COMPRESSORS

Presented by:
Presented to:
ANDRITH FABIAN GÜIZA ZAMBRANO
ING. NICOLAS SANTOS SANTOS
2134124
 AGEND

INTRODUCTION

TYPES OF COMPRESSORS

SPECIFYING A COMPRESSOR

CYLINDER SIZING

EXAMPLE
 WHEN COMPRESSORS ARE USED?

Compressors are used whenever it is necessary to flow gas

from a lower pressure to a higher pressure system. Flash gas
from low-pressure vessels used for multistage stabilization of
liquids, oil treating, water treating.

Sometimes this gas is used as fuel and the remainder flared

or vented. Often it is more economical or it is necessary for
environmental reasons to compress the gas for sales.

SURFACE PRODUCTIONS OPERATIONS, Volumen 2, Design of Gas-Handling Systems and Facilities

 In a gas field, a compressor used in this service is normally called a
"flash gas compressor." Flash gas compressors are normally
characterized by low throughput rate and high differential pressure.
The differential pressure is expressed in terms of overall compressor
ratio, 𝑅𝑇 , which is defined as

𝑃𝑑
𝑅𝑇 =
𝑃𝑠

Where RT = overall compressor ratio

Pd = discharge pressure, psia
Ps = suction pressure, psia

SURFACE PRODUCTIONS OPERATIONS, Volumen 2, Design of Gas-Handling Systems and Facilities

 TYPES OF COMPRESSORS

GPSA, SECTION 13, PAG 13-2

 RECIPROCATING COMPRESSORS

SURFACE PRODUCTIONS OPERATIONS, Volumen 2, Design of Gas-Handling Systems and Facilities, pag 256
SURFACE PRODUCTIONS OPERATIONS, Volumen 2, Design of Gas-Handling Systems and Facilities, pag 257
 High-speed reciprocating compressor packages

Size

• Numerous sizes from 50 hp to

3000 hp.

• 2, 4, or 6 compressor cylinders are

common.

SURFACE PRODUCTIONS OPERATIONS, Volumen 2, Design of Gas-Handling Systems and Facilities, pag 259
 CHARACTERISTICS

Advantages Disadvantages

• Can be skid mounted. • High-speed engines are not as fuel

• Self-contained for easy installation and efficient as integral engines
easily moved. (7,500 to 9,000 Btu/bhp-hr).
• Low cost compared to low-speed • Medium range compressor efficiency
reciprocating units. (higher than centrifugal; lower
• Easily piped for multistage than low-speed).
compression. • Short life compared to low-speed.
• Size suitable for field gathering • Higher maintenance cost than low-
offshore and onshore. speed or centrifugal
• Flexible capacity limits.
• Low initial cost.
 Low-speed units are typically
integral in design

"Integral" means that the

power cylinders that turn the
crank shaft are in the same
case (same housing) as the
cylinders that do the
compressing of the gas.

They tend to operate at 400-

600 rpm,
SURFACE PRODUCTIONS OPERATIONS, Volumen 2, Design of Gas-Handling Systems and Facilities, pag 260
 Large integral compressor. This would be typical of compressors in
the 2,000 hp to 13,000 hp size.

SURFACE PRODUCTIONS OPERATIONS, Volumen 2, Design of Gas-Handling Systems and Facilities, pag 262
 Small-horsepower skid-mounted integrals.
There are some low horsepower (140 to 360).
The major characteristics of low-speed
reciprocating compressors are:

Size

• Some one and two power cylinder field gas

compressors rated for 140 hp to 360 hp.

• Large sizes 2,000 hp increments to 12,000

hp. 2 to 10 compressor cylinders common.

SURFACE PRODUCTIONS OPERATIONS, Volumen 2, Design of Gas-Handling Systems and Facilities, pag 263
 Advantages Disadvantages

• High fuel efficiency (6-8,000 Btu/bhp-hr). • Usually must be field erected except for very
• High efficiency compression over a wide small sizes.
range of conditions. • Requires heavy foundation.
• Long operating life. • High installation cost.
• Low operation and maintenance cost • Slow speed requires high degree of vibration
when compared to high speeds. and pulsation suppression
 VANE-TYPE ROTARY COMPRESSORS

Size

• Common sizes up to 250 bhp, but mostly used

for applications under 125bhp.
• Available in sizes to 500 bhp.
• Discharge pressures to 400 psig.
• Single- or two-stage in tandem on same shaft.

SURFACE PRODUCTIONS OPERATIONS, Volumen 2, Design of Gas-Handling Systems and Facilities, pag 263
 VANE-TYPE ROTARY COMPRESSORS

Advantages Disadvantages

• Good in vacuum service. • Must have clean air or gas.

• No pulsating flow. • Takes 5 to 20% more horsepower than
• Less space. reciprocating.
• Inexpensive for low hp vapor recovery or • Uses ten times the oil of a reciprocating.
vacuum service Usually install after-cooler and separator to
recycle oil.
 HELICAL-LOBE (SCREW) ROTARY COMPRESSORS

Size

• Up to 6,000 hp in air service, but more

common below 800 hp,
• Up to 400 hp in hydrocarbon service,
• Discharge pressures to 250 psig.
• Single- or two-stage in tandern on same
shaft

SURFACE PRODUCTIONS OPERATIONS, Volumen 2, Design of Gas-Handling Systems and Facilities, pag 266
 HELICAL-LOBE (SCREW) ROTARY COMPRESSORS

Advantages Disadvantages

• Available as non-lubricated especially • In hydrocarbon service needs seal oil

for air service. with after-cooler and separator to recycle
• Can handle dirty gas. oil.
• Can handle moderate amounts of • At discharge pressure over 50 psig takes
liquids, but no slugs. 10 to 20% more horsepower than
• No pulsating flow. reciprocating.
• At low discharge pressure (<50 psig) • Low tolerance to change in operating
can be more efficient than conditions of temperature, pressure, and
reciprocating. ratio.

SURFACE PRODUCTIONS OPERATIONS, Volumen 2, Design of Gas-Handling Systems and Facilities, pag 267
 CENTRIFUGAL COMPRESSORS

Size

• Starts about 500 hp.

• 1,000 hp increments to
20,000 hp.

SURFACE PRODUCTIONS OPERATIONS, Volumen 2, Design of Gas-Handling Systems and Facilities, pag 268-270
 Advantages Disadvantages

• High horsepower per unit of space and • Lower compressor efficiency.

weight. • Limited flexibility for capacity.
• Turbine drive easily adapted to waste-heat • Turbine drives have higher fuel rate
recovery for high fuel efficiency. than reciprocating units.
• Easily automated for remote operations. • Large horsepower units mean that
• Can be skid mounted, self-contained. outage has large effect on process
• Low initial cost. or pipeline capabilities.
• Low maintenance and operating cost.
• High availability factor.
• Large capacity available per unit.

SURFACE PRODUCTIONS OPERATIONS, Volumen 2, Design of Gas-Handling Systems and Facilities, pag 270
 SPECIFYING A COMPRESSOR

In specifying a compressor it is necessary to choose the basic type, the number of

stages of compression, and the horsepower required. In order to do this the volume
of gas, suction and discharge pressure, suction temperature, and gas specific gravity
must be known.
1/𝑛
𝑃𝑑
𝑅= ˂3 𝑡𝑜 4
𝑃𝑠

where R = ratio per stage

n = number of stages
𝑃𝑑 = discharge pressure, psia
𝑃𝑠 = suction pressure, psia
A first approximation for horsepower can be made from
Figure 10-11 or from the following equation

BHP = 22 R n F 𝑄𝑔

where BHP = approximate brake horsepower

R = ratio per stage
n = number of stages
F = an allowance for interstage pressure drop
= 1.O for single-stage compression
1.08 for two-stage compression
1.10 for three-stage compression
𝑄𝑔 = flow rate, MMscfd
SURFACE PRODUCTIONS OPERATIONS, Volumen 2, Design of Gas-Handling Systems and Facilities, pag 272
 Procedure for More Accurate Determination of
Horsepower and Number of Stages

The discharge temperature for any single stage

of compression can be calculated from:
1 1
𝑃𝑑 𝑘𝑥𝑛
𝑇𝑑 = 𝑇𝑠
𝑃𝑠

where 𝑇𝑑 = stage discharge temperature, °R

𝑇𝑠 = stage suction temperature, °R
𝑃𝑑 = stage discharge pressure, psia
𝑃𝑠 = stage suction pressure, psia
k = ratio of gas specific heats, Cp/Cv
n = polytropic efficiency Horsepower reduction by multistaging
= 1.0 for reciprocating, 0.8 for centrifugal
 The brake horsepower per stage can be determined from:

𝑘
𝑄𝑔 𝑇𝑠 𝑘𝑛 𝑃𝑑 𝑘𝑛
𝐵𝐻𝑃 = 0.0857( 𝑍𝑎𝑣 ) −1
𝐸 𝑘−1 𝑃𝑠

Where BHP = brake horsepower per stage E = efficiency

𝑄𝑔 = volume of gas, MMscfd high-speed reciprocating units — use 0.82
𝑇𝑠 = suction temperature, °R low-speed reciprocating units — use 0.85
𝑍𝑠 = suction compressibility factor centrifugal units — use 0.72
𝑍𝐷 = discharge compressibility factor n = polytropic efficiency
𝑍𝑎𝑣 = (Zs + ZD)/2 k = ratio of gas specific heats, Cp/Cv
Ps = suction pressure of stage, psia
Pd = discharge pressure of stage, psia
 The following procedure can now be used to calculate the number of
stages of compression and the horsepower of the unit:

• First, calculate the overall compression ratio (Rt = Pd/Ps)- If the compressor
ratio is under 5, consider using one stage. If it is not, select an initial
number of stages so that R < 5. For initial calculations it can be assumed
that ratio per stage is equal for each stage.
• Next, calculate the discharge gas temperature for the first stage. If the discharge
temperature is too high (more than 300°F), a large enough number of stages has
not been selected or additional cooling of the suction gas is required. If the
suction gas temperature to each stage cannot be decreased, increase the
number of stages by one and recalculate the discharge temperature.
• Once the discharge temperature is acceptable, calculate the
horsepower required, and calculate suction pressure, discharge
temperature, and horsepower for each succeeding stage.

• If R > 3, recalculate, adding an additional stage to determine if this

could result in a substantial savings on horsepower,
 CYLINDER SIZING

Typically, in specifying a unit, the suction and discharge pressures,

capacity (MMscfd), inlet temperature, and gas properties are given. The
actual sizing of the cylinders is left to the manufacturer from his specific
combinations of standard cylinders, pistons, and liners.

The capacity of the cylinder is a function of piston displacement and

volumetric efficiency. This is in turn a function of cylinder clearance,
compression ratio, and gas properties.
 Piston Displacement

Single acting cylinder Single acting cylinder

(head end displacement) (crank end displacement)

(𝑑𝑐2 ) (𝑠) ( 𝑟𝑝𝑚) (𝑑𝑐2 −𝑑𝑟2 ) (𝑠) ( 𝑟𝑝𝑚)

𝑃𝐷 = 𝑃𝐷 =
2,200 2,200

Double acting cylinder

(sum of head end and crank Where PD = piston displacement, cfm
end displacement) s = stroke length, in.
rpm = compressor speed, rpm
(2(𝑑𝑐2 ) − (𝑑𝑟2 )) (𝑠) ( 𝑟𝑝𝑚) dc = diameter of cylinder, in.
𝑃𝐷 =
2,200 dr = diameter of rod, in.
 Volumetric Efficiency

1 𝑍𝑠
𝐸𝑣 = 96 − 𝑅 − 𝐶 𝑅𝑘 −1
𝑍𝑑

Ev = stage volumetric efficiency, %

R = compression ratio (Pt/Ps) of the compressor stage (based on absolute
pressure)
C = cylinder clearance, percent of piston displacement
Zs = compressibility factor at suction, psia
Zd = compressibility factor at discharge, psia
k = ratio of specific heats, Cp/Cv
 Cylinder Throughput Capacity

𝑞𝑎 = 𝐸𝑣 ∗ 𝑃𝐷 Where qa = gas throughput at suction conditions of

temperature and pressure, 𝑓𝑡 3 /min
Ev = volumetric efficiency
PD = piston displacement, 𝑓𝑡 3 /min
Ps = suction pressure, psia
Ts = suction temperature, °R
𝑞𝑎 𝑃𝑠
𝑄𝑔 = 0.051 Zs = compressibility at suction conditions
𝑇𝑠 𝑍𝑠 Qg = gas throughput, MMscfd
 ROD LOAD

Single-acting cylinder, head end Single-acting cylinder, crank end

𝑅𝐿𝑐 = 𝑎𝑝 𝑃𝑑 − 𝑃𝑢 + 𝑎𝑟 𝑃𝑢 𝑅𝐿𝑐 = 𝑎𝑝 𝑃𝑢 − 𝑃𝑠 + 𝑎𝑟 𝑃𝑠

𝑅𝐿𝑢 = 𝑎𝑝 𝑃𝑢 − 𝑃𝑠 − 𝑎𝑟 𝑃𝑢 𝑅𝐿𝑟 = 𝑎𝑝 𝑃𝑑 − 𝑃𝑢 − 𝑎𝑟 𝑃𝑑
 Double-acting cylinder

where RLC = rod load in compression, lb

𝑅𝐿𝑐 = 𝑎𝑝 𝑃𝑑 − 𝑃𝑠 + 𝑎𝑟 𝑃𝑠 RLr = rod load in tension, Ib
ap = cross-sectional area of piston, 𝑖𝑛2
Pd = discharge pressure, psia
Ps = suction pressure, psia
𝑅𝐿𝑟 = 𝑎𝑝 𝑃𝑑 − 𝑃𝑠 − 𝑎𝑟 𝑃𝑑 Pu = pressure in unloaded area, psia
ar = cross-sectional area of rod, 𝑖𝑛2
 EXAMPLE PROBLEM

Give:

Late in the field life it is desirable to compress the 100 MMscfd for the example
field downstream of the separator from 800 psig at 100°F to 1,000 psig. An
engine-driven separable compressor is available from surplus. The engine is
rated for 1,600 hp at 900 rpm. Horsepower is proportional to speed. The
compressor frame has six 7-in. bore by 6.0-in. stroke double-acting cylinders
with a minimum clearance of 17.92%, a rod load limit of 25,000 Ib, and rod
diameter of 1.75 in. Assume k = 1.26, Zs = 0.88, and Zd = 0.85.

Compute discharge temperature, volumetric efficiency, required clearance, rod

load, and required horsepower for the given conditions. Also calculate the
lowest suction pressure at which this unit can compress 100 MMscfd.
1. Calculate the gas discharge temperature

𝑘−1 1
𝑃𝑑 𝑘 ∗𝑛
𝑇𝑑 = 𝑇𝑠
𝑃𝑠

(1.26−1)1
∗
1.015 (1.26) 1
𝑇𝑑 = (560)
815

𝑇𝑑 = 586 ˚𝑅

𝑇𝑑 = 126˚𝐹
 2. Calculate the volumetric efficiency

1 𝑍𝑠
𝐸𝑣 = 96 − 𝑅 − 𝐶 𝑅𝐾 −1
𝑍𝑑

1.015
𝑅= = 1.245
815

1 0.88
𝐸𝑣 = 96 − 1.245 − 17.92 1.2451.26 −1
0.85

𝐸𝑣 = 90.6%
 3. Calculate the required clearance

2
2 𝑑𝑐 − 𝑑𝑟 2 (𝑠)(𝑟𝑝𝑚)
𝑃𝐷 =
2,200

2 7 2 − 1.75 2 (6)(900)
𝑃𝐷 =
2,200

𝑃𝐷 = 233
𝑃𝐷 = 6 233 = 1,398 𝑐𝑓𝑚
𝑞𝑎 = 𝐸𝑣 𝑃𝐷
𝑞𝑎 = 0.906 1,398
𝑞𝑎 = 1,267 𝑐𝑓𝑚 𝑎𝑡 𝑠𝑢𝑐𝑡𝑖𝑜𝑛 𝑐𝑜𝑛𝑑𝑖𝑡𝑖𝑜𝑛𝑠
 Convert to standard conditions:

(0.051)(𝑞𝑎 𝑃𝑠 )
𝑄𝑔 =
𝑇𝑠 𝑍𝑠

(0.051)(1,267)(815)
𝑃𝐷 =
(560)(0.88)

𝑄𝑔 = 106.9 𝑀𝑀𝑠𝑐𝑓𝑑

At the present operating condition, the throughput is too high. One can
decrease throughput by reducing speed, increasing clearance, which will
reduce volumetric efficiency, using a thicker cylinder liner to reduce
cylinder volume, or lowering suction pressure.
(a) Calculate required rpm to give desired throughput:

(0.051)(𝑞𝑎 )(815)
100 =
(560)(0.88)

𝑞𝑎 = 1,186 𝑐𝑓𝑚

𝑞𝑎 1,186
𝑃𝐷𝑡𝑜𝑡 = = = 1,309 𝑐𝑓𝑚
0.906 0.906
 𝑃𝐷𝑡𝑜𝑡 1,309
PD= = = 218 𝑐𝑓𝑚
6 6

(𝑃𝐷)(2,200)
r𝑝𝑚 =
6[2 𝑑𝑐 2 − 𝑑𝑟 2 ]

(218)(2,200)
r𝑝𝑚 =
6[2 7 2 − 1.75 2 ]

𝑟𝑝𝑚 = 842 𝑜𝑟 ≅ 850 𝑟𝑝𝑚 𝑖𝑠 𝑡ℎ𝑒 𝑠𝑢𝑖𝑡𝑎𝑏𝑙𝑒 𝑠𝑝𝑒𝑒𝑑

(b) Calculate the clearance that would be needed to reduce
the throughput from 106.9 MMscfd to 100 MMscfd:

𝑞𝑎 1,186
𝐸𝑣 = = = 0.848
𝑃𝐷 1,398

Now back calculate for the clearance that must be

added to produce this volumetric efficiency.

1 0.88
84.8 = 96 − 1.245 − 𝐶[(1.245)1.26 − 1]
0.85

𝐶 = 43.0%
(c) Calculate the size liner required to reduce piston displacement:
Assume 𝐸𝑣 remains constant. This may have to be determined
once a drawing of the specific cylinder and liner is available.
However, it should not vary greatly. The PD required is:

1,186
PD= = 1,309 𝑐𝑓𝑚
0.906

1,309 [2 𝑑𝑐 2 − 1.75 2 ](6)(900)

=
6 2,200

𝑑𝑐 = 6.78 𝑖𝑛.
 4. Calculate the rod load

𝑅𝐿𝑐 = 𝑎𝑝 𝑃𝑑 − 𝑃𝑠 + 𝑎𝑟 𝑃𝑠

2 2
7 1.75
𝑅𝐿𝑐 = 𝜋 1,015 − 815 + 𝜋 815 = 9,657 𝑙𝑏
2 2

𝑅𝐿𝑡 = 𝑎𝑝 𝑃𝑑 − 𝑃𝑠 − 𝑎𝑟 𝑃𝑑
2 2
7 1.75
𝑅𝐿𝑡 = 𝜋 1,015 − 815 − 𝜋 1,015 = 5,256 𝑙𝑏
2 2

The calculated rod load for both the compression and tension
modes are within the 25,000 lb máximum rod load limit.
5. Calculate the required horsepower needed for the given conditions:

𝑘−1
𝑄𝑔 𝑇𝑠 𝑘 𝑃𝑑 𝑘
𝐵𝐻𝑃 = 0.0857 𝑍𝑎𝑣 −1
𝐸 𝑘−1 𝑃𝑑

0.88 + 0.85
𝑍𝑎𝑣 = = 0.865
2

𝐸 = 𝐴𝑑𝑖𝑎𝑏𝑎𝑡𝑖𝑐 𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦 ∗ 𝑚𝑒𝑐ℎ𝑎𝑛𝑖𝑐𝑎𝑙 𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦

𝐸 = 0.87 ∗ 0.94 = 0.82

 1.26−1
(100)(560) 1.26 1,015 1.26
𝐵𝐻𝑃 = 0.0857 0.865 −1
0.82 1.26 − 1 815

𝐵𝐻𝑃 = 1,137 ℎ𝑝

This is less than is available

from our engine.
6. Calculate the lowest suction pressure.

If we use the mínimum clearance

𝑞𝑎 = 1,267 𝑐𝑓𝑚

𝑞𝑎 𝑃𝑠
𝑄𝑔 = (0.051)
𝑇𝑠 𝑍𝑠

Assume 𝑍𝑠 = 0.88 at the new lower 𝑃𝑠 .

 (100)(560)(0.88)
𝑃𝑠 = = 762.6 𝑝𝑠𝑖𝑎
(0.051)(1,267)

𝑃𝑠 = 747.9 𝑝𝑠𝑖𝑔

It would be posible to recalculate this by choosing a

new value for 𝑍𝑠 and calculating a new 𝐸𝑣 for this
condition, but the results will not change materially. By
inspection, neithe horsepower, rod load, nor discharge
temperature will limit this suction pressure.
 BIBLIOGRAPHY

GPSA, Section 13, Compressors

SURFACE PRODUCTIONS OPERATIONS, Volumen 1, Design of Gas-Handling

Systems and Facilities, Chapter 1

SURFACE PRODUCTIONS OPERATIONS, Volumen 2, Design of Gas-Handling

Systems and Facilities, Chapter 10, Chapter 11