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Welcome from
Le HAVRE
Customer
Training department
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Prsentation
Name : DIESNIS PatrickDepartment : Customer training
FAMILIARISATION ON CENTRIFUGAL
COMPRESSOR
Purpose of this training :
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DISTRIBUTION OF
THIS PRESENTATION
TO ANY NON-
DRESSER-RAND
EMPLOYEE IS
PROHIBITED!
This presentation consists of
Copyright items and may not be
reproduced in any format, including
electronic or printed format, without
the prior written approval of the author,
Dresser-Rand Product Training, Le
Havre, FRANCE.
DO NOT REMOVE
THIS SLIDE FROM
THIS PRESENTATION!
The content of this presentation is considered intellectual property
of Dresser-Rand S.A. The contents of this program, either in part or
whole, may be used for internal or external presentations. However,
the contents may not be distributed or copied by any means
(electronic, on paper, etc.), in part or in whole, to non-Dresser-Rand
employees.
This slide MUST NOT be removed from this presentation or any partthereof.
Warning
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General arrangement
Gas turbine
Compressors
Gear
LP & MP HP
LP & MP = D10R6B
HP = D4R8S
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General arrangement
LP & MP = D10R6B
HP = D4R8S
LM 2500
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Planning
Dresser-Rands presentation. Introduction on the centrifugal compressors :
Fundamentals.
Types et models.
Compressor components :
Static and rotating parts.
First day :
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Planning
Compressor components :Static and rotating parts.
Thrust and bearings.
Several types of seals :
With labyrinths, with oil, with gas.
Presentation of the DRs gas seals.
Oil system : Oil console, cooler.
Second day :
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Planning
Oil system : Continuation. The surge.
How does a centrifugal compressor operate ?
Maintenance
Questions / answers
Third day :
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DRESSER RAND
PRESENTATION
Presentation
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Fundamentals
Components & function
Systems
Operation
Maintenance
Short course topics
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FONDAMENTALS
Compressor types
Basic principles
Centrifugal applications
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Axial
Centrifugal
Reciprocating
Compressor types
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Axial Compressor
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Axial compressor
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Axial compressor
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Axial compressor
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Centrifugal Compressor
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Centrifugal compressor
Compresseur centrifuge
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Centrifugal Compressor
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Centrifugal Compressor
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Centrifugal Compressor
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Reciprocating compressor
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Reciprocating compressor
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BASIC PRINCIPLES
Centrifugal action
A centrifugal stage
Energy conversion
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Centrifugal action
Velocity relationship
A
B
Centrifugal force = m . . r
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Centrifugal action
Exit path
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Low velocity
Low pressure
Gas inlet
High velocity
Higher pressureGas outlet
Cover Blades Disk
Centrifugal action
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Centrifugal stage
Guide vanes
Return channel
Return bend
Return bend
ImpellerIncreases velocity
Increases static pressure
DiffuserReduces velocity
Increases static pressure
How a centrifugal compressor works ?
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P3,V1,T3
P2,V2,T2
P4,V2,T4
P5,V1,T5
P1,V1,T1 P - PressureV - Velocity
T - Temperature
Energy conversion
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APPLICATIONS
Application parameters
Applications / Services
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Gases - All types of gases
Speed - 3,500 to 26,500 RPM Pressure - Vacuum to 724 bars
Flow range - 22,6 14720 m3/ min
Number of stages - 1 to 10 impellers
Application parameters
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ReciprocatingCentrifugal
Axial
Inlet flow m3/h
Outlet pressure bars a
Application parameters
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Horizontal split Vertical split
Designation of centrifugal
compressors
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Axially split
Radially split
Types of multi-stages centrifugals
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Radially split compressor in service
Types of multi-stages centrifugals
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Types of multi-stages centrifugals
Centrifuge joint radial
Radially split compressor in service
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Axially split compressor on test
Types of multi-stages centrifugals
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Large volume
Lower MWP
Lower RPM s
Smaller volumeHigher MWP
Higher RPM s
Sizes of compressors
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Large volume
Lower MWP
Lower RPMs
Smaller volumeHigher MWP
Higher RPMs
Sizes of compressors
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Sizes of compressors
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Sizes of compressors
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The name DATUM is an acronym of :
Dresser-Rand Advanced Turbo Machine.
The name is made of 5 components as follows :
D X Y N Z
Designation of centrifugal
compressors
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D : always D for Datum
X : frame size, one or two digits, 2 through 28 in step of 2
Y : case split design as follows :
R for Radial (Barrel type)
A for Axial (Horizontal type)
N : total number of impellers, one or two digits
Z : casing configuration as follows :
S for straight through , compound or side stream
B for back to Back arrangement
D for double flow arrangement
Designation of centrifugal
compressors
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Size of Datums
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Designation of centrifugal
compressors
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Centrifugal flowpaths
P1
P3
P5
P7
P9
Straight thru
or series flow
P11
P13
P15
P17
P1 65 bars
T1 40C
P17 205 bars
T17 139C
D4R8S
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Centrifugal flowpaths
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Centrifugal flowpaths
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Low P
High P
Net Impeller Thrust
Balance
Piston
LP
HP
Net Balance Piston Thrust
Thrust
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Thrust
Dia E = 270 mm
Dia d = 140 mm
9 kg / cm ofthrust
7 kg / cm
Diffuser
Area for the
thrust
calculation
Dia D
9 kg / cm
Shaft diameter : d 140 mmOuter di ameter of the i mpell er under the laby : E 270 mm
Axial thrust at the inlet of the impeller : P1 7 kg / cmAxial thrust at the outlet of the impeller : P2 9 kg / cm
Area of the diameter 140 154 cm
Area of the diameter 270 573 cmArea for the thrust calculation : 573 154 = 419 cm
Pressure differential between the impeller inlet and outlet 2 kg / cm
4
dE 12 PP =
4
140270 79 = 419 cm multiplied by 2 kg / cm = 838 kg
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Balance line
P1
P2
P3
P4
P5
P6
P6 P1
P1
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Balance line
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Sidestream inlet
Series flow with sidestreams
P1
P3 P5 P7 P9
Sidestream outlet
Centrifugal flowpaths
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Compound
P1
P3
P5
P7 P9
Centrifugal flowpaths
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Parallel or double flow
P1 P1
P5 P3P3
Centrifugal flowpaths
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Centrifugal flowpaths
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Back to back
divisionwall
P1
P13
P7s
Centrifugal flowpaths
P1 = 9 bars A P7s = 23 bars A
P7d = 24 bars A P13 = 69 bars A
T1 = 40C
T7d = 115C
T7s = 40C
T13 = 130C
D10R6B
P7d
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Centrifugal flowpaths
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Casing
Compressor internals
Rotor assembly
Bearings
Shaft seals
Components and function
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Axial split
on steel or iron casing
Casing
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Casing before machining
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Casing D4
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Casing D10
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Head 1st Section D10
W1-1
Secondary seal
gas supply
U2-1
Primary
vent
V2-1
Secondary
vent
L1-1Primary seal gas
supply
F3-1
Separation
gas supply
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Head 2nd Section D10
F3-1 Separation
gas supply
L1-1
Primary seal gas supply
U2-1
Primary vent
V2-1 Secondary vent
W1-1 Secondary
seal gas supply
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Mono-head 1st Section D04
F3-1 Separation
gas supply
L1-1
Primary seal gas
supplyU2-1
Primary vent
V2-1 Secondary
vent
W1-1 Secondary
seal gas supply
T1-1 Balanceconnector
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Head fixation
Head
Casing
Retaining ring
Shear ring
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Retaining ring
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Head fixation
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Casing fixation
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COMPRESSOR
INTERNALS
Diaphragms
Inlet, discharge and divisionwall
Return bend
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Bundle Components
ROTOR
BEARINGS& SEALS
HEADS
RETURN
BEND
DIAPHRAGMS
VOLUTE
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Cast diaphragm
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Fabricated diaphragm
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Fabricated diaphragm
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Fabricated diaphragm
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Fabricated diaphragm
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Low solididy diffuser
(diffuser vane)
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Diaphragm size differences
Frame 28
SF = 2.44
Frame 16
SF = 1
OD = 41
Frame 2SF = 0.35
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Internal (bundle)
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Cartridge
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Cartridge
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Cartridge
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Inlet wall
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Division wall
Division wall
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Division wall
Division wall
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Diffusers and labyrinths
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Return Bend
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Return bend
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Return bend
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Cartridge
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ROTATING PARTS
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Rotor
assembly
Impellers
Rotor assembly
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Thrust disc
Impellers
Balance piston
Seal area
Shaft
Bearing journals
Impellerspacers
Drive
coupling
mount
Rotor assembly
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Rotor assembly
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Different scales
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Impeller assembly
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Cover Blades Disk
Manufacturing Cast
Riveted
Welded
Two pieceThree piece
Types Open
Semi-enclosed Enclosed
Impeller design & construction
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Impeller design & construction
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Impeller design & construction
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Impeller design & construction
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RIVETED
Z BLADE
RIVETED
Impeller design & construction
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Impeller design & construction
One Piece MillingImpeller machined
from solid forging
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Electron-braze process
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Electron beam welded joint
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Electron-braze Joint
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Braze strips
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Placement of braze strips
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Placement of braze strips
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Electron-beam welding machine
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Lifting of the rotor
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BEARINGS
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Thrust bearings
Radial bearings
Bearings
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Radial bearings
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Radial bearings
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Retainer
Pad or shoe
Sensor
Spring
Radial bearings
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DR radial bearings
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DR radial bearings
DR di l b i
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DR radial bearings
T l f h ki th b i
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Tool for checking the bearings
T l f h ki th b i
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Tool for checking the bearings
Th t b i
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Thrust bearings
Th t b i
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Outboard
thrust bearing
Inboard thrustbearing
Thrust bearing pad
Thrust
bearing
cover
Thrust disc
Compressor
rotor shaft
Thrust bearings
Th t b i
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Thrust bearings
Th t b i
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Thrust bearings
Outboard
Inboard
Th t b i HP
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Thrust bearings HP
Thrust disc
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Thrust disc
Thrust disc
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Thrust disc
Tool for thrust disc
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Tool for thrust disc
H d li fit th t di
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Hydraulic fit thrust disc
S i l t l
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Special tools
S i l t l
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Special tools
Shaft seals
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Shaft seals
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SEAL SYSTEM
With labyrinths
With oil
With gas
Seal inside the compressor
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External seals
Internal seals
Seal inside the compressor
Seal around the shaft
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Seal around the shaft
Seals
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Labyrinths seal
Oil film seal
Barrier seal
Gas seal
Seals
Interstage seals
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Interstage
laby seals
Location P1
P2
P3
P3
P4
P5
Function
Interstage seals
Interstage seals
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Interstage seals
Impulser
Shaft
Interstage
Laby seal
Labyrinths
ShaftGas
Interstage seals
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Interstage seals
Interstage seals
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Interstage seals
Interstage seals
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Interstage seals
Labyrinth hole pattern
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Labyrinth hole pattern
Labyrinth hole pattern
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Labyrinth hole pattern
Labyrinth hole pattern
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Labyrinth hole pattern
Labyrinth hole pattern
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y p
D10R6B Bundle assembly
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D10R6B Bundle assembly
D10R6B Bundle assembly
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D10R6B Bundle assembly
D04R8S Bundle assembly
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D04R8S Bundle assembly
D04R8S Bundle assembly
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D04R8S Bundle assembly
Labyrinth seals
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y
Labyrinth seals
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y
Labyrinth seals
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y
Oil seal
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Why ?
If no leak of the compressed fluid are allowed,
the system with labyrinths is reinforced with
oil seal.
Sometimes labyrinth seals are
replaced with oil seal.
Oil seal
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Yes but . !!!
Oil system imposes a seal oil circuit.
Seal oil circuit
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Seal oil circuit
Oil
tank
Pumps
Coolers
Filters
Single breakdown
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Labyrinth
Inner sealring
Outer seal ring
Low pressure reference
Sweet oil
Seal oil
supply
Sour
oil
Oil film seal
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Seal oil
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Barrier against gas
Lubrication of the seal
Removal of heat
Why ?
Gas seals
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Typical DR gas seal arrangement
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INBOARD OUTBOARD
Primary seal
(active)
Secondary seal
(backup)Barrier seal
Gas seals
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Simplified section
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Top of the grooves
Rotating ring
Static ring
L sleeve
Orings
Spring
DR Gas Seal
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3D pressure profile between the seal faces
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Over pressurized
areas are creating
the lift-off effect
The vertical projection of the3D pressure profile shows
isobar curves
Pressure profile
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-0.05
0
0.05
-0.05
0
0.05
0
10
20
30
40
50
60
Pressure (BarA)
Plane of Rotating Seat
Supply
Pressure
at O.D.
Atmospheric
Pressure
at I.D.
54.1
Isobars representation
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52.3
50.548.8
47
45.2
43.5
41.7
39.9
38.2
36.4
34.6
32.9
31.1
29.3
27.525.8
24
22.2
20.5
18.7
-0.05
0
0.05
-0.0500.05
11500 RPM 50 Bars
Isobars (Different speeds)
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11500 RPM , 50 Bars'PRESdr.RTT'
54.1
52.3
50.5
48.8
47
45.2
43.5
41.7
39.9
38.2
36.4
34.6
32.9
31.1
29.3
27.5
25.8
24
22.2
20.5
18.7
16.9
0.04
0.05
0.06
0.07
0.08
0.09
-0.050
500 RPM , 50 Bars'PRESBV.RTT'
52.3
50.5
48.7
46.8
45
43.2
41.3
39.5
37.7
35.8
34
32.2
30.3
28.5
26.7
24.8
23
21.2
19.3
17.5
15.7
13.8
0.04
0.05
0.06
0.07
0.08
0.09
-0.050
Isobars (Different pressures)
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11500 RPM , 150 Bars
11500 RPM , 2 Bars
'PRES150.RTT'157
151
146
141
136
131
125
120
115
110
105
99.5
94.3
89.1
84
78.8
73.6
68.4
63.258
52.9
47.7
0.04
0.05
0.06
0.07
0.08
0.09
-0.050
'PRES002.RTT'
3.47
3.06
2.65
2.24
1.83
1.42
0.04
0.05
0.06
0.07
0.08
0.09
-0.050
Gas seals with labyrinths
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Clean and dry
separation gas F3
Clean and dry
gas seal L1
Secondary
ventilation
V2
Primary
ventilation
U2
Seal sleeve
Rotating parts for
seal
Stationary
carbon ringSeparation
seal
Stop mode
Bearingvent H2
PressurisationRunning mode
Stop mode
Pressurisation
Running mode
ShutdownD10
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For the D04
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Gas seals Dresser Rand
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Conditioning skid
SOP
D10
D04
Conditioning skid
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Conditioning skid
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Gas seals cartridge
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Barrier seal
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SEAL SYSTEM
Summary
With labyrinths
With oil
With gas
Labyrinth seal system
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Compressor
Oil seal system
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Dry gas seals system
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Piping diagram
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LUBE OIL
SYSTEM
Lubrication system
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Oil console GA
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Lube oil console P&ID
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To the gear
Machines
From the
gear
Lube oil system P& ID
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Stop modeRunning mode
To
console
Console
Fromconsole
Dual filters
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Flow glass
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PCV 380 et 375
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Driven pump
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Oil demister
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MACHINERY
PROTECTION
Temperature system
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Machinery protection system
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Go to probe software 01
Go to probe software 02
Vibration system
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Shaft
Gap
Probe support
Probe cable
(50 ohms)
Extension cable
(95 ohms)
Connectingdevice
Proximitor
Power supply
-18 volts
direct current
SPower supply and
control feedback
Monitor or any
control material
Vibration system
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Gap = 1,8 mm
Gap = 0,8 mm
Gap = 0 mm
+10 V
-10 V
+2 V
-2 V
0 V
OUTPUT
COM
- 18 VDC
Vibration system
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Vibration system
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Axial probe
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Vibration system
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Temperature & vibration P&ID
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Machinery protection system
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Machinery protection system
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Compressor control system
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Local control (on control panel)
Start up / Shutdown / MonitoringUnit and auxiliaries
Remote control (DCS)Unit control system
Station control systemPlant control system
Local control (on skid)Emergency shutdownControl system of the machine
Compressor control system
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Local control (on skid)Emergency shutdownControl system of the machine
Compressor control system
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Local control (on control panel)
Start up / Shutdown / MonitoringCompressor and auxiliairies
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PERFORMANCE
CURVES
SURGE & ANTI SURGE
Go to anti surge software
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INSTALLATION
&
GROUTING
Alignment
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OFFSET
ANGULAR
VERTICAL
ALIGNMENT
HORIZONTAL
ALIGNMENT
Compressor shaft alignment
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Compressor shaft alignment
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Casing fixation
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Maintenance
on the DATUM
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Safety precautions
Disassembly
Inspection
Re-assembly Special tools
Spare parts
COMPRESSOR
MAINTENANCE
Pre-start inspection
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Gauges calibrated
Sensors check and calibrated
Hand valves in proper position
Check valves installed properly
Safety and shutdown devices checked and
operational
Pre-start checks
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Observe all vendor equipment instructions
Check casing drains for condensate
Turn on instrument air
Place the seal system in operation
Place the lube system in operation
Each shift
Routine operations
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Each shift Unit walk around (if possible)
Observe all pressures, temps, vibrations and flows
Record all pressures temps, vibrations, and flows
Compare readings to expected values
Take appropriate action
Weekly Check any filter differential pressure
Check actuation of standby / emergency pumps (if possible)
Record any findings
Quarterly Test safety devices (if possible)
Calibrate gauges and devices (if possible)
Perform oil analysis Record any findings
Safety precautions
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Wear personal protective. Check site for potential safety hazards /
evacuation procedures.
Follow vendors service procedures and
safety recommendations. Follow internal procedures.
Use hand / power / special tools properly.
Use safe rigging practice.
Cover any compressor openings.
Radial split disassembly
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Radial split disassembly
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Radial split disassembly
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Radial split disassembly
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Radial split disassembly
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Radial split disassembly
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Maintenance considerations
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BUNDLE CRADLE
SUPPORT BUNDLE
CRADLE
Maintenance considerations
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BUNDLE + ROTOR +
BEARINGS + SEALS
Inspection
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Disassembly inspection
Component inspection
visual & dimensional
Inspection methods Re-assembly inspection
Inspection records
Possible causes for an event
Small special tools
Special tools
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couplings, bearings,
and seals
Big special tools -
assembly and lifting
Inspection of special tools
Storage of special tools
Special tools
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Special tools
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Thrust disc
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Hydraulic fit thrust disc
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Special tools
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Special tools
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Compressor parts
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Special tools
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Bundle insertion tool
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Bundle cradle
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Questions
questio
ns?
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Doyou h
ave any
Centrifugal compressor
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QUIZ
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Thank you foryour attention