DonkinTurboCompressors PDF
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HIGH PERFORMANCE
DONKIN CENTRIFUGAL TURBO
COMPRESSOR SYSTEMS
HOWDEN PROCESS COMPRESSORS
1 HOWDEN PROCESS COMPRESSORS
Howden, the world's largest and longest established fan and compressor manufacturer
provides solutions for the air and gas handling needs of clients. James Howden,
a pioneering Scots engineer, founded the company in Glasgow in 1854. Today the
Group has subsidiaries in five continents and more than 15 countries worldwide.
Howden Process Compressors is the organisation within Howden that designs and manufactures
various types of blowers and screw compressor packages. Bryan Donkin, one of the longest
established designers of rotary blowers and compressors with a history extending back to 1856,
was integrated into Howden Process Compressors in 1997. A centre of excellence encompassing
all these compression technologies was developed at our manufacturing site in Scotland. Design,
application engineering, manufacturing, testing and after sales support are available for the full
range of compression products offered by the company.
THE HOWDEN PEDIGREE WORLDWIDE COVERAGE GUARANTEED The Howden Donkin range of integrally
Howden, Bryan Donkin, Sirocco, Reavell, Davidson, Worldwide Cover is achieved via Howden's geared, high efficiency turbo compressors
Neu, Sofrair and Berry all renowned worldwide comprehensive network of regional facilities, has been developed, over 40 years,
for their technical expertise in the design and and a network of technically qualified
manufacture of fans and blowers combined regional managers.
for use in a broad range of process
to provide an enviable resource of experience applications worldwide.
A thorough review of process requirements
for customer confidence.
by qualified project and applications personnel Product integrity, long operational life
Combining more than 150 years experience in ensures that the most cost effective and energy and maximum efficiency of compression
the utility, process gas, petrochemical and many efficient design proposal is submitted to the
other industries, we are uniquely placed to offer customer, whether for a centrifugal blower or
are the main focus of design.
customers an individually engineered compression a full process compression package installation.
solution to suit their particular application and
individual requirement.
Air blowers providing reaction air for the Blowers handling a wide range of process Maximum reliability
catalytic recovery of sulphur within the gases for the petrochem and heavy industry. Ease of maintenance
petrochemical industry. Skid mounted with integral lubrication
FUEL GAS BLOWERS Variable flow by means of variable vane
SULPHURIC ACID PLANT Blowers handling natural and dirty coke-oven, diffusers, pre-rotational inlet guide vanes
Combustion air blowers and process gas manufactured, landfill and other bio gases. or a combination of both systems
mixture cleaning, sometimes combined. (landfill extraction) Wide flow range, available to below
45% of design flow
FLUE GAS DESULPHURISATION CARBON BLACK PLANT Highest efficiency levels over entire
operating range
Oxidation air blowers associated with the Air blowers providing combustion air
cleaning of flue gases produced within power for the associated furnaces. Steep pressure/volume curve to
and heavy industry. give inherent stability and protection
against surge
WASTE WATER TREATMENT
Horizontally split gearbox for ease
INDUSTRIAL EFFLUENT TREATMENT Aeration blowers associated with the biological of maintenance and inspection
Aeration blowers associated with the biological treatment of effluent in municipal sewage
Well proven long working life.
treatment of effluent within industrial plants. treatment plants.
(Machines 30 years old still operational)
Two stage labyrinth or carbon ring sealing to
FURNACE/SMELTER/REACTOR AIR SUPPLY FERMENTATION give guaranteed oil free process gas delivery
Air blowers providing combustion or Air blowers associated with biochemical Compact packaged unit, factory assembled
reaction air primarily for the petrochemical fermentation within pharmaceutical and on underbed to minimise installation time
and metals industries. yeast production industry.
Capacity up to 250,000 m3/hr
Pressure up to 5 Bar A.
3 HOWDEN PROCESS COMPRESSORS
COMPRESSOR SPECIFICATIONS
SINGLE STAGE TURBO COMPRESSORS,
PROVEN RELIABILITY
Impeller: Induced backward
curved vane impeller
IMPELLER
Fully machined from solid aluminium forging
(ASTM B2471) by multi axis computerised
machining centre.
Also available in nickel-chrome corrosion
resisting steel.
Induced backward curve or radial profile.
Retained on high speed shaft by a central bolt.
Subjected to ultrasonic test before
final machining.
Split Gearbox: Horizontally split gearbox Dynamically balanced to ISO 1940 Specification.
provides easy access to gears and bearings Overspeed tested to a minimum 115%
of operating speed.
GEARBOX
Gearcase in cast iron grade 250
to BS 1452 (ASTM A48-83-35B).
Horizontally split for ease of maintenance.
Single helical speed increasing type.
Shafts and gearwheel are fully machined
from carbon steel forgings.
Gearing is to AGMA Quality 11 to 13
as required.
All gears have ground tooth profile.
AGMA service factor of 1.4 minimum.
API optional.
Protection Devices: PRESSURE LUBRICATION SYSTEM 4
Optional API lubrication system
Integrated lubrication system to provide
a safe and reliable oil supply.
Baseplate acts as oil reservoir.
Main oil pump is mechanically driven from
low speed shaft, sized to provide satisfactory
oil supply throughout run down period.
Electrically driven auxiliary oil priming pump,
complete with T.E.F.C. motor, used to prime
the system before start-up and act as a standby
unit in emergency and during shutdown.
Oil cooler of the water cooled shell and tube
type or air blast type.
Simplex oil filter, (Duplex optional).
Differential pressure indicator across filter.
Immersion heater and thermostat.
Oil temperature control valve.
API optional.
CASINGS
In cast iron grade 250 to BS 1452
(ASTM A48-83-35B).
RV2
SHAFT SEALS PS1 PS2 PI
BEARINGS
Low speed bearings are of the anti-friction type,
or Taperland Journal type if specified
or required due to loading.
TE TE
High speed bearings are of the tilting pad journal MAIN
type, to give almost vibration free operation at OIL
PUMP
high speed. PS
BLOWER
Axial loading is absorbed by thrust rings
MAIN DRIVE MOTOR
at periphery of lower speed gear wheel transferred
from high speed shaft via thrust collars to minimise
power loss. OIL TEMPERATURE
CONTROL VALVE
All bearings are oil lubricated from DPS PI
TI
the integral pressure oil lubrication system.
All bearings are easily accessible by removal OIL COOLER WATER
DUPLEX COOLED SHELL AND TUBE
of the top half gearbox casing. FILTER OR AIR BLAST TYPE
DP1
AUXILIARY
INSTRUMENTATION & PROTECTION DEVICES BREATHER/FILLER FILTER OIL PUMP
RV1
Oil pressure indicator at bearing supply manifold.
LI LS
Lube oil temperature after cooler monitoring. TS
THERMOSTATICALLY
High speed shaft journal bearing temperature CONTROLLED
IMMERSION HEATER BASEPLATE
OIL RESERVOIR
monitoring.
DRAIN
Process air temperature monitoring.
Pressure Lubrication Schematic
Lube oil pressure low (acts as both alarm and
also re-starts auxiliary oil pump in the event of
falling oil pressure).
Lube oil pressure low trip.
Oil reservoir temperature low switch (inhibits
blower operation with oil temperature below 20C).
Additional instrumentation can be provided
as required.
All alarm/trip/indication functions are displayed NOTE: To suit the individual applications,
various materials of construction are
at the local control panel (pages 8 & 9).
available to ensure maximum resistance to
API optional. corrosion, abrasion and high temperature.
5 HOWDEN PROCESS COMPRESSORS
CONTROL SYSTEMS
MAXIMISING OPERATING
EFFICIENCY
TYPES OF CONTROL SYSTEM AVAILABLE:
Variable Outlet Vane Diffuser (VVD)
Pre-rotational Inlet Guide Vane
Control (IGV)
Combined Inlet & Outlet Control
(CVC)
Howden Donkin control systems COMBINED CONTROL (CVC) INLET GUIDE VANE CONTROL (IGV)
maximise operating efficiency and The Howden Donkin combined vane Inlet guide vane control assembly is fitted to the
provide infinitely variable capacities control (CVC) features:- blower to enhance efficient capacity control
whilst retaining the simple constant speed motor.
over a wide duty range. Fully Enhances the advantages of both the variable
vane diffuser and inlet guide vanes. Guide vanes are manufactured from AISI 316
automatic capacity control is
stainless steel and equally spaced radially about
achieved from a single input signal, Maintains high design efficiency over a wider
the bore of the inlet branch, to pre-rotate the
range air flow and ambient temperature range
processed and relayed to the air before entering the impeller.
than either of the individual control systems.
electric, pneumatic or hydraulic Guide vanes are supported in self lubricated
guide vane actuators. Constant bearing sleeves, provided with an "O" ring seal
speed drive motors are retained at the vane shoulder to isolate linkage from the
flow medium.
to ensure maximum reliability.
Actuation is by a single spindle, via non-lubricated
linkage system.
Electric servo motor actuator fitted for modulating
control. (Pneumatic actuators can be provided).
PERFORMANCE CURVES
IMPELLER VARIABLE VANE
DIFFUSERS
VOLUTE
VVD: VARIABLE VANE DIFFUSER CONTROL
CASING
HEAD REL %
DOUBLE
LABYRINTH 110
SEAL
THRUST HIGH SPEED
COLLAR SHAFT Design Duty
105
100
INLET
AIR 100
FLOW
BEARINGS
95
95
90 90
INPUT
SHAFT
85
VARIABLE VANE
DIFFUSERS GEARBOX
80
VVD Control
0 20 40 60 80 100 120
DESIGN FLOW %
100
INLET
AIR 95 100
FLOW
BEARINGS
90
95
INPUT 85
SHAFT 90
INLET
GUIDE
VANES 80
GEARBOX
0 20 40 60 80 100 120
IGV Control DESIGN FLOW %
95
INLET
AIR
FLOW
BEARINGS
90
95
85
INPUT
SHAFT
INLET 80
GUIDE
VANES
VARIABLE VANE GEARBOX 0 20 40 60 80 100 120
DIFFUSERS
DESIGN FLOW %
CVC Control
7
The Howden Donkin master control MASTER CONTROLS proportional to the dissolved oxygen content in
the water this signal is fed to a process control
systems provide fully automatic control Two basic master control systems are in use:-
algorithm incorporated into the master control PLC.
of a multi-blower installation from a single Outlet pressure control (Fig.1)
process variable.Overall plant efficiency This signal is compared with the set point of the PC
The pressure is kept constant in the discharge
(manual or remotely adjustable) and any resultant
is maximised with the Howden Donkin manifold. Air is supplied through CONTROL
deviation signal is fed to the master control system
load sharing system' control philosophy. VALVES (V), which are controlled by the
algorithm. In turn this signal adjusts the position
process control system.
of the control system of individual blowers and
Pressure transmitter (PT) measures the supply ultimately stops/starts blowers as dictated by the
The Howden Donkin master control systems pressure to valves (V) and sends a 4-20 m.a. signal DT output signal.
are designed to control automatically, multiple to the PROCESS CONTROLLER (PC) within the
blower installations from a SINGLE process control MASTER CONTROL SYSTEM. This CONTROLLER TYPICAL MULTI BLOWER FLOW:
signal and to:- output signal then adjusts the compressor control Pressure system (Fig.3)
systems and also decides when individual
a) Allow the minimum number of operating Head
compressors should be started or stopped. (mWC)
Total head
blowers to satisfy demand for air. 14.0
12.0 Fouled diffusers
Pipe system (P)
b) Share the total load equally between the Process/flow control (Fig.2) 10.0
8.0
number of operational blowers to:- A direct FLOW CONTROL system is used in sewage 6.0
4.0
1 Compressor 2 Compressors 3 Compressors Submerge
pressure
in operation in operation in operation
achieve maximum overall efficiency; treatment aeration systems. As the quantity and 2.0
0.0
quality of effluent into the secondary aeration 50 100 150 200 250 300 Flow %
ensure all blowers have equal operating
zones varies, there is a need to vary the air flow
times and loads.
to achieve the desired final water discharge quality.
Alternatively the local control panel can be The signals from dissolved oxygen probes are taken
configured to provide a masterless control system. to transmitter (DT) which gives a 4-20 m.a signal
NOTE: The pressure loss (P in Fig. 3 ) through the pipework between blowers and varies with air flow rate. The HOWDEN
DONKIN MCP adjusts, AUTOMATICALLY, the outlet pressure set point to MINIMISE OUTLET PRESSURE and, therefore,
MINIMISE POWER ABSORBED.
10
COMPRESSOR RANGES
HOWDEN DONKIN SG RANGE OF CENTRIFUGAL AIR BLOWERS
MACHINE SIZE
26 30 35 40 45 52 60
70
1.5
80
PRESSURE RISE (BARS)
92
105
1.0
3000
2600
2200 2400
2000
1800
1600
0.5 1400
1200
1000
100 200 300 400 600 800
kW ABSORBED AT GEARBOX INPUT
0
0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40
1.6
613
729
473
355
310
10
613
729
473
355
310
1.4
Differential pressure BAR
9
1.2
8
DIFFERENTIAL PRESSURE BAR
1
944
1795
1454
1995
1223
7
3 Stages 0.8
6 6000kW
0.6 5000kW
4000kW
5
613
729
473
355
310
0.4 3000kW
200kW
300kW 2000kW
4 0.2
1500kW
400kW 600kW 800kW 1000kW
3 2 Stages 0
0 20 40 60 80 100 120
Flow m3/s
2
Single Stage
1
0
0 20 40 60 80 100 120
FLOW ( m3/s)
NOTE: Charts for use with inlet air density of 1.2 Kg/m3 (dry air at 15C and 1 atmosphere pressure).
For duties not covered by this chart please contact Howden Process Compressors.
11 HOWDEN PROCESS COMPRESSORS
Typical spares:
Bearings
Labyrinth seals
Bearing oil seals
13
ENVIRONMENTAL AND
INDUSTRIAL APPLICATIONS
Howdens broad experience covers the supply, not only of turbo compressors
but also of centrifugal fans, rotary screw and Roots positive displacement machines
for almost all industrial zones. Equipment is operational in over 40 countries on
6 continents for environmental, chemical, petrochemical, steel metal refining and
general industrial applications.
Howden Process Compressors Howden Hua Howden Ventiladores Ltda. Howden Turbowerke
Old Govan Road Suite 14A01 Jinyu Mansion Rua Dr. Sodr, 122 2 andar Naundorfer Strasse 4
Renfrew PA 4 8XJ 129A Xuanwumen Xidajie Vila Olimpia 04535 - 110 D - 01640 Coswig
United Kingdom Xicheng District, Beijing 100031 China Sao Paulo, Brazil Germany
Telephone: +44 141 304 3500 Telephone: +86 10 66419988 Telephone: +55 11 3089 0040 Telephone: +49 35 23 940
Email: [email protected] Email: [email protected] Email: [email protected] Email: [email protected]
Email: [email protected]