Centrifugal Compressors

Performance Curves
Factors that Affect Compressor
Performance

Topics
p

H
How
aC
Centrifugal
t if
l works
k /E
Energy C
Conversion
i

Performance Curves

Operation Limits: Surge & Overload

Factors Affecting Compressor Performance

Operational Iss
Issues
es Optimizing
Optimi ing Compressor
Efficiency

How A Centrifugal Works

Centrifugal Stage

Return Bend

Return Bend

Diffuser
Reduces Velocity
Increases Static Pressure

Return Channel

Guide Vanes

Impeller
p
Increases Velocity
Increases Static Pressure

How A Centrifugal Works

How A Centrifugal Works

Energy Conversion

P4,V4,T4

P5,V1,T5

P3,V1,T3

P5,V1,T5
P2,V4,T2

P1,V1,T1

P3,V1,T3

Head Concept
Mechanical: The work (energy) developed to raise a
weight of 1 pound by a distance of one (1) foot. Expressed
in foot-pound (or equivalent Kgm or Nm);

Gas Compressors: work done by the compressor /

amount of gas. The head expressed in feet, is the height to
which
hi h the
th gas could
ld b
be lift
lifted
d

Head Concept
The height to which the gas is lifted depends on the velocity
of the gas

For any given RPM, the head developed by the compressor

is fairly constant,
constant independent of the gas nature
nature.

Head is depending upon:

Compressor
C
geometry
t (i.e.
(i no off stages,
t
impeller
i
ll di
diameters)
t )
Compressor speed

Z: Compressibility Factor
R: Gas Constant = 1545 / MW
Ts: Suction Temperature (R)

M:

r: Pressure Ratio (Pd / Ps)

M Polytrophic
M:
P l
hi E
Exponent

Head Concept Example

Performance Curves

Basic Components

Fixed/Variable Speed
p

Surge/Overload

Effects on Performance

Compressor
p
Performance Curves illustrates the
operating range and flexibility of a given compressor

% Head, P
Pressure, P
Pressure R
Ratio

120%

110%
100%
105%
100%
95%
90%

90%
85%

80%

70%
60%
60%

80%

90%

% Inlet Capacity or Flow

100%

120%

Compressor Performance Curves

There are two types of curves that are generally required
required,
section and overall:

section refers to an impeller or sequence of impellers between two

nozzles such that there is no pressure drop or temp reduction
between impellers

overall refers to a complete compressor or compressor train

Note: a back-to-back unit with a crossover may often be considered a
two section compressor; but with respect to performance curves
two-section
curves, it is a
single section since no pressure drop or cooling is introduced between
the impellers

For single section compressors, the section curves and

overall curves are one in the same

Design Point is the point at which usual operation is

expected
t d and
d optimum
ti
efficiency
ffi i
iis . It iis th
the point
i t att which
hi h
the vendor certifies that performance is within the tolerance
% Head, P
Pressure, P
Pressure R
Ratio

120%

110%
100%

90%
80%

70%
60%
60%

80%

90%

% Inlet Capacity or Flow

100%

120%

Rated Point is intersection on the 100 % speed line

corresponding
di to the
h hi
highest
h
flflow off any operating
i point
i

% Head, P
Pressure, P
Pressure R
Ratio

120%

110%
100%

90%
80%

70%
60%
60%

80%

90%

% Inlet Capacity or Flow

100%

120%

Stability: the percent of change in capacity between the rated (design

point) capacity and surge (limit) point
point, all at constant speed
speed, is measured as
the stability of the centrifugal compressor. Indicates the capability of the
centrifugal compressor to operate at less than design flow

% Head, P
Pressure, P
Pressure R
Ratio

120%

110%
100%

90%
80%

70%
60%
60%

80%

90%

% Inlet Capacity or Flow

100%

120%

Turndown: the percent of change in capacity between the rated

% Head, P
Pressure, P
Pressure R
Ratio

(Design point) capacity and the surge (limit) point, all at constant head or
pressure is measured as turndown of the centrifugal compressor. Indicates
the capability of the centrifugal compressor to operate at less than design
flow 120%
110%
100%

90%
80%

70%
60%
60%

80%

90%

% Inlet Capacity or Flow

100%

120%

Rise to Surge:
Surge: the percent of change in discharge pressure between
the rated point and surge limit at constant speed
speed. High RTS means the
compressor can accommodate a modest increase in discharge pressure
with a little change in flow

% Head, P
Pressure, P
Pressure R
Ratio

120%

110%
100%

90%
80%

70%
60%
60%

80%

90%

% Inlet Capacity or Flow

100%

120%

Surge
g Phenomenon
At any given speed, there is minimum flow, below which, the
compressor cannott be
b operated
t d in
i a stable
t bl condition.
diti
Thi
This
minimum flow value is called surge point.

Surge is oscillation of the entire flow of the compressor

system and this oscillation can be detrimental to the machine.

Compressor surge may be evidenced by the following:

a) Excessive rotor vibration
b) Increasingly higher process gas temp
c) Rapid changes in axial thrust
d) Sudden changes in load
e) Audible sounds (if surge is severe)

Surge
g Damage
g of Compressor
p
Internals
High
g axial displacement
p

Deformation due to high

temperature

Resistance to Flow Causes

Surge Description

Pressure to Rise Which

Causes Flow to Decrease

Sudden Reversal of Flow

Slams Thrust Disc Against

% Head, P
Pressure, P
Pressure R
Ratio

120%

Inactive Thrust Bearing

110%
Pressure Builds along the

100%

Design Curve Back

to the Design Point

90%
80%
Pressure Ratio Drops Low Enough

70%

for Flow to Instantaneously

Build Back to the Design Curve

60%
60%

80%

90%

% Inlet Capacity or Flow

100%

120%

Surge
The frequency of the surge cycle varies inversely with the
volume of the system

If the check valve is located near compressor discharge

nozzle, the frequency will be much higher than of a system
with a large
g volume in the discharge
g upstream of the check
valve

The higher
g
frequency
q
y of the surge,
g , the intensity
y will be
lower (i.e. few cycles / minute up to more than 20 cycles /
sec)

The intensity of the surge increases with gas density ,

pressure and lower temperature

Surge - Effects of Gas Composition

Best Efficiency point
E%
Heavy Gas (propane, propylene)
Medium Gas (air, nitrogen, natural gas)
Light Gas (Hydrogen reach gases, i.e.
hydrocarbon processing plants)

Surge points

Surge - Effects of Gas Composition

Observations made in respect to the heavy
gas:

Th flow
The
fl
at surge iis hi
higher;
h

The stage produces more head than

corresponding to medium gas / light gas

The right
Th
i ht side
id off the
th curve tturns d
downward
d
(approaches stonewall) more rapidly

The curve is flatter in the opening stage (small

RTS)

Surge Control
IInputt Signals
Si
l R
Required
i d
1 - Suction Flow
2 - Suction Pressure
3 - Discharge Pressure
Suction

Flow Element

Flow
Transmitter FT

Pressure PT Pressure PT
Transmitter
Transmitter
PC
SP
U

Recycle
Valve
I/P

G D A AC G E
B I I OO B T
C
MCH

Surge Control
In the PLC

Discharge

Surge
g Control
Surge Controller Performance
Map

External Causes and Effects of Surge

g

Restriction in suction or discharge

g of system
y

Process changes in pressure, temperatures, or gas MW

Internal plugging of flow passages of compressor (fouling)

Inadvertent loss of speed

Instrument or control valve malfunction

Operator error

Misdistribution of load in parallel operation

Improper assembly of compressor (impeller overlap)

Restriction in Suction / Discharge

Parallel Operation
Typically, for parallel operation, the flow is not split evenly and one
section or compressor handles more flow than the other, but both
sections
ti
are required
i d tto make
k th
the same pressure ratio
ti

Careful analysis of the pressure ratio curves is required to insure

satisfactory operation and suitable overall range

similar pressure ratio curves

At the design flow
flow, section (1) is
much more flow than of section (2)

If the total flow is reduced 10%,

the compressor slows down to
maintain the same pressure ratio

The
Th flow
fl
to
t each
h section
ti iis
reduced 10% (dashed line) since
the pressure ratio curves have a
approximately the same rise

different pressure ratio curves (section 2 pressure ratio curve is

steeper
p than section 1))
If the total flow is reduced 10% the compressor slows down to maintain
pressure ratio
Section (1) reduces more than 10% ( about 12.5% - the dashed line)
since its curve is shallower
Section (2) reduces less than 10% (about 5% - dashed line) since its
curve is steeper
The two sections are now
operating at significantly different
portions of the curve and are now
handling a different percentage of
the total flow than they were at the
design point
point.

Section (1) is nearing surge.

Further reduction in flow would
force section one into surge

The difference in the curve

shape results in a reduced overall
range for parallel operation

Impeller
p
Overlap
p with Diffuser

Impeller Overlap with Diffuser

Positive overlap

Nominal

Non Desirable

Limited

Desired

Limited

Impeller Overlap with Diffuser

It is preferable that no impeller shall have negative overlap

The negative overlap is limited to 5% of the impeller tip

Instrument / Control System

y
Malfunction

Overload

% Head, P
Pressure, P
Pressure R
Ratio

120%

110%
100%
105%
100%
95%
90%

90%
85%

80%

70%
60%
60%

80%

90%

% Inlet Capacity or Flow

100%

120%

Choke Limit
Choke is the maximum flow that a centrifugal compressor
can handle at a given speed
speed. At that point
point, the compressor is
unable to produce any net overall pressure ratio.

The maximum flow region of the compressor performance

curve is where the gas speeds approach Mach 1

Gas compression
G
i iis no llonger occurring
i iin th
the compression
i
channels. This region of the curve, as it becomes almost
vertical at the choke limit,
limit is also know as Stonewall
Stonewall

Stonewall is usually not detrimental to the compressor, it

simply limits the maximum flow
flow. If choke occurs at an off
design condition, the maximum volume flow can be increased
byy increasing
g the rotational speed
p

API 617 7th Edition Performance

Curves

Performance Curves Inlet Gas

Condition Effects

Performance Curves Inlet Gas

Condition Effects

Factors Affecting Compressor

Performance
MW & Head - If MW increases,
increases the head for a given ratio will decrease
in direct proportion

Temp
e p & Head
ead - If tthe
e Tss increases,
c eases, tthe
e head
ead for
o ag
given
e ratio
at o will
increase in direct proportion

Zave & Head - If the average compressibility increases, the head will
increase in direct proportion

N and Head - If speed increases, the head will increase in direct

proportion

Flow

and Speed - If the speed increases, the flow will increase in direct
proportion

Factors Affecting Compressor

Performance
N & BHP - If the speed increases,
increases the BHP will increase in
proportion to the cube of the speed. (Because flow increases
directlyy as speed
p
and head increases as the square
q
of the
speed and BHP is the product of head X mass flow)

Density
e s ty - The
eo
only
y tthing
g a co
compressor
p esso impeller
pe e sees is
s inlet
et
capacity. Thus to get more capacity out of an existing
compressor it is necessary to change the density of the inlet
by:
decreasing the suction temperature
increasing the suction pressure
increasing the MW of the gas

Compressor Off - Design Performance

Performance curves for axial and centrifugal
g
compressors are usually based on constant inlet
conditions (Ps, Ts, MW). In actual service, these
compressors rarely
l see th
these b
base curve conditions
diti
exactly

If the field inlet conditions deviate more then 5% from

the curve inlet conditions then the field data can not be
accurately plotted on the curve without converting the field
data to curve conditions

To properly
T
l evaluate
l t th
the compressor (running
(
i off
ff
design), the performance parameters shall be corrected to
the design conditions

Operation Limitations
Compressor

Driver

Power

Process

Compressor Operation IssuesIssuesEfficiency Drop

Internal recycle
U t
Un-tuned
d Surge
S
Control
C t lS
System
t
Leakage via by-pass valve(s) in process
Compressor operated out of guaranteed
performance envelope
p
p
Impeller & Diaphragm erosion
Fouling

Internal Recycle Gap at the

diaphragm / guides splits

Internal Recycle Gap at the

diaphragm / guides splits

Labyrinth Leakage
Leakage proportional to:
P
Clearance
Diameter
1 / (No.Laby Teeth)0.5
Eye laby leakage is
approx. 10 times
spacer laby leakage

Eye Laby
Leakage
Spacer Laby
S
L b
Leakage

Internal Recycle Labyrinth Clearance

Process labyrinths can

be p
plugged
gg by
y wet
particles in the gas flow

Internal Recycle Labyrinth Clearance

Shaft Spacer

Impeller Cover

Internal Recycle Labyrinth Clearance

Impeller Cover

PEEK Labyrinth

PEEK Physical Properties

GRADE

Arlon CP
T l
Torlon
4340
Fluorosint
500

COEF.
THERMAL
EXPNSION
(F)
17 x 10 /-6
18 8
18.8

TENSILE
STRENGTH
(PSI)

ELONGATION
(%)

SPECIFIC
GRAVITY

11,080
12 900
12,900

2.0
66
6.6

1.45
1 44
1.44

19.4

1,100

10.0

2.32

Un-- tuned Surge Control System

Un

Recycle valve shall be calibrated at every planned S/D

fast opening ( < 1 sec)

total travel 0-100 %; 4 20 mA
mechanical
h i l stop
t tto coincide
i id with
ith 100 % close
l

Valve positioner shall match the command

FT instrument shall be calibrated at every planned S/D

Flow calculation block correct constants

constants, correct range

Fouling
is the deposit and the non uniform accumulation of
debris in the gas

Occurs due to carryy over of liquids

q
and debris from the
inlet suction scrubber

Polymerization may occur in wet gas and cracked gas

compressors applications if the temperature exceeds the
critical point beyond the polymerization process occurs
(235 F)

Fouling
g build up
p occurs usually
y on the impeller
p
hub and
shroud. There is also a build up on the blades ( on the
pressure side)

Fouling

IGV partially clogged

1st stage impeller hard deposits

Fouling
g Effects Charge
g Gas

3M7 Eroded Sleeves

Fouling
g Effects

April 25 '99

NPC Thai Fouling

Abrasive Scoring due to Fouling

Fouling
g Effects Charge
g Gas

3M7 - Deterioration of stage clearances

Techniques
q
to Prevent Fouling
g
Condition monitoring, both aerodynamic and
mechanical parameters

Process control

Online solvent injection

Coatings of Impellers and Diaphragms

Fouling - Condition Monitoring

(aerodynamic and mechanical parameters)

Monitor and trend the information regarding

process conditions
MW
Pressure
Temperature

Vibration monitoring
On
O line
li system
t
Off line system

ONLINE CONDITIONING
MONITORING

Condition Monitoring DR CPM Online System

Condition Monitoring DR CPM Online System

Condition Monitoring DR CPM Online System

Condition Monitoring DR CPM Online System

Condition Monitoring DR RECON Online System

THANK YOU

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