Engineering Encyclopedia: Classifying Compressors by Type

Engineering Encyclopedia
Saudi Aramco DeskTop Standards
Classifying Compressors By Type
Note: The source of the technical material in this volume is the Professional
Engineering Development Program (PEDP) of Engineering Services.
Warning: The material contained in this document was developed for Saudi
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of the Vice President, Engineering Services, Saudi Aramco.
Chapter : Rotating Equipment For additional information on this subject, contact

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Engineering Encyclopedia Rotating Equipment
Content Page
INTRODUCTION................................................................................................................ 1
CLASSIFYING DYNAMIC COMPRESSORS BY TYPES................................................. 3

Centrifugal ................................................................................................................ 4
Barrel ............................................................................................................ 6
Axially Split .................................................................................................. 8
Integrally Geared..........................................................................................11
Axial ........................................................................................................................15
Multi-Stage ..................................................................................................15
Single-Stage (Fans) ......................................................................................17
CLASSIFYING POSITIVE-DISPLACEMENT COMPRESSORS BY TYPE.....................19
Reciprocating...........................................................................................................20
Single-Acting ...............................................................................................20
Double-Acting..............................................................................................22
Dry/Lubricated .............................................................................................23
Rotary ......................................................................................................................24
Screw ...........................................................................................................24
Lobe .............................................................................................................28
Liquid-Ring..................................................................................................28
WORK AID 1: ILLUSTRATIONS USED TO CLASSIFY DYNAMIC
COMPRESSORS BY TYPE .....................................................................31
WORK AID 2: ILLUSTRATIONS USED TO CLASSIFY POSITIVE-

DISPLACEMENT COMPRESSORS BY TYPE .......................................37
GLOSSARY ..................................................................................................................42

Table of Figures Page
Figure 1. Compressor Application Range Chart........................................................ 2

Figure 2. Advantages and Disadvantages of Centrifugal and Axial Compressors...... 4
Figure 3. Single-Stage, Single-Flow Centrifugal Compressor................................... 5
Figure 4. Typical, Multi-Stage, Barrel Compressor .................................................. 7
Figure 5. Typical, Multi-Stage, Axially Split, Centrifugal Compressor....................10
Figure 6. Typical, Integrally Geared Centrifugal Compressor..................................13
Figure 7. Single-Stage Blower.................................................................................14
Figure 8. Multi-Stage Axial Compressor .................................................................16
Figure 9. Single-Stage Axial Compressor................................................................18
Figure 10. Advantages and Disadvantages of Reciprocating and Rotary
Positive-Displacement Compressors .......................................................19
Figure 11. Single-Acting Reciprocating Compressor ...............................................22
Figure 12. Double-Acting, Reciprocating Compressor.............................................23
Figure 13. Lubricated Screw Compressor................................................................26
Figure 14. Dry Screw Compressor...........................................................................27
Figure 15. Two-Lobe Compressor...........................................................................28
Figure 16. Liquid-Ring Compressor ........................................................................29
Figure 17. Sliding-Vane Compressor.......................................................................30
Figure 26. Integrally Geared, Centrifugal Compressor.............................................31
Figure 27. Multi-Stage, Axially Split, Centrifugal Compressor................................32
Figure 28. Single-Stage Blower...............................................................................33
Figure 29. Multi-Stage, Barrel, Centrifugal Compressor..........................................34
Figure 30. Single-Stage, Axial Compressor.............................................................35
Figure 31. Multi-Stage, Axial Compressor ..............................................................36
Figure 32. Liquid-Ring, Rotary Compressor............................................................37
Figure 33. Dry Screw Compressor...........................................................................38
Figure 34. Lubricated Screw Compressor................................................................39
Figure 35. Sliding-Vane, Rotary Compressor ..........................................................40
Figure 36. Two-Lobe, Rotary Compressor ..............................................................41
Figure 37. Double-Acting, Reciprocating Compressor.............................................41

INTRODUCTION
A compressor is defined as a device that causes a reduction in volume and an increase in the
pressure of a gas. A compressor moves a gas through a process system by increasing the energy
and the density of the gas. Because the action of a compressor is similar to a pump, a
compressor can be considered a gas pump. One of the most important effects of an increase in
gas energy is pressure. The amount of pressure increase above the pressure of the incoming gas
depends on the design and size of the compressor that is used. Because gas is compressible, its
volume will decrease as its energy is increased. As the gas is compressed, the absolute pressure
and volume vary inversely. If the temperature of a gas remains constant, which is an ideal
situation, and if the volume of that gas is reduced by one half, the pressure will double.
The use of compressors had expanded widely in industrial applications. Figure 1 is an

application range chart for the various specific types of compressors, which shows discharge
pressure (psig) versus inlet flow (ACFM). Refer to Figure 1 for the discussions of the various
compressors. With many manufacturers developing new and more efficient compressors, the
Mechanical Engineer must understand the types, the usage, and the limitations that are placed on
the different varieties of compressors. Because Saudi Aramco uses both dynamic and positive-
displacement compressors, this module focuses on the different compressor designs that are
available. This module describes the following topics that are pertinent to classifying
compressors by type:
• Classifying Dynamic Compressors by Types

• Classifying Positive-Displacement Compressors by Types
Saudi Aramco DeskTop Standards 1

Figure 1. Compressor Application Range Chart

CLASSIFYING DYNAMIC COMPRESSORS BY TYPES
Dynamic compression is defined as the compression of a gas with continuous flow and that is
due to the interaction between rotating vanes and the gas. Dynamic compressors develop a
pressure differential by the mechanical action of rotating vanes or impellers that impart velocity
to the continuously flowing gas. The velocity is then converted to increased pressure as the gas
is slowed down in a controlled manner. The slowdown of the gas flow is accomplished through
a restriction in the path through which the gas has to travel. As the size of the discharge path
size decreases, the pressure of the gas increases.
The dynamic compressor depends on motion to transfer energy from the compressor’s rotor to
the process gas. The characteristics of compression vary in accordance with the density of gas
that is compressed. There is no “containment” of the gas as in positive-displacement
compressors; therefore, the flow of gas is continuous. The following types of dynamic
compressors are discussed in this section:
• Centrifugal
• Axial
The basic difference between a centrifugal compressor and an axial compressor is the manner in
which the continuous flow of gas passes through the compressor. A centrifugal compressor acts
on a gas through use of blades on a rotating impeller. The flow in a centrifugal compressor is
radially through each impeller. The rotary motion of the gas results in an outward velocity due
to centrifugal forces. The tangential component of the outward velocity is transformed to
pressure by a diffuser. The flow in an axial compressor, as its name implies, is parallel to the
machine axis. An axial compressor acts on a gas through use of a series of rotating blades and
stationary blades. The lift and drag coefficients of shapes of the blades determine the
compressor’s characteristics.

Although centrifugal and axial compressors fall under the same classification, the differences in
their construction and design offer distinct advantages and disadvantages. Figure 2 shows the
advantages and disadvantages of centrifugal and axial compressors.
Compressor Type Advantages Disadvantages

Centrifugal Wide operating range Unstable at low flow
Low maintenance Moderate efficiency
High Reliability
Axial High efficiency Low pressure ratio per stage
Higher flow for given size Narrow flow range
Fragile and expensive blading
Also unstable at low flows
Figure 2. Advantages and Disadvantages of Centrifugal and Axial Compressors
Centrifugal
Centrifugal compressors are the most common type of dynamic compressors. Centrifugal
compressors operate on the principle of imparting velocity to a gas stream and then converting
this velocity energy into pressure energy. Centrifugal compressors are designed as single or
multi-staged and are driven directly by a prime mover or through gearing.
An operational description of a simple centrifugal compressor illustrates the relationship between

gas pressure and flow. Figure 3 shows a single-stage, single-flow centrifugal compressor with
the impeller overhung on a motor. This single-flow unit consists of the inlet nozzle, the impeller,
the diffuser, the volute, the discharge nozzle, and the driver (not shown). The gas enters the
compressor through the inlet nozzle, which is proportioned to permit the gas to enter the impeller
with minimum shock and turbulence. The impeller receives the gas from the inlet nozzle and
dynamically compresses it. The impeller also sets the gas in motion and gives it a velocity that is
slightly more than the tip speed of the impeller. The diffuser surrounds the impeller and serves
to gradually reduce the velocity of the gas (kinetic energy) into pressure (potential energy). The
volute casing surrounds the diffuser and collects the gas. From the volute, the gas exits the
compressor through the discharge nozzle. Some discharge nozzles act as conical diffusers, and
they further reduce the velocity of the gas to the final discharge flange velocity.

Figure 3. Single-Stage, Single-Flow Centrifugal Compressor
As shown in the application range chart, single-stage centrifugal compressors would normally
have an application that ranges between 90 and 150,000 inlet ACFM at 2 to 2,000 psig discharge
pressure. Multi-stage centrifugal compressors would normally have an application that ranges
between 900 and 200,000 inlet ACFM at 3 to 9,500 psig discharge pressure.
The following types of centrifugal compressors are discussed in this section of the module:
• Barrel
• Axially Split
• Integrally Geared
• Single-Stage Blower

Barrel
A typical, multi-stage, barrel-type centrifugal compressor is shown in Figure 4. Barrel

compressor casings can be of either forged steel, cast steel, or fabricated steel; however, if the
relative molecular mass specified is less than 14, or if the maximum allowable working pressure
exceeds 1000 psig, Saudi Aramco requires that the casing be made of forged steel. The
compressor casing is constructed as a complete cylinder, but at least one end of the compressor is
removable to allow access to internal components. Barrel-type centrifugal compressors are also
referred to as radially split centrifugal compressors. Sufficient space must be allowed at the rear
of the compressor for the removal of internal components.
Major Components - The following major components, which are discussed in detail in
module 212.03, are noted here for purposes of identification:
• Casing
• Inlet Nozzle
• Impeller
• Impeller Labyrinth Seals
• Diffuser
• Crossover
• Return Channel
• Discharge Nozzle
• Balance Piston Assembly
• Rotor Assembly
• Bearing Assemblies (Thrust and Journal Ends)
• Seal Assembly
• Inner Barrel

Figure 4. Typical, Multi-Stage, Barrel Compressor
Operation - In the operation of a barrel compressor, the gas enters the inlet nozzle at
approximately 125 ft/sec, where the gas is accelerated to approximately 250 ft/sec. The gas is
directed to the blades of the impeller to be further accelerated to approximately 800 ft/sec,
depending upon impeller design, and discharged to the diffuser that surrounds the impeller. The
diffuser gradually reduces the velocity of the gas to approximately 250 ft/sec to convert the
velocity energy to pressure. In a single-stage barrel compressor, the gas exits the diffuser
through a volute casing that surrounds the diffuser. The volute casing collects the gas, and a
further reduction in velocity of the gas to approximately 125 ft/sec may occur in the discharge
nozzle. The gas exits through the discharge nozzle. In a multi-stage barrel compressor, the gas
exits the diffuser and enters return channels. The return channels direct the gas into the impeller
of the next stage.

Applications - The application range chart that was shown previously in Figure 1 shows
discharge pressure (psig) versus inlet flow (ACFM) for centrifugal compressors. Because of the
barrel design, barrel compressors, instead of axially split centrifugal compressors, are normally
selected for higher pressure applications or for certain lower mole gas compositions (hydrogen
gas mixtures). Examples of Saudi Aramco applications where barrel compressors are used are as
follows:
• Sales Gas Compressors

• Gas Plant Compressors
• Gas Re-Injection Compressors
• Refinery Applications (Reformer and Hydrocracker Recycle)
The main reason for the use of barrel compressors in higher pressure applications is frame joint
sealing. Applications in which low mole gas compositions are compressed require the use of an
impeller with a larger than normal flow area. This arrangement requires the use of more than the
usual number of stages for a given head requirement since the density of the gas is low relative to
other gases and larger frame size for the flow that is handled.
The increase in frame size greatly impacts the amount of internal stresses on the casing,
especially at the joint flanges, and the required bolt loading of an axial split compressor. The
available space for bolting the casing halves of an axially split compressor is further restricted at
the two shaft penetrations. To achieve the required tightness, a high contact pressure at the
flange joints is required. The necessary forces in the bolts are often higher than would be
required by the static gas forces if the casing flanges were perfectly rigid and flat; therefore, the
barrel design is used for large compressor frame sizes and high pressure applications.
Barrel compressors are also used in these applications because the barrel design has circular
casing joints or flanges with a perfectly even load distribution. The leakage of gas at the two
covers can effectively be prevented by the metal-to-metal contact and endless O-rings that are
inserted into grooves on the end cap. By monitoring the pressure between two adjacent O-rings,
the tightness of the seal can be controlled. The barrel design has the advantage of positive
sealing, which prevents leakage of toxic, flammable, and explosive gases. For this reason, Saudi
Aramco Standards specify radially split casing construction for gases that contain hydrogen if the
hydrogen partial pressure exceeds 200 psig.
Axially Split
A typical, multi-stage, axially (horizontally) split, centrifugal compressor is shown in Figure 5.

The casing is divided into upper and lower halves along the horizontal centerline of the
compressor. The axially split casing allows access to the internal components of the compressor
without disturbing the rotor-to-casing clearances or the bearing alignment. If possible, process
piping nozzles should be mounted on the lower half of the compressor casing to allow
disassembly of the compressor without removal of the process piping.

Major Components - The following major components, which are discussed in detail in Module
212.03, are noted for purposes of identification:
• Inlet Nozzle
• Impeller
• Impeller Labyrinth Seals
• Diffuser
• Crossover
• Return Channel
• Balance Piston Assembly
• Rotor Assembly
• Bearing and Seal Assemblies (Thrust and Journal Ends)
• Side-Load Nozzles

Figure 5. Typical, Multi-Stage, Axially Split, Centrifugal Compressor

Operation - The operation of an axially split compressor is the same as the operation of the
barrel compressor pertaining to the gas flowpath and gas velocities. The incoming gas is
accelerated through the inlet nozzle to the impeller. A diffuser surrounds the impeller; the
diffuser serves to gradually reduce the velocity of the gas as the gas leaves the impeller, and it
converts the velocity energy to pressure. In a multi-stage, axially split compressor, the gas exits
the diffuser and enters return channels. The return channels direct the gas into the impeller of the
next stage.
Applications - The application range chart that was previously shown in Figure 1 shows
discharge pressure (psig) versus inlet flow (ACFM) for axially split, centrifugal compressors.
Some examples of Saudi Aramco applications for axially split, centrifugal compressors are as
follows:
• GOSP Compressors
• Vapor Recovery Compressors
• Refrigeration Compressors
• Refinery Applications (Offgas, Wet Gas, and Process Air)
Integrally Geared
Integrally geared compressors have a low-speed (bull) gear that drives two or more high-speed
pinions (rotors). The pinion sizes vary to allow for different rotation speeds. Impellers are
mounted at one end or both ends of each rotor. The rotors typically operate at speeds between
25,000 and 50,000 rpm. The overhung impeller design often uses an open impeller construction
that consists of a disc and blades, without an impeller cover. This type of impeller is
characterized by an inducer section that directs the gas flow into the eye of the impeller. The
detail in Figure 6 shows an inducer impeller. The blades of an inducer impeller extend down
around the hub radius so that the gas first encounters the blade pack while flowing axially.
Inducer impellers reduce the inlet speed of the gas for a given flow and speed; therefore, inducer
impellers can operate at a faster speed with a greater head output.
Each impeller has its own volute casing that contains the diffuser and the discharge volute and
that is bolted to the gear casing. To allow access to the gears, the gear casing may be
horizontally or vertically split.

Major Components - The following major components, which are discussed in Module 212.03,
are noted for purposes of identification:
• Volute Casing
• Stage Casing
• Stage Inlet Nozzle
• Stage Impeller
• Diffuser
• Stage Discharge Nozzle
• Bull Gear
• Pinion Gear
Operation - The gas enters the compressor through the first-stage inlet nozzle to the impeller.
Because of the inducer impeller design, the gas initially flows axially around the impeller hub.
The gas then begins to flow radially from the impeller as it approaches the impeller disc. The
impeller dynamically compresses the gas and discharges it to the diffuser. The diffuser
surrounds the impeller and gradually reduces the velocity of the gas as it leaves the impeller,
which is shown in Figure 6. The gas exits the diffuser through a volute casing. The volute
casing collects the gas, further reduces the velocity of the gas, and recovers additional velocity
energy. The gas exits the first stage through the first-stage discharge nozzle, enters an
intercooler (not shown), and is then piped to the second stage. The discharge from the second
stage enters an intercooler (not shown) and is then piped to the third stage. After the third stage,
the gas is discharged to the downstream piping. Gas velocities are approximately for barrel
compressor and axially split compressors.
Applications. Integrally geared centrifugal compressors are generally used for plant and
instrument air applications that require volumes in the range of 1000 to 30,000 ACFM and
discharge pressures in the range of 100 to 125 psig.

Figure 6. Typical, Integrally Geared Centrifugal Compressor
Single-Stage Blower
A single-stage blower, which is shown in Figure 7, contains an impeller that is located inside a
housing. The impeller is mounted on a shaft (not shown) and rotates inside the blower housing.
The impeller is turned either by a direct drive system or by a pulley and belt drive system if the
horsepower is below 125. A single-stage blower is commonly called a centrifugal fan.

Figure 7. Single-Stage Blower
Major Components - The major components that are associated with a single-stage blower
include:
• Inlet
• Impeller
• Volute
• Housing
• Outlet
Operation - The gas enters the blower axially to the impeller shaft through the inlet to the
impeller. The impeller moves the gas stream in a rotary motion, which results in an outward
velocity due to centrifugal forces. The movement of the gas stream outward creates a low-
pressure area at the center of the impeller (inlet). The low pressure at the center of the impeller
causes the gas stream to flow into the inlet of the blower. The rotary motion of the gas stream is
transformed to pressure by means of a volute. The volute is a gradually widening section of the
housing that surrounds the impeller and that gradually reduces the tangential or radial velocity of
the gas stream as the stream leaves the impeller. The volute converts the velocity to pressure and
directs the flow to the compressor outlet, where the gas exits in a stream perpendicular to the axis
of the blower impeller.

Applications. Single-stage blowers are preferred for high volume, low pressure applications.
Axial
Axial compressors accelerate the gas in a direction that is parallel to a rotating shaft and to pairs
of moving and stationary blades. The combination of a row of moving blades (rotating vanes)
and a row of stationary blades (stator vanes) forms a stage. The pressure rise per stage in an
axial compressor is small compared to the pressure rise per stage of a centrifugal compressor;
therefore, the axial compressor contains more stages than does a centrifugal compressor that
operates in the same pressure range. Roughly three axial stages are required for one centrifugal
stage.
Multi-Stage
An axial compressor that consists of more than one stage is classified as a multi-stage axial
compressor. As the volume or pressure requirements of the process increases, the number of
axial compressor stages increases. A typical, multi-stage, axial compressor is shown in Figure 8.
Major Components - The following major components, which are discussed in detail in Module
212.03, are noted for the purposes of identification:
• Shaft Seals
• Thrust Bearing
• Radical Bearings
• Inlet Nozzle
• Inlet Volute
• Rotor Shaft
• Stator Vanes
• Adjustable Stator Vanes
• Fixed Stator Vanes
• Rotating Vanes
• Tapered Cylindrical Casing
• Discharge Volute
• Discharge Casing

Operation. A multi-stage axial compressor consists of a rotor shaft with a series of rotating
blades and a tapered cylindrical casing with adjustable and fixed stator vanes. The gas enters
through an inlet nozzle that guides the gas to the inlet volute. The inlet volute guides and
accelerates the gas stream into the stator vanes. The stator vanes turn the gas stream to properly
orient the gas stream for the next row of rotating vanes. The rotating vanes increase the energy
of the gas by increasing the velocity of the gas. The stator vanes act as diffusers to provide
resistance to the gas flow, and they cause the gas stream to decrease in velocity and to increase in
pressure. Because rotating vanes and stator vanes alternate down the length of the casing, the
gas is both accelerated and decelerated several times before it leaves the compressor. As the gas
leaves the last set of stator vanes, it exits the compressor through the discharge volute and
discharge nozzle.
Applications - The application range chart that was previously shown in Figure 1 shows
discharge pressure (psig) versus inlet flow (ACFM) for axial compressors. Multi-stage axial
compressors are used for high flow applications with relatively low pressure ratios (80,000 -
800,000 inlet ACFM at 2 - 100 psig discharge pressure). Multi-stage axial compressors are
mostly used to provide combustion air to gas turbines and are also used to supply air to the
regenerator in fluid catalytic cracking units.
Figure 8. Multi-Stage Axial Compressor

Single-Stage (Fans)
Single-stage axial compressors or axial flow fans, as shown in Figure 9, typically draw on an
atmospheric pressure, and they have discharge pressures up to only a few psig. A single-stage
axial compressor moves the gas stream parallel to the compressor’s drive shaft. Single-stage
axial compressors consist of one row of blades that is attached to a shaft. When process
requirements vary significantly, the blades may have a variable pitch control system to vary the
discharge pressure and volume.
Major Components - The major components associated with a single-stage axial compressor
include:
• Compressor Housing
• Inlet Nozzle
• Inlet Volute
• Impeller
• Straightening or Guide Vanes
• Drive Shaft
Operation - Single-stage axial compressors use a series of impeller blades that are attached to a
rotating drive shaft to move a gas stream. As the gas enters the fan/compressor, an inlet nozzle
guides the gas to an inlet volute. The inlet volute guides and accelerates the gas stream into the
blades that are mounted on the impeller. Each blade increases the energy of the gas by
increasing the gas velocity. Some single-stage axial compressor/fans are equipped with
controllable pitch (blade angle) impellers for use in variable-air-volume systems. After the gas
flows through the impeller, it flows past straightening vanes (also called guide vanes). The
straightening vanes are designed to remove swirl from the gas (imparted by the impeller), to
straighten the air flow, and to act as diffusers to provide a resistance to gas flow. Resisting the
gas flow causes the gas pressure to increase while decreasing gas velocity. After the
straightening vanes, the gas exits the compressor through the discharge nozzle.

Figure 9. Single-Stage Axial Compressor
Applications. Single-stage axial compressors are used in applications in which large volumes of
compressed air or gas are required. Single-stage axial compressors are generally used for fan
installations, such as integral motor cooling fans, forced draft cooling systems, and induced draft
cooling systems.

CLASSIFYING POSITIVE-DISPLACEMENT COMPRESSORS BY TYPE
Positive-displacement compression is defined as the compression of a gas due to the mechanical

reduction of the volume in a confined space. The basic principle of positive-displacement
compression is that two objects cannot occupy the same space at the same time. In positive-
displacement compressors, gas is confined within a closed space or chamber, and the volume of
the chamber is reduced. As the volume of the chamber decreases, the energy of the gas that
occupies the chamber is increased, which causes the gas pressure and the temperature to
increase. Once the pressure is increased above the process discharge pressure, the gas is
discharged out of the compressor.
The following types of positive-displacement compressors will be discussed in this section:
• Reciprocating
• Rotary
The basic difference between a reciprocating compressor and a rotary compressor is the manner
in which the gas is compressed. A reciprocating compressor compresses the gas through the use
of pistons that move back and forth in cylinders to reduce the volume of the gas. A rotary
compressor compresses the gas through use of rotary motion of the compressor’s rotor. The
volume of the chamber that contains the gas is reduced as the rotor rotates.
Although reciprocating and rotary compressors fall under the same classification, which is
positive-displacement, there are differences in their construction and design, with the result that
each has its distinct advantages and disadvantages. Figure 10 shows the advantages and the
disadvantages of reciprocating and rotary positive-displacement compressors.
Compressor Type Advantages Disadvantages

Reciprocating Higher efficiency Pulsation
Higher pressure ratio Higher maintenance requirements
Rotary No pulsation Lower efficiency
Lower maintenance requirements Higher noise level (for certain
types)
Lower pressure ratio
Figure 10. Advantages and Disadvantages of Reciprocating and Rotary Positive-

Displacement Compressors

Reciprocating
A reciprocating compressor is a positive-displacement, constant-volume, variable-pressure

compressor. A reciprocating compressor is the most common type of positive-displacement
compressor.
Reciprocating compressors are available in single and multi-staged designs. Single-stage

reciprocating compressors are typically rated at discharge pressures of 25 to 100 psig, with some
units rated as low as 2 psig. Multi-stage reciprocating compressors are typically rated at
discharge pressures of 80 to 30,000 psig, with specially designed units rated in excess of 50,000
psig. As already mentioned, a reciprocating compressor is a positive displacement device.
Unlike centrifugal compressors, the reciprocating compressor cannot self-regulate its capacity
against a given discharge pressure. The inlet and outlet air flow of a reciprocating compressor is
a function of compressor speed and cylinder volume.
Some advantages of a reciprocating compressor over a centrifugal compressor are:
• Greater flexibility in capacity and pressure range.

• Higher compressor efficiency and lower power cost.
• Capability for delivering higher pressures.
• Capability for handling lower flowrates.
• Less sensitivity to gas composition, molecular weight, and density.
Because the design of a reciprocating compressor is such that the produced gas pressure is not
affected by the molecular weight of the gas (as in the case with dynamic compressors),
reciprocating compressors are used for most low molecular weight applications. Some Saudi
Aramco applications that use reciprocating compressors are as follows:
• Refinery Off-Gas Compressors

• Hydrocracker Make-Up Compressor (H2-Rich Gas)
• Low-Flow Plant and Instrument Air Compressors
• Nitrogen Compressors
• Refinery Low-Flow Recycle Compressors (H2-Rich Gas)
Single-Acting
Figure 11 is an illustration of a single-acting reciprocating compressor. Single-acting refers to

the action that takes place during a stroke of the piston.
A single-acting reciprocating compressor compresses gas on only one side of the piston. The
reciprocating motion of a single-acting compressor is defined by a suction stroke and a discharge
stroke (also called a compression stroke).

Major Components - The major components of a single-acting reciprocating compressor are as

follows:
• Crankshaft
• Cross-Heads
• Cylinders
• Piston
• Suction Valves
• Discharge Valves
• Piston Rod Packing
A crankshaft (not shown) is rotated by a prime mover. The crankshaft converts the rotary
motion of the prime mover into reciprocating motion of the pistons or crosshead through the use
of a connecting rod.
Operation - The compression cycle of a single-acting reciprocating compressor consists of two

strokes of the piston: the suction stroke and the compression stroke. The suction stroke begins
when the piston moves away from the inlet port of the cylinder. The gas that is in the space
between the piston and the inlet port expands rapidly until the pressure decreases below the
pressure on the opposite side of the suction valve. The pressure difference across the suction
valve causes it to open and admit gas into the cylinder. The gas flows into the cylinder until the
piston reaches the end of its stroke. The compression stroke starts when the piston starts its
return movement. When the pressure in the cylinder increases above the pressure on the
opposite side of the suction valve, the suction valve closes to trap the gas inside the cylinder. As
the piston continues to move toward the end of the cylinder, the volume of the cylinder decreases
and the pressure of the gas increases. When the pressure inside the cylinder reaches the design
pressure to overcome the pressure that is exerted by the discharge valve and the downstream
piping, the discharge valve opens and discharges the contents of the cylinder.

Figure 11. Single-Acting Reciprocating Compressor
Double-Acting
Double-acting also refers to the action that takes place during a stroke of the piston. A double-
acting reciprocating compressor draws a suction on one side of the piston as it discharges on the
other side of the piston. The double action of a double-acting reciprocating compressor reduces
discharge pressure pulsation and increases the output volume for a given cylinder design.
Double-acting pistons are standard for most process gas compressor cylinders.
Major Components - The major components of a double-acting reciprocating compressor are

basically the same as those of the single-acting reciprocating compressor; the exception is that
there are more suction valves and discharge valves in the double-acting reciprocating
compressor.
Operation - The cycle of a double-acting reciprocating compressor also consists of two strokes
of the piston, and the suction and discharge valves operate in a similar fashion to those valves in
the single-acting reciprocating compressor; however, in the case of a double-acting reciprocating
compressor, during movement of the piston, both the suction and the discharge process takes
place. A double-acting reciprocating compressor is shown in Figure 12. As the piston moves
towards the end of the cylinder head to discharge the compressed gas, the suction valve on the
crankshaft end of the cylinder opens to allow gas to fill the crankshaft end of the cylinder.
During the return stroke, the discharge valve at the crankshaft end opens and discharges the
compressed gas as the suction valve on the cylinder head opens to allow gas to fill the cylinder-
head end of the piston.

Figure 12. Double-Acting, Reciprocating Compressor
Dry/Lubricated
The design of the dry and lubricated reciprocating compressors are relatively similar. The
lubricated type is provided with oil injection ports, and, typically, it has a force-feed lubrication
system that is separate from the lubrication that is provided to the crankshaft. The dry
compressor only lubricates the crankshaft and crosshead. The lubricated type normally uses two
or three single-piece, diagonal-cut, Teflon rider rings on the compression piston or possibly a
three-piece bronze segmental ring. Dry reciprocating compressors use Teflon, special plastics,
or high-performance polymer rings as the sealing medium between piston and cylinder. Because
the sliding surfaces are lubricated on lubricated compressors, harder piston and rider ring
materials, such as glass and/or molybdenum-filled Teflon, can be used.
Due to the requirements of some gases, dry cylinder compressors are employed to avoid
contamination of the gas stream. Without the lubricant, which also serves as a sealing
mechanism, the cylinders are designed with extremely close tolerances. The lack of lubrication
also necessitates the use of special pistons and rings.
Special considerations exist for the use of dry compressors. The close tolerances and lack of
lubrication in a dry compressor make the cleanliness of the incoming gas stream an absolute
necessity. Suction filtration down to 1:m is necessary to ensure a longer operational life of the
piston, packing rings, and rider rings. To minimize cylinder and ring wear, dry compressor
piston speeds are usually limited to 600 ft/min.

The operation of dry and lubricated reciprocating compressors is the same as the operation of the
reciprocating compressor operations that were described in the single- and double-acting
reciprocating compressor sections. Dry reciprocating compressors are used in compressed air
and process applications where oil can contaminate the process.
Rotary
The following types of rotary compressors are discussed in this section:
• Screw
• Lobe
• Liquid Ring
• Sliding-Vane
Screw
Screw compressors are positive-displacement, constant-volume, variable-pressure compressors.

The application range chart that was shown previously in Figure 1 shows discharge pressure
(psig) versus inlet flow (ACFM) for screw compressors. Screw compressors are available up to
an inlet flow from 300 to 60,000 ACFM with discharge pressures up to 580 psig. Screw
compressors are available in lubricated or dry and in single-, two-, or three-stage designs.
Major Components - Figure 13 shows the basic construction of a lubricated screw compressor.
The single-stage design consists of a pair of rotors that mesh in a one-piece, dual-bore cylinder.
The male rotor usually consists of four helical threads that are spaced 90 degrees apart. The
female rotor usually consists of six helical grooves that are spaced 60 degrees apart. The rotor
speed ratio is inversely proportional to the thread-groove ratio. When the male rotor rotates at
1800 rpm in the four-thread, six-groove, screw compressor, the female rotor rotates at 1200 rpm.
Bearings support the rotor and assist in the maintenance of the close tolerances between the
threads and the grooves.
Operation - There are two main types of screw compressors: lubricated type and dry type.
Lubricated screw compressors use oil injected into the compression chamber to lubricate the
chamber and to absorb the heat of compression. Dry-type screw compressors do not use oil
injection. The physical operation of each type is similar.

Lubricated Screw Compressor - The screw compressor can be motor-driven or engine-driven

by direct, belt, or gear drive. Typically, the male rotor is connected to the driver; however,
female rotor drive is possible in some designs. The female rotor is driven by the male rotor
without metal-to-metal contact through the oil film developed between the rotors. In some
lubricated designs, timing gears are used to keep the two counterrotating screws in the proper
mesh. In a single-stage design, the air inlet is usually located at the top of the cylinder near the
drive shaft end. The discharge port is located at the opposite end of the cylinder. Compression
begins as the rotors unmesh at the air inlet port. Gas is drawn into the cavity between the male
rotor lobes (thread) and the female rotor grooves. As rotation continues, the rotor threads pass
the edges of the inlet ports and trap the gas in a cell formed by the rotor cavities and the cylinder
wall. Further rotation causes the male rotor thread to roll into the female rotor groove, which
reduces the volume and raises the cell pressure. Oil is injected after the cell is closed to the inlet
to seal the clearance between the male thread and female groove and to absorb the heat of
compression. Compression continues until the rotor threads pass the edge of the discharge port
and release the compressed gas and oil mixture.
Dry Screw Compressor - Similar to the lubricated screw compressor, the dry screw compressor
can be motor-driven or engine-driven by direct, belt, or gear drive. Typically, the male rotor is
connected to the driver; however, female rotor drive is possible in some designs. The female
rotor is driven by the male rotor without metal-to-metal contact through timing gears, as shown
in Figure 14. Because oil is not used to provide a seal, close tolerances are required between the
mating area of the male and female rotors and between the rotors and the casing. The close
tolerances required in the dry screw compressor make these compressors particularly sensitive to
the effects of dirt; therefore, they must be well protected through the use of intake filters. The
operation of the dry screw compressor is similar to the operation of the lubricated screw
compressor with the exception of the oil injection.

Figure 13. Lubricated Screw Compressor

Figure 14. Dry Screw Compressor
Applications - Dry screw compressors are generally used in refrigeration and plant and
instrument air systems in which oil-free air is required and in some hydrocarbon applications
when oil would affect the process condition (catalyst poisoning). Wet screw compressors are
generally used in hydrocarbon applications in which small amounts of oil are acceptable.
The following is a list of some of the advantages of the lubricated screw compressor over the dry
screw compressor:
• The injected lubricant provides internal cooling, which reduces or eliminates

polymerizing.
• Lubricated screw compressors can achieve considerably higher compression ratios.
• Lubricated screw compressors operate at lower discharge temperatures, e.g., 90°C
versus 250°C.

Lobe
The rotary lobe compressor, which is shown if Figure 15, is a positive-displacement, constant-
volume, variable-pressure, two-lobe rotary compressor. Rotary lobe compressors are also
available in three-lobe designs. As was previously shown in the application range chart, Figure
1, lobe compressors are available up to an inlet flow of 5,000 ACFM at pressure ranges from 5 to
25 psig. Most rotary lobe compressors provide oil-free compression.
A lobe compressor consists of identically synchronized rotors. The rotors are synchronized
through use of an external, oil-lubricated timing gear that positively prevents rotor contact and
that minimizes meshing rotor clearance in order to optimize efficiency. The rotors of the two-
lobe compressor each have two lobes. When the rotor rotates, gas is trapped between the rotor
lobes and the compressor casing. The rotating rotor forces the gas from the gas inlet port, along
the casing, to the gas discharge port. Discharge begins as the edge of the leading lobe passes the
edge of the discharge port. The trailing lobe pushes the entrapped gas into the discharge port,
which compresses the gas against the backpressure of the system. Lobe compressors are usually
supplied with noise enclosures or silencers to reduce their characteristic high noise level.
Figure 15. Two-Lobe Compressor
Liquid-Ring
The liquid-ring compressor, which is shown in Figure 16, is a positive-displacement, constant-

volume, variable pressure, two-stage compressor. As was previously shown in the application
range chart, Figure 1, liquid-ring compressors are available up to an inlet flow of 2,000 ACFM at
pressure ranges from a low vacuum (4 in Hg. Absolute) to 100 psig. Liquid-ring compressors
are most commonly used as vacuum pumps. Liquid-ring compressors are used in saturated gas
applications, especially in vacuum towers, to produce the necessary vacuum.

Liquid-ring compressors consist of a round, multi-blade rotor that revolves in an elliptical casing.
The elliptical casing is partially filled with a liquid, which is usually water, but it can be any
process-compatible fluid. As the rotor turns, the blades form a series of chambers that contain
gas with the liquid acting as a piston. The space between the blades serves as a rotor chamber.
The gas inlet and discharge ports are located at the inner diameter of the rotor chamber. As the
liquid leaves the rotor chamber, gas is drawn from the gas inlet into the rotor chamber through
the gas inlet ports. As the rotor continues to rotate, the liquid returns to the rotor chamber and
decreases the volume in the chamber. As the volume decreases, the gas pressure increases. As
the rotor chamber passes the gas discharge port, the compressed gas is discharged through the
gas outlet into a gas/liquid separator and then to the process.
Figure 16. Liquid-Ring Compressor
Sliding-Vane
A sliding-vane compressor, which is shown in Figure 17, is a positive-displacement, constant-

volume, variable-pressure compressor. Sliding-vane compressors are available in single- and
multi-stage arrangements. Typical single-stage capacities range through 3200 cubic feet per
minute and 50 psig; two-stage sliding-vane compressors can deliver pressures from 60 to 150
psig and flows up to approximately 1800 cubic feet per minute. The application range chart
(Figure 1) graphically compares the sliding-vane compressor capacity to the capacities of other
styles of compressors.

Sliding-vane compressors are typically found in applications such as air blast hole drilling,
pneumatic conveying, chemical and petroleum vapor recovery, gas transmission, and small plant
air systems.
A sliding vane compressor uses a series of vanes that slide freely in longitudinal slots that are cut
into the rotor. During operation, centrifugal force causes the vanes to move outward against the
casing wall. The chamber that is formed between the rotor, between any two vanes, and the
casing is referred to as a cell. As the rotor turns, an individual vane passes the inlet port to form
a cell between itself and the vane that precedes it. As an individual vane rotates toward the end
of the inlet port, the volume of the cell increases. The increase in the cell volume draws a partial
vacuum in the cell. The vacuum draws the gas in through the inlet port. When a vane passes the
inlet port, the cell is closed, and the gas is trapped between the two vanes, the rotor, and the
casing. As rotation continues toward the discharge port, the volume of the cell decreases. The
vanes ride against the casing and slide back into the rotor. The decrease in volume increases the
gas pressure. The high-pressure gas is discharged out of the compressor through the gas
discharge port. Sliding-vane compressors are characterized by a high noise level that results
from the vane motion.
Figure 17. Sliding-Vane Compressor

WORK AID 1: ILLUSTRATIONS USED TO CLASSIFY DYNAMIC

COMPRESSORS BY TYPE
Figure 26. Integrally Geared, Centrifugal Compressor

Figure 27. Multi-Stage, Axially Split, Centrifugal Compressor

Figure 28. Single-Stage Blower

Figure 29. Multi-Stage, Barrel, Centrifugal Compressor

Figure 30. Single-Stage, Axial Compressor

Figure 31. Multi-Stage, Axial Compressor

WORK AID 2: ILLUSTRATIONS USED TO CLASSIFY POSITIVE-

DISPLACEMENT COMPRESSORS BY TYPE
Figure 32. Liquid-Ring, Rotary Compressor

Figure 33. Dry Screw Compressor

Figure 34. Lubricated Screw Compressor

Figure 35. Sliding-Vane, Rotary Compressor

Figure 36. Two-Lobe, Rotary Compressor
Figure 37. Double-Acting, Reciprocating Compressor

GLOSSARY
balance piston A device that is installed on the shaft of a centrifugal compressor and
that reduces the forces on the thrust bearing.
casing The outer containment vessel of a compressor.
clearance volume A volume in a reciprocating compressor cylinder that is not swept by

the piston.
crankshaft The rotating element that transmits power from the driver to the
connecting rods and that converts the rotary motion of the prime
mover into the reciprocating motion of the pistons.
cross-head The mechanical element between the connecting rod and the piston
rod that absorbs the nonaxial forces from the connecting rod and that
transmits only axial forces to the piston rod.
cylinder The principal component of a reciprocating compressor, which

contains the piston, the suction and discharge valves, and the packing
around the piston rod.
diffuser A component of centrifugal compressors that is located after an

impeller. The diffuser converts velocity head to pressure head.
discharge volute Spiral-shaped casing that is designed to convert velocity energy to

pressure energy.
dynamic compression The compression of a gas with continuous flow due to the interaction
between a vane and a gas.
impeller The rotating element of a centrifugal compressor that develops

velocity head. Also called a wheel.
intercooler A gas cooler that is located between compressor stages.
piston The component that moves back and forth in the cylinder and that
compresses the gas.
positive-displacement Compression that occurs when a quantity of gas occupies a space and
compression is mechanically reduced. Such compression results in a corresponding
increase in pressure.

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Engineering Encyclopedia

Saudi Aramco DeskTop Standards

Classifying Compressors By Type

Chapter : Rotating Equipment For additional information on this subject, contact

CLASSIFYING DYNAMIC COMPRESSORS BY TYPES................................................. 3

WORK AID 2: ILLUSTRATIONS USED TO CLASSIFY POSITIVE-

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Table of Figures Page

Figure 1. Compressor Application Range Chart........................................................ 2

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The use of compressors had expanded widely in industrial applications. Figure 1 is an

• Classifying Dynamic Compressors by Types

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Figure 1. Compressor Application Range Chart

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CLASSIFYING DYNAMIC COMPRESSORS BY TYPES

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Compressor Type Advantages Disadvantages

Figure 2. Advantages and Disadvantages of Centrifugal and Axial Compressors

An operational description of a simple centrifugal compressor illustrates the relationship between

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Figure 3. Single-Stage, Single-Flow Centrifugal Compressor

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A typical, multi-stage, barrel-type centrifugal compressor is shown in Figure 4. Barrel

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Figure 4. Typical, Multi-Stage, Barrel Compressor

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• Sales Gas Compressors

A typical, multi-stage, axially (horizontally) split, centrifugal compressor is shown in Figure 5.

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Figure 5. Typical, Multi-Stage, Axially Split, Centrifugal Compressor

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Figure 6. Typical, Integrally Geared Centrifugal Compressor

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Figure 7. Single-Stage Blower

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Figure 8. Multi-Stage Axial Compressor

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Figure 9. Single-Stage Axial Compressor

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CLASSIFYING POSITIVE-DISPLACEMENT COMPRESSORS BY TYPE

Positive-displacement compression is defined as the compression of a gas due to the mechanical

The following types of positive-displacement compressors will be discussed in this section:

Compressor Type Advantages Disadvantages

Figure 10. Advantages and Disadvantages of Reciprocating and Rotary Positive-

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A reciprocating compressor is a positive-displacement, constant-volume, variable-pressure

Reciprocating compressors are available in single and multi-staged designs. Single-stage

Some advantages of a reciprocating compressor over a centrifugal compressor are:

• Greater flexibility in capacity and pressure range.

• Refinery Off-Gas Compressors

Figure 11 is an illustration of a single-acting reciprocating compressor. Single-acting refers to

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Major Components - The major components of a single-acting reciprocating compressor are as

Operation - The compression cycle of a single-acting reciprocating compressor consists of two

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Figure 11. Single-Acting Reciprocating Compressor