CENTRIFUGAL COMPRESSOR

Date : July, 02, 2008

Lecturer : D. S. Kim
 CENTRIFUGAL COMPRESSORS
CONTENTS

1. INTRODUCTION

2. SELECTION OF COMPRESSORS

3. BASIC OF CENTRIFUGAL COMPRESSORS

4. COMPRESSOR THERMODYNAMICS

5. COMPRESSOR EFFICIENCY

6. MULTI-STAGE COMPRESSORS

7. PRINCIPLE COMPONENTS OF A CENTRIFUGAL COMPRESSOR

8. LUBRICATION AND SEALING SYSTEM

9.COMPRESSOR CONTROLS

10.SURGE CONDITION AND ANTI-SURGE CONTROL

11.REFERENCE
 INTRODUCTION
‡ COMPRESSOR :Any machine which uses external energy to increase the
pressure of a gas/ mixture of gases is called a compressor.

‡ Compressors are broadly classified into the following two categories-

„ Positive Displacement Type
„ Dynamic Type

‡ Positive Displacement type compressors are those in which successive

volumes of gas are confined within some type of enclosure (compression
chamber) and elevated to a higher pressure. Eg. Reciprocating compressors,
screw compressors, sliding vane compressors etc.

‡ Dynamic compressors accelerate a continually flowing gas stream and

subsequently convert the velocity head into pressure. Eg.: Centrifugal
compressors, axial flow compressors, mixed flow compressors etc.
 INTRODUCTION
‡ INTRODUCTION:
Centrifugal Compressors are Rotary machines which are used to handl
e gases or Mixtures of gases (Compressible fluids) and Transfer the in
put power by rotary motion to the medium handled there by transferri
ng the kinetic energy of the impeller to pressure energy.
SELECTION OF COMPRESSORS
 BASIC OF CENTRIFUGAL
COMPRESSORS
‡ The centrifugal compressor has a radial bladed impeller mounted
on a shaft. The energy imparted to the gas as it passes through the
compressor is kinetic, due to the increased velocity and centrifugal
force acting on the gas.
As the gas is compressed radially, the width of the impeller is
progressively reduced towards the outlet. As the gas leaves the
impeller, it passes into a diffuser, the function of which is to reduce
the velocity of the gas and convert kinetic energy into pressure energy.
If the compressor has more than one stage on the same shaft, the
radial gas flows from one impeller is directed inwards to the eye of
the next impeller. This second impeller will be handling a gas at a
higher pressure and, therefore a smaller volume is required.
‡ Fig.: Section through a Multi-stage Barrel Centrifugal
Compressor
‡ Fig.: Horizontally split Five-stage compressor
‡ Fig.: Multi-stage Centrifugal Compressor with two side
streams
‡ Fig.: Impeller designs
‡ Fig.: Overhung impeller
‡ Fig.: Section through Single stage overhung impeller
compressor
 BASIC OF CENTRIFUGAL
COMPRESSORS
‡ Any centrifugal compressor has to meet a number of
requirements while in service, the most important ones
being-
„ The thermodynamic function for which it is intended
„ Stability in operation over long periods
„ MOC capable of withstanding the rigorous duties
„ afford maximum safety to the machine, the system in which it
operates and the personnel operating the system
„ Maintain the environment free from harmful gases handled by
the machine
„ Maintain the vibrations over a range of speeds within the
permissible limits
„ Maintain the noise generated within limits
 COMPRESSOR THERMODYNAMICS
‡ Compressor Thermodynamics::
The volume occupied by an ideal gas varies with pressure and tem
perature because inter molecular distance changes, where as the si
ze of molecules remains the same. Thermodynamic processes in i
deal gases takes place with specific heats at constant pressure (Cp)
and constant volume (Cv) and they obey the equation of state,
P = ρ RT.
When this equation is used in compressor calculations, the resultin
g error will grow with decrease in temperature and increase in pres
sure of the gas.
Thus it is applied to a real gas (like air) it will give error and it is t
olerable for final pressure up to 10 mpa and beyond 10 mpa equat
ion is used with a correction factor i.e.
P = Z ρ RT (where Z is compressibility factor)
COMPRESSOR THERMODYNAMICS
The first law of thermodynamics used along with ideal gas equation of
state results in the following equations which describes the process
of compression / expansion occurring in compressors.

1) Polytropic, where P / ρ n = constant ; pvn = constant

2) Adiabatic, where p /ρκ = constant; PV k = constant
3) Isothermal P / ρ = constant ; PV = constant

The Polytropic process is the general type of thermodynamic process

characterised by the polytropic exponent ‘n’ generally this value lies
between 1.25 to 1.45.
COMPRESSOR THERMODYNAMICS

The polytropic head ‘H’ of a compression stage is given by the

equation.

H= zRT0 (rn-1/n –1)

where,
Z is the compressibility factor ( to be ascertained from gas properties)
R is the gas constant which equals 848 / mol. wt
T0 is the absolute temperature at normal condition
COMPRESSOR THERMODYNAMICS
(k − 1)/(k ∗ 1/ η pol )
⎛P ⎞
ρ = ⎜⎜ ⎟⎟ f

⎝ P ⎠ i

pf / pI is the compression ratio

k is the ratio of specific heats (Cp/Cv)
n is the polytropic co-efficient
To develop same head gases of lower molecular weight need more comp
ression stages than that of higher mol. wt gases.
A Perfect adiabatic process can’t be attained in compressors since excha
nge of heat between the working medium and its surroundings are not pr
evented due to certain advantages.
The theory of compression also deals with the isentropic process wherei
n no internal heat is liberated by fluid friction. Apparently such a thing c
annot happen in real compressors.
COMPRESSOR THERMODYNAMICS
‡ Fig.: P-V Diagram of different compression processes
COMPRESSOR THERMODYNAMICS
‡ Fig.: S-T Diagram of different compression processes
 COMPRESSOR EFFICIENCY
‡ The efficiency of a compressor cycle is
η = cp(T2-T1)
cp(T2-T1) + q
where q is the external heat loss due to cooling.
However, the completeness of the process of compression is measured
by relative thermodynamic efficiencies ηise and ηisc
For the actual polytropic process in a compressor with an exponent ‘n’
and specific energy ‘L’, the isothermic and isentropic efficiencies are
given by
ηiso = Liso
L
ηise = Lise
L
Where Liso and Lise are specific energies of isothermal and isentropic
processes
 COMPRESSOR EFFICIENCY
The isentropic efficiency is used as a performance criterion for
centrifugal and axial flow compressors with low rate of cooling. This
is due to the fact that the standard of perfect performance for these
compressors is the isentropic process.
For the actual polytropic process, the formula can be expressed in
terms of stagnation parameters, provided q=0.
L= cp(T2*-T1*)
The above relationship suggests that

ηise = (p2*/p1*) k-1/k - 1

(T2*-T1*) - 1
 MULTI STAGE COMPRESSION
Industrial requirements call for high pressure compressors. It is
difficult to generate in one compression stage this high pressure. The
problem with centrifugal compressors is that impeller vanes fabricated
from known materials cannot be expected to withstand velocities high
enough to meet the pressure and efficiency demands.
The two consequences are that,
„ the gas being compressed should be cooled at the highest possible
rate &

„ compression should be carried out in series connected stages with

gas temperatures reduced in external coolers located between the
stages.
 MULTI STAGE COMPRESSION
The general arrangement of such a system is depicted in Fig.
Multistage compression accompanied by inter cooling saves a sizeable
amount of driving power. This is evident from Fig. In this diagram the
saving power is depicted by shaded areas 1’’-2’-2-2’’.

Most compressors employ cooling the gas in inter coolers located

between compression stages. A significant saving in power can be
achieved by this method. In centrifugal compressors the inter coolers
are usually installed between stage groups in order to make the plant
design simpler.
 MULTI STAGE COMPRESSION
Fig.: GA of a multistage centrifugal compressor
 MULTI STAGE COMPRESSION

Fig.: P-V & S-T diagrams of a two stage compressor

 PRINCIPLE COMPONENTS OF A
CENTRIFUGAL COMPRESSOR
‡ CASING
Casings are made of either castings or forging depending upon the
design pressure. Further they are categorized as horizontally split and
vertically split casings. Bearing housings are made integral part of
casings in order to reduce the span for higher stability. As per the
requirements of API 617, despite of the bearing housings being an
integral part of the casing, the bearings are made accessible for
inspection without de-pressurising the casing.
Low pressure casings are split horizontally along the centerline of the
m/c & incorporate nozzles in the upper or lower half of the casing.
High pressure m/c usually have the diaphragms and diffusers mounted
within a horizontally split inner casing which is fitted into a forged
steel barrel having removable ends.
Casings are not normally water cooled but occasionally it is necessary
to cool the diaphragms on multi-stage machines.
PRINCIPLE COMPONENTS OF A
CENTRIFUGAL COMPRESSOR
 PRINCIPLE COMPONENTS OF A
CENTRIFUGAL COMPRESSOR
‡ Fig.: Compressor casing forged
 PRINCIPLE COMPONENTS OF A
CENTRIFUGAL COMPRESSOR
‡ Fig.: Types of casings
 PRINCIPLE COMPONENTS OF A
CENTRIFUGAL COMPRESSOR
‡ Rotor: The rotor of a compressor consists of a shaft over which the
impellers, spacer bushes, balancing drum and thrust disc are mounted.
Generally shafts are made of high quality alloy steel forging and
impellers may be of cast, welded or riveted construction depending
upon the application and size. Each impeller is balanced and given an
overspeed test under vacuum conditions before being fitted on to the
shaft. The assembly is then dynamically balanced to specified limits.
The inlet area of each impeller is subjected to stage suction pressure,
while the remainder of the area is under higher pressure. This
unbalance causes a thrust towards the impeller suction which is
balanced by means of piston fitted on one end of the shaft and
subjected to suction pressure on its outer side. Additionally, a thrust
bearing is fitted so that axial movement of the shaft is limited and any
residual axial unbalance accommodated. As protection in the event of
shaft axial movement in excess of thrust bearing clearance, a shaft
axial movement device is incorporated.
 PRINCIPLE COMPONENTS OF A
CENTRIFUGAL COMPRESSOR
‡ Rotor assembly
 PRINCIPLE COMPONENTS OF A
CENTRIFUGAL COMPRESSOR
‡ Diaphragms: Diaphragms serve the dual function of acting as
partitions between suction and discharge of individual stages and to
guide the flow of medium from the impeller outlet of the previous
stage to the impeller eye of successive stage. These are provided with
vanes to distribute the gas evenly over the circumference. The
diaphragms are split horizontally and are provided with a suitable
arrangement at the parting plane to prevent gas leakage across.
Generally these are either cast out of meehanite or fabricated out of
steel.
 PRINCIPLE COMPONENTS OF A
CENTRIFUGAL COMPRESSOR
‡ Fig.: Diaphragm assembly
 PRINCIPLE COMPONENTS OF A
CENTRIFUGAL COMPRESSOR
‡ Bearings: The rotor is supported (in the casing) on two journel
bearings at the shaft extremities. These serve as support points for the
rotor. Pressurized oil admitted to the bearings continuously lubricate
the bearings & allow the rotor to have the rotation. The rotor bearing
system as a whole determines the stability of operation. Its all more
important that the system is designed with due care to eliminate
problems during normal operation.
The bearings can be of sleeve or tilting pad type. Tilting pad type
bearings are self aligning type units which take with ease ultimate
position of the shaft during operation. These bearings prevent
occurrence of oil whip phenomenon also. The bearing contact
surfaces with the rotor are aligned with babbit material of special
composition. The bearing shell and tilting pads are generally made
from steel.
 PRINCIPLE COMPONENTS OF A
CENTRIFUGAL COMPRESSOR
A thrust bearing is also provided on all centrifugal compressors to
take the thrust generated during operation. About 80-90% of the thrust
generated is already balanced across the balancing drum and the
remaining thrust alone is taken on the thrust bearing. It is chosen in
such a manner that it can take 3-5 times of the resultant thrust. A
thrust bearing comprises a cage, backing rings, thrust pads (double
acting type). Thrust pads are provided on both sides of the thrust disk.
These are designated as active and non-active pads.
 PRINCIPLE COMPONENTS OF A
CENTRIFUGAL COMPRESSOR
Fig: Journal bearing- Tilting pad type
 PRINCIPLE COMPONENTS OF A
CENTRIFUGAL COMPRESSOR
Fig: Journal bearing Shells
 PRINCIPLE COMPONENTS OF A
CENTRIFUGAL COMPRESSOR
Shafts and seals :
the shafts ends are to be sealed against leakage's due to many
reasons.the principle ones are,
- To reduce the leakage's substantially
- To avoid pollution
 PRINCIPLE COMPONENTS OF A
CENTRIFUGAL COMPRESSOR
Fig.: Labyrinth seal
 LUBRICATION & SEALING SYSTEM
‡ Oil System
The purpose of the oil system is to furnish clean oil under pressure to
y Lubricate the bearings and the teeth of flexible couplings

y Control circuits of drives and

y Shaft end seals (when oil seals are provided)

Lubricating oil circuits utilize low pressure oil in the range of 1.5 to 5
ata. Turbine control circuits need oil at higher pressure (sometimes
around 60 ata) for actuating the control elements through servomotors.
Seal oil pressures are dictated by the demands of the reference gas
pressure which is close to suction pressure. If it is a common system it
can be furnished by either the vendor of driver or compressor. If the
machine is steam turbine driven, normally the compressor vendor will
furnish the oil system. In this case, the steam turbine vendor has to
indicate his oil requirements along with the supply parameters thereof
to the compressor vendor.
LUBRICATION & SEALING SYSTEM
If the machine is gas turbine driven, the oil system is in the scope of
supply of gas turbine vendor. In order to effect saving on space, the
gas turbine base frame itself serves as the oil reservoir and hence the
oil system comes under the scope of gas turbine vendor.

In this case, the compressor vendor has to indicate his oil

requirements to the gas turbine vendor. Lube-oil systems can be
common for the drive and driven machine or independent.

A typical lube oil system conforming to API-614 is depicted in fig.

LUBRICATION & SEALING SYSTEM
Combined lube and seal oil systems can be considered in normal cases,
since seal oil requirements are smaller when compared to lubrication
and control oil requirements. Seal oil system (fig. Shows typical seal
oil system) can be made independent particularly for high pressure
compressors. The seal oil can be drawn from an independent seal oil
reservoir or by taking a tap-off from the lube oil delivery line and then
boosted further to seal oil pressure and cleaning it further to less than
10 microns particulate content and then fed to seals. An oil cleaning
equipment is also added to the oil system, which can be on-line or
switched on as needed, depending on the needs of the plant. Oil is
cooled before utilization for lubrication and sealing. Control oil is
maintained very clean but is not cooled before use.
LUBRICATION & SEALING SYSTEM
‡ Fig.: lubricating oil system schematic
LUBRICATION & SEALING SYSTEM
‡ Fig.: Seal oil system schematic
LUBRICATION & SEALING SYSTEM
‡ Fig.: Combined lube oil & seal oil system for motor
driven compressor
 LUBRICATION & SEALING SYSTEM
‡ LABYRINTH SEALS:
Labyrinth seals (Fig attached) are used where loss of gas can be
tolerated. The seal is produced from a number of circular strips in
series around the shaft. The strips are replaceable & have a knife edge
and are usually made of aluminium or leaded bronze, so that minimal
damage is done to the shaft in case of rubbing contact. PTFE has also
been used by some manufacturers. The shaft may sometimes be fitted
with a set of labyrinth strips interlocking with those in the housing,
and in some designs the labyrinth may be staggered on different
diameters to increase the length of the leakage path between
successive sets of labyrinths.The leakage past the seal is a function of
the clearance area, pressure differential, distance between the strips,
and thickness of the strips.
 LUBRICATION & SEALING SYSTEM
‡ LABYRINTH SEALS:

The leakage will vary according to density, viscosity, and expansion

characteristics of the gas. A number of seals may be fitted to the same
shaft with venting or buffer gas connections in between the seal
sections. Each stage of a multi-stage centrifugal compressor is usually
sealed from the next by a labyrinth seal. Pressure difference across
this type of seal is small, being the difference between the discharge
pressure of the first impeller and the inlet pressure of the second
impeller.
LUBRICATION & SEALING SYSTEM
LABYRINTH SEALS:
Labyrinths are also fitted around the eye of each impeller to seal
impeller discharge pressure from suction pressure and reduce back
flow to the suction. Labyrinth seals can be employed up to pressures
of 15 kg/cm². Above this pressure the labyrinth length becomes
excessive. The pressure drop across a tooth can be expected to be
about 0.3 kg/cm² with a running clearance of 0.2% of the shaft
diameter. Staggered labyrinths can reduce the total leakage by 30 to
40%.
LUBRICATION & SEALING SYSTEM
OIL RING SEALS:
For higher pressures, above 60 kg/cm²g, or where the gas is toxic and
must be contained, an oil ring seal is used (Figure). The shaft is fitted
with a renewable sleeve which passes through an oil chamber in the
seal housing. The seal chamber is closed at each end by floating rings.
The clearance between the ring and the shaft is kept small, and oil
pressure in the chamber is maintained above the gas pressure in the
compressor by a fixed amount (0.3 to 1.00 kg/cm²). This is usually
achieved by connecting the seal chamber to an overhead tank some
metres above the compressor, and connecting the surface of the oil in
the tank to the gas next to the seal, so that the seal oil pressure is
always higher than the gas pressure by an amount equal to the head of
liquid.
LUBRICATION & SEALING SYSTEM
A pressure regulating valve can be used instead of an overhead tank,
but in this case there is no “run-down” capacity if the seal oil pump
fails. Oil flows through the seal to cool it and is returned to a lower
storage tank for re-use. Oil leakage to the atmospheric side is also
collected for re-use. On the gas side of the seal, a single labyrinth
separates the compressor from a chamber adjacent to the seal. Seal oil
also leaks into the chamber and the oil and gas are taken to a
degassing tank. The tank is heated to separate the gas from the oil.
The gas is vented and the decontaminated oil returned to the tank or
disposed off. With only a small pressure difference across the inner
labyrinth the gas leakage is small.As in the case of the lubricating oil
system, it is convenient to group the components into a unit. If the
same oil is used in the seal as to lubricate the bearings, the two units
may be combined, both supplied from a single tank, pump, cooler, and
filter.If two units are provided, the instruments on the seal oil unit will
be similar to those used in the design of the lubricating oil unit.
LUBRICATION & SEALING SYSTEM
Fig.: Packing and Seals
LUBRICATION & SEALING SYSTEM
Fig.: Packing and Seals
LUBRICATION & SEALING SYSTEM
Fig.: Packing and Seals
LUBRICATION & SEALING SYSTEM
‡ MECHANICAL SEALS
Mechanical seals are suitable for moderate pressure (35 kg/cm²g)
where the leakage rate must be reduced to a minimum. In this case,
the oil which is supplied to cool the seal, circulates outside the faces.
The seal faces have a stationary seat and rotating seat, usually with a
floating carbon ring between the two. A very small quantity of oil
leaks past the seats to lubricate them and prevents leakage of gas past
the seal.This oil mixes with gas leaking from the compressor and can
be filtered from the leakage gas and returned to a low pressure point
in the system. The sour oil and gas leakage is generally of the order
of 10% of the leakage experienced with a liquid ring seal under
similar operating conditions. This small seal oil flow rate results in a
saving in the size of the oil unit. In certain cases (such as pressures
above 200 to 300 kg/cm²) both oil ring and mechanical seals are
required to achieve adequate sealing.
LUBRICATION & SEALING SYSTEM
In order to ensure no leakage of hazardous or toxic process gases to
the atmosphere it is usual to incorporate an overhead seal oil run down
tank. This must be sized to maintain the seal oil supply in the event of
pump failure during the time that the required is dependent on the
time taken for the compressor and any associated pipe work to be
depressurized completely. This can only be determined after
shutdown procedures are agreed and gas volumes and vent sizes are
fixed.
Another variation of the mechanical type seal is the “stand still” seal.
This provides for a spring loaded sealing ring to be held off its seat by
seal oil pressure. When pressure is removed, for instance when the
unit is shutdown, the ring closes onto its seat and the spring pressure
maintains the seal, isolating the inside of the compressor. This may
remove the necessity for an overhead seal oil rundown tank.
LUBRICATION & SEALING SYSTEM
Most suppliers design and manufacture their own shaft seals, but it
has become common practice to sub-contract both the seal oil and
lubricating oil units.
LUBRICATION & SEALING SYSTEM
‡ DRY GAS SEAL
Most compressors of today use oil free seals that have no contact
faces during operation. This makes them almost maintenance free.
The advantages are :
- Low power requirement
- No wear
- No seal oil system required
- No pressure / speed limitations
- No oil to gas pollution
 LUBRICATION & SEALING SYSTEM
‡ Basic sealing elements
Filled PTFE polymer Keyed in Polymer seal
OD polymer no decompression or design for low friction
chemical limit at both low and high
pressure

Controlled
Carbon / TC or Spring to provide Extrusion gap
Sic for optimal controlled sealing
frictional force
performance

Behind face seal

keyed to resist
reverse pressure
at standstill Tungsten Carbide
coating for minimum
friction and wear
LUBRICATION & SEALING SYSTEM
‡ DRY GAS SEAL
Principle of operation : The seal comprises two major sealing parts.
They are the stationary element, which is spring loaded with a carbon
face and a rotating tungsten carbide element. The latter has a number
of spiral grooves of 0.0025 to 0.010 mm thickness.

The principle of operation of the spiral groove seal is the balancing of

aerostatic and aerodynamic forces to provide a stable, minimal
running clearance.
LUBRICATION & SEALING SYSTEM
‡ DRY GAS SEAL
Principle of operation :
During rotation, the spiral grooves play a vital role by generating a
separating force which helps provide the means of achieving an
acceptable gap. The followings represents a spiral grooves.
LUBRICATION & SEALING SYSTEM
‡ DRY GAS SEAL
Grooves : Uni-Direction
LUBRICATION & SEALING SYSTEM
‡ DRY GAS SEAL
Groove : Bi-Direction
LUBRICATION & SEALING SYSTEM
‡ DRY GAS SEAL
Principle of operation :
The rotation of the seat scoops gas into the spiral grooves where it is
induced towards the center until meets the sealing dam.
This effect compresses the gas at the root of the grooves creating a
pressure increase and causing the flexibly mounted face to “lift off”
thus establishing an operating clearance.
Under design conditions the forces acting upon the seal in operation
can be graphically represented by those shown the following figure
producing an operating sealing gap of approximately 0.003mm.
LUBRICATION & SEALING SYSTEM
‡ DRY GAS SEAL
Principle of operation : Forces on the seal during operation
LUBRICATION & SEALING SYSTEM
‡DRY GAS SEAL : Gas Seal Skid and Control Panel

Complex Gas Seal control panel & SEPro system

booster for BP Horn Mountain
 LUBRICATION & SEALING SYSTEM
‡ Dry Gas Seal :Ensure the gas is
EXTERNAL
clean and dry
GAS
For extended reliability clean / dry
FILTER Filtered Process Gas
MODUL seal gas is VERY important
E
PROCESS „ Gas should be filtered to < 3
GAS
FI FI
micron
„ Coalescing filters can be used
to dry the gas
„ Heaters can be used to prevent
condensates
„ Heat tracing should be used to
prevent heat loss

Process Gas
 LUBRICATION & SEALING SYSTEM

EXTERNAL
GAS ‡Dry Gas Seal :
FILTER Filtered Process Gas Clean seal gas
MODULE injection
PROCESS – Normal operation
GAS
FI FI Flow path of seal gas
under normal dynamic
operating conditions

Process Gas
 LUBRICATION & SEALING SYSTEM

EXTERNAL Filtered N2 Secondary Gas N2

GAS SECONDARY
PCV
FILTER Filtered Process Gas FILTER
MODULE MODULE

PROCESS
GAS
PI
‡ Dry Gas Seal :
FI FI FI FI PI Ensure Barrier gas
supply pressure is
Barrier seal independently
pressure controlled
controlled Process + N2 „ Should be
with PCV’s
Gas to Flare controlled to 0.3-
PI PI 0.5 bar not flow
FO FO ‡ Barrier Seal

FI FI leakage
FLARE VENT changes with
time
„ Interlock with
Process Gas N2 to bearing oil
Atmosphere
 COMPRESSOR CONTROLS
Load capacity control:
The compressors normally operates along the characteristic curve
which is drawn for one speed. The compressor will operate at the
point of intersection of the characteristic curve and the system
resistance curve. If the speed is reduced, a new characteristic curve
applies and the machine will again settle at the intersection of the two
curves.
Speed control:
For constant inlet conditions, flow is proportional to speed. Pressure
rise is proportional to the square of the speed and power proportional
to the cube of speed. In this way the compressor can be made to
operate anywhere on the system characteristic curve between the
surge line and the maximum speed curve.
 COMPRESSOR CONTROLS
If a constant speed machine is indicated, the compressor can be
controlled by suction throttling. This has the effect of reducing the
mass flow and the discharge pressure of the gas to allow the machine
to operate along the lower characteristic curve. This method is cheap
to supply and simple to operate automatically and constant pressure
discharge can be monitored. It can however be applied only to
moderate changes in performance.
Variable angle inlet guide vanes impart a degree of pre-rotation to the
gas before it enters the impeller, with the effect of moving surge line
to the left. Guide vanes may be fitted to more than one impeller on
multi-stage machines to prevent impeller surging. This method gives a
more efficient method of control than suction throttling but is more
costly to install.
 COMPRESSOR CONTROLS
Adjustable diffuser vanes which reduce the channel angles and areas
can also give control down to 30% of design flow without surging but
this is expensive to install.
In the case of discharge pressure throttling, there is very little power
saving and the machine will operate along the design curve.
 COMPRESSOR CONTROLS
Fig.: Performance curve of centrifugal compressor
 COMPRESSOR CONTROLS
Fig.: Speed variation curve
 COMPRESSOR CONTROLS
Fig.: Inlet guide vane operation
 COMPRESSOR CONTROLS
Fig.: Suction throttling characteristic curve
 COMPRESSOR CONTROLS
Fig.: Centrifugal and Axial compressor characteristic
curves
COMPRESSOR SURGE CONDITIONS
& ANTI-SURGE CONTROLS
There is a minimum capacity for each compressor, at every speed,
below which operation becomes unstable. This instability is
accompanied by a characteristic noise known as Pumping or Surge.
The primary cause of this behavior lies in the shape of the head-
capacity curve which after reaching the maximum begins to drop
towards the zero capacity point. When the capacity is reduced below
this point, the pressure in the discharge pipe exceeds that produced by
the compressor and the flow tends to reverse momentarily. However,
as soon as the flow is further reduced, the pressure in the discharge
pipe drops and the compressor begins to discharge into the pipe again.
Such pulsations in pressure and capacity are magnified by the
response of the compressible gas in the discharge system.
Compressors should not be operated at volumes below the surge point.
 COMPRESSOR SURGE & ANTI-
SURGE CONTROLS
Following methods are predominantly used as Anti-Surge control. (It
shall be noted that often a combination of more than one of these
methods is used for Anti-surge control)-
„ Speed control
„ Inlet capacity control
„ Recirculation

Speed control: Fig illustrates control of surge through speed control.

Variable speed can be achieved by using variable speed drivers like
gas turbines, variable speed motors etc.
 COMPRESSOR CONTROLS
Fig.: Characteristic curves of a Cent. Comp.
illustrating the effect of speed control
 COMPRESSOR CONTROLS
Fig.: Flow control system with variable speed control
 COMPRESSOR CONTROLS
Fig.: Characteristic curves of a centrifugal compressor
illustrating Inlet guide-vane control
 COMPRESSOR CONTROLS
Inlet capacity control: Inlet guide vanes (IGV) can be adjusted to
reduce the capacity and increase the stable operating range. Although
the primary role of guide vanes is to provide pre-rotation ahead of the
impeller and thus to reduce entrance losses, the same vanes act as a
throttle to reduce the flow rate by reducing the gas density.

Recirculation: Surge is avoided by recycling or Recirculating part of

the gas into the machine through a bypass valve between discharge
and suction lines as indicated in the fig.

By proper use of one or more of these methods of control together

with adequate instrumentation, centrifugal compressors can be
equipped to deliver gas at constant discharge pressure, constant
suction pressure, constant volume flow or constant mass flow.
 COMPRESSOR CONTROLS
Fig.: Re-circulation
 REFERENCE(API STANDARD)
1. API 617 Centrifugal Compressor (7th, Jul. ’02)
2. API 612, Special Purpose Turbines(5th, Apr. '03)
3. API 612, Special Purpose Turbines(5th, Apr. '03)
4. API 614, Lubrication, Shaft-Sealing and Control Oil System(4th,
Apr. '99)
5. API 611, General Purpose Turbine - for lube oil pump
driver(4th, Jun.'97)
6. API 670, Vibration, Axial-Positioning, Bearing Temperature
Monitoring System(4th, Dec.'00)
7. API 671, Special Purpose Couplings(3rd, Oct.'98)
8. API 676, Positive Displacement Pumps-Rotary(2nd, '96)
9. API 941, Steel for hydrogen service
10. ASME PTC 10, Compressor and Exhausters
 REFERENCE(P & ID)
HAND OUT
THE END

Q&A

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