Pulse

Operating and Maintenance Manual – Az Zour Pulse Air
________________________________________________________________________________
Alghanim International General Trading & Contracting Co.
Title Operating and Maintenance Manual
Document No. Project Document Type UNID

Code
A/ZG/CAIR-MTS-142553 KWU3026 DD01 091132701
Handling : First issue
The Project Instruction Review
Section : Document Control Section : Project Management

Designation: Document Controller Designation : Project Director
Author : Reviewed by :
Date : Date :
Document Issues
Document Index Date of Issue Description of Issue
0 08/08/2014 First Issue
________________________________________________________________________________
1
Azzour South OCGT-9 Project
Alghanim International Gen. Trad. & Cont. Co.

Co – Job: 4960
2012
Serial N.:
UCV1003286
UCV1003287
4960SN03
UCV1003288
UCV1003289
4960SN04
Operating & Maintenance Manual
Sinergia Srl
Onore . Bg . Italy
Ph +39 034673515
www.sinergia-it.com
August 8, 2014
Operation & Maintenance Manual i
INDEX
INDEX
INDEX i
LIST OF FIGURES vii
LIST OF TABLES ix
1 PREFACE 1
2 GENERAL INFORMATION 3
2.1 MANUFACTURER 3
2.2 W ARRANTY 3
2.2.1 Controversies 4
2.3 NOTES ABOUT THE PRESENT MANUAL 4
2.3.1 Characters and symbols 4
2.3.2 Target group 5
3 PRODUCT DESCRIPTION 7
3.1 3COMPRESSING UNITS 8
3.1.1 Inlet air filter 10
3.1.2 Main motor 10
3.1.3 Screw air compressor modules 12
3.1.4 Lubricating system 19
3.1.5 Cooling system 20
3.1.6 Air/water separator 22
3.1.1 Control panel 23
3.1.2 Conditions of guaranteed performance 25
3.2 DRYING SYSTEM 25
3.2.1 Baseplate 27
3.2.2 Upstream filters 28
3.2.3 Heatless dryer DH400 29
3.2.4 Downstream filters 32
3.2.5 Control panel 33
3.2.6 Conditions of guaranteed performance 35
3.3 RISKS DUE TO DESIGN LIMITS 35
4 OPERATING PRINCIPLES 37
4.1 COMPRESSING UNITS 37
4.1.1 Inlet filtration 37
ii Operation & Maintenance Manual
Pulse air system
4.1.2 Compression 37
4.1.3 Condensate separation 40
4.1.4 Lubrication 40
4.1.5 Cooling 42
4.2 DRYING UNITS 42
4.2.1 Inlet filtration 42
4.2.2 Drying 43
4.2.3 Phases duration 50
4.2.4 Outlet filtration 50
5 CONTROL SYSTEM 53
5.1.1 Capacity control 53
5.1.2 Automatic start/stop control 53
5.1.3 Remote start/stop 54
5.1.4 Remote load/unload 54
5.1.5 Power outage restart 55
5.1.6 Sequencer control and timed lead/lag 55
5.1.7 HMI screen pages 55
5.1.8 Alarms 63
5.1.9 Start and stop 65
5.1.10 Load/unload 66
5.1.11 Remote signals 66
5.2 DRYING UNITS 67
5.2.1 HMI screen pages 68
5.2.2 Setting operating mode and parameters 70
5.2.3 Start and stop 71
5.2.4 Remote signals 72
6 STAFF SAFETY 73
6.1 SAFETY SYMBOLS 73
6.2 W ARNING SYMBOLS ON THE SKIDS 80
6.3 SAFETY DEVICES 81
6.4 CORRECT AND IMPROPER USE 81
6.5 RESIDUAL RISKS 82
6.6 AUTHORIZED PERSONNEL LOCATION 83
7 LOADING AND TRANSPORT 85
Operation & Maintenance Manual iii
INDEX
7.1 LOADING/UNLOADING 85
7.2 TRANSPORT 87
7.3 DAMAGE DUE TO TRANSPORT 88
8 PACKAGING 89
9 DELIVERY TO SITE 91
9.1 UNLOADING AND LAYDOWN 91
9.2 RECEIVING INSPECTION 91
9.3 PRESERVATION 91
10 STORAGE 93
10.1.1 Temporary storage (less than 6 months) 93
10.1.2 Long term storage (longer than 6 months) 94
11 INSTALLATION 97
11.1 REQUIREMENTS FOR INSTALLATION SITE 97
11.2 RISKS TO BE REMOVED AT THE INSTALLATION AREA 98
11.3 MECHANICAL INSTALLATION 99
11.3.1 Foundation 99
11.3.2 Anchoring to foundation 101
11.3.3 Assembling and connections 101
11.4 ELECTRICAL INSTALLATION 104
12 COMPLETION ACTIVITIES 109
12.1 PRE-COMMISSIONING 109
12.2 COMMISSIONING 110
13 START-UP 113
13.1 DOCUMENT COMPILATION 113
13.2 PRELIMINARY ACTIVITIES 113
13.3 PRELIMINARY CHECKS OF THE MACHINERIES 114
13.4 READY FOR PRESSURIZATION ACTIVITIES 115
13.5 PRESSURIZATION AND TURN ON 115
13.6 INTEGRATION IN THE COMPRESSED AIR SYSTEM 117
13.7 CHECKS AFTER FIRST START-UP 118
13.8 TESTS 118
14 MONITORING 119
15 SHUTDOWN AND RESTART 121
15.1 SUBSEQUENT STARTS 123
16 ANOMALIES AND TROUBLESHOOTING 125
iv Operation & Maintenance Manual
Pulse air system
17 MAINTENANCE AND REPAIRS 133

17.1.1 Draining the water system 135
17.1.2 Pre-lube oil pump 136
17.1.3 Replacement of air filter 139
17.1.4 Replacement of oil and oil filter 140
17.1.5 Gearcase breather maintenance 140
17.1.6 Verify condensate drain functionality 140
17.1.7 Check of separator drains 141
17.1.8 Condensate strainer cleaning 141
17.1.9 Airend bearing lubrication 141
17.1.10 Seal replacement of compressor module input shaft 141
17.1.11 Motor bearing greasing 142
17.1.12 Draining the water system 142
17.1.13 Pre-lube oil pump 143
17.2 DRYING UNITS 143
17.2.1 Replacement of desiccant material 144
17.2.2 Replacement of air filter cartridges 146
17.2.3 Silencer replacement 147
17.2.4 Replacement of pilot air filter 148
17.2.5 Drain check 149
17.3 CHECK OF ELECTRICAL SYSTEM 149
18 MATERIALS DISPOSAL 150
19 APPENDIXES 151
APPENDIX A: Process and instrument diagram for pulse air I
APPENDIX B: General arrangement drawings showing maintenance and laydown area requirements for
PA II
APPENDIX C: Installation layout III
APPENDIX D: Ultralube: Safety Data Sheet IV
APPENDIX E: Molecular sieve: Safety Data Sheet V
APPENDIX F: Power supply distribution arrangment VI
APPENDIX G: Electrical load list VII
APPENDIX H: Foundation drawing VIII
APPENDIX I: Compressor long term storage procedure IX
APPENDIX J: Control system configuration X
Operation & Maintenance Manual v
INDEX
APPENDIX K: Logic control diagrams with tripping logic diagrams XI

APPENDIX L: Wiring and schematic diagrams with fixing and installation detail for local control station XII
APPENDIX M: Instrument schedule XIII
APPENDIX N: Alarm annunciator list XIV
APPENDIX O: Spare part list for commissioning and start-up XVI
APPENDIX P: Spare part list for one year operation XVII
APPENDIX Q: Packing list XVIII
APPENDIX R: Equipment manuals XIX
Operation & Maintenance Manual vii
LIST OF FIGURES
LIST OF FIGURES
Figure 3.1: General arrangement of one train of the pulse air compressing plant at the installation site.
Orange dashed rectangles indicate the compressors, while the green dashed rectangle indicate
the drying skid. Tags “11SCAxxx-xxxxx” and “12SCAxxx-xxxxx” indicate a component of the first
and second train respectively. 7
Figure 3.2: Sierra SH75WC (INGERSOLL RAND) compressing units: front (up) and back (down) sides. 9
st nd
Figure 3.3: Double stage compressor block, with indication of the 1 and 2 stages and gear box details. 14
Figure 3.4: Compressing stages: low pressure first stage (right), high pressure second stage (left). 14
Figure 3.5: First compressor stage: low pressure stage. 15
Figure 3.6: Second compressor stage: high pressure stage. Detail of the profile shape. 15
Figure 3.7: Gear box components. 16
Figure 3.8: Bearing system of the high-pressure compressor. 17
Figure 3.9: Sealing system of the high pressure compressor. 18
Figure 3.10: Inlet/blow down valve of the double stage compressor. 19
Figure 3.11: Watercooled heat exchangers integrated into the compressor package. 21
Figure 3.12: Unit control panel. 24
Figure 3.13 Drying skid with two drying lines. Main components are indicated: A pre-filters; B vessel; C post-
filter; D control panel; E baseplate; F lifting lug; G safety valve. 26
Figure 3.14: Plan view of the drying skid with indication of the fundamental components: A baseplate; B pre-
filter; C dryer column; D post-filter; E-F piping, G control panel. Main connections are indicated:
TP106A dryer A air inlet; TP106B dryer B air inlet; TP107A dryer A air outlet; TP107B dryer B air
outlet; TP108 condensate drain of the drying package. Anchor holes for lifting (located at
baseplate corners), earth lugs and hazard pictograms are indicated. 27
Figure 3.15: Baseplate drawing of the drying skid with indication of main dimensions, earth and lifting lugs. 28
Figure 3.16: Dryer tower drawing with indication of main connections: air inlet N1; air outlet N2; connection to
pressure gauge N5; spare nozzle N6; connection to safety valve N7. Each vessel is equipped
with flanged openings for desiccant material loading N3 and unloading N4; nameplate NP; lifting
lugs, supporting brackets BS and earth pales EP. 31
Figure 3.17: Dryer local control panel. 34
Figure 4.1: Principle of operation of the inlet/blowdown valve during compressor load and unload phases. 38
Figure 4.2: Air path during the adsorption phase of left tower (4960SN04B) of the dryer 11SCA01-AT001.
The inlet valve AA007 and the outlet valve AA011 are open, while the inlet valve AA008 and the
outlet valve AA012 of the other column (4960SN04A), which is regenerating, are closed. 45
Figure 4.3: Air path (blue line) during the expansion and dehumidification phases of the right tower
(4960SN04A) of the dryer 11SCA01-AT001. The inlet valve AA008 and the outlet valve AA012
are closed, while the exhaust valve AA010 is open. The inlet valve AA007 and the outlet valve
AA011 of the other column (4960SN04B) which is in adsorption (red line), are open. 47
viii Operation & Maintenance Manual
Pulse air system
Figure 4.4: Air path (blue line) during the pressurization phase of the right tower (4960SN04A) of the dryer
11SCA01-AT001. The inlet valve AA008, the outlet valve AA012 and the exhaust valve AA010
are closed. The inlet valve AA007 and the outlet valve AA011 of the other column (4960SN04B)
which is in adsorption (red line), are open. 49
Figure 5.1: LAYOUT screen page. 55
Figure 5.2: Keyboard for value insertion. 57
Figure 5.3: First HOME page. 58
Figure 5.4: Second HOME page. 59
Figure 5.5: List of monitored parameters. 59
Figure ;.6: SETTING-BASIC screen page. 60
Figure 5.7: SETTING-ADVANCE screen page. 61
Figure 5.8: SETTING- ALARMS screen pages. 61
Figure 5.9:SETTING-TRANSMITTERS screen pages. 62
Figure 5.10: ACTIVE - ALARMS screen page, showing the last activated alarm. 63
Figure 5.11: HISTORY- ALARMS screen page with memorized past alarms. 63
Figure 5.12: Screen page indicating dryer status and main controlling parameters: dew point values and past
time from last column switch. 68
Figure 5.13: Screen page indicating dryer operating modality: local or remote, under dew point control or
foxed time. 68
Figure 5.14: Screen page indicating dryer operation under dew point control. 69
Figure 5.15: Screen page indicating the operating time interval of each dryer before switching. 69
Figure 5.16: Screen pages indicating alarm states, particularly warning due to: probe transmission error of
dew point value (a); bad dew point value (b); pre-filter clogging (c); post-filter clogging (d). 70
Figure 7.1: Lifting schemes of the compressing skids: by crane (up) or by forklift (down). The total weight of
each compressor is 2800 kg. 86
Figure 7.2: Hoisting scheme of the drying skids. The total weight of the skid is ~3100 kg. The center of
gravity is specified. See Figure 3.14 for the letter legend. 87
Figure 11.1: Foundation detail for the compressors. 100
Figure 11.2: Foundation detail of the drying skids. 100
Figure 11.3: Fixing system of the compressors (left) and drying skids (right). 101
Operation & Maintenance Manual ix
LIST OF TABLES
LIST OF TABLES
Table 2.1 Special meaning of characters and symbols used in the Manual 5
Table 3.1: Technical features of the main motor. 11
Table 3.2: Technical features of air screw compressor module. 13
Table 3.3: Screw compressor parameters. 16
Table 3.4: Cooling data. 22
Table 3.5: Technical features of upstream pre-filters. 29
Table 3.6: Technical features of dryer vessels 30
Table 3.7: Technical features of downstream post-filters. 32
Table 4.1: Actuated valve position during drying phases. 44
Table 6.1: Safety symbols used in the present manual. 74
Table 6.2: Continuation of Table 6.1. 75
Table 6.3: Decals associated to the compressors. 76
Table 6.8: Forbidden situations. 82
Table 11.1: Electrical data of the compressing units. 105
Table 11.2:Continuation of Table 11.1. 106
Table 16.1: Main potential anomalies of compressing skids. 125
Table 16.6: Main potential anomalies of drying skids. 130
Table 16.7: General anomalies. 131
Table 17.1: Maintenance schedule for 4-year operation prescribed by Sinergia for the main components of
the compressing skids. 137
Table 17.4: Maintenance schedule for 2-years operation prescribed by Sinergia for the main components of
the dryers. 143
x Operation & Maintenance Manual
Pulse air system

Operation & Maintenance Manual 1
PRODUCT DESCRIPTION
1 PREFACE
The present Operation and Maintenance Manual edited by Sinergia Srl. is an important tool for a better
understanding of the functionality of the air compressing plant, correct application and maintenance in
compliance with its end use.
This Manual must be always available at the plant location and permanently well kept on the plant to which it
is associated.
The personnel in charge of installation, use, maintenance and repair of plant components must consult this
Manual before the start of any activity, and scrupulously follow all the included instructions in order to avoid
any danger, damage to equipment and injuries to personnel.
This Manual is compliant with the Machine Directive 2006/42/CE and does not take into account local
regulations that, in any case, have to be strictly observed by the personnel.
NOTE:
The Customer must be ensure that the staff in charge of any activity on the air compressor plant
is adequately trained, has read and understand all the instructions.
PRODUCT DESCRIPTION
2 GENERAL INFORMATION
2.1Manufacturer
2.2Warranty
The warranty conditions included into the contract countersigned by Hyundai Engineering & Construction
Co., LTD and Sinergia Compression S.R.L, in the Art. 29 are reported in the following.
All the Goods furnished pursuant to the Contract and/or the Work performed are guaranteed to be new,
unused and of the best quality obtainable (unless otherwise authorized by the Purchaser), to conform in all
respects to the Contract, to be free from faulty design, workmanship or Goods and/or Work, to comply with
all applicable legal requirements or other regulations commonly accepted in the industry, and to be of
sufficient size and capacity so as to fulfil in all respects any operating conditions specified in the Contract.
The warranty period shall be 12 months from the date of issue of the Provisional Acceptance Certificate
issued by the Company or 18 months after Delivery whichever comes earlier. (Expected PAC: 30 June
2014).
The Warranty is valid only in case of a strict observation of Vendor’s (Sinergia) maintenance schedule with
any assistance done by specialized staff and with obligation to use only original spare parts.
Vendor shall not be responsible for repair, replacement, or making good of any defect or damage to the
goods arising out of or resulting from any of the following causes: misuse or improper operation of the goods
by the Purchaser, operation outside of the specifications stipulated in the supply contract’s technical
conditions and normal wear and tear of parts.
Vendor is willing to replace any parts proven to be defective during the said warranty period, provided that
the contractor gives a prompt written notice and satisfactory proof of such defect by sending the part to
Vendor. If after examination (shall be completed within 2 (two) weeks after receiving Purchaser’s written
notice) this part is proved to be defective, it will be replaced free of charge. Otherwise, it will be regularly
invoiced. In case the contractor is not able to send back the defective part, Vendor ask for a regular order
and will subsequently refund the given cost only if it can be proven that the defect falls within the warranty.
If any trouble or defect in the design, Goods, Work, workmanship, operating characteristics or performance
of any part of the Goods and/or Work arises or is in danger of arising, at any time up to twelve (12) months
from the effective date of the Performance Acceptance Certificate issued by Company, and the Vendor is
4 Operation & Maintenance Manual
Pulse air system
notified thereof, the Vendor shall, at its own cost and expense and as promptly as possible thereafter, make
all alterations, repairs and replacements as may be necessary to permit the Goods and/or Work to function
in accordance with the Contract and to fulfil the foregoing warranties.
Should the Vendor fail to correct or to commence and diligently proceed with taking appropriate actions to
correct the defective Goods and/or Work within a reasonable time of being called upon to do so, the
Purchaser may, at its option, remove and correct (whether by repair or replacement) such defective Goods
and/or Work at the Vendor's expense. The Purchaser may, however, at its option, elect to accept the
defective Goods and/or Work with an adjustment in the Contract Price. If, pursuant to the above warranties,
the Vendor alters, repairs or replaces any defective Goods and/or Work, the provisions of this Article shall
then apply to such altered, repaired or replaced Goods and/or Work for a period of one (1) year from the
date on such alterations, repairs or replacements were completed.
Notwithstanding the above, in case of an emergency or any HSE related issue, the Purchaser shall have the
right to remedy the defect by itself or have it remedied by third party(ies) at the Vendor’s expense , but only
after receiving the vendor’s written consent. (at least by email) The foregoing provisions of this Article.
If Vendor fails his guarantee obligations within reasonable time from Purchaser’s notice, Purchaser reserves
the right to take directly all corrective actions to make-good the supply according to the Contract
requirements. All relevant costs will be on Vendor’s account and Vendor will be back charged for them.
2.2.1 Controversies
Court of competent jurisdiction the court of competent jurisdiction for the settlement of any disputes that
might arise shall be the court of Bergamo (Italy). Any issues not explicitly clarified in these general warranty
terms shall be solved as per the Italian Civil Code.
2.3Notes about the present manual
The present manual includes information about the assembled air compressor plant and its components
designed and constructed by Sinergia. Concerning the equipment supplied by external providers, it is
fundamental to refer to their associated manuals.
2.3.1 Characters and symbols

Characters and symbols assumed with special meaning in the Manual are listed in the following table.
PRODUCT DESCRIPTION
Table 2.1 Special meaning of characters and symbols used in the Manual
Character/Symbol Definition
It indicates a key word or phrase for the comprehension

Bold and italic test
of the test
Green test It indicates a component of the drying skids

Blue test It indicates a component of the compressing units
 …………………………… It indicates a list of relevant features
 …………………………… It indicates a list of included components
 ………………………………… It indicates the steps of an activity that must be done in

the given sequence
o It indicates a sub-list of features
It indicates a sub- sub-list of features or components

-
(used for detailed specifications)
NOTE: It provides an advise to perform an operation as safe

…………………………………………………… and efficient as possible or an important remark
WARNING! It indicates the risk of potential material damages and it

provides recommends to avoid them
…………………
DANGER! It indicates the risk of potential serious injuries, and it

………………… provides recommends to avoid so dangerous situations
2.3.2 Target group

The present Manual addresses to the personnel in charge of installation, use, inspection, maintenance,
repair of the air compressor plant or any other activity with/on this machinery.
The staff must be specialized and authorized by the Manufacturer to perform all the necessary activities.
In case the personnel have not the required competences, training and proper instruction must be provided.
Sinergia can take responsibility for the necessary training under the Client request.
The Customer has to establish clearly the areas of responsibility and supervision of the personnel and must
ensure that the personnel fully understand the contents of the present Manual.
PRODUCT DESCRIPTION
3 PRODUCT DESCRIPTION
The air compressing plant for pulse air supply is intended to compress and dry air. It includes two trains,
each one constituted by:
 couple of compressing skids, which include a two stages, screw, oil free and water cooled
compressor coupled with inlet air filter, main motor, coolers, air/water separators and lubricating
system;
 couple of heatless dryers assembled on the same skid;
Figure 3.1 shows the general arrangement of each train at the final installation site with the interconnecting
piping between compressors and dryers.
Dryers:
Compressor: Compressor:
11/12SCA01-AT001
11/12SCA01-AN001 11/12SCA02-AN001
11/12SCA02-AT001
Figure 3.1: General arrangement of one train of the pulse air compressing plant at the installation site.
Orange dashed rectangles indicate the compressors, while the green dashed rectangle
indicate the drying skid. Tags “11SCAxxx-xxxxx” and “12SCAxxx-xxxxx” indicate a
component of the first and second train respectively.
NOTE:
Note that, all the interconnecting piping between are supplied by Sinergia.
In the following, the compressing and drying packages are described separately. Note that the
components/equipment are mentioned with the associated tags as per the P&ID drawings (APPENDIX A) in
different colors: orange for the compressors, green for the dryers. The following prefixes will be omitted for
brevity;
Pulse air system
 11SCA70 and 11SCA71 for the first 11SCA01-AN001 and second 11SCA02-AN001 compressors
respectively of the first train (Serial n.UCV1003286, UCV1003287);
 12SCA70 and 12SCA71 for the first 12SCA01-AN001 and second 12SCA02-AN001 compressors
respectively of the second train (Serial n.UCV1003288, UCV1003289);
 11SCA72 for the dryers 11SCA01-AT001 and 11SCA02-AT001 of the first train (Serial n. 4960SN04);
 12SCA72 for the dryers 12SCA01-AT001 and 12SCA02-AT001 of the second train (Serial n.
4960SN03).
3.13Compressing units
Each train includes two compressors model Sierra SH75WC (Figure 3.2), manufactured and supplied by
INGERSOLL RAND. The Sierra compressor is an electric motor driven, two stage, and dry screw
compressor complete with accessories piped, wired and baseplate mounted. It is a totally self–contained oil
free and water-cooled compressing package .A standard compressor is composed of the following:
Each compressing package (see Figure 3.2) includes:
 baseplate;
 sound attenuating canopy with quick-latch panels for easy accessibility and motor driven fan for air
cooling;
 inlet air filter;
 main motor;
 two compressing stages;
 lubricating system, which includes:
- gear case/sump;
- oil filter;
- oil pumps;
- oil cooler;
 first stage intercooler;
 inter stage condensate separator with automatic condensate drains;
 second stage after cooler;
 final stage condensate separator with automatic condensate drains;
 control instruments;
 control panel;
 valves;
 interconnecting piping for air, oil, water, condensate;
 electrical system;
 safety provisions.
PRODUCT DESCRIPTION
The motor and airend are integrally mounted. This assembly is isolated from the base by rubber isolation
mounts. Flexible pipe connections are used where necessary to isolate the main base and customer
connections.
Figure 3.2: Sierra SH75WC (INGERSOLL RAND) compressing units: front (up) and back (down) sides.
Pulse air system
3.1.1 Inlet air filter

The inlet air filter is a dry type self-cleaning filter, which allows reaching efficiently a high filtration degree
(99.9%) of particles of 3 micron and above.
The filter is equipped with a local differential pressure indicator (DPI-CP501) and a differential pressure
transmitter (DPIT-CP081) to monitor potential filter clogging. This instrument is smart type, Hart protocol,
complete of 5 way manifold and stainless steel tubing for connection.
The filter is equipped with a self cleaning system based on injection of compressed air taken from the outlet
line of the compressor and regulated by the temporized solenoid valve AA008. The break/work time intervals
are set as 10 and 1 seconds respectively.
3.1.2 Main motor

The Sierra compressing package is equipped with high performance Leroy Somer main electric motor
model LS 250 M, which is realized according to the EC 34 – “Rotating Electrical Machines”, IEC 72 –
“Dimensions and Output ratings” and IEC 85 – “Classification of Electrical Insulation”.
The motor is equipped with the “low voltage option pack” which includes:
 space heaters fitted to the motor stator. They provide trouble-free starting, and eliminate problems
caused by condensation (loss of insulation). They require independent power supply: 200/240V,
single phase, 50 Hz, to be connected in the starter box. The heaters must be switched off while the
motor is running.
 tropicalization, suitable for ambient with H.R. 95% and above;
 set of Resistance Temperature Detectors (RTD) PT 100, fitted to the motor windings, one per
phase, for thermal protection. Each PT100 is connected to Intellisys (tripping the machine);
 set of Resistance Temperature Detectors (RTD) PT 100 sensor on the bearings (1 on Non Drive
End and 1 on Drive End Bearing). Each PT100 is connected to Intellisys (tripping the machine).
The motor is a squirrel cage induction motor, foot and flange mounted. The frame design is specified to
provide maximum strength and rigidity for bearing support, uniform stator/rotor gap and permanent alignment
of all mating parts. The motor is integrally mounted with the airend. The assembly is isolated from the base
by rubber isolation mounts.
In order to utilize the inherent efficiency advantage of the motor and the airend, it is necessary to efficiently
transmit the power from the driver to the compressor. The integral gear drive system was chosen because
it is the most efficient, reliable and rugged design. Conservatively chosen speed optimizing gears are
mounted on the shafts from the male rotor and motor. The metric flanged motor is doweled for permanent
alignment to the airend. High quality gears drive the airend to rotate at a specific speed which allows
maximum airend efficiency. The gear housing is completely sealed against atmospheric contaminants to
ensure lifetime trouble free power transmission.
The main general features are:
 Duty type: S1;
 Service factor: 1.25;
 Service condition:
- Altitude (max): 1000 m a.s.l.;
- Temperature: 46 °C;
 Enclosure protection degree: IP55;
PRODUCT DESCRIPTION
 Mounting: B35;
 Insulation class: F;
 Temperature class: B;
 Drive: direct;
 Rotation: Counter clockwise (from drive end);
 Bearings:
- DE/ N-DE: 6314C3 / 6216C3;
- Grease: CPN 92844729;
- Grease amount: 20 g
Vacuum degassed ball bearings for the non-drive end and roller bearings for the drive end provide
dependable and reliable service. The motor shaft has the largest available standard diameter. This
means that larger bearings are fitted. These oversized bearings have an average applied life of
135,000 hours, which is approximately eight times greater than a standard bearing life. Both
bearings are grease lubricated with bearing housings having grease nipples and relief plug fittings to
simplify the lubrication procedures.
 The main technical features: are listed in Table 3.1.
Table 3.1: Technical features of the main motor.
Feature Unit of measure Value
Installed power kW 90
Adsorbed power kW 78
N. of poles - 2
Voltage V 415
Frequency Hz 50
Phase number - 3
Current Nominal A 147
Full load A 127
Locked rotor A 1307
Efficiency at full load % 95.22
Power factor (p.u) at full load % 0.899
Maximum speed at full load r.p.m. 2975
Motor speed r.p.m. 2955
Locked rotor torque / Nominal

% 317
load torque
Breakdown rotor torque /

% 383
Nominal load torque
Weight kg ~410
Pulse air system
3.1.3 Screw air compressor modules

The compressing unit includes two compressing stages:
st
 1 stage, low-pressure compressor stage;
nd
 2 stage high-pressure compressor stage.
The screw compressing modules are twin-shafted rotating displacement machines. The compression
principle is based on a purely rotational action. Each screw compressing stage includes male and female
rotors, which are the only moving parts of the module. Both rotors are equipped with screw-shaped lobes
(teeth), with very little clearance between them, and flutes. They run into the rotor housing, generating a
positive displacement. The inlet and outlet of the compressor medium takes place via special profiled
opening contours in the compressor stage housing.
The rotors are manufactured from high quality forged steel and stainless steel. First-stage rotors are
machined from E35 steel and second-stage rotors from X20CR13 stainless steel (400 series). Rotor
housings are in cast iron: GG20 (DIN 1691) material no. 0.6020. Components are machined and assembled
to ensure that tolerances are kept within the designed specifications. This is essential to producing airends
and compression modules with required performance and durability.
The suction side drive shaft is on the male rotor, in carbon steel, with cylindrical end.
The compressor stages are completely dry, namely lubrication is not used. Due to the absence of
lubrication, male and female rotor profiles must mesh in a contact-free manner, but with the smallest possible
gaps in between. To this aim, the high quality precision AGMA 12 class gearing is installed on the rotor
shafts.
The temperature immediately downstream each compressing stage is monitored by a temperature element
and a temperature indicator transmitter: TE-CT001 and TIT-CT001 for the first stage, TE-CT003 and TIT-
CT003 for the second stage.
0 0
The compressors are designed to operate at ambient temperature ranging from 2 C to 46 C. When
conditions other than the design levels described are encountered, contact the Manufacturer for additional
information.
The technical and performance features of the compressor modules are listed in Table 3.2.
PRODUCT DESCRIPTION
Table 3.2: Technical features of air screw compressor module.
GENERAL DATA
3
Capacity FAD ISO 1217 2009 Anne C at 10 bar(g) m /min 10.7
Compressor shaft power at 10bar(g) kW 78

3
Specific power at 10 bar(g) kW/m /min 7.3
UNLOADED COMPRESSOR SHAFT POWER
Unloaded kW 16
Full load operating pressure bar(g) 10
Maximum off line pressure bar(g) 10.2
Minimum operating pressure bar(g) 5
COMPRESSION MODULES
st nd
Rotor diameter (1 -2 stage) mm 108-72.9
st nd
Male motor speed (1 -2 stage) RPM 16133-19120
st nd
Tip speed (1 -2 stage) m/s 91-73
LUBRICATION DATA
Oil pressure -normal operation Bar(g) 3.1

o
Oil temperature-normal operation C 57
Oil pump Positive displacement, gear type
Sump capacity lt 34
Total system capacity lt 40
In the following, the features of the compressor module components are briefly illustrated.
3.1.3.1 Compressor block

The double stages compressor block, as Figure 3.3 shows, includes:
 low-pressure compressor stage;
 high-pressure compressor stage, with oil cooled housing;
 compressor stages flange-mounted directly to gear box;
 oil tank combined with gear box;
 oil pump driven directly by drive shaft; flange mounted on the outside.
Pulse air system
st nd
Figure 3.3: Double stage compressor block, with indication of the 1 and 2 stages and gear box details.
3.1.3.2 Compressor stages
Figure 3.4: Compressing stages: low pressure first stage (right), high pressure second stage (left).
st
The 1 low pressure compressing stage shown in Figure 3.5 is mainly characterized by:
 air-cooled rotor housing with exterior cooling fins;
 rotors arranged one upon the other.
nd
The 2 high pressure compressing stage shown in Figure 3.6 is mainly characterized by:
 liquid-cooled rotor housing with cooling jacked (by poached oil);
 rotor arranged side by side.
PRODUCT DESCRIPTION
Figure 3.5: First compressor stage: low pressure stage.
Figure 3.6: Second compressor stage: high pressure stage. Detail of the profile shape.
Pulse air system
Table 3.3: Screw compressor parameters.
Operative levels Unity of measure Value

3
Flow rate Nm /min 7.8
0
Operating temperature in/out C 46/46.3
Operating pressure in/out barg Atm / 10

0
Design temperature C -10÷+100
Design pressure barg 12
The module is equipped with an inter–stage safety valve (PSV-AA003) set at 3,1 bar(g), and a second stage
safety valve (PSV-AA002) set at max. 11,3 bar(g). The design of the pressurized system is well above the
safety valve settings.
3.1.3.3 Gear box

The gear box SG-CF502 arrangement is shown in Figure 3.7. The main feature of the gear box are:
 drive shaft sealed with single lip seal;
 driving wheel and pinion with helical toothing;
 sturdy antifriction bearings;
 coupling for oil pump driven directly by drive shaft.
Figure 3.7: Gear box components.

PRODUCT DESCRIPTION
The gearcase is vented by a mounted breather. The breather prevents oil vapor from escaping the sump
area. The breather exhaust is piped outside the airend canopy.
If minor leaks occur in the rotary single lip seal, they can collect in the exterior area of the sealing cover and
they are drained from there through a small connection pipe. Eventual leakages are returned directly to the
gear box’s oil tank through a re-feeding. To this aim, it is necessary to attach the pre-assembled tube to the
dedicated hose.
3.1.3.4 Bearing and sealing

 The bearing system includes (Figure 3.8):
o integral bearing housing with vertical split (discharge side);
o four cylindrical anti-friction roller bearings for the radial load support of the rotors;
o two ball bearings for the axial (thrust) load support of the rotors;
Since these air ends are designed to deliver a continuous flow of oil-free air it is essential that only
the finest quality oil and air seals are used. All air seals are made of stainless steel and all oil seals
are of a time proven labyrinth design. One set of air seals on each rotor is also vented to further
eliminate any chance of oil leakage into the chamber.
Figure 3.8: Bearing system of the high-pressure compressor.
 The sealing system is constituted by (Figure 3.9):

o compression side sealing system: the compression chamber is sealed toward the bearing area
by a sequence of floating stainless steel spring-supported metal rings (wear-free) that are
arranged with minimal clearance on the coated rotor shaft;
o oil side sealing system: the oil-lubricated bearing area is sealed toward the compressor
chamber by a combination of brass labyrinth seal ring (wear-free) and re-feeding thread;
o Sealing vent: the oil side and compression side sealing areas are separated by an
intermediate space that is ventilated outward via a drill hole, thus approximating atmospheric
pressure. The vented set of air seals on each rotor is used to further eliminate any chance of
oil leakage into the compression chamber. A compression medium leakage flow unavoidably
Pulse air system
escapes through all sealing vents, except from the suction side sealing vents of the low-
pressure compressor stages. This leakage can be up to 2% of the suction volumetric flow rate;
however, it is already calculated out of the guaranteed delivery quantity of the compressor
module.
Figure 3.9: Sealing system of the high pressure compressor.
3.1.3.5 Coating
Both the rotors and the internal surfaces of the cast iron chambers are treated with a special Ultracoat™
coating to preserve them from corrosion. Ultracoat™ is a patented process that robotically applies a micro
coating of organic, high temperature resins with PTFE and Molybdenumdisulfide to specially prepared
surfaces. This process creates a mechanical bond of coating to metal. Furthermore, it increases the
efficiency limiting the clearances with the air end (rotor to rotor / rotor to housing). Since the rotors are pinion
gear driven, no rotor contact can occur; consequently, this precisely applied coating should last the life of the
airend.
3.1.3.6 Inlet valve

The compressor module is equipped with an unique, fail-safe inlet throttle and blow off valve (Figure
3.10) with mechanical interlock to reduce the torque that the compressor system needs to start up and
because allow conserving energy when the unit is idle. This valve ensures that the system works dependably
thanks to the mechanical coupling function between inlet valve and relief valve and the hydraulic control.
The valve takes control of the two operational modes of the compressor: loaded and unloaded.
PRODUCT DESCRIPTION
Figure 3.10: Inlet/blow down valve of the double stage compressor.
The valve main components are:

 hydraulic control cylinder with internal spring for relief resetting: it opens or closes the air inlet
passage, guarantying a minimum quantity of air for the first stage cooling when the compressor is
unloaded;
 solenoid valve AA007 to control the cylinder operation;
 suction inlet valve VB-001;
 blow off valve GV-001 specifically designed for high temperatures (discharge temperatures);
 lever to connect mechanically control cylinder, inlet valve and relief valve.
The blow-down valve is operative under oil pressure and it opens during unloaded operation, expelling any
compressed air from the package.
The suction pressure is monitored by the indicator transmitter PIT-CP103.
3.1.3.7 Venturi nozzles

The noise at the discharge side flanges of both the compressing stages is attenuated by means of venturi
nozzles, which reduce the high frequency pulsations in the flow. Consequently, the downstream
components (e.g. coolers) are protected against peak pressure levels and noise emissions are reduced (in
conjunction with downstream noise reducers).
3.1.4 Lubricating system

The lubricating system is necessary to treat the lube oil required to lubricate gears and bearings and activate
the inlet/blow down valve.
The constituting main components are:
 oil sump, integral with the gear case SG-CF502;
 main lube oil pump (positive displacement), driven by the shaft, to provides lubricant to all bearings
and gears;
Pulse air system
 one stand-by, pre lube oil pump motor driven;

 lube oil cooler;
 duplex oil filters: two full flow oil filters, Spin-on type, with flow selector valve. The filters are rated
for 4 micron and above;
 overpressure valve PSV-AA001, which discharges the oil into the sump in the case that the circuit
pressure overcomes 6.1 bar(g).
 SAE “O” Rings to provide for positive alignment of all connections and eliminate leakage paths
common on other types of threated connections;
 gear case breather: replacement cartridge separates gear case oil mist during gear case ventilation
and vents into plenum area of enclosure to prevent vapour from being drawn into first stage inlet;
 control instruments:
- temperature control valve TCV-CT106, which controls the fast warm-up and a proper
operation temperature under any operation conditions; in fact it merges cooled (from the oil
cooler) and hot oil (from the oil tank) prior to deliver it to the duplex oil filter.
- temperature gauges TG-CT501 and TG-CT502 along the cooling water lines to and from the
oil cooler;
- temperature element TE-CT005 and indicator transmitter TIT-CT005 of the oil temperature at
the outlet of the second compressing stage;
- pressure indicator transmitters PIT-CT101 and PIT-CT102, to control the pressure before and
after the duplex oil filter;
- differential pressure indicator DPI-CT102, to control the pressure drop on the duplex oil
filters; this parameters allow monitoring potential filter clogging;
 interconnecting piping within oil reservoirs, oil pump, oil cooler, thermostatic valves, oil manifolds,
instruments and oil lubricant ports on the airend is realized in stainless steel 316L.
NOTE:
The compressors are supplied already filled with ULTRACOOLANT oil.
3.1.5 Cooling system

The compressor is water-cooled. The cooling system is integrated into the compressor package and single
inlet/outlet point connections are provided for cooling water at the side of the compressor package.
A cooling water solenoid valve YY-AA004 is installed within the cooling water manifold for starting/stopping
of the cooling water inlet flow. Cooling water flows in parallel through all the coolers, namely intercooler, after
cooler and oil cooler.
Isolation valves are installed on both the water inlet and outlet lines.
All the coolers are of surface type, namely the working fluids do not enter into contact during the heat
transfer, but they are separated by a heat transfer surface, which plays an active role. Particularly, they are
shell and tube exchanger, meaning that they consists of a copper stainless steel tube bundle (series of
tubes) enclosed by a shell.
PRODUCT DESCRIPTION
The intercooler and after cooler are “water in the shell” design. Consequently, the compressed air that must
be cooled flows into the tube bundle, while the cooling water runs into the shell, over the outside surfaces of
the tubes, so that it can adsorb the required heat.
The oil cooler employs “water in the tube”, thus the cooling water flows into the tube bundle, while the oil
flows into the shell.
Furthermore, the exchangers are of countercurrent type namely, the fluids flow in opposite directions,
improving the cooling efficiency. The heat exchangers are capable of cooling the compressor under
continuous full load conditions 24 hours/day. The cooling technical data are listed in Table 3.4.
Figure 3.11: Watercooled heat exchangers integrated into the compressor package.
The tube bundle of the coolers is secured at the extremities to the tube sheets and single segmental
baffles are used to support the tubes and to enable a desirable velocity to be maintained for the shell side
fluid. They are responsible for obstructing and redirecting the flow of fluid in the shell side. In fact, they direct
the water through the shell so that the water does not take a short cut through the shell side leaving
ineffective low water volumes. Baffles are fixed to the tube bundle in order that the bundle is still removable
for maintenance, and they are normal to the walls of the shell and force the water to flow at right angles to
the axis of the tubes. The increased turbulence results in greater heat transfer. Moreover, the baffles help in
keeping the tubes from sagging and increase the strength of the tubes by preventing their failure by flow-
induced vibration.
The Ingersoll Rand watercooled heat exchangers are completely design according the lastest version of
T.E.M.A. class “C”. These standards include: pressure classification, design of floating head, gasket, tube
sheet, channel and bonnet, nozzle, flange, tube, shell, baffle and temperatures, testing procedures,
Corrosion allowances and service limitations.
Pulse air system
Table 3.4: Cooling data.
COOLING DATA (46 °C max ambient temperature)
Heat removal @ 20 °C included latent heat:

- Intercooler - 1000kJ/h - 128
- Aftercooler - 1000kJ/h - 125
- oilcooler - 1000kJ/h - 36
Aftercooler inlet temperature ( at full load) °C 180
Aftercooler Cold Temperature Difference CTD °C 8.3

o
(based on 38 C and 40% relative humidity)
Maximum added static pressure Pa 62
Rejected heat 1000kJ/h 24
Water temperature rise @ 27 °C °C 12.8
Water pressure drop @ 5 bar inlet bar 0.4
Cooling water pressure min-max bar(g) 3-10
Maximum operating temperature °C 38
Maximum flow rate l/min 91
3.1.6 Air/water separator

The built–in intercooler and after-cooler reduces the discharge air temperature well below the dew point (for
most ambient conditions), therefore, considerable water vapor is condensed. To remove this condensation,
each compressor is furnished with two moisture separator/solenoid valve combinations, installed after the
intercooler and after the after-cooler. The drainage is managed by a temporized solenoid drain valve
(AA005/AA006). The valve is set to open for 1 seconds every 2 minutes. The two drains are collected in a
common single header.
Manual valves are installed to intercept (normally opened) and to bypass (normally opened) the temporized
drain valves. They are useful to check the operation of the solenoid valves and to perform maintenance
activity allow draining; to this aim open the bypass valve and close the intercepting one.
A strainer is provided upstream the condensate valves to prevent any particles from plugging the solenoid
valve.
The dripleg assembly and isolation valve are mounted near the compressor discharge. A drain line must be
connected to the condensate drain in the base.
A check valve is installed between the solenoid drain valve and the intercepting drain valve of the inter
stage separator; since this line is a low pressure point, the valve aim is to avoid potential condensate back
flow into the separator.
The temperature in the separators is monitored by the temperature element (TE-CT002/ TE-CT004) and
indicators (TIT-CT002/ TIT –CT004), while the pressure by the pressure indicator transmitter (PIT-CP104/
PIT-CP105).
PRODUCT DESCRIPTION
3.1.1 Control panel

Each compressor is equipped with an integrated Local Control Panel (LCP).
The control system is furnished with the Human Machine Interface (HMI) device, which is a graphical
interface that displays the status of the processes, the operating parameters such as temperatures,
pressures and other system variables, service devices, permissive and protective interlocks, etc....
The aim of this device is to provide operators, personnel in charge maintenance and management with the
tools necessary to access, control, set and view the parameters of a process.
The panel is integrated in the canopy of the compressing unit and characterized by:
 material: carbon steel;
 color: blue
 single-door on front side;
 protection degree: IP 65 enclosure.
Inside the LCP are installed: power distribution, PLC system and marshaling terminal strips with interposing
relays mounted on the front mounting plate.
On the front-side of the LCP are mounted (Figure 3.12):

 SIEMENS SIMATIC touch HMI KTP400 comfort panel;
o Display: 4.3 inch TFT widescreen display, 16 Mio colors;
o Resolution: 480 x 272 px;
o Installation cutout: 122 x 98 mm (W x H);
o Front panel: 140 x 116 mm (W x H);
o Device depth: 48 mm;
o Control elements:
- touch screen;
- 4 function keys with LED.
o User memory: 4 MB;
o Interfaces:
- 1 x RJ 45 Ethernet for PROFINET
- 1 x RS 485/422 for PROFIBUS/MPI
- 1 x USB-host, 1 x USB- device
- 2 x SD card slot
 Green lamp to indicate power supply;
 Emergency red mushroom pushbutton.

The LCP requires the power supply 415Vac / 50Hz / 3 Ph (including auxiliaries).
Pulse air system
The system of protection includes:

 thermal-magnetic circuit breaker;
 automatic circuit breaker;
 fuses;
 power terminal;
 all necessary electrical protections for safe and proper functioning.
Figure 3.12: Unit control panel.
Fuses, relays and terminal strip are installed to protect and exchange all necessary signals between PLC,
and DCS.
The PLC system is characterized by:

 CPU: SIMATIC S7-1200, CPU 1214C;
 Analog modulus: SIMATIC S7-1200, SM 1231, 8AI;
 Compact switch module CSM 1277.
The PLC is provided already configured and programmed to perform the logic sequence and functionality.
Application software has been developed with Development Application Tools provided by PLC system
supplier.
For detailed information about control refer to the wiring and schematic diagram (APPENDIX L).
PRODUCT DESCRIPTION
WARNING!
Presence of electrical supply!
Risk of electrical shock.
3.1.2 Conditions of guaranteed performance

Sinergia guarantees the compressing package performance:
 Flow rate: 7.8 Nm /min;
3
 Operating pressure: 10 barg;

 Operating temperature: 46.3 C;
o
under the following working conditions:

 Cooling water:
o Operating pressure: minimum 3 barg, maximum 10 barg;
o
o Maximum operating temperature: 38 C;
o Maximum flow rate: 91 LPM.
Each compressing module produce a sound level in “free field conditions” (per CAGI/PNEUROP, ±3 db(A))
of 76 db(A).
3.2Drying system
Each train includes ta couple of heatless dryers installed in parallel on the same skid (see Figure 3.13).
Pulse air system
G G
D
B B B B
D
A AA A CC C C
F E F
Figure 3.13 Drying skid with two drying lines. Main components are indicated: A pre-filters; B vessel; C
post-filter; D control panel; E baseplate; F lifting lug; G safety valve.
Each dryer is essentially constituted by:

 duplex upstream coarse coalescing pre-filters Walker filtration Model A203XA;
 heatless dryer;
 duplex downstream dust protection post-filters Walker filtration Model A203RX1;
 control pa;
 interconnecting piping;
 control instruments;
 electrical system;
 valves.
Figure 3.14 shows the plan view of the drying skid with indication of the fundamental components.
PRODUCT DESCRIPTION
Figure 3.14: Plan view of the drying skid with indication of the fundamental components: A baseplate; B
pre-filter; C dryer column; D post-filter; E-F piping, G control panel. Main connections are
indicated: TP106A dryer A air inlet; TP106B dryer B air inlet; TP107A dryer A air outlet; TP107B
dryer B air outlet; TP108 condensate drain of the drying package. Anchor holes for lifting
(located at baseplate corners), earth lugs and hazard pictograms are indicated.
The two dryers are identical and they can operate in parallel or one as the alternative to the other, namely
one works while the other is in standby. Each dryer is independent from the other; consequently, each dryer
is supplied with its wet air inlet and dry air outlet connection and its own control panel as shown in Figure
3.14.
In the following, the main dryer components are illustrated. For details of the equipment position mentioned
by green characters see APPENDIX A.
3.2.1 Baseplate
The baseplate is 3.95 m long, 1.6 m wide, 0.97 m high (including supports of skid components) and it is
constituted by painted, carbon steel beams S275J2 (painting in agreement with the Client painting
specification). It is equipped with lifting lugs for skid loading, unloading and placement, and stainless steel
plaque soldered with the basement on all the skid edges for ground connection (see ).
On the bottom flanges of the external baseplate beams there are the holes to anchor the baseplate to the
foundation (18).
Pulse air system
Figure 3.15: Baseplate drawing of the drying skid with indication of main dimensions, earth and lifting
lugs.
3.2.2 Upstream filters

A couple of coarse coalescence filters is installed in parallel at each dryer inlet connection for the treatment
of compressed air before drying. They are model A203XA, produced and supplied by Walker filtration.
They are designed to work one as the alternative to the other. To this aim, at the inlet line of each filter a
actuated valve is installed (AA017/AA018 for pre-filters of the dryer SCA01, AA019/AA020 for pre-filters of
the dryer SCA02 to intercept the standby filter and allow air flowing to the operating one.
Main pre-filters features are listed below:
 each filter includes one filtrating elements. The filtering material is needle-felt synthetic fiber;
 casing material: aluminum alloy;
 quality of outlet air in accordance with the ISO 12500-1 regulations;
 design code: ASME VIII Div. 1 Ed. 2013;
 technical features: Table 3.5.
PRODUCT DESCRIPTION
Table 3.5: Technical features of upstream pre-filters.

3
Flow rate Nm /h 400
Design pressure bar(g) 15
Operating pressure bar(g) 8.85
Design temperature °C -10÷+80
Operating temperature °C +46.3
Filtration degree micron 0.01
Pressure drop (clean-dirty) bar 0.1-0.4
Weight kg 4.4
Corrosion allowance mm 0
Pre-filters are equipped with:

 air inlet/outlet threated connections;
 drain threated connection;
 differential presure indicator (PDI-CP501/CP502 for pre-filters of the dryer SCA01, PDI-
CP505/CP506 for pre-filters of the dryer SCA02).

Each filter is connected to:
 differential pressure switch (PDIS-CP081 for pre-filters of the dryer SCA01, PDIS-CP083 for pre-
filters of the dryer SCA02) with interception valves and 5 ways stainless steel manifold equipped with
needle valves for drain, compensation and interception;
 automatic floating drain trap;
 drain manual intercepting valve (normally open);
 drain manual bypass valve (normally closed);
 downstream intercepting manual valve.
3.2.3 Heatless dryer DH400

Each dryer includes a couple of vessels for simultaneous adsorption and regeneration phases.
Main features of vessels are listed below:
 designed in compliance with ASME VIII Div. 1 Ed. 2013;
 Construction materials: carbon steel:
o vessels: shell SA106 Gr.B, head SA234 Gr.WPB
o fittings, flanges: SA105;
o pipes: SA106 Gr.B;
o plates: SA516 Gr.70;
Pulse air system
 filling drying material: molecular sieve;

 designed to receive saturated inlet air;
 technical features of vessels: Table 3.6.
Table 3.6: Technical features of dryer vessels
Inlet flow Nm3/h 400
Outlet flow Nm3/h 360
Average purging air Nm3/h 40
Operating air inlet temperature °C 46.3
Max admissible pressure @ temperature 80 °C bar(g) 15
Min temperature at @ pressure 15 bar(g) °C -10
Pressure drop bar(g) 0.3
Dew point °C @ -25 @

bar(g) atmospheric
Drying material content kg/vessel 110
Vessel volume lt 146
Empty vessel weight kg 171
Hydrotest weight kg 317
Corrosion allowances mm 2
As Figure 3.16 shows, each vessel is equipped with:

 inlet (N1) and outlet (N2) flanged connections;
 flanged connection for desiccant material loading (N3);
 flanged connection for desiccant material unloading (N4);
 nozzle (N5) for pressure gauge connection;
 spare nozzle (N6);
 nozzle (N7) for pressure safety valve connection;
 lifting lugs;
 earth plates;
 supporting brackets.
PRODUCT DESCRIPTION
Figure 3.16: Dryer tower drawing with indication of main connections: air inlet N1; air outlet N2;
connection to pressure gauge N5; spare nozzle N6; connection to safety valve N7. Each vessel
is equipped with flanged openings for desiccant material loading N3 and unloading N4;
nameplate NP; lifting lugs, supporting brackets BS and earth pales EP.
Each vessel is connected to:

 pressure gauge (PG-CP507/CP508 for towers of the dryer SCA01, PG-CP509/CP510 for towers of
the dryer SCA02);
 pressure safety valve (PSV-AA013/AA014 for towers of the dryer SCA01, PSV-AA015/AA016 for
towers of the dryer SCA02) set to a pressure of 15 bar(g);
 inlet: actuated valve for switching (AA007/AA008 for towers of the dryer SCA01, AA001/AA002 for
towers of the dryer SCA02);
 actuated exhaust valve (AA009/AA010 for towers of the dryer SCA01, AA001/AA002 for towers of
the dryer SCA02) and muffler;
 outlet: actuated valve (AA007/AA008 for towers of the dryer SCA01, AA003/AA004 for towers of the
dryer SCA02);
 purge valve;
 non return valve on the purge line.
Pulse air system
A dew-point transmitter (AT-CM102 for dryer SCA01, AT-CM101 for dryer SCA02) is installed on the outlet
line of each dryer for the control of the efficiency of the desiccant process.
3.2.4 Downstream filters

A couple of coarse coalescence filters is installed in parallel at each dryer inlet connection for the treatment
of instrument air to obtain the required high-level of purity. They are model A203RX1, produced and supplied
by Walker filtration.
They are designed to work one as the alternative to the other. To this aim, at the inlet line of each filter a
actuated valve is installed (AA021/AA022 for post-filters of the dryer SCA01, AA023/AA024 for post-filters of
the dryer SCA02 to intercept the standby filter and allow air flowing to the operating one.
Main pre-filters features are listed below:
 each filter includes one filtrating elements. The filtering material is needle-felt synthetic fiber;
 casing material: aluminum alloy;
 quality of outlet air in accordance with the ISO 12500-1 regulations;
 design code: ASME VIII Div. 1 Ed. 2013;
 technical features: Table 3.5.
Table 3.7: Technical features of downstream post-filters.

3
Flow rate Nm /h 360
Operating temperature °C +46.3
Filtration degree micron 1
Pressure drop (clean-dirty) bar 0.1-0.4
Weight kg 4.4
Corrosion allowance mm 0
Pre-filters are equipped with:

 air inlet/outlet threated connections ;
 drain threated connection;
 differential pressure indicator (PDI-CP503/CP504 for pre-filters of the dryer SCA01, PDI-
CP511/CP512 for pre-filters of the dryer SCA02).

Each filter is connected to:
PRODUCT DESCRIPTION
 differential pressure switch (PDIS-CP082 for pre-filters of the dryer SCA01, PDIS-CP084 for pre-
filters of the dryer SCA02) with interception valves and 5 ways stainless steel manifold equipped with
needle valves for drain, compensation and interception;
 drain manual valve (normally closed);
 downstream intercepting manual valve.
3.2.5 Control panel

Each dryer is equipped with its Local Control Panel (LCP) with the following main features:
 construction material: carbon steel;
 dimensions: 600x400x250 mm;
 degree of protection: IP 54;
 equipped with Siemens Micro PLC LOGO! TD logic module;
 power supply: 240 V/ 1 Ph/ 50 Hz;
 current: 3.3 A;
 installed and adsorbed power: 0.8 kW.
On the front side the following components are mounted (see Figure 3.17):
 Siemens LOGO! TD Text Display;
 indicating lamps:
o green lamp to indicate power supply;
o white lamp to indicate dryer operation;
o red lamps to indicate alarm state.
The system of protection includes:

 automatic circuit breakers;
 fuse disconnector;
 all necessary electrical protections for safe and proper functioning.
Pulse air system
Figure 3.17: Dryer local control panel.
Main features of the Programmable Logic Controller (PLC) are:

 Base module: LOGO! Basic 12/24V RCE with main features:
o Power supply 12/24 V DC;
o 8DI, 24 V DC (I1, I2 I7, I8: 0…10 V);
o 4DO, 10 A per relay;
 Two digital Expansion modules: DM8 12/24R with main features:
o Power supply V DC;
o 4DI, 12/24 V DC;
o 4AO, 5 A per relay;
 Text display: LOGO! TD with main properties:
o alimentazione elettrica indipendente dalla polarità 12 V DC or 24 V AC/DC
o IP65 se montato correttamente sul pannello;
o 4 lines with 12/16 characters per line;
o 6 standard and 4 additional Function Keys (F1-F4) as momentary inputs.
The PLC is provided already configured and programmed to perform the logic sequence and functionality.
The micro Programmable Logic Controller (PLC) controls all automatic operations:
 automatic valves of dryers;
PRODUCT DESCRIPTION
 dryer cycles based on dew point value control or fixed times;

 dryer alarms;
 dryer switch.
ì
WARNING!
Risk of electrical shock.
NOTE:
Sinergia does not supply cable glands for Customer side.
3.2.6 Conditions of guaranteed performance

Sinergia guarantees the dryer performance under the following working conditions:
 max inlet/outlet temperature: +46.3°C;
 operating inlet pressure: 8.85 bar(g);
 inlet flow: 400 Nm /h;
3
 operating outlet pressure: 8.65 bar(g);

 outlet flow: 360 Nm /h;
3
 regenerating air: 40 Nm /h (10%);

3
Under previous conditions, the following values of main parameters are guaranteed:
 dew point: -25°C @ outlet conditions;
 particle size: 0.01 micron;
 noise limit: 85 dB pondered at 1 m of distance.
3.3Risks due to design limits
In agreement with the Client’s requirements, the skids are not designed and constructed to withstand the
below conditions, which could cause both material damages and personnel injuries.
 Accidental loads:
the skids are not designed in order to support the additional stresses due to:
o further loads located above the dryer;
o snow;
o rain;
Pulse air system
o wind;
o seismic hazard.
 Fire:
the skids are equipped with safety valves, which could discharge overpressure due to temperature
increase. They are not equipped with further fire prevention systems (see Section 11.2).
 Accidental impacts:
the skids are not protected against accidental impacts, that must be taken into account depending on
the installation site.
The Client must provide to remove the associated risks at the installation site (see Section 11.2).
OPERATING PRINCIPLES
4 OPERATING PRINCIPLES
Each compressing and drying train includes a couple of compressing units and a couple of heatless dryers
designed to work one as the alternative to the other.
In fact each compressor can be set to follow an automatic lead/lag sequence and changeover every a set
time interval, as described in Section 5.1.6, while the dryers can be set to switch every a set time interval, as
described in Section 5.2.1.
In the present section, the operating principles of the compressing and the drying systems are illustrated
separately.
In this section, the operating principles of the compressing unit is described. Particularly, the following main
phases are described:
 inlet air filtration;
 air compression;
 condensate separation;
 lubrication;
 cooling.
4.1.1 Inlet filtration

The air enters the compressor through an opening at the right end of the enclosure. It travels through a
passageway lined with sound–absorbing material to the air filter. Crossing the filter, particles included into
the air are entrapped. The filter guarantees a considerable protection of the 99.9% from particles larger than
3 microns.
The inlet air filter is a dry type self-cleaning suction filter, which allows reaching efficiently a high filtration
degree (99.9%) of particles of 3 micron and above.
At the outside of the air filter, a silencer reduces the strong induced noise.
A differential pressure indicator transmitters DPIT-CP081and a local differential pressure indicator (DPI-
CP501 allow controlling the pressure drop across the filter, which is indication of the filter efficiency. In fact,
excessive values indicates filter clogging, thus they are signaled by an alarm.
To maintain the filter clean, compressed air is taken from the outlet line and injected on the filter following
break/work time intervals regulated by the solenoid valve AA008.
4.1.2 Compression
From the filter outlet, .via a round flexible hose, the air passes through the inlet/blow down valve BV-001
into the first compressing stage. This valve id described in Section 3.1.3.6. The suction pressure is
monitored by the pressure transmitter PIT-CP103; if the pressure is lower than the limit set according to the
load/unload status, an alarm or a shutdown (if negative) signal is transmitted.
Pulse air system
In the following, the function of this valve during the load and unload operation is illustrated, referring to the
Figure 4.1.
When the compressor is under full load operation, the inlet valve BV-001 (included into the blow down
valve) is open and suctions the ambient air. The control cylinder activates the inlet valve opening. In fact,
under load, the oil is loaded from the lube oil header into the cylinder due to the open position of the solenoid
valve AA007 in the direction from the oil header to the compressor. Consequently, due to the compression of
the internal spring, the inlet valve mechanically opens. Simultaneously, the relief valve (GV-001), whose
position is induced by the cylinder too, is closed and the relief line, both from the first and the second stages
is under pressure (this is the meaning of the “compressed medium” direction in the full load scheme of the
figure).
RELIEF VALVE
INLET VALVE
RELIEF VALVE
INLET VALVE
Figure 4.1: Principle of operation of the inlet/blowdown valve during compressor load and unload phases.
When the compressor is in unload operation, the solenoid valve is closed in the direction from the lube oil
header, while is open in the direction from the compressor to the lube oil header. Consequently, the
pressurized oil is discharged and the spring of the cylinder relaxes inducing the closure of the inlet air valve
and, via mechanical linkage, the opening of the relief valve. Thus, the air included in the relief line is
discharged to the atmosphere thought the silencer installed downstream the relief valve.
Note that:
 all the air line up to the second stage aftercooler, prior to the non-return valve CV-002, is
depressurized;
 the inlet valve is not completely closed, but a small amount of air is admitted to cool the first
compressing stage.
Under full load operation the first compressing stage compress the air from the atmospheric pressure to a
pressure between 1.7 to 2.6 bar(g).
The operating process of the screw compressing stage includes three main phases:
 Suction
In the meshing profile of the rotor couple, as the male rotor lobe exits from a flute in the female rotor
at the intake side, a chamber is formed (namely between the locking pair of lobes and the forward-
moving lobes). The chamber into which the gas flows has a closed V-shape. As rotation continues,
the filled flute leaves the intake port and migrates to the discharge end. The space on the inlet side is
continually expanded by the rotation of the rotors and reaches its maximum when the lobe profiles
cut off the inlet opening.
 Compression
Moving to the opposite side of the rotor pair, the male rotor lobe enters the flute of the female rotor
reducing the size of the previously formed chamber. Consequently, the gas is shifted to the still-
closed outlet and it is continuously compressed through the steady reduced working chamber.
The compression, which is determined by the geometry of the outlet contours (the “built in pressure
ratio”), is thereby reached.
 Exhaust
Before the male rotor lobe completely fills the flute of the female rotor thus, the chamber size
decreases approaching to zero, the gas reaches the outlet opening through which it is discharged.
The size of this aperture determines the length of time during which the gas remains in the flute, and
the pressure at which the gas is discharged.
These phases repeat various times (according to the number of lobes in the male rotor) at every rotation of
the male rotor, resulting in a quasi-continuous, low pulsation flow,
Then, the air is discharged through a Venturi nozzle, which dampens any pressure pulsation that may be
present and delivered to the intercooler.
The inter-stage is equipped with the pressure safety valve PSV-AA003, a safety device against abnormally
overpressures (higher than 3.1 bar.g).
Then the inter-stage separator removes any condensation that may be included into the air under certain
conditions of ambient humidity and temperature.
The temperature at the inter-stage separator (second stage inlet temperature) is controlled by the
temperature transmitters TIT-CT002, while the pressure (second stage inlet pressure) by the pressure
transmitter PIT-CP104. In case of excessive values of temperature or pressure, the compressor shutdown is
activated.
See the Sections 4.1.5 and 4.1.3 for the operating principles of the cooling and separation processes.
After the moisture separation the air is delivered to the second compressing stage, to reach a compressing
pressure of 10 bar.(g). The operating principle of the second stage is similar to that of the first stage except
that in the first stage the rotor housing is air cooled by exterior cooling fins, while in the second stage, it is
liquid cooled by a cooling jacked.
Note that, expansion joints prevent vibrations transmission. The compressed outlet air is dampened by the
Venturi nozzle and delivered firstly to the after cooler, which reduces the air temperature from a
Pulse air system
o o
temperature of 180 C to 46.3 C and then to the final stage separator for removal of moisture included into
the air.
Upstream the after cooler it is installed a check valve to prevent any air backflow into the compressor.
Consequently, as previously noted, during the compressor unload operation, the air piping up to this valve
becomes depressurized, while downstream it remains under pressure.
The final stage is equipped with the pressure safety valve PSV-AA002, a safety device against abnormally
overpressures (higher than 11.3 bar.g).
The discharge temperature at the final-stage separator (second stage inlet temperature) is controlled by the
temperature transmitters TIT-CT004, while the discharge pressure by the pressure transmitter PIT-CP105. In
case of high values of temperature, an alarm triggers, while if the pressure is excessive the compressor
shutdowns.
4.1.3 Condensate separation

A condensate separator is installed downstream the intercooler and the after cooler, to collect and drain any
condensation formed from the compressed air.
The separators are designed taking advantage of the cyclonic phenomena. Thanks to rotational effects and
gravity water droplets are separated from air. In fact, a high speed vortex is established within the separator
shell (cyclone). Air flows in a helical pattern, beginning at the top of the cyclone and ending at the bottom
end before exiting the cyclone in a straight stream through the center of the cyclone and out the top. Larger
(denser) particles in the rotating stream have too much inertia to follow the tight curve of the stream, and
strike the outside wall, then falling to the bottom of the cyclone. The gravity facilitates this process.
The condensate is drained through electrically operated solenoid
valves. Both valves are set to open for 5 seconds every 2 minutes.
Manual valves are located on the outside and right side of the
sub–base (refer to General Arrangement drawing
Trapped condensate accumulates ad the bottom of the separator and it is removed through the temporized
solenoid drain valve (AA005/AA006), which is set to open for 10 seconds every 3 minutes.
In case of maintenance, the solenoid valve can be intercepted (closing the intercepting valves) and
bypassed (opening the bypass valve), maintaining the plant in operation.
4.1.4 Lubrication
The lubricating circuit is necessary to treat the lube oil, which lubricates gears and bearings, cools the
second compressing stage and activates the inlet/blowdown valve.
4.1.4.1 Oil supply

The oil amount required for lubrication is loaded into the oil sump integrated into the gear case.
The toil temperature is monitored by the temperature transmitter TIT-CT005; if the measured temperature is
over the set threshold, the compressor shutdowns.
The oil circuit is equipped with a overpressure valve PSV-AA001, which prevents overpressures,
discharging the oil into the sump if the circuit pressure overcomes 6.1 bar(g). It also regulates the oil
pressure and may divert some oil flow back to sump.
4.1.4.2 Oil pumping

Two oil pumps pump the oil from the sump to the oil circuit. The main pump is integrated with the
compressing module within the gear case. It is a positive displacement gear–type pump, and it is driven by
the compressor shaft, therefore, it rotates at the main motor speed.
Furthermore, the system is equipped with an auxiliary, pre-lube pump, driven by an electrical motor. It is
used during the compressor start-up to fill the oil circuit up to the normal pressure operation conditions. After
10 sec. this pump stops, while the main pump continue to operate.
Note that, if the emergency stop pushbutton is activated, the auxiliary lube oil pump automatically stops.
From the pumps, the hot oil travels across the pressure relief valve PSV-AA001 to the oil cooler.
A check valve is installed downstream both pumps to prevent oil backflow during pump stand-by.
o
Since the required oil temperature for the lubrication functions is about 60 C, the thermostatic control valve
TCV-CT106 intercepts the oil coming from the oil cooler and directly from the oil sump, and merge them to
provide oil at the optimum temperature for bearing and gears.
The temperature of the oil injected into the compressing stages is then monitored by the temperature
element TE-CT005 and transmitted by transmitter TIT-CT005. In the case of excessive temperature, the
compressor shutdowns.
4.1.4.3 Oil filtration

Downstream the oil cooler, the oil is filter by a duplex oil filter. The two filters can operate together, in parallel,
or one as the alterative of the other, namely one works while the other one is in stand-by. The operating
modality is selected by the 3 ways inlet valve installed on the filter-connecting pipe. It has to be manually
regulated to direct the flow to both filters, or to one of the two. The purpose of this device is to increase the
service life of the filters by using both in parallel or allowing one of the filters in stand-by for maintenance
activity while the unit is in operation.
At each filter outlet, a check valve prevents air backflow to the standby filter.
Lube oil to be filtered enters in the filter casing and passes through the filtering cartridges where the filtering
material entraps contamination particulates, particles, oil deposits (e.g. due to oxidation) and acids. Dirty oil
accumulates at the bottom of the casing.
The pressure upstream and downstream the filters is measured by the transmitters PIT-CP101 and PIT-
CP102 respectively, while the transmitter DPI-CP102 monitors the pressure drop across the filters. An alarm
triggers if the pressure drop overcomes a set limit threshold, meaning that the duty filter is clogged and it
requires maintenance.
4.1.4.4 Oil distribution

Once the oil is filtered, it is delivered through a distributing manifold to the compressing modules, the gear
case and the load/unload valve.
Coolant for bearing and gear lubrication is injected through the “bearing and gear lubrication line”.
Pulse air system
The gear case is vented to a mounted breather. The breather prevents oil vapor from escaping the sump
area.
The oil pressure downstream the oil pumps is about 2.8 – 3.6 bar(g), at normal operating temperature (54 –
0
63 C), while along the lubrication lines, downstream the distributing manifolds the pressure required for gear
and bearing lubrication is about 1.5÷2 bar(g).
Before the oil injection into the second stage, the temperature transmitter TIT-CT005 monitors the oil
temperature and gives a shutdown signal for excessive temperatures.
4.1.5 Cooling
The air/oil cooling is achieved using water. The purpose of the coolers is to cool the air coming from the
o
compressing stages to a final outlet temperature of 46.3 C, related to a maximum inlet water temperature of
o o
38 C and a Cold Temperature Difference (CTD) of 8.3 C.
The cooling is achieved using the simple principle that if a hot fluid and a cold fluid are separated by a heat-
conducting surface, heat can be transferred from the hot fluid to the cold one.
The air cooler receives the air in the tube bundle and the cooling water at the shell side. The two fluids enter
into close contact through the tube bundle and the baffles. While the cooling water runs into the shell, over
the outside surfaces of the tubes, the hot air flows into the tube bundle countercurrent. The heat content is
exchanged from one fluid to the other and vice versa, consequently the air, which flows in the tubes, cools,
while the water adsorbs heat.
The operating principle of the oil cooler is the same, except that the oil flows at the shell side, while the
cooling water in the tube bundle.
4.2Drying units
Each train includes a couple of completely independent heatless dryers, as shown in Figure 3.1. The two
dryers can work one as the alternative to the other, namely, when the duty dryer operates, the other one is in
stand-by.
The operating principles of the two heatless dryers are identical, thus in the following they are described
referring to a single unit, particularly the dryer SCA01.
The fundamental phases of each heatless dryer operation are:
 inlet filtration;
 heatless drying;
 outlet filtration.
See APPENDIX A for details of equipment position mentioned in the following paragraphs by green
characters.
4.2.1 Inlet filtration

Compressed air is delivered to the filtration unit, which includes a couple of coarse coalescer pre-filters,
which work one as the alternative to the other. The air access to one filter or the other is automatically
controlled by the actuated valves installed upstream (AA017/AA018), one for each filter. Each pre-filter can
be totally intercepted for maintenance thanks to the manual valve installed downstream. The pre-filters
protects the adsorbent material by removing liquids and reducing the contamination level of compressed air;
in fact they are able to remove solid particulate larger or equal to 0,01 μm.
Furthermore, condensate, which accumulates at the bottom of the filter casing, is delivered to the drain main
collector through the floating drain trap. A manual valve (normally open) is installed upstream each drain trap
to intercept it and a bypass manual valve (normally closed) is installed to bypass it in case of maintenance or
emergency.
At the filter outlet the air is delivered to the dryer, in particular to the column that is in the adsorption phase
through the inlet actuated valve (AA007 or AA008).
A differential pressure switch (PDIS-CP081), common to both the pre-filters, allows monitoring the pressure
drop across the duty filter. If the differential pressure is over the set alarm threshold (300 mbar) an alarm
triggers, meaning that the filter is clogged and needs to be substituted. Consequently the two filters switch,
namely the actuated valve upstream the duty pre-filter closes (blocking the filter operation), while the
actuated valve upstream the other pre-filter opens, making it operative.
A five ways manifold with needle valves is installed upstream the differential pressure switch to allow
isolating it in case of maintenance, draining and compensation. Furthermore, a couple of manual valves is
installed to ensure the pressure switch isolation.
Each filter is also equipped with a differential pressure indicator (PDI-CP501/CP502) which allows local
monitoring of the pressure drop.
4.2.2 Drying
Dryer operating includes two main phases:
 adsorption;
 regeneration.
4.2.2.1 Adsorption
Filtered and saturated air enters at the bottom side of the column in adsorption phase through the associated
inlet actuated valve (AA007 or AA008) and crosses the adsorption material bed (molecular sieve). As air
flows up through this “on line” tower, its moisture content adheres to the desiccant surface and it is retained
within the required dew point value. Dry compressed air is then discharged from the tower to post-filtration.
Thanks to inlet air entering at the bottom of the “on line” tower and flowing up through the desiccant bed,
liquid condensate caused by system upset is kept away from the desiccant and remains at the bottom of the
tower from where it can be easily exhausted during the regeneration cycle.
A solid-state controller automatically cycles the flow of compressed air between the two towers, while the “on
line” tower is drying, the “off line” tower is regenerating.
At the column outlet, a percentage of desiccated air (10 %) is delivered to the regenerating column through
the purge valve, while the remaining amount is conveyed to the after-filters for further purification. The non-
return valves installed on the purge lines allow the air flux in the correct direction.
Figure 4.2 shows the path of compressed air from the inlet point to the outlet one during the adsorption
phase of column B (4960SN04B for dryer 11SCA01-AT001, 4960SN03B for dryer 12SCA01-AT001). During
this step, the inlet valve AA007 and the outlet valve AA011 are open, while the exhaust valve AA009 is
Pulse air system
closed. In the same time, the parallel line is in regeneration phase, thus the inlet valve AA008 and the outlet
valve AA012 of the column B are closed.
In the represented case the duty pre-filter is that activated by the valve AA018, consequently, the valve
AA017 is closed. Concerning the after filtration, the duty post-filter is that activated by the valve AA021,
consequently, the valve AA022 is closed.
Note that, if the dryer in stand-by, the valve AA021 remains open, while the valve AA022 is closed.
On the other hand, during the adsorption phase of column A (4960SN04A for dryer 11SCA01-AT001,
4960SN03A for dryer 12SCA01-AT001), the inlet valve AA008 and the outlet valve AA012 are open, while
the exhaust valve AA010 is closed. In the same time, the parallel line is in regeneration phase, thus the inlet
valve AA007 and the outlet valve AA011 of the column B are closed.
Table 4.1 lists the valve position during all the drying phases.
Table 4.1: Actuated valve position during drying phases.
Column A Column B
Column A
Column B
End phase Inlet Outlet Blow off Inlet Outlet Blow off
Regeneration
condition valve valve valve valve valve valve
AA008 AA0012 AA0010 AA007 AA0011 AA0009
Depressurization open open closed closed closed open

Regeneration
Dehumidification Cycle time> 6 min open open closed closed closed open
Adsorption
Pressurization Cycle time> open open closed closed closed closed

control cycle (6-
60 min)
Column switch
Depressurization closed closed open open open closed

Regeneration
Dehumidification Cycle time> 6 min closed closed open open open closed
Adsorption
Pressurization Cycle time> closed closed closed open open closed

control cycle (6-
60 min)
Column switch
Stand-by closed closed closed closed closed closed

Figure 4.2: Air path during the adsorption phase of left tower (4960SN04B) of the dryer 11SCA01-AT001.
The inlet valve AA007 and the outlet valve AA011 are open, while the inlet valve AA008 and the
outlet valve AA012 of the other column (4960SN04A), which is regenerating, are closed.
Pulse air system
4.2.2.2 Regeneration
One column is in the regeneration phase while the other one is in adsorption.
Regeneration (purging or “offline” cycle), is the process by which moisture accumulated during the “on line”
cycle (adsorption) is stripped away.
This phase includes three steps:
 expansion;
 dehumidification;
 pressurization.
Expansion
During the expansion the column is depressurized, namely the pressure inside the tank is discharged into
the atmosphere, dragging outside part of the moisture entrapped into the adsorbing material.
When column B (4960SN04B for dryer 11SCA01-AT001, 4960SN03B for dryer 12SCA01-AT001) is in
expansion the actuated inlet valve AA007 and outlet valve AA011 are closed. The pressurized air flows from
the top to the bottom of the tower and is discharged through the actuated valve AA009 and the silencer.
On the other hand, when column A (4960SN04A for dryer 11SCA01-AT001, 4960SN03A for dryer 12SCA01-
AT001) is in expansion the actuated inlet valve AA008 and outlet valve AA012 are closed. The pressurized
air flows from the top to the bottom of the tower and is discharged through the actuated valve AA010 and the
silencer.
Figure 4.3 shows the air path during expansion in column A.
Figure 4.3: Air path (blue line) during the expansion and dehumidification phases of the right tower
(4960SN04A) of the dryer 11SCA01-AT001. The inlet valve AA008 and the outlet valve AA012
are closed, while the exhaust valve AA010 is open. The inlet valve AA007 and the outlet valve
AA011 of the other column (4960SN04B) which is in adsorption (red line), are open.
Pulse air system
Expansion phase ends when the vessel pressure equals the atmospheric one.
Dehumidification
During the dehumidification, a percentage of dry air taken from the dryer outlet is delivered to the column
that is in the regeneration phase. As low-pressure and dry purge air flows gently through the regenerating
bed, from the top to the bottom of the tower, it attracts the moisture accumulated on the surface of the
desiccant during the adsorption phase, and exhausts it to the atmosphere.
In the present case, about the 10% of dry air (purge air) is delivered through the purge valve and the purge
line to the top of the column in regeneration (A or B). The check valves installed along the purge lines,
upstream the towers, prevent the air flux in the wrong direction. The moisture evaporates tanks to the dried
airstream and it is discharged to the atmosphere through the actuated valve (AA009 after column B or
AA0010 after column A) and the silencer.
Air path during dehumidification in columns A is the same shown in Figure 4.3.
Pressurization
After dehumidification, the column in regeneration is bringing back to the working pressure to avoid pressure
oscillations on the network when it is switched to the adsorption phase. To this aim, the actuated valve
(AA009 for column B or AA010 for column A) closes.
Air path during pressurization in columns A is shown in Figure 4.4.
Figure 4.4: Air path (blue line) during the pressurization phase of the right tower (4960SN04A) of the dryer
11SCA01-AT001. The inlet valve AA008, the outlet valve AA012 and the exhaust valve AA010
are closed. The inlet valve AA007 and the outlet valve AA011 of the other column (4960SN04B)
which is in adsorption (red line), are open.
Pulse air system
When pressure reaches the working value, the regenerated column is ready to start a new adsorption cycle.
The column that was in the adsorption process is automatically switched to regeneration and vice versa.
4.2.3 Phases duration

The desiccant material quantity has been designed to have a minimum regeneration cycle period.
The dryers can operate in two different modes: “fixed time mode” or “dew point control mode”.
In the first case, a total cycle period of 12 minutes (6+6 min) is required:
 adsorption: 6’;
 depressurization and purge: 4’;
 pressure build-up: 2’;
 stand-by –.
The moisture loading is affected by inlet temperature, pressure, relative humidity and flow. These conditions
vary throughout the day and rarely combine perfectly to produce maximum moisture loads. An inlet
temperature drop can significantly reduce the moisture load. Dryers are sized for “worst case scenario”
operation, with the fixed time control mode to accommodate maximum moisture loads, but since a fixed
duration cycle does not compensate for fluctuating loads, energy is wasted by regenerating more often than
necessary.
The dew point control mode is designed to adjust the energy use necessary to actual moisture load. Dew
point control eliminates the unnecessary use of energy by delaying regeneration until the total design
moisture load is achieved. Under dew point control, adsorption and regeneration cycles switch based on the
dew point value. If the dew point value transmitted by the transmitter AT CM102 is worse than the set point
equal to +5 °C, the adsorption time must increase at most up to the set maximum cycle time (60 min);
otherwise, the adsorption time must decrease at most up to the minimum set cycle time (6 min).
Due to less frequent cycling, switching valves and desiccant will last longer and require less maintenance.
4.2.4 Outlet filtration

A couple of filters is installed after the dryer to clean the compressed and dried air from eventual drying
agent, dust and abrasion particles (≥ 1 μm). The two post-filters are put in operation one as the alternative to
the other by the associated actuated valves (AA021/AA022). Each post-filter can be totally intercepted for
maintenance thanks to the manual valve installed downstream.
A manual drain valve, normally closed, is installed at the bottom of each filter to drain it.
At the filter outlet, the air is delivered to the unit outlet.
A differential pressure switch (PDIS-CP082), common to both the post-filters, allows monitoring the pressure
drop across the duty filter. If the differential pressure is over the set alarm threshold (300 mbar) an alarm
triggers, meaning that the filter is clogged and needs to be substituted. Consequently the two filters switch,
namely the actuated valve upstream the duty post-filter closes (blocking the filter operation), while the
actuated valve upstream the other post-filter opens, making it operative.
A five ways manifold with needle valves is installed upstream the differential pressure switch to allow
isolating it in case of maintenance, draining and compensation. Furthermore, a couple of manual valves is
installed to ensure the pressure switch isolation.
Note that, if the dryer in stand-by, the inlet valve of the post filter, which was the duty one remains open (e.g.
AA022), while the inlet valve of the post filter, which was in stand-by (e.g. AA022) is closed.
Each filter is also equipped with a differential pressure indicator (PDI-CP503/CP504) which allows local
monitoring of the pressure drop.
CONTROL SYSTEM
5 CONTROL SYSTEM
Each compressor and each dryer is equipped with its own local control panel, which includes a
Programmable Logic Controller (PLC), as described in Section 3.1.1 and 3.2.4. The control system is
equipped with a Human Machine Interface (HMI) device, which allows setting and controlling the operation
of the compressor. The control system displays the values of the parameters in proper engineering units and
indicates the associated condition: alarm, trip, fault, etc…The installed instrumentation and the relative
signals are indicated as on the P&I (APPENDIX A).
In the following section, the control system of the units is described.
5.1.1 Capacity control

The supplied compressors are characterized by various control potentialities.
5.1.1.1 Automatic unloaded start

The compressor always start in the unload mode. When unloaded, the inlet valve BV-001 is nearly closed,
the blowdown valve GV-001 is open and the compressor is operating at minimum power. After starting, the
compressor automatically loads if there is sufficient demand for air.
5.1.1.2 On–off line control

On–off line control delivers air at full capacity (compressor maximum efficiency condition) or operates at zero
capacity (compressor minimum power condition). The compressor controller responds to changes in plant air
pressure. It energizes the load solenoid valve YY-AA007A to actuate the hydraulic cylinder and load the
compressor whenever plant air pressure drops below the on–line pressure set point. The compressor then
operates to deliver full capacity air to the plant system. If the plant air system pressure rises to the off line set
point of controller, the load solenoid valve is de–energized, the hydraulic cylinder is de–actuated allowing the
machine to unload. The compressor continues to run with minimum power draw.
5.1.2 Automatic start/stop control

During periods of low air demand, if the line pressure rises to the upper set point, the controller begins to
time out. If the line pressure remains above the lower set point for as long as the set time, the compressor
stops. On the home page of the HMI appears the writing “Auto-restart”, indicating that the compressor has
shut down automatically and will restart automatically. The automatic restart occurs when the line pressure
drops to the lower set point.
The upper and lower set points and shutdown delay time are set on the control panel. There is a 10 second
delay after shutdown during which the compressor does not restart even if line air pressure drops below the
lower set point. This is to allow the motor to come to a complete stop and the controller to collect current
data of operating condition. If line air pressure is below the lower set point at the end of 10 seconds, the unit
starts unless the load delay timer is set greater than 10 seconds.
Pulse air system
5.1.2.1 Automatic start/stop operation

When in operation, the compressor must meet two specific timing intervals before the controller will stop the
unit in an Automatic Start/Stop situation.
In this framework, the timers are called timer ”A” and timer ”B”.
FIRST: Timer ”A” prevents the compressor from automatically starting more than 6 times an hour by
requiring the unit to run at least 10 minutes after each automatic start. This 10 minute run period can be
loaded, unloaded or a combination of the two and allows dissipation of heat generated within the motor
windings at start.
SECOND: After the compressor has started and reached the off–line setting and has unloaded, timer ”B”
requires the unit to run unloaded for a period of time that the operator can adjust between 2 and 20 minutes.
The setting of timer ”B” is part of the customer set–point routine and the timer cancels any accumulated time
if the compressor reloads before the timer cycle has finished.
NOTE: This unloaded run time may, or may not, be included in the mandatory 10 minute run time used to
cool the motor windings. When the compressor has completed the settings of both timer ”A” and timer ”B”,
the controller stops the compressor and displays “Auto-restart” in the message display of the home page of
the HMI.
Pressure sensor PIT-CP105 continues to monitor the package discharge pressure and sends information to
the controller, which automatically restarts the compressor when the pressure falls to the on–line setting.
An advantage to this method of automatic start/stop control is allowing the compressor to stop much sooner
in certain situations and timer settings, thereby reducing power costs.
5.1.3 Remote start/stop

The remote start/stop allows the operator to control the compressor remotely.
One contact can be wired to the starter interface board for remote start/stop. (Refer to the electrical
schematic for wiring locations).
On the control panel, the “Hardware control” option must be selected to enable the remote function.
WARNING!
Remote start/stop machine!
 Disconnect power before servicing.
 May start or stop at any time.
 Lock and tag out.
 Can cause severe injury or death.
5.1.4 Remote load/unload

The remote load/unload allows the operator to remotely load/unload the machine. To this aim two different
switches can be wired (refer to the electric al schematic for wiring location).
On the control panel, the “Hardware control” option must be selected to enable the remote function.
CONTROL SYSTEM
5.1.5 Power outage restart

The Power Outage Restart is for installations that have interruptions in their incoming power supply to the
compressor and must maintain an uninterrupted supply of compressed air. When turned on, the option
allows the compressor to automatically restart and load 10 seconds after incoming power is restored after a
power interruption. Suitable visible and audible warnings are given before restart.
5.1.6 Sequencer control and timed lead/lag

Sequencer control capability is available on the electronic control system by utilizing a sequencer interface.
The lead/lag sequencer modality can be enabled from the compressor control panels. See details in the
Setting-basic and Setting-advance pages (Section 5.1.7.2).
The two compressors can be set up in lead/lag situation, namely the lead compressor works, while the lag
one goes in load condition only if necessary. To actualize this situation, different off-line (pressure over which
the compressor enters in unload condition) and on-line pressures (pressure below which the compressor
enters in load condition) for the lead and lag situation are set for each compressor; particularly lower
pressures must be set for the lag condition (see the Setting-basic page in Section 5.1.7.2).
Furthermore, the lead/lag conditions can be set to switch after a set time interval.
5.1.7 HMI screen pages

Each compressor is equipped with a local control panel which includes a Programmable Logic Controller
(PLC), as described in Section 3.1.1. The control system is equipped with a Human Machine Interface
(HMI) device, which allows setting and controlling the operation of the dryer.
The Distributed Control System (DCS) monitors and manages all digital signals, namely pressure,
temperature and dew point values, measured by the probes installed on the machinery, and actuated valve
position, regulated by the associated solenoid valves and indicated by the supplied digital switches. The
control system displays the values of the parameters in proper engineering units and indicates the
associated condition: alarm, trip, fault, etc…
In the following, the screen pages of the compressor HMI are described.
The Figure 5.1 shows the base graphic of the HMI screen. The screen appears once the electrical panel is
turned ON.
Figure 5.1: LAYOUT screen page.

Pulse air system
 The upper bar indicates:

 name of current page;
 PLC date;
 PLC time.
 The lateral bar includes the main buttons, which allows navigating into the HMI pages. The pages are
gathered into three groups:
 HOME: page with the graphical representation of the plant with indication of the state of the
dryer, the process phases, the main control parameters and the pushbuttons for local start and stop
of the dryer.
 SETTING: pages for basic and advance setting of parameters for process control and alarm
management.
 ALARMS: pages with information about the last triggered alarm and the history of past
activated alarms.
To move from one page to another press the associated tactile zone over the desired symbol previously
illustrated. The selected, active group lights up orange.
To page through in the selected group, press the pushbutton, which represents the arrow:
 The lower bar indicates:

 compressor state, which can be one as follows:
 symbol indicating if the compressor is working in load or unload condition:
- load:
- unload
CONTROL SYSTEM
 control modality:
- local lead;
- local lag;
- remote hardware;
- remote Modbus.
Generally, the following setting characterizes the HMI screen pages:

 fields with orange background can be titles, indicate a process status or report the value of the
control parameter indicated above with black writing on yellow background;
 fields with white background are setting field where the operator must set main control parameters
or alarm thresholds;
 colored fields indicate the state of a component:
 colored buttons with black writing: buttons for selection of action indicated by the writing:
To insert the setting values, touch the white fields and the keyboard shown in Figure 5.2.
Figure 5.2: Keyboard for value insertion.
The keyboard pushbutton meaning is described in the following:

 ESC: quit from keyboard and annul the inserted value;
 BSP: delete the number before the cursor;
 NUMBERS: insert the value;
 ARROWS: move the cursor;
 +/-: insert the negative number; press this button after the number insertion.
Pulse air system
5.1.7.1 HOME
The home pages are shown in Figure 5.3-Figure 5.5.
 The first HOME page shown in Figure 5.3 indicates
o online pressure, namely the pressure below which the compressor starts to work in load
condition;
o offline pressure, namely the pressure over which the compressor enters in unload condition;
o the measured actual pressure, which is indicated also on the colored bar;
o Time to autorestart: time measured (in min. and sec.) from which the compressor operates in
unload condition. In auto-restart modality, once a set time interval is reached the compressor
stops;This time interval is set in the “BASIC SETTING” page;
o operating hours;
o measured actual temperature.
o
Figure 5.3: First HOME page.
 The second HOME page shown in Figure 5.4 indicates:

o time from which the compressor is powered on;
o compressor running time ;
o time from which the compressor is in load condition;
o number of starts;
o date and time (clock);
From this page date and time are set, using the “set time” pushbutton.
 The third and fourth HOME pages shown in Figure 5.5 list the measured parameters by control
instruments installed on the machine, which are monitored for a complete control of the compressor
operation. The instruments of measure are indicated by their associated tag, as per P&Id
(APPENDIX A).
CONTROL SYSTEM
Figure 5.4: Second HOME page.
Figure 5.5: List of monitored parameters.
5.1.7.2 SETTING
Under the SETTING menu, three pages are available for parameter setting:
 SETTING-BASIC: to set the basic parameters. This page has free access to everyone.
 SETTING-ADVANCE: to set and enable control modalities and set alarm thresholds. This page is
protected by password (set password at delivery: 1111).
 SETTING-TRANSMITTERS: to set the range of measure of the installed transmitters. This page is
protected by password (set password at delivery: 7858).
 The SETTING-BASIC page is shown in Figure ;.6. It includes the setting of the following parameters:
o Off line pressure of the lead (9 bar) and the lag (8 bar) compressor: pressure over which the
compressor enters in unload condition;
o Delta pressure of the lead (0.7 bar) and the lag (0.7 bar) compressor: subtracting this delta
value from the “off line pressure” the on line pressure is calculated, namely the pressure below
which the compressor start to work in load condition.
o Unload auto stop time: once the compressor reaches this set time from the unload condition
it automatically stops;
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o Purge filter Close/Open: the air filter cleaning system is activated for a time interval equal to
the set open time (1 sec.) every the set Close time (10 sec);
o Drain discharge: the drain valves of the condensate separators air filter opens for a time
interval equal to the set open time (1 sec.) every the set Close time (180 sec);
Figure ;.6: SETTING-BASIC screen page.
 SETTING-ADVANCE pages.
The first page shown in Figure 5.7 allows enabling the following control modalities:
o Automatic lead/lag sequence: the automatic switch of lead/lag condition between the two
compressors every the set lead/lag exchange time. This control modality must be enabled in
the present plant under local control;
o Hardware control: remote control commands from the Client (option) namely:
- remote control enable;
- remote tart/stop;
- remote load/unload enabled;
- remote load/unload switch.
o Modbus control: control commands from Modbus (via Ethernet). This control modality must
be disabled in the present plant;
o Poro (Power Auto Restart Option): if enabled, this option allows the compressor to
automatically restart after a blackout.
CONTROL SYSTEM
Figure 5.7: SETTING-ADVANCE screen page.
NOTE:
The lead/lag off-line and delta pressure, and the lead/lag exchange time must be the same on both the
control panels of the train.
The other pages shown in Figure 5.8 allow setting the alarm thresholds set for the compressor
control.
Figure 5.8: SETTING- ALARMS screen pages.

Pulse air system
 The SETTING-TRANSMITTERS pages are shown in Figure 5.9. They allows setting the measuring
range of the installed transmitters: minimum and maximum limits corresponding to the 4mA and
20mA signals. These values are set following the calibration values stated by the transmitter
manufacturer or ad hoc different calibrations and they can be selected to adjust the probe reading
errors. Nearby the setting columns, the page shows the actual values read by the probes.
Regarding the measuring ranges, see the instrument schedule in APPENDIX M.
Figure 5.9:SETTING-TRANSMITTERS screen pages.
5.1.7.3 ALARMS
The active alarm page automatically opens in case of a new triggered alarm and the alarm pushbutton
remains highlighted until the alarm is not reset.
As Figure 5.10 shows, for an activated alarm there is indication of:
 type: warning or trip (see Section 5.1.8);
 hour;
 date;
 status: in, namely activated alarm;
 description.
CONTROL SYSTEM
Each alarm must be recognized by the operator and reset pushing the RESET pushbutton (at the bottom of
the screen page).
All occurred alarms are memorized in the HISTORY-ALARMS page (Figure 5.11). In this page the input (in)
and output (out) status are memorized This is useful for future verifies analyses.
Figure 5.10: ACTIVE - ALARMS screen page, showing the last activated alarm.
Figure 5.11: HISTORY- ALARMS screen page with memorized past alarms.
5.1.8 Alarms
The control of each compressor includes various alarm signals, which can be of two types: warning or trip:
 warning indicates a not urgent alarm or notify anticipate if the temperature or pressure is in order to
exceed the normal operating limits. The warnings does not stop the compressor;
 trip stops the compressor immediately.
In case of trip, to restart the compressor it will be necessary to push the reset pushbutton.
Some alarms trigger due to the excess of an upper or lower admissible threshold that must be set in the
setting pages illustrated above. These alarms can be of four types:
 HH: very high alarm;
 H: high alarm;
 L: low alarm;
Pulse air system
 LL: very low alarm.

The set points of the thresholds are listed in the alarm annunciator list attached in APPENDIX N.
In the following, all the potential alarms are listed, distinguishing warning and trip type.
 Warning alarms:
o Error pressure transmitter CP-103
o Error temperature transmitter CT-005
o Oil pump overload 3M
o Oil pump starter fault 3M
o Air Filter Clogged DPAH CP-081
o Oil filter clogged PDAH (CP-101 - CP-102)
o Low 2 stage inlet pressure at load PAL- CP-104
o High discharge temperature TAHH- CT-004
o High filter differential pressure PDAH- CP-081
 Trip alarms
o Error differential pressure transmitter CP-081
o Emergency stop
o Main motor overload 1M
o Fan motor overload 2M
o Main motor starter fault 1M
o Low oil pressure PALL CP-102
o High oil temperature TAHH- CT-005
o Low vacuum pressure at load PALL- CP-103
o Low vacuum pressure at unload PALL- CP-103
o High 2 stage inlet pressure at load PAHH- CP-104
o High 2 stage inlet pressure at unload PAHH- CP-104
CONTROL SYSTEM
o High discharge pressure PAHH- CP-105

o High 1° stage discharge temperature TAHH- CT-001
o High 2° stage inlet temperature TAHH- CT-002
o High 2° stage discharge temperature TAHH- CT-003
5.1.9 Start and stop

5.1.9.1 Normal start
The compressor can be started from the HIM control system on the control panel under LOCAL mode or
from the external DCS under REMOTE mode. In the first case, the compressor is started by the F1-Starting
pushbutton while in the second case the compressor is controlled by the remote start/stop contact.
When the compressor is started, automatically:
 the pre-lube oil pump starts and runs for 10 seconds;

 the fan motor starts;
 the main motor starts.
5.1.9.2 Normal stop
The compressor can be stopped from the HIM control system on the control panel under LOCAL mode or
from the external DCS under REMOTE mode. In the first case, the compressor is stopped by the F2-
Stopping pushbutton, while in the second case the compressor is controlled by the remote start/stop
contact.
When the compressor is stopped, automatically:
 if the stop is pressed while unit is running unloaded, the compressor stops immediately, otherwise:
 the compressor immediately unloads;
 the compressor continue to run unloaded for 10 seconds;
 the compressor stops.
5.1.9.3 Emergency stop
If the machine has to be stopped in emergency, press the emergency stop button located on the
instrument panel. This will over–ride the normal unload/stop button and will immediately stop the machine
without the 10 second delay.
WARNING!
Never allow the machine to stand idle with pressure in the system.
Pulse air system
In the case of emergency due to the activation of the shutdown button on the control panel or to the ESD
signal, the automatic shutdown procedure is activated:
 immediate unload of the compressor;

 immediate stop of the compressor;
 immediate stop of the fan;
 heater disablement;
 auxiliary oil pump disablement.
5.1.9.4 Re-start after an emergency
To reset an emergency state:
 unblock the red emergency mushroom on the control panel;

 reset the state pushing the reset pushbutton on the “active alarm” page of the HMI.
If the unit has been switched off because of a machine malfunction, then identify and correct the fault before
attempting to re–start.
If the unit has been switched off for reasons of safety, then ensure that the machine can be operated safely
before re–starting.
Refer to the in Section 13.3 before re–starting the machine.
5.1.10 Load/unload
The compressor can be load or unload from the local control panel using the key pushbuttons:
 F3-Compressor load: pressing this button will cause the unit load if the unit is running and the
discharge pressure is less than the online pressure. This also return the machine to the operating
mode that is specified by the mode of operation set point.
 F4-Compressor unload: if the unit is running loaded, pressing this button will cause the unit to
unload. The unload indicator light will be on.
5.1.11 Remote signals

The PLC transmits and receives selected data link signals to the Distributed Control System (DCS), namely:
 Hardwired signals from LPC to DCS:
o automatic operation on (i.e. Auto start/stop on or off);
o load/unload status;
o run status;
o general warning alarm;
o general shutdown alarm.
CONTROL SYSTEM
 Hardwired signals from DCS to LCP

o Local/remote selection;
o Remote start/stop command.
5.2Drying units
The dryers are equipped with their own Local Control Panel (LCP). Furthermore, start and stop can be
performed locally or remotely from the Client Distributed Control System (DCS).
For more information about signal interface, refer to the dedicated wiring diagrams (APPENDIX L).
Each dryer is equipped with its own control panel and Programmable Logic Controller (PLC), as described in
Section 3.2.4. The control system is equipped with a Human Machine Interface (HMI) device (LOGO! TD
Text display), which allows setting and controlling the operation of the dryer.
The basic instructions of the LOGO! Display are:
 change the page: use the up/down arrow pushbuttons;
 insert the values in the pages:
o press ENTER until a cursor appears;
o use the left/right arrow to move the cursor;
o press the Ok pushbutton to insert the value;
o use the up/down arrow pushbuttons to increase/decrease the value;
o press the Ok pushbutton to definitively set the value.
 set the control advanced parameters:
o press the down arrow until timer page;
o press “ESC”;
o select “SET PARAM” to go to the menu.
 function keys: F1, F2, F3 and F4. Concerning the present machinery, they need to:
o F1: start the dryer under local control;
o F2: stop the dryer under local control;
o F3: change the control modality from local to remote pushing the associated button for at least
2 seconds;
o F4: change the control modality from dew point control to fixed time mode, pushing the
associated button for at least 5 seconds;
This pushbutton is used also to reset al alarm state.
In the following section, the screen pages of the HMI are described.
Pulse air system
5.2.1 HMI screen pages

The main screen pages of the text display are illustrated in the following Figure 5.12-Figure 3.14. Use up and
down arrow pushbuttons for page through.
 DRYER STATUS PAGE:
o DRYER: ON or OFF state of the dryer;
o REGENERATE#: column which is in the regeneration phase (A or B);
o DP: Dew Point value;
o TIME: past time from last column switch in minutes;
Figure 5.12: Screen page indicating dryer status and main controlling parameters: dew point values and
past time from last column switch.
 DRYER OPERATING MODALITY:

o DRYER: ON or OFF state of the dryer;
o MODE: mode of operation control: LOCAL (from the control panel) or REMOTE (from DCS);
o CYCLE: control mode phase cycles: AUTO (based on dew point control) or FIXED (following
fixed times for adsorbing and regenerating phases);
o TIME: actual cycle duration in minutes;
o
Figure 5.13: Screen page indicating dryer operating modality: local or remote, under dew point control or
foxed time.
 DRYER OPERATION UNDER DEW POINT CONTROL:

CONTROL SYSTEM
o REGULATION: indicates that the dryer can operate under dew point control mode, being
equipped with a dew point probe;
o
o DP: Dew Point value in C;
o
o SP: dew point set point (-25 C);
o OUT: percentage of dryer cycle: at 0% the cycle time is 60 minutes, at 100% it is 6 minutes.
Figure 5.14: Screen page indicating dryer operation under dew point control.
 DRYER SWITCH:
The dryers operate alternatively; this page allows setting the duration of the operating time
interval, after which the dryers switch.
Figure 5.15: Screen page indicating the operating time interval of each dryer before switching.
 ALARMS:
In case of alarm, the alarm page automatically appears, indicating:
o WARNING: type of alarm;
o instrument of measure which signals the malfunction: dew point probe (CM102), differential
pressure indicator (CP501/CP502) across pre-filters; differential pressure indicator
(CP503/CP504) across post-filters.
o cause of alarm: bad signal, high value, filter clogged;
o parameter associated to the alarm (if necessary).
The following figure shows the potential alarms:

Pulse air system
o bad transmission of the dew point probe (CM102), namely dew point probe signal in error
(<4mA or >20mA);
a) bad dew point value, over the set threshold;
b) clogged pre-filter, indicated by high differential pressure across the filter;
c) clogged post-filter, indicated by high differential pressure across the filter.
a) b)
c) d)
Figure 5.16: Screen pages indicating alarm states, particularly warning due to: probe transmission error
of dew point value (a); bad dew point value (b); pre-filter clogging (c); post-filter clogging (d).
The set points of the thresholds are listed in the alarm annunciator list attached in APPENDIX N.
5.2.2 Setting operating mode and parameters

The dryer can be managed from the control panel (LOCAL MODE) or from the external DCS (REMOTE
MODE). The control mode is indicated on the HMI text display, as illustrated in the previous section.
To change from LOCAL to REMOTE modality and vice versa press the F3 button for at least 5 seconds.
The dryer can operate under dew point control mode or fix time mode, as described in Section 4.2.3. The
Operator/Customer must select the operation modality on the HMI prior the dryer start. In particular, as
illustrated in Figure 5.13, on the HMI text display appears CYCLE AUTO if the cycle time is managed by the
Proportional Integral Derivative (PID) regulator based on the measures dew point value or CYCLE FIXE if
the cycle time is fixed.
To change from AUTO to FIXE and vice versa press F4 for at least 5 seconds.
CONTROL SYSTEM
To set the control advanced parameters, it is necessary to press the down arrow until timer page, then “ESC”
and “SET PARAM” to go to the menu.
Under dew point control, adsorption and regeneration cycles switch on the basis of the dew point value,
particularly the control is made by a PID (Proportional Integral Derivative) controller, which requires the
setting of proportional gain and integral time parameters. Thus, the following controlling parameters must be
set:
 Dew point set point SP: -25 C;
o
 Proportional gain Kc: 1;

 Integral time TI: 10 min;
 Minimum and maximum cycle times Cycle out:
- Gain A: 0.06 (parameter to define the maximum cycle time equal to 60 min)
- Offset B: 6 min (minimum cycle time);
Furthermore, the measuring range of the dew point probe is set, in order to identify the probe malfunction:
 Dew point probe minimum value Min: -80 C;
o
 Dew point probe maximum value Max: +20 C.

o
Threshold of high dew point over which the alarm trigger:

 Alarm DP (dew point alarm range)
- ON = 0: alarm insertion range;
- OFF= -50: alarm deactivation range (-50 = -5,0 °C ).
NOTE:
All others accessible parameters should not be changed.
5.2.3 Start and stop

The control system allows starting and stopping the dryer by suitable automatic procedures, which regulate
the position of the actuated valves, as described in Section 4.
The dryer can be started/stopped from the HIM control system on the control panel under LOCAL mode or
from the external DCS under REMOTE mode. In the first case the dryer starts by the F1 pushbutton and
stops by the F2 pushbutton, while in the second case the dryer is controlled by the remote start/stop
contacts.
Automatically the actuated valves place themselves.
When a dryer is stopped, automatically all discharging valves close, while one inlet valve always remains
open.
Pulse air system
5.2.4 Remote signals

The PLC transmits and receives selected data link signals to the Distributed Control System (DCS), namely:
 Hardwired signals from LPC to DCS:
o dew point measurement signal;
o run status;
o general alarm;
o general shutdown alarm;
o fault power supply.
 Hardwired signals from DCS to LCP
o Remote start/stop command.
STAFF SAFETY
6 STAFF SAFETY
The skids are designed and constructed in compliance with the most recent safety regulations. Nevertheless,
the personnel in charge of any activity on/with the machineries have to pay attention and comply with the
safety instructions prescribed in the present manual.
DANGER!
Danger due to incorrect behaviour!
Minor or relevant components damage and personnel injuries could be due to:
 not-observance of safety instructions;
 activity carry out by non-qualified personnel;
 machinery not use within design specifications;
 product modifications not authorized by the Manufacturer;
 incorrect maintenance.
Personnel must wear proper Personal Protective Equipment (PPE) depending on the performing activity.
In the manual, referring to the described activity, proper PPE are suggested. However, standard safety
regulations must be obeyed.
From a safety point of view, the units must be daily inspected, to ensure that operating conditions are safe
and eventually intervene to re-establish the dangerous ones.
Concerning the components which were provided by external suppliers, for further safety details consults the
associated handbooks in the appendixes.
WARNING!
Danger due Mobile Telephones!
The correct operation of this machine may be affected by the nearby use of a mobile
telephone. Ensure that such telephones, when in use, are kept at least 5 meters from the
perimeter of a machine which is operating or is being worked on whilst connected to its
power supply.
6.1Safety symbols
Table 6.1 lists symbols used in the present manual and/or attached on the units to indicate potential hazards
and prescription of Personal Protective Equipment (PPE). This table indicates also the activities during which
personnel must obey obligatory instructions and must pay attention to potential hazards.
Pulse air system
Table 6.1: Safety symbols used in the present manual.
Symbol Meaning Activity
Machinery/components lifting, handling,

Use indicated lifting points
placement and disassembly
Machinery/components lifting, handling,

Warning against hanging load
placement and disassembly
Use of forklift truck Unit lifting, handling, placement
Potential pressure discharges during start-

Warning against pressurized air/oil,
up, monitoring, maintenance and shut-down
Warning against high temperature of Excessive increase of surfaces temperature

0
surfaces (>60 C) during plant operation
Any activity during operating, powered

Warning against electrical voltage
packages
Use indicated terminals for ground

connection; presence of ground Installation, monitoring and maintenance
connection.
Tools or other object (such as cleaning rags)

Warning against tools and objects left on the separator during maintenance or
erroneously left on the unit repair activities could fall and cause
damages.
Potential leakages of lubricant oil

Warning against sliding: (compressing package) or water
(condensation or chiller cooling)
Safeguard against hazard of rotating

NEVER operate on rotating
components, shutting down the machineries
components
during maintenance or repair

NEVER remove protective guards components, letting in place the guards
while the machinery is operating

components, ensuring that the guards are in
Ensure that protective guards are
place before the start-up and while the
in place
machinery is operating or unattended
(operating or not)
Safeguard against noise and pressurized

air/oil, that can be violently ejected during
Use safety glasses and ear protectors
start-up, monitoring, maintenance and shut-
down
LOADING AND TRANSPORT
Table 6.2: Continuation of Table 6.1.
Use safety shoes and gloves All activities
Safeguard during lifting/handling (placement,

Use helmet disassembly) and maintenance suspended
activities
Safeguard during desiccant material

Use anti-dust mask
handling
For the compressors, see also the decals illustrated in the following tables.
Pulse air system
Table 6.3: Decals associated to the compressors.


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Pulse air system
6.2Warning symbols on the skids
On the equipment, hazard or relevant parts are indicated by proper symbols (see APPENDIX B). The
following indications are supplied.
Compressing skids:
 electrical supply;
 ground connections;;
 high surface temperatures;
 rotating parts;
 draining points;
 cooling water in and out;
 oil leak;
 pressurized vessels;
 air filter;
 guards to be maintained fitted;
 lifting eyebolts.
Drying skid
 electrical supply;
 ground connections;
 lifting eyebolts.
6.3Safety devices
In addition to chamfer of all edges, the skids are equipped with the following safety devices.
Compressing units:
 pressure safety valves PSV-AA003 and PSV-AA002 installed on the intercooling and aftercooling
lines respectively. They are set to 3.1 bar(g) and 11.3 bar(g) respectively;
 oil safety valve PSV-AA001;
 guards of rotating components to prevent any accidently touching;
 canopy to prevent any accidently touching and to reduce noise level;
 air silencer to exhaust air during the unload phase.
Drying units:
 one safety valve installed on each column (PSV-AA013-PSV-AA016) with discharge to safe area (at
the Client’s charge). They are set to 12.1 bar(g).
 silencer installed on the discharging lines to exhaust wet air during the depressurization phase.
6.4Correct and improper use
The compressing and drying trains have been designed and supplied for use only in the following specified
conditions and applications:
 compression and drying of normal ambient air free from unknown or undetectable additional gases,
vapors. or particles;
 operation within the ambient temperature range specified in the Section 11.1.
The use of the units in any of the situation types listed in Table 6.8:
 is forbidden;
 is not approved by the Vendor;
 may impair the safety of users and other persons;
 may prejudice any claims made against the Vendor.
Pulse air system
Table 6.8: Forbidden situations.
Use of air for direct human consumption.
Use of air for indirect human consumption, without suitable filtration and purity checks.
Use of the machine outside the ambient temperature range specified in the Section 11.1.
Use of the machine where there is any actual or foreseeable risk of hazardous levels of flammable
gases or vapors.
WARNING!
The plant is not intended and must not be used in potentially explosive atmospheres,
including situations where flammable gases or vapors may be present.
Use of the machine fitted with components non approved by the Vendor.
Use of the machine with safety or control components missing or disabled.
All the machineries must operate in compliance with data reported in the contract conditions and in the
declaration of conformity.
Uses or conditions, which differ from previous points, imply improper uses.
Clear misuse is the use of components as climbing aid. Vessels, connections, pipes, valves and other
elements are not design to that aim; they could fracture or became damaged.
6.5Residual risks
Although risks have been reduced as far as possible with accurate design and construction, some residual
risks persist.
Concerning the dryers, the residual risks are:
 discharge of air under pressure:
o the unit is equipped with pressure safety valves installed on the vessels against the risk of
blast due to too high overpressure. The vents must be in safe area (at the Client’s charge),
however the risk of safety valve discharge persist;
o although a silencer is installed, during the depressurization phase the discharge of air under
pressure generates a strong and sudden noise.
 Sliding:
o spilled desiccant agent beads on the floor during desiccant material empting and filling
could cause sliding.
Concerning the compressing skid, the residual risks are:

 discharge of air/oil under pressure:
o the unit is equipped with pressure safety valves installed on inter and final stages against the
risk of blast due to too high overpressure. The risk of safety valve discharge persist.
 sliding:
o oil leaks could cause sliding;
o cooling water leaks could cause sliding;
DANGER!
Danger due to material use!
 The following substances are used in the manufacture the compressors and may be
hazardous to health if used incorrectly:
- preservative grease
- rust preventative
- compressor coolant
The safety prescriptions of the lubricant oil required for the compressing unit
operation are included in the data sheet in APPENDIX D.
AVOID INGESTION, SKIN CONTACT AND INHALATION OF FUMES
 Maintenance of the dryers requires the replacement of the desiccant material,
whose safety datasheet is attached in APPENDIX E.
NOTE:
Note that, in case of fire, fire extinguishers suitable for devices under tension have to be used.
Do not use extinguishers intended for Class A or Class B fires on electrical fires. Use only extinguishers
suitable for class BC or class ABC fires.
Further residual risks which characterize the various life phases of the machinery are listed in the associated
following sections by “danger advises”.
6.6Authorized personnel location
Personnel are allowed staying in any position around both the compressing and drying units at the floor
level. For maintenance activity, which require elevated positions, a proper ladder or gangway must be
adopted.
The operator cannot use any components as support.
Attention must be paid to the discharges of safety valves. During inspections or maintenance activities of the
highest parts of the skids, personnel must never stay in front of them, except if the plant is depressurized.
7 LOADING AND TRANSPORT
7.1Loading/unloading
The compressors can be moved by a fork lift truck (2.5 ton / 5500 lbs minimum), inserting the forks in the
slots incorporated within their base. Alternatively, a crane or hoist can be used, adopting a special lifting
frame. The dryers must be moved by a crane, using a suitable lifting beam.
Details for lifting are reported both on the packages and in the general arrangement drawings (APPENDIX
B). Figure 7.1 and Figure 7.2 show the proper hoisting scheme for the compressing and drying skids
respectively, with indication of the total skid weight and the load for each lifting lug.
DANGER!
Danger due to improper lifting/handling!
 Lifting/handling and loading/unloading must be performed by qualified and

authorized technicians. Incorrect activity can cause material damages and
personnel injuries.
 Use proper handling equipment in regular state and with sufficient payload.
 Ensure that the correct fork lift truck slots or marked lifting / tie down points are
used whenever the machines are lifted or transported. Incorrect lifting could cause
material damages and personnel injuries.
 Keep the skids always in upright position to not compromise their efficiency.
 Do not work on or walk under the units while they are suspended.
 Obey safety precaution. Personnel in charge of lifting/handling must be equipped

with the necessary Personal Protective Equipment (PPE), namely safeguard
shoes, gloves and helmet. In-observance can cause personnel injuries.
Pulse air system
Figure 7.1: Lifting schemes of the compressing skids: by crane (up) or by forklift (down). The total weight
of each compressor is 2800 kg.
Figure 7.2: Hoisting scheme of the drying skids. The total weight of the skid is ~3100 kg. The center of
gravity is specified. See Figure 3.14 for the letter legend.
7.2Transport
The transport is excluded from the Sinergia Supply (Ex works Sinergia).
Equipment must be protected with care during the transport in order to avoid falls and/or damages.
WARNING!
Danger due to incorrect transport!
 Transport must be performed by qualified and authorized technicians. Incorrect
activity can cause material damages and personnel injuries.
 Accurately ensure and safeguard the skids.
 Do not place further loads over the packages: they can cause material damages.
The packages are not designed for mechanical loads.
 Keep the skids always in upright position.
 Obey safety precaution. In-observance can cause material and/or personnel
damages.
Pulse air system
NOTE:
Sinergia declines any responsibility for damages caused by not correct transportation beyond the scope
of supply.
7.3Damage due to transport
In case the packing and/or the skids have been damaged during transportation, both the hauler and the
manufacturer must be urgently contacted and a written report of damages must be sent to the Manufacturer.
WARNING!
Danger due to damaged components!
Do not put in operation a damaged unit: damaged components can cause working
anomalies and/or other damages.
PACKAGING
8 PACKAGING
According to the Customer requirements and specifics, the various supplied skids are packaged with a
seaworthy packaging, namely fumigated and marked wooden box coupled with sac barrier, coex cover
and dehydrating salts included.
To ensure a good protection during transportation, all flanged and threaded opening will be covered with
dedicated bolted and gasketed plugs.
This type of packing guarantees protection of the goods during both land/overseas transport and outside
storage for a period not longer than 6 months.
Separated boxes are provided, as listed in the packing list in APPENDIX Q.
NOTE:
Remove not damaged packing only at the final installation place, as it guarantees the protection against
atmospheric agents and corrosion.
DELIVERY TO SITE
9 DELIVERY TO SITE
9.1Unloading and laydown
At the installation site, all the packages must be unloaded as close as possible to the dedicated area in order
to minimize any probability of equipment damage.
All the prescriptions described in 7 regarding the loading are valid also for the unloading, thus refer to that
section for details.
9.2Receiving Inspection
Upon arrival at the final destination site, goods, including preservation and packing, shall be inspected for
signs of transport damage. Accordance with the packing list (APPENDIX Q) must be verified. Any
discrepancy must be notified immediately to the site manager and a written report of the damages must be
sent to the Manufacturer.
WARNING!
Danger due to unpack!
Pay attention to not damage the unit with the instruments used to unpack it.
9.3Preservation
Packages should remain intact until the installation and the assembly of the plant. The adopted packing (see
Section 8) has been decided considering a protection period of at most 6 months including shipping and idle
times before installation. If this time is expected to be exceeded, long tern preservation is required. Long
term storage procedures are described in Section 10.1.2.
STORAGE
10 STORAGE
In case it is necessary to store the packaged skids, the storage place must satisfy the following general
conditions:
 indoor would be the best, otherwise in a protected place under a roof, not exposed to rain, hail, sea
water, blowing sand…;
 flat surface, isolated from the ground (by a concrete cover to avoid moisture) and external vibrations;
 dry;
 dust-free;
 minimum temperature of +1 °C to avoid ice formation;
NOTE:
 The supplied packaging (see Section 8) guarantees protection of the goods for a period not longer
than 6 months from the packing, including land/oversea transport and outside storage.
 NEVER place heavy packages on other packages and ensure to not exceed the load capacity of the
supporting floor.
10.1.1 Temporary storage (less than 6 months)

In case of temporary storage (less than 6 months), the main concern is protection from weather agents.
a. Before the installation, components must be preserved in their original packaging. In fact, the
supplied packing guarantees protection during outside storage for a period not more than 6
months from the packing.
b. In the case of temporary storage of the skids during the plant life, due to the disconnection from
the external plant, it is fundamental to:
o drain accumulated condensate from filters and separators, clean and dry drainage
systems;
o accurately clean and dry all the components and equipment, included internal surfaces of
piping, tanks and any shell subjected to pressure under operation;
o ensure that everything is in good condition and not damaged; in the contrary case,
substitute or repair following Sinergia’s prescriptions.
o plug all flanged and threaded opening with bolted plugs of blind flanges with gaskets.
o grease bearings, gears, mechanical seals and threated connections;
o protect the skids accurately wrapping them with a plastic sheet or a tarpaulin;
o ensure the skids against potential accidental impacts by protections and information signs.
Pulse air system
10.1.2 Long term storage (longer than 6 months)

During long-term storage, it is fundamental also the prevention of external and internal surfaces of
components from corrosion that could be caused by condensation of air moisture due to changes of
ambient temperature from day to night and due to season succession. To this aim, anti-corrosion and anti-
rust protections must be adopted.
For the compressors see the ad hoc long term storage procedure (APPENDIX I).
Concerning the dryers follow the below prescriptions.
a. In the case of required long storage of the skids before the installation (namely, in the case the
skids are still packaged so as they were packed in the Sinergia’s factory) it is necessary to:
o unpack the skids;
o inspect the skids to ensure component integrity and not corrosion evidence;
o fill the skids with nitrogen. To this aim:
- close all open connections with blind flanges or threated plugs with gaskets;
- suck trapped air and fill with nitrogen; the oxygen content must be less than 2% of the
volume measured at the flushing outlet and the nitrogen pressure of 0.5÷1 bar.
To ensure the nitrogen filling of the entire drying circuit of each dryer, fill the skid both from
the inlet and outlet connections.
- install pressure gauges at the filling connections to monitor the nitrogen pressure.
- regularly check the nitrogen gas pressure in the equipment (monthly). In case the nitrogen
pressure is less than 0.5 bar(g), a refill is required. The refill shall not start before nitrogen
pressure is at 0.1 bar(g).
o if possible, replace the dehydrating salts inside the packing or apply a new long storage
packing.
- To change the salt sachets, specialized packing technicians must:
o open the box;
o cut the barrier;
o replace the salt sachets in same quantity;
o vacuum and seal again the barrier;
o close the wooden box.
- Alternatively, specific long term storage packing must be adopted, namely:
o sack-coupled barrier (film composed by layers of high density polyethylene,
aluminum foil and polyester or Valeron film). To protect the machinery against
moisture, it must be vacuum-sealed, namely the barrier bag has to be hermetically
sealed, so that it comes in the package by creating a vacuum that reduces the
volume of contained air. With the aim of absorbing moisture in the air at the time of
closing, a correct quantity of new desiccant bags of dehydrating salts have to be
included (hanged up at the upper parts of the skids) in the package.
o Vapor Corrosion Inhibitors (VCI) packaging. Adopting this method, an invisible layer
of protection against corrosion is due to the volatile active substances that
evaporates from the support material and condenses on the free surface of the metal
STORAGE
in a molecular layer. This type of protection can be adopted alone or integrated with
other packaging.
o if the previous processes cannot be performed, hang up enough sachets of
dehydrating salt at the upper parts of the skids to adsorb the humidity, avoiding the
contact with water (which could accumulate at the bottom of the skids), which could
induce corrosion. Then, protect the skids with a lorry tarpaulin accurately wrapped.
o ensure the skids against potential accidental impacts by protections and information
signs.
o concerning the single components installed on the skids, follow the long term storage
prescriptions listed below and suggested by the relative Manufacturers in the
associated handbooks attached in the appendixes.
b. In the case of long storage of the assembled skids during the plant life, due to the disconnection
from the external plant, it is necessary to:
o follow the prescriptions for the short-term storage (point b);
o inspect the skids to ensure component integrity and not corrosion evidence;
o fill the skids of nitrogen as described above at point a;
o apply a new long storage packing or protections as described above at point a;
o concerning the single components installed on the skids, follow the long term storage
prescriptions listed below and suggested by the relative Manufacturers in the associated
handbooks attached in the appendixes.
Particular attention must be paid to the following main components.

 Spare parts for commissioning, start-up and one year of operation (filtering cartridges, valves,
instruments, seal kits, gaskets, lubricant oil, grease…):
- store provided components in their original sealed packaging, indoor, in a closed, dry and
protected site;
- add sachets of dehydrating salt (or silica gel) in the containing boxes.
 Control panels:
- If disassembled from the skids, store indoor, in a closed and dry site, isolated from the
ground and protected against potential accidental impacts;
- apply vapor corrosion emitters inside the cabinets. As a limit alternative, include new sachets
of dehydrating salt (or silica gel) to adsorb humidity; hang up the salt sachets in the upper
part of the cabinet to avoid the water (which could accumulate at the bottom of the panel)
contact, which could induce corrosion. Regularly verify the adsorption capacity of the
sachets;
- tape openings to minimize air infiltration;
- wrap it with a plastic sheet or a tarpaulin;
 Electrical equipment and components:
- disassemble all the electric/electronic instruments installed on the skids;
Pulse air system
- store instruments and electronic equipment, which were disassembled or extracted by the
original packaging, indoor, in a closed and dry site, wrapped, protected by vapor corrosion
inhibitors devices, and placed in protective wooden boxes (inside the control panel is
possible) not in contact with the ground. Note that components sealed in plastic shrink-wrap
(i.e. spare parts) are not exempt from corrosion problems, since moisture will collect inside
the plastic, resulting in corrosion.
- store delicate instruments, as distribution components and programmable controllers, as
indicated at the previous point; in addition the storage place must be air conditioned.
 Carbon steel wrought surfaces, nor painted, nor galvanized:
- perform a treatment for rust prevention, applying a corrosion preventive compound, e.g.
TECTYL products or alternative protective products in agreement with Client’s specifications
or Sinergia’s prescriptions. These products must be applied after 12 mounts from shipment
and afterwards, every 6 mounts. Prior new application, the “old” protection must be removed
with vapor degreasing, hot alkaline wash, or low-pressure steam by normal dry cleaning
procedures.
 Small parts (threads, valve stems, flange mating faces, nuts and bolts, machined surfaces,…):
- clean all the parts;
- apply corrosion preventive compound;
- wrap with laminate craft papers or polyethylene sheets;
- store indoor, in a closed and dry site and placed in protective wooden boxes.
NOTE:
For any doubt, contact Sinergia.
Sinergia declines any responsibility for damages due to improper storage.
INSTALLATION
11 INSTALLATION
WARNING!
Danger due incorrect installation!
 The dryer installation must be performed by qualified and authorized technicians.
Incorrect installation could cause material damages and/or personnel injuries.
 NEVER left tools or other objects on the units; they could fall and cause damages.
 Obey safety precaution. Personnel in charge of installation must be equipped with

necessary Personal Protective Equipment (PPE), namely safeguard shoes, gloves
and helmet for lifting/handling activity. In-observance could cause personnel injuries.
11.1Requirements for installation site
Site conditions have a high influence on the plant efficiency. In order to guarantee its operation as efficient
and continuous as possible, and with minimum maintenance, the installation site must respect the design
conditions, in agreement with the Customer’s requirements or, in any case, it must be characterized by
features less hazardous (to the operation) than the design ones:
 indoor;
 safe area;
 maximum design ambient temperature: 50 °C;
 minimum ambient temperature: 2 °C;
 maximum ambient temperature: 46 °C;
 maximum humidity for air inlet: 95 %;
 design pressure: 0,99 bar (a);
 maximum water cooling temperature: 38°C;
 site adequately accessible for maintenance activity:
o free-space of at least 1 m above the skids;
o free-space of at least 1 m around the skids.
If headroom is restricted, then the exhaust should be ducted or deflected away from the
compressors.
Pulse air system
NOTE:
 The units are not suitable for use in flammable gas risk areas.
 If ducting is fitted, the sump breather needs to be piped outside the enclosure to avoid back
pressure into the compression module.
When the ambient conditions other than the design levels listed above are encountered, contact the Supplier
for additional information.
If necessary, the plant components must be preserved by suitable devices from pulsations of compressed
air and transmitted vibrations.
The units can be installed on any level floor with sufficient payload. A dry, well-ventilated area where the
atmosphere is as clean as possible is recommended.
Sufficient space all round and above the compressor must be allowed, to enable the effective removal of
the cooling air, which, in turn, will reduce the risk of re–circulating the cooling air back through the
compressor.
NOTE:
Hard surfaces may reflect noise with an apparent increase in the decibel level. When sound transmission
is important, a sheet of rubber or cork can be installed beneath the machine to reduce noise. It is
recommended that provision be made for lifting heavy components during major overhaul.
NOTE:
For any doubt, explanations and/or support concerning installation contact Sinergia Srl.
11.2Risks to be removed at the installation area
The Customer must provide for removal of some risks at the installation site:
 Blast:
it is important to install the skids far from components/systems at risk of explosion, which could
compromise both machineries and personnel.
 Fire:
it is important to install the skids far from components/systems at risk of fire, which could
compromise both machineries and personnel, and have a suitable fire prevention system.
NOTE:
Note that, in case of fire, fire extinguishers suitable for devices under tension have to be used.
Do not use extinguishers intended for Class A or Class B fires on electrical fires. Use only extinguishers
suitable for class BC or class ABC fires.
INSTALLATION
 Accidental impacts:
the units are not protected against accidental impacts, which could induce relevant damages.
Consequently, it is fundamental to safeguard them against moving means, which could operate at
the installation site, nearby the machinery, as for instance:
o trucks;
o fork lifts;
o cranes;
o etc…
NOTE:
Sinergia declines any responsibility for damages due to blast, fire or accidental impacts.
11.3Mechanical installation
WARNING!
Prescriptions for correct installation!
 If more than one compressor is connected to one common downstream plant,
effective isolation valves must be fitted and controlled by work procedures, so
that one machine cannot accidentally be pressurized / over pressurized by
another.
 Screw type compressors should not be installed in air systems with reciprocating
compressors without means of isolation such as a common receiver tank. It is
recommended that both types of compressor be piped to a common receiver
using individual air lines. Do not use a receiver tank or similar vessels that fail to
meet the design requirements of the compressor.
 Installation must be in accordance with recognized electrical codes and any
local Health and Safety Codes.
 The use of plastic bowls on line filters and other plastic air line components of the
compressing units without metal guards can be hazardous. From a safety stand-
point, metal bowl should be used on any pressurized system.
11.3.1 Foundation
The machines must be positioned securely and on a stable foundations. Any risk of movement should be
removed by suitable means, especially to avoid strain on any rigid discharge piping.
The foundations are at Customer’s charge. Sinergia provides the foundation detail drawing with all the
necessary indications for design and construction, namely the operating loads, the location of the anchor
points and the fixing systems, as shown in the following figures. The compressors and the dryer skids must
be anchored by the prescribed anchor bolts, as shown in Figure 11.3.
Pulse air system
Figure 11.1: Foundation detail for the compressors.
Figure 11.2: Foundation detail of the drying skids.
.
INSTALLATION
Figure 11.3: Fixing system of the compressors (left) and drying skids (right).
11.3.2 Anchoring to foundation

The anchor holes present on the baseplates need to anchor the skids to the foundations. The anchor details
are included in the foundation drawing. Before the installation, the location of the anchor holes needs to be
verified against the as-built location and dimensions of the anchor bolts pre-casted into the concrete
foundation. Any discrepancies should be noted and resolved avoiding modification of the baseplate anchor
holes.
To anchor the skids the below steps must be followed:
 location of the skid on the foundation;

 fixing of the baseplates to the foundation by suitable screw nuts turned (without tightening) on the
anchor bolts (after washer location);
 leveling of the skid. This step is critical and of fundamental importance. It must be performed by
qualified personnel using a machinist level, an industrial laser or an optical level located on the top
frame of the baseplates;
 screw nut tightening.

11.3.3 Assembling and connections
Prior to install and assemble, remove any packing and preservation materials that will interfere with the
activity. Furthermore, remove all temporary supports, protections, bracings, sea fastening stops, that were
installed to prevent equipment damage during shipping, storage and erection.
WARNING!
To prevent entry of dust, debris or water during assembling/connecting activities, maintain sealed the
plugs/enclosures installed prior the transport to cover all flanged and threaded openings, instrument
and electrical devices.
It is fundamental to ensure removing of plugs only at the realization of each connection. The original
plugs should be stored for potential future use.
Furthermore, prior to the installations/connections ensure that nothing is included into the connecting
piping.
Pulse air system
The installation must follow the installation layout (APPENDIX C), the P&IDs (APPENDIX A) and the general
arrangements (APPENDIX B).
NOTE:
All the interconnecting piping between the skids and the cooler are at Customer’s charge.
Authorized technicians must provide for the activities listed below.

 Compressing skid connections, as per the P&ID (APPENDIX A):
o compressed air discharge (TP-101) to connecting piping (at the Client’s charge) to the
downstream plant;
Discharge piping should be at least as large as the discharge connection of the compressor. All
piping and fittings should be suitably rated for the discharge pressure.
All air pressure equipment installed in or connected to the machine must have safe working
pressure ratings of at least the machine rated pressure, and materials compatible with the
compressor lubricant
WARNING!
Compressor reciprocal damages due to incorrect installation!
Since more than one compressor is connected to the common downstream plant,
effective check valves and isolation valves must be fitted and controlled by work
procedures, so that one machine cannot accidently be pressurized / over pressurized
by another.
o condensate drain outlet (TP-105), located at the base of the compressor, to open drain, which
is at Client’s charge;
WARNING!
Compressor damage due to incorrect drain!
 The drain line must slope downward from the base to work properly. Improper
condensate drain piping could cause compressor damage.
 Condensate drain lines CANNOT be piped together in a common header.
o cooling water inlet (TP-103) and outlet (TP-104) piping to water supply and discharge
respectively.
Carefully inspect the water system before installing the compressor package. Ensure that the
piping is free of scale and deposits that may restrict water flow to the compressing package.
Proper operation of the compressor requires that a maximum water flow of 91 lpm is provided at a
0
maximum supply temperature of 38 C.
Water temperature and pressure gauges should be installed in the water piping for use in any
fault finding of the water system.
INSTALLATION
Water cleanliness is extremely important Cleaning of cooling water as a result of fouling is a

Customer responsibility. Therefore, it is highly recommended that proper water strainers are
utilized. In addition, water quality must meet the requirements listed in 11.3.3.1.
o downstream discharging isolation valve (suggested, at the Client’s charge).
 Drying skid connections, as per the P&ID (APPENDIX A):

o inlet lines of the drying skids A/B to the compressing skid A/B (TP-106A/B);
o outlet lines of the drying skids A/B to the external Client’s plant (TP-107A/B);
o drain manifold (TP-108), which collects drains from inlet filters and condensate separator to
the Client’s draining system;
o discharge of pressure safety valves PSV-AA013/014, PSV-AA015/016 to safe area.
o Upstream and downstream interception valves (suggested, at the Client’s charge).
Technicians have to make inspections to ensure that:

 suitable fittings and pipes are used for connections as prescribed in the design;
 thread and bolt connections are not loose (i.e. due to vibration occurred during the transport). If so,
provide to tighten them again.
11.3.3.1 Water quality requirements

Water quality is often overlooked when the cooling system of a water cooled air compressor is examined.
Water quality determines how effective the heat transfer rate, as well as the flow rate will remain during the
operation life of the unit. It should be noted that the quality of water used in any cooling system does not
remain constant during the operation of the system. The water makeup is effected by evaporation, corrosion,
chemical and temperature changes, aeration, scale and biological formations. Most problems in a cooling
system show up first in a reduction in the heat transfer rate, then in a reduced flow rate and finally with
damage to the system.
There are many constituents in the water system that must be balanced to have a good, stable system. The
following major components should be monitored:
 SCALE: Scale formation inhibits effective heat transfer, yet it does help prevent corrosion. Therefore,
a thin uniform coating of calcium carbonate is desired in the inner surfaces. Perhaps the largest
contributor to scale formation is the precipitation of calcium carbonate out of the water. This is
dependent on temperature and pH. The higher the pH value, the greater the chance of scale
formation. Scale can be controlled with water treatment.
 CORROSION: In contrast to scale formation is the problem of corrosion. Chlorides cause problems
because of their size and conductivity. Low pH levels promote corrosion, as well as high levels of
dissolved oxygen.
 FOULING: Biological and organic substances (slime) can also cause problems, but in elevated
temperature environments such as cooling processes they are not a major concern. If they create
problems with clogging, commercial shock treatments are available. To ensure good operation life and
performance of the compressor cooling system, the recommended acceptable ranges for different
water constituents are included below:
Pulse air system
 Corrosivity (Hardness, pH, Total dissolved solids, Temperature at inlet and Alkalinity should be
analyzed monthly, or if stable for 3 to 4 months, analyzed quarterly. Acceptable concentration:
Langelier Index 0 to 1
 Iron content should be analyzed monthly. Acceptable concentration: 2 mg/l (2 ppm)
 Sulphate content should be analyzed monthly. Acceptable concentration: 50 mg/l (50 ppm)
 Chloride content should be analyzed monthly. Acceptable concentration: 50 mg/l (50 ppm)
 Nitrate content should be analyzed monthly. Acceptable concentration: 2 mg/l (2 ppm)
 Silica content should be analyzed monthly. Acceptable concentration: 100 mg/l (100 ppm)
 Dissolved Oxygen content should be analyzed daily, or if stable, analyzed weekly. Acceptable
concentration: 0 mg/l (0 ppm) (as low as possible)
 Oil and Grease content should be analyzed monthly. Acceptable concentration: 5 mg/l (5 ppm)
 Ammonia content should be analyzed monthly. Acceptable concentration: 1 mg/l (1 ppm)
11.4Electrical installation
DANGER!
 Electrical connections must be performed by qualified personnel and under the direct
responsibility of the Customer. Incorrect installation can cause material damages
and/or personnel injuries.
 Risk of electrical shock.
 Keep all parts of the body and any hand–held tools or other conductive objects,
away from exposed live parts of the compressor electrical system.
Danger due to improper electrical connection!

 Connect the units only to electrical systems that are compatible with their electrical
characteristics and that are within their rated capacity.
 Ensure that the control circuit is connected to the transformer tapping that matches the
supply voltage.
 Feeder cables must be sized by a competent electrical engineer to meet all power
requirements.
The client must perform the following wiring connections:

 compressor-compressor panels by the provided cable;
 local control panels to Distributed Control System (DCS) by contacts (if necessary to the
Client);
 power supply following the power supply distribution arrangement (APPENDIX F). For details about
the electrical data see Table 11.1. and the electrical load list in APPENDIX G.
INSTALLATION
For details about the control system configuration and wiring see the following documents:
 Control system configuration (APPENDIX J);
 Logic control diagrams with tripping logic diagrams (APPENDIX K);
 Wiring and schematic diagrams with fixing and installation detail for local control station (APPENDIX
L).
Table 11.1: Electrical data of the compressing units.
ELECTRICAL DATA
Main drive motor (@ 1000 m asl)
Installed power (nom. x 1.25 SF) kW 90
Adsorbed power kW 78
Number of poles - 2
Motor speed RPM 2955
Efficiency at full load % 95.22
Power factor at full load - 0.92
Compressor full load current @ 380V- 415 V A 138-127
Locked rotor current @ 380V- 415 V A 1188-1255
Power supply V/ph/Hz 415 / 3 / 50.

Fan motor
Installed power kW 0.52
Adsorbed power kW 0.37
Number of poles - 4
Motor speed RPM 1425
Efficiency at full load % 70
Power factor at full load - 0.7
Full load current A 1.1

Pre-lube oil pump
Current A 1.3

Pulse air system
Table 11.2:Continuation of Table 11.1.
Compressor control panel
Current A 1.3

Compressing package
Total installed power kW 91
Total adsorbed power kW 78.5
Current A 128
Dryer control panel
Installed power 0.8
Adsorbed power 0.8
Current 3.3
Power supply 240 / 1 / 50.
Furthermore, earth cable (yellow-green cable) must be connected to the specific ground lugs, whose
location is indicated by the corresponding symbols in the particular drawings and on the equipment.
WARNING!
Danger due to ground connection!
 Use indicated terminals for ground connections.
 Lack of earth connection can cause material damages and/or personnel injuries.
Wires section must be sized considering:

 power supply (see APPENDIX F, APPENDIX G);
 necessary cables length;
 installation type;
 ambient conditions;
 compliance with the rules in force in the installation country;
NOTE:
Sinergia does not supply cable glands for Customer side.
INSTALLATION
NOTE:
Sinergia declines any responsibility for damages due to incorrect installation.
COMPLETION ACTIVITIES
12 COMPLETION ACTIVITIES
Pre-commissioning and commissioning include various tasks, which can be always attributed to activities of
quality control and coordination during different phases:
 design;
 work management;
 delivery of the machinery.
These phases are planned by the Manufacturer, following a detailed procedure defined and agreed with the
Client.
In this framework, attention is focused on the last phase, which is carried out on site. In the following, main
aspects are reported.
12.1 Pre-commissioning
The main aim of the pre-commissioning phase is to guarantee the correct and adequate operation of all the
plant components, in compliance with the design.
NOTE:
Plant pre-commissioning must be performed by specialized staff, either technicians of Sinergia or third
parties authorized by it, otherwise, Sinergia’s warranty decays.
The pre-commissioning phase includes three main activities on site: conformity checks, static/de-energized
tests and piping test, as specified in the following.
\\
Conformity checks:
The skids must be totally checked to verify the conformity to contract and design specifications, by:
 visual check of each package component to visually verify condition, installation quality,
compliance with technical drawings and design specifications, Sinergia’s instructions, safety rules,
codes, standards and good practice;
 preliminary tests with equipment de-energized, including di-electric strength tests, loops and
circuits continuity tests, earth resistance measurements, insulation resistance measurements;
 check continuity of transmission and identification of indication, control and alarm signals of
instrumentation;
 continuity and insulation test for instrument cables;
 continuity and tightness test for pneumatic tubing;
 check fixing of pipe anchors, guides, spring hangers and supports;
 alleviate with suitable devices any excess stress that may be imposed on pipes, compressors or
pump flanges;
Pulse air system
 ensure that the position of the emergency stop device is known and recognized by its
markings.
Static/de-energized tests.
Equipment must be tested to ensure the goodness of critical components. This "cold" testing includes:
 verify calibration certificates of instruments;
 verify setting certificate of safety valves;
 check lubricating oil level; add lubricant if necessary (See Section 17.1.4);
 inspection and closure of all openings/connections;
 verify the installation of the interception valve downstream the compressor;
 before making any part or conductor electrically live, verify that electric motor/control wiring are not
exposed or saturated with moisture/water deposits; in this case dry off.
Once the pre-commissioning is performed, the “ready for commissioning” certificate must be issued.
12.2 Commissioning
The main aim of the commissioning phase is to guarantee that the assembled plant correctly runs, in
compliance with the project objectives and Client requirements.
The specific purposes are:
 to confirm that all components are correctly installed and activated in compliance with the design;
 to confirm the expected plant performance by a series of tests and measurements;
 to guarantee security conditions for personnel who will operate with/on the machinery;
 to verify the necessary documentation for operation and maintenance of the plant.
NOTE:
Plant commissioning must be performed by specialized staff, either technicians of Sinergia or third
parties authorized by it, otherwise, Sinergia’s warranty decays.
In order to transfer smoothly the plant from Sinergia to the Client, final operators in charge of any activity
on/with the machinery should assist the Commissioning team.
The commissioning phase includes three main activities on site: conformity checks, dynamic verifications
and running-in and on-line operational and functional tests, as specified in the following.
Dynamic verifications
Elementary electrical and communication plants, and instrumental functions must be tested to verify the
correct performance, in agreement with the design criteria.
 check of correct power supply and test;
COMPLETION ACTIVITIES
 check of all wirings;

 verify that the pneumatic actuators are powered;
 functional test of the electrical components (motor, oil pump, solenoid valves), instruments and
safety devices;
 correct visualization of the screen pages of the HMI on the unit control panel;
 emergency test of the instrument power supply system;
 test of the normal and emergency lighting;
 operational check of the manual and automatic control systems;
 check shutdown systems, interlocks and sequencers;
 ensure that the emergency stop device is functioning correctly and that the method of operation is
known;
 pre-lube oil pump rotates in the correct direction;
 check the rotation direction of the main motor of the compressing unit.
The correct motor rotation is clockwise when viewed from the rear or non–drive end of the motor. For
the compressor motor rotation check, the running of the motor must be as short a time as possible.
After depressing the start button, immediately depress the ”EMERGENCY STOP” BUTTON. Should
the motor rotation be incorrect, put the main isolator in the OFF position.
WARNING!
Wrong compressor rotation!
If the compressor is operated in the opposite direction of rotation, airend damage may
result and is not warrantable.
Running-in and on-line operational and functional tests.

Main process components must be tested in closed loop for a significant period of the plant, and whenever
possible. This phase could also include operating adjustments necessary for satisfactory operation.
 compressor running in load condition;
 vibrational and noise tests on the compressor;
 check temperature rise of motors, compressors, bearings and relays under load condition;
 leakage tests;
 check drainage correct operation;
 verify the reproduction of the equipment logic.
This phase must follow the “ready for commissioning” certificate issue.
From a practical point of view, the preliminary checks before the start-up and the activities required for
pressurization are the same required in the phase of start-up, described in the following section.
START-UP
13 START-UP
Start-up phase is planned by the Manufacturer, following a detailed procedure defined and agreed with the
Client. In the following, main aspects are reported.
This phase must follow the “ready for start-up” certificate issue.
NOTE:
Plant start-up must be performed by specialized staff, either technicians of Sinergia or third parties
authorized by it, otherwise, Sinergia’s warranty decays.
Initial compressor starting should be performed by an Ingersoll–Rand Qualified Service Technician.
In order to transfer smoothly the plant from Sinergia to the Client, final operators in charge of any activity
on/with the machinery should assist the Commissioning team.
13.1Document compilation
During Start-up, staff must note relevant aspects useful for the definition of the first start-up sequence and
procedure.
At the end of the start-up sequence, Start-up staff must issuance:
 certificate of ready for operation;
 punch list updated and closed.
Previous documents will be included in the start-up dossier.
13.2 Preliminary activities
Inspection activities must be carried out:

 physical check on the installation site, including Factory Acceptance Tests (FATs) and/or Site
Acceptance Tests (SATs);
 check of commissioning activities;
 thorough review of the commissioning Dossier;
 verify that the ambient temperature is not below or approaching 0 C , because the operation of the
0
regulation system, the unloader valve, the safety valve of the compressing units will be compromised.
Modifications are required for low ambient modifications; to this aim contact the Vendor.
Before the startup, the cooling water system must be vented as follows.
 Locate the water system vent cock on top of the intercooler.

 Open the water valve(s) allowing water to flow to the package.
Pulse air system
 Open the vent cock and allow all air to escape from the system.
When water is observed at the vent cock, close it. The system is now properly vented.
13.3 Preliminary checks of the machineries
Essential checks must be performed before the start-up:

 all the machineries are correctly installed;
 fixing is secure and stable;
 no extraneous corps or tools are left on the components: they could compromise of the start-up
and/or be a danger origin;
 no tubes or cables chafe against body corners;
 thread and bolt connections are tighten;
 all components of the pneumatic system which are pressurized (valves, flexible tubes, etc…) are in
perfect state;
 electric connections and voltage are correct;
 power supply is available;
 unit control panels are powered;
 set points are adjusted appropriately;
 control instruments are powered and functioning;
 instrument and component intercepting valves are open;
 pressure equipment installed in or connected to the machines have safe working pressure
ratings of at least the machine rated pressure.
Dryers:
 upstream and downstream intercepting valves of the dryers (if installed by the Client) are closed;
 purge valve is open;
 drain valves are in correct position (pre- filters: intercepting open, bypass closed; post-filter:
closed);
 manual intercepting valves of filters are open.
Compressing units:
WARNING!
Ensure that all protective covers/guards are in place before attempting to start the
machine.
 check lubricating oil level; add lubricant if necessary (See Section 17.1.4).
START-UP
 drain valves (if installed by the client) are in correct position;

 electrical wiring has been inspected and earthed;
 all power leads for tightness;
 all protective covers are in place;
 canopy/doors are closed;
 discharge air isolation valve is open (if installed by the Client);
 no persons are in a hazardous position;
13.4Ready for pressurization activities
Specific activities required to prepare pressurization and to bring the plant in operation must be performed:
 establish the list of available equipment;
 perform audit and technical reviews required for the issuance of the ’’ready for pressurization’’
certificate;
 check that all punch list items are clarified and treated accordingly. Verify that the punch list is
updated and closed;
 ensure safety equipment and critical utilities availability and reliability;
 ensure that there is a safe working procedure which has been issued by supervisory personnel, and
that it is understood by all persons concerned with the operation of the plant;
 ensure that the safety procedure to be applied is based on the appropriate national regulations;
 ensure that the safety procedure is followed at all times;
 carry out the final safety tests (Distributed Control System (DCS), Fire and Gas (F&G), deluge,
etc…);
 replace the following components, as detailed in the ”Spare part list for commissioning and start-
up” in APPENDIX O:
o compressing skids:
- filtering elements of air filtering system;
- oil filters;
- lubricating oil;
o drying skids:
- filtering cartridge of pre-/post-filters;
 issuance of the “ready for pressurization’’ document.
13.5 Pressurization and turn on
Once the “ready for pressurization’’ activities have been performed, pressurization, turn on and tests can
be performed.
Pulse air system
Each train can be started locally (from local control panels of compressors and dryers) or from remote
control, depending on the selected modality on the control panels.
DANGER!
Potential discharge of pressurized air!
 Air under pressure could be discharged both from the compressing and drying
skids; particles included in the air could be violently ejected causing severe
injuries to eyes and/or skin! Avoid contact.
 Plant operation generates a strong and sudden noise which could cause
damages to the auditory apparatus;
 In emergency case, the safety valves could discharge air under pressure.
 Do not point air nozzles or sprayers toward anyone.
Potential discharge of pressurized oil!
Lubricant could leak from the oil circuit.
Potential discharge of pressurized water!
Pressurized water squirts could be discharged from the cooling circuit causing
injuries to eyes and/or skin!
Risk of burn!
NEVER touch surfaces of the compressing units subjected to excessively high
o
temperatures, which can reach temperatures higher than 60 C.
Risk of electrical shock!
 Presence of electrical supply.
 Keep all parts of the body and any hand–held tools or other conductive
objects, away from exposed live parts of the compressor electrical system.
Risk of sliding!
Potential leakages of lubricant) or water (condensation or cooling circuit) could cause
sliding.
Never start-up the compressing units without all protective covers in place and
canopy/doors closed.
Obey safety precaution. Personnel in charge of start-up must be equipped with the
eye and hearing protections and instructed on their use in accordance with workplace
safety legislation. In-observance could cause personnel injuries.
The starting sequence of the compressors and the dryers is illustrated in in the Sections 5.1.9 and 5.2.3
respectively. In order to turn on one entire train follow the next steps:
START-UP
 switch on the main electrical isolation switch. The power on indicators on the panels will
illuminate, indicating that the line and control voltages are available;
 set the required parameters and the operation modality on the control panels of the
compressors (as described in Section 5.1.7). Pay attention to select the same setting parameters
on both the panels. Enable the automatic lead/lag sequencer and, optionally the hardware control.
 set the required parameters and the operation modality on the control panels of the dryers
(as described in Section 5.2.2). Pay attention to select the same setting parameters of both the
panels. Set the same time for the switch of the dryers.
 verify that the compressors are ready to start: the writing appears on the bottom bar on the
HMI;
 start both the compressors, one after the other (see Section5.1.9). Compressors will start and
load automatically if there is sufficient demand for air, otherwise they will run in unload condition.
 keep closed the outlet valves, which intercepts the dryers downstream (if installed by the Client);
 starts both the dryers, one after the other, as follows. Automatically one dryer will operate while
the other one will stay in stand-by.
slowly open the inlet valve, which intercepts the dryer upstream (if installed by the Client);
DANGER!
Danger due to rapid build-up of opressure!
Slowly open the compressed air inlet valve; a rapid build-up of pressure can cause dryer
damages, in particular life reduction of the molecular sieves. Furthermore, discharge of
pressure can cause severe personnel injuries.
ensure that there are no leakages;

let to pressurize;
when the desired pressure is achieved, turn on the dryer (see Sections 5.2.3).
NOTE:
Suggestion for first start up or after change of drying material:
since the drying material in the columns can be loaded of moisture depending on transport and storage
conditions, it is useful to run the dryer for some hours independently from the compressed air system,
without dried air consumption in order to achieve the desired efficiency.
13.6 Integration in the compressed air system
To integrate the train in the external air system, after the previous steps, the following instructions must be
executed:
Pulse air system
 ensure that the downstream line is pressurized;

 slowly open the outlet valve, which intercepts the dryer downstream (if installed by the Client);
 during outlet valve opening take under control the pressure indicator; pressure should not
decrease under the operating pressure. Eventually, keep the outlet valve in a slightly open position
until the downstream line has filled up completely. At that point, the valve can be completely
opened.
WARNING!
Danger due to abrupt drop in pressure!
Slowly open the compressed air outlet valve; a rapid drop in pressure can cause dryer
damages.
13.7 Checks after first start-up
After the first start-up it is necessary to inspect that:

 thread and bolt connections are tightened;
 piping joints have not been damaged;
 foundation bolts are regularly tight;
 clamps screws of cables are closed;
 no air or water leakages occur;
 the condensate drain flows out;
 all operating parameters are as designed.
13.8Tests
Once the process is in operation, performance tests must be carried out on plant and equipment.
Finally, product design specification conformity must be proved.
MONITORING
14 MONITORING
DANGER!
 In emergency case, the safety valves installed on the condensate separators
could discharge air under pressure. Although the discharges are above the eye
level, attention must be paid.
Risk of burn!
o
Risk of sliding!
Potential leakages of lubricant oil or water (condensation or cooling circuit) could
cause sliding
Make sure that all protective covers are in place and that while the compressing
module is left unattended (in operation or not) the canopy/access doors of the
protective canopy are closed and locked.
Obey safety precaution. All persons positioned near to operating machinery must be
equipped with the necessary Personal Protective Equipment (PPE), namely
safeguard shoes, gloves eye and hearing protections and instructed on their use in
accordance with workplace safety legislation. In-observance can cause personnel
injuries.
Pulse air system
NOTE:
Ensure that the machines are operating at the rated pressure
ANOMALIES AND TROUBLESHOOTING
15 SHUTDOWN AND RESTART
DANGER!
injuries to eyes and/or skin! Avoid contact.
Risk of burn!
o
Risk of sliding!
Potential leakages of lubricant) or water (condensation or cooling circuit) could cause
sliding.
Never start-up the compressing units without all protective covers in place and
canopy/doors closed.
Obey safety precaution. Personnel in charge of start-up must be equipped with the
eye and hearing protections and instructed on their use in accordance with workplace
safety legislation. In-observance could cause personnel injuries.
Pulse air system
The necessity to shut down the plant can occur in different cases:
 maintenance;
 emergency or breakdown;
 disassembly.
Attention must be paid to the sequence of the required steps to avoid the unit damage and to preserve the
machinery efficiency.
Depending on the reason of shutdown, different procedures may be necessary:
 stop of the process without complete depressurization;
 complete depressurization.
Complete depressurization is strictly prescribed in case of disassembly and some maintenance activity (see
Section17).
NOTE:
To assure the proper valve positioning, the supply of compressed air to instruments (pilot air) must
NOT be removed prior to shut down the train.
To shut down a train:
 intercept the dryers closing the manual valves downstream the post-filters, or the dryer
intercepting valves (if installed by the Client);
 stop the dryers (see Section 5.2.3); note that all the actuated valves close, except at least one
inlet valve.
 shut down the upstream compressors (see Section 5.1.9.2); automatically the compressors
depressurize upstream the discharge check valve CV-002 installed upstream the aftercooler. Allow
enough time for the automatic blowdown valve to complete the vent;
 open the main isolator switch;

 close the main isolation valve of the compressors;
 de-energized the plant.
To completely depressurize a train it is necessary to:
 maintain open the manual valves installed downstream the pre-filters in order to ensure the
depressurization of the discharging line of the compressor, downstream the discharge check valve
CV-002.
 open the bypass draining valves of the pre-filters;

 to depressurize the post-filters, open the draining valves of the post-filters.
NOTE:
Sinergia declines any responsibility for damages due to incorrect shutdown procedure.
15.1Subsequent starts
Prior to restart a train:
 check lubricating oil level in the compressors. Add if necessary;

 verify that main isolation valve of the compressors is open;
 verify that all guards and enclosure panels are in place;
 verify that the downstream interception valves of the dryers are closed.
To restart follow the same prescriptions indicated in Section 13.5 and 13.6. Note that, if the train was not
depressurized the upstream intercepting valves of the dryers (if installed by the Client) are already open and
the lines are already pressurized
16 ANOMALIES AND TROUBLESHOOTING
Table 16.1- Table 16.7 list the main anomalies, which could occur during the compressing and drying train
operation. Related potential causes and troubleshooting are also reported.
Concerning the components which were provided by external suppliers, for further details consults the
associated handbooks in the appendixes.
Table 16.1: Main potential anomalies of compressing skids.
Problem Probable cause Troubleshooting
Ready to start conditions on the HMI

Verify and resolve ready to start conditions
not satisfied
- Verify causes of shutdown on HMI of the unit
control panel
Emergency stop activated
- Solve the problem
- Reset the emergency state on the HMI
- Verify causes of alarm on HMI of the unit
control panel
Compressor Alarm state activated
- Solve the problem
fails to start
- Reset the alarm state on the HMI
Check for defective sensor, bad sensor connection

Sensor failure
or broken sensor wires.
Check fuses, transformers, wiring connections and

Unit control panel not powered
power supply
Display panel and power on light does Check wiring. Verify 24VDC is within voltage
not highlight tolerance
- Check for obstructions in air inlet air system

- Check for obstruction of the air passage to the
Low suction pressure at unload / inlet
unload circuit
restriction
- Verify correct position/operation of suction and
Compressor recycle valves
shuts down
- Check for obstructed or plugged inlet air filter

Low suction pressure at load / inlet
- Verify correct position/operation of suction and
restriction
recycle valves
- Check oil level in gearcase sight glass. The

level should be between ¾ to 4/4 full
- Check complete machine against leaks
- Check if the oil filter is dirty or plugged;
eventually replace filtering cartridge
- Check if the oil relief valve is leaking, removing
the tube on discharge side. Replace the valve
if leaking
Low pressure of lube oil circuit - Remove flex line from vent side of hydraulic
cylinder. If a large amount of oil exits the
cylinder, overhaul hydraulic cylinder valve
assembly
- Inspect tang drive removing the oil pump.
Replace pump and/or drive assembly if found
defective
- Check auxiliary oil pump correct operation
$
- See ( )in Table 16.4
- Verify adequate ventilation
- Check if the tube bundle of the oil cooler is
dirty or plugged; ; in case clean
High temperature of lube oil circuit
- Check if the thermostat element in oil
temperature control valve TCV-CT106 is
Compressor
defective
shuts down
- Verify that ambient temperature is not
excessive
- Verify adequate ventilation and operation of
canopy cooling fan
st - Check that intake filters are not plugged; in
High temperature of 1 compressing
st case clean or replace
stage (at the 1 stage discharge)
- Ensure that inlet control hydraulic cylinder is
fully stroking when compressor is loaded.
Replace inlet/unloading assembly if it is found
defective
- Check for contact of airend rotors
- Verify adequate ventilation and operation of
High temperature at the intercooler (at canopy cooling fan
nd
the 2 stage inlet) - Check if the tube bundle of the intercooler is
dirty or plugged; in case clean
- Verify that ambient temperature is not
excessive
nd - Verify adequate ventilation and operation of
High temperature of 2 compressing
canopy cooling fan
nd
(at the 2 stage discharge) - Check if the tube bundle of the intercooler is
dirty or plugged; in case clean
- Check for contact of airend rotors

nd
- Check for air leaks between 2 stage discharge
flange and discharge check valve
nd - Check discharge safety relief valve for leakage.
High 2 stage inlet pressure at load
Replace the valve if leaks.
- Check discharge manual condensate valve to
ensure that it is closed
nd Check position of the inlet throttle valve, adjust the

High 2 stage inlet pressure at unload
opening position to have the required pressure
- Check against obstructions of components installed

downstream: air side of aftercooler, discharge
moisture separator or discharge check valve
nd
High 2 stage pressure - Ensure that air network has adequate receiver
volume
- Ensure that isolation valve is fully open
- Ensure that discharge pipe is adequately sized
Check for overload causes

Check for los wires and supply voltage
For fan motor: check for obstructions at machine inlet
Overload of main or other motors
Compressor
and outlet openings
shuts down
Manually reset motor overload relay, and press reset
button.
- Check opening/closing time set points on the HMI

- Verify correct operation of separator drain valves;
High condensate level in the condensate
see (*) in
separators
- Table 16.7
- Check for obstructions of condensate drain system
control panel
Emergency stop
- Solve the problem
Remote stop/start failure - Check remore stop/start switch and wiring

Remote trip from emergency shutdown control panel
system - Solve the problem
Driven motor fault - Verify motor wiring and power supply
Check for defective sensor, bad sensor connection,

Failure of sensor
incorrect power supply or wiring
- Check suction valve correct operation

- See (*) in
- Table 16.7
Suction valve does not operate correctly in - Remove tube that runs from load solenoid
”load” condition valve to the hydraulic cylinder. Start
Compressor
compressor and press ”LOAD / UNLOAD”
fails to load button. If oil does not come out of solenoid
valve. replace valve.
If cylinder does not fully stroke when load/ unload

Leaking seals in hydraulic cylinder button is pressed, replace inlet/unloading valve
assembly.
High ambient temperature Verify that ambient temperature is not excessive
Verify adequate ventilation and operation of

High temperature at Low ventilation
canopy cooling fan
the discharging line
Tube bundle of the aftercooler is dirty or
Clean
plugged
Low 2nd stage inlet Tube bundle of the intercooler is dirty or

Clean
pressure plugged
Excessive pressure Obstructed filtering cartridge Replace filter cartridge

drop on inlet air filter
Deterioration of filter material Replace filter cartridge
Excessive pressure Obstructed filtering cartridge Replace filter cartridge

drop on oil filter
Deterioration of filter material Replace filter cartridge
($) Auxiliary oil pump failure See the associated manual in APPENDIX R
Auxiliary oil pump Fault of the pump driven motor See the associated manual in APPENDIX R
does not operate when
required
Drain valve AA005/AA006 of the first - Check valve correct operation

stage/second stage condensate separator - See (*) in
do not operate correctly - Table 16.7
Plugged condensate separator - Inspect and clean.

Water in the system
- Inspect and clean
Plugged drain line of the condensate
- Verify drain line installation; incline drain lines
separators
away from drain valves
Cooler core dirty - Inspect and clean
Compressor operating over pressure - Check and adjust controller set points
Pressure relief valve
opens Defective valve Replace valve
- Verify commands from unit control

Compressor in unload condition panel or DCS
- Off-line controller
Modify setting parameter on the HMI of

Controller load/unload set point too low
the unit control panel
- Check air piping and components for
leaks
- Verify that manual valves (normally
Air leaks
closed) are not open
Low system air pressure - Verify that actuated condensate valves
are not stuck open
- Check if the control hydraulic cylinder is
Unloading valve not fully open fully extended; if not replace
inlet/unloading valve assemblyt
System demand exceeds system

Check system consumptions
capacity
Check filter condition and replace as

Dirty air filter element
required
Too low outlet air flow rate Too low flow rate supplied by operating Check compressor operation
compressor/s Repair to increase inlet flow rate
Leaking or accidental break of some Check operating components for leaks

components
Loose components (nuts and bolts,…) Inspect and tighten
Defective bearing, gear or transmission - Immediately contact Supplier

Excessive mechanical
noise level.
components - Do not operate unit
- Enclosure panels not in place or not
Install/close the enclosure panels
closed
Loose components (nuts and bolts,…) Inspect and tighten

- Immediately contact Supplier
Excessive vibrations Motor or compressor bearing failure
- Do not operate unit
External sources Inspect area for the equipment

Table 16.6: Main potential anomalies of drying skids.
Excessive pressure drop on - Obstructed filtering cartridge - Replace filter cartridge

filter (pre or post) - Deterioration of filter material
Dew point deterioration Inlet air temperature higher than - Excessive increase of temperature due
design conditions to compressor operation:
 Check compressor operation
 Repair to reduce air temperature
Compressors pressurization lower - Check compressor operation

than design conditions - Repair to increase air compression
Excessive pressure drop on upstream Check differential pressure; eventually

filter replace filter cartridge
Drain from upstream filter does not - Incorrect operation of actuated drain
run correctly valves; check, replace or reactivate
- See (*) in
- Table 16.7
Table 16.7: General anomalies.
- Check air piping and components for

Low air pressure at discharge leaks
Air leaks
line - Verify that manual valves (normally
closed) are not open
(*) Lack or not sufficient pilot air supply Check supply of pilot air; restore the
Faulty Actuated valve minimum pressure of 5 bar(g)
Faulty solenoid valve - Solenoid does not receive electric

current; check the electric circuit
- High/low voltage; check correct voltage
- Check fuses on the PLC terminal strip
- Check wiring between solenoid and PLC
- Solenoid coil is burned out; replace the
coil
Faulty actuator - Check whether the actuator is receiving

pilot pressure
- Ensure the inlet valve is not plugged
- Check if seals are dirty or damaged and
eventually clean or replace
Valve leaking Disassemble, check if seals are dirty or

damaged and eventually clean or replace
the seals
Faulty valve Disassemble, clean and repack or

eventually replace the valve
Display panel showing ### Communication error between panel Check cable connections between HMI and
instead of process value and PLC PLC
PLC not responding Check advanced PLC diagnostic with

engineering station
Network error If anything else has been added to the

Ethernet network, check for IP addresses
conflicts
MAINTENANCE AND REPAIRS
17 MAINTENANCE AND REPAIRS
DANGER!
Danger due to incorrect activities!
 Machinery maintenance must be performed by qualified and authorized technicians.
 Attempt repairs only in clean, dry, well lighted and ventilated areas.
Danger due to rotating machineries!
 NEVER perform maintenance activity on working machineries.
 NEVER remove protective guards while the machinery is operating.
 NEVER perform maintenance activity on pressurized components as long as the units
are pressurized; discharge of pressurized air, oil or water could cause severe
injuries. Avoid contact.
 NEVER open any drain valve or remove components without first ensuring that the
compressor is FULLY SHUT– DOWN, power isolated and all air pressure relieved
from the system.
 Air under pressure could be discharged both from the compressing and drying skids;
particles included in the air could be violently ejected causing severe injuries to eyes
and/or skin!
 Plant operation generates a strong and sudden noise which could cause damages to
the auditory apparatus;
Pressurized water squirts could be discharged from the cooling circuit causing injuries to
eyes and/or skin!
Risk of burn!
 External surfaces are subjected to high temperatures (>60 C). NEVER perform
o
maintenance activity on hot surfaces.

 Pay attention to presence of electricity supply; risk of electrical shock.
 Maintain dry footing, stand on insulating surfaces and do not contact any other
portion of the machineries when making adjustments or repairs to exposed live parts of
the electrical system.
Pulse air system
 NEVER leave tools or other object (such as cleaning rags) on the units; potential
falls could cause damages of other components and/or personnel injuries.
 Pay attention to potential oil/water leakages from the compressors and/or

desiccant agent beads spilled on the floor; risk of sliding.
 NEVER perform welding operations or modifications on the components.

 NEVER use components, pipes or valves as climb support or holding points;
there is the risk of injuries due to slipping, components breaks, damages of the unit
due to applied stresses and/or discharge of compress air/oil or water.
 Prior to starting any maintenance activity ensure that:
o components/machinery under maintenance is depressurized
o electrical supply has been isolated;
o the machinery cannot be started accidentally by posting warning signs
and/or installing suitable anti–start devices;
o all residual electrical power sources (mains and battery) are isolated.
o warning signs indicating that maintenance activity is in progress are clearly
visible;
o maintenance instructions prescribed in the manuals associated to the
components under maintenance are followed.
 Prior to opening or removing panels/protections of a machinery, ensure that:
o who will operate on the machinery is aware of the reduced level of protection
and additional hazards, including hot surfaces and intermittently moving parts;
o the machinery cannot be started accidentally by posting warning signs
and/or installing suitable anti–start devices;
 Prior to attempting any maintenance work on a running machine, ensure that:
o the work carried out is limited to only those tasks which require the machine
to run.
o the work carried out with safety protection devices disabled or removed is
limited to only those tasks which require the machine to be running with
safety protection devices disabled or removed.
o all hazards present are known (e.g. pressurized components, electrically live
components, removed panels, covers and guards, extreme temperatures,
inflow and outflow of air, intermittently moving parts, safety valve discharge
etc.).
o appropriate personal protective equipment is worn.
o loose clothing, jewellery, long hair etc. is made safe.
o warning signs indicating that Maintenance Work is in Progress are posted in a
position that can be clearly seen
o
 Make sure that all protective covers are in place and that while the compressing
module is left unattended (in operation or not) the canopy/access doors of the
protective canopy are closed and locked.
 Obey safety precaution. Personnel in charge of maintenance and repairs must be

equipped with the necessary Personal Protective Equipment (PPE), namely
safeguard shoes, gloves, eye and hearing protections. In-observance could cause
personnel injuries.
It is recommended a preventive maintenance activity of the plant in order to ensure efficient operation and
high performance for a elevate number of years. The following sections illustrate the main maintenance
activity prescribed for the compressors and the dryers. Maintenance of the equipment installed on the skids
must be performed in agreement with the relative manuals (see, APPENDIX R).
The list of the spare parts prescribed by the Vendor are attached in APPENDIX O and APPENDIX P.
NOTE:
Use of spare parts in compliance with the Manufacturer requirements and guidelines is recommended.
Original spare-parts guarantee these aspects; non-original parts could damage or cause not correct
operation of the plant.
WARNING!
Danger due to incorrect activities!
Once required maintenance activity is performed, prior to put again the plant into
service, ensure that:
 the skids are suitably tested;
 all removed guards and safety devices are restored;
 the compressor canopy is replaced and the doors are closed;
 hazardous materials are effectively contained and disposed of.
17.1.1 Draining the water system

Should it become necessary to completely drain the water system, proceed as follows:
 Disconnect the inlet and discharge water lines from the connections located at the rear of the unit.
 Locate the oil cooler by removing the left and center rear panels. Remove the two drain plugs
located at the end of the cooler.
Pulse air system
 Allow the system to completely drain.

17.1.2 Pre-lube oil pump
For details about the auxiliary oil pump and its driven motor see the attached appendixes in APPENDIX R.
To remain efficient the compressor components require a routine maintenance, as scheduled in Table 17.1
Table 17.1: Maintenance schedule for 4-year operation prescribed by Sinergia for the main components of
the compressing skids.
COMPRESSING UNIT
Maintenance schedule
DAILY
FIRST 150 HOURS
1 MONTH
3 MONTHS
2000 HOURS
4000 HOURS
6 MOUNTS
8000 HOURS
1 YEAR
16000 HOURS
4 YEARS
40000 HOURS
Assembled components Kind of maintenance
COMPLETE SKID Visual and functional check *
DRAIN Functionality check *
Check the lubricating oil level and replenish

LUBRICANT OIL *X X X
as necessary.
Check differential pressure *

AIR FILTERS
Replace (every 2000 hours or 6 months) X X
CONDENSATE STRAINER Clean *
OIL FILTERS Change (every 2000 hours or 6 months) X X
- Check for build–up of foreign matter.

COOLERS - Clean if necessary by blowing out with *
air.
Operate manually to verify that the

valve mechanism is functioning
SAFETY VALVES *
correctly and that a small amount of air
is released.
Check all hoses for signs of

HOSES *
deterioration, cracks, hardening etc.
- Lubricate the main motor drive end

bearing.
MOTOR BEARINGS *
- Lubricate the main motor non–drive end
bearing.
LUBRICANT OIL Replace (4000h or 1 years operation) X X
CONDENSATE SOLENOID
Rebuild using field kits. *
VALVES
Inspect and replace if necessary.

BLOWDOWN SILENCER *X *X
(every 4000 hours or 6 months)
Clean
GEARCASE BREATHER *
(every 4000 hours or 6 months).
*: checks; X: replacements
Pulse air system
COMPRESSING UNIT
DAILY
FIRST 150 HOURS
1 MONTH
3 MONTHS
2000 HOURS
4000 HOURS
6 MOUNTS
8000 HOURS
1 YEAR
16000 HOURS
4 YEARS
40000 HOURS
Replace:
- seals (kit seal);
- motor coupling; X
PRE-LUBE PUMP - flexible insert;
- pump coupling;
Gears X
BALL VALVE Replace
(three ways, upstream oil X

filters)
Replace ball valves X
DRAIN line Replace:

- solenoid valves
(of condensate separators) X
- check valve
- strainer
gasket X
UNLOAD LINE Element foam
X
Element metallic
gasket X
BLOWDOWN VALVE - Kit retrofit valve blowdown
X
- Hydraulic cylinder
CHECK VALVES Replace seat and spring using field kit. X
- Fully inspect, all external surfaces, and
fittings.
CONDENSATE
- Report any excessive corrosion, *
SEPARATORS
mechanical or impact damage, leakage
or other deterioration.
Inspect, replace if required. *
STARTER CONTACTORS
X
Replace X
HYDRAULIC CYLINDER
Replace kit, retrofit valve, blowdown X
- Clean
* *
CONDENSATE STRAINER - Change the lubricating oil and filter
X X
element.
COMPRESSING UNIT
DAILY
FIRST 150 HOURS
1 MONTH
3 MONTHS
2000 HOURS
4000 HOURS
6 MOUNTS
8000 HOURS
1 YEAR
16000 HOURS
4 YEARS
40000 HOURS
CHECK VALVES Replace

- downstream oil filters
- upstream aftercooler X
- on inter stage separator
draining line
SOLENOID VALVE Replace

X
(oil circuit)
gasket
X
UNLOAD LINE
Element foam
X
Element metallic
Replace two ways valve
COOLING SYSTEM X
Remove from the compressor, inspect and

SAFETY VALVES *
re–calibrate.
HYDRAULIC CYLINDER Rebuild using field kit. *
Flexible hoses and their couplings must

be regularly inspected, be free from
HOSES defects X
Replace all every 4 years
DISCHARGE CHECK VALVE Replace. X
In the following sections, prescribed main maintenance activities on the compressing skids are reported.
Regarding the components supplied by external providers, refers to the associated ,manuals.
17.1.3 Replacement of air filter

Inlet filter condition can be checked by reading the inlet vacuum gauge. Normal operating range is 7.5 – 17.5
mbar (3–7” water). Filter(s) should be changed when vacuum exceeds 20 m.bar (8” water).
To change inlet filter, turn unit off, remove the right end enclosure panel. Unscrew the wingnut and remove
the cover to expose the filter.
Pulse air system
Remove the dirty filter. Clean all interior surfaces of the filter box as required. Install new filter element(s).
Replace cover and tighten wingnut. Reinstall enclosure panel. Start machine and run in load mode to verify
filter condition.
Parts required: two air filer elements.
17.1.4 Replacement of oil and oil filter

To change the oil and filter, the oil should be warm for more effective drainage. Remove the right end
enclosure panel. Remove the pipe plug from the oil drain connection in the rear of the baseplate. Place a
suitable drain pan under the drain connection and open the valve.
When the gearcase is empty, close the valve and replace the pipe plug. Position the empty drain pan under
the oil filter. Remove the filter and allow the oil to drain from the oil cooler as well. Wipe the sealing surface of
the filter adaptor with a clean, lint–free cloth. Remove the replacement filter from its protective package.
Apply a small amount of clean oil on the rubber seal and install the element. Screw the element on until the
seal makes contact with the seat on the adaptor head. Tighten the filter a further 1/2 to 3/4 of a turn.
Unscrew the oil filler cap and add oil until the level reaches the top of the gearcase sight glass.
Following oil and filter change start the compressor and run inunl oad mode. Check the oil filter and oil drain
valve for leaks. Inspect the gearcase sight glass, the correct oil level for the sump during operation is 3/4 to
4/4 full. Some amount of foaming in the sight glass is normal. The oil level is interpreted as the level in the
sight glass below the top foam, where a line of separation can be seen. If additional oil is required, stop the
compressor and add oil as needed.
Optional oil pressure and temperature gauges are available.
Tools required:
- Wide–blade screwdriver or 3/8” wrench or 3/8” socket with ratchet
- 400mm adjustable wrench
- 600mm adjustable wrench
- Oil filter wrench
Parts required:
- Oil filter element;
- Approximately 45 liters of ULTRA COOLANT lubricant (CPN 92692292)
17.1.5 Gearcase breather maintenance

To service the gearcase breather, remove the right end panel. Remove the breather cover by unscrewing the
four retaining screws. Remove all of the breather media and clean with a suitable solvent. Allow the media to
dry. Re–install the media, the cover, and the enclosure panel.
17.1.6 Verify condensate drain functionality

To verify the functionality of the condensate drains, simply observe the timed operation of each. Each drain
should open at least every 2 minutes while the compressor is loaded. (The intercooler drain exhausts at a
much lower pressure than the aftercooler).
17.1.7 Check of separator drains

To check operation of solenoid valves, open the manual bypass valves momentarily once per day. For
extended shutdown periods, the manual valves should be opened and left open.
Strainers are provided upstream of the condensate valves to prevent any particles from plugging the
solenoid valves. Before any maintenance is performed on the strainers or solenoid valves, the strainer
service valves should be closed, in order to isolate from possible high pressure.
17.1.8 Condensate strainer cleaning

In order to service the condensate strainers (both interstage and discharge), the strainer service valves
preceding the strainers should be closed. Remove the screens from the strainers, while noting the direction.
Clean any debris from the screens and reinstall. Open the strainer service valves.
17.1.9 Airend bearing lubrication

Airend bearings are lubricated by the compressor lubricating oil and require no maintenance.
17.1.10Seal replacement of compressor module input shaft

To replace the seals of the compressor module input shaft perform the steps as follows:
 Remove the main motor utilising appropriate lifting gear as recommended and following established
safe working practices.
 Loosen the grub screw on the compressor coupling half.

 Remove the 4 bolts retaining the seal housing and screw 2 of them to remove the housing
complete with seal.
 Remove the old seal from the housing.

 Remove the old wear sleeve from the input shaft.
 Clean the seal housing, input shaft, wear sleeve inside diameter and seal outside diameter
(Absolutely grease free).
 Apply Loctite 620 to the sleeve and shaft journal. Install the sleeve ensuring that the face of the
sleeve is 4mm from the shoulder on the shaft. Wipe excess Loctite.
 Apply Loctite 524 to the seal outer diameter and install into the seal housing with lip facing towards
the compressor.
 Allow to cure for 2 hours.

 Clean the gasket face of the seal housing and gearcase housing (Absolutely grease free).
 Apply Loctite 510 to the gasket face on the seal and gearcase housings.
 Lubricate the outside diameter of the installation tool with clean oil.
Pulse air system
 Using the seal installation tool, slide the seal housing into place on the bearing housing, being
careful not to tilt the housing and seal. Apply axial pressure to the end of the installation tool while
the seal leaves the tool and enters the wear sleeve. The seal will slip between the tool and the
sleeve if pressure is not applied.
 Apply Loctite 242 to the 4 seal housing bolt threads and tighten.
 Refit the coupling flush with the end of the input shaft. Apply Loctite 242 to the grub screws and
tighten.
 When refitting the motor, ensure that there is a 4mm gap between the two coupling half faces. If
necessary, loosen the grub screws and slide the motor coupling forwards or backwards to achieve
this (Loctite and retighten the grub screws).
 Allow 24 hours for all Loctite applications to cure before restarting the machine.
17.1.11Motor bearing greasing
To grease the motor bearings follow the next steps:
 Clean the area around the inlet and outlet plugs before removing the plugs.
 Add the specified quantity of recommended grease using a hand lever gun.
 Replace the inlet plug.
 Run the machine for 10 minutes.
 Replace the outlet plug.
NOTE:
Use High Temperature Grease UNIREX N 6 (CPN:92844729) grease (for cartridge of 400 g) or
equivalent.
WARNING!
 Do not over pack the motor bearings with grease as this may lead to motor failure.
 Ensure dirt and/or other contaminants are not introduced into the bearing during the
greasing process.
17.1.12Draining the water system

Should it become necessary to completely drain the water system, proceed as follows:
 Disconnect the inlet and discharge water lines from the connections located at the rear of the unit.
 Locate the oil cooler by removing the left and center rear panels. Remove the two drain plugs
located at the end of the cooler.
 Allow the system to completely drain.

17.1.13Pre-lube oil pump
For details about the auxiliary oil pump and its driven motor see the attached appendixes in APPENDIX R.
17.2Drying units
To remain efficient the dryer components require a routine maintenance, as scheduled in Table 17.4.
Table 17.4: Maintenance schedule for 2-years operation prescribed by Sinergia for the main components of
the dryers.
DRYER
DAILY
WEEKLY
6 MONTHS
1 YEAR
2 YEAR
COMPLETE DRYING SKID Visual and functional check *
Visual and functional check;

MEASURING INSTRUMENTS *
Check of system parameters

PRE-FILTERS
Replacement of filter cartridge X

AFTER FILTERS
Replacement of filter cartridge X
Check correct operation *

SILENCERS (2”)
Replacement of filter cartridge or silencer X
ACTUATORS (SR63, SR100)

- SR.63 (of dryer exhaust valves)
Seal replacement X
- SR75 (of filter valves)
- SR.,100 (of dryer inlet and outlet valves)
BALL VALVES
(dryer inlet and outlet valves, pre- and post- Seal replacement X
filter valves)
SPIRAL GASKETS
- #150 2" (dryer inlet and outlet valves, pre- Replacement X
and post-filter valves)
- #150 1" (dryer exhaust valves)
GRAPHITE GASKETS (#150 1") Replacement X
Pulse air system
DRYER
DAILY
WEEKLY
6 MONTHS
1 YEAR
2 YEAR
INSTRUMENT AIR FILTER Replacement X
DEW POINT TRANSMITTER Calibration *
FLANGED CONNECTIONS Check *
ELECTRICAL SYSTEM Check and test *
CHECK VALVES (12 “316) Replacement X
SOLENOID VALVES
- Nabur bistable ¼” (dryer inlet and outlet) Replacement X
- Nabur monostable ¼” (dryer exhaust and
filter inlet)
Check *
MOLECULAR SIEVE
Replacement X
CONDENSATE DRAIN TRAPS Replacement X
SAFETY VALVES Replacement X
In the following sections, main maintenance procedures on the dryers are reported. Regarding the
components supplied by external providers, refers to the associated ,manuals.
17.2.1 Replacement of desiccant material

Life of desiccant material (about 18-24 mounts) depends on installation condition and impurities included in
the compressed air; in fact oil, dust, dirty particles sediment on desiccant material reducing its active surface.
Furthermore, replacement interval time depends on the regular replacement of the upstream filter; in fact,
malfunctioning of filter reduces the efficiency of desiccant material.
In normal operation conditions (except anomalies or emergency), the dryer Manufacturer prescribes an
annual check and the replacement of desiccant material every two years.
Dryer vessels must be filled from the top and emptied from the bottom.
Due to the height of the unit, to reach the filling nozzles at the columns top, each column is equipped with an
eyebolt lifting where the operator must fix the safety harness. Position of filling and emptying nozzles and
lifting eyebolts is indicated in Figure 3.16..
Further details are reported in the General Arrangement (APPENDIX B).
WARNING!
Danger due incorrect behaviour!
 To reach the filling nozzle at columns top fix the safety harness to eyebolt lifting
located at columns top.
 NEVER use pipes or valves as climbing support or holding points; there is the
risk of injuries due to slipping components, components breaks, damages of the
unit due to applied stresses and/or discharge of compress air.
 Whenever it is necessary to use a rung ladder or a gangway, ensure that they are
appropriate to allow the operator to work in safe conditions.
 In addition to PPE mentioned in Section 17, wear an anti-dust mask to handle the
molecular sieves.
The steps of the procedure for desiccant material emptying are:
 shutdown and depressurize the dryer (sees Section 15);

 place a container under the column to collect the discharged material and avoid its dispersion;
 open the loading nozzle at the top of the column removing the blind flange;
 open the emptying nozzle at the bottom of the column removing the blind flange;
 left free-falling of the material from the tower into the placed container. In case the desiccant
material is so packed into the vessels that the flow is obstructed, help it inserting a small rod into
the unloading port.
WARNING!
Risk of sliding!
If the molecular sieve has been spilled on the floor, there is the risk of sliding on the agent
beads. Clean promptly the floor.
 carefully clean the base of the vessel from impurities and/or incrustations, draw using an
industrial vacuum cleaner;
 replace the flange seal and close the emptying nozzle;

 dispose the desiccant material as indicated in the safety datasheet (APPENDIX E).
The steps of the procedure for filling vessels with new desiccant material are:
 ensure that the emptying nozzle at the bottom of the column is closed;
 slowly discharge the desiccant material in the vessel to prevent chipping and generate dust
resulting in premature clogging of the filters;
Pulse air system
 fill the desiccant material in layers. If necessary, use a proper funnel and a small rod to distribute
the desiccant by through the opening of the vessel.
NOTE:
It is important to insert slowly the desiccant material to prevent chipping and generate dust resulting in
premature clogging of the filters.
Ensure a high bulk density inside the vessel. To this purpose, during the filling, beat regularly with a
rubber hammer on the exterior wall of the tank or use a vibrator applied to the vessel; these methods help
the material compaction. The desiccant material must fill completely the columns and must never be
pressed with any mechanical equipment.
 replace the flange seal and close the filling nozzle;

 pressurize the dryer (see Section 13.5);
 ensure that there are no leakages spraying water soapy on the filling and discharge nozzles;
 restart the dryer (see Section 15).
WARNING!
Desiccant material contact!
In case the adsorption material comes into contact with the eyes, immediately wash
them with abundant clean water.
17.2.2 Replacement of air filter cartridges

Filters prevent contamination of discharge dried air, as a consequence they must be checked daily and
replaced as often as required in case of excessive increase of differential pressure. Furthermore, a maximum
differential pressure of 0.4 bar(g) is allowed in order to prevent the cartridge collapse. In any case, in normal
operation conditions, Sinergia prescribes the replacement of filters cartridge every six mounts.
The dryer is equipped with a couple of pre-filters and a couple of post-filtering systems. Duplex filtering lines
are provided to work one as the alternative to the other. This allows performing maintenance activity on each
filter maintaining the plant pressurized. In fact, once the dryer is stopped, each filter can be intercepted
closing the downstream manual valve. Note that the actuated valves installed upstream each filter
automatically close when the filter is stopped except the inlet valve of the working filter.
The procedure for the filtering cartridge replacement requires:
 stop the dryer in which the filter which requires maintenance is included;
 intercept the filter closing the inlet manual valve;
 depressurize the filter casing opening the bypass drain valve for the pre-filters or the drain valve
for the post filters;
 close the drain valve;

 open the filter unscrewing the bolts of the closing blind flange;
 loosen and manually remove the cartridge;
 check the filter covering for dirty particles and eventually clean;
 replace a new cartridge and ensure that it is correctly placed;
WARNING!
Filters cartridges CANNOT be cleaned with compressed air.
 close the filter screwing the closing blind flange; change the gasket if damaged;
 verify that the pointer of the differential pressure gauge is on 0 position;
 dispose the cartridge as indicated in Section 18
 open the inlet manual valve;
 restart the dryer.
The procedure is the same also for the post-filters. Note that it is possible to intercept each post- filtering line
and not each single post-filter.
17.2.3 Silencer replacement

Silencer operation is fundamental during regeneration of desiccant material; malfunctioning or obstruction
may cause an excessive increase of pressure, which could irreparably damage the desiccant material and,
in extreme cases, cause the silencer burst.
WARNING!
Danger due to obstructed silencer
Obstruction of silencer may generate the build-up of dangerous overpressure, with
consequent burst of the silencer. Fragments ejection may cause personnel injury and
material damage.
Dryer Manufacturer prescribes a daily check and a replacement of the silencer every six mounts. However,
replacement is always required in case of excessive pressure in the columns during regeneration.
The procedure for silencer replacement comprises:
 shutdown and depressurize the dryer (see Section 15);

Pulse air system
 replace the silencer;

 dispose the silencer as indicated in Section 18.
The silencer is of standard type, composed by a cartridge in a casing. Instead of changing-out the silencer,
only its cartridge could be replaced.
The procedure for cartridges replacements comprises:

 remove the cap of the silencer;
 loose and manually remove the cartridge;
 check the cartridge covering for dirty particles and eventually clean;
 replace a new cartridge and ensure that is correctly placed;
 replace the cap;
 restart the dryer;
 dispose the cartridge as indicated in Section 18.
17.2.4 Replacement of pilot air filter
Filter of pilot air purify the air used by instruments command. A dirty or damaged filter may influence the
operation of valves. The Manufacturer prescribes an annual replacement of this filter following the steps:

 open the filter unscrewing the bottom casing;
 remove the filtering element by rotation;
 replace a new filtering element;
 close the filter screwing the bottom casing;

 dispose the cartridge as indicated in Section 18.
For further details eventually consult filter manual if available.
17.2.5 Drain check

Correct operation of condensate drains of dryer pre-filters is fundamental; malfunctioning may cause filter
filling of condense and consequent reduction of dryer performance. To check drain operation of pre-filters,
open the bypass drain valve and verify that no condensate drains. Drain of condensate would mean not
correct operation of the actuated condensate valve or not correct position of the intercepting valve.
17.3Check of electrical system
DANGER!
Danger due to presence of electrical supply!
Cables of electrical supply and of external lines are under power also after the train
shutdown. Before to start any activity on the electrical system, ensure that electrical
supply cables and external lines are voltage-free. Furthermore, ensure that electrical
supply cable to the skid components are secured against switch-on.
The electrical system must be checked every one year, following:
 shutdown and depressurize the train under review (see Section 15);
 make the electrical supply cables to the machineries voltage-free;
 secure the electrical supply cable against switch on during checks;
 check wirings and control panels for visible damage and corrosion.
MATERIAL DISPOSAL
18 MATERIALS DISPOSAL
Sinergia is actively engaged in environmental protection in agreement with ISO 14001 standards, and it
always designs, manufactures and develops all its products as recyclable as possible.
Recycling is a source of wealth, which contributes to pollution reduction by the recovery of materials for
reuse.
Recycling prevents the waste of potentially useful materials and reduces the consumption of both raw
materials and energy, consequently the emission of greenhouse gases.
In case of disposal of the machineries of the plant to which the present manual is associated, or of some of
their components, refer to the drawing/manuals for the constitutive material identification and classification in
recyclable or not. For detailed information of constituting materials of the components which were provided
by external suppliers, consults the associated handbooks in the APPENDIX R.
Concerning the lubricant oil and the desiccant material disposal, see the associated safety datasheet in
APPENDIX D and APPENDIX E respectively.
Materials can be disposed in agreement with the European Waste Catalogue (EWC) prescribed by the
European legislation (Decision 2000/532/EC). For countries outside the EU, please check the applicable
legislation.
When the units are to be permanently decommissioned or dismantled, it is important to ensure that all
hazard risks are either eliminated or notified to the recipient of the machine. In particular:
 do not destroy batteries or components containing asbestos without containing the materials
safely;
 do not dispose of any pressure vessel that is not clearly marked with its relevant data plate
information or rendered unusable by drilling, cutting etc;
 do not allow lubricants or coolants to be released into land surfaces or drains;
 do not dispose of a complete machine without documentation relating to instructions for its use;
Concerning condensate disposal, as waste water regulations vary by country and region it is the
responsibility of the user to establish the limitations and regulations in their particular area. Ingersoll–Rand
and its associated distributors are happy to advise and assist in these matters.
APPENDIXES
19 APPENDIXES
For brevity, the following appendixes are reported in the attached CD.
Operation & Maintenance Manual I
APPENDIXES
APPENDIX A: Process and instrument diagram for pulse air

Operation & Maintenance Manual II
APPENDIXES
APPENDIX B: General arrangement drawings showing maintenance and laydown

area requirements for PA
Operation & Maintenance Manual III
APPENDIXES
APPENDIX C: Installation layout

Operation & Maintenance Manual IV
APPENDIXES
APPENDIX D: Ultralube: Safety Data Sheet

Operation & Maintenance Manual V
APPENDIXES
APPENDIX E: Molecular sieve: Safety Data Sheet

Operation & Maintenance Manual VI
APPENDIXES
APPENDIX F: Power supply distribution arrangment

Operation & Maintenance Manual VII
APPENDIXES
APPENDIX G: Electrical load list

Operation & Maintenance Manual VIII
APPENDIXES
APPENDIX H: Foundation drawing

Operation & Maintenance Manual IX
APPENDIXES
APPENDIX I: Compressor long term storage procedure

X Operation & Maintenance Manual
Pulse air system
APPENDIX J: Control system configuration

Operation & Maintenance Manual XI
APPENDIXES
APPENDIX K: Logic control diagrams with tripping logic diagrams

Operation & Maintenance Manual XII
APPENDIXES
APPENDIX L: Wiring and schematic diagrams with fixing and installation detail for
local control station
Operation & Maintenance Manual XIII
APPENDIX M: Instrument schedule

Operation & Maintenance Manual XIV
APPENDIXES
APPENDIX N: Alarm annunciator list

Operation & Maintenance Manual XV
APPENDIXES
Operation & Maintenance Manual XVI
APPENDIXES
APPENDIX O: Spare part list for commissioning and start-up

Operation & Maintenance Manual XVII
APPENDIXES
APPENDIX P: Spare part list for one year operation

Operation & Maintenance Manual XVIII
APPENDIXES
APPENDIX Q: Packing list

Operation & Maintenance Manual XIX
APPENDIXES
APPENDIX R: Equipment manuals

Since 2003 Sinergia Srl has a quality management system in agreement with
UNI EN ISO 9001. The main aim is to manage as best as possible business
processes to guarantee always full satisfaction of the customers.
To constantly improve and consolidate the company ethic, aiming at both
minimum environmental impact of the production processes, and people health
and safety, in 2010 Sinergia adopted two very important integrated systems,
namely the environmental management system in agreement with UNI EN
ISO 14001 and the prestigious OHSAS 18001:2007 (Occupational Health and
Safety Assessment Series) certification.
The first system highlights the responsible and conscious behavior of the
company towards the environment, emphasizing the attention to energy
consumption, noise pollution, emissions into the atmosphere and waste
management in full agreement with the rules applicable to the business context.
OHSAS certification for own Employees Health and Safety Management
System is internationally recognized as the official standard on health and
safety at work. This certification underlines the company knowledge, the way it
controls risks and any unexpected occurrences that can originate from its
activities, and how it manages them to optimize the performances.
The management systems is certified by Lloyd’s Register, an independent
international body, worldwide leader in inspection services, auditing, goods’
analysis and services, and industrial systems.
Sinergia makes the best to design, propose solutions and work for products of
excellence quality, resistant, safe and in compliance with the user needs. To
this aim, Sinergia avails itself of international certifications, which enable
following the regulations concerning pressured equipment, namely PED and
ASME Stamp for European and American markets respectively.
Q.HS.E Management systems Product assurance systems:

Lloyd’s Register
ASME through: PED through:
Bureau Veritas Apave Italia CPM
Sinergia Srl
Onore . Bg . Italy
Ph +39 034673515
www.sinergia-it.com

Pulse

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Operating and Maintenance Manual – Az Zour Pulse Air

Alghanim International General Trading & Contracting Co.

Title Operating and Maintenance Manual

Document No. Project Document Type UNID

A/ZG/CAIR-MTS-142553 KWU3026 DD01 091132701

Handling : First issue

The Project Instruction Review

Section : Document Control Section : Project Management

0 08/08/2014 First Issue

Alghanim International Gen. Trad. & Cont. Co.

Operating & Maintenance Manual

17 MAINTENANCE AND REPAIRS 133

APPENDIX K: Logic control diagrams with tripping logic diagrams XI

Table 17.5: Continuation of Table 17.4. 144

2.3Notes about the present manual

2.3.1 Characters and symbols

It indicates a key word or phrase for the comprehension

Green test It indicates a component of the drying skids

 …………………………… It indicates a list of relevant features

 …………………………… It indicates a list of included components

 ………………………………… It indicates the steps of an activity that must be done in

o It indicates a sub-list of features

It indicates a sub- sub-list of features or components

NOTE: It provides an advise to perform an operation as safe

WARNING! It indicates the risk of potential material damages and it

DANGER! It indicates the risk of potential serious injuries, and it

2.3.2 Target group

3.1.1 Inlet air filter

3.1.2 Main motor

Feature Unit of measure Value

Current Nominal A 147

Full load A 127

Locked rotor A 1307

Efficiency at full load % 95.22

Power factor (p.u) at full load % 0.899

Maximum speed at full load r.p.m. 2975

Motor speed r.p.m. 2955

Locked rotor torque / Nominal

Breakdown rotor torque /

3.1.3 Screw air compressor modules

Table 3.2: Technical features of air screw compressor module.

Feature Unit of measure Value

Compressor shaft power at 10bar(g) kW 78

UNLOADED COMPRESSOR SHAFT POWER

Full load operating pressure bar(g) 10

Maximum off line pressure bar(g) 10.2

Minimum operating pressure bar(g) 5

Oil pressure -normal operation Bar(g) 3.1

Oil pump Positive displacement, gear type

Total system capacity lt 40

3.1.3.1 Compressor block

3.1.3.2 Compressor stages

Figure 3.5: First compressor stage: low pressure stage.

Table 3.3: Screw compressor parameters.

Operative levels Unity of measure Value

Operating pressure in/out barg Atm / 10

Design pressure barg 12

3.1.3.3 Gear box

Figure 3.7: Gear box components.

3.1.3.4 Bearing and sealing

Figure 3.8: Bearing system of the high-pressure compressor.

 The sealing system is constituted by (Figure 3.9):

Figure 3.9: Sealing system of the high pressure compressor.