![29 August 2023 51
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](https://image.slidesharecdn.com/compressors-250308095220-6ac43dc8/85/All-about-compressor-design-and-operation-51-320.jpg)
All about compressor design and operation
- 1. Compressors
- 2. Standards and Codes API STD 617 Centrifugal Compressors for Petroleum, Chemical, and Gas Industry Services API STD 619 Rotary Compressors for Petroleum, Petrochemical, and Gas Industry Services API STD 618 Reciprocating Compressors for Petroleum, Chemical, and Gas Industry Services API STD 681 Liquid Ring Vacuum Compressors for Petroleum, Chemical
- 3. Compressors Classification Kinetic A – Centrifugal B – Axial Positive Displacement C -Reciprocating D -Rotary *Screw * Lobe *Sliding Vane *Gear * Others
- 4. Main Types Of Compressors HIGH LOW V. HIGH NO NO YES LOW HIGH V. HIGH YES NO NO Pressure P Flow Rate Q S .R .V Efficiency Maint. cost Pulsation Surging Positive D.P. Centrifugal Axial Flow V. HIGH LOW LOW LOW MEDIUM V. HIGH NO YES YES
- 5. Compressor Selection Reciprocating Single stage Centrifugal Single stage Rotary-Screw
- 6. 29 August 2023 6 Different Types of Compressors Disadvantages Advantages Type Centrifugal Axial - Positive displacement - Wide operating range - Low maintenance - High reliability - Unstable at low flow - Moderate efficiency - High efficiency - High speed capability - Higher flow for a given size - Low pressure ratio per stage - Narrow flow range - Fragile and expensive blading - Pressure ratio capability not affected by gas properties - Good efficiencies at low specific speed - Limited capacity - High weight to capacity ratio - Higher maintenance requirements Introduces vibrations into the system - Bigger foundation requirements
- 7. 7 Centrifugal Axial Efficiency Specific speed N s Centrifugal Positive displacement Axial 50 % 60 % 70 % 80 % 90 % Pressure % Rated Capacity 100 % Positive Displacement
- 12. DIFFUSER IMPELLER TIP BALANCE PISTON
- 13. SPLIT TYPE COMPRESSORS 1- Horizontally Split High Flow Medium pressure
- 14. 2- Vertically Split (Double Barrel) high pressure and medium Flow
- 15. Axial Flow Compressors * API 617 * Very High Flow rate * Low pressure * Very High efficiency
- 16. Discharge Stationary Aerodynamics Inlet Cover Thrust Bearing Rotor Journal Bearing Dry Gas Seal Casing Dry Gas Seal Shear Ring Journal Bearing Balance Piston *API 617 * Medium pressure * High Flow rate * High efficiency
- 17. Reciprocating Compressor * API 618 * Low Flow rate * High pressure * Moderate efficiency
- 18. Rotary-Screw Compressor * API 619 * High Flow rate * High pressure * Moderate efficiency
- 19. ** Compressor Selection Application Operating parameter footprint/weight Availability Reliability maintenance drivers
- 22. ** Compressors components Rotor Shaft Thrust collars Impellers Spacers Diffusers Casing Mechanical Seals Couplings HSC LSC Gear Box Driver Anti- Surge System Lube Oil System Labyrinths Centrifugal Compressor
- 23. 23 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.
- 24. COOLER SCRUBBER 1St Stage ANTI-SURGE VALVE SCRUBBER ** Centrifugal Compressor Operation
- 25. COOLER SCRUBBER 1St Stage ANTI-SURGE VALVE COOLER SCRUBBER ANTI-SURGE VALVE SCRUBBER 2 Nd Stage ** Centrifugal Compressor Operation
- 26. COOLER SCRUBBER 1St Stage ANTI-SURGE VALVE COOLER SCRUBBER ANTI-SURGE VALVE COOLER SCRUBBER ANTI-SURGE VALVE SCRUBBER 2 Nd Stage 3 Rd Stage ** Centrifugal Compressor Operation
- 27. 8/29/2023 BY- H. Hassan 27 3 Stages Geared Centrifugal Compressor Cooler Cooler
- 29. 29 AXIAL FLOW COMPRESSORS CENTRIFGAL COMPRESSORS AND HAPPENS ONLY TO : But Does not Happen to Reciprocating Compressors
- 30. 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 SURGE PHENOMEN IN OUT
- 31. • FLOW-RATE IS NOT ENOUGH • GAS PROPERTY • FLATENESS OF P.C. AT LOW Q • COMPRESSOR PERFORMANCE Why SURGE PHENOMEN
- 32. • FLOW-RATE IS NOT ENOUGH • GAS PROPERTY This will happen at starting and shutdown, also at abnormal conditions. Gas is compressible but liquid is not.
- 33. • FLATENESS OF P.C. AT LOW Q • COMPRESSOR PERFORMANCE Centrifugal and Axial compressors are pumping gas continuously but reciprocating is not. Gas pressure has the same energy at horizontal portions of the performance curve
- 34. INLET FLOW RATE Q IS ENOUGH IN OUT NO SURGE IF
- 35. OUT 5 to 20 cycles per second IN IF INLET FLOW RATE Q IS NOT ENOUGH COMPRESSOR IS SURGING
- 36. 36 SURGE PHENOMENON H p A B Q M³/ hr 10000 6000
- 38. SURGE WILL DAMAGE THE COMPRESSOR THRUST BEARINGS EFFECT OF SURGE ON CENTRIFGAL COMPRESSOR ROTOR THRUST BEARINGS
- 39. SURGE WILL DAMAGE THE COMPRESSOR THRUST BEARINGS THRUST BEARINGS COMPRESSOR
- 40. 40 SURGE CYCLE Q M³/ hr - Q Hp B1 10000 6000 5 to 20 cycles per second
- 41. 1- BY PASS WITH ANTI - SURGE VALVE ANTI-SURGE METHODS 2 –BLOW OFF VALVE THIS METHODS IS COMMONLY USED FOR GAS COMPRESSORS THIS METHODS IS COMONLY USED FOR AIR COMPRESSORS
- 42. 42 1- BY PASS WITH ANTI - SURGE VALVE P,T FT UIC FY COMRESSOR COOLER ANTI-SURGE VALVE WILL OPEN ANTI-SURGE METHODS IN CASE OF COMPRESSOR SURGING
- 43. 43 6000 M 3 COMRESSOR 10000 M 3 4000 M 3 4000 M 3 6000 M 3 P,T FT UIC FY COOLER ANTI-SURGE VALVE FY = TRANSDUCER UIC = ANTI- SURGE INTEGRATED CONTROLER 1- BY PASS WITH ANTI - SURGE VALVE
- 44. 44 BY PASS WITH ANTI - SURGE VALVE GRAPHICALLY A H p C Q M³/ hr B SURGE CONTROL LINE RECYCLE TRIP LINE SURGE LIMIT LINE
- 45. 45 2 –BLOW OFF VALVE FY = TRANSDUCER UIC = ANTI- SURGE INTEGRATED CONTROLLER BLOW OFF VALVE Air 3 6000 M P,T F T UIC FY AIR COMRESSOR 10000 M 3
- 46. 46 2 – BLOW OFF VALVE A B GRAPHICALLY Q M ³/ hr Hp B1
- 47. 47 IN CASE OF GAS TURBINE AIR COMPRESSOR SURGE BLEED VALVE WILL OPEN COMPRESSOR TURBINE BLEED VALVE
- 49. 29 August 2023 49 Reciprocating Compressors
- 51. 29 August 2023 51 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
- 52. 29 August 2023 52 Crosshead Stuffing Box Packing Discharge Valves Suction Valves Piston Distance Piece Con-rod Crank Piston Rod Wiper Rings Reciprocating Compressors construction
- 53. Multi stage reciprocating compressor ACCUMILLATOR PULSATION DAMPENER GAS GAS COOLER SCRUBBER SCRUBBER ACCUMILLATOR PULSATION DAMPENER 1St 2nd 53
- 54. 54 COOLER SCRUBBER 1St Stag COOLER SCRUBBER COOLER SCRUBBER SCRUBBER 2 Nd Stage 3 Rd Stage Multi stage reciprocating compressor Compressors intermediate pressures
- 55. 29 August 2023 55 ACCUMILLATOR PULSATION DAMPENER Design applications of reciprocating compressors GAS COOLER SCRUBBER SCRUBBER ACCUMILLATOR PULSATION DAMPENER 1St 2nd
- 57. 29 August 2023 57 Reciprocating Compressors Flow Regulation 1- VARIABLE CLEARANCE 3- VARIABLE SPEED 4- BYPASS 2- SUCTION VALVE UNLOADERS • Manual Operated Clearance • Pneumatic Operated Clearance 5- Shut down the Compressor Periodically (Start-Stop Operation)
- 58. 29 August 2023 58 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. 1- VARIABLE CLEARANCE
- 60. Manual Operated Clearance CYLINDER HEAD 60 Clearance Head Controlling Nut VARIABLE CLEARANCE VOLUME Clearance Volume Effect
- 62. 29 August 2023 62 Point g suction valves open C = Clearance volume C v b a c g Pd Ps c1 M EFFECT OF CLEARANCE VOLUME At Point a suction valves closed Point b discharge valves open Point c discharge valves closed
- 63. Compression ratio Pressure ratio (ABSOLUTE) Pd P s = Volumetric efficiency = Va g V cylinder a M a g = = V cylinder Vb M C v b a c g Pd Ps c1 M b b M a M =
- 64. 29 August 2023 64 C v Pd Ps c1 M b a c Volumetric efficiency = Va g V cylinder a M a g = g
- 65. 29 August 2023 65 C v Pd Ps M b a c g Volumetric efficiency = Va g V cylinder a M a g =
- 66. 29 August 2023 66 v Pd Ps M C a b c g Volumetric efficiency = Va g V cylinder a M a g =
- 67. 29 August 2023 67 If C Increased suction valves will open at ( g ) C v a c g Pd Ps b M EV DECREASES Q DECREASES Volumetric efficiency = Va g V cylinder a M a g =
- 68. 29 August 2023 68 If C Decreased suction valves will open at (g) Q INCREASES Volumetric efficiency = Va g V cylinder a M a g = EV INCREASES C v a c g Pd Ps b M
- 69. 29 August 2023 69 Compression ratio Pressure ratio (ABSOLUTE) Pd P s = Volumetric efficiency = Va g V cylinder a M a g = = V cylinder Vb M C v b a c g Pd Ps c1 M b b M a M =
- 70. 29 August 2023 70 • 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)
- 71. 29 August 2023 71 SUCTION VALVE UNLOADER
- 72. 29 August 2023 72 Air Compressor Dryer https://www.youtube.com/watch?v=6tVw9VYQDIg
- 73. Wet Air to Atmosphere ACTIVATED REGENRATED Dry Air to instrument Receiver AIR COMPRESSORS DRYER TWO WAY VALVE TWO WAY VALVE AIR FROM COMPRESSOR
- 74. AIR COMPRESSORS DRYER REGENRATED ACTIVATED Wet Air to Atmosphere Dry Air to instrument Receiver AIR FROM COMPRESSOR
- 75. 29 August 2023 75 Reciprocating Compressor Operations https://www.youtube.com/watch?v=ooBJMI0H7PQ
- 76. Discussion
- 78. 29 August 2023 78 Rotary Compressor Relief Valve
- 79. 29 August 2023 79 Screw compressor • Dry Screw Compressor • Oil Flooded Screw Compressor
- 80. 29 August 2023 80 Rotary Screw Compressors
- 81. 29 August 2023 81 Rotary-Screw Compressor
- 82. 29 August 2023 82 Rotor profile of the four ------lobe male and the six lobe female
- 83. 29 August 2023 83 Oil – flooding system for a rotary screw air compressor. Oil injected to compressor compressor Air Outlet Dry Air Hot Oil Cold Oil
- 84. 29 August 2023 84 Multiple-screw double-end arrangement
- 85. 29 August 2023 85 ROTARY COMPRESSORS External Gear THE FLUID IS TRAPPED BETWEEN ROTOR AND
- 86. 29 August 2023 86 THREE LOBE COMPRESSORS
- 87. 29 August 2023 87 TWO LOBE COMPRESSOR
- 88. 29 August 2023 88 TWO LOBE COMPRESSOR
- 89. 29 August 2023 89 Gap, no contact Dry helical screw compressors. (driven by external timing gears).
- 90. 29 August 2023 90 TIMING GEAR FUNCTION 2- Keeps No Contact Between Rotors 1- Transmit Motion To Other Rotor 3- Prevent Wear Between Rotors
- 91. 29 August 2023 91 contact Injected oil Rotary helical screw oil injected compressor
- 92. 29 August 2023 92 Suction Discharge Rotary Vane Compressor
- 93. 29 August 2023 93 Rotary Vane Gas Compressors
- 94. 29 August 2023 94 THREE LOBE COMPRESSORS
- 95. 29 August 2023 95 TWO LOBE COMPRESSOR
- 96. 29 August 2023 96 External Gear THE FLUID IS TRAPPED BETWEEN ROTOR AND CASING
- 97. 29 August 2023 97 Internal Gear
- 98. 29 August 2023 98 Driving rotor Crest