CO2 COMPRESSOR

SIP COURSE

Prepared By: Mudassar Ahmed (Operations Engineer)

 SUMMARY

• Introduction
• Salient Features
• Process Description
• Steam turbine (UU-125)
• Lube oil system
• Woodward governor
• Compressor MCL (UK-131-132) & BCL (UK-133-134)
• Inter-stage coolers and seperators
• Anti Surge Control.
• Performance Curve
• Performance Evaluation
 INTRODUCTION

• A gas compressor is a mechanical device that increases the pressure of

a gas by reducing its volume. Compressors are commonly used in the
process industry and are often complex and expensive installation.
This means that special attention is required for operation of a
compressor
• CO2 compressor is multi stage steam turbine driven centrifugal
compressor. It increases CO2 gas pressure from 0.40 Kg/cm2g to
149Kg/cm2g.
• It was made by Dresser Rand.
• Centrifugal compressors use a rotating disk or impeller in a shaped
housing to force the gas to the rim of the impeller, increasing the
velocity of the gas. A diffuser (divergent duct) section converts the
velocity energy to pressure energy.
 STEAM TURBINE UU-125
• This turbine is a multistage condensing impulse type
machine, with an uncontrolled induction and eight stages.
• A condensing turbine is one which exhausts to a pressure
less than atmospheric pressure.
• An impulse turbine is a form of heat engine which
transforms the heat energy of the steam supplied to it into
useful work.
• In multistage turbines, the steam is expanded from the
initial pressure to the exhaust pressure in several stages
with the jets of each expansion process being made to strike
the buckets of the wheel in that particular stages.
 SPECIFICATIONS AND OPERATION OF UU-125

• Type : 1QS4HBIT2V1
• Make : DRESSER-RAND
• Governor Type : WOODWARD 505DG
• Stages : 08
• Inlet Steam : MIN NOR MAX
Pressure (kg/cm2) 41 42 43
Temperature (℃) 370 370 380
• Induction steam : 4.5kg/cm2 and temperature 240℃
• Turbine output Power : Rated at 10000 KW and 7382rpm
• Speed Range : 5167rpm to 7751rpm
• Safety Valve : 6 ̋ ̋TERRY & T valve (with manual
exerciser)
• Induction line size : 12 ̋
• Exhaust End : 48 ̋
• Electrical over speed trip : 8526rpm
• First Critical Speed : 2900rpm
• Second Critical Speed : Fully damped
• Lubrication : Forced
• Turbine Bearings : 200L/Min
• Lubrication Oil Pressure : 1.5 kg/cm2
• Oil Type : ISO VG32
• Inlet temperature at Bearings : 50℃
• Low lube oil pressure trip : 0.7 Bar
• Control Oil pressure : 8kg/cm2
• Low Control Oil pressure trip : 2kg/cm2
• Control oil Reset Pressure : 3kg/cm2
• Control Oil Flow : Steady state 45L/Min
• Transient: 150L/Min
• Shaft Diameter : 305mm
• Bearing Types : Steam End Side (TJ140/84) Exhaust End
Side (TJ160/96)
 UU-125 SPEED CONTROL (Woodward-
505)
• Speed control of the turbine is effected by a
WOODWARD electronic type governor. The
functions of the speed governing system is to
maintain practically constant speed regardless of
load by opening or closing the steam inlet valve
thereby increasing or decreasing the amount of steam
flowing to the turbine nozzles.
• A 4-20mA signal generated by the WOODWARD is
converted by an I/P converter integrated on the steam
control valve
 SEALING STEAM
• Shaft packing of the labyrinth type are provided at each end of
the turbine where the shaft projects through the casing.
• The function of this packing is to control the outward leakage
of steam at the steam end, where the pressure inside the
turbine case is greater than that of atmosphere, and the
entrance of air into the casing at exhaust end where the
pressure in the casing is less than that of atmosphere.
• The turbine is equipped with an automatic gland seal system to
prevent air from being drawn into the turbine and the
condenser.
• This system should not operate when the turbine rotor does not
move.
• Sealing steam is supplied at 2.8kg/cm2 (g) and at 142℃
temperature through PCV-125-07A which lets down the steam
pressure to 0.4 kg/cm2 (g) and PCV-125-07B release steam to
UU-125 exhaust duct when pressure increases above 0.7
kg/cm2 (g), 500 kg/hr steam is used for sealing.
 DIFFERENCE

• The pressure rise which is the main difference between fans,

compressors and blowers can be stated as follows:

Difference ΔP (psig)
Fans 2
Blowers 2~10
Compressors >10
 WHERE IT IS USED?

⮚ Process industry use centrifugal compressor to elevate gas pressure

for several purposes:
✔ To cause positive Flow through Process.
✔ For separating Heavy hydrocarbons.
✔ To obtain super cool gases for refrigeration.
✔ As a means to force gas product flow through pipelines.
 COMPRESSOR TYPES

COMPRESSOR

POSITIVE
DYNAMIC
DISPLACEMENT

RECIPROCATING ROTARY CENTRIFUGAL AXIAL

 STAGE IN A COMPRESSOR

✔ Stage refers to the area of compression within a compressor.

✔ A compressor can be either single or multistage.
✔ A single stage compressor consists of an impeller and its diffuser.

✔ A multi stage compressor has two or more impellers each with a

diffuser operating in series.
SINGLESTAGE COMPRESSOR
MULTISTAGE COMPRESSOR
MULTISTAGE COMPRESSOR
PRESSURE RATIO

✔ Pressure ratio is discharge

pressure of the compressor
divided by suction pressure.

✔ Pressure ratio is defined using

absolute pressure.

✔ Inter-cooling is used when R is

equal to or greater than 3 in
multistage compressors.
 COMPRESSION SECTION

• It refers to the area of compression between two consecutive

nozzles.
• Single-section design is used when one compression section meets
all design requirements.
• A multistage section design is used when the process requires side
flows, when the absorbed power must be reduced with intermediate
cooling, or when the discharge temperature for a single section
would be too high and intermediate cooling is required.
 WHY SELECT CENTRIFUGAL

The advantages of centrifugal compressors can be classified as:

⮚ They are more efficient than reciprocating ones
⮚ They provide high flowrates
⮚ They are compact, less site area
⮚ They need lower maintainance requirements
⮚ They are tolerant to liquid carry
 DISADVANTAGES

The disadvantages of centrifugal compressors can be classified as:

✔ Less efficient for small volumes.

✔ Discharge pressure limitation.

✔ Effect of gas density and temperature.

✔ Problem of surge phenomenon.

 CENTRIFUGAL FORCE

✔  Not a real force, but the perceived effect of inertia.

✔ As an object travels in a circle, it appears to have a force pulling it
outward. This is called a centrifugal force. This force is not to be
confused with a centripetal force which is the force pulling an object
in to the center as it moves in a circle.
✔ For every action there is an equal and opposite reaction. Centripetal
force, an action, has the reaction of centrifugal force. The two forces
are equal in magnitude and opposite in direction.
CENTRIFUGAL VS CENTRIPETAL

• Centripetal force is the

“pulling in towards the centre”
force
• Centrifugal force is the
“pulling away from the centre”
force

• Centripetal force
• Centrifugal force
 WHATS A CENTRIFUGAL COMPRESSOR

✔ The purpose of compression is

Impeller Vanes
simply to increase the pressure of
a gas from one level to another.
✔ Centrifugal Compressors are
mechanical devices in which the
energy of the fluid is increased
by the radial motion of the
Diffuser
rotating element (the Impeller).
 BASIC COMPONENTS

Impeller
The part of centrifugal compressor that moves the gas is the
impeller. As the impeller rotates, it moves the gas toward the outer
rim of the impeller and its velocity increases.
Diffuser
As the gas leaves impeller, it flows into a passage-way called the
diffuser. The diffuser being larger in volume, the velocity of gas
decreases and its pressure increases.
Volute
Gas passes from diffuser into the volute. In the volute, the
conversion from velocity to pressure continues.
BASIC COMPONENTS
 BASIC COMPONENTS

Two main components

1. Rotor Assembly (Rotating)
2. Casing & Diaphragms (Stationary)

Rotor Assembly:
• Impellers (Wheels)
• Shaft
• Sleeves
• Balancing Drum
• Thrust Disc mounted on shaft
 BASIC COMPONENTS

• Rotor:
It is a rotating assembly which consist of shaft, impellers, Shaft sleeves,
Balance drum, thrust runners and runner locknut/ lock washer.
• Impeller:
It is a rotating element which imparts velocity and pressure energy to
process gas.
• Diaphragms:
It is a stationary part which isolates stages, and is comprises of diffuser path,
return passage and guide vanes.
ROTATING COMPONENTS
ROTOR
ROTOR ASSEMBLY
 IMPELLER

✔The head to be produced and the volume flow to be handled describe

the design criteria for impellers.
✔Most multistage centrifugal compressors used closed impeller.
✔Number of impellers determined by thermo-dynamic operating
conditions, Limitation mechanical and dynamic behavior of the rotor.
✔Material of rotor, internals and casing selected on the basis of their
mechanical properties and compatibility with fluid to be compressed.
 IMPELLER
BLADES:
Increase velocity of the gas i.e static
pressure rise and imparting Kinetic
energy which converts to additional
pressure rise in the stationary parts.
HUB:
Part of impeller which attach to the
shaft. Confines the gas and acts to
drive the blades.
COVER:
Confines gas and prevent blades
distortion from rotational forces.
TYPES OF IMPELLERS
 TYPES OF IMPELLERS

Types of Impeller

Open Semi Open Closed

Impeller Impeller Impeller

Used for high heads Used for large flow, usually in Used mainly in
and small flow in single singly stage compressors, or as multistage compressor.
stage compressor only 1st stage in multistage
compressor
 BASIC PARTS

SLEEVES:
Installed between adjacent impellers to position the impellers along the shaft
,wearing surface for inter stage seals, isolate the shaft from process gas.
BALANCING DRUM:
Thrust equalizing component, one end at discharge pressure and other end at
comp. inlet pressure through balancing line. The pressure difference across
balancing drum causes thrust opposite to the rotor thrust. Balance approx
75% of the rotor thrust.
THRUST DISC:
Absorb net thrust of the rotor i.e portion of rotor thrust not equalized by
balancing drum, installed between thrust bearing assemblies.
 BASIC PARTS
Shaft sleeves Last stage
Balance drum
impeller

Inlet guide vane

 BALANCING DRUM

Difference in suction and discharge pressure creates an axial force or

thrust that pushes the rotor towards the suction end. On small or
low-pressure compressors, a thrust bearing can prevent axial motion
of the rotor. When the axial thrust is too great for a thrust bearing, a
balancing drum is used to equalize thrust. The balancing drum is
attached to the shaft at the discharge end of the compressor.
 BALANCING DRUM

One end of the drum (away from impellers) is vented to the suction
end of the compressor. The pressure on the vented end is suction
pressure. The non-vented side is exposed to the gas at discharge
pressure.

The difference in pressure exerts a force on balancing drum, in the

direction of the discharge end of the compressor. Impeller thrust
causes axial force in the direction of the suction end of the
compressor. The two forces balance each other because they are
exerted in opposite direction.
BALANCING DRUM PHILOSOPHY
 BASIC COMPONENTS

STATIONARY COMPONENTS:
• Casing
• Diaphragms

These components form the various

gas passages in the compressor i.e
Inlet Channel, Diffuser, Return bends,
Return Channel, and Discharge
Volute.
CASING
STATIONARY PARTS
COMPRESSOR CASING
 DIAPHRAGM & RETURN PASSAGE

✔ Diaphragm:

Multistage centrifugal compressor contains diaphragms located

between impellers. Adjacent walls of the diaphragm form a passage
called the diffuser that guides gases into the next impeller.
Diaphragms are made of cast iron or other hard metal such as steel
and are an integral part of casing.
✔ Return passage:

Its guides the gas to enter into next stage.

 DIAPHRAGM

Diffuser Path
Single
Diaphragm

Return
passage
 GUIDE VANES

✔ The gas that leaves an impeller passes though the diffuser

passage.
✔ In the return passage, guide vanes guide it into the next impeller.
The inlet guide vanes can be adjustable.
✔ With adjustable guide vanes, the angle of gas flow into the eye of
the impeller can be controlled.
✔ In this way capacity of compressor can be controlled.
GUIDE VANES
 GUIDE VANES

1. With adjustable guide vanes the gas flow can be controlled.

2. Compressor capacity can be controlled by adjustable vanes
 GUIDE VANES

Guide vanes are used to guide the flow efficiently into impeller eye.
DIFFUSER
 DIFFUSER

When gas leaves the impeller it enters into the diffuser where
velocity energy is converted into pressure energy
DIFFUSER
 COMPRESSION (MULTISTAGE)

• The compression of gases to higher pressures results in higher

temperatures, creating problems in compressor design. All basic

compressor elements, regardless of type, have certain design

limiting operating conditions. When any limitation is involved, it

becomes necessary to perform the work in more than one step of

compression process. This is termed multistage.

 BASIC WORKING

• Multi Stage Centrifugal Compressor

A multi-stage compressor employs more than one
impeller to impart energy into the gas.
• Principle:
The velocity is added to gas by the impeller of
each stage. This velocity is converted into pressure
within the diffuser. Thus, each impeller adds to the
total energy (pressure) of the gas.
Higher pressure can be obtained from a multistage
centrifugal compressor as compared to in a single
stage compressor.
 WORKING

After the gas passes through the first impeller, it

enters the diffuser, which reduces the velocity of
the gas by increasing the flow area radially. The
kinetic energy imparted to the gas by the
impeller is converted to pressure rise as a
consequence of this velocity reduction in the
diffuser.
After leaving the diffuser, the gas enters the
return bend, which guides the gas into the return
channel and finally into the next impeller. The
return channel includes guide vanes which
eliminate swirl in the gas caused by rotation of
the impeller.
After the gas passes through the last diffuser, it
enters the discharge volute which directs the gas
to the discharge nozzle.
WORKING
WORKING
WORKING
WORKING
WORKING
WORKING
 TYPES

• Construction Features of Centrifugal Compressors

– Two casing designs for centrifugal compressors are
• Horizontally split casing.
• Vertically split casing.
• Advantages & Disadvantages
– For easier accessibility of internal working parts the horizontally split
casing is preferred. Because to reach internal components in
horizontal casing only top half has to be removed. Whereas in
vertical casing the components have to be pulled from the casing.
– When a compressor is used for moderate to high pressures, to
minimize the chances of leaks, a vertically split casing is used.
Because horizontally split casing requires bigger sealing area.
 TYPES OF A CENTRIFUGAL COMPRESSOR
CASING
Rotor assembly housed in a
cylinder.
Types of Casing High pressure design.
Space required for maintenance.

Horizontal Split
Vertical Split Casing
Casing

HSC split along the rotor shaft. At 500 psig HSC lose
sealing capability, Up-nozzle or down nozzle arrangement.
Facilitate the checking of labyrinth clearances and O-rings.
One process stage have max 09 or 12 compression stages.
CASING
JOINTS ORIENTATION
 SEALING

• Rotor shaft passes through the diaphragms.

• Since diaphragm and rotor are not attached to each other, the gas can
flow from higher-pressure region to the lower pressure region
through the space between shaft and diaphragm.
• Seals are used between the shaft and the diaphragm to prevent
leakage.
• The most common type of seal is labyrinth seal.
LABYRINTH SEAL
 LABYRINTH SEAL

• Labyrinth Seal
It is a set of metal rings or teeth that encircle the shaft but do not
touch it. The rings or teeth are made of soft metal, and are sharp
so that in case of accidental contact, less friction is generated and
shaft is prevented from damage.
• Working principle
The spacers between the teeth form labyrinth passage. As the gas
enters the space between teeth, eddies are formed. It slows and
changes direction. The resulting turbulence resists the flow of
gas.
LABYRINTH SEAL
 LABYRINTH SEAL

⮚ Labyrinth type seal does not prevent all leakage. If the gas velocity is
high, some of the gas does not change direction in the seal but skips
between the teeth and the shaft in straight line. Where gas is flowing
at high velocity interlocking labyrinth seal is used. i.e. Labyrinth seal
interlocks with shaft teeth. Labyrinth seals do not prevent all leakage.
These seals are used in areas where it is acceptable to allow leakage.
Labyrinth seals are widely used as inter stage seals because the
pressure difference between stages is normally low enough for
labyrinth seal to be effective.
⮚ If the process gas of the compressor is hazardous or toxic, it cannot
be allowed to leak into the atmosphere, it must be ported. The port is
placed on the seal.
LABYRINTH SEAL
OIL FILM SHAFT SEAL
 MECHANICAL SEALS
• Contact Shaft Seals (Mechanical Seals)
– In these types of seals, contact between moving and
stationary seal part prevent leakage.
• Construction
– Any mechanical seal includes the following components.
1. Stationary sealing ring.
2. Secondary seal for this ring.
3. Rotating sealing ring.
4. Secondary seal for this ring.
5. Flexible member for pressing the two faces together e.g. Spring or
bellow.
MECHANICAL CONTACT TYPE SHAFT
SEALS
 SHAFT MOVEMENT

– A shaft can move in three ways.

• Rotation.

• Axial motion (thrust).

– Gas moving against the sides of the impellers tends to
cause end to end or axial motion.
• Radial motion.
– Any problem in rotor (such as unbalance or
misalignment) can cause up and down vibration.
SHAFT MOVEMENT
 BEARING

• Bearings permit the shaft to

rotate freely, but they prevent
axial or radial motion.
Generally, two types of
bearings are used in
compressors to restrict radial
and axial motion.
– Journal bearing is used
to prevent radial motion.
However, axial movement
is possible in journal
bearing.
 BEARING

• Thrust bearing
– It is used to prevent axial motion. It has two main parts.
• Thrust collar; it rotates with the shaft.
• Shoes: which prevent axial motion of shaft.
– Rubbing surfaces of both journal and thrust bearings is a low
friction metal (Babbitt) and is lubricated by a film of oil. The oil
is supplied to the bearing under pressure through grooves on the
bearing surface. The pressure of oil ensures an adequate flow to
prevent overheating.
THRUST BEARING
EXPLODED VIEW OF THRUST BEARING
 EFFECTS OF VARYING VARIOUS INLET
PARAMETERS

Increasing Increasing Increasing

Inlet Inlet Molecular Weight
Temperature Pressure of Gas

Pressure Differential Decreases Increases Increases

Compression Ratio Decreases Constant Increases
Inlet Density Decreases Increases Increases
Discharge Pressure Decreases Increases Increases
Discharge Temperature Decreases Constant Increases
Power Required Decreases Increases Increases
Head Developed Constant Constant Constant
Mass Flow Rate Decreases Increases Increases
 AUXILIARY EQUIPMENT

• Drive components
• Coolers

• Control
• Anti surge control
• Discharge pressure control

• Lube Oil System Seal Liquid System

• Compressor monitoring and safety Equipment
 TYPES OF DRIVES

Types of Drivers

Steam /
Electric
Gas
Motor
Turbines
Drive
Drive
 DRIVE COMPONENTS

Couplings:
Interconnect various units of a compressor train.

Diaphragm or curved tooth gear couplings are used. Gear couplings with
convex tooth, lube oil supplied for lubrication.

Gears:
Gears are used b/w driver and compressor or b/w two casings to drive at
optimum speed.
 COOLERS

Coolers are used

• To limit max temp of process gas
• To limit max temperature of components for safety reason
• To minimize the compressor power consumption.
Inter cooler/ after cooler categorized on the basis of working.
Cooling medium is cooling water or sea water.
Selection of fluid on tube side depends on.
• Clean gas.
• High pressure.
• Repair.
• Air coolers are much larger equipment.
 CONTROL

• To maintain constant pressure at intake/ discharge.

• Constant flow requirement.

• Operating Characteristics of compressor controlled.

• Varying impeller speed.

• Varying angle of incidence of gas by throttling.

 LUBE OIL SYSTEM

Supply oil to compressor and driver bearings and to gear and couplings.
• Oil reservoir
• Reservoir heater
• Pumps
• Relief valve
• Non-return valves
• Oil coolers (Twin)
• Oil filters (Twin)
• Pressure regulating valve.
• Pressure switch for auto cutting/ shutdown
• Rundown tank
• Return temperature switch
• Oil flow is regulated through orfices
• Vacuum dehydrator units.
 OIL CIRCULATION SYSTEM

To keep bearings lubricated, oil

is supplied under pressure to the
bearings. The lubrication system
keeps a supply of cool and clean
oil flowing to the system.
A sufficient quantity of oil is
stored in a reservoir.
 COMPRESSOR MONITORING

To ensure operation reliability safety of centrifugal compressor.

Mechanical parameter Constantly scanned and
Thermodynamic parameter evaluated
MONITORING:
Instruments for monitoring
Control Equipment
Alarm System
Interlock & Shutdown System
 COMPRESSOR MONITORING

BEARING MONITORING:
Smooth running of the shaft can be guaranteed only by bearings, that
function properly.
CHECK:
Monitoring lube oil draining from the bearing, wear of or any damage to
surface or insufficient clearance.
ANOTHER HAZARD:
High temperature reduce the viscosity of oil and hence lubricating effect.
THERMO COUPLE:
Thermo couple used for monitoring oil temperature, if set limit exceed, as
alarm initiated or compressor shutdown.
 MEASUREMENT OF VIBRATING & SHAFT
POSITION

Mechanical vibration of shaft & casing Indications of possible

and hazard to compressor
Axial displacement operation reliability

CAUSES OF SHAFT VIBRATION:

Deposition
Impeller Un-balances
Shaft distortion due to thermal stress and shock load
Changed bearing condition
Effects emanating from the driver or hear
 HOW TO MONITOR

Measurement performed by probes, that are calibrated for a certain

distance between shaft and probe head.
Probes produce electrical singed proportional to the amplitude of
vibration.
SHAFT POSITION INDICATOR:
Monitor the axial position of the shaft relative to the casing.
Axial Displacement Causes:
Wear of thrust bearing sudden loads, when compressor operating in
unstable region.
How it Monitor:
Electrical measurement by probes.
Alarm switches / shutdown switches installed which shutdown machine
when limit values are exceeded.
 SURGE

SURGE:

Surge occurs when the slope of pressure ratio versus capacity becomes
ZERO.
When a compressor start surge, the gas flows backward through rotor.
This reversal of flow pushes the rotor backward. The spinning wheels
of the rotor come closer to the stationary elements. (labyrinth seals)
 WHAT IS A SURGE?

• Compressor surge is an unstable flow pattern in a compressor where

the total flow across the airfoil alternately stops, flows backwards,
and then flows forward. 

• The surge flow has been defined by some as the flow at which the
head flow curve is perfectly flat and below which the head actually
decrease.
 SURGE POINT

• Surge is the condition of unstable flow within the compressor by

rapid flow and pressure oscillations, rapidly rising temperature,
thrust reversal and often damage.
• Its a condition of minimum flow and maximum head at a certain
compressor speed.
• Surging may cause high vibration problems in the compressor.

Following different steps should be taken to avoid surging are:

• Decrease the compressor speed.

• Open the vent valve.
• Open the anti surge valve.
• Adjust the guiding vanes of the impeller.
SURGING
FIGURE INCEPTION OF SURGE

SSB
SURGE
 SURGE CONTROL

Valve bypass piping to provide sufficient flow through compressor to keep

it away from surge.
REQUIREMENT:
1. Electronic system for the fast response time,
surge valve must be inter locked with trip
circuit i. e. it immediately opens on a train trip.
2. The control system logic requires flow &
pressure input.
3. Valve position operator capable of driving the
valve fully closed to fully opened in one
second and fully open to fully closed in ten
second.
4. Surge valve should be sized to pass full flow at
any point along the surge line with the valve at
60% open.
 ANTI SURGE CONTROL

• To protect machine from excessively high mechanical loading due to

unstable operating conditions, which primarily stress the bearings.
• Compressors are equipped with anti surge control.
• If the delivery required is below the minimum delivery volume of he
compressor, the surplus is led away as side stream via a valve.
Depending on the nature of gas, the surplus is either discharged to
the atmosphere or it is cooled and returned to the suction
ANTISURGE CONTROL LOOP
PERFORMANCE CURVES

110%

105%

100%

95%

90%
 STALL

• This usually happens in a low flow stage as it approaches the

surge.
• Stall is caused by the destabilization of the impeller or
diffuser flow or by unsteady interaction between the impeller
and diffuser.
STALL
 STONEWALL POINT

• It is also called choke point.

• At this point the Mach number equals to one.
• At this condition, impeller passage is choked and no more flow can
be passed.
• Industry practices limits Mach No. to 0.90 for any specified
operating point.
 PERFORMANCE EVALUATION

Performance Evaluation is done to find out how efficiently a compressor

is working. It is based on following process parameters:

• Compressor Speed
• Process Gas Flow Rate
• Steam Flow Rate
• Operating Suction & Discharge Temp. & Pres.
 PERFORMANCE EVALUATION
IS A CHECK TO PLANT
• Energy Consumption
• Performance Estimation
• Identify any abnormal performance deterioration.
• Optimum operating conditions
• Margins available in Machines.
• Cost saving.
Results:
• Safer Operation
• Better Control
• Better profit
 PROBLEMS

– Dirty Intercoolers
Increased gas temperature reduces the density into the
compression stage resulting in reduced stage ratio and reduced
rise to surge.
– Dirty Inlet Filter
Reduces the pressure into the first stage, this results in a lower
natural surge point. A lower natural surge point reduces the
throttle range.
– Hot Coolant
Increased gas temperature reduces the gas density into the
compression stage resulting in reduced stage ratio and reduced
rise to surge.
 PROBLEMS

– Hot Inlet Gas

Increased air temperature to the first stage reduces the gas density
into that stage resulting in reduced stage ratio. Since pressure is
multiplied as the gas moves through a multistage compressor, the
first stage has the most dramatic affect on rise to surge.
– Driver Input Speed
The ability  for a centrifugal compressor stage to make pressure falls
as the square of the stage speed. A reduction in the driver input speed
can dramatically affect the total machine ratio and therefore the rise
to surge.
 
 PROBLEMS

– Discharge valve closure

Discharge valve closure decreased the flow through the

compressor hence increase the pressure and causes surging
– Suction valve closure

Suction valve closure or suction vent opening causes pressure

drop in suction reducing flow and surging the machine
 PROBLEMS

– Inter stage vent malfunction

In a multistage compressor if inter stage vent valve malfunction
and opens the down stream stage will surge.
– Change in gas composition.
If the gas composition change it effects the head thus the
compressor can go into surge at the same speed.
– Recycle valve malfunction. 
Recycle valves are normally open during reduced flow
operation. if closes by accident or malfunction it will surge the
compressor. 
 COMPRESSOR TROUBLESHOOTING

Possible Cause Effect Possible Remedy

Excessive bearing Excessive vibration Replace Bearing
clearance
Rough rotor journal Excessive lube oil drain Polish journal surface or
surface temperature replace shaft.
Operating in critical Excessive vibration Operate other than
speed range critical speed
Build up of deposits on Excessive vibration due Clean deposit from
impeller to unbalance rotor / balance check
Build up of deposits on Flow effected Mechanically clean
diffuser diffuser
Unbalance rotor Excessive vibration Check rotor for rubbing /
deposition.
Rebalance
 COMPRESSOR TROUBLESHOOTING

Possible Cause Effect Possible Remedy

Damaged rotor Excessive vibration Replace rotor
Shaft misalignment Excessive vibration Correct misalignment

Compressor not up to Low discharge pressure Increase to required

speed operating speed
Leak in discharge piping Low discharge pressure Repair leak

Faulty lube oil pressure Low lube oil pressure Calibrate gauge
gauge
Faulty lube oil Excessive lube oil drain Calibrate gauge
Temperature gauge temperature
 COMPRESSOR TROUBLESHOOTING

Possible Cause Effect Possible Remedy

Oil reservoir low level Low lube oil pressure Add oil
Relief valve improperly Low lube oil pressure Adjust relief valve and
set or stuck open verify it setting

Poor lube oil condition Excessive lube oil drain Change oil
temperature Inspect and clean lube
oil strainer/ filters
Inspect bearing
Inadequate cooling water Excessive lube oil drain Increased cooling water
supply temperature supply to lube oil cooler

Bearing lube oil orifices Low lube oil pressure Inspect orifices and
missing / block deblock it.
 COMPRESSOR TROUBLESHOOTING

Possible Cause Effect Possible Remedy

Leak in oil pump suction Low lube oil pressure Tighten leaking
piping connections / replace
gasket
Oil leakages Low lube oil pressure Tighten flanged or
threaded connections/
replace defective gasket
or parts
Water in lube oil Excessive lube oil drain Carry out hydrostatic test
temperature of lube oil cooler to
identify leak tubes.
Repair it.
THANK YOU