Compressors

• Increase Pressure of gas by mechanically

reducing its volume

Compressors • Compressed:
– Air most frequent
– Natural Gas
– Oxygen
Copyright ©, 2005, – Nitrogen
William G. Beazley, PhD • Drives:
All Rights Reserved – Electric Motors
Other Copyrights Apply as Noted – Steam turbines, or
– Gas turbines

Compressor Family Tree

(Source: Compressed Air Challenge)
Centrifugal
• Used for:
– Low Pressures
– High Volume
• High Speed Impellers
• Configurations:
– Single Case, Single Stage
– Single Case, Multiple Stage
• Dynamic (Usually Centrifugal)
– Multiple Case, Multiple Stage
• Positive Displacement
– Reciprocating
– Rotary (e.g., liquid seal)
http://www.knowpressure.org/content/library/sourcebook/html/intr o_ca.htm

Positive Displacement or Centrifugal Compressors

Reciprocating • Originally built to handle only
large volumes of low pressure
gas and air (maximum of 40
• Used for: psig)
– Relatively Slow Speed • Developed to move large
– Small Volume volumes of gas with discharge
pressures up to 3,500 psig
– Extreme Pressures (50,000 PSI+) • Most frequently used for
medium volume and medium
• Configurations pressure air delivery
– Single Stage • One advantage is smooth
– Multiple Stage discharge of the compressed
air

http://www.tpub.com/content/fc/14104/css/14104_197.htm

1
 Centrifugal Compressor Operation Compressor Impellor Designs
• Centrifugal force same as utilized
by centrifugal pump • Note: Sometimes
– Air particles enter eye of impeller Process Pressures or
– As impeller rotates, air is thrown Other Improvements
against casing of compressor
compressing it Can Result from Just
– Pressure of air increases as it is Changing Impellors
pushed along path
• Note impeller blades curve forward,
opposite to backward curve in
typical centrifugal liquid pumps.
Centrifugal compressors can use a
variety of blade orientations
including both forward and
backward curves, etc.

Single Stage or Multistage Horizontal Slit-Case Centrifugal Compressor

(Source: General Electric Company)
Horizontal Split-Case
Compressor • Used for low to
(Source: Bausebacher and Hunt) medium pressure
service such as:
– Refrigeration Plants,
– Ethylene Plants,
– Catalytic Cracking
Plants,
– Urea Plants And
– Oxygen Plants.

http://www.gepower.com/prod_serv/products/compressors/en/index.htm

4000 HP Centrifugal Compressor Multi-Stage Centrifugal Compressors

for Overhead Gas Compressor (Photo: MAN Turbo)
(Source: YORK Process Systems)
• Several stages used to
reach a higher pressure
• Higher pressure air used
for:
– pneumatic control
devices,
– pneumatic sensors,
– pneumatic valve
operators,
– pneumatic motors, and
– starting air for diesel
engines.

http://www.manturbo.com/en/500/500_radial.php

http:// www.york.com/Products/Ref/PROCESSSYSTEMS/Default.asp#

2
 Vertical Split-Case Compressor Vertical Slit-Case Centrifugal Compressor
(Source: Bausebacher and Hunt)
(Source: General Electric Company)

• Used primarily for

high pressure
applications such
as:
– Ammonia, urea and
methanol synthesis,
– Refinery recycle and
– Natural gas
compression and
injection

http://www.gepower.com/prod_serv/products/compressors/en/index.htm

Reciprocating Air Compressor

Horizontal vs Vertical Split • Most common design.
• Elements:
• Horizontal: for gases with partial pressure – Compressing element -
fo H 2 <200 air cylinders, heads and
pistons, and air inlet and
– Pressures up to 600-800 PSIG discharge valves.
– Simpler maintenance –easy to remove rotore – Drive System for
transmitting power to
– Less Foot print air cylinder piston
– Less Costly – Self-contained
lubricating system
• Vertical: – Regulation or control
– Better Sealing Capability system
– Unloading system to
– Higher Pressure Capability reduce or eliminate starting
load

Air Compressors Typical Cycle for Reciprocating Single-

• Used widely throughout process
stage, Single-acting Compressor Cylinder
facilities in numerous
applications
• Compressed air uses operation
of:
– Equipment,
– portable tools,
– Process Sensors, and
– Process Actuators

Photos:
http://www.gardnerdenver.com/GDCorpPortal/RouteRequest?route=to&id=1129
http://www.waukeemeters.com/Pages/Rotary_Vane_Compressors.htm
http://www.rolls-royce.com/energy/products/oilgas/pipeline.jsp

3
 Parallel Cylinder Compressor
Multi-Stage Compressor

• Higher
• Equal Pressures Pressures
• More Mass Flow • Equal Mass Flow
• More Discharges • More Pressure
per Cycle Jumps per Cycle

Reciprocating Piston Compressor Heavy Duty Reciprocating Compressors

(Double-Acting) (Source: Dresser-Rand Company )

http://www.dresser -rand.com/recip/eq/hhe.asp

High Pressure Reciprocating Compressor

(Source: Burckhardt Compression AG)
Rotary Air Compressors
• Adaptable to direct drive:
– induction motors or
– multicylinder gasoline or diesel engines.
• Compact, relatively inexpensive, and require a
minimum of operating attention and maintenance
• Occupy a fraction of space and weight of
reciprocating machine of equivalent capacity.
• Three general groups:
High-pressure reciprocating compressor for low density polyethylene plants, with
1. slide vane-type,
discharge pressure up to 3500 bar (50,000 psi ), flow from 40'- 160'000 kg/h, and 2. lobe-type, and
shaft power up to 35'000 kW (47,000 HP)
3. liquid seal ring-type
http://www.burckhardtcompression.com/

4
 Slide Vane-Type Rotary Compressor
Sliding Vane Compressor

– Has longitudinal vanes, sliding radially in a slotted rotor

mounted eccentrically in a cylinder
– Centrifugal force carries sliding vanes against cylindrical
case with vanes forming individual longitudinal cells
– Suction port is located where cells are largest
– Eccentricity of rotor to discharge port compresses gas

Rotary Lobe-Type Air Compressor

Lobe-Type
– Two mating lobe-type rotors
mounted in a case Blower
– Lobes are gear driven at (Photo: Aerzen
close clearance, but without Canada Blowers
metal-to-metal contact and Compressors
– Suction to unit is located where Inc.)
cavity made by lobes is largest
– As lobes rotate, cavity size is
reduced, causing compression
– Compression continues until
discharge port reached and
vapor exits compressor at
higher pressure
http:// www.aerzen.ca/products.htm

Rotary Liquid Seal Ring Air Compressor Liquid Ring Compressor

• Forward inclined, open impeller, in oblong liquid filled cavity

• Centrifugal force collects seal liquid at outer edge cavity
– Oblong case creates large longitudinal cells, made smaller in rotation causing
the vapor within the cell to compress
– Suction port is positioned where longitudinal cells are largest
– Discharge port, where they are smallest
• Frequently used in specialized applications e.g.:
– Extremely corrosive and exothermic gasses
– Commercial nuclear plants (to establish initial condenser vacuum)
Photo: http://www.hivaceng.com/liquid_ring-pumps.html

5
 Compressor Coolers Compressor with Built-In Coolers
• Avoid moisture in compressed air systems: (Source: FS-Elliot)
– Air moisture capacity
• inversely proportional to pressure and
• proportional to temperature
– Pressure change of compressed air is larger than temperature
change causing moisture to condense
– Condensed moisture can cause corrosion, water hammers, and
freeze damage;
• Allows more air to be compressed for a set volume
– Intercooler, usually located after first stage discharge, before the
second stage suction.
– Aftercoolers follow compressor

Photo: http:// www.britheat.co.uk/applications.asp

http://www.machinedesign.com/ASP/viewSelectedArticle.asp?strArti cleId=58098&strSite= MDSite&catId=0

Rotary Screw Compressor Screw Type

Air
Compressor

http://www.tpub.com/content/fc/14104/css/14104_202.htm

Large Process Gas Screw Large Process Gas Screw Compressor

Compressor (Photo: Aerzen Canada Blowers and
(Photo: MAN Turbo) Compressors Inc.)

http:// www.aerzen.ca/products.htm
http://www.manturbo.com/en/500/500_screw.php

6
 Compressor Drives Tandem Compressor Arrangement
(Source: Bausebacher and Hunt)
• Electrical motors
• Gas Turbines
• Steam Turbines (60,000HP+)
– Condensing (Used Steam is condensed)
– Back Pressure (Steam Exits at a Lower but
Usable PT)
– Topping (High Pressure Steam is skimmed
leaving lower, more typical pressure exhaust
for process use elsewhere)

Electric Motor Compressor Drive Steam Turbine Compressor Drive

(Source: Bausebacher and Hunt) (Source: Bausebacher and Hunt)

Steam Turbine Condensing Turbine

(Photo: MAN Turbo)

http://www.manturbo.com/en/500/500_steam_types.php#condensation

7
 Steam Turbine Components Gas Turbine Compressor Drive
(Source: Bausebacher and Hunt)

Gas Turbine
(Photo: MAN Turbo) Gas Turbine Components

http://www.manturbo.com/en/500/500_ft8.php

Elevated Centrifugal Compressor with a

Single Condensing Steam Turbine Drive
(Source: Bausebacher and Hunt)

Compressor/Drive Configurations

8
 70,000+BHP (52,200+kW) Steam Turbine Driving Butadiene Production Plant Utilizing
Cracked Gas Compressors In Ethylene Plant Four 110 M-frame Compressors
(Source: Elliott Turbomachinery Co., Inc.) (Source: Elliott Turbomachinery Co., Inc.)

http://www.elliott-turbo.com http://www.elliott-turbo.com

Elevated Centrifugal Compressor with Multiple

Condensing Steam Turbine Drives
(Source: Bausebacher and Hunt)
Types of
Compressor
Systems
(Source: Bausebacher
and Hunt)

Types of Compressor Systems (cont’d) Gas Turbine Driven Propane Refrigeration

(Source: Bausebacher and Hunt)
Compressor In A Natural Gas Plant
(Source: Elliott Turbomachinery Co., Inc.)

http://www.elliott-turbo.com

9
Types of Compressor Systems (cont’d) A 1500 CFM
(Source: Bausebacher and Hunt) industrial air
compressor, with
"D" flange
mounted motor,
being used in a
steel mill
(Source: Elliott
Turbomachinery Co.,
Inc.)

http://www.elliott-turbo.com

Types of Compressor Systems (cont’d)

(Source: Bausebacher and Hunt)

Compressor Auxiliary Equipment

Lube Oil Console Lube Oil and Seal Oil Console

(Source: Bausebacher and Hunt)
• For Lubrication and sealing
• Sour Oil Traps
– Oil that has been contaminated by process
– Filter to remove impurities
• Degassing Tank
– Remove gasses from oil
• Oil Reservoir
– Store Oil awaiting use
– May be stored under pressure as backup to pumps
• Lube & Seal Oil Pumps
• Oil Heaters,Coolers
– Cold climate need oil heating, hot needs coolers
– Oil Temp must not “Shock” machine
– Used oil needs cooling
• Oil Filters – Remove Impurities

10
 Lube Oil Console
(Photo: Power Services Technologies, Inc.) Head or Run-Down Tank
• If Lube Oil power is lost Compressor must
run down
• Supplies oil to bearings while compressor
runs down
• Not pressurized: Gravity Flow

http://www.pstpower.com/prod01.htm

Seal Oil Console Surface Condensor

(Source: Bausebacher and Hunt) (Source: Bausebacher and Hunt)

• Designed for high volume low pressure

• Dome to slow gas velocity

Condensate Pump Air Blower

(Source: Bausebacher and Hunt) (Source: Bausebacher and Hunt)

• Can type pumps

• In ground to raise NPSH • Place Inlet Away from process discharges

11
 Inlet Air Filter Variations in Inlet Air Ducting
(Source: Bausebacher and Hunt) (Source: Bausebacher and Hunt)

• Clean Air before compression

• Dust accumulates and increases wear
• Preferred: Ducting inline with intake centerline (Option A)
• Often Self-Cleaning

Waste Heat Compressor

System Suction
(Source: Bausebacher
and Hunt)
Drum/Knockout
Drum
(Source: Bausebacher and Hunt)

• Removes liquid droplets

• Gas Turbines Generate Excessive Heat
from flow to suction
– Exit Temp about 1200 degrees F
• Liquid drops can damage
– Exhaust stack is usually high
compressor
• Heat Scavenged to heat steam or add heat to process
• Baffle & Demister force
– Usual use: Preheat boiler feedwater changes in flow direction,
– Most processes are flammable so caution rarely used velocity

Pulsation Dampeners on
Pulsation Process Gas Compressor
Dampener/ (Source: Burckhardt Compression AG)
Volume Bottle
(Source: Bausebacher
and Hunt)

• Pulsation Dampener has internal

baffles, etc. to control flow and
harmonics
• Volume Bottles have no internals
to control flow: Merely stores
volume at pressure
• Concrete foundations help limit
vibrations as well
http://www.hydrocarbons- technology.com/contractors/compressors/sulzer/sulzer3.html

12
 Vertically Mounted Bottles On Skid Mounted Reciprocating Gas
Reciprocating Gas Compressor Compressor
(Source: Peter Brotherhood Ltd) (Source: Peter Brotherhood Ltd)

http://www.hydrocarbons-technology.com/contractors/compressors/peter_brotherhood/ http://www.hydrocarbons -technology.com/contractors/compressors/peter_brotherhood/

8000 HP Magnetic Bearing Centrifugal

Pulsation Dampening
Pump
(Source: YORK Process Systems)
(Source: Hydropad)

http://www.flexicraft.com/hydrop2.asp?catid=6&subcatid=360

http:// www.york.com/Products/Ref/PROCESSSYSTEMS/Default.asp#

Lube Oil Console Maintenance

(Source: Bausebacher and Hunt) Lube Oil
Console
P&ID
(Source:
Bausebacher and
Hunt)

13
 Lube Oil Drain Line Requirements
Drain
• Addressed in API 614
Routing • Gravity Return Min slope ½” per ft
(Source:
Bausebacher and • All branch connections are a lateral
Hunt) • Run no more than half full
• Min size 1 ½” dia
• Stainless Steel

Seal Oil
Seal Oil Tank Location
(Source: Bausebacher and Hunt) Console
P&ID
(Source:
Bausebacher and
Hunt)

Surface Condenser Operation Surface Condenser

(Source: Bausebacher and Hunt) (Photo: Temaindia )

http:// www.temaindia.com/Product/product.html

14
 Surface Surface Condenser and Auxiliary Equipment
Condenser (Source: Bausebacher and Hunt)
(Photo: Holtec
International)

http://www.holtecinternational.com/ppe.html

Surface Condenser Elevation

(Source: Bausebacher and Hunt) Elevated
Compressor
(Source:
Bausebacher
and Hunt)

Compressor Maintenance
(Source: Texas Compressor Corporation)

Maintenance Requirements

http:// www.texascompressor.com/fieldservice.htm

15
 Compressor Maintenance Overhead Cranes
(Source: Capital Machinery Systems, Inc.)

• Sometimes needed to support maintenance

• Pull Piping
http:// www.texascompressor.com/fieldservice.htm
• Enclosed building to limit climate exposure

Grade Mounted
Centrifugal Compressor Grade Mounted
– No Shelter Centrifugal
(Source: Bausebacher and Hunt) Compressor –
Open-Sided Shelter
(Source: Bausebacher and Hunt)

Grade Mounted Elevated

Centrifugal Centrifugal
Compressor –
Compressor
Curtain Wall
– No Shelter
Shelter (Source: Bausebacher
(Source: Bausebacher and Hunt)
and Hunt)

16
 Reciprocating Compressor Open
Maintenance Installation/Enclosed Structure
Sequence (Source: Bausebacher and Hunt)
(Source: Bausebacher and
Hunt)

High Pressure Reciprocating Compressor

Planning for Cylinder Removal
(Source: Burckhardt Compression AG) (Source: Bausebacher and Hunt)

High-pressure reciprocating compressor for low density polyethylene plants, with

discharge pressure up to 3500 bar (50,000 psi ), flow from 40'- 160'000 kg/h, and
shaft power up to 35'000 kW (47,000 HP)

http://www.burckhardtcompression.com/

Centrifugal Compressor Area:

Centrifugal Compressor Area: No Shelter
(Source: Bausebacher and Hunt) Totally Enclosed Structure
(Source: Bausebacher and Hunt)

17
 Criteria for Setting Machine Elevations
(Source: Bausebacher and Hunt)

• A – Bottom-Mounted Nozzles
Setting
• B – Top- Mounted Nozzles
Elevations of
• C – Surface Condenser Mounted Directly Below Centrifugal
Turbine Compressors
(Source: Bausebacher and
• D – Tope Nozzle Allowing Exhaust Steam Line run Hunt)
to Surface Condenser Servicing Multiple Turbines

Setting Elevations of Steam Turbines Setting Elevations of Reciprocating

(Source: Bausebacher and Hunt) Compressors
(Source: Bausebacher and Hunt)

Centrifugal Reciprocating
Compressor with Compressor
Intercooler and with all
Piping Between Components
(Source: Bausebacher
Stages and Hunt)
(Source: Bausebacher and Hunt)

18
 Aftercooler P&ID Compressor Shelter Sizing Criteria
(Source: Bausebacher and Hunt) (Source: Bausebacher and Hunt)

Compressor Compressor Piping

Suction (Source: Marathon Technical Services)
Configurations
(Source: Bausebacher and Hunt)

http:// www.marathontech.ca/StationSupport.html

Wash Water Inlet Line Strainers

(Source: Bausebacher and Hunt)
Injection
(Source: Bausebacher and Hunt)

19

Maintenance Break-Out Flanges
(Source: Bausebacher and Hunt)
High Pressure Steam Inlet Piping
(Source: Bausebacher and Hunt)
Compressor Supports
(Source: Bausebacher and Hunt)
Operating Valve Accessibility
(Source: Bausebacher and Hunt)
Compressor Line Branches
(Source: Bausebacher and Hunt)
Hazards of Compressed Air
• At sufficient pressures, compressed air can cause serious
damage
• Ballistic hazards:
– Small leaks or breaks can cause minute particles to be blown at
extremely high speeds
– Wear safety glasses or goggles
• Noise:
– Compressors noise can be exceptional
– Compressor & drain valves lifting require hearing protection
– Posted as a hearing protection zone
• Air streams or sudden releases:
– Pressurized air can do same type of damage as pressurized water
– Closed valves slowly cracked open and both sides allowed to equalize
– Always depressurized systems before opening for maintenance
• Contaminants:
– Oil introduced in an air compressor can be compressed to point where
detonation takes place as in diesel engines.
– Detonation can cause equipment damage and personnel injury.
20
 Finding 1,500 LB Steam
• Can’t see it
• Find Bamboo pole search
• When pole is cut off the leak is found
Centrifugal Advantages
• Smaller, Lighter
• Smaller foundation
• Pulse free flow
• Oil free - no contamination
• Less maintenance/greater reliability
• Typically installed unspared
• Smooth Capacity changes from rated flow to surge
• More readily direct connected to steam and gas
turbines
• Can pass small amounts of dirt and moisture better
• Suitable for higher discharge temperatures
Compressors Summary
• Three common types of compressors are reciprocating,
rotary, and centrifugal.
• Single-stage reciprocating compressor has a piston
that moves downward during the suction stroke,
expanding the gas in the cylinder. The expanding gas
causes pressure in the cylinder to drop. When the
pressure falls below the pressure on the other side of the
inlet valve, the valve opens and allows gas in until the
pressure equalizes across the inlet valve. The piston
bottoms out and then begins a compression stroke.
The upward movement of the piston compresses the gas
in the cylinder, causing the pressure across the inlet
valve to equalize and the inlet valve to reseat. The piston
continues to compress gas during the remainder of the
upward stroke until the cylinder pressure is great enough
to open the discharge valve against the valve spring
pressure. Once the discharge valve is open, the gas
compressed in the cylinder is discharged until the piston
completes the stroke.
Compressor Coordination
• Need:
– Compressor footprint
– Rotor Centerline (for hoist)
– Key Interfaces, utilities
– Plant space
– Process PID
• Rotating equipment data per API 617
Reciprocating Advantages
• Readily direct connected to electric motors
• Generally more efficient from positive
displacement
• Generally Less efficiency reduction and reduced
flow rates or for multiple operating points
• Better Able to handle wide variations in pressure
ratio and molecular weight
• Can often handle multple services in one frame
• Better suited to high inlet pressures (seals work
better)
Compressors Summary (Cont.)
• The centrifugal force utilized by the centrifugal compressors is the
same force utilized by the centrifugal pumps. The gas particles enter
the eye of the impeller. As the impeller rotates, gas is thrown against
the casing of the compressor. The gas becomes compressed as
more and more gas is thrown out to the casing by the impeller
blades. The gas is pushed along the path on the inner wall of the
casing. The pressure of the gas is increased as it is pushed along
this path. There could be several stages to a centrifugal gas
compressor just as in the centrifugal pump, resulting in higher
pressure.
• Rotary compressors are driven by a direct drive that rotates a
mechanism (impellers, vanes, or lobes) that compresses the gas
being pumped. The actual compression of the gas takes place due
either to centrifugal forces or a diminishing gas space as the
impellers rotate.
21
 Compressors Summary (Cont.)
• Cooling systems are required to remove any heat added
by the compression. Cool gas takes less space and holds
Questions
less moisture. This reduces corrosion and allows more gas
to be compressed into a given volume.
• Hazards associated with compressed gas include.
• Small leaks or breaks can cause minute particles to be
blown at high speeds. Goggles or safety glasses should
be worn when working around compressed air or gas.
• Compressors, especially larger ones, can be quite noisy
when running. The cycling of automatic drain valves
contributes noise as well. Hearing protection should be
worn around compressors.
• Pressure swings may cause system damage. Closed
valves should be slowly cracked open and pressure should
be allowed to equalize prior to opening the valve further.
Systems should be depressurized prior to opening for
maintenance.
• Oil should be kept out of air systems to prevent possible
explosions.

Ejectors Eductors
• High Speed Stream Suck material out of • Hydraulic Process where high velocity
tube it passes stream adds momentum to another stream
to move both

22