Operator's Guide to Process Compressors


Book Description

The perfect primer for anyone responsible for operating or maintaining process gas compressors. Gas compressors tend to be the largest, most costly, and most critical machines employed in chemical and gas transfer processes. Since they tend to have the greatest effect on the reliability of processes they power, compressors typically receive the most scrutiny of all the machinery among the general population of processing equipment. To prevent unwanted compressor failures from occurring, operators must be taught how their equipment should operate and how each installation is different from one another. The ultimate purpose of this book is to teach those who work in process settings more about gas compressors, so they can start up and operate them correctly and monitor their condition with more confidence. Some may regard compressor technology as too broad and complex a topic for operating personnel to fully understand, but the author has distilled this vast body of knowledge into some key, easy to understand lessons for the reader to study at his or her own pace. This groundbreaking new work is a must-have for any engineer, operator, or manager working with process compressors. The main goals of this book are to: Explain important theories and concepts about gases and compression processes with a minimum of mathematics Identify key compressor components and explain how they affect reliability Explain how centrifugal compressors, reciprocating compressors, and screw compressors function. Explain key operating factors that affect reliabilityIntroduce the reader to basic troubleshooting methodologies Introduce operators to proven field inspection techniques Improve the confidence of personnel operating compressors by teaching them the basics of compressor theory Improve compressor reliability plantwide by teaching operating and inspection best practices Improve communication between operating and supporting plant personnel by providing a common vocabulary of compressor terms Help processing plants avoid costly failures by teaching operators how to identify early compressor issues during field inspections




A Simple Guide to Understanding Compressors


Book Description

This straightforward guide to compressors seeks to unveil a lot of myths surrounding compressors. In this book, we will be looking at most types of compressors, including the centrifugal compressors, the air compressors, and of course the most troublesome of all compressors, the reciprocating compressors. Having a compressor with minimal operating problems does not only depend on the selection of the right type and size for your job. Detailed specifications of all auxiliary equipment and operating conditions, as well as keeping constant vigilance over the engineering and installation is imperative. The Simple Guide will explain in a simple yet definitive manner which compressor type is best used for which job and what it can produce.




A Practical Guide to Compressor Technology


Book Description

A Complete overview of theory, selection, design, operation, and maintenance This text offers a thorough overview of the operating characteristics, efficiencies, design features, troubleshooting, and maintenance of dynamic and positive displacement process gas compressors. The author examines a wide spectrum of compressors used in heavy process industries, with an emphasis on improving reliability and avoiding failure. Readers learn both the theory underlying compressors as well as the myriad day-to-day practical issues and challenges that chemical engineers and plant operation personnel must address. The text features: Latest design and manufacturing details of dynamic and positive displacement process gas compressors Examination of the full range of machines available for the heavy process industries Thorough presentation of the arrangements, material composition, and basic laws governing the design of all important process gas compressors Guidance on selecting optimum compressor configurations, controls, components, and auxiliaries to maximize reliability Monitoring and performance analysis for optimal machinery condition Systematic methods to avoid failure through the application of field-tested reliability enhancement concepts Fluid instability and externally pressurized bearings Reliability-driven asset management strategies for compressors Upstream separator and filter issues The text's structure is carefully designed to build knowledge and skills by starting with key principles and then moving to more advanced material. Hundreds of photos depicting various types of compressors, components, and processes are provided throughout. Compressors often represent a multi-million dollar investment for such applications as petrochemical processing and refining, refrigeration, pipeline transport, and turbochargers and superchargers for internal combustion engines. This text enables the broad range of engineers and plant managers who work with these compressors to make the most of the investment by leading them to the best decisions for selecting, operating, upgrading, maintaining, and troubleshooting.







Operator's Guide to Rotating Equipment


Book Description

Every operator who is responsible for monitoring critical rotating equipment will greatly benefit from this handy reference book. The goal of this book is to present proven techniques that will enable rookie and veteran operators alike to detect problems early and, we hope, eliminate major outages and/or maintenance costs. To achieve this goal we shall explain the basics of lubrication systems, bearings, drivers, seals and sealing systems, for centrifugal and positive displacement pumps as well as turbines, centrifugal compressors and reciprocating compressors. We will then present common sense inspection methods for centrifugal and positive displacement pumps, gear boxes, motors, heat exchangers, and turbines.




A Guide To Practical Human Reliability Assessment


Book Description

Human error is here to stay. This perhaps obvious statement has a profound implication for society when faced with the types of hazardous system accidents that have occurred over the past three decades. Such accidents have been strongly influenced by human error, yet many system designs in existence or being planned and built do not take human error into consideration.; "A Guide to Practical Human Reliability Assessment" is a practical and pragmatic guide to the techniques and approaches of human reliability assessment HRA. lt offers the reader explanatory and practical methods which have been applied and have worked in high technology and high risk assessments - particularly but not exclusively to potentially hazardous industries such as exist in process control, nuclear power, chemical and petrochemical industries. A Guide to Practical Human Reliability Assessment offers the practitioner a comprehensive tool-kit of different approaches along with guidance on selecting different methods for different applications. It covers the risk assessment and the HRA process, as well as methods of task analysis, error identification, quantification, representation of errors in the risk analysis, followed by error reduction analysis, quality assurance and documentation. There are also a number of detailed case studies from nuclear, chemical, offshore, and marine HRA'S, exemplfying the image of techniques and the impact of HRA in existing and design-stage systems.




Compressors and Modern Process Applications


Book Description

A modern reference to the principles, operation, and applications of the most important compressor types Thoroughly addressing process-related information and a wider variety of the major compressor types of interest to process plants, Compressors and Modern Process Applications uniquely covers the systematic linkage of fluid processing machinery to the processes they serve. This book is a highly practical resource for professionals responsible for purchasing, servicing, or operating compressors. It describes the main features of over 300 petrochemical and refining schematics and associated process descriptions involving compressors and expanders in modern industry. The organized presentation of this reference covers first the basics of compressors and what they are, and then progresses to important operational and process issues. It then explains the underlying principles, operating modes, selection issues, and major hardware elements for compressors. Topics include double-acting positive displacement compressors, rotary positive displacement compressors, understanding centrifugal process gas compressors, power transmission and advanced bearing technology, centrifugal compressor performance, gas processing and turbo-expander applications, and compressors typically found in petroleum refining and other petrochemical processes. Suitable for plant operation personnel, machinery engineering specialists, process engineers,as well as undergraduate students of this subject, this book's special features include: Flow schematics of modern process units and processes used in gas transport, gas conditioning, petrochemical manufacture, and petroleum refining Listings of licensors for each process on the flow schematics Identification of each process flow schematic of compressors, cryogenic, and hot gas expanders at their respective locations Important overview of surge control, estimating compressor performance, applications for air separation and gas processing plants, petroleum refinery issues, and important criteria that govern compressor selection and application Placing hundreds of associated process flow schematics at the fingertips of professionals and students, author and industry expert Heinz Bloch facilitates comprehension of the workings of various petrochemical, oil refining, and product upgrading processes that are served by compressors.




Radial Flow Turbocompressors


Book Description

An introduction to the theory and engineering practice that underpins the component design and analysis of radial flow turbocompressors. Drawing upon an extensive theoretical background and years of practical experience, the authors provide descriptions of applications, concepts, component design, analysis tools, performance maps, flow stability, and structural integrity, with illustrative examples. Features wide coverage of all types of radial compressor over many applications unified by the consistent use of dimensional analysis. Discusses the methods needed to analyse the performance, flow, and mechanical integrity that underpin the design of efficient centrifugal compressors with good flow range and stability. Includes explanation of the design of all radial compressor components, including inlet guide vanes, impellers, diffusers, volutes, return channels, de-swirl vanes and side-streams. Suitable as a reference for advanced students of turbomachinery, and a perfect tool for practising mechanical and aerospace engineers already within the field and those just entering it.




3. Forsthoffer's Rotating Equipment Handbooks


Book Description

Over recent years there have been substantial changes in those industries which are concerned with the design, purchase and use of special purpose (ie critical, high-revenue) rotating equipment. Key personnel have been the victims of early retirement or have moved to other industries: contractors and end-users have reduced their technical staff and consequently have to learn complex material 'from scratch'. As a result, many companies are finding that they are devoting unnecessary man hours to the discovery and explanation of basic principles, and having to explain these to clients who should already be aware of them. In addition, the lack of understanding by contractors and users of equipment characteristics and operating systems often results in a 'wrong fit' and a costly reliability problem. Forsthoffer's Rotating Equipment Handbooks: Compressors provides detailed coverage of characteristics, types, operation in a process system, (using the concept of required and produced gas head) performance relationships, selection, what determines the turbo compressor curve shape, surge/stall/stonewall, the effects of fouling, the design basis of journal and thrust bearings, balance drums, seals, critical speeds, control and protection guidelines, series and parallel operation, component condition monitoring, troubleshooting and many other aspects. Forsthoffer's Rotating Equipment Handbook: Compressors is the third title in the five volume set. The volumes are: 1. Fundamentals of Rotaing Equipment; 2. Pumps; 3. Compressors; 4. Auxiliary Systems; 5. Reliability Optimization through Component Condition Monitoring and Root Cause Analysis'. * One of a five volume set which is the distillation of many years of on-site training by a well-known US Engineer who also operates in the Middle East. * A Practical book written in a succinct style and well illustrated throughout.




Forsthoffer's Proven Guidelines for Rotating Machinery Excellence


Book Description

Forsthoffer's Proven Guidelines for Rotating Machinery Excellence draws on Forsthoffer's 60 years of industry experience to get new operatives up to speed fast. Each of the topics covered are selected based on hard-won knowledge of where problems with rotating machinery originate. This easy to use, highly-illustrated book is designed to elevate the competence of entry level personnel to enable them to immediately contribute to providing optimum rotating machinery reliability for their companies. The first 3 chapters address practical personal rotating machinery awareness, detail how to optimize this awareness to identify "low hanging fruit" safety and reliability improvement opportunities and how to define and implement a cost-effective action plan. The remaining chapters focus on the function of key components in each type of rotating machinery and how to monitor and correct their condition before failure. The last chapter is an RCA (Root Cause Analysis) procedure chapter detailing effective Root Cause Identification before a Failure to prevent a costly failure and the need for a RCFA. - Real-life examples are provided from the field of operation and maintenance of rotating machinery, helping readers to implement effectively - Includes important advice on monitoring approaches for different types of machines, highlighting differences between working with pumps and compressors - A chapter on Root Cause Identification features proven methods to help your organization to prevent machinery failures