What is a Compressor

Compressor is a machine which delivers gas

at a pressure higher than that originally
existing.
Purpose of compression
1. To transmit power
2. To provide air for combustion
3. To transport & distribute gases.
4. To circulate gas through a process or system
5. To produce conditions more conductive to chemical
reactions.

Classification of
Compressor
Broad classification
is based accordingly to principle of
Energy Addition
1. Dynamic Compressors - Energy is continuously added
to the gas to increase its velocity. When liquid velocity is
subsequently reduced, this produces a pressure increase.
[a] Centrifugal Compressors
2. Positive Displacement Compressor Energy is
periodically added to the gas by the direct application of
force.
[a] Reciprocating Compressor
[b] Rotary Compressor
* In all of these, Centrifugal Compressors produces a smooth nonpulsating flow and constitute the most common type of
compressing device in a chemical plant.

Types of Compressors

Application Range of Various

Compressors

Centrifugal Compressor
In Centrifugal Compressors, Gas travels essentially
radially. The gas enters the intake (suction) volute of the
compressor & flows through the first stage inlet guide. The
gas at a radial direction flows into the eye of the first
stage impeller. Due to centrifugal force, the gas is
discharged from the periphery of the impeller at high
velocity. The gas flows into an annular passage between the
inlet wall & first stage diaphragm. The passage is diffusion
(increasing in area as gas flows towards return bend),
thereby converting part of the energy of velocity into
pressure. The gas the flows round the return bend through
a vaned annular passage in the diaphragm, and into the
second stage impeller. After subsequent stages of
compression, the gas flows into the discharge volute of the
compressor.

Flow diagram through

Impeller

Advantages of centrifugal
Compressor
1. Lower maintenance cost
2. No pulsation in gas flow
3. Silent & long continuous operation
4. Easy maintenance
5. Oil free during gas compression
6. Small space
7. Adaptability to high speed driver
8. Wider stability range

Components of Centrifugal
Compressors
1. Rotor
2. Impeller
3. Casing
4. Shaft sealing
5. Bearing
6. Diaphragm
7. Coupling

Components of Centrifugal
Compressor

Compressor rotor
components

Impeller - Diffuser

Impeller

Journal Bearing

Tilting Pad Journal bearing

Thrust
Bearing

Configuration of Compressor

Configuration of Compressor

Maintenance
[1] Bearing Inspection Checking of bearings
condition & clearances. (radial & thrust bearings)
[2] Alignment checking Checking of alignment
between driver & compressor.
[3] Shaft seals maintenance Labyrinth clearances
checking, Dry gas seals faces & elastomers checking.
[4] Complete Overhauling Dismantling of all
components & checking of their condition, clearances,
wear and replacement if required.
[5] History record This covers the date of trouble,
what was repaired or replaced, the probable cause,
comments on condition of parts when inspected and the
date for the next inspection.

Turbine Specification

Make
Siemens, Germany 1998
Type
Condensing cum extraction type
Rated power
6370 kw
Rated Speed
7600 rpm
Maximum continuous speed(mcs)
7980 rpm
Trip speed
8778 rpm
First critical speed
3890 rpm
Second critical speed
9500 rpm
Inlet steam press. Max/Min/Nor
113/98/101 Kg/cm2g
Inlet steam temp. Max/Min/Nor
520/500/505 *C
Extraction press. Max/Min/Nor
49/43.5/43.5 kg/cm2g
Extraction temp. Max/Nor
455/397 *C
Exhaust press.
0.138 kg/cm2A
Exhaust temp.
52 *C
Sealing steam
43.5 kg/cm2g
Sealing steam temp.
397 *C

Turbine Specification

Governor
Seal
Bearing
Over speed protection
L.O. Pump
Discharge press.
Control oil press.
L.O. press.
L.O. Flow to Compressor
Turbine
Gear box
Control oil
Filter
L.O. tank capacity
Overhead tank capacity

Digital nema class D woodward

Labyrinth
Tilting pad (Radial & Thrust)
Electrical & Mechanical
Gear pump
12 kg/cm2g
10 kg/cm2g
2 kg/cm2g
18 m3/h
5 m3/h
11.1 m3/h
4.3 m3/h
Cartridge type 10 micron
9880 liter
1600 liter

Compressor Specification
Make
Type
Casing

Hitachi, Japan
4 Stage co2 comp.(MCH & BCH)
MCH
Horizontally split
BCH
Vertically split
Seal
LP
Labyrinth (Aluminum), Hitachi
HP
Dry gas seal, John crane
Speed
7600/14744 rpm
Max. continuous speed 7980/15481 rpm
Min. speed
6460/12532 rpm
First critical speed
3350/8000 rpm
Power
5790 Kw

Compressor Specification

Stage
Impeller
Suction Press.
Suction temp.
Discharge press.
Discharge temp.

1/2/3/4
3/4/4/2
0.8/5/21/98 kg/cm2g
42/42/42/60 *C
5.5/22/98/180 kg/cm2g
157/178/201/135 *C

CO 2 COMPRESSOR
P.AIR
FV 1156

EA-1113

EA-1111
LPD

CW
TV-1162

FV1202

FA-1114

FA-1112
HV 1151

II

III

GB

IV

BCH

MCH
DC1102
FA-1111

UV 1158

CO2 FROM NH3

PLANT

EA-1112

Stripper

P.AIR

PV-1162

FV 1157

FA-1113

UV 1159

3-Steam system
Ensure steam is available.
Charging the SH,SM,SL header & its control valve
is in line.& its desuperheater is in line.
Also SH/SM/SL letdown control valve is in line.
SH press/temp
101 kg/cm2g/505 *C
SM press/temp
43.5 kg/cm2g/397*C
SL press/temp

5.0 kg/cm2g/160 *C

FAN AND BLOWER

Low pressure (1 atm)
and low P (0.01-0.15
kg/cm2) for FAN.
Blower P (0.15-1.5
kg/cm2)
High volume flow to
500 std m3/s
Efficiencies of 65-80%

DATA REQUIRED FOR SELECTION OF

COMPRESSOR:

Capacity
Suction pressure
Suction temperature
Discharge pressure
Gas composition
Type of driver
Utilities like cooling water, steam, N2,
electricity etc.

Selection results in calculation

Type of compressor
Number of casing / phases
Number of impellers in each phase
Speed of compressor
Compressor BKW
Driver rating
Operating range

Application Range of Various

Compressors
Discharge Pressure (Psia)

105

104

103

Centrifugal
102

101

Axial
Reciprocating

102

103

104

Inlet Flow (Acfm)

105

106

CENTRIFUGAL COMPRESSORS:
Centrifugal compressor works on the principle i.e.
accelerating a gas to a high velocity and converting its
KINETIC ENERGY (velocity) into POTENTIAL
ENERGY (pressure) by decelerating the gas.
The gas enters the eye of the impeller and is accelerated
to the outward edge of the impeller as it rotates. It then
enters a diffuser where its direction is changed, causing
deceleration. This deceleration converts the KE into the
PE, pressure.
If the gas is to be further compressed, then a return
chamber directs it from the diffuser to the eye of the next
impeller in series. The gas enters a collector or volute
when it is to leave the compression stage. It is
discharged to the process through a discharge nozzle.

SIGN FEATURES:

Based on the type of casing design,centrifugal compressors are

classified into two types:

1)

Horizontally split casing design(MCL/MCH type):- This design is

used for low working pressure below 40ata.These casings are in two
halves with horizontal parting plane.
DMCL Compressor have two stages of compression in parallel in a
single casing.The solution is most balanced.The other aspects of
construction are the same as for the MCL Compressor.

2)

Verically Split Casing design (BCL/BCH type):-This design is

made of barrel construction closed on the sides by end covers with
help of studs.This type of construction is suitable for high pressure
operations upto 750kg/cm2
Another type of compressor is the PCL(Pipeline compressor),which
has casing in the form of a cup with a single closing flange in the
vertical plane instead of two as with the BCL.

Horizontally split type

Compressor

Example of Designation of BCL

Compressor:
Example : 2BCL407/b
2

BCL

40

7 / b
Pr. rating (up to 350 ata)
No. Of impellers
(7 impellers on rotor)
Nominal dia. of impeller
(Impeller dia. of 40 cms appx.)
Constructional feature
(Barrel design)
Functional feature
(2 Compressor stages in series)

Compressor Components

Casing
Counter Casing (If Applicable)
Diaphragm
End Cover (If Applicable)
Shaft
Impellers
Shaft Seals
Journal Bearing
Thrust Bearing
Coupling

Major Components
Major Operating Components of a
Centrifugal Compressor fall into two
groups.
1. Rotating Assembly
2. Stationary Assembly

ROTATING ASSEMBLY

The Rotor is normally coupled to the driver by means of a flexible type

coupling. The rotor receives mechanical energy through this coupling, which
it imparts to the impeller(s) firmly mounted on the shaft.
The rotor can be of overhung or beam-style design. The overhung rotor
design has the impeller outboard of the bearing support system and the
beam-style design has the impeller(s) located between the journal bearings.

 The rotating element, which imparts

momentum to the gas during operation. The
impeller does all work on the gas. Its primary
purpose is to impact on the gas while spinning
very fast, thus, greatly increasing the velocity of
the gas. The pressure rise in the impeller is
approximately 2/3 of the total pressure increase
of the compressor.

Types of Impellers
The objective in selecting a given type and construction of an
impeller is to obtain the best performance with mechanical,
manufacturing, and cost limitations considered

PRESSURE INCREMENT IN COMPRESSOR

THRUST COLLAR

The THRUST COLLAR is mounted on the rotor and works in

conjunction with the thrust bearing. The thrust collar transmits the
axial thrust (movement) from the rotor to the thrust bearing. The
bearing housing encased within the compressor casing encloses the
thrust bearing. The loads that are absorbed through the housing to
the casing are then transferred to the compressor feet, which are
attached to sole plates, which are grouted to the base.

THRUST
COLLAR

Thrust Balance Piston

There exists some amount of thrust generated at each impeller
because of the differntial pressure prevailing across it. The
cumulative thrust generated across all the impellers is huge and it
needs to be supported by the thrust bearing. The thrust bearing size
becomes huge if all the gas thrust has to act on the bearing.
For this purpose a rotating element called Balancing Drum is
incorporated on the rotor. The drum is acted upon by a pressure
differential which pushes the rotor in a direction opposite to that of
the gas thrust. The thrust so generated balances the thrust
produced by the impellers.
Amount of balancing depends upon the size of the drum and
pressure differential created across it. The pressure differentiated is
maintained by an efficient seal placed over the balancing drum.

Construction of centrifugal compressor:

Every centrifugal compressor consist of
two parts:- An impeller which forces the
gas into the rotary motion by the action of
blades, and the casing which directs the
gas to the eye of the impeller and then
leads it away from the impeller perimeter
at a higher pressure. For most multistage
compressors, shaft end seals are located
inboard of the bearings. The internal
passages are formed by a set of
diaphragms.

STATIONARY ASSEMBLIES
DIAPHRAGM:

The DIAPHRAGM is a stationary element used wall between

individual stages of a multi-stage compressor. The diaphragm
accurately controls the direction and flow of gas through the
compressor, converting kinetic energy to pressure energy between
stages.
The interior of each diaphragm has a vaned return passage, which
directs the gas into the inlet guide vanes of the succeeding stage.
The diffuser and return passage are designed to gradually and
efficiently convert the velocity of the gas to the succeeding stage.
Approximately one-third of the stage pressure rise occurs in the
diffuser by converting gas velocity to pressure through diverging
walls.

DIFFUSER
The DIFFUSER is a stationary passageway
following an impeller in which velocity energy
imparted to the gas by the impeller is converted
into static pressure. There are three basic types
of diffusers.
1. Parallel Wall
2. Volute
3. Combination of Parallel Wall and Volute

Guide Vanes
The Guide Vanes are stationary elements, which
may be fixed or adjustable to provide a desired
flow direction of the gas inlet of an impeller.
Adjustable guide vanes are used when the
compressor is driven at a constant speed to shift
the compressor performance in a predictable
manner.

Casing & Cover

The Casing & Cover are the stationary
components, which contain the pressure and
enclose the rotor and associated internal
components. The casing and cover also include
the inlet and discharge connections. Three basic
categories are as follows:
1. Horizontally split compressor (used for low to
moderate pressures).
2. Vertically split barrel compressor (moderate to
high pressures).
3. Vertically split pipeline compressor (gas
transmission high flow/low head conditions).

SUPPORTING SYSTEMS
The Bearing Support system consists of
(1) Journal Bearing.
(2) Thrust Bearing

Journal Bearing
The Journal Bearings perform (3) major functions:
1. They support loads both steady state and dynamic.
2. They provide stiffness and dampening.
3. They control shaft position.
The conventional lubricated journal bearings are multi-shoe semi-self
aligning, tilting pad bearing. The self-adjusting action of these bearings
result in high dampening properties in the individual bearings pads, thus,
enabling the bearings to overcome instability and lessen vibration of the
compressor shaft. The tilting pad also assures complete freedom from oil
film whirl oil whip, which is a phenomenon that tends to be present with
high rotating speeds in a lightly loaded bearing when running at close to
twice a critical speed. This oil whip is characterized by high amplitude
shaft vibration at a frequency slightly less then one-half the rotative
speed.

Assembly of Journal Bearing

Thrust Bearings
Thrust Bearing is used to prevent axial motion of the
rotating shaft and thus holds the axial position of the
rotor assembly accurately within the compressor. There
is an axial thrust produced toward the eye of the impeller
due to the unbalanced pressure differential across the
impeller. This thrust load and the size of the thrust
balance drum is considered when sizing the thrust
bearing. The physical location of the thrust bearing is on
the suction side of the compressor outboard of the
journal bearing for beam-style rotors and between the
journal bearings on overhung rotors.

Assembly of Thrust Bearing

Types of Compressor End

Sealing Systems
Labyrinth Sealing
Floating Oil Seals
Oil Mechanical Seals
Air Injection Sealing System
Injection / Extraction Sealing
Dry Gas Seals

Sealing System

The Sealing of Compressor ends is accomplished

by Following methods

Liquid Film Shaft Seals

Labyrinth Seals
Mechanical Seals
Injection & extraction Sealing

Note : Selection of a particular sealing for a

compressor depend basically on the gas medium &
leakage quantity, cost of the gas, fire hazards etc.

Labyrinth Seals
This system is employed for gases like Air,
Nitrogen. The amount of gas leaking to ambient
is reduced by selecting adequate number of
labyrinth fins.
Some of the developments in a labyrinth type
seals are stepped type seals, honey comb type,
turbine type. These special types are employed
for higher differential pressures and space
restrictions in the machine.

Labyrinth Seals
A labyrinth seal is a mechanical seal that fits around
a shaft to prevent the leakage of oil or other fluids

 A labyrinth seal is composed of many straight threads

that press tightly inside another shaft, or stationary hole,
so that the fluid has to pass through a long and difficult
path to escape
For labyrinth seals on a rotating shaft, a very small
clearance must exist between the tips of the labyrinth
threads and the running surface
Labyrinth seals on rotating shafts provide non-contact
sealing action by controlling the passage of fluid through
a variety of chambers by centrifugal motion, as well as
by the formation of controlled fluid vortices. At higher
speeds, centrifugal motion forces the liquid towards the
outside and therefore away from any passages
Turbines use labyrinth seals due to the lack of friction,
which is necessary for high rotational speeds.

DRY GAS SEALS

The dry gas seals represent a significant advance in shaft
sealing. Gas seals eliminate the need for complex and
costly seal oil systems, and the ongoing maintenance
associated with them

Working Principle of Dry Gas Seals

Working Principle

A dry gas seal consists of a spring-loaded stationary ring (mounted

in the casing) held in a retainer against a rotating ring (mounted on
the rotor).
The contact face of the rotating ring incorporates special film-riding
geometries in the form of groves or tapered lands on the outer
portion. Filtered compressor discharge gas, maintained at a
pressure slightly above that of the process gas to be contained, is
introduced into the seal area.
As the gas pressure and shaft rotation interact in normal operation,
the geometry on the rotating ring creates a dynamic gas pumping or
"lifting" effect which pushes the spring-loaded stationary ring away
from the rotating ring.
A pressure dam effect created by the rings functions as the primary
seal and breaks down the gas pressure to just above atmospheric

Injection & extraction sealing

For gases like oxygen, raw gas & other explosive media
the sealing has to be perfect and where sealing medium
like oil cannot be used, the above sealing system is
selected.
The principle of this sealing is that vacuum is created by
a ejector at the shaft ends which sucks the gases and
thus prevents any outward leakage of the contained gas.

SURGE CONDITION
Surge - is the point at which the compressor cannot add enough energy to
overcome the system resistance. This causes a rapid flow reversal (i.e.
surge). As a result, high vibration, temperature increases, and rapid
changes in axial thrust can occur. These occurrences can damage the
rotor seals, rotor bearings, the compressor driver and cycle operation
1. As the flow through a centrifugal compressor is progressively reduced the
discharge pressure increases.
2. With this mass flow reduction, a recirculation pattern develops in the
impeller.
3. At some minimum flow, the recirculation flow pattern collapses. The impeller
can no longer develop the discharge pressure required to maintain flow
through the compressor.
4. Since the pressure developed is less than that in the downstream system
flow reversal occurs. The delivered flow from the compressor then
immediately drops to zero.
5. When the flow drops to zero, the pressure of the downstream system has
dropped.
6. Compressor flow will once again develop head and move toward maximum
head. If the position or status of the discharge valve or restriction has not
been altered, the flow and discharge pressure will change along the
compressor characteristic curve until the surge point is again reached.

BARREL PULLING
ARRANGEMENT

Rotor Assembly