Rotating Equipment Lec 4 (1-2)

16‐Sep‐20
ROTATING EQUIPMENT
Ahmed Yehia
Process Engineer
Ahmed Yehia – Process Engineer
1
16‐Sep‐20
YouTube channel:
https://www.youtube.com/channel/UCwTMkHhNLOQQ9aG
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CONTENTS
Section 4
• Positive displacement compressors
• Types, parts, and operation
• Dynamic (Centrifugal) compressors
• Types, parts, and operation
• Stall (or surge) and stone wall.
• Compressor selection
• Compressor/pump driver
• Steam turbine
2
16‐Sep‐20
‫ﺗﻛﻧوﻟوﺟﯾﺎ اﻟﺿواﻏط‬
COMPRESSORS
‫ﺣﻠزوﻧﯾﺔ‬
TYPES OF COMPRESSORS
Screw
‫ﻟﻘم ﻣﻧزﻟﻘﺔ‬
Slide vane
‫دوارة‬
Rotary ‫ﻓﺻوص‬
Lobe
‫ذات اﻻزاﺣﺔ اﻟﻣوﺟﺑﺔ‬
Positive displacement
Liquid Ring
‫اﻟﺿواﻏط‬ Scroll
Compressor
‫ﺗرددﯾﺔ‬ ‫ﻏﺷﺎء ﻣرن‬
Reciprocating Diaphragm
‫دﯾﻧﺎﻣﯾﻛﯾﺔ‬
Dynamic ‫ﻣﻛﺑس‬
‫ﺗدﻓﻖ ﻣﺣورى‬ Piston
‫طﺎردة ﻣرﻛزﯾﺔ‬ Axial flow
Centrifugal
‫ﺗدﻓﻖ ﻗطرى‬
Ahmed Yehia – Process Engineer Radial flow
3
16‐Sep‐20
THE PRINCIPLES OF COMPRESSION

• Gases and vapors are compressible.
• Compression decreases volume.
• Compression moves gas molecules close together.
• Compressed gases produce heat because of molecular
friction.
• The smaller the volume, the higher the pressure.
GENERAL COMPRESSOR THEORY

• Compressors are mechanical devices used to increase the pressure of
air, gas or vapor and in the process move it from one location to another.
• The inlet or suction pressure can range from low subatmospheric
pressure levels to any.
• The ratio of absolute discharge pressure to absolute suction pressure is
the compressor pressure ratio.
• To achieve high pressures multiple stages must be employed.
• Compression theory is primarily defined by the Ideal Gas Laws and the
First & Second Laws of Thermodynamics.
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16‐Sep‐20
1st 2nd 3rd 4th

stage stage stage stage
P0 P1 P2 P3 P4
Assume P4
r is The equal Pressure Ratio between stages. AND R =
P0
P1 P2 P3 P4
r = = = =
P0 P1 P2 P3
4 P1 P2 P3 P4 P4
4
r = * * * r =
P0 P1 P2 P3 P0
4 4 N
r = R r= R r = R Generally
COMPRESSORS STANDARDS
API STD 617
• Centrifugal Compressors for Petroleum, Chemical, and Gas Industry Services
API STD 618
• Reciprocating Compressors for Petroleum, Chemical, and Gas Industry
Services
API STD 619
• Rotary Compressors for Petroleum, Petrochemical, and Gas Industry Services
API STD 681
• Liquid Ring Vacuum Pumps and Compressors for Petroleum, Chemical
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16‐Sep‐20
COMPRESSOR TYPES
• Positive displacement compressors : confine a certain inlet volume of gas in a
given space and subsequently elevate this trapped amount of gas to some
higher pressure level.
• Rotary
• Reciprocating
• Dynamic compressors : are based on the principle of imparting velocity to a gas

stream and then converting this velocity energy into pressure energy.
• Radial (Centrifugal)
• Axial
COMPRESSOR TYPES
Positive D.P. Centrifugal Axial Flow
Pressure P V. HIGH HIGH LOW
Flow Rate Q LOW HIGH V. HIGH
Maint. cost V. HIGH LOW LOW
Pulsation YES NO NO
Efficiency LOW MEDIUM V. HIGH
Surging NO YES YES
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16‐Sep‐20
COMPRESSOR TYPES
• Positive displacement compressors exhibit a constant volume and a
variable pressure ratio.
• Low-speed centrifugal compressors approach being constant pressure
ratio and variable volume machines.
• Axial compressor characteristics are somewhere in between. Very high-
speed centrifugal compressors may have characteristics approaching
those of axials.
Pressure Efficiency
Positive
90 %
displacement
Axial Axial
80 %
Centrifugal
70 % Centrifugal
Positive
60 % Displacement
speed 50 %
100 %
% Rated Capacity Specific speed N s
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16‐Sep‐20
POSITIVE DISPLACEMENT
COMPRESSORS
RECIPROCATING TYPES
POSITIVE DISPLACEMENT
Screw
Slide vane
‫دوارة‬
Lobe
Liquid Ring
Compressor
Centrifugal
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16‐Sep‐20
RECIPROCATING
Screw
Slide vane
‫دوارة‬
Lobe
Liquid Ring
Compressor
Centrifugal
RECIPROCATING TYPES
• Positive Displacement Compressors, are machines in which successive
volumes of gas are confined within a closed space where the pressure is
increased as volume of the closed space is decreased.
• They are favored for low flow and high pressure services.
• Work by trapping and compressing specific volumes of gas between a
piston and a cylinder wall.
• The back and forth motion incorporated by a reciprocating compressor
pulls gas in on the suction (or intake) stroke and discharges it on the
other.
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16‐Sep‐20
RECIPROCATING TYPES
• Spring-loaded suction and discharge valves open/close automatically as
the piston moves up and down in the cylinder chamber.
• Reciprocating compressors are divided into single-acting and double-
acting.
• During operation, reciprocating compressors perform best with clean
gases. Entrained water, dirt, and impurities will cause excessive wear on
the piston and cylinder.
RECIPROCATING TYPES
• Larger footprint/weight
• Low Speed (300–1800 rpm)
• Generally used in low volumetric rate applications
• Higher maintenance
• Unaffected by changes in gas properties (MW, T)
• Most common driver – gas engine, electric motor
• Pulsating flow/vibration
10
16‐Sep‐20
RECIPROCATING TYPES
Types of reciprocating compressors
• There are two types of reciprocating compressors:
• High speed (separable)
• Low speed (integral)
• The high-speed category also is referred to as “separable,” and the low-
speed category also is known as “integral.”
RECIPROCATING TYPES
Separable compressors
• The term “separable” is used because this category of reciprocating
compressors is separate from its driver. Either an engine or an electric
motor usually drives a separable compressor.
• Operating speed is typically between 900 and 1,800 rpm.
• Separable units are easy to install, offer a relatively small initial cost, are
easily moved to different sites.
• Separable compressors have higher maintenance costs than integral
compressors.
11
16‐Sep‐20
RECIPROCATING TYPES
RECIPROCATING TYPES
12
16‐Sep‐20
RECIPROCATING TYPES
Integral compressors
• The term “integral” is used because the power cylinders that drive the
compressor are mounted integrally with the frame containing the
compressor cylinders.
• Integral units run at speeds of between 200 and 600 rpm.
• They are commonly used in gas plants. Integral compressors may be equipped
with two to ten compressor cylinders.
• Integral compressors require less maintenance than the separable units.
However, integral units require heavy foundations and a high degree of vibration
and pulsation suppression. They have the highest initial installation cost.
RECIPROCATING TYPES
13
16‐Sep‐20
RECIPROCATING TYPES
RECIPROCATING COMPRESSORS
Basic Parts of are:
• Piston or Diaphragm
• Connecting Rod
• Crankshaft
• Diver
• Piston Rings
• Suction Line
• Discharge Line
• Spring - Loaded Suction and Discharge Valves
14
16‐Sep‐20
Reciprocating compressors are available in :
• Single Acting (Trunk or automotive piston Type)
Trunk
• Double acting (Cross Head Type) Cylinder
Piston
Volume
Head-End Crank-End
Cylinder Cylinder Rod Connecting
Volume Volume Packing Rod
Crank
Piston Piston Cross

Rod Head
15
16‐Sep‐20
Frame
• The frame is a heavy, rugged housing containing all the rotating parts and
on which the cylinder and crosshead guide is mounted. Compressor
manufacturers rate frames for a maximum continuous horsepower and
frame load.
• Separable compressors are usually arranged in a balanced-opposed
configuration characterized by an adjacent pair of crank throws that are
180 degrees out of phase and separated by only a crank web. The cranks
are arranged so that the motion of each piston is balanced by the motion
of an opposing piston.
16
16‐Sep‐20
Frame
• Integral compressors typically have compressor and engine-power
cylinders mounted on the same frame and are driven by the same
crankshaft. Cylinders in integral compressors are usually arranged on
only one side of the frame (i.e., not balanced-opposed).
Cylinder
• The cylinder is a pressure vessel that contains the gas in the compression cycle.
Single-acting cylinders compress gas in only one direction of piston travel. They
can be either head end or crank end. Double-acting cylinders compress gas in
both directions of piston travel. Most reciprocating compressors use double-
acting cylinders.
• Choice of cylinder material is determined by operating pressure. Cast iron is
normally used for pressures up to 1,000 psi. Nodular iron is used for pressures
up to 1,500 psi. Cast steel is usually used for pressures between 1,500 and
2,500 psi. Forged steel is selected for cylinder operating pressures greater than
2,500 psi.
17
16‐Sep‐20
Cylinder
• A cylinder’s maximum allowable working pressure (MAWP) should be
rated at least 10% greater than the design discharge pressure (minimum
25 psi). The additional pressure rating allows a high-pressure safety
sensor (PSH) to be set above the design discharge pressure, and for a
relief valve (PSV) to be set at a pressure above the PSH.
• Wear compatibility of the rubbing parts (piston rings and cylinder bore,
piston rod and seal rings, etc.). Cylinders experience wear at the point of
contact with the piston rings. In horizontal arrangements, cylinder wear is
greatest at the bottom because of piston weight.
Cylinder
• Cylinders are frequently supplied with liners to reduce reconditioning
costs. Liners are pressed or shrunk in place to ensure that they do not
slip. Replacement of a cylinder liner is much less expensive than
replacing an entire cylinder. In addition, performance can be adjusted to
new requirements by changing the inside diameter of the liner. However,
cylinder liners increase the clearance between the valve and the piston,
diminish the effectiveness of jacket cooling, and decrease compressor
capacity from a given diameter.
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16‐Sep‐20
Cylinder
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16‐Sep‐20
Piston
• The piston is located at the end of the piston rod and acts as the movable
barrier in the compressor cylinder. Selection of material is based on
strength, weight, and compatibility with the gas being compressed. The
piston is usually made of a lightweight material such as aluminum or from
cast iron or steel with a hollow center for weight reduction. Thermoplastic
wear (or rider) bands often are fitted to pistons to increase ring life and
reduce the risk of piston-to-cylinder contact. Cast iron usually provides a
satisfactorily low friction characteristic, eliminating the need for separate
wear bands.
20
16‐Sep‐20
Piston
• Wear bands distribute the weight of the piston along the bottom of the
cylinder or liner wall. Piston rings minimize the leakage of gas between
the piston and the cylinder or liner bore. Piston rings are made of a softer
material than the cylinder or liner wall and are replaced at regular
maintenance intervals. As the piston passes the lubricator feed hole in the
cylinder wall, the piston ring gathers oil and distributes it over the length
of the stroke.
Distance piece
• The distance piece provides separation between the compressor cylinder
and the compressor frame. Distance pieces can be contained in either a
single- or double-compartment arrangement.
• Oil migrates between the cylinder and the crankcase. If oil contamination
is a concern, an oil slinger can be provided to prevent packing lube oil
from entering the compressor frame. For toxic service, a two-
compartment design may be used.
21
16‐Sep‐20
Distance piece
Crankshaft
The crankshaft rotates around the frame axis and drives the connecting
rod, piston rod, and piston.
• Connecting rod connects the crankshaft to the crosshead pin
• Crosshead converts the rotating motion of the connecting rod to a
linear, oscillating motion that drives the piston
• Piston rod connects the crosshead to the piston.
22
16‐Sep‐20
Crankshaft
Crankshaft
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16‐Sep‐20
Bearings
• Bearings located throughout the compressor frame assure proper radial and
axial positioning of compressor components. Main bearings are fitted in the
frame to properly position the crankshaft. Crank pin bearings are located
between the crankshaft and each connecting rod. Wrist pin bearings are located
between each connecting rod and crosshead pin. Crosshead bearings are
located at the top and bottom of each crosshead.
• Most of the bearings in reciprocating compressors are hydrodynamic lubricated
bearings. Pressurized oil is supplied to each bearing through oil supply grooves
on the bearing surface. The grooves are sized to ensure adequate oil flow to
prevent overheating.
Bearings
• Piston rod packing provides the dynamic seal between the cylinder and the piston rod. The
packing consists of a series of non-metallic rings mounted in a case and bolted to the
cylinder.
• Auxiliary connections to the packing may be required for:
• Cooling water
• Lubricating oil
• Nitrogen purging
• Venting
• Temperature measurement
• Lubrication must be finely filtered to avoid damage that would result from small particulate
matter entering the case.
24
16‐Sep‐20
Compressor valves
• The essential function of compressor valves is to permit gas flow in the
desired direction and to block all flow in the opposite (undesired)
direction. Each operating end of a compressor cylinder must have two
sets of valves. The set of inlet (suction) valves admits gas into the
cylinder. The set of discharge valves is used to evacuate compressed gas
from the cylinder. The compressor manufacturer normally specifies valve
type and size.
Compressor valves
25
16‐Sep‐20
PISTON COMPRESSOR BASIC PARTS

PISTON ROD PACKING

CROSS HEAD
26
16‐Sep‐20

CONNECTING ROD

CLEARANCE POCKETS
27
16‐Sep‐20

PULSATION DAMPENER
SINGLE-ACTING PARALLEL ARRANGEMENT
28
16‐Sep‐20
SINGLE-ACTING MULTISTAGE COMPRESSORS
29
16‐Sep‐20
30
16‐Sep‐20
DIAPHRAGM COMPRESSOR, SINGLE ACTING
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16‐Sep‐20
DIAPHRAGM COMPRESSOR, DOUBLE ACTING
Capacity Control
Constant Speed Control Variable Speed Control
Clearance Stroke Inlet Valve HydroCom system Bypass

Control length Unloading (stepless control) Control
32
16‐Sep‐20
INLET VALVE UNLOADING
%0 No Load %50 Load %100 Full load
CLEARANCE CONTROL
33
16‐Sep‐20
ROTATING EQUIPMENT
Ahmed Yehia
Process Engineer
34

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Rotating Equipment Lec 4 (1-2)

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16‐Sep‐20

Ahmed Yehia – Process Engineer

Ahmed Yehia – Process Engineer

Ahmed Yehia – Process Engineer

THE PRINCIPLES OF COMPRESSION

Ahmed Yehia – Process Engineer

GENERAL COMPRESSOR THEORY

Ahmed Yehia – Process Engineer

1st 2nd 3rd 4th

Ahmed Yehia – Process Engineer

Ahmed Yehia – Process Engineer

• Dynamic compressors : are based on the principle of imparting velocity to a gas

Ahmed Yehia – Process Engineer

Ahmed Yehia – Process Engineer

Ahmed Yehia – Process Engineer

Ahmed Yehia – Process Engineer

Ahmed Yehia – Process Engineer

Ahmed Yehia – Process Engineer

Ahmed Yehia – Process Engineer

Ahmed Yehia – Process Engineer

Ahmed Yehia – Process Engineer

Ahmed Yehia – Process Engineer

Ahmed Yehia – Process Engineer

Ahmed Yehia – Process Engineer

Ahmed Yehia – Process Engineer

Ahmed Yehia – Process Engineer

Ahmed Yehia – Process Engineer

Piston Piston Cross

Ahmed Yehia – Process Engineer

Ahmed Yehia – Process Engineer

Ahmed Yehia – Process Engineer

Ahmed Yehia – Process Engineer

Ahmed Yehia – Process Engineer

Ahmed Yehia – Process Engineer

Ahmed Yehia – Process Engineer

Ahmed Yehia – Process Engineer

Ahmed Yehia – Process Engineer

Ahmed Yehia – Process Engineer

Ahmed Yehia – Process Engineer

Ahmed Yehia – Process Engineer

Ahmed Yehia – Process Engineer

Ahmed Yehia – Process Engineer

Ahmed Yehia – Process Engineer

Ahmed Yehia – Process Engineer

Ahmed Yehia – Process Engineer

Ahmed Yehia – Process Engineer

Ahmed Yehia – Process Engineer

Ahmed Yehia – Process Engineer

Ahmed Yehia – Process Engineer

PISTON COMPRESSOR BASIC PARTS

Ahmed Yehia – Process Engineer

PISTON COMPRESSOR BASIC PARTS

Ahmed Yehia – Process Engineer

PISTON COMPRESSOR BASIC PARTS

Ahmed Yehia – Process Engineer

PISTON COMPRESSOR BASIC PARTS

Ahmed Yehia – Process Engineer

PISTON COMPRESSOR BASIC PARTS

Ahmed Yehia – Process Engineer

SINGLE-ACTING PARALLEL ARRANGEMENT

Ahmed Yehia – Process Engineer

SINGLE-ACTING MULTISTAGE COMPRESSORS

Ahmed Yehia – Process Engineer

Ahmed Yehia – Process Engineer