Eng.

\ WAEL ZAHRAN
 Centrifugal compressor training

Page 2 © Siemens AG 2007. All rights reserved.

 Content
What is the compressor?
Types of Compressors
What are the applications of centrifugal compressors?
Centrifugal Compressors (Principle of operation)
Major components
Capacity control methods
Mechanical seal & Dry Gas seal
Mechanical Stall
Surge & it’s Effect
Compressor oil system
Compressor Troubleshooting

QUESTIONS
Main menu

Condition monitoring

Operation

Lubrication
Control system
Seals
Bearings

Maintenance
Mechanical design
Trouble shooting
 What is the compressor?

PRESSURE RATIO
GAS GAS

Suction Pressure = Ps COMPRESSOR Discharge Pressure = Pd

Suction Temperature = Ts Discharge Temperature = Td
Suction Velocity = Us Discharge Velocity = Ud

Compressor = Black Box to increase Gas Pressure

 What is the compressor?
Compressor is a mechanical device used to increase the pressure
of a compressible fluid.

The inlet pressure level can be any value from a deep vacuum to
a high positive pressure.

The inlet and outlet pressure are related, corresponding with the
type of compressor and its configuration.
 COMPRESSOR TYPES
COMPRESSORS

STATIC DYNAMIC

RECIPROCATING SCREW CENTRIFUGAL AXIAL

 Compressors
Compressor selection
Positive displacement Turbo compressors dfgdfg
machine

Reciprocating Rotary vane Centrifugal

Screw compressors m Axial-flow compressors
compressors compressors compressors
Compression Volume Conversion of kinetic energy

Motion Reciprocating Rotating Rotating

Delivery Intermittent Quasi-continuous Continuous

Volume flow Low Low Low/medium Low/high Very high

Compression High Medium Medium Low

ration
Operation Constant volume - Variable pressure Variable volume - Quasi constant pressure

Principle

Function of a
To render a specific volume of gas from a given initial condition into a desired final condition (pressure/temperature)
a compressor
Types of Compressors
 Compressors

Intermittent Continuous
flow flow
Positive
Dynamic
Displacement

Reciprocating Rotary Radial flow Axial flow

Piston 1-Screw Centrifugal Axial

2-Sliding
vane

3-Liquid ring

4-Lobe
 Gas Compression
Compressor Selection and Rating

Is the discharge volume flow

greater than 300 m3/hr

YES NO

Will the molar mass (MW) change Is the pressure rise

by more than 20% greater than 7 bar

NO YES YES NO

Is the pressure rise

greater than 20 bar

YES NO

Use a centrifugal Use a reciprocating Use a screw Use a liquid ring

compressor compressor compressor compressor
 Gas Compression
Compressor Selection and Rating

A Gas engineer in the field is frequently required to determine

the desired specifications of a new compressor station or
selecting the operating point of an existing one. These
specifications are:

Type, number of stages, arrangements (parallel, series, inter and

after coolers), driver, speed, efficiency, power and/or capacity of
each stages or units, duty of coolers.

For determining the above specifications, these parameters are

required: Gas Composition(or specific gravity), inlet temperature
and pressure, total pressure ratio and total gas flow rate.
13
 Gas Compression
Compressor Head and Power

There are three ways in which the thermodynamic calculations

for compression can be carried out — by assuming:

1. Isentropic process, PV k = constant, k = isentropic factor

2. Polytropic process, PV n = constant, n = polytropic factor

3. Isothermal process, PV = constant

>
P2
W   V dP
P1

14
AVAILABLE COMPRESSOR TYPES

API 617 Centrifugal Compressors, have sometimes to compete with the

following types

Reciprocating Compressors API 618

Axial Compressors

Screw Compressors API 619

Classes and Comparisons Between Dynamic Compressors
Classes and Comparisons Between Dynamic Compressors

Barrel-type Centrifugal compressor Axial-radial high volume compressor

Classes and Comparisons Between Dynamic Compressors
Function Centrifugal Axial
Engine type Small engine Large engine
Mass flow rate < 15 kg/s Very large (> 100 kg/s)
Efficiency Low 86-87 % High 94 %
# of stages small large
Pressure ratio per stage High (5-7) Low (<1.5)
Pressure loss High for more than Low, thus allow using
one stage many stages
Fixing and easy Not easy
manufacturing
Cost Cheap, wider Very expensive
operating range
 What are the applications of compressors?

Gas compressors are used in various applications where

either higher pressures or lower volumes of gas are needed.
•In
•In pipeline
gas transport
turbine of purified
systems to naturalthe
compress gas intake
to
refrigeration (Home refrigerator) and air
move the gasair.
combustion from the production site to the
conditioner equipment to move heat from one
consumer.
place to another in refrigerant cycles (Heat pump)
 Centrifugal Compressors

Advantages:
* High horsepower per unit of space and weight.
* Turbine drive easily adapted to waste-heat recovery for high fuel efficiency.
* Easily automated for remote operations.
* Can be skid mounted, self-contained.
* Low initial cost.
* Low maintenance and operating cost.
* Large capacity available per unit.

Disadvantages:
* Lower compressor efficiency.
* Limited flexibility for capacity.
Centrifugal Compressors
 Bernoulli Equation

The Bernoulli Equation can be considered to be a statement of

the conservation of energy principle appropriate for flowing fluids.
The qualitative behavior that is usually labeled with the term
"Bernoulli effect" is the lowering of fluid pressure in regions where
the flow velocity is increased. This lowering of pressure in a
constriction of a flow path may seem counterintuitive, but seems
less so when you consider pressure to be energy density. In the
high velocity flow through the constriction, kinetic energy must
increase at the expense of pressure energy.
Bernoulli Equation

Play
Centrifugal Compressors
(Principle of operation)

Centrifugal compressors realize compression by

transferring momentum to the fluid and the
subsequent diffusion to convert the kinetic energy
into pressure. The momentum transfer takes place
at the doubly curved blades of the impeller that is
mounted on a rotating shaft.

Play
 A WORKING IMPELLER

Normally the tangential component of C1 is negligible

 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

Impellers
 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
Design

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

The major elements of the centrifugal compressor consist of:

(a)the inlet nozzle

(b)inlet guide vanes
(c)Impeller
(d)radial diffuser
(e)return channel
(f) collector volute
(g)discharge nozzle

Play
 CONSTRUCTION FEATURES

radial diffuser
inlet guide vanes collector volute

Impeller return channel

the inlet nozzle

discharge nozzle
CONSTRUCTION FEATURES
 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.
 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.
Design variations

horizontally split casing vertically split casing

 Drains

When these drains are present the compressor needs to be drained

before start up.
 Skid

Single base plate

Skid

Bolted base plate

Skid

Separate base plate

 Skid

FPSO 3 point mount base plate

 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

Play
 Impeller types

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.
 Impeller types

Three main types of impeller used in centrifugal compressors

are:

• Open Impeller
• Semi-open Impeller
• Enclosed Impeller
 Impeller types

Open impeller is used in single

stage compressors to produce
high head with but small flow
(capacity)
Impeller types

Semi-enclosed impeller is used

in single staged compressors
or in the first stage of multi-
stage compressors to produce
a large flow
 Impeller types

The enclosed impeller is

used in multi-stage
compressors where pressure
is increased in to a high
discharge pressure
 Impeller types

Different vane types are available in most compressors a 2d or 3d design. The

amount of flow and head the compressor has to deliver decides which vane type
will be used.

Enclosed impeller Open impeller

Inner barrel

Inner barrel
aero assembly
diaphragms
Inner assembly
rotor
Diaphragms

Stationary internal components within the compressor

change the direction and velocity of the gas stream,
directing the gas stream from the discharge of one
impeller into the eye of the following impeller.
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.
Diaphragms

Diaphragm with return channel

1 2 3

4
Diffusers
Diaphragms
 Rotor

Back to back rotor

The impellers are shrunk on to the shaft and positioned by a locating ring.
Bundle
Rotor building
Rotor Building

Parts Shrink fit

1 Machining 2 stacking
Shaft
Parts
Small parts
Machining
Impellers
Shrink fit
stacking
Balancing/
Final assembly
Balancing /
3 Final Assembly
High Speed
Robotic Balancing
Welding
Assembly in compressor
Shaft

Parts
Machining
Shrink fit
stacking

Balancing/
Final assembly
 Small parts
Parts Locating Ring
Machining

Shrink fit
stacking Balance Drum
Balancing/
Final assembly

Thrust Collar
 Impellers
Parts
Machining

Shrink fit
stacking

Balancing/
Final assembly
 Shrink fit stacking
Parts
Machining

Shrink fit
stacking

Balancing/
Final assembly
High speed balancing
Parts
Machining

Shrink fit
stacking

Balancing/
Final assembly
Assembly in compressor

Parts
Machining

Shrink fit
stacking

Balancing/
Final assembly
Casing
Casing
Casing
Play3

Play
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
Axial balancing
Per impeller the resulting axial force can
be easily calculated, making use of the
dimensions and the suction and discharge
pressure.

Above the inlet labyrinth

the force on the front and
rear sides becomes
cancelled out because
the discharge pressure
downstream of the
impeller continues as far
as the impeller inlet
labyrinth. The areas are
(about) equal.
Axial balancing

The force acting on the inlet side of the impeller, is:

area of suction region x suction pressure

The force acting on the same area, though on the rear side of the
impeller, is:
area of suction region x discharge pressure

Therefore, the actual force acting on the impeller is:

area of suction region x (discharge pressure – suction pressure)

The total axial thrust of a compressor rotor with several impellers is

equal to the sum of the axial thrusts of the individual impellers.
Suction pressure

Suction pressure

External seal
Suction pressure
The balance drum
 Axial thrust

Axial thrust compensation

Axial Axial
thrust “Back to back thrust
2. Process arrangement” 1.Process
stage stage
The balance drum
Axial thrust is minimized by the installation of a balance piston (or balance
drum) at the discharge end of the compressor immediately behind the last
impeller. The balance piston provides a surface area on which the full
discharge pressure acts, thus providing an opposite acting force. Discharge
gas is allowed to leak into a chamber formed by the back of the impeller
and the face of the balance piston where the discharge pressure acts on
the balance piston surface.
A further enhancement is to port suction pressure directly from the suction
side of the compressor to the opposite side of the balance piston. This
causes a pressure
 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 F1 F1

IMPELLER 3 IMPELLER 2 IMPELLER 1

The balance drum
The balance drum
The balance drum
Axial balancing
Per impeller the resulting axial force can
be easily calculated, making use of the
dimensions and the suction and discharge
pressure.
Above the inlet labyrinth
the force on the front and
rear sides becomes
cancelled out because
the discharge pressure
downstream of the
impeller continues as far
as the impeller inlet
labyrinth. The areas are
(about) equal.
Axial balancing
The force acting on the inlet side of the impeller, is:
area of suction region x suction pressure

The force acting on the same area, though on the rear side of the
impeller, is:
area of suction region x discharge pressure

Therefore, the actual force acting on the impeller is:

area of suction region x (discharge pressure – suction pressure)

The total axial thrust of a compressor rotor with several impellers is

equal to the sum of the axial thrusts of the individual impellers.
Suction pressure

Suction pressure

External seal
 Special tools

Now that the total axial thrust of the compressor rotor is calculated,
the necessary balancing surface of the balance drum can be
calculated. Due to the balance line, the pressure downstream of
the balance drum is more or less equal to the suction pressure
upstream of the first impeller.

This results in a force on the balancing surface of the balance

piston:

total axial force / (discharge pressure – suction pressure) 

balancing surface
Compressors
Types of Compressors

• Positive Displacement

• Rotating
Positive Displacement

• Reciprocating (Piston)

• Screw
Rotating

• Centrifugal

• Axial
Centrifugal compressors
• Widespread use, many applications
• Gas is accelerated outwards by rotating impeller
• Can be built for operation as low as 5 psi, or
operation as high as 8,000 psi (35 kPa or 55,000
kPa)
• Sizes range from 300 hp to 50,000 hp
DIFFUSERS
Cross section of horizontal split

Picture of horizontal split

Cross section of barrel type compressor

Picture of barrel type compressor

Cross section of bull gear compressor

Picture of bull gear compressor

IMPELLERS
Picture of (bull) gear and impellers
Single Case Compressor Centrifugal Impeller
Cross section of horizontal split
Discharge volutes Impeller inlet labyrinth
seals
Impellers
Shaft and labyrinth
Drive coupling seal

Journal bearing

Casing Thrust bearing

(horizontally split flange)
Compressor discharge
nozzle

Compressor inlet
nozzle
Picture of horizontal split
Cross section of barrel type compressor
Picture of barrel type compressor
Cross section of bull gear compressor

Labyrinth seals

Drive coupling

Impellers
Main gear

Journal bearing

Inlet guide vanes Pinion shafts

Gear casing
Compressor volutes
Picture of bull gear compressor
Picture of (bull) gear and impellers
Axial compressors
• Gas flows in direction of rotating shaft
• Can be built for lower pressures only 10 to 100 psi (0.7 to
6.8 Bar)
• High flow rate
• Efficient
• Not as common as centrifugal

Stator Blades
Rotor Blades Shaft

Casing

Rotor
Blades
Stator
Blades

Casing
Cross section of axial compressor
Guide-vane actuator
linkage Labyrinth seals
Compressor rotor

Rotor blades

Adjustable guide vanes

Compressor inlet Compressor outlet

nozzle Thrust bearing nozzle
Picture of axial compressor
Compressor system classifications

Single-Section, Three-Stage Single-Case, Two-Section, Six-Stage

Parallel Network Two-Case, Two-Section, Six-Stage

Series Network
Capacity control methods
1- Hot Gas Bypass
2Gas bypass
-Inlet Guideis Vanes
a means of recirculating hot discharge
gas back into the suction scrubber. A disadvantage is
3that the work
- Variable of compression
Frequency Drive on the recalculated gas
does not generate any compression effect.

Careful selection of equipment size and using

compressor that unload to a very low percentage of
full load capacity (10%).
Capacity control methods
2-Inlet Guide Vanes
Inlet guide vanes are used
to control the capacity of
the compressor. As the
inlet guide vanes start to
close, they change the gas
entry angle to the impeller
and reduce gas flow and
compressor capacity.
Capacity control methods
Capacity control methods
Capacity control methods
3- Variable Frequency Drive
Changing the compressor speed can also control compressor
capacity. Induction motors require a Variable Frequency Drive
(VFD) to change their speed.
Mechanical Stall

Stall is breaking away the flow from the

suction side of the blade airfoil.

Causes of stall
1. decrease the flow rate
2. increase the attack angle
ROTATING STALL

Rotating Stall is a local separation pattern

that rotates at a fraction of the spool RPM
NORMAL SPEED - STAGES MATCHED
LOW SPEED - STAGES NOT MATCHED
• At lower speeds the forward stages are more efficient than
the rear stages and produce more air flow than can pass
through the rear stages.

• As a result, the rear stages will become "choked" with air.

• This reduction of compressor air flow velocity causes the

compressor to go into a "stall" condition.
HOW AN AIR FOIL CREATS LOW
PRESSURE
• The air flow across the wing produces a pressure differential
across the wing which supports the airplane.

The Air Foil

HOW AN AIR FOIL CREATS LOW
PRESSURE
• Factors which affect the air flow and thus the amount of lift
attained are:

1) the air foil velocity

2) the shape of the air foil

3) the angle at which the air foil meets the air (angle of attack).
HOW AN AIR FOIL CREATS LOW
PRESSURE

Angle of Attack
HOW AN AIR FOIL CREATS LOW
PRESSURE

Stall
VICTOR DIAGRAMS

• A vector shows both direction of movement

and velocity.
VICTOR DIAGRAMS
BLOCKAGE OF FLOW CREATING A
STALL CONDITION
• The increase in incidence angle causes the compressor forward stages to
produce more air.
BLOCKAGE OF FLOW CREATING A
STALL CONDITION
• To prevent the compressor from stalling at low speed we
match the forward and rear stages by controlling air flow rate
into the forward stages.
INLET GUIDE VANES

• By controlling the angle at which the air enters the first three
rows of rotor blades in the compressor, a stall condition is
avoided during the engine start cycle.

• The angle of the inlet guide vanes, the first stage stator, and
the second stage stator are controlled automatically during
the start sequence.
Surge
Surge is lower limit of stable operation. It involves the
reversal flow due to some kind of aerodynamic
instability in the system.
Causes of Surge
•Starvation of compressor
•Increase the pressure in the system
•Malfunction of suction or discharge valves
•Stall may cause surge

Play
Play
Cycle of Surge
Cycle of Surge
Surge

Surge is the point at which the compressor cannot

add enough energy to overcome the system resistance or
backpressure
This causes a rapid flow reversal (i.e. surge). As a
result, high vibration, temperature increases, and rapid
changes in axial thrust can occur. These occurrences can
damage the rotor seals, rotor bearings, the compressor driver
and cycle operation. Most turbo machines are designed to
easily withstand occasional surging. However, if the machine
is forced to surge repeatedly for a long period of time, or if it
is poorly designed, repeated surges can result in a
catastrophic failure. Of particular interest, is that while turbo
machines may be very durable, the cycles/processes that they
are used within can be far less robust.
Surge Line
The Surge-line is the curve that passes through
the lowest flow points of each of the four speed lines.
As a test map, these points would be the lowest flow
points possible to record a stable reading within the
test facility/rig. In many industrial applications it may
be necessary to increase the stall line due to the
system exhibits a stalling characteristic or positive
slope within that range of flows. When placed in a
different system those lower flows might not be
achievable because of interaction with that system.
Choke
The speed lines of gas turbine centrifugal
compressors typically exhibit choke. This is a situation
where the pressure ratio of a speed line drops rapidly
(vertically) with little or no change in flow. In most cases
the reason for this is that close to Mach 1 velocities
have been reached somewhere within the impeller
and/or diffuser generating a rapid increase in losses.
Higher pressure ratio turbocharger centrifugal
compressors exhibit this same phenomenon. Real choke
phenomena is a function of compressibility as
measured by the local Mach number within an area
restriction within the centrifugal pressure stage.
Effect of Surge

• Noise operation.
• Change in position in axial direction.
• Temperature and pressure deviation in delivery side.
• Increasing in vibration.
• Mechanical damage of rotor blades, stator blades, and
bearings.
ANTI-SURGE SYSTEM

• The compressor cannot produce enough pressure to force all

its discharge air through the first stage turbine nozzle until it is
operating at nearly its design speed.

• To solve this problem we simply bypass some of the

compressor discharge air around the turbine section.

• Bypassing or bleeding air (about 10-15%) around the turbine

section during acceleration is a function of the Air Bleed
Valve.
Developing the compressor curve

Rc/ Rprocess,2
∆Pc/
Rprocess,1
Hp

Rc2

Rc1

Compressor
curve for a
specific speed
N1

Q2 Q1 Qs /
Qv /
Qm
Developing the compressor curve

process limit
Rc
adding control
margins
maximum speed
surge limit
power limit

stonewall or
choke limit

Actual available
stable zone
operating zone
of operation
minimum speed

Qs, vol
Developing the surge cycle on the compressor
curve (1)

Drop into surge 20 - 50 ms From A to B•

Jump out of surge 20 - 120 ms From C to D•
Surge cycle 0.3 - 3 seconds A-B-C-D-A•

H
B A Pd

Pv
D
Rlosses
C

Qs, vol
Anti-surge controller

VSDS

Compressor

FT PsT PdT
1 1 1

Suction UIC Discharge

1
Compressor performance control
• Also called:
– Throughput control
– Capacity control
– Process control

• Matches the compressor throughput to the load

• Can be based on controlling:
– Discharge pressure
– Suction pressure SIC

– Net flow to the user 1

• Blow off
• Recycle Process

• Guide vanes PT

• Speed 1

PIC
1
Compressor performance control

P1 Throttling
P2 Throttling Design Point
Recycle
Control
Disch. Press

Speed
control

Mass Flow
Anti surge Systems

• Anti surge valve

• Vane diffuser in highly flow rate

 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
 Labyrinth seal

Seal

Shaft Gas
 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.
 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
 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.
 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.
Barrier seal
Barrier seal
Centrifugal Compressors

Shaft ends :
Labyrinth seal
Gas seal
Oil seal
Bearing
Shaft Sealing
Shaft sealing is provided to minimize the gas
leakage along the shaft.

Shaft seal types:

•Labyrinth seal
•Fluid film seal
•Mechanical seal
•Dry gas seal
Labyrinth Seal
Consist of a series of a sharp edged
circular fins generating flow
resistance for rotating gas inside
the casing.
The labyrinth seal has a small
clearance along the rotating shaft
and therefore a minute amount of
gas does escape.
Labyrinth Seal
Labyrinth seals are installed
on the diaphragm assembly
to minimize internal leakage
along the shaft from the
progressively higher stage
pressures.
Inter-stage Seal
Inter-stage seal:
Due to the pressure rise across
successive compression stages, seals
are required at the impeller eye and
rotor shaft to prevent gas backflow
from the discharge to inlet end of the
casing
Oil Film Seal
The seal oil enters the seal between bushings,
flow around the shaft and forms an oil film. This
oil film prevents gas from escaping.
THE FUNDAMENTALS
Mechanical Seal Basics
Normally two components, one sealed to and
rotating with the shaft, one sealed to and remaining
static in the housing.
Each part has a technically flat polished sealing face.
The polishing allows the rotary face to run against the
static face while generating the minimum of friction.
A small amount of media enters between the faces
and acts as a running film further reducing friction. This
film evaporates before it reaches the inside of the
running faces.
THE FUNDAMENTALS
Mechanical seal

Consists of a static carbon ring

located in a steel retainer and
spring loaded against rotating
tungsten carbide seal rings.
Mechanical seal
•Sealing of the gas is achieved
at the radial interface of the
rotating and the stationary
rings in a unique way.
•The sealing surfaces are
lapped to a very high degree of
flatness while the rotating ring
has a series of spiral grooves
machined into it’s running
face.
 1-Principle of operation
Scarifying
elements
Vertical surface wear

Equipment

172
 2-Mechanical seal function and component
Rotary Elements Stationary Element
1- Carbon ring
2- Snap Ring Tungsten Carbide ring
3- “O” Rings Or
Silicon Carbide ring
4- Springs
5- Sleeve

Equipment

173
 LESSON NUMBER ONE
ALL
MECHANICAL SEALS
LEAK
Dry Gas Seal
Basic dry gas seals consist of a stationary ring held against a
rotating ring with spring pressure. The rotating ring has special
grooves or tapered lands cut into the outer portion of the face .

Dry filtered process gas or inert gas is introduced into the seal
area. As the shaft rotates, the gas is between the seal faces
along the grooves towards the smooth section of the face. The
action of the rotating grooved ring creates a pumping or lifting
effect that forces the stationary ring back against the springs
and away from the rotating face. This small gap. which may be
as small as 0.0002'" effectively restricts leakage to a minimum.
This minute gas leakage helps remove heat that is produced by
the constant action of gas shearing at the seal faces.
Dry Gas seal Grooves on rotating seat
Dry Gas seal Principle of Seat and Face
Dry Gas Seal
Clean gas Primary leak secondary leak Instrument
supply to flare to safe location air
Dry Gas seal
Principle of Seat and Face
To save location To flare
Flame arrestor
Flame arrestor is a piece of
equipment installed in an
industrial process to stop the
propagation of a deflagration
traveling along a pipeline by
extinguishing the flame. Flame
arresters are used on storage tank
vents, fuel gas pipelines, storage
cabinets, the exhaust system of
internal combustion engines, Davy
lamps and over proof rums.
Lube Oil System

The lube oil system consists of :

Oil reservoir.
Oil pump.
Oil cooler.
Oil filter.
Bearing.
Overhead tank.
Pressure regulator.
Sight glass.
RADIAL TILTING PAD
BEARING

CASING

SHAFT

Radial
Load
187
 Oil Wedge

Oil Wedge Effect Friction Effect

Shaft
188
 Oil Wedge Oil squeeze between
shaft and bearing pad
forming a solid
oil wedge

Oil adhere to
the rotating
shaft

189
RADIAL TILTING PAD
BEARING

TILTING PAD

SHAFT

PIN

OIL

CASING

190
Axial compressor
Typical Radial Tilt Pad Bearing
 Mars 100S Compressor Set

Tilt-Pad Thrust Bearing

Fluid Film Bearing

Tilting pad journal bearing

•The pads are fitted in a two piece bearing housing which positions
them radially and axially.
•The pads are held in the journal bearing housing by special pad
stops.
Fluid Film Bearing

•The bearings are lubricated by oil

from the main oil system.
•The oil is supplied via an hole in
the pad stop pins into the spaces
between the pads.
•Most of the oil is picked up by the
rotating movement of the shaft and
enters the space between the pads
and the rotating shaft.The rest of
the oil leaves the bearing housing
axially and flows into the oil drain
line.
Fluid Film Bearing

• Through the tilting action of

the pads, oil wedges will be
built up between the rotating
shaft and the stationary
bearing pads.
Fluid Film Bearing

Thrust bearing

Is a double acting thrust

bearing of the multiple pad,
self aligning and equalizing
type.
Fluid Film Bearing
Fluid Film Bearing

The rotor is axially positioned by the

thrust bearing, which also serves to
absorb any axial force on the
compressor.

The thrust bearing consists of :

- a steel rotating member ( thrust collar )
- two sets of stationary pivoted Babbitt-faced segments
( thrust pads)
- load equalizing leveling plate
QUESTIONS

Eng.\ WAEL ZAHRAN

Email: Mech_eng_w@yahoo.com