Professional Documents
Culture Documents
PIP REEC001
General Guidelines for Compressor Selection
March 1999
2. References....................................2
2.1 Process Industry Practices (PIP) .........2
2.2 Industry Codes and Standards.............2
2.3 Other References................................3
6. Basic Principles of
Compression ..............................18
6.1 General .............................................18
6.2 Centrifugal Compressors...................19
6.3 Reciprocating Compressors...............23
9. Ancillary Equipment...................29
List of Tables
1a. Summary of Typical Operating
Characteristics of Compressors
(English)........................................... 7
1b. Summary of Typical Operating
Characteristics of Compressors
(Metric)............................................. 8
2. Advantages and Disadvantages of
Different Compressors.................... 11
List of Figures
1. Types of Compressors...................... 6
2a. Typical Operating Envelopes of
Compressors (English) ..................... 9
2b. Typical Operating Envelopes of
Compressors (Metric) ..................... 10
3. Typical Single-Stage Compressor... 13
4. Typical Multi-Stage Compressor..... 14
5. Typical Axial Compressor............... 15
6. Typical Piston-Type Reciprocating
Positive Displacement Compressor 16
7. Typical Diaphragm-Type
Reciprocating Positive Displacement
Compressor.................................... 17
8. Typical Flooded Screw-Type Rotary
Compressor.................................... 18
9. Pressure-Volume Diagram for
Compression Processes ................. 19
10. Typical Performance Map of a
Centrifugal Compressor.................. 22
11. Pressure-Volume Diagram for
Reciprocating Compressor ............. 23
12. Ancillary and Supporting Systems for
Compressor Applications ................ 30
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PIP REEC001
General Guidelines for Compressor Selection
1.
March 1999
Introduction
1.1
Purpose
The purpose of this Practice is to provide an initial reference for engineers preparing to
deal with compressor vendors, for process engineers, and for project managers.
1.2
Scope
This Practice provides overall guidelines for selecting an appropriate compressor for a
specific process service. This Practice is neither a procurement document nor a
specification.
2.
References
The following references are a set of applicable standards and documents that the reader of this
Practice can use in selecting, specifying, purchasing, and testing compressors and their
auxiliary components for a given application. Short titles will be used herein when appropriate.
2.1
2.2
Page 2 of 30
API 613 - Special-Purpose Gear Units for Petroleum, Chemical, and Gas
Industry Services
API 614 - Lubrication, Shaft-Sealing, and Control-Oil Systems for SpecialPurpose Applications
PIP REEC001
General Guidelines for Compressor Selection
March 1999
API 677 - General-Purpose Gear Units for Petroleum, Chemical, and Gas
Industry Services
2.3
3.
Other References
Compressors: Selection and Sizing, 2nd ed., Gulf Publishing Co., Royce N.
Brown
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March 1999
Page 4 of 30
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PIP REEC001
General Guidelines for Compressor Selection
Polytropic Head: Reversible work required to compress a unit mass of the gas in a polytropic
compression process
Pressure (Compression) Ratio: Ratio of absolute discharge pressure to the absolute inlet
pressure
Relative Humidity: Ratio of actual vapor pressure to the pressure of saturated vapor at the
prevailing dry-bulb temperature
Section (of a Centrifugal Compressor): Group of stages (impellers and associated stationary
parts) in series. In other words, the term section defines all the compression components
between inlet and discharge flanges. A compressor case (body) may contain multiple sections if
the gas is removed for cooling and returned for further compression.
Shaft Power: Measured power input to the compressor. The term shaft power is expected to
replace the more commonly used term brake horsepower.
Specific Gravity: Ratio of the density of the gas at a standard pressure and temperature to the
density of dry air at the same pressure and temperature and a molecular weight of 28.970
Specific Volume: Volume occupied by a unit mass of the gas.
Stage of Compression (in Centrifugal Compressors): Refers to a single impeller with the
associated stationary parts. For axial machines, each set of blades (one rotating row followed
by one stationary row) represents a stage of compression. In reciprocating compressors, a
cylinder, piston, and associated valves and parts comprise a stage. Compressor stages for other
types of compressors can be defined in a similar manner.
Standard Conditions: Several definitions depending on the particular engineering society or
industry defining it. It is important to define clearly the standard that is being used be it in
SI units or English units.
Standard Volumetric Flow Rate: Volume throughput per unit time where the pressure and
temperature for defining the volume are standard values
Stonewall (Choke) Point: Occurs when flow in a centrifugal compressor cannot be increased
further. In this condition, sonic flow is approached in some part of the gas path within the
compressor.
Surge Point: Minimum flow point in a centrifugal or axial compressor. When flow is reduced
below this point, cyclic variation (and even reversal) of gas flow and discharge pressure
occurs.
Volumetric Efficiency: Ratio of the capacity of the compressor cylinder to the displacement of
the cylinder
4.
General
Compressors are the prime movers of gas and air in process industries. They are used to
increase the static pressure of the gas and deliver it at the specified pressure and flow rate in a
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PIP REEC001
General Guidelines for Compressor Selection
March 1999
process application. Part of the increase in static pressure is required to overcome frictional
resistance in the process. Compressors are available in a variety of types, models and sizes,
each of which fulfills a given need. The selection should represent the best available
configuration to meet a prescribed set of requirements.
Selection requires matching compressor capabilities to process requirements. Mechanical
integrity and process safety are very important considerations. The process requirements and
criteria must be established prior to selecting a compressor system. The compressor system
includes lubrication and seal systems and ancillary equipment such as drivers, couplings,
gearboxes and control systems. All components of the compressor system determine its
capacity, reliability and life-cycle costs. Life-cycle costs include initial capital, operating and
maintenance costs.
In general, field-proven equipment should be selected. However, where justifiable, newly
developed equipment may be selected with appropriate technical scrutiny and follow-up. In
some cases, more than one type or size of compressor may initially appear suitable for a given
application. In that case, a more detailed analysis may be justified to make a final, appropriate
selection.
5.
Types of Compressors
The two basic categories of compressors are dynamic (centrifugal and axial) and positive
displacement (reciprocating and rotary types). Figure 1 shows the various types of
compressors that fall into these two categories. Tables 1a and 1b and Figures 2a and 2b show
typical operating characteristics. Table 2 shows the general advantages and disadvantages of
the different types of compressors.
Compressors
Positive Displacement
Dynamic
Centrifugal
Reciprocating
Rotary
Axial
Piston
Screw (Wet/Dry)
Diaphragm
Lobe (Straight/Helical)
Thermal/Jet
Liquid Ring
Sliding Vane
Figure 1. Types of Compressors
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March 1999
Inlet
Capacity
(acfm)
Maximum
Discharge
Pressure
(psig)
Efficiency
(%)
Centrifugal
100 200,000
10,000
Axial
30,000 500,000
Operating
Speed
(rpm)
Maximum
Power
(HP)
70 - 85
1,800 50,000
50,000+
250
85 - 90+
2,000 10,000
100,000
Mainly air
10 - 20,000
60,000
80 - 90
200 - 900
20,000
Diaphragm
0.5 - 150
20,000
60 - 70
300 - 500
200
50 - 7,000
350
65 - 70
1,500 - 3,600
2000
300 - 25,000
15 - 600
55 - 65
1,000 15,000
7000
Rotary Lobe
15 - 30,000
5 - 25
55 - 65
300 - 4,000
500
Sliding Vane
10 - 3,000
150
40 - 70
400 - 1,800
450
Liquid Ring
5 - 10,000
80 - 150
25 - 50
200 - 3,600
400
Application
Dynamic
Compressors
Positive
Displacement
Compressors
Reciprocating (Piston)
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Inlet Capacity
3
(m /h)
Maximum
Discharge
Pressure
(bar)
Adiabatic
Efficiency
(%)
Operating
Speed
(rpm)
Maximum
Power
(MW)
170 - 340,000
690
70 - 80
1,800 - 50,000
38
50,000 850,000
14
85 - 90+
2,000 - 10,000
75
Mainly air
20 - 34,000
4,150
80 - 90
200 - 900
15
0 - 250
1,400
60 - 70
300 - 500
0.15
100 - 12,000
24
65 - 70
1,500 - 3,600
0.15
500 - 42,000
1 41
55 - 65
1,000 - 15,000
Rotary Lobe
25 - 50,000
0.3 - 1.7
55 - 65
300 - 4,000
0.4
Sliding Vane
15 - 5,000
10
40 - 70
400 - 1,800
0.35
Liquid Ring
10 - 17,000
5.5 - 10.5
25 - 50
200 - 3,600
0.3
Application
Dynamic
Compressors
Centrifugal
Axial
Positive
Displacement
Compressors
Reciprocating (Piston)
Diaphragm
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March 1999
100000
Reciprocating Compressor
Diaphragm Compressor
1000
100
Centrifugal Compressor
Rotary Screw
Compressor (Dry)
Axial Compressor
Liquid Ring
Compressor
10
Rotary Lobe
Compressor
Sliding Vane
Compressor
10000
Rotary Screw
Compressor (Wet)
0
0
10
100
1000
10000
100000
1000000
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March 1999
100000
Reciprocating Compressor
10000
1000
100
Liquid Ring
Compressor
Sliding Vane
Compressor
10
Rotary Screw
Compressor (Dry)
Axial Compressor
Diaphragm Compressor
Centrifugal Compressor
Rotary Lobe
Compressor
Rotary Screw
Compressor (Wet)
0
0
10
100
1000
10000
100000
1000000
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March 1999
Advantages
Dynamic
Compressors
Centrifugal
Axial
Thermal/Jet
Positive
Displacement
Compressors
Reciprocating
(Piston)
Diaphragm
Screw
Lobe
Sliding Vane
Liquid Ring
Disadvantages
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5.1
March 1999
Dynamic Compressors
5.1.1
General
Dynamic compressors function by imparting velocity to a gas, and
subsequently converting the kinetic energy of the moving gas to an increase in
static pressure. Two primary types of dynamic compressors are centrifugal
and axial. A combination of the two types may be used to satisfy a given set
of process requirements.
5.1.2
Centrifugal Compressors
Centrifugal compressors impart velocity to the gas through rotating impellers.
The gas is introduced at the eye of the impeller and discharged radially at the
outer circumference (impeller tip) at a higher velocity and kinetic energy. The
gas then passes through a stationary diffuser where its velocity is reduced, and
its kinetic energy is converted to static pressure. Part of the static pressure rise
occurs in the impeller and part in the diffuser. Impeller diameter and width,
rotational speed and the angle of the vanes that make up the impeller are
important parameters in the design of centrifugal compressors.
One or more impellers (stages) may be required to obtain the desired discharge
pressure. The temperature of the gas increases as it is being compressed. If the
discharge temperature is likely to increase beyond the maximum allowable
temperature before the desired discharge pressure is achieved, the gas must be
cooled before it can be compressed further. Heat exchangers, called
intercoolers, may be required to cool the gas. Typically, these intercoolers are
installed between compressor sections (one or more stages typically make up a
compressor section). Maximum allowable temperature is determined by:
1. Design or materials of the compressor
2. Avoiding excessive temperatures in the process
3. Fouling
4. Polymerization of the process
A seal system contains the process gas within the compressor as well as
prevents any contamination of the gas by bearing lubricants. Cross-sectional
views of a typical single-stage compressor and a typical multi-stage
compressor are shown in Figures 3 and 4 respectively. These compressors can
be designed to be non-lubricating if the process gas is required to be
oil-free.
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5.1.3
Axial Compressors
Gas moves axially along the compressor shaft (parallel to the machine axis)
through alternating rows of rotating and stationary blades. Each set of blades
(one rotating row followed by one stationary row) represents a stage of
compression. The rotating blades impart velocity to the gas; the stationary
blades slow the gas and direct it into the next row of rotating blades. As the
gas passes through each stage, its pressure and temperature are further
increased until it finally exits the compressor at the required pressure and
associated temperature.
Axial compressors require more stages to develop the same pressure rise as
centrifugal compressors, but can handle very high flows at very high
efficiency. Axial compressor design does not lend itself to intercooling, and
attainable discharge pressures are generally limited by temperature and
bearing span (which limits the number of blade rows). A typical axial
compressor cross-sectional view is shown in Figure 5.
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5.2
March 1999
General
Positive displacement compressors include reciprocating (piston and
diaphragm) and rotary (screw, lobe, sliding vane and liquid ring) compressors.
This category of compressor functions by enclosing an initial volume of gas
and reducing that volume mechanically thereby increasing its pressure.
Volume reduction is accomplished by one of the following:
5.2.2
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March 1999
5.2.3
Rotary
Rotary compressors generally have no suction or discharge valves, and use
suction and discharge ports that are alternately exposed and covered by the
rotating elements or sliding elements. Screw, rotary lobe, liquid-ring and
sliding vane-type compressors fall into this category. Most of the rotary
machines are specialized with limited applications. A typical flooded screwtype rotary compressor, cross-sectional view is shown in Figure 8.
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6.
General
The basic principles underlying the compression of gases in centrifugal and
reciprocating compressors are discussed briefly below. These two types cover the
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March 1999
Boyles Law
Charles Law
Avagadros Law
Bernoullis Equation
The thermodynamics of gas compression is derived from these laws. Few gases used in
the process industry, such as air, follow ideal gas relationships. Therefore, real gas
equations of state are used to characterize the behavior of most process gases.
6.2
Centrifugal Compressors
In a centrifugal compressor, gas compression is most accurately modeled by a
polytropic path defined by the relationship:
n
PV = constant
Where:
P
= Absolute Pressure
V = Specific Volume
n
= Polytropic Exponent
Absolute Pressure, P
Discharge
Polytropic Path
Adiabatic Path
Suction
Specific Volume, V
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The enthalpy rise of a gas can be obtained from a Mollier chart of the gas being
compressed if it is a single component. Frequently, however, process gases are a
mixture of several hydrocarbon gas elements. Computer programs are available to
calculate required thermodynamic properties of gas mixtures.
The polytropic exponent is not a constant during the compression cycle. However, for
most practical applications, it can be assumed to be a constant. Therefore, along a
polytropic path, the ratio of the reversible work input to the enthalpy rise is constant.
The exponent n is related to the ratio k of specific heats Cp/Cv and the polytropic
efficiency p approximately as follows:
n -1
k -1
k
1
p
The work input per unit mass is typically referred to as polytropic head and can be
evaluated as follows:
Polytropic Head, H p
n 1
Pd n
- 1
MW(n - 1) / n Ps
Z avg R Ts
Where:
Zavg = Average Compressibility Factor of the gas
R = Universal Gas Constant (English: 1545 ft-lbf/lbm-R; SI: 8314 J/kg-K)
MW = Gas Molecular Weight
T = Absolute Gas Temperature
P = Absolute Gas Pressure
Note: Subscripts s and d refer to suction and discharge conditions
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Efficiency, %
March 1999
Polytropic Head
Increasing Speed
Surge Point
Choke Point
Shaft Power
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6.3
Reciprocating Compressors
Compression in a reciprocating compressor can be depicted on a pressure volume
diagram shown in Figure 11. For the most part, the process can be represented as an
adiabatic process using the adiabatic exponent k. In this process:
k
PV = constant
Clearance Volume
Cylinder Pressure, P
Pd
Ps
Actual Capacity
Piston Displacement
Cylinder Volume, V
Figure 11. Pressure-Volume Diagram for Reciprocating Compressor
The adiabatic process was also depicted in the pressure-volume diagram shown in the
previous section.
Typically, reciprocating compressors do not have a performance curve like the one for
centrifugal units. These compressors can deliver whatever pressure is required to
overcome the discharge back pressure unless some material or design limit is reached.
Therefore, these machines must be provided with discharge relief valves to protect
against exceeding safety parameter. Compression stage ratios are typically 3:1.
Reciprocating compressors also do not have surge and choke limitations which are
associated with centrifugal compressors.
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The work required for adiabatic compression is obtained in a manner similar to the
polytropic process. However, the exponent n is replaced with the ratio of specific
heats, k.
Therefore:
Adiabatic Head, H ad =
Pd
MW( k 1) / k Ps
Z avg R Ts
k-1
k
- 1
The volumetric efficiency Ev is defined as the ratio of the gas handled at inlet
conditions to the theoretical volume displaced by the compressor expressed as a
percent.
Ev
Actual Capacity
Piston Displacement
Where:
rp = Pressure Ratio
c = Clearance Volume (see Figure 11)
L = Effects from internal leakage, gas friction, pressure drop through valves, etc.
(approximately 5% for lubricated compressors)
The volumetric efficiency defines the volume flow capability of a cylinder in terms of
inlet volume flow rate under a specific set of operating conditions. It is important to
recognize that the volumetric efficiency of a given cylinder configuration (fixed
diameter, stroke, speed, internal clearance volume) is not a constant parameter.
Volumetric efficiency decreases with increasing pressure ratio across the cylinder.
Additionally, volumetric efficiency decreases with increasing internal cylinder
clearance volume. Thus, the volumetric efficiency (hence, capacity) of a given cylinder
configuration can be altered by varying the internal clearance within the cylinder
control volume. This clearance can be varied through the use of fixed or variable
volume clearance pockets which add internal clearance volume to the cylinder when
manually or automatically actuated for capacity control.
The theoretical discharge temperature is given by:
k - 1
k 1
P
Td = Ts d
Ps
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7.
Selection Considerations
The following major areas should be considered when establishing compressor system selection
requirements:
7.1
Safety
Safety attributes include:
7.2
Over-pressure protection
Process and economic issues listed below should also be evaluated for safety
implications
Process
Key process variables which must be considered include:
Machinery interaction with the process gas (e.g., lubricants, buffer fluids, seal
media)
Typically, a normal operating point is specified in the selection process. This is the
point at which the process is expected to operate. However, it is common to expect
variations in operating conditions. It is, therefore, important to establish an expected
range of the above variables during normal operating, startup and shutdown
conditions.
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7.3
Life-cycle cost (trade-off between capital, operating cost and maintenance costs
over life of equipment)
User and vendor capabilities and facilities for maintaining the equipment
Available utilities
Environmental conditions
The above represent the most common, but important, attributes. Depending on the
application, other variables may have to be considered as well. The relative importance
of these variables should also be established to ensure that the best type and size of
compressor is selected.
8.
Lubrication Systems
8.1.1
General
Compressors usually require oil for bearing lubrication and bearing cooling.
Oil is supplied by the lubrication system. Components in a lubrication system
include an oil reservoir or tank, lube oil pump or pumps, oil filters, oil coolers,
and associated piping and instrumentation. The cleanliness of the lubrication
system is critical to long term reliability of the compressor system.
Lubrication systems should be constructed of stainless steel. If carbon steel
components are used, then provision for cleaning and passivating should be
included. Flushing and cleaning of the lubrication system constitute major
commissioning activities.
8.1.2
Centrifugal Compressors
Lubrication oil is required for the journal and thrust bearings. Lubrication oil
is supplied from a reservoir by a lube oil pump. This pump may be
compressor shaft-driven or independent. An independent main oil pump and an
auxiliary oil pump are preferred for centrifugal compressors.
8.1.3
Reciprocating Compressors
Reciprocating compressor cylinders may be lubricated or non-lubricated.
Lubricated reciprocating compressor cylinders utilize forced feed mechanical
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Rotary Compressors
Rotary compressors may be lubricated or non-lubricated. Flooded screw
compressors use common oil systems for lubricating the rotors, sealing
clearances, removing heat of compression and lubricating bearings. A large
amount of oil is circulated through the compressor. This oil is in contact with
process gas and must be separated from the gas and returned to the lubricating
points as well as to the compressor inlet.
Vane compressors inject a minimum amount of oil to lubricate the sliding
vanes in the cylinder.
Straight lobe and dry screw compressors do not use liquid for sealing the rotor
clearances and driving the non-coupled rotor. Lubrication is required for
bearings and gears. The compressors are furnished with seals which separate
the lubrication from the process. The size and complexity of the lubrication
and seal oil systems vary considerably with compressor size, type and
application. The rotor-to-rotor relationship is maintained by timing gears on
each rotor.
8.2
Seal Systems
8.2.1
General
Compressor seals are furnished to restrict or prevent process gas leaks to the
atmosphere or seal fluid leaks into the process stream over a specified
operating range, including start-up and shut-down conditions. Depending on
the application, the seals may be of a dry or liquid lubricated type. In
applications where leakage can be tolerated, a labyrinth seal may be used.
Seals may require a buffer gas, seal oil, or both. Manufacturers provide a
variety of seals and sealing systems to meet the intended service. If seals
require higher pressure oil than required by bearings, seal oil requirements
may be met by booster pumps or a separate system. Seal selection also
depends on whether the shaft is rotating or reciprocating.
If completely separate seal oil and lubrication systems are required, major
items such as coolers, filters, reservoirs and pumps must be furnished for each
of the seal oil and lubrication systems. If gas handled by compressor causes
contamination, chemical reaction or any other deterioration of oil, sealing
systems must completely isolate gas from lubrication.
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8.2.2
March 1999
Labyrinth
Circumferential Seal
Labyrinth
Circumferential Seal
Lip Seal
The liquid film seal or oil film seal is particularly applicable to high speed
machines. The actual seal is accomplished by a thin oil film supplied by the
seal oil pump to a space between the rotating and stationary seal elements.
This oil contacts process gas and must be degassed before return to the oil
reservoir. Contaminated oil must be reconditioned or discarded.
When handling hazardous, toxic, or emission-regulated gases, the seal also
must prevent gas leakage to the atmosphere after the compressor has tripped
due to seal oil system failure. Various devices within the seal support system
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are available to assure that the compressor seal contains the gas at a standstill,
even if no seal oil is being pumped to the seal. Elevated seal oil tanks can
provide for the necessary static differential pressure of the fluid above the
sealing pressure for a sufficient time to allow the compressor to be
depressurized before the elevated tank oil supply is depleted.
8.2.4
Packing Glands
Packing glands are another type of sealing system and are used in
reciprocating compressors to control gas leakage from the cylinders. The
packing gland contains a series of segmented packing rings around the piston
rod. A purge gas, such as nitrogen, may be used to provide a positive seal
from the atmosphere and improve the venting of the process gas from the
sealing area. The leakage is usually vented to a low pressure vent system or to
a low pressure flare header. Care should be exercised to ensure that the
packing gland pressure is compatible with the flare header pressure.
9.
Ancillary Equipment
Ancillary equipment and supporting systems that are part of the selection and operation of
compressors include the following:
Drivers
Couplings
Gearboxes
Pulsation Suppressors
Silencers
Discussion of the above topics is beyond the intended scope of this Practice. However, all of
them play a very important role in the selection, design, installation and reliable operation of
compression systems. Figure 12 summarizes the important sub-elements of these items. Details
may be obtained through the practices and standards listed in Section 2.
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Gear Box
Driver
Turbine
Motor
Engine
Coupling
Coupling
Compressor
(If Required)
Reducing/Increasing
Transmission
Clutch
Dynamic
Positive Displacement
Bearings
Bearings
Lubrication
Lubrication System
System
Bearing
Bearing Lubrication/Cooling
Lubrication/Cooling
Oil
Oil Reservoir/Filtration
Reservoir/Filtration
Lube
Lube Oil
Oil Pumps
Pumps
Piping/Instrumentation
Piping/Instrumentation
Shaft
Shaft Bearings
Bearings
(Journal,
(Journal, Pressure
Pressure Dam,
Dam,
Monitoring System
Vibration Condition
Process Control
Driver Load
Seal
Seal System
System
Seal
Seal
Sealing
Sealing Fluid
Fluid Supply
Supply System
System
Seal
Leakage
Control
Seal Leakage Control System
System
Atmospheric
Atmospheric Drain
Drain System
System
Operational
Operational and
and Control
Control Systems
Systems
Acoustical
Acoustical Control
Control
Cooling
Cooling System
System
Compressor
Compressor Cylinder
Cylinder
Lube/Seal
Lube/Seal Oil
Oil
Interstage/Aftercooler
Interstage/Aftercooler
Driver
Driver
Operating
Operating Limits
Limits (Surge,
(Surge, Choke)
Choke)
Capacity
Capacity Variance
Variance (Variable
(Variable Speed,
Speed, Inlet
Inlet Guide
Guide Vanes,
Vanes,
Suction
Suction Throttling,
Throttling, Discharge
Discharge Throttling)
Throttling)
Pulsation
Pulsation Suppressors
Suppressors
Tilt-Pad)
Tilt-Pad)
Thrust
Thrust Bearings
Bearings
Emergency
Emergency Shutdown
Shutdown (Overspeed
(Overspeed Trip,
Trip, High
High Thrust,
Thrust,
High
High Vibration)
Vibration)
(For
(For Positive
Positive Displacement
Displacement
Compressors
Compressors only)
only)
Coupling
Coupling
Lubricated
Lubricated
Non-Lubricated
Non-Lubricated (Flexible
(Flexible
Element,Disc,
Disc,Diaphragm)
Diaphragm)
Element,
Special
Special
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