Compressors

2007 ENGINEERING Training Session
Compressors
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2007 Engineering Training Session
Compressors
Bruce Lieberthal, Instructor
EDS-2007/CD-1
Types of Compressors
Compressors
Dynamic Positive Displacement
Radial Flow Axial Flow Rotary Reciprocating

(Centrifugal)
Single Rotor Two Rotor
Sliding Vane Liquid Ring Roots Screw
EDS-2007/CD-2
CD-R00-02
Approximate Ranges of Application for Reciprocating,
Centrifugal and Axial-Flow Compressors
Discharge Pressure, psia
EDS-2007/CD-3
CD-R00-01
Compressor Performance Characteristics
EDS-2007/CD-4
CD-R00-03
Process of Compression
Pressure Defined on PV Diagram
EDS-2007/CD-5
CD-R00-04
Approximate Polytropic Efficiencies
for Centrifugal and Axial-Flow Compressors
Polytropic Efficiency, EP
100 1000 10000 100000
Suction Volume ACFM

EDS-2007/CD-6
CD-R00-06
Reciprocating Compressor Efficiency
EDS-2007/CD-7
CD-R00-05
Compressors
Basic Theory
Hardware
Advantages/Disadvantages
Case studies
EDS-2007/CD-8
EDS-2007/CD-9
Compression
EDS-2007/CD-10
CD-R00-07
Discharge
EDS-2007/CD-11
CD-R00-08
Expansion
EDS-2007/CD-12
CD-R00-09
Intake
EDS-2007/CD-13
CD-R00-10
EDS-2007/Compressors-14
Magnum Valve
Two Stage Compression
CD-R00-11
Reciprocating Compressor Control
Suction Valve Unloaders
Cylinder Pockets
Bypass
EDS 2007/Compressors-24
Finger Type Unloader
Clearance Pocket
Clearance Pocket
Reciprocating Compressor Head
Variable Clearance Pocket
Single Cylinder Reciprocating
Compressor 150 BHP Frame Rating
Two Cylinder Balanced-Opposed
Reciprocating Compressor 400 BHP
Frame Rating
Pump to Point Cylinder Lubricator
Crankshaft
Connecting Rod
Cross Head
Packing Box
Reciprocating Compressor Piston Rod,
Two Compartment Distance Piece
Reciprocating Compressor
Frame Oil System Lubricator
Reciprocating Compressor Piston
Piston Rings, Rider Rings
Three Piece Piston
Mechanical Packing Nomenclature
Turbine-Gear Driven Reciprocating
Compressor-4800 BHP
High Speed Gear
Reciprocating Compressor Advantages
High Compression Ratios

Constant Volume/Wide Pressure Range
Molecular Weight Flexibility
Fairly Basic Evolved Technology
Efficiency
Reciprocating Compressor
Disadvantages
Foundation and Piping Requirements

Pulsating Flow
Vulnerable to Dirt and Liquid
Maintenance
Plot Area
Large Volumes Constraints
Lubrication Contaminating Process
Torsional Implications
Purchasing Reciprocating Compressors
Technical Evaluation
1. Scope of Supply (Per Spec and API 618)
2. Frame Loading
3. No. of Cylinders
4. Rod Loading
5. Cylinder Diameter
Purchasing Reciprocating Compressors
6. Piston Speed
7. Piston RPM
8. Exceptions to specs and standards
9. Power Requirement
10. Experience
Compressor Assembly
Recycle Gas Compressor
5 Stage Centrifugal Compressor
Stress Corrosion Crack
Stress Corrosion Crack
Centrifugal Compressor Control
Variable Speed
Suction Throttle Valve
Compressor Formulas
ACFM = SCFD (14.7) (T1°R)(Z1)/1440(P1)520

ACFM ~ SCFD/P1
Lb/Min = SCFD(MW)/1440(379.48)
Head (ft) ~ (P2/P1)/MW
HP ~ Head ( Lb/Min)
Compressor Formulas
M3/hr=NM3/hr(1.0335)(T1°K)Z1/
P1(Kg/cm2a)(273)
M3/hr=StdM3/hr(1.014)(T1°K)Z1/
P1(Kg/cm2a)(288)
Centrifugal Compressor Typical
Variable Speed Performance Curves
Percent Pressure Rise
CD-R00-12
Constant Speed Performance Curve
CD-R00-13
CD-R00-14
CD-R00-15
Suction Throttling
Rated TD Turb TD Disch TD Suct

SCFD 60 MM 48 48 48
FT 85300 68560 92130 89570
ACFM 22200 17750 17750 19750
BHP 2764 1785 2399 2331
Drivers
ELECTRIC MOTORS STEAM TURBINES
SSM VSM Cond Back Pressure
W/C A/C
Gas turbines, Gas engines Extraction, Induction
A Model of Surge
Surge Definition
Surge is self-oscillations of pressure and flow, including a flow
reversal. The surge flow reversal is the only point of the curve
when pressure and flow drop simultaneously.
Characteristic Curve of a Typical Centrifugal Compressor

– B to C in 20 to 50 mSec
– Cycle B to B at 0.33 to 3 Hertz
CD-R00-29
The Surge Phenomena
Rapid flow oscillations

Thrust reversals
Potential damage
Rapid pressure oscillations

with process instability
Rising temperatures inside

compressor
CD-R00-30
Surge Description
Flow reverses in 20 to 50 milliseconds

Surge cycles at a rate of 1/3 to 3 hertz
Compressor vibrates
Temperature rises
“Whooshing” noise
Trips may occur
Conventional instruments and human
operators may fail to recognize surge
Some Surge Consequences
Unstable flow and pressure

Damage in sequence with increasing severity
to seals, bearings, impellers, shaft
Increased seal clearances and leakage
Lower energy efficiency
Reduced compressor life
Platforming Recycle Gas Circuit
Net Gas S
e
Products p
Condenser a
Charge r
Heater a
t
o
r
C
F T
E
FR
FF
CD-R00-31
FCC Main Air Blower
PDRC
To Stack
F
r
a
Regenerator c
t
FRC i
Rx
o
T n
a
t
o
r
Feed
CD-R00-32
Antisurge Controller Operation
Surge Limit Line (SLL)

Surge Control Line (SCL)
ΔPc
Surge Control Equation:

Operating KΔ Pc + b1 = ΔPo minimum
Point
b ΔPo
1
CD-R00-33

ΔPc

Point
b ΔPo
1
CD-R00-33

ΔPc

Point
b ΔPo
1
CD-R00-33
Antisurge Controller Recycle Trip
Circuit Operation
Recycle Trip Line (RTL)
Surge Limit Line
(SLL) Surge Control Line (SCL)
ΔPc
Activates open loop

control
Prevents surge in all
but the most severe
disturbance
RT ΔPo
b
1
CD-R00-33
Simple Antisurge System
Flow measured in suction
Compressor (ΔPo)
Suction and discharge
pressure transmitters for
Inlet
Gas pressure differential
Discharge
Gas calculation
FT PT PT
Control strategy is
ΔPc
proportional plus integral
control to manipulate
recycle valve
UIC
Increase flow through
compressor and reduce
FT I/P FV discharge resistance when
Recycle required to prevent surge
CD-R00-35
FCC Axial Main Air Blower
with CCC Performance Controller
UA XA FR
CCC Performance Controller

CCC Antisurge Controller XIC
(process inputs are not shown) (DCS Faceplate only) FIC
PI TI
^
HIC HY
P
I
FC
HIC HY
(Signal to DFAH
ZI
I
P
Shutdown)
FT PT TE
ZT
Actuator
CD-R00-34
Mechanical Shaft Seal
(TSO-Carbon Seal)
Liquid Film Sleeve Seal
(TSO-Sleeve Seal)
Thrust Bearing
Journal Bearing
Compressor Lube Oil System
s/d: 2 out of 3 voting
Filters Coolers Pumps

Compressor Seal Oil System
Compressor Lube and Seal Oil System
Dry Gas Seal Spiral Groove Arrangement
Outer
Diameter
Land
Spiral
Groove
Groove
Diameter
Inner
Diameter
Rotation Relative
to Primary Ring
CD-R00-18
Single Dry Gas Seal
CD-R00-19
Principle of Operation
CD-R00-20
Design Comparisons
Unidirectional Bidirectional
Spiral Groove Spiral Groove
CD-R00-21
Dynamic Test Leakage
for a 4.937" Diameter Seal
2.5
18,000 RPM
9,000 RPM
2.0
Leakage (scfm)
1.5
1.0
0.5
0
0 200 400 600 800 1000 1,200
Pressure (psig)
CD-R00-22
Control System
Provides three main functions

– Filtration of buffer gas
– Regulation of buffer gas
– Monitoring of seal performance
Offers local indication of filter and seal
performance
Design is simple to operate and user friendly
with minimum maintenance requirements
To Flare To Flare
Dry Gas Seal

Typical Control Flow Adjust
System Meter Flow
Control
2
micron Flow
To Control P air filter Meter To Control
Room Room
To Control To Control
Room & gage Room &
Local Alarm PI Local Alarm
clock
Solenoid
SUCT DISC Valve
Pressure
(N.C.) Switch
Radial Radial
Bearing Bearing
John Crane
Gas Seal
CD-R00-23
Type 28 Seal Arrangements
Single Seal Tandem Seal
Double Opposed Seal Triple Seal
CD-R00-24
GC-100 Dura Seal®
Silcar
Antirotation Pin
Rotor
Garter
Spring
Dynamic
O-Ring
Carbon Stator
CD-R00-25
GC-300 Dura Seal®
CD-R00-26
GC-300 Dura Seal®
with Interstage Labyrinth
Secondary Inert Buffer Primary Primary
Buffer Supply Buffer Vent Buffer
Vent Supply
CD-R00-27
Comparison of Wet Seal vs. Dry Gas Seal
Wet Oil Seals Dry Gas Seal
Seal oil support Pumps, reservoirs, filters None
systems costs traps, coolers, consoles
Seal oil consumption 1-100 gallons/day No seal oil
Maintenance cost A major expenditure over Negligible
equipment life
Energy costs Seal Power loss: 10-30 HP 1-2 HP
Unit driven pumps: 20-100 HP
Process gas leakage Gas Leakage: 25 scfm & higher Less than 2 scfm
Oil contamination Of Pipelines: High clean up costs None
Of Process: Catalyst poisoning
Toxic and corrosion Buffer gas consumption (egN2) 2-4 scfm
applications 40-70 scfm
Unscheduled High Downtimes Very reliable
shutdowns
Aborted startups Frequent Rare
Dry Gas Seal Console
Dry Gas Seal Console
Compressor Dry Gas Seal System
CD-R00-28
Purchasing Centrifugal Compressors
1. Scope of Supply
2. Can it meet all operating points (N2 start)
3. Materials (Impeller yield strength)
4. Is proposal complete
5. Does proposal meet API 617
Purchasing Centrifugal Compressors
6. Efficiency of various operating points
7. Rotor dynamic stability (How many wheels)
8. Exceptions to specs and standards
9. Efficiency
10. Experience similar casing sizes, rotor

sizes, pressures, flows
Type of Tests Performed
Mechanical Test
– Small closed loop on helium
– Vacuum test
– Open system on air
Seal Check
Performance Test (on Freon)
System Test
Mechanical String
(With or without the contract driver)
Full Load, Full Pressure
Critical Speed
A critical speed is where the forcing

function or self-exciting frequencies are
sympathetic (at synchronous or
harmonics) to the resonances of a rotor,
bearing or support system.
Charlie Jackson
The Practical Vibration Primer
Centrifugal Compressor Disadvantages
Defined molecular weight

Small machines inefficient
Limited to approximately 1000 ACFM volume
Surge potential
Low mole weight compression ratio capability
More sophisticated technology
Centrifugal Compressor Advantages
High reliability–Low maintenance

Large volumes capacity
Tolerance of liquids and dirt
Smooth flow
Wide capacity range and ease of control
No process gas contamination problems
Compatibility with driver
Reciprocating
Centrifugal
Axial
Axial Flow Compressors
(Dynamic Type)
Axial Compressor Control
Variable Speed
Variable Stators
Bypass (snort for air blower)
Axial Compressor
Variable Speed Performance
CD-R00-16
Axial Compressor
Variable Stator Performance
CD-R00-17
Axial Compressor Control
Variable Speed
Variable Stators
Bypass (snort for air blower)
Axial Compressor Advantages
High Efficiency
Smaller Relative Casing Size (Lower Cost)
Low Maintenance – High Reliability
Speed Match With Power Recovery Turbine
Constant Volume for Wide Pressure Range
Compatibility With Driver
Smooth Flow
Axial Compressor Disadvantages
Decay of Performance With Blade Fouling

Sensitivity to Surging
Sophisticated Technology
Costs
Limited Experience With Hydrocarbons
Screw Compressors
No spare – 99% on stream reliability
vs. Centrifugal – can be more expensive,

noisy, less efficient
vs. Recip – no spare, usually less expensive

compared to two recips, less efficient, less
maintenance
Screw Compressors
Oil Flooded
– 6000 acfm
– 250 psi differential pressure
– 350 psi discharge pressure
Screw Compressors
Oil Flooded
– Slide valve control
– Oil carryover
– No timing gear
– Lower cost than dry screw
– PSA units
4. High Reliability
- Simple Structure, Principle, System Design etc.
Screw Compressor (Single Stage)

Screw Compressors
Dry Screw
– 30,000 acfm
– 250 psi differential pressure
– 200 discharge pressure (over 20,000 acfm)
– 500 discharge pressure (under 10,000 acfm)
Screw Compressors
Dry Screw
– No oil carryover
– Noisy – enclosure required
– Flow control – variable speed and spillback
– Styrene Off Gas, Pacol Recycle
Principle of Compression
Oil Flooded Screw
Screw Compressor (Tandem - Two Stages)
for high pressure ratio case
Slide Valve Mechanism
(1) In case of Turndown
Typical System
(Flow Diagram)
Red: Equipment
Blue: Gas
Yellow: Oil
Oil Carryover:
less than 1 ppm
by weight
Screw Compressors
DRY SCREW RECIPROCATING

Tolerance for dust or particulate Good Poor
Tolerance for liquids Excellent Poor
Tolerance for MW variations Excellent Excellent
Reliability Excellent (99.5%) Fair (93%)
Plot space Good Poor
Operating efficiency Poor Excellent
Capacity regulation Poor (for single speed) Fair
Gas pulsation Good Poor
Gas polymerization Excellent Poor
Screw Compressors
DRY SCREW CENTRIFUGAL

Tolerance for dust or particulate Good Good
Tolerance for liquids Excellent Good
Tolerance for MW variations Excellent Poor
Surge No Yes
Reliability Excellent (99.5%) Excellent (99.5%)
Plot space Good Good
Operating efficiency Poor Good
Capacity regulation Poor (for single speed) Good
Gas pulsation Good Excellent
Gas polymerization Excellent Poor

Compressors

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2007 ENGINEERING Training Session

Bruce Lieberthal, Instructor

Dynamic Positive Displacement

Radial Flow Axial Flow Rotary Reciprocating

Single Rotor Two Rotor

Sliding Vane Liquid Ring Roots Screw

Discharge Pressure, psia

100 1000 10000 100000

Suction Volume ACFM

 Suction Valve Unloaders

 High Compression Ratios

 Foundation and Piping Requirements

1. Scope of Supply (Per Spec and API 618)

8. Exceptions to specs and standards

 Suction Throttle Valve

 ACFM = SCFD (14.7) (T1°R)(Z1)/1440(P1)520

 Head (ft) ~ (P2/P1)/MW

Rated TD Turb TD Disch TD Suct

FT 85300 68560 92130 89570

ACFM 22200 17750 17750 19750

BHP 2764 1785 2399 2331

ELECTRIC MOTORS STEAM TURBINES

SSM VSM Cond Back Pressure

Gas turbines, Gas engines Extraction, Induction

Characteristic Curve of a Typical Centrifugal Compressor

 Rapid flow oscillations

 Rapid pressure oscillations

 Rising temperatures inside

 Flow reverses in 20 to 50 milliseconds

 Unstable flow and pressure

Surge Limit Line (SLL)

Surge Control Equation:

Surge Limit Line (SLL)

Surge Control Equation:

Surge Limit Line (SLL)

Surge Control Equation:

 Activates open loop

CCC Performance Controller

Filters Coolers Pumps

 Provides three main functions

Dry Gas Seal

Single Seal Tandem Seal

Double Opposed Seal Triple Seal

2. Can it meet all operating points (N2 start)

3. Materials (Impeller yield strength)

5. Does proposal meet API 617

6. Efficiency of various operating points

7. Rotor dynamic stability (How many wheels)

8. Exceptions to specs and standards

10. Experience similar casing sizes, rotor

A critical speed is where the forcing

 Defined molecular weight

 High reliability–Low maintenance

 Decay of Performance With Blade Fouling

 No spare – 99% on stream reliability

 vs. Centrifugal – can be more expensive,

 vs. Recip – no spare, usually less expensive

 Screw Compressor (Single Stage)

DRY SCREW RECIPROCATING

DRY SCREW CENTRIFUGAL

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Suction Valve Unloaders

High Compression Ratios

Foundation and Piping Requirements

Suction Throttle Valve

ACFM = SCFD (14.7) (T1°R)(Z1)/1440(P1)520

Head (ft) ~ (P2/P1)/MW

Rapid flow oscillations

Rapid pressure oscillations

Rising temperatures inside

Flow reverses in 20 to 50 milliseconds

Unstable flow and pressure

Activates open loop

Provides three main functions

Defined molecular weight

High reliability–Low maintenance

Decay of Performance With Blade Fouling

No spare – 99% on stream reliability

vs. Centrifugal – can be more expensive,

vs. Recip – no spare, usually less expensive

Screw Compressor (Single Stage)