Equipment No.: K-23202BService:: Net Gas CompressorEquipment type: Recip CompressorRotating Equipment Failure Analysis Report

Maint. Order/ Notification No.:96464134Problems detected via:

X

Routine findings.Request/Notification.Area.:2

PROBLEM DESCRIPTION

2nd stage discharge temperature high on 10/1/2014

BACKGROUND

The Equipment

Equipment Tag No: K-23202BEquipment Criticality: 2Service: Net Gas CompressorEquipment Type: Reciprocating Compressor (3-stage)Running Philosophy: 2 running 1 standby (N+1)Number of Stages : 3Number of Cylinders : 7Speed Range : Fixed 333 RPMRated Power : 5500 HPValve Unloaders : Yes Stage 1, 2, and 3 HEValve Type : Ring type valveLast Maintenance: 29th August 2013 Last PM: Maintenance Cost : RM 37,261ULPO : No

Sequence of Event

DATA /FINDINGS:

1. Maintenance / PM history

2. Verification at sitea. Visual/audio No abnormality observed

3. Valve skin temperature surveya. Valve skin temperature Last taken on 13/1/2012 (Refer ATT:1)

4. Pi Trendinga. Temperature trending5/01/2014-9/01/201426/12/2013-29/12/2013

b. Pressure trendingNo significant fluctuation or abnormalities observed

Parameter fluctuation observation based on Pi trending

LocationMinMaxIOWRemarks

Discharge temperature1st stg (cyl#1) 131.4136.7148

1st stg (cyl#3)131.7137.7148

1st stg (cyl#5)132.4137.9148

1st stg (cyl#7)132.3138.4148

2nd stg (cyl#4)133.1136.6148

2nd stg (cyl#6)133.4144.5148Abnormal high delta compared to cyl#4

3rd stg (cyl#2)123.9127.2135

Inlet compressor tempE-23203 51.60 C62.63 CNA

Motor amp202.4 A205.5 ANA

Pressure1st stg suction3.1263.140NA

1st stg discharge9.7610.005NA

2nd stg discharge25.9826.20NA

3rd stg suction23.4923.67NA

3rd stg discharge49.1252.30NA

5. Gas propertiesa. Gas Molecular weight : 3.87 ( Based on lab result dated 31/12/2013)

6. CRG Inspectiona. Leak test & visual inspection on discharge valve

Cy#6 HE

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X

X*

All HE discharge valve failed diesel leak test. Bottom HE discharge valve had visible chipping on 1 of the metal rings edge.

Cy#6 CE

All CE discharge valve passed diesel leak test.

7. Vendor refurbishment reporta. To be updated upon submission by vendor

FAILURE ANALYSIS

1.Failure analysis based on the reported problem

2.Further failure analysis on failed valve

POSSIBLE CAUSES

Based on the collected & available evidence it can be concluded that the possible failure was due to the following ;1. Possible mishandling or inconsistancy of valves spring installation during valve refurbishment which then lead to inconsistance spring movement which causing valves ring to lift tilted when slam shut condition. This was further aggriviated by the increase in compressor load. Due to the cyclic load, the valve ring edge was continuously slam to the valve seat causing it to chip. Hence, valve passing and eventually increase the discharge temperature of the 2nd stage (cylinder #6).

Failure componentFailure ModeFailure Cause

ValveValves ring edge chipping1.inconsistance spring movement creating tilted valves ring lift movement.

Failure Cause CategoryOperationalMaintenanceManufacturing DefectUnintended service conditionEnd of design life

X

RECOMMENDATIONS:

No.Recommended Action for improvementAction byRemarks

1Enforce mandatory valve refurbishment reportHoebieger

2

*Please mention in the remarks whether or not notification has been raised to appropriate parties who carry out the recommended actions.

PREPARED BYNAME : Muhammad Fadzlee SamsubahaDATE : 12/2/2014 APPROVED BY (TP)NAME : DATE :

ATTACHMENTATT:1 Previous Compressor Skin temperature survey

Lab sampling result