O&M Gas Turbine Course Phpc , Ha’py Gas Plant Solar Mars100 Man Turbo Gas compressor Turbine Department [email protected] 1 Instructor: Eng. Mohamed Elbarougy Phpc: Turbomachinery Team Leader Mobile : 0100214245 Work : 7638
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O&M Gas Turbine
Course Phpc , Ha’py Gas Plant
Solar Mars100 Man Turbo Gas compressor
Turbine Department [email protected]
1
Instructor: Eng. Mohamed Elbarougy Phpc: Turbomachinery Team Leader
Mobile : 0100214245
Work : 7638
O&M Gas Turbine Course
Turbine Department [email protected]
2
Basic Gas Turbine Knowledge
Basic mechanical Classification
Basic Ex
Basic of Electric and Instrument
Gas Turbine Main components
Ha’py Gas Turbine Systems
Enclosure and ancillary
Gas Compressor and yard valve
Dry Gas Seal
Operation
Solar turbine Manual
Books
شرح مبسط باللغه العربيه
Bearing types 7
Turbine Department [email protected]
BEARINGS CLASSIFICATION
ROLLING CONTACT ( ANTIFRICTION) BEARINGS SLIDING SURFACE ( FRICTION )BEARINGS
JOURNAL BEARINGS
Commonly Known As Roller Bearings Or Ball Bearings, Are Defined As Bearings Which Have Rolling Contact Between Their Surfaces.
THRUST BEARINGS
BALL CYLINDRICAL TAPER SPHERICAL
Deep Groove Cylindrical Spherical Roller Bearing
Tapered Roller Bearing
Angular Contact Thrust Taper Roller Bearing
Split Spherical Bearing
Self-aligning
WHAT IS THE BEARING FUNCTION?
Bearing Arrangement
-BEARINGS MOUNTING
a- Oil Bath
b- Electric Plates c- Induction Heaters
HOT MOUNTING
There Are Several Basic Rules For Mounting
1- Never Directly Strike The Rings ,Cage Or Rolling Elements Of A Bearing
While Mounting, A Ring May Crack Or Metal Fragments May Break Off.
2- Never Apply Pressure To One Ring In Order To Mount The Other.
3- Use An Ordinary Hammer , Since Soft Headed Hammers Leave Fragments.
Heating Tools
a- Oil Bath b- Electric Plates
c- Induction Heaters d- Heating Cabinets
Never Heat The Bearing To A Temperature Greater Than
125˚C,However,Because The Material May Change Metallurgical And
Produce Alterations In Diameter Or Hardness.
Never Heat A Bearing Using An Open Flame ,Local Overheating Must
Be Avoided, Use A Thermometer To Check The Bearing Temperature.
Push The Bearing Along The Shaft And Hold The Bearing In Position,
Pressing Until A Tight Fit Is Obtained.
Seal types Turbine Department [email protected]
B-OPPOSED ARRANGEMENT
SEALING DEVICES
GASKETS
1- Used To Seal Non-moving Connecting Surfaces .
2- Made From Compressible Materials That Can Be
Squeezed. ( Metal , Teflon, Cork, Paper, And Rubber)
Types Of Gaskets
1- Ring Gasket
2- Full-face Gaskets
3- Spiral Wound Gaskets
MEASURING THE CROSS SECTION AND INSIDE DIAMETER
SEAL FEATURE
DIR
EC
TIO
N
OF
R
OT
AT
ION
ROTATING FACE
SPIRAL RIDGE
O-RINGS
PACKING
DRY GAS SEAL
MECHANICAL SEAL
inner and outer diameters are
reinforced with several piles of metal
without filler to give greater stability and
better compression characteristics.
This type of gasket is able to accommodate pressures
from high vacuum to over 700 bar and seal at
temperatures from cryogenic to 1650°C
HOLLOW PUNCH TOOLS
O-RING SEALING APPLICATIONS
1- O-ring seal is a means of closing off
a passageway and preventing an
unwanted loss or transfer of fluid.
2-The classic O-ring seal consists of
two elements, the O-ring itself, and a
STATIC SEALS
LABYRINTH SEAL
TANDEM SEALS
DOUBLE SEALS
OUTSIDE-MOUNTED SEALS
1- used for low-pressure
applications since both seal faces,
the primary ring and mating ring,
are put in tension. This limits the
pressure capability of the seal. HEAVY DUTY MACHINE
EXTENSION GASKET CUTTER
DYNAMIC SEALS
GASKET CUTTING TOOLS
Atmos
Seal Head
2- used to minimize corrosion that might occur if
the metal parts of the seal were directly exposed
to the liquid being sealed.
Circulation Liquid in
and out to cool and
lubricate
Gland
Plate
Mating Rings
Liquid
Housing
Seal Head Seal Head
Neutral
Circulation
Liquid
Gland
Plate Atmos
Mating Rings
Bypass
Liquid
Inlet Housing
Liquid
Gland
Seal Head Seal Head
INSIDE-MOUNTED SEAL.
1- The most common installation
is an inside-mounted seal.
2- the liquid under pressure acts
with the spring load to keep the
seal faces in contact.
Gland
Plate Atmos
Seal Head liquid
1- Packing is used in the stuffing box
to control the leakage of the liquid
out, or the leakage of air in, where
the shaft passes through the casing.
PACKING TYPES
1- Metallic( lead, babbit,
aluminum and
copper)
2- Flexible graphite
3- Non-asbestos
liquid
1- Single seal
a. Internally mounted
b. Externally mounted
1- Dry gas seals are in the positive seal class and have the same basic design features as mechanical face seals with one significant difference. The dry gas seal has shallow grooves cut in the rotating seal face located part way across the face.
2- The grooves may be in a spiral pattern; the exact location and pattern vary from one manufacturer to another. Lubrication and separation is effected by a microscopically thin film of gas.
3- This implies some finite amount of leakage, which is quite small but must be accounted for in the design.
4- The stationery mounted seal unit comprises a spring loaded, ’O’ ring sealed carbon face, held as an integral unit in stainless steel retainer.
5- An 'O' ring sealed rotating seat, normally manufactured from tungsten carbide, is profiled with a series of spiral grooves having a depth of between 0.0025 to 0.010mm as illustrated.
BENEFITS
1- No Wear
2- No Seal Oil System
3- No Process Contaminations
4- Lower Power Consumption
5- Improved Rotor System Stability
6- Improved Operational Safety
Dry gas seal cartridge
Inner ring
hoop Star foil (filler)
outer ring
FLEXSEAL
Spiral
Winding
Manufactured To
ASME B16.20
Nominal Pipe Size
And Pressure Class
( Standard Gasket Only
Inner Ring
Winding Metal
And Filler Material
Manufactures Name
Or Trademark Outer
(Centering)
Ring
Outer Ring Material
( When Other Than
Carbon Steel )
Inner Ring Material
Stamped On Inner Ring
( When Other Than
Carbon Steel Or PTFE)
Advantages:
in which there is
little or no relative
motion between the
mating surfaces;
which must function between
surfaces with definite relative
motion, such as the seal on the
piston of a hydraulic cylinder.
‘ X-Tree’
‘Microdam’
‘ Biro’
‘Phoenix’
‘T’ Slot
Bi-Directional Groove Profiles
Neutral
Circulation
Liquid Gland
Plate
Mating Rings
Housing
Liquid Seal Head
A- BACK TO BACK
2- Multiple seal
a. Double seals
b. Tandem seals
Type 28AT
THE FUNCTION OF THE O-RING
1- The elastomer is contained in the gland and forced
into the surface imperfections of the glands and any
clearance available to it, creating a condition of “zero”
clearance and thus effecting a positive block
to the fluid being sealed.
2- The pressure which forces the O-ring to flow is
supplied by mechanical pressure or “squeeze,”
generated by proper gland design and material
selection and by system pressure transmitted by the
fluid itself to the seal element.
properly designed gland or cavity to contain the
elastomeric material.
Simplest and least expensive
of non-contacting types. Disadvantage :
Highest leakage rate among
non-contacting seals.
ROTAATING FACE
TUGETEN CARBIDE OR
SILICON CARBIDE
STATIONARY FACE
CARBON
GAP
SEAL GAS IN
GAS LEAKAGE
Compressor Type -1
Turbine Department [email protected]
10
DISPLACEMENT COMPRESSORS
ROTARY RECIPROCATING
SLIDING VANE SCREW
DYNAMIC
COMPRESSORS CLASSIFICATION
In Which Compression And Displacement Is Effected By The Positive
Action Of Rotating Elements; Gas Trapped Between Elements Is
Compressed And Displaced
1- Consists Of A Cylindrical Rotor In Which Flat, Sliding
Vanes Fit Into Radial Slots.
2-As The Rotor Turns, The Sliding Vanes Move Out Against
The Casing Wall Due To Centrifugal Force. Pockets Of Gas
Are Trapped Between The Vanes And The Wall. Due To The
Eccentricity, These Pockets Decrease In Volume, Thus
Compressing The Gas.
1-Consists Of Two Intermeshing Rotors, Machined In The Form Of
An Axial Screw And Enclosed In A Close-fitting Casing.
2-The Male Rotor Has Four Convex Lobes And The Female Rotor
Has Six Concave Flutes. The Rotors Do Not Come In Contact With
Each Other Or With The Casing, Thus Internal Lubrication Is Not
Required.
3-The Male Rotor Is Usually The Driven One And, In Turn, Drives
The Female Rotor By Means Of Timing Gears.
TIMING
GEARS
OIL
SEALS
AIR SEALS
DRIVEN GEAR
BALANCE
PISTON
MALE
ROTOR
FEMALE
ROTOR
BEARING
S
BEARING
S
WATER
JACKET
LOBE 1- Has Two Rotors, Revolving In Opposite Directions
Within A Casing.
2-one Rotor Is Driven Directly By The Driver And The
Other Is Driven Through The Timing Gears.
3- A Pocket Of Air Is Trapped Between The Lobe And
The Casing Wall. It Is Then Carried Around To The
Discharge On The Opposite Side Of The Casing.
ADVANTAGES
1-Compact.
2-Require No Inlet Or Discharge Valves
3-And Produce An Even Flow Of Oil Free Air.
Cylinder barrel, head and air passages
Are thoroughly water jacketed for cooling
Easily removable
cylinder head has
simple gasket
seal
Connectin
g
Rod
Crank Pin
Main
Bearing
crosshead
Piston
Air Packing Valve
Distance Piece
1- In Which The Air Is Compressed By A Piston Moving In A Reciprocating Manner Within A Cylinder.
2- The Cylinder Is Equipped With Intake And Discharge Valves To Control The Flow Of Air Entering And
Leaving. This Type Of Compressor Is Used In A Wide Variety Of Applications ,It Is Suitable For All
Ranges Of Pressure.
3- High Speed Units (800 - 1800 Rpm) -Low Speed Units (300 - 600 Rpm)
Compressor Type -2
Turbine Department [email protected]
11
DYNAMIC COMPRESSORS
AXIAL CENTRIFUGAL
COMPRESSORS CLASSIFICATION
DISPLACEMENT
OPERATION
1- Gas Is Drawn Into The Eye Of The Impeller Where It Is Accelerated
Through Centrifugal Force And Velocity Energy Is Imparted To The
Gas. As The Gas Is Discharged From The Impeller It Flows Into The
Diffuser Or Volute Where It Decelerates. This Velocity Is Transformed
Into Pressure Energy. The Process Is Repeated Through Every Stage
Of The Compressor, Resulting In A Higher Pressure Ratio For Multi-
stage Compressors.
COMPRESSOR CASINGS
HORIZONTALLY SPLIT
IMPELLERS
1- Consist Of Several Stages And Are Generally Used To
Move Large Volumes Of Gas
2- The Gas In An Axial Flow Compressor Flows In An
Axial Direction Through A Series Of Rotating Blades
(Rotor Disc) And Stationary Vanes (Stator) That Me
Attached To The Casing.
3- The Rotor Blades Increase The Gas Velocity. The
Velocity Is Then Converted Into Pressure As The Gas
Enters The Stator Section And Is Slowed Down.
SECTIONAL VERTICALLY SPLIT OPEN SEMI-CLOSED CLOSED
1- Simplest Design,
Usually Single Stage,
2-Consist Of A Series Of
Vanes Radiating Out From
A Central Hub.
3-Can Be Found In Rough
Service Environments And
Where Dirty Gases Need
To Be Moved.
1-Used In A Many Compressors,
And May Be Used In A Single
Stage Or Multi-stage Or Even As
The Final Stage In An Axial
Compressor.
2-The Blades Can Be Straight
Radial , Backward Leaning ,
Forward Leaning, Or A
Combination Of The Blades
1-Used Extensively In Single
And Multi-stage Units.
2-The Enclosure Of The
Vane Permits Higher
Pressure Ratios To Be
Achieved And The Close
Tolerances Between Impeller
And Diffusers Minimizes
Leakage, Resulting In Higher
Efficiencies.
1- Found On Small Units With Low-
pressure Ratios And Small Volumes.
2- Consist Of A Number Of
Sections, Each Bolting To Another
By Means Of Tie Rods.
1-Vertically Split Or Barrel Casings Are
Used In High-pressure Applications (Up To
10 000 Psig)
2- The Compressor Rotor And Impellers Are
Housed Inside A Horizontally Split Casing
Which Is Then Contained Within The Barrel.
3-The Barrel Casing Is Sealed By The Front
Cover, Which Is Bolted And Sealed With An
O-ring. Some Designs Incorporate A Single
End Cover Whereas Others Allow The
Removal Of Both Ends.
1-Enable Easy Removal Of The Upper
Section, Allowing Inspection Of The Rotor,
Impellers, Bearings And Seals.
2-The Casing Is Split Along The Centre Line
Of The Housing And Bolted Together By
Means Of A Large Flanged Area.
3-Sealing Is Metal To Metal, Which Presents
A Problem When Higher Pressures Are
Required. For This Reason, Horizontally
Split Casings Are Usually Limited To Less
Than 1000 Psig.
Advantages
1- High Horsepower Per Unit Of Space And
Weight
3- Easily Automated For Remote Operations
4- Skid Mounted Self-contained
5- Low Initial Costs Per Horsepower
6- Lower Maintenance Cost Than
Reciprocating
7- High Availability Factor
8- Larger Capacity Available Per Unit
Disadvantages
1- Lower Compressor Efficiency
2- Limited Flexibility For Capacity
3- Higher Fuel Rate Than Reciprocating
Units
4- Larger Horsepower Outage Disrupts
Process Or Pipeline Capabilities
NOTE
Thrust Bearing Failure Is One Of The Worst Types Of Failure That Can
Occur In A Dynamic Compressor. Due To The High Rotational Speeds
And The Close Clearances Between The Stationary And Rotating
Elements, Any Contact Due To Shaft Movement Results In Instant
Compressor Failure.
Blades fixation methods
Explosion proof Turbine Department [email protected]
12
• Zone Vs Div
• Ex protection and symbol
• photo
Combustor types
Turbine Department [email protected]
30
• Can-Annular combustor
• Annular-combustor
• Can combustor
Turbine Nozzle and Rotor Reaction
Turbine Department [email protected]
34
Gas turbines are in general or experimental use in
the following applications:
• Aircraft
• Power plants
• Standby equipment
• Boat and ship propulsion
• Gas pipeline compressor drives
• Railroad (have been used but are not common)
• Automotive (extensive experimentation in the past)
• Heavy mobile equipment (experimentation)
Turbine Systems
Turbine Department [email protected]
36
Lube Oil System
Start System
Air Intake and air utility
Fuel System
Enclosure
Fire and Gas
Gas Compressor and Yard Valve
Turbine Department [email protected]
72
Onshore Compression P&ID
Gas Compressor
Dry Gas Seal
Nitrogen Package
Yard Valve Components
Yard valve sequence
Turbine Operation
Turbine Department [email protected]
81
HMI Screens D2D
HMI screen turbine
Normal , Alarm & Shutdown Reading
Start up program
Turbine Flow Diagram
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