Ccfamgb SBM

Welcome from
Le HAVRE
Customer Training department

2012 by Dresser-Rand
Prsentation
Name : DIESNIS Patrick Department : Customer training Purpose of this training :

FAMILIARISATION ON CENTRIFUGAL COMPRESSOR
Warning
DISTRIBUTION OF THIS PRESENTATION TO ANY NONDRESSER-RAND EMPLOYEE IS PROHIBITED! This presentation consists of Copyright items and may not be reproduced in any format, including electronic or printed format, without the prior written approval of the author, Dresser-Rand Product Training, Le Havre, FRANCE. The content of this presentation is considered intellectual property of Dresser-Rand S.A. The contents of this program, either in part or whole, may be used for internal or external presentations. However, the contents may not be distributed or copied by any means (electronic, on paper, etc.), in part or in whole, to non-Dresser-Rand employees. DO NOT REMOVE THIS SLIDE FROM THIS PRESENTATION! This slide MUST NOT be removed from this presentation or any part thereof.
General arrangement
Gas turbine Compressors
LP & MP Gear LP & MP = D10R6B HP = D4R8S
HP
General arrangement
LP & MP = D10R6B HP = D4R8S
LM 2500
Planning
First day :
Dresser-Rands presentation. Introduction on the centrifugal compressors :
Fundamentals. Types et models.

Compressor components :
Static and rotating parts.
Planning
Second day :
Compressor components :
Static and rotating parts. Thrust and bearings.

Several types of seals :
With labyrinths, with oil, with gas.

Presentation of the DRs gas seals. Oil system : Oil console, cooler.
Planning
Third day :
Oil system : Continuation. The surge. How does a centrifugal compressor operate ? Maintenance Questions / answers
DRESSER RAND PRESENTATION

Presentation
Short course topics

Fundamentals Components & function Systems Operation Maintenance
FONDAMENTALS
Compressor types Basic principles Centrifugal applications
Compressor types
Axial Centrifugal Reciprocating
Axial Compressor
Axial compressor
Axial compressor
Axial compressor
Centrifugal Compressor
Compresseur centrifuge
Centrifugal compressor
Reciprocating compressor
Reciprocating compressor
BASIC PRINCIPLES
Centrifugal action A centrifugal stage Energy conversion
Centrifugal action
Velocity relationship
Centrifugal force = m . . r
Centrifugal action
Exit path
Centrifugal action
Cover Blades Disk
High velocity Higher pressure Gas outlet
Low velocity Low pressure Gas inlet
How a centrifugal compressor works ?

Centrifugal stage Return bend
Return bend
Diffuser
Reduces velocity Increases static pressure
Return channel
Impeller
Increases velocity Increases static pressure
Guide vanes
Energy conversion
P4,V2,T4
P2,V2,T2
P5,V1,T5
P1,V1,T1
P - Pressure V - Velocity T - Temperature

P3,V1,T3
APPLICATIONS
Application parameters Applications / Services
Application parameters
Gases - All types of gases Speed - 3,500 to 26,500 RPM Pressure - Vacuum to 724 bars Flow range - 22,6 14720 m3 / min Number of stages - 1 to 10 impellers
Application parameters
Outlet pressure bars a
Reciprocating
Centrifugal Axial
Inlet flow m3/h

Designation of centrifugal compressors
Horizontal split
Vertical split
Types of multi-stages centrifugals
Radially split
Axially split
Radially split compressor in service

Centrifuge joint radial
Radially split compressor in service

Axially split compressor on test

Sizes of compressors
Large volume Lower MWP Lower RPM s
Smaller volume Higher MWP Higher RPM s
Large volume Lower MWP Lower RPMs Smaller volume Higher MWP Higher RPMs

The name DATUM is an acronym of : Dresser-Rand Advanced Turbo Machine. The name is made of 5 components as follows : DXYNZ

D : always D for Datum X : frame size, one or two digits, 2 through 28 in step of 2 Y : case split design as follows : R for Radial (Barrel type) A for Axial (Horizontal type) N : total number of impellers, one or two digits Z : casing configuration as follows : S for straight through , compound or side stream B for back to Back arrangement D for double flow arrangement
Size of Datums
Centrifugal flowpaths
D4R8S
P5 P3 P7 P9 P11 P13 P15 P17
P1
P1 T1
65 bars 40C
P17
205 bars 139C

Straight thru or series flow
T17
Thrust
Balance Piston
High P
LP
Low P
HP
Net Balance Piston Thrust Net Impeller Thrust

9 kg / cm
Diffuser
Thrust
Dia D
9 kg / cm of thrust
Dia E = 270 mm
7 kg / cm
Area for the thrust calculation
Dia d = 140 mm
Shaft diameter : d Outer diameter of the impeller under the laby : E Axial thrust at the inlet of the impeller : P1 Axial thrust at the outlet of the impeller : P2 Area of the diameter 140 Area of the diameter 270 Area for the thrust calculation : 573 154 = Pressure differential between the impeller inlet and outlet
140 mm 270 mm 7 kg / cm 9 kg / cm 154 cm 573 cm 419 cm 2 kg / cm
E d P 2 P1 = 270 140 9 7 = 419 cm multiplied by 2 kg / cm = 838 kg 4 4
Balance line
Balance line
P2
P4
P6
P1
P3
P5
P6
P1
Shaft Impulser
Balance piston
P1<P2<P3<P4<P5<P6
Balance line
Sidestream inlet P5 Sidestream outlet P7 P9
P3
P1
Series flow with sidestreams
P5
P3
P7
P9
P1
Compound
P5 P3
P3
P1
P1
Parallel or double flow
D10R6B
P13
division wall
P7d
P1
P7s
P1 = 9 bars A P7d = 24 bars A
T1 = 40C T7d = 115C
P7s = 23 bars A P13 = 69 bars A
T7s = 40C T13 = 130C
Back to back
Components and function

Casing Compressor internals Rotor assembly Bearings Shaft seals
Casing
Axial split on steel or iron casing
Casing before machining
Casing D4
Casing D10
Head 1st Section D10

F3-1 Separation gas supply L1-1 Primary seal gas supply U2-1 Primary vent V2-1 Secondary vent
W1-1 Secondary seal gas supply
Head 2nd Section D10
W1-1 Secondary seal gas supply F3-1 Separation gas supply
V2-1 Secondary vent
L1-1 Primary seal gas supply U2-1 Primary vent

Mono-head 1st Section D04

T1-1 Balance connector W1-1 Secondary seal gas supply
V2-1 Secondary vent
F3-1 Separation gas supply L1-1 Primary seal gas supply

U2-1 Primary vent
Head fixation
Retaining ring Casing
Shear ring
Head
Retaining ring
Head fixation
Casing fixation
COMPRESSOR INTERNALS
Diaphragms Inlet, discharge and division wall Return bend
Bundle Components
ROTOR
HEADS
VOLUTE
BEARINGS & SEALS
RETURN BEND
DIAPHRAGMS
Cast diaphragm
Fabricated diaphragm
Low solididy diffuser (diffuser vane)
Diaphragm size differences
Frame 28 SF = 2.44 Frame 16 SF = 1 OD = 41 Frame 2 SF = 0.35
Internal (bundle)
Cartridge
Cartridge
Cartridge
Inlet wall
Division wall
Division wall
Division wall
Division wall
Diffusers and labyrinths
Return Bend
Return bend
Return bend
Cartridge
ROTATING PARTS
Rotor assembly
Rotor assembly
Impellers
Rotor assembly
Balance piston Impellers Drive coupling mount Shaft Thrust disc Bearing journals
Impeller spacers Seal area
Rotor assembly
Different scales
Impeller assembly
Impeller design & construction

Manufacturing
Cast Riveted Welded Two piece Three piece
Cover Blades Disk
Types
Open Semi-enclosed Enclosed
Z BLADE RIVETED
RIVETED
One Piece Milling

Impeller machined from solid forging
Electron-braze process
Electron beam welded joint
Electron-braze Joint
Braze strips
Placement of braze strips
Placement of braze strips
Electron-beam welding machine
Lifting of the rotor
BEARINGS
Bearings
Radial bearings
Thrust bearings
Radial bearings
Radial bearings
Radial bearings
Spring Sensor Retainer Pad or shoe
DR radial bearings
DR radial bearings
DR radial bearings
Tool for checking the bearings
Tool for checking the bearings
Thrust bearings
Thrust bearings
Inboard thrust bearing Outboard thrust bearing Compressor rotor shaft Thrust bearing cover
Thrust bearing pad Thrust disc
Thrust bearings
Thrust bearings
Inboard
Outboard
Thrust bearings HP
Thrust disc
Thrust disc
Tool for thrust disc
Hydraulic fit thrust disc
Special tools
Special tools
Shaft seals
SEAL SYSTEM
With labyrinths With oil With gas
Seal inside the compressor
External seals
Internal seals
Seal around the shaft
Seals
Labyrinths seal Oil film seal Barrier seal Gas seal
Interstage seals
Function
P3 P5
P2
Interstage laby seals
P4
Location
P1
P3
Interstage seals
Impulser
Labyrinths
Shaft
Shaft Gas
Interstage Laby seal
Interstage seals
Interstage seals
Interstage seals
Labyrinth hole pattern
D10R6B Bundle assembly
D10R6B Bundle assembly
D04R8S Bundle assembly
D04R8S Bundle assembly
Labyrinth seals
Labyrinth seals
Labyrinth seals
Oil seal
Sometimes labyrinth seals are replaced with oil seal.
Why ?
If no leak of the compressed fluid are allowed, the system with labyrinths is reinforced with oil seal.
Oil seal
Yes but . !!!

Oil system imposes a seal oil circuit.
Seal oil circuit

Seal oil circuit
Filters
Coolers
Pumps
Oil tank
Single breakdown
Seal oil supply Low pressure reference Labyrinth
Sweet oil
Outer seal ring
Inner seal ring
Sour oil
Oil film seal
Seal oil
Why ?
Barrier against gas Lubrication of the seal
Removal of heat
Gas seals
Typical DR gas seal arrangement
Primary seal (active)
Secondary seal (backup)
Barrier seal
INBOARD
OUTBOARD
Gas seals
Simplified section
Rotating ring Top of the grooves
Spring Orings
L sleeve Static ring
DR Gas Seal
3D pressure profile between the seal faces
Over pressurized areas are creating the lift-off effect

The vertical projection of the 3D pressure profile shows isobar curves
Pressure profile
Pressure (BarA) 60 50 40 30 20 10 0
Supply Pressure at O.D. Atmospheric Pressure at I.D. Plane of Rotating Seat

-0.05 -0.05 0.05
0.05 0
Isobars representation
54.1 52.3 50.5 48.8 47 45.2 43.5 41.7 39.9 38.2 36.4 34.6 32.9 31.1 29.3 27.5 25.8 24 22.2 20.5 18.7
-0.05
0.05
0.05
-0.05
Isobars (Different speeds)
11500 RPM , 50 Bars

'PRESdr.RTT' 54.1 52.3 50.5 48.8 47 45.2 43.5 41.7 39.9 38.2 36.4 34.6 32.9 31.1 29.3 27.5 25.8 24 22.2 20.5 18.7 16.9 0.04 0.05 0.06 0.07 0.08 0.09
-0.05
500 RPM , 50 Bars

'PRESBV.RTT' 52.3 50.5 48.7 46.8 0.04 45 43.2 41.3 0.05 39.5 37.7 35.8 0.06 34 32.2 0.07 30.3 28.5 26.7 0.08 24.8 23 0.09 21.2 19.3 17.5 15.7 13.8 12
-0.05
Isobars (Different pressures)

11500 RPM , 150 Bars
'PRES150.RTT' 157 151 146 141 136 131 125 120 115 110 105 99.5 94.3 89.1 84 78.8 73.6 68.4 63.2 58 52.9 47.7 0.04 0.05 0.06 0.07 0.08 0.09
-0.05
11500 RPM , 2 Bars

'PRES002.RTT' 3.47 3.06 2.65 2.24 1.83 1.42 0.04 0.05 0.06 0.07 0.08 0.09
-0.05
Gas seals with labyrinths

Running mode Pressurisation Stop mode
Clean and dry gas seal L1 Primary ventilation U2 Secondary ventilation V2 Clean and dry separation gas F3
Bearing vent H2
Seal sleeve Rotating parts for seal Stationary carbon ring Separation seal
D10
Stop mode Running mode Pressurisation Shutdown
For the D04
D04
Stop mode Running mode Pressurisation Shutdown
From D10 GS panel
Gas seals Dresser Rand
SOP
D10 D04 Conditioning skid

Conditioning skid
Conditioning skid
Gas seals cartridge
Barrier seal
SEAL SYSTEM Summary

With labyrinths With oil With gas
Labyrinth seal system
Compressor
Oil seal system
Dry gas seals system
Piping diagram
LUBE OIL SYSTEM
Lubrication system
Oil console GA
Lube oil console P&ID
Machines
From the gear
To the gear
Lube oil system P& ID
Running mode Stop mode
From console To console
Console
Dual filters
Flow glass
PCV 380 et 375
Driven pump
Oil demister
MACHINERY PROTECTION
Temperature system
Machinery protection system
Go to probe software 01 Go to probe software 02
Vibration system
Gap Probe support Shaft Probe cable (50 ohms)
Connecting device Extension cable (95 ohms) Proximitor Power supply -18 volts direct current
S
Power supply and control feedback
Monitor or any control material
Vibration system
OUTPUT COM - 18 VDC
+10 V
Gap = 1,8 mm
-10 V
Gap = 0,8 mm Gap = 0 mm
+2 V -2 V 0V
Vibration system
Vibration system
Axial probe
Vibration system
Temperature & vibration P&ID
Compressor control system

Local control (on skid) Emergency shutdown Control system of the machine Local control (on control panel) Start up / Shutdown / Monitoring Unit and auxiliaries Remote control (DCS) Unit control system Station control system Plant control system

Local control (on skid) Emergency shutdown Control system of the machine
Local control (on control panel) Start up / Shutdown / Monitoring Compressor and auxiliairies
PERFORMANCE CURVES SURGE & ANTI SURGE

Go to anti surge software
INSTALLATION & GROUTING
Alignment
OFFSET
VERTICAL ALIGNMENT
HORIZONTAL ALIGNMENT
ANGULAR
Compressor shaft alignment
Compressor shaft alignment
Casing fixation
Maintenance on the DATUM
COMPRESSOR MAINTENANCE
Safety precautions Disassembly Inspection Re-assembly Special tools Spare parts
Pre-start inspection
Gauges calibrated Sensors check and calibrated Hand valves in proper position Check valves installed properly Safety and shutdown devices checked and operational
Pre-start checks
Observe all vendor equipment instructions

Check casing drains for condensate Turn on instrument air Place the seal system in operation Place the lube system in operation
Routine operations
Each shift
Unit walk around (if possible) Observe all pressures, temps, vibrations and flows Record all pressures temps, vibrations, and flows Compare readings to expected values Take appropriate action
Weekly
Check any filter differential pressure Check actuation of standby / emergency pumps (if possible) Record any findings
Quarterly
Test safety devices (if possible) Calibrate gauges and devices (if possible) Perform oil analysis Record any findings
Safety precautions
Wear personal protective. Check site for potential safety hazards / evacuation procedures. Follow vendors service procedures and safety recommendations. Follow internal procedures. Use hand / power / special tools properly. Use safe rigging practice. Cover any compressor openings.
Radial split disassembly
Maintenance considerations
BUNDLE CRADLE
SUPPORT BUNDLE CRADLE

Maintenance considerations
BUNDLE + ROTOR + BEARINGS + SEALS
Inspection
Disassembly inspection Component inspection visual & dimensional Inspection methods Re-assembly inspection Inspection records Possible causes for an event
Special tools
Small special tools
couplings, bearings, and seals

Big special tools -
assembly and lifting

Inspection of special tools Storage of special tools
Special tools
Special tools
Thrust disc
Hydraulic fit thrust disc
Special tools
Special tools
Compressor parts
Special tools
Bundle insertion tool
Bundle cradle
Questions
Do
ve ha ou y
ue q ny a
s? ion st
Centrifugal compressor
QUIZ
Thank you for your attention

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Welcome from

Customer Training department

Name : DIESNIS Patrick Department : Customer training Purpose of this training :

LP & MP Gear LP & MP = D10R6B HP = D4R8S

LP & MP = D10R6B HP = D4R8S

Fundamentals. Types et models.

Static and rotating parts.

Static and rotating parts. Thrust and bearings.

With labyrinths, with oil, with gas.

DRESSER RAND PRESENTATION

Short course topics

Axial Centrifugal Reciprocating

High velocity Higher pressure Gas outlet

Low velocity Low pressure Gas inlet

How a centrifugal compressor works ?

P - Pressure V - Velocity T - Temperature

Inlet flow m3/h

Designation of centrifugal compressors

Types of multi-stages centrifugals

Types of multi-stages centrifugals

Radially split compressor in service

Centrifuge joint radial

Types of multi-stages centrifugals

Radially split compressor in service

Types of multi-stages centrifugals

Axially split compressor on test

Large volume Lower MWP Lower RPM s

Smaller volume Higher MWP Higher RPM s

Designation of centrifugal compressors

Designation of centrifugal compressors

Designation of centrifugal compressors

205 bars 139C

Straight thru or series flow

Net Balance Piston Thrust Net Impeller Thrust

Area for the thrust calculation

140 mm 270 mm 7 kg / cm 9 kg / cm 154 cm 573 cm 419 cm 2 kg / cm

E d P 2 P1 = 270 140 9 7 = 419 cm multiplied by 2 kg / cm = 838 kg 4 4

Series flow with sidestreams

Parallel or double flow

P1 = 9 bars A P7d = 24 bars A

T1 = 40C T7d = 115C

P7s = 23 bars A P13 = 69 bars A

T7s = 40C T13 = 130C

Components and function

Axial split on steel or iron casing

Casing before machining

Head 1st Section D10

W1-1 Secondary seal gas supply

Head 2nd Section D10

W1-1 Secondary seal gas supply F3-1 Separation gas supply

V2-1 Secondary vent

L1-1 Primary seal gas supply U2-1 Primary vent

Mono-head 1st Section D04

V2-1 Secondary vent

F3-1 Separation gas supply L1-1 Primary seal gas supply

U2-1 Primary vent

BEARINGS & SEALS

Low solididy diffuser (diffuser vane)

Diaphragm size differences

Frame 28 SF = 2.44 Frame 16 SF = 1 OD = 41 Frame 2 SF = 0.35

Diffusers and labyrinths

Impeller spacers Seal area