Makeup Gas Compressor

Observation, conclusion and recommendations
Group C
Submitted to
Eng. Mohamed Saleh Abd-El Moniem
Eng. Mohamed Ali
Eng. Ibrahim Hassan
Contents
1. Introduction
1.1. Makeup gas observation during mechanical PM.
1.2. Suction strainer condition and persisting blockage.
2. Summary
2.1. Observations during operation.
2.2. Following evidences.
3. Discussion
3.1. Green oil formation.
3.2. White dust scales.
3.3. Gray rigid scales.
3.4. Condensate formation.
4. Conclusions and recommendations.
5. Appendices.
1. Introduction
1.1. Makeup gas observation during mechanical PM:
It was found that:
1. Easily Removable Green oil formation on all four stages unloaders stim.
2.1.Both first and second stages unloaders and cylinders were clean.
2.2.Third stage contains big amounts of white dust, white scales and hard gray deposits inside
the suction distributer, on the suction unloader inlet, on the cylinder wall and discharge
valve.
2.3.Fourth stage had a much lower amount of the same foreign material.
3. Fourth stage had a condensed liquid.
1.2. Suction strainer condition and persisting blockage:

It was recently observed during the initial introduction of CCR make up gas especially
after long period of cut off that third stage suction strainer DP increases. Also when PV-
011A is opened second stage suction strainer DP increases dramatically.
2. Summary
2.1. Observations during operation:
1- During normal operation third stage limits the compressor capacity that could be caused by
many reasons such as the introduction of foreign material to the suction unloader or discharge
valve.
2- During normal operation fourth stage limits the compressor capacity that could be caused
by many reasons such as the introduction of foreign material to the suction unloader or
discharge valve.
3- second stage strainer is blocked when PV-011A is opened, may be because of its location as
low point that traps any condensate and/or foreign material in the valve upstream.
2.2. Following evidences:

Since the first and second stages found clean, the second source of makeup gas to the third stage
was the expected source of the foreign material presence in the3rdstage compressor internals.
This explains the blockage of the second stage strainer when PV-011A is opened and the
expected failure of third stage strainer.
3.Discussion
3.1. Green oil formation:
With high concentration of hydrogen chloride some of the unsaturated hydrocarbons
condense/polymerize forming such oil. And since it is present on the four stages unloaders stim,
so it is evidence of chloride presence in makeup gas from U-400.
third Stage stim First Stage stim

as illustrated in the pictures above, the green oil on the first stage stim is more than that on the
third stage's indicating the high presence of chlorides and unsaturated hydrocarbons in the first
than the third stage.
3.2. White dust scales:

Through our research on the web we found that CCRU catalyst attrition is a common problem
among this process which result in the presence of catalyst dust in the CCRU recycle gas.
3.3. Gray rigid scales:
It may be formed due to the presence of iron from the equipment's and sulfur from the feed of
CCRU resulting in the formation of iron sulfide which mix with the catalyst white dust forming
the gray rigid material.
3.4. Condensate formation:
it may be a result of DT between stage inlet gas temperature and jacket water outlet
temperature. As referred in Mr. Refaee Abd El Naeem previous report.
4.Conclusion and recommendations
The foreign material found may be from CCRU make up gas that could be catalyst
dust and/or ammonium salts.
We highly recommend:
1- the dismantle 200-FE304 and 200-FE011 in next shutdown to check up stream
condition and confirm the presence of the white dust and scales confirming
the conclusion of this investigation.
2- If confirmed, then fabrication of on stream filter and bypass is required to
avoid compressor internals damage or capacity drop.
3- Coordination with ANRPC about the expected drop of catalyst life and
frequent increment of makeup that finally end up with changing the catalyst.
5.Refrences:

Makeup Gas Compressor

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Observation, conclusion and recommendations

4. Conclusions and recommendations.

1.2. Suction strainer condition and persisting blockage:

2.2. Following evidences:

third Stage stim First Stage stim

3.2. White dust scales:

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