Shutdown due to abnormal noise on the

cylinder 4 K5452
Jan 19, Bahia Blanca, Argentina

ME: Nasif, Victoria.

RE: Quel, Julio

Dow.com
Event description
Date: January 7th.

Description: LDPE was proactively SD due to a abnormal noise detected on Hyper Compressor coming
from cyl#4, preliminary finding shows that one spring of the poppet valve was found broken,
therefore the plant should be ready to SU after valve replacement.

Unfortunately, LDPE train will remain down due to lack of steam supply from BB1. Steam leaks were
detected a month ago and have been increasing until current situation that header should be repair in
order to minimize potential risk. According to site utilities team this repair will take 7 days working
around the clock and 9 days of total downtime. BB1 is the only one supplier of high pressure steam
for LDPE.

AU Losses: TBD.

Eatool: TBD.

Trigger: AU Losses & Reliability.

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Findings Cylinder # 4 2nd stage

Coupling

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 Findings discharge valve (Cylinder # 4 2nd stage)
Parts Finding Days Pictures
running
G7 – Spring. • Discharge valve springs 182
broken. The cone was
found down without
spring pre load.

This valve was last replaced

during the pit stop due to
packing replacement in Jul-
18.
Cyl # 4 Cyl # 5
• The wearing rate in the 182 Days 730 Days
cone (discharge valve)
cylinder # 4 is more than
cylinder # 5 with less
hours running.

• Scratches inside both

cone. Cylinders 4&5.

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Findings gas packing (Cylinder # 4 2nd stage)

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 Findings high pressure packing (Cylinder # 4 2nd stage)
Parts Finding Days Pictures
running
E47 – • Radial ring opened on 183
Metallic packing cup # 3 and 2.
packing incl.
E12a + E70.
• Tangential ring broken
on packing cup # 4.

• Guide bush (E56) on

packing cup # 7 with a
de coloration.

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 Findings high pressure packing (Cylinder # 4 2nd stage)
Parts Finding Days Pictures
running
E47 – • Marks on cup # 3. This 183
Metallic is the face is in contact
packing incl. with cup #4. It was
E12a + E70. necessary to lapidate
and then machine this
cup 0.1 mm to mitigate
these marks. After that
it was discarded due to
out of tolerance.

• Tangential ring
different as per
Burckhardt design. The
KRANZ ring design has
more pieces and those
match with cup #3
marks.

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 Findings plunger (Cylinder # 4 2nd stage)
Parts Finding Days Pictures
running
E53 – • Diameter out of tolerance 2,570
Plunger. minimum φ read 82,72 mm. (No
data, at
According the maintenance least
procedure the minimum tolerance since Diameter out of tolerance.
is φ 82,87 mm. (0.10 mm bellow 2012)
nominal dimension)

Last inspection Nov-2016.

(Nominal dimension φ 82,97 mm)

• Fretting fatigue on the coupling

zone.

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 Findings coupling of plunger (Cylinder # 4 2nd stage)
E34 Parts Finding Days Pictures
E35 running
E34 – Piston • Surface 730
coupling nut. marks.

• Fretting
fatigue.

E44 – Conical • Surface 730

pressing corroded.
piece.

E44
E35 – • Fretting 730
The coupling was last inspected Pressing fatigue and
during the pit stop due to packing piece. high
replacement and re tightening in wearing
rate on the
Jul-18. outside.

• Surface
corroded. DOW RESTRICTED 9
Action taken – Cylinder #4 (2nd stage)
• Upgrade the maintenance procedure # 2678 (packing and valve replacement procedure) adding
the coupling inspection to detect the damage fond at this opportunity. On going.

• Replace pieces of the coupling damaged. Done.

• Replace the plunger according maintenance procedure # 2678 (packing and valve replacement
procedure). Done.

• Replace the cylinder #4 valve. Done.

• Replace the gas packing cylinder #4. Done.

• Inspect the cylinder #5 coupling regarding the failure fund at cylinder #4. Done.

• Share findings with Burckhardt (OEM). On going.

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 Cylinder # 5 2nd stage
During the Plant SD it was decided to inspect and repair the gas packing according the process
variable we were monitoring.
At this moment we also evaluated the cylinder 3, but it was not prioritized because the cylinder 5
suddenly increased oil leak, vibration levels and the plant team toke the decision to increase the oil
rate until the corrective action could be done.

The vibration and oil leak went up. The action

taken was to increase the oil rate.

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Findings Cylinder # 5 2nd stage

12
Findings gas packing (Cylinder # 5 2nd stage)
The inspection and findings will be pending until it can be repaired.

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 Findings plunger (Cylinder # 5 2nd stage)
Parts Finding Days Pictures
running
E53 – • Diameter out of tolerance 1,228
Plunger. minimum φ read 82,81 mm.

According the maintenance

procedure the minimum tolerance Diameter out of tolerance.
is φ 82,87 mm. (0.10 mm bellow
nominal dimension)

Last inspection Nov-2016.

(Nominal dimension φ 82,97 mm)

• Scratch at the oil packing

working zone.

After and before the scratch 0.1

mm difference on the diameter.

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 Findings coupling of plunger (Cylinder # 5 2nd stage)
E34 Parts Finding Days Pictures
E35 running
E34 – Piston • No 730
coupling nut. findings.

E44 – Conical • No major 730

pressing findings.
piece.

E44
E35 – • No major 730
The coupling has been running Pressing findings.
since Nov-16. piece.

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Action taken – Cylinder #5 (2nd stage)
• Replace pieces of the coupling in a preventive way. It was installed a new coupling. Done.

• Replace the toggle link E50. Done.

• Replace the plunger according maintenance procedure # 2678 (packing and valve replacement
procedure). Done.

• Replace the cylinder #4 valve. Done.

• Replace the gas packing #4. Done.

• Replace the oil packing. Done.

• Share findings with Burckhardt (OEM). On going.

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Compressor plungers days running

2 1

4 3

6 5

Cylinder Days Last replacement Action taken

number Running
1 (1st stage) 3,138 days Jun-12-2010

2 (1st stage) 3,138 days Jun-12-2010

3 (2nd stage) 2,570 days No data since 2012.

4 (2nd stage) 2,570 days No data since 2012. Replaced WO#20013016701

5 (2nd stage) 1,228 days Sep-04-2015 (WO#20007577675) Replaced WO#20013028250

6 (2nd stage) 1,727 days Apr-23-2014 (WO#20001339931)

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Thank
You
ME: Nasif, Victoria.
RE: Quel, Julio

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