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VSP White Tiger UCP@A - Report - Aug22 PDF
VSP White Tiger UCP@A - Report - Aug22 PDF
Stop Work Authority Issued Yes / No If Yes, Please Describe (Why, When & How
solved)
APPENDIX A:
APPENDIX B:
APPENDIX C:
APPENDIX D:
APPENDIX E:
APPENDIX F:
1.1 The compressor train designated as UCP-A was recently overhauled and re-
commissioning. I was assigned to assist on vibration trouble shooting on high vibration
problem during loading the unit and also conduct the site performance test on the
compressor train
1.4 Mr. Arthit Phuttipongsit, D-R FSE departed from Thailand on 14 August 2022 and
traveled to VSO Hite Tiger Platform on 15 August 2022.
2.1 The unit has started and put in normal service prior to my arrival on 15 August 2022,
2.2 The vibration testing was conducted on the unit during steady state, load variation test
transient shutdown and hot start up
2.3 The technical details on vibration and performance assessment have been concluded in
this report (See Appendixes)
APPENDIX A:
1.0 The vibration amplitudes measured on gas compressor set UCP-A during normal
operation after overhauled on 17 August 2022 at approximately 9242 rpm were
tabulated as follow.
Channel Location Direct 1X filter Gap.
pk-pk (m) Uncomp. (DC Voltages)
(m@degree) (Operation)
6YD_701Y LP Disc Brg 18.5 9.2@229 -10.4
6XD_701X LP Disc Brg 23.7 13.8@162 -10.2
7YD_702Y LP Suc Brg 9.3 5.1@133 -9.8
7XD_702X LP Suc Brg 15.0 9.4@77 -9.3
8YD_301Y HP Disc Brg 33.2 25.8@344 -9.8
8XD_301X HP Disc Brg 38.5 30.4@248 -9.4
9YD_302Y HP Suc Brg 22.1 15.7@17 -9.9
9XD_302X HP Suc Brg 23.5 15.7@286 -9.4
The data from the proximity transducers above, were evaluated against ISO 7919-
3 – Mechanical vibration of non-reciprocating machines – Measurements on rotating
shafts and evaluation criteria – Part 3: Coupled industrial machines. The shaft
relative vibration levels for this unit are fallen within Zone A, defined, as “The
vibration of newly commissioned machines would normally fall within this
zone.”
HPC- CBF 833 HIGH VIBRATION DATA DISCUSSION
1.1 The vibration testing was carried out during steady state operation, load variation
test, transient shutdown test and hot start up till normal operation as depicted in
speed trend plot below.
Hot restart up
1.2 During steady state operation the vibration of the unit appear to be stable & flatten
out with the fundamental synchronous vibration response excited by imbalance
force. Some of the vibration characteristics would be dominant in synchronous
frequency (1X frequency same as rotative speed) , open & circular orbital motion
with forward precession, etc.
1X Frequency
1.3 During load variation test, there was evidence sub-synchronous vibration excited and
cause increase vibration level as sub-synched modulate on top of original unbalance
component as depicted below.
Sub-Synchronous vib
1X Frequency
1.4 The exact cause of sub-synchronous vibration is not known but it is unlikely to be
related with bearing fluid induce instability, it more likely to be related with the gas
instability. It is obvious this sub-synchronous vibration appears to be excited at the
same period when the ASV controlling at “Surge Controlled Line” during load
variation.
1.5 There was evidence that during the appearance of sub-synchronous vibration, the
vibration amplitude become unstable and then momentary lead to “Rub”, induce
rotor thermal bow, cause very high unbalance vibration (Due to rotor bow) and
tripped the unit. The shutdown data during trip appear in fundamental heavy
unbalance rotor coasting down pass thru 1st critical speed.
Unstable vib
appear
Steady state operation with normal vibration level process changed & caused
unstable sub-synchronous vibration which increase the level of vibration (Not as high
to trip level) The increased vibration amplitude lead to light rub on the rotor and
lead temporary rotor thermal bow condition Rotor bow cause unbalance rotor (1X
-Synchronous vibration) Unbalance rotor get bigger orbital motion which tend to
rub more severe Increase more 1X synchronous vibration up to trip level then unit
shutdown with characteristic of unbalance rotor.
1.6 During re-start up the unit (Right after trip for high vibration), the HP rotor vibration
appear to be return back to normal condition with very well balance passing through
1st critical speed with maximum vibration amplitude less than 30 microns.
1.7 During re-start up period at approximately 8000 rpm, there was sign of the rotor rub
and cause high vibration (Solely 1X Synchronous vibration). Operator slightly
reduced unit speed and wait till the rotor bow condition improve then ramped up the
unit till normal operation with no significant issue from sub-synchronous vibration.
The recent start up seems to improve & reduce the severity from sub-synchronous
vibration during loading up the unit as per “Blue circle mark on plot above”.
1.8 the shaft centreline position for DE bearing appear slightly high position considering
given bearing clearance. This feature probably causes by light load on the bearing.
It may be possible the alignment of this bearing war set too low reference to the LP
TE bearing. However, there was no sign of sever high preload or severe mis
alignment concern.
1.9 With reference to ISO-7919-3 criteria, the units could be classified as normal &
acceptable for un-restricted long-term operation.
1.10 The subjected high vibration during loading the unit appear to be related with
period of ASV controlling at “Surge controlled line” and somehow this triggered the
sub-synchronous vibration and induced “Rub” and cause high vibration due to
temporary unbalance from rotor thermal bow. Note that the new overhauled unit
could be sensitive to rub condition as all the seal clearance still tight with minimum
clearance.
1.11 To minimize the impact of ASV trigger the sub-synchronous vibration & induce rub,
slightly increase the surge control line margin could be one of the options i.e., 10%
12% to get ASV respond earlier/ prior to sub-synchronous vibration trigger up.
Alternative would be put the ASV in manual mode and let operator manually
loading the unit while monitor & manage the sub-synchronous vibration.
1,12 The alignment between the LP & HP rotor should be checked for the next available
opportunity (Watching for HPC: DE bearing set too low reference to LP rotor)
1.13 The LP rotor appear to be well balance with maximum vibration amplitude less
than 20 microns passing through the 1St critical speed.
1.15 With reference to ISO-7919-3 criteria, the units could be classified as normal &
acceptable for un-restricted long-term operation.
APPENDIX B:
1.1 The test was conducted on UPC_A train on both LPC & HPC sections during
normal operation with anti-surge valves closed. The simplified process diagram
is depicted below.
1.2 The performance results are calculated based on “Recent Gas Analysis” (See
Appendix “Gas sample”) and assumes the gas properties during the testing
period are the same as provided gas analysis results.
1.3 As the current suction conditions of the unit are way off from the original design
which made the original performance maps inaccurate to be used as
Reference for performance evaluation. Therefore, a new “Prediction
performance maps were simulated/ re-generated (With the suction conditions
close to current operations) to be used as “Baseline reference” to evaluate the
performance of the unit.
The deviation of Machine Mach Number between the “Test condition” and
“Base line reference condition” are less than 5% for both sections, therefore
the “Similarity” during test conditions could be considered acceptable & valid.
1.4 It was assumed all instruments used for performance test were recently
calibrated and providing the accurate reading during the test. All the
performance test data was collected from Solar system via the CCR HMI
screen.
1.5 The “Flow” was calculated by flow element DP with the recent gas sample
analysis result and flow element datasheet information.
1.6 Performance calculations were done using the D-R proprietary Perform5
software, which is based on Lee-Kesler and Passat-Danner equation of states.
1.7 During my visit, there were questions from VSP personnel which requested to
document in the report. The detail of questions are discussed in “Performance
Discussion” Section:2
The “Power” deviation of both units could consider meet & comply with
the tolerance above. The Head coefficient deviations appear to be
slightly high.
1.11 The “Power Deviation” for both sections (LPC & HPC) could be considered
meets the API 617 tolerance base on Field Test measurement & evaluation.
1.12 The accuracy of the field performance test highly dependents with the
accuracy of instrument use to collect the raw data (which rarely comply with
the strict tolerances, redundancies, and accuracy that ASME PTC-10 test code
requirement), Gas properties accuracy also influence on the accuracy of
performance calculation. Therefore, the field performance assessment should
be used as a measure of compressor relative performance (i.e., trending)
rather than a measure of absolute compressor performance
2.0 PERFORMANCE DISCUSSION
2.1 VSP: During “Hot day”, ASV - LP sections for all units (A-E) would be slightly
opened & can not be fully closed during normal operation.
Currently, during normal operation for LP-section already closes to the “Surge
controlled line” and during the “Hot day” where the air temperature rises, air
density drops down, the total air mass flow to engine reduces and the engine
power reduces. This would lead to compressor capacity reduces and comes
close to “Surge controlled line” region then ASV opens to maintain minimum flow
as its function.
2.2 As the current suction conditions on both LPC/HPC section are way off from
original designed condition, thus the original performance maps as well as the
surge line could possibly be significant changed and no longer represent the
actual performance of the units. Therefore, the new performance maps with new
suction conditions are required to be able to accurately evaluate the operation
envelop as well as to re-map the surge control system
VSP: As all the units have been put in operation NOT the same working hours
(i.e., UCP@A just recently overhauled and sister units have been operating for
years, etc), would it be good idea to get new performance maps that can
commonly use for all unit? (i.e., average suction conditions for all unit)
The current surge control system is also compensation for suction temperature
& pressure deviation. Therefore, slightly deviation of these will not significant
impact the surge control accuracy
2.3 VSP: Currently, the scrubber inlet demister and interstage cooling pressure
drop had increased from previous original operation. How these pressure loss
impact to compressor performance?
The system pressure drop influences the compressor capacity. Lower suction
pressure (Increase pressure drop across scrubber demister/ strainer at suction
side) and higher discharge pressure (Increase pressure loss on interstage
cooler) would decrease the compressor capacity.
2.4 VSP: What impact to the compressor performance if the suction temp or the gas
molecular weight has been changed from original design?
The suction temp inversely proportional to the gas density (Higher suction temp
lower gas density & vice versa). The gas molecular weight proportional to the
gas density (Higher gas molecular weight higher gas density and vice versa)
For the most common compressor application where the discharge pressure is
maintained constant,
Lower gas density would need higher “Head” to maintain the same
discharge pressure (means inlet capacity decrease)
Higher gas density would need less “Head” to maintain the same
discharge pressure (means inlet capacity increase)
.
2.5 VSP: Why the compressor unable to deliver the required discharge pressure
which still fall within the design operating envelop? (i.e., currently the units can
deliver 114 Bar discharge pressure and unable to deliver the 117 Bar discharge
pressure as require)
2.6 VSP: VSP had changed new type of valve positioner for ASV valves, do those
valve need any special procedure to calibrate them?
In general, if the flow path does not change (i.e. valve size, seat, actuator, etc)
then general calibration with the fast opening check should be good enough for
ASV function (Typically, for fast opening time should be less than 2 seconds)
2.7 VSP: VSP requested for Compressibility Factor (Z) for the current gas analysis.
Base on the provided recent gas sample result the Z factors for suction and
average for 1St and 2nd sections as depicted below
1St Section 2Nd Section
3.0 RECOMMENDATIONS
3.1 Regarding to the issue of LPC operating point closes to surge control line which
sometimes drive the unit into recycle flow, below could be options
3.1.1 With reference to performance map, the curves typically fairly “Flat” at near
the surge zone and becomes much steeper at high flow approaching the
overload zone, therefore slightly change the “Head” near the surge point could
cause large change in compressor flow.
Therefore, improve the suction pressure loss from the piping system i.e.,
demister scrubber, strainer, interstage cooler (improve suction pressure of HPC),
etc would potentially improve the situation of LPC operating near surge control
line issue and discharge pressure low issue.
3.1.2 Alternatively, the surge control line margin could possibly reduce to
minimize recycle flow (i.e. from 10% 7%). If reduce the surge control line
margin, the surge verification test should be conducted to ensure the reduced
margin anti-surge system still respond satisfactory and sufficiently to protect the
surge event.
3.2 Updates the “Surge control map” in control system. Currently, the operation
conditions had been significantly changed from original design conditions i.e.,
change in gas properties, suction & discharge condition etc. Thus, the surge line
could also be changed and possibly lead to inaccurate on anti-surge protection
which configured/ referred to the original design.
3.3 Contact Dresser-Rand Engineering to get new updated performance map to get
clear view on how the compressor perform base on current operation conditions
i.e. current gas properties, suction & discharge conditions, required flow, driver
power, etc. And if the compressor performance (Base on current operating
conditions) has small margin to the process demand then revamp compressor
could be considered to be long term solution.
APPENDIX C:
PREDICTED/SIMULATED PERFORMANCE
CURVES_25AUG2022
Discharge Pressure Vs Standard Volume Flow Brake Power Vs Standard Volume Flow
5250 6500
5000
6000 9172
4750
5000 8735
4250 4146.07
4000 4468.71
4500
3750 8298
4000
3500
3250 3500 7862
91
3000 3000
72
7425
87
74344.84
35
2750
74344.84
2500
82
98
78 6988
2500 62
74
25 2000
2250 69
88
2000 1500
37500
43750
50000
56250
62500
68750
75000
81250
87500
93750
100000
106250
112500
118750
37500
43750
50000
56250
62500
68750
75000
81250
87500
93750
100000
106250
112500
118750
Standard Volume Flow, sm³/hr Standard Volume Flow, sm³/hr
Polytropic Efficiency Vs Standard Volume Flow Polytropic Head Vs Standard Volume Flow
0.8175 230
0.8100 0.81 220
0.8025 210
0.7950 200
188.3
0.7875 190
Polytropic Head, kJ/kg
Polytropic Efficiency
0.7800 180
0.7725 170
0.7650 160
0.7575 150
6988
91
72
7425
0.7500 140
87
35
0.7425 130
7862
82
98
0.7350 120
8298
74344.84
74344.84
78
6
0.7275 110
2
74
25
8735
0.7200 100 69
88
9172
0.7125 90
37500
43750
50000
56250
62500
68750
75000
81250
87500
93750
100000
106250
112500
118750
37500
43750
50000
56250
62500
68750
75000
81250
87500
93750
100000
106250
112500
118750
3750
12000 11838.33
3500
11500 3282.96
3250 8298
11000
3000
10500
2750 7862
10000
91
72
2500
9500 87
35
9000 2250 7425
82
98
2000
66453.29
8500
66453.29
78
62 6988
8000 1750
74
25
7500 69 1500
88
7000 1250
31250
37500
43750
50000
56250
62500
68750
75000
81250
87500
93750
100000
106250
31250
37500
43750
50000
56250
62500
68750
75000
81250
87500
93750
100000
106250
Standard Volume Flow, sm³/hr Standard Volume Flow, sm³/hr
Polytropic Efficiency Vs Standard Volume Flow Polytropic Head Vs Standard Volume Flow
0.7000 165.00
0.6950 157.50
0.6850 142.50
134.72
135.00
0.6800
Polytropic Head, kJ/kg
Polytropic Efficiency
127.50
0.6750
120.00
0.6700
112.50
91
0.6650
72
105.00
87
0.6600
3
97.50
5
82
0.6550 98
90.00
6988
78
0.6500 62
7425
82.50
66453.29
66453.29
7862
74
0.6450 25
8298
75.00
69
0.6400 88
8735
67.50
9172
0.6350 60.00
31250
37500
43750
50000
56250
62500
68750
75000
81250
87500
93750
100000
106250
31250
37500
43750
50000
56250
62500
68750
75000
81250
87500
93750
100000
106250