CENTRIFUGAL COMPRESSOR MAINTENANCE AND FAILURE ANALYSIS

CENTRIFUGAL COMPRESSOR MAINTENANCE AND FAILURE ANALYSIS

Training Centrifugal Compressor Maintenance and Failure Analiysis

Description Centrifugal compressors play a very essential role in many petrochemical and industrial plants. Centrifugal compressors runs at very high speeds, exposed to high temperature due to gas (air) compression. Their operation is confined between the Surge and Stonewall limits. The compressor performance also is affected by the variation in operating conditions. These make it very important to learn and understand the centrifugal compressor more deeply for smooth and free trouble operation. Failure analysis to provide basic concepts, principles, and to introduce the techniques and methodology of reliability assessment and evaluation as applied to mechanical components, equipment, and mechanical plant systems and sub-systems. To improve the understanding of failures as related to their nodes, causes and effect. Objective Give general description of air compression theory to optimalize compression process efficiently Give fundamental knowledge of compressor principle and air state of condition in compression process Give fundamental structure of compressor to ensure safe operating installation in all condition can be achieved. Give the knowledge to condition compressor operation and its maintenance to avoid the same failure. Be able to modify operating condition. Give the knowledge to determine disturbance source, be able to think systematically to analyze root cause of compressor failure

Outline

Fundamental of thermodynamic Compression process and work – Isothermal Adiabatic Polytrophic Fundamental theory of compressor Compressor development history Compressor classification Compressor work cycle Theoretic cycle Semi theoretic cycle Actual cycle Centrifugal compressor Head, losses and efficiency Characteristic at each speed Compressor installation Dynamic compressor Performance and condition definition Type of centrifugal compressor High casing Horizontal split casing Vertical split casing Package assembly Multi casing unit Centrifugal compressor application Characteristic of centrifugal compressor General detail of centrifugal compressor Impeller Diaphragm Inter stage packing Rotor assembly Casing Journal and thrust bearing Shaft seals Seal and lubrication system Gas cooling Pressure ratio and centrifugal characteristic curve Control of capacity Load curve Control method Surge control Parallel operation Unloading start Inner gear air centrifugal compressor Modulation pressure control Dual step capacity control Auto dual control Axial flow compressor Gas turbine compressor Centrifugal compressor Axial compressor Compressor performance Pressure loss at gas pipe installation Definition and accuracy Factors to estimate friction loss Pressure gradient in pipe General equation of various gas Natural gas piping equation Vacuum piping equation Fitting pressure loss Flexible pipe pressure loss Fundamentals of piston compressor Gas compression usage Compression method Type of compressor Compressor principles Standard, symbol, and definition Measurement unit Basic thermodynamic theory Compressibility Multi stage compressor Power consumption Positive displacement compressor Isothermal basis X-factor Compressibility correction Discharge temperature Application of theory Reciprocating compressor Clearance control Clearance control and variable compression ratio Effect of heat specific ratio to horse power Peak horse power and break horse power Effect of compressibility Effect of altitude eciprocating compressor Definition Characteristic Classification Cylinder Valve Cylinder cooling Non-cooled cylinder Air cooling cylinder Capacity control Manual control Main automatic control Load depletion to start Types of control Constant speed control Suction side throttling Variable speed control Installation, operation and maintenance Installation Placement Suction condition Foundation Piping Electric cabling Field testing Commissioning Running test Operation Responsibility Recording Cleaning Lubrication Safety Initial start Capacity control Spare parts Trouble shooting Inspection and maintenance Preventive maintenance Predictive maintenance Operation Procedure to run and to stop compressor Capacity control device Hazard prevention Automatic operation Maintenance Preliminary inspection Operating condition inspection Preventive maintenance Predictive maintenance Troubleshooting Introduction Implications of mechanical reliability Definition of mechanical reliability Reliability and rates of failures 11. System Safety Analysis Human Error Routine Operations Emergency Operations 12.Methods of Analysis Failures Modes and Effects Analysis (FMEA) Event Trees Fault trees 13.Fault-Tree Construction Nomenclature Fault classification Example 14.Analysis of in-service experience for repairable systems : A note on “ failure rate “ Reliability analysis under constant failure rate System availability

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