DESIGN DATA

J. Powell

API 617- CENTRIFUGAL COMPRESSORS FOR PETROLEUM, CHEMICAL, AND GAS SERVICE INDUSTRIES Terminology (Table 1)

Stability is the difference in capacity (in percent of rated capacity) between the rated capacity and Turndown is the percentage of change in capacity (referred to rated capacity) between the rated
the surge point at the rated speed (and rated gas properties). capacity and the surge point capacity at the rated head when the unit is operating at rated inlet temperature and gas composition. Rise to Surge is the percentage change in head (referred to rated head) between rated head and the surge point head when the unit is operating at rated speed (and rated gas properties). Trip Speed is the speed at which the independent emergency overspeed device operates to shut down a prime mover. For a gas turbine this is 110.3% of rated speed. For a stem turbine driver this is 115.5% of rated speed.

Head Capacity Characteristic (2.1.4) The head capacity characteristic curve shall rise continuously from the rated point to predicted surge. The compressor, without the use of a bypass, shall be suitable for continuous operation at any capacity at least 10% greater than the predicted approximate surge capacity shown in the proposal. Casings (2.2) Thickness of the casing shall be suitable for the maximum allowable working and test pressures and shall include at least a 3.175 mm corrosion allowance. Maximum allowable working pressure of the casing shall be at least equal to the specified relief valve setting. If relief valve setting is not specified, the maximum allowable working pressure shall be at least 1.25 times the maximum specified discharge pressure (gauge). System protection will be furnished by purchaser. Casings shall be made of steel for the following: a) Air or nonflammable gas at maximum allowable working pressure over 2760 kPa g (400 psig). b) air or nonflammable gas at a calculated discharge temperature over 260 oC at maximum continuous speed at any point within the operating range. c) Flammable or toxic gas. Cast iron or other materials of construction may be offered for operating conditions other than those specified for steel casing. Unless otherwise specified, casings shall be radially split when the partial pressure of hydrogen (at maximum allowable working pressure) exceeds 1380 kPa g (200 psig). Partial pressure of hydrogen is calculated by multiplying the highest specified mole (volume) of hydrogen by the maximum allowable working pressure.

Casing Connections (2.4) All process connections to the casing shall be suitable for the maximum allowable working pressure of the casing. Inlet and outlet connections shall be flanged or machined and studded, and oriented as specified. Inlet and outlet connections for barrel compressors shall be located in the outer casing, not in the end covers. On radially split overhung design compressors, the process inlet connection may be in the end cover. Flanges shall conform to ANSI B16.1 (cast iron), B16.5 (steel & alloy) or B16.42 (ductile iron). Steel flanges larger than 24 inch shall conform to API 605 or MSS SP-44.

Impeller Construction (2.6.7/8) Impellers may be closed consisting of a disk, vanes, and a cover; or semi-open consisting of disk and vanes. Impellers shall be of welded, riveted, milled or cast construction. Other manufacturing methods, such as electro erosion and brazing , may be permitted if approved by purchaser. Welded and riveted impellers may consist of forged and cast components. Impellers shall be heat treated and stress relieved after welding. Upgrade or weld repair of cast impellers may be permitted only with purchasers approval.

Bearings (2.7)
API 617 6th Ed.

DESIGN DATA

J. Powell

Hydrodynamic radial and thrust bearings shall be used unless specific approval to the contrary is obtained from purchaser. Guidelines for consideration of active magnetic bearings are given in Appendix J of API 617. However, the standard does not specifically recommend use of magnetic bearings. Sleeve or pad radial bearings shall be used and shall be split for ease of assembly.. Use of non split bearings requires purchaser approval. Bearings shall be precision bored with steel backed babbited replaceable pads or shells. Hydrodynamic thrust bearings shall be steel backed, babbited multiple segments designed for equal thrust capacity in both directions and arranged for continuous pressurised lubrication to each side. Both sides shall be tilting pads, incorporating a self leveling feature. Thrust bearings shall be sized for continuous operation under the most adverse specified operating conditions. Calculations of the thrust forces shall include but shall not be limited to the following factors: a) Seal maximum design internal clearances and twice the maximum design internal clearances. b) Pressurised rotor diameter step changes. c) Stage maximum differential pressures d) Specified extreme variations in inlet, interstage and discharge pressures. e) External thrust forces transmitted through the couplings. f) The maximum thrust force from the sleeve bearing type drive if the motor is directly connected. Hydrodynamic thrust bearings shall be selected at no more than 50% of the bearing manufacturers ultimate load rating. The basis for the sizing of thrust bearings shall be reviewed and approved by purchaser.

Critical Speeds (2.9.1)

A rotor-bearing system in resonance will have its normal vibration displacement amplified. The
commonly referred to as the first rigid (translatory or bouncing) mode, the second rigid(conical or rocking) mode, and the first, second, third nth bending modes.

magnitude of the amplification and the rate of phase angle change are related to the amount of damping in the system and the mode shape taken by the rotor. Note- The mode shapes are

When the rotor amplification factor (see Figure 8), as measured at the shaft radial vibration

probes, is greater than or equal to 2.5 the corresponding frequency is called a critical speed, and the corresponding shaft rotational frequency is also called a critical speed. A critically damped system is one in which the amplification factor is less than 2.5. Critical speeds and their associated amplification factors shall be determined analytically by means of a damped unbalanced response analysis, and shall be confirmed during the running test and any specified optional tests. The vendor who is specified to have unit responsibility shall determine that the drive train critical speeds (rotor lateral, system torsional, and blading modes) will not excite any critical speed of the machinery supplied. The vendor shall also determine that the entire drive train is suitable for the specified operating speed range, including any starting-speed detent requirements. A list of all undesirable speeds from zero to trip shall be submitted to the purchaser for review and included in the instruction manual.

Lateral Analysis (2.9.2) The vendor shall provide a damped unbalanced response analysis for each machine to ensure acceptable amplitudes of vibration at any speed from zero to trip. The damped unbalanced response analysis shall include, but not be limited to, the following considerations: a) Support stiffness, mass and damping characteristics. b) Bearing lubricant film stiffness c) Rotational speed including testing and start/stop sequences. d) Rotor masses e) Asymmetrical loading f) Influence of calculated values for hydrodynamic stiffness and damping generated by casing end seals.

API 617 6th Ed.

DESIGN DATA
Lateral Analysis contd

J. Powell

When specified, the effects of other equipment in the train shall be included in the damped

unbalanced response analysis (that is a train lateral analysis shall be performed). Note This
analysis should be considered for machinery trains with coupling spacers greater than 1 metre, rigid couplings, or both.

As a minimum the damped unbalanced response analysis shall include the following: a) A plot and identification of the mode shape at each resonant speed (critically damped or not) from zero to trip, as well as the next mode occurring above the trip speed. b) Frequency, phase and response amplitude data (Bode plots) at the vibration probe locations through the range of each critical speed, using the arrangement of unbalance in equation 2 for the particular mode. This unbalance shall be sufficient to raise the displacement of the rotor at probe locations to the vibration limit defined by equation 2.

Lv = 25.4 *
Where

12 ,000 N

(2)

Lv = Vibration limit (amplitude of unfiltered vibration) in micrometres p-p N = Operating speed nearest the critical of concern in rpm

This shall be no less than two times the unbalance defined by equation 3.

U max = 6350 * W / N
Where

(3)

Umax = input unbalance from the rotor dynamic response analysis in gram-millimetres W = Journal static weight load in kg, or for bending modes where the maximum deflection occurs at the shaft ends, the overhung weight load in kilograms

c) Modal diagrams for each response shall indicate the phase and major axis amplitude at each coupling engagement plane, centrelines of bearings, locations of vibration probes, and each seal area. Minimum design diametrical running clearance of seals shall also be indicated. d) To establish the validity of the analytical model, a verification test of the rotor unbalance is required at the completion of the mechanical running test. e) Unless otherwise specified, a stiffness map shall be provided of the undamped rotor response from which the damped unbalanced response analysis was derived. This plot shall show frequency versus support system stiffness f) For machines where bearing support system stiffness values are less than or equal to 3.5 times the bearing stiffness, use either the calculated frequency dependent support stiffness and damping values or the values derived from modal testing. The results of the damped unbalanced response analysis shall include Bode plots that compare absolute shaft motion with shaft motion relative to the bearing housing. The damped unbalance response analysis shall indicate that the machine in the unbalanced condition will meet the following acceptance criteria: a) If the amplification factor is less than 2.5, the response is considered critically damped and no separation margin is required. b) If the amplification factor is 2.5 to 3.55, a separation margin of 15 % above the maximum continuous speed and 5 % below minimum operating speed is required. c) If the amplification factor is greater than 3.55 and the critical response peak is above the trip speed, the required separation margin (a percentage of maximum continuous speed) is equal to the following:

6 SM = 126 100 AF 3
Where SM = Separation margin AF = Amplification factor

API 617 6th Ed.

DESIGN DATA
Torsional Analysis (2.9.4)

J. Powell

Excitations of undamped Torsional natural frequencies may come from many sources, which should be considered in the analysis e.g. a) Gear problems such as unbalance, and pitch line run-out. b) Start up conditions such as speed detents and other torsional oscillations. c) Torsional transients such as start up of synchronous electric motors and transients due to generator phase to phase ground fault. d) Torsional excitation resulting from drivers such as electric motors and reciprocating engines. e) Hydraulic governors and electronic feedback and control loop resonances from variable frequency motors. f) One and two times line frequency. g) Running speed or speeds. The undamped torsional natural frequencies of the complete train shall be at least 10 % above or 10 % below any possible excitation frequency within the specified operating speed range. Torsional criticals at two or more times running speeds shall preferably be avoided, or in systems in which corresponding excitation frequencies occur, shall be shown to have no adverse effect. In addition to multiples of running speed, torsional excitations that are not a function of operating speeds or that are non synchronous in nature shall be considered in the torsional analysis when applicable and shall be shown to have no adverse effect. Identification of these frequencies shall be the joint responsibility of the purchaser and vendor. When torsional resonances are calculated to fall within the margin specified and the vendor and purchaser have agreed that all efforts to remove the critical from within the limiting frequency range have been exhausted, a stress analysis shall be performed to demonstrate that the resonances have no adverse effect on the complete train. The acceptance criteria for this stress analysis shall be mutually agreed by purchaser and vendor. For motor driven units and units including gears, or when specified for turbine driven units, the vendor shall perform a torsional vibration analysis of the complete coupled train and shall be responsible for directing the modifications necessary to meet above specified requirements. In addition to the torsional analysis specified, the vendor shall perform a transient torsional vibration analysis for synchronous motor driven units or variable speed motors. The acceptance criteria for this analysis shall be mutually agreed upon by the purchaser and vendor.

Balance (2.9.5.2) Major parts of the rotating element e.g. shaft, balancing drum, impellers shall be dynamically balanced. The rotating element shall be multi plane dynamically balanced during assembly. This shall be accomplished after the addition of no more than two major components.

Vibration On Test (2.9.5.5) During the shop test of the machine, assembled with the balanced rotor, operating at its maximum continuous speed or any other speed within the specified operating range, the peak to peak amplitude of unfiltered vibration in any plane, measured on the shaft adjacent and relative to each radial bearing, shall not exceed the value in equation 5 or 25 micrometres (1.0 mils), whichever is less:

A = 25.4 *
Where

12 ,000 N

A = Amplitude of unfiltered vibration in micrometres p-p N = Maximum continuous speed in rpm

At any speed greater than the maximum continuous speed, up to and including the trip speed of the driver, the vibration shall not exceed 150 % of the maximum value recorded at the maximum continuous speed.

API 617 6th Ed.

DESIGN DATA

J. Powell

Materials (2.11) Materials of construction shall be the manufacturers standard for the specified operating conditions, except as required or prohibited by the data sheets or API 617. Appendix B lists materials that, when used with appropriate heat treatment and/or impact testing requirements, are generally considered acceptable. Metallurgy of all major components shall be clearly stated in the vendors proposal. Materials shall be identified with the applicable ASTM, AISI, ASME or SAE numbers. Materials exposed to a sour environment (wet H2S) as defined in NACE MR0175-93 shall be limited to a yield strength not exceeding 620 MPa (90,000 psi) and a hardness not exceeding Rockwell C22. Components that are fabricated by welding shall be stress relieved, if required, so that both welds and heat affected zones meet the yield strength and hardness requirements. The purchaser shall specify on the data sheets the presence and concentration of H 2S and water in the process gas. Note- Shafts in compressors of between bearings design may exceed the specified limits of
yield strength and hardness because of requirements for higher strength at reduced shaft sections near couplings and because of the levels of working stress in the portion of the shaft between bearings.

The purchaser shall specify the presence of any corrosive agents in the process gas, the process stream and the environment, including constituents that may cause stress corrosion cracking. Austenitic steels shall not be used in services where stress corrosion cracking is a possibility. If parts made from austenitic stainless steels are exposed to a process gas or environmental condition that promotes intergranular corrosion, and they could be fabricated, hard surfaced, repaired or overlayed by welding, then stabilised or low carbon grades are required. Note-

Overlays or hard surfaces that contain more than 0.10 percent carbon can sensitise both low carbon and stabilised grades of austenitic stainless steel unless a buffer layer that is not sensitive to intergranular corrosion is applied.

In hydrogen gas service at partial pressures greater than 689 kPa (100 psig) or at concentrations greater than 90 molal percent at any pressure, impeller materials that have a yield strength in excess of 827 MPa (120,000 psi) or hardness in excess of Rockwell C34 are prohibited. External components that are subject to rotary or sliding motion shall be of corrosion resistant materials suitable for the site environment. Minor parts that are not identified e.g. nuts, springs, washers, gaskets and keys shall have corrosion resistance at least equal to or superior to that of specified parts in the same environment. O-rings shall be compatible with all specified services, for high pressure services, special consideration shall be given to the selection of O-rings to ensure that they will not be damaged upon rapid depressurising of the compressors. For operating temperatures below -29 oC (-20 oF) or when specified for other low ambient temperatures, steels shall, have, at the lowest specified temperature, an impact strength sufficient to qualify under the minimum Charpy V-notch impact energy requirements of ASME VIII, Division 1, UG-84. For materials and thicknesses not covered by the code, the purchaser shall specify the requirements on the data sheets.

Drivers (3.1) The type of driver will be specified by the purchaser. The driver shall be sized to meet the maximum specified operating conditions, including external gear or coupling losses, and shall be in accordance with the applicable specifications. Anticipated process variations that may affect the sizing of the driver, such as changes in pressure, temperature, gas properties and plant start up conditions, shall be specified by the purchaser. The starting conditions for the driven equipment shall be specified by the purchaser and the starting method shall be mutually agreed. The drivers starting torque capabilities shall exceed the speed-torque requirements of the driven equipment. Steam turbine drivers shall be sized to deliver continuously 110% of the maximum power required for the purchasers specified conditions while operating at a corresponding speed with the specified steam conditions. Electric motor nameplate rating (excluding service factor) shall be at least 110% of the maximum power required (including gear and coupling losses) for any of the specified operating conditions. Motor starting torque requirements shall be met at a reduced voltage specified by purchaser (typically 80%) and the motor shall accelerate to full speed within a period of time agreed between purchaser and vendor (typically 30 s). Gas turbine drivers shall be sized as mutually agreed between purchaser and vendor.

API 617 6th Ed.

DESIGN DATA
Controls (3.4.2)

J. Powell

The compressor may be controlled on the basis of inlet pressure, discharge pressure, flow or some combination of these parameters. This may be accomplished by suction throttling, variable inlet guide vanes, speed variation, discharge blow-off, or a cooled bypass from discharge from discharge to inlet. The control system may be mechanical, pneumatic, hydraulic, electric , or any combination of these. The system may be manual or automatic with a manual over ride. The purchaser shall specify the source of the control signal, its sensitivity, and the equipment to be supplied by vendor. When specified, an anti-surge system shall be provided. The scope of supply for the anti-surge system is process dependent and should be mutually determined. For constant speed drive, the control signal shall actuate either a purchaser supplied control valve in the compressor inlet piping or adjustable inlet guide vanes provide by vendor as an integral part of the compressor. For a variable speed drive, the control signal shall act to adjust the set point of the drivers speed control system. Unless otherwise specified, the control range limits shall be from maximum continuous speed to 95% of the minimum speed required for any specified operating case or 70% of the maximum continuous speed, whichever is lower.

Testing (4.3) Normal tests Hydrostatic test of pressure containing parts at a minimum of 1.5 times the maximum allowable working pressure, but not less than 140 kPa g (20 psig). Impeller overspeed test of each impeller at not less than 115% of maximum continuous speed for 1 minute minimum. Critical dimensions shall be measured before and after each test. Mechanical running test per 4.3.4 including run at maximum continuous speed for 4 hours. Assembled compressor gas leakage test after mechanical running test Optional tests Performance test to ASME PTC 10 with minimum of 5 points at rated speed. For variable speed additional points may be specified. Complete unit test including compressor, gear, driver and auxiliaries, tested together during the mechanical running test. Tandem test during mechanical running test of casings arranged for tandem drive. Gear test with compressor during mechanical running test. Helium test of compressor casing for gas leakage at maximum allowable working pressure. Casing shall be submerged in water. Sound level test in accordance with purchaser requirements. Auxiliary equipment test such as oil system and control system in vendors shop. Post test inspection of compressor internals after satisfactory mechanical running test. Full pressure/full load/full speed test may be substituted for mechanical running test. Details shall be developed jointly by purchaser and vendor. Post test inspection of hydraulic coupling fit. Spare parts test such as rotors, gears, diaphragms, bearings and seals. Performance Curves (5.2.4, 5.3.3) Proposal Curves shall be marked as Predicted. Curves for variable speed compressors shall include the following: Discharge pressure, shaft power, polytropic head and polytropic efficiency versus inlet capacity from predicted surge to 115% rated capacity at minimum operating speed, 80%, 90%, 100%, 105% speed, and indicating the effects of specified inlet pressures, temperatures, and molecular weights. Specified operating points shall be noted. For steam turbine driven units, steam flow under conditions specified above and normal steam conditions, then at maximum power under most adverse steam conditions. For gas turbine driven units, fuel flow under conditions specified above and based on normal fuel and site ambient conditions, and then at maximum power and most adverse fuel and site ambient conditions.

API 617 6th Ed.

DESIGN DATA
Performance Curves contd

J. Powell

Curves for fixed speed compressors shall include the following: Discharge pressure, power, polytropic head and polytropic efficiency versus capacity from predicted surge point to 115% rated capacity at normal speed, indicating effects of specified molecular weights, inlet pressures, and temperatures. Alternate operating conditions requiring throttling shall be shown. Speed versus torque to overcome friction and windage for the compressor and gear unit, for normal starting conditions and also with specified suction conditions for emergency starting conditions. Motor current versus speed at rated voltage and at 80% of rated voltage. WK2 of the compressor, the gear, the motor, and the couplings referred to motor speed. Estimated times for acceleration to rated speed for throttled suction and for open suction at 80% of nameplate motor voltage, unless otherwise specified. Contract Curves Compressor serial number shall be shown on all curves. Curves submitted prior to final performance testing shall be labeled Predicted. Curves resulting from a test shall be labeled Tested. If a performance test is specified, the vendor shall provide test data and curves when the test has been completed. The surge points shall be shown on the performance curves. When specified, the vendor shall supply a nomograph (quadrant type performance curve) for each compressor section. These curves typically show the influence of variation in speed, inlet volume, inlet pressure, inlet temperature and molecular weight r composition of the gas on discharge pressure, discharge temperature, gas power, and efficiency. If a performance test is specified, the quadrant curve shall be based on the test results. The normal or rated point shall be plotted through each curve. For compressors that have a back to back impeller arrangement, the vendor shall furnish a curve showing the expected loading on the active or inactive side of the thrust bearing versus any combination of the differential pressures across the low pressure and high pressure sections of the casing.

API 617 6th Ed.