GE_centrifugal_compressors
GE_centrifugal_compressors
Introduction
General description and main features
Introduction Customer Training
What is a Compressor?
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Introduction Customer Training
What is a Gas?
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Introduction Customer Training
Gas compression
Gas
ps Gas
pd
Mechanical
power
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Introduction Customer Training
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Compression Services Customer Training
Re-injection plant
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Compression Services Customer Training
Vertically split
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Compressors overview Customer Training
Horizontally split
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Compressors overview Customer Training
Single Volute
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Compressors overview Customer Training
2 BCL 406
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Compressors overview Customer Training
Literal Part
2 BCL 406
Casing
B=barrel Diffuser
P=pipeline L=free vortex (not vaned)
M=Middle Split Impeller design
S=single volute C=closed
R=open
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Compressors overview Customer Training
N p<150 bar
A p<200 bar
BCL 406 /A
B p<300 bar
C p<400 bar
D p<550 bar
E p up to 1000 bar
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Compressors overview Customer Training
Pipeline compressors are designed to maximize compression efficiency over the broad range of
operating conditions required by gas pumping stations;
Suction and discharge nozzles for gas transportation are generally located opposite each other to
meet station layout requirements.
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Compressors overview Customer Training
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Compressors overview Customer Training
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Compressors overview Customer Training
C= closed type
R= open type
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Compressors overview Customer Training
2 BCL 406
Diffuser
No fixed blades
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Compressors overview Customer Training
n. of
Numerical Part
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Compressors overview Customer Training
2 BCL 406
Nominal size (mm)
400 mm
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Compressors overview Customer Training
Section arrangment
BCL...MCL...
suction discharge
In line configuration.
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Compressors overview Customer Training
Section arrangment
2 BCL... 2 MCL...
1 st
1 st discharge
suction
Two compression sections in a single
2 nd 2 nd casing;
discharge suction
Back to back configuration;
Tmax 250°C.
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Compressors overview Customer Training
Section arrangment
3 BCL... 3 MCL...
sidestreams
suction discharge
Sidestreams.
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Compressors overview Customer Training
Section arrangment
D BCL... D MCL...
suction
discharge
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Compressors overview Customer Training
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GE Oil & Gas
Oil & Gas Industry Applications
Shaft
Impellers
Thrust Collar
Coupling hub
Balance drum
Spacers
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Thrust Collar Customer Training
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Impeller Customer Training
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Impeller Customer Training
In order to minimize erosion and corrosion effects on impeller due to pitting or fouling phenomenon
related to gas composition, it is possible to use special stainless steel alloy with Ni-Cr-Mo or apply a
specific protective coating.
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Impeller Customer Training
The blades are bended The blades are bended and twisted
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Balancing Drum Customer Training
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Coupling Customer Training
HUB
No lubrication is needed
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Coupling Customer Training
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GE Oil & Gas
Oil & Gas Industry Applications
Diaphragms
Bearings Bearings
End cover
Seal
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Stator parts Customer Training
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BCL: Casing-Diaphragms Customer Training
LOWER HALF
UPPER HALF
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Casing-Diaphragms: bundle Customer Training
Diaphragms
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Casing-Diaphragms: bundle Customer Training
Blades
Labyrinth
seals
Impeller
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Casing-Diaphragms: bundle Customer Training
In new barrel compressors the inlet and disharge volutes are separated from the inermediate
diaphragms.
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Casing-Diaphragms: bundle Customer Training
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Horizontally split Customer Training
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Flanges and nozzles Customer Training
Suction
Discharge
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Flanges and nozzles Customer Training
In the barrel type for high or very high pressure, piping is directly connected to the casing
without nozzles;
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Shear and Shim rings Customer Training
Shim ring
Shear ring
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Head cover Customer Training
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Bearings Customer Training
Thrust bearing
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Thrust Bearings Components Customer Training
Thrust bearing are self equalizing: the bearing distributes the load equally between all pads.
Thrust collar
Thrust shoes
Pivot
Base ring
Leveling plates
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Journal Bearing Customer Training
Jourbal bearing
Tilting pads type are adopted.
The functions of the journal bearing are:
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Journal Bearing Customer Training
Bearings casing
Bearings pad
Pivot
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GE Oil & Gas
Oil & Gas Industry Applications
SUCTION DISCHARGE
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Suction Customer Training
Fin
Casing
Shaft
Blade
Inlet Volute
Impeller
Suction Nozzle
Suction Pipe
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Suction Customer Training
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Suction Customer Training
Disk
Key
Shaft
Labyrinth Labyrinth
Seal Seal
Suction
diaphragm
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Intermediate stages Customer Training
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Single stage Customer Training
Diffuser
Blades
Return channel
Labirinth
seals
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Single stage Customer Training
++ +
Increased
P3,C3 velocity
C3=C1
P2,C2
optimal condition ++
P4,C4
P1,C1
+ Gas Inlet
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Single stage Customer Training
Velocity 4
Pressure
Energy
2
1
Impeller Blade Diffuser Diffuser
Inlet Inlet Inlet Outlet
1 2 3 4
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Discharge Customer Training
Discharge volute
Last impeller
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GE Oil & Gas
Oil & Gas Industry Applications
P2 > P1
P2
P2
P1
Axial thrust
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Axial Thrust Customer Training
Balancing Drum
The BALANCE DRUM is a disk installed after the last impeller in order to balance part of the axial
thrust (80÷85%).
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Axial Thrust Customer Training
P2
P2
P1
Ps
R1 R2 Rd
Ps Pd Ps+ΔP
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Balancing line Customer Training
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GE Oil & Gas
Oil & Gas Industry Applications
Centrifugal Compressor
Performance Curves
Performance Curves Customer Training
Polytropic Head
Polytropic Efficiency
Pressure Ratio
Power
Discharge Temperature
Discharge Pressure
Qinlet
The performance curves are valid ONLY for the condition specified in the performance diaghram...
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Operating Range Maximum
continuous speed Customer Training
(MCS)
Normal operating
point
Discharge pressure (bar a)
Surge Limit
Line
Minimum
operating speed
(MOS) Choking Area
Qinlet
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Operating point Plant
Customer Training
resistance curve
Qinlet
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Customer Training
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Off-design conditions Customer Training
Discharge pressure
MW Ts Ps
MW Ts Ps
Qinlet
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Other map variation cause: Customer Training
Normal working
Discharge pressure
graph
Internal recycles
effect
Qinlet
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Regulation Customer Training
Speed Variation
Suction throttling
Variable inlet guide vanes (VIGV)
Discharge blowoff
Cooled bypass
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Regulation Customer Training
Discharge pressure
Qinlet
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Regulation Customer Training
Discharge pressure
Qinlet
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GE Oil & Gas
Oil & Gas Industry Applications
Choking Area
Qinlet
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Surge Customer Training
Surge is the left limit of performance curve, on the left of this line the compressor operates in
unstable condition;
All surge points, defined for different speeds represent the Surge Limit Line;
Surge Limit
Line
Discharge pressure
Qinlet
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Surge Customer Training
Normal operating P2
conditions P2 > P1
P1
Axial thrust
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Surge Customer Training
Surge condition P2
P1 > P2
P1
Axial thrust 83
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Factors leading to surge Customer Training
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Antisurge system Customer Training
Antisurge Valve
Instrumentation:
Electronic controller
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Antisurge system Customer Training
The purpose of the Antisurge Control System is to avoid that the operating point reaches the SLL.
The opening of the Antisurge Valve increases the suction flow moving the operating point along the
speed.
FT PT PT
COMPRESSOR
ANTISURGE
CONTROL
ANTISURGE VALVE
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Antisurge system Customer Training
…just a clarification:
The anti-surge controller is a special electronic device that interacts with the
main control panel but is not depending from it.
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GE Oil & Gas
Oil & Gas Industry Applications
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Lube Oil System P&ID Customer Training
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Tank
Centrifugal Compressor Training Course
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Lube Oil System P&ID Customer Training
Main
pump
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PCV
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Lube Oil System P&ID Customer Training
TCV
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Lube Oil System P&ID Customer Training
Filters
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GE Oil & Gas
Oil & Gas Industry Applications
Rotating part
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Sealing systems Customer Training
Process gas leakages between the Process gas leakages towards the
compression stages atmosphere
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Types of seals: Customer Training
Labyrinth seals
O-Ring gaskets
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Labyrinth Seals Customer Training
A labyrinth seal is a type of mechanical seal that minimize the gas leakages. Labyrinth seals on
rotating shafts provide non-contact sealing action by controlling the passage of fluid through a
series of teeth.
Efficiency
Eye of the impeller
Main purpose is to minimize internal leakages
Foot of the impeller close to the impellers due to different
pressure value at inlet and discharge.
Balance drum
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Shaft end sealing Customer Training
Balancing Drum
Balancing Line
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Dry gas seal system
Customer Training
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DGS: main components Customer Training
Athmosphere Process
side side
Spring
SHAFT
Rotating ring
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Operating conditions Customer Training
Gas is compressed and pressure increases setting the gap between the rings.
Dynamic
Pressurization The pressure profile at the
Static Pressure + interface is self adjuxting to
Spring Thrust restore to a position of equilibrium
Seal
gas
Process Side
Seal
gas
Stationary ring Rotating ring
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Dry gas seal Customer Training
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Gas source Customer Training
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Nomenclature TANDEM type: Customer Training
Primary vent (leakage from inbord seal Secondary vent (leakage from Outbord seal
+ intermediate buffer gas - to flare) STREAM 2 + separation gas - atmospheric) STREAM 4
Separation gas (N2)
Intermediate buffer STREAM 5
gas (N2)
STREAM 3
Seal gas STREAM 1
Atmosphere
(Bearing chamber)
Inboard seal
Carbon rings
Product side
Face
Seat Face
Seat
Inner seals Outboard seal Separation seal
Intermediate Labyrinth
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Dry gas seal: DOUBLE type Customer Training
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Tertiary seal Customer Training
The function of the tertiary seal is to avoid the oil vapours entering into the dry gas seal.
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Dry Gas Seal System P&ID Customer Training
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Buffer Gas
PCV
Seal Gas
PCV
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Dry Gas Seal System P&ID Customer Training
Primary Vent
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Dry Gas Seal System P&ID Customer Training
Secondary Vent
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Dry Gas Seal System P&ID Customer Training
Seal Gas
Heater
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GE Oil & Gas
Oil & Gas Industry Applications
Vibrations Overview
Mechanical behavior Customer Training
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Vibrations classification Customer Training
The typical vibrations of the centrifugal compressors can be classified with reference to
the frequency and the nature of the force causing vibrations.
Synchronous
The vibration frequency corresponds to the machine rotation speed (ωR)
Asynchronous
The vibration frequency is different from the machine rotation speed (ω R)
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Syncronous vibrations Customer Training
𝜔 = 𝜔𝑅
The most common causes are:
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Asyncronous vibrations Customer Training
𝜔 = 𝐾𝜔𝑅
Frequency of the vibration lower or higher than ωR
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Asyncronous vibrations Customer Training
𝜔 = 𝐾𝜔𝑅
Coupling misalignment;
𝜔 = 2𝜔𝑅
Loose of interference in some rotor components.
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Asyncronous Vibrations Customer Training
Aerodynamic effects
(rotating stall in diffusers) 𝜔 = ( 0.1 − 0.2 ) 𝜔𝑅
This occurs when the frequency of a periodic force (excitation frequency), applied to a rotor-
bearing system, corresponds to a natural frequency of that system.
A centrifugal compressor has many natural frequencies that are colled Critical
Speeds;The most important are the first and the second; It is necessary to determine the
field operation speeds that avoid the resonance.
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API 617 Customer Training
𝑆𝑀 𝑜𝑝𝑒𝑟𝑎𝑡𝑖𝑛𝑔
𝑠𝑝𝑒𝑒𝑑𝑠
𝑉𝑖𝑏𝑟𝑎𝑡𝑖𝑜𝑛 𝑙𝑒𝑣𝑒𝑙
𝑆𝑀
0.707 𝑝𝑒𝑎𝑘
𝑁1 𝑁2
𝑁𝑐1 𝑁𝑚𝑐 𝑁𝑐𝑛
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Customer Training
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