1. REVIEW AND RECOMMENDATIONS
CONDENSATE REMOVAL SYSTEM OF PROCESS AIR COMPRESSOR OF K-101B
REVIEW AND RECOMMENDATIONS
Presented by:
Saleha Quadsia
Management Associate (Process)

2. Objective
Review of condensate removal system of Ammonia Plant Process Air Compressor (K-101B) and recommendations for its improvement.

3. Contents Condensate Removal System (CRS) Types of CRS
Process Air Compressors (K-101A/B) CRS
Evaluation of Auto Drainers
Recommendations

4. Condensate Removal System
Liquid in gas can not be sent to the compressor as it will lead to mechanical failure.

5. Types Condensate Removal System
Manual
Mechanical float traps
Solenoid operated Mechanical float traps
Control Valves (Zero air-loss)
Condensate Removal System

6. Manual Operation
Operator manually open valves to discharge condensate.
Depends on people opening valves at the appropriate time for the necessary amount of time.
Often leads to excess loss because air escapes when the valves are left open to drain the condensate.
High noise level during air loss.

7. Mechanical Float Traps
Use a float connected by linkage to a drain valve that opens when an upper setting is reached and closes when the drain is emptied
Require considerable maintenance and prone to blockage from sediment in condensate.
Are prone to getting stuck in open position (leak excess air) and in the closed position (does not allow condensate to be drained)
Inverted bucket traps may require less maintenance, but will waste air if the condensate rate is inadequate to maintain the liquid level in the trap.

8. Solenoid-operated Drain Valves
Have timing devices that can be set to open for specified amounts of time at pre-set adjustable intervals.
The period during which the valve is open may not be long enough for adequate drainage of accumulated condensate.
The valve will operate even if little or no condensate is present, resulting in air loss.
Require strainers to reduce contaminants, which can block the inlet and discharge ports of these devices.

9. Control Valves Operates against level sensors and controller Zero loss
Considered very reliable
Limitation
Maintain level in knock out vessels

10. K-101A Condensate removal System K-101B Condensate removal System
Existing K-101A/B
K-101A Condensate removal System
K-101B Condensate removal System

11. Evaluation of Auto Drainers
Armstrong auto drainers 213 and each K.O. had two auto drainers in parallel.
Based on above the drainers were evaluated and results are as below:
Location
C-111A/B
C-108A/B
C-109A/B
Manufacturer
Armstrong
Model
213
Quantity 02
Orifice Size
1/4"
3/16"
Operating Pressure
2.24
6.33
14.91
Original Condensate load
527
389
132
Post revamp Condensate load
748
Delta P across drainer
2.04
6.13
14.71
Max condensate Discharge
907
1587
1451

12. Local Draining of Condensate
Condensate Removal of K-101A
Condensate Removal of K-101B

13. Condensate Removal of K-101A Condensate Removal of K-101B

14. Recommendations
Condensate removal system of existing K-101B should be upgraded to control valves from mechanical auto drainers, provided level can be maintained in KODs.
It is recommended to take the auto drainers in service and all local drainages vide bypass should be stopped due to following reasons,
High air losses (Limiting at full load)
High noise level
House keeping issues
Against engineering practices
If required, reliability of auto drainers may be enhanced by replacement of existing auto drainers with new.

15. THANK YOU!