Advances in Centrifugal

Gas Compressor
Technology
Martin Habel Michael Cave
Manager of Product Strategy
Group Manager, Aero Performance
Oil & Gas
San Diego, California Gas Compressor Engineering
San Diego, California

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Serving Oil & Gas and Transmission

Industry with Over 4700 Compressors

Over 4440 Multi-Stage Compressors

Over 240 Advanced Pipeline Compressors

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Overview
• Introduction
− Product Coverage and
Successful Applications
• New Technologies and Capabilities
− Development Tools and Test Capability
− Aerodynamic Test Facility
− Product Improvements
• Restage/Refurb
− Improving Performance of
Existing Equipment
• Advancing Technology
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Family of Compressors Matched to Turbines

• Matched to Power
Turbine Speeds
• Optimized for Oil
and Gas Industry
Needs
• Wide Range of
Flow, Head and
Power Options

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Compressor Evolution
Future

C404/6 Reliability
C65
C45 Value
C40
Flexibility
C133
C16
Efficiency
C168
C50 Today Pressure
C28
Capability
C30

1960
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Design Features ADVANCED IMPELLER

AERO/MECH DESIGN
EFFICIENT PRESSURE
RECOVERY AT
LOW DISCHARGE
LOSS
RADIAL
INLET

DRY TILT-PAD HIGH-PRESSURE

COUPLING THRUST DRY GAS SEALS
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Solid-Shaft Rotor vs Solar’s Modular Rotor

Solid-Shaft Rotor Modular Rotor

D D

D = Effective Shaft Diameter

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Design Challenges
Design Feature Disciplines Impacted
Impeller Tip Speed Aero, Structural
Impeller Blade Number Aero, Structural, Casting
and Thickness
Impeller Flowpath and Aero, Structural
Shape
Impeller Blade Fillet Size Aero, Structural, Casting
Impeller Shroud Structural, Vibration,
Thickness Casting
Stage Length, Bearing Aero, Rotordynamic,
Span Structural
Impeller Hub Diameter Aero, Rotordynamic,
Structural
Diffuser Diameter Aero, Cost, Weight ttsPAFE-compressors-8
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New Technologies and Capabilities

• Design Challenges
• Aerodynamic Tools
• Verification of Aerodynamics
• Aero Test Facility
• Rotordynamic Tools
• Verification of Rotordynamics
• Structural Tools

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Computational Fluid Dynamic (CFD) Tools

• Increased Computational Speed

• User Friendly
• Allow for Interaction between Design
Process and Aerodynamic Analysis
− Including Capability to Model Entire Stage
− Rotating and Stationary Parts Together

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Computational Fluid Dynamics (CFD) Tools

IMPELLER, DIFFUSER FLOW LINES AT

AND VOLUTE VOLUTE EXIT

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Aero Test Facility

• Scale Stage Testing

• Detailed Measurements
− Improved Prediction
Capability
− Understand Component
Performance
• Extend Aerodynamic
Design Knowledge

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Improved Rotordynamic Tools

• Bearing-Rotor Interaction
• Seal-Rotor Interaction
• Modeling of Bearings

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Unbalanced Sensitivity Calculations

1.2

Suction X
Suction Y
1
FERDA - 80/20 Mixing - Orbit
AMPLITUDES, MIL

FERDA - Adiabatic Brg - Orbit

0.8

0.6

0.4

0.2

1000 2000 3000 4000 5000 6000 7000 8000 9000 10000 11000 12000 13000

SPEED, RPM
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Proven Tools and Tested Configurations

• High Confidence in Predictions

• Solar’s Pre-engineered Rotor Systems
− Rotor Assembly of Each C406: Identical Seals,
Bearings and Bearing Spans
− Experience Data Accumulated with C406 Applies
to New Projects
• Validation Indicates
− High Repeatablity
− High First Time Test Success
− Firm Delivery Commitments

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C453 Centrifugal Compressors

New Part Numbers/ Designs Required

Parts Incremental to C452

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Pressure Capability

• Discharge Pressure Levels

− C166S - 3500 psi
− C33 - 2750 psi
− C404/6 - 2500 psi
• Process to Gain Increased Operating Experience
• Process Complemented by Continuous
Improvement in Dry and Wet Gas Seal Technology

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Product Improvements

Retrofitable Dry Gas Seals

C304 and C505J

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Product Upgrades
• Introduction of C16 “V” and C33 “E”
• New Casting Tooling Construction
Provided an Opportunity for Design
Improvements
• Family Center-Bodies Redesigned
− API 617 Compliant ANSI Flanges
− End Cap Drainage Improved
• C335 “E” Introduced
• C160V and C166V Rotor/Stator
Modules
− C160 R/S Interchangeable
• New C33E Stators Fit Existing C33
− Seals Interchangeable
− Bearings Changed
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Product Improvements

• Application of New Design Tools to Existing Product

• New C33 Impellers Reduced Stress Levels

Original “D” impeller Redesigned “D” impeller

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Performance Improvements
• New Aerodynamic Tools Provide
Performance Improvement to
Original “2D” Sator
Existing Product
• New C33 Impellers and Return
Vanes Provide Improved
Efficiency and Range through
Improved Aerodynamics
• Head per Stage Maintained
• Current Envelope Maintained to
Provide Retrofit Capability
Redesigned “2D” Stator

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Application of Advanced Tools

• Design Challenge for Multistage
Compressors
− Impellers Generate as Much Head
as Possible
− Balancing Efficiency and
Operating Range
− Keeping Short Axial Length
• Meeting Requirements Allows
− High Head Making Capability for
Given Rotor Length
− Impeller Velocity Head Per Stage
Increased by Reducing Impeller
Backsweep
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New C51 Multi -Stage Compressor

• Compressor Stage
Designed with Combined
Requirements
• Scaled Stage Tested 1.6 0.9

Isen. Efficiency
− Improve Head Per 1.4 0.8

Stage by 20% 1.2 0.7

− Did Not Sacrifice 1 0.6

Efficiency Goals 0.8 0.5

Isen. Head Coef.

0.6 0.4
C51 High-Head
Design
0.4 C404 Design 0.3

0.2 0.2
0.03 0.04 0.05 0.06 0.07 0.08 0.09
Inlet Flow Coefficient

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Results
• High Efficiency
• Wide Flow Range
• Repeatable 2.2
• Predictable Performance

Efficiency and head vs flow: Prediction vs site test data

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C51 Evolved from the C404/406

• Maintain Excellent Rotordynamic Behavior

• Increase Head per Stage
• Decrease Casing Diameter

C406
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C51 Multi-Stage Compressor Development

• C505 Replacement
• Matched to Mars and Titan Drivers
• High Efficiency in 2,000 – 10,000 ACFM
Flow Range
• Discharge Pressure: 2,250 to 3,000 psig
• 13,000 ft-lbf/lbm Average Head Per Stage

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C51 Mechanical Features

• Cast Steel Centerbodies
− Heat-Treated to Meet API and Pressure-Vessel Codes
• Investment-Cast Impellers
− NACE-Compliant 15-5PH Steel
• Optimized-Geometry
− Cast Ductile-Iron Inlet Housings and Exit-Volutes
• Steel Stubshafts
− Solar’s Typical Modular Rotors
• Cast Vane and Diaphragm Components
• Dry Gas Seals for Process-Gas Isolation within Flowpath
• Carbon Shaft-Seals for Lube System Isolation
• Tilt-Pad or Flexible-Pivot Journal Bearings
− Optional Damper-Bearing for Discharge End of Shaft
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C51 Bearings and Seals

• Dry Gas Seals

− Seal Design Based on Solar’s Experience
§ Standard Material and Design
§ Seal Diameter Same as C65
§ Incorporate Lab Seal between Primary
and Secondary Dry Gas Seal
• Bearings
− When Used on Mars Applications, Bearing
Speeds Similar to C65

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C51 Program Status

• Phase I (Current)
− C51 Rated 2250 psi, 24 X 20 Flanges (900 lb)
− 3 Casing Lengths
− Support for Shipments Beginning 1Q – ’05
• Phase II (Start 2005)
− Inter-Cooled Version (Replaces Tandems)
• Phase III
− C51 Rated 3000 psi, 16 x 16 Flanges (1500lb)

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C51 Long-Lead Components

C51 Centerbody C51 Inlet

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C51 Compressor Applications

• High Pressure Pipeline

− Good Efficiency, Wide Operating Range
• Gas Gathering
− Highly Flexible and Robust
• Gas Re-injection
− Rotordynamic Stability and Flexibility
• Gas Boost
− Good Efficiency, High Flexibility

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C51 Now Available

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Restaging Economics

• Increasing Compressor
Efficiency
• Elimination of Recycle Flow
− Savings in Power or
Fuel Consumption
• Increasing Power
Turbine Speed
• Screening Tool Available
− SoftMap

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Conclusion

• Cutting Edge New Products

• Proven and Reliable Technology
• Enhancements of Product Portfolio
• Delivering Value to Customer

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