Compressors

What are compressors ?

What is their significance/role in

continuous process industries?
• Compressors :
– Handles compressible fluid like air,
gases, vapours etc.
 Types of
Compressors

COMPRESSORS

POSITIVE DISPLACEMENT DYNAMIC TYPE

(COMPRESSING FLUID BY REDUCING (ACCELERATING AND
VOLUME OF COPRESSION CHAMBER) DECLERATING OF FLUID)

CENTRIFUGAL AXIAL
RECIPROCATING ROTARY TYPE
COMPRESSORS COMPRESSORS

HELICAL SPIRAL STRAIGHT SLIDE

SCREW AXIAL LOBE VANE
Selection Criterion :

• Application range.

• Reliability criterion.

• Operational range requirements.

 Application Range
105
Discharge Pressure Psia

104

103
Centrifugal
102
Axial

101
Reciprocating

102 103 104 105 106

Inlet Flow Atm.cfm
Characteristic Curve

Axial
Head Positive Displacement

Centrifugal

Capacity
• Therefore at constant speed–
– A Centrifugal compressor is
essentially a variable capacity,
constant pressure ( relatively )
machine.
– While axial flow & positive
displacement compressors are
constant capacity variable pressure
machines.
(This is an important factor in the
selection of type of compressor )
• Reliability, operating
characteristics and a very wide
operating range – all favors a
centrifugal compressor for
industrial use in most of the
cases.
Centrifugal
Compressor
 Centrifugal compressor
selection
• At constant speed :
– A positive displacement
compressor will always impart to
working fluid a predetermined
constant reduction in volume.
– While a centrifugal compressor will
always impart a constant change
in velocity of the fluid
 u

Cw
α

Cf
Q = Cf *A
C
Cr
H e= 1/g ( u2 Cw2 – u1 Cw1 )

For reduced capacity

u

Cw
Cf will decrease
α
&
Cf
C Cw will increase
Cr
Because of this reason for a centrifugal compressor
(with backward curved vane) following head-capacity
curve is obtained

Ideal
Head

Actual

Centrifugal compressor

Capacity
 Surge
– As we have seen in above theory that as
flow is reduced, the velocity of the fluid
jet leaving the vane is increased and
hence head is also increased. Also due
to reduction in flow the fluid channel
between two vanes is not completely
filled up which causes localized flow re-
circulation. A more decrease in flow
results in unstable operation and is
called “Surging of compressor”.
Horizontal split casing
Barrel type casing
 Main Parts
• Stator :
– Casing Upper Half
– Casing Lower Half
– ( Or Casing Barrel & counter
casing in case of Barrel type
compressor )
– Diaphragms ( Suction, discharge
and intermediate diaphragms )
 Main Parts
• Stator(contd…)
– Seal
• Seal for individual impeller
• Seal on balancing drum
• End gas seal ( labyrinth )
• End oil seal or dry gas seal or
injection seal
– Bearing Housing
• Incorporates radial bearing on one
side and radial and thrust bearing on
another side.
• Instruments on bearing housing :
1.For Temperature : Thermocouple on
bearing pads for direct measurement of
bearing temp
2.Axial position indicating probe
3.Radial vibration probes
4. Speed probe is generally mounted on
gas /steam turbine if the compressor is
turbo driven, but if compressor is motor
driven then a key phasor probe is installed
for analysis of vibration readings.
 Main Parts
• Rotor: As name implies it
consists of all rotating parts of
the compressor like :
– Impellers
– Shaft
– Balancing drum
– Coupling hub
– Thrust disc
 Protective Devices
• Emergency Stop Devices.
• Alarm Devices.
• Safety Valves.
• Anti Surge By-pass Valve
 Emergency Stop
• The conditions causing emergency stop may
be following ( only indicative and may vary
from case to case )
– Low lube oil pressure.
– Low level in seal oil tank ( if compressor
incorporates seal oil system )
– Over speed.
– Low control oil pressure ( for turbo driven )
– High differential pressure / high axial thrust
– High radial vibration
– In some cases high temperature after inter cooler or
after cooler
 Alarm Events
• All emergency stop conditions
will first generate alarm.
• Temperature ( of bearing,
process fluid, lube oil etc. )
• Pressure.
• Suction flow
• Low / high oil level in reservoir
• Low level in seal oil tank
Typical Bypass Anti Surge System
 Compressor Performance
Curve
Pressure

Compressor Surge
Line
Anti Surge Line
Psurge

P1 Design Point

Quantity Bypassed

Q
req.
Q
surge
Q1 Flow
Typical Compressor Performance
Map And Surge Control
Thrust Balancing
Types of Compressor End
Sealing Systems

 Labyrinth Sealing

 Floating Oil Seals

 Oil Mechanical Seals

 Air Injection Sealing System

 Injection / Extraction Sealing

 Dry Gas Seals

Gas Mechanical Sealing
System
Labyrinth Sealing With Steam
Ejector
Labyrinth Sealing With Gas
Ejector Recovery System
Labyrinth Sealing With
Air Injection
Floating oil seal
Dry Gas Seal
Dry Gas Seal
Advantages of Dry Gas Seal

• Atmospheric leakages are very low

• Oil free operation hence no oil
contamination to process gas
• Minimum auxiliary equipment
• Reduction in power loss
• Extremely compact and trouble free
Seal Gas Skid System
for Dry Gas Seals
• Supply Clean gas
• Monitor Seal
Leakage
• Supply Buffer Gas
• Initiate alarms &
shutdowns when
necessary
Applicable Standards

• API 610 Centrifugal Pumps

• API 611 Auxiliary Steam Turbines
• API 612 Drive Steam Turbines
• API 613 Gearbox
• API 614 Oil Systems
• API 616 Drive Gas turbines
• API 617 Centrifugal Compressors
 Applicable Standards

• API 670 Instrumentation

• API 671 Couplings
• API 672 Packaged, Integrally Geared
Compressors
• API 676 Positive Displacement Pumps
• IS 325 Auxiliary Electric Motors
• ASME PTC 10 Performance Test
• ASME Sec. VIII & IX Heat Exchangers
 Auxiliaries & Subsystems

Compressors require the following sub-

systems for their reliable, safe and
efficient operation;
• Lube oil
• Anti-surge and performance control
system
• Sealing (oil, DGS, ejector etc.) system
• Instrumentation and monitoring system
• Coolers and separators.