Centrifugal Compressors: Operation - ENG

GE
Oil & Gas
Centrifugal Compressors
Operation - ENG.
Course Description
This training is aimed at engineers working on GE Oil & Gas Centrifugal Compressors. The course gives
fundamental information on operation of GE centrifugal compressor in order to improve trainees’
knowledge and expertise. The attendees will be able to properly manage compressor operation,
interact with relevant job documentation and acquire optimal vision of main unit and auxiliaries
system operational sequences.
Expected Audience:
 Exploitation (ING CHEF, Nouveaux & Anciens)
Course Content:
1. GE CENTRIFUGAL COMPRESSORS INTRODUCTION
2. COMPRESSORS MAIN COMPONENTS REVIEW AND RELATIVE DRAWINGS

 Rotor Parts
 Stator Parts
3. OPERATING COMPRESSOR PERFORMANCE CURVES

 Performance curves detailed description
 Main thermodynamic parameters vs. Inlet Flow
 API datasheet
 Performances analysis based on job documentation
4. CONTROL OF COMPRESSOR OPERATION

 Basic principles of compressor operation
 System resistance Curve modification
 API 617 control methods
GE
Oil & Gas
5. OFF-DESIGN OPERATIONS
 Effect of the Molecular Weight variation
 Suction Temperature variation
 Suction Pressure variation
 Compressor Internal Leakage
 Fouling effect
6. ABNORMAL CONDITIONS AND ANTI-SURGE PROTECTION SYSTEM

 Rotating Stall
 Surge
 Choking or Stonewall
 Anti-surge system
 Anti-surge P&ID analysis
7. START-UP AND SHUT-DOWN COMPRESSOR SEQUENCE OVERVIEW

 Start-up basic description
 Typical Valve positioning during sequences
 Normal and Emergency shut-down
8. MINERAL LUBE OIL SYSTEM

 Description of operation
 P&IDs analysis
 Alarm and trips triggering
 Routine checks during normal operation
9. SEALING SYSTEM (DRY GAS SEALS)

 Description of operation
 P&IDs analysis
 Alarm and trips triggering
 Routine checks during normal operation
Course Duration: 2 Days

GE
Oil & Gas
CENTRIFUGAL COMPRESSOR - OPERATION ENG.

TRAINING MANUAL
Customized for: SONATRACH (ALGERIA)

GE Oil & Gas
GE Oil & Gas
Customer Training Job: 0621834
Customer : SONATRACH (ALGERIA)
This manual contains proprietary information of GE Oil & Gas – Nuovo Pignone
S.p.A. (“GE Oil & Gas”), and is furnished to its customers solely for customer
training courses purposes.
This manual shall not be reproduced in whole or in part nor shall its contents
be disclosed to any third party without the written approval of GE Oil & Gas.
The instructions and information contained in the manual do not purport to
cover all details or variations in equipment, or to provide for every possible
contingency to be met during installation, operation, and maintenance.
Should further information be desired or should particular problems arise that

are not covered sufficiently for the purchaser’s purpose, the matter should
be referred to GE Oil & Gas.
Reviewed Verified Validate

Massimiliano Romizi Vito Antonio Tondolo Cesare Sordi
Manual Specialist Mechanical Customer Training
Instructor Leader Manager
04/15/2013 04/18/2013 04/19/2013
GE Oil & Gas
GE Oil & Gas
CENTRIFUGAL COMPRESSOR
TRAINING MANUAL
INDEX
SEZ .1 Introduction & Overview
SEZ .2 Compressor Components
SEZ .3 Gas Path
SEZ .4 Compressor Performance Curves
SEZ .5 Compressor Regulation
SEZ .6 Abnormal Operating Conditions
SEZ .7 Off Design Conditions
SEZ .8 Antisurge Protection System
SEZ .9 Lube Oil System

SEZ .10 Sealing System
SEZ .11 Vibrations
SEZ .12 Start Up and Shutdown
SEZ .13 Drawings

GE Oil & Gas
GE Oil & Gas
TRAINING MANUAL
INDEX
SEZ .1 Introduction & Overview

GE Oil & Gas
Oil & Gas Industry Applications
Introduction and general overview

What is a compressor?
 Driven machine
 Rotating machine
 Its duty is to increase the gas pressure
How it works?
 Increase the kinetic energy throgh rotating components and converts it into static pressure through the stator
components, using the torque given by the driver
Why do I need to compress a gas?
 Transport
 Create chemical reactions
 Gas storage
 Enhance oil production
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Oil/Gas field Pipeline inspection device
Offshore production platform
Re-injection plant
Oil / gas processing plant

Gas boosting station
Subsea equipment
Power generation plant

Oil boosting station
Natural Gas storage plant

LNG liquefaction plant
LNG receiving plant

Refinery / Petrochemical /
fertilizer plant
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Standard guidelines about the minimum requirements for axial compressors, single-shaft and integrally geared process centrifugal
compressors and expander-compressor for use in the petroleum, chemical, and gas industries services that handle air or gas.
Vertically split Single Volute
Horizontally split
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Each GE NP centrifugal compressor is identified by a tag. The tag is divided into literal and numerical parts.
Both parts of the tag give only general information about the machine, for a first understanding, but to understand better the
whole components, service and other stuff please refer to the Data Sheet and Assembly Drawing.
The literal part gives information about the Casing, Impeller and Diffuser type.
GE NPTAGs
2 BCL 406
Casing Impeller design Diffuser
B=barrel C=closed L=free vortex (not vaned)

P=pipeline R=open
M=Middle Split
S=single volute
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2 BCL 406
BCL 406 /A
Casing design pressure rating
 N p<150 bar
 A p<200 bar
 B p<300 bar
 C p<400 bar
 D p<550 bar
 E p up to 1000 bar
The letter B identifies the Barrel type centrifugal compressor, vertically split according to API 617. The main casing is barrel
shaped and the two end covers are secured to the casing by means of stud bolt or shear rings. These compressors are the
most versatile one for what regards pressure range (Up to 1000Bar) and flow rate.
If present, the last letter of the tag identifies the Maximum pressure, hydrostatic, that the casing is able to resist.
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PCL 406
The letter P identifies the Pipeline type centrifugal compressor, vertically split according to API 617. The main casing is barrel
shaped and the two end covers are secured to the casing by means of stud bolt or shear rings.
Pipeline compressors are designed to maximize compression efficiency over the broad range of operating condition required
by gas boosting stations.
Suction and discharge nozzles are located on the opposite sides of the casing, to meet station layout requirement thus
reducing pressure drops.
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2 MCL 406
The letter M identifies the Middle split type centrifugal compressor, horizontally split according to API 617. The casing is
divided in two halves, then joined together along the centerline by means of stud bolts.
These compressors are used for low pressure, maximum 80 bar, and high flow rates.
Typical applications are LNG and Ethilene.
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SRL
Single stage
The letter S identifies the Single Volute type centrifugal compressor, same definitionaccording to API 617.
The impeller is directly connected to the shaft and each stage has is own discharge volute.
Single volute centrifugal compressors can be Integrally geared (left image) or Overhung (right image).
These kind of compressors are generally used for low flow rates and low pressure applications like Air compression.
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Impellers are the most important rotating part, for the compression process, and they are identified in the compressor tag by
the letters C or R.
C is for closed type: used for Barrel, Pipeline and Middle split compressors.
R is for open type: used for Single volute compressors
C= closed type R= open type
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2 BCL 406
Diffuser
The diffusers are the fixed part of the compression process.

In GE NP centrifugal compressor tag, the diffuser type is identified by the letter L which means ‘Free vortex’.
Free vortex also means that the diffuser is bladeless so the gas, once is discharged from the impeller, is free to expand
converting kinetic energy into pressure.
This design choice has an effect on the performance of the machine, this effect will be examined later on.
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The numerical part of the compressor tag gives us information about the Section arrangement, Nominal machine size and
number of impellers or compression stages.
Again please be aware that these are only general information and to retrieve more detailed ones always refer to Job
documentation.
Section arrangment Nominal diameter of the impeller 400 mm
2 BCL 406 n. of impellers
GE NPTAGs Numerical Part
Section arrangement describes in which way the impellers are installed within the machine.
The nominal diameter of the impeller is an indication about the size of the machine regarding to the impellers diameter, not
the actual impeller diameter.
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BCL...MCL...
If we suppose that there’s a box to be filled, before the first letter of the tag, and the box is left blank this means that the
centrifugal compressor is made of 1 compressor section.
Within this compressor section the impellers are installed on the shaft following an In-Line configuration.
This section arrangement can be easily recognized looking at the compressor, even when the machine is running, because
we will have 1 suction and 1 discharge nozzle.
SUCTION DISCHARGE
 One compression section;
 In line configuration.
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2 BCL... 2 MCL...
If before the first letter of the tag there is the digit 2, this means that the centrifugal compressor is made of 2 compressor
section.
Within this two compressor sections the impellers are installed on the shaft following a Back-to-Back configuration.
we will have 2 suction and 2 discharge nozzle.
According to the gas conditions, the gas can be cooled to reduce absorbed power and keep the gas temperature under
control
1 ST 1 ST
SUCTION DISCHARGE
 Two compressors working in series, in a single casing;

2 ND
DISCHARGE  Back to back configuration;
2 ND
SUCTION
 Intercooling between the two section;
 Tmax 250°C, this is true for all compressors
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3 BCL... 3 MCL...
If before the first letter of the tag there is the digit 3, this means that the centrifugal compressor is made of more than 1
compressor section.
Within this compressor sections the impellers are installed on the shaft following an In-Line configuration.
we will have 1 suction and 1 discharge nozzle plus one or more sidestreams.
SIDESTREAMS
SUCTION DISCHARGE
 More than two compression sections in a single

casing;
 Sidestreams.
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D BCL... D MCL...
If before the first letter of the tag there is the letter D, this means that the centrifugal compressor is made of 2 compressor
sections.
Within this compressor sections the impellers are installed on the shaft following a Back-to-Back configuration.
we will have 2 suction nozzles and 1 common discharge nozzle, the central impellers are connected to the same discharge
volute.
SUCTION
DISCHARGE
 Two compression sections in parallel in the same casing;
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 Service Conditions - Gas Flow, MW

- Pressure Ratio Multiple choice technically possible in
- Discharge Pressure many cases…
- Multiple operating Points Combined consideration of all the CTQs
- Turndown Requirements leads to the preferred solution.
Factors have different weights depending
 Performance - Efficiency over operating range on service and environment conditions
- Capacity Control Capability
- Limitations
 Other Technical Req’mts - Particular site conditions

- Industry Experience
- Environmental issues
In Addition:
 Investment cost & - Cost of complete Installation … Customer Preference !
Life cycle Cost - Cost of Energy
- Cost of Spares and Maintenance
- Cost of Lost Production
 Reliability - Continuous/Intermittent Service

- Uninterrupted Service Req’mts
 Maintenance - Maintainability
Requirements - Maintenance Intervals
- Parts & Service Availability
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GE Oil & Gas
TRAINING MANUAL
INDEX
SEZ .2 Compressor Components

GE Oil & Gas
Compressor components
Compressor components are divided in two categories:
• Rotating parts
• Fixed parts
Even if there are different types of centrifugal compressors, the components are mostly the same.
Due to the fact that a lot of machines can have the same TAG, are the internal components that really makes the difference
between machines used for different services and handling different type of gas.
In the next sections we will examine first the rotating components, then the fixed ones.
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As rotating part we identify all those components assembled to the shaft.

This will include the Coupling Hub, Balance drum, Spacers, Impellers and Thrust collar.
Coupling hub
Thrust Collar
Balance drum Impellers
Spacers
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The thrust collar transmits the rotor thrust to the thrust bearings and fixes the axial position of the rotor.
It is hydraulically shrink-fitted to the shaft which makes the assembly/disassembly procedure easier to perform.
The thrust collar can be also threaded for balancing.
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The impellers add energy to the gas.

Depending upon an application's requirements, impellers can be an open or closed design with various blade shapes.
The closed impeller consists of a hub, blades, and a cover or shroud. Open impellers consist of a hub and blades without a
shroud.
Impellers manufactoring is realized by Full Milling or Electrical Discharge Method.
The impeller is then balanced and tested at overspeed in a vacuum chamber to verify its integrity.
It is then dimensionally checked and dye penetrant tested once again.
Each impeller is balanced at low speed, and material is removed by grinding, or weight is added to achieve balancing. This is
repeated until the final balance indications fall within the minimum acceptable range.
The overspeed test is carried out for approximately five minutes. This test checks the physical integrity of the impeller under
high-speed conditions above the maximum continuous speed. The test is performed on each impeller by itself under vacuum
conditions.
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Impeller blades are backswept, according to sense of rotation, and we will examine the effect on the performance of the
machine later on.
2D Impellers are used to achieve high head value, in order to maximize the increase of gas pressure.
3D Impellers are used in high flow applications.
The blades are bended The blades are bended and twisted
Impellers are fully customized according to operating conditions and type of gas handled
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The balance drum is a disk of steel, installed after the last impeller.
Is interference fitted and keyed to the shaft and on one side has some
threaded holes to help rotor balancing.
The function of the balance drum is to compensate the majority of axial
thrust generated within the compressor.
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Connects elements between compressor and the remaining equipment of a compressor train.
FLEXIBLE DRY type design is used by GE NP
SPACER
HUB
Important advantages:
 No lubrication is needed
 Infinite life - no wearing components
 Lower forces on connected equipment

 20-30% in bending moment & 10% in axial
 Field interchangeable components
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Basically a flexible coupling has the following functions:
1. Physically connect two rotating shafts, transferring torque from the driver
2. Accommodate Parallel Offset and/or Angular misalignment
3. Compensate for axial movement of coupled shafts
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Flanges and Nozzles
Diaphragms
Bearings
Bearings
End cover
Seal
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As already said MCL compressors are also called Horizontally split, according to API617.
The two halves of the casings are joined at the horizontal centerline by hydraulically tightened stud bolts and nuts.
All connections, such as suction and discharge nozzles, side flow nozzles, and oil piping, are usually fitted to the lower half so
the upper half can be easily removed for inspection or maintenance.
BCL compressors instead are called Vertically split.

The casing can be cilindrical or bell shaped, in case of very high pressure applications, and the two end covers are joined to
the casing by means of hydraulically tightned stud bolts or shear rings.
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In BCL compressors the diaphragms in two halves may be placed into split cylinder halves called countercasings.
The assembled countercasings, called diaphragm bundle assembly, are horizontally split, to permit installation of the rotor.
When the bundle halves are bolted together with the rotor inside, a compressor bundle is formed.
There are two designs used for the diaphragm bundles. The first design uses a thin horizontally split countercasing with a
cylindrical outer surface.
The bore is machined with diaphragm seals.
These bundle halves are bolted together using a series of bolts.
In the second design, the diaphragms in each bundle half are held together by through bolt
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In MCL compressors the diaphragms are installed in each casing half, the diaphragms in the upper casing half are bolted so they do
not fall down during the casing assembly.
The end seals and bearings are contained at each end of casing assembly which allow to access without disassembling the whole
compressor casing.
MCL 1405 3 MCL 1404
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Nozzles are usually welded to the casings, only for very high pressure compressors (BCL type) the nozzles are machined inside
the casing and the piping is directly connected to the casing.
In BCL compressor the nozzles can be in the upper or in the lower part of the casing, according to process requirements.
In MCL compressor the nozzles are usually on the lower casing half, for easier maintenance.
Inlet
Discharge
Discharge Sideflow Inlet
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The functions of the journal bearing are:
• Support the rotor weight

• Create a lifting effect, with the lube oil
• Damping effect
Journal bearing with Tilting pads, tilting according to sense of rotationg, are
adopted in order to have a better stability, reducing cross coupling effects
and oil whips.
The pad surface is made of a thin layer of babbitt/non friction metal.
Bearings
shell
Bearings
pad Two types of possible lubrication:
Pivot • Direct lubrication: Lube oil is provided for each pad

through a groove manufactured on the pads
• Flooded lubrication: The oil enter from an orifice in the

upper part of the bearing and exits in the lower part
after the lubriction of pads.
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The function of the thrust bearing is to compensate part of the axial thrust.
The bearing is divided into an Active and an Inactive part, if the compressor
is operating properly the Inactive part is under the effect of the axial thrust
during transient operation.
Both Active and Inactive side are exactly the same.
The Thrust bearing type used is called ‘Double acting self equalizing’
because the load is equally distributed among the pads.
The pad surface is made of a thin layer of babbitt/non friction metal.
Thrust collar
Tilting pads
Two types of possible lubrication:
Pivot • Direct Lubricated: lube oil is provided for each pad

through a groove manufactured on the pads
Base ring • Flooded: Oil fills the bearing assembly and drains from
the top through a flow control orifice
Leveling plates
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Each centrifugal compressor has some on-board instruments.

Thermoelements, RTD or Thermocouples type, are installed on each bearing, either Journal or Thrust, to monitor the bearing
temperature.
In journal bearing they are positioned on the lower side of the bearing, in thrust bearing on different halves always to obtain a
correct temperature measurement.
Their number can vary upon specification.
Clarification: the thermoelements measure the temperature of the Babbit metal.
 Are stable over the long term;  Very fast response to temperature changes;
 Have high sensitivity;  Are small in physical size;
 Accurate reading over narrow temperature spans.
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During the operation of the compressor the change in compression process, due to various phenomenons like surge or
increased clearances, can create displacements or vibrations.
In order to monitor the effects on the compressor, axial displacement and radial vibration probes are used.
Both are Non-contacting probes, working with the eddy current principles, and usually connected to a Bently Nevada system
for monitoring.
Axial displacement probes are installed on the Thrust Bearing shaft end and are minimum 2.
Radial vibration probes are installed on each journal bearing and they work as a couple measuring vibration amplitudes on X
and Y axis.
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GE Oil & Gas
TRAINING MANUAL
INDEX
SEZ .3 Gas Path

GE Oil & Gas
Gas Path and Axial thrust

Gas Path & Axial Thrust
According to the section arrangement of a centrifugal compressor, the internal components can be resumed in different
sections.
This section nomenclature is used to identify the different areas where the gas passes and this is also called GAS PATH.
The gas flows through the compressor along the gas path.
Prior to starting, an overview is in order: a compression stage consists of the impeller, which is the rotating part, and the
diffuser, which is the stationary part.
We can split a compressor gas path into different main sections:
• Suction stage
• Discharge stage
• Intermediate stage/s (multistage compressors)
Related to the operation of the machine, and also explained in this section, there is the phenomen called Axial thrust.
In the next slides are showed the simplified assembly drawings of the GORGON LNG compressors (MR/PR).
2
Gas path and Axial thrust
11/06/2013
MCL 1405
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3 MCL 1404
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BCL 804
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Starting from the suction end we can say that the gas flow from the pipe arrives at the suction stage traveling in a radial
direction and must be reoriented into an axial direction to enter the impeller.
The purpose of the suction stage is to convey the gas into the first impeller with low load losses and with uniform pressure
and velocity.
Usually, the suction stage has a fin positioned at the opposite side of the suction flange, which splits the flow of the gas to
avoid gas recycling in the inlet volute.
Fin
Casing
Shaft
Blade
Inlet Volute
Impeller
Suction Nozzle
Suction Pipe
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Gas inlet
In this slide are showed some examples of real fins installed at compressor suction.
Even if these are MCL compressors.
Gas inlet
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The intermediate stages are the stages between the suction and the discharge; their number depends on how many
impellers are installed on the shaft.
Due to the fact that each compressor is fully customized, the geometry of the intermediate stages will change from
compressor to compressor, according to operating specifications.
Labirinth seals
Blades
Diffuser
Return
channel
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A compressor stage consists of the impeller, the diffuser and the return
P3,C3
channel.
The impeller rotates with the shaft, increasing both the velocity and
the pressure of the gas.
Regarding the pressure increase, we can say that it occurs within the
impeller and the diffuser, and that the magnitude of this increase
depends on the design of both of these.
P2,C2
P4,C4
P1,C1
Increased velocity and pressure
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Velocity
Pressure
Energy
4
1
Impeller Inlet Blade Diffuser Diffuser
Inlet Inlet Outlet 2
1 2 3 4
As shown in this diagram: in the impeller both the velocity and pressure increase; in the diffuser the pressure increases and
the velocity decreases due to the convergent design; and in the return channel there is no increase in pressure because the
convergent design is chosen only to avoid load losses.
The return channel is bladed in order to more effectively convey the gas toward the next impeller inlet, thus reducing load
losses, but there is no further increase of pressure downstream the diffuser outlet.
We can state that all the pressure increase realized within a compressor stage is made between the blade inlet and the
diffuser outlet.
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The discharge section of the gas path is the connection between the
inner parts of the compressor and the piping. The most important part
is the Discharge volute.
The discharge volute is installed after the last diffuser and convey the
gas into the discharge piping.
The volute has a variable section to impart low load losses to avoid
decreasing the pressure.
A fin is usually installed near the discharge flange to prevent gas
recirculation within the volute
Last impeller Discharge volute
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During operation, an axial thrust is generated inside the compressor along the entire length of the rotor.
This axial thrust is caused mainly by pressures acting against the impellers.
The disc side of the impeller is exposed to discharge pressure, while the hub side is exposed partly to the discharge pressure
and partly to suction pressure.
This pressure distribution generates a force normally in the direction of suction. The total value of this axial force depends on
pressure levels and the surface area of the impeller upon which these pressures act.
Because these forces do not mutually compensate each other, an axial load is generated upon the compressor rotor. In
multistage, high-pressure compressors this axial load may reach a very high value.
P2 > P1
P2
P2
P1
Axial thrust
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The amount of axial thrust is not constant, it varies depending on the pressure value and the amount of mass flow that the
compressor is elaborating.
The gas flow produces a thrust towards the discharge side of the compressor and its amount depends on the mass flow.
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To compensate for axial load, the thrust bearing is always installed on all compressors.
Additionally, to reduce the axial load applied to the thrust bearing to a more convenient value, and also to reduce the size of
the thrust collar which is an overhang mass often, a balancing drum is provided.
This balancing drum is placed after the last impeller of the rotor, at the discharge end of the compressor, so its weight is
supported by the journal bearings.
Balancing Drum
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One side of the balance drum is exposed to discharge pressure, while the other side is exposed to suction pressure through a
balancing line connected to the suction volute.
The diameter of the balance drum is designed to produce a thrust from the suction side to the discharge side of the
compressor.
This reduces the load coming from impellers that is placed upon the thrust bearing.
The compensation normally is not complete, thus avoiding any axial instability in the rotor.
P2
P2
P1
Ps
R1 R2 Rd
Axial Force Drum Force
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If the compressor is operating in the Certified point, the amount of axial thrust compensated by the balance drum is 80-85%
of the total axial thrust generated within the compressor, the remaining 15-20% is compensated by the thrust bearing.
Axial Force Drum Force
Balancing Line
Ps
Pd Ps+ΔP
Ps= Suction Pressure

Ps = Discharge Pressure
ΔP= Pressure Drop on balancing line
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GE Oil & Gas
TRAINING MANUAL
INDEX
SEZ .4 Compressor Performance Curves

GE Oil & Gas
Compressor Performance Curves

After several step and going through adimensional parameters, given by geometrical characthristics of the machine, and
dimensional parameters, the final result is a plot showing at various constant speeds and different suction flow rates the variation of
the following quantities:
• Polytropic Head
• Polytropic Efficiency
• Pressure Ratio
• Power
• Discharge Temperature
• Discharge Pressure
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Compressor performance curves
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The performance curves are valid ONLY for the condition specified in the performance diagram...
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On the performance curves we can identify:
The certified operating point: is the point with the highest efficiency in that operating conditions.
Minimum Operating Speed (MOS) : which is the minimum speed at which the compressor can safely operate. MOS is variable
and depends on compressor natural frequencies.
Maximum Continous Speed (MCS) : is the maximum speed at which the compressor can continously operate. MOS, in case of
variable speed driver, is always 105% of the speed of the driver (multiplied by gear box factor if present. In case of variable
frequency drivers, depends on the electric current frequency.
Maximum
continuous speed
(MCS)
Discharge pressure (bar a)
Certified operating point
105%
100%
98%
90%
80%
Minimum
operating speed 65%
(MOS)
Inlet capacity
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The operating range is identified in terms of speed by MOS and MCS (be aware that in case of fixed speed drivers there will be
only 1 curve so MOS and MCS will be the same).
In terms of flow the operating range goes between the Surge limit line SLL, the left limit of the curve, and the Choking area,
which is the right limit of the curve.
Operating range
Surge Limit
Line
105%
100%
98%
90%
80%
65% Choking Area
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External system
resistance curve
The plot represents the envelope of all the

possible operating conditions relevant to the
given suction parameters.
Each operating point is unique and it is always

105%
the intersection between the compressor
curve, at the given speed, and the plant
resistance curve. 100%
98%
90%
Operating
80% point
65%
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The plant resistance curve can change

during operation so the operating point can
change.
The plant resistance curve isn’t constant

because it depends from anything upstream
and downstream the compressor (valve,
vessels, coolers etc.).
105%
100%
98%
90%
80%
65%
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GE Oil & Gas
TRAINING MANUAL
INDEX
SEZ .5 Compressor Regulation

GE Oil & Gas
Compressor regulation
There are two ways in which the operating point can change:
• Modification of the system resistance curve by means of valves or other plant components;
• Increase /descrease the driver speed keeping the plant resistance curve almost constant;
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The following are the five process regulation methods defined by API 617, as stated in each compressor data sheet:
 Discharge blowoff
 Suction throttling
 Variable inlet guide vanes (VIGV)
 Cooled bypass
 Speed Variation
In the next slides we will have a brief explanation of all the regulation methods, regarding the system resistance curve change, using
a simplified process diagram for an in-line compressor.
Speed variation is often the best choiche that an operator can have to change compressor operating point, simply increasing or
decreasing the driver speed.
The compressor parameters will vary according to the following laws:
Where Q is the inlet flow, Hpol is the polytropic head, P the absorbed power.
K1, K2 and K3 are geometrical constant given by the compressor geometry and N is the speed.
3
10/06/2013
The plant resistance is decreased venting at the compressor discharge.
Notes
• Inefficient control method
• Waste of process gas
• Not recommended
Vent
valve
Check valve
Suction Discharge
Valve VIGV
valve
Pressurizing
valve
COMPRESSOR
Antisurge valve
4
10/06/2013
Variation of the plant resistance through a throttling valve at the compressor suction
Notes
• Power consumed changes proportional
to the load
• Throttle losses are across suction valve
• Will change suction conditions, creating
fluid dynamic instabilities
Throttle valve
Vent
valve
Check valve
Suction Discharge
Valve valve
Pressurizing
valve
COMPRESSOR
Antisurge valve
5
10/06/2013
The flow rate is adjusted using inlet variable guide vanes (VIGV)
Notes
• Power consumed is proportional to the load
• Power loss on inlet throttling is eliminated
• Regulation is made on velocity triangles, creating a
pre-rotation of the gas entering the impeller
• Used mostly for fixed speed drivers
Vent
valve
Check valve
Suction Discharge
Valve VIGV
valve
Pressurizing
valve
COMPRESSOR
Antisurge valve
6
10/06/2013
The plant resistance is changed using the antisurge valve, or another valve in parallel, not only as a protection system.
Vent
valve
Check valve
Suction Discharge
Valve valve
Pressurizing
valve
COMPRESSOR
Antisurge valve
7
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8
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GE Oil & Gas
TRAINING MANUAL
INDEX
SEZ .6 Abnormal Operating Conditions

GE Oil & Gas
Abnormal operating conditions

Looking back at this performance curve diagram, we said that the left and right limits for the perfomance map of a
centrifugal compressor are called: Surge limit line and Choking area.
To introduce the topic, choking is related to the maximum flow rate that the compressor can handle at a certain speed while
surge is related to fluid dynamic instabilities that will occur if the flow rates decreases over a certain threshold at a certain
speed.
Operating range
Surge Limit
Line
105%
100%
98%
90%
80%
65% Choking Area
2
10/06/2013
Choking rapresents the right limit of the perfomance curves.

It is the maximum flow that the compressor can handle at that speed, given by the geometry of the impellers.
Due to a change in system resistance, if the operating point reaches the choking limit, the flow remains constant but the
discharge pressure will rapidly drop.
Rapid decrease in performances and efficiency.

The increase of gas speed inside the compressor can lead to
high vibrations alarms.
3
10/06/2013
Choking is a physical limit of the compressor but it will mostly affect only the output.
No detection or protection system is required to provide choking.
What happens if the compressor chokes:
• The flow reaches M=1 at the inlet of the impeller (restricted section);
• Shock wave causes a dicontinuity of p and T.
• Maximum flow rate;
• Flow rate remains constant
• Discharge pressure will drop
• Gas velocity will increase
Shock wave
4
10/06/2013
Rotating stall is a transient phenomenon that occurs due to fluid dynamic instabilities.
• The fluid stream detachs from some blade of an impeller or a diffuser.
• The compressor elaborates a lower flow rate.
• The stall cells rotate in the same direction of rotor with

a speed equal to 20 – 50% of rotor speed.
Fluid stream
detachment
During rotating stall pressure pulsations at frequency much lower than rotation’s speed of the compressor (i.e. 10 - 30%) can be
noticed.
5
10/06/2013
What is it surge?
"Axis-symmetric stall", more commonly known as "compressor surge" or "pressure surge", is a complete breakdown in
compression resulting in a reversal of flow. This phenomenon occurs when the machine operates at a compression ratio close the
maximum that the compressor can furnish at the speed at which it is running.
What is it due to?
It’s due to the compressor's inability to continue working against the already-compressed gas behind it.
What happens?
The compressor either experiences conditions which exceed the limit of its pressure rise capabilities or is highly loaded such
that it does not have the capacity to absorb a momentary disturbance, creating a rotational stall which can propagate in less
than a second to include the entire compressor.
Which are the main factors leading to Surge?
During the normal operation: Increase of discharge pressure, downstream the compressor; decrease of suction pressure;
increase of suction temperature.
Due to high plant resistance, during Start up and Shutdown there’s a high risk of surge phenomenons.
6
10/06/2013
• Surge is the left limit of performance curve, on the left of this line the compressor operates in unstable condition;
• Represents the maximum polytropic head of the curve;
• All surge points, defined for different speeds represent the Surge Limit Line SLL;
7
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P2
P2 > P1
P1
Axial thrust
8
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P2
P1 > P2
P1
Axial thrust
9
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Flow Pressure
Time Time
Rapid flow oscillations Rapid pressure oscillations with process instability
Temperature
Rising temperatures
inside the compressor
Time
10
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• Flow reverses in 20 to 50 milliseconds
• Surge cycles at a rate of 0.3 sec to 3 sec per cycle
• Compressor vibrates, ‘shakes’
• Temperature rise
• “Whooshing” noise or “clanking” noise
• Conventional instruments and human operators may fail to recognize surge
11
10/06/2013
• Unstable flow and pressure
• Damage increasing with severity to seals, bearings, impellers and shaft
• Increased seal clearances and leakage
• Lower efficiency
• Trips
• Reduced compressor life
12
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GE Oil & Gas
TRAINING MANUAL
INDEX
SEZ .7 Off Design Conditions

GE Oil & Gas
Off Design Conditions

Off Design conditions
In order to define the performance when the operating parameters are different from those in design, we need to understand
which are the main factors influencing the machine performance to estimate the influence of such parameters, in quantity values
and their effect on the machine operation.
It is clear that during operation, different and combined parameters (contemporaneous changes in suction pressure, type of gas
etc.) can occur; it is therefore impossible to foresee the entire series of cases.
The operating parameters that can affect the performance of the machine are:
• Molecular weight
• Suction temperature
• Suction pressure
We will use the following formulas to explain the phenomenon
Head coefficient is function of the inlet flow.

ଶ
Impeller head is costant at fixed speed and inlet volume
W = weight flow
2
Off design conditions
10/06/2013
Considering the polytropic head costant an increase of the suction pressure leads to an increase of discharge pressure and
adsorbed power; viceversa if suction pressure decreases, this will lead to a decrease in discharge pressure and absorbed power.
௡ିଵ
݊ ‫݌‬ଶ ௡
ܰ ൌ ܿ‫ݐݏ݋‬
‫ܪ‬௣௢௟ = ܼ ܴܶ −1 ‫ܪ‬௣௢௟ ൌ ܿ‫ݐݏ݋‬
݊െ ͳ ଵ ଵ ‫݌‬ଵ ܳൌ ܿ‫ݐݏ݋‬
‫݌‬ଵ
ܲൌ ܲ ‫ ݎ‬ൌ ‫݀݁ݐܽݎ‬
ሺ‫݌‬ଵ) ௥ ௥
3
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If the suction temperature increases the pressure ratio decreases and the adsorbed power decreases, otherwise, if gas
temperature decreases, pressure ratio, absorbed power and compression efficiency will increase.
௡ିଵ ௡ିଵ
‫݌‬ଶ ௡ ‫ܪ‬௣௢௟ ήሺ݊ െ ͳሻ ‫݌‬ଶ ௡ ‫ܥ‬ଵ ܶଵ௥
= = ܲൌ ܲ
‫݌‬ଵ ܼଵܴܶଵ ή݊ ‫݌‬ଵ ܶଵ ܶଵ ௥
4
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If the gas molecular weight increases, discharge pressure and absorbed power will increase but the compression process is more
efficient due to an higher density of the gas.
௡ିଵ ௡ିଵ
1,545 ݊ 1,545 ‫݌‬ଶ ௡ ‫݌‬ଶ ௡ ‫ܪ‬௣௢௟ ή‫ ܹ ܯ‬ሺ݊ െ ͳሻ
ܴൌ ‫ܪ‬௣௢௟ = ܼଵ ܶଵ −1 =
‫ܹܯ‬ ݊െ ͳ ‫ܹܯ‬ ‫݌‬ଵ ‫݌‬ଵ ͳǡͷͶͷ ήܼଵܶଵ ή݊
‫ܹܯ‬
ܲൌ ܲ
‫ܹ ܯ‬௥ ௥
5
10/06/2013
Centrifugal compressor performances are affected also in case of:

• Internal leakages, created by increased clearances between rotating and fixed parts
• Fouling effects, created by dirty or sour gas
...increased labyrinth seals’ clearances ...foulings on impellers and diaphragm bundles
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GE Oil & Gas
TRAINING MANUAL
INDEX
SEZ .8 Antisurge Protection System

GE Oil & Gas
Antisurge protection system

The purpose of the antisurge control system is to keep the operating point, at each respective speed, from surpassing the
surge limit line SLL.
At the same time, the antisurge control system allows the compressor to maintain a safe working range.
The opening of the antisurge valve causes an increase of compressor suction flow that will reduce the slope of the external
system resistance curve, so the working point of the machine remains safely on the right of the critical surge flow.
External system
In order to maintain the compressor resistance curve
operation within a safe operating range, all
the centrifugal compressors are equipped Operating range
with an antisurge system.
Surge Limit
Line
105%
100%
98%
Operating
90% point
80%
65% Choking Area
2
10/06/2013
The Antisurge System is composed by:
• Antisurge Valve
• Instrumentation:
• Flow indicator trasmitter
• Pressure indicator trasmitter
• Electronic controller
Antisurge valve: Is a regulating valve, to avoid excessive recycles of flow that will reduce the output of the machine. Recycles
flow from discharge to suction in order to reduce system resistance. Cv of this valve, according to the stroke, is first
equiexponential, for smooth regulation, then linear, for protection. Is a Failure Open valve and is equipped with a solenoid
valve for quick opening. Antisurge valve fully open (ZSL XXX) is a permissive to start.
Instrumentation: The flow transmitter can be a rotameter, an annubar or, more commonly, a differential pressure transmitter
across a calibrated orifice. In the last case we need also to measure the gas temperature to calculate the right density of the
gas.
3
10/06/2013
The goal of this system is to maintain the operating point within a safe operating area.
But we have to avoid to reach the SLL, surge limit line.
For this reason, inside the controller, is stored another curve called SCL, surge control line, directly related to SLL.
The relationship between SLL and SCL is the safety margin that we want to maintain, usually the points on SCL have 10% flow
more than the points on the SLL at the same rotational speed.
If the operating point remains on the right of the SCL, the antisurge valve will remain closed, otherwise it will start to open.
During the Start-up the antisurge valve remains fully open until the compressor reaches the MOS, once reached that speed
the valve turns in control, according to where the operating point is.
As soon as the Shutdown sequence begins, antisurge valve becomes immediately fully open to prevent surge.
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GE Oil & Gas
TRAINING MANUAL
INDEX
SEZ .9 Lube Oil System

GE Oil & Gas
Lube oil system

Lube oil system
The function of the lube oil system is to provide the

right amount of lube oil to bearings with the desired
viscosity by regulating pressure and temperature.
2
Lube oil system
10/06/2013
Lube oil system
Tank
Lube oil system
10/06/2013
Lube oil system
Main
pump
Auxiliary pump Emergency pump Lube oil system

10/06/2013
Lube oil system
PCV
5
Lube oil system
10/06/2013
Lube oil system
TCV
6
Lube oil system
10/06/2013
Lube oil system
Filters
7
Lube oil system
10/06/2013
Lube oil system
8
Lube oil system
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GE Oil & Gas
TRAINING MANUAL
INDEX
SEZ .10 Sealing System

GE Oil & Gas
Sealing system
Sealing system
The function of the sealing system is to avoid gas leakages
Gap Statoric part
Rotating part
 Gas moves from high pressure sections to low pressure ones
 Gas property is to occupy all the available volume
2
Sealing system
10/06/2013
Sealing system
The function of the sealing system is to avoid two types of leakage
Process gas leakages between the Process gas leakages towards the
compression stages atmosphere
3
Sealing system
10/06/2013
Sealing system
 Fluid dynamic seals
 Labyrinth seals
 O-Ring gaskets
4
Sealing system
10/06/2013
Sealing system
A labyrinth seal is a type of mechanical seal that minimize the gas leakages. Labyrinth seals on
rotating shafts provide non-contact sealing action by controlling the passage of fluid through a
series of teeth.
Plain Stepped Abradable
Efficiency
 Eye of the impeller
Main purpose is to minimize internal leakages
 Foot of the impeller close to the impellers due to different
pressure value at inlet and discharge.
 Balance drum
5
Sealing system
10/06/2013
Sealing system
Mechanical dry gas seal are

supplied as cartridges.
6
Sealing system
10/06/2013
Sealing system
Stationary ring Seal gas
Athmosphere Process
side side
Spring
SHAFT
Rotating ring
7
Sealing system
10/06/2013
Sealing system
 Gas enters the groove moving towards the center;
 Gas is compressed and pressure increases setting the gap between the rings.
Dynamic
Pressurization The pressure profile at the
Static Pressure + interface is self adjuxting to
Spring Thrust restore to a position of equilibrium
Seal
gas
Process Side
Seal
gas
Stationary ring Rotating ring
8
Sealing system
10/06/2013
Sealing system
Shaft rotation Shaft rotation
9
Sealing system
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Sealing system
10
Sealing system
10/06/2013
Sealing system
Primary vent (leakage from inbord seal Secondary vent (leakage from Outbord seal
+ intermediate buffer gas - to flare) STREAM 2 + separation gas - atmospheric) STREAM 4
Separation gas (N2)

Intermediate buffer STREAM 5
gas (N2)
STREAM 3
Seal gas STREAM 1
Atmosphere
(Bearing chamber)
Inboard seal
Carbon rings
Product side
Face
Seat Face
Seat
Inner seals Outboard seal Separation seal
Intermediate Labyrinth
11
Sealing system
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Sealing system
Seal Seal gas

Buffer-Process gas gas supply leakage Separation gas
supply N2
N2
Process gas Bearings

side side
Inner seal Inboard seal Outboard seal Separation seal
12
Sealing system
10/06/2013
Sealing system
The function of the tertiary seal is to avoid the oil vapours entering into the dry gas seal.
13
Sealing system
10/06/2013
Sealing system
Buffer Gas Filters
14
Sealing system
Seal Gas Filters 10/06/2013

Sealing system
Buffer Gas
PCV
Seal Gas
PCV
15
Sealing system
10/06/2013
Sealing system
Primary Vent
16
Sealing system
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Sealing system
Secondary Vent
17
Sealing system
10/06/2013
Sealing system
Seal Gas
Heater
18
Sealing system
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Sealing system
19
Sealing system
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GE Oil & Gas
TRAINING MANUAL
INDEX
SEZ .11 Vibrations

GE Oil & Gas
Vibrations
Vibrations
The measure of the mechanical behavior of a compressor is given by the amplitude and frequency of the rotor vibrations.
The rotor vibration amplitude must not cause:
• Contact between rotating and stator parts;
• Dry gas seals overloading;
• Fatigue in the bearings.
The typical vibrations of the centrifugal compressors can be classified with reference to the frequency and the nature of the force
causing vibrations.
According to the first classification (frequency) the vibration may be:
• Synchronous
The vibration frequency corresponds to the machine rotation speed (ωR)
• Asynchronous
The vibration frequency is different from the machine rotation speed (ω R)
2
Vibrations
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Vibrations
The most common causes are:
• Unbalance in the rotor system;

• Rotor and stator parts contact;
• Fouling deposit.
It is necessary to do another distinction between frequency of the vibration and machine rotational speed
• Frequency of the vibration multiple of ωR
• Frequency of the vibration lower or higher than ωR
3
Vibrations
10/06/2013
Vibrations
• Coupling misalignment;
• Loose of interference in some rotor components.
4
Vibrations
10/06/2013
Vibrations
• High clearance in journal bearings

ோ
• Oil whip;
ோ
• Aerodynamic effects (rotating stall in diffusers)

ோ
• Cross - coupling
ோ
5
Vibrations
10/06/2013
Vibrations
Frequency of rotation Supersynchrounous Vibration

Subsybchrounous Vibration
Vibration amplitude
Frequency
6
Vibrations
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Vibrations
The main problem that we have to consider when a rotor-bearing system is subjected to a periodic force is the phenomenon of
RESONANCE.
• A system is in resonance when vibration amplitude becomes maximum;
• This occurs when the frequency of a periodic force (excitation frequency), applied to a rotor-bearing system, corresponds to a
natural frequency of that system.
A centrifugal compressor has many natural frequencies that are colled Critical Speeds.
The most important are the first and the second; It is necessary to determine the field operation speeds that avoid the resonance.
7
Vibrations
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Vibrations
To achieve this objective has been defined the Amplification Factor (AF).
According to API 617, it is an index of maximum vibration amplitude.
Amplitude
࡭࢓ ࢇ࢞
݊௖௥௜௧௜௖௔௟ ࡭࢓ ࢇ࢞
‫ ܨܣ‬ൌ
݊௨௣௣௘௥ െ ݊௟௢௪ ௘௥ ૛
n lower n critical n upper Speed
8
Vibrations
10/06/2013
Vibrations
Amplification Factor Determine:
• System Stability:
• Amount of System dampening needed.
Amplitude
࡭ࡲ ‫ ب‬૛Ǥ૞
࡭ࡲ ൐ ૛Ǥ૞
࡭ࡲ ൏ ૛Ǥ૞
Speed
9
Vibrations
10/06/2013
Vibrations
‫݃݊݅ݐܽݎ݁݌݋‬
‫ݏ݀݁݁݌ݏ‬
ܸܾ݅‫݈݁ݒ݈݁ ݊݋݅ݐܽݎ‬
ܵ‫ܯ‬ ܵ‫ܯ‬
ͲǤ͹Ͳ͹‫݇ܽ݁݌‬
ܰଵ ܰଶ
ܰ௖ଵ ܰ௠ ௖ ܰ௖௡
NC1 = Rotor first critical, center frequency, cycles per minute

Ncn = Critical speed, n th ܰ௖௜
Nmc = Maximum continuous speed, 105 percent ‫ ܨܣ‬ൌ
N1 = Initial (lower) speed at 0,707 x peak amplitude (critical) ܰଶ െ ܰଵ
N2 = Final (higher) speed at 0,707 x peak amplitude (critical)
SM = Separation margin
10
Vibrations
10/06/2013
Vibrations
• When the rotor amplification factor is greater than or equal to 2.5, the corresponding frequency is called a critical frequency,
and the corresponding shaft rotational frequency is called a critical speed;
• If the AF is less than 2.5, the response is considered critically dumped and no SM is required;
• If the AF is 2.5 to 3.55, a SM of 15% above the maximum continuous speed and 5% below the minimum operating speed is
required.
11
Vibrations
10/06/2013
Vibrations
Vibrations damping is performed by means of journal bearings, the damping effect depends on rotational speed and bearing
clearances.
To ensure that vibrations are damped correctly a test, lateral analysis, is performed.
Lateral analysis reports only the rotordynamic behaviour of the compressor, torsional analysis reports the rotordynamic
behaviour of the whole train, including drivers, gearboxes etc.
12
Vibrations
10/06/2013
Vibrations
13
Vibrations
10/06/2013
GE Oil & Gas
TRAINING MANUAL
INDEX
SEZ .12 Start Up and Shutdown

GE Oil & Gas
Start up and shutdown

The following procedure shows a basic start up, after

a depressurized shutdown, and both normal and
emergency shutdown procedures.
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18
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GE Oil & Gas
TRAINING MANUAL
INDEX
SEZ .13 Drawings

GE
Oil & Gas
Drawing’s Index - OPERATION ENG. TRAINING MANUAL
BCL505/N assembly drawing SOS9929211
3MCL1005 Assembly drawing SOS9929599
BCL804 Assembly drawing SOS9929139
MCL1002 Assembly drawing SOS9929137
BCL505/N Data sheet SOS9969954
Performance curves SOS9970028
Piping and instruments drawing SOM5081477
Instruments list SOM6609947
HMI Video pages SOM5461132
Control system functional description SOM6670429
Antisurge write-up SOS9983403
Antisurge valve dimensional drawing SOS7248866
Journal bearing opposite thrust bearing side SSO1165968
Journal bearing thrust bearing side SSO1166235
Dry gas seal drawing SOS01177
Thrust bearing SSO1848902
Rotor drawing SSO1873271
Utility consumption list SOM6609784
Cause-Effect diagram SOM6670438

Comparini M.
Boncinelli M.
Electronically approved draw. GE NuovoPignone Confidential DT-'C'

UCS HMI VIDEO PAGES SOM5461132
GE NuovoPignone - Electronically Approved Drawing - Checked: Garfagnini G.; Approved: Visintin F. - Internal DT-'N'
UCS
HMI VIDEO PAGES
AS BUILT
TITLE: UCS HMI VIDEO PAGES DOCUMENT CODE REVISION
SOM5461132 1
REVISION DESCRIPTION: APPROVED ELECTRONICALLY STORED
UPDATED TITLE BLOCK IN ALL SHEETS AND REVISED SHEETS 1, 34 AS BUILT WO DATE SECURITY CODE
CHECKED ELECTRONICALLY STORED
111305 21-May-13 N
EXECUTED CTQ
SCALE REPLACES/DERIVED FROM 1st ISSUE ORIGINAL JOB SIZE LANGUAGE
N/A N/A 28-Jan-10 160.8994÷97 4 A
THIS DOCUMENT IS AND CONTAINS CONFIDENTIAL AND PROPRIETARY INFORMATION OF Nuovo Pignone S.r.l. WHICH SHALL NOT BE USED OR DISCLOSED TO OTHERS, EXCEPT WITH THE SHEET
WRITTEN PERMISSION OF Nuovo Pignone S.r.l. . UNPUBLISHED WORK ©2013 Nuovo Pignone S.r.l.. ALL RIGHTS RESERVED. 1 of 40
INDEX
1. Start-up ....................................................................................................................................... 4
2. FSR Control ............................................................................................................................... 5
3. Fuel Gas .................................................................................................................................... 6
4. Fuel Gas DLE Details .............................................................................................................. 7
5. Fuel Gas Staging System ...................................................................................................... 8
6. VSV .............................................................................................................................................. 9
7. GG Control Device System ................................................................................................. 10
8. PT Control Device System .................................................................................................. 11
9. Start check .............................................................................................................................. 12
10. Start passed ............................................................................................................................ 13
11. Crank check ............................................................................................................................ 14
12. Ignition check ......................................................................................................................... 15
13. Load check .............................................................................................................................. 16
14. Trip Diagrams ......................................................................................................................... 17
15. Timers ....................................................................................................................................... 18
16. Fire & Gas ................................................................................................................................ 19
17. Water wash .............................................................................................................................. 20
18. Mineral Lube oil system ....................................................................................................... 21
19. Lube oil Cooler System........................................................................................................ 22
20. Mineral / Synthetic Oil Separator ...................................................................................... 23
21. Inlet Air ..................................................................................................................................... 24
22. Enclosure Ventilation ........................................................................................................... 25
23. Synthetic Oil Console ........................................................................................................... 26
24. Synthetic Lube On Base Plate .......................................................................................... 27
25. Hydraulic Starting System ................................................................................................. 28
26. Compressor Monitoring ....................................................................................................... 29
27. Gear Box Monitoring ........................................................................................................... 30
28. Anti-Surge-FV-01560 Screen .............................................................................................. 31
SOM5461132 1
REVISION DESCRIPTION: PAGE MARKER SECURITY CODE
UPDATED TITLE BLOCK N/A N
ORIGINAL JOB SIZE LANGUAGE
160.8994÷97 4 A
29. Anti-Surge-FV-01561 Screen .............................................................................................. 32
30. Process Gas System ............................................................................................................ 33
31. Compressor Seal Gas System ........................................................................................... 34
32. Trend screens......................................................................................................................... 35
33. Alarms ...................................................................................................................................... 40
SOM5461132 1
160.8994÷97 4 A
1. Start-up
SOM5461132 1
160.8994÷97 4 A
2. FSR Control
SOM5461132 1
160.8994÷97 4 A
3. Fuel Gas
SOM5461132 1
160.8994÷97 4 A
4. Fuel Gas DLE Details
SOM5461132 1
160.8994÷97 4 A
5. Fuel Gas Staging System
SOM5461132 1
160.8994÷97 4 A
6. VSV
SOM5461132 1
160.8994÷97 4 A
7. GG Control Device System
SOM5461132 1
160.8994÷97 4 A
8. PT Control Device System
SOM5461132 1
160.8994÷97 4 A
9. Start check
SOM5461132 1
160.8994÷97 4 A
10. Start passed
SOM5461132 1
160.8994÷97 4 A
11. Crank check
SOM5461132 1
160.8994÷97 4 A
12. Ignition check
SOM5461132 1
160.8994÷97 4 A
13. Load check
SOM5461132 1
160.8994÷97 4 A
14. Trip Diagrams
SOM5461132 1
160.8994÷97 4 A
15. Timers
SOM5461132 1
160.8994÷97 4 A
16. Fire & Gas
SOM5461132 1
160.8994÷97 4 A
17. Water wash
SOM5461132 1
160.8994÷97 4 A
18. Mineral Lube oil system
SOM5461132 1
160.8994÷97 4 A
19. Lube oil Cooler System
SOM5461132 1
160.8994÷97 4 A
20. Mineral / Synthetic Oil Separator
SOM5461132 1
160.8994÷97 4 A
21. Inlet Air
SOM5461132 1
160.8994÷97 4 A
22. Enclosure Ventilation
SOM5461132 1
160.8994÷97 4 A
23. Synthetic Oil Console
SOM5461132 1
160.8994÷97 4 A
24. Synthetic Lube On Base Plate
SOM5461132 1
160.8994÷97 4 A
25. Hydraulic Starting System
SOM5461132 1
160.8994÷97 4 A
26. Compressor Monitoring
SOM5461132 1
160.8994÷97 4 A
27. Gear Box Monitoring
SOM5461132 1
160.8994÷97 4 A
28. Anti-Surge-FV-01560 Screen
SOM5461132 1
160.8994÷97 4 A
29. Anti-Surge-FV-01561 Screen
SOM5461132 1
160.8994÷97 4 A
30. Process Gas System
SOM5461132 1
160.8994÷97 4 A
31. Compressor Seal Gas System <1>
SOM5461132 1
UPDATED TITLE BLOCK & REVISED WHERE SHOWN <1> N/A N
160.8994÷97 4 A
32. Trend screens
SOM5461132 1
160.8994÷97 4 A
SOM5461132 1
160.8994÷97 4 A
SOM5461132 1
160.8994÷97 4 A
SOM5461132 1
160.8994÷97 4 A
SOM5461132 1
160.8994÷97 4 A
33. Alarms
SOM5461132 1
160.8994÷97 4 A
Ferraro W. Boncinelli M.
Electronically approved draw. GE NuovoPignone Confidential DT-'C'

Centrifugal Compressors: Operation - ENG

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Centrifugal Compressors: Operation - ENG

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GE

Oil & Gas

1. GE CENTRIFUGAL COMPRESSORS INTRODUCTION

2. COMPRESSORS MAIN COMPONENTS REVIEW AND RELATIVE DRAWINGS

3. OPERATING COMPRESSOR PERFORMANCE CURVES

4. CONTROL OF COMPRESSOR OPERATION

6. ABNORMAL CONDITIONS AND ANTI-SURGE PROTECTION SYSTEM

7. START-UP AND SHUT-DOWN COMPRESSOR SEQUENCE OVERVIEW

8. MINERAL LUBE OIL SYSTEM

9. SEALING SYSTEM (DRY GAS SEALS)

Course Duration: 2 Days

CENTRIFUGAL COMPRESSOR - OPERATION ENG.

Customized for: SONATRACH (ALGERIA)

Customer Training Job: 0621834

Customer : SONATRACH (ALGERIA)

Should further information be desired or should particular problems arise that

Reviewed Verified Validate

SEZ .9 Lube Oil System

Customized for: SONATRACH (ALGERIA)

SEZ .1 Introduction & Overview

Customized for: SONATRACH (ALGERIA)

Introduction and general overview

Why do I need to compress a gas?

Offshore production platform

Oil / gas processing plant

Power generation plant

Natural Gas storage plant

LNG receiving plant

Vertically split Single Volute

B=barrel C=closed L=free vortex (not vaned)

C= closed type R= open type

The diffusers are the fixed part of the compression process.

Section arrangment Nominal diameter of the impeller 400 mm

2 BCL 406 n. of impellers

GE NPTAGs Numerical Part

 One compression section;

 Two compressors working in series, in a single casing;

 Tmax 250°C, this is true for all compressors

 More than two compression sections in a single

 Two compression sections in parallel in the same casing;

 Service Conditions - Gas Flow, MW

 Other Technical Req’mts - Particular site conditions

 Reliability - Continuous/Intermittent Service

SEZ .2 Compressor Components

Customized for: SONATRACH (ALGERIA)

As rotating part we identify all those components assembled to the shaft.

The impellers add energy to the gas.

FLEXIBLE DRY type design is used by GE NP

 Infinite life - no wearing components

 Lower forces on connected equipment

 Field interchangeable components

2. Accommodate Parallel Offset and/or Angular misalignment

3. Compensate for axial movement of coupled shafts

BCL compressors instead are called Vertically split.

MCL 1405 3 MCL 1404

Discharge Sideflow Inlet

The functions of the journal bearing are:

• Support the rotor weight

Pivot • Direct lubrication: Lube oil is provided for each pad

• Flooded lubrication: The oil enter from an orifice in the

The pad surface is made of a thin layer of babbitt/non friction metal.

Two types of possible lubrication:

Pivot • Direct Lubricated: lube oil is provided for each pad