Sulzer Technical Paper

Sulzer Turbo Services Sulzer Turbo Services
Volume 14, Spring 2007
11
A
A Sulzer
Sulzer Hickham
Hickham USA
USA Speciality
Speciality - Reducing Nitric Acid Plant Downtimes
A Sulzer Hickham USA Specialit
Reducing Nitric Acid Plant Downtimes
Reducing Nitric Acid Plant Down
In early August 2006 a chemical plant in
company has repaired 55 complete
machines, in addition to many spare
the Midwest experienced an unplanned
shutdown due to a power failure, which
rotors. Of these, several were comresulted in a lube oil loss to the nitric acid
plete, replacement or spare machines
Alexander
plant compressor train. The lube oil failure Peter that
were performance-matched to suit
President
plant
design. In fact, this same
caused catastrophic damage to the tail gas Sulzerthe
Turbo
Services
expander. Among other critical components,
customer has now asked Sulzer
the stator was almost completely destroyed DearHickham
USA
for a quote to provide
TurboTalk
Reader,
and there was no spare stator readily availa complete drop-in spare machine.
able. A new replacement stator was months Sulzer Turbo Services has a new slogan,
away, so after talking with another Sulzer Achieving the Extraordinary. Benjamin
Hickham USA customer, Sulzer Hickham Franklin once said: Well done is better than
USA was called on for help. Rather than well said. Our commitment to achieving
being without an expander for months, we what we promise is based on our culture,
were able to rebuild the machine to a bet- knowledge and processes, and is proven
ter than original condition with available out by our results. As a routine matter, we
inventory parts and ship to the customer in often do exceptional things in exceptionally
only two and a half weeks!
short periods of time. We have a history of
30 plus years of walking the talk.
Rotor from wrecked expander.
The Sulzer Hickham USA
Sulzer
Hickham
USA is
also
has
Expander Advantage
A key
element
of our success
our abilSulzer Hickham USA has some of the most ity tothe
ability At
to Sulzer
repair Turbo
theseServices
unique
innovate.
experienced personnel in the world for repair- we dont
machines
thaninnovation,
anyone elsewe
in
just quicker
talk about
ing expanders of this design, including per- do itthe
because
of a sigandindustry,
we do itpartly
quickly.
Our underlying
sonnel with vast experience in operating nitric technical
nificant
inventory
expander
parts.
strengths
andofthe
independence
acid plants. Approximately 80 machines of this in our
In this
particular
case, the
inventory
design
philosophies
combine
to
design were manufactured between 1962 and make
made
all theadifference,
for of
it included
available
wide range
innova1999 and many are still operating throughout tive solutions
a complete
stator,
wheels
and
blades
that allow our customers
to
fortheir
this critical
size machine.
the world. From 1990 up to the present, our return
components to service
sooner.
As an organization devoted to servicing
O
T
a
fi
Close-up of rotor thrust collar.
A unique machine
These nitric acid expanders are
unique in design due to the large
thermal variations that the machine is
exposed to. Unlike the average steam
turbine and centrifugal compressor,
small deviations from tolerance during the repair procedures cannot be
allowed, for the design is very unforgiving. Sulzer Hickham USA has
developed standardized repair procedures to assure a well performing
machine in the field. Over the years
we have also initiated several design
improvements proven to increase reliability and provide lower vibration on
these machines.
TurboTalk
Volume 14, 2007
In
p
a
lo
e
Reducing Nitric Acid Plant Downtimes
Outcome
The machine was installed and
aligned to Sulzer Hickham USA specifications. Upon startup, the customer
Peter Alexander
President
Sulzer Turbo Services
Dear TurboTalk Reader,

Sulzer Turbo Services has a new slogan,
Achieving the Extraordinary. Benjamin
Franklin once said: Well done is better than
well said. Our commitment to achieving
what we promise is based on our culture,
knowledge and processes, and is proven
out by our results. As a routine matter, we
often do exceptional things in exceptionally
short periods of time. We have a history of
30 plus years of walking the talk.
A Speciality
Plant Downtimes
ers are
e large
chine is
e steam
pressor,
nce durnnot be
y unforSA has
air proforming
e years
l design
ase reliation on
...continued from page 1
...continued from page 1

A key element of our success is our ability to innovate. At Sulzer Turbo Services
Outcome
we dont just talk about innovation, we
The
machine
was
installed
do it
and we do
it quickly.
Our and
underlying
aligned
to Sulzer
Hickham
specitechnical
strengths
and USA
the independence
fications.
startup,
the customer
in our Upon
design
philosophies
combine to
make available a wide range of innovative solutions that allow our customers to
return their critical components to service
sooner.
Close-up of rotor thrust collar.
A unique machine
These nitric acid expanders are
unique in design due to the large
thermal variations that the machine is
exposed to. Unlike the average steam
turbine and centrifugal compressor,
small deviations from tolerance during the repair procedures cannot be
allowed, for the design is very unforgiving. Sulzer Hickham USA has
developed standardized repair procedures to assure a well performing
machine in the field. Over the years
we have also initiated several design
improvements proven to increase reliability and provide lower vibration on
these machines.
Installed Sulzer Hickham USA inventory stator
proudly stated that the vibrations and

air leakage from the HP seal were
lower than they had ever experienced,
even when the machine was new.
John East
Sulzer Hickham USA
As an organization devoted to servicing

equipment, our energies are focused on
providing all of our customers with a slate
of options that best suit their needs. Unlike
many, our first response is not going to be:
You need to replace it. We are more likely
to ask which solution is best for you.
Installed Sulzer Hickham USA inventory stator
Our customers have the satisfaction of

proudly
stated
thewe
vibrations
and we will
knowing
thatthat
when
do commit,
air do
leakage
from we
thecan
HPtoseal
were
everything
keep
our promlower
than
they
had
experienced,
ises,
and
that
is ever
something
extraordinary
even
when the machine was new.
to achieve.
John
East
Peter
Alexander
Sulzer Hickham USA
2
TurboTalk
Cutaway of a typical nitric plant expander.
Volume 14, 2007
TurboTalk Volume
14, 2007

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Sulzer Turbo Services Sulzer Turbo Services

Volume 14, Spring 2007

Close-up of rotor thrust collar.

Volume 14, 2007

Reducing Nitric Acid Plant Downtimes

Dear TurboTalk Reader,

...continued from page 1

...continued from page 1

Close-up of rotor thrust collar.

Installed Sulzer Hickham USA inventory stator

proudly stated that the vibrations and

As an organization devoted to servicing

Our customers have the satisfaction of

Cutaway of a typical nitric plant expander.

Volume 14, 2007

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