1

Contents

Types of compressor
Compressor Applications
Basics of Centrifugal Compressor
Main Components of a multistage centrifugal Compressor
Performance curves
Surge

Stall
CCC anti surge system

Types of compressors
Compressors

Positive displacement

Reciprocating

Dynamic

Rotary
Centrifugal (Radial Flow)

Mechanical
Piston

Sliding Vane

Mixed Flow

Liquid Piston
Helical Lobe

Axial Flow

Straight Lobe
3

Compressor's Application

Basics of Centrifugal Compressor

Dynamic Compressors which are based on the principle of imparting

velocity to a gas stream and then converting this velocity energy into
pressure energy are termed as Centrifugal Compressors

Centrifugal Compressor Types

(On The Basis of Stages)

Single - Stage Centrifugal Compressor

As name refers, Single Stage Compressor employs only one

impeller to impart energy into the gas.

Multi - Stage Centrifugal Compressor

A multi-stage compressor employs more than one impeller to
impart energy into the gas. The velocity is added to gas by the
impeller of each stage. This velocity is converted into pressure
within the diffuser. Thus, each impeller adds to the total energy
(pressure) of the gas.
6

Centrifugal Compressor Types (On

the Basis of Casing Design)
Vertically split casing

When a compressor is used for moderate to high pressures, to

minimize the chances of leaks, a vertically split casing is used.
The casing is either cylindrical or bell shaped, depending upon the
pressure rating.
Diaphragms halves are placed into split cylinder halves called Barrel.

Horizontally split casing

This design is generally used at low pressure up to 35 bar.

The two halves of the casing are joined at the horizontal
centerline by hydraulically tightened stud bolts and nuts.
Horizontally split casing is preferred as accessibility to compressor
internals' is easier.
7

Main Components of a Multistage

Centrifugal Compressor
Rotor Shaft
Impeller
Thrust Collar
Balancing Drum
Seal
Bearings
Diaphragm
Guide Vanes
Coupling
Instrumentation
8

Compressor Rotor Assembly

Rotor Shaft

The shaft serves as the main element of the rotor, transmitting the
torque from the driver to the impellers. The largest diameter is located
in the middle of the shaft and supports the impellers and spacer
pieces.

Impeller
Impeller adds energy to the inlet gas

Impeller Types
Open Impellers
These are used for large heads and small to large flow in single
stage
compressors only. The flow is least controlled.

Semi-enclosed Impellers
These are used for large flow, usually in single stage compressors,
or as
the first stage in multistage compressors.

Enclosed impellers
Multistage compressors usually have enclosed impellers. The flow
of gas is best controlled in enclosed impellers. To prevent
vibration the impeller is shrunk onto the shaft and prevented from
turning on the shaft by a key and is well balanced.
10

11

12

Compressor Rotor Assembly

Thrust Collar

The thrust collar transmits the rotor thrust to the thrust

bearings and fixes the axial position of the rotor. It is
hydraulically shrink fitted on the rotor shaft.

13

Balance Drum

The centrifugal compressor rotor is subjected to an axial thrust

during operation. The balance drum compensates for the majority of
this thrust.

14

Diaphragms Assembly

Multistage centrifugal compressor contains diaphragms

located between impellers. Adjacent walls of the diaphragm form a
passage called the diffuser that guides gas into the next impeller.

Diaphragms are split horizontally and these halves are machined to

fit into the casing.

Grooves are machined on the faces of these diaphragm halves

for elastomers so as to avoid inter stage leakage.

15

Guide Vanes

The gas that leaves an impeller

passes though the diffuser
passage. In the return passage,
guide vanes guide it into the next
impeller.

The inlet guide vanes can be

adjustable. With adjustable
guide vanes, the angle of gas
flow into the eye of the
impeller can be controlled. In
this way capacity of compressor
can be controlled

16

Inter Stage Seals

shaft passes through the diaphragms. Since diaphragms and rotor

are not attached to each other, the gas can flow from higher- pressure
region to the lower pressure region through the space between
shaft and diaphragms. Seals are used between the shaft and the
diaphragms to prevent leakage. The most common type of seal used for
this purpose is labyrinth seal.

17

Inter Stage Seals

Labyrinth Seal

It is a set of metal rings or teeth that encircle the shaft but do not
touch it. The rings or teeth are made of soft metal, and are sharp so
that in case of accidental contact, less friction is generated and
shaft is prevented from damage.

Labyrinth Working Principle

The spacers between the teeth form labyrinth passage. As the

gas enters the space between teeth, eddies are formed. It slows the
gas velocity and changes direction. The resulting turbulence resists
the flow of gas.

18

Inter Stage Seals

Characteristics
Labyrinth Seal does not prevent all leakage. If the gas velocity is high,
some of the gas does not change direction in the seal but skips
between the teeth and the shaft in straight line. Where gas is flowing
at high velocity interlocking labyrinth seal is used. i.e. Labyrinth Seal
interlocks with shaft teeth. These seals are used in areas where
it is acceptable to allow leakage. Labyrinth seals are therefore
widely used as inter stage seals because the pressure
difference between stages is normally low enough for labyrinth
seal to be effective

19

Shaft End Seals

Shaft End Seals serve the following three purposes:

Increase compressor efficiency
Prevent process gas contamination / escaping
Avoid contact between the process gas and the lube oil

20

Seal components

21

Seal in Tandem Arrangement

Rotating ring

Stationary ring

Stationary ring
Rotating ring

Primary Seal

Secondary Seal

22

Working of DGS
Seal gas supply

Primary vent

Buffer gas supply

Secondary vent

Compressor shaft
Primary seal

Secondary seal

23

Compressor Bearings
Centrifugal Compressors are equipped with journal and thrust
bearings.

Journal Bearing
The

Rotor is supported at each end by Journal Bearings. Journal Bearings are

hydrodynamic bearings with tilting pads. Each pad develops an oil pressure wedge
that support the weight of the rotor.
A tilting pad is a steel block with a pivot button on its back that allow the pad to tilt
within the bearing seat. The bearing pad's surface is coated with a thin layer of white
babbit metal (alloy of Lead & Tin).
Recently

bearing manufacturers have developed a new design of bearing pad.

This new bearing pad has flexure pivot tilt instead of rocking pivot tilt. The one-piece
construction of this particular tilt pad bearing eliminates the multi-piece construction
and thus reduces the manufacturing tolerances.
A thermocouple also embedded into the selected pad to measure the
bearing's pad metal temperature.
Journal Bearings are also available in sleeve type construction
24

25

Compressor Bearings
Thrust Bearing

One of the most critical components of a centrifugal compressor is

the thrust bearing. Axial thrust is generated in a centrifugal
compressor by the pressure rise through the impellers. Major
portion of the axial thrust is countered by either a
balancing drum or by placing impellers in a back-to-back
arrangement. In either case, the small residual load is carried by the
thrust bearing. Thrust bearing must also be designed to
withstand the thrust reversals that may occur during normal
operating conditions

26

27

28

Couplings

Couplings are the connecting elements between the compressor and its
prime mover or between compressor's different stages. Construction

a particular flexible Shim Pack Coupling, there are two hubs, one installed
to each shaft end, a spacer and the flexible elements located
between the spacer and hubs. Previously 'Keyed Hubs' were designed but
now hubs are mostly hydraulically shrink fitted on the tapered shaft end.

Coupling Functions

Transmission of mechanical power from one shaft to the other.

To compensate all types of misalignment without inducing
abnormal stresses and load on connected equipment and without
significant loss of power.
To compensate the axial movement of the coupled shafts,
preventing either shaft from exerting excessive thrust on the other.
29

30

31

32

33

34

35

Stability Range and Pressure Raise to Surge

Stability Range
The Volume flow inlet variation that occurs
between the operating point and surge limit line
at constant speed
Pressure Raise to Surge
The variation of discharge pressure between
the operating point and the surge limit line at
constant speed
36

What is Compressor Surge?

Compressor surge is an unstable flow pattern in a compressor
where the total flow across the airfoil alternately stops, flows
backwards, and then flows forward.

The surge flow has been defined by some as the flow at which the
head flow curve is perfectly flat and below which the head actually
decrease.

37

Head required
Head

required
is the energy in foot
pounds required to
compress and deliver
one pound of given
fluid from one
energy level to another

p2

P1

E1

E2

Energy= FT- lbs (head Required)

38

Fluid Head
liquid

Gas

head=2.311xdiff P
Specific
gravity

Water

Head =

1545
M.W.

(T1)

K
K-1

(Z)

P2 K- 1
K
P1

-1

Diff P = 100 psi

Head = 231ft

Nitrogen = 100 ps
Head = 86,359 ft.
P1 = 14.7 psia T1 = 100F

p1 = 14.7 PSIA
T1 = 100F

231Ft

114.7
psi

pump

86,359Ft
114.7
psia

Compressor

39

.Head (energy) Required is Determined by:

System resistance (P2/P1)
Gas composition (Mw, Z,K)
Inlet temperature (T1)

Head Required increase if:

.(P2/P1) increases
. MW Decreases
. T1 Increase

Head Required Decrease if:

.(P2/P1Decreases
. MW Increases
. T1 Decrease

40

The diffrent types of Gas head

Vapour can be ideally compressed by any one of the
Following thermodynamic paths:
> Isothermal - isothermal compression occurs when the temperature
is kept constant during the compression process
I- e
P1V1= P2V2 = T constant
This requirees the removal of all heat of compression procees
Which is not practical

> Isentropic ( adiabatic) -

Adiabetic compression is when there is

no heat added or removed during compression process
K
k
i-e
P1V1 = P2V2
This is also practically not possible as there is always heat lost or
removed from system.

> Polytropic - Temp. not constant and heat lost.

n
n
i-e

P1 V1 = P2 V2
41

Pressure and Flow Variations During

Surging

42

43

Stall
This usually happens in a low flow stage as it approaches the
surge.
Stall is caused by the destabilization of the impeller or diffuser flow
or by unsteady interaction between the impeller and diffuser

44

CCC- SURGE
CONTROL SYSTEM

.000

DEV
9.3

ALT

OUT

Status
AUX

RUN
Antisurge Controller

Auto

AUT
MANO

Manual
RT
SO
Limit
Tracking

Tranfail
Fallback
ComErr

RESET
SAFETY
ON
DISPLAY
SURGE
COUNT

DISPLAY
LIMIT

MENU

SCROLL

Fault
Compressor Controls
Corporation

46

Auto
The green Auto LED lights to indicate automatic operation.

When operating automatically in its RUN state, the

Controller varies the valve position to satisfy the Surge
protection.

47

Manual
The yellow Manual LED lights to indicate Manual operation.
It flashes when operation is on manual and/or
Manual override is enabled

48

Manual
Override
Manual
Override (MOR)

To prevent surge, when controller is on

manual, it will revert to automatic if operating
point moves to the left of RT line.

However this behavior can be overrided by

enabling MOR. As a result Controller will
remain in manual state until operator will not
shift it to Auto mode.
49

CAUTION
Do not Permanently enable Manual Override
parameter as it disables all surge protection
while in manual.

50

RT

If the controller is on Manual, RT LED will be lit, when the

Margin of safety is below the threshold of Recycle Trip and
Will stay on until the Recycle trip response decays to zero.

51

SO

If the red SO LED is lit, the Safety On response is

detected One or more surges and increase the surge
control margin To prevent additional surging.

52

Limit
The yellow Limit LED is lit when either the discharge
pressure is above its threshold or suction pressure is
Below its limit.

This will increase the recycle rate above the level needed for
Surge protection.
The DISPLAY LIMIT key can be used to display the value
and set point of each limiting variable.

53

Tracking
When redundant controllers have installed, the green
TRACKING LED of active controller will be off and that
of tracking controller will be lit

54

Tranfail

The red TranFail LED is lit when any analog input signal
is beyond its transmitter testing range.

55

Fallback

The yellow Fallback LED is lit when one of the controllers

fall back strategies is being used b/c a required analog or
serial input has failed.

56

ComErr

The red CommErr LED is lit when the controller fails to

Detect an expected transmission on its port serial commUnication network.

57

Fault
The red Fault LED is lit when an internal fault has been
detected.
The controller out put signal is totally unpredictable when
FAULT LED ios lit.
Process disruption or damage can occur.

58

Raise Key
The RAISE key increases the actuator control signal if the
Controller is on manual.
Momentarily pressing the Raise key increases the signal
By 0.1%, while holding it down increases the output steadily
In larger increments.
It takes about 20 sec to change control signal by a full 100%

59

Lower Key
The LOWER key increases the actuator control signal if
the
Controller is on manual.
Momentarily pressing the Lower key decreasesthe signal
By 0.1%, while holding it down decreases the output steadily
In larger increments.
It takes about 20 sec to change control signal by a full 100%

60

AUTO / MANUAL KEY

The Auto/ Manual key toggles the controller between automatic

And Manual operation

61

RESET SAFETY ON
Each time a surge is detected, the controller increases the
surge marginby adding Safety On incremental Bias. Pressing
Reset Safety On key resets it to zero and restores the
Original Safety on Margin.

WARNING

To avoid repeated surging, Do not press Reset Safety On

While SO LED is lit unless cause of surging have been identifie
And corrected.
62

DISPLAY SURGE COUNT

Each time a surge is detected, the controller increases the
surge marginby adding Safety On incremental Bias.Pressing
Surge Count key displays the surge count in ALT read out.

63

DISPLAY LIMIT
If the DISPLAY LIMIT key is held down, the DEV and ALT
Read outs will display the value and set point for one of the
Limiting variables, while AUX read out displays Discharge
Or Suction to indicate which of those pressure is being
displayed.
Pressing this key does not affect the operation of control
algorithm

64

MENU / SCROLL
The MENU and SCROLL keys select the information
displayed by AUX read out. Pressing Menu advances that
Display thru the available menus, while pressing scroll
advances it to the next item in the currently selected Menu.

65

Deviation--- DEV
Each Three-digit Deviation readout displays the deviation of
Operating point from the Surge control line.

DEV : + ve : Acceptable Margin of Safety

DEV : 0

: Operation on SCL

DEV : - VE : Unsafe operation

66

ALT
The 3- character Alternate read out is normally Blank.
However it displays number of surges the Safety On
algorithm has detected whenever Display Surge Count
Key is held down.
This read out can also display the numerator of application
Function.

67

OUT
The 3- digit Output read out normally displays the actuator
control signal which shows both the actual output signal and
control valve position.

68

STATUS
Status RUN :Antisurge valve is being modulated to protect
running compressor from surging.

Status

Stop : Normal shutdown has ramped the antisur

valve open.

69

Antisurge Control
SO line
1

SL line
RT line
SC line

Tight shut off

line
70
0

SURGE CONTROL LINE

1

The surge control line defines the desired

min. distance between operating point and
surge limit line. SCL is always to the right of
SLL.

The antisurge response increases the recycle

rate when operating point is to the left of this
line (DEV<0) and reduces when on the right
side (DEV > 0).
71

RECYCLE TRIP LINE

It defines an operating limit beyond which the

Recycle trip response will ratchet the control
valve open.

As with control lines , distance is positive

when compressor is operating to the right of
RTL.

72

SURGE LIMIT LINE

Surge limit line is the locus of points for which

proximity to surge equals to one.

73

SAFETY ON LINE

SOL defines an operating limit beyond which

the compressor is assumed to be surging.

The Safety On response moves the surge

control line to the right if operating point
crosses the SOL.

74

TIGHT SHUT OFF LINE

Tight shut off response fully closes the

recycle valve, when operating point is to the
right of this line.

75