ALL ABOUT CENTRIFUGAL COMPRESSOR: Centrifugal Compressors Suction and Discharge Shutdown Valves and Discharge Check Valves

These devices are required to isolate the compressor for the same reasons they are required for reciprocating compressors. Discharge Check Valve (Each Stage) In reciprocating compressors the compressor valves themselves act as check valves, preventing backflow from high-pressure stages to lower pressure stages. Multistage centrifugal compressors require check valves on each stage to isolate each surge loop, as well as to prevent backflow during unusual operating conditions. Relief Valves The compressor can operate at any point on the performance curve, For the maximum value of suction pressure, the pressure rise across the machine at the surge control point must be less than the system pressure rating. If not, a relief valve should be installed. Suction Shut-down Bypass (Purge) Valve The suction shut-down bypass valve is used to purge the piping system of air prior to compressor start-up. This valve is small to prevent high gas purge rates from spinning the impellers. Discharge Coolers and Suction Scrubbers These items are required for the reasons discussed under reciprocating compressors.

Scrubbers
A scrubber is a two-phase separator that is designed to recover liquids carried over from the gas outlets of production separators or to catch liquids condensed due to cooling or pressure drops. Liquid loading in a scrubber is much lower than that in a separator. Typical applications include: upstream of mechanical equipment such as compressors that could be damaged, destroyed or rendered ineffective by free liquid; downstream of equipment that can cause liquids to condense from a gas stream (such as coolers); upstream of gas dehydration equipment that would lose efficiency, be damaged, or be destroyed if contaminated with liquid hydrocarbons; and upstream of a vent or flare outlet. Vertical scrubbers are most commonly used. Horizontal scrubbers can be used, but space limitations usually dictate the use of a vertical configuration.

Centrifugal Compressors Slowdown Valve

Slowdown valves must be installed in centrifugal compressors for the same reasons as in reciprocating compressors. They must be designed with more care than those on reciprocating units, since centrifugal compressors have oil film seals where the shaft goes through the case. These seals only work if the shaft is rotating. If the compressor shuts down, pressure must be relieved from the case before the shaft speed decreases to the point where the seal no longer will contain pressure. This requires careful attention to manufacturer furnished data as well as overall flare system design.

Centrifugal Compressors Speed Controller, Inlet Guide Vanes

Speed Controller A speed controller is needed in conjunction with the surge control system. A new headcapacity curve is established for each speed, as shown in Figure 10-14. Inlet Guide Vanes The performance curve can also be shifted to match the process requirements by variable inlet guide vanes. Located at the compressor inlet, these vanes change the direction of the velocity entering the first stage impeller. By changing the angle at which these vanes direct the flow at the impeller, the shape of the head capacity curve can be changed. As more velocity change is added to the inlet gas, the performance curve steepens with very little efficiency loss. Extreme changes in process conditions cannot be accommodated. The high cost of inlet guide vanes limits use to very large compressors where small improvements in efficiency can bring large rewards.

Centrifugal Compressors Flare Valve, Suction Pressure Throttle Valve

Flare Valve As suction pressure increases or discharge pressure decreases, the compressor head requirement will decrease and the flow rate will increase. A flare valve will avoid stonewalling or over ranging driver horsepower. Suction Pressure Throttle Valve A throttling device can also be placed in the suction piping to protect against overpressure or to limit the horsepower demand to the maximum available from the driver.

Centrifugal Compressors Recycle (Surge Control) Valve

A recycle valve is needed for surge control as well as for the conditions listed above for reciprocating compressors. At constant speed the head-capacity relationship will vary in accordance with the performance curve. For a constant compressor speed: If the flow rate to the compressor decreases, the compressor approaches the surge point and a recycle valve is needed. If the suction pressure decreases, and discharge pressure remains constant, the compressor head must increase, approaching the surge point in the process.

Centrifugal Compressors Surge Control and StoneWalling

Surge is the most important process design consideration for centrifugal compressors. The surge condition occurs when the compressor does not have enough flow to produce sufficient head. At this point, the gas in the discharge piping flows back into the compressor momentarily. This lowers the back-pressure of the system, establishing forward flow at a temporarily low head. The cycling from zero, or even backward flow to forward flow, is called surge and is very detrimental to the compressor bearings and seals. Most compressors can only sustain a very few cycles of surge before severe mechanical problems develop. Surge may be caused by an increase in head requirement or a loss in throughput. Figure 1014 shows the capacity curves for a typical compressor. The surge line for this particular compressor is shown. Any combination of speed, pressure, and flow rate to the right of the surge line is acceptable. Typically, a surge control line offsetting the theoretical surge limit given by the manufacturer is used to establish set points for a control system adjusting speed and recycle as shown in Figure 10-16.

Typical centrifugal compressor curve showing surge. A stonewall or choked flow condition occurs when sonic velocity is reached at the exit of a compressor wheel. When this point is reached, flow through the compressor cannot be increased even with further increase in suction pressure. If this occurs, the suction pressure will rise, Operation in this region will cause excessive use of horsepower, occasionally to the point of overload, and frequent flaring. If higher flow rates are desired, modifications to the impeller must be made, as shown in Figure 10-15.

Graphic illustration of a "stonewall" or a choked flow condition.