WHAT IS COMPRESSOR

COMPRESSOR ARE THE MACHINES

REQUIRED FOR
TRANSPORTATION/MOVEMENT OF
GAS IN A SYSTEM.THE PURPOSE OF
COMPRESSON IS TO INCREASE THE
PRESSURE OF GAS FROM ONE
LEVEL TO ANOTHER.

CLASSIFICATION OF
COMPRESSORS
TWO PRINCIPLE METHOD ARE USED
TO COMPRESS GASSES.FIRST IS TO
TRAP A VOL.OF GAS AND DISPLACE IT
BY POSITIVE ACTION OF PISTON OR
ROTATING MEMBER(POSITIVE
DISPLACEMENT) .THE SECOND
METHOD IS ACCOMPLISHED BY THE
MECHENICAL ACTION OF CONTURED
BLADES WHICH IMPART VELOCITY AND
HENCE PRESSURE TO THE GAS.

COMPRESSORS

POSITIVE DISPLACEMENT

DYNAMIC
( TURBO )

(COMPRESSION OF FLUID BY REDUCING

VOL.OF COMPRESSION CHAMBER)

RECIPROCATING

MIXED
FLOW

ROTARY
CENTRIFUGAL

HELICAL

LIQUID
RING

STRAIGHT
LOBE

SLIDE
VANE

AXIAL

DYNAMIC TYPE COMPRESSOR

THE MACHINE IN WHICH GAS IS
COMPRESSED BY DYNAMIC ACTION
OF IMPELLERS IMPARTING VELOCITY
AND PRESSURE TO FLOWING GAS.
THE VELOCITY HEAD IS CONVERTED
INTO PRESSURE PARTIALLY IN THE
ROTATING ELEMENT AND PARTIALLY
IN STATIONARY DIFFUSER OR BLADE.

CENTRIFUGAL COMPRESSOR
THE MACHINE IN WHICH
VELOCITY AND PRESSURE ARE
IMPARTED TO THE GAS IN RADIAL
DIRECTION BY ONE OR MORE
IMPELLER DIFFUSER
COMBINATION.

AXIAL COMPRESSOR
THE MACHINE IN WHICH
VELOCITY AND PRESSURE ARE
IMPARTED TO THE GAS IN AXIAL
DIRECTION BY ONE OR MORE
MOVING AND STATIONARY ROW
OF BLADES.

MIXED FLOW COMPRESSOR

THE DYNAMIC MACHINES WITH
IMPELLER,WHICH COMBINE SOME
CHARACTERSTICS OF BOTH
CENTRIFUGAL AND AXIAL TYPE.

COMPRESSOR SURGE
CONTROL PARAMETERS

CONSEQUENCES OF SURGING
1. Rapid flow and pressure oscillations
cause process instabilities .
2. Rising temperatures inside the
compressor
3. Tripping of the compressor
4. Mechanical damage

WHAT IS SURGING
Surging is defined as a self oscillation
of the discharge pressure and flow
rate, including a flow reversal. Every
centrifugal or axial compressor has
a characteristic combination of
maximum head and minimum flow.
Beyond this point, surging will occur.
During surging, a flow reversal is often
accompanied by a pressure drop.

RECIPROCATING COMPRESSOR
Reciprocating compressors are the best
known and most widely used
compressors
of the positive displacement type. They
operate on the principal of reducing the
volume (increase in pressure), of specified
quantity of trapped gas in an enclosure
and then compressed gas is pushed out of
the enclosure.

FUNCTIONING OF RECIP
COMPRESSOR
A simple reciprocating compressor
consists of a Crankcase, crank, piston
rod,cylinder, piston and valves. Earlier
reciprocating compressors were
single acting i.e.gas or air was
handled on one side of piston/cylinder.
Now double acting is commonly used
due to inherent advantage and higher
efficiency.

P-V DIAGRAM OF RECIP

COMPRESSOR

SCHEMATIC OF RECIP
COMPRESSOR

MULTISTAGING WITH
INTERCOOLING
Reduced work of compression, as due to
intercooling, compression is closer to isothermal
(gives rise to minimum work of compression). This
results in to savingof power and smaller sizes of
subsequent stages.
Lower discharge temperature and hence selection
of material of construction for cylinder and its
components and results in smaller size of
subsequent stages.
Limits pressure differential. This reduces excess
strains in the frame.
Good volumetric efficiency as compression is done
in more than one stage and hence compression
ratio is controlled.

CYLINDER LUBRICATION
Big reciprocating compressor cylinders
are lubricated to avoid wearand tear of
liner, piston rings, rider rings and
stuffing box. Lubricants are injected in
drops and are lost with the process
gas. It is necessary for the lubricant to
be compatible with the process gas
Generally recip compressors above
100 KW are lubricated type.

Non-Lubricated Type
There are many services in which oil
in any form in the compressed gas, is
not acceptable such as instrument air
compressor and some process gas
compressors.

CYLINDER COOLING
in big compressors where heat generation
is very high. Water jackets are cast as part
of the cylinder. Water is circulated in the
cylinder jacket
from external source.In some case the
cylinder jacket temperature is to be
maintained few degrees higher than the
process gas temperature to avoid
condensation during standstill, this is
possible with water-cooled cylinders by
maintaining the water temperature with use
of heaters.

COMPARISION
RECIP- USED FOR DISCH.PR 828 BAR
HYPERCOMPRESSOR ARE USED FOR LDPE PRODN ARE UP TO 3500
BAR.
CENTRIFUGAL- DISCH.PR.UP TO 1035 BAR.
CAPICITY- RECIP.COMPR.CAPACITY DEPENDS UPON CYL.SIZE,NO.OF
THROW AVAILABLE AND DRIVER SPEED.CENTRIFUGAL COMPR.CAN
DELIVER UP TO 680000 M3/HR BUT MIN.FLOW IS LIMITED BY SURGE
POINT.
MOLECULAR WT- RECIP.COMPR.PERFORMANCE DOES NOR AFFECTED
BY MOL.WT.BUT IN CENTRIFUGAL COMPR,COMPRESSION RATIO IS
HIGHLY DEPENDENT ON MOL.WT.HEAD IS DEVELOPED BY
INCREASING K.E. WHICH LATER ON CONVERTED TO PRESSURE IN
DIFFUSER.AMOUNT OF K.E.IS A FUNCTION OF GAS VELOCITY AND
MOL.WT.
COMPRESSION RATIO-THE MAX.COMPRN.RATIO A RECIP.COMPRESSOR
CAN HANDLE IS LIMITED BYGAS DISCH.TEMP.TYPICAL
COMPRESSION RATIO IS BETWEEN 1.2 TO 4.IN CENTR.COMPR.IT IS
DEPENDENT UPON GAS M.WT,NO.OF STAGES,COMPR.SPEED.

COMPARISION CONTD.
RELIBILITY-RECIP.COMPR.IS PROBALY NOT AS
RELIABLE AS CENTRIFUGAL AS IT HAS MORE MOVING
PART (PISTON RING,PRESSURE PACKING,RIDER RING )
WHICH LEADS TO MORE WEAR AND TEAR THAN ANY
PART OF CENTRIFUGAL COMPRESSOR.IN ADDITION
RECIP.COMPR.HAS VALVES WHICH IS A
MECH.DEVICE(SPRING LOADED CHECK VALVE)
REQUIRE CONSIDERABLE MAINTENANCE.ANOTHER
FACTOR IS CLEANINESS OF PROCESS GAS.WEAR LIFE
OFMOVING PART AND VALVES WILL BE LONGER IF
PROCESS GAS IS FREE FROM LIQUID AND SOLID
DEBRIS.
RELIBILITY OF CENTRIFUGAL COMPRESSOR IS 98-99
PERCENT.
TYPICALLY MAINTENANCE INTERVAL IS HIGH IN
CENTRIGUGAL COMPR.

COMPARISION CONTD.
CAPITAL AND OPERATING COSTRECIP.COMPR HAVE LOWER
CAPITAL BUT HIGH OPERATING
COST THAN CENTRIGUGAL
COMPR.

DOs & DONTs

Dos-Always ensure all start-up permissives like
lube oil pressure /temperature, process gas
suction pressure / temperature, suction /discharge
valve opening etc. are fulfilled before start up.
Ensure all operating parameters are within
operating window as specified in the data sheet.
Ensure functioning of all the protective devices for
safe operation of machine.
Ensure proper Standard Operating Procedures are
followed during operations.
Monitor regularly lube oil pressure and
temperature..

DOs & DONTs

CONTD.
Monitor regularly lube oil level in the sump and top up if
required.
Always ensure proper grade of oil is being topped up as
recommended by OEM.
Ensure proper guards are mounted on the machine that no
rotating parts are directly exposed.
Ensure draining and purging of the machine before taking it
into maintenance.
Ensure machine is positively isolated mechanically and
electrically before taking it into maintenance.
Use proper certified tools & tackles while working on
machine.

DOs & DONTs

CONTD.
DONts

Do not start the machine without understanding the

control, protective and monitoring system.
Do not allow cooling water to cool bearing oil sump
temperature to below recommended oil temperature.
Do not start dismantling the machine without
understanding dismantling procedure.
Do not disable or bypass any protection for the machine
without understanding the consequences and concerning
the experts.
Do not change any alarm or trip value setting without
concerning the experts.
Do not start maintenance work if the machine is not
properly isolated.