Equipment No.

K-23202B
Service:: Net Gas Compressor Equipment type:

Rotating Equipment Failure Analysis Report

Maint. Order/ Notification No.: Problems detected via:

Recip Compressor

96464134

Routine findings. Request/Notification.

Area.:

PROBLEM DESCRIPTION 2 stage discharge temperature high on 10/1/2014

nd

BACKGROUND The Equipment Equipment Tag No Equipment Criticality Service Equipment Type Running Philosophy Number of Stages Number of Cylinders Speed Range Rated Power Valve Unloaders Valve Type Last Maintenance Last PM Maintenance Cost ULPO Sequence of Event : K-23202B :2 : Net Gas Compressor : Reciprocating Compressor (3-stage) : 2 running 1 standby (N+1) :3 :7 : Fixed 333 RPM : 5500 HP : Yes Stage 1, 2, and 3 HE : Ring type valve th : 29 August 2013 : : RM 37,261 : No

16/8/2013 - 18/8/2013 Replacement of discharge valve(cyl#4,5 & 6) by CRG

29/8/2013 - 31/8/2013 Replacement of suction & discharge valve(cyl#5) by CRG

24/12/2013 - 9/1/2014 K-23202 B running in good condition mechanically

10/1/2014 Notification raise by OE2 (2nd stg discharge temperature high)

11 - 12/1/2014 CRG perform cyl#6 HE & CE discharge valve replacement

13/1/2014 K-23202B t/run by CBM . Condition good.

DATA /FINDINGS: 1. Maintenance / PM history

2. Verification at site a. Visual/audio No abnormality observed

Equipment No.:

K-23202B
Service:: Net Gas Compressor Equipment type:

Rotating Equipment Failure Analysis Report

Maint. Order/ Notification No.: Problems detected via:

Recip Compressor

96464134

Routine findings. Request/Notification.

Area.:

3. Valve skin temperature survey a. Valve skin temperature Last taken on 13/1/2012 (Refer ATT:1)

4. Pi Trending a. Temperature trending

26/12/2013-29/12/2013

5/01/2014-9/01/2014

b. Pressure trending

No significant fluctuation or abnormalities observed

Equipment No.:

K-23202B
Service:: Net Gas Compressor Equipment type:

Rotating Equipment Failure Analysis Report

Maint. Order/ Notification No.: Problems detected via:

Recip Compressor

96464134

Routine findings. Request/Notification.

Area.:

Parameter fluctuation observation based on Pi trending Location st 1 stg (cyl#1) st 1 stg (cyl#3) st 1 stg (cyl#5) st 1 stg (cyl#7) nd 2 stg (cyl#4) 2 stg (cyl#6) 3 stg (cyl#2) E-23203 1 stg suction st 1 stg discharge nd 2 stg discharge rd 3 stg suction rd 3 stg discharge
st rd nd

Discharge temperature

Min 131.4 131.7 132.4 132.3 133.1 133.4 123.9 51.60 C 202.4 A 3.126 9.76 25.98 23.49 49.12

Max 136.7 137.7 137.9 138.4 136.6 144.5 127.2 62.63 C 205.5 A 3.140 10.005 26.20 23.67 52.30

IOW 148 148 148 148 148 148 135 NA NA NA NA NA NA NA

Remarks

Abnormal high delta compared to cyl#4

Inlet compressor temp Motor amp

Pressure

5. Gas properties a. Gas Molecular weight : 3.87 ( Based on lab result dated 31/12/2013) 6. CRG Inspection a. Leak test & visual inspection on discharge valve

Cy#6 HE X X* X

All HE discharge valve failed diesel leak test. Bottom HE discharge valve had visible chipping on 1 of the metal rings edge.

All CE discharge valve passed diesel leak test.

Cy#6 CE

Equipment No.:

K-23202B
Service:: Net Gas Compressor Equipment type:

Rotating Equipment Failure Analysis Report

Maint. Order/ Notification No.: Problems detected via:

Recip Compressor

96464134

Routine findings. Request/Notification.

Area.:

7. Vendor refurbishment report a. To be updated upon submission by vendor

FAILURE ANALYSIS

1.Failure analysis based on the reported problem

Equipment No.:

K-23202B
Service:: Net Gas Compressor Equipment type:

Rotating Equipment Failure Analysis Report

Maint. Order/ Notification No.: Problems detected via:

Recip Compressor

96464134

Routine findings. Request/Notification.

Area.:

2.Further failure analysis on failed valve

POSSIBLE CAUSES Based on the collected & available evidence it can be concluded that the possible failure was due to the following ; 1. Possible mishandling or inconsistancy of valves spring installation during valve refurbishment which then lead to inconsistance spring movement which causing valves ring to lift tilted when slam shut condition. This was further aggriviated by the increase in compressor load. Due to the cyclic load, the valve ring edge was continuously slam to the valve seat causing it to chip. Hence, valve passing nd and eventually increase the discharge temperature of the 2 stage (cylinder #6). Failure component Valve Failure Mode Valves ring edge chipping Failure Cause 1.inconsistance spring movement creating tilted valves ring lift movement.

Failure Cause Category

Operational

Maintenance X

Manufacturing Defect

Unintended service condition

End of design life

Equipment No.:

K-23202B
Service:: Net Gas Compressor Equipment type:

Rotating Equipment Failure Analysis Report

Maint. Order/ Notification No.: Problems detected via:

Recip Compressor

96464134

Routine findings. Request/Notification.

Area.:

RECOMMENDATIONS: No. Recommended Action for improvement Action by Remarks 1 Enforce mandatory valve refurbishment report Hoebieger 2 *Please mention in the remarks whether or not notification has been raised to appropriate parties who carry out the recommended actions.

PREPARED BY NAME : Muhammad Fadzlee Samsubaha DATE : 12/2/2014

APPROVED BY (TP) NAME : DATE :

Equipment No.:

K-23202B
Service:: Net Gas Compressor Equipment type:

Rotating Equipment Failure Analysis Report

Maint. Order/ Notification No.: Problems detected via:

Recip Compressor

96464134

Routine findings. Request/Notification.

Area.:

ATTACHMENT

Equipment No.:

K-23202B
Service:: Net Gas Compressor Equipment type:

Rotating Equipment Failure Analysis Report

Maint. Order/ Notification No.: Problems detected via:

Recip Compressor

96464134

Routine findings. Request/Notification.

Area.:

ATT:1 Previous Compressor Skin temperature surve

Equipment No.:

K-23202B
Service:: Net Gas Compressor Equipment type:

Rotating Equipment Failure Analysis Report

Maint. Order/ Notification No.: Problems detected via:

Recip Compressor

96464134

Routine findings. Request/Notification.

Area.:

Equipment No.:

K-23202B
Service:: Net Gas Compressor Equipment type:

Rotating Equipment Failure Analysis Report

Maint. Order/ Notification No.: Problems detected via:

Recip Compressor

96464134

Routine findings. Request/Notification.

Area.:

Lab sampling result