Trouble Shooting

Vibrations. Misalignment
Damage to coupling
Unbalance of rotor
Unbalance of coupling
Condensate carryover
Stresses due to pipes
Surging
Bearings damage
 Trouble Shooting
Damage to In correct Lubrication
Bearings Misalignment
Improper clearances
unbalance of rotor /coupling
High bearing temperature
Impurities in oil
Improper assembly of bearing
 Trouble Shooting
Damage to Excessive axial thrust
Thrust bearing Incorrect lubrication
Improper assembly
Improper loading of machine
 Trouble Shooting
Damage to Misalignment and
Oil Seal vibrations
Rings Dirt in oil
Improper oil clearances
Insufficient oil pressure
Improper assembly
 Trouble Shooting

High axial Instrument fault

thrust. Excessive internal seal
clearances
Incorrect loading
Incorrect assembly of
coupling
 Trouble Shooting

Gas Instrument
Temperatu fault
re high Insufficient
cooling water
 Trouble Shooting
Low discharge Internal leakages are high
pressure at Drastic change in composition of
constant speed gas
 Trouble Shooting
Oil carryover High level and subsequent
in to overflow into gas system
compressor Malfunction of seal oil traps
Negative diff pressure between
balance gas and reference gas
HP oil seal clearances are high
Blockage in HP seal oil pipes
Recovery of gas from oil trap
system not functioning.
 Trouble Shooting
Surging of Insufficient gas at suction
compressor High internal leakages
Blockage in anti surge valve
Suction strainer choking
Malfunctioning of anti surge
system
Improper loading
 Lube oil console & Pumps
Dos Donts
Cut off power supply Start pump if oil level
to heater before start is low
Check auto change Start without min oil
over of pumps
temp(30-35 deg C)
Check coolers &
filters change over Close discharge of
Ensure N2 to standby pump
accumulator
 Lube oil console & Pumps
Dos Donts
De aerate PCV3 .1&3.2 during By pass the
start up and in operation lube oil low
De aerate coolers & filters before pressure trip.
change
Analyse oil samples at regular
intervals
Run the centrifuge at least 8hrs in
a day
 Seal oil System
Dos Donts
Check SO oil interlocks before Operate LCV in
start manual mode
Check So Trap Vents orifices for long time.
through ness By pass SO OH
Check Traps function tank level low
trip
 Process Gas System
Dos Donts
Carryout inert gas purging Start compressor
and take gas analysis. without SO system
Admit N2 to LO Tank, Brg Anti surge valve
Housings.degassing tank etc., in auto during start
Check Lo Pr to Brgs Operate the M/C
Start comp as per recommen- heavy gas leakages
ded procedure
 Process Gas System
Dos Donts
Load the compressor wrt comp Operate M/C with
characteristics
ASV in manual
Ensure correct compression at
after loading
intervals
Ensure correct flow Adjust safety
Ensure correct composition of gas valves while M/C
Monitor M/C parameters regularly is in operation
Turbo Machinery Overhaul
 Turbo Machinery Overhaul
Modern Turbo M/Cs run reliably for long.
Continuous monitoring
Good diagnostics
Preventive maintenance
Careful operation
With periodic inspections and minor
overhauls
 Turbo Machinery Overhaul
Reasons for Emergency Overhauls
a)Reduction/Deterioration of performance
b) Excessive Vibrations, Brg Temperatures.
c) Damage caused by surging, lube oil
failure etc.,
 Turbo Machinery Overhaul
Proper Overhaul involve
Preparation
Planning
Execution
Documentation of Overhaul activities
 Turbo Machinery Overhaul
Preparation & Planning
Purpose of Overhaul
Study History of M/C with records
compile data by observation of records
Identify the extent of overhaul
Identify the spares required
Check the availability
 Turbo Machinery Overhaul
Check the availability of data required for
overhaul like specs, drawings, manuals etc,
Check spares availability and usability
Availability of special tools
Spare rotor/ condition by physical
inspection
Safety aspects during overhaul like purging
toxic gases, covering opened pipes etc.,
 Turbo Machinery Overhaul
Execution of Overhaul
Preparation of Bar Chart of activities
Follow up of sequence of activities
recommended before opening the
equipments
Visual inspection of parts
Note down all information observed from
machines.
 Turbo Machinery Overhaul
Clean all parts with relevant solvents
Check all dimensions and record
Proceed with OEM recommendations w.r.t
corrections, replacements,repairs etc.,
 Turbo Machinery Overhaul
After machine is overhauled, assembled and
restarted compile the critical data
1) Basic Machine data
2) Performance pre and post overhaul levels
3) Spare parts consumed
4) Critical dimensions
5) Alignment
 Turbo Machinery Overhaul
6) Synopsis of various activities like time
taken, major deviations if any
7) Recommendations for next overhaul
8) Additional modifications required to be
made in next overhaul.
Turbo Machinery Overhaul