Beginner’s Guide

to
Centrifugal Compressor System
Design & Simulation

Vijay Sarathy J, M.E, C.Eng, MIChemE

Contents…
 Centrifugal Compressor (CC) System Characteristics
 Centrifugal Compressor (CC) Drivers
 Typical Single Stage System
 Start-up Scenario
 Shutdown Scenario
 Emergency Shutdown (ESD) Scenario

 Centrifugal Compressor (CC) System Design Philosophy

 Anti-Surge System
 Recycle Arrangements
 CC Driver Arrangements
 General Notes
Centrifugal Compressor (CC) System Characteristics…
 Compressor Maps dictate “behaviour” of the CC
 CC Maps are a plot between Polytropic Head (or pressure ratio) vs. Volumetric Flow

Surge Line Surge Margin

Polytropic Head [m or kJ/kg]

Speed 4

Efficiency [%]
Speed 1 Speed 4
Speed 3

Speed 2
Stone Wall
Speed 1 Region
Speed 2 Speed 3

Actual Volumetric Flow [m3/hr] Actual Volumetric Flow [m3/hr]

  n −1 
  
Z avg × R × Tin  n   Pout 
− 1
 n 
Hp = × ×   Compressor to be operated always away from the surge line
MW gas  n − 1   Pin 

   Absorbed power is the least at the surge line
Power = H p × Qin
 Range of CC operation is the enclosed region of the maps
H p = Polytropic Head , kJ / kg beyond which guarantee is not provided by the manufacturer
Qin = Mass Flowrate, kg / sec
 Typically operating point is maintained within 10% to 12% of the
R = Gas Cons tan t , 8.314kJ / kgmol K surge line. This can be increased on a case to case basis.
Z avg = Average compressibility factor
MW gas = Gas molecular weight , kg / kgmol
n = Polytropic exp onent
Tin = Inlet temperature, K Compressor to be operated within surge limits
Pout
= Pr essure ratio
Pin
Centrifugal Compressor (CC) Drivers…
Gas Turbines (GT)
 Widely used in the last 30 years.
 Disadvantage of COX and NOX
emissions & relatively lower
efficiencies.
 Intensive maintenance. GT
efficiency depends on ambient
conditions.
 Aero derivative turbines offer
the advantage of variable speed
due to twin shaft design.
Electric Motors (EM)
 Simple Layout, reduced civil
works.
 May avoid gearboxes for 3000
to 3600 rpm CC speeds
 CC’s coupled with Variable
Frequency drives offer more
operational flexibility
 EM efficiencies can reach as
high as 98%
 Motors Capacities ~ 75 MW
(e.g., Freeport LNG)
Steam Turbines (ST)
 Oldest mechanism
 Low usage in recent years
due to increasing capital &
operating costs (steam
boilers, equipment, etc. &
maintenance issues).
 Perceived as “Victorian”
technology

Factors affecting Driver Selection

Compression Capacity
Compressor Configuration
Compression Plant Location
Fuel / Power Requirements for CC operation
Flexibility of Operation

Driver selection key parameters include Power & Operating Conditions

Typical Single Stage Centrifugal Compressor System…
Anti-Surge Valve
3

Suction Hot Gas Bypass Discharge

Vent Valve
Scrubber Valve Scrubber
5
1 2

Discharge
Suction Cooler Block Valve
Block Valve 4

Driver

Compressor

 Suction Scrubber separates moisture & particulate matter  Decided to be added on a case to case basis
 Anti-surge Valve (ASV) protects the compressor from surge during start-up, shutdown & operating
conditions
 Hot Gas Bypass (HGB) Valve is used during shutdown operation for surge avoidance and as a last resort to
avoid overheating the compressor.
 Discharge Check Valve prevents backflow of fluid.
 Air coolers are used to cool the compressed discharge gas.
 Vent Valve is used for compressor system depressurization

One Stage CC System

Typical Simulation of Compressor Startup…
Anti-Surge Valve
3

Suction Hot Gas Bypass Discharge

Vent Valve
Scrubber Valve Scrubber
5
1 2

Discharge
Suction Cooler Block Valve
Block Valve 4

Driver

Compressor
Illustration Purposes
 Compressor is idle Rated Point

 Suction & discharge block valves are closed (1 & 2)

 ASV (3) is kept fully open while HGB (5) is kept closed
 CC Start-up with Driver (4)
 CC speed is ramped up in recycle mode
 Fluid flowing through CC increases & develops head
 MUST be ensured that the operating point stays away
from surge line
 Once operating speed is reached, suction & discharge
block valves (1 & 2) are opened with the anti-surge valve
being closed simultaneously at a certain rate.
m3/hr
Typical Simulation of Compressor Normal Shutdown…
Anti-Surge Valve
3

Suction Hot Gas Bypass Discharge

Vent Valve
Scrubber Valve Scrubber
5
1 2

Discharge
Suction Cooler Block Valve
Block Valve 4

Driver

Compressor
For illustration Purposes
 CC in operation Rated Point

 ASV (3) is opened till operating point moves away

from surge line. HGB (5) valve remains closed.
 Driver (4) Stops & CC system allowed to halt.
 Suction & discharge block valves (1 & 2) close at a
pre- determined rate.
 Operating point reaches zero flow
 MUST be ensured that the operating point stays
away from surge line during shutdown
Improper Shutdown Example…
CC System experiencing surge during ESD
 Operating Point crosses surge upper limit
 Some Possible Reasons
 Under sized ASV – Unable to handle ESD situation
 No Hot Gas Bypass valve/lines present
 Longer ASV response time caused due to
 Higher Discharge Volume
Operating point crosses
surge line during shutdown  ASV with low response
 Inter CC effect CC Series/Parallel arrangement
 Failure/Delayed signal to Anti-surge control system
 Failure of Check-valve at CC discharge

Note
 ASV sizing  Steady state calculation does not account for transient effects (equipment /piping volume).
 During design phase  Emergency shutdown operation can be performed to check for surge
 Dynamic simulation  Identifies if ASV is sufficient to handle surge during ESD also.
 An under designed ASV system requires installation of Hot Gas Bypass (HGB)
 System design with only ASV  Not always feasible due to control Valve limitations (Availability / Construction
limitations). Hence every Anti-surge system to be reviewed on a case-to-case basis.

Solution: Addition of HGB System

Typical Simulation of Compressor ESD with HGB…
Anti-Surge Valve
3

Suction Hot Gas Bypass Discharge

Vent Valve
Scrubber Valve Scrubber
5
1 2

Discharge
Suction Cooler Block Valve
Block Valve 4

0 Driver

Compressor
For illustration Purposes

 CC in operation Rated Point

 Driver Trips (4) due to power failure

 Signal from DCS reaches ASV controller in about
300 msec.
 ASV (3) opens with an ideal time of 2 sec & HGB (5-
On-Off Valve) opens immediately (with lag)
 Suction & discharge block valves (1 & 2) close at a
pre- determined rate.
 Operating point reaches zero flow
 MUST be ensured that the operating point stays
away from surge line during shutdown
Settling Out Conditions…

For illustration Purposes

Settling Out Conditions SOP & SOT Effects

 Pressure (SOP) & Temperature (SOT) is that  (↑) SOP & SOT  (↑) System Inertia (I)  (↑) CC Start-up
which exists when a moving fluid in a Power
compressor system volume comes to rest  CC driver start-up  f (I
CC Rotor + IGearbox+ IDriver + IGas SOP & SOT)
after the compressor is shutdown
 Dynamic Simulations  Predicts Start-up Power accurately
 Conditions are decided by amount of
upstream & downstream piping volume  CC Driver’s start-up incapability requires depressurization
 Downstream cooler duty influences initial  SOP & SOT affected by ambient conditions after shutdown.
SOT. Ambient Conditions decide final SOT

SOP & SOT  Decisive factor for CC Drivers Start-up Capability

Centrifugal Compressor System Design Philosophy…
Factors to be considered for Compressor System Design
 Minimum Power Requirements to reach rated point without surge
 CC Operation at Maximum Efficiency Point at rated conditions
Evaluation to be considered
 Robust Anti-surge System & HGB System (if necessary) for all operating weather
conditions, e.g., Hot, Ambient
 Minimum Piping & Equipment Volumes to reach rated point without surge & Cold weather
 Accurate Relief Valve Size for Depressurization during failure conditions
 Optimum Start-up Time inclusive of Gas Export Conditions
 CC Turn down operating scenarios to be considered

Compressor System FSD Start-up Methods (Common Ones)

 Throttling Valve (Fixed Speed Drives) - Regulatory valve at compressor suction reduces gas density during
start-up which reduces start-up power requirements. Limitation exists on the extent of lowering inlet pressure.
High pressure ratio causes compressor to surge at start-up and hence regulation of gas flow is necessary.
 Circuit Gas Depressurization – Represents monetary loss

Compressor System Controlling Methods

 Speed Control (VSD, e.g. GT/ST/VFD-EM)  e.g., Mark VI Controller for GT & Variable Frequency Drive for EM’s
 Suction Throttling (FSD, e.g. Induction EM + Gear Box)  Discharge pressure controlled by ASV
 Inlet Guide Vanes (IGV’s)  Functionality similar to a throttling valve but with highly increased capabilities
 Cold Discharge Bypass (FSD)  To regulate discharge pressures by recycling cold discharge gas to suction
 Discharge Venting (FSD)  To be avoided in case of hazardous gases

CC System Design Dependent on Scope of Operation FSD – Fixed Speed Drives

VSD – Variable Speed Drives
Typical Anti Surge System…
For illustration Purposes
3 Anti-Surge Valve

DCS
Suction Discharge
Vent Valve
Scrubber Scrubber

FT TT PT TT PT FT
1 2

Discharge
Suction Orifice Cooler
Orifice Block Valve
Block Valve 4 Measured
Measured

CC Driver

ASV Typical Requirements Types of ASV Opening Characteristics

 Fast Response to Surge < 2s (~4” to 16” valves)
 Fail Open Mode Type
 High Capacity to handle start-up’s & shutdown’s
 Fluid Velocities < 0.3 Mach to avoid possible ASV
& piping damage.
 Quick Opening – Suffers from Poor throttling
characteristics
 Equal Percentage – Valve opening occurs slowly
during the initial time period and accelerates after
the ~50% mark

 Stable Throttling  Linear – Traditionally used by most manufacturers.

 Actuator Opening time during surge  < 300ms
Lower response times is preferred.
 Noise Limit ~ 85 dB < 110 dB (Max)
Provides good pressure throttling.
 Blend of any of above characteristics  For Fast
response
Type 1: Suction Side Measurement

ASV Response to Surge Should be Fast Type 2: Discharge Side Measurement

(Note: Only one configuration used at a time)
Recycle Arrangements…
1. Basic Recycle System 2. Recycle System with Discharge Cooler

 (+) Small Discharge Volume, Fast response  (+) Full Recycle  Reduces surge to larger extent
 (-) Only Partial recycling  Absence of cooler causes  (-) Additional piping volume impacts recycle response
hot fluid to mix with incoming fluid. Applicable only
for small pressure ratios

3. Pre-cooling & Post-cooling 4. Cooler Recycle Loop

 (+) Small Discharge Volume, Fast response. 100%  (+) No Inline pressure loss
recycle possible. Improves compressor efficiency  (+) Small discharge volume, fast response
 (-) Requires an additional cooler (increases cost)
 (-) Additional cooler required
Recycle Arrangements (contd)…
5. Hot Gas Bypass 6. Parallel Recycle Valves

 (+) Provides good modulation during shutdown  (+) Good modulation during surge control & fast shutdown
 (-) Extra piping/HGB valve add to the overall cost  (-) Additional piping volume/valves impact cost

7. CC-2 larger than CC-1 8. Recycle for multiple CC’s

 (+) Good modulation during surge control & fast  (+) Modulates surge control for individual compressors
shutdown  (+) Similar to arrangement No.5 but with relatively
 (-) Additional piping volume/valves add to cost reduced piping costs due to combined ASV system
Centrifugal Compressor Driver Arrangements…
Series Arrangement – EM/VFD-EM/GT/ST
 (*) CC’s are driven independently.
 (-) Failure of one EM causes CC system shutdown
Series Arrangement – GT/ST – Common Shaft
 (+) Fuel requirements are simplified
 (+) Both compressors run at same speed
 (-) Additional power & shaft deflection to be considered.
 (-) Failure of driver causes CC plant shutdown
Parallel Arrangement – EM/VFD-EM/GT/ST
 (+) Failure of 1st CC does not stop the 2nd CC
 (-) Load sharing scheme to be provided
Series Arrangement – GT + VFD-EM Coupling
EM
 (+) Provides additional power during startup.
 (+) EM provides starting torque for GT till firing point
after which EM behaves as a generator
 (+) EM provides additional power to GT during summer
when GT efficiency is reduced.
General Notes…
 Surge can occur not only during start-up or shutdown but also during Normal Operating Conditions when the
following can take place - Load changes, process upsets, gas MW changes, operator errors, driver problems,
cooler failure, etc.
 Seal Gas System selection to be made taking into consideration hydrate formation.
 Increase in Gas MW causes shifting of CC maps to shift towards upper diagonal region while decrease in Gas
MW causes the shift to take place towards lower diagonal side.
 Hot Gas Bypass systems are decided by performing a dynamic simulation to check for adequacy of ASV
provision. In case of inadequacy, HGB system is added.
 The ASV system should not be oversized as it can result in poor regulation. Additionally it would bring the CC
operating point to the stone wall region due to excessive flow
 GT + VFD-EM combination used for very large trains (e.g., LNG Applications)
 Inertial effects of driver rotor determines start-up time. Increase in rotor mass adds to the inertia.
 Anti-surge Line  As close as possible to the discharge piping. However this position is also dependent on
vibrational effects.
 A limit of 50% HGB line sizing on volumetric flow is recommended to avoid overheating of CC. Actual sizing
could be made lower.

References…
 “Surge Avoidance for Compressor System”, Robert C. White, Rainer Kurz,

http://turbolab.tamu.edu/proc/turboproc/T35/16-WHITE.pdf