The Importance of Determining Number of Stages in Reciprocating Compressor and Bonus

Calculation Spreadsheet

Three previous posts show comparison of number of stages in determining reciprocating compressor
power.

[link]

Let’s summarize the results.

Parameter Unit 2-stage 3-stage 4-stage

Gas rate MMscfd 2.00 2.00 2.00
Intake pressure psia 100.00 100.00 100.00
Intake temperature F 100.00 100.00 100.00
Discharge pressure psia 900.00 900.00 900.00

1st stage discharge pressure psia 300.00 208.01 173.21

1st stage discharge temperature F 217.63 175.90 156.01
2nd stage suction pressure psia 295.00 203.01 168.21
2nd stage discharge pressure psia 900.00 427.44 294.20
2nd stage suction temperature F 120.00 120.00 120.00
2nd stage discharge temperature F 243.88 200.01 186.00
3rd stage suction pressure psia - 422.44 289.20
3rd stage discharge pressure psia - 900.00 510.17
3rd stage suction temperature F - 120.00 120.00
3rd stage discharge temperature F - 201.36 180.05
4th stage suction pressure psia - - 505.17
4th stage discharge pressure psia - - 900.00
4th stage suction temperature F - - 120.00
4th stage discharge temperature F - - 181.14

BHP 1st stage HP 134.60 94.58 76.12

BHP 2nd stage HP 133.21 96.26 79.11
BHP 3rd stage HP - 88.87 75.17
BHP 4th stage HP - - 70.12
Total BHP HP 267.81 279.71 300.51

We can see that the more stages we use, the higher total BHP is. Next question is, how to determine
number of stages?

Many references mentioned that number of stages of reciprocating compressor is determined by

allowable discharge temperature. If the calculated discharge temperature using one stage is too
high, it is obvious to add more stages.

In almost all multi-stage applications [1], the gas will be cooled between stages. In this case,
increasing the number of stages, up to a limit, will increase the efficiency of compressor. This is
because with intercooling, the compression more closely approximates an isothermal compression
with resulting lower power requirement. An alternative way of looking at this is on a pressure-
volume diagram below.
[figure]

The work required to compress gas is given by the area of the pressure vs volume diagram. Figure
above shows a single- and a two-stage compression for a given application. The diagram for single
stage compression is 1-2-3-4-1. For two-stage compression, it is 1-5-6-7-3-8-4-1. As the interstage
gas is cooled (5-6), its volume decreases. The work done as given by the areas of the diagrams is
obviously less in the two-stage case than in the single-stage case. Further, if any liquids are
condensed out of the gas in the intercoolers, the liquids must be separated from the gas and the
mass of gas compressed from the interstage to the final discharge is reduced with a further resulting
power reduction. However, as stages are added, the number of compressor valves the gas must flow
through in series, and the amount of interstage piping and coolers increase. If too many stages are
used, the pressure losses in the valves and piping will offset the gains from intercooling and the
efficiency will be reduced.

The cost of compressor to do a given task usually increases as the number of stages is increased
because of the additional compressor cylinders, coolers, and piping.

In other reference [2], the maximum compression ratio per stage is usually about 3:1 to 4:1. Higher
compression ratios can result it reduced volumetric and mechanical efficiencies and greater
mechanical stress. The outlet temperature also limits the compression ratio. The mechanical design
limit is usually 350oF to 400oF, but lower temperature may be required depending on the gas
properties. In addition, the pressure rise per stage is often limited by compressor valve design
considerations to 1000 psi or less.

API 618 recommended that the discharge temperature should be limited to 300 oF [3]. Higher
temperatures cause problems with lubricant coking and valve deterioration. In non-lube service, the
ring material is also a factor in setting the temperature limit. Packing life may be significantly
shortened by the dual requirement to seal both high pressure and high temperature gases. For this
reason, at higher discharge pressures, a temperature closer to 250 oF or 275oF may be the practical
limit.

In summary and for most field applications, the use of 300 oF maximum would be a good average.

So, back to the case we use. We can conclude that 2-stage reciprocating compressor is suitable for
the case. The discharge temperature for each stage is below 275-300 oF.

I hope you find this post useful.

Bonus

Here is the spreadsheet calculation for reciprocating compressor power based on GPSA.

[link]

References:

[1] Hanlon, Paul C., “Compressor Handbook”, McGraw-Hill, 2001

[2] Dimoplon, William, “What Process Engineers Need to Know About Compressors”

[3] GPSA Engineering Data Book