Advances In Compressor Surge Detection - Platt And McCaw - ICE 2003 - Feb 2003 - surge control.ppt
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Transcript of Advances In Compressor Surge Detection - Platt And McCaw - ICE 2003 - Feb 2003 - surge control.ppt
BP I,C&E CONFERENCE
ADVANCES IN COMPRESSOR SURGE DETECTION
John Platt & Jim McCraw
E&PTG - Houston
Northstar – HP CompressorStg 3-4 Diaph
“Bulb” “Box”
Northstar Update - Process - CODA
HP-B, 4th Stage - ESD (w/o 1-second delay), Aug 29, 2002
5225 NPT
4950 NPT
1.53
5.335.93
2.07
5.1934.894
1.0
1.2
1.4
1.6
1.8
2.0
2.2
2.4
2.6
2.8
3.0
3.2
3.4
3.6
3.8
4.0
4.2
4.4
0 10 20 30 40 50 60 70 80 90
Flow Function - Sqrt (h/Ps)
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
Pd/Ps CODA Surge Line CODA Overload Line ESD Decel -Seconds ESD Decel -Comp rpm
BackgroundBackground
Goal: To explore the effectiveness of using thrust bearing load changes to measure the onset of surge in centrifugal compressors.
How? By employing static and dynamic thrust load sensing equipment in the thrust bearing and the thrust bearing housing.
Engineered SolutionEngineered Solution
• Dynamic sensors between pads/links in RMT thrust bearings (4 load cells per Bearing- 8 Total)
• Static sensors behind Thrust Bearing - recessed in thrust housing (2 top half - 2 bottom half, 4 load cells per side - 8 total)
• Four Load Cells Per Thrust Bearing
• Wires Exit Bearings radially and come out Housing at Horizontal Split
RMT Thrust Bearings With Dynamic Load Cells
Dynamic Load Cells Wire ExitDynamic Load Cells Wire Exit
Load Cell Wire Bundle
Thrust Bearings
Thrust Housing
Static Load Cell CavitiesStatic Load Cell Cavities
Thrust Housing (Bottom Half)
Static load cells mounted in recessed hole in Thrust Housing
Thrust Housing
(Bottom Half- Rotated)
Static Load Cells Shown in Orange
Static Load Cells In Thrust HousingStatic Load Cells In Thrust Housing
Static Load Cells Wire Exit
Conducted FEA on housing
Results (based on 500 psi thrust load): Maximum stress = 5330 psi Maximum deflection = 0.47 mils
Visual results next 3 slides
Static SensorsStatic Sensors
FEA ResultsFEA Results - StressStress
FEA ResultsFEA Results - StressStress
FEA ResultsFEA Results - DeflectionDeflection
The Next Steps
•Static and Dynamic load cells were installed in the thrust bearing and the thrust bearing housing
•Shop factory testing indicated that load cells functioned properly
•Field testing / Operation will be the next step to determine if the these load cells prove to be beneficial to determine the onset of surge.
Joint GMRC / PRCI Project
• U$ 50,000 from GMRC
• U$ 50,000 from PRCI
• U$ 125,000 from US DoE / NETL
• Contractor: Southwest Research Institute
• In 2nd year of two year effort
• Discussions with potential commercialization partners