RHQ
Reliability Cell
अनुरक्षण एवं ननरीक्षण – उपकरण उपलब्धता, परम लक्ष्य ! 27.05.2025
Report on ROG-PSA 2nd Stage Compressor Failure dated 16.05.2025
Unit: ROG-PSA
Equipment: Refinery Off Gas Compressor
Tag No.: 9070-058-KA-CF-001/002/004
Date of incident: 16.05.2024
Time of incident: 19:25 hrs
Brief Process Details:-
• ROG PSA Unit is responsible for generation of hydrogen from refinery off-gas.
• The ROG PSA Unit is designed to process refinery hydrogen rich off-gas from three different
sources (“VGO-HDT LP”, “VGO-HDT MP” and “DHDT LP”).
• Design ROG PSA feed flow rate is 18.53 t/h Purge gas from the ROG PSA Unit is exported to
the refinery fuel gas system at battery limit.
• Purge Gas from ROG PSA is pressurized in 3 stage Fuel Gas Compressors 058- K-001, 58- K-002
and 58- K-004 to adequate pressure for export to refinery fuel gas network
Report on ROG-PSA 2nd Stage Compressor Failure dated 16.05.2025
Compressor Make M/s KOBELCO
Drive Motor with VFD
Model KS31LNZ
Chronology of events
16.05.2025 2nd Stage Compressor DE side Temperature increased & crossed the trip value 100 Deg C at
19:27 Hrs & Vibration reached to 8.69um from 3um.
On 17.05.2025 Trial was taken, however compressor tripped at 03:08 hours after reaching full load &
temperature Tag crossed trip value.
17.05.2025 @ 10:35 hours another trial was taken, During loading of compressor both value of
temperature reached till 94.85 deg C and returned back around 60 Deg C before tripping and the
compressor was under operation until 10:51 hours.
After reaching the full load, compressors were in operation for around 7 min where vibration started
increasing and tripped on 2nd stage NDE bearing vibration. Upon reaching full load noise was observed
coming from the compressor.
The compressor was eventually taken under maintenance to check bearing and internals.
Journal Bearings (DE and NDE both) for 2nd stage compressor female rotor were replaced and trial was
taken on 25.05.2025 @ 16:34 hours.
During 1st trial (16:34 hours to 17:27 hours) all machine parameters were within normal range however
after taking compressor in full load while reducing 2nd stage spillback below 5%, abnormal sound and
vibration increased from 11 um to 56 um. Thus the compressor was stopped from local panel.
2nd trial was taken at 18:27 hours dated 25.05.2025, however vibration crossed the tripping value
immediately.
NOTE: The compressor has had an history of multiple tripping since commissioning. As per record
available, compressor has tripped for 59 times since commissioning in Apr’23.
Why –Why Analysis
Activity chart for Restoration
SN Activity Plan Status/Target
1 Shutdown, Pressurize-depressurize, Isolation system Completed
2 Blinding of 2nd Stage compressor 27.05.2025
3 Remove oil and process piping/acoustic enclosure/ exhaust Fan/auxiliaries piping 27.05.2025
4 Remove instrumentation RTD’s, Vibration Probes 27.05.2025
5 Removal of coupling guard and coupling spacer 28.05.2025
6 Check alignment and remove coupling hub 28.05.2025
7 Dismantling and shifting to workshop 29.05.2025
8 Removal of Thrust disc & Bearings on both ends 30.05.2025
9 Removal of Timing gears and Dry Gas Seals on both ends for both screws 31.05.2025-01.06.2025
10 Remove rotor screw assembly 02.06.2025-03.06.2025
11 Cleaning of internals 04.06.2025
12 Measurement and clearance verification 04.06.2025
13 Installation of rotor screw assembly 05.06.2025-06.06.2025
14 Installation of Timing gears and Dry Gas Seals on both ends for both screws. 07.06.2025-08.06.2025
15 Installation of Thrust discs and bearings 09.06.2025
16 Assembly and Final Hydrotest 10.06.2025
17 Shifting to site and Coupling Alignment 11.06.2025
18 Installation of Probes and Auxiliary Piping 11.06.2025
19 Deblinding of lines and Flushing oil circuit 12.06.2025
20 Lining up process gas and Trial 12.06.2025
Thanks