Compressor design

Introduction Training
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Trouble shooting
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 Compressor design
Introduction Training
Flow path

Diffusers
Discharge Suction

Gas enters the

compressor through the
suction nozzle

Work is done by a
rotating shaft ▲
▲
▲
The rotating impellers
▲▲
increase the velocity
and pressure of the
gas
2007-02-22 Impellers
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 Compressor design
Introduction Training
Flow path

Diffusers

Discharge Suction

After leaving the impeller,

the gas flows through the
diffuser where velocity is
converted to pressure

Return vanes guide

▲
the flow to the next ▲
▲
impeller
▲▲

After passing all the stages

the gas leaves the
compressor Impellers
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 Compressor design
Introduction Training
Design

• Flow path
• Impeller + Diaphragm
• Inner Barrel + Bal. drum
• Shaft
• Rotor parts - Bearing
• Casing

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 Compressor design
Introduction Training
Design

Nozzle Nozzle
Discharge Suction

Inner Barrel
Fixed
Casing End Head

Inlet Area
Removable
End head Inlet
Plenum

Seals Bal. Drum Diaphragm Seals

Bearing Scroll Impeller Bearing
Bear. House Scroll plate Shaft/Rotor Bear. Bracket
Bear. Bracket Bear. House
Coupling

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 Compressor design
Introduction Training
Inner barrel

Inner barrel
aero assembly
diaphragms
Inner assembly
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rotor
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 Compressor design
Introduction Training
Diaphragms

The main function of

diaphragms is to guide
gas to the next
compressor stage.
A diaphragm consists of
2 parts, a front plate and
a back plate. The front
plate of the first and the
back plate of a second
diaphragm together form
the diffuser and the
return passage to the
inlet of the next impeller.
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2006 Dry Gas Seal Change Out Training for BG Tunisia PG I14314
 Compressor design
Introduction Training
Diaphragms

Diaphragm with return channel

1 2 3

4
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 Compressor design
Introduction Training
Rotor

The rotor assembly consists of a shaft fitted with

the following parts:
1 Thrust collar
2 Balance drum
3 Coupling hub
4 Impeller(s)

1 2 3

4
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 Compressor design
Introduction Training
Axial balancing

The pressure difference between discharge side

and suction side of the compressor produces an
axial force towards the suction side.The balancing
line provides suction pressure between the
balance drum and the seals. This causes a force
acting on the balance drum that counteracts the
mentioned force.

Balance line

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 Compressor design
Introduction Training
Axial balancing

The axial balancing system consists of a balancing

line, a balance drum and a balance ring.

BAL. FLOW

P1 P2 P1
BAL
DRUM

FB F3 F2 F1

IMPELLER 3 IMPELLER 2 IMPELLER 1

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 Compressor design
Introduction Training
Axial balancing

Suction pressure

External seal

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 Compressor design
Introduction Training
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
2007-02-22 rotor.
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2006 Dry Gas Seal Change Out Training for BG Tunisia PG I14314
 Compressor design
Introduction Training
Main parts

3 Rotor: A shaft with a

balance drum and
impellers
4 Seals: Seals make
the compressor gas
tight.
5 Bearing brackets:
The bearings are
seated in the sets
6 Probes: Measure
vibration level and axial
displacements.
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 Compressor design
Introduction Training
Impeller

Impellers form the core of the compressor because

the impeller performs work on the gas. The work is
converted into energy that the gas gains. As the
impeller rotates, the vanes of the impeller force the
gas in the impeller to move outward from the centre.
As the gas moves it gains both pressure and velocity.

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2006 Dry Gas Seal Change Out Training for BG Tunisia PG I14314
 Compressor design
Introduction Training
Seals

Seals form an essential part of compressors because

they prevent gas leakage to the environment and to
internal parts of the compressor. In the compressor
different types of seals are fitted at different places:

Labyrinth seal, throughout the compressor

Dry gas seal, at the inlet side and at the discharge
side
Barrier seal, between dry gas seals and oil bearings

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 Compressor design
Introduction Training
Labyrinth seal

Seal

Shaft Gas

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 Compressor design
Introduction Training
Dry gas seal

To prevent leakage of process gas along the

compressor shaft, a dry gas seal is installed at
both ends of the compressor.

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 Compressor design
Introduction Training
Dry gas seal

With rotation filtered process gas is drawn

inwards towards the root of the groove. Flowing
towards the root of the groove the gas gains
pressure.

Rotating ring
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 Compressor design
Introduction Training
Dry gas seal

At a certain point the gas has such pressure

level that the stationary ring lifts axially from the
rotating ring. Thus a gap forms, which prevents
leakage.

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 Compressor design
Introduction Training
Barrier seal

The barrier seal is mounted between the dry gas

seal and the radial bearing on each end of the
shaft. The main functions are:
Preventing lubrication oil from entering the dry gas
seal area.
Preventing process gas from entering the bearing
housing.

In the event of a failure of the sealing faces of the dry

gas seal, the barrier seal acts as a rundown seal and
minimises leakage of process gas into the bearing
housing during coast down and blow down of the
compressor.
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 Compressor design
Introduction Training
Barrier seal

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 Compressor design
Introduction Training
Barrier seal

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 Compressor design
Introduction Training
Bearings

The main function of the bearings is to provide

friction free rotation of the rotor. They also ensure
that rotation is the only possible movement. The
thrust bearing prevents axial movement and the
journal bearings prevent radial movement.

Thrust (axial) bearing Radial bearing

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 Compressor design
Introduction Training
Thrust bearing

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 Compressor design
Introduction Training
Radial bearing

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 Compressor design
Introduction Training
Radial vibration

The compressor has been

provided with radial
vibration probes to measure
the radial vibration of the
shaft.

Two probes are mounted at

an angle of 90º< near each
main bearing. This provides
accurate measurement of
radial vibrations.

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 Compressor design
Introduction Training
Axial displacement

The compressor shaft has

been provided with two axial
displacement probes. These
probes are mounted on the
thrust bearing side of the
compressor.

The compressor and gearbox

have each been provided
with an additional axial
probe, which functions as a
key phasor:
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 Compressor design
Introduction Training
Axial displacement

Each probe observes a

groove, machined in the
shaft. The groove provides a
so called once per turn event
which will provide a voltage
pulse every time the groove
passes the key phasor probe.
The key phasor pulse
provides a reference mark for
phase angle, frequency
measurements and all
vibration data acquisition.

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 Compressor design
Introduction Training
Gearbox

Usually the driver’s shaft rotates at a different

speed then the desired rotor speed. The gearbox
converts the driver shaft speed into the required
rotor speed.

The gearbox has

two shafts, a high
speed and a low
speed shaft.
Wheels of different
size convert the
rotational speed.
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 Compressor design
Introduction Training
Probes

Smallest clearance
1,4 mm HF signal from freely
ported shaft
Medium clearance
1,5 mm

Largest clearance
1,6 mm

HF signal from
vibrating shaft

Dynamic alteration
of clearance
1,6 Vs
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 Compressor design
Introduction Training
Flexible couplings

Flexible couplings connect the compressor shaft to

the gearbox shaft and the gearbox shaft to the
driver shaft. These flexible couplings can
compensate a small amount of misalignment.
A coupling guard is mounted to protect the coupling
from the environment.

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 Compressor design
Introduction Training
Special tools

Special tools are delivered with the compressor

to be able to do essential maintenance. Besides
some spanners, also hydraulic jacks are
delivered.

These are necessary

for (dis)mounting the
hydraulically fitted
parts like thrust collar
and coupling hub.

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