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SERVICE & SALES TRIP

To

Petro Ecuador
Esmeraldas Refinery

CONDUCTED BY

Service Engineer: Eric M. Johnson


Sales Manager: Alvaro Cadena
DATES AT SITE

January 29th, 2014 January 30th, 2014

Graham Trip Number 14-86880GT


Original Equipment Serial Number(s) 12-83993JC
56592M
77678M
4960M74
GRAHAM CORPORATION
Corporate and Sales Headquarters: 20 Florence Avenue, Batavia, New York 14020
Tel.: 585-343-2216 Fax: 585-343-1097 E-MAIL: service@graham-mfg.com WEBSITE:http://www.graham-mfg.com
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report.doc
Customer Petro Ecuador

Job Number 14-86880GT

Report Date February 17th, 2014

SERVICE TRIP TABLE OF CONTENTS

1. INTRODUCTION .......................................................................................................... 3

2. PURPOSE .................................................................................................................... 3

3. OBSERVATIONS AND MEASUREMENTS................................................................. 4

4. CONCLUSIONS ......................................................................................................... 12

5. RECOMMENDATIONS .............................................................................................. 13

6. APPENDIX A ............................................................................................................. 13

GRAHAM CORPORATION
Corporate and Sales Headquarters: 20 Florence Avenue, Batavia, New York 14020
Tel.: 585-343-2216 Fax: 585-343-1097 E-MAIL: service@graham-mfg.com WEBSITE:http://www.graham-mfg.com

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report.doc
Customer Petro Ecuador

Job Number 14-86880GT

Report Date February 17th, 2014

1. INTRODUCTION

Installed at the Esmeraldas facility are various Graham vacuum systems, including
two vacuum distillation tower ejector systems and at least 6 turbine exhaust
condensers with corresponding ejector venting equipment.

Below is a chart showing the various vacuum systems that were evaluated:

Equipment Description Year Built Serial Number


Turbo Compressor Exhaust 1975 2397
(Weiritam Condenser)
Turbo Compressor Exhaust 1984 56592M
(FC1)
Vacuum Distillation Unit 1974 Original 4650JC74
(VL-1) Replacements per 10-77678JC
Vacuum Distillation Unit 1983 Original 56479JC
(VL-J1) Replacements per 12-83993JC
Steam Turbine Generator 1974 4960-74-1
(Unit #1)
Steam Turbine Generator 1974 4960-74-12
(Unit #2)
Steam Turbine Generator 1974 4960-74-13
(Unit #3)
Steam Turbine Generator (-) To be Built
(Unit #4)

2. PURPOSE

The purpose of the visit was to evaluate the various systems to identify potential
problems, with a focus on piping layout and installation. Most of this equipment was
installed upwards of 40 years ago and an evaluation was deemed to be beneficial.
Training was also to be provided by Graham explaining the operation and
troubleshooting of the Graham equipment.

GRAHAM CORPORATION
Corporate and Sales Headquarters: 20 Florence Avenue, Batavia, New York 14020
Tel.: 585-343-2216 Fax: 585-343-1097 E-MAIL: service@graham-mfg.com WEBSITE:http://www.graham-mfg.com

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report.doc
Customer Petro Ecuador

Job Number 14-86880GT

Report Date February 17th, 2014

3. OBSERVATIONS AND MEASUREMENTS

The Weiritam condenser and air removal equipment was evaluated. No readings
were taken because access to test connections was limited, however based on the
findings its unlikely that the condenser is operating near the design point. The
operators indicated that this condenser system was only operating at 67% of the
desired capacity and that the system did not function well at higher load points.

Figure 1: Water Being Discharged from Vent Line

Large amounts of water were being discharged from the vent connection of the
aftercondenser. This indicates that the aftercondenser is flooded with liquid. When a
condenser is flooded with liquid, that liquid covers the tubes and reduces the
available surface area. This increases the back pressure on the upstream ejector
which can cause that ejector not to function properly.

It was discovered that the after condensate line had both a trap and loop seals. In
this type of system you need either a trap or a single loop seal, but using both
together often causes drainage problems like the one identified.
GRAHAM CORPORATION
Corporate and Sales Headquarters: 20 Florence Avenue, Batavia, New York 14020
Tel.: 585-343-2216 Fax: 585-343-1097 E-MAIL: service@graham-mfg.com WEBSITE:http://www.graham-mfg.com

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Customer Petro Ecuador

Job Number 14-86880GT

Report Date February 17th, 2014

The operators also indicated that the condensate traps were the originals supplied in
the 1970s. The operators claim to have had many problems with the traps sticking
or becoming blocked with debris. The debris being found was reported to be rust and
pipe scale, which is being caused by deteriorating steel condensate return lines.
Note that eventually the condensate lines could rust out and create air in-leakage.

The condensate piping should be re-piped as shown below:

Figure 2: Condensate Piping Arrangement Sketch

The condensate return lines from the inter and after condensers should utilize
a float trap or a loop seal but not both.

The piping should run continually downward or horizontal to the condenser,


while minimizing the number of 90 deg elbows.

If a trap is utilized a bypass line should be installed with isolation so that the
trap can be serviced while the equipment is in operation.
GRAHAM CORPORATION
Corporate and Sales Headquarters: 20 Florence Avenue, Batavia, New York 14020
Tel.: 585-343-2216 Fax: 585-343-1097 E-MAIL: service@graham-mfg.com WEBSITE:http://www.graham-mfg.com

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Customer Petro Ecuador

Job Number 14-86880GT

Report Date February 17th, 2014

While inspecting the condensate piping off of the Weiritam intercondenser it was
discovered that the condensate trap was isolated and the bypass line was open.
Bypass lines shouldnt be continually open under normal operation conditions.
Leaving the bypass line open allows air to cycle back from the intercondenser to the
main condenser where it reloads the first stage ejector. That line should be shut and
the trap utilized. The trap also needs to be installed below the intercondenser for it to
function properly, which it was not.

Figure 3: Intercondenser Drain Trap and Bypass Line


GRAHAM CORPORATION
Corporate and Sales Headquarters: 20 Florence Avenue, Batavia, New York 14020
Tel.: 585-343-2216 Fax: 585-343-1097 E-MAIL: service@graham-mfg.com WEBSITE:http://www.graham-mfg.com

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Customer Petro Ecuador

Job Number 14-86880GT

Report Date February 17th, 2014

The Graham surface condenser supplied on Graham Job 56592M was also
evaluated. A vacuum survey of this system was completed and the results of that
survey are located in Appendix A of the report.

The aftercondenser vent line was found to be piped in with the hogger exhaust line.
Under normal operation this doesnt cause a problem but if the hogger were to be
utilized in conjunction with the holding ejectors it will pressurize the aftercondenser
and prevent it from venting properly. These two lines should be piped separately.

Figure 4: Vent Line / Hogger Discharge


GRAHAM CORPORATION
Corporate and Sales Headquarters: 20 Florence Avenue, Batavia, New York 14020
Tel.: 585-343-2216 Fax: 585-343-1097 E-MAIL: service@graham-mfg.com WEBSITE:http://www.graham-mfg.com

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Customer Petro Ecuador

Job Number 14-86880GT

Report Date February 17th, 2014

A blind flange on the condenser water box was found to be missing hardware. This
provides a potential leak path where air could be pulled in.

Figure 5: Missing Hardware

The vacuum survey of the Graham condenser on the FC-1 unit indicated that it was
underperforming. The condenser is operating at 90% of its design capacity and is
operating 25 mmHg off of its design point, at a vacuum of 140 mmHgA versus the
design of 115 mmHgA.

The cooling water flow to the main condenser appears to be very high as evidenced
by the cooling water temperature rise of 5 degC when compared to the design
temperature rise of 13.9 degC. The cooling water supply temperature was 33.3 degC
which is below the design temperature of 35 degC. The cooling water conditions are
better than design although we cant eliminate fouling as a potential problem due to
the lack of cooling water pressures.

The second stage ejector is not meeting its design suction pressure. The second
stage ejector suction pressure was measured to be 215 mmHgA versus the design of
173 mmHgA. This indicates that either the system has a high noncondensable load
or there is a mechanical problem with that second stage ejector. The air leakage
meter was missing so no air readings could be taken and we could not perform a
mechanical inspection of the equipment.

The first stage ejector was operating with a poor backpressure. The uniform
temperature profile indicates that the ejector is not operating with a shockwave.

GRAHAM CORPORATION
Corporate and Sales Headquarters: 20 Florence Avenue, Batavia, New York 14020
Tel.: 585-343-2216 Fax: 585-343-1097 E-MAIL: service@graham-mfg.com WEBSITE:http://www.graham-mfg.com

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Customer Petro Ecuador

Job Number 14-86880GT

Report Date February 17th, 2014

The inter/after condenser cooling water temperature rise was 6.7 degC versus the
design temperature rise of 2.3 degC. It appears as though the inter/after condenser
has low cooling water flow or the equipment is being subjected to higher than design
condensable loads. High condensable loads could be explained by a steam leak at
the first stage ejector nozzle to steam chest connection.

The two vacuum distillation units were also examined. We did not take readings
because these systems have already been supplied with complete replacements.
More attention was given to the piping arrangement as the equipment is scheduled to
be replaced during the next turnaround.

Many of the old ejectors have substantial damage and have been repaired. I have
noted several of these field repairs below.

Figure 6: Repaired Ejectors

There is an issue with the recycle line piping. The recycle control lines are not
properly piped. They are currently piped from the discharge of the third stage
ejectors back to the suction of the first stage ejectors. This will cycle any
noncondensable loads back though all three stages of ejectors. This substantially
increase loading to the third stage which will then increases the corresponding
suction pressure. If the second stage ejectors reach the maximum allowable
discharge pressure, it will make the system unstable. The system should be installed
with the recycle line running from the first stage discharge to the first stage suction.
This would only recycle load around the first stage ejectors and would not add
additional load to the downstream equipment. This allows one to control the suction
pressure while maintaining stable ejector operation.

GRAHAM CORPORATION
Corporate and Sales Headquarters: 20 Florence Avenue, Batavia, New York 14020
Tel.: 585-343-2216 Fax: 585-343-1097 E-MAIL: service@graham-mfg.com WEBSITE:http://www.graham-mfg.com

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Customer Petro Ecuador

Job Number 14-86880GT

Report Date February 17th, 2014

Figure 7: Recycle Line at Third Stage Discharge

Figure 8: Recycle Line with Control Valve


GRAHAM CORPORATION
Corporate and Sales Headquarters: 20 Florence Avenue, Batavia, New York 14020
Tel.: 585-343-2216 Fax: 585-343-1097 E-MAIL: service@graham-mfg.com WEBSITE:http://www.graham-mfg.com

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Customer Petro Ecuador

Job Number 14-86880GT

Report Date February 17th, 2014

An examination of several other Graham condensers was also performed. Three


Graham condensers and corresponding air removal packages are located in the
utilities area of the plant. Petro Ecuador personnel indicate that a fourth generator
drive was to be built in the near future. We briefly examined these units but did not
have enough time to survey them or examine them in detail. The units were supplied
in 1974 and have been in service for 40 years.

Alvaro Cadena of Graham also provided training for the plant operators and
engineering personnel. Training included an explanation of how ejectors and
condensers worked and highlighted some troubleshooting techniques.

Figure 9: Training Seminar


GRAHAM CORPORATION
Corporate and Sales Headquarters: 20 Florence Avenue, Batavia, New York 14020
Tel.: 585-343-2216 Fax: 585-343-1097 E-MAIL: service@graham-mfg.com WEBSITE:http://www.graham-mfg.com

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report.doc
Customer Petro Ecuador

Job Number 14-86880GT

Report Date February 17th, 2014

4. CONCLUSIONS

The condensate return lines and traps on the inter and after condensers of the
Weiritam unit are not piped in a manner that is allowing the condensate to drain
properly. The after condenser was found to be flooded and the intercondenser trap
was bypassed. The piping has been installed with both traps and loop seals which
isnt recommended. One of the drain traps has been installed at an elevation that is
above the inter/after condenser. The equipment cannot function properly with this
piping arrangement.

The Graham condenser is underperforming even though it appears to have


substantially more cooling water flow than it was designed for. There appears to be
an issue with the air removal equipment or the system has excessive air in leakage.
The connections and air leakage meter were not there to make a decisive conclusion
for either of these causes. Main condenser fouling is also a potential issue but we do
not have cooling water pressures to support or dismiss this as a problem.

The vacuum distillation systems were not in good condition but are to be replaced
during the next turnaround. The recycle controls are not set up correctly and are
recycling around all three stages of ejectors. Setting up the recycle control lines to
cycle load around only the first stage ejectors provides for more stable operation.

The Graham condensers in the utilities area were not examined in detail but given
the equipment age a mechanical evaluate of the equipment could be done to help
verify the condition.

A training presentation was put on for Petro Ecuadors operators and engineers. It
outlined how ejectors and condensers work and provided information on how to
troubleshoot these types of systems.

GRAHAM CORPORATION
Corporate and Sales Headquarters: 20 Florence Avenue, Batavia, New York 14020
Tel.: 585-343-2216 Fax: 585-343-1097 E-MAIL: service@graham-mfg.com WEBSITE:http://www.graham-mfg.com

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Customer Petro Ecuador

Job Number 14-86880GT

Report Date February 17th, 2014

5. RECOMMENDATIONS

1) The drain traps and condensate return piping installed on the Weiritan condenser
should be replaced and re-piped. The re-piping should not be done in kind, but
should be re-piping to eliminate either the traps or the loop seals.

2) Bypass lines around drain traps should not be left open during normal operation
as it allows air to recycle which negatively impacts vacuum.

3) The hogger and vent piping on the Graham FC-1 condenser should be re-piped
separately so that the hogger does not pressurize the aftercondenser through its
vent line.

4) The missing hardware on the Graham FC-1 condenser hotwell blind flange should
be replaced to help prevent air in-leakage.

5) The Graham air removal equipment on the Graham FC-1 unit should be
mechanically evaluated for damage. The air leakage meter should also be fixed
so an air leakage rate can be obtained.

6) Ejector recycle control lines should be piped from the discharge of the first stage
ejectors back to the suction of the first stage ejectors. The recycle line installed
needs to be re-piped as it recycles around multiple ejector stages.

7) The two replacement vacuum distillation systems supplied on Graham jobs 10-
77678JC and 12-83993JC should be installed during the next turnaround.

8) The turbine generator condensers should be mechanically examined as they have


been in service for a very long time and may need to be replaced.

9) All steam piping should be insulated up to the steam chest of each ejector to help
prevent the condensate from forming in the steam lines.

10) Spare parts and replacements should be stocked. This equipment is all custom
designed and built, so they arent stocked. Lead times may be longer than
anticipated.

6. APPENDIX A
GRAHAM CORPORATION
Corporate and Sales Headquarters: 20 Florence Avenue, Batavia, New York 14020
Tel.: 585-343-2216 Fax: 585-343-1097 E-MAIL: service@graham-mfg.com WEBSITE:http://www.graham-mfg.com

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Engineer: EMJ Equipment Survey January 19th, 2014
Trip Number: 14-86880GT
Original Job: 56592M
Description Serial No. Motive Motive Suction Suction Discharge Discharge
Time PSIG (barG) deg F (deg C) inHgA (mmHgA) deg F (deg C) inHgA (mmHgA) deg F (deg C)
B Stage
Ejector Design -> 140 (9.65) D&S,360 (182.2) 3.5 (88.9) n/a 7.17 (182) n/a
56592-2 OFF OFF OFF OFF OFF OFF
56592-3 142 (9.8) 361 (182.8) 5.5 (140) 136 (57.8) 8.5 (215) 140 (60)

C Stage
Ejector Design -> 140 (9.65) D&S,360 (182.2) 6.81 (173) n/a 29.9 (760) n/a
56592-5 OFF OFF OFF OFF OFF OFF
56592-6 149.3 (10.3) 359 (181.7) 8.5 (215) 108 (42.2) 29.9 (760) 208 (97.8)
Engineer: EMJ Equipment Survey January 29th, 2014
Trip Number: 14-86880GT
Original Job: 56592M

Description Serial No. CW Inlet CW Inlet CW Outlet CW outlet Delta P Delta T Vapor Inlet Vapor Inlet Vapor Outlet Vapor Outlet Condensate Vapor P Flow
PSIG deg F PSIG deg F PSI deg F inHgA deg F inHgA deg F deg F inHgA gpm
Time (barG) (deg C) (barG) (deg C) (barG) (deg C) (mmHgA) (deg C) (mmHgA) (deg C) (deg C) (mmHgA) (m3/hr)
Main
Condenser Design -> n/a 95(35) n/a 120(48.9) 6.2(0.43) 25(13.9) 4.53(115) n/a 3.5(88.9) n/a 130(54.4) 1.03(26.1) 4,305(978)
56592-1 n/a 92 (33.3) n/a 101 (38.3) n/a 9 (5) 5.5 (140) 140 (60) n/a 136 (57.8) 126 (52.2) n/a n/a

Inter
Condenser Design -> n/a 130(54.4) n/a (-) n/a (-) 7.17(182) n/a 6.81(173) n/a 148(64.4) 0.35(9) 118(26.8)
56592-4 n/a 120 (48.9) n/a (-) n/a (-) 8.5 (215) 140 (60) n/a 108 (42.2) 136 (57.8) n/a n/a

After
Condenser Design -> n/a (-) n/a 134.1(56.7) n/a 4.1(2.3) 29.9(760) n/a 29.9(760) n/a 212(100) n/a 118(26.8)
56592-4 n/a (-) n/a 132 (55.6) n/a 12(6.7) 29.9 (760) 208 (97.8) n/a 192 (88.9) 157 (69.4) n/a n/a

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