Compressors
Compressors
STC-SV-08-3-A
12128 1/min
32 bar g
56 bar g Dry gas seal cartridge
Dry gas seal cartridge Impeller
Sensor
Rotor
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
Compressor
Applications
Refineries
Gas–Oil Separation GOSP
Gas (re)Injection Gas transmission
Gas Lift Gas transport (pipeline) Petrochemical
Export Gas storage
General chemical
Compressors
Dynamic Displacement
Integrally Geared Single Shaft
Radial Axial
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
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
Gaslift
Turbo radial
Naptha Cracking
(Ethylene)
Turbo
Screw / Rotary vane / Roots axial-(radial)
compared to reciprocating
Advantages Disadvantages
No pulsations Efficiency
Lower foundation cost and civil cost CAPEX
Minimum weight and space Operating range
No wearing parts Delivery time
Reliability and availability
Low noise emission
Smooth start up and control
Total Cost of Ownership
Comparative evaluation of compressor types
BEST WORST
1. Introduction.
2. Applications
3. Compressor Types
4. Centrifugal compressor
working principles
5. Compressor selection
6. Mechanical design
7. Aerodynamics
8. Rotordynamics
Working principle
▲
▲
▲
▲▲
Return vanes
guide the flow to
the next impeller
Performance curve
50
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
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
p1
T1
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
Larger
Pressure ratio
or larger
Mol weight
Smaller
Flow Larger
or lower Hub to Tip
temperature ratio
Impellers
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
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.
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.
SV-B SH-B
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
Inner
barrel
Aero Assembly
Diaphragms
Page 8 Dynaflow: 10/09/2009 E O OS RE
Compressor Mechanical design
Diaphragms
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
-Vaned
-Higher Head and efficiency
-Smaller flow range
Flow
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
Page 15
Back-to-back Rotor Dynaflow: 10/09/2009
E O OS RE
Typical compressor parts
Labyrinths
- 2 at each impeller.
Function:
Seal
- Minimizing recycle losses
Shaft Gas
1. Brazing Shroud
Brazing Blade
material Disc
2. Inside welding
Welding
seam
3. Slot welding
Slot seam
Probes
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
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
1. Introduction.
2. Applications
3. Compressor Types
4. Centrifugal compressor
working principles
5. Compressor selection
6. Mechanical design
7. Aerodynamics
8. Rotordynamics
Surge
Phenomenon
Protection
Stall
Phenomenon
Impeller stall
Diffuser stall
Noise
FLOW
Rapid flow oscillations
Thrust reversals
Potential damage
1 2 3
TIME (sec.)
TEMPERA
TURE Rising temperatures
inside compressor
1 2 3
TIME (sec.)
Conclusion:
The message is to avoid surge.
Therefore a Anti Surge Control System is installed at each compressor.
FT TT PT PT
FCV
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
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.
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
Noise:
Source
Any flow instability causes pressure variations and results is increased noise levels.
Especially flow incidence at vanes at high velocity can cause (tonal) noise.
Impeller vanes
Stator vanes
Rotor-stator interaction
Counter measures
Apply noise-enclosures around the equipment that makes the most noise. This is
often a gearbox or a gas turbine.
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.
1. Introduction.
2. Applications
3. Compressor Types
4. Centrifugal compressor
working principles
5. Compressor selection
6. Mechanical design
7. Aerodynamics
8. Rotordynamics
Rotor Vibrations
Lateral Torsional
Forced: Self-Excited:
• Unbalance • Oil Whirl
• Rotating Stall • Labyrinth Induced Whirl
• Surge • Thermal Instability
• Pressure Pulsation’s • Aerodynamic Whirl
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
Overhung Overhung
NDE
Bearing Span DE
Undamped Lateral
Critical Speeds
For a torsion analysis the whole rotating string has to be taken into account!
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
Most Sensitive
Element