K V PRASAD RAKOTI rakotipkv@indianoil -...
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ONLINE OPENING OF STUCK-UP WGC DISCHARGE VALVE K V PRASAD RAKOTI [email protected] Wet Gas Compressor (WGC) is super critical equipment in Gas Processing section of DCU. This is a two stage centrifugal compressor of Model: 2MCL 807 supplied by BHEL. Compressor driver is 8MW condensing type steam turbine of Model: NK- 32/45-3. There are two discharge valves in each stage of the compressor vide UV-10103 and UV-10105. Second stage Discharge Valve (UV-10105) is a special valve functions as SHUTOFF valve when compressor is in shutdown and act as an NRV when compressor is in running condition. This valve operation is limited by pneumatic actuator. This Valve supplied by Friulco Spa, Italy as per API 594/598. This paper explains the problem faced during the operation of coker wet gas compressor, consequences of this problem and its conventional methods to resolve the problem. Also explains an innovative idea which leads to resolve the issue by online. PROBLEM: Higher Differential pressure across Second Stage Compressor Discharge Valve UV- 10105 (5 Kg/Cm2). Normally it is 0.1-0.4 Kg/Cm2. Higher bearing temperatures CONSEQUENCES: Coker Wet gas Compressor discharge pressure has increased. Reduction in gas processing capacity which causes reduction in unit throughput. Machine running at high rpm and high bearing temperatures ACTION PLAN TO RECTIFY THIS PROBLEM: Root Cause for this problem is: Dry run of the stem with bush Action Plan to attend this problem: Valve Position: 40m height, 5Ton Planned to drop the valve and free the stem Required Shutdown duration: 5 days Resources required: 250T Crane, Skilled Riggers ON LINE OPENING OF STUCK-UP VALVE WITH SPECIAL PUSHER SLEEVE: To avoid the shutdown, we have planned to open the Stuck Up valve with Pusher Sleeve arrangement without taking any shutdown BENEFITS/ GAINS TO THE CORPORATION 5 days of DCU shutdown was avoided (Avoided Production Loss of Rs 18.52crores) (Rs/MT3859*MT400*Hrs24*Days5=18.52Cr) Reliability of WGC improved by reducing the load on compressor
Transcript of K V PRASAD RAKOTI rakotipkv@indianoil -...
ONLINE OPENING OF STUCK-UP WGC DISCHARGE VALVE
K V PRASAD RAKOTI [email protected]
Wet Gas Compressor (WGC) is super critical equipment in Gas Processing section of DCU. This is a two stage centrifugal compressor of Model: 2MCL 807 supplied by BHEL. Compressor driver is 8MW condensing type steam turbine of Model: NK- 32/45-3. There are two discharge valves in each stage of the compressor vide UV-10103 and UV-10105.
Second stage Discharge Valve (UV-10105) is a special valve functions as SHUTOFF valve when compressor is in shutdown and act as an NRV when compressor is in running condition. This valve operation is limited by pneumatic actuator. This Valve supplied by Friulco Spa, Italy as per API 594/598.
This paper explains the problem faced during the operation of coker wet gas compressor, consequences of this problem and its conventional methods to resolve the problem. Also explains an innovative idea which leads to resolve the issue by online.
PROBLEM: Higher Differential pressure across Second Stage Compressor Discharge Valve UV-
10105 (5 Kg/Cm2). Normally it is 0.1-0.4 Kg/Cm2. Higher bearing temperatures
CONSEQUENCES: Coker Wet gas Compressor discharge pressure has increased. Reduction in gas processing capacity which causes reduction in unit throughput. Machine running at high rpm and high bearing temperatures
ACTION PLAN TO RECTIFY THIS PROBLEM: Root Cause for this problem is: Dry run of the stem with bush Action Plan to attend this problem:
Valve Position: 40m height, 5Ton Planned to drop the valve and free the stem Required Shutdown duration: 5 days Resources required: 250T Crane, Skilled Riggers
ON LINE OPENING OF STUCK-UP VALVE WITH SPECIAL PUSHER SLEEVE:
To avoid the shutdown, we have planned to open the Stuck Up valve with Pusher Sleeve arrangement without taking any shutdown
BENEFITS/ GAINS TO THE CORPORATION
5 days of DCU shutdown was avoided (Avoided Production Loss of Rs 18.52crores) (Rs/MT3859*MT400*Hrs24*Days5=18.52Cr)
Reliability of WGC improved by reducing the load on compressor
