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RFC3, Zi 115.02.2007

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MAN TURBO TrainingMAN TURBO Training

CentrifugalentrifugalCompressorsompressorsBasic Trainingasic TrainingRotorotor

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15.02.2007 2

MAN TURBO AG

RFC3, ZiRFC3, Zi

Shaft

Material: forged steel

Balance drum integrated

Stiff rotor design

z No shaft sleeves or

z No spacer bushings

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MAN TURBO AG

RFC3, ZiRFC3, Zi

Blades

Shroud disc

Hub disc

Shaft

Impeller Design

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MAN TURBO AG

RFC3, ZiRFC3, Zi

Open impeller

without shroud

Milled from a solid forging

Impeller DesignRIKT 1st stage

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MAN TURBO AG

RFC3, ZiRFC3, Zi

Impellers

Form

z 2D or 3D as required by the flow

coefficient

Geometry

z fixed series of graduated geometry

z based on measured characteristics

and application charts

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MAN TURBO AG

RFC3, ZiRFC3, Zi

Impellers

Material selected

z to the compressed gas and

z to limit values e.g. sour gas

Manufacturing

z diameter < 700 mm

milled (5-axis NC) out of

solid hub and

brazed (high temperature

and vacuum)

z diameter > 700 mm

milled and

welded

z cast (investment casting)

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MAN TURBO AG

RFC3, ZiRFC3, Zi

Welded

Milled & Brazed

(Brazed or Welded)

Welded / Brazed as Functions of D2 and b2

Impeller ManufacturingBrazed or welded impellers

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MAN TURBO AG

RFC3, ZiRFC3, Zi

Impeller ManufacturingSpecials and Details

Riveting sometimes for old

compressors

z as spare parts

Annealing during welding and

brazing

z in softest condition

z to avoid cracks in heat-

affected zones

Heat treatment after brazing

and welding

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MAN TURBO AG

RFC3, ZiRFC3, Zi

ImpellersQuality Assurance

Design Test

z in our test compressors

z stress analysis by finiteelements method (FEM)

Quality Test

z ultrasonic examination

following brazing

z crack detection following

welding

z overspeed spin test

115% of max. operating

speed

z deformation measurement

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MAN TURBO AG

RFC3, ZiRFC3, Zi

ImpellersBalancing Procedure

Impeller individually balanced

before assembling onto shaft

Material removed from hub orshroud discs

Remaining unbalance with

zero marked

Shaft stacked with 180 offset

of zero markings of different

impellers

Assembled rotor high speedbalanced under Vacuum

Now only weights added not

removed.

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MAN TURBO AG

RFC3, ZiRFC3, Zi

Shrouded (closed) Impeller

Gold nickel

brazed impeller

High flowcoefficient

3D-blading

5-axes NC flankmilling

Ultra-sonic tested

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MAN TURBO AG

RFC3, ZiRFC3, Zi

Light Shrink Fit

z maximum

shrinkage of0.25% allows

circumferential

velocities of

340 m/s Dowel Pins

z 4 pc.

z Low Notch

Factor

No Unbalance

Caulked Labyrinth

Strips

Hub Disc

Shroud Disc

Blades

Impeller FixationPins and Labyrinths

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MAN TURBO AG

RFC3, ZiRFC3, Zi

Impeller FixationAdvantage of Pins versus Key

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MAN TURBO AG

RFC3, ZiRFC3, Zi

Each Impeller

low speed balanced

Rotorhigh Speed balanced

Impeller Assembly