OVERHAULING REPORT:

AIR COMPRESSOR (110-KA-701B)

Gas Cracker Unit-2

GAIL Pata

Overhauling Report on
AIR COMPRESSOR (110-KA-701B)

PREPARED BY:
GCU-2 Mechanical Department

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 OVERHAULING REPORT:
AIR COMPRESSOR (110-KA-701B)

INDEX

SL NO. DESCRIPTION PAGE NO.

1 INTRODUCTION 3
2 EQUIPMENT DETAILS 3
3 PREPERATIONS PRIOR TO MAINTENANCE 4
4 KEY OBSERVATION DURING DISMANTLING 4
5 MAINTENANCE ACTIVITY 5
6 SPARE PART CONSUMED DURING MAINTENANCE 6
7 FAILURE ANALYSIS & RECOMMENDATIONS 6
8 DRAWING OF EQUIPMENT FOR REFERENCE 7
9 DATASHEET OF EQUIPMENT FOR REFERENCE 9
10 SAP MAT. CODE OF DIFFERENT PARTS 13

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AIR COMPRESSOR (110-KA-701B)

1. INTRODUCTION:
There are 2 Nos. of AIR COMPRESSOR (Tag No: 110-KA-701A/B) installed in WAO
area in Hot Section of GCU-2 Plant.

On 19.08.2021, Operations reported that 110-KA-701B is not developing

adequate flow and pressure. We also observe the same situation. It was
decided to take the compressor for mechanical maintenance.

2. EQUIPMENT DETAILS:
TAG NO.: 110-KA-701A

APPLICATION: Air compressor

MAKE: Ingersoll Rand

SIZE & TYPE: 7x7 & 5x7 PHE-7 B0 C

NO. OF STAGES: Two

1st STAGE SUCTION PRESSURE: 3.4 kg/cm2 g

1st STAGE DISCHARGE PRESSURE: 7.38 kg/cm2 g

2nd STAGE SUCTION PRESSURE: 6.95 kg/cm2 g

2nd STAGE DISCHARGE PRESSURE: 12.9 kg/cm2 g

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AIR COMPRESSOR (110-KA-701B)

3. PREPERATIONS PRIOR TO OVERHAULING:

Inlet & Outlet Valves were closed for isolation.

System was depressurized by venting & draining.

Work Permit was applied & received for carrying out Overhauling
activities (CWP No: 2247077 & ELP No: 2247093).

Inlet & Outlet lines were blinded (3” 150# & 3” 300# respectively) to
ensure Positive Isolation.

After cross-checking all the above activities, overhauling activities of

Compressor were started.

4. KEY OBSERVATION DURING DISMANTLING:

First, HP side (2nd stage) Suction Valves were opened & dismantled. Rusting was
observed inside the valves. Valves were also passing.

Then, HP side (2nd stage) Discharge Valves were opened & dismantled. Rusting
was observed inside the Discharge Valves, too. Discharge Valve Plate was
found in damaged condition.

2nd stage piston assembly was dismantled. Assembly was found in rusted &
corroded condition.

Rider Rings were found to be in damaged condition.

Clearance between Piston & Cylinder is found out as below (in mm):

2.95

2.20 1.00

0.50
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 OVERHAULING REPORT:
AIR COMPRESSOR (110-KA-701B)

5. MAINTENANCE ACTIVITY:
2nd stage Cylinder, piston assembly were properly cleaned with emery paper.

2nd stage Suction Valves were dismantled, properly cleaned and overhauled.

2nd stage Discharge Valves (2 no.) were replaced with new ones.

2nd stage Rider Rings (2 no.) were replaced.

2nd stage Piston Rings (2 no.) were replaced.

Clearance between Piston & Cylinder after Piston Ring and Rider Ring replacement
is as below (in mm):

1.50

1.55 1.60

1.95
Top Dead Center (TDC) and Bottom Dead Center (BDC) were measured to be 2.32
mm and 1.23 mm respectively.

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 OVERHAULING REPORT:
AIR COMPRESSOR (110-KA-701B)

6. SPARE PARTS CONSUMED DURING MAINTENANCE:

Sl. No MATERIAL SAP CODE DESCRIPTION UNIT QTY

1 1578000053 ASSEMBLY PISTON ROD 7 IN, EA 1

P/N:42437921

2 1578000373 RING WRNG 5INCPI124WT AIR, EA 3

P/N:24187098

3 VALVE DISCHARGE, EA 2
1578000393 P/N:39329313

4 1578000413 VALVE DISCHRG(A36-400/600), EA 2

P/N:39590435

7. FAILURE ANALYSIS AND RECOMMENDATION:

Rusting and corrosion was there inside Compressor in various internal parts
because of presence of moisture content inside Compressor body. There was
corrosion inside compressor body.

Possible reasons for presence of moisture inside compressor body are either
presence of moisture in inlet air or malfunctioning of solenoid system for moisture
removing in various poistions of air pass inside the compressor.

To avoid any such failure of the Compressor, following are the

recommendations may be considered:

It is to be ensured that the inlet air remain moisture free.

Regular check-up of moisture removal system is to maintained to ensure

continuous functioning.

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AIR COMPRESSOR (110-KA-701B)

8. DRAWING OF EQUIPMENT (110-KA-701) FOR REFERENCE:

Cross Section of Compressor Cylinder

Free Air Unloader Assembly

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AIR COMPRESSOR (110-KA-701B)

Piston Rod Packing and Oil Scrapper Ring

Assembly of 2nd Stage Cylinder

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AIR COMPRESSOR (110-KA-701B)

9. DATASHEET OF EQUIPMENT (110-KA-701) FOR REFERENCE:

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 OVERHAULING REPORT:
AIR COMPRESSOR (110-KA-701B)

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AIR COMPRESSOR (110-KA-701B)

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AIR COMPRESSOR (110-KA-701B)

10. SAP MAT. CODE OF DIFFERENT PARTS :

COMPONENTS OF KA 701 MAPPED IN SAP

STOCK
IN
MATERIAL INSTALLED
S.NO. DESCRIPTION C&P
CODE QUANTITY
STORE
(NOS.)
1 ASMBL CRNKSFT IHE WT KEY,P:94441508-KIT 1578000013 7
ASBML ROD CONN COMP 7
2 ESV,P/N:37189610 1578000023 4
ELBOW MN BRG HUSNG0.50
3 NPT,P/N:94425162 1578000033 1 1
4 ASSEMBLY PISTON 7×7 PHE NL,P/N:42381988 1578000043 2 1
5 ASSEMBLY PISTON ROD 7 IN,P/N:42437921 1578000053 2 1
6 PISTON 5×7PHE-7 NL-2STG DSGN,P:39556527 1578000063 4 1
ROD PSTN LQUD
7 NITRIDED5×7PHE,P:39570973 1578000073 3 1
8 ASSEMBLY PIN CROSSHEAD,P/N:37087707 1578000083 1 1
9 GASKET BRG HSG DRIVE SIDE,P/N:39535224 1578000093 1 1
10 SEAL OIL CRANKSHAFT,P/N:37794377 1578000103 4 2
11 GASKET FRAME HEAD PHE,P/N:39550199 1578000113 2 1
12 GASKET COVER CORK,P/N:37068293 1578000123 4 4
13 GASKET PLATE PARTITION,P/N:37123171 1578000133 1 2
14 RING SCRAPPER 1.5 INCH ROD,P/N:54491378 1578000143 3 4
15 RING SCRAPPER 1.5 INCH ROD,P/N:54491386 1578000153 0 2
16 PACKING CSE WTR CLED4 CUPS,P/N:42431791 1578000163 2 1
17 GASKET PACKING CASE,P/N:30586127 1578000173 4 2
18 RING PACKNG SET PHE-7 NL,P/N:39321245IM 1578000183 5 8
19 GASKET WTR CVR6.5 IN CLNDR,P/N:17276841 1578000203 2 2
GASKET VLV CVR CU
20 SHROUDED,P/N:30550842 1578000213 4 2
21 SCREW SET HEX HEAD,P/N:30572580 1578000223 1 1
22 NUT HEX 1 IN,P/N:95077749 1578000233 4 6
23 RING PISTON,P/N:39321419IM 1578000243 4 2
RING WEARING7×7PHE-7
24 CPI,P/N:39321427IM 1578000253 4 2
25 ASEMBLY OIL STP PLTE EXPRT,P/N:37802279 1578000263 1 1
26 GASKET OUTER HEAD PHE,P/N:39550090 1578000273 3 2
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27 GASKET VALVE SEAT A36,P/N:54365648 1578000283 8 8
28 CRAB VLV A36,P/N:31174667 1578000293 2 4
29 GASKET OUTER HEAD PHE,P/N:39550082 1578000303 1 2
30 SCREW SET DISCH,P/N:30572945 1578000323 2 1
31 NUT PISTON,P/N:34578799 1578000333 1 1
32 NUT JAM 7 IN STROKE,P/N:30565675 1578000343 1 2
33 WASHER LOCK STAR 7 STK,P/N:30589568 1578000353 4 1
34 RING PISTON 5×7 ESV/PHE,P/N:39322334IM 1578000363 0 5
35 RING WRNG 5INCPI124WT AIR,P/N:24187098 1578000373 3 2
36 VLV INLT (AIRTOLD) 7INCYL,P/N:24191041 1578000383 0 2
37 VALVE DISCHARGE,P/N:39329313 1578000393 10 2
38 VLV INLT (AIRTO LD) 5INCYL,P/N:24191058 1578000403 0 2
39 VALVE DISCHRG(A36-400/600),P/N:39590435 1578000413 6 2
40 O-RING 2-1/2×2-3/4×39295,P/N:95018198 1578000423 4 1
41 FILTER OIL,P/N:30472161 1578000433 0 2
42 GASKET 3IN×300,P/N:95311981 1578000453 25 26
43 GASKET FLANGE 2×300,P/N:70212428 1578000463 22 23
44 GASKET FLANGE 1×300,P/N:70212394 1578000473 4 1
45 GASKET FLANGE 1-1/2×300,P/N:70212410 1578000483 4 1
46 GASKET FLANGE 2×150,P/N:70212337 1578000493 12 9
47 GASKET FLANGE 1/2×150,P/N:94496577 1578000503 15 15
48 GASKET FLANGE 1×150,P/N:70212253 1578000513 8 8
49 GASKET NUT (1/8 LEAD WIRE),P/N:37759438 1578000523 2 5
50 GASKET FLANGE 3×150,P/N:95930780 1578000573 6 3
51 ASSEMBLY DISCHARGE SEAT,P/N:37982188 1578000583 4 2
52 SEAT DISCHARGE,P/N:37982196 1578000593 7 2
53 BOLT CENTRE,P/N:37982204 1578000603 4 2
54 BOLT LOCK,P/N:33019225 1578000613 4 2
55 GUARD DISCHARGE,P/N:37982956 1578000623 2 1
56 PIN LOCATING,P/N:34032805 1578000633 4 2
57 PIN LOCATING,P/N:34032813 1578000643 4 2
58 PLATE VALVE,P/N:37944550 1578000653 7 4
59 WASHER LIFT,P/N:37945375 1578000663 4 2
60 PLATE DAMPING,P/N:34004960 1578000673 8 4
61 SPRING CLOSING,P/N:33426917 1578000683 16 4
62 NUT LOCK,P/N:33013889 1578000693 4 2
63 GUARD DISCHARGE,P/N:37982220 1578000703 2 2
64 WASHER LIFT,P/N:37944568 1578000713 4 2
65 SPRING CLOSING,P/N:33426909 1578000723 4 4
66 SUCTION SEAT, P/N:47534877001 1578000733 2
67 GUARD ASSY, P/N:47534878001 1578000743 3
68 REPAIR KIT, P/N:47534876001 1578000753 7
69 SPIRALOCK NUT, P/N:47534879001 1578000763 3
70 SUCTION SEAT, P/N:47534877001 1578000773 2
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71 GUARD ASSY, P/N:47534878001 1578000783 3
72 REPAIR KIT, P/N:47534875001 1578000793 7
73 SPIRALOCK NUT, P/N:47534879001 1578000803 3
74 ASMBL CRNKSFT IHE WT KEY,P:94441508-KIT 1578000015 0
ASBML ROD CONN COMP 7
75 ESV,P/N:37189610 1578000025 0
76 ASSEMBLY PISTON 7×7 PHE NL,P/N:42381988 1578000045 0 1
77 ASSEMBLY PISTON ROD 7 IN,P/N:42437921 1578000055 0 1
78 PISTON 5×7PHE-7 NL-2STG DSGN,P:39556527 1578000065 0 1
ROD PSTN LQUD
79 NITRIDED5×7PHE,P:39570973 1578000075 0 1

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