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- W3096650860 abstract "Abstract Maintaining the high level of reliability of Instrument Air compressor is essential for safe operation of Oil and Gas facilities however challenges remains to maintain high level of reliability in integrally geared design instrument air compressor due to exceptionally high speed (50,000 rpm) and minimal clearance bearing..etc. This paper presents success story of such compressor`s Reliability and MTBF improvement from 30 days to more than 36 months. Integrally geared compressor was installed and commissioned in year 2002 as facility upgrade project and never run continuously more than 30 days due to frequent high vibration trip and lead to consequence Risk of plant operation and upset due to non-availability of compressorExtremely high maintenance cost > $120,000 per year due to repeated maintenance intervention Identifying the common vibration malfunction like unbalance, misalignment, rubs, cracks, shaft bows are relatively easy, as the behavior/characteristics of these problems are well understood, however challenge remains for identifying the rare uncommon problems with limited information so this paper details interesting achievement of, how we diagnose and eliminate vibration issues. Structured root cause analysis of high vibration revealed cause of high vibrations are Bearing Frosting /Pitting contributed by buildup of Electrostatic current and discharge through bearing High residual magnetism, and compounded by Yellow deposits /varnish formation due to thermal oxidation which is result of high operating temperature and Oil disintegration. To eliminate above uncommon problems, following solution were identified as. Installation of current diverter rings (CDR) in motor, which avoided development of high shaft voltage from either motor or compressor by discharging to the ground.Removal of residual magnetism from rotor by On Site degaussing process.Maintained the lube oil supply temperature less than 60°C by upgrading the temperature control elements.To identify varnish formation, Perform proactive varnish potential test like membrane patch colorimetric (MPC) Implementation of above recommendations enhanced the equipment uptime with reduced maintenance effort and cost, which permanently resolved the high vibration issues and made the compressor reliable for uninterrupted supply of instrument air to process plant without major overhauling for more than 7 years as of now." @default.
- W3096650860 created "2020-11-09" @default.
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- W3096650860 date "2020-11-09" @default.
- W3096650860 modified "2023-09-27" @default.
- W3096650860 title "30 Days to 36 Months Plus Operation-Reliability Improvement Journey of Integrally Geared Compressors" @default.
- W3096650860 doi "https://doi.org/10.2118/203002-ms" @default.
- W3096650860 hasPublicationYear "2020" @default.
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