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Engineering Encyclopedia: Centrifugal Compressors
Engineering Encyclopedia: Centrifugal Compressors
CENTRIFUGAL COMPRESSORS
Note: The source of the technical material in this volume is the Professional
Engineering Development Program (PEDP) of Engineering Services.
Warning: The material contained in this document was developed for Saudi
Aramco and is intended for the exclusive use of Saudi Aramco’s employees.
Any material contained in this document which is not already in the public
domain may not be copied, reproduced, sold, given, or disclosed to third
parties, or otherwise used in whole, or in part, without the written permission
of the Vice President, Engineering Services, Saudi Aramco.
Centrifugal Compressors
Section Page
INTRODUCTION------------------------------------------------------------------------------------------ 3
COMPONENTS AND FUNCTIONS ------------------------------------------------------------------ 4
THERMODYNAMIC EQUATIONS FOR GAS COMPRESSION ------------------------------ 7
Head Calculation ---------------------------------------------------------------------------- 9
Centrifugal Compressors Are Polytropic--------------------------------------------- 11
POLYTROPIC EFFICIENCY ------------------------------------------------------------------------- 12
Compressor Discharge Temperature------------------------------------------------- 12
Power Requirements --------------------------------------------------------------------- 13
MOLLIER DIAGRAM METHOD --------------------------------------------------------------------- 15
CASING ARRANGEMENTS ------------------------------------------------------------------------- 17
Intercooling---------------------------------------------------------------------------------- 17
Sidestreams--------------------------------------------------------------------------------- 18
PERFORMANCE CURVES -------------------------------------------------------------------------- 19
ACTUAL VOLUME ------------------------------------------------------------------------------------- 23
FAN LAWS ----------------------------------------------------------------------------------------------- 24
SURGE ---------------------------------------------------------------------------------------------------- 26
Effects Of Surge --------------------------------------------------------------------------- 26
Stonewall ------------------------------------------------------------------------------------ 27
EFFICIENCY OF AN OPERATING MACHINE -------------------------------------------------- 28
Procedures ---------------------------------------------------------------------------------- 28
Method A - Driver Output vs. Compressor Input ------------------------------ 29
Method B - Temperature Rise ----------------------------------------------------- 29
Tracking Changes in Efficiency---------------------------------------------------- 30
Method C - Mollier -------------------------------------------------------------------- 30
Method D - Computer Program COMPRESS---------------------------------- 33
CONTROL SCHEMES FOR CENTRIFUGAL COMPRESSORS --------------------------- 34
Variable Speed----------------------------------------------------------------------------- 34
Suction Throttling -------------------------------------------------------------------------- 35
Discharge Throttling ---------------------------------------------------------------------- 36
Antisurge Control -------------------------------------------------------------------------- 37
Antisurge Controls for Air Compressors --------------------------------------------- 38
Combined Controls------------------------------------------------------------------------ 39
COMMON PROCESS PROBLEMS WITH CENTRIFUGAL COMPRESSORS --------- 41
WORK AID 1: CENTRIFUGAL COMPRESSOR - CALCULATION FORM -------------- 42
WORK AID 2: CALCULATION FORM - MOLLIER METHOD------------------------------- 44
Centrifugal Compressors
LIST OF FIGURES
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INTRODUCTION
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Case seals are located at each place where a shaft enters the
casing. Normally there are two seals for each casing. These
seals usually contain pressurized oil to prevent the leakage of
any gas from the inside of the compressor to the atmosphere.
However, gas seals can also be used. These seals direct small
amounts of leakage gas to flare (1 SCFM or less).
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Head Calculation
PV k = Constant
PV = ZRT
P
Work = 2 VdP
P1
If the proper substitution and integration are performed, the
resulting equation for each stage of compression is:
k −1
Z1RT1 P2 k
Work = − 1 Eqn. (1)
(k − 1) P1
MW
k
where:
Head is energy, even though the common units for it are feet.
Head is work per unit of mass. It is the work, or energy, needed
to lift a unit of mass to a height that is equivalent to the head.
Centrifugal Compressors
P(2.31)
Head = Eqn. (2)
S.G. relative to water
Note: Temperatures along the theoretical column are those that occur during compression. Temperatures are
higher during polytropic compression, therefore Polytropic Head > Isentropic Head.
Centrifugal Compressors
n−1
Z1RT1 P2 n
Head = − 1 Eqn. (3)
(n − 1) P1
MW
n
k −1
n −1 k
=
n Polytropic Efficiency
Centrifugal Compressors
POLYTROPIC EFFICIENCY
where:
Note that Eqn. (4) will give the efficiency at the machine's Best
Efficiency Point (BEP). At speeds and flow rates above or
below BEP, the efficiency will be lower.
n−1
P n
T2 = T1 2 Eqn. (5)
P1
Centrifugal Compressors
where:
T1 = Suction Temperature, ºR
T2 = Discharge Temperature, ºR
Power Requirements
lbM
(Hpoly )
Gas Horsepower (ghp ) = min
Eqn. (6)
Poly. Eff. (33,000)
where:
FT − LBF
Hpoly = Polytropic Head
LBH
lb MASS
= Gas Flow Rate, pounds per min ute
min
FT − LBF
33,000 = Conversion Factor
HORSEPOWER − MIN
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BTU FT − LBF
His = (h2 − h1) x 778 Eqn. (7)
LBM BTU
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(h2 − h1)is + h1
h2 actual = Eqn. (9)
Is. Eff .
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CASING ARRANGEMENTS
Intercooling
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Sidestreams
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PERFORMANCE CURVES
________________
* This assumption is valid for gas density changes of 20%. Greater changes affect the head produced. In
these instances, a new performance curve must be supplied by the original equipment manufacturer
(OEM).
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ACTUAL VOLUME
14.7 T1
ACFM = SCFM × × ×Z Eqn. (10)
P1 520
where:
lb mol
SCFM = × 379
min ute
lb hr
SCFM = × 379
60(MW )
T1 = Suction temperature, ºR
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FAN LAWS
N
Q2 = Q1 2 Eqn. (11)
N1
2
N
H2 = H1 2 Eqn. (12)
N1
3
N
bhp2 = bhp1 2 Eqn. (13)
N1
where:
H = Polytropic head
N = Speed, rpm
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SURGE
Effects Of Surge
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Stonewall
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Theoretica l ghp
Efficiency =
Actual ghp
Procedures
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Method A - Driver
Output vs. Compressor
Input
1. Calculate the gas horsepower using the process data and
compressor equations. If the gas is a pure compound, the
Mollier method can be used.
2. Calculate the actual work delivered to the gas by the driver.
After the driver horsepower is determined, subtract an
allowance for mechanical friction losses in the compressor.
3. Calculate the polytropic efficiency.
ghp
Polytropic Efficiency =
Driver bhp − Mechanical Losses
Method B -
Temperature Rise
It is possible to calculate the efficiency of a centrifugal
compressor from compressor data only. The method is as
follows.
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log T 2
T1
T1
m=
logP2
P1
k −1
Polytropic Efficiency = k
m
Tracking Changes
in Efficiency
The usual reason for calculating compressor efficiency is to
track changes in performance. The process engineer wants to
know whether the compressor is fouling, or if there is
mechanical deterioration due to erosion or corrosion. Method A
is not the best method for this purpose. Errors in data from the
driver will cause fluctuations in the calculated compressor
efficiency. For this purpose method, B is better because it uses
data only from the compressor. Note that accurate gas
analysis methods and gauge calibration are very important.
All suction/discharge temperature and pressure gauges should
be renewed or calibrated before any readings are taken. A small
inaccuracy in these values can lead to large inaccuracies in
efficiency. Gas samples should always be obtained from the
top of pipes and analyzed at the same temperature at which
they were taken.
Method C - Mollier
The efficiency of an operating compressor can also be
calculated using the Mollier method, if the gas is a pure
compound. The procedure is as follows.
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4. Calculate ∆h isentropic.
∆h isentropic
Isentropic Efficiency =
∆h actual
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Method D - Computer
Program COMPRESS
The fourth method for calculating compressor efficiency is by
using a computer program such as COMPRESS. The input
data are
• Gas composition
• Polytropic efficiency
• Gas horsepower
• Polytropic exponent n
• Polytropic head
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Variable Speed
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Suction Throttling
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Discharge Throttling
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Antisurge Control
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Combined Controls
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(Page 1 of 2)
Gas
MW
Suction Flow Rate: SCFM, lb/min, ACFM
P1 psia
P2 psia
r =P2/P1 = =
T1 ºF, ºR
Polytropic Efficiency:
From Manufacturer's Specification
or: 0.0109 ln (Suction ACFM) + 0.643
= 0.0109 ln ( ) + 0.643
=
lst Trial 2nd Trial 3rd Trial
T2, °K assumed
k avg
(k-1)/k
(n-1)/n =
(k − 1) k
Poly. Eff .
T2 = T1(r)(n-1)/n
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T2 calculated
(Page 2 of 2)
Z1 (GPSA 23-3)
Polytropic Head:
n−1
Z1(1544 )T1 n
Hpoly = (r ) − 1
(n − 1)
MW
n
Hpoly =
( )(1544 )( )
( )( )
[
( )( ) − 1]
Hpoly = feet
Gas Horsepower:
Hpoly × lb / min
ghp =
Poly Eff . × 33,000
ghp =
( )( )
( )(33,000 )
ghp =
= +
= hp
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(Page 1 of 3)
Gas:
T1 ºF
P2 psia
h1 Btu/lb
h2 isentropic Btu/lb
∆H isentropic = - ( )
= Btu/lb
Polytropic Efficiency:
= 0.0109 ln ( ) + 0.643
P
r= 2 = _____ = _____
P1
k =
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(Page 2 of 3)
Gas Horsepower:
= ( )(778)
= feet
ghp =
(Isentropic Head)(lb min )
(Isentropic Efficiency )(33,000 )
( )( )
( )(33,000 )
= hp
Mechanical Losses hp
(GPSA Figure 13-38)
= +
= hp
Polytropic Efficiency
Polytropic Head = Isentropic Head ×
Isentropic Efficiency
= x
= feet
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(Page 3 of 3)
Discharge Temperature:
Isentropic ∆h
Actual ∆h =
Isentropic Efficiency
= Btu/lb
Actual h2 = h1 + Actual ∆h
= +
= Btu/lb
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• Deposits on rotor
• Rotor erosion/corrosion
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GLOSSARY
PV
Also: Z =
RT
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Head, Isentropic The energy per unit weight of gas applied during an
ideal compression process.
Head, Polytropic The energy per unit weight of gas applied during
polytropic compression.
Labyrinth Seal A seal made of several rings in series that fit very
closely to a shaft and impeller eye. A labyrinth seal
minimizes leakage but cannot stop it completely.
Centrifugal Compressors
Centrifugal Compressors
REFERENCES
Vendors Bulletin
Supplementary Text
Industry Standard