501

Reverse Rotation in Centrifugal Compressors

40th Turbomachinery Symposium

12-15 September 2011 – Houston,TX
Presented by Amr Gad
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Outline

• Introduction
• Process overview
• Compressor design & construction
• Narrative of reverse rotation events
• Cause of reverse rotation
• Possible impacts of reverse rotation
• Mitigating actions taken
• Lessons learned
• Conclusion

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Introduction
RasGas
Condensate operation
Shutdown status Plant phase 1 Shutdown status
Phase 2 site Plant phase 2 phase 1 site
No compressors reverse – Loading Compressors Compressors reverse rotation
rotation
exists

Presentation Purpose :
1- Explain the impacts ,cause, and mitigations related to phase 1 compressors operation.
2- Phase 1 compressor operation lessons learned implemented in phase 2 .

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Process Overview

Phase 1 (since 2005)

• Six compressors.
• Design pressure ratio for LP ,MP, HP is about 3 for each stage
(Pd / Ps).
• Design overall pressure ratio for the machine about 28 (Pd /
Ps).
• Volume of suction vessels LP, MP, HP more than 50 meter
cube for each.

Phase 2 (since 2009)

• Four compressors in operation.
• Similar design pressure ratio & overall pressure ratio as phase
1.
• Triple the volume of suction vessels compare to phase 1.
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Process Overview

Cooler SDV
Open

SDV ITVs
Open ASV 100% Close

3RD

2N
D

1ST

Machines During Normal Operation

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Compressor Design & Construction

Phase 1
• Unit configuration: Fixed speed electric motor &
gear box& compressor.
• Compressor rated at: 3.7MW
• Motor rated at: 4.2 MW
• Gear box speed: 1480 / 10258 RPM
• Compressor operating speed: 10258 RPM
• Seal configuration: Unidirectional dry gas seal.
• Bearing construction:
• Compressor: Tilt pad self equalizing
• Motor: Cylindrical sleeve bearing
• Gear box design: Double helical.
• Lube oil: Rundown tank with two AC pumps (Main
& Auxiliary).
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Reverse Rotation Events

• Reverse rotation happened since commissioning of

the machines.
• However, they were only discovered after 18 month
of units operations. Late discovery was due to:
• No reverse rotation detection system installed.
• No prior experience in-house with reverse rotation in this type of
process configuration.

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Cause of Reverse Rotation

RCFA findings:
• Reverse hydraulic
flow due to large amount
of entrapped hydrocarbon
volume in the piping and
suction vessels of the MP &
HP sections.

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Cause of Reverse Rotation

• Hydraulic flow occurs

after 10-15 seconds from
a stop command till
compressor coast down
to zero RPM speed.

• Hydraulic flow during the

reverse rotation from
zero speed till 5000 RPM
and back to zero again
within 4 to 6 minutes.

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Cause of Reverse Rotation

Figure A
Speed trend (Figure A)
• Unit stop very fast after stop
command.
• Unit speed ramp up again in
reverse rotation to almost
5000 RPM for the compressor.
• After speed reaches 5000 RPM
it cost down again to zero
speed in about 4-6 minutes. Figure B
• This phenomena is repeated
each time the machine stops.

Flow rate trend (Figure B)

• Showing flow exchange &
equalizing between stages.

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Possible Impacts of Reverse Rotation

Existing unidirectional dry gas seal are not

Uncontrolled gas release
guaranteed for such modes of operations as per
from the compressors.
OEM guide lines.

Lube oil system design doesn’t support reverse

Bearings damage rotation with total electric power black out , as
auxiliary and emergency pumps is AC driven and
the overhead tank is designed for only 3 minutes .

Compressor components No detailed study conducted by OEM to confirm

failure due to reverse impacts on various machines components
rotation ( Impeller vanes, diffusers, Labyrinth seals ,…etc ).

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Mitigating Actions. Phase 1 Compressors

• Minimize the number of units starts and stops until

modify the system.
• Future installation of check valves at the suction of
the LP & MP.

Cooler SDV
Open

SDV
ITVs
Open ASV 100% Close

3R
D

2N
D
ST
1

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Mitigating Actions. Phase 2 Compressors

• Interim - modified the I&C for the ITV’s of the MP &

HP to fully close during machine stop.
• Final - install check valves at the suction of the LP,
MP and immediately after the discharge.

Cooler SDV
Open

SDV
ITVs,
Open ASV 100% Close
final position

3RD

2ND

1ST

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Mitigating Actions. Phase 2 Compressors

Shutdown with ITV closing

before tuning

Shutdown With ITV closing

after tuning

Shutdown with check valve installed

and ITV closure removed
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Lessons Learned

• Dynamic simulation requirements for such process

configurations.
• Mitigating actions to eliminate reverse rotation
should consider:
• ITV modification for complete closure during shutdown.
• Installation of check valves at suction lines.
• Machines construction should include mitigating
design:
• Bidirectional seal will eliminate risk from reverse rotation.
• Center pivot for tilting pad can accommodate reverse rotation
better than offset pivot design.
• API standard is for 3 minutes run down tank design and so,
emergency DC pump is an advantage.

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Conclusions

• Reverse rotation phenomena have potential to

occur in the LPG refrigeration cycles.
• Reverse rotation phenomena is more common in
the motor driven compressors with relatively low
machine inertia.
• Detailed surveillance of coast down speed trends of
new units is recommended to ensure detection of
Reverse Rotation:
• Reverse rotation phenomena may not increase vibration or axial
movements above alarm values.

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Thank You
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Pressure trends for unit stop

Plot-0

22 171PI1221B.PV
Pressure equalization
0.20
19 between the three stages BARG
in conjunction with the 171PI1224BA.PV

14
reverse rotation 4.40
BARA
171PI1226B.PV
4.41
9 BARG
171PI1228BA.PV
4.41
4 BARG
171PI1231B.PV
4.41
-1 BARG
11/23/2006 6:33:38 PM 7.47 minutes 11/23/2006 6:41:06 PM 171PI1233BA.PV
171K001B BOG COMP SUC 4.41
K001B 1ST SUCTION PRESS BARG
K001B 2ND SUCTION PRESS 171PI1236BA.PV
K001B 2ND SUCTION PRESS 4.38
K001B 3RD SUCTION PRESS BARG
K001B 3RD SUCTION PRESS 171PI1237B.PV
K001B DISCHARGE PRESS 4.40
171K001B C3 BOG COMP OUT

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• ASV improper function is potential cause for

reverse rotation during coast down.
• Experienced in LNG BOG compressor when opening time upon
shutdown is more than 2 seconds due to valves stuck or
instruments failures.

Plot-0
Plot-0

71FI3142A.PV 30 30 14000 3000 71FI3142A.PV

30 30 14000 3000
0. 0.
KNM3/H KNM3/H
71PI3129A.PV 71PI3129A.PV
25 25
0.3953 0.45781
BARG BARG
71SI3508A.PV 71SI3508A.PV
0. 20 0.
20
RPM RPM
71SI3510A.PV 71SI3510A.PV
0. 0.
RPM 15 RPM
15

10 10

5 5

0 0 0 0 0 0 0 0
6/6/2007 11:37:03 AM 10.08 minutes 6/6/2007 11:47:08 AM 10/6/2006 9:29:51 PM 2.23 minutes 10/6/2006 9:32:05 PM
71K051A BOG COMP DSCH 71K051A BOG DSCH PRES 71KX051A GR KYPHSRCOMP SD 71KX051A GR KYPHSRMTR SD 71K051A BOG COMP DSCH 71K051A BOG DSCH PRES 71KX051A GR KYPHSRCOMP SD 71KX051A GR KYPHSRMTR SD

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