Forsthoffer's Rotating Equipment Handbooks, Vol. 3: Compressors (Forsthoffer's Rotating Equipment Handbooks) PDF
Preview Forsthoffer's Rotating Equipment Handbooks, Vol. 3: Compressors (Forsthoffer's Rotating Equipment Handbooks)
Forsthoffer's Rotating Equipment Handbooks This page intentionally left blank Forsthoffer's Rotating Equipment Handbooks Volume 3: Compressors W E (Bill) Forsthoffer President, Forsthoffer Associates Washington Crossing, PA, USA ELSEVIER UK Elsevier Ltd, The Boulevard, Langford Lane, Kidlington, Oxford OX5 1GB, UK USA Elsevier Inc, 360 Park Avenue South, New York, NY 10010-1710, USA JAPAN Elsevier Japan, Tsunashima Building Annex, 3-20-12 Yushima, Bunkyo-ku, Tokyo 113, Japan Copyright © 2005 W E Forsthoffer. Published by Elsevier Ltd. All rights reserved. ISBN 1-85617-469-7 All rights reserved. No part of this publication may be reproduced, stored in a retrieval system or transmitted in any form or by any means: electronic, electrostatic, magnetic tape, mechanical, photocopying, recording or otherwise, without permission in writing from the publishers. British Library Cataloguing in Publication Data A CIP Catalogue record for this book is available from the British Library No responsibility is assumed by the Author or Publisher for any injury and/or damage to persons or property as a matter of products liability, negligence or otherwise, or from any use or operation of any methods, products, instructions or ideas contained in the material herein. Published by Elsevier Advanced Technology, The Boulevard, Langford Lane, Kidlington, Oxford OX5 1GB, UK Tel:-H44(0) 1865 843000 Fax:-h44(0) 1865 843971 Typeset by Land & Unwin Ltd., Northamptonshire Printed and bound in Great Britain by MPG Books Ltd, Bodmin, Cornwall Contents Preface Xlll Acknowledgements XV About the author xvii 1 Rotating equipment overview Introduction I Definition of rotating equipment I Classifications of rotating equipment 3 Site equipment examples 4 Performance and mechanical design similarities 6 The equipment 'train' or 'unit' 8 Important fundamentals 9 2 Compressor types and applications 13 Introduction 13 Positive displacement compressors 15 Dynamic compressors 21 3 Compressor characteristics 29 Inroduction 29 Positive displacement compressors 31 Actual volume, standard volume and mass flow 33 Dynamic compressors 36 4 Operation of a compressor in a system 43 Introduction 43 The definition of a process system 45 System resistance curves 46 The operating point 49 A positive displacement compressor in the process system 50 A dynamic compressor in the process system 50 5 The concept of fluid head 53 Introduction 53 Definition 54 Paths of compression 59 The different types of gas head 59 Dynamic compressor curves format 62 6 Performance relationships 63 Introduction 63 Satisfying the objective 64 Gas characteristics 65 Compression head 67 Impeller types and specific speed 67 Efficiency 70 Horsepower 71 The Fan Laws 72 7 What determines the turbo-compressor curve shape 73 Introduction 73 The compressor stage 73 Impeller with side plate removed 75 Impeller discharge velocities 77 Blading types 79 8 Surge (stall) and stonewall 83 Introduction 83 Surge facts 85 The limits of the curve 87 ••HBHBHHHHHHnHn^^ Contents What causes surge 88 What causes stonewall (choke) 91 9 Turbo-compressor individual stage and overall performance 95 Introduction 95 The stage curve 97 The overall curve 98 Determining section performance 100 10 The effect of a gas density change 103 Introduction 103 The factors involved 105 The effect on turbo-compressor pressure ratio 106 The effect on the compressor head 106 The effect on system resistance 109 The effect on turbo-compressor flow rate 109 The effect on power 110 11 The effect of fouling 113 Introduction 113 The mechanism of fouling 113 The effect of fouling on the operating point 114 The causes of fouling 117 Detecting fouling by condition monitoring 119 Preventing and correcting fouling 120 Corrective measures 123 12 Turbo-compressor control overview 125 Introduction 125 The objectives 127 Adjusting to system changes 128 Adjusting the turbo-compressor performance curve 130 Turbo-compressor protection 133 Contents mmmmmmmmaammmmmmmammmmm^ 13 Surge control systems 137 Introduction 137 System objectives 137 Available options 138 System design considerations 139 A history of system types 139 14 Turbo-compressor mechanical design overview 143 Introduction 143 The casing 145 The inlet guide vanes 146 The rotor 147 Diaphragms 148 Inter-stage seals 149 Shaft end seals 150 Journal bearings 153 Thrust bearings 154 15 Compressor casings and stationary internals 159 Introduction 159 Casing functions 160 Casing types 161 Casing fabrication options 165 Casing stresses and deflections 166 16 Centrifugal compressor rotor design 169 Introduction 169 Shaft end design 170 Rotor stiffness 172 Basic rotor configurations 172 Rotor assembly 173 Rotor balance 176 VIM 17 Flexible coupling design, installation and operation 179 Introduction 179 The coupling function 179 180 Types The coupling system 188 Coupling installation and removal 191 Enclosed coupling guards 194 Field retrofits from lubricated to dry couplings 195 18 Radial bearing design 197 Introduction 197 Anti-friction bearings 198 Hydrodynamic bearings 200 Hydrodynamic bearing types 202 Condition monitoring 205 Vibration instabilities 207 19 Critical speeds and rotor response 213 Introduction 213 Critical speeds 2 14 The rotor system (input) 217 Rotor response (output) 220 Measured rotor response 224 20 Rotor axial (thrust) forces 225 Introduction 225 The hydrodynamic thrust bearing 226 Impeller thrust forces 230 Rotor thrust balance 231 Thrust condition monitoring 233 21 Compressor seal system overview and types 237 Introduction 237 The supply system 24 1 The seal housing system 242 Seal supply systems 249 Seal supply system summary 256 Seal liquid leakage system 256
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