PLANT EQUIPMENTS

DG SET
AIR COMPRESSOR
LPG PUMP
LPG COMPRESSOR
DIESEL GENERATOR
A diesel generator is the combination of a diesel engine with an electrical generator (often
called an alternator) to generate electrical energy. Diesel generating sets are used in places
without connection to the power grid, as emergency power-supply if the grid fails.

Generating sets are selected based on the Electrical load they are intended to supply, the
electrical loads total characteristics (KVA and Harmonic Content including starting
currents (normally from motors) and non-linear loads.

Various capacity DG sets are provided at plants for various requirements as given below :
• 250 KVA, 380 KVA & 500 KVA, 650 KVA & 1250 KVA DG sets for operation of
entire plant operations
• 75 KVA to 125 KVA for exclusively emergency lighting load

DG sets are to be provided with acoustic enclosures as per State pollution control boards
guidelines and the sound level should not be more than 75-80 db outside the acoustic
enclosure.
DG WITH ACCOUSTIC
ENCLOSURE
SCHEDULED CHECKS
• Cooling system
• Radiator air restriction, hoses, connections, fluid concentration,
belts and louver operation
• Air intake system
• Check for leaks, holes and loose connections
• Fuel system
• Fuel levels and pump
• Exhaust system
• Check for leaks, restrictions.
• Electrical system
• Review meters and battery fluid
• Recharge Battery if needed
• Annual, semi-annual and quarterly checks
ANNUAL SEMI- ANNUAL AND
QUARTERLY CHECKS
Maintenance (annual)
• Change oil, filters

Engine not running, check:

• Electrical
• Oil and coolant levels
• Leaks, holes and connections

Battery and charger (semi-annual)

• Load, acid and specific gravity
• Corrosion cleaned
• Charger output (adjust if necessary)

Fuel system
• Leaks, water, sediment checks
• Day tank – float switch pump
• Governor linkage
ANNUAL SEMI- ANNUAL AND
QUARTERLY CHECKS
Coolant system (check only)
• Antifreeze, radiator and cap
• Leaks, hoses, belts and tension

Intake and exhaust (check only)

• Air cleaner, turbocharger, muffler and traps
• Leaks
• Breather, flex pipe, rain cap

Alternator
• Diodes, end bearing, brushes and folder
• A.V.R.
• A.C. wiring, exciter stator, over speed switch
• Breakers

Controls
• Voltage regulator, wiring relays, monitors and bulbs
ANNUAL SEMI- ANNUAL AND
QUARTERLY CHECKS
Transfer switch
• Time delays, exerciser clocks (adjust or reset as necessary)
• Clean cabinet

Engine running
• Record A.C. output
• Frequency
• Amps under load
PREVENTIVE MAINTENANCE
Checks to be done:-

A Checks – Daily.
B Checks – 300 Hrs / 6 Months.
C Checks – 1500 hrs / 1 Year.
D Checks – 6000 hrs/ 2 Years.
E Checks – 8000 hrs/ *ENGINE OPERATING CONDITIONS
SIGNIFY DETERIORATION
MAINTENANCE SCHEDULE
DG LOG BOOK
MAINTENANCE SCHEDULE FOR ALTERNATOR
AIR COMPRESSOR
Air compressors are used to increase the pressure of ambient air which
at higher pressures is used for industrial purposes. Compressors can be
classified based on their working principle.

Mainly we will discuss about Screw type and Reciprocating type of air
compressors, which are commonly used in our LPG Plants.
SCREW TYPE AIR
COMPRESSOR
Working Principle
A screw compressor consists of two rotors, one male and other
female. These rotors have asymmetric profile lobes, encircling the
rotors in the form of thread. A screw air compressor has no other
moving parts except these two rotors, which are separated by
thin film of lubricating oil. This results in less wear and tear of the
unit. The compressed air compresses the oil in the oil separator
tank and forces the oil into the compressor for the lubrication.

The compressed air / oil mixture form compressor flow into the
receiver – cum- oil tank, where most of the oil gets separated.
The oil collected in the separator element is send back to the
compressor through a calibrated nipple so that compressed air
does not go back to the compressor
SCREW TYPE AIR COMPRESSOR ROTOR
DETAIL
SCHEMATIC DIAGRAM
Nomenclature
1. Temp. Gauge for Air/ Oil (40-100 C) 21. Pressure Sensing Valve
2. Oil Pressure gauge for Comp. Oil (0-10 kg/sq. cm) 22. NRV 90%
3. Air Discharge Pressure Gauge (0-10 kg/sq. cm) 23. Bare Screw Compressor
4. Rubber Hose Oil Filter to Rotor Inlet 24. Coupling
5. Oil Filter Assembly 25. Adopter Assembly
6. Rubber Hose Oil Cooler to Oil Filter 26. Suction Control Valve
7. Rubber Hose Air/ Oil Tank to Oil Cooler
8. Axial flow Pan Assembly
9. A
[Link] Cooler cum After Cooler
[Link] Off Valve
[Link] Limiting Valve. 50%
13.1” Safety Valve.
[Link] Switch
[Link] Moisture Trap
[Link] Valve ¼” BSP, 3/2 way NC 220V
[Link] Pressure Gauge
[Link] Indicator
[Link] Filter
[Link] Releasing Valve 1/8”
AIR OIL SEPARATOR
Since compressed air in a screw compressor is mixed with lube oil in the
rotor. This lube oil needs be separated from air before air is supplied to
the plant. For this purpose Air Oil Separator tank consists air oil
separator element which separates oil from compressed air.

Air oil separator element needs cleaning / replacement after prescribed

no of running hours. If element is not damaged, the air will carry lot of
oil along with it in the pipeline which will deteriorate the quality of air.
At the same time it will increase the consumption of oil in the
compressor and will need regular top ups. If compressor is operated
without adequate oil level it may damage the screw assembly. Air oil
separator tank is provided with a drain cock which should be used to
drain accumulated moisture in the tank bottom, prior to the starting of
the compressor. Air-Oil Separator Element should be replaced whenever
choked.
 DAILY LOG BOOK
ANY
Lube OIL ABNOR TOTAL HOURS
Dt Shift Discharge Air CURRENT (AMPs) REM SIGN
MAL
NOISE

Dew Pt SHI
Start Stop Temp OPER FT
Pre Level Temp Pre Un Loaded Loaded Day Cum
Time Time After A OF
Drier F
PREVENTIVE MAINTENANCE
SCHEDULE
• Everyday
• Check for correct oil level in compressor air / oil tank.
• Check oil pressure of compressor.
• Check the service indicator, if provided. Clean suction air filter in dusty conditions.
• Drain condensate from air / oil tank.
• Drain moisture from mini moisture trap.
• Check for loading / unloading pressures.
• Every week or 50 Hours
• Clean compressor air suction filter element.
• Check the working of safety valve.
• Check the setting of pressure limiting valve (it should open only after 3.0 kg/sqcm pressure0 i.e. air is
Discharged from delivery valve only after air pressure has reached 3.0 kg/sqcm.
• Replace oil in oil bath filter
• Every 200 Hours
• Replace secondary oil filter element
• Clean primary oil filter
• Service pressure sensing valve
• Service actuator cylinder
• Every 500 Hours
• Clean oil cooler
• Change the lubricating oil of compressor every 1000 hours
PREVENTIVE MAINTENANCE
SCHEDULE
• Maintenance of other components depending upon the
running:-
• Moisture trap
• Pressure sensing Valve
• Pressure limiting Vavle
• Safety Valve
• Blow off valve
• Air Releasing Valve
• Actuator cylinder
• Suction Control Valve.
• Pressure Switch
• Solenoid valve
• Temperature Switch
• Differential Pressure Switch.
RECIPROCATION AIR
COMPRESSOR
Working Principle

It is a positive displacement type compressor. It consists of

cylinder and piston assembly, piston rod connected to a
crank shaft. The crank shaft is propelled by an electric motor
through belt drive. It consists of suction and discharge
valves. Capacity is controlled by discharge pressure switch
which trips the motor on reaching the set pressure.
SAFETY TRIPPINGS
• Low lube oil pressure tripping
• SRV of both stages.
• High discharge Temperature.
• High Discharge Pressure.
LPG PUMPS
LPG PUMPS
LPG pumps are used in the LPG Plant for cylinder filling operation.
Pump is used to pump the LPG from storage vessels to carousel in
the filling shed. Pump increases the pressure of the LPG by around
8 KG/Cm2 and sends in the filling pipeline.

Generally multistage centrifugal type of pumps are used. Pumps

are provided with mechanical seals and are driven by FLP electrical
motor. In general horizontal type of pumps are used, but for
mounded storage due to NPSH requirement, vertical canned type
of pumps are being used.

These specification cover requirement of centrifugal pump for

filling requirement of 24 head carousel in the LPG Plant. The Pump
shall generally conform to API 610 (6th edition).
TECHNICAL SPECIFICATIONS
TYPE MULTISTAGE HORIZONTAL / VERTICAL CENTRIFUGAL PUMP

DISCHARGE FLOW 50 CUM/HR FOR 24 HEAD CAROUSEL, MAY VARY AS PER

REQUIRMENT

SUCTION PRESSURE 2-8 KG / CM2

DISCHARGE PRESSURE 16.9 KG / CM2 Max
DIFFERENTIAL PRESSURE 8.5 KG / CM2
SPEED 2900 rpm
MECHANICAL SEAL SINGLE FOR DRIVE END
DOUBLE MECHANICAL SEAL FOR NON-DRIVE END, WHEREVER
REQUIRED.
Note: In case of Vertical Canned type pumps, Mechanical Seal is
provided only on the Drive End.

SEAL FLUSHING AS PER PLAN 52 OR AS PER REQUIREMENT

MECHANICAL SEAL MAKE As per OEM LIKE (EPIL, DURAMETTALIC, BURGMANN)
CROSS SECTIONAL VIEW OF MULTI
STAGE PUMP
DOUBLE MECHANICAL SEAL
Mechanical seal consists of Si-SiC,Carbon faces(Hard) and soft
face. One face(Soft) is mounted on the shaft sleeve which
rotates with the shaft and other is connected to the pump
casing. Sealing is obtained between these faces. For effective
working the mechanical seal, the faces should not have any type
of scratches. In case of scratches, these face should be lapped to
the finish.
The soft part or the sacrificial surface helps to increase the life
of the seal.
The Double mechanical seal helps in avoiding release of LPG
directly into atmosphere.
The outside Mechanical seal rarely comes in contact with LPG ,
hence has a longer life.
API PLAN-52
BRIEF DESCRIPTION
Mechanical seals provided in the LPG Pump needed to be cooled to take
away the heat generated in the faces of rotary and stationary parts of the
seal.

The single mechanical seal provided in the drive end is cooled by using
the LPG Bleed line while the Double Mechanical Seal is cooled using
flushing system(API Plan 52). Cooling system works on the principle of
thermosiphon, where oil is used in a closed loop to cool the mechanical
seal. Reservoir contains oil which is cooled by means of cooling water
line. Cold oil form the bottom of the reservoir enters the mechanical seal
and takes the heat generated away and enters the reservoir from top,
where it is cooled by water line. (Thermosyphon effect)
API - 52
 DAILY LOG BOOK
DISCH OIL WATER CURRENT ANY ABNORMAL
DATE SHIFT SUCT PRES TOTAL HOURS REMARK SIGN
PRES LEVEL FLOW (AMPs) NOISE

STOP SHIFT
START TIME Day’s Cum OPERATOR
TIME OFF
MAINTENANCE SCHEDULE AS PER
OISD-119
Horizontal Centrifugal Pumps (Both Ends Supported)

Following items shall be checked / recorded after specified period:

After 1000 running hours or 3 months whichever earlier

• Bearing lubricant (for water contamination and sediments)
• Oil ring for performance
• Deflector for looseness
• Constant level oiler for leakage
• Mechanical seal for leakage
• Seal flushing/quenching system (of Mechanical Seal) for clogging and chocking.
• Gland for leakage
• Cooling water flow in both the bearing housings
• Condition of bearing by sound and temperature (in running condition)
• Performance of all measuring instruments (Pressure / Temperature gauges and flow meters)
• Coupling guard
• Electric motor load current
• Axial position indicator (in case of multistage pump)
• Dowel pins (in position or not; wherever provided
MAINTENANCE SCHEDULE AS PER
OISD-119
• After 4000 running hours or 1 year whichever earlier
• Repeat all checks as per 1
• Flushing of bearing with lube oil and refilling of oil to required
level whether carried out or not.
• Flushing of cooling water lines and strainers, whether carried out
or not (to ensure proper flow of cooling water)
• Foundation, foundation bolts and supports
• Replacement of old packing with new ones and condition of
gland follower, lantern ring and sleeves (in case of gland packing)
• Condition of coupling, coupling bolts, nuts, spring washers and
their conformity to uniform size. Change grease in half coupling in
case of gear type.
MAINTENANCE SCHEDULE AS PER
OISD-119
• After 8000 hours or 2 years whichever earlier
• Repeat all checks as per 2 above
• Condition of outboard bearing, lock nut and lock washer (in case lock washer
found damaged and lock nut loose, shaft axial play shall be checked)
• Following items of journal bearings:
• Clearance of I/B and O/B bearings
• High spot (high spots shall be scrapped)
• Condition of thrust bearing, lock washer found damaged and lock nut loose shaft
axial play shall be checked).
• OISD RP123 shall be referred for inspection of bearings. (Replace the bearings
if necessary)
• Pump float (adjust if necessary)
• Oil filter for cleanliness if journal bearing is hydrodynamic.
• Condition of mechanical seals (OISD RP125, “Inspection and maintenance of
Mechanical Seals” shall be referred)
• Alignment (Misalignment shall be not more than 0.05 mm)
• Painting of equipment, whether carried or not.
MAINTENANCE SCHEDULE AS PER
OISD-119
• After 16000 hours or 4 years whichever is earlier.
Complete overhauling of the pump shall be carried out.
This shall include part wise inspection and checks
specified for 8000 hours
LPG COMPRESSOR
LPG Compressor in the LPG plant, is used for Bulk LPG decantation. Bulk LPG
decantation is done by way of differential pressure method. This differential pressure in
LPG Vapour is created by LPG Compressors. As per API 618 & API 619.
MAKE DRESSOR RAND INDIA PVT LTD
MODEL 7 X 7 ESH-1 NL-2
TYPE RECIPROCATING DOUBLE ACTING
SERVICE LPG UNLOADING
STAGE 1
STROKE (INCH) 7.00
CYLINDER DIA (INCH) 7.00
MATERIAL C.I.
LINER / MATERIAL C.I.
RAGULATION 0-50%-100%
UNLOADERS AND LOCAITON UL-90 (LOAD ON AIR FAILURES UNLOADER FINGER TYPE

INTAKE PRESSURE KG/SQCM 2 TO 11

INTAKE TEMPERATURE (DEG C) 35
DISCHARGE PRESSURE KG/SQCM 13.0
DISCHARGE TEMPERATURE (DEG C) 80 TO 40
PISTON DIAPLACEMENT CUM/HR 266.02
CAPACITY TO UNLOAD 4 NOS 15MT TANKERS IN 105 MINUTES

TOTAL BHP (MAX) 58

SPEED (RPM) 514
BELT DRIVEN 7 BELTS (SIZE C-158)
P & I DIAGRAM
 DAILY LOG BOOK
CURRENT
ANY
Date Shift / Time Lube OIL LPG LPG Temp Water (AMPs) ABNORMA TOTAL HOURS RE SIGN
Presssure Flow (Unload, 50%, L NOISE M
100% load)

Start Stop Shi

Time Time Pres Level Suct Disc Suct Disc 0 50 100 Day Cum Oper Off
PREVENTIVE MAINTENANCE
SCHEDULE AS PER OISD-120
• During first 1000 hours
• After 60 Hours
• Cross head nuts for tightness)

• After 500 Hours

• Check following for tightness:
• Cross head pin plate screws
• Piston lock nuts
• Connecting bolts – slide bodies to frame
• Correcting bolts – cylinder to slide bodies
• Tie bolts of big and connecting rod
• Stud bolts of main bearing cap
• Foundation bolts of main bearing cap
• Connecting bolts - cylinder supports
• Wear of not metallic shoes for piston (by feeling clearance between lowest point of piston and the sliding surface of
cylinder liner)
• The following of not metallic piston rings
• Radial wear
• Clearance between side of rings and grooves
• Ring and clearance
• The following of stuffing box with non metallic seal rings
• Radial clearance
• Clearance between side of rings and grooves
PREVENTIVE MAINTENANCE
SCHEDULE AS PER OISD-120
After 1000 Hours
• Condition of suction and discharge valve seats, plates and springs
• Crank case oil replacement
• Oil filter
After 2000 Hours
• Condition of compressor suction and discharge valve
• Oil filter
After 4000 Hours
• All checks of 2000 hours
• Crank case oil replacement
• Nuts connecting piston to cross head for tightness
• Piston ring end gap and side clearance of Teflon and graphite piston rings
• Piston shoes for wear
• Stuffing box seal ring radial wear, clearance between rings and grooves
• Foundation bolts for tightness
• All traps
• Safety interlocking of compressor for proper functioning
PREVENTIVE MAINTENANCE
SCHEDULE AS PER OISD-120
After 8000 Hours
• All checks of 4000 hours schedules
• The following for tightness
• Connecting bolts – cylinder supports
• Connecting bolts – cylinder to slide bodies
• Tie bolts of big end connecting rod
• Stud bolts of main bearing caps
• Connecting bots – slide bodies to frame
• Cylinder or cylinder liner for wear
• Piston ring grooves and piston shoes of white metal for wear
• Piston rod for wear, smoothness an deflection
• Metal piston ring for breakage of crack, end and side clearance
• Wear of seal rings of stuffing box provided with metal seal rings
• Suction valve unloader for proper operation
• Condition of not return valve in the discharge lines of the compressor
• Safety valves, whether recalibrated or not
• Tubes of inter cooler and after cooler whether cleaned and pressure tested or not
• Lube oil pump and lubricator whether serviced or not
• Piston end clearance with cylinder
PREVENTIVE MAINTENANCE
SCHEDULE AS PER OISD-120
• After 16000 Hours

• Complete overhauling of the compressor shall be carried out.

• Following Parts to checked during complete overhaul:-
• Suction and discharge valves
• Piston assembly
• Cylinder assembly
• Crank Shaft
• Crosshead assembly
• Lube oil system
• Gas cooler
• Crank shaft bearing
• Coupling and alignment.
SAFETY
TRIPPINGS/INTERLOCKS
• Low Suction Pressure Trip.
• High Discharge Pressure Trip
• High Temperature Trip.
• Low Cooling Water pressure Trip.
• Low Lube Oil Pressure Trip.
• Liquid Level Switch in Suction Vessel.

• Interlocking with Fire Fighting System.

• Interlocking with Service Water Pump.
THANK YOU