Unit No.

3 - Centrifugal compressors

UNITS IN THIS COURSE

UNIT 1 UNIT 2 UNIT 3 UNIT 4 AN INTRODUCTION TO COMPRESSORS AND TURBINES RECIPROCATING COMPRESSORS CENTRIFUGAL COMPRESSORS, TURBINES

Module No. 6 : Compressors & Turbines

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Unit No. 3 - Centrifugal compressors

TABLE OF CONTENTS
Para Page

4.0 4.1

COURSE OBJECTIVES BASIC PRINCIPLES OF STEAM TURBINES 4.1.1 Steam Turbine Speed Control

3 4 7 7 10 11

4.2

BASIC PRINCIPLES OF GAS TURBINES 4.2.1 Gas Turbine Speed Control -

4.3

BASIC PRINCIPLES OF TURBO-EXPANDERS

Module No. 6 : Compressors & Turbines

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Unit No. 3 - Centrifugal compressors

4.0

COURSE OBJECTIVES
This course describes the different types of compressors and turbines found in process plants. The course progresses in Units from basic terminology to the principles of operation of reciprocating and centrifugal compressors and steam and gas turbines. On completion of the course the student will be able to: Explain the basic terminology used in describing compressor and turbine operations. Explain the functions and classifications of compressors and turbines in process plants, and identify the different types of prime movers used to power compressors. Identify suction scrubbers and explain how they work. Explain the basic principles of operation of reciprocating compressors including capacity control methods, control of suction pressure, and automatic shutdown systems. Explain the basic principles of operation of centrifugal compressors including capacity control methods, surge control, and automatic shutdown systems. Explain the basic principles of operation of gas turbines, steam turbines, and turbo-expanders.

Module No. 6 : Compressors & Turbines

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Unit No. 3 - Centrifugal compressors

4.1

BASIC PRINCIPLES OF STEAM TURBINES Figure 4-1 shows the inside parts of a steam turbine.

Figure 4 -1 Steam Turbine These parts are: The casing. The steam chest (which is part of the casing). The rotors and rotor blades. The stators and stator blades.

Module No. 6 : Compressors & Turbines

The casing is very large and is made of heavy steel. The purpose of the casing is: To contain the other parts of the turbine. To provide a passage for the steam flow.

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Unit No. 3 - Centrifugal compressors

The steam chest is a part of the casing. It receives steam from the boiler. The purpose of the steam chest is: To direct the steam to the first row of stator blades.

Figure 4-2 shows the steam chest.

Module No. 6 : Compressors & Turbines

Figure 4 -2 Steam Chest The part of the turbine which rotates is called the rotor. In a simple steam turbine there may be only one set of rotor blades on one rotor disc. Large turbines have several rotor discs. Each rotor disc is like a wheel. The rotor blades are like the spokes of the wheel. The rotor blades are specially shaped and are fitted directly to the rotor shaft. Between each rotor disc is a stator disc. It looks a the rotor discs but the stator discs do not rotate. I each stator disc is to direct the steam onto the next 4-3 shows how this works with just one stator

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Unit No. 3 - Centrifugal compressors

Figure 4-3 Stator and Rotor Discs

A steam turbine works like this. High pressure steam from the boiler enters the steam chest. The first row of. stator blades -aim the steam at the first disc of rotor blades just behind the stator blades. The force of the steam against the rotor blades causes the rotor disc to rotate. Because the rotor disc is attached to the shaft, the shaft also rotates. Behind the rotor disc is another stator disc. The blades in this stator disc direct the steam onto the next rotor disc.

Module No. 6 : Compressors & Turbines

The same thing happens through all the stator and rotor discs in the turbine. To use all of the energy in the steam many rows of stator and rotor blades are used., Each row of stator or rotor blades is larger than the one before it to use all of the steam energy.

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Unit No. 3 - Centrifugal compressors

4.1.1

Steam Turbine Speed Control The operating speed of a steam turbine is set by the load it has to drive. The speed is regulated by the amount of steam that is allowed into the turbine. More steam, more speed. A governor is used control the amount of steam entering the turbine. The governor receive s a signal from instruments telling it to increase or decrease the speed of the turbine. These Instruments measure the thing which needs to be controlled. This could be:

The speed of the turbine itself if it is used as a constant speed machine. The flow from a pump or compressor. The discharge pressure of a pump or compressor. The, output of an electrical,. generator.

A turbine must, not run at a Speed more than its designed maximum speed limit. If a turbine runs too fast the rotor blades may break loose. Steam turbines are fitted with' an overspeed -trip. This is separate from the speed control governor. If the turbine starts to run too fast, the overspeed trip will Make the turbine shut down.

4.2

BASIC PRINCIPLES OF GAS TURBINES Figure 4 -4 shows the main parts of a simple gas turbine. These main parts are: The air compressor. The combustion chamber. The power turbine.

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Unit No. 3 - Centrifugal compressors

Figure 4-4 The Parts of a Gas Turbine The air compressor and the power turbine are- both inside a casing. The purpose of the casing is To contain the rotating parts of the turbine. To provide a passage for the hot gas flow.

Module No. 6 : Compressors & Turbines

The air compressor section of the turbine is like the centrifugal compressors described in Unit 3 of this course. The compressor section draws in atmospheric air, compresses it and discharges it to the combustion chamber. When the air leaves the compressor section it is at high pressure and hot. In the combustion chamber fuel is injected into the hot, compressed air and ignited. The fuel used is usually gas. A liquid fuel such as diesel oil can be used if the machine has the equipment to handle it. Such gas turbines are called dual fuel machines. The hot gas leaving the combustion chamber is directed to the power turbine. The power turbine is like the steam turbine described previously. It has discs of stator blades and discs of rotor blades. The discs of rotor blades are located between two discs of stator blades.

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Unit No. 3 - Centrifugal compressors

The power turbine drives the compressor section of the complete turbine unit as well as the driven machine such as an electrical generator, pump or compressor.

Figure 4-5 Gas Turbine

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A gas turbine works like this. I Atmospheric air is drawn into the compressor section of the machine and compressed. Fuel is added to the compressed air and ignited. Ignition causes the compressed air and gas mixture to become exhaust gas with a further increase in pressure. The exhaust gas drives the rotor of the power turbine.

The exhaust gases are discharged to atmosphere.

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Unit No. 3 - Centrifugal compressors

The sequences taking place in a gas turbine are continuous. There is a continuous flow of compressed air, continuous combustion in the combustion chamber, and continuous power output from the turbine assembly.

4.2.1

Gas Turbine Speed Control Gas turbines can run at speeds from 500 to 50 000 revolutions per minute (rpm). The speed at which a gas turbine must run is set by the load that it has to drive. The speed of the gas turbine is controlled by a governor. The governor works in the same way as the accelerator pedal (gas pedal) of a car. It controls the amount of fuel going into the gas turbine. The more fuel a gas turbine receives the faster, it will turn and the more power it will produce. Once the governor is set it will control the fuel flow to: keep the gas 9 turbine running at a constant speed.' A gas turbine must not run at a speed more than its design limit. If it does, rotor blades may break loose. Even if only one rotor blade breaks loose it will destroy, the gas turbine in a fraction of a second. For this reason gas turbines are fitted, with an overspeed trip. The overspe9d trip is mechanical and does, not depend on electricity or electronics to make it work. When the overspeed trip senses that the turbine is running too fast it shuts off the supply of fuel to the gas turbine. This causes the turbine to stop.

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Unit No. 3 - Centrifugal compressors

4.3

BASIC PRINCIPLES OF TURBO-EXPANDERS A turbo-expander is a machine that produces mechanical work through the expansion. of a gas from one, pressure level to a lower pressure level. Turbo-expanders can be used for: Energy recovery. Cooling a process gas. A combination of energy recovery, and cooling

If, at the end of a gas process, the gas still has high pressure, then this pressure energy can be used.' If the "gas is, used to drive a turbo-expander, the turbo-expander can be used as a prime mover to drive something else. That something else could be a pump, a compressor. The energy in the gas has compressor, or an electrical gene been changed to another form of energy which can be used, so there has been energy recovery. In a gas process where the gas is turned to liquid. (liquefied) the gas Must be cooled, as much as possible and as cheaply as possible before the gas passes to the refrigeration plant. `Expanding a gas causes cooling. Turbo-expanders are very' good for cooling gas." If the main purpose of the turbo-expander is to cool the gas it may also be possible to use the turbo-expander, for energy recovery. All turbo-expanders drive something but if the turbo-expander is used for cooling what it drives May be there only as a brake. The inside of a turbo-expander is very like a turbine. There are rows of stator blades alternating with rows of rotor blades. As the gas passes through each row of stator blades and rotor blades it expands.

Module No. 6 : Compressors & Turbines

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