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RE02

Centrifugal Compressor

Troubleshooting & Failure Analysis

Introduction

Centrifugal Compressor operate at high speeds and are usually directly connected to the driver so that transmission losses are small. Owning to their high speed, the Units are relatively small for a given capacity and head. Machine that pumps gases are known as Fans, Blowers or Compressor, depending on the pressure rise achieved. This course will investigate Methods of Control and Operation of such machines.

Objectives

The course commences with a study of the construction and operation centrifugal compressors. The approaches to the monitoring and maintenance of these machines are described and extensive use is made of case study material to underline the important aspects of the course.

Audience

This course is intended for engineers and technical staff involved in centrifugal compressor and steam turbine operation and maintenance.

Course Outline

Module 1 – Axial Centrifugal Compressor

·         Characteristic curves; invariant representations

·         Surge and stonewall; range of working efficiency

·         Capacity control methods

·         Start-up, vibration surveys

Module 2 – Steam Turbines

·         Characteristic of turbine: speed, specific consumption efficiency

·         Influence of inlet and exhaust steam state

·         Speed governor and control systems

·         Safety devices

Module 3 – Technology of Rotating Compressors and Turbines

·         Casings, diaphragms, stator, blades

·         Rotor, journal and thrust bearings, internal and shaft seals, coupling

·         Balance and critical speeds

·         Lubrication and seal systems

·         Typical mechanical incidents

Module 4 – Operation & Performance

·         Mechanical issues

·         Process aspects

·         Operating parameters; head, flow, rpm, efficiency

·         Characteristic curves

·         Effect of wear

Module 5 – Bearing Problems

·         Purpose, different types of oil and grease

·         Anti-friction bearings: types, lifetime, mounting, applications, related problems

·         Plain and pad bearings, thrust bearings, operation, maintenance, incidents

Module 6 – Couplings & Misalignment

·         Different types of couplings, related problems

·         Different methods of alignment

Module 7 – Rotors & Shafts

·         Single and multi-place balancing

·         Flexible rotors

·         Cracks in shafts

Module 8 – Vibration Monitoring

·         What to monitor and where]

·         Measurement devices

·         Overall and spectral measurements

·         Displacement probes

·         Vibration limits

·         Orbit analysis

·         Spectrum analysis