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Table of Contents
1.CENTRIFUGAL COMPRESSOR..................................................................................................................................2
1.1.TYPES OF CENTRIFUGAL COMPRESSOR...................................................................................................................................2
1.2.CONSTRUCTION OF CENTRIFUGAL COMPRESSOR......................................................................................................................3
1.3.IMPELLER AND NOZZLE ARRANGEMENTS OF MULTISTAGE CENTRIFUGAL COMPRESSOR.................................................................10
2.AXIAL COMPRESSOR.................................................................................................................................................14
2.1.INTRODUCTION................................................................................................................................................................14
2.2.CONSTRUCTION OF AXIAL COMPRESSOR.............................................................................................................................14
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CONSTRUCTION OF CENTRIFUGAL AND AXIAL COMPRESSOR
1. Centrifugal Compressor
1.1. Types of centrifugal compressor
In general the centrifugal compressors are divided in three different types
1.1.1. Horizontally split:
Horizontally-split casings consisting of half casings joined along the horizontal
center-line are employed for low pressure rating. The suction and delivery
nozzles as well as any side stream nozzles, lube oil pipes and all other
compressor-plant connections are located in the lower casing. With this
arrangement all that is necessary to raise the upper casing and gain access to all
internal components, such as the rotor, diaphragms and labyrinth seals is to
remove the cover bolts along the horizontal center-line.
Advantages:
• Typically less expensive to manufacture
• Easier to inspect / maintain in plant and refinery location
• Better for multiple body train.
• Minimum special tooling required.
• Low heaviest part for maintenance.
Disadvantages:
• Larger sealing surfaces.
• Low pressure ratings.
• Removal of overhead piping for up nozzle configuration.
1.1.2. Vertically split casing (Barrel):
Vertically-split casings are formed by a cylinder closed by two end covers: hence
the denotation ‘‘barrel,’’ used to refer to compressors with these casings. These
machines, which are generally multistage, are used for high pressure services
The barrel compressor has a horizontally split inner casing containing the rotor.
This inner casing is inserted into the barrel and closed by an end wall. Inside the
casing, the rotor and diaphragms are essentially the same as those for
compressors with horizontally-split casings. These compressor can withstand
higher pressure than a horizontally split compressor casing. The circular cover
can be made gas tight easier than the flat flange of the horizontally split
compressor. These compressors are used for low molecular gas application and
high pressure requirements.
Advantages:
• Reduced potential for gas leakage.
• Higher pressure rating.
• Can remove rotor and internal components without affecting external
piping.
• Removable inner bundle allows easy disassembly / transportation.
Disadvantages:
• Typically more expensive to manufacture.
• More difficult to maintain if in the middle of a multiple body train.
• Special tooling required for inner bundle removal.
• High “Heaviest part for maintenance”.
1.1.3. Pipeline or booster:
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These have bell-shaped casings with a single vertical end cover. They are
generally used for natural gas transportation to take care of the frictional loss in
the pipes. They normally have side suction and delivery nozzles positioned
opposite each other to facilitate installation on gas pipelines. These are typically
used in the gas transportation lines.
1.2. Construction of centrifugal compressor
Refer Figure 1, showing the major components / internals of a typical barrel type
centrifugal compressor.
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1.2.1. Casing:
Depending on the compressor family the casings can be Horizontal split or
vertical split. Figure 2 shows a typical cross section of a centrifugal compressor.
Outer casing contains a stator part, called a diaphragm bundle (B) and rotor
formed by a shaft (C), one or more impellers (D), a balance drum (E), and thrust
collar (F). The rotor is driven by means of a hub (G) and is held in position axially
by a thrust bearing (I), while rotating on journal bearings (H). The rotor is fitted
with interstage labyrinth seals (L) and, suitable end seals (M). Gas is drawn into
the compressor through a suction nozzle and enters an annular chamber (inlet
volute), flowing from it towards the center from all directions in a uniform radial
pattern. The gas flows into the suction diaphragm and is then picked up by the
first impeller.
Suction diaphragm
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1.2.2. Diaphragm:
A diaphragm consists of a stationary element which forms half of the diffuser wall
of the former stage, part of the return bend, the return channel, and half of the
diffuser wall of the later stage. Due to the pressure rise generated, the diaphragm
is a structural as well as an aerodynamic device. For the last stage or for a
single-stage compressor, the flow leaving the diffuser enters the discharge
volute.
Suction (inlet), intermediate and discharge diaphragms create the gas flow path
within the stationary components. The suction diaphragm conveys the gas into
the eye of the first impeller and can be fitted with adjustable guide vanes to
optimize the inlet flow angle. Intermediate diaphragms perform the dual function
of forming the diffuser passage (where gas velocity is transformed into pressure)
and the return passage to channel gas to the eye of the next impeller. The
discharge diaphragm forms the diffuser for the last impeller as well as the
discharge volute. The diaphragms are usually horizontally-split.
Easily removable labyrinth seals are installed on the diaphragms at impeller
shrouds, to prevent return flow from discharge to suction and on the shaft
sleeves to eliminate interstage leakage.
Interstage labyrinth seal:
Due to the pressure rise across successive compression stages, seals are
required at the impeller eye and rotor shaft to prevent gas backflow from the
discharge to inlet end of the casing. The condition of these seals directly affects
the compressor performance.
The simplest and most economical of all shaft seals is the straight labyrinth
shown in Figure 5. This seal is commonly utilized between compression stages
and consists of a series of thin strips or fins, which are normally part of a
stationary assembly mounted in the diaphragms. A close clearance is maintained
between the rotor and the tip of the fins. Tight clearance and flow turbulence
creates resistance to leakage flow.
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The labyrinth seal is equivalent to a series of orifices. Minimizing the size of the
openings is the most effective way of reducing the gas flow. Labyrinths clogged
with dirt (Figure 6 – where turbulence is reduced and leakage flow is increased)
and worn or wiped labyrinths with increased clearances (Figure 7 – Where
clearance is increased, turbulence is reduced resulting in increased leakage)
allow larger gas leakage. This can affect compressor operation, and therefore the
seals should be replaced.
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1.2.3. Rotor:
The rotor consists of shaft, impellers, sleeves, balance drum and thrust collar.
Impellers:
Impellers are shrunk or keyed or combination of shrink and key mounted on the
shaft depending on the operating speed and prevailing stress levels. Impellers
may be either of the closed (shrouded) or open (shroud less) design. The blades
are generally back-swept to different angles in accordance with the required
performance. The impeller pushes the gas outwards raising its velocity and
pressure. On the disc side, the impeller is exposed to discharge pressure (see
Figure 10) and on the other side partly to the same pressure and partly to suction
pressure. Thus a thrust force is created towards suction.
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seal preventing the leakage of gas from or atmospheric air into the
casing. In general, due to its appreciable expense and maintenance
requirements, usage of the oil seal is limited to applications where the
pressure level is high, where no leakage is tolerable or where for
reasons of unavailability of sealing gas, dilution of the product gas etc.
Liquid film seals are available in eight general types:
• Labyrinth
• Bushing (Carbon Ring)
• Windback (Reversed Helical Groove Bushing)
• Restricted Bushing (Trapped Bushing)
• Film-Riding Face Seal
• Contacting Face Seal
• Circumferential Seal
• Lip Seal
The liquid film seal or oil film seal is particularly applicable to high
speed machines. The actual seal is accomplished by a thin oil film
supplied by the seal oil pump to a space between the rotating and
stationary seal elements. This oil contacts process gas and must be
degassed before return to the oil reservoir. Contaminated oil must be
reconditioned or discarded.
When handling hazardous, toxic, or emission-regulated gases, the seal
also must prevent gas leakage to the atmosphere after the compressor
has tripped due to seal oil system failure. Various devices within the
seal support system are available to assure that the compressor seal
contains the gas at a standstill, even if no seal oil is being pumped to
the seal. Elevated seal oil tanks can provide for the necessary static
differential pressure of the fluid above the sealing pressure for a
sufficient time to allow the compressor to be depressurized before the
elevated tank oil supply is depleted.
1.2.5. Bearings:
1.2.5.1. Hydrodynamic bearings:
Journal bearings:
Purpose of journal bearing are
Support and distribute rotor weight and forces
Maintain concentricity
Provide stabilizing force
Tilting pad bearings are generally used, and are normally equipped
with thermocouples to monitor the bearing temperature.
Thrust bearings:
Purpose of thrust bearing are,
Absorb axial thrust generated by the pressure differentials on the rotor.
Axially position the rotor with respect to stationary parts.
Double-acting, tilting pad bearings with an equalizing device are
typically installed. The bearing pads can be fitted with thermocouples
for temperature monitoring and with load cells in high pressure
applications to measure axial thrust.
1.2.5.2. Active magnetic bearings:
In recent years several machines have been equipped with active
magnetic bearings. Operating on the principle of electromagnetic
suspension, the active magnetic bearings perform the same functions
as hydrodynamic journal and thrust bearings with two major
advantages:
1. Reduced mechanical losses owing to the absence of friction.
2. Adjustable axial and radial position and stiffness of the rotor and
damping characteristics of the bearings.
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1.3.5. Back-to-back:
The back to back design minimizes thrust when a high pressure rise is to be
achieved within a single casing. Note that the thrust forces acting across the two
sections act in opposing directions, thus neutralizing one another. The
arrangement is the best when gas must not migrate from the first section to the
second section in an iso-cool compressor.
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2. Axial Compressor
2.1. Introduction
Axial flow compressors are used wherever large volume of gas need to be compressed
on the basis of a relatively low intake / discharge pressure ratio (normally upto 1:12).
These machines typically find their industrial application in nitric acid plant, Fluid Catalytic
cracking unit, LNG facilities, air separation plants and as blast furnace blowers. Their
construction is typically extension of the centrifugal compressors.
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dovetail section that fits into the disc. The blades are held in place axially by
removable locking tabs that fit between the blade and disc.
2.2.8. Balance Piston:
The balance piston is an integral part of the rotor stub shaft on the discharge
end. The stationary labyrinth is supported by the discharge casing.
2.2.9. Shaft Seals:
Labyrinth type shaft seals are provided on each end of the rotor.
2.2.10. Bearing Housings
The bearing housings are horizontally split for access to all of the bearing parts
without having to disassemble the top half of the casing. The bearing housing
brackets are bolted and doweled to the casing.
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