APPENDIX 13

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0
1

General ................................................................................................................................................. 2
Package Units....................................................................................................................................... 3
1.1
Stabilizer Ovhd Compr. Unit (PU-01) : ....................................................................................... 3
1.2
Deethanizer Ovhd Compr. Unit (PU-04): .................................................................................... 3
1.3
Acid Gas Incinerator Unit (PU-02):............................................................................................. 3
1.4
TEG Dehydration System (PU-03):............................................................................................. 3
1.5
Propane Refrigeration System (PU-05): ...................................................................................... 4
1.6
Flare (PU-06): .............................................................................................................................. 5
1.7
Heat Medium System (PU-07):.................................................................................................... 5
1.8
Fire Water Pump Station (PU-08):............................................................................................... 8
1.9
Stationary Fire Fighting System (PU-20): ................................................................................... 8
1.10 Instrument Air Generation (PU-09): ............................................................................................ 8
1.11 Nitrogen Generation (PU-10): ..................................................................................................... 8
1.12 Service Generators (PU-11):........................................................................................................ 8
1.13 Loading Station (PU-13):............................................................................................................. 8
1.14 Raw Water Treatment (PU-15):................................................................................................... 8
1.15 Diesel Engine Generator (PU-17):............................................................................................... 8
2 Specific Process ................................................................................................................................... 9
2.1
TEG Dehydration System ............................................................................................................ 9
3 Improvement of Glycol-Condensate separation. ............................................................................... 11
4 Prevention of Hydrate Formation (Freeze Ups)................................................................................. 12
5 Fighting Hydrate Formation............................................................................................................... 13
6 Amine System .................................................................................................................................... 14
6.1
Amine Analysis.......................................................................................................................... 14
6.2
Troubleshooting ......................................................................................................................... 14
7 Vapor-Liquid Separators.................................................................................................................... 16
8 Pumps................................................................................................................................................. 17
9 Reciprocating Compressors ............................................................................................................... 18
10
Centrifugal Compressors ............................................................................................................... 20
11
Fractionation Columns................................................................................................................... 22
12
Flare ............................................................................................................................................... 23
12.1 Flame Stability ........................................................................................................................... 23
12.2 Ignition system / Pilot failure. Spark does not appear in ignition chamber. .............................. 23
12.3 Ignition system / Pilot failure. Spark appears, but there is not fireball generated. .................... 24
12.4 Ignition system / Pilot failure. Ignition is generated but pilots do not light. ............................. 24
12.5 Pilots are lit but will not prove................................................................................................... 24
12.6 Pilot fails frequently................................................................................................................... 25
13
Flow Measurement......................................................................................................................... 26
13.1 Orifice Meters ............................................................................................................................ 26
13.2 Turbine Meter ............................................................................................................................ 27
13.3 Rotameter ................................................................................................................................... 27
14
Control system ............................................................................................................................... 28

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General

Troubleshooting is described by suggesting possible causes of the more common problems

and discussing corrective measures.
It will be described in specific process and process equipments. Refer also to vendors manuals
for further information.
Package Units:
- Stabilizer Ovhd Compressor Unit (PU-01):
- Deethanizer Ovhd Compressor Unit (PU-04):
- Acid Gas Incinerator Unit (PU-02):
- TEG Dehydration System (PU-03):
- Propane Refrigeration System (PU-05):
- Flare (PU-06):
- Heat Medium System (PU-07):
- Fire Water Pump Station (PU-08):
- Stationary Fire Fighting System (PU-20):
- Instrument Air Generation (PU-09):
- Nitrogen Generation (PU-10):
- Service Generators (PU-11):
- Loading Station (PU-13):
- Raw Water Treatment (PU-15):
- Diesel Engine Generator (PU-17):

Specific Process:
- TEG Dehydration Unit
- Improvement of Glycol-Condensate separation
- Prevention of Hydrate Formation (Freeze Ups)
- Fighting Hydrate Formation
- Amine System
Process Equipments:
- Vapor-Liquid Separators
- Pumps
- Reciprocating Compressors
- Centrifugal Compressors
- Fractionation Columns
- Flare System
- Flow Measurement
- Control system

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Package Units

1.1

Stabilizer Ovhd Compr. Unit (PU-01) :

See manufacturers documentation.Operating and Maintenance Specification, point 5. Signs

of Irregularities, Doc-No.: 3498-1.

1.2

Deethanizer Ovhd Compr. Unit (PU-04):

See manufacturers documentation Operating and Maintenance Specification, point 5. Signs of

Irregularities, Doc-No.: 3498-2.

1.3

Acid Gas Incinerator Unit (PU-02):

See also manufacturers documentation.

1.4

TEG Dehydration System (PU-03):

See manufacturers document Operating Manual PU-03, Doc.-No.: 12466-01-90381

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1.5

Propane Refrigeration System (PU-05):

See also manufacturers documentation.

1.) High compressor discharge temperature:

Check accumulator (Liquid Receiver, GV-675) temperature:
If the accumulator (Liquid Receiver, GV-675) temperature is high, check:
a. Condenser Operation for fouling.
b. High air temperature.
c. Low fan speed.
If condensing temperature is normal, check for:
a. Non-condensables in Refrigerant (introduced air or poor Refrigerant Spec.).
b. Restriction in system, which is creating pressure drop.
2.) High Process temperature:
Check Refrigerant temperature from Chiller (GE-302):
If Refrigerant temperature is high and approach temperature on Chiller is normal, check:
a. Chiller pressure.
b. Refrigerant composition for heavy ends contamination.
c. Refrigerant circulation or kettle level (possible inadequate flow resulting in superheating of
Refrigerant)
d. Process overload of refrigerant system.
If Refrigerant temperature is normal, and approach to process temperature is high, check:
a. Fouling on Refrigerant side(lube oil or moisture)
b. Fouling on process side(wax or hydrates)
c. Process overload of Chiller capacity.
3.) Inadequate Compressor capacity:
Check:
a. Process overload of Refrigerant System.
b. Premature opening of hot gas bypass.
c. Compressor valve failure.
d. Compressor suction pressure restriction.
e. Low Compressor speed.
4.) Inadequate Refrigerant flow to Economizer (GE-676) or Chiller (GE-302):
Check:
a. Low accumulator level.
b. Expansion valve capacity.
c. Chiller or economizer level control malfunction.
d. Restriction in Refrigerant flow (hydrates or ice).
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1.6

Flare (PU-06):

See below and manufacturers document Installation, Operating and Maintenance Manual PU06, Doc.-No.: 12466-01-90645, Section 6.

1.7

Heat Medium System (PU-07):

See also manufacturers documentation.

1.) Leak Detection:
One of the simplest leak detectors for thermal fluid is the smoke that shows up when the hot
fluid is exposed to air. The amount of smoke depends on the size of the leak, the temperature
of the fluid and to some extent the airflow in the area. Small oozing leaks can produce an
exaggerated amount of smoke because there isn't enough fluid to form a drop. This steady
weeping smokes and then cooks onto the metal near the leak, leaving dark stains, or - in time a carbon crust.
With larger leaks, the fluid usually cools quickly as it drips or sprays into the air. Since smoke is
actually the reaction of the heat transfer fluid's volatile low-boiling portions (smaller molecules)
with oxygen in the air, this cooling reduces the vaporization of fluid which helps lessen the
amount of smoke. However, if the leak is large enough that its oxidation uses up all the fresh air
- or if ventilation is insufficient - vapor can accumulate and cause a potential fire hazard.
2.) Detecting Water in the System
Water in a running hot-oil system is relatively easy to detect:
Small water infiltrations (less than 300- 400 ppm) can show up as pump pressure
fluctuations. These fluctuations most always produce pump noise and dancing pressure-gauge
needles. While significant pump noise can mean a bad gauge or loose coupling, it almost
always points towards water.
It may be easy to ignore or misinterpret the fluctuations considering that fluid temperature at the
heater outlet is so much above water's atmospheric boiling point. However, the lowest fluid
temperature -- and pressure -- in the system is at pump suction. That temperature and pressure
determines whether the water will be liquid or gas at that point in the system.
So if the fluctuations or cavitations start suddenly while the system is heating up, you know
there are low levels of water in the fluid.

3.) Fluid Damage

There are three ways the fluid can be bruised: oxidation, overheating, and contamination.
Oxidation occurs when hot fluid comes in contact with the oxygen found in air. The fluid will
start to smoke (like overheated vegetable oil) and will become acidic and corrosive. And as the
fluid oxidizes, it becomes less efficient-and less resistant to heat.
Overheating occurs as the fluid's film temperature rises above its recommended maximum.
The fluid starts to distill, with the smaller molecules beginning to boil and vaporize. Viscosity
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(thickness) increases causing flow to decrease. This allows the fluid to linger in contact with the
heated surface and pick up too much heat. As temperatures continue to rise, the fluid's
molecules can break apart (called "cracking"). As the fluid's chemical bonds begin to break, the
fluid releases sooty carbon. Allowed to continue unchecked, the process repeats itself until all
the fluid has been reduced to carbon.
Contamination results from foreign matter in the system. In new systems, incomplete cleaning
can leave weld slag, spatter and flux, dust and dirt, and quench oils and protective lacquers to
mix with the fluid. In existing systems, dirty bruised fluid may remain, or a non-compatible fluid
may have been added.
4.) System Problems
Overheating is caused by loss of input heat control or a decrease in fluid flow.
Input Heat Control
Problems with the equipment include improper flame propagation in fossil-fired heaters, and
controller glitches or human failure. Power failures and "bumps" can drop the pump motor out.
The fluid, standing stagnant in the tubing of fossil- fired heaters, absorbs heat radiating and
convecting from the refractory and starts to boil*.
Flow
Reduction in flow is the most common cause of overheating. As flows decrease, fluid velocity
and turbulence also decrease, and the heat transfer fluid remains in prolonged contact with the
heated surfaces. Even though the system's bulk fluid temperature may not change much, the
film temperature can rise dramatically-and quickly. This extra heat is no longer transferred as
rapidly to the bulk of the fluid, and the fluid decomposes at the heated surface.
As molecules at the film layer degrade, carbon can be formed. This carbon adheres to the
heated surfaces and bakes on--thickening as the process repeats itself and successive layers
are added. Difficult to remove, the carbon coating acts as an insulator both in heater tubing and
on electrical heater elements, and can severely affect flows. The carbon that escapes or breaks
away from the heated surface is carried throughout the system, and can lodge in restrictions,
clog small channels and hang up control valves-further contributing to the problem.
In addition, the fluid is now more viscous. Not flowing as well, it remains in contact with the
heated surface longer, picking up even more heat and continuing to overheat, degrade and
foul.
Flows may decrease for a variety of reasons-contaminants lodged in valves, lines or strainers,
bypass valves hanging up, pump problems, out-of-spec components or the wrong valves
mistakenly closed.
Solutions
Never exceed the maximum film or bulk temperature of any heat transfer fluid. This is possible,
but in practice not very easy or inexpensive (power failures alone can victimize even the most
fail-safe system-not to mention operator error or worn components).
Specify a heat transfer fluid that does not foul when severely overheated.

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5.) Oxidation Symptoms

Hydrocarbon liquids will oxidize when exposed to continuous supplies of fresh air
Your heat transfer fluid will begin to darken and smell pungent ("acidy" or "vinegary"), as acidic
carbonaceous sludge* is produced. Eventually, the sludge deposits on all surfaces in the
system. Inside the heater these deposits harden and permanently reduce heat transfer. In the
heat user these deposits can plug up lines.
6.) Unusual Smells
Sniff the air in the heater room, and in the area near the heat user. If you detect a "varnishy,"
"burnt" or "acidy" pungent odor, the fluid is probably "bruised" and the odors may be escaping
from the system. You'll want to find the source of the leak, and determine if repairs are
necessary.
7.) Cleaning the System
This procedure will help remove the degraded fluid that contains acids and solid contaminants.
The cleaner the system, the longer and more efficiently it will operate. And the fluid will last
longer too.
1. Drain the existing fluid as completely as possible.
2. Remove solid matter from system. This may require chemical
cleaning with oxidizing agents, circulating hydrocarbon solvents or manual scraping of
surfaces.
3. Thoroughly flush with heat transfer fluid of the same type you will operate in the system.
4. Shortly after system startup, send a fluid sample to your thermal fluid supplier for analysis.

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1.8

Fire Water Pump Station (PU-08):

No special hints.
See also manufacturers documentation.

1.9

Stationary Fire Fighting System (PU-20):

No special hints.
1.10

Instrument Air Generation (PU-09):

No special hints.
See manufacturers documentation (on site only).
1.11

Nitrogen Generation (PU-10):

No special hints.
See manufacturers documentation (on site only).
1.12

Service Generators (PU-11):

No special hints.
This unit is a fully automated plant with no need for manual intervention, deviations are alarmed
and lead to the respective reaction of the unit control up to its shut down.
Refer to the manufacturers documentation Functional Description; Cause and Effect , Doc.no.: 100004069984; respectively 12466-01 911141.
1.13

Loading Station (PU-13):

No special hints.
See manufacturers documentation.
1.14

Raw Water Treatment (PU-15):

No special hints.
See manufacturers document Operating & Maintenance Manual Raw Water Treatment PU15, Doc.-No.: 12466-01-91502.
1.15

Diesel Engine Generator (PU-17):

No special hints.
See manufacturers documentation.

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Specific Process

2.1

TEG Dehydration System

1. High Exit Gas Dew Point
- Change in gas flow rate, temperature or pressure
- Insufficient glycol circulation
- Poor glycol re-concentration
- Current operating conditions different from design
- Malfunction of inlet separator.

2. High Glycol Losses

First determine where loss is occurring: from contactor (i.e. downpipe line), out of still column,
or leaking from pump.
a.
-

Loss from contactor

Inlet separator passing liquids
Carryover due to excessive foaming
Mist extractor plugged or missing
Lean glycol entering contactor too hot
Plugged trays in contactor
Excessive gas velocity in contactor

b.
-

Loss from still

Excessive stripping gas
Flash separator passing condensate
Packing in still column is broken, dirty, plugged
Insufficient reflux cooling at top of still
Too much cooling at top of still
Temperature at top of still is too high

c. Loss from separator

- Glycol dumped with hydrocarbons
d. Leak, spills, etc
- Check piping, fittings, valves, gaskets
- Check pumps, especially packing or mechanical seals.
3. Glycol Contamination
- Carryover of oils (e.g., compressor lube oils), brine, corrosion inhibitors, well
treating chemicals, sand, corrosion scales, etc., from inlet separators
- Oxygen leaks into glycol storage tanks, etc
- Inadequate pH control (low pH) increases corrosion
- Overheating of glycol in reboiler due to excessive temperature or hot spots on fire
tube
- Improper filtration, plugged filters, bypassing of filters
- Improper cleaning of glycol unit, use of soaps or acids
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4. Poor Glycol Re-Concentration
- Low reboiler temperature
- Insufficient stripping gas
- Rich glycol leaking into lean glycol in glycol heat exchanger
- Overloading capacity of reboiler
- Fouling of fire tubes in reboiler
- Low fuel rate or low Btu content of fuel
- Glycol foaming in still column
- Dirty and/or broken packing in still column
- Flooding of still column
- High still pressure
5. Low Glycol Circulation-Glycol Pump
- Checks pump operation. Check circulation by stopping glycol discharge from
contactor and timing fill rate of gauge column on chimney tray section.
- Check pump valves to see if worn or broken
- Plugged strainer, lines, filters.
- Vapor lock in lines or pump
- Low level in accumulator
- Excessive packing gland leakage
- Contactor pressure too high
6. High pressure drop across contactor
- Excessive gas flow rate
- Operating at pressures far below design
- Plugged trays and/or demister pads
- Glycol Foaming
7. High stripping still temperature
- Inadequate reflux
- Still column flooded
- Glycol foaming
- Carryover of light HC in rich glycol
- Leaking Reflux Coil
8. High Reboiler Pressure
- Packing in still column is broken and/or plugged with tar, dirty, etc
- Restricted vent line, not sloped
- Still column is flooded by excessive boil up rates and/or excessive reflux cooling.
- Slug of liquid HC enters stripper, vaporizes on reaching reboiler, and blows liquids
out of still.
9. Fire tubing Fouling/Hot Spots/Burn Out
- Buildup of salt, dust, scales, etc., on fire tube. Check inlet separator
- Deposition of coke, tar formed by glycol overheating and/or hydrocarbon
decomposition.
- Liquid glycol level drops exposing fire tubes
10. Low Reboiler Temperature
- Inadequately sized fired tube and/or burner.
- Setting temperature too low
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-

More water in inlet gas because pressure is low or temperature high

Temperature controller not operating correctly
Carryover of water from inlet separator
Inaccurate reboiler thermometer

11. Flash separator Failure

- Check level controllers
- Check control valves
- Excessive circulation

Improvement of Glycol-Condensate separation.

If condensate samples taken downstream of the vessels GV-419 and GV-420 appear cloudy,
then glycol-condensate separation is incomplete. (This is valid in case of used glycol injection,
see below.) Possible causes are:

Excessive gas velocities in the separator

Foaming and/or emulsion forming in the separator
Plugging of the glycol flow control valve
Improper operation of the liquid-level controllers in the vessel boots

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APPENDIX 13
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Prevention of Hydrate Formation (Freeze Ups)

4
See PFD:

12466-01 10102, 10103, 10113

In case of low throughput of Raw Gas to the Gas Treatment Plant at low ambient temperatures
(winter) and expected no hydrate inhibition at the well sites, it is advisable to use the preventive
injection of glycol (regenerated TEG) downstream the Shut-Off Valves (UV-G101H and UVG102H) in the hydrocarbon liquid lines from the Inlet Separators (GV-101/-102/-103).
The respective manually operated valves are situated near the injection points and the
respective flow meters (FI-G101J and FI-G102J) to adjust the throughput of glycol.
Another possibility of glycol injection is foreseen to the tube sheet of the Deethanizer
Condenser GE-407 in case of expected trouble with freezing there (in case that excessive
amount of water managed its way from the Inlet Separators down to Deethanizer Feed Drum
GV-419).
In case of malfunction of the glycol injection, check the following:

Be sure that the Inlet Separators are removing all free water and potential contaminants
such as salt and solids
Check the glycol circulation rate: make sure the circulation pump GP-370A/B is working
properly.
Check the glycol concentration. Hydrometers can provide simple and rapid
determination of approximate water content of glycol solutions. However, glycols often
become contaminated with salt or other chemicals that alter the specific gravity.
As the glycol for injection is taken as a small stream from the TEG Regeneration of the
Dehydration System, Unit 350, PU-03, refer to the manufacturer documentation of this
unit.

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5
See PFD:

Fighting Hydrate Formation

12466-01 10102, 10103, 10109, 10113

In case of expected trouble with freezing and especially in case of freezing that is already
developing it is possible to inject methanol to several points; these are:
Upstream of the inlet control valves upstream the Inlet Separators.
Upstream the level control valves of the Produced Water and the HC Liquids from the Inlet
Separators.
Upstream the Sweet Gas inlet of the Gas/Gas Exchanger GE-301A/B/C/D/E/F.
Upstream of the Sweet Gas inlet to Gas Chiller GE-302.
To the tube sheet of GE-302.
Downstream of the HC Liquid outlet of the Low Temperature Separator GV-304.
Upstream the vapor inlet to the Deethanizer Condenser GE-407 (tube side).
The respective manually operated valves are situated near the injection points and the
respective flow meters to adjust the throughput of methanol.
Normally all this valves are closed. Check at all respective flow meters that theres no flow.
As possible freezing wont develop in the whole plant use the methanol injection only at the
affected points.
In case of malfunction of the methanol injection, check the following:
Check the methanol concentration (100% methanol shall be used).
Check the function of the Methanol Injection Pump GP-161A/B.

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Amine System

6.1

Amine Analysis

The color of the regenerated solution can be most informative about the process:
- Straw or light brown: good condition and well regenerated
- Green: very fine FeS particles (less than 1 micron). Larger FeS particles are black
and will set
- Blue, green: copper or nickel presented.
- Amber, dark red: iron compounds complexed with the amine
- Red, brown: either oxidation products or thermal degradation.
The following analysis may be used to determine the condition of the amine:
- Alkalinity titration: amine concentration
- Gas Chromatography: free amine, degradation products, acid gas
- Total and primary nitrogen
- Acid gas loadings: H2S, CO2
- Karl Fischer: water content
- Element analyses: Fe; Cl; Al; Cu; Na; etc
- Foam: extent and stability
The weekly amine analysis is most informative. Check the amine concentration: too high
increases corrosion, and too low increases circulation rate and wastes fuel. Check the acid gas
loadings: rich stream too high increases the corrosion rate, and too low indicates inefficient use
of the amine and too high a circulation rate; lean stream too high indicates poor generation and
too high a circulation rate, and too low means unnecessary regeneration and fuel usage. Check
the pH: too low add soda ash. Check the make up water quality regularly.

6.2

Troubleshooting

Consult the daily record sheets. Sudden changes in operating conditions are the best clues for
malfunctions. Frequent problems and corrective procedures are:
1. Gas is not Sweet
- Check amine solution concentration. If too low: check makeup water addition.
- Check amine flow rate. If too low: Open bypass valve
- Check amine regeneration: increase heating rate
- Check reflux rate and temperature: probably too low, increase heating rate
- Check amine contactor column pressure. It may be too low
- Check for foaming: carryover into outlet separator and/or pressure fluctuations

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2. Amine solution not regenerated
- Check reboiler temperature, pressure and the reflux rate. If pressure in The
Amine Regenerator Reboiler GE-207 is exceeding 0,7 to 1.0 bar(g), thermal
decomposition of the amine is occurring (see also at Foaming)
- Check for leaks in lean/rich amine heat exchangers
- Check for foaming in amine contactor column: pressure fluctuations
3. Dirty, degraded amine
- Gas contains oxygen
- Storage tank and blanket gas valve is not functioning: repair
- Makeup water contains free oxygen: add oxygen scavenger
4. Excessive corrosion
- Amine concentration is too high: add makeup water
- Amine is highly degraded: replace
- Makeup water is high in dissolved solids: treat makeup water or use
demineralized water
- Insufficient amine filtration: increase filter rate or change filter elements more
frequently
- Oxygen is entering system: eliminate
- Velocities too high: reduce temperature to Amine Contactor.
5. Foaming of Amine Solution
Foaming is a very unpredictable phenomenon. It can be caused by any or a
combination of the following conditions:
- Dirty amine (solids): Check filter elements
- Degraded amine
- Liquid hydrocarbons in amine. Lower Temperature in Lean Amine than Sour Gas
Inlet causes condensation of hydrocarbons and foaming may occur
- Inlet Gas temperature too low: Hydrocarbon condensation
- Inlet amine temperature too low
- Wrong or off-spec. chemicals
- Well treating chemicals
- Surfactants
- Corrosion inhibitors
- Very fine particles; e.g., iron sulfide, in sour gas
- Inadequate cleaning of amine plant before start up
- Misuse or abuse of antifoam chemicals in amine units, too much or too little
defoamer
- Incoming gas is not adequately scrubbed and contains salt water or produced
water.
- Makeup water contains iron, sulfides, chlorides, etc (use demineralized water)

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APPENDIX 13
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7

Vapor-Liquid Separators
1. Low Liquid Level
- Level control valve opening too wide or trim cut out
- Drain valve open or leaking
- No fluid entering
2. High Liquid Level
- Level control valve closed or plugged
- Outlet Valve around control valve closed
- Separator Overloaded
3. Low Pressure in Separator
- Pressure control valve is not working
- Leaking safety relief valve
- Inlet Valve closed
4. High Pressure in Separator
- Pressure control valve is not working
- Valves downstream separator are closed
5. All the oil going out gas line
- Level control valve not open
- Block valve closed in liquids stream
- Separator or piping plugged
6. Mist going out gas line
- Plugged demister
- Improper liquid level (too high or too low)
- Foaming problem
7. Free gas going out oil valve
- Too Low level in separator
- Control valve not seating
- Vortex breaker plugged or damaged
8. Gas going out water valve
- Same as free gas going out oil valve
9. Too much gas going out oil valve
- Foaming Oil
- Too much pressure drop from separator to downstream equipments
- Condensate to downstream equipments too cold
10. Condensate and water not separating in Inlet Vessel Separator
- Not enough retention time

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11. Diaphragm operated Control valve not opening:
- Pilot Failure: supply gas failure; orifice stopped up; out of adjustment
- Broken valve stem
- Plugged Tubing
- Ruptured Diaphragm
- Stopped up vent in upper case
- Leak in line from pilot to valve

Pumps
1. Liquid not delivered
- Pump Not Primed
- Air or vapor pocket in line
- Pump not up rated speed
- Wrong rotation
- Impeller or passages clogged
2. Failure to deliver rated capacity and pressure
- NPSHA not sufficient
- Pump not up rated speed
- Wrong Rotation (reverse phases)
- Impeller or passages partially clogged
- Wear rings worn or impeller damaged
- Air or gases in liquid
- Viscosity or specific gravity not as specified
- Air or vapor pocket in suction line
- Air leak in stuffing box
- Total head greater than head for which pump designed
- Injection of low vapor pressure oil in lantern ring of hot pump
3. Pump loses prime
- Air leak in suction line
- Air leak in stuffing box
- Air or gases in liquid
4. Pump overloads driver
- Speed to high
- Specific gravity or viscosity too high
- Packing or mechanical seal too tight
- Misalignment
- Total head lower than rated head
- Low voltage or electrical trouble
- Trouble with engine, gear or other allied equipment
5. Pump Vibration
- Available NPSH not sufficient
- Air or gases in liquid
- Misalignment

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-

Worn bearings
Damaged rotating element
Foundation not rigid
Pump operating below minimum recommended capacity
Impeller Clogged

6. Stuffing box overheats

- Packing or mechanical seal too tight
- Packing or mechanical seal not lubricated
- Incorrect type of Packing or mechanical
- Gland cocked
7. Bearings overheat or wear rapidly
- Incorrect oil level
- Misalignment or piping strains
- Insufficient cooling water
- Bearings too tight or preloaded
- Oil rings not functioning
- Suction pressure appreciably different than specified
- Improper lubrication
- Vibration
- Dirt or water in bearings

Reciprocating Compressors
1. Compressor will not start
- Power supply failure
- Switchgear or starting panel
- Low oil pressure shut down switch
- Control panel
2. Motor will not synchronize
- Low voltage
- Excessive starting torque
- Incorrect power factor
- Excitation voltage failure
3. Low oil Pressure
- Oil pump failure
- Oil foaming from counterweights striking oil surface
- Cold oil
- Dirty oil filter
- Interior frame oil leaks
- Excessive leakage at bearing shim tabs and/or bearings
- Improper low oil pressure switch setting
- Low gear oil pump by-pass/relief valve setting
- Defective pressure gauge
- Plugged oil sump strainer
- Defective oil relief valve

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APPENDIX 13
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4. Noise in cylinder
- Loose piston
- Piston hitting outer head or frame end of cylinder
- Loose crosshead lock nut
- Broken or leaking valve(s)
- Worn or broken piston rings or expanders
- Valve improperly seated/damaged seat gasket
- Free air unloader plunger chattering
5. Excessive packing leakage
- Worn packing rings
- Improper lube oil and/or insufficient lube rate (blue rings)
- Dirt in packing
- Excessive rate of pressure increase
- Packing rings assembled incorrectly
- Improper ring side or end gap clearance
- Plugged packing vent system
- Scored piston rod run-out
6. Packing Over heating
- Lubrication failure
- Improper lube oil and/or insufficient lube rate
- Insufficient cooling
7. Excessive carbon on valves
- Excessive lube oil
- Improper lube oil (too light, high carbon residue)
- Oil carryover from inlet system or previous stage
- Broken or leaking valves causing high temperature
- Excessive temperature due to high pressure ratio across cylinders
8. Relief valve popping
- Faulty relief valve
- Leaking suction valves or rings on next higher stage
- Obstruction (foreign material, rags), blind or valve closed in discharge line
9. High discharge temperature
- Excessive ratio on cylinder due to leaking inlet valves or rings on next higher
stage
- Fouled intercooler/piping
- Leaking discharge valves or piston rings
- High inlet temperature
- Fouled water jackets on cylinder
- Improper lube oil and/or lube rate
10. Frame knocks
- Loose crosshead pin, pin caps or crosshead shoes
- Loose/worn main, crankpin or crosshead bearings
- Low oil pressure
- Cold oil
- Incorrect oil
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APPENDIX 13
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Knock is actually from cylinder end

11. Crankshaft oil seal leaks

- Faulty seal installation
- Clogged drain hole
12. Piston Rod oil scrapper leaks
- Worn scrapper rings
- Scrappers incorrectly assembled
- Worn/scored rod
- Improper fit of rings to rod/side clearance.

10

Centrifugal Compressors
1. Low discharge pressure
- Compressor not up to speed
- Excessive compressor inlet temperature
- Low inlet pressure
- Leak in discharge pipeline
- Excessive system demand from compressor
2. Compressor surge
- Inadequate flow through the compressor
- Change in system resistance due to obstruction in the discharge piping or
improper valve position
- Deposit buildup on rotor or diffusers restricting gas flow
3. Low lube oil pressure
- Faulty lube oil pressure gauge or switch
- Low level in oil reservoir
- Oil pump suction plugged
- Leak in oil pump suction piping
- Clogged oil strainers or filters
- Failure of both main and auxiliary pumps
- Operation at low speed without the auxiliary oil pump running (if main pump is
shaft-driven)
- Relief valve improperly set or stuck open.
- Leaks in the oil system
- Incorrect pressure control valve setting or operation
- Bearing lube oil orifices missing or plugged
4. Shaft Misalignment
- Piping strain
- Warped bedplate, compressor or driver
- Warped foundation
- Loose or broken foundation bolts
- Defective grouting

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APPENDIX 13
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5. High bearing Oil Temperature (Note: Lube oil temperature leaving bearings should never
permitted to exceed 82 C)
- Inadequate or restricted flow of lube oil to bearings
- Poor conditions of lube oil or dirt or gummy deposits in bearings
- Inadequate cooling water flow lube oil cooler.
- Fouled lube oil cooler
- Wiped bearing
- High oil viscosity
- Excessive vibration
- Water in lube oil
- Rough journal surface
6. Excessive vibration (Note: vibration may be transmitted from coupled machine. To
localize vibration, disconnect coupling and operate driver alone. This should help to
indicate whether driver or driven machine is causing vibration)
- Improperly assembled parts
- Loose or broken bolting
- Piping strain
- Shaft misalignment
- Worn or damaged coupling
- Dry coupling (if continuously lubricated type is used)
- Warped shaft caused by uneven heating or cooling
- Damaged rotor or bent shaft
- Unbalanced rotor or warped shaft due to severe rubbing
- Uneven build-up of deposits on rotor wheels, causing unbalance
- Excessive bearing clearance
- Operating at near critical speed
- Operating in surge region
- Liquids slugs striking wheels
- Excessive vibration of adjacent machinery (sympathetic vibration)
7. Water in lube oil
- Condensation in oil reservoir
- Leak in lube oil cooler tubes or tube-sheet

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APPENDIX 13
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11

Fractionation Columns
1. Blowing
- Caused by excessive vapor velocity through the tray openings at relative low liquid
loadings. Liquid is blown into a fine spray that leaves tray essentially dry. The high
velocity through the holes is caused by high vapor loading, low percent open area on
the tray, or both. Anti-blowing baffles and picket fence overflow weirs shall be used
for correction.
2. Low Tray Efficiency
- Caused by Dumping (excessive leakage of liquid through the tray openings)
- At low liquid rates the leakage through the drain holes may allow an unacceptably
large fraction of the liquid itself to bypass the contacting zone
3. Flooding
- Caused by an unsealed downcomer which results in vapor flowing up the downcomer
instead of through the tray contacting area. The increased aeration of liquid in the
downcomer can cause excessive backup and premature tray flooding at design or
lower rates.
- If liquid velocity into the downcomer is exceeded, the increased downcomer level due
to excessive aeration may cause flooding of the tray. In addition, the vapor in the
froth mixture may be of such magnitude that when it disengages on the tray below, it
establishes a vapor recycle that can overload the tray and result in premature jet
flooding.
- High tray pressure drop or insufficient disengaging of vapor in the downcomer results
in a buildup of froth in the downcomer and eventual tray flooding
- Insufficient tray spacing. Liquid exceeds maximum height in downcomer.
- Insufficient downcomer residence time.
4. Entrainment Flooding or Jet Flooding
- Caused by carryover or jetting of liquid droplets from one tray to the tray above
because excessive vapor velocity through the column free area. This condition is a
vapor handling limitation.
5. Weepage and pulsation
- Liquids leak through tray holes, risers or valves, instead of flowing over the weir. This
can occur with low vapour velocities.
6. Maldistribution of liquid
- Less than inch crest over outlet weir. Saw tooth weirs or picket fence weirs shall
be used for correction.
7. Maldistribution of vapors
- Uneven vapor flow caused by high hydraulic gradients or uneven liquid distribution.
Vapor tunnels and weir baffles shall be used for correction.
8. Hydraulic Jump
- Liquid jumps over downcomer. Anti-jump baffles shall be used for correction.

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APPENDIX 13
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12

Flare

12.1

Flame Stability

1. Flashback.
- It could occur if for a period of time, few or no gas is burned at the flare tip. If air
diffuses back into the flare stack, subsequent ignition can cause heating of the
flare tip (with resultant damage) or even an explosion. Prevention of flashback is
by purging adequately the flare system.
2. Blow-off.
- Velocity of the gas issuing the flare is quite high (above the flame velocity), the
position of the flame can lift off the top of the flare to a position where the velocity
of the gas plus entrained air is equal to the flame velocity. It is avoided by limiting
the flare-tip gas velocity.
3. Blow-out.
- Occurs when the flame is extinguished by Blow-off. It is avoided by limiting the
flare-tip gas velocity.
4. Burn-back.
- It is caused by low purge-gas rates, in which the flame front is inside and slightly
below the flare stack tip. It causes deterioration of the flare tip. One method to
avoid it is to increase the purge gas rate until the flame is plainly visible above the
flare tip.

12.2

Ignition system / Pilot failure. Spark does not appear in ignition

chamber.

1. Moisture.
- Check if ignition chamber is free of moisture, both inside the chamber and above
the spark plug where the ignition wire connects.
2. Pressure.
- High pressure inside the ignition chamber will prevent a spark from occurring.
Make sure an ignition line to a pilot is open and clear of obstructions or
condensate. Turn on the ignition air, then shut off the air. The pressure indicator
should quickly drop to zero differential pressure.
3. Power.
- Check that the primary power is reaching the ignition transformer.
4. Continuity.
- Check cable from transformer to spark plug. Replace if frayed or cracked. Confirm
connections are tight at both ends. Check that the casing of the ignition
transformer and the ignition chamber are grounded.

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12.3

Ignition system / Pilot failure. Spark appears, but there is not

fireball generated.

1. Improper Mixture.
- Check if the air and gas orifices are correct for the ignition gas utilized
2. Faulty solenoid valve.
- In automatic systems, solenoid valves are used to control the ignition air and fuel.
A faulty valve can cause a pulsating flow which will prevent the correct mixture
from being generated. A pulsating flow can be deduced from watching the needle
of the pressure gauge.

12.4

Ignition system / Pilot failure. Ignition is generated but pilots do not

light.

1. Condensate in ignition line.

- Open ignition line drain valves to drain condensate. If drain valves are not
available, allow ignition air to flow through line for a period of time to dry out the
line.
2. Detonation in Flame From Generator (FFG).
- A loud bang during ignition indicates a detonation is occurring in the ignition line.
This is typically caused by short FFG lines. Reduce the gas pressure around 0,15
bar(g). Reduce the air pressure to below 0,15 bar(g). Press the ignition
pushbutton and verify if ignition is occurring in the sight glass. If not, increase the
air pressure slightly. Press the ignition pushbutton and verify if ignition is
occurring in the sight glass. Repeat incrementing the air pressure and pressing
the ignition pushbutton until ignition occurs. Once ignition is achieved, allow
sufficient time for the ignition line to fill with fuel/air mixture.
3. Pilot gas failure.
- Verify that pilot gas is at the correct pressure and flowing to the pilot. Verify that
the pilot gas orifice is clear and sized according to data sheet. On a new
installation, make sure that the pilot gas has flowed long enough to purge all the
air from upstream piping.

12.5

Pilots are lit but will not prove.

1. Broken thermocouple.
- Disconnect thermocouples from terminals in panel and check continuity. If an
open circuit is detected, replace thermocouple at first opportunity.
2. Pilot proved set-point too high.
- Lower the set-point until the pilot proves.
3. Incorrect wiring.
- Confirm that thermocouples are correctly wired. Confirm that the ignition lines are
paired up with the correct thermocouples.
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APPENDIX 13
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12.6

Pilot fails frequently.

1. Pilot gas failure.

- Verify that the pilot gas is at the correct pressure and flowing to the pilot. Verify
that the pilot gas orifice is clear and sized according to data sheet. Verify that all
strainers are clear. Make sure that the pilot gas has flowed long enough to purge
all the air from upstream piping.
2. Intermittent Gas Pressure.
- Short duration reductions in pilot gas supply pressure can cause pilot failure.
Certain plant operations can cause such dips. A clue that this may be the case is
the pilot failure appears to occur around the same time every hour, day, week,
etc. To determine if such dips are occurring, log the pilot gas pressure over the
time in question. If such dips are occurring, steps should be taken to ensure a
constant gas supply pressure.
3. Blockage between mixer and pilot tip.
- Pilots that have experienced long term exposure to high temperatures can
become deformed or damaged. Such tips should be replaced. Pilots that have sat
idle for long periods may have acquired wasps nests or other obstructions inside
the pilot or around the tip. Clean out all such obstructions.
4. High winds.
- High winds can cause the pilot extinguish. Increasing the gas pressure can help
stiffen the flame and make it less susceptible to being blown out by the wind.
Wind shields can be used around the pilot mixer to improve flame stability.

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APPENDIX 13
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13

Flow Measurement

13.1

Orifice Meters

1. Low or no reading
- Orifice plate installed backward or oversize.
- Flow blocked upstream
- Density changes in process media
- Pressure-tap holes and/or piping plugged
- Bypass valve open or leaking
- Liquid or gases trapped in piping
- Block or shut-off valves closed
- Piping leaks, high-pressure side
- Housing filled with solids
- Gas trapped in housing in liquid service
- Liquid trapped in housing in gas service
- High-Pressure (HP) housing gasket leaks
- Pointer loose
- Mechanism out of calibration
- Corrosion or dirt in mechanism
2. Indicates high
- Orifice partially restricted or too small
- Leak in low-pressure side piping
- Loss of liquid in reference leg (liquid level)
- Gas trapped in low pressure housing, liquid service
- Liquid trapped in high pressure housing, gas service
- Low-pressure (LP) housing gasket leaks
- Bellows range spring broken
- Mechanism out of calibration
3. Erratic Indication
- Flow pulsating
- Liquid trapped in gas piping
- Gas bubble in liquid piping
- Vapor generator incorrectly installed
- Reference leg gassy or liquid vaporizing
- Obstructed bellows travel
- Gas trapped in DPU, HP or LP pressure housing
- Mechanism linkage dragging or dirty
- Pointer dragging on scale plate

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13.2

Turbine Meter
Condition
No output pulses from
amplifier module

Cause
1. Input Voltage to amplifier
below minimum required for
operation
2. Damage amplifier module
3. Receiver unit not operating
4. Turbo-meter rotor not
operating

Correction
1. Replace Pick-off
2. Replace amplifier
module
3. Refer to instruction
manual on defective unit
4. Trouble shoot rotor

Turbo-Meter rotor not

turning

1. Defective rotor shaft

bearings
2. Rotor Damaged by foreign
material passing through meter
1. Shared coupling
2. Rotor not turning
3. Bevel gears worn out
4. Gears in register cup worn
out
5. Defective accessory
equipment
6. Shaft not aligned with
coupling
7. Driven magnet slipping on
shaft
8. Broken shaft

1. Replace bearings
2. Send rotor to factory for
replacement or repair

No mechanical output

Inaccurate readout

13.3

1. Foreign material on rotor

blades
2. Rotor blades bent
3. Defective accessory
equipment
4. Defective magnet

1. Replace coupling
2. Trouble shoot rotor
3. Replace bevel gears
4. Replace defective
gears in register cup
5. Refer to instruction
manual on defective unit
6. Align shaft with
coupling
7. Tighten set screw in
magnet
8. Replace the broken
shaft
1. Check and clean
blades
2. Send to factory for
replacement or repair
3. Troubleshoot
equipment
4. Replace magnet

Rotameter

1. Measurement Error
- The presence of square-wave pulsations can cause a rotameter to overread by as
much as 100 percent. The higher the pulsation frequency, the less the float
oscillation, although the error can still be appreciable even when the frequency is
high enough so that the float is virtually stationary. Use of a damping chamber
between the pulsation source and the rotameter will reduce the error.
- Is correct scale mounted? Mount correct scale.
- Is float blocked? Remove measuring tube and clean float
- Check density, viscosity and temperature of measured fluid.
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APPENDIX 13
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14

Control system

Control system troubleshooting logically falls into two categories: (1) the repair of control
systems that previously functioned well, and (2) the successful modification or poorly
commissioned systems that have never worked properly due to improper application, poor
design, faulty hardware, or improper operating procedures.
1. Failed Systems
- First Step: Process operator discussion. It should yield some clues as the source of
the problem
- Next step: Process of elimination. If replacement of an element with a known good
causes the problem to disappear, this usually conclusive. However if situation
permits, the bad part should be temporarily re-installed to verify a hard failure
rather than a hung up condition which is often reset by the procedure of
substitution.
- A detailed system analysis is required if a control system has a number of
interactive or serially dependent components and especially if one more of
component is faulty. A complete control system diagram should be used to help
isolate possible problem areas, separate cascade loops, etc.

2. Poorly commissioned systems

- First Step: After determining how a particular control loop is meant to function, is to
put the final control element (e.g. valve) on manual control and adjust it for the
desired response of the controlled variable. If manual adjustment of the manipulated
variable does not cause some response in, or controlling action on, the controlled
variable then the control strategy is not suitable and some redesign is in order.
- If the process variable is controllable with the loop in the manual mode, note which
measurement must be observed to make the decision to open or close the valve;
then determine whether the automatic control system makes adjustments based
upon some variables. It may be necessary to change the control scheme to include
override control arrangements or two or more controllers in cascade to achieve the
desired automatic control.
3. Poor Performance
a. Excessive time delay between the actuation of the control element (valve) and the
resulting change in the measurement of the controlled variable
- To achieve stability in a system with excessive time delay, the controller gain must be
low and reset (integral) time must be long. Recovery from process upsets will be
slow.
b. Variation in loop gain due to a change in process conditions.
- It is a common problem in cascade control loops where the secondary controller is a
flow controller without square root extraction on the measurement signal. Since an
orifice plate differential pressure signal is proportional to the square of the flow, the
set-point controller should be also a flow-squared signal. This set point signal is
provided by the output of the primary controller in a cascade configuration.
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APPENDIX 13
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4. Common measurement problems

Variable

Pressure

Level (diff.
press.)

Flow

Temperature

Symptom

Problem Source

Solution

Zero shift, air leaks in

signal lines.

Excessive vibration
from positive
displacement
equipment

Use independent transmitter

mtg., flexible process
connection lines. Use liquid
filled gauge.

Variable energy
consumption under
temperature control

Change in
atmospheric pressure

Use absolute pressure

transmitter

Unpredictable
transmitter output

Wet instrument air

Mount local dryer. Use

regulator with sump, slope air
line away from transmitter

Permanent zero shift

Overpressure

Install pressure snubber for

spikes

Transmitter does not

agree with level.

Liquid gravity change

Gravity compensates
measurement, or recalibrate.

Zero shift, high level

indicated

Water in process
absorbed by glycol
seal liquid

Use transmitter with integral

remote seals

Zero shift, low level

indicated

Condensable gas
above liquid

Heat trace vapor leg. Mount

transmitter above connections
and slope vapor line away
from transmitter

Noisy
measurements, high
level indicated

Liquid boils at
ambient temperature

Insulate liquid leg

Low mass flow

indicated

Liquid droplet in gas

Gravity compensate
measurement, or recalibrate

Mass flow error

Static pressure
change in gas

Add pressure recording pen

Transmitter zero shift

Free water in liquid

Mount transmitter above taps

Measurement is high

Pulsation in flow

Add process pulsation damper

Measurement error

Non-Standard pipe
runs

Estimate limits of error

Measurement shift

Ambient temp.
change

Increase immersion length.

Insulate surface

Measurement not
representative of
process

Fast changing
process temperature

Use quick response or low

thermal time constant device

Indicator reading
varies second to
second

Electrical power
wires near
thermocouple
extension wires

Use shielded, twisted pair

thermocouple extension wire,
and/or install in conduit.

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