TECHNICAL REFRESHER TRAINING

FOR
MANUFACTURING/UTILITY/S&OM

ROTATING
EQUIPMENTS
ROTARY EQUIPMENTS
•PUMPS •BLOWERS
•COMPRESSORS •FINFAN COOLERS
•TURBINES •AGITATORS
•GEAR BOXES •SOOT BLOWERS
•ID / FD FANS •CLUTCHES
•Engines •Releif valves
 PUMP
•Pump is a device for lifting, transferring or
moving fluids by suction or pressure, from one
position to another.
•Centrifugal pump uses the kinetic energy of
the rotating impeller to impart motion to the
fluid.
•The rotating impeller accelerates the fluid
through its vanes and throws into the casing
where the kinetic energy of the moving fluid is
converted into potential energy.
 Classification of Centrifugal
pumps
•Based on the disposition of the shaft, centrifugal
pumps are classified as
- Horizontal pumps
- Vertical pumps
•Based on the direction of the fluid flow at the eye of
the impeller
- Radial flow pumps
- Mixed flow pumps
- Axial flow pumps
 Classification of Centrifugal
pumps
•Based on the type of impeller used
- Open impeller
- Semi open impeller
- Closed impeller
•Based on the number of impellers used
- Single stage pumps
- Multi stage pumps
 Classification of Centrifugal
pumps
•Based on the suction arrangement of the impeller
- Single end suction pumps
- Double end suction pumps
•Based on the operation,
- Parallel operation pumps
- Series operation pumps
 Basic parameters of pump
•Head
•Discharge
•Power
•Specific speed
•Efficiency
•Net Positive Suction Head
Total Head (H)

Pressure head or Head of a pump is (H) (in meters

of liquid column MLCM) defined as increase in the
energy per unit weight of fluid passing through the
pump, i.e., difference between the energy at the
outlet and at the inlet of the pump.

Total Head (H) (in meters – m)

Quantity of flow (or Discharge):
-The amount of fluid given by the pump in unit time.
-It can also be explained as the quantity of liquid
passing through the pump in unit time.
-Depending upon the conditions of service, the quantity
of flow is measured in volume or weight per unit time.
-Normal units adopted are cubic metre/hour (m3/hr);
litres/minute (lbm) in volumetric system
-tons/hour (t/hr); Kilograms/second (Kg/sec) etc., in
(weight) system.
The relation between volumetric and gravimetre
system.Weight (W) = Specific weight (rW) x Volume
(Q).
Power:
Power spent by the pump is measured in Kilowatt (KW).

WxH
=-------- KW
1000
rQH
= --------------- KW
1000

Where r in N/m3 ; Q in
m3/sec, H in m and W in
N/sec.
 SELECTION CRITERIA

SPECIFIC SPEED
SUCTION LIMITATION
NATURE OF LIQUID (VAPOUR PRESSURE ,
VISCOSITY,PH,ETC)
DELIVERY HEAD
FLOW REQUIREMENT
FLOOR AREA
 SPECIFIC SPEED

It is the speed at which a geometrically similar

impeller would operate if it were of such size as
to deliver 1 cub.m/hr. liquid against 1 m head.

As the specific speed increases, the ratio of the

impeller outlet diameter to the inlet or eye
diameter, decreases.
 SPECIFIC SPEED

GUIDE IN DETERMINING HOW CLOSE YOU

HAVE TO OPERATE TO THE B.E.P. OF A PUMP TO
PREVENT CAVITATION

THE NUMBERS RANGE BETWEEN 500 AND 20,000.

 SPECIFIC SPEED

If the specific speed is 500 to 1000, the impellers are

characterised by pure radial vanes with no curvature
from the inlet eye to the outside diameter.

This design is used for high heads at low flows.

 SPECIFIC SPEED

If the specific speed is 1500 to 3000, the

impellers are characterised by double curvature
or twist from the inlet eye to the outside
diameter.
The vane extends into the eye of the impeller.
It picks up the liquid before it makes the right
angle turn at the hub of the impeller.
It decreases picks up and entrance losses and
undue shock.
Used for the first stage of multistage pumps
and the radial type impeller is used for the
remaining stages.
This design is used for medium heads for a
wide rage of flows.
 SPECIFIC SPEED

If the specific speed is 5000 to 20000, the

impellers are characterised by axial vanes with
some curvature from the inlet eye to the outside
diameter.
Flow through the impeller is parallel to the axis
of the shaft.
This design is used for low heads at high
volume applications such as cooling water
services.
Why the CENTRIFUGAL PUMP ?
The centrifugal pump is the type most widely
used in the petroleum/ chemical industry
Transferring liquids of all types- raw materials,
materials in manufacture, and finished products-
as well as for general services of water supply,
boiler feed, condenser circulation, condense
return etc
Available through a vast range of size, in
capacities (0.5m3/ h to 2x104m3/h )
Head From a few meters to approximately 48
mpa
Total 1086 pumps in KRL
 ADVANTAGES
SIMPLICITY
LOW FIRST COST
AVAILABILITY IN RANGES OF APPLICATION
UNIFORM (NON PULSATING) FLOW
SMALL FLOOR SPACE
LOW MAINTENANCE EXPENSE
QUIET OPERATION
ADAPTABILITY FOR USE WITH A MOTOR OR A
TURBINE DRIVE
PUMPS CHECK POINTS
  1)Check / change lube oil
2)  Check/ Adjust Gland Packing Leakage, if applicable
3)  Check Connected Instruments
4)   Check / Tighten various Fasteners
5)       Observe and report any abnormal sound.
6)       Check vibration
7)       Check temperature of bearings
8)       Check mechanical seal for any leakage
 PUMPS CHECK POINTS CONTD….

9       Check mechanical seal surface temperature to ensure

flushing fluid flow.
10      Check seal pot oil level
11      Check cooling water flow to bearing housing/stuffing box.
12       Check coupling shim condition, if applicable.
13      Ensure free rotation by hand before starting.
14       Greasing of coupling if applicable.
15     Check motor amperage for overload.
16      Check direction of rotation.
 Troubleshooting of pumps

No liquid discharge from the pump may be caused by:

• Pump not primed

• Speed too low
• Suction lift too high
• Insufficient NPSH
• Impeller plugged
• Wrong rotation
• Air leaks or pockets in suction line
• Piping plugged
Insufficient liquid discharge may be caused by:

• Speed too low.

• Discharge head higher than anticipated.
• Suction lift too high.
• Insufficient NPSH
• Impeller or piping partly plugged.
• Wrong rotation
• Air leaks or pockets in suction line.
• Worn wearing rings
• Impeller / casing damages, corrosion, erosion
damages etc.
Insufficient Pressure may be caused by:

• Speed too low.

• Wrong rotation
• Air leaks or pockets in suction line.
• Worn wearing rings
• Impeller diameter too small.
• Impeller / casing damages, corrosion, erosion
damages etc.
Surges in performance may be caused by:

• Air leaks in suction line.

• Air pockets in suction line.
• Not enough NPSH available
• Air or gases in liquid.
• Impeller / casing damages, corrosion, erosion
damages etc.
• Impeller plugged.
Excessive power consumption may be caused by:

• Speed too low.

• Head too low (Pumping too much liquid)
• Specific gravity or viscosity of the liquid
pumped is too high.
• Mechanical defects – Worn wear rings,
deteriorated bearings, bent shaft, etc.
• Impeller / casing damages, corrosion, erosion
damages etc.
Noise in pumps may be caused by:

• Cavitation
• Insufficient NPSH
• Air leaks or pockets in suction line.
• Suction lift too high.
• Rotating parts rubbing.
• Impeller / casing damages, corrosion, erosion
damages etc.
• Bearing deterioration.
• Coupling damages.
• Bent shaft.
 Materials : Hardwares
• 300 series Stainless Steel like 316ss, 316Lss
• 400 series Stainless Steel like 410ss
• Duplex Stainless Steel
• Alloy 20
• Hastalloy B & C
• Monel
• Inconel
• Nickel
• Titanium
 Materials : Seal Faces
• Carbons :
– # 5 Carbon (273C)
– #17 Carbon (320 C)
– Antimony Impregnated Carbon (204 C)
– #18 Carbon (Salt Impregnated - SB 200 only)
– Special Grades
 Materials : Seal Faces
• Tungsten Carbide :
– TungCar 62-6 (Ni bonded) - 400 C
– TungCar 62-1 (Cobalt bonded) - 400 C

• Silicon Carbide :
– Silicon Carbide 1(Reaction bonded) - 427 C
– Silicon Carbide 2 ( - Sintered) - 427 C
 Materials : Seal Faces
• Peramic :
– Pure Aluminum Oxide - 177 C
• Weak in Thermal shock
• Good Chemical resistance
• Durchrome
– Chromic Oxide layer on metal body - 177 C
• Glass Filled Duraflon
– in TB seals
• Temperature limit of 71C as seal face
 Shaft Packings
Fully Interchangeable Shaft Packings

Viton - 204C
Pure Teflon - 177C
Neoprene - 107C
Glass Filled Teflon - 232C
Buna N - 107C
Teflon Encap. “O” ring - 204C
EPR /EPT - 177C
Kalrez - 315C
Tandem Seal
Metal Bellow Seal
Bearings
BEARING FUNCTION
BEARING LOAD
• ALSO CALLED JOURNAL OR SLEEVE
BEARINGS.
• CYLINDRICAL IN SHAPE
• DESIGNED TO FIT TIGHTLY IN THE
HOUSING
• CONSTRUCTED WITH A MATERIAL
OF LOW COEFFICIENT OF FRICTION
• ADVNTAGES ARE
-smaller outside diameter
-quiet operation,
-absorption of shock loads,
- enduring oscillating motion
(repetitive movement back and forth),
-low cost.
Hydrodynamic

Hydrodynamic (Fluid Film Bearings) – These

bearings are used in large machine
applications. Lubrication is drawn into the
region between the bearing’s moving parts.
When there is relative motion, the viscosity,
combined with the bearing surface shape,
generates pressure to keep surfaces separated.
Hydrostatic

Hydrostatic – Offering very low coefficients

of friction at all speeds, the main characteristic
of hydrostatic plain bearings is a high load
capacity. The load is carried by fluid pressure,
which creates decreased friction.
Plain Bearing Materials

Plain bearing materials are grouped into two

categories:

Lubricated
• Aluminum Based Alloys
• Copper Based Alloys
• Whitemetal
Dry

• Sintered Bronze
• PTFE
• Nylon
Bronze, Babbitt, oil Impregnated Sintered
bronze, Teflon©, and Ultra-High Molecular
Weight Polyethylene (UHMV-PE)
BEARING SEALS
 SEAL TYPES
• NON-RUBBING SEALS
• RUBBING SEALS
larger particulate contaminant protection, and
tolerate higher bearing operating speeds.
Steam Turbine
Constructional Features
 Steam turbine
A steam turbine is a heat
engine in which the high
pressure energy of steam is
transformed into kinetic
energy.
The high velocity steam is
deflected through blades
mounted on a rotor causing
a torque on the rotor.
 Advantages
The advantages of steam turbines are simplicity,
reliability and low maintenance cost. Space
requirements are much less than for diesel or steam
engines.
 Classification of Steam Turbines
1. Based on Blading Design
a) Impulse turbine
b) Reaction turbine
c) Combination of Impulse & Reaction turbine
2. Based on Application
a) Utility turbines
b) Industrial turbines
c) Nuclear turbines
d) Marine turbines
a) Utility Turbines
- Regenerative feed heating
- Regenerative feed heating with Reheat
- Combined cycle plants
 Classification of Steam
Turbines(contd..)
b) Industrial Turbines
• Captive Power plant
- Straight Condensing
- Straight Condensing with Injection
• Co-generation Power Plant (Power + Steam to process)
- Straight Back Pressure
- Extraction Condensing
- Extraction Back Pressure
- Double Extraction Back Pressure/ Condensing
- Extraction / Injection
• Drive Turbines
- Compressor drive
- Blowers drive
- Boiler feed pump drive, etc.)
 Impulse Stage
In the rotor blade row, energy is
extracted from the steam without
pressure drop and the force
exerted by the fluid on the blades
would be purely due to change in
the direction of flow ie due to
impulse action only. Such a stage
is known as impulse stage.
 Reaction Stage
If the blade forces are
partly due to pressure
drop across the rotor
blade row(reaction
principle) and partly due
to change in the direction
of the flow velocity
(impulse action). Such a
stage is known as the
reaction stage.
 Back Pressure Turbine
The steam is expanded
in the turbine with a
constant exit pressure
which is normally
equal to that of
process steam required
in the process plant.
 Condensing Turbine
In this type of turbine the steam is expanded to a very
low exit pressure by discharging the exhaust steam
into a condenser. Since the pressure drop is high
compared to a back pressure turbine, it will have
more number of stages.
 Extraction Turbine
In the extraction turbine, partly expanded steam is
extracted at one or more locations along the length
of the turbine for external process use.
Extraction Turbine
 BHEL Make Turbine Classification
Type BHEL Model No

Straight Back Pressure G –for inlet steam up to 80 ata

Extraction Back Pressure EG

Back Pressure HG–for inlet steam up to 141 ata

Back Pressure-Impulse MG–steam up to 141 ata & for high speed

Straight Condensing K

Extraction Condensing EK

Double flow condensing WK

Cross Section
Cross Section
Cross Section
Turbine Rotor
 Turbine Integral Systems

• Protection system Control &

Instrumentation
• Oil system
• Gland sealing system
• Turbine Drains
 Protection Requirements
•Over speed
• Low Lube oil pressure
• Low vacuum
• Axial shift
• High Vibration
• Bearing temperature
• Differential expansion
• High/low extraction pressure
• Exhaust temperature
• Generator / Compressor protections
• Manual / Remote trip
• Special protections
 Critical Speed
The rotational speed of the rotor or rotating element at
which resonance occurs in the system.

The shaft speed at which at least one of the "critical"

or natural frequencies of a shaft is excited.

The speed at which harmonic vibration occurs in a

rotating body as a result of its center of gravity being
slightly removed from the body's true center.
TURBINES CHECK POINTS
1)     Check / Change lube Oil
2)     Check Functioning of Oil circulation Rings
3)     Check / Adjust the speed of the Turbine
4)     Check connected instruments
5)     Check Tightness of Various Fasteners
6)     Check / change governor oil
 Routine Checks
•SHAFT VIBRATIONS ANALYSIS.
• AXIAL MOVEMENT OF ROTOR.
• BEARING METAL TEMP.
• OIL INLET TEMP.
• OIL DRAIN TEMP.
• COOLING WATER TEMP.
• CHANGE IN TEMP. ACROSS THE COOLER.
• STEAM INLET AND EXHAUST TEMP.
 Routine Checks
•OIL PRESSURE TO BRG INLETS.

•COOLING WATER PRESSURE,

•DIFF. PRESSURE ACROSS LO FILTER.

•OPERATION OF EMERGANCY OIL PUMP.

•WHEEL CHAMBER PR.

 Check During Shutdown
•OPERATION OF TRIP LEVER.
•OPERATION OF ESV.
•OPERATION OF CONTROL VALVES
•OPERATION OF CONTROL VALVE ACTUATORS.
•OIL LEVEL IN MAIN TANK.
•QUALITY OF OIL.
• OIL PUMP STRAINERS.
•TRIP INTERLOCKS.
 Minor Overhaul
•coupling-visual inspection for cracks, bolts
failure,run out & axial float, eccentricity.
•Bearings- scoring,clearances, DP test,
looseness , corrosion, cracks.
•Oil glands.
•Bearing housing & casing support system.
•ESV, Gov Valves are to be opened & cleaned.
 Minor O/H
INSPECTION OF
•Turbine drains for blockage, cracks.
•MOP : brgs, seal rings, rotor, impeller etc.
•governing system & protection system.
•Control oil and lube oil lines : leaks, cracks
distortions.
•Steam strainers.
•Heat exchangers/ coolers- flow obstructions,
Fouling, corrosion erosions leaks, cracks.
•Metallic hoses to be replacement.
 Major Overhaul
INSPECTION OF
• TURBINE INTERNALS, (CHECK FOR CRACKS ON BLADES & BRG.
SURFACES)
• STEAM CHAMBER,
•CONTROL VALVES,
•COOLERS & CONDENSOR.
•HIGH TEMP. ZONE BOLTS FOR DEFORMATIONS
• CLEANING OF INTERNALS,
• CHANGING OF WORN OUT GLAND FINS ON BOTH STATOR & ROTOR
• OIL TANK CLEANING
•CHECKING FOR ROTOR RUN OUTS.
 Major Overhaul
•INSPECTION OF..
• outer casing, steam chest, valve body & inner casing
•ESV casing glands
•labyrinth glands, bushes- for cracks,distortion, erosion and
mechanical damages.
•Valve seats, valve stem, valve cone, valve glands, hinged joints
•flange and joint bolts
•nozzles guide blades
•steam lines and connected drains
•rotors: sign of rubbing, gaps, erosion, distortions, run out:
•Moving blades: deposits, erosion, cracks seizure, rubbing twisting
 TYPES OF COMPRESSOR

•RECIPROCATING •CENTRIFUGAL
•ROTARY TYPE COMPRESSORS
•AXIAL COMPRESSORS
•HELICALSCREW
•SPIRALAXIAL
•STRAIGHT LOBE
•SLIDE VANE
SELECTION OF COMPRESSORS
Positive displacement machines below 3000
m³ / hr.
Axial compressors above 30,000 m³ / hr.
 Flow regions between 3000 - 12,000 m³ / hr.
Can be considered over-lapping between
positive displacement and centrifugal
compressors
Flow regions between 30,000 - 1,20,000 m³ / hr.
Can be considered over-lapping between
centrifugal and axial compressors.
 CENTRIFUGAL COMPRESSORS
Principle of Operation
By the centrifugal force acting on the media as it passes
out radially through the impeller. Compression of the medium
takes place due to the work done as the medium flows through
the streaming part
Achieve compression by applying inertial forces to the
gas (acceleration, deceleration, turning) by means of bladed
impellers.
About two-thirds (70%)of the pressure rise occurs in the
impeller itself with the remaining increase taking place in the
diffusion (velocity reduction) process.
The stationary components such as diffusers, guide vanes,
return channels can merely convert velocity energy into pressure
energy or vice versa and incur losses.
 ADVANTAGES OF CENTRIFUGAL
COMPRESSORS

•·        HIGH DEGREE OF BALANCING

•·        PULSATION FREE DELIVERY
•·  OBVIATES THE USE OF SURGE TANK
RECEIVERS
•·        EASY MAINTENANCE
•· BEST SUITED FOR PART LOAD
OPERATIONS
•·        LOWER NOISE LEVEL
• COMPACT
 TYPES OF CENTRIFUGAL
Horizontally split COMPRESSORS Vertically split
casing casing design
Used foe low
working pressure
Suitable for
normally BELOW
high pressure
40 ATA up To 750
Kf/cm2
2MCL COMPRESSOR
  
BCL COMPRESSOR
 Diaphragms
The diaphragms constitute the flow dynamic path of
the static part of a compressor
They form the separation walls between each
compression stage and the adjacent one
The adjacent surfaces of the diaphragms house the
diffuser passages which convert the kinetic energy of
the gas into pressure energy
A set of guide blades located on the return channels
convey and distribute the gas evenly to the eye of the
next impeller.
The diaphragms are made from high strength cast iron
or steel, based on design considerations, and are split
horizontally.
 Rotor
The rotor comprises a
shaft, impellers,
balancing drum, thrust
collar, spacer rings and
lack-nuts
1.SHAFT
IT IS PRECISION MACHINED FROM LOW ALLOY FORGINGS
AND GROUND AT THE JOURNAL PORTIONS.
ANY TWO IMPELLERS ARE PROTECTED BY CHROMIUM STEEL
SPACERS
2.IMPELLERS
ALLOY STEEL FORGINGS.
THEY ARE CLOSED TYPE, WITH BLADES CURVED
BACKWARDS, DYNAMICALLY BALANCED
A THRUST BEARING IS INSTALLED AT THE SUCTION END TO
TAKE AXIAL LOAD
 Rotor contd….

3 .BALANCING DRUM
Assembled on the shaft at the end adjacent
to the last stage impeller
As to reduce the axial thrust very much but
not altogether.
Balancing drum is made from forged
chromium - steel and is shrunk fitted and
keyed to the shaft.
Remaining unbalanced thrust is taken care of
by the thrust bearing.
 Rotor contd….
JOURNAL BEARINGS & THE THRUST BEARING

THE JOURNAL BEARINGS ARE NORMALLY OF

SLEEVE TYPE AND ARE FORCE FEED LUBRICATED
OIL UNDER PRESSURE ENTERS THE BEARINGS
RADIALLY AND LEAVES BY THE SIDED.
TO TAKE THE REMINDER OF THE AXIAL THRUST
THAT IS NOT FULLY BALANCED IN THE BALANCING
DRUM
LYBYRINTH SEALS & BALANCING
DRUM ARRANGEMENT
TYPES OF COMPRESSOR END SEALING SYSTEMS

           Labyrinth Sealing

           Floating Oil Seals
           Oil Mechanical Seals
           Air Injection Sealing System
           Injection / Extraction Sealing
           Dry Gas Seals
 
 LUBE OIL SYSTEM

• Lube oil console

• Overhead lube oil tank
• Coolers
• Filters
• Lube oil pipelines
• Bearing oil pressure
• Hydraulic Accumulators
• Hydraulic Accumulators
• Prevent the operation of the low oil pressure
tripping
• Accumulators are connected to the lube oil
system and the turbine governing oil system
• Accumulators have a flexible separator bag
charged with inert gas.
• The inert gas pressure to the accumulator must
be slightly lower than the oil pressure existing in
the line
 Seal Oil System
Step 1
Oil for the compressor shaft seal is tapped from the
lub oil down stream.
Step 2
The oil pressure in the discharge lines of the pump is
kept constantly higher than the reference gas
pressure of the compressor DPCV.
Step 3
The oil inlet to the seals is always kept higher than
the reference gas pressure by about 0.6 kg/cm2.
Step 4
This differential pressure is obtained by placing the
seal oil over head tank at about 7 m. above the
compressor center line.
Step 5
The oil level in the seal oil tank is maintained
constant by means of a level transmitter, a
level controller and level control valve.
Step 6
Continuous flow of oil to the compressor side
through the clearance b/w the high pressure
seal ring &shaft sleeve prevents the gas
leaking along the shaft sleeve past the seals
 RECIPROCATING COMPRESSORS

MAIN COMPONENTS

COMPRESSOR FRAME
CRANK SHAFT
CONNECTING ROD
CROSS HEAD
PISTONS
VALVES
PISTON
RODE BEARING
PISTON

PISTON
VALVE
 CRANK SHAFT

The rotary motion provided by the

driving power unit is converted into
reciprocating motion by the crankshaft.
Forgings of steel in one solid piece
Widely used style of crank is the center-
through design having the crank section
in the center providing bearing supports
on both sides of the crank
Dynamically balanced
 CONNECTING ROD

The connecting rod connects the crankshaft

to the cross head
Transforming the rotary motion at the crank
to a straight-line reciprocation at the
crosshead
Connecting rods are steel forgings of or
similar section for rigidity and lightweight
floating type-bearing liners are used
Bearings being full-floating; Pressure
lubricated free to rotate both in the bearing
journal and within the bearing housing.
 CROSS HEAD

Is a casting or forging which acts as a sliding

joint between the connecting rod and the
piston rod
The wearing surfaces of the crosshead are
usually cylindrical in shape
Crosshead guides are also cylindrical in shape
to mate the crosshead and also for easy
machining
 PISTONS
The compression of air/gas in an air/gas compressor is accomplished as
the air/gas trapped between the end of the cylinder and the end of the
piston is reduced in volume by the force of the advancing piston.
Material and construction must be capable of withstanding this
continual application of force . in the low-pressure stage of two stage
compressors, aluminum pistons are often used because of their
lightweight
A stronger cast-iron, aluminum alloy or alloy-steel piston is used for
high-pressure stages depending on the strength required
Pistons must slide freely back and forth in the cylinder,
Amount of clearance in terms of measurement is small, about 0.001’’
per inch of bore diameter,
To control or seal the air leakage, pistons are fitted with piston rings.
Two to eight rings depending on the service for which compressor is
designed.
 VALVES
Act as the path ways for gas flow
Compressor valves are a one-way, or check-type valve
Placed in the cylinder to permit air/gas to flow in one direction
either into or out of the cylinder
Operated by the action of the air or the gas it controls. They are
opened by the difference in pressure across the valves,
For large capacity compressors the channel type and annular
ring type valves are commonly used.
The annular ring/plate type valve type or plate type or
concentric ring type valves are used on larger capacity
compressors.
 With this valve a cushioning is effected when a small volume of
air is trapped between the channel and its spring causing the
channel to float silently to a stop. This positive cushioning action
prior to the critical point of valve impact with the stop plate
reduces valve breakage.
RECIPROCATING COMPRESSOR SYSTEMS

LUBE OIL SYSTEM

WATER COOLING ARRANGEMENT
AIR/GAS PRESSURE REGULATING
SYSTEM
UNLOADING SYSTEMS OF AIR
COMPRESSOR and
SAFETY DEVICES
RECIPROCATING COMPRESSORS
1)     Check / Top up crank case / cylinder lubricating oil
2)     Tighten all fasteners
3)  Check / clean the lube oil filter if differential pressu
observed to be high.
4)     Check the functioning of valves and unloaders.
5)     Check the Functioning of safety valves
6)     Check / clean / replace air filters in air compressors.
 
 ID/FD Fan
Fans are used for ventilating work supplying draft to
boilers and furnaces, moving large volumes of air or gas
through ducts, supplying air for drying, removing fumes
etc. They are usually of the centrifugal or the axial-
flow type. Both types are used for low pressure,
generally less than 0.5 psi
 ID and FD fan

ID and FD fan are used for creating

Mechanical draft
 Draft
Draft is defined as the difference between
atmospheric pressure and the static pressure of
combustion gases in a furnace or gas passage.
Draft is classified into natural and mechanical
draft.
Mechanical draft is created by the use of
mechanical fans.
 Forced draft fans
In forced
• draft fans(F.D.fans) draft is created by
pushing the air and combustion gases. When
using a forced draft system the entire furnace
casing is under a positive pressure. The casing
must be strong enough to withstand the internal
pressure.
 Induced draft fan
In induced draft fan (I.D.fans) draft is created
by pulling the air and gases through the
furnace. When using a induced draft fan
furnace pressure is lower than atmospheric.
The casing must be strong enough to
withstand the external pressure
 Balanced draft system
When furnace draft is maintained at
atmospheric pressure(or just below),by use of
a combination of forced and induced draft
fans, the draft is referred to as a balanced
draft system.
 Difference between ID & FD fan
The induced draft fan which is required to provide the
same volume of air is larger than a forced draft fan,
due to the following:
The ID fan must move a larger mass because the flue
gas consist of the mass of the fuel as well as air.
The ID fan must be able to handle any air leakage into
the boiler.
The ID fan must handle more volume of gases since
the temperature of the flue gas is higher than the air
moved by an F.D fan.
 Routine Checks
Check leakage of oil, air, and hot gas.
Check unusual noises if any
Check oil levels in bearings
Check bearing temp & vibration
Check rotation of bearing oil rings.
Check rubbing of rotating parts.
ID AND FD FAN BEARINGS
1)     Check and top up the oil in the bearing housing / gear box
2)     Lubricate all other bearings.
3)     Check and tighten fasteners
 
SOOT BLOWERS
1)     Check and top up gearbox oil
2)     Clean and lubricate the chain
3)     Operate and observe the functioning of limit switches
4)     Check/ tighten fasteners.
FINFANS
1)     Lubricate the bearings
2)     Check and tighten fasteners
3)     Check and adjust the belts
TANK MIXERS
1)     Lubricate the bearings
2)     Check and top up lube oil
3)     Tighten various fasteners
Adjust the gland follower if applicable
ENGINES
1)     Check / make up engine Oil
2)     Check / Make up Governor Oil
3)     Check the Condition of Air Cleaners, oil / fuel filters and
change if required
4)     Check/ Repair leakage
5)     Check / adjust water pump, radiator fan and Generator
Alternator belts.
6)     Check engine coolant / corrosion resistor and change if
required
GAS TURBINES
1)     Combustion inspection - 8000 Hrs. - 12000 Hrs
2)     Hot gas path inspection - 16000 Hrs- 24000 Hrs
3)     Major overhaul - 32000 Hrs - 48000 Hrs
 What is vibration ?

Vibration can be defined as the cyclic or oscillating motion

of a machine or machine component from its position of rest.

Vibration is caused by,

• Exciting force
• Freedom for movement
Physical observations not able to predict machine life properly……..

• Predictions differ according to persons.

• Accuracy of such assumptions are less.
• Problems can be detected only at final stages of machine damage.

Vibration analysis helps

in detecting the problems
at initial stages before they
cause any damage to machine.
Vibration monitoring can be used for,

1. Fans
2. Blowers
3. Pumps
4. Compressors
5. Turbines
6. Engines
7. Gear boxes
8. Electric motors
Causes of vibration are…….

1. Unbalance
2. Mechanical Looseness
3. Misalignment
4. Deterioration of bearings
5. Gear wear
6. Rubbing
7. Aerodynamic/Hydraulic problems
8. Resonance
9. Eccentricity
10. Electrical problems
11. Background disturbances
12. Coupling defects
13. Bad belts
14. Reciprocating forces
15. Bent shaft
16. Impeller / blade defects
 Harmful effects of vibration

1. Increased load on bearings

2. Reduced bearing life
3. Decreased equipment efficiency
4. Reduced output quality
5. Higher forces on mountings
6. Increased maintenance cost
7. Unsafe operating condition
 WHY USE VIBRATION?

• All machines vibrate.

• Developing problems are usually accompanied by an
increase in vibration.
• The vibration’s unique characteristics will be determined by
the nature of the developing fault.
 THE FOUR STAGES OF AN EFFECTIVE PREDICTIVE
MAINTENANCE PROGRAM.
Detection
•Trending a machines vibration level to detect and quantify any changes
from the norm.
Analysis
•When a significant change is detected the vibration is analysed to
determine the nature of the problem.
Correction
•The advanced warning provided by the detection and analysis enables
corrective action to be prepared and scheduled.
Verification
• After correction new readings are obtained to ensure that all defects have been
eliminated and to establish new baseline characteristics.
CHARACTERISTICS OF VIBRATION

• AMPLITUDE
• FREQUENCY
• PHASE

ANY VIBRATION CAN BE DEFINED BY THE

PARTICULAR COMBINATION OF THESE THREE
CHARACTERISTICS.
MEASUREMENT PARAMETERS,
WHAT DO THEY MEASURE?

• DISPLACEMENT - How far it moves

(Microns or Mils)

• VELOCITY - How fast it moves

(mm/sec or in/sec)

• ACCELERATION - How quickly velocity

changes
(g or mm/sec2 or in/sec2)
 VIBRATION FREQUENCY.

THE TIME REQUIRED TO COMPLETE ONE FULL CYCLE OF

VIBRATION IS CALLED THE PERIOD.

FREQUENCY IS THE RECIPROCAL OF THE PERIOD.

 COMPARISON OF
FREQUENCY AND TIME DOMAINS

Simple Wave forms

Complex Waveform

FMAX
Amplitude 9X
5X
3X Frequency
1X
Spectrum
Time Domain Plot
(Sec or Min) Frequency Domain
TMAX (CPM or Hertz)
 PARAMETER SELECTION
The measurement parameter that will give the greatest response to
any change in machinery condition whatever the cause.

• DISPLACEMENT :- 0 cpm - 600 cpm (STRESS).

• VELOCITY :- 6 00 cpm -120Kcpm (FATIGUE).

• ACCELERATION :- 120Kcpm < (FORCE).

 Spike energy

A parameter designed to detect low amplitude transient

impacts generated by microscopic surface flows in rolling
element bearings and gears.

The acceleration signal is processed via a high pass filter and a

peak detection circuit to produce a numerical value which is the
product of number and amplitude of impacts in unit time.

Unit of spike energy : gSE

 Acceleration enveloping

The enveloping process enhances the measurement of high frequency

repetitive small amplitude signals while suppressing the higher
amplitude low frequency signals as well as broad band random noises.

Signal is processed via a high pass filter and a peak detecting circuit
and then modulating and amplifying the signal to get a numerical value.

Unit of acceleration enveloping : gE

 WHY IS VELOCITY THE PARAMETER
NORMALLY USED

• IT GIVES EQUAL AMPLITUDE WEIGHTING TO ALL VIBRATION FREQUENCIES.

• MOST ROTATING MACHINES PRODUCE FREQUENCIES BETWEEN 6OOCPM TO

120KCPM WHERE VELOCITY IS THE MOST RESPONSIVE

• IT IS THE ONLY MEASUREMENT PARAMETER WHERE THE OVERALL VIBRATION

LEVEL CAN BE APPLIED DIRECTLY TO A STANDARD OF VIBRATION SEVERITY.
IE:-WHEN THE FREQUENCIES OF THE VIBRATION ARE UNKNOWN.
 CONDITION MONITORING

ONLINE VIBRATION
ANALYSIS
VIBRATION WITH
ANALYSIS DATA COLLECTOR

HIGH SPEED CRITICAL

TURBINES PUMPS –
COMPRESSORS FORTNIGHTLY.
GAS TURBINES
– SEMI CRITICAL
EQPTS -
Monitored
ON MONTHLY
continuously BASIS.
 Systems used for vibration monitoring

IRD 890 DATA COLLECTOR WITH E –MONITOR SOFTWARE

SKF DATA ACQUISITION DEVICE WITH MACHINE ANALYST

SOFT WARE

The system consists of portable data collector having data

storage capability and advanced software system using FFT
programs.

FFT is the process of transforming time domain signal to frequency

domain signal.
DIRECTIONS OF MEASUREMENT

Horizontal

Vertical

Axial

Any other direction if required.

 4 3

1 2 3 4
Vibration Frequency Analysis

- Vibration is generated out of machine defects.

- Each kind of machine defect generates unique kind of force

and hence Vibration.

- Each type of vibration produces different frequencies.

- Over all vibration is the resultant of all these forces.

- Spectrum is a graphical display of the amplitude versus frequency.

- From spectrum highest amplitudes are to be identified.

Vibration frequencies and the likely causes.

Frequency in Most likely causes Other possible causes &

terms of RPM remarks

1 X RPM Unbalance 1. Eccentric journals,

gears or pulleys
2. Misalignment or bent
shaft – if high axial
vibration
3. Bad belts-if rpm of
belt
4. Resonance
5. Reciprocating forces
6. Electrical problems
Vibration frequencies and the likely causes.

Frequency in terms Most likely causes Other possible

of RPM causes & remarks

2 X RPM Mechanical 1. Misalignment

looseness - if high axial
vibration
2. Reciprocating
forces
3. Resonance
4. Bad belts- if 2
x rpm of belt
Vibration frequencies and the likely causes.

Frequency in terms Most likely causes Other possible

of RPM causes & remarks

3 X RPM Misalignment 1. Usually

combination
of
misalignment
and excessive
axial
clearances
Vibration frequencies and the likely causes.

Frequency in terms Most likely causes Other possible

of RPM causes & remarks

Less than 1 X rpm Oil whirl 1. Bad belt

2. Background
(42 to 48 %) vibration
3. Sub harmonic
resonance
4. Beat vibration
Vibration frequencies and the likely causes.

Frequency in terms Most likely causes Other possible

of RPM causes & remarks

Synchronous Electrical problems 1. Broken rotor

(A.C. line bars
frequency) 2. Eccentric
rotor
3. Unbalanced
phases in
poly-phase
systems
4. Unequal air
gaps
Vibration frequencies and the likely causes.

Frequency in terms Most likely causes Other possible

of RPM causes & remarks

2 X synchronous Torque pulses Rare as a problem

frequency unless resonance is
excited
Vibration frequencies and the likely causes.

Frequency in terms Most likely causes Other possible

of RPM causes & remarks

Many times rpm Bad gears 1. Gear teeth times

(harmonically Aerodynamic rpm of bad gear
related frequency) forces 2. Number of fan
blades times rpm
Hydraulic forces 3. Number of
impeller vanes
Mechanical
times rpm
looseness
4. May occur at
2,3,4 and
Reciprocating sometimes higher
forces harmonics if severe
looseness
Vibration frequencies and the likely causes.

Frequency in terms of Most likely Other possible causes & remarks

RPM causes

High frequency Bad anti-friction 1. Bearing vibration may be

(not harmonically bearings unsteady amplitude and
related) frequency
2. Cavitations, recirculation
and flow turbulence cause
random, high frequency
vibration
3. Improper lubrication of
journal bearings (friction
excited vibration)
4. Rubbing
Vibration standards

ISO 2372
Manufacturers Guidelines
Comparison/Experience
 TECHNICAL TRAINING
Pressure Relief Valves
 Safety valves and relief
valves
Safety valves and relief valves are
pressure relieving devices used in
process and piping systems to
prevent excessive over-pressure
built-up and thus protect the piping
or equipment from failure.
 Safety valves and relief
valves
Safety valves are normally used for gas,
vapor and steam services. Safety valves are
characterised by a rapid full opening or "pop"
action of the valve at the set pressure .
Relief valves are used for liquid applications,
the valves open in proportional to the
increase of the system pressure from the set
pressure.
 safety-relief valves

There is one more category known as

safety-relief valves, which can be used
either as a safety valve or as a relief
valve depending on its application .
These valves are also characterised by
a rapid full opening of the valve at the
set pressure
Spring loaded safety valve
 Balanced safety valve
A balanced safety relief valve is a pressure relief
valve, which incorporates a means of minimising the
effect of backpressure on the operational
characteristics (opening pressure, closing pressure,
and relieving capacity).
Balanced safety valve
 Frequency of testing of
Pressure Relief Valves
Sl.No Location Frequency

1 Process Plant:  
a)Existing Unit Every shutdown but not later than
  4 years
b)New Unit   
   
i)Corrosive & high Within a year of commissioning
temp. areas
   
ii)Non-critical areas Within 2 years of commissioning

2 Spheres/Bullets/ Once in a year

Chemical storage

3 Steam Generators Each Statutory Inspection

4 Offsite Piping Once in 5 years

 Blowdown
The difference between the set pressure and
re-set pressure is known as the “blow down"
and is adjustable with the help of the blow
down ring provided.
 COLD SETTING
An increase in temperature causes a reduction in set
pressure of a safety valve or safety-relief valve.
Consequently, it is customary to compensate for this
effect by increasing the setting when a valve is set at
ambient conditions on a test stand and it is intended
for a higher Operating temperature in service.
Set Pressure Test Tests
Cold differential set pressure as specified by the manufacturer
shall be used for setting the valves on test bench
Always lower the pressure in the valve atleast 25% below
popping pressure before spring adjustment
Seat Tightness Test
Once the correct set pressure is established, the valve shall be
checked for seat tightness. For this the valve shall be brought to
90% of the set pressure and the discharge side shall be
observed for leakage.
Testing of Bellows
The bellow of the balance bellow type safety relief valve shall be
pneumatically tested for 1.1 times the maximum back pressure
acting on the valve
Thank you All