02 2 Design Rotor

Compressor - Design Features Rotors
Seals
Bearings
Lubrication
Control system
Operation
Condition monitoring
Mechanical design Maintenance
Trouble shooting
Power Generation 1
14.10.05 Compressor Training Ulrich Taetz PG I14314
.
Rotor
The rotor assembly consists of a shaft fitted with

the following parts: 1 Thrust collar
2 Balance drum
3 Coupling hub
4 Impeller(s)
5 Shaft
2
3 1
Power Generation 2
.
1
Rotor Design
1 - Inline design
2 - Back to back design
3 - Overhanging design
Power Generation 3
.
Rotor - Inline Design
Power Generation 4
.
2
Inline Design Rotor
Power Generation 5
.
Balance Piston
Power Generation 6
.
3
Inline Design Rotor
Power Generation 7
.
Back to Back Design Rotor
Power Generation 9
.
4
Back to Back Design Rotor
Power Generation 10
.
Integral Geared Type Compressor
Power Generation 11
.
5
Overhung Design
Overhung Impeller
Bearing
Bearing
Overhung Impeller
Power Generation 12
.
Rotors for Integrally Geared Compressor
Power Generation 13
.
6
Combinations - ARR Compressor
Back to back
Overhung Axial stages inline 2 Impellers

Impeller inline
Bearing Bearing
Power Generation 14
.
Impellers
Impeller design Impeller manufacturing

Impeller form Impeller manufacturing
- semi open - cast
- closed - milled
Blade shape Cover disc connection

- 2 dimensional - riveted
- 3 dimensional - welded
- soldered
Blade angle
- outlet angle
Power Generation 16
.
7
Impellers
[m/s]
Power Generation 17
.
Impellers
Power Generation 19
.
8
Impellers
3 Dimensional blades
2 Dimensional blades
Power Generation 20
.
Close Type Impeller
Hub disc with milled blades - 2 dimensional -
Cover disc
Power Generation 21
.
9
Impellers
Hub disc with milled blades -3 dimensional-
Cover disc
Power Generation 22
.
Impellers
Power Generation 23
.
10
Riveted Impeller
Power Generation 24
.
Welded Impeller
Power Generation 25
.
11
Welded Impeller
Power Generation 26
.
Spot Welding
Power Generation 27
.
12
Spot Welding
Power Generation 28
.
Brazed Impeller
Power Generation 29
.
13
Brazing Facility
Power Generation 30
.
Preparation for Brazing
Power Generation 31
.
14
Power Generation 32
.
Power Generation 33
.
15
Brazing Procedure
Power Generation 34
.
Quality Check
Power Generation 35
.
16
Quality Check
Power Generation 36
.
Quality Check
Power Generation 37
.
17
Milled Impeller
Power Generation 39
.
Milled Impeller
Power Generation 40
.
18
Milled Impeller
Power Generation 41
.
Impeller Over Speed Test Chamber
Power Generation 42
.
19
Impeller Over Speed Test Chamber
Power Generation 43
.
Impeller Connection
Fixed Removable
- Shrink fit - Flanged
- Hirth (crown geared)
- Slot and key
Power Generation 44
.
20
Impeller Shrinking
Power Generation 45
.
Impeller Shrinking
Power Generation 46
.
21
Impeller Shrinking
Power Generation 47
.
Impeller Shrinking
Rotor - inline design -
Power Generation 48
.
22
Balancing Chamber
Balancing
Power Generation 49
.
Power Generation 50
.
23
Manufacturing of Bull Gear
Power Generation 51
.
Bull Gear
Power Generation 52
.
24
Power Generation 53
.
Power Generation 54
.
25
Power Generation 55
.
Power Generation 56
.
26
Power Generation 57
.
AX Blade Connection
Power Generation 58
.
27
AX Blade Connection
Power Generation 59
.
AX Blade Connection
Power Generation 60
.
28
Axial Thrust Principle
A Propeller generates thrust against the air flow ( suction side)
side
Air flow
HÜK
Thrust Kurçak Airlines
Power Generation 61
.
Axial Thrust
Power Generation 62
.
29
Axial Thrust
Coating material
Al Si Polyester
Power Generation 63
.
Plasma Spraying for Abradable Seal Design
Power Generation 64
.
30
Plasma Spraying
Power Generation 65
.
Grooves
Power Generation 66
.
31
Spaltverluste
Minimale
Minimale Spaltverluste
Spaltverluste durch
durch
thermische
thermische Beschichtungen
Beschichtungen
Insbesondere
Insbesondere bei bei kleinen
kleinen Verdichtern
Verdichtern undund
hohen
hohen Drücken
Drücken kann
kann der
der Wirkungsgrad
Wirkungsgrad durchdurch
kreisende
kreisende Mengen
Mengen und
und Leckagen
Leckagen
beeinträchtigt
beeinträchtigt werden.
werden.
Zur
Zur Minimierung
Minimierung dieser
dieser Verluste
Verluste können
können wir
wir
die
die rotierenden
rotierenden Flächen
Flächen an an den
den Labyrinth-
Labyrinth-
dichtungen mit Hilfe moderner
dichtungen mit Hilfe moderner Verfahren Verfahren
thermisch
thermisch beschichten.
beschichten. Dabei
Dabei wird
wird eine
eine ddünne
ünne
Schicht
Schicht (Abradable)
(Abradable) aufgespritzt,
aufgespritzt, diedie ein
ein
Einlaufen
Einlaufen der
der Labyrinthspitzen
Labyrinthspitzen ermöglicht.
ermöglicht. Auf
Auf
diese
diese Weise
Weise reduzieren
reduzieren wirwir die
die Spalte
Spalte auf
auf ein
ein
Minimum.
Minimum.
Die
Die von
von uns
uns ausgewählten
ausgewählten Beschichtungs
Beschichtungs--
materialien
materialien sind
sind thermisch
thermisch sehr
sehr best
beständig
ändig und
und
widerstehen
widerstehen auch
auch höchsten
höchsten Fliehkraft-
Fliehkraft-
belastungen
belastungen und
und extremen
extremen
Schnellentlastungen.
Schnellentlastungen.
Mit
Mit unserem
unserem Know-how
Know-how und und dem
dem Einsatz
Einsatz
modernster
modernster Einrichtungen
Einrichtungen erzielen
erzielen wir
wir
hervorragende
hervorragende Beschichtungsqualitäten
Beschichtungsqualitäten ff ür ür
bessere
bessere Wirkungsgrade
Wirkungsgrade Ihrer
Ihrer Anlagen.
Anlagen.
Power Generation 67
.
Plasma Spraying for Abradable Seal Design
Power Generation 68
.
32
Generation of Axial Forces - SS
Compressors
63,1 bar
Suction pressure = 52,4 bar abs = 5240 kPa
Discharge pressure = 63,1 bar abs = 6310 kPa
Effective Area :
π
(0,508 2
− 0,254 2 * ) 4
= 0,152m2
Effective Pressure : Pressure Pressure
6310 − 5240 = 1070 kPa balanced balanced
Force :
1070kPa * 0,152 m 2 = 162kN
~16 tons ! 52,4 bar
Generated by one impeller only !

Power Generation 69
.
Axial Thrust Compensation SS Comp., In-

Line Design
F = ΣF -F =A x P [N]
R imp pist bea SS
F = Residual Axial Thrust [N]

R
F = Axial force generated by impeller [N]
imp
F = Axial force generated by balance piston [N]
pist
A = Area of thrust bearings [cm²]
bea
P = Specific surface stress [N/cm²]
SS
P is limited on thrust bearing pads to 30 ≤ P ≤ 60 [N/cm²]

SS SS
Power Generation 70
.
33
Axial Thrust
Balance line
Suction pressure
External seal
Balance
piston
Power Generation 71
.
Balance Line
P1 P2 P1
BALANCE
DRUM
FB F3 F1 F1
IMPELLER 3 IMPELLER 2 IMPELLER 1
Power Generation 72
.
34
Balance Line
Power Generation 73
.
Power Generation 74
.
35
Axial Thrust
Balance
piston
Axial thrust compensation
“Back to back
Axial thrust Axial thrust
2. Process stage
arrangement””
arrangement 1.Process stage
Power Generation 76
.
Axial Thrust
Power Generation 78
.
36
Axial Thrust
Psuction
Pdischarge
Axial thrust! Fresult

Power Generation 79
.
Compensation of Axial Thrust - Integrally

Geared
Residual
axial thrust
(aerodynamic)
Axial
thrust
1. stage
Axial
thrust
Axial forces 2. stage
(mechanical by gear
teeth angle)
Driving force will generate additional axial force due to gear teeth angle.
Power Generation 80
.
37
Axial Thrust
axial
bearings!
gear teeth
angle!
(Positive or
negative)
Power Generation 81
.
Compensation of Axial Thrust

Balance piston and balance line for integrally geared HVK (high pressure) with single stage pinion.
Balance piston.
Power Generation 82
.
38

02 2 Design Rotor

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02 2 Design Rotor

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Compressor - Design Features Rotors

Mechanical design Maintenance

The rotor assembly consists of a shaft fitted with

2 - Back to back design

Rotor - Inline Design

Back to Back Design Rotor

Integral Geared Type Compressor

Rotors for Integrally Geared Compressor

Overhung Axial stages inline 2 Impellers

Impeller design Impeller manufacturing

Blade shape Cover disc connection

Close Type Impeller

Hub disc with milled blades - 2 dimensional -

Hub disc with milled blades -3 dimensional-

Preparation for Brazing

Preparation for Brazing

Impeller Over Speed Test Chamber

- Shrink fit - Flanged

- Hirth (crown geared)

- Slot and key

Rotor - inline design -

Rotors for Integrally Geared Compressor

Rotors for Integrally Geared Compressor

Rotors for Integrally Geared Compressor

Thrust Kurçak Airlines

Plasma Spraying for Abradable Seal Design

Plasma Spraying for Abradable Seal Design

Discharge pressure = 63,1 bar abs = 6310 kPa

Effective Pressure : Pressure Pressure

6310 − 5240 = 1070 kPa balanced balanced

~16 tons ! 52,4 bar

Generated by one impeller only !

Axial Thrust Compensation SS Comp., In-

F = Residual Axial Thrust [N]

P is limited on thrust bearing pads to 30 ≤ P ≤ 60 [N/cm²]

IMPELLER 3 IMPELLER 2 IMPELLER 1

Axial thrust compensation

Axial thrust! Fresult

Compensation of Axial Thrust - Integrally

Compensation of Axial Thrust

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