modul ini akan membantu anda dalam melakukan perbaikan alat berat komatsu. ada akan diajarkan langkah langkah trouble shooting dan cara- cara perbaikannya sesuai dengan standard komatsuDeskripsi lengkap
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Deskripsi lengkap
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Full description
After observing many critical troubles in some system or the other over the period of time in various units & systems, it had occurred to me that most of the time we are not having any exact method...Full description
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modul ini akan membantu anda dalam melakukan perbaikan alat berat komatsu. ada akan diajarkan langkah langkah trouble shooting dan cara- cara perbaikannya sesuai dengan standard komatsuFull description
Full description
1106D Perkins Engine Trouble Shooting
FCC FUNDAMENTALS : OPERATIONS
& TROUBLESHOOTING
PRESENTED BY : S PALIT (DMPN)
CONCERNS IN FCC
• •
MAJOR PROBLEM AREAS
• • •
• •
CATALYST LOSS
CATALYST LOSS SYMPTOMS
CAUSES OF CATALYST LOSS
MECHANICAL CAUSES
TRICKLE VALVES ARE STUCK CLOSE OR OPEN DEFORMATION OF TRICKLE VALVE FLAPPER OR TRICKLE VALVES DISENGAGED
TRICKLE VALVE & SPLASH PLATE
MECHANICAL CAUSES (CONTD) SPALLED COKE OR REFRACTORY IN DIP LEG CAUSING RESTRICTION
HOLES ON CYCLONES CRACKS ON PLENUM CHAMBER DETACHED DIPLEG
A TYPICAL CYCLONE
MECHANICAL CAUSES (CONTD) IMPROPER STEAM / AIR RESTRICTION ORIFICES ON PURGES CAN LEAD TO CATALYST ATTRITION, THEREBY GENERATING FINES
CATALYST LOSS DUE TO OPERATIONS
INCREASE OF CATALYST LOADING TO CYCLONES
CATALYST LOSS DUT TO CATALYST
TROUBLESHOOTING
TROUBLESHOOTING VERIFY THE CATALYST LEVELS IN REACTOR AND REGENERATOR
CHECK THE CYCLONE VELOCITIES AND COMPARE WITH THE DESIGN
REDUCE CAT-OIL RATIO
CHECK PURGE POINT ROV
COKING / FOULING PROBLEM
REASONS FOR COKING / FOULING
CATALYST PROPERTIES RESPONSIBLE FOR COKING
OPERATIONAL CONDITIONS RESPONSIBLE FOR COKING LONG RESIDENCE TIME
LOW ROT
LOW WASH LIQUID FLOW LONG RESIDENCE TIME IN VAPOUR LINE
HIGH MCB LEVEL
FEED PROPERTIES LEADING TO COKING
ASPHALTENES AND RESID IF NOT CONVERTED IN RISER, LEADS TO COKING
MECHANICAL CONDITIONS LEADING TO COKING
TROUBLE SHOOTING
TROUBLESHOOTING
IMPROVE FEED ATOMISATION
INTRODUCE FEED WHEN REACTOR IS ADEQAUTELY HEATED DURING UNIT START UP
KEEP THE VELOCITY IN MCB EXCHANGER > 2.1 m/s
TROUBLESHOOTING MAINTAIN MCB TEMP < 360 deg C
MAINTAIN 1ST TRAY IN THE BOTTOM TEMP < 420°C BY PROVIDE ADEQUATE WASHING LIQUID TO MCB
MAINTAIN HIGH REACTOR TEMPERATURE IF POSSIBLE
FLOW REVERSAL NORMAL CATALYST FLOW PATH
REGENERATOR
REACTOR
REGENERATOR
FLOW REVERSAL
PROPER PRESSURE BALANCE ACROSS REACTOR AND REGENERATOR AIDS CATALYST MOVEMENT
PHENOMENON OF FLOW REVERSAL
OIL SOAKED CATALYST TO FLOW REVERSE FROM RISER TO REGENERATOR IN CASE THE DIFFERENTIAL PRESSURE ACROSS REGENERATED CATALYST SLIDE VALVE BECOMES NEGATIVE
THE HOT FLUE GAS FLOW TO REACTOR AND TO COLUMN IF THE PRESSURE DIFFERENTIAL ACROSS SPENT CATALYST SLIDE VALVE BECOMES NEGATIVE
CAUSES OF FLOW REVERSALS MAB TRIPPING PRESENCE OF WATER IN FEED HIGH OPENING OF SLIDE VALVES SUDDEN LOSS OF REACTOR / REGENERATOR LEVELS FAILURE OF REACTOR TEMP / LEVEL CONTROL
PROTECTION FROM FLOW REVERSAL
•
INDEPENDENT LOW DIFFERNTIAL PRESSURE OVERRIDE CONTROL FOR SLIDE VALVES
•
CHECKING OF FEED TANK HEATING COIL OUTLET AND REGULAR DRAINING OF FEED SURGE DRUM
•
EMERGENCY SHUT DOWN
HIGH REGENERATOR TEMPERATUR
HIGH REGENERATOR TEMPERATURE
HIGH REGENERATOR TEMPERATURE
HIGH REGENERATOR TEMPERATURE
HIGH REGENERATOR TEMPERATURE
HIGH REGENERATOR TEMPERATURE
RAISE CAT / OIL RATIO
IMPROVE FEED ATOMISATION
REMEDIES IMPROVE STRIPPING IN REACTOR
USE METAL PASSIVATOR
AFTER BURNING
CAUSES OF AFTER BURN
POOR AIR / CATALYST DISTRIBUTION
LIFT LINE WITH AIR RING AIR DISTRIBUTION PROBLEM
CAUSES OF AFTER BURN
LIFT LINE WITH AIR RING CAT DISTRIBUTION PROBLEM
CHANNELING OF CATALYST IN CURVED LIFT LINE
CAUSES OF AFTER BURN
REGEN INTERNALS CREATE TWO STAGE REGENERATION
CATALYST ENTERS ONE SIDE OF REGENERATOR
CAUSES OF AFTER BURN
EFFECT OF HIGH DENSITY CATALYST ON AIR DISTRIBUTION
REASONS OF AFTERBURNS OPERATING CAUSES
MECHANICAL CAUSES
EXCESS AIR
DAMAGED AIR RING
LOW CATALYST RESIDENCE TIME
DAMAGED CATALYST DISTRIBUTOR
AFTER BURN REMEDIES INCREASE STRIPPING STEAM RATE.
INCREASE THE CATALYST RESIDENCE TIME : RAISE THE REGENERATOR CATALYST BED LEVEL.
REDUCE FEED CCR
INCREASE CAT / OIL BY QUENCHING
CATALYST CIRCULATION
THE LIMITATION IN CATALYST CIRCULATION WILL LIMIT THE T’PUT OF THE UNIT.
EXTREME HIGH CAT CIRCULATION PROBLEM WILL LEAD TO UNIT SHUTDOWN
CATALYST CIRCULATION PROBLEM SYMPTOM: SLIDE VALVE FAR TOO OPEN EVIDNECE: SLIDE VALVE OPENING INDICATIONS
CAUSES: GATE OR ORIFICE TOO SMALL FOR FLOW SOLUTIONS: REPLACE WITH APPROPRIATE SIZE VALVE INCREASE REGEN PRESSURE / BED LEVEL
CATALYST CIRCULATION PROBLEM
SYMPTOM:
REASONS:
LOW DELTA P ACROSS SLIDE VALVE
HIGH PRESSURE D/S OF SLIDE VALVE
LOW PRESSURE U/S OF SLIDE VALVE
WHEN HIGH PRESSURE D/S
REASONS
HIGH DP ACROSS VAP LINE
HIGH DP ACROSS RISER
HIGH CAT CIRCULATION
LESS RISER GAS AT RISER BASE
VAP LINE COKING
CAUSES
HIGH RXR VAP LOAD
WHEN HIGH PRESSURE D/S
REASONS
HIGH DP ACROSS MF
HIGH VAP / LIQ RATES
PLUGGED TRAYS
HIGH DP ACROSS MF O/H CIRCUIT
CONDENSER FOULING
CAUSES
HIGHER RATES OF LIGHTER HC
WHEN HIGH PRESSURE D/S
HIGH DP ACROSS RISER
REPLACE RISER BEND
PROBLEMS
INCREASE RISER STEAM
HIGH DP ACROSS VAP LINE
COKING REDUCTION
SOLUTIONS
VAP LINE CLEANING DURING S/D
WHEN HIGH PRESSURE D/S
PROBLEMS HIGH DP ACROSS MF O/H CIRCUIT
HIGH DP ACROSS MF
ADJUST PUMP AROUND RATES
ADD TOP OR SIDE PUMP AROUNDS
CONDENSER CLEANING
SOLUTIONS
INCREASE WATER WASH TO CONDENSERS
WHEN LOW PRESSURE U/S
REASONS INSUFFICIENT PRESSURE BUILD UP IN STAND PIPE
DEFLUIDIZATION IN STAND PIPE
LOW CATALYST DENSITY IN STAND PIPE
DE-AERATION IN STAND PIPE
IMPROPER PLACEMENT OF AERATION TAPS
CAUSES
PLUGGED RO
WHEN LOW PRESSURE U/S PROBLEMS
DEFLUIDIZATION IN STAND PIPE
CHECK CATALYST PROPERTIES
DE-AERATION IN STAND PIPE
IMPROPER PLACEMENT OF AERATION TAPS
INCREASE AERATION GAS FLOW TO MAXIMIZE PRESSURE BUILD UP
SOLUTIONS
PLUGGED RO
FLUSH RO
LOSS IN PRODUCTS –
PROBLEM INDICATORS
CONVERSION
DRY GAS YIELD
GASOLINE YIELD
PROBLEM AREAS
FEED QUALITY
CATALYST QUALITY
OPERATING CONDITION
MECHANICAL DEFECT
LOW CONVERSION FEED QUALITY
CATALYST PROPERTIES
INCREASE IN METALS CONTENTS
LOW CATALYST ACTIVITY
HIGH FBP FEED
LOW SURFACE AREA
INCREASE IN FEED AROMATICITY / NAPHTHENECITY
HIGH CRC
LOW CONVERSION OPERATING CONDITIONS
MECHANICAL CONDITIONS
LOW CAT / OIL RATIO
PROBLEM IN FEED NOZZLE
LOW ROT
PROBLEMS IN REGEN INTERNALS
LOWER RATE OF FEED ATOMIZING STEAM
LOW F-CAT ADDITION RATE
TROUBLESHOOTING
CHECK FEED STOCK PROPERTIES
K-FACTORS, ANILINE POINT, SP. GR
CHECK E-CAT PROPERTIES
VERIFY ACCURACY OF INSTRUMENT INDICATIONS OF RR SECTION
CARRY OUT PRESSURE SURVEY OF FEED NOZZLES, AIR RINGS, ETC