Beruflich Dokumente
Kultur Dokumente
by
H. M. Davis
Manager, Ctntrifugal Compressor Engineering Department
DELA VAL Turbine Division, Tr<nton, N. J.
lNTROl)UCTJON
The process industry has experienced tremendous
growth during the past two decades. The growth of
single line m1d continuous process plants and the in
creasing u,;;e of automation have demonstrated tbe im
portcmee of component reliability. lVIachinery user are
now demanding dependahle performance, simplicity of
op1'ration and case of maintenance. The suppliers of
centrifugal compressors have heen forced to review their
designs and sometimes to design new equipment io satis
fy these users' demands. This paper discusses the ways
in which a centrifugal compressor can be built and usf:d
t.o satisfy a customer's operating and maintenance
requirements.
ABSTRACT
The operali(Jn and rnaintenance of centrifugal com
pre:;;;ors varie considerably depending upon the
speed, horsepower, and type of driver.
Typical centrifual compressors vary from high
speed, low flow applications to very large flow, low
speed machines. Each has its own operating and main
tenance problems.
(>ntrifugal compre:;sors are normally driven hy
electric motors and speed increasing gears for the lo w
flow, low horsepower applicationc;. The middle size
ranges arc usually rnotor-gear, steam turbine or gas
turbine direct connected combinations. The very large
flow, large horsepower machines are practically all steam
turbine driven with a few being driven hy ga" turbine
where natural gas fuel is available.
100.000
::;
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31:
0
-'
...
1w
..J
;!!;
15
Vi
:z
0
()
10,000
STEAM
TURBINE
ORIVER
MOTOR GEAR DRIVER
STEAM TUR61NE
GAS TURBINE
MOTOR GEAR
DRIVER
__L__j__t___J__L___\___j
1 ,000 L.__L__L_____L__.J____j___L___[
0
2
4
6
s
10
12
14
16
18
20 22 24
26 28
COMPRESSOR SPEED, RPM x 10-3
Figure 1.
11
Figure 4.
12
ROTOR DYNAMICS
Modern process compressors are buill in accordance
with the API specification 617. One important item
defined by this specification is the natural frequencies
of the rotor. These natural frequencies Inusl not occur
in the variable speed nwg:e of the compressor. The dy
namics of a rotor can be turlied w ith the help of the
computer and the effect on the rolrr of operative till
balance due to build-up misalig:nnu,n!. can be evaluated.
These rotor unbalm1ces w ill load the bearings. Com-
2 0
-+
CALCULATED
WITH UNBALANCE A T
300%
1.8
<t
Cl
U)
_j
:E
z
w
w
u
<t
_j
0...
U')
200%
1.6
200%
14
f2
(!)
z
0:
1.2
150%
1.0
<t
w
co
w
>
.a
100%
.6
4
50%
2
0
w
u
0::
8
SPEED,
Figure 5.
10
II
12
13
RPM
14
15
16
17
_j
w
a::
2.2
-
1.8
<(
c:i
250% w
200%
0
w
w
a.
(/)
!z 1.2
w
:IE
:IE
:::>
:::!1
1.0
<(
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g, .8
300%
1.6
(/)
150%
.6
(.)
a:::
0
LL.
(.!)
z
a:
<(
w
III
....
100%
50%
.4
.2
Figure
6.
OFF-DESIGN OPERATIO
Most compressor users take trouhle-free mechanical
operation for granted, hut they are concerned with com
pressor performance.
Figure a shOI\S a typical com
pressor performance curve. l"ncomplicatt>d and trouble
free operation can be expected in the stable performance
region to the right of the surge line. Surging, or un
stable operation, can occur in an centrifugal compresor
1rhen the inlet flow is reduced to approximately 60; of
the design inlet flow or lower.
Compressors that pro
duce large pressure ratios. ratio of inlet pressure to dis
charge pressure lend to have more 1iolent surp:es. \\"hen
the compressor is operated repeatedly or for prolonp:ed
periods of time in surge the pressure forces can damage
the internals of the machine.
For tho>'e applic-ations
where frequent surge operation can be expected the com
pressor internals should he made of steel. instead of the
more common cast iron material.
Figure <) sho11 s the
details of a five-slap:e compressor which hal' "heels, dif
fusers and return 'anes all made of steel plate material
desip:ned lo withstand surging.
When the compressor
is operated in surl!e continuously it absorbs approxi
mately -l-0'/r of the rated horsepower. howe\er the flow
thru-put is greatlv reduced and under some conditions
stops completely. The power required to dri1e the com
pressor in surge is therefore largely com erted to heal.
This causes excessi1e temperature build-up inside the
compressor and in a matter of seconds, if the conditions
are se1ere enough, can melt the soft lahHinth seals "hieh
control the internal leakage.
The co11pressor perform
ance suffer once the seal,; are damaged and the machine
must he opened and the st>als repl ced to restore it to
the ori;.dnal condition. Excessi1e temperatures in a com
pressor ha1ing a balance drum lain rinth seal made of
a soft material 11ith a low melting lmperalure can melt
the seal.
This will upset the rotor thrust balance and
01erloacl the thrust hearing:.
When the thrul hearin!!
fails the rotor 11ill shift axially and the impellers wi i l
ruh ai!ainst the stationary paris causini! further damai!e.
To help a1oid these operalinl! problems the compressor
can he JH"olicled "ith a hii!h temperature balance drum
seal made from compressed metal fihers that \1 ill \1ith
sland se1eral times the normal operating: discharge tem
peratures.
Another safety feature that can he employed is a
high temperature s11itch located in the balance drum
leakage pipe, as shown in Figure 10.
It is \\TOll/! to
locale this switch in the discharge pipe. In this location
the S\1itch does not protect the compressor since there
is not sufficient discharge flow to carry the heat to the
switch when the compressor is operated in surge. The
balance drum leakage pipe is the correct location for
this prolecli1e de1ice. There is leakage flow in this -pipe
e1en \1hen the comprcor is being operated completely
shut-off.
14
TF
"B"
Bearing Housing
(Upper Half)
:-;Pal
::i;,:ing
Dowel-
Pin
(J tl Seal
(Split)
Pad
Pin
Locking
Oil Outlet
Oil Inlet
(2
Holes)
"A"
Screw
(Both Sides)
Bearing Housing
"B"
(Lower Half)
SECTION "A-A"
SECTION "B-B"
Figure 7.
UNSTABLE
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SPEED
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INLET VOLUME
LOCATION OF SURGE
Figure 8.
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27
1-'
a>
OtL DRA\t.J
LOW
PRESSURE
S TATIONARY
HIGH PRESSURE
LOW
PRESSURE
LEAKAGE
PATH
LEAKAGE
PATH
S I MPLIES T DESIGN
LABYRINTH MATERILS
ALUMINUM, BRONZE,
BAB B I T, OR STEE L
STATIONARY
17
HIGH
PRESSURE
ROTATING
SURFACE (STEEL)
HIGH
PRESSURE
LOW
PRESSURE
LEAKAGE
PATH
ROTATING
RO TATING
STEEL
SURFACE
BABBIT, ALUMINUM,
NON-METALIC OR OTHE R
SOF T MATERIAL
D
Figure 1 1.
18
WIND BA CK
LABYRINTH
ATMOSPH ERIC
PRESSURE
HIGH
PRESSURE
GAS
HIGH PRESSURE
SEAL L EAKAG E
DRAIN
S E AL O I L
SUPP LY
Figure 12.
19
SEAL GAS
TO PR. REGULATOR
CONTAC T
SEAL
ATMOS PHRIC
PRESSURE
ROTATI NG
COLLAR
HIGH
PRESSURE GAS
BUFFER GAS
SUPPLY
SEAL LEAKAGE DRAIN
(H I GH PRESSURE)
SEAL OIL
DISCHARGE
Figure 13.
20
Figure 1-1.
(h namic
Figure 15.
"
o " RING
01 L PRESSURE
MOUNTING
ADAPTOR
MOUNT E D
A
Figure 1 o.
B
Hydraulically .ll ounted Coup/ing and Tools.
COUPLI NG
22
COMPRESSOR
FIXED FOOT
SLIDING KEY
FIXED PEDESTAL
COMPRESSOR-.......-/
'JI.d't-TEFLON SHIM
FOOT
f.L'I!FIXED PEDESTAL
DETAIL OF
SLID I N G FOOT
Figure 17.
Figure 18.
23
E
PARALLEL
SERIES FLOW
FLOW
BASIC
SUCTION IN
COMPRESSOR
ENDS
F
PARA LLEL
FLOW
SUCTION IN
CE NTER
-tt===:==::;:=;:::=rt
SERIES FLOW
TWO COOLING
POINTS
SERIES F LOW
ONE COOL! NG
POINT
SUCTION ON ENDS
COOL ENDS
.Q.
SERIES
SERIES FLOW
WITH DOUBLE
F L OW
ONE COOLING
FLOW INLET
POINT
AND SIDE
S TREAM
SUCTION IN
CENTER
WARM ENDS
Figure 19.
25
INTERNAL CONFIGURATION
The process market places very demanding and ever
changing requirements upon the selection and arrange
ment of the compressor internals and external casing
nozzle configuration. Centrifugal compressor selections
should be made with the ease of operation and mainte
nance aspects in mind as well as the compressing re
quirements. Figure 19 shows the most typical arrange
ments of the compressor internals and outer casing in
the form of simplified diagrams.
The operation and maintenance advantages are
listed for each as follows:
l. Single compressor body instead of two or more
results in a simpler system.
2. Hot discharge at center of case to reduce lubri
cation and oil seal problems.
CONCLCSION