Technical Paper July 2023

The auxiliary equipment improvement

to solve the existing problems and
improve the reliability of CO2 compressors

Authors
Hai Le Thanh
Tung Nguyen Thanh
Nghia Tran Dai
Ca Mau Petroleum Fertilizer Joint Stock Company (PVCFC)

Abstract
The CO2 compressor is important equipment in a fertilizer factory, it supplies compressed CO2 gas
into the reactor combined with liquid ammonia to form Urea. At Ca Mau Fertilizer Plant, from the
beginning, when this equipment was put into operation, there were many problems, especially
corrosion/erosion of labyrinth seals, high vibration, and compressor reverse rotation. With internal
resources, we have collected, evaluated, identified the causes, and proposed solutions to thoroughly
overcome these issues. Within the scope of this Technical Paper, we want to share the implementation
process and the results brought after improving the system.

Bank address:
RABOBANK Maastricht e.o. BIC: RABONL2U
P.O. Box 200 Account number: 1402.09.840
6200 AE Maastricht IBAN: NL07 RABO 0140 2098 40
The Netherlands

UreaKnowHow.com B.V.
Chamber of Commerce: 52907090
VAT number: NL 850659024.B.01

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 1. Introduction
According to Snamprogetti technology, CO2 compressor plays an important role in the Urea fertilizer
production line system, it is like the heart of the Urea factory. However, during the operation of the
compressor, many problems arose that cause the factory to stop actively and passively to handle.
After a long search for the root of the problems, the auxiliary system of the device has made important
improvements.
In this Technical Paper, we present notable improvements and made a major change to the operating
conditions of the auxiliary system, which can be considered a revolution that contributes to maintaining
the stable operation of the entire plant.
Ca Mau fertilizer factory started construction in 2008. In April 2012, the plant was put into commercial
operation with a designed capacity of 800,000 tons of granular urea per year. Natural gas sources for
the plant as raw materials and fuel are obtained from the PM3-CAA field.

2. Overview of technology and equipment

Urea is produced by synthesis from liquid NH3 and CO2 gas. In the R06101 synthesis reactor, NH3 and
CO2 react with each other to form ammonium carbamate, which will partly be extracted water to form
urea. The reactions are as follows:

2NH3 + CO2  NH2COONH4

NH2COONH4  NH2CONH2 + H2O

Under conditions in the synthesis reactor (T = 185 – 190 oC, P = 15.6 MPa (G)), the first reaction occurs
quickly and almost completely, the second occurs slowly and determines the speed of the reaction
conversion. The urea-forming metabolism depends on the ratio of the substances involved in the
reaction, the operating temperature and pressure, and the retention time in the reaction device.

The molar ratio of NH3/CO2 is about 3.1 – 3.6.

The molar ratio of H2O/CO2 is about 0.5 – 0.7.

Liquid ammonia from the Ammonia Unit at 25 oC, is fed to the Urea Unit through a filter, then enters
the ammonia recovery tower and then goes down to the ammonia tank. From the tank, ammonia is
pumped to a pressure of 2.25 MPa(G) by an ammonia booster pump. Part of this ammonia is fed to the
medium pressure absorption tower; the main part goes to the high-pressure synthesis package.

Ammonia from the outlet of the pump pumped with high-pressure ammonia boosts to approximately
22.9 MPa(G). Before entering the reactor, ammonia is heated in an ammonia preheater, and used as a
dynamic flow in a carbamate ejector. The liquid mixture of ammonia and carbamate comes out of the
carbamate ejector into the bottom of the reactor, where it will react with CO2 gas.

CO2 from the Ammonia Unit at a pressure of 0.04 MPa (A) and a temperature of 45 °C enters the CO2
compressor (K06101) and is compressed to a pressure of 157 MPa (G).

A small amount of air is introduced into the CO2 stream in front of the separator at the 2nd stage suction
of K06101 to passivate the stainless-steel surface of high-pressure devices, to protect them from
corrosion caused by reactants and products.

Function: CO2 compressor K06101 (with liquid separator at the suction end) is located upstream of
the synthesis tower. The CO2 compressor takes CO2 from the suction head at a pressure of 0.15MPa(A)
and compresses it to a certain pressure value that can be fed into the synthesis tower.

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Operation: Under normal process conditions, CO2 gas must reach a pressure of about 15.7 MPa(A) to
feed into the reactor. To achieve this pressure level, the compressor is designed in 4 stages. After each
stage of the compressor, the CO2 gas flow is passed through intermediate heat exchangers, where the
CO2 stream is cooled and the remaining steam in the air stream is condensed and separated in the
intermediate separator. The temperature of the CO2 gas at the 4th stage suction is controlled by a
temperature controller to avoid the CO2 phase transition that can cause compressor failure if the
temperature of the air flow drops below 45 oC. After level 4 of the compressor, CO2 is loaded into the
urea synthesis reactor R06101.

Figure 1. CO2 compressor system technology flowchart

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 Contents Design rated

Power normal (Kw) 10030 (Normal)

Inlet pressure at 1st stage (mbar-abs) 1.4

Inlet temperature at 1st stage (0C) 45

Discharge pressure at 4th stage (bar-abs) 162

Discharge temperature at 4th stage (0C) 117.1

Rated flow (kg/h) at 4th discharge stage 84 620

Speed of LP/HP compressor (RPM) 7800/13000

Max. Cont. of steam turbine (RPM) 8190

Number of stages 4

Table 1. The datasheet of CO2 centrifugal compressor

Physical parameters related to the stable operation of the machine such as rotor vibration, bearing
temperature, axial displacement of rotors is monitored via Bentley Nevada's (Baker Huge) System 1.
The system sets the low- and high-level warning values (trip value). When the values reach high warning
values, the system automatically stops to protect the device from further damage. The figure below
shows the interface of the System 1 system that displays the vibration, temperature, and axial
parameters needed follow-up. These parameters of the system are transmitted to the Distributed
Control System (DCS) for the operators to monitor.

Figure 2. System interface System 1 monitors the CO2 compressor.

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 Figure 3. The CO2 compressor package at site.

3. Recognition of the phenomenon

Abnormal problems when operating the compressor: After a period, the high-pressure compressor
begins to show abnormal phenomena (the low-pressure compressor operating parameters are normal):

­ The 3rd stage discharge temperature gradually decreases over time from 172 degrees Celsius to
133 degrees Celsius after operation of 0.5 months.
­ Meanwhile, the bearing temperature fluctuates in the range of about 3-4 degrees Celsius in
sinusoidal cycles, but the temperature is still within normal operating limits.
­ Along with that, vibration amplitudes vary ranging from 10 to 25 microns, similar to the
temperature.
­ At the same time, the axis displacement (rotor shift) tends to change in the direction towards
the non-driven side but does not reach the warning value.

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 Figure 4. Trend vibration and temperature of the CO2 high-pressure compressors abnormalities

Figure 5. The 3rd stage discharge temperature gradually decreases from 172 degrees Celsius to 133 degrees
Celsius and the turbine steam consumption gradually increases to nearly 3 ton/h.

Compressor reverse rotation during emergency stop

Based on monitoring mechanical parameters such as vibration, temperature remains within the
permissible threshold, the equipment continues to operate. However, after a period when the
compressor vibration value rises above the warning value, the compressor automatically stops urgently.
Moreover, when the compressor proceeds to an emergency stop due to a malfunction, another problem
of the compressor appears which is reverse rotation (this only happens when the 3rd stage discharge
temperature drops to less than ~155 degrees Celsius). This phenomenon is unusual, for other
compressors when having the abnormal thing, the steam supply to the turbine will close automatically,
the compressor discharge valve connected to the tower will separate the compressor from the system,
the surge valves FVC0201, FV0202 will also automatically open and the exhaust valve will open to
release gas at the outlet to the inlet and release gas of the whole system via blow of valve PV0203.
Then the compressor will gradually decelerate from the operating speed to 0 rpm. But this CO2
compressor gradually decelerates from about 12800 rpm to 0 rpm then increases again to about 6200
rpm and later drops to 0 rpm.

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 Figure 6. The speed trend plot and orbit plot during compressor emergency stop.

The corrosion/erosion labyrinth seal issues, damaged demister separators and abnormal
check valve of the 2nd stage discharge

Based on the operating parameters of the low-pressure compressor, abnormalities are not absorbed,
only the overhaul of the high-pressure compressor should be carried out. In the process of
implementation, detection of corrosion phenomena on the labyrinth seals, the demister of the separator
at the 2nd stage discharge of compressor S06121 is damaged as shown in Figure 7.

For corrosion/erosion labyrinth seals, not all labyrinth seals of high-pressure compressors are
corroded/eroded at all, but only labyrinth seals at both sides of compressor (Pos 1, Pos 2 position),
inter-stage labyrinth seal position (Pos 4 position) and balancing labyrinth position (Pos 3 position) as
shown in figure 7 have signs of corrosion/erosion. However, corrosion/erosion is strongest at Pos. 4.

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The check valve of the 2nd stage discharge of the low-pressure compressor detects an issue of disc bolt
leads to check valve open when having reverse gas flow as shown in Figure 8, the other check valves
have no abnormalities.

Figure 7. The labyrinth seals are corroded/eroded, the demister of the separator S06121 is deflected

Figure 8. The status of check valve of the 2nd stage discharge when removing for checking

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 4. Theoretical basis, assessment of causes and remedial solutions
Corrosion/erosion problems labyrinth seals at high-pressure CO2 compressor

Since the phenomenon that the 3rd stage discharge temperature decreases over time, the factory
technical team has identified a problem caused by the 4th stage suction temperature of CO2 flow of
approximately 48 degrees Celsius after exiting the heat exchanger and the separation returns to the 3 rd
stage discharge with the highest temperature of 172 degrees Celsius. Over time, due to inefficient
operation of the S06122 separator, water exists in the gas stream combined with CO2 gas at the weak
H2CO3 acid corrodes/erodes labyrinth seals of aluminum alloy materials. When the labyrinth seals are
corroded/eroded, the gap between the rotor and the compressor diaphragm increases, the internal gas
flow will gradually increase according to the actual geometric size, this gap is calculated to correspond
to a pipe size of 4.22 inches, while the 3rd stage discharge of the high-pressure compressor is 4 inches.
At the same time, because the gas flow goes to the balancing drum and the barrier flow supplies to the
dry gas seal are taken from the 3rd stage discharge of the compressor, the labyrinth seal, balancing
labyrinth in position Pos 1,2,3 is also corroded.

Based on the calculation of heat balance, based on the formula 𝑸 = 𝒎𝒄(𝒕𝟐 − 𝒕𝟏 ), we can calculate the
internal circulation flow from the 4 th stage suction with a temperature of 48 degrees Celsius to the 3rd
stage discharge approximately 37.142 kg/h, corresponding to nearly 1/3 of the flow value with the
normal operating value when the 3rd stage discharge temperature decreases from the normal operating
value; usually 172 degrees Celsius to 133 degrees Celsius when equilibrium is reached. That is why the
steam consumption for steam turbines increases gradually.

Size of space Internal flow from

The 4th stage The 3rd stage
between rotor 4th stage suction
suction discharge
Contents and labyrinth to 3rd stage
temperature temperature
seals at Pos 4 discharge
(0 C) (0 C)
(inch) (kg/h)

At normal
~0.1 48 172 Nearly zero
condition

At time of
labyrinth seals
4.22 48 133 37.142
at Pos 4 gone
away

Table 2: The 3rd stage discharge temperature parameters and the gap between the rotor and compressor
diaphragm at the labyrinth seals position No. Pos 4.

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 Figure 9. Drawings of high-pressure compressor cross-sections and process parameters

According to the analysis of the corrosion/erosion product of the main ingredient is Al, Al has reacted
with H2CO3 acid according to the Equation below:

2Al + 3H2CO3 → Al2(CO3)3 + 3H2

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 Figure 10. Results of corrosion/erosion product analysis

Thus, the water separation capacity of compressor separators may not reach the original desired design.
The factory has taken samples to evaluate the amount of water separated in the separators, paying
special attention to the evaluation of the water separation efficiency of the S06122 at the 4 th stage
suction, the detailed information as follows:

Theoretical water
separation at The actual amount
compressor load of of water separated
Separators Notes
100% is measured
(liters/h)
(liters/h)

S06119 Zero

S06120 1398.6 OK

S06121 518.4 OK

S06122 98.1 ~25 Failed

Table 3: Test results of separator efficiency

On the other hand, as recommended in the manual as mentioned in [3] “non-recommended use: if
pressure exceeds 70 bar, due to the consequent sharp decline in liquid removal efficiency and insufficient
turndown” the water could be gone along with gas flow comes to inside the compressor. Furthermore,
after checking the size of the inlets and outlets of this separator according to Norsok standard [4] the
existing nozzle size is not suitable, it is necessary to increase the size of the inlet and outlet of separator
nozzles from 6 inches to 8 inches according to the calculation results as shown in the below table. And
installing an additional cyclone separation level to increase the separator efficiency. Therefore, we

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calculated and assessed the condition, discussed, and agreed to come up with a solution to renovate
the inlet of the separator S06122 with detailed parameters as below.

In order to maintain a minimum vessel ID we are using a vane type mist eliminator instead of a
conventional mesh type mist eliminator since it has the ability to handle a greater throughput whilst
achieving the required removal efficiency of 99.99% removal of liquid droplets 10 micron and greater.

Separator S06122 has been designed as a two-stage design due to the operating pressure being above
70barg. At pressures above 70 barg the removal efficiency of a single stage mesh type or vane type
cannot meet the target removal efficiency of 99.99% removal of liquid droplets 10 micron and greater.
It should also be noted that the cyclone is coupled with a vane type in order to maximize the removal
efficiency and overall performance.

The cyclone consists of multiple standard cyclone pipes. An intense spinning motion is induced into the
gas entering the cyclone pipes with throws the liquid droplets onto the pipe wall due to the resulting
centrifugal forces.

The coalesced liquid is purged from the cyclone pipes through slots in the pipe wall and enters a
separation chamber from where the collected liquid drains to the vessel sump via downpipes. Overall, a
cyclone mist eliminator is able to provide higher capacity per unit vessel diameter than a vane type mist
eliminator or mesh type mist eliminator unit, whilst achieving similar droplet removal efficiency as a
properly sized vane type mist eliminator unit.

Nozzle Sizing:

The nozzle sizes are evaluated using the pv2 value for the inlet and gas outlet nozzles and thus sized
accordingly.

In order to keep inlet nozzle sizes to a minimum we’ve included a DynaFeedTM vane type inlet device
for each of the feed inlets. Also the DynaFeedTM will assist in breaking down the anticipated slug of
liquid prior to it damaging any internal equipment.

Nozzle Sizing Criteria: Inlet Nozzle with DynaFeedTM Vane Inlet Device Max pv2 = 8,000 Pa

 Outlet Nozzle Max pv2 = 4,500 Pa

 Liquid Outlet Nozzle Max velocity = 1 m/s

Based on the above mentioned criteria we’ve changed the following things

Increase inlet nozzle size from 150NB (6”) to 200NB (8”)

Increase gas outlet nozzle size from 150NB (6”) to 200NB (8”)

Check for adecquacy of nozzles

ID (mm) Rating DN(in) OD (mm) TK (mm)
Inlet nozzle inner diameter (Φ ) 146.00 900# 6 168 11
Gas outlet nozzle inner diameter (d 1) 146.00 900# 6 168 11
Liquid outlet nozzle ID (d 2 ) 49.22 900# 2 60 6

Momentum criterion
Inlet nozzle 7956 Pa vane or cyclonic, ρ in v 2 in < 8000 Pa OK
2
Gas outlet nozzle 7956 Pa ρGv G < 4500 Pa NOT OK

Table 4: Calculation results of checking the existing 6-inch inlet and outlet nozzle size of the separator

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Check for adecquacy of nozzles
ID (mm) Rating DN(in) OD (mm) TK (mm)
Inlet nozzle inner diameter (Φ ) 193.60 900# 8 219 13
Gas outlet nozzle inner diameter (d 1) 193.60 900# 8 219 13
Liquid outlet nozzle ID (d 2 ) 49.22 900# 2 60 6

Momentum criterion
Inlet nozzle 2573 Pa vane or cyclonic, ρ in v 2 in < 8000 Pa OK
2
Gas outlet nozzle 2573 Pa ρGv G < 4500 Pa OK
Table 5: Calculation results of checking the 8-inch inlet and outlet nozzle size expected to be upgraded

Operating Unit Values of old separator Values of upgraded

Conditions separator

Operating
kPag/C 8405/45 8405/45
Press./Temp.

Design Press./Temp. kPag/C 9000/80 9000/80

Pressure Drop kPa 5 5

Vapor

Mass Flowrate kg/hr 89185 (included 10% margin) 89185 (included 10% margin)

Density (@P&T) kg/m3 141.36 141.36

Viscosity cP 0.022 0.022

Water

Mass Flowrate kg/hr 109 109 (assumed)

Density (@P&T) kg/m3 995 995

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 Operating Unit Values of old Values of upgraded separator
Conditions separator
Viscosity cP 0.450 0.450

Vessel

Horizontal/Vertical Vertical Vertical

Shell ID mm 800 800

Total length mm 2480 2480

Nozzle inlet Inch 6 8

Nozzle outlet Inch 6 8

Internal Parts

Feed Inlet Vane Inlet Device Vane Inlet Device

Vane pack (Cross flow) Vane pack (Cross flow) and cyclone
Gas Outlet

Performance 99% removal liquid >99.99% removal of liquid droplets 10

droplets @>10µm micron and greater:

Removal of Droplets > 5µm: 90.5 %

Removal of Droplets > 10µm: 100 %
Removal of Droplets > 15µ: 100 %
Removal of Droplets > 20µm: 100 %
Table 5: Parameters of old S06122 separator and after renovation

The separator renovation details S06122

The old separator was designed with vane pack and demister used to separate water, after renovating
(retaining the separator vessel) the separator includes vane pack, demister and cyclone as shown below:

Figure 11. Old separator vessel configuration and new separator S06122

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The problem of compressor reverse rotation during an emergency shutdown

Normally, when an emergency stop occurs, the control system will trigger the logic of closing the valves
that isolate the compressor from upstream and downstream system along with closing the steam supply
valve to steam turbine. At the same time, the anti-surge valves will be opened, then the compressed
gas at the 4th stage discharge will reduce pressure to return to the 3rd stage suction and the compressed
gas at the 2nd stage discharge returns to the 1st stage suction. Along with that, valve PV0203 at the 2nd
stage discharge automatically opens and releases pressure for the whole system, gradually decreasing
to a value equal to the environment. Thus, the compressed gas flow always moves forward from the
inlet to outlet of the compressor, the system will always rotate forward before emergency stop.

However, because the check valve at 2nd stage discharge is not closed, instead of the pressure at the
2nd stage discharge depressurizing through the anti-surge valve FV0201, part of the pressure is released
through this check valve. Similarly, the pressure at the 4th stage discharge depressurizes through the
anti-surge FV0202 to the 3rd stage suction and through the gap inside the compressor due to the
labyrinth seals of the position Pos 4 is corroded/eroded. It is abnormal pressure drops at low-pressure
and high-pressure compressors that lead to the dynamic force decelerating the compressor speed from
12800 rpm to 0 within 10 seconds and continue to force the compressor rotates in the opposite direction
with the highest speed of 6200 rpm and decrease gradually reaching zero within about 140 seconds
later. We have that judgment because the premises will be detailed below.

As analyzed above, when the labyrinth seals are corroded/eroded, the gap between the rotor and
compressor diaphragm increases, the internal gas flow will gradually increase with the size one. In the
worst case, this clearance is increased to the maximum, it is calculated that the gap size corresponds
to a 4.22-inch pipe size while the 3rd stage discharge pipe of the high-pressure compressor is 4 inches,
so when the compressor comes to an emergency stop mode, the entire pressure at 4 th stage discharge
will return to the 3rd stage suction through the narrow gap inside the compressor. This internal gas flows
inside the compressor that makes a force on the rotor that creates reverse rotation of the whole
compressor chain.
The detailed cause assessment above is based on the FTA (Fault Tree Analysis) diagram below.

Analysis diagram for finding the cause of compressor reverse rotation during emergency shutdown (ESD)

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Based on the detailed analysis above, we can summarize the problems of the compressors and the
solution as shown in the following table:

No Phenomena Problem Cause Solution

The 3rd stage
The separator S06122 at
discharge Upgrade the
Corrosion/erosion labyrinth the 4th stage suction of
1 temperature separator
seals compressor does not work
gradually S06122
efficiently
decreases
Corrosion/erosion of
labyrinth seals, the
High vibrations and
2 resulting product of Ditto Ditto
oscillations
jamming against the rotor

Corrosion/erosion of
Bearing labyrinth seals, the
3 temperature resulting product of Ditto Ditto
fluctuations jamming against the rotor

Corrosion/erosion of
Variation of the
balancing labyrinth causes
high-pressure
4 high pressure difference Ditto Ditto
compressor rotor
between rotor sides
displacement

Corrosion/erosion of As above and

labyrinth seals causes install an
internal flow from the 4th additional
Compressor stage discharge to 3rd stage check valve
As above combined with
reverse rotation suction combined with at 3rd stage
5 no check valve at the 3rd
during an external flow due to the discharge.
stage discharge
emergency stop absence of a check valve at Repairing the
3rd stage discharge and check valve
failure of check valve at 2nd at 2nd stage
stage discharge discharge
Table 7: Statistics on causes and solutions to handle the compressor issues.

5. Results
After renovating the separator, installing a check valve at 3rd stage discharge, repair the one at 2nd
stage discharge, the existing problems of the system have been completely solved, the compressor
operating stably within the past 7 years, so far, we do not absorb any similar problems as before.
Specifically, the steam consumption of the turbine decreased, the phenomenon of reducing the 3 rd stage
discharge temperature after a period of operation, the high-pressure compressor displacement has not
changed abnormally and the compressor reverse rotation issue during an emergency shutdown is no
longer happen again, the detailed data as shown in the following figures.

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 Figure 12. The turbine's steam
consumption decreased and stability.

High-pressor
compressor rotor
3rd stage section 4th stage section
Is in normal
condition after
nearly 02 years of
operation

Sealing labyrinth.
3rd stage section 4th stage section
no signs of
corrosion/erosion

Balancing
labyrinth

No signs of 3rd stage section 4th stage section

corrosion/erosion

Figure 13. The compressor condition after nearly 2 years of operation has no signs of abnormalities.

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Figure 14. No compressor reverse rotation happened again during an emergency stop.

Figure 15. The axial mobility of the high-pressure compressor is stable.

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 6. Conclusions
For important rotary equipment, when finding the root causes of issues, not only checking the main
elements such as compressors, turbines, ... but also, it is necessary to review and check auxiliary
equipment. Particularly, the gas compressor system, the working efficiency of the separators greatly
affects the reliability of the equipment package, need be re-reviewed and evaluated immediately when
there are abnormalities, especially new equipment put into operation.
The improvement of the auxiliary system, especially the separator, plays a large role in dealing with
the root of the problems. It helps the safe and stable continuous operation of the factory. The sharing
of practical experiences and lessons learned from similar factories in the world always brings great
value to the process of optimizing technology for each factory.

Sources
1. Document of Saipem Technology Copyright 2010
2. Hitachi Compressor Manual 2010
3. Manual liquid/liquid and gas/liquid/liquid separators - Type selection and design rules dep
31.22.05.12-gen. January 2008 Design and engineering practice used by COMPANIES OF THE
ROYAL DUTCH/SHELL GROUP
4. Norsok Standard Rev. 2, November 2001
5. Documents for calculating internal separators.

Nomenclature
Q = Heat capacity J/K
0
t1 = Inlet temperature C
t2 = Outlet temperature 0C

C = Heat capacity J/K or J⋅K−1

ρ = Liquid density kg/m³
V = Gas velocity m/s

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