Gas Compression

Fundamentals

Imagination at work
 Discussion Points

Basic Terminology
Rod (Pin) Load
Rod (Pin) Reversal
Area Classifications
NEMA Enclosures
Wire Separation
Intro to PV Card
 TERMINOLOGY
(Jargon)
Gas Compressor Industry Language

Compression = to press together and force into less

space.

Compressor = a machine used for increasing the

pressure of gases.
 Packaged Compressor Unit

This is a complete unit mounted on a skid or skids

which includes the prime mover, compressor,
necessary cooling facilities, scrubbers, moisture traps,
safety controls and piping. In other words, a complete
unit ready to be connected to the suction and
discharge lines.
 Terminology
R/Rc = ratio of compression
Ps/P1 = suction pressure
Pd/P2 = discharge pressure
Ts/T1 = suction temperature
Td/T2 = discharge temperature
Ta = ambient temperature
Hp = horse power
HE = head end
CE = crank end
 Terminology

Ratio of Compression (RC)

RC = Discharge Pressure(Pd)psig + 14.7 = ??? psia
Suction Pressure (Ps)psig + 14.7 = ??? psia

Note: Elevation or Barometric pressure must be taken into

account when figuring Rc.
 Terminology
Finding Ratio of Compression (RC)
Example 1: Ps = 200 psig, Pd = 600 psig
Rc = 600 psig + 14.7 = 614.7 psia = 2.863
200 psig + 14.7 = 214.7 psia

Example 2: Ps = 20 psig, Pd = 600 psig

Rc = 600psig + 14.7 = 614.7psia = 17.7
20psig + 14.7 = 34.7psia

Note: If we had not converted to psia the ratio would have

been 30:1.
 Terminology
Finding Approximate HP Requirement:
To find the HP required for a “single”
stage unit (example 1):
Approximating HP Formula using
Example #1
HP = 21 x Rc x S x Q
Where:
HP = Horse Power
21 = Standard (Constant)
Rc = Ratio Of Compression
S = # of Stages
Q = Quantity in MMCFD
HP = 21 x 2.86 x 1 x 2 = 120.12 or 121
 Terminology
SA = Single Acting - The act of compressing
on one end of the compressor cylinder.

DA = Double Acting - The act of compressing

on both ends of the compressor cylinder.

Tandem = Two compressor cylinders either bolted

together or cast as one casting, using a
common piston rod with two piston sizes.
Single Acting Tandem – 2 Stage
Double Acting – Single Stage
Double Acting – 2 Stage
Typical Separators
 Terminology
Clearance Volume = The volume remaining in the compressor
cylinder at the end of the discharge
stroke. Normally expressed as a % of
piston displacement.

Displacement = Area of piston X length of stroke X # of

strokes per minute. For DA
compressors, the displacement on the `
CE is less than the HE due to the rod
area. Normally expressed in cubic feet
per minute or CFM.
 Terminology

Capacity = (Sometimes referred to as flow rate)

Volume of gas compressed and delivered at
specified conditions of temperature & pressure
measured at the compressor inlet. Usually
expressed as volume/unit of time - cubic feet
per minute or cubic feet per day.

Approach = 20ºF approach means the cooler will cool the

process gas to 120ºF when ambient
temperature is 100ºF.
 Terminology

 = The volume swept by the piston during the forward and/or

backward stroke.
 = Compressor speed is not a factor.
 = Normally expressed in cubic inches and calculated as follows:

Swept Volume HE = Area of Piston X Stroke in Inches

Swept Volume CE = (Area of Piston - Area of Rod) X Stroke in Inches

Total Swept Volume = (2 X Area of Piston - Area of Rod) X Stroke In Inches

 Terminology
Total Swept Volume Example (DA):

6” Diameter x 14” Stroke

3” Piston Rod Diameter

Total Swept Volume = (2 X 28.27 – 7.07) X 14

= (56.54 – 7.07) X 14
= 49.47 X 14
= 692.58 cu. In.
 Terminology

Units of Measure:

PSI = pounds per square inch

PSIG = pounds per square inch gauge
PSIA = pounds per square inch absolute
= gauge + atmospheric pressure
MMCFD = million cubic feet per day
MMSCFD = million cubic feet per day @ the
standard conditions of 14.65psia & 60°F
 Terminology
In-Hg = inches of mercury pressure
= can be a manometer or mercury filled
gauge, used where pressures are low &
extreme accuracy is desired
= 1” Hg = .491 PSI

In-H2O = inches of water pressure

= usually a manometer filled with water
= used for measuring very low pressure
= 1/13.6 as heavy as mercury
13.6” of H2O = 1” of Hg = .491 PSI
 Terminology

Temperature =
A measure of molecular energy…the higher the
temperature the more molecular energy.

Degrees Fahrenheit (°F) =

Temperature scale where, at sea level, the freezing
point of water is 32° & the boiling point is 212°. The
distance between these two points is 180°.
 Terminology

Temperature:
Degrees Centigrade or Celsius (º C) =
A scale used worldwide which relates to the metric
system. At sea level, the freezing point of pure water is 0º
& the boiling point is 100º. The distance between
these two points is 100º.
 Terminology

Inline
V Configuration Horizontal Opposed
Configuration Configuration
Separable Engine
In-Line 4
V - Six
Horizontal 4
 Terminology

Separable Compressor
Frame
 Terminology

Compressor

Engine
Separables Coupled
 Terminology
Left Bank Right Bank
Sheave
1L 1R 1
3 LH
2L 2R
2
3L 3R 2

1 RH
4L 4R
Flywheel
5L 5R 3
INTEGRAL ENGINE-
COMPRESSORS
Flywheel
Rod Load Definitions
External Rod Load
• The external rod load of a reciprocating compressor is a calculation considering the unit in a static
state. The calculation for deriving the ERL is:

• ERL = PD(HA) - PS(CA) where:

– PD = Discharge Pressure at the cylinder flange

– PS = Suction Pressure at the cylinder flange

– HA = Head End surface area of the piston

– CA = Crank End surface area of the piston

Internal Rod Load

• The internal rod load is often noted as the internal gas rod load of a reciprocating compressor and
the terms are synonymous. The IRL is a dynamic rod load calculation based upon the internal gas
pressures within the cylinder bore. These gas pressures take into account the dynamic pressure drop
characteristics found across the valves and gas passages. The IRL is calculated through 360°
rotation of the crankshaft with the highest values being used.

Net Rod Load

• The net rod load is considered a dynamic rod load rating. The NRL is the sum of the IRL calculation
and the inertia loads of the reciprocating weights. The NRL is calculated through 360 ° rotation of the
crankshaft with the highest values being used.
 ERL Compression

Area of piston in square inches times discharge

pressure, minus area of piston, minus area of rod
times suction pressure.

6” 2.5”

Pd=814.7 PSIA Ps=214.7 PSIA

= 28.274 x 814.7 - (28.274 - 4.909) x 214.7

= 23,035 - (23.365 x 214.7)
= 23.035 - 5016
= 18,019 #
 ERL Tension

Area of piston in square inches, minus area of rod

times discharge pressure, minus area of the piston
times suction pressure.

6” 2.5”

Ps=214.7 PSIA Pd=814.7 PSIA

= (28.274 - 4.909) x 814.7 - (28.274 x 214.7)

= 23.365 x 814.7 - (28.274 x 214.7)
= 19,035 - 6070
= 12,965 #
Piston Rods Exceeding Rod Load
Rod (PIN) Reversal
Oil

Crosshead Pin Crank Pin

Piston Rod
Crosshead Connecting Rod

Oil
Data needed for Compressor Sizing:
• Operating Conditions
• Gas properties (Gas Analysis)
• Approximate HP per application:
– Suction Pressure (PS)
– Discharge Pressure (Pd)
– Quantity of gas in MMCFD
• Conditions Assumed:
– Suction Temp (TS) = 80°F
– Ambient Temp (Ta) = 100°F
– Discharge Temp (Td) required approach = 20°F
– Altitude = < 1500’
– Atmospheric Pressure = 14psi
– Specific Gravity = 0.64
– “N” value = 1.26
– Sweet Gas
 Any
Questions?
Area Classification
Class I: Flammable gases and vapors – Within this class are four groups in
order of explosive potential – This is where most gas compression will be
found.
• Group A: Acetylene
• Group B: Hydrogen and other gases
• Group C: Ethylene and other gases
• Group D: Acetone, Butane, Ethane, Methane, and other gases

Class II: Combustible dusts

• Group E: Metallic dusts
• Group F: Carbonaceous dusts (e.g.coal)
• Group G: Agricultural, Chemical, and Plastic dusts

Class III: Combustible filings and fibers

Area Classification
The NEC(National Electric Code) and CEC(Canadian Electric Code) recognize
two further divisions distinguished by the likelihood of the material being
Present

Division 1: Areas where hazardous materials may be present under normal

operating conditions.
• Intrinsically Safe: A system comprising of equipment and interconnecting wiring
in which any spark or thermal effect in any part of the system intended for use in
the hazardous location is incapable under prescribed conditions of causing
ignition of the test gas mixture.

Division 2: Areas where hazards arise only as the result of leaks, ventilation, or
other unexpected breakdowns. As a rule of thumb the probability of the presence
of explosive materials must be less than 1% for an area to be assigned to Division
2.
• Non-incendive Circuit: A circuit in which any spark or thermal effect, that may
occur in normal use, is incapable of causing an ignition of the test gas mixture.
NEMA Enclosure Standards
NEMA = National Electrical Manufactures Association

NEMA 12 enclosures are intended for indoor use primarily to provide a

degree of protection against dust, falling dirt and dripping non-corrosive
liquids. They are not intended to provide protection against conditions such
as internal condensation.

NEMA 3 enclosures are intended for outdoor use primarily to provide a

degree of protection against windblown dust, rain, sleet, and external ice
formation. They are not intended to provide protection against conditions
such as internal condensation or internal icing.

NEMA 3R enclosures are intended for outdoor use primarily to provide a

degree of protection against falling rain; and to be undamaged by the
formation of ice on the enclosure. They shall meet rain entry, external icing,
and rust-resistance design tests. They are not intended to provide
protection against conditions such as dust, internal condensation, or
internal icing.
NEMA Enclosure Standards

NEMA 4 enclosures are intended for indoor or outdoor use primarily to

provide a degree of protection against windblown dust and rain, splashing
water, and hose-directed water. They are not intended to provide protection
against conditions such as internal condensation or internal icing.

NEMA 4X enclosures are intended for indoor or outdoor use primarily to

provide a degree of protection against corrosion, windblown dust and rain,
splashing water, and hose-directed water. They are not intended to provide
protection against conditions such as internal condensation or internal icing.
(Must specify 304 or 316 material, 304 will be standard)
NEMA Enclosure Standards

NEMA 7 enclosures are for indoor use in locations classified as Class I,

Groups A, B, C, or D, as defined in the National Electrical Code. NEMA 7
enclosures shall be capable of withstanding the pressures resulting from an
internal explosion of specified gases, and contain such an explosion
sufficiently that an explosive gas-air mixture existing in the atmosphere
surrounding the enclosure will not be ignited. Enclosed heat generating
devices shall not cause external surfaces to reach temperature capable of
igniting explosive gas-air mixture in the surrounding atmosphere.
Enclosures shall meet explosion, hydrostatic, and temperature design tests.
Note: If the NEMA 7 enclosure will be used in an outdoor environment a
NEMA 7, 4 enclosure can be specified for weather proof.
Wire Separation
Introduction to
Pressure-Volume Card

Imagination at work
 What is the P-V Card?

It is a primary tool for determining the

reciprocating compressor performance.
It describes the relationship of the internal
pressures and volumes of a particular end of the
compressor cylinder during the compression cycle.
 DISCHARGE DISCHARGE
VALVE CLOSES VALVE OPENS

DISCHARGE
VOLUME
PRESSURE

RE-EXPANSION COMPRESSION

SUCTION SUCTION
VALVE OPENS VALVE CLOSES
SUCTION INTAKE
VOLUME

STROKE OR VOLUME
MINIMUM CYLINDER MAXIMUM CYLINDER
VOLUME VOLUME

HEAD CRANK
END END

OUTBOARD INBOARD
DEAD CENTER DEAD CENTER
Typical Single Acting P-V Card

LOSS DUE TO
DISCHARGE VALVE

USEFUL
WORK
LOSS DUE TO
SUCTION VALVE
 Typical Double Acting PV Card

Valve Losses
300
Pressure

100

Valve Losses

Volume
 Analyzer Analysis – Real Cards
JC1C cylinder 8 6/30/2000 11:43:05 AM HE Period 10, CE Period 10
550

500

450

400
P re s s u re (p s ig )

Poor Pv Trace
350

300

250

200

0 25 50 75 100
Percent swept volume
JC1C cylinder 2 6/30/2000 11:43:05 AM HE Period 4, CE Period 6
250

225

200
P re s s u re (p s ig )

175

Acceptable Pv Trace 150

125

100

0 25 50 75 100
Percent swept volume
 Any
Questions?