Visit Report

General information Visit Report V02 - 092018

Customer name Anadolu EFES Biracilik ve Malt
Address Fatih Mah. Turgut Ozal Bul. No 48
TR-06980
City Kazan-Ankara
Country Turkey
Website
Project number 04.0931 & 04.3294 & 06.7235 & 10.5563 &
20.0237
Job number / Service Order 62022716
Visited by Mark van Cranenbroek
Date visit from/until 17 till 19-4-2024
Date of report 19-4-2024
System type 04.0931 – CO2 Recovery System
04.3294 – Gas washer & Overpressure
safety
06.7235 – HRS & Aerosolwasher
10.5563 – CO2 Recovery System
20.0237 – CO2 Recovery System

Plant / Site Energy Department Foreman

Contact person Sedat Toraman
Phone number
E-mail address sedat.toraman@tr.anadoluefes.com
Plant / Site Utility Department Supervisor
Contact person Ufuk Gurses
Phone number
E-mail address ufuk.gurses@tr.anadoluefes.com
Plant / Site Mechanical Engineer
Contact person Aleyna Gemici
Phone number
E-mail address aleyna.gemici@tr.anadoluefes.com
Plant / Site Automation Engineer
Contact person Can Akyol
Phone number
E-mail address can.akyol@tr.anadoluefes.com

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Assignment / Scope of work Comments

Plant line walk during operation (fill out of log Plant looks to be operating correctly but
sheet). has some issues with the NH3 screw
compressor.
No air purge’s seen on the glycol lines.
Interview/feedback from operators. Operators say they only have issues
with the NH3 screw compressor, and
then specifically with the fact it doesn’t
ramp up.
Plant adjustments (if possible). ……
Basic training of staff (if required). ……
Additional work required (add order?) ……
……

Summary of opening meeting with customer :

Opening meeting with the customer.
- Client would arrange support from several engineers, who would be constantly
available.
- Client is having issues with ramping up the capacity of the NH3 screw compressor.
They say it only runs on 100%, on the moment that they put water (23 degrees) over
the oil receiver.
This indicates that the oil cooler (who runs on -3 degrees Glycol) is (partly) blocked.
- During quick check of the plant, I’ve seen that 1 OGM probe needs a new coating,
and 1 is almost in need of a new coating.
The 3rd one is good.
When the Phase above 60, Amplitude below 6000, we advise to replace coating on
OGM probe to ensure a correct measurement.
- CO2 Compressors 2 & 3 run to cold on the cylinder blocks.
This can cause condensation inside the cylinder blocks, what’s creating rust.
Advise to run on a higher glycol temperature on the inlet and outlet of the cylinder
blocks.
- Client would check with the brewery production, if there was a drop production the
next few days, to be able to stop the HRS, to do a pressure test on it.
- In the past the client had a Mechanical Engineer who was able to do the
maintenance of the CO2 Compressor(s).
But this person isn’t working at the brewery anymore, so client prefers to get an offer
for spare parts and a maintenance engineer from Pentair.
Due to the language barrier, preferable is to send Ersin Yardim, who’s able to speak
the Turkish language and can do all the communication and training that is needed
without an interpreter / translator.
This is highly advised, due to the points that are seen during this service visit.

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Evaluation of general plant condition :

In general, the plant looks to be maintained quite well by the client.
However, the Compressors aren’t running within the specifications.

Due to the broken parts that need to be replaced, the issue with the “foamy glycol” couldn’t
be resolved.

Due to the broken magnetic valve, what most probably caused the aftercooler to get
damaged, the client wants to see warranty over this, due to the fact that the CO2 Recovery
Plant is just not running 2 years.
- Running hours of the CO2 Compressor: 7154 hours.
- Data of hand-over (according to Process Data Setpoint-list): 29 April 2022.
Project build and handed over by: Tanakorn Kiawkaew.

Shaft seal is leaking at the NH3 Compressor from project 20.0237 with 8256 running hours.
Advise to:
- Check alignment when compressor unit is still “hot”.
- Replace shaft seal.
- Align compressor block again with certificate.
- Advise to get SABROE / Johnson Controls on-site a.s.a.p.

On several points, the isolation is gone.

Advise to repair this.

Several points are repainted, please be aware that type plates must always be visible.

NH3 level in the CO2 Condenser from NH3 cooling unit 3 seems a bit low.
This needs to be double checked by the client.
When needed, they need to add some NH3, or exchange the Level Transmitter.

There’s a small NH3 leak at the cooling unit from project 04.0931 at a coupling from
V0820.1025 when they open V0820.1026, this needs to be solved / repaired by the brewery
due to safety issues / NH3 leakages.

Running hours:
CO2 Compressor 1: 7150 running hours.
CO2 Compressor 1, head cooling pump: 8282 running hours.
CO2 Compressor 1, cooling pump: 7150 running hours.
CO2 Compressor 2: 11124 running hours.
CO2 Compressor 2: head cooling pump: 11621 running hours.
CO2 Compressor 3: 80501 running hours.
CO2 Liquid Pump 1: 2061 running hours.
CO2 Liquid Pump 2: 18539 running hours.
NH3 Compressor 1: 8256 running hours.
NH3 Compressor 2: 11256 running hours.
NH3 Compressor 3: 27752 running hours.

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Performed operations

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Wednesday 17-4-2024:
- Had a short meeting with the client, and talked about the issue they had, and agreed
on a plan what to check.
- Tested CO2 Compressor units 1 and 2, to be 100% sure that there’s no leakage.
➔ Drained all glycol from CO2 Compressor 2, and started the pressure test with
water on the complete compressor unit.
Pressure test was OK.
➔ Drained all glycol from CO2 Compressor 1, and started the pressure test with
water on the complete compressor unit.
Pressure test was Not OK, because of a pressure drop of 0,2 bar.
Agreed to build the cooler out, the next day, to find the leakage.
- According to the client, they had a leak in the past on the aftercooler from CO2
Compressor 3 (NEA 2TZS25), and had 2 pipes leaking, and closed the pipes and
ordered a new aftercooler.
- According to the client, they’ve already tried to clean the oil cooler on the NH3
compressor, with CIP (Caustic solution).
➔ Agreed that they’re going to connect a steam line on it, and let it flow reversed,
compared of the normal glycol flow.
➔ Steam was 113 degrees Celsius (maximum temperature measured).
Flushed the oil cooler for approx. 3 hours, from which the last hour the
temperature wouldn’t rise anymore on the outlet.
- Pulled from both stages a valve, so see the inside.
From a discharge valve 1st stage, a corner is broken of the valve cage, advise to
replace it.
Also all the nuts where not on torque, according to the client, this comes because
they inspect the valves regularly and they didn’t know the correct torque.

Thursday 18-4-2024:
- Build out the aftercooler from CO2 Compressor 1 (from project 20.0237).
➔ Found ice inside the piping (gas side) of the aftercooler, what means that there’s
something wrong with the glycol circuit.
➔ After checking the magnetic valve V0650.0803 it was found faulty.
So this means that there was a constant flow over the aftercooler, with glycol of -
4 degrees Celsius.
➔ Pressure test on the aftercooler from CO2 Compressor 1 (from project 20.0237)
Result was that 1 of the cooling pipes was leaking a little bit, so we’ve closed this
pipe on both sides, and build it back into the compressor unit.
- Tested CO2 Compressor unit 3, to be 100% sure that there’s no leakage.
➔ Drained all glycol from CO2 Compressor 3, and started the pressure test with
water on the complete compressor unit.
Pressure test was Not OK, because of a pressure drop of 0,6 bar.
Customer already ordered a new cooler, so they don’t want to repair this cooler
again.
- The Temperature Transmitter (TT1030.0405) of the CO2 inlet at the HRS (project
06.7235) was broken due to bending, replaced it sensor and the measuring pipe for a
new one.
- Did a pressure test on the HRS (from project 06.7235), and the result was not OK.
Advise to exchange the HRS a.s.a.p.
- CO2 Compressors 2 & 3 are running to warm after the aftercooler and too cold on
the cylinder block.

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Advise to stay running within the original specifications.

Also the aftercooler seems to have not enough heat transfer between the hot CO2
gas and the cold glycol.
Also the AVTA’s of both CO2 Compressors are broken, so these need to be
exchanged a.s.a.p.
- Checked all thermostats (so called Klixons) and heating elements from all the
ACF/Dryers.
Several are broken, and are advised to be replaced a.s.a.p.
- Checked the NH3 Evaporator from NH3 Cooling Unit 1.
➔ Level pipe is not standing perfect vertical but has an angle.
This can cause issues in the future with the correct level measurement.
➔ Average of 59% liquid NH3 in the NH3 Evaporator, advised the client to bring it
down to 50%.
- Flushed oil cooler from NH3 compressor unit, to clean it.
Flushed it with steam at 112 degrees Celsius.
After several hours, the temperature was equal going down in temperature, what
shows it’s clean now.

Friday 19-4-2024:
- Adjusted the NH3 compressor, so that we run on 5 bar discharge instead of 4,4 bar.
However the discharge temperature would then get higher, what then would reduce
the capacity by the SABROE software.
Therefor on request of the client, I’ve put the discharge pressure back on 4,4 bar.
- Measured temperatures on the oil cooler from the NH3 compressor unit.
➔ Oil inlet: 79,2 degrees Celsius.
➔ Oil outlet: 59,8 degrees Celsius.
➔ Glycol inlet: -0,3 degrees Celsius.
➔ Glycol outlet: 7,6 degrees Celsius.
➔ Oil after 3-way valve / inlet NH3 compressor: 63,4 degrees Celsius.
- Measured also the NH3 gas.
➔ Inlet: 2,1 degrees Celsius.
➔ Outlet: 92,7 degrees Celsius.
This temperature is slowly climbing when it runs for a longer period of time.
When the complete compressor unit is cold, it’s OK, but after a while you see the
temperature climbing and reaching 100 degrees Celsius as well…
- No pressure difference / pressure drop over oil filter.
- On the shaft seal is an “oil leak collector” placed, who was completely full.
This is then approx. 500cc of oil that came out at the shaft, with 8256 running hours.
- Did a vibration test, with an “SKF DMVP50 Vibration Pen” (Serial number: 8967)
Measured on several spots on the NH3 compressor unit, and all seem to within the
specifications.
Vibrations were checked on the main frame, electric motor and the NH3 screw
compressor block.
- Checked capacity slide of NH3 compressor.
Seems to be working correctly.
➔ -2% when standing OFF.
➔ When starting up, it goes to -27%, before it starts to climb up.
➔ When on full capacity, it shows 100%.
- Checked power consumption at 100% capacity / 60 Hz.
Fase 1: 52,46 A. Fase 2: 51,11 A. Fase 3: 51,31 A.

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Pressure tests :
Compressor Unit 1: (from project 20.0237)
- NEA 2V1 – 370/180
- Serial number: 909001008
Construction year: 2021
- Tested complete unit on 17-04-2024.
Start pressure: 4,8 Bar @ 15:44
Stop pressure: 4,6 Bar @ 16:30
Result: NOT OK
- Tested after cooler (when build out of unit) on 18-04-2024.
Start pressure: 15,4 Bar @ 11:58
Stop pressure: approx. 13,4 @ 13:15
Result: NOT OK
➔ Repaired the leakage by closing the leaking pipe on both sides.
So after this it was OK again.
However the advice to exchange the cooler.
Compressor Unit 2: (from project 04.0931)
- NEA 2V2 – 335/170
- Serial number compressor: 502336
Serial number unit: 900712
Construction year: 2005
- Tested complete unit on 17-04-2024.
Start pressure: 4,4 Bar @ 11:20
Stop pressure: 4,4 Bar @ 12:41
Result: OK
Compressor Unit 3: (from project 10.5563)
- NEA 2TZS25 – 250/120
- Serial number: 507583
Construction year: 2011
- Tested complete unit on 18-04-2024.
Start pressure: 5,4 Bar @ 15:20
Stop pressure: 4,8 Bar @ 15:50
Result: NOT OK
➔ Client ordered a new cooler already, and when it arrives they’ll exchange the
cooler.
HRS unit: (from project 06.7235)
- Vahterus
- Serial number:
- Tested heat exchanger on 18-04-2024.
Start pressure: 23 Bar @ 11:55
Stop pressure: 16,5 Bar @ 13:21
Result: NOT OK
➔ New HRS heat exchanger needs to be offered, and then build-in by the client.

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Pictures

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Renunciation
Customer has been made aware of following critical issues and or equipment and hereby
acknowledges that Pentair will not be accountable for any breakdown, malfunction or
warranty claims for mentioned issues and or equipment including claims for other parts of
the plant that are a result of and find their origin in the mentioned issues and or equipment,
should the customer continue to operate the plant, without rectifying mentioned issues or
replacing the mentioned equipment by original parts first
• ……
• ……
• ……..

……………………………………………………………………………………………………………

Signature Customer Signature Pentair Engineer

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Action List
Actions for Customer
Arrange a new measuring cell for the OGM
probes who’re having a bad Amplitude.
(<6000) when the Phase is above 60.
Buy all offered parts.
Check warranty agreement according to
contract.
Actions for Pentair
Arrange new seal and NH3 engineer to
replace seal and align NH3 compressor unit.
Offer all needed parts.
Check warranty agreement according to
contract.

List of Critical spares – To be replaced as soon as possible

Quantity Item Description Tag No. Serial No. Article No.
1 OGM Probe revision & XT2650.2016 P30280
calibration
1 OGM Probe revision & XT0150.2016 P30274
calibration
Project 04.0931
1 Temperature Activator TA0620.0403
1 AVTA TC0620.0804
Project 06.7235
1 Heat exchanger (HRS) A1030.04
Project 10.5563
1 AVTA TC0640.0804
Project 20.0237
1 Magnetic Valve V0650.0803
1 Aftercooler A0650.03
General
10 Klixons 000.007

List of additional spares needed for next service visit

Quantity Item Description Tag No. Serial No. Article No.
Project 04.0931
1 Filling ACF/Dryer A0720.00
1 Complete maintenance set A0620.00 502336
(NEA 2V2 – 355/170)
1 Discharge valve cage 1st stage 1-093-000243
Project 10.5563
1 Filling ACF/Dryer A0740.00
1 Complete maintenance set 507583
(NEA 2TZS25 – 250/120)
1 Butterfly Valve (complete) V0640.0002
Project 20.0237
1 Filling ACF/Dryer A0750.00
1 Complete maintenance set A0650.00 909001008
(NEA 2V1 – 370/180)

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List of recommended spares to stock

Quantity Item Description Tag No. Serial No. Article No.
Project 04.0931
1 Complete maintenance set A0620.00 502336
(NEA 2V2 – 355/170)
1 Repair set V0720.0001
1 Repair set V0720.0007
1 Repair set V0720.0021
Project 10.5563
1 Complete maintenance set 507583
(NEA 2TZS25 – 250/120)
1 Repair set V0740.0001
1 Repair set V0740.0007
1 Repair set V0740.0021
Project 20.0237
1 Complete maintenance set A0650.00 909001008
(NEA 2V1 – 370/180)
1 Repair set
1 Repair set
1 Repair set
General
8 O-ring valve cage 1st stage 015 449 062
4 O-ring valve cage 2nd stage 005 449 056
4 O-ring valve cage 1st stage 1-010-000469
4 O-ring valve cage 2nd stage 005 449 056
10 Klixons 000.007

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Timesheet

Customer name Anadolu EFES Biracilik ve Malt

Address Fatih Mah. Turgut Ozal Bul. No 48
TR-06980
City Kazan-Ankara
Country Turkey

Project number 04.0931 & 04.3294 & 06.7235 & 10.5563 &
20.0237
Job number / Service Order 62022716
Visited by Mark van Cranenbroek
Date visit from/until 17 till 19-4-2024
Date of report 19-4-2024
System type 04.0931 – CO2 Recovery System
04.3294 – Gas washer & Overpressure safety
06.7235 – HRS
10.5563 – CO2 Compressor & ACF/Dryer
20.0237 – CO2 Recovery System

Week 17 Date From To Working Remarks

hours
Monday …… …… …… …… ……
Tuesday …… …… …… …… ……
Wednesday 17-4-2024 8:00 17:30 9,5 ……
Thursday 18-4 8:00 18:00 10 ……
Friday 19-4 8:00 16:15 8,25 ……
Saturday …… …… …… …… ……
Sunday …… …… …… …… ……

Signature :

……………………………………………………………………………………………………………

Signature Customer Signature Pentair Engineer

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Pentair Contact Details

Haffmans BV Union Engineering A/S

PHONE : +31 77 3232 300 PHONE : +45 76 20 77 00 MAIN

FAX : : +31 77 3232 323 FAX : +45 76 20 78 00 FAX
MARINUS DAMMEWEG 30, SNAREMOSEVEJ 27
5928 PW VENLO DK-7000 FREDERICIA
NETHERLANDS DENMARK

www.haffmans.nl www.union.dk

Technical Support CO2 Systems : Technical Support

NLVENService@pentair.com Union_Service@pentair.com
Phone : +31 773232 320 → Option 1 Phone : +45 7620 7700

Technical Support Biogas Systems : Spare Parts Union Plants :

NLVENService@pentair.com Spares-eur@union.dk
Phone : +31 773232 320 → Option 2 Phone : +45 7620 7700

Technical Support QC In / At Line & Lab : Spare Parts Witteman Plants :

NLVENQCSupport@pentair.com Spares-usa@union.dk
Phone : +31 773232 320 → Option 3 Phone : +45 7620 7700

Spare Parts & Service Engineers offers : Spare Parts & Service Engineers offers :
Spareparts@pentair.com Union_Service@pentair.com
Phone : +31 773232 320 → Option 4 Phone : +45 7620 7700

Service Engineers Planning : Service Engineers Planning :

NLVENServicePlanning@pentair.com Union_Service@pentair.com
Phone : +31 773232 320 → Option 5 Phone : +45 7620 7700

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