Theory of Compressors

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A Sunrise Project for a Sunshine FuturePARADEEP REFINERY PROJECTTHEORY OF COMPRESSORS

JITENDRA JAISWALSPNE(CG))1What is a Compressor ?

A Sunrise Project for a Sunshine FuturePARADEEP REFINERY PROJECTWhat is a Compressor? A mechanical device that increases the pressure of a gas by reducing its volume.

Similar to a pump Increases the pressure on a fluid and transports it through a pipe.

This is a critical rotary equipment, often called heart of an unit in an oil refineries.

Compressors harness the energy stored inside the gas/fluid when it was compressed.

converts power (electric, steam power or diesel engine or a gasoline engine) into kinetic energy .

2BASICS

A Sunrise Project for a Sunshine FuturePARADEEP REFINERY PROJECTWhat is key difference between a Fluid and a Gas? Compressibility Gases have high compressibility, while liquids do not. So a gas can be compressed easily.

What happens to the gas volume, as it is compressed? Decreases

What happens to the Temperature of the Gas as it is compressed? Increases

3CLASSIFICATION

A Sunrise Project for a Sunshine FuturePARADEEP REFINERY PROJECTTwo Categories of Compressors Positive Displacement Dynamic

4Positive Displacement Compressors

A Sunrise Project for a Sunshine FuturePARADEEP REFINERY PROJECTWhat is a Positive Displacement Compressor?A compressor that confines successive volumes of gas within a closed space in which the pressure of the gas is increased as the volume of the closed space is decreased.

Intermittent Flow

Two types: Reciprocating and Rotary

5Dynamic Compressors

A Sunrise Project for a Sunshine FuturePARADEEP REFINERY PROJECTWhat is a Dynamic Compressor? A compressor using a rotating mechanism to add velocity and pressure to gas.

Continuous Flow

Two types: Centrifugal and Axial

6PDRP Reciprocating/Rotary Compressors

A Sunrise Project for a Sunshine FuturePARADEEP REFINERY PROJECTUnits CompressorsTypeP&UPA & IA Compressors (02 nos.)Reciprocating HCDSH2 Distribution Compressors (03 nos.)Reciprocating AVUOff Gas Compressors(02 nos.)Reciprocating SR LPG TUAir Compressors (02 nos.)Reciprocating Units CompressorsTypeFGDLiquid ring Compressors (03 Nos.)Rotary7 Reciprocating Compressors of PDRP ( P&U/HCDS Units)

A Sunrise Project for a Sunshine FuturePARADEEP REFINERY PROJECT

PA&IA Comp (Reciprocating)

H2 Comp. (Reciprocating)

8 Reciprocating Compressors of PDRP ( AVU/ SR LPG Units)

A Sunrise Project for a Sunshine FuturePARADEEP REFINERY PROJECT Offgas Comp (Reciprocating)

Air Comp. (Reciprocating)

9 Rotary Compressors of PDRP (FGD Unit)

A Sunrise Project for a Sunshine FuturePARADEEP REFINERY PROJECT Liquid ring (Rotary)

10PDRP Centrifugal Compressors

A Sunrise Project for a Sunshine FuturePARADEEP REFINERY PROJECTUnits CompressorsTypeP&UPA & IA Compressors (04 nos.)Multistage CentrifugalAlkylationRefrigerant Compressor (01 no.)Multistage CentrifugalDCUWet Gas Compressor (01 no.)Multistage CentrifugalFCCWet Gas Compressor (01 no.)Multistage CentrifugalPRUVapor Recycle Compressor (01 no.)Multistage CentrifugalPRURefrigeration Compressor (01 no.)Multistage CentrifugalPRURefrigeration Gas Recycle (01 no.)Multistage CentrifugalSRUProcess Gas Compressors (03 Nos.)Multistage CentrifugalNHT/CCRCentrifugal Compressors (04 Nos.)Multistage CentrifugalLPG TUCentrifugal Compressors (01 Nos.)Multistage CentrifugalDHDTRecycle Gas Compressor (01 no.)Multistage CentrifugalVGORecycle Gas Compressor (01 no.)Multistage Centrifugal11Centrifugal Compressors of PDRP (DHDT/ P&U Units)


RGC (Centrifugal)

AI & PA Comp. (Centrifugal)

12 Cenrifugal Compressors of PDRP (FCC Unit)

A Sunrise Project for a Sunshine FuturePARADEEP REFINERY PROJECTMAB (Centrifugal)

WGC (Centrifugal)

13 Cenrtifugal Compressors of PDRP (NHT/CCRU Units)


NGC (Centrifugal)

NGC (Centrifugal)

RGC (Centrifugal)

14 Compressors of PDRP (VGO, DCU Units)

A Sunrise Project for a Sunshine FuturePARADEEP REFINERY PROJECTRGC (Centrifugal)

WGC (Centrifugal)15Reciprocating Compressors


16 Basics of Reciprocating Compressors

A Sunrise Project for a Sunshine FuturePARADEEP REFINERY PROJECTMost critical and expensive systems at a production facilityDeserves special attention.Uses pistons driven by a crankshaft to deliver gases at high pressure.The intake gas enters the suction manifold, flows into the compression cylinder where it gets compressed by a piston driven in a reciprocating motion via a crankshaft and discharged. Used in oil, gas, chemical & petrochemical industries. One specialty application is the blowing of plastic bottles made of PET.

17 Reciprocating Compressors

A Sunrise Project for a Sunshine FuturePARADEEP REFINERY PROJECT How does it work? Piston movement in a cylinder connected to a rod and crankshaft

Downward piston motion, low pressure gas enters the chamber

Upward piston motion, gas is compressed and exits the chamber

18 Reciprocating Compressors Types

A Sunrise Project for a Sunshine FuturePARADEEP REFINERY PROJECTThe reciprocating compressor consists of one or more cylinders, each with a piston that moves back and forth, displacing a positive volume with each stroke. They are single-acting or double-acting

They can be single stage or multi-stage

Single acting

Double acting19Multi stage Reciprocating Comp.


Saving in energy Low capital cost Option of drawing gases at different pressure Inter coolers are provided between stages. So inlet temp to each stage is same. 20 Gas compression cycle


21 Reciprocating Compressor Application

A Sunrise Project for a Sunshine FuturePARADEEP REFINERY PROJECT For high pressure delivery of gassesOil & Gas industriesNatural gas transmission lines Chemical plants/Fertilizer plantsRefrigeration plants Air compressing units

22 Rotary Compressor

A Sunrise Project for a Sunshine FuturePARADEEP REFINERY PROJECT How do they it work?

When a rotating mechanism spins past the inlet valve, it creates a vacuum.

The fluid flows out of the valve behind it, filling the vacuum.

As it approaches the outlet valve, the chamber shrinks, creating more pressure on the fluid.

The fluid has nowhere to go but out of the outlet valve, so it shoots out of it.

Then the rotating mechanism continues on to draw more fluid at the inlet valve.23 Rotary Compressor Types

A Sunrise Project for a Sunshine FuturePARADEEP REFINERY PROJECTCommon Types of Rotary Compressors Screw Vane Scroll24 Screw Type Rotary Compressor


Screw Type Rotary Compressor Two meshing helix screws Rotors Compact and smooth running Can be Oil Free and Oil FloodedOil Free No assistance from oil to cool and assist in sealing .Oil Flooded Oil injected to aid in sealing and provide cooling. Application: Food industry Beverage industry Brewing industry Automobile industry Aerospace25 Vane Type Rotary Compressor

A Sunrise Project for a Sunshine FuturePARADEEP REFINERY PROJECTVane Type Rotary CompressorsVane housing on an off centered shaft Vanes slide in and out always making contact with the compressor wallsGas enters in the largest openingExits in the smallest openingGood for low pressure applications EfficientHeat controlled by oil injectionApplication: MilitaryAutomobilesElectronics

26 Scroll Type Rotary Compressor

A Sunrise Project for a Sunshine FuturePARADEEP REFINERY PROJECTHow it works2 Spirals (1 stationary, 1 orbits without rotating)1st orbit entraps inlet gasSubsequent orbits compresses gas and exits out the centerGenerally 2-3 orbits for a full cycleAdvantagesCompactSteady flowLow energy useQuietSmooth operation

27 Scroll Type Rotary Compressor Application

A Sunrise Project for a Sunshine FuturePARADEEP REFINERY PROJECTApplicationRailwaysIndustrial coolingHeating, ventilation, and air conditioning (HVAC) systems28 Dynamic Compressors

A Sunrise Project for a Sunshine FuturePARADEEP REFINERY PROJECTWhat is a Dynamic Compressor?A compressor using a rotating mechanism to add velocity and pressure to gas.Continuous Flow

What are the Two Types of Dynamic Compressors?CentrifugalAxial 29 Centrifugal Compressors


30 Centrifugal Compressors

A Sunrise Project for a Sunshine FuturePARADEEP REFINERY PROJECT(1) casing (2) inlet cover(3) back plate (4) impeller (5) shaft (6) seal (7) journal bearings (8) thrust bearing (9) coupling hub(10) balance plane(11) variable inlet guide vanes.

31 Centrifugal Compressors

A Sunrise Project for a Sunshine FuturePARADEEP REFINERY PROJECTRotating disk (impeller) forces gas to the rim of the impeller, increasing velocityThe diffuser converts the velocity energy to pressure energy. Primarily used for continuous, stationary service in industries such as refineries, chemical plants and snow making operationsSingle Stage and Multi-Stage Compressors

32 Flow rate comparisons

A Sunrise Project for a Sunshine FuturePARADEEP REFINERY PROJECTPositive-displacement machines do not have a flow rate limitationThere is no minimum throughput requirement for these compressors.In centrifugal compressors, they cannot be operated below a certain minimum throughput volume33 Axial Compressors

A Sunrise Project for a Sunshine FuturePARADEEP REFINERY PROJECTAxial CompressorsGas flows parallel to the axis of rotationHas rotating and stationary componentsHigh Volume & High EfficiencyHigh CostApplication :Gas Turbines, Jet engines, Power stations

34Details of Reciprocating Compressors


35Basic components of Reciprocating Compressors

A Sunrise Project for a Sunshine FuturePARADEEP REFINERY PROJECTPiston Piston ringCylinder Suction loader valve Discharge valveCrank shaftConnecting rodCross head Piston rod

36Basic components of Reciprocating Compressors


37Cylinder Details


38 Details


39Suction Valve Details


40Piston Rings & Rider Ring Details


41Piston Details


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A Sunrise Project for a Sunshine FuturePARADEEP REFINERY PROJECTThank You43

Theory of Compressors

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