COMPRESSOR BASICSCOMPRESSOR BASICS

TYPES OF COMPRESSORSTYPES OF COMPRESSORS

POSITIVE DISPLACEMENT POSITIVE DISPLACEMENT COMPRESSORCOMPRESSOR

CENTRIFUGAL COMPRESSORCENTRIFUGAL COMPRESSOR

POSITIVE DISPLACEMENT POSITIVE DISPLACEMENT COMPRESSORCOMPRESSOR

PD COMPRSSOR WORK BY TRAPPING PD COMPRSSOR WORK BY TRAPPING A CERTAIN AMOUNT OF GAS AND A CERTAIN AMOUNT OF GAS AND FORCING IT INTO A SMALLER VOLUMEFORCING IT INTO A SMALLER VOLUME

A COMMON TYPE OF PD COMPR. IS A COMMON TYPE OF PD COMPR. IS RECIPROCATING COMPRESSOR. RECIPROCATING COMPRESSOR.

TWO OF THE MAIN PARTS OF TWO OF THE MAIN PARTS OF RECIPROCATING COMP. ARE RECIPROCATING COMP. ARE CYLINDER AND A PISTON CYLINDER AND A PISTON

GAS ENTERS THE CYLINDER AND IS GAS ENTERS THE CYLINDER AND IS TRAPPED INSIDE THE CYLINDER. THE TRAPPED INSIDE THE CYLINDER. THE GAS IS THEN FORCED INTO A GAS IS THEN FORCED INTO A SMALLER SPACE BY THE ACTION OF SMALLER SPACE BY THE ACTION OF THE PISTON.THE PISTON.

FORCING THE GAS IN SMALLER FORCING THE GAS IN SMALLER SPACE INCREASES THE PRESSURE, SPACE INCREASES THE PRESSURE, THE COMPRESSED GAS IS THEN THE COMPRESSED GAS IS THEN DISCHARGED.DISCHARGED.

CENTRIFUGAL COMPRESSORCENTRIFUGAL COMPRESSOR

IT USES A DEVICE CALLED IMPELLER TO IT USES A DEVICE CALLED IMPELLER TO SPIN THE GAS AROUNDSPIN THE GAS AROUND

THE ACTION OF THE IMPELLER THE ACTION OF THE IMPELLER ACCELERATE OR INCREASES THE SPEED ACCELERATE OR INCREASES THE SPEED OF THE GAS FLOW. IT GIVES THE GAS OF THE GAS FLOW. IT GIVES THE GAS ENERGY.ENERGY.

AS THE GAS FLOWS OUT IT SPEED OUT AS THE GAS FLOWS OUT IT SPEED OUT AND SLOW DOWN AND ITS ENERGY IS AND SLOW DOWN AND ITS ENERGY IS CONVERTED INTO PRESSURECONVERTED INTO PRESSURE

SHARING CHARACTERSTICSSHARING CHARACTERSTICS

COMPRSSORS ARE RATED FOR COMPRSSORS ARE RATED FOR DISCHARGE PRESSUR AND FLOW DISCHARGE PRESSUR AND FLOW RATERATE

ALL COMPRESSORS REQUIRE SOME ALL COMPRESSORS REQUIRE SOME FORM OF DRIVE MECHANISMFORM OF DRIVE MECHANISM

ELECTRIC MOTORS ARE COMMONLY ELECTRIC MOTORS ARE COMMONLY USED DRIVES.USED DRIVES.

COMPRESSOR HAZARDCOMPRESSOR HAZARD

MOVING PARTS MOVING PARTS HOT SURFACEHOT SURFACENOICYNOICYLEAKS FROM THE GAS SYSTEMLEAKS FROM THE GAS SYSTEMFLAMMABLE EXPLOSIVE GASES FLAMMABLE EXPLOSIVE GASES

(SPARK PRODUCING EQUIPMENT (SPARK PRODUCING EQUIPMENT SHOULD NEVER BE USED)SHOULD NEVER BE USED)

ACCESSORIES ACCESSORIES

LUBRICATION LUBRICATION

COOLINGCOOLING

FILTERINGFILTERING

LUBRICATION SYSTEMLUBRICATION SYSTEM

MAIN FUNCTION IS TO REDUCE MAIN FUNCTION IS TO REDUCE FRICTION BETWEEN THE MOVING FRICTION BETWEEN THE MOVING PARTSPARTS

LUBRICATION HELPS COOLING THE LUBRICATION HELPS COOLING THE COMPRESSOR MOVING PARTS AND COMPRESSOR MOVING PARTS AND HELP PREVENT THE LEAKING GAS HELP PREVENT THE LEAKING GAS OUT OF COMPRESSOR.OUT OF COMPRESSOR.

DESCRIPTIONDESCRIPTION

OIL FROM THE COMPRESSOR FLOWS INTO OIL FROM THE COMPRESSOR FLOWS INTO THE OIL PUMP.THE OIL IS THEN PUMPED THE OIL PUMP.THE OIL IS THEN PUMPED THROUGH FILTER WHICH REMOVES ANY THROUGH FILTER WHICH REMOVES ANY SOLID PARTICLE FROM THE OIL.SOLID PARTICLE FROM THE OIL.

OIL FLOWS THROUGH THE HEAT OIL FLOWS THROUGH THE HEAT EXCHANGER WHERE IT IS COOLEDEXCHANGER WHERE IT IS COOLED

FROM HEAT EXCHANGER MOST OF THE OIL FROM HEAT EXCHANGER MOST OF THE OIL FLOWS DIRECTLY TO COMPRESSOR FLOWS DIRECTLY TO COMPRESSOR LUBRICATION.LUBRICATION.

REST OF THE OIL GOES TO OILER.REST OF THE OIL GOES TO OILER.OILER SUPPLIES A SMALL AMOUNT OILER SUPPLIES A SMALL AMOUNT

OF OIL TO THE COMPRESSOR OF OIL TO THE COMPRESSOR CYLINDERCYLINDER

THE OIL LUBRICTES THE PISTON THE OIL LUBRICTES THE PISTON RINGS AND HELPS SEAL THE SPACE RINGS AND HELPS SEAL THE SPACE BETWEEN THE CYLINDER WALL AND BETWEEN THE CYLINDER WALL AND THE RING.THE RING.

COOLING COOLING WHEN A GAS IS COMPRESSED HEAT IS WHEN A GAS IS COMPRESSED HEAT IS

PRODUCED THIS HEAT CAN CAUSE TWO PRODUCED THIS HEAT CAN CAUSE TWO PROBLEM PROBLEM 1. EXCESS HEAT CAN BREAK DOWN OIL 1. EXCESS HEAT CAN BREAK DOWN OIL

CAUSING IT TO BE LOOSE ITS CAUSING IT TO BE LOOSE ITS LUBRICATING CHARECTORSTICLUBRICATING CHARECTORSTIC

2. GASED EXPAND WHEN THEY ARE 2. GASED EXPAND WHEN THEY ARE HEATED SINCE COMPRESSOR IS HEATED SINCE COMPRESSOR IS DESINGED TO COMPRESS GASES THE DESINGED TO COMPRESS GASES THE EFFECT CREATE ADDITIONAL FORCE EFFECT CREATE ADDITIONAL FORCE WHICH COMPRESSOR MUST OVERCOME.WHICH COMPRESSOR MUST OVERCOME.

HEAT REMOVALHEAT REMOVAL

AIR COOLING AND WATER COOLING AIR COOLING AND WATER COOLING ARE TWO TECHNIQUESARE TWO TECHNIQUES

1. AN AIR COOLED COMPRESSOR 1. AN AIR COOLED COMPRESSOR

EASILY IDENTIFIED BY MEAL FINS EASILY IDENTIFIED BY MEAL FINS

ON ITS CASING ON ITS CASING

THE FINS PROVIDE INCREASED THE FINS PROVIDE INCREASED

SURFACE AREA.SURFACE AREA.

2. ANOTHER WAY TO REMOVE THE 2. ANOTHER WAY TO REMOVE THE

EXCESS HEAT IS TO COOL THE GAS EXCESS HEAT IS TO COOL THE GAS

AFTER THE COMPRESSION IS AFTER THE COMPRESSION IS

COMPLETE, THE DEVICE THAT COMPLETE, THE DEVICE THAT

DOES THIS IS AN AFTERCOOLER OR DOES THIS IS AN AFTERCOOLER OR

INTERCOOLERINTERCOOLERDEPENDING UPON ITS LOCATION DEPENDING UPON ITS LOCATION

THESE EXCHANGERS ARE THESE EXCHANGERS ARE CLASSIFIED AS CLASSIFIED AS INTERCOOLERINTERCOOLER OF OF AFTER COOLERAFTER COOLER..

INSTRUMENTATION AND INSTRUMENTATION AND CONTROLCONTROL

THE PROPER OPERATION OF COMP. THE PROPER OPERATION OF COMP. DEPENDS UPON INSTRUMENTAITON DEPENDS UPON INSTRUMENTAITON AND CONTROL DEVICESAND CONTROL DEVICES

THESE DEVICES ALLOWS THE THESE DEVICES ALLOWS THE COMPRESSOR TO BE STARTED AND COMPRESSOR TO BE STARTED AND STOPPED.STOPPED.

THEY PROVIDE INFORMATION ABOUT THEY PROVIDE INFORMATION ABOUT THE COMPRESSOR OPERATING THE COMPRESSOR OPERATING CONDITIONSCONDITIONS

THEY MAINTAIN THE VALUES OF THEY MAINTAIN THE VALUES OF PROCESS VARIABLESPROCESS VARIABLES

THEY KEEP THE COMPRESSOR THEY KEEP THE COMPRESSOR OPERATION STABLEOPERATION STABLE

THEY CAN SHUT DOWN THE THEY CAN SHUT DOWN THE COMPRESSOR IF UNSAFE COMPRESSOR IF UNSAFE CONDTITON OCCUREDCONDTITON OCCURED

CONTROL PANEL MAY HAVE CONTROL PANEL MAY HAVE CONTROL TO REGULATE THE SPEED CONTROL TO REGULATE THE SPEED

CONTROL PANEL ME ALSO CONTAIN CONTROL PANEL ME ALSO CONTAIN ALARMS THAT LET THE PERSONNEL ALARMS THAT LET THE PERSONNEL KNOW WHEN ABNORMAL AND KNOW WHEN ABNORMAL AND POTENTIAL DAMAGING CONDITION POTENTIAL DAMAGING CONDITION EXISTSEXISTS

PRESSURE CONTROLLER CONTROLS PRESSURE CONTROLLER CONTROLS THE DISCHARGE PRESSUR AND IF IT THE DISCHARGE PRESSUR AND IF IT DEVIATES CONTROLLER DEVIATES CONTROLLER MANUPULATE THE INLET FLOW MANUPULATE THE INLET FLOW

SURGE CONTROLSURGE CONTROL

FOR A GIVEN DISCHARGE PRESSURE FOR A GIVEN DISCHARGE PRESSURE A COMPRESSOR HAS A CERTAIN A COMPRESSOR HAS A CERTAIN MINIMUM FLOW RATE. BELOW THIS MINIMUM FLOW RATE. BELOW THIS FLOW RATE THE COMPRESSOR FLOW RATE THE COMPRESSOR BECOME UNSTABLE. A DECREASE IN BECOME UNSTABLE. A DECREASE IN FLOW BELOW THE MINIMUM FLOW FLOW BELOW THE MINIMUM FLOW CAN CAUSE A SERIES OF CAN CAUSE A SERIES OF MOMENTARY REVERSAL OF FLOW MOMENTARY REVERSAL OF FLOW THROUGH THE COMPRESSOR. THIS THROUGH THE COMPRESSOR. THIS SITUATIION IS CALLED SITUATIION IS CALLED SURGESURGE

SURGING RESULTS IN VIOLENT SURGING RESULTS IN VIOLENT FLUCTUATIONS IN DISCHARGE FLUCTUATIONS IN DISCHARGE PRESSURE.PRESSURE.

WHEN AN ELECTRIC MOTOR IS USED WHEN AN ELECTRIC MOTOR IS USED AS DRIVER SURGING CAN CAUSE AS DRIVER SURGING CAN CAUSE EXTREME VARIANTION IN MOTOR EXTREME VARIANTION IN MOTOR CURRENT.CURRENT.

SYMPTOMS OF SURGING ARE LOW SYMPTOMS OF SURGING ARE LOW GAS FLOW, EXCESSIVE VIBRATION GAS FLOW, EXCESSIVE VIBRATION AND BANGING SOUND INSIDE AND BANGING SOUND INSIDE COMPRESSORCOMPRESSOR

TO PREVENT THE SURGING THE TO PREVENT THE SURGING THE FLOW RATE OF THE GAS THRU THE FLOW RATE OF THE GAS THRU THE COMPRESSOR MUST BE KEPT ABOVE COMPRESSOR MUST BE KEPT ABOVE THE MINIMUM STABLE FLOW RATE OR THE MINIMUM STABLE FLOW RATE OR SURGE POINTSURGE POINT

WHEN THE DEMAND IS LOW FLOW WHEN THE DEMAND IS LOW FLOW RATE IS MAINTAINED BY RATE IS MAINTAINED BY RECIRCULATING THE PORTION FROM RECIRCULATING THE PORTION FROM DISCHARGE TO BACK TO DISCHARGE TO BACK TO COMPRESSOR.COMPRESSOR.

START UPSTART UP

PREPARING THE COMPRESSOR FOR PREPARING THE COMPRESSOR FOR STARTUPSTARTUP

WARMING UP THE COMPRESSORWARMING UP THE COMPRESSORSTARTING THE GAS FLOW THRU STARTING THE GAS FLOW THRU

COMPRESSORCOMPRESSOR

COMPRESSORS GAS SUPPLY IS COMPRESSORS GAS SUPPLY IS AVAILABLE, CONTROLS ARE SET IN AVAILABLE, CONTROLS ARE SET IN POSITIONS.POSITIONS.

VALVE LINE UP MEANS ALL THE VALVE LINE UP MEANS ALL THE VALVE ARE PROPERLY SET.VALVE ARE PROPERLY SET.

START THE COMPRESSOR START THE COMPRESSOR AUXILARIES AND MAKE SURE THEY AUXILARIES AND MAKE SURE THEY ARE OPERATING PROPERLY.ARE OPERATING PROPERLY.

OPERATOR MUST CHECK THE OPERATOR MUST CHECK THE COMPRESSOR AND MAKE SURE THAT COMPRESSOR AND MAKE SURE THAT NO ABNORMAL CONDITION EXISTS.NO ABNORMAL CONDITION EXISTS.

IF THE COMPRESSOR HANDLES THE IF THE COMPRESSOR HANDLES THE FLAMMABLE GAS IT MUST BE PURGE FLAMMABLE GAS IT MUST BE PURGE WITH AN INERT GAS LIKE NITORGEN.WITH AN INERT GAS LIKE NITORGEN.

ONCE PURGED IT CAN BE STARTED ONCE PURGED IT CAN BE STARTED AND KEPT IN WARMING UP.AND KEPT IN WARMING UP.

ONCE THE COMPRESSOR AND ITS ONCE THE COMPRESSOR AND ITS PARTS RUNS FOR A WHILE AT A LOW PARTS RUNS FOR A WHILE AT A LOW SPEED THE COMPRSSOR CAN BE SPEED THE COMPRSSOR CAN BE BROUGHT UP TO NORMAL SPEED.BROUGHT UP TO NORMAL SPEED.

THIS INVOLVES THE INCREASE OF THIS INVOLVES THE INCREASE OF SPEED AT CERTAIN RATE CALLED SPEED AT CERTAIN RATE CALLED RAMP RATERAMP RATE

CRITICAL SPEED – FOR CETRUFUGAL CRITICAL SPEED – FOR CETRUFUGAL COMPRSSOR CERTAIN ROTATIONAL COMPRSSOR CERTAIN ROTATIONAL SPEED CAUSE SEVERE VIBRATION, IT SPEED CAUSE SEVERE VIBRATION, IT IS CALLED CRITICAL SPEED.IS CALLED CRITICAL SPEED.

IT IS DUE TO PHYSICAL IT IS DUE TO PHYSICAL CHARECTORSTIC OF MOVING PARTS CHARECTORSTIC OF MOVING PARTS OF COMPRESSOR.OF COMPRESSOR.

WHEN A CRITICAL SPEED IS REACHED WHEN A CRITICAL SPEED IS REACHED THE RAMP SPEED IS USUALLY THE RAMP SPEED IS USUALLY INCREADED TO PASS THROUGH THE INCREADED TO PASS THROUGH THE CRITICAL SPEED.CRITICAL SPEED.

OPERATIONOPERATION

ONCE STARTED COMPRESSOR ONCE STARTED COMPRESSOR SHOULD BE CHECKED ROUTINELY.SHOULD BE CHECKED ROUTINELY.

WHILE CHECKING A COMPRSSOR WHILE CHECKING A COMPRSSOR OPERATOR MUST KEEP IN MIND THAT OPERATOR MUST KEEP IN MIND THAT IT OPERATES AT VERY HIGH SPEED.IT OPERATES AT VERY HIGH SPEED.

AN IMPORTANT PART OF CHECKING A AN IMPORTANT PART OF CHECKING A COMPRSSOR IS TO LISTEN TO THE COMPRSSOR IS TO LISTEN TO THE ABNORMAL SOUND.ABNORMAL SOUND.

IT IS IMPORTANT TO CHECK THE IT IS IMPORTANT TO CHECK THE COMPRESSOR BEARING FOR COMPRESSOR BEARING FOR EXCESSIVE VIBRATION AND EXCESSIVE VIBRATION AND OVERHEATING IT INDICATE OVERHEATING IT INDICATE PROBABLE BEARING FAILURE.PROBABLE BEARING FAILURE.

COMPRESSOR AUXILIARY CHECK IS COMPRESSOR AUXILIARY CHECK IS IMPORTANT DURING OPERATION OF IMPORTANT DURING OPERATION OF COMP. LIKE OIL LEVEL IS IN NORMAL COMP. LIKE OIL LEVEL IS IN NORMAL RANGE,OIL IS CLEAR AND NOT MILKY.RANGE,OIL IS CLEAR AND NOT MILKY.

OIL PRESSURE IS IMPORTANT OIL PRESSURE IS IMPORTANT PARAMETER TO CHECK, INIDCATE PARAMETER TO CHECK, INIDCATE MALFUNCTION OF OIL PUMP OR OIL MALFUNCTION OF OIL PUMP OR OIL LEAK IN SYSTEM.LEAK IN SYSTEM.

OIL PARAMETER IS CRITICAL OIL PARAMETER IS CRITICAL PARAMETER, HIGHER THAN NORMAL PARAMETER, HIGHER THAN NORMAL OIL PRESSURE INDICATES THE OIL PRESSURE INDICATES THE CLOGGING OF SOME PART IN OIL CLOGGING OF SOME PART IN OIL LUBRICATION SYSTEM. LUBRICATION SYSTEM.