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270
Contents of Table
1.
Abstract
2.
Problem faced
3.
4.
5.
Lesson Learned
Appendix
1. Abstract
271
Background
After revamp of reformer CCR process where all three
compressors are running without stand-by, compressor valve life
decreased drastically from 1 year to a few(2~3) months.
Troubleshooting
Whole entire factors were investigated from process condition
change, piping layout, separating drum size and valve design.
Very viscous and sticky heavy hydrocarbon called `Green Oil was
found at the valves & cylinder could cause valve late closing and
consequential excessive impact stress during valve closing.
Increased colder spill-back by-pass flow could cool down gas
after separator drum made easy formation of heavy hydrocarbon
condensate.
Moreover liquid condensate could exist as slug at low point of
suction manifold piping directly connected to compressor suction.
Valve dynamics and pulsation after revamp was acceptable but
plate type valve seemed to be not good choice under service
including sticky liquid showing bouncing at edge of plate during
late closing.
1. Abstract
272
2. Problem faced
273
Reactor
Naphtha Feed
Recycle Gas
Compressor
H2
Consuming
Unit
Heater
Catalyst
CCR
Chloride &
Water
Injection
Chloride
Treater
Reformate
Separator
Operating Condition
Before Revamp
After Revamp
11.8 / 9.7
40 / 38
49~52 / 38
2.38 / 2.78
3.14 / 2.83
Mw (1st / 2nd)
2 out of 3
3 run out of 3
2. Problem faced
274
30 C
Spill-back By-pass(2nd )
To Downstream
H2 User unit
49~52 C
40~44 C
~88% H2
30 C
30 C
1st
2nd Stage
Stage
30 C
130 C
134 C
Separator
40 C
After Revamp
49~52 C
Treater
Suction Separator
40 C
Product Liquid
Product Liquid
Product Liquid
Spill-backed Gas
30 C
Compressor
Suction Separator
Spill-back By-pass
Suction Separator
Tie-Point
Green Oil
Condensed H/C
Very Viscous & Sticky
Corroded
FeCl2 + H2 = Fe + HCl
Catalyst
Al2O3
Fe
Al
Component found
NH4Cl,
FeCl2, Al2O3
7
Late closing
Late closing
Impact Velocity
(mm/sec)
Valve Lift(m)
0
-
Solution
Implementation
Phase
Phase I
Phase II
As separator operating
temperature decrease
~52 47 C
Demister
Stage
Velocity
Actual
Velocity
Allowable
Velocity
1st
1.3
< 2.3
2nd
0.4
< 1.7
Before Improve
100 /100/100%(36,798 Nm3/Hr)
Load
(29 % spill-backed)
After Improve
100 /75/75%
(15 % spill-backed)
~88% H2
1st Stage
Spill-back Bypass(2nd )
2nd Stage
Chloride
Treater
Separator
Product
Liquid
Product
Liquid
Product
Liquid
11
12
30 C
Spill-back By-pass(1st )
Spill-back By-pass(2nd )
45~47 C
40~44 C
1st Stage
30 C
2nd Stage
30 C
30 C
Chloride
Treater
Separator
Product Liquid
Product Liquid
Product Liquid
13
Implementation
Phase
Solution
Plate
Phase I
Poppet
Shape
Remark
- Widely Used
(Economical)
- Bounced at edge area
at late closing by sticky
liquid
- Better at sticktion
Improvement Idea
Implementation
Yr1
Yr2
Yr3 ~
Result
(Valve Life)
+:
12 Months
+++:
>16 Months
II
5. Lesson Learned
286
287
END of Document
A-1
Type
Possible Cause
Influence of
Liquid
Possibility
Process
Excessive
lubricant
Type
Possible Cause
Valve material
Mechanical
Possibility
Valve Design
Valve Type
Gas Pulsation
* It is evidently NOT a root cause. However if it is improved to other type valve less apt to sticktion,
it will withstand longer service life even at presence of sticky liquid.
A-3