Mitsubishi 7V-5 Compressor Test Results
Mitsubishi 7V-5 Compressor Test Results
June 10 2014
Compressor specification
Compressor Type 7V-5
Comp. Rated power 32MW
MCR 8328rpm
Shell Norske / Booster compressor
Suction pressure 23.1ata
Discharge pressure 87.7ata
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furnished and returned upon request. This document and such information is not to be reproduced, transmitted, disclosed or used otherwise in whole or in part without the written authorization of MCO.
2
2. Compressor in-house performance test result
120000
+22% 171
110000
161
SURGE LINE
100000
151 141
OPERATE
90000 131
1101
POLYTROPIC HEAD
80000
121
(N・m/kg)
70000 191
1131
60000
111
1121 105%
50000
181 98% Predicted
40000 1181 1171 1111 Tested on April 2nd 3rd
1161 90%
30000 1151 1141 80% Operating point
20000 70%
6000 8000 10000 12000 14000 16000 18000 20000 22000 24000 26000
INLET CPACITY (m3/h)
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furnished and returned upon request. This document and such information is not to be reproduced, transmitted, disclosed or used otherwise in whole or in part without the written authorization of MCO.
3
3. Root Cause Analysis
Root cause analysis was performed as per FTA.
Possibility
○ :High possible
Phenomenon Root Cause Investigation Result
△ :Possible
X :No possible
Impeller performance data used for performance calculation is deviated Check the impeller performance data with single stage test The impeller performance data was same as single
X
from single stage test result at laboratory. result at laboratory. stage test result at laboratry.
Predicted
Surge flow was correctly predicted by the impeller
performance Calculation error of surge flow prediction. Check the performance calculation. X
performance data.
Sensitive for surge flow due to the application of high Mach number. Check the Mach number with experiences. Mach number was within experiences. X
The impeller selection was same as performance
Impeller selection is different from performance calculation. Check the impeller selection with performance calculation. X
calculation.
Diffuser diameter and diffuser witdth were
Low diffuser diameter and/or narrow diffuser width. Check the diffuser diameter and diffuser width. X
correctly designed as per design manual.
Design
Check the distortion at upstream of impeller by CFD
Basic design Distorsion at upstream of impeller. Distorsion at upstream of impeller may occur. △
analysis
Large pressure loss at discharge scroll. Check the scroll area. Scroll area was optimum. X
IGV dimension was not correct. Check the dimension. The dimension was correct. X
Surge Manufacturing and Diffuser width was smaller than design. Check the dimension. The dimension was correct. X
Manufacturing
phenomenon was Assembling
observed at larger Labyrinth seal clearance was smaller than design. Check the dimension. The dimension was correct. X
flow than
predicted by more Discharge scroll dimension was not correct. Check the dimension. The dimension was correct. X
20%. The test condition was correctly calculated as per
ASME PTC-10 and predicted surge flow of test
Test Condition Test condition was not appropriate. Check the test condition as per ASME PTC-10 X
condition was consistent with that of design
condition.
The mode of the acoustic characteristics of test
Influence of the test loop arrangement. Comparison with experienced test loop. loop maight be related with the originating of flow △
point of surge.
Test facility
arrangement Designated test loop was not arranged. Check the test loop. Test loop arrange was correct. X
Leakage of test gas from test piping and/or tubing of instrument. Check the gas leakage. There was no leakage from test loop. X
Orifice dimension used for the flow calculation was
Orifice dimension for the flow calculation Check the dimensional of orifice. X
Performance same as dimension record.
test Orifice Plate was not placed in correct direction. Check the orifice direction Orifice was installed in correct direction. X
Flow rate
measurement by the Check the differential pressure by measuring pressure Differential pressure was checked by handy type
orifice Differential Pressure at orifice was not measured correctly X
before and after orifice by handy type instrument. instrument.
Flow rate calculation by the measured differential pressure was not
Check the flow rate calculation by hand calculation. Flow rate calculation was correct. X
conducted correctly.
Instruments was not calibrated correctly. Check the calibration record Instruments was calibrated correctly. X
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Range of instrument was not appropriate. Check the instrument range Range of instrument was appropriate. X
Instrument
Check the monitored speed and governing system
Rotational speed was not measured correctly Rotational speed was measured correctly X
[Link] is to be used solely for the purpose for which it is
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furnished and returned upon request. This document and such information is not to be reproduced, transmitted, disclosed or used otherwise in whole or in part without the written authorization of MCO.
4
3. Root Cause Analysis
CFD analysis result for suction casing
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furnished and returned upon request. This document and such information is not to be reproduced, transmitted, disclosed or used otherwise in whole or in part without the written authorization of MCO.
5
3. Root Cause Analysis
Asymmetrical flow was caused by the effect of flow pattern at suction volute.
Narrow path
Narrow path
Wide path
symmetrical flow pattern
Wide path
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furnished and returned upon request. This document and such information is not to be reproduced, transmitted, disclosed or used otherwise in whole or in part without the written authorization of MCO.
6
4. Countermeasure
Root cause 1 : Asymmetry flow pattern at inlet guide vane.
The number of IGV was increased and
IGV angle was changed to achieve
the robustness of small flow operation.
Pre-swirl 25DEG
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furnished and returned upon request. This document and such information is not to be reproduced, transmitted, disclosed or used otherwise in whole or in part without the written authorization of MCO.
7
4. Countermeasure
Root cause 2 : Acoustic characteristics of test loop.
Additional flow control valve was added at just downstream of compressor nozzle to
eliminate the effect of acoustic characteristics of test loop.
This document contains information proprietary to Mitsubishi Heavy Industries Compressor Corporation (MCO). It is submitted in confidence and is to be used solely for the purpose for which it is
furnished and returned upon request. This document and such information is not to be reproduced, transmitted, disclosed or used otherwise in whole or in part without the written authorization of MCO.
4. Countermeasure
Image of acoustic characteristics of closed loop.
Original closed loop
FCV
Compressor
Compressor is located on the position
Gas velocity fluctuation of test gas which is minimum gas velocity fluctuation in
the closed loop. Gas velocity fluctuation in
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the compressor is also small and stable.
This document contains information proprietary to Mitsubishi Heavy Industries Compressor Corporation (MCO). It is submitted in confidence and is to be used solely for the purpose for which it is
furnished and returned upon request. This document and such information is not to be reproduced, transmitted, disclosed or used otherwise in whole or in part without the written authorization of MCO.
8
9
5. Performance test result on June 3rd
In house performance test was performed on June 3rd 2014 after countermeasures
are completed . Surge flow was improved and all operating point can be covered by
the tested curve.
120000
171
110000 +5% 161
SURGE LINE
100000
151 141
OPERATE
90000 131
1101
POLYTROPIC HEAD
80000
121
(N・m/kg)
70000 191
1131
60000 105%
111
1121
50000
181 98%
Predicted
40000 1181 1171 1111 90%
1161 Tested on June 3rd
30000 1151 1141 80%
Operating point
70%
20000
6000 8000 10000 12000 14000 16000 18000 20000 22000 24000 26000
INLET CPACITY (m3/h)
This document contains information proprietary to Mitsubishi Heavy Industries Compressor Corporation (MCO). It is submitted in confidence and is to be used solely for the purpose for which it is
furnished and returned upon request. This document and such information is not to be reproduced, transmitted, disclosed or used otherwise in whole or in part without the written authorization of MCO.
10
6. Performance evaluation of test result
Actual gas conversion was performed based on the in-house performance test result
on June 3rd and confirmed that shaft power was within guaranteed value (+4%).
This document contains information proprietary to Mitsubishi Heavy Industries Compressor Corporation (MCO). It is submitted in confidence and is to be used solely for the purpose for which it is
furnished and returned upon request. This document and such information is not to be reproduced, transmitted, disclosed or used otherwise in whole or in part without the written authorization of MCO.
11
6. Performance evaluation of test result
All operating points specified on compressor data sheet can be covered by tested
curve.
Case 5 Case 3
Case 6
Case 4
Case 2
Predicted
Tested
Case 1 Operating
point
This document contains information proprietary to Mitsubishi Heavy Industries Compressor Corporation (MCO). It is submitted in confidence and is to be used solely for the purpose for which it is
furnished and returned upon request. This document and such information is not to be reproduced, transmitted, disclosed or used otherwise in whole or in part without the written authorization of MCO.
12
6. Performance evaluation of test result
CASING BHP REQUIRED (kW)
Case 1 Case 2 Case 3*1 Case 4 Case 5 Case 6
PREDICTED 31,705 30,368 29,852 30,306 25,632 31,723
TESTED 32,317 30,154 29,337 30,042 26,242*2 31,380
+1.9% -0.7% -1.7% -0.8% +2.4% -1.1%
SPEED (RPM)
Case 1 Case 2 Case 3*1 Case 4 Case 5 Case 6*3
PREDICTED 6,685 7,272 7,763 7,054 7,809 7,931
TESTED 6,651 7,248 7,763 6,988 7,842*2 7,995
-0.5% -0.3% 0% -0.9% +0.4% +0.8%
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furnished and returned upon request. This document and such information is not to be reproduced, transmitted, disclosed or used otherwise in whole or in part without the written authorization of MCO.
13
6. Performance evaluation of test result
The recycle flow of “Case 5” was increased to keep +10% anti surge line from tested
surge line. Predicted recycle flow : 19 (kg/s) (20% of total flow 97 kg/s), Tested recycle
flow : 25 (kg/s) (24% of total flow 103 kg/s).
Case 5 Case 3
Case 6
Case 4
Case 2
Predicted
Case 1 Tested
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furnished and returned upon request. This document and such information is not to be reproduced, transmitted, disclosed or used otherwise in whole or in part without the written authorization of MCO.
14
6. Performance evaluation of test result
Polytropic efficiency curve based on tested data on June 3rd is shown on following
figure.
Tested
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furnished and returned upon request. This document and such information is not to be reproduced, transmitted, disclosed or used otherwise in whole or in part without the written authorization of MCO.
15
6. Performance evaluation of test result
Predicted Tested
JOB NO. ITEM NO. JOB NO. ITEM NO.
CENTRIFUGAL AND AXIAL COMPRESSOR REVISION NO. 0 DATE March, 2013 CENTRIFUGAL AND AXIAL COMPRESSOR REVISION NO. DATE
DATA SHEET (API 617-7TH Chapter 2) PAGE 1 OF 7 BY S. Y oshida DATA SHEET (API 617-7TH Chapter 2) PAGE 1 OF 7 BY
SI UNITS SI UNITS
1 APPLICABLE TO: PROPOSAL PURCHASE AS-BUILT
1 APPLICABLE TO: ○ PROPOSAL ○ PURCHASE ● AS-BUILT
2 FOR A/S Norske Shell UNIT
2 FOR A/S Norske Shell UNIT
3 SITE Norway SERIAL NO.
3 SITE Norway SERIAL NO.
4 SERVICE Ny hamna Pipeline Compressor NO. REQUIRED Two (2)
4 SERVICE Ny hamna Pipeline Compressor NO. REQUIRED Two (2)
5 MANUFACTURER Mitsubishi Heav y Industries Compressor Corporation DRIVER TY PE (1-3.1.1) Variable Speed Electric Motpr
5 MANUFACTURER Mitsubishi Heav y Industries Compressor Corporation DRIVER TY PE (1-3.1.1) ELECTRIC MOTOR
6 MODEL 7V-5 DRIVER ITEM NO.
6 MODEL 7V-5 DRIVER ITEM NO.
7
7
8 INFORMATION TO BE COMPLETED: BY PURCHASER BY MANUFACTURER MUTUAL AGREEMENT (PRIOR TO PURCHASE)
8 INFORMATION TO BE COMPLETED: ○ BY PURCHASER □ BY MANUFACTURER △ MUTUAL AGREEMENT (PRIOR TO PURCHASE)
9 OPERATING CONDITIONS
9 OPERATING CONDITIONS
10 (ALL DATA ON PER UNIT BASIS) Case 1 Case 2 Case 3 Case 4 Case 5 Case 6
10 Case 1 Case 2 Case 3 Case 4 Case 5 Case 6
11 NO. OF OPERATING UNITS 2 2 2 2 1 1
11 Number of operating unit. 2 2 2 2 1 1
12 RECY CLE FLOW, kg/s (WET/DRY ) @ 30 oC 19.0
12 RECYCLE FLOW, kg/s (WET/DRY ) @ 30 oC 25
13 GAS HANDLED (ALSO SEE PAGE 2 )
13 ○ GAS HANDLED (ALSO SEE PAGE )
14 GAS PROPERTIES (1-[Link])
14 △ GAS PROPERTIES (1-[Link])
15 MMm 3/day (1.013 bar @ 0 oC DRY )
15 ○ Nm3/h(1.013BarA & 0゚C DRY ) 227 157 125 172 103 130
16 WEIGHT FLOW, kg/s (WET/DRY ) 226.8 156.6 125.4 172.4 97.0 129.8
16 ● WEIGHT FLOW (kg/h) (WET)(DRY ) 816480 563760 451440 620640 372073 467280
16' WEIGHT FLOW, kg/h (WET/DRY ) 816,480 563,760 451,440 620,640 349,200 467,280
19 TEMPERATURE (oC) 13.3 12.9 13.2 12.8 17.7 14.2 19 ● TEMPERATURE (゚C) 13.3 12.9 13.2 12.8 17.7 14.2
21 MOLECULAR WEIGHT 17.41 17.42 17.43 17.41 17.40 17.40 21 ● MOLECULAR WEIGHT 17.41 17.42 17.43 17.41 17.40 17.40
22 Cp/Cv (K1) OR (KAVG ) 1.438 1.392 1.371 1.405 1.362 1.367 22 ■ Cp/Cv (K1) OR (KAVG) 1.438 1.392 1.371 1.405 1.362 1.367
23 COMPRESSIBILITY (Z 1)OR(Z AVG ) 0.912 0.934 0.946 0.928 0.951 0.948 23 ■ COMPRESSIBILITY (Z1)OR(ZAVG) 0.912 0.934 0.946 0.928 0.951 0.948
24 INLET VOLUME, (m 3/h)(WET/DRY ) 26,514 25,411 25,039 25,373 20,512 26,803 24 ■ INLET VOLUME (m3/h) (WET)(DRY ) 26514 25411 25039 25373 21856 26803
25 DISCHARGE CONDITIONS 25 DISCHARGE CONDITIONS
26 PRESSURE (bar A) 86.00 86.00 86.00 86.00 86.00 86.00 26 ● PRESSURE (barA) 86.01 86.00 86.01 86.00 86.00 86.01
27 TEMPERATURE (oC) 84.2 108.2 126.7 100.2 140.2 130.1 27 ■ TEMPERATURE (゚C) 85.1 107.7 125.2 99.7 136.5 129.1
28 Cp/Cv (K2) OR (KAVG ) 1.421 1.375 1.346 1.389 1.329 1.342
28 ■ Cp/Cv (K2) OR (KAVG) 1.419 1.375 1.348 1.390 1.333 1.343
29 COMPRESSIBILITY (Z 2)OR(Z AVG ) 0.931 0.951 0.963 0.945 0.971 0.965
29 ■ COMPRESSIBILITY (Z2)OR(ZAVG) 0.931 0.951 0.962 0.944 0.969 0.965
30 GHP REQUIRED (kW)
30 □ BHP REQUIRED (kW)
31 CASING BHP REQUIRED (kW) 31,705 30,368 29,852 30,306 25,632 31,723
31 ■ CASING BHP REQUIRED (kW) 32,317 30,154 29,337 30,042 26,242 31,380
32 BHP REQUIRED AT DRIVER INCL EXT. LOSSES (kW) * 32,355 31,018 30,502 30,956 26,282 32,373
32 ■ BHP REQUIRED AT DRIVER INCL EXT. LOSSES (kW) 33,054 30,891 30,074 30,779 26,979 32,117
33 SPEED (RPM) 6,685 7,272 7,763 7,054 7,809 7,931
33 ■ SPEED (RPM) 6,651 7,248 7,763 6,988 7,842 7,995
34 TURNDOWN (%)
34 □ TURNDOWN (%)
35 POLY TROPIC HEAD (N-m/kg) 113,630 165,570 202,040 149,400 214,490 208,200
35 ■ POLY TROPIC HEAD (N-m/kg) 113860 165420 201550 149240 213240 207880
36 POLY TROPIC EFFICIENCY (%) 81.6 85.7 85.2 85.4 81.6 85.5
36 ■ POLY TROPIC EFFICIENCY (%) 80.2 86.3 86.5 86.0 84.4 86.3
37 CERTIFIED POINT Y es
37 ○ CERTIFIED POINT Y es
38 PERFORMANCE CURVE NUMBER
38 □ PERFORMANCE CURVE NUMBER
39 PROCESS CONTROL (1-[Link])
39 PROCESS CONTROL (1-[Link])
40 METHOD SUCTION THROTTLING VARIABLE INLET SPEED VARIATION DISCHARGE COOLED BY PASS
40 METHOD ○ SUCTION THROTTLING ○ VARIABLE INLET ● SPEED VARIATION ○ DISCHARGE ○ COOLED BY PASS
41 FROM bar A GUIDE VANES FROM 70 % BLOWOFF FROM
41 FROM (BarG) GUIDE VANES FROM 70 % BLOWOFF FROM
42 TO bar A (2-[Link]) TO 105 % TO TO
42 TO (BarG) (2-[Link]) TO 105 % TO TO
43 SIGNAL SOURCE (1-[Link])
43 SIGNAL ○ SOURCE (1-[Link])
44 TY PE ELECTRONIC PNEUMATIC OTHER
46 45 RANGE mA (BarG)
49 48 REMARKS:
49
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furnished and returned upon request. This document and such information is not to be reproduced, transmitted, disclosed or used otherwise in whole or in part without the written authorization of MCO.
16
Modification plan (As option)
In order to cover the predicted surge point, NEW impeller selection shall be applied and
following parts need to be manufactured .
・Stg.1, stg.2, stg.3. impellers.
・Shaft.
・Stg.1-2, stg.2-3, stg.3-4. diaphragm.
・Inlet wall.
This document contains information proprietary to Mitsubishi Heavy Industries Compressor Corporation (MCO). It is submitted in confidence and is to be used solely for the purpose for which it is
furnished and returned upon request. This document and such information is not to be reproduced, transmitted, disclosed or used otherwise in whole or in part without the written authorization of MCO.
17
Modification plan (As option)
PREDICTED PREDICTED
Unit TOLERANCE
(Original) (Modification)
(*) Rotating speed was adjusted in order to keep specified discharge pressure.
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furnished and returned upon request. This document and such information is not to be reproduced, transmitted, disclosed or used otherwise in whole or in part without the written authorization of MCO.
18
Modification plan (As option)
Predicted (original)
Predicted
(predicted based on
modification plan)
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furnished and returned upon request. This document and such information is not to be reproduced, transmitted, disclosed or used otherwise in whole or in part without the written authorization of MCO.
19
Modification plan (As option)
Original
Case 1 Case 2 Case 3*1 Case 4 Case 5 Case 6
Power (kW) 31,705 30,368 29,852 30,306 25,632 31,723
Speed (rpm) 6,685 7,272 7,763 7,054 7,809 7,931
Additional modification
Case 1 Case 2 Case 3*1 Case 4 Case 5 Case 6*3
Power (kW) 33,482 31,035 30174 31,047 25,306 32,246
+5.6% +2.2% +1.1% +2.4% -1.3% +1.6%
Speed (rpm) 6,982 7,426 7,861 7,221 7,814 8,059
+5.0% +2.1% +1.3% +2.4% +0.1% +1.6%
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This document contains information proprietary to Mitsubishi Heavy Industries Compressor Corporation (MCO). It is submitted in confidence and is to be used solely for the purpose for which it is
furnished and returned upon request. This document and such information is not to be reproduced, transmitted, disclosed or used otherwise in whole or in part without the written authorization of MCO.
20
Modification plan (As option)
Estimated schedule
・Manufacturing for following parts : 3 month
(When the all materials is existing in MCO factory.)
・Stg.1, stg.2, stg.3. impellers.
・Shaft.
・Stg.1-2, stg.2-3, stg.3-4. diaphragm.
・Inlet wall.
This document contains information proprietary to Mitsubishi Heavy Industries Compressor Corporation (MCO). It is submitted in confidence and is to be used solely for the purpose for which it is
furnished and returned upon request. This document and such information is not to be reproduced, transmitted, disclosed or used otherwise in whole or in part without the written authorization of MCO.