Professional Documents
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Performance Curves
Factors that Affect Compressor
Performance
Topics
p
H
How aC
Centrifugal
t if l works
k /E
Energy C
Conversion
i
Performance Curves
Operation Limits: Surge & Overload
Factors Affecting Compressor Performance
Operational Iss
Issues
es – Optimizing
Optimi ing Compressor
Efficiency
How A Centrifugal Works
Centrifugal Stage
Return Bend
Return Bend
Diffuser
Reduces Velocity
Increases Static Pressure
Return Channel
Impeller
p
Increases Velocity
Increases Static Pressure
Guide Vanes
How A Centrifugal Works
How A Centrifugal Works
Energy Conversion
P4,V4,T4
P5,V1,T5
P3,V1,T3
P5,V1,T5
P2,V4,T2
P1,V1,T1
P3,V1,T3
Head Concept
Mechanical: The “work” (energy) developed to raise a
weight of 1 pound by a distance of one (1) foot. Expressed
in foot-pound (or equivalent Kgm or Nm);
Gas Compressors: “ work” done by the compressor /
amount of gas. The head expressed in feet, is the height to
which
hi h the
th gas could
ld b
be lift
lifted
d
Head Concept
The height to which the gas is lifted depends on the velocity
of the gas
For any given RPM, the head developed by the compressor
is fairly constant,
constant independent of the gas nature
nature.
Head is depending upon:
• Compressor
C geometry
t (i.e.
(i no off stages,
t impeller
i ll didiameters)
t )
• Compressor speed
Z: Compressibility Factor
R: Gas Constant = 1545 / MW
Ts: Suction Temperature (°R)
Basic Components
Fixed/Variable Speed
p
Surge/Overload
Effects on Performance
Compressor
p Performance Curves illustrates the
operating range and flexibility of a given compressor
120%
Ratio
110%
Pressure R
100%
105%
Pressure, P
100%
90% 95%
90%
85%
80%
% Head, P
70%
60%
110%
Pressure R
100%
Pressure, P
90%
80%
% Head, P
70%
60%
120%
Ratio
110%
Pressure R
100%
Pressure, P
90%
80%
% Head, P
70%
60%
110%
Pressure R
100%
Pressure, P
90%
80%
% Head, P
70%
60%
110%
Pressure R
100%
Pressure, P
90%
80%
% Head, P
70%
60%
110%
Pressure R
100%
Pressure, P
90%
80%
% Head, P
70%
60%
High
g axial displacement
p
110%
Pressure R
90%
80%
% Head, P
E%
Heavy Gas (propane, propylene)
Medium Gas (air, nitrogen, natural gas)
Light Gas (Hydrogen reach gases, i.e.
hydrocarbon processing plants)
Surge points
Q
Surge - Effects of Gas Composition
IInputt Signals
Si l RRequired
i d
1 - Suction Flow
2 - Suction Pressure
3 - Discharge Pressure
Suction
Flow Element
Flow Pressure PT Pressure PT
Transmitter FT Transmitter Transmitter Discharge
PC G D A AC G E
Recycle SP B I I OO B T
Valve U C MCH
Surge Control
I/P In the PLC
Surge
g Control
120%
Ratio
110%
Pressure R
100%
105%
Pressure, P
100%
90% 95%
90%
85%
80%
% Head, P
70%
60%
Compressor
Driver
Power
Process
Compressor Operation Issues-
Issues-
Efficiency Drop
Internal recycle
U t
Un-tuned d Surge
S Control
C t lS System
t
Leakage via by-pass valve(s) in process
Compressor operated out of “guaranteed
performance envelope”
p p
Impeller & Diaphragm erosion
Fouling
Internal Recycle – Gap at the
diaphragm / guides splits
Internal Recycle – Gap at the
diaphragm / guides splits
Labyrinth Leakage
Leakage proportional to:
• P
• Clearance
• Diameter
•1 / (No.Laby Teeth)0.5
Eye Laby
Leakage
Spacer Laby
S L b
Leakage
Internal Recycle – Labyrinth Clearance
Impeller Cover
Internal Recycle – Labyrinth Clearance
Impeller Cover
PEEK Labyrinth
PEEK Physical Properties
GRADE COEF. TENSILE ELONGATION SPECIFIC
THERMAL STRENGTH (%) GRAVITY
EXPNSION (PSI)
(F)
Arlon CP 17 x 10 /-6 11,080 2.0 1.45
T l
Torlon 18 8
18.8 12 900
12,900 66
6.6 1 44
1.44
4340
Fluorosint 19.4 1,100 10.0 2.32
500
Un-- tuned Surge Control System
Un
Vibration monitoring
• On
O line
li system
t
• Off line system
ONLINE CONDITIONING
MONITORING
Condition Monitoring – DR CPM Online System
Condition Monitoring – DR CPM Online System
Condition Monitoring – DR CPM Online System
Condition Monitoring – DR CPM Online System
Condition Monitoring – DR RECON Online System
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