Operating Instructions Machine Unit Ruwais REC 2013: MAN Diesel & Turbo

Operating Instructions
Machine Unit
Ruwais REC 2013
MAN Diesel & Turbo
Operating Instructions for Machine Unit
Rev. Changed Date Checked Date Change no. Change description

H. Girschweiler 2015-01-12 H. Girschweiler 2015-01-12
Issued Date Checked Date Released Date
Type/Size: - Project no: H.7590010
Description: Operating Instructions Machine Unit Project: Ruwais REC 2013
Document: 10001567799 Type: MAN Part: 001 Rev: 00 Lang: EN Page: - MAN Diesel & Turbo SE
The reproduction, distribution and utilisation of this document, as well as the communication of its
contents to other, is prohibited without explicit authorisation. Offenders will be held liable for the
payment of damages. All rights reserved in the event of the grant of a patent, utility model or design.
The "Original Operating Instructions" as defined in Directive 2006/42/EG (Machinery Directive) is
the German language edition of the present Operating Instructions. Any edition in another
language therefore is a "Translation of the Original Operating Instructions".
MAN Diesel & Turbo | Operating Instructions | Machine Unit | Ruwais REC 2013 | 10001567799 | EN | 1/4 | 151438112820
Table of contents
1 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.1 Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
1.2 Operating Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
1.2.1 Contents overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
1.2.2 Target persons and obligation to read. . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5
1.3 Organizational measures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6
1.3.1 Location of the Operating Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6
1.3.2 Scope of validity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6
1.3.3 Property rights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-7
1.3.4 Manufacturer addresses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-8
1.4 After Sales Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-9
1.4.1 Services . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-9
1.4.2 Information in case of enquiries. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-10
1.4.3 Hotline service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-11
1.4.4 After Sales Service network . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-11
1.5 Assistance and conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-12
1.5.1 Text markings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-12
1.5.2 Item numbers and cross-references . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-13
1.5.3 Access assistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-14
1.6 Quality checks and tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-15
1.7 Further literature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-16
1.7.1 Further documentation on the machine unit . . . . . . . . . . . . . . . . . . . . . . .1-16
1.7.2 Service Bulletins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-16
Table of contents 1
2 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.2 Safety concept. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2.2.1 Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
2.2.2 Improper use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
2.2.3 Warnings and references for use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
2.2.4 Operating modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
2.2.5 User roles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
2.2.6 Spheres of responsibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
2.2.7 Hazard zones. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
2.2.8 General safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
2.3 Residual hazards and risks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
2.3.1 Residual risks to persons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
2.3.2 Residual risks to physical assets and property . . . . . . . . . . . . . . . . . . . . . 2-20
3 Design and function. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

3.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.2 Machine unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
3.3 Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3.3.1 Steam turbine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3.3.2 LP compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
3.3.3 HP compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
3.3.4 Couplings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
3.3.5 Process gas system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
3.3.6 Oil system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
3.3.7 Seal gas system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
3.3.8 Drainage system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
3.3.9 Control system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
3.3.10 Monitoring system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
3.4 Indicating instruments and operator controls . . . . . . . . . . . . . . . . . . . . . . 3-16
4 Normal operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

4.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.2 Prerequisites for start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
4.3 Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
4.4 Checks during operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
4.5 Shut-down in an emergency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22
4.6 Shut-down from normal operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23
4.7 Measures for standstill periods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24
2 Table of contents
5 Installation and commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5.1 Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2
5.2 Preparations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-3
5.2.1 Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-3
5.2.2 Scope of supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-4
5.2.3 Place of use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-5
5.2.4 Operating media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-6

5.3 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-7
5.3.1 Erection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-8
5.3.2 Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-9
5.4 Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-10
5.4.1 Checking of installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-11
5.4.2 Initial start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-12
6 Service, maintenance, and troubleshooting . . . . . . . . . . . . . . . . . . . . . 6-1

6.1 Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2
6.2 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-3
6.2.1 Maintenance schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-3
6.2.2 Maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-5
6.2.3 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-26
6.3 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-27
6.3.1 Inspection plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-27
6.3.2 Performance of inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-29
6.4 Malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-32
6.4.1 Detection of malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-32
6.4.2 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-33
6.5 Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-42
7 Decommissioning, dismantling, and disposal. . . . . . . . . . . . . . . . . . . . 7-1

7.1 Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-1
7.2 Decommissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-2
7.3 Dismantling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-3
7.4 Storage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-4
7.5 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-5
Table of contents 3
8 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
8.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
8.2 Machine unit data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
8.3 Operating data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
8.3.1 Switching values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
8.3.2 Emission values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
8.3.3 Operating media requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
8.4 Ambient conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8
9 Plans and Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
10 Operating Instructions for Components . . . . . . . . . . . . . . . . . . . . . . . . 10-1
List of procedures
List of tables
List of figures
Glossary
Index
4 Table of contents
1 Introduction
This Chapter addresses all users of machine unit Ruwais REC 2013. It provides
all information about the structure and configuration of the Operating
Instructions. Reading this Chapter allows quick access to the desired
information.
1-1
1.1 Overview
In the Sections below you will find information on the following subjects:
1.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.2 Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.2.1 Contents overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.2.2 Target persons and obligation to read . . . . . . . . . . . . . . . . . . . . . . . . 1-5
1.3 Organizational measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
1.3.1 Location of the Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . 1-6
1.3.2 Scope of validity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
1.3.3 Property rights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
1.3.4 Manufacturer addresses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
1.4 After Sales Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
1.4.1 Services . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
1.4.2 Information in case of enquiries . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
1.4.3 Hotline service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
1.4.4 After Sales Service network. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
1.5 Assistance and conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
1.5.1 Text markings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
1.5.2 Item numbers and cross-references . . . . . . . . . . . . . . . . . . . . . . . . 1-13
1.5.3 Access assistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
1.6 Quality checks and tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
1.7 Further literature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16
1.7.1 Further documentation on the machine unit . . . . . . . . . . . . . . . . . . 1-16
1.7.2 Service Bulletins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16
1-2 Introduction
1.2 Operating Instructions
The Operating Instructions provide guidelines for the intended use of the
machine unit and reference material.
They contain important information to help you achieve the following aims:
■ Operating the machine unit safely, properly and economically

■ Avoiding risks to people and physical assets
■ Reducing repair costs and downtimes
■ Increasing the reliability and the service life of the machine unit
Please contact MAN PrimeServ (see Section 1.4 After Sales Service) if
questions concerning the machine unit arise to which the Operating
Instructions do not give an answer or if there is a need for further clarification
concerning the handling of the Operating Instructions.
1.2.1 Contents overview
This Contents overview provides information about the versions of the

Operating Instructions and about the contents of each Chapter of the Operating
Instructions.
MAN Diesel & Turbo's Operating Instructions usually come in two versions:
■ Electronic version
The authoritative edition of the Operating Instructions is the edition
supplied by MAN Diesel & Turbo on the data carrier. This contains PDF
files with navigation assistance and links to drawings and schematic
diagrams and to the Operating Instructions for Components.
■ Hard copy version
In addition to the data carrier, a hard copy of the Operating Instructions
will be handed over to the operating company. This hard copy version is
subdivided into various folders as shown in Figure 1-1 Hard copy of the
Operating Instructions (numbers are exemplary).
Operating Instructions 1-3

1
1 4
5
2
6
Figure 1-1 Hard copy of the Operating Instructions

1 Operating Instructions for Machine Unit
2 Plans and Schematics
3 Operating Instructions for Components
Chapter structure The Operating Instructions are subdivided into the Chapters below:
■ Chapter 1 Introduction
❚ Contains information about the structure and configuration of the
Operating Instructions
❚ Describes the handling of the Operating Instructions and allows quick
access to the desired information
■ Chapter 2 Safety
❚ Contains information about the safety concept
❚ Explains the prerequisites for safe utilization of the machine unit
■ Chapter 3 Design and function

❚ Shows the arrangement of the components of the machine unit
❚ Describes the function of the machine unit and its components
■ Chapter 4 Normal operation

❚ Provides all the information required for safe and trouble-free use of
the machine unit during normal operation
❚ Describes what to do in an emergency
■ Chapter 5 Installation and commissioning

❚ Provides an overview of the work to be carried out for installation and
commissioning of the machine unit
1-4 Introduction
■ Chapter 6 Service, maintenance, and troubleshooting
❚ Provides information about the work required for service,
maintenance, and troubleshooting of the machine unit
❚ Describes what can be done and by whom
■ Chapter 7 Decommissioning, dismantling, and disposal

❚ Provides all the information required for decommissioning,
dismantling, storage, and disposal of the machine unit

■ Chapter 8 Technical Data
❚ Provides machine unit data
❚ Specifies operating media requirements
■ Chapter 9 Plans and Schematics

❚ Contains an overview of the plans and schematics which are part of
the Operating Instructions
■ Chapter 10 Operating Instructions for Components
❚ Contains an overview of the Operating Instructions for Components
including related technical data and drawings
1.2.2 Target persons and obligation to read
MAN Diesel & Turbo have prepared the present Operating Instructions for
specific target persons, binding them to fulfil a corresponding obligation to read.
These Operating Instructions address the authorized users of the machine unit.
The operating company of the machine unit determines who will be authorized
as user.
The Operating Instructions differentiate between different user roles since the
requirements in respect of the users vary depending on their particular activity.
You will find the definitions of the user roles with the requirements for the
corresponding roles in Section 2.2.5 User roles. You may assume one or more
of these user roles provided you meet the corresponding requirements.
Every user of the machine unit is obligated to read the Operating Instructions.
The user must observe the directions and information included in the Operating
Instructions for any and all activities on the machine unit.
NOTICE
The information, specifications, and requirements contained in these
Operating Instructions constitute a minimum standard which must
be adhered to by you in any case to ensure safe operation.
Operating Instructions 1-5

1.3 Organizational measures
Organizational measures in relation to the Operating Instructions include the
assurance of ready access to the complete Operating Instructions and the
allocation of the Operating Instructions to a specific machine unit.
1.3.1 Location of the Operating Instructions
Ensure permanent access to the current edition of the Operating Instructions by

keeping it in the immediate vicinity of the machine unit. This applies throughout
the entire service life of the machine unit.
Perform the activities as specified in the revision notice if you receive a revised
version of the Operating Instructions from MAN Diesel & Turbo.
In this way, you will allow users quick access to up-to-date information about
the machine unit.
1.3.2 Scope of validity
The Operating Instructions exclusively refer to the following machine unit:
Table 1-1 Machine unit data

Manufacturer MAN Diesel & Turbo Schweiz AG
MAN Diesel & Turbo project name Ruwais REC 2013
MAN Diesel & Turbo project number H.7590010
Year built 2013
Site location Ruwais / U.A.E.
Table 1-2 Machine data
LP compressor HP compressor Steam turbine
Machine type A 63-13 RB 90-5 DK 080/170R
Tag number of machine train 2640-K-001 1st Stage 2640-K-001 2nd Stage 2640-TK-001
Machine number, train 1 62011 62012 6761
Table 1-3 Operating company

Company ABU DHABI OIL REFINING COMPANY
1-6 Introduction
Table 1-4 Engineering company
Company SAMSUNG ENGINEERING Co., Ltd.
Address 500 Sagil-dong, Gangdong-gu

Seoul 134-090
South Korea
Project name Carbon Black and Delayed Coker Project
Project number SO-2542
Order number 5636-2640-PO-MK-001
1.3.3 Property rights
MAN Diesel & Turbo reserve all property rights in these Operating Instructions.
Therefore observe the following rules:
■ Copies including excerpts, whatever the kind and whatever the intended
application may be, may only be made with MAN Diesel & Turbo's prior
consent.
■ Prevent third parties' access to the Operating Instructions. This also
applies to excerpts and copies of any kind.
■ Inform MAN Diesel & Turbo without delay if you transfer the machine unit
to another owner, and pass the Operating Instructions on to the new
owner.
In the event of infringement, MAN Diesel & Turbo reserve the right to take
appropriate legal action.
Organizational measures 1-7

1.3.4 Manufacturer addresses
Table 1-5 Manufacturer addresses provides an overview of the manufacturer

addresses.
Table 1-5 Manufacturer addresses
MAN Diesel & Turbo SE MAN Diesel & Turbo SE
Steinbrinkstraße 1 Egellsstraße 21
46145 Oberhausen 13507 Berlin
GERMANY GERMANY
Phone: +49. 208.692.01 Phone: +49. 30.440402.0
Fax: +49. 208.669.021 Fax: +49. 30.440402.2000
MAN Diesel & Turbo Schweiz AG

Hardstrasse 319
8005 Zürich
SWITZERLAND
Phone: +41. 44.278.2211
Fax: +41. 44.278.2261
For all products and services of MAN Diesel & Turbo please visit us online at:
www.mandieselturbo.com
1-8 Introduction
1.4 After Sales Service
After the machine unit has been handed over the MAN Diesel & Turbo After
Sales Service will be the competent contact for all after-sales service issues.
After Sales Service of MAN Diesel & Turbo is an independent business division
registered under the trade name of MAN PrimeServ.
The MAN PrimeServ personnel are responsible for all services in connection
with maintenance, troubleshooting, inspection, and service and maintenance.
The MAN PrimeServ personnel also carry out work beyond the scope
described in Chapter 6 Service, maintenance, and troubleshooting.
1.4.1 Services
MAN PrimeServ offers the following services:

■ Troubleshooting during operation of the machine unit
■ OEM spare parts supplies and stock-keeping of spare parts
❚ Efficient OEM (original equipment manufacturer) spare parts supplies
for full operability and availability of your machines and plant units
❚ Opportunity to place spare parts orders via the Internet
■ Maintenance
MAN PrimeServ offers you two alternatives of planning and performing
inspection and maintenance work:
❚ Provision of all the personnel required for the work
❚ Provision of supervisory personnel for the performance of work by the
operating company or by a subcontractor commissioned by the
operating company
■ Inspections and repair work
Experienced MAN PrimeServ personnel manage repair work and
comprehensive general overhauls of individual machines and machine
units all over the world. The MAN PrimeServ personnel reliably check the
machine condition within a short time and with minimum installation
effort. In this way you can order a preventive diagnostic service.
■ 24/7 hotline
You can reach experienced MAN PrimeServ personnel 365 days a year,
24 hours a day. As an original equipment manufacturer, MAN PrimeServ
is familiar with all technological solutions for leading-edge mechanical and
systems engineering.
■ Technical consulting service
Benefit from the comprehensive technical consulting service of
MAN PrimeServ for planned modifications, refurbishments or current
operation issues. You can rely on qualified technical, commercial and
logistic consultation.
After Sales Service 1-9

■ Laboratory services
The service laboratory of MAN PrimeServ, accredited in compliance with
DIN EN 45001, uses state-of-the-art technical equipment and provides
support for analyses as well as the selection of appropriate materials and
protective measures.
■ Training
MAN PrimeServ will train you and your staff, and offer you training
programmes that cater for functions from operator to plant manager.
These training programmes can be arranged on the premises of
MAN PrimeServ, locally on your site or as a combination of the two.
■ Condition monitoring
The irds® Intelligent Remote Diagnostic System in combination with the
adams® automatic data analysis & mailing system can be an integral part
of service contracts and offers many opportunities to optimize plant
operation.
■ Engineering studies
If required, MAN PrimeServ also performs engineering studies in respect
of conversion options, refurbishments or relocations. These studies are
based on the following factors:
❚ Long-standing global experience
❚ Data bases for technical, commercial and logistic advice
❚ Documentation on measures performed in the past
1.4.2 Information in case of enquiries
When contacting MAN PrimeServ, please have the following details at hand:
■ Details according to Table 1-1 Machine unit data
■ Designation of the relevant parts with Tag number or ID number in
accordance with the drawings and spare parts lists
■ Type of malfunction
■ Your contact data:
❚ Contact person
❚ Phone number
❚ Address
❚ Time of day for possible queries
1 - 10 Introduction
1.4.3 Hotline service
MAN Diesel & Turbo offer their customers a 24/7 hotline service where you can
reach experienced MAN PrimeServ personnel 24 hours a day, 7 days a week,
all year round:
+49. 208.692.9000
1.4.4 After Sales Service network
The worldwide MAN PrimeServ After Sales Service network is coordinated from
our headquarters in Oberhausen, Berlin and Zurich.
The staff of the After Sales Service network are competent contacts for all
technical questions. These staff will be pleased to render advice and
assistance.
For the services of MAN PrimeServ please visit us online at:
www.mandieselturbo.com/primeserv
After Sales Service 1 - 11

1.5 Assistance and conventions
Assistance to the reader in using the Operating Instructions is based on the
text-marking conventions described below and on various ways of access
assistance.
1.5.1 Text markings
Text markings in these Operating Instructions will help you find important
contents more quickly.
The Operating Instructions describe the sequences of actions to be carried out

by the user based on procedures, the title of the procedure defining the
objective of the sequence of actions. The sequence of actions is described by
instructions. The following conventions apply to procedures:
■ Numbering of procedures
A procedure is marked with the word Procedure and the associated two-
part number (number of Chapter - sequence number in ascending order).
Example: Procedure 4-1 Preparing the machine unit
■ Instructions
The user is instructed by main steps numbered in ascending order.
Complex main steps may be split up into sub-steps.
Strictly follow the sequences of actions in the order shown herein in order
to avoid personal injury or physical damage due to potential malfunctions.
❚ Unconditional instructions
Unconditional instructions have to be carried out by the user in any
case.
Example:
3 Vent the filter.
3.1 Open the vent valve.
3.2 Wait until air is no longer visible in the sight glass.
3.3 Close the vent valve.
❚ Conditional instructions following a check
An unconditional instruction for a check is followed by a conditional
instruction. The user carries out this conditional instruction only if that
condition is fulfilled. A conditional instruction is additionally marked
with an asterisk (*) and generally has the following phrase pattern: "In
case (of) [condition]: [Instruction]".
Example:
3 Check the filter for leakage.
4* In case of leakage: Have the leakage eliminated.
1 - 12 Introduction
❚ Conditional instructions in case of operational requirements
The user carries out this conditional instruction only if he wants to fulfil
an operational requirement. A conditional instruction is additionally
marked with an asterisk (*) and has the following phrase pattern: "To
[requirement]: [Instruction]".
Example:
5* To perform maintenance work: Carry out the necessary

procedures.
■ Result
Once performed, an instruction can bring about a result. Results are
marked with a simple arrow.
Example: → The control system executes Step 6 automatically.
■ End of procedures
The end of each procedure is marked with a double arrow.
Example: ⇒ Procedure 4-1 Preparing the machine unit has been
completed.
1.5.2 Item numbers and cross-references
The Operating Instructions use the following types of item numbers and cross-
references:
■ Item numbers
Parts in Figures are numbered in clockwise sequence.
■ References to item numbers
References in the text to item numbers are placed in brackets. They refer
to the associated Figure above the text section.
■ Tag numbers
In addition to the designation, the components of the machine unit are
identified by a Tag No. (identification number).
Assistance and conventions 1 - 13

1.5.3 Access assistance
The Operating Instructions provide access assistance which allows quick

access to the desired information:
■ Table of Contents
The Table of Contents lists the titles of the first three Chapter levels.
■ Index
The alphabetical index is provided to quickly make you conversant with
the Operating Instructions and to find important subjects directly. Each
index entry consists of one main keyword with which sub-keywords may
be associated. The associated page number shows where you will find
information regarding that particular keyword.
■ List of Figures
The List of Figures shows all figures included in the Operating Instructions
in alphabetical order. The associated page number shows where you will
find the respective figure.
■ List of Tables
The List of Tables shows all tables included in the Operating Instructions
in alphabetical order. The associated page number shows where you will
find the respective table.
■ List of Procedures
The List of Procedures shows all procedures included in the Operating
Instructions in alphabetical order. The associated page number shows
where you will find the respective procedure.
■ Glossary
The Glossary contains definitions of terms which are important for
understanding the Operating Instructions.
1 - 14 Introduction
1.6 Quality checks and tests
MAN Diesel & Turbo carry out extensive quality checks and tests for quality
assurance before delivering the machine unit. The associated processes and
methods are defined in the integrated Management System and described in
the Quality Manuals of MAN Diesel & Turbo.
The Inspection and Test Plans (ITP) form the basis for carrying out the quality
checks and tests on the individual machines and machine parts. The quality
checks and tests include the activities below, for instance:
■ Balancing or overspeed testing of shafts and gear wheels
■ Overspeed testing of rotor assemblies
■ Testing of casings / housings and connecting piping for leaks
■ Performance of gear unit test runs
The results are documented in test reports. These test reports are then
integrated in the Quality Documentation of MAN Diesel & Turbo (see Section
1.7.1 Further documentation on the machine unit).
Quality checks and tests 1 - 15

1.7 Further literature
Within the scope of the overall documentation on the machine unit and
MAN PrimeServ activities MAN Diesel & Turbo offer various additional literature.
1.7.1 Further documentation on the machine unit
MAN Diesel & Turbo supply a separate documentation including various

documents which are required either for preparing the site or for performing
after-sales services.
■ Installation Manual
In the separate Installation Manual you will find information on mobilization
of the jobsite. This includes information such as spheres of responsibility,
transport, storage, preservation, site mobilization, preparation of
foundations, installation and cleaning of pipework.
■ Quality Documentation
The Quality Documentation, which is supplied separately, is a compilation
of material certificates and test reports for the machine unit.
1.7.2 Service Bulletins
The MAN PrimeServ Service Bulletins form part of the information service by
MAN PrimeServ. In these Service Bulletins you will find many helpful
recommendations for the operation of your machines, such as:
■ technical recommendations for machine operation and maintenance
■ technical improvements
■ presentations of new services and service concepts
■ information about service contracts regarding major overhauls, repairs,
refurbishments or relocations
■ organizational changes
If you are interested in these Service Bulletins, please contact one of the service
centres or MAN PrimeServ.
1 - 16 Introduction
2 Safety
information about the safety concept and the minimum requirements for safe
utilization of the machine unit.
2.1 Overview
2.1 Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1
2.2 Safety concept . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2
2.2.1 Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3
2.2.2 Improper use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5
2.2.3 Warnings and references for use . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6
2.2.4 Operating modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-7
2.2.5 User roles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-8
2.2.6 Spheres of responsibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-9
2.2.7 Hazard zones. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-10
2.2.8 General safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-13
2.3 Residual hazards and risks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-17
2.3.1 Residual risks to persons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-18
2.3.2 Residual risks to physical assets and property . . . . . . . . . . . . . . . . .2-20
2-1
2.2 Safety concept
The safety concept adopted by MAN Diesel & Turbo establishes rules for the
authorization to use the machine unit and defines the responsibility of its
individual users. The safety concept of the machine unit depends on the
intended use of the machine unit and the existing residual hazards. The present
Operating Instructions are an essential component part of the safety concept.
The machine unit has been designed and built by MAN Diesel & Turbo
according to the state of the art and the generally accepted safety rules. In spite
of this, its use may cause danger to the lives and health of users or third parties,
to the machine unit or to other physical goods or assets.
The machine unit is designed to meet high safety standards when employed for
the intended use:
■ Components and component parts of the machine unit which are located
in the ATEX zones have been designed by MAN Diesel & Turbo for use in
potentially explosive atmospheres in accordance with the information in
Section 8.2 Machine unit data.
■ MAN Diesel & Turbo have designed the machine unit such that
hazardous media cannot escape during normal operation.
■ A trip feature has been provided by MAN Diesel & Turbo for the machine
train, which is triggered if any critical operating value reaches the set limit
value. If the operating company decides to dispense with such a tripping
feature this decision will expressly be its own responsibility.
In addition to the information in this Chapter, concrete safety information for the
prevention of risks, marked with symbols, is included in the other Chapters.
Furthermore the pictograms, signs and labels on the machine unit must be
observed and must always be kept in legible condition.
Observance of all safety information is mandatory for protecting all users

against hazards and for the safe operation of the machine unit.
2-2 Safety
2.2.1 Intended use
This Section defines the intended use of the machine unit.
For the technical data please refer to Chapter 8 Technical data and to the
Operating Instructions for Components (see Chapter 10 Operating Instructions
for Components).
Machine unit Ruwais REC 2013 is exclusively intended for compressing the
specified process gases.For information about the composition of the process
gases please refer to the API data sheets (see Chapter 9 Plans and
Schematics).
Limits of application of compressors
The statements below apply analogously to both compressors.
In normal operation, the compressor must not be run below the minimum back-
pressure line nor must the maximum pressure limit be exceeded. Operation
outside these limits may lead to damage to the compressor or component parts
of the machine train.
Once the compressor has reached the rated speed of the machine train,
operate the compressor exclusively within the permitted range according to the
schematic drawing in Figure 2-1 Limits of application. For the effective limits
applicable to normal operation please refer to the Performance Maps for the
compressor (see Chapter 9 Plans and Schematics).
1 2 3
p
5 4
V
Figure 2-1 Limits of application
1 Surge line
2 Control line
3 Maximum pressure limit / Power limit
4 Minimum back-pressure line
5 Permitted range (hatched)
p Outlet pressure / pressure ratio
V Volume flow / mass flow
Safety concept 2-3

Use of the machine unit for the intended purpose also includes the following:
■ Compliance with these Operating Instructions including the Annexes and
in particular with the instructions on operation, maintenance and
inspection
■ Compliance with the relevant safety regulations
■ Compliance with the operating company's service instructions
■ Operation of the machine unit within the specified limits of application
■ Operation of all equipment, especially pressure equipment, in the
specified operating conditions.
■ Use of the machine unit in the atmospheric conditions according to
Section 8.4 Ambient conditions
■ Utilization of operating media according to Section 8.3.3 Operating media
requirements
2-4 Safety
2.2.2 Improper use
Improper use of the machine unit may lead to personal injury and to damage to
physical assets or property.
Any personal injury or damage to physical assets or property caused by

improper use will be the operating company's responsibility. In particular,

MAN Diesel & Turbo exclude any responsibility in the event of improper use.
The following actions, in particular, shall be considered as improper use:

■ Non-compliance with the safety regulations relating to activities on the
machine unit
■ Non-compliance with the present Operating Instructions
■ Operation of the machine unit with disabled, modified or defective safety
facilities
■ Operation of the machine unit by unauthorized persons (see Section
2.2.5 User roles)
■ Operation of the machine unit for a purpose other than the intended use
according to Section 2.2.1 Intended use without the manufacturer's
written consent
■ Operation of the machine unit with another than the specified process
gas
■ Operation of the machine unit outside the specified limits of application
■ Operation of equipment and especially of pressure equipment outside the
defined operating conditions
■ Use of operating media other than those defined in Section 8.3.3
Operating media requirements
■ Use of spare parts supplied by third parties
■ Use of individual devices and equipment in other applications than those
intended for this machine unit
■ Operation of equipment and apparatus in a potentially explosive
atmosphere if the equipment or apparatus is not approved for operation
in a potentially explosive atmosphere
■ Operation of equipment and apparatus in a potentially explosive
atmosphere for which such equipment or apparatus is not approved
according to its classification
■ Conversion or modification of the machine unit and of connected supply
lines and process gas pipes without the manufacturer's written consent
■ Modification of the programmable controller without the manufacturer's
written consent
■ Performance of work beyond the scope described in these Operating
Instructions or deviating from this scope that is carried out by the
operating company or by a third party called in by the operating company
■ Violation of statutory provisions and regulations in the country of use,
especially the accident prevention regulations
Safety concept 2-5

2.2.3 Warnings and references for use
Warnings caution against hazardous situations which may arise out of certain
activities.
Warnings given in these Operating Instructions are basically structured as
follows:
■ Signal word
The following signal words are possible:
❚ DANGER
❚ WARNING
❚ CAUTION
❚ NOTICE
■ Description of hazard
The hazard description describes the hazardous situation.
■ Consequences
The consequences point out the potential implications of the hazardous
situation.
■ Remedies
The remedies show measures which help you avoid such consequences.
The signal words are linked to different hazard levels:

■ DANGER
Signal word DANGER characterizes a hazardous situation which will
inevitably lead to death or serious injury if you do not avoid this situation.
Example:
DANGER
Risk arising from escaping toxic process gas when work
is done in the hazard zone!
This will lead to death or serious injury.

• Purge the process gas system before entering the
hazard zone.
• Wear the specified personal protective equipment.
■ WARNING
Signal word WARNING characterizes a hazardous situation which may
lead to death or serious injury if you do not avoid this situation.
2-6 Safety
Example:
WARNING
Risk arising from the explosion of escaping process gas!
This may lead to death or serious injury.

• Make sure process gas cannot escape into the
atmosphere.
■ CAUTION
Signal word CAUTION characterizes a hazardous situation which may
lead to minor or moderate injury if you do not avoid this situation.
Example:
CAUTION
Risk arising from inhalation of filter dust when opening the
suction strainer!
This may cause injury to the respiratory passages.

• When cleaning the suction strainer always use
adequate respiratory equipment.
■ NOTICE
Signal word NOTICE characterizes a hazardous situation which may lead
to damage to physical assets if you do not avoid this situation.
Signal word NOTICE characterizes further additional information which
will make handling of the machine unit easier for you.
Example:
NOTICE
Carry out this work carefully to avoid environmental pollution.
2.2.4 Operating modes
The operating company may possibly plan various operating modes for the
machine unit.
In such a case observe the separately prepared service instructions.
Safety concept 2-7

2.2.5 User roles
For ensuring safety, MAN Diesel & Turbo specify certain requirements in respect
of the users of the machine unit. Only persons who satisfy these requirements
are authorized to work on the machine unit.
All persons who work on the machine unit are designated by
MAN Diesel & Turbo as users. Since the requirements in respect of these users
vary considerably depending on their activity, a distinction is made between the
following user roles:
Engineering The engineering company is the contractual partner of the manufacturer

company MAN Diesel & Turbo. The engineering company designs the overall process
plant or parts of it and supplies them to the operating company. When
purchasing the machine unit, the engineering company may be legally bound
by the manufacturer to comply with certain obligations.
Operating company The operating company is the contractual partner of the engineering company.
When purchasing the machine unit, the operating company may be legally
bound by the engineering company to comply with certain obligations.
Operator The operator is a skilled person authorized by the operating company, who
operates the machine unit in normal operation. The operator must have
completed professional training in the technical sector, e. g. as a mechanic,
instrumentation technician, electrician, fitter. The operator must have been
specially trained in operating the machine unit.
Service technician The service technician is a skilled person authorized by the operating company
who carries out maintenance and cleaning activities and eliminates
malfunctions. The service technician must have completed professional training
in the technical sector, e. g. as a mechanic, instrumentation technician,
electrician, fitter.
Technical expert Anyone who has concerned himself in detail with the subject matter, who has
been trained accordingly, and who - based on his experience - is capable of
carrying out certain activities is regarded as a technical expert. This group of
persons includes individual, specially trained MAN Diesel & Turbo employees.
Authorized inspector An authorized inspector is a technical expert who has taken a relevant
examination with a supervisory public institution. As a rule this person is a third-
party employee, in Germany e. g. an employee of the TÜV Technical
Inspectorate.
Supervisor A supervisor is a specially trained MAN PrimeServ technician possessing an in-

depth knowledge of the machine unit.
2-8 Safety
2.2.6 Spheres of responsibility
MAN Diesel & Turbo require qualified personnel on site to ensure

unobjectionable service and safe operation of the machine unit.
MAN Diesel & Turbo therefore specify certain requirements in respect of the
users of the machine unit. Users must have the required qualification and
experience for carrying out work in the assigned sphere of responsibility safely
and independently.
Engineering The engineering company is responsible for the correct interaction between
company machine unit and overall process plant.
Operating company The operating company is responsible for the following aspects of use of the
machine unit:
■ Intended use of the machine unit
■ Planning, implementation, and checking of all safety measures which are
required as defined for the intended use
■ Compliance with the requirements specified by MAN Diesel & Turbo in
respect of the users
■ Training, authorization, and checking of users of the machine unit
especially as far as the following aspects are concerned:
❚ operation of the machine unit in normal operation
❚ training of behaviour in the event of malfunctions
■ Performance of a risk assessment, taking into consideration:

❚ assessment of concrete risks to users on site
❚ generally valid statutory regulations
❚ national laws and regulations on accident prevention, occupational
safety, and environmental protection
❚ regulations on the handling of hazardous substances
❚ regulations on protective equipment for the protection of personnel
■ Preparation of service instructions (internal instructions by the operating

company to the operators), taking into consideration:
❚ the present Operating Instructions
❚ the results of the hazard analysis
■ Compliance with all rules and codes in force on site:

❚ laws
❚ regulations
❚ directives
■ Provision of equipment for the protection of personnel and checking its

use
■ Provision of workshop equipment for carrying out service and
maintenance work
Safety concept 2-9

NOTICE
Operation of the machine unit is exclusively at the operating
company's risk. In particular, MAN Diesel & Turbo disclaim any
responsibility in the event that information, specifications or
requirements contained in these Operating Instructions are not
complied with.
Operator The operator employed by the operating company is responsible for normal
operation of the machine unit. The work to be carried out by the operator is
described in Chapter 4 Normal operation. Any activities beyond those
described there must not be performed by the operator. Malfunctions which
occur during normal operation have to be reported by the operator to the
operating company's service technicians without delay. The operator is
responsible for using his personal protective equipment.
Service technician The service technician employed by the operating company is responsible for
maintenance, cleaning, and troubleshooting of the machine unit. The service
technician is responsible for using his personal protective equipment.
Technical expert Based on his expert knowledge the technical expert carries out activities which
require special training.
Authorized inspector The authorized inspector inspects the work carried out by the technical expert
and issues respective certificates. He may, however, also carry out the technical
expert's tasks and inspect them himself.
Supervisor Installation and commissioning of the machine unit are managed by an

MAN PrimeServ supervisor. The supervisor gives on-site directions for safe and
cost-effective installation and commissioning.
2.2.7 Hazard zones
There are several hazard zones at the operating company's overall process
plant.
The operating company must define and mark these hazard zones.
Safe location is a secured hazard zone. From here, hazardous media (e. g.
condensate or seal gas) may be discharged into the atmosphere. This zone
must be in compliance with statutory provisions to prevent that the discharged
media pose a risk to people, physical assets or the environment.
The hazard zones at the machine unit are marked with warning signs.
Refer to document Overview of Hazard Zones (Safety Arrangement) to find the

arrangement of safety signs on the machine unit (see Chapter 9 Plans and
Schematics).
2 - 10 Safety
Safety signs The following types of safety signs may be fitted to the machine unit or be used
in the Operating Instructions:
■ Warning signs (yellow, triangular)
■ Prohibition signs (red-bordered, round)
■ Mandatory signs (blue, round)
■ Rescue signs (green, square)
The safety signs have the following meanings:
Table 2-1 Safety signs

Symbol Meaning Symbol Meaning
Warning of a general point of Warning of flammable

danger substances
Warning of explosive Warning of potentially

substances explosive atmosphere
Warning of toxic substances Warning of high voltage
Warning of hot surface Warning of danger from

suspended load
Warning of risk of tripping Warning of risk of falls
Warning of automatic starting Warning of health-hazardous

substances
Warning of hand injury Warning of risk of slipping
Warning of pressurized Warning of discharge of hot or

housings and casings harmful media
Warning of risk of Warning of gas cylinders

unconsciousness /
suffocation from inhalation of
nitrogen
Warning of hazard to the Warning of risk of

environment entanglement
Prohibition (to be used in Smoking prohibited

combination with another
safety sign only)
Fire, open flames, and Authorized persons only

smoking prohibited
Safety concept 2 - 11
Symbol Meaning Symbol Meaning
Do not use as lifting point Read the Operating

Instructions
Use eye protection Wear a safety helmet
Wear hearing protection Use safety helmet, eye
protection and hearing
protection
Use protective gloves Use protective shoes
Emergency-stop button
2 - 12 Safety
2.2.8 General safety information
During operation of the machine unit high pressures and temperatures can
develop in various components. Rotors and couplings reach high speeds. The
operating media in the machine unit may be flammable, explosive, toxic and/or
hazardous to the environment.
While performing any activities near the machine unit in particular observe the
following rules of conduct in order to avoid risks to persons or to the
environment and an impairment of the machine unit when operating it for the
intended use:
■ Personal rules of conduct
❚ Observe these Operating Instructions.
❚ Comply with the operating company's safety regulations for the
machine unit and for the media used.
❚ Observe the generally valid safety standards.
❚ Wear the required personal protective equipment (at least eye
protection, hearing protection, safety helmet and protective shoes) as
well as tight-fitting clothing.
❚ Do not wear jewellery.
❚ Tie long hair back or use an appropriate hairnet to keep the hair in
place.
❚ Avoid direct contact of operating media with the skin.
❚ Always carry out all activities on the machine unit with great care.
Never open or close shut-off valves in lines / pipes if you are unable to
assess the consequences.
❚ Climb onto the machine unit only at the facilities intended for this.
Never use pipes/lines, valves and fittings etc. as climbing aids.
❚ Whenever possible keep an adequate distance from the machine unit,
especially during start-up and shut-down.
■ Operational rules of conduct
❚ Use the machine unit only for the intended purpose according to
Section 2.2.1 Intended use.
❚ Start up the machine unit only in a technically unobjectionable and
operative condition as well as with intact and enabled protection and
safety equipment.
❚ Prevent unintended interventions into protection and safety equipment
by design measures (e. g. by fitting locking or shut-off devices) and by
instructing the users periodically.
❚ Always keep the safety signs on the machine unit intact and clearly
legible.
❚ Always have these Operating Instructions as well as the operating
company's service instructions at hand.
❚ Keep unauthorized persons away from the machine unit.
❚ Shut down the machine train manually if the preset limit for a critical
operating value was reached and tripping was not triggered or if
tripping is not envisaged in this instance.
If operation of the machine train is continued in spite of critical
operating values being reached, this may lead to machine damage
and also personal injury. Continued operation under these
circumstances will be solely the operating company's responsibility.
MAN Diesel & Turbo will not accept any liability in such a case.
Observe the following rules of conduct in the event of damage to minimize its
consequences:
■ Rules of conduct in the event of personal injury (first aid)
For your own sake, make every effort to obtain comprehensive first-aid
training. The rules of conduct below only provide an overview of possible
measures.
❚ Rescue injured people from the hazard zone while keeping your own
protection in mind.
❚ Take life-saving measures such as cardiopulmonary resuscitation at
once if required.
❚ Stop profuse bleeding with a compression bandage.
❚ Place shock victims in a suitable shock position.
❚ Place injured or unconscious persons in recovery position.
❚ Call a doctor in any case.
■ Rules of conduct in case of fire

❚ Alarm rescue and ambulance services and persons in danger.
❚ Leave the hazard zone immediately.
❚ Shut down the machine train and the auxiliary systems.
❚ In case the process gas is flammable: Depressurize the machines and
isolate the machines from the process gas system.
❚ Protect yourself with adequate protective clothing.
❚ Extinguish the fire by means of fire-extinguishing agents permitted by
the operating company for the machine unit.
❚ Within the hazard zone keep possible risks of explosion or suffocation
in mind.
❚ Observe the instructions by the operating company of the machine
unit.
❚ Observe the general rules and provisions for fire fighting.
■ Rules of conduct in the event of steam leakage

❚ Cordon off a large sector around the hazard zone.
❚ Shut down the steam turbine.
❚ Close the live-steam main gate valve.
❚ Eliminate the steam leakage.
2 - 14 Safety
■ Rules of conduct in case of gas leakage
❚ Alarm rescue and ambulance services and persons in danger.
❚ Keep ignition sources away from the machine unit.
❚ Shut down the machine train.
❚ Cordon off a large sector around the hazard zone.

❚ Enter the hazard zone with specified protective clothing only.
❚ Eliminate the gas leakage.
For safety information on media that are hazardous to health and may be
present in the overall process plant, primarily refer to the hazardous-substance
information issued by the operating company of the machine unit. In the Section
below you will find further safety information and rules of conduct to be
observed when handling the media present in the machine unit.
2.2.8.1 Natural gas (CnHm)
Natural gas is handled in the process gas carrying components and the
connected process gas piping. This is a hazardous substance with the following
properties that pose risks for human health and the environment:
■ Highly flammable
■ Colourless and odourless
■ Lighter than air
■ Can form explosive mixtures with air
■ Risk of suffocation when inhaled in high concentrations
■ Not toxic
Protective measures Observe the following safety measures:

and rules of conduct
■ Keep away ignition sources.
■ Fire, open flames, and smoking are prohibited.
■ Do not carry out work that can produce ignition sparks on the machine
unit when it is filled with natural gas, such as welding, grinding, separating
or cutting.
■ Ensure very good ventilation at the machine location, especially in the roof
area.
■ Take measures against electrostatic charging if there is a risk of formation
of explosive gas mixtures.
■ In the working area of the machine unit use only electrical equipment
permitted for use in explosion-protection zone 2.
■ In the working area of the machine unit wear conductive safety shoes.
■ In the working area of the machine unit wear protective gloves.
■ In the working area of the machine unit wear safety goggles for protection
against mechanical injury resulting from escaping gas.
Rules of conduct if ■ Cordon off a large sector around the hazard zone.
gas escapes
■ Do not enter the machine house without a self-contained breathing
apparatus (isolating equipment).
■ Wear flame-retarding, antistatic protective clothing and protective gloves
made of leather.
■ Stop the escape of gas.
■ Adequately vent the machine house.
■ Verify freedom from gas by means of suitable testing apparatus.
Rules of conduct in ■ In closed rooms: Do not extinguish the flames before the gas outflow has
case of fire been stopped; otherwise there is the risk of a potentially explosive cloud
being formed.
■ Do not extinguish flames using water or foam, use dry chemicals or CO2
instead.
First-aid measures ■ Remove people from the hazard zone.

■ After inhalation: Supply fresh air.
■ In case of cessation of breathing: Use an oxygen-flow breathing system.
2 - 16 Safety
2.3 Residual hazards and risks
Residual risks may arise in various life phases of the machine unit (e. g. during
service and maintenance) or as a result of leakage caused by defects. They may
put the lives and health of users or third parties at risk or may adversely affect
the machine unit and other physical assets.
Residual hazards and risks are listed in the following tables. Some of these
residual hazards are potentially always present while other residual hazards only
become evident on the occurrence of specific events.
Observe the following rules to avoid risks arising from residual hazards:
■ Keep these residual hazards in mind when staying near the machine unit.
■ Observe the rules of conduct according to Section 2.2.8 General safety
information.
■ Observe the warnings in these Operating Instructions.
■ Observe the safety signs on the machine unit. An explanation of the safety
signs will be found in Section 2.2.7 Hazard zones.
Residual hazards and risks 2 - 17

2.3.1 Residual risks to persons
The following residual risks to persons involving potential injury exist on the
machine unit:
Table 2-2 Residual risks to persons
Type of risk Possible cause
1. Mechanical
Parts falling down, tilting or slipping away during
❚ Parts falling down
transport or storage of component parts or components
❚ Movable parts ❚ Entanglement of clothing or parts of the body in open

or exposed movable parts (e. g. rotor, partially open
coupling guard)
❚ Unexpected movement of parts while work is being
done on the machine unit (e. g. in the event of
unintended actuation, automatic movement of a
swing check valve, or sudden opening of doors or
flaps)
❚ Conditionally movable pipes ❚ Unexpected movement of pipes while work is being

done on the machine unit (e. g. as a result of sudden
pressure changes in inadequately fixed pipes, work on
unsecured piping that is under force)
❚ Parts flung around ❚ Parts breaking off as a result of overload

❚ Loose or loosened parts in an air draught
2. Electrical Contact with live parts (e. g. in the case of lacking

isolation from external voltage, missing cover, defective
insulation, unauthorized work)
3. Thermal ❚ Contact with hot surfaces that have heated up during

operation
❚ Contact with cold surfaces which have cooled off
during operation (e. g. in the event of icing by cold or
escaping gas)
4. Acoustic Exposure to noise in the vicinity of the running machine

unit or in the case of escaping media (e. g. opening
process gas valve)
5. Vibration No risk to be expected
6. High-frequency radiation No risk to be expected
7. Materials and substances

Mechanical or acoustic exposure (e. g. when draining or
❚ Media escaping under high
venting non-secured piping, if seals are defective, when
pressure
opening pipes/lines or equipment)
❚ Escaping steam Thermal or mechanical exposure (e. g. if steam escapes

at the shaft ends of the steam turbine or if a rupture disk
bursts)
❚ Exploding or burning media Explosion or burning of media (e. g. caused by

extraneous gases in the intake duct, by flammable
deposits or by wash liquid, by the ignition of escaping oil
on hot surfaces)
2 - 18 Safety
❚ Inhaled media Inhalation of harmful media that leak or form (e. g. in the
event of the fire fighting system being triggered or
insulation catching fire, when opening vessels that have
been preserved with nitrogen or in the event of leakage
from such vessels)
❚ Exploding process gas Explosion of escaping process gas by self ignition or

spark ignition (e. g. if seals are defective or when
opening pipes/lines or equipment)
Explosion of chemically reacting process gas (e. g.
oxygen with oil/grease, oxygen with inappropriate
materials)
❚ Inhaled process gas Inhalation of escaping toxic or suffocating process gas

(e. g. if seals are defective, when opening pipes/lines or
equipment)
❚ Inhaled oil mist Inhalation of escaping oil mist (e. g. if seals are defective,
if the oil mist separator is defective)
❚ Escaping sour condensate Contact with escaping condensate (e. g. if seals are
defective, when opening pipes/lines or equipment, when
draining process gas coolers)
❚ Inhaled filter dust Inhalation of filter dust (e. g. during exchange of filters, in
case of inadequate maintenance)
8. Poor ergonomics Bad posture when handling heavy parts incorrectly
9. Malfunctions or failure of Unintended starting of machinery as a result of

systems omissions or incorrect operation
10. Lack of care

Unintended contact with solid bodies or with media
❚ Misconduct
(e. g. when tripping over obstacles, when falling from
ladders, in confined spaces, when releasing non-
secured pipes and lines under force, when slipping on
leaking liquids, if media are not handled with adequate
care)
❚ Misuse Disregarding the present Operating Instructions (e. g.

closing shut-off valves in impulse lines which must be
open during normal operation)
Residual hazards and risks 2 - 19

2.3.2 Residual risks to physical assets and property
The following residual risks to physical assets and property exist on the machine
unit, involving potential damage to physical assets or property:
Table 2-3 Residual risks to physical assets and property
1. Mechanical
Parts falling down, tilting or slipping away during
❚ Parts falling down
transport or storage
❚ Parts flung around ❚ Parts breaking off as a result of overload

❚ Loose or loosened parts in an air draught
2. Electric Fire caused by short circuit (e. g. if the insulation is

defective)
3. Thermal No risk to be expected
4. Acoustic No risk to be expected
5. Vibration No risk to be expected
6. Radiation No risk to be expected
7. Materials and substances

Mechanical exposure (e. g. when draining or venting
❚ Media escaping under high
non-secured piping, if seals are defective, when opening
pressure
pipes/lines or equipment)
❚ Other exploding or burning Explosion or burning of media (e. g. caused by

media extraneous gases in the intake duct, by flammable
deposits, by wash liquid)
❚ Exploding process gas Explosion of escaping process gas caused by

spontaneous or external ignition (e. g. if seals are
defective or when opening pipes or equipment)
Explosion of chemically reacting process gas (e. g.
oxygen with oil/grease, oxygen with inappropriate
materials)
8. Inadequate ergonomic No risk to be expected

conditions
9. Malfunctions or system Unintended starting of machinery as a result of

failures omissions or incorrect operation
10. Lack of care

Hard contact with solid parts (e. g. when tripping over
❚ Misconduct
obstacles, when loosening non-secured pipes which are
under force)
❚ Misuse Non-compliance with these Operating Instructions (e. g.

closing shut-off valves in impulse lines which have to be
open during normal operation)
2 - 20 Safety
3 Design and function

This Chapter addresses all users of machine unit Ruwais REC 2013. It gives an
impression of the arrangement of the machine unit components and describes
the function of the machine unit and its components.
3.1 Overview
3.1 Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1
3.2 Machine unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2
3.3 Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3
3.3.1 Steam turbine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3
3.3.2 LP compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4
3.3.3 HP compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-6
3.3.4 Couplings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-8
3.3.5 Process gas system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-9
3.3.6 Oil system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-9
3.3.7 Seal gas system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-12
3.3.8 Drainage system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-13
3.3.9 Control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-13
3.3.10 Monitoring system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-14
3.4 Indicating instruments and operator controls. . . . . . . . . . . . . . . . . . . .3-16
3-1
3.2 Machine unit
This Section describes the design and the function of the machine unit.
Figure 3-1 Machine unit Ruwais REC 2013 shows the arrangement of the
components set up directly at the machine unit.
1 2
3
4
5
6
7
8
9
10
Figure 3-1 Machine unit Ruwais REC 2013

1 Steam turbine
2 Coupling 1 with coupling guard
3 Seal gas rack LP1 Compressor
4 LP compressor
5 Coupling 2 with coupling guard
6 Seal gas rack HP compressor
7 HP compressor
8 Table foundation
9 Oil rundown tank
10 Oil system
Various views of the machine unit are also shown in the General Arrangement
(see Chapter 9 Plans and Schematics).
The machine unit is used for pressure generation in a propane dehydrogenation

plant.
3-2 Design and function

3.3 Components
The Sections below briefly describe the design and function of the components
and systems of the machine unit. For an overview of the Operating Instructions
for Components please refer to Chapter 10 Operating Instructions for
Components.
3.3.1 Steam turbine
Steam turbine 2640-TK-001 is an MAN Diesel & Turbo condensing steam

turbine type DK080/170R.
1 2 3 4 5 6 7
Figure 3-2 Steam turbine

1 Bladder accumulator control oil
2 Bearing housing (journal bearing)
3 Rotor turning gear
4 Trip valve
5 Steam turbine
6 Bearing housing (combined journal/thrust bearing)
7 Oil rundown tank
Components 3-3
The steam turbine depressurizes high-energy steam, thus converting thermal
energy into mechanical energy. The mechanical energy generated by the steam
turbine is utilized as drive power for the machine train.
For a detailed description please refer to the Operating Instructions for Steam
Turbine (see Chapter 10 Operating Instructions for Components).
3.3.2 LP compressor
LP compressor 2640-K-001 1st Stage is a horizontally split 13-stage axial

compressor type A 63-13.
1 2 3 4 5 6 7
Figure 3-3 LP compressor

1 Bearing housing suction-end (thrust and journal bearing)
2 Compressor casing
3 Balancing piston pipes
4 Suction nozzle
5 Jacking oil pump
6 Discharge nozzle
7 Bearing housing discharge-end (journal bearing)
The compressor compresses the process gas according to the laws of fluid
mechanics. The mechanical energy transmitted by the driver is transmitted
through the rotor blades to the process gas flowing in through the suction
nozzle. After an incremental increase in pressure in the individual blade rows,
the process gas enters the downstream process through the discharge nozzle.

When the compressor is being depressurized, a depressurization rate of
20 bar/min must not be exceeded. Higher rates will cause damage to the inner
casing seals. Contact MAN Diesel & Turbo if higher depressurization rates may
occur during compressor operation.
The compressor consists of the assemblies below:

■ Casing
The casing is horizontally split and serves the following purposes:
❚ Supporting the internals and attachments
❚ Routing the process gas
❚ Absorbing the resulting forces
■ Shaft
The shaft carries the rotor blades and transmits the mechanical energy
from the driver through the rotor blades to the process gas.
■ Shaft seal
The shaft is equipped with a dry gas seal at either end to prevent process
gas from escaping to the immediate surroundings of the compressor.
■ Shaft bearing
The rotating shaft floats on an oil film in the bearings. These transmit the
forces from the shaft via the bearing housings to the compressor support.
The compressor is equipped with two bearing housings with oil-
lubricated bearings:
❚ A journal bearing is located at the driven end (DE).
❚ At the non driven end (NDE) there are the thrust bearing and the journal
bearing.
■ Stator vanes
One stator vane row each, fixed in the casing, is arranged between each
rotor blade row.
Each stator vane row redirects the process gas and thus contributes to
converting the kinetic energy of the process gas into pressure.
■ Balancing piston pipes
The balancing piston pipes return the process gas, which has escaped
via the discharge-end labyrinth seal, to the suction end of the
compressor. This pressure compensation and the corresponding shape
of the pistons keep the resulting axial force of the rotor within a specified
range. They also subject the dry gas seals to equal pressure.
■ Detecting elements
The compressor has detecting elements to take up and transmit various
values to the monitoring system.
Components 3-5
3.3.3 HP compressor
HP compressor 2640-K-001 2nd Stage is a vertically split 5-stage barrel

compressor of RB 90-5 type.
1 2 3 4 5 6
Figure 3-4 HP compressor

1 Bearing housing suction-end (journal bearing)
2 Suction nozzle
3 Balancing piston pipes
4 Casing
5 Discharge nozzle
6 Bearing housing discharge-end (journal bearing)
The compressor compresses the process gas according to the laws of fluid
mechanics. The mechanical energy transmitted by the driver is transmitted in
the compressor stages to the process gas flowing in through the suction
nozzle. After an incremental increase in pressure in the individual compressor
stages, the process gas enters the downstream process through the discharge
nozzle.
When the compressor is being depressurized, a depressurization rate of

20 bar/min must not be exceeded. Higher rates will cause damage to the inner
casing seals. Contact MAN Diesel & Turbo if higher depressurization rates may
occur during compressor operation.

The compressor consists of the assemblies below:
■ Casing
The casing is of the barrel type and has its end closed with a lid. The
casing rests on brackets mounted on the base frame and serves the
functions below:
❚ Supporting the internals and attachments
❚ Routing the process gas

❚ Absorbing the resulting forces
■ Shaft
The shaft carries the impellers and transmits the mechanical energy from
the driver through the impellers to the process gas.
■ Shaft seal
The shaft is equipped with a dry gas seal at either end to prevent process
gas from escaping to the immediate surroundings of the compressor.
■ Shaft bearing
The rotating shaft floats on an oil film in the bearings. These transmit the
forces from the shaft via the bearing housings to the compressor support.
The compressor is equipped with two bearing housings with oil-
lubricated journal bearings.
■ Diffusers
Downstream of each impeller there is a diffuser which is fixed in the
casing.
Each of the diffusers contributes to converting the kinetic energy of the
process gas from the impeller into pressure.
■ Balancing piston pipes
The balancing piston pipes return the process gas, which has escaped
via the discharge-end labyrinth seal, to the suction end of the
compressor.
■ Detecting elements
The compressor has detecting elements to take up and transmit various
values to the monitoring system.
Components 3-7
3.3.4 Couplings
Coupling 1 is a flexible steel multiple-disk coupling. Equalizing shaft

misalignment, it transmits the torque via flexible steel multiple-disk packages.
Coupling 2 is a rigid coupling. It transmits the torque entirely rigidly and at the
same time absorbs the shaft axial thrust.
The couplings interconnect the components according to the table below,

transmitting speed and torque.
Table 3-1 Arrangement of couplings

Coupling driven end non-driven end
Coupling 1 Steam turbine LP compressor
Coupling 2 LP compressor HP compressor
For a detailed description please refer to the Operating Instructions for Coupling
(see Chapter 10 Operating Instructions for Components).

3.3.5 Process gas system
The process gas system consists of pipes and assemblies in which the process
gas is handled. The defined connection points form the interface between the
scope of supply of MAN Diesel & Turbo and the operating company.
The process gas system will be established completely by others.
None of the assemblies are included in the scope of supply of

MAN Diesel & Turbo.
The following assemblies are included in the third-party scope of supply:

■ Process gas coolers
The process gas coolers cool the process gas after compression.
■ Recycle valve 1st stage
As soon as a risk of surging arises as a result of an insufficient flow rate,
the controller opens recycle valve UV 092 as wide as necessary. This way,
process gas is recycled through the recycle line from the LP compressor
discharge end to the suction end, increasing the flow rate through the
compressor.
■ Recycle valve 2nd stage
As soon as a risk of surging arises as a result of an insufficient flow rate,
the controller opens recycle valve UV 096 as wide as necessary. This way,
process gas is recycled through the recycle line from the compressor
discharge end to the suction end, increasing the flow rate through the
compressor.
■ Swing check valves
The swing check valves prevent process gas from flowing back from the
process into the discharge pipe of the relevant compressor.
■ Process gas piping
The process gas pipes interconnect the component parts of the process
gas system.
3.3.6 Oil system
The oil system supplies both the necessary lube oil for the bearings and other
lubrication points of the machine unit and the control oil for controllers and
actuators. It is designed for circulation which is maintained by oil pumps. The
lube oil cools and lubricates the components of the machine unit which are
supplied with lube oil, reduces corrosion effects and minimizes wear of the
machine bearings.
Components 3-9
The oil system comprises the following assemblies:
■ Oil reservoir
Oil reservoir 2640-K-001-F1 holds the oil required by the machine unit
components. During its dwell time in the reservoir the oil calms down,
allowing the trapped air to escape. This air is discharged by the oil mist
separator.
■ Oil heater
Oil heater 2640-K-001-EE1A/B heats the oil to the required start-up
temperature before the machine train is started up. It also maintains the
oil temperature in the set-point range while the machine train is at
standstill.
■ Oil mist separator
Oil mist separator 2640-K-001-K1 is mounted on the oil reservoir and
consists of a blower with electric drive motor 2640-K-001-MK1 and a
filter.
The oil mist separator serves the following purposes:
❚ Generation of a negative pressure in the oil reservoir and in the oil
return lines to prevent any escape of oil mist at bearing points and
coupling guards
❚ Expulsion of trapped gas from the returning oil to prevent spreading of
an explosive atmosphere
■ Oil pumps
The oil system of the machine unit has two equivalent oil pumps. Main oil
pump 2640-K-001-G1A driven by a steam turbine and a standby oil
pump 2640-K-001-G1B with electric drive motor. The main oil pump
generates the oil pressure required by the machine unit components
during normal operation. The inactive (standby) oil pump delivers the oil
pressure that is required if the main oil pump should fail.
■ Cooling oil pump
Cooling oil pump 2640-K-001-G2 cools the live-steam end steam turbine
bearings while the machine train is shut down if the main oil pump and
the standby oil pump should fail.
■ Jacking oil pumps
Jacking oil pumps 2640-K-001-G3 and 2640-K-001-G4 provide high oil
pressure to jack up the shaft in the machine bearings before start-up and
during shut-down of the machine train in order to overcome the break-
away torque during start-up more easily and to reduce wear.
■ Rundown tank
Rundown tank 2640-K-001-F2 is mounted some metres above the
machine unit and allows safe shut-down of the machine train in case the
oil pumps should fail.
3 - 10 Design and function

■ Bladder accumulator
Bladder accumulators 2640-K001-V4A/B buffer the oil pressure when
the oil pumps are switched over.
■ Oil cooler
The water-cooled oil cooler 2640-K-001-E1A/B cools the oil.
The double design allows changeover of cooling during operation.

■ Oil temperature control valve
Oil temperature control valve TCV 935 regulates the oil temperature to the
set-point level by mixing cooled and uncooled oil.
■ Cooling oil filter
Cooling oil filter 2640-K-001-V5 filters the oil required for cooling the live-
steam end bearing of the steam turbine to remove dirt particles. The
cross-filter differential pressure instrument monitors the degree of filter
fouling. If the set limit value is reached, the monitoring system triggers an
alarm.
■ Lube oil filter
Lube oil filter 2640-K-001-V3A/B filters the circulating oil to remove dirt
particles. The cross-filter differential pressure instrument monitors the
degree of filter fouling. If the set limit value is reached, the monitoring
system triggers an alarm.
The double filter design makes it possible to change over filtering during
operation.
■ Control oil pressure control valve
Control oil pressure control valve PCV 943A keeps the oil pressure
downstream of the oil filter constant at the set-point level. This is achieved
by the valve returning some of the oil directly into the oil reservoir
depending on the current oil pressure.
■ Lube oil pressure control valve
Lube oil pressure control valve PCV 943B reduces the oil pressure to the
level required for lube oil supply.
■ Oil pipes
The oil pipes interconnect the component parts of the oil system.
For a detailed description please refer to the Operating Instructions for Oil
System (see Chapter 10 Operating Instructions for Components).
Components 3 - 11
3.3.7 Seal gas system
The seal gas system supplies the required gases to the shaft seals of the
compressors to ensure safe sealing of the compressors during standstill and
operation. The seal gas system also directs leakage gas from the shaft seals to
the atmosphere.
The gases fed in serve the following functions:
■ The filtered nitrogen serves two purposes:
❚ As seal gas it serves to operate the dry gas seal.
❚ As separation gas it isolates the dry gas seal from the atmospheric
end.
■ The cooling gas cools the discharge-end dry gas seals on the process-
gas end of the compressors. The cooling gas is taken from the second
stage of the HP compressor.
■ The external buffer gas serves the following purposes:
❚ In case of very humid process gas operation it protects the process-
gas end dry gas seal. A gas type compatible with the process gas is
used as buffer gas.
❚ In case of nitrogen operation the dry gas seal is cooled at the process
gas end. Nitrogen or instrument air are used as buffer gas.
The operator shall allow the supply of external buffer gas manually by
opening the corresponding valves.
The seal gas system consists of the assemblies below:

■ Seal gas / separation gas filter
Seal gas / separation gas filter 2640-K-001-V1A/B cleans the seal gas for
both compressors so as to avoid contamination and, as a result,
malfunctions of the dry gas seal. The cross-filter differential pressure
instrument monitors the degree of filter fouling. If the limit value is
exceeded, the monitoring system triggers an alarm.
The double filter design allows the cleaning of the fouled filter during
operation.
■ Seal gas control valve
Seal gas control valve PCV 941A regulates seal gas pressure and flow
rate to the dry gas seals of the LP compressor to the specified value.
Some of the seal gas is fed as separation gas to the separation gas
control valve of the LP compressor.
■ Separation gas control valves
Separation gas control valves PCV 941B and PCV 942 regulate the
separation gas pressure and flow to the outer sealing rings to the
specified value.
For a detailed description please refer to the Operating Instructions for Seal Gas

3.3.8 Drainage system
Both compressors are provided with a separate drainage system.
The drainage system of the compressor drains condensate from the

compressor. It consists of the assemblies below:
■ Shut-off valves
The shut-off valves in the drain lines prevent process gas from escaping
from the compressor during normal operation and allow manual draining
of condensate.
■ Drain lines
The drain lines interconnect the component parts of the drainage system.
3.3.9 Control system
The control system for the machine unit is a control system by Messrs CCC.
The components of the control system have the following functions:

■ Visualization unit
The visualization unit displays the operating state of the machine unit. The
indications include e. g. whether components are active or not, and
operating values.
■ Anti-surge control LP compressor
Anti-surge control FIC 936 prevents surging of the compressor and as
such impermissible loads. When the duty point approaches the surge
line, the anti-surge control increases the flow rate through the
compressor by opening process gas valves (see Section 3.3.5 Process
gas system).
Different response lines are filed for the provided process gases.
■ Anti-surge control HP compressor
Anti-surge control FIC 090 prevents compressor surging, thus preventing
impermissible loads. When the duty point approaches the surge line, the
anti-surge control increases the flow rate through the compressor by
opening process gas valves (see Section 3.3.5 Process gas system).
Different response lines are filed for the provided process gases.
Components 3 - 13
■ Reverse flow protection
Reverse flow protection FIC 935, apart from the anti-surge control
system, gives additional safety to protect the compressor.
The reverse flow protection intervenes in several stages if an alarm event
occurs:
❚ First alarm event: Triggering of an alarm
❚ Second alarm event within a short period of time: Sending a signal to
open the recycle valves
❚ Third alarm event within a short period of time: Sending a signal to trip
the machine train
■ Surge counter
The surge counter records any occurring surges.
■ Start-up interlock
The start-up interlock prevents the machine train from being started up
while operating values are impermissible.
3.3.10 Monitoring system
The monitoring system consists of the assemblies below:

■ Measured value transmitters (e. g. for temperatures, vibrations, positions)
■ Oscillators / proximity sensors
■ Electronic monitoring unit
The electronic monitoring unit of the monitoring system is located in the control
room of the overall process plant.
The monitoring system of the machine unit ensures that malfunctions of the
machine unit are detected at an early stage. During operation, the monitoring
system constantly monitors the critical operating values marked -x- in the table
below. For preset limit values please refer to the relevant document (see
Chapter 9 Plans and Schematics). Depending on its design the monitoring
system records the operating values periodically.
Table 3-2 List of monitored operating values

Measuring point LP compressor HP compressor
Bearing temperature x x
Shaft vibrations x x
Axial shaft position x

MAN Diesel & Turbo have defined a number of critical operating values which,
if they differ abnormally from the set-point value, may lead to machine damage
or personal injury. For each of the critical operating values there are one or more
limit values depending on the hazard potential involved:
■ First limit value
When the first limit value is reached, this event is an unusual but non-
hazardous deviation from the set-point. The monitoring system issues an

optical and/or acoustic signal as pre-alarm or alarm. It is the operator's
task to determine and eliminate the cause.
■ Second limit value
Reaching the second limit value is an unusual and possibly hazardous
deviation from the specified value. In such a case MAN Diesel & Turbo
require that the monitoring system trigger a trip of the machine train.
Depending on the hazard potential involved, one of the following sequences

may occur according to Table 3-3 Possible sequences for limit values for each
of the operating values.
Table 3-3 Possible sequences for limit values

Limit value reached Sequence 1 Sequence 2
First limit value Alarm Pre-alarm
Second limit value, if set Trip Alarm
The document listing alarm values (see Chapter 9 Plans and Schematics)
shows the applicable sequence for every critical operating value.
For the exact locations of the measured value transmitters please refer to the
P&I Diagram (see Chapter 9 Plans and Schematics).
Components 3 - 15
3.4 Indicating instruments and operator controls
This Section briefly describes the locations and functions of indicators and
operator controls of the machine unit.
Emergency-stop Emergency-stop buttons are arranged in the following locations:
button
■ on the local control panel
■ on the machine unit
Actuation of an emergency-stop button triggers an emergency stop of the

machine train.
Indicators Local indicators e. g. for temperatures, pressures, volume flow rates, and
speeds are provided in the following locations:
■ on the local control panel
■ on the machine unit
■ on the local rack
For an overview of the indicators on the machine unit please refer to the P&I
Diagrams (see Chapter 9 Plans and Schematics).
Valves and fittings Valves and fittings e. g. for controlling flow media or isolating pipework are
provided in the following locations:
■ on the local rack
■ in the process gas system
■ in the piping of the auxiliary systems
For an overview of the valves and fittings on the machine unit please refer to the
P&I Diagrams (see Chapter 9 Plans and Schematics).

4 Normal operation
information about the requirements and main activities for safe and economical
operation of the machine unit in normal operation.
For normal operation the information concerning safety (see Section 2.2.8
General safety information and Section 2.3 Residual hazards and risks) must be
observed without fail.
4.1 Overview
4.1 Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1
4.2 Prerequisites for start-up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2
4.3 Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-15
4.4 Checks during operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-18
4.5 Shut-down in an emergency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-22
4.6 Shut-down from normal operation . . . . . . . . . . . . . . . . . . . . . . . . . . .4-23
4.7 Measures for standstill periods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-24
4-1
4.2 Prerequisites for start-up
In this Section you will find all the procedures you have to perform prior to start-
up of the machine train.
■ Procedure 4-1 Preparing the machine unit
■ Procedure 4-2 Supplying the machine unit with operating media
■ Procedure 4-3 Enabling the control panel
■ Procedure 4-4 Draining the machine unit
■ Procedure 4-5 Starting up the seal gas system for the atmospheric end
■ Procedure 4-6 Starting up the seal gas system for the process gas end
■ Procedure 4-7 Starting up the oil system
■ Procedure 4-8 Purging the machine unit
■ Procedure 4-9 Preparing steam turbine and allocated systems
■ Procedure 4-10 Establishing the operating conditions
4-2 Normal operation

Procedure 4-1 Preparing the machine unit
Responsibility Operator
Prerequisites All items in the following list must be satisfied:
■ Installation according to Section 5.3 Installation has been completed
■ Commissioning according to Section 5.4 Commissioning has been
completed
■ The machine unit is not pressurized
■ The overall process plant is ready for operation
■ All test certificates are available
■ All maintenance records have been completed
1 Keep an operation log including time, date, and persons responsible,

which covers:
❚ Operating values
❙ Start-ups
❙ Shut-downs
❙ Operating hours
❙ Coast-down times
❙ Measures initiated for standstill periods
❙ Manual interventions into the control system of the machine unit
❚ Malfunctions
❙ Trips and their causes
❙ Emergency stops by means of an emergency-stop button and their
causes
❙ Leakage
❙ Elimination of malfunctions
❚ Maintenance and inspection
❙ Maintenance work
❙ Inspections
❙ Repairs
❙ Conversions
❙ Spare parts used
2* To start up the machine unit after more than 6 months of standstill:

Have the machine unit started up by MAN PrimeServ.
3 Check the machine unit for:

❚ Leakage
❚ Damage
❚ Corrosion damage
❚ Damage to protective coating or coats of paint
4* In case of leakage or damage:

Have the leakage or damage eliminated by the service technician in order
to avoid personal injury and to ensure safe operation.
Prerequisites for start-up 4-3

5 Check whether the following parts of the machine unit are securely
mounted, correctly aligned and lubricated where necessary to avoid
impermissibly high forces, torques and moments or leakage:
❚ Piping supports
❚ Springs
❚ Guides
❚ Plugs and blind flanges
❚ etc.
6* In case parts are loose, not aligned or not lubricated:

Have the defects eliminated by the service technician.
7 Make the components of the machine unit ready for operation according
to the procedures on the following pages of this Section.
8* For components which are not included in the MAN Diesel & Turbo scope
of supply:
Make all further components of the machine unit ready for operation
according to the manufacturers' operating instructions.
⇒ Procedure 4-1 Preparing the machine unit has been completed.

Procedure 4-2 Supplying the machine unit with operating media
Prerequisites Procedure 4-1 Preparing the machine unit has been completed
1 Make the required operating media of the specified quality available to the
consumers. Observe the specified requirements to ensure safe operation
of the machine unit. For information about the required operating media
for components in MAN Diesel & Turbo's scope of supply please refer to
the Consumption List (see Chapter 9 Plans and Schematics).
2 Provide the operating media required for operation of the steam turbine
according to the specifications in the Operating Instructions for Steam
3 Constantly monitor energy supply of the machine unit in order to ensure

safe operation.
4 Open all shut-off valves in the impulse lines to the instruments.
5 Close all equalizing valves on the instruments to prevent any escape of

process gas.
⇒ Procedure 4-2 Supplying the machine unit with operating media has
been completed.
Procedure 4-3 Enabling the control panel

Prerequisites Procedure 4-2 Supplying the machine unit with operating media has been
carried out
1 Enable the control panel in accordance with the manufacturer's

instructions.
⇒ Procedure 4-3 Enabling the control panel has been completed.

Procedure 4-4 Draining the machine unit
Prerequisites None
NOTICE
MAN Diesel & Turbo recommend that the following should be paid
attention to during the draining process:
• For initial start-up from the depressurized state or after
maintenance work: Carry out this procedure before you pressurize
the compressors.
• During operation or pressurized standstill: As a rule, draining is not
required.
• After depressurized shut-down: Comply with the procedures in
Section 4.6 Shut-down from normal operation.
WARNING
Risk of explosion of escaping process gas when draining
is carried out during operation!

• Make sure that the drain lines are rated for the
maximum operating pressure and are routed to a safe
location.
• Wear the specified personal protective equipment and
comply with the safety regulations.
• Carry out draining carefully.
1 Drain the LP compressor.

1.1 Open the shut-off valve in the drain pipe.
1.2 Wait until water stops escaping from the drain pipe.
1.3 Close the shut-off valve in the drain pipe.
2 Drain the HP compressor.

2.1 Open the shut-off valve in the header.
2.2 Open the shut-off valve in the first drain line.
2.3 Wait until water stops escaping from the header.
2.4 Close the shut-off valve in the first drain line.
2.5 Repeat instructions 2.2 to 2.4 for the other drain pipes.
2.6 Close the shut-off valve in the header.
3 Remove the plugs and blind flanges from the drain valves.

WARNING
Risk arising from the explosion of escaping process gas!

• Make sure process gas cannot escape into the

atmosphere.
• Wear the specified personal protective equipment and
comply with the safety regulations.
4 Drain the following components of the machine unit.

❚ Process gas piping
❚ Instruments
❚ Process gas cooler
❚ Impulse lines
❚ Seal gas piping
❚ Seal gas / separation gas filter
4.1 Slowly open the drain valves.

4.2 Wait until liquid stops escaping.
4.3 Close the drain valves completely.
5 Reinstall all previously removed plugs and blind flanges.
⇒ Procedure 4-4 Draining the machine unit has been completed.

Procedure 4-5 Starting up the seal gas system for the atmospheric end
Prerequisites Procedure 4-4 Draining the machine unit has been carried out
NOTICE
For further information about starting up the seal gas system please
refer to the Operating Instructions for Seal Gas System (see Chapter
10 Operating Instructions for Components).
1 Set all shut-off valves of the seal gas system to their operating positions
according to the P&I Diagram (see Chapter 9 Plans and Schematics).
2 Open the shut-off valves in the vent lines.
3 Secure the lockable shut-off valves to prevent unintended opening or

closing and keep the keys in a suitable place.
4 Pressurize the atmospheric-end shaft seals with seal/separation gas.
5 Check the seal/separation gas filter for leakage.
6* In case of leakage:
Terminate seal/separation gas supply and have the leakage eliminated.
7 Check the operating values based on the alarm values at the indicators
below (for alarm values see the relevant document; see Chapter 9 Plans
and Schematics):
❚ Differential pressure at indicator PDI 935 of the seal gas/separation
gas filter
❚ Pressure at indicator PI 937 of the 1st stage seal gas
❚ Pressure at indicator PI 941A of the 1st stage seal gas
❚ Pressure at indicator PI 939 of the 2nd stage seal gas
❚ Pressure at indicator PI 941B of the 2nd stage seal gas
8* In case of unusual deviations from the set-point:

Have the malfunction eliminated immediately.
⇒ Procedure 4-5 Starting up the seal gas system for the atmospheric end
has been completed.

Procedure 4-6 Starting up the seal gas system for the process gas end
Prerequisites Procedure 4-5 Starting up the seal gas system for the atmospheric end has
been carried out
1* To operate the compressors with very wet process gas:

Proceed as follows:
1.1 Provide a gas that is compatible with the process gas as an
external buffer gas.
1.2 Open the closed shut-off valve at transfer point 6.02.
1.3 Open the shut-off valves in the pipes to the inner side of the dry gas
seals.
2* To operate the compressors with nitrogen:

Proceed as follows:
2.1 Provide nitrogen or instrument air as an external buffer gas.
2.2 Open the closed shut-off valve at transfer point 6.02.
2.3 Open the shut-off valves in the pipes to the inner side of the dry gas
seals.
3* To change back the operation of compressors to dry and clean process

gas:
Proceed as follows:
3.1 Terminate the supply with external buffer gas.
3.2 Close the shut-off valve at transfer point 6.02 and lock it in the
closed position.
3.3 Close the shut-off valves in the pipes to the inner side of the dry gas
seals.
⇒ Procedure 4-6 Starting up the seal gas system for the process gas end
has been completed.

Procedure 4-7 Starting up the oil system
Prerequisites Procedure 4-6 Starting up the seal gas system for the process gas end has
been carried out
1 When starting up the oil system also note the following documents in
addition to the instructions given in this procedure:
❚ Operating Instructions for Oil System (see Chapter 10 Operating
Instructions for Components)
2 Check the level in oil reservoir 2640-K-001-F1 at oil level indicator LI 936.
3* In case the oil level is too low:

Have oil topped up by the service technician according to Section 6.2.2
Maintenance work.
4 Switch oil heater 2640-K-001-EE1A/B to automatic mode.
5 Make bladder accumulators 2640-K001-V4A/B ready for operation as

specified by the manufacturer.
6 Open the shut-off valve in the oil supply line to the bladder accumulators.
NOTICE
The shut-off valves in the balancing pipes of oil cooler and oil filter
that are locked in the open state (LO) allow unrestricted thermal
expansion in any case. Close these valves only for service and
maintenance work.
7 Set all valves to their operating positions according to the P&I Diagram
8 Switch on drive motor 2640-K-001-MK1 of oil mist separator 2640-K-

001-K1.
9 Set the bypass flow valve in the bypass pipe of the oil mist separator such
that a negative pressure of 5-10 mbar results in the oil reservoir.
10 Check the negative pressure in about the first four weeks of operation
periodically because the operating condition of the oil mist separator will
stabilize only when the filter element is saturated.
11* In case the negative pressure is not correct:

Correct the negative pressure.
4 - 10 Normal operation
12 Wait until the oil temperature in the oil reservoir has reached at least 10 °C
according to the local thermometer to prevent damage to the oil pump
due to viscous oil.
NOTICE
Switch on the oil pumps only after you have started the seal gas
system at the atmospheric end in order to avoid damage to the dry
gas seals.
13 Start up main oil pump 2640-K-001-G1A.
14 Adjust the specified cooling water flow rate to the drive steam turbine of
the main oil pump.
15 Switch auxiliary oil pump 2640-K-001-G1B to automatic mode.
16 Vent all instruments and then close the vent valves on the instruments.
17 Wait until the oil temperature at indicator TI 944 has reached at least
35 °C.
18 Vent oil cooler 2640-K-001-E1A/B on the oil side.

18.1 Open the oil-side vent valve of the oil cooler through which the oil
flows.
18.2 Wait until air is no longer visible in the sight glass of the oil return line
and there is an uninterrupted oil flow.
18.4* To vent the second oil cooler:
Proceed as follows:
❙ Switch over to the other oil cooler according to Section 6.2.2
Maintenance work.
❙ Repeat the venting steps for the second oil cooler.
Prerequisites for start-up 4 - 11

19 Vent oil cooler 2640-K-001-E1A/B on the water side.
19.1 Open the shut-off valves in the cooling water lines of the oil cooler.
19.2 Remove the blind flange from the water-side vent valve.
19.3 Slowly open the vent valve.
19.4 Wait until water only escapes from the vent valve.
19.6 Repeat the venting steps for the second oil cooler, if required.
19.7 Repeat venting after a couple of hours to ensure complete venting.
19.8 Reinstall the blind flange.
19.9 On the customer's cooling water system, adjust the cooling water
flow rate to the oil cooler to the specified set-point value and
maintain this value to prevent fouling of the oil cooler by sludge.
20 Vent lube oil filter 2640-K-001-V3A/B.

20.1 Open the vent valve of the oil filter through which the oil flows.
20.2 Wait until air is no longer visible in the sight glass of the oil return line
and there is an uninterrupted oil flow.
20.4* To vent the second oil filter:
Proceed as follows:
❙ Switch over to the other oil filter according to Section 6.2.2
Maintenance work.
❙ Repeat the venting steps for the second oil filter.
21 Check the differential pressure at differential pressure instrument PDI 936

of the lube oil filter.
NOTICE
While the oil temperature is below the operating temperature,
differential pressure instrument PDI 936 will read a higher value than
under operating conditions.
22* In case the differential pressure is too high:

Service the oil filter in accordance with Section 6.2.2 Maintenance work
to avoid machine damage due to inadequate oil supply.
23 Switch on cooling oil pump 2640-K-001-G2.
24 Vent cooling oil filter 2640-K-001-V5.
25 Set cooling oil pump 2640-K-001-G2 to automatic mode.
26 Switch on the jacking oil pumps.
NOTICE
The jacking oil pumps are controlled via the control system of the
steam turbine.
27 Set the jacking oil pumps to automatic mode.
28 Check the filling level of rundown tank 2640-K-001-F2 at oil level indicator
LI 935.
29* In case the rundown tank is not filled sufficiently:

Fill the rundown tank.
29.1 Slowly open the shut-off valve in the bypass line of the check valve
to the rundown tank.
29.2 Wait until the filling level is reached.
29.3 Close the shut-off valve.
30 Vent the oil supply line to the bladder accumulators.

30.1 Open the valve in the drain pipe.
30.2 Wait until the noise which is indicative of air bubbles has stopped.
30.3 Close the valve.
30.4 Repeat the venting steps for the second bladder accumulator.
31 Check the oil system for leakage or for escaping oil mist.
32* In case of leakage or escaping oil mist:

33 Check the sight glasses in the oil return lines for oil flow.
34* In case the oil flow is inadequate:

35 Check the oil supply pressures in the supply lines to the bearings against
the alarm values (alarm values in relevant document; see Chapter 9 Plans
and Schematics).
36* In case the oil supply pressure is outside the normal range:
⇒ Procedure 4-7 Starting up the oil system has been completed.
Prerequisites for start-up 4 - 13

Procedure 4-8 Purging the machine unit
Prerequisites Procedure 4-7 Starting up the oil system has been carried out
NOTICE
Carry out this procedure only at the time of initial start-up and after
maintenance work.
CAUTION
Risk arising from inhalation of nitrogen!
This may cause suffocation.

• Ensure adequate ventilation of the work environment.
1 Have the service technician introduce process gas or nitrogen into all
process gas carrying components of the machine unit.
2 Have the machine unit purged until all extraneous gases have been
expelled from the machine unit.
⇒ Procedure 4-8 Purging the machine unit has been completed.
Procedure 4-9 Preparing steam turbine and allocated systems

Prerequisites Procedure 4-8 Purging the machine unit has been carried out
1 Perform the work required for preparing the steam turbine and the
allocated systems in accordance with the Operating Instructions for
Steam Turbine (see Chapter10 Operating Instructions for Components).
⇒ Procedure 4-9 Preparing steam turbine and allocated systems has been
completed.
Procedure 4-10 Establishing the operating conditions

Prerequisites Procedure 4-9 Preparing steam turbine and allocated systems has been carried
out
1 Establish the operating conditions for process gas operation of the

machine unit.
⇒ Procedure 4-10 Establishing the operating conditions has been

completed.
4.3 Start-up
In this Section you will find the procedure for starting up the machine train. Carry
out this procedure only after you have completed all procedures in accordance
with Section 4.2 Prerequisites for start-up successfully.
Procedure 4-11 Starting normal operation of the machine train

Prerequisites The following prerequisites must be satisfied:
■ All procedures in Section 4.2 Prerequisites for start-up have been carried
out as required
■ All the protective equipment has been fitted
■ All the safety equipment is ready for operation
■ The machine train is at standstill
■ The control system is in one of the following operating states:
❚ Step 05/2
❚ Step 06
❚ Step 07
1 Visually check all valves for their correct start-up positions according to
the valve position table in the Function Diagram (see Chapter 9 Plans and
Schematics).
2* In case the valve start-up positions are incorrect:

Set the valves to their correct positions and eliminate the cause of the
incorrect positions.
3 Check the indicators for alarm signals.
4* In case of alarm signals which are not due to standstill of the machine
train:
Eliminate the malfunction in accordance with Section 6.4.2
Troubleshooting and then reset the alarms.
5 Check whether all start-up interlocks have been cancelled.
6* In case start-up interlocks have not been cancelled:

Carry out the work that is necessary to make machine unit components
ready for start-up which are not ready for start-up or to start them up
according to the Function Diagram and the Operating Instructions for
Components (see Chapter 9 Plans and Schematics and Chapter 10
Operating Instructions for Components).
Start-up 4 - 15
7* To start the machine train from Step 06 or Step 07:
Start Step 01 Compressor train start-up preparation by giving command
ALARM RESET.
→ The control system gets automatically to Step 02 Compressor train
ready for start-up after the corresponding conditions are met.
8* In case of start-up conditions are not met:
Take the required measures to meet all start-up conditions again.
→ The control system gets to Step 02 Compressor train ready for start-
up again after all conditions are met again.
9 Select the current process gas at the superimposed control system to

ensure that the anti-surge control system uses the allocated response
lines.
10 Start Step 03 Compressor train start-up by giving the command

COMPRESSOR TRAIN START-UP.
11 Start the steam turbine according to the Operating Instructions for Steam
→ The control system performs the following step automatically:
❚ Step 04 Compressor train in normal operation
→ The compressors are now in normal operation.
12 In all operating modes run the compressors only in the permitted range
(definition see Section 2.2.1 Intended use).
13* In case the pressure drops below the Minimum Back-Pressure Line:
Increase the back pressure by taking measures at the process-gas end.
14 Operate the steam turbine according to the Operating Instructions for

Steam Turbine (see Chapter 10 Operating Instructions for Components).
15 Listen for unusual noise from the machine unit and watch the monitoring
instruments for unusual indications.
16* In case of unusual noise or unusual indications:

Proceed as follows:
16.1 Eliminate the cause of the malfunction immediately.
16.2* In case the cause of malfunction cannot be eliminated or is
unknown and there are severe malfunctions:
Shut down the machine train and have the cause of the malfunction
eliminated.
17 Check the operating values based on the alarm values at the indicators
below (for alarm values see the relevant document; see Chapter 9 Plans
and Schematics):
❚ 1st stage DGS rack
❙ Differential pressure at indicators PDXI 938 and PDXI 939 in the
internal seal gas pipe
❙ Flow rate at indicators FI 938 and FI 939 in the internal seal gas pipe
❙ Flow rate at indicator FI 937 in the balancing pipe
❚ 2nd stage DGS rack
❙ Differential pressure at indicators PDXI 936 and PDXI 937 the
internal seal gas pipe
❙ Flow rate at indicators FI 940 and FI 941 in the internal seal gas pipe
❙ Flow rate at indicator FI 942 in the balancing pipe
18* In case of unusual deviations from the set-point:

19 Have automatic cut-in of the auxiliary oil pump checked by the service
technician (see Section 6.2.2 Maintenance work).
⇒ Procedure 4-11 Starting normal operation of the machine train has been
completed.
Start-up 4 - 17
4.4 Checks during operation
In this Section you will find all procedures for checks during operation. The first
procedure gives you an overview. Carry out the subsequent procedures
depending on operational requirements.
■ Procedure 4-12 Carrying out operation checks
■ Procedure 4-13 Carrying out the hourly operation check
■ Procedure 4-14 Performing the daily operation check
Procedure 4-12 Carrying out operation checks

Prerequisites The machine train has been started up
1 Check the following points on the monitoring system and on the control
system:
❚ Are alarm signals pending?
❚ Are the operating values in the permitted range?
2* In case of alarm signals or impermissible or unusual operating values:

Inform the service technician immediately.
3 Perform the required service and maintenance work for the steam turbine
and the allocated systems in accordance with the Operating Instructions
for Steam Turbine (see Chapter10 Operating Instructions for
Components).
4 Carry out the following procedures at the specified time intervals:

❚ Procedure 4-13 Carrying out the hourly operation check
❚ Procedure 4-14 Performing the daily operation check
⇒ Procedure 4-12 Carrying out operation checks has been completed.
Procedure 4-13 Carrying out the hourly operation check
Prerequisites Machine train has been started up
1 Read the operating values.

2* In case automatic recording of operating values is not provided:

Enter the operating values into the operation log; this will enable you to
quickly react to changes in the operating values and to identify trends.
3 Listen for unusual noise from the machine unit and watch the monitoring
instruments for unusual indications.
4* In case of unusual noise or unusual indications:

Proceed as follows:
4.1 Eliminate the cause of the malfunction immediately.
4.2* In case the cause of malfunction cannot be eliminated or is
unknown and there are severe malfunctions:
Shut down the machine train and have the cause of the malfunction
eliminated.
⇒ Procedure 4-13 Carrying out the hourly operation check has been
completed.
Checks during operation 4 - 19

Procedure 4-14 Performing the daily operation check
Prerequisites None
WARNING
Risk of explosion of process gas in case of leakage!

• Keep ignition sources away from the process gas
system.
• Leave the area of the machine unit at once if you
suspect signs of hazardous leakage.
1 Check the process gas system and the seal gas system for leakage.
Proceed as detailed below to prevent personal injury or damage to
physical assets and to ensure safe operation.
2.1* In case of a major amount of process gas escaping:
Shut down the machine train at once according to Section 4.5
Shut-down in an emergency and depressurize the pipe concerned.
2.2 Inform the service technician immediately.
2.3 Have the cause of the leakage eliminated.
WARNING
Risk arising from escaping steam in the event of leakage!

• Wear the required personal protective equipment.
• Carry out the work carefully.
3 Check the steam system for leakage.
Proceed as described below to avoid personal injury or damage to
4.1* In case of a major amount of steam escaping:
Shut down the machine train at once according to Section 4.5
Shut-down in an emergency and depressurize the pipe concerned.

4.4 Dispose of the accumulated condensate.
5 Inspect the auxiliary systems of the machine unit for leakage.
Proceed as described below to avoid personal injury or damage to
6.1* In case of a major amount of operating media escaping:
Shut down the machine train according to Section 4.6 Shut-down
from normal operation and depressurize the pipe concerned.
6.4 Remove the spilled operating media.
6.5 Dispose of the removed operating media in an environmentally
sound manner.
⇒ Procedure 4-14 Performing the daily operation check has been

completed.
Checks during operation 4 - 21

4.5 Shut-down in an emergency
In this Section you will find the procedure for shutting down the machine train
in an emergency. Carry out this procedure only if there is no other way to avert
impending danger.
In case preset limit values according to the relevant document (see Chapter 9
Plans and Schematics) are reached, the control system will initiate an automatic
shut-down according to the procedure below.
Procedure 4-15 Shutting down the machine train in an emergency

Responsibility Users
Prerequisites None
1 Actuate one of the emergency-stop buttons.

→ The control system performs the following actions automatically:
❚ Switching off the steam turbine
❚ Opening or closing the process gas valves to the intended position
→ The machine train is depressurized and at standstill.
2 Investigate the causes of the emergency stop.
3* In case the causes are not clear:

Contact MAN PrimeServ (see Section 1.4 After Sales Service) to decide
on the further course of action.
4 Eliminate the cause of the emergency stop.
5 Depending on operational requirements carry out the procedures

described in Section 4.4 Checks during operation.

described in Section 4.7 Measures for standstill periods.
⇒ Procedure 4-15 Shutting down the machine train in an emergency has

been completed.
4.6 Shut-down from normal operation
In this Section you will find the procedure for shutting down the machine train
from normal operation. This procedure describes the preferred course of action
for shut-down. Shut down the machine train by actuating the emergency-stop
button only in case of emergency to avoid unnecessary loads on the machine
unit.
Procedure 4-16 Shutting down the machine train

Prerequisites The machine train is in normal operation
1* To shut down manually from Step 04 Compressor train in normal

operation:
Start Step 05/1 Stop compressor train by giving command STOP
COMPRESSOR TRAIN.
❚ Delayed switching off the steam turbine
→ The machine train coasts down to pressurized standstill (Step 05/2).
2* To trip due to a trip condition from any step:

Have Step 06 or Step 07 started.
❚ Tripping the steam turbine with or without delay
→ The machine train is in pressurized (Step 06) or depressurized (Step

07) standstill.
3* To assess the coast-down time:

Measure the coast-down time of the machine train and enter the coast-
down time in the operation log, which will enable you to draw conclusions
if machine damage should occur later.

described in Section 4.4 Checks during operation.

described in Section 4.7 Measures for standstill periods.
⇒ Procedure 4-16 Shutting down the machine train has been completed.
Shut-down from normal operation 4 - 23

4.7 Measures for standstill periods
In this Section you will find all procedures for measures to be taken for standstill
periods of the machine train. The first procedure gives you an overview. Carry
out the procedures below depending on operational requirements.
■ Procedure 4-17 Performing measures for standstill periods
■ Procedure 4-18 Shutting down the steam turbine and allocated
systems
■ Procedure 4-19 Shutting down the oil system
■ Procedure 4-20 Purging the process gas system with nitrogen
■ Procedure 4-21 Terminating supply of the machine unit with operating
media
■ Procedure 4-22 Shutting down further components of the machine
unit
■ Procedure 4-23 Preservation of the machine unit
Procedure 4-17 Performing measures for standstill periods

Prerequisites The machine train has been shut down
1 Carry out Procedure 4-18 Shutting down the steam turbine and allocated
systems.
2 Depending on the particular situation and the expected standstill period,

protect the machine unit from detrimental external influences such as:
❚ soiling (e. g. by entry of dust or foreign matter)
❚ corrosion (e. g. as a result of rain water, wet air or condensate from the
process gas)
❚ mechanical damage
❚ fault current
3* To shut down the machine train for a period longer than approx. 48 hours:
Carry out the procedures listed on the following pages of this Section.
4* To shut down the machine train for a period longer than approx. 6
months:
Have the machine unit additionally provided with long-term preservation
by MAN PrimeServ.
⇒ Procedure 4-17 Performing measures for standstill periods has been

completed.
Procedure 4-18 Shutting down the steam turbine and allocated systems
Prerequisites Machine train has been shut down
1 Perform the work required for shutting down the steam turbine and the
allocated systems in accordance with the Operating Instructions for
Steam Turbine (see Chapter10 Operating Instructions for Components).
⇒ Procedure 4-18 Shutting down the steam turbine and allocated systems
has been completed.
Procedure 4-19 Shutting down the oil system

Prerequisites Procedure 4-18 Shutting down the steam turbine and allocated systems has
been carried out
NOTICE
Depending on the operating conditions, do not carry out this
procedure at low ambient temperatures to avoid damage as a result
of subcooling.
1 To avoid machine damage keep the oil system in operation until the
machine bearings have cooled off and the pressure inside the machines
is equal to atmospheric pressure.
2 Switch off jacking oil pumps and secure them against unintended starting
to avoid damage.
3 Switch off cooling oil pump 2640-K-001-G2 and secure it against

unintended starting to avoid damage.
4 Switch off auxiliary oil pump 2640-K-001-G1B and secure it against

5 Switch off main oil pump 2640-K-001-G1A and secure it against

6 Switch off oil heater 2640-K-001-EE1A/B.
7 Wait until rundown tank 2640-K-001-F2 is completely empty.
8 Switch off drive motor 2640-K-001-MK1 of oil mist separator 2640-K-

001-K1 as soon as the oil mist has escaped from the oil system.
9 Service lube oil filter 2640-K-001-V3A/B as per Section 6.2.2

Maintenance work.
Measures for standstill periods 4 - 25

10 Clean cooling oil filter 2640-K-001-V5.
11* To shut down the oil system for a short time:

Maintain the specified cooling water flow through oil cooler 2640-K-001-
E1A/B.
12* To shut down the oil system for a prolonged time:
Proceed as follows:
12.1 Close the shut-off valves in the cooling water lines of the oil cooler.
12.2 Empty the oil cooler on the water side.
12.3 Pass dry, warm air through the cooling water lines of the oil cooler
until they are dry.
12.4 Purge the oil cooler with nitrogen.
12.5 Isolate the oil cooler against air by permanently pressurizing or filling
it with nitrogen.
⇒ Procedure 4-19 Shutting down the oil system has been completed.
Procedure 4-20 Purging the process gas system with nitrogen
Prerequisites Procedure 4-19 Shutting down the oil system has been carried out
NOTICE
This procedure is not required after compressor operation with

nitrogen.
CAUTION

1 Have the service technician introduce dry nitrogen into all process gas
carrying components of the machine unit.
2 Have the machine unit checked for process gas residues by means of gas
detectors. Purge until the machine unit is free from process gas residues.
3 Have the service technician hermetically isolate the machine unit from the
process gas system of the overall process plant, e. g. by fitting blanking
plates in the process gas pipes.
⇒ Procedure 4-20 Purging the process gas system with nitrogen has been
completed.
Procedure 4-21 Terminating supply of the machine unit with operating media
Prerequisites Procedure 4-20 Purging the process gas system with nitrogen has been carried
out
NOTICE
Depending on operational requirements maintain power supply to
the machine unit so that electrical devices can be kept in operation.
1 Terminate the supply of all operating media to the machine unit.
⇒ Procedure 4-21 Terminating supply of the machine unit with operating

media has been completed.
Measures for standstill periods 4 - 27

Procedure 4-22 Shutting down further components of the machine unit
Prerequisites Procedure 4-21 Terminating supply of the machine unit with operating media
has been carried out
1 Shut down the other machine unit components according to the
Operating Instructions for Components in MAN Diesel & Turbo's scope
of supply (see Chapter 10 Operating Instructions for Components).
2* For components which are not included in MAN Diesel & Turbo's scope
of supply:
Shut down the other components of the machine unit according to the
manufacturers' operating instructions.
3 Drain the machine unit according to Section 4.2 Prerequisites for start-
up.
4* To shut down power supply completely:

Terminate power supply to the machine unit.
⇒ Procedure 4-22 Shutting down further components of the machine unit

has been completed.
Procedure 4-23 Preservation of the machine unit

Prerequisites Procedure 4-22 Shutting down further components of the machine unit has
been carried out
1 Have the individual components of the machine unit preserved by the

service technician. For a list of the Operating Instructions for Components
in the MAN Diesel & Turbo scope of supply please refer to Chapter 10
Operating Instructions for Components.
→ The machine unit has now been preserved for a standstill period of up
to 6 months.
⇒ Procedure 4-23 Preservation of the machine unit has been completed.
5 Installation and commissioning

This Chapter addresses the operating company of machine unit Ruwais REC
2013. It provides an overview of the work to be carried out for preparation of
installation, for installation, and for commissioning of the machine unit.
For installation and commissioning the information concerning safety (see

Section 2.2.8 General safety information and Section 2.3 Residual hazards and
risks) must be observed without fail.
The contractual agreements between MAN Diesel & Turbo and the operating
company or the operating company's representative take precedence over the
information in this Chapter.
Also observe the more detailed information about preparation of installation and
installation in the separate Installation Manual.
MAN Diesel & Turbo recommend having installation and commissioning of the
machine unit carried out by MAN Diesel & Turbo erection personnel.
5-1
5.1 Overview
5.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
5.2 Preparations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
5.2.1 Transport. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
5.2.2 Scope of supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
5.2.3 Place of use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
5.2.4 Operating media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
5.3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
5.3.1 Erection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
5.3.2 Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
5.4 Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
5.4.1 Checking of installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
5.4.2 Initial start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
5-2 Installation and commissioning

5.2 Preparations
Efficient preparation which the operating company is to carry out includes the
following items to ensure smooth and trouble-free installation:
■ Provision of transport capacities
■ Checking of supply
■ Preparation of place of use
■ Provision of energies and operating media
5.2.1 Transport
Transport of the machine unit to the jobsite is carried out as contractually

agreed between MAN Diesel & Turbo and the operating company or the
subcontractor commissioned by the operating company.
On the basis of the most important points the following procedure describes the
work to be carried out by you in respect of transport.
Procedure 5-1 Performing transport

Responsibility Operating company
Prerequisites The machine unit is ready for transport
1 Have transport up to the jobsite carried out as contractually agreed

between MAN Diesel & Turbo and the operating company.
2 Contact MAN Diesel & Turbo to agree on the required slinging gear and
transport and handling equipment on site.
3 Make the agreed slinging gear and transport and handling equipment
available in time (e. g. rotatable suspension lugs WBG-V/WBG, no rigid
lifting eye bolts to DIN 580).
NOTICE
Lashing eyes are intended only for the purpose of lashing the cargo.
Never use lashing eyes which are marked as such for the purpose of
slinging and lifting the cargo.
4 For transport only use the slinging points provided for this purpose.
5 Carry out transport on the site in compliance with the applicable transport
regulations.
⇒ Procedure 5-1 Performing transport has been completed.
Preparations 5-3
5.2.2 Scope of supply
As a rule, the machine unit is delivered by MAN Diesel & Turbo completely
piped and cabled up to the base frame edges. Junction boxes or take-over
point flanges form the interfaces for the relevant operating media.
On arrival of the consignment at site the operating company must promptly
check the scope of supply for completeness and proper condition. Delayed
claims will not be accepted by MAN Diesel & Turbo.
Before every transport, MAN Diesel & Turbo mark the component parts of the
consignment with a label and enclose a packing list with the consignment.
On the basis of the most important points the following procedure describes
how to check the scope of supply.
Procedure 5-2 Checking the consignment

Prerequisites The consignment has arrived
1 Check the packaging and parts of the consignment which are not
packaged by reference to the data in the Installation Manual.
2* In case parts are missing or packaging is damaged:

Proceed as contractually agreed or in accordance with the information in
the Installation Manual.
3 Jointly with the MAN Diesel & Turbo erection personnel check the supply
for completeness and integrity in accordance with the information in the
Installation Manual.
4* In case component parts are missing or damaged:

Proceed as contractually agreed or as specified in the Installation Manual.
⇒ Procedure 5-2 Checking the consignment has been completed.

5.2.3 Place of use
The place of use envisaged for the machine unit must satisfy the requirements
for safe installation of all components.
work to be carried out by you as regards preparation of the place of use.
Procedure 5-3 Preparing the place of use

Prerequisites None
1 Prepare the place of use in respect of the following points according to

the information in the Installation Manual:
❚ Traffic and work areas
❚ Magazines for tools and other material
❚ Adequate lighting
❚ Safety facilities, especially if hazardous gases are used (e. g. use of fire
alarm units, optimum configuration of buildings without formation of
troughs)
2 Prepare the installation areas in accordance with the information in the

relevant documents.
3 Take appropriate structural measures to protect the machine unit against

harmful ambient influences (e. g. coal dust, sand, lightning, etc.) as far as
possible.
4 Properly earth the machine unit at all the points envisaged for this
purpose.
⇒ Procedure 5-3 Preparing the place of use has been completed.
Preparations 5-5
5.2.4 Operating media
Energy supply to the machine unit is made from external energy sources. The
operating company provides the required operating media.
work to be carried out by you in respect of the operating media.
In Section 4.2 Prerequisites for start-up and in the Installation Manual you will
find further information about energy supply.
Procedure 5-4 Ensuring supply and disposal of operating media

Prerequisites None
1 For all supply and disposal lines use materials that are permitted for the
maximum possible operating values such as pressure, flow rate,
temperature, etc. This applies in particular also to the drain and vent lines.
2 Ensure supply and disposal of the required operating media on the jobsite
as well as monitoring of supply during operation.
3* To provide more than one supply voltage:

Completely isolate the supply voltages against each other.
⇒ Procedure 5-4 Ensuring supply and disposal of operating media has been
completed.

5.3 Installation
Efficient installation includes the following points to ensure reliable
commissioning:
■ Erection
■ Connections
Work carried out by Carry out the work determined by contractual agreement between
the operating MAN Diesel & Turbo and the operating company or its representative.
company
Installation of Carry out the project specific installation of components of the machine unit in
components accordance with the manufacturers' information in the Operating Instructions
for Components (see Chapter 10 Operating Instructions for Components).
Material For installation only use materials of the specified quality. Ensure that materials
cannot be mixed up (e. g. bolts or screws).
Safety facilities Never use equipment parts with safety function for any other tasks in order not
to impair their safety-relevant function. Observe the regulations and principles
applicable to their design, especially in respect of the following points:
■ fail-safe behaviour
■ redundancy
■ diversity
■ self-monitoring
■ maximum occurring pressure
■ adequate response times
Pressure equipment For the design and installation of pressure equipment observe the applicable
regulations, the safety data sheets and the contractual agreements in order to
ensure safe operation. Ensure adequate safeguarding of pressure equipment.
MAN Diesel & Turbo do not stipulate specific intervals for process gas pipe
inspection and maintenance.
Installation 5-7
5.3.1 Erection
Erection of the machine unit including alignment is carried out as contractually

agreed between MAN Diesel & Turbo and the operating company or the
subcontractor commissioned by the operating company.
work to be carried out by you as regards erection of the machine unit.
Procedure 5-5 Erecting the machine unit

Prerequisites Procedure 5-4 Ensuring supply and disposal of operating media has been
carried out
1 Have trained and skilled personnel execute the work concerning erection
of the machine unit which the operating company has to carry out as
contractually agreed.
2 Have the contractually agreed work done by MAN Diesel & Turbo field
service personnel.
⇒ Procedure 5-5 Erecting the machine unit has been completed.

5.3.2 Connections
Connections for the required operating media are provided at the defined
interfaces in accordance with the General Arrangement drawing and the Pipe
Connection List (see Chapter 9 Plans and Schematics).
work to be carried out by you as regards connections.
Procedure 5-6 Establishing the connections

Prerequisites Procedure 5-5 Erecting the machine unit has been carried out
1 Determine the connection points in accordance with the General

Arrangement drawing (see Chapter 9 Plans and Schematics).
2 Route the required operating media to the relevant connection points.

Observe the current national regulations for the respective operating
media.
3 For all pipes, lines, valves and fittings use materials that are permitted for
the maximum possible operating values such as pressure, flow rate,
temperature, etc.
4 Clean all pipes carefully on the inside.
5 Arrange pipes and valves/fittings such that risks to persons can be

excluded. Observe the principles below:
❚ Ensure low-stress installation of piping
❚ Provide pipe fastenings such that the fastenings cannot work loose in
the event of predictably occurring forces (e. g. movements due to
pressure changes, vibrations).
❚ If rupture disks are available: Fit rupture disks such that the escaping
jet will not cause any damage if the disk bursts
⇒ Procedure 5-6 Establishing the connections has been completed.
Installation 5-9
5.4 Commissioning
Efficient commissioning includes the following points to ensure reliable
operation and safe handling:
■ Checking of installation
■ Initial start-up
5 - 10 Installation and commissioning

5.4.1 Checking of installation
After installation of the machine unit have all the performed work and the safe
condition of the machine unit checked before arranging for start-up of the
machine unit.
work to be carried out by you as regards the check of installation.
Procedure 5-7 Performing the installation check

Prerequisites Procedure 5-6 Establishing the connections has been carried out
NOTICE
MAN Diesel & Turbo disclaim any responsibility in the event that
information, specifications or requirements contained in these
Operating Instructions are not complied with.
1 Have MAN Diesel & Turbo field service personnel carry out all required
checks and inspections to avoid machine damage as a result of
inadequate installations.
2 Have the following points checked in particular:

❚ Cleanliness inside the pipes
❚ Installation of piping according to General Arrangement
❚ Installation of wiring
❚ Installation of safety facilities, warning signs, and safety signs
❚ Usability of walkways and work rooms
❚ Implementation of measures by the operating company required for
protection of the machine unit (e. g. installation of safety valves,
mounting of protective equipment, final inspection of all pressure
equipment, performance of pressure tests)
3* In case defects are found:

Have the defects eliminated immediately.
4 Check whether the temporary suction strainer has been replaced by the
fitting piece included in the supply.
5* In case the suction strainer is still installed:

Have the temporary suction strainer removed and replaced with the fitting
piece included in the supply.
⇒ Procedure 5-7 Performing the installation check has been completed.
Commissioning 5 - 11
5.4.2 Initial start-up
For safety reasons, initial start-up of the machine unit must be carried out by
MAN Diesel & Turbo erection personnel only.
work to be carried out by you as regards initial start-up.
Procedure 5-8 Performing initial start-up

Prerequisites Procedure 5-7 Performing the installation check has been carried out
1 Have MAN Diesel & Turbo erection personnel carry out an initial operation
to avoid machine damage such as may result from inadequate start-up.
2 Have MAN Diesel & Turbo erection personnel carry out and record an
overspeed test on the steam turbine to check and document the
complete measuring circuit.
3 Take over the machine unit from MAN Diesel & Turbo erection personnel
on the basis of a handover record.
4 Jointly with the MAN Diesel & Turbo field service personnel prepare an
inspection plan with all the necessary information such as day of
preparation, date and scope of the next inspection, and all requirements
stipulated by the national legislation.
⇒ Procedure 5-8 Performing initial start-up has been completed.
5 - 12 Installation and commissioning

6 Service, maintenance, and troubleshooting

This Chapter addresses the service technician of machine unit Ruwais REC
2013. It provides information about the work required for service, maintenance,
and troubleshooting of the machine unit. The Chapter also explains which type
of work you can carry out and which work may, for safety reasons, only be
carried out by MAN PrimeServ.
For service, maintenance, and troubleshooting the information concerning

safety (see Section 2.2.8 General safety information and Section 2.3 Residual
hazards and risks) must be observed without fail.
For all work in connection with service, maintenance, and troubleshooting

please also observe the following:
■ Carry out work on electrical installations only if you have been adequately
trained and are familiar with all relevant regulations and standards
concerning the handling of hazardous voltage. Make sure electric power
supply has been reliably interrupted for carrying out such work.
Otherwise, have such work carried out by trained and skilled personnel
only.
■ Depressurize all piping.
■ Ensure correct safeguarding of the machine unit, e. g. by fitting locks or
posting warning boards.
■ Inform the operator about any intended work.
6-1
■ Carry out work for service, maintenance, and troubleshooting only if at
least one other person is present. This ensures mutual protection in the
case of hazardous work.
■ For work in connection with service, maintenance, and troubleshooting
exclusively use the specific slinging gear and transport and handling
equipment to ensure adequate carrying capacity (e. g. rotating
suspension lugs / load rings WBG-V/WBG, no rigid lifting eye bolts to DIN
580).
■ Do not use any seals that have been in use before.
■ Only use as-new and correct MAN Diesel & Turbo original spare parts
(e. g. screws, pins, nuts, seals) because MAN Diesel & Turbo have
matched the materials used to the machine unit.
6.1 Overview
6.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
6.2 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
6.2.1 Maintenance schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
6.2.2 Maintenance work. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
6.2.3 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-26
6.3 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-27
6.3.1 Inspection plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-27
6.3.2 Performance of inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-29
6.4 Malfunctions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-32
6.4.1 Detection of malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-32
6.4.2 Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-33
6.5 Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-42
6-2 Service, maintenance, and troubleshooting

6.2 Maintenance
Maintenance comprises all measures which the operating company should
take to maintain the desired condition of the machine unit.
6.2.1 Maintenance schedule
Correct maintenance of the machine unit depends on numerous factors.

Maintenance is influenced, amongst other things, by the following factors:
■ Ambient conditions
■ Quality of process gas
■ Quality of operating media
■ Number of start-ups
■ Standstill periods
■ Required availability of the machine unit
MAN PrimeServ recommends establishing a specific maintenance strategy

jointly with the operating company. The strategy is to take into account the
operating company's experience gained during operation of the machine unit.
MAN PrimeServ also offers specific training courses for correct maintenance of
the machine unit.
Maintenance work The maintenance work listed in Table 6-1 Routine maintenance work at
on the machine unit intervals in time and Table 6-2 Routine maintenance work depending on hours
in operation is described in Section 6.2.2 Maintenance work. Carefully comply
with the maintenance schedule to ensure safe and economical operation of the
machine unit.
Table 6-1 Routine maintenance work at intervals in time

Interval Maintenance activity
Daily ❚ Checking the level in the oil reservoir
Monthly ❚ Draining oil sludge from the oil reservoir

❚ Testing functioning of the cooling oil pump
❚ Testing the auxiliary oil pump for automatic cut-in
Every three months ❚ Comparing the recorded operating values from the
operation log throughout this period to determine
trends
Every 6 months ❚ Servicing the oil filter

❚ Servicing the oil cooler
❚ Servicing the seal/separation gas filter element
Maintenance 6-3
Annually ❚ Checking the gas pressure in the bladder accumulator

❚ Performing inspection stages 1 to 3 in accordance
with the inspection concept (see Section 6.3
Inspection)
❚ Carrying out periodic inspections on pressure
In compliance with the legal and
regulatory requirements in the equipment and recording the results in the inspection
country of the operating company plan
Table 6-2 Routine maintenance work depending on hours in operation

0 operating hours ❚ Taking an oil sample of approx. 2 kg from the oil

reservoir; keep this sample available for the entire life
cycle of the machine unit
after 500 operating hours ❚ Analysing the oil quality
every 4 000 operating hours, at ❚ Analysing the oil quality

least once a year
Operation checks Operation checks which the operator of the machine unit must carry out
regularly are listed in Section 4.4 Checks during operation.
Maintenance work In addition to the maintenance work listed here, the service technician must
on components follow the maintenance procedures specified by the manufacturers of the
individual machine unit components. For a list of the Operating Instructions for
Components in the MAN Diesel & Turbo scope of supply please refer to
Chapter 10 Operating Instructions for Components.

6.2.2 Maintenance work
This Section describes only the maintenance work which is in the sphere of
responsibility of the operating company's service technician. For safety reasons
work which requires special training and expertise may only be carried out by
MAN PrimeServ within the scope of inspections.
The following maintenance work is described in this Section:

■ Procedure 6-1 Taking an oil sample
■ Procedure 6-2 Analysing the oil quality
■ Procedure 6-3 Draining oil sludge from the oil reservoir
■ Procedure 6-4 Checking level in oil reservoir
■ Procedure 6-5 Topping up oil
■ Procedure 6-6 Changing oil
■ Procedure 6-7 Servicing the cooling oil filter
■ Procedure 6-8 Changing over the lube oil filter
■ Procedure 6-9 Servicing the lube oil filter
■ Procedure 6-10 Changing over the oil cooler
■ Procedure 6-11 Servicing the oil cooler
■ Procedure 6-12 Checking the gas pressure in the bladder accumulator
■ Procedure 6-13 Testing the cooling oil pump
■ Procedure 6-14 Testing the auxiliary oil pump for automatic cut-in
■ Procedure 6-15 Servicing the seal/separation gas filter element
Maintenance 6-5
Procedure 6-1 Taking an oil sample
Responsibility Service technician
Prerequisites The oil system has been started up; preferably the machine train has been
started up, too
Tools The following materials must be available:
■ New, dry sample bottle from polypropylene, aluminium or glass with a
capacity of more than 3 litres
■ Collecting vessel for flushing oil with a capacity of more than 5 litres
■ Lint-free cloth
NOTICE
This procedure describes how to take an oil sample for a routine
analysis. Contact MAN PrimeServ if sampling is required for a
problem analysis. A problem analysis may be necessary in the
following instances:
• Suspicion of inadequate thermal stability of the oil
• Suspicion of bearing and gear unit wear
• Suspicion of increased contamination
• Suspicion of entry of gas
NOTICE
The oil sampling port is located between the lube oil filter and the
bladder accumulator.
CAUTION
Risk arising from hot oil!
This may lead to burn injury.

• Carry out the work carefully.
1 Prepare the sampling point.

1.1 Place the collecting vessel underneath the sampling point.
1.2 Clean the opening of the sampling valve using the lint-free cloth.
1.3 Quickly and briefly open the sampling valve up to the stop to ensure
that flushing is carried out in gushes and re-close it.
1.4 Repeat this flushing in gushes several times until a quantity of about
5 litres is reached.
1.5 Dispose of the collected flushing oil in an environmentally sound
manner.

2 Prepare the sample bottle to obtain a representative oil sample.
2.1 Drain a small quantity of oil into the sample bottle, taking care that
the sample bottle does not get into contact with other objects of
any kind.
2.2 Close the sample bottle and shake it vigorously.
2.3 Open the sample bottle and place the lid upside down to avoid
contamination.
2.4 Dispose of the flushing oil in an environmentally sound manner.
2.5 Repeat Instruction 2.1 to Instruction 2.4 two to three times.
3 Fill the sample bottle with oil up to the top and close it immediately such
that it is airtight. Observe the same precautionary measures as for the
previous instruction.
4 Mark the sample bottle with the information below:

❚ General information
❙ Designation of plant unit
❙ Name and phone number of the person taking the sample and of
the plant manager
❚ Oil data
❙ Producer, type, and grade of oil
❙ Designation of the oil system
❙ Charge of the oil system
❙ Number of starts of the oil system
❙ Operating hours of the oil
❚ Sampling data
❙ Date
❙ Sampling point
❙ Operating condition of the machine train
5 Protect the sample bottle from light and temperatures above 28 °C to

prevent any change in the oil sample.
⇒ Procedure 6-1 Taking an oil sample has been completed.
Maintenance 6-7
Procedure 6-2 Analysing the oil quality
Prerequisites Procedure 6-1 Taking an oil sample has been carried out
1 Have the oil sample examined by a chemical laboratory or by your oil

supplier's technical service.
2 Check whether the oil meets the requirements as described in Section
8.3.3 Operating media requirements to avoid machine damage through
organometallic compounds or as a result of insufficient properties.
3* In case of incorrect oil properties:

Contact MAN PrimeServ (see Section 1.4 After Sales Service) to decide
on the further course of action.
⇒ Procedure 6-2 Analysing the oil quality has been completed.

Procedure 6-3 Draining oil sludge from the oil reservoir
Prerequisites None
Tools Collecting vessel
NOTICE
Oil sludge may accumulate in the oil reservoir during operation and
extended standstill periods.
1 Place the collecting vessel underneath the drain valve on oil reservoir
2640-K-001-F1.
2 Remove the blind flange from the drain valve of the oil reservoir.
NOTICE
Carry out such work carefully to avoid environmental pollution by
escaping oil sludge containing oil and pollutants.
3 Open the drain valve on the oil reservoir.
4 Drain the oil sludge into the collecting vessel.
5 Close the drain valve on the oil reservoir as soon as oil flows out.
6 Reinstall the blind flange.
7 Dispose of the oil sludge in an environmentally sound manner.
8 Check the level in the oil reservoir in accordance with Procedure 6-4
Checking level in oil reservoir.
⇒ Procedure 6-3 Draining oil sludge from the oil reservoir has been
completed.
Maintenance 6-9
Procedure 6-4 Checking level in oil reservoir
Prerequisites None
1 Check the oil level in oil reservoir 2640-K-001-F1 at indicator LI 936.
2* In case the oil level is at the normal mark:
Do not top up oil.
3* In case the oil level is near the minimum mark:

Top up oil according to Procedure 6-5 Topping up oil.
⇒ Procedure 6-4 Checking level in oil reservoir has been completed.
Procedure 6-5 Topping up oil

Prerequisites The required quantity of fresh oil is available (for the requirements see Section
8.3.3 Operating media requirements)
Tools Filling hose, filter with same filter mesh as the oil filter element
1 Remove the lid from the filling nozzle of oil reservoir 2640-K-001-F1 and
check the filling and transport devices for soiling.
2* In case the filling or transport devices are soiled:

Clean the filling and transport devices carefully to avoid machine damage
through pollutants in the oil.
3 Connect the filling hose to the filling nozzle. Make sure the installed
strainer remains in the filling nozzle.
4 Fill in oil through the filling hose and the filter up to the normal mark or at
most up to the maximum mark to avoid damage by an excessive oil
quantity.
5 Remove the filling hose and the filter from the filling nozzle.
6 Put the lid back again on the filling nozzle of the oil reservoir.
⇒ Procedure 6-5 Topping up oil has been completed.
6 - 10 Service, maintenance, and troubleshooting

Procedure 6-6 Changing oil
■ The machine train has been shut down
■ The oil system has been shut down and has cooled down
Tools The following materials must be available:

■ An adequate number of collecting vessels for used oil
■ Filter with same filter mesh as the oil filter element
1 Remove the blind flange from the drain valve of the oil reservoir.
NOTICE
leaking oil.
2 Empty the oil reservoir by draining or pumping the used oil into the
collecting vessel.
3 Open the manhole cover on the top of the oil reservoir.
CAUTION
Risk arising from oil mist which is hazardous to health!
This may cause injury to the respiratory organs.

• Prior to entering, verify that permission for entering the
oil reservoir has been given.
• Make sure there is somebody outside the oil reservoir
to keep watch.
• Observe the further safety regulations for entering
reservoirs (e. g. wear protective clothing, allow oil mist
to escape, ensure adequate ventilation).
CAUTION
Risk arising from oily reservoir bottom!
This may result in injury from falls.

• When working on the inclined bottom inside the oil
reservoir take care to avoid slipping.
4 Enter the oil reservoir.
Maintenance 6 - 11
5 Remove all pollutants from the oil reservoir.
6 Leave the oil reservoir.
7 Close the manhole cover.
8 Close the drain valve.
9 Reinstall the blind flange on the drain valve.
10 Clean oil residues from oil coolers 2640-K-001-E1A/B in accordance with

Section 6.2.2 Maintenance work.
11 Service oil filters 2640-K-001-V3A/B according to Section 6.2.2

Maintenance work.
12 Clean or if necessary change the filter element of the oil mist separator
according to the Operating Instructions for Oil System (see Chapter 10
13 Top up oil according to Procedure 6-5 Topping up oil.
14 Keep a sample of approx. 2 kg of the fresh oil as a reference for later

analyses of oil.
⇒ Procedure 6-6 Changing oil has been completed.

Procedure 6-7 Servicing the cooling oil filter
■ The machine train has been shut down
■ Procedure 4-19 Shutting down the oil system has been carried out
■ A new filter element, sealing material and cleaning material are available
Tools Collecting vessel for used oil
NOTICE
Carry out work according to the Operating Instructions for Oil
1 Close the shut-off valves of oil filter 2640-K-001-V3A/B that are locked in
open state.
NOTICE
leaking oil.
2 Empty the oil filter.

2.1 Open the vent valve of the oil filter for depressurization.
2.2 Place the collecting vessel underneath the drain valve.
2.3 Remove the blind flange from the drain valve.
2.4 Open the drain valve and wait for the oil to run completely from the
filter housing into the collecting vessel.
2.5 Dispose of the drained oil in an environmentally sound manner.
3 Open the oil filter housing.
4 Service the filter element in accordance with the filter manufacturer's

information.
5 Remove the parts loosely fitted in the filter housing. Note the sequence
and direction of installation.
6 Clean the removed parts.
7 Remove oil sludge and impurities from the filter housing.
8 Clean the filter housing sump and the complete interior of the filter
housing.
Maintenance 6 - 13
9 Clean the sealing faces of filter housing and filter housing lid.
10 Reinstall the cleaned parts with new seals into the filter housing observing
the correct sequence and direction.
11 Fit the filter element with new seals carefully into the cleaned filter housing
to avoid damage to the filter element. Wet the sealing faces, O-rings, etc.
with oil to ensure that they are correctly located during installation.
12 Fasten the filter element.
13 Mount the cleaned filter housing lid with a new seal.
14 Screw down the filter housing lid.
17 Close the vent valve.
18 Open the shut-off valves of the oil filter and lock them in open position.
⇒ Procedure 6-7 Servicing the cooling oil filter has been completed.

Procedure 6-8 Changing over the lube oil filter
Prerequisites Oil pressure is present and the valve in the balancing pipe is open
1 Open the vent valve of the inactive oil filter 2640-K-001-V3A/B.

2 Slowly switch the 3-way valve on the oil filter over to the inactive oil filter.
3 Close the vent valve of the activated oil filter.
⇒ Procedure 6-8 Changing over the lube oil filter has been completed.
Maintenance 6 - 15
Procedure 6-9 Servicing the lube oil filter
■ Procedure 6-8 Changing over the lube oil filter has been carried out
■ A new filter element, sealing material and cleaning material are available
Tools A collecting vessel for used oil
NOTICE
Carry out work according to the Operating Instructions for Oil
1 Close the valve that has been locked in the open position in the balance
line.
NOTICE
leaking oil.
2 Empty the fouled oil filter 2640-K-001-V3A/B.

2.1 Open the vent valve of the fouled oil filter for depressurization.
2.2 Place the collecting vessel underneath the drain valve.
2.3 Remove the blind flange from the drain valve.
2.4 Open the drain valve and wait for the oil to run completely from the
filter housing into the collecting vessel.
3 Open the oil filter housing.
4 Service the filter element in accordance with the filter manufacturer's

information.
5 Remove the parts loosely fitted in the filter housing. Note the sequence
and direction of installation.
6 Clean the removed parts.
7 Remove oil sludge and impurities from the filter housing.
8 Clean the filter housing sump and the complete interior of the filter
housing.
9 Clean the sealing faces of filter housing and filter housing lid.

10 Reinstall the cleaned parts with new seals into the filter housing observing
the correct sequence and direction.
11 Insert the filter element with new seals carefully into the cleaned and clean
filter housing to avoid damage to the filter element. Wet the sealing faces,
O-rings, etc. with oil to ensure that they are correctly located during
installation.
12 Fasten the filter element.
13 Mount the cleaned filter housing lid with a new seal.
14 Screw down the filter housing lid.
17 Close the vent valve.
18 Open the valve in the balancing line.
19 Wait until the serviced oil filter is filled with oil and oil flows back through
the vent line on the sightglass to the oil reservoir.
20 Check the serviced oil filter for leakage.

Proceed as follows:
21.1 Close the valve in the balance line.
21.2 Eliminate the leakage.
21.3 Open the valve in the balancing line.
21.4 Continue with Instruction 20.
22 Lock the valve in the balancing pipe in the open position.
⇒ Procedure 6-9 Servicing the lube oil filter has been completed.
Maintenance 6 - 17
Procedure 6-10 Changing over the oil cooler
Prerequisites Oil pressure is present and the valve in the balancing pipe is open
NOTICE
For safety reasons, fill the clean oil cooler first with oil and only then
with cooling water. In reverse order, cooling water might enter the oil
system in case of leakage.
1 Close the shut-off valves in the cooling water lines of the shut-down oil
cooler.
2 Open the oil-side vent valve of the inactive oil cooler 2640-K-001-E1A/B.
3 Slowly switch the 3-way valve on the oil cooler over to the inactive oil
cooler.
4 Close the oil-side vent valve of the started-up oil cooler.
5 Open the shut-off valves in the cooling water lines of the started-up oil
cooler.
6 Vent the started-up oil cooler on the water side to ensure proper
operation.
6.1 Remove the blind flange.
6.2 Open the water-side vent valve.
6.3 Wait until water only escapes from the vent valve.
6.4 Close the water-side vent valve.
6.5 Reinstall the blind flange.
⇒ Procedure 6-10 Changing over the oil cooler has been completed.

Procedure 6-11 Servicing the oil cooler
■ Procedure 6-10 Changing over the oil cooler has been carried out
■ The oil cooler has cooled down
Tools One collecting vessel each for oil and for water and lifting gear of adequate
carrying capacity for the component parts of the oil cooler
1 Close the valve that has been locked in the open position in the balance
line.
NOTICE
leaking oil.
2 Empty the fouled oil cooler 2640-K-001-E1A/B on the oil side.

2.1 Open the oil-side vent valve of the oil cooler for depressurization.
2.2 Place the collecting vessel underneath the oil-side drain valve of the
oil cooler.
2.3 Remove the blind flange from the oil-side drain valve.
2.4 Open the oil-side drain valve and wait for the oil to run completely
from the cooler housing into the collecting vessel.
2.5 Close the oil-side drain valve.
2.6 Reinstall the blind flange on the oil-side drain valve.
3 Empty the fouled oil cooler on the water side.

3.1 Close the shut-off valves in the cooling water lines of the oil cooler.
3.2 Open the water-side vent valve of the oil cooler for
depressurization.
3.3 Place the collecting vessel underneath the water-side drain valve of
the oil cooler.
3.4 Remove the blind flange from the water-side drain valve.
3.5 Open the water-side drain valve and wait for the cooling water to
run completely from the cooler housing into the collecting vessel.
3.6 Close the water-side drain valve.
3.7 Reinstall the blind flange on the water-side drain valve.
4 Clean the oil cooler in accordance with the manufacturer's information or

have MAN PrimeServ or a specialized firm clean the oil cooler to ensure
that cleaning is carried out properly.
Maintenance 6 - 19
5 Open the valve in the balancing line.
6 Wait until the serviced oil cooler is filled with oil and oil flows back through
the vent line on the sightglass to the oil reservoir.
7 Check the serviced oil cooler for leakage.
Proceed as follows:
8.1 Close the valve in the balance line.
8.3 Open the valve in the balancing line.
9 Lock the valve in the balancing pipe in the open position.
⇒ Procedure 6-11 Servicing the oil cooler has been completed.

Procedure 6-12 Checking the gas pressure in the bladder accumulator
Prerequisites The oil is pressurized
Tools Filling and testing device
NOTICE
This procedure applies to both bladder accumulators.
1 Close the shut-off valve upstream of the bladder accumulator.
2 Drain the oil from the bladder accumulator.

2.1 Open the drain valve.
2.2 Wait until the complete oil quantity has drained into the oil reservoir.
2.3 Close the drain valve.
3 Connect the filling and testing device to the bladder accumulator.
4 Check the preload pressure in the bladder accumulator.
5* In case the preload pressure is smaller than the value on the rating plate:
Refill gas in accordance with the manufacturer's information until the
preload pressure is reached.
6 Disconnect the filling and testing device from the bladder accumulator.
7 Open the shut-off valve upstream of the bladder accumulator.
8 Vent the oil supply line to the bladder accumulator.

8.1 Open the drain valve.
8.2 Wait until the noise which is indicative of air bubbles has stopped.
8.3 Close the drain valve.
⇒ Procedure 6-12 Checking the gas pressure in the bladder accumulator

has been completed.
Maintenance 6 - 21
Procedure 6-13 Testing the cooling oil pump
Prerequisites The machine train and the oil system are ready for operation
1 Switch on cooling oil pump 2640-K-001-G2 manually.
2 Check the oil pressure delivered by the cooling oil pump.
3* In case the oil pressure is adequate:

Continue with Instruction 5.
→ The test has been successful.
4* In case the oil pressure is inadequate:

Have the cause determined and eliminated by MAN PrimeServ
immediately (see Section 1.4 After Sales Service).
5 Switch off the cooling oil pump and set it to automatic mode.
⇒ Procedure 6-13 Testing the cooling oil pump has been completed.

Procedure 6-14 Testing the auxiliary oil pump for automatic cut-in
■ Main oil pump 2640-K-001-G1A is in operation
■ Auxiliary oil pump 2640-K-001-G1B is set to automatic mode
1 Slowly open the shut-off valve in the test line downstream of pressure
transmitter PT 944.
→ The oil pressure at pressure transmitter PT 944 decreases below the
value at which the auxiliary oil pump cuts in automatically.
2 Check the oil pressure delivered by the auxiliary oil pump.
3* In case the oil pressure is adequate:

Continue with Instruction 6.
→ The test has been successful.
4* In case the oil pressure is not adequate:

Eliminate the cause of the malfunction immediately.
5* In case the cause of malfunction cannot be eliminated:

Take the measures below:
5.1 Have the cause determined and eliminated by MAN PrimeServ
immediately (see Section 1.4 After Sales Service).
5.2 Pay particularly close attention to the operating values of the oil
supply system so that you can manually intervene immediately if
there should be signs of malfunction.
6 Close the shut-off valve in the test line downstream of pressure

transmitter PT 944.
7 Switch off the auxiliary oil pump and set it to automatic mode.
⇒ Procedure 6-14 Testing the auxiliary oil pump for automatic cut-in has
been completed.
Maintenance 6 - 23
Procedure 6-15 Servicing the seal/separation gas filter element
■ A new seal gas filter element is available
■ A new O-ring is available
■ Shut-off valve in the pressure compensating pipe is open
CAUTION

1 Fill the non-fouled seal gas filter with seal gas.

1.1 Slowly open the vent valve of the non-fouled seal gas filter.
1.2 Re-close the vent valve when the seal gas filter is filled with seal
gas.
2 Switch the control lever on the seal gas filter over to the filter chamber of
the non-fouled seal gas filter.
3 Empty the non-fouled seal gas filter.

3.1 Briefly open the drain valve of the non-fouled seal gas filter.
3.2 Re-close the drain valve when water does not escape any longer.
4 Close the shut-off valve that has been locked in the open position in the
pressure balance line between the filters.
5 Slowly open the vent valve of the fouled seal gas filter to depressurize it.
6 Service the filter element according to the Operating Instructions for Seal
Gas System (see Chapter 10 Operating Instructions for Components).
7 Close the drain valve of the serviced seal gas filter.
8 Close the vent valve of the serviced seal gas filter.
9 Open the shut-off valve in the pressure balance line between the filters.
10 Check the serviced seal gas filter for leakage.

Proceed as follows:
11.1 Close the shut-off valve in the pressure balance line.
11.3 Open the shut-off valve in the pressure balance line.
12 Lock the shut-off valve in the pressure balancing pipe in the open
position.
⇒ Procedure 6-15 Servicing the seal/separation gas filter element has been
completed.
Maintenance 6 - 25
6.2.3 Cleaning
Regular cleaning of the machine unit increases the safety of operating

personnel and extends the service life of the machine unit. Method and
frequency of cleaning mainly depend on the conditions on the installation site,
on the ambient air and on the climate.
Procedure 6-16 Cleaning the machine unit
Prerequisites None
1 Regularly and carefully clean dust, soiling, ice and snow from the machine
unit, especially from all safety signs, walkways, handles, steps, railings,
pedestals, platforms, ladders, etc. to ensure secure footing.
2 Regularly clean all indicators and operator controls in order to ensure

readability and operability at all times.
3 Check for operating media leaks or spills.
4* In case of operating media leaks or spills:

Clean the machine unit and the foundation immediately in order to
prevent injury from falls by slipping on dirty ground and any penetration of
hazardous substances into the soil. Have the cause of any leakage
eliminated, as required.
5 Remove any tools and/or replacement parts from the machine unit which
have possibly been left lying around.
⇒ Procedure 6-16 Cleaning the machine unit has been completed.

6.3 Inspection
Inspection comprises all measures which the operating company should take
to maintain the desired condition of the machine unit.
6.3.1 Inspection plan
The inspection intervals are influenced by various factors such as:

■ Operating company's maintenance philosophy
■ Operational factors
❚ Required availability of the machine unit
❚ Quality of process gas
❚ Quality of operating media
❚ Load conditions and number of start-ups
❚ Operating hours and standstill periods
■ Other influences
❚ Age of the machine unit
❚ Ambient conditions
❚ Extraordinary occurrences (e. g. lightning, earthquake)
MAN PrimeServ recommends establishing a specific inspection plan jointly with

the operating company to ensure safe and economical operation of the
machine unit.
The dates fixed for inspections must be complied with. The machine unit must
be inspected even if there are no apparent defects. The objective of the
inspection is to detect and eliminate conceivable defects at an early stage thus
preventing downtimes of the machine unit.
In case you have operated the compressor for a total of more than 5 hours
below the minimum back-pressure line call in MAN PrimeServ to carry out an
unscheduled inspection.
Table 6-3 Recommended inspection plan

Year 1 2 3 4 5 6 7 8 9 10
Stage 1 X X X X X X X X
Stage 2 X X
Stage 3 X X
After 5 years of operation, the inspection intervals are mainly dependent on the
operating conditions and the inspection results.
Inspection 6 - 27
MAN Diesel & Turbo distinguish between the following inspection stages (see
procedures below):
■ Inspection stage 0
Routine maintenance work according to operational requirements,
carried out by the operating company's service technician during ongoing
operation, e. g. filter change. The maintenance schedule and the
maintenance work are described in Section 6.2 Maintenance.
Inspection for checking and determining the operating values and for
checking the safety systems during ongoing operation. Old or defective
seals will be replaced to ensure safe operation. The values determined are
the basis for inspection stage 3.
Inspection for checking the main components and determining the
condition of the machine unit during a short-term standstill. Also includes
the work of inspection stage 1.
General overhaul. Inspection stage 3 should be carried out 6 to 12
months after inspection stage 1. The work operations for the general
overhaul should be planned on the basis of the values determined during
inspection stage 1.

6.3.2 Performance of inspection
The activities described here require special training and expertise and must for
safety reasons only be carried out by MAN PrimeServ within the scope of the
inspections.
■ Procedure 6-17 Performing inspection stage 1

Procedure 6-17 Performing inspection stage 1

■ The operating company has issued release for work
■ 1 service technician of the operating company is available
■ MAN PrimeServ personnel are available
■ Consumables and replacement parts are available ready to use
Time requirement 2-3 days for examinations and operating data analysis, 1-2 days for reporting
NOTICE
On no account disable or dismantle the safety facilities of the
machine unit, in order to ensure safe inspection.
1 Have MAN PrimeServ carry out the following work:

❚ Analysis of operating values and operation log
❚ Analysis and assessment of findings
❚ Making recommendations
❚ Carrying out maintenance work jointly with the service technicians of
the operating company, e. g.:
❙ Replacing seals
❙ Checking automatic starting of the standby oil pump
❚ Checking the monitoring system
❚ Checking the control system
❚ Checking the auxiliary systems
❚ Preparing report
⇒ Procedure 6-17 Performing inspection stage 1 has been completed.
Inspection 6 - 29
■ The machine unit has been shut down according to Section 4.7
Measures for standstill periods and has cooled down
■ 1-2 service technicians of the operating company specialized in the field
of mechanics are available
■ The following materials are available ready to use:
❚ Consumables and replacement parts
❚ Sealants and lubricants according to the Consumption List
❚ Special tools which were supplied by MAN Diesel & Turbo along with
the machine unit
❚ Standard tools
❚ Lifting gear
Time requirement 2 days for preparation, 5 days downtime of machine unit
1 Before starting work, secure the machine unit against unintended start-
up e. g. by fitting a lock to the main switch to ensure safe inspection.
2 Have MAN PrimeServ carry out the work below:

❚ Work as for inspection stage 1
❚ Carrying out maintenance work jointly with the service technicians of
the operating company, e. g.:
❙ Checking the bearings
❙ Checking the alignment

■ Inspection stage 1 must have been carried out 6-12 months earlier for
planning the general overhaul
■ The machine unit has been shut down according to Section 4.7
Measures for standstill periods and has cooled down
■ 1-2 service technicians of the operating company each specialized in one
of the fields below are available:
❚ Instrumentation
❚ Mechanics (one per machine)

■ The following materials are available ready to use:
❚ Consumables and replacement parts
❚ Sealants and lubricants according to the Consumption List
❚ Special tools which were supplied by MAN Diesel & Turbo along with
the machine unit
❚ Standard tools
❚ Lifting gear
Time requirement Varies, depending on the configuration of the machine unit and the findings of
inspection stage 1
1 Have MAN PrimeServ carry out the work below:

❚ Work as for stage 2
❚ Carrying out maintenance work jointly with the operating company's
service technicians, e. g.
❙ Opening machines
❙ Inspecting safety facilities completely
❙ Inspecting instrumentation completely
❙ Inspecting the monitoring system completely
Inspection 6 - 31
6.4 Malfunctions
In this Section you will find all the information necessary for detecting
malfunctions and for troubleshooting.
6.4.1 Detection of malfunctions
Malfunctions on the machine unit can be recognized by you from the following
signs and by means of the following auxiliaries:
■ Critical operating values
The monitoring system of the machine unit monitors all critical operating
values according to the relevant document (see Chapter 9 Plans and
Schematics). The monitoring system triggers an alarm or a trip if a set limit
value is reached.
■ Leakage
Leakage from piping or apparatus is indicative of malfunctions which you
must correct immediately in order to avoid any risk to persons or to the
environment and to ensure safe operation of the machine unit.
■ Change in operating values
Any change in the operating values of the machine unit under constant
operating conditions is indicative of a malfunction.
■ Malfunctions on components
The operating instructions for the individual components describe how to
detect malfunctions of machine unit components (see Chapter 10
■ irds®
❚ MAN Diesel & Turbo recommend using the irds® intelligent remote
diagnostic system. irds® provides various functions such as transfer,
reception and archiving of measuring data, automatic measuring-data
analysis with e-mail notification and detailed analyses of measuring
data by MAN PrimeServ.
❚ Continuous evaluation of the long-term behaviour of the machine unit
provides for quick detection of irregularities. In case of a malfunction,
irds® gives MAN PrimeServ personnel nearly instantaneous access to
current and archived measuring data. Especially in conjunction with
service contracts MAN PrimeServ is thus given the opportunity of
quickly analysing deviations from the target state and initiating
corrective measures immediately.
❚ If you are interested in using irds®, please contact MAN PrimeServ
(see Section 1.4 After Sales Service).

6.4.2 Troubleshooting
In the event of alarm signals initially check the following points as a matter of
principle:
■ Are all shut-off valves in the impulse lines to the instruments open?
■ Are the instruments in good order?

■ Are the cables connected properly to the instruments?
Before looking for other causes remedy any defects immediately or have them
remedied.
The tables below show how to eliminate malfunctions on the machine unit. The
tables provide the following information:
■ Indication
❚ An "x" in the first column indicates that the monitoring system will
trigger a trip of the machine train if the deviation from the set-point is
too high.
❚ The second column specifies the Tag No. of the signal allocated to the
alarm.
❚ "Indication" is omitted in the case of general malfunctions which are
not indicated by a fault indication.
■ Possible cause
This column describes possible causes that may have triggered the
indicated alarm. Observe the specified sequence when tracing faults.
■ Remedy
This column gives advice on how to react to the respective malfunction.
Observe the specified sequence during troubleshooting. If you cannot
eliminate the malfunction by adopting the remedies described, please
contact MAN PrimeServ (see Section 1.4 After Sales Service).
Eliminate malfunctions which occur on the machine unit components according

to the operating instructions for the component concerned (see Chapter 10
Malfunctions 6 - 33
This Section describes the malfunctions below:
■ Malfunction 1 Bearing temperature too high
■ Malfunction 2 Shaft vibration too high
■ Malfunction 3 Casing vibrations too high
■ Malfunction 4 Excessive axial displacement
■ Malfunction 5 Flow rate in balance piston line too high
■ Malfunction 6 Process gas flow LP compressor too little (reverse flow
protection)
■ Malfunction 7 Surge event has occurred
■ Malfunction 8 Oil level in oil reservoir too low
■ Malfunction 9 Temperature in the oil reservoir outside the permitted
range
■ Malfunction 10 Differential pressure across oil filter too high
■ Malfunction 11 Oil supply pressure too low
■ Malfunction 12 The auxiliary oil pump has started automatically
■ Malfunction 13 Oil supply temperature too high
■ Malfunction 14 Escape of oil / oil mist at the labyrinth seals
■ Malfunction 15 Differential pressure across seal gas / separation gas
filter too high
■ Malfunction 16 Pressure in the seal gas supply outside the permitted
range
■ Malfunction 17 Flow rate in seal gas supply outside the permitted
range
■ Malfunction 18 Differential pressure in seal gas supply too low
■ Malfunction 19 Separation gas supply pressure too low
Malfunction 1 Bearing temperature too high

Indication 1) Possible cause Remedy
LP Compressor ❚ Consequence of Malfunction 11 Oil ❚ Carry out the remedy shown there.
x TA 942A/B/C/D supply pressure too low
x TA 942E/F/G/H
HP Compressor ❚ Consequence of Malfunction 13 Oil ❚ Carry out the remedy shown there.
x TA 942J/K/L/M supply temperature too high
❚ Mechanical problems (e. g. defective ❚ Shut down the machine train in the
seals, defective bearings, normal manner.
misalignment) ❚ Contact MAN PrimeServ.
1) Malfunctions indicated with an -x- cause a trip of the machine train if the deviation from the set-point
is too high.

Malfunction 2 Shaft vibration too high
LP Compressor ❚ Fastening means loosened ❚ Tighten all fastening means.

x VA 942A/B/C/D
HP Compressor ❚ Flow problems, e. g. caused by the ❚ Check the process gas system and try
x VA 942E/F/G/H machine train rotating in reverse to eliminate the cause.
❚ Mechanical problems (e. g. defective ❚ Shut down the machine train in the
bearings, misalignment) normal manner.
❚ Contact MAN PrimeServ.
1) Malfunctions indicated with an "x" cause a trip of the machine train if the deviation from the set-point
is too high.
Malfunction 3 Casing vibrations too high

LP Compressor ❚ Fastening means loosened ❚ Tighten all fastening means.

VA 943A
HP Compressor ❚ Consequence of Malfunction 2 Shaft ❚ Carry out the remedy shown there.
VA 943B vibration too high
❚ Mechanical problems ❚ Shut down the machine train in the

normal manner.
is too high.
Malfunction 4 Excessive axial displacement

x ZA 942A/B/C ❚ Defect on balance piston ❚ Shut down the machine train in the
normal manner.
❚ Defect in thrust bearing ❚ Shut down the machine train in the

normal manner.
is too high.
Malfunction 5 Flow rate in balance piston line too high

LP Compressor ❚ Defect on balance piston labyrinth ❚ Shut down the machine train in the
FA 937 seals normal manner on the next occasion.
HP Compressor ❚ Contact MAN PrimeServ.
FA 942
is too high.
Malfunctions 6 - 35
Malfunction 6 Process gas flow LP compressor too little (reverse flow
protection)
Y 935A (SURGE ❚ First alarm event occurred ❚ Wherever possible take measures at
ALARM LEVEL 1) the process gas end to increase the
flow rate.
Y 935B (SURGE ❚ Second alarm event occurred within a ❚ Investigate the cause of the alarm
ALARM LEVEL 2) short period of time events and eliminate it.
❚ Reset the alarm after the reverse flow
protection has completed the
envisaged actions. This will restore
normal operation of the compressor.
x Y 935C (SURGE ❚ Third alarm event occurred within a ❚ Wait until the machine train has come
TRIP) short period of time to a standstill after the reverse flow
protection has triggered a trip.
❚ Investigate the cause of the alarm
events and eliminate it.
❚ Reset the alarm.
❚ Start up the machine train again.
is too high.
Malfunction 7 Surge event has occurred

YQ 935 ❚ Unfavourable operating conditions ❚ Shut down the machine train in the
normal manner.
❚ Contact MAN PrimeServ to decide on
the further course of action.
is too high.
Malfunction 8 Oil level in oil reservoir too low

LA 936 ❚ Oil loss as a consequence of leaks ❚ Look for leaks and eliminate them, if
(e. g. in the oil cooler) any.
❚ Top up oil according to Procedure 6-5
Topping up oil.
is too high.

Malfunction 9 Temperature in the oil reservoir outside the permitted range
TA 943 ❚ During the warm-up phase: Value used ❚ Reset the alarm.
by controller
❚ During normal operation: Defect in oil ❚ Eliminate the malfunction on the oil
heater heater.
is too high.
Malfunction 10 Differential pressure across oil filter too high

Lube oil filter ❚ Oil filter fouled ❚ Lube oil filter: Change over to the clean
PDA 936 oil filter according to Procedure 6-8
Cooling oil filter Changing over the lube oil filter.
PDA 937 ❚ Clean the fouled oil filter in accordance
with Procedure 6-7 Servicing the
cooling oil filter or Procedure 6-9
Servicing the lube oil filter.
is too high.
Malfunctions 6 - 37
Malfunction 11 Oil supply pressure too low
x PXA 936A/B/C ❚ Air in the oil system ❚ Vent the oil system.
❚ Oil pressure control valve not set ❚ Set the oil pressure control valve to the
correctly specified value.
❚ Consequence of Malfunction 8 Oil level ❚ Carry out the remedy shown there.
in oil reservoir too low
❚ Consequence of Malfunction 10 ❚ Carry out the remedy shown there.

Differential pressure across oil filter too
high
❚ Oil cooler fouled ❚ Switch over to the clean oil cooler

according to Procedure 6-10 Changing
over the oil cooler.
❚ Clean the fouled oil cooler according to
Procedure 6-11 Servicing the oil
cooler.
❚ Auxiliary oil pump has not cut in ❚ Switch on the auxiliary oil pump
automatically manually.
❚ Eliminate the cause of inadequate oil
pressure.
❚ Auxiliary oil pump delivers insufficient ❚ Shut down the machine train in the
pressure or is defective normal manner.
is too high.
Malfunction 12 The auxiliary oil pump has started automatically

PA 942B ❚ Consequence of Malfunction 11 Oil ❚ Carry out the remedy shown there.
supply pressure too low
❚ Main oil pump delivers insufficient ❚ Shut down the machine train in the
pressure or is defective normal manner.
is too high.

Malfunction 13 Oil supply temperature too high
TA 944 ❚ Oil heater defective ❚ Eliminate the malfunction of the oil

heater as specified by the
manufacturer.
❚ Oil temperature control valve not set ❚ Set the oil temperature control valve to
correctly the specified value.
❚ Oil temperature control valve defective ❚ Eliminate the malfunction of the oil
temperature control valve as specified
by the manufacturer.
❚ Cooling water flow rate to the oil cooler ❚ Set the cooling water flow rate to the oil
too low cooler to the specified value.
❚ Oil cooler fouled ❚ Switch over to the clean oil cooler

according to Procedure 6-10 Changing
over the oil cooler.
❚ Clean the fouled oil cooler according to
Procedure 6-11 Servicing the oil
cooler.
is too high.
Malfunction 14 Escape of oil / oil mist at the labyrinth seals

❚ Oil mist separator switched off ❚ Switch on the oil mist separator.
❚ Filter on oil mist separator fouled or ❚ Have the filter element on the oil mist
damaged separator repaired.
❚ Negative pressure in oil reservoir not ❚ Adjust the negative pressure to 5 - 10

set correctly mbar.
❚ Ports on the oil system not properly ❚ Properly close all ports on the oil
closed system.
❚ Oil mist separator defective ❚ Have the oil mist separator repaired.
is too high.
Malfunction 15 Differential pressure across seal gas / separation gas filter too
high
PDA 935 ❚ Filter element fouled ❚ Change over to the clean seal gas /
separation gas filter.
❚ Carry out Procedure 6-15 Servicing the
seal/separation gas filter element.
is too high.
Malfunctions 6 - 39
Malfunction 16 Pressure in the seal gas supply outside the permitted range
LP Compressor ❚ Consequence of Malfunction 15 ❚ Carry out the remedy shown there.

PA 937 Differential pressure across seal gas /
HP Compressor separation gas filter too high
PA 939
❚ Shut-off valve in incorrect position ❚ Set the shut-off valve to the correct
position (see P&I Diagram).
❚ Pressure control valve not set correctly ❚ Set the pressure of the pressure control
valve to the specified value (see P&I
Diagram).
❚ Pressure control valve defective ❚ Repair the pressure control valve.
is too high.
Malfunction 17 Flow rate in seal gas supply outside the permitted range

FA 938 Pressure in the seal gas supply outside
FA 939 the permitted range
HP Compressor
FA 940 ❚ Defect in dry gas seal ❚ Shut down the machine train in the
FA 941 normal manner.
is too high.
Malfunction 18 Differential pressure in seal gas supply too low


x PDXA 936A/B/C Pressure in the seal gas supply outside
x PDXA 937A/B/C the permitted range
HP Compressor
x PDXA 938A/B/C ❚ Defect in dry gas seal ❚ Shut down the machine train in the
x PDXA 939A/B/C normal manner.
is too high.

Malfunction 19 Separation gas supply pressure too low

PA 941A Pressure in the seal gas supply outside
HP Compressor the permitted range
PA 941B
❚ Shut-off valve in an incorrect position ❚ Set the shut-off valve to the correct
position (see P&I Diagram).
❚ Pressure control valve not set correctly ❚ Set the pressure of the pressure control
valve to the specified value (see P&I
Diagram).
❚ Pressure control valve defective ❚ Repair the pressure control valve.
is too high.
Malfunctions 6 - 41
6.5 Repair
Repair will become necessary if machine unit parts show a defect. Put a
machine unit into use again only after the defect has been eliminated. For repair
work on the machine unit please contact MAN PrimeServ (see Section 1.4 After
Sales Service).
If necessary, you may return single parts of the machine unit to
MAN Diesel & Turbo for repair. If this need arises, please contact
MAN PrimeServ. A No-Objection Certificate form will then be furnished to you
which you are requested to fill in and return along with the parts concerned, as
appropriate.
For safety reasons (special tools, transport means etc.) repair work should only
be carried out by MAN PrimeServ. MAN Diesel & Turbo disclaim any
responsibility in case that repair work should be carried out incorrectly or
improperly by the operating company or by third parties.

7 Decommissioning, dismantling, and disposal

This Chapter addresses the operating company and the service technician of
machine unit Ruwais REC 2013. It provides information about the requirements
and describes the main activities for decommissioning, dismantling, storage,
and disposal of the machine unit.
For decommissioning, dismantling and disposal the information concerning

safety (see Section 2.2.8 General safety information and Section 2.3 Residual
hazards and risks) must be observed without fail.
7.1 Overview
7.1 Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-1
7.2 Decommissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-2
7.3 Dismantling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-3
7.4 Storage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-4
7.5 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-5
7-1
7.2 Decommissioning
The following procedure shows how to decommission the machine unit in order
to temporarily or finally prevent its further utilization.
Procedure 7-1 Decommissioning the machine unit
Prerequisites All procedures in Section 4.7 Measures for standstill periods have been carried
out
1 Take measures to prevent further utilization of the machine unit.
2 Purge all process gas carrying spaces and piping with nitrogen.
3 Check the machine unit for process gas residues by means of gas
detectors.
NOTICE
Even after thorough purging it cannot be assumed with certainty that
all hazardous gases have been removed.
WARNING
Risk arising from explosion of residual gas!

• Purge the machine unit with nitrogen.
• Observe the safety instructions.
• Keep away ignition sources.
4 Purge until all process gas has been expelled from the machine unit.
5 Completely isolate the machine unit from all connected systems (e. g.
process gas system, energy supply system).
6* To recommission the machine unit at a later time:

Have the machine unit provided with long-term preservation. Contact
MAN PrimeServ (see Section 1.4 After Sales Service).
⇒ Procedure 7-1 Decommissioning the machine unit has been completed.
7-2 Decommissioning, dismantling, and disposal

7.3 Dismantling
The following procedure shows how to dismantle the machine unit in order to
utilize it otherwise or to dispose of it.
Procedure 7-2 Dismantling the machine unit


Prerequisites Procedure 7-1 Decommissioning the machine unit has been carried out
1* To re-use the machine unit:

Have the machine unit dismantled by MAN PrimeServ (see Section 1.4
After Sales Service).
2* To dispose of the machine unit:
NOTICE
The operating company is obligated to place an order for dismantling
the machine unit and in particular the pressure equipment only with
specialist companies to whom the necessary devices and equipment
items as well as the required skilled personnel are available for
carrying out the work safely.
Call in a competent firm to carry out the following work:

❚ Disconnecting the power supply
❚ Disconnecting the operating media supply
❚ Draining all operating media from the machine unit
❚ Disposing of all operating media in an environmentally sound manner
in accordance with the national regulations for disposal
❚ Removing the cabling and piping connections to control panel and
machine unit
❚ Dismantling individual components of the machine unit in accordance
with the Operating Instructions for Components (see Chapter 10
Operating Instructions for Components)
❚ Dismantling the remaining plant unit parts
⇒ Procedure 7-2 Dismantling the machine unit has been completed.
Dismantling 7-3
7.4 Storage
The following procedure shows how to store the dismantled machine unit in
order to reuse it later.
Procedure 7-3 Storing the dismantled machine unit
Prerequisites Procedure 7-2 Dismantling the machine unit has been carried out
1 Have the machine unit provided with long-term preservation. Contact

MAN PrimeServ (see Section 1.4 After Sales Service).
2 Store the preserved machine parts in a dry and roofed location.
⇒ Procedure 7-3 Storing the dismantled machine unit has been completed.

7.5 Disposal
The following procedures show how to dispose of the machine unit component
parts.
■ Procedure 7-4 Disposing of packaging, operating media, wear parts,
and cleansing agents
■ Procedure 7-5 Disposing of the dismantled machine unit
Procedure 7-4 Disposing of packaging, operating media, wear parts, and cleansing
agents
Prerequisites None
1* To dispose of packaging:
Always dispose of packaging in an environmentally sound manner and in
compliance with the applicable local regulations for disposal. Call in a
recycling company, if necessary.
2* To dispose of operating media:

Always dispose of operating media in accordance with the
manufacturer's instructions, in an environmentally sound manner and in
accordance with the applicable local regulations for disposal. Call in a
3* To dispose of wear parts:

Always ensure an environmentally sound disposal of wear parts in
4* To dispose of cleansing agents:

Always ensure disposal of the cleansing agents in accordance with the
manufacturer's information, in an environmentally sound manner and in
⇒ Procedure 7-4 Disposing of packaging, operating media, wear parts, and

cleansing agents has been completed.
Disposal 7-5
Procedure 7-5 Disposing of the dismantled machine unit
Prerequisites Procedure 7-2 Dismantling the machine unit has been carried out
NOTICE
The operating company is obligated to place an order for disposal of
the machine unit and in particular of the pressure equipment only
with specialist companies to whom the necessary devices and
equipment items as well as the required skilled personnel are
available for carrying out the work safely.
1 Call in a specialist firm or contact MAN PrimeServ (see Section 1.4 After
Sales Service) to dispose of the dismantled machine unit properly.
⇒ Procedure 7-5 Disposing of the dismantled machine unit has been

completed.

8 Technical data
the key data of the machine unit.
8.1 Overview
8.1 Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-1
8.2 Machine unit data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-2
8.3 Operating data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-3
8.3.1 Switching values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-3
8.3.2 Emission values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-3
8.3.3 Operating media requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-3
8.4 Ambient conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-8
8-1
8.2 Machine unit data
In this Section you will find general technical data of the machine unit.
Table 8-1 Technical data of machine unit
Designation Value Unit
Manufacturer MAN Diesel & Turbo Schweiz AG
Year built 2013
Speed 4829 .. 5965 rpm
For the composition of the process gases and other data please refer to the API
data sheets (see Chapter 9 Plans and Schematics).
Table 8-2 ATEX classification

Designation Value
❚ Zone ❚ 2
❚ Explosion group ❚ IIC
❚ Temperature class ❚ T3
Further technical data of the machine unit will be found in document Technical
Data General Arrangement and Foundation Drawing (see Chapter 9 Plans and
Schematics).
For additional technical data of the individual components of the machine unit
please refer to the Operating Instructions for Components (see Chapter 10
8-2 Technical data

8.3 Operating data
In this Section you will find information about the operating data of the machine
unit and the requirements in respect of the operating media to be used. The
data provided are design data and may be liable to changes in the course of
operation of the machine unit. For the current operating data refer to the
operation log kept by the operating company.
The inspection intervals shown below are merely recommendations and do not
guarantee or otherwise warrant trouble-free operation.
8.3.1 Switching values
The switching values for the following situations are shown in the relevant
document (see Chapter 9 Plans and Schematics):
■ Start-up interlocks
■ Alarms
■ Tripping
8.3.2 Emission values
The noise emission data are valid for normal operation; they were determined
on the basis of the applicable standards.
Table 8-3 A-weighted sound pressure level (LPA)

Machine unit without noise control enclosure 90 dB(A)
Table 8-4 A-weighted sound power level (LWA)

Machine unit without noise control enclosure 113 dB(A)
8.3.3 Operating media requirements
In the Sections below you will find information about the operating media
requirements. The operating media used in the machine unit must satisfy these
requirements.
Operating data 8-3

8.3.3.1 Operating media quantities
The required quantities of operating media are listed in the Consumption List
8.3.3.2 Instrument air quality requirements
The instrument air must be free from dust and oil and satisfy the requirements
listed in the table below.
Table 8-5 Instrument air requirements

Operating temperature 30 °C
Particle size max. 1 μm
Particle density max. 1 mg/m3
Dew point -40 °C
Water content max. 120 mg/m3
Residual oil content max. 0.1 mg/m3
8.3.3.3 External buffer gas quality requirements
To operate the dry gas seals, only external buffer gas according to the P&I
Diagram and the Consumption List (see Chapter 9 Plans and Schematics) may
be supplied to the seal gas system.
8.3.3.4 Seal gas / separation gas quality requirements
To operate the dry gas seals and the secondary seals, only seal gas/separation
gas according to the P&I Diagram and the Consumer List (see Chapter 9 Plans
and Schematics) may be supplied to the seal gas system.
The seal gas / separation gas must be available during start-up, normal
operation, shut-down and standstill of the machine train.
8.3.3.5 Cooling water quality requirements
The cooling water must meet the requirements according to the P&I Diagram
and the Consumer List (see Chapter 9 Plans and Schematics).
8-4 Technical data

8.3.3.6 Oil quality requirements
The oil used must have the following basic properties and meet the
requirements in Table 8-6 Oil requirements:
■ Free from metals or organometallic compounds
■ High ageing stability

■ High oxidation and temperature stability
■ Low tendency to separate oil-insoluble products under temperature load,
no tendency to form film layers
■ Suitable for high service temperatures
❚ up to 120 °C (248 °F) hot-spot temperatures for turbine oils
❚ up to 135 °C (275 °F) specifically for gas turbines
■ Suitable for temperatures in continuous operation up to approx.

105±5 °C (221±9 °F)
■ Suitable for oil reservoir continuous temperatures up to max. 70 °C
(158 °F)
■ High wear-reducing effect under boundary and mixed-friction conditions
■ Favourable air release and water separation properties
■ Low foaming tendency
■ Satisfactory corrosion protection for ferrous and non-ferrous metals
Table 8-6 Oil requirements
Property Requirement Test method
Viscosity ISO VG 46 DIN 51562-1

DIN EN ISO 3104
ASTM D 445
Viscosity index min. 95 DIN ISO 2909

ASTM D 2270
Density at 15 °C (59 °F) max. 0.90 g/cm3 (56 lb/ft3) DIN 51 757
ISO 3675
ASTM D 1298
Appearance light and clear visual, 10 cm coat thickness
Colour max. 2 DIN ISO 2049

ASTM D 1500
Flash point min. 180 °C (355 °F) DIN ISO 2592

ASTM D 92
Flow point min. 10 °C (18 °F) lower than the DIN EN ISO 3016
minimum ambient temperature of the oil ASTM D 97
system, in no case, however, higher than
-9 °C (16 °F)
Operating data 8-5

Total acid number (TAN) ASTM D 664

❚ KOH without EP additives ❚ max. 0.25 mg/g
❚ KOH with EP additives ❚ max. 0.35 mg/g
Neutralization index DIN 51 558-1
ASTM D 974
❚ KOH without EP additives ❚ max. 0.25 mg/g
DIN EN ISO 2160
❚ KOH with EP additives ❚ max. 0.35 mg/g
ISO 6618 / 6619
Ash (oxide ash) max. 0.01% by mass DIN EN ISO 6245

ASTM D 482
Metals / organometallic compounds Zn / Cu : max. 5 mg/kg optional

Other: max.10 mg/kg
Water content max. 150 mg/kg DIN 51 777-1

DIN EN ISO 12937
ASTM D 1744
Water separation property after max. 300 seconds DIN 51 589

steam treatment
Water separation property at 54 °C max. 20 minutes DIN ISO 6614

(129 °F) (40-40-0) ASTM D 1401
Air release property at 50 °C (122 °F) DIN ISO 7120

ISO 9120
❚ ISO VG 32 or 46
ASTM D 3427
❚ ISO VG 68 ❚ max. 5 minutes
❚ max. 6 minutes
Corrosive effect on copper at 100 °C max. 2 DIN EN ISO 2160

(212 °F) / 3 h ASTM D 130
Corrosion protection properties in Method B: passed DIN ISO 7120

synthetic sea water ASTM D 665
Solid foreign matter with 0.45 μm max. 50 mg/kg Membrane filtration

filter
Fouling class max. 17 / 15 / 12 ISO 4406

max. 6 NAS 1638
max. 7 SAE AS 4059
Foaming characteristics DIN 51 566

ASTM D 892 (Sequence 1-3)
❚ Foam formation ❚ max. 150 / 50 / 150 ml
ISO 6247 - Sequence 1
❚ Foam stability (10 minutes) ❚ 0 / 0 / 0 ml
Load carrying ability (load stage) min. 6 ASTM D 5182

ISO 14 635-1
IP 334
EP additives (EP = Extreme Pressure) Only permitted if the required load stage -
cannot be complied with otherwise
8-6 Technical data

Table 8-7 Requirements in respect of the ageing behaviour of oils
TOST ageing stability at least 4000 hours DIN 51 587

ASTM D 943
Oxidation stability acc. to RPVOT at least 450 minutes ASTM D 2272

(Rotating Pressure Vessel Oxidation

Test)
Temperature stability behaviour of Good stability, low tendency to form MAN Diesel & Turbo internal
turbine oils films standard
Operating data 8-7

8.4 Ambient conditions
The following ambient conditions apply to the machine unit:
Table 8-8 Ambient conditions
Erection - -
❚ outdoors
❚ roofed (not heated)
❚ Mezzanine
Environment - -
❚ corrosive atmosphere
❚ potentially explosive atmosphere
Elevation above mean sea level 11 m
Barometric pressure - bar
Ambient temperature normal - °C
min. 5 °C
max. 49 °C
8-8 Technical data

9 Plans and Schematics

This Chapter addresses all users of machine unit Ruwais REC 2013. It contains
a list of the plans and schematics enclosed for operation and service and
maintenance.
Plans, schematics and spare parts drawings which refer directly to a

component are filed in the respective operating instructions for the component
concerned. For an overview of the Operating Instructions for Components
please refer to Chapter 10 Operating Instructions for Components.
Please note the following information depending on the form of Operating

Instructions used:
The documents can be found in the separate folders Plans and
Schematics of the hard copy version.
In the electronic version, a mouse click on red and underlined text will
open the indicated document.
If necessary, choose the settings in your PDF viewing application such
that each linked document is displayed in a separate window. In this way
you can toggle between several open documents at any time.
9-1
Table 9-1 List of plans and schematics
Title Drawing number
To open linked documents in a new window: Choose settings in your PDF viewing
application accordingly.
Volume 2
General Arrangement drawings
1 Arrangement of Safety Signs 10001347714
2 General Arrangement 10001347710
3 Foundation Drawing 10001347711
4 Technical Data - Foundation Drawing 10001348067
5 Transport Drawing 10001583167
P&I Diagrams and operation documents
6 P&I Diagrams 10001348058
7 List of Pipe Connections 10001348062
8 Function Diagram & Alarm List 10001348059
9 Consumption List 10001348063
10 Start-up Diagram 10001546497
11 Performance Curves 10001447825
12 Cause and Effect Diagram 10001580265
Instrumentation and Electrical Installations
13 Instrument Arrangement 10001347713
14 Instrument List 10001569201
15 I/O Signal List 10001348061
16 Field Wiring Diagram 10001475255
17 Compressor Control Narratives 10001348059 002
Miscellaneous
18 Spare Parts List LP Compressor 10001757640 / 152702
19 Spare Parts List HP Compressor 10001733689 / 152283
20 API Data Sheets -
9-2 Plans and Schematics

10 Operating Instructions for Components

This Chapter addresses all users of machine unit Ruwais REC 2013. It contains
a list of the Operating Instructions for Components enclosed for operation and
service and maintenance.
Please note the following information depending on the form of Operating

Instructions used:
The documents can be found in the separate folders Operating
Instructions for Components of the hard copy version.
In the electronic version, a mouse click on red and underlined text will
open the indicated document.
If necessary, choose the settings in your PDF viewing application such
that each linked document is displayed in a separate window. In this way
you can toggle between several open documents at any time.
10 - 1
Table 10-1 List of Operating Instructions for Components
Component Manufacturer Type Tag No.
To open linked documents in a new window: Choose settings in your PDF viewing application accordingly.
Volume 3 .. 6: Steam turbine
1 Steam turbine MAN Diesel & Turbo DK080/170R 2640-TK-001
Volume 7 .. 8: Oil system
2 Oil system Rockfin - -
3 Jacking oil pump Hartmann + Lämmle - -
4 Oil Conditioner Hydac - -
Volume 9: Seal gas system
5 Seal gas system LP De Pretto - -
6 Seal gas system HP De Pretto - -
7 Dry gas seal LP + HP John Crane - -
Volume 10: Further components
8 Proximity Probe Housings Bently Nevada 31000/32000 -
9 Probes 8 mm Bently Nevada 3300XL 8mm -
10 Container for spare rotor LP BePro TMPTC-0093 -
11 Container for spare rotor HP BePro TMPTC-0117 -
12 Lifting device 4 tons Evers - -
15 Noise insulation Novisol - -
16 Coupling 1 Euroflex RH8320 -
10 - 2 Operating Instructions for Components

List of procedures
Analysing the oil quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-8
Carrying out operation checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-18
Carrying out the hourly operation check . . . . . . . . . . . . . . . . . . . . . . . . . .4-19
Changing oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-11
Changing over the lube oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-15
Changing over the oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-18
Checking level in oil reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-10
Checking the consignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-4
Checking the gas pressure in the bladder accumulator . . . . . . . . . . . . . . .6-21
Cleaning the machine unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-26
Decommissioning the machine unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-2
Dismantling the machine unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-3
Disposing of packaging, operating media, wear parts, and
cleansing agents. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-5
Disposing of the dismantled machine unit . . . . . . . . . . . . . . . . . . . . . . . . . .7-6
Draining oil sludge from the oil reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . .6-9
Draining the machine unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-6
Enabling the control panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5
Ensuring supply and disposal of operating media . . . . . . . . . . . . . . . . . . . .5-6
Erecting the machine unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-8
Establishing the connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-9
Establishing the operating conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-14
Performing initial start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-12
List of procedures 1
Performing inspection stage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-29
Performing measures for standstill periods . . . . . . . . . . . . . . . . . . . . . . . . 4-24
Performing the daily operation check . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
Performing the installation check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
Performing transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Preparing steam turbine and allocated systems . . . . . . . . . . . . . . . . . . . . 4-14
Preparing the machine unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Preparing the place of use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Preservation of the machine unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28
Purging the machine unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
Purging the process gas system with nitrogen . . . . . . . . . . . . . . . . . . . . . 4-27
Servicing the cooling oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13
Servicing the lube oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
Servicing the oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19
Servicing the seal/separation gas filter element . . . . . . . . . . . . . . . . . . . . 6-24
Shutting down further components of the machine unit . . . . . . . . . . . . . . 4-28
Shutting down the machine train in an emergency . . . . . . . . . . . . . . . . . . 4-22
Shutting down the machine train . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23
Shutting down the oil system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25
Shutting down the steam turbine and allocated systems . . . . . . . . . . . . . 4-25
Starting normal operation of the machine train . . . . . . . . . . . . . . . . . . . . . 4-15
Starting up the oil system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Starting up the seal gas system for the atmospheric end . . . . . . . . . . . . . . 4-8
Starting up the seal gas system for the process gas end . . . . . . . . . . . . . . 4-9
Storing the dismantled machine unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
Supplying the machine unit with operating media . . . . . . . . . . . . . . . . . . . . 4-5
Taking an oil sample. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
Terminating supply of the machine unit with operating media . . . . . . . . . . 4-27
Testing the auxiliary oil pump for automatic cut-in . . . . . . . . . . . . . . . . . . 6-23
Testing the cooling oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22
Topping up oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
2 List of procedures
List of tables
Ambient conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8
Arrangement of couplings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
ATEX classification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
A-weighted sound power level (LWA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
A-weighted sound pressure level (LPA) . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
Engineering company . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Instrument air requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
List of monitored operating values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
List of Operating Instructions for Components . . . . . . . . . . . . . . . . . . . . 10-2
List of plans and schematics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
Machine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Machine unit data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Manufacturer addresses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Oil requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
Operating company . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Possible sequences for limit values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
Recommended inspection plan. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-27
Requirements in respect of the ageing behaviour of oils . . . . . . . . . . . . . . 8-7
Residual risks to persons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
Residual risks to physical assets and property . . . . . . . . . . . . . . . . . . . . 2-20
Routine maintenance work at intervals in time. . . . . . . . . . . . . . . . . . . . . . 6-3
Routine maintenance work depending on hours in operation . . . . . . . . . . 6-4
List of tables 1
Safety signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Technical data of machine unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
2 List of tables
List of figures
Hard copy of the Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4
HP compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-6
Limits of application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3
LP compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4
Machine unit Ruwais REC 2013 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2
Steam turbine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3
List of figures 1
2
List of figures
Glossary
This glossary defines terms which will facilitate your understanding of the
Operating Instructions.
The definitions are primarily guided by the European directives and standards.
Assembly A component is made up of several assemblies. Assemblies consist of one or

several component parts.
Commissioning By commissioning, the machine unit is made ready for use and handed over
to the operating company. Following handover the machine unit is in
operation.
Component A component is a self-contained functional unit which is part of the machine
unit. A component may be a machine, an auxiliary system or an individual
component part. A component is made up of individual assemblies.
Decommission- The machine unit is no longer used and is finally decommissioned. On
ing decommissioning the operation permit expires. The machine unit can only be
used again after renewed commissioning, i.e. with a new operation permit.
Handover Handover is the point in time where commissioning is completed and the
machine unit is taken over (for operation) by the operating company.
Initial start-up Initial start-up is carried out during commissioning.
Inspection An inspection is a check that is carried out regularly. At predetermined time
intervals components of the machine unit have to be partly disassembled and
the assemblies or component parts subjected to a detailed inspection. The
aim of an inspection is to determine potential sources of damage in good time,
before failures and severe damage result.
GL - 1
Intended use The intended use defines the mode of utilization of the machine unit. This
results from the design and construction of the machine unit.
Machine A machine as defined in the Machinery Directive is a totality of interconnected
parts or devices of which at least one component part is movable. A machine
may either be operative independently or only in combination with other
machines and auxiliary systems of a machine unit.
Machine train A machine train consists of machines whose rotors are coupled and co-rotate.
Machine unit A machine unit is an operational entity which is made up of individual
components. A component may be a machine, an auxiliary system or an
individual component part.
Maintenance Maintenance comprises all measures which are taken to avoid predictable
malfunctions or defects. The aim is to maintain the functional integrity of the
machine unit. Example: Regular cleaning of oil filter.
Malfunction A malfunction is a situation where the functional integrity of the machine unit is
affected or will predictably be affected in the near future. Standstill periods due
to (production) disorders within the overall process plant are not malfunctions
of the machine unit. The following situations are regarded as malfunctions of
the machine unit:
■ Trip (e. g. if set limit values are reached)
■ Alarm signals of the monitoring system
■ Deterioration of performance of functions
■ Impending deterioration of functional integrity
Normal Normal operation is an operating condition in which the machine unit fulfils, or
operation is able to fulfil, its envisaged function. Normal operation includes standstill
periods which are not caused by the machine unit itself (e. g. general
interruptions of production).
Operation Operation starts with handover of the operational machine unit to the
operating company and ends with (final) decommissioning. Operation thus
also includes any standstill periods. Standstills may be due to the following
reasons:
■ General interruption of utilization (normal operation)
■ Malfunction (special operation)
■ Service and maintenance (special operation)
Overall process The overall process plant constitutes the primary production process to which
plant the machine unit contributes a part. Within the overall process plant the
machine unit is only one of several functional units.
Procedures A procedure is a sequence of actions that have to be performed according to
instructions. These instructions form a sequence of complex, interrelated work
steps resulting in the fulfilment of a task (e. g. Starting up the steam turbine).
GL - 2 Glossary
Repair Repair includes all measures necessary to restore the required condition of the
machine unit.
Repair is required in the following instances:
■ in case of a technical defect
■ in case of a predictably occurring technical defect (e. g. if wear is
detected).
Service and Service and maintenance comprise all activities carried out to maintain or
maintenance restore the functional integrity of the machine unit. This includes maintenance,
inspection, and repair.
Shut-down Shut-down is the termination of processes or movements. It involves a
sequence of automatic functions which are performed depending on the type
of shut-down and on the program. In the case of rotating machines,
for instance, shut-down is the controlled reduction of speed up to standstill of
the rotor(s) and in the case of auxiliary systems the controlled reduction of oil
pressure, oil temperature, cooling water flow rate, etc.
The types of shut-down are as follows:
■ Manual shut-down
The operator initiates this process when he no longer needs the machine
for the intended use.
■ Trip
The unit control system triggers this process if a set limit value is reached
for which tripping is provided.
■ Emergency stop
The operator initiates this process if an emergency arises during
operation (e. g. fire, risks to people or to the environment).
Skilled person A skilled person is a person who, based on his/her special training and
experience, is capable of recognizing risks and avoiding potential hazards
which may arise from operation or service and maintenance of a product (from
EN 62079).
Special Special operation is an operating condition in which the machine unit is not in
operation normal operation, i.e. is not able to perform its intended function. The reasons
for this result from the machine unit itself. The term "special operation" is the
opposite of the term "normal operation".
Start-up Start-up is the initiation of processes or movements. In rotating machines this
is, for instance, the controlled increase of speed from standstill up to operating
speed, in auxiliary systems the controlled increase of oil pressure, oil
temperature, cooling water flow rate, etc. up to the operating value.
GL - 3
Surging Every turbocompressor typically tends to surge if it is running in unfavourable
operating conditions. This surging phenomenon occurs when, given a specific
outlet pressure, the volume flow rate falls below the respective minimum limit.
When the volume flow rate drops below the minimum value the process gas
flow stalls at critical points in the compressor. As a result, the usable cross-
section for the flow is reduced to virtually zero. The pressure built up at the
discharge end expands abruptly backwards through the compressor. This
reverse flow causes the pressure to decrease until the direction of flow
changes once again. The compressor builds up pressure again and the cycle
starts anew.
This is a cyclic process with a frequency of approx. 0.5 to 2 Hz involving high
vibration levels, heavy pulsation and a rapid temperature rise in the
compressor. This surging may result in damage to rotary or stationary
component parts of the compressor.
GL - 4 Glossary
Index
A Access assistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-14
After Sales Service
MAN PrimeServ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-9
Ambient conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-8
Assistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-12
Authorized inspector
Sphere of responsibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-10
User role . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-8
B Bladder accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-11
C Chapters of the Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4

Checks during operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-18
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-26
Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1, 5-10
Components
Design and function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3
Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-1
Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-9
Contents overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
Control oil pressure control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-11
Control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-13
Control valve chest
manual warm-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-14
Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-12
Conventions for procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-12
Index 1
Cooling oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Cooling oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Couplings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Cross-references . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
D Decommissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Depressurization rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5, 3-6
Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Dismantling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
Drainage system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
E Electronic version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Emergency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22
Emergency-stop button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Emission values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
Energy supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Engineering company . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Sphere of responsibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
User role . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Erection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
F Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
H Hard copy version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Hazard zones . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
HP compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
I Improper use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

Indicating instruments
Design and function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-27
Inspection plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-27
Inspection stages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-28
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Installation and connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Installation Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16
Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Internet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
irds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-32
2 Index
Item numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-13
J Jacking oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-10

L Leakage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-32
Literature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-16
LP compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4
Lube oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-9
Lube oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-11
Lube oil pressure control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-11
M MachineDesign
unit
and function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2
Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-2
Machine unit data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-3
Maintenance schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-3
Maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-5
Malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-32
MAN PrimeServ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-9
Manufacturer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6
Manufacturer addresses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-8
Measures
Standstill periods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-24
Monitoring system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-14
N Normal operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1
O Oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-11

Oil heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-10
Oil mist separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-10
Oil pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-10
Oil reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-10
Oil system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-9
Oil temperature control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-11
Operating company . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6
Sphere of responsibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-9
User role . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-8
Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
Operating media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-4
Operating modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-7
Index 3
Operator
Sphere of responsibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
User role . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Operator controls
Design and function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
P Place of use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Plans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
Preparation for installation and commissioning . . . . . . . . . . . . . . . . . . . . . 5-3
Prerequisites for start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
PrimeServ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Procedures
Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
Process gas coolers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Process gas piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Process gas system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Project name . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Project number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Property rights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Q Quality checks and tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15

Quality Documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16
R Recycle valve 1st stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

Recycle valve 2nd stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-42
Residual hazards and risks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
Residual risks to persons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
Residual risks to physical assets and property . . . . . . . . . . . . . . . . . . . . 2-20
Rundown tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
S Safe location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Safety concept . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Safety information
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
Natural gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
Safety signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
Seal gas / separation gas filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Seal gas control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Seal gas system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Separation gas control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Service and maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Service Bulletins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16
4 Index
Service technician
User role . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-8
Shut-down from normal operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-23
Shut-down in an emergency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-22
Site location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6
Sphere of responsibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-9
Standstill periods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-24

Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-15
Start-up interlock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-14
Steam turbine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-4
Supervisor
User role . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-8
Surge counter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-14
Swing check valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-9
Switching values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-3
Systems
Design and function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3
T Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-1

Technical expert
User role . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-8
Text markings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-12
Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-3
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1
U User
Users
roles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-8
User role . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-8
V Valves and fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-16

Visualization unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-13
W Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6
Y Year built . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6
Index 5
6
Index

Operating Instructions Machine Unit Ruwais REC 2013: MAN Diesel & Turbo

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Operating Instructions Machine Unit Ruwais REC 2013: MAN Diesel & Turbo

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Operating Instructions

Operating Instructions for Machine Unit

Rev. Changed Date Checked Date Change no. Change description

3 Design and function. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

4 Normal operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

5.2.4 Operating media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-6

6 Service, maintenance, and troubleshooting . . . . . . . . . . . . . . . . . . . . . 6-1

7 Decommissioning, dismantling, and disposal. . . . . . . . . . . . . . . . . . . . 7-1

9 Plans and Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1

10 Operating Instructions for Components . . . . . . . . . . . . . . . . . . . . . . . . 10-1

■ Operating the machine unit safely, properly and economically

1.2.1 Contents overview

This Contents overview provides information about the versions of the

Operating Instructions 1-3

Figure 1-1 Hard copy of the Operating Instructions

■ Chapter 3 Design and function

■ Chapter 4 Normal operation

■ Chapter 5 Installation and commissioning

■ Chapter 7 Decommissioning, dismantling, and disposal

dismantling, storage, and disposal of the machine unit

■ Chapter 9 Plans and Schematics

1.2.2 Target persons and obligation to read

Operating Instructions 1-5

Ensure permanent access to the current edition of the Operating Instructions by

1.3.2 Scope of validity

The Operating Instructions exclusively refer to the following machine unit:

Table 1-1 Machine unit data

MAN Diesel & Turbo project name Ruwais REC 2013

MAN Diesel & Turbo project number H.7590010

Year built 2013

Site location Ruwais / U.A.E.

Table 1-2 Machine data

LP compressor HP compressor Steam turbine

Machine type A 63-13 RB 90-5 DK 080/170R

Machine number, train 1 62011 62012 6761

Table 1-3 Operating company

Address 500 Sagil-dong, Gangdong-gu

Project name Carbon Black and Delayed Coker Project

Project number SO-2542

Order number 5636-2640-PO-MK-001

1.3.3 Property rights

Organizational measures 1-7

Table 1-5 Manufacturer addresses provides an overview of the manufacturer

Table 1-5 Manufacturer addresses

MAN Diesel & Turbo Schweiz AG

MAN PrimeServ offers the following services:

After Sales Service 1-9

1.4.2 Information in case of enquiries

1.4.4 After Sales Service network

For the services of MAN PrimeServ please visit us online at:

After Sales Service 1 - 11

The Operating Instructions describe the sequences of actions to be carried out

5* To perform maintenance work: Carry out the necessary

1.5.2 Item numbers and cross-references

Assistance and conventions 1 - 13

The Operating Instructions provide access assistance which allows quick

Quality checks and tests 1 - 15

MAN Diesel & Turbo supply a separate documentation including various

1.7.2 Service Bulletins

Observance of all safety information is mandatory for protecting all users

This Section defines the intended use of the machine unit.

Limits of application of compressors

The statements below apply analogously to both compressors.