Synthesis Gas Compressor (K1431) Seal Leakage Problem at NFL Vijaipur Line-1 Plant

摘要

Synthesis gas compressor (K1431) at NFL, Vijaipur unit-1 is of M/s Dresser-Rand make and is in operation since 1987. In May-2012 energy saving project was implemented and ammonia production was increased from 1520 to 1750 MTPD. Machine had a problem of high oil consumption since 2012. Oil consumption in the month of November, 2016 was as high as 420 liters per day. Inner Seal labyrinths of LP side used to be eroded/corroded during inspection in every shutdown. OEM suggested replacing the Labyrinth material to PEEK. Same was not implemented. On 12~(th) November, 2016 when seal were opened, condensate was found in machine and both labyrinth as well as second suction side impeller labyrinth were found corroded/eroded. It was suspected that due to low capacity of separators, condensate was getting carried over. Interstage separator capacity was increased by lowering the LG level from 60% to 40% and level troll of level transmitter by 300 mm. Compressor is in line since 16~(th) November, 2016 with oil consumption less than 420 liters per month. This article gives insight into problem and solution of synthesis gas compressor oil consumption in line-1.