Ex-R101-B Elliott Compressor Bundle Refurbishment Final Report Oct-2014

Report presented to
HABSHAN for ADMA OPCO
Inspection of 25MB4-4 COMPRESSOR BUNDLE
Equipment: 25MB4-4 s/n A808292/4
Elliott Ref.: SQ4379
Customer Ref.: ELAS811/14
Revision 2
8 October 2014
Elliott Group
Elliott Turbomachinery S.A.
Zona Industriale n. 1
54011 Frazione Albiano Magra
AULLA (MS) - Italy
Tel. +39 0187 41311
Fax +39 0187 413000
CONTACT DETAILS
End User Adma Opco
Sales Rep. NA
Address
Contact
E-mail
Tel
Fax
Mobile
Seller data
Company Elliott Turbomachinery S.A.
Address Zona Industriale n. 1
54011 Frazione Albiano Magra, Aulla (MS)
Italy
Tel. (+39) 0187 41311
Fax (+39) 0187 413000
Sales contact YAQOOB YOUSIF, Sales Engineer

E-mail YYousif@elliott-turbo.com
Tel
Technical contact Sandro Barbagelata, Shop Engineer

E-mail sbarbage@elliott-turbo.com
Tel (+39) 0187 4131310
Status updates Susan Hepburn, Production Controller

E-mail shepburn@elliott-turbo.com
Tel (+39) 0187 4131304
REVISION TRACKING
Rev. Date Description Initials
2 21 august 2014 Initial issue SB
1 18 September 2014 Change following customer discussions SB
2 8 October 2014 Updated with disassembled rotor findings SB
Sede legale: Svizzera

Codice Fiscale e N. Iscrizione CCIAA: 00566420451
R.E.A. Massa Carrara 91801
P.IVA: IT00566420451 Page 2 of 13
Elliott Group
AULLA (MS) - Italy
Tel. +39 0187 41311
Fax +39 0187 413000
TABLE OF CONTENTS
Contact Details 2
Revision Tracking 2
Table Of Contents 3
Inspection Workscope 4
1 Findings 4
1.1 Visual Examination 5
1.2 Dimensional Inspection 6
1.3 Rotor Concentricity Check 7
1.4 Non Destructive Examination 7
1.5 After rotor disassembled components inspection 7
2 Repair Proposal 7
3 Commercial proposal 9
3.1 Repairs and new parts per contract 9
3.2 Repairs and new parts off contract 9
4 Terms and conditions 10
5 PHOTOS 12

P.IVA: IT00566420451 Page 3 of 13
Elliott Group
AULLA (MS) - Italy
Tel. +39 0187 41311
Fax +39 0187 413000
INSPECTION WORKSCOPE
Casing works:
- Receive, identify and log all owner supplied materials upon receipt and verify against the packing list
- Open bundle top casing and remove rotor
- Disassemble diaphragms from casing
- Visual inspect bundle interiors before cleaning
- Sand blast parts
- Check sand blasting cleaning
- Remove seals from diaphragms
- Visual inspect diaphragms and casing
- Dimensional inspect casing and diaphragms
- MPI on casing and diaphragms
- Hold for discussion findings with Customer
Rotor works:
- Visual inspection of compressor rotor before cleaning
- Sand blast rotor
- Visual inspection of compressor rotor
- Dimensional inspection of assembled rotor on key dimensions
- Check concentricity of rotor
- Check blue contact at coupling taper
- Survey coating thicknesses
- Check gaps between each impeller and sleeve.
- Check axial position of impellers
- Perform MPI on assembled rotor
- Strip rotor completely

- Check concentricity of bare shaft
- Dimensional inspection of shaft on shrink diameters
- MPI on bare shaft
- Abrasive clean all the major disassembled parts
- Dimensional inspection of impellers
- Dimensional inspection of reusable shaft sleeves
- MPI on Impellers
- Visual inspection of compressor impeller
1 FINDINGS
Bundle was received on its own steel container, not cleaned and as removed from the plant
conditions.

P.IVA: IT00566420451 Page 4 of 13
Elliott Group
AULLA (MS) - Italy
Tel. +39 0187 41311
Fax +39 0187 413000
In general we can say that the entity of the process deposits and rust found is reasonably
good compared with previous bundles received. The HP section is quite clean, while the LP
section has a lot of process deposits completely filling the seals.
Diaphragms and rotor appear not to have been previously coated, and therefore is not one of
the bundle or rotor refurbished in the recent years. In fact the rotor was punched with the
reference of our job SQ3042 (2005). In that occasion the rotor was not yet coated.
We must remark two major findings discovered during disassemble process:

1. One big washer (approx. 1,5 inches OD) was found into the last LS section impeller
vanes. It evidently passed through the whole LP section causing damages on all the
impellers.
2. Two seals antirotation key of diaphragms item 14 and 8 were found out form their
seats and therefore compressed in the split line between the two diaphragm halves,
and then opening the diaphragm and evidently forcing the casing.. In fact casing was
found with evident longitudinal seizing marks on the outer diameter and blue check of
split lines showed contact just at the two sides (ends) of the casing. Obviously
diaphragms split line is damaged where the key has been compressed.
1.1 Visual Examination

Casing and diaphragms: The split line bolts are in quite bad shape and different from the
original ones.
On the lower half at the outer diameter are present different seizing marks.
Diaphragms antirotation screws need replacement.
Diaphragm split line keys have been modified and need replacement.
All seals of the low pressure section were filled with process deposit and have been
destroyed to be removed. All other seals were anyway scored in the fins and got some
difficulties to be removed and went damaged.
Seals antirotation keys were or missing, or had to be destroyed to be removed. (two were
found out form the seat).
Some porosity (see non destructive test section) and wearing is noticeable in the flow path
areas of the casing.
All diaphragms are in quite good shape excluding:
 Item 13 has some welding buttons in the seal grooves. It is an evident previous repair
and will be left as it is.
 Item 14 is damaged in the split line by the key out of seat.
 Item 8 is damaged in the split line by the key out of seat. Respect item 14 damage is
lighter.
 Item 6 is damaged in the split line key (see picture).

P.IVA: IT00566420451 Page 5 of 13
Elliott Group
AULLA (MS) - Italy
Tel. +39 0187 41311
Fax +39 0187 413000
Rotor (starting from coupling):

Taper land is visually in relatively good conditions, but evidently worn and with some
assemble/disassemble scratches/seizing marks. In fact the blue check is pour.
All shaft end seal areas are definitely scored and journal land is slightly scored.
Both rotating contact ring locknut are reusable. Rotating contact rings are heavily worn in
one face and definitely scrap.
All impeller eyes were previously chrome/HVOF repaired. Coating thickness is well into the
acceptable limits and then would allow reapplication of the coating excluding items 8 and 7
where it is close to the maximum allowed.
Impeller item 2 stage 1: vanes leading edges are badly damaged by FOD (washer). It is also
evident erosion around leading edge welds.
Impeller item 3 stage 2: vanes leading edges are badly damaged by FOD.
Impeller item 4 stage 3: vanes leading edges are badly damaged by FOD.
Impeller item 5 stage 4: few vanes leading edges are damaged by FOD.
Balance piston is slightly scored by the seals.
Impeller item 9 stage 8: has the eye diameter scored
All sleeves have light scores and can be reused.
Journal land and mainly seal areas are scored. The thrust disk fitting diameter has evident
and deep fretting damages.
Thrust disk is lightly scored in the active face and is presenting light fretting in the bore.
Thrust disk nut is slightly scored. It can be reused.
1.2 Dimensional Inspection

Casing and diaphragms: Casing diaphragm seating diameters are in tolerance. Casing outer
diameter is acceptable as well. Diaphragm’s outer diameters are all (excluding item 14)
slightly under the tolerance. Combined dimensional inspection of casing inner diameter and
diaphragm outer diameters showed a relevant increase (more than 30% over the max) of the
clearance only for diaphragm item 7. Considering the 30% deviation minimal acceptable,
only the item 7 needs outer diameter repair.
Rotor: The rotor dimensional inspection is acceptable, no major deviations were found in the
main diameters and impellers axial positions.
Impeller eyes items 3, 5 are very slightly under tolerance. Deviation can be neglected.
Both shaft ends sleeves (items 21 and 22) were found half of mm over the tolerance. This
issue was already discussed in 2005.

P.IVA: IT00566420451 Page 6 of 13
Elliott Group
AULLA (MS) - Italy
Tel. +39 0187 41311
Fax +39 0187 413000
The thrust disk bore diameter is 2 hundreds of mm over the tolerance.
1.3 Rotor Concentricity Check

Acceptable.
1.4 Non Destructive Examination

Casing and diaphragms: Casing is presenting large areas with porosities probably due to
corrosion problem. Considering that the scope of the inner casing is to be just a carrier for
the diaphragms and that the porosity found is not creating structural problems, it can be
accepted as it is.
MPI on diaphragms did not highlighted further indications other that what evident at visual
inspection.
Rotor: no further indications other that what evident at visual inspection.
1.5 After rotor disassembled components inspection

After rotor disassemble the components were further inspected with the following results:
Shaft: no further findings.
Impellers (focusing attention to the inner surfaces):
 Item 02 is badly damaged in the leading edges and eroded in the welds. It needs
weld repair. The bore diameter is larger than the tolerance and needs HVOF repair.
 Item 03 is badly damaged in the leading edges. It needs weld repair. The bore
diameter is larger than the tolerance and needs HVOF repair.
 Item 04 is badly damaged in the leading edges. It needs weld repair. The bore
 Item 05 is slightly damaged in the leading edges. It can be just dressed. The bore
 Item 06 is very slightly eroded in the leading edges, but can be left as it is.
 Item 07 is fine. The bore diameter is larger than the tolerance and needs HVOF
repair.
 Item 08 is fine.
 Item 09 is fine.
 MPI on impellers did not showed further indications respect visual evidence.
Sleeves and balance pistons are reusable.
2 REPAIR PROPOSAL
Concerning the thrust disk it is scrap due to the bore oversized and with fretting erosion.

P.IVA: IT00566420451 Page 7 of 13
Elliott Group
AULLA (MS) - Italy
Tel. +39 0187 41311
Fax +39 0187 413000
To return fully functional the bundle asset we propose the following main repairs:
 Supply new set of casing bolts and pins
 Supply new diaphragms antirotation screws need replacement
 Supply new diaphragm split line keys
 Supply a new set of inner seals
 Supply a new set of seals antirotation keys
 Perform local weld repair on the damages key slots on diaphragm split lines items 14,
8 ,6
 Apply weld buttons on diaphragm item 7 to restore outer diameter and casing
clearance deviation.
 Weld repair n. 3 impellers.
 Dress blades leading edges of 4th stage impeller.
 Weld repair both shaft ends
 Replace HVOF coating on impeller eyes stages 5 ,6 ,7 ,8
 Perform HVOF coating on impeller bores stages 1, 2, 3, 4, 7 (items 2, 3, 4, 5, 7)
 Supply new thrust disk and lockwasher
 Supply new rotating contact rings
 Apply electro less nickel plating to diaphragms and rotor parts
 Casing modification for field realignment of drain holes according previous job design.
As per previous jobs the external o-rings and rotor high speed balance are excluded from the
repair proposal.
Main repairs and replacement schema. For full list see above.

P.IVA: IT00566420451 Page 8 of 13
Elliott Group
AULLA (MS) - Italy
Tel. +39 0187 41311
Fax +39 0187 413000
3 COMMERCIAL PROPOSAL
3.1 Repairs and new parts per contract
Unit Total
Pos. Description Q.ty
price price
Refurbishment of bundle assembly
Ref. ATTACHMENT-1, page 185 of contract no. 144438
Includes:
- Rotor refurbishment per ATTACHMENT-2, page 186 of contract no. 144438
- Basic overhaul and reassembly of bundle per ATTACHMENT-1
- All new seals
1 - Application of anti-fouling coating on all rotor impellers, rotor sleeves and casing € 188,000 1 € 188,000
diaphragms
Does NOT include:
- Component repairs per ATTACHMENT-3, page 186 of contract no. 144438
- New parts per ATTACHMENT-5 & -6, pages 190-191 of contract no. 144438
- High speed balancing
2 Weld repair both shaft ends € 35,500 1 € 35,500

3 Impeller eye diameter HVOF repair € 3,800 4 €15,200

Impeller leading edges weld repair (considered equivalent to eye weld
4 repair) € 11,600 3 € 34,800
5 Thrust disk P/N 880687-1 € 12,400 1 € 12,400

6 Rotating contact ring P/N 869158-1 € 1,500 2 € 3,000

7 Impeller bore diameter HVOF repair € 3,800 5 €19,000

8 Impeller stage 4 dress €1,500 1 €1,500

3.2 Repairs and new parts off contract

Unit Total
Pos. Description Q.ty
price price
Casing modification for field realignment of drain holes according
1 1
previous job design.
Different diaphragm overhaul, including restoration of OD, split line
2 weld repair to remove key footprints, dressing and supply of hardware € 22,000 1 € 22,000
(Diaphragm split line keys p/n 891077-xx where xx are different extensions for each
stage)
3 Anti-rotation screw for inner casing p/n P21Z9000-1 € 373 6 € 2,238
4 Thrust disk lock washer p/n 846887-8 € 1,556 1 € 1,556
5 Casing bolts and pins n. 20 p/n P23T3262 + n. 4 p/n P36K262 € 866 1 € 866
6 Seals anti-rotation keys p/n P37B54 € 109 8 € 872

P.IVA: IT00566420451 Page 9 of 13
Elliott Group
AULLA (MS) - Italy
Tel. +39 0187 41311
Fax +39 0187 413000
The standard delivery for the repairs and parts listed above is 24 weeks since order confirmation
excluding rotor high speed balancing.
Deliveries exclude holiday periods and are based on the current workload and shelf availability of
spare parts and wrought products. They need to be confirmed or reviewed at the time of the order.
4 TERMS AND CONDITIONS

In the absence of any written agreement to the contrary, Elliott’s Standard Terms and Conditions of
Sale for Repairs shall apply on everything not explicitly declared in this document.
Prices for the repair activities and the replacement parts are quoted in Euro (€), ex-works, La Spezia
(ITALY), packed in the original shipping case.
In the rare event that a defect should arise in either repair workmanship or materials used in the
repair, Elliott guarantees to correct the defect in its workshop and at its own expense on an ex-
works basis, provided the defect is notified to Elliott in writing and within:
- 8760 running hours
- 12 months from installation
- 18 months from ex-works delivery
whichever expires first.
All parts deemed scrap will be disposed of by Elliott unless a request to have them returned is
received within a month of issue of the (this) order confirmation.
Repaired components should be picked up as soon as possible after the notification from Elliott that
they are ready. After one month of issue of the “readiness to ship” communication, Elliott will apply
a symbolic storage fee of €100 per month per component for the duration of the delay.
This proposal is valid for acceptance within 60 days. No contract in respect of this proposal shall be
deemed to exist until a Purchase Order signed by a duly authorized officer of the purchaser has
been accepted in writing by a duly authorized officer of Elliott.

P.IVA: IT00566420451 Page 10 of 13
Elliott Group
AULLA (MS) - Italy
Tel. +39 0187 41311
Fax +39 0187 413000

P.IVA: IT00566420451 Page 11 of 13
Elliott Group
AULLA (MS) - Italy
Tel. +39 0187 41311
Fax +39 0187 413000
5 PHOTOS
High pressure side conditions as opened Low pressure side conditions as opened
Split line key slot damaged

Washer found in the rotor
First stage impeller leading edges erosion on welds

and FOD example.
Thrust disk land fretting

P.IVA: IT00566420451 Page 12 of 13
Elliott Group
AULLA (MS) - Italy
Tel. +39 0187 41311
Fax +39 0187 413000
Seizing marks on the casing outer diameter
Scored shaft end seal area
Footprint of the seal antirotation key wrongly positioned

Casing porosities (should be flat surface)

P.IVA: IT00566420451 Page 13 of 13

Ex-R101-B Elliott Compressor Bundle Refurbishment Final Report Oct-2014

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Report presented to

HABSHAN for ADMA OPCO

Inspection of 25MB4-4 COMPRESSOR BUNDLE

Equipment: 25MB4-4 s/n A808292/4

Elliott Ref.: SQ4379

Customer Ref.: ELAS811/14

End User Adma Opco

Sales contact YAQOOB YOUSIF, Sales Engineer

Technical contact Sandro Barbagelata, Shop Engineer

Status updates Susan Hepburn, Production Controller

Sede legale: Svizzera

Sede legale: Svizzera

- Strip rotor completely

Sede legale: Svizzera

We must remark two major findings discovered during disassemble process:

1.1 Visual Examination

Sede legale: Svizzera

Rotor (starting from coupling):

1.2 Dimensional Inspection

Sede legale: Svizzera

The thrust disk bore diameter is 2 hundreds of mm over the tolerance.

1.3 Rotor Concentricity Check

1.4 Non Destructive Examination

1.5 After rotor disassembled components inspection

Sede legale: Svizzera

Sede legale: Svizzera

2 Weld repair both shaft ends € 35,500 1 € 35,500

3 Impeller eye diameter HVOF repair € 3,800 4 €15,200

5 Thrust disk P/N 880687-1 € 12,400 1 € 12,400

6 Rotating contact ring P/N 869158-1 € 1,500 2 € 3,000

7 Impeller bore diameter HVOF repair € 3,800 5 €19,000

8 Impeller stage 4 dress €1,500 1 €1,500

3.2 Repairs and new parts off contract

3 Anti-rotation screw for inner casing p/n P21Z9000-1 € 373 6 € 2,238

4 Thrust disk lock washer p/n 846887-8 € 1,556 1 € 1,556

6 Seals anti-rotation keys p/n P37B54 € 109 8 € 872

Sede legale: Svizzera

4 TERMS AND CONDITIONS

Sede legale: Svizzera

Sede legale: Svizzera

Split line key slot damaged

First stage impeller leading edges erosion on welds

Thrust disk land fretting

Sede legale: Svizzera

Seizing marks on the casing outer diameter

Scored shaft end seal area

Footprint of the seal antirotation key wrongly positioned

Sede legale: Svizzera

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