Trouble Shooting

Vibrations.

Misalignment
Damage to coupling
Unbalance of rotor
Unbalance of coupling
Condensate carryover
Stresses due to pipes
Surging
Bearings damage

Trouble Shooting
Damage to
Bearings

In correct Lubrication
Misalignment
Improper clearances
unbalance of rotor /coupling
High bearing temperature
Impurities in oil
Improper assembly of bearing

Trouble Shooting
Damage to
Excessive axial thrust
Thrust bearing Incorrect lubrication
Improper assembly
Improper loading of machine

Trouble Shooting
Damage to
Oil Seal
Rings

Misalignment and
vibrations
Dirt in oil
Improper oil clearances
Insufficient oil pressure
Improper assembly

Trouble Shooting
High axial Instrument fault
thrust.
Excessive internal seal
clearances
Incorrect loading
Incorrect assembly of
coupling

Trouble Shooting

Gas
Temperatu
re high

Instrument
fault
Insufficient
cooling water

Trouble Shooting
Low discharge Internal leakages are high
pressure at
Drastic change in composition of
constant speed gas

Trouble Shooting
Oil carryover High level and subsequent
in to
overflow into gas system
compressor Malfunction of seal oil traps
Negative diff pressure between
balance gas and reference gas
HP oil seal clearances are high
Blockage in HP seal oil pipes
Recovery of gas from oil trap
system not functioning.

Trouble Shooting
Surging of
compressor

Insufficient gas at suction

High internal leakages
Blockage in anti surge valve
Suction strainer choking
Malfunctioning of anti surge
system
Improper loading

Lube oil console & Pumps

Dos
Cut off power supply
to heater before start
Check auto change
over of pumps
Check coolers &
filters change over
Ensure N2 to
accumulator

Donts
Start pump if oil level
is low
Start without min oil
temp(30-35 deg C)
Close discharge of
standby pump

Lube oil console & Pumps

Dos
Donts
De aerate PCV3 .1&3.2 during
By pass the
start up and in operation
lube oil low
De aerate coolers & filters before
pressure trip.
change
Analyse oil samples at regular
intervals
Run the centrifuge at least 8hrs in
a day

Seal oil System

Donts
Dos
Check SO oil interlocks before Operate LCV in
manual mode
start
for long time.
Check So Trap Vents orifices
By pass SO OH
through ness
tank level low
Check Traps function
trip

Process Gas System

Donts
Dos
Start compressor
Carryout inert gas purging
without SO system
and take gas analysis.
Admit N2 to LO Tank, Brg Anti surge valve
Housings.degassing tank etc., in auto during start
Operate the M/C
Check Lo Pr to Brgs
heavy gas leakages
Start comp as per recommended procedure

Process Gas System

Dos
Load the compressor wrt comp
characteristics
Ensure correct compression at
intervals

Ensure correct flow

Ensure correct composition of gas
Monitor M/C parameters regularly

Donts
Operate M/C with
ASV in manual
after loading
Adjust safety
valves while M/C
is in operation

Turbo Machinery Overhaul

Turbo Machinery Overhaul

Modern Turbo M/Cs run reliably for long.

Continuous monitoring
Good diagnostics
Preventive maintenance
Careful operation
With periodic inspections and minor
overhauls

Turbo Machinery Overhaul

Reasons for Emergency Overhauls
a)Reduction/Deterioration of performance
b) Excessive Vibrations, Brg Temperatures.
c) Damage caused by surging, lube oil
failure etc.,

Turbo Machinery Overhaul

Proper Overhaul involve
Preparation
Planning
Execution
Documentation of Overhaul activities

Turbo Machinery Overhaul

Preparation & Planning
Purpose of Overhaul
Study History of M/C with records
compile data by observation of records
Identify the extent of overhaul
Identify the spares required
Check the availability

Turbo Machinery Overhaul

Check the availability of data required for
overhaul like specs, drawings, manuals etc,
Check spares availability and usability
Availability of special tools
Spare rotor/ condition by physical
inspection
Safety aspects during overhaul like purging
toxic gases, covering opened pipes etc.,

Turbo Machinery Overhaul

Execution of Overhaul
Preparation of Bar Chart of activities
Follow up of sequence of activities
recommended before opening the
equipments
Visual inspection of parts
Note down all information observed from
machines.

Turbo Machinery Overhaul

Clean all parts with relevant solvents
Check all dimensions and record
Proceed with OEM recommendations w.r.t
corrections, replacements,repairs etc.,

Turbo Machinery Overhaul

After machine is overhauled, assembled and
restarted compile the critical data
1) Basic Machine data
2) Performance pre and post overhaul levels
3) Spare parts consumed
4) Critical dimensions
5) Alignment

Turbo Machinery Overhaul

6) Synopsis of various activities like time
taken, major deviations if any
7) Recommendations for next overhaul
8) Additional modifications required to be
made in next overhaul.

Turbo Machinery Overhaul