History Analysis of C-201

CO2 Compressor
Page |2 SUMMARY OF C201
1971 TO 2021

Machine Information (C201 CO2 Compressor)

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1971 TO 2021

EXECUTIVE SUMMARY:
C-201:
History:
 Compressor was commissioned in 1971.
 Cracked piston C201A 1st stage was replaced with a new one and old one send to Karachi got
repaired from Metalock Company in TA 1974.
 Also in TA 1974, U-tube type heaters designed by technical department and fabricated by
Engineering Dept. were installed at 4 th stage suction of the both compressors to minimize
corrosion by vaporizing the water carry over (plate No. 5).
 Cracked lower LG was replaced & OB suction & discharge valves were replaced in Jan 1980.
 Also in Jan 1980, RS1 & RS2 of the 3rd stage and FS1, FD6, FD7 and RD5 of the 2 nd stage were
replaced after compressor (C201A) was shut down due to high 2 nd stage discharge pressure.
 Continuing in Jan 1980, 4th 1/B suction valve replaced 1st seat was found to have been damaged
by foreign material. (C201A)
 4th stage out board suction valve’s seat was found broken into pieces. It was replaced along
with the discharge valve as material from the suction valve had gone into it. Second stage valve
FS1 was also replaced. Leakage at the first stage suction bottle and at the 2 nd & 3rd intercooler
was repair welded. (C201A)
 2nd stage valves FS1 & FS 4 and 5th stage OB suction valve were replaced. (C201A)
 5th Ob discharge valve gasket and valve seat were found damaged and were replaced. IB suction
and discharge valve were also inspected and replaced. (C201A)
 The OB discharge valve of 5th stage was removed to inspect progress of the crack after which it
was re fixed. Likewise the OB suction valve was also opened to investigate cause of frequent
jack bolt tightening. Its crab was replaced. Liner was found to have loosened in the cylinder
(C201A)
 5th OB valve was replaced along with the valve cover, and set screw. The OB discharge valve
was also replaced in June 1980. (C201A)
 1st discharge drum developed a crack at the west cylinder connection twice in July 1980 & was
welded.
 Crack developed at 1st stage suction bottle in September 1980 & was welded.
 Broken frame extension to spacer bolts of the 2 nd stage cylinder were replaced in October 1980
& crack on the 1st stage suction pulsation bottle was repair welded and corroded drain line of
the 3rd Auto drainer was replaced
 Replaced 5 defective valves at the 1st stage east cylinder 4th stage OB discharge valve was also
replaced and crack at the 1st suction pulsation bottle was repair welded in December 1980.
 1st west piston assembly was knocking so replaced in December 1980.
 3rd stage piston was inspected. Some of the white metal of its rider rings was found detached. A
reconditioned piston was fitted in its place. Jan 19881
 There were seven partial stoppages of one Urea line for short duration for maintenance on
carbon dioxide compressor C201A/B. Feb 1981
 In April 1981, 1st East Piston assembly and cylinder was inspected. It was found cracked at the
inner side of the piston rod collar. Possible cause being insufficient diametrical clearance as the
piston was of original specified size and had not been machined down to revised outer dia. A
new piston and rod assembly was fitted. 4 th stage: replaced suction and discharge valve and
inter stage coolers rupture disc. 5th Stage: Replaced suction and discharge valves and piston rod
assembly, new assembly, piston rings and packing set were installed. Replaced # 7 Main bearing
as its lower shell was found damaged at its thrust face.

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1971 TO 2021
th
 In July 1981, replaced 4 stage piston and rod assembly with new packing rings as the old
assembly was leaking. Also, replaced 4th IB & OB suction valves.
 In September 1981, Fourth stage outboard suction valve was replaced. First knockout drum
crack was repair welded.
 In February 1982, Main bearings no. 4, 5 & 6 were replaced as their clearances were excessive.
The 5th stage piston rod and packing assembly was replaced along with the 4 th & 5th stage
suction & discharge valves. The 1st suction was cut open and its internals were repaired at the
cracked cross.
 In April 1982, two defective valves of 3rd stage were replaced.
 In August 1982, defective 4th stage discharge outboard valve was replaced.
 In October 1982, a crack in its 1st suction bottle was welded; valves suspected of having
problems at its 1st west, 4th & 5th stages were replaced. On start up its 5 th stage packing
assembly started leaking gas into its cooling water it was replaced along with the piston & rod
assembly.
 In November 1982, a crack in the compressor’s suction bottle was repair welded & its 4 th stage
IB suction valve was replaced as it had been running hot.
 In TA 1983, both cylinder heads were opened for general inspection of 1 st stage. Piston rings
were found overheated again similar to last year which indicates the oil film was not properly.
So it was recommended to increase the oil drops from 20 to 25 per minute. Also, the discharge
valve (RD-6) of 2nd stage and discharge valve (RD-5) of 3 rd stage were replaced. Suction valves
ports of 4th stage were found damaged. 5th Stage Suction and discharge valve were replaced.
 In January 1984, 4th Stage crosshead, piston & piston rod, oil scrapper rings, packing assembly
were replaced and all suction & discharge valve ports seats were lapped. In 5 th Stage, new
piston rod assembly, piston rings, oil scrapper rings, packing assembly, suction & discharge
valves were fitted.
 In May 1984, 3rd stage valve F S2 & F S3 was replaced along with one broken stud when 2 nd
stage discharge pressure increased.
 In July 1984, three suction and three discharge valve of 1 st stage east cylinder were replaced.
 In August 1984, four suction and seven discharge valves of 1st stage east side were replaced,
along with one suction & one discharge valves of 4 th stage front side.
 In October 1984, 1st stage west cylinders valve RS4 was replaced.
 In November 1984, all front side suction and discharge valve of the 1 st stage east cylinder were
replaced. One valve’s plate had broken while its broken springs had lodged in some of the other
valves.
 In TA 1985, 4th & 5th Stage suction and discharge valve assemblies were replaced.
 In TA 1987, all suction and discharge valve of 3 rd, 4th & 5th stage and discharge valves of 2nd stage
were replaced.
 In TA 1989, 1st stage suction bottle west side flange pad underneath crack was repaired and
new portion of pad was installed. All suction & discharge valves of all stages (east & west) were
also replaced. 1st KOD foundation bolts were re-grouted. 3 rd Stage RS2 valve crab and jack bolt
were found damaged
 In TA 1990, 1st stage valve (FD5, FD6, RD5, RD6) East & (RD6, RD8) West were replaced for
which high temperature was registered before shutting down the compressor. 2 nd stage FS3,
FS4, RS1, RS2, RD4 valves were replaced & 3 rd stage FS2, FS3, RS1, RS2, RS3, RD5 valves were
replaced. 4th & 5th Stage all suction and discharge valves were replaced.
 In January 1991, third auto drainer system line was replaced with SS316 line due to excessive
pin holes.
 In Feb 1991, third stage RS2 and RD4 and out board suction valves of fourth stage were
replaced. Suction and discharge valves of 4th & 5 th stage were replaced.

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1971 TO 2021
 In September 1991, Overhauling I replacement of S & D valves of all cylinders was done.
Removal & refitting of 4th stage cylinders at compressors for replacement of broken frame
bolts & KOD foundation rebuilding was done. 3rd stage FS3, FD5 valves were replaced as found
defective during air run. 4th stage packing was replaced with new lapped packing since existing
packing had leaked at 250 psig air pressure. One new spare air filter was manufactured.
 In December 1991, broken spindle of 3rd UN loader assembly was replaced, and valve was
reinstalled. Both suction & discharge valves of 4 th stage were replaced due to 3rd stage high
pressure.
 In TA 1992, 1st stage suction bottle was found cracked near cylinder inlet on West side. Crack
was dye checked, grinded and welded. All suction & discharge valve of 1 st, 4th & 5th Stages and
valve seat gaskets were replaced.
 In Feb 1992, discharge valves of both 4th & 5th stage were replaced.
 In April 1992, 3rd auto drainer was overhauled twice due to improper functioning.
 5th stage suction valves were replaced in August & September 1992.
 In TA 1993, 1st stage west, 3rd, 4th & 5th stage piston assemblies were replaced along with oil
scrapper rings & packings. Discharge valves of both 1st stages, suction & discharge valves of
(3rd stage & 5th stage were replaced. 1st stage cracked, suction bottle was welded. Damaged
valve crabs 2 each on 3rd & 4th stages and damaged valves covers, one on 3rd stage and two
on 5th stage were also replaced.
 In ESD 1993, 1st stage suction bottle crack was repaired. 1st stage east FS1 & FD6, FS4 and 5th
stage all suction & discharge valves were replaced.
 In September 1993, all suction and discharge valves of 4th & 5th stage were replaced. 1st stage
suction bottle cracks were repaired.
 In Feb 1994, all the 4th stage valves were replaced due to Popping of 3rd stage PSV and
dislocated valve FD6 of 3rd stage was also replaced.
 In June 1994, Spare 5th stage cylinder was returned to warehouse after replacing the damaged
liner and drilling the valve holes in it.
 In July 1994, cracks of 1st stage (West) suction bottle were repair welded. All valves of 4th &
5th stages while valve number FS1. FS3, RS1, RS3 RD5 and RD6 of 3rd stage were replaced.
 In TA 1995, Crankcase oil leakage rectification was carried out in the presence of Dresser-Rand
VSM. Suction and discharge valves of all stages were replaced. 1 st suction bottle cracks were
repaired by welding new plates and west side flange was also replaced. Connecting rods of big
end bearings of 2nd & 4th stage were replaced. Cooling water return header isolating valve was
also provided.
 In January 1996, suction and discharge valves of all the stages were replaced. Crankcase oil of
both compressors was replaced.
 In July 1996, all suction & discharge valves of 3rd stage were replaced because of high discharge
pressure of 2nd stage & valve crab of RD6 was found cracked and misaligned.
 In August 1996, compressor was attended due to leakage at 4th stage Suction bottle. Nozzle of
3rd UN loader was replaced. 3rd stage discharge valves (FD4 & F05) were replaced.
 In January 1998, suction and discharge valve of all the stages were replaced. Crankcase oil and
motor bearing oil of compressor were replaced.
 In May 1998, 3rd stage frame extension upper 5 nos. studs were found broken, causing severe
vibration of 3rd cylinder. Base plate of spring support of 3rd discharge bottle was found sunk,
on west side in its concrete foundation.
 In January 1998, all suction and discharge valves of all the stages were replaced. , 1 st stage east
cylinder FS3 crab was found broken.
 In August 1999, 3rd state discharge valve (RD3), crab baskets were replaced due to knocking as
its jack bolt had almost come out.

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1971 TO 2021
rd
 3 stage frame extension studs were found broken in September & October 1999.
 Due to high discharge pressure of 4th stage, all valves of fifth stage were replaced twice in April
2000. Also, fifth cylinder was replaced with the spare cylinder (Which was removed from C201B
because of lube plug failure and its liner was replaced in 1994).
 In July 2000, Due to high discharge pressure of 4th stage, all valves & piston rod assembly of 5 th
stage were inspected. Both lube oil plugs were found leaky. Severe pitting was observed all
over the suction passage and around the top lube plug.
 From July to November 2000, high discharge pressure of 4th stage was observed multiple
times.
 In January 2001, all suction and discharge valves of all the stages were replaced. Crankcase oil,
lubricator oil and motor bearing oil of compressor were replaced. Both first & third stages were
removed for replacement of broken frame extension bolts & then fitted back.
 In March 2001, Fifth stage outboard suction valve was replaced due to knocking sound.
 In June 2001, both discharge valves were replaced of 5th stage discharge valves.
 In TA 2002, all Piston rod assemblies (except first stage cylinders), piston rings, piston rod
packing’s, oil scraper rings, all suction and discharge valves of all the stages, Crankcase oil,
lubricator oil and motor bearing oil of compressor were replaced. 4th stage cylinder was
replaced due to damaged suction outboard valve seat.
 In Feb 2002, six nos. suction valves of 1st stage west side cylinder were replaced due to high
temperature.
 In July 2002, 5th stage outboard suction valve jack bolt cap along with gasket was replaced due
to leakage.
 In September 2002, all valves of 4th & 5th stage were inspected and were replaced including
valves gaskets.
 In TA 2003, suction and discharge valves of all stages (except first stage suction valves for which
valve seats were reused with new springs and valve plates), crank case oil, lubricator oil and
motor bearing oil of compressor were replaced.
 In March 2003, Suction valves of 5th stage were replaced due to high 4th stage discharge
pressure.
 In August 2003, compressor was attended due to knocking sound of fourth stage inboard
suction valve. Both suction valves were replaced along with seized jack bolt and valve cover of
inboard suction valve.
 In TA 2004, piston rod assemblies along with piston rings and piston rod packing & scrapper
rings were replaced. Suction and discharge valves of all stages (except first stage suction valves
for which valve seats were reused with new springs and valve plates), crank case oil, lubricator
oil and motor bearing oil of compressor were replaced.
 In March 2004, damaged lock ring of east cylinder east pocket valve bush of 1st stage was
replaced.
 In TA 2005, first stage (east side) suction valves FS1, FS4 & RS4 were replaced.
 In February 2005, fifth stage packing was replaced due to leakage. Piston rod assembly and
suction & discharge valves were replaced.
 In TA 2006, Suction and discharge valves of all stages were replaced. Modified valves with non
metallic valves plates of M/s Hoerbiger Singapore were installed on discharge side of 1st stage
east cylinder and suction & discharge sides of 4th stage.
 In August 2006, all valves, packing’s, piston rod assemblies and crankcase oil were replaced.
 In November 2006, seven broken studs of 1st stage at west side were removed by welding and
new studs were installed. RS2 suction valve of 3rd stage was also replaced along with valve
gasket. Barring device was assembled with spare cylinder due to broken shaft.
 In December 2006, compressor was attended due to high discharge temperature of first stage
(east side). Piston rod assembly was replaced along with all front end suction and discharge

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1971 TO 2021
valves. Three broken studs of same stage were removed by welding and new studs were
installed. Barring device which was removed previously due to broken shaft was installed back.
 In January 2007, four valves of 1st stage east cylinder were replaced.
 From February to May 2007, 4 times broken studs were found in 1st stage east cylinder.
 In August 2007, third stage front suction valves FS1 & FS3 were replaced due to damaged valve
plates.
 In October 2007, damaged third stage FS2 valve was replaced.
 In TA 2008, suction and discharge valves of all stages were replaced. Modified valves with non
metallic valves plates of M/s Hoerbiger Singapore were installed on discharge side of both 1st
stage cylinders and suction & discharge sides of 5th stage.
 In TA 2009, Non-metallic piston rings were installed on 4th stage piston for the 1st time. All
suction valves of 1st stage were replaced with non-metallic valves, whereas non-metallic
discharge valves of 1st stage, which were partially installed in TA-06 and TA-08, were only
inspected due to better service life. Suction and discharge valves of 2nd and 3rd stages were
replaced with non-metallic valves. Non-metallic valve plates and springs of 4th stage non-
metallic valves were replaced.
 In July 2009, 3rd stage FS2 (front suction non-metallic valve) and FD3 (front discharge
nonmetallic valve) were replaced with metallic valves due to high inter stage pressure at 2nd
stage. Both inboard and outboard suction valves of 4th stage were replaced due to high inter
stage pressure at 3rd stage, whereas valve plate of 4th suction inboard valve was found broken.
Both inboard and outboard suction valves of 5 th stage were also replaced due to high inter
stage pressure at 4th stage, whereas 5th stage outboard valve was found completely broken.
 In TA 2010, both suction valves of fifth stage were replaced with new ones & fourth stage both
discharge valves were replaced with spares. All metallic valves have now been completely
replaced with Hoerbiger non-metallic valves.
 In July 2010, non-metallic valve of third front suction (FS3) was replaced due to second stage
high inter stage pressure.
 In August 2010, all second & third stages suction & discharge valves were replaced with metallic
valves due to high inter stage pressure of second stage.
 In October 2010, fifth stage both suction & discharge valves were replaced with spare ones due
to high inter stage pressure of fourth stage.
 In TA 2011, TC3 rod of 5th stage was installed for the first time along with non-metallic piston
rings & rider bands to enhance reliability of piston rod packing & liner. Non-metallic piston rings
of 4th stage were replaced with new ones. Second and third stage piston rod assemblies were
left unattended as per decision to go for two years service due to TC3 rods as recommended by
vendor. All metallic valves have now been completely replaced with M/s Hoerbiger non-
metallic valves.
 In January 2014, metallic piston rings were installed in place of non metallic piston rings.
Suction and discharge valves of 4th and 5th stages were repaired.
 In July 2016, cage of o/b suction valve found cracked. Replaced cage and all SUC/DIS valves
(Metallic).
 In February 2018, detailed maintenance of C201 was done.
 In TA 2020, 5th Stage Suction valves (non-metallic/ replaced in 2018) are replaced with
refurbished non- metallic valves. Discharge valves (metallic / replaced in 2018) are replaced
with refurbished metallic one. Piston was added with new non metallic piston rings and rider
rings.
 In April 2021, 05 no's stud of 4th stage frame extension was broken.

Recommendations:
TO: All Concerned
FROM; Engineering

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Page |8 SUMMARY OF C201
1971 TO 2021
February 12, 1995
SUBJECT: MINUTES OF BWETING WITH DRESSER-RAND - VSM
Please find herewith minutes of meeting with Dresser-Rand
VSM Mr. Dave Scott held in Conference Room on .29-01-95
PARTICIPATNS PLANT MANAGER, ASSTT. PLANT MANAGER, EM, TM, PM, ATM, ARM, UEIC (UREA), I/C
E&I), I/C W/S, AME (NH3), AME (UREA), AME (UTY).INSTT. ENGR
A. H.P. CO2 COMPRESSOR C201A
1. Mr. Dave briefed all the participants regarding the details of the work carried out on C201A. He
particularly mentioned the distortion of 1st stage suction bottle flanges. He emphasized that after
welding, flanges should be machined on boring machine before installation. He also briefed about the
job to be done on C201B in next TA.

2. DH enquired about the present condition of foundation below the recently repaired foundation of
C201A, it was declared satisfactory by.VSM He pointed out that cleaning of foundation be done with
some solvent to remove previous oil already present under the crankcase pan.

3. On OH enquiry for after checks on C201A Mr. Dave- Scott told that it is advisable to check all bolts for
any looseness after 100 HRS at full load operation.

4. VSM suggested that every year crankcase should be flushed with flushing oil by using 100 mesh
temporary strainers crankcase can be flushed by providing a bypass connection.

5. On enquiry from DH regarding non-metallic valve for C201A/B compressor, Mr. Scott said that
modified valve usually give good service life and also valve repair is minimized. Dresser-Rand should be
contacted for design and price.

6. Mr. Dave Scott pointed out that alignment procedure carried out was the Dresser-Rand
recommended procedure. He promised to send standard recommended cylinder alignment procedure.

7. DH enquired about V 'the cylinder lubrication oil requirements in each stage of the compressor
without Jeopardizing the equipment, Mr. Dave clearly explained that there is no hard and fast rule, but
usually it is 8-10 drops/min for packing and 10-15 drops/min for cylinder provided correct oil is being
used. He also elaborated that inlet gas to each stage should be completely dry. Dresser-Rand should be
contacted for non-lubricated type packing & piston rings.

8. Regarding 5th stage cylinder alignment, it was indicated by DH that replies from Dresser-Rand is still
awaited Mr. Dave Scott promised to convey it to Dresser-Rand. He further elaborated that a ring should
be fitted on the spigot Joint of 5th stage to standardize it. He also agreed to send standardization
procedure for the 5th stage including welding and post heat treatment

9. It was asked by DH if vibration monitor equipment be installed on the compressor. Mr. Scott pointed
out that usually "Gently NEVADA" system is installed on each cylinder. He agreed to provide specs. He
further emphasized that insulation under the 0/B bearing of motor be checked every year by meggering
it, as poor insulation may lead to thrust bearing pitting and crankcase explosion in some cases.

10. On loosening of valve cover J/bolts, he indicated to use proper torque tightening.

11. On provision of final stage K.0 drum for oil removal Mr. Scott promised to contact Dresser-Rand and
reply shall be sent later.

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1971 TO 2021
12. One K.O.D float switches, Mr. Dave Scott suggested replacing them with new type, and Dresser-Rand
should be consulted for any improvement.

13. On main and big end bearing babbiting, Mr. Scott suggested to contact Dresser-Rand, it was his
opinion that DH should not babbit them.

14. Regarding improvements in auto drainer system, he suggested to consult Dresser-Rand

C 201AB problems, modifications, and recommendations

Modifications carried out
• TA-1974- U-tube type heaters designed by technical department and fabricated by Engineering Dept. were installed
at 4th stage suction of the both compressors to minimize corrosion by vaporizing the water carry over (plate No. 5)
• Sep-1991- Removal & refitting of 4th stage cylinders at compressors for replacement of broken
frame bolts & KOD foundation rebuilding was done (C201AB)
• June 1994- 5th cylinder liner replacement (Spare)
• Apr-2000- fifth cylinder was replaced with the spare cylinder (C201A)
• Jan-2006-Modified valves with non metallic valves plates were installed on discharge side of 1st stage east cylinder
and suction & discharge sides of 4th stage. (C201A)
• Jan-2006-Modified valves with non metallic plates installed at 4th stage suction & Discharge side (C201B)
• TA-2008-Modified valves with non metallic valves plates were installed on discharge side of both 1st stage
cylinders and suction & discharge sides of 5th stage (C201A)
• TA-2008-Modified valves with non metallic plates installed at 4th stage suction & discharge sides (C201B)
• TA-2009-Non-metallic piston rings were installed on 4th stage piston for the 1st time. All suction valves of 1st stage
were replaced with non-metallic valves, whereas non-metallic discharge valves of 1st stage, which were partially
installed in TA-06 and TA-08, were only inspected due to better service life. Suction and discharge valves of 2nd
and 3rd stages were replaced with non-metallic valves (C201A)
• TA-2009-Modified valves with non metallic plates installed at 1st discharge side and 5th stage (C201B)
• TA-2010- All metallic valves have now been completely replaced with non-metallic valves (C201A)
• TA-2010- Metallic suction valves of first stage and metallic suction & discharge valves of second & third stages
were replaced with non-metallic ones. Valve plates & springs of fourth stage suction valves were replaced with
upgraded valve plates (C201B)
• TA-2011- TC3 rod of 5th stage was installed for the first time along with non-metallic piston rings & rider bands to
enhance reliability of piston rod packing & liner. Non-metallic piston rings of 4th stage were replaced with new
ones (C201A)
• TA-2011- Fifth stage piston rod assembly with TC3 rod was installed for the first time along with non-metallic
piston rings & rider bands to enhance reliability of piston rod packing & liner. New metallic piston rod packing’s
and scraper rings were installed. All piston rod assemblies of other stages were left unattended as per decision to
go for two years of service due to TC3 rods as recommended by vendor (C201B)
• Jan-2014-Metallic piston rings were installed in place of non metallic piston rings (C201A)

Major problems & Discussion with OEM

 29-Jan-1995- SUBJECT: MINUTES OF METING WITH DRESSER-RAND - VSM regarding problems occurred at C201AB
during operation detail is attached in history

Currently facing problems

 Frame extension broken of studs occurred occasionally at both compressors
 1st stage suction and discharge bottles cracks appeared occasionally
 Suction jack bolts of 4th & 5th stage seized occasionally
Recommendations
TA-2010- Both cylinder heads were opened for general inspection of 1st stage. Piston rings were found overheated again similar
to last year which indicates the oil film was not properly. So it was recommended to increase the oil drops from 20 to 25 per
minute (C 201A)

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1971 TO 2021

Fatimafert. Limited