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Simulation Model of a Variable Speed Centrifugal Compressor.

(by A.E. for mychemengmusings.wordpress.com)

(newly updated and improved editing Jan 2020)

In practice there are opportunities to optimize or modify conditions or re-design operational
systems where a variable speed centrifugal compressor is involved. An example is the case
where we have an existing refrigeration system that needs to be improved and or optimized or
cooling conditions or energy consumption needs to be minimized. To study the existing system
and identify possible ways to improve the operation a simulation model can be of great help.
This post gives an example of how a simulation model of an actual existing variable speed
centrifugal compressor (vsccr) can be made and implemented in excel.
The developed model includes accounting for the compression of a non-ideal gas, as well as the
dealing with the fact that in a real, actual rotating machine the compression process proceeds in
a non-ideal fashion requiring more ‘shaft-power’ than theoretically calculated. The degree of non-
ideality of the gas handled by the compressor, reflected in the “gas compressibility factor ‘Z’ “, is
described with the “Zv-correlation” (presented in earlier posts). The energetic losses incurred
(due to non-ideal compression) during the operation of the existing compressor machine are
accounted for by a newly developed correlation for the “adiabatic efficiency factor” , allowing the
actual, real shaft-power required to operate the machine to be determined.
Let us begin with reviewing what we know of the existing variable speed centrifugal compressor
“vscCR-01”. But first as this post will be long I have divided it the following sections:

‘1. The variable speed centrifugal CompressoR “vscCR-01”.

‘1.1 The Compressor’s Performance Chart
‘1.2 The Gas inlet conditions and the Gas Quality
‘1.3 The Power Consumption Chart of “vscCR-01”.
‘2. A Compressor’s Operating Window (in general).
‘3. A simple Model to describe the surge-line in a compressor map
‘3.1 The surge point.
‘3.2 Modeling of the conditions at the point of incipient surge.
‘3.3 Describing the surge curve on a head versus volumetric flow rate
map.
‘4. Compressor Modeling considerations.
‘5. The Adiabatic Head, Adiabatic Efficiency and the Adiabatic Temperature rise
‘6. A Compressor’s operation at off-design conditions
‘6.1 The influence of speed on the volumetric flow rate
‘6.2 The influence of speed on the Adiabatic Head
‘6.3 Summary and the “Fan Laws”
‘7. Modeling the existing “vscCR-01”.
‘7.1 Fingerprinting the Head versus Flow characteristic of the machine
‘7.2 Fingerprinting the machine’s Adiabatic Efficiency Factor
‘8. The Simulation of the existing compressor “vscCR-01”.
‘8.1 Formulating the Simulation Model and its steps in excel.
‘8.2 Excel Spreadsheet print out of the Simulation Model calculations
‘9. The Simulation Model Results
‘9.1 Comparing Simulation results with actual Manufacturers performance
Charts for Discharge pressure and Shaft Power versus Volumetric
suction flow
‘9.2 Inter – and extrapolated Performance Charts
’10. Conclusion.

Note: a new pdf version with added updates and improved editing of this post is here
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1. The variable speed centrifugal CompressoR “vscCR-01”

1.1 The existing Compressor’s Performance Chart.

The Manufacturer had provided us with a chart with a set of performance curves showing
how the machine behaves. The curves in Diagram-1 show the discharge pressure versus the
volumetric gas inlet flow for the machine. In general the manufacturer may also provide a
chart showing the outlet- over inlet pressure ratio (P2 / P1) versus the gas volume inlet flow.
The compressor has been designed for a given set of operating conditions specified by the
flow rate, the temperature, gas quality and inlet and outlet pressure. At gas flow rates higher
than the design point the discharge pressure diminishes. At flow rates lower than that point
the pressure increases. Below is shown the manufacturer’s chart as Diagram-1, showing the
outlet pressure versus the inlet suction volume flow rate performance for three speeds of the
existing machine “vscCR-01”.

Performance Curves of Variable Speed Centrifugal Compressor vscCR-01

42
40
38
36
Discharge Pressure P2 --------> Bar absolute

34
32
30
28
26
24
22 8330 rpm
20
18
7000 rpm
16
5870 rpm
14
12
10
8
6
4
2
0
1500 2000 2500 3000 3500 4000 4500 5000

Suction Volumetic Gas Flow Q1 ------> m3 / hour

Diagram -1 Manufacturer’s performance chart of “vscCR-01”.

1.2 The Gas inlet conditions and the Gas quality

The inlet conditions and the quality of the gas for which this compressor is designed and to
which the above performance curves apply is summarized below:

Suction conditions Gas Quality

Compressibility
Inlet Pressure Inlet Temper. Mol Weight
Factor
P1 in Barabs T1 in Deg.C MW Z1 K

10.5 27 41.74 0.838 1.1644

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1.3 The Power consumption Chart of “vscCR-01”.

The shaft power required to run the compressor for each of these same three speeds as given
by the manufacturer in the previous chart is shown in the next graph. Sometimes manufacturers
combine the two charts into one.
Note: these power numbers do not include the mechanical losses in gearbox and the
inefficiencies of the driver of the compressor (either e.g. electric motor or steam turbine).

Power Consumption of Variable Speed Centrifugal Compressor vscCR-01

2500

2000
Shaft Power -------- > kWatt

1500

1000

500

0
1500 2000 2500 3000 3500 4000 4500 5000

Suction Volumetric Gas Flow ---------> m3 / hour

Diagram -2 Manufacturer’s Shaft Power for “vscCR-01”.

2 A Compressor’s Operating Window (in general)

A compressor is designed for a specific operating point, that is for a given gas flow rate, gas
quality, suction and discharge conditions at its best energetic efficiency point.
The variable flow rate – at design rotation speed – is at the low end bounded by the ‘surge’ point,
while on the high end it is limited by conditions at which the flow reaches ‘choke’ conditions at
which point the discharge pressure starts to steeply drop at increasing flow rates. Choke
conditions arise at a particular point along the flow path inside the machine when the local
velocity of the gas approaches the speed of sound. These limiting flow rates are portrayed in the
following diagram of pressure ratio versus suction volumetric flow rate:
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surge line

point of choke
incipient point
surge

constant
speed S
operating
point
P2/P1

Suction Volumetric Flow Rate

Diagram -3 Outlet over inlet pressure versus inlet volumetric flow rate

For other speeds of rotation similarly the operating points form a curved line bounded on two
sides by the ‘surge’ point, the minimum flow rate below which no stable compressor operation is
possible and at the high end the maximum flow rate above which the compressor starts to
“choke”, manifested by a sharp drop in the outlet pressure at increased the gas flows caused by
the gas velocities inside the machine approaching the speed of sound. Such set of curves is
often called the Performance Map or Chart of the vsccr ( see Diagram 1 )
In general the area in which the compressor is allowed to operate, the ‘Operating
Window’ is bounded on four sides. On the left hand side the operating area is bounded
by the surge line, while on the right hand side the choke points giving the maximum gas
flow rates the compressor can handle. The operating area is furthermore constrained by
the minimum and maximum allowable speeds. When considering lowering operating
speed a limitation maybe imposed by the ‘self resonance’ speed of the rotor, the “rotor’s
critical speed”. For operation of speeds at the high end, a limit may be posed by the
occurrence of high frequency vibrations, by shaft torque limitations or the driver’s
maximum power limitations.

3 A Simple model to describe the surge–line in a compressor map

3.1 The surge point

Consider a centrifugal compressor with a performance curve like the one shown in the previous
Diagram continuously operating at a speed “S”. If the flow is being reduced below its ‘normal’
operating point, the compressor’s discharge pressure increases. As the flow is reduced further, a
point is reached where the machine approaches an unstable condition at which an incipient
surging of the compressor is imminent. This condition is often accompanied by noise, a surging
sound, vibrations and in the extreme case, if the starving of feed gas is prolonged and
intensified, by shaking of the entire machine on its foundation! This condition, obviously, has to
be avoided.
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The model developed below is based on the notion that at the surge point a gross back flow
inside the machine occurs. In other words, surge occurs when the pressure difference between
the compressor’s discharge and suction cannot be sustained at the low flow rate and the
developed higher outlet pressure P2 overcomes the internal back flow resistance along the flow
path inside the machine and the gas starts to flow in reverse!
Whereas normally the gas flows from the inlet, through the first impeller onto the next impellers
mounted on the shaft, at the surge point the gas starts to flow from the discharge side pressure
P2 back towards the suction side at P1.

P2
P1 , T1

F
kg/s

In other words, at the surge point, the pressure difference of outlet - minus inlet pressure
overcomes the dynamic internal flow resistance of the internals in the centrifugal machine. It is
assumed here that the flow path over a series of impellers can be lumped together. When the
pressure ratio over the machine is large and inter-stage cooling is used then the present the
model has to be applied over each of the non- cooled sections.

3.2 Modeling the conditions at the point of incipient surge

In this simple model the operating point at which surge occurs is equated with the condition at
which the pressure difference P2 minus P1 overcomes the flow resistance of the machine’s
internal flow-path. This resistance is chosen to be described with a “Fanning friction factor” type
equation. The condition (flow “F” at speed “S”) at which the compressor goes into surge than is
1
described as : P2 P1 PR K v2
2

in which equation the gas density, ‘Rho’, and the velocity, ‘v’, are based on an average between
inlet and outlet. The average velocity can be related to the average volumetric gas flow (for the
mass flow of “F” kg/s) divided by the cross sectional area A characterizing the internal flow path
2
1 Q
P2 P1 K avg
2 A avg

The steady state continuity of mass-flow along the flow path from suction to outlet is:

1 Q1 2 Q2 avg Qavg F
and hence
2
1 F
P2 P1 K avg
2 avg A

in which ‘rho–avg’ symbolizes the average gas density over the inlet and outlet of the
compressor, and re-arranging:
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2
K 1 Fw
P2 P1
A2 2 avg

The average gas density is taken as the algebraic average of inlet and outlet gas density

K 1 2 2
P2 P1 Fw
A2 2 1 2

This simple model says that in a P2 - P1 versus mass-flow diagram, the surge points vary with
the square of the mass flow rate, forming a single line with a parabolic shape. The factor ½ *
K/A^2 characterizes the internal back flow resistance of the gas through the compressor from
suction to outlet and hence is assumed to be constant for the particular machine and gas under
consideration.

When determining the (incipient) surge points of a compressor in the field, a plot of the pressure
difference or the discharge pressure versus the mass flow rate through the machine, will show
the surge points as a forming one line with an upward parabolic shape.

Note (1): If the compression ratio is high and the absolute discharge pressure is significant with
respect to the gas’ critical pressure the average gas density increases more than in strict
proportion with the absolute discharge pressure; this additional increase is accounted for by the
‘gas compressibility factor “Z” ‘. As a result the parabolic shaped surge curve tends to be
“flattened”. In this case the Fw * ( 1/ rhoavg))^0.5 needs to be plotted. Example: propylene at
from 10 -> 30 bara ; critical pressure 46 bara

Note (2): determining the actual surge point on an installed machine is not a routine field test, but
it may need to be done when the anti-surge protection control system needs to be upgraded to
allow operation closer to the surge line, in order to save energy operating costs. (energy cost
saving incentive has to be carefully weighed against the risk of damaging the machine!)

Note (3): in multistage compressors with high pressure ratio’s the surge line can deviate from the
parabolic profile when at different speeds the impeller in which the surge occurs may shift to
another impeller. In a well designed compressor the different impellers are appropriately
designed for the different speeds

The compressor performance curves and surge points can be presented in a variety of ways.
Often the manufacturer will provide compressor curves including the surge line in a
P2/P1 versus the suction volumetric gas flow diagram or shown in a head versus volumetric
suction gas flow rate diagram.
The particular expressions for the surge line in different type of diagrams can be derived from the
above equations.

3.3 Describing the surge curve in a head versus volumetric flow map

Taking again equation (1) as a starting point, the head developed over the
machine relates to the pressure difference as:

K 1 2 2
P2 P1 1 Q12
A2 2 1 2
converts into :
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P2 P1 K 1 2 2
Q1 1
1 A2 2 1 2

Note that the dimension of the left hand side expression is Nm/kg.
Combining with the real gas density relation (that introduces compressibility factor “Z”) gives:

P2 P1 K 1 2 2
Q1
1 A2 2 P2 Z 1 T1
1
P1 Z 2 T2

re-writing it as :

P2 P1 K 1 2 2
Q1 h
1 A2 2

with “eps-h” being defined as:

2
h SQRT
P2 Z1 T1
1
P1 Z 2 T2

Thus the surge line is of parabolic shape if we plot Q1* eps-h versus the head !

4 Compressor Modeling Considerations

In general terms we know what the purpose of the rotating machine is: the raising of the pressure
of a stream of gas through a compression process. We know that it is a centrifugal compressor
machine which is able to handle large volumetric flows of gas. The internal free volume for the
gas to pass through the machine is small. Hence the time span the gas resides inside the
machine is short and the time to exchange heat between the flowing gas and the rotor and
housing is short. Our first assumption is therefore the process of compression occurs adiabatic,
i.e. no heat is transferred from or into the gas.
In a well designed machine the flow path and the sizing of the impeller(s) channels and the
diffuser(s) are streamlined and dimensioned such that the energy flow-losses are kept to a
minimum for operation at the ‘design point’. In other words the amount of losses of energy
associated with pressure- or kinetic energy of the moving gas being converted into an
(additional) gas temperature rise are minimized. The gas involved in the compression process
is, for our case of the machine as given in section 1, clearly a real gas as the compressibility
factor at inlet is stated by the manufacturer to be smaller than 1 and given as: 0.838.

A detailed, stage to stage description and modeling of the compressor is not possible because of
lack of detail of the shaping and sizing of the internal rotary and stationary parts of the
compressor, details manufacturers are (very) reticent to share. For example we have no
information on how many stages of compression are implemented (how many impellers mounted
on the same rotor) inside the machine and other details on the construction and sizing of the
internals.
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We therefore will take the following modeling approach. We are defining an ‘equivalent
compressor’ consisting of a one stage ‘ideal’ isentropic compression step combined with a
coupled ‘energy loss process’ step to mirror the actual loss processes going on inside the actual
machine. This loss process can be characterized by an overall efficiency factor that links the
ideal, isentropic compression power with the actual shaft power consumption of the actual
machine operating under the conditions of flow, pressure ratio and speed.
The ‘ideal’ compression step is thought of to be an isentropic compression process. The implicit
assumptions underlying such process are that it proceeds in a reversible and adiabatic manner.
In other words the gas is compressed in a quasi-static fashion without addition or removal of heat
and hence the gas is brought from its inlet state at the suction end of the machine to its final
state at the discharge end of the machine following a (thermodynamical) path (‘line’) of constant
entropy. The energy losses that occur during the compression in the actual machine are
accounted for by the ‘Adiabatic Efficiency’ factor. This factor thus varies, as said, with feed rate,
suction – and discharge pressure and speed!

The following Diagram -4 summarizes the modeling approach with the help of the following
block flow diagram:

Suction Flow at Actual

P1 Machine Discharge Flow
Speed at P2
Variable Speed
Shaft Power Centrifugal
Compressor

Simulated
Suction Flow at Machine Discharge Flow
Adiabatic (isentropic) at P2
P1
compression
Shaft Energy Loss
Power Process
Speed

Note: In this simulation model we have chosen to describe the gas compression as an isentropic
compression process inside the machine. An alternate choice is to describe the compression as
a polytropic gas compression process. Such model may be given in a separate presentation.

5 Isentropic Compression: the Adiabatic Head, the Adiabatic Efficiency and

the Adiabatic temperature rise

In a continuously operating centrifugal compressor the increase in pressure is created by the

rotating impellers mounted on the same shaft. We are looking at the behavior of the machine
from an overall point of view and describe the compression across the entire machine, from inlet
to outlet on a one stage process basis.
The compressor brings the gas from the inlet state (1), along an isentropic path to outlet state
(2). In larger industrial compressors the mass-flow rate is substantial and the speed at which the
compression process takes place is sufficiently fast (short residence time), that (almost) no heat
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exchange with the environment can take place. In other words the process is adiabatic. Work
required for the isentropic compression process is given by the following equation :

k 1
R k P2 k
H ad Z1 T1 1
MW k 1 P1

in which Had = the energy required to compress the gas from pressure P1 to
pressure P2. Expressed in Joule/kg. Also called the adiabatic head
of the machine; in earlier post called the Ideal Compression Energy
(ICE).
Z1 = the compressibility factor of the gas at inlet conditions
MW = the molecular weight of the gas fed to the machine in kg/kmol
R = the universal gas constant equal to 8.3145 kJ/kmol
k = the specific heat capacity ratio of the gas Cp/Cv

The power to be added to the flow of gas during compression then is:

Gad Fw H ad

Gad = adiabatic gas compression power (gas horse power) is expressed

in kiloJoule/kg x kg/s or kWatt.
Fw = mass flow of gas to the compressor, kg/s

The Gas Power ‘Gad’ is the energy flow required to sustain the compressor’s pressure ratio for
the given gas feed flow rate according to an isentropic process. In reality, in an actual
compressor the rotating impeller(s) on the shaft impart energy to the flowing gas, while the gas is
following its ‘tortuous’ path through the machine. The entropy of the gas in reality will not stay
constant due to friction losses, convection losses and shock losses (‘velocity vector mismatches
along the flow path) in particular during off-design operating conditions. Hence in actuality a
larger power is required to drive the compressor shaft than reflected by the formulas above.
Therefore , the energetic in-efficiencies we are gong to account for it by way of the “Adiabatic
Efficiency Factor”. The actual power required at the shaft of the compressor is:

Gad Fw H ad
Ps
ad ad

in which Ps = the actual shaft power, Nm/s

eta-ad = the adiabatic efficiency of the compressor

Note that the adiabatic efficiency is linked to the particular compressor machine under
consideration and the particular gas being compressed at the measured operating point (P2/P1,
Q1 and rotating speed S).
The usefulness of this efficiency factor is that the gas horsepower Gad can be directly computed
from first principles (isentropic compression formula) and the efficiency factor encapsulates all
deviations from the isentropic process in the real compressor.
Hence, when the adiabatic efficiency is known for a given compressor and a given gas, the shaft
power required to drive the machine can be straightforwardly calculated.
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The temperature increase due to the isentropic compression can be calculated from

k 1
P2 k
T2 T1
P1

in which: T2 = the absolute discharge temperature , oK

T1 = the absolute suction temperature, oK
k = the specific heat capacity ratio of the gas Cp/Cv

6 A Compressor’s Operation at off-design conditions.

The map that was provided by the manufacturer of how the compressor behaves for the volume
feed rate range and the three speeds already gives an impression of how the compressor
performance looks at operating points other than the original design point for the specified design
feed gas quality. Now, if we want to describe the behavior of the compressor for other speeds
than we could do a simple inter- or even extrapolation of the curves given as a very rough first
approach. If however we also want to predict the behavior of the machine not only for other
speeds but also for other feed gas conditions or even other molecular weights than such
approach is not good enough if not very risky. We need therefore to take a closer look at what
happens inside a centrifugal compressor.

6.1 The influence of speed on the volumetric flow

Consider a radial impeller with diameter ‘D’ and the ‘eye’ of the impeller (gas inlet annular
opening) with diameter ‘d’. The impeller has been constructed with a certain number of vanes
creating ‘channels’ through which the gas flows through these channels towards the outer
diameter of the impeller. The area of the impeller over which the gas flows is equal to Pi/4 * D^2
(ignoring for the moment the area the vanes and the ‘eye’ ). If the impeller is constructed with a
channel depth ‘w’, then the total (static) volume of the channels is Pi/4* D^2 * w. If upon every full
rotation the impeller can displace and refresh this channel volume once then at a rotational
speed ‘S’ the impeller moves a volume at a rate that is proportional to:

Qimp / 4 D2 w S

The width of the channel is a design parameter of the impeller which we could characterize as
fraction of the impeller diameter

Qimp / 4 D3 w / D S

Whether upon every revolution each channel is ‘emptied and refreshed’ once that will in reality
depend on the actual flow pattern and the path the gas follows over the impeller. The movement
of gas over the impeller is determined by the forces – generated by the rotation – acting on it. To
describe the path a pocket of gas takes over the impeller we have to shift our frame of reference
by stepping –in mind - onto the impeller as it were and look at it as if from a rotating observer’s
point of view. In this reference frame we ‘see’ two apparent forces working on a pocket of gas.
The first force acts in the radial direction: the centrifugal force. The second force, called the
Coriolis force, acts in a direction that is opposite to the direction of rotation. As a result of these
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two combined forces we see the gas moving over the impeller along a path that is curved in a
way opposite to the direction of rotation. The total, actual suction flow ‘Q1’ to the inlet of the
impeller then is determined by the relative velocities and flow pattern over the impeller. We can
thus write :

Q1 f Qimp or Q1 f / 4 D3 w / D S

In which ‘Q1’ is the actual total suction volume flow rate and ‘f ‘ is a factor reflecting the actual
flow pattern. Alternatively we can express this relation as:

Q1
f ~ constant
D3 w S
4 D

Thus this expression is approximately constant as long as the ‘flow pattern’ remains ‘similar’.
The factor ‘f ‘ then characterizes this flow pattern.
In other words we could say that ‘f ’ is like a ‘fingerprint’ of the flow pattern created by the
dimensioning and design of the impeller operating at speed ‘S’.
At this point we can draw one clear conclusion from these considerations:

===> In essence a centrifugal Compressor is a “ volume moving machine”

Note: in API 67 the flow factor ‘phi’ is defined as: Q1/ (Pi/4* D^2 * U ) in which ‘U’ is equal to the
tip speed of the impeller. And as ‘U’ = omega* D/2 , hence ‘phi’ is proportional to D^3.

6.2 The influence of speed on the adiabatic head.

The centrifugal force acting on a gas pocket with mass ‘m’ performs ‘work’ on it while the pocket
moves from inlet of the impeller to its outer edge. The centrifugal force varies with the distance
‘r ‘ from the centre of rotation and is thus is a function of the position ‘r ‘ for a given angular
velocity ‘omega’ in radian per second :
2
Fce m r dr

2
The differential work done is: dE Fce dr m r dr

2
upon integration: E m 1/ 2 D 2
the Head (units: Nm/kg or J/kg) for the pocket of gas increases to:

2
E / m 1/ 2 D2
The total Head increase of the gas produced by the impeller then is:

2
H imp D2

The angular velocity ‘omega’ (in radian/sec) is related to the rotational speed
by the relation: omega = 2 * Pi * S and thus we can write:
 12

2
H imp 4 S 2 D2

This head increase of the gas is reflected by both the increase in pressure (gas density) and the
increase in gas velocity, or in other words by the increase in both potential energy as well as
kinetic energy. The ‘velocity head‘ associated with the kinetic energy of the gas exiting the
impeller is next, along the flow path, converted by the diffuser, located in the stationary part of
the machine, where it gets, for the greater part, converted back into additional ‘pressure head’
thus adding to the overall ‘pressure head’ produced by the compressor machine.

For the total pressure head developed by the compressor machine (impeller+diffuser) we can
write:
2
H ad hf H imp or H ad hf 4 S 2 D2

which expression we alternatively we can write as :

H ad
2
hf ~ constant
4 S 2 D2

This expression is approximately constant as long as the ‘overall flow pattern’ in the machine
remains ‘similar’. The factor ‘hf ’ then can be said to characterize this overall flow pattern.

From the above considerations we can conclude that:

=====> in essence a centrifugal compressor is a ‘head’ producing machine

Note: API 67 defines the “head coefficient mu “ as : Had/ (S^2 * D^2)

6.3 Summary and the “Fan Laws”

From the expression given in section 6.1 giving the relationship between the rotational speed
and the volumetric gas flow rate we have defined the flow factor ‘f’ that characterizes the flow
pattern over the impeller(s). In section 6.2 giving the relation between rotational speed and the
‘head’ generated we have defined the ‘head factor ‘hf’ that characterizes the overall flow pattern
in the machine. These two factors are coupled together via the prevailing flow pattern.

We can take a “fingerprint“ of the machine under consideration and its ‘head producing
capability’ by plotting how the head factor ‘hf ‘ varies with the flow factor ‘f ‘.
Such plot is unique to the machine and independent of speed of rotation, gas MW, and inlet
conditions (gas density)! The numerical relationship between ‘ hf ‘ and ‘ f ‘ can be captured
through regression fitting a quadratic or a polynomial mathematical expression through the data
points of ‘hf’ versus ‘f’.

Fan Laws
The relationships described in the previous sections about the influence of speed on volumetric
flow and head developed, is sometimes presented in a form that is called “The Fan Laws”. We
have seen that the suction volumetric flow ‘Q1’ divided by the speed ‘S’ is only dependent on the
geometric configuration of the compressor internals and the inside ‘flow-pattern’. Therefore for
 13

conditions where the flow-pattern is the same or similar, we can say that for small variations in
speed and volume flow rate that:

Q1 Q2
Q/S = constant and hence ===>
S1 S2

and similarly for the adiabatic head ‘Had’ developed we can write:

H ad1 H ad 2
Had / S^2 = constant and hence ===>
S12 S 22

in which the subscripts 1 and 2 here refer to two different conditions and not to inlet and outlet
per se.
The ‘Fan Laws’ are often applied to predict changes in operating performance for running the
machine under off-design conditions. These ‘laws’ are valid , as discussed in sections 6.1 and
6.2, as long as such deviations from design conditions are not too drastic, and hence the
‘sameness’ or ‘similarity’ of flow- and head patterns assumptions are not violated.

7 Modeling of the existing “vscCR-01” compressor

7.1 Fingerprinting the Head versus Flow characteristic of the machine

We want to create a simulation model of our “vscCr-01” compressor whose performance charts,
provided by the manufacturer of the machine, has been shown in section 1. To do that we first
need to take the “Fingerprint” of this compressor. By making use of what has been given in
sections 4, 5, 6. We begin by defining two variables as follows:
Q1 H ad
Q* and H*
S S2
in which ‘Q1’ is the suction volumetric flow rate ‘S’ the speed of rotation and ‘Had’ the adiabatic
head. With the relations from section 6.1 and 6.2 we can see that:
Q1
Q* f / 4 D3 w / D
and S
H ad
H* hf 4 D2
S2
The right hand side of both equations contains particular data about the detailed construction
and sizing of the specific internals of our compressor, which Information however we do not have
available. Nevertheless, by using the two new variables Qstar “Q* “ and Hstar “H* “ we are still
able to determine and plot the relationship between ‘hf ‘ and ‘f ‘under the proviso that this is valid
only for this machine; and that is no problem at all , it is in fact exactly what we want in making a
simulation model for our particular machine “vscCR-01” !

The first step therefore is to calculate the values of H* and Q* from each of the points along the
Manufacturer’s performance curves. The next step is to plot these values of H* and Q* in a
single graph. In doing so we should find all original three (speed) curves to merge into one single
curve. With this plot of a single curve of H* versus Q* , we will have found the unique fingerprint
of the Head versus Volume flow rate of this machine vscCR-01.
 14

The shape of this H* versus Q* curve is influenced , in general, by the number of stages, the
detailed geometric design of impellers, the diffuser design and the shaping of the internal flow
channels in the machine.

To obtain values for H* between zero and one and work with simple numbers we have
introduced a constant factor of 1000 in the calculation of the square of the rotation speed as
follows H* = Had / (S/1000)^2. For the calculation of Q* no such factor was (necessary) to be
included. Thus Q* was calculated as Q1/ S , with Q1 in m3/hr and speed S expressed in rev/min
( rpm). These calculated values were plotted and the following Graph was obtained:

Had / (S/1000)^2 versus Q1 /S for vscCR-01

1

0.9
Had / (S/1000)^2 --------> (kJ/kg) / (rpm/1000^2)

0.8

0.7
7000 rpm
0.6
8330 rpm
0.5

0.4

0.3

0.2

0.1

0
0.2 0.25 0.3 0.35 0.4 0.45 0.5 0.55 0.6

Q1/ S ---------> m3/h / rpm

Diagram -5 Plotting H* versus Q* (according to initial definitions of these variables)

Only the two curves with the highest speeds are shown in this Graph. We can observe from it
that H* values look in a similar range for both speeds, however these two curves have not
merged into a single line! Why is this so? The speed change does not appear too drastic.

Upon further thinking about this we can see that in our preliminary definition of Q* we have
based it on the inlet flow Q1, but the ‘fingerprint’ is characteristic for what flow-pattern happens
inside the machine not what enters the machine. In other words H* should be related to the
average volume flows inside the machine. This reminds me of how we have developed the
relation for the surge line through the use of the average volume flow through the machine.
Another consideration is that the gas is strongly non- ideal and the effects of the gas
compressibility factor Z should be taken into account.

Therefore we are re-defining Q* as:

Q1
Q* h
S1

in which eps-h is equal to (see section 3.)

 15

2
h Sqrt
P2 Z1 T1
1
P1 Z 2 T2

A minor modification was already made to H* too, as explained earlier, but this is just a constant
scaling factor to obtain H* values between 0 and 1 as follows:

H ad
H* 2
with ‘S’ being the speed in rpm.
S / 1000

These last two adjustments to H* and Q* are the final definitions we are working with to
determine the “fingerprint” of the machine .

After re-calculating the values for the newly defined H* and Q* variables for the points in the
manufacturer’s performance charts, we get the following new Graph:

Had / (S/1000)^2 versus Q1 /S * eps-h for vscCR-01

1

0.9
Had / (S/1000)^2 --------> (kJ/kg) / (rpm/1000^2)

0.8

0.7
7000 rpm
0.6
surge point 8330 rpm
0.5

0.4

0.3

0.2

0.1

0
0.2 0.25 0.3 0.35 0.4 0.45

Q1/ S * eps-h -----------> m3/h / rpm

Diagram -6 Plotting the newly defined H* versus Q*

The two curves have now coalesced into one, single relationship. This relation forms the
“fingerprint” of the machine. This “fingerprint” relation we can capture through regression on the
data for H* versus Q* for 8330 rpm (has most data points). This fingerprint relation will be
referred to by the symbol “H*fp”.
The (quadratic) regression yields the following equation:

H fp 7.5658 [Q* ]2 3.6042 Q* 0.4985

 16

It should be pointed out that in this graph of the fingerprint ‘H*fp’ versus Q* , the surge line has
been reduced to one point. From its H*fp - Q* coordinates the whole surge curve can be re-
developed by applying the reduction transformation in reverse.

7.2 Fingerprinting the machine’s Adiabatic Efficiency Factor

To be able to predict the shaft power we need the adiabatic efficiencies of the operation of this
machine. The power absorbed by the adiabatic isentropic compression of the gas, Gad, is equal
to the product of the calculated adiabatic head and the mass flow rate. ( kW = kg/s * kJ/kg )

Gad Fw H ad
From the Manufacturers data for the required shaft power (section 1) together with the calculated
Gas-power absorbed by the adiabatic isentropic compression of the gas the Adiabatic Efficiency
Factor was back calculated for all the manufacturer’s data points , a total of 25 points ( for the
three speeds).
ad Gad / Ps
With these efficiency data in hand the question now became: can these efficiencies be related to
the operating conditions in particular to Q* ? If so how? As discussed before no theoretical
relation for the adiabatic efficiency for the off-design operating conditions and/or machine design
parameters exists to our knowledge. Therefore, by trial and error it was found that the adiabatic
efficiency, Eta-ad, could be correlated with Q* (defined as Q1/S * eps-h) as follows:

0.39
ad S / 1000
6.0793 8.4779 Q
Q1 / S

A graphical representation of this equation is shown below:

Correlating Adiabatic Efficiency with Q1/S*eps-h for vscCR-01

4.5

4
Eta /(Q1/S)*(S/1000)^0.39 --------->

3.5

3
Eta/(Q1/S) * (S/1000)^0.39 =

2.5 -8.4779*Q1/S * eps-h + 6.0793

for three speeds 5870 , 7000 and 8330 rpm

2
y = -8.4779x + 6.0793
25 datapoints
R2 = 0.9966
1.5

0.5

0
0.00 0.05 0.10 0.15 0.20 0.25 0.30 0.35 0.40 0.45 0.50
Q1/S * eps-h ----------->

Diagram -7 Correlation of Adiabatic Efficiency factor with Q*

 17

8 Simulation of the existing Compressor “vscCR-01”

Now that we have the two key ‘fingerprint’ correlations characterizing the existing compressor
(model identification) we can formulate and set up the calculation sequence to simulate the
compressor’s discharge pressure and gas density as well as the shaft power required to drive
the compressor shaft for a given volumetric feed rate and speed. We can set up the calculation
steps of the simulation model and implement these in excel as follows.

8.1 Formulating the Simulation Model and its calculation steps in excel.

The sequence of calculation steps and the equations involved in this simulation model are shown
in the next Diagram. There are two parts to the Model. The first part ‘A’ deals with the calculation
of the adiabatic head for the speed ‘S’ and volumetric feed flow ‘Q1’ from which the ratio of
discharge- over inlet pressure can be calculated followed by the absolute discharge pressure P2
and T2 and the compressibility factor Z2 and so on . The simulation model is ‘solved’ by
iterative calculations using simple substitution as convergence technique.
Note that excel needs to be put into ‘Manual Calculation’ mode.
In part B ,once the outlet conditions P2, T2 , Z2 have been arrived at, the Adiabatic efficiency
Factor can be calculated together with the Adiabatic Gas power. Next the shaft power predicted
by the simulation model can be calculated.

CALCULATION STEPS OF THE SIMULATION MODEL

PART -A- THE ADIABATIC ISENTROPIC HEAD Had and Pressure Ratio P2/P1

Steps Description

Input : Q1 suction vol feed rate in m3/hour

Input rotational speed S in rpm
Input inlet pressure P1 (10.5 Barabs)
Input : inlet temperature T1 ( 300.16 oK)
Input : inlet compressibility factor Z1 ( 0.838)
Calculate Feed mass flow rate in kg/s
Assume values for the discharge conditions P2 ( bara) and T2 (degr. K)
Calculate the Reduced outlet Pressure and Reduced outlet Temperature (P2/Pcrit ; T2/Tcrit)
Calculate outlet compressibility Factor Z2 using the Zv correlation
Calculate eps-h factor from eps-h=Sqrt[ 2/(1+P1*Z2*T2/(P2*Z1*T1))
+ P2*Z1*T1/(P1*Z2*T2))] ]
Calculate Q* = Q1/S * eps-h
Calculate H* = -7.5658 * (Q*)^2 +3.6043 * (Q*) + 0.4985
Calculate pressure ratio P2/P1 from H*
P2 / P1 = [ (H*)*(S/1000)^2 *MW / (Z1*R*T1*) *(k-1)/k + 1 ]^(k/(k-1))
Calculate outlet temperature from T2 = T1 *( P2/P1)^((k-1)/k)
(re)-Calculate P2

PART -B- THE ADIABATIC EFFICIENCY FACTOR AND SHAFT POWER

Calculate the Adiabatic Head from Had = (H*) * (S/1000)^2

Calculate the Adiabatic Gas Power Gad from from Gad = Had * Fw
Calculate the Adiabatic Efficiency Factor from
Eta-ad = [ -8.4779 * (Q*) + 6.0793 ] * Q1/S * ( S/1000)^(-0.39)
Calculate Simulated Shaft Power Ps = Gad / Eta-ad in kW

Diagram 8 Simulation Model Calculation steps showing iteration

 18

In the next section a copy of the excel worksheet with the implementation of these steps and the
resulting calculations for the model is given.

8.2 Excel Spreadsheet printout of the Simulation Model (steps)

The constants in the two ‘fingerprint’ equations for H*fp and the adiabatic efficiency Eta-ad are
shown in green above the respective columns. A pseudo Zcrit parameter of 0.26 is used for the
feed gas mixture used in the Zv equation.
0.39
-7.5658 Zcrit = -8.4779
this facor is calculated H*fp
3.6042 0.26 6.0793
iteratively
0.4985

Mass inlet speed Vol Eff Q/S * H~ P2/P1 P2 T2 calc P2red T2red Z2 P2 P2/P1 Shaft Eta-ad P2 calc Calc
Flow capacity rpm eps-h eps-h calc calc calc Manufact Manufact Power Calc Error% Shaft Power
kg/sec m3/hr Barabs kW kW
Fw Q S P2 Ps calc Ps
13.97 2400 7000 0.77 0.262 0.923 2.340 24.57 65.3 0.53 0.93 0.720 24.32 2.316 1000 0.619 1.0 1022
14.56 2500 7000 0.77 0.274 0.918 2.329 24.46 65.1 0.53 0.93 0.720 24.17 2.302 1024 0.628 1.2 1042
15.72 2700 7000 0.77 0.297 0.901 2.295 24.10 64.4 0.52 0.92 0.723 23.87 2.273 1067 0.643 1.0 1080
16.89 2900 7000 0.78 0.322 0.874 2.242 23.54 63.2 0.51 0.92 0.728 23.39 2.228 1100 0.649 0.6 1114
17.47 3000 7000 0.78 0.336 0.856 2.206 23.17 62.5 0.50 0.92 0.731 23.09 2.199 1120 0.649 0.3 1129
18.63 3200 7000 0.80 0.364 0.809 2.117 22.23 60.5 0.48 0.91 0.738 22.36 2.130 1143 0.641 0.6 1151
19.22 3300 7000 0.80 0.379 0.778 2.061 21.64 59.3 0.47 0.91 0.743 21.82 2.078 1152 0.633 0.8 1157
19.80 3400 7000 0.81 0.395 0.742 1.996 20.96 57.8 0.46 0.91 0.748 21.32 2.030 1162 0.621 1.7 1159
20.38 3500 7000 0.82 0.412 0.699 1.921 20.17 56.0 0.44 0.90 0.754 20.29 1.933 1172 0.606 0.6 1153
18.92 3250 8330 0.66 0.257 0.925 3.246 34.09 81.3 0.74 0.97 0.640 34.18 3.255 1829 0.665 0.3 1826
19.22 3300 8330 0.66 0.261 0.924 3.241 34.03 81.2 0.74 0.97 0.641 34.03 3.241 1843 0.669 0.0 1840
20.38 3500 8330 0.66 0.279 0.915 3.210 33.70 80.7 0.73 0.97 0.644 33.66 3.206 1906 0.683 0.1 1895
20.96 3600 8330 0.67 0.288 0.909 3.187 33.46 80.4 0.73 0.97 0.646 33.39 3.180 1937 0.688 0.2 1922
22.13 3800 8330 0.67 0.307 0.892 3.123 32.79 79.4 0.71 0.97 0.652 32.71 3.115 1980 0.694 0.3 1973
23.29 4000 8330 0.68 0.328 0.867 3.032 31.84 77.9 0.69 0.96 0.660 31.86 3.034 2027 0.693 0.1 2021
23.87 4100 8330 0.69 0.339 0.851 2.974 31.23 76.9 0.68 0.96 0.665 31.26 2.977 2044 0.690 0.1 2042
24.46 4200 8330 0.70 0.351 0.831 2.905 30.50 75.8 0.66 0.96 0.671 30.50 2.905 2060 0.684 0.0 2061
25.62 4400 8330 0.72 0.379 0.778 2.727 28.63 72.7 0.62 0.95 0.687 28.73 2.736 2074 0.663 0.3 2087
26.20 4500 8330 0.73 0.395 0.742 2.610 27.41 70.5 0.60 0.94 0.697 27.46 2.615 2078 0.645 0.2 2090
26.78 4600 8330 0.75 0.414 0.695 2.467 25.90 67.8 0.56 0.93 0.709 25.81 2.458 2073 0.622 0.3 2078
27.37 4700 8330 0.77 0.436 0.632 2.282 23.96 64.1 0.52 0.92 0.724 23.93 2.279 2067 0.588 0.1 2040
11.65 2000 5870 0.84 0.286 0.911 1.822 19.13 53.5 0.42 0.89 0.762 19.20 1.829 595 0.625 0.3 585
12.81 2200 5870 0.84 0.316 0.881 1.789 18.78 52.7 0.41 0.89 0.765 18.90 1.800 618 0.638 0.6 609
13.39 2300 5870 0.85 0.332 0.861 1.766 18.54 52.1 0.40 0.89 0.767 18.70 1.781 628 0.641 0.9 620
14.56 2500 5870 0.86 0.365 0.805 1.704 17.90 50.5 0.39 0.89 0.772 18.10 1.724 650 0.637 1.1 634
15.14 2600 5870 0.86 0.383 0.769 1.666 17.49 49.4 0.38 0.88 0.775 17.70 1.686 662 0.629 1.2 638

Diagram -9 Copy of excel worksheet for compressor simulation model

The calculated P2 values can be compared with the manufacturer’ P2 data shown on the right
hand side in bold numbers. The absolute percentage error in the calculated discharge pressure
P2 is on average 0.6%. See the penultimate column. The model’s calculation results for the
Adiabatic Efficiency factor and the calculated Shaft Power, required to run the compressor, are
shown on the very right hand side columns.

9 Simulation Model Results

The results obtained with the simulation model of “vscCR-01” are presented in the form
of a series of Graphical representations where simulation results are co-plotted with
manufacturer’s data for both discharge pressure and shaft power consumption.
 19

9.1 The discharge pressure and shaft power simulation results are shown
in the next Diagrams (click on picture to enlarge):

Simulated and Actual Performance Curves of compressor vscCR-01

42
40
38
Discharge Pressure --------> Bar absolute

36
34
32
30
28
26
24
22
20
18
16
14
12
10 Manufacturer's Data
8 Simulation Model Data
6 Surge Curve
4
2
0
1500 2000 2500 3000 3500 4000 4500 5000

Suction Volumetic Gas Flow Q1 ------> m3 / hour

Diagram -10 Discharge pressure versus volumetric flow for 3 speeds

Simulated and Actual Power Consumption of Compressor vscCR-01

2500

2000
Shaft Power -------- > kWatt

1500

1000

500

0
1500 2000 2500 3000 3500 4000 4500 5000 5500

Suction Volumetric Gas Flow Q1 ---------> m3 / hour

Diagram -11 Shaft Power versus volumetric gas flow for the same three speeds.
 20

9.2 Simulation results for inter- and extrapolated compressor speeds

The simulation model can be used to predict the discharge pressure performance curves for
other speeds:

Simulated and Actual Perormance Curves Centrifugal Compressor vscCR-01

42
40
38
Discharge Pressure --------> Bar absolute

36
34
32
30
28
26
8800 rpm
24
22
7800 rpm 8330 rpm
20
18
7000 rpm
16 5780 rpm
14
12
10 Manufacturers data
8 Simulation Model Data
6
Surge Curve
4
2
0
1500 2000 2500 3000 3500 4000 4500 5000 5500

Suction Volumetic Gas Flow Q1 ------> m3 / hour

Diagram -12 Discharge pressure versus volumetric gas flow for 5 speeds

Simulated and Actual Power Consumption of Compressor vscCR-01

3000

2500
Shaft Power ---------> kW

2000

1500

1000

500

0
1500 2000 2500 3000 3500 4000 4500 5000 5500
Suction Volumetric Gas Flow Q1 -------> m3/hour

Diagram -13 Shaft Power versus Volumetric gas flow for 5 speeds
 21

10. Conclusion

In this post a model is developed and described that allows an existing variable speed
compressor to be simulated with good accuracy. In addition a simple description of the
surge line is discussed.
The actual compressor’s performance, in terms of volume flow processed, pressure rise
achieved and shaft power consumption required, is simulated by modeling the behavior
of the machine as the result of two concurrently proceeding parallel processes. In one
process a ‘real’ gas is compressed in an adiabatic and isentropic fashion. In the other
process the energetic ‘loss’ behavior is described in relation to the operating
performance and characterized by the “Adiabatic Efficiency Factor”. This factor relates
the calculated adiabatic compression power with the actual shaft power of the actual
compressor machine
A ‘fingerprint’ of the machine’s characteristic adiabatic head production capability (hf) is
taken as a function of the machine’s “volume- moving” capability (or flow factor “f” as
defined by Q1/S * eps-h ) (model identification). The energetic loss processes occurring
in the actual compressor are captured with the Adiabatic Efficiency Factor.
Similarly a ‘fingerprint’ of the Adiabatic Efficiency Factor was taken with the help of a
newly developed relation that correlates this factor the flow factor “f” .
It should be noted that this correlation is strictly valid only for our particular machine
under consideration “vscCR-01”.
The simulation model developed here can be made to apply to other compressors as
well as long as the particular ‘fingerprints” for the machine under study are determined.
To be precise as long as the expression for ‘H*fp’ versus Q* is determined and the
‘adiabatic efficiency factor’ are correlated to Q* for that machine under study anew. The
correlation we found to apply to our machine may roughly apply to other machines and
may be a good start to develop your own : for example it may require just some “tuning”
or at worst require you to develop of a new correlation for your machine under study!
It should be noted that the model includes the accounting for the fact that the gas being
handled is a real gas with large deviations from ideal (from a value of 1.0) These Z
values are calculated with the ‘Zv correlation’ presented in earlier posts.