Definitions

Cylinder Characteristics

 Bore

D
Cylinder Characteristics
 Stroke

S
Cylinder Characteristics

 Fixed Clearance
Head End
Clearance
Cylinder Characteristics
 Cylinder clearance volume is expressed
as % of swept volume

clearance volume, in 3
CL% = 3
x 100
swept volume, in
Cylinder Characteristics
 Compressor Valves

Suction Suction

Discharge Discharge
Sequence of Events - PT

Pdis

Expansion Compression

Psuc
Sequence of Events - PV

Discharge Pdis

Expansion Compression

Psuc

Intake
Volumetric Efficiency

 Measure how efficient the cylinder is at

displacing volume

 Function of clearance and compression ratio

 Portion of stroke when valves are open - gas

flowing
Volumetric Efficiency
 98 - Rflg  Zsph  k1 
VE, % = .98  CL   Rflg  1
 100  Zd  

Pdis

Volumetric Efficiency
Psuc

Intake
Compressor Sizing
What is a gas?

 It is a fluid
 It is compressible
 It will completely fill the volume in which it is
contained
 We generally deal with gas mixtures
 These mixtures generally behave as equivalent
ideal gas
Getting Started

 Minimum Information Required

– Suction Pressure
– Discharge Pressure
– Volume
Very Helpful Information

 Suction Temperature
 Specific Gravity - Gas Analysis if Possible
 Driver Type
– Engine
– Electric Motor
 Elevation
 Desired Intercooler Temperature
Gas Composition

 The proportion of each gas component will

determine the properties of the equivalent gas
 Compressor calculations require:
– Specific Gravity S.G.
the ratio of the molecular weight of a given
gas to the molecular weight of dry air at
STP (14.7 psia & 60oF
– Ratio of Specific Heats k
– Compressibility z
Gas Composition

 Compressor calculations require:

– Ratio of Specific Heats k
the rate of change that energy is
transferred into the gas
– Compressibility z
a gas’ behavior from ideal volume
relationships
Gas Composition

Gas S.G. K
Air 1.0 1.40
Nat’l 0.65 1.27
Nat’l 1.52 1.13
Special Considerations

 Gas Composition
– Hydrogen Sulfide H 2S
– Carbon Dioxide CO2
– Wet Gas
 Speed Limitations
 Pressure Variations
 Flow Variations
Hydrogen Sulfide - H2S

 Lubrication
– H2S combines with water to form sulfuric
acid
– Sulfuric acid dilutes cylinder lube oils
 Toxicity
– H2S can kill you
 Stress Corrosion Cracking
– Special materials
 Hydrogen Sulfide - H2S

H2S Percent (PPM)** 0-2 Minutes 2-15 Minutes 15-30 Minutes 30 Minutes-1Hour 1-4 Hours 4-8 Hours 8-48 Hours
0.005 (50) ……………… ……………… ………………. Mild conjunctivitis; res- …………… …………… ……………
0.010 (100) piratory tract irritation
0.010 (100) ……………… Coughing; irritation Disturbed respiration;Throat irritation Salivation and mucous Increased Hemorrhage
0.015 (150) of eyes; loss of pain in eyes; discahrge; sharp pain symptoms* and death*
sense of smell sleepiness in eyes; coughing
0.015 (150) ……………… Loss of sense of Throat and eye Throat and eye Difficult breathing; Serious irritating Hemorrhage
0.020 (200) smell irritation irritation blurred vision; light shy effects and death*
0.025 (250) Irritation of eyes; Irritation of eyes Painful secretion of Light shy; nasal catarrh; Hemorrhage and death* …………….. ……………
0.035 (350) loss of sense of tears; weariness pain in eyes; difficult
smell breathing
0.035 (350) ……………… Irritation of eyes; Difficult respiration Increased irritation of Dizziness; weakness; Death* ……………
0.045 (450) loss of sense of coughing; irritation eyes and nasal tract; dull increased irritation;
smell of eyes pain in head; weariness; death
light shy
0.050 (500) Coughing; collapse Respiratory disturbances; Serious eye irritation; Severe pain in eyes and …………………… …………….. ……………
0.060 (600) and unconsciousness irritation of eyes; collapse palpitation of heart; head; dizziness; trembling
few cases of death* of extremities; great
weakness and death*
0.060 (600) Collapse* Collapse* ………………… ……………………… …………………… …………….. ……………
0.070 (700) unconsciousness; unconsciousness;
0.080 (800) death* death*
0.100 (1000)
0.150 (1500)
* Data secured from experiments with dogs which have a susceptibility similar to men. ** PPM-parts per million
 Hydrogen Sulfide - H2S
Sour Gas - Hydrogen Sulfide Gas Mixture
Sour Level Sweet to 100 100 ppm to 2 > 2 mole %
ppm mole %
Bearings and STD STD STD
Bushings
No Yellow Opt( 1) Opt( 1) Opt( 1)
Metals
Piston Rod STD SST(2) SST(2)
Valves STD STD SST(5)
Distance Piece/ STD S2C / L2C S2C / L2C
Crosshead
Guide
Packing STD Purge(6) Purge(6)
Cylinder Bolting STD(4) STD(4) STD(4)
Sour Gas Bolting Opt(7) Opt(7) Opt(7)
Cylinder Body STD(8) STD(8) STD(8)
Material
Flushing Oil No Yes(9) Yes(9)
316 SST Tubing Opt(10) Opt(10) Opt(10)
and Fittings
Separate Lube Opt(12) Opt(12) Opt(12)
for Cylinder and
Packing
Carbon Dioxide - CO2

 Lubrication
– CO2 with water to form carbonic acid
– Carbonic acid dilutes most cylinder lube oils
 Materials
– Carbonic acid causes corrosion of carbon
steel
Carbon Dioxide - CO2
 Wet Gas

 Wet Gas is any gas or gas mixture in which one or

more of the constituents is at or very close to its
saturated vapor pressure.
 The constituent may or may not be water vapor.
 Special attention must be paid to the gas separation
and piping upstream of the compressor.
 The separators must be designed such that no free
liquids are permitted to enter the compressor or
accumulate in the piping or bottles.
 Wet gas will tend to dilute cylinder lube oil
 Example Problem
 Elevation 0 feet ASL
14.7 psia atm. pressure
 Inlet Pressure 15 psig 29.7 psia
 Inlet Temperature 120OF 580OR
 Interstage Temp. 120OF 580OR
 Discharge Pressure 1000 psig 1014.7 psia
 Required Capacity 4.0 MMSCFD
 Specific Gravity 0.65 dry analysis / gas is
water saturated
Gas Analysis

 Gas analysis provided on a dry basis

 Must add water back in to gas analysis
 Calculate the % volume of water vapor the gas
can hold at inlet conditions.
 Look up partial pressures on Water Vapor
Saturation Pressure table.
– @ 120oF partial pressure = 1.6924 psia
– divide the partial pressure by the absolute pressure
1
.69
2 4
0.
0 5
69=
5.
6 9
%
29.
7
 Water Vapor Correction
 Normalize the gas stream to account for the water content
Component Dry Wet
Methane 90.13 85.0
Ethane 4.24 4.0
Propane 2.12 2.0
i-Butane 1.06 1.0
n-Butane 1.06 1.0
Pentane 1.06 1.0
Hexane + .32 .3
Water vapor - 5.7
Total 100 100
What Now?

 Determine number of Stages

 Determine Approximate Horsepower
Determine Number of Stages

 Overall Compression Ratio

CR = Pdis CR =1014.7ps ia3
4.
2
Psuc 29.7p s
ia
 Rule of Thumb
– Usually 2.5 to 4.5 ratios per stage
– Ratio per stage limited by
» Discharge temperature
» Rod load
Number of Stages

CR per stage = n CR
 n = number of stages
Two Stage CR = 34.2  5.84
2

 R=3 34.23
Three Stage C .24
Estimate Horsepower

 Rule of Thumb
– BHP/MMSCFD = 22 x # of stages x CR /stg x F
» F = 1.0 Single Stage
» F = 1.08 Two Stage
» F = 1.15 Three Stage
 Our Example
– 22 x 3 x 3.24 x 1.15 =246 BHP / MMSCFD
– 4.0 MMSCFD x 246 BHP/MMSCFD = 983 bhp
What We Know

 Three Stage Application

 Requires Approximately 1000 bhp

 Select a Driver
– Engine Size
– Speed
 Select a Frame and Cylinders
Selecting an Engine

 Consider
– parasitic loads - engine driven cooler / aux generators
– elevation derate
– fuel derate
 Assume 1100 BHP engine @ 1200 rpm
Select a Compressor Frame

 Consider
– piston speed
– rod load ratings

 Assume 4.5 inch stroke @ 1200 rpm

– 900 FPM average piston speed
– 2.0 inch diameter piston rod
 Select Compressor Cylinders

1 st Stage
– Calculate Inlet Flow ACFM

4,000,000 SCFD 14.7 psia 580 R Zs

ACFM = x x x = 1533 acfm
1440 min / day 29.7 psia 520 R Zstd

 Cylinder Displacement
– Use 0.70 as a divisor of ACFM to estimate cylinder
displacement
1533
2190cfm
0.7
Calculate 1st Stage Cylinder
Bores (Assume two first stage cylinders)
Disp = Sweptvol * rpm

SweptVol = A HE
+ ACE  * stk

A HE
= A CE
+ A ROD

SweptVol  stk *  A HE  A HE  A ROD 

Disp  stroke * rpm *  2 * A HE  A ROD 

Disp A
2 * rpm * stk
 ROD
2
 A HE

1
 4  Disp A  2
 *  ROD
  Diam
 2 * rpm * stk 2 
  
1
 4  1095 *1728   2

  *  2 *1200 * 4.5  2  
  
  Diam
Diam  15 inches
Calculate 2nd Stage Cylinder
Bore
 First estimate interstage pressure
Pdis1 = Psuc1 x CRstage
Pdis1 = 29.7 psia x 3.24 = 96 psia
 Calculate 2nd stage cylinder bore

14.7 psia 580 R Zs

ACFM = 4,000,000 SCFD x x x = 473 acfm
1440 min / day 96 psia 520 R Zstd
473 acfm
cfm =
0.70
D = 13.26 in use 13.0 in
Evaluating Performance

Check:
 Capacity
 Rod Load
 Discharge Temperatures
 Working Pressures
 Variables that Affect Capacity

 Affects Inlet Volume - Volumetric Efficiency

– clearance volume , %
– Compression Ratio
– Gas “K” value

1
  Zsuc  
 
98 - CR stage
VE = 0.98  CL 
x CR stage K - 1
 100  Zdis  
acfm = displacement x volumetric efficiency
 Discharge Temperature

 Adiabatic Discharge Temperature:

K 1
 PD  K
TD  TS  
ADIA  PS 
Multi-Stage Notes

 For any multistage compressor, the same mass

flow will go thru all stages provided there are
no sidestreams in or out. - i.e. water or
hydrocarbon knockout
 On a multistage compressor, the interstage
pressures adjust to make all cylinders pass the
same amount of gas.