CCFAMGB SBM

8/2/2019 CCFAMGB SBM

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2012 by Dresser-Rand

Welcome from

Le HAVRE

Customer

Training department


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Prsentation

Name : DIESNIS PatrickDepartment : Customer training

FAMILIARISATION ON CENTRIFUGAL

COMPRESSOR

Purpose of this training :


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DISTRIBUTION OF

THIS PRESENTATION

TO ANY NON-

DRESSER-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.

DO NOT REMOVE

THIS SLIDE FROM

THIS PRESENTATION!

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.

This slide MUST NOT be removed from this presentation or any partthereof.

Warning


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General arrangement

Gas turbine

Compressors

Gear

LP & MP HP

LP & MP = D10R6B

HP = D4R8S


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General arrangement

LP & MP = D10R6B

HP = D4R8S

LM 2500


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Planning

Dresser-Rands presentation. Introduction on the centrifugal compressors :

Fundamentals.

Types et models.

Compressor components :

Static and rotating parts.

First day :


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Planning

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.

Second day :


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Planning

Oil system : Continuation. The surge.

How does a centrifugal compressor operate ?

Maintenance

Questions / answers

Third day :


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DRESSER RAND

PRESENTATION

Presentation


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Fundamentals

Components & function

Systems

Operation

Maintenance

Short course topics


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FONDAMENTALS

Compressor types

Basic principles

Centrifugal applications


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Axial

Centrifugal

Reciprocating

Compressor types


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Axial Compressor


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Axial compressor


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Axial compressor


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Axial compressor


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Centrifugal Compressor


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Centrifugal compressor

Compresseur centrifuge


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Reciprocating compressor


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Reciprocating compressor


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BASIC PRINCIPLES

Centrifugal action

A centrifugal stage

Energy conversion


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Centrifugal action

Velocity relationship

A

B

Centrifugal force = m . . r


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Centrifugal action

Exit path


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Low velocity

Low pressure

Gas inlet

High velocity

Higher pressureGas outlet

Cover Blades Disk

Centrifugal action


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Centrifugal stage

Guide vanes

Return channel

Return bend

Return bend

ImpellerIncreases velocity

Increases static pressure

DiffuserReduces velocity

Increases static pressure

How a centrifugal compressor works ?


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P3,V1,T3

P2,V2,T2

P4,V2,T4

P5,V1,T5

P1,V1,T1 P - PressureV - Velocity

T - Temperature

Energy conversion


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APPLICATIONS

Application parameters

Applications / Services


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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



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ReciprocatingCentrifugal

Axial

Inlet flow m3/h

Outlet pressure bars a



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Horizontal split Vertical split

Designation of centrifugal

compressors


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Axially split

Radially split

Types of multi-stages centrifugals


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Radially split compressor in service



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Centrifuge joint radial

Radially split compressor in service


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Axially split compressor on test



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Large volume

Lower MWP

Lower RPM s

Smaller volumeHigher MWP

Higher RPM s

Sizes of compressors


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Large volume

Lower MWP

Lower RPMs

Smaller volumeHigher MWP

Higher RPMs



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The name DATUM is an acronym of :

Dresser-Rand Advanced Turbo Machine.

The name is made of 5 components as follows :

D X Y N Z


compressors


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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


compressors


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Size of Datums


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compressors


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Centrifugal flowpaths

P1

P3

P5

P7

P9

Straight thru

or series flow

P11

P13

P15

P17

P1 65 bars

T1 40C

P17 205 bars

T17 139C

D4R8S


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Low P

High P

Net Impeller Thrust

Balance

Piston

LP

HP

Net Balance Piston Thrust

Thrust


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Thrust

Dia E = 270 mm

Dia d = 140 mm

9 kg / cm ofthrust

7 kg / cm

Diffuser

Area for the

thrust

calculation

Dia D

9 kg / cm

Shaft diameter : d 140 mmOuter di ameter of the i mpell er under the laby : E 270 mm

Axial thrust at the inlet of the impeller : P1 7 kg / cmAxial thrust at the outlet of the impeller : P2 9 kg / cm

Area of the diameter 140 154 cm

Area of the diameter 270 573 cmArea for the thrust calculation : 573 154 = 419 cm

Pressure differential between the impeller inlet and outlet 2 kg / cm

4

dE 12 PP =

4

140270 79 = 419 cm multiplied by 2 kg / cm = 838 kg


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Balance line

P1

P2

P3

P4

P5

P6

P6 P1

P1


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Balance line


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Sidestream inlet

Series flow with sidestreams

P1

P3 P5 P7 P9

Sidestream outlet



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Compound

P1

P3

P5

P7 P9



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Parallel or double flow

P1 P1

P5 P3P3



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Back to back

divisionwall

P1

P13

P7s


P1 = 9 bars A P7s = 23 bars A

P7d = 24 bars A P13 = 69 bars A

T1 = 40C

T7d = 115C

T7s = 40C

T13 = 130C

D10R6B

P7d


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Casing

Compressor internals

Rotor assembly

Bearings

Shaft seals

Components and function


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Axial split

on steel or iron casing

Casing


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Casing before machining


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Casing D4


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Casing D10


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Head 1st Section D10

W1-1

Secondary seal

gas supply

U2-1

Primary

vent

V2-1

Secondary

vent

L1-1Primary seal gas

supply

F3-1

Separation

gas supply


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Head 2nd 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


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Mono-head 1st Section D04

F3-1 Separation

gas supply

L1-1

Primary seal gas

supplyU2-1

Primary vent

V2-1 Secondary

vent

W1-1 Secondary

seal gas supply

T1-1 Balanceconnector


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Head fixation

Head

Casing

Retaining ring

Shear ring


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Retaining ring


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Head fixation


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Casing fixation


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COMPRESSOR

INTERNALS

Diaphragms

Inlet, discharge and divisionwall

Return bend


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Bundle Components

ROTOR

BEARINGS& SEALS

HEADS

RETURN

BEND

DIAPHRAGMS

VOLUTE


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Cast diaphragm


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Fabricated diaphragm


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Low solididy diffuser

(diffuser vane)


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Diaphragm size differences

Frame 28

SF = 2.44

Frame 16

SF = 1

OD = 41

Frame 2SF = 0.35


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Internal (bundle)


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Cartridge


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Cartridge


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Cartridge


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Inlet wall


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Division wall

Division wall


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Division wall

Division wall


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Diffusers and labyrinths


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Return Bend


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Return bend


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Return bend


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Cartridge


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ROTATING PARTS


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Rotor

assembly

Impellers

Rotor assembly


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Thrust disc

Impellers

Balance piston

Seal area

Shaft

Bearing journals

Impellerspacers

Drive

coupling

mount

Rotor assembly


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Rotor assembly


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Different scales


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Impeller assembly


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Cover Blades Disk

Manufacturing Cast

Riveted

Welded

Two pieceThree piece

Types Open

Semi-enclosed Enclosed

Impeller design & construction


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RIVETED

Z BLADE

RIVETED



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One Piece MillingImpeller machined

from solid forging


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Electron-braze process


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Electron beam welded joint


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Electron-braze Joint


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Braze strips


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Placement of braze strips


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Placement of braze strips


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Electron-beam welding machine


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Lifting of the rotor


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BEARINGS


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Thrust bearings

Radial bearings

Bearings


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Radial bearings


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Radial bearings


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Retainer

Pad or shoe

Sensor

Spring

Radial bearings


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DR radial bearings


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DR radial bearings

DR di l b i


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DR radial bearings

T l f h ki th b i


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Tool for checking the bearings

T l f h ki th b i


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Tool for checking the bearings

Th t b i


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Thrust bearings

Th t b i


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Outboard

thrust bearing

Inboard thrustbearing

Thrust bearing pad

Thrust

bearing

cover

Thrust disc

Compressor

rotor shaft

Thrust bearings

Th t b i


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Thrust bearings

Th t b i


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Thrust bearings

Outboard

Inboard

Th t b i HP


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Thrust bearings HP

Thrust disc


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Thrust disc

Thrust disc


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Thrust disc

Tool for thrust disc


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Tool for thrust disc

H d li fit th t di


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Hydraulic fit thrust disc

S i l t l


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Special tools

S i l t l


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Special tools

Shaft seals


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Shaft seals


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SEAL SYSTEM

With labyrinths

With oil

With gas

Seal inside the compressor


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External seals

Internal seals

Seal inside the compressor

Seal around the shaft


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Seal around the shaft

Seals


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Labyrinths seal

Oil film seal

Barrier seal

Gas seal

Seals

Interstage seals


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Interstage

laby seals

Location P1

P2

P3

P3

P4

P5

Function

Interstage seals

Interstage seals


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Interstage seals

Impulser

Shaft

Interstage

Laby seal

Labyrinths

ShaftGas

Interstage seals


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Interstage seals

Interstage seals


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Interstage seals

Interstage seals


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Interstage seals

Labyrinth hole pattern


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y p

D10R6B Bundle assembly


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D04R8S Bundle assembly


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Labyrinth seals


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y

Labyrinth seals


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y

Labyrinth seals


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y

Oil seal


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Why ?

If no leak of the compressed fluid are allowed,

the system with labyrinths is reinforced with

oil seal.

Sometimes labyrinth seals are

replaced with oil seal.

Oil seal


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Yes but . !!!

Oil system imposes a seal oil circuit.

Seal oil circuit


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Seal oil circuit

Oil

tank

Pumps

Coolers

Filters

Single breakdown


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Labyrinth

Inner sealring

Outer seal ring

Low pressure reference

Sweet oil

Seal oil

supply

Sour

oil

Oil film seal


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Seal oil


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Barrier against gas

Lubrication of the seal

Removal of heat

Why ?

Gas seals


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Typical DR gas seal arrangement


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INBOARD OUTBOARD

Primary seal

(active)

Secondary seal

(backup)Barrier seal

Gas seals


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Simplified section


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Top of the grooves

Rotating ring

Static ring

L sleeve

Orings

Spring

DR Gas Seal


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3D pressure profile between the seal faces


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Over pressurized

areas are creating

the lift-off effect

The vertical projection of the3D pressure profile shows

isobar curves

Pressure profile


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-0.05

0

0.05

-0.05

0

0.05

0

10

20

30

40

50

60

Pressure (BarA)

Plane of Rotating Seat

Supply

Pressure

at O.D.

Atmospheric

Pressure

at I.D.

54.1

Isobars representation


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52.3

50.548.8

47

45.2

43.5

41.7

39.9

38.2

36.4

34.6

32.9

31.1

29.3

27.525.8

24

22.2

20.5

18.7

-0.05

0

0.05

-0.0500.05

11500 RPM 50 Bars

Isobars (Different speeds)


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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

-0.050

500 RPM , 50 Bars'PRESBV.RTT'

52.3

50.5

48.7

46.8

45

43.2

41.3

39.5

37.7

35.8

34

32.2

30.3

28.5

26.7

24.8

23

21.2

19.3

17.5

15.7

13.8

0.04

0.05

0.06

0.07

0.08

0.09

-0.050

Isobars (Different pressures)


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11500 RPM , 150 Bars

11500 RPM , 2 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

63.258

52.9

47.7

0.04

0.05

0.06

0.07

0.08

0.09

-0.050

'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

-0.050

Gas seals with labyrinths


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Clean and dry

separation gas F3

Clean and dry

gas seal L1

Secondary

ventilation

V2

Primary

ventilation

U2

Seal sleeve

Rotating parts for

seal

Stationary

carbon ringSeparation

seal

Stop mode

Bearingvent H2

PressurisationRunning mode

Stop mode

Pressurisation

Running mode

ShutdownD10


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For the D04


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Gas seals Dresser Rand


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Conditioning skid

SOP

D10

D04

Conditioning skid


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Conditioning skid


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Gas seals cartridge


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Barrier seal


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SEAL SYSTEM

Summary

With labyrinths

With oil

With gas

Labyrinth seal system


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Compressor

Oil seal system


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Dry gas seals system


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Piping diagram


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LUBE OIL

SYSTEM

Lubrication system


185/243


Oil console GA


186/243


Lube oil console P&ID


187/243


To the gear

Machines

From the

gear

Lube oil system P& ID


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Stop modeRunning mode

To

console

Console

Fromconsole

Dual filters


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Flow glass


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PCV 380 et 375


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Driven pump


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Oil demister


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MACHINERY

PROTECTION

Temperature system


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Machinery protection system


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Go to probe software 01

Go to probe software 02

Vibration system


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Shaft

Gap

Probe support

Probe cable

(50 ohms)

Extension cable

(95 ohms)

Connectingdevice

Proximitor

Power supply

-18 volts

direct current

SPower supply and

control feedback

Monitor or any

control material

Vibration system


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Gap = 1,8 mm

Gap = 0,8 mm

Gap = 0 mm

+10 V

-10 V

+2 V

-2 V

0 V

OUTPUT

COM

- 18 VDC

Vibration system


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Vibration system


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Axial probe


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Vibration system


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Temperature & vibration P&ID


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Compressor control system


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Local control (on control panel)

Start up / Shutdown / MonitoringUnit and auxiliaries

Remote control (DCS)Unit control system

Station control systemPlant control system

Local control (on skid)Emergency shutdownControl system of the machine



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Local control (on skid)Emergency shutdownControl system of the machine



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Local control (on control panel)

Start up / Shutdown / MonitoringCompressor and auxiliairies


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PERFORMANCE

CURVES

SURGE & ANTI SURGE

Go to anti surge software


210/243


INSTALLATION

&

GROUTING

Alignment


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OFFSET

ANGULAR

VERTICAL

ALIGNMENT

HORIZONTAL

ALIGNMENT

Compressor shaft alignment


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Compressor shaft alignment


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Casing fixation


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Maintenance

on the DATUM


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Safety precautions

Disassembly

Inspection

Re-assembly Special tools

Spare parts

COMPRESSOR

MAINTENANCE

Pre-start inspection


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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


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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

Each shift

Routine operations


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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


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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


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Maintenance considerations


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BUNDLE CRADLE

SUPPORT BUNDLE

CRADLE

Maintenance considerations


228/243


BUNDLE + ROTOR +

BEARINGS + SEALS

Inspection


229/243


Disassembly inspection

Component inspection

visual & dimensional

Inspection methods Re-assembly inspection

Inspection records

Possible causes for an event

Small special tools

Special tools


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couplings, bearings,

and seals

Big special tools -

assembly and lifting

Inspection of special tools

Storage of special tools

Special tools


231/243


Special tools


232/243


Thrust disc


233/243


Hydraulic fit thrust disc


234/243


Special tools


235/243


Special tools


236/243


Compressor parts


237/243


Special tools


238/243


Bundle insertion tool


239/243


Bundle cradle


240/243


Questions

questio

ns?


241/243


Doyou h

ave any

Centrifugal compressor


242/243


QUIZ


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Thank you foryour attention

Documents

CCFAMGB SBM