Process Fundamentals

Compressor Anti-Surge Control near-miss incident

The author root cause analyzed the near miss incident of compressor anti-surge control to resume production and surge prevention.

Root Cause Analysis (RCA): Compressor near ½-RPM frequency high magnitude shaft vibrations.

Root Cause Analysis (RCA): Malfunctioning inlet check valves caused 5-year long chaos at each stop/trip of the compressor.

[RCA] Refrigeration Compressor Turbine Not-tripping when needed Trip Throttle Valve threatened potential compressor wrecks eliminated.

Root Cause Analysis: K-602 Process Air Compressor too frequent & too lengthy overhauls Eliminated. RCA problem and solution provided.

Steam Turbine Driven centrifugal compressors K-601’s IP case discharge temperatures gradually increases & lead to plant shutdown.

Root Cause Analysis (RCA): Persisting K-601 steam turbine driven centrifugal compressors Discharge Head 3‑monthly leaks.

Root Cause Analysis (RCA): Yearly production reduced due to the steam turbine driven centrifugal compressors leak due to broken instrument.

Root Cause Analysis (RCA): 50% only heat transferring from Heat Exchanger threatens urea plant commissioning indefinite halt.

Dosing pumps provide low volume, controllable discharge rates that are used to inject various chemicals, solutions of various viscosities.