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PRESENTATION

RELIABILITY OF HYDROGEN AREA DIAPHRAGM COMPRESSOR

BRIEF AREA CODIFICATION


1. Area 100 - Catalyst & Co catalysts Storage & Metering 2. Area 200 -Bulk Polymerization 3. Area 300 -Polymer Degassing & Propylene Recovery 4. Area 400 -Block Copolymerisation 5. Area 500 -Polymer steaming & Drying 6. Area 600 -Polymer powder Storage & Extrusion

CONT
7. Area 700- Pellets Analysis, Homogenization, Storage & Bagging 8. Area 800-Process Facilities 9. Area 900- Liquid Effluent Treatment

H2 SUPPLY WITH PLANT INTERLINKING


The project deals with the reliability of makeup compressor in hydrogen area
It has very important role to play in case of not only PP but also for LLDPE/HDPE. In case of the failure or any malfunctioning of

the Booster compressors it is the duty of the make-up compressors to maintain bullet pressure so that it can supply when needed.

RELIABILITY CHECKS
Quality maintenance procedures. Timely inspections of all systems incorporated. Study of all previous maintenance history cards to find the trend of failure. Prior intimation of future problems by use of Condition Monitoring systems.

MAKE-UP COMPRESSOR SPECIFICATIONS


Make: Burton Corblin,France Model:A5CCL60/150 Type: Diaphragm type, 2 stages Suction pressure: 17.5-kg/cm2 abs Suction temperature: 45 Deg C Discharge pressure: 101kg/cm2 abs Capacity: 392 Nm3/hr Speed: 400 RPM Motor power:75KW Diaphragm Crack Detection system:yes.

TYPES OF COMPRESSORS

WHY DIAPHRAGM COMPRESSOR

WHY DIAPHRAGM COMPRESSOR

High efficiency: Carefully controlled cavity contours & clearance volume results in high volumetric efficiency with high compression ratio. Compression without contamination: The Burton Corblin triple diaphragm construction completely isolates the gas from the reciprocating & lubricated parts thus ensuring contamination free compression. Low stress cavity contour: Stresses in the diaphragm are kept well within the elastic limit, & the theoretical stress levels are below the endurance limit of the material. Cool running: Because of the large surface area of the heads & diaphragms, the presence of pulsing oil & cooling of the upper heads (process side), these types of compressors run considerably cooler than conventional piston type reciprocating compressors. Trouble free operation & Low Maintenance: Wear parts are minimized & all reciprocating components are constantly lubricated. Thus maintenance activities are also reduced.

OPERATING PRINCIPLE OF DIAPHRAGM COMPRESSOR

COMPONENTS LIST
Gas Plate Oil Plate Suction Valve Plates O ring Oil Pressure Limiter Piston Eccentric Perforated Plate Diaphragm Group Discharge valve Plates bolts Non-return Valve Piston pin Gear Lube-oil pump Compensating Pump

LUB-OIL CIRCUIT OIL COMPENSATION FOR RELIABLE GAS COMPRESSION & PRIMING

COMPENSATING PUMP-A GLANCE Makes up the oil loss past the piston in the hydraulic pump. Driven by the crankshaft itself. Pumping element mounted on the eccentric, which due to its non-centric rotation cause the pump to suck & discharge. An oil-overflow valve resends the excess oil back to sump.

DIAPHRAGMS LIFE,RELIABILITY & INTEGRITY OF CRACK DETECTION SYSTEM Three diaphragms (SS) in a set. Gas side Solid metallic. Intermediate - Diaphragm with pressure tapping slot in periphery. Oil side Diaphragm with pressure tapping hole matching with I/M side diaphragm & similar hole in Perforated plate.

AVERAGE SERVICE LIFE OF DIAPHRAGM 3000-4000 HRS

CRACK DETECTION

PROBLEMS FROM HISTORY RECORDS & RECOMMENDATIONS Problem: Compressor tripping due to crack detection signal. Cause: All three diaphragms broken. Reason: Clearance between plunger & liner became 0.15 instead of 0.06 mm.

Cont
The cushioning effect of oil was absent due to high clearance Striking of diaphragm with perforated plate & subsequent breaking. Action Taken: New perforated plate, plunger & liner fitted.

Cont
Recommendations: To avoid such future happenings we should 1. Maintain minimum lube-oil pressure to be 2.4 bar g. Check in every 3 months. 2. Periodic cleaning/ inspection of lube-oil filter. 3. Ferrography test or dust particle /moisture content of oil to check in the interval of 6 months. Oil to change also after every 3000 hours of operation.

Cont
Problem: Compressor tripping Cause: 2-nd stage gas side diaphragm broken. Possible Reason: Metal fatigue Puncture by dirt or Deformed clamping area or Corrosion Action taken:Diaphragm replaced with new set.

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Recommendations: To avoid such future happenings Bolt tightening to be done as per recommendation (Torque chart). Diagonal Sequencing to maintain.

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Problem: 1st stage discharge temp. higher. Reason: The spring of the valve was found in damaged condition. Action taken: Valve replaced. Recommendation: Valve inspection to be done in the span of every 1 year.

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Problem: 1st stage gas discharge pressure not building (40 kg/cm2 max). Reason: Possibly due to Low oil pressure in 1 st stage cylinder. Leaking 1 st stage discharge &suction valve Low gas suction pressure Inadequate limiter function Air locking

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Action taken: Oil circuit from compensating pump, 1 st stage suction to oil delivery line cleaned. 1-st stage suction & discharge valves removed & replaced with spare. Oil pressure limiter cleaned Recommendation: 1. Valve inspection in every 12 month. 2. Periodic cleaning/inspection of Compensating Pump strainer.

Problem: Heavy leak from 2-nd stage gas plate & gas side diaphragm. Reason: Some probable reasons can be: Aging effect Gas & Oil plate studs not properly tightened. Resulting in Damage in gas plate contour. Improper sequencing of bolt tightening.

MY OBSERVATION

Cont
Action taken: Diaphragm set was replaced with new ones & plate bolt tightening with 72 N.m torque. Gas plate changed(15 years service). Proposed action plan: Bolt tightening to do as per sequence & recommendation (Max 70 Nm. allowed). During any scheduled PM job diaphragm, gas plate & perforated plate sealing surface flatness & finish to check.

FAIURE ANALYSIS : ROOT CAUSE STUDY


Though the diaphragm compressor ensures the most reliable & uncontaminated compression, it has some weak links that causes its components to fail repeatedly.The endeavor here is to locate those areas & giving useful recommendations to increase the life of diff. Parts.

1. Diaphragm: This is the heart of the compression system. Problems come from Improper fitment Non-uniform mechanical loading or clamping Thermal deformation Inadequate pressure from oil side

How reliable are the parts

CONT.
Recommended Practice: Before fitting of diaphragms sealing area finish (10 mm from circumference),complete drying out of anti-oxidant solvent etc to ensure.

Tightening force

Sealing surface Damaged metal to metal sealing

CONT.
In every month lube-oil condition to check (at least visual inspection) as dirt carry-over by oil can deposit on diaphragm & it gets punctured due to thermal stress. Monthly observation of plate bolt tightening torque to ensure over or under stressing of diaphragm & subsequent leak-zone.

CONT.
2. Gas Plate: Mainly looses its reliability & creates leak passage due to damage in the concavity of its profile. They may be caused due to: Overheating Mechanical stressing/flexing (banging diaphragm etc.) Erosion by particle carried over by hydrogen

CONT.
Whenever the plate is opened the

inside cavity to check properly.

Peripheral clamping surface should have proper finish. If area found damaged lapping of gas plate & perforated plate to be done accordingly.

CONT.
3. Compensating Pump: Problem due to:

Jammed oil strainer Narrowing of oil circuit due to dirt accumulation. Improper priming causing air trapping/ cavitation.

CONT.
To do checklist: Cleaning of strainer once in every 3 months At the same interval cleaning & dechocking of oil tubing's with plant air.No jamming of Eccentric bearings to ensure. Whenever pump opened priming to be done properly.

CONT.
4. Main lube-oil Pump: Problem can occur due to unclean oil filter. The normal starting pressure should be from <5 bar G with a working pressure of 2.4 bar G but particles blocking filter reduce the lube-oil pr(overheating & wearing out of internals). In every 4-6 months lube-oil quality & filter to check for cleanliness.

CONT.
5. Suction & Discharge valves: They affect the operability due to: Jamming due to dirt carryover from GC side. Leaking/ Passing (Thermal stress & Overpressure Damaged spring (loss of rigidity by thermal distortion)

CONT.

CONT.

To check: 1. Deposition of dust & particles on valve seat to check in every 4-6 months. 2. Spring stiffness to verify. 3. Leak test can be done to check for passing valve. In general we can sense passing (valve gets heated). NRV to check also during PM job for neatness.

CONT.
6. Oil-Pressure Limiter: Concerning areas are Stem can get jammed open/ closed causing higher or lower oil pressure. Spring Loosely fitted or over tightened. Wear particles coming into limiter & blocking it. Coke formation on spring also takes place, damaging its flexure.

CONT.
TO ensure: Stem & spring cleaning in every 4-6 months Spring tightening to be checked to ensure limiter opening at 10% over pressurization from specified gas discharge pressure. Spring condition (broken,loss of rigidity due to thermal distortion) to check.

CONT.
7. Flange joints: Leaking joints in flanges pose one of the biggest threats . Damaged plates Oring Improper or under tightening of bolts To minimize leaks All joints to clean at regular intervals. Gasketing, Orings to check. Recommended bolt torque to check time by time.

SAFETY VS. RELIABILITY


While judging the compressor reliability we have to take into account the safety of the Human & Environmental safety

2. Machine safety Vibration Analysis Ferrographic Techniques Apart from these good condition of trips & alarms, safety valves etc. to ensure.

THANK YOU

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