CENTRIFUGAL

COMPRESSORS
Fabrizio Tani
October 23rd 2001

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WHAT IS A COMPRESSOR?
PRESSURE RATIO
GAS
Suction Pressure = Ps
Suction Temperature = Ts
Suction Velocity = Us

GAS

COMPRESSOR

Discharge Pressure = Pd
Discharge Temperature = Td
Discharge Velocity = Ud

Compressor = Black Box to increase Gas Pressure

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EFFICIENCY

Ratio advantages / price

OR

Ratio cost in perfect world / cost in real world

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ADIABATIC PROCESS:
No exchange heat with external environment
First law of thermodynamics

Q W H

Q HeatInput
W WorkInput
H Enthalpy

Adiabatic Process :

W H

Q0

H f P, T

Absorbed Power (P) = Specific Work (W) x Gas Flow (G)

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ISENTROPIC PROCESS
A further hypothesis:
NO LOSSES
The isentropic process associated to the real adiabatic process has:

same suction conditions Ps,Ts

same discharge pressure Pd
lower discharge temperature Tis

Isentropic Process = All Energy to Compress Gas

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ISENTROPIC EFFICIENCY
Specific Work:

W vdp
The ratio of isentropic work to the total adsorbed energy

is

Wis

The ratio between what we would pay to obtain a

needed result in a perfect world and what we pay to
obtain the same result in the real world
Isentropic efficiency is a function of pressure ratio
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TOTAL ADSORBED ENERGY

minus

LOSSES

ISENTROPIC WORK

Losses always associated to the real process

No analytical way to describe the real process point by point

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Solution to control the process

isoentrope from suction conditions to

the final discharge pressure
WORK INPUT ONLY

isobar at constant discharge pressure

to achieve the discharge temperature
HEAT INPUT ONLY

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For each step the isentropic work

dwis vdp
We define the equation:

vdp
e
dH

e is the constant for which the path passes

through suction and discharge conditions and
the isentropic efficiency of each step

The equation define the theoretical process called

POLYTROPE
POLYTROPIC WORK:
The sum of all the isentropic works step by step

Wp
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vdp

pol.

POLYTROPIC EFFICIENCY
The ratio of polytropic work to the
total adsorbed energy

Wp

The ratio between the advantage we

can obtain with the use of a certain
tool and the price we have to pay
For a perfect gas

n K 1

n 1 K

Polytropic efficiency is not pressure ratio dependant

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DIFFERENT POINTS OF VIEW

CUSTOMER NEEDS

A way to compare compressor of different

manufacturers for the same service
A method to check the performance of the
machine at site

Verify the performance

MANUFACTURER NEEDS

Define a relationship between the

performance and the geometry

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Achieve the performance

A WORKING IMPELLER

Normally the tangential component of C1 is negligible

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The radial component of gas

velocity is associated to the flow
Multiply the inlet radial
velocity by the area at inlet to
obtain the volume flow at
impeller suction
The tangential component of gas
velocity is associated to the work
made on the fluid

Euler equation
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EULER EQUATION
The energy exchanged, per unit of weight of fluid, between
impeller outlet and inlet by its angular speed

W u 2 C 2u u1C1u
In the hypothesis that C1u is negligible

W u 2 C 2u
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EULER EQUATION

W u 2 C 2u

Based on mechanical principles

FIRST LAW EQUATION

Based on thermal quantities

W is the same!
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W H

DIMENSIONAL ANALYSIS
To predict performance we need non dimensional coefficients
representing a physical phenomenon that are:

independent of the actual size of the machine

independent of the actual impellers speed
independent of gas characteristics

The non dimensional coefficients are:

Inlet Flow Coefficient

Outlet Flow Coefficient
Peripheral Mach Number
Reynolds Number
Head Coefficient

Results of experimental works carried out on models of the real stages

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INLET FLOW COEFFICIENT

The ratio between the radial component of the gas
velocity at inlet and impeller speed in the same
point
C1r
1 identifies gas
1
u1
angles at inlet

OUTLET FLOW COEFFICIENT

The ratio between the radial component of the gas
velocity at outlet and impeller peripheral speed
C2 r
2
u2
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vo
A different form 2 1 const
vi

PERIPHERAL MACH NUMBER

The ratio of impeller peripheral speed to the
velocity of sound at impeller inlet:
u2
Mu
ain
A measure of gas compressibility

REYNOLDS NUMBER
ub
Re

u
b

gas suction density

impeller peripheral speed
impeller exit width
dynamic viscosity

It can be read as ratio of inertia forces to viscous surface forces

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HEAD COEFFICIENT
The ratio between the tangential component of the
gas velocity at outlet and impeller peripheral speed

C2 u

u2

Euler equation

W u 2 C 2u

W u 22
A measure of the impeller capacity to
energise the gas
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NON DIMENSIONAL
PERFORMANCE CURVES
f 1
p g 1
p h 1
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Summary:
Input data:
Suction Pressure
Suction Temperature
Gas Composition
Discharge Pressure
Status Equation (BWRS: Benedict Webb Rubin Starling)

Experimental data:
Flow Coefficient
Head Coefficient

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Discharge Pressure
Absorbed Power
Efficiency

Main Design Criteria of

Compressor
- Efficiency:
84 - 87 % for compression ratio up to 2
more than 75 % for compression ratio above 2
- Operating range: from 70 to 140 % of the design point

Design Point

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Manufacturing Complete Range of Centrifugal Compressors

A comprehensive production for On-Shore and Off-Shore Services since 1960
from the High Volumes - Low Pressure Applications
to the Low Volumes - High Pressure Applications

NATURAL GAS
Oil Production
Gas Production
Gas Lift
Pipeline
Gas Re-injection
Gas Storage

PETROCHEMICALS

REFINERY

Syngas & Fertilizers:

CO2 compressor for UREA Plants
Ammonia Synthesis
Methanol Synthesis

Fluid catalytic cracking

Reforming
Hydrocracking

Over
Over 3500
3500 Units
Units Sold
Sold
World
World Leader
Leader in
in Gas
Gas Compression
Compression
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LNG

Liquefied Natural Gas

Low Pressures - High Volumes

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Low Pressures - High Volumes

MCL - 2MCL - 3MCL - DMCL Compressors
High Volume Flows [up to 200,000 m3/h for MCL - 300,000 m3/h for DMCL]
Low Discharge Pressures [up to 40 bar]
Casings either cast or fabricated
Cast Iron Diaphragms
Radial and Thrust Bearings Tilting Pad type
Shaft End Seals both Oil film type or dry gas seal type

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Casings and Diaphragms for High Pressure Compressors

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High/Very High pressures - Low Volumes

BCL (/N-/A-/B-/C-/D) - 2BCL (/N-/A-/B-/C-/D) - 3BCL

Compressors for casing rating ranging up to 15000 Psi (API)

Medium to Low Volume Flows [ranging from 80,000 m 3/h down to 300 m 3/h]
Medium to Very High Discharge Pressures [experienced up to 700 bar]
Forged Steel Casings
Forged Steel Inner Casing
Cast Iron Diaphragms (forged steel for high differential Pressures)
Radial and Thrust Bearings Tilting Pad type
Shaft End Seals both Oil film type or dry gas seal type

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Gas Pipeline Compressor - PCL

Beam Type

Late ral Flanges

On e to Thr ee Impel lers
High Pressure Ratio
A xial Thrust Bala nce
Sizes 300 to 1 000
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Overhung Type

Axial Inlet
Sin gle Impeller
High Volumes, Low Pressure Ra tio
Hyd rostatic Lift
Size 800 to 1 000

Barrel Casing With Cartridge Concept Internals

for Easy Maintenance

3D Impeller Technology
Machined by 5-Axis Milling Machines
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Gas Pipeline Compressor

- PCL
Vertically Split Pipeline Compressors

Medium to High Volume Flows [ranging from 80,000 m3/h down to 3000 m3/h]
Low to Medium Discharge Pressures [experienced up to 110 bar]
Low Compressor Ratio [experienced up to 2]
High Polytropic Efficiency [experienced up to 0.86 with vaned Diffusor]
Axial Gas Inlet Arragement or Traditional Side Inlet Flange Configuration
Forged Steel Casings and inner casing
Radial and Thrust Bearings Tilting Pad type (option for magnetic bearings)
Shaft End Seals with Tandem Dry Gas Seals
Standardized casings for one to three impellers and direct coupling to NP Gas Turbines

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Compressor Selection
The compressor is normally driven by Gas Turbine or Electric Motor
Compression selection steps:
Estimated absorbed power with dedicated software
Selection of the suitable GT model
Rotating speed becomes an input, related to the selected GT
Final selection of compressor by specific software
Compressor Configurators are the E-tools to perform a selection
via INTERNET
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STAGES STANDARDIZATION
Predesigned and tested stages are used to meet
the requested performance and to avoid rotating
stall on statoric and rotating components

Standardization Ensures Reliability of Predicted Performances

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Shaft end sealing

TANDEM SEALS

EXPERIENCED UP TO 210 BAR STATIC

TRIPLE SEALS

EXPERIENCED UP TO 290 BAR DYNAMIC AND 310 BAR STATIC

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Shaft end sealing

Nuovo Pignone
LARGE EXPERIENCE ON DRY GAS SEALS
Over 200 Compressors with Dry Gas Seals
Sealing pressures at Settling Out conditions up to 4200 PSIA
Dry Gas Seals size up to 250MM

Dry Gas Sealing system for 2BCL306C

Statoil Veslefrikk Compressor
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HONEYCOMB labyrinths
on balancing drums and impellers
to increase rotor system damping capabilities
for High Pressure Applications.

Honeycomb for Improved Rotor Stability

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Propane Compressor installed at Bintulu Plant

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