Compressors, an introduction

Dynaflow

2009-09-10

© Siemens AG 2008. All rights reserved.

Agenda

1. Introduction.

2. Applications

3. Compressor Types

4. Centrifugal compressor
working principles

5. Compressor selection

6. Mechanical design

7. Aerodynamics

8. Rotordynamics
Energy
Oil&Gas Solutions
Rotating equipment

Steam turbine Gas turbine Electric motor

Compressor
Applications

Upstream Midstream Downstream

Oil exploration and production Transport, Storage, Liquefaction Processing

Refineries
Gas–Oil Separation GOSP
Gas (re)Injection Gas transmission
Gas Lift Gas transport (pipeline) Petrochemical
Export Gas storage

General chemical

Gas Gathering LPG

Gas field depletion LNG,
Boil off gas
GTL
CNG
Compressor types

Compressors
Dynamic Displacement
Integrally Geared Single Shaft
Radial Axial

STC-GV STC-GC STC-GV STC-SH STC-SV STC-SP STC-SI STC-SX STC-SR

Others
Rotary Reciprocating
one rotor two rotors
Labyrinth Diaphragm
Vane Liquid ring Screw Roots
Overview Compressor Working Principles

Positive Displacement

Reciprocating

V1

V2

χ
P2
p1
= ( )V1
V2

volume reduction
 Overview Compressor Working Principles

Centrifugal

Tip diameter

1
Blade inlet diameter
1 Eye diameter
1

Hub diameter

Velocity increase

http://www.geocities.com/mojju/me797/Compressors101.swf

2 Compressors types animation.swf

Reciprocating
DynamicCompressor Types

Single shaft compressors

Axial/axial-radial
compressors Integrally geared compressors

Ç
Performance characteristic for various compressor types
Application range of different types of compressors

Polyethylene

MD experimental

Reciprocating
Discharge pressure [bar]

Reinjection

Ammonia Synthesis, Hydrocracking

Gaslift

Turbo radial
Naptha Cracking
(Ethylene)

Turbo
Screw / Rotary vane / Roots axial-(radial)

Actual suction volume [m3/h]

Turbocompressor

compared to reciprocating

Advantages Disadvantages

ƒ No pulsations ƒ Efficiency
ƒ Lower foundation cost and civil cost ƒ CAPEX
ƒ Minimum weight and space ƒ Operating range
ƒ No wearing parts ƒ Delivery time
ƒ Reliability and availability
ƒ Low noise emission
ƒ Smooth start up and control
ƒ Total Cost of Ownership
Comparative evaluation of compressor types

BEST WORST

Capital Cost Screw Axial

Maintenance Centrifugal Reciprocating

Efficiency Reciprocating Screw

Flexibility Reciprocating Axial

Agenda

1. Introduction.

2. Applications

3. Compressor Types

4. Centrifugal compressor
working principles

5. Compressor selection

6. Mechanical design

7. Aerodynamics

8. Rotordynamics
 Working principle

Work is done by Diffusers convert

rotating impellers, velocity into
increasing the pressure
velocity of the gas Discharge Suction

▲
▲
▲

▲▲
Return vanes
guide the flow to
the next impeller
 Performance curve

50

Head is the amount of work

necessary to move one unit45

of mass through the system40

35

30
Polytropic Head [kJ/kg]

⎧ n −1
⎫
n ⎪⎛ p2 ⎞ n
⎪
H pol 25
= zRT1 ⎨ ⎜ ⎟ − 1⎬
n − 1 ⎪⎜⎝ p1 ⎟⎠ ⎪
20
⎩ ⎭
15

10

0
2,000 4,000 6,000 8,000 10,000 12,000 14,000
M3/HR
Actual volumetric inlet flow
performance curve

compressor characteristic

The final shape of the performance curve is determined by various losses.

These losses and the final curve are indicated in the figure below.

TH
EO
SH RE
OC D IS TIC
LO K AL
SS K FR CH
ES IC
TIO AR
N AC
HEA D

& TE
LE RIS
AK TIC
AG
EL
OS
Stable performance SE
curve FR S
IC
TIO
N
LO
S SE
S
SH
O CK
LO
SS
SPEED = CONSTANT ES

FLOW
Performance map
Agenda

1. Introduction.

2. Applications

3. Compressor Types

4. Centrifugal compressor
working principles

5. Compressor selection

6. Mechanical design

7. Aerodynamics

8. Rotordynamics
Selection

What is the basic function of a compressor?

Move a quantity of gas against the head dictated by the system characteristics

p1

T1

p2 (p2 > p1)

•
m

gas composition
Selection

Input Output

Casing/frame size
Flow
Pressure
Volume flow Impeller diameter,
Temperature
Head type, flow coefficient
Composition
Process variation
Rotational speed

Number of impellers

Required power
Mechanical constraints
Available drivers Performance Map
 Impellers

Master blade contour

Larger
Pressure ratio
or larger
Mol weight

Smaller
Flow Larger
or lower Hub to Tip
temperature ratio
Impellers

Q.H. OPERATING POINTS + ESTIMATED IINITAL + INTERMEDIATE + FUTURE COMPRESSOR CURVE

FUTURE ROTOR
3 + 3 impellers in series
200.00

- NEW ROTOR
- SAME PIPING
ecc18
ec17
ec 6
15
14

133
2

ecc10
12
1

elcc1
lc1

lc1
175.00
elc
e

l
12
13

20
20

ec lc9
11
150.00

810
INITIAL ROTOR

elc
290
Polytropic Head [kJ/kg]

- SAME ROTOR
llcc1

2 + 2 impellers in series
125.00 - CHANGE PIPING
lc7ec9
09
5 6

74.5
lcc11l7c1

74
20

73
8 l

68.5
8
ec
lc1

100.00
e c6
l
20 l c7
INITIAL ROTOR
2 + 2 impellers parallel
06 c5
6
75.00 105
ec

100
lc4

90
5
ec

04 3
50.00
20 lc

4
ec

02

.5
20
hcc3
70

+1
e
lc2
0)

SURGE

02
hcc2
5
(6

72 70

20
25.00

4
04

hc
6550
20

3
hc

hc
ec
0.00
0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000

Q volume [m^3/hr]
Agenda

1. Introduction.

2. Applications

3. Compressor Types

4. Centrifugal compressor
working principles

5. Compressor selection

6. Mechanical design

7. Aerodynamics

8. Rotordynamics
Compressor Mechanical design
Exploded view

Page 2 Dynaflow: 10/09/2009 E O OS RE

 Compressor Mechanical design
Main parts

1 Casing:
The casing is designed to
withstand the pressure
inside the compressor and
contains the basic
compressor components.

2 Inner barrel:
The inner barrel contains the
aero assembly and the rotor.

Page 3 Dynaflow: 10/09/2009 E O OS RE

Compressor Mechanical design
Main parts

3 Rotor:
A shaft with impellers and a
balance drum

4 End Sealing:
Makes the compressor
gas tight.

5 Bearing brackets:
Supports the axial and
radial bearings

6 Probes:
Measure vibration level and
axial displacements.

Page 4 Dynaflow: 10/09/2009 E O OS RE

 Compressor Mechanical design
Compressor Casing

SV-B SH-B

Page 5 Dynaflow: 10/09/2009 E O OS RE

Compressor Mechanical design
Flowpath in the compressor

Discharge Compressor Inlet

Nozzle Stage Nozzle

Volute Inlet
Plenum

Spool Piece
Inner assembly (not standard in
every compressor)

Inner barrel
Aero Assembly
Inner assembly Diaphragms
Rotor
Page 6 Dynaflow: 10/09/2009 E O OS RE
Compressor Mechanical design
Inner assembly of bundle

aero assembly

Inner assembly

rotor

Page 7 Dynaflow: 10/09/2009 E O OS RE

Compressor Mechanical design
Aero assembly

Inner
barrel

Aero Assembly

Diaphragms
Page 8 Dynaflow: 10/09/2009 E O OS RE
 Compressor Mechanical design
Diaphragms

The main function of diaphragms is to

guide gas to the next compressor stage.

Complete Diaphragm
assembly
Return Channel Blades

A diaphragm consists of 2
1 1 2
parts, a front plate and a back
plate. The front plate of the
first (1) and the back plate of
a second (2) diaphragm
together form the vaneless
diffuser and the return
passage to the inlet of the
next impeller.
The diffusers are usual vaneless, but for some applications LSVs are applied.
Page 9 Dynaflow: 10/09/2009 E O OS RE
Compressor Mechanical design
Diffuser types

Diffussor types and differences:

-Vaneless
-Lower Head and efficiency
-Wider flow range

-Vaned
-Higher Head and efficiency
-Smaller flow range

Page 10 Dynaflow: 10/09/2009 E O OS RE

Compressor Mechanical design
Return vanes

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Compressor Mechanical design
Return vanes

Flow

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Typical compressor parts
Flow distribution of Inlet plenum with spoolpiece

Page 13 Dynaflow: 10/09/2009 E O OS RE

Typical compressor parts
Milled volute

Page 14 Dynaflow: 10/09/2009 E O OS RE

Typical compressor parts
Rotor

The rotor assembly consists of a shaft fitted with the following parts:
1 Thrust collar
3 2
2 Balance drum
1
3 Coupling hub
4 Impeller(s)
5 Shaft
5

4 In-line Rotor

The impellers are

shrunk on to the shaft
and positioned by a
locating ring.

Page 15
Back-to-back Rotor Dynaflow: 10/09/2009
E O OS RE
Typical compressor parts
Labyrinths

Labyrinth seals can be found:

- 2 at each impeller.

- Between the end sealing and the impellers

- On the balance drum

- Where the shaft protrudes from the bearing

bracket

Function:
Seal
- Minimizing recycle losses

Shaft Gas

Page 16 Dynaflow: 10/09/2009 E O OS RE

Compressor Mechanical design
Impeller manufacturing

1. Brazing Shroud
Brazing Blade
material Disc

2. Inside welding
Welding
seam

3. Slot welding
Slot seam

Page 17 Dynaflow: 10/09/2009 E O OS RE

Compressor Mechanical design
Compressor End

Probes

Bearing bracket End Sealing

Radial and Axial Oil bearings Dry Gas seal, Barrier seal, Labyrinth
Page 18 Dynaflow: 10/09/2009 E O OS RE
Compressor Mechanical design
Active Magnetic Bearings

Technical Data:
Type: STC-SV-08-3-A
Power: 5186 kW
n: 12128 1/min
P1 : 32 bar g
P2 : 56 bar g Dry gas seal cartridge
Dry gas seal cartridge Impeller
Medium: Natural Gas
Sensor
Sensor

Auxiliary bearing
Auxiliary bearing

Rotor

Magnetic radial
bearing

Page 19 Dynaflow: 10/09/2009 E O OS RE

 Compressor Mechanical design
ECO type compressor

Top back-up
Due to integral design: bearing

Axial AMB
-No protruding shaft
Top end radial
-No end sealing AMB
-No lube oil Motor
casing

Motor
section

Compressor /
motor rotor
Compressor
casing
Compressor
section
Bottom end
radial AMB
Bottom back-up
bearing

Page 20 Dynaflow: 10/09/2009 E O OS RE

Agenda

1. Introduction.

2. Applications

3. Compressor Types

4. Centrifugal compressor
working principles

5. Compressor selection

6. Mechanical design

7. Aerodynamics

8. Rotordynamics

Page 21 Dynaflow: 10/09/2009 E O OS RE

 Compressor aerodynamics
Instabilities

The following instabilities occur in a compressor:

ƒ Surge
ƒ Phenomenon
ƒ Protection

ƒ Stall
ƒ Phenomenon
ƒ Impeller stall
ƒ Diffuser stall

ƒ Noise

Page 22 Dynaflow: 10/09/2009 E O OS RE

Aerodynamic instabilities
1. Surge

Major process parameters

during surge

FLOW
Rapid flow oscillations
Thrust reversals
Potential damage
1 2 3
TIME (sec.)

PRESSURE Rapid pressure

oscillations with process
instability
1 2 3
TIME (sec.)

TEMPERA
TURE Rising temperatures
inside compressor

1 2 3
TIME (sec.)

Page 23 Dynaflow: 10/09/2009 E O OS RE

Aerodynamic instabilities
1. Surge

Factors leading to onset of surge:

ƒ Start-up
ƒ Shutdown
ƒ Operation related:

Surge is harmful to the compressor:

ƒ Oscillating flow causes rotor vibrations
ƒ Reversed flow with heats up the gas in the impellers.
ƒ Rapid changes in axial thrust may damage the thrust bearings.
ƒ Sudden changes in load may damage the internals as well as the driver.
ƒ Instable flow and pressure causes problems in process control and equipment.
ƒ Operating a compressor in surge will reduce its life time.

Conclusion:
ƒ The message is to avoid surge.
ƒ Therefore a Anti Surge Control System is installed at each compressor.

Page 24 Dynaflow: 10/09/2009 E O OS RE

Aerodynamic instabilities
1. Surge: Control

Typical Anti Surge control

Compressor

FT TT PT PT

Cooler Controller Obtains: Pd/Ps, Ts, V

Stored: Surge control
line
Pd/Ps = f (V, Ts)

FCV

Page 25 Dynaflow: 10/09/2009 E O OS RE

Aerodynamic instabilities
2. Rotating stall: Phenomenon

Lift (Bernoulli):
Lift
- V1 > V2
- P1 < P2
v1, P1
a

V2, P2

Smooth flow

a a

As angle (a) of attack increases: If angle (a) of attack > critical angle:
- Lift increases - Break down of flow
- Break away starts - Lift collapses STALL

Page 26 Dynaflow: 10/09/2009 E O OS RE

 Aerodynamic instabilities
2. Rotating stall: Impeller stall

side
n
Suctio

e
Discharge sid
4. In the re-established flow the
boundary layer is developing
again at the blade suction
side, till separation occurs.
The whole cycle starts again.

3. Flow increases due to

1. Due to low flow separation on 2.
the blade suction side causing
flow blockage and flow
reversal.
reversal flow helps to re-
Flow moves out of this establish the normal flow
passage into the next conditions.
passage and creates
separation at the discharge
side of this passage

The stall appears to be moving in the direction of the rotor rotation,

at a Sub synchronous vibration at 5–20% of the compressor speed.

Page 27 Dynaflow: 10/09/2009 E O OS RE

 Aerodynamic instabilities
2. Rotating stall: Vaneless diffuser stall
Diffuser stall is induced by friction:
• Friction decreases the gas velocity.

U2
• Mainly effecting radial component.
C2 α2 W2 β2 stall cell
• Gas stays longer in diffuser.
• Result instable flow = STALL
stall cell
• Sub synchronous vibration at
7–15% of compressor speed.

Counter measure:
• Narrowing diffuser width
tang. Efficiency will drop with increasing flow.
Stream lines velocity
• Apply vaned diffuser
between rad.
stall cells
stall cell

Page 28 Dynaflow: 10/09/2009 E O OS RE

 Aerodynamic instabilities
Noise

Noise:

Source
ƒ Any flow instability causes pressure variations and results is increased noise levels.
ƒ Especially flow incidence at vanes at high velocity can cause (tonal) noise.
ƒ Impeller vanes
ƒ Stator vanes
ƒ Rotor-stator interaction

Counter measures
ƒ Apply noise-enclosures around the equipment that makes the most noise. This is
often a gearbox or a gas turbine.
ƒ The compressor it selves produces less noise due to the rather thick casing, but the
generated noise will be transported forward into the downstream piping.

Movie to visualize rotating stall in a laboratory? (takes few minutes)

Page 29 Dynaflow: 10/09/2009 E O OS RE

Agenda

1. Introduction.

2. Applications

3. Compressor Types

4. Centrifugal compressor
working principles

5. Compressor selection

6. Mechanical design

7. Aerodynamics

8. Rotordynamics

Page 30 Dynaflow: 10/09/2009 E O OS RE

Rotor dynamics
Vibrations:

Rotor Vibrations

Lateral Torsional

Forced: Self-Excited:
• Unbalance • Oil Whirl
• Rotating Stall • Labyrinth Induced Whirl
• Surge • Thermal Instability
• Pressure Pulsation’s • Aerodynamic Whirl

Page 31 Dynaflow: 10/09/2009 E O OS RE

Rotor dynamics
Lateral vibrations

Lateral vibrations

Synchronous Asynchronous

Sub- Super-
synchronous synchronous
Page 32 Dynaflow:
Dynaflow: 10/09/2009
10/09/2009 E O OS RE
Rotordynamics
Lateral analysis

Lateral Rotor Model

Overhung Overhung
NDE
Bearing Span DE

Page 33 Dynaflow: 10/09/2009 E O OS RE

Rotordynamics
Lateral analysis

Undamped Lateral Critical Speed Map

Operating Speed Range

Undamped Lateral
Critical Speeds

Page 34 Dynaflow: 10/09/2009 E O OS RE

Rotordynamics
Lateral analysis

Undamped Lateral Critical Speed Mode Shapes

Page 35 Dynaflow: 10/09/2009 E O OS RE

 Rotordynamics
Torsional analysis

For a torsion analysis the whole rotating string has to be taken into account!

Campbell Diagram for System Torsional Natural Frequencies

40000

ev

v
ev

Re
R
2/

4/R

3/
30000

Torsional
Torsional Critical Speed [RPM]

Critical Speed
20000 Excitation Frequency
17080
ev
1 /R
Gas Turbine
10000 8918 Operating Speed
Range
3097 Compressor
Operating Speed
0 Range
0 5000 10000 15000 20000
Page 36
Operating Speed [RPM] Dynaflow: 10/09/2009 E O OS RE
Rotordynamics
Torsional analysis

Rotor Configuration with Relative Angular Amplitude

Most Sensitive
Element

Page 37 Dynaflow: 10/09/2009 E O OS RE

Rotor dynamics
Vibrations:

So far the Rotor dynamics

ÆProceed with Noise and Mechanical response by Dynaflow

Page 38 Dynaflow: 10/09/2009 E O OS RE

Thank you