Disclosed embodiments relate generally to the field of turbomachinery, and, more particularly, to a rotor structure for a turbomachine, such as a compressor, and method for arranging the rotor structure
Turbomachinery is used extensively in the oil and gas industry, such as for performing compression of a process fluid, conversion of thermal energy into mechanical energy, fluid liquefaction, etc. One example of such turbomachinery is a compressor, such as a centrifugal compressor.
Aspects of disclosed embodiments are directed to a rotor structure in a compressor. The rotor structure includes a tie bolt and two rotor shafts respectively affixed to respective ends of the tie bolt. A plurality of impeller bodies is supported by the tie bolt. A plurality of hirth couplings is used to mechanically couple the plurality of impeller bodies to one another along the rotor axis. A first impeller body of the plurality of impeller bodies is arranged to provide a first stage of compression, and each subsequent impeller body provides a subsequent stage of compression. Each respective impeller body defines a respective Di/D2 ratio. The Di/D2 ratio of at least one of the impeller bodies is different than the Di/D2 ratio of the remaining impeller bodies. Based on the different Di/D2 ratio, respective surfaces defined by the inlet of such impeller body are located at a different distance relative to the rotor axis compared to location of respective surfaces defined by the respective inlets of the remaining impeller bodies. Di is indicative of a respective inner diameter of a flow path into an inlet of a respective impeller body, and D2 is indicative of respective outer diameter of the respective impeller body.
In certain embodiments, a variation of the rotor structure along the rotor axis is based on a variation of respective Di/D2 ratios of one or more impeller bodies of the plurality of impeller bodies. The variation of the rotor structure along the rotor axis may involve locating the respective surfaces defined by the respective inlets of the one or more impeller bodies at a varying distance relative to the rotor axis. The location of the respective surfaces defined by the respective inlets of the one or more impeller bodies at the varying distance relative to the rotor axis is arranged to reduce or otherwise lower the inlet Mach number in the compressions stages by the one or more impeller bodies and adjust rotor stiffness along the rotor axis.
In certain embodiments, at least one spring biasing mechanism arranged to adjust radial stiffness at a respective location of the tie bolt. The respective location where the at least one spring biasing mechanism is arranged may be at or proximate the midspan section of the tie bolt.
In certain embodiments, a multi-nut-retaining arrangement may be involved. The multi-nut-retaining arrangement may be made up of at least two retaining nuts having a different diameter with respect to one another. The different diameter of the at least two retaining nuts is effective for configuring a radially-outward perimeter having a multi-step configuration in a respective rotor shaft of the two rotor shafts.
The multi-step configuration at the radially-outward perimeter of the respective rotor shaft defines a number of axially-extending segments in the respective rotor shaft, each of the axially-extending segments having a different diameter with respect to one another.
Further aspects of disclosed embodiments may be directed to a method for arranging a rotor structure of a compressor. The rotor structure includes a tie bolt and two rotor shafts respectively affixed to respective ends of the tie bolt. A plurality of impeller bodies is supported by the tie bolt. A plurality of hirth couplings is used to mechanically couple the plurality of impeller bodies to one another along the rotor axis. A first impeller body of the plurality of impeller bodies is arranged to provide a first stage of compression, and each subsequent impeller body provides a subsequent stage of compression. The rotor structure includes a tie bolt and two rotor shafts respectively affixed to respective ends of the tie bolt. A plurality of impeller bodies is supported by the tie bolt. The method allows arranging a first impeller body of the plurality of impeller bodies to provide a first stage of compression, and further allows arranging each subsequent impeller body to provide a subsequent stage of compression. Each respective impeller body defines a respective Di/D2 ratio. The Di/D2 ratio of at least one of the impeller bodies is different than the Di/D2 ratio of the remaining impeller bodies. Based on the different Di/D2 ratio, respective surfaces defined by the inlet of said impeller body are located at a different distance relative to the rotor axis compared to location of respective surfaces defined by the respective inlets of the remaining impeller bodies. Di is indicative of a respective inner diameter of a flow path into an inlet of a respective impeller body, and D2 is indicative of respective outer diameter of the respective impeller body.
In certain embodiments, the method allows arranging a variation of the rotor structure along the rotor axis based on variation of respective Di/D2 ratios of one or more of impeller bodies of the plurality of impeller bodies. The variation of the rotor structure along the rotor axis may involve locating the respective surfaces defined by the respective inlets of the one or more impeller bodies at a varying distance relative to the rotor axis. The locating of the respective surfaces defined by the respective inlets of the one or more impeller bodies at the varying distance relative to the rotor axis is arranged to reduce inlet Mach number in the compressions stages by the one or more impeller bodies and adjust rotor stiffness along the rotor axis.
As would be appreciated by those skilled in the art, turbomachinery, such as centrifugal compressors, may involve rotors of tie bolt construction (also referred to in the art as thru bolt or tie rod construction), where the tie bolt supports a plurality of impeller bodies and where adjacent impeller bodies may be interconnected to one another by way of elastically averaged coupling techniques, such as involving hirth couplings or curvic couplings. These coupling types use different forms of face gear teeth (straight and curved, respectively) to form a robust coupling between two components. These couplings and associated structures may be subject to greatly varying forces (e.g., centrifugal forces), such as from an initial rotor speed of zero revolutions per minute (RPM) to a maximum rotor speed, (e.g., as may involve tens of thousands of RPM).
The present inventors have recognized that attaining high performance and reliable operation in a centrifugal compressor may involve appropriately harmonizing or otherwise balancing the interaction of potentially conflicting design criteria, such as may involve rotordynamics and aerodynamics. Accordingly, disclosed embodiments benefit from an integrated approach conducive to harmonizing potentially conflicting design considerations, such as involving location of the flow passages (i.e., aerodynamics) and rotor stiffness (i.e., rotordynamics) in a centrifugal compressor.
The present inventors have further recognized that a compressor design that appropriately reduces the relative Mach-number at the inlet of a given impeller may be effective to achieve a desired efficiency over the useful flow range of the compressor (e.g., satisfactory aerodynamics performance from a minimum fluid flow to a maximum fluid flow). This low Mach-number design may involve a reduced Di/D2 ratio, where Di is indicative of a respective inner diameter of a flow path into the inlet of a respective impeller, and D2 is indicative of a respective outer diameter of the respective impeller. A reduced Di/D2 ratio permits locating the impeller's inlet area at a shorter distance relative to the rotor axis and this is beneficial from an aerodynamics perspective. However, such a low Mach-number design may entail a reduced rotor stiffness, such as, at least in part, due to the incrementally thinner structures that may be associated with a reduced size of Di.
Disclosed embodiments reliably and cost-effectively harmonize aerodynamics and rotordynamics by permitting sufficiently low inlet relative Mach numbers while maintaining sufficiently high rotor stiffness. A reduced Di/D2 ratio essentially allows “sinking” the aero flow path onto the rotor, which may be particularly beneficial at the first stage of compression in view of the challenging aerodynamics requirements typically encountered at the first stage of compression.
Disclosed embodiments can additionally accommodate respectively varying Di/D2 ratios for the respective stages of compression disposed along the rotor axis downstream from the first stage of compression. These respectively varying Di/D2 ratios may be tailored to harmonize aerodynamics and rotordynamics at each of such stages in an integrated and cohesive way. That is, a designer has the flexibility to make appropriate tradeoffs in disclosed embodiments to satisfactorily meet aerodynamics and rotordynamics requirements using a balancing approach.
In the following detailed description, various specific details are set forth in order to provide a thorough understanding of such embodiments. However, those skilled in the art will understand that disclosed embodiments may be practiced without these specific details, that the aspects of the present invention are not limited to the disclosed embodiments, and that aspects of the present invention may be practiced in a variety of alternative embodiments. In other instances, methods, procedures, and components, which would be well-understood by one skilled in the art have not been described in detail to avoid unnecessary and burdensome explanation.
Furthermore, various operations may be described as multiple discrete steps performed in a manner that is helpful for understanding embodiments of the present invention. However, the order of description should not be construed as to imply that these operations need be performed in the order they are presented, nor that they are even order dependent, unless otherwise indicated. Moreover, repeated usage of the phrase “in one embodiment” does not necessarily refer to the same embodiment, although it may. It is noted that disclosed embodiments need not be construed as mutually exclusive embodiments, since aspects of such disclosed embodiments may be appropriately combined by one skilled in the art depending on the needs of a given application.
In one disclosed embodiment, a tie bolt 102 extends along a rotor axis 103 between a first end and a second end of the tie bolt 102. A first rotor shaft 1041 may be fixed to the first end of tie bolt 102. A second rotor shaft 1042 may be fixed to the second end of tie bolt 102. Rotor shafts 1041, 1042 may be referred to in the art as stubs shafts. A plurality of impeller bodies 106, such as impeller bodies 1061 through 106n, may be disposed between rotor shafts 1041, 1042. In the illustrated embodiment, the number of impeller bodies is six and thus n=6; it will be appreciated that this is just one example and should not be construed in a limiting sense regarding the number of impeller bodies that may be used in disclosed embodiments. The embodiment illustrated in
The plurality of impeller bodies 106 is supported by tie bolt 102 and is mechanically coupled to one another along the rotor axis by way of a plurality of hirth couplings, such as hirth couplings 1081 through 108n-1. In the illustrated embodiment, since as noted above, the number of impeller bodies is six, then the number of hirth couplings would be five. It will be appreciated that two additional hirth couplings 1091 and 1092 may be used to respectively mechanically couple the impeller bodies 106n, 1061 respectively proximate to the first and second ends of tie bolt 102 to rotor shafts 1041, 1042.
As indicated in block 123, each respective impeller body defines a respective Di/D2 ratio. As indicated in block 124, the Di/D2 ratio of at least one of the impeller bodies is different than the Di/D2 ratio of the remaining impeller bodies. As indicated in block 125, based on the different Di/D2 ratio, respective surfaces defined by the inlet of the at least one of the impeller bodies may be located at a different distance relative to the rotor axis compared to the location of respective surfaces defined by the respective inlets of the remaining impeller bodies. As can be appreciated in
A reduced Di/D2 ratio permits locating the impeller's inlet area at a shorter distance relative to the rotor axis. Do is indicative of the outer diameter of the flow path into the inlet 110 of the respective impeller body 106. It will be appreciated that an adjustment in Di—to locate the inlet area at a desired location—can lead to an adjustment in Do.
Returning to
Based on the respective ratios Di/D2 selected for the one or more impeller bodies, step 136 allows varying the rotor structure along the rotor axis to improve rotordynamics while meeting respective varying aerodynamics requirements at respective compression stages by the one or more of impeller bodies. As noted in block 138, the varying of the rotor structure along the rotor axis while meeting respective varying aerodynamics requirements at respective compression stages by the one or more of impeller bodies, is effective for harmonizing the compressor aerodynamics and the rotordynamics of the rotor structure.
In one non-limiting embodiment, a respective range of ratio Di/D2 may vary from a value of 0.2 (or approximately 0.2) to a value of 0.65 (or approximately 0.65). In another non-limiting embodiment, a respective range of ratio Di/D2 may vary from a value of 0.25 (or approximately 0.25) to a value of 0.5 (or approximately 0.50). That is, the respective Di/D2 ratios defined by the respective impeller bodies can take any value within the foregoing ranges.
In one non-limiting embodiment, the variation of the rotor structure along the rotor axis may comprise locating respective surfaces defined by respective inlets of the one or more impellers at a selectively varying distance relative to the rotor axis based on the respective Di/D2 ratios selected for the one or more of impeller bodies. The foregoing allows improving rotordynamics while satisfactorily meeting the respective varying aerodynamics requirements at the respective compression stages by the impeller bodies.
It can be shown that the natural vibration frequency of a rotating body is determined by the square root of the ratio of stiffness to mass of the body. Thus, the increased radial stiffness provided by tolerance ring 154 is effective to reduce a possibility that the natural vibration frequency in a disclosed rotor structure would fall within the range of rotational speeds of the rotor, which, as would be appreciated by those skilled in the art, is a benefit to the rotordynamics of the rotor structure.
In one non-limiting embodiment, a groove 152 may be defined at a radially-inner surface of impeller body 1063 (i.e., the impeller body disposed at the midspan of the tie bolt) to accommodate wave or corrugation features in tolerance ring 154. As may be better appreciated in
It will be further appreciated that regardless of the modality, the spring biasing mechanism need not be limited to a singular spring biasing mechanism disposed at the midspan section of the tie bolt 102 since multiple spring biasing mechanism could be effectively used to provide radial stiffness at multiple locations of the tie bolt 102. For example, in certain alternative embodiments, without limitation, two spring biasing mechanism (e.g., two tolerance rings 154) may be disposed each at approximately ⅓ of the tie bolt length. Accordingly, it will be appreciated that the arrangement illustrated above should be construed as one non-limiting example for adjusting radial stiffness at one or more locations of tie bolt 102.
Further non-limiting examples of modalities of spring biasing mechanisms that may be used may include a wave spring, a C-shaped spring, a segmented O-ring, a spring energized segmented O-ring, a leaf spring, etc. It will be appreciated that any of such spring biasing mechanisms may be made-up of open or gapped structures that, for example, can permit fluid communication between neighboring chambers (e.g., internal chambers sharing boundaries with tolerance ring 154) and this reduces the possibility of pressure differentials that otherwise could develop between such chambers if a gasket-type of element, such as a monolithic O-ring, was used in lieu of an open structure. Without limitation, depending on the mechanical design of the rotor structure and the spring biasing mechanism, in certain embodiments, pressure equalizing vent paths may be disposed around the spring biasing mechanism.
Without limitation, the multi-nut-retaining arrangement may further involve a second nut 162 having a smaller diameter relative to the diameter of main nut 160. Without limitation, second nut 162 may provide a further threaded-connection with respect to tie bolt 102 and includes an axial face abutting against a corresponding axial face (e.g., at a proximate end 164) of rotor shaft 1042 and in effect retains a distal end 166 (opposite the proximate end 164) of rotor shaft 1042 against first impeller body 1061.
As schematically represented by twin-headed arrows labeled S1 through S5, the multi-nut-retaining arrangement (e.g., involving at least two nuts) comprising different diameter sizes is effective to configure rotor shaft 1042 with a radially-outward perimeter having a multi-step configuration along rotor axis 103. This allows reducing the respective diameters of a number of axially-extending segments in rotor shaft 1042 (for the sake of avoiding visual cluttering, just two of such segments are schematically indicated in
The foregoing arrangement in turn allows reducing respective diameters of journal bearings, thrust bearings and gas seals (e.g., part of a dry fluid seal system) respectively in correspondence with the axially-extending segments in rotor shaft 1042. This diameter reduction is effective for attaining respective reductions in sliding speeds between moving components in the journal bearings, thrust bearings and gas seals, which is a feature conducive to superior durability and reliability of the foregoing components.
In operation, disclosed embodiments can make use of structural and/or operational relationships (e.g., adjusting respective Di/D2 ratios of the impellers) designed to harmonize potentially conflicting design considerations, such as involving the flow passages (i.e., aerodynamics) and rotor stiffness (i.e., rotordynamics) in a centrifugal compressor. Additionally, in operation disclosed embodiments can accommodate in a given rotor structure respectively varying Di/D2 ratios tailored to harmonize aerodynamics and rotordynamics at each of the compression stages in an integrated and cohesive way.
In operation, disclosed embodiments can make use of one or more spring biasing mechanisms arranged to adjust radial stiffness at respective locations of the tie bolt, which is a feature effective to reduce a possibility that the natural vibration frequency in a disclosed rotor structure would fall within the range of rotational speeds of the rotor.
In operation, disclosed embodiments can make use of a multi-nut-retaining arrangement for implementing in a rotor shaft a radially-outward perimeter with a multi-step configuration. This feature allows reducing the respective diameters of a number of axially-extending segments in the rotor shaft and in turn allows reducing respective diameters of journal bearings, thrust bearings and gas seals in correspondence with the axially-extending segments in the rotor shaft. Without limitation, this diameter reduction is effective for attaining respective reductions in sliding speeds between moving components in the journal bearings, thrust bearings and gas seals.
While embodiments of the present disclosure have been disclosed in exemplary forms, it will be apparent to those skilled in the art that many modifications, additions, and deletions can be made therein without departing from the scope of the invention and its equivalents, as set forth in the following claims.
Filing Document | Filing Date | Country | Kind |
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PCT/US2020/032830 | 5/14/2020 | WO |
Publishing Document | Publishing Date | Country | Kind |
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WO2021/230869 | 11/18/2021 | WO | A |
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Entry |
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International Search Report and Written Opinion of the International Searching Authority dated Jan. 26, 2021 corresponding to PCT Application No. PCT/US2020/032830 filed May 14, 2020. |
Number | Date | Country | |
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20230175513 A1 | Jun 2023 | US |