Stress Analysis of Centrifugal Compressor

Connected Piping Systems using Caesar II

Introduction:

Centrifugal compressors are considered to be one of the most critical equipments in the
piping industry. For increasing the pressure of gaseous fluids centrifugal compressors are
widely used in refineries and petrochemical complexes. From stress analysis point of view
the compressor systems are critical because:

 Equipment being rotary it is prone to vibration.

 The allowable nozzle loads are very less. Normally combined suction and discharge
nozzle analysis is required to be performed.
 As the pressure increases due to compression the pipe thickness increases which
increases the rigidity of connected pipe and automatically the loads at nozzle
increases.

However good part is that normally compressor connected pipes does not have much
temperature.

In this article I will try to explain the procedure to analyse the method followed to analyse
such systems.
Fig.1: Typical Piping System Connected to Centrifugal Compressor

Inputs required for analysis:

The following documents are required while analyzing a compressor connected piping
system.

 Process P&ID.
 Line List for line parameters.
 Pipe Material Specification.
 Equipment Vendor GA drawing.
 Suction and discharge nozzle displacements in proper axes with direction.
 Line isometrics.
 Allowable nozzle loads.

Building the system in Caesar II:

In Fig. 1, a typical piping model connected to a centrifugal compressor and scrubber is

shown. If we have to analyse such systems then the following steps we have to follow:

 Model the pipe from isometrics in similar way as you normally do for the other
systems. Use Line parameters from PMS and Line List. If the line is insulated then
take exact density of the insulating material as that value will impact the analysis. If
fluid density is available then use it otherwise leave it blank (zero density as normally
gas). A Caesar plot of the above system is shown below for your reference.
Fig. 2: Caesar Plot of the system shown in Fig. 1

 It is very difficult to model the compressor using GA drawings and get the actual
thermal displacements at the nozzle points. So vendor provides the thermal
displacement values at operating temperature. So now find the compressor nozzle
displacements from GA drawing or mail communications and input the same at
compressor nozzle node as shown in Fig 3.

Fig. 3: Caesar Spreadsheet Explaining the input of nozzle displacements.

  Model the scrubbers taking data from Vendor GA.
 Now prepare all the load cases and run the system statically to check the results. Make
the system stresses within code allowable limit. Make scrubber nozzles within vendor
allowable. Refer the next paragraphs for compressor nozzle qualification.

In general practice compressor nozzles are to be qualified by API 617 or NEMA SM 23.
There are three separate checking to ensure proper working of the compressor.

1. Individual component forces (Fx, Fy, Fz and Mx, My, Mz, each component at each
nozzle) at nozzle point must be within the limit specified in code. (For equations refer
annex 2E of API 617)
2. The resultant force and resultant moment of each nozzle (suction and discharge
separately) must be within limit specified in code. (For equations refer annex 2E of
API 617)
3. The combined resultants of the forces and moments of the inlet, sidestream, and
discharge connections resolved at the centerlines of the largest connection (resolution
point) should not exceed the limit specified in code. (For equations refer annex 2E of
API 617)

Always remember that Caesar axis and API axis may not be same. So you need to convert the
allowable forces in proper Caesar axis and then compare. The API 617 axis system is
reproduced in Fig. 4 for your reference.

Fig. 4: Co-ordinate system as per API 617 for nozzle force and moments.

Sometimes vendor allows using some factor. Always check with vendor at early stage of
project and agree on this.

Resolution point is the point with respect which all forces and moments of suction and
discharge nozzles will be resolved for combined study. As per code it is the flange face of
largest compressor nozzle (normally the suction nozzle). Measure the position (dimensions)
of the other nozzle with respect to this point for combined study. A typical diagram showing
suction and discharge nozzles from a GA drawing is reproduced in Fig. 5 for your
understanding.

Fig. 5: Typical GA drawing showing suction and discharge nozzle.

Qualification of Compressor Nozzles:

From the above paragraph it is clear that to qualify the compressor nozzles you need to model
and analyse the discharge nozzle and connected piping system (discharge side piping is
shown in Fig. 9). So follow the same procedure as mentioned for suction nozzle and analyse.

Compressor nozzle loads are checked in NEMA SM 23 module of Caesar. To perform the
same click on Analysis and then NEMA SM23 as shown in Fig 6.
Fig. 6: Opening NEMA SM 23 module in Caesar II

The module will open the spreadsheet (Shown in fig. 7) where you have to enter the
parameters of suction and discharge nozzles, loads at suction and discharge nozzle and
distance from resolution point. Enter the factor of allowable increase if vendor allows to do
so. Normally as per API 617 the value is 1.85

Fig. 7: NEMA SM 23 spreadsheet in Caesar II

If you provide node number Caesar will automatically select the loads from your static
analysis upon clicking the proper load case.
After loads are provided for both suction and discharge nozzle click on the run button to see
the analysis results. It will show the results as passed or failed. If failed check the reason for
failing and reduce the same force or moment value to get it qualified. A typical output report
is shown in Fig. 8 for your reference.

Fig.8: Typical Caesar Output of NEMA SM 23 module

Additional considerations for Compressor Piping Analysis:

 Perform alignment check (Anchor free analysis) in a separate file and keep nozzle
movements within limit as specified in API RP 686.
 In most of the cases supports near compressor suction and discharge nozzles are
Spring hangers. So create an additional load case as WNC+H- (SUS) type and qualify
the nozzles in that case too.
 Normally Compressor nozzles are qualified in operating temperature (and sustained)
only. However if client asks you have to do so in design temperature case.
 If variable springs are used to qualify Compressor nozzles keep the variability as low
as possible (less than 10%).
 Normally modal frequency analysis is not required for centrifugal compressor
connected systems.
 In general, Compressor nozzles are not required to qualify in occasional load cases.
 Don’t forget to request nozzle displacements at early stage of project.
Fig. 9: Compressor Discharge side piping of a typical system