Compressors

1
 Standards and Codes
API STD 617

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

DIFFUSER
* High Flow rate
* Medium pressure

11
* high pressure
* medium Flow
Axial Flow Compressors
* API 617
* Very High Flow
rate
* 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
** 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 W.H

2- Compressor will be equipped with a

complete surge control system.

3- It is advisable to use dry gas seal

system instead of wet seal one.
19
** 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

Sealing
System
1- Packing seals
PACKING THROAT BUSH
LANTERN RING
WITHOUT
PACKING
SLEEVE
FOLLOWER
GLAND

Equipment

• Wear is
directly on shaft
PACKING THROAT BUSH
LANTERN RING
WITH
PACKING
SLEEVE
FOLLOWER
GLAND

SLEEEVE

Equipment

* Wear is on
the sleeve
Horizontal Surface wear Shaft wear

Equipment

Now it is essential to find a solution to avoid shaft wear,

Such as finding another surface of another parts to be
worn but easy and cheap to be replaced, It is the
MECHANICAL SEAL
2- Mechanical Seals
 Vertical surface wear Scarifying
elements

Equipment
 Single mechanical seal
Rotary Elements Stationary Element
1- Carbon ring
2- Snap Ring Tungsten Carbide ring
3- “O” Rings Or
Silicon Carbide ring
4- Springs
5- Sleeve

Equipment
SINGLE IMPELLER PUMP

MECHANICAL SEAL

HANGED BEAM
IMPELLER
 MULTI STAGE PUMP

MECHANICAL SEALS

DRIVE END NON-DRIVE END

IN-BETWEEN TWO
BEARINGS IMPELLER
 Mechanical seal and bearings arrangement

oil

Equipment
Tank
Tank Non-sparking material bush

Packing Adjusting nut

Tandem Seal
Product Buffer fluid
Circulation Circulation

Equipment
Tandem Seal PBF
PBF = 1 bar max

Buffer fluid
Product Buffer fluid
Circulation
Circulation
Circulation
Pp
Equipment
Double Seal

Product Barrier fluid Flushing

Circulation Circulation Liquid

Equipment
Double Seal PBF
(Min) PBF = 1.1 Pp
Not less than ( 2+Pp ) bar Barrier
fluid
Circulation
Product Barrier fluid Flushing
Circulation Circulation Liquid
Pp
Equipment
 Mechanical seal and bearings arrangement

Balancing
Pressure
Room

P4 P
Ps

Ps P 4 P
 Tandem Seal
Outboard Seal
Clean liquid
Clean buffer
fluid lubricates
this seal

Buffer fluid is
at low
(atmospheric)
pressure.

Inboard Seal
Product fluid
lubricates this
42
Use API Plan 52 seal
Double seals: Back-to-back
Pressurised
barrier fluid
Liquid is circulated
Is not
Clean
Barrier fluid
lubricates
both sets of
seal faces.

43 Use API Plan 53

 Double seals: Face-to-face

Rotating
Mating Stationary
Ring seals

44
 BALANCING DRUM
Balancing
BALANCING LINE Pressure
Room
P1 P2 P3 P4

P4 P0
P0

P4 P0

P4 – P0 P4 – P0
 Surge
Phenomenon

46
 HAPPENS
ONLY TO :
CENTRIFGAL
COMPRESSORS

AND AXIAL FLOW

COMPRESSORS
But Does not Happen to
Reciprocating
47 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
54
 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

58
5 to 20 cycles per second
ANTI-SURGE METHODS

1- BY PASS WITH ANTI - SURGE VALVE

THIS METHODS IS COMONLY

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
60
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

61
FY = TRANSDUCER
BY PASS WITH ANTI - SURGE VALVE
GRAPHICALLY

B
H
p C A

SURGE CONTROL LINE

RECYCLE TRIP LINE

SURGE LIMIT LINE

62
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

FY63 = TRANSDUCER
2 – BLOW OFF VALVE
GRAPHICALLY

Hp B

A
B1

Q M ³/ hr

64
 IN CASE OF GAS TURBINE
AIR COMPRESSOR SURGE
BLEED VALVE WILL OPEN

BLEED VALVE

COMPRESSOR TURBINE

65
Mokveld Anti-Surge Valve Spring Loaded during
normal operation

Valve Disk Valve Seat

moves LHS
to open
 a

webs
a
Section a-a
 Compressors
Troubleshooting

68
Common Failure Modes of CENTRIFUGAL COMPRESSORS

THE PROBLEM

CAN NOT DO ALIGNMENT

MECH SEAL FAILURE
WATER IN LUBE OIL
LOSS OF P DISH.
HIGH VIBRATION

COMP. SURGING

HI BEARING OIL T

START
LOW OIL PR

MOTOR TRIP
TRIP
FAIL TO
MOTOR
THE CAUSE

Insufficient inlet quantity 0

Lube Oil heat exch. Tubes leak 0
Inlet gas “ liquid slugging” 0
Operating in critical speed range” 0
Operating in surge region” 0 0 0
Piping strain 0 0
Poor oil condition 0
Rotor imbalance 0 0 0
Misalignment 0 0 0
Buffer gas low pressure 0 0
Journal/thrust bearing damaged 0 0 0
Oil reservoir low temperature 0
Common Failure Modes of CENTRIFUGAL COMPRESSORS

THE PROBLEM

CAN NOT DO ALIGNMENT

MECH SEAL FAILURE
WATER IN LUBE OIL
LOSS OF P DISH.
HIGH VIBRATION

COMP. SURGING

HI BEARING OIL T

START
LOW OIL PR

MOTOR TRIP
TRIP
CAN NOT
MOTOR
THE CAUSE
Build up of deposits on diffuser 0
Buildup of deposits on rotor 0 0
Change in system resistance 0 0
Clogging oil strainer/ filter 0
Condensate in oil reservoir 0
Damaged rotor 0
Dry gear coupling 0
Excessive bearing clearance 0
Excessive Inlet temperature 0
Failure in main and auxi oil pump 0 0
Faulty temperature switch 0 0 0
Improper assembled parts 0 0 0
Positive Displacement
Compressors

71
Reciprocating
Compressors
RECIPROCATING COMPRESSORS:
FLOW RATE REGULATION

• VARIABLE CLEARANCE
• Manual Operated Clearance
• Pneumatic Operated Clearance
• SUCTION VALVE UNLOADERS

• VARIABLE SPEED

• BYPASS
VARIABLE
CLEARANCE
VOLUME
Pneumatic Variable Clearance
Indicator Diagram P

Three Load points

1=Full load
Pneumatic
Variable Volume
Clearance P
B = Open A Open

One ½ Load

Volume
P

B, D= Open A,C Open

No Load

Volume
•Manual Operated Clearance

Safety lock
RECIPROCATING GAS GAS
SCRUBBER
COMPRESSOR
COOLER

PULSATION
ACCUMILLATOR
DAMPENER

2nd 1St

PULSATION
DAMPENER ACCUMILLATOR

GAS
SCRUBBER
Pulsation Dampener P

REDUCE PRESSURE
FLUCTUATION

Relief
Accumulator Valve
Q

KEEP ENOUGH
QUANTITY IN SUCTION
• VARIABLE CLEARANCE

Before CF = 2 C
3
operating
CR = 1 C
3

CF CR
After
operating
CF = 1 C
2
1
CR = 2
C

Piston Rod
Expands

CF CR
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

 Vag ag
Volumetric efficiency = =
V cylinder aM

Pd c b

Ps M
c1 a
g
v

C
 Vag ag
Volumetric efficiency = =
V cylinder aM

Pd
c b

Ps g
M
a
v

C
 Vag ag
Volumetric efficiency = =
V cylinder aM

c b
Pd

M g a
Ps
v

C
If C Increased suction valves will open at ( g
)
Vag ag
Volumetric efficiency =
V cylinder = aM

Pd c b
EV DECREASES

Ps M g a
v
Q DECREASES

C
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
 c b
Pd

Ps M c1 g b a
v

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

Compression ratio = V cylinder = aM

Vb M bM
RECIPROCATING
COMPRESSORS
INTERMEDIATE
PRESSURES
Example 1

4 Stages Reciprocating Air comp has

outlet pressure P4 = 80 barg
what are the intermediate pressures
1st 2nd 3rd 4th
stage stage stage stage

P0 P1 P2 P3 P4
0 barg 80 barg
 1st 2nd 3rd 4th
stage stage stage stage

P0 P1 P2 P3 P4
0 barg 80 barg
Assume
P4
r is The equal Pressure Ratio between stages. AND R =
P0
P1 P2 P3 P4
r = = = =
P0 P1 P2 P3
4 P4
4 P1 P2 P3 P4 r =
r = * * * P0
P0 P1 P2 P3
Generally
4 4 N
r = R r = R r = R
 1st 2nd 3rd 4th
stage stage stage stage

P0 P1 P2 P3 P4
0 barg 80 barg
P4 (80 +1) 81
R = = = = 81
P0 (0 +1) 1
N 4
r = R = 81 = 3
P1 = r * P0 = 3 * 1 = 3 bara = 2 barg
P2 = r * P1 = 3 * 3 = 9 bara = 8 barg
P3 = r * P2 = 3 * 9 = 27 bara = 26 barg

P4 = r * P3 = 3 * 27 = 81 bara = 80 barg
 Example 2

3 Stages Reciprocating Gas compressor

has
Outlet pressure P3 = 127 barg
Inlet pressure P0 = 1 barg
what are the intermediate pressures
1st 2nd 3rd stage
stage stage
P0 P1 P2 P3

1 barg 127 barg

 1st 2nd 3rd stage
stage stage
P0 P1 P2 P3

1 barg 127 barg

Assume

3 P1P2 P3 3 P3
r = * * r =
P0 P1 P2 P0
P3 3 P3
R= BUT r =
P0 P0
3 3
r = R r = R
R =r = P
3 3 (127 +1) 128
= = 2 = 64
P0 (1+1)

3
r = R = 64 = 4

P1 = r * P0 = 4 * 2 = 8 bara = 7 bar g

P2 = r * P1 = 4 * 8 = 32 bara = 31 bar g

P3 = r * P2 = 4 * 32 = 128 bara = 127 bar g

Example 2

3 Stages Gas compressor has

Outlet pressure = 255 bar g
Inlet pressure = 3 bar g
What are the intermediate pressures

1st 2nd 3rd stage

stage stage
P0 P1 P2 P3

3 barg 255 barg

 1st 2nd 3rd stage
stage stage
P0 P1 P2 P3
3 barg
255 barg
3 P3 (255 +1) 256
R = r = = = = 64
P0 (3+1) 4

3
r = R = 64 = 4

P1 = r * P0 = 4 * 4 = 16 bara = 15 bar g

P2 = r * P1 = 4 * 16 = 64 bara = 63 bar g

P3 = r * P2 = 4 * 64 = 256 bara = 255 bar g

Common Failure Modes of RECIPROCATING COMPRESSORS

THE PROBLEM

SHORT BEARING LIFE

EXCESSIVE WEAR

HIGH GAS-AIR TEMP

EXCESSIVE HEAT

HIGH VIBRATION
LOW Q DISH.
LOW P DISH.
NO Q DISH.

HIGH NOISE
HIGH A mps

MOTOR TRIP
THE CAUSE
INSUFFICIENT LUBE OIL (Lubricators) 0* 0 0 0 0
Misalignment 0 0 0
Excessive system pressure 0 0 0 0 0 0
Unloader problem 0 0 0
Insufficient air/ gas in suction 0 0 0 0
Internal parts wear fluid end 0 0 0
Strainer partially clogged 0 0 0
Internal parts wear Power end 0 0 0
Intermediate S.R.V. problem 0 0
Insufficient intercoolers cooling 0 0
Insufficient lube oil cooling 0 0 0
WRONG DIRECTION OF ROTATION 0 0
Common Failure Modes of ROTARY COMPRESSORS

THE PROBLEM

SHORT BEARING LIFE

EXCESSIVE WEAR

HIGH GAS-AIR TEMP

EXCESSIVE HEAT

HIGH VIBRATION
LOW Q DISH.
LOW P DISH.
NO Q DISH.

HIGH NOISE
HIGH A mps

MOTOR TRIP
THE CAUSE
INSUFFICIENT LUBE OIL 0 0 0 0 0 0
Misalignment 0 0 0 0
EXCESSIVE SYSTEM PRESSURE 0 0 0 0 0 0
EXCESSIVE INLET TEMPERATURE 0 0
INSUFFICIENT AIR-GAS IN SUCTION 0 0 0 0
INTERNAL COMPONENT WEAR 0 0 0
STRAINER PARTIALLY CLOGGED 0 0 0 0
SPEED TOO LOW 0 0
R. VALVE LEAKS OR WRONG SET 0 0
ROTARY ELEMENTS BINDING 0 0 0 0 0 0
PIPING STRAIN 0 0 0 0
WRONG DIRECTION OF ROTATION 0 0
Common Failure Modes of ROTARY COMPRESSORS

THE PROBLEM

SHORT BEARING LIFE

EXCESSIVE WEAR

HIGH GAS-AIR TEMP

EXCESSIVE HEAT

HIGH VIBRATION
LOW Q DISH.
LOW P DISH.
NO Q DISH.

HIGH NOISE
HIGH A mps

MOTOR TRIP
THE CAUSE
INSUFFICIENT LUBE OIL 0 0 0 0 0 0
MISALIGNMENT 0 0 0 0
EXCESSIVE SYSTEM PRESSURE 0 0 0 0 0 0
EXCESSIVE INLET TEMPERATURE 0 0
INSUFFICIENT AIR-GAS IN SUCTION 0 0 0 0
INTERNAL COMPONENT WEAR 0 0 0
STRAINER PARTIALLY CLOGGED 0 0 0 0
SPEED TOO LOW 0 0
R. VALVE LEAKS OR WRONG SET 0 0
ROTARY ELEMENTS BINDING 0 0 0 0 0 0
PIPING STRAIN 0 0 0 0
WRONG DIRECTION OF ROTATION 0 0
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
 Distance Piston Suction
Crank Con-rod Valves
Piece
Piston
Rod

Stuffing Discharge
Wiper Box Valves
Crosshead
Rings Packing