WET GAS COMPRESSOR

OVERHAULING REPORT

Manufacturer: BHEL Hyderabad

Model: 2MCL 528

UNIT: DCU BORL

Duration: 4th April to 27th April 2015

Execution Department: Rotary-Mechanical

BORL In-charge:

1) Mr. Manish Pandey( Sr. Manager)

2) Mr. Manish Singh(Deputy Manager)
3) Mr. Manoj Kumar Gupta(Assistant Manager)
4) Mr. Deepak Jha(Assistant Engineer II)
5) Mr. Narayan Kholi (Assistant Engineer I)

Execution Contractor: Gangotri Turbo Tech., Hyderabad

1) Mr. Gopal Chavan

2) Mr. Ananya
3) Mr. Sreenivas reddy
 INDEX:

1. Purpose
2. Scope Of Work
3. Major Observations
4. Activities carried Out
a) Dismantle of Compressor
b) Assemble of Compressor
5. Post Maintenance Observations
6. Measurement Sheet
a) Labyrinth Clearances
b) Bearing Clearances
c) Rotor Run-out
d) Miscellaneous Readings
e) Alignment
f) Vibration & temperature readings
g) Bearing Demagnetization
7. Spares Consumed
Purpose: To Inspect and overhaul the compressor after continuous running
since commissioning.

Scope of work:
1. Dismantling of compressor
2. Inspection of impellers, bearings, Mechanical seal and all internal parts.
3. Clearance measurement of every internal and external part.
4. Assembling of Compressor.
5. Trial Run

Major Observations:
1. Rusting on both side Mechanical seals observed.
2. Black Colour liquid found out on primary seal filters in a considerable
amount.
3. 2.7mm pre-stretching found out on coupling which is too high than
acceptable (2.0mm).
4. Labyrinths of End Gas seals were bent.
5. Minor scoring marks observed on the rotor at thrust collar position.
6. Dark brown deposits observed on the impellers of final stages.
7. Casing Partition O-ring was found completely pressed.
8. High Magnetization value observed on the Journal and thrust bearings.
9. Journal and Thrust Bearings were found in good condition and positive
results observed in DP test.
Activities carried out:

a) Dismantle of compressor
1. Decoupled the coupling
2. Measured the rotor centre and thrust float
3. Removed Lube oil lines, seal gas lines, vent lines and then blinded each
of these lines.
4. Removed all vibration probes and RTD of both side.
5. Thrust & journal bearings removed, cleaned, Dye penetration test
performed and clearances measured.
6. Removed both side Mechanical seal in the Presence of vendor (M/s
Eagle Burgmann).
7. Lifted up Top casing half & shifted it to ground level.
8. Inspection of each component carried out and all requisite clearances
were measured.
9. Lifted the Rotor and kept it into the rotor stand.
10.Removed all diaphragms from bottom and top half of casing.
11. Both halves of Casing, diaphragms and rotor were cleaned with cloths,
steel wire brush, solvent (diesel) and Water jet.
12. Demagnetization of Journal Bearings, Thrust bearing and rotor carried
out.
13.Checked run out on the Shaft at each location.
b) Assemble of compressor
1. Assembled the diaphragms on both halves of casing.
2. Rotor and Labyrinth are positioned in bottom casing and seal clearances
measured.
3. Upper half casing is placed over the bottom casing and tightened all
casing bolts.
4. Mechanical Seals, Journal bearing and thrust bearings are installed.
5. Alignment and Coupling done.
6. Flushed and assembled all lube oil, Seal & vent lines.
Post Maintenance Observations:
1. Trial taken as per protocol with nitrogen.
2. Compressor is running normal with bearing temperatures within limits.
3. All the vibration values are in limits.

Measurement Sheets:

a) Labyrinths Clearances

Clearances
Sl.No. Position Description
Design Limit Actual Value
R+L R L
1 1st Impeller eye 1.2-1.3 0.4 0.45
2 2nd Impeller eye 1.15-1.25 0.45 0.45
3 3rd Impeller eye 1.1-1.2 0.35 0.45
4 Labyrinths seal clearances 4th Impeller eye 1.1-1.2 0.45 0.45
5 on Impeller Eye 5th Impeller eye 1.0-1.1 0.45 0.45
6 6th Impeller eye 1.0-1.1 0.45 0.45
7 7th Impeller eye 0.95-1.05 0.5 0.45
8 8th Impeller eye 0.95-1.05 0.5 0.5
9 B/w 1st and 2nd Impeller 0.5-0.6 0.37 0.3
10 B/w 2nd and 3rd Impeller 0.5-0.6 0.3 0.3
11 B/w 3rd and 4th Impeller 0.5-0.6 0.25 0.3
Labyrinths seal clearances
12 B/w 4th and Centre Impeller 0.5-0.6 0 0.3
between Impellers
13 B/w 5th and 6th Impeller 0.5-0.6 0.25 0.25
14 B/w 6th and 7th Impeller 0.5-0.6 0.2 0.25
15 B/w 7th and 8th Impeller 0.5-0.6 0.3 0.3
16 Labyrinths seal clearances NDE End Seal 0.5-0.7 0.25 0.25
17 on End Seals DE End Seal 0.5-0.7 0.25 0.35
18 Balancing Drum Clearances BD Seal 0.5-0.6 0.3 0.3
 b) Bearing Clearances
Clearances
Sl.No. Description
Design Limit Before O/H After O/H
1 Radial Journal Bearing DE 0.18-0.20 0.19 0.18
2 Radial Journal Bearing NDE 0.18-0.20 0.18 0.18
3 Thrust Bearing 0.25-0.35 0.36 0.28

Thrust Bearing Pad Thickness

Sl.No. Pad Number Thickness Pad Number Thickness
1 Active Pad No.1 19.84 Inactive Pad No.1 19.80
2 Active Pad No.2 19.86 Inactive Pad No.2 19.82
3 Active Pad No.3 19.85 Inactive Pad No.3 19.85
4 Active Pad No.4 19.86 Inactive Pad No.4 19.85
5 Active Pad No.5 19.84 Inactive Pad No.5 19.85
6 Active Pad No.6 19.85 Inactive Pad No.6 19.84
7 Active Pad No.7 19.80 Inactive Pad No.7 19.84
8 Active Pad No.8 19.81 Inactive Pad No.8 19.85
9 Active Pad No.9 19.85 Inactive Pad No.9 19.84
10 Active Pad No.10 19.84 Inactive Pad No.10 19.85
11 Active Pad No.11 19.84 Inactive Pad No.11 19.84
12 Active Pad No.12 19.83 Inactive Pad No.12 19.87

c) Rotor Run-out
Rotor Run-Out
Sl.No. Position Value
1 Coupling Taper 0.01
2 DE Journal Bearing 0.00
3 DE Mechanical Seal 0.02
4 Discharge End Seal 0.00
5 1st Impeller eye 0.01
6 2nd Impeller eye 0.02
7 3rd Impeller eye 0.05
8 4th Impeller eye 0.04
9 Centre Bush 0.02
10 8th Impeller eye 0.04
11 7th Impeller eye 0.02
12 6th Impeller eye 0.01
13 5th Impeller eye 0.02
14 Suction End Seal 0.02
15 NDE Mechanical Seal 0.02
16 NDE Journal Bearing 0.00
17 Thrust Collar 0.01
18 Thrust Collar Nut 0.01
 d) Miscellaneous Readings

Sl.No. Description Readings

Before O/H After O/H
1 DBSE 502 502.5
2 DE Side Seal spacer Thickness 10.6 10.6
3 NDE Side Seal spacer Thickness 10.03 10.03
4 Rotor Free float 3.6 3.3
5 Thrust Collar Spacer Thickness 7.7 7.7
6 Coupling Shim turbine Side 1.6 1.6
7 Coupling Shim compressor Side 1.2 2.8
8 Max Radial Brg Pad Thickness difference DE 0.02 0.02
9 Max Radial Brg Pad Thickness difference NDE 0.02 0.02
10 DE Journal Bearing Interference 0.05 0.05
11 NDE Journal Bearing Interference 0.05 0.05
12 Pre-stretching on Coupling 2.7 1.7

e) Alignment
Alignment Reading before Overhauling

0.00 0.00

+0.39 +0.37 +0.02 -0.35

R A

+0.74 -0.15

Alignment Reading after Overhauling

0.00 0.00

+0.40 +0.33 -0.02 +0.01

R
A

+0.73 -0.03
 f) Vibration & Temperature Readings

Sl.No. Description Tag No. Unit Before After

1 14ZI6002A MM -0.114
Axial Displacement
2 14ZI6002B MM -0.141
3 14TI6005A DEG.C 66
Thrust Bearing Temp. Active
4 14TI6005B DEG.C 67
5 14TI6005C DEG.C 54
Thrust Bearing Temp. Inactive
6 14TI6005D DEG.C 56
7 14TI6004A DEG.C 89
NDE Radial Bearing Temp.
8 14TI6004B DEG.C 54
9 14TI6004A DEG.C 74
DE Radial Bearing Temp.
10 14TI6004B DEG.C 71
11 14VI6004A um 11
DE bearing Vibration
12 14VI6004B um 16
13 14VI6003A um 11
NDE bearing Vibration
14 14VI6003B um 11

g) Bearings Demagnetization
Sl.No. Description
1 DE Journal bearing (Top)
2 DE Journal bearing (Bottom)
3 NDE Journal bearing (Top)
4 NDE Journal bearing (Bottom)
5 Tilting Pad Journal bearing
Before Demagnetization Before Demagnetization
6 0
8 0
-10 0
-10 0
0 NOT REQUIRED

Spare Consumed:
Sl.No. Material Description Qty Unit
1 "O" RING VITON DIA 2.62X 12 Mtr
2 Coupling Spacer SHIM(0.4 MM ) 4 EA
3 DRY GAS SEAL (T.B. SIDE) 1 EA
4 DRY GAS SEAL (O.T.B. SIDE) 1 EA