Major Revamp And Retrofit Of Identical Process Compressor Trains.

Abstract

Major uprates of process compressor train performance can be achieved utilizing the existing machinery. The following is a broad overview of a project to revamp two identical compressor trains to achieve levels well over original design flow. Significant internal modifications to an air compressor, a process compressor, and an expander have achieved most of our planned flow increase. The first train was modified in April 1986, and the second was modified in August 1986. An additional extensive uprate of our existing steam turbine driver to almost double the design power rating will push performance even beyond the envisioned maximum rate. This project was developed and managed by plant engineers. This paper documents the development, manufacturing, and startup phases of both the performance uprate as well as a seal system redesign for increased reliability. The mechanical redesign was primarily done by the original equipment manufacturers (OEMs). Contributions from corporate specialists, after market suppliers and independent consultants were also vital to the project's success. Measures taken to ensure the performance of the contractors and confidence in the reliability of the end products are described. The mechanical performance is up to company expectations now, but not without first overcoming a few obstacles. Actual operating rates are beyond expectations, primarily due to the effect of liquid carryover into the process compressor. Troubleshooting and performance testing techniques are described.