Compressor Rotor Shaft

Name: Compressor Rotor Shaft for High-Stress Rotating Systems – Frigate
Price: 249.00 USD
Availability: InStock

Compressor Rotor Shaft must sustain continuous torsional cycling under varying speeds and load conditions, especially in multistage centrifugal and axial compressors. Failure often originates from stress concentration zones due to insufficient shaft geometry or sub-optimal fillet transitions. To eliminate such issues, the Compressor Rotor Shaft is designed with precision-profiled fillets, optimized shaft diameters, and fatigue-resistant materials with high torsional modulus. These parameters ensure resistance to crack initiation in zones of torque reversal, even during surge or trip events.

Material Grade & Specification

AISI 4140 Alloy Steel (or equivalent), API Spec 617, ASTM A182 F22 (for high strength)

Dimensional Tolerances

±0.005 inches (±0.13 mm) for critical dimensions, ±0.002 inches (±0.05 mm) for shaft OD and ID

Surface Finish Requirement

Ra ≤ 1.6 µm (63 µin) for sealing surfaces, Ra ≤ 3.2 µm (125 µin) for non-critical areas

Heat Treatment Specification

Quenching and Tempering (QT) to 28-32 HRC (Hardness) for enhanced fatigue resistance and strength

Concentricity Requirement

≤ 0.001 inches (0.025 mm) for critical concentricity of the shaft bore and outer diameter

Product Description

Compressor Rotor Shaft exposed to high-temperature gradients undergoes axial elongation and bending, which can distort the shaft centerline and lead to seal face misalignment. Controlled thermal expansion properties are critical for preventing thermal bowing. The Compressor Rotor Shaft is manufactured using alloys with low thermal expansion coefficients and undergoes thermal gradient simulation to ensure minimal axial and radial distortion during thermal transients, especially in compressors handling superheated steam or hot gas mixtures.

Shaft Alignment Tolerances

≤ 0.002 inches (0.05 mm) for alignment tolerances to ensure proper rotor performance

Hardness Requirement

28-32 HRC (after heat treatment) for optimal wear resistance and fatigue strength

Non-Destructive Testing (NDT) Requirement

Ultrasonic Testing (UT), Magnetic Particle Testing (MT), Dye Penetrant Testing (DPT) as per API standards

Vibration and Balance Testing Requirement

Dynamic balancing to ISO 1940 Grade 6.3 or per custom specifications for minimal vibration

Certification Standard

API Spec 617, ISO 9001:2015, PED (Pressure Equipment Directive), ATEX (if required)

Technical Advantages

Rotor imbalance caused by axial misalignment or out-of-roundness directly affects compressor performance and bearing life. The Compressor Rotor Shaft is finished to sub-10 micron runout tolerances with critical surface zones ground to high roundness and coaxiality standards. This ensures stable operation at high RPMs and minimizes unbalance excitation forces transmitted to impellers and bearing housings, particularly in applications where shaft speed exceeds 10,000 RPM.

Compressor Rotor Shaft operating in offshore or sour service must withstand corrosion fatigue, pitting, and sulfide stress cracking. Use of duplex stainless steels, Cr-Mo alloys, and custom superalloy grades is tailored based on process fluid composition and NACE MR0175/ISO 15156 compliance. The Compressor Rotor Shaft undergoes full microstructural evaluation post-heat treatment to validate phase stability and resistance to chloride-induced cracking, supporting reliable operation in acid gas or wet CO₂ environments.

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Industry Applications

Petrochemical Gas Compressors

Handles high-pressure hydrogen and hydrocarbon gases in axial or centrifugal compressors operating under continuous duty and elevated thermal gradients.

Refinery Recycle Compressors

Transfers cracked gas streams through multistage compressors requiring tight rotor balancing and high resistance to corrosion and thermal distortion.

Natural Gas Pipeline Boosters

Used in high-speed centrifugal compressors for gas transmission systems requiring precise shaft alignment and long operational life cycles.

Offshore Platform Compressors

Supports sour gas compression in marine environments with high chloride exposure, demanding sulfide stress cracking resistance and corrosion-resistant metallurgy.

Cryogenic Air Separation Units

Operates in low-temperature oxygen and nitrogen compressors, requiring dimensional stability of the rotor shaft at sub-zero operating conditions.

Ammonia and Urea Plant Compressors

Withstands high axial thrust and dynamic loads in synthesis gas compressors subjected to chemically aggressive and high-temperature process streams.

Residual Stress Optimization

Excess residual stresses within the Compressor Rotor Shaft are a primary cause of fatigue failure, especially at change-of-section regions. Advanced stress-relief heat treatments combined with CNC-controlled finish machining sequences reduce tensile stress peaks. Shot peening and subcritical tempering processes are employed based on shaft diameter and length to minimize distortion. This enables the Compressor Rotor Shaft to maintain dimensional integrity across full pressure-temperature cycles without inducing internal stress fractures.

Shaft-to-impeller and shaft-to-coupling interfaces are often overlooked yet are essential for rotor stability. The Compressor Rotor Shaft is machined to precise interference fits or custom taper geometries with controlled microfinish on mating surfaces. Axial alignment and torque coupling are verified through 3D metrology and fit-check simulations to ensure interface reliability under dynamic loading. This is especially critical where torsional oscillations are transmitted through spline or keyed joints in gear-driven compressor trains.

Having Doubts? Our FAQ

Check all our Frequently Asked Question

How does Frigate ensure concentricity across long Compressor Rotor Shafts?

Frigate uses CNC turning centers with live tool support and steady-rest positioning for controlled concentric machining. Shaft journals and impeller seats are machined in a single setup to minimize axis deviation. CMMs validate runout and concentricity to within ±5 microns. This ensures minimal vibration in high-speed compressor assemblies.

What quality checks does Frigate perform on forged Compressor Rotor Shafts before final machining?

Frigate conducts ultrasonic testing to detect internal voids, inclusions, or delaminations in the forged shaft blanks. Magnetic particle inspection is done on fillet zones to check for surface cracks. Hardness is mapped across longitudinal and radial sections for uniformity. Grain flow orientation is also verified post-forging to confirm axial alignment.

How does Frigate address rotor dynamic behavior in critical-speed-sensitive applications?

Frigate performs rotor dynamic analysis using FEA tools to identify natural frequencies and critical speed separation margins. The Compressor Rotor Shaft’s stiffness and mass distribution are adjusted to push critical speeds beyond operational RPM. Shaft geometry is iteratively tuned based on modal analysis. This prevents resonance-induced failures in multi-stage compressors.

What surface treatments does Frigate apply to reduce wear on Compressor Rotor Shaft contact areas?

Frigate applies nitriding or HVOF (High Velocity Oxy Fuel) coatings on journal and coupling regions depending on wear requirements. Surface hardness is increased without affecting core ductility. Coated areas are finish-ground to tight surface roughness specifications (Ra < 0.4 µm). This extends shaft life in applications with frequent start-stop cycles.

How does Frigate handle shaft distortion during welding of Compressor Rotor Shaft assemblies?

Frigate uses sub-arc or TIG welding with controlled interpass temperatures and distortion fixtures to manage welding-induced stress. Post-weld heat treatment is applied to relieve thermal stresses. Shaft alignment is rechecked using laser measurement systems after welding. Final machining is deferred until the shaft stabilizes thermally and mechanically.

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