NATURAL GAS

COMPRESSOR BASICS
 Outline
• Basic definitions and conventions
• Throws, cylinders, and stages
• Driver and compressor matches
• Compressor components
• Cylinder design features
• Rod load and rod reversal
• Capacity control devices and systems
Basic Definitions
and
Conventions
Separable Cut-Away
Standard rotation:
Clockwise viewed
from the driver toward
Throw 6
the compressor
Throw 5

Throw 4
Throw 3

Throw 2
Throw 1

Driver
Throws, Cylinders
and
Stages
Throw vs. Stage of Compression

THROW: A location on the crankshaft where

a compressor piston and cylinder
may be located

STAGE of COMPRESSION:
Process by which the pressure of
gas is increased
Throw vs. Stage of Compression
• Each Cylinder is located on a Throw
- Maximum of 2-cylinders per throw (Tandem)
- A Throw may also be “blank”
• A Separate Stage of Compression may be
accomplished by one or more cylinders
- Linked in parallel = one stage
- Linked in series = two or more stages
• Rule of Thumb Limit on Compression Ratio
- Ratio per Stage is 4.0 (Maximum)
- Temperature Increases as Compression Ratio Increases
Parallel & Series Schematics
Gas Engine Driven Package
Stream Summary
 Pressure: 64 psig
15
206°F
206FFF
Temperature: 206°F
60°F
60
206
 Pressure: 557psig
61
189
184 psig
Temperature: 293°F
275°F
120°F
275 F
120
293
 Pressure: 557
547 psig
psig
Temperature: 293°F
120°F
120 FF
293
Separable Cut-Away
2-Throw
4-Throw
6-Throw
Double-Acting Cylinder
Double Acting / D.A. cylinder
Double Acting Piston and Rod
 Tandem Cylinders

Crank Head
End End

P or SP-CE and P or SP-HE

Throw 1 Balance
throw

JGM:N:P:Q/1 frame
 Applications
• PRODUCTION • PIPELINE
- Gas Gathering - Booster
- Gas Lift - Mainline - Transmission
- Well Depletion - Storage - Injection &
• PROCESS Withdrawal

- Propane Refrigeration • AIR

- Residue Gas - Seismic Air - High
- Natural Gas Vehicle Pressure
Refueling (CNG) - Air Drilling Booster
- Fuel Gas Booster - Process Air
 Tandem Cylinders

HE CE

JG-HE and JG-CE

(OUTBOARD) (INBOARD)
 JG Tandem Piston & Rod
Assembly
Head-end

Crank-end
 SG-CE Tandem Cylinders
SG-FS-HE and SG-CE
SG-FS-HE

CNG Cylinders

CE Suction
HE Suction
Concentric
Valve

SG-CE SG-FS-HE

Rod Packing
HE Discharge

CE Discharge
 Tail Rod Cylinder
Suction
Pressure Packing

Tail Rod

Pressure Packing

Discharge
 Stage Stage
#4 #2
C
Throw Throw
O #1 #3

O Driver Compressor
L Throw Throw
E #2 #4

Stage Stage
R #3 #1
Electric Motor Driven Package
Typical Separator Arrangement
gas

gas + moisture

liquids
Level
switch Level
controller

Level sight glass

Separable Package
Driver and Compressor
Matches
 Compressor & Engine
• Compressor speeds
– Compressor speed should match or exceed driver speed

• Engines rated for generator speeds--not compressor speeds

- 900 RPM - 1200 RPM - 1800 RPM (60 hz)
- 1000 RPM - 1500 RPM (50 hz)

• Compressor Constraints
- VALVE LIFT - Durability & Efficiency
- Piston SPEED - Efficiency & Wear
- RPM - Inertia Loads & Valve Life
- ROD LOAD - Stresses
- Discharge Temperature
 Engine Market

FORCES DRIVING THE ENGINE

MARKET ARE…...
• Economy
- Rotating Speeds
• Ecology
- Emissions - Available engine emissions
control systems
 Driver Availability
• Engines
- Gas-Fueled
- Diesel-Fueled
- Dual-Fueled
• Electric Motors
- Induction (constant or variable speed)
- Synchronous (constant or variable speed)
• Turbine / Gear
- Combustion Turbines
- Steam
 Common Engine Drivers
SERIES HP RPM FRAMES
WAUKESHA
VSG 166-250 1200-1800 JGI,JGM,JGP
VGF 160-1175 1000-1800 JG,JGA,JGR,JGW,JGJ
VHP 366-1980 800-1200 JGK,JGH,JGE,JGT
AT 1246-4500 800-1000 JGC,JGD,JGU, JGZ,
CAT
3300 95-220 1200-1800 JGJ,JGM,JGP,JGI
3400 325-637 1200-1800 JG,JGA,JGW,JGR,JGJ
3500 670-1725 900-1400 JGK,JGH,JGE,JGT
3600 1775-4735 750-1000 JGC,JGD, JGU, JGZ,
CM34 6000-8000 750 KBB,KBV
 Common Engine Drivers
SERIES HP RPM FRAMES
WÄRTSILÄ
34SG-C 5000-7600 750 KBB,KBV
Compressor Components
Basic Compressor Components
Frame, spacer bars and
bearing cap are match
marked to help have them
reassembled that same way
they were manufactured

Match Marks
JGM:N:P:Q/2 frame
 Throw Positions

Throw 2
Throw 1

Throw 1
Models with 1-1/8” Dia. Piston Rod
Models with 1-1/2” Dia. & larger Piston Rod
 Connecting rod bushing

Split shell bearing

Connecting Rod Assembly

 Crosshead

Crosshead pin

Thru bolt and Nylock nut

Crosshead pin caps

Crosshead Components
Separable Cut-Away
Different Weight
Crossheads
Different Weight Balance
Nuts
 Standard on:
JGM, JMP, JGN,
JGQ, JG, JGA,
JGR,JGJ

Crosshead Guide / Distance

Piece Arrangement
Standard on all except: Optional on:
JGM, JGP, JGN, JGQ, JG, JG, JGA,
JGA, JGR, JGJ JGR, JGJ

Crosshead Guide / Distance

Piece Arrangement
 Optional on all
except:
JGM, JGP,
JGN, JGQ

Crosshead Guide / Distance

Piece Arrangement
Ariel Plate Valve
Ariel Plate Valve
Bolt Valve type CT Suction valve
•High Speed Valve
Threaded Boss
•Used in many Ariel Cylinders

Guard
•Applied in standard applications
in Low to Medium pressures:
Springs

Guide Ring •Field Compressors

•Gas Processing
Wafer Spring
•Pipeline
Valve Plate

Seat
 Ariel Valves
Spring Plate Valve Coil Spring Valve
Center Bolt
Guard
Spring Plates

Anti-Stiction Plate
Coil Springs
Backing Plate
Valve Plate
Guide Ring

Valve Seat
 APV
1. Seat
3. Locating Pins
5. HTCX Rings
6. Wear Plate
7. Synchronization Plate
8. Guide Ring
9. Springs
11. Threaded Washer
Poppet Valve
 Valve Assembly
Valve Cap Retainer Valve

Cap Bolts
“O” Ring Seat Gasket
Cylinder Design
Features
Ariel Cylinder Design Features

• Non-cooled cylinders
• ASME code cylinder design method
• Ion-nitriding
• Unlined cylinder bores
Cylinder Water Jackets
 Non-Cooled Cylinders
• Shorter, less complex cylinders.
• More passage volume, less pulsation.
 Ariel Non-Cooled Cylinders
Advantages
• Reduces pulsation due to increased passage volume
• Eliminates cylinder cooling system maintenance and
associated environmental concerns
• Simplifies cylinder casting
• Simplifies compressor package layout and reduces
installation cost
• Improves accessibility
• Employs pressure vessel design
ASME Code Cylinder Design

• Cylinder MAWP based on minimum value of:

– Burst test pressure ÷ design factor
– Allowable bolt loading
– Flange rating
Hydrotest
Cylinder Burst
 Ion Nitriding of Cylinder Bore

ION NITRIDING: A thermal process by which

nitrogen ions are diffused into the metal surface
forming nitride compound layers.

• Increased surface hardness to 50 Rockwell

• Low temperature hardening process which does
not distort cylinder
Ion Nitrider
 Un-Lined Cylinder Bores
Ariel cylinder bores are NOT lined

• Cylinder bores are ion-nitrided to improve

wear resistance
• Simple cylinder design allows for
inexpensive and expedient replacement, if
required
• Cylinders have re-bore capability up to .050”
on diameter
 Rod Load
and
Rod Reversal
Rod Load

• Inertia Loads
• Gas Loads
• Combined Loads
• Rod Load Limits
 Inertia Loads
• Needed to Accelerate and Decelerate
Reciprocating Components
– Piston and Rod Assembly
– Cross Head Assembly
 Gas Load

• Gas Pressure Against Piston Areas

• Compressive Force on Head End (Out-board)
• Tensile Force on Crank End (In-board)
• Calculated with Internal Pressures
Average Gas Load
 Combined Load

• Sum of Inertia and Instantaneous Gas Load

• Must Have Load Reversal between the
Crosshead Pin and Crosshead Pin Bushing
 Rod Load Limits
• Established Design Limits to Avoid
– Tension Failure
– Compression Failure
– Cycling Fatigue
(Compression + Tension)
Connecting
Rod
Cross Head
Pin Bushing
Suction

Discharge
Suction

Discharge
Suction

Discharge
Suction

Discharge
Suction

Discharge
Double Acting
Suction

Discharge
Suction

Discharge
Suction

Discharge
Suction

Discharge
Suction

Discharge
Suction

Discharge
Single Acting - Head End
Suction

Discharge
 Cylinder Characteristics

• Bore

D
 Cylinder Characteristics

• Stroke

S
Cylinder Characteristics
• Piston area, in2
πD 2
A =
4

• Swept volume, in3

2
SV = A,in x S,in
 Cylinder Characteristics
• Cylinder clearance volume is expressed
as % of swept volume

clearance volume, in3

CL% = 3
x 100
swept volume, in
Cylinder Characteristics
• Compressor Valves

Suction Suction

Discharge Discharge
Sequence of Events - PT
Pdis

Expansion

Compression

Psuc
Sequence of Events -
PV
Discharge
Pdis

Compression

Expansion

Psuc Intake
 Flow

Q inlet volume = Displacement x Volumetric Efficiency

Volumetric Efficiency
■ Measure how efficient the cylinder
is at displacing volume
■ Function of clearance and
compression ratio
■ Portion of stroke when valves are
open - gas flowing

1
VE = 100 - CL(r k
− 1)
 Capacity Control
• Added clearance volume
• Gas in larger clearance volume takes
longer to expand
• Reduced volumetric efficiency
What is Clearance Volume?
How does it affect Capacity?
• Clearance is: Cylinder Volume not swept
by the piston.

• Normal Clearance is: the Minimum Fixed

Clearance of a cylinder.

• Added Clearance is: any Clearance

above Normal.
Cylinder Characteristics
• Fixed Clearance
Head End
Clearance
 Volumetric Efficiency

 Zs 1 
VE% = 100 - CR - CL CR − 1
K

 ZD 
• VE = volumetric efficiency
• CR = compression ratio
• CL = % clearance
 Inlet Flow

  Zs 1  
ACFM = PD x 100 - CR - CL CR K − 1
  ZD 
• PD = piston displacement, cfm
• VE = volumetric efficiency
• CR = compression ratio
• CL = % clearance
Capacity Control Devices
and
Systems
 Capacity Control
Why do we need Capacity Control
Devices?
Reduce flow / horsepower
Changing Conditions
Rod Loads / Temperatures
Factors Affecting Capacity
• CLEARANCE VOLUME
• DISPLACEMENT
– Speed
– End Deactivation
• GAS CONDITIONS
– Pressures
– Suction Temperature
– Specific Gravity
 Clearance Volume…
What Is It and How It Affects Capacity?

• Clearance Is Cylinder Volume Not Swept

by the Piston.
• Normal Clearance is the Minimum Fixed
Clearance of a Cylinder
• Added Clearance is any Clearance
above Normal
 Normal Head End Clearance
Head End Clearance
Normal Crank End Clearance
Crank End
Clearance
Volumetric Efficiency
Pdis

Volumetric Efficiency
Psuc

Intake
 Capacity Control
Pocket closed Pocket 50% open

66% VE

36% VE
Fixed Clearance
 Capacity Control
Pocket closed Pocket 50% open

66% VE

36% VE
Capacity Control
Pocket closed Pocket 50% open

66% VE

36% VE
Devices and Methods to Change
Clearance
• Variable Volume Pockets
• Fixed Volume Pockets
• High Clearance Assemblies
• High Clearance Valves
• End Deactivation
 Capacity Control Devices
• VVCP -variable volume clearance
pocket
• PFCVP-pneumatic fixed volume
clearance pocket
• HCA - high clearance assemblies
• SVUL - suction valve unloader
• H.E. Bypass
 Capacity Control Devices
• Variable Volume Clearance Pocket

Cylinder with
Variable Volume
Clearance Pocket

Cross-Section
 Capacity Control Devices
• Variable Volume Clearance Pocket
Normal Clearance

Clearance added to
“fixed” clearance with
installation of VVCP
 Capacity Control Devices
• Variable Volume Clearance Pocket
Step-Cut Joint
Piston Ring Gas Vent Grease Fitting

Shrunk On Spring Loaded

Piston “V” Packing
 Capacity Control Devices
• Variable Volume Clearance Pocket
Fixed clearance

Clearance added to
“fixed” clearance with
installation of VVCP
VVCP Position
 Capacity Control Devices
• Pneumatic Fixed Volume Clearance Pocket
 Capacity Control Devices
• Pneumatic Fixed Volume Clearance Pocket
Gas + Actuation
Plug Closed Gas Vent
Actuation
Gas Vent

Activation gas
inlet 70-125 psig

Plug Open Breather Vent

 Capacity Control Devices
• Pneumatic Fixed Volume Clearance Pocket

Normal Clearance

Clearance added to
“fixed” clearance with
installation of FVCP Clearance added by
opening pocket
Multi-Pocket Head

(2) 17-7/8X, 20-1/8X, 22X

(3) 24-1/4X
 Capacity Control Devices
• High Clearance Assemblies

High Clearance
Valve
Assembly
Spacer
 Valve Assembly
Valve Cap Retainer Valve

Cap Bolts
“O” Ring Seat Gasket
Capacity Control Devices
• High Clearance Assembly
 Capacity Control Devices
• High Clearance Assembly

Spacer Spacer
Installed not
Installed
Methods of End Deactivation

• Valve Removal
• Finger Type Suction Valve
Unloaders
• Head End Bypass
Deactivated End PV Diagram
 Suction Valve Removal
Standard Double-Acting Cylinder with all Valves Installed
 Suction Valve Removal
Double-Acting Cylinder with Head End
Suction Valves Removed Note: Cap is flush to cylinder body
Suction Valve Unloader
Suction Valve with Unloader
and Piston Actuator
 Valve Unloaders
Finger Unloader with stack actuator
Suction Valve Control
Suction Valve Unloader
• Suction Valve Unloaders
– Check with AE for all
applications
– Reduce HE suction valve
equivalent area by 7.5%
– Limited use above 750 psig
– Use a SVU on each head
end suction valve (there
are some exceptions)
 Suction Valve Unloader

Actuation Gas Inlet

60 - 100 psig Gas +
Actuation Gas
Vent
Unloader
Assembly
Attached to
Suction Valve

Fingers Keep
Suction Valve Plates One on each Head
Open End suction Valve
Head End Bypass
Bypass open

Bypass closed
Combo H.E. Bypass/ FVCP
Head End Bypass
 Q=3.05 1st 2nd
Capacity Control
Tdis 255 4.5
287
11K 1st stage Psuc 55 psig 6.25K 2nd stage
CRL 17155 15969
0%
Pdis 650 psig
4.0

0% 38%
3.5
70%
38%
Flow, MMSCFD

3.0
75%

2.5

2.0

1.5

Q=2.35 1st 2nd Q=2.35 1st 2nd

1.0
Tdis 233 308 180 213 221 Tdis 260 281
CRL 13889 16767 CRL 17951 15774
0.5
160 180 200 220 240 260

Interstage Pressure, psig

 Ariel Product Support
• 95% of spare parts orders ship within 24
hours of order receipt
• 3-year warranty on all major parts
• 12 months on all other parts manufactured
by Ariel
• Spare parts are available for all units back
to Ariel serial #1
 Ariel Technical Support
• Compressor Performance Program
• Application Data Book
• Application/Field Service Engineering
• Operators Manuals
• Service and Technical Schools
• Distributor Resources
– Operations experience
– Applications
– Installation and start-up assistance
– Parts and service
– Contract compression available through some distributors
Ariel Serial #1
 Typical
Off-Shore
Package

Minimal
Foundations
Turbine-Driven JGK/4
Turbine-Driven JGC/6
Electric Motor Driven JGC/6
Multiple-Unit Compressor Station
Blackjack Road Plant
 Capacity Control Devices
• VVCP……………….Variable Volume Clearance Pocket
• PFVCP……………...Pneumatic Fixed Volume Clearance Pocket
• HCA…………………High Clearance Assemblies
• DDFVCP……………Double Deck Fixed Volume Clearance Pocket
• SVUL……………….Suction Valve Unloader
• End Deactivation…Remove Head End Suction Valves
• H.E. Bypass…….…Head End Bypass