Rotating Machinery Engineering
Rotating Machinery Engineering
Rotating Machinery Engineering
Code OGS-ZTP-ME-TRM-0001
MAIN TOPICS
INTRODUCTION
PUMPS – ROTATING
PUMPS – RECIPROCATING
COMPRESSORS – RECIPROCATING
• Vacuum pumps
TURBINES – GAS
Condition Monitoring
CONCLUSIONS
2
INTRODUCTION: COURSE OBJECTIVE 1
This training module is intended to provide a full understanding of rotating and
reciprocating machinery involved in a Oil & Gas Plant
3
INTRODUCTION: COURSE OBJECTIVE 2
Trainees should understand:
Gas Turbines.
4
INTRODUCTION: COURSE OBJECTIVE 3
When to choose a reciprocating pump instead of a rotating one.
Machinery Efficiency
5
Definitions (1)
Machine: a system of moving organs, which interact each other to produce a useful effect.
Fluid Machines
Engines Mills
Reciprocating Rotating
6
Definitions (2)
Useful Effect
Efficiency
Specific Consumption
Boundary Conditions
Ambient Conditions
Power
Load
7
Main Criteria of Design (1)
To select the best machine according to process requirements it is essential to define:
• Efficiency
8
Main Criteria of Design (2)
When we select a machine normally we refer these parameters in shape that permit us to
compare the solutions of those ones proposed by the market.
• “normalised diameter”,
• “normalised rpm”
9
Operating Conditions
Machinery are able to produce a useful effect whose magnitude is closely related to:
• Boundary conditions;
• Availability;
• Efficiency.
Design Point is the operating condition, at ISO reference (T = 288.15 K, p=101,325 kPa, 50%
humidity, New & Clean), at which the machine can reach the designed magnitude of useful
effect prescribed by the constructor.
To identify the operating point at different ambient condition, the constructor provides
Performances Maps, that indicate the efficiency and the workload of machine at various
conditions.
10
Pumps Overview (1)
Volumetric Flow
PUMPS CHOICE
CRITERIA : Geodetic Drop
Machine Efficiency/Draw Power
Cost
11
Pumps Overview (2)
Type Volumetric Flow Geodetic Drop
Reciprocating
Rotating
12
Pumps Overview (3)
System-Pump
Coupling
13
Start
Yes
Pumps shall be API 610 See B.4.2.3
Pumped fluid Hydrocarbon ?
No Yes
No
Yes
Discharge Pressure sup 16 barg ?
No Yes
No
Yes
No
15
Compressors Overview (1)
to win losses
COMPRESSORS: to reach a specific process point of
pressure
16
Compressors Overview (2)
Reciprocating
Rotating
17
Compressors Overview (3)
18
Turbines Overview (1)
Turbines: use a drop of available pressure to develop mechanical work on
the annexed shaft.
Turbine
Types
Hydraulic Gas/Steam
19
Turbines Overview (2)
20
Turbines Overview (3)
Steam turbine profiles are designed to sustain temperature lower than 1000°C
The choice depends on the overall efficiency and moreover on the sustainable conditions of the
machine.
21
ACTIVITY – Contents Review
22
Safety requirement during Mechanical work activities
Site inspection
Issuing the work procedure
Risk assessment to Identify the associated hazards and existing controls and additional required
controls including Simultaneous Operations (SIMOPS) Hazards and Emergency Procedure in cases
of spill leakage, fire, explosion
evolved personnel competency
To issue mechanical or electrical certificate if required
Lifting plane has been done by Authorized lifting supervisor.
Work Permit and associated Certificates when the work specified has been completed and the
work site is in a safe condition.
To ensure that the conditions and precautions specified on a Work Permit are understood and
are strictly adhered to by those carrying out the job covered by a Work Permit.
TBT – Tool Box Talk, is conducted to communicate the procedure steps, risk assessments sections
and to ensure that the conditions and precautions specified on a
Material Safety Data Sheet (MSDS) are understood and are strictly adhered to by those carrying
out the job covered
Ensure that the work environment is monitored on continues basis and ensure no deviation from
the approved work scope covered by the permit
To ensure plant and equipment is handed back to operations in a safe condition.
23
PUMPS
PUMPS
24
Pumps
Pumps
develop fluid at constant mass flow develop fluid at finite volumes as well as
rotary pumps
use profile to give the drop of pressure
use gears to give the drop of pressure
25
Pump Drive Selection
The driver selection for process pumps is normally made between the two following types:
26
Pump drive selection: Electric
Motor Induction Type(1)
This motor is favoured because of its low installation cost and low maintenance.
Electric motors can be installed for the main and spare pumps even in critical services in the
following cases:
When electric power is supplied to the plant from two external, independent sources and
the electric system is designed in order to have an automatic shifting from one source to the
other.
When the spare pump is fed from a preferential electrical supply line and it has automatic
starting.
27
Pump drive selection: Electric Motor
Induction Type (2)
The electric motor driven pumps in the process units are classified as follows:
28
Pump drive selection: Electric Motor
Induction Type (3)
The electric motors of the majority of the pump are included in the following categories:
29
Pump drive selection: Steam Turbine
Steam turbines are used as pump drivers for the following reasons:
The steam turbines used for pump drivers are generally back-pressure type because condensation
is usually not justified for the limited power involved.
30
ROTATING PUMPS
PUMPS - ROTATING
31
Pump Classification type identification and API 610
for Centrifugal pumps
This International Standard specifies requirements for centrifugal pumps, including pumps
running in reverse as
hydraulic power recovery turbines, for use in petroleum, petrochemical, and gas industry process
services. It does
not cover seal less pumps. This International Standard is applicable to overhung pumps,
between-bearings pumps,
and vertically-suspended pumps (see Table 1). Clause 8 applies to specific types of pumps. All
other clauses of
32
Rotating Pumps 1
API 610 standard for Centrifugal pumps for petroleum,
petrochemical and natural gas industries
• KINETIC PUMPS
• POSITIVE-DISPLACEMENT PUMPS.
33
Rotating Pumps 2
Fields of application of the various types of pumps
34
Rotating Pumps 3
35
Rotating Pumps – Machinery
Description 1
36
Rotating Pumps – Machinery
Description 2
Vertical single stage :
has a casing designed to be bolted directly into the piping like a valve
37
Rotating Pumps – Machinery
Description 3
38
Rotating Pumps – Machinery
Description 4
Horizontal Single
Stage Overhung
Pump
39
Rotating Pumps – Machinery
Description 5
Horizontal Multistage
Between Bearings Pump
40
Rotating Pumps – Machinery
Description 6
Most commercial pumps have diverging channels called volutes cast into the
discharge portion of the casing.
Liquid leaving the impeller at a high velocity enters the volute and has its velocity
reduced causing a pressure rise
41
Rotating Pumps – Machinery
Description 7
The single volute design In cases where this radial force In order to have balanced radial
imposes a radial force on the results in excessive shaft deflection, force, higher efficiency and
impeller due to variations of a double volute design is used. compact size, some process
pressure around the impeller pump designs employ a vaned
periphery. diffuser
42
Rotating Pumps – Machinery
Description 8
Conventional centrifugal pumps are they cannot evacuate vapor from their
not Self priming. suction line so that liquid can fill the line
and pump casing
43
Rotating Pumps – Machinery
Description 9
Most of the centrifugal pump types are self venting by the arrangement of
the suction and discharge nozzles.
44
Rotating Pumps – Machinery
Description 10
Some centrifugal pump types having inlet and discharge connections in
the bottom casing half are not self venting
They are provided with valved vents which require manual operation to
release trapped vapour and adequately fill the casing with liquid for
starting.
45
ACTIVITY – Centrifugal pump
components
A. Stuffing Box
B. Packing
C. Shaft
D. Shaft Sleeve
E. Vane
F. Casing
G. Eye of impeller
H. Impeller
I. Casing wear ring
J. Impeller
K. Discharge nozzle
46
Rotating Pumps – Design 1
47
Rotating Pumps – Design 2
The force that tends to overcome cavitation is provided by the difference
between the liquid’s static suction pressure and its vapour pressure at the
operating temperature Net Positive Suction Head
Required NPSH (NPSHr) = necessary head for the liquid to flow without
vaporization from the pump inlet to the point where the static pressure is
lowest.
48
Rotating Pumps – Design 3
When the available NPSH is low (0,3÷2 m), it must be accurately calculated because the type of
pump, the choice of model and its cost are very sensitive to the available NPSH value.
49
Rotating Pumps – Design 4
The consequences of having NPSHa<NPSHr are not the same for all
liquids:
The consequences are more serious for pure liquids because all of the
liquid tends to vaporize at the same pressure and temperature;
Mixtures, instead, have a boiling curve for which only a minimal part of the
liquid starts to vaporize after dropping below the boiling pressure.
The gradient of the vapour pressure curve against temperature at pumping conditions
influences the sensitivity of the required NPSH. Why?
50
Rotating Pumps – Design 5
Barrel-type vertical pumps
Advantages: Drawbacks:
51
Rotating Pumps – Operating
Conditions 1
Components of
differential pressure
Static: Variable:
Dynamic:
Static level calculated as the The pressure drop of
Pressure drop through the
difference between the control valve that is
delivery-side equipment
maximum level in the modulated according to
between the pump and the
discharge vessel and the process requirements. It is
final vessel and including heat
minimum level in the suction only present in centrifugal
exchangers, ovens, filters, etc.
vessel. pumps.
52
Rotating Pumps – Operating
Conditions 2
Characteristic curve of a centrifugal pump
53
Rotating Pumps – Operating
Conditions 3
Pump Impeller Classification (Low Specific Speed)
54
Rotating Pumps – Operating
Conditions 4
Pump Impeller Classification (High Specific Speed)
55
Rotating Pumps – Operating
Conditions 5
Max
Max
Max head discharge Max viscosity Efficiency Max temp.
Pump type capacity
(m) pressure (Pa s) % (°C)
(m3/h)
(kPa)
Horizontal
Single stage 1.100 150 4.000 0,650 20 ÷ 80 450
Two stage 300 400 4.000 0,450 20 ÷ 75 450
Chemical 250 70 1.500 0,650 20 ÷ 75 200
Slurry 250 100 4.000 0,650 20 ÷ 80 450
Monobloc 4.500 1.500 70.000 0,450 20 ÷ 70 550
Multi stage 2.500 4.000 40.000 0,450 65 ÷ 90 450
Vertical
Single stage 2.500 250 4.000 0,650 20 ÷ 85 350
Multi stage 18.000 1.800 5.000 0,450 25 ÷ 90 250
In line 2.700 200 3.500 0,450 20 ÷ 80 250
High speed 90 1.800 14.000 0,100 55 ÷ 85 200
Axial 100.000 5 1.000 0,650 65 ÷ 85 65
56
Installation pre-commissioning and Centrifugal Pumps
commissioning Refer to API RP686
57
Centrifugal pumps check list
In addition to the general points, the following particular
points are also of importance:
Sealing
- Check that soft packing rings in the stuffing box are of correct material and the
packing and gland are properly installed.
- Check the location and connections of the lantern ring and check whether proper
seal liquid is used, if applicable.
- Check that the type of mechanical seal and its material are in accordance with
specification.
- Check whether the seal piping arrangement is correctly installed in accordance
with the specified API plan.
Utilities
Safety devices Function testing
58
HAZARD ASSESSMENT
The hazards associated with a large centrifugal pump have to be
considered over its complete operating / maintenance cycle, and not
just steady load operations.
Mal-operation / excursions / drive system failures and emergencies
must all be covered.
The majority of hazards relate to the process fluid, either by a direct
release, or by the consequent effects on upstream & downstream
systems from a pump failure.
Failure of static components through fatigue, erosion or corrosion.
Failure of dynamic components leading to high fatigue loads on
other components with potentially rapid catastrophic deterioration of
seal or nozzles.
Failure of the pipe system due to extreme pressures or temperatures
– either externally applied or generated by the operating pump or
system, resulting from events such as pressure surges, process
density, or composition changes.
59
RECIPROCATING PUMPS
RECIPROCATING - PUMPS
60
API STANDARD 674 for Positive Displacement
Pumps-Reciprocating
61
Reciprocating Pumps - Machinery
Description 1
Positive-displacement pumps work by imparting a propelling force to a fixed volume
of liquid from the inlet conditions to the outlet conditions.
RECIPROCATING PUMP
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Reciprocating Pumps - Machinery
Description 2
Positive-displacement pumps have a lower speed of rotation than kinetic pumps
and are therefore physically larger for a given capacity.
In general centrifugal pumps are used for capacity higher than 2-5 m3/hr and for
differential pressure up to 30-40 kg/cm2.
63
Reciprocating Pumps - Machinery
Description 3
64
Reciprocating Pumps - Machinery
Description 4
Check valves, mounted in the head, open and close in response to small
changes in pressure to maintain a one-way flow of liquid.
The pump cylinder with its check valves is often accessible from the
outside to allow easier servicing of the check valves and replacement of
the pump seals. This part of the pump is called the pump head.
65
Reciprocating Pumps - Machinery
Description 5
Pump flow varies with time:
The pressure inside the pump changes in the same way as flow
going from zero to a maximum value;
staying at zero during the intake stroke.
66
Reciprocating Pumps - Machinery
Description 6
67
Reciprocating Pumps - Machinery
Description 7
68
Reciprocating Pumps - Machinery
Description 8
TYPES OF RECIPROCATING PUMP
Single acting: it pumps one cylinder volume per shaft revolution (action
on one side of the piston).
Double acting: it pumps two cylinder volumes per shaft revolution
(action on both sides of the piston)
69
Reciprocating Pumps - Machinery
Description 9
70
ACTIVITY – Reciprocating Pump
Components
71
Reciprocating Pumps - Guidelines 1
Guidelines for reciprocating pumps
Communication between:
the piping system designer,
72
Reciprocating Pumps - Guidelines 2
ACOUSTICAL CONSIDERATIONS IN PIPING DESIGN
“The interaction of the pump, pulsation control devices, and piping system produces potentially
harmful pulsations when there is resonant interaction between the various elements in the
system”
The system designer can help to minimize this interaction by avoiding resonant lengths of
constant diameter pipe for constant speed pumps.
When resonant lengths of constant diameter pipe are used and the resonant frequency
matches multiples of plunger frequency, one can expect major changes to the system as a
result of the acoustical simulation analysis.
73
Reciprocating Pumps - Guidelines 3
74
Reciprocating Pumps - Guidelines 4
75
Reciprocating Pumps - Guidelines 5
ACOUSTICAL SIMULATION REQUIRES:
Detailed drawings of each vessel, showing:
the location of all nozzles,
the length
When two or more pumps are connected to the same piping system, a
clear description is required explaining how they will operate.
76
Reciprocating Pumps - Design 1
DESIGN TEMPERATURE
77
Reciprocating Pumps - Design 2
DESIGN PRESSURE
The design pressure for these pumps is fixed by the set of the safety
valve on the pump discharge.
The set point of the safety valve is normally obtained by adding to the
maximum operating pressure 10% or 2 kg/cm2 whichever is greater.
78
Reciprocating Pumps - Design 3
FLANGE RATINGS
The pump vendor usually selects the same rating for the suction flange
as for the discharge flange.
79
Reciprocating Pumps - Design 4
Typical speed ratings values for reciprocating pumps
Stroke Length Single-Acting Plunger Type Pumps Double-Acting Piston type Pumps
Revolutions per Meters per Feet per Revolutions per Meters per Feet per
(mm) (in)
Minute Minute Minute Minute Minute Minute
80
Reciprocating Pumps - Design 5
SPARE EQUIPMENT
ELEMENTS TO GUIDE TO DECIDE COMMON SPARING
The required head capacity point of each service must lie within the
performance range of the common spare
81
Reciprocating Pumps - Design 6
If a high flow service is common spared with a low flow service, the
common spare must be designed for high flow, and, when operating as a
spare for the low flow service, may need low flow recycle to avoid
cavitation and overheating.
Design pressure and temperature, and resulting flange ratings for the
common spare must be adequate for both services.
82
Reciprocating Pumps - Design 7
Where one of the service liquids contains water and the other acid the
possibilities for the two streams mixing through the suction and discharge
piping manifolding and causing severe corrosion are too great.
83
Reciprocating Pumps - Design 8
NPSH IN RECIPROCATING PUMPS
Increase the number of pump heads (a triplex has a smaller C value than a
duplex, etc.)
Install pulsation dampers on the suction piping, close to the pump inlet nozzle.
85
Reciprocating Pumps - Design 10
MATERIAL CLASS SELECTION GUIDE
I-1 I-2 S-1 S-3 S-4 S-5 S-6 S-8 S-9 C-6 A-7 A-8 D-1
Cast Cast Carb. Carb. Carb. Carb. Carb. Carb. Carb. 12% 316
AUS Duplex
Iron iron steel steel steel steel steel steel steel CHR AUS
86
Reciprocating Pumps - Design 11
Temperature °C Pressure range Material class
Service
Fresh water, condensate, cooling tower water < 100 All I- 1 or 1-2
< 120 All I- 1 or 1-2
87
Reciprocating Pumps - Design 12
88
Reciprocating Pumps - Design 13
LUBRICATION:
Bearings and bearing housings shall be arranged for hydrocarbon oil
lubrication.
The following auxiliary equipment shall be furnished when required by the
vendor or when specified:
Oil flow indicator
Oil strainer
Oil cooler
89
Reciprocating Pumps - Design 14
LUBRICATION:
Unless otherwise specified, bearing oil temperature shall not exceed 70°C
(160°F) anywhere in the system.
When necessary or when specified, an oil cooler shall be supplied.
An oil reservoir shall be supplied:
With a sufficient capacity to avoid frequent refilling
To eliminate air and to minimize flotation of foreign matter to the pump suction
90
Reciprocating Pumps - Design 15
91
Reciprocating Pumps - Operating
Conditions 1
RECIPROCATING PUMP EFFICIENCY
The efficiency of a pump is given by the product of the hydraulic,
volumetric and mechanical efficiencies.
The hydraulic efficiency of a reciprocating pump is given by the ratio:
H
i (1)
H Hp
H = pump head
Hp = total pressure drop due to traversing the inlet and outlet valves.
92
Reciprocating Pumps - Operating
Conditions 2
Volumetric efficiency
Is given by the ratio between the flow effectively pumped and the
theoretical one
Is also expressed as its complement to one and, in this case, it is called
slippage. Slippage must not be greater than 5%, but in new pumps or
ones in good condition, it is around 1%.
Mechanical efficiency
Varies from approximately 50% for small pumps and from approximately
90% for larger pumps.
The efficiency of a reciprocating pump can be estimated with relevant
software.
93
Reciprocating Pumps - Operating
Conditions 3
Influence of viscosity, density and solids content
94
Reciprocating Pumps - Operating
Conditions 4
Typical performance values for piston pumps
Max Discharge
Capacity Max Head Max Viscosity Max Temp.
Pump type Pressure (kPa Efficiency (%)
(m3/h) (m) (Pa·s) (°C)
abs)
Piston plunger 2-3000 3500 350000 1.000 55-85 290
95
Reciprocating Pumps - Operating
Conditions 5
EFFECTS OF LIQUID CHARACTERISTICS ON PUMP PERFORMANCE
LIQUID VISCOSITY:
The effect of viscosity on the rate at which the liquid flows into the
cylinder of direct acting pumps can affect the piston speed requirements.
For power pumps handling viscous liquids of 4000 SSU and greater a
mechanical efficiency correction factor of 90% should be used.
96
Reciprocating Pumps - Operating
Conditions 6
EFFECTS OF LIQUID CHARACTERISTICS ON PUMP PERFORMANCE
LIQUID DENSITY:
97
Reciprocating Pumps - Operating
Conditions 7
EFFECTS OF LIQUID CHARACTERISTICS ON PUMP PERFORMANCE
FLUID TYPE:
amount
98
Reciprocating Pumps - Operating
Conditions 8
RECIPROCATING PUMP CONTROL
99
Reciprocating Pumps - Operating
Conditions 9
RECIPROCATING PUMP CONTROL
100
Reciprocating Pumps - Operating
Conditions 10
RECIPROCATING PUMP CONTROL
101
ACTIVITY - Miniquiz
In an axial flow centrifugal pump, the liquid enters at the centre of the
impeller and is directed out along the impeller blades in a direction at
right angles to the pump shaft
True
False
102
Installation pre-commissioning and commissioning
GENERAL
Allowance shall be made for grouting between the rough surface of the
concrete and the underside of the base plate Whereas most pump units and
small compressors are mounted on base plates, some Equipment may be
mounted directly on the foundations. In these cases, sole plates shall be
Provided, which are grouted on the foundation to facilitate easy removal and
re-installation Of the equipment during maintenance.
Vertical close-coupled pumps shall be mounted on sole plates. A foundation
layout and a Sole plate should be applied.
Lifting of the base plate during installation shall be done in accordance with
the
Manufacturer's instructions to prevent permanent distortion.
Refer to API RP686
FOUNDATION BOLTS
LEVELLING
GROUTING
103
Check list
Lubrication
- Check the bearings and the bearing housings for cleanliness and ensure that
lubricating rings have adequate free movement.
- Check the correct position and level of the constant-level oiler.
- Check that the bearing housing contains oil up to the correct level or is properly
greased.
If oil-mist lubrication is applied, check that the system is lined up correctly and is
clean.
Sealing
- Check that soft packing rings in the stuffing box are of correct material and the
packing and gland are properly installed.
- Check the location and connections of the lantern ring and check whether proper
seal liquid is used, if applicable.
- Check that the type of mechanical seal and its material are in accordance with
specification.
-Check that the seal piping arrangement is correctly installed in accordance with
the specified API plan.
Utilities
Safety device - Check whether a safety/relief valve is installed and check the set
pressure.
Function testing
104
COMPRESSORS
COMPRESSORS
105
API standards 617 for Axial and Centrifugal Compressors
106
Compressors
Compressors
107
RADIAL FLOW COMPRESSORS
COMPRESSORS
-
RADIAL FLOW
108
Radial Flow Compressors
109
Compressors
110
Radial Flow Compressors –
Machinery Description 1
111
Radial Flow Compressors –
Machinery Description 2
112
Radial Flow Compressors –
Machinery Description 3
113
Radial Flow Compressors –
Machinery Description 4
114
Radial Flow Compressors –
Machinery Description 5
115
Radial Flow Compressors –
Machinery Description 6
116
Radial Flow Compressors –
Single Stage
Machinery Description 7
117
Radial Flow Compressors –
Machinery Description 8
Axial split machines
118
Radial Flow Compressors –
Machinery Description 9
Radial split machines
119
Radial Flow Compressors –
Machinery Description 10
Integrally Geared Centrifugal Compressor
120
Radial Flow Compressors – Design 1
drop of pressure β
β
High Drop Multistage
121
Radial Flow Compressors – Design 2
Multistage split
122
Radial Flow Compressors – Design 3
Impeller Design
123
Radial Flow Compressors – Design 4
Impeller Design
124
Radial Flow Compressors – Design 5
Rotor Support
Single bearing housing containing a
thrust bearing and a pair of radial Single Stage
bearings.
125
Radial Flow Compressors – Design 6
Multistage centrifugal compressors develop a
considerable thrust load from the discharge end toward
Balance Pistons
the inlet due to the pressure difference across each of the
impellers.
126
Radial Flow Compressors – Design 7
Main shaft seals
Seals
127
Radial Flow Compressors – Design 8
128
Radial Flow Compressors – Design 9
129
Radial Flow Compressors – Design
10
Unless otherwise specified, instrumentation shall
Controls & conform to the requirements of API Standard 614,
Instrumentation including supplied API 614 data sheets.
130
Radial Flow Compressors – Design
11
Electrical equipment be suitable for the hazard
classification specified.
131
Radial Flow Compressors –
Operating Conditions 1
Characteristics of a Radial Flow Compressor
132
Radial Flow Compressors –
Operating Conditions 2
Curve Slope
For a compressor stage is determined by impeller blade geometry and the
characteristics of the compressed gas.
For a compressor section is further influenced by rotational speed and the
number of compressor stages that make up the compressor section.
Speed and gas characteristics affect the curve slope due to their impact
on gas volume reduction for a single compressor stage.
Changes in curve shape and operating range will become more significant
as the number of impellers in a compressor section increases.
Choke
the maximum flow limit that is approached as the velocity of the gas
stream relative to the impeller blades nears the sonic velocity of the gas
mixture being compressed.
133
Radial Flow Compressors –
Operating Conditions 3
Surge
The minimum flow limit of a compressor stage is determined by the
unstable cyclic phenomenon known as surge.
Stability & Turndown
The term “stability” is used to define the available operating range from
the Normal duty point to surge flow.
Turndown takes into account the effects of control methods such as
suction throttling or speed control
Head Capacity Curves for Variable Speed Machines
By variation of speed, a wide range of operating conditions are
achievable.
134
ACTIVITY – What is this?
135
Checklist
Lube oil/seal oil or seal gas system
- Check that the gaskets fitted are of the correct material and pressure
class.
- Fill the system with the correct amount of flushing oil. Start flushing the
system after any special instructions of the Manufacturer have been
followed (e.g. concerning bearings and/or seals etc.), and continue flushing
until API 614 cleanliness criteria have been met.
- After the lubrication and sealing system has been properly flushed, drain
the flushing oil.
Oil tanks shall be cleaned and inspected after the flushing procedure.
Replace filter elements and clean the filters. Remove all the special
precautions installed for the system flushing.
- Check precharge pressure of accumulators.
- Fill the lube and seal oil system with the correct amount of oil of the
specified grade.
- Check the levels throughout the system (overhead system properly
filled/vented).
- Check tightness of the seal
136
HAZARD ASSESSMENT
Process Gas Hazards
Gas Compressors are used to increase the pressure of a process gas, in
order to drive it into a pipeline system to an onshore process plant, to use
on the producing well as gas lift, to re-inject gas for reservoir pressure
maintenance and for use as a fuel gas.
Turbo compressors are preferred for high mass flow systems because of their simplicity and
reliability compared with screw or reciprocating compressors. In order to achieve the
required pressure ratio, several compression stages may be required, in one or more
casings. Each compression stage is carried out by a rotor in a matching diffuser.
This document focuses on the single shaft multi-stage "Barrel" design of
compressor typically used for hydrocarbon gas compression in the oil & gas
industry. Materials of construction must be mechanically capable, and compatible with
process fluids anticipated throughout the field lifetime.
Mechanically linked compressors, working together with drive and support
equipment, may be regarded as a single system for design and safety purposes.
The major hazards relate to the inventory of flammable gas that can be released if there is
an equipment failure. Hazard assessment must relate to the complete package and not just
the compressor body. The injury risk from a mechanical failure is relatively low, as the robust
casing will retain parts. Hot / moving parts may still cause injury local to the machine. Most
compressors have gas seals on moving drive shafts or piston rods. These are safety critical
items when handling hazardous materials.
137
AXIAL FLOW COMPRESSORS
138
Axial Flow Compressors 1
Axial compressor = the flow is parallel to the machine axis with the
gas passing through alternating rows of stationary and rotating blades.
Kinetic energy is imparted to the gas by the rotating blades and is
converted into pressure by diffusion in the space between individual
rotating and stationary blades.
139
Axial Flow Compressors – Design 1
Axial compressors with multiple compressor stages
have cast or fabricated casings which are horizontally
split to facilitate rotor removal.
The stator blading is supported by either the main
Casings pressure casing or by an inner casing called a blade
carrier.
Most casing designs are limited to 100 to 150 psig (7
to 10 barg).
140
Axial Flow Compressors – Design 2
The rotors are usually of forged solid design.
Welded hollow rotors may be applied to limit the
moment of inertia in larger capacity compressors.
141
Axial Flow Compressors – Design 3
Discharge Temperature
Head Capability
Side Streams
142
Axial Flow Compressors – Design 4
Side Streams -Almost all axial compressor models have simple straight
through gas flow paths using one casing for one process compression
stage.
143
Axial Flow Compressors – Design 5
Specifying Curve Shape
Designers should consult machinery specialists to obtain vendor typical performance curves
showing:
the effect of speed range (if speed is variable)
144
Axial Flow Compressors – Design 6
Identify the orientation of the compressor main process connections.
Main Process Connection Orientation
Shaft Seals
Specify the shaft seals as labyrinth type for axial compressors in air service.
Common Oil Oil System Pump Drivers Seal Oil and Gas Seal
Systems Systems
145
Axial Flow Compressors – Design 7
Controls and Instrumentation
Variable Speed
146
Axial Flow Compressors – Design 8
Piping Arrangements
Physical arrangement and mechanical design of the piping system associated with compression
services are performed during project detail engineering.
The main features of compression service designers are given in the following requirements:
1. Access for Compressor Maintenance
147
Axial Flow Compressors – Operating
Conditions 1
The operating conditions of an axial flow compressors are defined regarding to desired
performances.
Ambient/Inlet conditions
Compressor efficiency
148
Axial Flow Compressors – Operating
Conditions 2
Ambient/Inlet conditions
Ambient/Inlet conditions may varies in terms of pressure, temperature and humidity. These
parameters act on the fluid modifying its density at the inlet.
Compressor efficiency
The efficiency of a compressor depends on operating conditions (mass flow, ambient
conditions/inlet conditions) and moreover on fouling and blade degradation.
149
Check list
1. Check the bearings and bearing housings for cleanliness.
2. Check that the lube oil system is in accordance with the flow diagram.
3. Check that the entire lube oil system has been properly flushed and is clean.
4. If a separate seal oil system is installed, check that it is in accordance with the flow
diagram.
5. Check that the entire seal oil system has been properly flushed and is clean.
6. Check that the cooling water system is in accordance with the flow diagram.
7. Check that the entire cooling water system has been properly flushed and is clean.
8. If the compressor is driven by means of V-belts, check the tension of these belts
and the pulley alignment.
9. Check the suction line for absolute cleanliness. Any dirt or welding scale from the
suction line is disastrous for a screw compressor.
10. Check the discharge line for cleanliness and check valve orientation.
11. Check whether safety devices are properly installed and in accordance with data
sheets and flow diagram.
150
RECIPROCATING COMPRESSORS
RECIPROCATING
COMPRESSOR
151
API STANDARD 618 for Reciprocating compressors
152
Reciprocating Compressors
153
Reciprocating Compressors –
Description 1
154
Reciprocating Compressors –
Description 2
156
Reciprocating Compressors –
Description 4
Main types of compressors:
157
Reciprocating Compressors –
Description 5
158
Reciprocating Compressors –
Description 6
Main types of compressors:
Crosshead piston:
• Description: The piston is driven by a fixed piston rod that passes through a stuffing or
packing box and is connected to a crosshead. The crosshead, in turn, is connected to the
crankshaft by a connecting rod.
• Advantage: A variable length or double distance piece is used to keep crankcase lubrication
from being exposed to the process gas
159
Reciprocating Compressors –
Description 7
Multistage Compressor
160
Reciprocating Compressors –
Description 8
161
Reciprocating Compressors – Design
GENERAL DESIGN
1
excitation of torsional, acoustical,
Constant speed operation TO AVOID and/or mechanical resonances
162
Reciprocating Compressors – Design
2
Other design parameters:
• Allowable speed
• Allowable Discharge Temperature
• Critical Speed
• Compressor Cylinder
• Cylinder Cooling
• Cylinder Connection
• Compressor Frame Lubrication
• Cylinder and Packing Lubrication
• Materials
163
Reciprocating Compressors -
Operating Conditions 1
164
Reciprocating Compressors -
Operating Conditions 2
CONTROL DEVICES
Automatic-start-and-
Constant-speed control
stop control
165
Reciprocating Compressors -
Operating Conditions 3
Inlet-Valve Unloaded
166
Reciprocating Compressors -
Operating Conditions 4
Clearance-Control Cylinder
167
Reciprocating Compressors -
Operating Conditions 5
168
Reciprocating Compressors -
Operating Conditions 6
Sectional view of a cylinder equipped with a hand-operated valve lifter on one end and a variable-
volume clearance pocket at other end
169
Reciprocating Compressors -
Operating Conditions 7
Starting Stopping
compressor compressor
Start with A and D Close C
open
Close D Close B
Open B
Slowly open C
170
Reciprocating Compressors -
Operating Conditions 8
171
Reciprocating Compressors -
Operating Conditions 9
172
Reciprocating Compressors -
Operating Conditions 10
173
Reciprocating Compressors -
Operating Conditions 11
174
ACTIVITY - Metallic Diaphragm
Compressors
175
Check list
1. Check the crankcase and crossheads for cleanliness and make sure the crankcase can be properly
vented.
2. Check line-up of lube oil system and that it is in accordance with flow diagram.
3. Check that the entire lube oil system has been properly flushed and is clean.
4. Check line-up of cooling water system and that it is in accordance with flow diagram.
5. Check that the cooling water system has been properly flushed and is clean.
6. Check line-up of vent and drain system of cylinder stuffing box and cylinder
compartment distance pieces, taking into account local safety regulations for disposal of hazardous
or toxic gases.
7. Check line-up of purge system to cylinder stuffing-box gland or cylinder compartment distance
pieces.
8. Check the barring gear for correct functioning.
9. Check crankshaft deflection before and after coupling-up of driver.
10. Check the suction and discharge valve assembly and valve housing for cleanliness and check
valve lift. Check that valves are assembled correctly. If valve unloaders are mounted, check correct
functioning and sequence.
176
HAZARD ASSESSMENT
Most early gas compressors were of reciprocating design; more recently even high-pressure
applications can be met with high-speed multi stage centrifugal compressors.
177
GAS TURBINES
GAS TURBINES
178
API STANDARD 616 for Gas Turbines
This standard covers the minimum requirements for open, simple, and
regenerative-cycle combustion gas turbine units for services of mechanical drive,
generator drive, or process as generation. All auxiliary equipment required for
operating, starting, and controlling gas turbine units and for turbine protection is
either discussed directly in this standard or referred to in this standard through
references to other publications.
Specifically, gas turbine units that are capable of continuous service firing gas or
liquid fuel or both are covered by this standard.
179
Gas Turbines
Gas Turbines are commonly implemented inside of a Power Plant as SCGT or CCGT.
180
Gas Turbines – Description 1
Radial-Flow Turbine: It is normally used for smaller loads and over a smaller
operational range than the axial turbine
More robust
181
Gas Turbines – Description 2
Axial-Flow Turbine have flow that enters and leaves in an axial direction
182
Gas Turbines – Description 3
The available drop of
pressure is entirely
consumed through nozzle
path
183
Gas Turbines – Description 4
The gas is expanded in the nozzle, converting the high thermal energy into kinetic energy
The static pressure decreases in the nozzle with a corresponding increase in the absolute
velocity.
The absolute velocity is then reduced in the rotor, but the static pressure and the relative
velocity remain constant
184
Gas Turbines – Description 5
In a Reaction Turbine, both the nozzles and blades act as expanding nozzles.
The static pressure decreases in both the fixed and moving blades.
The fixed blades act as nozzles and direct the flow to the moving blades at a velocity
slightly higher than the moving-blade velocity.
185
Gas Turbines – Description 6
Turbine-Blade Cooling:
Air is bled from the compressor and is directed to the stator, the rotor, and other parts of
the turbine rotor and casing to provide adequate cooling.
The effect of the coolant on the aerodynamic, and thermodynamics depends on the type of
cooling involved
186
Gas Turbines – Description 7
187
Gas Turbines – Description 8
The most frequently used blade cooling designs are:
Film and Convection Cooling This type of blade design has a midchord region
that is convection cooled, and the leading edges
which are both convection and film cooled
188
Gas Turbines – Design 1
Major Cycles - The major application of most gas turbines is in an open cycle in
which air is the working medium
Single Shaft
Three Shafts
189
Gas Turbines – Design 2
The simple cycle, or the Brayton cycle, is the most common type of cycle being used in the gas-
turbine field today.
Efficiency
Efficiency can be improved by increasing the pressure ratio or the turbine inlet temperature
The efficiency of the various components such as the compressor, combustor, and turbine
affects the overall thermal efficiency
190
Gas Turbines – Design 3
The Regenerative Cycle:
The amount of fuel needed can be reduced by the use of a regenerator in which the hot
turbine exhaust gas is used to preheat the air between the compressor and the combustion
chamber.
The work output per pound of air is about the same or slightly less than that experienced
with the simple cycle
The point of maximum efficiency in the regenerative cycle occurs at a lower pressure ratio
191
Gas Turbines – Design 4
The reheat cycle:
Consists of a two-stage turbine with a combustion chamber before each stage
The reheat is done between the power turbine and the compressor trains.
Greater work
Reheat Cycle
Only the high pressure turbine drives the
compressor
192
Gas Turbines – Design 5
193
Gas Turbines – Design 6
The Combined Cycle the combination of gas turbine technologies with the steam
turbine
A percentage of steam could be injected into the boiler for Nox reduction
Repowering of single cycle with a steam turbine can increase overall efficiency
about 3-4 %
194
Gas Turbines – Design 7
Turbine life is very sensitive to blade metal temperature and blade material.
195
Gas Turbines – Operating Condition
1
50-70% of Turbine work load is for the compressor
Humidity must be lesser then a 30 % in mass. If the treated fluid is air and it is dry an
evaporative cooler have to be provided before the compressor entrance.
Periodical water solvent cleaning of turbine airfoils have to be provided to save the machine
from fouling, that decreases the efficiency.
196
Gas Turbines – Operating Condition
2
Design of airfoils have to be done to reduce Losses
A shut down monitor have to be provided in case of acceleration rate is not maintained
Bleed valves for avoiding compressor surges in start-up and shut-down modes have to be
provided.
197
ACTIVITY – Combined Cycle
198
check list 1
Since construction details and auxiliary equipment can vary widely from
Manufacturer to Manufacturer, it is important to consult the Manufacturer's
instruction manual for any additional checking not mentioned below.
1. Check the equipment supplied against the schedule of auxiliary and associated
equipment for correct calibration and settings.
2. Check that the casing, shaft and exhaust duct can expand with increasing
temperatures. However, transverse movement of the casing should be prevented.
The casing foundation bolts should have adequate clearance under their heads to
allow for expansion of the casing.
3. Check that the cooling system is in accordance with the flow diagram.
4. Check that the entire cooling system has been properly cleaned.
5. Check that the entire lube oil oil system has been properly flushed and is clean.
6. Check that the entire hydraulic oil system has been properly flushed and is
clean.
7. Check that the fuel supply system is in accordance with the flow diagram.
8. Check that the entire fuel supply system has been properly flushed and is clean.
199
check list 2
9. Check the correct functioning and setting of gas fuel supply system pressure regulators and
isolating/venting valves.
10. Operate the fuel control system statically and check for correct equipment response.
11. After commissioning the compressor washing system, ensure that it operates correctly
according to the Manufacturer's manual.
12. Check all air intake bypass doors and mechanized shutters for cleanliness and correct
operation.
13. Check whether safety devices are properly installed and in accordance with the data sheets
and the flow diagram.
14. Check that the lube oil tanks contain oil up to the correct level.
15. Check that the auxiliary lube oil pump cuts in at the correct oil pressure.
16. Check that the line-up of the governing system is in accordance with the drawings. If
possible, operate the system and check the proper functioning of relay valves, control valves
and the main stop valve after correct hydraulic oil pressure is obtained. If the main stop valve is
operated without oil pressure, check proper functioning manually.
17. Check the proper functioning of all safety devices. Safety devices which cannot be tested
when machine is not running should be checked during the initial run.
18. Check fire protection and gas detection systems for correct operation according to the
Manufacturer's manual.
200
check list 3
19. Initial run (non-fired) All pre-commissioning runs shall take place under the supervision and
responsibility of the Supplier's engineer and in accordance with the Manufacturer's
instructions.
20. Second motoring run Repeat item 19 but with gas start selected.
21. Commissioning run This run is to take place under the supervision and responsibility of the
Supplier's engineer and in accordance with the Manufacturer's instructions.
22. Check whether noise exceeds specified limits.
23. Take a vibration frequency analysis for future reference.
24. Take an oil sample.
25. Compile a checklist of safety devices to be calibrated. This checklist shall include all test
information.
201
CONDITION MONITORING
Condition monitoring can provide very valuable information about the status and
safety of rotating equipment while it is running. The only hazards associated with
carrying out condition monitoring activities might relate to the manual taking of oil
samples, and attempting to maintain shaft sensors on running plant. Lack of
condition monitoring should not contribute to safety hazards, as condition
monitoring should not be a substitute for protective safety systems, though
effective monitoring will reduce the demand rate on the protective device.
Inspection & overhaul activity timing may be based on the assumption of
appropriate condition monitoring being in place. If this is not the case, these
intervals should be reduced.
Equally, there is a good case for extending maintenance intervals based on effective
condition monitoring, provided that favorable results are achieved, as in good oil
sample test results.
202
CONDITION MONITORING
General machine Systems
Vibration techniques
Hot/ Noisy bearings Lubricant Analysis
Ultra sound Techniques
Thermal Inspection Techniques
Look listen feel
203
MEG System overview
204
MEG recovered in the MEG recovery unit, is stored in the MEG
Storage Tank 230-TK-7660.
MEG is pumped to the subsea system especially the locations
where there is potential hydrate formation such as Joule-
Thompson expansion and temperature drops (upstream and / or
downstream X-tree choke valve and vent points…etc.)
MEG solution is typically pumped into the subsea system via high
duty reciprocating pumps through a set of MEG filters to remove
the solids and debris going to the subsea system, figure 2.2 is a
simple overview of MEG storage and injection system. MEG
makeup and charging is provided using MEG loading pump.
Corrosion inhibitor is injected into the MEG injection pumps
common suction line to inject the corrosion inhibitor into the
subsea flow line.
205
CHOKE VALVE
206
207
MEG injection pump.
Due to the criticality of the MEG injection continuity
process, it’s a mandatory to provide a sparing pump with
at least (2* 100 %) injection pumps. Two of these pumps
will run continuously and at a fixed flow rate (manual
adjustment of flow is possible). Provision should be made
in the pipe work manifolds to allow for future addition of
further MEG Injection Pumps if required.
The MEG Injection Pump shall be fed from the MEG
storage tank. MEG Injection Pump is provided with a high
enough capacity and operating pressures to overcome
the hydraulic losses to the subsea system.
208
MEG injection pump.
209
MEG RECOVERY UNIT
Large glycol reclamation plants that recover mono-
ethylene glycol (MEG) used for hydrate inhibition
typically apply flash vaporization under vacuum to
remove dissolved and suspended solid contaminants.
Heat is transferred to the salty rich glycol feed at the
lowest possible temperature by direct contact with hot
recycled liquid, followed by distillation to recover clean
salt-free re-concentrated glycol.
210
MEG RECOVERY UNIT
211
LIQUID SEA VACUUM RING PUMP
Liquid ring pumps are mainly composed of a rotor
positioned eccentrically in a cylindrical body. When the
rotor rotates, an annular ring of liquid is formed,
moving with the rotor. In the section where the rotor
axis and the body are closer, the liquid completely fills
the chamber. With proceeding the rotation, the liquid,
that follows the body contour, recedes from the axis,
leaving a space, connected to the pump inlet, that is
filled by the incoming gas.
212
LIQUID SEA VACUUM RING PUMP
213
CONCLUSION
214
Conclusion 1
215