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GE_centrifugal_compressors

The document provides an overview of GE Oil & Gas's centrifugal compressors, detailing their function, design, and applications in the oil and gas industry. It covers the components of compressors, including rotating and stator parts, and explains the processes involved in gas compression. Additionally, it outlines various compressor types and their configurations used in upstream, midstream, and downstream operations.

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ashumishra007
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© © All Rights Reserved
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Available Formats
Download as PDF, TXT or read online on Scribd
0% found this document useful (0 votes)
161 views

GE_centrifugal_compressors

The document provides an overview of GE Oil & Gas's centrifugal compressors, detailing their function, design, and applications in the oil and gas industry. It covers the components of compressors, including rotating and stator parts, and explains the processes involved in gas compression. Additionally, it outlines various compressor types and their configurations used in upstream, midstream, and downstream operations.

Uploaded by

ashumishra007
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
You are on page 1/ 123

GE Oil & Gas

Oil & Gas Industry Applications

Introduction
General description and main features
Introduction Customer Training

What is a Compressor?

A machine used to increase the


pressure of a GAS

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Introduction Customer Training

What is a Gas?

Gas is one of the three classical states of


matter characterized by molecular weight
(MW), pressure (p) and temperature (T)

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Introduction Customer Training

Gas compression

Gas
ps Gas
pd
Mechanical
power

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Introduction Customer Training

What we need to compress a gas?

For many reasons: to transport it,


to enhance an oil field production, etc…

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Compression Services Customer Training

Oil/Gas field Pipeline inspection device

Offshore production platform

Re-injection plant

Oil / gas processing plant


Gas boosting station
Subsea equipment

Power generation plant


Oil boosting station

Natural Gas storage plant


LNG liquefaction plant

LNG receiving plant


Refinery / Petrochemical /
fertilizer plant

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Compression Services Customer Training

Upstream Midstream Downstream Distribution

• Exploration & • Pipelines • Refinery • NGV Re-fuelling


Production  HCU, HDT, HDS
 Gas Boosting  Cubogas
 Re-injection  Recycle
 HP Transport  Air Feed
 Gas Lift  FCC
 Gas Storage (Injection +
 Gas Gathering • Petrochemical/
 Export Gas withdrawal)
Fertilizers
•Gas Plants  Syngas
 Feed Gas
(Ammonia, Methanol)
 Gas Treatment
 Refrigeration
• LNG  CO2 Compression
 Mixed Refrigerant (Urea)
 Propane
 Feed Gas
 Charge Gas
 Ethylene & derivatives
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GE Oil & Gas
Oil & Gas Industry Applications

Nuovo Pignone Compressors


Compressors overview Customer Training

Vertically split

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Compressors overview Customer Training

Horizontally split

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Compressors overview Customer Training

Single Volute

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Compressors overview Customer Training

Nuovo Pignone TAGs

2 BCL 406

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Compressors overview Customer Training

Nuovo Pignone TAGs

Literal Part

2 BCL 406
Casing
B=barrel Diffuser
P=pipeline L=free vortex (not vaned)
M=Middle Split Impeller design
S=single volute C=closed
R=open

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Compressors overview Customer Training

Barrel Type 2 BCL 406

Casing design pressure rating

 N p<150 bar
 A p<200 bar

BCL 406 /A
 B p<300 bar
 C p<400 bar
 D p<550 bar
 E p up to 1000 bar

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Compressors overview Customer Training

Pipeline Type PCL 406

pmax 150 bar

 Pipeline compressors are designed to maximize compression efficiency over the broad range of
operating conditions required by gas pumping stations;

 Suction and discharge nozzles for gas transportation are generally located opposite each other to
meet station layout requirements.

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Compressors overview Customer Training

Middle Split Type


2 MCL 406

Low pressure applications

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Compressors overview Customer Training

Single Volute Type


Integrally geared
SRL

 Impeller overhung mounted on the shaft; Single stage


 Each impeller has the discharge volute.

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Compressors overview Customer Training

2 BCL 406 IMPELLERS design

C= closed type

R= open type

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Compressors overview Customer Training

Free vortex DIFFUSER

2 BCL 406

Diffuser

No fixed blades

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Compressors overview Customer Training

Nuovo Pignone TAGs

Section arrangment Nominal diameter of the


impeller

n. of

2 BCL 406 impellers

Numerical Part

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Compressors overview Customer Training

2 BCL 406
Nominal size (mm)

400 mm

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Compressors overview Customer Training

Section arrangment
BCL...MCL...
suction discharge

 One compression section;

 In line configuration.

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Compressors overview Customer Training

Section arrangment
2 BCL... 2 MCL...
1 st
1 st discharge
suction
 Two compression sections in a single
2 nd 2 nd casing;
discharge suction
 Back to back configuration;

 Cooling of the gas;

 Tmax 250°C.

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Compressors overview Customer Training

Section arrangment
3 BCL... 3 MCL...
sidestreams
suction discharge

 More than two compression sections


in a single casing;

 Sidestreams.

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Compressors overview Customer Training

Section arrangment

D BCL... D MCL...
suction

discharge

 Two compression sections in parallel in the


same casing;

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Compressors overview Customer Training

Technology Selection Map

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GE Oil & Gas
Oil & Gas Industry Applications

Compressor rotating parts


Rotating parts Customer Training

Shaft
Impellers
Thrust Collar
Coupling hub

Balance drum
Spacers
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Thrust Collar Customer Training

 Transmits the rotor thrust to the thrust bearing;


 Fixes the axial position of the rotor;
 Hydraulically shrink-fitted to the shaft;

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Impeller Customer Training

The function of the


impeller is to add
energy to the gas.

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Impeller Customer Training

In order to minimize erosion and corrosion effects on impeller due to pitting or fouling phenomenon
related to gas composition, it is possible to use special stainless steel alloy with Ni-Cr-Mo or apply a
specific protective coating.
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Impeller Customer Training

The blades are bended The blades are bended and twisted

Impellers are fully customized

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Balancing Drum Customer Training

 Balances part of the axial thrust;

 Interference fitted and keyed;

 Positioned after the last impeller;

 Holes for rotor balancing.

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Coupling Customer Training

Connects elements between compressor and the remaining equipment of a compressor


train.

FLEXIBLE DRY type design is mostly used by NP

HUB

No lubrication is needed

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Coupling Customer Training

Basically a flexible coupling has the following functions:

1. Physically connect two rotating shafts

2. Accommodate Parallel Offset and/or Angular misalignment

3. Compensate for axial movement of coupled shafts

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GE Oil & Gas
Oil & Gas Industry Applications

Compressor stator parts


Stator parts Flanges and Nozzles
Customer Training

Diaphragms

Bearings Bearings

End cover
Seal
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Stator parts Customer Training

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BCL: Casing-Diaphragms Customer Training

LOWER HALF

UPPER HALF

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Casing-Diaphragms: bundle Customer Training

Diaphragms

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Casing-Diaphragms: bundle Customer Training

Return channel Diffuser

Blades
Labyrinth
seals

Impeller

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Casing-Diaphragms: bundle Customer Training

Suction volute Discharge volute

In new barrel compressors the inlet and disharge volutes are separated from the inermediate
diaphragms.
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Casing-Diaphragms: bundle Customer Training

The upper half of the bundle is lowered on the lower


half.

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Horizontally split Customer Training

The diaphragms are installed in the casing without a countercasing

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Flanges and nozzles Customer Training

Suction
Discharge

Discharge Sideflow Suction

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Flanges and nozzles Customer Training

In the barrel type for high or very high pressure, piping is directly connected to the casing
without nozzles;

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Shear and Shim rings Customer Training

Shim ring

Locking system using


shear and shim rings

Shear ring
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Head cover Customer Training

The functions of the head cover are:

 Close the bundle inside the casing;


 Guide the flow;

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Bearings Customer Training

Thrust bearing

Tilting pads type are adopted. The function of the thrust


bearing is to compensate part of the axial thrust.

 Direct Lubricated: lube oil is provided for each pad


through a groove manufactured on the pads

 Flooded: Oil fills the bearing assembly and drains


from the top through a flow control orifice

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Thrust Bearings Components Customer Training

Thrust bearing are self equalizing: the bearing distributes the load equally between all pads.

Thrust collar
Thrust shoes

Pivot

Base ring

Leveling plates

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Journal Bearing Customer Training

Jourbal bearing
Tilting pads type are adopted.
The functions of the journal bearing are:

 Support the rotor weight


 Create a lifting effect
 Damping effect

Two types of possible lubrication:

 Direct lubrication: Lube oil is provided for each pad through a


groove manufactured on the pads

 Flooded lubrication: The oil enter from an orifice in the upper


part of the bearing and exits in the lower part after the
lubriction of pads.

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Journal Bearing Customer Training

Bearings casing

Bearings pad

Pivot

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GE Oil & Gas
Oil & Gas Industry Applications

Centrifugal Compressor Gas Path


Gas Path Customer Training

SUCTION DISCHARGE

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Suction Customer Training

The gas flow is directed towards the


eye of the first impeller.

Fin
Casing
Shaft
Blade

Inlet Volute
Impeller
Suction Nozzle

Suction Pipe

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Suction Customer Training

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Suction Customer Training

Disk

Key

Shaft

Labyrinth Labyrinth
Seal Seal
Suction
diaphragm

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Intermediate stages Customer Training

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Single stage Customer Training

Diffuser

Blades

Return channel
Labirinth
seals

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Single stage Customer Training

++ +
Increased
P3,C3 velocity

C3=C1
P2,C2
optimal condition ++

P4,C4
P1,C1
+ Gas Inlet

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Single stage Customer Training
Velocity 4
Pressure
Energy

2
1
Impeller Blade Diffuser Diffuser
Inlet Inlet Inlet Outlet

1 2 3 4
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Discharge Customer Training

Discharge volute

Last impeller

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GE Oil & Gas
Oil & Gas Industry Applications

Centrifugal Compressor Axial Thrust


Axial Thrust Customer Training

P2 > P1

P2
P2

P1

Axial thrust
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Axial Thrust Customer Training

Balancing Drum

The BALANCE DRUM is a disk installed after the last impeller in order to balance part of the axial
thrust (80÷85%).

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Axial Thrust Customer Training

P2
P2

P1
Ps

R1 R2 Rd

Axial Force Drum Force


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Axial Thrust Customer Training

Axial Force Balancing Drum Force


Line

Ps Pd Ps+ΔP

Ps= Suction Pressure


Ps = Discharge Pressure
ΔP= Pressure Drop on balancing line

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Balancing line Customer Training

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GE Oil & Gas
Oil & Gas Industry Applications

Centrifugal Compressor
Performance Curves
Performance Curves Customer Training

Performance curves describe the relation of the centrifugal compressor operating


parameter and the inlet capacity.

 Polytropic Head
 Polytropic Efficiency
 Pressure Ratio
 Power
 Discharge Temperature
 Discharge Pressure

Qinlet
The performance curves are valid ONLY for the condition specified in the performance diaghram...
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Operating Range Maximum
continuous speed Customer Training
(MCS)

Normal operating
point
Discharge pressure (bar a)

Surge Limit
Line

Minimum
operating speed
(MOS) Choking Area
Qinlet
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Operating point Plant
Customer Training
resistance curve

 The plot represents the


envelope of all the possible
operating conditions relevant
to the given suction parameter.

 The actual operating point is


unique and it is always the
intersection between the
compressor curve at the given
speed and the plant
resistance curve. Operating
point

Qinlet
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Customer Training

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Off-design conditions Customer Training
Discharge pressure

MW Ts Ps

MW Ts Ps

Qinlet
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Other map variation cause: Customer Training

Normal working
Discharge pressure

graph

Internal recycles
effect

Qinlet

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Regulation Customer Training

According to API 617 the following regulating methods are defined:

 Speed Variation
 Suction throttling
 Variable inlet guide vanes (VIGV)
 Discharge blowoff
 Cooled bypass

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Regulation Customer Training

Discharge pressure

Qinlet
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Regulation Customer Training

Discharge pressure

Qinlet
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GE Oil & Gas
Oil & Gas Industry Applications

Choke, Stall, Surge and


Anti-surge Control System
Choking Customer Training

Choke rapresents the right limit of performance


curve.
Discharge pressure

Rapid decrease in performances and


efficiency.

Choking Area
Qinlet

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Surge Customer Training

 Surge is the left limit of performance curve, on the left of this line the compressor operates in
unstable condition;

 Represents the maximum polytropic head of the curve;

 All surge points, defined for different speeds represent the Surge Limit Line;

Surge Limit
Line
Discharge pressure

Qinlet
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Surge Customer Training

Flow inside the impeller

Normal operating P2
conditions P2 > P1

P1

Axial thrust
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Surge Customer Training

Flow inside the impeller

Surge condition P2

P1 > P2

P1

Axial thrust 83
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Factors leading to surge Customer Training

During NORMAL OPERATION:

 High discharge pressure (Increase of plant resistance);

 Reduction of suction pressure;

 Increase of suction temperature.

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Antisurge system Customer Training

The Antisurge System is composed by:

 Antisurge Valve

 Instrumentation:

 Flow indicator trasmitter

 Pressure indicator trasmitter

 Electronic controller

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Antisurge system Customer Training

The purpose of the Antisurge Control System is to avoid that the operating point reaches the SLL.
The opening of the Antisurge Valve increases the suction flow moving the operating point along the
speed.

FLOW PRESSURE PRESSURE


TRANSMITTER TRANSMITTER TRANSMITTER

FT PT PT

COMPRESSOR

ANTISURGE
CONTROL

ANTISURGE VALVE
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Antisurge system Customer Training

…just a clarification:

The anti-surge controller is a special electronic device that interacts with the
main control panel but is not depending from it.

The systems work together but are separately.

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GE Oil & Gas
Oil & Gas Industry Applications

Lube Oil System


Lube Oil System Customer Training

The function of the lube oil system is to provide the


right amount of lube oil to bearings with the desired
viscosity by regulating pressure and temperature.

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Lube Oil System P&ID Customer Training

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Tank
Centrifugal Compressor Training Course
22/11/2012
Lube Oil System P&ID Customer Training

Main
pump

91

Auxiliary pump Emergency pump Centrifugal Compressor Training Course


22/11/2012
Lube Oil System P&ID Customer Training

PCV

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Lube Oil System P&ID Customer Training

TCV

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Lube Oil System P&ID Customer Training

Filters

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GE Oil & Gas
Oil & Gas Industry Applications

Dry Gas Seals System


Sealing systems Customer Training

The function of the sealing system is to avoid gas leakages

Gap Statoric part

Rotating part

 Gas moves from high pressure sections to low pressure ones

 Gas property is to occupy all the available volume

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Sealing systems Customer Training

The function of the sealing system is to avoid two types of leakage

Process gas leakages between the Process gas leakages towards the
compression stages atmosphere

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Types of seals: Customer Training

 Fluid dynamic seals

 Labyrinth seals

 O-Ring gaskets

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Labyrinth Seals Customer Training

A labyrinth seal is a type of mechanical seal that minimize the gas leakages. Labyrinth seals on
rotating shafts provide non-contact sealing action by controlling the passage of fluid through a
series of teeth.

Plain Stepped Abradable

Efficiency
 Eye of the impeller
Main purpose is to minimize internal leakages
 Foot of the impeller close to the impellers due to different
pressure value at inlet and discharge.
 Balance drum
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Shaft end sealing Customer Training

Balancing Drum

Shaft End Seal Shaft End Seal

Balancing Line
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Dry gas seal system
Customer Training

Mechanical dry gas seal are


supplied as cartridges.

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DGS: main components Customer Training

Stationary ring Seal gas

Athmosphere Process
side side

Spring

SHAFT
Rotating ring

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Operating conditions Customer Training

 Gas enters the groove moving towards the center;

 Gas is compressed and pressure increases setting the gap between the rings.
Dynamic
Pressurization The pressure profile at the
Static Pressure + interface is self adjuxting to
Spring Thrust restore to a position of equilibrium
Seal
gas

Process Side

Seal
gas
Stationary ring Rotating ring
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Dry gas seal Customer Training

Shaft rotation Shaft rotation

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Gas source Customer Training

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Nomenclature TANDEM type: Customer Training
Primary vent (leakage from inbord seal Secondary vent (leakage from Outbord seal
+ intermediate buffer gas - to flare) STREAM 2 + separation gas - atmospheric) STREAM 4
Separation gas (N2)
Intermediate buffer STREAM 5
gas (N2)
STREAM 3
Seal gas STREAM 1

Atmosphere
(Bearing chamber)
Inboard seal

Carbon rings
Product side

Face
Seat Face
Seat
Inner seals Outboard seal Separation seal
Intermediate Labyrinth
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Dry gas seal: DOUBLE type Customer Training

Seal Seal gas


Buffer-Process gas gas supply leakage Separation gas
supply N2
N2

Process gas Bearings


side side

Inner seal Inboard seal Outboard seal Separation seal

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Tertiary seal Customer Training

The function of the tertiary seal is to avoid the oil vapours entering into the dry gas seal.

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Dry Gas Seal System P&ID Customer Training

Buffer Gas Filters

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Seal Gas Filters 22/11/2012


Dry Gas Seal System P&ID Customer Training

Buffer Gas
PCV

Seal Gas
PCV

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Dry Gas Seal System P&ID Customer Training

Primary Vent

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Dry Gas Seal System P&ID Customer Training

Secondary Vent

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Dry Gas Seal System P&ID Customer Training

Seal Gas
Heater

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GE Oil & Gas
Oil & Gas Industry Applications

Vibrations Overview
Mechanical behavior Customer Training

The measure of the mechanical behavior of a compressor is given by the amplitude


and frequency of the rotor vibrations.

The rotor vibration amplitude must not cause:

 Contact between rotating and stator parts;

 Dry gas seals overloading;

 Fatigue in the bearings.

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Vibrations classification Customer Training

The typical vibrations of the centrifugal compressors can be classified with reference to
the frequency and the nature of the force causing vibrations.

According to the first classification (frequency) the vibration may be:

 Synchronous
The vibration frequency corresponds to the machine rotation speed (ωR)
 Asynchronous
The vibration frequency is different from the machine rotation speed (ω R)

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Syncronous vibrations Customer Training

𝜔 = 𝜔𝑅
The most common causes are:

 Unbalance in the rotor system;


 Rotor and stator parts contact;
 Fouling deposit.

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Asyncronous vibrations Customer Training

It is necessary to do another distinction between frequency of the vibration and


machine rotational speed

 Frequency of the vibration multiple of ωR

𝜔 = 𝐾𝜔𝑅
 Frequency of the vibration lower or higher than ωR

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Asyncronous vibrations Customer Training

Frequency of the vibration multiple of ωR

𝜔 = 𝐾𝜔𝑅

The most common causes are:

 Coupling misalignment;

𝜔 = 2𝜔𝑅
 Loose of interference in some rotor components.

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Asyncronous Vibrations Customer Training

Frequency of the vibration lower or higher than ωR


The most common causes are:

 High clearance in journal bearings 𝜔 = 0.5 𝜔𝑅

 Oil whip; 𝜔 = ( 0.4 − 0.5 ) 𝜔𝑅

 Aerodynamic effects
(rotating stall in diffusers) 𝜔 = ( 0.1 − 0.2 ) 𝜔𝑅

 Cross - coupling 𝜔 = 0.2 𝜔𝑅


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What are the problems? Customer Training

The main problem that we have to consider when a rotor-bearing system is


subjected to a periodic force is the phenomenon of RESONANCE.

 A system is in resonance when vibration amplitude becomes maximum;

 This occurs when the frequency of a periodic force (excitation frequency), applied to a rotor-
bearing system, corresponds to a natural frequency of that system.

A centrifugal compressor has many natural frequencies that are colled Critical
Speeds;The most important are the first and the second; It is necessary to determine the
field operation speeds that avoid the resonance.

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API 617 Customer Training

𝑆𝑀 𝑜𝑝𝑒𝑟𝑎𝑡𝑖𝑛𝑔
𝑠𝑝𝑒𝑒𝑑𝑠
𝑉𝑖𝑏𝑟𝑎𝑡𝑖𝑜𝑛 𝑙𝑒𝑣𝑒𝑙

𝑆𝑀

0.707 𝑝𝑒𝑎𝑘

𝑁1 𝑁2
𝑁𝑐1 𝑁𝑚𝑐 𝑁𝑐𝑛

NC1 = Rotor first critical, center frequency, cycles per minute


Ncn = Critical speed, n th 𝑁𝑐𝑖
Nmc = Maximum continuous speed, 105 percent 𝐴𝐹 =
N1 = Initial (lower) speed at 0,707 x peak amplitude (critical) 𝑁2 − 𝑁1
N2 = Final (higher) speed at 0,707 x peak amplitude (critical)
SM = Separation margin

122
Centrifugal Compressor Training Course
22/11/2012
Customer Training

123
Centrifugal Compressor Training Course
22/11/2012

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