Request a solution
Request a solution

Butadiene Recycle
Gas Compressor

Overhauling & Commissioning

Plant Petrochemical Plant
Application Butadiene Recycle
Volume 13062 m3/hr.
READ MORE
Plant Petrochemical Plant
Application Butadiene Recycle
Volume 13062 m3/hr.

Problem Statement

One of our Esteemed Clients approached us to provide an Emergency Solution for Excessively Leaking Mechanical Seals in their Butadiene Recycle Gas Compressor, which is operational in their Petrochemical Plant. Due to the compressor’s intricate design and confined access points, approximately 80% of the unit’s components required disassembly to facilitate access to the sealing system. This operation was performed under the oversight of the OEM of the mechanical seals, ensuring compliance with the manufacturer’s technical standards and procedural specifications.

The decommissioned seals were successfully removed, and the new mechanical seals, provided by the OEM, were installed. However, Despite numerous attempts by OEM’s Engineers, the leakage problem could not be resolved, leading to operational inefficiencies and potential risk to the compressor’s integrity. Multiple attempts were made by the OEM engineers to address the leakage through reconditioning and adjustments, but these efforts failed to rectify the problem.

Eventually, the Client’s AED Management escalated the situation and requested the intervention of TESCO Engineering’s Fluid & Gas Sealing Division. The division was tasked with conducting a diagnostic analysis to identify the leakage cause and develop an optimized sealing solution to restore compressor performance and prevent further degradation.

Scope of Work - MechanicalSeals

The Fluid & Gas Sealing Division team received the previously failed mechanical seals for refurbishment and carried out the following procedures

  • Fabrication of Specialized Tools: Custom-designed tools were created for the disassembly and inspection of the seals.
  • Surface Finish Inspection: Metal components in the sealing area were inspected, achieving a dynamic finish of 32 RMS and static sealing area finish of 63 RMS, in line with API 682 standards.
  • Rotary Carbon Face Replacement: The Rotary Carbon Face was replaced to restore sealing integrity.
  • Re-lapping & Cleaning of Stationary Face: The Stationary Face was re- lapped and cleaned within two light bands for optimal sealing.
  • O-Ring and Packing Replacement: All O-rings were replaced with FFKM material, and PTFE packing was replaced to ensure high chemical and thermal resistance.
  • Final Assembly: The mechanical seals were reassembled to original specifications.
  • Integrity Testing: Integrity testing was performed per API 682 standards to ensure proper sealing performance under operational conditions.

Conclusion - MechanicalSeals

The process, from receiving the Mechanical Seal to the Refurbishment, 
was completed in our facility within 48 hours.

The teams from our Fluid & Gas Sealing and Turbomachinery Divisions worked together to Install The Seals in the compressor. Following the installation, Integrity and Performance testing were conducted in Front of the Client’s Team, lasting over 30 minutes, during which the Compressor Passed Successfully.

Scope of Work - Compressor

  • The compressor was decommissioned from the site and transported to the TESCO Engineering facility for further assessment.
  • Disassembly, Inspection, and Maintenance were carried out in accordance with initial diagnostic findings, spatial measurements, and equipment-specific observations.
  • The compressor rotor journals underwent polishing and were determined to be within acceptable operational tolerances.
  • Inspection of the probe track burnishing areas revealed compliance with minimum specifications.
  • A Non-Destructive Testing (NDT) assessment was conducted on the timing gears, radial and thrust bearing assemblies, and the drive coupling hub.
  • The Radial Journal Bearings were replaced with new components, and the associated thermocouples were substituted and subjected to functional testing.
  • The compressor’s mechanical shaft seals were replaced with a combination of OEM and TESCO Engineering-refurbished seals.
  • Reassembly of the compressor was performed, with specific adjustments made to the thrust bearing clearance, as the male rotor thrust bearing clearance was found to exceed OEM tolerances during disassembly.
  • The compressor rotor timing gears were reinstalled, with the rotor timing verified and calibrated, as necessary.
  • Interlobe and rotor inlet and outlet end clearances were meticulously verified.
  • Post-adjustment of running clearances, the mechanical seals underwent testing under simulated field conditions.
  • Lubricating oil was injected into the seal chambers at a regulated pressure corresponding to field conditions, and the test results were deemed satisfactory.
  • The compressor was subsequently fully reassembled and shipped back to the site for reinstallation.

Result

  • The compressor was installed and laser-aligned with an offset alignment 
to the gearbox, followed by the execution of the gearbox-to- motor offset alignment.
  • The compressor was successfully commissioned, and the lube oil system control pressures were adjusted and verified according to the package design documentation.
  • The field instruments were then reinstalled, adjusted, and function tested.
Spread two fingers to zoom in

Explore similar projects

Read more Case Studies
Read more Case Studies

Partner with the Industry Leader

Need innovative engineering solutions? Reach out to TESCO Engineering for state-of-the-art products and expert support in the petrochemical and specialized industries.

Request a solution