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GE centrifugal compressors.pdf

This document provides an overview of centrifugal compressors and their components. It discusses what a compressor and gas are, and how compression is used to transport gas for various oil and gas industry applications. The key components of a centrifugal compressor are described, including the rotating parts like the shaft, impellers, and balance drum, and the static parts such as casings, diaphragms, bearings, seals, and flanges. Designs like vertically split, horizontally split, and single volute compressors are also covered.

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Introduction General description and main features GE Oil & Gas Oil & Gas Industry Applications
Customer Training 2 Centrifugal Compressor Training Course 22/11/2012 What is a Compressor? A machine used to increase the pressure of a GAS Introduction Customer Training
Customer Training 3 Centrifugal Compressor Training Course 22/11/2012 What is a Gas? Gas is one of the three classical states of matter characterized by molecular weight (MW), pressure (p) and temperature (T) Introduction Customer Training
4 Centrifugal Compressor Training Course 22/11/2012 Customer Training Gas compression Gas ps Gas pd Mechanical power Introduction
Customer Training 5 Centrifugal Compressor Training Course 22/11/2012 What we need to compress a gas? For many reasons: to transport it, to enhance an oil field production, etc… Introduction
6 Centrifugal Compressor Training Course 22/11/2012 Customer Training Compression Services Pipeline inspection device Offshore production platform Subsea equipment Oil/Gas field Re-injection plant Oil / gas processing plant LNG receiving plant LNG liquefaction plant Gas boosting station Oil boosting station Power generation plant Natural Gas storage plant Refinery / Petrochemical / fertilizer plant
7 Centrifugal Compressor Training Course 22/11/2012 Customer Training Compression Services Distribution Midstream Downstream Upstream • Exploration & Production  Re-injection  Gas Lift  Gas Gathering  Export Gas •Gas Plants  Feed Gas  Gas Treatment • LNG  Mixed Refrigerant  Propane • Pipelines  Gas Boosting  HP Transport  Gas Storage (Injection + withdrawal) • Refinery  HCU, HDT, HDS  Recycle  Air Feed  FCC • Petrochemical/ Fertilizers  Syngas (Ammonia, Methanol)  Refrigeration  CO2 Compression (Urea)  Feed Gas  Charge Gas  Ethylene & derivatives • NGV Re-fuelling  Cubogas
Nuovo Pignone Compressors GE Oil & Gas Oil & Gas Industry Applications
9 Centrifugal Compressor Training Course 22/11/2012 Customer Training Vertically split Compressors overview
10 Centrifugal Compressor Training Course 22/11/2012 Customer Training Horizontally split Compressors overview
11 Centrifugal Compressor Training Course 22/11/2012 Customer Training Single Volute Compressors overview
12 Centrifugal Compressor Training Course 22/11/2012 Customer Training Nuovo Pignone TAGs BCL 406 2 Compressors overview
13 Centrifugal Compressor Training Course 22/11/2012 Customer Training Nuovo Pignone TAGs BCL 406 Casing B=barrel P=pipeline M=Middle Split S=single volute Impeller design C=closed R=open Diffuser L=free vortex (not vaned) 2 Literal Part Compressors overview
14 Centrifugal Compressor Training Course 22/11/2012 Customer Training 2 BCL 406 BCL 406 /A Casing design pressure rating  N p<150 bar  A p<200 bar  B p<300 bar  C p<400 bar  D p<550 bar  E p up to 1000 bar Barrel Type Compressors overview
15 Centrifugal Compressor Training Course 22/11/2012 Customer Training  Pipeline compressors are designed to maximize compression efficiency over the broad range of operating conditions required by gas pumping stations;  Suction and discharge nozzles for gas transportation are generally located opposite each other to meet station layout requirements. pmax 150 bar PCL 406 Pipeline Type Compressors overview
16 Centrifugal Compressor Training Course 22/11/2012 Customer Training Low pressure applications 2 MCL 406 Middle Split Type Compressors overview
17 Centrifugal Compressor Training Course 22/11/2012 Customer Training SRL Integrally geared Single stage  Impeller overhung mounted on the shaft;  Each impeller has the discharge volute. Single Volute Type Compressors overview
18 Centrifugal Compressor Training Course 22/11/2012 Customer Training IMPELLERS design R= open type C= closed type 2 BCL 406 Compressors overview
19 Centrifugal Compressor Training Course 22/11/2012 Customer Training Free vortex DIFFUSER Diffuser No fixed blades 2 BCL 406 Compressors overview
20 Centrifugal Compressor Training Course 22/11/2012 Customer Training Nuovo Pignone TAGs BCL 406 n. of impellers Nominal diameter of the impeller Section arrangment 2 Numerical Part Compressors overview
21 Centrifugal Compressor Training Course 22/11/2012 Customer Training Nominal size (mm) 400 mm BCL 406 2 Compressors overview
22 Centrifugal Compressor Training Course 22/11/2012 Customer Training BCL...MCL... Section arrangment suction discharge  One compression section;  In line configuration. Compressors overview
23 Centrifugal Compressor Training Course 22/11/2012 Customer Training 2 BCL... 2 MCL... Section arrangment 1 st suction 1 st discharge 2 nd suction 2 nd discharge  Two compression sections in a single casing;  Back to back configuration;  Cooling of the gas;  Tmax 250°C. Compressors overview
24 Centrifugal Compressor Training Course 22/11/2012 Customer Training 3 BCL... 3 MCL... Section arrangment  More than two compression sections in a single casing;  Sidestreams. suction discharge sidestreams Compressors overview
25 Centrifugal Compressor Training Course 22/11/2012 Customer Training D BCL... D MCL... Section arrangment suction discharge  Two compression sections in parallel in the same casing; Compressors overview
26 Centrifugal Compressor Training Course 22/11/2012 Customer Training Technology Selection Map Compressors overview
Compressor rotating parts GE Oil & Gas Oil & Gas Industry Applications
28 Centrifugal Compressor Training Course 22/11/2012 Customer Training Rotating parts Shaft Thrust Collar Impellers Spacers Balance drum Coupling hub
29 Centrifugal Compressor Training Course 22/11/2012 Customer Training Thrust Collar  Transmits the rotor thrust to the thrust bearing;  Fixes the axial position of the rotor;  Hydraulically shrink-fitted to the shaft;
30 Centrifugal Compressor Training Course 22/11/2012 Customer Training Impeller The function of the impeller is to add energy to the gas.
31 Centrifugal Compressor Training Course 22/11/2012 Customer Training Impeller In order to minimize erosion and corrosion effects on impeller due to pitting or fouling phenomenon related to gas composition, it is possible to use special stainless steel alloy with Ni-Cr-Mo or apply a specific protective coating.
32 Centrifugal Compressor Training Course 22/11/2012 Customer Training The blades are bended Impeller The blades are bended and twisted Impellers are fully customized
33 Centrifugal Compressor Training Course 22/11/2012 Customer Training Balancing Drum  Balances part of the axial thrust;  Interference fitted and keyed;  Positioned after the last impeller;  Holes for rotor balancing.
34 Centrifugal Compressor Training Course 22/11/2012 Customer Training Coupling FLEXIBLE DRY type design is mostly used by NP HUB No lubrication is needed Connects elements between compressor and the remaining equipment of a compressor train.
35 Centrifugal Compressor Training Course 22/11/2012 Customer Training Coupling Basically a flexible coupling has the following functions: 2. Accommodate Parallel Offset and/or Angular misalignment 1. Physically connect two rotating shafts 3. Compensate for axial movement of coupled shafts
Compressor stator parts GE Oil & Gas Oil & Gas Industry Applications
37 Centrifugal Compressor Training Course 22/11/2012 Customer Training Stator parts Diaphragms Bearings Seal End cover Flanges and Nozzles Bearings
38 Centrifugal Compressor Training Course 22/11/2012 Customer Training Stator parts
39 Centrifugal Compressor Training Course 22/11/2012 Customer Training BCL: Casing-Diaphragms LOWER HALF UPPER HALF
40 Centrifugal Compressor Training Course 22/11/2012 Customer Training Casing-Diaphragms: bundle Diaphragms
41 Centrifugal Compressor Training Course 22/11/2012 Customer Training Casing-Diaphragms: bundle Labyrinth seals Diffuser Return channel Blades Impeller
42 Centrifugal Compressor Training Course 22/11/2012 Customer Training Casing-Diaphragms: bundle Suction volute Discharge volute In new barrel compressors the inlet and disharge volutes are separated from the inermediate diaphragms.
43 Centrifugal Compressor Training Course 22/11/2012 Customer Training Casing-Diaphragms: bundle The upper half of the bundle is lowered on the lower half.
44 Centrifugal Compressor Training Course 22/11/2012 Customer Training Horizontally split The diaphragms are installed in the casing without a countercasing
45 Centrifugal Compressor Training Course 22/11/2012 Customer Training Flanges and nozzles Discharge Sideflow Suction Discharge Suction
46 Centrifugal Compressor Training Course 22/11/2012 Customer Training Flanges and nozzles In the barrel type for high or very high pressure, piping is directly connected to the casing without nozzles;
47 Centrifugal Compressor Training Course 22/11/2012 Customer Training Shear and Shim rings Shear ring Shim ring Locking system using shear and shim rings
48 Centrifugal Compressor Training Course 22/11/2012 Customer Training Head cover The functions of the head cover are:  Close the bundle inside the casing;  Guide the flow;
49 Centrifugal Compressor Training Course 22/11/2012 Customer Training Bearings Thrust bearing  Direct Lubricated: lube oil is provided for each pad through a groove manufactured on the pads  Flooded: Oil fills the bearing assembly and drains from the top through a flow control orifice Tilting pads type are adopted. The function of the thrust bearing is to compensate part of the axial thrust.
50 Centrifugal Compressor Training Course 22/11/2012 Customer Training Thrust Bearings Components Thrust bearing are self equalizing: the bearing distributes the load equally between all pads. Thrust shoes Base ring Leveling plates Thrust collar Pivot
51 Centrifugal Compressor Training Course 22/11/2012 Customer Training Journal Bearing Jourbal bearing Tilting pads type are adopted. The functions of the journal bearing are:  Support the rotor weight  Create a lifting effect  Damping effect Two types of possible lubrication:  Direct lubrication: Lube oil is provided for each pad through a groove manufactured on the pads  Flooded lubrication: The oil enter from an orifice in the upper part of the bearing and exits in the lower part after the lubriction of pads.
52 Centrifugal Compressor Training Course 22/11/2012 Customer Training Journal Bearing Bearings pad Bearings casing Pivot
Centrifugal Compressor Gas Path GE Oil & Gas Oil & Gas Industry Applications
54 Centrifugal Compressor Training Course 22/11/2012 Customer Training SUCTION DISCHARGE Gas Path
55 Centrifugal Compressor Training Course 22/11/2012 Customer Training Shaft Inlet Volute Fin Casing Blade Impeller Suction Nozzle Suction Pipe Suction The gas flow is directed towards the eye of the first impeller.
56 Centrifugal Compressor Training Course 22/11/2012 Customer Training Suction
57 Centrifugal Compressor Training Course 22/11/2012 Customer Training Labyrinth Seal Suction diaphragm Labyrinth Seal Shaft Key Disk Suction
58 Centrifugal Compressor Training Course 22/11/2012 Customer Training Intermediate stages
59 Centrifugal Compressor Training Course 22/11/2012 Customer Training Single stage Labirinth seals Diffuser Return channel Blades
60 Centrifugal Compressor Training Course 22/11/2012 Customer Training C3=C1 optimal condition Gas Inlet Increased velocity P4,C4 P1,C1 P2,C2 P3,C3 + + + ++ + Single stage
61 Centrifugal Compressor Training Course 22/11/2012 Customer Training Single stage Impeller Inlet Blade Inlet Diffuser Inlet Diffuser Outlet Velocity Pressure Energy 1 2 3 4 1 2 3 4
62 Centrifugal Compressor Training Course 22/11/2012 Customer Training Last impeller Discharge volute Discharge
Centrifugal Compressor Axial Thrust GE Oil & Gas Oil & Gas Industry Applications
64 Centrifugal Compressor Training Course 22/11/2012 Customer Training Axial Thrust Axial thrust P2 > P1 P2 P2 P1
65 Centrifugal Compressor Training Course 22/11/2012 Customer Training Axial Thrust Balancing Drum The BALANCE DRUM is a disk installed after the last impeller in order to balance part of the axial thrust (80÷85%).
66 Centrifugal Compressor Training Course 22/11/2012 Customer Training Axial Thrust P2 P1 P2 Ps R1 R2 Rd Axial Force Drum Force
67 Centrifugal Compressor Training Course 22/11/2012 Customer Training Axial Thrust Balancing Line Ps Pd Ps+ΔP Ps= Suction Pressure Ps = Discharge Pressure ΔP= Pressure Drop on balancing line Axial Force Drum Force
68 Centrifugal Compressor Training Course 22/11/2012 Customer Training Balancing line
Centrifugal Compressor Performance Curves GE Oil & Gas Oil & Gas Industry Applications
70 Centrifugal Compressor Training Course 22/11/2012 Customer Training Performance Curves  Polytropic Head  Polytropic Efficiency  Pressure Ratio  Power  Discharge Temperature  Discharge Pressure Performance curves describe the relation of the centrifugal compressor operating parameter and the inlet capacity. The performance curves are valid ONLY for the condition specified in the performance diaghram... Qinlet
71 Centrifugal Compressor Training Course 22/11/2012 Customer Training Operating Range Maximum continuous speed (MCS) Minimum operating speed (MOS) Discharge pressure (bar a) Normal operating point Qinlet Choking Area Surge Limit Line
72 Centrifugal Compressor Training Course 22/11/2012 Customer Training Operating point Plant resistance curve Operating point  The plot represents the envelope of all the possible operating conditions relevant to the given suction parameter.  The actual operating point is unique and it is always the intersection between the compressor curve at the given speed and the plant resistance curve. Qinlet
73 Centrifugal Compressor Training Course 22/11/2012 Customer Training
74 Centrifugal Compressor Training Course 22/11/2012 Customer Training Off-design conditions Discharge pressure MW MW Qinlet Ts Ts Ps Ps
75 Centrifugal Compressor Training Course 22/11/2012 Customer Training Other map variation cause: Normal working graph Internal recycles effect Discharge pressure Qinlet
76 Centrifugal Compressor Training Course 22/11/2012 Customer Training According to API 617 the following regulating methods are defined:  Speed Variation  Suction throttling  Variable inlet guide vanes (VIGV)  Discharge blowoff  Cooled bypass Regulation
77 Centrifugal Compressor Training Course 22/11/2012 Customer Training Discharge pressure Regulation Qinlet
78 Centrifugal Compressor Training Course 22/11/2012 Customer Training Discharge pressure Regulation Qinlet
Choke, Stall, Surge and Anti-surge Control System GE Oil & Gas Oil & Gas Industry Applications
80 Centrifugal Compressor Training Course 22/11/2012 Customer Training Choking Choking Area Choke rapresents the right limit of performance curve. Rapid decrease in performances and efficiency. Discharge pressure Qinlet
81 Centrifugal Compressor Training Course 22/11/2012 Customer Training Surge  Surge is the left limit of performance curve, on the left of this line the compressor operates in unstable condition;  Represents the maximum polytropic head of the curve;  All surge points, defined for different speeds represent the Surge Limit Line; Surge Limit Line Discharge pressure Qinlet
82 Centrifugal Compressor Training Course 22/11/2012 Customer Training Surge P2 P1 P2 > P1 Flow inside the impeller Axial thrust Normal operating conditions
83 Centrifugal Compressor Training Course 22/11/2012 Customer Training Surge P2 P1 Flow inside the impeller Axial thrust P1 > P2 Surge condition
84 Centrifugal Compressor Training Course 22/11/2012 Customer Training Factors leading to surge During NORMAL OPERATION:  High discharge pressure (Increase of plant resistance);  Reduction of suction pressure;  Increase of suction temperature.
85 Centrifugal Compressor Training Course 22/11/2012 Customer Training The Antisurge System is composed by:  Antisurge Valve  Instrumentation:  Flow indicator trasmitter  Pressure indicator trasmitter  Electronic controller Antisurge system
86 Centrifugal Compressor Training Course 22/11/2012 Customer Training Antisurge system PRESSURE TRANSMITTER ANTISURGE VALVE COMPRESSOR FT PT PT ANTISURGE CONTROL FLOW TRANSMITTER PRESSURE TRANSMITTER The opening of the Antisurge Valve increases the suction flow moving the operating point along the speed. The purpose of the Antisurge Control System is to avoid that the operating point reaches the SLL.
87 Centrifugal Compressor Training Course 22/11/2012 Customer Training …just a clarification: The systems work together but are separately. Antisurge system The anti-surge controller is a special electronic device that interacts with the main control panel but is not depending from it.
Lube Oil System GE Oil & Gas Oil & Gas Industry Applications
89 Centrifugal Compressor Training Course 22/11/2012 Customer Training Lube Oil System The function of the lube oil system is to provide the right amount of lube oil to bearings with the desired viscosity by regulating pressure and temperature.
90 Centrifugal Compressor Training Course 22/11/2012 Customer Training Lube Oil System P&ID Tank
91 Centrifugal Compressor Training Course 22/11/2012 Customer Training Lube Oil System P&ID Main pump Auxiliary pump Emergency pump
92 Centrifugal Compressor Training Course 22/11/2012 Customer Training Lube Oil System P&ID PCV
93 Centrifugal Compressor Training Course 22/11/2012 Customer Training Lube Oil System P&ID TCV
94 Centrifugal Compressor Training Course 22/11/2012 Customer Training Lube Oil System P&ID Filters
Dry Gas Seals System GE Oil & Gas Oil & Gas Industry Applications
96 Centrifugal Compressor Training Course 22/11/2012 Customer Training Sealing systems The function of the sealing system is to avoid gas leakages Statoric part Rotating part Gap  Gas property is to occupy all the available volume  Gas moves from high pressure sections to low pressure ones
97 Centrifugal Compressor Training Course 22/11/2012 Customer Training Sealing systems The function of the sealing system is to avoid two types of leakage Process gas leakages between the compression stages Process gas leakages towards the atmosphere
98 Centrifugal Compressor Training Course 22/11/2012 Customer Training Types of seals:  Fluid dynamic seals  Labyrinth seals  O-Ring gaskets
99 Centrifugal Compressor Training Course 22/11/2012 Customer Training Labyrinth Seals Plain Stepped Abradable A labyrinth seal is a type of mechanical seal that minimize the gas leakages. Labyrinth seals on rotating shafts provide non-contact sealing action by controlling the passage of fluid through a series of teeth. Efficiency Main purpose is to minimize internal leakages close to the impellers due to different pressure value at inlet and discharge.  Eye of the impeller  Foot of the impeller  Balance drum
100 Centrifugal Compressor Training Course 22/11/2012 Customer Training Balancing Line Shaft End Seal Shaft End Seal Balancing Drum Shaft end sealing
101 Centrifugal Compressor Training Course 22/11/2012 Customer Training Dry gas seal system Mechanical dry gas seal are supplied as cartridges.
102 Centrifugal Compressor Training Course 22/11/2012 Customer Training DGS: main components Stationary ring Rotating ring Spring Seal gas SHAFT Process side Athmosphere side
103 Centrifugal Compressor Training Course 22/11/2012 Customer Training Operating conditions Static Pressure + Spring Thrust Dynamic Pressurization Process Side Stationary ring Rotating ring Seal gas Seal gas The pressure profile at the interface is self adjuxting to restore to a position of equilibrium  Gas enters the groove moving towards the center;  Gas is compressed and pressure increases setting the gap between the rings.
104 Centrifugal Compressor Training Course 22/11/2012 Customer Training Shaft rotation Shaft rotation Dry gas seal
105 Centrifugal Compressor Training Course 22/11/2012 Customer Training Gas source
106 Centrifugal Compressor Training Course 22/11/2012 Customer Training Intermediate Labyrinth Product side Outboard seal Inboard seal Seal gas STREAM 1 Primary vent (leakage from inbord seal + intermediate buffer gas - to flare) STREAM 2 Intermediate buffer gas (N2) STREAM 3 Secondary vent (leakage from Outbord seal + separation gas - atmospheric) STREAM 4 Separation gas (N2) STREAM 5 Atmosphere (Bearing chamber) Separation seal Inner seals Carbon rings Face Seat Seat Face Nomenclature TANDEM type:
107 Centrifugal Compressor Training Course 22/11/2012 Customer Training Process gas side Bearings side Buffer-Process gas supply Seal gas supply N2 Seal gas leakage Separation gas N2 Inner seal Inboard seal Outboard seal Separation seal Dry gas seal: DOUBLE type
108 Centrifugal Compressor Training Course 22/11/2012 Customer Training Tertiary seal The function of the tertiary seal is to avoid the oil vapours entering into the dry gas seal.
109 Centrifugal Compressor Training Course 22/11/2012 Customer Training Dry Gas Seal System P&ID Seal Gas Filters Buffer Gas Filters
110 Centrifugal Compressor Training Course 22/11/2012 Customer Training Dry Gas Seal System P&ID Buffer Gas PCV Seal Gas PCV
111 Centrifugal Compressor Training Course 22/11/2012 Customer Training Dry Gas Seal System P&ID Primary Vent
112 Centrifugal Compressor Training Course 22/11/2012 Customer Training Dry Gas Seal System P&ID Secondary Vent
113 Centrifugal Compressor Training Course 22/11/2012 Customer Training Dry Gas Seal System P&ID Seal Gas Heater
Vibrations Overview GE Oil & Gas Oil & Gas Industry Applications
115 Centrifugal Compressor Training Course 22/11/2012 Customer Training The measure of the mechanical behavior of a compressor is given by the amplitude and frequency of the rotor vibrations. The rotor vibration amplitude must not cause:  Contact between rotating and stator parts;  Dry gas seals overloading;  Fatigue in the bearings. Mechanical behavior
116 Centrifugal Compressor Training Course 22/11/2012 Customer Training The typical vibrations of the centrifugal compressors can be classified with reference to the frequency and the nature of the force causing vibrations. According to the first classification (frequency) the vibration may be:  Synchronous The vibration frequency corresponds to the machine rotation speed (ωR)  Asynchronous The vibration frequency is different from the machine rotation speed (ω R) Vibrations classification
117 Centrifugal Compressor Training Course 22/11/2012 Customer Training Syncronous vibrations 𝜔 = 𝜔𝑅 The most common causes are:  Unbalance in the rotor system;  Rotor and stator parts contact;  Fouling deposit.
118 Centrifugal Compressor Training Course 22/11/2012 Customer Training Asyncronous vibrations It is necessary to do another distinction between frequency of the vibration and machine rotational speed  Frequency of the vibration multiple of ωR  Frequency of the vibration lower or higher than ωR 𝜔 = 𝐾𝜔𝑅
119 Centrifugal Compressor Training Course 22/11/2012 Customer Training Asyncronous vibrations Frequency of the vibration multiple of ωR 𝜔 = 𝐾𝜔𝑅 The most common causes are:  Coupling misalignment;  Loose of interference in some rotor components. 𝜔 = 2𝜔𝑅
120 Centrifugal Compressor Training Course 22/11/2012 Customer Training Asyncronous Vibrations Frequency of the vibration lower or higher than ωR The most common causes are:  High clearance in journal bearings  Oil whip;  Aerodynamic effects (rotating stall in diffusers)  Cross - coupling 𝜔 = 0.5 𝜔𝑅 𝜔 = ( 0.4 − 0.5 ) 𝜔𝑅 𝜔 = ( 0.1 − 0.2 ) 𝜔𝑅 𝜔 = 0.2 𝜔𝑅
121 Centrifugal Compressor Training Course 22/11/2012 Customer Training What are the problems? The main problem that we have to consider when a rotor-bearing system is subjected to a periodic force is the phenomenon of RESONANCE.  A system is in resonance when vibration amplitude becomes maximum;  This occurs when the frequency of a periodic force (excitation frequency), applied to a rotor- bearing system, corresponds to a natural frequency of that system. A centrifugal compressor has many natural frequencies that are colled Critical Speeds;The most important are the first and the second; It is necessary to determine the field operation speeds that avoid the resonance.
122 Centrifugal Compressor Training Course 22/11/2012 Customer Training NC1 = Rotor first critical, center frequency, cycles per minute Ncn = Critical speed, n th Nmc = Maximum continuous speed, 105 percent N1 = Initial (lower) speed at 0,707 x peak amplitude (critical) N2 = Final (higher) speed at 0,707 x peak amplitude (critical) SM = Separation margin API 617 𝑁1 𝑁2 𝑁𝑐1 0.707 𝑝𝑒𝑎𝑘 𝑆𝑀 𝑜𝑝𝑒𝑟𝑎𝑡𝑖𝑛𝑔 𝑠𝑝𝑒𝑒𝑑𝑠 𝑁𝑐𝑛 𝑁𝑚𝑐 𝑉𝑖𝑏𝑟𝑎𝑡𝑖𝑜𝑛 𝑙𝑒𝑣𝑒𝑙 𝐴𝐹 = 𝑁𝑐𝑖 𝑁2 − 𝑁1 𝑆𝑀
123 Centrifugal Compressor Training Course 22/11/2012 Customer Training

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GE centrifugal compressors.pdf

  • 1.
    Introduction General description andmain features GE Oil & Gas Oil & Gas Industry Applications
  • 2.
    Customer Training 2 Centrifugal CompressorTraining Course 22/11/2012 What is a Compressor? A machine used to increase the pressure of a GAS Introduction Customer Training
  • 3.
    Customer Training 3 Centrifugal CompressorTraining Course 22/11/2012 What is a Gas? Gas is one of the three classical states of matter characterized by molecular weight (MW), pressure (p) and temperature (T) Introduction Customer Training
  • 4.
    4 Centrifugal Compressor TrainingCourse 22/11/2012 Customer Training Gas compression Gas ps Gas pd Mechanical power Introduction
  • 5.
    Customer Training 5 Centrifugal CompressorTraining Course 22/11/2012 What we need to compress a gas? For many reasons: to transport it, to enhance an oil field production, etc… Introduction
  • 6.
    6 Centrifugal Compressor TrainingCourse 22/11/2012 Customer Training Compression Services Pipeline inspection device Offshore production platform Subsea equipment Oil/Gas field Re-injection plant Oil / gas processing plant LNG receiving plant LNG liquefaction plant Gas boosting station Oil boosting station Power generation plant Natural Gas storage plant Refinery / Petrochemical / fertilizer plant
  • 7.
    7 Centrifugal Compressor TrainingCourse 22/11/2012 Customer Training Compression Services Distribution Midstream Downstream Upstream • Exploration & Production  Re-injection  Gas Lift  Gas Gathering  Export Gas •Gas Plants  Feed Gas  Gas Treatment • LNG  Mixed Refrigerant  Propane • Pipelines  Gas Boosting  HP Transport  Gas Storage (Injection + withdrawal) • Refinery  HCU, HDT, HDS  Recycle  Air Feed  FCC • Petrochemical/ Fertilizers  Syngas (Ammonia, Methanol)  Refrigeration  CO2 Compression (Urea)  Feed Gas  Charge Gas  Ethylene & derivatives • NGV Re-fuelling  Cubogas
  • 8.
    Nuovo Pignone Compressors GEOil & Gas Oil & Gas Industry Applications
  • 9.
    9 Centrifugal Compressor TrainingCourse 22/11/2012 Customer Training Vertically split Compressors overview
  • 10.
    10 Centrifugal Compressor TrainingCourse 22/11/2012 Customer Training Horizontally split Compressors overview
  • 11.
    11 Centrifugal Compressor TrainingCourse 22/11/2012 Customer Training Single Volute Compressors overview
  • 12.
    12 Centrifugal Compressor TrainingCourse 22/11/2012 Customer Training Nuovo Pignone TAGs BCL 406 2 Compressors overview
  • 13.
    13 Centrifugal Compressor TrainingCourse 22/11/2012 Customer Training Nuovo Pignone TAGs BCL 406 Casing B=barrel P=pipeline M=Middle Split S=single volute Impeller design C=closed R=open Diffuser L=free vortex (not vaned) 2 Literal Part Compressors overview
  • 14.
    14 Centrifugal Compressor TrainingCourse 22/11/2012 Customer Training 2 BCL 406 BCL 406 /A Casing design pressure rating  N p<150 bar  A p<200 bar  B p<300 bar  C p<400 bar  D p<550 bar  E p up to 1000 bar Barrel Type Compressors overview
  • 15.
    15 Centrifugal Compressor TrainingCourse 22/11/2012 Customer Training  Pipeline compressors are designed to maximize compression efficiency over the broad range of operating conditions required by gas pumping stations;  Suction and discharge nozzles for gas transportation are generally located opposite each other to meet station layout requirements. pmax 150 bar PCL 406 Pipeline Type Compressors overview
  • 16.
    16 Centrifugal Compressor TrainingCourse 22/11/2012 Customer Training Low pressure applications 2 MCL 406 Middle Split Type Compressors overview
  • 17.
    17 Centrifugal Compressor TrainingCourse 22/11/2012 Customer Training SRL Integrally geared Single stage  Impeller overhung mounted on the shaft;  Each impeller has the discharge volute. Single Volute Type Compressors overview
  • 18.
    18 Centrifugal Compressor TrainingCourse 22/11/2012 Customer Training IMPELLERS design R= open type C= closed type 2 BCL 406 Compressors overview
  • 19.
    19 Centrifugal Compressor TrainingCourse 22/11/2012 Customer Training Free vortex DIFFUSER Diffuser No fixed blades 2 BCL 406 Compressors overview
  • 20.
    20 Centrifugal Compressor TrainingCourse 22/11/2012 Customer Training Nuovo Pignone TAGs BCL 406 n. of impellers Nominal diameter of the impeller Section arrangment 2 Numerical Part Compressors overview
  • 21.
    21 Centrifugal Compressor TrainingCourse 22/11/2012 Customer Training Nominal size (mm) 400 mm BCL 406 2 Compressors overview
  • 22.
    22 Centrifugal Compressor TrainingCourse 22/11/2012 Customer Training BCL...MCL... Section arrangment suction discharge  One compression section;  In line configuration. Compressors overview
  • 23.
    23 Centrifugal Compressor TrainingCourse 22/11/2012 Customer Training 2 BCL... 2 MCL... Section arrangment 1 st suction 1 st discharge 2 nd suction 2 nd discharge  Two compression sections in a single casing;  Back to back configuration;  Cooling of the gas;  Tmax 250°C. Compressors overview
  • 24.
    24 Centrifugal Compressor TrainingCourse 22/11/2012 Customer Training 3 BCL... 3 MCL... Section arrangment  More than two compression sections in a single casing;  Sidestreams. suction discharge sidestreams Compressors overview
  • 25.
    25 Centrifugal Compressor TrainingCourse 22/11/2012 Customer Training D BCL... D MCL... Section arrangment suction discharge  Two compression sections in parallel in the same casing; Compressors overview
  • 26.
    26 Centrifugal Compressor TrainingCourse 22/11/2012 Customer Training Technology Selection Map Compressors overview
  • 27.
    Compressor rotating parts GEOil & Gas Oil & Gas Industry Applications
  • 28.
    28 Centrifugal Compressor TrainingCourse 22/11/2012 Customer Training Rotating parts Shaft Thrust Collar Impellers Spacers Balance drum Coupling hub
  • 29.
    29 Centrifugal Compressor TrainingCourse 22/11/2012 Customer Training Thrust Collar  Transmits the rotor thrust to the thrust bearing;  Fixes the axial position of the rotor;  Hydraulically shrink-fitted to the shaft;
  • 30.
    30 Centrifugal Compressor TrainingCourse 22/11/2012 Customer Training Impeller The function of the impeller is to add energy to the gas.
  • 31.
    31 Centrifugal Compressor TrainingCourse 22/11/2012 Customer Training Impeller In order to minimize erosion and corrosion effects on impeller due to pitting or fouling phenomenon related to gas composition, it is possible to use special stainless steel alloy with Ni-Cr-Mo or apply a specific protective coating.
  • 32.
    32 Centrifugal Compressor TrainingCourse 22/11/2012 Customer Training The blades are bended Impeller The blades are bended and twisted Impellers are fully customized
  • 33.
    33 Centrifugal Compressor TrainingCourse 22/11/2012 Customer Training Balancing Drum  Balances part of the axial thrust;  Interference fitted and keyed;  Positioned after the last impeller;  Holes for rotor balancing.
  • 34.
    34 Centrifugal Compressor TrainingCourse 22/11/2012 Customer Training Coupling FLEXIBLE DRY type design is mostly used by NP HUB No lubrication is needed Connects elements between compressor and the remaining equipment of a compressor train.
  • 35.
    35 Centrifugal Compressor TrainingCourse 22/11/2012 Customer Training Coupling Basically a flexible coupling has the following functions: 2. Accommodate Parallel Offset and/or Angular misalignment 1. Physically connect two rotating shafts 3. Compensate for axial movement of coupled shafts
  • 36.
    Compressor stator parts GEOil & Gas Oil & Gas Industry Applications
  • 37.
    37 Centrifugal Compressor TrainingCourse 22/11/2012 Customer Training Stator parts Diaphragms Bearings Seal End cover Flanges and Nozzles Bearings
  • 38.
    38 Centrifugal Compressor TrainingCourse 22/11/2012 Customer Training Stator parts
  • 39.
    39 Centrifugal Compressor TrainingCourse 22/11/2012 Customer Training BCL: Casing-Diaphragms LOWER HALF UPPER HALF
  • 40.
    40 Centrifugal Compressor TrainingCourse 22/11/2012 Customer Training Casing-Diaphragms: bundle Diaphragms
  • 41.
    41 Centrifugal Compressor TrainingCourse 22/11/2012 Customer Training Casing-Diaphragms: bundle Labyrinth seals Diffuser Return channel Blades Impeller
  • 42.
    42 Centrifugal Compressor TrainingCourse 22/11/2012 Customer Training Casing-Diaphragms: bundle Suction volute Discharge volute In new barrel compressors the inlet and disharge volutes are separated from the inermediate diaphragms.
  • 43.
    43 Centrifugal Compressor TrainingCourse 22/11/2012 Customer Training Casing-Diaphragms: bundle The upper half of the bundle is lowered on the lower half.
  • 44.
    44 Centrifugal Compressor TrainingCourse 22/11/2012 Customer Training Horizontally split The diaphragms are installed in the casing without a countercasing
  • 45.
    45 Centrifugal Compressor TrainingCourse 22/11/2012 Customer Training Flanges and nozzles Discharge Sideflow Suction Discharge Suction
  • 46.
    46 Centrifugal Compressor TrainingCourse 22/11/2012 Customer Training Flanges and nozzles In the barrel type for high or very high pressure, piping is directly connected to the casing without nozzles;
  • 47.
    47 Centrifugal Compressor TrainingCourse 22/11/2012 Customer Training Shear and Shim rings Shear ring Shim ring Locking system using shear and shim rings
  • 48.
    48 Centrifugal Compressor TrainingCourse 22/11/2012 Customer Training Head cover The functions of the head cover are:  Close the bundle inside the casing;  Guide the flow;
  • 49.
    49 Centrifugal Compressor TrainingCourse 22/11/2012 Customer Training Bearings Thrust bearing  Direct Lubricated: lube oil is provided for each pad through a groove manufactured on the pads  Flooded: Oil fills the bearing assembly and drains from the top through a flow control orifice Tilting pads type are adopted. The function of the thrust bearing is to compensate part of the axial thrust.
  • 50.
    50 Centrifugal Compressor TrainingCourse 22/11/2012 Customer Training Thrust Bearings Components Thrust bearing are self equalizing: the bearing distributes the load equally between all pads. Thrust shoes Base ring Leveling plates Thrust collar Pivot
  • 51.
    51 Centrifugal Compressor TrainingCourse 22/11/2012 Customer Training Journal Bearing Jourbal bearing Tilting pads type are adopted. The functions of the journal bearing are:  Support the rotor weight  Create a lifting effect  Damping effect Two types of possible lubrication:  Direct lubrication: Lube oil is provided for each pad through a groove manufactured on the pads  Flooded lubrication: The oil enter from an orifice in the upper part of the bearing and exits in the lower part after the lubriction of pads.
  • 52.
    52 Centrifugal Compressor TrainingCourse 22/11/2012 Customer Training Journal Bearing Bearings pad Bearings casing Pivot
  • 53.
    Centrifugal Compressor GasPath GE Oil & Gas Oil & Gas Industry Applications
  • 54.
    54 Centrifugal Compressor TrainingCourse 22/11/2012 Customer Training SUCTION DISCHARGE Gas Path
  • 55.
    55 Centrifugal Compressor TrainingCourse 22/11/2012 Customer Training Shaft Inlet Volute Fin Casing Blade Impeller Suction Nozzle Suction Pipe Suction The gas flow is directed towards the eye of the first impeller.
  • 56.
    56 Centrifugal Compressor TrainingCourse 22/11/2012 Customer Training Suction
  • 57.
    57 Centrifugal Compressor TrainingCourse 22/11/2012 Customer Training Labyrinth Seal Suction diaphragm Labyrinth Seal Shaft Key Disk Suction
  • 58.
    58 Centrifugal Compressor TrainingCourse 22/11/2012 Customer Training Intermediate stages
  • 59.
    59 Centrifugal Compressor TrainingCourse 22/11/2012 Customer Training Single stage Labirinth seals Diffuser Return channel Blades
  • 60.
    60 Centrifugal Compressor TrainingCourse 22/11/2012 Customer Training C3=C1 optimal condition Gas Inlet Increased velocity P4,C4 P1,C1 P2,C2 P3,C3 + + + ++ + Single stage
  • 61.
    61 Centrifugal Compressor TrainingCourse 22/11/2012 Customer Training Single stage Impeller Inlet Blade Inlet Diffuser Inlet Diffuser Outlet Velocity Pressure Energy 1 2 3 4 1 2 3 4
  • 62.
    62 Centrifugal Compressor TrainingCourse 22/11/2012 Customer Training Last impeller Discharge volute Discharge
  • 63.
    Centrifugal Compressor AxialThrust GE Oil & Gas Oil & Gas Industry Applications
  • 64.
    64 Centrifugal Compressor TrainingCourse 22/11/2012 Customer Training Axial Thrust Axial thrust P2 > P1 P2 P2 P1
  • 65.
    65 Centrifugal Compressor TrainingCourse 22/11/2012 Customer Training Axial Thrust Balancing Drum The BALANCE DRUM is a disk installed after the last impeller in order to balance part of the axial thrust (80÷85%).
  • 66.
    66 Centrifugal Compressor TrainingCourse 22/11/2012 Customer Training Axial Thrust P2 P1 P2 Ps R1 R2 Rd Axial Force Drum Force
  • 67.
    67 Centrifugal Compressor TrainingCourse 22/11/2012 Customer Training Axial Thrust Balancing Line Ps Pd Ps+ΔP Ps= Suction Pressure Ps = Discharge Pressure ΔP= Pressure Drop on balancing line Axial Force Drum Force
  • 68.
    68 Centrifugal Compressor TrainingCourse 22/11/2012 Customer Training Balancing line
  • 69.
    Centrifugal Compressor Performance Curves GEOil & Gas Oil & Gas Industry Applications
  • 70.
    70 Centrifugal Compressor TrainingCourse 22/11/2012 Customer Training Performance Curves  Polytropic Head  Polytropic Efficiency  Pressure Ratio  Power  Discharge Temperature  Discharge Pressure Performance curves describe the relation of the centrifugal compressor operating parameter and the inlet capacity. The performance curves are valid ONLY for the condition specified in the performance diaghram... Qinlet
  • 71.
    71 Centrifugal Compressor TrainingCourse 22/11/2012 Customer Training Operating Range Maximum continuous speed (MCS) Minimum operating speed (MOS) Discharge pressure (bar a) Normal operating point Qinlet Choking Area Surge Limit Line
  • 72.
    72 Centrifugal Compressor TrainingCourse 22/11/2012 Customer Training Operating point Plant resistance curve Operating point  The plot represents the envelope of all the possible operating conditions relevant to the given suction parameter.  The actual operating point is unique and it is always the intersection between the compressor curve at the given speed and the plant resistance curve. Qinlet
  • 73.
    73 Centrifugal Compressor TrainingCourse 22/11/2012 Customer Training
  • 74.
    74 Centrifugal Compressor TrainingCourse 22/11/2012 Customer Training Off-design conditions Discharge pressure MW MW Qinlet Ts Ts Ps Ps
  • 75.
    75 Centrifugal Compressor TrainingCourse 22/11/2012 Customer Training Other map variation cause: Normal working graph Internal recycles effect Discharge pressure Qinlet
  • 76.
    76 Centrifugal Compressor TrainingCourse 22/11/2012 Customer Training According to API 617 the following regulating methods are defined:  Speed Variation  Suction throttling  Variable inlet guide vanes (VIGV)  Discharge blowoff  Cooled bypass Regulation
  • 77.
    77 Centrifugal Compressor TrainingCourse 22/11/2012 Customer Training Discharge pressure Regulation Qinlet
  • 78.
    78 Centrifugal Compressor TrainingCourse 22/11/2012 Customer Training Discharge pressure Regulation Qinlet
  • 79.
    Choke, Stall, Surgeand Anti-surge Control System GE Oil & Gas Oil & Gas Industry Applications
  • 80.
    80 Centrifugal Compressor TrainingCourse 22/11/2012 Customer Training Choking Choking Area Choke rapresents the right limit of performance curve. Rapid decrease in performances and efficiency. Discharge pressure Qinlet
  • 81.
    81 Centrifugal Compressor TrainingCourse 22/11/2012 Customer Training Surge  Surge is the left limit of performance curve, on the left of this line the compressor operates in unstable condition;  Represents the maximum polytropic head of the curve;  All surge points, defined for different speeds represent the Surge Limit Line; Surge Limit Line Discharge pressure Qinlet
  • 82.
    82 Centrifugal Compressor TrainingCourse 22/11/2012 Customer Training Surge P2 P1 P2 > P1 Flow inside the impeller Axial thrust Normal operating conditions
  • 83.
    83 Centrifugal Compressor TrainingCourse 22/11/2012 Customer Training Surge P2 P1 Flow inside the impeller Axial thrust P1 > P2 Surge condition
  • 84.
    84 Centrifugal Compressor TrainingCourse 22/11/2012 Customer Training Factors leading to surge During NORMAL OPERATION:  High discharge pressure (Increase of plant resistance);  Reduction of suction pressure;  Increase of suction temperature.
  • 85.
    85 Centrifugal Compressor TrainingCourse 22/11/2012 Customer Training The Antisurge System is composed by:  Antisurge Valve  Instrumentation:  Flow indicator trasmitter  Pressure indicator trasmitter  Electronic controller Antisurge system
  • 86.
    86 Centrifugal Compressor TrainingCourse 22/11/2012 Customer Training Antisurge system PRESSURE TRANSMITTER ANTISURGE VALVE COMPRESSOR FT PT PT ANTISURGE CONTROL FLOW TRANSMITTER PRESSURE TRANSMITTER The opening of the Antisurge Valve increases the suction flow moving the operating point along the speed. The purpose of the Antisurge Control System is to avoid that the operating point reaches the SLL.
  • 87.
    87 Centrifugal Compressor TrainingCourse 22/11/2012 Customer Training …just a clarification: The systems work together but are separately. Antisurge system The anti-surge controller is a special electronic device that interacts with the main control panel but is not depending from it.
  • 88.
    Lube Oil System GEOil & Gas Oil & Gas Industry Applications
  • 89.
    89 Centrifugal Compressor TrainingCourse 22/11/2012 Customer Training Lube Oil System The function of the lube oil system is to provide the right amount of lube oil to bearings with the desired viscosity by regulating pressure and temperature.
  • 90.
    90 Centrifugal Compressor TrainingCourse 22/11/2012 Customer Training Lube Oil System P&ID Tank
  • 91.
    91 Centrifugal Compressor TrainingCourse 22/11/2012 Customer Training Lube Oil System P&ID Main pump Auxiliary pump Emergency pump
  • 92.
    92 Centrifugal Compressor TrainingCourse 22/11/2012 Customer Training Lube Oil System P&ID PCV
  • 93.
    93 Centrifugal Compressor TrainingCourse 22/11/2012 Customer Training Lube Oil System P&ID TCV
  • 94.
    94 Centrifugal Compressor TrainingCourse 22/11/2012 Customer Training Lube Oil System P&ID Filters
  • 95.
    Dry Gas SealsSystem GE Oil & Gas Oil & Gas Industry Applications
  • 96.
    96 Centrifugal Compressor TrainingCourse 22/11/2012 Customer Training Sealing systems The function of the sealing system is to avoid gas leakages Statoric part Rotating part Gap  Gas property is to occupy all the available volume  Gas moves from high pressure sections to low pressure ones
  • 97.
    97 Centrifugal Compressor TrainingCourse 22/11/2012 Customer Training Sealing systems The function of the sealing system is to avoid two types of leakage Process gas leakages between the compression stages Process gas leakages towards the atmosphere
  • 98.
    98 Centrifugal Compressor TrainingCourse 22/11/2012 Customer Training Types of seals:  Fluid dynamic seals  Labyrinth seals  O-Ring gaskets
  • 99.
    99 Centrifugal Compressor TrainingCourse 22/11/2012 Customer Training Labyrinth Seals Plain Stepped Abradable A labyrinth seal is a type of mechanical seal that minimize the gas leakages. Labyrinth seals on rotating shafts provide non-contact sealing action by controlling the passage of fluid through a series of teeth. Efficiency Main purpose is to minimize internal leakages close to the impellers due to different pressure value at inlet and discharge.  Eye of the impeller  Foot of the impeller  Balance drum
  • 100.
    100 Centrifugal Compressor TrainingCourse 22/11/2012 Customer Training Balancing Line Shaft End Seal Shaft End Seal Balancing Drum Shaft end sealing
  • 101.
    101 Centrifugal Compressor TrainingCourse 22/11/2012 Customer Training Dry gas seal system Mechanical dry gas seal are supplied as cartridges.
  • 102.
    102 Centrifugal Compressor TrainingCourse 22/11/2012 Customer Training DGS: main components Stationary ring Rotating ring Spring Seal gas SHAFT Process side Athmosphere side
  • 103.
    103 Centrifugal Compressor TrainingCourse 22/11/2012 Customer Training Operating conditions Static Pressure + Spring Thrust Dynamic Pressurization Process Side Stationary ring Rotating ring Seal gas Seal gas The pressure profile at the interface is self adjuxting to restore to a position of equilibrium  Gas enters the groove moving towards the center;  Gas is compressed and pressure increases setting the gap between the rings.
  • 104.
    104 Centrifugal Compressor TrainingCourse 22/11/2012 Customer Training Shaft rotation Shaft rotation Dry gas seal
  • 105.
    105 Centrifugal Compressor TrainingCourse 22/11/2012 Customer Training Gas source
  • 106.
    106 Centrifugal Compressor TrainingCourse 22/11/2012 Customer Training Intermediate Labyrinth Product side Outboard seal Inboard seal Seal gas STREAM 1 Primary vent (leakage from inbord seal + intermediate buffer gas - to flare) STREAM 2 Intermediate buffer gas (N2) STREAM 3 Secondary vent (leakage from Outbord seal + separation gas - atmospheric) STREAM 4 Separation gas (N2) STREAM 5 Atmosphere (Bearing chamber) Separation seal Inner seals Carbon rings Face Seat Seat Face Nomenclature TANDEM type:
  • 107.
    107 Centrifugal Compressor TrainingCourse 22/11/2012 Customer Training Process gas side Bearings side Buffer-Process gas supply Seal gas supply N2 Seal gas leakage Separation gas N2 Inner seal Inboard seal Outboard seal Separation seal Dry gas seal: DOUBLE type
  • 108.
    108 Centrifugal Compressor TrainingCourse 22/11/2012 Customer Training Tertiary seal The function of the tertiary seal is to avoid the oil vapours entering into the dry gas seal.
  • 109.
    109 Centrifugal Compressor TrainingCourse 22/11/2012 Customer Training Dry Gas Seal System P&ID Seal Gas Filters Buffer Gas Filters
  • 110.
    110 Centrifugal Compressor TrainingCourse 22/11/2012 Customer Training Dry Gas Seal System P&ID Buffer Gas PCV Seal Gas PCV
  • 111.
    111 Centrifugal Compressor TrainingCourse 22/11/2012 Customer Training Dry Gas Seal System P&ID Primary Vent
  • 112.
    112 Centrifugal Compressor TrainingCourse 22/11/2012 Customer Training Dry Gas Seal System P&ID Secondary Vent
  • 113.
    113 Centrifugal Compressor TrainingCourse 22/11/2012 Customer Training Dry Gas Seal System P&ID Seal Gas Heater
  • 114.
    Vibrations Overview GE Oil& Gas Oil & Gas Industry Applications
  • 115.
    115 Centrifugal Compressor TrainingCourse 22/11/2012 Customer Training The measure of the mechanical behavior of a compressor is given by the amplitude and frequency of the rotor vibrations. The rotor vibration amplitude must not cause:  Contact between rotating and stator parts;  Dry gas seals overloading;  Fatigue in the bearings. Mechanical behavior
  • 116.
    116 Centrifugal Compressor TrainingCourse 22/11/2012 Customer Training The typical vibrations of the centrifugal compressors can be classified with reference to the frequency and the nature of the force causing vibrations. According to the first classification (frequency) the vibration may be:  Synchronous The vibration frequency corresponds to the machine rotation speed (ωR)  Asynchronous The vibration frequency is different from the machine rotation speed (ω R) Vibrations classification
  • 117.
    117 Centrifugal Compressor TrainingCourse 22/11/2012 Customer Training Syncronous vibrations 𝜔 = 𝜔𝑅 The most common causes are:  Unbalance in the rotor system;  Rotor and stator parts contact;  Fouling deposit.
  • 118.
    118 Centrifugal Compressor TrainingCourse 22/11/2012 Customer Training Asyncronous vibrations It is necessary to do another distinction between frequency of the vibration and machine rotational speed  Frequency of the vibration multiple of ωR  Frequency of the vibration lower or higher than ωR 𝜔 = 𝐾𝜔𝑅
  • 119.
    119 Centrifugal Compressor TrainingCourse 22/11/2012 Customer Training Asyncronous vibrations Frequency of the vibration multiple of ωR 𝜔 = 𝐾𝜔𝑅 The most common causes are:  Coupling misalignment;  Loose of interference in some rotor components. 𝜔 = 2𝜔𝑅
  • 120.
    120 Centrifugal Compressor TrainingCourse 22/11/2012 Customer Training Asyncronous Vibrations Frequency of the vibration lower or higher than ωR The most common causes are:  High clearance in journal bearings  Oil whip;  Aerodynamic effects (rotating stall in diffusers)  Cross - coupling 𝜔 = 0.5 𝜔𝑅 𝜔 = ( 0.4 − 0.5 ) 𝜔𝑅 𝜔 = ( 0.1 − 0.2 ) 𝜔𝑅 𝜔 = 0.2 𝜔𝑅
  • 121.
    121 Centrifugal Compressor TrainingCourse 22/11/2012 Customer Training What are the problems? The main problem that we have to consider when a rotor-bearing system is subjected to a periodic force is the phenomenon of RESONANCE.  A system is in resonance when vibration amplitude becomes maximum;  This occurs when the frequency of a periodic force (excitation frequency), applied to a rotor- bearing system, corresponds to a natural frequency of that system. A centrifugal compressor has many natural frequencies that are colled Critical Speeds;The most important are the first and the second; It is necessary to determine the field operation speeds that avoid the resonance.
  • 122.
    122 Centrifugal Compressor TrainingCourse 22/11/2012 Customer Training NC1 = Rotor first critical, center frequency, cycles per minute Ncn = Critical speed, n th Nmc = Maximum continuous speed, 105 percent N1 = Initial (lower) speed at 0,707 x peak amplitude (critical) N2 = Final (higher) speed at 0,707 x peak amplitude (critical) SM = Separation margin API 617 𝑁1 𝑁2 𝑁𝑐1 0.707 𝑝𝑒𝑎𝑘 𝑆𝑀 𝑜𝑝𝑒𝑟𝑎𝑡𝑖𝑛𝑔 𝑠𝑝𝑒𝑒𝑑𝑠 𝑁𝑐𝑛 𝑁𝑚𝑐 𝑉𝑖𝑏𝑟𝑎𝑡𝑖𝑜𝑛 𝑙𝑒𝑣𝑒𝑙 𝐴𝐹 = 𝑁𝑐𝑖 𝑁2 − 𝑁1 𝑆𝑀
  • 123.
    123 Centrifugal Compressor TrainingCourse 22/11/2012 Customer Training