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CENTRIFUGAL
COMPRESSORS
Fabrizio Tani
October 23rd 2001
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WHAT IS A COMPRESSOR?
COMPRESSOR
PRESSURE RATIO
GAS
Suction Pressure = Ps
Suction Temperature = Ts
Suction Velocity = Us
GAS
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

H W Q A =
Adiabatic Process :
H W A =
0 = Q
( ) T P f H , =
Enthalpy H
WorkInput W
HeatInput Q
=
=
=
Absorbed Power (P) = Specific Work (W) x Gas Flow (G)
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A further hypothesis:
NO LOSSES
same suction conditions Ps,Ts
same discharge pressure Pd
lower discharge temperature Tis
The isentropic process associated to the real adiabatic process has:
ISENTROPIC PROCESS
Isentropic Process = All Energy to Compress Gas
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ISENTROPIC EFFICIENCY
The ratio of isentropic work to the total adsorbed energy
q
is
is
W
W
=
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
}
= vdp W
Specific Work:
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TOTAL ADSORBED ENERGY
minus
ISENTROPIC WORK
LOSSES
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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The equation define the theoretical process called
POLYTROPE
For each step the isentropic work
dw vdp
is
=
dH
vdp
e =
e is the constant for which the path passes
through suction and discharge conditions and
the isentropic efficiency of each step
We define the equation:
POLYTROPIC WORK:

The sum of all the isentropic works step by step
W vdp
p
pol
=
}
.
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POLYTROPIC EFFICIENCY
For a perfect gas
The ratio of polytropic work to the
total adsorbed energy
q
p
p
W
W
=
q
p
n
n
K
K
=

1
1
Polytropic efficiency is not pressure ratio dependant
The ratio between the advantage we
can obtain with the use of a certain
tool and the price we have to pay
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CUSTOMER NEEDS
DIFFERENT POINTS OF VIEW
MANUFACTURER NEEDS
A way to compare compressor of different
manufacturers for the same service
A method to check the performance of the
machine at site
Define a relationship between the
performance and the geometry
Verify the performance
Achieve the performance
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A WORKING IMPELLER
Normally the tangential component of C
1
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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The energy exchanged, per unit of weight of fluid, between
impeller outlet and inlet by its angular speed
EULER EQUATION
u u
C u C u W
1 1 2 2
=
In the hypothesis that C
1u
is negligible
u
C u W
2 2
=
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EULER EQUATION
u
C u W
2 2
=
Based on mechanical principles
H W A =
FIRST LAW EQUATION
Based on thermal quantities
W is the same!
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To predict performance we need non dimensional coefficients
representing a physical phenomenon that are:
DIMENSIONAL ANALYSIS
Results of experimental works carried out on models of the real stages
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
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The ratio between the radial component of the gas
velocity at inlet and impeller speed in the same
point
INLET FLOW COEFFICIENT

1
identifies gas
angles at inlet
1
1
1
u
C
r
=
OUTLET FLOW COEFFICIENT
The ratio between the radial component of the gas
velocity at outlet and impeller peripheral speed
2
2
2
u
C
r
=
A different form
const
v
v
i
o
1 2
=
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The ratio of impeller peripheral speed to the
velocity of sound at impeller inlet:
PERIPHERAL MACH NUMBER
A measure of gas compressibility
in
a
u
Mu
2
=
REYNOLDS NUMBER

ub
= Re
gas suction density
u impeller peripheral speed
b impeller exit width
dynamic viscosity
It can be read as ratio of inertia forces to viscous surface forces
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A measure of the impeller capacity to
energise the gas
HEAD COEFFICIENT
The ratio between the tangential component of the
gas velocity at outlet and impeller peripheral speed
2
2
u
C
u
= t
t
2
2
u W =
u
C u W
2 2
=
Euler equation
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NON DIMENSIONAL
PERFORMANCE CURVES
( )
1
t f =
( )
1
tq g
p
=
( )
1
q h
p
=
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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
Discharge Pressure
Absorbed Power
Efficiency
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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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LNG
Liquefied Natural Gas
NATURAL GAS
Oil Production
Gas Production
Gas Lift
Pipeline
Gas Re-injection
Gas Storage
PETROCHEMICALS
Syngas & Fertilizers:
CO2 compressor for UREA Plants
Ammonia Synthesis
Methanol Synthesis
REFINERY
Fluid catalytic cracking
Reforming
Hydrocracking
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
Over 3500 Units Sold
World Leader in Gas Compression
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Low Pressures - High Volumes
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MCL - 2MCL - 3MCL - DMCL Compressors
High Volume Flows [up to 200,000 m
3
/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
Low Pressures - High Volumes
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Casings and Diaphragms for High Pressure Compressors
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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
High/Very High pressures - Low Volumes
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Overhung Type Beam Type
Axial Inlet
Single Impeller
High Volumes, Low Pressure Ratio
Hydrostatic Lift
Size 800 to 1000
Lateral Flanges
One to Thr ee Impel lers
High Pressure Ratio
Axial Thrust Balance
Sizes 300 to 1000
Gas Pipeline Compressor - PCL
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3D Impeller Technology
Machined by 5-Axis Milling Machines
Barrel Casing With Cartridge Concept Internals
for Easy Maintenance
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Vertically Split Pipeline Compressors

Medium to High Volume Flows [ranging from 80,000 m
3
/h down to 3000 m
3
/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
Gas Pipeline Compressor - PCL
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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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EXPERIENCED UP TO 210 BAR STATIC
TANDEM SEALS
TRIPLE SEALS
EXPERIENCED UP TO 290 BAR DYNAMIC AND 310 BAR STATIC
Shaft end sealing
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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