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Compressor Operation
Table of Contents:
Principles of Operation .......................................................................................................................... 3 Compressor .................................................................................................................................. 3 Lubrication .................................................................................................................................... 4 Surge Control Line Theory ........................................................................................................... 5 Compressor Safety Guidelines ............................................................................................................. 6 Routine Startup ...................................................................................................................................... 7 Routine Shutdown.................................................................................................................................. 8 Special Requirements for Elevated Inlet Pressures ........................................................................... 9 Operation Restriction .................................................................................................................... 9 Design Criteria .............................................................................................................................. 9 Compressor Safety Mechanisms ........................................................................................................ 10 Operating Principle ..................................................................................................................... 10 Recommended Measurement Points ......................................................................................... 10 Alarm and Trip Conditions .......................................................................................................... 10 The Operating Data Record ................................................................................................................. 11 Revision History ................................................................................................................................... 13
NOTE: The intent of this specification is to provide general operating guidelines for centrifugal compressors, surge line control theory, and routine startup and shutdown procedures. This document does not incorporate all operating scenarios, and any questions regarding the compressor operation should be directed to Cameron.
Principles of Operation
Compressor
Camerons centrifugal line of multi-stage gear (MSG) compressors utilize dynamic compression to generate the necessary pressure and flow requirements of air, nitrogen, or a specific process gas. The centrifugal compressor consists of a low speed increasing gear (bullgear) which rotates high speed output shafts (pinions) and mounted impellers. A typical compressor gearbox can have one to three high speed output shafts as well as a total of one to six impellers, or stages of compression. Depending on the customers requirements, a compressor package may have multiple processes on the same gearbox, or even multiple interconnected gearboxes. Gas enters each stage axially, where the high speed rotating impellers greatly increase the velocity of the gas, through the principle of centrifugal force. As the high velocity gas leaves the impeller, it enters the small space of the diffuser. The non-rotating diffuser surrounds the impeller, reducing the velocity of the gas, causing the gass pressure and temperature to increase. A scroll or volute casing surrounds the diffuser, providing a smooth exit path with minimal pressure loss. If higher pressure is required for the process, the gas goes through an intercooler where heat is removed from the gas before continuing to the next stage(s) of compression, until the necessary process conditions are achieved.
Lubrication
The lubrication system provides a constant supply of cooled and filtered oil to the compressor bearings and gear sprays. Unlike some other types of rotating equipment, high speed, integrally geared compressors cannot operate, even for very brief periods, without adequate lubrication. No interruption can be permitted in the lube oil supply. Before startup, the electrically driven auxiliary oil pump is started to provide lubrication to the bearings and gearing, and to obtain a permissive start signal. During startup, the mechanically driven main oil pump comes up to speed and takes over the function of providing oil flow and pressure. The auxiliary oil pump is signaled to switch off and remains off during normal operation. During normal operation, oil is drawn from the reservoir by the main oil pump. Oil is prevented from being pumped back in the reservoir through the auxiliary pump by a check valve. Another check valve blocks the oil flow through the main pump when the auxiliary pump is operating. Cooling water flowing through the oil cooler removes heat from the oil. Regulating the oil flow through the oil cooler maintains the operating temperature of the oil. The oil filter removes particulate, which could be harmful to compressor bearings and gearing. Oil temperature and pressure are sensed using pressure transmitters and RTDs. The proper operating pressure is maintained by a pressure regulator, which takes place before the oil enters the compressor gearbox and returns excess oil to the reservoir. The oil entering the manifold of the compressor gearbox is distributed through oil passages to the journal bearings and thrust bearings. The oil is also distributed to nozzles, which are positioned to direct a constant spray of oil at the gear mesh to lubricate and cool the gearing. Should a malfunction result in loss of oil pressure, it will be detected by the oil pressure transmitter, activating an alarm and starting the auxiliary pump. Normal oil pressure will be restored by the auxiliary pump, and the compressor will continue operating. If the oil pressure continues to decrease to the trip set point, the compressor driver will be automatically shutdown.
Figure 3 above shows the pressure vs. flow relationship of the compressor. At start-up the compressor will begin to produce flow and the operating point will move along the flow axis until the process begins to produce a back pressure. The operating point then moves up the curved operating line. Which curved operating line it follows is dependent upon changes in IGV setting and process demands. This curved line is showing that while the pressure is increasing the flow is decreasing. If left unchecked, the pressure would increase and the flow decrease until the compressor surged. The dots on the figure represent the points at which the compressor surged. After locating four points, a line can be drawn as a best fit between these points. This is considered the surge line for the compressor. The compressor is considered in surge for all points to the upper left of this line. Points below the surge line are in the normal operating region. The surge line is dependent upon many factors including process conditions, such as inlet temperature. Therefore, the control line may need to be periodically redefined according to process changes and climate cycles.
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Safety Disclaimer
The owner or operator of the compressor is hereby notified and forewarned that any failure to observe common safety precautions, whether stated herein or not, may result in damage or injury. Cameron disclaims responsibility or liability for damage caused by failure to observe those specified, or other common precautions or by failure to exercise ordinary caution, common sense and due care required in operating or handling the compressor even though not expressly specified above.
Routine Startup
Use this procedure to start the compressor on a routine basis. Some steps may occur automatically as part of the control system start sequence.
WARNING
Only fully trained personnel should be allowed to start and operate this compressor. Failure to comply may result in serious injury or death. 1. Refer to the manufacturers instructions for the main drive controller (starter) and carry out the recommended pre-starting procedures. 2. Check that the oil level in the oil reservoir sight gauge is above the center (normal operating level). 3. Apply instrument air to the control panel, control valves, transmitters, and buffered oil seals (if applicable). 4. Turn on the cooling water supply to the oil cooler, intercoolers, and aftercoolers. 5. Apply power to the compressor control system. 6. Apply air (or electrical power as needed) to the oil reservoir venting system and adjust appropriately to maintain the proper vacuum. 7. Start the auxiliary lube oil pump. 8. Check that the bypass valve or blow-off valve is open, and the inlet guide vane or throttle valve is closed for compressor startup. 9. For compressors that operate at an elevated inlet pressure, vent the gas in the compressor so that no load is applied to the compressor during startup. No load is defined as 10% or less of the design mass flow. Alternative methods of reducing mass flow to the compressor must be approved by Cameron on an application specific basis. 10. Check the lube oil pressure and temperature. Normal operating pressure for the lubrication system is 20 PSI (1.38 BAR, 0.14 Mpa). Normal operating temperature, measured at the gear case inlet, is 110F to 130F (43C to 55C). Minimum oil temperature for startup is 70F (21C).
CAUTION
Unusual sounds or excessive vibration can indicate internal rubbing, worn bearings, or shaft misalignment. Stop the compressor immediately if noise indicates a mechanical malfunction. 11. Start the main drive motor and allow the compressor to come up to speed. 12. Put the compressor on line according to the instructions supplied with the control system.
Compressor Operation (IL-2861) Page 8 of 13 13. Check the compressor for gas or oil leaks. 14. Check that the inlet gas temperature is maintained within 10F (5.6C) of temperature listed in the data sheets for this compressor. 15. Check oil pressure and temperature; verify auxiliary oil pump shuts down.
WARNING
DO NOT operate the compressor at pressures greater than the nameplate rating. Doing so could result in equipment damage or personal injury.
Routine Shutdown
Use the following procedure to shutdown the compressor under normal conditions. Some steps may occur automatically as part of the control system stop sequence. 1. Open the intercooler shell drains just prior to shutting down the compressor. 2. Unload the compressor according to the instructions previously provided (see startup step #8 and #9). 3. Press the stop button on the drive motor starter panel. This starts the auxiliary oil lube pump which should be allowed to run for 30 minutes after the compressor shutdown to remove heat from the gearbox. Allow cooling water to continue circulating through the lube oil cooler. It is recommended that the auxiliary oil pump remain on during shutdown to prevent condensation and possible corrosion of compressor gearing if the compressor is outdoors or in ambient temperatures below 50F (10C). 4. Oil reservoir venting must remain on while the auxiliary oil pump is on and/or compressor is running, to prevent oil seepage from the oil seals. 5. Turn off the supply of instrument air to the control panel and control valves. 6. Allow the cooling water and oil to circulate to remove heat for at least 30 minutes after shutdown and then turn off the water supply. During this time the oil reservoir venting system should remain running.
Operation Restriction
The compressor user/operator is required to provide inlet pressure protection to prevent overpressurizing and/or overloading the compressor. Inlet pressure control is preferred to discharge pressure control because both over-pressure and overload protection is necessary. Without inlet pressure control, higher than desired mass flow could still pass through the machine. Cameron recommends that the inlet pressure not be allowed to exceed 110% of the design inlet pressure condition as stated on the compressor nameplate. After startup, the compressor must be brought to the design pressure ratio(s). This pressure ratio needs to be maintained during the loading and normal operation of the compressor. The compressor must be kept out of surge during the loading sequence and operation.
WARNING
Failure to apply this method of operation may produce aerodynamic instabilities in one or more stages with possible substantial increase in rotor vibration and subsequent compressor damage.
NOTE
Brief excursions above the design inlet pressure are acceptable. However, it is understood that these excursions are created by system upsets and time allotted is for control and adjustments only.
Design Criteria
For every contract, unless otherwise specified, pressure containing components (scrolls, piping, seals, intercoolers, etc) and mechanical components (gearing, bearings, etc) are designed using an overpressure tolerance of 10% above the specified design operating conditions. Any requirements in excess of 10% must be specified prior to the design of the compressor and may impact cost of the overall package. Surge recycle valves need to be sized to accommodate both normal and startup operation to prevent surging of the compressor.
WARNING
Operation above the mechanical design limits will cause premature wear and/or severe damage to the compressor.
Operating Principle
Strategically located sensor devices provide measurements of the compressors vital operating parameters. A typical control system monitors these measurements and responds to specific changes that occur. The control system may provide a display of current readings for adjustment, data logging, trending, or other diagnostics. In the event of a condition that deviates from predetermined values, the control system may also display a log of events.
Operating Data Record Information Pressure Points: Vibration Points: System Gas Pressure First Stage Vibration Compressor Discharge Pressure Intermediate Stage(s) Vibration Oil Pressure Final Stage Vibration Inlet Filter Pressure Drop Inboard Motor Bearing Vibration Oil Filter Pressure Drop Outboard Motor Bearing Vibration Temperature Points: Last Stage Inlet Gas Temperature Oil Temperature Second Stage Inlet Gas Temperature Inboard Motor Bearing Temperature Outboard Motor Bearing Temperature Motor Stator Temperature (A, B, C) Additional Points: Main Drive Motor Current Compressor Flow Time Date Operators Initials
o Stage 6 Inlet Temperature: Vibration Levels o o o o o Stage 1 Vibration: Stage 2 Vibration: Stage 3 Vibration: Stage 4 Vibration: Stage 5 Vibration:
o Stage 6 Vibration: Lubrication System o o o Oil Temperature: Oil Pressure: Oil Filter Pressure Drop:
o Oil Tank Vacuum: Cooling System o Coolant Temperature: (In / Out) / / o Coolant Pressure: Drive Motor o o o Motor Current: Ambient Temperature: Motor Bearing Temperatures: (In / Out)
Revision History
Rev ID 01 ECO Number 2433145 Date 1/20/2010 Author N.Botkins Change Description Initial Release
Prepared By: N.Botkins / C.Impastato Reviewed By: N.Botkins / C.Impastato Approved By: C. Impastato Approved By:
Approval
Nicholas Botkins
Digitally signed by Nicholas Botkins DN: cn=Nicholas Botkins, c=US, o=Cameron Compression, ou=Project Engineer, email=nicholas.botkins@c-a-m.com Reason: I am approving this document Date: 2010.01.20 11:32:18 -05'00'
Date
Charles Impastato
Digitally signed by Charles Impastato DN: cn=Charles Impastato, o=Cameron Compression, ou, email=Charles.Impastat@c-a-m.com, c=US Date: 2010.01.20 12:26:13 -05'00'
Spec to be electronically distributed to CTC-MSG IL&EDR Distribution Listing in Global Contacts. Ref. DEP-1108