Turbo machines lab

Centrifugal and Reciprocating

Compressors

Y Upendra Sravan-08bme257
V Ravi Teja-08bme240
Y Murali Krishna-08bme256
V Sandeep Kumar-08bme255
What is Compressor?????

……...a device used for pumping

compressible fluids i.e,
air, gas & steam
What is the basic difference
between Compressor & Blower

….pressure rise above 0.35 bar

is compressor and below is blower
Compressor Classification
a) By principle of operation
b) By construction type
c) By staging
d) By service duty
e) Lubricated/ non lubricated
 Classification
Operation Staging Service Lubricated /
Principle Non Lube

Positive Displacement/ Single / Multi stage Critical service or

Dynamic or Turbo non critical duty
Positive Displacement
(Increase press. by reducing volume)
Types are -
• Reciprocating
• Rotary - Screw, Vane , Liquid
Ring & Lobe
• Diaphragm
Dynamic or Turbo Compressors

(By imparting K.E. to air/gas and then

converting it into pressure)
Types are -
• Centrifugal or Radial Compressors
• Axial Flow Compressors
Classification by staging of compressors

Single Stage ( compression of gas in one stage)

Multi-stage ( compression of gas in more then one stage )

Classification by Duty

Critical Duty : Whereby stoppage of compressor will lead

to interruption in the process and heavy loss in terms of
production and would need elaborate start-up cycle
including, re-heating recharging the catalyst etc.

Utility Duty: Is basically for those applications where in

even if the compressor is shut the plant operation will not
be terminated
Lubricated or Non Lube Compressors

Lubricated Compressors : Where the gas is mixed with

lubricant

Non Lubricated Compressors: Where process gas or air

remains uncontaminated by the the lubricant during the
compression process
Basic Terminology for Compressors-
Flow rate: m3/hr , cfm ( 1cfm = 0.5886 m3/hr)
Pressure ratio: ratio of absolute discharge press. /
absolute inlet pressure
Absolute press = gauge pressure + atmospheric pressure
Atmospheric pressure= pressure exerted by atmosphere
At sea level atms press. = 1.033 kg/cm2 A = 1.013 barA = 14.696 pisA =
760 mmHg= 1atms
Parameters for selection of compressor-
Application:
Gas handled:
Gas analysis:
Flow rate:
Suction Pressure :
Suction Temperature:
Mol wt. of Gas:
Z (Compressibility) & Cp/Cv:
Discharge Pressure:
Drive System:
Basic Terminology for Compressors-
NTP Conditions and STP conditions

NTP conditions ( Nm3/hr)

At sea level (1.033 kg/cm2A, 273 deg. , 0% r.h.)
STP conditions ( sm3/hr or scfm)
At sea level (1.033 kg/cm2A, 288 deg. , 0% r.h.)
Reciprocating Compressors-
Selection:
- Flow rate till 10000m3/hr
- Pressure till 3500 bar, Power till
7000 kW
Construction:
Basic Design : As per API- 618
-Vertical
-Horizontal
-Horizontal Balanced Opposed ( mostly
used now)
for variable
Suitable :pressure ratio and constant capacity at given speed
Reciprocating Compressors-
Drive System:
-Belt or Direct Driven
Drivers:
-Induction & Syn. Motors , also single bearing motors with rigid coupling
-Diesel or Gas Engines
Capacity Control:
-Suction Valve un-loaders (thru stepped control)
-Recycling or spill back
-VFD
Main Components: Cylinders, valves, piston, rings, cross head, connecting rod,
crank-shaft
 Reciprocating Compressors-
Advantages:
- simple & open in construction
- site repairs possible
-do not require specialist at site
-not effected by changes in ambient conditions
-no adverse effect due to changes in the gas mol. Wt.
-single and multistage with inter-cooling
-achieve very high pressure ratios
-low & medium speed machines (250 - 1200 rpm), low noise level
-cooling of cylinder jackets & inter-cooling keeps temp. down and saves power
-non lubricated cylinders by using special piston/ rider rings
Reciprocating Compressors-
Disdvantages:
-Maintenance prone mainly valves, piston/rider rings
-Large bulky foundation
-Long installation time
-In fact large compressors are assembled at site
-Hooking up of auxiliaries such lube oil console, tempered c/w
console for cyl. Jacket cooling, mounting of pulsation separators etc.
-Pulsating flow requires costly piping and flow analysis
-Step-less capacity regulation not possible
-Loss in capacity with operation
-Standby machines required
Reciprocating Compressors-
Main Applications:
-In general engg.industries as plant & instrument air
compressors till about 250 kW. Electric motor drive
(where compressed air is used as energy source)
-Pneumatic conveying
-Fuel Gas Boosters to Gas Turbines ( Acc. API-618 with
electric motor driver till 2000 kW
-Gas booster, gas lift and gas re-injection compressors with gas
engine drive in natural gas fields and pipeline transmission
-CNG compressors for filling ( gas engine as well as motor
driven)
Reciprocating Compressors-
Main Applications:

-Refineries : Recycle , Make Up Compressors till 6000 kW

with low speed syn. Motors & also for feed gas, off gas &
recycle gas compressors for H2 plants
-LNG Re-gassification terminals: Boil off gas compressors for
very low temp. -160 deg.cel.
-Cryogenic plants for oxygen and nitrogen: As nitrogen & o
gas boosters (mainly in steel, copper, plants
-PSA based N2 & oxygen plants: ( paper, refinery,
petrochemicals etc.)
Reciprocating Compressors-
Major manufacturers ( World wide )
Process applications acc. API-618 , till 6000 kW
- Peter Brotherhood, U.K.
- Nouvo Pignone ( G.E.), Florence, Italy
-Thomassen, Rheden, Netherlands
-Dresser Rand, Painted Post, USA
-Neuman Essar, Germany
-Mitsui Engg & Shipbulding, Japan
-Kobe Steel, Japan
Reciprocating Compressors-
Major manufacturers ( India )
Process applications acc. API-618 , till 600 kW
- Dresser Rand, Naroda.
Plant & Instrument Air ( till 350 KW)
- Atlas Copco, Nasik ( formarly CP India)
-Ingersoll Rand, Naroda
-K.G. Khosla Compressors
Reciprocating_Compressor_Principles_-_sample.flv

Reciprocating_Compressor_-_Mechanism_Design.flv
- CENTRIFUGAL OR RADIAL FLOW COMPRESSORS

Selection:

Radial Compressors

- Centrifugal Compressors Flow rate: 2000 to 4,50,000 m3/hr

- Pressure ratio till 60, Power till

50,000 kW
Basic Design : As per API- 617 or API-672
These are horizontal split casing or barrel type for high press. appl
Single shaft single stage/Multistage, multi-casing compressors
Multi shaft integrally geared single or multi stage compressors
Drive System:
-Directly coupled with driver or through gear box
Drivers:
-Induction & Syn. Motors
-Steam or Gas Turbine
-Combination drive train with induction motor generator
and turbine
-Variable
Capacity Inlet guide vanes/ VDV or combination of both
Control:
-Recycling
-Speed Variation
-Combination of IGV and speed control
Main Components of Centrifugal Compressor are:
Inlet Guide Vane , Impeller & rotor, diffuser (vaned or vane-less) ,volute
casing ,sealing system

Main Components of Axial Compressor are:

Inlet Guide Vane , Inlet nozzle ring, set of rotating vanes, stationary
blades that acts a diffusers
Advantages:
- reliable and suitable for uninterrupted operation without standby
- no wearing parts, compact design, easy installation
-consistent performance
-can handle very large flow rates
-high polytropic efficiency
-single and multistage with inter-cooling
-variable capacity at constant speed
-can handle most of the process gases besides air
-non lubricated / oil free compression

-flexibility in driver selection

Disadvantages:
-Sensitive to changing ambient conditions
-Special protection system against surge
-Change in gas mol. wt. limits the operation
-Special arrangement to ensure no liquid carry over from process
-Elaborate filtration system required for the air
-High noise level.
-Special care to be taken for the variation in frequency
-Any dirt build/ polymer build up alter the performance adversely
-Due to high speed vibration monitoring system to be installed
-High initial cost
Main Applications:
-Standard Centrifugal Compressors
General Engg & other industries such as Glass, Automobiles,
Electronics, Synthetic Fibers, Textiles, plant & instrument air
compressors for steel plants, refinery, power plants etc.
Normally with flow rates starting higher then 2000 m3/hr till
15000 m3/hr as single or multiple units
Process Applications of Centrifugal Compressors

Steel Plant-
Blast Furnace Blowers
( 20000 to 8,00,000 m3/hr, press till 4.5 bar)
Type: Centrifugal multistage without inter cooling, Axials
Drive System: Motor, Steam Turbine thru gear box
Two or three units continuos operation
This application is characterized by rapid fluctuations in
pressure and flow
Process Applications of Centrifugal Compressors

Steel Plant-
Coke Oven Exhausters and boosters
Motor & Steam Turbine Drive
Combination drive
Cryogenic Oxygen Plant ( Air Separation Units)
Feed Air, Air Booster , N2 & O2 Boosters
( Rating 1000 kW till 20,000 kW)
Process Applications of Centrifugal Compressors

Ammonia/ Urea Plants-

Ammonia Refrigration Gas Compressor
Typ. Parameters: 40000 nm3/hr , 5.2 / 21 bar )
Power ratting till 6000 KW
Driver: Motor / Steam Turbine
Urea Synthesis
CO2 Gas Compressor 30000 nm3/hr , 1.5 / 200 bar)
Power Rating: till about 7000 KW
Process Applications of Centrifugal Compressors

Process Parameters of compressors at Typical Industries

Syn Gas Compressor : syn gas 79000 nm3/hr, 25 / 230 bar
recycle gas 360000 nm3/hr , 217 / 242 bar

3Speed
casing15000
compressor
rpm
Main Air Blower : 26050 nm3/hr , 1.01/ 34.5 bar, 8800 rpm
2 casing compressor
Ammonia ref. Comp : 31790 nm3/hr , 2.6 / 18.6 bar, 9500 rpm,
single casing machine
Process Applications of Centrifugal Compressors

Refinery
-Main Air Blower FCCU (centrifugal or axial motor, steam turb)
40000 nm3/hr till 1,20,000 nm3/hr @ 3.5 bar, till 12 MW
Drive: Motor, Steam Turbine, Power recovery train - Typical Industries
-Wet gas compressor ( Motor Drive) till 3 MW
-Hydrocracker - Recycle Gas Compressor - Steam Turbine
Driven till 4.5 MW ( H2 +HC mol wt. 8 450000 nm3/hr 150 / 200 bar)
-Hydrotreater/ DHDS -Recycle Compressors- Steam Turbine Drive
SRU- Clause Air Compressors - 35000 nm3/hr , 2.2 bar
Motor Drive or Steam Turbine Drive
Chemicals
-Sulphuric Acid Plant ,Air Blower till 300000 nm3/hr and 8000 kW
Motor ,or steam turbine or motor generator + turbine
-Caustic soda plant Chlorine gas compressor till 1500 kW
with freon intercoolers
-Soda Ash ( CO2 compressors)
Oil & Gas
Pipeline compressors with Gas Turbine Drive
Gas lift and Reinjection compressors with Gas Turbine drive
Process Applications of Centrifugal Compressors

Copper Smelters
-Convertor Blowers
Till 4500 kW for supply cold air blast into convertor
( 60000 nm3/hr @ 3 bar)
-SO2 Blowers till 4000 kW
Petrochemicals
PA, MA, Plant
Process Air Compressor with steam turbine & combination drive train
till 3500 kW, Flow Rates till 70000 nm3/hr @ 2.0 bar
Process Applications of Centrifugal Compressors

Power Generation
-Fuel gas compressors to Gas Turbine
-IGCC units gassifier syn gas booster
Major manufacturers ( World wide )
Process applications acc. API-617 & API-672
- MAN Turbo,Germany U.K.
-Siemens,Germany (formerly Demag)
-Novuo Pignone, Italy -Elliot, USA
-Dresser Rand, France
-Ebara, Japan , -MHI, Japan ,-Kobe Steel, IHI & KHI Japan
-AG KK&K, Germany
-Atlas Copco ,USA & Germany
-BHEL, India
Centrifugal_Compressor_Principles_-_Sample.flv