Compressors

API STD 617 Standards and Codes

Centrifugal Compressors for Petroleum, Chemical, and Gas Industry Services

API STD 618

Reciprocating Compressors for Petroleum, Chemical, and Gas Industry Services

API STD 619

Rotary Compressors for Petroleum, Petrochemical, and Gas Industry Services

API STD 681

Liquid Ring Vacuum Compressors for Petroleum, Chemical
 Compressors Classification
Kinetic

A – Centrifugal
B – Axial

Positive Displacement

C -Reciprocating
D -Rotary
*Screw
* Lobe
*Sliding Vane
*Gear
* Others
 Main Types Of Compressors

Positive D.P. Centrifugal Axial Flow

Pressure P V. HIGH HIGH LOW

Flow Rate Q LOW HIGH V. HIGH

S .R .V YES NO NO

Efficiency LOW MEDIUM V. HIGH

Maint. cost V. HIGH LOW LOW

Pulsation YES NO NO

Surging NO YES YES

 Compressor Selection

Rec
Mu iproca
lt i s t
tage ing Centrifuga
l
Multi stag
e
Centrifugal
Single stage

Rotary-Screw

Reciprocating
Single stage
 Different Types of Compressors
Disadvantages Advantages Type
Wide operating range - Unstable at low flow -
Low maintenance - Centrifugal
Moderate efficiency -
High reliability -

High efficiency - Low pressure ratio per stage -

High speed capability - Narrow flow range
Axial-
Higher flow for a given - Fragile and expensive blading -
size
-

Limited capacity -
- Pressure ratio High weight to capacity ratio -
capability not affected Higher maintenance requirements -
by gas properties Positive
Introduces vibrations into the
- Good efficiencies at low system displacement
specific speed Bigger foundation requirements -
6
June 9, 2024
Pressure Efficiency
Positive
% 90
displacement
Axial Axial
% 80
Centrifugal
% 70 Centrifugal
Positive
% 60 Displacement

% 50

Ns
% 100

Rated Capacity % Specific speed

7
IMPELLERS
IMPELLERSIN
INROW
ROW
MULTI-STAGE
MULTI-STAGE
COMP.
COMP.
OPPOSITE
OPPOSITE IMPELLERS
IMPELLERS
MULTI-STAGE
MULTI-STAGECOMP.
COMP.
IMPELLERS
IMPELLERSIN
INROW
ROW
MULTI-STAGE
MULTI-STAGE
PUMP
PUMP
 IMPELLER TIP BALANCE PISTON

DIFFUSER
 SPLIT
SPLITTYPE
TYPE
COMPRESSORS
COMPRESSORS
1- Horizontally Split
High Flow Medium pressure
2- Vertically Split (Double Barrel)
high pressure and
medium Flow
 API 617 *
Very High Flow rate *
Axial Flow Compressors
Low pressure *
Very High efficiency *
 Inlet
Discharge Stationary
Aerodynamics

Shear Ring

Casing

Dry Gas Seal

Cover
Thrust
Journal Bearing
Bearing

Balance Piston Dry Gas Seal

Rotor Journal Bearing

API 617 * Medium pressure*

High Flow rate * High efficiency *
 Reciprocating Compressor

API 618 * Low Flow rate *

High pressure * Moderate efficiency *
Rotary-Screw Compressor
API 619 *
High Flow rate *
High pressure *
Moderate efficiency *
 ** Compressor Selection

Application
Operating parameter
footprint/weight
Availability
Reliability
maintenance
drivers
 Centrifugal Compressor

20
 Centrifugal Compressors

Radial Radial
Bearings Bearings

.Mech Mechanical
Thrust
Seal Seal
Bearing
Impellers
 Centrifugal Compressor

Compressors components **
Rotor Shaft Impellers Thrust collars Spacers

Diffusers
Casing
Labyrinths
Mechanical Seals
Couplings HSC LSC

Gear Box
Anti- Surge System
Lube Oil System
Driver
General
General aspects
aspects
1- A Complete spare balanced rotor to be ideally
stored in ware house

2- Compressor will be equipped with a complete

surge control system.

3- It is advisable to use dry gas mechanical seal

system instead of wet mechanical seal one.

23
Centrifugal Compressor Operation **

SCRUBBER ANTI-SURGE
SCRUBBER
VALVE

COOLER

1St Stage
Centrifugal Compressor Operation **

SCRUBBER ANTI-SURGE ANTI-SURGE

SCRUBBER SCRUBBER
VALVE VALVE

COOLER COOLER

1St Stage Nd
Stage 2
Centrifugal Compressor Operation **

SCRUBBER ANTI-SURGE ANTI-SURGE ANTI-SURGE

SCRUBBER SCRUBBER SCRUBBER
VALVE VALVE VALVE

COOLER COOLER COOLER

1St Stage Nd
Stage 2 Rd
Stage 3
 Cooler
3 Stages
Geared Centrifugal
Compressor

Cooler

06/09/2024 BY- H. Hassan 27

 Surge
Phenomenon

28
 HAPPENS
HAPPENS
:: ONLY
ONLYTO
TO
CENTRIFGAL
COMPRESSORS

AND AXIAL FLOW

COMPRESSORS
But
But Does
Does not
not Happen
Happen to
to
Reciprocating
Reciprocating
29 Compressors
Compressors
SURGE
SURGE PHENOMEN
PHENOMEN
It is the flow back of gases from the outlet of the
Last stage of the compressor towards the suction and
return again to discharge

IN OUT
 SURGE
SURGE PHENOMEN
PHENOMEN
Why
• FLOW-RATE IS NOT ENOUGH

• GAS PROPERTY

• COMPRESSOR PERFORMANCE

• FLATENESS OF P.C. AT LOW Q

• FLOW-RATE
IS NOT ENOUGH
This will happen at
starting and shutdown,
also at abnormal conditions.
• GAS PROPERTY

Gas is compressible but liquid is not.

• COMPRESSOR PERFORMANCE
Centrifugal and Axial compressors are pumping
gas continuously but reciprocating is not.

• FLATENESS OF P.C. AT LOW Q

Gas pressure has the same energy at

horizontal portions of the performance curve
NO
NO SURGE
SURGE IF
IF

INLET
INLETFLOW RATE Q
FLOWRATE Q IS
ISENOUGH
ENOUGH

IN OUT
 IF INLET FLOW RATE Q
IS NOT ENOUGH

COMPRESSOR
IS SURGING

IN OUT

to 20 cycles per second 5

 SURGE PHENOMENON

SSOR
P RE G
M
CO RGIN
SU

B
H A
p

INE
EL
RG
SU

6000 10000
Q M³/ hr
36
 Compressor Turbine

MOTION
MOTION

HYDRAULIC HYDRAULIC
ENERGY ENERGY
 EFFECT OF SURGE ON
CENTRIFGAL COMPRESSOR
ROTOR
THRUST
BEARINGS

SURGE
SURGE WILL
WILL DAMAGE
DAMAGE THE
THE COMPRESSOR
COMPRESSOR
THRUST
THRUSTBEARINGS
BEARINGS
 THRUST
BEARINGS

COMPRESSOR

SURGE
SURGE WILL
WILL DAMAGE
DAMAGE THE
THE
COMPRESSORTHRUST
COMPRESSOR THRUST BEARINGS
BEARINGS
 SURGE CYCLE

Hp
B1 B
A

NE
LI
E
RG
SU

Q- 6000 10000 Q M³/ hr

40
toto20
20 cycles
cycles per second 55
per second
ANTI-SURGE
ANTI-SURGE METHODS
METHODS

BY PASS WITH ANTI - SURGE VALVE -1

THIS METHODS IS COMMONLY

USED FOR GAS COMPRESSORS

BLOW OFF VALVE– 2

THIS METHODS IS COMONLY

USED FOR AIR COMPRESSORS
 ANTI-SURGE
ANTI-SURGE METHODS
METHODS
BY PASS WITH ANTI - SURGE VALVE -1 IN CASE OF
COMPRESSOR
SURGING

COMRESSOR

FT P,T
COOLER

UIC
FY ANTI-SURGE
VALVE WILL
OPEN
42
 BY PASS WITH ANTI - SURGE VALVE -1

COMRESSOR

3 3 3
M 6000 M 10000 M 6000

3
3 M 4000
M 4000 FT P,T

COOLER

UIC

FY ANTI-SURGE
VALVE

UIC = ANTI- SURGE INTEGRATED CONTROLER

43
FY = TRANSDUCER
 BY PASS WITH ANTI - SURGE VALVE
GRAPHICALLY
B
H
p C A

SURGE CONTROL LINE

RECYCLE TRIP LINE

SURGE LIMIT LINE

Q
44
M³/ hr
 BLOW OFF VALVE– 2
AIR
COMRESSOR

33
10000
MM 6000

Air
F P,T
BLOW
T OFF
FY VALVE
UIC

UIC = ANTI- SURGE INTEGRATED CONTROLLER

FY45 = TRANSDUCER
 BLOW OFF VALVE – 2
GRAPHICALLY

Hp B

NE
LI
TR
OL B1
N
CO
E
RG
SU

Q M ³/ hr

46
 IN CASE OF GAS TURBINE
AIR COMPRESSOR SURGE
BLEED VALVE WILL OPEN

BLEED VALVE

COMPRESSOR TURBINE

47
 Positive Displacement
Compressors

48
 Reciprocating Compressors

June 9, 2024 49
Reciprocating Compressors Construction
Reciprocating
Reciprocating Compressors
Compressors properties
properties

• Lower Power Density

• Low Speed (300–1800 rpm)

• Generally used in low volumetric rate applications
(< 500 acfm [850 m3/h] )
• Higher maintenance
• Unaffected by changes in gas properties (MW, T)
• Most common driver – gas engine, electric motor

• Pulsating flow/vibration
June 9, 2024 51
 Reciprocating Compressors construction
Distance Piston Suction
Crank Con-rod Valves
Piece
Piston
Rod

Stuffing Discharge
Wiper Box Valves
Crosshead
June 9, 2024
Rings Packing 52
 Multi stage reciprocating compressor
SCRUBBER
GAS
COOLER

PULSATION
ACCUMILLATOR
DAMPENER

2nd 1St

PULSATION
DAMPENER ACCUMILLATOR

GAS
SCRUBBER
53
 Multi stage reciprocating compressor
Compressors intermediate pressures

SCRUBBER SCRUBBER SCRUBBER SCRUBBER

COOLER COOLER COOLER

1 St Nd
2 Rd
3
Stag Stage Stage 54
Design
Designapplications
applications
of
ofreciprocating
reciprocating SCRUBBER
compressors
compressors COOLER

PULSATION
ACCUMILLATOR
DAMPENER

2nd 1St

PULSATION
DAMPENER ACCUMILLATOR

GAS
SCRUBBER

June 9, 2024 55
56 June 9, 2024
Reciprocating
Reciprocating Compressors
Compressors Flow
Flow Regulation
Regulation

1- VARIABLE CLEARANCE
• Manual Operated Clearance
• Pneumatic Operated Clearance
2- SUCTION VALVE UNLOADERS

3- VARIABLE SPEED
4- BYPASS
5- Shut down the Compressor Periodically
57
June 9, 2024(Start-Stop Operation)
 1- VARIABLE CLEARANCE
Manual Operated Clearance
There is a clearance existed in the cylinder head.
A piston rod complete with an adjustable nut is
connected to piston with packing to seal the
clearance volume in font of the compressor piston.
The more the clearance volume in font of the comp.
piston, The less the compressor flow rate.

No effect of the clearance volume in font of the

piston on the compressor discharge pressure.
June 9, 2024 58
 Clearance Volume Effect

Clearance
Volume

Clearance Head
Nut
 Clearance Volume Effect

VARIABLE CYLINDER HEAD

CLEARANCE
VOLUME

Clearance Head
Controlling Nut
Manual Operated Clearance
60
VARIABLE
CLEARANCE
VOLUME

61 June 9, 2024
EFFECT
EFFECTOF
OF Pd c b
CLEARANCE
CLEARANCE
VOLUME
VOLUME

Ps M c1 a
At
At g
v
Point a suction valves closed

Point b discharge valves open C

C = Clearance volume
Point c discharge valves closed

Point g suction valves open

June 9, 2024 62
 Pd c b

Ps M c1 g b a
v

P d
Pressure ratio = )ABSOLUTE(
Ps
Volumetric efficiency =
V ag ag
V cylinder
=
aM
Compression ratio = V cylinder = a M
Vb M bM
 Vag ag
Volumetric efficiency =
V cylinder = aM

Pd c b

Ps M
c1 a
g
v

June 9, 2024 64
 Vag ag
Volumetric efficiency =
V cylinder = aM

Pd
c b

Ps g
M
a
v

June 9, 2024 C 65
 Vag ag
Volumetric efficiency =
V cylinder = aM

c b
Pd

M g a
Ps
v

June 9, 2024 66
 If C Increased suction valves will open at ( g )
Vag ag
Volumetric efficiency =
V cylinder =
aM

c b
EV DECREASES Pd

Ps M g a
v
Q DECREASES

C
June 9, 2024 67
 If C Decreased suction valves will open at (g)

Vag ag
Volumetric efficiency =
V cylinder = aM

EV INCREASES
c b
Pd

Ps g
M a
v
Q INCREASES
C
June 9, 2024 68
 c b
Pd

Ps M c1 g b a
v

P d
Pressure ratio = )ABSOLUTE(
Ps
Volumetric efficiency =
V ag ag
V cylinder
=
aM

Compression ratio = V cylinder = aM

June 9, 2024
Vb M 69
bM
• SUCTION VALVE UNLOADERS

There are an unloaders existed on suction valves of

the compressor and pneumatically operated
If the unloaders energized, the suction valves will
be opened.
If there are 4 suction valves and the unloaders are
energized for :
1- One suction valve (Capacity will be ¾ max. Q)
2- Two suction valve (Capacity will be ½ max. Q)
3- Three suction valve (Capacity will be ¼ max. Q)
4- Four suction valve (Capacity will be = 0 Q)
June 9, 2024 70
 SUCTION
VALVE
UNLOADER

June 9, 2024 71
 Air Compressor Dryer
https://www.youtube.com/watch?v=6tVw9VYQDIg

June 9, 2024 72
AIR
AIRCOMPRESSORS
COMPRESSORSDRYER
DRYER Dry Air to instrument Receiver

TWO WAY
VALVE

AIR FROM
COMPRESSOR

TWO WAY
VALVE

Wet Air
ACTIVATED to Atmosphere REGENRATED
AIR
AIRCOMPRESSORS
COMPRESSORSDRYER
DRYER Dry Air to instrument Receiver

AIR FROM
COMPRESSOR

REGENRATED Wet Air

to Atmosphere ACTIVATED
 Reciprocating Compressor Operations

https://www.youtube.com/watch?v=ooBJMI0H7PQ

June 9, 2024 75
Discussion
Rotary
Compressors

77
Rotary
Compressor

Relief
Valve

June 9, 2024 78
 Screw compressor
• Dry Screw Compressor

• Oil Flooded Screw Compressor

June 9, 2024 79
Rotary Screw Compressors

June 9, 2024 80
 Rotary-Screw Compressor

June 9, 2024 81
Rotor profile of the four ------lobe male and the six lobe female

June 9, 2024 82
Oil – flooding system for a rotary screw air compressor.

Cold Oil

Hot Oil

compressor Dry Air

Air Outlet

Oil injected to
compressor

June 9, 2024 83
 Multiple-screw double-end arrangement
June 9, 2024 84
ROTARY External Gear
ROTARY
COMPRESSORS
COMPRESSORS

THE FLUID IS TRAPPED BETWEEN ROTOR

June 9, 2024 85 AND
 THREE
THREELOBE
LOBE
COMPRESSORS
COMPRESSORS

June 9, 2024 86
 TWO
TWOLOBE
LOBE
COMPRESSOR
COMPRESSOR

June 9, 2024 87
 TWO
TWOLOBE
LOBE
COMPRESSOR
COMPRESSOR

June 9, 2024 88
 .Dry helical screw compressors
.)driven by external timing gears(

,Gap
no contact

June 9, 2024 89
 TIMING
TIMING GEAR
GEAR FUNCTION
FUNCTION

1-
1- Transmit
Transmit Motion
Motion
To
To Other
Other Rotor
Rotor

2-
2- Keeps
Keeps No
No Contact
Contact
Between
Between Rotors
Rotors

3-
3- Prevent
Prevent Wear
Wear
Between
Between Rotors
Rotors

June 9, 2024 90
Rotary helical screw oil injected compressor

contact

Injected oil

June 9, 2024 91
 Rotary Vane Compressor

Discharge

Suction

92
June 9, 2024
 Rotary Vane Gas Compressors

June 9, 2024 93
 THREE
THREE LOBE
LOBE
COMPRESSORS
COMPRESSORS

June 9, 2024 94
 TWO
TWO LOBE
LOBE
COMPRESSOR
COMPRESSOR

June 9, 2024 95
 External
External
Gear
Gear

THE
June 9, 2024 FLUID IS TRAPPED BETWEEN ROTOR AND
96 CASING
 Internal Gear

June 9, 2024 97
 Driving Crest
rotor
June 9, 2024 98