COMPRESSORS PERFORMANCE AND MAINTENANCE

COMPRESSORS
Performance, Maintenance and Troubleshooting

FOR JUNIOR ENGINEERS
Presented By
Hesham M. Abdelgayed, MSc.
Rotating Equipment Section Head

Egyptian Natural Gas Company, Gasco
PhD Student,
Mechanical Engineering Department
University Of Alexandria
Different States of Matter
Compressible and Incompressible Fluids
Fluids
Incompressible
Fluids Compressible Fluids
Introduction
It is a device used to move gases by increasing pressure of any compressible fluid;

Definition gas or vapor.
+ High level
Discharge pressure
Inlet pressure
352 Uranium hexafluoride
0
Compressor Atmospheric
Molecular weight rang
- Sub atmospheric
Compressor
2 Hydrogen
Introduction
Why do we increase pressure? To create flow !
Compressor
Station
Compressor
Station
Compressor
Station
Production Processing Transmission & Storage Distribution
32,000 Compressors 5,000 Compressors 8,500 Compressors 0 Compressors

Introduction
Types of
COMPRESSORS
Compressors
Intermittent flow Continuous flow
Positive displacement
Dynamic Ejector
Reciprocating Rotary
Radial Mixed Axial

Mechanical • Helical lobe
flow flow flow
piston • Straight lobe
• Sliding vanes
• Liquid piston
Introduction
A defined amount of  The compressible fluid

compressible fluid is taken continuously enters the
into the compressor from the Continuous Flow compressor, pressurized, and
suction line, then compressed, discharged without any
then discharged into the interruptions in the fluid flow.
discharge line before a new
charge is taken and the Intermittent Flow
process repeated.
Introduction
Compressors
Selection
Introduction
Compressors
Selection
Introduction
Centrifugal Compressors
API 617
Reciprocating Compressors
API 618
Screw Compressors
API 619
Continuous Flow Compressors
Theory of Pressure rise is achieved by adding kinetic energy/velocity to a continuous flow of

Compression fluid through the rotor or impeller. This kinetic energy is then converted to an
increase in static pressure by slowing the flow through a diffuser. The pressure rise in
impeller is in most cases almost equal to the rise in the diffuser section.
Axial Compressor Centrifugal Compressor

Theory of
Compression
Axial Compressor
Theory of
Compression
Axial Compressor
Theory of
Compression
Axial Compressor
Theory of
Compression Centrifugal Compressor
Theory of
Theory of
Theory of
Compression Ejector
Theory of
Compression Ejector
Centrifugal Compressor
Advantages
• Continuous operation
• Low initial costs per horsepower
• Lower maintenance cost than reciprocating
• High horsepower per unit of space and weight
Disadvantages
• Lower compressor efficiency compared with axial
Continuous Flow Compressors Centrifugal Compressors
Construction
Construction
1 Casing:
The casing is designed to withstand the
pressure inside the compressor and contains
the basic compressor components.
2 Inner barrel:
The inner barrel contains the aero
assembly and the rotor.
Construction
Construction Horizontally Split
Components
Casings
The casing is split along the
centerline of the housing and
bolted together by means of a
large flanged area. Sealing is
metal to metal, which
presents a problem when
higher pressures are required.
For this reason, horizontally
split casings are usually
limited to less than 1000
psig
Construction Horizontally Split
Components
Casings
Construction Vertically Split
Components
Casings
The casing is used in high-pressure
applications (up to 10000 psig). The
barrel casing is sealed by the front
cover, which is bolted and sealed with
an O-ring.
Construction
Components
Casings
Vertically Split
Construction
3 Rotor: shaft with a balance drum

and impellers
The basic function of a centrifugal compressor shaft is to transmit the torques encountered
Construction when starting and during operation while supporting the impeller and other rotating parts.
Components
Rotor
Impellers contain eye, shroud, and blades.

Construction
Components
Impeller

Construction
Components
Impeller

Construction
Components
Impeller
Very High Head High Head Very high Flow

Very Low Flow High Flow Very Low Head

Construction
Components
Impeller
Open
Semi-Closed Closed
Construction
Construction
Inlet Section
Construction
Components
Inter-stage Seal and Barrier Seal
Construction
Components
Inter-stage Seal and Barrier Seal
Labyrinth Seal
Construction
Components
Diaphragms
Construction
Components
Diaphragms
Construction
Construction
BAL. FLOW
Components
Thrust Force Balancing
P1 P2 P1
BAL
DRUM
FB F3 F1 F1
IMPELLER 3 IMPELLER 2 IMPELLER 1

Construction
Components
Construction
Components
Construction
4 Seals: Seals make the compressor gas tight.

Construction
4 Seals: Seals make the compressor gas tight.

Construction
Components
End Shaft Seal
Construction
Components
Dry Gas Seals and
Barrier Seal
Construction
Components
Dry Gas Seals and
Barrier Seal
Construction Buffer Seal – Carbon Ring Seals
Components
Barrier Seal
Construction
Construction
5 Bearings : The bearings are seated in the sets

Construction Wedge Action

Construction
Thrust Bearings
Construction Journal Bearings

Construction Journal Bearings

Oil System
Oil System
Construction
6 Probes: Measure vibration level and axial displacements.

Construction
Surge
Surge
Perofmance
Curves
Surge
Positive Displacement Compressors
Reciprocating
Compressors
Positive Displacement Compressors Reciprocating Compressors
Construction
Components
Piston and
Main Packing
Construction
Components
Pressure and
Rider Rings
Construction
Components
Valves - Plate
Heavy-duty compressors
use a form of plate valve.
The part that closes against
a valve seat is a flat metal
plate. The plates are held
tightly against the seat by a
set of springs.
Construction
Components
Valves - Plate
Heavy-duty compressors
use a form of plate valve.
The part that closes against
a valve seat is a flat metal
plate. The plates are held
tightly against the seat by a
set of springs.
Construction
Components
Valves – Channel
Construction
Components
Valves – Channel
Channel valves are good for medium to low

pressure service, with a maximum pressure
differential of 34 atm. They are tolerant of
dirty environments, and offer a particularly
advantageous flow pattern in sizes up to 133
mm diameter.
Construction
Components
Valves - Poppet
• These are shaped like the valves in an
automobile engine.
• These are separate, round poppets to seat
against holes in the valve seats.
• Poppets are made of low friction material
(e.g. Bakelite), they provide a low-pressure
drop and are often used when ratios of
compression are low and also for high flow
rates.
Construction
Components
Valves
Construction
Components
Valves
Construction
Components
Clearance
Pocket
Construction
Components
Oil Wiper Unit
Construction
Components
Cross Head
Construction
Components
Cross Head
Construction
Components
Bearings
Construction
Components
Bearings
Lube Oil
System
Lube Oil
System
Capacity
Control
Multi-Cylinder
Compressor
Positive Displacement Compressors Screw Compressors
Process
Diagram
Process
Diagram
Compressor
Compartment
Thank you for
your attention!
Any Questions?
Contact Details
Hesham AbdelGayed
Tel: 01002729088
Hekhalil@gmail.com

COMPRESSORS PERFORMANCE AND MAINTENANCE

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COMPRESSORS PERFORMANCE AND MAINTENANCE

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COMPRESSORS

Performance, Maintenance and Troubleshooting

Rotating Equipment Section Head

It is a device used to move gases by increasing pressure of any compressible fluid;

Why do we increase pressure? To create flow !

Production Processing Transmission & Storage Distribution

32,000 Compressors 5,000 Compressors 8,500 Compressors 0 Compressors

Radial Mixed Axial

A defined amount of  The compressible fluid

Theory of Pressure rise is achieved by adding kinetic energy/velocity to a continuous flow of

Axial Compressor Centrifugal Compressor

Construction Horizontally Split

Construction Horizontally Split

Construction Vertically Split

3 Rotor: shaft with a balance drum

Impellers contain eye, shroud, and blades.

Impellers contain eye, shroud, and blades.

Impellers contain eye, shroud, and blades.

Very High Head High Head Very high Flow

Impellers contain eye, shroud, and blades.

IMPELLER 3 IMPELLER 2 IMPELLER 1

4 Seals: Seals make the compressor gas tight.

4 Seals: Seals make the compressor gas tight.

Construction Buffer Seal – Carbon Ring Seals

5 Bearings : The bearings are seated in the sets

Construction Wedge Action

Construction Journal Bearings

Construction Journal Bearings

6 Probes: Measure vibration level and axial displacements.

Channel valves are good for medium to low

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