Compressors

Compressors
Copyright , 2008, William G. Beazley, PhD All Rights Reserved Other Copyrights Apply as Noted

Increase Pressure of gas by mechanically reducing its volume Compressed:

Air most frequent Natural Gas Oxygen Nitrogen

Drives:
Electric Motors Steam turbines, or Gas turbines

FEA Model from US DOE/Southwest Research Institute

Compressor Family Tree

(Source: Compressed Air Challenge) Used for:

Centrifugal
Low Pressures High Volume

High Speed Impellers Configurations:

Single Case, Single Stage Single Case, Multiple Stage Multiple Case, Multiple Stage

Dynamic (Usually Centrifugal) Positive Displacement

Reciprocating Rotary (e.g., liquid seal)
http://www.knowpressure.org/content/library/sourcebook/html/intro_ca.htm

Positive Displacement or Reciprocating

Used for:
Relatively Slow Speed Small Volume Extreme Pressures (50,000 PSI+)

Centrifugal Compressors
Originally built to handle only large volumes of low pressure gas and air (maximum of 40 psig) Developed to move large volumes of gas with discharge pressures up to 3,500 psig Most frequently used for medium volume and medium pressure air delivery One advantage is smooth discharge of the compressed air
http://www.tpub.com/content/fc/14104/css/14104_197.htm

Configurations
Single Stage Multiple Stage

Centrifugal Compressor Operation

Centrifugal force same as utilized by centrifugal pump
Air particles enter eye of impeller As impeller rotates, air is thrown against casing of compressor compressing it Pressure of air increases as it is pushed along path

Compressor Impellor Designs

Note: Sometimes Process Pressures or Other Improvements Can Result from Just Changing Impellors

Note impeller blades usually curve forward, opposite to backward curve in typical centrifugal liquid pumps. Centrifugal compressors can use a variety of blade orientations including both forward and backward curves, etc.

Simple Blower

Centrifugal Compressor Case Designs

http://www.cfsan.fda.gov/~ear/nss2-43a.html

Single Stage or Multistage Horizontal Split-Case Compressor

(Source: Bausebacher and Hunt)

Horizontal Slit-Case Centrifugal Compressor

(Source: General Electric Company) Used for low to medium pressure service such as:
Refrigeration Plants, Ethylene Plants, Catalytic Cracking Plants, Urea Plants And Oxygen Plants.

http://www.gepower.com/prod_serv/products/compressors/en/index.htm

4000 HP Centrifugal Compressor for Overhead Gas Compressor

(Source: YORK Process Systems)

Multi-Stage Centrifugal Compressors (Photo: MAN Turbo)

Several stages used to reach a higher pressure Higher pressure air used for:
pneumatic control devices, pneumatic sensors, pneumatic valve operators, pneumatic motors, and starting air for diesel engines.

http://www.york.com/Products/Ref/PROCESSSYSTEMS/Default.asp#

http://www.manturbo.com/en/500/500_radial.php

Vertical Split-Case Compressor

(Source: Bausebacher and Hunt)

Vertical Slit-Case Centrifugal Compressor

(Source: General Electric Company)
Used primarily for high pressure applications such as:
Ammonia, urea and methanol synthesis, Refinery recycle and Natural gas compression and injection
http://www.gepower.com/prod_serv/products/compressors/en/index.htm

Horizontal vs Vertical Split

Horizontal: for gases with partial pressure of H2 <200
Pressures up to 600-800 PSIG Simpler maintenance easy to remove rotor Less foot print Less costly

Reciprocating Compressors

Vertical:
Better sealing capability Higher pressure capability

Reciprocating Air Compressor Elements

Compressing element - air cylinders, heads and pistons, and air inlet and discharge valves. Drive System for transmitting power to air cylinder piston Self-contained lubricating system Regulation or control system Unloading system to reduce or eliminate starting load

Air Compressors
Used widely throughout process facilities in numerous applications Compressed air uses operation of:
Equipment, portable tools, Process Sensors, and Process Actuators

Photos: http://www.gardnerdenver.com/GDCorpPortal/RouteRequest?route=to&id=1129 http://www.waukeemeters.com/Pages/Rotary_Vane_Compressors.htm http://www.rolls-royce.com/energy/products/oilgas/pipeline.jsp

Typical Cycle for Reciprocating Singlestage, Single-acting Compressor Cylinder

Parallel Cylinder Compressor

Equal Pressures More Mass Flow More Discharges per Cycle

Multi-Stage Compressor
Higher Pressures Equal Mass Flow More Pressure Jumps per Cycle

Reciprocating Piston Compressor (Double-Acting)

Heavy Duty Reciprocating Compressors

(Source: Dresser-Rand Company )

High Pressure Reciprocating Compressor (Source: Burckhardt Compression AG)

High-pressure reciprocating compressor for low density polyethylene plants, with discharge pressure up to 3500 bar (50,000 psi), flow from 40'- 160'000 kg/h, and shaft power up to 35'000 kW (47,000 HP)
http://www.dresser-rand.com/recip/eq/hhe.asp

http://www.burckhardtcompression.com/

Rotary Compressors
Adaptable to direct drive:
induction motors or multicylinder gasoline or diesel engines.

Rotary Compressors

Compact, relatively inexpensive, and require a minimum of operating attention and maintenance Occupy a fraction of space and weight of reciprocating machine of equivalent capacity. Three general groups:
1. slide vane-type, 2. lobe-type, and 3. liquid seal ring-type

Slide Vane-Type Rotary Compressor

Sliding Vane Compressor

Has longitudinal vanes, sliding radially in a slotted rotor mounted eccentrically in a cylinder Centrifugal force carries sliding vanes against cylindrical case with vanes forming individual longitudinal cells Suction port is located where cells are largest Eccentricity of rotor to discharge port compresses gas

Rotary Lobe-Type Air Compressor

Two mating lobe-type rotors mounted in a case Lobes are gear driven at close clearance, but without metal-to-metal contact
Suction to unit is located where cavity made by lobes is largest As lobes rotate, cavity size is reduced, causing compression Compression continues until discharge port reached and vapor exits compressor at higher pressure

Lobe-Type Blower
(Photo: Aerzen Canada Blowers and Compressors Inc.)

http://www.aerzen.ca/products.htm

Rotary Liquid Seal Ring Air Compressor

Liquid Ring Compressor

Forward inclined, open impeller, in oblong liquid filled cavity Centrifugal force collects seal liquid at outer edge cavity
Oblong case creates large longitudinal cells, made smaller in rotation causing the vapor within the cell to compress Suction port is positioned where longitudinal cells are largest Discharge port, where they are smallest

Frequently used in specialized applications e.g.:

Extremely corrosive and exothermic gasses Commercial nuclear plants (to establish initial condenser vacuum)

Photo: http://www.hivaceng.com/liquid_ring-pumps.html

Rotary Screw Compressor

Screw Type Air Compressor

http://www.tpub.com/content/fc/14104/css/14104_202.htm

Large Process Gas Screw Compressor

(Photo: MAN Turbo)

Large Process Gas Screw Compressor

(Aerzen Canada Blowers and Compressors Inc.)

http://www.manturbo.com/en/500/500_screw.php

http://www.aerzen.ca/products.htm

Compressor Coolers
Avoid moisture in compressed air systems:
Air moisture capacity
inversely proportional to pressure and proportional to temperature

Multistage Compressor with Intercooler (Red-Bag)

Double acting cylinder Two suction, compression and discharge areas per cylinder Intercooler
http://www.red-bag.com/cms/index.php?section=70

Pressure change of compressed air is larger than temperature change causing moisture to condense Condensed moisture can cause corrosion, water hammers, and freeze damage;

Allows more air to be compressed for a set volume

Intercooler, usually located after first stage discharge, before the second stage suction. Aftercoolers follow compressor

Photo: http://www.britheat.co.uk/applications.asp

Independent from all other foundations. Supports compressor and all its auxiliary equipment. Cylinder supports
are supplied by vendor if required attached to foundation concrete. Attached to foundation concrete Springs used locally to support snubbers .

Foundation & Support For Cylinder & Snubbers

(Red-Bag)

Compressor with Built-In Coolers (Source: FS-Elliot)

Snubber supports

http://www.red-bag.com/cms/index.php?section=70

http://www.machinedesign.com/ASP/viewSelectedArticle.asp?strArticleId=58098&strSite=MDSite&catId=0

Compressor Drive Types

Compressor Drives Electrical motors Gas Turbines Steam Turbines (60,000HP+)

Electric Motor Compressor Drive

(Source: Bausebacher and Hunt)

Gas Turbine Compressor Drive

(Source: Bausebacher and Hunt)

Gas Turbine
(Photo: MAN Turbo)

Gas Turbine Components

http://www.manturbo.com/en/500/500_ft8.php

Steam Turbine Types

Condensing -(Used Steam is condensed) Back Pressure (Steam Exits at a Lower but Usable PT) Topping (High Pressure Steam is skimmed leaving lower, more typical pressure exhaust for process use elsewhere)

Steam Turbine Compressor Drive

(Source: Bausebacher and Hunt)

Steam Turbine

Steam Turbine Components

Condensing Turbine
(Photo: MAN Turbo)

Compressor/Drive Configurations

http://www.manturbo.com/en/500/500_steam_types.php#condensation

Elevated Centrifugal Compressor with a Single Condensing Steam Turbine Drive

(Source: Bausebacher and Hunt)

Tandem Compressor Arrangement

(Source: Bausebacher and Hunt)

70,000+BHP (52,200+kW) Steam Turbine Driving Cracked Gas Compressors In Ethylene Plant (Source: Elliott Turbomachinery Co., Inc.)

Butadiene Production Plant Utilizing Four 110 M-frame Compressors

(Source: Elliott Turbomachinery Co., Inc.)

http://www.elliott-turbo.com

http://www.elliott-turbo.com

Elevated Centrifugal Compressor with Multiple Condensing Steam Turbine Drives

(Source: Bausebacher and Hunt)

Types of Compressor Drive Systems

(Source: Bausebacher and Hunt)

10

Elevated Centrifugal Compressor with Gas Turbine Drive and Waste Heat Recovery
(Source: Bausebacher and Hunt)

Inlet Air Filter for Gas Turbine

(Source: Don Griser, Fluor)

Gas Turbine Driven Propane Refrigeration Compressor In A Natural Gas Plant

(Source: Elliott Turbomachinery Co., Inc.)

Outdoor Compressor Installation with Electric Motor Drive

(Source: Bausebacher and Hunt)

http://www.elliott-turbo.com

A 1500 CFM industrial air compressor, with "D" flange mounted motor, being used in a steel mill
(Source: Elliott Turbomachinery Co., Inc.)

Types of Compressor Systems (contd)

(Source: Bausebacher and Hunt)

http://www.elliott-turbo.com

11

Accessory Systems for Turbine Drives

(H Padleckas and Dore Chakravarty)

Compressor Auxiliary Equipment

http://commons.wikimedia.org/w/index.php?title=Image:Turbine_generator_systems1.png

Lube Oil Console

(Source: Bausebacher and Hunt)

Lube Oil and Seal Oil Console

For Lubrication and sealing Sour Oil Traps
Oil that has been contaminated by process Filter to remove impurities

Degassing Tank
Remove gasses from oil

Oil Reservoir
Store Oil awaiting use May be stored under pressure as backup to pumps

Lube & Seal Oil Pumps Oil Heaters,Coolers

Cold climate need oil heating, hot needs coolers Oil Temp must not Shock machine Used oil needs cooling

Oil Filters Remove Impurities

Lube Oil Console

(Photo: Power Services Technologies, Inc.)

Head or Run-Down Tank

If Lube Oil power is lost Compressor must run down Supplies oil to bearings while compressor runs down Not pressurized: Gravity Flow

http://www.pstpower.com/prod01.htm

12

Seal Oil Console

(Source: Bausebacher and Hunt)

Compressor Piping
(MAVCC)

Removable Spools Needed for Horizontal Top Nozzle Compressor Piping

(MAVCC)

Air Blower with Elevated Inlet

(Source: Bausebacher and Hunt)

Place Inlet Away from process discharges

Inlet Air Filter

(Source: Bausebacher and Hunt)

Variations in Inlet Air Ducting

(Source: Bausebacher and Hunt)

Clean Air before compression Dust accumulates and increases wear Often Self-Cleaning Ladder Access to Filter

Preferred: Ducting inline with intake centerline (Option A)

13

Waste Heat Recovery System

(Source: Bausebacher and Hunt)

Pulsation Control

Gas Turbines Generate Excessive Heat Exit Temp about 1200 degrees F Exhaust stack is usually high: May require Dispersion Study Heat Scavenged to heat steam or add heat to process Usual use: Preheat boiler feedwater Most processes are flammable so caution rarely used

Pulsation Dampener/ Volume Bottle

(Source: Bausebacher and Hunt)
Pulsation Dampener has internal baffles, etc. to control flow and harmonics Volume Bottles have no internals to control flow: Merely stores volume at pressure Concrete foundations help limit vibrations as well

Pulsation Dampeners on Process Gas Compressor

(Source: Burckhardt Compression AG)

http://www.hydrocarbons-technology.com/contractors/compressors/sulzer/sulzer3.html

Vertically Mounted Bottles On Reciprocating Gas Compressor

(Source: Peter Brotherhood Ltd)

Skid Mounted Reciprocating Gas Compressor

(Source: Peter Brotherhood Ltd)

http://www.hydrocarbons-technology.com/contractors/compressors/peter_brotherhood/

http://www.hydrocarbons-technology.com/contractors/compressors/peter_brotherhood/

14

Reciprocating Compressors with Pulsation Control

(DOE/SWRI)

Pulsation Control Schematic

(DOE/SWRI)

Modern Large High-Speed Separable Compressors Running in the 500 to 1,000 RPM Range in the 8,000 to 10,000 HP Range

Schematic of Gas Flow in a Compressor Application Illustrating the Need for Pulsation Filters

Pulsation Bottle Frequency Response

(DOE/SWRI)

Compressors Pulsation Bottles, Chokes

(DOE/SWRI)

Filter Bottle Helmholtz Response

Low-Speed Compressor with a Two-Bottle Manifold System Installed and a Two Bottle, Three-Cylinder Conceptual Bottle Design

Compressor Remediation for Vibration

(DOE/SWRI)

Bottle Design Affects Compressor Performance

(DOE/SWRI)

Modern High-Speed Unit (2,000 to 3,000 HP) Unsuccessful Design Required Multiple Gussets to Fix the Design Problems

Bottle redesign would allow both a complete removal of the nozzle orifice and single-acting operation maintaining a high turndown capability. An estimated 9% increase in compressor efficiency is expected with the new bottle design.

15

Air Supply Pulsation Dampening

(Source: Hydropad)

Lube/Seal Oil

http://www.flexicraft.com/hydrop2.asp?catid=6&subcatid=360

Lube Oil Console Maintenance

(Source: Bausebacher and Hunt)

Lube Oil Console P&ID

(Source: Bausebacher and Hunt)

Lube Oil Drain Routing

(Source: Bausebacher and Hunt)
Gravity flow from compressor down to lube oil reservoir. Most lines are stainless steel. Pull Space for exchanger tubes.

Drain Line Requirements

Addressed in API 614 Gravity Return Min slope per ft All branch connections are a lateral Run no more than half full Min size 1 diameter Stainless Steel

16

Seal Oil Tank Location

(Source: Bausebacher and Hunt)

Seal Oil Console P&ID

(Source: Bausebacher and Hunt)

Surface Condenser and Auxiliary Equipment (Source: Bausebacher and Hunt)

Condensate Handling

Surface Condensor
(Source: Bausebacher and Hunt)

Condensate Pump
(Source: Bausebacher and Hunt)

Designed for high volume low pressure Dome to slow gas velocity

Can type pumps In ground to raise NPSH

17

Surface Condenser Elevation

(Source: Bausebacher and Hunt)

Elevated Compressor
(Source: Bausebacher and Hunt)

Compressor Maintenance
(Source: Texas Compressor Corporation)

Maintenance Requirements

http://www.texascompressor.com/fieldservice.htm

Centrifugal Compressor Turnaround

(Source: Adam Lukenbach, Dow)

Centrifugal Compressor Rotor (Multistage)

(Source: Adam Lukenbach, Dow)

18

Compressor Maintenance
(Source: Capital Machinery Systems, Inc.)

Typical Compressor Layout Model

(Source: Don Griser, Fluor)
Relief Valve not Accessible!

http://www.texascompressor.com/fieldservice.htm

Overhead Pipe Problems Seen in Model

(Source: Don Griser, Fluor)
Discharge piping is routed over the pumps. No space to walk around.

Grade Mounted Centrifugal Compressor No Shelter

(Source: Bausebacher and Hunt)

Grade Mounted Centrifugal Compressor Curtain Wall Shelter

(Source: Bausebacher and Hunt)

Grade Mounted Centrifugal Compressor Open-Sided Shelter

(Source: Bausebacher and Hunt)

Breakout flanges permit pipe to be removed over turbine.

19

Elevated Centrifugal Compressor No Shelter

(Source: Bausebacher and Hunt)

Maintenance Sequence
(Source: Bausebacher and Hunt)

Reciprocating Compressor Open Installation/Enclosed Structure

(Source: Bausebacher and Hunt)

High Pressure Reciprocating Compressor (Source: Burckhardt Compression AG)

High-pressure reciprocating compressor for low density polyethylene plants, with discharge pressure up to 3500 bar (50,000 psi), flow from 40'- 160'000 kg/h, and shaft power up to 35'000 kW (47,000 HP)
http://www.burckhardtcompression.com/

Planning for Cylinder Removal

(Source: Bausebacher and Hunt)

Supports and Foundations

20

Compressor Supports
(Source: Bausebacher and Hunt)

Compressor Line Branches

(Source: Bausebacher and Hunt)

Two Compressor Mounting Methods

(DOE/SWRI)

Steel Skid
Steel Skid:

Concrete Block Foundation

Compressor, driver, piping, vessels, and associated equipment are all located on steel base or skid. Normally, skid is portable so compressor package is assembled in a shop and the whole unit delivered to installation site. With larger, heavier equipment, skid may be delivered to the site with only some equipment and piping in place, and larger items, such as engine and/or compressor, are mounted after skid is installed at site.

Block mounting: All equipment is attached directly to a concrete foundation that has been constructed at the field site.

Compressor PR Valve Placed Near Support (Source: Don Griser, Fluor)

Compressor Piping Sleeper Supports (Source: Don Griser, Fluor) Pulsation Bottle Supports (Source: Don Griser, Fluor)

21

Compressor Piping Clamping (Source: Don Griser, Fluor)

Compressor Auxiliary Pipe Supports (Source: Don Griser, Fluor)

Centrifugal Compressor Area: No Shelter

(Source: Bausebacher and Hunt)

Combining Requirements on Layout

Centrifugal Compressor Area: Totally Enclosed Structure

(Source: Bausebacher and Hunt)

Criteria for Setting Machine Elevations

(Source: Bausebacher and Hunt)

A Bottom-Mounted Nozzles B Top-Mounted Nozzles C Surface Condenser Mounted Directly Below Turbine D Tope Nozzle Allowing Exhaust Steam Line run to Surface Condenser Servicing Multiple Turbines

22

Setting Elevations of Centrifugal Compressors

(Source: Bausebacher and Hunt)

Setting Elevations of Steam Turbines

(Source: Bausebacher and Hunt)

Straight run requirements of compressor piping may set height

Setting Elevations of Reciprocating Compressors

(Source: Bausebacher and Hunt)

Centrifugal Compressor with Intercooler and Piping Between Stages

(Source: Bausebacher and Hunt)

Compressor Suction Drum/Knockout Drum

(Source: Bausebacher and Hunt)

Reciprocating Compressor with all Components

(Source: Bausebacher and Hunt)

Removes liquid droplets from flow to suction Liquid drops can damage compressor Baffle & Demister force changes in flow direction, velocity

23

Aftercooler P&ID
(Source: Bausebacher and Hunt)

Compressor Shelter Sizing Criteria

(Source: Bausebacher and Hunt)

Compressor Suction Configurations

(Source: Bausebacher and Hunt)

Compressor Piping
(Source: Marathon Technical Services)

http://www.marathontech.ca/StationSupport.html

Wash Water Injection

(Source: Bausebacher and Hunt)

Inlet Line Strainers

(Source: Bausebacher and Hunt)

24

Maintenance Break-Out Flanges

(Source: Bausebacher and Hunt)

Spectacle Blinds to Isolate Compressors

(GCPTA) http://www.gcpta.org/

Operating Valve Accessibility

(Source: Bausebacher and Hunt)

High Pressure Steam Inlet Piping

(Source: Bausebacher and Hunt)

Compressor Coordination
Need:
Compressor footprint Rotor Centerline (for hoist) Key Interfaces, utilities Plant space Process PID
Maintenance Accessible Compressor Layout (Source: Don Griser, Fluor)

Rotating equipment data per API 617

25

Centrifugal Advantages
Smaller, Lighter Smaller foundation Pulse free flow Oil free - no contamination Less maintenance/greater reliability Typically installed unspared Smooth Capacity changes from rated flow to surge More readily direct connected to steam and gas turbines Can pass small amounts of dirt and moisture better Suitable for higher discharge temperatures

Reciprocating Advantages
Readily direct connected to electric motors Generally more efficient from positive displacement Generally Less efficiency reduction and reduced flow rates or for multiple operating points Better Able to handle wide variations in pressure ratio and molecular weight Can often handle multple services in one frame Better suited to high inlet pressures (seals work better)

Questions

Finding 1,500 LB Steam

Cant see it Find Bamboo pole search When pole is cut off the leak is found

Compressors Summary
Three common types of compressors are reciprocating, rotary, and centrifugal. Single-stage reciprocating compressor has a piston that moves downward during the suction stroke, expanding the gas in the cylinder. The expanding gas causes pressure in the cylinder to drop. When the pressure falls below the pressure on the other side of the inlet valve, the valve opens and allows gas in until the pressure equalizes across the inlet valve. The piston bottoms out and then begins a compression stroke. The upward movement of the piston compresses the gas in the cylinder, causing the pressure across the inlet valve to equalize and the inlet valve to reseat. The piston continues to compress gas during the remainder of the upward stroke until the cylinder pressure is great enough to open the discharge valve against the valve spring pressure. Once the discharge valve is open, the gas compressed in the cylinder is discharged until the piston completes the stroke.

Compressors Summary (Cont.)

The centrifugal force utilized by the centrifugal compressors is the same force utilized by the centrifugal pumps. The gas particles enter the eye of the impeller. As the impeller rotates, gas is thrown against the casing of the compressor. The gas becomes compressed as more and more gas is thrown out to the casing by the impeller blades. The gas is pushed along the path on the inner wall of the casing. The pressure of the gas is increased as it is pushed along this path. There could be several stages to a centrifugal gas compressor just as in the centrifugal pump, resulting in higher pressure. Rotary compressors are driven by a direct drive that rotates a mechanism (impellers, vanes, or lobes) that compresses the gas being pumped. The actual compression of the gas takes place due either to centrifugal forces or a diminishing gas space as the impellers rotate.

26

Compressors Summary (Cont.)

Cooling systems are required to remove any heat added by the compression. Cool gas takes less space and holds less moisture. This reduces corrosion and allows more gas to be compressed into a given volume. Hazards associated with compressed gas include.
Small leaks or breaks can cause minute particles to be blown at high speeds. Goggles or safety glasses should be worn when working around compressed air or gas. Compressors, especially larger ones, can be quite noisy when running. The cycling of automatic drain valves contributes noise as well. Hearing protection should be worn around compressors. Pressure swings may cause system damage. Closed valves should be slowly cracked open and pressure should be allowed to equalize prior to opening the valve further. Systems should be depressurized prior to opening for maintenance. Oil should be kept out of air systems to prevent possible explosions.

Hazards of Compressed Air

At sufficient pressures, compressed air can cause serious damage Ballistic hazards:
Small leaks or breaks can cause minute particles to be blown at extremely high speeds Wear safety glasses or goggles

Noise:
Compressors noise can be exceptional Compressor & drain valves lifting require hearing protection Posted as a hearing protection zone

Air streams or sudden releases:

Pressurized air can do same type of damage as pressurized water Closed valves slowly cracked open and both sides allowed to equalize Always depressurized systems before opening for maintenance

Contaminants:
Oil introduced in an air compressor can be compressed to point where detonation takes place as in diesel engines. Detonation can cause equipment damage and personnel injury.

Compressor Layout Model (Source: Don Griser, Fluor)

Compressor within Plant Model (Source: Don Griser, Fluor)

Compressor Layout Model with Structure (Source: Don Griser, Fluor)

Compressor Foundation Designs (Source: Don Griser, Fluor)

27

Compressor Piping Routed Down to Sleeper Supports (Source: Don Griser, Fluor)

Clean Compressor Layout and Routing (Source: Don Griser, Fluor)

28