32 Chemical Manufacturing
Plant optimisation for fertiliser manufacturers Paul Richardson, Service Center Manager at Sulzer’s Middlesbrough Service Center, looks at how revitalising existing rotating equipment can offer a cost-effective improvement in efficiency and reliability in the manufacturing process for fertilisers and other chemicals.
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he equipment used to manufacture fertiliser in the chemical industry operates in a challenging environment, which can cause accelerated wear, reducing efficiency. The need to minimise capital expenditure means that replacement of machinery is not always a viable strategy. Rather than purchase new machinery, it can be more cost-effective to repair or modify existing plant equipment to extend its service life and make it more effective. PROACTIVE MAINTENANCE Generally, turbines, compressors and pumps are all subject to a variety of process-driven Stator rewinds extend the service lives of generators and large motors. conditions that contribute to corrosion, erosion, fouling and various other processrelated issues and can be managed through effective maintenance performance, allow remedial actions to be planned in during intervention. Rotating equipment that is in direct contact with regular maintenance windows. the process media and under constant attack presents a major The advance warning also ensures that all the necessary challenge. It is possible, however, to reduce degradation to a personnel and parts can be assembled to ensure the most efficient minimum by selecting the correct protective coating. use of time and any external resources that may be required. In the harshest of operating conditions, solid and/or liquid particles can pass through the equipment causing erosion. REDUCING DOWNTIME This can result in moderate to severe material loss and change Shutdown periods provide an extended opportunity to carry out aerodynamic efficiencies significantly. If left unattended, it can even maintenance as well as refurbishment and upgrade work. As affect the critical components’ strength and lead to premature such, they allow companies to improve the performance and blade/vane wear and failure in service. reliability of their equipment without affecting productivity. In situations where these circumstances exist, and their However, with many legacy pieces of equipment used in the effect needs to be minimised, specialised coatings can improve chemical manufacturing sector, some may no longer have support protection against fouling and erosion. These can be applied to from the OEMs, which means that alternative solutions need to both stationary and rotating blades as well as diaphragms, guide be found when repairs and upgrades are required. In other cases, vanes, rotors and impellers. The exact composition of these OEMs’ lead-times may not meet the needs of the business, and an coatings can be tailored to specific applications and will include independent maintenance provider could be the best solution. an aluminium base coat for corrosion protection as well as an In situations where the speed of response is essential to inorganic sealer and a specialist non-stick final layer. minimise downtime, taking advantage of an experienced maintenance provider’s services and expertise could be the best IMPROVING RELIABILITY solution. The most effective way of avoiding downtime caused by machinery breakdown is to employ preventative maintenance CASE STUDY: RAPID REWIND techniques, such as vibration monitoring, partial discharge analysis For example, a CO2 compressor powered by an ageing 1,300 and thermal imaging. These procedures can be very useful in kW high voltage motor had been identified for a complete rewind monitoring the overall condition of equipment and its remaining during a planned shutdown period. Sulzer identified the rewind lifetime. option as the most cost-effective solution to extend the motor’s Analysing trends can reveal issues that would otherwise not reliable service life without impacting productivity. be seen without disassembling the machine. Early indications The project called for a complete rewind to be delivered within of issues with bearings, coils, vane clearances or just general a 30-day window, which would require a fast turnaround. Since
Quarter 1 2021
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