Centrifugal Compressor System Design: Sachin Anjan, Probite Design Systems Pvt. LTD

Centrifugal Compressor
System Design
Sachin Anjan,
Probite Design Systems Pvt. Ltd.
Centrifugal Compressor
Yours truly
looking from NDE
end.
Great learnings
from that site ☺
2
Compressor Situations
3
Compressor Situations and Selections
Oil and Gas Refinery Petrochemicals
◎ Export gas ◎ FCC Wet gas ◎ Cracked gas
compressor compressor compressor
◎ Flash gas compressor ◎ Hydroprocessing H2 ◎ Refrigeration
◎ Vapour recovery recycle compressor compressor
compressor ◎ Hydroprocessing H2 ◎ Synthesis gas
◎ Gas injection make-up compressor compressor
compressor
◎ Expander – Utility and Effluent Systems
Recompressor
◎ Instrument air compressor
◎ Molecular sieve
regeneration ◎ Flare gas recovery compressor
compressor
XYZ = Predominantly Centrifugal compressor
ABC = Predominantly Reciprocating / Screw compressor
LMN = All options equally in use
4
Compressor System Design
◎ Inputs
○ Process data
◎ Activities
○ Compressor stages
○ Compressor hydraulics
○ Design case management
○ Compressor system settle-out pressure
○ Compressor – system design integration
◎ Outputs
○ Compressor datasheet
○ Compressor system design conditions
5
○ Compressor package specifications
Compressor System Design Evolution
https://www.researchgate.net/figure/Aspen-HYSYS-
https://www.sciencedirect.com/scienc flowsheet-for-internal-cooling-process-improved-
e/article/abs/pii/S0263876208000555 case_fig5_293044124
Conceptual Process Design → I will need

Process Development → I will multiple stages as pressure ratio is high
need a compressor there as
resistance > driving force
Centrifugal
Compressor
Process FEED → Would I need two casings with
Datasheet intercooling or all stages can be in a
6 single casing?
Compressor Stages - Interpretation
Process Stage → Side draw /

Side-feed / Intercooling
Vendor → Impeller –
Piping Engineer → Diffuser stage
Casing as a stage
7
Process Stages
Process Stages:
1. Side-stream e.g. from HP
separator / MP separator
2. Side-draw e.g. export gas
compressor draw for fuel gas
3. Discharge temperature more
than 150 oC
4. For optimum work; many
stages resembles isothermal
o Intercooler added to limit discharge
temperature
o Side-stream pressure preferably to have
equal pressure ratio across each stage
8
Casing Stages
Final Configuration
o Calculated Number
of impeller /
diffuser stages ~ 9
o Maximum number
of impeller /
diffuser stages = 12
One casing sufficient,
but two Casings may
https://books.google.co.in/books?id=L- be needed due to
tZUIKvRoIC&pg=PA270&lpg=PA270&dq=elliott+compressor+25MB+head+per+stage&source=bl&ots=S
Zafe7v66n&sig=ACfU3U1fix_vPfeWJBkzc- intercooling
9 RGYAXQZVLTLA&hl=en&sa=X&ved=2ahUKEwibv5i3lKvvAhVgyDgGHaCECtAQ6AEwEXoECAQQAw#v=on
epage&q=elliott%20compressor%2025MB%20head%20per%20stage&f=false
Compressor Hydraulics
◎ Compressor hydraulics
○ From pressure control point on suction to compressor
suction flange
○ From pressure control point on discharge to compressor
discharge flange
◎ From known suction pressure and discharge pressure
at compressor flange, estimate compressor head
◎ Pressure drop elements – suction
○ Suction scrubber
○ Strainer + suction line losses
○ Flowmeter for anti-surge
◎ Pressure drop elements – discharge
○ Check valves
○ Compressor aftercooler + discharge line losses
○ Flowmeter for anti-surge
10 ○ Control valve
Feed Gas Compressor
11
A
Feed Gas Compressor – 2
12 A B C
Feed Gas Compressor – 3
C
B
13
Feed Gas Compressor
Suction Discharge
◎ Process data ◎ Process data
○ Source pressure = 42.3 ○ Destination pressure =
bara 49.3 bara
○ Source temperature = 50 ◎ Pressure drop elements
oC
○ Aftercooler = 0.2 bar
○ Gas flow = 372953 kg/hr ○ Feed/product exchanger =
○ Gas MW = 19.14 0.4 bar
○ Gas Z factor = 0.924 ○ Adsorbent beds + filters =
○ Gas Cp/Cv = 1.39 2 bar
◎ Pressure drop elements ○ Cold box = 0.3
○ Line loss = 0.2 bar ○ Control valve = 6.8 bar
○ Anti-surge flowmeter = 0.2 ○ Line losses = 1 bar
bar
○ Strainer loss = 0.05 bar
14
Calculating Compressor Parameters
1) Inputs: 2) Calculations
Suction flowrate kg/hr 372953.5 Suction pressure barg 40.85
Discharge pressure barg 58.987
Suction temperature deg C 50 Pressure ratio 1.4
Gas MW 19.14 Suction density kg/m3 32.3
Zaverage 0.924 Volumetric flowrate m3/hr 11555.0
Cp/Cv 1.39
Adiabatic efficiency 0.79
Source pressure barg 41.3 Discharge temperature deg C 93.5
Suction pressure drop bar 0.45
Polytropic exponent 1.5
Destination pressure barg 48.287 Suction vol flowrate m3/hr 11555.0
Discharge pressure drop bar 10.7 Polytropic head kJ/kg 49.8
Polytropic efficiency 80
Polytropic head m 5072.34
Work kW 6443.77
15

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Centrifugal Compressor

Conceptual Process Design → I will need

Process Stage → Side draw /

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