Beginners 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
MWgas 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) Electric Motors (EM) Steam Turbines (ST)
Widely used in the last 30 Simple Layout, reduced civil Oldest mechanism
years. works.
Low usage in recent years
Disadvantage of COX and NOX May avoid gearboxes for 3000 due to increasing capital &
emissions & relatively lower to 3600 rpm CC speeds operating costs (steam
efficiencies. boilers, equipment, etc. &
CCs coupled with Variable
maintenance issues).
Intensive maintenance. GT Frequency drives offer more
efficiency depends on ambient operational flexibility Perceived as Victorian
conditions. technology
EM efficiencies can reach as
Aero derivative turbines offer high as 98%
the advantage of variable speed
Motors Capacities ~ 75 MW
due to twin shaft design.
(e.g., Freeport LNG)

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 Power
which exists when a moving fluid in a CC driver start-up f (ICC Rotor + IGearbox+ IDriver + IGas SOP & SOT)
compressor system volume comes to rest
after the compressor is shutdown Dynamic Simulations Predicts Start-up Power accurately
Conditions are decided by amount of CC Drivers start-up incapability requires depressurization
upstream & downstream piping volume SOP & SOT affected by ambient conditions after shutdown.
Downstream cooler duty influences initial
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 EMs
Suction Throttling (FSD, e.g. Induction EM + Gear Box) Discharge pressure controlled by ASV
Inlet Guide Vanes (IGVs) 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) Quick Opening Suffers from Poor throttling
Fail Open Mode Type characteristics

High Capacity to handle start-ups & shutdowns Equal Percentage Valve opening occurs slowly
Fluid Velocities < 0.3 Mach to avoid possible ASV during the initial time period and accelerates after
the ~50% mark
& piping damage.
Stable Throttling Linear Traditionally used by most manufacturers.
Provides good pressure throttling.
Actuator Opening time during surge < 300ms
Lower response times is preferred. Blend of any of above characteristics For Fast
Noise Limit ~ 85 dB < 110 dB (Max) 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 CCs

(+) 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 Parallel Arrangement EM/VFD-EM/GT/ST

(*) CCs are driven independently. (+) Failure of 1st CC does not stop the 2nd CC
(-) Failure of one EM causes CC system shutdown (-) Load sharing scheme to be provided

Series Arrangement GT/ST Common Shaft Series Arrangement GT + VFD-EM Coupling

EM

(+) Fuel requirements are simplified (+) Provides additional power during startup.
(+) Both compressors run at same speed (+) EM provides starting torque for GT till firing point
after which EM behaves as a generator
(-) Additional power & shaft deflection to be considered.
(+) EM provides additional power to GT during summer
(-) Failure of driver causes CC plant shutdown
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