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SOLAR GAS BOOST SOLAR GAS BOOST COMPRESSOR OUTLINE COMPRESSOR OUTLINE Pengenalan Centrifugal Gas Compressor Pengenalan Centrifugal Gas Compressor Prinsip Kerja Gas Compressor Prinsip Kerja Gas Compressor Compressor Component dan Fungsinya Compressor Component dan Fungsinya Staging Selection Staging Selection Performance Evaluation Performance Evaluation Compressor Cleaning / Stripdown Compressor Cleaning / Stripdown Restage Restage

Boost Compressor

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Page 1: Boost Compressor

SOLAR GAS BOOST SOLAR GAS BOOST COMPRESSOR OUTLINECOMPRESSOR OUTLINEPengenalan Centrifugal Gas CompressorPengenalan Centrifugal Gas CompressorPrinsip Kerja Gas CompressorPrinsip Kerja Gas CompressorCompressor Component dan FungsinyaCompressor Component dan FungsinyaStaging SelectionStaging SelectionPerformance EvaluationPerformance EvaluationCompressor Cleaning / StripdownCompressor Cleaning / StripdownRestageRestage

Page 2: Boost Compressor

Pengenalan Centrifugal Gas Pengenalan Centrifugal Gas CompressorCompressor

Centrifugal Gas Compressor adalah salah satu Centrifugal Gas Compressor adalah salah satu Compressor yang termudah yang ada untuk Compressor yang termudah yang ada untuk menaikan tekanan dari gas dengan aliran menaikan tekanan dari gas dengan aliran kontinyu. kontinyu. Solar Compressor FamilySolar Compressor Family

-- CC--160160-- CC--284284-- CC--306306-- CC--338338-- CC--505505

Page 3: Boost Compressor

Prinsip Kerja Gas Boost Prinsip Kerja Gas Boost CompressorCompressor

Prinsip Kerja Centrifugal Gas Prinsip Kerja Centrifugal Gas Compressor adalah mengubah Compressor adalah mengubah energy kecepatan dari gas menjadi energy kecepatan dari gas menjadi energy tekanan dan Fungsinya untuk energy tekanan dan Fungsinya untuk menaikan tekanan dari gas untuk menaikan tekanan dari gas untuk keperluan tertentu. keperluan tertentu.

Page 4: Boost Compressor

Gas Flow Through Impeller

Page 5: Boost Compressor

Compressor Stage Component

Page 6: Boost Compressor

Compressor ComponentCompressor Componentdan Fungsinyadan Fungsinya

Casing & End Cap.Casing & End Cap.RotorRotorStatorStatorBearingBearingSealSeal

Page 7: Boost Compressor

Housing & End CapHousing & End CapSebagai manifold / penampungan Sebagai manifold / penampungan

gas inlet (suction cavity) dan gas gas inlet (suction cavity) dan gas outlet (discharge cavity) yang outlet (discharge cavity) yang designnya pressurenya designnya pressurenya disesuaikan dengan Kondisi disesuaikan dengan Kondisi operasinya / operating point.operasinya / operating point.

Page 8: Boost Compressor

Housing & End CapHousing & End CapGas Compressor C-304

Page 9: Boost Compressor

StatorStatorMerupakan bagian yang diam / stationary yang Merupakan bagian yang diam / stationary yang

terdiri dari :terdiri dari :-- Guide Vane Guide Vane -- Diffuser.Diffuser.

Guide Vane berfungsi sebagai pengarah dari aliran Guide Vane berfungsi sebagai pengarah dari aliran untuk menuju ke impeller.untuk menuju ke impeller.

Diffuser berfungsi untuk mengubah energy Diffuser berfungsi untuk mengubah energy mekanik / gerak dalam hal ini kinetik energy mekanik / gerak dalam hal ini kinetik energy menjadi energy tekanan / pressure.menjadi energy tekanan / pressure.

Page 10: Boost Compressor

RotorRotorMerupakan susunan dari beberapa Merupakan susunan dari beberapa buah impeller yang stagingnya telah dibuah impeller yang stagingnya telah disesuaikan dengan kebutuhansesuaikan dengan kebutuhanoperasinya dan berfungsi untukoperasinya dan berfungsi untukmempercepat aliran gas sebelummempercepat aliran gas sebelummemasuki diffuser daipada statormemasuki diffuser daipada stator

Page 11: Boost Compressor

RotorRotor

Center StudPin

Page 12: Boost Compressor

BearingBearingBerfungsi untuk meredam getaran yang ditimbulkan Berfungsi untuk meredam getaran yang ditimbulkan oleh compressor dan type yang digunakanoleh compressor dan type yang digunakankebanyakan adalah Hydrodynamic journal bearingkebanyakan adalah Hydrodynamic journal bearingyang lazim kita sebut sebagai tilt pad bearingyang lazim kita sebut sebagai tilt pad bearing

Alasan kenapa memilih Tilt pad bearing Alasan kenapa memilih Tilt pad bearing -- Effekivitas untuk meredam getaran sangat tinggiEffekivitas untuk meredam getaran sangat tinggi-- Meniadakan oil whirl / oil whipMeniadakan oil whirl / oil whip-- Life timenya relative lama Life timenya relative lama

Page 13: Boost Compressor

Tilting Pad BearingTilting Pad Bearing

Page 14: Boost Compressor

Thrust Bearing• Berfungsi untuk menahan gaya axial

• Ada dua macam type– Tilt pad thrust bearing– Non Tilt pad thrust bearing

• Ada yang dilengkapi dengan sensor, untuk memonitor thrust bearing temperature

Page 15: Boost Compressor

Tilt Pad Thrust Bearing

Pad

Temperature sensor

Page 16: Boost Compressor

SealsSealsSeal System terdiri :Seal System terdiri :-- Labyrinth : Labyrinth : Bentuknya sekatBentuknya sekat--sekat yang tiap ujungnya berbertuksekat yang tiap ujungnya berbertukruncing / tajam dan berada dikedua sisi impeller atau stubruncing / tajam dan berada dikedua sisi impeller atau stubshaft dan berfungsi untuk meminimize / mengurangishaft dan berfungsi untuk meminimize / mengurangikebocoran gas diantara tiapkebocoran gas diantara tiap--tiap stage didalamtiap stage didalamcompressor .compressor .

-- Buffer Gas / Seal GasBuffer Gas / Seal GasBerfungsi untuk menjaga agar seal oil / lubrikasi tidakBerfungsi untuk menjaga agar seal oil / lubrikasi tidakmasuk kedalam compressor / processmasuk kedalam compressor / process

-- Seal Oil Seal Oil Berfungsi untuk menjaga agar process gas tidak masukBerfungsi untuk menjaga agar process gas tidak masukkedalam system pelumasan / lubrikasi. kedalam system pelumasan / lubrikasi.

Page 17: Boost Compressor

Labyrinth Seal (1)

Stationary Housing

Rotating Shaft

Kondisi Seal sebelum ber-operasi

Kondisi Seal sesudah ber-operasi

Soft Babbit Replaceable liner

Gas Flow

Page 18: Boost Compressor

Labyrinth Seal (2)

Labyrinth

Seal

Page 19: Boost Compressor

Seal Oil dan Buffer Gas Sistem

Fungsi :“Sebagai sealing antara sistem oil dan sistem gas”

Seal Oil : Mencegah masuknya gas ke sistem oil

Buffer Gas : Mencegah masuknya seal oil ke compressor casing

Page 20: Boost Compressor

Seal Oil & Seal Buffer Gas

Page 21: Boost Compressor

Seal Oil & Seal Buffer Gas (cont,d)

Buffer Gas DP

Page 22: Boost Compressor

Seal Oil & Seal Buffer Gas (cont,d)

P = 55 psig

Lubricating Oil

P = P-suct+ 20 psi

Seal Oil

P-suct / P-dischGasdalam Compressor

DischargeSuction

Seal Oil dan Buffer Gas Drain

P = P-suct+ 15 psi

Buffer Gas

Buffer Gas SealBalance Piston Seal

(Discharge)

Page 23: Boost Compressor

Komponen Seal oil System• Auxiliary Seal Oil Pump

– Start saat tekanan prelube > 6 psig

– Berhenti saat loading speed (90% NGP)

– Saat engine Shutdown, Start pada saat NGP < 90% , berhenti Pcasing < 4 psig

S-21

Page 24: Boost Compressor

Komponen Seal oil System (1)

Main Seal Oil PumpMengambil alih Auxiliary Seal Oil Pump pada NGP > 90% 2000 rpm pada 100% NGP

Flow RegulatorMenjaga aliran seal oil konstan pada setiap tekanan

Page 25: Boost Compressor

Komponen Seal oil System (2)

Differential Pressure RegulatorSeal Oil DP Regulator

Menjaga tekanan seal oil 20 psid di atas tekanan suction

Buffer Gas DP RegulatorMenjaga tekanan buffer gas 15 psid di atas tekanan suction

Tekanan acuan : Tekanan Suction atau Drain Cavity ( Seal Oil dan Buffer Gas Out )

Page 26: Boost Compressor

Komponen Seal oil System (3)

Seal Oil INSeal Oil Return

Buffer Gas

Diaphragm

Seal Oil DP Regulator

Page 27: Boost Compressor
Page 28: Boost Compressor

Maximum Seal Oil Leakage

Page 29: Boost Compressor

Komponen Seal oil System (3)

Seal Oil Separator / Trap

Memisahkan gas dari seal oil agar tidak masuk ke Lube Oil Tank

Meyakinkan seal oil tidak tertarik ke pipeline melalui booster compressor

Seal Oil kembali ke tank dibantu oleh tekanan gas di atasnya

Page 30: Boost Compressor

High Pressure Oil Trap

Page 31: Boost Compressor

Type Seal Oil Trap

Spring

Oil return port

Floater

Gas outSeal Oil & Gas Mixed

Oil out

Page 32: Boost Compressor

Sistem Buffer GasInternalGas dari Balance Piston labyrinth seal (discharge) diregulasi tekananya, diinjeksikan sebagian ke suction bearing capsule

EksternalGas dari discharge elbow diregulasi tekanannya, diinjeksikan ke suction dan discharge bearing capsule

Page 33: Boost Compressor

Sistem Buffer Gas-Internal

BG Reg.

To Suction Brg. Capsule

To Suction pipe

Page 34: Boost Compressor

Sistem Buffer Gas-External

BG Reg

External Buffer Gas

sources

Page 35: Boost Compressor

Buffer Gas DP Operating Range

Model No. Buffer Gas DP (psig)

Minimum Nominal Maximum

C-16 5 15 50

C-16H 5 15 50

C-160 5 15 50

C-28 5 15 50

C-30 5 15 50

Page 36: Boost Compressor
Page 37: Boost Compressor

Dry Seal SystemIn this system, separation of lube oil and process gas is accomplished by a series of seals, installed between

the inboard journal bearing and the impeller.

Buffer Gas• Buffer gas is injected between the primary seal and the labyrinth seal on the rotor hub, at pressure

above suction pressure.• The differential pressure and proportional flow path sizes causes most of the buffer gas flows across

labyrinth seal and back to suction chamber of the compressor.• The remaining small amount of buffer gas flows across primary seal and is vented from the seal

assembly through a fixed orifice and flame arrester to a safe area.• A secondary seal is installed adjacent to the primary seal, acting as a backup in the event of failure of

the primary seal.• Different pressure regulator maintain a differential of approximately 20 psi above suction pressure.

Buffer Air• The buffer air seal is a split-ring circumferential seal, adjacent to the inboard journal bearing of the

compressor rotor.• Air or Nitrogen is supplied to the seal at a regulated pressure. Small portion flows across the inner

seal seal and out the secondary seal vent. The balance of the buffer air flows across outer portion seal into lube oil drain (mixed with LO draining from journal bearing)

• Different pressure regulator maintain a differential of approximately 10 psi between seal inlet and the secondary seal vent port

Page 38: Boost Compressor

Dry Seal SystemComponent Description

• Buffer Air DP Regulator– Normally open diaphragm and poppet type– Secondary vent pressure and spring act on the OPEN side of the valve diaphragm– Seal inlet pressure acts on the CLOSE side of the valve diaphragm– The opposing forces maintain equilibrium at the pre-adjusted set point of the valve

Normally 10 psid

• Buffer Air DP Transmitter– Connected between seal inlet and secondary seal vent line– Sends an electrical signal proportional to the pressure across the inboard buffer air seal

to the control system– If DP falls below 7 psi, and ALARM will be activated– If DP falls below 4 psi, a Fast stop SHUTDOWN will be initiated.

• Buffer Gas DP regulator– Normally open, Diaphragm and poppet type– Suction pressure and spring pressure acting on the OPEN side of the diaphragm– Buffer Gas inlet on the CLOSE side of the diaphragm– The valve is adjusted to balance the diaphragm at nominal pressure of 20 psid

Page 39: Boost Compressor

Dry Seal System• Buffer Gas DP Transmitter

– Connected between suction (reference) line and the buffer gas seal inlet line– If DP falls below 7 psi, with engine speed at 90 % or higher– If DP falls below 4 psid, with engine speed at 90 % or higher

• Buffer Gas Filter DP Transmitter– Monitor DP filters, provides a proportional signal to control system

indicating filter condition– If DP exceeds 40 psid, ALARM signal will be initiated

• Buffer Gas Flow-Limiting Orifice– 0.295 size orifice, installed in the buffer gas IN line– Limits the flow of gas as the labyrinth seal wears and its clearances increases

• Buffer Gas Flow-Monitoring Orifice– 0.25 size orifice, installed in the primary seal vent line, to measure seal leakage flow

In the vent line

– A relief valve, connected in parallel with the orifice, is adjusted to open at 30 psid, provides an escape gas in the event of a serious failure of the primary seal. Reducing the possibility of ove-pressurizing the buffer air seal and contaminating the lube oil system with gas.

Page 40: Boost Compressor

Dry Seal System• Primary Seal Vent Alarm and Shutdown Transducer

– Connected to the primary seal vent line– Provide signal to the control system representing the absolute pressure at the vent port– If the pressure at the vent line 12 psig, ALARM signal will be activated– If the pressure at the vent line 20 psig, SHUTDOWN signal will be activated

NOTEThe back pressure at the primary seal vent must not exceed 5 psig

Page 41: Boost Compressor

A

S/D

S/D

A

A S/D

A

S/D

R

R

AIR / N2

BUFFER GAS

PRIMARY SEAL VENT

SECONDARY SEAL VENT

BALANCE PISTON

2nd seal Hi Flow Alarm switch

LO INLO IN

Page 42: Boost Compressor
Page 43: Boost Compressor

Balance Piston & Seal

• Balance piston adalah bagian dari rotor yang digunakan untuk mengurangi gaya axial

• Balance Piston ada pada sisi discharge, setelah internal staging yang terakhir

Page 44: Boost Compressor

Balance Piston & Seal (1)

Page 45: Boost Compressor

Balance Piston & Seal (2)

Balance Piston

Page 46: Boost Compressor

Balance Piston & Seal (3)

Page 47: Boost Compressor

PERFORMANCE

OFCENTRIFUGAL COMPRESSOR

Page 48: Boost Compressor

Performance EvaluationPerformance EvaluationEvaluasi Penting karena :Evaluasi Penting karena :

Mengetahui existing Performance (Optimal atau Tidak)Mengetahui existing Performance (Optimal atau Tidak)Mengetahui Kondisi Kompressor (Fouling, excessive seal wear dll)Mengetahui Kondisi Kompressor (Fouling, excessive seal wear dll)Mengambil keputusan perlu atau tidak compressor cleaning atauMengambil keputusan perlu atau tidak compressor cleaning ataucompressor Recompressor Re--StagingStaging

Adapun Performance Evaluation meliputi :Adapun Performance Evaluation meliputi :-- Compressor TheoryCompressor Theory-- Physical Properties of GasPhysical Properties of Gas-- Head, Flow and EfficiencyHead, Flow and Efficiency-- Compressor Performance Curve / MapCompressor Performance Curve / Map-- Compressor Horse PowerCompressor Horse Power-- Performance Analysis and Their Problem A risePerformance Analysis and Their Problem A rise

Page 49: Boost Compressor

Compressor Theory

• Persamaan Euleur

• Persamaan Bernouli

• Hukum-hukum Thermodinamika– Process Adiabatik / Isentropik – Process Polytropic

Page 50: Boost Compressor

Energi Gas

• Terdiri dari : Head (tekanan) dan Flow

• Horse Power = Head X Flow

• Head adalah besaran enersi yang diberikan kepada gas untuk setiap satu besaran massa.

Page 51: Boost Compressor

Gas Physical Properties

• Specific Gravity

• Ratio of Specific Heat

• Compressibility factor

Page 52: Boost Compressor

Specific Gravity (s.g)• Adalah : Perbandingan molecular weight dari

gas mixture terhadap Molecular weight udara.

• Molecular weight udara = 28.964

Mol weight gas mixture• SG = ---------------------------------

28.964

Page 53: Boost Compressor

Compressibility factor (Z)

• Adalah factor koreksi volume dari perhitungan gas ideal menjadi gas actual.

• Harga Z selalu < 1

Page 54: Boost Compressor

Compressibility factor (Z)

Page 55: Boost Compressor

Sample of Gas Analysis

Page 56: Boost Compressor

Perhitungan SG

Page 57: Boost Compressor

Compression Head

53.35 x Z av x k x T1 (k-1)/k

Head = ----------------------------------[ (P2/P1) - 1]

SG x (k-1)

Head = Ft. Lbs force / Lbs mass.

Z ave =Compressibility factor

k = Ratio of specific heat

T1 = Temperature gas suction (Deg R)

P1 = Pressure gas suction (psia)

P2 = Pressure gas discharge (psia)

SG = Specific Gravity gas

Page 58: Boost Compressor

Horse Power Required

1.6417 x 0.001 x Head x Flow MMSCFD x SG

HP = ----------------------------------------------------------------

Efficiency

HP = Horse power yang dibutuhkan oleh

compressor yang tersedia pada shaft compressor.

Page 59: Boost Compressor

Isentropic Efficiency

(k-1)/k

T1 [ (P2/P1) - 1 ]

Eff = -----------------------------------

T2 - T1

Page 60: Boost Compressor

Compressor Curve / MapAda tiga macam Curve

– Dimensional Curve– Semi-Dimensional Curve– Head vs Capacity (Flow) Curve

Rule :The Head versus Capacity curve is the only curve necessary

Page 61: Boost Compressor

Dimensional CurveUse for Bid evaluation

Pressure versus Standard FlowDetermines operating rangeBased on Constant Suction or Discharge PressureNo Longer of value after purchase decision

Can determine specific operating ConditionPower & Speed

Shape of curve very demendent on base conditionsSuction TemperatureSuction PressureDischarge PressureGas Composition

Page 62: Boost Compressor

Semi-Dimensional CurveUse for Bid evaluation

Pressure Ratio versus Standard Flow divided by pressureDetermines operating rangeBased on Constant Suction or Discharge PressureNo Longer of value after purchase decision

Can determine specific operating ConditionPower & Speed

Shape of curve very demendent on base conditionsSuction TemperatureSuction PressureDischarge PressureGas Composition

Page 63: Boost Compressor

Head versus Capacity CurveOnly affected slightly by changes in base

conditions– Suction and Discharge Temperature– Discharge Pressure– Gas Composition

Used to determine the condition of an operating compressor– Compare actual efficiency to nominal (curve)

efficiency– Compare actual speed to nominal (curve) speed

Page 64: Boost Compressor

Performance Diagnostics Method

1. Actual versus Nominal Data• Actual

Speed MeasuredEfficiency Calculated (from measured data)

• NominalSpeed From Head – Capacity curveEfficiency From Head – Capacity curve

Page 65: Boost Compressor

Performance Diagnostics Method2. Creates 9 possibilities

EFFICIENCY SPEED COMMENTS

OK OK Compressor probably OK

OK LOW Check speed, P1, P2, and SG measurement

OK HIGH Possible compressor damage

LOW OK Possible compressor damage, Check T1, 2

LOW LOW Data probably suspect, Check P1,2 and SG

LOW HIGH Possible comp. Damage. Check Flow measurement

HIGH OK Comp. Probably OK. Data possibly suspect. Check T1,2 measurement

HIGH LOW Comp. Probably OK. Data definitely suspect. Check T1,2 measurement

HIGH HIGH Comp. Probably OK. Data definitely suspect. Check T1,2 measurement

Page 66: Boost Compressor

Yard Valve Sequence

Page 67: Boost Compressor

Yard Valve Sequence

Page 68: Boost Compressor

Yard Valve Sequence

Page 69: Boost Compressor
Page 70: Boost Compressor