The Synthesis Compressor Train at Indo Gulf Fertilisers (IGF), Jagdishpur, India, supplied by Nuovo Pignone (GE Oil & Gas), is driven by a 26 MW condensing cum extraction steam turbine. In April - May 2007, IGF carried out a revamp of the machine for increased load operation by modifying the recycle wheel When operation of the plant at the higher load, IGF observed wide variations in the radial vibration of Front End Journal Bearing of 2nd Barrel which started to increase in the evening and attained a maximum value at about mid night and then it started to recede. A similar phenomenon was also observed in the Journal Bearing Temperature. IGF also observed sudden variations in vibrations & bearing temperature whenever there is sudden change in ambient conditions like heavy rains. During Annual Turnaround of plant IGF dismantled all barrels of synthesis gas compressor and observed severe corrosion in the end gas seals and inter-stage labyrinths of all three barrels- a serious concern for reliable & safe operation of machine. This paper deals with IGF experience of unique behaviour of vibration levels / bearing temperatures in synthesis gas machine post revamp, severe corrosion of the end gas seals & labyrinth seals of the barrels, the root cause analysis carried out by IGF along with Original Equipment Manufacturing (OEM), strengthening of the operation philosophy and the short term/long term measures taken by IGF to take care the problem of severe corrosion and improving the reliability of Synthesis gas compressor. This paper highlights the learning on how important it is to evaluate the machines / equipment holistically &from all process / mechanical point of view during design/execution stage, particularly during revamping of plants. The views expressed herein are of the Authors and not of the Organization - Indo Gulf Fertilisers (A Unit of Aditya Birla Nuvo Ltd.)
展开▼
