COMPRESSORS

RECIPROCATING
COMPRESSOR
SELECTION
BASICS
PRESSURE

• Absolute & Gage

– Actual pressure  Absolute pressure
– Gage reading  Gage pressure
– Pabs = Pg + Patm (1.013 bar)
– Liquid calculations  gage pressure
– Gas calculations  absolute pressure
• Bar and Psi
– 1 bar = 14.5 psi
– 100 psi = 7 bar
– P = 50 psia = 3.5 bara
– P = 300 psig = 21 barg
TEMPERATURE

– Celsius & Kelvin (absolute)

• T(K) = T(C) + 273
• All calculations  Kelvin
– Fahrenheit & Rankin (absolute)
• T(R) = T(F) + 460
• T(F) = T(C) × 9/5 +32
• T(F) ≈ 2 × T(C)
IDEAL GAS LAW

 
𝑷 ∙ 𝑽 =𝒎 ∙ 𝑹 ∙ 𝑻
𝐽 
 𝑃𝑎  𝑘𝑔
𝑘𝑔 ∙ 𝐾  𝐾
 𝑚 3

÷ 𝑻𝒊𝒎𝒆
 

 
𝑷 ∙ 𝑸 =𝒎
˙ ∙ 𝑹∙𝑻
 𝑚3   𝑘𝑔
𝑠 𝑠
FLOW RATE
  𝒎
˙ ∙𝑹∙𝑻  
𝑸=
𝑷

V (Q) V (Q)

Compressor capacity  suction (inlet) flow rate

Qcompressor = 200 LPM  Qsuction (inlet)

STANDARD FLOW RATE

  𝒎
˙ ∙𝑹∙𝑻𝒔  25o C
𝑸 𝒔=
𝑷𝒔 1.013 bar
 STANDARD FLOW RATE: EXAMPLE

 𝑷 ∙ 𝑸   𝑷 𝒔 ∙𝑸 𝒔
= 𝒎=
˙
𝑹∙𝑻 𝑹∙𝑻𝒔

 𝟕 × 𝟏𝟎𝟓 ∙ 𝟐𝟎𝟎
  𝟓
𝟔𝟎 × 𝟏𝟎𝟎𝟎 𝟏 . 𝟎𝟏𝟑 × 𝟏𝟎 ∙ 𝑸 𝒔
=𝟎 . 𝟎𝟐𝟕𝟏 𝒌𝒈 / 𝒔=
𝟐𝟖𝟕 ∙ ( 𝟐 𝟕 +𝟐𝟕𝟑 ) 𝟐𝟖𝟕 ∙ ( 𝟐𝟓 +𝟐𝟕𝟑 )

𝑸
  𝒔=𝟏𝟑𝟕𝟑 𝑺𝒕𝒂𝒏𝒅𝒂𝒓𝒅 𝑳𝑷𝑴
  𝟔𝟎 𝒎𝒊𝒏/ 𝒉
× 𝟑
𝟏𝟎𝟎𝟎 𝑳/ 𝒎
𝑸
  𝒔=𝟖𝟐. 𝟑𝟕 𝑺𝑪𝑴𝑯
 COMPRESSION PROCESS

P2
h Enthalpy
𝑇
  h 𝑒𝑜𝑟𝑒𝑡𝑖𝑐𝑎𝑙 𝑃𝑊 h2 𝑠 − h1
=𝜂𝑖𝑠𝑒 =
𝐴𝑐𝑡𝑢𝑎𝑙 𝑃𝑊 h 2 −h 1
h2
h2s
h=𝑐
  𝑝∙ 𝑇

Theoretical

Isentropic

power
Actual
𝑇 2𝑠− 𝑇1 P1

power
 
𝜂𝑖𝑠𝑒 =
𝑇 2 −𝑇 1
T2
𝛾 −1
𝑇
  2𝑠 𝑃
𝑇1
=
( )
𝑃1
2 𝛾
h1 Entropy
s
SELECTION OR
SIZING
Selection

Sizing
 Selection
&
Sizing
Selection

Sizing
Cylinder bore, number of stages, number of cylinders per
stage
RC MANUAL
SELECTION
 PROBLEM

 JOB:
 Compressing H2 from 10 bara & 47o C to 120 bara at a rate of 0.4 kg/s.
 REQUIRED:
o Select the suitable RC frame and size the cylinders in each stage.
 DATA:
o H2 (R = 4124 J/kg-K & γ = 1.4)
o Use the following brochure of Dresser-Rand

Stroke In. Number of Nominal Rated Max. Allowable Rod

Model Rated rpm
(mm) Cylinders Power hp (kW) Load lbs. (kN)
5D-VIP2 5 (127) 2 1875 (1398) 45,000 (200) 1500
5D-VIP4 5 (127) 4 3750 (2797) 45,000 (200) 1500
5D-VIP6 5 (127) 6 5625 (4195) 45,000 (200) 1500
6D-VIP2 6 (152.4) 2 1500 (1119) 45,000 (200) 1200
6D-VIP4 6 (152.4) 4 3000 (2237) 45,000 (200) 1200
6D-VIP6 6 (152.4) 6 4500 (3356) 45,000 (200) 1200
7D-VIP2 7 (177.8) 2 1800 (1343) 45,000 (200) 1000
7D-VIP4 7 (177.8) 4 3600 (2685) 45,000 (200) 1000
7D-VIP6 7 (177.8) 6 4800 (3580) 45,000 (200) 1000
NUMBER OF STAGES: CRITERIA
Prevent
lubricant breakdown
Maximum temperature < 150o C And hence:
Piston ring wear
Valve failure

P2
T

T2
T2s

𝑇
  𝑑 ≈ 𝑇2𝑠 P1

𝛾−1
𝑇
  𝑑 𝑃𝑑
( )
=
𝑇 𝑠 𝑃𝑠
𝛾

T1

s
 47o C 378o C
10 bara 120 bara

NUMBER OF STAGES: DECISION

 Assume a single-stage compressor

1 . 4 −1
  𝑇𝑑 1 .4 183o C 47o C
= ( 12 ) Td = 651 K = 378 C o
4 7+273 34.64 bara 34.64 bara

Intercooler
 Assume a two-stage compressor
47o C 183o C
10 bara 120 bara
1. 4 − 1
  𝑇𝑑
= ( √ 𝟏𝟐 ) 1 . 4 Td = 183o C
4 7+273
132o C
 Assume a three-stage compressor 120 bara

1 .4 −1
  𝑇𝑑 𝟑 1.4
= ( √ 𝟏𝟐 ) Td = 132 C
o
47o C
4 7+273 10 bara
 COMPRESSOR STAGES

47o C
52 bara
47o C 132o C
10 bara 52 bara

132o C
120 bara

132o C 47o C
23 bara 23 bara

Note: the number of

cylinders per stage is
undefined yet
INLET (SUCTION) FLOW RATES
  𝑷𝟏 ∙𝑸 𝟏 𝑷𝟐 ∙ 𝑸 𝟐 𝑷𝟑 ∙ 𝑸 𝟑
𝒎=
˙ = =
𝑹 ∙ 𝑻𝟏 𝑹 ∙𝑻 𝟐 𝑹 ∙𝑻 𝟑
  𝟏𝟎 ×𝟏𝟎𝟓 ∙ 𝑸 𝟏 𝟐𝟑 ×𝟏𝟎𝟓 ∙ 𝑸 𝟐 𝟓𝟐 ×𝟏𝟎𝟓 ∙𝑸 𝟑
𝟎 . 𝟒= = =
𝟒𝟏𝟐𝟒 ∙ ( 𝟒𝟕+ 𝟐𝟕𝟑 ) 𝟒𝟏𝟐𝟒 ∙ ( 𝟒𝟕+ 𝟐𝟕𝟑 ) 𝟒𝟏𝟐𝟒 ∙ ( 𝟒𝟕+ 𝟐𝟕𝟑 )
  𝒎𝟑 𝒎𝟑 𝒎𝟑
𝑸 𝟏=𝟎 . 𝟓𝟐𝟖 ,𝑸 𝟐 =𝟎 . 𝟐𝟑 , 𝑸 𝟑= 𝟎 .𝟏
𝒔 𝒔 𝒔
0.1 m3/s

0.528 m3/s

0.23 m3/s
SHAFT POWER
𝐶𝑜𝑚𝑝𝑟𝑒𝑠𝑠𝑖𝑜𝑛
  𝑝𝑜𝑤𝑒𝑟 =𝑚
˙ ( h𝑜𝑢𝑡 − h𝑖𝑛 )= 𝑚𝑐
˙ 𝑝 ( 𝑇 𝑜𝑢𝑡 −𝑇 𝑖𝑛 )
𝜸 −𝟏
 
𝑷𝒔𝒉 = 𝑷 𝒊𝒏 ∙ 𝑸 𝒊𝒏
𝜸 𝒓𝒑
( 𝜸
−𝟏
𝜸 − 𝟏 𝜂𝑖𝑠𝑒 ∙𝜂 𝑚𝑒𝑐 h )
𝜂  𝑖𝑠𝑒 ∙ 𝜂𝑚𝑒𝑐 h ≈ 0 .82
𝟏 .𝟒 −𝟏
 
𝟓
𝑷𝒔𝒉 ,𝟏 𝒔𝒕 =𝟏𝟎 × 𝟏𝟎 ∙ 𝟎 .𝟓𝟐𝟖
𝟏. 𝟒
𝟏. 𝟒 −𝟏 (
𝟐 . 𝟐𝟖𝟗
0 . 82
−𝟏𝟏. 𝟒
=𝟔𝟎𝟏 . 𝟔 𝒌𝑾 )
𝟏 . 𝟒 −𝟏
 
𝟓
𝑷𝒔𝒉 ,𝟐 𝒏𝒅 =𝟐𝟑 × 𝟏𝟎 ∙ 𝟎 . 𝟐𝟑
𝟏.𝟒
𝟏 . 𝟒 −𝟏 (
𝟐. 𝟐𝟖𝟗
0 . 82
−𝟏𝟏 .𝟒
= 𝟔𝟎𝟏. 𝟔 𝒌𝑾 )
𝟏 . 𝟒 −𝟏
 
𝟓
𝑷𝒔𝒉 ,𝟑 𝒓𝒅 =𝟓𝟐× 𝟏𝟎 ∙𝟎 . 𝟏
𝟏.𝟒
𝟏 . 𝟒 −𝟏 (
𝟐. 𝟐𝟖𝟗
0. 82
−𝟏 𝟏 .𝟒
= 𝟔𝟎𝟏. 𝟔 𝒌𝑾 )
 𝑷𝒔𝒉 =𝑷 𝒔𝒉 ,𝟏 𝒔𝒕 + 𝑷 𝒔𝒉, 𝟐 𝒏𝒅 + 𝑷𝒔𝒉 ,𝟑 𝒓𝒅 =𝟏𝟖𝟎𝟓 𝒌𝑾
 FRAME SELECTION

 𝑷𝒔𝒉 =𝟏𝟖𝟎𝟓 𝒌𝑾

Model Stroke In. Number of Nominal Rated Max. Allowable

Rated rpm
(Frame) (mm) Cylinders (throws) Power hp (kW) Rod Load lbs. (kN)
5D-VIP2 5 (127) 2 1875 (1398) 45,000 (200) 1500
5D-VIP4 5 (127) 4 3750 (2797) 45,000 (200) 1500
5D-VIP6 5 (127) 6 5625 (4195) 45,000 (200) 1500
6D-VIP2 6 (152.4) 2 1500 (1119) 45,000 (200) 1200
6D-VIP4 6 (152.4) 4 3000 (2237) 45,000 (200) 1200
6D-VIP6 6 (152.4) 6 4500 (3356) 45,000 (200) 1200
7D-VIP2 7 (177.8) 2 1800 (1343) 45,000 (200) 1000
7D-VIP4 7 (177.8) 4 3600 (2685) 45,000 (200) 1000
7D-VIP6 7 (177.8) 6 4800 (3580) 45,000 (200) 1000

So use frame 5D-VIP4

 COMPRESSOR SPEED

As the compressor speed increases, the shaking forces, friction

between piston and cylinder and valve wear increase
 Criteria: piston speed

Depends on manufacturing technology

Model Stroke In. Piston speed
Rated rpm
(Frame) (mm) (m/s)
5D-VIP2 5 (127) 1500 6.4
5D-VIP4 5 (127) 1500 6.4
5D-VIP6 5 (127) 1500 6.4
6D-VIP2 6 (152.4) 1200 6
6D-VIP4 6 (152.4) 1200 6
6D-VIP6 6 (152.4) 1200 6
7D-VIP2 7 (177.8) 1000 5.9
7D-VIP4 7 (177.8) 1000 5.9
7D-VIP6 7 (177.8) 1000 5.9
 NUMBER OF CYLINDERS PER STAGE

 𝑷𝒔𝒉 ,𝟏 𝒔𝒕 =𝟔𝟎𝟏 . 𝟔 𝒌𝑾 , 𝑷𝒔𝒉 ,𝟐 𝒏𝒅 =𝟔𝟎𝟏 . 𝟔 𝒌𝑾 , 𝑷𝒔𝒉 ,𝟑 𝒓𝒅 =𝟔𝟎𝟏 .𝟔 𝒌𝑾

Model Stroke In. Number of Nominal Rated Max. Allowable

Rated rpm
(Frame) (mm) Cylinders (throws) Power hp (kW) Rod Load lbs. (kN)
5D-VIP4 5 (127) 4 3750 (2797) 45,000 (200) 1500

  𝑷𝒔𝒉 , 𝒔𝒕𝒂𝒈𝒆
 𝑷 𝒔𝒉 𝒑𝒆𝒓 𝒄𝒚𝒍𝒊𝒏𝒅𝒆𝒓 =𝟕𝟎𝟎 𝒌𝑾 ¿

So use one cylinder per stage

CYLINDER DIAMETER: INLET (SUCTION) FLOW RATE

  =𝜂 ∙ 𝑉 ∙ 𝑁
𝑄 𝑖𝑛 𝑣𝑜𝑙 𝑑
60

  𝜋 2
𝑉 𝑑= 𝐷 𝐿 × 2× 𝑁 𝑐𝑦𝑙
4
𝜸− 𝟏
 
𝜂 𝑣𝑜𝑙=1 −0 . 03 −0 . 03 − 𝒓 𝒑 ( 𝜸
)
−𝟏 ∙ 𝐶
P decrease &
T increase
inside cylinder
Slip (0.030.05)
P
Vstroke
Vloss

V
CYLINDER DIAMETER
  1500
𝑄𝑖𝑛 =𝜂 𝑣𝑜𝑙 ∙ 𝑉 𝑑 ∙
60
 

  𝑚3
𝑄1=0 . 528 → 𝐷 1=0 .34 𝑚 ≅ 14
𝑠
  𝑚3
𝑄 2=0 . 23 → 𝐷 2=0 .225 𝑚 ≅ 9
𝑠
  𝑚3
𝑄 3=0. 1 → 𝐷 3 =0 .15 𝑚 ≅ 6
𝑠
RC SELECTION
USING
SOFTWARE