CENTRIFUGAL COMPRESSORS

N.B.HEMANT HUMAR

04/02/2004 HEMANT 1
 CLASSIFICATION OF COMPRESSORS

C o m p re s s o rs

D y n a m ic P o s it iv e D is p la c e m e n t

M e d iu m t o la r g e flo w s L o w t o m e d iu m flo w s
L o w t o m e d iu m p r e s s u r e P r e s s u r e n o lim it a t io n

C e n t r ifu g a l A x ia l R e c ip r o c a t in g R o ta ry
(u p to 1 5 0 0 0 0 m 3 /h r) ( flo w > 1 0 0 , 0 0 0 m 3 / h r ) < 2 0 0 0 m 3 /h r

A x ia lly S p lit P is t o n S c re w

R a d ia lly S p lit L a b y r in t h Lobe

I n t e g r a lly G e a r e d D ia p h r a g m

04/02/2004 HEMANT 2
VARIOUS TYPES OF COMPRESSORS:
 STRAIGHT THROUGH
 STRAIGHT THROUGH – BACK TO BACK
 SIDE STREAM ( EXTRACTION / INJECTION )
 BARREL TYPE
 SINGLE STAGE COMPRESSORS
 HIGH SPEED INTEGRALLY GEARED COMPRESORS

04/02/2004 HEMANT 3
 Typical Construction
Centrifugal Compressor (Radial Split)
A- Casing
B-Diaphragm
Bundle
C-Rotor
D-Impellers
E-Balance Drum
I-Thrust Bearing
H-Journal Bearing
F-Thrust Collar
L-Labyrinth
M-Seals

04/02/2004 HEMANT 4
 TYPICAL CENTRIFUGAL COMPRESSOR

04/02/2004 HEMANT 5
04/02/2004 HEMANT 6
 GENERAL INFORMATION / CONSIDERATIONS
 CAPACITY RANGE FOR CENTRIFUGAL COMPRESSORS -
1,700 TO 170,000 m3 /hr
 HORIZONTALLY SPLIT COMPRESSORS:
 WITH NOZZLES ON THE BOTTOM HALF , MAINTENANCE

WITHOUT DISTRIBING THE PROCESS PIPING.

 WITH PRESSURES ABOVE 500 psig THESE COMPRESSOR

CASINGS LOOSE THEIR SEALING CAPABILITY

 VERTICALLY SPLI COMPRESSORS:
 MAINTENANCE WITHOUT DISTRUBING THE PROCESS
PIPING
 FOR PRESSURES ABOVE 500 PSIG THIS TYPE OF

CASINGS SHALL BE USED.

04/02/2004 HEMANT 7
 GENERAL INFORMATION / CONSIDERATIONS (Contd.)

 NUMBER OF CASINGS FOR COMPRESSORS IS GENERALLY

LIMITED TO 3
 SINGLE STAGE COMPRESSORS:
 SIMILAR TO SINGLE STAGE, OVERHUNG C.F. PUMPS.

 PRESSURE RATIO ~ 1.6

04/02/2004 HEMANT 8
SPECIFYING FLOW TO A COMPRESSOR MANF.

 MASS FLOW
 IT IS DIFFICULT TO APPRECIATE SIZE OF COMPRESOR

 CONFUSION ON ACCOUNT OF WATER VAPOR

 ACTUAL FLOW
 DISADVANTAGEOUS IN CASE OF SIDE LOAD COMPR.S

 STANDARD FLOW / NORMAL FLOW

04/02/2004 HEMANT 9
COMPRESSOR PERFORMANCE CALCULAION

WHY COMPRESSIBILITY FACTOR :

 IDEAL GAS EQUATION : PV = RT
 NO GAS CONFIRMS TO IDEAL GAS BEHAVIOUR.
 INTRODUCTION OF DEVIANCE PARAMETER TO APPLY THE
IDEAL GAS EQUATION TO REAL GAS EQUATION
 HENCE: PV = ZRT

04/02/2004 HEMANT 10
CALCULATION OF COMPRESSIMILITY FACTOR
 ASSUMPTION - LAW OF CORRESPONDING STATES
 CALCULATE REDUCTION PRESSURE FOR EACH COMPONENT
OF THE GAS COMPOSITION MULTYPLIED BY THE MOLE
FRACTION

Pr = P / Pc
Pc = Critical pressure

P = Pressure of the gas

 AND ADD ALL REDUCED PRESSURES TO FIND REDUCED
PRESSURE OF THE GAS MIXTURE

04/02/2004 HEMANT 11
 SIMILARLY CALCULATE REDUCED PRESSURE FOR EACH
COMPONENT OF THE GAS COMPOSITION MULTYPLIED BY
THE MOLE FRACTION

Tr = T / Tc
Tc = Critical Temperature
T = Temperature of the gas
 AND ADD ALL REDUCED TEMPERATURES TO FIND REDUCED
TEMPERATURE OF THE GAS MIXTURE
 OBTAIN THE COMPRESSIBILITY FACTOR FROM THE
COMPRESSIBILITY FACTOR CHART

04/02/2004 HEMANT 12
CALCULATION OF MOL. WEIGHT, Cp AND K
 MOL. WEIGHT CONTRIBUTION OF EACH COMPONENT = MOL.
WEIGHT OF THE COMPONENT X MOLE FRACTION
 ADD MOL. WT. CONTRIBUTION FOR ALL COMPONENTS TO
OBTAIN THE MOL.WT. OF THE GAS MIXTURE

 Cp CONTRIBUTION OF EACH COMPONENT = Cp OF THE

COMPONENT X MOLE FRACTION
 ADD Cp CONTRIBUTION OF ALL COMPONENTS TO OBTAIN
THE Cp OF THE GAS MIXTURE
 K = Cp / ( Cp – 8.314 )

04/02/2004 HEMANT 13
TYPICAL PERFORMANCE
CURVE
OF
CENTRIFUGAL
COMPRESSOR

04/02/2004 HEMANT 14
SYSTEM RESISTANCE AND PERFORMANCE

N1
Δ PRESSURE

N2
N3
N4

CAPACITY

04/02/2004 HEMANT 15
PERFORMANCE VARIATIONS:
 CHANGE IN INLET PRESSURE
 POWER REQUIREMENT DIRECT PROPORTONALLY CHANGE

 INLET FLOW ILL ALSO CHAGE IN THE SAME WAY

 THE PEFORMANCE CURVE FALLS LOWER TO RATED

 VARIATION IN INLET TEMPERATURE

 PR. RATIO INVERSELY PROPORTIONAL TO INLET TEMP.

HENCE FOR LOWER TEMP. THE DISCH. TEMP. INCREASES

 MASS FLOW INCREASES AND SO AS THE POWER

 THE PEFORMANCE CURVE RISES ABOVE ORIGINAL CURVE

04/02/2004 HEMANT 16
PERFORMANCE VARIATIONS (Contd..):
 VARIATION IN MOLECULAR WEIGHT
 PRESSURE RATIO DIRECTLY PROPORTIONAL TO MW

 DISCHARGE PRESSURE INCREASES

 POWER REQUIREMENT INCREASES

 VARIATION IN Z AND Cp/Cv VALUES

 FOR AIR APPLICATIONS THESE VARIATIONS ARE VERY

LESS. SO NEGLIGIBLE
 FALL IN COMPRESSIBILITY RAISES THE PERF. CURVE

 FALL IN Cp/ Cv ALSO RAISES THE PERF. CURVE

 VARIATION IN RPM ( Hp DIR. PROP. TO N2 )

04/02/2004 HEMANT 17
SURGE AND STONE WALL

 SURGE IS THE MINIMUM STABLE FLOW POINT

 STONE WALL IS THE MAXIMUM STABLE POINT
 BEYOND THE SURGE AND STONE WALL POINTS THE
COMPRESSOR’S OPERATION IS UNPREDICTABLE.
 COMPRESSOR SURGE IS DAMAGING TO THE COMPRESSOR.

04/02/2004 HEMANT 18
ANTI SURGE CONTROL:

 HARDWARE REQUIRED FOR ANTI SURGE CONTROL:

 RECYCLE PIPING LOOP

 ANTI SURGE VALVE WITH NECESSARY VALVE

ACCESSORIES
 INSTRUMENTATION FOR MEASURING THE FLOW

THROUGH THE COMPRESSOR

 INSTRUMENTATION MEASURING INLET & OUTLET

PRESSURES & TEMPERATURES

04/02/2004 HEMANT 19
 ANTI SURGE CONTROL

04/02/2004 HEMANT 20
 ANTI - SURGE CONTROL:

04/02/2004 HEMANT 21
METHOD OF CAPACITY CONTROL

 SUCTION / DISCHARGE THROTTLING

 BYPASS
 IGVs
 SPEED VARIATION

04/02/2004 HEMANT 22
CAPACITY CONTROL BY SPEED VARIATION
Hea
d

Speed

Flow
04/02/2004 HEMANT 23
COMPRESSOR MONITORING AND SAFETY EQPT.

 BEARING / TEMPERATURE MANITOR

 MEASUREMENT OF VIBRATION
 SHAFT POSITION

04/02/2004 HEMANT 24
HIGH SPEED CENTRIFUGAL COMPRESSORS:
 CAPACITIES FROM 10 ACFM TO 100000 ACFM
 POWER RANGING FROM 15 HP – 2500 HP OR MORE
 SPEEDS UPTO 5800 RPM TO 50000 RPM
 DIAMETER OF THE IMPELLERS FROM 5” TO 36”
 USED FOR LOW CAPACITIES AND HIGH HEAD REQUIREMENTS
 TO DECIDE APPLICEBILITY OF HIGH SPED COMPRESSORS – USE
BALJE’S CHART
 FOR PRESSURE RATIO – 1.005 TO 3.5
 TYPICAL APPLICATIONS:
 MOLECULAR SEIVE ABSORPTION / REGENERATION

 VAPOR RECOVERY / BOG

 GAS RECYCLE SYSTEMS

 CHLORINE, NITROGEN ETC.

04/02/2004 HEMANT 25
AXIAL FLOW COMPRESSORS:

 INCREASING TENDENCY FOR USE OF AXIAL COMPRESSORS

 HIGHER EFFICIENCIES COMPARED TO RADIL TYPE
 APPLICATION
 REFINERIES – CATALYTIC CRACKING

 BUTADIENE -6000 TO 150000 ICFM @ 20 -30 PSIG AIR

 NITRIC ACID PLANTS

 AIR SEPARATION PLANTS

 BLAST FURNACES

04/02/2004 HEMANT 26
04/02/2004 HEMANT 27