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16 - CHM - Chemical and Process Engineering

CHM 121 - Ethylene Plant Cracked Gas Compressor Operation, Control &Troubleshooting

Code Start Date Duration Venue
CHM 121 03 June 2024 5 Days Istanbul Registration Form Link
CHM 121 08 July 2024 5 Days Istanbul Registration Form Link
CHM 121 12 August 2024 5 Days Istanbul Registration Form Link
CHM 121 16 September 2024 5 Days Istanbul Registration Form Link
CHM 121 21 October 2024 5 Days Istanbul Registration Form Link
CHM 121 25 November 2024 5 Days Istanbul Registration Form Link
CHM 121 30 December 2024 5 Days Istanbul Registration Form Link
Please contact us for fees


Course Description

This 5-day course will be dealing with the Cracked Gas Compressor and its driver “steam turbine” operation controls, troubleshooting and other related operational issues such as fouling, leaks, emergency shutdown, trips, process safety and start-up permissible. 

The cracked gas compressor is one of the most critical pieces of equipment in an ethylene plant and may be the limiting factor in ethylene plant performance optimization. The high potential for severe fouling leads to deterioration of plant performance with associated significant economic penalties in energy and productivity losses.

This training course will empower participants with detailed information and knowledge necessary to thoroughly understand the cracked gas compressor operation and control and will also provide participants with the necessary experience and confidence to work in any organisation requiring assistance and experience in cracked gas compressor operation and control. 

By undertaking this course, participants will be able to independently drive and oversee cracked gas compressor operation and optimization and contributing to a significant responsibility and function for their organisation. 

Course Objectives

  • Recognize centrifugal compressors working principles for successful operations of your plan
  • Optimize the operation efficiency of your compressors
  • Realize centrifugal compressors construction details 
  • Apply the best practices and guidelines for operation problem solving and troubleshooting
  • Analyze the problems in operation related to Surge and Fouling
  • Undertake critical action that would save the organisation maintenance and operational costs
  • Conduct regular checks and inspections to ensure that gas compressors are working at optimal efficiency and quality 
  • Provide adequate confidence and knowledge to train other professionals on best practices and precautions 

Who Should Attend?

  • Plant Operation & Maintenance teams
  • Operation Engineers, Supervisors, Team leaders 
  • Process engineers, Inspection and Reliability Engineers 
  • Engineers and supervisors concerned with safety, optimization and operating issues of the cracked gas compressor.

Course Details/Schedule

Day 1

  • General description and main features of centrifugal compressors 
  • Compressible fluids, compression and gas transport
  • Centrifugal compressor basic principles
  • Operation principle, and energy conversion
  • Parts and components of a centrifugal compressor
  • Centrifugal compressor configuration in-line, double flow, compound, back-to-back
  • Cracked gas compressor process loop & P&IDs

Day 2

  • Compressor loadsharing control and surge detection techniques 
  • Surge control: variable-pressure surge control system components and operation
  • Constant-pressure surge control system components and operation
  • Invariant compressor map coordinates
  • Instrumentation & control, (emergency shutdown, trips, process safety and start-up permissible)
  • Simple anti-surge control, recycle valve sizing
  • Compressor protection & complex anti-surge control
  • Surge detector requirements & P&IDs

Day 3

  • Ethylene plant cracked gas compressor operations control
  • Compressor selection, sizing and troubleshooting 
  • Compressor performance control, & performance curves
  • Efficiency and aerodynamics limits
  • Velocity triangles. 
  • Rotor dynamics, natural frequencies and critical speeds
  • Charge gas compression and caustic wash & P&IDs

Day 4

  • Compressor driver: Steam Turbine fundamentals and design
  • Barring or turning gears
  • Trip-throttle or main stop valves
  • Speed control & over speed trip devices
  • Gland seal systems, condenser system
  • Auxiliary systems and compressor packages: Lubrication, sealing, and control systems
  • Seal gas/oil & lube oil system of centrifugal compressor & P&IDs 
  • Lube oil purifiers

Day 5

  • Compressor reliability improvement with advanced chemical treatments
  • Fouling & corrosion in cracked gas compressor 
  • CGC fouling experiences
  • Identification of turbine fouling
  • Impacts of compressor-turbine fouling
  • Turnaround inspections
  • Countermeasures for fouling control, compressor wash oil review
  • Case study: fouling, locations & mechanisms, causes, monitoring, & control method