2017 COMPRESSION SOURCING TECHNOLOGY SUPPLEMENT Ratings • Specs • Information
The Industry’s Leading Reference Tool For Packagers, Purchasers And Training Providers
CTSSnet.net CTSS net.net COMPRESSION TECHNOLOGY SOURCING SUPPLEMENT
COMPRESSOR Dedicated To Gas Compression Products & Applications
Technology Te Th T hat Transforms. Gas Compression Ratings Gross Horsepower (kW) w/o Fan E NGINE M ODEL
C/R
2200
1 0.5:1
–
–
49 (37)
–
10.5:1
–
–
84 (63)
99 (74)
8.5:1
–
–
116 (87)
–
10 .5:1
–
–
99 (74)
–
10.5:1
–
99 (74)
118 (88)
135 (101)
8.5:1
–
–
175 (130)
–
8.5:1
–
–
190 (142)
–
GTA8.3SLB (3, 5)
8.5:1
–
145 (108)
175 (130)
–
QSL9G (1, 4)
9.7:1
–
–
175 (130)
–
G855 (2, 4)
10:1
–
157 (117)
188 (140)
–
G855E (1, 4)
10:1
–
157 (117)
188 (140)
–
GTA855 (2, 4)
8.5:1
–
–
225 (168)
–
8.5:1
–
–
225 (168)
–
8.5:1
–
–
256 (191)
–
GTA855 (3)
8.5:1
–
238 (177)
286 (213)
–
KTA19GCE (2, 4)
8.5:1
265 (198)
–
–
–
KTA19GCE (2, 4, 6)
8.5:1
–
–
380 (283)
–
KTA19GCE (3)
8.5:1
–
–
420 (313)
–
G5.9 (2, 4, 6)
C ONTINUOUS R ATING HP ( K W) W ) @ RPM 1200 1500 1800
GTA5.9 (3) G8.3 (2, 4, 6)
GTA8.3 (3)
GTA855E (1, 4)
Notes (1) COMPLIANT-CAPABLE COMPLIANT-CAPABLE – This engine is capable of meeting the SI NSPS regulations from the factory. However, the owner/operator is required to conduct site compliance testing and submit documentation per the EPA SI NSPS requirements. Engines with the “E” designation include a factory-supplied air/fuel ratio controller and a Cummins Emission Solutions Three-Way Catalyst (TWC). (2) CUSTOMER-COMPLIANT UPGRADEABLE – This engine is capable of operating with a TWC at this rating. It is the responsibility of the owner/operator to upgrade the engine with an air/fuel ratio controller and a TWC capable of meeting the SI NSPS regulations. The owner/operator is required to conduct site compliance testing and submit documentation per the EPA SI NSPS requirements. (3) This engine is not capable of meeting the EPA EPA SI NSPS regulations, and is offered only for use outside the U.S. (4) Catalyst rating. (5) This engine emits 2.0 gr/hp-hr NOx, 4.0 gr/hp-hr CO, 1.0 gr/hp-hr VOC. This engine does not meet the revised EPA SI NSPS requirements for non-emergency engines, and is offered only for use outside the U.S. (6) Factory integrated Murphy Engine Integrated Control System (EICS) available.
In the gas compression industry, you need an engine that will run every minute of every day for years. That’s Cummins. We offer a full lineup of naturally aspirated and turbocharged gas-fueled engines. Every engine is built with many of the same rugged components used in our high-compression diesel engines, and is backed by the dependable parts and service capabilities of Cummins worldwide distribution network. To learn more, contact your local Cummins distributor, call us at 1-800-268-6467 or visit our web site at CumminsOilandGas.com. ©2017 Cummins Inc., Box 3005, Columbus, IN 47202-3005 U.S.A.
2017 PUBLICATION STAFF Associate Publisher ...................Mark Thayer Senior Editor ................................... DJ Slater
COMPRESSION SOURCING TECHNOLOGY SUPPLEMENT CONTENTS
Senior Editor ................. Michael J. Brezonick
n
Associate Editor ........................... Klinton Silvey
n
Index To Manufacturers’ Sections And Products ................................3 Product Directory and Buyers’ Guide ...............................................16
Associate Editor ...............................Jack Burke Associate Editor ............................Chad Elmore
Karpowicz Copy Editor ............................... Jerry Karpowicz Publication Manager .................. Katie Bivens Circulation Manager ...................... Sue Smith Graphic Artist ...........................Brenda Burbach Graphic Artist .................................Carla Lemke Graphic Artist ............................... Alyssa Loope
COMPRESSORS Including: Centrifugal, Reciprocating And Rotary Compressors And Turboexpanders n n n
PUBLICATION HEADQUARTERS 20855 Watertown Road, Suite 220 Waukesha, Wisconsin 53186-1873 Telephone: (262) 754-4100 Fax: (262) 754-4175
HOUSTON, USA Mark Thayer, Associate Publisher 12777 Jones Road, Suite 225 Houston, Texas 77070 Telephone: (281) 890-5287
GERMANY Lisa Hochkofler, Advertising Manager Gabriele Dinsel, Advertising Manager Niemöllerstr. 9 73760 Ostfildern, Germany
n n n
Centrifugal Compressor Specificatio Specifications ns ............................................33 Turboexpander Specificatio Specifications ns .........................................................41 Reciprocating & Rotary Compressor Specification Specifications s .........................44 Tech Brief: Compressors And Expanders .........................................71 SI Units… Units… The The International International Standards System ...............................132 Conversion Factors SI – Metric/Decimal Metric/Decimal System ............................133
PRIME MOVERS Including: Reciprocating Engines, Turbines And Electric Motors n n n n n n
Natural Gas Engine Specification Specifications s .................................................145 Mechanical Drive Gas Turbine Turbine Specification Specifications s .................................149 Mechanical Drive Steam Turbine Specificatio Specifications ns .............................153 Electric Motor Specificatio Specifications ns ................................................ ........155 Variable Speed Drive Specification Specifications s .............................................. 157 Tech Brief: Brief: Prime Prime Movers Movers For Mechanical Drives ...........................162
Telephone: +49 711 711 3416 74 0 Fax: +49 711 3416 74 74
UNITED KINGDOM Ian Cameron, Regional Manager/Editor Linda Cameron, Advertising Manager 40 Premier Avenue Ashbourne, Derbyshire, DE6 1LH, United Kingdom Telephone: +44 20 31 79 29 79 Fax: +44 20 31 79 29 70
INSTRUMENTATION INSTRUMENTA TION & CONTROLS Including: Monitoring And Engineering Services n
Tech Brief: Un-Balancing Act ........................................................193
COMPONENTS Including: Heat Exchangers, Lubrication, Filters, Seals, Valves, Etc.
ITALY Roberta Prandi, Regional Manager/Editor Via Cerere 18 38062 Arco, Italy
n
Telephone: +39 0464 014421
n
SWEDEN Bo Svensson, Field Editor/Business Manager Dunderbacksvagen 20 612-46 Finspong, Sweden Telephone: +46 70 2405369 Fax: +46 122 14787
n
SYSTEM REPAIR Including: Overhaul And Service n n
JAPAN Akiyoshi Ojima, Branch Manager 51-16-301 Honmoku Sannotani, Naka-ku Yokohama, 231-0824 Japan Telephone: +81 45 624 3502 350 2 Fax: +81 45 624 3503
KOREA D. S. Chai, Sales Manager Dongmyung Communications Inc. 82 Pyeongchangmunhwa-ro, Jongno-gu Seoul, 03011 Korea Telephone: +82 2 391 4254 Fax: +82 2 391 4255
DIESEL & GAS TURBINE PUBLICATIONS .................... .................... ............. ... Michael J. Osenga President .......... Executive Vice President ....Michael J. Brezonick 2017 EDITION
Tech Brief: Brief: Nontraditional Nontraditional Vibration Mitigation Methods For Reciprocating Compressor Compressor Systems ............................... ......202 Tech Brief: Brief: Slow Slow Rolling Rolling Centrifugal Compressors ..........................210 Tech Brief: Lube Reduction In Reciprocating Compressors ............212
n
Tech Brief: Case Study: Packing Vent Monitoring ..........................218 Tech Brief: Creating The The Perfect Impeller Shape Shape By Scalloping ......228 Compressor Horsepower Selection Chart ................................ ......229
PACKAGERS Including: Compression And Power Generation n n
Packager Guide 2017 ...................................................................233 Directory Of Advertisers ...............................................................240
Published March 2017 by Diesel & Gas Turbine Publications, 20855 Watertown Road, Suite 220, Waukesha, WI 53186-1873, USA. Copyright 2017. All Rights Reserved. This book or parts thereof may not be reproduced in any form without written permission of the Publisher. Additional copies of the COMPRESSION TECHNOLOGY SOURCING SUPPLEMENT are available for $35.00/copy postpaid. Send order to the Publisher’s Circulation Office: 20855 Watertown Road, Suite 220, Waukesha, WI 53186-1873, USA. When ordering from outside the United States, remit in U.S. funds. Printed in USA. 1
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INDEX TO MANUFACTURERS’ SECTIONS AND PRODUCTS ATLAS COPCO (SHANGHAI) PROCESS EQUIPMENT
A
CO. LTD. .............. .........................140, ...........140, 141
ANDREAS HOFER HOCHDRUCKTECHNIK GMBH .............. .............................142, ...............142, 143
Ruhrorter Str. 45 45478 Mülheim an der Ruhr GERMANY Phone: +49 208 469 96-0 Fax: +49 208 469 96-11 Email:
[email protected] [email protected] e Website: www.andreas-hofer. www.andreas-hofer.de de Compressor Sets, Electrically Engine-Driven Compressors, Air Compressors, Diaphragm Compressors, Gas Compressors, Oil-Free Compressors, Oil-Injected Compressors, Piston Compressors, Reciprocating Compressors, Skid-Mounted Packing Assemblies Services, Compressors Overhaul & Repair
ATLAS COPCO GAS AND PROCESS ..............140, 141
Schlehenweg 15 50999 Cologne GERMANY Phone: +49 2236 9650 0 Email: atlascopco.energas@ de.atlascopco.com Website: www.atlascopco-gap.com Compressors, Air Compressors, Gas Compressors, Piston Compressors, Reciprocating Expanders Turboexpander ATLAS COPCO COMPTEC LLC ...............140, 141
46 School Road Voorheesville, New York 12186 USA Tel: +1-518-765-3344 Fax: +1-518-765-3357 For Product Listing See Atlas Copco Gas And Process
ARIEL CORPORATION ...................COMPRESSORS ............... ....COMPRESSORS TAB
35 Blackjack Road Mt. Vernon, Ohio 43050 USA Phone: +1 740-397-0311 Fax: +1 740-397-3856 Email:
[email protected] Website: www.arielcorp.com Compressors, Gas Compressors, Reciprocating 2017 EDITION
16F China Venturetech Plaza No.819 Nanjing West Road Shanghai, 200041 CHINA Tel: +86 021 22 08 48 76 Fax: +86 021 62 15 19 63 For Product Listing See Atlas Copco Gas And Process ATLAS COPCO INDIA LTD. .............. ......................140, ........140, 141
Sveanagar, Bombay Pune Road, Dapodi Pune, 411012 INDIA Tel: +91 20 398523010 Fax: +91 20 27145948 For Product Listing See Atlas Copco Gas And Process ATLAS COPCO SERVICE CENTER NORTH AMERICA ...........140, 141
950 Hall Court Deer Park (Houston), Texas 77536 USA +1-281-542-0920 For Product Listing See Atlas Copco Gas And Process
ATLAS COPCO MAFI-TRENCH COMPANY LLC ...............140, ...............140, 141 14 1
3037 Industrial Parkway Santa Maria, California 93455 USA Tel: +1-805-928-5757 Fax: +1-805-925-3861 For Product Listing See Atlas Copco Gas And Process 3
B
BORSIG ZM COMPRESSION GMBH .........119
Seiferitzer Allee 26 08393 Meerane GERMANY WWW.CTSSNET.NET WWW.CTS SNET.NET CTSS
Phone: +49 3764 5390-0 Fax: +49 3764 5390-5092 Email:
[email protected] Website: www.borsig.de/zm Analysis, Software Compressor Condition Monitoring Compressor Sets, Electrically Engine-Driven Compressor Sets, Natural Gas Engine-Driven Compressors, Air Compressors, Centrifugal Compressors, Gas Compressors, Oil-Free Compressors, Piston Compressors, Reciprocating Compressors, Skid-Mounted Controls, Compressor Packings, Oil Wiper Safety Systems Services & Training Services, Compressors Overhaul & Repair Services, Engineering Services, Turbomachinery Overhaul & Repair Valves, Compressor Valves, Overhaul
BURCKHARDT COMPRESSION AG ...............144 Im Link 5, PO Box 65 8404 Winterthur SWITZERLAND Phone: +41 (0) 52 262 55 00 Fax: +41 (0) 52 262 00 51 Email:
[email protected] Website: www.burckhardtcompression.com Compressors, Gas Compressors, Oil-Free Compressors, Oil-Injected Compressors, Piston Compressors, Reciprocating Compressors, Skid-Mounted 2017 EDITION
Compressors, Stationary Monitors, Compressor Systems Services & Training Services, Compressors Overhaul & Repair Services, Engineering Valves, Compressor
BURCKHARDT COMPRESSION BRAZIL LTDA. ........................144 Trav. Claudio Armando, 171 Building no. 41 09861-730 São Bernardo do Campo BRAZIL Phone: +55 11 4344 2900 Fax: +55 11 4356 2901 Email: info.brasil@ burckhardtcompression.com Website: www.burckhardtcompression.com For Product Listing See Burckhardt Compression AG
BURCKHARDT COMPRESSION (CANADA) INC. ......................144 5080 Timberlake Boulevard Unit 26 Mississauga, Ontario L4W 4M2 CANADA Phone: +1 905-602-8550 Fax: +1 905-602-8619 Email: tim.lillak@ burckhardtcompression.com Website: www.burckhardtcompression.com For Product Listing See Burckhardt Compression AG
Website: www.burckhardtcompression.com For Product Listing See Burckhardt Compression AG
BURCKHARDT COMPRESSION (ESPAÑA) S.A. .......................144 Avenida de los Pirineos, 25 Nave 2, 28703 San Sebastián de los Reyes (Madrid) SPAIN Phone: +34 (91) 567 57 27 Fax: +34 (91) 567 57 87 Email: info.spain@ burckhardtcompression.com Website: www.burckhardtcompression.com For Product Listing See Burckhardt Compression AG
BURCKHARDT COMPRESSION (FRANCE) S.A.S. ....................144 Parc de l ‘Horloge, Bat cerithe 204 21/23 rue du Petit Albi 95800 Cergy Saint Christophe FRANCE Phone: +33 (1) 75 72 03 50 Fax: +33 (1) 75 72 03 40 Email: francois.bouziguet@ burckhardtcompression.com Website: www.burckhardtcompression.com For Product Listing See Burckhardt Compression AG
BURCKHARDT COMPRESSION (DEUTSCHLAND) GMBH .......144
BURCKHARDT COMPRESSION (INDIA) PVT. LTD. ..................144
Kruppstrasse 1a 41469 Neuss GERMANY Phone: +49 (0) 2137 91700 Fax: +49 (0) 2137 9170 29 Email: info.deutschland@ burckhardtcompression.com
Gat No. 304, Village Kondhapuri Pune-Nagar Road, Taluka Shirur Dist. Pune 412 209 INDIA Fax: +91 (0) 2137 669496 Email: info.india@ burckhardtcompression.com
4
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Website: www.burckhardtcompression.com
Website: www.burckhardtcompression.com
For Product Listing See Burckhardt Compression AG
For Product Listing See Burckhardt Compression AG
BURCKHARDT COMPRESSION (ITALIA) S.R.L. .......................144
BURCKHARDT COMPRESSION KOREA LTD. ..........................144
Via E. Mattei 2 20852 Villasanta (MB) ITALY Phone: +39 039 96368 00 Fax: +39 039 96368 15 Email: info.italia@ burckhardtcompression.com Website: www.burckhardtcompression.com For Product Listing See Burckhardt Compression AG
#1518 Land Mark Tower 308 Gangnam-daero Gangnam-gu Seoul 135-937 KOREA Phone: +82 2 538 6060 Fax: +82 2 538 2641 Email: seung-kweon.lee@ burckhardtcompression.com Website: www.burckhardtcompression.com For Product Listing See Burckhardt Compression AG
BURCKHARDT COMPRESSION (JAPAN) LTD. .........................144
Yamazaki Bldg. 4F, 3-7-2 Irifune, Chuo-ku Tokyo 104-8563 JAPAN Phone: +81 3 3537-8870 to 8876, and 8878 Fax: +81 3 3537 8877 Email: info.japan@ burckhardtcompression.com Website: www.burckhardtcompression.com For Product Listing See Burckhardt Compression AG
BURCKHARDT KOMPRESÖR SAN. VE TIC. LTD. STI. .........144
Imes Sanayi Sitesi, B Blok, sk 204, No.: 19/B Ümraniye / Dudullu Istanbul TURKEY Phone: +90 216 313 83 00 Fax: +90 216 420 21 23 Email: sakir.cakin@ burckhardtcompression.com 2017 EDITION
BURCKHARDT COMPRESSION KOREA BUSAN LTD. ............144
10, Mieumsandan 1ro, 15beon-gil Gangseo-gu Busan 46730 KOREA Phone: +82 51 711 11 20 Fax: +82 51 711 11 21 Email: info.koreabusan@ burckhardtcompression.com Website: www.burckhardtcompression.com For Product Listing See Burckhardt Compression AG
BURCKHARDT COMPRESSION (MIDDLE EAST) FZE ..............144
PO Box 262944 Jebel Ali Free zone Dubai UAE Phone: +971 887 00 42 Fax: +971 887 00 52 Email: info_dubai@ burckhardtcompression.com 5
Website: www.burckhardtcompression.com For Product Listing See Burckhardt Compression AG
BURCKHARDT COMPRESSION (SHANGHAI) CO. LTD. ..........144
Building 6 No. 509 Renqing Road Pudong, Shanghai 201201 P.R. CHINA Phone: +86 21 5072 0880 Fax: +86 21 5072 0389 Email: keven.li@ burckhardtcompression.com Website: www.burckhardtcompression.com For Product Listing See Burckhardt Compression AG
BURCKHARDT COMPRESSION SINGAPORE PTE LTD. ..........144
29A, Benoi Road Singapore 627775 SINGAPORE Phone: +65 6795 8684 Fax: +65 6795 1472 Email: patrick.chong@ burckhardtcompression.com Website: www.burckhardtcompression.com For Product Listing See Burckhardt Compression AG
BURCKHARDT COMPRESSION SOUTH AFRICA (PTY) LTD. ..............................144
Unit 66 / 5 Sunnyrock Park 5 Sunrock Close 1401 Sunnyrock SOUTH AFRICA Phone: +27 (010) 593 1915 Email: rene.mueller@ burckhardtcompression.com Website: www.burckhardtcompression.com For Product Listing See Burckhardt Compression AG WWW.CTSSNET.NET CTSS
BURCKHARDT COMPRESSION (UK) LTD. ................................144
Units 1 & 2, Arena 14, Bicester Park Charbridge Lane, Bicester Oxfordshire OX26 4SS U.K. Phone: +44 1869 326800 Fax: +44 1869 326808 Email: colin.webb@ burckhardtcompression.com Website: www.burckhardtcompression.com For Product Listing See Burckhardt Compression AG
BURCKHARDT COMPRESSION (US) INC. .................................144
7240 Brittmoore Road, Suite 100 Houston, Texas 77041 USA Phone: +1 281-582-1050 Fax: +1 281-582-1060 Email: bcus.webquery@ burckhardtcompression.com Website: www.burckhardtcompression.com For Product Listing See Burckhardt Compression AG
C
COMOTI - ROMANIAN RESEARCH & DEVELOPMENT INSTITUTE FOR GAS TURBINES..............123
220D luliu Maniu Ave 061126 Bucharest 6 ROMANIA Phone: +4 021 434 02 40 Fax: +4 021 434 02 41 Email:
[email protected] Website: www.comoti.ro Acoustical Pulsation Analysis Bearings, Tilting Pad Blades & Nozzles, Gas Turbines 2017 EDITION
Blowers Compressor Condition Monitoring Compressor Sets, Electrically Engine-Driven Compressor Sets, Gas Turbine- Driven Compressor Sets, Natural Gas Engine-Driven Compressor Valve Condition Monitoring Compressors, Air Compressors, Centrifugal Compressors, Gas Compressors, Oil-Free Compressors, Oil-Injected Compressors, Rotary Screw Compressors, Screw Computer-Controlled Engine Testing Controls, Electronic Emissions Analyzers Emissions Controls Engines, Gas Turbine Engines, Natural Gas (Spark Ignited) Engines, Research Expanders Gas Turbines Gear Systems Gears, Custom Machining Packages, Engine Compressor Packages, Engineering & Design Packages, Motor Compressor Power Turbines Research & Development Rotors, Turbomachinery Services, Compressors Overhaul & Repair Services, Diagnostics Services, Engineering Services, Field Pulsation, Vibration-Analysis Services, Gas Turbine Overhaul & Repair Services, Turbomachinery Overhaul & Repair Silencers Silencers, Acoustical Silencers, Exhaust Silencers, Intake Air Turboexpander 6
CORKEN INC. A UNIT OF IDEX CORPORATION...............238, 239
3805 NW 36th Street Oklahoma City, Oklahoma 731122983 USA Phone: +1 405-946-5576 Fax: +1 405-948-7343 Email:
[email protected] Website: www.corken.com Compressors, Air Compressors, Gas Compressors, Oil-Free Compressors, Oil-Injected Compressors, Piston Compressors, Portable Compressors, Reciprocating Compressors, Skid-Mounted Compressors, Stationary Packages, Engineering & Design Pumps, Boiler-Feed Pumps, Chemical Pumps, Condensate Or Condensate Return Pumps, Hazardous-Liquid Pumps, Heavy-Duty Pumps, High-Pressure Pumps, High-Temperature Pumps, Hydraulic Pumps, Hydraulic Gear-Type Pumps, Lubricating-Oil Pumps, Magnet Drive Pumps, Positive-Displacement
COZZANI, DOTT. ING. MARIO COZZANI SRL ........................217
Viale XXV Aprile 7 19021 Arcola (SP) ITALY WWW.CTSSNET.NET CTSS
Phone: +39 0187 95581 Fax: +39 0187 955853 Email:
[email protected] Website: www.cozzani.com Actuators, Electric Actuators, Pneumatic Actuators, Solenoid Component Reconditioning Compressors, Capacity Control Devices Seats, Valve Valve Springs Valves, Check Valves, Compressor Valves, Overhaul Valves, Seats & Rings
Actuators, Electric Actuators, Pneumatic Actuators, Solenoid Component Reconditioning Compressors, Capacity Control Devices Seats, Valve Valve Springs Valves, Check Valves, Compressor Valves, Overhaul Valves, Seats & Rings E
...............THIRD COVER, 115, 192
OIL & GAS MARKETS .......................... SECOND COVER
500 Jackson Street MC60610 Columbus, Indiana 47201 USA Phone: +1 812-377-9441 Email:
[email protected] Website: www.cumminsengines. com/oil-and-gas Engine Maintenance, Overhaul & Parts Services Engines, Gas Turbine Engines, Natural Gas (Spark Ignited) D DOTT. ING MARIO COZZANI SRL ........................217
Viale XXV Aprile 7 19021 Arcola (SP) ITALY Phone: +39 0187 95581 Fax: +39 0187 955853 Email:
[email protected] Website: www.cozzani.com 2017 EDITION
F
FLSMIDTH INC. PNEUMATIC TRANSPORT
ELLIOTT GROUP
CUMMINS INC.
Services, Turbomachinery Overhaul & Repair Steam Turbines Turbochargers, Repairs
901 North Fourth Street Jeannette, Pennsylvania 15644 USA Phone: +1 724-527-2811 Email:
[email protected] Website: www.elliott-turbo.com Compressors, Air-Starting Compressors, Centrifugal Compressors, Gas Controls, Compressor Controls, Surge Controls, Temperature Controls, Vibration Drives, Compressor Drives, Hydraulic-Pump Expanders Packages, Motor Compressor Packages, Steam Turbine Compressor Power Turbines Rotors, Turbomachinery Seals, Dry Gas Services & Training Services, Compressors Overhaul & Repair Services, Engineering Services, Failure-Analysis Services, Gas Turbine Overhaul & Repair 7
..........................................125, 129
2040 Avenue C. Bethlehem, Pennsylvania 18017 USA Phone: +1 610-264-6800 Fax: +1 610-264-6307 Email:
[email protected] Website: www.flsmidth.com/compressors Blades, Rotary Compressor Compressor Divider Block Lubrication Systems Compressors, Air Compressors, Gas Compressors, Oil-Injected Compressors, Rotary Sliding Vane Packages, Motor Compressor Services, Compressors Overhaul & Repair G
GEA REFRIGERATION ITALY OIL & GAS ...............................237
via delle Officine Barbieri, 7 Castel Maggiore Bologna ITALY Phone: +39 051718603, Mobile 3482575334 Fax: +39 051 718699 Email:
[email protected] Website: http://gea.com WWW.CTSSNET.NET CTSS
Chillers Compressor Sets, Electrically Engine-Driven Compressor Sets, Natural Gas Engine-Driven Compressors, Centrifugal Compressors, Gas Compressors, Integral Compressors, Oil-Free Compressors, Oil-Injected Compressors, Piston Compressors, Reciprocating Compressors, Rotary Screw Compressors, Screw Compressors, Skid-Mounted Coolers, Intercooler Type Coolers, Lube Oil Coolers, Water Cooling Systems Inlet Cooling Systems Packages, Engine Compressor Packages, Engineering & Design Packages, Gas Turbine Compressor Packages, Motor Compressor Packages, Piping, Structural Analysis Services & Training Services, Compressors Overhaul & Repair Services, Engineering Services, Failure-Analysis H
HOERBIGER ........................134, 135
Seestadtstrasse 25 1220 Vienna AUSTRIA Phone: +43 1 740 04-0 Email: info-hkth-marketing@ hoerbiger.com Website: www.hoerbiger.com Acoustical Pulsation Analysis Actuators, Electric Air Actuators, Hydraulic 2017 EDITION
Adapters, Indicator Valve Air/Fuel Ratio Controls Blades & Nozzles, Gas Turbines Blades, Rotary Compressor Blades, Turbine Blades, Turbocharger Component Reconditioning Compressor Condition Monitoring Compressor Cylinder & Packing Lubrication Compressor Frame End Parts Compressor Valve Condition Monitoring Compressors, Capacity Control Devices Compressors, Reciprocating Compressors, Reconditioned Controllers, Engine System Controls, Compressor Controls, Electrohydraulic Controls, Knock Detection & Control Crankshafts Crankshafts, Reconditioning Cylinder Lubrication Systems Cylinders Cylinders, Engine Cylinders, Light-Alloy Cylinders, Liners & Sleeves Cylinders, Reconditioning Emissions Controls Engine Maintenance, Overhaul & Parts Services Engines, Conversion Systems/ Components Liners, Cylinder Liners, Reconditioning Cylinder Monitors, Compressor Systems Monitors, Load Monitors, Pressure Monitors, Temperature Monitors, Vibration Packing Assemblies Packing Cases Pistons Pistons, Reconditioning Rings, Compressor Rings, Packing 8
Rings, Piston Rings, Power Rings, Pressure Breaker Rings, Rider Rings, Sealing Rings, Turbocharger-Sealing Rings, Wiper Rotors, Turbomachinery Services & Training Services, Compressors Overhaul & Repair Services, Engineering Services, Failure-Analysis Services, Field Pulsation, Vibration-Analysis Services, Turbomachinery Overhaul & Repair Valves, Check Valves, Compressor Valves, Crankcase Relief Valves, Explosion Relief Valves, Fuel Valves, Relief & Safety Valves, Seats & Rings Valves, Starting Air HOERBIGER CORP. OF AMERICA INC. COMPRESSOR VALVE AND SEALING SYSTEMS .......134, 135
3350 Gateway Drive Pompano Beach, Florida 33069 USA Phone: +1 954-974-5700 Email: info-americas@ hoerbiger.com Website: www.hoerbiger.com For Product Listing See HOERBIGER
HOERBIGER SERVICE INC. SERVICE PROVIDER: USA ..........................................134, 135
8448 North Sam Houston Parkway West Houston, Texas 77064 Unites States Phone: +1 281-955-5888 WWW.CTSSNET.NET CTSS
Email: info-americas@ hoerbiger.com Website: www.hoerbiger.com For Product Listing See HOERBIGER
Compressors, Piston Compressors, Reciprocating Valves, Pressure Valves, Relief & Safety Valves, Shut-Off K
HOERBIGER SERVICE INC. ..........................................134, 135
1358 West Newport Center Drive Deerfield Beach, Florida 33442 USA Phone: +1 954-422-9850 Email: info-americas@ hoerbiger.com Website: www.hoerbiger.com For Product Listing See HOERBIGER
HOERBIGER (CANADA) LTD. SERVICE PROVIDER:
M KOBELCO COMPRESSORS AMERICA INC. .........................FOURTH COVER
1415 Louisiana Street Suite 4111 Houston, Texas 77002 USA Phone: +1 713-655-0015 Fax: +1 713-982-8450 Email:
[email protected] Website: www.kobelcocompressors.com
CANADA ..........................134, 135
441 South Avenue, PO Box 3427 Spruce Grove, Alberta T7X 3A7 Canada Phone: +1 780-960-6656 Email:
[email protected] Website: www.hoerbiger.com For Product Listing See HOERBIGER
HOFER KOMPRESSOREN
Compressors, Air Compressors, Centrifugal Compressors, Gas Compressors, Integral Compressors, Oil-Free Compressors, Oil-Injected Compressors, Piston Compressors, Reciprocating Compressors, Rotary Screw Compressors, Screw L
........................................142, 143
Ruhrorter Strasse 45 45478 Muelheim GERMANY Fax: +49 208 46996 11 Email:
[email protected] Website: www.andreas-hofer.de Compressor Sets, Electrically Engine-Driven Compressors, Diaphragm Compressors, Gas Compressors, Oil-Free Compressors, Oil-Injected 2017 EDITION
Compressors, Air Compressors, Gas Compressors, Oil-Free Compressors, Piston Compressors, Reciprocating Compressors, Rotary Screw Compressors, Screw Compressors, Skid-Mounted Compressors, Stationary
LEOBERSDORFER MASCHINENFABRIK (LMF) ...............................136, 137
Suedbahnstr. 28 2544 Leobersdorf AUSTRIA Phone: +43 2256 9001-0 Fax: +43 2256 9002 Email:
[email protected] Website: www.LMF.at 9
MAN DIESEL & TURBO SE ..................138, 139
Steinbrinkstrasse 1 46145 Oberhausen GERMANY Phone: +49 (0) 208 692 01 Fax: +49 (0) 208 669 021 Email:
[email protected] Website: www.mandieselturbo.com Compressor Sets, Electrically Engine-Driven Compressor Sets, Gas Turbine- Driven Compressors, Air Compressors, Axial Compressors, Centrifugal Compressors, Gas Compressors, Integral Compressors, Oil-Free Compressors, Rotary Screw Compressors, Screw Compressors, Skid-Mounted Compressors, Stationary Controls, Compressor Drives, Compressor Engine Maintenance, Overhaul & Parts Services Engines, Gas Turbine Expanders Monitors, Compressor Systems Monitors, Engine System WWW.CTSSNET.NET CTSS
Packages, Engine Compressor Packages, Motor Compressor Power Turbines Protective Controls Reactor Systems Rotors, Turbomachinery Service Systems & Training, Gas Turbines Services & Training Services, Compressors Overhaul & Repair Services, Engineering Services, Gas Turbine Overhaul & Repair Steam Turbines
MAN DIESEL & TURBO SE ..................138, 139
Egellsstrasse 21 13507 Berlin GERMANY Phone: +49 (0) 30 44 04 02 0 Fax: +49 (0) 30 44 04 02 2000 Email:
[email protected] Website: www.mandieselturbo.com For Product Listing See MAN Diesel & Turbo SE, Germany
MAN DIESEL & TURBO SCHWEIZ AG .................138, 139
Hardstrasse 319 8005 Zurich SWITZERLAND Phone: +41 44 278 2211 Fax: +41 44 278 2261 Email:
[email protected] Website: www.mandieselturbo.com For Product Listing See MAN Diesel & Turbo SE, Germany
MAN DIESEL & TURBO SE ..................138, 139
Werftstrasse 17 94469 Deggendorf GERMANY 2017 EDITION
Phone: +49 (0) 991 381-0 Fax: +49 (0) 991 381-5156 Email:
[email protected] Website: www.mandieselturbo.com Apparatus Construction Reactor Systems
MITSUBISHI HEAVY INDUSTRIES COMPRESSOR INTERNATIONAL ........................................127, 201
14888 Kirby Dr. Houston, Texas 77047 USA Phone: +1 832-710-4551 Fax: +1 832-710-4600 Email:
[email protected] Website: www.mhicompressor.com/en Blades, Rotary Compressor Blades, Turbine Castings, Centrifugal Castings, Compressor Castings, Turbine Component Component Reconditioning Compressor Sets, Electrically Engine-Driven Compressor Sets, Gas Turbine-Driven Compressor Sets, Natural Gas Engine-Driven Compressors, Air Compressors, Centrifugal Compressors, Diaphragm Compressors, Gas Compressors, Integral Compressors, Skid-Mounted Compressors, Stationary Condensers Consulting Expanders Forgings, Compressor Forgings, Turbine Components Impellers, Turbine & Turbochargers Machining 10
Mechanical Fasteners Nuts, Cap Packages, Engineering & Design Packages, Motor Compressor Packages, Steam Turbine Compressor Project Management Rings, Labyrinth Rotors, Turbomachinery Services & Training Services, Compressors Overhaul & Repair Services, Diagnostics Services, Engineering Services, Failure-Analysis Services, Field Pulsation, Vibration-Analysis Services, Turbomachinery Overhaul & Repair Shafts Steam Turbines Stud Bolts Tilting Pads Turboexpander MITSUBISHI HEAVY INDUSTRIES COMPRESSOR CORPORATION ..........................................127, 201
4-6-22, Kan-on-shin-machi Nishi-ku, Hiroshima, 733-8553 JAPAN For Product Listing See Mitsubishi Heavy Industries Compressor International N
NEAC COMPRESSOR SERVICE USA INC. .........................142, 143
1502 East Summitry Circle Katy, Texas 77449 USA Phone: +1 281-493-2357 Fax: +1 281-493-2554 WWW.CTSSNET.NET
CTSS
Email:
[email protected] Website: www.neacusa.com Compressors, Reconditioned Controls, Vibration Monitors, Compressor Systems Monitors, Load Monitors, Pressure Monitors, Temperature Monitors, Vibration Pistons, Reconditioning Project Management Rings, Packing Rings, Piston Service Tools & Equipment Services & Training Services, Compressors Overhaul & Repair Services, Diagnostics Services, Engineering Services, Failure-Analysis Services, Field Pulsation, Vibration-Analysis Services, Laser Measurements Services, Shutdown Valves, Check Valves, Compressor Valves, Overhaul
NEAC COMPRESSOR SERVICE GMBH & CO. KG ............142, 143
Werkstrasse 52531 Übach-Palenberg GERMANY Phone: +49 2451 481 03 Fax: +49 2451 481 300 Email:
[email protected] Website: www.neac.de Compressors, Reconditioned Controls, Vibration Monitors, Compressor Systems Monitors, Load Monitors, Pressure Monitors, Temperature Monitors, Vibration Pistons, Reconditioning Project Management Rings, Packing Rings, Piston 2017 EDITION
Service Tools & Equipment Services & Training Services, Compressors Overhaul & Repair Services, Diagnostics Services, Engineering Services, Failure-Analysis Services, Field Pulsation, Vibration-Analysis Services, Laser Measurements Services, Shutdown Valves, Check Valves, Compressor Valves, Overhaul
NEAC COMPRESSOR SERVICE S.R.L. ..............................142, 143
Via Giorgio Stephenson, 94 20157 Milan ITALY Phone: +39 02 390994 8 Fax: +39 02 39005005 Email:
[email protected] Website: www.neac.it Compressors, Reconditioned Controls, Vibration Monitors, Compressor Systems Monitors, Load Monitors, Pressure Monitors, Temperature Monitors, Vibration Pistons, Reconditioning Project Management Rings, Packing Rings, Piston Service Tools & Equipment Services & Training Services, Compressors Overhaul & Repair Services, Diagnostics Services, Engineering Services, Failure-Analysis Services, Field Pulsation, Vibration-Analysis Services, Laser Measurements Services, Shutdown Valves, Check Valves, Compressor Valves, Overhaul 11
NEAC COMPRESSOR SERVICE LTDA. .............142, 143
Rua Gabriela de Melo 401 Bairro Olhos D’ Água 30390-080 Belo Horizonte MG-BRAZIL Phone: +55 312 126 95 53 Fax: +55 312 126 95 00 Email:
[email protected] Website: www.neac.de Compressors, Reconditioned Controls, Vibration Monitors, Compressor Systems Monitors, Load Monitors, Pressure Monitors, Temperature Monitors, Vibration Pistons, Reconditioning Project Management Rings, Packing Rings, Piston Service Tools & Equipment Services & Training Services, Compressors Overhaul & Repair Services, Diagnostics Services, Engineering Services, Failure-Analysis Services, Field Pulsation, Vibration-Analysis Services, Laser Measurements Services, Shutdown Valves, Check Valves, Compressor Valves, Overhaul
NEAC COMPRESSOR SERVICE LTD. ................142, 143
178/1 Moo 7 T. Phe, A. Muang Rayong, 21160 THAILAND Phone: +66 38 923 722 Fax: +66 38 923 896182 Email:
[email protected] Website: www.neac.net Compressors, Reconditioned Controls, Vibration Monitors, Compressor Systems WWW.CTSSNET.NET
CTSS
Monitors, Load Monitors, Pressure Monitors, Temperature Monitors, Vibration Pistons, Reconditioning Project Management Rings, Packing Rings, Piston Service Tools & Equipment Services & Training Services, Compressors Overhaul & Repair Services, Diagnostics Services, Engineering Services, Failure-Analysis Services, Field Pulsation, Vibration-Analysis Services, Laser Measurements Services, Shutdown Valves, Check Valves, Compressor Valves, Overhaul
Packing Assemblies Services & Training Valves, Overhaul
Werkstrasse 52531 Übach-Palenberg GERMANY Phone: +49 2451 481 01 Fax: +49 2451 481 139 Email:
[email protected] Website: www.neuman-esser.com
Compressor Sets, Electrically Engine-Driven Compressor Sets, Natural Gas Engine-Driven Compressors, Air Compressors, Gas Compressors, Oil-Free Compressors, Oil-Injected Compressors, Piston Compressors, Reciprocating Compressors, Skid-Mounted Packing Assemblies Services, Compressors Overhaul & Repair Services, Shutdown Valves, Overhaul
Compressor Sets, Electrically
NEUMAN & ESSER RUS LTD.
NEUMAN & ESSER DEUTSCHLAND GMBH & CO. KG VERTRIEB UND ANLAGENTECHNIK ........142, 143
Engine-Driven Compressor Sets, Natural Gas Engine-Driven Compressors, Air Compressors, Capacity Control Devices
NEUMAN & ESSER USA INC. .........................142, 143
1502 East Summitry Circle Katy, Texas 77449 USA Phone: +1 281 497 5113 Fax: +1 281 497 5047 Email:
[email protected] Website: www.neuman-esser.com
Compressors, Diaphragm Compressors, Gas Compressors, Oil-Free Compressors, Oil-Injected Compressors, Piston Compressors, Reciprocating Compressors, Skid-Mounted Packages, Engineering & Design Packages, Piping, Structural
Compressor Sets, Electrically Engine-Driven Compressor Sets, Natural Gas Engine-Driven Compressors, Air Compressors, Capacity Control Devices Compressors, Diaphragm Compressors, Gas Compressors, Oil-Free Compressors, Oil-Injected Compressors, Piston Compressors, Reciprocating Compressors, Skid-Mounted Packages, Engineering & Design Packages, Piping, Structural Analysis 2017 EDITION
Analysis Packing Assemblies Services, Compressors Overhaul & Repair Valves, Overhaul
NEUMAN & ESSER (BEIJING) CO. LTD. .......142, 143
Room A-2610, Tower A Eagle Run Plaza, Xiaoyun Road Chaoyang District, Beijing 100125 CHINA Phone: +86 10 84464234 Fax: +86 10 84464245 Email:
[email protected] Website: www.neuman-esser.com 12
..........................................142, 143
Gilyarovskogo Street 4, Build 5 129090 Moscow RUSSIA Phone: +7 495 204 87 97 Fax: +7 495 204 0 Email:
[email protected] Website: www.neuman-esser.de/ru Compressor Sets, Electrically Engine-Driven Compressor Sets, Natural Gas Engine-Driven Compressors, Air Compressors, Gas Compressors, Oil-Free Compressors, Oil-Injected Compressors, Piston Compressors, Reciprocating Compressors, Reconditioned Compressors, Skid-Mounted Packing Assemblies Services, Compressors Overhaul & Repair Services, Shutdown Valves, Check Valves, Overhaul NEUMAN & ESSER ITALIA S.R.L. ..........................................142, 143
Via Giorgio Stephenson, 94 20157 Milan ITALY Phone: +39 02 390994 1 WWW.CTSSNET.NET
CTSS
Fax: +39 02 3551529 Email:
[email protected] Website: www.neuman-esser.com Compressor Sets, Electrically Engine-Driven Compressor Sets, Natural Gas Engine-Driven Compressors, Air Compressors, Capacity Control Devices Compressors, Diaphragm Compressors, Gas Compressors, Oil-Free Compressors, Oil-Injected Compressors, Piston Compressors, Reciprocating Compressors, Skid-Mounted Packages, Engineering & Design Packages, Piping, Structural Analysis Packing Assemblies Valves, Overhaul
NEUMAN & ESSER GULF FZE .......................142, 143
MB-7, Blue Sheds PO Box 61449 Jebel Ali Free Zone, Dubai UNITED ARAB EMIRATES Phone: +971 4 883 2177 Fax: +971 4 883 8124 Email:
[email protected] Website: www.neuman-esser.com Compressors, Capacity Control Devices Compressors, Diaphragm Compressors, Reconditioned Services, Compressors Overhaul & Repair Services, Shutdown Valves, Check Valves, Compressor Valves, Overhaul
NEUMAN & ESSER ENGINEERING (INDIA) PVT. LTD. ........................142, 143
T-121/122, MIDC, Bhosari Pune 411 026 INDIA 2017 EDITION
Phone: +91 20 3062 3250 Fax: +91 20 3062 3251 Email:
[email protected] Website: www.neuman-esser.com Compressor Sets, Electrically Engine-Driven Compressor Sets, Natural Gas
Compressors, Skid-Mounted Packing Assemblies Services, Compressors Overhaul & Repair Services, Shutdown Valves, Check Valves, Overhaul
Engine-Driven Compressors, Air Compressors, Capacity Control Devices Compressors, Diaphragm Compressors, Gas Compressors, Oil-Free Compressors, Oil-Injected Compressors, Piston Compressors, Reciprocating Compressors, Reconditioned Compressors, Skid-Mounted Packages, Engineering & Design Packages, Piping, Structural Analysis
NEUMAN & ESSER AMÉRICA DO SUL LTDA. ..............................142, 143
Rua Gabriela de Melo 401 Bairro Olhos D’ Água 30390-080 Belo Horizonte MG-BRAZIL Phone: +55 312 126 95 99 Fax: +55 312 126 95 00 Email:
[email protected] Website: www.neuman-esser.com Compressor Sets, Electrically Engine-Driven Compressor Sets, Natural Gas Engine-Driven
Packing Assemblies Services, Compressors Overhaul & Repair Services, Shutdown Valves, Check Valves, Overhaul
Compressors, Air Compressors, Capacity Control Devices Compressors, Diaphragm Compressors, Gas Compressors, Oil-Free Compressors, Oil-Injected
NEUMAN & ESSER EGYPT LTD. ...................142, 143
2 Dr. El Mahrouki Str., Mohandessin City-Dokki PO Box 2734 11511 Cairo EGYPT Phone: +2 02 33 47 77 91 Fax: +2 02 33 46 09 49 Email:
[email protected] Website: www.neuman-esser.com Compressors, Air Compressors, Gas Compressors, Oil-Free Compressors, Oil-Injected Compressors, Piston Compressors, Reciprocating 13
Compressors, Piston Compressors, Reciprocating Compressors, Skid-Mounted Packages, Engineering & Design Packages, Piping, Structural Analysis Packing Assemblies Services, Compressors Overhaul & Repair Valves, Overhaul
NEUMAN & ESSER SOUTH EAST ASIA LTD. .......................142, 143
178/1 Moo 7 T. Phe, A. Muang Rayong, 21160 THAILAND WWW.CTSSNET.NET
CTSS
Phone: +66 38 923 700 Fax: +66 38 896 182/3 Email:
[email protected] Website: www.neuman-esser.com Compressor Sets, Electrically Engine-Driven Compressors, Capacity Control Devices Compressors, Diaphragm Compressors, Gas Compressors, Oil-Free Compressors, Oil-Injected Compressors, Piston Compressors, Reciprocating Compressors, Skid-Mounted Packages, Engineering & Design Packages, Piping, Structural Analysis Packing Assemblies
Compressors, Stationary Consulting Cylinder Lubrication Systems Packages, Engine Compressor Packages, Engineering & Design Packages, Foundation, Platform Deck, FPSO Module Design Packages, Motor Compressor Project Management Services & Training Services, Compressors Overhaul & Repair Services, Divider Block Lubrication Systems Services, Engineering Services, Failure-Analysis S
P SIAD MACCHINE IMPIANTI S.P.A. COMPRESSORS DIVISION ....117
PSE ENGINEERING GMBH COMPRESSION SYSTEMS ........................ ............... ......... PACKAGERS TAB
Ahrensburger Strasse 1 30659 Hannover GERMANY Phone: +49 (0) 511 2614-20-0 Fax: +49 (0) 511 2614-20-11 Email:
[email protected] Website: www.pse-eng.de Compressor Condition Monitoring Compressor Sets, Electrically Engine-Driven Compressor Sets, Natural Gas Engine-Driven Compressors, Gas Compressors, Oil-Free Compressors, Oil-Injected Compressors, Piston Compressors, Portable Compressors, Reciprocating Compressors, Reconditioned Compressors, Skid-Mounted 2017 EDITION
Via Canovine 2/4 24126 Bergamo ITALY Phone: +39 035 327611 Fax: +39 035 316131 Email:
[email protected] Website: www.siadmi.com Compressor Frame End Parts Compressor Sets, Electrically Engine-Driven Compressor Sets, Natural Gas Engine-Driven Compressors, Air Compressors, Gas Compressors, Oil-Free Compressors, Oil-Injected Compressors, Piston Compressors, Reciprocating Compressors, Reconditioned Compressors, Skid-Mounted Compressors, Stationary Cylinders, Reconditioning Services & Training Services, Compressors Overhaul & Repair 14
Services, Engineering Services, Failure-Analysis
SOLAR TURBINES INCORPORATED ................... .............. ..... PRIME MOVERS TAB
9330 Sky Park Court Mail Zone SP4-B San Diego, California 92123 USA Phone: +1 858-694-2444 Fax: +1 619-544-2444 Email:
[email protected] Website: www.solarturbines.com Compressor Sets, Gas Turbine- Driven Compressors, Centrifugal Compressors, Gas Engine Maintenance, Overhaul & Parts Services Engines, Gas Turbine Packages, Engine Compressor Packages, Foundation, Platform Deck, FPSO Module Design Service Systems & Training, Gas Turbines Services & Training Services, Compressors Overhaul & Repair Services, Gas Turbine Overhaul & Repair
STASSKOL GMBH ..............142, 143
Maybachstrasse 2 39418 Stassfurt GERMANY Phone: +49 3925 288 100 Fax: +49 3925 288 105 Email:
[email protected] Website: www.stasskol.de Packings, Intermediate Packings, Oil Wiper Packings, Piston Rod Rings, Compressor WWW.CTSSNET.NET
CTSS
Rings, Floating-Sealing Rings, Guide Rings, Packing
For Product Listing See Voith Turbo BHS Getriebe GmbH
Rings, Piston Rings, Rider
VOITH TURBO BHS
Rings, Sealing
GETRIEBE GMBH ..................113
Rings, Wiper Seals, Shaft Sleeves, Shaft Valves, Overhaul
STASSKOL INC. ..................142, 143
19911 Morton Road, Suite 200 Katy, Texas 77449 USA Phone: +1 713 384-9489 Fax: +1 713 384-0 Email:
[email protected] Website: www.stasskol.com
Hans-Boeckler-Strasse 7 87527 Sonthofen GERMANY Phone: +49 8321 802 0 Fax: +49 8321 802 689 Email:
[email protected] Website: www.voith.com/bhs Bearings, Journal or Sleeve Type Bearings, Tilting Pad Couplings, Diaphragm Couplings, Gear-Type Couplings, Shaft Drives, Gear Reduction
Packings, Intermediate
Gear Systems
Packings, Oil Wiper
Gearboxes
Packings, Piston Rod
Gears, Custom
Rings, Compressor
Gears, Epicyclic
Rings, Floating-Sealing
Gears, Helical
Rings, Guide
Gears, Increasers
Rings, Packing
Gears, Ring
Rings, Piston
Gears, Spur
Rings, Rider
Gears, Stationary
Rings, Sealing
Gears, Stationary/Industrial Drive
Rings, Wiper
Gears, Turbo
Valves, Overhaul
Actuators, Electric Actuators, Hydraulic Controls, Compressor Controls, Fuel Consumption Controls, Speed Converters, Torque Couplings, Flexible Couplings, Fluid Couplings, Gear-Type Couplings, Shaft Drives, Compressor Drives, Turbine Starting Drives, Variable-Speed Services & Training Servo Motors Shafts Torque Converters Z
Rotor Turning Gears
Sleeves, Shaft
11700 Katy Freeway Energy Tower, Suite 250 Houston, Texas 77079 USA Email: www.voith.com/vsd Website:
[email protected]
Gears, Turbo
Reducers, Gear
Seals, Shaft
VOITH TURBO INC. .............. ....................113 ......113
Services & Training
ZOLLERN BHW GLEITLAGER GMBH & CO. KG PLAIN BEARING TECHNOLOGY ................226, ................226, 227
V
VOITH TURBO GMBH & CO. KG INDUSTRY .............. ............................ .................113 ...113
VOITH TURBO USA ....................113
4357 Ferguson Drive Cincinnati, Ohio 45245 USA Phone: +1 513-797-8101 Fax: +1 513-797-8103 Email:
[email protected] Website: www.usa.voithturbo.com 2017 EDITION
Voithstrasse 1 74564 Crailsheim GERMANY Phone: +49 7951 32 0 Fax: +49 7951 32 500 Email:
[email protected] Website: www.voithturbo.com
Alte Leipziger Straße 117-118 38124 Braunschweig GERMANY Phone: +49 (5522) 3127-0 Fax: +49 (5522) 3127-99 Email:
[email protected] Bearing Shells Bearings, Journal or Sleeve Type Bearings, Thrust
For Product Listing See Voith Turbo Inc. 15
Bearings, Tilting Pad Bushings WWW.CTSSNET.NET
CTSS
PRODUCT DIRECTORY AN A ND BUYERS’ GUIDE
A
AIR/FUEL RATIO CONTROLS HOERBIGER .................. 134, 135
ACOUSTICAL PULSATION ANALYSIS COMOTI - Romanian Research & Development Institute for Gas Turbines Turbines .... 123 HOERBIGER .................. 134, 135
ACTUATORS, ELECTRIC Cozzani, Dott. Ing. Mario Cozzani Srl ................ 217 Dott. Ing Ing Mario Cozzani Srl .... 217 Voith Turbo Inc. ...................... 113
ACTUATORS, ELECTRIC AIR HOERBIGER .................. 134, 135
ANALYSIS, SOFTWARE BORSIG ZM Compression GmbH ............ 119
APPARATUS CONSTRUCTION MAN Diesel & Turbo SE ...................................... ......................... ............. 138, 139 139
B BEARING SHELLS ZOLLERN BHW Gleitlager GmbH & Co. KG Plain Bearing Technology .................. 226, 227
Voith Turbo BHS Getriebe GmbH .................... .................... 113 ZOLLERN BHW Gleitlager GmbH & Co. KG Plain Bearing Technology .................. 226, 227
BLADES & NOZZLES, GAS TURBINES COMOTI - Romanian Research & Development Institute for Gas Turbines Turbines .... 123 HOERBIGER .................. 134, 135
BLADES, ROTARY COMPRESSOR FLSmidth Inc. Pneumatic Transport .....125, 129 HOERBIGER .................. 134, 135
ACTUATORS, HYDRAULIC
BEARINGS, JOURNAL OR SLEEVE TYPE
HOERBIGER .................. 134, 135
Voith Turbo BHS Getriebe GmbH GmbH .................... .................... 113
Voith Turbo Inc. ...................... 113
Cozzani, Dott. Ing. Mario Cozzani Srl ................ 217
ZOLLERN BHW Gleitlager GmbH & Co. KG Plain Bearing Technology .................. 226, 227
Dott. Ing Ing Mario Cozzani Srl .... 217
BEARINGS, THRUST
ACTUATORS, SOLENOID
ZOLLERN BHW Gleitlager GmbH & Co. KG Plain Bearing Technology .................. 226, 227
ACTUATORS, PNEUMATIC
Cozzani, Dott. Ing. Mario Cozzani Srl ................ 217
Mitsubishi Heavy Industries Compressor International ...................................... .......................... ............ 127, 201 201
BLADES, TURBINE HOERBIGER .................. 134, 135 Mitsubishi Heavy Industries Compressor International ................. 127, 201
BLADES, TURBOCHARGER HOERBIGER .................. 134, 135
Dott. Ing Ing Mario Cozzani Srl .... 217
ADAPTERS, INDICATOR VALVE HOERBIGER .................. 134, 135 2017 EDITION
BEARINGS, TILTING PAD
BLOWERS
COMOTI - Romanian Research & Development Institute for Gas Turbines .... 123
COMOTI - Romanian Research & Development Institute for Gas Turbines Turbines .... 123
16
WWW.CTSSNET.NET
CTSS
BUSHINGS
HOERBIGER .................. 134, 135
ZOLLERN BHW Gleitlager GmbH & Co. KG Plain Bearing Technology .................. 226, 227
PSE Engineering GmbH Compression Systems ............................ ......................... ... Packagers Tab
C CASTINGS, CENTRIFUGAL Mitsubishi Heavy Industries Compressor International ...................................... ....................... ............... 127, 201
COMPRESSOR CYLINDER & PACKING LUBRICATION HOERBIGER .................. 134, 135
COMPRESSOR DIVIDER BLOCK LUBRICATION SYSTEMS FLSmidth Inc. Pneumatic Transport ......125, 129
CASTINGS, COMPRESSOR Mitsubishi Heavy Industries Compressor International ...................................... ....................... ............... 127, 201
CASTINGS, TURBINE COMPONENT Mitsubishi Heavy Industries Compressor International ...................................... ....................... ............... 127, 201
CHILLERS GEA Refrigeration Italy Oil & Gas ....................... ............................. ...... 237
COMPONENT RECONDITIONING Cozzani, Dott. Ing. Mario Cozzani Srl ................ 217
COMPRESSOR FRAME END PARTS HOERBIGER .................. 134, 135 SIAD Macchine Impianti S.p.A. Compressors Division .......... 117
COMPRESSOR SETS, ELECTRICALLY ENGINE-DRIVEN Andreas Hofer Hochdrucktechnik GmbH ...................................... ......................... ............. 142, 143 143 BORSIG ZM Compression GmbH ............ 119 COMOTI - Romanian Research & Development Institute for Gas Turbines .... 123
Dott. Ing Ing Mario Cozzani Srl .... 217
GEA Refrigeration Italy Oil & Gas .......................... ............................. ... 237
HOERBIGER .................. 134, 135
Hofer Kompressoren ...... 142, 143
Mitsubishi Heavy Industries Compressor International ...................................... ....................... ............... 127, 201
MAN Diesel & Turbo SE ...................................... ......................... ............. 138, 139 139
COMPRESSOR CONDITION MONITORING BORSIG ZM Compression GmbH ............ 119 COMOTI - Romanian Research & Development Institute for Gas Turbines Turbines .... 123 2017 EDITION
Mitsubishi Heavy Industries Compressor International ...................................... ......................... ............. 127, 201 201 NEUMAN & ESSER (Beijing) Co. Ltd. .......... 142, 143 143 NEUMAN & ESSER Deutschland GmbH & Co. KG Vertrieb und Anlagentechnik ............ 142, 143 17
NEUMAN & ESSER Italia S.r.l. ..................... ..................... 142, 143 NEUMAN & ESSER RUS Ltd. ...................... 142, 143 NEUMAN & ESSER South East Asia Ltd. .... 142, 143 NEUMAN & ESSER USA Inc. ....................... ....................... 142, 143 NEUMAN & ESSER América do Sul Ltda. ................. 142, 143 NEUMAN & ESSER Engineering (India) Pvt. Ltd. ........................ ........................ 142, 143 PSE Engineering GmbH Compression Systems ............................Packagers Tab SIAD Macchine Impianti S.p.A. Compressors Division .......... 117
COMPRESSOR SETS, GAS TURBINE-DRIVEN COMOTI - Romanian Research & Development Institute for Gas Turbines .... 123 MAN Diesel & Turbo SE ...................................... ....................... ............... 138, 139 Mitsubishi Heavy Industries Compressor International ...................................... ....................... ............... 127, 201 Solar Turbines Incorporated .......................Prime Movers Tab
COMPRESSOR SETS, NATURAL GAS ENGINE-DRIVEN BORSIG ZM Compression GmbH ............ 119 COMOTI - Romanian Research & Development Institute for Gas Turbines .... 123 GEA Refrigeration Italy Oil & Gas ........................ ............................. ..... 237 Mitsubishi Heavy Industries Compressor International ...................................... ....................... ............... 127, 201 WWW.CTSSNET.NET
CTSS
NEUMAN & ESSER (Beijing) Co. Ltd. .......... 142, 143 143
Kobelco Compressors America Inc. ........... Fourth Cover
NEUMAN & ESSER América do Sul Ltda. Ltda. ... 142, 143 143
NEUMAN & ESSER América do Sul Ltda. Ltda. ... 142, 143
Leobersdorfer Maschinenfabrik (LMF) 136, 137
NEUMAN & ESSER Deutschland GmbH & Co. KG Vertrieb und Anlagentechnik ............ 142, 143
MAN Diesel & Turbo SE ...................................... ......................... ............. 138, 139 139
NEUMAN & ESSER Deutschland GmbH & Co. KG Vertrieb und Anlagentechnik ............ 142, 143
NEUMAN & ESSER Italia S.r.l. ..................... ..................... 142, 143 143 NEUMAN & ESSER RUS Ltd. ...................... 142, 143 NEUMAN & ESSER USA Inc. ....................... ....................... 142, 143 NEUMAN & ESSER Engineering (India) Pvt. Ltd. ........................ ........................ 142, 143 PSE Engineering GmbH Compression Systems ............................ ....................... ..... Packagers Tab SIAD Macchine Impianti S.p.A. Compressors Division ............... 117
Mitsubishi Heavy Industries Compressor International ...................................... ......................... ............. 127, 201 201 NEUMAN & ESSER (Beijing) Co. Ltd. .......... 142, 143 143 NEUMAN & ESSER América do Sul Ltda. ... 142, 143 NEUMAN & ESSER Deutschland GmbH & Co. KG Vertrieb und Anlagentechnik ............ 142, 143 NEUMAN & ESSER Egypt Ltd. ..................... ..................... 142, 143 NEUMAN & ESSER Italia S.r.l. ..................... ..................... 142, 143 143 NEUMAN & ESSER RUS Ltd. ...................... 142, 143
COMPRESSOR VALVE CONDITION MONITORING
NEUMAN & ESSER USA Inc. ....................... ....................... 142, 143
COMOTI - Romanian Research & Development Institute for Gas Turbines Turbines .... 123
NEUMAN & ESSER Engineering (India) Pvt. Ltd. ...................................... ......................... ............. 142, 143 143
HOERBIGER .................. 134, 135
COMPRESSORS, AIR Andreas Hofer Hochdrucktechnik GmbH ...................................... ....................... ............... 142, 143 Atlas Copco Gas and Process ................. ................. 140, 141 141 BORSIG ZM Compression GmbH ............ 119 COMOTI - Romanian Research & Development Institute for Gas Turbines Turbines .... 123 Corken Inc. A Unit of IDEX Corporation ...................................... ....................... ............... 238, 239 FLSmidth Inc. Pneumatic Transport ... 125, 129 2017 EDITION
SIAD Macchine Impianti S.p.A. Compressors Division .......... 117
COMPRESSORS, AIR-STARTING Elliott Group ................. Third Cover, 115, 192
NEUMAN & ESSER Gulf FZE ...................... 142, 143 NEUMAN & ESSER Italia S.r.l. ..................... ..................... 142, 143 NEUMAN & ESSER South East Asia Ltd. .... 142, 143 NEUMAN & ESSER USA Inc. ....................... ....................... 142, 143 NEUMAN & ESSER Engineering (India) Pvt. Ltd. ...................................... ....................... ............... 142, 143
COMPRESSORS, CENTRIFUGAL BORSIG ZM Compression GmbH ............ 119 COMOTI - Romanian Research & Development Institute for Gas Turbines .... 123 Elliott Group ................. Third Cover, 115, 192 GEA Refrigeration Italy Oil & Gas ........................ ............................. ..... 237 Kobelco Compressors America Inc. .......... .......... Fourth Cover MAN Diesel & Turbo SE ...................................... ....................... ............... 138, 139
COMPRESSORS, AXIAL
Mitsubishi Heavy Industries Compressor International ...................................... ....................... ............... 127, 201
MAN Diesel & Turbo SE ...................................... ......................... ............. 138, 139 139
Solar Turbines Incorporated .......................Prime Movers Tab
COMPRESSORS, CAPACITY CONTROL DEVICES
COMPRESSORS, DIAPHRAGM
Cozzani, Dott. Ing. Mario Cozzani Srl ................ 217 Dott. Ing Mario Cozzani Srl .... 217
Andreas Hofer Hochdrucktechnik GmbH ...................................... ....................... ............... 142, 143
HOERBIGER .................. 134, 135
Hofer Kompressoren ...... 142, 143
18
WWW.CTSSNET.NET
CTSS
Mitsubishi Heavy Industries Compressor International ...................................... 127, 201 NEUMAN & ESSER América do Sul Ltda. ..... 142, 143 NEUMAN & ESSER Deutschland GmbH & Co. KG Vertrieb und Anlagentechnik ............ 142, 143
Hofer Kompressoren ...... 142, 143 Kobelco Compressors America Inc. .......... Fourth Cover Leobersdorfer Maschinenfabrik (LMF) ........................... 136, 137 MAN Diesel & Turbo SE ...................................... 138, 139
MAN Diesel & Turbo SE ...................................... 138, 139 Mitsubishi Heavy Industries Compressor International ...................................... 127, 201
COMPRESSORS, OIL-FREE Andreas Hofer Hochdrucktechnik GmbH
NEUMAN & ESSER Gulf FZE ...................... 142, 143
Mitsubishi Heavy Industries Compressor International ...................................... 127, 201
NEUMAN & ESSER Italia S.r.l. ..................... 142, 143
NEUMAN & ESSER (Beijing) Co. Ltd. .......... 142, 143
BORSIG ZM Compression GmbH ............ 119
NEUMAN & ESSER South East Asia Ltd. .... 142, 143
NEUMAN & ESSER América do Sul Ltda. ... 142, 143
Burckhardt Compression AG
NEUMAN & ESSER USA Inc. ....................... 142, 143
NEUMAN & ESSER Deutschland GmbH & Co. KG Vertrieb und Anlagentechnik ............ 142, 143
COMOTI - Romanian Research & Development
NEUMAN & ESSER Engineering (India) Pvt. Ltd. ...................................... 142, 143
COMPRESSORS, GAS Andreas Hofer Hochdrucktechnik GmbH ...................................... 142, 143 Ariel Corporation ........................Compressors Tab
NEUMAN & ESSER Egypt Ltd. ..................... 142, 143
Corken Inc. A Unit of IDEX Corporation ...................................... 238, 239
NEUMAN & ESSER RUS Ltd. ...................... 142, 143
Hofer Kompressoren ...... 142, 143
NEUMAN & ESSER South East Asia Ltd. .... 142, 143
BORSIG ZM Compression GmbH ............ 119
NEUMAN & ESSER Engineering (India) Pvt. Ltd. ...................................... 142, 143
Corken Inc. A Unit of IDEX Corporation ...................................... 238, 239
Institute for Gas Turbines .... 123
GEA Refrigeration Italy
NEUMAN & ESSER USA Inc. ....................... 142, 143
COMOTI - Romanian Research & Development Institute for Gas Turbines .... 123
.............................................. 144
NEUMAN & ESSER Italia S.r.l. ..................... 142, 143
Atlas Copco Gas and Process ................. 140, 141
Burckhardt Compression AG .............................................. 144
...................................... 142, 143
PSE Engineering GmbH Compression Systems ............................ Packagers Tab SIAD Macchine Impianti S.p.A. Compressors Division .......... 117 Solar Turbines Incorporated .......................Prime Movers Tab
Oil & Gas ............................. 237
Kobelco Compressors America Inc. .......... Fourth Cover Leobersdorfer Maschinenfabrik (LMF) ........................... 136, 137 MAN Diesel & Turbo SE ...................................... 138, 139 NEUMAN & ESSER (Beijing) Co. Ltd. .......... 142, 143 NEUMAN & ESSER América do Sul Ltda. ... 142, 143 NEUMAN & ESSER Deutschland GmbH & Co. KG Vertrieb und Anlagentechnik ............ 142, 143 NEUMAN & ESSER
Elliott Group ................. Third Cover, 115, 192
COMPRESSORS, INTEGRAL
FLSmidth Inc. Pneumatic Transport ... 125, 129
GEA Refrigeration Italy Oil & Gas ............................. 237
NEUMAN & ESSER Italia S.r.l. ..................... 142, 143
GEA Refrigeration Italy Oil & Gas ............................. 237
Kobelco Compressors America Inc. ........... Fourth Cover
NEUMAN & ESSER
2017 EDITION
19
Egypt Ltd. ..................... 142, 143
RUS Ltd. ...................... 142, 143 WWW.CTSSNET.NET
CTSS
NEUMAN & ESSER South East Asia Ltd. .... 142, 143
NEUMAN & ESSER
NEUMAN & ESSER USA Inc. ....................... 142, 143
NEUMAN & ESSER
NEUMAN & ESSER Engineering (India) Pvt. Ltd. ............ 142, 143
NEUMAN & ESSER
PSE Engineering GmbH Compression Systems ............................ Packagers Tab SIAD Macchine Impianti S.p.A. Compressors Division .......... 117
RUS Ltd. ...................... 142, 143 South East Asia Ltd. .... 142, 143 USA Inc. ....................... 142, 143 NEUMAN & ESSER Engineering (India) Pvt. Ltd. ...................................... 142, 143 PSE Engineering GmbH Compression Systems ............................ Packagers Tab
NEUMAN & ESSER Egypt Ltd. ..................... 142, 143 NEUMAN & ESSER Italia S.r.l. ..................... 142, 143 NEUMAN & ESSER RUS Ltd. ...................... 142, 143 NEUMAN & ESSER South East Asia Ltd. .... 142, 143 NEUMAN & ESSER USA Inc. ....................... 142, 143 NEUMAN & ESSER Engineering (India) Pvt. Ltd.
COMPRESSORS, OIL-INJECTED
SIAD Macchine Impianti S.p.A. Compressors Division .......... 117
Andreas Hofer Hochdrucktechnik GmbH ...................................... 142, 143
COMPRESSORS, PISTON
PSE Engineering GmbH Compression Systems ............................Packagers Tab
Andreas Hofer
SIAD Macchine Impianti S.p.A.
Burckhardt Compression AG .............................................. 144 COMOTI - Romanian Research & Development Institute for Gas Turbines .... 123 Corken Inc. A Unit of IDEX Corporation ...................................... 238, 239 FLSmidth Inc. Pneumatic Transport ... 125, 129 GEA Refrigeration Italy Oil & Gas ............................. 237 Hofer Kompressoren ...... 142, 143 Kobelco Compressors America Inc. ........... Fourth Cover NEUMAN & ESSER (Beijing) Co. Ltd. .......... 142, 143 NEUMAN & ESSER América do Sul Ltda. ... 142, 143 NEUMAN & ESSER Deutschland GmbH & Co. KG Vertrieb und Anlagentechnik ............ 142, 143 NEUMAN & ESSER Egypt Ltd. ..................... 142, 143 NEUMAN & ESSER Italia S.r.l. ..................... 142, 143 2017 EDITION
Hochdrucktechnik GmbH
...................................... 142, 143
Compressors Division .......... 117
...................................... 142, 143 Atlas Copco Gas and Process ................. 140, 141
COMPRESSORS, PORTABLE Corken Inc.
BORSIG ZM Compression GmbH ............ 119 Burckhardt Compression AG .............................................. 144
A Unit of IDEX Corporation ...................................... 238, 239 PSE Engineering GmbH Compression Systems
Corken Inc. A Unit of IDEX Corporation ...................................... 238, 239 GEA Refrigeration Italy Oil & Gas ............................. 237
............................Packagers Tab
COMPRESSORS, RECIPROCATING Andreas Hofer
Hofer Kompressoren ...... 142, 143
Hochdrucktechnik GmbH
Kobelco Compressors America Inc. .......... Fourth Cover
...................................... 142, 143
Leobersdorfer Maschinenfabrik (LMF) ........................... 136, 137 NEUMAN & ESSER (Beijing) Co. Ltd. .......... 142, 143 NEUMAN & ESSER América do Sul Ltda. ... 142, 143 NEUMAN & ESSER Deutschland GmbH & Co. KG Vertrieb und Anlagentechnik ............ 142, 143 20
Ariel Corporation ......................... Compressors Tab Atlas Copco Gas and Process ................. 140, 141 BORSIG ZM Compression GmbH ............ 119 Burckhardt Compression AG ................. 144 Corken Inc. A Unit of IDEX Corporation ...................................... 238, 239 WWW.CTSSNET.NET
CTSS
GEA Refrigeration Italy Oil & Gas ............................. 237
NEAC Compressor Service GmbH & Co. KG .......... 142, 143
Leobersdorfer Maschinenfabrik (LMF) ........................... 136, 137
HOERBIGER .................. 134, 135 Hofer Kompressoren ...... 142, 143
NEAC Compressor Service USA Inc. ....................... 142, 143
MAN Diesel & Turbo SE ...................................... 138, 139
Kobelco Compressors America Inc. ........... Fourth Cover
NEUMAN & ESSER Gulf FZE ...................... 142, 143
Leobersdorfer Maschinenfabrik (LMF) ........................... 136, 137
NEUMAN & ESSER RUS Ltd. ...................... 142, 143
NEUMAN & ESSER (Beijing) Co. Ltd. .......... 142, 143
NEUMAN & ESSER Engineering (India) Pvt. Ltd. ...................................... 142, 143
NEUMAN & ESSER América do Sul Ltda. ... 142, 143
COMPRESSORS, SKIDMOUNTED Andreas Hofer Hochdrucktechnik GmbH ...................................... 142, 143 BORSIG ZM Compression GmbH ............ 119
PSE Engineering GmbH Compression Systems ............................ Packagers Tab
Burckhardt Compression AG .............................................. 144
SIAD Macchine Impianti S.p.A. Compressors Division .......... 117
Corken Inc. A Unit of IDEX Corporation ...................................... 238, 239
COMPRESSORS, ROTARY SCREW
GEA Refrigeration Italy Oil & Gas ............................. 237
NEUMAN & ESSER RUS Ltd. ...................... 142, 143
COMOTI - Romanian Research & Development Institute for Gas Turbines .... 123
Leobersdorfer Maschinenfabrik (LMF) ........................... 136, 137
NEUMAN & ESSER South East Asia Ltd. .... 142, 143
GEA Refrigeration Italy Oil & Gas ............................. 237
NEUMAN & ESSER USA Inc. ....................... 142, 143
Kobelco Compressors America Inc. ........... Fourth Cover
NEUMAN & ESSER Engineering (India) Pvt. Ltd. ...... ...................................... 142, 143
Leobersdorfer Maschinenfabrik (LMF) ........................... 136, 137
NEUMAN & ESSER Deutschland GmbH & Co. KG Vertrieb und Anlagentechnik ............ 142, 143 NEUMAN & ESSER Egypt Ltd. ..................... 142, 143 NEUMAN & ESSER Italia S.r.l. ..................... 142, 143
PSE Engineering GmbH Compression Systems ............................ Packagers Tab SIAD Macchine Impianti S.p.A. Compressors Division .......... 117
COMPRESSORS, RECONDITIONED HOERBIGER .................. 134, 135
MAN Diesel & Turbo SE ...................................... 138, 139
COMPRESSORS, ROTARY SLIDING VANE FLSmidth Inc. Pneumatic Transport ... 125, 129
COMPRESSORS, SCREW
MAN Diesel & Turbo SE ...................................... 138, 139 Mitsubishi Heavy Industries Compressor International ...................................... 127, 201 NEUMAN & ESSER (Beijing) Co. Ltd. .......... 142, 143 NEUMAN & ESSER América do Sul Ltda. ... 142, 143 NEUMAN & ESSER Deutschland GmbH & Co. KG Vertrieb und Anlagentechnik ............ 142, 143 NEUMAN & ESSER Egypt Ltd. ..................... 142, 143 NEUMAN & ESSER Italia S.r.l. ..................... 142, 143
NEAC Compressor Service Ltd. .................. 142, 143
COMOTI - Romanian Research & Development Institute for Gas Turbines .... 123
NEAC Compressor Service Ltda. ................ 142, 143
GEA Refrigeration Italy Oil & Gas ............................. 237
NEUMAN & ESSER South East Asia Ltd. .... 142, 143
NEAC Compressor Service S.r.l. ................ 142, 143
Kobelco Compressors America Inc. ........... Fourth Cover
NEUMAN & ESSER USA Inc. ....................... 142, 143
2017 EDITION
21
NEUMAN & ESSER RUS Ltd. ...................... 142, 143
WWW.CTSSNET.NET
CTSS
NEUMAN & ESSER Engineering (India) Pvt. Ltd. ...................................... 142, 143 PSE Engineering GmbH Compression Systems ............................ Packagers Tab SIAD Macchine Impianti S.p.A. Compressors Division .......... 117
PSE Engineering GmbH Compression Systems ............................ Packagers Tab
CONTROLS, VIBRATION
CONTROLLERS, ENGINE SYSTEM
NEAC Compressor
HOERBIGER .................. 134, 135
NEAC Compressor
CONTROLS, COMPRESSOR BORSIG ZM Compression GmbH ............ 119
Burckhardt Compression AG
Elliott Group ................. Third Cover, 115, 192
Corken Inc. A Unit of IDEX Corporation ...................................... 238, 239 Leobersdorfer Maschinenfabrik
................. Third Cover, 115, 192 Service Ltd. .................. 142, 143 Service Ltda. ................ 142, 143
COMPRESSORS, STATIONARY .............................................. 144
Elliott Group
HOERBIGER .................. 134, 135
NEAC Compressor Service S.r.l. ................ 142, 143 NEAC Compressor Service GmbH & Co. KG .......... 142, 143 NEAC Compressor Service USA Inc. ....................... 142, 143
MAN Diesel & Turbo SE ...................................... 138, 139
CONVERTERS, TORQUE
Voith Turbo Inc. ...................... 113
Voith Turbo Inc. ...................... 113
CONTROLS, ELECTROHYDRAULIC
COOLERS, INTERCOOLER TYPE
HOERBIGER .................. 134, 135
GEA Refrigeration Italy
(LMF) ........................... 136, 137 MAN Diesel & Turbo SE ...................................... 138, 139 Mitsubishi Heavy Industries Compressor International ...................................... 127, 201 PSE Engineering GmbH Compression Systems ............................ Packagers Tab SIAD Macchine Impianti S.p.A. Compressors Division .......... 117
Oil & Gas ............................. 237
CONTROLS, ELECTRONIC COMOTI - Romanian Research & Development Institute for Gas Turbines .... 123
CONTROLS, FUEL CONSUMPTION Voith Turbo Inc. ...................... 113
COMPUTER-CONTROLLED ENGINE TESTING COMOTI - Romanian Research & Development
CONTROLS, KNOCK DETECTION & CONTROL HOERBIGER .................. 134, 135
Institute for Gas Turbines .... 123
COOLERS, LUBE OIL GEA Refrigeration Italy Oil & Gas ............................. 237
COOLERS, WATER GEA Refrigeration Italy Oil & Gas ............................. 237
COOLING SYSTEMS GEA Refrigeration Italy Oil & Gas ............................. 237
CONTROLS, SPEED CONDENSERS
Voith Turbo Inc. ...................... 113
Voith Turbo BHS
Mitsubishi Heavy Industries Compressor International
CONTROLS, SURGE
...................................... 127, 201
Elliott Group ................. Third Cover, 115, 192
CONSULTING CONTROLS, TEMPERATURE
Compressor International
Elliott Group ................. Third Cover, 115, 192
2017 EDITION
Getriebe GmbH .................... 113
COUPLINGS, FLEXIBLE Voith Turbo Inc. ...................... 113
Mitsubishi Heavy Industries ...................................... 127, 201
COUPLINGS, DIAPHRAGM
22
COUPLINGS, FLUID Voith Turbo Inc. ...................... 113 WWW.CTSSNET.NET
CTSS
COUPLINGS, GEAR-TYPE Voith Turbo BHS Getriebe GmbH .................... 113
D
DRIVES, COMPRESSOR
Voith Turbo Inc. ...................... 113
Elliott Group ................. Third Cover, 115, 192
COUPLINGS, SHAFT
MAN Diesel & Turbo SE ...................................... 138, 139
Voith Turbo BHS
Voith Turbo Inc. ...................... 113
Getriebe GmbH .................... 113 Voith Turbo Inc. ...................... 113
DRIVES, GEAR REDUCTION
CRANKSHAFTS
Voith Turbo BHS Getriebe GmbH .................... 113
HOERBIGER .................. 134, 135
CRANKSHAFTS, RECONDITIONING HOERBIGER .................. 134, 135
DRIVES, HYDRAULIC-PUMP Elliott Group ................. Third Cover, 115, 192
DRIVES, TURBINE STARTING Voith Turbo Inc. ...................... 113
CYLINDER LUBRICATION SYSTEMS
DRIVES, VARIABLE-SPEED
HOERBIGER .................. 134, 135
Voith Turbo Inc. ...................... 113
PSE Engineering GmbH Compression Systems ............................ Packagers Tab
E
EMISSIONS ANALYZERS CYLINDERS HOERBIGER .................. 134, 135
CYLINDERS, ENGINE HOERBIGER .................. 134, 135
CYLINDERS, LIGHT-ALLOY HOERBIGER .................. 134, 135
CYLINDERS, LINERS & SLEEVES
COMOTI - Romanian Research & Development Institute for Gas Turbines .......... 123
EMISSIONS CONTROLS COMOTI - Romanian Research & Development Institute for Gas Turbines .... 123 HOERBIGER .................. 134, 135
HOERBIGER .................. 134, 135
ENGINE MAINTENANCE, OVERHAUL & PARTS SERVICES
CYLINDERS, RECONDITIONING
Cummins Inc. Oil & Gas Markets ............................. Second Cover
HOERBIGER .................. 134, 135
HOERBIGER .................. 134, 135
SIAD Macchine Impianti S.p.A.
MAN Diesel & Turbo SE ...................................... 138, 139
Compressors Division .......... 117 2017 EDITION
Solar Turbines Incorporated .......................Prime Movers Tab
23
ENGINES, CONVERSION SYSTEMS/COMPONENTS HOERBIGER .................. 134, 135
ENGINES, GAS TURBINE COMOTI - Romanian Research & Development Institute for Gas Turbines .... 123 Cummins Inc. Oil & Gas Markets ............................. Second Cover MAN Diesel & Turbo SE ...................................... 138, 139 Solar Turbines Incorporated .......................Prime Movers Tab
ENGINES, NATURAL GAS (SPARK IGNITED) COMOTI - Romanian Research & Development Institute for Gas Turbines .... 123 Cummins Inc. Oil & Gas Markets ............................. Second Cover
ENGINES, RESEARCH COMOTI - Romanian Research & Development Institute for Gas Turbines .... 123
EXPANDERS Atlas Copco Gas and Process ................. 140, 141 COMOTI - Romanian Research & Development Institute for Gas Turbines .... 123 Elliott Group ................. Third Cover, 115, 192 MAN Diesel & Turbo SE ...................................... 138, 139 Mitsubishi Heavy Industries Compressor International ...................................... 127, 201 WWW.CTSSNET.NET
CTSS
F FORGINGS, COMPRESSOR Mitsubishi Heavy Industries Compressor International ...................................... 127, 201
FORGINGS, TURBINE COMPONENTS Mitsubishi Heavy Industries Compressor International ...................................... 127, 201
G GAS TURBINES COMOTI - Romanian Research & Development Institute for Gas Turbines .... 123
GEAR SYSTEMS COMOTI - Romanian Research & Development Institute for Gas Turbines .... 123 Voith Turbo BHS Getriebe GmbH .................... 113
M
GEARS, INCREASERS Voith Turbo BHS Getriebe GmbH .................... 113
MACHINING
GEARS, RING
COMOTI - Romanian Research & Development Institute for Gas Turbines .... 123
Voith Turbo BHS Getriebe GmbH .................... 113
GEARS, SPUR Voith Turbo BHS Getriebe GmbH .................... 113
Mitsubishi Heavy Industries Compressor International ...................................... 127, 201
MECHANICAL FASTENERS Mitsubishi Heavy Industries
GEARS, STATIONARY
Compressor International
Voith Turbo BHS Getriebe GmbH .................... 113
...................................... 127, 201
GEARS, STATIONARY/ INDUSTRIAL DRIVE Voith Turbo BHS Getriebe GmbH .................... 113
GEARS, TURBO Voith Turbo BHS Getriebe GmbH .................... 113 Voith Turbo Inc. ...................... 113
MONITORS, COMPRESSOR SYSTEMS Burckhardt Compression AG .............................................. 144 HOERBIGER .................. 134, 135 MAN Diesel & Turbo SE ...................................... 138, 139 NEAC Compressor Service Ltd. .................. 142, 143 NEAC Compressor
I
Service Ltda. ................ 142, 143 NEAC Compressor
GEARBOXES Voith Turbo BHS Getriebe GmbH .................... 113
GEARS, CUSTOM COMOTI - Romanian Research & Development Institute for Gas Turbines .... 123 Voith Turbo BHS Getriebe GmbH .................... 113
IMPELLERS, TURBINE & TURBOCHARGERS Mitsubishi Heavy Industries Compressor International ...................................... 127, 201
INLET COOLING SYSTEMS GEA Refrigeration Italy Oil & Gas ............................. 237
L GEARS, EPICYCLIC Voith Turbo BHS Getriebe GmbH .................... 113
LINERS, CYLINDER HOERBIGER .................. 134, 135
Service S.r.l. ................ 142, 143 NEAC Compressor Service GmbH & Co. KG .......... 142, 143 NEAC Compressor Service USA Inc. ....................... 142, 143
MONITORS, ENGINE SYSTEM MAN Diesel & Turbo SE ...................................... 138, 139
MONITORS, LOAD HOERBIGER .................. 134, 135 NEAC Compressor Service Ltd. .................. 142, 143 NEAC Compressor
GEARS, HELICAL Voith Turbo BHS Getriebe GmbH .................... 113 2017 EDITION
LINERS, RECONDITIONING CYLINDER HOERBIGER .................. 134, 135 24
Service Ltda. ................ 142, 143 NEAC Compressor Service S.r.l. ................ 142, 143 WWW.CTSSNET.NET
CTSS
NEAC Compressor Service GmbH & Co. KG .......... 142, 143 NEAC Compressor Service USA Inc. ....................... 142, 143
MONITORS, PRESSURE
N
Italia S.r.l. ..................... 142, 143
NUTS, CAP
NEUMAN & ESSER
Mitsubishi Heavy Industries Compressor International ...................................... 127, 201
HOERBIGER .................. 134, 135 NEAC Compressor Service Ltd. .................. 142, 143 NEAC Compressor Service Ltda. ................ 142, 143 NEAC Compressor Service S.r.l. ................ 142, 143 NEAC Compressor Service GmbH & Co. KG .......... 142, 143 NEAC Compressor Service USA Inc. ....................... 142, 143
MONITORS, TEMPERATURE HOERBIGER .................. 134, 135 NEAC Compressor Service Ltd. .................. 142, 143 NEAC Compressor Service Ltda. ................ 142, 143 NEAC Compressor Service S.r.l. ................ 142, 143 NEAC Compressor Service GmbH & Co. KG .......... 142, 143
NEUMAN & ESSER
USA Inc. ....................... 142, 143 NEUMAN & ESSER Engineering (India) Pvt. Ltd. ........................ 142, 143
P PACKAGES, ENGINE COMPRESSOR
PSE Engineering GmbH Compression Systems ............................Packagers Tab
COMOTI - Romanian Research & Development Institute for Gas Turbines .... 123
PACKAGES, FOUNDATION, PLATFORM DECK, FPSO MODULE DESIGN
GEA Refrigeration Italy Oil & Gas ............................. 237
PSE Engineering GmbH
MAN Diesel & Turbo SE ...................................... 138, 139 PSE Engineering GmbH Compression Systems ............................ Packagers Tab Solar Turbines Incorporated .......................Prime Movers Tab
PACKAGES, ENGINEERING & DESIGN COMOTI - Romanian Research & Development Institute for Gas Turbines .... 123
Compression Systems ............................Packagers Tab Solar Turbines Incorporated .......................Prime Movers Tab
PACKAGES, GAS TURBINE COMPRESSOR GEA Refrigeration Italy Oil & Gas ............................. 237
PACKAGES, MOTOR COMPRESSOR COMOTI - Romanian Research & Development
NEAC Compressor Service USA Inc. ....................... 142, 143
Corken Inc. A Unit of IDEX Corporation ...................................... 238, 239
MONITORS, VIBRATION
GEA Refrigeration Italy Oil & Gas ............................. 237
FLSmidth Inc.
Mitsubishi Heavy Industries Compressor International ...................................... 127, 201
GEA Refrigeration Italy
HOERBIGER .................. 134, 135 NEAC Compressor Service Ltd. .................. 142, 143 NEAC Compressor Service Ltda. ................ 142, 143 NEAC Compressor Service S.r.l. ................ 142, 143
NEUMAN & ESSER Deutschland GmbH & Co. KG Vertrieb und Anlagentechnik ............ 142, 143
NEAC Compressor Service GmbH & Co. KG .......... 142, 143
NEUMAN & ESSER South East Asia Ltd. .... 142, 143
NEAC Compressor Service USA Inc. ....................... 142, 143
NEUMAN & ESSER América do Sul Ltda. ... 142, 143
2017 EDITION
25
Institute for Gas Turbines .... 123 Elliott Group ................. Third Cover, 115, 192 Pneumatic Transport ... 125, 129 Oil & Gas ............................. 237 MAN Diesel & Turbo SE ...................................... 138, 139 Mitsubishi Heavy Industries Compressor International ...................................... 127, 201 PSE Engineering GmbH Compression Systems ............................Packagers Tab WWW.CTSSNET.NET
CTSS
PACKAGES, PIPING, STRUCTURAL ANALYSIS
NEUMAN & ESSER
GEA Refrigeration Italy Oil & Gas ............................. 237
NEUMAN & ESSER
NEUMAN & ESSER América do Sul Ltda. ... 142, 143 NEUMAN & ESSER Deutschland GmbH & Co. KG Vertrieb und Anlagentechnik ............ 142, 143 NEUMAN & ESSER Italia S.r.l. ..................... 142, 143 NEUMAN & ESSER South East Asia Ltd. .... 142, 143 NEUMAN & ESSER USA Inc. ....................... 142, 143 NEUMAN & ESSER Engineering (India) Pvt. Ltd. ........................ 142, 143
Italia S.r.l. ..................... 142, 143
RUS Ltd. ...................... 142, 143 NEUMAN & ESSER South East Asia Ltd. .... 142, 143 NEUMAN & ESSER
Elliott Group ................. Third Cover, 115, 192 Mitsubishi Heavy Industries Compressor International ...................................... 127, 201
PACKING ASSEMBLIES Andreas Hofer Hochdrucktechnik GmbH ...................................... 142, 143 HOERBIGER .................. 134, 135 NEUMAN & ESSER (Beijing) Co. Ltd. .......... 142, 143
PACKING CASES HOERBIGER .................. 134, 135
PACKINGS, INTERMEDIATE STASSKOL GmbH ......... 142, 143
Mitsubishi Heavy Industries Compressor International ...................................... 127, 201 NEAC Compressor Service Ltda. ................ 142, 143
STASSKOL Inc. .............. 142, 143
PACKINGS, OIL WIPER
NEAC Compressor Service GmbH & Co. KG .......... 142, 143
Compression GmbH ............ 119 STASSKOL GmbH ......... 142, 143 STASSKOL Inc. .............. 142, 143
PACKINGS, PISTON ROD
NEAC Compressor Service USA Inc. ....................... 142, 143 NEAC Compressor Service Ltd. ...................................... 142, 143 PSE Engineering GmbH Compression Systems ............................Packagers Tab
STASSKOL GmbH ......... 142, 143 STASSKOL Inc. .............. 142, 143
PROTECTIVE CONTROLS
PISTONS
MAN Diesel & Turbo SE ...................................... 138, 139
HOERBIGER .................. 134, 135
PISTONS, RECONDITIONING HOERBIGER .................. 134, 135
NEUMAN & ESSER Deutschland GmbH & Co. KG Vertrieb und Anlagentechnik ............ 142, 143
NEAC Compressor
2017 EDITION
MAN Diesel & Turbo SE ...................................... 138, 139
NEAC Compressor Service S.r.l. ................ 142, 143
NEAC Compressor
NEUMAN & ESSER Engineering (India) Pvt. Ltd. ........................ 142, 143
Elliott Group ................. Third Cover, 115, 192
PROJECT MANAGEMENT
NEUMAN & ESSER América do Sul Ltda. ... 142, 143
NEUMAN & ESSER Egypt Ltd. ..................... 142, 143
COMOTI - Romanian Research & Development Institute for Gas Turbines .... 123
USA Inc. ....................... 142, 143
BORSIG ZM
PACKAGES, STEAM TURBINE COMPRESSOR
POWER TURBINES
Service Ltd. .................. 142, 143 Service Ltda. ................ 142, 143 NEAC Compressor Service S.r.l. ................ 142, 143 NEAC Compressor Service GmbH & Co. KG .......... 142, 143 NEAC Compressor Service USA Inc. ....................... 142, 143 26
PUMPS, BOILER-FEED Corken Inc. A Unit of IDEX Corporation ...................................... 238, 239
PUMPS, CHEMICAL Corken Inc. A Unit of IDEX Corporation ...................................... 238, 239
PUMPS, CONDENSATE OR CONDENSATE RETURN Corken Inc. A Unit of IDEX Corporation ...................................... 238, 239 WWW.CTSSNET.NET
CTSS
PUMPS, HAZARDOUS-LIQUID
R
NEAC Compressor Service USA Inc. ....................... 142, 143
Corken Inc. A Unit of IDEX Corporation ...................................... 238, 239
REACTOR SYSTEMS MAN Diesel & Turbo SE ...................................... 138, 139
STASSKOL GmbH ......... 142, 143
PUMPS, HEAVY-DUTY
REDUCERS, GEAR
STASSKOL Inc. .............. 142, 143
Corken Inc. A Unit of IDEX Corporation ...................................... 238, 239
Voith Turbo BHS Getriebe GmbH .................... 113
RINGS, PISTON
PUMPS, HIGH-PRESSURE
RESEARCH & DEVELOPMENT
NEAC Compressor
COMOTI - Romanian Research & Development Institute for Gas Turbines .... 123
NEAC Compressor
Corken Inc. A Unit of IDEX Corporation ...................................... 238, 239
PUMPS, HIGH-TEMPERATURE Corken Inc. A Unit of IDEX Corporation ...................................... 238, 239
PUMPS, HYDRAULIC Corken Inc. A Unit of IDEX Corporation ...................................... 238, 239
NEAC Compressor Service GmbH & Co. KG ..................... 142, 143
HOERBIGER .................. 134, 135
RINGS, COMPRESSOR HOERBIGER .................. 134, 135 STASSKOL GmbH ......... 142, 143 STASSKOL Inc. .............. 142, 143
Service Ltd. .................. 142, 143 Service Ltda. ................ 142, 143 NEAC Compressor Service S.r.l. ................ 142, 143 NEAC Compressor Service GmbH & Co. KG .......... 142, 143 NEAC Compressor Service USA Inc. ....................... 142, 143
RINGS, FLOATING-SEALING
STASSKOL GmbH ......... 142, 143
STASSKOL GmbH ......... 142, 143
STASSKOL Inc. .............. 142, 143
STASSKOL Inc. .............. 142, 143
RINGS, POWER HOERBIGER .................. 134, 135
PUMPS, HYDRAULIC GEAR-TYPE
RINGS, GUIDE
Corken Inc. A Unit of IDEX Corporation ...................................... 238, 239
STASSKOL Inc. .............. 142, 143
RINGS, PRESSURE BREAKER
RINGS, LABYRINTH
HOERBIGER .................. 134, 135
PUMPS, LUBRICATING-OIL
Mitsubishi Heavy Industries Compressor International ...................................... 127, 201
Corken Inc. A Unit of IDEX Corporation ...................................... 238, 239
STASSKOL GmbH ......... 142, 143
RINGS, RIDER HOERBIGER .................. 134, 135
STASSKOL GmbH ......... 142, 143
STASSKOL GmbH ......... 142, 143
STASSKOL Inc. .............. 142, 143
STASSKOL Inc. .............. 142, 143
RINGS, PACKING
RINGS, SEALING
HOERBIGER .................. 134, 135
HOERBIGER .................. 134, 135
NEAC Compressor Service Ltd. .................. 142, 143
STASSKOL GmbH ......... 142, 143
PUMPS, MAGNET DRIVE Corken Inc. A Unit of IDEX Corporation ...................................... 238, 239
PUMPS, POSITIVE-DISPLACEMENT Corken Inc. A Unit of IDEX Corporation ...................................... 238, 239 2017 EDITION
NEAC Compressor Service Ltda. ................ 142, 143 NEAC Compressor Service S.r.l. ................ 142, 143 27
STASSKOL Inc. .............. 142, 143
RINGS, TURBOCHARGER-SEALING HOERBIGER .................. 134, 135 WWW.CTSSNET.NET
CTSS
RINGS, WIPER HOERBIGER .................. 134, 135 STASSKOL GmbH ......... 142, 143 STASSKOL Inc. .............. 142, 143
ROTOR TURNING GEARS Voith Turbo BHS Getriebe GmbH .................... 113
ROTORS, TURBOMACHINERY COMOTI - Romanian Research & Development Institute for Gas Turbines .... 123
SERVICE SYSTEMS & TRAINING, GAS TURBINES
NEAC Compressor Service GmbH & Co. KG .......... 142, 143
Solar Turbines Incorporated .......................Prime Movers Tab
NEAC Compressor Service USA Inc. ....................... 142, 143
MAN Diesel & Turbo SE ...................................... 138, 139
NEUMAN & ESSER USA Inc. ....................... 142, 143
SERVICE TOOLS & EQUIPMENT
PSE Engineering GmbH Compression Systems ............................Packagers Tab
NEAC Compressor Service Ltd. .................. 142, 143 NEAC Compressor Service Ltda. ................ 142, 143 NEAC Compressor Service S.r.l. ................ 142, 143
Elliott Group ................. Third Cover, 115, 192 HOERBIGER .................. 134, 135 MAN Diesel & Turbo SE ...................................... 138, 139 Mitsubishi Heavy Industries Compressor International ...................................... 127, 201
S SAFETY SYSTEMS BORSIG ZM Compression GmbH ............ 119
SEALS, DRY GAS Elliott Group ................. Third Cover, 115, 192
SEALS, SHAFT
NEAC Compressor Service GmbH & Co. KG .......... 142, 143 NEAC Compressor Service USA Inc. ....................... 142, 143
SERVICES & TRAINING BORSIG ZM Compression GmbH ............ 119 Burckhardt Compression AG .............................................. 144 Compressors Division ............ 117 Elliott Group ................. Third Cover, 115, 192 GEA Refrigeration Italy Oil & Gas ............................. 237 HOERBIGER .................. 134, 135 MAN Diesel & Turbo SE ...................................... 138, 139 Mitsubishi Heavy Industries Compressor International
STASSKOL GmbH ......... 142, 143
...................................... 127, 201
STASSKOL Inc. .............. 142, 143
NEAC Compressor Service Ltd. .................. 142, 143
SEATS, VALVE Cozzani, Dott. Ing. Mario Cozzani Srl ................ 217 Dott. Ing Mario Cozzani Srl .... 217 2017 EDITION
NEAC Compressor Service Ltda. ................ 142, 143 NEAC Compressor Service S.r.l. ................ 142, 143 28
SIAD Macchine Impianti S.p.A. Solar Turbines Incorporated .......................Prime Movers Tab Voith Turbo BHS Getriebe GmbH .................... 113 Voith Turbo Inc. ...................... 113
SERVICES, COMPRESSORS OVERHAUL & REPAIR Andreas Hofer Hochdrucktechnik GmbH ...................................... 142, 143 BORSIG ZM Compression GmbH ............ 119 Burckhardt Compression AG .............................................. 144 COMOTI - Romanian Research & Development Institute for Gas Turbines .... 123 Elliott Group ................. Third Cover, 115, 192 Engineering (India) Pvt. Ltd. ........................ 142, 143 FLSmidth Inc. Pneumatic Transport ... 125, 129 GEA Refrigeration Italy Oil & Gas ............................. 237 HOERBIGER .................. 134, 135 MAN Diesel & Turbo SE ...................................... 138, 139 Mitsubishi Heavy Industries Compressor International ...................................... 127, 201 NEAC Compressor Service Ltd. .................. 142, 143 WWW.CTSSNET.NET
CTSS
NEAC Compressor Service Ltda. ................ 142, 143 NEAC Compressor Service S.r.l. ................ 142, 143 NEAC Compressor Service GmbH & Co. KG .......... 142, 143 NEAC Compressor Service USA Inc. ....................... 142, 143 NEUMAN & ESSER NEUMAN & ESSER (Beijing) Co. Ltd. .......... 142, 143
NEAC Compressor Service S.r.l. ................ 142, 143 NEAC Compressor Service GmbH & Co. KG .......... 142, 143 NEAC Compressor Service USA Inc. ....................... 142, 143
NEUMAN & ESSER Deutschland GmbH & Co. KG Vertrieb und Anlagentechnik ............ 142, 143 NEUMAN & ESSER Egypt Ltd. ..................... 142, 143 NEUMAN & ESSER Gulf FZE ...................... 142, 143 NEUMAN & ESSER RUS Ltd. ...................... 142, 143 PSE Engineering GmbH Compression Systems ............................ Packagers Tab SIAD Macchine Impianti S.p.A. Compressors Division .......... 117 Solar Turbines Incorporated .......................Prime Movers Tab
SERVICES, DIAGNOSTICS COMOTI - Romanian Research & Development Institute for Gas Turbines .... 123 Mitsubishi Heavy Industries Compressor International ...................................... 127, 201
SERVICES, FAILURE-ANALYSIS Elliott Group ................. Third Cover, 115, 192
PSE Engineering GmbH
GEA Refrigeration Italy Oil & Gas ............................. 237
Compression Systems ............................ Packagers Tab
SERVICES, ENGINEERING BORSIG ZM Compression GmbH ............ 119 Burckhardt Compression AG .............................................. 144 COMOTI - Romanian Research & Development Institute for Gas Turbines .... 123 Compressors Division ............ 117 Elliott Group ................. Third Cover, 115, 192 GEA Refrigeration Italy Oil & Gas ............................. 237 HOERBIGER .................. 134, 135 MAN Diesel & Turbo SE
HOERBIGER .................. 134, 135 Mitsubishi Heavy Industries Compressor International ...................................... 127, 201 NEAC Compressor Service Ltd. .................. 142, 143 NEAC Compressor Service Ltda. ................ 142, 143 NEAC Compressor Service S.r.l. ................ 142, 143 NEAC Compressor Service USA Inc. ....................... 142, 143 NEAC Compressor Service GmbH & Co. KG .......... 142, 143 PSE Engineering GmbH Compression Systems ............................Packagers Tab SIAD Macchine Impianti S.p.A. Compressors Division .......... 117
...................................... 138, 139 Mitsubishi Heavy Industries Compressor International ...................................... 127, 201 NEAC Compressor Service Ltd. .................. 142, 143 NEAC Compressor Service Ltda. ................ 142, 143 NEAC Compressor Service S.r.l. ................ 142, 143
NEAC Compressor Service Ltd. .................. 142, 143
NEAC Compressor Service
NEAC Compressor Service Ltda. ................ 142, 143
NEAC Compressor Service
2017 EDITION
SIAD Macchine Impianti S.p.A.
SERVICES, DIVIDER BLOCK LUBRICATION SYSTEMS
NEUMAN & ESSER América do Sul Ltda. ... 142, 143
PSE Engineering GmbH Compression Systems ............................Packagers Tab
GmbH & Co. KG .......... 142, 143 USA Inc. ....................... 142, 143 29
SERVICES, FIELD PULSATION, VIBRATION-ANALYSIS COMOTI - Romanian Research & Development Institute for Gas Turbines .... 123 HOERBIGER .................. 134, 135 Mitsubishi Heavy Industries Compressor International ...................................... 127, 201 NEAC Compressor Service Ltd. .................. 142, 143 NEAC Compressor Service Ltda. ................ 142, 143 WWW.CTSSNET.NET
CTSS
NEAC Compressor Service S.r.l. ................ 142, 143
NEUMAN & ESSER
NEAC Compressor Service GmbH & Co. KG .......... 142, 143
NEUMAN & ESSER
NEAC Compressor Service USA Inc. ....................... 142, 143
NEUMAN & ESSER
SERVICES, GAS TURBINE OVERHAUL & REPAIR COMOTI - Romanian Research & Development Institute for Gas Turbines .... 123 Elliott Group ................. Third Cover, 115, 192
Egypt Ltd. ..................... 142, 143
Gulf FZE ...................... 142, 143
RUS Ltd. ...................... 142, 143 NEUMAN & ESSER
NEAC Compressor Service USA Inc. ....................... 142, 143 NEAC Compressor Service GmbH & Co. KG ..................... 142, 143
SILENCERS, INTAKE AIR COMOTI - Romanian Research Institute for Gas Turbines .... 123
SERVICES, TURBOMACHINERY OVERHAUL & REPAIR
COMOTI - Romanian Research
NEAC Compressor Service S.r.l. ................ 142, 143
Institute for Gas Turbines .... 123
Pvt. Ltd. ........................ 142, 143
Solar Turbines Incorporated .......................Prime Movers Tab
NEAC Compressor Service Ltda. ................ 142, 143
& Development
& Development
BORSIG ZM
NEAC Compressor Service Ltd. .................. 142, 143
COMOTI - Romanian Research
Engineering (India)
MAN Diesel & Turbo SE ...................................... 138, 139
SERVICES, LASER MEASUREMENTS
SILENCERS, EXHAUST
Compression GmbH ............ 119
& Development Institute for Gas Turbines .... 123 Elliott Group
SLEEVES, SHAFT STASSKOL GmbH ......... 142, 143 STASSKOL Inc. .............. 142, 143
STEAM TURBINES Elliott Group ................. Third Cover, 115, 192 MAN Diesel & Turbo SE ...................................... 138, 139
................. Third Cover, 115, 192
Mitsubishi Heavy Industries
HOERBIGER .................. 134, 135
Compressor International
Mitsubishi Heavy Industries
...................................... 127, 201
Compressor International ...................................... 127, 201
SERVO MOTORS Voith Turbo Inc. ...................... 113
STUD BOLTS Mitsubishi Heavy Industries Compressor International ...................................... 127, 201
SHAFTS T
Mitsubishi Heavy Industries
SERVICES, SHUTDOWN
Compressor International
NEAC Compressor Service Ltd. .................. 142, 143
...................................... 127, 201
NEAC Compressor Service Ltda. ................ 142, 143 NEAC Compressor Service S.r.l. ................ 142, 143 NEAC Compressor Service GmbH & Co. KG .......... 142, 143 NEAC Compressor Service USA Inc. ....................... 142, 143 NEUMAN & ESSER (Beijing) Co. Ltd. .......... 142, 143 2017 EDITION
Voith Turbo Inc. ...................... 113
TILTING PADS Mitsubishi Heavy Industries Compressor International ...................................... 127, 201
SILENCERS COMOTI - Romanian Research & Development Institute for Gas Turbines .... 123
SILENCERS, ACOUSTICAL COMOTI - Romanian Research & Development Institute for Gas Turbines .... 123 30
TORQUE CONVERTERS Voith Turbo Inc. ...................... 113
TURBOCHARGERS, REPAIRS Elliott Group ................. Third Cover, 115, 192 WWW.CTSSNET.NET
CTSS
TURBOEXPANDER Atlas Copco Gas and Process ................. 140, 141 COMOTI - Romanian Research & Development Institute for Gas Turbines .... 123
Burckhardt Compression AG .............................................. 144
NEAC Compressor Service USA Inc. ....................... 142, 143
Cozzani, Dott. Ing. Mario Cozzani Srl ................ 217
NEUMAN & ESSER (Beijing) Co. Ltd. ................ 142, 143
Dott. Ing Mario Cozzani Srl .... 217
NEUMAN & ESSER América do Sul Ltda. ... 142, 143
HOERBIGER .................. 134, 135
Mitsubishi Heavy Industries Compressor International ...................................... 127, 201
NEAC Compressor Service Ltd. .................. 142, 143
V
NEAC Compressor Service S.r.l. ................ 142, 143
VALVE SPRINGS Cozzani, Dott. Ing. Mario Cozzani Srl ................ 217
NEAC Compressor Service Ltda. ................ 142, 143
NEAC Compressor Service GmbH & Co. KG .......... 142, 143
Dott. Ing Mario Cozzani Srl .... 217
NEAC Compressor Service USA Inc. ....................... 142, 143
VALVES, CHECK
NEUMAN & ESSER Gulf FZE ...................... 142, 143
Cozzani, Dott. Ing. Mario Cozzani Srl ................ 217
NEUMAN & ESSER Deutschland GmbH & Co. KG Vertrieb und Anlagentechnik ............ 142, 143 NEUMAN & ESSER Egypt Ltd. ..................... 142, 143 NEUMAN & ESSER Engineering (India) Pvt. Ltd. ........................ 142, 143 NEUMAN & ESSER Gulf FZE ...................... 142, 143 NEUMAN & ESSER Italia S.r.l. ..................... 142, 143 NEUMAN & ESSER
Dott. Ing Mario Cozzani Srl .... 217
VALVES, CRANKCASE RELIEF
HOERBIGER .................. 134, 135
HOERBIGER .................. 134, 135
NEUMAN & ESSER USA Inc. ....................... 142, 143
VALVES, EXPLOSION RELIEF
STASSKOL GmbH ......... 142, 143
NEAC Compressor Service Ltd. .................. 142, 143 NEAC Compressor Service Ltda. ................ 142, 143 NEAC Compressor Service S.r.l. ................ 142, 143 NEAC Compressor Service GmbH & Co. KG .......... 142, 143 NEAC Compressor Service USA Inc. ....................... 142, 143 NEUMAN & ESSER Engineering (India) Pvt. Ltd. ........................ 142, 143 NEUMAN & ESSER Egypt Ltd. ..................... 142, 143 NEUMAN & ESSER Gulf FZE ...................... 142, 143
RUS Ltd. ...................... 142, 143
STASSKOL Inc. .............. 142, 143
HOERBIGER .................. 134, 135
VALVES, PRESSURE VALVES, FUEL
Hofer Kompressoren ...... 142, 143
HOERBIGER .................. 134, 135
VALVES, RELIEF & SAFETY VALVES, OVERHAUL
HOERBIGER .................. 134, 135
BORSIG ZM Compression GmbH ............ 119
Hofer Kompressoren ...... 142, 143
Cozzani, Dott. Ing. Mario Cozzani Srl ................ 217
VALVES, SEATS & RINGS Cozzani, Dott. Ing.
Dott. Ing Mario Cozzani Srl .... 217
Mario Cozzani Srl ................ 217
NEAC Compressor Service Ltd. .................. 142, 143
Dott. Ing Mario Cozzani Srl .... 217 HOERBIGER .................. 134, 135
NEUMAN & ESSER RUS Ltd. ...................... 142, 143
NEAC Compressor Service S.r.l. ................ 142, 143
Hofer Kompressoren ...... 142, 143
VALVES, COMPRESSOR
NEAC Compressor Service Ltda. ................ 142, 143 NEAC Compressor Service
VALVES, STARTING AIR
BORSIG ZM Compression GmbH ............ 119 2017 EDITION
GmbH & Co. KG .......... 142, 143 31
VALVES, SHUT-OFF
HOERBIGER .................. 134, 135 WWW.CTSSNET.NET
CTSS
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s n o i t a c i f i c e p S c i s a B 7 1 0 2
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2017 EDITION
33
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s n o i t a c i f i c e p S c i s a B 7 1 0 2
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N E D W O H
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5 8 1
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0 5 1
0 5 1
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0 1 6
0 1 6
5 7 3
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0 5 1
0 5 1
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0 5 1
5 7 2
0 6 1 1
0 1 6
0 1 6
0 1 2
0 8 5
0 5 4 1
0 5 4 1
0 5 4 1
0 5 4 1
0 0 6
5 8 1
2 1 2
5 5 2
5 2 4
0 5 8
0 3 1
0 6
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5 2 4
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7 . 7 1 4
7 . 9 7 6
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8 . 9 0 5
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8 . 9 0 5
2 . 1 9 9
9 . 0 7 6 1
6 . 5 6 2 2
0 2 1
7 2 1
0 7 1
5 5 2
0 5 3
0 9
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2 4 1
5 5 2
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6 . 5 1
6 . 6 5
3 . 3 1 1
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8 . 9 3 3
5 . 2 4
4 . 7 2 1
6 . 1 4 1
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8 . 0 7
2 . 8 9 1
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6 . 9 4 8
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0 0 5 6
0 0 5 7
0 0 0 9
0 0 0 , 5 1
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0 0 7 1
0 0 7 1
0 0 0 4
0 0 0 8
0 5 7 , 4 1
0 0 0 , 4 2
0 0 8 1
0 0 0 6
0 0 0 , 1 1
0 0 0 , 8 1
0 0 0 , 0 1
0 0 0 , 8 1
0 0 0 , 5 3
0 0 0 , 9 5
0 0 0 , 0 8
0 5 1 4
0 0 5 4
0 0 0 6
0 0 0 9
0 0 5 , 2 1
0 0 0 3
0 0 8 1
0 0 8 3
0 0 0 5
0 0 0 9
0 0 5
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0 0 0 2
0 0 0 4
0 0 2 8
0 0 0 , 2 1
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s n o i t a c i f i c e p S c i s a B 7 1 0 2
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0 0 0 , 8 1
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0 0 0 , 8 1
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0 0 0 5
0 0 0 3
0 0 0 1
0 0 0 5
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0 0 0 , 0 2
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0 0 0 3
0 0 5 1
0 0 0 , 0 5
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0 0 0 , 0 8
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l l l l l O O O O O
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* This company is not represented in the 2017 Supplement with a section describing its products.
2017 EDITION
48
WWW.CTSSNET.NET
CTSS
s n o i t a c i f i c e p S c i s a B 7 1 0 2
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0 0 7 1
0 0 0 3
0 0 6 3
0 0 1 5
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0 0 8 4
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2 3 1
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0 6 1
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6
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* This company is not represented in the 2017 Supplement with a section describing its products.
2017 EDITION
49
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CTSS
s n o i t a c i f i c e p S c i s a B 7 1 0 2
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5 2 8
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9 6
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8 5 7
8 5 7
8 5 7
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8 5 7
8 5 7
7 2 8
7 2 8
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0 0 5 5 4 4
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0 0 6
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* This company is not represented in the 2017 Supplement with a section describing its products.
2017 EDITION
50
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s n o i t a c i f i c e p S c i s a B 7 1 0 2
x 0 a 5 m 4
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0 0 6
0 5 4
0 5 4
0 0 6
0 2 7
0 0 6 3
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7 7 2
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7 7 2
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0 0 0 1
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0 8 6 3
0 0 8 7
0 0 5 , 1 2
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0 0 9
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0 0 2 , 5 4
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0 0 0 , 0 7 6
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4 6 9 , 8 8
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8 2 9 , 7 7 1
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0 0 0 , 0 5 3
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7 2 8
7 2 8
7 2 8
7 2 8
7 2 8
7 2 8
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3 1
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9 7 3
9 7 3
9 7 3
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0 0 0 , 2 1
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e g n a R w o l F t e l n I
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) s e u n i t n o C (
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s n o i t a c i f i c e p S c i s a B 7 1 0 2
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0 4 4
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6 6 9 9 2 2
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6 4 4 , 3 3 1
6 4 4 , 3 3 1
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0 0 0 , 0 4
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8 2 9 , 7 7 1
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3 3 1 , 9 8 2
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9 9 7 7 3 3
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X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X E L 3 0 8 2 C P D X A J A
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E L 2 0 8 2 C P D X A J A
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D T S 1 0 8 2 C P D X A J A
E L 1 0 8 2 C P D X A J A
E L U 1 0 8 2 C P D X A J A
D T S 2 0 2 2 C P D X A J A
E L 2 0 2 2 C P D X A J A
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) s e u n i t n o C (
* This company is not represented in the 2017 Supplement with a section describing its products.
2017 EDITION
52
WWW.CTSSNET.NET
CTSS
s n o i t a c i f i c e p S c i s a B 7 1 0 2
x 0 a 0 0 m 1
0 0 0 1
0 3 3
0 3 3
0 3 3
0 3 3
0 3 3
0 0 6
0 5 4
0 0 8 1
0 0 0 0 2 2 2 4 7 7 7
0 0 0 0 0 0 0 0 5 5 0 0 0 0 0 0 2 2 2 2 2 2 2 2
4 6 2
4 6 2
4 6 2
4 6 2
4 6 2
7 2 3
7 2 3
0 5 7
0 0 0 5 5 5 8 2 2 2
0 0 0 1
0 0 0 1
0 0 2 1
0 0 2 1
0 0 2 1
0 0 0 1
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) m p r ( e g n a R d e e p S n 0 i 5 m 2
8 5 3 5 2
3 0 8 3
7 3 2 2
4 7 4 4
1 1 7 6
4 6 8 1
8 2 7 3
3 9 5 5
8 7 6 1
4 1 0 2
4 8 9 2
6 7 4 4
8 6 9 5
2 5 1 6
8 4 9 8
0 1 1
0 0 0 0 7 7 5 0 6 6 2 2
0 0 7 1
0 0 1 5
0 0 0 3
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0 0 0 9
0 0 5 2
0 0 0 5
0 0 5 7
0 5 2 2
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r e w o P t u p n I m u m i x a M p h
0 0 4 3
) e g a t S r e P ( o i t a R n o i s s e r p m o C s n o t d a o L d o R w e e l b a w o l l A m u m i x a M N b l r
a e r u s s e r P g n i k r o W b e l b a w o l l A m u m i x a M g i s p
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5 5 8 8 3 3 1 , 9 8 2
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3 3 1 , 9 8 2
5 1 6 , 3 3 3
5 1 6 , 3 3 3
5 1 6 , 3 3 3
5 1 6 , 3 3 3
5 1 6 , 3 3 3
5 1 6 , 3 3 3
7 9 0 , 8 7 3
7 9 0 , 8 7 3
0 3 2 , 7 6 6
0 3 2 , 7 6 6
0 3 2 , 7 6 6
7 9 0 , 8 7 3
0 3 2 , 7 6 6
0 0 0 , 0 5 2
0 0 0 , 0 5 2
0 0 0 , 0 4 1
0 0 0 , 0 5 3
0 0 0 , 5 6
0 0 0 , 5 6
0 0 0 , 5 6
0 0 0 , 5 7
0 0 0 , 5 7
0 0 0 , 5 7
0 0 0 , 5 7
0 0 0 , 5 7
0 0 0 , 5 7
0 0 0 , 5 8
0 0 0 , 5 8
0 0 0 , 0 5 1
0 0 0 , 0 5 1
0 0 0 , 0 5 1
0 0 0 , 5 8
0 0 0 , 0 5 1
0 0 2 , 6 5
0 0 2 , 6 5
0 0 5 , 1 3
0 0 5 , 8 7
8 8 8 8 8 8 8 8 8 6 6 6 6 6 6 6 6 6 5 5 5 5 5 5 5 5 5
4 3 0 1
4 3 0 1
4 3 0 1
4 3 0 1
4 3 0 1
4 3 0 1
4 3 0 1
0 0 3
0 0 0 0 0 5 0 0 0 2 0 0 6 3 4
0 5 2 8
0 0 0 , 5 1
0 0 0 , 5 1
0 0 0 , 5 1
0 0 0 , 5 1
0 0 0 , 5 1
0 0 0 , 5 1
0 0 0 , 5 1
0 5 3 4
0 0 0 , 0 9
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0 5 2 8
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x a n m i m / 3 m n i m
S R x a O m m f S c a n i S m E d e t c e j n I l i O = I O R e e r F l i O = F O P l l o r c S M l a d i o h c o r T O g n i R - d i u q i L y C r e n a V g n i d i l S a t o w e r c S e l g n i S Y R ) w e r c S ( e b o L l a c i l e H R e b o L t h g i a r t S A T g m g a r h p a i D n t d e s o p p O / d e c n a l a B O i a c o r e l b a r a p e S R i p c e n e v i r D e n i g n E l a r g e t n I D R s e g a t S e l p i t l u M N e g a t S e l g n i S A G n o i t a n g i s e D l e d o M N I T A C e c n e r e f e R e g a P g o l a t a C O r e R r u t P c I a f u C n a E M R
I O , F O
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I O , F O
I O , F O
I O , F O
I O , F O
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0 0 6 3
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r e m e s s e B r 2 e 1 p V o o M C G
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S A G & L I O E G
G A N E R O S E R P M O K G U A H
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* This company is not represented in the 2017 Supplement with a section describing its products.
2017 EDITION
53
WWW.CTSSNET.NET
CTSS
s n o i t a c i f i c e p S c i s a B 7 1 0 2
x a m
0 0 0 1
0 5 7
0 0 5
0 0 0 5
0 0 6 3
0 0 6 3
0 0 0 3
0 0 6 3
0 0 6 3
0 0 6 3
0 0 6 3
0 0 6 3
0 0 6 3
0 0 0 6
0 0 0 4
0 0 5 4
0 0 5 4
0 0 5 4
0 0 5 4
n i m
0 0 2
0 0 2
0 0 2
0 0 0 3
0 0 8 1
0 0 8 1
0 0 8 1
0 0 8 1
0 0 8 1
0 0 8 1
0 0 8 1
0 0 8 1
0 0 8 1
0 0 5 1
0 5 2 1
0 0 5 1
0 0 5 1
0 0 5 1
0 0 5 1
W k
0 0 5 2
0 0 3 1
0 5 9 1
0 0 0 0 5 5 5 5 1 1 1 1
0 6 2
0 6 2
0 5 4
0 5 4
0 5 4
0 5 4
6 6 1
0 0 5 3
0 5 3
0 5 3
6 6 7
6 6 7
p h
0 0 4 3
6 6 7 1
9 4 6 2
0 0 0 0 0 0 0 0 2 2 2 2
0 5 3
0 5 3
0 0 6
0 0 6
0 0 6
0 0 6
3 2 2
0 9 6 4
0 7 4
0 7 4
8 2 0 1
8 2 0 1
) e g a t S r e P ( o i t a R n o i s s e r p m o C
4
2 1
3
0 0 0 0 1 1 1 1
0 1
0 1
0 1
0 1
0 1
0 1
0 3 1
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0 0 0 , 0 0 5
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0 0 5 , 9 4
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0 5 3
0 0 0 3
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1 1 1 1 2 2 2 2
1 2
1 2
1 2
1 2
1 2
1 2
2 0 2 6
4 2
4 2
4 2
4 2
0 0 1 5
0 0 5 , 3 4
0 0 5 6
5 5 5 5 0 0 0 0 3 3 3 3
5 0 3
5 0 3
5 0 3
5 0 3
5 0 3
5 0 3
0 0 2 7 3 8
0 5 3
0 5 3
0 5 3
0 5 3
8 6 5
0 1
3 8
2 6 6 9 . 8 8 . 8 . 5 9 9
3 9 . 1 1
8 2 . 4 1
8 3 . 6 1
6 2 . 2 2
7 5 . 4 2
4 6 . 7 2
6 8 . 9
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2 7 . 3 1
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7 5 3
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9 3 8 2 0 8 4 4 2 2 3 3
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4 0 5
8 7 5
6 8 7
7 6 8
6 7 9
8 3 4 8 3 6
4 8 4
1 0 6
8 1 7
6 8 7
5 . 3
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F O
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I I I I O O O O
I O
I O
I O
I O
I O
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I I O O
I O
I O
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X X X X
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r e w o P t u p n I m u m i x a M
s n o t d a o L d o R w e e l b a w o l l A m u m i x a M N b l r
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e g n a R w o l F t e l n I
x a n m i m / 3 m n i m
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X X
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) s e u n i t n o C (
N E D W O H
* This company is not represented in the 2017 Supplement with a section describing its products.
2017 EDITION
54
WWW.CTSSNET.NET
CTSS
s n o i t a c i f i c e p S c i s a B 7 1 0 2
x a m
0 0 5 4
0 0 5 4
0 0 6 3
0 0 6 3
0 0 6 3
0 0 6 3
0 0 6 3
0 0 6 3
0 0 6 3
0 0 6 3
0 0 6 3
0 0 6 3
0 0 6 3
0 0 6 3
0 0 6 3
0 0 0 2
n i m
0 0 5 1
0 0 5 1
0 0 5 1
0 0 5 1
0 0 5 1
0 0 5 1
0 0 5 1
0 0 5 1
0 0 5 1
0 0 5 1
0 0 5 1
0 0 5 1
0 0 5 1
0 0 5 1
0 0 5 1
0 0 7
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6 6 7
6 6 7
0 5 1 1
0 5 1 1
0 5 1 1
0 5 1 1
0 5 1 1
0 5 1 1
4 4 0 2
4 4 0 2
4 4 0 2
4 4 0 2
5 3 3 4
5 3 3 4
5 3 3 4
0 0 0 5
p h
8 2 0 1
8 2 0 1
2 4 5 1
2 4 5 1
2 4 5 1
2 4 5 1
2 4 5 1
2 4 5 1
1 4 7 2
1 4 7 2
1 4 7 2
1 4 7 2
4 1 8 5
4 1 8 5
4 1 8 5
0 0 7 6
) e g a t S r e P ( o i t a R n o i s s e r p m o C
2 1
2 1
2 1
2 1
2 1
2 1
2 1
8
2 1
2 1
2 1
8
2 1
2 1
2 1
2 1
4 2
4 2
4 2
4 2
4 2
4 2
4 2
4 1
4 2
4 2
4 2
4 1
4 2
4 2
4 2
4 2
0 5 3
0 5 3
0 5 3
0 5 3
0 5 3
0 5 3
0 5 3
0 0 2
0 5 3
0 5 3
0 5 3
0 0 2
0 5 3
0 5 3
0 5 3
0 5 3
7 5 . 4 2
5 5 . 3 3
2 3
6 3
8 4 . 3 4
8 4
9 9 . 3 5
9 8 . 3 6
8 . 6 7
6 9
8 0 1
8 2 1
4 . 7 1 1
5 . 5 3 1
1 . 8 5 1
6 . 3 5 1
7 6 8
6 7 9
9 2 1 1
0 7 2 1
5 3 5 1
4 9 6 1
5 0 9 1
8 5 2 2
0 1 7 2
8 8 3 3
1 1 8 3
7 1 5 4
4 4 1 4
3 8 7 4
0 8 5 5
0 2 4 5
I O
I O
I O
I O
I O
I O
I O
I O
I O
I O
I O
I O
I O
I O
I O
I O
X
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0 3 1 / 5 n 5 e i 2 d V w R o H W
5 4 1 / 5 n 5 e i 2 d V w R o H W
5 6 1 / 5 n 5 e i 2 d V w R o H W
3 9 1 / 5 n 5 e i 2 d V w R o H W
0 2 2 / n 5 e 5 d 2 w V o R H W
2 3 1 / 1 n 2 e i 3 d V w R o H W
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3 9 1 / 1 n 2 e i 3 d V w R o H W
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) s e u n i t n o C (
N E D W O H
* This company is not represented in the 2017 Supplement with a section describing its products.
2017 EDITION
55
WWW.CTSSNET.NET
CTSS
s n o i t a c i f i c e p S c i s a B 7 1 0 2
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0 0 0 2
0 0 0 2
0 0 0 , 5 1
0 0 5 9
0 0 5 9
0 0 5 7
0 0 5 7
0 0 7 4
0 0 7 4
0 5 7 3
0 5 7 3
0 0 6
0 0 6
0 0 6
0 0 5
0 0 5
5 7 3
0 0 2 1
0 0 0 1
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0 0 7
0 0 7
0 0 5 7
0 5 7 4
0 5 7 4
0 0 0 4
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0 0 3 2
0 0 3 2
0 0 0 2
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0 0 3
0 0 3
0 0 3
0 5 2
0 5 2
0 9 1
0 0 5
0 0 0 0 0 0 3 3 3
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0 0 0 5
0 0 0 5
5 3 0 0 5 5 5 7 1 0 0 3 3 7 2 2 6 6 9 9 2 2 2
5 8 9 2
5 8 9 2
0 0 8
0 0 3 2
0 0 6 5
0 0 3 , 0 1
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0 0 0 , 3 3
0 0 6 4
0 4 5 7 7 6 2 2 4
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0 0 7 6
0 0 7 6
6 0 0 0 8 0 0 5 2 8 8 2 1
0 0 0 4
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0 9 0 1
0 3 1 3
0 2 6 7
0 0 0 , 4 1
0 5 9 , 0 2
3 1 9 , 4 4
4 5 2 6
2 7 4 6 6 2 3 3 6
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2 1
4 4 4 4 4 4 4 4 4
5
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5
6 5 4
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r e w o P t u p n I m u m i x a M 0 5 2 1
0 5 0 3
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s n o t d a o L d o R w e e l b a w o l l A m u m i x a M N b l r
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x a n m i m / 3 m n i m
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6 6 2 , 2 9 3
6 6 2 , 2 9 3
6 6 2 , 2 9 3
5 8 1 , 8 8
5 8 1 , 8 8
5 8 1 , 8 8
4 2
4 2
4 4 5 0 9 4 1 9 1 9 1 9 1 1
0 0 6
0 0 6
0 0 6
0 0 6
0 0 6
0 0 6
0 0 6
0 0 5 3 3 6 1
0 5 3
0 5 3
6 1 6 1 6 1 6 0 0 2 0 2 0 2 0 2 0 3 1 2 1 2 1 2 1 2 1
0 0 7 8
0 0 7 8
0 0 7 8
0 0 7 8
0 0 7 8
0 0 7 8
0 0 7 8
5 5 1 3 3 9 4 4 3 2
2 9 1
5 . 2 9 2
0 4 1 5 2 3 5 8 7 5 3 5 2 4 6 6 9 6 1 2 2 3
4 2 9 4 3 4
3 3 2
5 7 7 6
2 3 3 , 0 1
6 0 0 9 5 6 7 2 0 9 3 0 5 9 4 6 9 8 4 , 3 4 8 8 2 3 8 1 2 2 2 3 5 8 8 2 1
1 7 7 6 3 3 5 1 7 1 1 1
3 9 0 1 9 6 1
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0 1 1 / 4 0 2 P H n e d w o H
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0 1 1 / 5 5 2 P H n e d w o H
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) s e u n i t n o C (
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* This company is not represented in the 2017 Supplement with a section describing its products.
2017 EDITION
56
WWW.CTSSNET.NET
CTSS
s n o i t a c i f i c e p S c i s a B 7 1 0 2
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* This company is not represented in the 2017 Supplement with a section describing its products.
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57
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0 0 7 , 1 1
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* This company is not represented in the 2017 Supplement with a section describing its products.
2017 EDITION
58
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s n o i t a c i f i c e p S c i s a B 7 1 0 2
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2 7
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5
5
5
5
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. C N I P M O C Y H
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2017 EDITION
61
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2017 EDITION
62
WWW.CTSSNET.NET
CTSS
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2017 EDITION
63
WWW.CTSSNET.NET
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S R O S S E R P M O C O L F O R
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2017 EDITION
64
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2017 EDITION
65
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2017 EDITION
66
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2017 EDITION
67
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2017 EDITION
68
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2017 EDITION
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S R x a O m m f S c a n i S m E d e t c e j n I l i O = I O R e e r F l i O = F O P l l o r c S M l a d i o h c o r T O g n i R - d i u q i L y C r e n a V g n i d i l S a t o w e r c S e l g n i S Y R ) w e r c S ( e b o L l a c i l e H R e b o L t h g i a r t S A T g m g a r h p a i D n t d e s o p p O / d e c n a l a B O i a c o r e l b a r a p e S R i p c e n e v i r D e n i g n E l a r g e t n I D R s e g a t S e l p i t l u M N e g a t S e l g n i S A G n o i t a n g i s e D l e d o M N I T A C e c n e r e f e R e g a P g o l a t a C O r e R r u t P c I a f u C n a E M R
1 7 7 2 . . 3 . 2 . 1 . 3 . 3 . 7 . 3 . 8 . 4 . . 9 . . 6 . 8 . 8 . 7 . 3 0 1 4 6 9 6 2 5 0 4 3 1 8 7 3 8 3 1 1 1 1 1 8 9 1 1 2 2 3 3 4 5 5 6 7 7 8
0 7 5 8 4 7 2 2 0 0 6 8 5 0 0 1 1 3 8 9 2 5 8 1 4 1 4 7 0 7 6 5 0 5 0 1 5 0 9 9 8 9 4 8 6 8 9 0 3 5 5 5 8 0 3 6 7 9 1 3 3 3 4 4 5 6 2 3 4 5 7 8 1 2 1 1 1 1 1 1 1 1 2 2 2 2 2
5 2 . 1 1 1 1 0 1 0
I I I I I I I I I I I I I I I I I I I I I I I I I I F O O O O O O O O O O O O O O O O O O O O O O O O O O O
X X X X X X X X X X X X X X X X X X X X X X X X X X X
X X X X X X X X X X X X
1 0 3 G S V
1 6 3 G S V
1 0 4 G S V
1 0 5 G S V
1 0 6 G S V
1 0 7 G S V
1 9 2 G S S V
1 4 3 G S S V
1 5 4 G S S V
1 0 6 G S S V
1 5 7 G S V
1 0 9 G S V
1 5 0 1 G S V
1 0 2 1 G S V
1 5 5 1 G S V
1 5 8 1 G S V
1 0 1 2 G S V
1 0 4 2 G S V
1 0 6 2 G S V
1 0 8 2 G S V
1 0 0 3 G S V
t c a p m o C V F T S V F C C S R W W W W W
*
*
G N I R U T C A F U N A M R E T C L I L V L
N E R O S S E R P M O K H T B P M V G
* This company is not represented in the 2017 Supplement with a section describing its products.
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TECH BRIEF The following section covering Compressors and Expanders has been reproduced, by permission, from the Engineering Data book, 13 th edition, published by the Gas Processors Suppliers Association. The complete Engineering Data Book can be ordered from GPSA, 6526 East 60 th Street, Tulsa, Oklahoma 74145, www.gpaglobal.org.
Compressors And Expanders FIG. 13-1 Nomenclature
ACFM = A p A r BHP C
= = = =
Cp Cv D d E
= = = = =
EP = F = GHP = H = h = ICFM = k = MCp = MCv = MW MN N Nm n P Pc PD PL
= = = = = = = = =
pPc PR pTc Q Qg
= = = = =
R =
conditions) cross sectional area of piston,sq in cross sectional area of piston rod, sq in brake or shaft horsepower cylinder clearance as a percent of piston displacement specific heat at constant pressure, BTU/(lb °F) specific heat at constant volume, BTU/(lb °F) cylinder inside diameter, in piston rod diameter, in overall efficiency High speed reciprocating units — 0.82 Low speed reciprocating units — 0.85 extracted horsepower of expander an allowance for interstage pressure drop, Eq 13-4 gas horsepower, actual compression horsepower, excluding mechanical losses, BHP head, ft lb/lb enthalpy, Btu/lb inlet cubic feet per minute, usually at suction conditions Cp/Cv molar specific heat at constant pressure, BTU/(lb mole °F) molar specific heat at constant volume, BTU/(lb mole °F) molecular weight, lb/lb mole machine mach number speed, rpm molar flow, moles/min polytropic exponent or number of moles pressure, psia critical pressure, psia piston displacement, ft3/min pressure base used in the contract or regulation, psia pseudo critical pressure, psia reduced pressure, P/Pc pseudo critical temperature, °R inlet capacity (ICFM) standard gas flow rate, MMSCFD
2017 EDITION
r s sm SCFM
universal gas constant = 10.73
psia ft3 lb mole °R
lb/ft3 ft lb or lb mole °R lb mole °R
=
1545
=
1.986
= = = =
compression ratio, P2/P1 entropy, BTU/(lb °R) surge margin cubic feet per minute measured at 14.7 psia and 60°F length of piston movement, in absolute temperature, °R critical temperature, °R reduced temperature, T/Tc temperature, °F impeller tip speed specific volume, ft3/lb velocity ft/s volumetric efficiency, percent work, ft lb weight flow, lb/min temperature rise factor mole fraction compressibility factor average compressibility factor = (Zs + Zd)/2 efficiency, expressed as a decimal density, lb/ft3
stroke T Tc TR t U V v VE W w X y Z Zavg
= = = = = = = = = = = = = = = = =
Btu lb mole °R
Subscripts avg d g is L
average discharge gas isentropic process standard conditions used for calculation or contract m = mechanical p = polytropic process S = standard conditions, usually 14.7 psia, 60°F s = suction t = total or overall 1 = inlet conditions 2 = outlet conditions
71
= = = = =
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TECH BRIEF
DEFINITIONS OF WORDS AND PHRASES USED IN COMPRESSORS AND EXPANDERS
Capacity: (Actual Flow) of a compressor is the volume rate of flow of gas compressed and delivered referred to conditions of pressure, temperature and gas composition prevailing at the compressor inlet.
Absolute pressure: the pressure measured from an absolute vacuum. It equals the algebraic sum of barometric pressure and gauge pressure.
Standard or normal flow: the rate of flow under certain ‘standard’ conditions, for example 60 F and 14.7 psia (US Standard) or 15 C and 101.325 kPa (GPA-SI Standard).
Static pressure: the pressure in the gas measured in such a manner that no effect is produced by the velocity of the gas stream. It is the pressure that would be shown by a measuring instrument moving at the same velocity as the moving stream and is the pressure used as a property in defining the thermodynamic state of the fluid.
Mass flow: the rate of flow in mass units.
°
°
Isentropic compression: refers to the reversible adiabatic compression process. Isentropic work (head): the work required to compress a unit mass of gas in an isentropic compression process from the inlet pressure and temperature to the discharge pressure.
Stagnation (total) pressure: the pressure which would be measured at the stagnation point when a moving gas stream is brought to rest and its kinetic energy is converted to an enthalpy rise by an isentropic compression from the flow condition to the stagnation condition. It is the pressure usually measured by an impact tube. In a stationary body of gas, the static and stagnation pressures are numerically equal.
Isentropic power: defined as the power required to compress isentropically and deliver the capacity of the compressor from the compressor inlet conditions to the compressor discharge pressure. Isentropic efficiency: the ratio of the isentropic work to the work required for the compression process.
Velocity pressure (dynamic pressure): the stagnation pressure minus the static pressure in a gas stream. It is the pressure generally measured by the differential pressure reading of a Pitot tube
Polytropic compression: a reversible compression process between the compressor inlet and discharge conditions, which follows a path such that, between any two points on the path, the ratio of the reversible work input to the enthalpy rise is constant. In other words, the compression process is described as an infinite number of isentropic compression steps, each followed by an isobaric heat addition. The result is an ideal, reversible process that has the same suction pressure, discharge pressure, suction temperature and discharge temperature as the actual process.
Absolute temperature: the temperature above absolute zero. It is equal to the degrees Fahrenheit plus 459.66, and is stated as degrees Rankine. Static temperature: the temperature that would be shown by a measuring instrument moving at the same velocity as the fluid stream. It is the temperature used as a property in defining the thermodynamic state of the gas.
Polytropic work (head): the reversible work required to compress a unit mass of the gas in a polytropic compression process.
Stagnation (total) temperature: that temperature which would be measured at the stagnation point if a gas stream were brought to rest and its kinetic energy converted to an enthalpy rise by an isentropic compression process from the flow condition to the stagnation condition.
Compressors Depending on application, compressors are manufactured as positive-displacement, dynamic, or thermal type (Fig. 13-2).
compressors in which the rotating element (impeller or bladed rotor) accelerates the gas as it passes through the element, converting the velocity head into static pressure, partially in the rotating element and partially in stationary diffusers or blades.
Positive displacement types fall in two basic categories: reciprocating and rotary.
Ejectors are “thermal” compressors that use a high velocity gas or steam jet to entrain the inflowing gas, then convert the velocity of the mixture to pressure in a diffuser.
The reciprocating compressor consists of one or more cylinders each with a piston or plunger that moves back and forth, displacing a positive volume with each stroke.
Fig. 13-3 covers the normal range of operation for compressors of the commercially available types.
The diaphragm compressor uses a hydraulically pulsed flexible diaphragm to displace the gas.
The advantages of a centrifugal compressor over a reciprocating machine are:
Rotary compressors cover lobe-type, screw-type, vane-type, and liquid ring type, each having a casing with one or more rotating elements that either mesh with each other such as lobes or screws, or that displace a fixed volume with each rotation. The dynamic types include radial-flow (centrifugal), axialflow, and mixed flow machines. They are rotary continuous-flow
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1.
Lower installed first cost where pressure and volume conditions are favorable,
2.
Lower maintenance expense,
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TECH BRIEF
3.
Greater continuity of service and dependability,
4.
Less operating attention,
5.
Greater volume capacity per unit of plot area,
6.
Adaptability to high-speed low-maintenance-cost drivers.
On multistage machines, intercoolers may be provided between stages. These are heat exchangers which remove the heat of compression from the gas and reduce its temperature to approximately the temperature existing at the compressor intake. Such cooling reduces the actual volume of gas going to the high-pressure cylinders, reduces the horsepower required for compression, and keeps the temperature within safe operating limits.
The advantages of a reciprocating compressor over a centrifugal machine are:
Reciprocating compressors should be supplied with clean gas as they cannot satisfactorily handle liquids and solid particles that may be entrained in the gas. Liquids and solid particles tend to destroy cylinder lubrication and cause excessive wear. Liquids are non-compressible and their presence could cause major damage to the compressor cylinder or frame components.
1.
Greater flexibility in capacity and pressure range,
2.
Higher compressor efficiency and lower power cost,
3.
Capability of delivering higher pressures,
4.
Capability of handling smaller volumes,
5.
Less sensitive to changes in gas composition and density.
Reciprocating compressors are typically designed to one of the following industry standard specifications:
RECIPROCATING COMPRESSORS
API Standard 618 “Reciprocating Compressors for Petroleum, Chemical, and Gas Industry Services.”
Reciprocating compressor ratings vary from fractional to more than 40,000 hp per unit. In gas processing it would be unusual for units larger than 10,000 hp to be used. Pressures range from low vacuum at suction to 30,000 psi and higher at discharge for special process compressors.
ISO Standard 13631: 2002, “Petroleum and Natural Gas Industries — Packaged Reciprocating Compressors.” Low to moderate speed compressors, typically 300–700 rpm, have historically been used in refineries, chemical plants and also can be used in gas plant service. They are normally driven by electric motors. These compressors are typically applied in accordance with API Standard 618 “Reciprocating Compressors for Petroleum, Chemical and Gas Industry Services.”
Reciprocating compressors are furnished either single-stage or multi-stage. The number of stages is determined by the overall compression ratio. The compression ratio per stage (and valve life) is generally limited by the discharge temperature and usually does not exceed 4, although small-sized units (intermittent duty) are furnished with a compression ratio as high as 8.
Moderate to high speed compressors, typically 600–1800 rpm packaged separable compressors are used for field gas compression, mid-stream compression, gas plant and mainline compression. These units are normally driven by gas engines or electric motors. These compressors are typically applied in accordance with ISO Standard 13631.
Gas cylinders are generally lubricated, although a non-lubricated design is available when warranted; example: nitrogen, oxygen, and instrument air.
FIG. 13-2 Types of Compressors
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A low speed “integral” compressor refers to a compressor driven by a gas engine where the power cylinders of the engine that turn the crankshaft are in the same housing as the gas compression cylinders. (See Fig. 13-4). These compressors are no longer manufactured but there are a number of them still in operation in pipeline boosting service as well as inlet compression service at field gas plants. Integral compressors were designed to API 11 which is no longer supported by API.
of the gas in going from suction to discharge conditions. Years ago the capability of easily generating P-H diagrams for natural gases did not exist. The result was that many ways of estimating the enthalpy change were developed. They were used as a crutch and not because they were the best way to evaluate compression horsepower requirements. Today the engineer does have available, in many cases, the capability to generate that part of the P-H diagram required for compression purposes. This is done using equations of state on a computer. This still would be the best way to evaluate the compression horsepower. The other methods are used only if access to a good equation of state is not available.
Performance Calculations
The engineer in the field is frequently required to: 1.
2.
determine the approximate horsepower required to compress a certain volume of gas from some intake conditions to a given discharge pressure, and
Section 13 continues to treat reciprocating and centrifugal machines as being different so far as estimation of horsepower requirements is concerned. This treatment reflects industry practice. The only difference in the horsepower evaluation is the efficiency of the machine. Otherwise the basic thermodynamic equations are the same for all compression.
estimate the capacity of an existing compressor under specified suction and discharge conditions.
The following text outlines procedures for making these calculations from the standpoint of quick estimates and also presents more detailed calculations. For specific information on a given compressor, consult the manufacturer of that unit.
The reciprocating compressor horsepower calculations presented are based on charts. However, they may equally well be calculated using the equations in the centrifugal compressor section, particularly Equations 13-25 through 13-43. This also includes the mechanical losses in Equations 13-37 and 13-38.
For a compression process, the enthalpy change is the best way of evaluating the work of compression. If a P-H diagram is available (as for propane refrigeration systems), the work of compression would always be evaluated by the enthalpy change
There are two ways in which the thermodynamic calculations for compression can be carried out — by assuming:
FIG. 13-3 Compressor Coverage Chart
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1.
isentropic reversible path — a process during which there is no heat added to or removed from the system and the entropy remains constant, pv k = constant
increases as it passes from suction to discharge in the compressor, k is normally determined at the average of suction and discharge temperatures.
2.
polytropic reversible path — a process in which changes in gas characteristics during compression are considered, pvn = constant
For a multi-component gas, the mole weighted average value of molar heat capacity must be determined at average cylinder temperature. A sample calculation is shown in Fig. 13-7.
Fig. 13-5 shows a plot of pressure vs. volume for each value of the above exponents. The work, W, performed in proceeding from p1 to p2 along any polytropic curve (Fig. 13-5) is
The calculation of pPc and pTc in Fig. 13-7 permits calculation of the reduced pressure P R = P/pPc mix and reduced temperature TR = T/pTc mix. The compressibility Z at T and P can then be determined using the charts in Section 23.
W=
2 1 V
dp =
p2 p 1 V
dp
Eq 13-1
If only the molecular weight of the gas is known and not its composition, an approximate value for k can be determined from the curves in Fig. 13-8.
The amount of work required is dependent upon the polytropic curve involved and increases with increasing values of n. The path requiring the least amount of input work is n = 1, which is equivalent to isothermal compression, a process during which there is no change in temperature. For isentropic compression, the exponent used is k = ratio of specific heat at constant pressure to that at constant volume.
Estimating Compressor Horsepower Equation 13-4 is useful for obtaining a quick and reasonable estimate for compressor horsepower. It was developed for large slow-speed (300 to 450 rpm) compressors handling gases with a specific gravity of 0.65 and having stage compression ratios above 2.5.
It is usually impractical to build sufficient heat-transfer equipment into the design of most compressors to carry away the bulk of the heat of compression. Most machines tend to operate along a polytropic path which approaches the isentropic. Most compressor calculations are therefore based on an efficiency applied to account for true behavior.
CAUTION: Compressor manufacturers generally rate their machines based on a standard condition of 14.4 psia rather than the more common gas industry value of 14.7 psia. Due to higher valve losses, the horsepower requirement for high-speed compressors (1000 rpm range, and some up to 1800 rpm) can be as much as 20% higher, although this is a very arbitrary value. Some compressor designs do not merit a higher horsepower allowance and the manufacturers should be consulted for specific applications.
A compression process following the outer curve in Fig. 13-5 has been widely referred to in industry as “adiabatic”. However, all compression processes of practical importance are adiabatic. The term adiabatic does not adequately describe this process, since it only implies no heat transfer. The ideal process also follows a path of constant entropy and should b e called “isentropic,” as will be done subsequently in this chapter.
MCp – MCv = R = 1.986 Btu/(lbmol °F )
Equation 13-3 which applies to all ideal gases can be used to calculate k.
Brake ratio horsepower = (22) stage
Where:
Eq 13-2
MMcfd =
By rearrangement and substitution we obtain: k=
Cp Cv
=
MCp MCv
=
MCp MCp – 1.986
(F) (# of stages) (MMcfd) Eq 13-4
F =
Eq 13-3
To calculate k for a gas we need only know the constant pressure molar heat capacity (MCp) for the gas. Fig. 13-6 gives values of molecular weight and ideal-gas state heat capacity (i.e. at 1 atm) for various gases. The heat capacity varies considerably with temperature. Since the temperature of the gas
Compressor capacity referred to 14.4 psia and intake temperature 1.0 for single-stage compression 1.08 for two-stage compression 1.10 for three-stage compression
Equation 13-4 will also provide a rough estimate of horsepower for lower compression ratios and/or gases with a higher specific gravity, but it will tend to be on the high side. To allow for this the tendency is to use a multiplication factor of 20 instead of 22 for gases with a specific gravity in the 0.8 to 1.0
FIG. 13-4 FIG. 13-5
Integral Engine Compressor
Compression Curves
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TECH BRIEF
FIG. 13-6 Molar Heat Capacity MCp (Ideal-Gas State), Btu/(lb mo l • °R) *Data source: Selected Values of Properties of Hydrocarbons, API Research Project 44; MW updated to agree with Fig. 23-2 Gas
Chemical formula
Mol wt
Temperature 0°F
50°F
60°F
100°F
150°F
200°F
250°F
300°F
Methane
CH4
16.043
8.23
8.42
8.46
8.65
8.95
9.28
9.64
10.01
Ethyne (Acetylene)
C2H2
26.038
9.68
10.22
10.33
10.71
11.15
11.55
11.90
12.22
Ethene (Ethylene)
C2H4
28.054
9.33
10.02
10.16
10.72
11.41
12.09
12.76
13.41
Ethane
C2H6
30.070
11.44
12.17
12.32
12.95
13.78
14.63
15.49
16.34
Propene (Propylene)
C3H6
42.081
13.63
14.69
14.90
15.75
16.80
17.85
18.88
19.89
Propane
C3H8
44.097
15.65
16.88
17.13
18.17
19.52
20.89
22.25
23.56
1-Butene (Butlyene)
C4H8
56.108
17.96
19.59
19.91
21.18
22.74
24.26
25.73
27.16
cis-2-Butene
C4H8
56.108
16.54
18.04
18.34
19.54
21.04
22.53
24.01
25.47
trans-2-Butene
C4H8
56.108
18.84
20.23
20.50
21.61
23.00
24.37
25.73
27.07
iso-Butane
C4H10
58.123
20.40
22.15
22.51
23.95
25.77
27.59
29.39
31.11
n-Butane
C4H10
58.123
20.80
22.38
22.72
24.08
25.81
27.55
29.23
30.90
iso-Pentane
C5H12
72.150
24.94
27.17
27.61
29.42
31.66
33.87
36.03
38.14
n-Pentane
C5H12
72.150
25.64
27.61
28.02
29.71
31.86
33.99
36.08
38.13
Benzene
C6H6
78.114
16.41
18.41
18.78
20.46
22.45
24.46
26.34
28.15
n-Hexane
C6H14
86.177
30.17
32.78
33.30
35.37
37.93
40.45
42.94
45.36
n-Heptane
C7H16
100.204
34.96
38.00
38.61
41.01
44.00
46.94
49.81
52.61
Ammonia
NH3
17.0305
8.52
8.52
8.52
8.52
8.52
8.53
8.53
8.53
Air
28.9625
6.94
6.95
6.95
6.96
6.97
6.99
7.01
7.03
H2O
18.0153
7.98
8.00
8.01
8.03
8.07
8.12
8.17
8.23
Oxygen
O2
31.9988
6.97
6.99
7.00
7.03
7.07
7.12
7.17
7.23
Nitrogen
N2
28.0134
6.95
6.95
6.95
6.96
6.96
6.97
6.98
7.00
Hydrogen
H2
2.0159
6.78
6.86
6.87
6.91
6.94
6.95
6.97
6.98
Water
Hydrogen sulfide
H2S
34.08
8.00
8.09
8.11
8.18
8.27
8.36
8.46
8.55
Carbon monoxide
CO
28.010
6.95
6.96
6.96
6.96
6.97
6.99
7.01
7.03
Carbon dioxide
CO2
44.010
8.38
8.70
8.76
9.00
9.29
9.56
9.81
10.05
* Exceptions: Air — Keenan and Keyes, Thermodynamic Properties of Air, Wiley, 3rd Printing 1947. Ammonia — Edw. R. Grabl, Thermodynamic Properties of Ammonia at High Temperatures and Pressures, Petr. Processing, April 1953. Hydrogen Sulfide — J. R. West, Chem. Eng. Progress, 44, 287, 1948.
FIG. 13-7 Calculation of k Determination of mixture mol weight
Example gas mixture
Determination of MCp, Molar heat capacity
Mol fraction y
Individual Component Mol weight MW
methane
0.9216
16.04
14.782
8.95
8.248
666
615.6
343
316.1
ethane
0.0488
30.07
1.467
13.78
0.672
707
34.6
550
26.8
propane
0.0185
44.10
0.816
19.52
0.361
616
11.4
666
12.3
Component name
Individual Component MCp @ 150°F*
Determination of pseudo critical pressure, pPc, and temperature, pT c
p
@ 150°F
Component critical pressure Pc psia
Component critical temperature Tc°R
c
i-butane
0.0039
58.12
0.227
25.77
0.101
528
2.1
734
2.9
n-butane
0.0055
58.12
0.320
25.81
0.142
551
3.0
765
4.2
i-pentane
0.0017
72.15
0.123
31.66
0.054
490
0.8
829
Total
1.0000
MW =
17.735
MC p =
MCv = MCp – 1.986 = 7.592
9.578
pPc =
667.5
1.4 pTc =
363.7
k = MC p/MCv = 9.578/7.592 = 1.26
*For values of MCp other than @ 150°F, refer to Fig. 13-6
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ing degrees. The degree in which any gas varies from the ideal is expressed by a compressibility factor, Z, which modifies the ideal gas equation:
FIG. 13-8 Approximate Heat-Capacity Ratios of Hydrocarbon Gases
to
PV = nRT
Eq 13-5
PV = nZRT
Eq 13-6
Compressibility factors can be determined from charts in Section 23 using the pPR and pTR of the gas mixture. For pure components such as propane, compressibility factors can be determined from the P-H diagrams, although the user would be better advised to determine the compression horsepower using the P-H diagram (see Section 24). For the purpose of performance calculations, compressor capacity is expressed as the actual volumetric quantity of gas at the inlet to each stage of compression on a per minute basis (ICFM). From SCFM Q = SCFM
520 P Z 14.7
T1 Z1 1
Eq 13-7
L
From weight flow (w, lb/min) Q=
10.73 wT1 Z1 MW P1 ZL
Eq 13-8
From molar flow (Nm, mols/min)
379.5 14.7 Q= 520
NmT1 Z1 P1 ZL
Eq 13-9
From these equations, inlet volume to any stage may be calculated by using the inlet pressure P1 and temperature T1. Moisture should be handled just as any other component in the gas.
range; likewise, use a factor in the range of 16 to 18 for compression ratios between 1.5 and 2.0. Curves are available which permit easy estimation of approximate compression-horsepower requirements. Fig. 13-9 is typical of these curves.
In a reciprocating compressor, effective capacity may be calculated as the piston displacement (generally in cu ft/min) multiplied by the volumetric efficiency.
Example 13-1 — Compress 2 MMcfd of gas at 14.4 psia and intake temperature through a compression ratio of 9 in a 2-stage compressor. What will be the horsepower?
The piston displacement is equal to the net piston area multiplied by the length of piston sweep in a given period of time. This displacement may be expressed:
Solution Steps
For a single-acting piston compressing on the outer end only, (stroke) (N) (D2) PD = (4) (1728)
From Equation 13-4 we find the brake horsepower to be: (22) (3) (2) (2) (1.08) = 285 BHP
Eq 13-10
= 4.55 (10 –4) (stroke) (N) (D2)
From Fig. 13-9, using a k of 1.15, we find the horsepower requirement to be 136 BHP/MMcfd or 272 BHP. For a k of 1.4, the power requirement would be 147 BHP/MMcfd or 294 total horsepower.
For a single-acting piston compressing on the crank end only, (stroke) (N) (D2 – d2) PD = (4) (1728)
Eq 13-11
= 4.55 (10 –4) (stroke) (N) (D2 – d2)
The two procedures give reasonable agreement, particularly considering the simplifying assumptions necessary in reducing compressor horsepower calculations to such a simple procedure.
For a double-acting piston (other than tail rod type), (stroke) (N) (2 D2 – d2) PD = (4) (1728)
Detailed Calculations There are many variables which enter into the precise calculation of compressor performance. Generalized data as given in this section are based upon the averaging of many criteria. The results obtained from these calculations, therefore, must be considered as close approximations to true compressor performance.
Eq 13-12
= 4.55 (10 –4) (stroke) (N) (2 D2 – d2)
Volumetric Efficiency In a reciprocating compressor, the piston does not travel completely to the end of the cylinder at the end of the discharge stroke. Some clearance volume is necessary and it includes the space between the end of the piston and the cylinder head when
Capacity Most gases encountered in industrial compression do not exactly follow the ideal gas equation of state but differ to vary-
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FIG. 13-9 Approximate Horsepower Required to Compress Gases
the piston is at the end of its stroke. It also includes the volume in the valve ports, the volume in the suction valve guards, and the volume around the discharge valve seats.
VE = 100 – r – C
clearance volume, cu in. piston displacement, cu in.
(100)
Eq 13-13
For double acting cylinders, the percent clearance is based on the total clearance volume for both the head end and the crank end of a cylinder. These two clearance volumes are not the same due to the presence of the piston rod in the crank end of the cylinder. Sometimes additional clearance volume (external) is intentionally added to reduce cylinder capacity.
Eq 13-14
One method for accounting for suction and discharge valve losses is to reduce the volumetric efficiency by an arbitrary amount, typically 4%, thus modifying Equation 13-14 as follows:
The term “volumetric efficiency” refers to the actual pumping capacity of a cylinder compared to the piston displacement. Without a clearance volume for the gas to expand and delay the opening of the suction valve(s), the cylinder could deliver its entire piston displacement as gas capacity. The effect of the gas contained in the clearance volume on the pumping capacity of a cylinder can be represented by:
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Volumetric efficiencies as determined by Equation 13-14 are theoretical in that they do not account for suction and discharge valve losses. The suction and discharge valves are actually spring-loaded check valves that permit flow in one direction only. The valve springs require a small differential pressure to open. For this reason, the pressure within the cylinder at the end of the suction stroke is lower than the line suction pressure and, likewise, the pressure at the end of the discharge stroke is higher than line discharge pressure.
Clearance volume is usually expressed as a percent of piston displacement and referred to as percent clearance, or cylinder clearance, C. C=
Zs (r1/k) – 1 Zd
VE = 96 – r – C
Zs Zd
(r1/k) – 1
Eq 13-15
When a non-lubricated compressor is used, the volumetric efficiency should be corrected by subtracting an additional 5% for slippage of gas. This is a capacity correction only and, as a
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first approximation, would not be considered when calculating compressor horsepower. The energy of compression is used by the gas even though the gas slips by the rings and is not discharged from the cylinder.
The horsepower rating of a compressor frame is an indicator of the supporting structure and crankshaft to withstand the torque (turning force) and the loads. Rod loads are established to limit the static and dynamic loads on the frame, crankshaft, connecting rod, frame, crosshead, piston rod, bolting, and pro jected bearing surfaces.
If the compressor is in propane, or similar heavy gas service, an additional 4% should be subtracted from the volumetric efficiency. These deductions for non-lubricated and propane performance are both approximate and, if both apply, cumulative.
Rod loads are calculated differently based upon the compressor manufacturer. Some manufacturers use flange-to-flange pressures while others use internal pressures and others may se combined rod loads (gas load plus inertia load).
Volumetric efficiencies for “high speed” separable compressors in the past have tended to be slightly lower than estimated from Equation 13-14. Recent information suggests that this modification is not necessary for all models of high speed compressors.
Many manufacturers also require a load reversal of the load at the crosshead pin. This load reversal is required so that lube oil can lubricate and cool the crosshead pin and bushings.
In evaluating efficiency, horsepower, volumetric efficiency, etc., the user should consider past experience with different speeds and models. Larger valve area for a given swept volume will generally lead to higher compression efficiencies.
Gas rod loadings may be calculated by the use of Equations 13-19 and 13-20. Load in compression = P d A p – Ps (A p – A r) = (Pd – Ps) A p + Ps A r Eq 13-19
Equivalent Capacity
Load in tension = Pd (A p – A r) – Ps A p
The net capacity for a compressor, in cubic feet per day @ 14.4 psia and suction temperature, may be calculated by Equation 13-16a which is shown in dimensioned form: ft min VE% PD 1440 [ [ 100 ] min] d MMcfd = 3
14.4
Ps
= (Pd – Ps) A p – Pd A r
Eq 13-20
3 lb –6 MMft Z14.4 2 10 3 in ft
lb Zs in2
Eq 13-16a
which can be simplified to Equation 13-16b when Z 14.4 is assumed to equal 1.0. MMcfd =
PD VE Ps 10 –6 Zs
Eq 13-16b
For example, a compressor with 200 cu ft/min piston displacement, a volumetric efficiency of 80%, a suction pressure of 75 psia, and suction compressibility of 0.9 would have a capacity of 1.33 MMcfd at 14.4 psia. If compressibility is not used as a divisor in calculating cu ft/min, then the statement “not corrected for compressibility” should be added.
Using Equations 13-19 and 13-20, a plus value for the load in both compression and tension indicates a reversal of loads based on gas pressure only. Inertial effects will tend to increase the degree of reversal.
In many instances the gas sales contract or regulation will specify some other measurement standard for gas volume. To convert volumes calculated using Equation 13-16 (i.e. at 14.4 psia and suction temperature) to a P L and TL basis, Equation 13-17 would be used: MMscfd at PL, TL = (MMcfd from Eq 13-16)
14.4 TL ZL PL T s Zs
Eq 13-17
Discharge Temperature
The true rod loads would be those calculated using internal cylinder pressures after allowance for valve losses. Normally, the operator will know only line pressures, and because of this, manufacturers generally rate their compressors based on linepressure calculations.
The temperature of the gas discharged from the cylinder can be estimated from Equation 13-18, which is commonly used but not recommended. (Note: the temperatures are in absolute units, °R or K.) Equation 13-32 gives better results. Td = Ts (r(k –1)/k)
A further refinement in the rod-loading calculation would be to include inertial forces. While the manufacturer may consider inertial forces when rating compressors, useful data on this point is seldom available in the field. Except in special cases, inertial forces are ignored.
Eq 13-18
The discharge temperature determined from Equation 1318 is the theoretical value. It neglects heat from friction, irreversibility effects, etc., and is therefore too low,
Rod Loading
A tail-rod cylinder would require consideration of rod crosssection area on both sides of the piston instead of on only one side of the piston, as in Equations 13-19 and 13-20.
Each compressor frame has definite limitations as to maximum load-carrying capacity. The load-carrying of a compressor involves two primary considerations: rod loading and horsepower.
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2.
100 psia x 3 = 300 psia (1st stage discharge pressure). Suction pressure to second stage is given by 300 psia – 5 = 295 psia Where the 5 psi represents the pressure drop between first stage discharge and second stage suction. 900 psia = 3.05 (compression ratio for 2nd stage) 295 psia
Detailed Horsepower Calculation
It may be desirable to recalculate the interstage pressure to balance the ratios. For this sample problem, however, the first ratios determined will be used.
A more detailed calculation of reciprocating compressor power requirements can be performed using th e following equation: BHP/stage = 3.03 Zavg [QgTs/E] (k/(k-1)) [(Pd/Ps)
((k–1)/k)
–1]
3.
From Fig. 13-8 a gas with specific gravity of 0.8 at 150°F would have an approximate k of 1.21. For most compression applications, the 150°F curve will be adequate. This should be checked after determining the average cylinder temperature.
4.
Discharge temperature for the 1st stage may be obtained by using Fig. 13-32 or solving Equation 13-18. For a compression ratio of 3, discharge temperature = approximately 220°F. Average cylinder temperature = 160°F.
5.
In the same manner, discharge temperature for the second stage (with r = 3.05 and assuming interstage cooling to 120°F) equals approximately 244°F. Average cylinder temperature = 182°F.
6.
From the physical properties section (Section 23), estimate the compressibility factors at suction and discharge pressure and temperature of each stage.
PL TL
Eq 13-21
The total horsepower for the compressor is the sum of the horsepower required for each of the stages that are utilized. For multistage machines an allowance should be made for the interstage pressure drop associated with piping, cooler, scrubber, etc., typically 5–10 psi. Procedure 1.
Calculate overall compression ratio (rt = Pdfinal/Ps).
2.
Calculate the compression ratio per stage, r, by taking the s root of rt, where s is the number of compression stages. The number of stages, s, should be increased until the ratio per stage, r, is < ~ 4. This should generally result in stage discharge temperatures of < 300°F depending on the interstage cooler outlet temperature assumed.
1st stage:
Zs =
0.98
Zd =
0.97
3.
Multiplying r by the absolute suction pressure of the stage being considered will give you discharge pressure of the stage.
Zavg =
4.
Calculate the horsepower required for the stage using Equation 13-21.
2nd stage: Zs =
0.94
Zd =
0.92
5.
Subt r ac t the assumed interstage pressure loss from the discharge pressure of the preceding stage to obtain the suction pressure for the next stage.
Zavg =
0.93
6.
Repeat steps 4 and 5 until all stages have been calculated.
7.
Sum the stage horsepowers to obtain the total compressor power required.
7.
Calculate the horsepower required for the first and second stages from Equation 13-21:
BHP for 1st stage = 3.03 (0.975) [2 560/0.82] 14.65 [1.21/(1.21 – 1)] [(300/100)((1.21 – 1)/1.21) – 1] 520 = 137.6
Example 13-2 — Compress 2 MMscfd of gas measured at 14.65 psia and 60°F. Intake pressure is 100 psia, and intake temperature is 100°F. Discharge pressure is 900 psia. The gas has a specific gravity of 0.80 (23 MW). What is the required brake horsepower, assuming a high speed compressor?
BHP for 2nd stage = 3.03 (0.93) [2 580/0.82] 14.65 [1.21/(1.21 – 1)] [(900/295)((1.21 – 1)/1.21) – 1] 520 = 138.2
Assume E = 0.82 1.
0.975
Total BHP required = 137.6 + 138.2 = 275.8
Compression ratio is Note that in Example 13-1 the same conditions result in a compression power of 285 BHP which is close agreement.
900 psia =9 100 psia This would be a two-stage compressor; therefore, the ratio
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Limits to compression ratio per stage — The maximum ratio of compression permissible in one stage is usually limited by the discharge temperature or by rod loading.
to either form or line the pressure wall. There are two types. The wet liner forms the pressure wall as well as the inside wall of the water jacket. The dry type lines the cylinder wall and is not required to add strength.
When handling gases containing oxygen, which could support combustion, there is a possibility of fire and explosion because of the oil vapors present.
Standard cylinder liners are cast iron. If cylinders are required to have special corrosion or wear resistance, other materials or special alloys may be needed.
To reduce carbonization of the oil and the danger of fires, a safe operating limit may be considered to be approximately 300°F. Where no oxygen is present in the gas stream, temperatures of 350°F may be considered as the maximum, even though mechanical or process requirements usually dictate a lower figure.
Most compressors use oils to lubricate the cylinder with a mechanical, force-feed lubricator having one or more feeds to each cylinder. The non-lubricated compressor has found wide application where it is desirable or essential to compress air or gas without contaminating it with lubricating oil.
Packing life may be significantly shortened by the dual requirement to seal both high pressure and high temperature gases. For this reason, at higher discharge pressures, a temperature closer to 250°F or 275°F may be the practical limit.
For such cases a number of manufacturers furnish a “nonlubricated” cylinder (Fig. 13-13). Non-metallic packing seal rings of a type that requires no lubricant is used on the stuffing box. Although oilwiper rings are used on the piston rod where it leaves the compressor frame, minute quantities of oil might conceivably enter the cylinder on the rod. Where even such small amounts of oil are objectionable, an extended cylinder connecting piece can be furnished. This simply lengthens the piston rod so that no lubricated portion of the rod enters the cylinder.
In summary, and for most field applications, the use of 300°F maximum would be a good average. Recognition of the above variables is, however, still useful. Economic considerations are also involved because a high ratio of compression will mean a low volumetric efficiency and require a larger cylinder to produce the same capacity. For this reason a high rod loading may result and require a heavier and more expensive frame.
A small amount of gas leaking through the packing can be objectionable. Special distance pieces are furnished between the cylinder and frame, which may be either single-compartment or double-compartment. These may be furnished gas tight and vented back to the suction, or may be filled with a sealing gas or fluid and held under a slight pressure, or simply vented.
Where multi-stage operation is involved, equal ratios of compression per stage are used (plus an allowance for piping and cooler losses if necessary) unless otherwise required by process design. For two stages of compression the ratio per stage would approximately equal the square root of the total compression ratio; for three stages, the cube root, etc. In practice, especially in high-pressure work, decreasing the compression ratio in the higher stages to reduce excessive rod loading may prove to be advantageous.
Compressor valves for non-lubricated service operate in an environment that has no lubricant in the gas or in the cylinder. Therefore, the selection of valve materials is important to prevent excessive wear.
Cylinder Design
Piston rod packing universally used in non-lubricated compressors is of the full-floating mechanical type, consisting of a case containing pairs of non-metallic rings of conventional design.
Depending on the size of the machine and the number of stages, reciprocating compressors are furnished with cylinders fitted with either single- or double-acting pistons, see examples in Figs. 13-10 through 13-12. In the same units, double-acting pistons are commonly used in the first stages and occasionally single-acting in the higher stages of compression.
When handling oxygen and other gases such as nitrogen and helium, it is absolutely necessary that all traces of hydrocarbons in cylinders be removed. With oxygen, this is required for safety, with other gases to prevent system contamination.
Cylinder materials are normally selected for strength; however, thermal shock, mechanical shock, or corrosion resistance may also be a determining factor. The table below shows discharge pressure limits generally used in the gas industry for cylinder material selection.
High-pressure compressors with discharge pressures from 5,000 to 30,000 psi usually require special design and a complete knowledge of the characteristics of the gas.
Cylinder Material
Discharge Pressure (psig)
Cast Iron
up to 1,200
Nodular Iron
about 2,500
Cast Steel
1,200 to 3,000
Forged Steel
above 2,500
As a rule, inlet and discharge gas pipe connections on the cylinder are fitted with flanges of the same rating for the following reasons: Practicality and uniformity of casting and machinery, Hydrostatic test, usually at 150% design pressure, Suction pulsation bottles are usually designed for the same pressure as the discharge bottle (often federal, state, or local government regulation).
API standard 618 recommends 1000 psig as the maximum pressure for both cast iron and nodular iron.
Reciprocating Compressor Control Devices
Cylinders are designed both as a solid body (no liner) and with liners. Cylinder liners are inserted into the cylinder body
Output of compressors must be controlled (regulated) to match system demand.
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FIG. 13-10 Low Pressure Cylinder with Double-Acting Piston
FIG. 13-11
FIG. 13-12
High Pressure Cylinder with Double-Acting
Single-Acting Plunger Cylinder Designed for
Piston and Tail-Rod
15,000 psig Discharge
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Automatic-start-and-stop control, as its name implies, stops or starts the compressor by means of a pressure-actuated switch as the gas demand varies. It should be used only when the demand for gas will be intermittent.
FIG. 13-13 Piston Equipped with Teflon ® Piston and Wear Rings for a Single-acting Non-Lubricated Cylinder
Constant-speed control permits the compressor to operate at full speed continuously, but loaded part of the time and fully or partially unloaded at other times. Two methods of unloading the compressor with this type of control are in common use: inletvalve unloaders, and clearance unloaders. Inlet-valve unloaders (Fig. 13-14) operate to hold the compressor inlet valves open and thereby prevent compression. Clearance unloaders (Fig. 13-15) consist of pockets or small reservoirs which are opened when unloading is desired. The gas is compressed into them on the compression stroke and expands back into the cylinder on the return stroke, reducing the intake of additional gas. Motor-driven reciprocating compressors above 100 hp in size are usually equipped with a step control. This is in reality a variation of constant-speed control in which unloading is accomplished in a series of steps, varying from full load down to no load. Five-step control (full load, three-quarter load, one-half load, one-quarter load, and no load) is accomplished by means of clearance pockets. On some makes of machines inlet-valve and clearance control unloading are used in combination. A common practice in the natural gas industry is to prepare a single set of curves for a given machine unless there are side loads or it is a multi-service machine.
In many installations some means of controlling the output of the compressor is necessary. Often constant flow or a specific power is required despite variations in operating conditions. Compressor capacity, speed, or pressure may be varied in accordance with the requirements. The nature of the control device will depend on the regulating variable — whether pressure, flow, temperature, or some other variable — and on type of compressor driver.
Fig. 13-16 shows indicator cards which demonstrate the unloading operation for a double acting cylinder at three capacity points. The letters adjacent to the low-pressure diagrams represent the unloading influence of the respective and cumulative effect of the various pockets as identified in Fig. 13-15. Full load, one-half, and no load capacity (used for start-up only) is obtained by holding corresponding suction valves open or adding sufficient clearance to produce a zero volumetric efficiency. Zero-capacity operation includes holding all suction valves open.
Unloading for Starting — Practically all reciprocating compressors must be unloaded to some degree before starting so that the driver torque available during acceleration is not exceeded. Both manual and automatic compressor startup unloading is used. Common methods of unloading include: discharge venting, discharge to suction bypass, and holding open the inlet valves using valve lifters.
Fig. 13-17 shows an alternative representation of compressor unloading operation with a step-control using fixed volume clearance pockets. The curve illustrates the relationship between compressor capacity and driver capacity for a varying compressor suction pressure at a constant discharge pressure and constant speed. The driver can be a gas engine or electric motor.
Capacity Control — Capacity control is required to either regulate capacity or maintain the compressor load within the driver rating. Capacity control devices/unloading devices can be manually actuated or actuated by air or gas pressure depending on their design. A falling pressure indicates that gas is being used faster than it is being compressed and that more gas is required. A rising pressure indicates that more gas is being compressed than is being used downstream and that less gas is required.
The purpose of this curve is to determine what steps of unloading are required to prevent the driver and piston rods from serious overloading. All lines are plotted for a single stage compressor.
A common method of controlling the capacity of a compressor is to vary the speed. This method is applicable to variable frequency drive (VFD) electric motor driven compressors and to units driven by internal combustion engines. In these cases the regulator actuates the VFD controller or fuel-admission valve on the compressor driver to control the speed.
The driver capacity line indicates the maximum allowable capacity for a given horsepower. The cylinder capacity lines represent the range of pressures calculated with all possible combinations of pockets open, as necessary, to cover the capacity of the driver. Starting at the end (line 0-0) with full cylinder capacity, the line is traced until it crosses the driver capacity line at which point it is dropped to the next largest cylinder capacity and follow until it crosses the driver line, etc. This will produce a “saw tooth” effect, hence the name “saw tooth” curve. The number of “teeth” depends upon the number of combinations of pockets (opened or closed) required for unloading. If suction valves were also unloaded then there would be more “teeth” on the curve.
Electric motor-driven compressors usually operate at constant speed, although variable speed drives are becoming increasingly more common. For constant speed motors other methods of controlling the capacity are necessary. On reciprocating compressors up to about 100 hp, two types of control are usually available. These are automatic-start-and-stop control and constant-speed control.
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The same method is followed for multi-stage units. For each additional stage another “saw tooth” curve must be constructed, i.e., for a two stage application, two curves are required to attain the final results.
There are several types of pulsation chambers. The simplest one is a volume bottle, or a surge drum, which is a pressure vessel, unbaffled internally and mounted on or very near a cylinder inlet or outlet.
Although control devices are often automatically operated, manual operation is satisfactory for many services. Where manual operation is provided, it often consists of a valve, or valves, to open and close clearance pockets. In some cases, a movable cylinder head is provided for variable clearance in the cylinder (Fig. 13-18).
FIG. 13-16 Indicator Diagram for Three Load Points of Operation
Gas Pulsation Control
Pulsation is inherent in reciprocating compressors because suction and discharge valves are open during only part of the stroke.
due to overshoot & undershoot
Pulsation must be damped (minimized) in order to: a.
provide smooth flow of gas to and from the compressor,
b.
prevent overloading or underloading of the compressors, and
c.
reduce overall vibration.
Undershoot
FIG. 13-14 Inlet Valve Unloader
and all suction valves unloaded during start-up only
FIG. 13-17 “Saw Tooth” Curve for Unloading Operation FIG. 13-15 Pneumatic Actuated Valves Controlling Four Fixed Pockets in Compressor for Five-Step Control
s n o i t i d n o C d r a d n a t S t a y t i c a p a C
Constant Discharge Pressure and Speed
A open
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A/B open
A/B/C open
A/B/C/D open
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A manifold joining the inlet and discharge connections of cylinders operating in parallel can also serve as a volume bottle.
At 600 psi inlet pressure, the suction bottle multiplier is approximately 7.5. Suction-bottle volume = (7.5) (424) = 3,180 cu in.
Performance of volume bottles is not normally guaranteed without an analysis of the piping system from the compressor to the first process vessel.
NOTE: When more than one cylinder is connected to a bottle, the sum of the individual swept volumes is the size required for the common bottle.
Volume bottles are sized empirically to provide an adequate volume to absorb most of the pulsation. Several industry methods were tried in an effort to produce a reasonable rule-ofthumb for their sizing. Fig. 13-19 may be used for approximate bottle sizing.
For more accurate sizing, compressor manufacturers can be consulted. Organizations which provide designs and/or equipment for gas-pulsation control are also available. Having determined the necessary volume of the bottle, the proportioning of diameter and length to provide this volume requires some ingenuity and judgment. It is desirable that manifolds be as short and of as large diameter as is consistent with pressure conditions, space limitations, and appearance.
Example 13-3 Indicated suction pressure = 600 psia Indicated discharge pressure = 1400 psia
A good general rule is to make the manifold diameter 1-1/2 times the inside diameter of the largest cylinder connected to it, but this is not always practicable, particularly where large cylinders are involved.
Cylinder bore = 6 in Cylinder stroke = 15 in 2
/4) (15) = 424 cu in
Inside diameter of pipe must be used in figuring manifolds. This is particularly important in high-pressure work and in small sizes where wall thickness may be a considerable percentage of the cross sectional area. Minimum manifold length is
From Fig. 13-19:
FIG. 13-18 Sectional View of a Cylinder Equipped with a Hand-Operated Valve Lifter and Variable-Volume Clearance
FIG. 13-19 Approximate Bottle Sizing Chart
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determined from cylinder center distances and connecting pipe diameters. Some additions must be made to the minimum thus determined to allow for saddle reinforcements and for welding of caps.
Torsional Analysis
It is customary to close the ends of manifolds with welding caps which add both volume and length. Fig. 13-20 gives approximate volume and length of standard caps.
inertia and gas loads from the pistons in a reciprocating compressor or engine; or
All rotating equipmen t experiences a torsional load. Examples of torsional loads are:
the torque fluctuations from a synchronous motor during startup.
Pulsation Dampeners (Snubbers)
A complete drive train (for example reciprocating compressor, coupling, and an electric motor) will have torsional natural frequencies. Those torsional natural frequencies are analogous to mechanical natural frequencies of piping or the compressor shaft. For the mechanical natural frequency, the deflection occurs in a horizontal or vertical direction. For a torsional natural frequency, the deflection is a twisting about the axis of the shaft. Consider fixing one end of a shaft and twisting the free end; when released the shaft will rotate back and forth. The frequency of the oscillation is the torsional natural frequency.
A pulsation dampener is an internally-baffled device. The design of the pulsation dampening equipment is based on an acoustical study which takes into account the specified operating speed range, conditions of unloading, and variations in gas composition. Analog evaluation is accomplished with an active analog that simulates the entire compressor, pulsation dampeners, piping and equipment system and considers dynamic interactions among these elements.
When the system is started and the compressor is loaded what is the impact? Typically the torsional loads will happen at run speed and harmonics. If a torsional natural frequency occurs near a frequency where there is significant torsional energy, the results can be catastrophic! Destroyed coupling, broken compressor shaft or broken motor shaft are potential consequences of torsional resonance. The cost of repair can be large, but the downtime and cost of having the unit unavailable for 1-2 months is often much larger.
Pulsation dampeners also should be mounted as close as possible to the cylinder, and in large volume units, nozzles should be located near the center of the chamber to reduce unbalanced forces. Pulsation dampeners are typically guaranteed for a maximum residual peak-to-peak pulsation pressure of 2% of average absolute pressure at the point of connection to the piping system, and pressure drop through the equipment of not more than 1% of the absolute pressure. This applies at design condition and not necessarily for other operating pressures and flows. A detailed discussion of recommended design approaches for pulsation suppression devices is presented in API Standard 618, Reciprocating Compressors for General Refinery Services.
A torsional failure will typically occur without warning. The vibration sensors installed at bearings or on component frames are designed to detect lateral (horizontal or vertical) vibrations, and will not detect torsional problems. The best insurance against a torsional failure is a design study before a unit is built.
As pressure vessels, all pulsation chambers (volume bottles and dampeners) are generally built to Section VIII of ASME Code and suitable for applicable cylinder relief valve set pressure.
A design study will consider each component and the role it plays in the torsional system. Manufacturing tolerances, installation differences, and loading all play a critical part in the system’s ability to operate without failure. As well as the normal operating loads, the torsional analysis should consider the loads of other operating scenarios, such as compressor valve failures (upset) or the unit startup (transient).
Suction pulsation chambers are often designed for the same pressure as the discharge units, or for a minimum of 2/3 of the design discharge pressure.
FIG. 13-20 Welding Caps
Pipe size 4" 6"
Standard weight
Extra strong
Volume, cu in.
Length, in.
24.2
2
1
3
1
11
77.3
Volume, cu in.
Length, in. 2
1
3
1
122.3
4
11
20.0 2
Double Extra strong
65.7
15
3
2
48
4
120
5
148.5
4
10"
295.6
53 4
264.4
53 4
12"
517.0
67 8
475.0
67 8
14"
684.6
7 13 16
640.0
713 16
16"
967.6
9
911.0
9 10 1 16
11 1 4
1938.0
11 1 4
13 7 16
3313.0
13 7 16
1432.6
10
20"
2026.4
24"
3451.0
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16
1363.0
18"
1
16
86
Length, in.
2
8"
16
Volume, cu in.
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With early involvement by designers, the system can be modified. Changing the coupling size or style, adding a flywheel, changing shaft material or size are all easily done if the components have not been built. Modifications to a system that is already built can be expensive and may require re-design. If this occurs, delivery of the unit will be delayed.
Fig. 13-22 efficiency values should be used as a reference only. The efficiencies of centrifugal compressors rely on the ability to select optimized impeller flow coefficients fo r the specified process conditions, and will deteriorate for non-optimal impeller flow coefficients and high compression ratios or compressors with more than 4–5 impellers.
Torsional design analyses should be done on all new units unless there is successful operating experience with a similarly configured compressor (the same compressor frame, cylinders, staging, coupling and driver) and similar operating conditions (the same pressures, temperatures and load steps). Consideration should be given to doing a torsional analysis on existing units where the operating conditions will be changed significantly from the existing conditions, and especially if the unit is being restaged.
These efficiencies reflect compressor designs after say 1998; in general earlier designs could be 4% lower in efficiency. Most centrifugal compressors operate at speeds of 3,000 rpm or higher, a limiting factor being impeller stress considerations as well as velocity limitation of 0.8 to 0.85 Mach number at the impeller tip and eye. Recent advances in machine design have resulted in production of some units running at spee ds in excess of 40,000 rpm. Centrifugal compressors are usually driven by electric motors, steam or gas turbines (with or without speed-increasing gears), or turboexpanders.
Troubleshooting Minor troubles can normally be expected at various times during routine operation of the compressor. These troubles are most often traced to dirt, liquid, and maladjustment, or to operating personnel being unfamiliar with functions of the various machine parts and systems. Difficulties of this type can usually be corrected by cleaning, proper adjustment, elimination of an adverse condition, or quick replacement of a relatively minor part.
There is an overlap of centrifugal and reciprocating compressors on the low end of the flow range, see Fig.13-3. On the higher end of the flow range an overlap with the axial compressor exists. The extent of this overlap depends on a number of things. Before a technical decision could be reached as to the type of compressor that would be installed, the service, operational requirements, and economics would have to be considered.
Major trouble can usually be traced to long periods of operation with unsuitable coolant or lubrication, careless operation and inadequate maintenance, or the use of the machine on a service for which it was not intended.
Design requirements for centrifugal compressors are covered by API Standard 617.
Components of Centrifugal Compressors
A defective inlet valve can generally be foun d by feeling the valve cover. It will be much warmer than normal. Discharge valve leakage is not as easy to detect since the discharge is always hot. Experienced operators of water-cooled units can usually tell by feel if a particular valve is leaking. The best indication of discharge valve trouble is the discharge temperature. This will rise, sometimes rapidly, when a valve is in poor condition or breaks. This is one very good reason for keeping a record of the discharge temperature from each cylinder.
Figs. 13-23 through 13-25 provide cross sectional drawings and identification of major components for typical centrifugal compressors. The essential components of a centrifugal compressor that accomplish the compression task are described in the following text referring to Figure 13-24. The gas entering the inlet nozzle of the compressor is guided (often with the help of guide vanes) to the inlet of the impeller. An impeller consists of a number of rotating vanes that impart mechanical energy to the gas. As we will see later, the gas will leave the impeller with an increased velocity and increased static pressure. In the diffuser, part of the velocity is converted into static pressure. Diffusers can be vaneless or contain a number of vanes. If the compressor has more than one impeller, the gas will be again brought in front of the next impeller through the return channel and the return vanes. If the compressor has only one impeller, or after the diffuser of the last impeller in a multi stage compressor, the gas enters the discharge system. The discharge system can either make use of a volute, which can further convert velocity into static pressure, or a simple cavity that collects the gas before it exits the compressor through the discharge nozzle.
Recording of the interstage pressure on multistage units is valuable because any variation, when operating at a given load point, indicates trouble in one or the other of the two stages. If the pressure drops, the trouble is in the low pressure cylinder. If it rises, the problem is in the high pressure cylinder. Troubleshooting is largely a matter of elimination based on a thorough knowledge of the interrelated functions of the various parts and the effects of adverse conditions. A complete list of possible troubles with their causes and corrections is impractical, but the following list of the more frequently encountered troubles and their causes is offered as a guide (Fig. 13-21).
The rotating part of the compressor consists of all the impellers. This rotor runs on two radial bearings (on all modern compressors, these are hydrodynamic tilting pad bearings), while the axial thrust generated by the impellers is balanced by a balance piston, and the resulting force is balanced by a hydrodynamic tilting pad thrust bearing.
CENTRIFUGAL COMPRESSORS This section is intended to supply information sufficiently accurate to determine whether a centrifugal compressor should be considered for a specific job. The secondary objective is to present information for evaluating compressor performance. Fig. 13-22 gives an approximate idea of the flow range that a centrifugal compressor will handle. A multi-wheel (multistage) centrifugal compressor is normally considered for inlet volumes between 500 and 200,000 inlet acfm. A single-wheel (single stage) compressor would normally have application between 100 and 150,000 inlet volume. A multiwheel compressor can be thought of as a series of single wheel compressors contained in a single casing.
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To keep the gas from escaping at the shaft ends, dry gas seals are typically used on both shaft ends. Other seal types have been used in the past, but virtually all modern centrifugal compressors used in the oil and gas industry use dry gas seals. Refer to the Dry Gas Seals discussion for additional information.
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The entire assembly is contained in a casing. For discharge pressures below about 3400 kPa (500 psi), the casing is horizontally split to allow the installation of the rotating components. For higher pressures, the compressors are usually of the barrel type. The pressure containing casing, consists of a center body with end caps on either end. Bearings, seals, shaft and aerodynamic components (both rotating and stationary) can slide in and out of the center body once one of the endcaps is removed (Fig 13-25).
The centrifugal compressor approximates the constant headvariable volume machine, while the reciprocating is a constant volume-variable head machine. The axial compressor, which is a low head, high flow machine, falls somewhere in between. A compressor is a part of the system, and its performance is dictated by the system resistance. The desired system capability or objective must be determined before a compressor can be selected. Fig. 13-27 is a typical performance map which shows the basic shape of performance curves for a variable-speed centrifugal compressor. The curves are affected by many variables, such as desired compression ratio, type of gas, number of wheels, sizing of compressor, etc.
Performance Calculations The operating characteristics must be determined before an evaluation of compressor suitability for the application can be made. Fig. 13-26 gives a rough comparison of the characteristics of the axial, centrifugal, and reciprocating compressor.
FIG. 13-21 Probable Causes of Reciprocating Compressor Trouble Trouble Compressor Will not Start
Motor Will Not Synchronize
Low Oil Pressure
Noise In Cylinder
Excessive Packing Leakage
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Probable Cause(s)
Trouble
1. Power supply failure. 2. Switchgear or starting panel. 3. Low oil pressure shutdown switch. 4. Control panel. 1. Low voltage. 2. Excessive starting torque. 3. Incorrect power factor. 4. Excitation voltage failure. 1. Oil pump failure. 2. Oil foaming from counterweights striking oil surface. 3. Cold oil. 4. Dirty oil filter. 5. Interior frame oil leaks. 6. Excessive leakage at bearing shim tabs and/or bearings. 7. Improper low oil-pressure switch setting. 8. Low gear oil pump by-pass/relief valve setting. 9. Defective pressure gauge. 10. Plugged oil sump strainer. 11. Defective oil relief valve. 1. Loose piston. 2. Piston hitting outer head or frame end of cylinder. 3. Loose crosshead lock nut. 4. Broken or leaking valve(s). 5. Worn or broken piston rings or expanders. 6. Valve improperly seated/damaged seat gasket. 7. Free air unloader plunger chattering. 1. Worn packing rings. 2. Improper lube oil and/or insufficient lube rate (blue rings). 3. Dirt in packing. 4. Excessive rate of pressure increase. 5. Packing rings assembled incorrectly. 6. Improper ring side- or end-gap clearance. 7. Plugged packing vent system. 8. Scored piston rod. 9. Excessive piston rod run-out.
Probable Cause(s)
Packing OverHeating
1. Lubrication failure. 2. Improper lube oil and/or insufficient lube rate. 3. Insufficient cooling.
Excessive Carbon On Valves
1. Excessive lube oil. 3. Oil carryover from inlet system or previous stage. 4. Broken or leaking valves causing high temperature. 5. Excessive temperature due to high pressure ratio across cylinders.
Relief Valve Popping
1. Faulty relief valve. 2. Leaking suction valves or rings on next higher stage. 3. Obstruction (foreign material, rags), blind or valve closed in discharge line.
High Discharge Temperature
1. Excessive compression ratio on cylinder due to leaking inlet valves or rings on next higher stage. 2. Fouled intercooler/piping. 3. Leaking discharge valves or piston rings. 4. High inlet temperature. 5. Fouled water jackets on cylinder. 6. Improper lube oil and/or lube rate.
Frame Knocks
1. Loose crosshead pin, pin caps or crosshead shoes. 2. Loose/worn main, crankpin or crosshead bearings. 3. Low oil pressure. 4. Cold oil. 5. Incorrect oil. 6. Knock is actually from cylinder end.
Crankshaft Oil Seal Leaks
1. Faulty seal installation. 2. Clogged drain hole.
Piston Rod Oil Scraper Leaks
1. Worn scraper rings. 2. Scrapers incorrectly assembled. 3. Worn/scored rod. 4. Improper fit of rings to rod/side clearance. Courtesy of Ingersoll-Rand Co
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Approximate Centrifugal Compressor Flow Range
With variable speed, the centrifugal compressor can deliver constant capacity at variable pressure, variable capacity at constant pressure, or a combination variable capacity and variable pressure.
Nominal flow range (inlet acfm)
Similarity Law (Fan Law)
FIG. 13-22
Average polytropic efficiency
Average isentropic efficiency
Speed to develop 10,000 ft head/wheel
100-
500
0.68
0.65
20,500
500-
7,500
0.78
0.76
10,500
7,500- 20,000
0.84
0.81
8,200
20,000- 33,000
0.84
0.81
6,500
33,000- 55,000
0.84
0.81
4,900
55,000- 80,000
0.84
0.81
4,300
80,000-115,000
0.84
0.81
3,600
115,000-145,000
0.84
0.81
2,800
145,000-200,000
0.84
0.81
2,500
Under certain simplifying conditions, operating points of a compressor at different speeds can be compared (Kurz and Ohanian, 2003). This fact is captured in the fan law, which is strictly only true for identical Mach numbers in all stages, but which is still a good approximation for cases where the machine Mach number: MN =
u
Eq 13-22
k1Z1RT1
changes by less than 10% (for single and two stage compressors). The more stages the compressor has, the less deviation is acceptable (Kurz and Fozi, 2002). The fan law is based on the fact that if for two operating points A and B all velocities change by the same factor (which in particular means that none of the flow angles change), then the compressor will show the follow-
FIG. 13-23 Example Centrifugal Compressor Showing Nomenclature of Key Parts
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system, such as pipeline application where pressure increases with capacity.
ing relations between two different operating points : Q A N A HisA 2 N A A
= = =
QB
Eq 13-23a
Fig. 13-28 shows a higher compression ratio. The range of stable operation is reduced because of the larger compression ratio. This is indicated by the surge line in Fig. 13-28 being further to the right than in Fig. 13-27.
NB HisB
Eq 13-23b
NB2
Estimating Performance
B
and therefore GHP A GHPB = 3 N A NB3
Figs. 13-29 through 13-36 may be used for estimating compressor performance. These curves are only suitable for estimating only and are not intended to take the place of a “wheel-bywheel” selection by the compressor manufacturer, nor should the curves be used to calculate performance using field data in an attempt to determine a variance from predicted performance based on manufacturer’s data. Fig. 13-29 is used to convert scfm to icfm. All centrifugal compressors are based on flows that are converted to inlet or actual cubic feet per minute. This is done because the centrifugal wheel is sensitive to inlet volume, compression ratio (i.e., head), and specific speed.
Eq 13-24
This does not imply that the system within which the compressor operates will force the compressor to operate along the fan line. In general, the system will enforce a head and flow relationship that is not (at least not exactly) following the fan law. The intersection of the new resulting system pressure (not described by the fan law), and the new operating condition of the compressor (as described by the fan law) sets the new operating condition of the system.
Fig. 13-30 is a useful curve to find inlet (actual) cfm when the weight flow in lb/min is known. Actual cfm and inlet cfm both denote the gas at suction conditions. These terms are often used interchangeably. This curve can be used in reverse to determine mass flow.
Fig. 13-27 depicts typical performance curves with a small compression ratio. The system resistance has been superimposed on the chart: Line A represents typical system resistance of a closed system, such as a refrigeration unit where there is a relatively constant discharge pressure. Line B is an open-end
FIG. 13-24 Typical Centrifugal Compressor Cutaway
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Fig. 13-31 is used to determine the approximate discharge temperature that is produced by the compression ratio. Discharge temperatures above the 400°F range should be checked since mechanical problems as well as safety problems may exist. This curve includes compressor efficiencies in the range of 60 to 75%.
Find: Discharge temperature Answer: t2 = 230°F (approximately) from Fig. 13-31. Note: for a natural gas with k = 1.30 t2 = 480°F (excessively high). Fig. 13-33 gives the approximate horsepower required for the compression. It includes overall compressor efficiencies in the range of 60 to 70%.
Example 13-4 — Given: r = 10.0; Q1 = 10,000 icfm k = 1.15; t1 = 0°F
FIG. 13-25 Centrifugal Compressor Cross Section
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Example 13-5 — Given:
Weight flow, w, = 1,000 lb/min
FIG. 13-26
head = 70 000 ft-lb/lb
Compressor Head
Find: Horsepower Answer: GHP = 3,000 from Fig. 13-33. Fig. 13-36 predicts the approximate number of compressor wheels required to produce the head. If the number of wheels is not a whole number, use the next highest number.
Calculating Performance When more accurate information is required for compressor head, gas horsepower, and discharge temperature, the equations in this section should be used. This method applies to a gas mixture for which a P-H diagram chart is not available. To calculate the properties of the gas, see Figs. 13-6 and 13-7. All values for pressure and temperature in these calculation procedures are the absolute values. Unless otherwise specified, volumes of flow in this section are actual volumes.
FIG. 13-27
FIG. 13-28
Compressor Performance, Low Compression Ratio
Compressor Performance, Higher Compression Ratio
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FIG. 13-29 ICFM to SCFM Z=1
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FIG. 13-30 Mass Flow to Inlet Volume Flow Z=1
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FIG. 13-31 Approximate Discharge Temperature Z=1
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FIG. 13-32 Head Z=1
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FIG. 13-33 Approximate Horsepower Determination
FIG. 13-34 Efficiency Conversion
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To calculate the inlet volume: Q=
which also can be written in the form:
(w) (1,545) (T1) (Z1) (MW) (P1) (144)
Eq 13-25
Hp =
If we assume the compression to be isentropic (reversible adiabatic, constant entropy), then: His =
ZRT MW (k – 1)/k
P2 P1
(k – 1)/k
– 1
GHP =
Eq 13-26
1545 ZavgT1 P2 MW (n – 1)/n P1
(n – 1)/n
Eq 13-34b
– 1
Eq 13-35
(w) (Hp) ( p) (33,000)
Polytropic and isentropic head are related by
Since these calculations will not be wheel-by-wheel, the head will be calculated across the entire machine. For this, use the average compressibility factor:
FIG. 13-35 Mechanical Losses
Z1 + Z2 Zavg = 2
Max Flow (inlet acfm)
Casing Size
Nominal Speed (rpm)
The heat capacity ratio, k, is normally determined at the average suction and discharge temperature (see Figs. 13-7 and 13-8).
1
7,500
10,500
2
20,000
8,200
Isentropic Calculation
3
33,000
6,400
4
55,000
4,900
5
115,000
3,600
6
150,000
2,800
To calculate the head: ZavgRT1 His = MW (k – 1)/k
P2 P1
(k – 1)/k
– 1
Eq 13-27a
a. Bearing horsepower losses
which can also be written in the form: His =
1545 ZavgT1 P2 MW (k – 1)/k P1
(k – 1)/k
– 1
80 70 60 50 40
Eq 13-27b
The gas horsepower can now be calculated from: GHP =
Eq 13-28
(w) (His) ( is) (33,000)
p h
30 , s s
The approximate theoretical discharge temperature can be calculated from: ideal =
T1
P2 P1
T2 = T1
(k – 1)/k
– 1
6 # , e z i s g n i a s C
5 #
4 #
lo g
20 ni r a
1 # d n a 2 #
3 #
e B
Eq 13-29 Eq 13-30
ideal
10
The actual discharge temperature can be approximated:
actual =
T1
P2 P1
(k – 1)/k
– 1
7
Polytropic Calculation Sometimes compressor manufacturers use a polytropic path instead of isentropic. Polytropic efficiency is defined by:
p h s s ol
Eq 13-33 l a -sl
P2 P1
(n – 1)/n
– 1
8 10
20
5 #
4 #
3 #
1 # d n a 2 #
i O
The equations for head and gas horsepower based upon polytropic compression are: ZavgRT1 MW (n – 1)/n
5 6
20 e
(See Fig. 13-34 for conversion of isentropic efficiency to polytropic efficiency.)
Hp =
4
z e i s g i n s a C
30 ,
p
3
b. Oil-seal horsepower losses 70 60 50 6 40 # ,
Eq 13-32
T2 = T1 + Tactual
2
Shaft speed, N, thousand rpm
is
n k = (n – 1) (k – 1)
1
Eq 13-31
10
Eq 13-34a
7
1
2
3
4
5 6
8
10
20
Shaft speed, N, thousand rpm Courtesy Chemical Engineering Magazine
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Hp =
His
p
To find the discharge enthalpy:
Eq 13-36
is
h2 =
The approximate actual discharge temperature can be calculated in an analagous manner to Equations 13-29 through 13-32 but replacing (k–1)/k and is with (n–1)/n and poly respectively.
Eq 13-43
To convert to polytropic head it will be necessary to assume a polytropic efficiency. See Fig. 13-22 for an efficiency corresponding to the inlet flow. Fig. 13-34 will give a corresponding adiabatic efficiency. The polytropic head may now be determined from Equation 13-36.
Fig. 13-35 shows losses related to the shaft speed and casing size for conventional multistage units. Bearings and seal losses can also be roughly computed from Scheel’s equation: Eq 13-37
When a P-H diagram is available, it is the fastest and most accurate method of determining compressor horsepower and discharge temperature.
Eq 13-38
Centrifugal Refrigeration Compressors
To calculate the total compressor horsepower:
Compression ratio per wheel will vary on the order of 1.5 to 2.75 per wheel depending on the refrigerant and speed.
The mechanical losses of centrifugal compressors (including windage, bearings) are typically between 1 and 2% of the total power, with the lower number for larger machines. Gearbox losses are usually 2 to 3%, for parallel shaft gearboxes, with the higher number for higher gearbox ratios, especially for gearboxes with an idler gear.
Due to the ease of applying external side loads to centrifugal machines, it is quite common to flash refrigerant from the condenser en route to the evaporators and/or to accept side loads from product being cooled by refrigerant at higher pressures than the lowest evaporator level.
Compressor Speed
Since side-loading is the practice rather than the exception, it is common to let the centrifugal compressor manufacturer obtain the desired performance characteristics from the following data: evaporator temperature levels; refrigeration loads required in MMBtu/hr; heat rejection medium (air or water); and type of driver.
The basic equation for estimating the speed of a centrifugal compressor is: N = (Nnominal)
+ h1
From Fig. 13-36 and Equations 13-39 and 13-40, the speed and number of wheels can be estimated.
After the gas horsepower has been determined by either method, horsepower losses due to friction in bearings, seals, and speed increasing gears must be added.
BHP = GHP + mechanical losses
is
The actual discharge temperature can now be obtained from the P-H diagram. The gas horsepower can be calculated using Eq 13-28 and Eq 13-35.
Mechanical Losses
Mechanical losses = (GHP)0.4
his
(No. of wheels) (H max/wheel) Eq 13-39 H total
where the number of wheels is determined from Fig. 13-36. Nominal speeds to develop 10,000 feet of head/wheel can be determined from Fig. 13-22. However, to calculate the maximum head per wheel, the following equation based on molecular weight (or more accurately, density) can be used. H max/wheel = 15,000 – 1,500 (MW)0.35
GENERAL Flow Limits
Eq 13-40
Two conditions associated with centrifugal compressors are surge (pumping) and stone-wall (choked flow).
This equation will give a head of 10,000 ft for a gas when MW = 30 and 11,000 ft when MW = 16.
At some point on the compressor’s operating curve there exists a condition of minimum flow/maximum head where the developed head is insufficient to overcome the system resistance. This is the surge point. When the compressor reaches this point, the gas in the discharge piping back-flows into the compressor. Without discharge flow, discharge pressure drops until it is within the compressor’s capability, only to repeat the cycle.
P-H Diagram When a P-H diagram is available for the gas to be compressed, the following procedure should be used. Fig. 13-37 represents a section of a typical P-H diagram. For the given inlet conditions, the enthalpy can be shown as point 1 on the P-H diagram. For a single compression stage, starting from Point 1 follow the line of constant entropy to the required discharge pressure (P2), locating the isentropic discharge state point (2is). With these two points located the differential isentropic enthalpy can be calculated from the following equation: is =
h2is – h1
The repeated pressure oscillations at the surge point should be avoided since it can be detrimental to the compressor. Surging can cause the compressor to overheat to the point the maximum allowable temperature of the unit is exceeded. Also, surging can cause damage to the thrust bearing due to the rotor shifting back and forth from the active to the inactive side. “Stonewall” or choked flow occurs when sonic velocity is reached at any point in the compressor. When this point is reached for a given gas, the flow through the compressor cannot be increased further.
Eq 13-41
To convert to isentropic head, the equation is: His = his (778 ft lb/Btu)
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Eq 13-42
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FIG. 13-36
FIG. 13-37
Wheels Required
P-H Diagram Construction
discharged from the compressor casing after one or more stages of compression and, after being cooled, is returned to the next stage or series of stages for further compression.
Interstage Cooling Multistage compressors rely on intercooling whenever the inlet temperature of the gas and the required compression ratio are such that the discharge temperature of the gas exceeds about 300°F.
Intercoolers usually are mounted separately. When there are two or more compressor casings installed in series, individual machines may or may not be cooled or have intercoolers. In some cases, it may be advantageous to use an external cooler to precool gas ahead of the first wheel.
There are certain processes that require a controlled discharge temperature. For example, the compression of gases such as oxygen, chlorine, and acetylene requires that the temperature be maintained below 200°F.
Journal and Thrust Bearings Radial journal bearings are designed to handle high speeds and heavy loads and incorporate force-feed lubrication. They are self-aligning, straight sleeve, multi-lobe sleeve, or tilting pad type, each sized for good damping characteristics and high stability.
The thermal stress within the horizontal bolted joint is the governing design limitation in a horizontally split compressor case. The vertically split barrel-type case, however, is free from the thermal stress complication.
Tilting pad bearings have an advantage over the sleeve type as they eliminate oil whip or half-speed oil whirl which can cause severe vibrations.
Substantial power economy can be gained by precooling the gas before it enters the interstage impellers. Performance calculations indicate that the head and the horsepower are directly proportional to the absolute gas temperature at each impeller.
Bearing sleeves or pads are fitted with replaceable steelbacked babbitted shells or liners.
The gas may be cooled within th e casing or, more commonly, in external heat exchangers.
Axial thrust bearings are bidirectional, double faced, pivoted-shoe type designed for equal thrust capacity in both directions and arranged for force-feed lubrication on each side.
Two methods of cooling within the casing are used — water cooled diaphragms between successive stages and direct liquid injection into the gas.
Thrust bearings are sized for continuous operation at maximum differential pressure including surge thrust loads, axial forces transmitted from the flexible coupling and electric motor thrust.
Diaphragm cooling systems include high-velocity water circulation through cast jackets in the diffuser diaphragms. The diaphragm coolers are usually connected in series.
On units where the thrust forces are low, a tapered land thrust bearing may be used but must be selected for proper rotation direction. At times a combination of pivoted-shoe and tapered land is recommended.
Liquid injection cooling is the least costly means of controlling discharge temperatures. It involves injecting and ato mizing a jet of water or a compatible liquid into the return channe ls. In refrigeration units, liquid refrigerant is frequently used for this purpose. Injected liquid also functions as a solvent in washing the impellers free of deposits. Nevertheless, the hazards of corrosion, erosion, and flooding present certain problems resulting in possible replacement of the compressor rotor.
Compressor designs with impellers arranged in one direction usually have a balance drum (piston) mounted on the discharge end of the shaft to minimize axial loads on the thrust bearing.
External intercoolers are commonly used as the most effective means of controlling discharge temperatures. The gas is
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Fig. 13-38 illustrates typical journal and thrust bearings generally used in horizontally and vertically split casings.
Advantages Reduced space/weight requirements due to elimination of the need for a bearing lube oil system
Bearing supports are cast integral with, or bolted to, the case with isolated bearing chambers to prevent lubricating oil leakage into the gas system or contamination of the oil or the gas. Bearing housings are horizontally split and readily accessible for inspection and maintenance. Provisions are made to accommodate pick-ups and sensors for vibration and temperature monitoring.
Reduced long term costs for maintenance and repairs Reduced bearing-related losses (near zero friction) Increased reliability and availability Improved machine monitoring/diagnostic capabilities
Magnetic Bearings
Higher speeds possible.
Magnetic bearings are a relatively new development that are gaining in popularity. An active magnetic bearing comprises two main components — a mechanical part and an electronic part. The mechanical parts of the bearing are similar to an electric motor with a rotor and stator. An iron core in the stator is wound with coils through which is fed an electric current, thereby inducing a magnetic field. This magnetic field produces the forces that support the compressor shaft.
Limitations Generally physically larger than “conventional” bearings Higher complexity Requires electrical power See Fig. 13-39 for a schematic of a typical magnetic bearing arrangement.
The electronic part of the active magnetic bearing is the digital control system. It includes sensors that measure the exact position of the shaft. Deviations from the desired position of the shaft will trigger the software in the control system to adjust the current flowing through the electromagnets that determine the strength of the magnetic field. The currents are adjusted according to a set algorithm that corrects the deviation. Magnetic bearings are available in radial and axial/thrust designs.
Shaft Seals Shaft seals are provided on all centrifugal compressors to limit, or completely eliminate, gas leakage along the shaft where it passes through the casing. With the wide range of temperature, pressure, speed, and operating conditions encountered by compressors, there can be no one universal seal, or seal system, to handle all applications.
FIG. 13-38
Basically, the designs of seals available are: labyrinth (gas), restrictive ring (oil or gas), liquid film (oil), and mechanical (contact) (oil or gas).
Journal and Thrust Bearing Assembly
A mechanical (contact) seal, Fig. 13-40, has the basic elements similar to the liquid film seal. The significant difference is that clearances in this seal are reduced to zero. The seal operates with oil pressure 35 to 50 psi above internal gas pressure as opposed to 5 psi in the liquid film seal. The mechanical (contact) seal can be applied to most gases, but finds its widest use on clean, heavier hydrocarbon gases, refrigerant gases, etc. A mechanical gas seal uses the process gas as working fluid to eliminate the seal oil system. See Figs. 13-41 through 13-46. The liquid film seal, Figs. 13-44 and 13-45, was also developed for the severe conditions of service but requires higher oil circulation rate than the mechanical (contact) type. The seal consists of two sleeves which run at close clearance to the shaft with a liquid injected between the sleeves to flow to the seal extremities. The sleeves are lined with babbitt or a similar non-galling material which is compatible with the properties of the compressed gas and the sealing liquid. The sealing liquid, usually a lubricating oil, is introduced between the two rings at a controlled differential pressure of about 5 psi above the internal gas pressure, presenting a barrier to direct passage of gas along the shaft. This fluid also performs the very important functions of lubricating the sleeves and removing heat from the seal area.
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FIG. 13-39
FIG. 13-40
Active Magnetic Bearing System
Mechanical (Contact) Shaft Seal
FIG. 13-41 Single Gas Seal
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FIG. 13-42 Double Gas Seal
FIG. 13-43 Tandem Gas Seal
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lift-off pressure is 689 kPad (100 psid). Seal leakage is the same as, or less than, that during rotating conditions. This is the typical occurrence with pressurized equipment prior to start-up.
Dry Gas Seals Dry gas seals are used to prevent process gas from leaking along the rotating shaft of the compressor into the environment. Each seal consists of two rings, one of t hem a spring loaded seal face, the other a seat.
Rotation, Case is Unpressurized: The seal faces remain in contact up to lift-off speed, which normally occurs at 150 rpm. Separation is caused by hydrodynamic effect due to the groove configuration in the face of the rotating seal member. This is the typical condition in an unpressurized seal at start-up.
One ring is stationary with the compressor casing, t he other rotates with the shaft. Silicon carbide, silicon nitride, tungsten carbide or carbon are typical materials for the seal rings.2 The flat faces of the seal rings form the seal. Grooves, measuring a few microns in depth, are machined into one of the rings. When the machine is at stand-still the axially moveable seal ring is pressed on the other ring by the springs. Parting of the two faces is affected by the pressure differential across the seal faces, and the rotation of the shaft. During operation of the compressor, the forces from the springs, and the aerodynamic force created by the grooves due to gas flowing through the seal, are in equilibrium, and maintain a very narrow gap between the stationary and rotating face. Therefore, very low leakage can be maintained, while the fact that there is no mechanical contact between the rings avoids any seal deterioration, as long as the seal gas is free of solids and liquids.
Rotation, Case Is Pressurized: The seal faces will maintain an equilibrium gap depending on the speed and pressure conditions. For tandem dry gas seals, which are most commonly used in natural gas compression, we have two seals combined: The primary face seal is exposed to the high-pressure seal gas on one side and approximately atmospheric pressure on the other, while the seal gas pressure is held slightly higher than the compressor suction pressure. By taking the full pressure drop, this seal provides the main sealing function. Filtered seal gas is injected between the process gas and the primary seal at a pressure nominally higher than the suction pressure. Most of the seal gas leaks into the compressor through the labyrinths at the shaft into the compressor suction flow. This portion of the primary seal gas is not lost, but is recycled. The quantity of this recycled gas is quite small (less than 0.1%) when compared to the compressor inlet flow; yet, it provides an important protective barrier for the dry seal. An even smaller portion of the primary seal gas leaks across the face seal to the primary seal vent. This leakage is lost to vent or flare. Both leakage rates, i.e., flow through the labyrinth and through the face seal, decrease as a fraction of compressor flow with increasing compressor frame size.
The seals see, in general, 4 (four) modes of operation: No Rotation, Case is Unpressurized: The seal faces are held in contact by spring load. No Rotation, Case Is Pressurized: The seal faces remain in contact up to a certain pressure differential. At this pressure and above, the seal faces separate as the pressure overcomes the spring force between the faces. Normally, this
FIG. 13-44 Liquid Film Shaft Seal with Pumping Bushing
FIG. 13-45 Liquid Film Shaft Seal with Cylindrical Bushing
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The secondary face seal acts as a backup to th e primary face seal. It is similar to the primary seal and becomes active when the primary seal fails. It operates at near zero pressure-differential during normal running conditions. In order to protect the secondary face seal from failure, the secondary vent pressure should never be allowed to exceed the primary vent pressure. It is not necessary to inject seal gas ahead of the secondary seal as primary seal gas that leaks through the primary seal has already been filtered.
Gas/Oil Interface. One of the main reasons for the interest in compressors with dry seals is that there is no process gas/lube oil interface. For transmission service, a dry seal system eliminates the addition of oil to the gas in the pipeline. For wellhead or field gas service, it eliminates sour gas carryover into lube oil tanks, oil degradation, and lube oil tank explosive mixture levels. Pressurized Hold. Pressurized holds of longer time are possible. As environmental limits become stricter, it will be increasingly advantageous to leave the compressor pressurized instead of blowing to vent at every shutdown.
Some tandem dry seals also have an intermediate labyrinth seal located between the primary and secondary seals . The function of this intermediate labyrinth is to facilitate the use of a secondary seal gas. Secondary seal gas, usually an inert gas like nitrogen, may be injected between the secondary seal and the intermediate labyrinth. This gas also requires the same cleanliness as the primary seal gas.
Degassing. Degassing flues/tank connections on wet seal units have a 127 mm (5 in.) of water column limit, while dry seal vent connections have a 34.5 kPag (5 psig) limit. This makes it much easier to capture and run leakage gas into a flare system.
The seal gas is usually process gas that has been filtered, and conditioned in the dry gas seal system. The dry gas seal system is set up to provide clean, filtered process gas to the seals. A typical dry gas seal system is designed to: Provide clean and dry seal gas to the face of the dry seal to prevent contamination and early failure of the seal.
Seal Gas Quantity. The seal gas flow to the dry seal cavities is easier to limit and is less than buffer gas flows on wet seal compressors. The parasitic power requirement to compress seal gas is less with a dry gas seal system. And disadvantages: The cost of dry seals is higher in comparison to oil seals.
Monitor the leakage past the primary dry seal and alarm or shutdown if abnormal conditions exist.
The dry seal cavities must have clean, dry gas to avoid contaminating the seals.
Provide clean air or nitrogen to the separation seals.
Lubrication and Seal-oil Systems
Optionally, provide clean nitrogen to the intermediate labyrinth when needed.
On all centrifugal compressors that have force-fee d lubricated bearings, a lubrication oil system is required. When oil-film or mechanical (contact) seals are used, a pressurized seal-oil system must be provided.
Dry gas seals need to be protected from lube oil migrating from the bearings of the compressor to the dry gas seals. This is accomplished by a separation seal (often referred to as buffer seal). This separation seal uses separation (or buffer) gas, usually air or nitrogen to avoid lube oil migration into the dry gas seal.
Each system is designed for continuous operation with all the elements (oil reservoir, pumps with drivers, coolers, filters, pressure gauges, control valves, etc.) piped and mounted on a flat steel fabricated base plate located adjacent to the compressor. The compressor manufacturer normally supplies both systems in order to have overall unit responsibility.
Compared with oil seal systems, dry gas seal systems have the following advantages: The dry gas seal system does not require external power source .
Depending on the application, lubrication and seal-oil systems may be furnished as combined into one system, or as one lubrication system having booster pumps to increase the pressure of only the seal oil to the required sealing level. In service involving heavily contaminated gases, separate lube-oil and seal-oil systems should be used.
FIG. 13-46 Combined Seal-Oil and Lube-Oil System with External Sweet Buffer Gas
The lubrication system may supply oil to both compressor and driver bearings (including gear), couplings (if continuously lubricated), as well as turbine governor, trip and throttle valve, and hydraulic control system. A single lubricant shall be used in all system equipment, usually an oil, having approximate viscosities of 150 Saybolt Universal Seconds (SUS) at 100°F and 43 SUS at 210°F. In addition to all the elements of a common pressurized lubrication system, the seal oil system requires a collection system for the oil. Depending on the gas composition, a degassing tank may be installed in the seal oil trap return line to remove the oil-entrained gas prior to return of the seal oil to the common oil reservoir. The flow past the outer sleeve passes through an atmospheric drain system and is returned to the reservoir. The relatively low flow through the inner sleeve is collected in a drain trap or continuous drainer and may be returned to the reservoir or
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discarded, depending upon the degree and type of contamination which occurred while it was in contact with the internal gas.
Drivers — Centrifugal compressors can be driven by a wide variety of prime movers including electric motors, steam turbines, gas combustion turbines, and gas-expander turbines. Each driver has its own design parameters. A motor drive presents limitations in operation of the compressor due to constant and low speed. The constant speed restriction is minimized by suction or discharge throttling. The low speed restriction is corrected by introduction of a speed increasing gear. A steam turbine, on the other hand, has variable speed capability that allows more control of the compressor capacity or discharge pressure, and its high speed permits the compressor to be directly connected to the driver. In the case of a single-shaft gas turbine, the power output is limited at a reduced speed.
Compressors using only liquid film seals should be provided with a seal-oil system which incorporates an overhead surge tank. The surge tank provides seal-oil capacity for coastdown of the machine and blowdown of the gas present in case of a compressor shutdown. In combined seal-oil and lube-oil systems when large amounts of contaminants are present in the process gas, the seal-oil design may call for buffer gas injection to form a barrier between the compressed gas and the seal oil. Fig. 13-46 shows clean sweet buffer gas being injected into the center of a labyrinth seal preceding the oil film seal with seal oil supplied between the two sleeves. Part of the seal oil flows across the inner sleeve and mixes with buffer gas and then drains into the seal oil trap. The other part of the seal oil flows across the outer sleeve, mixes with the bearing lube oil drain flow, and returns to the common lube- and seal-oil reservoir.
CONTROL SYSTEMS Centrifugal compressor controls can vary from the very basic manual recycle control to elaborate ratio controllers. The driver characteristics, process response, and compressor operating range must be determined before the right controls can be selected.
FIG. 13-47 Pressure Control at Variable Speed
The most efficient way to match the compressor characteristic to the required output is to change speed in accordance with the fan laws (affinity laws, see Equations 13-23 and 13-24):
FIG. 13-50 Volume Control at Constant Speed
FIG. 13-48 Volume Control at Variable Speed
FIG. 13-51 Effect of Adjustable Inlet Guide Vanes on Compressor Performance
FIG. 13-49 Pressure Control at Constant Speed
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N1 N2
=
Q1 Q2
=
H1
The final element is a suction throttle valve (STV) that reduces the flow of gas into the compressor.
Eq 13-44
H1
One of the principal advantages of using steam or gas turbines as drivers for compressors is that they are well suited to variable-speed operation. With such drivers, the speed can be controlled manually by an operator adjusting the speed governor on the turbine or, alternatively, the speed adjustment can be made automatically by a pneumatic or electric controller that changes the speed in response to a pressure or flow signal.
A process pressure increase over a set value would cause a signal to reach the suction throttle valve (STV) and would partially close the valve in order to reduce the inlet pressure.
Volume Control at Constant Speed The control scheme for this arrangement is shown in Fig. 13-50. The flow transmitter (FT) senses the process flow using an orifice or venturi as the primary flow element (FE), converts this to a signal that is proportional, and sends this signal to the flow controller (FC). The flow controller amplifies the transmitter signal and sends a modified signal to the final element. Reset and derivative controller actions may be required.
Pressure Control at Variable Speed The control system operates as follows: The pressure transmitter (PT) in Fig. 13-47 senses the process discharge pressure. It converts this signal to a signal proportional to the process pressure and sends it to the pressure controller (PC).
The final element is the compressor guide-vane mechanism. The guide vanes are adjusted by means of a positioning cylinder. This cylinder is operated by a servo-valve (SRV) that receives a signal from the flow controller.
The pressure controller amplifies the transmitter signal and sends a modified signal to the final control element. Depending on system requirements the controller may require additional correction factors called integral (reset) and rate.
Here, an increase in flow above the set point causes a signal to reach the final element, which will result in the required degree of closing of the guide vanes to decrease flow.
The final element in this case is speed control. This varies the turbine-governor speed setting within a predetermined range.
Adjustable Inlet Guide Vanes — The use of adjustable inlet guide vanes is the most efficient method of controlling a constant speed compressor. The vanes are built into the inlet of the 1st stage, or succeeding stages, and can be controlled through the linkage mechanism either automatically or manually.
As the load decreases, the discharge pressure will rise. An increase in process pressure above the set-point value will cause the signal to reach the governor and reduce the speed, maintaining the desired system discharge pressure.
The vanes adjust the capacity with a minimum of efficiency loss and increase the stable operating range at design pressure. This is accomplished by pre-rotation of the gas entering the impeller which reduces the head-capacity characteristics of the machine. Fig. 13-51 illustrates the effect of such cont rol at various vane positions.
Volume Control at Variable Speed If the nature of the process requires constant volume delivered, then the arrangement shown in Fig. 13-48 would be used. Here, the flow transmitter (FT) senses the process flow, co nverts the signal to a signal proportional to the process flow, and sends it to the flow controller (FC). The flow controller amplifies the transmitter signal and sends a modified signal to the final element. Integral (reset) and rate correction factors may be needed.
Prior to control selection, the economics of inlet guide vanes must be considered because of their higher initial cost, complex mechanism, maintenance, and requirement for frequent adjustment.
Anti-surge Control Surge Control systems are by nature surge avoidance systems. In general, the control system sensors measure the gas flow through the compressor and the head it generates. To determine compressor head, pressure and temperatures at suction and discharge are measured. The knowledge of head and flow allows the comparison of the present operating point of the compressor with the predicted surge line (Fig. 13-52). If the process forces the compressor to approach the surge line, a recycle valve in a recycle line is opened. This allows the actual operating point of the compressor to move away from surge ( Kurz and White, 2004).
The final element is speed control, which is accomplished by a mechanism that varies the turbine-governor speed setting. An increase in flow over set point would cause a signal to reach the governor and reduce the speed to maintain the desired system flow. When using electric motors as constant speed drivers (Fig. 13-49), the centrifugal compressor is normally controlled by a suction throttling device such as butterfly valve or inlet guide vanes. Throttling the suction results in a slightly lower suction pressure than the machine is designed for, and thus requires a higher total head if the discharge pressure remains constant. This can be matched to the compressor head-capacity curve, i.e., higher head at reduced flow. In throttling the inlet, the density of the gas is reduced, resulting in a matching of the required weight flow to the compressor inlet-volume capabilities at other points on the head/capacity curve.
One of the complications is, that the calculation of head and flow from pressure differentials over a flow element, and suction and discharge pressures and temperatures (as described earlier), requires the knowledge of the gas composition. In many applications, the gas composition can change. However, by normalizing the flow and the head appropriately (White and Kurz,2006) a surge limit line can be defined that is invariant to changes in gas composition.
Pressure Control at Constant Speed The control system shown in Fig. 13-49 has the pressure signal sensed and amplified in a similar manner as described in the scheme for variable speed control (Fig. 13-47).
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A key issue in surge control is the accuracy of the flow measurement. It is therefore recommended to use properly installed
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FIG. 13-52 Typical Compressor Map (Variable Speed)
Courtesy of Solar Turbines Incorporated
orifices or venture flow meters. Using the pressure differential between compressor flange and impeller eye is also a very effective method. Properly installed ultrasonic flow meters have also been used successfully. It is not recommended to use pitot type or elbow flow meters for flow measurements in surge control systems because the signals tend to be weak, with a low signalto-noise ratio.
4. Recycle valve correctly selected for the compressor: the valves must fit the compressor. They must be capable of large and rapid, as well a small and slow, changes in capacity. 5. Recycle valve correctly selected for the system volumes: The valve must be fast enough and large enough to ensure the surge limit is not reached during a shutdown. The piping system is the dominant factor in the overall system response. It must be analyzed and understood. Large volumes will preclude the implementation of a single valve surge avoidance system.
A surge avoidance system determines the compressor operating point using the pressure, temperature and flow data provided by the instrumentation. The system compares the compressor operating point to the compressor’s surge limit. The difference between the operating point and the surge limit is the control error. A control algorithm (P+I+D) acts upon this difference, or “error,” to develop a control signal to the recycle valve. When opened, a portion of the gas from the discharge side of the compressor is routed back to the suction side and head across the compressor is prevented from increasing further. When the operating point reflects more flow than the required protection margin flow, the surge control valve moves toward the closed position and the compressor resumes normal operation.
It must be understood that the anti-surge control system must be designed to operate under three, very different, scenarios: 1. Unit Startup: In this condition the recycle valve is typically kept at a fixed position to allow the compressor to start, and ultimately reach the discharge pressure necessary to open the check valve, and feed gas in to the process.
There are 5 essentials for successful surge avoidance:
2. Process Control: with a properly sized recycle valve, a centrifugal compressor can stay on-line even at a no-flow condition. Well-designed surge control systems can allow reduction of the process flow to zero while keeping the compressor on line. This will also make the transition from fully closed recycle valve to an increasingly open recycle valve smooth and without upset to the process.
1. A precise surge limit model: It must predict the surge limit over the applicable range of gas conditions and characteristics. 2. An appropriate control algorithm: It must ensure surge avoidance without unnecessarily upsetting the process. 3. The right instrumentation instruments must be selected to meet the requirements for speed, range, and accuracy.
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3. Emergency shutdown: During certain emergency situations, the compression units have to be shut down instantly. To that end, the fuel supply, electricity supply,
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or steam supply to the driver are cut instantly. In this situation, the compressor will decelerate rapidly under its inertia. Typical a compressor may lose 30% of its speed in the first second. Because the speed reduction also reduces the head-making capability of the compressor, the recycle valve has to open quickly to relieve the pressure on the discharge side of the compressor.
and driver, also consider monitoring vibration at the gear shaft bearings. The main system components are: variation transducer(s), signal amplifier(s) with d-c power supply, and vibration monitor and/or analyzer. Vibration transducers fall into three categories: displacement probe, velocity pick-up, and accelerometer.
In some instances it is necessary to use multiple loops or multiple valves in parallel to accomplish a system that both allows the necessary accuracy in flow control for process control, as well as the fast reaction for an emergency shutdown.
The displacement probe is most commonly used for equipment with high value, as it can measure shaft vibration relative to bearing housing. Output signal from each transducer is small and, therefore, it must be amplified before being transmitted to a vibration monitor or analyzer.
A typical anti-surge control system is shown in Fig. 13-53 The usual method for surge avoidance (“anti-surge control”) consists of a recycle loop that can be activated by a fast acting valve (“anti-surge valve”) when the control system detects that the compressor approaches its surge limit.
Fig. 13-54 shows a vibration severity chart for use as a guide in judging vibration levels as a warning of impending trouble. For more information on vibration monitoring systems, see API Standard 670, Noncontacting Vibration and Axial Position Monitoring System, and API Standard 678, AccelerometerBased Vibration Monitoring System.
Vibration Control System This control system may be provided to monitor the driver behavior at the shaft bearings for detection of excessive lateral vibration and axial movement and for protection against possible machinery failure through alarm and/or shutdown devices.
Torsional analysis is also recommended for centrifugal compressors. The analysis is not as complex as for that required for reciprocating compressors due to the limited operating envelop of centrifugal compressor, and the fact that the energy sources are not as great as those within reciprocating compressors. Reference the discussion of torsional analysis in the Reciprocating Compressor section for additional information.
The system may protect not only the compressor but also the driver, such as a steam or gas turbine, that usually runs at the same high speed as the compressor. When a speed increasing or reducing gear unit is furnished between the compressor
FIG. 13-53 Example Anti-Surge Control System courtesy of Solar Turbines Incorporated
ENGINE
COMPRESSOR
W AFTERCOOLER
SV
TT
FT
PT
PT
DV
TT
LV SCRUBBER
ANTI-SURGE CONTROLLER LIMIT SWITCH 4-20mA
POSITION TRANSMITTER 4-20mA
SOLENOID ENABLE 24VDC
SV LV VV DV
= = = =
SUCTION VALVE LOADING VALVE VENT VALVE DISCHARGE VALVE
TT = TEMPERATURE TRANSMITTER FT = FLOW TRANSMITTER PT = PRESSURE TRANSMITTER
FAIL OPEN ANTI-SURGE CONTROL VALVE
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Successful rotor design is the result of accurate calculation of critical speeds. A critical speed occurs at a condition when the rotor speed corresponds to a resonant frequency of the rotorbearing support system. Under no circumstances should the compressor be allowed to run at a critical speed for a prolonged length of time as the rotor vibrations amplified by this condition can cause machinery failure.
OPERATIONAL CONSIDERATIONS Rotor Dynamics and Critical Speeds The demand for smooth-running turbomachinery requires careful analysis of rotor dynamics taking into account bearing performance, flexibility, critical speed, and rotor response. Equally important is to analyze the dynamic behavior o f the compressor for sudden changes in load due to start-up, shutdown, or loss of power supply.
Critical Speed Map A critical speed map is o ne of various methods used to predict the operational behavior of the rotor. First, the critical speeds for a given rotor geometry are calculated for a range of assumed bearing-support stiffness values. The result is a map like that shown in Fig. 13-55. The bearing stiffness characteristics are determined from the geometry of the bearing support system, and cross-plotted on the critical speed map.
FIG. 13-54 Vibration Severity Chart 1
The map depicts the values of the undamped critical speeds and how they are influenced by bearing stiffness. The intersections of the bearing stiffness curve and the critical speed lines represent the undamped critical speeds. The intersection points generally indicate margins between the criticals and the operating speed range. However, the use of this map is very limited because it is based on a simplified undamped, circular synchronous analysis with no cross-coupled or unbalance effects. It is a good trending tool showing a machine’s basic dynamic characteristics. It may not accurately depict peak response frequencies. The critical speed map is used extensively because it enables determination of bearing or support stiffness by correlating test-stand data.
Unbalance Response Analysis This method predicts rotor-bearing system resonances to greater accuracy than the critical speed map. Here, bearing support stiffness and damping are considered together with synchronous vibration behavior for a selected imbalance distribution. A computer is normally required to solve the resulting differential equations. Satisfactory results depend on the accurate input of bearing stiffness and damping parameters. Several runs are usually made with various amounts and locations of unbalance. The plot of results of a typical unbalance response study is shown in Fig. 13-56. Each curve represents the rotor behavior at a particular station or axial location such
FIG. 13-55 Undamped Critical Speed Map
FIG. 13-56 Unbalanced Response Plot
lsi m sl e v e L n iot ra bi V
Rotational Speed - RPM
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as those corresponding to the midspan, bearings, and overhangs.
2.
a. Pressure at intermediate nozzles, psia
No rotor can be perfectly balanced and, therefore, it must be relatively insensitive to reasonable amounts of unbalance.
b. Temperature at intermediate inlet flange, °F c. Flow (actual, mass flow, std flow) and gas composition at intermediate inlet flange if side stream is added or liquid drop-out occurs in the interstage cooler.
The unbalance-response results predict the actual amplitudes that permit calculations of the unbalance sensitivity. This is expressed in mils of vibration amplitude per ounce-inch or gram-inch of unbalance.
3. Discharge Conditions (at the compressor discharge flange):
The peaks of the response curves represent the critical speed locations. Fig. 13-57 shows limits of placement of critical speeds as specified in the API Standard 617, Centrifugal Compressors for General Refinery Services.
a. Pressure, psia b. Temperature, oF 4. Control setting (depending on the type of compressor controls)
Critical speeds should not encroach upon operating speed ranges, and the separation margin of encroachment (SM) from all lateral modes is required to be at least: 1.
Twenty (20) percent over the maximum continuous speed for rigid shaft rotor systems.
2.
Fifteen (15) percent below any operating speed and twenty (20) percent above the maximum continuous speed for flexible shaft rotor system.
Intermediate conditions (if applicable)
a. Compressor speed, rpm b. Guide vane setting 5. Driver Power a. If available, determine driver power output independently of compressor power measurement
Troubleshooting Operational troubles occurring in service may be due to a variety of causes.
FIG. 13-57 Rotor Response Plot
If the trouble cannot be traced to adverse gas flow conditions or liquid “slugs” present in the system, Fig. 13-58 can be used as a guide for troubleshooting frequently encountered problems. Careless operation and maintenance needs little comment. Lack of proper care of any machine is bound to result in a succession of minor troubles eventually leading to a major breakdown.
INTEGRALLY GEARED COMPRESSORS An integrally geared compressor utilizes a central driven bull gear with typically 2–4 high speed pinion-driven shafts. One or two impellers can be mounted on each pinion shaft. See Figures 13-59 and 13-60. This forms a compact unit for the multistage compression of a wide range of gases. Integrally geared compressors offer the following potential advantages: low power consumption due to different impeller speeds, tailored aerodynamics and optimized auxiliaries. wide operating range and improved part-load efficiencies due to adjustable inlet guide vanes at the first or at all compression stages.
Field Performance
multiservice capability.
Once the compressor has been installed, it is often desirable to measure its performance. The following parameters needs to be determined: 1.
packaged designs available. A package includes the compressor, process coolers, lube oil console, process piping and all tubing and wiring.
Inlet conditions (at the compressor inlet flange):
Design requirements of integrally geared compressors are covered by API Standard 617.
a. Flow (scfm, acfm, or lb/min) b. Gas composition
AXIAL COMPRESSORS
c. Pressure, psia d. Temperature, °F
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Axial compressors are basically high-flow, low-pressure machines, in contrast to the lower flow, high-pressure centrifugal compressors (the axial compressors used in gas turbines are of-
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ten designed for higher pressures and compression ratios). Axial compressors are generally smaller and significantly more efficient than comparable centrifugal compressors. The characteristic feature of an axial compressor, as its name implies, is the axial direction of flow through the machine. An axial flow compressor requires more stages than a centrifugal due to the lower pressure rise per stage. In general, it takes approximately twice as many stages to achieve a given pressure ratio as would be required by a centrifugal. Although the axial compressor requires more stages, the diametral size of an axial is typically much lower than for a centrifugal. The axial compressor’s capital cost is usually higher than that of a centrifugal but may be justified based on efficiency and size.
rotor to the gas in order to generate an increase in gas pressure. A multistage axial flow compressor has two or more rows of rotating blades operating in series on a single rotor in a single casing. The casing contains the stationary vanes (stators) for directing the air or gas to each succeeding row of rotating blades. These stationary vanes, or stators, can be fixed or variable angle, or a combination of both. A cross-sectional view of a typical axial flow compressor is shown in Fig. 13-61. Performance Capabilities — The volume range of the axial compressor starts at approximately 30,000 cfm with a typical upper end of the flow range at 400,000 cfm. Much larger axial machines have been built. As can be seen in Fig. 13-3, the flow range for the axial overlaps the higher end of the range for
The axial compressor utilizes alternating rows of rotating and stationary blades to transfer the input energy from the
FIG. 13-58 Probable Causes of Centrifugal Compressor Trouble
Trouble
Low Discharge Pressure
Compressor Surge
Low Lube Oil Pressure
Shaft Misalignment
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Probable Cause(s)
Trouble
1. Compressor not up to speed. 2. Excessive compressor inlet temperature. 3. Low inlet pressure. 4. Leak in discharge piping. 5. Excessive system demand from compressor. 1. Inadequate flow through the compressor. 2. Change in system resistance due to obstruction in the discharge piping or improper valve position. 3. Deposit buildup on rotor or diffusers restricting gas flow. 1. Faulty lube oil pressure gauge or switch. 2. Low level in oil reservoir. 3. Oil pump suction plugged. 4. Leak in oil pump suction piping. 5. Clogged oil strainers or filters. 6. Failure of both main and auxiliary oil pumps. 7. Operation at a low speed without the auxiliary oil pump running (if main oil pump is shaft-driven). 8. Relief valve improperly set or stuck open. 9. Leaks in the oil system. 10. Incorrect pressure control valve setting or operation. 11. Bearing lube oil orifices missing or plugged. 1. Piping strain. 2. Warped bedplate, compressor or driver. 3. Warped foundation. 4. Loose or broken foundation bolts. 5. Defective grouting.
High Bearing Oil Temperature Note: Lube oil temperature leaving bearings should never be permitted to exceed 180°F.
Excessive Vibration Note: Vibration may be transmitted from the coupled machine. To localize vibration, disconnect coupling and operate driver alone. This should help to indicate whether driver or driven machine is causing vibration.
Water In Lube Oil
112
Probable Cause(s) 1. Inadequate or restricted flow of lube oil to bearings. 2. Poor conditions of lube oil or dirt or gummy deposits in bearings. 3. Inadequate cooling water flow to lube oil cooler. 4. Fouled lube oil cooler. 5. Wiped bearing. 6. High oil viscosity. 7. Excessive vibration. 8. Water in lube oil. 9. Rough journal surface. 1. Improperly assembled parts. 2. Loose or broken bolting. 3. Piping strain. 4. Shaft misalignment. 5. Worn or damaged coupling. 6. Dry coupling (if continuously lubricated type is used). 7. Warped shaft caused by uneven heating or cooling. 8. Damaged rotor or bent shaft. 9. Unbalanced rotor or warped shaft due to severe rubbing. 10. Uneven build-up of deposits on rotor wheels, causing unbalance. 11. Excessive bearing clearance. 12. Loose wheel(s) (rare case). 13. Operating at or near critical speed. 14. Operating in surge region. 15. Liquid “slugs” striking wheels. 16. Excessive vibration of adjacent machinery (sympathetic vibration). 1. Condensation in oil reservior. 2. Leak in lube oil cooler tubes or tube-sheet.
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typical centrifugal compressor coverage. At the lower en d of the axial’s flow range, a thorough evaluation of axial vs centrifugal must normally be made. However, at the higher end flows, the axial compressor often becomes the obvious choice. As stated previously, the physical size of the axial is far smaller than the comparable centrifugal machine that would be required, and the efficiency of the axial is usually better. In many high flow applications, the axial is often a better match for the drivers that would typically be selected. Because of the low pressure rise per stage, axial compressors are always manufactured as multistage machines. Axial compressors are in general low pressure machines. Typical discharge pressures are usually less than approximately 100 psig. They are very commonly utilized in refineries and other industrial processes for high volume, low pressure air supply applications. The most common application of axial compressors, besides aircraft jet engine use, is in gas turbines. In gas turbine applications, the axial air compressor is often designed to operate at final discharge pressures of up to around 500 psig. Horsepower requirements for axial flow compressors in process service typically range from 3,000 to 65,000 HP for single casing units, depending on flow and pressure ratio require-
ments. Efficiencies for axial compressors are high, especially for larger machines, and can reach 90% (adiabatic). Design requirements for centrifugal compressors are covered by API Standard 617. SCREW COMPRESSORS Screw compressors, also known as helical lobe compressors, fall into the category of rotary positive displacement compressors. Fig. 13-62 shows a cutaway cross-section of a typical rotary screw compressor. Rotary screw compressors are available in oil-free (dry) or oil-injected designs. Oil-free compressors typically use shaftmounted gears to keep the two rotors in proper mesh without contact. Applications for oil-free compressors include all processes that cannot tolerate contamination of the compressed gas or where lubricating oil would be contaminated by the gas. Oil-injected screw compressors are generally supplied without timing gears. The injected lubricant provides a layer separating the two screw profiles as one screw drives the other. Oilinjected machines generally have higher efficiencies and utilize
FIG. 13-59 Typical Integrally Geared Compressor Showing Nomenclature of Key Parts
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Customer: LNG producers throughout the world.
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Challenge: Select a compression partner to ensure years of efficient, reliable production.
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Result: Elliott refrigeration compressors and unmatched experience have been central to successful LNG projects for decades.
They turned to Elliott for leadership in LNG compression. From the first commercial LNG baseload plants to today’s mega-plants in Russia, the Middle East and Asia, LNG producers have chosen Elliott for efficient, reliable compressors and matchless expertise. Elliott’s proven experience with different processes and drivers is supported by manufacturing centers in the US and Japan, and a global network of service centers. Who will you turn to?
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The world turns to Elliott. www.elliott-turbo.com
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FIG. 13-60 Typical Integrally Geared Compressor Arrangement Showing Nomenclature of Key Elements
FIG. 13-61 Typical Axial Compressor Showing Nomenclature of Key Parts
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SIAD Macchine Impianti, beyond technology All our compressors have a distinctive characteristic, because they are the result of almost a century of experience and are a perfect combination of innovation, constantly evolving expertise and in-depth knowledge of gases. It is our know-how that goes beyond the latest technology! For further information:
[email protected]
SIAD Macchine Impianti. Compressors, Air Separation Units, Welding and Services.
Made in Italy
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FIG. 13-62 Rotary Screw Compressor
FIG. 13-63 Working Phases of Rotary Screw Compressor
(a)
(b)
Suction intake .Gas enters through the intake aperture and flows into the helical grooves of the rotors which are open.
Compression process. As rotation of the rotors proceeds, the air intake aperture closes, the volume diminishes and pressure rises.
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(c) Discharge . The compression process is completed, the final pressure attained, the discharge commences.
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API 618 - Reciprocating Compressors
API 617 - Integrally Geared Centrifugal Compressors
for Process Gases
for Process Gases
Horizontal and vertical design with up to a maximum of 6 axes.
Discharge pressure: Capacity/ow: Power:
Discharge pressure: Capacity/ow: Power:
... 1,000 bara ... 115,000 m³/h ... 16,000 kW
Typical elds of application: Chemical and petrochemical industries Crude oil recovery Oil and gas industries Refnery technology Natural gas - production, transport, storage Power plants
... 150 bar ... 300,000 m³/h ... 25,000 kW
BORSIG BlueLine
Combines control system, emergency shutdown, machine protection and condition monitoring for reciprocating and centrifugal compressor units
Compressor Services Compressor Parts
Compressor valves & reconditioning Engineering & consultancy Capacity control systems Individual products & special applications
Installation & Commissioning Overhauling Spare Parts Management
BORSIG ZM Compression GmbH www.borsig.de/zm Seiferitzer Allee 26, 08393 Meerane / Germany Phone: +49 (0) 3764 / 5390-0, Fax: +49 (0) 3764 / 5390-5092 E-mail:
[email protected]
Maintenance Engineering Training
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the oil for cooling as well, which allows for higher compression ratios in a single screw compressor stage.
Rotary screw compressors in use today cover a range of suction volumes from 180 to 35,000 acfm, with discharge pressures up to 750 psig. Typical adiabatic efficiency will be in the range of 70 to 80%.
If an oil-injected compressor is used, the downstream oil separation is critical and often the cause for operating problems. A standard design should have primary separation and secondary separation using coalescing filters. Depending upon the process service, the oil content of the compressed vapor may need to be removed down to 100 ppb levels.
Design requirements for screw compressors are covered under API Standard 619.
ROTARY-SLIDING VANE COMPRESSORS
Although originally intended for air compression, rotary screw compressors are now compressing a large number of gases in the hydrocarbon processing industries. In particular, screw compressors are widely used in refrigeration service and are gaining in popularity in the gas production business in booster and gas gathering applications.
Rotary-sliding vane compressors (Fig. 13-64) are positive displacement machines. They have several applications, including vapor recovery and vacuum service. Each unit has a rotor eccentrically mounted inside a water jacketed cylinder. The rotor is fitted with blades that are free to move radially in and out of longitudinal slots. These blades are forced against the cylinder wall by centrifugal force. Fig. 13-65 illustrates how individual pockets are thus formed by the blades, and how the gas inside these pockets is compressed as the rotor turns. Oil is injected into the flow stream to lubricate the vanes, and is recovered via a downstream scrubber and recycled to the inlet.
Gas compression is achieved by the intermeshing of the rotating male and female rotors. Power is applied to the male rotor and as a lobe of the male rotor starts to move out of mesh with the female rotor a void is created and gas is taken in at the inlet port. As the rotor continues to turn, the intermesh space is increased and gas continues to flow into the compressor until the entire interlobe space is filled. Continued rotation brings a male lobe into the interlobe spacing compressing and moving the gas in the direction of the discharge port. The volume of gas is progressively reduced as it increases in pressure. Further rotation uncovers the discharge port and the compressed gas starts to flow out of the compressor. Continued rotation then moves the remaining trapped gas out while a new charge is drawn into the suction of the compressor into the space created by the unmeshing of a new pair of lobes as the compression cycle begins again. Fig. 13-63 provides a sequence of drawings showing the compression process. Screw compressors are usually driven by constant speed motors, with capacity control normally achieved via an internal regulating device known as a slide valve. By moving the slide in a direction parallel to the rotors, the effective length of the rotors can be shortened. This provides smooth control of flow from 100 percent down to 10 percent of full compressor capacity.
Sliding vane compressors are available in single- and multistage configurations. Typical single-stage capacities are ranging through 3200 cfm and 50 psig; two-stage compressors deliver pressures from 60 to 150 psig and flows up to approximately 1800 cfm. Most applications of rotary-sliding vane compressors in oil and gas service involve fairly small units, normally under 150 HP.
Jet Pump Technology1,2 Jet pumps, also known as jet compressors, eductors or ejectors, are simple devices that use a high pressure (HP) fluid to increase the pressure of a lower pressure fluid (LP). In gas production, jet pumps have been successfully used in the following applications: boosting production of gas wells, preventing flaring of LP gas (vapor recovery), de-bottlenecking compressors, eliminating intermediate compressors, preventing HP wells from imposing back pressure on LP wells, and de-liquefication of liquid-loaded wells. In general, jet pumps are less efficient fluid movers as compared to a compressor or multi-phase compressor but their attractiveness is their low cost, tolerance to presence of some liquids in gas and their simplicity compared
FIG. 13-6 Sliding Vane Compressor and Principal Components: Rotor and Shaft (1), Bearings (2) , Blades (3), Mechanical Seals (4), Cylinder and Housing (5), Heads and Covers (6), Gaskets (7), Lube Supply Line (8), Coupling (9)
FIG. 13-6 Operating Principle of Sliding Vane Compressor
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to other systems such as compressors. If there is a local high pressure source, or a compressor with excess capacity or in a recycle mode, a jet pump can provide a cost effective solution to increase or maintain production or boost the pressure of low pressure (LP) processed gas. The primary components are a nozzle on the HP fluid side, a LP fluid inlet nozzle, a mixing tube and a diffuser, as shown in Fig 13-66. In most gas production applications, the high pressure source is gas. The high pressure gas flows through the nozzle where some of the pressure (potential) energy is converted into kinetic energy (velocity). As a result, a low pressure zone is produced in front of the nozzle, at which point the low pressure fluid is introduced. The combined stream flows through the mixing tube to transfer momentum and energy between the two streams. The fluid is then expanded in a diffuser where the velocity of the fluid is reduced and pressure of the system is increased.
available LP/HP flow ratio is dependent upon the field installation and the HP source availability, but often it is 1:1 or less. The performance of gas-gas jet pumps deteriorates if there are liquids present in the LP fluid. The reduction in perfor mance is a result of the additional energy required to boost the pressure of the liquid phase, which has significantly more mass than the gas phase. In addition, increasing liquids in the LP stream can choke the flow of the jet pump due to the rapid decrease of the sonic velocity of the combined stream. The impact of liquids on performance is typically minimal up to 2 volume % liquid at operating pressure and temperature. Presence of liquids in the HP source is also problematic, as the liquids restrict flow through the nozzle. Gas-liquid separators, or other facility separators such as a test separator or a compact separator, may be used to separate the phases to achieve acceptable jet pump performance.
In vapor recovery applications, the high pressure source is sometimes a liquid. For example in well field applications, the produced water can be pumped up to high pressure and used to boost the LP gas pressure to gas pipeline pressures. The high pressure vapor and water stream are then separated, the vapor flows into the outlet gas pipeline, and the water is recycled for jet pump use.
FIG. 13-66 General Configuration of a Jet Pump
The primary factors governing jet pump performance are the HP/LP pressure ratio (PR), and the LP/HP mass flow ratio. Other operating conditions, such as temperature and fluid physical properties will factor into the performance of the jet pump, but to a lesser extent. The resulting discharge pressure is primarily a function of the downstream production and process system. Figure 13-67 provides typical performance of a jet pump under a range of gas pressures and flow ratios. In general, the LP pressure can be increased from a few percent up to five fold with a single jet pump. In “typical” applications the discharge pressure is 1.5 to 3 time greater than the low pressure source. The
FIG. 13-67 HP to LP Pressure Ratios
Courtesy of CALTEC, Limited
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Turboexpanders The use of turboexpanders in gas processing plants began in the early sixties. By 1970, most new gas processing plants for ethane or propane recovery were being designed to incorporate the particular advantages characteristic of an expander producing usable work and lower temperatures. This is due to the expander following an isentropic path as compared to an isenthalpic path of a JT valve, and thereby provide more effective cooling for a given pressure drop. The trend in the gas processing industry continues toward increased use of the turboexpander.
expansion. The outlet temperature and pressure would be higher than that accomplished in the expander (nearly isentropic) expansion process.
Current turboexpander process applications include: Hydrocarbon Dewpoint, NGL and LPG Recovery, LNG, Nitrogen Rejection, Helium Recovery, Air Separation Units, and Nitrogen Refrigeration Cycles. Section 16, Hydrocarbon Recovery, provides descriptions of a number of common turboexpander process applications for hydrocarbon recovery.
Also, because the path to Point 4 is adiabatic without the gas doing work, the gas does not cool to as low a temperature as the path to Point 3. That is, the path (2) to (3) is isentropic expansion producing work and thereby cooling the gas more than the simple isenthalpic (J-T) expansion path.
Note that the pressure at Point 4 is not as low as that attained by flow through the expander (Point 3). This is because it has been assumed for this example that, without the expander running (therefore the brake compressor also not running), the process cannot restore the demethanizer overhead vapor to the residue gas pressure using the separate recompressor alone.
The higher temperature at Point 4 results in a reduction of product recovery. The use of the expander brake compressor to boost the residue gas pressure will allow a lower expansion pressure without the use of more residue compression.
Selection of a turboexpander process cycle is indicated when one or more of the following conditions exist: 1. “Free” pressure drop in the gas stream. 2. High ethane recovery requirements (i.e., over 30% ethane recovery).
THERMODYNAMICS
A turboexpander (often just referred to as ‘expander’) recovers useful work from the expansion of a gas stream. The expander operates isentropically in the ideal case and produces something less than the theoretical work in the real case. In the process of producing work, the expander lowers the bulk stream temperature which can result in partial liquefaction of the bulk stream. A simple schematic of an expander is given in Fig. 13-70.
3. Compact plant layout requirement. 4. Flexibility of operation (i.e., easily adapted to wide variation in pressure and products). There are multiple factors in addition to the ones listed above that affect a final process selection. If two or more of the above conditions are coexistent, generally a turboexpander process selection will be the best choice.
An example calculation of an expander operating on pure methane is provided to demonstrate the thermodynamic principles of expanders.
Fig. 13-68 shows a typical low temperature turboexpander process for recovering ethane and heavier hydrocarbons from a natural gas stream.
Gas inlet conditions (t 1, P1) to the expander are generally set by upstream conditions. The outlet pressure P 2 from the expander is often set by the desired NGL recovery and recompressor power considerations. Fig. 13-71 gives an example calculation.
Fig. 13-69 represents the pressure-temperature diagram for this expander process. The solid curve represents the plant inlet gas. The solid line on the right is the dew point line. At a fixed pressure and, if the temperature of the gas is to the right of this dew point line, the gas is 100 percent vapor. If the gas is cooled, liquid starts to condense when the temperature reaches the dew point line. As cooling continues, more liquid is condensed until the bubble point line is reached — the solid line on the left. At this point, all of the gas is liquid. Additional cooling results in colder liquid.
Outlet conditions for the expander processing a multi-component stream must be determined by trial-and-error calculations if one were to do them by hand. For multicomponent streams, such as natural gas, the hand calculations are iterative, tedious, and are only close approximations for expander performance. Expander and compressor performance is typically modeled using current process simulators.
Downstream of the gas treating facilities, the inlet gas is represented by point 1 on both Fig. 13-68 and 13-69. As the gas is cooled by the gas/gas exchangers and demethanizer side exchanger, its temperature moves along the dotted line to point 2 (Fig. 13-69). At 2, the gas enters the expander inlet separator where the condensed liquid is separated from the vapor. This vapor now has its own pressure-temperature diagram, as represented by the dashed curve. At the expander inlet, the gas is on its dew point line.
In many applications the loading device for the turboexpander is a centrifugal compressor. Shaft and bearing losses in the order of 2% are usually deducted to calculate net power input to the driven end from the expander. MECHANICAL
Mechanical design of the turboexpander is the business of several manufacturers. Any specific information must come from such supplier.
As the gas flows through the expander, its pressure-temperature path is shown by the dashed line from point 2 to point 3. Point 3 represents the outlet of the expander. The importance of using the expander as a driver for a compressor can be seen in Fig. 13-69. If the gas had been expanded without doing any driver work, the expansion path would be from point 2 to point 4. This is called a Joule-Thomson, or constant enthalpy
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Of the various general turbine types available, the radial reaction turbine design is dominant in cryogenic turboexpander natural gas plant applications. These units operate over wide ranges of inlet flow and pressure conditions, by utilizing vari-
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TECH BRIEF
able inlet guide vanes. They operate at very high rotating speeds and thus are subject to the design and operating cautions common to similar sophisticated rotating equipment. The most common configuration is a turboexpander-compressor where the expander power is used to compress gas in the process. In this case, the compressor wheel operates on the same shaft as the expander wheel. Other applications of the power recovery are expander-pump or expander-generator drives. These normally require gearing to reduce the expander speed to that required for the driven unit. Since power recovery and refrigeration effect are primary benefits of expander applications, rotating speeds are set to optimize the expander efficiency. This will usually result in a compromise in the compressor end design and lower compressor efficiencies. Usual efficiencies quoted for radial type units are 80 to 83% for the expander and 68 to 70% for the compressor. Some areas requiring extra attention in the installation of turboexpanders are listed below. The list is by no means comprehensive, but these items require more than the normal amount of concern in designing the installation of a turboexpander unit for cryogenic operation. 1. The expander inlet gas stream must be free of solid or liquid entrainment. Liquids are removed in a high pressure separator vessel. An inlet screen of fine mesh is usually required for solids removal. Monitoring of the pressure drop across this screen is recommended. Formation of solids (ice, carbon dioxide, amines, heavy oils) will often occur here first and can be detected by an increase in pressure drop across the screen. 2. Source of the seal gas, particularly during start-up, is an important consideration. The stream must be clean, dry, sweet, and of sufficient pressure to meet the system requirements.
3. Normally a quick closure shutoff valve is required on the expander inlet. Selection of this valve and actuator type must take into account start-up, operating, and shutdown conditions. 4. Vibration detection instrumentation is useful but not mandatory. Its application is normally an owner and vendor option and influenced by operating economics. 5. Loading of the flanges by the process piping system must be within prescribed limits to avoid distortion of the case, resulting in bearing or wheel rubbing problems. 6. Failures due to mechanical resonance have occurred in turboexpanders. Even though the manufacturer will exert his best efforts at the manufacturing stage to avoid this problem, in-plant operation may uncover an undesirable resonance. Th is must be solved in conjunction with the manufacturer and may involve a redesign of the wheels, bearing modifications, vane or diffuser redesign, etc. The installation of a turboexpander-compressor unit also requires the proper design of a lube system, instrumentation, etc., in common with other industrial rotating equipment. It is common practice to install a turboexpander-compressor with no special anti-surge instrumentation for the compressor unit. This is acceptable if it can be determined that the gas flow through the compressor is balanced with flow through the expander and the two will vary simultaneously.
Auxiliary Systems Both lubricated and non-lubricated turboexpander designs are available. Lubrication System — The lubrication system circulates cooled and filtered lube oils to the turboexpander bearings as shown on Fig. 13-72. The principle components of the system
FIG. 13-68 Example Expander Process
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Simple, reliable efcient Vapor Recovery? LPG Transfer? Natural Gas Boosting?
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are monitored on the lube console and normally consist of two electric motor-driven lube oil pumps, an oil cooler, a dual filter valve, a bladder type with switching coastdown accumulator, and a pressurized reservoir with mist eliminator.
The lube-oil reservoir serves as a surge tank to enhance pump suction as well as to serve as a degassing drum permitting process seal gas to be released from the oil. If necessary, the reservoir should be equipped with a heater to bring the oil up to temperature for a “cold” start.
The lube oil pumps (one stand-by) must maintain a constant flow to the radial and thrust bearings. Absence of oil, or improper filtration, can cause bearing damage. Most manufacturers recommend a light turbine oil (315 SSU at 100°F) for best machine performance.
Seal Gas System — The seal gas system prevents loss of process gas and assures protection against entry of lube oil into process gas areas. To accomplish this, a stream of “seal gas” is injected into each labyrinth shaft seal at a pressure higher than that of the process gas. The leaking seal gas is collected in the oil reservoir, then returned through a mist eliminator to the fuel gas system, or put back into the compressor suction end.
The lube oil cooler is an integral part of the system to reject heat that is generated across the bearings. It can be of a fan air cooled type or shell and tube design, water cooled. If the cooling water is scale forming, duplicate coolers (one stand-by) are recommended.
The system for seal gas injection consists of a liquid collector, electric heater (if required), twin filters, and differential pressure regulators.
Lube oil filtration is extremely important due to close tolerances between bearing surfaces.
If recompression is necessary for the gas processing plant, sales gas is ideal for use as seal gas. If no recompression is provided, a stream can be taken from the expander inlet separator, warmed and used as seal gas. A minimum seal gas temperature (about 70°F) is required to prevent oil thickening.
FIG. 13-69 Pressure-Temperature Diagram for Expander Process
Seal gas filtration is essential because of close clearances provided between the shaft and seals.
FIG. 13-71 Expander Example Calculation Flow: 60 MMscfd
T1 = –60°F P1 = 900 psia P2 = 300 psia
Composition: 100% C1 60
lb MMscfd//1d/1 lbmol lbmol/16 lb = 6588 = 105408 24 hr/379.5 scf hr/lbmol hr
Using Fig. 24-
for Enthalpy & Entropy values.
At Inlet conditions BTU , lb
h1 = 295
BTU lb°F
s1 = 1.0
At P2 = 300 psia and assuming 100% efficiency (ideal) BTU lb°F
s2 = 1.0
T2 ideal –160°F BTU h2 ideal 260 lb
BTU BTU = (295 – 260) = 35 lb lb Assume 80% expander efficiency: ideal
FIG. 13-70 Simple Expander
actual
=
(0.80)
(35 BTU ) lb
= 28
BTU lb
T2 actual –157°F Work produced =
(28 BTU ) (105408 lb = 2951424
Horsepower =
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)
BTU hr
BTU = 1160 HP hr BTU 2545 HP
2951424
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TECH BRIEF
Seal gas flow requirements are determined by the expander manufacturers as a part of their performance rating.
Control Systems Process — Control of t he process streams begins with proper dehydration and filtering. Generally a final protective screen upstream of the expander is designed into the piping system to form a protective barrier against carbon dioxide or water freezing. As a further protection against water freezing, methanol in jection connect ions are incorporated into the system upstream of the expander.
Generally an oil flow bypass valve is included to permit excess flow to bypass the expander bearings and return to the reservoir. For temperature control, the oil must be cooled to prohibit heat buildup which occurs through the bearings. Also, a temperature control bypass is included in the circuit for an extra measure of control to keep the oil from getting too cool. Seal Gas — Use a suitable gas stream with filtering and pressure control to maintain proper gas pressure at the shaft seals. If the seal gas is delivered from a cold supply point (expander inlet separator) then a means of heating the gas is necessary.
Machine — The expander speed is established by th e manufacturer, given the process conditions. The expander manufacturer determines the wheel diameter and specific speed for maximum efficiency.
The seal gas should be introduced before the lube oil system is started because there might be a pressure upset which would put enough oil into the process to cause a problem.
As plant operating conditions change, the expander speed may change. Fig. 13-73 shows the change in efficiency as a function of change in design flow rate.
Each of the main rotating components (radial bearings, thrust bearings, and shaft seals) can be damaged or eroded by improper oil filtration, lack of oil flow, improper gas dehydration, and improper seal gas filtration.
Gas entering the expander is directed by adjustable nozzles into the impeller. About one-half of the pressure drop across the expander takes place in the nozzles, imparting kinetic e nergy to the gas which is converted to shaft horsepower by the expander wheel. Pressure reductions are normally limited to 3-4 ratios. Greater ratios reduce expander efficiency to the extent that 2stage expansion may be advisable.
Shutdown — A number of conditions during the operation of expanders justify prompt shutdown to avoid serious damage. Some of these conditions are: High Vibration
The adjustable inlet nozzles function as pressure control valves. A pneumatic operator takes a split range signal (3 to 9 psi) to stroke the nozzles. On increasing flow beyond the full open nozzle position, a 9 to 15 psi signal from a pressure controller opens a bypass control valve. This valve is called the J-T (Joule-Thomson) valve.
Low Lube Oil Flow
Thrust bearing force imbalance is caused by difference in pressures between the expander discharge and compressor suction. With a differential of the order of 20 psi, the thrust loads are usually within the capabilities of the thrust bearings. At higher pressure differentials, it is essential that steps be taken to control the thrust loads against each other, thereby the net thrust load will not exceed the thrust bearing capacity.
High Lube Oil Temperature
High Inlet Separator Level High Inlet Screen Pressure Drops High Thrust
FIG. 13-72 Lube Oil Schematic
This is done by providing a force-measuring load-meter on each thrust bearing, Fig. 13-74, and a thrust control valve which controls the thrust by control of pressure behind the thrust balancing drums or behind one of the seals. These two load-meters indicate thrust bearing oil film pressure (proportional to bearing load) and the third shows the pressure behind the balancing drum as controlled by the valve in its vent as a means of adjusting the thrust load. Vibration comes from an unbalanced force on one of the rotating components, or it could come from an outside source such as pipe vibration or gas pulsation. Most expanders are supplied with monitoring and shutdown devices for shaft vibration. These devices are set to shut down the expander before damage occurs. Lube Oil — The lube oil must be filtered. Most systems use a primary and secondary filtering system. Controls are provided to ensure oil flow to bearings at proper pressure and temperature. Two (2) lube oil pumps are furnished, the second pump serving as a standby. The standby oil pump is controlled automatically to cut in to provide oil pressure upon failure of the main pump or reduction in pressure for other reasons.
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Simple, reliable efcient
FLSmidth’s Ful-Vane™ rotary vane compressors are designed for long life, low operating costs, and minimal downtime. With only two bearings and no valves, pistons, crankshafts, or helical screws, field maintenance is easier than with other compressor technologies. Our B3000™ carbon fiber blades outlast the competition. In addition, the cylinder and rotor can each be re-machined several times - resulting in a number of Ful-Vane compressors still in operation since the 1940s. • • • • • •
Suitable for casing head, flare, natural, and bio gases Durable carbon fiber blades extend the cylinder life Total capacity control with VFD and/or gas bypass Single-stage to 3000 SCFM, two-stage to 1800 SCFM Working pressures to 300 PSIG Made in the USA since 1929
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Low Lube Oil Pressure
FIG. 13-73 Example Change in Efficiency with Flow Rate
High Speed Two primary actions of a shutdown signal are to block gas flow to the expander and the compressor. This is accomplished by actuating quick acting shutdown valves at the expander inlet and outlet and the compressor inlet . Simultaneously, a pressurized bladder supplies oil to the bearings during the expander coast down. The expander bypass valve (J-T) opens automatically and is positioned by the split-range pressure controller to keep the plant on-line in the J-T mode. Field Performance — Field measurements can be made to check efficiencies and horsepower of the expander. The process of calculations is just the reverse of selecting a machine performance.
Knowing the gas composition, mass flow (lbs/hr), inlet and outlet conditions (pressure, temperature) for the expander, the actual difference in enthalpy can be determined for each unit.> actual =
=
ht2P2 – ht1P1
h actual h ideal
EPactual =
lbs/hr 2,545
FIG. 13-74 Typical Expander/Compressor Cross-Section with Thrust Balancing Schematic
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REFERENCES
Gas Machinery Research Council, “Application Guideline for Centrifugal Compressor Surge Control Systems,” 2008 .
1 Sarshar, M.M, Beg, Dr. N.A., “Applications of jet pump technology to enhance production from gas fields”, Offshore Gas Processing, Feb. 2009. 2 Sarshar, M.M, Beg, Dr. N.A., “The applications of Jet Pump Technology to Boost Production from Oil and Gas Fields”, Gastech, March 2011.
BIBLIOGRAPHY American Petroleum Institute Standards — API 614 — “Lubrication, Shaft-Sealing and Control Oil Systems for Special-Purpose Applications.” American Petroleum Institute Standards — API 617 — “Axial and Centrifugal Compressors and Expander Compressors for Petroleum, Chemical and Gas Industry Services.” American Petroleum Institute Standards — API 618 — “Reciprocating Compressors for General Refinery Services.” American Petroleum Institute Standards — API 619 — “Rotary Type Positive Displacement Compressors for Petroleum, Chemical and Gas Industry Services.” American Petroleum Institute Standards — API 670 — “Non-Contacting Vibration and Axial Position Monitoring System .” American Petroleum Institute Standards — API 678 — “Accelerometer Based Vibration Monitoring Systems.” Bergmann, D./Mafi, S., “Selection Guide for Expansion Turbines,” Hydrocarbon Processing, Aug. 1979. Bloch, Heinz P., “A Practical Guide to Compressor Technology,” McGraw-Hill Book Co., Inc., New York, New York . Brown, R. N., “Control Systems for Centrifugal Gas Compressors,” Chemical Engineering, Feb. 1964. Criqui, A. F., “Rotor Dynamics of Centrifugal Compressors,” Solar Turbines International, San Jose, California.
Gas Machinery Research Council,”Guideline for Field Testing of Reciprocating Compressor Performance,” 2009 . Gibbs, C. W., “Compressed Air and Gas Data,” Ingersoll Rand Co. International Organization of Standardization Standard ISO 13631: 2002 — Petroleum and Natural Gas Industries — Packaged Reciprocating Compressors. Kurz, R., “The Physics of Centrifugal Compressor Performance,” Pipeline Simulation Interest Group, 2004. Kurz, R., and Fozi, A. A., 2002, “Acceptance Criteria for Gas Compression Systems,” ASME Paper GT2002–20282. Mokhatab, S., Poe, W. A., Speight, J. G., “Handbook of Natural Gas Transmission and Processing,” Gulf Publishing, 2006. Neerken, R. F. “Compressor Selection for the Process Industries,” Chemical Engineering, Jan. 1975. Perry, R. H./Chilton, C. H., “Chemical Engineers Handbook,” Fifth Edition, Section 6, McGraw-Hill Book Co., Inc., New York, New York. Poling, B. E., Prausnitz, J. M., O’Connell, J. P., “The properties of Gases and Liquids,” 5th ed., McGraw-Hill, 2001. Rasmussen, P., Kurz, R., “Centrifugal Compressor Applications: Upstream and Midstream,” 38th Turbomachinery Symposium, Houston, . 2009 Texas, Reid, C. P., “Application of Transducers to Rotating Machinery Monitoring and Analysis,” Noise Control and Vibration Reduction, Jan. 1975. Scheel, L. F., “Gas and Air Compression Machinery,” McGraw-Hill Book Co., Inc., New York, New York. Swearingen, J. S., “Turboexpanders and Expansion Processes for Industrial Gas,” Rotoflow Corp., Los Angeles, California. White, R. C., Kurz, R., “Surge Avoidance for Compressor Systems,” 35 th Turbomachinery Symposium, Houston, Texas, 2006. CTSS
Gas Machinery Research Council, “Guideline for Field Testing of Gas Turbine and Centrifugal Compressor Performance,” 2006.
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SI UNITS…
THE INTERNATIONAL STANDARDS SYSTEM
The system outlined here is the International System of Units (Systeme International d’ Unites), for which the abbreviation SI is being used in all languages. The SI system, which is becoming universally used, is founded on seven base units, these being: Length.......................... ..................... . meter Mass .................... ...................... .... kilogram Time.................................................second Electric current ................... ............ ampere Thermodynamic temperature ............Kelvin Luminous intensity..................... ..... candela Amount of substance...........................mole
m kg s A K cd mol
POWER The derived SI unit for power is the Watt (W), this being based on the SI unit of work, energy and quantity of heat – the Joule (J). One Watt (1 W) is equal to one Joule per second (1 J/s). One Watt is a very small unit of power, being equivalent to just 0.00134102 horsepower, so for engine ratings the kilowatt (kW) is used, 1 kW being equal to 1.341 hp and 1 hp being the equivalent of 0.7457 kW. The British unit of horsepower is equal to 1.014 metric horsepower (CV, PS, PK, etc.).
Reciprocating Internal Combustion engines. Known as PTC 17, this code is intended for tests of all types of reciprocating internal combustion engines for determining power output and fuel consumption. In its Section 2, Description and Definition of Terms, both the FPS and corresponding SI units of measurements are given.
SPECIFIC CONSUMPTION Fuel consumption measurements will be based on the currently accepted unit, the gram (g), and the Kilowatt Hour (kWh). Also adopted is heat units/power units so that energy consumption of an internal combustion engine referred to net power output, mechanical, is based on low unsaturated heat value of the fuel whether liquid or gaseous type. Thus the SI unit of measurement for net specific energy consumption is expressed: g/kWh. 1 g/kWh = 0.001644 lb/hph = 0.746 g/hph = 0.736 g/metric hph 1 lb/hph = 608.3 g/kWh 1 g/hph = 1.341 k/kWh 1 g/metric hph = 1.36 g/kWh
WEIGHTS AND LINEAR DIMENSIONS For indications of “weight” the original metric kilogram (kg) will continue to be used as the unit of mass, but it is important to note that the kilogram will no longer apply for force, for which the SI unit is the Newton (N), which is a kilogram meter per second squared. The Newton is that force which, when applied to a body having a mass of one kilogram, gives it an acceleration of one meter per second squared. “Weight” in itself will no longer apply, since this is an ambiguous term, so the kilogram in effect should only be used as the unit of mass. Undoubtedly, though, it will continue to be common parlance to use the word “weight” when referring to the mass of an object. The base SI unit for linear dimensions will be the meter, with a wide range of multiples and submultiples ranging from exa (10 18) to atto (10 -18): A kilometer is a meter x 10 3, for example, while a millimeter is a meter x 10 -3. To give an idea of how currently used units convert to SI units, the tables below give examples. KILLOWATTS (kW) TO HORSEPOWER (hp) (1 Kw = 1.34102 hp)
1 kW = 1.341 hp = 1.360 metric hp 1 hp = 0.746 kW = 1.014 metric hp 1 metric hp = 0.735 kW = 0.986 hp
TORQUE The derived SI unit for torque (or moment of force) is the Newton meter (Nm), this being based on the SI unit of force — the Newton (N) – and the SI unit of length – the meter (m). One Newton (1 N) is equivalent to 0.2248 pound-force (lbf) or 0.10197 kilogram-force (kgf), and one meter is equal to kilogram force (kgf) and one member is equal to 3.28084 feet (ft), so one Newton meter (1 N m) is equal to 0.737562 pound-force (lbf ft). or 0.101972 kilogram-force meter (kgf m). 1 Nm = 0.738 lbf ft = 0.102 kgf m 1 lbf ft = 1.356 Nm = 0.138 kgf m 1 kgf m = 9.807 Nm = 7.233 lbf ft
PRESSURE AND STRESS Although it has been decided that the SI derived unit for pressure and stress should be the Pascal (Pa), this is a very small unit, being the same as one Newton per square meter (1 N/m 2), which is only 0.000145 lbf/in 2 or 0.0000102 kgf/cm 2. So many European engine designers favor the bar as the unit of pressure, one bar being 100,000 Pascal (100 kPa), which is the equivalent of 14,504 lbf/in 2 or 1.020 kgf/cm 2, so being virtually the same as the currently accepted metric equivalent. On the other hand, for engine performance purposes, the millibar seems to be favored to indicate barometric pressure, this unit being one thousandth of a bar. Then again, there is a school that favors the kiloNewton per square meter (kN/m 2), this being the same as a kilopascal, and equal to 0.145 lbf/in 2 or 0.0102 kgf/cm2. 1 bar = 14.5 lbf/in2 = 1.0197 kgf/cm 2 1 lbf/in2 = 0.069 bar 1 kgf/cm2 = 0.98 bar The American Society of Mechanical Engineers in 1973 published its Performance Test Codes for 2017 EDITION
HEAT RATE Heat Rate is a product of Lower Heating Value (LHV) of Fuel (measured in Btu/lb or kJ/g for liquid fuel and Btu/ft3 or kJ/m3 for gas fuel) multiplied times (sfc) specific fuel consumption (measured in lb/hph or g/kWh). For Liquid Fuel Heat Rate (Btu/hph) = LVH (Btu/lb) X sfc (lb/hph) For Gaseous Fuel Heat Rate (Btu/hph) = LVH (Btu/ft 3) X sfc (ft3 /hph) To convert these units to SI units: Btu/hph X 1.414 = kJ/kWh Or Btu/kWh X 1.055 = kJ/kWh
LUBRICATING-OIL CONSUMPTION Although the metric liter is not officially an SI unit, its use will continue to be permitted, so measurement of lube-oil consumption will be quoted in liters per hour (liters/h). 1 liter/h = 0.22 Imp gal/h 1 Imp gal/h = 4.546 liters/h
TEMPERATURES The SI unit of temperature is Kelvin (K), and the character is used without the degree symbol (°) normally employed with other scales of temperature. A temperature of zero degree Kelvin is equivalent to a temperature of -273.15°C on the Celsius (centigrade) scale. The Kelvin unit is identical in interval to the Celsius unit, so direct conversions can be made by adding or subtracting 273. Use of Celsius is still permitted. 0 K = 273°C; absolute zero K 1°C = 273 K 132
kW 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
hp 1.341 2.682 4.023 5.364 6.705 8.046 9.387 10.728 12.069 13.410 14.751 16.092 17.433 18.774 20.115 21.456 22.797 24.138 25.479 26.820
kW 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40
hp 28.161 29.502 30.843 32.184 33.526 34.867 36.208 37 .549 38 .890 40.231 41.572 42.913 44.254 45.595 46.936 48.277 49.618 50.959 52.300 53.641
kW 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60
hp 54.982 56.323 57.664 59.005 60.346 61.687 63.028 64.369 65.710 67.051 68.392 69.733 71.074 72.415 73.756 75.097 76.438 77.779 79.120 80.461
kW 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80
hp 81.802 83.143 84.484 85.825 87.166 88.507 89.848 91.189 92.530 93.871 95.212 96.553 97.894 99.235 100.577 101.918 103.259 104.600 105.941 107.282
kW 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100
hp 108.623 109.964 111.305 112.646 113.987 115.328 116.669 118.010 119.351 120.692 122.033 123.374 124.715 126.056 127.397 128.738 130.079 131.420 132.761 134.102
POUNDS FORCE FEET (lbf ft) TO NEWTON METERS (Nm) (1 lbf ft = 1.35582 Nm) lbf ft Nm lbf ft 1 1.356 21 2 2.712 22 3 4.067 23 4 5.423 24 5 6.779 25 6 8.135 26 7 9.491 27 8 10.847 28 9 12.202 29 10 13.558 30 11 14.914 31 12 16.270 32 13 17.626 33 14 18.981 34 15 20.337 35 16 21.693 36 17 23.049 37 18 24.405 38 19 25.761 39 20 27.116 40
Nm 28.47 2 29.82 8 31.184 32.540 33.896 35.251 36.607 37.963 39.319 40.675 42.030 43.386 44.742 46.098 47.454 48.810 50.165 51.521 52.877 54.233
lbf ft 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60
Nm lbf ft 55.589 61 56.944 62 58.300 63 59.656 64 61.012 65 62.368 66 63.724 67 65.079 68 66.435 69 67.791 70 69.147 71 70.503 72 71.808 73 73.214 74 74.570 75 75.926 76 77.282 77 78.638 78 79.993 79 81.349 80
Nm lbf ft 82.705 81 84.061 82 85.417 83 86.772 84 88.128 85 89.484 86 90.840 87 92.196 88 93.552 89 94.907 90 96.263 91 97.619 92 98.975 93 100.331 94 101.687 95 103.042 96 104.398 97 105.754 98 107.110 99 108.466 100
Nm 109.821 111.177 112.533 113.889 115.245 116.601 117.956 119.312 120.668 122.024 123.380 124.715 126.001 127.447 128.803 130.159 131.515 132.870 134.226 135.582
These tables are reproduced from the booklet “Vehicle Metrics” published by Transport and Distribution Press Ltd., 118 Ewell Road, Surbiton, Surry, KT6 6HA England. WWW.CTSSNET.NET
CTSS
CONVERSION FACTORS
absolute atmosphere absolute British thermal unit British thermal unit/hour Celsius cubic foot/minute centimeter square centimeter cubic centimeter cubic foot Fahrenheit foot/second foot-pound gallon horsepower inch inch mercury inch water kilocalorie kilogram kilojoule kilopascal kilowatt liter meter millimeter square meter cubic meter cubic meter/minute mile per hour Newton Pascal normal* cubic meter/hour pound/square inch pound/square inch absolute pound/square inch gage standard* cubic foot standard* cubic foot/minute square
*“Normal” = 0°C and 1.01325x105 Pascals *“Standard” = 59°F and 14.73 psia
mm 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
kg 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
in 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748 0.787
lb 2.204 4.409 6.614 8.819 11.023 13.228 15.432 17.637 19.843 22.046 24.251 26.455 28.660 30.865 33.069 35.274 37.479 39.683 41.888 44.093
To Convert From English
sq. in. sq. ft. lb/cu.ft. lbf lb /ft f Btu Btu/hr Btu/scf in ft yd lb hp psi psia psig in. Hg in. H2O °F °F (Interval) ft-lb mph ft/sec cu. ft. gas (US) cfm scfm To Convert From Old Metric
To S.I. Metric
Multiply By
mm 2 m2 kg/m 3 N N/m kJ W kJ/mm 3 mm m m kg kW kPa kPa abs kPa gage kPa kPa °C = °C (Interval) N • m km/hr m/sec m3 L m3 /min nm3 /min
645.16 0.0929 16.0185 4.4482 14.5939 1.0551 0.2931 37.2590 25.400 0.3048 0.914 0.4536 0.7457 6.8948 6.8948 6.8948 3.3769 0.2488 (°F -32) 5/9 5/9 1.3558 1.6093 0.3048 0.0283 3.7854 0.0283 0.0268
To S.I. Metric
Multiply By
cm2 kcal kcal/hr cm kg/cm2 bars atm cm Hg cm H 2O nm3 /hr
mm 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40
MILLIMETERS (mm) TO INCHES (in) (1 millimeter = 0.03937 inch) in mm in mm in mm 0.827 41 1.614 61 2.402 81 0.866 42 1.654 62 2.441 82 0.906 43 1.693 63 2.480 83 0.945 44 1.732 64 2.520 84 0.984 45 1.772 65 2.559 85 1.024 46 1.811 66 2.598 86 1.063 47 1.850 67 2.638 87 1.102 48 1.890 68 2.677 88 1.142 49 1.929 69 2.717 89 1.181 50 1.968 70 2 .756 90 1.220 5 1 2.008 71 2 .795 91 1.260 5 2 2.047 72 2 .835 92 1.299 53 2.087 73 2 .874 93 1.339 54 2.126 74 2.9 13 94 1.378 55 2.165 75 2.95 3 95 1.417 56 2.205 76 2.99 2 96 1.457 57 2.244 77 3.03 2 97 1.496 58 2.283 78 3.07 1 98 1.535 59 2.323 79 3.11 0 99 1.575 60 2.362 80 3.150 100
kg 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40
KILOGRAMS (kg) TO POUNDS (lb) (1 kilogram = 2.20462 pounds) lb kg lb kg lb 46.297 41 90.390 61 134.482 48.502 42 92.594 62 136.687 50.706 43 94.799 63 138.891 52.911 44 97.003 64 141.096 55 .116 45 99.208 65 143.300 57.320 46 101.413 66 145.505 59.525 47 103.617 67 147.710 61.729 48 105.822 68 149.914 63.934 49 108.026 69 152.119 66.139 50 110.231 70 154.324 66.343 51 112.436 71 156.528 70.548 52 114.640 72 158.733 72.753 53 116.845 73 160.937 74.957 54 119.050 74 163.142 77.162 55 121.254 75 165.347 79.366 56 123.459 76 167.551 81.571 57 125.663 77 169.756 83.776 58 127.868 78 171.961 85.980 59 130.073 79 174.165 88.185 60 132 .277 80 176.370
2017 EDITION
TEMPERATURE CONVERSION TABLES*
CONVERSION FACTORS
ABBREVIATIONS abs ata Btu Btu/hr °C cfm cm cm2 cm3 cu.ft. °F ft/sec ft-lb gal hp in in. Hg in. H2O kcal kg kJ kPa kW L m mm m2 m3 m3 /min mph N N/m2 Nm3 /hr psi psia psig scf scfm sq
SI — METRIC/DECIMAL SYSTEM
kg 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100
mm2 kJ W mm kPa kPa kPa kPa kPa nm3 /min
in 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504 3.543 3.583 3.622 3.661 3.701 3.740 3.779 3.819 3.858 3.898 3.937
To Old Metric cm2 m2 kg/m3 N N/m kcal kcal/hr kcal/nm3 cm m m kg kW kg/cm2 bars abs ata cm Hg cm H2O °C = °C (Interval) N • m km/hr m/sec m3 L m3 /min nm3 /hr
100. 4.1868 1.16279 10. 98.0665 100. 101.325 1.3332 9.8064 0.0176
By Albert Sauveur
Multiply By 6.4516 0.0929 16.0185 4.4482 14.5939 0.252 0.252 0.1565 2.540 0.3048 0.914 0.4536 0.7457 0.070 0.0716 0.070 2.540 2.540 (°F -32) 5/9 5/9 1.3558 1.6093 0.3048 0.0283 3.7854 0.0283 1.61
C -17.8 -17.2 -16.7 -16.1 -15.6 -15.0 -14.4 -13.9 -13.3 -12.8 -12.1 -11.7 -11.1 -10.6 -10.0 -9.44 -8.89 -8.33 -7.78 -7.22 -6.67 -6.11 -5.56 -5.00 -4.44 -3.89 -3.33 -2.78 -2.22 -1.67 -1.11 -0.56 0 0.56 1.11 1.67 2.22 2.78 3.33 3.89 4.44 5.00 5.56 6.11 6.67 7.22 7.78 8.33 8.89 9.44
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49
C 38 43 49 54 60 66 71
100 110 120 130 140 150 160
0 to 100 C 10.0 10.6 11.1 11.7 12.2 12.8 13.3 13.9 14.4 15.0 15.6 16.1 16.7 17.2 17.8 18.3 18.9 19.4 20.0 20.6 21.1 21.7 22.2 22.8 23.3 23.9 24.4 25.0 25.6 26.1 26.7 27.2 27.8 28.3 28.9 29.4 30.0 30.6 31.1 31.7 32.2 32.8 33.3 33.9 34.4 35.0 35.6 36.1 36.7 37.2 37.8
50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100
F 122.0 123.8 125.6 127.4 129.2 131.0 132.8 134.6 136.4 138.2 140.0 141.8 143.6 145.4 147.2 149.0 150.8 152.6 154.4 156.2 158.0 159.8 161.6 163.4 165.2 167.0 168.8 170.6 172.4 174.2 176.0 177.8 179.6 181.4 183.2 185.0 186.8 188.6 190.4 192.2 194.0 195.8 197.6 199.4 201.2 203.0 204.8 206.6 208.4 210.2 212.0
100 to 1000 F C 212 77 230 82 248 88 266 93 284 99 302 100 320 104
170 180 190 200 210 212 220
F 338 356 374 392 410 413 428
F 32 33.8 35.6 37.4 39.2 41.0 42.8 44.9 46.4 48.2 50.0 51.8 53.6 55.4 57.2 59.0 60.8 62.6 64.4 66.2 68.0 69.8 71.6 73.4 75.2 77.0 78.8 80.6 82.4 84.2 86.0 87.8 89.6 91.4 93.2 95.0 96.8 98.6 100.4 102.2 104.0 105.8 107.6 109.4 111.2 113.0 114.8 116.6 118.4 120.0
C 110 116 121 127 132 138 143 149 154 160 166 171 177 182 188 193 199 204 210 216 221 227 232 238 243 249 254 260 266 271 277 282 288 293 299 304 310 316 321 327 332 338 343
100 to 1000 – cont. F C 230 446 349 240 464 354 250 482 360 260 500 366 270 518 371 280 536 377 290 554 382 300 572 388 310 590 393 320 608 399 330 626 404 340 644 410 350 662 416 360 680 421 370 698 427 380 716 432 390 734 438 400 752 443 410 770 449 420 788 454 430 806 460 440 824 466 450 842 471 460 860 477 470 878 482 480 896 488 490 914 493 500 932 499 510 950 504 520 968 510 530 986 516 540 1004 521 550 1022 527 560 1040 532 570 1058 538 580 1076 590 1094 600 1112 610 1130 620 1148 630 1166 640 1184 650 1202
C 538 543 549 554 560 566 571 577 582 588 593 599 604 610
1000 to 1630 F C 1832 816 1850 821 1868 827 1886 832 1904 838 1922 843 1940 849 1958 854 1976 860 1994 866 2012 871 2030 877 2048 882 2066 888
1000 1010 1020 1030 1040 1050 1060 1070 1080 1090 1100 1110 1120 1130
660 670 680 690 700 710 720 730 740 750 760 770 780 790 800 810 820 830 840 850 860 870 880 890 900 910 920 930 940 950 960 970 980 990 1000
F 1220 1238 1256 1274 1292 1310 1328 1346 1364 1382 1400 1418 1436 1454 1472 1490 1508 1526 1544 1562 1580 1598 1616 1634 1652 1670 1688 1706 1724 1742 1760 1778 1796 1814 1832
1500 1510 1520 1530 1540 1550 1560 1570 1580 1590 1600 1610 1620 1630
F 2732 2750 2768 2786 2804 2822 2840 2858 2876 2894 2912 2930 2948 2966
Note: The numbers in bold face type refer to the temperature either in degrees Centigrade or Fahrenheit which is desired to convert into the other scale. If converting from Fahrenheit degrees to Centigrade degrees, the equivalent temperatures will be found in the left column; while if converting from degrees Centigrade to degrees Fahrenheit, the answer will be found in the column on the right.
VOLUME
PISTON SPEED
WEIGHT/HORSEPOWER
CONVERSION FACTORS
CONVERSION FACTORS
CONVERSION FACTORS
1 L = 61.02 cu. in. 10 cu. in. = 0,164 L
L
cu. in.
1 m/s = 196.9 ft./min. 100 ft./min. = 0,51 m/s
m/s
ft./min.
1 kg/metric hp = 2.235 lb./hp 1 lb/hp = .4474 kg/metric hp
kg/metric hp
lb/hp
lb 178.574 180.779 182.984 185.188 187.393 189.598 191.802 194.007 196.211 198.416 200.621 202.825 205.030 207.235 209.439 211.644 213.848 216.053 218.258 220.462
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A NEW FIT FOR INNOVATIVE COMPRES SOLUTION NEEDED TO COMPLY WITH ZERO EMISSION? COMBINE A GAS-TIGHT RECIP CRANKCASE WITH LEAKAGE-FREE DIAPHRAGM HEADS. The NEA hybrid is the answer to the high technical demands of emission- and oil-free compression. This innovative concept combines NEA’s gas-tight crankcase with HOFER’s diaphragm head. The multi-stage, one crank drive system offers a leakage-free solution for low suction and high discharge pressure ratios at high mass flows. Once installed, NEAC Compressor Service, the service provider of the GROUP, cares for the fully sustainable lifetime of all compression systems. Additionally, NEA GROUP also proves its OEM in-depth know-how when it comes to revamp & modernization of diaphragm compressors from HOFER as well as from other brands. A new fit for innovative compression.
www.andreas-hofer.de
[email protected] Phone: +49 (0) 208 / 4 69 96-28
www.neuman-esser.com
[email protected] Phone: +49 (0) 2451 / 481-147
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LEADING COMPRESSOR TECHNOLOGY – LOWEST LIFE CYCLE COSTS www.burckhardtcompression.com
POWERING THE FUTURE Thoroughly Proven Power Solutions Maybe you need a turbine compressor set for natural gas transmission, gas gathering or some other process. Or perhaps you need power and heat for continuous duty industrial processes. No matter what the job or where the location, Solar Turbines can provide the power. With more than 60 years of experience in the gas turbine industry, we know turbines. From 1 to 22 MW, we offer the most complete line of mid-range gas turbines in the industry. Solar designs, manufactures and services turbomachinery systems that keep fuel consumption to a minimum and limit greenhouse gas emissions. We’ve got the experience gained from more than 15,000 gas turbines installed in 100 countries with over two billion field operating hours. You can expect your Solar ® gas turbine to perform to the highest standards of excellence. Powering the future through sustainable, innovative energy solutions. Visit us at www.solarturbines.com , call +1-619-544-5352 or email
[email protected] for more information. ©2017 Solar Turbines Incorporated
EXPERIENCE YOU CAN COUNT ON Experience Our Culture of Customer Care Your success is important to us, and we’ll help you succeed with total life-cycle support for your equipment. Our customer support personnel make up the world’s largest, best-trained and most experienced turbomachinery services team. We’ve been designing and manufacturing turbines for more than 60 years, so we know what we’re doing. And we continue to provide innovative technology to extend and maximize your equipment life cycle. Solar offers remote monitoring and predictive diagnostics through InSight Platform - the industry’s most advanced equipment health management technology. It provides intelligence that can cut unplanned downtime and save you money - all from the comfort of your office or even half a world away. ™
Visit us at www.solarturbines.com, call +1-619-544-5352 or email
[email protected] for more information. ©2017 Solar Turbines Incorporated
s n o i t a c i f i c e p S c i s a B 7 1 0 2
r e h t O - N I D - E A S - O S I . o N d r a d n a t S & m e t s y S g n i t a R
x 5 a m W k n i m
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l e u f G N . t f 0 0 2 3 @ p h s u o u n i t n o C
l e u f G N . t f 0 0 2 3 @ p h s u o u n i t n o C
l e u f G N . t f 0 0 2 3 @ p h s u o u n i t n o C
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2 3 A
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L 3 . 4
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l e d o M e n i g n E 6 6 6 6 0 6 - 6 - 9 - 1 - 4 K C C C C
e c n e r e f e R e g a P g o l a t a C
2017 EDITION
r e r u t c a f u n a M
*
. O C E N I G N E W O R R A
*
*
M G S ' K C U B
. C N I R A L L I P R E T A C
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s n o i t a c i f i c e p S c i s a B 7 1 0 2
r e h t O - N I D - E A S - O S I . o N d r a d n a t S & m e t s y S g n i t a R
p h
6 4 0 3 O S I
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4 7 9 1 7 1 C T P I S N A
4 7 9 1 7 1 C T P I S N A
4 7 9 1 7 1 C T P I S N A
4 7 9 1 7 1 C T P I S N A
4 7 9 1 7 1 C T P I S N A
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4 7 9 1 7 1 C T P I S N A
4 7 9 1 7 1 C T P I S N A
4 7 9 1 7 1 C T P I S N A
4 7 9 1 7 1 C T P I S N A
4 7 9 1 7 1 C T P I S N A
2 4 1
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x a m
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n i m
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x a m
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d e s o p p O : O l a t n o z i r o H : H e p y T - e e V : V e n i L - n I : L n o i t a r u g i f n o C & s r e d n i l y C f O r e b m u N
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E L 3 0 8 2 C P D x a j A
D T S 2 0 8 2 C P D x a j A
E L 2 0 8 2 C P D x a j A
D T S 1 0 8 2 C P D x a j A
E L 1 0 8 2 C P D x a j A
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l e d o M e n i g n E
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r e r u t c a f u n a M
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s S a S G E & N I r S e U w B o P D s N n A e R - m e R i E S ) n S f o i o S t s E r i a v R P i D ( D
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) s e u n i t n o C (
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s n o i t a c i f i c e p S c i s a B 7 1 0 2
4 7 9 1 7 1 C T P I S N A
A M E D , 4 7 9 1 7 1 C T P I S N A
A M E D , 4 7 9 1 7 1 C T P I S N A
A M E D , 4 7 9 1 7 1 C T P I S N A
A M E D , 4 7 9 1 7 1 C T P I S N A
A M E D , 4 7 9 1 7 1 C T P I S N A
A M E D , 4 7 9 1 7 1 C T P I S N A
A M E D , 4 7 9 1 7 1 C T P I S N A
A M E D , 4 7 9 1 7 1 C T P I S N A
A M E D , 4 7 9 1 7 1 C T P I S N A
A M E D , 4 7 9 1 7 1 C T P I S N A
A M E D , 4 7 9 1 7 1 C T P I S N A
A M E D , 4 7 9 1 7 1 C T P I S N A
A M E D , 4 7 9 1 7 1 C T P I S N A
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A M E D , 4 7 9 1 7 1 C T P I S N A
A M E D , 4 7 9 1 7 1 C T P I S N A
A M E D , 4 7 9 1 7 1 C T P I S N A
A M E D , 4 7 9 1 7 1 C T P I S N A
A M E D , 4 7 9 1 7 1 C T P I S N A
A M E D , 4 7 9 1 7 1 C T P I S N A
A M E D , 4 7 9 1 7 1 C T P I S N A
A M E D , 4 7 9 1 7 1 C T P I S N A
0 3
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4 9 9
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x 8 a 4 m 1
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2017 EDITION
r e r u t c a f u n a M
*
S A G & L I O E G
) s e u n i t n o C (
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CTSS
s n o i t a c i f i c e p S c i s a B 7 1 0 2
) W k ( e g n a R r e d n i l y C r e P t u p t u O
1 / 6 4 0 3 O S I & 0 8 > # e n a h t e M
7 3 2 2
2 8 9 2
5 5 3 3
9 7 9 5
0 0 0 , 0 1
0 0 2 9
0 0 0 , 0 1
0 6 2 , 9 1
0 5 5 , 7 1
0 5 5 , 7 1
. l e u f l a u D . d e e p s t n a t s n o C . 6 4 0 3 O S I
. l e u f l a u D . d e e p s t n a t s n o C . 6 4 0 3 O S I
A M E D , 4 7 9 1 7 1 C T P I S N A
A M E D , 4 7 9 1 7 1 C T P I S N A
A M E D , 4 7 9 1 7 1 C T P I S N A
1 / 6 4 0 3 O S I
1 / 6 4 0 3 O S I
1 / 6 4 0 3 O S I
4 9 1 1
0 9 7 1
7 8 3 2
9 7 6 1
4 1 0 2
4 8 9 2
6 7 4 4
8 2 7 3
1 8 0 1
8 0 8 1 7 8 1 9 6 8 1 4 1 1 1
5 9 8
3 4 3 1
0 9 7 1
3 4 3 1
1 1 6 1
7 8 3 2
1 8 5 3
8 8 7 9 2 5 5 1 0 4 2 1 2
7 0 0 1
2 4 3 1
2 1 0 2
3 8 6 2
9 1 0 3
0 7 6 5
0 2 3 4
0 5 0 4
0 2 3 4
0 1 8 , 8 1
0 0 1 , 7 1
0 0 7 , 1 1
x 0 a 0 6 m 1
0 0 4 2
0 0 2 3
0 5 2 2
0 0 7 2
0 0 0 4
0 0 0 6
0 0 0 5
5 7 1 1
0 0 5 1
9 9 9 1
8 9 9 2
7 9 9 3
8 9 4 4
9 2 1 8
0 1 4 , 3 1
7 3 3 , 2 1
0 1 4 , 3 1
8 2 8 , 5 2
5 3 5 , 3 2
5 3 5 , 3 2
n 0 i 0 m 2 1
0 0 8 1
0 0 4 2
0 0 8 1
0 6 1 2
0 0 2 3
0 0 8 4
0 4 5 0 2 1 4 6 7 6 3 1 2
9 4 3 1
9 4 8 1
8 9 6 2
7 9 5 3
7 4 0 4
9 0 7 7
3 9 7 5
1 3 4 5
3 9 7 5
4 2 2 , 5 2
1 3 9 , 2 2
0 9 6 , 5 1
2 2 2 6 . 6 . 6 . 2 2 2 1 1 1
4 6 . 8
4 6 . 8
4 6 . 8
3 1 . 8
2 2 2 1 1 4 7 . 9 . 9 . 2 . 6 . 2 3 2 2 0 4 . 6 . 6 . 6 . 6 . 5 0 0 2 9 9 9 9 9 2 2 2 2 2 2 1 1 1 1 1 9 1 1 1 1 1
0 5 4 1
0 5 2 2
1 / 6 4 0 3 O S I
0 x 0 a 2 m 1
0 0 0 0 2 2 1 1
0 3 3
0 3 3
0 3 3
0 3 3
0 0 0 0 0 0 0 0 0 0 0 0 4 4 4 0 0 0 0 0 0 0 0 0 0 5 5 5 1 1 1 0 2 2 8 0 0 0 0 0 5 1 1 1 1 1 1 1 1 1 7 7 7 7 5 5 5
n 0 i 0 m 9
0 0 0 0 9 9
0 7 2
0 7 2
0 7 2
0 7 2
0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 5 5 5 0 0 0 0 0 0 2 2 2 2 0 0 0 7 7 7 2 1 9 9 9 9 9 7 7 7 7 5 5 5
x 9 a 4 m 1
9 9 4 4 1 1
8 6 1
8 6 1
4 7 3
4 7 3
0 9 3 . 1 . 0 . 4 . 4 . 4 . 4 . . 4 . 6 6 6 6 6 2 0 0 0 3 3 0 0 5 8 8 8 8 8 3 0 6 0 2 9 1 5 1 1 1 1 1 3 5 4 5
n 2 i m 1 1
2 2 1 1 1 1
4 3 1
4 3 1
9 9 2
9 9 2
0 . 2 . 8 . . 8 9 8 9 6 3 2 4 1 1
8 . 7 6 1
8 . 7 6 1
7 . 7 6 1
7 . 7 6 1
0 5 5 7 7 7 0 9 9 1
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V L V 6 8 2 1 1
V 0 1
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V V V 6 V 0 6 1 0 2 V , , 2 6 6 V 1 , 2 L L V V V V , 1 2 2 2 6 8 8 6 1 6 8 , , 1 1 1 1 1 1 1 1 2 ; 2 ; L ; 1 L 8 L 1 ; 6 , 9 L 6 9
6 7 . 1 1
6 7 . 1 1
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4 2 . 1 1
5 5 . 6 2
5 5 . 6 2
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) m m ( e k o r t S
0 0 0 6 6 6 2 2 2
6 5 3
6 5 3
8 0 5
8 0 5
0 6 6 5 0 0 0 0 0 0 0 0 0 0 0 0 0 1 1 6 0 0 0 0 0 0 0 0 0 8 8 8 3 2 2 1 3 3 3 3 3 4 4 4 4 5 5 5
) m m ( e r o B
0 0 0 4 4 4 2 2 2
6 5 3
6 5 3
7 5 4
7 5 4
5 6 8 2 0 0 0 0 0 5 0 0 0 0 0 0 7 1 3 5 2 2 2 2 2 9 4 2 4 0 0 6 2 2 2 1 2 2 2 2 2 2 3 3 3 5 5 4
r e m e s s e B r 0 e 1 p V o o M C G
r e m e s s e B r 2 e 1 p V o o M C G
r e m e s s e B r 0 e 3 p 3 o o W C 8
r e m e s s e B 0 r 3 e 3 p o W o 2 C 1
) l y c / L ( r e d n i l y C r e P t n e m e c a l p s i D
6 7 . 1 1
l e d o M e n i g n E
L G P P F 5 H H G 7 2 V V V
G A 2 2 L 6
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A H S S E E K N U I A G N W E S ' S E A G G
R E W O P S A M T E A T G S I I Y N S
G 8 0 4 2
e c n e r e f e R e g a P g o l a t a C
2017 EDITION
1 / 6 4 0 3 O S I & 0 8 > # e n a h t e M
A M E D , 4 7 9 1 7 1 C T P I S N A
d e s o p p O : O l a t n o z i r o H : H e p y T - e e V : V e n i L - n I : L n o i t a r u g i f n o C & s r e d n i l y C f O r e b m u N
S E N I G N E S A G L A R U T A N
1 / 6 4 0 3 O S I & 0 8 > # e n a h t e M
. e n i g n E s a G . d e e p s t n a t s n o C . 6 4 0 3 O S I
A M E D , 4 7 9 1 7 1 C T P I S N A
) r a b ( e r u s s e r P e v i t c e f f E n a e M e k a r B m u m i x a M
) m p r ( e g n a R d e e p S d e t a R
1 / 6 4 0 3 O S I & 0 8 > # e n a h t e M
. l e u f l a u D . d e e p s t n a t s n o C . 6 4 0 3 O S I
A M E D , 4 7 9 1 7 1 C T P I S N A
x a m W k n i m
p h
1 / 6 4 0 3 O S I & 0 8 > # e n a h t e M
. l e u f l a u D . d e e p s t n a t s n o C . 6 4 0 3 O S I
A M E D , 4 7 9 1 7 1 C T P I S N A
r e h t O - N I D - E A S - O S I . o N d r a d n a t S & m e t s y S g n i t a R
e g n a R t u p t u O
1 / 6 4 0 3 O S I & 0 8 > # e n a h t e M
. e n i g n E s a G . d e e p s t n a t s n o C . 6 4 0 3 O S I
r e r u t c a f u n a M
G 2 1 4 2
G 6 1 4 2
G A 2 2 L 8
G A 2 2 V 2 1
G A 2 2 V 6 1
G A 2 2 V 8 1
G A 8 2 V 8 1
G S 4 3 W
D G 2 3 W
V 0 V 2 , V V 8 6 8 8 1 , 1 1 1 2 ; 1 L 9
F D 4 3 W
G S 0 5 W
8 8 . 3 1 1
F D 0 5 W
9 3 . 6 9
D G 6 4 W
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s n o i t a c i f i c e p S c i s a B 7 1 0 2
) m p r ( d e e p S t f a h S t u p t u O m u m i x a M
0 5 6 , 3 1
5 2 5 , 1 1
5 7 0 , 2 1
5 7 0 , 2 1
5 7 9 9
5 7 9 9
0 8 7 3
5 8 0 8
5 2 8 6
5 0 4 6
0 0 8 4
0 0 8 4
0 0 8 4
0 0 8 4
0 5 8 4
0 5 8 4
0 7 5 3
0 7 5 3
9 2 4 3
9 2 4 3
0 0 2 6
o i t a R e r u s s e r P
9 . 4 1
3 . 2 1
8 . 3 1
5 . 4 1
8 . 6 1
9 . 8 1
3 1
4 1
7 . 8 1
3 . 4 2
6 . 0 2
3 . 1 2
7 . 1 2
0 . 2 2
6 . 1 2
1 . 2 2
3 . 4 3
1 . 6 3
3 . 2 2
8 . 2 2
8 1
8 4 9 , 0 1
5 3 0 8
5 5 6 7
5 3 5 7
3 4 9 9
8 8 2 7
3 5 8 7
8 3 7 7
7 2 0 7
9 5 4 6
0 5 6 9
0 4 5 9
0 4 3 9
0 4 3 9
0 2 9 8
0 1 9 8
0 6 2 8
0 9 5 8
1 0 9 6
5 7 8 6
4 4 6 9
8 3 7 7
6 1 6 7
6 5 2 7
2 4 1 7
8 2 0 7
8 0 9 6
3 4 4 7
4 4 3 7
1 6 6 6
2 2 1 6
9 1 8 6
3 4 7 6
2 0 6 6
9 9 5 6
6 0 3 6
9 9 2 6
7 3 8 5
1 7 0 6
1 4 5 6
6 1 5 6
6 1 8 6
W k
0 0 7 5
4 8 6 7
4 6 3 8
8 3 2 9
8 2 4 , 3 1
8 1 9 , 4 1
9 9 2 , 9 1
0 4 2 , 5 2
9 6 6 , 3 3
9 0 0 , 1 4
0 5 9 , 7 2
0 5 1 , 9 2
0 5 6 , 0 3
0 5 9 , 0 3
0 9 9 , 2 3
0 0 8 , 3 3
0 1 2 , 4 5
0 2 8 , 1 6
1 9 0 , 3 3
7 3 7 , 3 3
6 6 4 , 3 2
p h b
0 4 6 7
0 0 3 , 0 1
6 1 2 , 1 1
8 8 3 , 2 1
0 0 0 , 8 1
6 0 0 , 0 2
1 8 8 , 5 2
7 4 8 , 3 3
1 5 1 , 5 4
4 9 9 , 4 5
5 6 4 , 7 3
5 7 0 , 9 3
4 8 0 , 1 4
5 9 4 , 1 4
0 3 2 , 4 4
6 1 3 , 5 4
9 7 6 , 2 7
7 7 8 , 2 8
6 7 3 , 4 4
2 4 2 , 5 4
9 6 4 , 1 3
0 5 7 T G S
E L D 2 6 G 1 1 2 B R l a i r t s u d n I
2 6 G 1 1 2 B R l a i r t s u d n I
E L D 2 6 T G 1 1 2 B R l a i r t s u d n I
2 6 T G 1 1 2 B R l a i r t s u d n I
E L D 1 6 T G 1 1 2 B R l a i r t s u d n I
E L W 0 6 t n e r T l a i r t s u d n I
E L D 0 3 T G 1 1 2 B R l a i r t s u d n I
0 3 T G 1 1 2 B R l a i r t s u d n I
S H G 0 3 A R T C E V
h W k / J k
e t a R t a e H h p h / u t B
S E N I B R U T S A G E V I R D L A C I N A H C E M
s n o i t i d n o C O S I t A t u p t u O s u o u n i t n o C
r e b m u N l e d o M 0 0 1 T G S
e c n e r e f e R e g a P g o l a t a C
2017 EDITION
r e r u t c a f u n a M
0 0 2 T G S
) W M 8 ( 0 0 3 T G S
) W M 9 ( 0 0 3 T G S
) W M 3 1 ( 0 0 4 T G S
) W M 5 1 ( 0 0 4 T G S
0 0 5 T G S
0 0 6 T G S
0 0 7 T G S
1 6 T G 1 1 2 B R l a i r t s u d n I
E L D 0 6 t n e r T l a i r t s u d n I
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) s e u n i t n o C (
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s n o i t a c i f i c e p S c i s a B 7 1 0 2
) m p r ( d e e p S t f a h S t u p t u O m u m i x a M
0 0 6 3
0 0 2 6
0 0 6 3
0 0 2 6
0 0 6 3
0 0 6 3
3 4 7 3
0 0 8 1
0 0 5 , 2 1
0 0 9 7
0 0 8 7
0 0 5 6
0 0 5 6
0 0 1 6
0 0 1 6
o i t a R e r u s s e r P
8 1
2 2
3 2
4 2
3 2
8 2
0 3
7
5 1
6 1
9 1
6 1
8 1
2 2
3 2
9 8 5 9
0 8 9 8
4 1 1 9
6 3 9 8
4 0 1 9
9 4 5 8
6 6 5 8
8 1 1 , 4 1
0
0
0
0
0
0
6 7 7 6
7 4 3 6
0 4 4 6
6 1 3 6
3 3 4 6
2 4 0 6
4 5 0 6
8 7 9 9
5 3 8 , 0 1
9 4 6 7
7 7 8 6
0 0 4 7
2 9 9 6
W k
1 7 8 , 3 2
5 9 3 , 1 3
9 6 3 , 1 3
9 2 2 , 4 3
2 5 8 , 3 3
2 2 3 , 4 4
0 3 8 , 9 4
0 0 0 2
0 0 6 5
2 8 9 , 1 1
0 0 5 , 6 1
2 9 8 , 7 1
p h b
1 1 0 , 2 3
2 0 1 , 2 4
5 6 0 , 2 4
2 0 9 , 5 4
5 9 3 , 5 4
6 3 4 , 9 5
2 2 8 , 6 6
2 8 6 2
0 1 5 7
8 6 0 , 6 1
7 2 1 , 2 2
4 9 9 , 3 2
G 1 6 R D
G 0 4 A R T C E V
P G 1 6 R D
4 G 0 4 A R T C E V
4 G 1 6 R D
C P G 3 6 R D
G P G 3 6 R D
G 3 2 G K
2 5 T L a v o N
2 0 1 E G
6 1 T L a v o N
h W k / J k
0 7 6 4
0 7 6 4
4 1 7 5
1 1 1 5
9 2
9
1 1
7 1
2 1
0
0
0
0
0
0
8 4 3 6
2 9 9 6
5 7 0 6
4 1 7 8
3 1 4 8
4 8 8 6
7 4 6 7
9 0 6 , 3 2
7 3 0 , 2 3
0 9 5 , 4 3
5 5 8 , 3 4
0 7 4 , 9 2
9 6 9 , 3 3
2 7 7 , 3 3
5 3 5 , 3 4
0 6 6 , 1 3
2 6 9 , 2 4
5 8 3 , 6 4
9 0 8 , 8 5
0 2 5 , 9 3
3 5 5 , 5 4
8 8 2 , 5 4
0 8 3 , 8 5
5 2 T G P
+ 5 2 T G P
4 G + 5 2 T G P
D P 0 0 0 6 M L
) C ( 2 0 0 5 S M
) D ( 2 0 0 5 S M
) E ( 2 0 0 5 S M
) B ( 1 0 0 6 S M
e t a R t a e H h p h / u t B
S E N I B R U T S A G E V I R D L A C I N A H C E M
s n o i t i d n o C O S I t A t u p t u O s u o u n i t n o C
r e b m u N l e d o M
e c n e r e f e R e g a P g o l a t a C
2017 EDITION
r e r u t c a f u n a M
*
*
S S E N I S U B D N A R R E S S E R D
S A G & L I O E G
0 2 T G P
) s e u n i t n o C (
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s n o i t a c i f i c e p S c i s a B 7 1 0 2
) m p r ( d e e p S t f a h S t u p t u O m u m i x a M
0 0 6 3
0 0 0 3
0 0 5 6
0 0 1 6
0 0 1 6
0 0 6 3
0 3 9 3
0 3 9 3
8 2 4 3
8 2 4 3
0 0 2 8
0 0 2 8
0 0 2 5
0 0 2 5
0 0 0 5
0 0 7 3
0 0 6 , 2 1
0 5 4 9
0 5 4 9
0 0 0 5
0 0 4 , 5 1
o i t a R e r u s s e r P
3 1
3 1
8 1
2 2
3 2
8 2
2 3
2 3
0 4
2 4
0 . 4 1
6 . 6 1
5 . 9 1
0 . 3 1
5 . 1 2
5 . 1 2
5 1
0 1
1 1
8 . 0 2
4 . 8
0
0
0
0
0
0
0
0
0
0
0 3 4 , 1 1
5 4 8 , 0 1
5 8 2 , 0 1
0 5 2 , 1 1
0 0 0 , 0 1
5 6 8 9
0 9 5 , 0 1
0 4 8 , 1 1
0 2 3 , 1 1
3 1 3 9
8 1 5 , 4 1
8 1 7 7
8 4 3 7
1 3 0 7
3 6 3 6
8 6 3 6
7 1 9 5
0 6 9 5
0 9 8 5
0 8 5 7
7 8 6 5
0 8 0 8
5 6 6 7
0 7 2 7
5 5 9 7
0 7 0 7
5 7 9 6
0 8 4 7
0 7 3 8
0 0 0 8
2 8 5 6
9 5 2 , 0 1
W k
7 2 2 , 6 8
2 4 1 , 0 3 1
3 9 5 , 3 2
8 2 8 , 1 3
8 4 3 , 4 3
5 5 8 , 3 4
0 0 3 , 4 5
7 8 7 , 2 5
6 9 1 , 8 9
5 5 5 , 0 1 1
0 0 5 6
0 0 3 8
0 0 7 , 6 1
0 0 7 , 6 1
0 0 0 , 6 2
0 0 7 , 6 2
0 0 9 6
0 0 5 , 0 1
0 0 5 , 2 1
0 8 7 , 6 2
5 6 2 2
p h b
0 3 6 , 5 1 1
0 2 5 , 4 7 1
8 3 6 , 1 3
2 8 6 , 2 4
1 6 0 , 6 4
9 0 8 , 8 5
8 1 8 , 2 7
7 8 7 , 0 7
1 8 6 , 1 3 1
4 5 2 , 8 4 1
5 1 7 8
0 3 1 , 1 1
0 0 4 , 2 2
0 0 4 , 2 2
0 7 8 , 4 3
0 0 8 , 5 3
0 5 2 9
0 8 0 , 4 1
0 6 7 , 6 1
0 1 9 , 5 3
8 3 0 3
) 1 7 T D ( 0 0 0 6 T G U
) 0 7 T D ( 0 0 0 8 T G U
) 0 9 G D ( 0 0 0 5 1 T G U
) 2 L 9 5 J D ( 0 0 0 6 1 T G U
) 0 8 U D ( 0 0 0 5 2 T G U
) 0 8 N D ( 0 0 0 5 2 T G U
N 0 1 4 0 3 1 M H T
N 2 1 4 0 3 1 M H T
8 T F M
0 4 E S A
h W k / J k
e t a R t a e H h p h / u t B
S E N I B R U T S A G E V I R D L A C I N A H C E M
s n o i t i d n o C O S I t A t u p t u O s u o u n i t n o C
r e b m u N l e d o M ) A E ( 1 0 0 7 S M
e c n e r e f e R e g a P g o l a t a C
2017 EDITION
r e r u t c a f u n a M
) E ( 1 0 0 9 M
5 2 T G P
+ 5 2 T G P
4 G + 5 2 T G P
) m p p 5 1 (
F P 0 0 0 6 M L
+ F P 0 0 0 6 M L
G P 0 0 0 6 M L
*
B P 0 0 1 S M L
+ B P 0 0 1 S M L
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S A G & L I O E G
C P & R T G
0 0 2 6 T G M 9 3 1 , 8 3 1
1 0 2 , 7 2 1
E S O B R U T ) & N E L S E U S A E I H D R N E A B O M (
I H S I B U S T I M
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s n o i t a c i f i c e p S c i s a B 7 1 0 2
) m p r ( d e e p S t f a h S t u p t u O m u m i x a M
0 0 8 1
0 0 8 1
0 0 8 1
0 0 8 1
0 0 8 1
0 0 5 1
0 0 8 1
0 0 8 1
0 0 8 1
0 0 8 1
0 0 8 1
0 0 0 7
5 5 8 8
0 0 5 9
0 0 5 9
5 0 6 , 1 1
0 0 3 , 4 1
0 0 5 , 6 1
0 0 5 , 5 1
0 0 3 , 2 2
o i t a R e r u s s e r P
1 . 4
1 . 4
6 . 8
2 . 7
5 . 8
5 . 8
6 . 9
2 . 7
2 . 7
5 . 8
2 . 7
1 . 4 2
1 . 6 1
1 . 7 1
3 . 6 1
5 . 6 1
2 . 2 1
3 . 0 1
3 . 0 1
7 . 6
h 0 W 4 6 , k / 2 J 2 k
4 1 8 , 2 2
4 5 8 , 7 1
2 3 2 , 8 1
7 5 6 , 6 1
9 6 1 , 6 1
6 8 5 , 5 1
5 3 8 , 6 1
8 1 7 , 6 1
4 6 5 , 5 1
3 3 8 , 6 1
0 0 0 9
0 3 9 9
5 6 4 , 0 1
0 3 8 , 0 1
0 7 1 , 0 1
0 5 2 , 1 1
0 0 0 , 2 1
0 7 8 , 2 1
5 5 6 , 4 1
0 0 0 , 6 1
3 2 1 , 6 1
8 1 6 , 2 1
5 8 8 , 2 1
1 7 7 , 1 1
7 2 4 , 1 1
5 1 0 , 1 1
8 9 8 , 1 1
4 1 8 , 1 1
9 9 9 , 0 1
6 9 8 , 1 1
0 6 3 6
0 2 0 7
5 9 3 7
5 5 6 7
0 9 1 7
0 5 9 7
5 8 4 8
0 0 1 9
0 6 3 , 0 1
W 9 k 2
8
6 9 4
4 9 7
3 9 9
2 9 1 1
1 7 4 1
9 8 5 1
6 8 9 1
3 8 3 2
7 7 1 3
0 7 9 3
0 7 3 , 2 2
0 7 7 , 6 1
0 6 8 , 1 1
0 6 8 9
0 2 3 8
0 4 7 5
0 7 5 4
0 0 5 3
5 8 1 1
p h b
0 0 4
5 6 6
5 6 0 1
1 3 3 1
8 9 5 1
2 7 9 1
0 3 1 2
2 6 6 2
4 9 1 3
9 5 2 4
2 2 3 5
0 0 0 , 0 3
0 9 4 , 2 2
0 0 9 , 5 1
0 2 2 , 3 1
0 5 1 , 1 1
0 0 7 7
0 3 1 6
0 0 7 4
0 9 5 1
R M 1 0 4 T N C
R M 1 0 6 T N C
R M 1 0 0 1 T N C
M 1 0 3 1 T N C
M 1 0 6 1 T N C
M 2 0 0 2 T N C
M 1 0 0 2 T N C
M 1 0 6 2 T N C
M 1 0 1 3 T N C
M 1 0 1 4 T N C
M 1 0 4 5 T N C
0 5 2 n a t i T
0 3 1 n a t i T
0 0 0 0 7 s 1 9 u s s r r r u a a a M M T
0 6 s u r u a T
0 5 r u a t n e C
0 4 r u a t n e C
0 2 n r u t a S
e t a R t a e H h p h / u t B
S E N I B R U T S A G E V I R D L A C I N A H C E M
s n o i t i d n o C O S I t A t u p t u O s u o u n i t n o C
r e b m u N l e d o M
e c n e r e f e R e g a P g o l a t a C
2017 EDITION
r e r u t c a f u n a M
*
b a T s r e v o M e m i P r
. D T L . O C S M E T S Y S R E W O P A T A G I I N
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0 0 0 , 4 1
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0 5 7
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0 0 9
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0 0 5
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s n o i t a c i f i c e p S c i s a B 7 1 0 2
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s n e p O = O n g d e t a o C b i R = R n i l o r e t a W / r i A = W / A o i o t C r i A / r i A = A / A a c i e l b a l i a v A ) f N i f o o r P n o i s o l p x E / Y ( c e t n i o P g n i t a r e p O p d e t a R t A ) i h P s o c ( r o t c a F r e w o P l a m r o N S c t n i o P g n i t a r e p O d e t a R t A i ) % ( y c n e i c i f f E r o t o M s a B x a 7 n o i t a r e p O D F V m 1 r o F e g n a R d e e p S 0 n i 2 m
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t r a h C n o i t c e l e S r e w o p e s r o H r o s s e r p m o C
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) . t 0 2 3 2 1 5 3 3 5 7 1 5 3 7 8 5 4 6 9 2 6 0 F ) 0 7 3 1 9 7 6 5 4 3 3 2 1 8 . G 7 2 2 2 1 1 1 1 1 1 1 1 1 9 8 7 6 5 4 3 3 2 2 u I 6 8 6 5 0 8 8 0 2 6 0 6 C S 0 2 3 0 0 2 5 8 2 5 6 2 0 8 7 5 4 4 3 2 2 0 2 2 2 2 1 1 1 1 1 1 1 1 1 9 8 7 6 5 4 3 2 2 6 n P ( o i E 0 0 1 9 9 4 3 3 5 7 1 6 9 6 6 8 6 6 8 0 3 l l i R 0 6 3 9 7 6 5 4 3 2 2 1 1 1 1 1 1 1 1 9 8 7 6 5 4 3 3 2 M U 6 2 2 1 1 r S 0 4 3 3 3 8 7 7 9 2 6 9 2 0 1 3 1 1 3 5 e S 5 5 2 9 7 5 4 3 2 2 1 0 P E 5 2 2 1 1 1 1 1 1 1 1 1 9 8 7 6 5 4 3 2 r R 8 4 6 7 2 1 1 3 7 9 0 5 4 0 8 6 6 7 e P 0 4 1 8 6 5 4 3 2 1 0 0 w E 0 5 2 2 1 1 1 1 1 1 1 1 1 8 7 6 5 4 3 2 o p G 0 1 5 8 9 5 4 5 7 9 0 2 8 7 7 2 0 0 1 e R 5 4 0 7 5 4 3 2 1 0 0 9 7 6 5 5 4 3 2 s r A 4 2 2 1 1 1 1 1 1 1 1 o H 0 3 6 0 2 8 7 8 9 1 4 1 0 2 5 3 3 H C 0 3 9 7 5 3 2 1 0 8 4 2 1 1 1 1 1 1 1 9 9 8 7 6 5 4 3 2 S e I k D 0 3 6 0 3 0 9 8 9 1 5 3 3 5 8 6 a 5 3 8 6 4 3 1 0 7 r 3 2 1 1 1 1 1 1 9 8 8 7 6 5 4 3 2 B ( 0 8 5 1 3 1 6 5 6 8 2 6 4 5 7 0 0 1 7 5 3 2 0 9 8 7 7 6 5 4 3 3 3 2 1 1 1 1 1
F ° 0 0 1 E R U T A R E P S M E A T G N L A O I R T U C T U A S N 3 4
0 3 3 9 3 7 5 0 6 3 2 0 3 3 4 7 1 5 4 5 7 2 2 1 1 1 1 9 8 7 6 6 5 4 3 2 0 7 9 6 7 0 8 9 1 4 9 4 2 2 0 8 4 2 0 9 7 6 6 5 4 4 3 2 2 1 1 1 1 5 8 0 8 7 7 4 1 6 1 0 1 4 7 2 7 5 1 1 1 1 9 8 7 6 5 4 4 3 2
Y T I L I B 0 8 1 6 5 2 1 3 6 0 4 8 I F 5 6 3 0 8 7 6 5 4 4 3 2 ° S 1 1 1 1 0 S 6 E 5 6 1 2 4 1 2 4 7 0 4 D R 2 5 2 9 7 6 5 4 3 3 2 N P 1 1 1 A M O 7 0 4 4 8 2 0 1 2 5 . 4 C 0 4 0 7 6 5 4 3 2 1 R 1 1 1 D O E F 5 2 7 6 6 5 8 2 R D 7 1 8 6 4 3 2 U E S T A C 0 9 3 3 9 E E 5 9 6 4 2 M R R D 5 5 5 6 F O 2 2 6 3 C C . : S 1 T = ” 0 5 0 0 0 0 0 0 0 0 0 0 0 0 E M O 0 0 0 0 0 0 0 0 0 5 N 2 5 7 0 5 0 5 0 5 0 5 0 5 0 5 T M 0 0 N “ 1 2 3 4 5 6 7 8 9 0 1 1 1 1 2 2 3 3 4 4 5 5 6 6 7 7 O N 1 2
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TECH BRIEF The following section covering Prime Movers has been reproduced, by p ermission, from the Engineering Data book, 13 th edition published by the Gas Processors Suppliers Association. The complete Engineering Data Book can be ordered from GPSA, 6526 East 60 th Street, Tulsa, Oklahoma 74145, www.gpaglobal.org.
Prime Movers For Mechanical Drives “Prime movers for mechanical drives ” is a common term for machines made for transferring mechanical energy to pumps and compressors, including: •
Steam turbines
•
Gas turbines
•
Electrical motors
•
Internal combustion engines
Special considerations for the use of prime movers as drives for generators are not included in this chapter.
In a single-stage turbine, steam is accelerated through one cascade of stationary nozzles and guided into the rotating blades or buckets on the turbine wheel to produce power. A Rateau design has one row of buckets per stage (Fig. 15-2). A Curtis design has two rows of buckets per stage and requires a set of turning vanes between the first and second row of buckets to redirect the steam flow (Fig. 15-3). A multi-stage turbine utilizes either a Curtis or Rateau first stage followed by one or more Rateau stages. Single-stage turbines are usually limited to about 2500 horsepower although special designs are available for larger units. Below 2500 horsepower the choice between a single and a multi-stage turbine is usually an economic one. For a given shaft horsepower, a single-stage turbine will have a lower capital cost but will require more steam than a multi-stage turbine because of the lower efficiency of the single-stage turbine.
STEAM TURBINE TYPES Mechanical drive steam turbines are major prime movers for compressor, blower, and pump applications. Steam turbines are available for a wide range of steam conditions, horsepower, and speeds. Typical ranges for each design parameter are: Inlet Pressure, psig Inlet Temperature, °F Exhaust Pressure, psig Horsepower Speed, rpm
Single Stage/Multi-Stage
Condensing/Non-Condensing
30 – 2000 saturated – 1000 saturated – 700 5 – 100,000 1800 – 14,000
The energy available in each pound of steam which flows through the turbine is a function of the overall turbine pressure ratio (inlet pressure/exhaust pressure) and inlet temperature. Condensing turbines are those whose exhaust pressure is below atmospheric. They offer the highest overall turbine pressure ratio for a given set of inlet conditions and therefore require the lowest steam flow to produce a given horsepower. A cooling medium is required to totally condense the steam.
Steam turbines used as process drivers are usually required to operate over a range of speeds in contrast to a turbine used to drive an electric generator which runs at nearly constant speed. Significant hardware differences exist between these two applications. Only variable speed process drivers will be covered here.
Non-condensing or back-pressure turbines exhaust steam at pressures above atmospheric and are usually applied when the exhaust steam can be utilized elsewhere.
Mechanical drive steam turbines are categorized as: •
Single-stage or multi-stage
Extraction/Admission
•
Condensing or non-condensing exhausts
•
Extraction or admission
•
Impulse or reaction
Some mechanical drive steam turbines are either extraction or admission machines. Steam is extracted from, or admitted to, the turbine at some point between the inlet and exhaust (Fig. 15-4). Admission or extraction units may be either controlled or uncontrolled. An uncontrolled turbine accepts or provides steam based only on the characteristics of the steam sys-
FIG. 15-1 Nomenclature
A = ASR = BMEP = D = F = f = h = hf = hg =
N P s sf sg S TSR v
area, sq in. actual steam rate, lb/(hp hr) brake mean effective pressure, psi diameter, in. steam low, lb/hr frequency, Hz specific enthalpy of superheated steam, Btu/lb specific enthalpy of saturated water, Btu/lb specific enthalpy of saturated steam, Btu/lb
2017 EDITION
•
ρ
162
= = = = = = = = =
number of power strokes per min number of magnetic poles in motor specific entropy of superheated steam, Btu/(lb °F) specific entropy of saturated water, Btu/(lb °F) specific entropy of saturated steam, Btu/(lb °F) piston stroke, ft theoretical steam rate, lb/(hp hr) velocity, ft/sec density, lb/cu ft •
•
•
•
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FIG. 15-2
FIG. 15-3
Rateau Design
Curtis Design
tem to which the extraction or admission line is connected. A controlled turbine will control the flow of extraction or admission steam based on some process measurement such as pressure or flow. In general, if the horsepower associated with the extraction or admission flow is greater than 15% of the total turbine horsepower, a controlled extraction (or admission) turbine is used.
fully open and its primary function is to shut off the steam supply in response to a trip (shutdown) signal. In addition a trip-and-throttle valve can be used to modulate the steam flow during start-up and can be either manually or hydraulically positioned from zero lift to 100% lift. The stop valve can only be positioned either in the closed or fully open positions. In order to minimize the pressure drop through the trip-and-throttle valve, maximum inlet velocities are usually limited to 150 ft/ sec. Velocities above this level will usually result in high pressure drops which will reduce turbine efficiency.
Impulse/Reaction Turbines are further categorized by the philosophy employed in the steam path design and are divided into two major design concepts: impulse and reaction. In an impulse turbine the pressure drop for the entire stage takes place across the stationary nozzle. In reaction designs, the pressure drop per stage is divided equally between the stationary nozzles and the rotating blades (Fig. 15-5). For given horsepower, speed and steam conditions, a reaction turbine will, in general, employ approximately three times more stages than an impulse turbine in the same turbine span. Most U.S. mechanical drive steam turbines are of the impulse type.
Inlet Control Valves
Trip and Throttle Valve/Stop (Block) Valve
The primary function of the inlet control valve(s) is regulation of the steam flow to provide the appropriate horsepower and speed. These valves may also close in response to a shutdown signal. Throttling which occurs across the control valve(s) reduces the thermal performance of the turbine. This efficiency loss is a function of the control valve design and overall turbine pressure ratio. For a given amount of throttling, turbines with large pressure ratios suffer smaller efficiency losses than turbines with smaller pressure ratios (Fig. 15-7).
A trip-and-throttle valve or stop valve, or both, may be positioned between the steam supply and the turbine inlet control valve(s) (Fig. 15-6). During normal operation this valve remains
Multi-stage turbines may have a single inlet control valve o r several control valves to regulate the inlet steam. Typical multivalve steam turbines will have from three to eight control valves
STEAM TURBINE COMPONENTS
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FIG. 15-4 Extraction/Admission Flow Turbines
FIG. 15-5
FIG. 15-6
Turbine Types
Single Valve with Hand Valves
Nozzles/Blades (Buckets) On constant speed turbines a design objective is to avoid all bucket resonances at the operating speed. On variable speed turbines, although the design objectives remain the same, it is seldom possible to avoid all blade resonance because of the wide operating speed range. In these cases it is important to identify all blade resonance and to verify that all stresses are well below the material strength.
(Fig. 15-8). Multi-valve turbines have higher efficiencies at reduced loads because only the flow through one of the control valves is incurring a throttling loss (Fig. 15-9).
Exhaust Casings
Turbines with a single control valve will often employ hand valves to improve efficiency at reduced loads. For the turbine shown in Fig. 15-6 both hand valves would be open at or near full load. As the load on the unit is reduced one or both of these hand valves can be closed to reduce throttling loss. Fig. 15-10 shows the efficiency advantage at reduced loads.
2017 EDITION
Turbine exhaust casings are categorized by pressure service (condensing or non-condensing) and number of rows of the last stage buckets (single flow, double flow, triple flow). Non-condensing exhausts are usually cast steel with most of the applications between 50 and 700 psig exhaust pressure. Most con-
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FIG. 15-7
FIG. 15-9
Loss in Available Energy of Steam due to 10% Throttling
Multi-Valve vs Single-Valve Performance Characteristic (Typical Non-Condensing Turbine) Turbine Pressure Ratio = 8.0
FIG. 15-8 Multi-Valve Inlet
FIG. 15-10 Single-Valve with Hand Valves Performance Characteristic (Typical Non-Condensing Turbine) Turbine Pressure Ratio = 8.0
densing exhausts are steel fabrications although some utilize cast iron construction. Maximum exhaust flange velocities are typically 450 ft/sec. Velocities above this level will usually result in substantial increases in exhaust hood losses and will decrease turbine efficiency.
ternal to the turbine, can be used to remove a large percentage of the moisture, improving the turbine efficiency and reducing the impact erosion on the buckets. Stainless steel moisture shields can also be used to minimize the impact erosion of the stationary components.
Moisture Protection As steam expands through the turbine both the pressure and temperature are reduced. On most condensing and some non-condensing exhaust applications, the steam crosses the saturation line thereby introducing moisture into the steam path. The water droplets which are formed strike the buckets and can cause erosion of the blades. In addition, as the water is centrifuged from the blades, the water droplets strike the stationary components, also causing erosion. Where the moisture content is greater than 4%, moisture separators, which are in-
2017 EDITION
Control Systems Mechanical governors were the first generation control systems employed on mechanical drive turbines. Shaft speed is sensed by a fly-ball governor with hydraulic relays providing the input to the control valve. A second generation control system was developed and utilized analog control circuitry with
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the fly-ball governor replaced by speed pick-ups and the hydraulic relays with electronic circuit boards. A third generation control system was developed and replaced the electronic circuitry with digital logic. A microprocessor is used and the control logic is programmed into the governor. The major advantage of this system is the ability to utilize two governors simultaneously, each capable of governing the turbine alone. If the primary governor incurs a fault, the back-up governor assumes control of the turbine and provides diagnostic information to the operator.
Operation at Part Load Most equipment driven by steam turbines are centrifugal machines where horsepower varies as the cube of speed. Part load efficiency varies as a function of speed, flow, and the number of stages. By assuming horsepower to vary as the cube of speed the turbine part load efficiency can be approximated as a percentage of the design efficiency (Fig. 15-11).
EXAMPLES Figs. 15-11 through 15-19 and 24-30 and 24-31 allow estimates to be made of steam rate, turbine efficiency, number of stages, and the inlet and exhaust nozzle diameters. The following examples illustrate the use of these figures:
STEAM TURBINE EFFICIENCY Factors Affecting Efficiency The objective of the steam turbine is to maximize the use of the available steam energy where the available steam energy is defined as the difference between the inlet and exhaust energies (enthalpies) for a 100% efficient constant entropy (i.e., isentropic) process. There are numerous loss mechanisms which reduce the efficiency from the isentropic such as throttling losses, steam leakage, friction between the steam and the nozzles/ buckets, bearing losses, etc. Efficiency can range from a low of 40% for a low horsepower single-stage turbine to a high approaching 90% for a large multistage, multi-valve turbine.
Example 15-1 — Given a steam turbine application with the following characteristics:
Inlet Pressure
600 psia
Inlet Temperature
750°F
Exhaust Pressure
2 psia
Required Horsepower
6000 hp
Speed
7000 rpm
Determine:
Techniques to Improve Efficiency Various te chniques are employed to maximize turbine efficiency, each designed to attack a specific loss mechanism. For example, the number of stages utilized can range from the fewest possible to develop the load reliably to the thermodynamically optimum selection. Spill bands can be utilized to minimize throttling losses. High efficiency nozzle/bucket profiles are available to reduce friction losses. Exhaust flow guides are available to reduce the pressure within the exhaust casing.
•
The actual steam rate (ASR).
•
The inlet and exhaust nozzle diameters.
•
The approximate number of stages.
•
The steam rate at a partial load of 4000 hp and 6100 rpm.
Solution Steps Using Figs. 24-30 and 31, the theoretical steam rate (TSR) may be determined from the difference in the inlet enthalpy and the theoretical exhaust enthalpy (i.e. isentropic exhaust
The specific features employed on a given application are usually based on the trade-off between capital investment and the cost to produce steam over the life of the turbine.
FIG. 15-12 Basic Efficiency of Multi-Valve, Multi-Stage Condensing Turbines FIG. 15-11 Part Load Efficiency Correction Factor vs Percent Power Multi-Valve Steam Turbines
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enthalpy), but first the inlet and exhaust states should be confirmed. Fig. 24-31 for superheated steam indicates that the inlet is superheated (i.e., 750°F is above the saturation temperature of 486.2°F), and gives an inlet entropy of 1.6109 Btu/(lb °F). From Fig. 24-30, for saturated steam at the turbine exhaust pressure of 2 psia absolute, the liquid and vapor entropies are 0.1750 and 1.9200 Btu/(lb °F). Since the inlet entropy is within this range, the theoretical exhaust must be two-phase. Had the exhaust-vapor entropy been equal to the inlet entropy, the exhaust would be single-phase vapor (i.e. at its dewpoint). Had the exhaust-vapor entropy been below the inlet entropy, the assumed two-phase exhaust would have been incorrect and Fig.
24-31 instead of 24-30 would be applicable. Inlet conditions at 600 psia and 750°F (the average of the values at 700°F and 800°F on Fig. 24-31):
•
s
= 1.6109 Btu/(lb °F) •
h = 1379.4 Btu/lb
•
Exhaust conditions at 2.0 psia: sf = 0.1750 Btu/(lb °F) •
sg = 1.9200 Btu/lb °F) •
hf = 94.03 Btu/lb
FIG. 15-13
hg = 1116.2 Btu/lb
Basic Efficiency of Multi-Valve, Multi-Stage Non-Condensing Turbines
Letting x equal the liquid fraction in the exhaust, and equating the inlet and exhaust entropies: 1.6109 = x (0.1750) + (1 – x)(1.9200) x = 0.1771 1 – x = 0.8229 (vapor fraction in the exhaust) Exhaust enthalpy = (0.1771)(94.03) + (0.8229)(1116.2) = 935.2 Btu/lb Enthalpy change = 935.2 – 1379.4 = –444.2 Btu/lb Substituting Btu = (hp hr)/2544: •
Enthalpy change = (–444.2/2544) = (–1/5.727)(hp hr)/lb •
TSR = the absolute value of the inverse of the enthalpy change = 5.727 lb/(hp hr) •
Basic efficiency = 0.729 (Fig. 15-12) Inlet saturation temperature = 486.2°F (first column Fig. 24-31) Inlet superheat = 750 – 486 = 264°F Superheat efficiency-correction factor = 1.03 (Fig. 15-14)
FIG. 15-14
FIG. 15-15
Superheat Efficiency Correction Factor for Condensing Turbines
Superheat Efficiency Correction Factor for Non-Condensing Turbines
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Speed efficiency-correction factor = 0.957 (Fig. 15-16)
A 30 in. exhaust nozzle would be selected.
Corrected efficiency = (0.729)(1.03)(0.957) = 0.719
The number of stages may be estimated using Fig. 15-18. Drawing a horizontal line from the 7000 RPM indicates that between 1.5 and 2 stages per 100 Btu/lb of available energy would be acceptable.
ASR = 5.727/0.719 = 7.97 lb/(hp hr) •
F = (6000 hp) 7.97 lb/(hp hr) •
Available Energy (theoretical)(i.e., the isentropic enthalpy change calculated above)
= 47,800 lb/hr The inlet and exhaust diameters may be estimated from the equation: D=
= 444.2 Btu/lb Number of Stages
(0.051) (F) (ρv)
Eq 15-1
(1.5) (444) = = 7 (approximately) (100)
A reasonable rule of thumb for maximum velocity o f the inlet steam is 150 (ft/sec). ρ =
D=
or,
0.88 lb/ft3 @ 600 psia and 750°F
=
(0.051) (47,800) (0.88) (150)
(2) (444) (100)
= 9 (approximately)
Nine stages would provide increased efficiency but at additional cost.
D = 4.3 in.
At partial load of 4000 hp and 6,100 RPM and assuming seven stages from Fig. 15-11, a part load efficiency factor of approximately 0.96 is obtained. From Fig. 15-12, the basic efficiency at 4000 hp and 6,100 RPM is estimated to be 0.71.
A 4 in. NPS (minimum) inlet nozzle would be selected. For exhaust sizing a maximum steam velocity of 450 ft/sec is a reasonable rule of thumb. ρ =
Number of Stages
Efficiency = (0.96) (0.71) = 0.68
0.0057 lb/ft3 @ 2 psia
Actual Steam Rate = 5.73/0.68 = 8.43 lb/(hp hr) •
D=
(0.051) (47,800) (0.0057) (450)
F = (4000) (8.43) = 33,700 lb/hr Example 15-2 — Determine the ASR and total steam requirements for a multi-stage turbine and a single-stage turbine at the following conditions:
D = 30.8 in.
FIG. 15-16 Speed Efficiency Correction Factor for Condensing and Non-Condensing Turbines
Inlet Pressure
250 psig
Outlet Pressure
100 psig
Inlet Temperature
500°F
Horsepower
900 hp
Speed
5000 rpm
FIG. 15-17 Pressure Ratio Efficiency Correction Factor, Non-Condensing Turbines
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TSR = the absolute value of the inverse of the enthalpy change = 33.5 lb/(hp hr)
Solution Steps
•
For a multi-stage turbine:
Basic efficiency = 66% (Fig. 15-13)
Examining Figs. 24-30 and 31 in the same way as in Example 15-1, the turbine inlet is superheated, and the exhaust is two-phase.
Inlet saturation temperature = 406.0 °F (interpolating between 260 and 280 psia on Fig. 24-31)
Inlet conditions at 250 psig (264.7 psia) and 500°F (interpolating linearly between 240 and 260 psia on Fig. 24-31):
Inlet superheat = 500 – 406 (Fig. 24-31) = 94°F
s = 1.5873 Btu/(lb °F)
Efficiency-correction factor for superheat = 0.99 (Fig. 15-15)
h = 1261.8 Btu/lb
Efficiency-correction factor for speed = 1.01 (Fig. 15-16)
•
Exhaust conditions at 100 psig (i.e. 114.7 psia). From Fig. 24-30 interpolating linearly between 89.64 psia at 320°F and 117.99 psia at 340°F, get the following for 114.7 psia:
Pressure ratio = (114.7 psia)/(264.7 psia) = 0.433 Efficiency-correction factor for pressure ratio = 0.97 (Fig. 15-17)
sf = 0.4872 Btu/(lb °F) •
ASR = [33.5 lb/(hp hr)]/[(0.66) (0.99) (1.01) (0.97)] •
sg = 1.5918 Btu/(lb °F) •
= 52.3 lb/(hp hr) •
hf = 308.9 Btu/lb
F = [52.3 lb/(hp hr)] (900 hp) •
hg = 1189.5 Btu/lb
= 47,100 lb/hr
Letting x equal the liquid fraction in the exhaust, and equating the inlet and exhaust entropies:
For a single-stage turbine ASR = [75 lb/(hp hr)] (0.93) (Fig. 15-19) •
1.5873 = x (0.4872) + (1 – x) (1.5918)
= 70 lb/(hp hr)
x = 0.0041
•
F = [70 lb/(hp hr)] (900 hp)
1 – x = 0.9959 (fraction vapor in exhaust)
•
= 63,000 lb/hr
Exhaust enthalpy = (0.0041)(308.9) + (0.9959)(1189.5) = 1185.9 Enthalpy change = 1185.9 – 1261.8 = –75.9 Btu/lb Substituting 1 Btu = (hp hr)/2544: •
FIG. 15-19
Enthalpy change = (–75.9/2544) = (–1/33.5)(hp hr)/lb) •
Single-Stage Application
FIG. 15-18 Stages Required per 100 Btu/lb of Available Energy as a Factor of Normal Turbine Speed
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tion levels, etc.). This can often be done by an operator at a location remote from the actual turbine installation.
GAS TURBINES General
Installation
Gas turbines are extensively used in all phases of the gas industry as a source of shaft power. They are used to drive compressors, generators, and other equipment required to produce, process, and transport natural gas. The main advantages of gas turbines are: •
Compact, light weight design.
•
Minimal maintenance.
•
Short installation time.
The relatively light weight, compact size, and simple design of gas turbines make them an attractive choice where power must be quickly installed in the field. The gas turbine is often delivered on an integral one-piece baseplate with all auxiliary equipment installed and tested by the manufacturer. Thus, con struction and start-up time are minimized.
GAS TURBINE TYPES The gas turbine was first widely used as an aircraft power plant. However, as they became more efficient and durable, they were adapted to the industrial marketplace. Over the years the gas turbine has evolved into two basic types for highpower stationary applications: the industrial or heavy-duty design and the aircraft derivative design.
Compact, Lightweight Design The compact, lightweight design of gas turbines makes them ideally suited for offshore platform installations, portable generating sets, remote sites, or any application where size and weight are important considerations.
Heavy Duty
Maintenance
The industrial type gas turbine is designed exclusively for stationary use. Where high power output is required, 35,000 hp and above, the heavy duty industrial gas turbine is normally specified. The industrial gas turbine has certain advantages
Once installed, the gas turbine requires a minimum of routine maintenance. It is important to monitor the operating parameters of the turbine (pressures, temperatures, speed, vibra-
FIG. 15-20 Typical Gas Turbine Skid Layout
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which should be considered when determining application requirements. Some of these are:
•
Lighter and more compact, an asset where weight limitations are important such as offshore installations.
•
Less frequent maintenance.
Single Shaft/Split Shaft
•
Can burn a wider variety of fuels.
•
Available in larger horsepower sizes.
Gas turbine designs are also differentiated by shaft configuration. In a single shaft design, all rotating components of the gas turbine are mounted on one shaft. In a split shaft design, the air compressor rotating components are mounted on one shaft, and the power turbine rotating components are mounted on another shaft. The driven equipment is connected to the power turbine shaft. The single shaft design is simpler, requiring fewer bearings, and is generally used where the speed range of the driven equipment is narrow or fixed (as in generator sets). It requires a powerful starting system since all the rotating components (including the driven equipment) must be accelerated to idle speed during the start cycle.
Aircraft Derivative An aircraft derivative gas turbine is based on an aircraft engine design which has been adapted for industrial use. The engine was originally designed to produce shaft power and later as a pure jet. The adaptation to stationary use was relatively simple. Some of the advantages of the aircraft derivative gas turbines are: •
Higher efficiency than industrial units.
•
Quick overhaul capability.
A split shaft design is advantageous where the driven equipment has a wide speed range or a high starting torque. The air compressor is able to run at its most efficient speed while the FIG. 15-21 Gas Turbine Internals
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power turbine speed varies with the driven equipment. The split shaft design allows a much smaller starting system since only the air compressor shaft is accelerated during the start cycle.
FIG. 15-22 Ideal Brayton Cycle
GAS TURBINE CYCLES The basic gas turbine cycle is termed the Brayton cycle. The ideal Brayton cycle is a closed cycle consisting of an isentropic compression process; a constant pressure external heating process; an isentropic expansion process; and finally a constant pressure external cooling process which returns the working substance to the inlet state of the compression process. A schematic and TS diagram of the ideal Brayton cycle are shown in Fig. 15-22. The turbomachinery used in the process includes an axial flow or centrifugal compressor and an axial or radial flow turbine.
FIG. 15-23 Simple Open Cycle
Simple Open Cycle The simple open cycle gas turbine takes atmospheric air into the compressor as the working substance. Following compression, the air enters the combustion chamber where the temperature is raised by the combustion of fuel. The gaseous combustion products are then expanded back to the atmosphere through a turbine. A diagram of this cycle is shown in Fig. 1523. The turbine in this system derives enough power from the high temperature gas to drive both the compressor and load.
Regenerative Ideal Brayton Cycle The use of a regenerator in an ideal Brayton cycle acts to reduce the amount of available energy lost by external heat exchange. The system schematic is illustrated in Fig. 15-24. This available energy loss is due to irreversible heat input and is illustrated in Fig. 15-25. A heat exchanger or regenerator is placed in the system to transfer heat internally from the hot exhaust gas to the cooler air leaving the compressor. This preheating of the combustion air thus reduces the amount of external heat input needed to produce the same work output.
FIG. 15-24 Regenerative Ideal Brayton Cycle
Combined Cycle Instead of using the hot exhaust gas for regeneration, this approach uses exhaust gas to generate steam. This steam can be used either as a supplement to the plant steam system or to generate additional horsepower in a Rankine cycle. In the basic Rankine cycle, the hot exhaust gas passes successively through the superheater, evaporator, and economizer of the steam generator before being exhausted to the atmosphere. The steam leaving the boiler is expanded through a steam turbine to generate additional power. The cycle is closed by the addition of a condenser and feed water pump completing a basic Rankine cycle. Since the steam cycle does not require any additional fuel to generate power, the overall thermal efficiency is increased. Fig. 15-26 shows schematically a typical installation and its TS diagrams.
FIG. 15-25 Ideal Brayton Cycle Available Energy
AUXILIARY SYSTEMS Lube Systems Two types of oils are used in lubricating gas turbine equipment. They are mineral and fire-resistant synthetic based oils. The oil type used depends on the bearing construction of the particular turbine. Babbitt type sleeve and thrust bearings, typical of heavy duty turbines, use a mineral based oil. Driven equipment such
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as compressors, gear, and generators also use this type oil, thus a common, combined lube system can be provided for the train.
There are various types of filters. The main types are as follows:
Aircraft derivative gas gen erators all incorporate anti-friction type ball and/or roller bearings. A synthetic oil is used in this service and is provided in a separate system from the mineral oil system used to lubricate the driven equipment. An oil scavenging system is also typical of these gas generators. Engine mounted pumps are used to scavenge oil from the main bearing pumps and return it to the reservoir.
Inertial — This type removes the larger particulates from the inlet air. Prefilters — These are medium filters usually made of cotton fabrics or spun-glass fibers, used to extend the life of a high efficiency filter further downstream. Coalescers — These filters are used to remove moisture from the inlet air system.
Air Filtration
High Efficiency Media — These filters remove smaller dirt particles from the inlet air.
The primary reason for inlet air filtration is to prevent unwanted dirt from entering the gas turbine. B y reducing the contaminants which contribute to corrosion, erosion, and fouling, the gas turbine life is extended.
Marine or Demister — These filters are used in marine environments to remove both moisture and salt. Self-Cleaning — These filters are composed of a number of
FIG. 15-26 Combined Cycle
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high efficiency media filter “banks.” Air is drawn through the media at a low velocity and, at a predetermined pressure drop across the system, a reverse blast of air removes built-up dirt on the filter and lowers the pressure drop. This filter can be used in any environment. It is particularly useful in colder climates where ice build-up is a problem. The reverse blast of air also removes any ice that has built up on the filter.
sary to provide gas and fire detection and fire extinguishing equipment inside the enclosure. The last major source of noise to be silenced is the gas turbine exhaust noise. Since most turbines exhaust vertically, there is generally no need for an elbow. However, a silencer with acoustic baffles is needed and the exhaust ducting should be sound insulated.
Another method of eliminating icing problems is to install an anti-icing system. In this system, heated air from the gas generator discharge is introduced through distribution manifolds immediately downstream of the inlet air silencer.
GAS TURBINE PERFORMANCE The performance of a gas turbine is usually expressed in terms of power and heat rate. Power is the net power available at the output shaft of the turbine after all losses and power take-offs have been subtracted.
The selection of a filtration system is largely dependent on the site location and operating conditions. Fig. 15-27 suggests filtration for various types of environments.
Heat rate is a measure of thermal efficiency or the amount of heat energy (in the form of fuel) which must be input to the gas turbine to produce the output power. Heat rate is usually expressed in terms of Btu/(hp hr) or Btu/(kW hr) based on the lower heating value of the fuel. Heat rate and thermal efficiency are related as follows:
Since filters do protect the gas turbine and help extend its useful life, some type of filtration is always recommended.
•
Acoustics The noise created by a gas turbine engine is considerable and must be reduced to protect plant personnel and minimize environmental impact. The main sources of noise in a gas turbine installation are the intake, the exhaust, and casing radiated noise.
Thermal efficiency =
=
Power and heat rate both vary depending on environmental conditions such as ambient air temperature, altitude, barometric pressure, and humidity. Therefore, when performance is stated for a gas turbine, the ambient conditions must be defined. In order to compare different gas turbines, a set of standard conditions known as ISO (International Standards Organization) conditions have been defined as follows: ISO Conditions: Ambient Temperature = 59°F = 15°C Altitude = 0 ft (sea level) Ambient Pressure = 29.92 in. Hg Relative Humidity = 60% All gas turbine performance is stated in ISO conditions. To arrive at site rated horsepowers, the ISO conditions must be corrected for the following: Altitude (Fig. 15-28) Inlet Losses (Fig. 15-29) Exhaust Losses (Fig. 15-30) Temperature (Fig. 15-31) Humidity (below)
Casing radiated noise can be reduced by using an acoustical enclosure over the turbine. If an enclosure is used, it is necesFIG. 15-27
For changing relative humidity, the power output does not change, and the heat rate changes only slightly. For example, for an increase in relative humidity from 60 to 100 percent, a typical correction factor for the heat rate is 1.0016. For a decrease to zero percent, a typical correction factor is 0.9979.
Gas Turbine Air Filtration
Suggested Filtration High Efficiency Media
Urban/Industrial
Inertial & High Efficiency Media
Desert
Inertial and Media or SelfCleaning
Tropical
Inertial & Media
Arctic
High Efficiency Media with Anti-Icing or Self-Cleaning
Offshore
Demisters
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3414 Btu (LHV) Heat Rate, kW hr •
A variety of methods can be used to attenuate noise. The most common are the use of silencers and enclosures. The inlet noise is the first area considered since this is where the largest amount of sound power is produced. Inlet noise is the loudest directly in front of the inlet opening. Consequently, the least expensive method for obtaining some of the required noise reduction is to place an elbow at the inlet. Additional silencing is usually necessary and can be attained by the use of acoustic baffles before the elbow.
Rural Country
2544 Btu (LHV) Heat Rate, hp hr •
The noise associated with the intake is characterized as high frequency noise. This type of noise is the loudest and most disturbing to the ear since it is in a range where hearing is most sensitive. The second most objectionable noise is produced by the gas generator and power turbine and is radiated from the casing. Although the exhaust noise contains more energy, the casing noise is more objectionable since it contains more noise in a frequency range where the ear is most sensitive. The exhaust noise is a low frequency noise which is only slightly audible. It does, however, possess a considerable amount of energy which results in a detectable pressure change.
Type of Environment
•
Performance is also affected by other installation variables including power take-offs and type of fuel used. Inlet loss is the pressure drop which occurs as the outside air passes through the inlet filters and plenum. Similarly, exhaust loss is the pressure drop through the exhaust stack, silencers, and heat recovery equipment (if any) which creates a back pressure on the turbine. Power take-offs include any devices such as oil pumps, generators, etc. which are directly driven from the gas turbine output shaft and thus reduce the available output power. Sometimes it is necessary to correct power and/or heat rate for the
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type of fuel used in the gas turbine. The tu rbine manufacturer’s performance brochure should be consulted for necessary corrections.
FIG. 15-28 Altitude Correction Factor
The following example shows the method of calculating performance for a gas turbine at site conditions using data typically supplied in the manufacturer’s performance brochure. Example 15-3 — Calculate maximum available site power and heat rate for the example gas turbine at the following conditions:
Turbine ISO Horsepower =
27,500
Turbine ISO Heat Rate
=
7,090 Btu/(hp hr)
Ambient Temperature
=
80°F
Altitude
=
1000 ft (above sea level)
Inlet Pressure Drop
=
4 in. H2O
Exhaust Pressure Drop
=
2 in. H2O
Relative Humidity
=
60%
Fuel
=
Natural Gas
•
Solution Steps Find the power altitude correction factor from Fig. 15-28. For 1000 ft altitude, the correction factor is 0.965. Find power inlet loss correction factor from Fig. 15-29. For 4 inches of water, the correction factor is 0.984. Find power exhaust loss correction factor from Fig. 15-30. For 2 inches of water, the correction factor is 0.9965. Find the power ambient temperature correction factor from Fig. 15-31. For 80°F the correction factor is 0.915.
FIG. 15-29 Inlet Loss Correction Factor
Since relative humidity is 60% and fuel is natural gas, no corrections are required. Calculate the maximum available site power by multiplying maximum-no-loss power by each of the correction factors. Power (site) = power (0.965) (0.984) (0.9965) (0.915) Power (site) = 27,500 (0.965) (0.984) (0.9965) (0.915) Power (site) = 23,800 hp For the heat rate find the inlet loss correction factor, exhaust loss correction factor, and ambient temperature correction factor from Figs. 15-29, 15-30, and 15-31, respectively. (Note: Heat rate is not affected by altitude.) Inlet loss factor = 1.0065 Exhaust loss factor = 1.003 Temperature factor = 1.03 Calculate site heat rate by multiplying no-loss heat rate by the correction factors. Heat rate (site) = (Heat rate) (1.0065) (1.003) (1.03) Heat rate (site) = [7090 Btu/(hp hr)](1.0065)(1.003)(1.03) Heat rate (site) = 7370 Btu/(hp hr) •
•
The above calculation procedures may vary slightly with different manufacturers but will follow the same principles. Basic specifications for some of the commonly used gas turbine engines are shown in Fig. 15-32.
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Gas Turbine Emissions
FIG. 15-30 Exhaust Loss Correction Factor
The gas turbine, in general, is a low emitter of exhaust gas pollutants relative to other heat engines in similar service. This is because the fuel is burned with ample excess air to ensure complete combustion at all but minimum load conditions. It is unique in its ability to burn a wide variety of fuels making each application unique in terms of exhaust emissions. However, gas turbine engine emissions recently have become a major factor in the design, selection, and operation of the unit. Various federal, state, and local authorities have issued standards and codes to control pollution of the atmosphere. Carbon monoxide (CO) emissions occur because of incomplete combustion of fuel carbon. CO emissions for distillate and other liquid fuels are generally higher than for natural gas. Unburned hydrocarbons (UHC) are formed by the incomplete combustion of fuel. Like CO emissions, they are directly related to combustion efficiency. However, because most gas turbine units on the market today have good combustor designs, the CO and UHC emissions are of secondary importance to NO x emissions. Sulfur oxides (SOx) exhausted from gas turbines are a direct function of sulfur content in the fuel. The high temperature and oxygen content during combustion tends to favor the formation of SO 3 and SO2 at equilibrium. Sulfur oxide emissions from pipeline natural gas are virtually zero while wellhead gases, process gases, coal gases, and other fuels may contain significant quantities of sulfur in the form of H 2S. Gas turbine particulate emissions are influenced by the fuel properties and combustion conditions. Particulates generally refer to visible smoke, ash, ambient non-combustibles, and products of erosion and corrosion in the hot gas path. Particulate and smoke emissions are usually small when burning natural gas, but are a significant consideration when operating on liquid fuels.
FIG. 15-31 Ambient Temperature Correction Factor
Of the exhaust components the most significant are the oxides of nitrogen (NOx). The amount of NO x produced is a function of the fuel burned, firing temperature, compressor discharge temperature, and residence time in the combustion zone. Since the trend towards high turbine efficiencies leads to higher pressure ratios and firing temperatures, the emission rates of NOx are higher for these units. Nitrogen oxides are categorized into two areas according to the mechanism of formation. NO x formed by oxidation of free nitrogen in the combustion air or fuel is called “thermal NO x,” while that due to oxidation of organically bound nitrogen in the fuel is referred to as “organic NO x.” As implied by the name, thermal NOx are mainly a function of the stoichiometric flame temperature. The formation of thermal NO x is on the order of parts per million (by volume) or ppmv; however, the conversion of organic NOx is virtually 100%. Efforts to reduce thermal NOx by reducing flame temperatures have little effect on, and actually may increase, organic NO x. UHC emissions can be reduced by proper combustor design for maximum efficiency. Sulfur oxides can be eliminated by removing sulfur compounds from the fuel. Similarly, particulates can be minimized by appropriate fuel treatment. However, reduction of NOx formation also produces increased inefficiency. Two general approaches are used for NO x reduction: •
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The use of an inert heat sink such as water or steam in jection.
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FIG. 15-32 2011 Basic Specifications — Gas Turbine Engines (Mechanical Drive)
Model
Power Rating (ISO Rating) hp
At ISO RATING CONDITIONS Heat Rate (LVH) Btu/hp-hr
Pressure Ratio
Power Shaft RPM
Turbine Inlet Temp. °F
Exhaust Flow lb/s
Exhaust Temp °F
Dresser- Rand
VECTRA 30G
31,469
6816
17.9
6510
1530
149.7
1017
VECTRA 40G
42,102
6347
22.4
6510
1521
190.2
979
VECTRA 40G4
45,902
6316
23.6
6510
1571
198.4
1006
DR-63G PC
59,436
6042
27.9
3780
1578
280.0
855
DR-63G PG
66,822
6054
29.7
3930
1666
259.3
907
GE10-2 DLE
15907.2
7762.2
15.8
7900
103.6
912
GE10-2
16288.1
7620.9
15.6
7900
103.6
901
PGT16
19143.1
7042.7
20.1
7900
103.8
928
PGT20 SAC
24300.4
6974.1
19.7
6500
138.0
895
PGT20 DLE
24926.9
6984.7
19.8
6500
137.3
915
PGT25 DLE
31194.9
6793.2
17.9
6500
151.0
983
PGT25 SAC
31205.6
6756.4
17.9
6500
151.9
971
MS5002C
37950.9
8700.9
8.8
4670
274.0
963
39520
8714
9.1
4670
270.0
1004
PGT25+DLE
41673.6
6207.2
21.5
6100
184.7
934
PGT25+SAC
42070.7
6187.4
21.5
6100
185.8
932
MS5002E
42912.7
7052.6
17
5714
225.5
947
MS5002D
43717.3
8411.1
10.8
4670
311.7
948
PGT25+G4 DLE
45164.3
6207.2
23
6100
197.3
955
PGT25+G4 SAC
45492.8
6208.7
23
6100
198.4
954
45553
8413
10.4
4670
308.0
993
LM6000 PD
58809.2
5985.3
28.3
3600
274.9
851
LM6000 PF
58809.2
5985.3
28.3
3600
274.9
851
MS6001B
58955.4
8140.4
12.3
5160
322.3
1016
LM6000 PC SAC FIXED IGV
59384.5
5971.9
27.9
3600
276.9
850
LM6000 PC SAC OPEN IGV
59558.8
5976.1
28.2
3600
278.9
846
59663.4
5967.6
28.1
3600
278.2
849
MS7001EA
121362
7584.1
12.9
3600
662.0
1011
LMS100
134370
5767.6
40
3600
456.1
783
MS9001E
175272
7357.9
12.8
3000
926.6
1001
THM 1203A
8046
10870
7.8
7800
1724
78.0
959
THM 1304-10R
12606
7011
10
9030
1787
100.0
THM 1304-10
13008
8715
10
9030
1787
100.0
932
THM 1304-11
15019
8206
10.8
9030
1823
108.0
941
GE Oil & Gas
MS5002C POWER CRYSTAL
MS5002D POWER CRYSTAL
LM6000 PC SAC VARIABLE IGV
MAN Diesel & Turbo SE
Data reproduced by permission from Diesel & Gas Turbine Worldwide Catalog, courtesy of Diesel & Gas Turbine Publications.
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FIG. 15-32 (Cont’d) 2011 Basic Specifications — Gas Turbine Engines (Mechanical Drive) Power Rating (ISO Rating) hp
Heat Rate (LVH) Btu/hp-hr
Pressure Ratio
Power Shaft RPM
THM 1304-12
16226
8001
11
THM 1304-14
17701
7881
FT8
34690
LM2500-PE
Model
At ISO RATING CONDITIONS Turbine Inlet Temp. °F
Exhaust Flow lb/s
Exhaust Temp °F
9030
108.0
959
11
9030
108.0
1013
6615
19.5
5775
188.5
856
30180
6784
17.9
3600
152.0
975
LM2500-PH
36210
5986
19.3
3600
167.0
932
LM2500+(PK)
41840
6440
22
3600
192.0
959
LM6000
60346
MTU Friedrichshafen GmbH
Rolls-Royce 501-KC5
5500
8495
9.4
34.2
1060
501-KC7
7400
7902
13.5
46.2
968
Avon2648
21923
8323
9.6
179.0
799
Avon2656
22807
8022
9.6
179.0
788
RB211 - G62
39600
6705
20.8
209.0
916
RB211 - GT62
41450
6585
21.7
214.0
918
RB211 - GT61
44650
6285
21.7
210.0
RB211 - H63
50848
6134
23
235.0
RB211 - H63
59005
6247
25.1
254.6
Trent 60 DLE
70418
5939
34
337.8
Trent 60 WLE
79120
6074
35.3
358.6
SGT-100
7640
7738
14.9
13650
43.4
1009
SGT-200
10300
7616
12.6
11525
64.9
919
SGT-300
11000
7738
13.3
63.9
928
SGT-400
18000
7028
16.8
86.8
1031
SGT-500
26177
7373
13
215.9
696
SGT-600
34100
7250
14
8085
177.0
1009
SGT-700
42960
6805
18
6930
208.0
982
SGT-750
49765
6362
23.8
6405
249.8
864
Saturn 20
1590
10370
6.7
22300
14.3
968
Centaur 40
4700
9125
10.3
15500
41.8
833
Centaur 50
6130
8500
10.3
16500
41.5
959
Taurus 60
7700
7965
11.5
13950
47.7
950
Taurus 70
10310
7310
16.5
11400
58.6
923
Mars 90
13220
7655
16.3
9400
88.5
869
Mars 100
16000
7370
17.7
9500
93.1
905
Titan 130
20500
7025
16.1
8500
110.3
941
Titan 250
30000
6360
24.1
7000
150.4
869
824
Siemens AG Energy Sector
10000
Solar Turbines Incorporated
Data reproduced by permission from Diesel & Gas Turbine Worldwide Catalog, courtesy of Diesel & Gas Turbine Publications.
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•
Modifications of fuel-air ratios and combustor design.
match the requirements of the driven load and the available power supply. Starting, pull-in, and pull-out torques can be selected over a wide range. Power factor improvement is available with rated power factor of unity, leading, or even lagging.
In addition to these two methods, catalytic combustion is being researched.
Water or Steam Injection — Water or steam injection is an effective way to reduce NOx exhaust emissions. Two areas of caution in the design of this system must be considered. The first is the dynamic effect that water injection has on the combustion zone in terms of flame stability and dynamic pressures. Inadequate design could adversely affect hardware life. Also the rate of CO emissions increases with the rate of water injection. It is not effective in reducing organic NOx emissions and may actually contribute to them.
ELECTRICAL SYSTEM Induction Motors In general, induction motors tend to draw more starting current at a lower power factor than synchronous motors of the same size and speed. This results in a greater voltage drop on the system when the motor is started. If the motor is driving a high inertia load, such as a fan or compressor, the lower terminal voltage will increase the temperature rise of the squirrel cage winding during acceleration. As a rule of thumb, voltage drops on starting greater than 20% may require special motor designs. These designs may reduce the full load efficiency of the motor during normal operation by one or two percent. It is best to furnish a power supply that will limit the voltage drop to 20% or less when starting the largest motor on a fully loaded bus.
Modification of Fuel-Air Ratio and Combustor Design An increased number of gas turbines are available with low NOx design based on modifications to fuel-air ratio and combustor design. NOx content in flue gas as low as 10–25 ppm can be achieved by this method. Different vendors have different approaches to effectively control the fuel-air ratio to reduce NOx content. However, low NOx turbines are available, both for single-fuel and dual-fuel systems from most vendors.
Once started the induction motor is a stable machine. Most motors can easily ride through a 25 to 30% dip in system voltage caused by external faults or switching. Overall system stability and continuity may be achieved by using large induction motors. This is, however, accomplished at the expense of lower power factor and efficiency.
Low NOx designs make the gas turbines more complex, especially for dual-fuel systems. It is therefore recommended to carefully review the need for dual-fuel low NOx machines. In summary, the characteristics of gas turbine emissions must be considered for each application, since each is unique to the turbine, installation, fuel, and operation. All these factors are important in matching the gas turbine to the job.
Synchronous Motors The synchronous motor is usually easier to start than an induction machine. The system voltage drop on starting is less for a given horsepower motor. However, synchronous motors have less thermal capacity in their windings and may be more severely taxed when accelerating high inertia loads.
ELECTRIC MOTORS Electric motor drives offer efficient operation and add flexibility to the design of petroleum refineries, petrochemical plants, and gas processing plants. Electric motors can be built with characteristics to match almost any type of load. They can be designed to operate reliably in outdoor locations where exposed to weather and atmospheric contaminants. Proper motor application is essential if reliable performance is to be achieved. Critical items to consider are load characteristics for both starting and running conditions, load control requirements, power system voltage and capacity, and any conditions at the plant site that could affect the type of motor enclosure.
Once synchronized and running, synchronous motors present special system problems. They may tend to pull out of synchronism on voltage dips that induction motors can ride through. A gradually increasing load from zero to 125% of rated load will be easily accommodated. A suddenly applied load of 125% can easily cause the motor to pull out of synchronism with the electrical system. When applying large synchronous machines to a syste m it is important to perform a transient load study. This will help ascertain if the electrical system is capable of supporting the motor demands under transient conditions.
Speed
A-C MOTOR TYPE AND SELECTION
3000 to 3600 rpm — Synchronous motors are seldom economical for this range because of the high cost of rotor construction. Although large (i.e., greater than 22,000 hp) two-pole 3600 rpm synchronous motors have been built, slower speed motors with step-up gears, or squirrel-cage induction motors are usually a more economic choice.
One of the first considerations in motor selection is to choose between a squirrel cage induction and a synchronous motor. The induction motor has th e advantage of simplicity. It is a rugged machine and has an outstanding record for dependability. In general it can accelerate higher load inertias than synchronous motors and usually will do so in less time. Induction motor control is simple and no excitation equipment is required. Its principal disadvantages are that it operates at lagging power factor and has higher inrush (starting) current. Up to about 5000 horsepower, induction motors are normally preferred. Above this, induction and synchronous motor costs converge, and synchronous motors are often chosen.
900 to 1800 rpm — Synchronous motors above 5000 hp are widely used for pumps and for centrifugal compressors with speed increasers. The need for power-factor correction, high efficiency, low inrush, or constant speed may favor synchronous motors below 5000 hp. For applications above 2500 hp requiring speed increasers, 1200 rpm unity-power-factor synchronous moto rs should be evaluated against 1800 rpm motors since the lower-speed motors are slightly more energy efficient. For 1200 rpm loads, synchronous motors may be more economical at 1250 hp and above.
The constant-speed synchronous motor has inherent advantages that often make it the logical choice for industrial drive applications at lower power ratings. Load speed can be exact. Torque characteristics of the motor can be varied by design to
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For 900 rpm loads, synchronous motors should be considered at 1000 hp and above.
FIG. 15-33 Energy Evaluation Chart NEMA Frame Size Motors, Induction
Motor requirements below 500 hp in the 900 to 1800 rpm speed range are normally handled by standard induction motors.
514 to 720 rpm — Synchronous motors are often selected above 1 hp per rpm, such as 800 hp at 720 rpm, 700 hp at 600 rpm, and 600 hp at 514 rpm.
HP
Below 514 rpm — The synchronous motor should be considered for sizes down to 200 hp because of higher efficiency, improved power factor, and possible lower cost. At high voltages (4 kV and above), the synchronous motor becomes more economical at even lower horsepowers.
Approx. Full Load RPM
Amperes Based on 460V
Efficiency in Percentage at Full Load
Standard Efficiency
High Efficiency
Standard Efficiency
High Efficiency
1
1,800 1,200
1.9 2.0
1.5 2.0
72.0 68.0
84.0 78.5
1-1/2
1,800 1,200
2.5 2.8
2.2 2.6
75.5 72.0
84.0 84.0
2
1,800 1,200
2.9 3.5
3.0 3.2
75.5 75.5
84.0 84.0
3
1,800 1,200
4.7 5.1
3.9 4.8
75.5 75.5
87.5 86.5
5
1,800 1,200
7.1 7.6
6.3 7.4
78.5 78.5
89.5 87.5
7-1/2
1,800 1,200
9.7 10.5
9.4 9.9
84.0 81.5
90.2 89.5
10
1,800 1,200
12.7 13.4
12.4 13.9
86.5 84.0
91.0 89.5
15
1,800 1,200
18.8 19.7
18.6 19.0
86.5 84.0
91.0 89.5
Motor enclosure selection should be predicated upon the environmental conditions under which the motor must operate. Directly related to this is the amount of maintenance required to provide long-term reliability and motor life. In general, the more open the enclosure is to the atmosphere, the lower the first cost of the machine but the higher the maintenance costs that may be necessary. Enclosures frequently used in a-c motors are listed below.
20
1,800 1,200
24.4 25.0
25.0 24.9
86.5 86.5
91.0 90.2
25
1,800 1,200
31.2 29.2
29.5 29.1
88.5 88.5
91.7 91.0
30
1,800 1,200
36.2 34.8
35.9 34.5
88.5 88.5
93.0 91.0
Drip-Proof
40
1,800 1,200
48.9 46.0
47.8 46.2
88.5 90.2
93.0 92.4
50
1,800 1,200
59.3 58.1
57.7 58.0
90.2 90.2
93.6 91.7
60
1,800 1,200
71.6 68.5
68.8 69.6
90.2 90.2
93.6 93.0
75
1,800 1,200
92.5 86.0
85.3 86.5
90.2 90.2
93.6 93.0
100
1,800 1,200
112.0 114.0
109.0 115.0
91.7 91.7
94.5 93.6
125
1,800 1,200
139.0 142.0
136.0 144.0
91.7 91.7
94.1 93.6
150
1,800 1,200
167.0 168.0
164.0 174.0
91.7 91.7
95.0 94.1
200
1,800 1,200
217.0 222.0
214.0 214.0
93.0 93.0
94.1 95.0
Motor Voltage The proper selection of voltage for a given motor drive can vary from a routine procedure to a complex study requiring a complete electrical system analysis. In many instances the inplant distribution system is well established at a particular voltage, say 2300 (2.3 kV). The new machine may be small compared to available system capacity on the 2.3 kV bus so no problem is involved in purchasing a standard motor of that voltage. In more complicated cases additional substation capacity may be necessary to accommodate the new machine. However, wh en very large units are to be added, many factors must be considered. A new distribution voltage level, a new transmission line, or a higher voltage transmission from the electric utility might be necessary.
MOTOR ENCLOSURES
These are generally used only indoors or in enclosed spaces not exposed to severe environmental conditions. Maintenance requirements will depend upon general cleanliness of the location and any chemical contaminants in the area.
Weather-Protected Type I This is the least costly outdoor machine. It is essentially a drip-proof guarded motor with heaters and outdoor bearing seals and is very susceptible to weather and atmospheric contamination. Considerable maintenance may be required to ensure satisfactory winding and bearing life.
Weather-Protected Type II This is the more commonly used outdoor enclosure. It is more expensive than the WP-I but minimizes the entrance of water and dirt. Maintenance is less than for WP-I types. Chemical contaminants in gaseous form may be carried into a WP-II machine with the ventilating air and attack parts that are vulnerable to them.
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The synchronous generator needs precise prime-mover speed control to maintain its output at correct frequency. When connected to a public utility system such a machine cannot be allowed to deviate more than a fraction of a cycle from rated frequency without being tripped off the line. However, speed changes do not affect the voltage or power output of the generator — only the frequency.
Totally Enclosed Forced Ventilated (TEFV) TEFV enclosures can be used indoors or outdoors in dirty or hazardous environments. Since the motor cooling air is piped in from a separate source the influx of dirt and gaseous contaminants is minimized. Maintenance is minimal depending upon the cleanliness of the cooling air.
Totally Enclosed Water-to-Air Cooled (TEWAC) The totally enclosed water-to-air cooled machine uses an air to water heat exchanger to remove heat generated by motor losses. It is the quietest enclosure available and will usually result in the lowest maintenance costs. It will breathe during shutdown but often a breather filter is used to remove particulate contaminants. It is more efficient than a TEFC motor because it does not have the external fan to drive. Its first cost is greater than WP-II but less than TEFC, excluding any additional capital cost for a cooling water system. Operating costs are higher because of the necessity to continuously supply it with cooling water.
For the induction machine, voltage and frequency remain constant, set by the connected po wer system, whatever the driven speed. The speed change does directly affect the power output of the generator and therefore the temperature of its windings. Unless other machines are coupled into the same drive to dampen speed swings, close control of rpm is almost as necessary to the induction generator as to the alternator. Smaller generators (down to 300 kW) are finding many uses. Among them: •
•
Totally Enclosed Fan Cooled (TEFC)
•
This is the highest degree of enclosure for an air cooled machine. In large sizes, the TEFC motor has an air-to-air heat exchanger. Internal motor air is recirculated around the outside of the tubes while outside air is driven through the tubes by a shaft driven fan. These motors are quite e xpensive especially in large sizes because of the high volume of cooling air required relative to motor size. These motors are indicated for use in very dirty or hazardous locations. The TEFC enclosure minimizes the maintenance required for these very dirty applications. However, the machines will breathe when shut down and vapor and gaseous contaminants can be drawn into them. TEFC motors are usually noisy because of the large external fan.
•
Generating power through expansion of compressed gases in cryogenic production. Recovering energy from single-stage waste steam turbines in the 5-175 psig inlet pressure range.
Because of the continuing increase in the cost of electric energy, variable speed drives offer an economical means of reducing energy requirements in many areas of operation.
Variable Frequency Electric Motors For many years variable speed applications relied on either d-c motors or a constant speed a-c motor coupled to various mechanical systems to provide the range of speeds required. Solidstate electronics provide an effective means of speed control for a-c motors by changing the frequency of the electrical signal. They can be used with both induction and synchronous motors.
An explosion-proof machine is a totally enclosed machine whose enclosure is designed and constructed to withstand an internal explosion. It is also designed to prevent the ignition of combustibles surrounding the machine by sparks, flashes, or explosions which may occur within the machine casing.
A standard a-c motor operating at 60 hertz will operate at a constant speed, depending upon the number of magnetic poles it has in accordance with the formula:
THE INDUCTION GENERATOR
120f rpm = P
The induction generator can be used as a convenient means of recovering industrial process energy that would otherwise be wasted. Excess steam or compressed gas can often drive such a generator to convert useless energy to valuable kilowatts.
Eq 15-2
However, if the input frequency can be varied in accordance with the speed requirements, then a wide range of speeds can be obtained. For example, with a frequency range from 50 to 120 hertz, a 4-pole motor has a speed range from 1500 through 3600 rpm.
Fixed Speed Electric Motors With Fluid Couplings The speed of an equipment item driven by a fixed-speed electric motor can be varied with a fluid coupling. This is essentially a pump discharging to a power-recovery turbine, both in the same casing. The pump is connected to the driver shaft and the turbine to the driven shaft. The turbine speed is varied by varying the amount of fluid in the casing. Increasing the fluid increases the circulation between the pump and turbine, thereby increasing the speed of the turbine. A fluid coupling
Important differences exist between the induction generator and the more widely used synchronous generator. These are basically the same as the differences between induction and synchronous motors. Besides low cost and simplicity of control an important benefit is that the induction machine is instantly convertible from generator to motor operation or vice versa.
2017 EDITION
Producing electric power from the expansion of geothermal steam.
SPEED VARIATION
Explosion-Proof
An induction generator is simply an induction moto r driven above its synchronous speed by a suitable prime mover. This results in production rather than consumption of electric energy. Normally the induction generator does not differ in any aspect of electrical or mechanical construction from an induction motor. Only the operating speed range separates one mode of behavior from the other.
Recovering energy of compression on the downhill side of a natural gas pipeline.
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costs less than electronic speed control but is less efficient. For example, the typical efficiency for electronic speed control is about 92–95% from minimum to normal speed, but for a fluid coupling is about 95% at normal speed, and can range from 50 to 70% at 50% speed, depending on the coupling make and type.
INTERNAL COMBUSTION ENGINES Internal combustion engines are classified according to the type of fuel used and the method of fuel ignition. Many subclassifications are used to describe engines according to their speed, cycle arrangements, mechanical configuration, and other design characteristics.
Engine Types Spark ignition and compression ignition are the two methods of initiating combustion used in reciprocating internal combustion engines. In practice the ignition method also defines the fuels or range of fuels used.
Spark Ignition — Natural gas, liquefied petroleum gas (LPG), or gasoline are the fuels used in spark ignition engines. They are often referred to as gas engines or gasoline engines and resemble in appearance (except perhaps for size) and operation the engines used in automobiles. High voltage electrical energy fires one or more spark plugs per cylinder to ignite the air/fuel mixture. Most spark ignition engines can be easily modified to burn any of the above fuels. Often the fuel delivery system is the only part of the engine requiring significant changes. Compression Ignition (Diesel) — Engines that use heat of compression as the ignition source are almost always referred to as diesel engines. A broad range of liquid fuels can be burned in a diesel engine provided proper attention is paid to the handling and preparation of the fuel as well as to the design of the engine. The type and quality of the fuel can have a significant effect on the service life of the engine. Diesel fuels are classified under an ASTM designation D-975. This specification covers limits for three grades of fuel which can be purchased commercially (Fig. 15-34). Engine manufacturers may also publish limits for the fuels they recommend be used in specific engines. Dual-Fuel — Dual-fuel engines may operate in one of two modes. One mode is as an ordinary diesel engine. It may also operate on a gaseous fuel with a pilot injection of liquid diesel fuel for ignition. The pilot fuel provides less than 10% of the total fuel energy at full load. Four-Stroke-Cycle — Most spark ignition engines use a four-stroke-cycle which is completed in two crankshaft revolutions and consists of the following piston strokes: 1. An intake stroke to draw the fuel/air mixture into the engine cylinder. 2. A compression stroke which raises the pressure and temperature of the mixture. 3. The expansion or power stroke from the ignition and combustion of the fuel mixture. 4. An exhaust stroke to free the cylinder of combustion products. The four cycle diesel engine operates in a similar fashion. During the intake stroke only air is introduced into the cylinder. Compression of air alone causes a higher temperature to be reached in the cylinder. The fuel is injected into the cylinder at the very beginning of the expansion stroke and spontaneously ignites.
2017 EDITION
Two-Stroke-Cycle — The four cycle engine requires two revolutions of the crankshaft for each power stroke. To get a higher output from the same size engine, the two-stroke-cycle was developed. This cycle is applicable both to compression ignition and spark ignition engines. The two-stroke-cycle is completed in one revolution of the crankshaft and consists of two piston strokes: the compression stroke and the expansion stroke. Combustion air intake occurs at the end of the expansion and the beginning of the compression stroke. Ignition and combustion occurs at the end of the compression and beginning of the expansion stroke.
Supercharged Engines — A supercharged engine has a compressor to increase the density of the combustion air before it is inducted into the cylinder. Supercharging increases the power output from a given cylinder size by increasing the engine mean effective pressure. Two types of supercharging are common: mechanical compressors driven by an engine auxiliary output shaft or a separate prime mover and exhaust turbine driven compressor which obtains its power from expansion of the engine exhaust. This later type of supercharger is commonly called a turbocharger.
Methane Number Most of the fuels used in internal combustion engines today, whether liquid or gaseous, are composed primarily of hydrocarbons (hydrogen and carbon). Natural gas is the most popular and widely used of the petroleum gases. Other gas sources, such as digester gas, or gas derived from coal which contain hydrocarbons, are also used in engines with varying degrees of success. Natural gas is a mixture of gases, some combustible and some inert. Different sources of natural gas, for example pipeline natural gas, LNG, CNG, etc. will have different compositions. Consequently, it is necessary to understand the characteristics and behavior of an individual fuel source. For gaseous fuels, the methane number is the determining parameter for knock resistance of a gas stream in an internal combustion engine. It is comparable to the motor octane number of gasoline. Engine knocking must be avoided as it can cause excessive temperatures and pressures which degrade the components of the engine. Typical natural gas streams have a methane number ranging from 75–98.1 The methane number is a function of gas composition, and uses a reference fuel blend of methane, with a methane number of 100, and hydrogen, with a methane number of 0. The determination of methane number is done via a prescribed engine test. The time and cost associated with engine testing makes this method an impractical approach to determining the methane number of a fuel source. There are a number of correlations available to determine methane number. There are differences in the prediction of methane number, in some cases on the order of 10%. Accordingly, the reader is advised to access the proprietary methods of their engine manufacturer to determine the suitability of a gaseous fuel for a particular application. Engine manufacturers will specify the minimum methane number of the fuel source required for their engines, typically 65 or greater.
Speed Most process plant engines are used to drive equipment with a limited range of speed requirements, and which can be selected to operate near the point of highest efficiency. Speed increasing or decreasing gears may be used to match an engine
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with a particular service. Internal combustion engines are classified according to speed in the following broad categories:
•
High speed — above 1500 rpm Medium speed — 700 to 1500 rpm Low speed — below 700 rpm
•
Heat rejection at a turbo aftercooler if applicable [100 to 500 Btu/(bhp • hr)]. Heat rejection at the lube-oil cooler [300 to 900 Btu/(bhp • hr)].
New technologies have reduced specific weights (i.e. lb/bhp), increased fuel efficiencies, lengthened the periods between overhauls, and reduced emissions. Precisely programmed electronically controlled fuel injection incorporates ambient and other important operating conditions to minimize fuel consumption and emissions over full operating ranges. Many engine designs include pre-combustion chambers that jet flames into the main combustion chambers effectively igniting leaner air/fuel mixtures (i.e. “lean burn”) resulting in higher efficiencies and lower emissions. New thermal-barrier coatings (TBCs) insulate many engine components from thermal shock and reduce heat losses that would otherwise decrease thermal efficiencies.
High speed engines can offer weight and space advantages but will usually require more maintenance than a medium or low speed engine. High speed engines are often selected for standby or intermittent applications. As a general rule the lower the speed the longer the service life. Although internal combustion engines are usually selected to run over a limited speed range, they will operate well over large ranges of speed just as an automobile engine does.
PERFORMANCE RATING Several measurements of performance can be used to compare engines. Four commonly used measurements are:
Engine Energy Balance A gas engine converts the combustion energy in the fuel to mechanical power and heat. The combustion energy is usually distributed as follows:
1. Specific fuel consumption, (lb or Btu)/(bhp<$E• >hr) 2. BMEP, psi 3. Specific weight, lb/bhp
% Range
4. Output per unit of displacement, bhp/cu in. The relationship between brake mean effective pressure (BMEP) and brake horsepower (bhp) is given below. BMEP =
(bhp) (33,000) (S) (A) (N)
Eq 15-3
25–40
Heat rejected to oil cooler
3–5
Heat rejected to turbo aftercooler
4–9 25–30 3–6
The mechanical power is the sum of the brake horsepower (bhp) (i.e. available shaft power), and the power to drive such engine auxiliaries as a lube-oil pump, cooling-water pump, radiator fan, and alternator (for a spark ignition engine). Fig. 15-35 includes engine power ratings, specific fuel requirements (i.e., “heat rates”), heat rejections and exhaust con-
The power delivered is directly related to atmospheric conditions. Operation in areas of low atmospheric pressure (high altitudes) will reduce the power output. High inlet air temperature will also reduce the power output. Engines are rated for various altitudes above sea level (i.e. barometric pressures) and ambient temperatures (e.g. 1500/3000 feet and 90°F according to DEMA; 1500 feet and 85°F; and so forth). A rule of thumb for derating naturally aspirated engines is 3.5% reduction in power for each 1000 ft above the rating altitude, and 1% reduction for every 10°F above the rating temperature. For exact deration of naturally aspirated engines, or for turbocharged engines, the manufacturers must be consulted.
FIG. 15-34 Grades of Diesel Fuel, ASTM D-975 (1995) Classification
Following are gas-engine design parameters. The values vary considerably depending on the engine type, make and model, and on the site conditions, but ranges of typical values are given. Fuel-gas requirements (i.e. heat rate) [6500 to 8500 Btu/ (bhp • hr), LHV]. Heat rejection at the power-end exhaust manifold [1500 to 3000 Btu/(bhp • hr) with jacket water cooling, or 800 to 1500 without].
2017 EDITION
Heat rejected to cylinder cooling
Heat rejected to atmosphere (i.e. surface heat loss)
The intended use of the engine will determine the most important measure of performance. For an aircraft engine the first and third items may be the most important; while for a stationary engine in continuous service with no space or weight limitations, the first item would be of primary importance.
•
30–40
Heat rejected to exhaust
The value of N is equivalent to RPM for two-stroke-cycle engines, and RPM divided by two for four-stroke cycle. BMEP indicates how much turbocharging increases the brake horsepower which is the power delivered to the driven equipment by the engine output shaft.
•
Mechanical power
183
1-D
2-D
4-D
Flash point, °F Min
100
125
130
Carbon Residue, % Max
0.15
0.35
–
Water and Sediment, % by Vol Max
0.05
0.05
0.50
Ash, % by Wt Max
0.01
0.01
0.10
Distillation °F 90% Pt Max Min
550 –
640 540
– –
Viscosity at 104°F Centistokes Min Max
1.3 2.4
1.9 4.1
5.5 24.0
Sulfur, % by Wt
0.05
0.05
2.0
Cetane No. Min
40
40
30
Aromaticity, % by Vol Max
35
35
–
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AUXILIARIES
ditions for a variety of gas engines. The values are based on full design operating power at the speeds noted for various altitudes above sea level and ambient temperatures.
Bearings
An engine’s power efficiency, typically called “thermal efficiency,” is calculated from the following equation: Thermal Efficiency =
Hydrodynamic journal bearings are found in all types of industrial turbomachinery, which include pumps, electric motors, steam turbines, electric generators, and gas compressors. The hydrodynamic bearing types most commonly found in turbomachinery are:
100 x 2544 Heat Rate (Btu/(bhp hr), LHV) •
The total heat rejected is calculated from the following equation: Heat Rejected = (Heat Rate – 2544) Btu/(bhp hr)
•
Plane cylindrical
•
Pressure dam
•
Tilting pad
•
The heat rejected to the engine exhaust gas is calculated from the following equation:
For all bearing types, the fundamental geometric parameters are journal diameter, pad arc angle, length-to-diameter ratio, and running clearance. Some bearing types, such as tilting pad bearings, have additional geometric variations including number of pads, preload, pad pivot offset angle, and orientation of the bearing (on or between pads). The key operating conditions are oil viscosity, oil density, rotating speed, gravity load at the bearing, and applied external loads (such as gear mesh or pump volute loadings). A machinery expert should be consulted for further details concerning types of bearings and their applications and designs.
Exhaust Heat = Total heat rejected minus the sum of the Btu/(bhp hr) heat rejected to cylinder cooling, oil cooling, turbo aftercooling, and enginesurface heat loss to the atmosphere •
It is technically feasible to recover part of the heat. Low temperature heat at about 180°F, for such as space heating, can be recovered from the cooling circuits for cylinder jackets, lube oil and turbo charged air. Higher level heat at above 300°F can be recovered by heat exchange with engine exhaust. Below 300°F water vapor will condense with CO 2 absorption, acid formation, and resulting corrosion. A heat recovery arrangement is illustrated in Fig. 15-36. Technical feasibility depends upon the economic criteria and improves as the engine size increases. Heat recovery can increase the overall thermal efficiency to as high as 75%. For example, an engine’s thermal efficiency can be increased from a typical regular value of 33% to 75% by recovering about 60% of the heat normally rejected to the coolant and exhaust.
Gears There are many different types of open gears such as spur, helical, spiral bevel, and worm. This section will focus on enclosed high speed helical gear reducers or increasers commonly used in the natural gas, refinery, and petrochemical industries. Speed Increasers and Reducers — Speed increasers are usually used on centrifugal compressors, axial compressors, blowers, and centrifugal pumps driven by motors, turbines, and industrial combustion engines. Speed reducers are used on reciprocating compressors, rotary positive displacement compressors, centrifugal pumps, generators, and fans driven by turbines and motors.
Example 15-4 —Calculate the thermal efficiency, total heat re jected, and total exhaust heat for a Waukesha L7042GL at 1200 RPM, 77°F and sea level, and its full power rating.
Solutions Steps From Fig. 15-35
High Speed Gears — High-speed gears are generally defined as having either or both of the following:
Full Power
= 1480 bhp
Heat rate
= 7284 Btu/(bhp hr), LHV
1. Pinion speed of at least 2,900 rpm.
•
2. Pitch line velocities above 5,000 ft/min.
Heat rejected to water cooling, oil cooling, turbo = 1953 + 298 + 427 + 189 intercooling, and radiation = 2867 Btu/(bhp hr)
There are units operating with pitch line velocities in excess of 35,000 ft/min and transmitting 30,000 hp.
•
Therefore: Thermal efficiency
=
Gearing — High speed gears can be selected with either single helical gearing (used extensively in Europe) or opposed double helical (i.e., “herringbone”) gearing (predominant in the United States). Pros and cons of each type of gear design are numerous with double helical gearing being more efficient because there is only one thrust bearing required. The thrust bearing is usually on the low speed shaft.
100 x 2544 = 34.9% 7284
Heat rejected per bhp = 7284 – 2544 = 4740[Btu/(bhp hr)] •
Total heat rejected
= 4740 [Btu/(bhp hr)] 1480 bhp = 7.0 MMBtu/hr •
Surface Finish — High speed gears are classified as precision quality gears. Fig. 15-37 shows a minimum surface finish and quality required for various pitch line velocities as recommended in Figure 1, page 14 of AGMA 2001-C95, Fundamental Rating Factors and Calculation Methods for Involute Spur and Helical Gear Teeth.
Exhaust heat per bhp = 4740 – 2867 = 1873 Btu/(bhp hr) •
Total exhaust heat
2017 EDITION
= 1873 [Btu/(bhp hr)] 1480 bhp = 2.77 MMBtu/hr •
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FIG. 15-35 (Cont’d.) Engine Ratings and Operating Parameters
. n o i t a m r o f n i t c a x e r o f r e r u t c a f u n a ) r m h o · t r p e h b f e ( / R u . t y B l n o n o s i e t c n e i j g e n R e t a w e e H n f o e v i t a t n e s e r p e r e r a d n a s e c i v r e s e n i g n e n i s n o i t a i r a v o t e u d e t a m i x o r p p a e b y a m s e r u g i F : e t o N
t F s u ° a p h m x e E t
9 9 7 7 7 7
7 9 7
4 6 8 8 4 6 3 6 8 9 9 2 4 6 9 7 2 6 6 5 3 4 2 5 0 7 2 3 1 9 3 1 8 3 1 6 3 1 0 0 6 9 4 9 4 3 0 1 2 1 6 7 0 2 1 0 1 8 1 1 0 1 8 1 1 8 1 1 8 1 1 1 7 1 1 1 1 0 1 8 8 1 1 1 7 1 1 1 7 1 1 8 8
] ) r t h s · u t e p a a h h r x b ( / E b l [
2 2 8 . 8 . 9 9
4 8 . 9
9 7 5 0 7 1 1 2 4 2 7 2 7 5 6 4 5 3 5 3 7 7 3 4 1 4 7 7 4 5 7 5 . 9 5 5 . 4 8 7 . 3 9 . 8 . . 9 . 6 . 6 . 3 . 6 . 3 . 6 . 3 . 4 . 4 . 9 . 8 . 6 . 0 . 1 . 6 . 4 . 8 . 6 . 0 . 1 0 0 6 9 9 9 6 6 6 6 9 9 6 6 6 1 1 1 1 1 1
. e . t i a e e r e H s s h e o p c a L s f o r u m t S A
) 5 ) 5 ( ( 4 4 9 9
) 5 ( 2 9
4 5 4 8 3 0 8 7 9 9 2 5 7 7 8 6 9 1 9 6 5 0 3 1 7 4 0 5 8 4 7 0 1 5 6 3 7 2 2 1 2 8 1 3 1 1 2 2 1 1 1 1 3 9 1 3 4 0 2 3 4 1 3 8 1 0 4 8 3 1 2 4 3 3 8 8
/ r r e e l o o l o o b o r c r c u r e T t e t f n A I
) 7 ) 7 ( ( ) ) 5 5 ( ( 3 4 3 2 1 2
) 7 ( ) 5 ( 0 4 2
3 5 5 3 2 2 2 6 5 3 8 7 0 0 4 8 4 7 9 7 4 9 7 8 8 7 8 8 3 0 5 9 2 2 5 6 4 — 4 1 — 4 1 4 1 4 1 — 4 6 1 1 — 3 3 1 — 4 9 1 1 4 9 1 0 7 3 7
r e l o o C l i O
) 5 ) 5 ( ( 5 9 5 9 2 2
) 5 ( 5 9 2
5 3 3 4 2 3 1 1 7 6 3 4 9 6 7 8 2 8 3 3 1 2 2 9 6 2 7 3 7 8 7 0 2 4 2 2 4 3 2 4 2 2 4 4 2 3 2 6 3 8 3 1 3 0 4 3 3 3 3 4 3 8 3 9 2 4 2 4 3 2 3 6 3 2 6 2 1 2
r e t a r e l W t o e o k C c a J
) 6 ) 6 ( ( ) 5 ) 5 ( ( 5 4 2 7 4 7
) 6 ( ) 5 ( 0 0 7
8 5 5 4 5 4 9 0 0 7 9 8 6 0 8 7 8 8 9 7 4 9 4 7 3 2 8 1 0 7 4 5 7 7 5 7 8 4 9 6 3 5 0 3 0 5 4 8 7 8 5 8 4 5 6 7 1 5 9 5 2 6 2 1 2 2 9 2 8 1 2 2 8 1 3 2 9 1 3 2 4 2 0 2 2 2 2 1 6 1 2 2 4 2 9 1 4 2 3 2 1 2
) t ] r h m · q p e h V R H ( L l b e / u u t F [ B
5 3 5 3 5 3 5 3 5 3 4 , 4 , 4 , 4 , 4 , 5 5 5 5 5
0 3 7 0 7 4 7 6 5 6 5 1 9 7 2 3 2 9 2 9 1 9 8 2 9 3 7 6 3 3 8 0 8 3 4 1 6 9 5 4 8 3 3 9 1 8 9 0 3 0 5 7 5 5 6 5 7 1 7 5 7 8 7 1 7 4 7 1 7 3 7 0 7 3 7 3 7 3 6 6 7 3 7 2 7 8 7 9 7 1 8 0 8 4 7 9 6 9 7 1 7 9 7 6
P ) E i s M p B (
7 7 8 7 7 8 7 8 2 8 2 2 8 2 2
0 0 0 0 0 0 5 8 8 8 8 6 6 8 8 0 0 6 6 0 0 6 8 8 5 6 5 6 5 8 3 9 6 9 4 9 3 1 6 1 9 6 1 6 1 6 1 6 1 6 1 6 1 9 3 1 3 1 1 1 1 1 1 3 1 1 1 3 1 2 2 2 2
r e P e s l e c k y o r C t S
4 4 4 4 4
4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4
d ) l l e m u e p F p ( r S
0 0 0 0 0 5 7 5 7 5 7 5 7 5 7
0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 8 8 8 8 8 8 8 8 8 8 2 2 2 2 2 2 2 2 2 2 2 2 2 2 0 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 0 1
t a r d e e e ) w p p o S h P l l b ( l l u u F F
9 1 1 1 5 2 3 4 5 6 0 6 4 2 6 , , , , , 3 5 7 9 2 1
0 5 6 5 5 8 0 0 5 0 5 0 5 3 5 0 0 0 0 0 0 0 0 6 5 0 8 2 8 0 8 0 8 0 8 0 8 2 4 1 3 4 4 4 8 4 2 0 4 0 4 2 3 3 5 3 5 0 8 0 8 0 1 0 1 5 7 7 8 8 2 1 1 3 1 0 1 4 1 4 1 6 1 9 1 9 1 6 3 8 4
) G G G 4 G G S S S ( S 4 S 4 4 a 4 3 3 4 3 l 3 i 3 V V 0 V s L 6 t 6 L 9 2 r 1 1 2 a W
I I I L L L I I L I L I G L I a T I S G L S G S G G S G T L S G S G S 1 G S G S h G L G 5 5 G 2 2 G 4 G 0 0 G L G 4 G 0 L 4 4 G G S 1 G s 8 8 G G 4 2 G 4 4 9 4 2 7 9 8 9 7 2 7 6 4 2 4 8 9 6 9 4 4 e 1 1 8 2 4 1 2 0 7 5 7 7 2 4 3 3 0 5 2 4 3 0 5 3 5 5 5 5 7 k F F 1 7 7 0 9 9 2 V 6 V F H H H L 3 L P P 3 5 7 7 3 F 3 L L u L L F L P 2 F F L L L P 1 1 a W
r g e n d i n l i l o y o C C
2017 EDITION
E N I G N E
I + +
186
6 1 g / n 6 i t 4 a r 0 x 3 O O S N I h m t a r i w g e 5 c . n 0 a n r o d o d c e c s a a n b i n s o n i t o a i t i m d r o n o f n g c i n e e i c t n t n i e g r s e n t e . f e r s e e y r B l l 0 t o a d t o 0 n a a c 3 e c a h 3 r n e G o g r t n e a d d i l t o n e t w e o a t s c e 4 s a y i r k 3 b c c n a a M n e j e o i e C i c g t r i h a t G , a f f 0 m o 0 r E h c t o h t g T a 6 3 f n i H i h H d t G e , t n h n E a t i a i L g n t w n i o k e B e d s e 0 r c 2 a e d 5 0 0 v j u 3 5 l 3 2 s G c e n , d i E G A u e l s L d i h c n r B a t i n y e n 6 l l A o ) 1 t o T i p 5 0 u u n o o 3 c 0 c l r n G i i o i , 4 e c 3 d o E t s r G e T a L , b H o h p t B A ( s i r t e o 2 N i t 1 u l a c o 5 0 t 0 d a r 3 o e 4 i t 3 d % G c c c r , G e e E r i j 0 c e , a e 1 t n r L 0 a e a e w g t B 0 c a 3 r n t e 8 r a 3 m a 0 e h h o G r k 5 f c l e r e l e l c h 3 a T o J G A s P t L : ) : ) e T t ) ) ) ) ) o 1 2 3 4 5 6 7 N ( ( ( ( ( ( (
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TECH BRIEF
FIG. 15-36 Example Engine Heat Recovery Arrangement
Gear Ratings Various parameters affecting the durability, strength ratings, and scoring temperatures include:
Horsepower — The horsepower rating of high speed gears is determined from the durability rating and stren gth rating on the gear or pinion as specified in AGMA 6011-G92, Specifications for High Speed Helical Gear Units. In addition, the rating is limited by the scuffing temperature as determined in accordance with AGMA 217.01, Information Sheet, Gear Scoring Design Guide for Aerospace Spur and Helical Power Gears, and Annex A of AGMA 2001-C95. Durability — The durability hp rating for a specific gear set is primarily dependent on the speed and allowable contact stress of the gear and does not vary significantly with tooth size. The allowable contact stress is dependent on the surface hardness of the gear or pinion tooth and varies with material composition and mechanical properties. Strength — The strength hp rating for a specific gear set varies mainly with the speed, allowable fatigue stress of material, and with tooth thickness. The tooth form, pressure angle, filet radius, number of teeth, h elix angle, and pitch line velocity also affect the strength horsepower rating. Allowable fatigue stress is dependent on the tensile strength of the material and varies with heat treatment and chemical composition.
2017 EDITION
Scuffing Temperatures — The scuffing or flash temperature index is the calculated temperature of the oil in the gear mesh. This temperature is arrived at by calculating the temperature rise of the lubricant in the mesh and adding it to the inlet oil temperature. The temperature rise for a given set of gears increases with the tooth loading, speed, and surface finish (i.e. increasing roughness). The temperature of the gears will increase as the pitch is decreased, pressure angle is decreased, or helix angle is increased.
Design Factors The following design factors must be considered for high speed drives.
Housings — Must be of rugged design for strength and rigidity to maintain precise alignment of gears and bearings. Bearings — Should be split-sleeve, babbitt lined, steelbacked precision journal bearings with thrust faces for axial loads. Fixed pad or tilting pad (Kingsbury type) should be used where required. Tilt pad radial bearings may also be required for high rpm, high load applications. Shafts — Precision machined from heat treated, high quality alloy (4140 is common) steel. Adequately sized to rigidly maintain gear alignment and protect from overload.
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Couplings
FIG. 15-37 Gear Quality Pitch Line Velocity (ft/min)
Surface Quality (RMS) (micro inches)
Minimum Gear Quality Number
Under 8,000
45
10
8,001 – 10,000
32
11
10,001 – 20,000
32
12
20,001 – 30,000
20
12-13
Over 30,000
16
12-14
Pinions — Normally cut integral with shaft from a high quality forging that is through hardened or surface hardened by carburizing or nitriding. Grinding is the most common finishing method but precision hobbing, shaving, or lapping are also used.
A coupling is required to connect a prime mover to a piece of driven machinery. The purpose of a coupling is to transmit rotary motion and torque from one piece of machinery to another. A coupling may also serve a seco ndary purpose such as accommodating misalignment of the two pieces of equipment. There are two general categories of couplings: rigid and flexible.
Rigid Couplings — Rigid couplings are used when the two machines must be kept in exact alignment or when the rotor of one machine is used to support the rotor of another machine. Very precise alignment of machine bearings is necessary when using this type of coupling. Manufacturing tolerances are also extremely important. One common application for rigid couplings is in the pump industry where the prime mover, generally an electric motor, is positioned vertically above the pump. Flexible Couplings — Flexible couplings, in addition to transmitting torque, accommodate unavoidable misalignment between shafts. Mechanically flexible couplings provide for misalignment by clearances in the design of the coupling. The most common type of mechanically flexible coupling is the geartype. Material flexible couplings use the natural flexing of the coupling element to compensate for shaft misalignment. Metal, elastomer, or plastic having sufficient resistance to fatigue failure may be used for the flexing elemen t of the coupling. Many types of flexible couplings are in common use and selection for a particular application depends on many factors including cost, horsepower, shaft speed, and reliability. A specialist should always be consulted for proper selection on any critical piece of equipment.
Gears — Usually made from a high quality forging that is through hardened or surface hardened by carburizing or nitriding and is separate from the low speed shaft. Gear may be integral with the shaft when operating conditions re quire. Grinding is the most common finish method but precision hobbing, shaving, or lapping are also used. Dynamic Balance — Balance all rotating elements to assure smooth operation at high rpm. Seals — Shaft seal should be of the labyrinth type, with clearance between shaft and seal of 0.020 to 0.030 inch. To prevent oil leakage through the clearance, the labyrinth is made interlocking with grooves machined in the cap to create air back pressure during rotation to retain the lubricant.
Vibration Monitoring The oldest and most basic type of vibration measurement involved the use of the human senses to feel and listen to a machine. The basic approach has not changed, just the method. It was always difficult to justify enough time for o ne individual, or a group of individuals, to acquire periodic measurements on a large number of machines. Also, with the advent of high speed, high performance machines, failures can occur faster than personnel can react. In addition, very subtle changes can occur over a long period of time, making it difficult to realize by the human senses, but still affecting the machine’s mechanical stability and safety. Vibration monitoring is simply the full-time electronic measurement and monitoring of vibration levels from a given machine. Typically, the monitoring responds to the overall signal input from the transducer regardless of the source of vibration (in-balance, bearing wear, coupling problems, misalignment, etc.).
High speed gears are usually used on critical process trains where down time is quite costly and catastrophic failure must be avoided at all costs. Therefore, gear drives are becoming more and more instrumented. Optional monitoring equipment often specified by users include: •
•
•
•
•
•
Vibration probes and proximitors (to measure shaft vibration). Keyphasors (provide timing and phase reference). Accelerometers (measure casing acceleration). Direct reading dial type thermometers in stainless thermowells (measure bearing temperature). Resistance temperature detectors (RTDs) and thermocouples (measure bearing temperature).
A typical vibration monitor provides two levels of alarm: alert and danger, that can be adjusted to fit the characteristics of a given machine. These set points have associated relays which can be connected to external audible or visual annunciators on the control panel. If the alert or danger set point is exceeded, the monitor and annunciator will alert operations and maintenance personnel of this event. Ideally, the alert alarm will indicate that the machine condition has changed significantly, but allow some discrete time before the machine is in a dangerous condition. For most applications, if the machine does reach the danger level of vibration and continued operation would probably result in machine failure, automatic shutdown is mandatory regardless of the time lag that has occurred between alert and danger signal.
Temperature and pressure switches (alarm and shutdown functions).
Lubrication The majority of high horsepower, high speed gears are lubricated from a common sump which also lubricates the driving and the driven equipment. These systems are normally designed to operate with a high grade turbine o il with a minimum viscosity of 150 SSU at 100°F. A good operating pressure range for the oil is 25 to 50 psi, with 25 micron filtration.
2017 EDITION
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TECH BRIEF
There are three types of vibration sensors: (1) accelerometers, (2) (2 ) velocity transducers, and (3) proximity probes. For most large critical machinery, and certainly for machinery with fluid film-type bearings, the important measurement to be made is rotor motion relative to the machine bearing or bearing support. For this application, the proximity probe transducer has proven to be the most reliable indicator of machinery malfunctions. The proximity probe is a noncontacting transducer, typically installed on the bearing or bearing housing, and observes the rotor radial dynamic motion and position with respect to the bearing clearance. This same type of proximity probe can be used to measure axial position and vibration as well. For machines which exhibit significant amounts of casing motion, it may be necessary to add to this system a seismic transducer measuring measuring machine casing vibration. Some unique applications dictate that measurements are necessary in the high frequency region, where accelerometers are typically employed. The American Petroleum Institute (API) has published a specification describing vibration monitoring systems, API 670, “Vibration, Axial Position, and Bearing Temperature Monitoring Systems.”
REFERENCE 1. Malenshek, M., Olsen, Daniel B., “Methane number testing of alternative gaseous fuels,” Fuel 88 (2009), pg 650–656.
BIBLIOGRAPHY Brown, T., Cadick, J. L., “Electric Motors are the Basic CPI Prime Movers,” Chemical Engineering, Vol. 86, No. 6, 1979. Gartmann, Hans, Editor, “DeLaval Engineering Handbook,” McGrawHill Book Company, 1970. Karassik, I. J., Krutzsch, W. C., Fraser, W. H., Messina, J. P., Editors, “Pump Handbook,” McGraw-Hill Book Company, 1976. Kosow, I. L., “Control of Electric Machines,” Prentice-Hall, 1973. Kubesh, John T., “Effect of Gas Composition on Octane Number of Natural Gas Fuels,” SwRI-3178-4.4, GETA 92-01, GRI-92/0150, May 1992. Kubesh, John, King, Steven R., Liss, William E., “Effect of Gas Composition on Octane.” Molich, K., “Consider Gas Turbines for Heavy Loads,” Chemical Engineering, Vol. 87, No. 17, 1980. Neerken, R. F., “Use Steam Turbines as Process Drivers,” Chemical Engineering, Vol. 87, No. 17, 1980. “Number of Natural Gas Fuels,” Society of Automotive Engineers, Inc., SAE 922359, 1992. Obert, E. F., “Internal Combustion Engines,” International Textbook Co., 1968. Salamone, D. J., “Journal Bearing Design Types and Their Applications to Turbomachinery,” Proceedings of the Thirteenth Turbomachinery Symposium, Turbomachinery Laboratories, Department of Mechanical Engineering, Texas A&M University, 1984. Sawyer, J. W., Editor, “Gas Turbine Handbook,” Gas Turbine Publications, Inc., 1966. Spletter, Kathy, Kathy, Adair, Lesa, Lesa, “Processing,” Oil and Gas Gas Journal, Journal, May 21, 2001. CTSS
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CONVERSION FACTORS
absolute atmosphere absolute British thermal unit British thermal unit/hour Celsius cubic foot/minute centimeter square centimeter cubic centimeter cubic foot Fahrenheit foot/second foot-pound gallon horsepower inch inch mercury inch water kilocalorie kilogram kilojoule kilopascal kilowatt liter meter millimeter square meter cubic meter cubic meter/minute mile per hour Newton Pascal normal* cubic meter/hour pound/square inch pound/square inch absolute pound/square inch gage standard* cubic foot standard* cubic foot/minute square
*“Normal” = 0°C and 1.01325x105 Pascals *“Standard” = 59°F and 14.73 psia
mm 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
kg 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
in 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748 0.787
lb 2.204 4.409 6.614 8.819 11.023 13.228 15.432 17.637 19.843 22.046 24.251 26.455 28.660 30.865 33.069 35.274 37.479 39.683 41.888 44.093
To Convert From English
sq. in. sq. ft. lb/cu.ft. lbf lb /ft f Btu Btu/hr Btu/scf in ft yd lb hp psi psia psig in. Hg in. H2O °F °F (Interval) ft-lb mph ft/sec cu. ft. gas (US) cfm scfm To Convert From Old Metric
To S.I. Metric
Multiply By
mm 2 m2 kg/m 3 N N/m kJ W kJ/mm 3 mm m m kg kW kPa kPa abs kPa gage kPa kPa °C = °C (Interval) N • m km/hr m/sec m3 L m3 /min nm3 /min
645.16 0.0929 16.0185 4.4482 14.5939 1.0551 0.2931 37.2590 25.400 0.3048 0.914 0.4536 0.7457 6.8948 6.8948 6.8948 3.3769 0.2488 (°F -32) 5/9 5/9 1.3558 1.6093 0.3048 0.0283 3.7854 0.0283 0.0268
To S.I. Metric
Multiply By
cm2 kcal kcal/hr cm kg/cm2 bars atm cm Hg cm H 2O nm3 /hr
mm 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40
MILLIMETERS (mm) TO INCHES (in) (1 millimeter = 0.03937 inch) in mm in mm in mm 0.827 41 1.614 61 2.402 81 0.866 42 1.654 62 2.441 82 0.906 43 1.693 63 2.480 83 0.945 44 1.732 64 2.520 84 0.984 45 1.772 65 2.559 85 1.024 46 1.811 66 2.598 86 1.063 47 1.850 67 2.638 87 1.102 48 1.890 68 2.677 88 1.142 49 1.929 69 2.717 89 1.181 50 1.968 70 2 .756 90 1.220 5 1 2.008 71 2 .795 91 1.260 5 2 2.047 72 2 .835 92 1.299 53 2.087 73 2 .874 93 1.339 54 2.126 74 2.9 13 94 1.378 55 2.165 75 2.95 3 95 1.417 56 2.205 76 2.99 2 96 1.457 57 2.244 77 3.03 2 97 1.496 58 2.283 78 3.07 1 98 1.535 59 2.323 79 3.11 0 99 1.575 60 2.362 80 3.150 100
kg 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40
KILOGRAMS (kg) TO POUNDS (lb) (1 kilogram = 2.20462 pounds) lb kg lb kg lb 46.297 41 90.390 61 134.482 48.502 42 92.594 62 136.687 50.706 43 94.799 63 138.891 52.911 44 97.003 64 141.096 55 .116 45 99.208 65 143.300 57.320 46 101.413 66 145.505 59.525 47 103.617 67 147.710 61.729 48 105.822 68 149.914 63.934 49 108.026 69 152.119 66.139 50 110.231 70 154.324 66.343 51 112.436 71 156.528 70.548 52 114.640 72 158.733 72.753 53 116.845 73 160.937 74.957 54 119.050 74 163.142 77.162 55 121.254 75 165.347 79.366 56 123.459 76 167.551 81.571 57 125.663 77 169.756 83.776 58 127.868 78 171.961 85.980 59 130.073 79 174.165 88.185 60 132 .277 80 176.370
2017 EDITION
TEMPERATURE CONVERSION TABLES*
CONVERSION FACTORS
ABBREVIATIONS abs ata Btu Btu/hr °C cfm cm cm2 cm3 cu.ft. °F ft/sec ft-lb gal hp in in. Hg in. H2O kcal kg kJ kPa kW L m mm m2 m3 m3 /min mph N N/m2 Nm3 /hr psi psia psig scf scfm sq
SI — METRIC/DECIMAL SYSTEM
kg 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100
mm2 kJ W mm kPa kPa kPa kPa kPa nm3 /min
in 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504 3.543 3.583 3.622 3.661 3.701 3.740 3.779 3.819 3.858 3.898 3.937
To Old Metric cm2 m2 kg/m3 N N/m kcal kcal/hr kcal/nm3 cm m m kg kW kg/cm2 bars abs ata cm Hg cm H2O °C = °C (Interval) N • m km/hr m/sec m3 L m3 /min nm3 /hr
100. 4.1868 1.16279 10. 98.0665 100. 101.325 1.3332 9.8064 0.0176
By Albert Sauveur
Multiply By 6.4516 0.0929 16.0185 4.4482 14.5939 0.252 0.252 0.1565 2.540 0.3048 0.914 0.4536 0.7457 0.070 0.0716 0.070 2.540 2.540 (°F -32) 5/9 5/9 1.3558 1.6093 0.3048 0.0283 3.7854 0.0283 1.61
C -17.8 -17.2 -16.7 -16.1 -15.6 -15.0 -14.4 -13.9 -13.3 -12.8 -12.1 -11.7 -11.1 -10.6 -10.0 -9.44 -8.89 -8.33 -7.78 -7.22 -6.67 -6.11 -5.56 -5.00 -4.44 -3.89 -3.33 -2.78 -2.22 -1.67 -1.11 -0.56 0 0.56 1.11 1.67 2.22 2.78 3.33 3.89 4.44 5.00 5.56 6.11 6.67 7.22 7.78 8.33 8.89 9.44
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49
C 38 43 49 54 60 66 71
100 110 120 130 140 150 150 160 160
0 to 100 C 10.0 10.6 11.1 11.7 12.2 12.8 13.3 13.9 14.4 15.0 15.6 16.1 16.7 17.2 17.8 18.3 18.9 19.4 20.0 20.6 21.1 21.7 22.2 22.8 23.3 23.9 24.4 25.0 25.6 26.1 26.7 27.2 27.8 28.3 28.9 29.4 30.0 30.6 31.1 31.7 32.2 32.8 33.3 33.9 34.4 35.0 35.6 36.1 36.7 37.2 37.8
50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 93 94 94 95 95 96 97 98 99 100
F 122.0 123.8 125.6 127.4 129.2 131.0 132.8 134.6 136.4 138.2 140.0 141.8 143.6 145.4 147.2 149.0 150.8 152.6 154.4 156.2 158.0 159.8 161.6 163.4 165.2 167.0 168.8 170.6 172.4 174.2 176.0 177.8 179.6 181.4 183.2 185.0 186.8 188.6 190.4 192.2 194.0 195.8 197.6 199.4 201.2 203.0 204.8 206.6 208.4 210.2 212.0
100 to 1000 F C 212 77 230 82 248 88 266 93 284 99 302 100 320 104
170 170 180 180 190 190 200 200 210 210 212 212 220
F 338 356 374 392 410 413 428
F 32 33.8 35.6 37.4 39.2 41.0 42.8 44.9 46.4 48.2 50.0 51.8 53.6 55.4 57.2 59.0 60.8 62.6 64.4 66.2 68.0 69.8 71.6 73.4 75.2 77.0 78.8 80.6 82.4 84.2 86.0 87.8 89.6 91.4 93.2 95.0 96.8 98.6 100.4 102.2 104.0 105.8 107.6 109.4 111.2 113.0 114.8 116.6 118.4 120.0
C 110 116 121 127 132 138 143 149 154 160 166 171 177 182 188 193 199 204 210 216 221 227 232 238 243 249 254 260 266 271 277 282 288 293 299 304 310 316 321 327 332 338 343
100 to 1000 – cont. F C 230 446 349 240 464 354 250 482 360 260 500 366 270 518 371 280 536 377 290 554 382 300 572 388 310 590 393 320 608 399 330 626 404 340 644 410 350 662 416 360 680 421 370 698 427 380 716 432 390 734 438 400 752 443 410 770 449 420 788 454 430 806 460 440 824 466 450 842 471 460 860 477 470 878 482 480 896 488 490 914 493 500 932 499 510 950 504 520 968 510 530 986 516 540 1004 521 550 1022 527 560 1040 532 570 1058 538 580 580 1076 590 590 1094 600 600 1112 610 610 1130 620 620 1148 630 630 1166 640 640 1184 650 650 1202
C 538 543 549 554 560 566 571 577 582 588 593 599 604 610
1000 to 1630 F C 1832 816 1850 821 1868 827 1886 832 1904 838 1922 843 1940 849 1958 854 1976 860 1994 866 2012 871 2030 877 2048 882 2066 888
1000 1010 1020 1030 1040 1050 1060 1070 1080 1090 1100 1110 1120 1130
660 660 670 670 680 680 690 690 700 700 710 710 720 720 730 730 740 740 750 750 760 760 770 770 780 780 790 790 800 800 810 810 820 820 830 830 840 840 850 850 860 860 870 870 880 880 890 890 900 900 910 910 920 920 930 930 940 940 950 950 960 960 970 970 980 980 990 990 1000 1000
F 1220 1238 1256 1274 1292 1310 1328 1346 1364 1382 1400 1418 1436 1454 1472 1490 1508 1526 1544 1562 1580 1598 1616 1634 1652 1670 1688 1706 1724 1742 1760 1778 1796 1814 1832
1500 1500 1510 1510 1520 1520 1530 1530 1540 1540 1550 1550 1560 1560 1570 1570 1580 1580 1590 1590 1600 1600 1610 1610 1620 1620 1630 1630
F 2732 2750 2768 2786 2804 2822 2840 2858 2876 2894 2912 2930 2948 2966
Note: The numbers in bold face type refer to the temperature either in degrees Centigrade or Fahrenheit which is desired to convert into the other scale. If converting from Fahrenheit degrees to Centigrade degrees, the equivalent temperatures will be found in the left column; while if converting from degrees Centigrade to degrees Fahrenheit, the answer will be found in the column on the right.
VOLUME
PISTON SPEED
WEIGHT/HORSEPOWER WEIGHT/HORSEPOW ER
CONVERSION FACTORS
CONVERSION FACTORS
CONVERSION FACTORS
1 L = 61.02 cu. in. 10 cu. in. = 0,164 L
L
cu. in.
1 m/s = 196.9 ft./min. 100 ft./min. = 0,51 m/s
m/s
ft./min.
1 kg/metric hp = 2.235 lb./hp 1 lb/hp = .4474 kg/metric hp
kg/metric hp
lb/hp
lb 178.574 180.779 182.984 185.188 187.393 189.598 191.802 194.007 196.211 198.416 200.621 202.825 205.030 207.235 209.439 211.644 213.848 216.053 218.258 220.462
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SI UNITS…
THE INTERNATIONAL STANDARDS SYSTEM
The system outlined here is the International System of Units (Systeme International d’ Unites), for which the abbreviation SI is being used in all languages. The SI system, which is becoming universally used, is founded on seven base units, these being: Length.......................... ..................... . meter Mass .................... ...................... .... kilogram Time.................................................second Electric current ................... ............ ampere Thermodynamic temperature ............Kelvin Luminous intensity..................... ..... candela Amount of substance...........................mole
m kg s A K cd mol
POWER The derived SI unit for power is the Watt (W), this being based on the SI unit of work, energy and quantity of heat – the Joule (J). One Watt (1 W) is equal to one Joule per second (1 J/s). One Watt is a very small unit of power, being equivalent to just 0.00134102 horsepower, so for engine ratings the kilowatt (kW) is used, 1 kW being equal to 1.341 hp and 1 hp being the equivalent of 0.7457 kW. The British unit of horsepower is equal to 1.014 metric horsepower (CV, PS, PK, etc.).
Reciprocating Internal Combustion engines. Known as PTC 17, this code is intended for tests of all types of reciprocating internal combustion engines for determining power output and fuel consumption. In its Section 2, Description and Definition of Terms, both the FPS and corresponding SI units of measurements are given.
SPECIFIC CONSUMPTION Fuel consumption measurements will be based on the currently accepted unit, the gram (g), and the Kilowatt Hour (kWh). Also adopted is heat units/power units so that energy consumption of an internal combustion engine referred to net power output, mechanical, is based on low unsaturated heat value of the fuel whether liquid or gaseous type. Thus the SI unit of measurement for net specific energy consumption is expressed: g/kWh. 1 g/kWh = 0.001644 lb/hph = 0.746 g/hph = 0.736 g/metric hph 1 lb/hph = 608.3 g/kWh 1 g/hph = 1.341 k/kWh 1 g/metric hph = 1.36 g/kWh
WEIGHTS AND LINEAR DIMENSIONS For indications of “weight” the original metric kilogram (kg) will continue to be used as the unit of mass, but it is important to note that the kilogram will no longer apply for force, for which the SI unit is the Newton (N), which is a kilogram meter per second squared. The Newton is that force which, when applied to a body having a mass of one kilogram, gives it an acceleration of one meter per second squared. “Weight” in itself will no longer apply, since this is an ambiguous term, so the kilogram in effect should only be used as the unit of mass. Undoubtedly, though, it will continue to be common parlance to use the word “weight” when referring to the mass of an object. The base SI unit for linear dimensions will be the meter, with a wide range of multiples and submultiples ranging from exa (10 18) to atto (10 -18): A kilometer is a meter x 10 3, for example, while a millimeter is a meter x 10 -3. To give an idea of how currently used units convert to SI units, the tables below give examples. KILLOWATTS (kW) TO HORSEPOWER (hp) (1 Kw = 1.34102 hp)
1 kW = 1.341 hp = 1.360 metric hp 1 hp = 0.746 kW = 1.014 metric hp 1 metric hp = 0.735 kW = 0.986 hp
TORQUE The derived SI unit for torque (or moment of force) is the Newton meter (Nm), this being based on the SI unit of force — the Newton (N) – and the SI unit of length – the meter (m). One Newton (1 N) is equivalent to 0.2248 pound-force (lbf) or 0.10197 kilogram-force (kgf), and one meter is equal to kilogram force (kgf) and one member is equal to 3.28084 feet (ft), so one Newton meter (1 N m) is equal to 0.737562 pound-force (lbf ft). or 0.101972 kilogram-force meter (kgf m). 1 Nm = 0.738 lbf ft = 0.102 kgf m 1 lbf ft = 1.356 Nm = 0.138 kgf m 1 kgf m = 9.807 Nm = 7.233 lbf ft
PRESSURE AND STRESS Although it has been decided that the SI derived unit for pressure and stress should be the Pascal (Pa), this is a very small unit, being the same as one Newton per square meter (1 N/m 2), which is only 0.000145 lbf/in 2 or 0.0000102 kgf/cm 2. So many European engine designers favor the bar as the unit of pressure, one bar being 100,000 Pascal (100 kPa), which is the equivalent of 14,504 lbf/in 2 or 1.020 kgf/cm 2, so being virtually the same as the currently accepted metric equivalent. On the other hand, for engine performance purposes, the millibar seems to be favored to indicate barometric pressure, this unit being one thousandth of a bar. Then again, there is a school that favors the kiloNewton per square meter (kN/m 2), this being the same as a kilopascal, and equal to 0.145 lbf/in 2 or 0.0102 kgf/cm2. 1 bar = 14.5 lbf/in2 = 1.0197 kgf/cm 2 1 lbf/in2 = 0.069 bar 1 kgf/cm2 = 0.98 bar The American Society of Mechanical Engineers in 1973 published its Performance Test Codes for 2017 EDITION
HEAT RATE Heat Rate is a product of Lower Heating Value (LHV) of Fuel (measured in Btu/lb or kJ/g for liquid fuel and Btu/ft3 or kJ/m3 for gas fuel) multiplied times (sfc) specific fuel consumption (measured in lb/hph or g/kWh). For Liquid Fuel Heat Rate (Btu/hph) = LVH (Btu/lb) X sfc (lb/hph) For Gaseous Fuel Heat Rate (Btu/hph) = LVH (Btu/ft 3) X sfc (ft3 /hph) To convert these units to SI units: Btu/hph X 1.414 = kJ/kWh Or Btu/kWh X 1.055 = kJ/kWh
LUBRICATING-OIL CONSUMPTION Although the metric liter is not officially an SI unit, its use will continue to be permitted, so measurement of lube-oil consumption will be quoted in liters per hour (liters/h). 1 liter/h = 0.22 Imp gal/h 1 Imp gal/h = 4.546 liters/h
TEMPERATURES The SI unit of temperature is Kelvin (K), and the character is used without the degree symbol (°) normally employed with other scales of temperature. A temperature of zero degree Kelvin is equivalent to a temperature of -273.15°C on the Celsius (centigrade) scale. The Kelvin unit is identical in interval to the Celsius unit, so direct conversions can be made by adding or subtracting 273. Use of Celsius is still permitted. 0 K = 273°C; absolute zero K 1°C = 273 K 191
kW 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
hp 1.341 2.682 4.023 5.364 6.705 8.046 9.387 10.728 12.069 13.410 14.751 16.092 17.433 18.774 20.115 21.456 22.797 24.138 25.479 26.820
kW 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40
hp 28.161 29.502 30.843 32.184 33.526 34.867 36.208 37 .549 38 .890 40.231 41.572 42.913 44.254 45.595 46.936 48.277 49.618 50.959 52.300 53.641
kW 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60
hp 54.982 56.323 57.664 59.005 60.346 61.687 63.028 64.369 65.710 67.051 68.392 69.733 71.074 72.415 73.756 75.097 76.438 77.779 79.120 80.461
kW 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80
hp 81.802 83.143 84.484 85.825 87.166 88.507 89.848 91.189 92.530 93.871 95.212 96.553 97.894 99.235 100.577 101.918 103.259 104.600 105.941 107.282
kW 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100
hp 108.623 109.964 111.305 112.646 113.987 115.328 116.669 118.010 119.351 120.692 122.033 123.374 124.715 126.056 127.397 128.738 130.079 131.420 132.761 134.102
POUNDS FORCE FEET (lbf ft) TO NEWTON METERS (Nm) (1 lbf ft = 1.35582 Nm) lbf ft Nm lbf ft 1 1.356 21 2 2.712 22 3 4.067 23 4 5.423 24 5 6.779 25 6 8.135 26 7 9.491 27 8 10.847 28 9 12.202 29 10 13.558 30 11 14.914 31 12 16.270 32 13 17.626 33 14 18.981 34 15 20.337 35 16 21.693 36 17 23.049 37 18 24.405 38 19 25.761 39 20 27.116 40
Nm 28.47 2 29.82 8 31.184 32.540 33.896 35.251 36.607 37.963 39.319 40.675 42.030 43.386 44.742 46.098 47.454 48.810 50.165 51.521 52.877 54.233
lbf ft 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60
Nm lbf ft 55.589 61 56.944 62 58.300 63 59.656 64 61.012 65 62.368 66 63.724 67 65.079 68 66.435 69 67.791 70 69.147 71 70.503 72 71.808 73 73.214 74 74.570 75 75.926 76 77.282 77 78.638 78 79.993 79 81.349 80
Nm lbf ft 82.705 81 84.061 82 85.417 83 86.772 84 88.128 85 89.484 86 90.840 87 92.196 88 93.552 89 94.907 90 96.263 91 97.619 92 98.975 93 100.331 94 101.687 95 103.042 96 104.398 97 105.754 98 107.110 99 108.466 100
Nm 109.821 111.177 112.533 113.889 115.245 116.601 117.956 119.312 120.668 122.024 123.380 124.715 126.001 127.447 128.803 130.159 131.515 132.870 134.226 135.582
These tables are reproduced from the booklet “Vehicle Metrics” published by Transport and Distribution Press Ltd., 118 Ewell Road, Surbiton, Surry, KT6 6HA England. WWW.CTSSNET.NET
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Customer: Vertically integrated global petrochemical company, Texas.
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Challenge: Build a world-scale olefin plant to process plentiful, low-cost shale gas.
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Result: Three trains of reliable, efficient Elliott steam turbines and compressors ensure the customer’s competitive advantage in world markets.
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TECH BRIEF
Un-Balancing Act A new control method for back-to-back compressors with a side stream in flash gas compression trains n Figure 1. Process simplified schematic.
BY DAVID ROSSI, LAURENCE CASALI AND MARCO PELELLA Introduction
separation unit 1 is sent to a further phase of separation (separation unit 2) followed by the condensate stabilizer column. The recovered condensate is routed to the condensate export line. The gas coming from the separation phase 2 is named side stream gas (low molecular weight gas) and is used to feed the second section of the FGC system. The gas coming from the column is named feed gas (high molecular weight) and is used to feed the first section of the FGC system. The gas delivered by the FGC system is recycled back to the initial separation unit and to the injection gas compressors. The recycle allows increasing the injected gas flowrate and maximizing the condensate recovery. The main purposes of the process described above can be summarized as follows: • Maximize the well’s production by gas injection. • Maximize the gas injection. • Maximize the condensate recovery. In order to handle the feed gas and the side stream gas characterized by different molecular weight, each FGC train consists of a two-section centrifugal compressor. To reduce the footprint and the costs, it is preferable to adopt a backto-back configuration for the compressors. Usually a 2 x 50% compression trains-in-parallel configuration is used. Figure 1 shows a typical schematic diagram of the flash gas compression trains driven by fixed-speed electric motors. The first section suction header, common to both trains, recovers flash gas primarily from the condensate stabilizer
Generally, in the oil and gas industry, flash gas compression (FGC) systems are designed to recover flash gas from condensate stabilization units, which are installed in the facilities processing the fluid extracted from production wells. The main objective is to recover and stabilize the condensate by increasing the amount of intermediate and heavy hydrocarbon components. Figure 1 shows a simplified schematic of the typical process in which the FGC system operates. The fluid taken from the wells is sent to the initial separation unit in order to separate the two/three phase mixture and recover the liquid phase. The gas stream is sent to a further separation unit (separation unit 1) where the heavier components are condensed in order to recover additional liquid, while the separated gas containing the lighter components is sent to the injection compressors. The liquid coming from the initial separation unit and the David Rossi is a senior control technologist within the control algo-
rithms and systems development of the turbo machinery solutions engineering department at GE Oil & Gas in Florence, Italy. Contact him at:
[email protected]. Laurence Casali is principal engineer for system operability of centrifugal compressor and turbo ex- pander applications in GE Oil & Gas in Florence, Italy. Contact her at:
[email protected]. Marco Pelella is engineering man- ager for system operability of centrifugal compressor and turbo expander applications at GE Oil & Gas in Florence, Italy. Contact him at:
[email protected].
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n Figure 2. Back-to-back configuration. column. The section section suction header, also common to both trains, recovers flash gas from the separation unit 2. Both trains discharge into a common discharge header for recycle to the inlet separators.
internal labyrinth seal leakages were assumed negligible. Based on labyrinth seal design, its typology and machine arrangement, it resulted that the leakages could not be neglected and had an impact on the operability of the FGC system. The following section describes the issues experienced at a specific site.
End user inputs The process requirements and the boundary conditions for the FGC system are provided by the end user. In order to reach the required performance of the condensate stabilizer column, the pressure at the outlet of the column is regulated by a pressure controller (Figure 1). In addition, the pressure at the outlet of the separation unit 2 is controlled in order to ensure the desired separation (Figure 1). The FGC system has to handle all the flow coming from the column (feed gas) and the separation unit 2 (side stream gas). The end user provides the mass flow and the correspondent molecular weight delivered respectively to the first section and second section suction headers for each operating condition (normal running an d startup). Based on the well-estimated condition, the end user can also provide the estimated mass flow trends as a function of time. On each suction header, a flare line is installed to send the excess produced gas to the flare and limit the suction header pressure. The requirement is to minimize the opening of the flare valves in order to limit the quantity of gas released to atmosphere and maximize the production. A backpressure control valve (Figure 1) is located downstream of the FGC system to keep the discharge header pressure at a certain value set by the end user based on the requirement of the downstream units. The FGC has to develop the required pressure ratio to feed the downstream units.
Issues experienced at site Each FGC train consists of a two-section centrifugal compressor with back-to-back configuration. This splits the whole compression in two sections with an interstage process gas cooler. The two groups of impellers in series are faced. Two balance drums are present: the first one (extremity drum) connecting the first impellers of the two compression sections, and the second one (intermediate drum) connecting the two sections’, discharges (Figure 2). These are the internal labyrinth seal leakages of the compressors. The flash gas compressors are designed to operate with high molecular weight on the first section (feed gas) and lower molecular weight on the second section (mixture of feed gas and side stream gas). The pressure ratio across the entire compression system is given by the process boundary conditions. In case of low feed gas flow or low feed gas molecular weight, the first section may operate in partial recycle. Due to the backto-back configuration, the first section recycled flow includes the internal labyrinth seal leakages from the second section. These leakages result in a significant drop of the gas molecular weight processed by the first section, leading to the reduction of the compressor performance (lower pressure ratio). The performance reduction will result in additional recycling, which leads to a further first section molecular weight leaning. In this way, the compressor performance will continuously worsen up to the potential complete off line condition. The effect of the molecular weight variation on the pressure ratio for a fixed-speed compressor can be explained considering the general formula of the Polytropic Head (Hpol) for an ideal gas:
Original control philosophy Before the introduction of the new control strategy described in this paper, the control philosophy for an FGC system with the configuration described above was to control the suction pressure of each compression section by manipulating the recycle valves of each compression section. The set points were provided by the process control system based on the process requirements. This control philosophy was based on the fact that the
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Pout Pin
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n Figure 3. Normal operation with recycle valves fully closed.
where: n = polytropic exponent R0 = universal gas constant MW = molecular weight Tin = inlet temperature Pin = inlet pressure Pout = outlet pressure But Hpol can be also written as follows:
Hpol= ( ,Mu) u2
second section suction pressure: A decrease of molecular weight will result in an increase of suction pressure. Since the first section discharge pressure corresponds to the second section suction pressure (for the sake of simplicity in the present paper, the second section suction pressure and the first section discharge pressure are considered equal; this is valid if pressure drops are neglected), the first section pressure ratio directly affects first section suction pressure. As explained above, the pressure ratio for a fixed-speed compressor operating on the surge control line (SCL) is directly affected by the gas molecular weight: the decrease of molecular weight will result in a first section suction pressure increase. This phenomenon led to some issues at site during both startup/loading and normal operations. In particular, two issues were experienced during compression train startup/ loading phase. The opening of both the first section recycle valve and the side stream led to a lightening of the molecular weight in the first section causing a significant reduction of the first section pressure ratio. The first section was not able to achieve the desired pressure ratio to bring the compression train online. Closing the side stream resulted in a second section molecular weight higher than the normal one, leading to an increased absorbed power. Consequently, the electric motor trip occurred from overcurrent.
2
where: = flow coefficient (nondimensional flow) Mu = machine Mach number = head coefficient (nondimensional polytrophic head), function of and Mu u2 = peripheral speed at impeller outlet diameter Equation 2 shows that the Polytrophic Head developed by a compressor section is constant for a given speed and flow coefficient (in first approximation the M u influence can be neglected). Under the same assumptions, from equation 1, it can be concluded that, considering that the FGC is a fixed speed application, the second section pressure ratio depends on the suction gas flow and molecular weight. Since the discharge pressure is fixed by the process boundary conditions, flow and molecular weight directly affect the
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TECH BRIEF n Figure 4. Low feed gas flow operation: first section recycle valve opening.
Other issues were experienced in normal operation due to a process upset leading to a reduction of available feed gas flow. Two compression trains were running in order to handle the side stream flow and avoid flaring. However, due to the low feed gas flow shared between the two trains, the first section recycle valve opened on both trains, leading to first section molecular weight leaning and consequently bringing the compression trains offline and causing production loss. Flash gas compression train 2 (FGC2) was running, delivering the required discharge pressure. Then, flash gas compression train 1 (FGC1) was started up and brought
on line, starting to deliver the required discharge pressure. As soon as FGC1 was on line, the feed gas flow to FGC2 decreased leading to the opening of the FGC2 first section recycle valve. Then, the FGC2 first section suction pressure increased above the first section header pressure, indicating that the first section went off line. The same phenomenon occurred on FGC1, since the first section recycle valve could not close. As previously described, the pressure ratio of a fixedspeed compressor is directly related to the gas composition (i.e., molecular weight) of the processed gas; in particular,
First Stage Suction Header (Feed) FGC1 Second Stage
FGC1 First Stage
Driver
Discharge Header
Internal Seal Labyrinth Leakage
IT
Second Stage Side Stream Suction Header
PT V
Throttling Valve THF1
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Throttling Valve THS1
Backpressure Control Valve PCV
PT
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FGC2 Second Stage
FGC2 First Stage
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To Production Separators
Internal Seal Labyrinth Leakage
IT
PT
Throttling Valve THF2 Throttling Valve THS2
V
Recycle Valve Recycle Valve
Bias PIC
SP Feed_DCS
n Figure 5. Process schematic diagram.
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TECH BRIEF n Figure 6. Compressor startup with feed gas only.
otherwise the system will end to the offline condition. In this situation, the only terms which can be controlled in order to maintain the unit in operation is the side stream flow to the second section, requiring the introduction of a throttling valve in the side stream line. Figure 5 shows the throttling valves added on both feed gas (THF1 and THF2) and side stream (THS1 and THS2) lines for both compression trains. The regulation system should exploit the capacity of the compression system by maximizing the feed gas flow and consequently introducing side stream gas flow as much as possible. The direct measurement of the current gas composition was not applicable. The side stream throttling valve controller was developed based on the effects of the gas leaning on both sections to the available measured parameters (pressures, as described in the previous sections). This is an example of so-called inferential control in the oil and gas industry, applied in general to control product qualities without an on-stream analyzer. It is also a good example on how minimizing the number of measurement devices by leveraging the physic-based approach that connects different process/machine variables. More specifically, being the downstream pressure fixed by the backpressure control valve, an increase of the side stream flow with a consequent molecular weight reduction produces the increasing of the second section suction pressure and consequently of the first section suction pressure. In the event of recycling in the first section, the seal gas leakage is also contributing to this increase. By considering this crucial parameter, it is possible to indirectly estimate the overall compressor system performance, given the upstream maximum allowed pressure as the highest achievable limit (i.e., flare PCV set point, with some margin to allow proper controllability). The side stream flow is adjusted accordingly: the flow is increased
the first compressor section, designed to operate with the feed gas (high molecular weight), reduces its performances if recycling lower gas molecular weight, with the consequences (lean-out) already described in the previous sections. Preventing this phenomenon became the main requirement for the control system described [1]. In the aim to minimize the recycled flow on the first section, the upstream pressure cannot be further regulated by acting on the recycle valve, which should intervene only in case of minimum flow, i.e., from the anti-surge controller limiting the compressor operating point on the SCL. In view of these considerations, a throttling valve has been introduced in the feed gas inlet line. During normal operation, with sufficient feed gas flow availability, none of the recycle valves need to open, while the feed gas header pressure can be regulated just acting on the throttling valve (i.e., THF in the following scheme). In the event of feed gas flow reduction, the compressor’s first section operating point moves towards the SCL; in case the flow is lower than the minimum amount to remain inside the compressor envelope (i.e., to the right of SCL), the first section recycle valve recirculates the missing amount of flow, keeping the compressor operating point on the SCL. As explained, this will lead to leaning of the first section gas, reducing its pressure ratio capability and consequently shifting the operating point down along the SCL. Moreover, considering now the compressor’s second section, for which its pressure ratio is also a function of the molecular weight, the reduction of feed gas results in a reduction of its pressure ratio. As a consequence, since the discharge pressure is fixed by the backpressure control valve, the second-stage suction pressure increases. The first section discharge pressure (being actually the same) follows suit, which will also contribute — together with the leaning of the gas — to the rise of the first section suction pressure. Feed gas header pressure should not reach the limit imposed by the flare located on the first suction header,
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TECH BRIEF splitting of the incoming feed gas. An adjustable balancing factor may be introduced in order to correct possible performance differences between the two parallel trains. In case the first section of any compressor is forced to recycle some gas (i.e., reaching the SCL), the increasing of its suction pressure (i.e., the feed gas throttling valve downstream pressure), results in lower feed gas flow to that unit. This reduction corresponds to an increasing of flow to the other unit: the system will enter in the lean-out phenomenon, losing the unit that has opened the recycle valve first. This kind of issue can be avoided by linking the opening of both first section recycle valves of the parallel trains, even if only one of the recycle valves needs to increase the compressor flow. Also, the parallel compressor shall increase its recycled flow in order to preserve the correct splitting of the feed gas. An adjustable balancing factor may be introduced in order to correct possible performance differences between the two parallel trains. The first section suction pressure control through the side stream flow adjustment, can be implemented with a simple PID regulator, with some additional feature aimed to account for the delay on the loop response and nonlinearity between different operating conditions. Similarly the feed gas header pressure control can also be implemented as a PID regulator. Moreover, additional regulators are introduced to manage compressor operation limits as follows: In case of abundant feed gas, the unit may reach its driver power limitation; in this case part of the feed gas cannot be processed. An electric motor current limiting loop acts on feed gas throttling valves, limiting its opening, bringing the flare PCV above the set point, i.e., flaring this extra gas. The side stream will keep adjusting consequently. In case of lower side stream gas production, a low-pressure limiting regulator acts on the side stream throttling valves to avoid the excessive reduction of the side stream header. An adjustable balancing factor may be introduced in order to correct possible performance differences.
n Figure 7. Throttling valves opening. if the upstream pressure can rise further, otherwise is decreased if the pressure is going above the predefined limit. This method permits to push the operability of the compressor to its physical limit within the boundaries imposed by the process, despite gas flow or gas composition changes, compressor performance degradation, etc. It is unavoidable that the excess of side stream gas, even if minimized, will result in flaring. This is typically not desirable, if allowed at all. Should this occur, alternative process configurations shall be adopted, which are not in the scope of this paper. The flash gas compressor leaning phenomenon also affects the operability of parallel compressors, typically applied on flash gas processes. In this case, the available feed gas flow is split between the parallel units, introducing an additional degree of freedom. During compressor startup, performed in full recycle mode, the side stream gas cannot be introduced, otherwise the compressor will never get to the required pressure ratio, being completely filled with low molecular weight gas through the seal leakage. Considering the low-feed gas flow availability, starting a compressor while the parallel train is already online (i.e., in normal operation, forwarding flow to downstream process) could deprive the running unit of the minimum feed gas flow required to prevent its lean out. The proper regulation of the feed gas and side stream throttling valves during the startup and loading phases is essential to reduce the disturbance introduced to the compressor in operations. Initially, the running compressor’s pressure ratio capability goes beyond its design, since it is filled by feed gas only. The feed gas throttling valve (THF in the following scheme) shall introduce a pressure drop limiting the amount of flow moved downstream to the process. This is another reason that contributed to the introduction of the feed gas line throttling valve. Balancing the load of two or more parallel compressors — if the feed gas flow is enough to keep the first stage recycle valves closed — can be achieved by splitting the feed gas flow between the compressors. Actual feed gas incoming flow is not measured, but can be estimated with a good approximation. In fact, each feed gas throttling valve has the same inlet conditions, and the downstream pressure is regulated through the side stream flow. Keeping both feed gas throttling valves at the same position results in an acceptable
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Advanced dynamic simulation With the aim to minimize the issues during the implementation of the new control software at site, an advanced dynamic simulation was performed. This activity included: Analyzing the interaction between the process/machine •
n Figure 8. Feed gas flow to both compression trains.
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n Figure 9. Performance reduction. to the downstream process. FCG1 is acquiring the total feed gas flow, while part of the side stream flow is sent to the flare. FGC2 is initially at standstill condition with the isolation valves closed and the recycle valves fully open. Then, FGC2 is initiated and brought online to achieve parallel train operation. Figure 8 shows the feed gas flow to both compression trains during the scenario. At about 100 seconds, the feed gas flow towards FGC2 is opened to pressurize the compression loop up to the desired starting pressure. At about 800 seconds, the FGC2 electric motor is started. THF1 is regulated by the control system, while THF2 is kept at a preset position in order to limit the feed gas flow going to FGC2 and mitigate the disturbance on FGC1. Once FGC2 reaches the rated speed, the loading sequence is enabled. The recycle valves start to close and the compressor pressure ratio increases. At a certain point, the side stream flow towards FGC2 will be enabled. The FGC1 discharge pressure is constant, since the compression train is already online delivering flow to the downstream process, while the FGC2 discharge pressure increases during the loading phase. At about 2000 seconds, FGC2 is able to deliver the required discharge pressure and start to send flow to the downstream process. At this point, the throttling valve THF2 is opened following a dedicated ramp. Once the valve reaches the same opening of THF1, the opening ramp is disabled and the valves of the parallel trains are regulated by the control system. Figure 8 shows that the feed gas flow is balanced between the two compression trains.
parameters in order to optimize the control algorithm and the process production parameters. • Testing and validating the new control algorithm. • Pre-tuning the new control software. The dynamic model of an actual FGC system was developed in Aspen HYSYS and linked to the actual control software (antisurge/load sharing/master performance) through an OPC protocol. The model included the process boundary conditions in order to take into account the requirements from the end user. Some critical transient scenarios were identified and simulated. In this paper, the results relevant to the following scenarios are presented: • Feed gas flow reduction when two compression trains are running in parallel. • Startup of one compression train when the parallel one is running, delivering flow to the down stream process.
Feed gas flow reduction In this scenario, the two compression trains are initially running in parallel. The process conditions are such that the total feed gas flow is handled by the FGC system, while part of the side stream flow is sent to the flare. The upset scenario is a reduction of the feed gas flow. Then, the flow is increased again to the initial value and the first suction header flare set point is increased according to the process constraints in order to acquire the entire side stream flow. When the feed gas flow decreases (between 200 and 500 seconds), the first section recycle valves open on both compression trains and consequently, the side stream throttling valves (THS1 and THS2) partially close (Figure 7) to prevent the molecular weight reduction on the first section. As soon as the feed gas flow is increased again to the initial value (between 1200 and 1500 seconds), the side stream throttling valve open and the flow to the flare decreases. At about 2600 seconds, the first suction header flare set point is increased. In this way, the FGC system can handle the available side stream flow and no gas is sent to the flare anymore.
Fouling and parallel unbalanced operation During operations, a decrease in the performance of both compressors took place, both in terms of polytropic head and polytropic efficiency. Initially it was attributed to a reduction of molecular weight lighter than expected, while a more detailed analysis showed that the root cause was the presence of fouling on the internal surfaces of both rotoric and statoric parts. Figure 9 shows the assessment of compressor performance in terms of measured efficiency and head, normalized with the expected values at a given speed. In case the
Start up of one compression train while the parallel one is running In this scenario, FGC1 is initially running, delivering flow
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n Figure 10. Efficiency and head parameters of both compressors over time. since no seal replacement was carried out on the cleaned compressor. Furthermore the increase of performance experienced during solvent injection upstream of the compressor’s first inlet flange — while all the other operating conditions remained fixed — confirmed the fouling as the major cause of performance degradation over time. Operating the two compressors in the above conditions means running two different compressors in parallel operation where the original control software was meant to equally balance the flow through the two machines. This control configuration resulted in nonoptimized operation under the maximization of side stream flow handled by the compressors. In other words, in some operating conditions, the flared side stream was not minimized. This required unbalancing the two compressors, by changing the balancing factor previously described, to allow more flow into the more efficient compressor (first section throttling valves parameters), and allowing more margins from the suction header set point of the less efficient compressor (second section recycle valves parameters and bias factors). These parameters were tuned at site through a step-by-step procedure. CTSS
measured values match the expected figures, the performance parameter is equal to 1, independently by the flow parameter, while in the graph, a deviation from the expected values is observed especially at high flows. This deviation has been attributed to a fouling issue, since the increase of roughness on the internal surfaces, coupled with a reduction of impellers widths, produces an increase of losses and a reduction of the input work coefficient that is proportional to the handled flow. In other words, in case of fouling, the performance deviates from expected values, more on the choking side than on the surge side of the compressor map. One of the two compressors’ bundles was dismantled and brought back to the OEM factory for inspection and overhauling to restore the original performances. After cleaning the rotor and the statoric parts, the bundle was sent to the site and reinstalled in its casing. Figure 10 shows the trends over a one-month period of the efficiency and head parameters of both compressors — the cleaned one and the other that remained in operations. The performance of the cleaned compressor settled around value 1 in comparison with the other compressor performance that remained well below 1. This also confirmed that the decrease of performances could not be related to a lower than expected molecular weight and the internal leakages that were supposed to increase over time,
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Reference
[1] “Method and system for operating a back-to-back compressor with a side stream”, GE Patent Number 274627, Inventors: David Rossi, Lorenzo Gallinelli, Laurence Casal.
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Nontraditional Vibration Mitigation Methods For Reciprocating Compressor Systems CLD, TMD used for two different configurations Editor’s Note: This abridged paper was originally pre- sented at the 10 th EFRC, Düsseldorf, Germany, Sept. 14- 15, 2016.
BY ANDRÉ EIJK BSC, DORUS DE LANGE MSC, ERIK SLIS BSC, AND JAN DE VREUGD PHD Summary Introduction Experience in several projects has shown that it was very difficult to solve the vibration problems from reciprocating compressors with the traditional mitigation measures. This was the reason to start a research and development (R&D) project of which the target was to investigate the effectiveness of nontraditional mitigation techniques. This R&D project focused on the investigation of constrained layer damping (CLD) and tuned mass damper systems (TMD) for reciprocating compressor systems. TMD and CLD have been used for ships and space applications. The target of the project was to optimize the use of CLD and TMD for reciprocating systems that experience excessive vibration levels in the field. This paper summarizes the investigative work performed on the potential of using CLD and a TMD for two different configurations. The first configuration is a U-pipe, which is a typical configuration for a pipe between the separator and
n Figure 1. Constrained layer damping. suction pulsation damper. The second configuration is a large suction pulsation damper of an underground gas storage (UGS) system. The large vibration levels of both configurations could not be mitigated with traditional vibration mitigation techniques. Measurements have shown that the reduction in dynamic response (vibration and cyclic stress levels) can be increased significantly for both structures with a damped TMD or CLD.
André Eijk has been at TNO since 1979 and is a senior mechani- cal consultant. He is specialized in the area of pulsation and vi- bration related problems of pipe systems, compressors, pumps and process equipment. Contact him at:
[email protected]. Jan de
Mechanical vibrations, tuned mass damper systems and constrained layer damping Background CLD Systems This chapter only summarizes some basic understanding on constrained layer damping. More detailed explanation can be found in several publications as listed in references 2-13. For reciprocating compressor systems, the damping ratio is typically less than 5%. A possible method to increase the damping ratio, and consequently reduce vibration and cyclic stress levels, can be achieved by the application of
Vreugd has been working in the optomechatronics department of TNO since 2011 specializing in thermal and mechanical problems. Contact him at:
[email protected]. Dorus de Lange graduated in 2011 with an MSc in space systems engineering from the TU Delft and started working as a mechanical and thermal analyst at TNO Opto-mechanics in Delft. Contact him at:
[email protected].
Erik Slis studied engineering physics at the Rijswijk Institute of Technology, majoring in applied physics. He has been at TNO for more than 10 years, with expertise in fluid and structural dynam- ics. Contact him at:
[email protected].
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n Figures 2 and 3. Stress strain relation for different types of materials. CLD. The CLD consists of a “sandwich”, which is formed by laminating a damping layer (viscoelastic material) in between two structural constraining base layers (Figure 1). When the system deforms during vibration, shear strains will be developed in the damping layer and energy is lost through shear deformation of the material. Viscoelastic material combines the properties of a purely elastic and purely viscous material. For an elastic material, the strain and stress response are perfectly in-phase. This results in an elastic energy storage during deformation and all energy is released during relaxation. A viscous material has 90° phase shift between the strain and stress. This results in all energy being lost in a cycle. A viscoelastic material is somewhere in between the purely elastic and viscous behavior. The stress-strain relation for different materials is shown in Figures 2 and 3. The stress-strain relationship for a linear viscoelastic material under repeated cyclic loading is for that reason an ellipse (Figure 3). The slope of the major a xis of the ellipse is a measure of the stiffness and the area is a measure of the damping. The elastic element can be modelled by a linear spring with a stiffness coefficient E and the viscous element by a dashpot with a coefficient of viscosity . Hence, viscoelastic models are combinations of linear spring and dashpots.
n Figure 5. Temperature effect on loss factor. The most common model is the Maxwell model as illustrated in Figure 4. Viscoelastic materials, like polymers and rubbers show large changes in properties with temperature variation. If well-chosen and used in the right temperature regime, they can possess high damping properties. Prediction of thermalmechanical stresses and deformations requires, therefore, the input of accurate temperature-dependent properties. The damping dependency on temperature is schematically illustrated in Figure 5. At lower temperatures the polymer is in its glassy state, while in the transition region the material possess the highest damping performance. At high temperatures the polymer behavior is rubbery like. For these reasons the temperature effect of the damping properties must always be taken into account during the design of a CLD. Figure 6 shows the effect on damping [16] on the application of CLD in space structures. The required material data of the viscoelastic material shall be provided by the manufacturer. However, the provided data is not always sufficient. Measurements of the required material
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TECH BRIEF relative high frequency (up to 100 Hz) when compared with civil structures. This can lead to fatigue failure of the TMD and mounting system. An example of a TMD is shown in Figure 7, and is typically tuned to the mechanical natural frequency (MNF) of the primary system. The terms m 1, k 1, c 1, x 1 represent the mass, stiffness, damping and displacement of the structure of interest to which the TMD is mounted. Additionally, m 2, k 2, c 2, x 2 represent the mass, stiffness, damping and displacement of the TMD and F(t) represents the excitation force. As the two masses move relative to each other (90 degrees out of phase), the passive damper is stretched and compressed, reducing the vibrations of the structure by increasing its effective damping ratio. One of the disadvantages of TMD systems is that they are typically effective over a narrow frequency band and must be tuned to a particular MNF for that reason. They are not effective if the structure has several closely spaced MNFs, and they may even increase the vibration and cyclic stress levels if not tuned well. This can happen, for example, if the MNF of the system after the installation of the TMD is shifted to a frequency where the amplitude of the pulsation-induced force is larger. The TMD system must always be tuned in the field to account for differences between the model and reality. Also the TMD shall always be designed with an adjustable mass and/or spring. If possible, measurements of the MNFs and mode shapes of the structure can be used to tune the simulation model. The MNF of the primary system can be split into a lower f 1 and higher f 2 frequency by attaching a spring-mass tuned to the same fundamental natural frequency f n of the primary system as shown in Figure 8. ≈
n Figure 6. Measured quality factor as a function of temperature for a particular material. properties are strongly recommended. This is normally done with a Dynamic Mechanical Analyser (DMA). A DMA [16], also known as dynamic mechanical spectroscopy, is a technique used to study and characterize materials and is very useful for studying the viscoelastic behavior of polymers. A sinusoidal stress is applied to the sample and the deflection of the specimen is measured, allowing one to determine the material properties such as complex modulus. The measured damping characteristics are implemented in ANSYS [14]. Background on TMD systems [17-19] A TMD is a passive device consisting of a mass, a spring and a damper that is attached to a structure in order to reduce the vibration and cyclic stress levels of the structure. The TMD concept was first applied in reducing the rolling motion of ships as well as ship hull vibrations. It is a commonly applied and accepted method in the civil industry for buildings and bridges for low frequencies. However, it has not been applied for many structures in the oil and gas industry, especially for compressor and pump systems. The challenge in rotating equipment systems is the
n Figure 8. Demonstrating the effectiveness of a TMD. The most significant design variable for the damper is the mass ratio µ as de-fined in equation 1, where m1 and m2 are respectively the mass of the TMD and mass of the structure of interest. When the mass ratio increases, the TMD becomes more effective and robust. In most applications the mass ratio is designed to be in the range of 1-10%. In the design of a TMD, the mechanical natural frequency
n Figure 7. Schematic of a TMD. 2017 EDITION
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n Figure 9 (left). Original system as built. Figure 10 (right). System with additional stiffening.
of the damper f d is defined by equation 2 and, the damping ratio of the damper opt can be calculated from equation 3.
µ=
m2 m1
ƒd
=
ƒ n
1+µ
= opt
term, can be achieved if the lowest MNF is increased up to 20% above the excitation frequency. This finally led to a rather stiff structure because of the absence of a stiff structure in close vicinity of the piping (Figure 10). This was one of the motivations to investigate nontraditional vibration mitigation techniques, which are easier and cheaper to install to ensure a reliable, safe and efficient operation for the long term. For that reason, the application of a CLD and damped TMD with CLD has been investigated in the research project for such a U-pipe configuration.
3µ 8(1+µ)
3
Equations 1, 2 and 3
If there is zero damping then resonance occurs at the two undamped resonant frequencies of the combined system f 1 and f 2 . The other extreme case occurs when there is infinite damping, which has the effect of locking the spring k 2 . In this case, the system has one degree of freedom with stiffness of k 1 and a mass of m1 + m2. Using an intermediate value of damping somewhere between these extremes, it is possible to control the vibration of the primary system over a wider frequency range. The damping of the TMD, which has been investigated in the research program, is achieved by the application of a CLD, which is adhesively bonded to the spring (Figure 12). The effect of the damped TMD with a CLD will be demonstrated by two examples that will be discussed in the next section.
Tuned mass damper system A finite element model of a 6 in. (152.4 mm) schedule 40 pipe system was generated and tuned to the measured mode shape. The next step was to design the TMD in such a way that the MNF of 57 Hz of the primary system is split into a lower f 1 and higher f 2 MNF of respectively +20% and -20% around the MNF of 57 Hz. It was calculated that only a very small mass of 5.5 lbs. (2.5 kg) (pipe has a weight of 143 lbs. ( 65 kg) was required to achieve this. Moreover, a simple leaf spring has been used for the spring and the TMD could be tuned by adjusting the lengthwise position of the of the spring leaf. Because the compressor has a large speed range variation, the two MNFs f 1 and f 2 would always be excited by varying the compressor speed because it was not possible to shift them out of the complete compressor speed range. Without additional damping of the TMD, it was shown that the pipe vibrations would still exceed the allowable level with the TMD installed. Besides that, the additional damping was also required to avoid fatigue failure of the TMD itself. To dampen the vibrations of the pipe and TMD, a CLD was chosen because it has a relative large damping ratio for the complete speed range, is low cost and easy to install. The viscoelastic properties of the CLD were measured with the DMA technique [16] and have been implemented in the ANSYS [14] model. The CLD has been adhesively bonded to both sides of the leaf spring (Figure 12), and the dimensions have been further optimized with the ANSYS model. Figure 11 shows the different vibration levels as a function of frequency (FRF: Frequency Response Function) and it can be seen that the TMD is very effective. The ratio of vibration levels of the pipe without (blue line) and with (red dotted line) the damped TMD is a factor of 26. This ratio is based on ≈
Example from a U-pipe configuration Introduction
When activating a reciprocating compressor system, unallowable vibration levels were experienced in the U-pipe configurations installed between the separator and suction pulsation damper (Figure 9). The high vibration levels were measured at 57 Hz perpendicular to the plane of the pipe system. It was measured that the high vibration levels were caused by the excitation of an MNF of 57 Hz by the cylinder stretch displacement of three times the compressor speed. This was also calculated during the design of the system, but it was not clear why the measured vibration levels were much higher than calculated. From field measurements it was shown that the difference between the calculated and measured vibrations were caused by a much lower damping ratio of 0.8% for both pipes while 2% had been modelled. It was calculated that the high vibrations would lead to fatigue failure. For that reason, the system could not be operated up to maximum compressor speed, leading to a loss in production. Acceptable vibration and cyclic stress levels, leading to a safe and reliable system for the long
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TECH BRIEF used to measure the FRFs. The FRFs of the pipe without and with the TMD are shown in Figure 13. From the FRFs, it can be concluded that the measured MNF of the lowest mode shape is 50 Hz instead of the calculated value of 57.22 Hz. This was caused by the flexural flexibility of the mounting plates, causing rotational compliance rather than full fixation. TMD is very effective because the measured ratio in vibration levels with and without the TMD is 42. This is even larger than the calculated value, and is probably caused by the flexible mounting plate, which means that the model differs from the actual system. Moreover it is noted that the absolute value of the vibration levels from Figures 11 and 13 cannot be compared because the excitation methods are different. So only the ratio of the vibration levels can be compared for that reason.
n Figure 11. Calculated FRFs for pipe and TMD to tune the mode shape at 57.22 Hz. the fact that the frequency, f 1 of 45 Hz can also be excited because the compressor can be operated over the entire speed range (worst-case scenario). If the compressor had a fixed speed, the ratio would be much higher. The vibration and cyclic stress levels will be reduced with the same factor if the pipe is excited with the same force at the frequency f 1 of 45 Hz. Moreover it can be concluded that the ratio in vibration levels with and without the CLD mounted on the TMD is a factor of three for the TMD and two for the pipe system.
Constrained layer damping The second method of increasing the damping and so reducing the vibration and cyclic stress levels was the investigation of the effectiveness of CLD added to the pipe. The effectiveness of the CLD is largest when it is mounted on the locations with the largest strain. For the U-pipe, the largest strain will occur in the vertical parts at the mounting plates. For that reason, the CLD has been mounted on the two vertical straight pipe sections of the U-pipe. The CLD is also very effective because the ratio in vibration levels with and without the CLD is 23 for the mode of interest. This is in the same order of that of the damped TMD (Figure 11). Figure 14 shows the test pipe with the CLD adhesively bonded to the vertical parts of the pipe. The measured ratio in vibration levels with and without the CLD is 20, which is in the same order of the calculated value of 26. Example of a large pulsation damper Introduction
n Figure 12. U-pipe with TMD.
Inspired by the results of the TMD and CLD of the U-pipe, which were shown to be very effective, the idea was proposed to apply this also for a suction pulsation damper. The reason that a suction damper has been chosen is that severe vibration problems have occurred in several projects
Measurements have been carried out on the test pipe at the test laboratory with the TMD attached as shown in Figure 12. An impulse hammer excitation method has been
n Figure 13. Measured FRFs of bare U-pipe (left) and with TMD (right). 2017 EDITION
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TECH BRIEF acceptable vibration levels. For that reason the focus was on the investigation of applying a damped TMD. A finite element model of the pulsation damper has been generated, and two typical mode shapes have been selected for improvement of the system, because experience has shown that these modes have exhibited large vibration problems. The two investigated modes illustrated in Figure 16 are: (1) Rotation of the damper around the cylinder nozzles denoted as mode 1 at 27 Hz; and (2) Vertical translation of the overhanging end, denoted as mode 2 at 77 Hz. These are typical modes of such a damper.
n Figure 14. Test pipe including the CLD. with these dampers, and it was shown that it is sometimes very difficult to reduce the vibrations in the field to acceptable levels with traditional vibration mitigation measures. Arguably, cylinder stretch is the major source of most of the suction damper vibration problems. Frequencies between 50 and 100 Hz have been observed in several projects. In general, stiff structures, which support the suction dampers, are applied to shift the MNF far enough from the excitation frequencies. However, because of the rather high frequencies and high elevation of these dampers for large compressors, stiffening is not feasible anymore. For that reason the application of a CLD or a TMD could be a feasible solution to mitigate the vibrations. Unfortunately, it was not possible to test this in the field, but a spare pulsation damper could be borrowed from RWE for the tests at the laboratory as shown in Figure 15. The damper has a mass of 6614 lb. (3000 kg). Preliminary calculations with the application of only CLD attached to the damper have shown that the damping could be increased by a factor of two, which is much less than the values of the U-pipe. The reduction of vibration levels with a factor of two was not enough to achieve
n Figure 16. Mode shape at 27 and 77 Hz.
n Figure 17. TMD.
n Figure 15. Suction pulsation damper. 2017 EDITION
n Figure 18. TMD to tune mode 2 (vertical mode). 207
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n Figure 19. TMD to tuned mode shape one (rotation around nozzles). Similar to the TMD of the U-pipe, the first step was to determine the mass of the TMD for the two selected modes. The calculated mass for mode one and mode two are respectively 165 lb. (75 kg) and 44 lb. (20 kg). The target was to apply one TMD system that could be used for both modes. For that reason, one geometry was chosen with adjustable masses. The spring of the TMD was a leaf spring with a CLD layer adhesively bonded on both sides. The damping effect of a CLD is largest at the location with the largest strain. This is at the “bottom” of the leaf spring as shown in Figure 17 and has been achieved by applying a curved geometry at that location. The curved geometry also has the advantage of reducing the cyclic stress in the TMD. A detailed view of the TMD is shown in Figure 17. Figure 18 shows the TMD mounted on the cap of the damper to tune mode two (vertical
mode). Figure 19 shows the TMD mounted to tune mode one (rotation around the nozzles). From the results of the calculations, the minimum calculated ratio of quality factor of the damper without and with the damped TMD is a factor of 13 for mode one and 14 for mode two. From the measured FRFs as shown in Figure 20 and Figure 21, the minimum reduction factor of the vibration levels is 17 for mode 1 ( f 2 ) and 13 for mode 2 ( f 2 ). This means that the quality of the model is good. The measurements also show that the measured frequency of 76 Hz is a local resonance of the baffle choke tube inside the damper. This mode is also damped significantly by the TMD, which is a positive side effect, and the conclusion is that the application of the damped TMD is very effective. The measured frequencies of mode one and
n Figure 20. FRF of mode one of the pulsation damper.
n Figure 21. Suction pulsation damper.
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TECH BRIEF References [1] Hartog, J. P. D. (1956). Mechanical Vibrations, McGraw-Hill. [2] R. Plunkett, C. T. Lee, 1969, Length Optimization for Constrained Viscoelastic Layer Damping. [3] Y. LU, 2009, Noise reduction of a refrigerator compressor by applying multiple adjustable constraining bands with damping layers. [4] H. Zheng, G.S.H. Pau, G. R. Liu, 2002 , Optimization of passive constrained layer damping treatments for vibration control of cylindrical shells. [5] Q. Qiu, Z.P. Fang, H.C. Wan, 2006, Transfer function method for frequency response and damping effect of multilayer PCLD on cylindrical shell. [6] I. Saidi, A.D. Mohammed, E.F. Gad, J.L. Wilson, N. Haritos, Optimum Design for Passive Tuned Mass Dampers Using Viscoelastic Materials. [7] H. Zheng, G.S.H. Pau, G. R. Liu, 2005, Minimizing vibration response of cylindrical shells through layout optimization of passive constrained layer damping treatments. [8] J.J. Hollkamp, R.W. Gordon,1996, An experimental comparison of piezoelectric and constrained layer damping. [9] E. Balmes, et al, 2010, Constrained viscoelastic damping, test/analysis correlation on an aircraft engine. [10] E.M. Kerwin, 1958, Damping of flexural waves by a constrained viscoelastic layer. [11] D.J. Mead, S. Markus, 1968, The forced vibration of a three-layer, damped sandwich beam with arbitrary boundary conditions. [12] R. Taulbee, 2013 , Vibro-acoustic analysis of a thin cylindrical shell with minimal passive damping patches. [13] C.A. Gallimore, 2008, Passive viscoelastic constrained layer damping application for a small aircraft landing gear system. [14] ANSYS reference manual. [15] J. de Vreugd, D. de Lange, J. Winters, J. Human, F. Kamphues, E. Tabak, “Damping in Space Construction s,” Conference on Space Constructions, Materials and Environmental Testing, 2014. [16] Dynamic Mechanical Analysis: A Practical Introduction, 2nd Edition, Kevin Menard, CRC Press, 2008. [17] Webster, A.C.and R. Vaicaitis (1992). “Application of Tuned Mass Dampers To Control Vibrations of Composite Floor Systems.” Engineering Journal/American Institute of Steel Construction, Q3/1992:116-124. [18] Al-Hulwah, K. I. (2005). Floor Vibration Control Using Three Degree of Freedom Tuned Mass Dampers. The School of Engineering, University of Dayton. PhD Inman, D. J. (1996). Engineering Vibration, Prentice-Hall, Inc. [19] Optimum Design for Passive Tuned Mass Dampers Using Viscoelastic Materials Australian Earthquake Engineering Society 2007 Conference (I Saidi1, A D Mohammed2, E F Gad1, 3, J L Wilson1, N Haritos3).
mode two deviate from the calculated frequencies. As explained for the pipe, this is caused by the imperfect clamping of the nozzle end. After detailed inspection of the TMD, it was also concluded that the bonding of the CLD at the foot was not optimal, caused by the curvature. The curvature causes a tensile (peel) stress, which an adhesive bonding layer cannot handle very well. The damping of the TMD with CLD has a very large effect in reducing the vibration and cyclic stress levels. To be able to optimize a TMD, it is strongly recommended to measure, if possible, the MNFs in the field. Conclusions and recommendations The project has shown that a large reduction in vibration levels of parts of reciprocating compressor systems can be achieved with nontraditional vibration mitigation techniques, such as CLD and damped TMDs. The advantages of a CLD are that they are very effective in reducing the risk of fatigue failures at low costs. They are also easy to install and are very effective for a large frequency range. The prediction and optimization of the damping performance after application of CLD can be made by finite element modelling. Such a model requires the input of the viscoelastic properties that are measured with a dynamic mechanical analyzer (DMA). The effect of temperature must be included in the DMA because the viscoelastic properties are strongly temperature dependent. Experiments with a U-pipe configuration with CLD have shown a reduction factor of 20. Tests with a damped TMD with CLD, have shown even a larger reduction factor of 42, which is significant. For larger structures, such as suction pulsation dampers, it is more beneficial to apply a damped TMD instead of a CLD because it is more effective. Moreover, the additional damping of the TMD reduces the risk of fatigue failures of the TMD. To design the best TMD, the dynamic properties of the system, such as mode shape, mechanical natural frequency and damping ratio, must be widely known, and if possible, shall be measured. Moreover the TMD should be designed in a way that it can be tuned in the field. Experiments with a large pulsation damper have shown a reduction factor between 13 and 17, depending on the mode of interest for a variable-speed compressors. In case of a fixed compressor speed, the reduction factor is much larger and reaches the quality factor at resonance of the original system. Another research project revealed that CLD is a very effective way of mitigating vibrations experienced in screw and turbo compressor applications where frequencies are generally much higher. Acknowledgement The authors would like to thank RWE Gasspeicher GmbH, for lending the pulsation damper. CTSS
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Slow Rolling Centrifugal Compressors Proper electric motor bearings can mitigate rotor-stator rubs during a hot restart of a centrifugal compressor BY MANTOSH BHATTACHARYA
A
phenomenon known as “temporary rotor bow” can occur with centrifugal compressors during startup after a short shutdown (known as a hot restart). After the centrifugal compressor stops, the rotor starts to cool and buoyant convection current leads to development of thermal gradient across the axis of compressor rotor. As the hot gases rise, the lower part of rotor cools faster than the upper segment. The thermal gradient generates over a period of time and causes the rotor to bow due to differences in stress along the two halves. A compressor can be slow-rolled to get rid of thermal bow of steam and large gas turbines. One OEM of aeroderivative gas turbines (two shafts GT) has employed this technique [1]. With large electric motor driven centrifugal compressors having similar configurations, however, this is not feasible with standard rotor bearing design. This paper suggests the type of bearings that may be used in heavy-duty electric motors that use variable-speed drives (VSD) to enable slow roll of centrifugal compressors. To exercise the slow-roll option in heavy-duty variablefrequency drive (VFD) electric motors, the bearings must be capable of withstanding high journal load with lowsliding velocity. In this case, a different bearing arrangement is needed. For VFD drives running between 0 and 10% of maximum speed, most produce fluctuating torques that are several times larger than those generated over the remainder of the speed range. Because of this, most users choose to begin the active operating range at a speed above 10%. Thus, when starting VSD induction motors, they behave in the same manner as in a fixed-speed system since the variable frequency drive is kept out of the loop. To fix the slow-roll speed of the driver and centrifugal compressor, the hydrodynamic bearing lubrication cannot be compromised at any point of operation. With this information, the slow roll can start only with a
n Figure 1. Stribeck curve. speed of 150 rpm for a 1450 rpm electric motor. For example, if the compressor’s first resonant speed is 4000 rpm with an operating speed of 11,000 rpm and a gearbox speed ratio of seven, the motor has to run below 400 rpm during the slow roll of the compressor. This means the slow roll window is 200 to 400 rpm. The hydrodynamic lubrication follows the Stribeck curve in which the required operating regime must be hydrodynamic, which is attained just at lift speed. On lift off speed of journals, Vogelhoff’s empirical equation can be used for estimation if hydrostatic jacking is needed. The empirical formula for lift off velocity is as follows: Nt = (S x PL / µ) (C/Rs) x 60 Where S = Somerfield number; PL = bearing unit load; µ = dynamic viscosity; C = radial clearance; Rs = journal surface asperity. The liftoff speed must satisfy Somerfield number criteria [2]. Based on the above formula, hydrodynamic lubrication cannot be achieved with a heavy-duty electric motor with low journal speed at high journal loads. In this case, “hybrid” bearings should be explored as an option to use in a system. A hybrid bearing is a combination of a hydrostatic and hydrodynamic journal bearing. At
Mantosh Bhattacharya is a rotating equipment technical specialist for Petrofac in the United Arab Emirates. He has 25 years of experi- ence with rotating equipment.
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n Figure 2. Scheme of jacking for a hydrostatic bearing.
the speed parameter value of zero, the bearing operates at pure hydrostatic mode, with load-carrying capacity based on the supplied pressure of the lubricant injected as jacking oil. At higher speed (higher than lift off velocity) hydrodynamic action dominates [3]. The operational philosophy is that large, heavy-duty rotors, like the main steam turbines in power plants, use a jacking oil system. Jacking oil is supplied under the rotor at a pressure sufficient to lift the rotor off the bearing surface while the machine is slowly rotated, for instance, on the turning gear. During startup of a slow roll, the journal should be jacked up using a hydraulic jacking system up to a certain speed (slightly above the lift off speed). Hybrid bearings in heavy duty VSD motors can be explored by OEMs to evaluate how they can be incorporated into the design, especially to introduce slow roll to mitigate high vibration due to possible transient rotor bow. It should be noted that recessed journal bearings are sometimes
unable to generate substantial hydrodynamic lubrication at higher speed because the bearing land area encroaches on the recess area. Whole entry hybrid bearings may be used for better performance and reduce the cost of manufacturing. If the motor is required to be slow rolled, then it is also imperative to ensure that the rotor armature and cooling system is designed to adequately dissipate the generated heat. Slow rolling a heavy-duty electric motor can remove transient bending of the motor rotor occurring due to differential cooling. The duration of slow roll is to be set in such way that it removes the thermally induced bow of the motor rotor as well as the compressor rotor. If the main lubrication pump is shaftdriven, then its capability to pump the required oil pressure and volume must be ensured during slow roll. The bottom half shell B is provided with two hydrostatic pockets (one on either side of the vertical center line) with connection for the high-pressure jacking system (Figure 3). The slow-roll speed should be selected in such a way that it has a minimum of 10% separation margin of lateral critical speeds of motor and train torsional critical speeds. A separate Campbell diagram for torsional critical speeds should be plotted, with careful consideration of the slow-roll speed selected for the compressor and driver. Adequate protection is also required to protect the driving motor for possible sub synchronous vibration and other instabilities due to the use of hybrid lubrication, which has been reported in some cases. CTSS References
[1] Method and device for controlling a hot restart of a centrifugal compressor — U.S. patent 9243644, by Gianni Bagni, Antonio Baldassarre, Leonardo Baldassarre, and Michele Fontana. [2] On lift off velocity of Journal Bearing — Tribology Letters, December 2005, by M.M. Khonsari & X.Lu. [3] Hydrostatic and hybrid bearing design, by W. B. Rowe-Butterworths, 1983.
n Figure 3. Hybrid bearing. 2017 EDITION
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Lube Reduction In Reciprocating Compressors Method designed to ensure proper operation of lubrication systems
systems is how the oil is used. The drivetrain reuses its oil many times before this fluid is replaced. A cylinder lube system only uses its oil once before the oil is consumed in the compression process. Making efficient use of oil within the cylinder lubrication system is key when minimizing operating costs while maximizing equipment reliability. This paper presents the established method for maintaining the cylinder lubrication system and determining appropriate lubrication rates. The cylinder lubrication system, also known as the forcefeed system, uses a positive displacement plunger pump to feed oil to a divider valve, which proportions the oil to critical areas within the cylinder and packing. The flow rate of oil at the critical areas is on the order of drops of oil per minute. The oil must be delivered at sufficient pressure to overcome gas pressure present at each critical area. These pressures typically range from almost atmospheric to 3000 psig (20,786 kPa gauge). Once the oil is injected to the critical area, the oil either migrates to lower pressure regions or mixes with the gas flowing thru the compressor cylinder. A 1000 hp (0.75 MW) compressor can consume 2000 gal. (7570 L) of oil annually, while larger compressors can approach 6000 gal. (22,712 L) annually. Considering oil can cost $7 to $15 per gallon for mineral oils and $20 to $50 per gallon for synthetic lubricants, the annual oil cost for one compressor can reach $250,000. This annual cost does not take into consideration the associated costs in collection, hauling and disposal of oil downstream of the compressor. These additional costs can significantly add to the annual oil cost related to compression.
Editor’s Note: This paper was presented in October at the Gas Machinery Conference in Denver, Colorado. BY JUSTIN YANCE AND JOE HAGAN
Abstract
Tens of thousands of reciprocating compressors operating in North America each consume as much as US$250,000 per year in lubricating oil. In general, most of these compressors are consuming more oil than necessary, so operating costs could be significantly reduced. Cost reduction can be achieved with relatively simple steps to ascertain the correct type and quantity of oil being delivered to each lube point, without changing the designs or materials of the wearing components. This paper describes the established method, as well as steps to ensure the lube system is operating correctly, to provide long-term reliable compressor operation. Introduction
Maintaining proper lubrication on reciprocating gas compressors is imperative to equipment reliability. Compressors most often operate continuously, which accumulates considerable runtimes on wearing components. Reciprocating compressors rely upon two lubrication systems that deliver oil to critical components in the drivetrain, cylinders, and packings. The first is a recirculating system, which protects bearings, bushings, thrust plates and crossheads in the drivetrain. The second system is a total-loss system, which provides oil to the cylinder bore, piston rings, piston rod, and packing rings. The major difference between these two
Design considerations
Justin Yance is a design engineer for Ariel Corp., where he is involved with compressor lubrication systems and other related projects. Yance has more than 15 years of experience in design, manufacturing and troubleshooting compressor equipment. Joe Hagan is a technical service engineer for Ariel Corp., where he specializes in troubleshooting and analyzing field failures. He has more than seven years of experience in troubleshooting and analyzing compressor equipment, field data collection and vibration analysis.
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Reciprocating gas compressors are used in a wide range of applications. The details for each application need to be evaluated by the compressor manufacturer to determine the worst operating case so an oil type and lube rate can be recommended. Typically, the worst case is the operating case having the greatest final-stage discharge pressure. The oil type recommended is based on the expected viscosity loss once the oil is inj ected to each critical
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n This sample was taken from the third stage, throw No. 1 at the beginning of test with normal lube rates. This is the first sheet of cigarette paper and it is soaked completely through with oil. operating at the frame rated speed. Operation at slower speeds is reduced proportionally (operating at half-speed requires half the “normal” lube rate at rated speed). For the first 200 hours of compressor operation, a break-in lube rate is recommended which increases the amount of oil to 150 to 200% of the normal rate. The additional break-in oil helps cool components and flushes away wear debris as components conform to each other. The recommended cylinder lube rates and oil types are in most cases conservative to account for some level of unknown or upset conditions. Lube recommendations are made based upon grouping applications into general gas stream categories. Two applications may share the same category but differ in how aggressive the conditions actually are toward the lubricating oil. Depending on the severity of service, some amount of lube rate reduction can usually be expected once the break-in period has ended. Compressors that had their cylinder lubrication systems sized for an estimated set of conditions may arrive at an oil type or lube rate that is grossly inadequate or excessive for their actual conditions. In some cases, this can impact the divider valve selection, force-feed pump sizing, and need for an independent oil supply if the oil recommendation can’t also be used for the compressor frame. It is important to note that packings can generate different amounts of heat depending upon the compressor
area of the cylinder lube system. Oil viscosity is affected by gas composition, cleanliness, pressure and operating temperature. In general, heavier hydrocarbon gases and higher discharge pressures cause the cylinder oil to become more diluted, resulting in decreased viscosity and thinner oil films protecting components. To avoid losing too much viscosity, heavier ISO grade mineral oi ls or synthetic lubricants resistant to dilution are recommended. Liquid contamination (e.g., water, hydrocarbon) and oil starvation also interfere with oil film quality by decreasing oil viscosity and/or removing the oil film. Poor lubrication results in excessive temperatures, which decreases component life. In extreme cases, a thermal runaway condition can lead to rapid component failure. Lubrication rates determine how often oil needs to be added to critical areas in the cylinder lubrication system. Compressor original equipment manufacturers (OEMs) have arrived at their own methods for determining lubrication rates. Ariel starts with a base rate that ranges between 0.3 to 0.5 pints/day/inch of part diameter. The size of compressor frame determines which base rate is used. The lubrication rate is altered via a base rate multiplier depending on the discharge pressure and gas composition. Base rate multipliers range between 0.5 and 3 depending on severity of service. The calculation determines the normal lubrication rate requirement for a component
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n This is the second sheet of paper from the sample in from the third stage, throw No. 1. This paper is marked with oil that soaked through the first sheet. This is an example of over-lubrication. • Leaks (e.g., damaged connections, tubing, fittings, O-rings) • Lubed component wear and geometry changes • Oil supply (day tank) feed line arrangement • Line sizing to improve oil flow • Heat tracing to improve oil flow • Filtration to improve oil quality • Faulty check valve The current compressor setup needs to be reviewed before pursuing a lube rate reduction. Factors may be found that developed or were not considered in initially sizing the cylinder lube system. The cylinder lube system setup needs to be correct and deemed in good working condition (reliable) prior to reducing the lubrication rates. Systems should already exhibit satisfactory component service lives and performance prior to reducing lube rates. The cylinder lubrication system is typically sized for a particular worst-case compressor operating condition or application. The system needs to tolerate the most difficult application the compressor will see while in service. Depending on the age of the equipment or how the unit was sized, the cylinder lubrication system may no longer be op erating correctly or be sized for the compressor application. The cylinder lube system hardware and lube sheets may need to be updated to achieve an appropriate starting lube rate for the current operation. Lube rate reductions must be done methodically to
application. The additional heat generated by the packing may warrant increasing the recommended oil viscosity to offset the viscosity lost at the increased temperature. Large amounts of heat generation will require the packing to be cooled with water — or in some cases oil — in order to maintain a reasonable operating temperature. Considerations for lube reduction
Many factors can influence the lubrication rate requirement and how reliably oil is delivered to critical areas in the cylinder lube system. Below are the most common factors that need consideration prior to modifying lube rates: Lube rate factors: • Gas composition and quality • Compressor operating speed • Oil type and viscosity grade for cylinder lube system • Part geometry (e.g., cylinder bore sizes) • Cylinder discharge pressure • Operating temperature • Force-feed pump and divider valve sizing • Recycling gas saturated with lubricating oil • Deactivating cylinder operation • Frequent start/stop operation Oil delivery factors: • Force-feed pump and divider valve bore/piston wear • Installation and sizing of balance valves • Correct lube line arrangement to/from divider valves 2017 EDITION
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TECH BRIEF normal lube rate typically reduces oil consumption by 33% to 50%. Some equipment may inadvertently operate for ex tended periods at the break-in rate because the lube rates were never reduced after the break-in interval. Inspection prior to lube reduction It is important to identify any history related to acceler-
ated wear on components such as piston rings, wear bands and packing. Related issues on wear components may lead to further investigation into what the failure mode is and may result in any lube reduction being suspended until further investigation is performed. To aid in recognizing any accelerated wear on components lubricated by the force-feed lubrication system, a thorough inspection should be performed. Parameters to be recorded: • Measured packing leakage/vent temperature prior to shutdown
• Piston rod diameters • Piston ring /wear band groove widths / depths • Cylinder bore inside diameters • Packing case dimensions with regards to packing cup depth • Piston ring radial thicknesses, widths • Wear band radial thicknesses, widths • Cigarette paper tests showing lubrication quality in cylinder bores on all stages • Force-feed lubrication system should be reviewed to be in good operation. This inspection should include a pressure test of divider valves.
nThis paper is from the third stage, throw No. 1 after 7022 hours running at 50% lubrication reduction. Oil soaked through the first sheet and lightly marked the second sheet. This indicates an adequately lubricated cylinder. avoid under-lubricated conditions that accidentally damage components due to increased operating temperatures. Excessive temperatures can cause piston/packing rings along with other major components like piston rods and cylinder bores to fail. Component failures can accrue significant costs depending on their severity: • Labor (overtime) = $2000/day • Packing and piston ring replacement = $3000 • Expedited shipping = $4000 • Cylinder replacement = $25,000 • Lost production = $40,000/day The reduction process requires slowly decreasing the lube rates and performing periodic inspections after each reduction. This verifies the amount of oil and quality on components. Evidence of marginal lubrication indicates when lube rates need to be increased. It is difficult to inspect oil films inside the packing due to how the cases are constructed. For these components, the vent line leakage and/or tubing contact tempera ture can be monitored to note changes in operating condition. A consistent tubing location (nearest the packing case) and method for verifying contact temperature is required.
Tools required for inspections:
• Gas flowmeter to measure packing leakage • Thermometer to monitor packing vent/drain temperatures • Vernier calipers • OD micrometers for all piston groove diameters • ID micrometers or dial bore gauges for cylinder bore diameters • Depth micrometer • Unwaxed cigarette papers Once all information is gathered prior to testing, the ap plication can then be reviewed to be a good candidate for further lube reduction. If all inspections reveal that the unit has not experienced excessive wear and shows to have good quality lubrication on all wear components, the lubri cation reduction procedure can be instituted and followed. Field lubrication reduction procedure
Once an application is determined to be a good candidate for lubrication reduction, procedures must be instituted to en sure proper application of lubrication to all force-feed components and six parameters are monitored closely. To determine proper lubrication to all components, inspections at regular time intervals must be done. These inspections include:
Break-in lube rates New ring components are fed additional oil as they break-
in during their first 200 hours of operation. After the breakin period, lubrication rates must be manually reduced from the break-in rate to the normal lube rate. Changing to the 2017 EDITION
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TECH BRIEF take into account emissivity and area of the measurement surface. A baseline temperature measurement with new packing is required to identify any increase in leakage.
Cylinder lubrication paper test This test estimates the amount of oil present on the cylinder bore by transferring oil from the bore to thin layers of unwaxed cigarette paper. The paper test should be performed within one hour of stopping the unit to get the best representation of cylinder oil film during operation. The test is carried out by the following steps: Using light pressure, wipe the cylinder bore with two layers of regular unwaxed cigarette paper together. Begin at the top and wipe downward about 20° (between 0.35 to 4.0625 in. depending on bore size) along the bore circumference. The paper against the bore surface should be stained (wetted with oil), but the second paper should not be soaked through. Repeat the test at both sides of the bore at about 90° from the top, using two clean papers for each side. Paper against the bore surface not stained through may indicate under-lubrication; both papers stained through may indicate over-lubrication.
Visual inspection of cylinder bores, crosshead guide compartments and piston rods Worn sliding surfaces can accelerate ring wear and increase leakage rates. A visual inspection of cylinder bores and crosshead guide compartments to identify any wear materials that have been removed from components. Piston rods should be visually inspected for scoring or signs of excess heat. Inspections should be conducted at the time intervals outlined in Table 1. At the conclusion of the test at the 8000 hour mark, along with the inspections outlined above, piston assemblies should be removed to inspect piston ring grooves, piston rings, wear bands, piston rods and cylinder bores. All dimensions should be compared to original measurements at the start of the test to identify any considerable wear. If at any point in the test packing leakage/temperatures increase or lubrication quality is marginal on any cylinder bore, the lubrication reduction should not continue. If cylinders appear under lubricated, lubrication should be increased in 10% increments until proper lubrication is restored on cylinder surfaces. If specific lube points appear to have marginal lubrication, the divider valve arrangement may be able to be reconfigured by the compressor OEM to tailor oil delivery to specific points based upon paper test results. Ideally, all cylinder lube points will have enough oil on the bore to only saturate one layer of cigarette paper. CTSS
•
•
Packing leakage inspection Packing leakage flow rate is an indicator of how well packing rings seal and whether sealing surfaces are worn or damaged. Measure packing leakage from packing vent/drain to monitor increased gas leakage due to wear occurring in the packing case. This can be done with a portable or permanent gas flow meter. Measure packing vent temperature as close as possible to crosshead guide. This measurement will indicate if increased packing leakage is occurring. Using an infrared thermometer, be sure to •
•
Elapsed Time Interval
Total Run Time
0
0
200 hrs
200 hrs
0
1 month
1 month
10
1 month
2 months
20
1 month
3 months
30
1 month
4 months
40
1 month
5 months
50
6 months
8000 hrs
50
Startup at break-in lube rates
Total Lube Reduction From Normal Rate (%)
Break-in rates are 150-200% of normal Set system to normal lube rates Review conditions Reduce lube 10% from normal rate Shut down for inspection. If satisfactory, move to next step. Reduce lube an additional 10% Shut down for inspection. If satisfactory, move to next step. Reduce lube an additional 10% Shut down for inspection. If satisfactory, move to next step. Reduce lube an additional 10% Shut down for inspection. If satisfactory, move to next step. Reduce lube an additional 10% Shut down for inspection. If satisfactory, move to next step. Continue operation at 50% Shut down for complete inspection.
nTable 1. Lubrication reduction time intervals. 2017 EDITION
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TECH BRIEF
Case Study: Packing Vent Monitoring Atmos Energy uncovers the root cause of a compressor cylinder packing case failure
Editor’s Note: This paper was presented in October at the Gas Machinery Conference in Denver, Colorado. BY DANNY ATHAR
Abstract Atmos Energy investigated the root cause of compressor cylinder packing case failure. The objectives were to reduce unscheduled outages for packing case replacements and to reduce gas losses. As Atmos Energy investigated the causes of packing failure, it designed a monitoring system to indicate the condition of the packing material. As an extension of this, Atmos Energy built a system to measure the gas leakage rate from each individual cylinder packing case. The system provides a visual indication of the rate relative to new packing. The system keeps a numerical measurement of the quantity of gas vented to atmosphere, which also helps keep track of fugitive emissions. The original packing vent monitor (PVM) and subsequent iterations have been implemented at several Atmos facilities.
n Figure1. Typical reciprocating compressor rod packing system (U.S. EPA, 2006a) Agency (EPA) in response to the federal “Climate Action Plan: a Strategy to Reduce Methane Emissions,” stated that the growth in the oil and gas sector has the potential to increase air emissions. A significant source of these emissions is from gas compressors — specifically the seals around mechanical components that leak as they degrade over time. Green House Gas Monitoring 40 CFR Part 98, Subpart W, is the primary regulation that affects fugitive emissions measuring and reporting. The Greenhouse Gas Reporting Program started in 2012, and requires facilities producing over 25,000 metric tons per year of CO 2 to report fugitive emissions annua lly to the EPA. The EPA provides calculation methods, and facilities are expected to use Best Available Monitoring Methods (BAMM).
Packing case In a reciprocating compressor, gas enters the suction manifold, flows into compressor cylinder and is then compressed by a piston. The rod attached to the piston has a series of flexible rings in machined metal cups (“packing”) to create a seal that limits the amount of natural gas that may escape along the piston rod (Figure 1). The direct relationship between running hours and packing degradation results in an increase in gas leakage over time. In addition, small leaks per cylinder among the thousands of compressors throughout the oil and gas sector (processing, transmission, and storage) add up to significant methane emissions.
Compression overview Atmos Energy has 16 facilities throughout their system composed of 11 compressor stations and 5 gas storages totaling approximately 102,000 hp (76 MW). These include: • 8 turbines with centrifugal compressors • 24 separable high-speed compressors • 5 integral low-speed compressors
Regulation A 2014 report by the U.S. Environmental Protection Danny Athar is an engineer for Atmos Energy Storage & Compression Group. He has been in the industry for nine years with a focus on improving field operations.
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SI UNITS…
THE INTERNATIONAL STANDARDS SYSTEM
The system outlined here is the International System of Units (Systeme International d’ Unites), for which the abbreviation SI is being used in all languages. The SI system, which is becoming universally used, is founded on seven base units, these being: Length.......................... ..................... . meter Mass .................... ...................... .... kilogram Time.................................................second Electric current ................... ............ ampere Thermodynamic temperature ............Kelvin Luminous intensity..................... ..... candela Amount of substance...........................mole
m kg s A K cd mol
POWER The derived SI unit for power is the Watt (W), this being based on the SI unit of work, energy and quantity of heat – the Joule (J). One Watt (1 W) is equal to one Joule per second (1 J/s). One Watt is a very small unit of power, being equivalent to just 0.00134102 horsepower, so for engine ratings the kilowatt (kW) is used, 1 kW being equal to 1.341 hp and 1 hp being the equivalent of 0.7457 kW. The British unit of horsepower is equal to 1.014 metric horsepower (CV, PS, PK, etc.).
Reciprocating Internal Combustion engines. Known as PTC 17, this code is intended for tests of all types of reciprocating internal combustion engines for determining power output and fuel consumption. In its Section 2, Description and Definition of Terms, both the FPS and corresponding SI units of measurements are given.
SPECIFIC CONSUMPTION Fuel consumption measurements will be based on the currently accepted unit, the gram (g), and the Kilowatt Hour (kWh). Also adopted is heat units/power units so that energy consumption of an internal combustion engine referred to net power output, mechanical, is based on low unsaturated heat value of the fuel whether liquid or gaseous type. Thus the SI unit of measurement for net specific energy consumption is expressed: g/kWh. 1 g/kWh = 0.001644 lb/hph = 0.746 g/hph = 0.736 g/metric hph 1 lb/hph = 608.3 g/kWh 1 g/hph = 1.341 k/kWh 1 g/metric hph = 1.36 g/kWh
WEIGHTS AND LINEAR DIMENSIONS For indications of “weight” the original metric kilogram (kg) will continue to be used as the unit of mass, but it is important to note that the kilogram will no longer apply for force, for which the SI unit is the Newton (N), which is a kilogram meter per second squared. The Newton is that force which, when applied to a body having a mass of one kilogram, gives it an acceleration of one meter per second squared. “Weight” in itself will no longer apply, since this is an ambiguous term, so the kilogram in effect should only be used as the unit of mass. Undoubtedly, though, it will continue to be common parlance to use the word “weight” when referring to the mass of an object. The base SI unit for linear dimensions will be the meter, with a wide range of multiples and submultiples ranging from exa (10 18) to atto (10 -18): A kilometer is a meter x 10 3, for example, while a millimeter is a meter x 10 -3. To give an idea of how currently used units convert to SI units, the tables below give examples. KILLOWATTS (kW) TO HORSEPOWER (hp) (1 Kw = 1.34102 hp)
1 kW = 1.341 hp = 1.360 metric hp 1 hp = 0.746 kW = 1.014 metric hp 1 metric hp = 0.735 kW = 0.986 hp
TORQUE The derived SI unit for torque (or moment of force) is the Newton meter (Nm), this being based on the SI unit of force — the Newton (N) – and the SI unit of length – the meter (m). One Newton (1 N) is equivalent to 0.2248 pound-force (lbf) or 0.10197 kilogram-force (kgf), and one meter is equal to kilogram force (kgf) and one member is equal to 3.28084 feet (ft), so one Newton meter (1 N m) is equal to 0.737562 pound-force (lbf ft). or 0.101972 kilogram-force meter (kgf m). 1 Nm = 0.738 lbf ft = 0.102 kgf m 1 lbf ft = 1.356 Nm = 0.138 kgf m 1 kgf m = 9.807 Nm = 7.233 lbf ft
PRESSURE AND STRESS Although it has been decided that the SI derived unit for pressure and stress should be the Pascal (Pa), this is a very small unit, being the same as one Newton per square meter (1 N/m 2), which is only 0.000145 lbf/in 2 or 0.0000102 kgf/cm 2. So many European engine designers favor the bar as the unit of pressure, one bar being 100,000 Pascal (100 kPa), which is the equivalent of 14,504 lbf/in 2 or 1.020 kgf/cm 2, so being virtually the same as the currently accepted metric equivalent. On the other hand, for engine performance purposes, the millibar seems to be favored to indicate barometric pressure, this unit being one thousandth of a bar. Then again, there is a school that favors the kiloNewton per square meter (kN/m 2), this being the same as a kilopascal, and equal to 0.145 lbf/in 2 or 0.0102 kgf/cm2. 1 bar = 14.5 lbf/in2 = 1.0197 kgf/cm 2 1 lbf/in2 = 0.069 bar 1 kgf/cm2 = 0.98 bar The American Society of Mechanical Engineers in 1973 published its Performance Test Codes for 2017 EDITION
HEAT RATE Heat Rate is a product of Lower Heating Value (LHV) of Fuel (measured in Btu/lb or kJ/g for liquid fuel and Btu/ft3 or kJ/m3 for gas fuel) multiplied times (sfc) specific fuel consumption (measured in lb/hph or g/kWh). For Liquid Fuel Heat Rate (Btu/hph) = LVH (Btu/lb) X sfc (lb/hph) For Gaseous Fuel Heat Rate (Btu/hph) = LVH (Btu/ft 3) X sfc (ft3 /hph) To convert these units to SI units: Btu/hph X 1.414 = kJ/kWh Or Btu/kWh X 1.055 = kJ/kWh
LUBRICATING-OIL CONSUMPTION Although the metric liter is not officially an SI unit, its use will continue to be permitted, so measurement of lube-oil consumption will be quoted in liters per hour (liters/h). 1 liter/h = 0.22 Imp gal/h 1 Imp gal/h = 4.546 liters/h
TEMPERATURES The SI unit of temperature is Kelvin (K), and the character is used without the degree symbol (°) normally employed with other scales of temperature. A temperature of zero degree Kelvin is equivalent to a temperature of -273.15°C on the Celsius (centigrade) scale. The Kelvin unit is identical in interval to the Celsius unit, so direct conversions can be made by adding or subtracting 273. Use of Celsius is still permitted. 0 K = 273°C; absolute zero K 1°C = 273 K 219
kW 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
hp 1.341 2.682 4.023 5.364 6.705 8.046 9.387 10.728 12.069 13.410 14.751 16.092 17.433 18.774 20.115 21.456 22.797 24.138 25.479 26.820
kW 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40
hp 28.161 29.502 30.843 32.184 33.526 34.867 36.208 37 .549 38 .890 40.231 41.572 42.913 44.254 45.595 46.936 48.277 49.618 50.959 52.300 53.641
kW 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60
hp 54.982 56.323 57.664 59.005 60.346 61.687 63.028 64.369 65.710 67.051 68.392 69.733 71.074 72.415 73.756 75.097 76.438 77.779 79.120 80.461
kW 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80
hp 81.802 83.143 84.484 85.825 87.166 88.507 89.848 91.189 92.530 93.871 95.212 96.553 97.894 99.235 100.577 101.918 103.259 104.600 105.941 107.282
kW 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100
hp 108.623 109.964 111.305 112.646 113.987 115.328 116.669 118.010 119.351 120.692 122.033 123.374 124.715 126.056 127.397 128.738 130.079 131.420 132.761 134.102
POUNDS FORCE FEET (lbf ft) TO NEWTON METERS (Nm) (1 lbf ft = 1.35582 Nm) lbf ft Nm lbf ft 1 1.356 21 2 2.712 22 3 4.067 23 4 5.423 24 5 6.779 25 6 8.135 26 7 9.491 27 8 10.847 28 9 12.202 29 10 13.558 30 11 14.914 31 12 16.270 32 13 17.626 33 14 18.981 34 15 20.337 35 16 21.693 36 17 23.049 37 18 24.405 38 19 25.761 39 20 27.116 40
Nm 28.47 2 29.82 8 31.184 32.540 33.896 35.251 36.607 37.963 39.319 40.675 42.030 43.386 44.742 46.098 47.454 48.810 50.165 51.521 52.877 54.233
lbf ft 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60
Nm lbf ft 55.589 61 56.944 62 58.300 63 59.656 64 61.012 65 62.368 66 63.724 67 65.079 68 66.435 69 67.791 70 69.147 71 70.503 72 71.808 73 73.214 74 74.570 75 75.926 76 77.282 77 78.638 78 79.993 79 81.349 80
Nm lbf ft 82.705 81 84.061 82 85.417 83 86.772 84 88.128 85 89.484 86 90.840 87 92.196 88 93.552 89 94.907 90 96.263 91 97.619 92 98.975 93 100.331 94 101.687 95 103.042 96 104.398 97 105.754 98 107.110 99 108.466 100
Nm 109.821 111.177 112.533 113.889 115.245 116.601 117.956 119.312 120.668 122.024 123.380 124.715 126.001 127.447 128.803 130.159 131.515 132.870 134.226 135.582
These tables are reproduced from the booklet “Vehicle Metrics” published by Transport and Distribution Press Ltd., 118 Ewell Road, Surbiton, Surry, KT6 6HA England. WWW.CTSSNET.NET
CTSS
TECH BRIEF an excessive leak, the rotary meter became very audible and produced a distinct “whistle.” When the whistle sounded, the operator isolated each cylinder until the noise stopped. This indicated that particular cylinder had worn out packing, because the tolerances in a rotary meter are quite small, oil build up or debris in the line could cause the meter to lock and create backpressure in all of the packing vent lines.
Background South of Denton, Texas, Atmos Energy has a compressor station that runs continuously and is critical to system supply. During 2011, this operation was frequently interrupted by unscheduled downtime due to packing cases failing at a high rate. Packing material was being replaced every two months instead of every two years as budgeted. Frequent downtime cost of materials and operator call-outs; unscheduled outages became an unacceptable system supply problem. Atmos Energy’s solution for the unscheduled outages was to monitor the flow of vent gas that blows by as the cylinder packing wears out. Monitoring each compressor cylinder individually allowed operations to detect excessive leaks and determine which packing cases required maintenance. Operations could then alert system supply of an upcoming outage, purchase materials and schedule the work.
Mass flowmeter A third design was proposed that utilized a mass flowmeter to directly measure the flow of packing vent gas. Atmos selected a mass flowmeter that was relatively inexpensive and easy to install. Functionality is simple with no moving parts, and similar devices are used by the EPA in its fugitive emissions studies. Atmos investigated several companies that could provide flowmeters for this application, while considering size, mounting options, communications, cost and delivery. A device that fit the specifications was a flow switch by Fluid Component International (FCI). Though a flowmeter and a switch are available by FCI, Atmos opted for only the switch, as it would be a good inexpensive start for the project. Each flow switch has a 10 LED displa y as a visual indicator of the flow rate, which can be calibrate d in the field. A single LED represents new packing with the nominal leak rate of 5 to 10 scfh (0.14 to 0.3 Nm³/hr) and each additional LED represents an increment in leak rate for the cylinder.
Three-way valve The first iteration of the PVM design included adding a three-way valve in-line with each packing vent line, which allowed the operator to isolate the vent gas from the common line and flow through a test vent. During daily checks, the operator tested each cylinder for excessive venting. This required some finesse on the operator’s part, as they had to physically feel the passing gas venting through the test vent. Differentiating between normal and excessive venting required the operator to test a new set of packing as a “control.” This technique was effective, albeit rudimentary and possibly inconsistent.
n Figure 2. Rotary meter installed on common packing vent line. n Figure 3. Initial setup of flow switch and test valve.
Rotary meter A second design improved on the original by utilizing a rotary meter (Figure 2) to measure the flow of vent gas at a common line, since all of the compressor cylinder’s packing vent lines connected at that point and then vented to atmosphere. The rotary meter worked well in conjunction with the previous valve technique by providing direct measurement of the flow. When there was
2017 EDITION
Pilot installation To save on space, Atmos ordered the remote mount kit for each flow switch. The configuration (Figure 3) has a flow sensor in-line with the packing vent line and has a communication cable connected to a remote mounted display unit. Operations initially relied on visual displays
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TECH BRIEF
n Figures 5 and 6. Calibrating the flow switch in the field. being that calibration utilized the LED lights with a flowmeter to get an accurate number. The range used was based on packing leak rates published by Ariel: 5 scfh to a maximum of 120 scfh (0.14 to 3.58 Nm³/hr). Each flowmeter had to be calibrated individually in the manner displayed in Figures 5 and 6.
n Figure 4. Flow sensor and test vent installed. only, with no signals going to the plant control system. There was concern that oil and debris build up in the flow switch could cause false readings or produce backpressure. This was resolved by mounting th e flow sensor vertically and utilizing the three-way valve as a test vent (Figure 4). Prior to installation, each flow switch was calibrated in order to provide a relatively consistent display for leaks. Similar to prior attempts, the general rate was opted for rather than a quantitative display. A secondary meter for verification was used to calibrate each flow switch. Each flow switch was then set to zero and air was cycled through the flow switch and the second meter.
n Figure 7. Flowmeter on common line with isolation valves.
Refining calibration The flow switch installation was well received by operations. Daily checks allowed the operator to see all the displays together and as time went by, the operator noted that the number of LEDs increased as the packing wore out. The main criticism of the design was the need for an improved calibration method for the flow switches and way to quantify flow. After a successful pilot study, another PVM system was installed at a different mainline compressor station that has identical compressor units. The installation was nearly identical to the first station, the only difference
2017 EDITION
PLC implementation The next installation (Figure 7) was at a storage facility located in north Texas. The facility has smaller compressors with less room to work with around the compressor cylinders. In addition, there was a PVM system previously installed by the skid packager. A differential pressure (DP) gauge on the common packing vent line displayed a reading in the control room and was configured such that a high DP would alert the operators to an excessive leak in one or more of the packing cases.
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TECH BRIEF an excessive leak, alerting the operators to isolate each cylinder to find the leaking packing. Prior to storage in jectio n season, operation s can run the compressors and note their packing case conditions to establish a base case condition. Atmos installed the latest design (Figure 8) at another storage facility in east Texas with five compressors. For this installation, operations plumbed the tubing so each cylinder isolation valve is next to the flowmeter, allowing a single operator to check for individual cylinder leaks.
n Figure 8. Flowmeter with isolation valves plumbed together. This method was inaccurate because the numbers would jump around on the scree n and confuse operato rs. There was no method to isolate each cylinder when a high DP alarm was displayed. Because of the lack of room to work around each cylinder, Atmos took a slightly different approach to this design by replacing the DP device with a flowmeter and adding isolation valves to each cylinder. The flowmeter’s analog output was tied to the PLC and programmed to show the leak rate. An alarm would display if there were
Summary Atmos started with a quick solution to a problem that was both time consuming and costly. The PVM system evolved from a makeshift hands-on device to an automated system, benefitting Atmos operations by preventing unscheduled outages and monitoring fugitive emissions. Though each facility had different design preferences, ultimately the PVMs serve the same purpose and provide resolution to common problem. Future considerations Atmos will be looking at the possibility to log leak rates for each compressor and trend the data so they can determine what conditions reduce the life of packing. This system is something Atmos would like to include in the specifications for all new compressor packages. CTSS
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TECH BRIEF
Creating The Perfect Impeller Shape By Scalloping Sulzer study shows designs, operations can lead to impeller failure Editor’s Note: This article was originally published in the third issue of the Sulzer Technical Review 2015. BY KIRILL GREBINNYK
A
n Australian industrial gas company contracted Sulzer to perform an engineering study to analyze a recent impeller failure. The impeller is part of a multistage, integrally geared compressor used in the production of oxygen for industrial processes. The compressor works as a booster compressor and is located after the main air compressor. It compresses air from 72.5 to 464 psi(g) (5 to 32 bar[g]). The impeller failed during operation after being in service for almost 40,000 operating hours. Four sections of the cover plate showed cracks with missing pieces of material (Figure 1). Failure analysis of the original impeller Engineers at Sulzer’s service center performed a failure analysis to identify the reasons for the crack initiation, its propagation and the liberation of the cover plate material. Metallography was performed by collecting a replica of the fracture surface and inspecting it under a scanning electron microscope (SEM). Characteristic marks on the surface (so-called “beach” marks) indicated high-cycle fatigue failure. No material or workmanship defects were found, which led Sulzer to the conclusion that the failure had been caused by fatigue mechanisms related to the interaction of the impeller with external excitation forces. Because of the lower supply needs of the plant, the compressor operating regime had been changed from the rated point to a turndown mode over the last few months prior to the failure . To run the compressor at turndown, the inlet guide vane (IGV) position had been set close to design limits. This change may have increased flow instability. It is likely that these events, combined with a near-resonant situation caused by the proximity of
n Figure 1. The cover plate of the impeller showed cracks with missing pieces of material.
a natural frequency mode with a forcing function, induced fatigue, which initiated cracks in the impeller and caused them to propagate. The impeller was ring tested to determine its natural frequencies. These natural frequencies were later used to validate the numerical model by comparing them with the frequencies obtained from a 3-D finite element analysis (FEA). The following numerical studies were performed for the original (baseline) impeller using ANSYS software: “Free-free” modal analysis (with no rotational speed or other loads applied) to determine the impeller natural
Kirill Grebinnyk is an aerodynamics engineer at Sulzer (Houston Service Center). He has 10 years of experience in design and re- pairs of turbomachinery. His primary areas of expertise are fluid dynamics, failure analysis, structural and modal analysis and test-
•
ing of the rotating equipment.
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3 STAGE
t r a h C n o i t c e l e S r e w o p e s r o H r o s s e r p m o C
STAGE 2
STAGE 1
0 5 0 5 7 8 3 2 2 4 6 0 6 5 6 9 2 0 1 7 4 2 1 0 9 8 7 6 6 4 3 2 1 0 9 8 0 3 7 1 6 2 8 4 2 3 2 2 2 2 2 1 1 1 1 1 1 1 1 1 1 8 7 7 6 5 5 4 4 3 3 1 0 1 7 2 4 4 0 8 9 1 3 7 3 3 3 6 5 1 6 4 2 1 0 8 7 7 6 5 4 3 2 1 9 6 5 7 0 4 9 4 0 6 2 1 3 2 2 2 2 2 1 1 1 1 1 1 1 1 1 9 8 7 6 6 5 4 4 4 3 3 1 0 7 4 9 0 0 6 5 6 7 0 4 0 0 1 3 0 0 6 3 3 1 9 8 7 6 6 5 4 3 2 1 5 3 3 4 8 2 6 2 8 3 9 1 3 2 2 2 2 1 1 1 1 1 1 1 1 1 1 9 8 7 6 5 5 4 4 3 3 2 1 0 3 0 6 6 6 3 2 2 4 7 1 7 7 8 0 5 0 6 3 2 0 9 8 7 6 5 5 3 2 1 1 2 9 0 0 5 9 4 9 5 0 7 0 3 2 2 2 2 1 1 1 1 1 1 1 1 1 1 9 7 7 6 5 4 4 3 3 3 2 1 0 9 7 2 1 2 9 8 9 1 4 8 4 4 5 5 0 9 5 3 2 0 8 7 6 6 5 4 3 2 1 0 8 6 7 9 2 6 1 7 2 8 4 0 2 2 2 2 2 1 1 1 1 1 1 1 1 1 1 8 7 6 5 5 4 4 3 3 2 2 1 0 5 3 9 6 8 5 4 5 7 0 4 1 1 2 1 5 3 3 6 9 4 9 4 9 5 0 5 9 5 2 1 9 8 7 6 5 5 4 3 2 1 0 8 7 6 5 4 4 3 3 2 2 2 9 2 2 2 2 1 1 1 1 1 1 1 1 1 1 1 0 1 0 6 1 4 1 0 1 3 7 1 8 8 7 6 1 9 0 3 6 1 6 0 6 2 0 9 5 2 1 9 8 7 6 5 4 4 2 1 0 9 8 6 6 5 4 4 3 3 2 2 9 2 2 2 2 1 1 1 1 1 1 1 1 1 1 0 6 5 1 6 0 7 6 7 0 3 7 4 4 2 2 7 6 7 0 3 8 2 7 2 5 8 4 3 0 9 7 6 5 5 4 3 2 1 0 9 7 6 5 5 4 3 3 2 2 8 2 2 2 2 1 1 1 1 1 1 1 1 1 1 0 2 2 5 1 5 3 2 3 6 9 3 1 0 7 8 3 2 3 6 0 4 0 3 0 8 4 2 0 8 7 6 5 4 3 3 2 1 9 8 7 6 5 4 4 3 2 2 8 2 2 2 2 1 1 1 1 1 1 1 1 1 0 7 7 8 6 0 8 8 9 2 5 9 7 3 2 3 9 8 0 3 6 0 5 5 7 3 1 9 8 6 5 4 4 3 2 1 0 9 8 6 5 5 4 3 3 2 7 2 2 2 1 1 1 1 1 1 1 1 1 1
) . t 0 2 3 2 1 5 3 3 5 7 1 5 3 7 8 5 4 6 9 2 6 0 F ) 0 7 3 1 9 7 6 5 4 3 3 2 1 8 . G 7 2 2 2 1 1 1 1 1 1 1 1 1 9 8 7 6 5 4 3 3 2 2 u I 6 8 6 5 0 8 8 0 2 6 0 6 C S 0 2 3 0 0 2 5 8 2 5 6 2 0 8 7 5 4 4 3 2 2 0 2 2 2 2 1 1 1 1 1 1 1 1 1 9 8 7 6 5 4 3 2 2 6 n P ( o i E 0 0 1 9 9 4 3 3 5 7 1 6 9 6 6 8 6 6 8 0 3 l l i R 0 6 3 9 7 6 5 4 3 2 2 1 1 1 1 1 1 1 1 9 8 7 6 5 4 3 3 2 M U 6 2 2 1 1 r S 0 4 3 3 3 8 7 7 9 2 6 9 2 0 1 3 1 1 3 5 e S 5 5 2 9 7 5 4 3 2 2 1 0 P E 5 2 2 1 1 1 1 1 1 1 1 1 9 8 7 6 5 4 3 2 r R 8 4 6 7 2 1 1 3 7 9 0 5 4 0 8 6 6 7 e P 0 4 1 8 6 5 4 3 2 1 0 0 w E 0 5 2 2 1 1 1 1 1 1 1 1 1 8 7 6 5 4 3 2 o p G 0 1 5 8 9 5 4 5 7 9 0 2 8 7 7 2 0 0 1 e R 5 4 0 7 5 4 3 2 1 0 0 9 7 6 5 5 4 3 2 s r A 4 2 2 1 1 1 1 1 1 1 1 o H 0 3 6 0 2 8 7 8 9 1 4 1 0 2 5 3 3 H C 0 3 9 7 5 3 2 1 0 8 4 2 1 1 1 1 1 1 1 9 9 8 7 6 5 4 3 2 S e I k D 0 3 6 0 3 0 9 8 9 1 5 3 3 5 8 6 a 5 3 8 6 4 3 1 0 7 r 3 2 1 1 1 1 1 1 9 8 8 7 6 5 4 3 2 B ( 0 8 5 1 3 1 6 5 6 8 2 6 4 5 7 0 0 1 7 5 3 2 0 9 8 7 7 6 5 4 3 3 3 2 1 1 1 1 1
F ° 0 0 1 E R U T A R E P S M E A T G N L A O I R T U C T U A S N 3 4
0 3 3 9 3 7 5 0 6 3 2 0 3 3 4 7 1 5 4 5 7 2 2 1 1 1 1 9 8 7 6 6 5 4 3 2 0 7 9 6 7 0 8 9 1 4 9 4 2 2 0 8 4 2 0 9 7 6 6 5 4 4 3 2 2 1 1 1 1 5 8 0 8 7 7 4 1 6 1 0 1 4 7 2 7 5 1 1 1 1 9 8 7 6 5 4 4 3 2
Y T I L I B 0 8 1 6 5 2 1 3 6 0 4 8 I F 5 6 3 0 8 7 6 5 4 4 3 2 ° S 1 1 1 1 0 S 6 E 5 6 1 2 4 1 2 4 7 0 4 D R 2 5 2 9 7 6 5 4 3 3 2 N P 1 1 1 A M O 7 0 4 4 8 2 0 1 2 5 . 4 C 0 4 0 7 6 5 4 3 2 1 R 1 1 1 D O E F 5 2 7 6 6 5 8 2 R D 7 1 8 6 4 3 2 U E S T A C 0 9 3 3 9 E E 5 9 6 4 2 M R R D 5 5 5 6 F O 2 2 6 3 C C . : S 1 T = ” 0 5 0 0 0 0 0 0 0 0 0 0 0 0 E M O 0 0 0 0 0 0 0 0 0 5 N 2 5 7 0 5 0 5 0 5 0 5 0 5 0 5 T M 0 0 N “ 1 2 3 4 5 6 7 8 9 0 1 1 1 1 2 2 3 3 4 4 5 5 6 6 7 7 O N 1 2
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TECH BRIEF
n Figure 2. The interference diagram (above) revealed a resonance frequency that caused the fracture. The mode shape of the resonance frequency identified (right) resembles the crack shape. frequencies and validate them against the frequencies obtained from the ring test. Steady-state structural analysis to determine impeller stresses from steady loads at operating speed. Pre-stressed modal analysis to determine the impeller natural frequencies at operating speed, accounting for the effects of stiffness change due to rotation. The steady-state structural analysis revealed that there was a high stress concentration located at the fillet between the vane and the cover plate at the outside of the impeller diameter. This location matched the suspected site of the crack initiation. The stress was close to the material yield strength limit, but it was very localized and could not be deemed high enough to initiate a crack by itself. For a fracture to initiate, there had to be an additional source of stress related to the impeller interference with the diffuser vane passing frequency. The engineers used an interference diagram, also known as a SAFE diagram. This is a graphical analytical tool proposed by Murari Singh to identify resonance in turbomachinery components. It aids in determining natural frequencies that can potentially be excited depending on the running speed and number of stationary components (inlet guide vanes, diffusers) and rotating vanes interacting in the particular stage. The interference diagram created for the current case study is shown in Figure 2. Based on the diffuser and impeller vane counts and the possible interactions between them, the impeller mode shapes corresponding to the sixth nodal diameter were identified as potentially excitable mode shapes. For resonance •
•
2017 EDITION
to be possible, the impeller frequency on the diagram must coincide with both the compressor operating speed line and the exciting force mode shape (harmonics) identified as a potential excitation source. There is an impeller natural frequency at 4884 Hz, which lies within 5% of the running speed line. Because the mode shape associated with this frequency closely resembles the failure pattern observed, this was identified as the frequency that was excited and that caused the failure (Figure 2). This interference did not cause any issues when the compressor was running near rated operating point. However, in turndown mode, backflow effects from the diffuser might have appeared because of the low flow and they may have caused resonance, which is unexpected at other regimes. Increased alternating stresses due to the resonance caused the dynamic stress amplitude to increase and initiate the crack.
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CONVERSION FACTORS
absolute atmosphere absolute British thermal unit British thermal unit/hour Celsius cubic foot/minute centimeter square centimeter cubic centimeter cubic foot Fahrenheit foot/second foot-pound gallon horsepower inch inch mercury inch water kilocalorie kilogram kilojoule kilopascal kilowatt liter meter millimeter square meter cubic meter cubic meter/minute mile per hour Newton Pascal normal* cubic meter/hour pound/square inch pound/square inch absolute pound/square inch gage standard* cubic foot standard* cubic foot/minute square
*“Normal” = 0°C and 1.01325x105 Pascals *“Standard” = 59°F and 14.73 psia
mm 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
kg 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
in 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748 0.787
lb 2.204 4.409 6.614 8.819 11.023 13.228 15.432 17.637 19.843 22.046 24.251 26.455 28.660 30.865 33.069 35.274 37.479 39.683 41.888 44.093
To Convert From English
sq. in. sq. ft. lb/cu.ft. lbf lb /ft f Btu Btu/hr Btu/scf in ft yd lb hp psi psia psig in. Hg in. H2O °F °F (Interval) ft-lb mph ft/sec cu. ft. gas (US) cfm scfm To Convert From Old Metric
To S.I. Metric
Multiply By
mm 2 m2 kg/m 3 N N/m kJ W kJ/mm 3 mm m m kg kW kPa kPa abs kPa gage kPa kPa °C = °C (Interval) N • m km/hr m/sec m3 L m3 /min nm3 /min
645.16 0.0929 16.0185 4.4482 14.5939 1.0551 0.2931 37.2590 25.400 0.3048 0.914 0.4536 0.7457 6.8948 6.8948 6.8948 3.3769 0.2488 (°F -32) 5/9 5/9 1.3558 1.6093 0.3048 0.0283 3.7854 0.0283 0.0268
To S.I. Metric
Multiply By
cm2 kcal kcal/hr cm kg/cm2 bars atm cm Hg cm H 2O nm3 /hr
mm 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40
MILLIMETERS (mm) TO INCHES (in) (1 millimeter = 0.03937 inch) in mm in mm in mm 0.827 41 1.614 61 2.402 81 0.866 42 1.654 62 2.441 82 0.906 43 1.693 63 2.480 83 0.945 44 1.732 64 2.520 84 0.984 45 1.772 65 2.559 85 1.024 46 1.811 66 2.598 86 1.063 47 1.850 67 2.638 87 1.102 48 1.890 68 2.677 88 1.142 49 1.929 69 2.717 89 1.181 50 1.968 70 2 .756 90 1.220 5 1 2.008 71 2 .795 91 1.260 5 2 2.047 72 2 .835 92 1.299 53 2.087 73 2 .874 93 1.339 54 2.126 74 2.9 13 94 1.378 55 2.165 75 2.95 3 95 1.417 56 2.205 76 2.99 2 96 1.457 57 2.244 77 3.03 2 97 1.496 58 2.283 78 3.07 1 98 1.535 59 2.323 79 3.11 0 99 1.575 60 2.362 80 3.150 100
kg 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40
KILOGRAMS (kg) TO POUNDS (lb) (1 kilogram = 2.20462 pounds) lb kg lb kg lb 46.297 41 90.390 61 134.482 48.502 42 92.594 62 136.687 50.706 43 94.799 63 138.891 52.911 44 97.003 64 141.096 55 .116 45 99.208 65 143.300 57.320 46 101.413 66 145.505 59.525 47 103.617 67 147.710 61.729 48 105.822 68 149.914 63.934 49 108.026 69 152.119 66.139 50 110.231 70 154.324 66.343 51 112.436 71 156.528 70.548 52 114.640 72 158.733 72.753 53 116.845 73 160.937 74.957 54 119.050 74 163.142 77.162 55 121.254 75 165.347 79.366 56 123.459 76 167.551 81.571 57 125.663 77 169.756 83.776 58 127.868 78 171.961 85.980 59 130.073 79 174.165 88.185 60 132 .277 80 176.370
2017 EDITION
TEMPERATURE CONVERSION TABLES*
CONVERSION FACTORS
ABBREVIATIONS abs ata Btu Btu/hr °C cfm cm cm2 cm3 cu.ft. °F ft/sec ft-lb gal hp in in. Hg in. H2O kcal kg kJ kPa kW L m mm m2 m3 m3 /min mph N N/m2 Nm3 /hr psi psia psig scf scfm sq
SI — METRIC/DECIMAL SYSTEM
kg 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100
mm2 kJ W mm kPa kPa kPa kPa kPa nm3 /min
in 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504 3.543 3.583 3.622 3.661 3.701 3.740 3.779 3.819 3.858 3.898 3.937
To Old Metric cm2 m2 kg/m3 N N/m kcal kcal/hr kcal/nm3 cm m m kg kW kg/cm2 bars abs ata cm Hg cm H2O °C = °C (Interval) N • m km/hr m/sec m3 L m3 /min nm3 /hr
100. 4.1868 1.16279 10. 98.0665 100. 101.325 1.3332 9.8064 0.0176
By Albert Sauveur
Multiply By 6.4516 0.0929 16.0185 4.4482 14.5939 0.252 0.252 0.1565 2.540 0.3048 0.914 0.4536 0.7457 0.070 0.0716 0.070 2.540 2.540 (°F -32) 5/9 5/9 1.3558 1.6093 0.3048 0.0283 3.7854 0.0283 1.61
C -17.8 -17.2 -16.7 -16.1 -15.6 -15.0 -14.4 -13.9 -13.3 -12.8 -12.1 -11.7 -11.1 -10.6 -10.0 -9.44 -8.89 -8.33 -7.78 -7.22 -6.67 -6.11 -5.56 -5.00 -4.44 -3.89 -3.33 -2.78 -2.22 -1.67 -1.11 -0.56 0 0.56 1.11 1.67 2.22 2.78 3.33 3.89 4.44 5.00 5.56 6.11 6.67 7.22 7.78 8.33 8.89 9.44
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49
C 38 43 49 54 60 66 71
100 110 120 130 140 150 160
0 to 100 C 10.0 10.6 11.1 11.7 12.2 12.8 13.3 13.9 14.4 15.0 15.6 16.1 16.7 17.2 17.8 18.3 18.9 19.4 20.0 20.6 21.1 21.7 22.2 22.8 23.3 23.9 24.4 25.0 25.6 26.1 26.7 27.2 27.8 28.3 28.9 29.4 30.0 30.6 31.1 31.7 32.2 32.8 33.3 33.9 34.4 35.0 35.6 36.1 36.7 37.2 37.8
50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100
F 122.0 123.8 125.6 127.4 129.2 131.0 132.8 134.6 136.4 138.2 140.0 141.8 143.6 145.4 147.2 149.0 150.8 152.6 154.4 156.2 158.0 159.8 161.6 163.4 165.2 167.0 168.8 170.6 172.4 174.2 176.0 177.8 179.6 181.4 183.2 185.0 186.8 188.6 190.4 192.2 194.0 195.8 197.6 199.4 201.2 203.0 204.8 206.6 208.4 210.2 212.0
100 to 1000 F C 212 77 230 82 248 88 266 93 284 99 302 100 320 104
170 180 190 200 210 212 220
F 338 356 374 392 410 413 428
F 32 33.8 35.6 37.4 39.2 41.0 42.8 44.9 46.4 48.2 50.0 51.8 53.6 55.4 57.2 59.0 60.8 62.6 64.4 66.2 68.0 69.8 71.6 73.4 75.2 77.0 78.8 80.6 82.4 84.2 86.0 87.8 89.6 91.4 93.2 95.0 96.8 98.6 100.4 102.2 104.0 105.8 107.6 109.4 111.2 113.0 114.8 116.6 118.4 120.0
C 110 116 121 127 132 138 143 149 154 160 166 171 177 182 188 193 199 204 210 216 221 227 232 238 243 249 254 260 266 271 277 282 288 293 299 304 310 316 321 327 332 338 343
100 to 1000 – cont. F C 230 446 349 240 464 354 250 482 360 260 500 366 270 518 371 280 536 377 290 554 382 300 572 388 310 590 393 320 608 399 330 626 404 340 644 410 350 662 416 360 680 421 370 698 427 380 716 432 390 734 438 400 752 443 410 770 449 420 788 454 430 806 460 440 824 466 450 842 471 460 860 477 470 878 482 480 896 488 490 914 493 500 932 499 510 950 504 520 968 510 530 986 516 540 1004 521 550 1022 527 560 1040 532 570 1058 538 580 1076 590 1094 600 1112 610 1130 620 1148 630 1166 640 1184 650 1202
C 538 543 549 554 560 566 571 577 582 588 593 599 604 610
1000 to 1630 F C 1832 816 1850 821 1868 827 1886 832 1904 838 1922 843 1940 849 1958 854 1976 860 1994 866 2012 871 2030 877 2048 882 2066 888
1000 1010 1020 1030 1040 1050 1060 1070 1080 1090 1100 1110 1120 1130
660 670 680 690 700 710 720 730 740 750 760 770 780 790 800 810 820 830 840 850 860 870 880 890 900 910 920 930 940 950 960 970 980 990 1000
F 1220 1238 1256 1274 1292 1310 1328 1346 1364 1382 1400 1418 1436 1454 1472 1490 1508 1526 1544 1562 1580 1598 1616 1634 1652 1670 1688 1706 1724 1742 1760 1778 1796 1814 1832
1500 1510 1520 1530 1540 1550 1560 1570 1580 1590 1600 1610 1620 1630
F 2732 2750 2768 2786 2804 2822 2840 2858 2876 2894 2912 2930 2948 2966
Note: The numbers in bold face type refer to the temperature either in degrees Centigrade or Fahrenheit which is desired to convert into the other scale. If converting from Fahrenheit degrees to Centigrade degrees, the equivalent temperatures will be found in the left column; while if converting from degrees Centigrade to degrees Fahrenheit, the answer will be found in the column on the right.
VOLUME
PISTON SPEED
WEIGHT/HORSEPOWER
CONVERSION FACTORS
CONVERSION FACTORS
CONVERSION FACTORS
1 L = 61.02 cu. in. 10 cu. in. = 0,164 L
L
cu. in.
1 m/s = 196.9 ft./min. 100 ft./min. = 0,51 m/s
m/s
ft./min.
1 kg/metric hp = 2.235 lb./hp 1 lb/hp = .4474 kg/metric hp
kg/metric hp
lb/hp
lb 178.574 180.779 182.984 185.188 187.393 189.598 191.802 194.007 196.211 198.416 200.621 202.825 205.030 207.235 209.439 211.644 213.848 216.053 218.258 220.462
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TECH BRIEF showed an efficiency reduction of about 0.8% and minor flow imperfections caused by the scalloped redesign, which were both deemed acceptable by the Sulzer engineers and the customer. In general, all the characteristics of the redesigned impeller remained nearly unchanged from the original design and would not affect the performance of the unit (Figure 3). Based on the results of the redesign, the new, scalloped impeller design was approved for manufacturing. The entire project, including root cause failure analysis, engineering studies and redesign, was completed in 1 4 weeks. Fabrication and testing of the redesigned impeller The redesigned impeller was fabricated and tested within a 20-week period after all studies had been completed. Sulzer in Switzerland manufactured the impeller, making use of their experience and their proprietary technologies for brazing joints of a complex curvature. The new impeller was nondestructively tested after fabrication and after spin testing at 15% above the maximum operating speed. Ring testing was performed on the new impeller stacked on the shaft to confirm modal characteristics (Figure 4). Measured natural frequencies of the impeller appeared to be within 3% of the predicted frequencies, which confirmed the accuracy of the numerical studies and analysis. The study shows that multiple design and operational factors can be responsible for an impeller failure. The contribution of external factors can change depending on unit operating conditions, causing the equipment to fail in a specific mode. A complete redesign of an impeller to mitigate some of the problems identified by the root failure cause analysis can be a very resource-consuming engineering project. Such drastic changes can lead to necessary changes in other components of the machine (e.g., housing, stationary diffuser vanes, shaft), or changes in impeller performance, which affect process requirements. Scalloping can provide an effective solution to alter the impeller modal characteristics without affecting performance if the optimal scallop shape is chosen. CTSS
n Figure 3. CFD analysis confirmed the performance of the redesigned impeller. Impeller redesign procedure Two main factors contributed to the impeller failure: stress concentration at the cover plate fillet and resonance caused by the interference of one of the impeller natural frequencies with the diffuser passing frequency. The goals of the redesign were to reduce the stresses in the cover plate fillet area and to achieve at least 5% separation margin between the impeller natural frequencies and excitation force frequencies. The engineers hoped to avoid future resonance problems regardless of the operating mode. A complete redesign of the impeller could have been performed, but it would have ended up being highly expensive in terms of engineering time and labor. The impeller would have needed multiple design iterations. It would have involved stage housing and stationary components modifications as well as performance revision. In addition, it would eventually have resulted in extended delivery time to the customer and higher modification expenses. To accelerate the redesign process and return the impeller to service as quickly as possible, Sulzer engineers decided to scallop a new impeller to achieve the redesign targets. Scalloping is a machining procedure that removes material from the impeller periphery. Sulzer analyzed and compared various scallop designs to determine the optimal scallop shape based on the following criteria: reduced stress levels, separation between the impeller frequencies and the frequencies of the excitation forces, and minimum scallop depth to maintain performance levels. The cover plate fillet stress concentration, identified as one of the factors contributing to the failure, was significantly reduced with the cover plate scalloping. Also, scalloping both the cover plate and back plate provided significantly better results in terms of natural frequency separation margins obtained. 3-D computational fluid dynamics (CFD) verified the performance of the scalloped impeller. The CFD analysis
2017 EDITION
n Figure 4. After fabrication, the redesigned impeller was tested and fulfilled all requirements.
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COMPRESSOR Dedicated To Gas Compression Products & Applications
PACKAGER GUIDE
2017 www.compressortech2.com
A listing of global compressor packagers, along with primary contact information, types of compressors offered and the capacity range of the packages they produce. If your company is missing from this listing, please contact
[email protected]. A PDF of this listing is available on our website.
2017 EDITION
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Oil-injected screw compressor package with inlet fltration unit
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CP547A
2017 EDITION
CORKEN, INC. • A Unit of IDEX Corporation 3805 N.W. 36th St., O klahoma City, OK 73112 U.S.A. Phone (405) 946-5576 • FAX (405) 948-7343 Website: www.corken.com • E-mail: c
[email protected] @CorkenInc 238
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See corken.com for more information
Operating Specifications: • Horsepower/(kW): 7.5 to 75 (5.6 to 55.9) • Working Pressure: Up to 1,650 psi (113.8 bar g) • Single- and Two-Stage Compression • Air and Water Cooled Models • Double or Triple Packed Configurations • Lubricated and Oil-Free Models
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Industries Served: Process: Chemical and Petrochemical Processing
Energy: Oil and Natural Gas Production Alternative Fuels Refined Petroleum Products 291-107 Compressor Package Unit Model 291 single-stage compressor packaged with a gas engine drive designed for tank maintenance evacuation and emergency evacuation situations. 2017 EDITION
FT491-109F Compressor Package Unit Model FT491 single-stage, flanged compressor packaged with an electric motor drive designed for liquefied gas transfer applications using vinyl chloride, butadiene, and methyl chloride. 239
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COMOTI - Romanian Research & Development Institute for Gas Turbines....................................123 www.comoti.ro
MAN Diesel & Turbo SE ...............................138, 139 www.mandieselturbo.com
Corken Inc. A Unit of IDEX Corporation .........................238, 239 www.corken.com
Mitsubishi Heavy Industries Compressor International ...........................127, 201 www.mhicompressor.com/en
Cozzani, Dott. Ing. Mario Cozzani Srl ...................217 www.cozzani.com
NEUMAN & ESSER GmbH & Co. KG ..........142, 143 www.neuman-esser.com
Cummins Inc. Oil & Gas Markets .............................. Second Cover www.cumminsengines.com/oil-and-gas
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PSE Engineering GmbH Compression Systems ......................Packagers Tab www.pse-eng.de
Dott. Ing Mario Cozzani Srl ...................................217 www.cozzani.com
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SIAD Macchine Impianti S.p.A. Compressors Division .........................................117 www.siadmi.com
Elliott Group ..............................Third Cover, 115, 192 www.elliott-turbo.com
Solar Turbines Incorporated .......... Prime Movers Tab www.solarturbines.com
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FLSmidth Inc. Pneumatic Transport ...................................125, 129 www.flsmidth.com/compressors
Voith Turbo BHS Getriebe GmbH .........................113 www.voith.com/bhs Voith Turbo Inc. .....................................................113
[email protected]
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GEA Refrigeration Italy Oil & Gas .............................................................237 http://gea.com
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ZOLLERN BHW Gleitlager GmbH & Co. KG Plain Bearing Technology ...........................226, 227 www.zollern.com
GPA/GPSA - Gas Processors Association ...................................................... Components Tab https://gpsa.gpaglobal.org/ 2017 EDITION
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World-scale propylene producer, China. Ensure the success of the enterprise’s first PDH project. Elliott Group is selected as the world’s most entrusted PDH compressor supplier.
They turned to Elliott for unparalled experience in olefins compression. Elliott Group has decades of experience in high volume flow olefins compression that meets the most exacting standards. Elliott’s global sourcing capabilities provide world-scale producers with unmatched reliability, efficiency, and value over the life of their investment. Who will you turn to?
C O M P R E S S O R
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The world turns to Elliott. www.elliott-turbo.com
TEMPORARY RELIEF
Take a couple of aspirin and call KOBELCO.
in the morning.
FOR THE CURE
Call KOBELCO first and avoid pain relievers altogether. KOBELCO has been curing gas compressor headaches for almost 100 years. Simply stated, we know compressors. After consulting with you on the required specifications, Kobelco will manufacture a custom engineered compressor package that can be delivered and serviced anywhere in the world. Providing our clients with the best possible solution and service is our top priority.
Kobelco Compressors America, Inc. Houston Office:
[email protected] p. (713) 655-0015 f. (713) 982-8450 • Tokyo, Japan
• Houston, Texas
• Munich, Germany
• Jurong, Singapore
• Dubai, U. A. E.
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I I I I I I I I I I I I I I I I I I I I I I I I I O O O O O O O O O O O O O O O O O O O O O O O O O
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0 7 C C
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0 2 1 C C
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0 5 1 C C
5 7 1 C C
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0 5 2 C C
0 0 3 C C
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0 . 0 . 0 . 0 . 0 . 0 . 0 . 0 . 0 . 0 . 0 . 0 . 0 . 0 . 0 . 0 . 0 . 0 . 0 . 0 . 0 . 0 . 0 . 0 . 0 . 0 . 0 . 0 . 0 . 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2
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s n o t d a o L d o R w e e l b a w o l l A m u m i x a M N b l r
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3 8 3 . 2 . 1 . 3 . 7 . 6 . 4 . 7 . 2 . 6 . 3 . 6 . 3 . 2 . 4 . 7 . 2 . 6 . 3 . 6 . 3 . 2 . 4 . 9 . . 1 . 5 . . 5 2 4 7 0 1 4 7 0 7 2 4 7 0 1 4 7 0 4 0 7 3 1 2 9 1 1 1 1 1 2 2 2 2 3 3 4 4 5 6 6 7 9 1 1 1 1 2 2 2 2 2
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