Centrifugal

Compressors
Introduction
 What is the compressor ?
 Why we need compressors ?
 How is the compressor classified ?
 What are the types of compressors in brief ?
 Describe in detail centrifugal compressor
 Types ?
 Mechanical construction ?
 Protection?
 Operation ?
 Maintenance ?
What is the Compressor?

Is a device used to increase the upstream pressure

than the downstream pressure of a compressible
fluid by adding energy to it and direct most of
this energy to be a pressure energy
Why we need compressors ?

Compressors are used in several industries like:

 Liquid recovery
 Storage
 Process circulation
 Gas transmission
 Gas Injection
 How is the compressor classified?
COMPRESSORS
Intermittent flow Continuous flow

Positive displacement

Dynamic Ejector
Reciprocating Rotary

Radial Mixed Axial

Mechanical •Helical lobe flow flow flow
piston
•Straight lobe
•Sliding vans
• Liquid piston
 Comparison between compressor types
Compression Volume Conversion of kinetic energy
Motion Reciprocati Rotating Rotating
ng
Delivery Intermittent Quasi-continuous Continuous

Volume flow Low Low Low/medium Low/high Very high

Compression High Medium Medium Low

ration

Operation Constant volume - Variable pressure Variable volume - Quasi constant pressure

Principle

Function of a To render a specific volume of gas from a given initial condition into a desired final condition
a compressor (pressure/temperature)
 Working area of different compressor
types At Q-H curve
200

Multistage
Reciprocating
Pressure ratio

20
Single stage Recip.
Multistage
Centrifugal Multistage Axial
Rotary
compressors
2 Single S Cen.

102 103 104 105 106

Flow rate (CFM)
 Performance curves for different
compressor types

140
Positive
Centrifugal Displacement
Percent Pressure Ratio

120 Compressors Compressors

or Head

100
Design Point
80
Axial-Flow
Compressor
60

50 60 70 80 90 100 110 120

Percent Flow
Centrifugal Compressor
classification
Centrifugal compressor classified

 By impeller mounting
 By impeller type
 By casing split
 By number of stages
By impeller mounting
between bearings impeller
By impeller mounting
Overhung impeller
By impeller type
Closed impeller

Open impeller

Semi-open impeller
Impeller nomenclature
Impellers types
By casing split
Horizontal split casing
By casing split
Vertically split casing
Centrifugal Compressor
Parts
 Cross section of vertically split
Nozzle Nozzle
Discharge Suction

Inner Barrel
Fixed
Casing End Head

Inlet Area
Removable
End head Inlet
Plenum

Seals Bal. Drum Diaphragm Seals

Bearing Scroll Impeller Bearing
Bear. House Scroll plate Shaft/Rotor Bear. Bracket
Bear. Bracket Bear. House
Coupling
 Cross section of horizontal split
Discharge volutes Impeller inlet
labyrinth seals
Impellers
Shaft and labyrinth
Drive coupling seal

Journal bearing

Casing Thrust bearing

(horizontally split
flange) Compressor discharge
nozzle

Compressor inlet
nozzle
Centrifugal compressor statoric parts
Casing
Casing
Bundle
Diaphragm
Suction Diaphragm
Suction Diaphragm with the Antiswirl
IGV - Inlet Guide Vanes
End Head with First Stage IGV
Diffuser - Half
Intermediate Diaphragm
Discharge Diaphragm
Seals
Labyrinth
Interstage seal
Labyrinth
s
Labyrinth seals

Gas flow

Shaft
Pressure

Volume

Velocity
Labyrinth seal

Impeller

Stepped Labyrinth seal

Gas equalisation chamber
Interstage seal
Honeycomb
O-Segment Grooves
 Bearings
Bearings can be classified into four basic categories:

• Rolling contact, load supported by balls or rollers

• Hydrostatic, load supported by high pressure fluid
• Hydrodynamic, load supported by a lubricant film
• Magnetic, load supported by magnetic fields
Journal bearing DE
Journal bearing

Tilting pad
Journal Bearing Oil Flow Control
Journal Bearing Equipped
with Thermocouple
Journal Bearing Equipped
with vibration probes
Lubricant flow path

cool oil
introduced
directly into
the oil film,
insulating the
shoe surface
from hot oil
that adheres
to the shaft.
Journal and thrust bearing NDE
Thrust bearing
Tilting pad
Thrust Bearing side and housing
Thrust bearing components
Lubricant flow path
cool oil
introduced
directly into
the oil film,
insulating the
shoe surface
from hot oil
that adheres
to the shaft.
Journal bearing
Or by using oil nozzles:

3
 Hydrodynamic principle

Because of its adhesion to the journal and its

Lubrication
resistance to flow (viscosity), is dragged by
RTD’ s the rotation of the journal so as to form a
wedge-shaped film between the journal and
journal bearing.
 Hydrodynamic principle
Applications
Position RTD

Bearing health is commonly monitored through the

use of temperature detectors.
The recommended location for a detector is termed
the "75/75 location”.

This position represents the most critical area

because it is the point where peak film pressures,
minimum film thickness, and hot temperatures co-
exist.
Thermo elements
Position of RTD
Radial Probes Installed
Proximity Probes
Wiring
Instruments Location
Centrifugal compressor rotoric parts
Shaft
Solid-shaft and modular rotor
Impellers
Impellers
2-D Blade
3-D Blade
 Impeller manufacturing By milling

5 Axis-milling
By welding

Robotic welding
By Riveting
Shrink fit & stacking
Shrink fit & stacking
Rotor
Rotor
CC Rotor Assembly
Spacer
Rotor balancing
Ballance drum with
Balancing Drum

Surface Treated for Honey Comb Ballance drum with 3-D

Seals appl Impeller - Closed
Thrust Collar
Dry Gas Seal & tertiary seal
Construction:
Dry Gas Seal - Components
 Spiral Groove Sealing Surface
Rotating Mating Ring
clockwise
shaft rotation

spiral
groove
Inner
groove
diameter
Sealing
dam
Opposing outer
face inner diameter
diameter

86
 Spiral
grooves

Sealing
dam

Carbon Tungsten Tungsten carbide ring

Ring Ring
 Operating Principle

The type 28 Non-contacting Dry Gas Seal operates by generating a thin gas
film between the rotating and stationary components.

With rotation, gas is drawn

towards the root of the grooves
on the face of the dynamic
component.
The resistance to this gas flow
increases the pressure between
the components creating a
minute gap.
88
 GAS Spiral grooves

Sealing dam

Groove
diameter

Rotating or Rotating or
stationary stationary
ring ring

BEFORE ROTATION Tungsten carbide ring

 GAS
Spiral grooves

Sealing dam

Groove
diameter

Rotating or Rotating or
stationary stationary
ring ring

AFTER ROTATION Tungsten carbide ring

Spiral Groove Operation

Rotational direction Gas Enters And is

• Gas pressure rises Induced Towards
the Center
along spiral grooves

• Cushion of gas

separates sealing faces Gas is Compressed and

Sealing Dam Pressure Increases to Set
Sealing Gap

• Contact eliminated
Gas Rushes into Gas
spiral grooves
Gas

Gas Gas

Gas Gas
Dry Gas seal is a self adjusting Seal

Spiral grooves
GAS
Sealing dam

Inner
diameter

Carbon Rotating
ring ring Rotating ring
Tungsten carbide
If Gap increased

Closing force FC FO Opening force

FC FO

Compression

Expansion

Spring Product
Gas film
load pressure
Pressure distribution
Forces acting on the seal

Closing force FC = FO Opening force

FC FO

Compression

Expansion

Spring Product
Gas film
load pressure
Pressure distribution

Normal operation
Gap will be reduced

Closing force FC FO Opening force

FC FO

Compression

Expansion

Spring Product
Gas film
load pressure
Pressure distribution
Back To Normal operation

Closing force FC = FO Opening force

FC FO

Compression

Expansion

Spring Product
Gas film
load pressure
Pressure distribution

Normal operation
Film Thickness - How Small ?
Human Hair

Fluid Film
Face 2 um

Seat
Centrifugal Compressor
Operation
Compressor flow path
Diffusers

Discharge Suction

▲
▲
▲

▲▲

Impellers
Compressor flow path two stages
CC 1st stage
CC inter-stage
Variations in Pressure, Temperature and Velocity in a
Centrifugal Compressor

Suction Impeller Diffuser Volute

Cover

Pressure Temperature Velocity

Horizontal split casing rotor & diaphragm
Single stage multi impellers
compressor rotor and diaphragm
Thrust Equalisation

Buffer Gas
Developing the compressor curve
process limit
Rc
adding control
margins
maximum speed

power limit
surge limit

stonewall or
choke limit
Actual available
stable zone
operating zone
of operation
minimum speed

Qs, vol
Centrifugal Compressor
Protection
Centrifugal compressor protected against:

 Excessive thrust
 Surge
 High temperature
 High vibration
 Overspeed
Axial force on impeller
Axial force on thrust bearing

BAL. FLOW

P2
P1 BAL P1
DRUM

F rw F pist F imp F imp F imp F thb

IMPELLER 3 IMPELLER 2 IMPELLER 1

Fthb = ∑ Fimp - Fpist - Frw

where

Fimp = Force generated by impeller

Fpist = Force generated by balance piston
Frw = Force caused by rotor weight
Fthb = Resulting force on thrust bearing
 Balance Gas

Balance Gas

Thrust Bearing Balance Drum

Thrust

Suction Discharge
Balance line
Axial balancing

Suction pressure
Thrust
Oil Pressure Diagram in the Rings
Schematic
Oil Seal P&I Diagram
Avional Labyrinths
 Thrust Equalisation and Reference gas

Reference Gas

Equalising Gas

Balance Gas

Seal oil supply

Thrust

Seal oil To sour To sour

return to seal oil pot seal oil pot Seal oil return
to main tank
main tank
Buffer Gas PDIC
Equalising Gas Line

PDI Buffer Gas supplied from discharge of

the compressor, after the aftercooler

Balance Gas
Buffer Gas Operation Buffer Gas Injection

Seal oil supply

Sour seal oil return Sweet seal oil return

Wet seals system design methodology
 LNG Seal Oil System

LIC
Overhead Seal Oil Tank

Level Control

Filters
Reference Gas

Pressure Control
Coolers

Temp Control

Vent to Atm
Main Oil
Reservoir Degassing
Tank Sour Seal Oil Pots
Heater
 LIC Failure

LIC
Overhead Seal Oil Tank

Level Control

Filters
Reference Gas

Pressure Control
Coolers

Temp Control

Main Oil
Reservoir Degassing
Tank Sour Seal Oil Pots
Heater
 ROs blocked

LIC
Overhead Seal Oil Tank

Level Control

Filters
Reference Gas

Pressure Control
Coolers

Temp Control

Main Oil
Reservoir Degassing
Tank Sour Seal Oil Pots
Heater
Reference Gas
Reference Gas

Seal oil supply

60kPa head