Saudi Aramco Public Reliability Enhancement of Plant Air

Saudi Aramco: Public

Reliability Enhancement of Plant Air Compressors at Qurayyah Sea Water Plant Sharib Khan CMRP, CRL, Vib Analyst Cat-III PHOENIX, AZ June 26 -27, 2019 Saudi Aramco: Public 2

Reliability Enhancement of Plant Air Compressors at Qurayyah Sea Water Plant Outline: Problem Statement Solution Options Implementation Conclusion PHOENIX, AZ June 26 -27, 2019 Saudi Aramco: Public

Problem Statement PHOENIX, AZ June 26 -27, 2019 Solution Options Saudi Aramco: Public Implementation Benefits

Problem Statement Failure PHOENIX, AZ June 26 -27, 2019 • Solution Options Implementation Conclusion Plant air compressor failures led to very low mean time between failure (MTBF) Saudi Aramco: Public

Problem Statement • Failure Solution Options Conclusion Plant air compressor failures led to very low mean time between failure (MTBF) Oil Cooler Damage PHOENIX, AZ June 26 -27, 2019 Implementation Saudi Aramco: Public

Problem Statement Failure • Solution Options Conclusion Plant air compressor failures led to very low mean time between failure (MTBF) Gears damaged PHOENIX, AZ June 26 -27, 2019 Implementation Saudi Aramco: Public

Problem Statement Failure • Solution Options Conclusion Plant air compressor failures led to very low mean time between failure (MTBF) Pinion Gear Damage PHOENIX, AZ June 26 -27, 2019 Implementation Saudi Aramco: Public

Problem Statement Failure PHOENIX, AZ June 26 -27, 2019 • Solution Options Implementation Conclusion Failures due to air coolers defects, or failure lead to damage to air frame parts Saudi Aramco: Public

Problem Statement Solution Options Failure Air Cooler Bundle Damage PHOENIX, AZ June 26 -27, 2019 Saudi Aramco: Public Implementation Conclusion

Problem Statement Solution Options Failure Air Cooler Housing PHOENIX, AZ June 26 -27, 2019 Saudi Aramco: Public Implementation Conclusion

Problem Statement Solution Options Failure Scaling inside airframe PHOENIX, AZ June 26 -27, 2019 Saudi Aramco: Public Implementation Conclusion

Problem Statement Failure Solution Options Broken High Speed Impeller Vane Second Stage Impeller Damage PHOENIX, AZ June 26 -27, 2019 Saudi Aramco: Public Implementation Conclusion

Problem Statement Solution Options Failure • Cost of Repair is very high almost $250, 000 Saudi Aramco: Public Implementation Conclusion

Problem Statement Consequences Solution Options • • • Conclusion Low MTBF (9 months) Unavailability of equipment High cost of repairs Bad actors Break-in Maintenance Planning Schedule Existing Controls § Pd. M (Bi- monthly vibration survey) § Pd. M (Quarterly LCM) § Yearly PM (Electrical) § Five (5) yearly T&I of Air and Oil Coolers PHOENIX, AZ June 26 -27, 2019 Implementation Saudi Aramco: Public

Problem Statement Solution Options Implementation Conclusion Yearly Overhaul Compressor only One Year PM Five Year T&I Benefits Three year PM Clubbed with T&I PHOENIX, AZ June 26 -27, 2019 Efforts Saudi Aramco: Public

Problem Statement Solution Options Implementation Conclusion • Easiest path is to “do nothing” • Continue doing the Annual PM and major repair of compressor when breakdown • Continue doing the 5 -Yearly T&I for the Coolers • Introduction of enhanced annual PM and 3 year PM and Clubbed with T&I • Include Auxiliary equipment like IGV and Discharge Check Valve servicing/ overhaul on a 3 -year basis during PM PHOENIX, AZ June 26 -27, 2019 Saudi Aramco: Public

Problem Statement Solution Options Implementation Conclusion Use high pressure jetting to clean the tubing on Intercooler and Aftercoolers every 5. 0 years for poor heat transfer due to scale build-up. Replace corroded air volutes with new ductile cast iron and coat them internally with Belzona coating. Install new stainless steel vaned diffuser assemblies on all three stages of air compressor unit which are superior to the original Aluminum diffusers. PHOENIX, AZ June 26 -27, 2019 Saudi Aramco: Public

Problem Statement Solution Options Implementation Conclusion • Enhanced Yearly PM – Laser Alignment between driver motor & Compressor – Check and stroke Inlet Guide Valve and Surge Valve – Check for any leakages on intercooler and after cooler and Clean or replace the clogged drain lines. – Check & Calibrate the inlet air filter differential pressure transmitter. – Replace Lube Oil Filters – Check the flow and leakages of Cooling Water, repair if required PHOENIX, AZ June 26 -27, 2019 Saudi Aramco: Public

Problem Statement Solution Options Implementation Conclusion • New 3 -year PM Drive Motor test with MCE or megger Cleaning of air frame for scale removal Chemical cleaning of Cooler Bundles Auxiliary equipment like IGV and Discharge Check Valve servicing/overhaul – Blast & Re-coat corroded intercooler shells and air pipings with special high temperature coatings – Replace all air intake filters – – PHOENIX, AZ June 26 -27, 2019 Saudi Aramco: Public

Problem Statement PHOENIX, AZ June 26 -27, 2019 Solution Options Saudi Aramco: Public Implementation Conclusion

Problem Statement Solution Options Implementation Cost effective solution and early fault elimination Enhance equipment reliability by increasing MTBF Facilitate proactive job planning Reduction in MTTR PHOENIX, AZ June 26 -27, 2019 Saudi Aramco: Public Conclusion

Conclusions Most of the Reliability is inbuilt during the design stage. Reliability can be severely effected with neglect in operation and inadequate maintenance practices Most of the improvement in reliability can be achieved while taking care of Auxiliaries of the plant air compressors By dedicating more time to PM and reliability functions, reactive fire-fighting work will decrease, thereby reducing downtime and driving improved reliability Reliability improvement can be achieved with experience and collaboration with operation and maintenance crew. PHOENIX, AZ June 26 -27, 2019 Saudi Aramco: Public

Questions & Thank You ! Sharib A. Khan CMRP, CRL, Vibration Analyst Cat III, Tap. Root Analyst Reliability Engineer Sea Water Injection Department, Saudi Aramco PHOENIX, AZ June 26 -27, 2019 Saudi Aramco: Public