Re-rate Feasibility Analysis of Centrifugal Compressor

Compressor can be modified to obtain increased production

through increasing its capacity, pressure or both. This is termed
as rerating of compressor.
One way to obtain an increase production lies in the purchase
of new equipment, but however one can rerate, i.e. rebuilt, an
existing compressor to provide the required increased
parameters. Even if the compressor requires a new rotor and an
internal stationary hardware, one can usually still salvage the
compressor casing.
Most often greater throughput can be obtained only with a
minor change in pressure levels. In such cases, we can probably
reuse a significant amount of existing hardware.
Some problem always appears when considering rerating. No
way exists to change the casing size or the bearing centerline
distance. One cannot change the nozzle locations, and only a
limited number of impellers will fit in any section of the
compressor.
When considering rerate the following questions and answers
shall be kept ready in mind: What pressure levels we need for
the compressor? How will the compressor’s operation affect the
overall process?
In order to determine the rerate feasibility of a compressor, we
must consider:
1. Capacity – Will the size of nozzle accept the projected
increase in flow?
2. Kilowatt - Will the motor, motor-gear, turbine, turbine-gear
handle the increased kilowatt?
3. Pressure – Can the casing accommodate the intended
pressure levels? Can the compressor aerodynamically meet
these levels?
4. Speed – Will the compressor handle the required speed within
the API (taking into consideration of all critical speeds).
We will now review these four considerations, presenting them,
as above, in order of their importance.

Rerate Feasibility: Capacity

The most important consideration for capacity lies in nozzle

sizes. One must determine whether the nozzle size will pass the
required volume-flow with a reasonable pressure-drop. An
existing compressor possess fixed nozzle size- the geometric
size of the nozzle sets the maximum volume flow
possible. Hence we can reduce the analysis to the consideration
of inlet velocities.
Although inlet-velocity limits vary with conditions, a rule-of-
thumb sets the limit at a maximum of 43 m/s (140 f/s) for air
and lighter gases.

The following equation determines the actual inlet velocity Va:

Va = 3.06 Q / D2 . . . . . .(1)

D= Inside diameter of the nozzle flange in inch

Q= Flange inlet volume flow ft3/min based on rated inlet
conditions, i.e. inlet pressure, compressibility factor and
molecular weight.

Since velocity limitations set the maximum capacity, the

maximum velocity of 43 m/s (140 f/s) can limit one when
rerating a compressor. With geometrically sound inlet piping,
we may get higher inlet velocities possible.
Manufacturers furnish compressors with inlet nozzles other than
the main inlet. The design some compressors with side-load
nozzles, some with inter-stage cooling nozzles, some with a
combination of both. We shall use the above inlet-velocity
criteria for all inlet nozzles, and check all inlet nozzles for gas
velocities.

The more the inlet velocity, the more will be the power. The
more the inlet velocity, the less will be the Polytropic head.

Once we can decide the compressor can pass the desired

capacity, we can investigate the effect of the increase on the
kilowatt required.
Rerate Feasibility: Kilowatt

We must include power requirements as the second major

consideration in a rerate feasibility analysis. This holds
especially true in the case of motor driven compressors, since
customers do not purchase oversized motors along with the
original equipment. However one can usually rebuild gears and
turbines to provide greater power capacity. It may be required
to buy a new motor which may lead in some cases to
foundation problems.

The compressor will require power approximately proportional

to the increase in flow desired. This means that an increase in
flow of 20% will dictate an increase in kilowatt of at least 20%
(or 12 times the original power). Moreover, the manufacturer
will usually advise at least an additional 10% kilowatt
availability to take care of overload. Therefore, a 20% flow
increase will result in an increase of approximately 32% in
power requirements.
1.2+ 1.2x10%= 1.32
With this additional 2% shall be considered for gear loss in a
motor- gear-compressor unit.
If the driver cannot deliver the required horsepower to the
compressor, we need to buy a new driver or relax the scheduled
production increase until we can reduce the required flow to
within the capabilities of the driver.

Rerate Feasibility: Pressure

We then consider the Hydrostatic test pressure. Compressor
casing is hydrostatically tested to 150% of the maximum
expected operating pressure. Compressor aerodynamics may
set the maximum operating pressure, or the process may set it
by employing a Relief Valve in the system.
If the expected pressure levels of the new process exceed the
name plate maximum pressure, one should make a new
hydrostatic test. When the compressor is made up of multi
sections with inter-stage cooling, then all sections shall be
hydrostatically tested with the inlet section at a lower pressure
than the outlet section. In such cases we shall review both
sections for the possibility of exceeding the maximum sectional
safe operating pressure.

Then we shall investigate the compressor’s aerodynamic ability

to deliver the required head, i.e. polytropic head which is the
amount of work done by the compressor. The following equation
relates the polytropic head Hp (in Feet) to the desired pressure
ratio rp:

Hp = ZRT [n/(n-1)] [rp (n-1)/n - 1] . . . . (2)

Z: Average compressibility factor

R: Gas constant, 1545/mol.wt
T: Inlet temperature, oR
rp : Compression ratio, Pdis/Pinlet
(n-1)/n : Polytropic exponent ratio, 0.349
(n-1)/n =[ k/(k-1)]ηp
(k-1)/k: Specific heat exponent, 0.255

Although the polytropic efficiency can vary from 68% on small

impellers to 83% on ideal impellers , for a feasibility analysis
one can assume a polytropic efficiency of 70%.
The following equation can give both the original polytropic
head and the rerate polytropic head requirement. With the
original rated speed known, from the Fan Law, we can also find
the rerate polytropic head requirement.

Nrerate = Noriginal (Hp rerate/ Hp original)1/2 . . . (3)

N: rpm
Hp: polytropic head, Ft

The speed calculated from the above Fan Law may turn out too
high for safe operation. However the manufacturer can
sometimes obtain increased polytropic head by adding an
impeller, or replacing the existing impellers with ones of lower
backward lean. The manufacturer will ultimately have to
determine the feasibility of obtaining the required head.
We can make a quick estimate of the maximum head capability
of our compressor. If the compressor contains a “blank” stage
(space with no impellers), the following equation will determine
the approximate maximum head capability with no change in
speed:

Hp max = Hp original [(a+b)a] . . . . (4)

a: Number of impellers in original rotor

b: Number of “blank” stages in original configuration
One can then apply the “Fan Law” along with the above
equation to determine the approximate polytropic-head
capability of the compressor. This procedure should yield a
polytropic head within 10% of the maximum compressor
capability.

Let us consider we have compressor comprised of two sections,

sections 1 and 2. Let us determine the head for section 1,
based on the operating parameters of section 1, i.e. inlet
temperature, inlet pressure, discharge pressure. Similarly the
head for section 2 based on section 2’s operating parameters.
The sum of all sectional head requirements yields the total head
requirements for the rerate. One can determine the total head
requirements for the original rated point in a similar manner,
derive the approximate rerate speed from Nrerate = Noriginal
(Hp rerate/ Hp original) as before.

Increase in head affects the power requirement. Horse power

directly proportional to the polytropic head:

GHP = W Hp / (33000 ηp) . . . .(5)

GHP= Gas horse power

W = Weight flow, pound per min
Hp= Polytropic head
An increase of 20% in polytropic head will raise 20% power
requirement. For example, if an increase of 20% in weight flow
is coupled with one of 205 in polytropic head, the power
requirement will rise by 44% (1.20 x 1.20 = 1.44). To this figure,
an additional of 10% horsepower
shall be added for overload. A 2% gear loss should also be
added.

Rerate Feasibility: Speed

The final consideration is that of rotational speed. Two major
criteria shall be satisfied:
1. The rotational speed must be slow enough not to overstress
the impellers
2. The rotational speed shall fall within certain limits of
compressor’s first and second critical speeds.
The first criteria above is the best from the stand points of
mechanical tip-speed limitations. Mechanical tip speed U (ft/s)
shall be calculated by –

U = πdn/720 . . . (6)

d : Tip dia of largest impeller, inch

n: rpm

Mechanical tip speed varies with material of construction of

impeller, thickness of impeller, size of impeller and
manufacturer. A typical mechanical tip speed might be 900 f/s
(274 m/s).

Let us take a sample problem as a lesson. Let us consider a

centrifugal compressor handling dry air having the following
name plate data:

Inlet capacity = 11000 icfm (18689.12 m3/h)

Inlet temperature = 90 oF (32.22 oC)
Rated inlet pressure = 55 psia (3.86 kg/cm2a)
Rated power input = 1700 hp (1267.69 kW)
Rated speed = 8100 rpm
Max continuous speed = 8500 rpm
First critical speed = 4800 rpm
Rated molecular weight = 28.97
K = Cp/Cv = 1.4
Max discharge pressure = 65 psia (4.57 kg/cm2a)

The following data are found out from the data file:

The second critical speed = 10800 rpm

Smallest weel diameter = 22 inch
Inlet nozzle diameter as 20 inch (508 mm) from the certified
cross sectional drawing.
Desired rerate :
a) Inlet capacity to 12300 icfm (20897.83 m3/h)
Discharge pressure to 60 psia (4.218417 kg/cm2)

Let us find out :

Inlet velocity based on new inlet volume flow

Using eqn (1)

Va= 3.06 Q/D2 = 3.06 [12300/ (20)2] = 94 ft/s

This is an acceptable inlet velocity, the proposed capacity is

feasible.

b) Since the rated inlet conditions have not changed, the

increase in weight flow will be proportional to the increase in
volume flow, and therefore the power requirement due to the
change in volume flow will be increased proportionally;

GHP rerate / GHP original = W rerate / W original = Q rerate / Q

original = 12300/ 11000 = 1.12

GHP rerate = 1.12 GHP original = 1.12x 1700 = 1910 hp

Additional of 10% horsepower of this
1910 x 1.10 = 2100 hp
Plus 2% gear loss shall be considered with this.
c) Since the name plate maximum discharge pressure is 65
psia, the compressor will not have to undergo hydrostatic
pressure test, the process will not allow 65 psia to be exceeded.

d) Using eqn 2
Original:
Hp = ZRT [n/(n-1)] [rp (n-1)/n - 1]

(n-1)/n =[ k/(k-1)]ηp = [1.4 / (1.4- 1)](0.76) = 2.66 putting

this value into the above eqn
Hp = ZRT [n/(n-1)] [rp (n-1)/n - 1]
= (1.0) x (1.545/ 28.97) x (550)x (2.66) x (55/14.5)1/2.66 -
1
= 50700 ft
Rerate:
Hp = (1.0)(1545/28.97)(550)(2.66)[(60/14.5)1/2.66 -1]
= 55000 ft

The new required speed can be calculated from “Fan Law”

eqn (3)
Nrerate = Noriginal (Hp rerate/ Hp original)1/2
 = 8100(55000/50700)1/2
= 8440 rpm

From eqn (6)let us find out the mechanical tip speed

corresponding to the above new rpm ,
U = πdn/720
= (3.14x 22x 8440) / 720
= 810 ft/s which is satisfactory.

API states that the second critical speed shall be 20% above the
maximum operating speed.
Assuming the new rerate rpm is the height for the new
parameters, the new critical speed shall be at least:
8440 x 1.2 = 10128 rpm
The second critical speed (10800 rpm) is more than the above
value and therefore the rotational speed is feasible.

e) The increase in GHP will be calculated as follows:

The new horse power will be proportional to the increase in
polytropic head and the weight flow (volume flow):

GHP rerate / GHP original = (Hp rerate/ Hp original) (Q rerate / Q

original)
 GHP rerate / GHP original =
(55000/50700)(12300/11030)
GHP rerate / GHP original = 1.12
So, GHP rerate = 1.12 x GHP original
= 1.12 x 1700
= 2060 hp
20% shall be added with this in case of gear loss.

Since the inlet velocity, maximum operating pressure and the

required rotational speed are within satisfactory limits the
rerate is feasible.