Abstract: This paper provides a comprehensive study pertaining to diagnosis of intermittent high vibrations on an industrial gas turbine using detailed vibrations analysis, followed by its rectification. Engro Polymer & Chemicals Limited, a Chlor-Vinyl complex located in Pakistan has a captive combined cycle power plant having two 28 MW gas turbines (make Hitachi) & one 15 MW steam turbine. In 2018, the organization faced an issue of high vibrations on one of the gas turbines. These high vibration peaks appeared intermittently on both compressor’s drive end (DE) & turbine’s non-drive end (NDE) bearing. The amplitude of high vibration peaks was between 150-170% on the DE bearing & 200-300% on the NDE bearing from baseline values. In one of these episodes, the gas turbine got tripped on “High Vibrations Trip” logic actuated at 155µm. Limited instrumentation is available on the machine, which is monitored with GE Bently Nevada 3300 system having two proximity probes installed at Turbine NDE, Compressor DE &at Generator DE & NDE bearings. Machine’s transient ramp-up & steady state data was collected using ADRE SXP & DSPI 408. Since only 01 key phasor is installed at Turbine high speed shaft, a derived drive key phasor was configured in ADRE to obtain low speed shaft rpm required for data analysis. By analyzing the Bode plots, Shaft center line plot, Polar plot & orbit plots; rubbing was evident on Turbine’s NDE along with increased bearing clearance of Turbine’s NDE radial bearing. The subject bearing was then inspected & heavy deposition of carbonized coke was found on the labyrinth seals of bearing housing with clear rubbing marks on shaft & housing covering at 20-25 degrees on the inner radius of labyrinth seals. The collected coke sample was tested in laboratory & found to be the residue of lube oil in the bearing housing. After detailed inspection & cleaning of shaft journal area & bearing housing, new radial bearing was installed. Before assembling the bearing housing, cleaning of bearing cooling & sealing air lines was also carried out as inadequate flow of cooling & sealing air can accelerate coke formation in bearing housing. The machine was then taken back online & data was collected again using ADRE SXP & DSPI 408 for health analysis. The vibrations were found in acceptable zone as per ISO standard 7919-3 while all other parameters were also within vendor defined range. As a learning from subject case, revised operating & maintenance regime has also been proposed to enhance machine’s reliability.
Abstract: The effect of additional magnesium oxide (MgO) was
investigated by using the tungsten oxide supported on silica catalyst
(WOx/SiO2) physically mixed with MgO in a weight ratio 1:1. The
both fresh and spent catalysts were characterized by FT-Raman
spectrometer, UV-Vis spectrometer, X-Ray diffraction (XRD) and
temperature programmed oxidation (TPO). The results indicated that
the additional MgO could enhance the conversion of trans-2-butene
due to isomerization reaction. However, adding MgO would increase
the amount of coke deposit on the WOx/SiO2 catalyst. The TPO
profile presented two peaks when the WOx/SiO2 catalyst was
physically mixed with MgO. The further peak was suggested that
came from coke precursor could be produced by isomerization
reaction of undesired product. Then, the occurred coke precursor
could deposit and form coke on the acid catalyst.
Abstract: The effect of N2 pretreatment on the catalytic activity
of tungsten-based catalysts was investigated in the metathesis of
ethylene and trans-2-butene at 450oC and atmospheric pressure. The
presence of tungsten active species was confirmed by UV-Vis and
Raman spectroscopy. Compared to the WO3-based catalysts treated
in air, higher amount of WO4 2-tetrahedral species and lower amount
of WO3 crystalline species were observed on the N2-treated ones.
These contribute to the higher conversion of 2-butene and propylene
selectivity during 10 h time-on-stream. Moreover, N2 treatment led to
lower amount of coke formation as revealed by TPO of the spent
catalysts.
Abstract: Propylene self-metathesis to ethylene and butene was
studied over WOx/SiO2 catalysts at 450oC and atmospheric pressure.
The WOx/SiO2 catalysts were prepared by incipient wetness
impregnation of ammonium metatungstate aqueous solution. It was
found that, adding nano-sized extra supports (SiO2 and TiO2) by
physical mixing with the WOx/SiO2 enhanced propylene conversion.
The UV-Vis and FT-Raman results revealed that WOx could migrate
from the original silica support to the extra support, leading to a
better dispersion of WOx. The ICP-OES results also indicate that
WOx existed on the extra support. Coke formation was investigated
on the catalysts after 10 h time-on-stream by TPO. However, adding
nano-sized extra supports led to higher coke formation which may be
related to acidity as characterized by NH3-TPD.
Abstract: The steam cracking reactions are always accompanied with the formation of coke which deposits on the walls of the tubular reactors. The investigation has attempted to control catalytic coking by the applying aluminum, zinc and ceramic coating like aluminum-magnesium by thermal spray and pack cementation method. Rate of coke formation during steam cracking of naphtha has been investigated both for uncoated stainless steel (with different alloys) and metal coating constructed with thermal Spray and pack cementation method with metal powders of Aluminum, Aluminum-Magnesium, zinc, silicon, nickel and chromium. The results of the study show that passivating the surface of SS321 with a coating of Aluminum and Aluminum-Magnesium can significantly reduce the rate of coke deposition during naphtha pyrolysis. SEM and EDAX techniques (Philips XL Series) were used to examine the coke deposits formed by the metal-hydrocarbon reactions. Our objective was to separate the different stages by identifying the characteristic morphologies.
Abstract: This work aims to test the application of computational fluid dynamics (CFD) modeling to fixed bed catalytic cracking reactors. Studies of CFD with a fixed bed design commonly use a regular packing with N=2 to define bed geometry. CFD allows us to obtain a more accurate view of the fluid flow and heat transfer mechanisms present in fixed bed equipment. Naphtha was used as feedstock and the reactor length was 80cm. It is divided in three sections that catalyst bed packed in the middle section of the reactor. The reaction scheme was involved one primary reaction and 24 secondary reactions. Because of high CPU times in these simulations, parallel processing have been used. In this study the coke formation process in fixed bed and empty tube reactor was simulated and coke in these reactors are compared. In addition, the effect of steam ratio and feed flow rate on coke formation was investigated.