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Compressors: How to Achieve High Reliability & Availability
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Compressors: How to Achieve High Reliability & Availability
by Fred K. Geitner, Heinz P. Bloch
Compressors: How to Achieve High Reliability & Availability
Cover
About the Authors
Copyright
Dedication
Contents
Preface
1: Introduction, Compression Principles, and Internal Labyrinths
Density and Compression Ratios
Heat and Mass Concepts Simplified
The Concept of “Head” and Other Parameters
Positive Displacement versus Dynamic Compressors
Internal Labyrinth Seals
Preinvesting with Future Uprating in Mind
What We Have Learned
References
2: Selection Factors for Process Compressors
What We Have Learned
References
3: Operating Characteristics of Turbocompressors
Surge
Compressor Speed
Inlet Pressure and Temperature
Effect of Gas Properties
Effect of Speed Changes
Changing Suction Temperature
What We Have Learned
Reference
4: Wet and Dry Gas Seals for Centrifugal Compressors
The Case against Wet Seals
How Gas Seals Function
Minimizing the Risk of Sealing Problems
Seal Safety and Reliability
Making Good Choices
What We Have Learned
References
5: Bearings, Stability, and Vibration Guidance
Mechanical Design
Destabilizing Forces and Aerodynamic Cross Coupling
Fractional Frequency Activity in Bearings
Examining What Can Be Done about Instability
Thrust and Radial Tilt Pad Bearings
Bearing Clearances
Vibration and Acceptable Limits
What We Have Learned
References
6: Lube and Seal Oil Systems
Layout Guidance
Examine What Often Goes Wrong
Main versus Standby Pump
Slow-Roll Precautions
System Reservoirs
Heating Requirements
Filters and Coolers
Centrifugal Compressor Lube/Seal Reservoir Explosion Hazards
What We Have Learned
References
7: Impellers and Rotors
Construction, Inspection, and Repair of Impellers
Two-Dimensional versus Three-Dimensional Impeller Blading
Careful Design Needed to Avoid Failures
What We Have Learned
Reference
8: Compressor Maintenance and Surveillance Highlights
Preventive and Predictive Maintenance Explained
Compressor Maintenance in Best Practices Plants
Emergency Repairs Should Be Minimized
Effectiveness of Selective Preventive Maintenance
Know Your Existing Program
Maintenance Improvement
What We Have Learned
References
9: Inspection and Repair Guidelines for Rotors
Phase I (Initial Preparation)
Preliminary Work Lists and Tabulations of Deliverables for Work Performed during Planned Shutdowns
Inspection
Cleaning
Deficiency Mapping
Phase II (Repairs)
Phase III (Assembly and Balancing)
Phase IV (Preparation for Storage or Shipment)
What We Have Learned
Reference
10: Machinery Quality Assessment
Detailed Specifications Are Needed
Briefing Project Executives on MQA
Only Competent Manufacturers Are Invited to Submit Bids
Contractor Piping and Instrumentation
What We Have Learned
References
11 Compressor Failure Analysis Overview
Case History Dealing with Impeller Failure
Failure Analysis Step No. 1: The “Seven Root Cause Category” Approach
Failure Analysis Step No. 2: “FRETT”
Step No. 3: Validation, or Relating Analytical Models to Field Experience
What We Have Learned
References
Bibliography
12 Reciprocating Compressors: Background and Overview
Introduction
Basic Operating Principle Explained
Downstream Process Reciprocating Compressors: Major Components
Lubrication
Cylinders
Valves
Pistons
Piston Rod
Packing
What We Have Learned
References
13 Compressor Operation and Capacity Control
Starting Reciprocating Compressors
Performance Control and Throughput Adjustment
Multiple Services
Calculations
Piston Displacement
Compression Ratio
Clearance
Volumetric Efficiency
Basic Equations
What We Have Learned
References
14 Reciprocating Compressor Maintenance
Compressor Cylinder
Rod Load
Piston and Liner Care
Packing Care
Valve Care
Valve Repair Practices
Noise and Vibration
Frame (Crankcase) Repair Practices
Foundations
Crankshaft Deflections
What We Have Learned
References
15 Maintenance and Operations Interfaces
Shutdowns
Monitoring and Record Keeping
Cleanliness and Tools
Major Overhaul Checklist for Reciprocating Compressors
What We Have Learned
Bibliography
16 Surveillance, Monitoring, and Troubleshooting Reciprocating Compressors
Surveillance
General
Valves
Packing Vents
Vibration and Noise
Lubrication
Cylinder Cooling
Monitoring
Temperature Measurement
Efficiency Calculations
Troubleshooting
Quick Troubleshooting Guide
Compressor Will Not Start
Low Oil Pressure
Frame Knocks
Noise in Cylinder
Excessive Packing Leakage
Packing Overheats
High Discharge Temperature
Low Suction Pressure
References
17 Reciprocating Compressor Upgrading, Rebuilding, and Remanufacturing
Inspection, Overhaul, and Repair
Rebuilding
Upgrading, Conversion, Rerate, Revamp, or Reapplication Decisions Resulting in Rebuilding, Refurbishment, and Remanufacturing of Existing Reciprocating Compressors
Contact with Service Shops
OEM versus Non-OEM Compressor Rebuilding, Refurbishment, Upgrading, Conversion, Rerating, Revamping, Reapplication, and Remanufacture
What We Have Learned
Reference
18 Training Competent Compressor Engineers
Role Statement and “Phase One” of In-House Training
The Structure of Training
“Phase Two” Training: Digging Up the Facts
Training Plans Beyond Phases I and II
Putting the Training to Practice
What We Have Learned
References
Index
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