Failure Analysis of Reciprocating CO2 Compressor

• Published in: Journal of failure analysis and prevention Vol. 21; no. 2; pp. 595 - 603
• Main Authors: Dsilva, Preetish C., Shetty, Preethi, Sondar, Pavankumar R., Ganesh Kumar, B., Hegde, Subray R.
• Format: Journal Article
• Language: English
• Published: Materials Park Springer Nature B.V 01-04-2021
• Subjects: Ammonia; Bacteria; Biodegradation; Carbon dioxide; Failure analysis; Fluid penetrant testing; Inspection; Microstructural analysis; Morphology; Piston rings; Plant shutdowns; Polyether ether ketones; Suction
• ISSN: 1547-7029; 1864-1245
• DOI: 10.1007/s11668-020-01109-z

This work presents failure analysis of a heavy-duty, four-stage, double-action, reciprocating CO2 compressor, which resulted in the shutdown of an ammonia plant. The failure occurred in the fourth stage of the compressor, during which the piston rod, piston rings, a suction valve, and associated valve cage are found fractured. The failure analysis includes details of site visit, visual inspection, dye penetrant test, fractography, and microstructural analysis. Furthermore, Xanthoproteic test was conducted on the extracts of the failed piston rings that confirmed the presence of bacterial cellular protein. When the morphology of the failed piston ring was studied using a scanning electron microscope, unique degradation features and the presence of bacterial metabolic products were observed conforming to the growth of bacteria. In-service biodegradation of the piston ring material (polyether ether ketone composite) is adjudged as the root cause for the compressor failure.