DRN./ DSP REV IND. ALTERATION BY DATE DRG. NO SH.

CHK. SPT 25.05.20 10 / 10
SK 07.06.20
DSP REV.
APPD
2