
Operator's Guide to Process Compressors
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Gas compressors tend to be the largest, most costly, and most critical machines employed in chemical and gas transfer processes. Since they tend to have the greatest effect on the reliability of processes they power, compressors typically receive the most scrutiny of all the machinery among the general population of processing equipment. To prevent unwanted compressor failures from occurring, operators must be taught how their equipment should operate and how each installation is different from one another.
The ultimate purpose of this book is to teach those who work in process settings more about gas compressors, so they can start up and operate them correctly and monitor their condition with more confidence. Some may regard compressor technology as too broad and complex a topic for operating personnel to fully understand, but the author has distilled this vast body of knowledge into some key, easy to understand lessons for the reader to study at his or her own pace.
This groundbreaking new work is a must-have for any engineer, operator, or manager working with process compressors.
The main goals of this book are to:
* Explain important theories and concepts about gases and compression processes with a minimum of mathematics
* Identify key compressor components and explain how they affect reliability
* Explain how centrifugal compressors, reciprocating compressors, and screw compressors function.
* Explain key operating factors that affect reliabilityIntroduce the reader to basic troubleshooting methodologies
* Introduce operators to proven field inspection techniques
* Improve the confidence of personnel operating compressors by teaching them the basics of compressor theory
* Improve compressor reliability plantwide by teaching operating and inspection best practices
* Improve communication between operating and supporting plant personnel by providing a common vocabulary of compressor terms
* Help processing plants avoid costly failures by teaching operators how to identify early compressor issues during field inspections
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Robert X. Perez is mechanical engineer with more than 40 years of rotating equipment experience in the petrochemical industry. He has worked in petroleum refineries, chemical facilities, and gas processing plants. Currently, he provides engineering consulting services and rotating equipment training. He earned a BSME degree from Texas A&M University at College Station, an MSME degree from the University of Texas at Austin and holds a Texas PE license. Mr. Perez has written numerous machinery reliability articles for magazines and conferences proceedings and has authored 4 books and coauthored 4 books related to machinery reliability. He resides in San Antonio, Texas.
Content
Preface xv
1 Introduction to Gases 1
1.1 Ideal Gases 4
1.2 Properties of Gases 5
1.3 Temperature 5
1.4 Pressure 6
1.5 Gas Laws 7
1.6 Gas Mixtures 10
1.6.1 Dalton's Law of Partial Pressures 10
1.7 Molecular Weight of a Gas Mixture 11
1.8 Gas Density 13
1.9 Density of Mixtures 14
1.10 Heat of Compression 15
2 Commonly Used Compressor Flow Terms 19
2.1 Ideal Gas Law 20
2.1.1 Example of How to Convert from SCFM to ACFM 22
2.2 Visualizing Gas Flow 23
2.3 Compressibility Factor (Z) 25
2.4 Sizing Compressors 27
3 Compression Processes 31
3.1 Adiabatic Compression 33
3.2 Polytropic Compression 37
3.2.1 Polytropic Example #1 40
3.2.2 Polytropic Example 2 40
4 What Role the Compression Ratio Plays in Compressor Design and Selection 43
4.1 Compression Ratio versus Discharge Temperature 44
4.2 Design Temperature Margin 46
4.2.1 Design Trade-Offs 49
5 An Introduction to Compressor Operations 53
5.1 Compression Basics 53
5.2 Defining Gas Flow 55
5.3 Compressor Types 56
5.4 Multistaging 59
5.5 Key Reliability Indicators 60
6 Centrifugal Compressors 63
6.1 Centrifugal Compressor Piping Arrangements 66
6.2 Start-Up Configuration 68
6.3 Centrifugal Compressor Horsepower 68
6.4 Troubleshooting Tips 70
6.5 Centrifugal Compressor Start-Ups 71
6.6 Centrifugal Compressor Checklist 72
7 How Process Changes Affect Centrifugal Compressor Performance 75
7.1 Baseball Pitcher Analogy 75
7.2 How Gas Density Affects Horsepower 78
7.3 Theory versus Practice 80
8 How to Read a Centrifugal Compressor Performance Map 83
8.1 The Anatomy of a Compressor Map 85
8.1.1 Flow Axis (See Figures 8.2 and 8.3) 85
8.1.2 Head or Pressure Ratio Axis (See Figures 8.2 and 8.3) 86
8.1.3 Predicted Surge Line (See Figures 8.2 and 8.3) 86
8.1.4 Predicted Capacity Limit (Figures 8.2 and 8.3) 86
8.1.5 Surge Margin (See Figure 8.2) 87
8.1.6 Speed Lines (See Figures 8.2 and 8.3) 88
8.2 Design Conditions 88
9 Keeping Your Centrifugal Compressor Out of Harm's Way 91
9.1 Compressor Operating Limits 93
9.2 Compressor Flow Limits 93
9.3 Critical Speeds 95
9.4 Horsepower Limits 96
9.5 Temperatures 97
10 Troubleshooting Centrifugal Compressors in Process Services 101
10.1 The Field Troubleshooting Process-Step by Step 105
10.1.1 Step 1: Define the Problem 105
10.1.2 Step 2: Collect All Pertinent Data 105
10.1.3 Step 3: Analyze the Body of Data as a Whole 106
10.1.4 Step 4: Act and Confirm 106
10.2 The "Hourglass" Approach to Troubleshooting 108
10.3 Thinking and Acting Globally 109
10.4 Troubleshooting Matrix and Table 110
10.5 Centrifugal Compressor Troubleshooting Example 110
11 Reciprocating Compressors 117
11.1 Reciprocating Compressor Installations 124
11.1.1 How Process Conditions Affect Reciprocating Compressor Performance 126
11.2 Reciprocating Compressor Start-Ups 128
11.3 Reciprocating Compressor Checklist 129
11.4 Criticality 131
12 Troubleshooting Reciprocating Compressors in Process Services 133
12.1 The Field Troubleshooting Process-Step by Step 137
12.1.1 Step 1: Define the Problem 137
12.1.2 Step 2: Collect All Pertinent Data 137
12.1.3 Step 3: Analyze the Body of Data as a Whole 138
12.1.4 Step 4: Act and Confirm 138
12.1.5 Troubleshooting Matrix and Table 140
12.1.6 Reciprocating Compressor Troubleshooting Example 140
13 Screw Compressors 147
13.1 Oil Injected Screw Compressors 150
13.2 Screw Compressor Modulation 151
13.3 Pressure Pulsation Issues 152
13.3.1 Absorptive Type Dampeners 154
13.3.2 Reactive Type Dampeners 154
13.3.3 Combination Type (Reactive and Absorptive) 154
13.3.4 Oil Contamination 155
13.3.5 How Process Conditions Affect Screw Compressor Performance 156
13.4 Troubleshooting Screw Compressors 156
14 Compressor Start-Up Procedures 159
14.1 Compressor Start-Up Risks 160
14.2 Generic Start-Up Procedure 162
14.3 Centrifugal Compressor Start-Ups 165
14.4 Reciprocating Compressor Start-Ups 167
14.5 Screw Compressor Start-Ups 170
15 Compressor Trains: Drivers, Speed Modifiers, and Driven Machines 173
15.1 Driven Process Machines 174
15.1.1 Drivers 175
15.1.1.1 AC Electric Motors 176
15.1.2 Steam Turbines 177
15.2 Gas Turbines 178
15.2.1 Natural Gas Engines 179
15.2.2 Speed Modifiers 180
15.2.2.1 Gear Boxes 180
15.3 Useful Gearbox Facts 182
15.4 Combination Machines 182
15.4.1 Turboexpanders 182
16 Compressor Components 185
16.1 Bearing Types 185
16.2 Rolling Element Bearings 187
16.3 Plain Bearings 188
16.4 Compressor Bearings 189
16.5 Modeling Fluid Film Bearings 190
16.6 Thrust Loads 192
16.7 Kingsbury Thrust Bearing 193
16.8 Compressor Seals 194
16.8.1 Labyrinth Seals 194
16.8.2 Oil Film Seal 194
16.8.3 Face Contact Wet Seals 196
16.9 Seal Oil System 197
16.10 Dry Gas Seals 197
16.11 Seal Gas Quality and Control 198
16.12 Reciprocating Compressors - Packing 199
17 The Importance of Lubrication 201
17.1 Lubrication Regimes 203
17.2 Lubricating Oils 206
17.3 Compressor Lubricating Oil Systems 206
17.3.1 Lubrication Monitoring 209
17.4 Oil Foaming 210
17.4.1 Excessive Foam 211
18 Inspection Ideas for Operators and Field Personnel 213
18.1 Equipment Field Inspections 213
18.1.1 Audible Inspections 215
18.1.2 Visual Inspections 216
18.1.3 Tactile Inspections 217
18.1.4 Smell 219
18.2 Tools Available to Quantify What You Have Detected 220
18.2.1 Audible Inspection Methods 220
18.2.1.1 Ultrasonic Gun 220
18.2.1.2 Stethoscope 220
18.2.1.3 Metal Rod 220
18.3 Visual Inspection Methods 221
18.3.1 Infrared or IR Gun 221
18.4 IR Camera 222
18.4.1 Strobe Light 223
18.5 Inspection Methods Using Vibration and Temperature Measurement Equipment 224
18.5.1 Vibration Meter with Accelerometer 224
18.5.2 Temperature Measurement Equipment 226
18.6 Generic Monitoring Guidelines 227
19 Addressing Reciprocating Compressor Piping Vibration Problems: Design Ideas, Field Audit Tips, and Proven Solutions 229
19.1 Piping Restraints 232
19.2 Pipe Clamping Systems 233
19.3 Guidelines 233
19.4 Piping Assessment Steps 235
19.4.1 First, Perform the Following Pre-Field Analysis Steps 235
19.4.2 Next 235
19.4.3 Problem Locations 236
19.5 Attaching Pipe Clamps to Structural Members 237
19.5.1 Installation Examples 240
19.5.2 Here Are a Few More Pipe Clamp Tips 240
20 Collecting and Assessing Piping Vibration 243
20.1 Piping Analysis Steps 245
20.2 Piping Vibration Examples 246
Appendix A: Practice Problems Related to Chapters 1 Through 4 Topics 249
Appendix B: Glossary of Compressor Technology Terms 261
Index 273
Chapter 1
Introduction to Gases
Gases represent a state of matter that has no fixed shape or fixed volume, which consist of tiny, energetic particles, i.e., atoms or molecules, that are widely spaced (Figure 1.1). Compared to the other states of matter, solids and liquids, gases have a much lower density, i.e., they have a small mass per unit volume, because there is a great deal of empty space between gas particles. At room temperature and pressure, the gas inside a container occupies only 0.1% of the total container volume. The other 99.9% of the total volume is empty space (whereas in liquids and solids, about 70% of the volume is occupied by particles). Gas particles move very fast and collide with one another, causing them to diffuse, or spread out, until they are evenly distributed throughout the volume of their container. You will never see only half of a balloon filled with air.
Figure 1.1 Gas atoms or molecules are constantly moving and colliding with one another.
Although both liquids and gases take the shape of their containers, gases differ from liquids in that there is so much space between gas molecules that they offer little resistance to motion and can be compressed to smaller and smaller volumes. As seen in Figure 1.2, as a gas is compressed, the molecules making up the gas get closer together and create a higher internal pressure.
Figure 1.2 As gas is compressed, the gas molecules get closer together.
Hydrogen is the lightest known gas. Any balloon filled with hydrogen gas will float in air if the total mass of its container is not too great. Helium gas is also lighter than air and has 92% of the lifting power of hydrogen. Today all airships, i.e., blimps, use helium instead of hydrogen because it offers almost the same lifting power and is not flammable.
Gases can be monatomic, diatomic, and polyatomic. Monatomic gases are gases composed of single atoms, diatomic gases are those composed of two atom molecules, and polyatomic gases are those made up of molecules with more than two atoms. Noble gases such as helium, neon, argon, etc., are normally found as single atoms, since they are chemically inert. Gases such as nitrogen (N2), oxygen (O2), and carbon monoxide (CO) tend to be found as diatomic molecules (Figure 1.3). Carbon dioxide (CO2), and methane (CH4) are examples of polyatomic gas molecules (Figure 1.3).
Figure 1.3 Oxygen, nitrogen, and carbon monoxide are examples of diatomic molecules. Carbon dioxide, water, nitrogen monoxide, methane, sulfur dioxide, and ozone are examples of polyatomic molecules.
Gases can be found all around us. In fact, the earth's atmosphere is a blanket of gases composed of nitrogen (78%), oxygen (21%), argon (1%), and then trace amounts of carbon dioxide, neon, helium, methane, krypton, hydrogen, nitrous oxide, xenon, ozone, iodine, carbon monoxide, and ammonia.
Because of the large distances between gas particles, the attractions or repulsions among them are weak. The particles in a gas are in rapid and continuous motion. For example, the average velocity of nitrogen molecules, N2, at 68 °F is about 1640 ft/s. As the temperature of a gas increases, the particles' velocity increases. The average velocity of nitrogen molecules at 212 °F is about 1886 ft/s. The particles in a gas are constantly colliding with the walls of the container and with each other. Because of these collisions, the gas particles are constantly changing their direction of motion and their velocity. In a typical situation, a gas particle moves a very short distance between collisions. For example, oxygen, O2, molecules at normal temperatures and pressures move an average of 0.000003937 inches between collisions.
1.1 Ideal Gases
Scientists often simplify the model of gases by imagining the behavior of an ideal gas. An ideal gas differs from a real gas in that the particles are assumed to be point masses, that is, particles that have a mass but occupy no volume. It is also assumed that there are no attractive or repulsive forces at all between the particles. When all these assumptions are incorporated into a gas model, the "ideal gas model" is obtained. As the name implies, the ideal gas model describes an "ideal" of gas behavior that is only approximated by reality. Nevertheless, the model has been proven to reasonably explain and predict the behavior of typical gases under typical conditions.
Note: Under ordinary conditions, the properties of gases predicted by the ideal gas law are within 5% of their actual values.
1.2 Properties of Gases
The ideal gas model is used to predict changes in four related gas properties: volume, number of particles, temperature, and pressure. Volumes of gases are usually described in cubic feet, ft3, or cubic meters, m3, and numbers of particles are usually described in moles.
1.3 Temperature
Temperature is a physical quantity expressing how hot or cold a system of atoms or physical object is. Technically, temperature is the proportional measure of the average kinetic energy related to the random motions of the constituent particles of matter in a system. Temperature is an important property of a system because it is an indication of the direction in which heat energy will spontaneously flow. Remember that heat energy always flows from a hotter body (one at a higher temperature) to a colder body (one at a lower temperature).
Temperature is a measure of the total heat energy in a system.
Gas temperatures can be measured with thermometers, infrared guns, and thermocouples. Readings can be reported in degrees Fahrenheit, °F, or Celsius, °C. However, engineers generally use Rankine, or Kelvin temperatures for calculations.
1.4 Pressure
Remember that gases have no definite shape or volume; they tend to fill whatever container they are in. They can compress and expand and have extremely low densities when compared to a liquid or solid. Combinations of gases tend to mix together spontaneously; that is, they form gas mixtures. Air, for example, is a solution of mostly nitrogen and oxygen. Any understanding of the properties of gases must be able to explain the properties of gas mixture.
The kinetic theory of gases indicates that gas particles are always in motion and are colliding with other particles and the walls of the container holding them. Although collisions with container walls are elastic (i.e., there is no net energy gain or loss because of the collision), a gas particle does exert a force on the wall during the collision. Each time a gas particle collides with and ricochets off one of the walls of its container, it exerts a tiny force against the wall. The accumulation of all these forces distributed over the area of the walls of the container causes something we call pressure. Pressure (P) is defined as the force of all the gas particle-wall collisions divided by the area of the wall:
In English units, pressure is measured in psi, or pounds per square in. The formal, SI-approved unit of pressure is the pascal (Pa), which is defined as 1 N/m2 (one newton of force over an area of one square meter). However, this is usually too small in magnitude to be useful. A common unit of pressure is the atmosphere (atm), which was originally defined as the average atmospheric pressure at sea level.
1.5 Gas Laws
When seventeenth-century scientists began studying the physical properties of gases, they noticed simple relationships between some of the measurable properties of gases. For example, scientists noted that for a given quantity of gas, usually expressed in units of moles, i.e., number of molecules [n] in a system, if the temperature (T) of the gas is kept constant, pressure and volume are related: as one variable increases, the other variable decreases. Conversely, as one variable decreases, the other variable increases. Therefore, we say that pressure and volume are inversely related.
take pressure (P) and volume (V), for example:
There is more to it, however: pressure and volume of a given amount of gas at a constant temperature are numerically related. If you take the pressure value and multiply it by the volume value, the product is a constant for a given amount of gas at a constant temperature:
(1.1)
If either volume or pressure changes while the amount and temperature stays the same, then the other property must change so that the product of the two properties still equals that same constant. That is, if the original conditions are labelled P1 and V1 and the new conditions are labelled P2 and V2, we have
(1.2)
where the properties are assumed to be multiplied together. Leaving out the middle part, we have simply:
(1.3)
This equation is an example of a gas law. A gas law is a simple mathematical formula that allows you to model, or predict, the behavior of a gas. This particular gas law is called Boyle's Law, after the English scientist Robert Boyle, who first announced it in 1662. Figure 1.4 shows two representations of what Boyle's Law describes.
Figure 1.4 Starting with a piston having a given pressure and volume (far right piston), the volume continuously decreases as the applied pressure increases. If you plot pressure (P) as a function of the volume (V) for a given amount of gas at a certain temperature, you will get a plot that...
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