TOPIC:
Mitigating Coupling Failures: Insights from a Centrifugal Gas Compressor Incident Triggered by Sudden Acceleration
INSTRUCTOR(S):
-
Marco is responsible for the regional engineering, fleet technical support, consulting and technical solution development in the Americas.
Before joining the site in Brookshire, TX in 2017, he was with MAN Energy Solutions Switzerland for over 9 years. In this position, he managed the MAN PrimeServ’s application engineering team. He was in charge of thermodynamic revamp designs, technical customer support and trouble shooting on axial and centrifugal compressors as well as on steam turbines.
Marco received his diploma in Mechanical Engineering FH (Bachelor of Science) with a major in thermodynamics and thermal applications from the University of Applied Science in Zurich in 2008 and post-graduated in General Management (MBA). Parallel to his studies, he started his career as design engineer in the textile industry in 2002.
-
Bhavin joined Everllence, formerly know as MAN Energy Solutions in 2007 as trainee engineer at the India office. He served as a Field Engineer for about 10 years in India, Canada and USA.
For the last 8 years, he has been working as a Senior Applications and Consulting Engineer for the Americas Region, focusing on operational issues and turbomachinery modifications.
He completed his Bachelors degree in Mechanical engineering from North Maharashtra University in India in 2007.
He then completed a Master of Science in Mechanical Engineering degree from University of Texas at Austin in 2022. He is an APEGA licensed Engineer. Additionally, he is a CAT II vibration analyst, supporting OEM and third-party fleet for vibration issues.
Throughout his career in the turbomachinery industry, he acquired core skills in thermodynamics, vibration analysis and diagnosis, data modeling and analysis, dynamic system modeling and simulations and root cause failure analysis to name a few.
DETAILS:
One (1) hour presentation, including up to 15 min. Q&A
DESCRIPTION:
This presentation explores a detailed case study of a coupling failure and significant damage experienced by a centrifugal gas compressor within a nitric acid compressor train, triggered by a sudden acceleration following a control system modification in 2023. The incident occurred on June 24, 2023, and involved a comprehensive analysis of the factors leading to the coupling's failure.
The study provides an in-depth examination of the calculations and findings related to the failure, emphasizing the impact of the abrupt acceleration during the start-up phase. The analysis identifies critical factors contributing to the failure, including the absence of an acceleration protector and deviations from the recommended start-up procedures.
The presentation offers conclusions and actionable recommendations aimed at preventing similar incidents in the future. It underscores the importance of implementing an acceleration protection mechanism and adhering strictly to specified start-up sequences. By sharing these insights, the presentation seeks to enhance understanding of coupling failure mechanisms and promote best practices in the maintenance and operation of industrial machinery. This case study serves as a valuable resource for improving operational reliability and safety in similar industrial settings.