Chapter 1

General Information

INTRODUCTION
This technical manual supplies information for the installation, operation, and maintenance
for your Elliott equipment. To avoid operational and maintenance difficulties, special
attention should be given to the precautionary instructions emphasized throughout the
manual.
Table of Contents contains Customers Order Information, Equipment Data and
Limitations, Warranty and Safety.
Chapter 1 - General Information provides a description of the equipment and procedures
for unpacking, handling and storage.
Chapter 2 - Installation discusses the basic foundation requirements along with the
alignment procedures, piping recommendations and other installation details.
Chapter 3 - Operation provides equipment guidelines for start-up and shutdown
procedures including recommended safety precautions to observe during operation.
Chapter 4 - Maintenance supplies a recommended routine maintenance schedule along
with disassembly, assembly and adjustment procedures.
Chapter 5 - Lubrication describes the lubrication system, the oil requirements and gives
consideration to the care of the lubricating oil.
Chapter 6 - Control System furnishes information required for operating, adjusting and
maintaining the control system.
Chapter 7 - Troubleshooting provides probable causes of problems and the necessary
corrective actions.
Chapter 8 Accessories - contains instructions and/or data and drawings applicable to
various accessory components provided with the equipment.
Chapter 9 Service/Parts/Sales provides the Normal Maintenance Parts List,
information on how to order parts and where to obtain service assistance and training for
operators and maintenance personnel.
Chapter 10 Technical Drawings - contains specific drawings for your equipment. The
drawing numbers may have a suffix number, or group number identifying the applicable
assembly on the drawing. Be sure to use the suffix listed when making reference to a
drawing.

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SHIPMENT PREPARATION
After shop testing, the equipment is prepared for shipment. The shipping preparation is
suitable for six months outdoor storage. Nonetheless, indoor storage, (inside a building
where the equipment will remain dry and at a constant temperature) is preferable over
outdoor storage.
Compressors
Normally, compressors are shipped completely assembled with the casing main joint bolts
torqued to specification. When the compressor is shipped as an assembly, the main joints
have been tested and should not be disturbed during installation and commissioning.
However, in the case of large frame compressors, due to handling and shipping
constraints, units may be shipped in halves which require field assembly.
Cortec VCI (Vapor Corrosion Inhibitor) 309 is fogged, or using equivalent means, into the
compressor internals. Bearing cases are inspected and cleaned, and bearings, retainers,
and journals coated with Chevron rust preventative. Vibration probes are removed,
identified, and separately boxed for shipment. In addition, for packaged equipment,
auxiliary piping, instruments, and instrument racks/panels may be removed and shipped
separately to prevent damage during transit. All items removed from the package are
suitably identified for field assembly.
On small rotors, clear plastic material is wrapped around shaft journals, and the bearing
retainer cap is replaced, locking the rotor in place. On large rotors, clear plastic material is
placed on top of shaft journals and the bearing retainer cap is replaced, locking the rotor in
place.
CAUTION
Leave clear plastic locking devices on shaft journals
while handling the equipment. Remove plastic before
alignment and/or startup.
Shaft ends and coupling hubs, if installed, are coated with Tectyl 506 and then wrapped
with waterproof paper. In addition, a metal protective cover is installed to protect the shaft
end during shipment.
Rotors
Rotors shipped out of the casing are thoroughly slushed with Tectyl 506 or equivalent.
Bearing journals and all other critical areas (e.g. shaft ends, shaft seals, etc.) are wrapped
securely with Grade L-2 waterproof paper. The rotor is then put in its shipping container
or secured to the shipping skid. At the points where the rotor is supported, not the
journals, TFE (Polytetra-fluorethylene) and copper sheeting are used between the rotor
and the support. When a spare rotor is purchased, it is treated with Tectyl 506 or
equivalent and placed in an export quality wood box or (if purchased) metal rotor
container. With indoor storage, this protection is good for approximately three years
provided the protective wrapping is not damaged.

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Lubrication and Seal Oil Consoles
After factory testing, the lubrication and seal oil console and oil header piping are drained
and cleaned. Most systems today are stainless steel and do not require additional
protection for shipment.
Exposed machined surfaces, pipe flanges, and tank openings are coated with Tectyl 506
or equivalent, and covered with rubber gasketed metal covers. Unpiped threaded
openings are plugged or capped. Pipe connections are metal tagged for reassembly
identification in the field. When possible, piping, valves, and regulators are shipped as
part of the assembled console. However, components vulnerable to handling and
shipping damage are removed, packaged, and shipped in separate containers.
The equipment is placed on skids and enclosed in boxes constructed to suit the
requirements of the shipment. The packing list is placed in a waterproof envelope and
attached to the main box.
RECEIVING SHIPMENT
Closely inspect the shipment for damage. Immediately notify the transporting agent of any
damaged items. Define the extent of the damage in as much detail as possible.
Photographs of damaged items can also be very useful for settling damage claims.
Use the packing list as a check-off list to inventory the entire shipment.
missing items immediately, to the Elliott Company office.

Report any

HANDLING
Lifting and handling the equipment must be carefully planned around the availability of
cranes, lifts and hoists at the installation site. Exact procedures for handling the
equipment are left to those responsible for the handling task.
To help plan handling the equipment, approximate sizes and mass of the major
components are shown on the outline drawings. The values shown on the outline drawing
do not normally include the weight of shipping skids or crating. When lifting or handling a
compressor independent of the baseplate, the lifting slings should cradle the casing. Keep
the equipment level, and protect all machined surfaces when lifting or handling any
rotating equipment. Also, leave all protective covers in place.
CAUTION
Do not lift equipment using lifting connections on the
top half casings. These connections are for lifting only
the top half casing.

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LONG TERM STORAGE AND ALTERNATIVE SHIPPING PREPARATIONS
Our equipment is shipped to worldwide locations for many different applications under a
myriad of local conditions. For this reason, alternative shipping preparations may include,
but are not limited to, nitrogen purging, complete internals coated with a permanent rust
preventative, or instructions to regenerate the Cortec VCI-309. If there are any questions
regarding the equipment preservation, our local field service office is to be consulted.
For new equipment that has not been placed in service, provide maximum protection
(approximately 3 years), by storing the equipment on a level surface, in a dry building
having a constant temperature of approximately 60 to 70F (16 to 21C).
In any case, periodic inspections are recommended for all idle or stored equipment.
Check the preservative for deterioration and inspect the equipment for corrosion. Remove
corrosion immediately and apply a fresh coat of preservative. If there are questions
regarding the condition of the equipment, consult the local Elliott field service office.

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COMPRESSOR DESCRIPTION
MB Compressor
This section describes the Elliott multistage barrel (MB-Line) centrifugal compressor with
an outer casing and clarifies components which are common to the MB-Line compressor.
A better understanding of the main compressor components can be obtained by referring
to the Compressor Assembly drawing in Chapter 4 and the description which follows.
The compressor consists of a horizontally split inner casing which houses the rotor, inlet
guide vanes, diaframs and intake and discharge walls. Also, the balancing piston seal,
shaft end and interstage seals are contained in the inner casing. By pulling the barrel out
of the compressor casing, and lifting off the top half of the inner barrel, all compressor
internals, including impellers and seals, are accessible for inspection. The shaft bearings,
thrust and journal, are contained in the bearing housings which are located at the inlet and
discharge ends of the main casing. Specific operating conditions are determined for each
job and are listed in the Compressor Operating Data, found in the Equipment Data section
of this manual. The compressor is made up of stationary and rotating components.
Casing
The casing is designed with an outer casing barrel and horizontally split inner casing. The
inner casing is completely assembled and slid into the outer casing on assembly. The end
wall is held in place by a closure key which completes the casing assembly.
Inlet Guide Vanes
Located in front of each impeller are inlet guide vanes which provide proper gas flow
direction for the gas as it enters the impellers. Inlet guide vanes are an integral part of the
diafram.
Diaframs
The diaframs serve as partitions between the various stages and are made of steel. They
also form passages to direct the flow from the impeller discharge to the inlet guide vanes
of the next stage. The accurately machined surfaces form spaces in which the impellers
rotate. The extension of these surfaces form the diffuser which effectively converts the
velocity of the gas to pressure energy. The diaframs also contain the interstage seals.
Inlet Wall
The inlet wall forms the inlet passage for the gas flow.
interstage seal at the eye of the first stage impeller.

The inlet wall contains the

Discharge Wall
The discharge wall forms the outlet passage for the gas flow. The discharge wall contains
the balance piston labyrinth seal assembly.
Discharge Volute
The discharge volute is a spiral-shaped chamber which collects the gas as it leaves the
last impeller. This volute further decreases the veloctiy of the gas, converting the kinetic
energy to pressure. The gas is then discharged form the compressor through a discharge
pipe.

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Interstage Labyrinth Seals
The purpose of the interstage labyrinth is to minimize leakage between the stages. The
labyrinth seal at the impeller entrance is called the impeller eye labyrinth seal while the
one located behind the impeller is called the shaft labyrinth seal.
The labyrinth material is normally an abradable material. The interstage labyrinths consist
of a series of concentric metal teeth integral with the shaft sleeves and/or impeller.
Balance Piston Labyrinth Seal
To minimize the amount of gas leakage past the balancing piston and create a pressure
differential, a balance piston labyrinth seal is fitted in the discharge volute. The labyrinth
teeth on the balance piston are steel and the seal material is abradable.
Casing End Seals Tandem DGS/PDGS Gas Face Seals
Multi-stage centrifugal compressors have several areas, which require sealing. Primarily,
the purpose of seals is to minimize leakage. The amount of leakage permitted, the type of
gas being compressed, and the operating pressure of the compressor determine the type
of seal used.
Shaft seals, located at each end of the compressor, are used to separate the gas stream
from the bearing chambers. This compressor has Burgmann Tandem DGS/PDGS gas
face seals.
Refer to drawings in the Maintenance chapter showing a tandem gas seal cartridge. The
gas seal cartridge consists of a primary (inboard) and secondary (outboard) seal
assembly in a tandem arrangement. The principle components are the rotating mating
ring and the stationary primary ring. The mating ring has a partial spiral groove pattern on
the sealing face that, when rotating, pumps gas inwards towards a non-grooved portion of
the face that serves as a barrier to gas flow. The end of the grooves function as a dam,
causing a pressure increase, which acts to separate the primary ring from the mating ring.
Separation forces increase instantaneously, if the faces tend to approach each other,
preventing face-to-face contact and wear. The mating ring is made of silicon carbide to
prevent wear. The primary ring is made of silicon carbide and is spring loaded to close
the faces at standstill and no pressure differential. Lift off, or face separation, usually
occurs at low speeds. Face separation can also be achieved without rotation by applying
gas pressure of about 100 to130 psig to the seals. (Hydrostatic lift off)
Note: For Bi-Directional seals, the principles of operation remain the same as UniDirectional seals even though the groove patterns differ in appearance.
In addition to the gas seal cartridge, there must always be an inboard labyrinth to restrict
buffer flow and promote cleanliness. An outboard separation seal is provided to prevent
bearing oil from entering the gas seal. See Buffer Gas System.
If the gas seals need to be stored after removal, they must be done so with the installation
plates assembled. This holds the rotating and stationary elements in alignment. It is
important that the appropriate installation plate be on its corresponding seal. The original
packing crates, with foam, and plastic seal covering should be used. Grease paper, oil
paper, or waxed cotton should not be used. The crates, with seals, should then be kept in
a warm dry dust free atmosphere lying on a flat surface.

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If the seals are to be stored inside the compressor for long periods, it is necessary to
insure that the seal faces are not contaminated with oil. This is necessary to prevent the
seal faces from binding together.
It is recommended that seals be returned for external and internal O-ring replacement after
being stored for 4 to 5 years, as their performance will deteriorate after this period of time.
Contact your local Elliott Company representative.
Buffer Gas System Tandem DGS/PDGS Gas Face Seals
Gas face seals eliminate the need for seal oil. To prevent liquids or particles that could
damage the gas seal cartridge, clean filtered process gas or inert gas is injected into the
seal cavity between the inboard seal assembly and labyrinth, at a pressure slightly above
that being sealed. This buffer gas must be operative prior to pressurization of the
compressor casing. A backup source must be available in the event of a loss of the
primary buffer source. The inboard labyrinth allows the filtered buffer gas to flow back into
the compressor, which ensures a clean seal environment. The buffer gas will also leak
through the inboard seal faces into the cavity between the inboard and outboard seal
assemblies. The outboard seal assembly seals off the primary seal leakage, which is then
vented to a flare. This outward leakage is an indication of seal health and must be
continuously monitored. Any increasing or decreasing trend in flow rate indicates a
deterioration of seal health. The compressor should not be operated under any conditions
if this leakage is found to be nil. The outboard seal also acts as a safety seal in the event
of excessive primary seal leakage. Inert buffer gas is also injected into the separation seal
to prevent bearing oil from getting into the gas seal parts. Separation seal buffer gas must
provide a positive flow prior to turning on the oil system.
Journal Bearings Spherical Seat
The two horizontally split tilt shoe type bearings support and radially position the rotor.
The bearings are positioned and prevented from rotating relative to the shaft by use of an
anti-rotation pin or capscrew between the bearing base ring and the bearing retainer cap.
The journal bearings are the spherical seated tilting pad type and are pressure lubricated.
The drawings located in the Maintenance chapter provide additional information.
The tilt shoe type bearing assembly consists of separate items, namely, the cylindrically
shaped base ring, and the tilting shoe assembly, comprised of five shoes and five seats.
The base ring is horizontally split and mounted in the bearing retainer. The base ring
supports the tilting shoe assembly. The five babbitted faced shoes are spaced 72o apart.
The shoe is free to tilt as required to support the load, and pivots at its center on the seat,
on a finely ground surface. Due to the spherical surface, the pad is able to compensate
for some shaft misalignment, in addition to compensating for shaft/bearing concentricity.
The seats are made of alloy steel or copper alloy.
The base ring incorporates babbitted wiper rings at each end. The clearance of the two
babbitted wiper rings is larger than the tilt shoe clearance, insuring that the journal rides
on the tilt shoes and no contact is made on the wiper rings. At the same time, the wiper
rings aid in controlling oil flow through the bearing, and insure flooding of the bearing.
The journal bearings are lubricated and cooled by oil supplied under pressure. Oil enters
the journal bearings through drilled passages which open into the bearing.

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Thrust Bearing
The purpose of the thrust bearing is to absorb rotor thrust and to position the rotor axially
within the compressor casing. A thrust bearing disk fitted to the rotor shaft assembly
transmits the rotor thrust to the thrust bearing.
The thrust shoes of the thrust bearings are steel-backed or copper-backed, tin base
babbitt. The shoes are free to form a wedge shaped oil film between the shoe surface and
the thrust disk by pivoting on self-equalizing links. If specified, thrust shoes are supplied
with embedded thermocouples or resistance temperature detectors. RTDs are standard
offering.
Chapter 4 provides additional thrust bearing information including maintenance,
adjustments, etc. The thrust bearing is also pressure lubricated.
The rotating component of the compressor consists of the following:
Shaft
The shaft is made of forged steel. Mounting the impellers, shaft sleeves, thrust disk,
balancing piston, rotating seal parts and coupling on the shaft comprises the rotor
assembly.
Impeller
The impellers are made of alloy steel. They are the closed type, with backward leaning
blades. The impeller construction can be of welded or brazed construction. The welded
construction can have separate or milled integral blades. The brazed impellers have
blades milled integral to the cover. The impellers are accurately machined and balanced,
then shrunk on to the shaft.
Shaft Sleeve
Sleeves are used between impeller wheels for spacing or aerodynamics. The sleeves are
also shrunk on the shaft, forming a part of the rotor assembly.
Thrust Disk
The thrust disk, which is hardened and ground on both sides, is mounted on the shaft.
The thrust disk with the thrust bearing maintains the proper axial position of the rotor and
also transmits the rotor thrust through the thrust bearing and to the bearing retainer.
Balance Piston
Due to the pressure rise developed through the impeller, a pressure difference exists
across the hubs and covers such that the impellers have a net thrust in the direction of the
compressor inlet. The majority of this thrust is counteracted by the balance piston drum
located behind the last impeller. This is accomplished by subjecting the area on the
outboard side of the balancing piston to a low pressure (approximately inlet pressure),
thereby creating a pressure differential opposite in direction to that on the impellers. This
low pressure is achieved by connecting the area behind the balance piston to the inlet of
the machine by a balance piston line. The impeller thrust, not balanced by the balance
piston, is absorbed by the thrust bearing. A balance piston labyrinth seal minimizes the
amount of gas leakage past the balancing piston.

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After all the components have been assembled, comprising the rotor assembly, the rotor is
then indicated for concentricity and final balance.
The coupling connects the rotor assembly to the driving machine.
OPERATING PRINCIPLES
A centrifugal compressor converts the energy of centrifugal force into the useful work of
compressing gas. The compressor has multi-stage construction with the rotor located
between shaft bearings. Specific operating conditions are determined for each job and
are listed in the Compressor Operating Data, found in the Equipment Data section of this
manual. In the centrifugal compressor, the gas travels more in a radial direction than in
the axial direction. The gas is compressed by the mechanical action of rotating blades or
impellers imparting velocity to the flowing gas.
The air or gas enters the compressor through the inlet flange and is directed into the inlet
or eye of the first impeller through a set of inlet guide vanes. The guide vanes serve to
direct the gas in the proper direction.
The impeller rotates at high speed which varies, depending on the type and size of the
compressor. This high rotative speed causes the gas to be thrown outward by centrifugal
force and with high velocity. Centrifugal force creates a lower pressure at the impeller
inlet so that more gas is forced in by the external pressure in the suction pipe.
The velocity is decreased and converted into pressure in the diffuser channel following the
impeller. The gas then crosses over and returns to the next impeller through a set of
return channels, including guide vanes to properly direct the gas into the next impeller. As
the gas goes through each stage, its pressure is increased.
After the gas leaves the last impeller, it is collected in a spiral-shaped chamber (volute)
from which it passes into the discharge pipe.

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NOTES

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OF CONTENTS