TECH brief

Key Performance Evaluation Parameters For Centrifugal of parameters need to be Compressors > Relationships considered during bid evaluation processes
By Mehul Patel

nowledge of the various performance evaluation parameters typically used during the bid evaluation process for a centrifugal compressor is an important step toward the selection of machines that fit most economically and effectively with the application. Explained here are generic boundary limit criteria and the preferred operating envelope for centrifugal compressor performance curves, API 617 performance guarantee limits and impeller performance evaluation. Smooth and trouble-free operation of compressors is an absolute necessity for continuous operation of oil and gas production facilities. Hence, during a detailed design project, evaluation of compressor performance at various operating conditions is an important compressor preorder activity for engineering contractors. Typically, compressors in offshore installations face varying flow and pressure during the life of production platforms. In late-life scenarios, the production of gas from a well can drop to as low as 15% of compressor designed capacity. In such instances, the selection of operating envelopes for a compressor is a very important bid evaluation activity (to reduce recycle flow and thus the power loss). An engineering contractors responsibility is to select a machine with optimal efficiency and with a sufficiently broad operating envelope to cover the entire life of a platform with minimum changes. Operating envelope for compressor performance curve While assessing compressor performance, the following relationships should be considered in addition to required shaft power and polytropic efficiency (Figure 1). Stability Range = (Qr Qs) / Qr (1) Turndown Range = (Qr Qt) / Qr (2) Pressure (Head) Rise to Surge = Hs / Hr (3) Overload Range = Qo / Qr (4)

Where Qr = rated capacity Qs = capacity at surge on compressor rated speed curve Qt = capacity at rated head on surge line Hr = rated head Hs = head at surge on compressor rated speed curve Qo =  capacity at rated speed where polytropic head is 85% of polytropic head at Qr Qstonewall =  capacity where decrease in polytropic head is 10% for 1% increase in inlet volute and shall be 110% of Qr (See equations 5 and 6 in glossary at end)

n Figure 1. This is the typical performance curve of a centrifugal

compressor. Compressor characteristics vary with the difference in molecular weight of process gases tabulated below (Table 1). In general, with higher molecular weight or number of stages, the turndown ratio becomes smaller and pressure rise becomes higher. The following should be used as typical guidelines for compressor operating envelope range: Performance guarantee According to API 617: Variable speed unit: Head and capacity shall have zero negative tolerance at the normal operating point (or other point as specified), and the power at this point shall not exceed 104% of the suppliers predicted shaft power value. This tolerance shall be inclusive of all test tolerances. WWW.CTSSNET.NET CTSS

Mehul Patel is principal machinery engineer at Chicago Bridge & Iron Co. (CB&I) in London, U.K. Before joining CB&I in February, 2012, he was with WorleyParsons in the U.K. and L&T-Chiyoda Ltd. in India. Patel, who has a mechanical engineering degree from North Gujarat University, India, has a background in executing front-end engineering and design and detailed design engineering for rotating machinery. Contact him at: MVPatel@cbi.com

2013 EDITION

TECH brief
Constant speed unit: The capacity shall have zero tolerance. The head shall be within the range of 100 to 105% of the normal head. The power, based on measured head at normal capacity, shall not exceed 107% of the value at the specified normal operating point. Process/Customer requirement: Turndown ratio and/or pressure rise to surge ratio shall be checked against varying process requirement for the operating envelope of performance curve.
M.W. < = 10 Stability Range Turndown Ratio Head Rise To Surge Overload Range 10<M.W.<4 M.W. > = 44

in cases where it exceeds 1, then Relative Mach number (Ma rel) at impeller inlet shall be further investigated. In such cases, suppliers verification is a must as impeller inlet diameter is generally not available to engineering contractors. Conclusion Performance evaluation of a compressor involves optimization between: 1. Operating envelope; 2. Performance guarantee; and 3. Impeller performance parameters. Glossary Polytropic head: Expression used for centrifugal compressors to denote the meter-kg of work required per kg of gas. Stability range: Flow measurement term that indicates the flow range on a compressor performance curve for a particular constant speed or inlet guide vane (IGV) angle. At low flow end (left side), it is limited by the surge point and at high flow end (right side), it is limited by the rated point. It is a very important parameter for an operations group as it tells them of the flexibility of compressor operation for varying process demands (without changing speed or IGV angle). Turndown ratio: Flow measurement term that indicates the flow range upon which compressors can develop constant (rated) head. In other words, it tells users how much they can turn down (reduce) the flow rate while keeping the discharge pressure constant. Inlet flow can be reduced by changing/reducing either speed or IGV angle. This term is very important for an operations group specifically for reduced plant operation. Pressure rise to surge: Ratio of pressure (or head) at rated point to pressure (or head) at surge. Overload range: Represents the ability of a compressor to handle maximum flow. It is a ratio of rated flow to end of curve flow. Sonic speed: Velocity of sound and represented as Vsound = (n x R x T / MW) ^ 0.5 Where n = adiabatic constant R = gas constant = 8.314 (J/molK) T = temperature (kelvin) MW = molecular weight (5) In compression applications, the pressure wave generated by gas particles travels at sonic speed. Mach number (Ma or M): The speed of an object moving through air, or any fluid substance, divided by the speed of sound characteristic of that substance. M = Vo / Vs (6) Where Vo = Velocity of object relative to the medium Vs = Velocity of sound in the medium The Mach number is commonly used both with objects traveling at high speed in a fluid, and with high-speed fluid flows inside channels such as nozzles, diffusers or wind tunnels. Machine Mach number: Ratio of impeller tip speed to velocity of sound. Relative Inlet Mach number: Ratio of relative inlet gas velocity to velocity of sound. CTSS WWW.CTSSNET.NET CTSS

30 35 25% 120
In Between

20 25 510% 105 to 110%

n Table 1. The molecular weight of process gasses affects computer characteristics. Impeller performance For evaluating impeller performance, flow coefficient (F), pressure coefficient (C) and Mach number (Ma) are generally used (see glossary at end). Flow Coefficient (F ): It is a ratio of actual inlet gas flow to impeller characteristic (machine) flow. F = Q / [(/4) x D22 x U2] (7) Where Q = actual inlet gas flow (m3/sec) D2 = impeller outside diameter (m) U2 = impeller tip speed (m/s) Impellers having a flow coefficient (F) between 0.01 and 0.09 are normally considered to be within proven range. Where flow coefficient (F) > 0.1, 3-D impellers are normally used. In such cases, suppliers experience should be investigated as flow passages in impellers become unusually narrow. In recent years, flow coefficient (F) > 0.1 has become quite common for high flow centrifugal compressors. Head/Pressure Coefficient (C): It is a ratio of polytropic head to Eulers head. C = Hp / [(1/g) x U22] (8) Where Hp = polytropic head (m) g = 9.8 (m/sec2) U2 = impeller tip speed (m/s) Impellers having pressure coefficient (F) in range of 0.50 to 0.55 for one stage of a multistage compressor is normally considered to be within proven range. Machine Mach number (Ma): It is a ratio of impeller tip speed to velocity of gas (sonic velocity) through the impeller. Ma = U2 / a (9) Where U2 = impeller tip speed (m/s)  a = sonic speed or velocity of gas through impeller (m/s) Machine Mach number is always preferred within 1, but 2013 EDITION