Volume 03 Issue 10-2023
324
International Journal of Advance Scientific Research
(ISSN
–
2750-1396)
VOLUME
03
ISSUE
10
Pages:
324-331
SJIF
I
MPACT
FACTOR
(2021:
5.478
)
(2022:
5.636
)
(2023:
6.741
)
OCLC
–
1368736135
A
BSTRACT
The paper deals with the issues of testing of centrifugal compressor casings for strength and density. Based
on the literature review of theoretical analyses of previously developed test benches at the compressor
engineering and manufacturing company “Kazankompressormash” and their shortcomings identified, a
modernization of the density test bench was carried out. For more efficient testing on the new modernized
test bench, a notional layout of the site was designed. Presented a brief description of the new test bench
and justified its operational safety and productivity. Provided are conclusions on the application of the
conditional site layout and on test methodology.
K
EYWORDS
Centrifugal compressor, casing, bench, strength, density, fluid.
Journal
Website:
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Research Article
STRENGTH AND DENSITY (TIGHTNESS) TEST OF
CENTRIFUGAL COMPRESSOR CASING
Submission Date:
October 20, 2023,
Accepted Date:
October 25, 2023,
Published Date:
October 30, 2023
Crossref doi:
https://doi.org/10.37547/ijasr-03-10-50
Karimov Shavkat
Tashkent State Technical University Named After Islam Karimov, Republic Of Uzbekistan, Tashkent,
Universitet 2 Street, Phd Of Technical Sciences And Head Of Department “Machines And Equipment Of The
Oil And Gas Industry And Pipeline Transport Systems”
, Uzbekistan
Gafforov Humoyun
Tashkent State Technical University Named After Islam Karimov, Republic Of Uzbekistan, Tashkent,
Universitet 2 Street, Assistant Of Department “Machines And Equipment Of The Oil And Gas Industry And
Pipeline Transport Systems”
, Uzbekistan
Sadikov Abdujamil
Tashkent State Technical University Named After Islam Karimov, Republic Of Uzbekistan, Tashkent,
Universitet 2 Street, Professor Of Department “Machines And Equipment Of The Oil And Gas Industry And
Pipeline Transport Systems”
, Uzbekistan
Volume 03 Issue 10-2023
325
International Journal of Advance Scientific Research
(ISSN
–
2750-1396)
VOLUME
03
ISSUE
10
Pages:
324-331
SJIF
I
MPACT
FACTOR
(2021:
5.478
)
(2022:
5.636
)
(2023:
6.741
)
OCLC
–
1368736135
I
NTRODUCTION
As it is known, centrifugal compressor machines
are widely used in chemical, oil, gas and many
other industries. The relevance of the study lies in
the fact that the use of centrifugal machines in
production cycles of increased danger makes
significant demands on the reliability of their
casings. The housing must be fully hermetically
sealed and withstand the stated characteristics.
Otherwise, the housings of high-pressure
machines represent a potential hazard that can
lead to severe consequences under certain
conditions. For example, loss of tightness is often
accompanied by explosion and fire. Thus,
operating personnel can receive thermal burns, if
the
depressurized
compressor
contained
corrosive gases, there is a risk of poisoning of
personnel. It is therefore essential for the safety
of the personnel operating the compressor that
the compressor remains hermetically sealed
during operation.
а) b)
Figure 1. a) The figure is showing the schematic
drawing of the bench under the code №7029
-
6433 for pneumatic tests, which was developed
and operated at the manufacturing company
"Kazancompressormash" and contains the
following elements: 1,3,7 - pipeline; 2 - ball valve;
4,8 - casing; 5 - pressure gauge (MO-11203 0-100
kgf/cm2); 6 - air reducer RV-90; 9 - metal hose
(D4.498094-2-6-350-2,5); 10 - frame. b) The
figure is presenting the pneumatic principle
diagram of the bench with designations such as K-
ball valve, M-pressure gauge, P-air reducer.
Brief conclusions. Identification of shortcomings
and statement of task.
- There are no safety valves in the div 8, which
is located up to the supply line, i.e. up to the hose
9 and located under the second pressure gauge on
the left side;
- The pressure reducer is mounted on the same
housing as the meter and supply line, making
them difficult to service;
Volume 03 Issue 10-2023
326
International Journal of Advance Scientific Research
(ISSN
–
2750-1396)
VOLUME
03
ISSUE
10
Pages:
324-331
SJIF
I
MPACT
FACTOR
(2021:
5.478
)
(2022:
5.636
)
(2023:
6.741
)
OCLC
–
1368736135
- According to the circuit diagram it can be seen
that there is no separate line for depressurization
after the end of the test;
- The test product is connected by means of a
metal hose to a housing that is connected to the
second control gauge, which adversely affects the
performance and reliability of the instrument;
- In accordance with Fig. 1 (a), this design is not
suitable from the point of view of safety for the
operating personnel, since the test bench must be
located outside the test area.
- The bench does not provide a reference
timeclock to measure time during testing,
resulting in lost time for operators.
In addition, it is recommended to design a
conditionally optimal site layout for a more
efficient operation of the bench.
Description of the modernized bench.
a)
b)
C)
Figure 2. a) The figure is demonstrating the
modernized pneumatic test bench and contains
the following elements:
1- pressure gauge (MO-11203 0-100 kgf/cm2); 2
- ramp; 3 - viewing glass; 4 - casing; 5 - air reducer
RV-90; 6
–
ball valve (YGT 10SH.100.00.01.NJ2); 7
- feed line; 8 - reset line; 9 - metal hose
Volume 03 Issue 10-2023
327
International Journal of Advance Scientific Research
(ISSN
–
2750-1396)
VOLUME
03
ISSUE
10
Pages:
324-331
SJIF
I
MPACT
FACTOR
(2021:
5.478
)
(2022:
5.636
)
(2023:
6.741
)
OCLC
–
1368736135
(D4.498094-2-6-350-2,5); 10 - pipeline; 11-
Electronic table clock Quartz -2 C.
b) 3D model of the developed bench, except for
the ball valve.
The pneumatic test bench contains a protective
wall made of 16 mm thick steel sheet, on which a
frame is fixed on the front side with bolts and
nuts, and a sight glass is placed inside the frame.
On the rear side to the protective wall is welded
frame, and to the frame of the div, for the
installation of instrumentation such as two
pressure gauges and pressure reducer. To
connect the system with each other, 8 mm
diameter stainless steel pipelines are used, and a
high-pressure metal hose is used to connect the
system with the test object. For gas supply and
discharge, ball valves are used, which are parallel
fixed on the rear surface of the protective wall by
means of clamps. The test bench also has an
electronic clock with a remote control for more
accurate and efficient testing.
c) The figure is presenting the pneumatic principle diagram of the new bench.
Designation
Product Title
Quantity
Remark
V1, V2
Ball valve (YGT 10SH.100.00.01.NJ2)
2
Purchased
PG1, PG2
Pressure gauge (MO-11203 0-100
kgf/cm
2
)
2
R
Air reducer RV-90
1
RV1
Relief valve GA 81806 121 3 DN 6 P=5
kgf/cm
2
1
RV2
Relief valve GA 81806 121 3 DN 6 P=20
kgf/cm
2
1
RV3
Relief valve GA 81806 121 3 DN 6 P=32
kgf/cm
2
1
RV4
Relief valve GA 81806 121 3 DN 6 P=50
kgf/cm
2
1
The test bench allows testing products with air pressure of 50 atm. Due to the use of a high-precision
pressure regulator, the equipment allows for precise adjustment of the actuation pressure. Housing
elements of the stand are made of stainless steel.
Volume 03 Issue 10-2023
328
International Journal of Advance Scientific Research
(ISSN
–
2750-1396)
VOLUME
03
ISSUE
10
Pages:
324-331
SJIF
I
MPACT
FACTOR
(2021:
5.478
)
(2022:
5.636
)
(2023:
6.741
)
OCLC
–
1368736135
Figure 3. The figure below shows the layout of the site for a more efficient booth operation.
The pneumatic test section consists of two test
boxes. The first box contains the pneumatic test
bench (1) itself, a bath (3) with overall
dimensions of 3 by 3.5 meters, a crane (4) with a
lifting capacity of 5 tons and racks (5) for storing
plugs and fixtures. The walls of the first box are
made of steel plates, which are welded to support
pipes.
The second box, in its turn, consists of a
monoblock base, which is designed for two
compressors (6,7), and one of the compressors is
used to supply pressure to the stand, and the
second one as a backup. Also on the doors of the
boxes there are signs (2) with the inscriptions
"entry prohibited high pressure".
Volume 03 Issue 10-2023
329
International Journal of Advance Scientific Research
(ISSN
–
2750-1396)
VOLUME
03
ISSUE
10
Pages:
324-331
SJIF
I
MPACT
FACTOR
(2021:
5.478
)
(2022:
5.636
)
(2023:
6.741
)
OCLC
–
1368736135
Figure 4. This figure below shows a schematic
drawing of the casing of centrifugal compressor
(4GC2-115).
This case from the compressor of the vertical
connector respectively on both sides has covers
and they are as you can see plugged with special
plugs in the form of a mushroom. The four div
flanges are fitted with process plugs, fasteners
and process gaskets as required by the process.
The two upper plugs have one M20x1.5 threaded
hole each for gas supply and pressure gauge
installation. And a pressure gauge with
appropriate pressure measuring limits is
installed there as well. The casing also has four
small holes at the bottom for condensate drainage
and these should also be plugged. Then the case is
immersed in bath water and the fitting of the plug
is connected from the tested housing to the bench
and depending on the test pressure, we supply
pressurized air with the help of a compressor. As
it has noticed the tightness of the casing is
checked by bubble method.
C
ONCLUSION
In this article a pneumatic bench for density
testing of centrifugal compressor casings with
specified parameters is considered and
developed:
Working gas for testing
–
Air;
The highest permissible pressure
–
8.825 MPa.
The following was implemented:
1) Based on the identified deficiencies, the design
of the pneumatic stand was modernized;
2) Assembly and detail drawings of the pneumatic
bench, frame, individual pipework for each line,
instrument housings, adjusting handles, as well as
drawings of parts such as clamping bracket,
fitting and sight glass were developed.
3) A data sheet for the modernized test bench was
compiled.
4) The procedure and methodology of initial
certification,
requirements
for
testing,
requirements for the test bench and test site,
preparation of assemblies for hydraulic testing
and the procedure for testing were developed.
The casing of the 4GC2-115 centrifugal
compressor contains a shell with two inlet and
outlet ports welded to it, located on different
sides to the longitudinal axis of the casing. The
disadvantage of such a housing is the presence of
welded joints, which at high flow rates and
pressures cannot provide reliability and
durability of the structure. The study of strength
and density of the casing by the method of
hydraulic tests on the developed stand showed
that the greatest stresses occur exactly in the
places of welding of the cylinder with the inlet and
outlet nozzles.
Volume 03 Issue 10-2023
330
International Journal of Advance Scientific Research
(ISSN
–
2750-1396)
VOLUME
03
ISSUE
10
Pages:
324-331
SJIF
I
MPACT
FACTOR
(2021:
5.478
)
(2022:
5.636
)
(2023:
6.741
)
OCLC
–
1368736135
Figure 5. This figure above shows a forged steel casing with openings for compressor inlet and
outlet connections.
It is recommended to make the case from steel
forgings with holes for inlet and outlet spigots of
the compressor, in which the end planes of inlet
and outlet spigots will be formed for fixing the
mating flanges of inlet and outlet pipelines. The
disadvantage of the specified solution is the
presence of significant pressure losses, leading to
a decrease in the efficiency of the compressor, and
high metal intensity.
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Shnepp, V. B. Design and calculation of
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Volume 03 Issue 10-2023
331
International Journal of Advance Scientific Research
(ISSN
–
2750-1396)
VOLUME
03
ISSUE
10
Pages:
324-331
SJIF
I
MPACT
FACTOR
(2021:
5.478
)
(2022:
5.636
)
(2023:
6.741
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OCLC
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1368736135
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