Centrifugal Compressors For Oxygen Service
Centrifugal Compressors For Oxygen Service
Centrifugal Compressors For Oxygen Service
FOR
OXYGEN SERVICE
AIGA 071/13
Replaces AIGA 071/11
Doc 071/13
CENTRIFUGAL COMPRESSORS
FOR
OXYGEN SERVICE
Disclaimer
All publications of AIGA or bearing AIGAs name contain information, including Codes of Practice, safety procedures and other
technical information that were obtained from sources believed by AIGA to be reliable and/ or based on technical information
and experience currently available from members of AIGA and others at the date of the publication. As such, we do not make
any representation or warranty nor accept any liability as to the accuracy, completeness or correctness of the information
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third parties is purely voluntary and not binding.
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to or use of information or suggestions contained in AIGAs publications.
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information or suggestions contained in AIGAs publications by any person or entity (including AIGA members) and AIGA
expressly disclaims any liability in connection thereto.
AIGAs publications are subject to periodic review and users are cautioned to obtain the latest edition.
Reproduced with permission from European Industrial Gases Association. All rights reserved.
AIGA 071/13
Acknowledgement
This document is adopted from the European Industrial Gases Association document IGC 27/12
Centrifugal compressors for oxygen service. Acknowledgement and thanks are hereby given to
EIGA for permission granted for the use of their document.
AIGA 071/13
Table of Contents
1
Introduction .................................................................................................................................... 1
1.1
General .................................................................................................................................... 1
1.1.1
Objective............................................................................................................................ 1
1.1.2
Other Specifications .......................................................................................................... 2
1.1.3
Terminology....................................................................................................................... 2
1.2
Application of this document ................................................................................................ 2
1.2.1
Oxygen purity .................................................................................................................... 2
1.2.2
Oxygen enriched gases..................................................................................................... 3
1.2.3
Moisture............................................................................................................................. 3
1.2.4
Axial turbo compressors.................................................................................................... 3
1.2.5
Discharge pressure ........................................................................................................... 3
1.2.6
Suction pressure ............................................................................................................... 3
1.2.7
Driver ................................................................................................................................. 3
1.2.8
Maximum operating temperature ...................................................................................... 3
1.2.9
Speed ................................................................................................................................ 3
2.
3.
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3.5.3
Rotor assembly ............................................................................................................... 16
3.6
Seals ...................................................................................................................................... 16
3.6.1
Internal rotor seals........................................................................................................... 16
3.6.2
Atmospheric rotor seals................................................................................................... 17
3.6.3
Bearing housing seal....................................................................................................... 17
3.6.4
Separation of rotor process gas seal and oil seals ......................................................... 17
3.7
Bearings and bearing housings.......................................................................................... 18
3.7.1
Bearing type .................................................................................................................... 18
3.7.2
Thrust bearing size.......................................................................................................... 18
3.7.3
Provision for vibration probes.......................................................................................... 18
3.7.4
Bearing failure - Resultant rubs....................................................................................... 19
3.8
Rotor dynamic analysis, verification tests and data to be provided............................... 19
3.8.1
Summary ......................................................................................................................... 19
3.8.2
References ...................................................................................................................... 19
3.9
Balancing and vibration....................................................................................................... 19
3.9.1
Balancing......................................................................................................................... 19
3.9.2
Vibration alarms and trips................................................................................................ 20
3.10
Insulation and earthing .................................................................................................... 20
4.
Auxiliaries design..................................................................................................................... 21
4.1
Coolers .................................................................................................................................. 21
4.1.1
Scope of supply............................................................................................................... 21
4.1.2
Types of cooler................................................................................................................ 21
4.1.3
Vents and drains ............................................................................................................. 22
4.2
Process pipework................................................................................................................. 22
4.2.1
Extent .............................................................................................................................. 23
4.2.2
Connections .................................................................................................................... 23
4.2.3
Welding............................................................................................................................ 23
4.2.4
Prefabrication .................................................................................................................. 23
4.2.5
Vents to atmosphere ....................................................................................................... 23
4.2.6
Special piping .................................................................................................................. 23
4.2.7
Bellows ............................................................................................................................ 24
4.2.8
Gaskets ........................................................................................................................... 24
4.2.9
Acoustic and thermal insulation ...................................................................................... 24
4.2.10 Silencers.......................................................................................................................... 24
4.2.11 Vaned elbows.................................................................................................................. 24
4.3
Manual valves ....................................................................................................................... 24
4.3.1
Manually operated main isolation valves ........................................................................ 24
4.3.2
Manual valves which form part of the oxygen compressor envelope ............................. 24
4.4
Main suction filter ................................................................................................................. 24
4.4.1
Rating .............................................................................................................................. 24
4.4.2
Materials and design strength ......................................................................................... 24
4.4.3
Flow direction .................................................................................................................. 25
4.4.4
Free area ......................................................................................................................... 25
4.4.5
Precaution against installation errors .............................................................................. 25
4.4.6
Inspection ........................................................................................................................ 25
4.5
Lubricating oil system ......................................................................................................... 25
4.5.1
General............................................................................................................................ 25
4.5.2
Oil pumps ........................................................................................................................ 25
4.5.3
Filter................................................................................................................................. 25
4.5.4
Oil heater ......................................................................................................................... 25
4.5.5
Oil vapour extractor system............................................................................................. 26
4.5.6
Oil tank ............................................................................................................................ 26
4.5.7
Control ............................................................................................................................. 26
4.6
Seal gas system.................................................................................................................... 26
4.6.1
Compressor seal gas system.......................................................................................... 26
4.6.2
Bearing seal gas system ................................................................................................. 26
4.6.3
Schematic diagrams........................................................................................................ 26
4.7
Controls and instrumentation ............................................................................................. 29
4.7.1
General............................................................................................................................ 29
4.7.2
Control system ................................................................................................................ 29
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4.7.3
Anti-surge system............................................................................................................ 31
4.7.4
High oxygen temperature protection ............................................................................... 32
4.7.5
High bearing temperature protection............................................................................... 32
4.7.6
Vibration and shaft position ............................................................................................. 32
4.7.7
Safety shutdown system valves ...................................................................................... 33
4.7.8
Oxygen humidity.............................................................................................................. 34
4.7.9 ............................................................................................................................................... 34
5.
6.
7.
Operation .................................................................................................................................. 41
7.1
General .................................................................................................................................. 41
7.1.1
Combustible matter ......................................................................................................... 42
7.1.2
Machine rubs................................................................................................................... 42
7.1.3
Rotor/bearing instability................................................................................................... 42
7.1.4
Machine vibrations .......................................................................................................... 42
7.1.5
Leaking cooler tubes ....................................................................................................... 42
7.1.6
Gas leakage hazard ........................................................................................................ 42
7.1.7
Compressor surge........................................................................................................... 42
7.2
Safety certificates ................................................................................................................. 42
7.3
Qualifications and training for operating personnel ........................................................ 42
7.4
Hazard area ........................................................................................................................... 42
7.5
Fire drills................................................................................................................................ 42
7.6
Emergency purge and vent systems .................................................................................. 43
7.7
Record of machine operation.............................................................................................. 43
7.8
Tripping devices ................................................................................................................... 43
7.8.1
Operating checks ............................................................................................................ 43
7.8.2
Trip override .................................................................................................................... 43
7.9
Interlock systems ................................................................................................................. 43
7.10
Oil strainers ....................................................................................................................... 43
7.11
Startup procedures........................................................................................................... 43
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8.
Maintenance.............................................................................................................................. 44
8.1
General .................................................................................................................................. 44
8.1.1
Method............................................................................................................................. 44
8.1.2
Functional test ................................................................................................................. 44
8.2
Cleanliness during maintenance ........................................................................................ 44
8.3
Rotor checks ......................................................................................................................... 44
8.3.1
Compressor open for overhaul........................................................................................ 44
8.3.2
Check balance of spare rotors ........................................................................................ 44
8.4
Spare parts ............................................................................................................................ 45
8.4.1
Manufacturer replacements ............................................................................................ 45
8.4.2
Oxygen components ....................................................................................................... 45
9.
10.
References ................................................................................................................................ 46
Figures
Figure 1 Centrifugal oxygen compressor impact force distribution on barrier ........................................ 9
Figure 2 Earthing of compressor shafts................................................................................................ 21
Figure 3 Single shaft gas supply schematic diagram ........................................................................... 27
Figure 4 Geared compressor seal gas supply schematic diagram ...................................................... 27
Figure 5 Centrifugal oxygen compressor system flow diagram............................................................ 35
Tables
Table 1 Minimum instrumentation of oxygen compressors........................................................... 30
Table 2 Failure modes and operating speeds of system valves........................................................... 34
Amendments to AIGA 071/11
Section
2.2.2.3.1
3.3.2
3.4.1.2.1
3.4.1.6
3.5.3
3.6.1.1
4.1.2.5
4.7.1
4.7.5
5.2
5.4.4
Change
Editorial to align style with IHC associations
Clarification of piping systems
Clarification of limitation of use
Addition of Casings and volutes
Clarification of agreements
Clarification of machining element
Change from overhang to overhung
Clarification of which openings
Addition of term first out
Change from white metal to bearing pad
Clarification of responsibilities
Change broken to removed for clarity
AIGA 071/13
Introduction
This document has made a significant contribution to the safe compression of oxygen primarily
because the manufacturers and users have fully and openly shared their philosophies and
experiences. It is recognised by the Working Group members that the feedback of operating
experiences makes a powerful contribution to safe operation and design.
Oxygen compression represents a special risk in that the compressor can burn violently. This
document defines design and operating parameters for centrifugal oxygen compressors. Compliance
with this document can reduce the likelihood of, and the hazards arising from, a fire in a compressor
to a level equal to or lower than those commonly accepted in the air separation industry
The document requires that all those who build and operate centrifugal oxygen compressors that
have been specified to comply with the document should contribute towards it by fully reporting the
circumstances surrounding oxygen fires. For the purpose of safe operation of the compressor and its
auxiliaries the user and the manufacturer shall establish full agreement on the possible and expected
modes of compressor operation (e.g. specified operating points, normal operating range, start-up and
shutdown, etc.)
The industrial gases companies have engaged, through the International Harmonization Council
(IHC), comprised of the Asia Industrial Gases Association (AIGA), Compressed Gas Association
(CGA) and the European Industrial Gases Association (EIGA), Japan Industrial and Medical Gases
Association (JIMGA) in a process of developing harmonized safety practices and this publication is
one of them.
1.1 General
1.1.1 Objective
The objective of this document is to provide guidance on the design, manufacturer, installation and
operation of centrifugal oxygen compressors, thereby safeguarding personnel and equipment. Fire in
an oxygen compressor can be caused by a variety of reasons which include mechanical deterioration
resulting in excessive vibration and/or loss of running clearances within the compressor; ingress of oil
(e.g., through the seal system) or foreign bodies passing through the machine.
An oxygen compressor shall be provided with a safety support system that shall minimise the
development of a potentially dangerous operating condition. In the event of an incident on the
compressor, which results in combustion of the materials of construction, the safety systems shall be
designed to minimise the effect of the fire.
The safe and reliable compression of oxygen using centrifugal compressors can only be achieved by
the successful combination of many factors. The document identifies and addresses these factors:1.1.1.1 Design of the compressor system (Sections 3 & 4)
Robust and well proven compressor design
Stable rotor system
Safe materials in critical areas
Comprehensive instrumentation
Safety shutdown system
Auxiliary system
1.1.1.2 Cleaning, preservation and inspection (Section 5)
Correct and properly enforced procedures carried out by well trained personnel.
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Shall is used only when procedure is mandatory. Used wherever criterion for
conformance to specific recommendation allows no deviation.
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1.2.9 Speed
Speeds shall be according to ref [5] (API 617 Section 1.5 (7th Edition 2002) e.g. Rated Speed, Normal
Speed, Maximum Continuous Speed as well as Trip Speed.
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2. Compressor installation
2.1 Hazard area
2.1.1 Description
The hazard area is defined as the area where an incident is most likely to occur and as a
consequence is capable of causing danger and/or injury to personnel.
Note:
The term hazard area should not be confused with Electrical Hazardous Area Classification.
It is necessary to consider a number of pertinent factors when determining whether or not an area
should be classified as a hazard area. These include:
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panels shall be closed. Routine visual inspection shall be done remotely through approved safety
windows or by using cameras, or other devices.
Before entering the hazard area, after the compressor has been shut down or changed over to dry air
or nitrogen, the atmosphere within the enclosure shall be analysed to ensure that it is safe to enter.
The oxygen concentration shall be between 19.5% and 23.5%. When personnel are within the area,
the oxygen concentration shall be continuously monitored.
2.1.4 Equipment location
2.1.4.1 Equipment that shall be within the hazard area
Compressor casings/volutes;
Suction filter;
Throttling valves and downstream piping to the first elbow or tee e.g. recycle valve;
The first elbow in each pipe to and from the compressor; and
All valves and controls that require manual adjustment while the unit is operating on
oxygen service shall be capable of operation from outside the safety barrier.
2.1.4.3 Equipment that may be either inside or outside the hazard area
If located within the hazard area these valves shall be protected from the effect of the fire with their
own shield;
The gearbox and lube oil reservoir location is determined by the compressor design and equipment
layout;
a. Driver
If the driver is not an electric motor then it shall be outside the hazard area. In
the case of an electric motor drive it is preferred that it should be located outside
the hazard area.
If the motor is located within the hazard area, the safety barrier ventilation should
be arranged in such a way that air from outside the enclosure is drawn across the
motor to ensure that in the event of an oxygen leak an oxygen concentration build
up around the motor is minimized; and.
If located within the hazard area, the number of connections shall be minimized to prevent oil
leaks
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2.1.5 Service pipes and electric cables within the hazard area
If it is not possible to avoid the routing of service pipes and cables through the hazard area then they
should be protected against fire as far as practicable.
2.2 Safety barrier
2.2.1 Purpose
The primary purpose of a safety barrier is to prevent injury to personnel. It has a secondary function
in that it lessens damage to adjacent equipment. A safety barrier achieves the above by preventing
flames, jets of molten metal or projectiles that have caused burn through of any of the oxygen
containing equipment within the hazard area from penetrating or collapsing the barrier in the event of
an oxygen fire.
2.2.2 Responsibilities
It is the responsibility of the user to design and specify the safety barrier. The manufacturer shall
supply any necessary information as required.
2.2.3 Nature of Burn through
2.2.3.1 Likely burn through positions
The majority of fires start in areas of high internal component or gas velocity. Therefore the areas
around the impeller or recycle valve are likely sites. Burn through is most likely to occur at places
close to the seat of the fire where the gas pressure and/or velocity are high and the thermal mass is
low. Therefore the primary risk areas are:
a. compressor casing;
b. compressor shaft seals;
c.
d. first and second bends in the process pipework immediately upstream and downstream of the
compressor flanges;
e. recycle valve and its associated outlet pipe and the first downstream bend
f.
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exceeded. This is a particularly difficult design problem in the case where the safety barrier is also an
acoustic shield.
2.2.3.2.4 High velocity projectiles
The release of pressure and the rotational energy of the rotor accelerate projectiles which either pass
through holes burnt in the casing or rip holes in the casing and go on to hit the safety barrier. The
barrier shall be strong enough to withstand the impact.
2.2.4 Strength and burn through criteria
The barrier shall withstand the force resulting from the impact of a jet of molten metal issuing from a
hole burnt in the compressor or pipe work, hitting the safety barrier, plus the overpressure due to the
release of the stored inventory of the oxygen. The above requires calculation on a case-by-case
basis because it varies with the size and the discharge pressure of the compressor. The minimum
force that the barrier shall be able to sustain is 2 KPa projected over the wall area. This value is
based on the accumulated experience of members of this Working Group.
The barrier shall be designed to resist the effect of a jet of molten steel for 30 seconds without being
breached. (see 2.2.5).
Therefore, the design shall consider the following load types:
sustain temperature of molten metal
blast and overpressure; and
projectile impingement.
2.2.5 Materials of construction
Concrete safety barriers are a very effective way of meeting the strength and burn through criteria
and have been used successfully (see 2.2.4). Experience has shown that the concrete can be badly
damaged - but not breached by the direct impact of molten metal and flame.
Steel structures have been used successfully. The detail design shall ensure a structure which has
no weak point that can be breached by the overpressure or the impact from jets of molten metal or
projectiles. Structural steel members, carbon steel walls, doors and closure plates that are likely to
be exposed to the impact of a jet of molten metal shall be protected by a fire resistant heat shield
The fire resistant heat shield may be a plaster like material which is trowelled on or it can be in the
form of panels. Calcium silicate or shale board has been found to be effective. Not only shall the
material form an effective heat shield but it shall also be mechanically strong enough to resist the
scouring effect of the jet of molten steel. It is for this reason that the rockwool used in acoustic
shields is not acceptable as a heat shield in this application. The fire resistant heat shield shall be
supported so that it is prevented from being broken up by the force of the jet. Field trials by one of the
working group members have shown that a layer of heat resistant material 20mm thick will satisfy the
required burn through criteria.
Inspection ports, if provided, shall be covered with reinforced glass or equivalent and shall meet the
required strength criteria.
2.2.6 Layout of the safety barrier
The barrier shall meet the following criteria:
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Vertical sides shall extend at least 0.6m (2 ft) and 15 degrees in the vertical elevation view
above the height of any part of the compressor or piping that contains oxygen and no less
than 2.4m (8 ft) above the walking area.
The barrier shall block any line of sight to permanently installed platforms or buildings within
30m that have normal traffic or occupancy.
There should be space inside the barrier to allow for normal maintenance.
The design of the safety barrier shall be such that, when all the closure plates are in place
and the doors shut and locked or latched, the wall shall provide a complete unbroken barrier
with no weak spots. Consideration shall be made for emergency egress. Labyrinth entrances
are also allowed as shown in Figure 1.
If the barrier has a roof, ventilation ports shall be located at high level pointing in a safe
direction.
The safety barriers shall be designed to cope with the inventory of high pressure gas that is
released when burn through occurs. If the barrier has an open top or a partial roof this does
not represent a problem. If the compressor is fully enclosed, normally for acoustic reasons,
then sufficient open area shall be provided to avoid over pressuring the enclosure. The
following ways of achieving the required open area are recommended:
Acoustic doors, which are self-opening, hinged so as to have a small angular moment
of inertia.
Concrete or steel caps, which are lifted by the gas pressure, provided that the caps
are adequately restrained.
Note: The open area shall be sited away from the compressor where the hazard is least. The open area shall be
sited in a position so that the operation of the doors and the blast of hot gas shall not cause a hazard to personnel.
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10
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Greater number of seals letting down to atmospheric pressure and in close proximity to the
gearbox;
In general the stable rotor dynamic design of integrally geared compressors is more difficult
to achieve than in single shaft compressors. Therefore additional consideration in the rotor
dynamic design must be taken to provide acceptable rotor stability in oxygen service; and
11
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Contamination:
Oil, improper design of bearings/seals and/or associated vents and drains.
Resonance:
Debris in dead areas.
3.3 Materials: General
3.3.1 Construction materials
Compressor components that come into contact with oxygen shall be selected for their oxygen
compatibility. Materials that fulfil these criteria usually have the following properties:
high ignition temperature;
high thermal conductivity;
high specific heat; and
low heat of combustion.
3.3.2 Use of aluminium
Because of its high heat of combustion the use of aluminium or alloys containing aluminium shall be
limited for oxygen wetted or potentially oxygen wetted parts. However, aluminium will not sustain
combustion below certain pressures and purities. The use of aluminium shall be limited to a pressure
less than or equal to 0.2 MPa gauge for the oxygen purity range covered by this publication.
In addition the maximum permitted aluminium content in a copper alloy is 2.5%.
3.3.3 Oxygen compatibility of non-metallic materials
Non-metallic materials (such as for gaskets, O-rings, lubricants) that have been approved by BAM.
(Federal Institute for Material Testing, Berlin) Ref [7] or ASTM for the relevant oxygen duty are
acceptable. This does not preclude other methods of determining compatibility by other independent
bodies, laboratories and manufacturers.
3.4 Casings, diaphragms, diffusers and inlet guide vanes
3.4.1 Casings
3.4.1.1 Casing allowable working pressure
Calculations shall be carried out to determine the maximum pressure that the casing can experience
during operation. It shall be the highest pressure of the following options that can be reached in the
casing (or subdivision of casings into chambers) multiplied by an agreed safety factor between the
user and the manufacturer.
The maximum operating pressure, at the surge limit resulting from the maximum specified
suction pressure at the maximum continuous operating speed. Agreed deviations from gas
properties and suction temperature are to be considered.
Note:
In some instances a rotor stability test at greater than the maximum design operating pressure is specified. If this is
the case it should be taken into account when specifying the casing allowable working pressure.
The maximum pressure that results from the maximum specified suction pressure and the
greatest pressure rise possible with the given maximum drive power at the maximum
continuous operating speed. Agreed deviations from gas properties and suction temperature
are to be considered.
The maximum equilibrium pressure reached in the compressor system under certain running
or shutdown conditions.
12
AIGA 071/13
If the casing pressure is limited by a safety device set to a pressure agreed between the user
and manufacturer then this pressure can be used as the casing allowable working pressure.
The casing may also be sub-divided into chambers for calculation and testing. In this case,
the maximum possible pressure in these chambers is then to be used as a basis, taking into
consideration the aforementioned aspects.
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14
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3.4.3.2 The design of the variable inlet guide vanes shall take into account
Excitation due to the flow disturbances caused by the stage inlet piping;
The design shall be such that either it is physically impossible for the vanes to go to the fully
shut position or, if the vanes are permitted to go to the fully shut position, there shall be
sufficient flow area to prevent the vanes being overloaded and to dissipate the heat caused
by windage;
The design shall avoid the risk of oxygen leakage to the atmosphere. The use of a seal gas
system is recommended; and
Suitable materials for oxygen service which shall be resistant to impingement and high
velocity of gas
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3.5.2 Shafts
The shafts of centrifugal compressors shall be forged from one piece and checked for defects using
ultrasonic tests. The electrical and mechanical run-outs in the planes of the vibration probes shall be
reduced to 6 micron peak to peak or less during the course of the manufacturing programme.
3.5.3 Rotor assembly
Shaft sleeves are permissible. Components shrunk onto or fitted to the shaft shall be carefully
degreased before fitting.
For single shaft compressors, assembled rotors with shrunk on components shall be submitted to an
over speed run prior to the final rotor balance in order to release all unequal settings of components
on the shaft. Whenever a rotor is rebuilt, over speed shall be considered prior to balancing, see 3.9.1.
Thrust collars shall be machined as part of the solid shaft or positively retained using a locknut, shear
ring or grip enhancement method. The use of a simple interference fit shall not be used.
3.6 Seals
3.6.1 Internal rotor seals
Depending on the type of compressor (single shaft or integrally geared), the internal rotor sealing has
the function of keeping as low as possible the amount of gas leaking between impeller outlet and
impeller inlet and between adjacent stages. Adequate clearances shall be provided between sealing
tips and sealing faces, so that contact is limited to an amount agreed between manufacturer and user
under all operating conditions. The internal seals of an oxygen compressor shall be only of the
labyrinth type. The design and the choice of materials for the tips and sealing faces shall be such that
in the event of contact the least possible amount of heat is developed and the resulting heat is readily
dissipated.
3.6.1.1 Rotating tips
The following materials shall be used:
Stationary face silver layer bonded to a copper alloy or nickel alloy backing
The thickness of the silver layer shall, as a minimum, take into account the shaft movement that will
occur in the event of;
The silver shall be of such a thickness that the rotating tip will not cut through the silver layer and
touch the copper alloy or nickel alloy backing.
The above criteria apply to both radial and axial labyrinths. It is important with this type of seal that the
tips and the silver are designed in a way that ensures that the tips cut satisfactorily into the silver face.
Silver has shown itself to be a very safe material for use in seals. Experience has shown that it is safe
to permit the rotating tips to cut into the stationary silver face during rotor excursions that occur during
start-up and surge. The amount of cut in shall be agreed between manufacturer and user.
For overhung impellers, e.g., gear type compressor, the benefits of a silver counter face are well
established in seal design. However, rotating labyrinth running against silver stationary counter face
can lead to violent rotor excursions in the event of rub.
16
AIGA 071/13
Stationary tip silver mounted on copper alloy or nickel alloy base; and
The stationary tip shall be of sufficient width to provide adequate strength and of sufficient height to
prevent contact between the rotating shaft and the stationary copper or nickel alloy base in the event
of a rotor excursion due either to a bearing failure or rotor instability. This criteria applies to both
radial and axial labyrinths.
3.6.2 Atmospheric rotor seals
3.6.2.1 Function
The function of the atmospheric sealing is to preclude the possibility of any escape of oxygen out of
the compressor as well as the possibility of the introduction of air or oil via the seal.
The seal must be effective during all operating conditions including standstill, start-up and run down,
see 4.6.
3.6.2.2 Compressor atmospheric rotor seals - Labyrinth type
The atmospheric rotor seals shall be of the labyrinth type which is the only type of seal permitted by
the document except under exceptional circumstances (see 3.6.2.3). With respect to design,
materials and clearances this type of seal shall comply with 3.6.1.
At least 3 sealing chambers shall be provided. The inner chambers are connected to the suction in
order to reduce the differential pressure across the seal to a minimum. The centre chamber is for
venting or exhausting. The outer chamber is for the supply of seal gas.
It is an important safety feature and therefore a requirement of the document that the internal
pressure of outer and centre seal chambers can be measured. The method of achieving this should
be to provide separate measuring connections close to the seal chambers to ensure that the pressure
measurement is affected as little as possible by the gas flow in the seal system. If the design of the
compressor makes it impossible to fit separate measuring connections, when that it is agreed
between the manufacturer and the user, it is acceptable to measure the pressure away from the seal
chambers provided that the pressure drop due to flow between the seal chamber and the measuring
point is insignificant compared to the pressure being measured. The manufacturer shall provide
pressure drop calculations at seal clearances which are four times design. In the case of design
clearances which are zero or negative the above calculation shall be based upon on clearances
agreed between the manufacturer and the user.
3.6.2.3 Compressor atmospheric rotor seals - Alternative types
There are certain applications such as pipe line compressors where the use of labyrinth seals
presents operating difficulties. Other types of seals may be considered as agreed between the
manufacturer and the user.
3.6.3 Bearing housing seal
The function of this seal is to prevent oxygen from getting into the oil system and to prevent oil vapour
escaping from the oil system. There are no special oxygen requirements. A labyrinth seal using
normal seal materials has proved satisfactory.
3.6.4 Separation of rotor process gas seal and oil seals
As contamination of the process gas seals by oil and/or oil mist as well as oxygen into the lubricated
parts can lead to major safety hazards, precautions shall be taken to avoid such situations.
17
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two non-contacting shaft vibration probes at right angles to one another on or near each high
speed bearing and
18
AIGA 071/13
The partners in the rub shall be any combination of silver, copper alloy, nickel alloy, high alloy
steel, e.g., a cast iron to low alloy steel rub is not permitted, and
At the rub site there is high heat capacity and good heat transfer.
At the design stage the manufacturer shall supply a table of clearances and materials that
demonstrates that the above requirements have been complied with.
3.8 Rotor dynamic analysis, verification tests and data to be provided
3.8.1 Summary
An important contributor to the safe compression of oxygen is a well-designed compressor and an
important aspect of the compressor design is a stable and well damped rotor system. An unstable
rotor results in high vibrations and large rotor deflections, which in turn cause high speeds rubs which
are a prime cause of oxygen fires. It is for this reason that the document emphasises the need for
detailed mathematical modelling of the rotor system over the whole range of expected operating
parameters followed by tests in the workshop or field to verify that the rotor system is satisfactory.
3.8.2 References
This document basically follows internationally recognised standards and practices API 617 (7th
Edition 2002) Ref [5] item 2.6 shall be used as the basis including testing and acceptance criteria,
with the exceptions and clarifications given as follows.
For compressors with rigid coupling, train analysis shall always be performed (API 617 Item
2.6.2.6) Ref [5].
An internal rub on an oxygen compressor is of much greater importance than on, for
example, an air compressor since it represents a possible source of ignition. For this reason
the maximum amplitude of any component within the oxygen envelope shall not exceed 75%
of the internal clearance when the displacement at the probe location is at the trip level
according to 3.9.2 (API 617 Item 2.6.2.12).Ref [5]
Additional testing is proposed when either safety margins or clearance requirements have not
been met. Since stable rotor-dynamics are essential for an oxygen compressor any failure to
meet the design requirements must be rectified to meet the requirements of 3.8.
Due to their physical nature any responding shaft vibrations that occur can always be related to
forced, to self-excited or to parameter excited vibrations. The sources of these vibrations and their
effects on the rotor system shall be analysed by calculations, if they are expected to occur in the
actual design.
3.9 Balancing and vibration
3.9.1 Balancing
High speed balancing shall be considered on all rotors of single shaft compressors running above
their first bending critical. The first bending critical is the mode in the real rotor system corresponding
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AIGA 071/13
to the first critical of the same rotor in rigid bearings. The assembled rotors shall be balanced at their
maximum operating speed. Balance corrections shall be done according to the mode shapes without
any unallowable influence of the low speed balanced quality according to Ref [6] (ISO 1940]
The acceptance criteria to be met for the high speed balancing shall be as follows:
The bearing pedestal vibrations shall be in accordance with Ref [8] (ISO 10816) and shall not exceed
the following limits:
At critical speeds = 4.5 mm/s (RMS)
within the operating speed range (from minimum operating speed to maximum continuous
speed) v rms = 1.8 mm/s
up to and including trip speed = 4.5 mm/s (RMS)
The relative shaft vibrations in normal operating conditions shall be in accordance with API
617 item 2.6.8.8
3.9.2 Vibration alarms and trips
There is no recognized rule for setting alarm and trip levels. Many operators base the setting upon
the actual running levels achieved in operation. Unless otherwise specified by the manufacturer of the
compressor, the values set out below are based on API 617 [5] and should be regarded as maximum
levels provided that these levels are below 75% of the nominal clearance.
Where:
Nmax = max continuous speed (rpm)
A=Amplitude of unfiltered vibration in micron peak-to-peak
3.10 Insulation and earthing
Great care shall be taken to insulate and earth the electric drive motor correctly to prevent currents
circulating through the compressor which, experience has shown, can damage the bearings,
couplings, and gear teeth. This phenomenon can occur in all types of compressor but special care is
required in the case of oxygen compressors because the consequence of bearing damage could be a
fire. Earthing of the compressor shafts is an optional requirement of the document.
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AIGA 071/13
21
AIGA 071/13
There is no simple way of checking its cleanliness in the field.
The following procedure has been found to work well and is recommended:
clean for oxygen service, assemble the cooler completely and seal all openings with heavy
blanks in dedicated workshop; and
ensure that the blanks are only removed under the supervision of the designated person,
(see 6.1).
If the cooler shell is made of carbon steel or cast iron the parts which are in contact with oxygen shall
be preserved and protected against corrosion. Furthermore:
zinc coating, in this application is permitted by the document, with the provision that good
adherence is assured by compliance with the following conditions:
if zinc coating is used, the preferred thickness of the zinc is between 200-600 micron
but a greater thickness is acceptable if good adherence has been verified.
22
AIGA 071/13
4.2.1 Extent
The recommendations contained in this section shall be limited to the piping directly associated with
the oxygen compressor and included within the oxygen compressor unit. In general terms this is the
oxygen compressor envelope which is limited to the piping downstream of the suction isolating valve
and will include the inlet filter system, all piping between the compressor and non-integral coolers,
bypass valves and associated piping and discharge piping from the compressor through to the outlet
shut-off valve.
4.2.2 Connections
All connections 40mm nominal bore or larger shall be flanged or welded.
4.2.3 Welding
The use of backing rings is forbidden. The root runs of all butt welds shall be made by a method that
will minimise slag formation, a suitable method would be gas shielded arc welding. The welds shall be
smooth and of regular form. Any slag or weld droplets shall be removed.
Welding checks shall be carried out. The methods and extent shall be agreed between the
manufacturer and the user.
4.2.4 Prefabrication
To reduce the possibility of contamination on site due to ingress of moisture and dirt, oxygen piping
should preferably be prefabricated except for the closing ends. All ends shall be suitably capped prior
to dispatch to site.
4.2.5 Vents to atmosphere
Vent outlets shall be directed away from personnel and shall be located so that a concentration of
oxygen is avoided. In the case of continuous vents, it is recommended that a dispersion calculation is
carried out. The vent line is continuously exposed to the atmosphere and shall therefore be
constructed of corrosion resistant material. The design of the pipework shall preclude the
accumulation of water, Ref [11].
4.2.6 Special piping
Piping downstream of a recycle or dump valve shall be considered as a pressure letdown station and
shall meet the requirement according to 4.2. The material selection for the recycle valve and the
dump valve as well as the downstream piping shall be agreed between the manufacturer and the
user.
A type of pressure reducing system which has proved satisfactory is the use of a matched
combination of a valve plus a static pressure reducing device. This is typically either a multi hole
radial diffuser or a multi plate axial diffuser. In this system the pressure let down is shared between
the valve and device and it is normally designed so the velocity in the pipework downstream of the
device is sufficiently low to permit the pipework to be made of carbon steel.
Note: The velocity in the individual diffuser holes will be sonic and the materials used shall take this into account. It is
recommended that the valve and pressure-reducing device be purchased as a matched pair from the same supplier.
Whatever solution is chosen shall result in a low noise and low vibration pressure reducing system.
The recycle system shall be designed to pass 120% of the surge flow or 100% of the rated flow,
whichever is the greater, at all operating conditions up to the maximum continuous speed. The
recycle system, except for the special pressure reducing section described above may be made of
carbon steel provided that the velocities comply with the limits specified in AIGA 021 [2 ]. This
includes the point of entry to the main suction line and the main suction line itself.
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AIGA 071/13
The entry of the recycle stream into the suction line shall be upstream of the suction filter. In order to
prevent damage to the suction filter the distance between the entry point and the suction filter shall be
not less than twice the diameter of the suction piping.
4.2.7 Bellows
Bellows shall be entirely of metallic construction and made from corrosion resistant materials. They
shall have a smooth inner sleeve to reduce turbulence and dust accumulation. Before assembly of the
sleeve the inside of the corrugations shall be inspected for cleanliness.
4.2.8 Gaskets
Refer to 3.3.3
4.2.9 Acoustic and thermal insulation
Pipe external acoustic and thermal insulation material shall be compatible with oxygen at atmospheric
pressure. Care shall be taken to ensure that the pipe insulation is sealed against the ingress of oil
vapour. The material used shall be agreed by the manufacturer and the user. Pipe internal insulation
is not permitted by the document.
4.2.10 Silencers
Silencers are forbidden in the recycle or interstage pipework. It is preferred that silencing of the
suction is achieved by insulating the suction pipe but if this is not practical then the use of suction
silencers is permitted. Suction silencers, if fitted, shall be located upstream of the suction filter. The
silencer shall be manufactured using oxygen compatible materials and the design shall be so that the
possibility of the internals breaking up is prevented.
4.2.11 Vaned elbows
Vaned elbows are permitted by the document. They shall be treated as impingement sites and
therefore if fabricated in carbon steel shall comply with the impingement site velocity criteria
according to 4.2. The formation of internal slag shall be precluded by the use of a welding procedure
that uses inert gas shielding. The design of the vaned section shall facilitate post fabrication oxygen
cleaning and inspection.
4.3 Manual valves
4.3.1 Manually operated main isolation valves
The manually operated main isolation valves are not covered by this document. Refer to 4.2
4.3.2 Manual valves which form part of the oxygen compressor envelope
Manual valves which form part of the oxygen compressor envelope, but which cannot be operated
while on oxygen and not in oxygen flow path, which therefore will not experience high velocity oxygen
may be made of carbon or low alloy steel. Valves which can be operated on oxygen shall be made of
copper alloy, nickel alloy or stainless steel, e.g., low point drains and instrument root valves.
4.4 Main suction filter
A filter shall be provided in the main suction line as close as practicable to the machine inlet flange. It
shall be installed before startup and remain throughout the lifetime of the machine.
4.4.1 Rating
The filter rating shall be capable of capturing all particle sizes larger than 150 micron maximum.
4.4.2 Materials and design strength
Refer to 4.2
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AIGA 071/13
25
AIGA 071/13
26
AIGA 071/13
STOP COMPRESSOR
STOP AUXILIARY
OIL PUMP
STOP COMPRESSOR
STOP AUXILIARY
OIL PUMP
STOP COMPRESSOR
STOP AUXILIARY
OIL PUMP
STOP COMPRESSOR
STOP AUXILIARY
OIL PUMP
PDALL
PDALL
PDALL
PDALL
PDAL
PDAL
PDAL
PDAL
PDI
PDI
PDI
PDI
TO MACHINE SUCTION
SAFETY O/S
BARRIER I/S
O/S SAFETY
I/S BARRIER
OXYGEN LEAKAGE FROM SEALS
BALANCE PISTON
LEAKAGE TO LOWER
PRESSURE LOCATION
IF ANY
BALANCE PISTON
LEAKAGE TO LOWER
PRESSURE LOCATION
IF ANY
L.P.
CASING
H.P.
CASING
Y
Y
PAL
PAL
PI
PLL
I/S SAFETY
O/S BARRIER
PI
VENT TO
SAFE LOCATION
COMPRESSOR
SEAL GAS
START PERMISSIVE
AUX.PUMP PERMISSIVE
STOP COMPRESSOR
THE DIAGRAM SHOWN IS SUITABLE FOR ELECTRIC MOTOR DRIVEN COMPRESSORS WITH
SUCTION PRESSURES OF LESS THAN APPROX. 0.2MPAG. MODIFICATION MAY BE NEEDED
FOR APPLICATIONS INVOLVING TURBINE DRIVE AND OR HIGHER SUCTION PRESSURE.
PDI
F. O.
BEARING
SEAL GAS
FILTER
Safety Barrier
PDALL
PDALL
PDAL
PDAL
PDT
PDT
O/SB
I/SB
ATMOSPHERIC
VENT
O/SB
Safety Barrier
I/SB
OIL
SEAL
Safety Barrier
OIL
SEAL
I/SB
BEARING
O/SB
START PERMISSIVE
AUX PUMP PERMISSIVE
STOP COMPRESSOR
PALL
PAL
PAL
BEARING
OIL
SEAL
PI
OIL
SEAL
PI
PDI
SEAL GAS SUPPLY
DRY OIL FREE AIR
OR NITROGEN
DRAIN
TO MACHINE SUCTION
Safety Barrier
I/SB
O/SB
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AIGA 071/13
monitor the differential pressure between the seal inner chamber and seal centre
chambers; and
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Table 1 Minimum instrumentation of oxygen compressors
Function
Indicator
Alarm
Trip
1.0
Oxygen
1.1
Lo
1.2
(Hi)
1.3
(Hi)
1.4
(Lo)
1.5
Hi
Hi
1.6
1.7
Compressor flow
2.0
2.1
Lo
2.2
Lo
Lo
2.3
(Lo)
3.0
3.1
()
(Lo)
4.0.
4.1
(Hi)
4.2
Lo
Lo
4.3
Lo
4.4
Hi
(Hi)
4.5
Hi
(Hi)
4.6
Lo
(Lo)
5.0
5.1
Hi
Hi
5.2
Hi
Hi
6.0
Miscellaneous
6.1
Hi
6.2
Surge detection
NOTES
-
= not required
Hi, Lo = mandatory
(), (Hi), (Lo) = recommended
1.
2.
3.
4.
30
Interlock
(Lo )
Lo
(Lo)
AIGA 071/13
Operation of quick acting valves downstream of the compressor may be a potential cause
of surge and for this reason the entire anti-surge control system shall have a fast response
time;
The recycle valve and its associated downstream pipework shall be designed for
continuous operation;
If operation close to surge is required the effects of changes of pressure and temperature
(gas and cooling water) on the surge characteristic should be considered;
The position of the suction throttling device relative to the recycle line (see diagram
4.7.11). If the device is positioned downstream of the recycle line then it shall be equipped
with a mechanical minimum opening stop so that there is still sufficient flow area to allow
the anti-surge system to be effective;
There is no simple algorithm which describes the position of the surge line of a multistage,
inter cooled centrifugal compressor under varying conditions of capacity control, suction
and cooling water temperature. The complexity of the modulating anti-surge system
depends upon how close to surge it is intended to operate, how wide the variation in
operating conditions are; and how severe the potential system upsets are;
The anti-surge control line shall be set at least 8% by flow (at the design operating
pressure) from the surge line and the following verifications shall be done:
o
The manufacturer shall calculate the surge points depending on site conditions
(i.e. varying inlet and cooling water temperatures). These predicted surge points
shall be checked on site over as wide a range as possible.
When the surge map has been produced an anti-surge controller shall be
designed to fit the surge map.
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AIGA 071/13
o
Consideration should be given to fitting a device which senses the rate at which
the compressor is approaching surge and, if this is greater than a predetermined
value then the recycle valve is opened a preset amount. The subsequent action
depends upon the design of the system.
Note:
It is considered acceptable to use the main plant control computer (DCS) to carry out the anti-surge control functions
provided that it can meet the above speed requirements and that it is as secure as a separate stand-alone controller. No
delays, other than those required to combat transient electrical disturbances, shall be permitted.
ensure that the sensing device does not restrict the movement of the pad(s).
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AIGA 071/13
The measurement point should form an integral part of the shaft.
4.7.6.1.3 Keyphaser
Provision shall be made to fit a keyphaser probe on each high speed shaft.
4.7.6.2 Gearbox
High speed parallel shaft of separate gear boxes shall have probes as the compressor (see
4.7.6.1.1).
Epicyclic gearboxes shall be fitted with an accelerometer based alarm and trip system.
4.7.6.3 Vibration probe monitoring system
The unfiltered output of at least one radial probe per location and the output of all axial probes shall
be monitored continuously.
The time delays built into the alarm and trip system shall be reduced to a practicable minimum.
Failure of the system shall give an alarm.
Provision shall be made for the connection of vibration frequency analysis and phase displacement
measurement equipment.
If starting on inert gas then a manual or time delay startup override is acceptable. If starting on
oxygen then the trip system shall remain live and starting can be achieved using a trip multiplier
during the run up period.
4.7.7 Safety shutdown system valves
4.7.7.1 Purpose
The purpose of the safety shutdown system is to isolate the oxygen compressor and dump the
oxygen inventory and minimize the consequences of a possible fire.
The system shall consist of the following valves:
automatic suction isolation valve;
discharge non return valve;
automatic discharge isolation valve;
high pressure and low pressure (if required) dump vent; and
recycle valve.
The failure modes and operating speeds should be as shown in Table 2 and their position in the
system according to the Figure 5
If the low pressure coolers are gas in shell then a Low Pressure dump vent is sometimes required to
meet the requirement of reducing the discharge pressure to 0.1 MPa in 20 seconds, (see 2.4.2).
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AIGA 071/13
Valve action
Valve duty
On
Compressor
Shutdown
On Loss of
Control
Signal
On Loss
of
Electrical
Signal or
Motive
power
Shut
Not
Applicable
Shut
Automatic Suction
(1)
isolation valve
Automatic Discharge
isolation valve
Shut
Shut
Not
Applicable
Open
Not
Applicable
Speed of action
10 sec
(2)
10 sec
(2)
(3)
. (4)
2 sec.max
Intermediate dump
vent (if fitted)
Open
Not
Applicable
Recycle valve
Open
Open
Open
(4)
Shut
2 sec.max
Open
2 sec Max.
1.
For normal shutdown, the automatic suction valve can remain open if the suction pressure is < 0.1 MPa
2.
The (maximum) time given above for closing the isolation valves shall be adjusted so that the dump vent valves
and recycle valve have opened first.
3.
If the valve loses supply it will fail into the correct position for isolating the compressor and may lead the
compressor toward surge. However, the compressor is protected against surge according to 4.7.3
4.
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AIGA 071/13
35
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5. Inspection and shipping
5.1 Introduction
Compressors can be shipped from suppliers works either as fully assembled, and tested, oxygen
clean units or as separate components to be erected on site. This can include site fabricated piping.
Any combination between the two above extremes is also possible.
5.2 Responsibility
Whatever the extent of prefabrication, there shall be a designated person responsible for ensuring
that the compressor is correctly built. On request, the manufacturer or their representative shall
provide from his staff an experienced oxygen compressor erector, who will be in charge of the unit
until it is handed over to the user. It can be seen however that, if units or subassemblies are brought
to site cleaned, tested and sealed, then the designated persons responsibilities extend back to the
manufacturers and major sub suppliers works.
5.3 Inspection and cleanliness standards
Cleaning methods and acceptance criteria to be followed shall be those shown in AIGA 012 Cleaning
of equipment for oxygen service Ref. [3].
The criteria clean for oxygen service shall apply to:
All parts that come in contact with oxygen; and
Systems that supply gas to the oxygen compressor (e.g. startup gas) to the extent that the
gas supplied is free of particles and hydrocarbons.
5.4 Preservation of oxygen cleanliness during shipping and storage
5.4.1 Equipment
All equipment sent to site clean for oxygen service shall be protected against contamination and
corrosion. A label stating, cleaned for oxygen service shall be visible from outside the package.
The size and complexity of the equipment being shipped dictates the appropriate method of
preservation.
5.4.2 Individual components
Individual items such as valves, regulators, filters etc which are being shipped separately shall be
protected, either by sealing within a strong clean plastic bag or for smaller components by vacuum
wrapping.
Note:
If the component requires protection against rusting then the plastic bag shall contain bags of desiccant with a colour
change additive to detect moisture.
AIGA 071/13
Rust protection can be provided by one of the following means:
Bags of desiccant, which contain colour change additive to detect moisture, shall be attached
to the inside of appropriate opening covers and elsewhere within the subassembly as
required. The number and position of the desiccant bags shall be painted on the
subassembly exterior; or
Pressurising the subassembly with dry oil free nitrogen. The subassembly shall be fitted with
a pressure gauge and have a notice painted on it warning that it is pressurised.
Colour change type moisture detectors shall be fixed to the inside of selected opening covers to give
confirmation that the preservation measures have been effective.
5.4.4 Arrival on site
When oxygen clean components and subassemblies arrive on site the preservation arrangements
shall only be altered or removed with the approval of the designated person.
If the preservation is found not to be intact and if the moisture detectors, if fitted, have changed colour
then the subassembly shall be opened for inspection and recleaned until the designated person is
satisfied that the equipment is clean for oxygen service.
6. Erection and commissioning
6.1 Erection
6.1.1 Responsibility
(See Section 5)
The increased emphasis on packaged compressors means that the responsibility for the correct
erection and the maintenance of cleanliness of the compressor system may well extend back to the
manufacturers and major sub-suppliers works. Section 5.3, applies to the cleanliness standards
throughout the erection of the compressor unit. The designated person shall keep a chronological
record showing who carried out the main assembly work and who took the as built measurements
and carried out the testing. This applies even if the person concerned came from another firm. It is
also recommended that he keeps an Oxygen Cleanliness Log which records the time, person and
place that each part of the oxygen circuit, including the gas feeds to the compressor were approved
as clean for oxygen service. It should also record the inspection method used, e.g. ultra violet light,
solvent analysis, etc.
The compressor should remain under the direction of the manufacturer until the provisional handing
over has occurred. This normally takes place after a successful initial oxygen run.
6.1.2 Clearances
All axial and radial clearances between stationary and rotating parts of the compressor shall be
measured and the results recorded during preparation in workshop or during erection at site.
6.1.3 Prevention of undue forces
To prevent undue forces being imposed on the compressor all joints shall be assembled without
undue stress. Flanges shall be parallel and correctly aligned. This requirement applies to each
flange of the compressor and the pipework.
6.1.4 Tools
The tools, appliances and measuring devices used during installation and assembly of the
compressor and auxiliary equipment which come into contact with oxygen shall be cleaned with a
suitable cleaning agent. Tools for the lubricating oil system or other parts of the machine shall not be
used for oxygen carrying components. Only lint free cleaning cloths shall be used. When using lifting
tackle, any contamination by oil from the ropes, gears or other sources of lubrication shall be
prevented.
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AIGA 071/13
6.1.5 Hazard area
At an appropriate stage of erection the hazard area shall be declared a clean area and access
restricted to authorised personnel only. All personnel entering the clean area should wear clean
shoes or overshoes and clean overalls without pockets. Personnel shall be instructed in the need for
cleanliness.
6.1.6 Oil flushing
Flushing of the lube oil system shall not be carried out unless the seal gas system and its associated
interlocks with the lube oil system are fully functional. It is recommended that the lube oil system be
checked for leaks during flushing by raising the temperature of the oil slightly above its normal
operating point.
6.1.7 Foundation sealing
In order to prevent oil impregnation, the foundation of the compressor and associated equipment
should be properly sealed prior to the commissioning of the lube oil system.
6.1.8 Purging after assembly
Once the compressor has been closed up, an oil-free, dry, non-flammable gas purge shall be
maintained in the compressor via the labyrinth seals and at other points (e.g., coolers, piping,
gaseous drain points) as necessary to ensure that a non-corrosive atmosphere is maintained in the
machine.
6.2 Testing and commissioning
6.2.1 Introduction
High energy costs ,high site costs and the ability of manufacturers to test at full power in their works
complete compressor assemblies in their contract configuration has meant that in some instances the
best option is to ship from the manufacturers works as a complete fully tested, oxygen clean
compressor system. However, in other instances the best option is to site erect and site fabricate the
compressor system.
It can be seen from the above that the section on testing must be flexible enough to cope with widely
different circumstances. It is for this reason that the document now stipulates what objectives the
testing shall achieve, and the type of test and readings that shall be taken to meet the objective. It
does not stipulate where and in what order the testing shall be done.
6.2.2 General
Any instrumentation required for testing the machine, e.g., pressure gauges, flow meters should only
be used for this duty. When they are used on site they shall be specifically cleaned and marked FOR
OXYGEN USE ONLY. All parts which are normally under pressure including the instrumentation, gas
and oil pipework shall be subjected to a pressure test, unless specified elsewhere in the document.
The type of test and test pressure shall be agreed between the manufacturer and the user.
6.2.3 Testing objectives
It is not permitted to put the compressor into oxygen service unless the testing has achieved the
following objectives:
Demonstration of the mechanical integrity of the complete compressor system over the
predicted operating range;
Verification of the rotor dynamic prediction and the stability of the rotor;
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AIGA 071/13
Flow
Suction Pressure
Design
Speed
Discharge pressure
Flow
Min. to Max.
Suction pressure
Design
Discharge pressure
Speed
Min. to max.
Oil temp
Max. to min.
Duration
As required
39
AIGA 071/13
*Note:
To test the stability of the rotor it might be required to run on a safe gas just below the relief valve set pressure or at a
higher molecular weight to give an equivalent density.
It is assumed that all the instruments have already been calibrated and loop checked.
6.2.7.3 Test to be carried out with the compressor running
AIGA 071/13
Check the operation of the dump vent and isolation system and check that the discharge
pressure falls to 0.1 MPa g in 20 seconds.
The entire compressor system has been certified clean for oxygen service.
There is satisfactory proof that the pipeline upstream of the compressor has been cleaned for
oxygen service. This can be demonstrated by blowing through with dry air upstream of the
filter at a velocity not less than normal operating velocity for a period of several hours. This
blow through shall be vented upstream of the suction filter and as close to it as possible.
The hazard area is clean and free from all combustible materials and that the safety barrier
that surrounds the hazard area is complete and fully functional.
41
AIGA 071/13
7.1.1 Combustible matter
Dust, oil, grease and other forms of combustible matter readily ignite in oxygen.
7.1.2 Machine rubs
Rubs in a machine can cause ignition, due to localised high temperatures being generated.
7.1.3 Rotor/bearing instability
Rotor or bearing instability can cause large shaft deflection leading to dangerous rubs.
7.1.4 Machine vibrations
Machine vibrations due to misalignment, rotor unbalance, gearing defects, etc can cause bearing
failures, subsequently leading to rotor rubs.
7.1.5 Leaking cooler tubes
Leaking cooler tubes result in rusting in the casing, forming a dust nucleus for ignition.
7.1.6 Gas leakage hazard
Leakage and accumulations of gases can occur without operators being aware. Any source of open
flame or ignition can cause a fire in operators clothes which may be saturated with oxygen. Oxygen
deficiency can cause asphyxiation.
7.1.7 Compressor surge
Surge is a cause of strong vibrations and excitation of the shaft and impellers that can lead to rubs
and mechanical failure which in turn can cause a fire.
7.2 Safety certificates
When the responsibility for the machine changes hands, from the manufacturer to the user, operator
to maintenance personnel, etc., a certificate is required confirming that the machine is in a suitable
condition.
7.3 Qualifications and training for operating personnel
The operating personnel should have special training in machine operation and should be fully aware
of the special significance to be attached to variation in instrumentation readings.
Certain knowledge of the machine construction is necessary to fully understand the importance of
oxygen safety. Every opportunity should be given for operating personnel to maintain close liaison
with the machine manufacturers engineers during erection and maintenance.
7.4 Hazard area
If it is considered necessary to enter the hazard area for the analysis of defects when the machine is
operating it must first be changed over to dry clean air or inert gas. It should be noted that, in the
vicinity of the hazard area, both an oxygen enrichment and an oxygen deficiency can occur, due to,
for example leaking flanges or defective seal systems. The oxygen concentration shall be between
19.5% and 23.5%.
7.5 Fire drills
All personnel whose work is associated with an oxygen compressor installation should be instructed
in the special hazards involved. The difference between fire in an oxygen enriched atmosphere
(more than 23.5% oxygen) in contrast to fire in ordinary air, should be emphasised. The person in
charge in the event of an incident should be known. Instructions should be augmented by frequent
drills so action can be taken immediately on the occurrence of a hazard condition. The local fire
fighting authority should also be aware of these considerations (See 2.4).
42
AIGA 071/13
7.6 Emergency purge and vent systems
If an emergency inert purge system that may be operated from pressurised storage systems is
installed it should be regularly checked to ensure that adequate gas supplies are available.
7.7 Record of machine operation
The manufacturers commissioning engineer shall prepare a log of normal operating conditions,
derived from commissioning and design data, and this shall form the basis of the log sheet for use by
operating personnel.
Log sheets should be regularly compiled for the machine. If automatic logging is used it is still
essential that the log sheet be regularly scrutinised at least once per shift by the supervisor.
A record of the number of machine starts and hours run shall be kept.
7.8 Tripping devices
7.8.1 Operating checks
The operation of tripping devices, control valves and check valves, should be checked on routine
shutdowns, by actuating such trips, valves, etc. where this can be done without affecting the safety of
the machine and/or installation.
7.8.2 Trip override
Permanent trip overrides shall not be used. Temporary override is allowed during startup sequences
and other exceptional circumstances provided that such situation is supervised and agreed. Where a
machine is shutdown by one of its protective trip functions it shall not be restarted until the reasons
have been fully investigated.
7.9 Interlock systems
Operators shall be familiar with the principles and operations of any interlock system installed.
7.10 Oil strainers
Regular attention shall be paid to routine examination of oil strainers and magnetic filters if installed.
All oil spillage occurring from filter examination should be thoroughly cleaned up immediately and
prevented from spreading.
7.11 Startup procedures
Routine operation of an oxygen compressor can require shutdown and subsequent startup as a
normal procedure. The decision as to whether to start up directly on oxygen or on dry, clean air or
inert gas shall be taken by the user.
Caution: There shall be no startup of a machine after a trip without a pre-established procedure
Dry clean air or inert gas shall be used for start-up on the following occasions:
start-up of a new machine after erection;
start-up of a machine after maintenance of the following type:
o maintenance that has necessitated the purging of the machine with dry clean air or
inert gas;
o replacement of bearings;
o resetting of the anti-surge control system; and
o startup of a machine after prolonged standstill.
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Dry clean air or inert gas or oxygen is permissible for start-up on the following occasions:
startup as a normal procedure after a planned shut-down;
startup of an operational stand-by machine previously on oxygen service; and
startup of a machine after maintenance, except the types of maintenance under 7.11.1.
8. Maintenance
8.1 General
8.1.1 Method
Because of the possible consequence of a breakdown while a centrifugal compressor is in oxygen
service, its maintenance should be to the highest possible standards. To achieve these standards
maintenance personnel should be properly trained and careful records should be kept of all
maintenance work undertaken.
The frequency and content of maintenance work should be agreed between the manufacturer and the
user. In the event of adverse trends being observed in machine operation the machine should be
shutdown for examination and remedial action taken. Regular and detailed analysis of the running
data is of the utmost importance in ensuring the safe operation of the compressor. This data can be
used as a guide in establishing the period between major overhauls.
It is not possible to state a precise period between major overhauls which covers all circumstances.
The period will depend upon the following:
manufacturers recommendations;
number of hours run;
number of starts, since the last overhaul; and
previous operating behaviour and history.
It is recommended that the manufacturer be involved in major maintenance or repair work. The
requirements and standards covered in Section 6 shall be complied with.
Note:
It has been noted that a number of fires have occurred immediately after overhauls. It is therefore recognised that
internal inspections could also be the cause of an increased risk.
AIGA 071/13
precaution is important for rotors that have been in storage for more than 1 year and particularly for
rotors with shrunk on components.
8.4 Spare parts
8.4.1 Manufacturer replacements
It is recommended that replacements for all parts originally manufactured by the machine
manufacturer should be purchased from the manufacturer. All other replacement parts should be in
accordance with the manufacturers specification.
8.4.2 Oxygen components
All components that come into contact with oxygen gas should be preserved as specified in 5.4.
Balancing certificates, etc., included with spare rotors should be transferred to the operators
maintenance records, when a change of rotors takes place.
9. Instruction manual
9.1 General
The instruction manual shall highlight the specific safety aspects in operating and maintaining oxygen
compressors and the need for a high standard of cleanliness. The instruction manual shall cite this
document as a reference.
9.1.1 Manufacturer / user input
Within the framework of the preparations made by the user for a major overhaul it is recommended
that the user invites the manufacturer to discuss the following objectives.
Exchange of information between the manufacturer and user with the objective of ensuring
that the highest safety standards are maintained.
Review the operating manual taking into consideration operating experience gained by the
user and the latest standards of the manufacturer.
The minutes of the meeting should then form part of the instruction manual.
9.2 List of minimum information
9.2.1 Instruction manual
The instruction manual shall contain the following information as a minimum:
compressor design data and performance characteristics including the surge line
description of the following items, placing emphasis on the details which are special for
oxygen service:
compressor
seal system
associated equipment
installation;
operation with starting, shut-down and restarting procedures to safeguard the compressor;
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maintenance with disassembly and assembly procedure and spare parts stocking conditions;
overall drawing with seal and bearing clearances and tolerances; and
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