REVIEW AND RECOMMENDATIONS CONDENSATE REMOVAL SYSTEM OF PROCESS AIR COMPRESSOR OF K-101B REVIEW AND RECOMMENDATIONS Presented by: Saleha Quadsia Management Associate (Process)

Objective Review of condensate removal system of Ammonia Plant Process Air Compressor (K-101B) and recommendations for its improvement.

Contents Condensate Removal System (CRS) Types of CRS Process Air Compressors (K-101A/B) CRS Evaluation of Auto Drainers Recommendations

Condensate Removal System Liquid in gas can not be sent to the compressor as it will lead to mechanical failure.

Types Condensate Removal System Manual Mechanical float traps Solenoid operated Mechanical float traps Control Valves (Zero air-loss) Condensate Removal System

Manual Operation Operator manually open valves to discharge condensate. Depends on people opening valves at the appropriate time for the necessary amount of time. Often leads to excess loss because air escapes when the valves are left open to drain the condensate. High noise level during air loss.

Mechanical Float Traps Use a float connected by linkage to a drain valve that opens when an upper setting is reached and closes when the drain is emptied Require considerable maintenance and prone to blockage from sediment in condensate. Are prone to getting stuck in open position (leak excess air) and in the closed position (does not allow condensate to be drained) Inverted bucket traps may require less maintenance, but will waste air if the condensate rate is inadequate to maintain the liquid level in the trap.

Solenoid-operated Drain Valves Have timing devices that can be set to open for specified amounts of time at pre-set adjustable intervals. The period during which the valve is open may not be long enough for adequate drainage of accumulated condensate. The valve will operate even if little or no condensate is present, resulting in air loss. Require strainers to reduce contaminants, which can block the inlet and discharge ports of these devices.

Control Valves Operates against level sensors and controller Zero loss Considered very reliable Limitation Maintain level in knock out vessels

K-101A Condensate removal System K-101B Condensate removal System Existing K-101A/B K-101A Condensate removal System K-101B Condensate removal System

Evaluation of Auto Drainers Armstrong auto drainers 213 and each K.O. had two auto drainers in parallel. Based on above the drainers were evaluated and results are as below: Location C-111A/B C-108A/B C-109A/B Manufacturer Armstrong Model 213 Quantity 02 Orifice Size 1/4" 3/16" Operating Pressure 2.24 6.33 14.91 Original Condensate load 527 389 132 Post revamp Condensate load 748 Delta P across drainer 2.04 6.13 14.71 Max condensate Discharge 907 1587 1451

Local Draining of Condensate Condensate Removal of K-101A Condensate Removal of K-101B

Condensate Removal of K-101A Condensate Removal of K-101B

Recommendations Condensate removal system of existing K-101B should be upgraded to control valves from mechanical auto drainers, provided level can be maintained in KODs. It is recommended to take the auto drainers in service and all local drainages vide bypass should be stopped due to following reasons, High air losses (Limiting at full load) High noise level House keeping issues Against engineering practices If required, reliability of auto drainers may be enhanced by replacement of existing auto drainers with new.

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