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Tyht PDF
Tyht PDF
by
H. M. Davis
Manager, Ct•ntrifugal Compressor Engineering Department
DELA VAL Turbine Division, Tr<�nton, N. J.
I
100.000
i
::;
"-
'-'
31:
0
-'
...
1-
w
..J
STEAM
;!!;
TURBINE
15
Vi
ORIVER
�
:z
0
10,000 � 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. jl,'fulti-stage Fabricated Case Compressor. Figure 2. Application Chart for Centrifugal Compressors.
10
CENTRIFUGAL COMPRESSOR OPERATION AND MAINTENANCE 11
RANGE OF APPLICATION
Figure 2 is a curve which shows the limits of appli·
cations for centrifugal compressors in terms of flow and
speed. The speed is limited by the stresses in the im
pellers. The small flow, high speed compressors have
the same working stress levels as the large flow, low
speed machines. The compressor applications in the
low flow range are almost entirely driven by motors and
speed increasing gears. The compressors in the mid
range of flows are driven by motor-gears, steam turbines,
and some gas turbines. The large, high flow compressors
are practically all driven by steam turbines.
The size and operating speed of a centrifugal com
Figure 3. Four-Stage Barrel Compressor. pressor have a direct effect on the operation and the
maintaining of the compressor.
series and is designed to compress 4000 cfm of gas from A small machine such as the one shown in Figure 3,
an inlet pressure of 25 psi to a discharge pressure of besides having high rotating speeds, is usually high pres
425 psi. Each impeller imparts velocity (kinetic) energy sure as well. Shaft alignment is more critical since the
shaft ends are small and external pipe forces must re puter analysis allows the engineer to predict these bear
ceive proper attention to ensure good operation of the ing loadings and to design a dependable maintenance
equipment. Maintenance is easier due to the light weight free machine.
of the compressor components, hut the clearances of the
internal seals and hearings must be watched more closely Figure 5 shows the calculated and measured rotor
due to their small physical size. response curves for an eight-stage compressor rotor.
The measured values were obtained first during the
A large compressor, such as the one shown in Figure mechanical test of the compressor. Although the vibra
4, is more difficu It to vwrk on due to its size and weight. tion level w as less than 0.7 mils and the bearing forces
The clearances between rotating and stationary parts is were below the design dynamic load limit, the steepness
less critical hut the shaft alignment i� more difficult to of the vibration curve near the maximum operating
obtain, although more liberal tolerances are acceptable, speed was understandably cauiie for concern. The rotor
because the components are not easy to move and special was modified and retested.
lifting facilities are required. The foundation for these
large machines is also of special concern because unless These results are shown in 6. The test
the supports are de,.igned, constructed, and maintained shows quite low vibration amplitudes and low bearing
properly the machinery may never achieve trouble-free loading. The compressor, once in actual service, w ill
become unbalanced due to build-up on the rotor. The
operation.
difference between the calculated and measured response
curves shows that this compressor will be tolerant !o
ROTOR DYNAMICS con:oiderable rotor deposits before it w ill have to be
Modern process compressors are buill in accordance cleaned. ! ightly loaded j ournal bearings, such as those
with the API specification 617. One important item used in compressors, can he unstable at high speeds, and
defined by this specification is the natural frequencies a number of "'olutions to this problem have been used.
of the rotor. These natural frequencies Inusl not occur The tiltinf!; pad hearing, like the one shown in Figure 7,
in the variable speed nwg:e of the compressor. The dy is widely usNl in compressors. Each shoe tilts inde
namics of a rotor can be �turlied w ith the help of the pendently to maintain its load carrying hydrodynamic
computer and the effect on the rolr•r of operative till · pressure wt.�dgf:. Extensive service in many types of
balance due to build-up misalig:nnu,•n!. can be evaluated. cornprr:ssors have proven the dependability of this
These rotor unbalm1ces w ill load the bearings. Com- hearing.
22
CALCULATED WITH UNBALANCE A T ANTI·NODE OF 2nd CRITICAL
-+
300%
+ MEASU R ED WITH NON·CONTACT PICKUP
2 0
1.8
200%
1.6 w
<t u
0::
f2
Cl
14 200%
U)
_j (!)
z
:E 1.2 0:
<t
� 150% w
z co
w 1.0
� w
w >
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u .a
<t
_j 100%
0... w
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.6
a
4
50%
+
/
2
0
0 2 3 4 5 6 7 8 9 10 II 12 13 14 15 16 17
SPEED, RPM
2.2
300%
- CALC ULATED WITH UNBALANCE AT ANTI-NODE OF 2nd CRITICAL
1.8
250% w
<(
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200%
(/)
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w z
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150%
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ALLOWA BLE DYNAMIC L OAD
100% �
.6
.4
50%
.2
OFF-DESIGN OPERATIO� are se1·ere enough, can melt the soft lahHinth seals "hieh
Most compressor users take trouhle-free mechanical control the internal leakage. The co1�1pressor perform
operation for granted, hut they are concerned with com ance suffer� once the seal,; are damaged and the machine
pressor performance. Figure a shOI\S a typical com must he opened and the st>als repl� ced to restore it to
pressor performance curve. l"ncomplicatt>d and trouble the ori;.dnal condition. Excessi1e temperatures in a com·
free operation can be expected in the stable performance pressor ha1ing a balance drum lain rinth seal made of
region to the right of the surge line. Surging, or un a soft material 11ith a low melting l�mperalure can melt
stable operation, can occur in an� centrifugal compres»or the seal. This will upset the rotor thrust balance and
1rhen the inlet flow is reduced to approximately 60�; of 01·erloacl the thrust hearing:. When the thru�l hearin!!
the design inlet flow or lower. Compressors that pro· fails the rotor 11ill shift axially and the impellers wi i l
duce large pressure ratios. ratio of inlet pressure to dis ruh ai!ainst the stationary paris causini! further damai!e.
charge pressure lend to have more 1iolent surp:es. \\"hen To help a1·oid these operalinl! problems the compressor
the compressor is operated repeatedly or for prolonp:ed can he JH"ol·icled "ith a hii!h temperature balance drum
periods of time in surge the pressure forces can damage seal made from compressed metal fihers that \1 ill \1ith
the internals of the machine. For tho>'e applic-ations sland se1eral times the normal operating: discharge tem
where frequent surge operation can be expected the com peratures.
pressor internals should he made of steel. instead of the
more common cast iron material. Figure <) sho11 s the Another safety feature that can he employed is a
details of a five-slap:e compressor which hal' "heels, dif high temperature s11itch located in the balance drum
fusers and return 'anes all made of steel plate material leakage pipe, as shown in Figure 10. It is \\TOll/! to
desip:ned lo withstand surging. When the compressor locale this switch in the discharge pipe. In this location
is operated in surl!e continuously it absorbs approxi the S\1itch does not protect the compressor since there
mately -l-0'/r of the rated horsepower. howe\·er the flow is not sufficient discharge flow to carry the heat to the
thru-put is greatlv reduced and under some conditions switch when the compressor is operated in surge. The
stops completely. · The power required to dri1·e the com balance drum leakage pipe is the correct location for
pressor in surge is therefore largely com erted to heal. this prolecli1·e de1ice. There is leakage flow in this -pipe
This causes excessi1·e temperature build-up inside the e1en \1hen the comprc��or is being operated completely
compressor and in a matter of seconds, if the conditions shut-off.
14 PROCEEDINGS OF THE FIRST TURBOMACHINERY SYMPOSIUM
TF "B"
Bearing Housing
(Upper Half)
:-;Pal
::i;,:·ing
Dowel-·
Pin
(J tl Seal
(Split)
Pad
Pin
Locking
Oil Outlet Screw
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is extremely dirty and internal washing cannot be used -" t--t----.
-- -- - - SPEED
it may be necessary to shut down in o rder to clean the
compressor internals to restore full flow capacity.
/ ""
- --
The internal seals that prevent leakage around the
-- --
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100%
?
impellers are normally of the labyrinth type, as shown 0 -- -- -- - -
"%
in Figure llA. They consist of a series of circumferen·
-
tial knife points that are positioned closely to the rotating ...
-- --�--
... �, r--"-
impeller. In order for the compressor to maintain the a:
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(I)
(I)
7 �%
design performance these knife points must not be dam· ...
a:
aged by rubbing, erosion, corrosion, or plugged-up w ith 11.
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LEAKAGE LEAKAGE
PATH PATH ROTATING
SURFACE (STEEL)
S I MPLIES T DESIGN
LABYRINTH MATERILS MORE DIFFIC ULT T O
ALUMINUM, BRONZE, MANUFAC TURE B U T PRO DUC E S
BAB B I T, OR STEE L A TI G HTER S EAL
SAME MATERIAL AS II A
A 8
LOW HIGH
PRESSURE PRESSURE
LEAKAGE
PATH
ROTATING RO TATING
STEEL SURFACE
c D
shaft runout indicates that the impeller is not square tinely check the balance of complete rotors and make
on the shaft and must be adjusted before checking the corrections on the first and last impellers. This practice
balance. When the balance check, after installing an is wrong for flexible rotors that have more than three
impeller on the shaft, indicates that an unbalance exists, impellers. The only sure way to balance a completely
the correction is made to the last impeller that was assembled high speed rotor is to use a high speed bal
mounted. This procedure if strictly followed can pro· ance machine. The rotor unbalance must be checked
duce a well balanced rotor even when the balancing is throughout the operating speed range and any correc
done in a low speed balance machine. Figure 1-t shows tions that are made to the rotor must be made at the
a typical low speed balance machine. Some users rou- plane of unbalance. Most balance shops in this country
18 PROCEEDINGS OF THE FIRST TL'RBOMACHINERY SYMPOSIUM
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
SEAL GAS
SEAL OIL SUPPLY
TO PR. REGULATOR
CONTAC T
SEAL
ATMOS PHRIC
PRESSURE
ROTATI NG
COLLAR
HIGH
PRESSURE GAS
BUFFER GAS
SUPPLY
SHAFT END
CH ECK NUT
MOUNTING
ADAPTOR
A B
COMPRESSOR
FIXED FOOT
SLIDING KEY
FIXED PEDESTAL
COMPRESSOR-.......-/
FOOT �'JI.d'�t-TEFLON SHIM
f.L'I!��FIXED PEDESTAL
DETAIL OF
SLID I N G FOOT
E A
PARA LLEL
FLOW
SUCTION IN
CE NTER
-tt=���==:==�::;:=;:::=rt
SERIES FLOW SERIES F LOW
TWO COOLING ONE COOL! NG
POINTS POINT
SUCTION ON ENDS
COOL ENDS
H .Q.
SERIES FLOW SERIES F L OW
WITH DOUBLE ONE COOLING
FLOW INLET POINT
AND SIDE SUCTION IN
S TREAM CENTER
�
WARM ENDS
compressor mount with holddown shoulder bolts that :-t Reduced po11er required to compress gas results
allow the case to slide axially upon lubricated shims but in a smaller dri1·er.
limit the vertical movement of the case. With this ar
L Back to hack impellers reduce natural rotor
rangement a vertical key and keyway are located be
thrust and allows for more internal seal wear hefore over·
tween the case and foundation on the vertical centerline
loading thrust hearing. Increase time l1etween 0\·erhauls.
to prevent transverse movement of the case. This mount·
ing requires a special foundation to support the vertical 5. Cold inlet at center of case to reduce lubrication
key and also regular lubrication of the shims. and oil seal prohlems.
The compressor case mounting shown in Figure 18 6. Smaller compressor and higher speed to do the
allows for thermal growth of the case in all directions, same compression job. Reduced foundation and main
provides centerline support for the case, has four mount· tenance problems.
ing pads that are all bolted and doweled to the founda
7. Single inlet to better suit external piping ar·
tion, and requires no maintenance. The ruggedness of
this support will allow for considerable external forces rangement.
to be exerted upon the casing without changing the shaft B. Single discharge to better suit external piping
alignment. arrangement.
<), No external balance piston leakage pipe. Com
INTERNAL CONFIGURATION
pressor can tolerate increased balance seal 11ear without
The process market places very demanding and ever upsetting thrust balancing s� stem and 0\·erloading thrust
changing requirements upon the selection and arrange·
bearing.
ment of the compressor internals and external casing
nozzle configuration. Centrifugal compressor selections 10. Hot or cold sections of case are adjacent to
should be made with the ease of operation and mainte· reduces thermal gradients and distortion of the case.
nance aspects in mind as well as the compressing re· :\lakes alignment easier to achie1 e.
quirements. Figure 19 shows the most typical arrange·
ments of the compressor internals and outer casing in CONCLCSION
the form of simplified diagrams.
t
This paper has been presented to show that centrifu
The operation and maintenance advantages are gal compressors can be designed, applied, and selected
listed for each as follows: llith the customers operation and waintenance require·
'
l. Single compressor body instead of two or more ments in mind, without making an ompromises in the
results in a simpler system. actual compressor performance. . of the items cov
ered in this paper would make · . itable subjects for
2. Hot discharge at center of case to reduce lubri separate, full length, presentations, lipwe1·er the time and
cation and oil seal problems. space available does not make thif-.treatment possible.