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

Centrifugal
Single stage

Rotary-Screw

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

- High efficiency - Low pressure ratio per stage

Axial - High speed capability - Narrow flow range
- 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
Positive by gas properties Introduces vibrations into the
displacement - Good efficiencies at low system
specific speed - Bigger foundation requirements

6
29 August 2023
Pressure Efficiency
Positive
90 %
displacement
Axial Axial
80 %
Centrifugal
70 % Centrifugal
Positive
60 % Displacement

50 %

Ns
100 %

% Rated Capacity Specific speed

7
IMPELLERS IN ROW
MULTI-STAGE
COMP.
OPPOSITE IMPELLERS
MULTI-STAGE COMP.
IMPELLERS IN ROW
MULTI-STAGE
PUMP
 IMPELLER TIP BALANCE PISTON

DIFFUSER
 SPLIT TYPE
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 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 2 Nd Stage

** Centrifugal Compressor Operation

SCRUBBER ANTI-SURGE ANTI-SURGE ANTI-SURGE

SCRUBBER SCRUBBER SCRUBBER
VALVE VALVE VALVE

COOLER COOLER COOLER

1St Stage 2 Nd Stage 3 Rd Stage

 Cooler
3 Stages
Geared Centrifugal
Compressor

Cooler

8/29/2023 BY- H. Hassan 27

 Surge
Phenomenon

28
 HAPPENS
ONLY TO :
CENTRIFGAL
COMPRESSORS

AND AXIAL FLOW

COMPRESSORS
But Does not Happen to
Reciprocating
29 Compressors
SURGE 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 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 SURGE IF

INLET FLOW RATE Q IS ENOUGH

IN OUT
 IF INLET FLOW RATE Q
IS NOT ENOUGH

COMPRESSOR

IS SURGING
IN OUT

5 to 20 cycles per second

 SURGE PHENOMENON

B
H A
p

6000 10000
Q M³/ hr
36
 Compressor Turbine

MOTION

MOTION

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

SURGE WILL DAMAGE THE COMPRESSOR

THRUST BEARINGS
 THRUST
BEARINGS

COMPRESSOR

SURGE WILL DAMAGE THE

COMPRESSOR THRUST BEARINGS
 SURGE CYCLE

Hp
B1

-Q 6000 10000 Q M³/ hr

40
5 to 20 cycles per second
ANTI-SURGE METHODS

1- BY PASS WITH ANTI - SURGE VALVE

THIS METHODS IS COMMONLY

USED FOR GAS COMPRESSORS

2 –BLOW OFF VALVE

THIS METHODS IS COMONLY

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

COMRESSOR

FT P,T
COOLER

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

COMRESSOR

3 3 3
6000 M 10000 M 6000 M

3
3 4000 M
4000 M 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

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

33
10000
6000MM

Air
F P,T
BLOW
T OFF
FY VALVE
UIC

UIC = ANTI- SURGE INTEGRATED CONTROLLER

FY45 = TRANSDUCER
 2 – BLOW OFF VALVE
GRAPHICALLY

Hp B

A
B1

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

29 August 2023 49
Reciprocating Compressors Construction
Reciprocating Compressors 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
29 August 2023 51
 Reciprocating Compressors construction
Distance Piston Suction
Crank Con-rod Valves
Piece
Piston
Rod

Stuffing Discharge
Wiper Box Valves
Crosshead
29 August 2023
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

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

PULSATION
ACCUMILLATOR
DAMPENER

2nd 1St

PULSATION
DAMPENER ACCUMILLATOR

GAS
SCRUBBER
29 August 2023 55
56 29 August 2023
Reciprocating Compressors Flow 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
(Start-Stop Operation)
29 August 2023
 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.
29 August 2023 58
 Clearance Volume Effect

Clearance
Volume

Clearance
Head
 Clearance Volume Effect

VARIABLE CYLINDER HEAD

CLEARANCE
VOLUME

Clearance Head
Controlling Nut
Manual Operated Clearance
60
VARIABLE
CLEARANCE
VOLUME

61 29 August 2023
EFFECT OF Pd c b
CLEARANCE
VOLUME

Ps M c1 a
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

29 August 2023 62
 Pd c b

Ps M c1 g b a
v

Pd
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

29 August 2023 64
 Vag ag
Volumetric efficiency = =
V cylinder aM

Pd
c b

Ps g
M
a
v

29 August 2023 C 65
 Vag ag
Volumetric efficiency = =
V cylinder aM

c b
Pd

M g a
Ps
v

29 August 2023 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
29 August 2023 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
29 August 2023 68
 c b
Pd

Ps M c1 g b a
v

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

Compression ratio = V cylinder = aM

69
29 August 2023
Vb M 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)
29 August 2023 70
 SUCTION
VALVE
UNLOADER

29 August 2023 71
 Air Compressor Dryer
https://www.youtube.com/watch?v=6tVw9VYQDIg

29 August 2023 72
AIR COMPRESSORS DRYER Dry Air to instrument Receiver

TWO WAY
VALVE

AIR FROM
COMPRESSOR

TWO WAY
VALVE

Wet Air
ACTIVATED to Atmosphere REGENRATED
AIR COMPRESSORS 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

29 August 2023 75
Discussion
Rotary
Compressors

77
Rotary
Compressor

Relief
Valve

29 August 2023 78
 Screw compressor
• Dry Screw Compressor

• Oil Flooded Screw Compressor

29 August 2023 79
Rotary Screw Compressors

29 August 2023 80
 Rotary-Screw Compressor

29 August 2023 81
Rotor profile of the four ------lobe male and the six lobe female

29 August 2023 82
Oil – flooding system for a rotary screw air compressor.

Cold Oil

Hot Oil

compressor Dry Air

Air Outlet

Oil injected to
compressor

29 August 2023 83
 Multiple-screw double-end arrangement
29 August 2023 84
ROTARY External Gear
COMPRESSORS

THE FLUID IS TRAPPED BETWEEN ROTOR

29 August 2023 85 AND
 THREE LOBE
COMPRESSORS

29 August 2023 86
 TWO LOBE
COMPRESSOR

29 August 2023 87
 TWO LOBE
COMPRESSOR

29 August 2023 88
 Dry helical screw compressors.
(driven by external timing gears).

Gap,
no contact

29 August 2023 89
 TIMING GEAR FUNCTION

1- Transmit Motion
To Other Rotor

2- Keeps No Contact
Between Rotors

3- Prevent Wear
Between Rotors

29 August 2023 90
Rotary helical screw oil injected compressor

contact

Injected oil

29 August 2023 91
 Rotary Vane Compressor

Discharge

Suction

92
29 August 2023
 Rotary Vane Gas Compressors

29 August 2023 93
 THREE LOBE
COMPRESSORS

29 August 2023 94
 TWO LOBE
COMPRESSOR

29 August 2023 95
 External
Gear

THE
29 August 2023 FLUID IS TRAPPED BETWEEN ROTOR AND
96 CASING
 Internal Gear

29 August 2023 97
 Driving Crest
rotor
29 August 2023 98