Details

Operator's Guide to Process Compressors


Operator's Guide to Process Compressors


1. Aufl.

von: Robert X. Perez

190,99 €

Verlag: Wiley
Format: PDF
Veröffentl.: 16.04.2019
ISBN/EAN: 9781119581420
Sprache: englisch
Anzahl Seiten: 300

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Beschreibungen

<p><b>The perfect primer for anyone responsible for operating or maintaining process gas compressors.</b></p> <p>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.</p> <p>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.</p> <p>This groundbreaking new work is a must-have for any engineer, operator, or manager working with process compressors.</p> <p><b>The main goals of this book are to:</b></p> <ul> <li>Explain important theories and concepts about gases and compression processes with a minimum of mathematics</li> <li>Identify key compressor components and explain how they affect reliability</li> <li>Explain how centrifugal compressors, reciprocating compressors, and screw compressors function.</li> <li>Explain key operating factors that affect reliabilityIntroduce the reader to basic troubleshooting methodologies</li> <li>Introduce operators to proven field inspection techniques</li> <li>Improve the confidence of personnel operating compressors by teaching them the basics of compressor theory</li> <li>Improve compressor reliability plantwide by teaching operating and inspection best practices</li> <li>Improve communication between operating and supporting plant personnel by providing a common vocabulary of compressor terms</li> <li>Help processing plants avoid costly failures by teaching operators how to identify early compressor issues during field inspections</li> </ul>
<p>Preface xv</p> <p><b>1 Introduction to Gases 1</b></p> <p>1.1 Ideal Gases 4</p> <p>1.2 Properties of Gases 5</p> <p>1.3 Temperature 5</p> <p>1.4 Pressure 6</p> <p>1.5 Gas Laws 7</p> <p>1.6 Gas Mixtures 10</p> <p>1.6.1 Dalton’s Law of Partial Pressures 10</p> <p>1.7 Molecular Weight of a Gas Mixture 11</p> <p>1.8 Gas Density 13</p> <p>1.9 Density of Mixtures 14</p> <p>1.10 Heat of Compression 15</p> <p><b>2 Commonly Used Compressor Flow Terms 19</b></p> <p>2.1 Ideal Gas Law 20</p> <p>2.1.1 Example of How to Convert from SCFM to ACFM 22</p> <p>2.2 Visualizing Gas Flow 23</p> <p>2.3 Compressibility Factor (Z) 25</p> <p>2.4 Sizing Compressors 27</p> <p><b>3 Compression Processes 31</b></p> <p>3.1 Adiabatic Compression 33</p> <p>3.2 Polytropic Compression 37</p> <p>3.2.1 Polytropic Example #1 40</p> <p>3.2.2 Polytropic Example 2 40</p> <p><b>4 What Role the Compression Ratio Plays in Compressor Design and Selection 43</b></p> <p>4.1 Compression Ratio versus Discharge Temperature 44</p> <p>4.2 Design Temperature Margin 46</p> <p>4.2.1 Design Trade-Offs 49</p> <p><b>5 An Introduction to Compressor Operations 53</b></p> <p>5.1 Compression Basics 53</p> <p>5.2 Defining Gas Flow 55</p> <p>5.3 Compressor Types 56</p> <p>5.4 Multistaging 59</p> <p>5.5 Key Reliability Indicators 60</p> <p><b>6 Centrifugal Compressors 63</b></p> <p>6.1 Centrifugal Compressor Piping Arrangements 66</p> <p>6.2 Start-Up Configuration 68</p> <p>6.3 Centrifugal Compressor Horsepower 68</p> <p>6.4 Troubleshooting Tips 70</p> <p>6.5 Centrifugal Compressor Start-Ups 71</p> <p>6.6 Centrifugal Compressor Checklist 72</p> <p><b>7 How Process Changes Affect Centrifugal Compressor Performance 75</b></p> <p>7.1 Baseball Pitcher Analogy 75</p> <p>7.2 How Gas Density Affects Horsepower 78</p> <p>7.3 Theory versus Practice 80</p> <p><b>8 How to Read a Centrifugal Compressor Performance Map 83</b></p> <p>8.1 The Anatomy of a Compressor Map 85</p> <p>8.1.1 Flow Axis (See Figures 8.2 and 8.3) 85</p> <p>8.1.2 Head or Pressure Ratio Axis (See Figures 8.2 and 8.3) 86</p> <p>8.1.3 Predicted Surge Line (See Figures 8.2 and 8.3) 86</p> <p>8.1.4 Predicted Capacity Limit (Figures 8.2 and 8.3) 86</p> <p>8.1.5 Surge Margin (See Figure 8.2) 87</p> <p>8.1.6 Speed Lines (See Figures 8.2 and 8.3) 88</p> <p>8.2 Design Conditions 88</p> <p><b>9 Keeping Your Centrifugal Compressor Out of Harm’s Way 91</b></p> <p>9.1 Compressor Operating Limits 93</p> <p>9.2 Compressor Flow Limits 93</p> <p>9.3 Critical Speeds 95</p> <p>9.4 Horsepower Limits 96</p> <p>9.5 Temperatures 97</p> <p><b>10 Troubleshooting Centrifugal Compressors in Process Services 101</b></p> <p>10.1 The Field Troubleshooting Process—Step by Step 105</p> <p>10.1.1 Step 1: Define the Problem 105</p> <p>10.1.2 Step 2: Collect All Pertinent Data 105</p> <p>10.1.3 Step 3: Analyze the Body of Data as a Whole 106</p> <p>10.1.4 Step 4: Act and Confirm 106</p> <p>10.2 The “Hourglass” Approach to Troubleshooting 108</p> <p>10.3 Thinking and Acting Globally 109</p> <p>10.4 Troubleshooting Matrix and Table 110</p> <p>10.5 Centrifugal Compressor Troubleshooting Example 110</p> <p><b>11 Reciprocating Compressors 117</b></p> <p>11.1 Reciprocating Compressor Installations 124</p> <p>11.1.1 How Process Conditions Affect Reciprocating Compressor Performance 126</p> <p>11.2 Reciprocating Compressor Start-Ups 128</p> <p>11.3 Reciprocating Compressor Checklist 129</p> <p>11.4 Criticality 131</p> <p><b>12 Troubleshooting Reciprocating Compressors in Process Services 133</b></p> <p>12.1 The Field Troubleshooting Process—Step by Step 137</p> <p>12.1.1 Step 1: Define the Problem 137</p> <p>12.1.2 Step 2: Collect All Pertinent Data 137</p> <p>12.1.3 Step 3: Analyze the Body of Data as a Whole 138</p> <p>12.1.4 Step 4: Act and Confirm 138</p> <p>12.1.5 Troubleshooting Matrix and Table 140</p> <p>12.1.6 Reciprocating Compressor Troubleshooting Example 140</p> <p><b>13 Screw Compressors 147</b></p> <p>13.1 Oil Injected Screw Compressors 150</p> <p>13.2 Screw Compressor Modulation 151</p> <p>13.3 Pressure Pulsation Issues 152</p> <p>13.3.1 Absorptive Type Dampeners 154</p> <p>13.3.2 Reactive Type Dampeners 154</p> <p>13.3.3 Combination Type (Reactive and Absorptive) 154</p> <p>13.3.4 Oil Contamination 155</p> <p>13.3.5 How Process Conditions Affect Screw Compressor Performance 156</p> <p>13.4 Troubleshooting Screw Compressors 156</p> <p><b>14 Compressor Start-Up Procedures 159</b></p> <p>14.1 Compressor Start-Up Risks 160</p> <p>14.2 Generic Start-Up Procedure 162</p> <p>14.3 Centrifugal Compressor Start-Ups 165</p> <p>14.4 Reciprocating Compressor Start-Ups 167</p> <p>14.5 Screw Compressor Start-Ups 170</p> <p><b>15 Compressor Trains: Drivers, Speed Modifiers, and Driven Machines 173</b></p> <p>15.1 Driven Process Machines 174</p> <p>15.1.1 Drivers 175</p> <p>15.1.1.1 AC Electric Motors 176</p> <p>15.1.2 Steam Turbines 177</p> <p>15.2 Gas Turbines 178</p> <p>15.2.1 Natural Gas Engines 179</p> <p>15.2.2 Speed Modifiers 180</p> <p>15.2.2.1 Gear Boxes 180</p> <p>15.3 Useful Gearbox Facts 182</p> <p>15.4 Combination Machines 182</p> <p>15.4.1 Turboexpanders 182</p> <p><b>16 Compressor Components 185</b></p> <p>16.1 Bearing Types 185</p> <p>16.2 Rolling Element Bearings 187</p> <p>16.3 Plain Bearings 188</p> <p>16.4 Compressor Bearings 189</p> <p>16.5 Modeling Fluid Film Bearings 190</p> <p>16.6 Thrust Loads 192</p> <p>16.7 Kingsbury Thrust Bearing 193</p> <p>16.8 Compressor Seals 194</p> <p>16.8.1 Labyrinth Seals 194</p> <p>16.8.2 Oil Film Seal 194</p> <p>16.8.3 Face Contact Wet Seals 196</p> <p>16.9 Seal Oil System 197</p> <p>16.10 Dry Gas Seals 197</p> <p>16.11 Seal Gas Quality and Control 198</p> <p>16.12 Reciprocating Compressors – Packing 199</p> <p><b>17 The Importance of Lubrication 201</b></p> <p>17.1 Lubrication Regimes 203</p> <p>17.2 Lubricating Oils 206</p> <p>17.3 Compressor Lubricating Oil Systems 206</p> <p>17.3.1 Lubrication Monitoring 209</p> <p>17.4 Oil Foaming 210</p> <p>17.4.1 Excessive Foam 211</p> <p><b>18 Inspection Ideas for Operators and Field Personnel 213</b></p> <p>18.1 Equipment Field Inspections 213</p> <p>18.1.1 Audible Inspections 215</p> <p>18.1.2 Visual Inspections 216</p> <p>18.1.3 Tactile Inspections 217</p> <p>18.1.4 Smell 219</p> <p>18.2 Tools Available to Quantify What You Have Detected 220</p> <p>18.2.1 Audible Inspection Methods 220</p> <p>18.2.1.1 Ultrasonic Gun 220</p> <p>18.2.1.2 Stethoscope 220</p> <p>18.2.1.3 Metal Rod 220</p> <p>18.3 Visual Inspection Methods 221</p> <p>18.3.1 Infrared or IR Gun 221</p> <p>18.4 IR Camera 222</p> <p>18.4.1 Strobe Light 223</p> <p>18.5 Inspection Methods Using Vibration and Temperature Measurement Equipment 224</p> <p>18.5.1 Vibration Meter with Accelerometer 224</p> <p>18.5.2 Temperature Measurement Equipment 226</p> <p>18.6 Generic Monitoring Guidelines 227</p> <p><b>19 Addressing Reciprocating Compressor Piping Vibration Problems: Design Ideas, Field Audit Tips, and Proven Solutions 229</b></p> <p>19.1 Piping Restraints 232</p> <p>19.2 Pipe Clamping Systems 233</p> <p>19.3 Guidelines 233</p> <p>19.4 Piping Assessment Steps 235</p> <p>19.4.1 First, Perform the Following Pre-Field Analysis Steps 235</p> <p>19.4.2 Next 235</p> <p>19.4.3 Problem Locations 236</p> <p>19.5 Attaching Pipe Clamps to Structural Members 237</p> <p>19.5.1 Installation Examples 240</p> <p>19.5.2 Here Are a Few More Pipe Clamp Tips 240</p> <p><b>20 Collecting and Assessing Piping Vibration 243</b></p> <p>20.1 Piping Analysis Steps 245</p> <p>20.2 Piping Vibration Examples 246</p> <p>Appendix A: Practice Problems Related to Chapters 1 Through 4 Topics 249</p> <p>Appendix B: Glossary of Compressor Technology Terms 261</p> <p>Index 273</p>
<p><b>Robert X. Perez</b> 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.
<p><b>The perfect primer for anyone responsible for operating or maintaining process gas compressors.</b> <p>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. <p>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. <p>This groundbreaking new work is a must-have for any engineer, operator, or manager working with process compressors. <p><b>The main goals of this book are to:</b> <ul> <li>Explain important theories and concepts about gases and compression processes with a minimum of mathematics</li> <li>Identify key compressor components and explain how they affect reliability</li> <li>Explain how centrifugal compressors, reciprocating compressors, and screw compressors function.</li> <li>Explain key operating factors that affect reliabilityIntroduce the reader to basic troubleshooting methodologies</li> <li>Introduce operators to proven field inspection techniques</li> <li>Improve the confidence of personnel operating compressors by teaching them the basics of compressor theory</li> <li>Improve compressor reliability plantwide by teaching operating and inspection best practices</li> <li>Improve communication between operating and supporting plant personnel by providing a common vocabulary of compressor terms</li> <li>Help processing plants avoid costly failures by teaching operators how to identify early compressor issues during field inspections</li> </ul>

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