Dgs Report New

Kuwait Oil Company
BS-131 Dry Gas Seal K-2102 RCA Report
June 12, 2017
Presented by:
Equip Sup & Reliability Operations Support (Gas) Group
DGS RCA Report
TABLE OF CONTENTS
SECTION 1 3
1. EXCUSIVE SUMMERY 3
1.1 INTRODUCTION 3
1.2 PROBLEM DEFINITION 4
1.3 FAILURE SIGNIFICANT 7
1.4 FAILURE HISTORY 8
1.5 INVESTIGATION METHODS 9
1.6 CONTRIBUTE FACTORS 10
SECTION 2 12
2. ROOT CAUSE ANALYSIS 12

2.1 RCA INTRODUCTION 12
2.2 RCA SCOPE 15
2.3 RCA TEAM 17
2.4 RCA CASE 1 18
2.5 RCA CASE 2 19
2.6 CORRECTIVE ACTION PLAN 20
2.7 CONTROL PLAN 20
SECTION 3 21
3. APPENDICES
6/12/2017 DGS RCA Report Page 2

DGS RCA Report
Chapter 1
EXCUSIVE SUMMERY
1.1 Introduction
A Booster Station is part of an oil-field facility installed to fully utilize the

separated gas from the Gathering Centers. The compressed gas and
condensate are transmitted separately through pipelines to Mina Al-Ahmadi
LPG Plant.
There are two phases to implement this duty, each phase has three
compressor units (trains) connected in series LP1, LP2 & HP. The compressors
which made by GE is BCL type (for LP1 & LP2) driven by industrial GE gas
turbine frame 5. Compressor is considered to be the heart of the station &
any unexpected failure will directly impact in to the final production .The
DGS which made by John Crane fixed on both DE & NDE sides function is to
prevent compressed gas from leaking to atmosphere , its tandem
arrangement with labyrinth design as shown figure 1.
To insure that good performance function of DGS, dry gas & separation air
should provide without contamination at specific flow / pressure during
running or offload condition

DGS RCA Report
Figure 1
1.2 Problem Definition

In Dec – 2016 DE & NDE Dry gas seal cartridge were replaced due to high LEL
on secondary vent, so the old seal has been sent to John crane facility for
inspection.
DGS was serviced one year and two months , the next failure was
catastrophic & face broken into piece in March 2017 with only 3 months of

DGS RCA Report
service where the seal service life should be 3-5 years at normal operation
condition (Figure 2).
Figure 2
In our analysis we will study the two cases separately, based on John Crane
inspection reports (Appendix) the seal was exposed to contamination, this
contamination will go between stationary & rotatory part inside the seal at
the same time between two face as a result the spiral grove on mating ring
will not be able to build separation pressure & contact face will occur. The
main evidence in the report showing running marks on metal seat & mating
ring as result of contamination.
Treatment of gas should be implemented by eliminate condensate &
contamination before enters the seal, and this consider to be function
filtration system. As same as the treatment should implement to the process
gas by minimizing condensation using inlet scrubber .

DGS RCA Report
On another hand at 9th March 2017 we have visit the site to trace causes of
this issue and condensate was found on both separation air filter & seal gas
filter.
and once we remove the separation air filter we found filter saturated with
water in addition drops of water was stick on the filter shell wall, also
condensate gas found on the seal gas filter side which evaporate quickly .
The second failure occurred in march 2017 on DE side of the same
compressor which happened in short time ( less than three months ) has a
different scenario . As per John crane inspection report attached at appendix
show that matting ring fractured and carbon ring was worn-out due to
rubbing (Figure 3 ).

DGS RCA Report
In this case the contamination considered to play week contributed factor if

we noted the time to fail is only three months plus the both seal exposed to
the same gas inlet parameters and there is no failure reported on NDE side.
In our RCA report we consider over compressed as strong evidence of failure.
1.3 FAILURE SIGNIFICANT
At last failure on March 2017, the compressor was forced outage for 7 days ,
there was potential daily production losses of 250 MSCFD discharge from HP
compressor . Further the DGS repairing at John crane facility and new seal
was installed.
Figure 4 illustrate the replacement cost & potential down time for DGS.
Figure 4
DGS RCA Report
1.4 DGS failure History

As seen in figure the BS-131 commissioned in 2007, at 2015 the DGS was
replaced at Major inspection so almost 8 years of service without fail. After
replacing the seal it was stand one year & two months only.
The next failure in 2017 is unique & has different scenario, its stand only for
less than three months as showing in figure 5.
12/13/2016
DGS failed & replaced
4/30/2007 4/11/2015 3/3/2017
BS-131 Commissioning DGS Replaced during MI DGS catastrophic DE failure
1/1/2008 1/1/2009 1/1/2010 1/1/2011 1/1/2012 1/1/2013 1/1/2014 1/1/2015 1/1/2016 1/1/2017
4/07 10/17
Figure 5

DGS RCA Report
1.5 INVESTIGATION METHODS
Our investigation is built on collecting data since 2015 from Major inspection
until date, we have reviewed maintenance reports, Data sheets, following
procedure practices & daily operation & maintenance activity, we also did
site visits & meetings with different sections in order to gather the most
possible information which will help us to complete RCA. We are trying to
use only proved information & attested evidences certified with images &
documentation. Our main source of information will be:
1- Site visit & sampling for condensate & contamination.

2- Normal images & thermographic images for seal piping system
3- Meeting with different departments such as maintenance, operation,
instrument , vendor & GMSR
4- Documents like maintenance procedure, instrument report, events report
& drawing.
5- Chemical sampling Result of substance collected inside failed DGS
reported by JC.
6- Fuel Gas analysis report.

DGS RCA Report
1.6 CONTRIBUTE FACTORS
The main key to keep DGS working with higher performance & keep running
for long time is to control the parameters enter the seal, if we consider seal
as system, the main input & output factors can affect the function of it will
be:
1- Fuel gas
2- Separation air
3- Primary vent
4- Secondary vent
5- Oil drain
6- Hardware design & installation.
To understand the full picture, we will explain each point individually.

1- Fuel gas
When we talk about fuel gas we talk about:
a- Quality of the gas; no heavy hydrocarbon & no debris
b- Dryness; there is no condensation, we have to insure that temperature of
dew point as per design in addition use lean gas within desire specification
limit.

DGS RCA Report
c- Quantity of the gas (flow rate) /pressure; this related to orifice size,
labyrinth clearance & controlling system.
2- Separation air
As fuel gas system, the supplying air flow should maintain to desire
parameters & should be clean & dry
3- Primary vent
Any excessive pressure should not keep up inside the seal, it will be vented to
flare, and the flow of primary vent gas indicates the health of primary seal.
another point worth to mention here that in some case when condensate
entering the deal , the column of condensation will build up by the time &
finally flow back into the seal chamber which will harm the seal faces .
4- Secondary Vent
Secondary seal is the backup for primary seal in case of failure , the
secondary vent should keep air or mixed air with gas out of seal chamber ,
increasing of LEL level indicate secondary seal fail or in some case insufficient
air flow . As primary vent it’s no permit to accumulate any condensation on
vent line.

DGS RCA Report
Chapter 2
Root Cause Analysis
2.1 RCA Introduction
Root cause analysis (RCA) is a method of problem solving used for identifying
the root causes of faults or problems. A factor is considered a root cause if
removal thereof from the problem-fault-sequence prevents the final
undesirable event from recurring ; whereas a causal factor is one that affects
an event's outcome, but is not a root cause. Though removing a causal factor
can benefit an outcome, it does not prevent its recurrence with certainty.
On another hand there are many tools and techniques to perform root cause
analysis:
• Cause and effect diagram or fishbone diagram

• Failure mode and effects analysis (FMEA)
• Pareto analysis — 80/20 rule
• Fault tree analysis
• Barrier analysis
• Cause mapping

DGS RCA Report
 5 whys
 Apollo methodology
In our RCA we used APOLLO methodology & and software (RealityCharting

TM).
In our RCA we have two different modes of failure, the first occur in Dec
2016 and the other considered as catastrophic failure in Mar 2017. The time
between the two failures doesn’t exceed three months, so this RCA will help
to indicate the Root causes for both cases and recommended action to
prevent reoccurring.
Based on John crane Last inspection report dated on 2017, the seal matting
ring founded fracture into pieces & heavy running marks on the seat plus
carbon worn-out due to rubbing on mating ring, the most likely scenario that
seal face was running under compression, This could be happened because
of wrong assembly or Axial displacement of the shaft.
In this case it’s highly recommended to insure to do proper assembly of the
seal as same as follow right installation procedure.
At the same time to insure long life of DGS , it should run out of
contamination, in case of gas or separation air enters with condensate or

DGS RCA Report
non-specific condition the two faces of seal will not be able to build pressure
to maintain gap which not exceed 3 micron &contact will occurred.
To achieve that, dry gas filter designed to remove condensate & any debris to
prevent from entering the system, so gas should be heated to desire
temperature to insure correct dew point, as same as separation air entering
the seal should be dry & coalescing filter should be able to remove
condensate water.
You can see next figure how much condensate water passing the filter enter
into seal (Figure 7 ) .
In our case the coalescing air filter is manually drained every shift as routine
task.

DGS RCA Report
At the same time lab Chemical analysis should be taken for the samples
collect while inspection or during site visit as below:
1- Condensate water & to calculate daily amount to indicate efficiency of the
coalescing filter
2- Black powder & rust taken from gas filter
3- Contamination inside DGS cartridge.
4- Black contamination around cartridge.
5- Fuel gas.
At conclusions the most significant cause of RCA study can be listed as

1- Insufficient control on gas inlet condition
2- Condensate at gas inlet.
3- Capability of filtration system
4- Assembly from manufacture
5- DGS shimming.
2.2 RCA Purpose
During our RCA we do analysis for all possible root causes to understand
relation between each potential causes. After identify the root cause we
determine recommendations to prevent reoccurrence failure, we also put
DGS RCA Report
control plan to monitor the process & to insure implementation of

improvement.
On other hand this report seek to understand the value of root cause analysis
(RCA) recommendations for practice improvement purposes , Increasing
awareness of failure effect and rising levels of individuals training .

DGS RCA Report
RCA Team Member

From 9th to 11th March 2017 we have met with different teams from
different departments like operation & maintenance , during meeting we are
trying to collect evidences & data related to the last two failure trying to find
the contribute factors effecting the performance of DGS .
Member name Email Position

Ahmed Al-Qattan AEQattan@kockw.com Snr.Engineer ( Equip Sup & Reliability )
Karim Abdulhadi Kabdelhadi@kockw.com Engineer ( Equip Sup & Reliability )
Hamad Al-Baghli hbaghli@kockw.com Engineer ( Equip Sup & Reliability )
Ahmed Al-jamman Ajamaan@kockw.com Snr.Engineer Mechanical Maint
Mohamed Darweesh MDSaqer@kockw.com Snr.Engineer ( Equip Sup & Reliability )
Rohshen Mathew Rmathew@kockw.com Engineer ( Equip Sup & Reliability )
Abdulrahaman Hassan Abhassan@kockw.com Snr. Gas Engineer
Yaqoub Yosef Yykhalaf@kockw.com Engineer ( Equip Sup & Reliability )
Yuiry Oryeshkin Yuriy@johncrane.com John crane Tech

RCA Case 1 (failure 2016)
Action ID: 9
seal face fixed with wrong Caused this point clarified with
direction JC
By
Root Cause (C) ID: 6

Ruled out R
Assembly issue Caused
By
Condition ID: 10
possible scenario R
wrong material Caused
More Info Needed
By
consideration R
A
Condition ID: 4 ID: 14
Root Cause (A)
seal faces over Caused wrong Axial movement confirmed by GMSR , no
Caused
compressed adjustment of the shaft issue
By By
while installation
consideration scenario R Ruled-out R
Root Cause (A) ID: 15
wrong fitting installation done under

Caused supervision of GE as
By reference

Ruled-out R
seal installation Caused
By

consideration R installation done under
Seal damage while Caused
installing supervision of GE as
By reference
Ruled-out R
Action ID: 68
improper torque applying Caused

during installation O ring was cut two times
Action ID: 58 By
wrong shimming Caused

possible root cause
By O ring was cut two times R
No more information R
Action ID: 62 Condition ID: 69
available
filter o ring damage Caused Wrong material used Caused Material used
By By recomended by GE
consideration R Ruled-out R
Condition ID: 74
wrong o ring size Caused

No issue reported
ID: 18
By
Root Cause (C)
low gas flow Caused No or low fuel gas flow i...
By Ruled out R
consideration R
Condition ID: 70
Filter material Caused

More Info Needed
Condition ID: 59 By
filter system passing Caused

condensate JC observation R
By
Condition ID: 17 Strong site evidence R

Condition ID: 63 Condition ID: 71
Seal Over heated Caused seal faces over compresse...
filter capability Caused mesh size Caused
By More Info Needed
By By
evidence from discoloring R

consideration R consideration R
A
ID: 1 ID: 12 Condition ID: 72
Primary Effect Action
Dry Gas Seal DE Fractured seal faces , filter size Caused
Caused Caused More Info Needed
catastrophic failure Damage O ring & By
By discoloring metal By
Inspection evidence R Root Cause (C) ID: 21 Meeting with JC R

Condition ID: 64
Contamination Caused reported as poor
Auto drain system not Caused
By preform well performance , drain
By manually
Site evidence R
week evidence R
Action ID: 65
using process (rich) Caused Process gas spaded

instead of lean gas long time
By
Ruled-out R
Action ID: 75
Dimster carry over Caused

No issue reported
By

Ruled-out R
poor gas / air quality Caused Scrubber poor Caused
performance
By By
Action ID: 76
site evidence R consideration R
Auto drain pump starting Caused
problem No problem reported
By
Ruled-out R
Please Choose ID: 77
Gas contain heavy Caused

hydrocarbons substance cleared by operation
By
Ruled-out R
Condition ID: 45
wrong set point Caused set point has never

By changes , always 1 bar
Ruled-out R
reference line choke Caused Accumulated Caused

ID: 43 contamination Root cause
Root Cause (A) By By
fuel gas valve loose Caused
control
By
consideration R Line found block 2016 R
consideration R
Condition ID: 55
malfunction mechanically Caused no malfunction reported

component by instrument
By
Condition ID: 54
Ruled-out R
valve performance Caused
By

Condition ID: 56
No or low fuel gas flow Caused consideration R
wrong instrument signal Caused
inlet the seal No false signal
By
By
consideration R
Ruled-out R
Root Cause (C) ID: 44 Condition ID: 49
Insufficient orifice size Caused size wrong calculation Caused orifice size confirmed
By By with JC
consideration R calculation by JC R
Condition ID: 51
gas leak or passing Caused No physical leaking

By found
Ruled-out R

RCA Case 2 (failure 2017) Condition ID: 57
Long distance heater Caused Contribute Factor

By
Action ID: 52 AContribute Factor ID: 76
Condition ID: 54
Low speed runing compressor in recycling
Caused Caused Contribute Factor site observation R
mode for long time Low temperature inlet Caused
By By
By
Evidence R Operation R Condition ID: 56

Condition ID: 53 site observation R
Poor heat tracing & Caused
high dew point insufficient insulation Contribute Factor
Caused By
temperature for inlet gas
By
site observation R
site observation R Action ID: 55
Using rich gas during Caused Process discharge seal

standby line spaded
By
ruled-out R
Auto drain system not Caused under size Caused

Action ID: 45
preform function Design related to the flow rate
Condensate gas passing By By
Caused
through filter in to the
By Action ID: 62
seal
consideration R ruled-out R
condensate not fully drain Caused
before startup
Site inspection R By
Action ID: 78
consider scenario R
manual drain not perform Caused Drain done every shift
By reported by maintenance
ruled-out R
Action ID: 49 Condition ID: 65 Action ID: 79 Condition ID: 66
back flow from primary Caused long pipe distance to flare Caused Accumulate condensation Caused no drain point in the line Caused
vent by gravity effect . Contribute Factor
By By By By
consider scenario R site observation R consider scenario R site observation R
High Air Dew point Caused Super cooling Caused

temperature temperature 290-26 c system design condition
By By
instrument evidence R process condition R
Action ID: 61 Action ID: 67
condensate water from Caused multifunction of air dryer Caused

instrument compressor Contribute Factor
during start up By By
consider scenario R reported frequently R
maintenance
Action ID: 51 Action ID: 81 Condition ID: 82
back flow from secondary Caused Accumulate Caused No drain point on the line Caused
vent condensation Contribute Factor
By By By
consideration R consider scenario R design condition R
Condition ID: 69
filter design size isue Caused Contribute Factor

By
design condition R
Action ID: 83
improper fixing filter Caused Contribute Factor

By
Action ID: 47 ID: 70

Action
Action ID: 3
condensate water enter consideration R
Contamination inside seal Caused Filter O ring damage Caused
Caused Seal
By By
By
Condition ID: 108
Site evidence R site observation R
Site inspection R Oring material Caused
No issue as reported
By
consideration R
Action ID: 68
condensate passing the Caused

filter
By ID: 109
Condition
material Caused As per GE design
site inspection R By
Condition ID: 71
consideration R
Filter quality Caused
By
Condition ID: 110

JC observation R
Mesh size Caused As per GE design
By
Primary Effect ID: 1
Dry Gas Seal NDE & DE consideration R

Caused
Failure
By
Auto drain function Caused under capacity Caused Contribute Factor

By By
consideration R Evidence ,manually drain R

Condition ID: 73
Labyrinth seal design Caused Contribute Factor

By
evidence R
insufficient separation Caused Orifice size Caused

air flow As per GE standard
By By
Action ID: 48
consideration R JC Report R
lube oil penetrate Caused
secondary seal
By
Condition ID: 125

inspection report R
High Lube oil high Caused No issue with oil
pressure pressure was reported
By
consideration R
Action ID: 134
Process contamination Caused process liquid carried o...

carried over
By
evidence R
Action ID: 94
wrong material selection Caused

More Info Needed
By
Action ID: 91
consideration R
Wrong assembly Caused
By
Action ID: 95
consideration R
wrong seal configuration Caused
More Info Needed
By
consideration R
Action ID: 96
seal shimming Caused Contribute Factor

By

Root cause R
DSG under compressed Caused Wrong installation Caused
forces procedure
By By

Consider scenario R consideration R
seal fitting Caused stator sleeve fitting Caused
No issue with fitting
By By
consideration R ? R
Action ID: 122
bearing shimming Caused no change on thrust

By bearing clearance
Action ID: 98
consideration R
Axial movement of shaft Caused
By
Action ID: 123

Possible scenario R
Compressor exposed to Caused no reported issue due to
hydraulic forces like high vibration
surge By
possible scenario R
Condition ID: 115
wrong setpoint Caused Set point was reviewed ,

By Ok

consideration R
Inlet Scrubber High Caused Condensate Caused
Root cause
Level By Pump Malfunction By
Condition ID: 116 Condition ID: 128 Action ID: 129
Evidence R Evidence R
wrong reference Caused contamination inside Caused process liquid carried Caused
pressure signal feed back process pipe over
By By By
Condition ID: 131

Condition ID: 114 possible scenario R possible scenario R Evidence R
process gas quality Caused
Flow control valve Desired Condition
Caused By
malfunction
By
Action ID: 117
Evidence R
wrong calibration Caused valve calibrated in last
consideration R
By three month
consideration R
Action ID: 119
mechanically problem Caused No issue was reported

By since last MI
Action ID: 118

consideration R
poor valve responding Caused
By
Action ID: 120

consideration R
electronic element Caused No issue was reported
problem since last MI
By
consideration R

DGS RCA Report
Corrective action
Our recommended actions will include preventive action & corrective action,
all individual team responsibility is to insure performance quality & all team
should work together for implementing this actions.
ID Case description Case Type Action By Recommendation

Compressor recycling for To discuss with operation to minimize offload
76 Contribute factor operation
long time period as possible
Poor heat tracing for fuel gas to verify with GE to install Heat tracing & fix
56 Contribute factor GE
inlet insulation
Long heater distance from
57 Contribute factor GE The same action above
DGS inlet
66 No drain point on PV line Contribute factor GMSR GE to Perform modification to install drain point
train the staff to apply the right torque while
83 Improper Air filter fix Contribute factor Maintenance
fixing filter
111 Auto Drain water system Contribute factor GE GE Improve the design
GE/ GMSR/
96 Seal Shimming Contribute factor perform the right shimming for the seal
JC
GE to verify with JC about DGS separation seal
73 labyrinth seal design Contribute factor GE / JC
design
67 Malfunction Dryer Contribute factor GMSR IMPROVE PM for dryer
Condensate pump GMSR To Re-evaluated pump design with
132 Root case OTS
Malfunction vendor for the condition capacity
82 No drain point on sV line Contribute factor GE same action as ID 66
69 Filter low capacity Contribute factor GE GE to review the filter design
Control Plan
After identify the root cause & implementing corrective action there should
be way to measure & control the improvement successes , to insure the quality
of the plan , the value should be determined .

DGS RCA Report
The main goal to our case is to insure dry-clean gas inter to the seal plus good
controlling for parameters.to perform that the system should be monitoring for
critical parameters values that have big impact on DGS performance .
Corrective Measurement
ID Condition Monitoring & control action
Action value
Compressor recycling for Minimize
76 Load % / time Daily Events report / DCS
long time recycling
Design & fix heat Temperature to be daily monitoring &

Poor heat tracing for fuel Seal gas inlet
56 tracing - recorded – should be within design
gas inlet temp
insulation range
Long heater distance from
57 Same above Same above Same above
DGS inlet
Fix drain at lower Level – sight
66 No drain point on PV line Weekly check level as routine task
point glass
Leader supervision – perform
83 Improper Air filter fix Conduct training Actual practice
procedure check list
Record value & compare with pervious
96 Seal Shimming Correct shimming Shims Thickness
-
Improve the If apply , test should be performed for
73 labyrinth seal design MOC
design checking effectiveness of change
67 Malfunction Dryer Perform PM PM Compliance- Check dryness every startup & record
air dryness
Condensate pump Pump Trip events –

132 analysis for process gas – level
Malfunction performance re- scrubber level alarming
evaluate
Fix drain at lower Level – sight
82 No drain point on SV line Weekly check as routine
point glass
Test new design , take condensate
Improve filter Drained water
69 Filter low capacity sample , insure auto drain is capable to
design capacity
perform draining
All respective team should work together to apply improvement , if this not
working in this case RCA should be repeated again & searching for new factor
until improvement done .

Report
Turbomachinery Solutions
RCA Report on Seal Failure on LP2 PH 2 Compressor

BCL 806 installed at BS-131, Kuwait Oil Company
John Crane Document No. TGME-741-17

Customer Reference No. 2000748692
Customer Kuwait Oil Company
Compressor Tag No: 131-K-2102 (Ph2 LP2)
Site Location BS-131, North Kuwait
Issue Date 30th April 2017
Prepared by Yuriy Oryeshkin
Issue Description of Changes Date
A Original Version 30th April 2017

“The information contained in, or attached to this communication contains confidential information and is intended solely for the use of the individual or entity to whom they are
addressed and is subject to legal privilege. Do not copy it for any purpose, or disclose its contents to any other person without the written permission of John Crane.”
Page 1 of 44
Report
CONTENTS
1.0 Executive Summary……………………………………………………………………………2
2.0 Problem definition………………………………………………………………………………6
3.0 Reported Timeline……………………………………………………………………………...7
4.0 RCA Team Members…………………………………………………………………………..8
5.0 Summary of seal Inspection……………………..……………………………………………9
6.0 Root Cause Analysis………………………………………………………………………….11
7.0 RCA Solutions, Conclusions, Recommendations………………..………………………..13
List of Annexures:
 Annex 1 DGS Drawings
 Annex 2 DGS System P&IDs
 Annex 3 DGS Inspection Reports
 Annex 4 Apollo RealityChart
 Annex 5 Apollo Action List (at time of RCA report)
 Annex 6 RCA Action Support Notes
Page 2 of 44
Report
Abbreviations and Definitions

Table 1.
DGS Dry Gas Seal
DGSS Dry Gas Seal System
SOP Settle-Out Pressure
ROI Return of investment
GAD General Arrangement Drawing
PH1; PH 2 Phase 1 and Phase 2 of the BS-131 Project
SOW Scope of Work
CW and CCW Clockwise and counterclockwise direction of shaft rotation
SG Seal Gas
LP Low Pressure
PV Primary Vent
SV Secondary vent
HP High Pressure
DE Drive End
NDE Non-Drive End
LO Lube Oil
US Upstream of
DS Downstream of
JB Journal Bearing
TB Thrust Bearing
KOC Kuwait Oil Company
JC Consultant, John Crane - Turbomachinery Group
TBA To be advised
Page 3 of 44
Report
1.0 Executive Summary
Root Cause Failure investigation has been carried out at KOC. It was related to premature and
catastrophic seal failures on Drive End side of the Compressor type BCL-806 Tag Number 131-
K-2102 installed in position LP-2 at Phase-2 Booster Station-131 during winter 2016-2017
Root cause analysis meeting was organized by KOC and carried out using the Apollo
methodology and software (RealityCharting TM ). The “WHAT” of RCA problem definition is
Primary Failure Effect and was agreed to be “Drive End Seal Failure SN: 10083673”. With the
DGS inspection observations and consequent RCA process most significant root-cause
relationship contributing in observed failure scenarios identified as:
 Insufficient Seal Gas Flow and Seal Gas Control
 Inadequate Gas Conditioning
 Inadequate Coalescing Filtration of Separation Air
 Breach of axial Rotor-Stator relationship during Compressor assembly (related to last
incident only)
This is not final issue of the report because many action points still need to be clarified, such as
obtained chemical analysis of samples, dimensional review of the seal components, site
clarifications about seal installation and last day of operation, and many others. It is expected
that after completion of all action points and receiving all clarifications from involved parties’ root-
cause can be narrowed down. But it is for sure will be more than one issue.
Solutions to the root cause need to be agreed and accepted by their owner - KOC. We hope that
after submission of the Report the proposed solutions will be further investigated by KOC and
progressed.
We also hope the RCA Action list will be completed in a timely and thorough fashion and
distributed to ensure positive progress and prompt completion of this RCA.
This will ensure there are no further root causes or contributory factors.
Page 4 of 44
Report
2.0 Problem Definition

There are two seal failures reported on Drive End side of the Nuovo Pignone Compressor 131-K-
2102 type BCL-806 installed LP-2 at Phase-2 Booster Station 131 during winter 2016-2017. Last
Seal with serial number SN: 10083673 failed on DE side of the compressor in February 2017
within 15 days of operation. Previously installed seal SN: 0309-0484 failed on the same location in
December 2016 after 1.2 years of service which is also indicates unsatisfactory performance.
Seal Reports are given in Annex 3.
WHAT: Dry Gas Seal Failure SN: 10083673
WHEN: February 2017. Exact day and time KOC to clarify.
At the time of failure compressor was on Recycle (Off –Load) mode due to unavailability of
process gas.
WHERE: Drive end, Discharge side, Opposite to Thrust End of the Low Pressure Booster Gas
Compressor type BCL-806 Tag No: 131-K-2102, Phase 2 of Gas Booster Station BS-131,
Northern Kuwait.
SIGNIFICANCE:
Safety: At risk
Environment: Hydrocarbon gas released to atmosphere
Cost: To be advised by KOC for final report
Frequency: Two seal failures in 3 months
Table 2.
Failed seals subject to RCA
Seal Type/Arrangement 3095/28AT Tandem with GE-NP Separation Labyrinth
Seal Drawing No. S/42317,Issue F & S/42318,Issue F
Shaft End and rotation CW, NDE CCW, DE
Seals replaced in December 2016
Inspection Report No: 4397430 4397431

Cartridge number 0309-0483, 0309-0484,
Seals replaced in March 2017
Report No: 4406263 4406264
Seal Cartridge number 10001183 Failed Catastrophically

Page 5 of 44
Report
3.0 Reported Timeline
 BS-131 Compressor Station commissioned in 2007

 There were three cases of premature seal failure on HP Compressors BCL-504 in
2008, 2010 and 2011. Main reason of the seal failure was liquid contamination of
the inboard (primary) and outboard (secondary) seal stages (refer to Seal
Inspection reports 08/056A&B, 10/KSA22, 11/073A&B)
 In 2015 removed seals from LP-2 Compressors at BS131 Station Phase 1 and
Phase 2 during planned maintenance after more than 7 years of operation shown
similar evidences of heavy liquid contamination. (Seal Inspection Reports No:
JDUB15/031, JDUB 15/153, JDUB 15/154, JDUB 15/029)
 The seals with serial numbers 0309-0483, CW, NDE and 0309-0484, CCW DE has
been removed from BCL-806 Compressor Tag No: 131-K-2102, LP-2 Ph-2 in
period 18-24 December 2016 by KOC personnel. The seals failed after 1 year and
2 months of operation. DGS DE side secondary (outboard) seal developed High-
High vent gas content above % LEL during start-up and then Off-Load operation
(Recirculation). At the same time Primary Vent pressure and flow was zero. During
inspection in JC MEA it was reported significant liquid contamination (refer to
Inspection Reports: 4397430 & 4397431 and Preliminary Reliability Report
TGME-707-17). Seal inspection have been witnessed by KOC representatives.
 Newly refurbished seals with Serial Numbers 10083673 and 10001183 installed at
the same time and failed after 15 days in operation in March 2017. It was reported
that seal failure happen during off-load /recycling mode. Inspection reports are
4406263 and 4406264 are attached in Annex 3.
 GE FSE replaced the seals in period from 10 to 15 March 2017. Then compressor
restarted and still operates normally.
Page 6 of 44
Report
4.0 RCA Team Members
In period 9-12 April during site visit to BS-131 two RCA brainstorming sessions and follow-up
meetings have been attended with KOC Specialists representing Maintenance, Operation and
Reliability teams. Some engineers have been interviewed on site for understanding site conditions
and possible root-cause relationship of the latest and previous seal failures.
Table 3. RCA Members Contact Details
Name Position Contact Details
Mohammed Darweesh Senior Engineer (Equip Sup & Reliability) MDSaqer@kockw.com

Abdul Salam Operations Support Gas Group
Al-Saqer Kuwait Oil Company (KOC)
Ahmad Ebrahim Senior Engineer (Equip Sup & Reliability) AEQattan@kockw.com

Al-Qattan Operations Support Gas Group
Yaqoub Yousef Senior Engineer (Equip Sup & Reliability) YYKhalaf@kockw.com

Al-Khalaf Operations Support Gas Group
Hamad Al-Baghli Engineer (Equip Sup & Reliability) HBaghli@kockw.com

Operations Support Gas Group Tel: +965 238 79418
Roshan Elias Mathew Engineer (Equipment and Reliability)

RMathew@kockw.com
Elias Operation Support (Gas ) Group
Web: www.kockw.com
Kuwait Oil Company (KOC) Tel: +965 238 79419
Keyur Champaneria Sr. Technician Vibration Kuwait Oil Company (KOC)

Operations Support (GAS) Group Through Gulf Spic General
Cont.
Email: CKeyur@Kockw.com|
Tel: +965 238 21414
Patil, Jayant John Crane Kuwait Jayant.Patil@johncrane.com

Country Manager
Singewar, Jaideep John Crane Kuwait, Jaideep.Singewar@johncrane

Service Engineer
Page 7 of 44
Report
5.0 Failed Seal Observations
Table 4. Seal failure observation in March 2017. Cartridge number 10008373, Report 4406264
Observations Primary (Inboard) Secondary (Outboard)
Black Dry Deposits (chemical analysis

Contamination Black dry deposits
in progress)
Mating Ring Fractured Fractured
Primary Ring Heavy Running marking Heavy Running marking
Axial Movement Free Free
Rotor Metalwork heavy rubbing, Thermal discoloration Good Condition
Stator Metalwork heavy rubbing, thermal discoloration Good Condition
O-Rings compression set, thermal damage Compression Set
Liquid Contamination Fractured SiC IB Heavy running T-82 Seal Replaced

liquid like Crude Oil’ and OB Seats marking on IB& with labyrinth
OB Primary Ring
Compression Set and Solid Mechanical Contact at high speed and heavy
thermal degradation of Contamination rubbing between Retainer Inner and Spacer
the O-Rings Sleeve. Metal discoloration, bluing
Page 8 of 44
Report
Pictures below representing failure evidence of the cartridge SN:10008373
Pictures 1,2. Inboard Mating Ring: Fractures, stains of liquid.
Pictures 3,4. Inboard Primary Ring: heavy Running marking, Dry Contamination. Liquid stains.
Pictures 5,6. Outboard Mating Ring: Fractures
Page 9 of 44
Report
Pictures 7, 8 shows initiating point of cracks located at ID of both seats
Pictures 9,10 Rubbing and discoloration marks on Spacer Sleeve and Retainer Inner
Pictures 11,12 Thermal degradation and compression set on O-Rings at Inboard seal stage.
Page 10 of 44
Report
Pictures 13,14. Drive End, Discharge side Seal Bore contamination as found after seal removal.
Table 5. Cartridge number 3090-0484, Report 4406263
Observations Primary (Inboard) Secondary (Outboard)
Contamination Not visible Not visible
Mating Ring Light Running Marking Light Running Marking
Primary Ring Damaged drive flange Light Running Marking
Axial Movement Free Free
Rotor Metalwork Good Condition Good Condition
Stator Metalwork Good Condition Good Condition
O-Rings Wear marking Wear marking
There were no any major issues with the seal installed at NDE, Suction and Thrust End.
For detailed observations please refer to Inspection Reports 4406263 and 4406264 in Annex 3.
For better understanding all seal failure modes and different issues reported since 2008 till date
on HP and LP Compressors of BS-131 Phase 1 and 2 General Observation spreadsheet is
compiled and also presented in the same Annex 3.
Page 11 of 44
Report
6.0 Root Cause Analysis
During attending the site and participating in the RCA meeting organised by KOC at 10-11 April
2017 preliminary seal failure evidence was known only. After site visit John Crane team
continued working on RCA report in Dubai using Apollo methodology and dedicated software
RealityCharting. We expect this will be recognized and accepted because KOC Engineers use
similar approach to RCA. The task list was generated in Apollo Software (refer to Annex 5).
It was agreed during the meeting that “WHAT” of the RCA problem definition which is primary
failure effect to be Drive End Seal catastrophic failure in February 2017 when both Inboard and
Outboard Silicon Carbide Seats have been found fractured. Taking into consideration that
previously installed seal on the same compressor also failed prematurely it was decided to
consider information pertaining other past failures during the same RCA process. It is worthy to
say this seal is not first from BS-131 Compressor Station which has been found with fractured
seat on inspection. In 2011 similar damage was reported on the Secondary (Outboard) Mating
Ring of the cartridge 0308-0433 removed from HP Compressor BCL 504, refer to Inspection
Report 11/073B, issued 31/03/2011 by JC UK (Annex 3). Retrospective review of the inspection
reports has been carried out during this RCA investigation and shown that big number of
previously inspected seals have evidences of heavy contamination with both solids and liquids.
In the seal cartridge SN:10083673 after catastrophic damages, big amount of carbon particles
released from Primary Rings along with extreme temperatures inside the seal at the time of
failure erased all traces of liquids. However after studying seal components in details it was
possible to identify solid residue inside the Retainer Inner, stain marks whose could be
indication of evaporated liquid. Therefore latest failure mode can be in line with all previous
ones. Dry residue of contaminants collected from the seal surfaces then samples sent to
laboratory for analysis. This action will be on John Crane’s side. For such damages to occur
various issues external to the seals must be considered and investigated. They are:
 Liquid hydrocarbon formation in the Seals and Primary Vent lines - strong evidence
 Hydrocarbon liquid ingress from process side of the Compressor - strong evidence
 Lubricating Oil penetration from the Bearings - strong evidence
 Seal manufacturing and assembly issues – under investigation
 Seal Installation issues – under investigation
Page 12 of 44
Report
Solutions to the root cause must meet the solution criteria as per the Apollo methodology. They
are:
 The solution prevents a reoccurrence of the root cause. In the context of this RCA we do
not wish the root cause to reoccur within the previous failure timescales.
 The solution is within our control (KOC and JC).
 Meets your goals and objectives. In this case, to meet KOC 5 years maintenance change
out periods.
 Does not cause other problems.
Considering all the above RCA Action List was produced (See Annex 5) and communicated
within this report. The RCA action list tasks can be categorized as follows:
 Seal Gas Flow and seal gas control improvement (RCA Action List task 8, 9, 18, 24, 25,
26, 27)
 Seal Gas Conditioning improvement (RCA Action List task 13, 16, 20,)
 Metalwork / assembly checks – to ensure there are no manufacturing or assembly errors
that could have contributed to the root cause (RCA Action List task 19, 21, 29, 30, 31)
 On site system and trend checks - to study and ensure there were no external system
factors contributing to the root cause (RCA Action List task 1, 2, 5, 10, 11, 12, 14, 15,
17, 28, 37)
 Seal Installation review (RCA Action List task 3, 4, 6, 7, 22, 23, 34)
 Other non-root cause related tasks (RCA Action List task 32, 33, 35, 36)
As mentioned already, the RCA Action list is a current live document at the time of this report
writing. However, some tasks have been already completed and their conclusions provided in
Annex 6 RCA Action Support Notes.
Page 13 of 44
Report
7.0 RCA Solutions, Conclusions and Recommendations
It was already concluded that number of possible root causes more than one and further
investigation required to finalize all clarifications. This will more likely add few more issues in the
final list.
As of now it is clear that insufficient Seal Gas Flow along with inadequate Gas Conditioning are
two major contributing factors in frequent seal failure on LP2 PH-2 Compressor.
Regarding last failed seal on DE side of the compressor there is still live hypothesis that seal
could have failed due to rubbing contact between stationary and rotary seal parts which is more
likely to happen when seal rotor axial position was away from drawing requirements. Further
clarifications required in order to confirm or rule this hypothesis out.
Along with stated above whose are definitely root cause of the seal failure we need to mention
few more issues not directly involved in latest catastrophic scenario, but could have contributed
in seal previously observed seal deterioration, shortening service life as well as affecting Seal
Gas Panel monitoring functions. This is about Quality of Separation Air which is fully dependent
on Filtration Efficiency and current arrangements of the interconnecting pipes.
All solutions generated in Apollo RealityCharting are shown in the Annex 5 along with Action
List to be followed-up.
More important issues and recommended solutions are mentioned below:
1. Improve Seal Gas Control and increase seal gas flow towards the seals. In current
situation seal gas flow is below accepted standards in industry. Taking into consideration
presence of hydrocarbon liquid in the process gas John Crane recommends to increase
seal gas flow from current 2-3 m/sec to 10-12 meters per second which could be
adequate protection for the seals in this application. For this reason we recommend:
a. Review capacity of the seal gas supply lines and associated system components
in order to evaluate how they match new flow requirements. If required, to replace
seal gas supply lines with adequately sized equipment for recommended flow.
(John Crane can help in this upon getting all equipment details and relevant
drawings with Data Sheets)
b. As a short term solution it is recommended to increase seal gas flow up to top limit
of existing system capacity: change set points on PDCV-5400, enlarge size of FO-
5570 and FO5571.
Page 14 of 44
Report
c. In order to avoid erroneous signal from PDIC-5427 to ensure that negative
impulse line inspected and cleaned / purged from process contamination at every
possible opportunity.
2. Improve Seal Gas Conditioning. Lean Seal Gas imported from Refinery is only one dry
gas at all site operating conditions. In situations when Reach Gas used for seal gas
supply there is highly possible liquid contamination of the seals especially in winter
conditions. We recommended following:
a. To confirm that Lean Gas is available at all times during compressor operation,
stand still and SOP. Once confirmed, remove Reach Gas as a source for seal gas
supply on permanent basis.
b. If Reach Gas still required to be used for some reasons then significantly improve
all seal gas interconnecting lines thermal insulation and trace heating.
Alternatively consider installation Seal Gas Heater into the Control Panel or
Filtration / Gas Treatment Skid. Reach Gas should be delivered to the seals with
temperature not below 55-60°C at coldest site ambient conditions.
3. Thoroughly observe shaft-casing relative position during seal installation and compressor
assembly.
a. Insure correct shims are always used for the seals and thrust bearing
b. Insure shaft to casing reference is as per seal GAD
c. Involve GE-NP or John Crane FSE in seal replacement
There are some recommendations below not directly related to last seal failure, however contributing in
seal deterioration and compromised service life.
4. Improve filtration quality and efficiency of the Separation Air Filters 131-FT-2102A/B.
Filter upgrade can be achieved with minimum investments and John Crane can help with
this in order to avoid outboard seal contamination, corrosion of seal parts, affecting
conditions in Secondary Vent line.
5. Minimize Off-Load (Recycling) mode duration during compressor operation. As reported
two seals have been failed on recycling, therefore this operation is to be avoided and
effect on seal performance further studied.
Page 15 of 44
Report
ANNEX 1, DRY GAS SEAL GENERAL ARRANGEMENT DRAWINGS
Page 16 of 44
ITEM COMPONENT CODE DESCRIPTION MATERIAL QTY
DRAWING No ISSUE MODIFICATIONS:- ISSUE 'A' ORIGINAL.
ISS. 'B' ITEM 18 WAS 5 OFF : ITEM 27 DELETED. -RL- 23/5/02.ISS 'C' ITEM 27 ADDED & ITEM 18 QTY WAS 7 OFF JSD-13.6.03. ISS 'D' - ITEM 6 WAS S/94463/1/348. ITEM 24 WAS S/96792/1/603. ITEM 26 MOVED TO 65. ITEM 63 MOVED TO 66. 01 2740/123/387 O' RING FLUOROCARBON 01
ECN 22439. JA 07/11/12. ISS 'E' - PORT AT PRIMARY LEAKEAGE WAS HIDDEN. ECN 30586. JA 28/05/13. ISSUE 'F' -ECN No.78118- ITEM 24 I/M DRAWING WAS S/96792/1/603 -PK- 11/06/14. 02 2750/123/387 O' RING FLUOROCARBON 01
S/42317 F 03
04
2780/123/387
2810/123/387
O' RING
O' RING
FLUOROCARBON
FLUOROCARBON
04
01
05 2820/123/387 O' RING FLUOROCARBON 02
180 06 SC-S/42317-PR-9028 PRIMARY RING CARBON 02
PORTING DETAILS. T ROT ATI ITEM 06 I/M = S/94463/1/348
168 AF O
VIEWED FROM 07 S/94469/1/229 RETAINER INNER ST.ST. BS410S21 01
0.7/0.9
SH
N
A CLEAN GAS INJECTION 145 ARROW 'X'. 08 S/94332/1/229 RETAINER OUTER ST.ST. BS410S21 01
(CLEARANCE)
09 S/97270/1/506 SLEEVE ST.ST. 17-4 PH 01
B PRIMARY LEAKAGE 35 33 18 29 20 104 10 S/97271/1/506 SPACER SLEEVE ST.ST. 17-4 PH 01
11 S/97272/1/229 LOCKING SLEEVE ST.ST. BS410S21 01
C BUFFER GAS INJECTION (PLUGGED) 99.2 12 S/94468/1/229 THRUST RING ST.ST. BS410S21 02
SPIRAL GROOVE PATTERN 13 S/88179/1/229 DRIVE BUTTON ST.ST. BS410S21 02 SEAL CONSUMPTION (Std. lt./min.)
IS ANTI-CLOCKWISE
IN FROM O/D TO I/D. 14 S/94471/1/229 SETTING RG INNER ASM ST.ST. BS410S21 01 (per compressor side)
D SECONDARY LEAKAGE
A B C 15 S/94336/1/229 SETTING RG OUTER ASM ST.ST. BS410S21 01
SEAL CARTRIDGE SHOWN ON THIS DRG. IS FOR
16 S/87095/1/229 SEAL SPACER ST.ST. BS410S21 01 CASE RATED WINTER
THE C.W ROTATION OF THE COMPRESSOR. S.O.P.
05 SUMMER 2004 2010
E NITROGEN PURGE 21 16 05 25 CARTRIDGE FOR C.C.W. ROTATION IS SHOWN ON 17 S/87096/1/229 FACE RETAINER ST.ST. BS410S21 01
D E
DRG. No. S/42318.
18 S/85023/1/951 TOLERANCE RING MONEL K500 05
PRIMARY EXPECTED 15 15 22
17 19 07 04
6 21 08 19 7814/301/015 CAP HEAD SCREW DUPLEX 06
6 6 VENT GUARANTEED 23 23 33
20 7920/301/050 CAP HEAD SCREW DIN 912 - 12.9 12
21 7925/301/015 CAP HEAD SCREW DUPLEX 12
PROCESS ATMOSPHERIC 22 7712/301/050 CAP HEAD SCREW DIN 912 - 12.9 01
INTERMEDIATE
LABYRINTH
EXPECTED NA NA NA
GUARANTEED NA NA NA
SIDE SIDE 23
24
7921/301/015
SC-S/42317-MR-CW-9222
CAP HEAD SCREW
MATING RING
DUPLEX
SILICON CARBIDE
06
02 SECONDARY EXPECTED 3 3 3
'X' ITEM 24 I/M = S/96792/1/640 VENT GUARANTEED 4 4 4
25 A/79093/1/033 SPRING HASTELLOY 'C' 28
09 26 POWER Kw <5 <5 NA
27 S/98112/1/246 FINGER SPRING INCONEL X750 02
NOT JC T 28 GAS SEAL COMPRISES OF ITEMS 01 TO 27 INCLUSIVE
03
SUPPLY
50 2750/123/387 BS 'O'-RING FLUOROCARBON 01
SPACER NOT
J.C.UK SUPPLY 51 2770/123/387 BS 'O'-RING FLUOROCARBON 02
52 S/94338/1/637 BUSHING SEGMENT CARBON 12
18.5 53 S/94339/1/229 BUSHING HOUSING ASM ST.ST. BS410S21 01 OPERATING CONDITIONS
1 KEY 12x6x6 54 S/94472/1/663 SLEEVE ASM C.W ST.ST/TUNG CARB 01
RATED WINTER
55 S/94341/1/229 CLAMP PLATE ASM ST.ST. BS410S21 01 CASE
SUMMER 2004 2010 S.O.P.
56 S/94342/1/229 THRUST PLATE ASM ST.ST. BS410S21 01
57 S/94343/1/951 GARTER SPRING STAINLESS STEEL 02 PRESSURE @ BUFFER
15.84 15.97
58 S/88439/1/951 SPRING ST.ST. BS302S26 24 SOURCE BAR G
8 59 S/94344/1/229 SETTING PLATE OUTER ST.ST. BS410S21 01
KEYWAY
60 S/94345/1/229 SETTING PLATE INNER ST.ST. BS410S21 01 TEMPERATURE @
131 101
61 7710/301/050 CAP HEAD SCREW DIN 912 - 12.9 06 BUFFER SOURCE°C
SHAFT
2.8
PRESSURE @ SEAL
SLEEVE
COMPLETE SEAL ASM COMPRISES ITEMS 01 TO 62 INCLUSIVE 5.14 5.14 9.53
Ø 407 H7
+0.081
BAR G
Ø 422 H7
-0.02
Ø 420 H7
±0.01
±0.01
-0.02
+0.081
17.5 4.5
+0
±0.01
64 S/67543/1/199 ASM. PARTS
±0.01
+0
-0
01 24 06 03 12 25 03 18 06 12 23 ADDITIONAL ITEMS DO NOT ADD TO BOM ESTIMATED
Ø 237 h7
-0
127 96 -3
TEMPERATURE @ SEAL °C
-0.02
HOUSING
6 65 S/94337/1/199 SPARES KIT - T28 01
HOUSING
SLEEVE
Ø 251.98
Ø 310
Ø 249.98
+0
SHAFT
Ø 252.02
Ø 240
SLEEVE
SHAFT
66 S/94346/1/199 SPARES KIT - T82 01
Ø 306
Ø 250.02
SPEED RPM
Ø 260
4650 4560 0
27 18 13 10 02 18 24 27 18 03 11
Ø 236.04
SLEEVE
SHAFT
SPEED RANGE
Ø 236
88.5 MIN.SPEED RPM RATED RPM MAX. CONT. RPM TRIP RPM
T82 SLEEVE 4904
3269 4670 5148
MASS OF ROTOR = 45.3 Kg
DESIGN PRESSURE = 19 BAR G (STATIC) 19 BAR G (DYNAMIC)
MASS OF SEAL = 95.92 Kg.
DESIGN TEMPERATURE =-20°C/200°C
174 123 MOMENT OF INERTIA = 0.985 Kgm
2
AXIAL MOVEMENT = ±2.5

1 HOLE Ø10 ON 4 PINS Ø8 59.5 RADIAL MOVEMENT = ±0.6
390 PCD 97.19
4 HOLES M10 x 16 DEEP EQUISPACED BALANCE QUALITY = ISO 1940 G2.5
EQUISPACED ON 390 PCD CENTER OF GRAVITY
ON 264 PCD N.P JOB No = 1101738 MATL TO NACE MR-75-01
(FOR BARRIER SEAL
N.P SPEC No = SOS9952426/4
11
& NP EXTRACTION DEVICE)
N.P.SEAL CODE = RT9421552
30°
53 101 46 76.5 28.5 N.P.TERTIARRY SEAL CODE = RT9421554
45° 4 HOLES Ø10
EQUISPACED
ON 264 PCD. 20 66
1 PIN Ø8
ON 390 PCD. 4 CLEARANCE HOLES TO 55
7 SUIT 4 M10 HOLES ON 390 PCD 45
4
2 CLEARANCE HOLES TO SUIT ±0.1 3 x 30°
40 36 13
M16 HOLES ON 390 PCD. SEAL
1 PIN Ø3 51 51 SEAL DATA
POSITIONED X 1 =387 X 2 =348 X 3 =229 X 4 =603
SEAL DESCRIPTION SEAL ASSEMBLY CODE
6-M6 X 20 AT TDC
°
20 12.187" T.28/X 1 X2 X 3 X 4 H/D/X1 X2 X 3 X 4 H/D 3095/28AT/--/S42317
15
ON 380 PCD 6-M5 x 20
A.P.I. CODE A.P.I.PLAN
CIRCLIP NOT 4
15 J.C SUPPLY.
SERVICE DATA
FLUID SEALANT
HYDROCARBONS
15°
6-M5 x 20
15
-0.1
-0.2
° 22 SEAL PRES SUC.PRES VIS.AT P.T
SEE TABLE
SETTING PLATE
Ø 410
Ø 295.5
14
Ø 286.5
SETTING PLATE INNER
SETTING PLATE INNER
TEMP DEL.PRES VP.AT P.T

Ø 279
SEE TABLE
Ø 270.5
5
Ø 330
Ø 247.5
SHAFT SPEED SP.GR HAZARD CODE
+0.2
+0.1
4 PINS Ø8 SEE TABLE

61 55 52 56 52 53 62 60 62
Ø 237
Ø 314
ON 264 PCD
20 6 ADMIN DATA DRAWN DATE CHK'D APP'D ORIG SCALE INST CODE
Ø 237
3 x 10° SETTING RINGS MUST

2 HOLES M16 X 15 DEEP 54 50 57 58 57 59 BE REMOVED BEFORE DAA 14/4/02 RL IMG 1.5:1
DIAMETRICALLY OPPOSITE
ON 390 PCD. PART VIEW SHOWING
6-M6 X 20
SHAFT IS ROTATED. S/40529
J.C UK EXTRACTION. SETTING RINGS.
ON 264 PCD S/41951 FILE REFERENCE CAT
DRAWING No ISSUE
SETTING RINGS MUST
VIEW OF SEAL IN DIRECTION OF ARROW 'X' GS03478
T82 REMOVED.
BE REMOVED BEFORE NOTE: ONLY ITEMISED PARTS WILL BE SUPPLIED BY JOHN CRANE UK LTD.
SHAFT IS ROTATED.
02/50016G P S/42317 F
THE FOLLOWING NOTES ARE IMPORTANT AND MUST BE OBSERVED FOR CORRECT SEAL INSTALLATION AND OPERATION CAD ENGINEERED
CAD ENGINEERED
11. VENT GAS ENTRAPMENT BEFORE STARTUP TITLE INSTALLATION OF A TANDEM T28AT SEAL IN A
1. REMOVE ALL SHARP EDGES ON SHAFT &/OR SLEEVE BEFORE INSTALLATION OF SEAL 6 WHEN SHAFT IS SLEEVED THROUGH STUFFING BOX, SLEEVE MUST BE LIQUID TIGHT THROUGH BORE. 12. LAST SHOULDER OVER WHICH SEAL MUST NUOVO PIGNONE COMPRESSOR BCL806
PASS WHEN FITTING,TO BE PREPARED FOR KOC KUWAIT 250mm
2. SURFACE OF SHAFT OR SLEEVE ON WHICH SEAL IS INSTALLED MUST BE MACHINED TO 1.6 µmRa AS DIAGRAM BELOW.
FINISH OR BETTER & THEN HIGHLY POLISHED.
7. SHAFT OR SLEEVE MUST BE OF CORROSION RESISTANT MATERIAL WITH A HARDNESS OF 125 BRINELL THRUST BEARING SIDE
MINIMUM & BE MACHINED TO DIMENSIONS & TOLERANCES STATED. BREAK (C.W)
DEFINITION 3
3. LUBRICATE SHAFT/SLEEVE & SEAL WEDGE RING/O RING/BELLOWS TO ASSIST INSTALLATION OF SEAL 8. END OF SEAL CHAMBER & AXIS OF SHAFT MUST BE AT 90° TO EACH OTHER WITHIN F.I.M. 0.05
0.01
WITH 361-366 BUCKINGHAM AVENUE
4. LUBRICATE SEAT (MATING RING),SEALING MEMBER & HOUSING TO ASSIST INSTALLATION 9. PRESSURE IN SEAL CHAMBER MUST BE MAINTAINED AT MINIMUM ABOVE MAXIMUM SLOUGH
10°
PRESSURE GENERATED AT INNER SEAL.
1 RAD ENGLAND John Crane UK Ltd
5. MUST BE CIRCULATED AROUND SEAL FACE (PRIMARY RING)/THROUGH SEAT (MATING RING) 10. BEFORE COMPLETING SEAL INSTALLATION WIPE LAPPED SURFACES OF SEAT (MATING RING) Engineered Sealing Systems
(AT NOT LESS THAN )IN ORDER TO REMOVE HEAT GENERATED,OR FAILURE MAY OCCUR. & SEAL FACE (PRIMARY RING) PERFECTLY CLEAN. SL1 4QX
THE COPYRIGHT IN THIS DRAWING IS OWNED BY JOHN CRANE UK LTD. THE INFORMATION CONTAINED IN IT IS CONFIDENTIAL TO THIS COMPANY AND MUST NOT BE DISCLOSED WITHOUT ITS WRITTEN CONSENT John Crane International
0 EMISSIONE-ISSUE
ESEG. CONTR. APPR. DATA

REV. DESCRIZIONE-DESCRIPTION PREP'D CHK'D APPR'D DATE
ITEM
TITOLO-TITLE
DRY GAS SEAL DWG

N° SOS ******
COMMESSA SCALA LINGUA TAVOLA
JOB SCALE LANG. SHEET
FIRENZE
1101733 A 1/1
SOSTITUISCE IL - REPLACES SOSTITUITO DA - REPLACED BY
Il presente documento e' proprieta' del NUOVO PIGNONE. A termine di legge ogni diritto e' riservato.
This document is the property of NUOVO PIGNONE. All rights are reserved according to law.
F
7 8
QUESTO DISEGNO E' STATO ESEGUITO CON TECNICHE CAD - THIS DRAWING WAS MADE WITH CAD TECHNIQUES
ITEM COMPONENT CODE DESCRIPTION MATERIAL QTY
DRAWING No ISSUE MODIFICATIONS:- ISSUE 'A' ORIGINAL.
ISS. 'B' ITEM 18 WAS 5 OFF : ITEM 27 DELETED. -RL- 23/5/02.ISS 'C' ITEM 27 ADDED & ITEM 18 QTY WAS 7 OFF JSD-13.6.03. ISS 'D' - ITEM 6 WAS S/94463/1/348. ITEM 24 WAS S/96792/1/603. ITEM 26 MOVED TO 65. ITEM 63 MOVED TO 66. 01 2740/123/387 O' RING FLUOROCARBON 01
ECN 22440. JA 07/11/12. ISS 'E' - PORT AT PRIMARY LEAKEAGE WAS HIDDEN. ECN 30586. JA 28/05/13. ISSUE 'F' -ECN No.78118- ITEM 24 I/M DRAWING WAS S/96792/1/603 -PK- 11/06/14. 02 2750/123/387 O' RING FLUOROCARBON 01
S/42318 F 03
04
2780/123/387
2810/123/387
O' RING
O' RING
FLUOROCARBON
FLUOROCARBON
04
01
05 2820/123/387 O' RING FLUOROCARBON 02
180 06 SC-S/42317-PR-9028 PRIMARY RING CARBON 02
PORTING DETAILS. T ROT ATI ITEM 06 I/M = S/94463/1/348
168 AF O
VIEWED FROM 07 S/94469/1/229 RETAINER INNER ST.ST. BS410S21 01
0.7/0.9
SH
N
A CLEAN GAS INJECTION 145 ARROW 'X'. 08 S/94332/1/229 RETAINER OUTER ST.ST. BS410S21 01
(CLEARANCE)
09 S/97270/1/506 SLEEVE ST.ST. 17-4 PH 01
B PRIMARY LEAKAGE 35 33 18 29 20 104 10 S/97271/1/506 SPACER SLEEVE ST.ST. 17-4 PH 01
11 S/97273/1/229 LOCKING SLEEVE ST.ST. BS410S21 01
C BUFFER GAS INJECTION (PLUGGED) 99.2 12 S/94468/1/229 THRUST RING ST.ST. BS410S21 02
SPIRAL GROOVE PATTERN 13 S/88179/1/229 DRIVE BUTTON ST.ST. BS410S21 02 SEAL CONSUMPTION (Std. lt./min.)
IS CLOCKWISE
IN FROM O/D TO I/D. 14 S/94335/1/229 SETTING RG INNER ASM ST.ST. BS410S21 01 (per compressor side)
D SECONDARY LEAKAGE
A B C 15 S/94336/1/229 SETTING RG OUTER ASM ST.ST. BS410S21 01
SEAL CARTRIDGE SHOWN ON THIS DRG. IS FOR
16 S/87095/1/229 SEAL SPACER ST.ST. BS410S21 01 CASE RATED WINTER
THE C.C.W ROTATION OF THE COMPRESSOR. S.O.P.
05 SUMMER 2004 2010
E NITROGEN PURGE 21 16 05 25 CARTRIDGE FOR C.W. ROTATION IS SHOWN ON 17 S/87096/1/229 FACE RETAINER ST.ST. BS410S21 01
D E
DRG. No. S/42317.
18 S/85023/1/951 TOLERANCE RING MONEL K500 05
PRIMARY EXPECTED 15 15 22
17 19 07 04
6 21 08 19 7814/301/015 CAP HEAD SCREW DUPLEX 06
6 6 VENT GUARANTEED 23 23 33
21 7925/301/015 CAP HEAD SCREW DUPLEX 12
PROCESS ATMOSPHERIC 22 7712/301/050 CAP HEAD SCREW DIN 912 - 12.9 01
INTERMEDIATE
LABYRINTH
EXPECTED NA NA NA
GUARANTEED NA NA NA
SIDE SIDE 23
24
7921/301/015
SC-S/42317-MR-CCW-9222
CAP HEAD SCREW
MATING RING
DUPLEX
SILICON CARBIDE
06
02 SECONDARY EXPECTED 3 3 3
'X' ITEM 24 I/M = S/96792/1/640 VENT GUARANTEED 4 4 4
25 A/79093/1/033 SPRING HASTELLOY 'C' 28
09 26 POWER Kw <5 <5 NA
27 S/98112/1/246 FINGER SPRING INCONEL X750 02
NOT JC T 28 GAS SEAL COMPRISES OF ITEMS 01 TO 27 INCLUSIVE
03
SUPPLY
50 2750/123/387 BS 'O'-RING FLUOROCARBON 01
SPACER NOT
J.C.UK SUPPLY 51 2770/123/387 BS 'O'-RING FLUOROCARBON 02
52 S/94338/1/637 BUSHING SEGMENT CARBON 12
18.5 53 S/94339/1/229 BUSHING HOUSING ASM ST.ST. BS410S21 01 OPERATING CONDITIONS
1 KEY 12x6x6 54 S/94340/1/663 SLEEVE ASM C.C.W. ST.ST/TUNG CARB 01
RATED WINTER
55 S/94341/1/229 CLAMP PLATE ASM ST.ST. BS410S21 01 CASE
SUMMER 2004 2010 S.O.P.
56 S/94342/1/229 THRUST PLATE ASM ST.ST. BS410S21 01
57 S/94343/1/951 GARTER SPRING STAINLESS STEEL 02 PRESSURE @ BUFFER
15.84 15.97
58 S/88439/1/951 SPRING ST.ST. BS302S26 24 SOURCE BAR G
8 59 S/94344/1/229 SETTING PLATE OUTER ST.ST. BS410S21 01
KEYWAY
60 S/94345/1/229 SETTING PLATE INNER ST.ST. BS410S21 01 TEMPERATURE @
131 101
61 7710/301/050 CAP HEAD SCREW DIN 912 - 12.9 06 BUFFER SOURCE°C
SHAFT
2.8
PRESSURE @ SEAL
SLEEVE
COMPLETE SEAL ASM COMPRISES ITEMS 01 TO 62 INCLUSIVE 5.14 5.14 9.53
Ø 407 H7
+0.081
BAR G
Ø 422 H7
-0.02
Ø 420 H7
±0.01
±0.01
-0.02
+0.081
17.5 4.5
+0
±0.01
64 S/67543/1/199 ASM. PARTS
±0.01
+0
-0
01 24 06 03 12 25 03 18 06 12 23 ADDITIONAL ITEMS DO NOT ADD TO BOM ESTIMATED
Ø238 h7
-0
127 96 -3
TEMPERATURE @ SEAL °C
-0.02
HOUSING
6 65 S/94337/1/199 SPARES KIT 01
HOUSING
SLEEVE
Ø 251.98
Ø 310
Ø 249.98
+0
SHAFT
Ø 252.02
Ø 240
SLEEVE
SHAFT
66 S/94346/1/199 SPARES KIT 01
Ø 306
Ø 250.02
SPEED RPM
Ø 260
4650 4560 0
27 18 13 10 02 18 24 27 18 03 11
Ø 236.04
SLEEVE
SHAFT
SPEED RANGE
Ø 236
88.5 MIN.SPEED RPM RATED RPM MAX. CONT. RPM TRIP RPM
T82 SLEEVE 4904
3269 4670 5148
MASS OF ROTOR = 45.3 Kg
DESIGN PRESSURE = 19 BAR G (STATIC) 19 BAR G (DYNAMIC)
MASS OF SEAL = 95.92 Kg.
DESIGN TEMPERATURE =-20°C/200°C
174 123 MOMENT OF INERTIA = 0.985 Kgm
2
AXIAL MOVEMENT = ±2.5

1 HOLE Ø10 ON 3 PINS Ø8 59.5 RADIAL MOVEMENT = ±0.6
390 PCD 97.19
4 HOLES M10 x 16 DEEP EQUISPACED BALANCE QUALITY = ISO 1940 G2.5
EQUISPACED ON 390 PCD CENTER OF GRAVITY
ON 264 PCD N.P JOB No = 1101738 MATL TO NACE MR-75-01
(FOR BARRIER SEAL
N.P SPEC No = SOS9952426/4
11
& NP EXTRACTION DEVICE)
N.P.SEAL CODE = RT9421553
30°
53 101 46 76.5 28.5 N.P.TERTIARRY SEAL CODE = RT9421555
45° 3 HOLES Ø10
EQUISPACED
ON 264 PCD. 20 66
1 PIN Ø8
ON 390 PCD. 4 CLEARANCE HOLES TO 55
7 SUIT 4 M10 HOLES ON 390 PCD 45
4
2 CLEARANCE HOLES TO SUIT ±0.1 3 x 30°
40 36 13
M16 HOLES ON 390 PCD. SEAL
1 PIN Ø3 51 51 SEAL DATA
POSITIONED X 1 =387 X 2 =348 X 3 =229 X 4 =603
SEAL DESCRIPTION SEAL ASSEMBLY CODE
6-M6 X 20 AT TDC
°
20 12.187" T.28/X1 X 2 X 3 X 4 H/D/X 1 X2 X 3 X 4 H/D 3095/28AT/--/S42318
15
ON 380 PCD 6-M5 x 20
A.P.I. CODE A.P.I.PLAN
CIRCLIP NOT 4
15 J.C SUPPLY.
SERVICE DATA
FLUID SEALANT
HYDROCARBONS
15°
6-M5 x 20
15
-0.1
-0.2
° 22 SEAL PRES SUC.PRES VIS.AT P.T
SEE TABLE
SETTING PLATE
Ø 410
Ø 295.5
14
Ø 286.5
SETTING PLATE INNER
SETTING PLATE INNER
TEMP DEL.PRES VP.AT P.T

Ø 279
SEE TABLE
Ø 270.5
5
Ø 330
Ø 247.5
SHAFT SPEED SP.GR HAZARD CODE
+0.2
+0.1
3 PINS Ø8 SEE TABLE

61 55 52 56 52 53 62 60 62
Ø 237
Ø 314
ON 264 PCD
20 6 ADMIN DATA DRAWN DATE CHK'D APP'D ORIG SCALE INST CODE
Ø 238
3 x 10° SETTING RINGS MUST

2 HOLES M16 X 15 DEEP 54 50 57 58 57 59 BE REMOVED BEFORE DAA 14/4/02 RL IMG 1.5:1
DIAMETRICALLY OPPOSITE
ON 390 PCD. PART VIEW SHOWING
6-M6 X 20
SHAFT IS ROTATED. S/40530
J.C UK EXTRACTION. SETTING RINGS.
ON 264 PCD S/41950 FILE REFERENCE CAT
DRAWING No ISSUE
SETTING RINGS MUST
VIEW OF SEAL IN DIRECTION OF ARROW 'X' GS03479
T82 REMOVED.
BE REMOVED BEFORE NOTE: ONLY ITEMISED PARTS WILL BE SUPPLIED BY JOHN CRANE UK LTD.
SHAFT IS ROTATED.
02/50016G P S/42318 F
THE FOLLOWING NOTES ARE IMPORTANT AND MUST BE OBSERVED FOR CORRECT SEAL INSTALLATION AND OPERATION CAD ENGINEERED
CAD ENGINEERED
11. VENT GAS ENTRAPMENT BEFORE STARTUP TITLE INSTALLATION OF A TANDEM T28AT SEAL IN A
1. REMOVE ALL SHARP EDGES ON SHAFT &/OR SLEEVE BEFORE INSTALLATION OF SEAL 6 WHEN SHAFT IS SLEEVED THROUGH STUFFING BOX, SLEEVE MUST BE LIQUID TIGHT THROUGH BORE. 12. LAST SHOULDER OVER WHICH SEAL MUST NUOVO PIGNONE COMPRESSOR BCL806
PASS WHEN FITTING,TO BE PREPARED FOR KOC KUWAIT 250mm
2. SURFACE OF SHAFT OR SLEEVE ON WHICH SEAL IS INSTALLED MUST BE MACHINED TO 1.6 µmRa AS DIAGRAM BELOW.
FINISH OR BETTER & THEN HIGHLY POLISHED.
7. SHAFT OR SLEEVE MUST BE OF CORROSION RESISTANT MATERIAL WITH A HARDNESS OF 125 BRINELL OPPOSITE THRUST BEARING SIDE
MINIMUM & BE MACHINED TO DIMENSIONS & TOLERANCES STATED. BREAK (C.C.W)
DEFINITION 3
3. LUBRICATE SHAFT/SLEEVE & SEAL WEDGE RING/O RING/BELLOWS TO ASSIST INSTALLATION OF SEAL 8. END OF SEAL CHAMBER & AXIS OF SHAFT MUST BE AT 90° TO EACH OTHER WITHIN F.I.M. 0.05
0.01
WITH 361-366 BUCKINGHAM AVENUE
4. LUBRICATE SEAT (MATING RING),SEALING MEMBER & HOUSING TO ASSIST INSTALLATION 9. PRESSURE IN SEAL CHAMBER MUST BE MAINTAINED AT MINIMUM ABOVE MAXIMUM SLOUGH
10°
PRESSURE GENERATED AT INNER SEAL.
1 RAD ENGLAND John Crane UK Ltd
5. MUST BE CIRCULATED AROUND SEAL FACE (PRIMARY RING)/THROUGH SEAT (MATING RING) 10. BEFORE COMPLETING SEAL INSTALLATION WIPE LAPPED SURFACES OF SEAT (MATING RING) Engineered Sealing Systems
(AT NOT LESS THAN )IN ORDER TO REMOVE HEAT GENERATED,OR FAILURE MAY OCCUR. & SEAL FACE (PRIMARY RING) PERFECTLY CLEAN. SL1 4QX
THE COPYRIGHT IN THIS DRAWING IS OWNED BY JOHN CRANE UK LTD. THE INFORMATION CONTAINED IN IT IS CONFIDENTIAL TO THIS COMPANY AND MUST NOT BE DISCLOSED WITHOUT ITS WRITTEN CONSENT John Crane International
0 EMISSIONE-ISSUE
ESEG. CONTR. APPR. DATA

REV. DESCRIZIONE-DESCRIPTION PREP'D CHK'D APPR'D DATE
ITEM
TITOLO-TITLE
DRY GAS SEAL DWG

N° SOS ******
COMMESSA SCALA LINGUA TAVOLA
JOB SCALE LANG. SHEET
FIRENZE
1101733 A 1/1
SOSTITUISCE IL - REPLACES SOSTITUITO DA - REPLACED BY
Il presente documento e' proprieta' del NUOVO PIGNONE. A termine di legge ogni diritto e' riservato.
This document is the property of NUOVO PIGNONE. All rights are reserved according to law.
F
7 8
QUESTO DISEGNO E' STATO ESEGUITO CON TECNICHE CAD - THIS DRAWING WAS MADE WITH CAD TECHNIQUES
Report
ANNEX 2, DRY GAS SEAL SYSTEM P&ID DRAWINGS
Page 17 of 44
Report
ANNEX 3, DRY GAS SEAL INSPECTION REPORTS
Page 18 of 44
Report
ANNEX 4, APOLLO REALITY CHART
Page 19 of 44
0 0 0
Action ID: 8
Shaft Overspeed Caused

No Evidence
By
No evidence R
0 0 1 0 0 0
Excessive Centrifugal Caused Failed Overspeed Caused

Stress protection No evidence
By By
0 0 0
? R No evidence R
Condition ID: 132
Different thermal Caused

0 0 0 Desired Condition
expansion rate Seat &
Condition ID: 135 By
Sleeve
Centrifugal forces limit Caused
exists Desired Condition
By material properties R
0 0 0 0 0 0
design conditions R
Rubbing hardware 0 0 0
Closed radial clearance Caused Temperature exceeds Caused Seal Overheated ID: 54
design limits Condition
By By 0 0 0
Process Labyrinth out of Caused ID: 58
More Info Needed Condition
Spec / worn out
By Balance Drum seal
Material properties R Inspection Evidence R Caused
Desired Condition
By
0 0 0
KOC to clarify R
0 0 1 ID: 57
Condition
Condition ID: 136
Design Conditions R
DE sealing Pressure Caused
Design radial clearance Caused higher than NDE
exist Desired Condition By
By 0 0 0
Action ID: 59
Site readings R
? R
0 0 0 0 0 0 Balance seal leakage Caused
ID: 19 ID: 55
More Info Needed
Action Action By
DE Seal Gas Supply Caused Lost SG Positive flow to Caused
Failed Discharge end seal
By By
Review trends R
Inspection Evidence R Evidence of Crude R

0 0 1 0 1 0
Low Seal Gas Flow Caused System Set-up Caused

More Info Needed
By By
0 0 0
Site readings R site evidence R
Condition ID: 56
Drive End is Discharge Caused

End Desired Condition
By
Design conditions R
0 0 0
0 0 0 Action ID: 46
Condition ID: 17
External Gas Source Caused
Lack of cooling Failure No Evidence
Caused By
By
ruled-out R
Discoloration marks R
0 0 0
Action ID: 47
SG Filter Blockage Caused

No evidence
By
ruled-out R
0 0 0
Action ID: 48
Seal Gas PDCV-5400 Caused

Failure No evidence
By
1 0 0 0 1 0 0
ruled out R
Condition ID: 20 Root Cause (C) ID: 50
Seal Gas Control issue Caused Undersized FO-5570 & Caused

5571 More Info Needed
By By
0 0 1
Condition ID: 49
Engineering study R Orifice Calculation R
Low Seal Gas flow Caused
By
1 0 0

Site Observations R
Differential pressure Set Caused
Point Low More Info Needed
By
0 0 0
Orifice Calculations R
Action ID: 52
0 0 0 Incorrect Valve Line-up Caused

ID: 12
No evidence
Action By
Contacted Seat ID with Caused
Sleeve
By Ruled-out R
Seal Inspection Evidence R 1 0 0

1 0 0 1
Action ID: 18 Reference Line Caused

Contaminated / Blocked More Info Needed
Rubbing By
Rubbing: Sleeve with Caused Rubbing hardware
Retainer
By
Liquid contamination R
inspection evidence R
2 0 0
1 0 0 0
Condition ID: 15
Seal Overheated Incorrect shimming Caused

Caused More Info Needed
By By
Evidence of discoloration R possible root cause R
0 0 0
Action ID: 25
Incorrect Clamping of Caused

seal stator More Info Needed
By
possible root cause R
1 1 0 0 0 0 1 0 0 1 1 0 0
Root Cause (A) ID: 23 Condition ID: 26 Condition ID: 28 Root Cause (C) ID: 29
Seal Rotor Moved Caused Excessive rotor Caused Off-Spec Process ( Caused Off-Load / Recycling Caused
towards process expansion / contracting Pressures, temperatures, Operation More Info Needed
By By flow) By By
Reference 1 R contributing factor R Reported by KOC R Reported by KOC R
0 0 0 0 0 0
Action
Seat Bore stress Caused Wrong reference used at Caused
0 0 0 compressor assembly More Info Needed
By By
Action ID: 21
Direct contact Caused

Seat Inspection evidence R Possible root cause R
By
0 0 1 0 0 0
observation R
ID: 43 ID: 44
Action Action
Rotor set out of position Caused Thrust Bearing shimming Caused
More Info Needed
By By
0 0 0
Possible root cause R root causepossible t R
Condition ID: 123
Operation Caused
Desired Condition
By
0 0 0
Historical trends R
Condition ID: 22
Debris in the seal Caused

More Info Needed
By
Inspection Evidence R
0 0 0
Condition ID: 125
Operation Caused
Desired Condition 0 0 1 0 0 0
By
Failed drainage from Caused LCV-5400 Fails closed Caused

0 0 0 0 0 0 More Info Needed
Historical trends R separation air port
Condition ID: 16 Action ID: 89 By By
Centrifugal Forces Caused Inadequate Particulate Caused

Desired Condition Filtration More Info Needed
By By Inspection required R Inspection required R
0 0 0 0 0 0 0 0 0
Operation R Site observation R
Condition ID: 13 Action ID: 92 Condition ID: 103
High temperature Caused Bearing Oil Ingress Caused Low Separation Air Flow Caused
More Info Needed No evidence
By By By
Seal Inspection evidence R Systematic observations R ruled-out R

0 0 0
Condition ID: 11
0 0 1 0 0 0
Rotating shaft Caused ID: 104 ID: 105
Desired Condition Action Action
By Air flow bypasses LCV-5400 fails open
Caused Caused
labyrinth More Info Needed
By By
Historical trends R
0 0 1 0 0 0
Action ID: 31 Action ID: 32 Inspection required R Inspection required R
Fretting in abutment area Caused Relative movement Caused Seal Built form shows
By By no evidence 0 0 1 1 0 1
0 0 0 Action ID: 94 Root Cause (C) ID: 140
Condition ID: 30
Water carry-over through Caused Air Coalscer Filter issue Caused
Evidence not found R Ruled-out R
separation air line More Info Needed
Stress raisers on Seat Caused By By
By
0 0 0
Condition ID: 121 evidence R ? R

investigated R
shaft rotation Caused
0 0 1 Desired Condition
By 0 0 0
Action ID: 3
Condition ID: 98
Inboard and Outboard Caused
Seat Fracture Historical trends R Ambient conditions: Caused
By winter Desired Condition
0 0 0
By
Condition ID: 33
Inspection Report: 440624 R Shaft Vibration Caused

No evidence February R
By 0 0 0
Action ID: 93
0 0 0 0 0 0
no records R Water Ingress from SV Caused Action ID: 95 Action ID: 102
By Condensation in Water Condensation

0 0 0
Caused Caused
Secondary Vent More Info Needed
Action ID: 38 By By
0 0 0
considered R
ID: 34 Seat Damped under Caused
Action More Info Needed
shroud drive Witnessed during site visit R KOC to clarify R
Seat swash By
Caused Seal Built Form shows
By no evidence
0 0 0
Forensic analysis R
Action ID: 106
studied R Liquid Back Flow down

0 0 0 0 0 0
Caused
0 0 0
from SV More Info Needed
Action ID: 36 Condition ID: 86 ID: 90 By
Action
Seat Rotation Caused Excessive Torque Caused Liquid Evaporated / Caused
No evidence solidified 0 0 0
By By By KOC to clarify R
Condition ID: 107
Line was not cleaned Caused

reported R evidence not found R Inspection evidence R from previous incident More Info Needed
By
0 0 0
Condition ID: 35
2 0 0 1 0 0 1
0 0 0
High Stress ID: 87 ID: 88 KOC to clarify R
Caused Condition Condition ID: 100
Concentration from drive Condition
By Contamination Caused Liquids and Solids Caused No Secondary Vent Drain Caused
penetration to the seal Design Conditions
By By
By
potential R
0 0 0
Reported Evidence R Inspection Evidence R 0 0 0
ID: 37 as per design R
Condition ID: 109
Action
Different Expansion Caused
Desired Condition Back Flow Down Flare Caused
By Line More Info Needed
By
material properties R
KOC to clarify R
0 0 0 0 0 0 0 0 1 1 0 1
Action ID: 41 Action ID: 108 Condition ID: 110 Root Cause (C) ID: 112
Excessive Slow Rolling Caused Liquid Hydrocarbons Caused Winter Temperatures Caused Missing Thermoinsulation Caused
No evidence from Primary Vent and heat tracing More Info Needed
By By By By
0 0 0
Condition ID: 40
no evidence R observations R failure report R Site Observation R
Chipping on the Seat Caused
By
0 0 1 0 0 1
not possible to find-out R
Solid Contamination Caused Contamination Missing drains in PV line Caused
More Info Needed
By By
Inspection evidence R ? R
0 0 0 0 0 0
Condition
0 0 0
BD O-Ring squeeze Caused Lean Gas: no issues
Squeeze as per design Caused Condition ID: 116
Desired Condition
By By Gas Heater far away Caused
More Info Needed
0 0 1
By
ruled-out R 2 0 1
ID: 113 Phase Diagram R
Condition ID: 117
Root Cause (C)
Inefficient Gas Caused Site Observation R
0 0 0 0 0 0 Reach Gas temperature Caused
Conditioning
ID: 63 ID: 66
By below dew point
Action Condition By
0 0 1
Seal Hang-closed Caused Excessive Spring Load Caused 0 0 1
No evidence Condition ID: 118
By By Evidence of contamination R ID: 115
Condition Thermal Image Report R
Lines not insulated nor Caused
Reach Gas: Wet Gas heat traced More Info Needed
Caused By
Inspection Evidence R Checked R By
0 0 0
Site Observation R
0 0 1 Phase Diagram R Condition ID: 129
Action ID: 67
Gas Composition Caused
Contamination enters BD Contamination Desired Condition
Caused 0 0 1 1 0 0 1 By
Polymer area
By Condition ID: 91 Action ID: 119
High Temperature in the Caused Rubbing Caused Rubbing: Sleeve with Reta... Provided by KOC R
0 0 0 seal
evidence R By By
Condition ID: 64
Operation Caused
Desired Condition Evidence R Evidence R
By
0 0 2 0 0 2
Confirmed R
ID: 120
Action ID: 73 Condition
Seal Over-compression Seal Rotor Moved towards... Seal Gas Control issue Caused Seal Gas Control issue
Caused
or under-compression By
By
Inspection Evidence R ? R
1 0 0 1 0 0 0
Action ID: 72 ID: 69
Action
Seal Installation Caused Fit to wrong compressor Caused Confirmed correct
end fitment
By By
0 0 0 considered scenario R Ruled-out R

Primary Effect ID: 1
Drive End Seal Failure Caused 0 0 0 0 0 0

SN: 10083673 ID: 68 ID: 70
By Action Condition
Reverse Rotation Caused Unidirectional Seal Caused
Desired Condition
By By
considered scenario R by design R
0 0 0
Action ID: 71
Seat with CW grooves fit Caused Confirmed correct

into CCW seal fitment
By
0 0 0
ruled out R
Action ID: 130
Loose Compressor parts Caused

More Info Needed
By
0 0 1 0 0 1

KOC to clarify R
Free Relative Movement Caused Loose Parts Caused
By By
0 0 0 0 0 0
Condition ID: 62 Action ID: 131

Considered R Considered scenario R
Forced Contact Caused Loose seal parts Caused
More Info Needed
By By
0 0 0
Condition ID: 76
Inspection Evidence R No evidence R
Operation Caused
Desired Condition
By
design condition R
0 0 0
Condition ID: 78
Dimensional error of seal Caused

components More Info Needed
By
inspected, no issues R
0 0 0
Action ID: 79
Excessive rotor axial Caused

movement More Info Needed
2 0 0 0 By
Action ID: 74
Rubbing hardware 0 0 1 0 0 0
Caused Maintenence report R
By
Debris from PV Line Caused Line not cleaned during Caused
maintenance
By By
Excessive rotor axial Caused
movement
2 0 0 0 By
Action ID: 74
Rubbing hardware 0 0 1 0 0 0
Caused Maintenence report R
By
Debris from PV Line Caused Line not cleaned during Caused
maintenance More Info Needed
By By
Inspection evidence R
Possible scenario R Clarify with KOC R
0 0 0
0 0 0 ID: 83
Condition
Condition ID: 80
Loose seal components Caused
Debris in the seal No Evidence
Caused By
interspace
By
0 0 0
checked, no evidence R
Evidence R Action ID: 127
Seat Fracture Caused

More Info Needed
By
0 0 0
Action ID: 126

Inspection Evidence R
Released from Caused
disintegrated Seat
By
0 0 0
Condition ID: 128

evidence R
Shaft Rotation Caused
Desired Condition
By
0 0 1
Action ID: 84
design conditions R
Installation Caused Seal Installation
By
0 0 0
Inspection evidence R
Condition ID: 45
Reverse Pressurization Caused

No evidence
By
0 0 0
no evidence R
Action ID: 122
Compressor Operation Caused

Desired Condition
By
Operator's Report R
0 0 0
Condition ID: 6
Not sufficient process gas Caused Other Cause Paths More

By Productive
0 0 0
Condition ID: 5
Ops Report R
Off-Load Operation Caused
By
0 0 0
Action ID: 7
Reported by Ops team R
Decision by Production Caused Other Cause Paths More
Dept Productive
By
from Interview R
Report
ANNEX 5, APOLLO ACTION LIST , KOC RCA APRIL 2017

(AT A TIME OF REPORT WRITING)
Page 20 of 44
Report
Table 6.
No: Action Item,
Linked cause Owner Due Date
Find Out Why:
1 Find evidence Yuriy
Excessive centrifugal stress 04/30/2017
for Oryeshkin
2 Roshan Elias
Find out why Debris in the seal 04/30/2017
Mathew
3 Find evidence for Roshan Elias 04/30/2017
Incorrect Shimming
Mathew
4 Find evidence for Incorrect Clamping of seal Roshan Elias 04/30/2017
stator Mathew
5 Find out why Off-Load Operation KOC Operation 04/30/2017
6 Find evidence for Wrong reference used at KOC 04/30/2017

compressor assembly Maintenance
7 Find evidence for KOC 04/30/2017
Thrust Bearing shimming
Maintenance
8 Find evidence for Process labyrinth out of spec/ KOC 04/30/2017
worn out Maintenance
Balance line leakage
Maintenance
10 Find evidence for Lines not cleaned during KOC 04/30/2017
maintenance Maintenance
LCV-5400 Failed closed
Maintenance
12 Find evidence KOC 04/30/2017
Water Condensation
Maintenance
13 Find out why KOC 04/30/2017
Inadequate particulate filtration
Maintenance
LCV-5400 Failed open
Maintenance
Page 21 of 44
Report
No: Action Item,
Find Out Why:
15 Find evidence Line was not cleaned from KOC
04/30/2017
for previous incident Maintenance
16 Missing Thermo Insulation and KOC
Find out why 04/30/2017
Trace Heating Maintenance
Back flow down flare line
Maintenance
Seal Gas Control issue
Maintenance
19 Find out why Seat Fracture Yuriy 04/30/2017
20 Find out why KOC 04/30/2017

Gas Heater far away
Maintenance
21 Find evidence for Seat damped under shroud 04/30/2017
Yuriy
drive
22 Find evidence for 04/30/2017
Loose Compressor Parts Roshan
23 Find out why High temperature in the seal Yuriy 04/30/2017
24 Find evidence for Reference line contaminated/ KOC 04/30/2017

blocked Maintenance
25 Find out why Undersized FO-5570 and FO- 04/30/2017
Roshan
5571
26 Find out why Differential Pressure Set Point 04/30/2017
Roshan
too Low
27 Find out why System set-up Roshan 04/30/2017

Liquid back flow down from SV
Maintenance
Page 22 of 44
Report
No: Action Item, Find

Out Why:
29 Find out Design radial clearance Yuriy 04/30/2017
30 Dimensional error of the seal

Find evidence for Yuriy 04/30/2017
components
31 Find evidence for Loose seal parts Yuriy 04/30/2017
32 Find out why Missing drains in SV lines KOC 04/30/2017
33 Find out why Missing drains in PV lines KOC 04/30/2017
34 Find evidence for 04/30/2017

Excessive rotor movement Roshan
35 Find evidence for Air Coalescer Filter issues Roshan 04/30/2017
36 Find out why Air Coalescer Filter issues Yuriy 04/30/2017
37 Find evidence for External contamination in the 04/30/2017

Yuriy
seal internals
Page 23 of 44
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ANNEX 6, RCA ACTION SUPPORT NOTES
Page 24 of 44
Report
6.1 BS-131 Booster Station Details
Gas Booster Station BS-131 is situated in North Kuwait onshore close to border of Iraq.
The Station has been commissioned and started operation in 2007. Process Gas is reach
and wet gas from three-phase separators installed at Oil Gathering Stations. Some amount
of crude can be carried over through the process loops. Crude from the process lines is
collected and drained to close drain system in suction scrubbers installed on each
compressor
stage of the Booster Station.
Site annual temperature fluctuation as per Data Sheet is:
 Minimal -3°C winter
 Maximal + 50°C summer.
 Dust.
There are 6 compressors installed on BS-131, they supplied and commissioned in two
phases:
Phase 1: 131-K-1101, Low Pressure 1st Stage Compressor type MCL
131-K-1102, Low Pressure Second Stage Compressor BCL806
131-K-1103, High Pressure Compressor BCL 504
Phase 2: 131-K-2101, Low Pressure 1st Stage Compressor type MCL

131-K-2102, Low Pressure Second Stage Compressor BCL806
131-K-2103, High Pressure Compressor BCL 504
Page 25 of 44
Report
6.2 Compressor Details

Conditions described below for the equipment included in the investigation:
Table 7
131-K-2102 (LP2 PH 2) Compressor operating conditions
winter considered
Description Unit Value Note
Equipment Tag No. 131-K-2102, Phase LP2
Compressor Type/Model and Serial

BCL806, C12264
Number
Manufacturer GE-NP
Speed: Normal/MCS/Trip/Slow roll RPM 4508/4904/5149/15
Suction Pressure Bar A 6.14/6.48
Suction Temperature ºC 65°
Discharge Pressure Bar A 23.44/26.98
Discharge Temperature ºC 125/ 162
Settle Out Pressure, Bar G 9.52 Bar G
Settle Out Temperature, ºC Ambient
Start-up Seal Gas Pressure US of

Bar G 22
the gas panel
Start-up Seal Gas Pressure

Bar G Suction plus 1 Bar
downstream of gas panel
Start-up Gas temperature US of

ºC Ambient
Gas Panel
Start-up Gas temperature DS of

ºC Ambient or below
Gas Panel
Page 26 of 44
Report
Seal Gas Supply Pressure 22 (Lean Gas) or
Bar G
(normal conditions) 60 (Reach Gas)
Seal Gas supply Temperature
ºC Ambient
(normal conditions)
Expected from
Process Gas Composition -
KOC
External Gas Composition 1 (Lean
- Provided Dry at all time
Gas from Refinery)
Wet, cannot be
External Gas Composition 2 (Reach used without
- Provided
Gas from export header) proper
conditioning
It is known that 2 BCL 806 LP-2 compressors installed at Phase 1 and LP2 Phase 2 have
almost identical seal gas system arrangement, service and type. During site survey all
operational Gas Compressor Units were attended by JC Turbomachinery Engineer and to
carried out detailed review to capture individual operation of seal gas system, review “as-built”
design and layout, process variations, details of operation and control as well as maintenance
history.
Page 27 of 44
Report
6.3 Previous seal observations
This report is written based on the observations made during the inspection of Dry Gas Seals
(DGS) cartridge 10083673 & 10001183 which was conducted on April 2017 in John Crane MEA
service Centre, copies of inspection reports are shown in Appendix 3. Since November 2015
KOC sent to John Crane 7 seals from the LP-2 PH 1 & 2 compressors type BCL 806 with
evidence of liquid contamination.
Majority of the inspection reports issued by John Crane up to date point wet sticky black/brown
hydrocarbon contamination at inboard stage of the seal.
Presence of wet hydrocarbon always found at the back of face retainer and its screws cavities.
The IB seat with black hydrocarbon contamination at its spiral grooves and at bottom of sealing
dam area. These hydrocarbon particles while passing from the seal face would have made
running marks on the seat and primary ring sealing face.
The black hydrocarbon contamination can be seen at outboard stage also with accumulation at
spiral grooves on the seat face and primary ring ID near balance diameter O-ring. Also
outboard stage balance diameter O-ring at its inner diameter had severe wear.
Severity of contamination is always higher at Drive End which is discharge side of the
compressor.
Apparently wet hydrocarbon contamination at IB stage of the DGS has been there since
equipment commissioning. Wet hydrocarbon and dry black and brown colour solid particles
presence always deteriorates DGS performance.
Table 5 below presents failure evidences reported during seal inspection in John Crane since
day one of this site.
Page 28 of 44
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6.4 LP2 PH 2 Compressor Operating Conditions (Normal and Off-load)
Study Off-Load Operation of the Compressor is crucial in understanding the potential seal
failure. It is still under review. It will require further communications with KOC for studying all
details of compressor operation at the day of failure whose potentially contributing into root
cause. Clarification from site will help to close action points:
Page 29 of 44
Report
6.5 Seal Gas Composition and phase analysis
Picture 15. Phase diagram for Lean Gas used as a seal gas.
Lean Gas is safe to use as a seal gas in all operating range of summer and winter
temperatures. This gas does not require any heating or insulation on the seal gas supply
lines nor any gas conditioning, except fine particulate filtration.
Picture 16. Phase diagram prepared for Reach Gas.
Page 30 of 44
Report
6.6 Seal Gas Condition.
As already shown on the Phase diagram, Lean Gas provided from Refinery is safe to use in all
range of operating conditions and ambient temperatures without heating. However Reach Gas
collected from Export Gas Header after Dehydration Unit used as alternative seal gas source
when pressure in the Lean Gas line from Refinery drops below 22 Bar G.
During site visit thermal images have been collected for seal gas supply lines and found close
to ambient despite of available heat tracing and cladding. Therefore current thermal insulation
and heat tracing of the seal gas system lines considered as unsatisfactory.
Picture 17, 18 . Fragment of Thermographic Imaging Report for LP-2 PH2 Compressor.
Full report is given below.
Pictures 19,20. Shows Trace Heating without Thermal Insulation on the Seal gas supply line
upstream of the filtration skid.
The line coming from Fuel Gas skid Heater is not insulated on all its length which is around 300
meters. Seal Gas leaving the Heater with temperature 55-60°C arrives to the Gas Filters with
Page 31 of 44
Report
ambient temperature and then after expansion in the control valve gas temperature drops below
ambient.
Start-up as well as seal gas for normal operation is taken from Fuel Gas system. Seal Gas
supply line from compressor discharge is disconnected and not in use. It is expected that seal
gas supply temperature will be +28 to 125 above dew point, as specified in Utility Consumption
List, Doc. No: N.SOM 6604707/4. This condition is only satisfied for Lean Gas Composition.
Also existing P&ID drawing No: SOK0862078/1 requires that “Entire Seal Gas Piping Network
(except seal gas panel) will be heat insulated by the Contractor. Thermal Insulation should be in
accordance with KOC Spec. No: 015-NH-1003” (See Note 3).
If Reach Gas used as a seal gas then gas conditioning shall be improved. This gas is not safe
to use in current system condition due to possibility of liquid hydrocarbons condensation in all
range of winter as well as summer ambient temperatures. Gas from this source still requires
conditioning equipment: as minimum as Gas Heater in the seal gas skid along with proper
thermal insulation and heat tracing of all seal gas supply lines to be able to provide seal gas
temperature at the compressor nozzle not below 55°C.
Page 32 of 44
Report
6.6 Seal Gas Flow.

During site visit it was found that Lean Seal Gas Flow across 6.3 mm Orifice FO-5570 and FO-
5571 in operation with 1.0 Bar DP is around 16 Nm3/Hr. This flow can provide clean seal gas
velocity across Process labyrinth less than 3 m/sec. This is inacceptable velocity for protecting
the seals against dirty process gas entering the seals.
When Reach Gas used as a seal gas, with the same differential pressure 1 bar across 6.3 mm
Orifice only 12.91 Hm3/Hr gas flow can be provided. With this flow it is only possible to achieve
2 m/sec gas velocity across inner process labyrinth. This is inacceptable velocity which is much
below all industry standards.
Compressor Data Sheet, Utility Consumption List specified BCL 806primary Seal Gas Flow for
start-up is 78 Nm3/Hr at pressure 25 bar G and temperature 16° to 41° C.
It is recommended to increase seal gas flow across process labyrinth in order to achieve as
minimum as 10-12 m/sec which require 60-70 Nm3/Hr flow per one seal. Along with changing
orifice size from current 6.3 to 12 mm and provide 3 bar g differential pressure set point for
PDCV-5400 all seal gas supply line instruments, equipment inclusively Filters and other piping
components need to be carefully reviewed in order not to exceed their operating limits. Utility
Consumption List provided by KOC shows Fuel Gas Flow during start-up 78 Nm3/Hr whose
could be assumed as design flow for the system. We actually recommend to double Flow
across seal gas lines. Design conditions and flow capability of the seal gas system components
needs to be clarified and confirmed whether this achievable or not. This will require full
engineering review which is easy to be carried out by Compressor OEM. This action can be
performed as long term solution. For short term Seal Gas flow can be quickly increased to 80
Nm3/Hr per compressor, which can provide 5-6 m/sec gas velocity across process labyrinth.
This velocity is not fully adequate to conditions inside the compressor with observed amount of
liquid hydrocarbons travelling across process lines. However it will improve situation quickly.
Situation with using Reach Gas as a seal gas is more difficult.
From one side reach gas still requires thorough conditioning which therefore some investments.
From another it is more difficult to achieve adequate seal gas flow through the same line due to
increased molecular weight MW = 24.44 for Reach Gas and MW= 16.61 for Lean Gas. We
recommend to get rid of Reach Gas as a seal gas for all LP Compressors on Phase 1 & 2. This
needs to be considered by KOC in case Lean Gas source from Refinery available at all times.
Page 33 of 44
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Currently KOC use logic to change source from Lean Gas to Reach Gas when pressure in Lean
Gas line drops below 22 Bar G. This limitation most likely configured for Turbine Fuel Gas.
However Lean Gas still can be used as a seal gas in LP-1 and LP-2 Compressors when
pressure in the line drops much more down. Final value can be evaluated by KOC Engineering
basing on the Utility consumption List for all 4 Compressors. Below is given labyrinth flow alomg
with orifice flow calculation.
Page 34 of 44
Report
Calculated Lean seal gas flow across orifice 6.3 mm
Calculated Reach Seal Gas Flow across orifice 6.3 mm
Page 35 of 44
Report
6.7 Seal Gas Line cleanliness.

As reported by site personnel Main Coalescing Seal Gas Filters 131-FT-2102A&B quite often
being clogged with solid particles and require replacement when DP reach set point of 1 Bar D.
It is reported solid contamination which looks like black powder. Sample of contamination have
been collected during site visit and sent for laboratory analysis. Laboratory Reports will be
submitted to KOC upon completion of chemical analysis. This action point is on John Crane.
Pictures 21, 22 Seal Gas Filter Cartridges removed from 131-FT-2102A&B
Pictures above shows presence of solid contamination on clean side of the Filters.
Despite of enormous amount of solid contaminants collected in the filter cartridges there are still
numerous observations confirming presence of solid particles in the seals during inspection.
Quality of filtration needs to be improved. KOC to consider Seal Gas Filter upgrade or installation
additional particulate filtration unit in the seal gas lines.
Page 36 of 44
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6.7 Compressor process gas

By definition process gas in this application is called as “Wet Gas” and contains heavy liquid
hydrocarbons whose can easily condense in the process loops as well as carry over liquids like
crude together with solids along the process lines. There is strong evidence that process lines
contain some amount of liquid hydrocarbons.
It is drained from suction scrubbers, compressor drain lines on regular basis.
Pictures 23.24. Liquid Hydrocarbons entering seal cavity from process side.
Special attention need to be given in operation and maintenance for PDCV-5400 and seal gas
control loop with PDIC-5427 to prevent accumulation of liquids in the impulse lines responsible
for sensing reference pressure (-) impulse line for PDIT 5427. Otherwise casing pressure
signal can be erroneous, therefore seal gas control loop would not function properly.
Pictures 25, 26. Heavy Contamination of the reference gas line, negative impulse line for PDIT-
5427.
Page 37 of 44
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6.8 Separation Air quality and separation flow control
As per original design, dry gas seal cartridge shall be supplied with T-82 Separation seal
contacting type with segmented carbon rings. This arrangement is still reflected on the seal
general arrangement drawings. As soon as segmented carbon ring not in use it is
recommended to update seal GAD to reflect “as-built” design. Contacting carbon ring seals
typically consumes considerably less separation gas flow in comparison with non-contacting
labyrinth. Changing to Labyrinth technology usually means using a different control philosophy
for the separation seal gas. A clearance Labyrinth by design uses considerably more N2/Air
than the T82/3 would…the T82 is normally pressure controlled whilst the Laby would be flow
controlled.
In order to cover this difference GE provided to all 6 compressors installed at KOC separation
air supplied from Turbine cooling air system to accommodate increased separation flow
required for labyrinth. Air is taken from axial compressor discharge, cooled down and supplied
to the seal gas skid. Purge of separation gas is controlled by flow: after coalescing filters PCV-
5521 drops pressure from 6.6-6.9 Bar g down to 2 Bar g and then flow controlled/ throttled in
orifice with diameter 12 mm on the way to DE and NDE labyrinth seals. This is for LP-2 PH2
Compressor. For PH-1 Compressor Separation gas after PCV is supplied in two parallel lines:
one line equipped with control valve provides separation gas to DE and NDE labyrinths through
5 mm orifice. Another line without any valves supply separation air to the labyrinth seals
through orifices with size 8 mm. KOC is requested to explain difference in design and reason
behind of this solution.
For subject Compressor LP-2 Ph-2 with 12 mm Orifice in individual separation gas supply lines
34 Nm3/Hr delivered to the separation labyrinth.
Calculated gas velocity is 13 ± 1 m/sec across each separation labyrinth (Inner and outer) with
current differential pressure set-up across 12 mm orifice in the 1-1/2” line separation gas
labyrinth for LP-2 PH-2 machine. This gas velocity across labyrinth is considered safe for
preventing oil ingress.
However there are still reported cases of oil ingress into outboard seal stage (Secondary Seal)
during seal inspection. KOC to pay attention to correct operation and regular maintenance of
LCV-5400 and LCV-5401. This type of device if fails closed can cause lube oil build-up in the
Page 38 of 44
Report
drain line, which eventually will flood the secondary vent annulus and goes further to the seals.
If LCV fails open then separation gas flow will be partially released to oil drain, as such it will
compromise separation gas flow to labyrinths.
Pictures 27, 28 show internal Arrangement of the Coalescing Filters 131-FT-2105A&B with
cartridge in position.
There is visible contamination of clean side of the filter with water droplets.
During Coalescer Air Filter inspection it was noticed big amount of water droplets on the filter
clean side as well as inside the outlet pipe connected to labyrinth seal. There is possibility of
liquid water carry-over towards the separation labyrinth, therefore half of this water accumulates
in the secondary vent lines.
Operation Personnel drains water from Air filters every 8 hours. There is still some amount
passing the filters and moves towards the seals. Recommended action: Efficiency of Air
Coalescer Filter 131-FT-2105A&B need to be improved.
Quality requirements for separation air are specified in the compressor Utility Consumption List.
It shall be Oil Free, Dry, Filtered. Normally separation air requires to be dry to the same level as
instrument air or nitrogen from Plant Nitrogen system. In normal operation air is taken from axial
compressor delivery, therefore capacity of the Coalescer Filters should be suitable for worth
case scenario when humidity of atmospheric air reach it maximum values specified for this
area. It is evidence that in current situation quality of the air is below accepted industry
standards. Requires improvement.
Page 39 of 44
Report
Pictures 29, 30 show contamination of Outboard seal stage arrived from Secondary vent port.
(Report 4397430, S/N: 0309-0483 and Report 4344482, S/N: 0208-0423)
Rust is expected to be originated from carbon steel Air supply pipe between Air Cooler and DGS
Filtration skid. KOC already studied this issue and taken decision to replace carbon steel piping
with SS piping. Action is added to existing RCA report as relevant to scope of investigation and
passing solution criteria.
Picture 31. Solids like rust taken from internal part of used Air Filter.
Page 40 of 44
Report
6.9 Flare and Primary vent Conditions
As soon as Reach Gas is used in some periods of operation as a Seal Gas there is possibility
of liquid hydrocarbon condensation in the Primary vent lines, inside the seals as well as flare
line on it’s way to the Flare Header. The pipe connecting primary vent monitoring loop in the
panel with flare header which is starting from TP-611 have a length of approximately 150-200
meters with big numbers of bends, lot of rising and horizontal lines.
Atmospheric conditions in the line with ambient

temperatures during winter season will cause
hydrocarbons condensation resulting in
contamination of instruments in Primary vent
monitoring loop entering Panel by gravity. There
is no any low point drains or inspection points
provided in the line in order to assess
conditions. This could be one of the potential
reasons of zero primary vent flows reported in
some seals. Recommended to incorporate low
point drain with first available opportunity and
inspect/ drain it on regular basis.
Picture 32 . Interconnecting line between Primary Vent in the Gas Panel and Flare header.
Interconnecting Line of primary vent to Flare Header is insulated on its first 1.5 meters of length.
Page 41 of 44
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6.10 Secondary Vent Conditions
Due to inefficient coalescing filtration

separation air is injecting big amount of
water in vapor form as well as water
droplets have been carried over towards
separation labyrinth. Eventually half of this
water goes through the secondary vent line
to atmospheric vent located at the safe
area on the top of Compressor Shelter. At
certain winter conditions there is high
probability that water vapors will condense
in the secondary vent line and flow back to
the seal area by gravity.
Picture 33. Secondary vent piping with Flame arrestor
It is advisable to install drains at low point of the secondary vent pipes and inspect/ drain it on
regular basis until situation with wet separation air improved.
Observation is also made that Flame arrestor is located close to compressor. There is still gas-
air mixture sometimes can reach above LEL % and exist downstream of Flame arrestor on full
length of the 3” secondary vent line up to exit to atmosphere on the top of the shelter. However
Pipe is not protected against fire in this area. Action is not related to this particular failure mode,
however we recommend to install Flame arrestor (one more, if required) at the end of the vent
line close to the top of the Compressor Shelter.
Recommended action points in SV line:
 To provide quality of separation air the same as Instrument Air or Plant Nitrogen quality.
 To introduce low point drain valves in the individual secondary vent line close to
compressor nozzles at DE and NDE. Provide drains and inspection on regular basis.
 To install one more Flame arrestor at the exit of secondary vent gas to atmosphere at
the top of Compressor Shelter.
Page 42 of 44
Report
6.11 Seal Installation (operating axial positioning)
Rubbing marks between Retainer Inner and Spacer Sleeve reported during seal inspection.
As described in RCA RealityChart one of the reasons of excessive heat generation could be direct
contact between Spacer Sleeve and Retainer Inner.
Pictures 34, 35 show rubbing contact on surfaces of the Retainer Inner and Spacer Sleeve
(Items 07 and 10)
Pictures 36, 37 DGS schematic drawing shows design clearance between two rubbed compressor
parts.
Direct contact is only possible when Seal Rotor axially shifted towards Seal Stator by 5.2 mm.
This could be possible as a cumulative effect of different events affecting rotor - stator relative axial
positioning. Some of them related to seal assembly, others to installation and operation.
Last GE-NP FSE Report submitted during seal replacement in March 2017 mentioned that new DE
shim installed 6.5 mm thick.
Page 43 of 44
Report
There are few questions about this:

 How seal parts were manufactured and assembled?
 Why shim thickness was 6.5 mm and not 8.0 mm as per GAD?
 What was thickness of the removed shim?
 How Dry Gas seal and Separation labyrinth housing have been clamped? Is any
possibility to get any component loose or misplaced?
 How rotor was locked axially during shaft to casing measurements and seal installation
 What was rotor positioning relatively casing? Any thrust collar shim changed? Or any
possibility to miss or confuse thrust bearing shim installation?
Recommended clarification actions assigned to John Crane and KOC in order to establish whether
this is root cause or consequential seal damage.
Page 44 of 44
John Crane Europe, Asia, Africa
International Sealing Systems
DRY GAS SEAL INSPECTION REPORT

DRAFT
KOC
PROJECT:
COMPRESSOR: NUOVO PIGNONE BCL806
DATE: 29/11/2015
REPORT No: JDUB15/154
FILE REFERENCE: 02/50016/G
S.O.4344482
SEAL INFORMATION
CARTRIDGE No: 0208-0423 SEAL CODE: 3095/28AT/--/S42317
EQUIPMENT No: 20043693 GLOBAL PART No: 87039585
SHAFT ROTATION: CW COMPRESSOR END: CW
OPERATING CONDITIONS
FLUID: HYDROCARBONS SEAL PRESS: 19 BAR G TEMP: -20ºC200 ºC SHAFT SPEED: 4670 RPM
SUMMARY
GENERAL APPEARANCE:
Dry gas seal received in a wooden box. The axial movement of the whole cartridge felt normal.
INBOARD STAGE:
The axial movement of the inboard retainer assembly felt normal. Liquid hydrocarbon contaminants were found inside of the retainer assembly.
Running marks are found on the sealing surface of the mating ring(see pic 1 & 2). Running marks are visible on the sealing surface of the
inboard primary ring (see pic 3 & 4).
OUTBOARD STAGE:
The axial movement of the outboard retainer assembly felt normal. Hydrocarbon contaminants were found in the inside of the retainer
assembly. Running marks are visible on the sealing surface of the mating ring (see pic 5 & 6). Running marks are found on the sealing surface
of the primary ring (see pic 7 & 8).
SEPARATION SEAL:
The T82 Barrier seal not returned with seal.
'O'-RINGS
O-rings are in good condition and will be replaced as per John Crane standard repair procedure.
INSPECTED BY: SHAJAN BABY

The information contained in, or attached to this communication contains confidential information and is intended solely for the use of the
individual or entity to whom they are addressed and is subject to legal privilege.
Do not copy it for any purpose, or disclose it's contents to any other person without the written permission of John Crane.
M300.1.1 Issue R
PROJECT NAME : KOC
REFURBISHMENT REQUIREMENTS CARTRIDGE No: 0208-0423
20043693
T28 AT DRAFT EQUIPMENT No:
SEAL CODE : 3095/28AT/--/S42317
REPORT NUMBER :
FILE REFERENCE :
JDUB15/154
02/50016/G
S.O.4344482 GLOBAL PART No: 87039585
INSPECTION DATE : 29/11/15 ECN RAISED / No: CAR RAISED: SUB:
PART CODE / CORRECT TO

DESCRIPTION MATERIAL LATEST GA
WORK REQUIRED ADDITIONAL COMMENTS
ISSUE 'F' MIN SEAT SIZE
MATING RINGS ACQUISITION No: ALLOWED -0.15 mm
INBOARD MATING RING SC-S/42317-MR-CW-9222 YES CLEAN RELAP REGROOVE AND REUSE S02-0533 RUNNING MARKS
OUTBOARD MATING RING SC-S/42317-MR-CW-9222 YES CLEAN RELAP REGROOVE AND REUSE S07-1103 RUNNING MARKS
PRIMARY RINGS ACQUISITION No:
INBOARD PRIMARY RING SC-S/42317-PR-9028 YES REPLACE F07-0118 RUNNING MARKS

OUTBOARD PRIMARY RING SC-S/42317-PR-9028 YES REPLACE F07-0119 RUNNING MARKS
METAL PARTS
RETAINER INNER S/94469/1/229 YES REPLACE PITTING MARKS

RETAINER OUTER S/94332/1/229 YES REPLACE PITTING MARKS
SLEEVE S/97270/1/506 YES CLEAN AND REUSE SERVICEABLE CONDITION
SPACER SLEEVE S/97271/1506 YES CLEAN AND REUSE SERVICEABLE CONDITION
LOCKING SLEEVE S/97272/1/229 YES CLEAN AND REUSE SERVICEABLE CONDITION
INBOARD THRUST RING S/94468/1/229 YES REPLACE NOT SUITABLE FOR NEW O-RING CUSTOM FIT
OUTBOARD THRUST RING S/94468/1/229 YES REPLACE NOT SUITABLE FOR NEW O-RING CUSTOM FIT
FACE RETAINER S/87096/1/229 YES CLEAN AND REUSE SERVICEABLE CONDITION
SEAL SPACER S/87095/1/229 YES REPLACE PITTING MARKS
SETTING PLATE INNER S/94471/1/229 YES CLEAN AND REUSE SERVICEABLE CONDITION
SETTING PLATE OUTER S/94336/1/229 YES CLEAN AND REUSE SERVICEABLE CONDITION
CONSUMABLES
'O'-RINGS FLUOROCARBON YES REPLACE AS STANDARD TYPICAL DETERIORATION

DRIVE BUTTONS ST. ST.BS410S21 YES REPLACE AS STANDARD TYPICAL DETERIORATION
TOLERANCE RING MONEL K500 YES REPLACE AS STANDARD TYPICAL DETERIORATION
FINGER SPRING INCONEL X750 YES REPLACE AS STANDARD TYPICAL DETERIORATION
SPRINGS HASTELLOY 'C' YES REPLACE AS STANDARD TYPICAL DETERIORATION
CAP HEAD SCREW DUPLEX YES REPLACE AS STANDARD TYPICAL DETERIORATION
CAP HEAD SCREW DIN 912-12.9 YES REPLACE AS STANDARD TYPICAL DETERIORATION
SEPARATION SEAL RETURNED NO NACE REQUIREMENT: YES PARTS ENGRAVED WITH GMI: YES PARTS CLEANED: YES
SHIPPING CASE SIZE: NEW CASE REQUIRED: YES SPARES KIT: NEW KIT REQUIRED
HAVE ALL PARTS ON THE PARTS ASSEMBLY LIST FOR THIS SEAL HAVE BEEN ACCOUNTED FOR: NO BAY LOCATION:
PROJECT NAME : KOC
CARTRIDGE No: 0208-0423
EQUIPMENT No: 20043693
DETAILED ASSESSMENT SEAL CODE : 3095/28AT/--/S42317
GLOBAL PART No: 87039585
DRAFT FILE REFERENCE : 02/50016/G
REPORT NUMBER : JDUB15/154
INSPECTION DATE : 29/11/2015
PICTURE 1
The BLUE arrows in the pictures on the left match the

positions of the BLUE arrows in the drawings below
The RED in the drawings below indicates the surfaces

visible in the pictures on the left.
Section1
Picture 1 shows the inboard mating ring assembly.
PICTURE 2
Section2
Picture 2 shows the inboard mating ring. Running marks and abutment marks are
visible on the sealing dam surface of the mating ring. This mating ring will need to
be re-lapped, re-polished and re-grooved.
PROJECT NAME : KOC
PICTURE 3


Section1
Picture 3 shows the inboard retainer assembly.
PICTURE 4
Section2
Picture 4 shows the Running marks are found on the sealing surface of the
primary ring. This primary ring will need to be replaced.
PROJECT NAME : KOC
PICTURE 5


Section1
Picture 5 shows the outboard mating ring assembly.
PICTURE 6
Section2
Picture 6 shows the outboard mating ring. Running marks are found on the sealing
surface of the mating ring. This mating ring will need to be re-lapped,re-polished
and re-grooved.
PROJECT NAME : KOC
PICTURE 7


Section1
Picture 7 shows the outboard retainer assembly.
PICTURE 8
Section2
Picture 8 shows the outboard retainer. Liquid contamination and running marks
are found on the sealing surface of the primary ring. This primary ring will need to
be replaced.
PROJECT NAME : KOC
PICTURE 9


Section1
Picture 9 shows the inboard retainer.
PICTURE 10
Section2
Picture 10 shows the close-up view of the balanced diameter. Pitting marks visible
on the balanced diameter. This will need to be replaced.
PROJECT NAME : KOC
PICTURE 11


Section1
Picture 11 shows the out board retainer.
PICTURE 12
Section2
Picture 12 shows the pitting marks visible in the O-ring groove of the outboard
retainer. This retainer will need to be re-placed.
PROJECT NAME : KOC
PICTURE 13


Section1
Picture 13 shows the seal spacer.
PICTURE 14
Section2
Picture 14 shows the pitting marks found in the O-ring groove of the seal spacer.
This seal spacer will need to be replaced.
PROJECT NAME : KOC
RETURNED ITEMS
ITEMS RETURNED
1 T28AT Dry gas seal assembly.

DRAFT
KOC
PROJECT:
COMPRESSOR: NUOVO PIGNONE BCL806
DATE: 29/11/2015
FILE REFERENCE: 02/50016/G
S.O.4344480
SEAL INFORMATION
CARTRIDGE No: 10001184 SEAL CODE: 3095/28AT/--/S42318
SHAFT ROTATION: CCW COMPRESSOR END: CCW
FLUID: HYDROCARBONS SEAL PRESS: 19 BAR G TEMP: -20ºC/200 ºC SHAFT SPEED: 4670 RPM
SUMMARY
GENERAL APPEARANCE:
Dry gas seal received in a wooden box. The axial movement of the whole cartridge felt normal.
INBOARD STAGE:
The axial movement of the inboard retainer assembly felt normal. Black hydrocarbon contaminants were found inside of the retainer assembly.
Running marks are found on the sealing surface of the mating ring (see pic 1 & 2). Running marks and chipping are visible on the sealing
surface of the inboard primary ring (see pic 3 & 4).
OUTBOARD STAGE:
The axial movement of the outboard retainer assembly felt normal. Hydrocarbon contaminants were found in the inside of the retainer
assembly. Running marks are visible on the sealing surface of the mating ring (see pic 5 & 6). Running marks are found on the sealing surface
of the primary ring (see pic 7 & 8).
SEPARATION SEAL:
T82 Barrier seal was not returned with the seal.
'O'-RINGS
O-rings are in good condition and will be replace as per John Crane standard repair procedure.

M300.1.1 Issue R
PROJECT NAME : KOC
REFURBISHMENT REQUIREMENTS CARTRIDGE No: 10001184
10001184
T28 AT DRAFT EQUIPMENT No:
SEAL CODE : 3095/28AT/--/S42318
REPORT NUMBER :
FILE REFERENCE :
JDUB15/153
02/50016/G
S.O.4344480 GLOBAL PART No: 89277716

INBOARD MATING RING SC-S/42317-MR-CCW-9222 YES CLEAN RELAP REGROOVE AND REUSE S07-1183 RUNNING MARKS
OUTBOARD MATING RING SC-S/42317-MR-CCW-9222 YES CLEAN RELAP REGROOVE AND REUSE S07-1184 RUNNING MARKS
INBOARD PRIMARY RING SC-S/42317-PR-9028 YES REPLACE 28205-4 RUNNING MARKS

OUTBOARD PRIMARY RING SC-S/42317-PR-9028 YES REPLACE 28205-1 RUNNING MARKS
METAL PARTS
RETAINER INNER S/94469/1/229 YES REPLACE PITTING MARKS

RETAINER OUTER S/94332/1/229 YES CLEAN POLISH BALANCE DIAMETER AND REUSE SERVICEABLE CONDITION
SLEEVE S/97270/1/506 YES REPLACE GALLING
SPACER SLEEVE S/97271/1/506 YES CLEAN AND REUSE SERVICEABLE CONDITION
SEAL SPACER S/87095/1/229 YES REPLACE PITTING MARKS
SETTING PLATE INNER S/94335/1/229 NO REPLACE WAS NOT MACHING WITH THE DRAWING
CONSUMABLES
'O'-RINGS FLUOROCARBON YES REPLACE AS STANDARD TYPICAL DETERIORATION

CAP HEAD SCREW DUPLEX YES REPLACE AS STANDARD TYPICAL DETERIORATION
CAP HEAD SCREW DIN 912-12.9 YES REPLACE AS STANDARD TYPICAL DETERIORATION
SHIPPING CASE SIZE: E NEW CASE REQUIRED: YES SPARES KIT: NEW KIT REQUIRED
PROJECT NAME : KOC
CARTRIDGE No: 10001184
PICTURE 1


Section1
Picture 1 shows the inboard mating ring assembly.
PICTURE 2
Section2
Picture 2 shows the inboard mating ring. Running marks are visible on the sealing
surface of the mating ring. This mating ring will need to be re-lapped, re-polished
and re-grooved.
PROJECT NAME : KOC
PICTURE 3


Section1
Picture 3 shows the inboard retainer assembly.
PICTURE 4
Section2
Picture 4 shows the running marks and inner diameter chipping are found on the
sealing surface of the outboard primary ring. This primary ring will need to be
replaced.
PROJECT NAME : KOC
PICTURE 5


Section1
Picture 5 shows the outboard mating ring assembly.
PICTURE 6
Section2
Picture 6 shows the outboard mating ring. Running marks are found on the sealing
surface of the mating ring.This mating ring will need to be re-lapped,re-polished
and re-grooved.
PROJECT NAME : KOC
PICTURE 7


Section1
Picture 7 shows the outboard retainer assembly.
PICTURE 8
Section2
Picture 8 shows the outboard retainer. Running marks are found on the sealing
surface of the primary ring. This primary ring will need to be replaced.
PROJECT NAME : KOC
PICTURE 9


Section1
Picture 9 shows the inboard retainer.
PICTURE 10
Section2
Picture 10 shows the pitting marks found on the balancing diameter of the inboard
retainer. This retainer will need to be replaced.
PROJECT NAME : KOC
PICTURE 11


Section1
Picture 11 shows the seal spacer.
PICTURE 12
Section2
Picture 12 shows the pitting marks are found in the O-ring groove of the seal
spacer. This seal spacer will need to be replaced.
PROJECT NAME : KOC
PICTURE 13


Section1
Picture 13 shows the sleeve.
PICTURE 14
Section2
Picture 14 shows the deep galling marking visible inside the sleeve that has
damaged the o-ring groove. This sleeve will need to be replaced.
PROJECT NAME : KOC
RETURNED ITEMS
ITEMS RETURNED
1 T28AT Dry gas seal assembly.

- INTERNAL -
KOC KUWAIT
PROJECT:
COMPRESSOR: NUOVO PIGNONE
DATE: 23/04/2015

FILE REFERENCE: 02/50016G
S.O.4317214
SEAL INFORMATION
CARTRIDGE No: 10001183 SEAL CODE: 3095/28AT/--/S42317
FLUID: HYDROCARBONS SEAL PRESS: 19 BAR G (STATIC) TEMP: MIN SHAFT SPEED: 4904
19 BAR G (DYNAMIC) 20ºC/200ºC
SUMMARY
GENERAL APPEARANCE:
The Dry Gas seal was received in a wooden box. Hydrocarbon contamination are visible on outer surface of the seal assembly. Axial movement
of the whole cartridge felt normal.
INBOARD STAGE:
Axial movement of the retainer assembly felt normal. Sticky liquid hydrocarbon contamination visibleon the retainer assembly. Running marks
are visible on the sealing area of the primary ring (see pic 1 & 2), Running marks and abutment marks visible on the sealing surface of the
mating ring (See pic 3 & 4).
OUTBOARD STAGE:
Axial movement of the retainer assembly felt normal. Sticky liquid hydrocarbon contamination visibleon the retainer assembly. Running marks
are visible on the sealing surface area of the primary ring (see pic 5&6). Lines and abutment marks visible on the polished surface of the seat
(see pic 7&8).
BARRIER SEAL
Barrier seal was not returned
POLYMER SEALS / 'O'-RINGS

All O-rings are showing sign of typical deterioration and will be replaced as per John Crane standard procedure.

M300.1.1 Issue R
PROJECT NAME : KOC KUWAIT
REFURBISHMENT REQUIREMENTS CARTRIDGE No: 10001183
T28 AT - INTERNAL - SEAL CODE : 3095/28AT/--/S42317
REPORT NUMBER :
FILE REFERENCE :
JDUB15/029
02/50016G
S.O.4317214 GLOBAL PART No: 87039585

INBOARD MATING RING SC-S/42317-MR-CW-9222 YES REPLACE SO7-1185 VISIBLE RUNNING AND ABUTMENT MARKS
OUTBOARD MATING RING SC-S/42317-MR-CW-9222 YES REPLACE SO7-1186 VISIBLE RUNNING AND ABUTMENT MARKS
INBOARD PRIMARY RING SC-S42317-PR-9028 YES REPLACE 28205 2 RUNNING MARKS

OUTBOARD PRIMARY RING SC-S42317-PR-9028 YES REPLACE 28205 3 RUNNING MARKS
METAL PARTS
RETAINER INNER S/94469/1/229 YES REPLACE RUNNING MARK VISIBLE AROUND THE SEAL AREA
RETAINER OUTER S/94332/1/229 YES REPLACE RUNNING MARK AND ABUTMENT MARK VISIBLE AROUND THE SEAL AREA
SLEEVE S/97270/1/506 YES CLEAN AND REUSE SERVICEABLE CONDITION
SPACER SLEEVE S/97271/1/506 YES CLEAN AND REUSE SERVICEABLE CONDITION
SEAL SPACER S/87095/1229 YES REPLACE PITTING MARK IN THE ORING GROOVE
SETTING PLATE INNER S/9447/1/229 YES CLEAN AND REUSE SERVICEABLE CONDITION
CONSUMABLES
'O'-RINGS VARIOUS MTL's YES REPLACE AS STANDARD TYPICAL DETERIORATION

BOLTING DIN 912-12.9 YES REPLACE AS STANDARD TYPICAL DETERIORATION
BOLTING DUPLEX YES REPLACE AS STANDARD TYPICAL DETERIORATION
INSPECTED BY: Shajan Baby
SHIPPING CASE SIZE: N/A NEW CASE REQUIRED: YES SPARES KIT: NEW KIT REQUIRED
DETAILED ASSESSMENT CARTRIDGE No:
EQUIPMENT No:
SEAL CODE :
10001183
10001183
3095/28AT/--/S42317
- INTERNAL - KOC KUWAIT
FILE REFERENCE : 02/50016G

PICTURE 1 PICTURE 2
Picture 1 shows the inboard primary ring. Picture 2 shows the running marks visible on the sealing area of the primary
ring. After polishing and re-calibration the primary ring is under the calibration
requirements. This primary ring will need to be replaced.
EQUIPMENT No:
SEAL CODE :
10001183
10001183
3095/28AT/--/S42317

PICTURE 3 PICTURE 4
Picture 3 shows the inboard mating ring. Picture 4 shows the running marks and abutment marks visible on the sealing
surface of the mating ring. This mating ring will need to be replaced.
EQUIPMENT No:
SEAL CODE :
10001183
10001183
3095/28AT/--/S42317

PICTURE 5 PICTURE 6
Picture 5 shows the out board primary ring. Picture 6 shows the running marks visible on the polished surface area of the
primary ring. After polishing and re-calibration the primary ring is under the
calibration requirements. This primary ring will need to be replaced.
EQUIPMENT No:
SEAL CODE :
10001183
10001183
3095/28AT/--/S42317

PICTURE 7 PICTURE 8
Picture 7 shows the outboard mating ring. Picture 8 shows running marks and abutment marks visible on the sealing
surface of the mating ring. This mating ring will need to be replaced.
EQUIPMENT No:
SEAL CODE :
10001183
10001183
3095/28AT/--/S42317

PICTURE 9 PICTURE 10
Picture 9 shows the inboard retainer assembly. Picture 10 shows the running mark visible around the balanced diameter of
the retainer. This retainer will need to be replaced.
EQUIPMENT No:
SEAL CODE :
10001183
10001183
3095/28AT/--/S42317

Picture 11 shows the outboard retainer assembly assembly. Picture 12 shows the pitting mark visible around balanced diameter of the
retainer. This retainer will need to be replaced.
EQUIPMENT No:
SEAL CODE :
10001183
10001183
3095/28AT/--/S42317

Picture 13 shows the seal spacer. Picture 14 shows the pitting's visible in the o-ring groove of the seal spacer.
The seal spacer will have to be replaced.

RETURNED ITEMS
ITEMS RETURNED
1 T28 AT Dry gas seal assembly
INTERNAL
REPORT

John Crane Middle East FZE PO BOX 61040, Dubai, UAE: 24 hour Emergency Line: 0044 7889 653846
KOC
PROJECT:
COMPRESSOR: NUOVO PIGNONE COMPRESSOR BCL806

DATE: 07.02.2016
SEAL INFORMATION
Picture Insert DRAWING No: S/42317 CARTRIDGE No: 0309-0483

GLOBAL PART No: 87039585 SEAL CODE: 3095/28AT/--/S42317
FILE REFERENCE: 02/50016G REPORT No: 4397430
GENERAL FINDINGS
REASON FOR RETURN: RELIABILITY GROUP INVESTIGATION WITNESS INSPECTION: YES
MAIN SEAL FINDINGS:

T28 AT TANDEM
1st STAGE 2nd STAGE 3rd STAGE
CONTAMINATION: WET BLACK/BROWN STICKY WET BLACK/BROWN STICKY ???
MATING RING: CHIPPING LIGHT RUNNING MARKING ???
PRIMARY RING: RUNNING MARKING RUNNING MARKING ???
AXIAL MOVEMENT: FREE MOVEMENT FREE MOVEMENT ???
ROTOR METAL WORK: GOOD CONDITION GOOD CONDITION ???
STATOR METAL WORK: BAL DIAMETER MARKING REPLACE GOOD CONDITION ???
'O'-RINGS: REPLACE AS STANDARD WEAR MARKING ???
SEPARATION SEAL FINDINGS: NOT RETURNED
CONTAMINATION: ???
??? ???
ROTOR METAL WORK: ???
STATOR METAL WORK: ???
'O'-RINGS: ??? INSPECTED BY: Shajan Baby
ADDITIONAL JOHN CRANE PRODUCTS AND SERVICES CONTACT 0044 1753 224000 FOR INFORMATION
SPARE SEALS NEW SEALS SERVICE VISITS SYSTEMS COUPLINGS BEARINGS FILTRATION SEPARATION SEALS
M300.2.1 Issue C
DETAILED REFURBISHMENT REQUIREMENTS
INTERNAL PROJECT NAME : KOC
T28 AT REPORT CARTRIDGE No: 0309-0483
REPORT NUMBER : 4397430 SEAL CODE : 3095/28AT/--/S42317
FILE REFERENCE : 02/50016G DRAWING No: S/42317
INSPECTION DATE : 07.02.2016 GLOBAL PART No: 87039585 GCN RAISED / No:
DESCRIPTION WORK REQUIRED ADDITIONAL COMMENTS
MATERIAL LATEST GA
ALLOWED
18.09 mm
MATING RINGS ACQUISITION No:
INBOARD MATING RING SC-S/42317-MR-CW-9222 REPLACE S03-2173 CHIPPING MARKS ON ID AND OD
OUTBOARD MATING RING SC-S/42317-MR-CW-9222 RELAP REGROOVE AND REUSE 733775 RUNNING MARKS

INBOARD PRIMARY RING SC-S/42317-PR-9028 REPLACE 4500825755 RUNNING MARKS
OUTBOARD PRIMARY RING SC-S/42317-PR-9028 REPLACE 4500825755 RUNNING MARKS
METAL PARTS
RETAINER INNER S/94469/1/229 REPLACE AXIAL WEAR MARKS ON BALANCED DIAMETER
RETAINER OUTER S/94332/1/229 CLEAN POLISH BALANCE DIAMETER AND REUSE SERVICEABLE CONDITION
SLEEVE S/97270/1/506 CLEAN AND REUSE GOOD CONDITION
SPACER SLEEVE S/97271/1/506 CLEAN AND REUSE GOOD CONDITION
LOCKING SLEEVE S/97272/1/229 CLEAN AND REUSE GOOD CONDITION
INBOARD THRUST RING S/94468/1/229 REPLACE NOT SUITABLE FOR NEW O-RING CUSTOM FIT
OUTBOARD THRUST RING S/94468/1/229 REPLACE NOT SUITABLE FOR NEW O-RING CUSTOM FIT
SEAL SPACER S/87095/1/229 CLEAN AND REUSE GOOD CONDITION
FACE RETAINER S/87096/1/229 CLEAN AND REUSE GOOD CONDITION
SETTING RING INNER ASM. S/94471/1/229 CLEAN AND REUSE GOOD CONDITION
SETTING RING OUTER ASM. S/94336/1/229 CLEAN AND REUSE GOOD CONDITION
CONSUMABLES
'O'-RINGS FLUOROCARBON REPLACE AS STANDARD REPLACE AS STANDARD
DRIVE BUTTONS ST.ST. BS410S21 REPLACE AS STANDARD REPLACE AS STANDARD
TOLERANCE RING MONEL K500 REPLACE AS STANDARD REPLACE AS STANDARD
SPRINGS HASTELLOY 'C' REPLACE AS STANDARD REPLACE AS STANDARD
FINGER SPRING INCONEL X750 REPLACE AS STANDARD REPLACE AS STANDARD
CAP HEAD SCREW DIN 912 - 12.9 REPLACE AS STANDARD REPLACE AS STANDARD
CAP HEAD SCREW DUPLEX REPLACE AS STANDARD REPLACE AS STANDARD
SEPARATION SEAL RETURNED: NO NACE REQUIREMENT: YES PARTS ENGRAVED WITH GMI: YES PARTS CLEANED YES
SHIPPING CASE SIZE: N/A NEW CASE REQUIRED: NO SPARES KIT: NEW KIT REQUIRED
ALL PARTS ON THE PARTS ASSEMBLY LIST FOR THIS SEAL HAVE BEEN ACCOUNTED FOR: YES BAY LOCATION: N/A
M300.2.1 Issue C
PROJECT NAME : KOC
SEAL CODE : 3095/28AT/--/S42317
DRAWING NUMBER: S/42317
DETAILED OBSERVATIONS GLOBAL PART No: 87039585
INTERNAL FILE REFERENCE : 02/50016G
REPORT REPORT NUMBER : 4397430
INSPECTION DATE : 07.02.2016
PICTURE 1
The picture above shows the inboard mating ring assembly.
PORTING
A DETAILS
PICTURE 2
A = CLEAN GAS INJECTION

B = PRIMARY LEAKAGE
C = BUFFER GAS INJECTION(PLUGGED)
D = SECONDARY LEAKAGE
E = NITROGEN PURGE
The picture above shows the close-up view of inboard mating ring. Chipping marks can be
seen on inner sealing side and drive diameter of the mating ring.
M300.2.1 Issue C
PROJECT NAME : KOC
SEAL CODE : 3095/28AT/--/S42317
PICTURE 3
The picture above shows the inboard primary ring assembly.
PORTING
A DETAILS
PICTURE 4

B = PRIMARY LEAKAGE
E = NITROGEN PURGE
The picture above shows the close-up view of the inboard primary ring. Running marks are
visible on the sealing surface of the primary ring. Contimantion is also rpesent on the
primary ring.
M300.2.1 Issue C
PROJECT NAME : KOC
SEAL CODE : 3095/28AT/--/S42317
PICTURE 5
The picture above shows the outboard mating ring assembly.
PORTING
A DETAILS
PICTURE 6

B = PRIMARY LEAKAGE
E = NITROGEN PURGE
The picture above shows the close-up view of outboard mating ring. Running and
abutment marks are visible on the sealing dam surface of the mating ring. Contimantion
depsoits can also be seen on the outbaord mating ring.
M300.2.1 Issue C
PROJECT NAME : KOC
SEAL CODE : 3095/28AT/--/S42317
PICTURE 7
The picture above shows the outboard primary ring assembly.
PORTING
A DETAILS
PICTURE 8

B = PRIMARY LEAKAGE
E = NITROGEN PURGE
The picture above shows the close-up view of the outboard primary ring. Running marks
are visible on the sealing surface of the primary ring. Contamination can also be saying on
the outboard mating ring.
M300.2.1 Issue C
PROJECT NAME : KOC
SEAL CODE : 3095/28AT/--/S42317
PICTURE 9
The picture above shows the close-up view of the inboard retainer. Axial wear marking is
visible on the balanced diameter of the retainer.
PORTING
A DETAILS
PICTURE 10

B = PRIMARY LEAKAGE
E = NITROGEN PURGE
The picture above shows the close up view of the condition of outboard retainer balance
diameter O-ring. The O-ring has shown signs of severe wear.
M300.2.1 Issue C
PROJECT NAME : KOC
SEAL CODE : 3095/28AT/--/S42317
PICTURE 11
The picture above shows the brown coloured liquid hydrocarbon contaminantion. This is
visible on the atmosphere stage of the seal.
PORTING
A DETAILS
PICTURE 12

B = PRIMARY LEAKAGE
E = NITROGEN PURGE
The picture above shows the black/brown coloured hydrocarbon contamination visible
around the outer diameter of the inboard stage.
M300.2.1 Issue C
PROJECT NAME : KOC
SEAL CODE : 3095/28AT/--/S42317
PICTURE 13
The picture above shows the hydrocarbon contaminants are visible on the drive lugs of the
inboard retainer.
PORTING
A DETAILS
PICTURE 14

B = PRIMARY LEAKAGE
E = NITROGEN PURGE
The picture above shows the hydrocarbon contaminants particles are visible on the
outboard primary ring assembly .
M300.2.1 Issue C
PROJECT NAME : KOC
SEAL CODE : 3095/28AT/--/S42317
ITEMS RETURNED GLOBAL PART No: 87039585
ITEMS RETURNED
1 T28AT Dry gas seal cartridge.
M300.2.1 Issue C
PROJECT NAME : KOC
SEAL CODE : 3095/28AT/--/S42317
TRANSIT CASE GLOBAL PART No: 87039585
Picture Insert
T28AT Dry gas seal received in a John Crane flight case.
M300.2.1 Issue C
INTERNAL
REPORT

John Crane Middle East FZE PO BOX 61040, Dubai, UAE: 24 hour Emergency Line: 0044 7889 653846
KOC
PROJECT:
COMPRESSOR: NUOVO PIGNONE COMPRESSOR BCL806

DATE: 07.02.2016
SEAL INFORMATION
Picture Insert DRAWING No: S/42318 CARTRIDGE No: 0309-0484

GLOBAL PART No: 87039586 SEAL CODE: 3095/28AT/--/S42318
FILE REFERENCE: 02/50016G REPORT No: 4397430
SHAFT ROTATION: CCW COMPRESSOR END: CCW
GENERAL FINDINGS
REASON FOR RETURN: RELIABILITY GROUP INVESTIGATION WITNESS INSPECTION: YES
MAIN SEAL FINDINGS:

T28 AT TANDEM
1st STAGE 2nd STAGE 3rd STAGE
CONTAMINATION: WET BLACK/BROWN STICKY WET BLACK/BROWN STICKY ???
MATING RING: LIGHT RUNNING MARKING LIGHT RUNNING MARKING ???
PRIMARY RING: HYDROCARBON CONTAMINATED HYDROCARBON CONTAMINATED ???
AXIAL MOVEMENT: RESTRICTED MOVEMENT FREE MOVEMENT ???
ROTOR METAL WORK: GOOD CONDITION GOOD CONDITION ???
STATOR METAL WORK: GOOD CONDITION GOOD CONDITION ???
'O'-RINGS: REPLACE AS STANDARD WEAR MARKING ???
SEPARATION SEAL FINDINGS: NOT RETURNED
CONTAMINATION: ???
??? ???
ROTOR METAL WORK: ???
STATOR METAL WORK: ???
'O'-RINGS: ??? INSPECTED BY: Shajan Baby
M300.2.1 Issue C
DETAILED REFURBISHMENT REQUIREMENTS
INTERNAL PROJECT NAME : KOC
T28 AT REPORT CARTRIDGE No: 0309-0484
REPORT NUMBER : 4397430 SEAL CODE : 3095/28AT/--/S42318
FILE REFERENCE : 02/50016G DRAWING No: S/42318
INSPECTION DATE : 07.02.2016 GLOBAL PART No: 87039586 GCN RAISED / No:
DESCRIPTION WORK REQUIRED ADDITIONAL COMMENTS
MATERIAL LATEST GA
ALLOWED
18.09 mm
MATING RINGS ACQUISITION No:
INBOARD MATING RING SC-S/42317-MR-CCW-9222 RELAP REGROOVE AND REUSE 7337774 RUNNING MARKS
OUTBOARD MATING RING SC-S/42317-MR-CCW-9222 RELAP REGROOVE AND REUSE S03-2176 RUNNING MARKS

INBOARD PRIMARY RING SC-S/42317-PR-9028 REPLACE 102396707-1 STICKY HYDROCARBON CONTAMINATED
OUTBOARD PRIMARY RING SC-S/42317-PR-9028 REPLACE 102396707-2 STICKY HYDROCARBON CONTAMINATED
METAL PARTS
RETAINER INNER S/94469/1/229 CLEAN AND REUSE GOOD CONDITION
RETAINER OUTER S/94332/1/229 CLEAN AND REUSE GOOD CONDITION
SLEEVE S/97270/1/506 CLEAN AND REUSE GOOD CONDITION
SPACER SLEEVE S/97271/1/506 CLEAN AND REUSE GOOD CONDITION
LOCKING SLEEVE S/97273/1/229 CLEAN AND REUSE GOOD CONDITION
INBOARD THRUST RING S/94468/1/229 REPLACE NOT SUITABLE FOR NEW O-RING CUSTOM FIT
OUTBOARD THRUST RING S/94468/1/229 REPLACE NOT SUITABLE FOR NEW O-RING CUSTOM FIT
SEAL SPACER S/87095/1/229 CLEAN AND REUSE GOOD CONDITION
FACE RETAINER S/87096/1/229 CLEAN AND REUSE GOOD CONDITION
SETTING RING INNER ASM. S/94335/1/229 CLEAN AND REUSE GOOD CONDITION
SETTING RING OUTER ASM. S/94336/1/229 CLEAN AND REUSE GOOD CONDITION
CONSUMABLES
'O'-RINGS FLUOROCARBON REPLACE AS STANDARD REPLACE AS STANDARD
DRIVE BUTTONS ST.ST. BS410S21 REPLACE AS STANDARD REPLACE AS STANDARD
TOLERANCE RING MONEL K500 REPLACE AS STANDARD REPLACE AS STANDARD
SPRINGS HASTELLOY 'C' REPLACE AS STANDARD REPLACE AS STANDARD
FINGER SPRING INCONEL X750 REPLACE AS STANDARD REPLACE AS STANDARD
CAP HEAD SCREW DIN 912 - 12.9 REPLACE AS STANDARD REPLACE AS STANDARD
CAP HEAD SCREW DUPLEX REPLACE AS STANDARD REPLACE AS STANDARD
SEPARATION SEAL RETURNED: NO NACE REQUIREMENT: YES PARTS ENGRAVED WITH GMI: YES PARTS CLEANED YES
SHIPPING CASE SIZE: N/A NEW CASE REQUIRED: NO SPARES KIT: NEW KIT REQUIRED
ALL PARTS ON THE PARTS ASSEMBLY LIST FOR THIS SEAL HAVE BEEN ACCOUNTED FOR: YES BAY LOCATION: N/A
M300.2.1 Issue C
PROJECT NAME : KOC
SEAL CODE : 3095/28AT/--/S42318
PICTURE 1
The picture above shows the inboard mating ring assembly.
PORTING
A DETAILS
PICTURE 2

B = PRIMARY LEAKAGE
E = NITROGEN PURGE
The picture above shows the close-up view of inboard mating ring. Running marks are
visible on the sealing dam surface of the mating ring. Contamination deposits are also
present on the inboard mating ring.
M300.2.1 Issue C
PROJECT NAME : KOC
SEAL CODE : 3095/28AT/--/S42318
PICTURE 3
The picture above shows the inboard primary ring assembly.
PORTING
A DETAILS
PICTURE 4

B = PRIMARY LEAKAGE
E = NITROGEN PURGE
The picture above shows the close-up view of the inboard primary ring. Running marking
and sticky hydrocarbon contamination is visible on the sealing surface of the primary ring.
M300.2.1 Issue C
PROJECT NAME : KOC
SEAL CODE : 3095/28AT/--/S42318
PICTURE 5
The picture above shows the outboard mating ring assembly.
PORTING
A DETAILS
PICTURE 6

B = PRIMARY LEAKAGE
E = NITROGEN PURGE
The picture above shows the close-up view of outboard mating ring. Running and
abutment marks are visible on the sealing dam surface of the mating ring. Contmaination
deposits can also be seen on all of the surface of the outboard mating ring.
M300.2.1 Issue C
PROJECT NAME : KOC
SEAL CODE : 3095/28AT/--/S42318
PICTURE 7
The picture above shows the outboard primary ring assembly.
PORTING
A DETAILS
PICTURE 8

B = PRIMARY LEAKAGE
E = NITROGEN PURGE
The picture above shows the close-up view of the outboard primary ring. Running marking
and sticky hydrocarbon contamination is visible on the sealing surface of the primary ring.
M300.2.1 Issue C
PROJECT NAME : KOC
SEAL CODE : 3095/28AT/--/S42318
PICTURE 10
The picture above shows the close-up view of the inboard retainer. sticky hydrocarbon
contamination is visible on most of the surface of the retainer.
PORTING
A DETAILS
PICTURE 10

B = PRIMARY LEAKAGE
E = NITROGEN PURGE
The picture above shows the black/brown coloured hydrocarbon contamination covered
all over the inboard retainer screws.
M300.2.1 Issue C
PROJECT NAME : KOC
SEAL CODE : 3095/28AT/--/S42318
PICTURE 12
The picture above shows the close-up view of the outboard retainer. Black coloured
hydrocarbon contamination is visible on the balanced diameter of the retainer.
PORTING
A DETAILS
PICTURE 12

B = PRIMARY LEAKAGE
E = NITROGEN PURGE
The picture above shows the close up view of the condition of outboard retainer balanced
diameter O-ring. The O-ring has shown signs of severe wear.
M300.2.1 Issue C
PROJECT NAME : KOC
SEAL CODE : 3095/28AT/--/S42318
PICTURE 13
The picture above shows the hydrocarbon contamination on the atmoshere side of the
seal assembly.
PORTING
A DETAILS
PICTURE 14

B = PRIMARY LEAKAGE
E = NITROGEN PURGE
The picture above shows the sticky hydrocarbon contamination around the outer surface
of the inboard retainer.
M300.2.1 Issue C
PROJECT NAME : KOC
SEAL CODE : 3095/28AT/--/S42318
ITEMS RETURNED GLOBAL PART No: 87039586
ITEMS RETURNED
1 T28AT Dry gas seal cartridge.
M300.2.1 Issue C
PROJECT NAME : KOC
SEAL CODE : 3095/28AT/--/S42318
TRANSIT CASE GLOBAL PART No: 87039586
Picture Insert
T28AT Dry gas seal received in a John Crane flight case.
M300.2.1 Issue C
ND

LP2 2 STAGE COMPRESSOR BCL806
ITEM 131-K-2102

INSTRUMENT LIST
CUSTOMER : THE CONSORTIUM OF FLUOR & SKEC FOR KUWAIT OIL COMPANY
PLANT LOCATION : NORTH KUWAIT
JOB N° : 110.1839
PROJECT : UPGRADING OF BOOSTER STATION BS-131
Electronically approved draw. GE NuovoPignone DT-'N'

Reference Drawings:
(LP2) PIPING AND INSTRUMENTS DIAGRAM: SOK0862089/1
CONTRACTOR DETAILS:
TYPICAL FOR ALL
INSTRUMENTS PROJECT TITTLE:
NEW BOOSTER STATION BS-132 &

ENHANCEMENTS TO BS-131
L= LOW (ALARM) DOCUMENT TITTLE:
H= HIGH (ALARM)
UCP upgrade in BS-131
LL= LOW LOW (TRIP)
HH= HIGH HIGH (TRIP)
C= CONTROL ITEM 131-K-2102
I=INTERLOCK
PURCHASER DRG. No. REV. VENDOR DRG. No. REV.
SOM6606377
A 6
SHEET. No. 1 OF 10 SHEET. No. 1 OF 10
TITLE: DOCUMENT CODE REVISION

LP2 2nd STAGE COMPRESSOR BCL806 INSTRUMENT LIST
SOM 6606377 6
REVISION DESCRIPTION: APPROVED: Sciuto A.
TITLE BLOCK REVISED ON ALL SHEETS. CUSTOMER LABEL REVISED ON SHEET 1 DATE SECURITY CODE
CHECKED: Ciminelli G.
13-Jun-12 N
EXECUTED: CTQ
SCALE REPLACES/DERIVED FROM 1st ISSUE ORIGINAL JOB SIZE LANGUAGE

N/A N/A 23-Apr-03 110.1839 3 A
THIS DOCUMENT IS AND CONTAINS CONFIDENTIAL AND PROPRIETARY INFORMATION OF Nuovo Pignone S.r.l. WHICH SHALL NOT BE USED OR DISCLOSED TO OTHERS, EXCEPT WITH THE SHEET
WRITTEN PERMISSION OF Nuovo Pignone S.r.l.. UNPUBLISHED WORK ©2012 Nuovo Pignone S.r.l. ALL RIGHTS RESERVED 1 of 10

JOB TAG NP TAG INSTRUMENT SERVICE LOC. MANUFACT. MODEL N.P. CODE P&I REV RANGE UNIT L H LL HH C I
TYPE

131-FG- - FLOW GLASS COMPRESSOR JOURNAL BEARING LOCAL N.P. STD. 3”#150RF-R9 ITN66026.02 SOK0862089 sh.03 5 - -

5616 LUBE OIL DRAIN

131-FG- - FLOW GLASS COMPRESSOR JOURNAL/THRUST LOCAL N.P. STD. 3”#150RF-R9 ITN66026.02 SOK0862089 sh.03 5 - -
5617 BEARINGS LUBE OIL DRAIN

131-FG- - FLOW GLASS COMPRESSOR SPACER LOCAL N.P. STD. 1 1/2”#150RF- ITN66026.02 SOK0862089 sh.03 5 - -
5620 R9
LUBE OIL DRAIN

131-FO- - FLOW ORIFICE COMPRESSOR JOURNAL BEARING LOCAL N.P. STD. 1”1/2#150RF- ITN82101.11 SOK0862089 sh.03 5 Ø 11 mm
5612 LUBE OIL FLOW ORIFICE R9
131-FO- - FLOW ORIFICE COMPRESSOR JOURNAL BEARING LOCAL N.P. STD. 1”1/2#150RF- ITN82101.11 SOK0862089 sh.03 5 Ø 11 mm
5613 LUBE OIL FLOW ORIFICE R9

131-FO- - FLOW ORIFICE COMPRESSOR THRUST BEARING LUBE LOCAL N.P. STD. 2”#150RF-R9 ITN82101.11 SOK0862089 sh.03 5 Ø 12 mm
5614 OIL FLOW ORIFICE
131-PI- - PRESSURE LUBE OIL HEADER PRESSURE LOCAL NUOVA MGS 18/3 SOS0350600 SOK0862089 sh.03 5 0÷2 BARg
5627 INDICATOR
FIMA RMO45479
131-PI- - PRESSURE COMPRESSOR JOURNAL BRG. LUBE LOCAL NUOVA MGS 18/3 SOS0350600 SOK0862089 sh.03 5 0÷2 BARg

5628 INDICATOR OIL SUPPLY PRESSURE
FIMA RMO45480

131-PI- - PRESSURE COMPRESSOR THRUST BRG. LUBE OIL LOCAL NUOVA MGS 18/3 SOS0350600 SOK0862089 sh.03 5 0÷2 BARg
5629 INDICATOR SUPPLY PRESSURE
FIMA RMO45481
131-PI- - PRESSURE COMPRESSOR JOURNAL BRG. LUBE LOCAL NUOVA MGS 18/3 SOS0350600 SOK0862089 sh.03 5 0÷2 BARg
5630 INDICATOR OIL SUPPLY PRESSURE
FIMA RMO45480

131-TE- - RTD COMPRESSOR JOURNAL BRG. METAL LOCAL THERMOEN- RTD PT 100 SOS76690 SOK0862089 sh.03 5 0 ÷ 150 °C
5550 TEMPERATURE GINEERING 3 wires
RTO69851
5551 TEMPERATURE (SPARE) GINEERING 3 wires
RTO69851
5552 TEMPERATURE GINEERING 3 wires
RTO69849

FOR LUBE OIL AND PROTECTION SYSTEM SOM 6606377 6
REVISION DESCRIPTION: PAGE MARKER SECURITY CODE
NO REVISION IS INTRODUCED IN THIS PAGE N/A N
ORIGINAL JOB SIZE LANGUAGE
110.1839 3 A

TYPE
5553 TEMPERATURE (SPARE) GINEERING 3 wires
RTO69849
131-TE- - RTD COMPRESSOR THRUST BRG. METAL LOCAL THERMOEN- RTD PT 100 SOS76690 SOK0862089 sh.03 5 0 ÷ 150 °C
5554A TEMPERATURE GINEERING 3 wires
RTO69849
5554B TEMPERATURE GINEERING 3 wires
RTO69849
5556A TEMPERATURE GINEERING 3 wires
RTO69849
5556B TEMPERATURE GINEERING 3 wires
RTO69849
131-TI- - TEMPERATURE COMPRESSOR JOURNAL BEARING LOCAL NUOVA TB 8 SOS0350599 SOK0862089 sh.03 5 0 ÷ 100 °C
5615 INDICATOR LUBE DRAIN TEMPERATURE
FIMA RTO68021
131-TI- - TEMPERATURE COMPRESSOR THRUST/JOURNAL LOCAL NUOVA TB 8 SOS0350599 SOK0862089 sh.03 5 0 ÷ 100 °C
5616 INDICATOR BEARING LUBE DRAIN TEMPERATURE
FIMA RTO68021
131-TI- - TEMPERATURE COMPRESSOR SPACE LOCAL NUOVA TB 8 SOS0350599 SOK0862089 sh.03 5 0 ÷ 100 °C
5619 INDICATOR
LUBE DRAIN TEMPERATURE FIMA RTO68021
131-TIT- - TEMPER. COMPRESSOR JOURNAL BRG. METAL GB ROSEMOUNT 3144 Supplied by SOK0862089 sh.03 5 0 ÷ 150 °C 120 130
5550 INDICATOR TEMPERATURE Seal Panel
TRASMITTER Manufacturer
131-TIT- - TEMPER. COMPRESSOR JOURNAL BRG. METAL GB ROSEMOUNT 3144 Supplied by SOK0862089 sh.03 5 0 ÷ 150 °C 120 130
5552 INDICATOR TEMPERATURE Seal Panel
TRANSMITTER Manufacturer
131-TIT- - TEMPER. COMPRESSOR THRUST BRG. METAL GB ROSEMOUNT 3144 Supplied by SOK0862089 sh.03 5 0 ÷ 150 °C 120 130
5554A INDICATOR TEMPERATURE Seal Panel
5554B INDICATOR TEMPERATURE Seal Panel
5556A INDICATOR TEMPERATURE Seal Panel
5556B INDICATOR TEMPERATURE Seal Panel


110.1839 3 A

TYPE
131-XE- - VIBRATION COMPRESSOR BRG. RADIAL LOCAL BENTLY 3300 ITN63002 SOK0862089 sh.03 5 0 ÷ 200 micron 122 181
5514X/Y PROBE VIBRATIONS (X/Y AXIS) NEVADA
SERIES RJO04208
131-XE- - VIBRATION COMPRESSOR BRG. RADIAL LOCAL BENTLY 3300 ITN63002 SOK0862089 sh.03 5 0 ÷ 200 micron 122 181
5515X/Y PROBE VIBRATIONS (X/Y AXIS) NEVADA
SERIES RJO04208
131-XT- - VIBRATION COMPRESSOR BRG. RADIAL LOCAL BENTLY 3300 ITN63002 SOK0862089 sh.03 5
5514X/Y PROXIMITOR VIBRATIONS (X/Y AXIS) NEVADA
SERIES RJO04218
131-XT- - VIBRATION COMPRESSOR BRG. RADIAL LOCAL BENTLY 3300 ITN63002 SOK0862089 sh.03 5
5515X/Y PROXIMITOR VIBRATIONS (X/Y AXIS) NEVADA
SERIES RJO04218
131-ZE- - DISPLACEMENT COMPRESSOR ROTOR AXIAL LOCAL BENTLY 3300 ITN63002 SOK0862089 sh.03 5 -1 ÷ +1 mm +/- +/-
5515A/B PROBE DISPLACEMENT NEVADA 0,50 0,70
SERIES RJO04207
131-ZT- - DISPLACEMENT COMPRESSOR ROTOR AXIAL LOCAL BENTLY 3300 ITN63002 SOK0862089 sh.03 5
5515A/B PROXIMITOR DISPLACEMENT NEVADA
SERIES RJO04218

110.1839 3 A

TYPE
131-FV- - ON/OFF VALVE COMPRESSOR START-UP PRIMARY LOCAL FISHER 1018S.00 Supplied by SOK0862089 sh.04 5 - BARg
5412 SEAL GAS ON/OFF VALVE
Air Skid
131-FV- - ON/OFF VALVE COMPRESSOR SEPARATION LOCAL FISHER 1018S.00 Supplied by SOK0862089 sh.04 5 - BARg
5520 LABYRINTH AIR SUPPLY (INSTRUMENT
AIR) ON/OFF VALVE Air Skid
131-FY- - SOLENOID COMPRESSOR START-UP PRIMARY LOCAL ASCO EV 8327G042 Supplied by SOK0862089 sh.04 5 - -
5412 VALVE SEAL GAS ON/OFF VALVE
Air Skid
131-FY- - SOLENOID COMPRESSOR SEPARATION LOCAL ASCO EV 8327G042 Supplied by SOK0862089 sh.04 5 - -
5520 VALVE LABYRINTH AIR SUPPLY ON/OFF VALVE
131-FV-5520 ACTUATION Air Skid
131-LCV- - AUTOMATIC COMPRESSOR SEPARATION LOCAL ARMSTRONG 21-312-F Supplied by SOK0862089 sh.04 5 - -
5500 TRAP LABYRINTH AIR FILTERS DRAIN
Air Skid
131-LCV- - AUTOMATIC COMPRESSOR SEPARATION LOCAL ARMSTRONG 21-312-F Supplied by SOK0862089 sh.04 5 - -
5501 TRAP LABYRINTH AIR FILTERS DRAIN
Air Skid
131-LCV- - AUTOMATIC MAIN LAST CHANCE COALESCER LOCAL ARMSTRONG 2413 HLS-F Supplied by SOK0862089 sh.04 5 - -
5408 TRAP FILTER DRAIN
Air Skid
131-LCV- - AUTOMATIC STAND-BY LAST CHANCE COALESCER LOCAL ARMSTRONG 2413 HLS-F Supplied by SOK0862089 sh.04 5 - -
5409 TRAP FILTER DRAIN
Air Skid
131-LG- - LEVEL GLASS MAIN LAST CHANCE COALESCER LOCAL KLINGER R100-DG Supplied by SOK0862089 sh.04 5 - -
5402 FILTER LEVEL
Air Skid
131-LG- - LEVEL GLASS STAND-BY LAST CHANCE COALESCER LOCAL KLINGER R100-DG Supplied by SOK0862089 sh.04 5 - -
5405 FILTER LEVEL
Air Skid
131-LIT- - LEVEL MAIN LAST CHANCE COALESCER LOCAL FOXBORO IDP-10 Supplied by SOK0862089 sh.04 5 0 ÷ 300 mm 25 200
5403 INDICATOR FILTER LEVEL
TRANSMITTER Air Skid
131-LIT- - LEVEL MAIN LAST CHANCE COALESCER LOCAL FOXBORO IDP-10 Supplied by SOK0862089 sh.04 5 0 ÷ 300 mm 250
131-LIT- - LEVEL STAND-BY LAST CHANCE COALESCER LOCAL FOXBORO IDP-10 Supplied by SOK0862089 sh.04 5 0 ÷ 300 mm 25 200
131-LIT- - LEVEL STAND-BY LAST CHANCE COALESCER LOCAL FOXBORO IDP-10 Supplied by SOK0862089 sh.04 5 0 ÷ 300 mm 250


FOR SEPARATION AIR/SEAL GAS SYSTEM SOM 6606377 6
110.1839 3 A

TYPE
131-PCV- - PRESSURE COMPRESSOR SEPARATION LOCAL FISHER 67CFR Supplied by SOK0862089 sh.04 5 - BARg 2,2
5520 CONTROL LABYRINTH ON/OFF VALVE 131-FV-5520
VALVE INSTR. AIR PRESS. REDUCER Air Skid
131-PCV- - PRESSURE COMPRESSOR SEPARATION LOCAL FISHER 95H Supplied by SOK0862089 sh.04 5 - BARg 2
5521 CONTROL LABYRINTH AIR SUPPLY PRESSURE
VALVE REDUCER Air Skid
131-PCV- - PRESSURE COMPRESSOR PRIMARY SEAL GAS LOCAL FISHER 67CFR Supplied by SOK0862089 sh.04 5 - BARg 2,2
5522 CONTROL (START-UP) VALVE 131-FV-5412
VALVE INSTRUMENT AIR PRESS. REDUCER Air Skid
131-PDI- - D.P. INDICATOR COMPRESSOR PRIMARY SEAL GAS GB NUOVA FIMA MD15 Supplied by SOK0862089 sh.04 5 0÷1 BAR
5424 FILTER DIFFERENTIAL PRESSURE
Air Skid
131-PDI- - D.P. INDICATOR PRIMARY SEAL GAS DIFFERENTIAL GB NUOVA FIMA MD15 Supplied by SOK0862089 sh.04 5 0 ÷ 15 BAR
5428 PRESSURE
Air Skid
131-PDI- - D.P. INDICATOR COMPRESSOR SEPARATION GB NUOVA FIMA MD15 Supplied by SOK0862089 sh.04 5 0÷2 BAR
5523 LABYRINTH AIR FILTERS DIFFERENTIAL
PRESSURE Air Skid
131-PDIT- - D.P. INDICATOR COMPRESSOR PRIMARY SEAL GAS GB FOXBORO IDP-10 Supplied by SOK0862089 sh.04 5 0÷1 BAR 0,7
5425 TRANSMITTER FILTER DIFFERENTIAL PRESSURE
Air Skid
131-PDIT- - D.P. INDICATOR COMPRESSOR PRIMARY SEAL GAS GB FOXBORO IDP-10 Supplied by SOK0862089 sh.04 5 0÷1 BAR 1
5426 TRANSMITTER FILTER DIFFERENTIAL PRESSURE
Air Skid
131-PDIT- - D.P. INDICATOR PRIMARY SEAL GAS DIFFERENTIAL GB FOXBORO IDP-10 Supplied by SOK0862089 sh.04 5 0 ÷ 15 BAR 2,9 2,9
5429 TRANSMITTER PRESSURE
Air Skid
131-PDIT- - D.P. INDICATOR COMPRESSOR SEPARATION GB FOXBORO IDP-10 Supplied by SOK0862089 sh.04 5 0 ÷ 1,5 BAR 1,5
5524 TRANSMITTER LABYRINTH AIR FILTERS DIFFERENTIAL
PRESSURE Air Skid
131-PDIT- - D.P. INDICATOR COMPRESSOR SEPARATION GB FOXBORO IDP-10 Supplied by SOK0862089 sh.04 5 0÷2 BAR 2
5525 TRANSMITTER LABYRINTH AIR FILTERS DIFFERENTIAL
PRESSURE Air Skid
131-PI- - PRESSURE COMPRESSOR SEPARATION LOCAL FISHER SUPPLIED Supplied by SOK0862089 sh.04 5 0÷8 BARg
5520 INDICATOR LABYRINTH ON/OFF VALVE 131-FV-5520 WITH PRESS.
INSTRUMENT AIR PRESSURE 67 REDUCER Air Skid
131-PI- - PRESSURE COMPRESSOR SEPARATION GB NUOVA FIMA MGS 18/3 Supplied by SOK0862089 sh.04 5 0 ÷ 8,5 BARg
5521 INDICATOR LABYRINTH AIR FILTERS INLET
PRESSURE Air Skid
131-PI- - PRESSURE COMPRESSOR SEPARATION GB NUOVA FIMA MGS 18/3 Supplied by SOK0862089 sh.04 5 0÷2 BARg
5526 INDICATOR LABYRINTH AIR FILTERS OUTLET
PRESSURE Air Skid


110.1839 3 A

TYPE
131-PI- - PRESSURE INSTRUMENT AIR PRESSURE FOR 131- LOCAL FISHER SUPPLIED Supplied by SOK0862089 sh.04 5 0÷8 BARg
5528 INDICATOR FV-5412 VALVE WITH PRESS.
67 REDUCER Air Skid
131-PIT- - PRESS. COMPRESSOR PRIMARY SEAL GAS GB FOXBORO IGP-20 Supplied by SOK0862089 sh.04 5 0 ÷ 20 BARg 6
5432 INDICATOR FILTERS OUTLET PRESSURE
131-PIT- - PRESS. COMPRESSOR SEPARATION GB FOXBORO IGP-20 Supplied by SOK0862089 sh.04 5 0 ÷ 8,5 BARg 6 6
TRANSMITTER PRESSURE Air Skid
131-PIT- - PRESS. COMPRESSOR SEPARATION GB FOXBORO IGP-20 Supplied by SOK0862089 sh.04 5 0÷2 BARg 1,7
5527 INDICATOR LABYRINTH AIR FILTERS OUTLET
TRANSMITTER PRESSURE Air Skid
131-PSV- - SAFETY VALVE COMPRESSOR PRIMARY SEAL GAS Loose CROSBY JOS Series Supplied by SOK0862089 sh.04 5 - BARg 30
5430 FILTER PRESSURE SAFETY VALVE
Air Skid
131-PSV- - SAFETY VALVE COMPRESSOR PRIMARY SEAL GAS Loose CROSBY JOS Series Supplied by SOK0862089 sh.04 5 - BARg 30
5431 FILTER PRESSURE SAFETY VALVE
Air Skid
131-PSV- - SAFETY VALVE COMPRESSOR SEPARATION Loose CROSBY 102 JOS Supplied by SOK0862089 sh.04 5 - BARg 14
5530 LABYRINTH AIR FILTERS
Air Skid
131-PSV- - SAFETY VALVE COMPRESSOR SEPARATION Loose CROSBY 102 JOS Supplied by SOK0862089 sh.04 5 - BARg 14
5531 LABYRINTH AIR FILTERS SAFETY
VALVE Air Skid
131-RO- RESTRICTION SEAL GAS FILTER COALESCER DRAIN LOCAL N.P. STD. 2”#150RF-R9 ITN82101.11 SOK0862089 sh.04 5 Ø 10 mm
5450 ORIFICE RESTRICTION ORIFICE
131-TE- - RTD COMPRESSOR SEPARATION LOCAL FISHER HSI65 Supplied by SOK0862089 sh.04 5 0 ÷ 100 °C
5570 LABYRINTH AIR FILTERS INLET
TEMPERATURE ROSEMOUNT Air Skid
131-TIT- - TEMPER. COMPRESSOR SEPARATION GB FISHER 3144 PD Supplied by SOK0862089 sh.04 5 0 ÷ 100 °C 80
TRANSMITTER TEMPERATURE ROSEMOUNT Air Skid

110.1839 3 A

TYPE
131-GF- - GAS DETECTOR COMPRESSOR SECONDARY VENT GAS LOCAL MSA 410 PRP SOS86564 SOK0862089 sh.05 5
5400 - CATHALITIC DETECTION ITALIANA
RAO18507222
131-GF- - GAS DETECTOR COMPRESSOR SECONDARY VENT GAS LOCAL MSA 410 PRP SOS86564 SOK0862089 sh.05 5
5401 - CATHALITIC DETECTION ITALIANA
RAO18507222
131-GFT- - GAS DETECTOR COMPRESSOR SECONDARY VENT GAS LOCAL MSA RG-3 SOS86564 SOK0862089 sh.05 5 0 ÷ 100 % LEL 40 60
5400 - ADAPTER DETECTION ITALIANA
RAO18507222
131-GFT- - GAS DETECTOR COMPRESSOR SECONDARY VENT GAS LOCAL MSA RG-3 SOS86564 SOK0862089 sh.05 5 0 ÷ 100 % LEL 40 60
5401 - ADAPTER DETECTION ITALIANA
RAO18507222
131-FIT- - FLOW COMPRESSOR PRIMARY VENT SEALS GB ASA C6 Supplied by SOK0862089 sh.05 5 0 ÷ 1,3 Nm3/h 0,15 1,2
5408 INDICATOR VENT FLOW Seal Panel
131-FIT- - FLOW COMPRESSOR PRIMARY VENT SEALS GB ASA C6 Supplied by SOK0862089 sh.05 5 0 ÷ 1,3 Nm3/h 0,15 1,2
5409 INDICATOR VENT FLOW Seal Panel
131-FO- - FLOW ORIFICE COMPRESSOR SEPARATION LABIRINTH GB N.P. STD. 11/2”#150RF- Supplied by SOK0862089 sh.05 5 Ø 12.1 mm
5406 AIR SUPPLY FLOW ORIFICE R9 Seal Panel
Manufacturer
131-FO- - FLOW ORIFICE COMPRESSOR SEPARATION LABIRINTH GB N.P. STD. 11/2”#150RF- Supplied by SOK0862089 sh.05 5 Ø 12.1 mm
5407 AIR SUPPLY FLOW ORIFICE R9 Seal Panel
Manufacturer
131-FO- - FLOW ORIFICE COMPRESSOR PRIMARY SEAL GAS GB N.P. STD. 1/2” Supplied by SOK0862089 sh.05 5 Ø 3.7 mm
5414 FLOW ORIFICE Seal Panel
Manufacturer
131-FO- - FLOW ORIFICE COMPRESSOR BALANCING LINE FLOW LOCAL N.P. STD. 6”#300RF-R9 ITN82101.11 SOK0862089 sh.05 5 Ø 108 mm
5415 ORIFICE
131-FO- - FLOW ORIFICE COMPRESSOR PRIMARY SEAL GAS LOCAL N.P. STD. 1”#300RF-R9 ITN82101.11 SOK0862089 sh.05 5 Ø 6.3 mm
5570 FLOW ORIFICE
131-FO- - FLOW ORIFICE COMPRESSOR PRIMARY SEAL GAS LOCAL N.P. STD. 1”#300RF-R9 ITN82101.11 SOK0862089 sh.05 5 Ø 6.3 mm
5571 FLOW ORIFICE
131-FV- - ADJUST. FLOW COMPRESSOR PRIMARY SEALS VENT GB CIAS PVENT NP Supplied by SOK0862089 sh.05 5 - -
5408 ORIFICE FLOW REGULATOR Seal Panel
Manufacturer
131-FV- - ADJUST. FLOW COMPRESSOR PRIMARY SEALS VENT GB CIAS PVENT NP Supplied by SOK0862089 sh.05 5 - -
5409 ORIFICE FLOW REGULATOR Seal Panel
Manufacturer


FOR SEAL GAS SYSTEM SOM 6606377 6
110.1839 3 A

TYPE
131-LCV- - AUTOMATIC COMPRESSOR SEPARATION LOCAL ARMSTRONG 31LD RSO10597 SOK0862089 sh.05 5 - -
5400 TRAP LABYRINTH CAVITY DRAIN
131-LCV- - AUTOMATIC COMPRESSOR SEPARATION LOCAL ARMSTRONG 31LD RSO10597 SOK0862089 sh.05 5 - -
5401 TRAP LABYRINTH CAVITY DRAIN
131-PCV- - PRESSURE COMPRESSOR PRIMARY SEAL GAS GB MASONEILAN 77 Supplied by SOK0862089 sh.05 5 - BARg 4
5523 CONTROL VALVE 131-PDCV-5400 INSTRUMENT Seal Panel
VALVE AIR PRESSURE REDUCER Manufacturer
131- - D.P. CONTROL PRIMARY SEAL GAS PRESSURE GB MASONEILAN VARIPAK Supplied by SOK0862089 sh.05 5 - BAR 1
PDCV- VALVE CONTROL VALVE Seal Panel
5400 Manufacturer
131-PDI- - D.P. INDICATOR COMPRESSOR PRIMARY SEAL GAS GB NUOVA MGS 13/200 Supplied by SOK0862089 sh.05 5 0÷6 BAR
5413 DIFFERENTIAL PRESSURE Seal Panel
FIMA Manufacturer
131-PDI- - D.P. INDICATOR COMPRESSOR PRIMARY VENT FLOW GB NUOVA MGS 13/200 Supplied by SOK0862089 sh.05 5 0÷1 BAR
5416 REGULATOR DIFFERENTIAL PRESSURE Seal Panel
FIMA Manufacturer
131-PDI- - D.P. INDICATOR COMPRESSOR PRIMARY VENT FLOW GB NUOVA MGS 13/200 Supplied by SOK0862089 sh.05 5 0÷1 BAR
5418 REGULATOR DIFFERENTIAL PRESSURE Seal Panel
FIMA Manufacturer
131-PDI- - D.P. INDICATOR COMPRESSOR PRIMARY SEAL ENDS GB NUOVA MGS 13/200 Supplied by SOK0862089 sh.05 5 0 ÷ 1000 mmH2O
5421 DIFFERENTIAL PRESSURE Seal Panel
FIMA Manufacturer
131-PDIT- - D.P. INDICATOR COMPRESSOR PRIMARY SEAL ENDS GB FOXBORO IDP10 Supplied by SOK0862089 sh.05 5 0 ÷ 1000 mmH2O 750
5420 TRANSMITTER DIFFERENTIAL PRESSURE Seal Panel
Manufacturer
131-PDIT- - D.P. INDICATOR COMPRESSOR PRIMARY SEAL ENDS GB FOXBORO IDP10 Supplied by SOK0862089 sh.05 5 0 ÷ 1000 mmH2O 500
Manufacturer
131-PDIT- - D.P. INDICATOR COMPRESSOR PRIMARY SEAL GAS GB FOXBORO IDP10 Supplied by SOK0862089 sh.05 5 0÷6 BAR 0,7 1,5
Manufacturer
131-PDY- - I/P CONVERTER COMPRESSOR SEAL GAS PRESSURE GB MASONEILAN 80/2 Supplied by SOK0862089 sh.05 5 - -
5400 CONTROL VALVE 131-PDCV-5400 I/P Seal Panel
CONVERTER Manufacturer
131-PI- - PRESSURE COMPRESSOR SEPARATION GB NUOVA MGS 18/3 Supplied by SOK0862089 sh.05 5 0÷2 BARg
5412 INDICATOR LABYRINTH AIR SUPPLY PRESSURE Seal Panel
FIMA Manufacturer
131-PI- - PRESSURE COMPRESSOR SEPARATION GB NUOVA MGS 18/3 Supplied by SOK0862089 sh.05 5 0 ÷ 1000 mmH2O
FIMA Manufacturer


110.1839 3 A

TYPE
131-PI- - PRESSURE COMPRESSOR SEPARATION GB NUOVA MGS 18/3 Supplied by SOK0862089 sh.05 5 0 ÷ 1000 mmH2O
FIMA Manufacturer
131-PI- - PRESSURE COMPRESSOR BALANCING PRESSURE GB NUOVA MGS 18/3 Supplied by SOK0862089 sh.05 5 0 ÷ 0,6 BARg
5422 INDICATOR Seal Panel
FIMA Manufacturer
131-PI- - PRESSURE INSTRUMENT AIR PRESSURE FOR 131- GB NUOVA MGS 18/3 Supplied by SOK0862089 sh.05 5 0÷8 BARg
5529 INDICATOR PDCV-5400 VALVE Seal Panel
FIMA Manufacturer
131-PIT- - PRESSURE COMPRESSOR SEPARATION GB FOXBORO IGP20 Supplied by SOK0862089 sh.05 5 0÷2 BARg 1,5
131-PIT- - PRESSURE COMPRESSOR PRIMARY SEALS VENT GB FOXBORO IGP20 Supplied by SOK0862089 sh.05 5 0÷5 BARg 5
5417 INDICATOR PRESSURE Seal Panel
131-PIT- - PRESSURE COMPRESSOR PRIMARY SEALS VENT GB FOXBORO IGP20 Supplied by SOK0862089 sh.05 5 0÷5 BARg 5
5419 INDICATOR PRESSURE Seal Panel

110.1839 3 A
Unit start-up procedure
1. Acknowledge all alarms
2. Be sure Master selector on Auto mode (OFF, Crank, Fire, Manual, Auto)
3. Press MASTER RESET.
4. Check if unit Ready to start if green then continue with No. 5 if not check the one not
green and right click in an empty area and select help to know the reason.
5. Select Start from MASTER CONTROL.
6. Reset ESDVs from DCS (Turbine page)
7. Start gas coolers after firing.
8. Wait until complete sequence.
Note: Before you start a depressurized unit be sure to convert the unit before it in sequence to
Manual mode and increase the discharge pressure to get a pressure above to the low low
suction pressure for the unit you want to start.
Example: You want to start LP2 and it was depressurized.
Change LP1 Master Selector to Manual then increase the speed until the discharge pressure
reach about 5.6 bar, the start the LP2. By doing the above mentioned the LP2 will not trip on
Low low suction during startup, when the complete sequence achieved in LP2 change LP1 to
Auto mode.
Phases load and off-load
From Absorber Inlet scrubber page on DCS you will find in the top of screen LOAD/OFFLOAD
Just click on it, then you can select LOAD or OFFLOAD according the Phase situation.
Transfer load & shutdown phase 1
Let us assume that both phases are running and you as operator asked to shutdown phase 1 &
depressurize it for any purposes survey or maintenance. The booster situations is:
Phase 1: taking most of the LP gas also lift gas & fuel from it.
Phase 2: taking some of the LP gas & HP gas.
Procedure for Shutdown phase 1:
1. Phase 1: Increase the LP1 suction set point from SPEED CONTROL gradually and increase
opening percentage of HP flow control valves if required.
2. Phase 2: start closing the HP flow control valves gradually.
3. By doing the a above steps the LP flow will diverted to Phase 2.
4. Increase back pressure set point on phase 2 more than phase 1 to divert lift gas & fuel
from phase 2.
5. Phase 1: stop Reboiler, glycol pump and glycol coolers.
6. Phase 1: Off-Load the train.
7. Phase 1: close back pressure PCV slowly.
8. Phase 1: close export ESDV0038 and the upstream ROV.
9. Phase 1: close the manual valve of 8" fuel line after gas dehydration to stop phase 2
export from coming through fuel system (No check valve).
10. Phase 1: stop the units manually.
11. Phase 1: after speed reached 0 changed the VALVE CONTROL to Manual from HMI for
each unit.
12. Phase 1: Open compressors SBDV manually from HMI to depressurization for each unit.
13. Phase 1: to depressurize gas dehydration inform instrument staff to open SBDV0034
from ESD system or open a bypass on SBDV-0034.
14. Phase 1: close manual valve for corrosion inhibitor for gas, condensate and lift from the
skid itself for phase 1.
Notes:
 Phase 2 is our priority to be running which means do the correct action to keep it
running by monitoring the suction and discharge pressure for each compressor & Phase
1 going to be stopped any way.
 Before maintenance start work in oily water header manual valve of oily water header
to C-0401 should be closed and spaded also all sumps pumps should be off.
 If work on reboiler manual valve on the outlet of still column should be closed.
 It is depend on maintenance work spades should be provide.
 Check the instructions to close the lift gas or not.
 Flare pilots are supplied from phase 1 only.
 Finally any maintenance work you have to do all the precautions required to be safe.
Regards,
Mohd Otaibi
211.00 [5359]
MIN. LIFT REQ. FOR MAINTENCE
1 - -_ _ 42.84[1088] 32.38[822] 45.00[1143] 182.00[4623]

I I
REFERENCE
MOTOR (CONDUIT BOX)

&; 8.02 [204]
RTO LOCATION
CAN BE ROT A TEO IN
SANDEUUS INSTRUMENTS II:
24.00 [610] 90 DEG. INTERVALS
.50 NPT R5H-4A 3EEL-L2-S4o- TMT18l
12.00 [305] TO
8X .75 [19] f------I- (TYPICAL)
(REFER
DRAWING FOR
ABB MOTOR
&; 10.00 [254] I I 8.00 [203]"
DIMENSIONAL DETAILS)
r Al 1 1. 50 [38]
4X 125 1.125
[125 28] 125 9.75
FOUNDA TION HOLES [125
)
I
248]
FOR M24 BOLTING ¢l~OO
(BOWLS)
[125 35~
8X .50-13 UNC-2B (BARREU
FOR JACKING BOLTS
10.50 [2b7]-I--_.-J
NOT BY RUHRPUMPEN
(TYPICAL)
~ 21.00 [533] ~ - 1- 1 • 25 [32]
r---~~fl\&. ITEM No's

3X .250-20 UNC-2B
FOR MOUNTING SAMI VBS VIBRATION SWITCH -t- I 1.25 [32]
PUMP No.
131 G 2101 A
MOTOR No.
131 GM 2101 A
RUHRPUMPEN SERIAL No.
200220-1
-:~
&; 131-G-2101 B 131-GM-2101 B 200220-2
&.
DRAWING STATUS
CUSTOMER DATA
D FOR INFORMATION ONLY
YEW "A" "A" CUSTOMER P.O.: 890870 ;
D FOR APPROVAl
TO Io4EET DElJVERY PROMISE
CUSTOMER: GOULDS PUMPS / FLUOR A~O S&K I
PUMP DRIVER DIMENSIONS ARE iii YES 'DIMENSIONS IN iii YES APPRQVA! QRAWING NQIE ONE APPROVEO copy !.lUST ee: END USER: KUWAIT OIL COMPANY
SUCTION SIDE: MAWP MAK-E: ABB IN INCHES 0 NO ~R~RtJ~M~~ NO o 1. PURCHASER'S COUUD/TS AND/OR CORRECnCliS. 'MTHIN
RETIJRNEC BY': OJ MAY 04
LOCATION: KUWAIT
&.00 CLASS 000 R.F. -WELDING NECK FLANGE 85.0 BARG lHE SCOPE OF' CONTRACT WILL BE ),lACE' ON THE FlRSl
CO\IPL£TED CERlIFJtD DRAWINC SUB/rolITTEO BY
D RE -ISSUE FOR REViEW OF
DISCH. SIDE: MAWP FRAME: 280SM ENCLOSURE: EexnA 11 T3 SUCTION & DISCHARGE NOZZLE LOCA ;]ON DIMENSIONS RUHRPUIoIPEN. IHC. AND RE:lURNEO FOR CORREClION. CHANGES ONLY PROJECT NAME: UPGRADING OF BS-131
4.00 CLASS 000 R.F. WELOINGNECK .FLANGE 85.0 BARG TYPE: ~ KW:_7_5_ _ RPM: ~ ARE ± _12S· ~ CORRt.CTlONS, AJ.. TERAlIOHS, ADD nONS ANO OR
UAHUFACTURING PROCESS HAS BEOl STARTED
SERViCE: CONDENSAIE TRANSFER PUMPS
ANY OTHERS REOUESTED CHANGE YIIU AFFECT

'~_ DESCRIPTION
CONNECTION VOLTS: 440 PHASE: 3 ALL OTHER INSTALLAnON DIMENSIONS ARE ± . SO' 1A00IFlCAlIOOS OUTSIOE SCOPE OF' CONlRACT PRICE AND/OR oru\IERY PRONIS[.
CYCLES: '50 OR MADE AFTER FlRST SU8WITTAl LlAY REOUIRE FLOW: 20 m 3hr
1 COUPUNG GUARD (BRASS) THRUST POT BY RUHRPUMPEN
J,1.j AOOITIOHAl ENGlNEERINC SERVICE OiARc:t. • FINAL
SEE DRIVER PRINT FOR DIMENSIONS FORCES & MOMENTS UANUFAC1URINC PROC£SS HAS eEEN STARlm T1DH: 743 m
'2 3 PIECE SPACER COUPLING BY RUHRPUMPEN MECHANICAL SEAL
API 010 8TH EDITION FORCES &: MOMENTS
:i IlEJr.lS COHOI'OONAlLY APPROVEO OR WI'ni OEFERRED
APPROVAl BY PUROi....SER., ),lUST et 9(OnCAlLY
ANY REOUESTED etlANGE WILL AFFECT
.-.,.,,
FRICE AND/OR DEUVER,Y PRON&.
'3 COULPING GUARO (BRASS) PUMP 8Y RUHRPUMPEN MFGR.: JOHN CRANE
F=FORCE (N)
toI=MOtolENTS (N-to() SUCT OISCH
1423 £
STArrD OlHER'MSE OELI\IERY ),lAY BE AfFECTED.
AS BUILT 26 APR as :.voh KH PROCESSOR ~ Rutvpumpen, Inc.
4 PIECE COUPLING BY RUHRPUMPEN TYPE & SIZE: TYPE 48 ~ FX 2491
1779 .£SUBMIT AS FINAl 24 FEB as :voh KH
V. HACKATHORN RUHRPUMPEN Tulsa, OK U.SA
;'MX FY,MY FY 3114 '-/
.E CH ANI CAL SEAL BY RUHRPUMPEN API CODE: BSAFN DATE
1& ivoh
~-~."
FZ 2040 11% REVISED PER CUSTOMER 28 .AJLY 04 KH
10 APR 04 DRAW""G llTI.E OUTLINE DRAWING
'6 THRUST POT BY RUHRPUMPEN APPROXIMA TE WEIGHTS FR 4492 2535
l..&,.
REVISED AS NECESSARY FOR BEEFy FABS 16 .AJLY Q.4 v,h KH
'7 SUCTION VENT; 1.00 FLG CL filO MX 2305 1329 PRODUCT MANAGER 950 VLTF-22 STAGE
DIS01~~ &.
VALVED PUMP W!THRUST POT: 3040 KG (0700 LB)
'B PLAN 13 CONN; .750 CL 000 £ MY 1180 078
ORIGINAL DRAWING K. HISEY
DRAWING NO. ROO2084 J
b
BY RUHRPUMPEN DRIVER: 005 KG (1400 LB) BY REv.
1003 LlR DESCRIPTION DATE CHK. DATE
fg BARREL DRAIN; .75 FLG CL ODD VALVED TOTAL WEIGHT: 370'5 KG (8100 LB)
FY.MY
MZ 1703
1803 10 APR 04 DCN- 054345 I E
MR 3132 REVISIONS
THRUST POT SHAFT
ITEM No's
PUMP No. MOroR No. RUHRPUMPEN SERIAL No.
131-G-2101 A 131-GM-2101 A 20022 &-1
131-G-2101 8 131-GM-2101 8 2oo22&-2
PUMP SHAFT
DRAWING STAllJS CUSTOMER DATA
o fOR INfORMATION ONLY
CUSTOMER P.O.:_8=-90:.=..=8:.:.70-=----_________
,----=:-----------11 0 ~~~~...'" CUSTOMER: GOULDS PUMPS / FlUOR AND S &: K

APPROVAL DRAWING NOTE END USER: KUWAIT OIL COMPANY
1. P1.IRQ'.ASI!;R'S ~M£HTS .\Nl)jOIt COAA:£CltOflS. jlj!nI!N
l'Ht SCOPE CF' C!JNT'RACT WIll. S£ !MOE ON: iHE M5i o LOCAnON:~KU~W~A~'T~________~_____
COIIiPt.E:ltD CERTlf'lED ORA'MHC SlJ81oIH'iEO BY
~EH,. He. MID R£'ruRNED FOR: CORR£cncN.
~
.
~~~itJ~~..:~~ !'l>...ST'!L"'" PROJECT NAME: UPGRAOING OF 8S-131
SERVICE: CONDENSATE TRANSfER PUMPS
.! !o. Part De~criotion IMoterial lat •. ~ Ruhrpurnp Inc.

2'00 RING, SPUT, DRIVE COUPLING lsI!.. LC ""'.... ,....""",, RUHRPUMPEN Tulsa, OKen.U.sA
'9 COUPLING. THRUST POT lSI!.. 1045 ~----------------~---+-+~~--- 1~O~RA~~~C~~:R~£-------------------4
'-/
,,30 COUPLING, PUMP
532
24 FEB 05 i";;;;;:;::=-==..~ 4 PIECE COUPLING DRAWING
PLA TE. ADJUSTING
538
07&-2
COUPLING SPACER
KEY. PUMP HALF COUPLING
I"" I 0=.'""01< DRAWING NO. R0020 9 8 REV.
S
REVISIONS 054561
/
£ £ £ £
J
I
I
I ITEM No's
MOTOR No. RUHRPUMPEN SERIAL No.
I
I--
PUMP No.
131-G-2101 A
131-GM-2101 A 200220--1
Ref.No. Port Description IMoteriol IRef.No. IPort Description Moteriol
131-G-2101 8 131-GM-2101 8 200220--2
72 BARREL SH ISEE NOTE 125b 1 RING, SPUT, DRIVE COUPLING 1 STL LC
7B CASE SERIES, 1st STAGE A487 CAbNMB 317 BEARING, BODOM CASE GRAPHALLOY FAB NOTE: PIPE: A10b,B
78-1 CASE SERIES A487 CAbNMB 317-1 BEARING, SERIES CASE GRAPHALLOY PLATE: A 516, 70 r-- .
78-2 CASE SERIES, TOP A487 CAbNMB 317-2 BEARING. SEAL CHAMBER GRAPHALLOY FLANGES: Al05 DRA....~NG STAnJS CUSTOMER DATA
79 L CASE BODOM A487 CAbNMB 508 THRUST POT SEE R002097 POST WELD HEAT TREAT TO MEET 0 FOR INFORMATION ONi Y CUSTOMER P.O.: 890870
82~ INOZZLE HEAD SH SEE NOTE 52 b RING. RETAINING .EXT 1. 438 SST SPCL NACE MR 01 75. 0 FOR APPROVAL CUSTOMER: GOULDS PUMPS / flUOR AND S " K
11 b. SEAL CHAMBER SST 31 bl 529 COUPLING, THRUST POT STL 1045 APPROVAL DRAWING NOTE r~:JD~~ci::'i.'ti~ BE END USER: KUWAIT Oil COMPANY
120
._ MECHANICAL SEAL ASSEMBL Y 530 COUPLING, PUMP STL 1045 .. ~~':'~·i"cg::i:';';":[C;;.c.:':'o"ic~~ ";:~~ RE ISSUE FOR REVIEW OF lOCA liON: KUWAIT
lb7 I SHAFT PUMP A479 TYPE 41D 532 PLATE • ADJUSnNG STL 10....• 5 CDUPt.mIl ""'1INC.
RUHRPUWPEH. 1F1EOANDDRA.....'
RElURNEDsuaUITrnl ay
F'OR: CORREcnQII. 0 CHANGES ONLY PROJECT NAME-• UPGRAOING OF 85-131
17b_ IMPELLER 1st STAGE A487 CAb"lMB 5 38 COUPLING SPACER STL 1045 2. CDRREenD.S; ALTtRAnoNS. ADDmD.S AND OR ~~~~JQ':i'=o'!::;:J~')'k,,& SERVICE: CONDENSATE TRANSFER PUMPS
17&-1. IMPELlER. VLTL B50 W/BALANCE HOLES' A487 CAbNMB b7b KEY PRL, 1st STAGE IMPELLER SST 18-8 ~oo:;:;.n~D~~'i'~:~'::~.. AND/OR DElJV<RYPRD..SE.
PRICE flOW: 20 m3hr
17&-2 IMPELLER, VLTL 850 W!OUT BALANCE HOLES A487 CAbNMB b7&-1 KEY PRL, SERIES IMPEllER SST 18-8 AN ADDITIONAl ,"CO.Effi<., SEI!~CE CHARGE.
1. /TELIS CONOLnONAlLY APPRO\'ED OR WITH OEFERRED
• ~~~=R'" PROCESS HAS BEEN SYARID)
N4'( REQUESlm CHANCE 'MLl. A"FECT
TOH: 743 m
j---3 IMPELLER, VLTH 850 W!OUT BALANCE HOLES A4B7 CAbNMB b7&-2 KEY PRL. PUMP COUPLING SST 18-8 ~:~v~~~c~:..,~;~';."/:.=~Y P",e< AND/OR OiJJ",,"Y PROMISE. ~
:-. ' WEAR RING. IMP, 1st STAGE, EYE A479 TP 410 FLEXiTALUC SST ~lbl;E\ I PROCESSOR R'P 'N Ruhrpumpen, Inc.
---0:01 -,. WEAR RING, IMP, 1st STAGE. HUB A479TP 410 744 GASKET, BARREL ! GRAPHITE &,.' v. HACKAlHORN RUH'-.YMPS Tulsa. OK U.s.A
~
.. _0., WEAR RING. CASE, BODOM A479 TP 410 747 O-RING, CASE. SERIES AFLAS IA ~1TEAPR 04 DRA..,NG TITLE
;:.
205-J WEAR RING, SERIES, 1st STAGE, BACK A479 TP 410 747-2 O-RING, SEAL CHAMBER KALREZ 1& .E~u~&W~I'lLSDt,Pcj,I~'ii~~'1.hc';!f:A~E~s~f.YElyE 24 FEB 05 voh KH PROOUC7 MANAGER SECTIONAL DRAWING
205-:<
- WEAR RING, SERIES, 1st STAGE. EYE A479 TP 410 9'50 GUARD RING RTNG 1.438 SST 31 [) !A ORIGINAL DRAWING K. HISEY DRAWING NO. R0020 9 ') I REV.
205-3 WEAR RING. CASE, SERIES. BACK A479 TP 410 LTR DESCRIPTION DAlE BY CHK. DAlE . B
205-4
WEAR RING, CASE. SERIES, EYE A479 TP 410 REVISIONS 22 APR 04 DCN- 05434&
·J ,"
NOTE: WATER COOUNG PROVlSIQ.'1S PROVIDED.

4 @
"l" ,,'54
PUMP No.
131-G-2101 A
131-G-210l 8
ITEM No's
MOTOR No.
1 '11-GM-2101 A
131
RUHRPUMPEN SERIAL No.
200221>-1
200221>-2
NOTE: PIPE: A100.6/A536 DRAWING STATUS CUSTOMER DATA

PLATE: A510.7O o FOR INFORMAnON ONLY
CUSTOMER P.O.:_B=-9:.:0=-:B:.:7O-=-_ _ _ __
Ref.No. Part Description Material Rel.No. Part Description Malerlal

o FOR APPROVAL
1'0 NEG Dtl.I\ItRT PROMISE
CUSTOMER: GOULDS PUMPS I flI10R AND S « K
0Nt: APF'ROYC!:D_
RE1URH£O _ )JUS'f
C'a"l' _ __Be END USER: KUWAIT OIL COMPANY
A97 FlEXIABlE COUPLING, TSKS ASSEMBLY o7&-4 KEY PRL. THRUST POT SST< la-B APPROVAl DRAWING NoTE
~
11:>1 SHAFT. lliRUST POT SST 41 I:> 697 PIN. ANTI-ROTATlON SST SPCL. !. PURQiASm"S ~rs AND/OR (»RRtCflOIf5. 'MrHll\!
1'tI£ ScoPE (.f' CO'H'lRAC'f 'lI4LL at WADE ON T!1E FIAST
o RE-ISSUE FOR REVIEW QE
CHANGES ONLY PROJECT NAME: UPGRADING OF 85-131
221 SLEEVE Oil STL LC 747-3 O-RING, lliRUST POT NITRILE ~ CEf\MCO OftA'WIHG SUawtmn 6Y
~PE:N INC,. AW R£1'UfI'NSl FOR CORRECllON.
~U~~:~~Jr'~J~tLST~ SERVICE! CONDENSATE TRANSFER PUMPS
346 SlEEVE•. BEARINGr BALL STL lC 818 COPPER 2. CORR!.CflOH$. AtltR"'TION5. ADomON$: ANO OR 2 O-'m:...-"_"_
PRICE AHD/OR OE!J\£R'Y PRQj,qS(. ~
IoIOOIFlCA'f1G'tiS OU1'3lQE: scOPE q a:.lHTRAC1 • flli& fLOW:.-'___ _ _ _ _ _ _ __
481:> RING. SEALING - V NITRILE ASSY. OR WADE ~ flItS! SUEl),lI1'TAl. "'AY REQuIRE
S08 lliRUST POT SEE NOTE -1878 ~~--

INUT. LK cor<" .
"tV ,STL LC
f.If AIlOHIOflAl ENcmt£RIHG SERWX QiAR«.
WAHUrACTURINt; PROCESS HAS BttJI STA.R1'EO
ANT REOJESn::o CtiAHG£: WlU. AFrEel
TOH: 743 m
PRla: ;U4D/Off OEU\!ERY PROMts[..
1 COVER, lliRUST POT STL LC STL LC ~ _.."l1C.
.~&-1
'.
RING, RING EXT L 7")0
BEARING, BAll. THRUST
SST SPCL.
ASSY.
I~l 126 ~ ~I ~ I KH r~~O:a=thorn RUHRPUMPEN
'-'"
Tubs. OK lI.SA.
<; BEARING. BALL RADIAL ASSY.

bbS GAUGE, LEVEL ASSY. ST POT SECTIONAL
673 WASHER, LK BBRG 40 STL LC
D£SCRIPTlOU OATE
073-1 WASHER. LK 6BRG 00 STL LC 054347
070- 3 KEY PRL FLEXIABLE COUPLING SST 18-B REVISIONS
API PLAN 13
Item No. Oly. Port Description I Material
01 36" PIPE, SMLS .75 SCM. 160 SST 315
&, 02 3 GASKET CL-60D FLEXITALLIC
03 1 ORIFICE, PLATE SST 16-8
&, 04 3 FLANGE••75 CL-600 itF.S.W. SST 316
SEAL LEAK DETECTOR

Item No.1 Oty. I Port Oescription I Maleriol
&, 05 6" PIPE. SMLS .SO SCM. 160 SST 316
06 SOL PRESSURE SWITCH .500NPT ASSY
I
FLARE CONNEClION
Item No. Oly. Port Description Material
07 6 PIPE. SMLS .50 SCH. 160 SST 316
08 3 GASKET•. CL-600 FLEXITALUC
09 1 ORifiCE. PLATE SST 18 8
10 1 FLANGE••50 CL-600 R.'.S. W. SST 316
II 1 FLANGE. .50 CL-600 SUNO SST 316
LABELED: "V'
"VENT" ON SEAL &,
PRESSURE SWITCH TAG D'S"
131-PSHH-603'5
131-PSHH-603b 1"'1
ITEM No's
LABELED: l1FU &, PUMP No. MOTOR No. RUHRPUMPEN SERIAL No.
"FLUSH" ON SEAL LABELED: 110'" 131-G-2101 A 131-GM-2101 A 200221>-1
"DRAIN" ON SEAL 131-G-2101 8 131-GM-2101 B 20022 &-2
01 DR6W1NQ STAruS CUSTOMER DATA

o FOR INfORM ATION ONI Y
CUSTOMER P.O.: 890870
o FQR APeBQVAL
TO MEET DWVER'f PROIJISE
CUSTOMER: GOULDS PUMPS I flUOR 00 S .I< K
A.eeflDI!AL DRAWING NOTE ONE APPROvED COPy MUST a'E END USER: KUWAIT OIL COMPANY
ItE1U~O 8'1: 10 ~AV 04
1. pu~'S COMMENTS AH'O/Cft CORREC'tlOHS. YIITHIN
LOCAliON: KUWAlT
!H£ !SClP( OF COliTRAcr 'MU. ae:: UA/lE ON THe fiRSt
couPU:tm cornFlEO ORA'MNG SUSWI11'DJ: By o BE-ISSUE FOB REVIEW Of
R1JH~. INC. AHO F<£lURHEf} FCR ~REC1lON. CHA~G~S Q!l~Y PROJECT NAME: UPGRADING Of 85-131
IJANUFACruRi/'JO PROCESS HAS es£N STAR1£()
SERVICE; CONDENSATE TRANSFER PUMPS
2.=~~o:s~~~~~n=~~ ANY Olli(RS RE0UE51EQ CHANce Wll.L. Aftt:Cr
PRICE ,A.NOlOR OOJ\ERY PROMISt.
OR IIAO£ AFTER FIRST SUSJ,GTTAI. }lAY REQUIRE
AN ADtnTlON.Al £NCI.'<I:u;;RIHG stR\IIa! CHAAG£.
Fl,0W; 20 m 3hr
• FINAL
1. IrtlIS CC«oillOHAU..Y APf"t«)V[D M 'M1H IlEfERRm
t,I~UfACruRIN'C PROC(S:S HAS W-E/If STAAlED 1JlH: 743 m
J<J<IY REQUESTED CHANGE 'MLL "mCT
APi"'ROVAl,. BY PURCHASER, MUSt Be: SPtaFlCMJ.Y F>RIa: ANOIOR DEUVERY PRCWISE,
~
$'fAJm OTHaRWiSE OElJVERY MAY SE AFFtC1ED.
PROCESSOR Ruhrpumpen, h::.
APJ PLAN 1 3 V. HACKATHORN RUHRPUMPEN T~~ U~
DATE
22 APR 04
""'-"
ORA"'WG nllE
REV. F'LANGES TO 600 If; REV. PER CUSTOMER 11/29/04
"""
KH
PRODUCT i"iANAGER API PLAN 13 wi SEAL lEAK DETECTOR
K. HISEY
LlR DESCRiPTION DATE BY CHK. DATE
DRAWING NO. ROO2096
RFVl<:I()N<: 22 APR 04 DCN- 054348
DRAWING No. ~~ COMPONENT ~~......~ .... ~..
HSP-1018876-! ~--r/ 1 2.125 8UO 1903iMATING RING SILlCOH CAR
~2 0000 2.27 9549 !O-RING VITON OR En
3: lC4-a
:U 25 OD2 8270 PRIMARY RING CARSON
'" 0000 2-2.7 9549 C)-RING VITON Olt Et"
5 ,,9 2:125 020 0550 ReTAINEit 316
I) t863 SPRING 316 S. S.
7 9 212.5 011 0550 OISC 316 S.S.
8 A9 2125 cas 015150 SNAp RING 316 S.$. it
9 1125 2005 000 0550 CUP jilT SET SCREW 316 S.S. :J
10 212$ 19U 0550 GlANo PLATE ASS'Y 316 S.S. 11
\J1''''!'l'VIJ ru:r I':nI'TV
¢ 6.750
I
GLAND 0.0.
SHAFT
ROTATION
@~ ..
III 3.939 CCUll'ER.. c:.r...ooo;wxse
III 3.937
BORE.
III
3.000 CUSTOMER NAME: RUHRPUMPEN INC.
SEAL 0.0. CUSTOMER LOCATION: TULSA. OK.
END USER NAME: KUWAIT OIL COMPANY
END USER LOCATION : KUWAIT
RUHRPUMPEN PROJECT# 200226
RUHRPUMPEN PART# 2009599
TBD: SEAL FACES MUST
SEAL ASS'" 00. ~_ ~:::~!;~:gg: I~i~-~o W.~tAI : : = 1 1
E INSTALLED DRY.
JoiTl3;,RG •.ASS·Y NO.
SEAL f-D.
UTa.RG.
ASS'Y ITEMS I NULtSER

"CSV"I EauIPMENT REFERENCE ,CUSTOMER INFORMATIcN: .,
UNIT BY: nN'lnUF,R·
RUHRPUMPEN
14. GLAND PLATE MUST CONTACT HOUSING. DO NOT OVERSTRESS.

EC01PMENT TYPe:
13. SPACER (ITEM # 28) IS ONLY FOR THE PURPOSE OF PROPER~Y ~FUUI' o llGITA1'C)R
OIL COMP.ANY
LOCATING S~. AFTER GLAND PLATE, BEARING; SHAFT, & SEAL "FV"
00"'''
~~~~~E~i~ ~~;I~~~EA~A~~~Ssg~~ ~ ~iXiI~LAR.
PARTS AND LOCK IN PLACE WITH CN" SCREWS (ITEM /I 29) PROVIDED.
A&B
~~","13 n~(~:E061 316/318

316/316
m~__
ru_~_.
RECIROILATlON FROM SEAL i:HAMSER
TIlROUGH ORIFICE {AS REQUIRED}
__
INLET
PLUGGED
DRAIN "CSO"
TOSUCTICW·. . . .
CONNECTIONS PROVIDED FeR GLAND PLATE
ORIFICE SIZE
//e2.5 ll
GPM
POSSIBLE FUTURE QUENOI.
ENDVIEW DETAIL
SCALE: 0.750;=1
FlOW !!ATE
THe FOLl.OWING OOTeS ARE IMPORTANT AND lAJST BE OBSERVED FOR CORRECT SEAL INSTAL.l.ATIOH ANn OPERATION
CAD ENGINEERED
1.lWolOo'E ALL SHARP e.tIGES f;N SfW<1' ANlIOO SL".Il'VE 8!:FCRE lN$TAl.t.ATle:N 011' SI!AL. $.lIHat SJW'T IS- sumvec 'nU'II:;UGf StUP'FlHG SlO'K. $t..EE\IE II.JST 8E L.XOJU) TIGKr 'flGlCl..klM et:Ra. SIZE: Jij2. 12.5 J ~1. 875
~·~~~:a~.OOSI...EEVECN1MlCH:seAt.t$IKSTAL..l.5l)ILIS1'UiW\CKlHEDTO 63 AA 7"~~&~~~~~REf~~A~OftZSBRtHEU. T"Y'PE! 2648-2C TANOEWCARlRIOGE
. wrrn UGHT WEIGHT OIL.

3.l.1J8RlCAn
"'UlBIUCAT'E stW"T/su:EVE & SI!At.. 1IBlCI!!. ItlNGt'O-RIHGI$I!l.'I..OWS 'TO .t.SSl:ST rNSTAU.AT'lai Of SEAl.
IATtNG RING (tteAT).$lt<I.I..tm U9oI8ER I'Hl H:'.:tJSlM* 't'I) ASSIST INSTALLATI(';N.
~·I·i""j"'ii""'.i-iiii·I""iISIOFii"""'iiiilUlTii"IAiT~"i·~TO''''''''i·I''"'''"'iii.i.~rn<i'i.i·i.Qi>~'I·'I·~i·IIDi~~~?~5t::~i JOHN CRANE INC.
fQtemational Sealing Systems
IL P1l~~ 8£ C!RCtA..ATEl) AII!CU4D PRnwrr JUtG tHAI. I'AeE)~ NA.'l"tNG fttJllr; ($SAT) o. dFORI' ~ sat. IlGTALtJII1"1CN W!~ lAPPltD slNACI!'S OF wrrtN3 JUN:i ($CAT) • 6400 Oaldon Street
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M~r1l>n Grove. IL 60053. U.S.A.
nflS MJi1)1I.U t PfttNr. JUGtETIC l'Af"It 1!iTC. i IS $tJa.Jf;CT 10 It£'tUIW Ofi oa.wu ~ _tnt AI,,!. IX)Pl:eS AN:! Al..L Ut~_. OEStQNSi NO
Doc No' 17831-131-MA-E-M0068
Project No.: 574401
fill~1I Item No.: 131-G-2101A1B
FUI4~l iil:b CENTRIFUGAL PUMP Revision:

By:
O·
KE Chk'd:AC
Date: 24-03-2004
Appr'd:RB
SPECIFICATION SHEET Unit:
(~) P.O. No.:

Inquiry No.: ERM No.
Sheet 2 of 6 Procurement No.: REV
1 ' Client: Kuwait Oil Company Supplier: In Industries Applicable 10: 0
2 Project: Upgrading of 88·131 Mfr.: RuhrPumpen Ref. P&ID: 17831·131·GB·8·G0522 0
3 Site: B8·131 Phase 2 Model No. 950 VLT 4X6X20 Serial No. 0
4 Service: Condensate Transfer Pump Tolal Req.: 2 No. of Spares: 1 0
5 Type: VS6 Case: Design Governing Case: Design
6 Requisition/Spec. Nos: I Pump Size I No. Stages: 122 0
7 Note: Information Below to be Completed: 0 By Purchaser. o By Manufacturer. o By Manufacturer or Purchaser.
8 GENERAL (3.1.1)
9 Pumps To Operate In: No. Motor Driven: 2 No. Turbine Driven: NA 0
10 With: Pump Item No.: 131-G·21 01 AlB Pump Item No.:
11 Gear Item No.: Motor item No.: 131-GM-2101A18 Turbine item No.:
12 Gear Provided By: Motor Provided By: ABB Turbine Provided By: 0
13 Gear mounted By: Motor Mounted By: RuhrPumpen Turbine Mounted By: 0
14 Gear Data Shl. No's.: Molor Data Sht No: 17831·131·EA-E·E0524 Turbine Data Sht No: 0
15 o OPERATING CONDITIONS o SITE AND UTILITY DATA (CONT'D)
16 o Capacity (normallratad): 15 120 m'/h Water Source: 0
17 Other: Refe r to note (3) Chloride Concentration: ppmw (3.5.2.6) 0
18 o Suction Pressure (max/rated): 34.96 (2) 120.93 (2) barg Instrument Air. MinIMax: I barg
19 o Discharge Pressure: 63.52 (2) barg OLIQU!D
20 o Differential Pressure: 42.59 (2) bar o Type or Name of Liquid: Hydrocarbon condensate
21 o Differential Head: 743 (2) m NPSH Avail: 1.485 (2) m o Pumping Temperature:
22 o Process Variations: (3.1.2) Normal: 57 Max: Min: ·C 0
23 o Starting Conditions: (3.1.3) o Vapor Pressure: 21.85 bara @ 57 ·C 0
24 Service: Intermittent (3) StartalDay: o Density:
25 o Parallel Operation Req'd:J2.1.11) Normal: 585 Max.: kg/m'
26 o SITE AND UTILITY DATA Min.: kg/m'
27 Locallon: (2.1.29) o Specific Heat kJ/kg·K
28 o Viscosity: 0.178 cP @ 57 ·C 0
29 o Eleclrical Area Classification: (2.1.2213.1.5) o Max. Viscosity: cP
30 Class GR: Div o Corrosive/Erosive Agent (Note 1) (2.11.1.8) 0
31 o Winterization Req'd: o Chloride Concentration: ppmw (3.5.2.6)
32 o Tropicalizatlon Req'd: o H2S Concentration: (Note 1) ppmw (2.11.1,11)
33 Site Data: (2.1.29) Liquld:(2.1.3) o Hazardous Yes o Flammable 0
34 OElevallon: 46 m o Other
35 o Barometer: 754 mmHg(a) PERFORMANCE
36 o Range of Ambient Temps.: Proposal Curve No.: 3-0265-001 > 0
37 MiniMax: ·3 I 55 ·C o RPM @ Design: 3000 rpm 0
38 o Relative Humidity: o Impeller Dia. Rated: 171 mm 0
39 MinIMax: 6
I 100 % MiniMax: 178 1178 mm 0
40 o Unusual Conditions: (2.1.23) Sandstorms (Ref. KOC-G-(07) o Rated Power. 49.7 kW 0
41 o Utility Conditions: Efficiency: 47.7 % 0
42 Steam: Drivers Heating o Minimum Continuous Flow:
43 bara ·C bara 'C Thermal: 7.5 m'/h 0
44 Min.: Stable: 15 m'/h 0
45 Max.: o Preferred Operating Region: 29.7 to 50 m'/h 0
46 Electricity: Drivers Heating Control Shutdown o Allowable Operating Region: 15 to 50 m'/h 0
47 Volt V 440 250 o Max. Head @ Rated Impeller: 840 m 0
48 Freq: Hz 50 50 o Max. Power @ Rated Impeller. 62 kW 0
49 Phase: 3 1 o NPSHR At Rated Capacity: 2.3 m (2.1.8) 0
50 Cooling Water. (2.1.17) o Suction Specific Speed: 12644 (2.1.9) 0
51 Temp. Inlet: NA ·C o Max. Sound Pressure Level: 87 dBA (2.1.H) 0
52 Max. Return: ·C o Est. Max. Sound Press. Level: TBA dBA (2.1.14) 0
53 Press. Norm.: bara Remarks: 1} Equipment is in sour seNice, design to NACE R0175 0
54 Design (minimax): I barg 2) Reference elevation is grade, no margin has been subtracted from
55 Min. Return: bara calculated NPSH to give NPSHa.
56 Max. A1low,6.P: bar 3) Pump may be in continuous seNice for extended periods or
57 recycle mode. Overheating shall be avoided.
Map d version 1. 02112103
No~ca: This document n,anot bunpubliahed end Is tf'MtSCle ptopf!ll1yol!he Auor D,nlaI, encfls 181'11 10 Iht borto'WlW klrbi$ coollr:Son~us:e only81'ld In eonsideral/Qn 01 the loan of Ihis cklcull\(!nt, the botro'M'lt agrees (Q,.tvm it
(i IAP,ll,,'t 1.dwg
17831-131-MA-E-M0068
Project No.: 574401
~~ Item No.: 131-G-2101NB
FLUla,tl~bI CENTRIFUGAL PUMP Revision: 0' Date: 24·03·2004

I By: KE Chk'd:AC Appr'd:RB
@ P.O. No.:
1 Case: Design Governing Case: Design
·i
6
2
3
5 Type:
CONSTRUCTION
Application Standard: API 610 8TH Ed. + Spec.015-GH·10003
Add"d,m. S,,.O Sp". 000-"A-E-"0001
zzle Connections: (2.3.2)

VS6
o Shaft Diameter Between Brgs.:
o Span Belween Bearings Clr Line:
o Span Belween Bearing & Impeller:
CONSTRUCTION (CO NT)
mm
mm
mm
7 Size ANSI Facing

8 mm Rating
9 Suction 6" 600# RF Side COUPLINGS: (3.2.2) Drlver·Pump 0
10 Discharge 4" 600# RF Side 0 Make: Ruhr I Metastream 0
11 o Model: TsKs flexible 0
12 0 Coupling Rating: hp/100rpm
13 Pressure Casing Connections: (2.3.3) 0 Lubrication: None 0
14 SaNiee: No. Size mm Type 0 Limited End Float Required:
15 Drain. 1 3/4" y Flanged & valved 0 Spacer Length: mm 0
16 Vent 1 1" y Flanged & valved 0 Service Factor. 0
17 Driver Half Coupling Mounted By: (3.2.11)
18 • 600 Ib rating Coupling par API 671: (5.2.7) 0
19 BASEPLATES:
20 o API Baseplate Number: (Appendix M)
21 o Cylindrical Threads Req'd.: (2.3.3) o Non-Grout Construction: (3.3.13/5.3.7.3.5)
22 CASING MOUNTING: In line separate mounting plate Remarks: 3) Non sparking type coupling guard required (brass). 0
23
24
25 CASING SPLIT: Radial
26 MATERIAL
27 0 Appendix H Class: API S-6 (2.11.1.1)
28 CASING TYPE: Vertical double casing 0 Min. Design Metal Temp.: (2.11.4.5) 'C 0
29 o Impellers Mounted: Vertically Suspended 0 Barrel/Case: CS 0
30 Impeller: 12% Cr 0
31 0 Case/Impeller Wear Rings: 12% Cr Hd ( 0
32 CASE PRESSURE RATING: 0 Shaft: AISI4140 0
33 o Max. Allowable Working Pressure: 0 Diffusers: 12 %Cr 0
34 46.9 barg @ 58 'C 0 Coupling Hubs: 0
35 o Hydro Test Pressure: 70.3 barg 0 Coupling Spacer. 0
36 o Suction Press. Regions of Multistage or Double Casing (2.2.4) 0 Coupling Diaphragms:
37 Remarks: 4) Earthing clips as per 015-CB-1013. 0
36 . ROTATION: (Viewed From Coupling End) CCW 5) Equipment is sour service, NACE MR0175 & Spec.
39 131-GA-E-GOO01 shall apply.•
40 o Impellers Individually Secured: (5.2.2.2) Keyed 0
41 Remarks: BEARINGS AND LUBRICATION
42 BEARING: (Type/Number)
43 o Bolt OH3 Pump To Pad/Foundation: (5.1.2.4) o Radial: Grah. alloy I TBA 0
44 SHAFT: o Thrust Ball ITBA 0
45 I0 Shaft Diameter At Coupling: mm o Review and Approve Thrust Bearing Size (5.2.5.2.4)
46 REMARKS: 1) Pump mounting flange shall be supplied with 2 sets LUBRICATION: (2.10) Radial product I Thrust oil bath 0
47 of gaskets. Flanges shall have smooth finish facing with
48 250·500AARH. t Level Oiler Preference: (2.9.2.2)
49
50
2) Pumps to be provided with can drain pipe
gate valve & blind flange.
& vent terminating with W ressure Lube Sys: (5.2.6)
51 API-610: API-614:
52 0 Oil Vise.. ISO Grade: (5.2.6.5)
53 0 Oil Heater Req'd: None (2.9.2.9/5.2.6.3) 0
54 0 Oil Pressure To Be Greater Than Coolant Pressure: (5.2.6.2.b)
55
56 Remarks:
57
Nob: This doCumenl has not been publlshe<l and is Iha 80M PtQPort)' olltle Flu« Oanlel. emf Is lent 10 the borrowel' for his c:onfidenliaJ use o~ .r,d in cotllit::llmllion of Ih8loan oi Ihlr; documenl,lha borrower agrees: 10 I'$tum it Map ed Version 0, 02112103
II
~~~~~- ...... ~~-

- - --
17831 131 MA E M0068
Project No.: 574401
~~~ Item No.: 131-G-2101A1B
nlMlt
_---l i5X~
- ,'l\nliia CENTRIFUGAL PUMP Revision:
By;
O·
KE
Date: 24-03-2004
Chk'd:AC Appr'd:RB
@
" -
P.O. No.:
2 MECHANICAL SEAL OR PACKING SEAL FLUSH PIPING: (CONTINUED)
3 SEAL DATA: (2.7.2) 0 Piping Assembly: (3.5.2.10.1)
4 0 Attached Data Sheet: API 682 Flanged
5 0 Appendix H Seal Code: BSAFN (2.11.1.1) 0 Pressure Switch (Plan 52153). Yes 0
6 0 Seal Manufacturer: John Crane Type: 0
7 0 Size and Type: 48MP I 485C 0 Pressure Gauge (Plan 52153). Yes 0
8 0 Manufacturer Code: I 0 Level Switch (Plan 52/53). No 0
9 SEAL CHAMBER DATA: (2.1.6/2.1.7) Type:
10 0 Temperature: ·C o Level Gauge (Plan 52153). No 0
11 0 Pressure: barg o Temperature Indicator (Plans 21. 22, 23, 32, 41): No 0
12 0 Flow: m'lmin o Heat Exchanger (Plan 52/53). No 0
13 0 Seal Chamber Size: (Table 2.3)
14 o Total Length: mm o Clear Length: mm
15 SEAL CONSTRUCTION: PACKING DATA: (Appendix C)
16 o Sleeve Material: 316 st. St Manufacturer: 0
17 o Gland Material: 316St. St Type: 0
18 o AUl(. Seal Device: (2.7.3.20) Size And No. Rings: mm I
19 o Jacket Required: (2.7.3.17) 0 Packing Injection Required.
20 GLAND TAPS: (2.7.3.14) 0 Flow mO/min @ barg
21 .0 Flush (F) o Drain (D) 0 Lantern Rings:
22 0 Quench (0) o Cooling (C)
23 0 Heating (H) 0 Leakage STEAM AND COOLING WATER PIPING
24 0 Balance Fluid (E) 0 lubrication (G) o Cooling Water Piping Plan: None (3.5.4.1) 0
25 0 Barrier/Buff. (S) 0 Pumped Fluid (P) 0 Cooling Water Requirements:
26 o Extemal Fluid Injection (X) Seal Jacket/Brg. Hsg.: mO/min @ berg
27 SEAL FLUIDS REQUIREMENT AND AVAILABLE FLUSH LIQUID: Seal Heat Exchanger: m'/min @ barg
28 Note: If Flush Liquid Is Pumpage Liquid (As In Flush Piping) Quench: m'lmin @ barg
29 (Plans 11to 41), Following Flush liquid Data Is Not Required. Total Cooling Water: m'/h
30 0 Supply Temperature Min.lMax.: I ·C 0 Piping/Tublng Req'd.:
31 0 Density: kg/mO @ ·C 0 Stear:n Piping:
32 0 Name Of Fluid: Remarks:
33 0 Specific Heat: kJlkg·K
34 0 Vapor Pressure bara @ ·C INSTRUMENTATION
35 0 Hazardous Vibrations:
36 0 Flammable o Other 0 NoncontacUng (API 670)
37 0 Flow Rate MinIMax.: I m'Jh 0 Transducer
38 0 Pressure Required MiniMax.: I bara 0 Provision For Mounting Only: (2.9.2.11)
39 o Temperature Required MiniMax.: I ·C 0 Flat Surface Req'd: (2.9.2.12)
40 BARRIER/BUFFER FLUID: (2.7.3.21) 0 See Attached API-670 Data Sheet
41 0 Supply Temperature MinIMax.:: I ·C 0 Monitors and Cables: (3.4.3.3)
42 0 Density: kg/m' @, 'C Remarks: Vibration switch on pump thrust bearing lenninating in 0
43 0 Name Of Fluid: junction box located on pump mounting flange.
44 0 Vapor Pressure bara @ ·C TEMPERATURE AND PRESSURE:
45 0 Hazardous o Radial Srg. Metal Temp.: Yes 0
46 0 Flammable o Other 0 Thrust Srg. Metal Temp.: No 0
47 0 Flow Rate MIniMax.: I m'/h 0 Provision For Instruments Only.
48 0 Pressure Required MiniMax.: I bara 0 See Attached API-670 Data Sheet.
49 0 Temperature Required MiniMax.: I ·C 0 Temp. Gauges: (3.4.1.3)
50 ~UENCH FLUID: 0 Press. Gauge Type: (3.4.2.2)
51 o Name of Fluid: Location:
52 o Flow Rate: m'lmin See Gem, Remarks nole (2).
53 SEAL FLUSH PIPING: (2.7.3.19 and Appendix 0) SPARE PARTS (TABLE 6.1)
54 o Seal Flush Piping Plan: API Plan 13 0 Start-Up. Yes 0
55 Material: Stainless Steel Type: Flanged pipe 0 Normal Maintenance. Yes 0
56 0 Auxiliary Flush Plan: API Plan 52 o Specify. Ref. KOC Spec. KOC-G-009 Spare Parts. 0
57 Material: Stainless Sleel Type: Flanged pipe 0
Nol!ce: 'This dOCtJment has: not betO publishlld and is !he SOfe ptoperty of the F\uat DanifrI. ami 1$111%11 to U'Wt borrower tilt hit eonrldetllialusa tiNy and in considera!it)n of &he loan.of!hls doa.Imenl. (be borrower 8;re910 relum n Ma d Vers on 1. 02112103
()
Doc No' 17831 131 MA-E M0068 - - .
Project No.: 574401
tt~H Item No.: 131·G-2101NB
Ft~al•• !L~. CENTRIFUGAL PUMP Revision: O· Date: 24-03-2004

By: KE Chk'd:AC Appr'd:RB
SPECIFICATION SHEET I
Unit:
@ P.O. No.:
2 MOTOR DRive WEIGHTS (CONT'Dl
:; o Mlr: ABB Turbine Driven: 0
4 o Power: 75 kW 0 Speed: 3000 rpm rad/s 0 Weight 01 Baseplate: NA kg 0
5 o Orientation: Vertical 0 Weight OfTurbine: kg 0
6 o Frame: 280SG 0 Weight Of Gear: kg 0
7 o Service Factor. 0 Total Weight kg
8 0 440 V 3 Phase 50 Hz Remarks:
9 o Typa: induction
10 o Enclosure: TEFC/EExnA 0
11 o Minimum Starting Voltage: (3.1.6) V OTHER PURCHASER REQUIREMENTS
12 o Temperature Rise: ·C 0 Coordination Meeting Requlrad. (6.1.3) Yes 0
13 o Full Load Amps: A 0 Review Foundation Drawings. (2.1.27)
14 o Locked Rotor Amps: A 0 Review Piping Drawings. Yes 0
15 o Insulation: F 0 Observe Piping Checks. 0
16 o starting MethOd: DOL 0 Observe Initial Allgnment Check.
17 o Lube: 0 Check Alignment At Operating Temp.
18 o Vertical Thrust Capacity. 0 Connection Design Approval. (2.11.3.5.4)
19 Up: N Down: N 0 Rigging Device Req'd For Type OH3
20 o Bearings: (Type/Number) Pump. (5.1.2.7)
21 Radial; / 0 Hydrodynamic Thrust Bearing Size 0
22 / Review Req'd. (5.2.5.2.4) 0
23 Remarks: 1) Ref. KOC Specs. 015·PH-1908 Induction Motors & 0 Lateral Analysis Req'd. (5.1.3.315.2.4.1) No 0
24 Ooo-EA-E-E0003 Addendum to Spec. o Rotor Dynamic Balance. No (5.2.4.2) 0
25 o Mount Seal Reservoir Off Baseplate. (3.5.1.4) Yes 0
26
27
SURFACE PREPARATION AND PAINT
Manufacturer's Standard;
~ U,," _,.•""
tor Vertical Storage. (5.2.9.2)
NA 0
28 Other: Analysis. (2.8.2.6)

29 o Progress Reports Required. (6.3.4)
30 PUMP: Remarks: 3) Vendor to demonstrate maximun allowable vibration at
31 0 Pump Surface Preparation SSPC-SP-: 10 minimum flow.
32 o Primer:
33 o Finish Coat: QA INSPECTION AND TEST
34 BASEPLATE: (3.3.18) 0 Review Vendors QA Program: (4.1.7)
35 o Baseplate Surface Preparation SSPC-SP-: 10 0 Performance Curve Approval:
36 t%Primer: 0 Shop Inspection: (4.1.4)
37 : o Test with Substitule Seal. (4.3.3.1.2) No 0
38 SHIPMENT: (4.4.1) Test Required Observed Witnessed
39 0 Shipment Destinatlon. Hydrostatic: (4.3.2) Yes Yes 0
40 o Export Boxing Req'd. Yes Performance: (4.3.3) Yes Yes 0
41 o Outdoor Storage More Than 6 Months. Yes NPSH: (4.3.4.1) Yes Yes 0
42 SPARE ROTOR ASSEMBLY pACKAGED FOR: Complete Unit Test: (4.3.4.2) Yes Yes 0
43 SOund level Test: (4.3.4.3) Yes Yes 0
44 Shipping PreparalioJl: 0 CleanliJless Prior To Final
45 Remarks: 2) Ref. Specs. KOC·G·004 Packing, Marking & Assembly: (4.2.3.1)
46 Documentation & KOC-P-001 Shop & Field Painting. 0 Nop;le Load Test: (3.3.6)
47 0 Bearing Hsg Resonance
48 o WEIGHTS Test: (4.3.4.5)
49 Motor Driven: 0 RemOve/Inspect Hydrodynamic
50 o Weighl Of Pump: 2694 kg Bearings Aller Test: (5.2.8.5) 0
51 o Weight Of Baseplate: kg 0 Auxiliary Equip. Test: (4.3.4.4)
52 o Weight Of Motor: 555 kg 0 Witnessed Motor Test Yes Yes 0
53 kg 0 Vibration Test Yes Yes 0
54 -§ Total Welaht: 3249 kg 0 Matertal Certification Required: (2.11.1.7) 0
55 o Casing. Yes o Impeller. Yes 0 Shaft. Yes 0
56 o Other: DIN 50049 3.1b
57
Nob: this QQet.lmenl. has not be\ln p!.lbllsMd 80d is the &0Ie: ~ of the Fluor Daniel, and -is lent to !he borrowtr for his. c:onlldlmtial Wie only and in ccntiOeration ollhe loan of .Ibi& tJoc:umenl.1he borrower a!ilrees 10 ralum It
( , Map ed Version O. 0211003
DOC No' 17831·131·MA·E·M0068
Project No.: 574401
li~~ item No.: 131-G·2101NB
nU~al~m~ CENTRIFUGAL PUMP Revision:

By:
o·
KE Chk'd:AC
Date: 24-03-2004
Appr'd:RB
® Sheet 6 of 6
P.D.No.:
Inquiry No.:
Procurement No.:
ERM No.
REV
2 QA INSPECTION AND TEST (CONT'D) Remarks: 6) As per approved QA I QC plan. 0
:3 0 Casllng Repair Procedure Approval Req'd: (2.11.2.5)
4 Yes 0
5 0 Inspection Req'd For Connection Welds: (2.11.3.5.6)
6
7 0 Inspection Req'd For Castings: (4.2.1.3) Ref. KOC Spec.
8 015·WH·1003 Inspection of castings for pressure service.
9 0 Additional Inspection Req'd For: (4.2.1.3) Remarks: 7) DELETE 0
10 MPI see remark (6). 0
11 0 Alternate Acceptance Criteria (See Remarks) (4.2.2.1)
12
13 0 Hardness Test Req'd For: (4.2.3.2)
14
15 0 Welting Agent Hydrotest. (4.3.2.5)
16 I Remarks: S) All extemal surfaces of carbon steel components 0
17 0 Vendor Submit Test Procedures. (4.3.1.216.2.5) exposed to atmosphere shall be fully painted in accordance with
18 Yes specification KOC-P-001 & addendum 17831-000-HA-E-H0226. 0
19 0 Record Final Assembly Running Clearances. Yes Including outer casing. 0
20 0 Inspection Checklist. (Appendix N) Yes 0
21
22 GENERAL REMARKS
23 Remarks: 1) Prima!), seal & auxilla!), gas seal leak detection Remarks:
24 system shall be provided.
25
/' 26
i
27
\---./
28
29
30 Remarks: 2) Supply inclusions: vibration switch & temperature Remarks: 0
31 transmitter (RTD) for pump thrust bearing housing & pressure
32 switch for Auxilla!), gas seal.
33
34
35
36
37 Remarks: 3) Nameplate data to be fumished in accordance with Remarks: 0
38 015-GH·1003 paragraph 4.2.2.aq, with the exception of the units.
39 All units of measura shall be DUAL (m3/h (USGPM); m (ft); barg
40 (PSI).
41
42
43
44 Remarks: 4) Supplier shall provide 2 sets of gaskets for pump Remarks: 0
45 mounting flange.
46
47
48
49
50
51 Remarks: 5) DELETE Remarks: 0
52
53
54
55
56
57
Notic:e: Thls dOCument hu fIQl bMtJ. publi:shed and is lhO &Ole proporty ()f\t)jl Fklor Dal'lial, and i$ kttil to !hit bmmwer torN. confidential use only and in eonstoel'liSon ollhe loan of" doeumant, ~ barrow., .Ofeu 10 relUM
( !
Map d VersiOn O. Q"'12103
3. PROCESS DESCRIPTION
OVERVIEW
FIELD SERVICE
REPORT
Customer Name KUWAIT OIL COMPANY KSC CLOSED

Site Name BOOSTER STATION 131
Work Scope MAJOR INSPECTION
Technology Centrifugal Compressor - BCL
Submitted Date 31 January, 2015
Serial # C12264
Type of Intervention CS GLOBAL
Site Activity Job # 2856311
This Preliminary Field Service Report is intended to provide you with a preliminary description of the activities performed by our FSEs at site.This
Preliminary Field Service Report is not intended to provide you with recommendations or instructions on future use of your equipment. The purpose
of the preliminary recommendations and/or instructions contained in this report, if any, is to highlight potentially material issues and other
significant information for the operation of your equipment that our FSE has identified. The recommendations and/or instructions included herein
are based solely on the information available to the FSE on site as of the date hereof. Final recommendations and/or instructions on future use of
your machine and equipment, if any, will be issued in the Final Field Service Report. Such Final Field Service Report will be based on our analysis of
all other information available to GE OilGas. To the extent any recommendation and/or instruction is contained herein, you should rely on such
recommendation and/or instruction only for the interim period until you receive from us the Final Field Service Report. From that moment on you
should rely solely on the recommendation and/or instruction included in the Final Field Service Report. GE assumes no liability in connection with
customer’s failure to comply with the above.
GE Field Service Representative Customer Representative

Bisori, Mirko Sivadas
GE Oil & Gas
PRELIMINARY FIELD SERVICE REPORT
1. GENERAL INFORMATION
1.1 Customer Site Data
Site Address AHMADI BUILDING MAIN OFFICE KOC COMPLEX
Country KUWAIT
Site DUNS Number 635176134
1.2 Customer Representative Data
Customer Representative SIVADAS
Customer Contact Phone Number
Customer eMail - Required
1.3 GE Reference Contact
Project Manager Name
Field Project Engineer Name
WM/IM/FC Name Aldoseri Ahmed
Site Manager Name
Report Written by- FSE Name Bisori, Mirko
31/1/2015 STRICTLY CONFIDENTIAL (v 1.0.1) 1

GE Oil & Gas
2. MACHINE DATA
2.1 Equipment Data
Service Hours 61707
Starts Number 542
Trip Number 492
Fuel Type(s) METHANE
Driven Equipment Gas turbine
Combustion System (if any)
Type of Service/Application
2.2 Machine Status
Status at FSE Arrival On Site OUT OF SERVICE
Status at FSE Departure From Site IN OPERATION
FSE Arrival Date On Site 07 January, 2015
FSE Departure Date From Site 04 February, 2015
2.3 Outage Service Period
From 05 January, 2015
To 28 January, 2015
2.4 Unit Reference Data
Original Job Number (Manufacturing) 1101839
Cod Date (installation unit date) 16 March, 2006
GE s/n C12264
Name Plate C12264
Customer Tag # KT-2102
Related s/n
OEM 1 s/n
OEM 1 Brand
OEM 2 s/n
OEM 2 Brand
OEM 3 s/n
OEM 3 Brand

GE Oil & Gas
3. OVERALL SUMMARY
3.1 Executive Summary
Were performed a major inspection on BCL806, and after checked the completely isolation of the compressor from all kind of
energy type, the activities was started on 7th January. As for all major, the machine must be completely dismantled in order to
check and verify the integrity of all internal parts.
We started to remove pipes on NDE and I noticed that from flange XXI coming from separation channel (XXVI) flowed a big
quantity of oil as shown in the (pic.1) slightly unusual for the position. Continuing with the disassembly, we removed the turning
gear and we found on gear of it, some damaged teeth on the anti-rotation row (pic.2) probably caused by an incorrect rotation
of the rotor. Step by step have been removed trust active bearing, collar, inactive bearing and journal bearing where was found
an anti-rotation pin damaged (pic.3). On DGS, after removed separation and tertiary seal, we noticed that its face was wet of oil.
(pics.4-5). Even on the body after removed it was dirty of crude oil that had also blocked the end labyrinth (pics.6-7). From DE
side, after alignment check, we started to remove HUB that was found placed out of specification. Nothing to highlighter for
bearing tertiary and separation but as per NDE side, the DGS was wet of oil and when we removed it, was more dirty of crude
oil than the previous one, as per the end seal (pics. 8-9). Due to this issue I asked to remove the blind flange VIII, the drain of
primary vent and a lot of crude oil has leaked (pic.10). We removed the head flange on NDE side, the quill (found very dirty) and
before to remove the bundle, we discovered some pieces of temporary strainer between bundle and casing (pic.11). The bundle
was removed with difficulty, and once outside, we noticed on the bottom of casing a lot of crude oil that suggests the failure or
incorrect use of drains (pic.12). Bundle was split, rotor removed and while the channel was clean, inside the diaphragm were a lot
of crude oil (pics. 13-14-15). The cleaning of all diaphragms was performed with hydro cleaner as the rotor, and the result was
acceptable but not perfect. In the same time after customer's request, the O-ring on head flange DE side have been replaced but
not in a properly way as the abradable seal, found in very bad condition (pic.16). After an acceptable cleaning of all internal and
external parts, we started with the reassembly of the machine. Internal seals was changed, rotor centering in the bundle, closed
and push back inside the casing. Nothing to highlight during reassembly, all parts replaced are mentioned in the material list. All
instrumentation was checked by electrician as the calibration of the probes.Pipes around the compressor that during the
disassembly was blown with air and plugged, have been installed.Support of firegas has been modified to be remove easy when
necessary (pics. 17-18-19).
Pic.1 Oil from vent pressure intake for connect XXVI Pic. 2 Turning gear clutch

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Pic. 3 Anti-rotation pin on JB NDE side damaged. Pic. 4 Oil contamination on DGS NDE
Pic. 5 DGS NDE Pic. 6 DGS NDE

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Pic. 7 End labirynt NDE Pic. 8 DGS DE
Pic. 9 End labirynt Pic.10 Crude oil coming from drain of connection XXIII

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Pic. 11 Pieces of strainer. Pic. 12 Crude oil on casing botton.
Pic. 13 Contamination on diaphragm Pic. 14 Inside diaphragm

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Pic. 15 Cleaning of diaphragm Pic. 16 Abradable seal
Pic. 17 Support FG Pic. 18

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Pic. 19 Pic. 20 Rust between shear rings and casing.
Pic. 21 Rust between shear rings and casing.
3.2 Conclusion & Recommendation

As per the MCL installed before this machine that was found very dirty of crude oil, I suggest to check the proper functioning of
scrubber before to start up of the machine.
The temporary strainer found installed after long time and damaged in various parts, was without mesh that certainly now is
located somewhere in the process. It would be advisable to track it and remove it before it can cause serious damage to the
system. NB. that from our procedure SIC00007 the temporary strainer have to be removed after pipes cleaned.
Before of every start of the compressors, (if are stop for long time), remember to open the drain on bottom casing to remove
any liquid substance present inside the compressor.
Keep under control the pressure on balancing line, having regard to the conditions of the old seal, this had to be higher than
the suction.
Organize for the future shut down, a cleaning system more efficient in order to remove and clean better all parts.
All parts of the compressor not painting like head flanges with shear rings, legs, plates, pin a bolt around the compressor must
be keep preserved to help the maintenance and the duration of parts to avoid like this time, to find parts nailed on the casing
due to the rust (pics.21-22).

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4. ACTIVITY REPORT
5, JANUARY 2015
MOBILIZATION Progress: 0%
Travel from Florence to Kuwait.
6, JANUARY 2015
MOBILIZATION Progress: 0%
Preparing documentation for work at site.
7, JANUARY 2015
Disassembly Activities Progress: 0%
We started to disassembly pipes on NDE side in order to remove the Head flange.
Coupling guard removed.
Expansion joint removed.
Coupling and Hub removed.
8, JANUARY 2015
The pipes removed have been clean and plugged.

After the installation of locking shaft device, the displacement has been checked.
Alignment checked.
Turning gear removed.
Start to disconnect the instruments on NDE side.

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9, JANUARY 2015
All thermo elements have been disconnected.
Trust bearing (active and no active) removed.
Trust collar removed.

Journal bearing removed.
Separation flange e tertiary seal removed.
10, JANUARY 2015

DGS on NDE side has been removed.

End labyrinth removed.
DE side, Journal bearing removed.
Separation flange and tertiary seal removed.
11, JANUARY 2015

Disassambly activities Progress: 0%
DGS removed on DE side.
End labyrinth removed.

Shear rings removed.
Special tools was find in the customer field. We organized the transportation to the site.
NB. The Head flange cannot be removed because the special tools touch with the inlet process pipe.

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12, JANUARY 2015

The scaffold has been done in order to remove the process pipe.
All nuts on inlet process pipe are loose.
13, JANUARY 2015

Inlet process pipe has been removed

All special tools installed on the casing in order to remove the bundle.
Hydraulic equipment assembly and ready to use.
14, JANUARY 2015

Nothing Selected Progress: 0%
Bundle has been removed and split.

Rotor removed from bundle and place on support.
15, JANUARY 2015

Rotor moved to the designated area for cleaning.

All labyrinth seals from upper and bottom casing have been removed.
Diafragm on upper casing removed.

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16, JANUARY 2015

Nothing Selected Progress: 0%
All diaphragms from the bottom casing have been removed.

Start with cleaning activities on: diaphragms, inside the casing and bundle.
NB. The strainer on inlet pipe has been removed and found damaged.
We received a request from customer, they want to change the O-rings on the head flange DE side and for
that, I suggested to remove the outlet pipe and rotate 180° the compressor. This activity can also help us to work
in totally safety and in quality, specially for cleaning the diaphragm inside and for remove the heavy abradable
seal that must be replaced.
17, JANUARY 2015

Re-assambly activities Progress: 0%
The diaphragm was cleaned by hot water jet and are installed back on the half upper bundle.
Labyrinth seals installed and lock by screws.
18, JANUARY 2015

The upper half bundle has been rotated and ready for clearance check.
Bottom half bundle has been complete with diaphragms.
All seals installed.
The rotor has been carefully cleaned and ready to be installed on bundle.
On the rotor were performed dimensional measurements with the seals.

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19, JANUARY 2015

Rotor has been installed in the bottom half bundle with the shim to simulate the bearing.
Rotor has been moved inside the bundle to adjust the centering.
Lead wire has been installed on rotor, spacer and impeller to check the clearance between it and labyrinth.
Bundle closed and re-open to remove the lead wire and definitely close after installed the new O-ring on
centerline.
20, JANUARY 2015

Bundle has been torque and ready for re-install on bundle.

Special tool for insert the bundle has been installed.
We started to remove the Head flange on DE side.
NB. After discussion with the customer they did not agree with my suggestion and pushed the team to change
it without rotate the compressor. This will certainly have an impact on the quality of work because, for lack of
space, inappropriate tools for lifting (can not be lifted perfectly in vertical position), the impossibility of clean the
flange, casing and the diaphragm internally, the replaced of internal seal very difficult for safety, cannot be
performed a properly good job.
21, JANUARY 2015

Shear rings removed on DE head flange.

Lifting tools (chain block 10T) have been prepared for flange lifting.
Special "C" tool has been removed on NDE flange and installed on DE.

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22, JANUARY 2015

Head flange on DE side has been removed.

O-rings changed.
Head flange reinstalled.

Shear rings installed.
23, JANUARY 2015

Abradable seal installed and torque.

Final cleaning inside bundle has been done as per drain.
Bundle has been pulled inside the casing with new O-ring.
All special tools have been removed from the bundle and casing.
Head flange NDE side has been installed after replace one damages pin for anti-rotation of bearing (found
broken during the reassembly).
24, JANUARY 2015

Measurement of DGS spacer have been taken, and it was sent to the workshop for machinery.
End labyrint seal NDE installed.
DGS installed.
Tertiary and separation seal installed.

Thickness ring installed and tight.

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New JB on NDE side has been installed.
25, JANUARY 2015

Trust bearing inactive side installed with new pads and thermo-elements tested by electrician.
Trust collar installed and lock with new safety plate.
After removed 0.1mm from active side, the trust was installed.
Rotor float has been checked.
Measurement of DGS spacer have been taken on DE, and it was sent to the workshop for machinery.
26, JANUARY 2015

We started to install lube oil pipes on NDE side.

DGS on DE installed.
Tertiary and separation seal installed.
Thickness ring installed and tight.

New JB installed with new thermo-elements checked by electrician.
27, JANUARY 2015

Total float has been checked in order to calibrate the axial brobe by the electrician team.
Labyrint on turning gear shaft changed.

All pipes on NDE (airoil) installed.

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28, JANUARY 2015

Turning gear installed with the support.

The activities will be stopped in order to wait the rotor installation on turbine to verify the alignment.
Started to store all material used during our activities inside a wood box after preserved with grease.
29, JANUARY 2015

Scaffolding has been removed and hand rail replace.

Housekeeping ongoing.
30, JANUARY 2015

Housekeeping Progress: 0%
Material has been inventoried and placed in a common box. Fire and gas support has been modified.
31, JANUARY 2015

Housekeeping Progress: 0%
Materials have been moved on the specified container to keep preserved all parts.

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ATTACHMENTS
MAINTENANCE FORM
MAINTENANCE FORM Mest Finali.pdf

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Mest Finali
Total Number of Pages: 13
Related to:
Maintenance Form
31/1/2015 STRICTLY CONFIDENTIAL (v 1.0.1)

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BCL-PCL COMPRESSOR TYPE
FIELD INSPECTION REPORT
CC-B/PCL-TYPE-0010
Report # : 02/15
CUSTOMER: KOC KUWAIT OIL COMPANY
PLANT: KOC BS 131
LOCATION: NORTH KUWAIT
CUSTOMER ORDER:
GE OIL&GAS JOB #: 2856311
COMPRESSOR TYPE: BCL 806
UNIT TAG N. 1101839
SERIAL N. C12264
CUSTOMER WORK PERMIT N.
HOURS AFTER LAST INSPECTION:
Reports for alignment and coupling installation will be made

OTHER ADDITIONAL DATA REPORT
separately for all machine.
TYPE OF
INTERVENTION:
ON CALL TURN KEY GLOBAL X LUMP SUM OTHER
EVENT TYPE: EMERGENCY: SCHEDULED: X

NUMBER OF MINOR
OVERHAUL TYPE: Minor INSPECTIONS *
(*) indicate the number of Minor have been performed
Major X
OPERATION PERFORMED V
OVERHAUL INSPECTION OVERHAUL INSPECTION

START DATE: 07 / 01 / 2015 FINISH DATE: 4 / 2 / 2015
START TIME [24h] : 6 : 00 COMPLETION TIME [24h] : 20 : 00
TOTAL INSPECTION WORK DAYS : 29 N. 1 SHIFT OF 13 HOURS
ON SITE NP'S REPRESENTATIVE(s)/TITLE(s) CUSTOMER'S REPRESENTATIVE(s)/TITLE(s)
Mirko Bisori
Name(s): Name(s):
LFSE
Sign(s): Sign(s):
Issued by: MIRKO BISORI Rev. 0 Date: 04/02/2015 Page 1 out of 13

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MAINTENANCE FORMS INDEX
CC-B/PCL-TYPE-0020
Customer: Plant: UNIT TAG N.: Report #:
INSPECTION
START DATE: / / START TIME[24h]: : FSE's Name: Mirko Bisori
INSPECTION
FINISH DATE: / / FINISH TIME[24h]: : FSE's Name:
OPERATIONS TO PERFORM: X OPERATIONS PERFORMED V
Minor Major
CC-BCL/PCL-FIELD INSPECTION REPORT CC-B/PCL-TYPE-0010 X X V
MAINTENANCE FORMS INDEX CC-B/PCL-TYPE-0020 X X V
GENERAL INFORMATION CC-B/PCL-TYPE-0021 X X
RUNNING DATA RECORD CC-B/PCL-TYPE-7030 X X
MEASURAMENT TOOLS CC-B/PCL-TYPE-1015 X X
DIAL GAUGE ALIGNMENT CC-B/PCL-TYPE-1010 X X
LASER ALIGNMENT CC-B/PCL-TYPE-1020 X X
COUPLING CC-B/PCL-TYPE-5020 X X
JOURNAL BEARING NDE SIDE CC-B/PCL-TYPE-2038 X X V
JOURNAL BEARING DE SIDE CC-B/PCL-TYPE-2039 X X V
THRUST BEARING CC-B/PCL-TYPE-2040 X X V
OIL SEAL NDE CC-B/PCL-TYPE-5030 X X
OIL SEAL DE CC-B/PCL-TYPE-5031 X X
LABYRINTHS CC-B/PCL-TYPE-5034 X X V
END SHAFT LABYRINTH CC-B/PCL-TYPE-5035 X X V
NDE SIDE - DGS MECHANICAL SEAL CC-B/PCL-TYPE-5038 X X V
DE SIDE - DGS MECHANICAL SEAL CC-B/PCL-TYPE-5039 X X V
SUMMARY CLEARANCE NDE SIDE CC-B/PCL-TYPE-5040 X X V
SUMMARY CLEARANCE DE SIDE CC-B/PCL-TYPE-5041 X X V
DGS MECAHNICAL SEAL ASSEMBLY CC-B/PCL-TYPE-5042 X X
DIAPHRAGMS BUNDLE CONDITION CC-B/PCL-TYPE-5050 X
DIAPHRAGMS BUNDLE ASSEMBLY CC-B/PCL-TYPE-5051 X
DIAPHRAGMS & DIFFUSERS CONDITION CC-B/PCL-TYPE-5052 X

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MAINTENANCE FORMS INDEX
CC-B/PCL-TYPE-0020
Serial N°: NP Job Number: Inspection Job Number:
N.Documents Attached : N.Photo Enclosed: Notes:
Inspection Date: FSE's Name: FSE's Name:
OPERATIONS TO PERFORM: X OPERATIONS PERFORMED V
Minor Major
OIL SEPARATION CC-B/PCL-TYPE-5060 X X
CASING CC-B/PCL-TYPE-5070 X
HEAD FLANGE CC-B/PCL-TYPE-5080 X V
IGV DRIVE ASSEMBLY CC-B/PCL-TYPE-5090 X
ROTOR CC-B/PCL-TYPE-6000 X
ROTOR COMPONENT CC-B/PCL-TYPE-6001 X
ROTOR GEOMETRICAL DIMENSIONAL CHECK CC-B/PCL-TYPE-6002 X
REPLACED PART LIST PARTS_IN_OUT X X

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JOURNAL BEARING - NDE SIDE CC-B/PCL-TYPE-2038
INSPECTION
START DATE: / / START TIME[24h]: : FSE's Name:
INSPECTION
Serial N. C12264 CC Type BCL 806 Job 1101839
DIR. OF ROTATION cw X ccw 2025 Journal Bearing - Tilting pads Type
General Assembly Dwg. SOS 94072
5 1 ROTOR DWG SSO 1871714
Bearing DWG SSO 1170675

4 2
3 Clearance spec. DWG SOS 0350998

S
DWG
MIN MAX
0,26 0,329
BEFORE OVERHAUL
Average of 5 measurement
PAD THICKNESS " S" = mm
1 30,17 1 30,16 1 30,18 1 30,17 1 30,17 S= 30,17
BEARING SERIAL N. Internal Bearing house Diameter 260,02
Shaft Diameter 200

ROTOR SERIAL N.
Bearing Clearance 0,32
TOLERANCE BETWEEN BEARING AND CAP Clearance mm. Interference mm
AFTER OVERHAUL
1 30,18 1 30,16 1 30,15 1 30,17 1 30,14 S= 30,16
BEARING SERIAL N. SSQ 4851863 Internal Bearing house Diameter 260,02
Shaft Diameter 200

ROTOR SERIAL N. 307088 M
ADJUSTEMENT BEARING CLEARANCE Reason

Restored Changed Excessive Insufficient
ITEM REPLACED : 7410 -Tilting pads x 5295 - Tilting holder X 4215 - Oil gard ring X 8205 - Screws x
8 4 5 7 8 4 5 7
2 2 2 4 2 2 2 4
0 1 9 1 0 1 9 1
Event 5 5 5 0 Event 5 5 5 0
0025 Overheating 2650 Melting
0150 Loosening 3550 Hammerimg
1050 Elett. Erosion 3650 Micromelting
1250 Cracking 4200 Pitting
1600 W.M. Disjunct 4810 Costum. request
1850 Erosion 4850 Scoring
2000 Plastics def. 6000 Deposits
2600 Fretting 6700 Wear
NOTES
COMMENTS For the presence of entire new bearing, has been completely replaced.

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JOURNAL BEARING - DE SIDE CC-B/PCL-TYPE-2039
INSPECTION
INSPECTION
Serial N. CC Type Job
DIR. OF ROTATION cw ccw 2025 Journal Bearing - Tilting pads Type
General Assembly Dwg. SOS 94072
5 1 ROTOR DWG SSO 1871714
Bearing DWG SSO 1170540

4 2
3 Clearance spec. DWG SOS 0350998

S
DWG
MIN MAX
0,26 0,329
BEFORE OVERHAUL
1 30,18 1 30,16 1 30,17 1 30,17 1 30,17 S= 30,17
Shaft Diameter 200

ROTOR SERIAL N.
AFTER OVERHAUL
1 30,16 1 30,15 1 30,16 1 30,17 1 30,15 S= 30,158
Shaft Diameter 109,96

ROTOR SERIAL N.
ADJUSTEMENT BEARING CLEARANCE Reason

Restored Changed Excessive Insufficient
ITEM REPLACED : 7410 -Tilting pads X 5295 - Tilting holder X 4215 - Oil gard ring X 8205 - Screws X
8 4 5 7 8 4 5 7
2 2 2 4 2 2 2 4
0 1 9 1 0 1 9 1
Event 5 5 5 0 Event 5 5 5 0
0025 Overheating 2650 Melting
0150 Loosening 3550 Hammerimg
1050 Elett. Erosion 3650 Micromelting
1250 Cracking 4200 Pitting
1600 W.M. Disjunct 4810 Costum. request
1850 Erosion 4850 Scoring
2000 Plastics def. 6000 Deposits
2600 Fretting 6700 Wear
NOTES
COMMENTS For the presence of entire new bearing, has been completely replaced.

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THRUST BEARING CC-B/PCL-TYPE-2040
INSPECTION
INSPECTION
Bearing type Kingsbury x Glacier Siemens Double collar
Outer Part
Active x Inner part
Active
Inactive Inactive x
ACTIVE SIDE INACTIVE

6 1 F A SIDE
Labyrinth
2 B
5 E
4 3
D C
Rotor serial N. 307088 A General Assembly Dwg. SOS 94072 Clearance Dwg SOS 0350998
ROTOR AXIAL DISPLACEMENT WITHOUT THRUST BRG & DGS
THRUST COLLAR SIDE before overahul OPP. THRUST COLLAR SIDE Thrust bearing Clearance DWG
DWG (Min) DWG (Min)
WITH SEALS MIN MAX
Measured Measured
0,35 0,45
ROTOR AXIAL DISPLACEMENT WITHOUT THRUST BRG & DGS
G= Labyrinth Clearance DWG
THRUST COLLAR SIDE after overahul OPP. THRUST COLLAR SIDE
DWG (Min) 3 4 DWG (Min) MIN MAX

WITH SEALS
Measured 3,4 4,5 Measured 0,6 0,7
Measurement and Clearance

Before overhaul After overhaul
Inner shim S2 mm 49,67 49,67
Outer shim S1 mm 8,05 7,95
Axial Clearance H mm 0,32
N.D.E. Side Reference between shaft end and support mm 396,12
D.E. Side Reference between shaft end and support mm 274
O.C.R. Diameter (Oil dicharge Orifice) mm
Item replaced
7410 Pads x 5295 Holder x 3622 Leveling plate x 8225 Screw
3 5 8 7
6 2 2 4
2 9 0 1
EVENTO / Event
1 2 3 4 5 6 7 8 9 A B C D E F G H I 2 5 5 0
0025 Overheating
0150 Loosening
1050 Elett. Erosion
1600 W.M. Disjunct
1850 Erosion
2000 Plastics def.
2650 Melting
3550 Hammerimg
3650 Micromelting
4200 Pitting
4810 Costum. request
4850 Scoring
5050 Breaking
6000 Deposits
6700 Wear
NOTES WERE REPLACED NEW PADS IN THE OLD CASING
COMMENTS

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LABYRINTHS CC-B/PCL-TYPE-5034
INSPECTION
INSPECTION
NOTE: AVERAGE CLEARANCE LABYRINTHS CHECK WHEN REQUIRED ON GENERAL ASSEMBLY DWG
ROTOR Serial N.
307088 A
GENERAL ASSEMBLY DWG

SSO 1871714
CLEARANCE SPEC. DWG

SOS 0350998
Balancing Drum
Labyrinth
POSITION 1 2 3 4 5 6 7 8 9
X min 1,05 1,00 1,00 0,95 0,90 0,65
Right
Y max 1,20 1,15 1,15 1,10 1,05 0,80
X min 1,05 1,00 1,00 0,95 0,90 0,65
Left
DRAW
Y max 1,20 1,15 1,15 1,10 1,05 0,80

X min 1,05 1,00 1,00 0,95 0,90 0,65
Top
Y max 1,20 1,15 1,15 1,10 1,05 0,80
X min 1,05 1,00 1,00 0,95 0,90 0,65
Bottom
Y max 1,20 1,15 1,15 1,10 1,05 0,80
*AA*
Right 1,00 0,90 1,10 0,95 0,80 0,55

Left 1,00 0,90 0,95 1,00 1,00 0,70
MEASURED
Top 1,05 1,15 1,00 0,90 0,90 0,70

Bottom 1,10 1,00 1,00 1,10 1,00 0,65
Avg from min(x) to
max(y)
Min value not less than
min(x)
X min 0,55 0,55 0,55 0,50 0,50
Right
Y max 0,65 0,65 0,65 0,60 0,60
X min 0,55 0,55 0,55 0,50 0,50
Left
DRAW
Y max 0,65 0,65 0,65 0,60 0,60

X min 0,55 0,55 0,55 0,50 0,50
Top
Y max 0,65 0,65 0,65 0,60 0,60
X min 0,55 0,55 0,55 0,50 0,50
Bottom
Y max 0,65 0,65 0,65 0,60 0,60
*AB*
Right 0,50 0,50 0,50 0,40 0,45

Left 0,50 0,60 0,65 0,55 0,50
MEASURED
Top 0,60 0,55 0,60 0,55 0,55

Bottom 0,55 0,65 0,65 0,60 0,50
Avg from min(x) to
max(y)
Min value not less than
min(x)
*AF* = DIAPHRAGMS DELIVERY GAP
POSITION 1 2 3 4 5 6 7 8 9 10
DRAW
RILEVATO
ROTOR AXIAL DISPLACEMENT
NDE SIDE DE SIDE

DWG (min) DWG (min)
WITHOUT SEALS
ACTUAL ACTUAL
DWG (min) DWG (min)

WITH SEALS
ACTUAL ACTUAL
NOTES
COMMENTS

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END SHAFT LABYRINTH CC-B/PCL-TYPE-5035
INSPECTION
INSPECTION
BALANCING DRUM LABYRINTH

3
THRUST COLLAR SIDE OPP.THRUST COLLAR SIDE
END SHAFT LABYRINTH END SHAFT LABYRINTH
1 A B 2
GENERAL ASSEMBLY DWG SOS 94072 CLEARANCE DWG SOS 0350998 ROTOR SERIAL N. 307088 A
MEASUREMENT
DWG MEASURED DWG MEASURED
Min Max (Diametral clearance) Min (Axial Clearance)
1 0,6 0,7 0,6 A 4,2 4
2 0,6 0,7 0,63 B 4,2 3,7
3 NA NA
ROTOR AXIAL DISPLACEMENT
THRUST COLLAR SIDE THRUST COLLAR OPP. SIDE

DWG DWG
WITHOUT SEALS
ACTUAL ACTUAL
DWG DWG
WITH SEALS
ACTUAL ACTUAL
NOTES THE VALUES OF ROTOR DISPLACEMENT ARE ALREADY REPORTED
COMMENTS

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NDE SIDE - DGS MECHANICAL SEAL CC-B/PCL-TYPE-5038
INSPECTION
INSPECTION
ROTOR SERIAL N. 307088 A ROTOR DWG SSO 1871714
CALCULATION OF RING THICKNESS BEHIND DGS CARTRIDGE
DGS WITHOUT EXTERNAL SHEAR RING (BURGMANN TYPE)
DGS SERIAL N.
DGS DRAWING
RING (S)
DGS WITH EXTERNAL SHEAR RING X
SHEAR RING
DGS SERIAL N.
0309-0483
DGS DRAWING
SOS 9980683
RING (S)
MEASUREMENT
X I S = (X-I)
MEASURED 299,4 272 7,7
NOTES THE PICTURE IS FOR DEMONSTRATION PURPOSES ONLY
COMMENTS

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DE SIDE - DGS MECHANICAL SEAL CC-B/PCL-TYPE-5039
INSPECTION
INSPECTION
ROTOR SERIAL N. 307088 A ROTOR DWG SSO 1871714
CALCULATION OF RING THICKNESS BEHIND DGS CARTRIDGE
DGS WITHOUT EXTERNAL SHEAR RING (BURGMANN TYPE)
DGS SERIAL N.
DGS DRAWING
RING (S)
DGS WITH EXTERNAL SHEAR RING X
SHEAR RING
DGS SERIAL N.
0309-0484
DGS DRAWING
SOS 9980684
RING (S)
MEASUREMENT
X I S = (X-I)
MEASURED 299,4 272 7,4
NOTES THE PICTURE IS FOR DEMONSTRATION PURPOSES ONLY
COMMENTS

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SUMMARY CLEARANCE
NDE SIDE
CC-B/PCL-TYPE-5040
INSPECTION
INSPECTION
NDE side HEAD

FLANGE
QR
X1
D I L
B C E F G
H
DWG ROTOR SERIAL N. 307088 A

POS.
ITEM DESCRIPTION MEASURED

Min Max
END LABYRINTH A 0,6 0,7 0,6 GEN.ASSEMBLY DWG. SOS 94072
THRUST BEARING B 0,35 0,45 0,32
CLEARANCE
JOURNAL BEARING C 0,26 0,329 0,3 SPECIFICATION N.
SOS 0350998
TERTIARY SEAL D 0,8 0,9 0,8
TERTIARY SEAL E 0,8 0,9 0,8
LP SEAL RING F NA
OIL SEALS
LP SEAL RING G NA
LP SEAL RING H NA
HP SEAL RING I NA
EXTERNAL THRUST
SHAFT DIAMETE(ext) F 249,99 BEARING SHIM
7,95
DGS MECH.SEALS
DGS CARTRIDGE (int.) F1 250,02

DIAMETERS
INTERNAL THRUST
SHAFT DIAMETE(ext) G 251,98 BEARING SHIM
49,67
DGS CARTRIDGE (int.) G1 252,02
SHAFT DIAMETE(ext) H DGS SHIM 7,7
DGS CARTRIDGE (int.) H1
END SHAFT LABYRINTH L 0,7 0,6

AXIAL CLEARANCE BETWEEN SHAFT & LABYRINTH X1 Min 4,2 4
ReferenceMeasurment between End shaft - End casing QR 396,12
FINAL ROTOR AXIAL DISPLACEMENT
NDE SIDE DE SIDE
DWG 3 4 DWG
MEAS 3,4 4,5 MEAS
NOTES
COMMENTS

g GE Oil & Gas
Global Services
SUMMARY CLEARANCE
DE SIDE
CC-B/PCL-TYPE-5041
INSPECTION
INSPECTION
DE side HEAD QR
FLANGE
X2
M
COUPLING
A ROTOR
D C
L I HG F E
DWG ROTOR SERIAL N. 307088 A

POS.
ITEM DESCRIPTION MEASURED

Min Max
END LABYRINTH A 0,6 0,7 0,63 GEN.ASSEMBLY DWG. SOS 94072
THRUST BEARING B
CLEARANCE
JOURNAL BEARING C 0,26 0,329 0,306 SPECIFICATION N.
SOS 0350998
TERTIARY SEAL D 0,8 0,9 0,8
TERTIARY SEAL E 0,8 0,9 0,8
LP SEAL RING F
OIL SEALS
LP SEAL RING G
LP SEAL RING H
LP SEAL RING I
SHAFT DIAMETE(ext) F 250 DGS SHIM tickness 7,4

DGS MECH.SEALS
DGS CARTRIDGE (int.) F1 250,02

DIAMETERS
SHAFT DIAMETE(ext) G 251,99

DGS CARTRIDGE (int.) G1 252,02
SHAFT DIAMETE(ext) H
DGS CARTRIDGE (int.) H1
AXIAL CLEARANCE BETWEEN SHAFT & LABYRINTH X2 Min 4,2

DWG MEASURED
Min Max DX * SX* TOP BOTTOM
END SHAFT LABYRINTH L 0,6 0,7 0,63

BALANCING DRUM LABYRINTH M 0,45 0,55 0,43
ReferenceMeasurment between End shaft - End casing QR
NOTES For end shaft and balancing drum, the values on DX* are measured
COMMENTS

g GE Oil & Gas
Global Services
HEAD FLANGE CC-B/PCL-TYPE-5080
INSPECTION
INSPECTION
1050 BARREL BCL x 2BCL PCL BCL-c/d
GENERAL ASSEMBLY
DWG
SOS 94072
NDE side HEAD FLANGE

SERIAL N.
NDE side HEAD FLANGE
DWG
SSO 1453770
DE side HEAD FLANGE

SERIAL N.
DE side HEAD FLANGE
DWG
SSO 1453771
INDICATE ON THE DRAWING THE DAMAGED AREA/POSITION
Corrosion Erosion Damage Deformation Scratched Other
NDE DE NDE DE NDE DE NDE DE NDE DE NDE DE

Internal Diameters
O'ring Seat-Groove X X
Shear ring Seat-Groove
Item replaced
2440 Non drive end side 2435 Drive end side
Viton X Viton X
4100 O-Ring Silicon 4101 O-Ring Silicon
Teflon Teflon
8205 Nut 8205 Nut

3120 Gasket 3120 Gasket
0230 Back-up Ring 0230 Back-up Ring
2 4 8 3 0 2 4 8 3 0
Event 7 1 2 1 2 7 1 2 1 2
2 0 0 2 3 2 0 0 2 3
2 0 5 0 0 2 0 5 0 0
1100 Corrosione
1250 Cracking
1300 Damage
1450 Deformation
1850 Erosion
2000 Plastics def.
2630 Extrusion
2700 Seizure
4000 Leak
4010 Hardering
5050 Breaking
6000 Deposits
NOTES
COMMENTS
Issued by: MIRKO BISORI Rev. 0 Date: 04/02/2015 Page 13 Out of 13

Component Code Out Code In Serial Number Out Serial Number In Drawing Quantity
QUILL SWR9606009 SWR9606009 SOS94072 1
O-RING NA KHE037603501 SOS94072 1
O-RING NA KHE041203501 SOS94072 1
SEAL RING NA RAO11500 SOS94072 4
O-RING NA KHE582605308 SOS94072 2
PIN 30X190 NA FPG30190 SOS94072 4
NUT NA FFF060240450 SOS94072 4
WASHER DI.25 NA FNC34250 SOS94072 4
SAFETY PLATE NA SSP76303 SSO1871714 1
LOCKING NUT SWP57578 SWP57578 SSO1871714 1
THICKNESS RING SWR4256643 SWR4256643 SSO1871714 2
O-RING NA KHE221803501 SSO1871714 2
SCREW NA RGQ13045 SSO1871714 1
LABYRINTH SEAL
RING SWS5748412 SWS5748412 SOS94072 1
LABYRINTH SEAL
RING SWS5748312 SWS5748312 SOS94072 1
LABYRINTH SEAL
RING SWS5748212 SWS5748212 SOS94072 1
LABYRINTH SEAL
RING SWS5748112 SWS5748112 SOS94072 1
LABYRINTH SEAL
RING SWS5748012 SWS5748012 SOS94072 1
LABYRINTH SEAL
RING SWS5747906 SWS5747906 SOS94072 1
LABYRINTH SEAL
RING SWS57489 SWS57489 SOS94072 1
LABYRINTH SEAL
RING SWS57490 SWS57490 SOS94072 1
LABYRINTH SEAL
RING SWS57491 SWS57491 SOS94072 1
LABYRINTH SEAL
RING SWS57492 SWS57492 SOS94072 1
LABYRINTH SEAL
RING SWS57493 SWS57493 SOS94072 1
LABYRINTH SEAL
RING SWS4085300 SWS4085300 SOS94072 2
LABYRINTH SEAL
RING SWR57497 SWR57497 SOS94072 1
LABYRINTH SEAL
RING SWS57807 SWS57807 SOS94072 2
LABYRINTH SEAL
RING SWS57806 SWS57806 SOS94072 2
LABYRINTH SEAL
RING SSS6290600 SSS6290600 SOS94072 1
LABYRINTH SEAL
RING KHE291603501 KHE291603501 SOS94072 4
GAS SEAL SET
THRUST SIDE RTO9421552 1000-1183 CW 0309-0483 CW SOS94072 1
GAS SEAL SET OPP.

THRUST SIDE RTO9421553 1008-3673 CCW 0309-0484 CCW SOS94072 1
JOURNAL BEARING
TS SSO1170675 SSO1170675 SOS94072 1
JOURNAL BEARING
OTS SSO1170540 SSO1170540 SOS94072 1
THRUST BEARING
PAD ACTIVE NA RCQ3611794 SSO1655895 3
THRUST BEARING
PAD INACTIVE NA RCQ3611795 SSO1655895 3
THRUST BEARING
COMMON PAD NA RCQ3609902 SSO1655895 6
GASKET NA RAZ16070 SOS94072 1
O-RING NA KHE405203501 SWO0452222 4
O-RING OR41300-DI
329,80X3,53 NA KHE329803501 SWO0452222 4
O-RING_DI
417,96X6,99 NA KHE417906901 SSO1170540 1
O-RING_DI
417,96X6,99 NA KHE417906901 SSO1170540 1
GASKET D 7 NA MAV200132 SOS94072 20MT
FIELD SERVICE REPORT
CUSTOMER NAME KUWAIT OIL COMPANY KSC

SITE NAME BOOSTER STATION 131
WORK SCOPE Forced Unplanned
TECHNOLOGY CENTRIFUGAL COMPRESSOR – BCL 806
SUBMITTED DATE 10 MARCH 2017
SERIAL # C12264
TYPE OF INTERVENTION DGS replacement and diagnostic
SITE ACTIVITY JOB # 2856311
GE REPRESENTATIVE Faccendi Sergio
CUSTOMER RAPRESENTATIVE YAQOUB AL - KHALAF
GE CSA RAPRESENTATIVE THOBIAS TONY
EXECUTIVE SUMMARY
Arrive on the site Friday 10-03-2017, and I found the unit 2 BCL 806, complete
clean, and the borescope inspections to DGS line already done, all component
NDE side, included DGS, complete assembled and tested, on the NDE side the
operator change, tertiary seal labyrinth, during measurement, old labyrinth
clearance is 0,88mm, new one 0,82 mm, 2° labyrinth 0,88mm, new 0,82mm, axial
bump test check, found 0,30mm, change also the DGS spacer thick after check the
dastans from DGS housing to speller ring shaft, the clearance is 168,15mm , new
ring installed is 8,5mm, check and change also the internal buffer gas labyrinth,
old clearance is o,66 mm, the new is 0,63mm, the other parts journal bearing
pads, and trust bearing pads is all conformed, no need change.
During my presence, make inspection on the flange DE side, after see all is
conformed, start to prepare and assembling the DGS DE side, complete the DGS
installation, cleaning and prepare the tertiary seal DE, also on the site change the
labyrinth after measurement, old labyrinth found clerance0,84, new one 0,82,
second labyrinth 0,84, new 0,84, the DGS spacer ring thick is 6,5 mm, change the
ring after the measurement from DGS housing, to speller ring, the distance
is168,19mm, must prepare and installed the journal bearing DE, also the journal
pads is conformed, and not need change.
Complete cleaning and assembly the support cover for journal bearing, check the
DBSE and found 1434,05, old one is1434,0, prepare the hub, shims and spacer for
coupling installation after pre-streaking the distant is 848,23, complete the
coupling installation, tight the bolt 400 Nm, complete the compressor reassembly
job with, load coupling guard installation, all DGS pipe line, instrumentation
connected and calibrated, reassembled the turning gear NDE side.
OLD DGS NDE SIDE OLD DGS DE SIDE OLD DGS DE SIDE
Noted the different contaminations on the DGS photo, the NDE side have less
Contaminations, other ways the DE side have more contaminations, the different
situation is regarding the flow that come from suction, and go to discharge.
Pipe and DGS line, dismount and clean, after that make borescope inspection
Airline changed from CS to SS, the tertiary labyrinth changed DE and NDE side
DGS and tertiary seal assembling, after borescope inspection, change the space
Thick ring, and tertiary labyrinth.
Journal bearing DE assembling, and instrument setting in all compressor area
Coupling hub installed check DBSE 1 and 2, space connected, baring gear re install
CONTROLLED VALUES
DBSE - 1 OLD 848,30 mm NEW 848,23mm

DBSE – 2 OLD 1434,0 mm NEW 1434,05 mm
NDES
TERTIARY SEAL NDE -1- OLD O,88mm NEW 0,82mm
TERTIARY SEAL NDE- 2- OLD O,88mm NEW 0,82mm
AXIAL BUMP TEST 0,30mm
DGS SPACER THICK 8,5mm HOUSING FACE TO RING 168,15
DES
TERTIARY SEAL - 1- OLD 0,84mm NEW 0,82mm
TERTIARY SEAL -2- OLD 0,84mm NEW 0,84mm
INTERNAL LABYRINTH SEAL 0,66mmOLD 0,63mm NEW
DGS SPACER RING THICK 6,5 mm DGS HOUSING FACE TO RING 168,19
LOAD COUPLING TORQUE VALUE 400 Nm
CONCLUSION & RACCOMANDATION

After see all component and check the DGS, and process,
Is sure that the failure issue come from process, the process,
Have so excesses liquid condensate and about that the DGS
have frequently problems, I see that about the mechanicals,
Parts is all conformed, and not need any modifications.
Instrument problems found, the buffer gas line from fuel gas is
Complete conformed, I suggest for tracing and insolated all DGS
line, and increase the differential pressure on buffer gas line
now at site have 1 bar, but from instrument list report the data
1,5 bar, I open SR number 90286356, about that, and
engineering compartment ask for increase the pressure just 3
bar.
Engineering comment
 Liberatori, Gabriele (105705612)
2017-03-15 01:12:10
2d ago
o First Reply Preliminary, make sure that the source
of the gas to the seals is dry and without moisture.
Check that coalesce filters are working properly and
the LCV valve (5408-5409-5500-5501 as per P&ID)
open and close properly. Furthermore, given that
the Dray Gas Seal that is frequently subject to
failure is the DE side one (delivery side), this
suggests that there is a considerable influence of
process gases. Since between the DE and NDE sides
there is some pressure difference, as normal system
balancing line limit, which suggests that most
probably the DP between seal gas injection and
balance line is low. The instrument list reported 1.5
bar as set point. As per information from the site,
currently the differential measured is approximately
1 bar. For these reasons, it is strongly required to
re-increase the differential pressure at least at 1.5
bar (as required by instrument list) and depending
by the availability of gas at the source, up to 3 bar,
at the scope to minimize the risk of contamination
by process gas due to eventually criticality at the
balancing line.
First Reply Resolution Date2017-03-15 01:12:09
START UP
During start up all right not problems found all constants is conformed
Need only soon possible, adjust the pressure, and setting about the
instrument list data, see photo.
The unit BCL 806 run with load, 100% without any problems, about
the failure issue, please follow the engineering GE compartment
comment.
DGS NDE INSPECTION
During wait for startup, open for inspection the John crane dry gas seal NDE
The seal from DE not open for check because receive many contaminations,
And better send direct to John crane for have back a detailed report.
On the NDE- DGS during inspections don’t found many dirty in side, but only
Little condensate on the primary ring area, the seal has at complete clean all
Parts, and reassembly correctly, after that check the springing all is ok, for
reinstalled and running again, important, I won’t to remember that I am
authorized to inspect the DGS, bat I cannot issue contaminations report,
And I cannot issue any guarantee to the seal inspected.
Thanks to all team Best Regards.
Faccendi Sergio
Field Service Report
Dec 2016 Intervention – KOC BS-131
Subject: PH-II LP2 BCL806 Compressor DGS Primary vent flow Zero
Issue Description: The machine was last inspection done Jan 2015 and was running no issues
from last inspection, customer noticed in March 2016 the DGS primary vent flow very very low,
this issue is slowly increased and primary vent flow completely became zero. Customer had an
opportunity to check primary vent flow with GE FSE was at site opened primary vent pipes
flange joints at both ends on compressor then no flow observed from vent outlet / port and the
same time had a secondary vent flow reached alarm and after some time reached to trip,
machine was tripped N number of times on secondary vent flow HH trip. This Issue was heighted
to GE Engineering by CSA site team with the case SR#: 90258549
Following some note for each Day activities:

Day – 1
• Spoke with site engineer for gate pass Gate passes ready, entered in to plant
• Meet and Great with Customer, had meeting with customer
• DGS issues discussed and schedule also discussed
• All drain and vent pipes removed from coupling guard
• Esthetic panels removed between GT to Compressor
• NDE side all seal Gas and lube oil pipes removed,
Day – 2
• NDE & DE side instruments RTD’s, axial probes and redial probes removed
• Coupling spacer removed, half coupling hub removed with hydraulic device and applied
redial pressure at 1.9 Kg/cm2 hub came out.
• Hub to shaft face out measured 0.50 mm, hub internal and shaft external area are good
• NDE side turning gear covers removed, and turning gear taken out, NDE side turning gear
coupling taken out from the shaft, some of the pins came along with coupling and some of
the pin stay in shaft, thrust bearing labyrinth seal removed, and labyrinth found Ok
• DE side Journal bearing housing removed, suitable Guide pins/bars are not available, Journal
bearing removed, the bottom pads of journal bearing white metal partially worn and with
full of rubbing impression, some scoring line are observed, may be due to oil impurity
• DE side dummy bearing installed for Shaft rest on support.
Day – 3
• DE side tertiary seal outer closing flange removed,
• DE side tertiary seal labyrinth type outer housing removed, found heavy dust deposits in
between tertiary seal both labyrinths, it seems Tertiary seal air inlet is not good quality, this
dust is accumulated inside from the Tertiary Seal Buffer Air inlet.
• Tertiary seal sleeve locking ring taken out
• DE side tertiary seal labyrinth type inner housing removed
• Tertiary seal sleeve removed, DGS setting plate fixing screes not available,
• Screes found in ware house, and setting plates fixed on DGS
• Special tools installed for DGS removal, DGS removed.
• Dummy bearing installed at DE side, Rotor locking tool installed,
• Rotor thrust float checked found 0.35 mm, Rotor axially locked
Day – 4
• Non-Active thrust bearing removed, used M24 guide pins only available two but need four
• Thrust collar taken out with 1.4 Kg/cm2 redial pressure, for removing lock nut C - wrench is
suitable not available,
• Active thrust bearing removed, used long guide pins M36 threads for supporting and sliding
• NDE side Journal bearing housing removed, Journal bearing removed.
• NDE side outer closing flange of tertiary seal removed,
• Tertiary seal outer part with labyrinth type housing removed
• Tertiary seal sleeve lock nut removed and sleeve taken out,
• Tertiary seal Inner part with labyrinth type housing removed
• DGS setting plate screws another set not available, same screws removed from DE side DGS
and used for NDE side for setting plate fixing.
• Special tools installed on DGS, DGS removed. DGS was very hard to remove, special tool
(Bell) fixing screws twice broken due to non-standard screw given by customer. Finally, I
insisted to arrange Ellan (socket head cap) screws then DGS removed.
• Inside the DGS ports some oil found and seal gas port dirty contamination found.
• All DGS system pipes and inside ports cleaning under progress.
Day – 5
• NDE side DGS ports cleaning completed,
• DGS reference dimensions measured, and spacer ring size measured, existing spacer is
under size, new spacer size given for machining.
• Buffer Air filter skid lines all cleaned found lot-off carbon deposit inside the lines, up-stream
line is made cast iron pipe, it is making carbon formation inside the line, filter cartridges
removed
Day – 6
• Main Dry Gas Seal free rotation checked after opening from sealed cover
• Axially moved for checking, setting plates fixed and special tool installed,
• NDE side Main Dry Gas Seal installed, special tools removed and setting plates removed,
• Tertiary seal sleeve free ness checked, it is very close tolerance,
• Slowly inserted sleeve but not entered fully, removed back with pullers it took much long
time, due to pullers are broken, Special tools pullers available only two sets, and some of
these are rusty, made few more sets for removal of sleeve.
• Those pullers also broken, finally removed, some line marks observed and those line marks
are cleaned very well.
Day – 7
• Tertiary seal new sleeve dimensions measured, very close clearances, so then took to work
shop far away from site for polishing inside the sleeve, after polishing with fine emry / stone
paper tolerance dimensions achieved, sleeve installed.
• Inboard tertiary seal with housing labyrinth type installed.
• Locking rings new are not available, old locking rings are slightly scratched inside the free
dimension, customer could have purchased new set of locking rings along with new tertiary
seal sleeves, old locking nuts again took to work shop cleaning the free dimensions and then
NDE side locking ring installed.
• Out board tertiary seal with housing labyrinth type installed, segment ring & outer closing
flange fixed.
• NDE side Journal bearing installed. Inboard thrust bearing installed. Thrust collar fixed with
hydraulic device, now collar is under hydraulic pressure.
Day – 8
• Thrust collar special tools taken out, collar lock nut installed and locked with locking washer,
• Non-Active thrust bearing installed, All RTD’s taken out.
• Axial probes fixed and setting completed as before.
• Thrust bearing end labyrinth installed, turning gear coupling assembly done.
• DE side rotor locking devise taken out and dummy journal bearing removed,
• DE side DGS reference dimensions measured and spacer ring given for machining.
• NDE side turning gear installed and guard assembly completed,
• NDE side all oil lines and seal gas lines air blowing and re-installed.
Day – 9
• DE side DGS spacer ring received from machining, final dimension is 6.50 mm thick, installed
• Main Dry Gas Seal free rotation checked after opening from sealed cover
• Axially moved for checking, setting plates fixed and special tool installed,
• DE side Main Dry Gas Seal installed, special tools removed and setting plates removed,
• Tertiary seal sleeve installed, Inboard tertiary seal with housing labyrinth type installed.
• Locking rings new are not available, DE side old locking ring installed.
• Out board tertiary seal with housing labyrinth type installed, segment ring & outer closing
flange fixed.
Day – 10
• DE side Journal bearing all pads replaced, due to scoring marks on pads and heavy rubbing
on bottom two pads only, partially white metal pealed from bottom two pads, customer
doesn’t have set of pads, so full bearing replaced.
• Bearing clearance checked and found OK within acceptable
• DE side Journal bearing installed and its housing also installed,
• RTD’s checked by instruments and found Ok, its routing done,
• Half Coupling hub installed and kept under axial pressure for 4 hrs.
Day – 11
• Half coupling special tools removed, Hub face out checked Ok,
• Coupling spacer installed with Match marks, all coupling bolts tightening done with toque
vales as per drawing (400 Nm)
• DE side all seal gas pipes reinstalled,
• Load Coupling guard assembly completed,
Day – 12
• GT panel at load coupling side closed,
• DE side compressor instruments fixing completed,
• Buffer gas filters installed and all piping completed,
• All mechanical activities completed.
• Lube oil circulation started, De-Isolation completed of process gas lines.
Day – 13
• Buffer gas lined-up, Lube oil pump started and circulated
• N2 pursing done, Unit started all parameters are healthy
• Compressor loaded all seal gas parameters are within acceptable
Summary: Arrived at site had discussion with customer on above issue, machine is under shut
down, all lube oil and seal gas piping removed both DE & NDE side Load coupling guard coupling
spacer taken out from its location, NDE side Turning gear removed and turning coupling also
removed, turning gear two latch teeth are partially damaged, but this is no issue, DE side
coupling hub taken from location by hydraulic device with radial pressure 1.9 Kg/Cm2, the
hydraulic device is not properly preserved, its working but its handling is very difficult, FSE was
recommended to replace same device in last turnaround Sept 2015 no cation from customer
side, after that Journal bearing housing and bearing removed then Tertiary seal removed, in
between tertiary seal in board & out board housing found lot off dirty of rust particles and sand
particles in tertiary seal air inlet port, DE side DGS removed dummy bearing and Rotor locking
special tool installed for locking the rotor.
Thrust bearing clearance / Float checked found 0.35 mm, non-active thrust bearing removed
and then thrust collar taken out with hydraulic device, Active thrust bearing removed nothing
found all thrust pads are in good condition, no rubbing marks or scoring found. Journal bearing
removed pads are ok but rubbing shining marks appeared on bottom pads Tertiary seal inboard
and out board housing removed in between housings found lot off sand deposited in buffer air
inlet port relevant pictures attached and then main DGS removed, in intermediate injection port
blinded bottom side oil rest found, all piping of seal gas removed all ports very well cleaned.
NDE side refurbished JC DGS installed with correct size of spacer ring placed, tertiary seal
labyrinths are in good condition so, same installed inboard and outboard along with housing
with sleeve locked the seal with locking ring, Journal bearing installed, Active thrust bearing and
thrust collar placed in position then in-active thrust bearing installed. DE side DGS installed after
ensuring the proper cleaning the DGS chamber area and with correct size of spacer ring, Tertiary
seal labyrinth type installed with inboard & outboard housing and sleeve locked with locking
ring, DE side journal bearing installed with pads housing assembled, thrust bearing float checked
found as before then half coupling fixed with special tools, coupling spacer installed all bolts
torque tightened but suitable torque wretch is not available with the customer, coupling guard
closed and all piping re-installed back.
The Buffer air is supply from turbine Axial compressor discharge line with 220 deg. C
temperature getting cooled to 25 deg. C through coolers by corban steel pipes due to
the drastic cooling down may be forming the moisture and its forming the rust this
carrying to tertiary seal even though filters are in place.
Conclusions and comments:
To the unit from externally all measure taken for such issue to the system performance,
the internal performance of DGS will be analyzed by OEM, the DGS report will be the
conclusion of the above issue.
DGS conclusion report cloud be shared with GE for further review and will be support
for next any such occurrence repeats.
Recommendation to customer:
Customer need to procure recommended special tools for smooth maintenance and
need to preserve / store properly in good condition to use full for every shut down,
Customer eventually replacing the air filters frequently once in a week or so, better to
fabricate the Air supply lines with SS it may not make any such rust.
Some spares were missing; it is need to ensure the availability for next intervention.
All finding and observations are explained in above with relevant pictures with this
customer need to take care of any crude ingress in to compressor along with the gas
and dust or foreign objects / particles in to the seal gas and buffer air system for this
customer have to ensure all auxiliaries upstream could be maintained effectively in
operation to ensure cleanliness of gas to compressors and its sealing systems.
SPECIAL TOOLS PARTIALLY DAMAGED NEED TO PURCHAGE:
Some of the essential special tools and spare parts which was needed for this time listed and
attached to this report for customer action.
SPARE PARTS: Valve block for Primary vent LP1 – 4 pcs; For LP2 – 4 pcs
And similar valve block for HP compressor also need 4 pcs so, total 12 pcs for all machines
O-Rings for Tertiary Seal Housing face;

Position# Quantity
SHORT OF SPECIAL TOOLS FOR ASSEMBLY / DIS-ASSEMBLY OF DGS
JUST NOTICED ITEMS ONLY
Variable Sector / Spanner $ 90 – 150 for Collar nut RCQ 44873 1 pc
TA’s signature_____________________________
_____________________________

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Kuwait Oil Company

BS-131 Dry Gas Seal K-2102 RCA Report

June 12, 2017

2. ROOT CAUSE ANALYSIS 12

6/12/2017 DGS RCA Report Page 2

A Booster Station is part of an oil-field facility installed to fully utilize the

6/12/2017 DGS RCA Report Page 3

1.2 Problem Definition

6/12/2017 DGS RCA Report Page 4

6/12/2017 DGS RCA Report Page 5

6/12/2017 DGS RCA Report Page 6

In this case the contamination considered to play week contributed factor if

1.3 FAILURE SIGNIFICANT

6/12/2017 DGS RCA Report Page 7

1.4 DGS failure History

BS-131 Commissioning DGS Replaced during MI DGS catastrophic DE failure

6/12/2017 DGS RCA Report Page 8

1.5 INVESTIGATION METHODS

1- Site visit & sampling for condensate & contamination.

6/12/2017 DGS RCA Report Page 9

1.6 CONTRIBUTE FACTORS

To understand the full picture, we will explain each point individually.

6/12/2017 DGS RCA Report Page 10

6/12/2017 DGS RCA Report Page 11

2.1 RCA Introduction

• Cause and effect diagram or fishbone diagram

6/12/2017 DGS RCA Report Page 12

In our RCA we used APOLLO methodology & and software (RealityCharting

6/12/2017 DGS RCA Report Page 13

6/12/2017 DGS RCA Report Page 14

At conclusions the most significant cause of RCA study can be listed as

3- Capability of filtration system

4- Assembly from manufacture

2.2 RCA Purpose

control plan to monitor the process & to insure implementation of

6/12/2017 DGS RCA Report Page 16

RCA Team Member

Member name Email Position

6/12/2017 DGS RCA Report Page 17

Root Cause (C) ID: 6

consideration scenario R Ruled-out R

Root Cause (A) ID: 15

wrong fitting installation done under

Root Cause (A) ID: 7

Root Cause (A) ID: 16

improper torque applying Caused

wrong shimming Caused

wrong o ring size Caused

Filter material Caused

filter system passing Caused

Condition ID: 17 Strong site evidence R

evidence from discoloring R

Inspection evidence R Root Cause (C) ID: 21 Meeting with JC R

using process (rich) Caused Process gas spaded

Dimster carry over Caused

Condition ID: 60 Condition ID: 67

Gas contain heavy Caused

wrong set point Caused set point has never

Condition ID: 47 Condition ID: 52

reference line choke Caused Accumulated Caused

malfunction mechanically Caused no malfunction reported

Root Cause (C) ID: 3

gas leak or passing Caused No physical leaking