Troubleshooting in

SYNGAS PLANT

Presentation by
S.B.V.PRASADA RAO
1
 Objective
The aim of this presentation is to explain troubleshooting in the following units in
SYNGAS PLANT
 Sales gas from ARAMCO
 Feed gas compressor
 Hydrogenation and de-sulfurization
 Reformer
 Process gas cooling
 AMDEA wash unit
 CO2 compressor
 Temperature swing Adsorption
 Cold box
 CO compressor
 Pressure swing Adsorption
 PCRU

Note: Consider instrument / equipment malfunction is one of the probable cause in all
cases. So it was not mentioned every case.
 What is troubleshooting ?
 Definition
Troubleshooting is a process of identifying, planning and
resolving a problem.
 Steps in troubleshooting process
1. Verify that a problem is actually exits
2. Isolate the cause of the problem
3. Correct the cause of the problem
4. Verify that the problem has been corrected
5. Follow up to prevent future problems.
 SYNGAS PLANT BLOCK FLOW DIAGRAM
SALES GAS
FROM ARAMCO
CO2
HYDROGEN HP STEAM CO2
COMP

NG DE - STEAM CO2
comp SULFURIZATION REFORMING REMOVAL

SYN GAS
COLD BOX TSA
RAW HYDROGEN
RH2

CO
COMP PSA

OXO GAS TO BUTANOL PLANT CO HYDROGEN

HYDROGEN TO BUTANOL PLANT

4
SALES GAS FROM ARAMCO

5
 Troubleshooting in sales gas from ARAMCO

Wobbe index increased /decreased

Wobbe index increased Wobbe index decreased

 Potential cause  Potential cause
a) % higher hydro carbons came down
a) % of higher hydro carbons
in sales gas
increased in sales gas.
b) % of nitrogen increased in sales gas
 Consequence  Consequence
a) OXO gas production will a) OXO gas production will come
increase for same feed to down
reformer.  Action
 Action a) Increase OXO gas target in ALC
according to requirement
a) Reduce Oxo gas target in ALC
b) If nitrogen % increases in the sales
b) Increase excess steam factor gas then increase purge flow from
in ALC CO/N2 column, increase re-boiling
flow to CO/N2 column

6
 Troubleshooting in sales gas from ARAMCO

% sulfur and nitrogen in sales gas

High sulfur in sales gas % Nitrogen very low in sales gas

 Consequence  Consequence
a) Could not able to maintain
potential sulfur breaks CO/CH4 &CO/N2 columns
though to reformer pressure 2035PIC-3698.
 Action  Action
a) Increase the hydrogen a) Reduce nitrogen purge from
CO/N2 column by 2035FIC-
flow to maximum level 1698
b) Give sales gas sample b) Introduce nitrogen flow to
and ZNO beds outlet CO/N2 column feed through
sample to lab 2035FV-1400
c) Reduce re-boiling flow to
c) Confirm the analyzer is
CO/N2 column by 2035FV-1620
working properly
7
FEED GAS COMPRESSOR
 Troubleshooting in Feed compressor
Suction pressure low 2008PI-3861A/81A
 Potential cause
1.Suction strainer DP is high
2.2008PV-3006A/B mal function
3.Sales gas supply pressure from ARAMCO is low
4.Sale gas filter DP is high
5.20V-0801 demister blockage
 Consequence
1.Mas flow thorough compressor will come down
 Action
1. if suction pressure is very low first reduce the plan the load.
2.If suction strainer DP is high (>600mbar) change over the compressor.
3.Check 2008PV-3006A/B, if any deviation then then take other valve in to
service and isolate problematic control valve.
4.If sales gas filter DP is high, change over it.
5.If 20V-0801 demister blockage, need take shut down and clean it.
9
 Troubleshooting in Feed compressor

Discharge pressure low 2008PI-3861B/81B

 Potential cause
1. Suction pressure low
2. Mal functioning of spill back valve
3. Loader valves passing
 Consequence
1. Could not able to supply NG feed to reformer
 Action
1. if suction pressure is very low , take the actions as mentioned above
2. Check physical opening of spill-back valve, if any deviation then
change over the compressor and fix it.
3. if loader valves are passing, then change over the compressor and fix
it.
4. If stand by compressor NRV is passing then isolate stand by
compressor’s discharge block valve.
10
 Troubleshooting in Feed compressor

Discharge pressure fluctuations 2008PI-3861B/81B

 Potential cause
1. 2008PV-3006A/B hunting
2. Spillback valve hunting
3. Loader valves problem
4. Reformer feed valve (2015FV-1001)hunting
 Consequence
1. feed flow and pressure fluctuations to reformer
 Action
1. take feed valve 2015FV-1001 in to manual mode and check it, still it is
fluctuating then check spillback valve and 2008PV-3006A/B valves in
the field.
2.If 2008PV-3006A/B is hunting then take other valve in to service and
isolate problematic control valve.
3.if spillback valve is hunting then change over the compressor.
11
 Troubleshooting in Feed compressor
Discharge temperature is high
 Potential cause
1. sale gas temperature is high from ARAMCO
2. Bypass cooler fouling
3. Cooling water temperature is high
4. High nitrogen % in sales gas
 Consequence
1. chance to damage of compressor pickings
2. Chance to trip of the compressor (due to high high temperature)
 Action
1. check cooling water supply temperature from UTOS, if require increase
cooling water flow to bypass cooler.
2. If bypass cooler is fouling then change over the compressor and clean
it.
3. If % of nitrogen is very high also discharge temperature will increase
(due to density change), check with ARAMCO and fix it.
12
HYDROGENATION & DE-SULFURIZATION UNIT
Troubleshooting in hydrogenation & de-sulfurization

Low hydrogen flow 2008FALL-1001

 Potential cause
• PSA trip
• 2008FV-1001 mal function
 Consequence
• potential sulfur breaks though to reformer
 Operator action
• the minimum requirement of hydrogen flow is 2.5 to 3.0mole % of
sales gas feed.
• Check the flow from PSA, If PSA tripped, establish the hydrogen flow
from EC/PDH plants.
• If 2008FV-1001 malfunction, establish hydrogen flow though it
bypass valve.
• If EC /PDH plants could not able to supply hydrogen & our PSA could
not able to re-start then trip the reformer and stop feed compressor.
14
Troubleshooting in hydrogenation & de-sulfurization
Low temperature at inlet to hydrogenator <330°C
 Potential cause
• 2015TV-4507 mal function
• Steam drum pressure low.
• Extreme fouling in feed preheater 20E-0801 
 Consequence
• Less sulfur conversion and absorption efficiency, potential
breakthrough of sulfur to Reformer
 Action
• Check 2015TV-4507 control valve opening, if TV closes then open it by
hand jack.
• If stem drum pressure is low the increase steam drum pressure up to
normal operating pressure (46bar)
• Confirm sulfur slip from absorber by lab analysis
• If sulfur is breaking through (>0.1ppm), take shut down of reformer.
• If exchanger 20E-0801 is fouling then clean it during shutdown.
15
Troubleshooting in hydrogenation & de-sulfurization

Hydrogenation Reactor bed temperature high 2008TI-4002/07

 Potential cause
 methanation, high olefins in sales gas, RG Boiler fouling
 Consequence
 Methanation reaction will happen in the reactor
 Operator action
 Methanation from CO/CO2 and H2 ( this reaction typically only achieve when
hydrogen partial pressure is > 3.0 bar. This reaction is Strong exothermal reaction
( 75°C per % CO in natural gas).
 Reduce inlet temperature by 2015TIC-4507.
 If the temperature raise in the hydrogenation reactor more than 400°C (due to
methanation) then shut down feed compressor and reformer, purge and cool
down the reactor with nitrogen.
 If the bed temperature raise is due to PGC fouling, then reduce plant. (If the bed
temperature >400°C then cocking formation will happen. Reactor and piping
design temperature is 425°C)

16
Troubleshooting in hydrogenation & de-sulfurization

Sulfur break through from Zink oxide beds

 Potential cause
1. High sulfur in sales gas
2. Low hydrogen flow (2008FIC-1001)
3. Low temperature at hydrogenation reactor inlet
4. Zink oxide beds life expired
 Operator action
1. Confirm the sulfur in sales gas and sulfur outlet of zinc oxide both the
beds by lab analysis. If sulfur is high in sales gas and beds outlet then cut
off feed to reformer.
2. Check the hydrogen flow, maintain flow ≈ 60kg/hr.
3. If hydrogenation reactor inlet temperature is <330°C, take the actions as
mentioned in the above slide.
4. Check sulfur out let of Zink oxide beds (lead and lag), if sulfur is more the
0.15ppm from the lead bed (ie., bed life expired) replace the catalyst for
lead bed.
17
REFORMER
 Troubleshooting in Reformer
Process chemistry & Equilibrium
Process chemistry 3. High steam /feed ratio
•CH4+H2O→CO+3H2-Heat •Improves CH4 conversion
•CH4 +CO2→2CO+2 H2- Heat •But enhances CO2 formation
•CO+ H2O→ CO2+ H2 + Heat  
Process equilibrium 4. Low steam /feed ratio
•Decrease CH4 conversion
1. High temperature •But enhances CO formation
•Improves CH4 conversion
•Improves CO formation 5. High operating pressure
•But increases catalyst tube wall •Reduce CH4 conversion
temperature •Results Higher reformer tube wall
thickness
 2. Low temperature  
•Decrease CH4 conversion 6. low operating pressure
•Enhance CO2 formation •improve CH4 conversion
•But enhances catalyst tube wall life time •results lower reformer tube wall
thickness
19
 Troubleshooting in Reformer

Carbon formation on catalyst

Chemistry Consequence
1.carbon formation a)Carbon covers the catalyst surface
a.CH4 ↔ C+ 2H2 b)
Pressure drop increases across the tubes
b.C2H6 ↔2C+3H2 (Usually only in severe situations)
c)Carbon fills catalyst bed voids
d)
Carbon lay down on the inside of the
2.Boudouard reaction
tube wall
2Co ↔ C+CO2
e)Lower catalyst activity
f)Hot bands will appear on tubes
3.CO reduction
Operator action
CO+H2 ↔ C+H2O
a)Increase excess steam factor in ALC ( to
increase steam/feed ratio)
Probable cause
b)
Reduce plant load
a)Steam to feed ratio is too low c)If the carbon is deposited heavily then
b)
Catalyst is not active enough shut down the plant and steaming the
c)Higher hydro carbons are present catalyst.
d)
Tube walls are too hot (high flux)
20
 Troubleshooting in Reformer

catalyst poisoning by sulfur

 Potential cause
Poor hydrogenation reaction and H2S absorption

Consequence
a)Sulfur sticks on the nickel surface and forms
nickel sulfide
b)Can totally deactivate a reforming catalyst.
c)Giraffe neck can observe on reformer tube

Action
a)Steaming the catalyst will slowly strips off the
sulfur (Sulfur poisoning is reversible but may
loose some catalyst activity permanently).
b)If Sulfur outlet of de-sulfurization unit is
>0.1ppm, replace zinc oxide catalyst.
21
 Troubleshooting in Reformer
Flame impingement
Potential cause
a) Blockage of port in burners
b)Miss alignment of burner
c)Fuel header pressure is too high
d)Poor burner design
e)Burner block damaged
Consequence
a)Direct impingement of flame on tube. This is the
worst since the tube wall temperature will be raised
can lead to rapid tube failure
b)Impingement of hot flue gas on the tube. Normally
observed as shimmering on the tube surface, will
lead to premature failure in long term.
Action
a)clean the burners and align the burners properly
b)Always try to keep all HP and LP fuel burners are in
service to avoid high fuel header pressure.
Note: Design tube metal temperature = 976°C
22
 Troubleshooting in Reformer

Bowing of reformer tubes

 Potential cause
a) If tubes receive differential amounts
of heat from adjacent burner rows
b) If top springs are not functioning
properly
 Consequence
Each side expands differently then
the tubes will blow
 Action
a) Adjust the flame pattern of the
burners
b) Always try to keep all HP and LP fuel
burners are in service.
c) Check the functioning of spring
supports.
d) change the tube if more than ID
outside of the center line of the lane

23
 Troubleshooting in Reformer

Reformer tube appearance (due to Catalyst deactivation)

 Hot Band
• Cause: catalyst deactivation due to
carbon deposition
• Action: steaming or replacement of
catalyst
 Tiger tailing
• Cause: voids in the catalyst bed
• Action: Hammer the tube
 Giraffe necking
• Cause: catalyst deactivation
( sulfur), voids in the catalyst bed)
• Action: replace catalyst
 Hot tube
• Cause: excessive catalyst
deactivation, restricted flow
( broken catalyst)
• Action: replace catalyst

24
 Troubleshooting in Reformer

High methane slip in reformed gas

 Potential cause
1. Low reformed gas outlet temperature
2. Steam to feed ratio is low
3. % Higher hydro carbons are high in sales gas
4. Catalyst deactivation due to sulfur
 Consequence
1. Loos of CO and Hydrogen production
 Action
1. Confirm the methane slip by lab analysis
2. Increase reformer out let temperature (not more than 880°)
3. Increase excess steam factor
4. If the catalyst exposed to sulfur, shut down the plant and steaming
to be done.

25
 Troubleshooting in Reformer

CO2 recycle is high (2025FI-1005)

 Potential cause
1. Low reformed gas outlet temperature
2. Steam to feed ratio is high
3. % Higher hydro carbons are high in sales gas
 Consequence
1. Over loading of AMDEA wash unit
2. Overloading of CO2 compressor
 Action
1. Increase reformer out let temperature (not more than 880°)
2. If steam to feed ratio is more, reduce excess steam factor
3. If % higher hydrocarbons are high, reduce plant load.

26
 Troubleshooting in Reformer

NOX high in flue gas ( 2015AI-5003)

 Potential cause
1. High combustion air flow
2. Oxygen analyzer mal function
3. NOx analyzer malfunction
 Consequence
1. High NOx leads environmental issue
 Action
1. Cheek reformer flame pattern, if possible reduce combustion air
flow.
2. If required clean the burners
3. Confirm oxygen in flue gas by lab analysis
4. If require calibrate oxygen analyzer and NOx analyzers.

Note: Maximum NOx allowed by Royal commission is 38.5 ng/joule.

27
 Troubleshooting in Reformer

High reformed gas temperature 2015TI-4506

Potential cause
a)change in the fuel composition by TSA steps /cold box upsets
b)Sudden reduction in combustion air flow
c)Wrong fuel flow indication
d)ALC mal function
e)Oxygen analyzers wrong indications.
f)Reformer feed composition change
Consequence
a)over heating of the tubes.
b)Chance to trip of reformer ( trip=900°C)
Action
a) check combustion air flow and all fuel flows.
b) If ALC is mal functioning , immediately take out fuel and combustion air flow
controllers from ALC and control the reformed gas temperature.
c) If required stop ALC and restart ALC program
d) If there is any deviation in oxygen analyzers give for calibration.
28
 Troubleshooting in Reformer

High Flue gas temperature 2015TI-4510A/B/C (>1040°C) and down stream

Potential cause
a)Reformer tube failure
Consequence
a)All flue gas temperature profile will
increase.
b)All waste heat recovery coils will expose to
high temperatures which leads to damage
of waste heat recovery coils
c)Reformer box pressure will increase ( if leak
is high)
d)Oxygen in flue gas will come down

Action
a) Confirm and shutdown the reformer.
29
 Troubleshooting in Reformer

High Flue gas temperature 2015TI-4518/11/12/13 and down stream

Potential cause
a)Feed super heater coil leak
Consequence
a)All flue gas temperature profile 2015TI-4518/11/12/13 and
down stream will increase.
b)All waste heat recovery coils will expose to high
temperatures which leads to damage of waste heat recovery
coils
c)Reformer box pressure will increase ( if leak is high)
d)Oxygen in flue gas will come down
Action
a) Confirm and shutdown the reformer.
30
 Troubleshooting in Reformer

High mixed feed temperature 2015TIC-4505

Potential cause
a)Too much excess combustion air flow
b)2015TV-4505A is not operable
c)Reformer tube failure
d)Feed super heater (20E-1503/1504) coil leak
Consequence
a)if the reformer inlet temperature is increases more than 560°C, chance of thermal
cracking at inlet of the pig tails, which leads to failure of inlet pig tails (reformer inlet
line design temperature is 575°C)
Action
a)check combustion air flow and oxygen in the flue gas. Adjust combustion air flow.
b)Check physical opening of 2015TV-4505A, if it is not operable then open it by using
hand jack and control the temperature.
c)If required reduce plant load.
d)Check flue gas temperature profile, if any abnormal temperatures are observed, base
on the zone suspect reformer tube failure or feed super heater coil failure. Confirm
and take immediate shut down of reformer.
31
 Troubleshooting in Reformer

Low mixed feed temperature 2015TIC-4505

Potential cause
a)Water carry over from steam drum
b)Water carry over from PCRU vaporizer
c)Hydrogenation reactor inlet temperature low
d)2015TV-4505A mal function
Consequence
a)Heat load on reformer will increase.
Action
a)Check steam drum level, if any deviation calibrate level transmitters.
b)Check PCRU vaporizer level, if any deviation calibrate level transmitters.
c)If hydrogenator inlet temperature is low, take actions as mentioned in the
above troubleshooting.
d)Check opening physical opening of 2015TV-4505A, if any deviation fix it
or if not close it by hand jack.
32
 Troubleshooting in Reformer
Steam drum level high
Potential cause
a)Steam drum level transmitter mal function
b)Control valve problem
Consequence
a)chance to damage of demister
b)Water will carry over which leads to damage of super heater.
c)Salts will carry over and which will deposit on the reformer catalyst.
d)Salts will not be removed properly from steam drum if the level is higher than the CBD
Sparger.
e)Hammering will come in cyclone separators.
f)HP steam temperature will be low due to water carry over.
Action
a)compare the steam level indication with local level gauges, if any deviation calibrate the
transmitters.
Note: maintain steam drum level around 55%.
33
 Troubleshooting in Reformer
Steam drum level low

 Potential cause
a) BFW failure from UTOS
b) Steam drum level transmitter mal function
c) Issue with 2087P-8701
 Consequence
a) If steam drum level is very low chance to starvation of 20E-
1506A/B/C/D exchangers.
b) Salts will not be removed properly from steam drum if the level is
lower than the CBD Sparger.
 Action
a) compare the steam drum level indication with local level gauges,
if any deviation calibrate the transmitters.
Note: maintain steam drum level around 55%.
34
 Troubleshooting in Reformer
Combustion air fan vibrations are high

Potential cause
1)Suction filter DP high
2)High combustion air flow ( more than design)
3)Back pressure from reformer box.
4)Back pressure due to combustion air distribution header valves throttled or closed
5)Lube oil header pressure low
6)Lube oil temperature high
7)Moisture in lube oil
8)Vibration probe/communication issue
9)Improper supports.
10)
Other mechanical problems
Consequence
1)Leads to trip of FD fan on high high vibrations.
2)Leads to damage of equipment.
35
 Troubleshooting in Reformer
Combustion air fan vibrations are high

Action
1)If vibrations are high, first reduce combustion air flow
2)If suction filter (20F-1501) high DP, reduce plant load and replace the filter
elements during shutdown.
3)Check reformer box pressure and ID fan condition.
4)Check opening combustion air distribution valves, if any throttled condition
open it.
5)If lube heeder pressure is low, then check filter DP, pump discharge
pressure/PCV condition/lube oil console level.
6)If require change over lube oil filter/ change over the lube oil pump.
7)Check lube oil temperature, if require open cooling water to lube oil cooler.
8)Check lube oil heater malfunction if any.
9)Confirm vibrations by inspection team.
10)
If any problem with vibration probe/ communication ,fix it
11)
Check the supports and other mechanical problem
36
 Troubleshooting in Reformer
Phosphate in steam drum CBD
Free Phosphate low Free Phosphate high
 Potential cause  Potential cause
• Low phosphate dosing High phosphate dosing
• CBD opening high  Consequence
 Consequence • high PH
• Salts will not be removed • caustic corrosion
properly. • high conductivity
• Scaling will deposit in  Action
exchanger and turbine • Adjust phosphate pump
blades stroke and CBD opening
 Action depends on CBD analysis.
• Adjust phosphate pump
stroke and CBD opening
depends on CBD analysis.

37
 Troubleshooting in Process gas cooling

Seperator-1/2 levels are high

 Potential cause
1) Clogging of level control valves
2) Malfunction of Level control valves (2020LV-2002/2004)/level transmitters
3) 2020XV-6061/6062 mal function
4) BFW preheater leak (20E-2001)
5) RG boiler (20E-1502) tube leak
 Consequence
1) Created back pressure to reformed gas
2) Water will go to AMDEA wash column
 Action
1) Check physical opening of 2020LV-2002/2004 & 2020XV-6061/6062, if any
deviation fix it.
2) if level control valves clogged, control separators levels by opening its bypass
valves. Later clean the controllers.
3) Check separators levels in field, if any deviation fix it .
4) If BFW preheater/RGB tube is leaking, shut down the plant and fix it.
38
 Troubleshooting in Process gas cooling
Seperator-2 outlet temperature high (>60°)
 Potential cause
1) Fin fans tripped
2) 2025TV-4007B malfunction.
3) High plant load and high steam/feed ratio
4) Ambient temperature is too high
5) Fins blocked with dust
 Consequence
1) High temperature leads to cut off reformed gas to AMDEA wash column by
2020TAHH-4005.
 Action
1) Check both fans running status and speed.
2) If any of the fans tripped, try to start immediately.
3) If steam/feed ratio is high, reduce it.
4) Check physical opening of 2025TV-4007B, if any deviation fix it.
5) If temperature is not coming in to range, reduce plant load.
6) If fins are blocked with dust, clean it during shutdown.
39
CO2 REMOVAL UNIT
 Troubleshooting in AMDEA wash unit
High CO2 slip at outlet of Absorber
 Potential cause
1)High foaming in AMDEA wash column or regeneration column
2)Low lean AMDEA circulation flow
3)High reformed gas temperature
4)Analyzer mal function.
5)Regeneration column temperature low
6)High lean solution temperature
7)Absorber bottom level mal function
8)% of CO2 is high in reformed gas
9)Low AMDEA concentration
10)Regenerator column pressure high
11)Low filtration flow
 Other causes
1)Carbon filter life exhausted
2)20E-2501A/B communication (rich to lean solution)
3)20E-2502A/B communication ( cooling water to lean solution)
4)Absorber beds collapse
5)Regenerator beds collapse
 Consequence
1) Over loading of TSA system, which leads to CO2 carry over to cold box
41
 Troubleshooting in AMDEA wash unit
High CO2 slip at outlet of Absorber
Action
1)
Add anti foam If any foaming observed in absorber/ regenerator
2)
If CO2 slip is >20ppm, first reduce plant load.
3)
Increase lea solution flow.
4)
Check regeneration column temperature, if required increase steam to re-boiler.
5)
Confirm analyzer indication by lab sample
6)
Check reformed gas temperature, if it is >60°C then control the temperature by fin fan speed
7)
if lean solution temperature is >45°C, increase cooling water to 20E-2502A/B
8)
Check physical bottom levels for absorber and regenerator, if any deviation fix it.
9)
If CO2 recycle is more, check wobbe index, steam to feed ratio and reformer outlet temperature.
10)
Check AMDEA concentration by lab, if it is low then add AMDEA solution to system
11)
Check filtration flow ( it should be minimum 10% of lean circulation flow)
12)
Check carbon filter outlet solution quality, if any carbon carry over found, isolate the filter and back wash it
or replace the carbon.
13)
Check cartridge filter DP, if it is > 3.0 bar , replace the element.
14)
If suspect any passing of 20E-2501A/B ( rich to lean) confirm by inlet and outlet lab sample. If found
passing change over the exchanger.
15)
If suspect any passing of 20E-2502A/B (cooling water to lean) confirm by inlet and outlet lab sample. If
found passing change over the exchanger.
16)
If CO2 slip still not comes in to range then finally inspect the absorber and regenerator columns beds and
internals by NDT
42
 Troubleshooting in AMDEA wash unit
AMDEA wash column level high
 Potential cause
1)Mal functioning of level transmitters
2)Mal functioning of 2025LV-2003/2025XV-6051/2025PV-3009
3)Mal functioning of 2025FV-1003
 Consequence
1)Leads to trip AMDEA unit by 2025LAHH-2003.
2)High level leads to damage of packing beds.
 Action
1)Check wash column bottom level in filed, if any deviation fix it.
2)If 2035FV-1003/2025PV-3009 any mal function, these can be
controlled by its bypass valves.
3)If 2025LV-2003/2025XV-6051 closes, it leads to shut down by
2025LAHH-2003.

43
 Troubleshooting in AMDEA wash unit
Regeneration gas over head separator level high
 Potential cause
1)Poor pumping by 20P-2502A/B
2)Regenerator top temperature high
3)Regenerator flooding
4)Regenerator top temperature high
5)Regenerator pressure low
 Consequence
1)Chace to trip CO2 compressor due to level 2025LAHH-2006
2)If the flooding too much then chance to go AMDEA in to CO2
compressor
 Action
1)Check reflux pump condition, if require changer over the pump or run
both pumps till the level comes in to range
2)If regenerator temperature is high then reduce heat input for reboiler.
3)If regenerator DP is high, add antifoam.
4)If require reduce plant to control regenerator flooding.
44
CO2 COMPRESSOR
 Troubleshooting in CO2 compressor
Suction pressure low 2025PI-3801

 Potential cause
1)mal function of suction guide vane valve
2)suction strainer block
3)Suction Check valve at struck
 Consequence
1) If the compressor suction pressure is low, compressor will surge.
 Action
1) Check the opening of the suction guide vane in the field, if there is any
deviation in output or control valve is not operable then shut down and fix it.
2) If the compressor could not able to develop pressure / flow due to suction
strainer high DP (>0.1bar), stop the compressor and clean the strainer.
3) If there is no strainer DP, suction guide vane functioning is ok, CO2 is venting
in the suction through 2025PV-3021B but the suction pressure is low that
means compressor suction check is stuck. Stop the compressor and inspect
the check valve function.
46
 Troubleshooting in CO2 compressor
Suction / Inter stage temperatures are high

 Potential cause
1) Cooling water supply temperature is high
2) 20-2504 / Inter stage coolers exchangers fouling.
 Consequence
1) If the suction temperature/inter stage temperatures are high then mass
flow through the compressor will come down which leads to surging of
the compressor.
 Action
1) Check cooling water supply temperature and pressure from UTOS
2) If required open cooling water to inter stage coolers and 20E-2504.
3) If the temperatures are not come in to range then reduce the load on the
compressor
4) If the exchangers are fouling then check condition of the compressor and
if required shut down the compressor and clean the exchangers.
47
 Troubleshooting in CO2 compressor
Discharge pressure is low (2025PI-3807)

Potential cause
1.Compressor suction pressure is low
2.CO2 density low ( due to 20E-2503 leak or 2030LV-2601 &2689 passing)
3.Mal functioning of guide vane opening/spill back valve/anti-surge valve
Consequence
1.Could not able to supply CO2 to reformer
2.Seal gas flows will come down which lead to damage of compressor seals.
Action
1.Check the suction pressure , if it is low take actions according to above mentioned trouble shooting
2.Check seal gas flows, if there is no seal gas flow to any stage , take shut down of the compressor.
3.Check all indications which are going to CCC, if any deviation, fix it.
4.Check the opening of anti-surge valve; spill back valves are matching with controllers outputs. If any
deviation fix it.
5.If 20E-2503 (re-boiler) leak then syngas will passing in to CO2. Confirm the passing by lab sample. If
the passing high then compressor could not able to develop the pressure due to low density. Shut
down AMINE unit and fix the passing.
6.Check 20V-3001 &3002 physical levels in the field, if any deviation fix it.

48
 Troubleshooting in CO2 compressor
Discharge pressure is high (2025PI-3807)

 Potential cause
1) Mal functioning of guide vane valve / anti-surge valve
2) Inter stage temperatures are too high
3) Sudden back pressure from reformer
 Consequence
1) Leads to surging of the compressor
 Action
1) Check opening of guide vane and anti surge valve, if any deviation fix
it.
2) If inter stage temperatures are high, take according to above
mentioned troubleshooting.

49
 Troubleshooting in CO2 compressor

CO2 compressor surging

 Potential cause
1. High suction temperature
2. Low suction pressure
3. Inter stage temperatures are high
4. High discharge pressure
5. Less mass flow though compressor
6. Water carry over (mal function of suction &inter stage separators
levels)
7. CO2 density low
8. Flow transmitter wrong indication
9. Spill back valve mal function
10. Anti-surge valve malfunction
11. Suction guide vane valve hunting

50
 Troubleshooting in CO2 compressor

CO2 compressor surging

 Consequence
1. Compressor surging will leads damaging of compressor internal
parts.
 Action
1. according to root cause take actions as mentioned in related
trouble shootings.
2. Check all indications which are going to CCC, if any devication, fix it.
3. IF the compressor is surging it will trip automatically by CCC, if not
take immediate shutdown of compressor.

51
 Troubleshooting in CO2 compressor
Low seal gas flow to primary seals
 Potential cause
1) Seal gas filter DP high
2) Compressor discharge pressure low
3) High level in seal gas separator
4) Inter stage separator levels malfunction.
 Consequence
1) Low seal gas flow leads to damaging of seals.
 Action
1) If seal gas filter DP is >1.0 bar, change over the filter.
2) Check compressor discharge pressure, if it is low then take actions according to
above mentioned trouble shooting.
3) check seal gas separator level is high, if it is high, drain it.
4) If water is coming in the seal gas separator then check inter stage temperatures,
physical levels of inter stage secretors.
5) Adjust seal gas flows to individual seals.
52
 Troubleshooting in CO2 compressor

Low seal gas flow to secondary seals

 Potential cause
1) Nitrogen header pressure low
 Consequence
1) Low seal gas flow leads to damaging of seals.
2) Chace to enter lube oil in to seals
 Action
1) Compressor will trip if nitrogen pressure is <0.1bar
2) Adjust seal gas flows to individual seals
3) Check seal leak off pressures.

53
 Troubleshooting in CO2 compressor
Bearings temperature are high
 Potential cause
1) Lube oil header pressure low
2) Lube oil header temperature is high
3) Moisture in lube oil
4) Fouling of lube coolers.
5) Lube oil quality (viscosity)
6) Other mechanical problems
 Consequence
1) Leads to damage of bearings
2) Compressor vibrations will increase
 Action
1) Check lube oil filter DP, if it is > 1.0bar, change over the filter.
2) Still header pressure is low , check PCV functioning.
3) If lube oil header temperature is high, increase cooling water to lube oil coolers or if require
change over lube oil cooler
4) Check if any lube oil heater mal function.
5) Check lube oil quality by lab ( moisture and viscosity)
6) If moisture is high, connect centrifuge to lube oil console.
7) If any other quality problems, replace the oil.
54
TEMPERATURE SWING ADSORPTION (TSA)
 Troubleshooting in TSA
High CO2 at TSA outlet
Potential cause
1)TSA inlet CO2 slip (2030AI-5001A) high (>20ppm)
Consequence
1)CO2 will form dry ice ,it will clog the flow/reduced heat transfer/damage of Cold Box
internal equipment (Exchangers/Process Lines etc.,)
Action
1)Check and Confirm that TSA inlet CO2 Slip (2030AI-5001) is normal (< 20 PPM)
2)if CO2 slip exit TSA is increasing, Reduce Plant load,
3)Monitor Cold Box Process Gas Exchangers DP (2035PDI-3617A/B) in Syngas Path, if it
is increasing then immediately reduce load on the cold box
4)Reduce TSA operation factor/CO2 operation factor (2030HIC-6053/6055) by 0.01 in
small decrements.
5)Take Offline TSA inlet and Outlet samples and Compare with Online Analyzers
(2030AI-5001A/B)
6) Monitor TSA outlet CO2 slip (2030AI-5001B) continuously.
7)If CO2 slip is not decreasing exit TSA unit then stop TSA Unit & cold box and fix the
problem in AMDEA unit, then restart TSA safely.
56
 Troubleshooting in TSA
High moisture at TSA outlet
Potential cause
1)TSA inlet temperature high.
2)2030V-3001 level high.
Consequence
1)moisture will form ice inside Cold Box Process Lines and it will clog the flow/reduced
heat transfer/damage of Cold Box internal equipment (Exchangers/Process Lines
etc.,)
Action
1)check 2030V-3001 level in filed level gauge, if any deviation fix it.
2)Check functioning of 2030LV-2601
3)If TSA inlet temperature is more than normal operating temperature then increase
cooling water flow to 20E-3001
4)Take TSA outlet sample and Compare with Online Analyzers .
5)Monitor Cold Box Process Gas Exchangers DP (2035PDI-3617A/B) across Syngas Path,
if it is increasing then immediately reduce load on the cold box.
57
 Troubleshooting in TSA

TSA Skid Valves response delay alarm

 Potential cause
• Mal functioning of any control valve in skid.
 Consequence
• Regeneration sequence will step time out, leads to shutdown of TSA
unit.
 Action
• Check and confirm the position of defected TSA skid valves status in
field and DCS are same. If not, call Maintenance immediately and fix it.

58
 Troubleshooting in TSA

Regeneration Gas Temperature low (2030TI-4637)

 Potential cause
• 2030PV-3691 mal functioning.
• LP steam temperature low ( more condensate).
• 2030LT-2693 mal functioning
• Air lock in 20E-3004 shell side.
 Consequence
• It may leads trip of TSA due to heating fault
 Action
• Check and confirm that 2030LV-2693 is operating normal
• Compare the Level in 20E-3004 by field LG with 2030LT-2693.
• Check and Confirm that 2030PV-3691 is operating Normal.
• Check and Confirm that pressure as indicated by 2030PI-3691 is normal.
• Check and Confirm that LP steam Header Pressure and Temperatures are normal.
Check the trap functioning.
• Open 20E-3004 shell side 1” vent to atmosphere to bleed any air.
59
 Troubleshooting in TSA

Product Filter DP is high (2030PDI-3672A/B)

 Potential cause
• Dust from TSA desiccant
• Indication mal function.
• TSA bed collapse
 Consequence
• Cold box feed will come down.
 Action
• Change over the filter.
• After change over filter also DP high with new filter then confirm the
bed collapse and shut down the plant.

60
COLD BOX
 Troubleshooting in Cold Box

DP high in 20E-3501A/B for syngas stream (2035PDI-3617A/B)

 Potential cause
1) High moisture in TSA outlet syngas
2) High CO2 in TSA outlet syngas
 Consequence
1) Ice / dry ice formation in 20E-3501A/B which leads blockage of syngas
stream.
 Action
1) If moisture /CO2 is high in syngas to cold box, take actions as
mentioned in the respective troubleshooting.
2) If DP is >500 mbar, cutoff syngas to cold box and derime the cold box

62
 Troubleshooting in Cold Box

Low temperature in syngas or methane streams (<-182°C)

 Potential cause
• Extreme cooling in cold box
 Consequence
• Methane will solidify If temperature is < -182°C
 Action
• Control the cooling effect in cold box by reducing expander
speed, methane purge, liquid nitrogen.
• If methane solidifies , flow will be restricted ,then warm that
stream till get all temperatures normal.

63
 Troubleshooting in Cold Box
Raw Hydrogen purity low (<95%)
 Potential cause
1) Syngas temperature high at inlet to methane wash column (>-176°C)
2) Low Methane reflux flow to methane wash column (2035FIC-1679)
3) 3rd column bottom temperature low (<-145°C)
4) Liquid CO stand pipe level low
 Consequence
1) Effect raw hydrogen purity.
2) Loss of CO production
 Action
1) maintain syngas inlet temperature (2035TI-4627) to methane wash
column ~ -176°C to -178°C
2) If methane reflux is low then increase off set value 2000HIC-6298 in ALC.
3) maintain 3rd column bottom temperature ~ -144° to -145°C by adjusting
2035FIC1658/2035FIC1693/2035HIC2650A.
4) Maintain liquid CO stand pipe level to get 20E-2503 temperatures.
64
 Troubleshooting in Cold Box
High CO in cold box tail gas (>20%)
 Potential cause
1) Low Methane reflux flow to hydrogen stripper(2035FIC-1678)
2) Hydrogen stripper bottom temperate high (>-155°C)
3) 3rd column bottom temperature low (<-145°C)
4) Excess nitrogen purge flow
 Consequence
1) Loss of CO production to tail gas
 Action
1) Maintain hydrogen stripper temperature profile by 2035HIC-4639/2035FIC-
1657.
2) Maintain sufficient methane reflux flow to hydrogen stripper
3) maintain 3rd column bottom temperature ~ -144° to -145°C by adjusting
2035FIC1658/2035FIC1693/2035HIC2650A.
4) Adjust nitrogen purge from 20C-3504 according to 2035AI-5003C
5) If require reduce LP CO flow to 20C-3504.
65
 Troubleshooting in Cold Box
Methane wash column DP high (2035PDI-3633)

 Potential cause
1) 20C-3501 bottom level very high ( 2035LIC-2635A/2636A)
2) Excess methane reflux flow (2035FIC-1679)
 Consequence
1) Liquid will carry over through raw hydrogen stream.
2) Chance to damage of beds in methane wash column)
 Action
1) Check opening and flow of 2035FIC-1679), if it is high reduce it.
2) If bottom level transmitters are mal function, calibrate it.

66
 Troubleshooting in Cold Box
Hydrogen stripping column DP high (2035PDI-3649)

 Potential cause
1) 20C-3502 bottom level very high ( 2035LIC-2650)
2) Excess methane reflux flow (2035FIC-1678)
 Consequence
1) Liquid will carry over through tail gas.
2) Chance to damage of beds in hydrogen stripping column)
 Action
1) Check opening and flow of 2035FIC-1678), if it is high reduce it.
2) If bottom level transmitters are mal function, calibrate it.

67
 Troubleshooting in Cold Box
Hydrogen stripping column bottom temp. low (<-160°C)

 Potential cause
1) Less re-boiling flow (2035FIC-1657)
2) Stripper feed temperature low (2035TIC-4639)
 Consequence
1) Dissolved hydrogen will escape to CO/CH4 column)
 Action
1) Adjust CO re-boiling flow
2) Increase stripper feed temperature (2035TIC-4639)

68
 Troubleshooting in Cold Box
CO/CH4 column DP high (2035PDI-3668)

 Potential cause
1) 20C-3502 bottom level very high ( 2035LIC-2673A/B)
2) Hydrogen stripping column bottom temperature low
 Consequence
1) Methane will carry over to CO/N2 column.
2) Chance to damage of beds in CO/CH4 column)
 Action
1) If bottom level transmitters are mal function, calibrate it.
2) Maintain hydrogen stripping column bottom temperature ≈ -158°C

69
 Troubleshooting in Cold Box
CO/CH4 column bottom temperature low (<-145°C)

 Potential cause
1) Low CO re-boiling flow (2035FIC-1658)
2) High reflux flow (2035FIC-1693)
 Consequence
1) Loss of production as CO will carry over to cold box tail gas.
2) Raw hydrogen purity will effect due to high CO in liquid methane.
 Action
1) Adjust reflux flow through 2035FIC-1693.
2) Adjust re-boiling flow 2035FIC-1658)
3) Adjust feed ratio 2035HIC-2650A.
4) Maintain column bottom temperature around -144°C.

70
 Troubleshooting in Cold Box
CO/N2 column pressure low
 Potential cause
1) High nitrogen purge flow (2035FIC-1698)
2) Mal function of purge flow indication.
3) Mal function of pressure indication (2035PIC-3698)
4) %Nitrogen in sales gas is very low.
 Consequence
1) Methane pump suction head will effect.
2) Methane will carry over to CO/N2 column.
3) CO/CH4 column bottom level come down
 Action
1) Check nitrogen purge flow and column pressure.
2) If nitrogen in sales gas is very low and CO/N2 column pressure
3) Adjust 2035PDIC-3685.
4) could not able to control then inject required nitrogen to CO/N2 column through
2035FIC-1400.
71
 Troubleshooting in Cold Box
CO/N2 column DP high

 Potential cause
1) Column bottom level high (2035LIC-2690)
2) High LP CO re-boiling flow (2035FIC-1620)
3) Mal function of 2035PDV-3685.
 Consequence
1) CO will carry over through nitrogen purge
2) Column beds will damage
 Action
1) Check bottom level of the column 2035LIC-2690, if required calibrate
it.
2) Adjust LP CO re-boiling flow (2035FIC-1620)

72
 Troubleshooting in Cold Box
Methane pump is not developing pressure
 Potential cause
1) CO/CH4 column bottom level low / mal function
2) CO/CH4 column bottom temperature high
3) Suction strainer blockage.
4) Pump suction temperature high due to poor insulation.
5) Suction 2035XV-6674 mal function.
6) Vapor lock.
7) Minimum flow valve mal function.
8) Other mechanical problems.
 Consequence
1) Cloud not able to pump liquid methane to 1st , 2nd columns & purge.
 Action
1) Check CO/CH4 bottom level, if required calibrate it.
2) Check 2035XV-6674 and minimum flow control valve.
3) Check pump suction temperature, check column bottom temperature.
4) Bleed the vapor lock through pump discharge PSV bypass valve.
5) Change over the pump.
6) Identify other mechanical problems if any.
73
CO COMPRESSOR
 Troubleshooting in CO compressor
Inter stage temperature are high
 Potential cause
1) Cooling water supply temperature is high
2) Inter stage coolers exchangers fouling.
 Consequence
1) inter stage temperatures are high then mass flow through the compressor
will come down which leads to surging of the compressor.
2) Leads to trip of compressor with high discharge temperatures
3) Chance to carbon formation if the temperature is >125°C
 Action
1) Check cooling water supply temperature and pressure from UTOS
2) If required increase cooling water flow to inter stage coolers
3) If the temperatures are not come in to range then reduce the load on the
compressor
4) If the exchangers are fouling then check condition of the compressor and if
required shut down the compressor and clean the exchangers.
75
 Troubleshooting in CO compressor
Discharge pressure low 2035PI-3809/12
Potential cause
1)Low suction pressure
2)Guide vane valves (2035PIC-3801/02/09/12) malfunction
3)Anti surge valves (2035FV-1801/02/03) malfunction
4)Mal function of parameters which are going to CCC
5)Suction strainers blockage (1st/ 3rd/6th stages)
6)Gas density low
7)3rd /6th suction check valves struck
Consequence
1)Could not able to supply CO to OXO gas
2)Insufficient seal gas flows to primary seals witch leads damage of seals.

76
 Troubleshooting in CO compressor
Discharge pressure low 2035PI-3809/12
Action
1)Check suction pressure of the compressor, adjust anti-surge valves
opening according to surge deviation.
2)Check opening of all guide vanes and ASV n field, if any deviation, fix it.
3)Check all parameters which are going to CCC, if any deviation fix it.
4)Check suction strainers DP, if it is high and sufficient flow could not able
to establish thorough compressor then take shutdown and clean the
strainers.
5)If any hydrogen is passing to 1st suction of the compressor then gas
density will change, keep isolate 2035PV-3004A during normal operation.
6)If require check gas sample by lab to confirm any exchangers leaking in
cold box.
7)Check if any check valves are struck at 3rd and 6th suction by comparing
the upstream and down stream pressures.
77
 Troubleshooting in CO compressor

CO compressor surging
Potential cause
1.High suction temperature
2.Low suction pressure
3.Inter stage temperatures are high
4.High discharge pressure
5.Less mass flow though compressor
6.CO density low
7. 2nd /5th /6th discharge flow transmitters wrong indication
8.Anti-surge valve malfunction
9.Guide vane valves (2035PIC-3801/02/09/12) malfunction
Consequence
1.Compressor surging will leads damaging of compressor internal parts.
Action
1.according to root cause take actions as mentioned in related troubleshooting.
2.IF the compressor is surging it will trip automatically by CCC, if not take
immediate shutdown of compressor.
 Troubleshooting in CO compressor

Bearing temperatures are high

Potential cause
1)Lube oil header pressure low
2)Lube oil header temperature is high
3)Moisture in lube oil
4)Fouling of lube coolers.
5)Lube oil quality (viscosity)
6)Mechanical problems
Consequence
1)Leads to damage of bearings
2)Compressor vibrations will increase
 Troubleshooting in CO compressor

Bearing temperatures are high

Action
1)Check lube oil filter DP, if it is > 1.0bar, change over the filter.
2)Still header pressure is low , check PCV functioning.
3)If lube oil header temperature is high, increase cooling water to
lube oil coolers or if required change over the cooler
4)Check if any lube oil heater is mal function.
5)Check lube oil quality by lab ( moisture and viscosity)
6)If moisture is high, connect centrifuge to lube oil console.
7)If any other quality problems, replace the oil.
 Troubleshooting in CO compressor

Low seal gas flow

Low seal gas flow to primary seals Low seal gas flow to secondary seals
 Potential cause  Potential cause
1) Primary Seal gas filter DP high 1) Secondary Seal gas filter DP high
2) Compressor discharge pressure 2) Nitrogen header pressure low
low
 Consequence
 Consequence
1) Low seal gas flow leads to
1) Low seal gas flow leads to
damaging of seals.
damaging of seals.
 Action 2) Chace to enter lube oil in to
1) If primary seal gas filter DP is >1.0 seals
bar, change over the filter.  Action
2) Check compressor discharge 1) Compressor will trip if nitrogen
pressure, if it is low then take pressure is <3.0bar
actions according to above 2) Adjust seal gas flows to
mentioned trouble shooting. individual seals
3) Adjust seal gas flows to individual 3) Check seal leak off pressures.
seals.
81
 Troubleshooting in CO compressor
High moisture in LP CO
 Potential cause
1) 20E-3507 tube leak ( cooling water leaking in to CO)
 Consequence
1) Moisture/water become dry ice in cold box coolers leads to damage
of exchanger in cold box
 Action
1) Confirm on line moisture analyzer indication is correct or not. If
required calibrate it.
2) Confirm moisture by in LP CO by lab analysis
3) If any leak confirmed, take shutdown of cold box and co compressor.

Note: if moisture is coming after immediate start up of compressor, it

could be cause of any of the inter stage cooler leaking.
82
PRESSURE SWING ADSORPTION (PSA)
 Troubleshooting in PSA
Skid valve response delay alarms
 Potential cause
• Mal functioning of any control valve in the skid
 Consequence
• Any PSA skid Valve Alarm leads to Initiation of Process Mode
Changeover Sequence there by defective PSA bed will go to OFF line.
 Action
• There will be disturbance in Product H2 header Pressure (2040PIC-
3003) after Changeover of Process Mode (from 6 PSA beds to 5/4
Beds Operation), immediately reduce product H2 in reformer fuel to
sustain the header pressure.
• Inform Butanol Panel Operator about H2 Pressure fluctuation
• Inform Oxo Panel Operator about to cut off H2 to Oxo Reactors1 & 2
temporarily.
84
 Troubleshooting in PSA
PSA Outlet Product Gas is getting OFF-SPEC
Potential cause
•PSA feed composition change
•Feed temperature high
•Moisture in PSA feed
Consequence
•Impurities in Product H2 will effects OXO and Butanol plant operation.
Action
•Check and Confirm that PSA is not operating more than design load. If operating at
higher loads, reduce PSA feed gas to improve the quality.
•Check and Confirm that PSA feed gas composition is ON-SPEC.,
•Reduce PSA purge gas pressure (2040PIC-3004)
•Check PSA feed temperature, if require open cooling water to 20E-3003.
•Reduce PSA Operation Factor by 0.01 with an interval of 30 minutes.
•Check 20V-3002 physical level, if any deviation fix it.
•Check and Confirm PSA online Analyzers (2040AT-5001A/B/C) are working fine by giving
offline samples.
85
PCRU
 Troubleshooting in PCRU
Collection drum PH & conductivity

PH low Conductivity high

 Potential cause  Potential cause
• Try-act dosing low foreign matter from process
• High dissolved CO2 in process condensate ( either catalyst
condensate dust/other foreign matter)
 Consequence  Consequence
• Equipment Corrosion • Equipment Corrosion
 Action • Scaling formation.
• Adjust try-act pump stroke  Action
depends on online • Adjust try-act pump stroke
analyzer/lab analysis. and vaporizer CBD opening
depends on CBD analysis.

87
 Troubleshooting in PCRU

PCRU Vaporizer level low

 Potential cause
• 2087P-8702 poor pumping
• 2087LV-2002 mal function
• HP steam flow high to vaporizer
• mal functioning of Vaporizer level / Collection drum level
 Consequences
• HP steam to vaporer will close on LL level.
• Effect the steam/feed ratio
• Chance to damage of vaporizer tube bundle.
 Action
• Check 2087P-8702A/B pump performance.
• If require start stand by pump/ change over it.
• If stand by pump back rotation due to check valve passing, isolate its discharge valve.
• Close CBD for vaporizer.
• Check the opening of pump minimum flow valve and 2087LV-2002.
• If 2087LV-2002 mal function, open its bypass valve and control the level.
• Check vaporizer level/collection drum level in field, if any deviation fix it.
88
 Troubleshooting in PCRU

PCRU Vaporizer level high

 Potential cause
• 2087LV-2002 mal function.
• Vaporizer level mal function.
• HP steam flow is low to vaporizer

 Consequences
• Vaporizer HH level leads to stop 2087P-8702 and closes 2087LV-2002
• Carry over of water to process steam

 Action
• Check 2087LV-2002 opening in field, if any devotion, control the level by
throttling its upstream isolation valve.
• Check vaporizer level field, if any deviation fix it.
• Check HP steam flow valve 2087FV-1001, if any issue use its bypass valve.
89
Questions ?
PRASADA RAO