Centrigual Compressors Course - Very Good PDF

Centrifugal Compressors
A basic overview
Presented By : Muhammad Junaid

Contents
Theory of compression
Purpose of compression
Understanding of key terms
Kinetic theory of gases
Compressibility
Methods of compression
Types of compressors
Centrifugal compressors
Advantages and disadvantages
Basic construction
Understanding compressor curves
Basic operation
Compressor arrangements
Maintenance
Purpose of compression
Compression
Process of increasing the pressure of a fluid in order to make it travel to another place
Compressor
Mechanical equipment that is used to increase the pressure of a compressible fluid.
Why compressors are required

Increase temperature and pressure of gas for certain reactions to take place.
Liquefaction of gases for storage purposes
Refrigeration effect
Pressurized air is used for measuring and control
Applications in industry
In every field of life.
Absolute Pressure
Capacity of a compressor
Volume of gas handled in a unit time.
Its units are cubic feet per minute
Capacity is always measured at compressor suction flange.
SCFM and ACFM

Pressure Ratio (R)

Efficiency
State and state functions

Kinetic theory of gases
The average kinetic energy of the

molecules does not change with time.
The average kinetic energy of the

molecules is proportional to absolute
temperature.
Law of Conservation of Energy
Trap quantities of gas, reduce the volume, push the compressed gas out
of the enclosure.
Trap gas, carry it without volume change to the discharge opening.

Compress the gas by backflow from discharge system, then push the
compressed gas out of the enclosure
Compress by the mechanical action rotating impellers or bladed rotors

that impart velocity and pressure
Entrain the gas in a high velocity jet of the same or another gas and
convert the high velocity of the mixture into pressure in a diffuser.
Continuous and intermittent
Compressors can be subdivided into two broad groups based on

compression mode.
 Intermittent
This compression is cyclic in nature. A specific quantity
of gas is ingested by the compressor, acted upon and
discharged, before the cycle is repeated.
 Continuous
The compression mode in which gas is moved into the
compressor, acted upon, moved through compressor,
and discharged without interruption of the flow at any
point in the process.
Compressors
Positive displacement Dynamic
Ejector
Reciprocating Rotary Centrifugal Axial
Single acting Double acting Lobe Screw Vane
Diaphragm Liquid ring Scroll

Applications of compressors
Working Principle
The working principle is based upon

imparting kinetic energy to a fluid
stream and conversion of this dynamic
energy into static energy, i.e., from
velocity into pressure.
The specific compression energy

transmitted to the gas by the impeller
is called "head."
The discharge pressure of a turbo

compressor, which is affected by gas
inlet conditions, is a function of head.
Disadvantages
Less efficient for small volumes.
Discharge pressure limitation.
Effect of gas density and temperature.
Problem of surge phenomenon.
Advantages
Discharge flow is relatively free of pulsation.
Mechanical design permits high through puts, capacity limitation is
rarely a problem.
Centrifugal Compressors are capable efficient performance over a wide
range of pressure and capacities even at constant speed operation.
These are relatively small, occupy less space, operate with minimum
attention and quieter.
Less contamination due to lubricants.
Construction
Major components of a centrifugal compressor include:
Impeller
The part of centrifugal compressor that moves the gas is the impeller. As the impeller
rotates, it moves the gas toward the outer rim of the impeller and its velocity
increases.
Diffuser
As the gas leaves impeller, it flows into a passage-way called the diffuser. The diffuser
being larger in volume, the velocity of gas decreases and its pressure increases
Volute
Gas passes from diffuser into the volute. In the volute, the conversion of velocity
energy to pressure energy continues.
Casing
It is the outer cover of a centrifugal compressor which contains inlet and discharge
nozzles.
Construction
A centrifugal compressor has two main type of parts;
Rotor assembly
Main shaft
Impellers
Thrust runner
Disc spacer
Balance drum
Stationary parts
Casing
Nozzles
Volutes
Bearings
Shaft seals
Construction
Rotor shaft
Construction
Impellers
The impellers add energy (velocity) to the gas.
There are three types of impellers
Open impeller
Semi closed impeller
Closed impeller
Construction
Thrust collar
Construction
Thrust collar
Construction
Balance drum
Construction
Casing
Construction
Volute and diffuser
Construction
Bearings
Construction
Radial bearings
Construction
Radial bearings
Construction
Radial bearing lubrication
Construction
Thrust bearing
Construction
Thrust bearing lubrication
Construction
Shaft end seals
Construction
Non contact type mechanical seal
Construction
Mechanical oil seals
Construction
Dry gas seal
Construction
Inter stage seals
Construction
Guide vanes
Construction
Coupling
Understanding Compressor Curves
P1 C
P3
Source Destination
Single speed compressor drive with suction and discharge pressure control
Compressor curve System curve

Head
Surge
Operating point
Stone wall
Flow
Incoming flow to compressor decreases
Head
Surge
Stone wall
Flow
Incoming flow to compressor decreases below surge limit
Head Surge control

Surge point
Stone wall
Flow
Gas Demand Increases
Head
Surge
Stone wall
Flow
Variable speed compressor drive with speed controller

Understanding Compressor curves
Head
maximum speed
surge limit
stonewall or
choke limit
minimum speed
Flow
Incoming flow to compressor decreases
Head
Surge N1
N2
Line N3
N4
Nmin
Stone
wall
Flow
Incoming flow to compressor decreases below surge limit
Head SCL
Surge N1
N2
Line N3
N4
Nmin
Stone
wall
Flow
Gas demand increases
Head
Surge N1
N2
Line N3
N4
Nmin
Stone
wall
Flow
Gas MW increases
Head
Surge Nmax
Line Nmax
Nmin
Nmin
Stone
wall
Flow
Basic Operation
Start up Sequence
All jobs completed and blinds removed

All instrument calibrated and in service
System Purging
Lube oil Circulation
Cooling water circulation
System pressurization
Sealing system
Start up
Basic Operation
Proper Oil lubrication
Basic Operation
Bad Oil viscosity
Basic Operation
Lube Oil system
Basic Operation
Lube Oil tank
Basic Operation
Instrumentation on LO tank
Basic Operation
Lube Oil Pump
Basic Operation
Lube Oil Cooler
Basic Operation
Lube Oil Filter
Basic Operation
Lube Oil Circulation
Basic Operation
Start up Procedure
Open suction valve

Open discharge valve (discharge check valve closed).
Open bypass or vent valve
Start and bring up to speed
Close bypass or vent
Place bypass or vent on automatic control
Basic Operation
Start up Procedure
Basic Operation
Thermodynamic condition
A compressor's efficiency is reflected by its thermodynamic

performance Evaluation of performance requires acquisition of the
following data.
Suction and discharge pressures of each stage

Suction and discharge. temperatures of each stage
Volume flow
Density
Operating speed
Power consumption
Cooling water Flow rate,
Fouling
Basic Operation
Mechanical condition
The most critical components of a compressor are the rotor, its bearings
and seals. Monitoring of mechanical compressor functions, therefore,
will center around the behavior of these components. The following
data allow assessment of the mechanical condition:
Radial vibration
Shaft position
Bearing temperature
Lube-oil supply pressure and temperature
Seal-oil supply temperature, and differential pressure between oil supply
and reference gas
Seal buffer-gas pressures and differential pressures
Compressor speed (with variable speed driver)
Basic Operation
Common Problems
Dirty Intercoolers - Increased gas temperature reduces the density into the
compression stage.
Hot Coolant - Increased gas temperature reduces the gas density into the compression
stage.
Dirty Inlet Filter - Reduces the pressure into the first stage.
Driver Input Speed - The ability for a centrifugal compressor stage to make pressure
falls as the square of the stage speed. A reduction in the driver input speed can
dramatically affect the total machine ratio.
Discharge valve closure - Discharge valve closure decreased the flow through the
compressor hence increase the pressure and causes surging .
Suction valve closure- Suction valve closure or suction vent opening causes pressure
drop in suction reducing flow and surging the machine.
Inter stage vent malfunction- In a multistage compressor if inter stage vent valve
malfunction and opens the down stream stage will surge.
Change in gas composition. If the gas composition change it effects the pressure thus
the compressor can go into surge at the same speed
Recycle valve malfunction. Recycle valves are normally open during reduced flow
operation. if closes by accident or malfunction it will surge the compressor.
Basic Operation
What word strikes fear in

the heart of centrifugal
compressor operators?
SURGE!
Basic Operation
Surging
Flow reverses in 20 to 50 milliseconds
Surge cycles at a rate of 0.3 s to 3 s per cycle
Compressor vibrates
Temperature rises
“Whooshing” noise or “Clanking” noise
Trips may occur
Conventional instruments and human operators may fail to recognize

surge
Trend of major process parameters during surge
FLOW
• Rapid flow oscillations
• Thrust reversals
• Potential damage
1 2 3
TIME (sec.)
PRESSURE
• Rapid pressure oscillations with
process instability
1 2 3
TIME (sec.)
TEMPERATURE • Rising temperatures inside

compressor
1 2 3
TIME (sec.)
Surge representation on compressor curves
Pd
• Compressor reaches surge point A
• • From A to B 20 - 50 ms Drop into surge Pv
•
Compressor looses
Compressor itsstarts
abilitytotobuild
make pressure
• pressure
From C•to DCompressor
20 - 120“rides”
ms curve
Jumptowards surge
out of surge Rlosses
• Suddenly
• P
Point
d drops
A and thus
is -reached P v > P d
• • A-B-C-D-A
Plane• goes 0.3
tosurge 3 seconds
stall -cycle
Compressor Surge cycle
surges
The is complete
Pd Pd = Compressor discharge pressure

B A Pv = Vessel pressure
Rlosses = Resistance losses over pipe
•Pressure builds • System pressure is going down
• D
Resistance goes
• up
Compressor is again able to overcome Pv
C •Compressor “rides”
• the curve “jumps” back to
Compressor
•Pd = Pv + Rlosses performance curve and goes to point D
• Because Pv > Pd the flow reverses • • Forward
Electroflow is re-established
motor is started
• • Result of flow reversal is that pressure
Compressor operating point goes to point Bgoes • Machine accelerates to nominal
down speed
• Pressure goes down => less negative flow • Compressor reaches performance
• Operating point goes to point C curve
• Note: Flow goes up faster because
pressure is the integral of flow
Machine shutdown Qs, vol

no flow, no pressure
Some surge consequences
Unstable flow and pressure
Damage in sequence with increasing severity to seals, bearings,

impellers, shaft
Increased seal clearances and leakage
Lower energy efficiency
Reduced compressor life

Surge
Factors leading to onset of surge
Startup
Shutdown
Operation at reduced throughput
Operation at heavy throughput with:
- Trips - Power loss
- Operator errors - Process upsets
- Load changes - Gas composition changes
- Cooler problems - Filter or strainer problems
- Driver problems
Surge is not limited to times of reduced throughput. Surge can occur at
full operation
Anti surge control
adding
Rc control
margins
stable zone
Actual available
of operation
operating zone
Qs, vol
Discharge Pressure
Discharge Temperature
INPUT
Suction Flow
Suction Temperature
Suction Pressure
Anti-surge Controller
Anti-Surge Valve OUTPUT

Discharge Pressure
Discharge Temperature
INPUT
Suction Flow
Suction Temperature
Suction Pressure
Anti-surge Controller
Anti-Surge Valve OUTPUT

Single stage compressor
Single stage compressor with internally split flow
Multistage compressor
Multistage compressor with single intercooler
Multistage compressor with double intercooler
Multistage compressor with double inlet
Multistage compressor with side streams
Compressor drivers
Commonly used drivers for a centrifugal compressor are:
Steam Turbine
Electric motor
Induction
Synchronous
Gas Turbine
Expander

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Centrifugal Compressors

Presented By : Muhammad Junaid

Why compressors are required

Understanding of key terms

Volume of gas handled in a unit time.

Its units are cubic feet per minute

Capacity is always measured at compressor suction flange.

SCFM and ACFM

Understanding of key terms

State and state functions

Kinetic theory of gases

The average kinetic energy of the

The average kinetic energy of the

Trap gas, carry it without volume change to the discharge opening.

Compress by the mechanical action rotating impellers or bladed rotors

Compressors can be subdivided into two broad groups based on

Positive displacement Dynamic

Reciprocating Rotary Centrifugal Axial

Single acting Double acting Lobe Screw Vane

Diaphragm Liquid ring Scroll

The working principle is based upon

The specific compression energy

The discharge pressure of a turbo

The impellers add energy (velocity) to the gas.

There are three types of impellers

Compressor curve System curve

Head Surge control

Variable speed compressor drive with speed controller

All jobs completed and blinds removed

Open suction valve

A compressor's efficiency is reflected by its thermodynamic

Suction and discharge pressures of each stage

What word strikes fear in

Flow reverses in 20 to 50 milliseconds

Surge cycles at a rate of 0.3 s to 3 s per cycle

“Whooshing” noise or “Clanking” noise

Trips may occur

Conventional instruments and human operators may fail to recognize

TEMPERATURE • Rising temperatures inside

Pd Pd = Compressor discharge pressure

Machine shutdown Qs, vol

Unstable flow and pressure

Damage in sequence with increasing severity to seals, bearings,

Increased seal clearances and leakage

Lower energy efficiency

Reduced compressor life

Anti-Surge Valve OUTPUT

Anti-Surge Valve OUTPUT

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