TMS- CARDIFF

Okpo, South Korea – January 2014

CRYOSTAR Equipment for LNG Tankers:

Dual Fuel Diesel Electric 4-Stage
Module 3.1- HD CM400/55 Construction

LSE-CP_En_03.2_Rev02
www.cryostar.com [email protected] LSE-DFDEP_En_03.2_Rev02
MODULE 3.1 – COMPRESSOR HD CONSTRUCTION – SINGLE STAGE

The following document contains partly confidential

information, and is provided for training purposes to
selected shipyards and their customers.

It must not be used for any other purpose, and may not be
provided to a third party without our consent.

This document contains representative data only, and does

not replace the manuals or technical documentation issued
for the vessel.
© Cryostar France, 2013

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 COURSE SYLLABUS

 Location onboard the ship

 Principle
 Main data
 Gear Box
 Compressor impeller
 Impeller Sealing
 Coupling
 Bulkhead seal
 Compensator
 IGV control
 HIC pneumatic device
 Performance curves
 Electrical Motor

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BOG Compressor: principle reminder

T2> T1
A gas compressor is a rotating
machine that increases the pressure High Pressure
of a gas by reducing its volume. (radial outlet)
Compression of a gas naturally
increases its temperature.

DISCHARGE
Low Pressure
(axial inlet)
T1
COMPRESSOR
=
COMPRESSION
+
HEAT PRODUCTION SUCTION

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HD single stage compressor (and LD Steam )

High Duty
Low Duty
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 Main Data

 The compressor portion of the machine is of axial

inflow type, with variable inlet guide vanes.

The compressor is designed to operate

over the range of pressures and flow
rates defined in the performance curve.

Behind the impeller there is an insulating

plate, used as a thermal barrier between
process and gearbox.

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 Main Data

H/D Compressors are mainly used to/for:

Transfer generating vapour to the shore during loading

Transfer generating vapour to the shore during initial cooling down
Recirculation of hot cargo vapour to warm-up cargo tank
Displacing the inert gas contained in the cargo tanks (progressive
purging) by LNG vapour
Aeration of cargo tank
……

L/D Compressors are used to :

Maintain the cargo tank pressure

Supply the boil-off vapour to the main boilers/engines as fuel gas
during the voyages

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Main Data
Bulkhead

Motor Bulkhead Seal

Gearbox

IGV Controller
Local Panel

Compressor
housing

LO Cooler
Steam
Skid Heater
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Main Data
Impeller
High Duty Compressor design data

Shaft speed 11200 RPM

Wheel diameter 400 - 500 mm
Inlet guide vanes setting +80° to -30 °
Typical compressor
Flange (in/out) 24” / 20”

Shroud

Diffuser

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Main Data

The 3D high efficiency compressors’ impellers are of axial inflow type

with advanced aerodynamic design maximizing the isentropic efficiency.

Compressor Impeller

Different Impeller type

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Main Data

Determination of resonance frequencies

at an early stage of the design cycle
Safe operating range definition
Determination of actual versus allowable
stress level

Mode shapes for compressor impeller

Typical FEC mesh using ~200000 elements

per blade passage
Stress concentration due to static gas pressure &
centrifugal load (in Pa)
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Main Data
Dynamic fine balancing

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Main Data

Compress Compress
or diffusor or casing

Rotor:
Shaft + Wheel
Compressor
Wheel
(impeller)

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Main Data
Compressor
diffuser

INLET

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Main Data

A diffuser is a flow element that allows the flow to decelerate, due to an increase in flow area,
and this in turns permits the static pressure to rise.

OUTLET
Diffuser blades: radial

Diffusers
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 Main Data

The compressor is of axial Impeller

inflow and radial outflow type.
Inlet Guide Vanes allow to
control the machine.

IGV

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 Main Data

Shaft Impeller

Polygon Fit

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 Main Data
Heat Barrier
Compressor

Heat Barrier
“Vetronite”

Gearbox

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 Main Data

Skid

All devices are fixed on this frame.

Motor and compressor are mounted
on this common bed.

It reinforces the ship’s deck.

Shaft alignment is maintained.

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MODULE 3.1 – COMPRESSOR HD CONSTRUCTION – SINGLE STAGE
 Main Data

Bulkhead

Any partition that separates different compartments or space from one to another on a ship.
This vertical partition is used to separate the compressor room and the motor room, and avoids gas
leaking to the motor side

Ship’s
Bulkhead
Cargo Machinery Room Motor Room

Proven Bulkhead Seal

Ship’s deck

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MODULE 3.1 – COMPRESSOR HD CONSTRUCTION – SINGLE STAGE
 Gearbox Gearbox
Compressor
Speed-increasing, two shaft parallel gear.

H/D Compressor :
Compressor shaft speed : 11200 rpm Motor
E-motor shaft speed : 3550 rpm(60 Hz)
Ratio : 3.155
3550 x 3.155 = 11200 rpm

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Gearbox:

Thrust bearing Mech. LO pump

Low speed shaft

Radial bearings

Compressor
Thrust collar High speed
shaft

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 Gearbox: lubrication

Oil diffuser

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 Gearbox: bearings

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 HD & LD gearboxes:

 Similar design (not 2-stage)

 Different shaft diameter.

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Compressor: wheel sealing

Behind the compressor wheel

Oil Trap
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 Coupling
Hubs

 Transmission of rotating movement

from gearbox hub to compressor.

 Spring pack flexible type.

 Assembled between the motor and

the gearbox hub.

 Designed to accept some axial and

radial stresses.

Copper, non sparking, Coupling

coupling protection.

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 Characteristics (in most cases)

Material: Steel / Stainless steel

It’s a twin universal design with space for
bridging variable distances between shaft ends.

=> torsionally rigid, multiple disc coupling with

radially removable spacer.

Item Description

1 Hub
2 Disc packs

3 Set of fit-bolts

4 Spacer

5 Flange

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MODULE 3.1 – COMPRESSOR HD CONSTRUCTION – SINGLE STAGE
 Bulkhead seal

 Allows penetration of gearbox Oil

shaft through the bulkhead into OUT
Seal Cartridge
Motor room.

 Balanced rotating double

Coupling
mechanical seal.

 Oil-filled cartridge type tandem

carbon seal on the gearbox low
speed shaft.

 Oil supply from the main lube-oil

stream.
Oil
Gearbox IN
 Oil barrier pressure 1,5 to 3 bar

 Oil flow also dissipates shaft heat.

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MODULE 3.1 – COMPRESSOR HD CONSTRUCTION – SINGLE STAGE
 Bulkhead seal HD

Gearbox shaft easily accessible

from motor room.

Accepts the shaft movement of

gearbox bearings.

But can be damaged by

inappropriate dismantling.

Residual oil is normal and is

collected into the oil collector on the
motor side.

The carbon rings are changed

every 2 dry dock

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MODULE 3.1 – COMPRESSOR HD CONSTRUCTION – SINGLE STAGE
 Bulkhead seal

Oil OUT

Gearbox

Coupling

Seal Cartridge Oil IN

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MODULE 3.1 – COMPRESSOR HD CONSTRUCTION – SINGLE STAGE
 Advantages of the bulkhead seal:

When the system is stopped, oil remains inside the

element and the sealing effect is maintained.

No care is needed for the stand-by machines, seal

gas is not required.

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 Compensator bellow

Compensates for the bulkhead wall deformation

after welding for integration

Bulkhead

Compensator
bellow

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MODULE 3.1 – COMPRESSOR HD CONSTRUCTION – SINGLE STAGE
 Compensator bellow

 Stainless steel expander welded in between 2 flanges.

 Bolted on bulkhead seal assembly and bulkhead

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 IGV actuator

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IGV actuator

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 IGV Actuator

A mechanical device that converts pneumatic or hydraulic pressure

into linear or rotary motion.

Operating medium : dry and filtered compressed air or any non-

aggressive gaseous medium.

The Cryostar actuator system consists in a valve (pressure

regulator), an actuator, a pneumatic positioner, an electrical position
transmitter and a limit switch.

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MODULE 3.1 – COMPRESSOR HD CONSTRUCTION – SINGLE STAGE
 IGV actuator: previous type

Actuator is controlled from the CCR or locally via the HIC and I/P converter
Start interlock (ZSL)
Pneumatic
Limit switch positioner and
ZSL feedback card

Pneumatic
actuator I/P converter
(remote control
via CCR)

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MODULE 3.1 – COMPRESSOR HD CONSTRUCTION – SINGLE STAGE
 IGV actuator: previous type

 The control device transmits actuating signals to the actuator via I/P
converters. These signals are translated into a rotary motion.

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 IGV actuator

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 IGV Actuator: new type

 Actuator is controlled from the CCR (Even locally) through the ABB positioner
which manages:

- IGV Closed position

- IGV I/P Converter
- IGV position feedback

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 IGV pneumatic actuator Principle

The linear motion of 2 opposing pistons is translated into a rotary motion by a

rack-and-pinion system.

Double acting actuators are provided with 2 chambers which are alternately
pressurized :

1 2

Pressurization of the external chamber results in a right hand rotation of

1 the pinion shaft (closed position).

Pressurization of the internal chamber results in a left hand rotation of

2 the pinion shaft (open position).

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 The HIC: pneumatic station for previous system

Manual control of the pneumatic pressure to

the IGV actuator.

The operator can locally control the IGV setting

by adjusting PCV knob (range of 0.2 to 1.0 bar).

Pressure limiter

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 The HIC: manual operated pneumatic station

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 New IGV local controller

No more HIC local controller

Local control on the cubicle (+/-)

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CM400: performance curves

predicted case
Warranty case predicted case with
IGV less opened

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CM 400 Design Case A:

- 100%Methane
- Inlet temperature:-140°C
- Pressure: 2 Bar A

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MODULE 3.1 – COMPRESSOR HD CONSTRUCTION – SINGLE STAGE
 Electrical Motor
Drives the compressor.
The motor is not Cryostar scope of supply
Cryostar defines however:
- the needed shaft power
- the starting torque
- the allowable size and properties.
Depending on technical rules, yards or owners
preferences, motors are either air, or water cooled.
Motors are:
-60 Hz for HD
-LD is fixed speed (60Hz) or Frequency drive for the LD

Water cooled motor

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Electrical Motor

Water cooled motor

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CM 400:
- 100%Methane
- Inlet temperature:-140°C
- Pressure: 2 Bar A

What will be the resulting

mass flow if IGV opening is
+50°?

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THANK YOU FOR YOUR ATTENTION

ANY QUESTION?

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