©), REFINERY ENGINEERING a SCHOOL OF TRAINING CENTRIFUGAL COMPRESSORS CONTENT! H PAGE NO. 1. Compressor Selection: What to specify? 1 2. Types of compressors and Design/Construction Features 13 3. Principles of operation of Centrifugal 5 Compressors 42 4, Seals and Sealing Systems. 56 8. Wuality Control Checks and various tests 61 6. Surge ana its control 65 7. Instrumentation and Controls 69 6. Start up loading and Shut down Procedures 16 9. Do's and Don'ts for Compressor operation 62 10. 66 Tips for effective operation and maintenanceREFINERY ENGINEERING! centrifugal ]OOL OF TRAININ ne Compressors Selection Moistute Separators No compressor specification is complete without mentioning the need of mois ture separators following intercoolers or at the inlet of compressor when liv quids may be present in the gas stream. If separators are not present or inadequately sized, it may lead to ingress of liquid particles inside compressor causing high rotor vibrations, pitting and corrosion/errosion of impellers and seals, clogged gas passages etc. Suction Filters Centrifugal compressors are basically gas handling units and effective removal of foreign particles like dust, ash, tar etc. ahead of compressor will contribute to minimum maintenance and long trouble’ free operation. Deposits of solids inside compressor tend to restrict the flow and causesunbalance in rotor. _Degree of filtration and type of filter, particle size and analysis of dust should be mutually discussed to ensure machine safety and process compatability. Excess capability Due to peculiar drooping characteristic curve of centrifugal ‘compressor at any speed, virtually no j+ssibility exists for increasing the discharge pressure for “additional volume of gas over desigged value, In View of this, the compre-, ssor miust be built with excess capability for achieving’ higher plant loads beyond rated one. This implies that the driver also must be suitably sized over and above the ten percent reserve specified in API Standards. Parallel Operation “ . In some cases additional compressors are envisaged for augmenting existing capacity. These compressors are required to operate in parallel with existing machines. Since no two compressors can’ have identical characteristics, -it is quite likely that these machines will operate at different loads. In extreme case, the desired plant load augmentation can not be achieved due to the opera- ting point of one of the machines shifting towards surge limit. Hence following points need careful consideration, while deciding parallel operation of compressor. - System resistance Un-fortiiiately, many users take it as granted that machine designers are fully aware of variation in system resistance with plant load. It is there- fore extremely important that all aspects of system resistance shail -be ali = 7 BO REFINERY ENGINEERING centrifugal 23 Compressors 4 SCHOOL OF TRAINING Selection thoroughly discussed before recommending parallel operation. = Characteristics of existing machines The actual characteristics of existing machines under all operating conditions should be furnished to enable selection of a compressor with optimum mat- ching characteristrics, = Control system Generally, system resistance curve does not follow compressor characteri- stics. This implies that’ the selection of proper control system is necessary for successful parallel operation. Ee Operation at off-design point Sometimes," compresor is required to operate at conditions which are entirely differnt {rom shose specified in the contract. This may involve operation at different suction and discharge conditions and/or with different type of gas resulting in lower compressor efficiency and higher operational cost. If such off design conditions are envisaged during contract. stage, an optimum size of unit could be selected Third Party Inspection It is a common practice to insist upon inspection of components during manufa- cturing stage by an independent agency, However the scope of inspection is unclear or not defined completely resulting in delays in execution of project and also involving unnecessary controversies on minpr issues. It is desirable that various stages of inspection should be clearly defined in the contract in respect of major equipments. Information on utilities The availability of utilities like steam, water, electric power, power factor, nitrogen should be clearly specified in the contract with their parameters to enable proper selection and sizing of auxiliary equipments. The actual quality of cooling water available at site invariably differs from the quality of cooling water specified in contract. This affects the cooler performance and reduces tube life. Hence correct cooling water analysis and fouling factor should be furnished for correct material selection and sizing of coolers, fitters etc.Céntrigugal Compressors \ai/ SCHOOL OF TRAINING Selection | a er REFINERY ENGINEERING Noise control aie It is generally thought that noise {s generated only by the compressor and little care is taken in the design, sizing and layout arrangement of various other ‘equipments. 7 : In order to reduce total noise, the various contributions must be identified and evaluated. The ideal method for reducing noise is to prevent generation of noise by better design such as : fe = use of acoustic abatement in compressox hall proper dimensioning of compressor hall, to eliminate noise due to resonance better ventilation in compressor hall with preferably sides open atleast upto working level. a “use of special low noise valves. ' cs Isolation of background plant noise. proper location of high noise auxiliary equipment. tay But this may involve higher cost. Practical approach would be to try to reduce noise level after the compressor and auxiliary equipments are installed by use of acoustic abatement. 2 Ef instrumentation & Controls The objective of any compressor control is to achieve smooth capacity regualtion |: and to prevent the compressor from surging, even though the process flow reduces below the surge limit of compressor. In order to achieve this objective effectively it is advisable to include complete compressor control in the scope 7 ‘of machine manufacturer, who has better knowledge about the performance characteristic of machine and correct type of instruments necessary for the services 5 . ; Splitting the scope of instrumentation and controls between the user and the : vendor can cause misunderstandings due to enormous. work involved in mutual , discussion, approval of drawings and specifications and defining scope of ca supply in every case. Any communication gap can lead to delays in commi- i ssioning of units particularly when special instruments are involved which are : not readily available. .a Oy REFINERY ENGINEERING Scecaeaeactae Compressors La/ SCHOOL OF TRAINING Selection Electric motor for compressor drive The Choice of electrical motor as a drive for compressor is being favoured due to lower installation cost and where cheap and reliable electric power supply is available. Although electric motors are considered more reliable, following points if not properly taken care of, may cause serious problems while running the unit. Motor voltage During start up motor draws high currents resulting in line voltage dip, the magnitude of which depends upon size of electrical system. "In cases where motor driving the compressor is the largest in the plant, voltage dip can be 20% or more. Since reduced applicd voltage reduces motor torque by square of applicd voltage thé matching of motor torque under worst voltage condition to that of compressor torque should be ensured. It is a common practice to have a minimum of ten percent margin between torque capability of motor and the torque required by the compressor from zero full speed. Compressor torque ‘Compressor torque comprises of [riction, inerti. and’ thermodynainic power. The often neglected factor is the inertia. To ensure safe acceleration the inertia of total train reierred to motor speed should be correctly evalua- ted. The starting of motor with a load inertia larger than the inertia for which the motor was designed may cause increase in starting time and it will be detrimental to the motor. Sealing system Taking into account the type of gas and process limitation, customer should select a simple sealing system. = Simple labyrinth sealing This ledds to leakage of considerable amount of process gas to the opera- ting floor. The limitation should be considered before the selection.= ; Pg ; ¢EFINERY ENGINEERIN¢ centrifugal 6 c SCHOOL OF TRAINING compressors Selection Rn = Injection system ‘ If the process gas accepts the contamination’by the sealing gas then this type of sealing is best advisable. = Injection and ejection system : With this system, a little amount of process gas is thrown to atmosphere. Therefore customer should design his plant for this continuous leakage of the gas. : = Oil seals (floating seals) | ~ Seal oil system is slightly complicated to the one said above. During normal ; operation, the sealing of process gas is achieved. owever during seal - oil failure the trapped gas should be (evacuated) vented. = Mechanica! Seals In this type ‘of sealing system a continuous contact will be there between stationery & rotating parts of. equipment. During seal oil failure these seal seal the trapped gas. Thus loss of parent gas is kept very minimum. However maintenance point of view these seals are very disadvantageous ’ to the operating personnel. . Conclusion It may be noted that customer/consultant are requested to indicate as much as details to manufacturer during enquiry stage. As such a good specification and enquiry will contribute the reliability of the unit as well as a reasonable : cost. érin ‘REFINERY ENGINEERING SCHOOL OF TRAINING Data required © to make out a tender ; Listed below are tho essential technical information needed in each enquity, in ordor to solect the most suitable compressor and diive for a given duty : 1) Type of gas and its main charact- eristics, such as molecular weight, specific heat ratio, compressibility factor, relative humidity, or otherwise the ‘938 composition, pressure is actual and not absolute, the atmospheric pressure to which it rofers should also be indicated) Temperature ii) Temperature 4) Cooling wi i) Temperature ii) Prossure : iil) - Analysis : labl In addition, the customer should pacify all operating characteristics with regard ta his equiremonts, type of control, etc. It should also be indicated whether the compressor isto be installed indoors or in the ‘opon, as well as details of the ambient’ conditions. Centrifugal a Compressors Selection Selection of Compressor type and caiculation of shaft power cexample) Tho following two diagrams give an approximate method of selecting the type of compressor for a givon duty and calculating its absorbed power. The resulting date should not be taken as exact, Bear in mind that the diagrams are not valid for ‘isothermal’ machines, those with intercoolers or other sppcial types. To illustrate the practical use of the diagrams, the following exampio will help: = Gas to be compressed Nitrogen = Molecular weight 28 of specific heats 1 = Capaci 46,000m* ihe = ‘Suction pressure 1.033 kg] om’ abs. = Suction temperature 37°C Discharge pressure 3.1 Kg/ ‘om! abs.Centrifugal Compressors Selection ‘azis sosssidwiop 0 YoRs325, {QOL OF TRAINING s ‘©, REFINERY ENGINEERING o é Tree phe oaTeemery4 2 g 3 & g 3 € 8 Compressors Selection 1OOL OF TRAINING REFINERY ENGINEERING, ie g ooyon at wu 8198 iantess Te ity? samiod 384s Jo UOHEINIEDss. ‘Oy REFINERY ENGINEERING 4 Las |OOL OF TRAINING centrifugal Compressors Selection TECHNICAL DATA FOR COMPRESSOR EQUIPMENT CUSTCMER TYPE OF PLANT NO. OF UNITS REQUIRED SITE CONDITIONS : (a) Altitude (metres above sea level) (b) Temperature: Winter °C (minimum) Summer °C (maximum) (c) Relative humidity () Barometric pressure (e) Area classification (f° Installation SERVICE CONDITIONS : (a) Gas handled (b) Composition of gas % by volume (c) Particulate matter, dust concentration (if any) in the gas (d) Molecular weight {e) Cp/cv (ft) Compressibility fector at suction and discharge Fouling factor of gas (9 OPERATING CONDITIONS : {a) Suction pressure (ata) (b) Suction temperature (°C) (c) Relative humidity (%) (d) Discharge pressure’ (ata) {e) Discharge temp. (°C) (f) Capacity handled (per unit) NM3/HR (Dry) or KGS/HR (Dry) CENTRIFUGAL AXIAL ANY ONE OF THE TWO. Hazardous/Non-hazardous. Indoor/Outdoor/Under-roof: ‘Sy REFINERY ENGINEERING. centrifugal peeps ‘SCHOOL OF TRAINING roa. Compressors (ga) Injection/Extraction (if any) Copacity (NM? /-HA) Pressure (ata) . Temperature (°C) Gas/composition (4) TYPE OF DRIVE : © Steam turbine 0 Electric motor © Gas turbine s (a) Steam parameters for Go. | drive turbine. YS .Steam inlet Min, (ata/*C) Nor. (ata/°Cy ere Max. (ata/°C) Extraction Min. (ata/°C) Nor, (ata/*C) Max. (ata/°C) Exhaust Min. (ata/°C) Nor. (ata/°C) : Min. (ata/°C) cn Extr. Quantity Min./ : Nor. /Max. (t/h) | : (b) Electric motor: ve Type Supply voltage Cycles Phaso Construction : (c) i) Parameters for gas : turbine and composi- tion of fuel : _ i) Method of start up (power/steam parametresee 5 0 Dy REFINERY ENGINEERING centetfugal Las SCHOOL OF TRAINING + 123 Compressors | Selection (5) UTILITY CONDITIONS : (a) Steam for auxiliaries. » .. pressure (min./ Nor./ max.) temp. (min./ nor./ max.) £ exhaust pressure (min./nor./ max.) (b) Electrivity for auxitiaries Supply voltage Cycle Phase Perce eeeeeeeeeee eee eee eeeeeemeee —— PEEeeee ence eee cence SE ee er eee ee ee pease renee eae Pee (c) Cooling water Temp. °C (max./min) : Preeeeeeeee cece Pressure (ata) pL Allowabletemp. raise (°C) 9: Fouling factor Eee eee Type of water Cen Eee een et eee coerce (d) Electricity for instruments Supply voltage (AC/DC) Cycle Phase e) Instrument air (Kg Cm?) (f) Pressure N: available (pressure/°C) Any gas available for injection/ejection sealing system (if needed) Type of gas Pressure (ata) Temperature (°C) (6) ANY OTHER INFORMATION : SPECIFIC REQUIREMENT ETC. (IF ANY) eee In case more than one unit is required, : SEPERATE FOR EACH UNIT Whether lube oil system shouldbe =: COMMON FOR ALL THE UNITS: 13: mo, ¢ > REFINERY ENGINEERING cowpRTPUGAL COMPRESSORS SCHOOL OF TRAINING TYPES AND CHARACTERISTICS Types and characteristics of | i production of Centrifugal Compressors : Mc TYPE ISOTHERMAL TYPE ! ‘Mulistage Compressors for low and Multistage Compressors ‘medium pressures with horizontaly medium preseures with hot ‘pli casings. They can bo used in split casings that allow ins i + ethylene plants, lube oil plants, cof two high efiiency itor inary processes, ciy gas distibu- coolers after each compression stage. tion, ete, “They avo mainly used in factionating plants, for insicumont aie and for 2 mc TYPE process arin largo synthesis plants. Maitstage Compressors for low and modi prossutes with horaontaly WC TYPE split casings provided with intermedi- Multistage Compressors for high i ‘Mo,uction and discharge nozzies. pressures with vorically split casings. Used in tho same fild as MC, they Mainly uted for make-up and recycle allow grouping of two comprossion _aarvice in high prssure proceusea - + stages inthe samo machine wit ‘of rolinoios, petiochemical plants, Inarmadiata cooling. ammonie, methanol and urea ‘ : ‘yobs plans. ‘Machining 2 2MCL compressor in closed condition 8A & Vo TYPE ‘Single Suge Compressor for low rossvies mainly used aa blowers ‘or boostors In industies,relinsios ‘end petrochemical processes when Iaxge volumes of gases have to be ‘handled ot tow pressure PR & PC TYPE Single and Multistage Comprassors for high prossuros with votically, split easings. Those are mainly Used in pipe line booster suations, for naturel ges gathering end for recycle ‘services In medium high pressure processes,= : ‘Oy REFINERY ENGINEFRIN centrifugal 1: Compressors SCHOOL OF TRAININ qypes and Characteristics MC type : “"""""2MC type low and medium low and medium pressure multistage pressure multistage Compressors , Compressors ‘This type of compressor comes in ' special duties, this is obtained by “Their charactoristics are similar to the form of one ofthe thitean soles, using fully enclosed cl seals, The the MC ones but exch casing houses, characte by Internal sealing between tho various two compression stagot In stogas i gonoralyetfected by back-to-back arangoment. tn this ot ofthe brine ps, suplenanary eucon nd rexsot and the suction an charge nozzles alto ean uch ancl in The Impaler and its provided for pocial requirement. designed withthe required characte fata used are the sam as for tic of tha machine asthe prime AC rype compressors. However, waren Getenaing on te compression consiveration (surge limit slope pele raqurements due to the . tato requed andthe type of gas oF the basic capacly-compreasion cular sence, as for instance handled ratio plots oc). tow temperatures or cortosivecom- nents ofthe gas handled are ‘The horizontally split casing is “howe comprassors canbe proved Ta neal consisreon. ‘thor mada from special cast ron with Itarmadlage wction “They ara used whan latormediate* pec cat on pd entacionnazoe ruled fr TY ‘toa accordiag the duty othe eas ech x raigerting _Co0Kna pte ge necesay, eeopmmner ‘yetes. For compression of very “Thess machines are widely ompoy- ‘The Journal beings ae ofthe ‘igh volumes they are also avATABIe gd ag charge gee compressor in leave ypa andthe rust basing In double ow veson This soliton eiytane plant in ct caching wot the sting ped type. parts th comoressor rota plant In 60, comprasion tine Spoods to be maintained within the for ute plants for extraction of ue “The shat end seating ie achloved by speed renge of soum turbines {gen lube ol plone, In abn aia by extcion oro thoy can be det coupled dn onan Injection sytane. Wowove, tor tothe comprewor ‘atigoalng parte.Sy REFINERY ENGINEERING SCHOOL OF TRAINING centrifugal Compressors Types and Characteristicg BC type high pressure multistage Compressors Eight series of machines covor the capacity range of type of compressor with operating: pressures up to 100 ata. The numbor of impellers varies from 2 10 9 for oach series. The outer teasing is formed of a barrel, normally in forged steel, closed at each end by a cover. The rotor diaphragm assembly is introduced axially into the casing. Tho bearings, the housing of which is integral with tho ond covers, ily access “The end seals aro genorally of the oil type. Main bearings, thrust beating impollors and internal compressor parte are identical with those of the MC type. This type of ‘compressor Ia characterised by ‘exceptional sturdinoss. Isothermal Cornpressors with built-in intercoolers Five series of machines cover the entira range of this type of com- pressor which has been designed ‘0 compress air oF nitrogen from atmospheric pressure up to 18 ata of ‘even higher. They are normally manufactured with 4 or § impollors. ‘When passing from one stage to tho next the compressed gas passes through two built-in cooler artangad in parallal which limit the discharge temperature and thereby reduce tha power required for * compression. coolers with thoir high 1 finned tubes, ate 6: removable through the cover provi- ‘This type of compressor is suitable for continuous operation for ‘oxfemely tong periods in tho open undar widely differing climatic conditions and demand vary little attention, ' ‘When gas inter-cooling is required these comprossors are provided ‘with intermediate suction and dolivery nozzles. In this case the impellers ara arranged back to back in ‘two groups to minimise axial thrust. ‘Special versions for highor ta6 (up to 360 ata) aro also for use in ammonia and ‘methanol synthesis plants. dad in the upper compressor casing. Downstream of each:cooler, moisture trap is incorporated. Spocial cast iron is used for the casing itself. The bearings, impellers and ond seals have tho ‘same characteristics as those of the MC compressor. Due to high thermodynamic effici- ‘oncy and advanced consteuctional dusign of this type of compressor, considerable saving in power, and reduction in the mass of foundation, ‘erection and maintenance cost, are achieved. —art REFINERY ENGINEERING SCHOOL OF TRAINING Centrifugal Compressors Types and Characteristics High pressure Low pressure single and multistage single stage PRand PC "closed type impstet. The single place cast o forged stasl casing is designed for presque up to 100 at ‘The suction and dolivery soz are suzably arranged t init the ‘haut on the easing. Depending on ‘the method of deving, the casing In elthor aupolid with is own, ‘pedestal or flanged to the goar box ‘a8 forthe fow pressure single stage ‘machines. Oil seals are generally ‘usad for shalt ond sealing ‘These comprossora are specially ‘dauigned for gas pipeline boosting stations, natural gas gathering fond recycle sanvicos fn medium snd, high pressure processes. PCL comprossor fot Natural gas service undergoing post test ‘manipulations SR and VC Compressors These have a single open or closed type impair. Th casing ls ther ‘rom cast ron or tabvicated sto ‘The infot nozzle is usually onthe sama exis as tha of the compressor shaft while tho discharge nozzle is genstatly verically upwards. When driven trough @ geer box, ‘compass casing ts usually Hanged. to the goar box is ‘ovor-hung on the high speed shat ‘of tho goar ox. The enti unt Is ‘generally mounted on # common base ‘late which houses the lube cil ‘osowit, The rest of the lubscating ‘equipment (1. standby motor Rese ‘compact packsge unit for esty yoy Inuallatlon. +7). es 2 olds wo eae CENTRIFUGAL COMPRESSORS Las SCHOOL OF TRAININS CONSTRUCTIONAL FEATURES Casings Gonuitugat compressors have two \ypes of ca Hotizonally spt or Voricaliy spit sod whan the working vit, ‘and have complete access tothe pressure and type of gas demand ts, the main dividing flange such an arrangoment. All intenal one hove tobe urectwedprt ote pe aaa stn a lich the bongs, inpsioe, Hose the hetanay alt, HORIORT ANE Seu: ‘but in addition, itis enclosed in a boc forged se eye a : {Bay top one wich {ensily accessibe som the outido ee eee ‘Tho tower half of tha besring pie ee ‘housing is intagrel withthe end * ‘Tho casings of MC, 2MC and Titesebn woes oe ce itis possible to withdraw the {SOTHERMAL compressors fal ee Say ee In thi group, plete internal eesornbly the varlous paris without VERTICALLY SPLIT In this typo, the compressor casing is divided fa the hovizonta piano in the middla and conssis of an Lupper and lower part. All nevossary ‘auachments, nists and outers ‘uch as suction and discharye noedlos (and intermediate ones where thoy (exist) and lubo ol pipany connec tion are usually built into the lower halt so that ths upp hall an bo eal ited. With tis wrange- iting olf and ges passeges in high pressure ‘compressor end cover .Diaphragms ‘The diaphragms form the dynamic slow path of she gas within tho stationary pat of the compross ‘They are divided into thee typ Auction, Intermediate and discharge. ‘The suction disphragm guides the gas into the eye of the fst iempeter and con be provided with ‘adjustable Inter guide vanas to vary the inlet engle ofthe gos. Tho intermediate diaphregms ‘perform the dual task of forming the diffusion passages In which ‘the gas velocity is transformed into pressure and the return passages to [Buide the gaa to the eye of the next Impaler. ‘The difturere can bo either tho free vortex aype oF the vane type. The diftusar blading, while improving the thermodynamic efficlency, ‘cent exty of the machine I Final nachnung operations on 4 + HP compressor dilvayms pack GC REFINERY ENGINEERING Aas SCHOOL OF TRAINING 18 dlifusor of the last impolor ax wall 4&8 discharge volume. Tho diaphragms aro usually spit {two halves, In the MC and ISOTHERMAL satas the upper halvos ‘ate fixed to tha upper hall ofthe ‘casing to facilitate easy Inepacion of thy tor. Each diaphragm labyrinth rings to fact tho sealing ‘or the impellor shroud and prevent @ return flow from the discharge ‘pace to suction of each impeller, {and on the shaft spacer sleavas ‘ut out interstage lonkage. Tho sanling rings are easly removable, Centrifugal Compressors ~ Constructional+ | reariegy tnonced ar undoqoes Centrifugal 2 Dy RELINERY ENGINEERING” | | Compressors = SCHOOL OF TRAINING 7 f Constructional Features ‘The fotor consists of shal, im- pally, balancing drum and thrust calla. Te ghaf i usuaty mad rom soy staat and te inpatoe and baluncing dia ao shrunk on it Spacers of -Aultablp, material are used to ta oft opan or losed ypu. The closed onc, rm | backwards, depending on the equited aed cure, ‘The open Impeliers are machined — | tomtatilaciaeiea | Meet ets om as. | Brcatsiintstnette | ‘Ean overspeed test before being (ried tp Fe shat. “The balancing drum nude of oxysd ‘ape a designed f0 balance the axial ‘ thausts acting an the impelire duo ‘to the gat. Tho thrust buxing ‘absorbs tha reskdua tnust. i Al tts ao dynamical talon. | > 4 for han tas which hve a sie the amo bihunce bs checked alton ‘hvlnking each impleLubrication system A carefully designed tube ot system fensures an uninterupted supply of fed lube cil othe journal and ‘thrust boariags. The entire console 1a dosigned es a compact unit, suitable for quaranteed continuous ‘operation af the compressor, All ancillary equifment mentionad Dbalow are Intagraly mounted on. ‘ot ecarval 4)" Ol pump driven by a steam, turbine or en electric motor. 1b) Full flow oll cooter. ©) Twin titers (6 microns degree ‘of fivation) allowing oplace- ‘mont of fitoring sloment without Interrupting the oil ow. 14) Automatie bypass valve for maln- ~ At vattous points on the intercon- ‘pecting piping. apart trom the valves ‘te. indicating instruments and safoty aquipmont, are incorporated {for auiomatic and manual conuol of ‘sha unit. For continuously operating ‘compressors, tho ua oi systum is provided with two pumps, two ‘coolers and two liters such thatthe ‘change-over from one to the othar sakat place without interrupting Ww of oil, Even in such cases i pump is driven diectly stam i supplied complato with on ary pump for operation during ‘tart-up and shut down. Bearings auallyfres-od plain typo bear Inge ne ied. They ore oxenaly ‘mounted and can thersters bo inspucted without roloasing the prtaur inside tho compress Depending onthe elastic buheviout Oo he ror, aliptcal or iting ped type main bauings ar used, nich se highly effective in dampening Pibrationg. Thoy redesigned Tn con- ion ‘uh. ary alactzqnic cqmputer bin Ryne OPE ay REFINERY ENGINEERING SCHOOL OF TRAINING ‘that vibration requoncy while taking Into ‘lect of tha impatior, ‘The thrust boating ie of the pad type to enaure equal thrust dietbution and hes a conto! ring 10 minimise the fucitonal losses ‘due fo oll entrainment. 20 ;ount the gyroscopic centrifugal Compressors = Constructional Features Simpliied tube oll schemeShaft end seals These serve to eliminate or reduce to aminimum: (2) theleakooe ‘of comaresand ges form, oF (B) the ‘enw of ale Into the compressor ‘casing. The choice of the type of foal ls made keeping In view. tho (te chavacteristcs and its condition. LABYRINTH SEALS Whore sight loakago of gus can bbe pormitted, a cores of abyrinun ‘sale ae used to minimise the Taakage. In this case, the gas tying 10 excape fiom the shalt end is of thin ngs ey are mado {rom light alloy or other coxosion ‘odatant matefal loss hard than th aa easily removable. Thetounbe of lobe and their clearance depends on tho ‘operating conditions. When po leakage whatsouver is ‘perissibie (poisonous or explosive shaft isl to prevunt damagu tothe Shainin avant cont. aomae woe “gatoa, ato) in the compressor ‘house, labyrinth seals ere combi ‘with extraction of Inaction syetams, ‘which prevent leakage of gaa tothe saumozpher Ol SEALS The ail seals consist of two outing tings. Tho preasure. This flows through the Clearance space batwoen tho shaft ‘nd the seal sings. Tho oil escaping ‘on the low pressure side retuene to the reservoir und ia ecirculated, ingross of cil nto the gas _space is provonted by # la {abyringh og provided with an Intermediate prossure balancing ‘chambor placed betwoon the oll seat ‘and the compressor isl ‘Simpliiad oll seal scheme : s. & ‘Oy REFINERY ENGINEERIN Centrifugal c = SCHOOL OF TRAINING ‘cea eee Constructional Features i ! | ' SEAL OWL CIRCUIT ‘The soa oll clicut supplies clean, {itor ol tothe oll seas at the ‘cones presaure and temperature, ‘Tha ean! ol clagiam shows a ‘ypleal oil ecu for tha seal elements BC type compressor. ‘The main aloments ere dataled in ‘he diagiem. COMPRESSOR AUXILIARIES ‘Apart trom comptesson and dive turbines, auxilrios euch as Ibo and sea ol aystom, heat ‘exchanger, ppg etc. are aupelied bby BHEL. |a7 Dy REFINERY ENGINEERING SCHOOL OF TRAINING Control systems |. toe totowing metods or ave SUCTION THROTTLING | abe for malnalnng the cnpaciy, This method is fraquonty used and | the suction or diacherge pressures constant under varying process conditions VARIATION OF COMPRESSOR SPEED minimum obtainable capacity 1 dictated by the surge limit of the compressor. ADJUSTABLE INLET GUIDE VANES or gas turbine, an and hydraulic torque convertor or ‘any other vatable speed drive. DISCHARGE THROTTLING A throttling valv is ited in the lscherge piping. The prossure at the compressor outlet nozzle wil ‘increase in order to recover the rormal value down streaen of th valve. The miimurh cepacty is aicerained by drawing a vartical line ‘passing trough tha tit of com- (reetor stably. Those vanes induce a pre-rotation ‘of the gas by altering its dection of flow, thus varying the compression ratio and capacity of the compressor. ‘In multistage machines, for cons- tructional reasons, hese guide vanes can only be fitted Before the first stage ‘or through a sarva-mot centrifugal Compressors = Constructional Features ‘Tho eystom Ia standard on ll planta ‘and cons into opention aso relat rmachanipm, or when the other control aystemaata no longer capable of handling excess capacity or praseure, Capac conto RR oy aussie gute vane Maint 27 ctor cring 3 eZee ov sed sain FMM by icbuge rcrtngat >) ReFIN ete Hee ve 4 NGINTFRIN CENTRIFUGAL COMPRESSORS SCHOOL OF TRAINING DESIGN FEATURES 1 qe 4 1.1 432 Introduction: Centrifugal compressors find their application in a variety of the industries associated with the manufacture of fertilisers, petrochemicals, oil refineries and steel plants for various services covering the range from a suction capacity of 1000m?/hr to 350000m*/hr and for a pressure ratio. as high as 10. Based on the type of casing design, compressors are classified into two types 1, Horizontally split casing 2. Vertically split casing design Horizontally split casing design(MCL’ type) This design is used for low working pressures below 40ate, ‘These casings are in two halves with horizontal parting plane. Main nozzles and auxiliary connections are provided in the lower half of casing and the upper half serves only as a cover which may be lifted by removing the bolts on the parting plane giving free access to the internale of the compressor for inspection and maintenance. VERTICALLY SPLIT CASING DESIGN(BCL type) is made of parrel construction closed of the sides by end covers with the help of studs, This type of construction ig suitablé for high pressure operations ppto 750 xe/ en? Sealing is provided between the casing and closing flanges with the help of endless '0' rings. Compressors are aleo built in single casing with two identical compression stages in parallel arranged pack to back which.handle double the quantity to that of a single stage compressor. In case of. two 4 compression stages in series, the outlet gas from the firet phase is cooled in a heat exchanger and the cooled gas is compressed in the second stage. In= G27 AETINERY ENGINEERING oe aL? SCHOOL OF TRAINING : 24: Compressors = Design Features these types ‘of compressors also, the dompresaion stages are arranged bark to back. Two types of BHEL compressors have been mentioned - MCL and BCL, It has been said that the first have horizontally split casings and are suitable for pressures upto 40 ke/cm®, whilst the second are of the barrel type in one piece, suitable for high pressures and having closures in the vertical plane, Another type of compressor is the PCL, which has casing in the form of a cup with a single closing flange in the vertical plane instead of two as with the BOL, It is used exclusively for the transfer of gas in gas pipeline service and it is for this reason easily recognised by the two flanged nozzles projecting from the casing: suitable for connecting directly into the line. The flexibility of being able to use from one to three impellers in the same forged casing, together with the robust, simple construction, render this type of machine easily adaptable and excellent 4 for continuous “heavy duty" service. The SR and VC compressors have a single stage { and are suitable for low pressures, The first have Bee normally a cast-iron case, whilst the others are fabricated. The overhung impeller can be of the open or closed type, ‘The suction flange is, in general, , on the axis of the machine dhaft, whilst the delivery ie in the vertical plane at the termination of the _ volute, These compressors are used as blowers or “boosters” in industry, refineries and in petrochemical | vt processes when large volumes of low pressure gas are : involved. The DMCL compressors have two stages of compression in parallel in a single casing. The two stages are PRESSE eee HEH= a 2d REFINERY ENGINEER paren ‘SCHOOL OF TRAINING #25 3 ‘ Compressors - Design Features identical and their delivery is on the vertical centre line. This solution 1s the most balanced possible. The last impeller of each stage, that is, the one nearest the centre-line of the compressor is a double flow type. A machine designed in this way enables a Particular quantity of gas to be compressed with Ampellers of lower diameter. The other aspects of construction are the same as for the MCL compressor. The 2MCL is a type of compression with compressor stages in counter opposed sets. It is used when intermediate cooling of the compressed gas is required. For particular requirements, it is possible to use supple mentary volutes on intake and delivery. The 3MCL compressors have 2 or more stages in line with extraction on injection of side loads. The number of extractions and injections varies from instance to instance (the number 3 before the frame designation is conventional.) ‘he weight flow through the machine ia not constant during the compression. 5 There remains finally the 28CL compressor, a barrel | type machine and therefore suitable for high pressures. This type also has the compression stages arranged in counter-opposed stages. 1,3 The designation that distinguishes BHEL compressors is formed by two groups, one of letters and one of numbers. The groups of letters define the characteristics of the stationary part with particular reference to the case (1,e. BCL indicates the compressor 1s a barrel type suitable for high pressures whilst MCL indicates compressore suitable for relatively low pressures with horizontal split casings). A letter or a number before ‘this group defines the arrangement of the compressor ‘ stages or alternatively refers to intermediate extraction= i ao ‘O), REFINERY ENGINEERIN : centrifugal 2 26 4 Compressors = SCHOOL OF TRAINING Design Features 2.0 201 or injection. Por example: 2BCL 457 designates a barrel type compressor with counter-opposed compression stages in series with impellers of 450m diameter having seven stages compression. In addition to. the normal BCL suitable for pressures upto 70kg/¢m2,, Classes BCL/a-b-6, have been developed for pressures upto 200ke/cm2, 350ke/em2, 500kg/cm2 and 700kg/cm2, respectively. Compressors are also designed with intermediate extraction ° or with injection quantity in which case the mass flow : through the compressor is not the same, However the constructional features are basically same as those of other types of compressors indicated above except for the additional nozzles required for the purpose of injection or extraction. Design features ‘ The performance of the compressor is assumed on the following criteria. a) Thermodynamic performance achieving the required compression with the minimum power consumption and optimum sizing of impellers. b) rouble free_run of the unit. This is achieved by proper dimensioning of the mechanical parts followed by the study of flexural and torsional behavior of the rotors and finally by a proper assembly of the unit. The important elements of the centrifugal compressors are casings, diaphragms, rotors, seals, bearings, couplings.REFINERY ENGINEERING ae COMPRI OR_ASSEMBLY BCL Li SCHOOL OF IRAINING =COMPRESSOR ASSEMBLY = 2 BCL 07 Bs, REFINERY ENGINEERING : 28 : Ah / sion OF TRAINING7 Dy REFINERY ENGINEERING Ah / seu JOOL OF TRAINING + 290 4 COMPRESSOR ASSEMBLY ~ MCL 2Pn FS, REFINERY ENGINEERING’ 30 Va SCHOOL OF TRAINING COMPRESSOR asshe Se. 27 HO REFINERY ENIGINEERIN Heer AL SCHOOLOF TRAINING COMPRESSOR ASSEMBLY = 2 MCL i Pol J 3 J}oo 8 Oy REFINERY ENGINEERING ane COMPRESSOR ASSEMBLY - 2 MCL SCHOOL C7 TRAININGete >, REFINERY ENGINEERING centrifugal Af J sot octu SCHOOL OF TRAINING 7 Poteet oeeet Design Features Materials It is now necessary to consider the materials used for construction of the principal components that make up @ compressor, The materiais used for the various compressor types differ, mainly for the external parts of the machine. The materials used for the rotor and the other internal parts differs more on account of the temperature, the corrosive nature of the gas or the stress levels involved than the machine type. Casings As already said, the case of the BCL type hao a barrel form with nozzles and supports welded to it, The barrel is a forging; this method of production renders the material more homogeneous and therefore more resistant to stress. Normally, carbon steel is used for the barrel nozzles and the supports and for the covers. The material ASTM A105 GR.II (with carbon content of 0,2 - 0,25% instead of 0,35% as in the stds.) sufficient to obtain good mechanical characteristics and at the same time suitable for welding. The POL also has a Casing and ‘forged cover in ASTM, A 105-the nozzles however aro cast because they have a complicated form : The: MCL compressor casing is machined from cast iron or steel as statel in API standard or stated by the client. In general a grade of steel called mechanite CD cast iron with a tensile atrength of 25-30kg/mm2 and a compressive strength of 70kg/mm2 which is better than many steels ip used, When it is necessary to use= 7 Hy REFINERY ENGINEERING Centrifugal Compressors ~ SCHOOL OF yf) SCHOOL OF TRANING a + ret Design Features a cast steel the material ASTM, A.216 WCA ie used. For low temperature operation one of the four grades of the steel ASTM A 352 1s used depending on. the actual temperature conditions, Finally for corrosive fluids, ASTM. A, 351 Gr. Cai5 (13% Cr) steel or alternatively Gr, CFS is employed. Diaphragms: The diaphragns constitute the dynamic profile of the stator parte of the compressor. . They are divided into three types viz., suction, intermediate and delivery. Suction diaphragms guide the gas to the first impeller. Intermediate diaphragms have the function of transforming the kinetic energy into pressure, serves return channel to guide the gas to the next impeller with shocklese entry. Delivery diaphragm forms the diffuser for the last impeller ana delivery spiral. Diffuser ean bo free vortex design or bladed type. Bladed diffusers are generally not used! as they restrict the operating range and compressor cha: f teristics are very much sensitive to change in volume flows. Diaphragus are almost always cast, on account of their complicated form, Normally, Mechanite type GD or spheroidale cast iron are used sometimes with additions of nickel to improve the resilience characteristics at low temperature (1 + 1,5% Mi). If the operating temperature is less then = 100°C, ASTM, A 352 steel is used in one of the six grades available” or alternatively ASTM:4;331 grade CFS, For the intermediate diaphragms of the 2CM and 2BCL compressor or for any diaphragms supporting high A p, a more“suitable material such as carbon steel plate or’ forging which has higher mechanical strength than cast iron is required.2.6 2.7 8 29S ket NGINFERING centrifugal ey: SCHOOL IN Design Features _mechanical characteristics than is generally required for 35 or , Compressors - End_covers: These components are used for the purpose of closing either side of the barrel which also house the bearings and seala oil seals, Various oil and gas connections are made on the end covers, Generally the end covers are made out of solid forgings. Depending upon the gas medium either carbon steels or stainless steels are selected. Rotor: The heart of the compressor is the rotor consisting of the shaft, impellers, balancing drum, shaft sleeves, thrust collar. The shaft is made of heattreated low alloy steel on which the impellers are hot shrunk and keyed. Sleeves of special material are mounted on the shaft to protect the shaft from the contact of the gas medium, Shafts The material used for the shafts of all types of compressor is 40 NiCrMo7 Steel. In reality, this material has better normal usage by centrifugal compressors and it is for this reason that other manufacturers use carbon steel. This material reacts very well to heat treatment, infact, shafts of normal dimension made of this material are treated throughout their section, contrary to the normal practice with carbon steel of undergoing only a surface treatment. Since there is little interest in obtaining. very high rupture on yield loads but rather toughness and ductility, tempering is at aibigher temperature than normal, sufficient however, to reach a rupture load higher than 100 kg/mm2 and 2 yield of 65 + 75 ke/u2.a” 2s REEINERY ENGINEERING centrifugal : 36 Compressors - A gL F scoot or mans esi acatures 2.9 a Impellers Ee i The impellers are the most stressed component, in fact, there is the tendency to exploit them to a maximum so ag to reduce the number of stages. They are constructed in 9 steel with high mechonical characteristics but low carbon content to ensure satisfactory welding of the vanes. Except in special cases KMN COGNE a low alloy steel is normally used, This material is (also good for low temperatures) having 2% chrome 1% molybdenum and 0.13+0.17% carbon. Certain other manufacturers use a steel having a higher carbon content, obtaining thereby superior mechanical characteri- stics but giving rise to doubts about the soundness of the welds. Given that the weld and the surround zone are the same, a phenomenon of intergranular corrosion , would appear to occur, It is for this reason that there is a need to call for a limit on the carbon content, The intergranular corrosion weakens the metallurgical bond between each grain which leads to the mechanical degeneration of the material. The presence of carbon in the steel greater than that soluble in the austinitic matrix determines the potential sensitivity of the material to intergranular corrosion. This 1s s0 since carbon is principally responsible for the precipitation of the carbides and for the impoverishment in chromium at the grain boundaries. The carbides precipitated to the grain boundaries can be points initiating failure while the impoverishment of chromium renders the material sensitive to corrosion. The t{me the material is subjected to a temperature of (400+900°0) whether during the process of refinement, after heat restment, preheating or during welding this can provoke the precipitation of the carbides of chromium eat EEEREFINERY ENGINEERING at SCHOOL OF TRAINING CENTRIFUGAL COMPRESSoRS = METHODS OF MANUFACTURE in quantities much greater, the greater the quantities of carbon in the steel. When the impeller is to be used in a corrosive fluid @ steel with a high chromium content is used such as X120r13 (13% of Cr), in particularly corrosive conditions a greater percentage of chromium may be required KX02 grade (15-1980r); if finally 1t is not the problem of Corrosion there is a further problem concerning stress level, recourse can be made to ateel of 17-4 PH, 17% Or 4% Ni precipitation hardened at low temperature. This steel with 9% Ni is used for impellers required for low temperatures, good mechanical properties being obtained at temperatures as low as -196°C, Methods of manufacture The most common method of manufacture of the impellers is by welding. { 1) Intemal welding: Impeller is fabricated from solid forged discs, Depending on the size of impellers, the vanes are formed by either milling process or by welding separate vanes which are prebent to required shape. The internal conventional manual welding ie employed to join the hub with vanes and shroud. As the welding is carried out by manual process, special care ia to be taken in the following areas. 1, To have homogeneity of the properties of both hub’ ang shroud, both the forgings are drawn from the sane melt. 2, The heat treatment of the impellers in an inert atmosphere to control the scale formation due to the oxidation. ‘3. Proper sequence of welding and uniformity of the weld fillet deposited,™ 27 Oy, REFINERY ENGINEERING centrifugal 1 38: - Ls SCHOOL OF TRAINING peagbe! i en eeS cire 3.2 3.3 4. Continuous monitoring of the weld quality during the process of manufacture by liquid dye penetrant test at various stages. i Spark erosion: Spark erosion method ie used when the conventional internal welding cannot be carried out because of narrower passages of the impeller channels. The procedure allows manufacture of impellers for compressors handling capacities as low as 100 m*/hr. The impellers made with this procedure have mechanical/ thermodynamic characteristics better than those made by other method. The process essentially consists of forming the shape of the channel of the impellers by removing the material by spark erosion, The electrode is made of pure copper machined to the exact shape of channel. Impellers with channels as small as 3m can be manufactured with this method, Bxternal welding: For hendling very low volumetric flows and higher heads, new series of inpellera are developed and the characteristics of such impellers are very low outlet vane angles (15° to 18°) and lower radii of curvature. These characteristics result in a very long channel passage and the Conventional welding becomes impossible. External welding process has been specially developed to overcome this manufacturing constraint. Following are the salient features of thie manufacturing process: -Manufacture hub with blind grooves with corresponding vanes on shroud. =Match the grooves with vanes.3.4 3.5 e206 centrifugal », REFINERY ENGINEERING Saag Compressors ~ SCHOOL OF TRAINING Methods of Manufacture -Welding of root of groove by TI@ automatic process with pulsed current, The material at the bottom of the groove 1s fused to the vane arranged exactly beneath the grodve without filler material. : ~Subsequent layers of welding by TIG welding with ‘filler material. -Suitable heat treatment process to achieve desired mechanical properties. -Pinish machining. Advantages: 1) The external welding process does not E have the weld deposit in the internal as passages and hence smoother gas passages are obtained. 2) he entire process is automatic and the quality of welding is consistent. Balancing drum: On an impeller stage in a centrifugal compressor there exists an axial thrust equal to the difference of thrust between suction and delivery sides of the impeller, This thrust adds up in a compressor for the number of impellers provided in a stage and it ie too high to be taken by the thrust bearing all by itself. én equalising drum is fitted on the shaft both sidesof which are subjected to a differential pressure. The size is so selected that 90% of the thrust load due to the gas is compensated by the drum and the residual thrust is supported by the thrust bearing.2 40 + Compressors = = ; & ¥ REFINERY ENGINEERING Centrifugal Aub / so00. OF TRAINING Methods of Manufacture 3.6 3.7 3.8 Spacer Slesves: Spacer sleeves positioned in between the impellers have two functions. 1) fo protect the shaft from corrosive fluids. 2) To establish the relative position of the impellers on the rotor. The spacer outer profile also guides the gas into the suction of the impeller. Generally sleeves are made from 13% Or steels with less carbon content. The spacers are mounted under interference to ensure their positioning during running. i Bushes under 011 seals: The bushes positioned on the shaft under 011 seals protect the shaft from the wearing action of high flow of seal oil. These bushes are made by an overlay of hardened material (Colmonoy 6) of 600 BEN. For high pressure compressors colmonoy is unsuitable because of very high inter= ferences required and hardened low alloy steels are used. Bearings: The journal ani thrust bearings are of white metalled type with force feed lubrication. These are housed outside the compressor casing and they can be accessed without dismantling the complete machine. a) Lemon type or elliptical type of bearings are generally employed for low speed and heavily loaded rotors and for high speed machines, to have better damping characteristics, tilting pad bearings are used. The selection of the bearing mainly depends on “the rotor lateral behavior evaluated in critical speed analysis,centrifugal 2°39, nesineny ENGINEERING a eeHagtee Compressors - Ag A scuoo TRAINS Methods of Manufacture Thrust bearings are of tilting pad type with self- equalising features. Thrust bearings are lubricated by forced feed lubrication, Oil film between the collar and the shaft supports the rotor. 4 fundamental parameter while choosing these bearings is the product of specific load and peripheral speed. This parameter has to be contained within Certain limits based on method . of lubrication and materials of bearing and shaft. Improvements in the Design: Periodical review of the design is made for achieving more reliable efficient and trouble free operation of compressors at site, The research and development at collaborator's works and at BHEL enables modification of existing design or adoption of new design philosophy. Also based on the feed-back from various sites, improvements in design are caryied out in the existing design.") REFINERY ENGINEERING = 5 yn, OL OF TRAINING CENERIFUGAL COMPRESSORS ~ i PRINCIPLES OF OPERATION 4.0 PRINCIPLES OF OPERATION OF A CENTRIFUGAL COMPRESSOR As already mentioned a centrifugal compressor confers a certain quantity of energy to increase the discharge pressure and delivers a particular quantity of fluid depending on the thermodynamic characteristics. : In general the fluid is directed to the inlet flange : with a velocity of about 30m/sec., when it undergoes a slight initial expansion to beyond 60m/sec., to the ; eye of the first impeller to which corresponds the initial conditions of compression indicated by Vo, Po and to. Such conditions are easily determined on the basis of the reduction in enthalpy and temperatures in the above mentioned initial expansion given respectively byt- : 2 2 cy? - cg : Hos and t= Ang, ; 29427 C, * Velocity at inlet of 1st Impeller. = Velocity at inlet of suction flange. 9.81 M/ec.” a 4 At this point the fluid enters the first impeller, which ‘confers a certain quantity of energy to it, bringing it to the final condition v1, Py and T1, volume, pressure, temperature at inlet, According to the theory of Euler the energy given to a unit weight of fluid passing through the channel between the two vanes of the impeller is equal to the change of its momentum.’ ee See eeeCentrifugal REFINERY ENGINEERING Compressors = ete Principles of 101 Tr D- |L_ OF TRAINING Operation. Am ot (uz¢2 cos o¢2 - 1 wy cos &x 4) Notation - Wy, W, = Relative velocity 2, blade at suction, delivery, angie at outlet. C1 Cy = Absolute Velocity at suction, delivery. C2 U = Horiz. Comp. of Abs. velocity at discharge, I" = Radial C2 e ~ Regt yefockepeae °F discharge. : U4 U, * Tip speed of blade at 2 inlet & outlet. Since in general O¢ ,90 (radial inlet) the expression iz becomes: 7 Aw sh c2 u, cos uu 7) 2 eS For convenience’ the co-efficient of head may be defined: v 2 cosO<. 2 Cou a" 25 = : u2 U2 Therefore: : : 1 2 Tinde vead = Anu = > U2 where u, = Zo 7 de = ext. dia of Impeller \ The quantity of energy per unit weight is called effective ‘head (i eff) and does not take into account the losses in the suction and discharge passages. The co-efficient of head “U2 is a function of the geometry of "the vanes and of the capacity as can be seen from the diagram:Centrifugal Compressors = a 44 63 Principles of Operation In the diagram is also.shown qualitatively the trend of the polytropic efficiency y, that takes account of the abrasion, the impact and the turbulance, of the real fluid on the channels and vanes. The polytropic head that the gas can utilize is only a Proportion of the effective and is given by: i 2 Hp = “Up Hege = T2 “Up 9/9 =Z, RP, K fr K-1 107 1 ger “p (Perv as Y Wherer ‘ 7a universal gas constant : ° 11" Suction Temperature 7 - - »- = molecular weight of the gas ‘p= potytropic efficiency. 2m*= average compressibility of the gas K = cp/ey (Specific heat at constant pressure) Specific heat at constant volume Pressure ratio p= et ‘Oy REFINERY ENGINEERIN Centrifugal Compressors - gj, J sacon or anus a 45 5 Principles of Operation The polytropic head takes account of the thermodynamic properties of the gas. In point 2 of the preceeding diagram, corresponding to the maximum polytrépic efficiency, one has a capacity for which the fluid flow to the inlet of the impeller has a greater angle of incidence to the vane. At this point, the polytropic head which is proportional to the product V/2"\p is less than the surge limit where it assumes the maximum value. It can be seen that the thermodynamic characteristics of the gas can be changed at the outlet as a function of the inlet conditions, Suppose only the molecular weight (/t) is changed maintaining the volumetric capacity and the speed (rpm), If in the formula for the polytropic head AA is increased, this diminish the constant R of the gas and hence ought to augment the ——) of the term in brackets, given that the other parameters do not! depend on At. The consequence is that with the same head the pressure ratio is increased therefore the greater the gas density (weight) the easier it is to compress. If instead the suction temperature is increased this diminishes the term in brackets of the polytropic head formula and there- fore the pressure ratio diminishes as a consequence, in order to maintain the head for a given fluid with the same volumetric capacity and the same speed (rpm) the pressure ratio increases with reduction in the suction temperature and vice versa. On the contrary, notwithstanding what 4s said about the pressure ratio, this does not depend on the suction pressure Po because in such a case the product PoVo = RTo ramains constant and from the polytropic head formula it is seen that not changing other parameters (within certain limits) it will not vary. o Hi} & + 46 ¢ ti CHOOL OF TRAININ Principles of Operation | eo Centrifugal REFU ”, REFINERY ENGINEERING Compressors = The influence of K (ratio of specific heads) on the pressure ratio ia not great since this appears twice in the formula once upside down which compensates to some measure. Inetead the variation in the average compressibility of gas (%j) influences the compression ratio more in particular to an increase of Zm corresponds to a decrease of and vice versa, If the number of impellers increases, to see how the thermodynamic characteristics of the aspirated gas : influences the discharge for example, 2 stages of compression carried qut with impellers having the same characteristics, it is necessary to examine what will happen in the case of a gas having a small molecular weight, In this case the intake and delivery volumes differ slightly and are: Qo = GVo} a xq zg < 7 ~ 4 »,”y, REFINERY ENGINEERING Centrifugal Compressors - eg? SCHOOL CF TRAINING Seals & Sealing ms Systems 4 « I. ° i o H S H. a oO 2 O,: = : a Sy REFINERY ENGINEERING sees ‘| eh Pi CENTRIFUGAL, COMPRESSORS - PLOW CHART : Sone eee eee j OF QUALITY ASSURANCE CHECKS CENTRIFUGAL COMPRESSOR MANUFACTURE. ce | | Bi alome Centrifugal Compressors-| 4 REFINERY ENGINEERING. Je’ lists in Centrifugal UL) sacasormae + 625 Compressor Manufacture (ol aiaae Tears: ee 1 IMPELLER OVERSPEEDING * Bach impator of individually overaped vale of 115% of Maximum continuous 3 spad impetiors lor any permanent delormations and microcracks a the wolds. ‘Spin last equipment tor compressor impallors. 5 paLanoina J Ezchimpate is palance before Is ove sped telco ite tsanbiod on he eh Hse ope Dancing and it eases refer “one to he accuses spa ie Schenck 50 VB Dynamic Balancing Machine. (W)_NO-LOAD MECHANICAL AUN TEST: (Mechanica un ta is cated out 19 verily the yernal cubs jeial condition of Ihe unit assembly and help i onic ‘Riecientey gh saya we ee econ {ost is carried ayt under casing evacus condition. a {ube and seat oil channels in ihe compressor casing. find smooth-running at Maximum ‘Broadly, the following verifications ava carried out ed for a period al four hours, nabbecbistiuns . f al overspeed ar trip speed (110% of § Rotor balance 18 minutes. © Bearing atignmont, clearance and adequacy of, lubrication © Clearances at inter-stage tabyrinth seals and tiquid fitm shalt seals (TANDEM MECHANICAL RUN TEST: During this test, shop driver. shop tube oil compressor ings of the 1rain ave arranged st Is carried out as sbove. The train componer iy Ie checked during this (ust Tandem Mechanical Aun Test Quality Assurances, Check|’Centrifugal Compressors REFINERY ENGINEERING IEEINERY ENGINEERIN' Quality Assurances, dheck lists in Centrifugal SCHOOL OF TRAINING Compressor Manufacture TD) STaNG MECHANICAL RUN TENT. In case of stsing mochanieal running tes! the job ‘drat is used proterably on its own base ‘and with ariginal piping within the cont [EL_ THERMODYNAMIC PERFORMANCE TEST ‘Thus test is carried oul (0 establish the nd temperature, oi thermodynamic performance ol the machine with ‘ge of ofl rough ecied gas of known properties under ‘specified conditions. ‘A.comprossor can be testod with a suitable test ‘Gee whose physical and thermodynamic Bropertion are well known and the results aro ry elfort is made to to Converted into expecied performance of ine same 4 ge. The perlormance ‘compressor for lis design or specilied ges under ressuro falio vs. tow, lis design operating condition. pow ‘head vs. tow, flow vs. ‘ASME PTO-10 and BS standards stipul ceeains pel sante ‘arlous types of leale for dfteront types ol gases. A permanent closed ioop piping system, wilh he : ‘@xchangars, piping, valves otc. wilh suitable t Niner sconpncr iawn napecind oe Siete Ah ls it tw aoe nd eect orn usted at por pa loop lt designed for 15 aig. and high pressure (Oa) the teat a tocmed as Ciase-t leon Gesloaea fee For conducting performance tests and static seats ‘Class It and Ciass ib tests are conducted when fests, a diaphvagm compressor of 600 kg/cm? tha compretscr tn ee anniy condi It id pressure rating Is installed with the nitrogen gas: sai! teats, the Jsulls ave to be converted: peeen trom ano riormance dats oxpected for ho speciliod {nfunger specilied conaiione using he parlect dation to Ihe existing lacs us lawn, Power tos! codes spociy ihe lint of Giterence tor maximum and minimum ‘comprossiblty functions (x8) for tho test and Spocité pasos hese limits are excoeded Giaserlll tot caleulavons shail be adopted, The ‘Conversion offer results to specified conditions emade using teal gas equations In case of Gisss=it tate. ‘The compressor and the complete systom 1s checked for alr/ gas leaks. (008 is acmitied al iow parameters and purged lil the purity i achieved. ‘After the gas analysis ls satistactory tl ‘Compressor fe started and slowly brought to the feat speed. After oblaining the test parametors — such as Inlel pressure, temperature low and speed — the diacharge pressure paral (F_STATIC SEALS TEST ‘Aller completing the mechanical run test, liquid film (shai and) soals are assembled in postion. ‘The compfessor is pressurised to operating ‘by an inert gas sucr as nilrogen. A remial pressure of 0.5 Kg/em is maintained ‘between the seal oil jnlel and the gas inside (ie falerence gas). The leakage seal oil across the HP teal fs mansured for known period while the shalt is under manual rotation. Wath this i is possible {0 judge the sour ol leakage and the fitness o he seal, Liquid Film Shatt Soals under “Static Soals Tost”0, @% A &y REFINERY ENGINEERING La SCHOOL OF TRAINING fugal Compressor Manufacture Centrifugal Compressors = Quality Assurances, 64 Check lists in Centri- the HP soal rings ar LP seal ring ‘cloarancs ‘enlarged to auit the tow pressure gas conditions, of ine fas, Sometimes tho roducod numb the sour (HP) oll for a specitieg pe Generally his test is conducted at low pressure and at ow speeds LUBE OIL CONSOLES: Lube Oli Conpoles for compressors and their ‘drive turbines are functionally tested as per APL 814, The functional test includes checking the performance of motor/ turbine. pump sets, onto! valves, relia! valves, accumulator, coolers and fillers. The test also includes the simulal ‘of change-over of pumps, coolers and lilters. THe following operations are eneured duting the test 1. The operation of control valves at set pressuros and lows, m 4. Automatic takeover of pumps, 5. Alarm and tep settings of pressure switches, 6. Cleantiness af ine aystem, INSTRUMENTATION FOR TESTS: Highly sophisticated and precision instruments are available for measuring various parameters ‘during machanical run tests a6 par API 612, 614, 617 and perlormance tests as per ASME-PTC -6, PTC-10. Calibration of these instruments is carried out at works belora and alter tho lest. The following are come of tho important insteuments, available with us. MICRO PROCESSOR-COMPUTER/SYSTEM CONTROLLER {in tune with the modern trandi in the evolution of Mechanical and 11 {CADAS) is not only ‘with full graphics fa 1) Relay Multiplexer Assembly with Thermocouple islion and low inermal relay, ‘muliploxer for T.O-s. by Pressures and ai I pressure. measuring facility on relay muliplaxer assemblies, (6) Speed & Froquoncy Measurements on high requency reciprocel counter assembly, 4) Pulue Measurements for Turbine Flow Meters, #) Stain Moafuroment. ) Current O/A Converter. {9)High Voltage Actuation (220 V) for process ‘controlling. During the performance twst, the dats is acqui by Autom ‘Acquisitions ang Control Uni (HP. 9054) trom various sensors such as pressure transducers, differential pressure transduce rexstance thormal detectors and thermocouples, flow meters and various magnatic Instrumentation and contcoi Pano! bsBo 2 65 7 Rd REFINERY ENGINEERING CENTRIFUGAL COMPRESSORS Ag / scuoou OFTRAINING SURGE AND ITS CONTROL Surge can be dofined as the expneity below which the centrifugal compressor performance becomes unstable. The surging conditions occur when the inlet capucity is reduced below s particular limit, Thia consists because of the collapse of the prescure developing capability of the machine, At a given speed, ap the inlet capacity is reduced, the discharge pressure of the wachine goor on incrcusing. When surging occurs, the high prossure cao at the discharge of the machine flows back through the compressor in a complete reversal of the normal direction of flow. Once the discharge pressure is dissipated cuffictently, the conditions causing + the collapse of pressure no longer cxist snd the compressor rogumos normal flow and discharge prescure. If the discha ‘conditiona on the’machine have not changed, the collapse of preseuro ‘producing ability will repeat and cycle through the sane sequonce, The percontago flow rt which the surge occurs Pap m ceutritugal compressor depends upon the scrodynamte design, gas propertios, stability of flow, system gyaracteriatica, stage companonta deaign otc. The above surging 16 formed’as overall machine surging. But in certain occagions, the flow components of stage may have a mild surging with the flow reversals within ite geometric domaine without causing tho overall curging of the machine, or without hampering the overall pressure producing capability of the machine. Such mild surging cannot have sudible noise or pressure fluctuations which can be felt externally. Most often, tho mild surging of individual componen ta creates enoygh flow fluctuations that the adjacent epmponents byeak dpwy dye to spotability and the overal] “‘machine goog into pur, » |, Al} necensary procautions during installation of the machine in & syatem shall be taken to prevent surging for th? fojlowing reasona, Surging condition imposes transient ‘ zi : contd. Pagt