Centrifugal

Compressors

By
P.R.Bhatt
 INTRODUCTION

• Compressors used to increase the

pressure of a gas.
• Gases being compressible,
compression causes volume reduction
there by increase in pressure &
temperature. Temperature needs to be
controlled.
 CLASSIFICATION

COMPRESSORS

POSITIVE DYNAMIC
DISPLACEMENT

RECIPROCATING ROTARY TYPE CENTRIFUGAL AXIAL

SCREW LIQUID LOBE SLIDE

RING VANE
 Types of Compressors

• Positive Displacement (PD) : Operate by trapping

a specific volume of gas and forcing it into a
smaller volume
– 2 Basic Designs for PD Compressors
• Rotary
• Reciprocating
• Centrifugal : Operate by accelerating the gas and
converting the energy to pressure
– 2 Basic Designs for Centrifugal Compressors
• Centrifugal
• Axial
 Positive Displacement
Compressors: Rotary Design
• Rotary compressors compress gases with
lobes, screws, and vanes into smaller
volumes by rotating motion.
• 4 Primary Types of Rotary Compressors:
– Rotary Screw
– Sliding Vane
– Lobe
– Liquid Ring
Rotary Screw Compressor
WORKING PRINCIPLE

Gas Compression
Sliding Vane Type Compressor

• Uses a slightly off-center rotor with sliding vanes

to compress gas.
• Inlet gas flows into the vanes when they are fully
extended and form the largest pocket. As the
vanes turn toward the discharge port, the gases are
compressed.
• As the volume decreases, the pressure increases
until maximum compression is achieved. Then the
gas is discharged out the compressor.
Sliding Vane Type Compressor
 Lobe Type Compressor

Designed to have constant

volume discharge pressures and
constant speed drivers.
Lobe Type Compressors can be
used as compressors or vacuum
pumps.
Lobe Type Compressor CS
 Liquid Ring Compressor
• Used to compress hazardous and toxic gases as well
as hot gases.
• As the rotor turns, the fluid is centrifugally forced to
the outer wall of the elliptical casing. An air pocket
is formed in the center of the casing.
• As the liquid ring compressor rotates, a small % of
the liquid escapes out the discharge port. Make up
water or seal liquid is added to the compressor
during operation. The liquid helps cool the
compressed gases.
Liquid Ring Compressor
 Reciprocating Compressors

• Most common type of compressors.Work by trapping and

compressing specific volumes of gas between a piston and a
cylinder wall.
• The back and forth motion incorporated by a reciprocating
compressor pulls gas in on the suction (or intake) stroke and
discharges it on the other.
• Spring-loaded suction and discharge valves open/close
automatically as the piston moves up and down in the
cylinder chamber.
C. S. VIEW OF RECI
COMPRESSOR
 Axial Compressor

• Gas flow is moves along the shaft (axially).

• Rotating blades attached to a shaft push gases
over stationary blades called stators.
• Multi-Stage axial compressors can generate very
high flow rates.
• Axial compressors are usually limited to 16 stages
(due to temperature/material limitations)
Axial Compressor CS
Axial Compressor
 Centrifugal Compressors

• Centrifugal compressors accelerates the

velocity of the gases (increases kinetic
energy) which is then converted into
pressure as the gas flow leaves the volute
and enters the discharge pipe.
• Deliver much higher flow rates than
positive displacement compressors.
 Types Of Centrifugal Compressors

• 2 Types of Centrifugal Compressors

– Single- Stage : Compress the gas once.
• Use for high gas flow rates, low discharge
pressures
– Multi- Stage : Take the discharge of one
stage and pass it to the suction of another
stage.
• Use for high gas flow rates, high discharge
pressures
Single Stage CF Compressor
Multi Stage CF Compressor
 SELECTION
105

104

Centrifugal
103 Reciprocating
gh

g
j22
10
10

Axial
10

Screw
10 102 103 104 105 106
dfg
CAPACITY cfm
PERFORMANCE CURVES

Centrifugal

Axial
Positive
Displacement
 Vtip
Producing Head

Vhub
Gas Compression
Conversion: Velocity to Pressure

Pressure

Velocity

Impeller Diffuser Impeller Diffuser

Stage
CONSTRUCTIONAL FEATURES

• Casing
• Impellers
• Bearings – Radial/Thrust
• Balancing Drum
• Inter stage Labyrinth
• Seals
• Coupling
• Capacity Control
 CASING
• Horizontal Split
These casings are used for low & medium
working pressure (@30 bar).Two half casings
are joined along the horizontal center line & all
connections,nozzles,oil piping usually at bottom
casing.
• Vertical Split (Barrel Type)
These casings are used for high working
pressure (@700 bar) and for certain gases
vertical split casing is preferred choice
(i.e.Ammonia,H2S,etc).
 Horizontal Split

• Horizontal
Split:By
removing upper
half of
casing,all
components are
accessible.
Horizontal Split-GCA1
Horizontal Split-GCKR-K45LP
 Vertical Split (Barrel Type)

• Vertical Split
(Barrel
Type):By
removing inner
barrel in axial
direction,all
components are
accessible.
CENTRIFUGAL COMPRESSOR
ROTOR ASSEMBLY
 Impellers

Increases Velocity Of Gas By Centrifugal Action.

Increased Gas Velocity Finally Converted In To
Pressure at Diffuser Outlet.Depending upon the
flow requirement 2D or 3D type impeller selected.
• Cast impellers:Made by metal casting
• Welded Impellers:Made by Welding/ Brazing
• Three Dimensional impellers: Made by Milling
Operation
Impeller
 Impeller
Cover
I-Seal

Hub

Blade

Blade Height
Centrifugal compression
Multi-Stage Compressor
Multistage Centrifugal-YORK
 Diaphragms

• Diaphragms are used to create stationary

gas flow path and consists of suction
vane,diffuser and return gas path.
• The intermediate diffuser of diaphragm
converts velocity of gas to pressure,then the
return channel conveys gas to suction eye of
next impeller.
Diaphragms
Diaphragms
Side Loads
 Bearings
• A device that supports, guides, and reduces
the friction of motion between fixed and
moving machine parts.
• Three major types:
• Rolling-element bearings.
• Sleeve bearings.
• Hydrodynamic/Journal/Tilt Pads Bearings.
 Rolling-element bearings

• Rolling element, or “anti-friction” bearings, make use of

spherical or cylindrical rolling elements captured between
inner and outer rings.
• The rolling elements support the load, and transmit rotation
by rolling, rather than sliding.
 Rolling-element bearings

Ball bearings can operate at higher speeds (but with less load),
Roller bearings operate at lower speeds but with heavier loads.
Difference is due to point contact versus line contact.
Sleeve bearings
• Ball bearing-Point
contact.
• Roller bearing-Line
contact.
• Sleeve bearing-No
contact due to oil
film between
bearing & shaft.
Fluid Film Bearing
 Journal Bearings
The general principle is that a shaft rotates inside a
bearing bore slightly larger than the shaft diameter, and a
lubricant is supplied to the annular gap.
The portion of the shaft within the bearing is called the
journal.
Fluid Film “Sleeve” Bearing
 Journal Bearings
The function of the journal bearings is to support
the rotor radially/centrally in the outer casing.
At rest, there is metal-to-metal contact between the
journal and the bearing, along the line of contact.
Once rotation begins, a lubricant film develops
between the journal and the bearing.
As the speed increases, a wedge of lubricant forms,
supporting the shaft away from the bearing, and
preventing wear/contact.
Tilt Pad type Journal Bearing
RADIAL BEARINGS
 Tilt Pad type Journal Bearing

• To increase rotor
stability.
• Better dampening
effect.
• Better oil flow path.
• Self aligning.
Journal Bearing
Journal & Thrust Bearings-GEOG
 Thrust Bearings

Function of the Thrust bearing

is:

1.To keep the rotor in exact center

position in the casing to avoid metal
to metal contact axially.
2.To absorb residual axial thrust on
the rotor.
THRUST BEARINGS
THRUST BEARINGS
PROXIMITY PROBE ARRANGEMENT FOR
VIBRATIONS MEASUREMENTS
Bearing Temperature RTD
 Balancing Drum

• To Balance Axial Thrust Of Rotor by

labyrinth seal at Discharge end.
Axial Thrust Balancing
Thrust Load
Thrust Load
 Inter-stage Labyrinth

• To Prevent Inter
stage Gas
Passing/Leakage.
Inter stage Labyrinth Seal
Arrangement of Labyrinth Seals
Arrangement of Labyrinth Seals
 Seals
• Mainly Four Types of Seals:
• Labyrinth Seal:Low pressure,for non flammable gas
(Air,N2,CO2).
• Oil Film Seal:Gas must not leak to atmosphere,for
all Gas,seal oil supplied at slightly higher pr than
process gas.
• ISO Carbon/Contact Seal:Gas must not allow to
leak,high reliable seal,for all Gas,low to high
pressure.
• Dry Gas Seal:For Clean Gas Only.This type of seal
can controls leakage to atmosphere.
Labyrinth Seals
Labyrinth Seals
Oil Film Seal
Buffer Gas Oil Film Seal
Oil Flow to seal
Contact Seal
Contact Seal
Oil flow to contact seal
DRY GAS SEAL
Dry Gas Seal View
Gas Seal Operating Principal
Rotating Seat
Double Tandem Dry Gas Seal
 Coupling

• Followings are widely used Compressor

couplings:
• Gear Type Coupling:Lubrication
required.More radial misalignment.
• Disc Type Coupling: Offset will be
absorbed by the deformation of Disc.
• Diaphragm Type coupling:Offset will be
absorbed by the deformation of Diaphragm.
Gear Type Coupling
Gear Type Coupling GCA1
Disc Type Coupling
Diaphragm Type coupling
 Compressor Curve

100% Load Design

Surge Line Condition

Design Head @ 100%

HEAD

FLOW (P.R.V) Design Flow @ 100%

 Capacity Control
How can we control the capacity of the
compressor?
1.Pre-Rotation Vanes - Better Turndown
Inlet Volume Flow Control
2.Rotor Speed - Better Energy
Driver Speed Control
3.Pneumatic Control-Bypass System
Discharge Flow Control
Pre-Rotation Vanes (PRV)
 PRV Control

Stonewall

Closed Vane Surge

Head System Line

Open Vane Surge

Flow
 PRV Control

Stonewall

Better Turndown
Head System Line

Flow
 Speed Control

110%

Better Power
100%
Head 90%

Flow
 Efficiency Comparison

Speed Control

Eff.
PRV Control

Flow
Pneumatic Bypass Control
Bypass Valve

Suction Pressure

Control

Driver

Control

PRV ~ f(P or T) Air Supply

 Causes of Surge

• Anything that affects the compressor Head

or Mass flow.
• High discharge pressure
• Low suction pressure
• High suction temperature
• Bypass valve not working
• Low suction liquid level/flow
Surge Line
 Anti Surge Control

100% Load Design

Surge Line Condition

Design Head @ 100%

.
HEAD
. Minimum PRV Operating
Line

FLOW (P.R.V) Design Flow @ 100%

L O System
 Lubricant Purposes
• Prevent metal-to-metal contact
• Remove or help dissipate heat
• Protect metal surfaces from corrosion
• Minimize Friction/wear
• Protect parts from contamination
 MONITORING

MACHINE TRAIN DIAGRAM - VIBRATION MONITORIN

FFT VIBRATION SPECTRUM
Cracked Gas Compressor Train
THANK YOU