Beruflich Dokumente
Kultur Dokumente
Author
Prem Baboo
Sr. Manager (Prod)
National Fertilizers Ltd., Vijaipur, India
An emergency shutdown system trips the machine in case of any abnormality with
simultaneous opening of the vent control valve at 2nd stage discharge (HV-61) and
recycle control valve connecting 4th stage discharge and 1st stage suction (HV-62).
Fig-1
Reverse rotation was observed in 31/41 Unit CO2 Compressors. Following were
observations:
1. During stopping it was observed that in 8-10 seconds time speed comes down
and then it again increases to around 2900 rpm. Then after 20-150 seconds the
speed comes down to minimum.
2. It had been physically observed that shaft rotates in reverse rotation as observed
from turbine rear side.
3. The Chart of rpm Vs Time as shown in the fig-3
Fig-2
9000
8000
8250
7000
RPM
6000
5000
4000
3000
2908
2000
1000
0
1
2
3
4
5
6
7
8
9
10
10
20
30
40
50
60
70
80
90
100
110
120
130
140
150
160
170
180
Time in Sec
Fig-3
Compressor internals
1. Slow roll in either direction can damage wear parts.
2. Reverse flow creates internal differential pressures that were not considered in the
compressor design. Sleeves and wear parts can be displaced.
High runaway rotational speed
1. Balance issues.
2. Impeller stresses can be exceeded.
compressors under similar conditions had also been observed at IFFCO, Aonla &
Phulpur plants, whereas similar phenomenon is not observed at NFCL, Kakinada(AP)
and BACL, Shahjahanpur(U.P.) During reverse rotation, shaft of the machine has been
physically observed to rotate in reverse direction (as observed from turbine rear side).
The rise & fall of inter stage pressures as observed and recorded does not indicate
malfunctioning of any control valve or NRV in interconnecting pipeline of Low pressure
Casing (MCL) & high pressure Casing (BCL).
As per the original trip interlock, various loading/vent valves provided in the surge
protection system of the compressor used to operate in following manner:
With the implementation of above changes improvement was observed in speed charts
in 31/41 units range of speed has come down. In our CO2 Compressors NRV is installed
in between low pressure side (MCL) and high pressure side (BCL). Also a final stage
discharge knock out drum (MV-8) with upstream / downstream NRV is provided just
before the entry point of CO2 into the urea reactor. From CO2 Compressors platform
final discharge line to MV-8 length is around 100 meters.
RPM
9000
8000
7000
6000
5000
4000
3000
2000
1000
0
Time in Sec
Fig-4
The efforts however have been able to prevent reverse rotation of 31/41TK-1/K-1.
It is with this intent to prevent reverse rotation in 31/41 CO2 compressors that we
attract your kind attention to this problem.
Conclusion
A simple modification of the trip interlock to include the post trip opening of second
discharge recycle control valve permitted the recycle of high pressure gas to save the
whole train from rotating in reverse direction. The total net effect of the above
modification was in the form of drastic reduction in reverse gas flow torque on the LP
rotor immediately after trip due to sudden increase in first suction pressure together
with simultaneous increase in quantity of gas released from second stage discharge.
Although the gas reversal through the third stage remained Unchanged, the reverse
torque generated on the whole train due to reversal of gas through MCL and BCL
combined together substantially reduced due to reduction of gas reversal through MCL.
As a result, at any point of time during coast down, the residual forward torque of the
whole train due to inertia of rotation in the forward direction prevailed over the reverse
torque created due to reversal of gas through both BCL & MCL and the resultant
forward torque forced the rotor train to continue rotation in forward direction.
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