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Contents of Table
1. Abstract
2. Problem faced
5. Lesson Learned
Appendix
1. Abstract
271
Background
After revamp of reformer CCR process where all three
compressors are running without stand-by, compressor valve life
decreased drastically from 1 year to a few(2~3) months.
Troubleshooting
Whole entire factors were investigated from process condition
change, piping layout, separating drum size and valve design.
Very viscous and sticky heavy hydrocarbon called `Green Oil’ was
found at the valves & cylinder could cause valve late closing and
consequential excessive impact stress during valve closing.
Increased colder spill-back by-pass flow could cool down gas
after separator drum made easy formation of heavy hydrocarbon
condensate.
Moreover liquid condensate could exist as slug at low point of
suction manifold piping directly connected to compressor suction.
Valve dynamics and pulsation after revamp was acceptable but
plate type valve seemed to be not good choice under service
including sticky liquid showing bouncing at edge of plate during
late closing.
1
1. Abstract
272
Reactor
Naphtha Feed
Recycle Gas
Compressor
H2
Consuming
Heater Unit
CCR Net Gas Chloride
Catalyst
Compressor Treater
Chloride &
Water Reformate
CCR Injection Separator
3
2. Problem faced
274
40~44 C 30 C
~88% H2 30 C 30 C
1st Stage 2nd Stage
130 C
134 C
Gas Temperature Profile
Chloride
Treater
Separator Before
Revamp After Revamp
49~52 C
Suction Separator
40 C
40 C
Product Liquid Product Liquid Product Liquid
Spill-backed Gas
30 C
1st Stage
Suction Manifold
Suction Separator
Spill-back By-pass
Suction Separator
Tie-Point
6
3. Root Cause failure Analysis
277
7
3. Root Cause failure Analysis
278
Impact Velocity
(mm/sec)
Valve Lift(m)
9
4. Solution Provided and its Result
280
~88% H2
1st Stage 2nd Stage
Chloride
Separator Treater
12
4. Solution Provided and its Result
283
45~47 C
40~44 C 30 C
1st Stage 2nd Stage
30 C
30 C
Chloride
Separator Treater
13
4. Solution Provided and its Result
284
Shape
15
5. Lesson Learned
286
END of Document
Appdx. Specification of Net Gas Compressor
288
A-1
Appdx. Root Cause Analysis Table
289
A-2
Appdx. Root Cause Analysis Table
290