Safeguarding Rotating Equipment in Ethylene Plants
Safeguarding Rotating Equipment in Ethylene Plants
Safeguarding Rotating Equipment in Ethylene Plants
Safeguarding
Rotating Equipment in
Ethylene Plants
Kazim Akhtar Protect compressors and turbines by using
ABB Lummus Global, Inc.
piping strainers and following the line cleaning
procedures outlined in this article.
C
onstruction debris and foreign objects can serious- unit with suction line sizes in the range of 24–42-in. diam-
ly damage compressors. To establish the location eter. The charge gas compressors are driven by an extrac-
and type of suction strainers to be installed, line tion/condensing steam turbine.
sizes and cleaning methods need to be considered. The propylene refrigeration compressor unit is com-
Unless they are properly designed and installed, strainers prised of one large casing and typically three to four sec-
may represent more danger than benefit to the machine, tions with side-stream flow nozzles. The initial suction
because of their potential for failure or plugging (Figure line size can range from 36-in. to 60-in. diameter. The
1). This article describes the type of process compressors propylene refrigeration compressor is also driven by an
installed in ethylene plants, the extent of piping and extraction/condensing steam turbine.
cleaning methods employed, and types of strainer The ethylene refrigeration compressor unit is typically
designs to be considered. a single compressor casing with three sections with side-
In an ethylene plant, the charge gas train is typically stream nozzles. The initial suction line is in the range of
comprised of three compressor casings and four or five 18–24-in. diameter. The compressor is driven by a con-
compression stages. The first compressor case (first sec- densing turbine or by an induction motor through a gear.
tion) handles large-volume flows.
The configuration is a double Line cleaning methods
flow inlet casing with balanced For large compressor lines,
opposed impellers discharging in mechanical cleaning (e.g., wire
the middle of the casing. For brushing by hand, blowing and
world-class ethylene plants, each hydrojetting) is preferred. Weld
suction line of the casing can beads in large lines should be
range from 36-in. to 78-in. diam- ground out. All cleaned pipe must
eter. The second compressor cas- be inspected, using a boroscope
ing is a two-section intercooled where necessary. Small lines can be
unit. The possible suction line hydrojetted and then air- or steam-
size range for this casing is blown at high velocity. The com-
30–54-in. diameter. The third pressor should be isolated from pip-
high-pressure casing (discharge ing during cleaning operations to
■ Figure 1. If not properly designed and installed, strainers
pressures of 500–550 psia) is nor- may be more dangerous than beneficial because of their poten- prevent debris from collecting in
mally a two-section intercooled tial for failure, as shown by this damaged T-strainer screen. the casing and causing damage.
before the plant dry-out operation. The charge gas train was
used to compress air for the dry-out operation. The first-stage KAZIM AKHTAR is the department manager for mechanical engineering of ABB
inlet strainer was inspected after about six weeks of air run. Lummus Global (3010 Briarpark Drive, Houston, TX 77042; E-mail:
The strainer was broken into many pieces. Fortunately it did kazim.akhtar@us.abb.com). His department is involved in the specification,
design, selection, shop test acceptance and startup coordination of rotating
not cause any damage to the compressor. Other large strainers and static equipment for major refinery, petrochemical, and oil and gas
were also found to be damaged on inspection. After ensuring projects. Akhtar received a BS in mechanical engineering from Texas A&M
that the lines were clean, all strainers were removed from the Univ. and an MS in industrial engineering from the Univ. of Houston. He is
an active member of API, ASME and AIChE, and is a registered professional
process compressors’ piping. engineer in Texas.
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