Issue:

Excessive moisture levels in the process inlet gas affected two machines, A and B. Moisture levels spiked, reaching up to 2100 ppm, far exceeding the HH alarm threshold of 500 ppm.Despite these spikes, no Emergency Shutdown (ESD) system was triggered. The elevated moisture levels posed a risk to equipment performance and corrosion.

Root Cause:

The issue was traced to the degradation of the moisture absorber leading to decreased moisture removal capacity and excessive moisture entering the system.

Actions Taken:

The moisture absorber was replaced, restoring the gas dryer’s functionality and eliminating moisture spikes.

The system’s inlet gas moisture levels returned to normal, resolving the issue for both machines.

Outcome:

Complete Resolution: After the absorber replacement, excessive moisture was no longer detected in the system.

Cost Savings: The timely intervention prevented potential damage to equipment, avoiding expensive repairs, unplanned shutdowns, and potential production losses.

Corrosion Prevention: By eliminating excess moisture, the risk of corrosion in the system was significantly reduced, which could have otherwise led to costly maintenance and downtime.

Worst-case scenario Avoided: Had the issue persisted, both machines could have suffered extensive damage, triggering an emergency shutdown. Corrosion would have further escalated repair costs and extended downtime.

Key Takeaways:

Timely maintenance and replacement of critical components like the moisture absorber can prevent major operational disruptions.

Regular monitoring and quick corrective action are essential to safeguarding equipment performance and minimizing maintenance costs.

The total data sampling for the 7-month operating period in 2024 comprises 60,204 data points, which indicate that inlet gas moisture consistently spiked, exceeding the high alarm limit.

Excessive moisture

After changes absorber

After the absorber replacement, excessive moisture was no longer detected in the system.