Centrifugal

Compressors
Construction and
Maintenance

Presented by: S. H. Butt

CONTENTS
 Compressor
 Compressor Types
 Centrifugal Compressor
 Centrifugal Compressor Construction
 Centrifugal Compressor Instrumentation
 Centrifugal Compressor Auxiliaries
 Maintenance Philosophy
 Compressor Assembly / Disassembly CBT
 Alignment
 Maintenance Tips / Safety Precautions
Compressor
 A compressor is a device used to increase the
pressure of a compressible fluid.
 The inlet and outlet pressure are related
corresponding with the type of compressor
and its configuration.
 Application of compressed gas vary from
home refrigerator to large petrochemical plant
installations.
 Compressors

Intermittent Continuous
Flow Flow

Positive Displacement Dynamic Ejector

Reciprocating Rotary Centrifugal

(Radial Flow)
Mechanical Sliding Vane Mixed Flow
Piston Liquid Piston
Helical Lobe Axial Flow
Straight Lobe
Centrifugal Compressor
 Centrifugal Compressor

 Dynamic Compressors which are based on

the principle of imparting velocity to a gas
stream and then converting this velocity
energy into pressure energy are termed as
Centrifugal Compressors‟.
Compressors Application

Compressor’s Application
Main Components
 Impeller
 The part of centrifugal compressor that moves the gas is the
impeller. As the impeller rotates, it moves the gas toward the
outer rim of the impeller and thus its velocity increases.

 Diffuser
 As the gas leaves impeller, it flows into a passage-way called the
diffuser. The diffuser being larger in volume, the velocity of gas
decreases and its pressure increases.

 Volute
 Gas passes from diffuser into the volute. In the volute, the
conversion of velocity energy to pressure energy continues.
Centrifugal Compressor Types
(On The Basis of Stages)

 Single - Stage Centrifugal Compressor

 As name refers, Single Stage Compressor employs
only one impeller to impart energy into the gas.
 Multi - Stage Centrifugal Compressor
 A multi-stage compressor employs more than one
impeller to impart energy into the gas.
 The velocity is added to gas by the impeller of each
stage. This velocity is converted into pressure within
the diffuser. Thus, each impeller adds to the total
energy (pressure) of the gas.
Multi – Stage Centrifugal Compressor
 Multi – Stage Centrifugal Compressors are
available in different arrangements, each having
distinct flow path and characteristics.
 Straight-Through Flow
 Double Flow
 Side Streams
 Iso-Cooling (cooling between stages)
 Double Iso-Cooling
 First Section Double-Flow
 Back-to-Back
 Back-to-Back with Recirculation Feature
Centrifugal Compressor Types
(On the Basis of Casing Design)

 Horizontally split casing.

 This design is generally used at low pressure up to 60
bar.
 The two halves of the casing are joined at the
horizontal centerline by hydraulically tightened stud
bolts and nuts.
 Horizontally split casing is preferred as accessibility to
compressor internals‟ is easier.
Centrifugal Compressor Types
(On the Basis of Casing Design)

 Vertically split casing.

 When a compressor is used for moderate to high
pressures, to minimize the chances of leaks, a
vertically split casing is used.
 The casing is either cylindrical or bell shaped,
depending upon the pressure rating.
 Diaphragms halves are placed into split cylinder
halves called Barrel.
Nomenclature
Compressor Rotor Assembly
 The main rotating components of a typical
centrifugal compressor are described below:
 Rotor Shaft
 The shaft serves as the main element of the rotor,
transmitting the torque from the driver to the impellers. The
largest diameter is located in the middle of the shaft and
supports the impellers and spacer pieces.
 Impeller
 The impellers add energy (velocity) to the gas.
Compressor Rotor Assembly
Impeller Types
 Open Impellers
 These are used for large heads and small to large flow in single
stage compressors only. The flow is least controlled.
 Semi-enclosed Impellers
 These are used for large flow, usually in single stage
compressors, or as the first stage in multistage compressors.
 Enclosed impellers
 Multistage compressors usually have enclosed impellers. The
flow of gas is best controlled in enclosed impellers. To prevent
vibration the impeller is shrunk onto the shaft and prevented
from turning on the shaft by a key and is well balanced.
Compressor Rotor Assembly
 Thrust Collar
 The thrust collar transmits the rotor thrust to the thrust
bearings and fixes the axial position of the rotor. It is
hydraulically shrink fitted on the rotor shaft.
 Balance Drum
 The centrifugal compressor rotor is subjected to an axial
thrust during operation. The balance drum compensates for
the majority of this thrust.
 Spacers
 Spacers located between the impellers determine the axial
position of each impeller. It also provides a sealing surface
for the labyrinth seals located between impellers and also
protects the shaft from seal rub and corrosion.
Diaphragms Assembly
 Multistage centrifugal compressor contains diaphragms
located between impellers. Adjacent walls of the
diaphragm form a passage called the diffuser that guides
gas into the next impeller.

 Diaphragms are split horizontally and these halves are

machined to fit into the casing.

 Grooves are machined on the faces of these diaphragm

halves for elastomers so as to avoid inter stage leakage.
Guide Vanes
 The gas that leaves an impeller passes though
the diffuser passage. In the return passage, guide
vanes guide it into the next impeller.

 The inlet guide vanes can be adjustable. With

adjustable guide vanes, the angle of gas flow into
the eye of the impeller can be controlled. In this
way capacity of compressor can be controlled.
Inter Stage Seals
Rotor shaft passes through the diaphragms.
Since diaphragms and rotor are not attached
to each other, the gas can flow from higher-
pressure region to the lower pressure region
through the space between shaft and
diaphragms. Seals are used between the
shaft and the diaphragms to prevent
leakage. The most common type of seal
used for this purpose is labyrinth seal.
Inter Stage Seals
 Labyrinth Seal
 It is a set of metal rings or teeth that encircle the shaft
but do not touch it. The rings or teeth are made of soft
metal, and are sharp so that in case of accidental
contact, less friction is generated and shaft is
prevented from damage.
 Labyrinth seals are available in the following
configurations:
 Plain Labyrinth Seal
 Step Labyrinth Seal
 Abradable Labyrinth Seal
Inter Stage Seals
 Labyrinth Working Principle

The spacers between the teeth form

labyrinth passage. As the gas enters the
space between teeth, eddies are formed. It
slows the gas velocity and changes
direction. The resulting turbulence resists
the flow of gas.
Inter Stage Seals
 Characteristics
 Labyrinth Seal does not prevent all leakage. If the gas
velocity is high, some of the gas does not change
direction in the seal but skips between the teeth and
the shaft in straight line. Where gas is flowing at high
velocity interlocking labyrinth seal is used. i.e.
Labyrinth Seal interlocks with shaft teeth.
 These seals are used in areas where it is acceptable
to allow leakage. Labyrinth seals are therefore widely
used as inter stage seals because the pressure
difference between stages is normally low enough for
labyrinth seal to be effective.
Shaft End Seals
Shaft End Seals serve the following three
purposes:

 Increase compressor efficiency

 Prevent process gas contamination

 Avoid contact between the process gas and the

lube oil
Shaft End Seals
 Labyrinth Seal
 Labyrinth seal may also be used as shaft end seals.
These seals are used when no leakage of poisonous
or explosives gases to the atmosphere is allowed.
 The space between the seals can be injected with a
buffer gas at a pressure higher than the process gas
pressure. This solution is used when no leakage of a
potentially poisonous or explosive gas to the
atmosphere is allowed
Shaft End Seals
 Oil Seal
 Oil seals consist of steel rings with babbitted bores,
like bearing. They are free to move radially as the
shaft moves. They have lapped surfaces on their
mating faces.
 Seal oil is injected between the one inner ring on the
compressor side and the outer rings at a pressure
slightly higher than that of the gas pressure. Some of
the oil flow inside the casing, which is drained away as
contaminated seal oil or sour oil.
Shaft End Seals
 Mechanical Seal
 Mechanical seal is a positive type of seal and is used in
flammable and toxic services. A conventional Mechanical Seal is
consists of following parts:
 Carbon Ring
 Rotating Seal Ring (Seat)
 Stationary Sleeve
 Springs and Spring Retainer

Oil is injected into the seal to keep the two faces apart
during operation. This oil gets contaminated with the
process gas and therefore drained away as
„contaminated oil‟
Shaft End Seals
 Dry Gas Seal
 Main parts of Dry Gas Seal are same as that of normal
Mechanical Seal. However, rotating seat is
manufactured from tungsten carbide or silicon carbide
and it is profiled with a series of spiral grooves. Depth
of grooves ranges between 0.0025 to 0.01 mm
 When the compressor is pressurized, sealing dam
seals the gas. When compressor is running, gas
enters the spiral grooves and its pressure increases as
it travels in. This increases in pressure forces the two
faces apart approx. by 3 microns, and maintains this
operating clearance.
Shaft End Seals
 Dry Gas Seal eliminated many problems, which the
operators were experiencing with oil seals. Major
advantage is a reduction in contamination of the
process gas that commonly occurs with the use of seal
oil.
 Consequently, there is an increased efficiency and a
cost reduction in compressor usage.
 Dry Gas Seals are available as Single, Tandem and
Triple Dry Gas Seal units according to the number of
seal rings.
 The single Dry Gas Seal is used mainly for carbon
dioxide or non toxic applications.
DGS Working Principle
 DGS Installed in CO2 Comp.

SEAL VENT CLEAN GAS

BEARING GAS
SIDE SIDE
DGS Installed in Syn. Gas Comp.
CLEAN PRIMARY SECONDARY
GAS VENT VENT

NITROGEN
SUPPLY

GAS BEARING
SIDE SIDE
 DGS Sealing System (Syn Comp)

N2 SUPPLY

SEC. VENT

PRIM. VENT

CLEAN GAS

FILTER
5 MICRONS

COMPRESSOR
DISCHARGE GAS
Bidirectional DGS

Bidirectional
T - Grooves
DGS Common Problems
 Injection Gas Contamination

 Failure of Elastomers

 Chemical Incompatibility
Compressor Bearings
Centrifugal Compressors are equipped with
journal and thrust bearings.
 Journal Bearing
 The Rotor is supported at each end by Journal
Bearings. Journal Bearings are hydrodynamic
bearings with tilting pads. Each pad develops an oil
pressure wedge that support the weight of the rotor.
 A tilting pad is a steel block with a pivot button on its
back that allow the pad to tilt within the bearing seat.
The bearing pad‟s surface is coated with a thin layer of
white babbit metal (alloy of Lead & Tin).
Compressor Bearings
 Recently bearing manufacturers have developed a
new design of bearing pad. This new bearing pad has
flexure pivot tilt instead of rocking pivot tilt. The one-
piece construction of this particular tilt pad bearing
eliminates the multi-piece construction and thus
reduces the manufacturing tolerances.
 A thermocouple is embedded into the selected pad to
measure the bearing‟s pad metal temperature.
 Journal Bearings are also available in sleeve type
construction
Compressor Bearings
 Thrust Bearing
 One of the most critical components of a centrifugal compressor
is the thrust bearing. Axial thrust is generated in a centrifugal
compressor by the pressure rise through the impellers.

 Major portion of the axial thrust is countered by either a

balancing drum or by placing impellers in a back-to-back
arrangement. In either case, the small residual load is carried by
the thrust bearing.

 Thrust bearing must also be designed to withstand the thrust

reversals that may occur during normal operating conditions.
Couplings
Couplings are the connecting elements between the
compressor and its prime mover or between
compressor‟s different stages.

 Construction
 In a particular flexible Shim Pack Coupling, there are two hubs,
one installed to each shaft end, a spacer and the flexible
elements located between the spacer and hubs.

 Previously „Keyed Hubs‟ were designed but now hubs are mostly
hydraulically shrink fitted on the tapered shaft end.
Couplings
 Coupling Functions
 Efficient transmission of mechanical power from one
shaft to the other.
 To compensate all types of misalignment without
inducing abnormal stresses and load on connected
equipment and without significant loss of power.
 To compensate the axial movement of the coupled
shafts, preventing either shaft from exerting excessive
thrust on the other.
Hub /Coller Mounting Tools

Oil responsible for

expanding the hub

Oil responsible for

pushing the hub
Compressor Instrumentation
The instrumentation installed on centrifugal
compressors is essential for checking their
performance and activate a protection system if
necessary. Compressor manufacturers employ a
variety of instruments for monitoring rotor radial
vibration, axial displacement of the rotor and
bearing temperature.
Compressor Instrumentation
 Vibration Probes
 Proximity probes are used to detect both radial
vibrations and axial displacement of the rotor. These
probes should be firmly secured to the compressor
casing and should be positioned close to the shaft for
accurate readings.
 Thermo elements
Journal bearings and thrust bearing temperatures
can be obtained by the following two way:
 By inserting a thermo element in one or more pads
close to the bearing white metal.
 By immersing a thermo element in the compressor oil
discharge pipe.
Probe Position
Probe
In-line with
shaft

Thrust Shaft
Probe
In-line with Thrust Collar
Collar
Axial Displacement Probe

SHAFT
PROBE 45O
Radial Vibration Probe
SPRING MASS SYSTEM
Sensing Signal

OUTPUT
COM
-24 V DC
Vibration Monitoring System

Display

Oscillator Modulator
(Driver)

Extension Cable
Trend Recorder

Proximity Probe /
Rotor Eddy Current Probe
Rotor Damage
Diaphragm / Seals Damage
Compressor Instrumentation
 Antisurge Sysytem
 The purpose of the antisurge control system is to
keep the operating point, at each respective speed,
from surpassing the surge limit line. At the same time,
the antisurge control system allows the compressor to
maintain a safe working range.
 The control system accomplishes this task by opening
the antisurge valve at the appropriate moment. If this
system is not used, instability can occur, which can
potentially damage the compressor.
Compressor Lubrication System
 Lube oil is used to create lift by forming a film of
oil between the shaft and bearings and to cool
the bearings.
 Maintaining correct oil viscosity is very important.
Good oil viscosity works to maintain the correct
operating characteristics of bearings, improves
rotor dynamics behavior and reduces compressor
vibrations.
 The same trouble may occur if the oil flow to the
bearings is insufficient or if dirt is present in the
oil.
Compressor Lubrication System
 Lubrication circuit consists of the following
components:
 Oil Tank

 Oil Pumps

 Oil Filters

 Oil Coolers

 Pressure Control Valve (PCV)

Maintenance Concept

 Troubleshooting
 Correct installation of centrifugal compressor units and
a maintained inspection schedule enhance machine
operation, minimizes the risk of shutdowns and
emergencies. However, when problems arise, it is
extremely important to identify the possible causes
and accordingly to take appropriate remedies.
Maintenance Philosophy
The maintenance philosophy may be divided into
the following three types:
 Major Maintenance
 Major maintenance refers to accessing the internal
parts of the compressor, such as the rotor, diaphragm
bundle and internal labyrinth seals.
 Minor Maintenance
 Minor maintenance refers to accessing such area as
the journal and thrust bearings and the shaft end
seals.
Maintenance Philosophy
 Preventive Maintenance
 Preventive maintenance consists of precautionary
actions that occur at prescribed inspection intervals
and routine check periods. These inspections are
conducted to prevent possible equipment breakdown
or failure during operation.
 Depending upon the specific compressor component,
preventive maintenance inspections and actions vary
in regard to their prescribed performance intervals.
 Consult compressor‟s maintenance manuals for
specific preventive maintenance actions and their
intervals.
Compressor Maintenance
 Abnormal Noise and Vibrations
 Probable causes may be misalignment, coupling
failure, unbalanced rotor, worn out or loose bearings

 Journal Bearing Failure

 Journal bearing failure can be attributed to improper
lubrication, incorrect bearing clearance, presence of
any crush
Compressor Maintenance
 Thrust Bearing Failure

 Consider excessive thrust or improper lubrication as

potential causes of failure of the thrust bearing.

 Bearing failure can also be happened due to faulty

bearing fitting and axial probe setting.

Compressor Maintenance
 Seal Failure
 Excessive machine vibrations can contribute to oil seal
ring failure. Insufficient oil supply can also damage the
oil seals.
 In case of dry gas seal, incorrect seal assembly,
excessive vibrations and dirty gas can cause severe
damage to the seal.
Alignment
Bringing the rotating members of driver and
driven machine in line / desired line is referred as
Alignment
 Radial alignment
 Radial Vertical Alignment
 Radial Horizontal Alignment

 Axial Alignment
 Axial Vertical Alignment
 Axial Horizontal Alignment
Important Tips for Alignment
 Always carry out the alignment job in the early
part of the day. This will help in precluding the
error, which can occur due to sunlight.
 Shims should be kink free. Also try to keep the
number of shims as less as possible.
 Before alignment, always ensure that there is no
“soft footing” in the machine. If it exists, remove it
prior to align.
 Before decoupling the machine, always take
alignment reading. It serves as a reference
reading, as some time it becomes difficult to get
the desired readings.
Important Tips for Alignment
 Connected piping / supports have a tendency to
induce stresses in the machines during operation
if they are not properly designed. If machine gets
misaligned during operation, review the
connected piping and supports.
 Do not expect symmetrical thermal growth in
unsymmetrical machines.
 If the machine to be aligned has six feet, it should
be aligned by Graphical Method.
Maintenance & Safety Tips

 Arrange all tools necessary for service in a

container near the machine.
 Use the set of special tools supplied by
manufacturer.
 Isolate the compressor from the process gas.
 Isolate electrically the equipment.
 Make sure that the driver cannot be started.
 During assembly, fully comply with assembly
drawings. Follow bolt torque sequence and
torque values given in the instruction manual.
Maintenance & Safety Tips
 Lift, by some millimeters, the upper half – casing
by means of lifting screws only.
 Rest the rotor on wooden V-notch stand. Cover
the V-notch with soft gasket material.
 Clean the rotor with proper thinner/kerosene oil in
a ventilated place.
 Do not remove diaphragms unless found
damaged.
 Do not remove any part of the rotor except for the
thrust collar.
Maintenance & Safety Tips
 Do not use a chisel to remove gaskets attached
to the surface. Carefully slide a blade between
gasket and surface. Damaging to the
compressor-sealing surface can be avoided in
this way.
 If the bearings are found damaged, perform
thorough cleaning to avoid further damage due to
contamination of oil by metallic particles.
 Use soft hammer during replacement of labyrinth
seal. Do not force it, it is advisable to remove and
adjust.
Maintenance & Safety Tips
 Do not attempt to expand the hub without some
restraint for the hub.
 Avoid injury from high pressure oil leaks by
wearing heavy gloves and a face shield.
 When the rotor is supported by the internal
labyrinths, it must not be moved or the labyrinth
will be damaged.
 Take care not to damage the bearings
thermocouple leads and the cables of proximity
probes.
Maintenance & Safety Tips
 Cover up all the pipe openings, when bearing
casing halves are dismantled during major or
minor machine maintenance.
 When hoisting system are used, ensure that they
are perfect. Best practice is to check all these
equipment before the commencement of any
major maintenance.
 Copper based anti-seize compounds can cause
corrosion failures and should never be used.
 While lifting the bearing casing upper covers,
take care not to damage the flat faces.
Maintenance & Safety Tips
 During assembling, apply equal amount of liquid
sealant on the flat faces.
 During assembling of horizontal split casing,
follow the studs tightening sequence from center
to extreme sides.
 While adjusting the rotor float, always keep the
shim behind the active side thrust bearing.
Ensure the installed shim should be kink free.
 Always use appropriate design bridge to hold the
rotor, when complete bearing block is required to
be removed.
Maintenance & Safety Tips
 Always keep the seal oil run down tanks in a
good condition.
 Flush the lube oil circuit thoroughly if any
maintenance job is done. Best practice is to
replace all the cartridge filters.
Anti Static Brush
Anti Static Brush
Anti Static Brush

Anti Static Brush

Centrifugal Compressor
End Show
Bearings Lubrication
Bearings Lubrication
Shaft End Seal
Shaft End Seal
Proximity Probes (Radial)
Compressor Maintenance

Major Maintenance
Minor Maintenance
Preventive Maintenance
Compressor Maintenance
Compressor Maintenance
Centrifugal Compressor Types
Horizontal Split Casing
Centrifugal Compressor Types
Centrifugal Compressor Types
Vertical Split Casing
(Bundle or Barrel Pulling)
Barrel Construction
Compressor Diaphragms
Compressor Diaphragms
Barrel Construction
Inter Stage Seals
Labyrinth Seals
Labyrinth Seals
Rotor End Seals
Shaft End Seal
Mechanical Oil Seals
Mechanical Seal
Dry Gas Seals
Dry Gas Seals
Radial Bearing
JOURNAL BEARING ARRANGEMENT
Thrust Bearing
THRUST BEARING ARRANGEMENT
THRUST BEARING EXPLODED VIEW
Rotor Assembly
Coupling
Thrust Collar
Axial Compressors
Axial Thrust
Balance Drum
Train Alignment
Thrust Bearing Failure
Side Stream

Side Stream Nozzles permit

introducing or extracting gas at
selected pressure levels
First Section Double-Flow

Capacity of this compressor is significantly

increased by arranging double-flow
compression in the first section
Iso-Cooling

When gas temperature

within the compressor
reaches 200 to 400 F,
efficiency is improved and
compressor intake power
reduced by cooling
Back-to-Back

Minimizes thrust when high pressure rise is

to be achieved within one casing.
Straight-Through Flow

A conventional arrangement. May employ

as many as 12 stages
Double-Flow

Double the possible maximum flow

capability of the compressor.
Double Iso-Cooling

High molecular mass gases such as

chlorine, heat much more rapidly during
compression. For the compression of such
gases, this arrangement is employed
Back-to-Back plus Recirculation

This unit is typical for

combined feed gas and
circular service. Last stage
flow is combined with
recycle flow.
Flexure Pivot Tilt Pad Bearing
Compressor Main Components
Impeller Types
Impeller Nomenclature
Guide Vanes
Labyrinth Working Principle
Multi Stage Compressor
BCL Assembly
BCL Assembly
BCL Assembly
BCL Assembly
MCL Assembly
MCL Assembly
MCL Assembly
MCL Assembly
MCL Assembly
MCL Assembly
MCL Assembly
MCL Assembly
MCL Assembly
BLP Assembly
BLP Assembly