Enhancing Plant Air Compressor Reliability at Qurayyah Sea Water Plant

2. Reliability Enhancement of Plant Air Compressors at Qurayyah Sea Water Plant Sharib KhanCMRP, CRL, Vib Analyst Cat-III

3. Reliability Enhancement of Plant Air Compressors atQurayyah Sea Water Plant • Problem Statement Outline: Solution Options Implementation Conclusion

4. Implementation • Problem Statement • SolutionOptions Benefits

5. Implementation • Problem Statement • SolutionOptions Benefits

6. Plant air compressor failures led to very low mean time between failure (MTBF) • Problem Statement • Implementation • Conclusion • SolutionOptions Failure

7. Problem Statement • Implementation • Conclusion • SolutionOptions • Plant air compressor failures led to very low mean time between failure (MTBF) Failure Oil Cooler Damage

8. Problem Statement • Implementation • Conclusion • SolutionOptions • Plant air compressor failures led to very low mean time between failure (MTBF) Failure Gears damaged

9. Problem Statement • Implementation • Conclusion • SolutionOptions • Plant air compressor failures led to very low mean time between failure (MTBF) Failure Pinion Gear Damage

10. Problem Statement • Implementation • Conclusion • SolutionOptions • Failures due to air coolers defects, or failure lead to damage to air frame parts Failure

11. Problem Statement • Implementation • Conclusion • SolutionOptions Failure Air Cooler Bundle Damage

12. Problem Statement • Implementation • Conclusion • SolutionOptions Failure Air Cooler Housing

13. Problem Statement • Implementation • Conclusion • SolutionOptions Failure Scaling inside airframe

14. Problem Statement • Implementation • Conclusion • SolutionOptions Failure Broken High Speed Impeller Vane Second Stage Impeller Damage

15. Problem Statement • Implementation • Conclusion • SolutionOptions Failure • Cost of Repair is very high almost $250,000

16. Problem Statement • Implementation • Conclusion • SolutionOptions • Low MTBF (9 months) • Unavailability of equipment • High cost of repairs • Bad actors • Break-in Maintenance Planning Schedule Consequences PdM (Bi- monthly vibration survey) Existing Controls Yearly PM (Electrical) PdM (Quarterly LCM) Five (5) yearly T&I of Air and Oil Coolers

17. Benefits Problem Statement • Implementation • Conclusion • SolutionOptions Three year PM Clubbed with T&I Yearly Overhaul Compressor only Five Year T&I One Year PM

18. Problem Statement • Implementation • Conclusion • SolutionOptions • Easiest path is to “do nothing” • Continue doing the Annual PM and major repair of compressor when breakdown • Continue doing the 5-Yearly T&I for the Coolers • Introduction of enhanced annual PM and 3-year PM and Clubbed with T&I • Include Auxiliary equipment like IGV and Discharge Check Valve servicing/ overhaul on a 3-year basis during PM

19. Problem Statement • Implementation • Conclusion • SolutionOptions Use high pressure jetting to clean the tubing on Intercooler and Aftercoolers every 5.0 years for poor heat transfer due to scale build-up. Replace corroded air volutes with new ductile cast iron and coat them internally with Belzona coating. Install new stainless steel vaned diffuser assemblies on all three stages of air compressor unit which are superior to the original Aluminum diffusers.

20. Problem Statement • Implementation • Conclusion Solution Options • Enhanced Yearly PM • Laser Alignment between driver motor & Compressor • Check and stroke Inlet Guide Valve and Surge Valve • Check for any leakages on intercooler and after cooler and Clean or replace the clogged drain lines. • Check & Calibrate the inlet air filter differential pressure transmitter. • Replace Lube Oil Filters • Check the flow and leakages of Cooling Water, repair if required

21. Problem Statement • Implementation • Conclusion Solution Options • New 3-year PM • Drive Motor test with MCE or megger • Cleaning of air frame for scale removal • Chemical cleaning of Cooler Bundles • Auxiliary equipment like IGV and Discharge Check Valve servicing/overhaul • Blast & Re-coat corroded intercooler shells and air pipings with special high temperature coatings • Replace all air intake filters

22. Problem Statement • Implementation • Conclusion Solution Options

23. Problem Statement • Implementation • Conclusion Solution Options

24. Problem Statement Implementation • Conclusion Solution Options Cost effective solution and early fault elimination Enhance equipment reliability by increasing MTBF Facilitate proactive job planning Reduction in MTTR

25. Conclusions Most of the Reliability is inbuilt during the design stage. Reliability can be severely effected with neglect in operation and inadequate maintenance practices Most of the improvement in reliability can be achieved while taking care of Auxiliaries of the plant air compressors By dedicating more time to PM and reliability functions, reactive fire-fighting work will decrease, thereby reducing downtime and driving improved reliability Reliability improvement can be achieved with experience and collaboration with operation and maintenance crew.

26. Questions & Thank You ! Sharib A. Khan CMRP, CRL, Vibration Analyst Cat III, TapRoot Analyst Reliability Engineer Sea Water Injection Department, Saudi Aramco