M16-Unit 3 - Centrifugal Comp. (Zadco-AHRT)

ZIRKU ISLAND TRAINING
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MECHANICAL TRAINING SECTION
MODULE 16
UNIT 3
CENTRIFUGAL
COMPRESSORS
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COMP. REF.: REVISION 01 PAGE 1 of 27
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TABLE OF CONTENTS
Paragraph Page
3.0 OBJECTIVES
3.1 INTRODUCTION
3.2 CENTRIFUGAL COMPRESSORS
3.2.1 Axial Compressors
3.2.2 Radial Compressors
3.2.2.1 Diaphragm
3.3 SEALING CENTRIFUGAL COMPRESSORS
3.4 COMPRESSOR BEARINGS
3.5 COMPRESSOR LUBRICATION SYSTEM
3.6 CENTRIFUGAL COMPRESSOR CONTROLS
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3.0 OBJECTIVES
The trainee will be able to:
 Name the two types of centrifugal compressor.
 Describe the operation of a centrifugal compressor.
 Name and describe the two designs of compressor casing.
 Describe various methods of sealing compressors.
 Explain the purpose of a volute and diffuser.
 Describe the most common types of compressor bearing.
 Describe the centrifugal compressor lubrication system.
 Describe centrifugal compressor methods.
3.1 INTRODUCTION
Centrifugal compressors are dynamic compressors. They can be

either radial or axial types and are normally very large units. A
centrifugal compressor is similar in design to a centrifugal pump.
3.2 CENTRIFUGAL COMPRESSORS
3.2.1 Axial Compressors
Motion or movement along the axis of a shaft is called axial motion

(see figure 3.1).
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Figure 3-1.
A compressor that moves gas parallel to the axis of the shaft is

called an axial compressor. An axial compressor has two sets of
blades, stator and rotor. The rotor blades are attached to the shaft
and rotate with it. The stator blades are attached to the casing
and are fixed. They are arranged so that there is a set of stator
blades between each two sets of rotor blades (see figure 3-2).
Figure 3-2
The rotor blades act in the same way as the blades of a fan. They
force the gas to move or flow as they rotate. They give the gas
both velocity and pressure. As the gas leaves the rotor blades it is
forced into the stator blades. The openings between the stator
blades act as diffusers and decrease the velocity of the gas. As the
velocity decreases the pressure increases. Each set of stator and
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rotor blades increases the gas pressure. Most axial compressors

use many sets of rotor and stator blades to increase the pressure.
The blades of an axial compressor reduce in size towards the

discharge end of the compressor.
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As the gas flows from the suction to the discharge port, the gas
has to occupy less space. This causes the pressure increase (see
figure 3.3).
Figure 3-3
Axial compressors are smaller and more efficient than a centrifugal

compressor with the same capacity.
3.2.2 Radial Compressors
The impeller is the part of a centrifugal compressor that moves the

gas. It is made up of two plates that are separated by blades.
(see figure 3.4).
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Figure 3-4
As the impeller rotates, the blades force the gas in the impeller to
move. The molecules in the gas tend to move out in a straight line
from the suction eye (centre) of the impeller. (see figure 3.5).
Figure 3-5.
As the molecules move outwards they gain velocity. They also

tend to oppose the push of the impeller, which increases the
pressure in the gas (see figure 3.6).
Figure 3-6
The increase in velocity away from the eye creates a low pressure
area at the suction eye itself. This low pressure area causes a
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suction that allows more gas to enter the compressor. The

impeller does work on the gas which converts into energy.
As the gas leaves the impeller it is thrust into a passageway called

the diffuser (see figure 3.7).
Figure 3-7
The radius of the diffuser is larger than the radius of the impeller.
This means the spiral flow path of the gas through the diffuser is
larger. The diffuser decreases the velocity of the gas and
increases the pressure.
The gas leaves the diffuser and passes into the volute. Inside the
volute the velocity continues to convert to pressure. (see figure
3.8).
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Figure 3-8
3.2.2.1 Diaphragm
Multi-stage compressors have diaphragms between each stage.

The walls of the diaphragms form a passage which is the diffuser.
After the gas travels through the diffuser it enters the return
passage. The return passage guides the gas into the next stage
(see figure 3.9).
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Figure 3-9
Diaphragms are normally made of cast iron or other hard metals

such as steel. They do not rotate with the shaft but are part of the
casing.
Diaphragms can be horizontally split or fully circular (one-piece).

Heat from the compressed gas can cause the casing to expand.
This causes the diaphragms to expand.
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In large horizontally split compressors this can cause leaks and a

lower gas pressure (see figure 3.10).
Figure 3-10.
Compressors casing design.
There are two designs of compressor casing, they are:
 Horizontally split casings.
 Vertically split casings.
The split of the casing allows the internal components to be

reached for repair or replacement. Horizontally split casings come
in two halves that are bolted together to form a tight enclosure
(see figure 3.11).
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Figure
On a horizontally split casing 3-11.inlet and discharge nozzles,
the main
side connections, and other attachments are often built into the
lower half of the casing. This allows the top half of the casing to
be removed so that the internal parts are easily accessible.
Horizontally split casings are only used up to pressures of 700 PSI
because of gasket leaks.
Vertically split casings have only one removable side, the other side
is part of the casing. (see figure 3.12).
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Figure 3-12.
A vertically split casing is sealed by two covers which are bolted to

the ends of the casing. To get to the internal parts the cover has
to be removed. The working parts of the compressor are often
called the bundle. The bundle is horizontally split to allow
installation or removal of the rotor as one unit. The bundle of a
vertically split casing is made up of various compressor parts.
Another type of rotor assembly is the stacked rotor. Stacked
rotors consist of a stub shaft at each end, a balancing piston,
several impellers, spool pieces and other parts.
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They are held together with a heavy centre bolt. (see figure
3.13).
Figure 3-13.
In vertically split casings, joints where the gas can escape are only
at the ends. (see figure 3.14).
Figure 3-14).
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Horizontally split casings, however, have a much larger joint area

where the gas can escape. (see figure 3.15).
Figure 3-15
3.3 SEALING CENTRIFUGAL COMPRESSORS
Since most centrifugal compressors are usually multi-stage

compressors, sealing between each stage is very important. A
tight seal will let the compressor develop pressure and be more
efficient. (see figure 3.16).
Figure 3-16
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There are several ways of sealing centrifugal compressors.
 Labyrinth seals. Labyrinth seals are used to seal the shaft

between the different stages in a multi-stage compressor. They
are the simplest type of seal. They are usually made of a soft
material such as bronze, babbit, or aluminium. A series of
grooves are machined to sharp edges that maintain a close
clearance between the mating parts. They can be either
stationary or rotating. Some leakage from the high pressure
side to the low pressure side is allowed. They are normally
used on low pressure centrifugal compressors, and operate
without oil. (see figure 3.17).
Figure 3-17.
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 Carbon rings. These are dry contact seals that are made up
of several high quality carbon rings. The carbon rings are held
in place by stainless steel spacers and axial springs. The whole
seal assembly can be removed from the compressor when it is
worn, or if there is broken segments. Sometimes a
combination of carbon rings and labyrinth seals is used. The
number of rings required will depend on the gas pressure in the
compressor. Carbon rings resist wear better than some other
seals. They are not, however, as efficient as a labyrinth seal
(see figure 3.18).
Figure 3-18.
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 Mechanical contact seals. Mechanical contact seals consist

of machined rotating and stationary surfaces. The surfaces are
in direct contact with each other to prevent any leakage. They
are mainly used for low pressure gas that is not corrosive. A
common type of mechanical seal has a rotating contact ring, a
full floating wear ring, a stationary ring, and a spring loading
device.
A small amount of lubricating oil is used to remove any friction

(see figure 3.19).
Figure 3-19.
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 Liquid film seals. Liquid film seals are the most common type
of seals used on high pressure or heavy duty compressors. A
typical seal consists of two or more rings that do not rotate.
They are free to float with the movement of the shaft. Oil is
injected between the rings at a pressure above the suction
pressure of the compressor. Labyrinth seals are placed on the
gas side to prevent any leakage of oil into the gas flow. (see
figure 3.20).
Figure 3-20
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3.4 COMPRESSOR BEARINGS
The most common centrifugal compressor bearings are as follows:
 Plain journal bearings Used to restrict radial movement (see

figure 3.21).
Figure 3-21.
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 Tilting pad journal bearings Oil becomes trapped in the

wedges between the shaft and the tilting pads. The oil
prevents friction between the shaft and the pads. (see figure
3.22).
Figure 3-22.
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 Thrust disc or collar bearings The thrust collar rotates with

the shaft. Axial motion is prevented by the thrust pads. In
normal operation the thrust collar and the thrust shoes are
separated by a film of thin oil. (see figure 3.23).
Figure 3-23.
Balancing drum.
The balancing drum or piston is fixed to, and rotates with the
shaft at the discharge end of the compressor. It is surrounded by
a seal that keeps leaks to a minimum.
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The side of the drum nearest to the end of the shaft is vented to
the suction end of the compressor (see figure 3.24).
Figure 3-24.
The pressure at the vent is the same as the suction pressure of the
compressor. The non-vented side of the drum is exposed to the
pressure of the discharge gas. The discharge gas pushes against
the balancing drum. It places a force in the direction of the
discharge of the discharge of the compressor. Its function is to
control the axial thrust of the gas pressure. The area on the
vented side of the drum in relation to the suction pressure, is equal
to the area on the non-vented side in relation to the discharge
pressure.
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3.5 COMPRESSOR LUBRICATION SYSTEM
The bearings of a centrifugal compressor are supplied under

pressure with lubricating oil. If the oil pressure is lost the bearings
are not lubricated. The lubrication system keeps a supply of clean
oil flowing to the bearings. (see figure 3.25).
Figure 3-25
Oil is forced from the reservoir to the bearings by means of the

main oil pump. It then passes through the filter. Centrifugal
compressors are fitted with oil filters to clean the lubricating oil.
The differential pressure is the difference between the filter
inlet pressure and the outlet pressure. Differential pressure
gauges indicate the condition of the filter. A change in the gauge
reading is a good indication that the filter is becoming clogged up
with dirt and needs replacing.
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From the filter the oil passes through the cooler. The lubricating
oil must be kept cool so that it can cool the bearings. If the oil
becomes too hot it will become thin. Thin oil will not provide a
protective film between the moving parts. However, if the oil is
too cold it will not flow through the bearings correctly.
The oil lubrication system has two filters. The filters are provided
with switching and isolating valves to allow for a filter change
without shutting down the compressor. One filter must always be
in service. The differential pressure gauge is installed to indicate
the condition of the filter in service.
Because the lubrication system is so important there is a back-up

pump, filter and cooler. If the oil pressure falls an alarm will alert
the operator.
If the oil pressure drops below a certain pressure, the overhead

dump valve will release a supply of lubricating oil to the bearings.
The overhead dump valve is located above the compressor. It is a
back-up reserve system for short term lubrication. It will operate if
there is a shutdown or when a pump suddenly fails. The dump
valve is a tank filled with oil, that will supply a gravity fed supply of
oil to the bearings.
The oil system has low level switches in the oil reservoir which
start an alarm and can shutdown the compressor. Sight glasses
are placed on the oil lines flowing from the bearings so that the
operator can see the oil flow.
Normally the lubrication system should continue during a

compressor shutdown because large units take a long time to stop.
During the shutdown lubrication is very important.
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3.6 CENTRIFUGAL COMPRESSOR CONTROLS
Most compressors must have some type of control system. The

drive system (prime mover) is normally a gas or steam turbine.
However, electric motors are sometimes used to run low speed
units.
Several methods are used to control the operation of compressors.

Each method must operate safely and stay within safe operating
limits.
Many large centrifugal compressors have a pressure release.

This allows all the pressure to be vented from the cylinder and
discharge lines when the unit is stopped. When the compressor is
restarted the unit is still vented until the operating speed is
reached. The pressure release then closes and the compressor
begins to compress the gas. (see figure 3.26).
Figure 3-26.
Surge.
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Surge is a condition which affects only centrifugal compressors. It

is the rapid flow of gas back and forth within the compressor.
Surging is caused by the re-circulation of gas starting at the
impeller edge.
A compressor will have a demand for air when it is started-up.

This is because there is little resistance to the discharge of the air.
With little resistance at the discharge end of the compressor, the
compressor capacity at first is high. As more air is delivered and
the system fills up, the capacity need of the system is reduced. If
the system does not use the air as quickly as the compressor
delivers it, the pressure in the system will increase. With an
increase in pressure in the system, the resistance to the discharge
of the compressor increases. This will cause the capacity of the
compressor to decrease and make it work harder. The pressure in
the system will increase until it is higher than the pressure within
the compressor. Then the flow will stop. At this point the air may
flow from the system into the compressor. The rapid flow of gas
back and forth into the compressor is called surging. It can cause
severe vibrations in the compressor and piping which can cause
damage to the compressor. To stop surging from occurring the
compressor must maintain an output close to the design output.
664573168.doc 5/13/23

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ZIRKU ISLAND TRAINING

3.2 CENTRIFUGAL COMPRESSORS

3.2.1 Axial Compressors

3.2.2 Radial Compressors

3.3 SEALING CENTRIFUGAL COMPRESSORS

3.4 COMPRESSOR BEARINGS

3.5 COMPRESSOR LUBRICATION SYSTEM

3.6 CENTRIFUGAL COMPRESSOR CONTROLS

The trainee will be able to:

 Name the two types of centrifugal compressor.

 Describe the operation of a centrifugal compressor.

 Name and describe the two designs of compressor casing.

 Describe various methods of sealing compressors.

 Explain the purpose of a volute and diffuser.

 Describe the most common types of compressor bearing.

 Describe the centrifugal compressor lubrication system.

 Describe centrifugal compressor methods.

Centrifugal compressors are dynamic compressors. They can be

3.2 CENTRIFUGAL COMPRESSORS

3.2.1 Axial Compressors

Motion or movement along the axis of a shaft is called axial motion

A compressor that moves gas parallel to the axis of the shaft is

rotor blades increases the gas pressure. Most axial compressors

The blades of an axial compressor reduce in size towards the

Axial compressors are smaller and more efficient than a centrifugal

3.2.2 Radial Compressors

The impeller is the part of a centrifugal compressor that moves the

As the molecules move outwards they gain velocity. They also

suction that allows more gas to enter the compressor. The

As the gas leaves the impeller it is thrust into a passageway called

Multi-stage compressors have diaphragms between each stage.

Diaphragms are normally made of cast iron or other hard metals

Diaphragms can be horizontally split or fully circular (one-piece).

In large horizontally split compressors this can cause leaks and a

Compressors casing design.

There are two designs of compressor casing, they are:

 Horizontally split casings.

 Vertically split casings.

The split of the casing allows the internal components to be

A vertically split casing is sealed by two covers which are bolted to

Horizontally split casings, however, have a much larger joint area

3.3 SEALING CENTRIFUGAL COMPRESSORS

Since most centrifugal compressors are usually multi-stage

There are several ways of sealing centrifugal compressors.

 Labyrinth seals. Labyrinth seals are used to seal the shaft

 Mechanical contact seals. Mechanical contact seals consist

A small amount of lubricating oil is used to remove any friction

3.4 COMPRESSOR BEARINGS

The most common centrifugal compressor bearings are as follows:

 Plain journal bearings Used to restrict radial movement (see

 Tilting pad journal bearings Oil becomes trapped in the

 Thrust disc or collar bearings The thrust collar rotates with

3.5 COMPRESSOR LUBRICATION SYSTEM

The bearings of a centrifugal compressor are supplied under

Oil is forced from the reservoir to the bearings by means of the

Because the lubrication system is so important there is a back-up

If the oil pressure drops below a certain pressure, the overhead

Normally the lubrication system should continue during a

3.6 CENTRIFUGAL COMPRESSOR CONTROLS

Most compressors must have some type of control system. The

Several methods are used to control the operation of compressors.

Many large centrifugal compressors have a pressure release.

Surge is a condition which affects only centrifugal compressors. It