Compressors and Modern Process Applications

346 Pages·2006·66.258 MB·English

by  Bloch, Arvind Godse

Compressors and Modern
Process Applications
Compressors and Modern
Process Applications
Heinz P. Bloch
Process Machinery Consulting
West Des Moines, Iowa
A JOHN WILEY & SONS,INC.,PUBLICATION
The equipment and process descriptions used in this book represent configurations and practices in successful use at the time they were being submitted to
the principal author (typically years 2001–2005). However, technology does not stand still. It will thus be to the user’s advantage to seek information on new
developments and to consider occasional upgrade measures that may have been either implemented or advocated for equipment and processes since then.
We wish to emphasize that neither the contributors nor the publishers and/or holders of process licenses are representing this text to be a stand-alone
implementation document. Also, the various photos and illustrations (see credits page xi) may not always represent the most up-to-date equipment and
component configuration. Accordingly and before proceeding with the purchase of equipment and processes, the reader must consult with the other parties
and obtain their written updates, comments, and concurrence.
Copyright © 2006 by John Wiley & Sons, Inc. All rights reserved.
Published by John Wiley & Sons, Inc., Hoboken, New Jersey.
Published simultaneously in Canada.
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Library of Congress Cataloging-in-Publication Data:
Bloch, Heinz P., 1933–
Compressors and modern process applications / Heinz P. Bloch.
p. cm.
Includes index.
ISBN-13: 978-0-471-72792-7 (cloth)
ISBN-10: 0-471-72792-X (cloth)
1. Compressors. I. Title.
TJ990.B54 2006
621.5'1—dc22
2005035955
Printed in the United States of America.
10 9 8 7 6 5 4 3 2 1
Contents
Preface ix Chapter 2. Rotary Compressors as a Category 21
2.1 Helical Screw Compressors 21
Illustration Credits and Photo Acknowledgments xi 2.2 Overview of Operating Principles 21
and Basic Construction
PART I 2.3 Considerations for Screw 24
Compressor Staging
Chapter 1. Positive Displacement Compressors 3 2.4 Reasons for Using Screw 29
1.1 Reciprocating Compressors 3 Compressors
1.2 Major Components Described 3 2.5 Oil-Free Versus Oil-Flooded 29
1.2.1 Crankcase 3 Twin-Screw Compressors
1.2.2 Crankshaft 4 2.5.1 Bearings 29
1.2.3 Connecting Rod 4 2.5.2 Shaft Seals 30
1.2.4 Crosshead 4 2.5.3 Internal Seals 30
1.2.5 Lubrication 4 2.6 Screw Compressor Volume Control 30
1.2.6 Cylinder Materials 5 Control by Variable Speed 30
1.2.7 Cylinder Sizing 5 Bypass 31
1.2.8 Cylinder Cooling 6 Full-Load/Idling Speed 31
1.2.9 Pistons 10 Governor
1.2.10 Piston Rods 10 Suction Throttle Control 31
1.2.11 Packing 11 2.6.1 Volume Control for Screw 31
1.2.12 Gaskets 12 Compressors Equipped with Oil
1.3 Comparison between Reciprocating 12 Injection (Oil-Flooded
and Centrifugal Compressors Compressors)
1.3.1 Gas Properties and 13 2.7 Screw Compressor Auxiliaries 31
Process Conditions 2.7.1 Suction Scrubber and 31
Gas Analysis 13 Drain Seal Drum
Molecular Weight 14 2.7.2 Primary Oil Separator 32
Polytropic Exponent 14 and Oil Reservoir
Flow Rate 15 Principles of Oil Separation 32
Inlet and Discharge Pressure 16 2.7.3 Secondary Separator 33
Temperature 16 2.7.4 Oil Cooler 33
Heat Balance 16 2.7.5 Compressor Aftercooler and 33
1.4 Series and Parallel Operation 16 Discharge Scrubber
Compressors and Modern Process Applications. By Heinz P. Bloch. v
Copyright © 2006 John Wiley & Sons, Inc.
vi CONTENTS
2.7.6 Oil Purifier or Oil 33 Dry Gas Seal Support 70
Conditioner Systems
2.8 Issues with H S in All Gas 33 Reliable Auxiliaries are 72
2
Compressors Important for Dry Gas
2.9 Considerations for Upstream 33 Seals
Separators
Chapter 4. Power Transmission and Advanced 75
2.9.1 Process Example 33
Bearing Technology
2.9.2 Reviewing the Problem and 34
4.1 Couplings for Rotary Positive- 75
Outlining the Solution
Displacement and Centrifugal
Contaminant Removal 34
Compressors
Design Peculiarities of 34
4.1.1 Coupling Functional 75
Self-Cleaning Reverse-
Parameters Types, and
Flow Mist Coalescers
Configurations
Conventional Equipment 35
4.1.2 Marine-Style Couplings 78
Examined
and Reduced Moment
Case Histories Involving 37
Geometries
KTCs and Claimed
4.1.3 Coupling Assembly and 78
“Equivalents”
Selection Summary
Gas Analysis and Its Value 37
4.2 Magnetic Bearings for Compressor 79
Upstream Separator 37
Rotors
Recommendations Can
4.2.1 Early Applications of 79
Be Generalized
Magnetic Bearings
4.2.2 Operating Principles of 79
Chapter 3. Understanding Centrifugal Process 39
Active Magnetic Bearings
Gas Compressors
Explained
3.1 Where Centrifugal Compressors 39
4.2.3 Load Capacity 81
Excel
4.2.4 Magnetic Bearing Hardware 81
3.2 Centrifugal Compressors, Fans, or 40
Radial Magnetic Bearings 81
Blowers?
Magnetic Thrust Bearings 82
3.3 Centrifugal Compressor 40
Auxiliary Bearings 82
Configurations and Components
Magnetic Bearing Control 83
3.3.1 Horizontally Split 40
System
Compressor Casings
4.2.5 Technology Status and Case 85
3.3.2 Vertically Split Compressor 42
Histories
Casings
Case History No. 1—Cycle 85
3.3.3 Compression Stages Versus 47
Gas Compressor Used for
Sections
Polyethylene Production
3.3.4 Compressor Impellers 47
Case History No. 2— 85
Impeller Geometry 49
Natural Gas Storage
3.3.5 Impeller Arrangements on 51
Compressor
Compressor Shafts
4.2.6 Application Summary 86
3.3.6 Diffusers 52
4.3 Externally Pressurized Bearings 86
3.3.7 Internal Labyrinths 55
4.4 General Condition Monitoring of 87
3.3.8 Bearings 56
Process Gas Compressors
3.3.9 Shaft Seals 62
4.5 Combining Troubleshooting and 88
Dry Gas Seals and 66
Continuous Monitoring of Dynamic
Support Systems:
Data for Critical Machinery
Benefits and Options
4.5.1 Overview of Recent 88
Life Cycle Cost 67
Developments
Comparison of Dry
4.5.2 Innovative Data Acquisition 88
Gas Versus Wet Sealing
Tools
Systems
4.5.3 Early Case Study Tells the 89
Principles of Dry Gas 67
Story
Seals and Construction
4.5.4 Current Application 89
Features
Explained
CONTENTS vii
4.5.5 Anticipating Future 93 Chapter 7. Application Considerations 115
Developments 7.1 Applications and Industry Sectors 115
7.2 Air Separation Plants and 115
Chapter 5. Centrifugal Compressor Performance 95 Compressors for Instrument and
5.1 Compression Processes and 95 Plant Air Services
Efficiencies: Polytropic Versus 7.3 Natural Gas Processing Industry 115
Isothermal 7.4 Offshore Industry 117
5.2 Specific Speed (N) and the Flow 95 7.5 Refining Industry 118
s
Coefficient ((cid:1)) 7.6 Petrochemicals and Fertilizers 119
5.2.1 Flow Coefficient ((cid:1)) 95 7.7 Steel Industry 124
5.2.2 Pressure Coefficient or 96 7.8 Special Applications 126
Head Coefficient ((cid:2))
5.2.3 Mach Number 97 Chapter 8. Using API-617 as a Purchase 127
5.2.4 Surge and Surge Control 99 Specification for Centrifugal
Variable Speed Operation 107 Compressors
and Surge Issues 8.1 Compressor Revamps 131
5.2.5 Development of Head 107
5.3 Estimating Compressor Performance 107
5.4 Controls 107 PARTII 133
5.4.1 Integrating Machine and 108
Process Control Strategies Segment 1 Gas Processing 157
5.5 Throughput Control Options 109
Segment 2 Refining Processes 209
Chapter 6. Testing 111
6.1 Centrifugal Compressor Testing 111 Segment I3 Petrochemical Processes 269
6.2 Types of Performance Tests 111
6.3 The ASME Power Test Code 113 References 329
(ASME PTC 10)
6.3.1 Future Value of Performance 114 Index 331
Testing
Preface
WHY THIS BOOK WAS COMPILED self-contained and will be very useful to readers interested in
how and why the physical equipment works. The later chap-
The segregation of job functions into project, maintenance, ters allow more advanced readers to see the underlying analy-
administrative, operations, purchasing, and so on often leaves ses that make possible the design of virtually all compres-
gaps in the sum total of the understanding needed to optimize sors. We must keep in mind, however, that dealing with
the safety, reliability, and profitability of modern process essentials may not leave enough room for discussion of every
plants. Yet, each of these job functions is known to have an detail, and an expert will certainly appreciate this fact. So,
influence on the business-related goals of an industrial facili- for all details not to be within the scope of this text should
ty. Therefore, a measure of knowledge of capital equipment come as no surprise; squeezing decades of compressor de-
and processes must be imparted to the various groups in- sign, maintenance, and operating know-how into an introduc-
volved in the facility’s. Intelligent discourse must exist and tory overview text is simply not possible. An expert will also
certain basic facts must be accepted by the various parties. agree that persons performing some job functions have nei-
Needless to say, compressors represent a multimillion dol- ther the need nor the time for reading hundreds of pages of
lar investment for many plants, and profitability can be nei- compressor details. On the other hand, a text that is aimed at
ther reached nor sustained by organizations that neglect this imparting an understanding of critically important parame-
critically important asset. This is clearly brought out in more ters and interactions is both feasible and worth the effort.
detailed compressor texts; these are available and listed in the This, too, is what we have set out to achieve here.
references. However, whereas these more detailed texts have The entire text will prove useful to managers, engineers,
often been recommended for and by machinery reliability and technicians who need overview-type access to compres-
professionals, a condensed overview of compressor design, sor-related issues that range from specification, through fab-
operation, and maintenance is desired by other job functions rication and field erection, to compressor operation and
and will thus be given in this book. This material will assist maintenance. Recognizing the mechanical/process interac-
the very wide spectrum of readers whose process involve- tion, the text in Part II endeavors to transition to process-flow
ment brings them into contact with large process compres- schemes in three major segments. These three segments deal
sors. As an example and to run a smooth organization, termi- with petroleum refining, petrochemical, and gas processes.
nology must be unified and misconceptions dispelled Each segment identifies application and location of gas com-
wherever they creep into our thinking. That is one of the aims pressors and turboexpanders in over 300 processes that uti-
of this book. lize these machines. Many compressor essentials are de-
Along these lines, our overview of process gas compres- scribed in conjunction with the first two segments of Part II,
sors dealing with positive-displacement machines, and espe- dealing with refining processes and petrochemical processes,
cially the later chapters concerned with centrifugal compres- respectively. Turboexpander details are highlighted in con-
sors, are intended to equip the reader with the essentials. As junction with the third segment, explaining what the hydro-
is done in certain encyclopaedias, the beginning chapters are carbon processing industry collectively calls “gas processes.”
Compressors and Modern Process Applications. By Heinz P. Bloch. ix
Copyright © 2006 John Wiley & Sons, Inc.
x PREFACE
Finally, we have made a conscious effort not to duplicate were ably assisted by Larry Miller and Christopher Starszak.
either the approach or the content of other books by the lead At Demag Delaval, now Mannesmann Demag Delaval, we
author or, for that matter, any compressor and compressor are very much indebted to David Kiser. Dave went the extra
application text known to be available today. We are certain distance with his competent support.
this book will be useful as a stand-alone text or as a compan- Virtually all turboexpander illustrations and details on ap-
ion text to other books. Also, many university students will plications in the United States and overseas were provided by
appreciate the value of this book as they embark on and Mafi-Trench (Santa Maria, California). Duane Bergmann
progress in careers in the process industries. We would be and Randy Dirlam were most helpful in collecting the needed
gratified to have been of assistance. data.
Through these contributors, we also obtained worldwide
application and location information for the compressors de-
ACKNOWLEDGMENTS signed and manufactured by their respective companies. But
consulting companies and individual reliability professionals
The narrative of the centrifugal compressor text was coau- were also very responsive when we asked their permission to
thored by Heinz Bloch and Arvind Godse. At the time of con- incorporate elements of their work in our text.
tributing the bulk of Chapters 3 through 8, Mr. Godse was Manjul Saxena compiled data on dry gas seals and Mike
engaged in providing project-technical and equipment relia- Saunders of Houston-based Flexelement Texas collaborated
bility engineering services in Muscat, Oman. Because this on the overview material dealing with couplings. The mate-
material forms the essence of these important chapters, rial on computerized machinery data evaluation we owe to
Arvind derserves special mention and thanks. Ken Atkins of Engineering Dynamics (San Antonio, Texas)
Almost all of the material on positive-displacement ma- and Chet Farabaugh of Kingsbury, Inc. (Philadelphia, Penn-
chines originates with a professional colleague and highly es- sylvania) compiled the segments on magnetic bearing tech-
teemed mentor, Ralph James, Jr. His untimely death in 1979 nology.
is still recalled and his contributions to the practical side of Gulf Publishing Company’s HP publisher Gene Swantek
reliability engineering will not be forgotten by those who (now retired) graciously allowed us to use process schematics
knew him. Ralph was once challenged to perform the tor- from Hydrocarbon Processing’s different refinery, petro-
sional analysis of a machinery train from memory. He did it, chemical, and gas processing handbooks. Uri Sela (Walnut
right then, on the back of an envelope. Creek, California) gave us excellent suggestions on how to
Indeed, we rarely accomplish much without additional organize this book so as to best serve our target audience.
contributors. In this instance, we wish to acknowledge that Again, we are expressing sincere appreciation to everyone
most of the compressor illustrations were provided by A-C for extending cooperation and permission to both use and
Compression, Appleton, Wisconsin, and Demag Delaval further develop the information contained in this text.
(now Mannesmann Demag Delaval), with major plants in
Duisburg, Germany, and Trenton, New Jersey. At A-C, we HEINZP. BLOCH
Illustration Credits and
Photo Acknowledgments
Aerzener Maschinenfabrik: See “Maschinenfabrik Aerzen,” King Tool Company, Longview, Texas: Gas Filtration and
below. Moisture Separation Equipment, Reverse-Flow Coa-
A-C Compressor Corporation, Appleton, Wisconsin: Recip- lescers, etc. (2-10 through 2-13)
rocating and Rotary Displacement Compressors, Dynamic Kingsbury, Inc., Philadelphia, Pennsylvania: Hydrodynamic
Compressors, (3-16, 3-20, 7-1, II-1 through II-7) Radial and Thrust Bearings, Magnetic Bearings (3-23, 4-6
Ameridrives Couplings, Erie, Pennsylvania: Power Transmis- through 4-16)
sion Products, (4-1, 4-2) MAN-GHH, Oberhausen, Germany: Reciprocating and Ro-
API/American Petroleum Institute, Alexandria, Virginia: API tary Displacement Compressors, Dynamic Compressors,
Standards (1-5, 2-4, 2-5, 3-5) Turboexpanders, Steam Turbine Drivers, etc. (2-2, 2-6)
Babcock-Borsig, Berlin, Germany: Reciprocating and Rotary Mannesmann Demag Delaval, Duisburg, Germany: Recipro-
Displacement Compressors, Dynamic Compressors, Tur- cating and Rotary Displacement Compressors, Dynamic
boexpanders, Steam Turbine Drivers, etc. (1-7, 1-11, 6-1, 7-9) Compressors, Turboexpanders, Steam Turbine Drivers, etc.
(3-2 through 3-4, 3-8 through 3-13, 3-15, 3-17, 3-19, 3-21,
Burckhardt Compression, Winterthur, Switzerland: Recipro-
3-27, 5-8, 7-2, 7-3, 7-4, II-8 through III-15)
cating and Rotary Displacement Compressors, Labyrinth
Piston Compressors, (1-1, 1-3, 1-13, 1-14) Mafi-Trench Corporation, Santa Maria, California: Turboex-
panders (I-1 through I-12)
Cooper-Bessemer (now Rolls Royce), Middlesex/ UK and
Houston/Texas: Centrifugal Compressors for Pipeline Ser- Maschinenfabrik Aerzen, Aerzen, Germany, also Coatesville,
vices (7-5, 7-6) Pennsylvania: Blowers, Rotary Displacement Compres-
sors, (2-1, 2-3)
Demag: See Mannesmann Demag Delaval, below.
Mitsubishi Heavy Industries (MHI), Tokyo, Japan: Recipro-
Dresser-Rand Corporation, Olean, New York: Dynamic Com-
cating and Rotary Displacement Compressors, Dynamic
pressors, Turboexpanders, Steam Turbine Drivers, etc. (Ta-
Compressors, Turboexpanders, Steam Turbine Drivers, etc.
bles 3-1 and 3-2)
(3-28, 7-12)
Dresser-Rand Corporation, Painted Post, New York: Recipro-
Nuovo Pignone, Florence, Italy: Dynamic Compressors, Tur-
cating and Rotary Displacement Compressors, (1-2, 1-4,
boexpanders, Steam Turbine Drivers, Reciprocating and
1-6, 1-9, 1-12)
Rotary Displacement Compressors, etc. (1-8, 1-10, 2-7, 2-
Flexelement Texas, Houston, Texas: Couplings (4-3 through
8, 7-7, 7-10, 7-11)
4-5)
Sulzer Turbo, Winterthur, Switzerland: Dynamic Compres-
John Crane Company, Morton Grove, Illinois: Sealing Prod-
sors, Turboexpanders, Steam Turbine Drivers, etc. (3-1, 5-
ucts (3-30, 3-32)
1, 7-8)
Kaydon Ring and Seal, Inc., Baltimore, Maryland: Gas, Oil,
Zurn Industries. See Ameridrives Couplings.
and Water Seals, Face-type and Circumferental geome-
tries: (3-24 through 3-26)
Compressors and Modern Process Applications. By Heinz P. Bloch. xi
Copyright © 2006 John Wiley & Sons, Inc.