Process Engineering Equipment Handbook Episode 1 Part 6 pot

C-100 FIG. C-77 Combined booster and primary compressor for an ethylene plant in Spain. Suction pressure 1.7 bar abs, discharge pressure 286 bar abs. Compressor runs at 300 rpm with a power input of 2330 kW. (Source: Sulzer-Burckhardt.) FIG. C-78 Compressor installation in Germany. 2600 m 3 /h of hydrogen at 1 bar abs are compressed to 325 bar abs. The five- stage machine operates at 585 rpm with a power requirement of 700 kW. (Source: Sulzer-Burckhardt.) FIG. C-79 Skid-mounted hydrocarbon gas compressors for offshore duty in Greece. Suction volume 2850 m 3 /h, discharge pressure 19 bar abs, speed 420 rpm, power input 400 kW. (Source: Sulzer-Burckhardt.) FIG. C-80 Chlorine compressor installed in a chlorine production plant in Colombia. 605 m 3 /h of Cl 2 are compressed to 8.5 bar abs. The compressor operates at 480 rpm, the power input is 65 kW. (Source: Sulzer-Burckhardt.) 77 78 79 80 Compressors C-101 FIG. C-81 Hydrogen producing and bottling plant in Great Britain with two natural gas and four hydrogen compressors. The hydrogen compressors operate at 650 rpm, the discharge pressure is 235 bar abs and the power 80 kW. (Source: Sulzer- Burckhardt.) FIG. C-82 Hydrogen sulfide compressor supplied for a chemical plant to compress 1040 m 3 /h H 2 S to 31.4 bar abs. The speed is 495 rpm and the power input 280 kW. (Source: Sulzer-Burckhardt.) FIG. C-83 Nonlubricated high-pressure compressor in Finland, compressing 750 Nm 3 /h dry hydrogen from 17 to 230 bar abs in three stages. Shaft power is 100 kW. (Source: Sulzer-Burckhardt.) FIG. C-84 Two-stage compressor in the natural gas storage facility of Stadtwerke Bremen, Germany. Suction pressure 70 bar, discharge pressure 166 bar, speed 585 rpm, power 420 kW. (Source: Sulzer-Burckhardt.) 81 82 83 84 C-102 Compressors FIG. C-85 Tube trailer filling station; a typical application for hydrogen compressors. (Source: Sulzer-Burckhardt.) FIG. C-86 Compressor in a chemical works for hydrogen bottling in Brazil. (Source: Sulzer- Burckhardt.) The crank pin bearings are forced-feed lubricated, while all other mechanical components as well as pistons and cylinders are amply lubricated by means of splash lubrication. The crankcase is sealed and vented to the compressor suction side. Cylinders. The cylinders are made of treated high-quality cast iron and jacketed for ample cooling. The pistons are manufactured of high-quality cast iron and incorporate specially selected cast-iron piston ring combinations. The combined and concentric suction and discharge plate valves are removable as a unit. See Fig. C-92. Cooling and piping. Water or another liquid coolant provides for all the compressor cooling requirements. From a manifolded inlet, the coolant is distributed to all critical points such as cylinder jackets by means of high-strength flexible hoses. See Fig. C-93. The separators located at the outlet of each stage are regularly drained by means of diaphragm valves actuated by a timer-controlled solenoid. The condensate and escaping gas are led from the separators into a condensate receiving tank from where the gas is recycled into the suction line while the condensate can be manually drained off to atmosphere. Instrumentation. Each compressor stage is equipped with a pressure gauge and safety valve. The gauges are arranged in a compact panel, which also contains the indicating oil-pressure switch. Temperature switches monitor the gas temperature on selected stages. The outlet of the safety valves is piped back to the suction of the compressor. Level gauges for crankcase oil and for condensate receiving tank are also included. See Fig. C-94. Arrangement and drive. The basic gas compression system consists of a packaged unit with a sturdy steel skid (see Fig. C-95) on which the complete compressor, Compressors C-103 FIG. C-87 Mobile high-pressure nitrogen plant with low-pressure air feed module, PSA module, and diesel-driven nitrogen compressor module for oil-well servicing. (Source: Sulzer-Burckhardt.) flywheel, V-belt drive, coolers, separators, condensate receiving tank, and piping (see also Fig. C-94) are installed. An integral universal motor base is also provided. The skid, designed on the basis of field measurement data and of finite element calculations, is supplied with six vibration dampening elements. The air compression system has a similar arrangement as above, but with open relief valves and with an automotive-type suction filter instead of the flexible inlet header. See also Figs. C-96 through C-98. C-104 Compressors FIG. C-88 Compressor selection, dimensions, coding, and materials. (Source: Sulzer-Burckhardt.) Compressors C-105 FIG. C-89 Main compressor operating data (air and similar gases). (Source: Sulzer-Burckhardt.) C-106 Compressors FIG. C-90 Main compressor operating date (gases). (Source: Sulzer-Burckhardt.) Compressors C-107 FIG. C-91 In pressure-tight execution (optional) the crankcase is equipped with oil-cooled double mechanical seals. (Source: Sulzer-Burckhardt.) FIG. C-92 Typical valve (CT compressor type). (Source: Sulzer-Burckhardt.) FIG. C-93 Typical pressure gauge and safety valve on each compressor stage. (Source: Sulzer- Burckhardt.) Standard supply scope. This may differ according to customers’ specifications. Compressor crank mechanism ᭿ Crankcase with crankshaft seal for suction pressures up to 1.1 bar abs and vent line to suction or crankcase with mechanical seals for suction pressures from 1.2 to 16 bar abs (see Figs. C-96 through C-98). ᭿ Two crankcase purging gas valves (gas compression only) ᭿ Oil pump (crankshaft-driven), filter, pressure gauge, and level sight glass Gas stream ᭿ Flexible hose on suction or automatic-type air filter ᭿ Interconnecting gas piping from first stage to outlet separator on last stage ᭿ Shell and tube gas cooler and separator after each stage ᭿ Automatic condensate drain consisting of: ᭿ diaphragm valve on each separator ᭿ condensate receiving tank with level sight glasses ᭿ manual drain valve on the condensate tank ᭿ return line condensate tank-suction line ᭿ Pressure gauge and relief valve after each stage ᭿ Flexible hose on discharge with nonreturn valve and compression fitting C-108 Compressors FIG. C-94 Standard panel, including optional contamination indicator for oil filter and gauge with pressure limit switch for sequential condensate drain system. (Source: Sulzer-Burckhardt.) FIG. C-95 Typical compressor skid. (Source: Sulzer-Burckhardt.) [...]... 430 Thermal shock stress N/mm2 (t = 10 0 °C) 80 10 0 1. 25 0.55 0.89 220 1. 80 : 1. 40 1. 10 0. 51 58 0.32 0 .14 Thermal expansion coefficient 10 -6/ °C 18 0 2 1 GGG NiCr 20 2 Type D2 GGG Ni 35 Type D5 Endurance limit N/mm2 Cast iron GG 18 Austenitic Steel CrNi Youngs modulus N/mm2 3 Tensile strength N/mm2 Combined Properties 85,000 11 .70 204,000 20 410 12 5,000 17 .6 12 7,000 4.50 temperature conditions It allows... replacement whatsoever 1st replacement after 2nd replacement after 3rd replacement after No replacement whatsoever 1st replacement after 2nd replacement after 1st replacement after 2nd replacement after No replacement No replacement No replacement One bearing lost after No further replacement 14 ,350 h 36, 993 h 61 , 790 h 14 ,350 h 36, 993 h 36, 993 h 61 , 790 h 14 ,350 h Compressors C -12 9 FIG C -11 6B The labyrinth-piston... (Source: Sulzer-Burckhardt.) C -12 3 C -12 4 Compressors FIG C -11 1 The crankshaft seal for compressors with gas-tight crankcase (Source: SulzerBurckhardt.) (A) (D) (B) (C) FIG C -11 2 Valve design troubleshooting: stress graphs and computer modeling (Source: Sulzer-Burckhardt.) Compressors FIG C -11 3 Sealing labyrinth R&D rig (Source: Sulzer-Burckhardt.) C -12 5 C -12 6 Compressors FIG C -11 4 Stress map taken during... FIG C -11 8 Cutaway view of a double-acting labyrinth piston (Source: Sulzer-Burckhardt.) Compressors C -13 1 FIG C -11 9 Coefficient of thermal expansion for cast iron and steel in function of % Ni and temperature (Source: SulzerBurckhardt.) TABLE C -12 Candidate Materials for Low Temperature Components—Comparative 2 3 18 5 Ratio 410 2 1 230 : 300 19 0 Ratio 460 : 60 0 430 Thermal shock stress N/mm2 (t = 10 0 °C)... C -11 The process data for the compressor in this application are as follows: Design and material selection of pistons and cylinders (application case study) Compressors FIG C -11 5 C -12 7 Experimental rigs for R&D work (Source: Sulzer-Burckhardt.) Gas Suction Discharge Suction Discharge Suction Discharge 1st 1st 2nd 2nd 3rd 3rd CH4 (98%) + N2 (2%) 1. 0 36 bar -90 5.2 bar +25 5.2 bar +25 13 .6 bar +38 13 .6. .. compressor performance emerges See Figs C -11 1 through C -11 3 Dynamic crank throw behavior This remains a subject of investigation Compressor parts are not entirely rigid, but rather flexible, and may oscillate or vibrate during operation It is important to have fundamental and detailed knowledge of means to eliminate or suppress undesired movements See Figs C -11 4 and C -11 5 Acoustic calculations Nowadays these... ambient to -15 0°C during startup It is for this reason that no slow cooling-down procedure prior to startup is required (Source: Sulzer-Burckhardt.) FIG C -11 7A Four labyrinth-piston compressors, type 3K 14 0-3C, in a storage facility in Sweden handling cold ethylene at -95 °C suction temperature from 1. 01 bar abs to 31. 5 bar abs in three stages (Source: Sulzer-Burckhardt.) C -13 0 Compressors FIG C -11 7B Transitions... manufacturing process after each important step All pressure-stressed parts, such as cylinders, cylinder covers, (A) (B) FIG C -10 3A, B Design features of D- and E-type compressors with open distance piece (Source: Sulzer-Burckhardt.) C -11 7 (C) (D) FIG C -10 3C, D Design features of the totally closed K-type compressor with gas- and pressure- tight crankcase (Source: Sulzer-Burckhardt.) C -11 8 FIG C -10 4 Dimensions... barometric pressure boils off at - 16 0°C This temperature is well below the limit where some of the common engineering Exposure to cryogenic temperatures C -12 2 Compressors FIG C -10 7 The compressor valve (Source: Sulzer-Burckhardt.) Compressors FIG C -10 8 The piston rod gland (Source: Sulzer-Burckhardt.) FIG C -10 9 The piston rod guide bearing (Source: Sulzer-Burckhardt.) FIG C -11 0 The crankshaft seal for open-type... blocks, is available with suction volumes up to 11 , 000 m3/h and discharge pressures exceeding 300 bar See Figs C -10 2 through C -10 4 for various types Design features of the totally closed “K”-type compressor with gas- and pressuretight crankcase are illustrated in Fig C -10 3C and D See these figures and Fig C -10 5 Common features The labyrinth piston (see Fig C -10 6) ᭿ May be double- or single-acting (depending . seal for suction pressures up to 1. 1 bar abs and vent line to suction or crankcase with mechanical seals for suction pressures from 1. 2 to 16 bar abs (see Figs. C- 96 through C-98). ᭿ Two crankcase. on compressor performance emerges. See Figs. C -11 1 through C -11 3. Dynamic crank throw behavior. This remains a subject of investigation. Compressor parts are not entirely rigid, but rather flexible,. See Figs. C -11 4 and C -11 5. Acoustic calculations. Nowadays these are important. With computer technology one can choose between both digital and analog studies according to API 61 8 . New design