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Application Note: What's Stonewall?
Application Note: What's Stonewall?
Whats stonewall?
Stonewall occurs in a centrifugal compressor when the velocity of the gas in at least one stage reaches the speed of
sound (Mach 1) at the gas conditions in that part of the machine. In a centrifugal compressor, this usually occurs
near the eye of the impeller. When the velocity of the gas reaches Mach 1, the flow will no longer increase, regardless
how much the pressure ratio drops across the stage.
Stonewall in a centrifugal compressor was once thought to be an insignificant event. This is no longer the case.
Compressor manufacturers have found that prolonged operation of the compressor in stonewall can lead to fatigue
failures of the impeller cover and blades. There is also an increase in the compressor discharge temperature due to
the increase in entropy across the region of sonic velocity.
It is not always possible during the process design stage of a project to evaluate whether or not a compressor will
be susceptible to stonewall operation just by reviewing the compressor characteristic curves and the process design
data. A high fidelity dynamic simulation of the compressor and associated process can be very useful in determining
whether or not a stonewall control system is warranted.
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APPLICATION NOTE
STONEWALL AND ITS PREVENTION
Head
Surge Limit
Characteristic Lines
Stonewall Limit
Inlet Flow
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APPLICATION NOTE
STONEWALL AND ITS PREVENTION
Example Application
There are certain ethylene plant designs that include a side draw from the discharge of the third stage of a four-stage
propylene refrigeration compressor (PRC). The gas extracted from the PRC is used for heat in a reboiler for the C2
splitter. If this flow is excessive, the third stage can be pushed into stonewall and the fourth stage can be driven into
surge. All the flow through the fourth stage comes from the third stage and if the third stage is operated in stonewall,
the discharge pressure of the third stage will drop significantly and consequently the fourth stage pressure ratio will
increase significantly. This increase in the fourth stage pressure ratio will push the fourth stage back to its surge line,
but no additional flow will be available for the fourth stage because its all passing through the side draw port of the
third stage.
To Condenser
Stonewall
Control
Valve
Anti-surge Recycle
Heat for
C2 splitter
reboiler
From Chillers
Surge
Controller
Setpoint
Pd/Ps
Surge Limit
Characteristic Lines
Stonewall
Controller
Setpoint
Stonewall Limit
h/Ps
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