Technical Paper May 2019

Lessons from the Field - Ejector Systems

Author
Mr. Jim Lines
Graham

Summary
Ejector systems provide extremely reliable performance, but they do require periodic maintenance. It
is recommended that routine surveys be performed to document actual behavior and performance of
the ejector system. An ejector system may be performing at less than optimal conditions for a variety
of reasons, such as improper utilities, fouled condensers, mechanical damage, excessive process load,
excessive noncondensible load or improper installation. A skilled vacuum technician, most often from
the ejector system manufacturer, should conduct the routine surveys and issue performance reports.
The performance surveys may be conducted on line without affecting the process. The performance
reports will document actual performance at a point in time, discuss corrective action where applicable
and offer preventative maintenance suggestions.
If performance problems arise, the original supplier of the vacuum system should be consulted. If
necessary, a request should be made for a service engineer to be dispatched to offer support on site.
Actual corrective action to take is situation dependent and requires a thorough understanding of
variables that influence ejector system performance.

1
 LESSONS FROM THE FIELD
- EJECTOR SYSTEMS
James R. Lines, Graham Corporation,
USA, presents the problems associated
with ejector system performance and
subsequent solutions.

Figure 1. Ejector cross-sectional drawing

pressure.
Hydrocarbon Engineering has previously reported on ejector system
fundamentals, operating characteristics, and guides for Both precondenser and vacuum system were supplied by the ejector
troubleshooting1. Moving on from that stage, the current article provides system manufacturer. The manufacturer dispatched a service engineer
real world ejector system performance limitations uncovered during to the site to survey the equipment and its performance. Figure 3
routine performance surveys. Corrective action undertaken to improve depicts the pressure profile of the equipment.
performance is documented and discussed in detail. Principles from the
initial article are used as the tools to define the cause of a particular The service engineer initially inspected vapor piping and condensate
limitation and the eventual solution. It should be noted that the corrective drain legs to ensure equipment layout was satisfactory. Attention was
actions described were unique to the particular problems discussed. It then focused on the utilities. Motive steam pressure was measured at
will not always be possible to apply the same procedure to a the inlet to each ejector, and actual motive steam supply pressure to the
comparable performance problem. A review of general corrective ejectors was 140 psig (9.7 barg). The ejector motive steam nozzles
techniques is discussed where applicable. Ejector system were designed to pass the required steam at 125 psig (8.6 barg).
manufacturers should be consulted as a first course of action, and Although the motive steam pressure was above design and,
guide fixes are often possible. consequently, more steam was being consumed by the ejectors, the
Survey 1 - nylon intermediate production excessive steam consumption was not enough to cause poor
performance.
facility
Nitrogen gas bleed for pressure control The cooling water inlet temperature to the condensers was below
A North American petrochemical company manufacturing nylon design, and temperature rise across each condenser was less than
intermediates was operating a vacuum flasher supported by a the design. Inlet cooling water was designed for 89.6 °F (32 °C) and the
precondenser and two stage ejector system. Overhead load from the water flowed in series from the first intercondenser to the
vacuum flasher consisted of 160 000 pph (72 600 kg/hr) of mixed aftercondenser. The actual inlet water was at 85 °F (29.4 °C). The total
nitriles at a pressure of approximately 35 torr. temperature rise across both condensers at design was 29 °F (16.1
°C). The actual temperature rise was 13 °F (7.2 °C). The lower
The precondenser produced adequate vacuum, but the two stage temperature rise would suggest greater cooling water usage or lower
ejector system that extracted non-condensibles from the precondenser condensible vapor discharge from the precondenser, neither of which
was performing in an unstable manner. Suction pressure of the first would cause poor ejector system performance.
stage ejector was cycling between the design 35 torr and up to as high
as 75 - 80 torr. An ejector system experiencing unstable suction pressure is typically
operating in a broken mode. Broken ejector performance is often
Vacuum flasher pressure was unaffected by the ejector instability, caused by low motive steam pressure, which has already been ruled
however, plant personnel had concerns that poor ejector performance out, a fouled intercondenser, high cooling water temperature or water
may at some point have a negative impact on vacuum flasher operating flow, both of which have been ruled out, non-condensible loading.

While inspecting the ejector system, the service engineer noticed a

periodic audible change in ejector operation. This audible change plus
an unstable suction and discharge pressure first stage ejector
confirmed that this particular ejector was the trouble

The service engineer noticed plant personnel had installed a

pneumatically controlled control valve that bled nitrogen to the suction
of the first stage ejector. Plant personnel installed a nitrogen bleed as a
means of controlling suction pressure to allow the vacuum flasher to
operate at a consistent pressure even at reduced charge rates.
Pressure in the top of the vacuum flasher was sensed and a signal
sent to the control valve to bleed nitrogen to the first stage ejector if the

Figure 2. Precondenser to left of vacuum flasher

vacuum flasher pressure fell below design. Bleeding nitrogen, which is
non-condensible, to the suction of a multi-stage condensing ejector Once the first stage ejector began to handle more non-condensible
system will result in unstable performance. loading than it was designed for, the down-stream ejector could not
handle that increased non-condensibles, plus the proportionate
An ejector system is designed to handle non-condensible loading increase in vapors of saturation, at the achievable discharge pressure
associated with the process. Ejectors downstream of the first of the first stage ejector. This discontinuity in the achievable discharge
intercondenser are designed to handle process related non- pressure of the first stage ejector and suction pressure maintained by
condensibles and associated vapors of saturation. Bleeding in nitrogen the second stage ejector based on higher non-condensible loading
to act as an artificial load for the first stage ejector and to elevate resulted in the first stage ejector breaking operation.
suction pressure resulted in non-condensible overloading of the
downstream ejector, which is the ejector that is downstream of the The service engineer instructed plant personnel to dis-assemble the
first intercondenser. nitrogen bleed arrangement and to install recycle control piping around
the first stage ejector. For any multi-stage condensing ejector system,
the preferred way to maintain performance and suction pressure is to
Design Values
40 torr recycle discharge from an ejector immediately preceding the first
34 torr Actual Values intercondenser back to the suction of the system. In this way, non-
36 torr
condensible loading is never allowed to increase above design, thus
33-75 torr
ensuring broken ejector operation will not occur. Again, vacuum flasher
PIC pressure is sensed and a signal sent to the recycle control valve,
Vacuum Flasher
which will modulate and permit the recycle of vapor flow back to the
1 st Stage Ejector
suction of the first stage ejector. Once the plant installed this form of
Precondenser recycle control, stable ejector operation was maintained.

A caveat for this correction is that the most practical method of

228 torr

N 2 Supply 240 torr

controlling operating pressure of a precondenser/ejector system is to
200-262 torr
control cooling water flowrate. Cooling water flowrate may be reduced
279 torr
when process charge rate is below design. By lowering water
flowrate, the water temperature rise across the precondenser will
increase, which has the effect of lowering the Imtd. Controlling lmtd will
1 st Intercondenser
control operating pressure of the precondenser.
2 n d Stage Ejector

940 torr The recycle control arrangement suggested and used to correct first
773 torr stage ejector instability will not work if the operating pressure of a
precondenser permits condensation of steam. The composition of
Aftercondenser
recycle flow around an ejector consists of non-condensibles plus
steam. As the recycle flow is brought around to the suction of the first
Figure 3. Survey 1 pressure profile stage ejector, the recycled steam will be drawn to the precondenser if
the operating pressure permits condensation of steam. When this
10 torr Design Values occurs and recycled flow goes to the precondenser rather than
8-13 torr Actual Values through the first stage ejector, control of suction pressure is not
possible.

1 st Stage Ejector
Survey 2 - West Coast fuels refinery
Vacuum
Distillation
Unit 65 torr Improper replacement intercondenser
50-70 torr
A West Coast refiner was operating a fuels vacuum distillation unit that
experienced erratic performance after replacing an intercondenser
supplied by the original ejector system manufacturer with one designed
st
1 Intercondenser
and built by a local heat exchanger fabrication shop. The as sold
nd
system was designed to provide performance described in Figure 4.
62 torr 2 Stage Ejector
The service engineer had no prior knowledge that the user installed a
46-60 torr replacement intercondenser.

230 torr The first stage ejector was operating in a broken mode, with both
suction and discharge pressure remaining unstable. Furthermore,
shellside pressure drop across the first intercondenser was almost
2n d Intercondenser three times the design pressure drop.
Motive steam supply condition was approximately at the design value,
3r d Stage Ejector
so the service engineer ruled out inadequate steam pressure. High
215 torr
pressure drop across the first intercondenser would suggest a fouling
problem, cooling water flowrate limitation, high inlet water temperature,
800 torr high noncondensible loading, or excessive hydrocarbon loading. Prior
to detailing a method to determine the actual cause, the service
engineer discussed general performance characteristics with unit
Aftercondenser operators. At that time, it was discovered that the first intercondenser
was replaced.
Figure 4. Survey 2 pressure profile
 Design Values
resulted in a design having fully baffled flow, and consequently,
Turbine Actual Values excessive pressure drop on the vapor side.

75 torr
In this particular instance, high pressure drop across the shellside
113 torr
Surface Condenser caused the system to break performance. The first stage ejector could
not overcome the added pressure drop and reach a discharge
pressure where the second stage ejector would operate. This
1 st Stage Ejector discontinuity resulted in the first stage ejector breaking operation,
50 torr
which was characterized by unsteady suction pressure and back-
113 torr
156 torr Excessive
streaming of motive steam into the vacuum distillation tower. Both
Vapor Plume performance conditions were unsatisfactory to the refiner.
250 torr

Although the plant engineers were reluctant to accept that the

2 nd Stage Ejector condenser was the problem, they did agree to install a new condenser
designed by the ejector system manufacturer. Once the properly
designed condenser was installed and the system restarted,
Combined
Inter/Aftercondenser performance returned to a satisfactory level.
Figure 5. Survey 3 pressure profile.
Survey 3 - Canadian ammonia/urea fertilizer
10 torr Design Values complex
24-25 torr Actual Values

An ammonia plant syngas compressor provided less than design

horsepower due to high back pressure from a condensing turbine
1 st Stage Ejector
steam surface condenser. The turbine exhaust condenser maintained
113 torr back pressure, but based on the cooling water temperature,
Vacuum 100 torr
Distillation the expected back pressure should have been 75 torr. A service
Unit
114-124 torr
1 st Intercondenser engineer was dispatched to the site to evaluate the steam surface
condenser and exhauster performance to determine the cause of the
elevated back pressure.

95 torr 2 nd Stage Ejector

The steam surface condenser was supported by a two stage ejector
105-115 torr system condenser exhauster (Figure 5). The service engineer noticed
292 torr
a substantial exhaust plume from the aftercondenser vent.
249-253 torr

Normally, steam surface condenser and exhauster systems are

2 nd Intercondenser
vacuum tight, with air inleakage less than Heat Exchange Institute
3 rd Stage Ejector design values, with typical air inleakage of 5 Ibs/hr or less. An
280 torr
excessive exhaust plume from an aftercondenser does suggest high
248-252 torr
890 torr air inleakage. There was an air leakage meter installed on the vacuum
864 torr
system, and when activated, the measurement was off the scale.
1 st Intercondenser Isolated
The service engineer elected to isolate the surface condenser from the
100 torr 95 torr Aftercondenser
ejector system. By isolating the surface condenser, it would be
114-124 torr 105-115 torr
possible to determine if excessive air leakage was from the surface
condenser or upstream piping, or if it was within the exhauster itself.
Once a surface condenser is isolated from a vacuum system and the
5 psi operating pressure of the condenser does not appreciably increase
∆ P Tubeside
104 torr
25 psi
90 torr
over time, the air inleakage must be downstream of the surface
105 torr 86 torr
condenser.

Figure 6. Pressure and temperature profile. The condenser was isolated from the vacuum system and pressure
stayed fairly constant. This confirmed the air inleakage was
Upon visual inspection of the installed unit and its name-plate, the downstream of the condenser and that it was in the exhauster system.
service engineer realized it was the design of another vendor. That A closer look at the installation determined that a l/4 in. instrument
vendor did match the original intercondenser’s tube count and external connection was left open and was not plugged. Evidently, a pressure
dimensions, but after a thorough review of fabrication drawings, it was gauge was damaged and plant personnel removed it but failed to
evident the vendor failed to design the shellside baffling properly to replace it. The open connection permitted substantial quantities of air to
manage hydraulic and thermal requirements. Vacuum condensers have leak into the ejector system and cause poor operation. The condenser
special shell side baffling to ensure minimal pressure drop, non- was then brought on line once the connection was plugged and after
condensible gas cooling, and separation of non-condensibles and the system was allowed to stabilize, steam surface condenser
condensate. It is typical to have different baffle spacing at strategic operating pressure reached 80 torr, which was in the range of what
locations within the shell of a vacuum condenser or to incorporate a was expected. The syngas compressor returned to full power once
long air baffle design. The vendor who replaced the intercondenser this correction was made.
used conventional software to model the performance. This in turn
Survey 4 - Gulf Coast refinery optimal conditions for a variety of reasons,
such as improper utilities, fouled
condensers, mechanical damage,
Fouled intercondenser excessive process load, excessive non-
A Gulf Coast refiner was operating a damp crude condensible load or improper installation.
vacuum distillation tower that was designed for 10
torr tower top pressure but was maintaining only 24 A skilled vacuum technician, most often
-25 torr. The first stage ejector was surging and from the ejector system manufacturer,
back-streaming into the vacuum distillation unit. A should conduct the routine surveys and
factory service engineer was dispatched to the site issue performance reports. The
to perform a system survey and evaluate causes of performance surveys may be conducted
the poor performance. on line without affecting the process. The
performance reports will document actual
Figure 6 documents as sold performance and what performance at a point in time, discuss
was measured in the field. corrective action where applicable and
offer preventative maintenance
Broken first stage ejector performance may be suggestions.
Figure 7. First stage ejectors for
caused by improper motive steam pressure, elevated
inlet cooling water temperature, lower than design CVDU. If performance problems arise, the original
cooling water flowrate, a fouled first intercondenser, or poor operation supplier of the vacuum system should be
of a downstream ejector. The performance survey indicated motive consulted. If necessary, a request should be made for a service
steam supply conditions were satisfactory. Cooling water temperature engineer to be dispatched to offer support on site. Actual corrective
rise and pressure drop across the first intercondenser suggested the action to take is situation dependent and requires a thorough
problem was here. understanding of variables that influence ejector system performance.

Design cooling water temperature rise across the first intercondenser References
was 14 °F (7.8 °C), however, the actual temperature rise was 19 °F 1 LINES J R and SMITH R T, Ejector system troubleshooting,
(10.6 °C). Possible causes for an elevated temperature rise would be Hydrocarbon Engineering, Part 1 January/February 1997 pp. 69 - 78 ,
lower than designed cooling water flow or an increase in condensible Part 2 March/April 1997 pp 35 - 40
load to the condenser. Pressure drop across the tubeside of the con- Palladian Publications 1999
denser gave an indication that something was wrong. The actual
tubeside pressure drop was 25 psi (1.7 bar) while the design was only
For More Information
5 psi (0.35 bar).
Please Contact:
The tubeside of the condenser was fouled and the increased pressure
drop across the condenser caused the recirculating pumps to circulate
less water. Tubeside fouling to produce such an elevated pressure Graham Corporation
drop would be severe and actual tube blockage must have occurred.

Tubeside fouling deterred heat transfer and did not permit proper
20 Florence Avenue
condensation of shell side vapors. This increased the pressure drop on Batavia, New York 14020
the shell side of the condenser and elevated its operating pressure. By
USA
not permitting proper condensation of shellside vapors, the increased
outlet flow of vapors caused an increase in pressure drop.
Telephone: 716 343 2216 Fax: 716 343 1097
The first stage ejector could not overcome the elevated shell side
pressure drop and, consequently, broke operation. The broken Website: http/www.graham-mfg.com
operation resulted in unstable suction pressure, surging and back-
streaming of motive steam into the vacuum distillation unit. The first
intercondenser was pulled from the platform and taken down to grade.
At grade, the bundle was removed to inspect the shell side for fouling
and to rod out the tubes. The shell side did not experience excessive
fouling, but the tubeside had tubes blocked with solidified calcium
carbonate and other inverse solubility salts.

Once the tubeside was cleaned and returned to acceptable condition,

the bundle was reinstalled in the condenser, and the condenser taken
up to the vacuum unit for re-hook up. When the system was brought in
service, the tower top pressure was maintained at approximately 10
torr and system performance was stable.

Conclusion
Ejector systems provide extremely reliable performance, but they do
require periodic maintenance. It is recommended that routine surveys
be performed to document actual behavior and performance of the
ejector system. An ejector system may be performing at less than