PCST Module 3.1

Trainee Handbook
Module 3.1
Describe the Operation of Rotating Equipment
Training & Development

January 2012
© Copyright Saudi Aramco, 2012.
All rights reserved. No portion of this book may be reproduced, by any process
or technique, without the express written consent of Saudi Aramco.
TABLE OF CONTENTS
Unit 3: Describe the Operation of Plant Equipment
Module 3.1
Describe the Operation of Rotating Equipment
TRAINEE HANDBOOK
Information Sheets 1
Exercise A 12
Exercise B 25
Exercise C 32
Exercise D 51
Exercise E 71
Glossary 75
January 2012
INFORMATION SHEET
Enabling Objectives
Terminal Objective
3.1.1 Given access to illustrations
Given access to illustrations and drawing, the trainee and drawing, the trainee
will correctly identify the major parts, and describe will correctly identify the
the operation of an electric motor. major parts, and describe
the operation of the specified
3.1.2 *rotating equipment.
Given access to illustrations and drawing, the trainee
will correctly identify the major parts, and describe *Rotating equipment is
the operation of turbine engines. defined as motors, turbine
engines, pumps, and
3.1.3 compressors.
will correctly identify the major parts, and describe
the operation of an internal combustion (diesel)
engine.
3.1.4
the operation of pumps.
3.1.5
the operation of compressors.
Module 3.1 January 2012 1

INFORMATION SHEET
INTRODUCTION
This module introduces four drivers that are

commonly used in the plants. These are electric
motors, steam and gas turbines, and diesel engines.
Motors use electrical power to create rotational
force. Turbine engines are powered either by gas or
by steam. Diesel engines are internal combustion,
fuel burning in the engines moves pistons which
rotates a shaft. Most cars have internal combustion
engines.
Lubrication is a vital part of the operation of

rotating mechanical devices. Bearings and gears
must be lubricated to run smooth and last long.
2 January 2012 Process Control Systems Technician

INFORMATION SHEET
PART I OBJECTIVE 3.1.1
Identify the Major Parts, and Describe the

Operation of an Electric Motor
Electric motors are the most commonly used drivers

in the plants. The most common type is the single-
speed, three-phase, squirrel-cage induction motor.
In this part, you will learn the major parts and

operation of an electric motor.
MAJOR PARTS OF AN ELECTRIC MOTOR
The major parts of an electric motor are shown in

figure 1.
TERMINAL BOX
FAN STATOR
SHAFT
MOTOR
HOUSING BEARING
ROTOR
Figure
Figure11
Major
Major Parts of an
Parts of anElectric
ElectricMotor
Motor
PCST
Module 3.1

INFORMATION SHEET
Motor Housing
The motor housing is normally made of cast iron.

The housing holds and protects the internal parts
of the motor.
When an electric motor is running, it generates

heat. A closed motor has a cooling fan inside a fan
housing that protects the fan from damage from
foreign objects and personnel from the rotating fan
blades.
Terminal Box
Electrical connections between the motor and

electric power lines are made inside the terminal
box. This is shown in figure 2.
Figure 2
Terminal
Figure 2 Box
Terminal Box
PCST
Module 3.1

INFORMATION SHEET
Stator
The stator is stationary, which means it does not

rotate. It is made of laminated, or layered, sheets of
iron that are assembled together. The stator winding
are coils of copper wire wound around the core. In
some large electric motors, the windings are copper
bars. The stator is shown in figure 3.
STATOR
WINDINGS
STATOR
CORE
Figure 3
Figure 3
Stator
Stator
PCST
Module 3.1

INFORMATION SHEET
Rotor
The rotor is the rotating part of the motor. The

rotor consists of copper or aluminum bars
embedded in an iron core that is assembled on a
steel shaft. This is shown in figure 4.
SHAFT
ROTOR
(ALUMINUM OR COPPER BARS
EMBEDDED IN THE IRON CORE)
Figure 4
Figureand
Rotor 4 Shaft
Rotor and Shaft
PCST
Module 3.1
The rotor is centered in the stator and rotates
freely.
Ball Bearings
BALL The ball bearings hold the shaft in

the motor housing. Ball bearings
roll, reducing friction between the
rotating shaft and the motor
housing. The bearings in some
motors are pre-lubricated by the
manufacturer. Ball bearings are
shown in figure 5.
SHAFT Figure 5
Ball Bearings
Figure 5
6 Bearings
Ball January 2012 Process Control Systems Technician
PCST
Module 3.1
INFORMATION SHEET
Shaft
The shaft is made of steel and transfers the rotation

of the motor to the driven device. In a device like
an electric fan, the driven component will be
attached directly to the shaft of the motor. Other
devices will use gear boxes or mechanical couplings
to transfer power from the motor.
PRINCIPLES OF OPERATION
Electromagnetic induction – the
Electric motors operate on the principle of current flow in one conductor
inducing a voltage in the other
electromagnetic induction. conductor.
Magnetism
A magnet produces magnetic lines of force. One end

of a magnet is the north pole the other end is called
the south pole. If you try to place the north (or
south) poles of two magnets close together, they will
move apart. Like poles repel each other. This is shown
in figure 6.
Figure 6
Figure 6 Poles
Magnetic
Magnetic Poles
PCST
Module 3.1
INFORMATION SHEET
If you place the north pole of one magnet close to

the south pole of the other magnet, they will
attract, move together. Opposite poles attract each
other.
Electromagnetism
If you pass electric current through a coil of wire, a

magnetic field is generated around the coil. One
end of the coil becomes the north pole (positive),
and the other end becomes the south pole
(negative). The polarity (which end are north and
which end is south, or which end is positive and
which end is negative) depends on the direction of
current flow.
Electricity flowing through a coil generates a

magnetic field. If dc (direct current) is flowing, the
magnetic field has a fixed polarity. If ac (alternating
current) is flowing, the magnetic field will alternate
between polarities. This is shown in figure 7.
CURRENT AC CURRENT
MAGNETIC FIELD
MAGNETIC FIELD
Figure 7
Figure 7
Generating an Electromagnetic Field
Generating Electromagnetic Field
8 PCST
January 2012 Process Control Systems Technician
Module 3.1
INFORMATION SHEET
DC Current
With dc (direct current), the magnitude and V

BATTERY OUTPUT
direction remains the same over time. This is shown

in figure 8.
0
TIME
You will learn more about ac and dc in later units. Figure 8

Figure 8Current
Direct
Direct Current
AC Current PCST
Module 3.1
An alternating current (ac) is an electrical current

Magnitude – great size
whose magnitude and direction vary in a cycle. An or quantity, the amount of
alternating current (ac) flows first in one direction, something.
and then in the other. It reverses many times each

+
second. The usual waveform of an ac circuit is a
sine wave. This is shown in figure 9.
0
The sine wave is a representation of ac voltage and

–
current. One cycle of a sine wave has a positive and TIME
negative alternation. Figure 9

Figure 9
AC Sine
AC Sin Wave
Wave
PCST
Electromagnetic Induction Module 3.1
In an electromagnet, current is
passed through a coil to create
a magnetic field. In the same
way, a moving magnetic field
will create a current in a
conductor coil. This process is COIL A COIL B
called electromagnetic
induction. Figure 10 shows two AC IN
INDUCED
AC OUT
coils, A and B, which are close,
but do not touch.
Figure 10
Figure 10 Electromagnetic Induction
Electromagnetic Induction
PCST
Module 3.1
INFORMATION SHEET
If coil A is connected to an alternating current (ac),

an alternating magnetic field will form around it.
This fluctuating magnetic field induces an electric
current into coil B. The direction of the ac induced
into coil B will always be opposite to the ac in coil
A. The polarities of their magnetic fields will also
be opposite.
Note: Only an alternating current applied to one coil can

induce a current into another coil. A direct current will not
induce current into another coil.
OPERATION
Electromagnetic induction is a basic principle in the

operation of induction motors. Look at figure 11.
The stator winding is coil A and the copper bars of
the rotor make up coil B.
COIL A (STATOR) COIL B (STATOR)
Figure 11
Figure 11
Electromagnetic Induction
Electromagnetic Induction Operation
PCST
Module 3.1
When ac is connected to the stator winding, it
creates an alternating magnetic field. The alternating
magnetic field induces an alternating current into
the rotor bars. The current in the rotor creates its
own magnetic field opposite to the field in the
stator.

INFORMATION SHEET
The ac applied to the stator produces a rotating

magnetic field in the stator. Because the magnetic
field in the rotor is opposite, it is attracted to the
rotating field in the stator. This causes the rotor to
rotate within the stator.
Protection
Almost all electric motors are protected by circuit

breakers. Circuit breakers protect electrical
equipment from too much current. When a circuit
breaker trips (opens), the electrical path to the
motor is broken and the motor will stop. The cause
of too much current must be corrected before the
motor can be restarted.

INFORMATION SHEET
exercise a
Directions: Answer the following questions or complete the
statements by circling the correct response.
1. The most common type electric motor is the

single-speed, three-phase motor.
a. 2-cylinder reciprocating
b. synchronous
c. induction
d. phase shift
2. In an electric motor, the stator does not

.
a. have coils of copper wire

b. use ac
c. rotate
d. induce a voltage
3. The rotor consists of copper bars embedded in

an iron core on a steel .
a. shaft
b. housing
c. stator
d. ball bearing

INFORMATION SHEET
4. In a motor, ball bearings are used to reduce

friction between the rotating shaft and the
.
a. moving parts
b. stator
c. ball bearing
d. motor housing
5. If the north pole of one magnet is placed close

to the south pole of another, the magnets will
.
a. move apart
b. actuate
c. induce a current
d. attract
6. Only an alternating current applied to one coil

can induce into another .
a. stator
b. coil
c. rotor
d. core
7. When ac is connected to the stator winding, it

induces an alternating current into the
.
a. rotor bars
b. primary winding
c. rotary shaft
d. stator core

INFORMATION SHEET
8. Almost all electric motors are protected by

.
a. fuses
b. disconnect switch
c. trip micro switch
d. circuit breaker
9. When a circuit breaker trips, the electrical path

to the motor is .
a. fused
b. broken
c. re-connected
d. preserved

INFORMATION SHEET
SUMMARY
In this part, you learned that electric motors are the

most commonly used drivers and that the most
common type is the single-speed, three-phase,
squirrel-cage induction motor. You also learned that
the motor housing is made of cast iron and it holds
and protects the internal parts of the motor and
that when running an electric motor generates heat
and that a closed motor has a cooling fan inside a
housing.
You learned that the stator does not rotate and it is

made of laminated, or layered, sheets of iron that
are assembled together. The rotor rotates freely and
is mounted on a shaft and centered in the stator.
You also learned that when ac is connected to the
stator winding, it creates an alternating magnetic
field which induces an alternating current into the
rotor bars where the rotor creates its own magnetic
field opposite to the field in the stator. Because the
magnetic field in the rotor is opposite to the
rotating field in the stator, the rotor will rotate
within the stator.
This completes part I. If you have any questions,

ask the instructor.

INFORMATION SHEET
PART II OBJECTIVE 3.1.2

Operation of Turbine Engines
Steam turbine engines are used to drive large

pumps, compressors, and generators. Dry steam
produced in a boiler is used to operate the turbines.
Dry steam does not contain the tiny droplets of
water found in normal steam.
If you boil water in an open pot, you can see steam

rise and disappear. If the pot is sealed while boiling,
it will explode. Why will it explode?
When water changes to steam, steam expands.

Because the steam cannot escape, it creates pressure.
As more water changes to steam, the pressure builds
up until the pot explodes.
A boiler works the same as the

sealed pot. The boiler produces
pressurized steam that can be used
to do work. This is shown in figure
STEAM OUT
12.
This is the basic principle of steam

turbine engines.
WATER
HEAT
Figure 12
Producing Steam
16 12
Figure January 2012 Process Control Systems Technician
Producing Steam
PCST
Module 3.1
INFORMATION SHEET
OPERATION OF A STEAM TURBINE
A simple boiler and steam turbine is shown in figure

13. High temperature steam from the boiler enters
the steam chest. The high pressure steam rushes
through the first row of stator blades. The stator
blades aim the steam at the rotor blades. The force
of the steam causes the rotor blades and shaft to
rotate.
STEAM OUTLET
GOVERNOR STEAM INLET

VALVE
STEAM FLOW
STEAM
CHEST
STEAM TURBINE
STATOR
ROTOR
BURNER BOILER
Figure 13
Figure 13
Simple Boiler and Steam Turbine
Simple Boiler and Steam Turbine
PCST
Module
To take3.1advantage of all of the energy in the steam,
many rows of stator and rotor blades are used. For
the same reason, each succeeding row of blades is
larger, to capture all of the steam energy.
The operating speed of a steam turbine is

determined by the load it must drive. A turbine
may operate at a speed required to drive a pump to
provide a certain flow rate. To increase the flow rate,
the turbine engine speed must be increased. The
speed is controlled by the amount of steam allowed
into the engine. More steam equals more speed.

INFORMATION SHEET
The turbine governor controls the speed of the

turbine rotation by regulating the amount of steam
to the engine. This is shown in figure 14.
SPEED CONTROL
GOVERNOR GOVERNOR
VALVE
SHAFT
INLET
STEAM
CHEST
TRUST STATOR ROTOR

BEARING
STEAM OUTLET
Figure 14
Figure Turbine
Steam 14
Steam Turbine
PCST
Module 3.1
The over speed trip mechanism shuts down the
turbine whenever its rotating speed exceeds a set
limit.
GAS TURBINE ENGINES
A gas turbine engine burns fuel to create the force

necessary to turn the turbine. Instead of steam, hot
exhaust gases push the blades.
A gas turbine is an axial flow engine. This means

that air and gas flow through the engine along a
central shaft. Operating power is developed inside
the engine. Rows of stator and rotor blades are used
to develop rotational force.

INFORMATION SHEET
There are five major sections in a gas turbine

engine. These are:
o Starter
o Compressor
o Combustion
o Turbine
o Exhaust
These parts are shown in figure 15.
INTAKE
COMPRESSOR COMBUSTION EXHAUST
STARTER
TURBINE
Cold Section Hot Section
Figure 15
Figure Parts
Major 15 of a Gas Turbine
Major Parts of a Gas Turbine
PCST
Module 3.1
Starter Section
The starter section consists of a starter engine and

torque converter. A gas turbine cannot start up
without a starter to rotate the compressor shaft. The
engine produces the speed required to force
compressed air into the combustion section. Gas
turbines may use electric or diesel motors as starters.
A torque converter (transmission), transfers the

speed of the starter engine to the compressor.
INFORMATION SHEET
Compressor Section
This section provides compressed air to the

combustion section. The air inlet directs air from
the atmosphere into the compressor section. The
engine sucks huge amounts air when it operates. Air
inlets are pointed upward and covered with a screen
to keep foreign objects out. A filter system removes
dust and sand from the air before it enters the
compressor.
The compressor forces the incoming air into smaller

and smaller volumes. The stator and rotor blade
rings get smaller and smaller as the air goes through
the compressor. See figure 16.
AIR INLET
ROTATING BLADE DISCS
STATOR BLADE DISCS

AIR INLET
Figure 16
Figure 16 Section
Compressor
Compressor Section
PCST
Module 3.1
As air is compressed, it gets very hot.

INFORMATION SHEET
Combustion Section
The combustion section consists of the burner cans

and the transition piece. The burner cans mixes and
burns the compressed air and fuel gas producing hot
exhaust gas. See figure 17.
BURNER CAN TRANSITION

PIECE
HOT GAS
IGNITER
Figure 17
Figure 17
Combustion Section
Combustion Section
PCST
Module 3.1
The transition piece carries the hot exhaust gas from
the burner can to the turbine stator. Transition
pieces are tapered to form a nozzle at the exit. The
nozzle directs the hot gas into the turbine section
with a large amount of force.

INFORMATION SHEET
Turbine Section
The turbine section produces the power output

from the turbine. The section has a cylinder. Inside
the cylinder, there are alternating stators and rotors,
as shown in figure 18.
EXHAUST
STACK
TRANSITION
PIECE
LOAD TURBINE
STATORS
LOAD TURBINE
ROTORS
ROTOR
SHAFT
Figure 18
Figure 18
Turbine Cylinder
Turbine and Exhaust Sections
PCST
Module 3.1
The stator is a row of fixed blades that direct the
flow of hot gas from transition pieces onto the
rotor disc. The rotor disc is attached to the rotor
shaft. The flow of hot gas turns the rotor disc and
shaft which is the driver for the turbine.

INFORMATION SHEET
Exhaust Section
The exhaust section has only one part—the exhaust

stack. The exhaust stack directs the hot gas and
unused pressure upward into the atmosphere so it
can lose its remaining energy safely. See figure 18.
Some systems use the hot exhaust gas for heating. In

this case, large pipes are used to carry the hot gas
away from the engine.
Journal Bearings
All rotating machinery needs lubrication. The gas

turbine engine uses journal bearings. This is shown
in figure 19.
OIL INLET HOUSING
BEARING
LINER
CLEARANCE
SHAFT
(JOURNAL)
Figure 19
Figure 19
Journal Bearings
Joirnal Bearing
PCST
Module 3.1
INFORMATION SHEET
In a journal bearing, the shaft (journal) rotates on a

layer of oil or grease that separates the two parts.
Instead of only reducing friction, the lubricant is
thick enough that, once rotating, the surfaces do
not make contact. If oil is used, it is pressurized
and fed into a hole in the bearing.

INFORMATION SHEET
exercise b
1. Dry steam does not contain the tiny droplets

of .
a. nitrogen
b. water
c. crude
d. H2S
2. If you seal a pot while it is boiling, it will

.
a. not allow steam to form

b. boil faster
c. overheat
d. explode
3. In a steam turbine, the stator blades aim the

steam at the .
a. rotor blades
b. governor valve
c. steam chest
d. compressor

INFORMATION SHEET
4. The force of the steam causes the rotor blades

and to rotate.
a. stator blades
b. governor
c. shaft
d. exhaust fan
5. The operating speed of a steam turbine is

determined by the .
a. number of blades
b. pressure of the steam
c. temperature of the steam
d. load it must drive
6. A gas turbine burns fuel to create the force

necessary to turn the .
a. turbine
b. starter engine
c. hot gases out
d. journal bearing
7. A gas turbine is an
engine.
a. split compressor
b. axial flow
c. cross flow
d. radial

INFORMATION SHEET
8. In an axial flow engine, air and gas flow

through the engine along .
a. an exhaust duct
b. an air intake duct
c. a row blades
d. a central shaft
9. When air is compressed, it becomes

.
a. very dry
b. very hot
c. moisture free
d. colder
10. The burner mixes and burns the compressed air

and fuel gas producing hot .
a. exhaust gas
b. air
c. water
d. steam
11. The flow of hot exhaust gas turns the

.
a. stator disc
b. governor valve
c. exhaust fan
d. rotor disc and shaft

INFORMATION SHEET
SUMMARY
In this part, you learned that steam turbines are

used to drive large pumps, compressors, and
generators and that dry steam, which do not
contain droplets of water, is used to operate the
turbines. You also learned that if you boil water in
an open pot, you can see steam rise and disappear
and if the pot is sealed while boiling, it will
explode because when water changes to steam,
steam expands. If cannot escape, it creates pressure.
As more water changes to steam, the pressure builds
up until the pot explodes.
You also learned that a gas turbine burns fuel to

create the force necessary to turn the rotor blades
and that instead of steam, hot exhaust gases push
the blades. You learned that a gas turbine is an axial
flow engine which means air and gas flows through
the engine along a central shaft and the operating
power is developed inside the engine and rows of
stator and rotor blades are used to develop
rotational force.
This completes the information for part II. If you

have any questions, ask the instructor.

INFORMATION SHEET
PART III OBJECTIVE 3.1.3
Describe the Operation of an Internal Combustion

(Diesel) Engine
Diesel engines and gasoline engines are very similar.

Internal combustion means
They are both internal combustion engines designed that fuel is burned inside
to convert the chemical energy in fuel into cylinders.
mechanical energy. This mechanical energy moves
pistons up and down inside cylinders. The pistons
are connected to a crankshaft. The up-and-down
motion of the piston (linear motion) creates the
rotary motion needed to turn a drive shaft. The
major parts of a diesel engine are shown in figure 20.
FUEL INJECTOR
CRANKSHAFT
CYLINDER
PISTON
Figure 20
Figure 20
Major Part of a Diesel Engine
Major Part of a Diesel Engine
PCST
Module 3.1

INFORMATION SHEET
INTAKE EXHAUST In both engines, fuel is converted into energy

VALVE VALVE
through a series of small explosions or combustions.
The major difference between diesel and gasoline is
AIR
the way these explosions occur. In a gasoline
engine, fuel is mixed with air, compressed by
pistons, and ignited by sparks from spark plugs. In
a diesel engine, the air is compressed first, and then
the fuel is injected. Because air gets very hot when
it is compressed, the injected fuel ignites.
The diesel engine uses a four-stroke combustion

cycle. The four strokes are:
o Intake stroke – The intake valve opens, air is

Figure 21 drawn into the cylinder by the piston moving
Air Intake
Figure 21 Stroke down. This is shown in figure 21.
Air Intake Stroke
PCST
INTAKE
Module 3.1
EXHAUST o Compression stroke – The piston moves up
VALVE VALVE
and compresses the air. See figure 22.
o Combustion stroke FUEL
– As the piston INJECTOR
reaches the top, fuel

INTAKE EXHAUST
is injected and VALVE VALVE
ignited by the hot
compressed air,
forcing the piston
back down, as
shown in figure 23.
Figure 22
Air Compression
Figure 22 Stroke
Air Compression Stroke
PCST
Remember,
Module 3.1 the diesel engine have
no spark plugs, it compresses air,
and then injects the fuel directly
into the combustion chamber. The
heat of the compressed air ignites Figure 23
the fuel. Figure 23 Compression Stroke
Combustion Stroke
30 January 2012 Process
PCSTControl Systems Technician
Module 3.1
INFORMATION SHEET
o Exhaust stroke – The piston moves to the top, INTAKE

EXHAUST
pushing the burnt fuel and air out the exhaust VALVE
VALVE
valve. This is shown in figure 24.
As you can see, the piston moves up and down

inside the cylinder. Piston rings around the piston
ensure a tight fit between the piston and the walls
of the cylinder.
The pistons are connected to the crankshaft by the

connecting rods. See figure 25.
PISTONS
CONNECTING
ROD Figure 24
Figure 24
Exhaust Stroke
Exhaust Stroke
PCST
CRANKSHAFT Module 3.1
Figure 25
FigureConnecting
Piston, 25 Rod, and Crankshaft
Piston, Connecting Rod, and Crankshaft
PCST
Module 3.1
The crankshaft changes the up and down motion of
the pistons into rotary motion. The rotary motion
from the engine is used to drive pumps,
compressors, generators, and vehicles.

INFORMATION SHEET
exercise c
1. Internal combustion engines are designed to

convert the chemical energy of fuel into
.
a. #600 steam
b. mechanical energy
c. exhaust
d. solar energy
2. The up-and-down motion of the piston creates

the rotary motion needed .
a. to move the cylinders

b. when reversing
c. to open the exhaust valves
d. to turn a drive shaft
3. In a diesel engine, air is compressed first, and

then the fuel is .
a. injected
b. exhausted
c. compressed
d. ignited by a spark

INFORMATION SHEET
4. During the intake stroke, air is drawn into the

cylinder by the piston .
a. rings
b. moving down
c. moving upward
d. closing
5. During the combustion stroke in a diesel

engine, fuel is injected and ignited by the
.
a. down stroke of the piston

b. up stroke of the piston
c. hot compressed air
d. spark plug
6. The pistons are connected to the crankshaft by

the .
a. connecting rod
b. valve lifting rods
c. transmission shaft
d. drive shaft

INFORMATION SHEET
SUMMARY
In this part, you learned that diesel engines and

gasoline engines are very similar and that they are
both internal combustion engines designed to
convert chemical energy into mechanical energy.
This mechanical energy creates the rotary motion
needed to turn a drive shaft.
You also learned that diesel engines uses a four-

stroke combustion cycle and the four strokes are the
intake, compression, combustion, and exhaust.
This completes the information for part. If you have

any questions, ask the instructor.

INFORMATION SHEET
PART IV OBJECTIVE 3.1.4

Operation of Pumps
INTRODUCTION
Pumps are used to move liquids from one place to

another through pipes. Pumps are made of different
materials in different sizes and shapes. They have
different construction and operating features to meet
different needs. In this part, we will discuss the
three types of pumps most commonly used in the
plants. These are centrifugal, rotary, and
reciprocating pumps.
CENTRIFUGAL PUMPS
Centrifugal pumps operate on the principle of

centrifugal force. Centrifugal force is a spinning
force that tends to move a body away from the
center of a circle.
DISCHARGE
OUTLET
A centrifugal pump uses
centrifugal force to push fluids
DISCHARGE HOUSING
through a pipe. There are FLANGE
SHAFT
many different types of
centrifugal pumps. But they
all have the same basic parts, IMPELLER
SUCTION
and they all work on the same FLANGE
basic principle.
Figure 26 shows a centrifugal SUCTION

INLET
pump with one impeller.
Figure 26
Simple Centrifugal Pump
Module 3.1 FigureJanuary

26 2012 35
Simple Centrifugal Pump
PCST
Module 3.1
INFORMATION SHEET
Major Parts
Suction Inlet
Liquid enters the pump through the suction inlet,

Upstream and Downstream
– upstream is where the flow the upstream side of the pump. The pipe that
is coming from, downstream is carries the liquid is bolted or screwed to the
where the flow is going.
suction flange.
Impeller and Shaft
The impeller, which is mounted on a shaft, moves

the liquid through the pump. A motor or engine
connected to the shaft drive the impeller.
There are three types of impellers. The type used

depends upon the pump size, type of liquid that is
pumped, and the required discharge pressure.
Housing
The housing encloses the

DISCHARGE
rotating parts of the pump.
OUTLET The most common type of
STUFFING BOX
pump is the single-suction,
single-volute pump, which is
SHAFT
shown in figure 27.
HOUSING
The volute is the spiral

shaped part of the housing
that is around the impeller.
The volute gathers the liquid
SEALS
and directs it to the outlet.
SUCTION
INLET
IMPELLER
Figure 27
Figure Parts
Major 27 of a Centrifugal Pump
Major Parts of Centrifugal Pump
PCST
Module 3.1
INFORMATION SHEET
Discharge Outlet
The discharge outlet is the downstream side of the

pump. Liquids leave the pump through the
discharge outlet.
Bearings
The rotating shaft is supported by ball bearings

which reduce vibration and allow the impeller to
rotate at high speed. Ball bearings are usually packed
with lubricating grease when they are manufactured.
Seals
All pumps develop pressure to pump liquid. The

pressurized liquid must be contained by a seal to
prevent leakage around the drive shaft. Large pumps
usually have mechanical seals while small pumps
may use a stuffing box or packing box to seal the
shaft.
In a mechanical seal, one part

rotates on the shaft while the SEAL RING STATIONARY FACE SEAL
COVER
COOLING INLET
other part remains stationary.
Pressure between the parts
prevents leaks. A mechanical
seal is shown in figure 28. SEALING
SURFACE
SEAL RING
ROTATING FACE
SHAFT COIL SPRING
PUMP MOTOR
Figure 28
Figure 28 Mechanical Seal
Mechanical Seal
PCST
Module 3.1 Module 3.1
January 2012 37
INFORMATION SHEET
In a stuffing box or packing box, different types of

fiber material provide the seal. This is shown in
figure 29.
Figure 29
Figure 29
Stuffing Box Seal
Stuffing Box Seal
PCST
Module 3.1
Packing always has a small amount of leakage. In
some pumps, a small amount of leakage is
acceptable. However, it would be dangerous to
allow liquids such as gasoline to leak. For this
reason, these pumps normally use mechanical seals.

INFORMATION SHEET
OPERATION
Single Stage Pump
A single stage centrifugal pump is shown in figure

30. Liquid enters the single-stage pump through the
suction inlet (1) and goes into the suction eye of
the impeller (2).
The centrifugal force of the impeller throws the

liquid at a high speed against the walls of the
housing. As liquid enter the narrow part of the
volute, the pressure increase. The volute directs the
liquid to the discharge outlet of the pump (3). The
spiral shape of the volute directs the pressurized
liquid out of the pump at a high speed.
3 DISCHARGE
OUTLET
2
SUCTION INLET 1
VOLUTE
Figure 30
FigureStage
Single 30 Centrifugal Pump
Single Stage Centrifugal Pump
PCST
Module 3.1

INFORMATION SHEET
Multistage Pump
A multistage pump has two or more impellers. Each

impeller is called a stage and operates the same as a
in a single stage pump. Figure 31 is a cutaway view
of a multistage pump with three impellers. All
impellers are attached to the same shaft and rotate
at the same speed.
1 8
4
5
7
2
3
6
Figure 31
Figure 31
Operation of a Multistage Centrifugal Pump
Operation of a Multistage Centrifugal Pump
PCST
Module 3.1 1. Liquid enters the pump through the suction
inlet.
2. The liquid goes into the suction eye of the

first impeller.
3. The liquid is thrown out of the impeller at a

higher pressure.
4. The pressurized liquid leaves the first stage and

goes into the suction eye of the second stage.
5. The liquid leaves the second stage at an even

higher pressure.
6. The discharge of the second stage goes into

the eye of the third stage.

INFORMATION SHEET
7. When the liquid is thrown out of the third

stage, its pressure is increased again.
8. Liquid leaves the pump through the discharge

outlet.
Each stage increases the discharge pressure of the

liquid. The greater the pressure needed, the more
stages required.
Centrifugal pumps must be primed before they are

Cavitation – the rapid
started. Primping means filling the pump with
formation and collapse of air
liquid to remove any trapped air or gas bubbles. Air bubbles in a liquid caused
or gas that is trapped inside a centrifugal pump can by the movement of an
impeller.
cause cavitation.
Cavitation causes severe vibration and may destroy

the pump bearings.
ROTARY PUMPS
Rotary pumps are positive displacement pumps.

Displacement occurs when a solid object occupies
the space of a fluid and the fluid is forced to move.
In a positive displacement pump, the moving parts
of the pump (pumping element) occupy the space
of (displace) the liquid and force the liquid out of
the pump.
There are two basic types of positive displacement

pumps, rotary and reciprocating.
In a rotary pump, a pumping element rotates on a

shaft. A volume of liquid is drawn into the pump
through the suction element. The pumping element
then displaces all of the liquid, pushing it out the
discharge outlet. The same volume of liquid that
enters the suction must leave the discharge.

INFORMATION SHEET
Major Parts
The major parts of all rotary pumps are the same.

Figure 32 shows the parts of a rotary gear pump.
DRIVEN
HOUSING GEAR
SUCTION DISCHARGE
INLET OUTLET
DRIVEN
GEAR
Figure 32
Figure 32
Major Parts of a Rotary-Gear Pump
Major Parts of a Rotary-Gear Pump
PCST
Module 3.1
Suction Inlet
Liquid enters the pump through the suction inlet

which is the upstream side of the pump.
Pumping Element/Drive Shaft
The pumping element moves liquid through the

pump and is different in the various types of
pumps.
A single drive shaft turns the drive gear. The pump

is normally driven by an electric motor connected
to the drive shaft.

INFORMATION SHEET
Housing
The housing encloses the moving parts and provides

a chamber that holds the liquid as it is pressurized
by the pumping element.
Discharge Outlet
The discharge outlet is on the downstream side and

carries the pressurized liquid away from the pump.
Operation
Rotary-Gear Pump
The pumping element consists of two gear wheels

inside the housing. The drive gear is connected to
the shaft and electric motor. The driven gear is
turned by drive gear. The close-fitting teeth are what
make the pump work. Refer to figure 30.
A specific volume of liquid is trapped between the

gear teeth and the housing. The rotation of the
gears discharges the liquid at a high speed.

INFORMATION SHEET
Screw Pump
Screw pumps are made in many different shapes

but they all operate in a very similar way. The
pumping element in a screw pump is made up of a
number of meshed screws. Figure 33 shows a screw
pump with housing and three screws.
HOUSING POWER
ROTOR
SUCTION DISCHARGE
INLET OUTLET
SCREWS
Figure 33
FigurePump
Screw 33
Screw Pump
PCST
Module 3.1
The center screw is driven by a motor. The other
screws rotate because they are meshed with the
threads of the center screw. When the center screw
rotates, all three screws turn. Liquid flows into the
pump through the suction inlet and is squeezed
along the thread toward the discharge outlet at the
center of the screw. The rotation of the screws
forces the liquid out of the pump at a high speed.

INFORMATION SHEET
Sliding-Vane Pump
ROTOR DRIVE SHAFT
The pumping element in a SUCTION DISCHARGE

INLET OUTLET
sliding-vane pump is a rotor
with sliding vanes. This is
shown in figure 34.
The rotor is slotted and each

slot is fitted with a vane that
is free to slide in and out.
SLIDING
When the rotor turns, VANES
HOUSING
centrifugal force keeps the

Figure 34
vanes against the wall of the Figure 34 Sliding Vane Pump
Sliding Vane Pump
housing. The liquid is trapped PCST
in the space between the rotor Module 3.1
vanes and the housing. The

liquid is carried from the
suction inlet to the discharge
outlet.
Lobe Pump
The lobe pump consists of

DRIVE SHAFT LOBE
two close-fitting parts called
rotors. Each rotor has three
lobes. The lobes are the
rounded ends of the two SUCTION DISCHARGE
rotating parts. This is shown INLET OUTLET
in figure 35.
PRESSURE
SEALING
AREA
In the lobe pump, the drive PRESSURE
SEALING
rotor is driven by a drive AREA
shaft. The other rotor is driven

HOUNSING ROTOR
by the drive rotor. The two
rotors fit very close together in Figure 35
Figure 35 Lobe Pump
the pump housing. As the Lobe Pump
PCST
rotors turn, liquid is drawn Module 3.1

INFORMATION SHEET
into the suction inlet and the housing fills with

liquid. As the lobes mesh in the center of the
pump, liquid is squeezed out through the discharge
outlet.
Rotary pumps have a constant rate of output. Every

time the pump rotates one full turn, a specific
amount of liquid is pumped through it. This is
important when the pump is used to supply
measured amounts of liquid.
RECIPROCATING PUMPS
Reciprocating pumps are positive displacement. The

word reciprocating means to move with a back and
forth motion. In a reciprocating pump, a piston
moves back and forth in a cylinder.
Remember, in the diesel engine, the linear (back

and forth) motion of the piston provided rotary
motion to the crankshaft. In a reciprocating pump,
the rotary motion of a drive motor provides linear
(back and forth) motion to the piston. This is
shown in figure 36.
CYLINDER
PISTON
CONNECTING
ROD
CRANK SHAFT
Figure 36
Figure 36
Reciprocating Motion
Reciprocating Motion
PCST
Module 3.1
INFORMATION SHEET
As you can see in figure 36, one end of the crank is

attached to a rotating shaft and the other is
connected to the piston. The crank changes the
rotary motion of the shaft to reciprocating motion
in the piston.
Major Parts
The single-acting and double-acting pumps have the

same basic parts. This is shown in figure 37.
HOUSING DISCHARGE OUTLET

VALVE
PISTON RINGS
PISTON
SHAFT
CYLINDER
SUCTION INLET
VALVE
Figure 37
FigureParts
Major 37 of a Single Acting Pump
Major Parts of a Single Acting Pump
PCST
Module 3.1
Suction Inlet Valve
The suction inlet valve is a spring-operated one-way

valve that allows liquid to flow into the cylinder.
Cylinder
The cylinder is made of steel or cast iron and has a

smooth, machined surface. The piston moves back
and forth inside the cylinder.

INFORMATION SHEET
Piston
The piston is cylindrically shaped and is slightly

smaller than the cylinder. The piston moves back
and forth inside the cylinder.
Discharge Outlet Valve
The discharge outlet valve is a spring-operated

one-way valve that allows flow in only one
direction, out of the cylinder.
Housing
The housing joins all working parts together.
Operation
Single-Acting Pump
A single-acting reciprocating pump uses separate

suction and discharge strokes to move liquid
through the pump. When the pump piston is
pulled out of the cylinder, it
DISCHARGE VALVE creates suction (vacuum) in
(CLOSED)
the cylinder. The suction is
strong enough to overcome
the force of the suction valve
spring. Liquid is then sucked
into the cylinder. This is
SUCTION
STROKE shown in figure 38.
SUCTION VALVE
(OPEN)
Figure 38
Suction Stroke
Figure 38
Suction Stroke
PCST
Module 3.1

INFORMATION SHEET
When the piston moves forward, the pressure of the

liquid opens the discharge outlet valve forcing the
liquid out of the cylinder into the discharge pipe.
The spring and pressure in the cylinder holds the
inlet valve closed. This is shown in figure 39.
DISCHARGE VALVE
(OPEN)
DISCHARGE
STROKE
SUCTION VALVE
(CLOSED)
Figure 39
Figure 39 Stroke
Discharge
Discharge Stroke
PCST
Module 3.1
During the suction stroke, no liquid is forced into
the discharge line which causes the discharge
pressure to fall. During the discharge stroke, liquid
forced into the pipeline raises the pressure. This
rapid change in pressure causes pulsation. To reduce
pulsation, a double-action reciprocating pump is
used.

INFORMATION SHEET
Double-Acting Pump
SUCTION
In the double-acting pump,
there is a suction and
2 discharge valve on either side
SUCTION SUCTION
1 VALVE VALVE of the piston. During each
(OPEN) (CLOSED)
stroke, the piston provides
RETURN
STROKE suction at one end and
discharge at the other. These
are forward and return strokes.
A double-acting pump is
shown in figure 40.
3
DISCHARGE DISCHARGE
4 VALVE VALVE
(OPEN) (CLOSED)
DISCHARGE
Figure 40
Figure 40
Double-Acting Pump
Double-Acting Pump
PCST
Module 3.1 The forward stroke creates suction behind and
pressure ahead of the piston. Liquid is sucked into
the piston through suction valve (1) and forced out
through discharge valve (3) and into the discharge
line.
During the return stroke, suction valve (2) is

opened and the cylinder fills with liquid. The liquid
in the cylinder from the forward stroke is forced
out of the discharge valve (4).
A double-acting pump reduces pulsing. It does not

eliminate it. When the piston changes direction,
and flow stops and pressure in the discharge line
falls slightly.

INFORMATION SHEET
exercise d
1. Pump move liquids from one place to another

through .
a. open face housings

b. inlet valves
c. variable openings
d. connecting pipes
2. Centrifugal force is a spinning force tends to

move a body away from the center of a
.
a. circle
b. triangle
c. cube
d. reciprocating pump
3. The impeller moves the liquid through the

.
a. seals
b. basic parts
c. pump
d. stuffing box

INFORMATION SHEET
4. The volute is the spiral shaped part of the

.
a. impeller
b. housing
c. stuffing box
d. outlet
5. As liquid enters the narrow part of the volute,

the .
a. pressure increases
b. pressure decreases
c. temperature decreases
d. temperature increases
6. In a multistage centrifugal pump,

.
a. pressure decreases at each stage

b. temperature decreases at each stage
c. temperature increases at each stage
d. pressure increases at each stage
7. In a positive displacement pump, the moving

parts of the pump occupy the space of the
liquid and force the .
a. liquid to compress
b. liquid through the suction valve
c. liquid out of the pump
d. liquid to expand

INFORMATION SHEET
8. In a rotary pump, the same volume of liquid

that enters the suction must leave
.
a. through centrifugal force

b. the discharge
c. suction valves
d. through the volute
9. In a reciprocating pump, the rotary motion of

the drive motor provides linear (back and
forth) motion of the .
a. rotary shaft
b. cylinder
c. piston
d. drive shaft

INFORMATION SHEET
SUMMARY
In this part, you learned that pumps are used to

move liquids from one place to another and that
they have different construction and operating
features to meet different needs. A centrifugal pump
uses centrifugal force to push fluids through a pipe
and there are many different types of centrifugal
pumps and they all work on the same basic
principle.
You also learned that there are two types of positive

displacement pumps, rotary and reciprocating. In a
positive displacement pump, the pumping element
occupies the space of the liquid and force the liquid
out of the pump. In a rotary pump, the same
volume of liquid that enters the suction must leave
the discharge and in a reciprocating pump, the
rotary motion of a drive motor provides back and
forth motion to the piston.
This completes this section. If you have any

questions, ask the instructor.

INFORMATION SHEET
PART V OBJECTIVE 3.1.5
Identify the Major Parts and Describe the

Operation of Compressors
INTRODUCTION
Compressors are used to increase the pressure of

gases and are required for several plant operations
and processes. For example, compressors provide
compressed air to operate machines, tools, and some
instruments.
They are also used to compress natural gas before

fractionation and fuel gas for turbine engines.
Centrifugal and reciprocating compressors are very

similar to the centrifugal and reciprocating pumps.
Remember, an axial compressor is used in the gas
turbine engine.
CENTRIFUGAL COMPRESSOR
A centrifugal compressor is similar to a centrifugal

pump. The compressor is usually a very large, high-
volume machine driven by large electric motor,
steam turbine, or gas turbine engine.
Centrifugal compressors operate on the principle of

centrifugal force. The amount of force depends on
the size and speed of the impeller and the mass of
the object.
Liquids can build up high pressures in a centrifugal

pump at rotational speeds from 1800 revolutions per
minute (rpm) to 3600 rpm. Gases must be rotated

INFORMATION SHEET
at speeds up to 10,000 rpm to obtain the same

pressures. For this reason, centrifugal compressors
operate at high speeds and may have many stages.
Single-Stage Compressor
The major parts of a single-stage centrifugal

compressor are shown in figure 41.
DISCHARGE
OUTLET
DIFFUSER
SHAFT
EYE
IMPELLER
SUCTION
INLET
VOLUTE
Figure 41
Figure
Part of 41
a Single-Stage Compressor
Single-Stage Compressor Major Parts
PCST
Module 3.1
Note that this is very similar to the single stage
centrifugal pump.
Suction Inlet
The suction inlet leads directly into the impeller

suction eye. The inlet is flanged so that a pipe can
be connected.

INFORMATION SHEET
Impeller/Shaft
The impeller and shaft are similar to that in a

centrifugal pump. The vanes direct gas outward
through centrifugal force. The impeller is mounted
on a shaft that is rotated by a motor or engine.
Diffuser
A diffuser is made up of small vanes, or blades that

are fixed around the walls of the volute. The vanes
change the direction of the gas thrown out of the
impeller.
Discharge Outlet
Compressed gas leaves through the discharge outlet.

The outlet is flanged so that a line can be attached.
Single-Stage Operation
A single-stage compressor has an impeller that

throws the gas outward from the impeller eye. The
gas hits a set of diffuser vanes
and changes direction as it DISCHARGE
passes through. The change of
direction decreases the speed STATIONARY
DIFFUSER
of the gas and increases its VANES
pressure.
The volute is a passageway

that gradually increases in size.
See figure 42.
ROTATING
Figure 42 IMPELLER
Operation of the Single-Impeller VOLUTE
Centrifugal Compressor

Figure 42
Operation of the Single-Impeller Centrifugal
PCST
Module 3.1
INFORMATION SHEET
As the gas pass through, it expands and the pressure

drops slightly. The pressure at the discharge outlet
is slightly lower than the pressure through the
diffuser vanes. The higher pressure gas will flow
toward the area of lower pressure. This ensures a
smooth flow of gas out of the compressor.
Multistage Centrifugal Compressor
Large centrifugal compressors are multistage to

produce higher pressures. This is the same as in
multistage centrifugal pumps. The major parts of a
multistage compressor are shown in figure 43.
DIAPHRAGMS EXHAUST
SHAFT
INTAKE
IMPELLER
LABYRINTH
SEALS
Figure 43
Figure 43
Multistage Compressor
Multistage Compressor
PCST
Module 3.1

INFORMATION SHEET
Notice that the compressor has the same parts as the

single-stage compressor, with the following additions:
o Diaphragms
o Impellers
o Labyrinth Seals
Diaphragms
The diaphragms are disc shaped parts that are

located between each impeller. Figure 44 shows the
diaphragms and impellers. The diffusers are the open
channels between the diaphragms. The diffusers
form a passage from one impeller to the next, as gas
is thrown out of one impeller, it makes a 180°
change of direction through the diffusers on its way
to the next impeller. The change of direction slows
the gas and increases its pressure.
DIAPHRAGMS
SHAFT EYE
SEAL SEAL
IMPELLERS
Figure 44
Figure 44 and Impellers
Diaphragms
Diaphragms and Impellers Cross Section
PCST
Module 3.1
INFORMATION SHEET
Impellers
The impellers rotate at the same speed. In a

compressor, a given amount of compressed gas takes
up less volume when it is discharged. For this
reason, each successive impeller is smaller than the
one before it.
Labyrinth Seals
Labyrinth seals are used to prevent leaks along the

compressor shaft. The seal consists of a series of
thin fins, or teeth. The teeth are mounted in a
stationary ring around the shaft. Most seals are
made of aluminum or brass. A labyrinth seal is
shown in figure 45.
SHAFT
LABYRINTH SEAL
Figure 45
Figure 45 Seal
Labyrinth
Labyrinth Seal
PCST
Module 3.1

INFORMATION SHEET
When the seals are first installed, they touch the

shaft. Friction causes the seals to wear and create
their own clearance.
The multistage centrifugal compressor operates the

same as the multistage centrifugal pump. This is
shown in figure 46.
1. Gas enters the compressor through the suction

inlet and goes into the suction eye of the first
impeller.
2. Centrifugal force throws the gas out of the
impeller at a high speed and pressure.
3. The gas changes direction around the
diaphragm, losing speed and increasing pressure.
4. The pressurized gas goes into the eye of the
second stage.
5. Centrifugal force again increases the speed of
the gas.
6. The change of direction slows the gas and
increase the pressure.
7. The gas enters the eye of the third impeller.
DISCHARGE
OUTLET
9
SUCTION INLET
1
4 6 8
3 5 7
IMPELLERS
Figure 46
Multistage
Figure 46 Centrifugal Compressor Operation
Multistage Compressor Operation
PCST 3.1
Module January 2012 61
Module 3.1
INFORMATION SHEET
8. Centrifugal force again increases the speed of

the gas.
9. The compressed gas leaves through the

discharge outlet.
Remember – each stage increases the pressure of the

gas. The greater the pressure needed, the more
stages required.
CAUTION
If liquid enter into a compressor it can damage
the high speed impellers.
RECIPROCATING COMPRESSORS
Reciprocating compressors operate the same as

reciprocating pumps. They use motors or engines as
drivers and the parts are very similar.
Single-Acting
SUCTION Compressor
DISCHARGE VALVE
VALVE
In the single-acting
CYLINDER compressor, gas is compressed
PISTON
on one side of the piston.
There are only two valves,
GUIDE ROD suction and discharge. This is
shown in figure 47.
The operation of the single-

CONNECTING acting compressor is the same
ROD
as the single-acting pump. The
CRANKSHAFT only difference is the unloader
which is a pressure relief valve.
OIL
Figure 47
Reciprocating Compressor
Figure 47
Reciprocating Compressor
PCST
Module 3.1
INFORMATION SHEET
Cylinder/Piston
The cylinder houses the piston. The cylinders are

normally air cooled by cooling fins which form part
of the casing.
The piston compresses the gas in the cylinder.

Pistons hold several piston rings which form a tight
seal against the cylinder wall. Pistons are driven by
connecting rods attached to a crankshaft.
Suction Valve
The suction valve is a spring-operated one-way valve
that allows gas into.
Discharge Valve
The discharge valve allows gas to flow out of the

cylinder.
Crankshaft
Transfers drive from a motor through the connecting

rod to the pistons.
Double-Acting SUCTION
Compressor
SUCTION SUCTION
CYLINDER
VALVE 2 VALVE 1
In the double-acting (CLOSED) (OPENED)
compressor, gas is compressed

on both sides of the piston. RETURN
STROKE
There are two valves on both
ends of the cylinder. This is
shown in figure 48.
DISCHARGE
VALVE DISCHARGE
(OPENED) PISTON VALVE 1
(CLOSED)
Figure 48 DISCHARGE
Double-Acting Compressor

Figure 48
Double-Acting Compressor
PCST
Module 3.1
INFORMATION SHEET
The operation of the double-acting compressor is

identical to the operation of the double-acting
pump.
Remember, the pump moves liquid and compressors

compresses gas.
Single-Stage and Two-Stage Compressors
There are single-stage and two-stage reciprocating

compressors.
Single-Stage Compressors
Single-stage compression occurs when gas is drawn

into a compressor on one stroke of the piston and
discharged on the return stroke, as shown in figure
49.
SUCTION STROKE COMPRESSION STROKE
Suction Disharge
Valve Valve
Compression
Discharge
Suction
Clearance
Space
Figure 49
Figure 49
PCST
Module 3.1
INFORMATION SHEET
Two-Stage Compressor
A two-stage compressor consists of two single stage

compressors. It is used when a very high final
pressure is required. The discharge of the first
compressor (first stage) is input to the suction of the
second compressor (second stage). See figure 50.
DISCHARGE
14.7 PSI
80° F
DISCHARGE
30 PSI
180° F AIR
INTAKE
28 PSI FIRST STAGE

100° F
INTERCOOLER
SECOND STAGE
90 PSI
220° F
Figure 50
Figure 50
Two Stage Compressors
Two Stage Compressors
PCST
Module 3.1
Look at figure 50. Notice that the discharge from
the first stage goes to an intercooler where the gas is
cooled before it is input to the second stage.
Compressing a gas raises its temperature. The gas
must be cooled before it enters the second stage.

INFORMATION SHEET
AXIAL COMPRESSOR
In an axial compressor, the flow is along the axis of

the shaft. The axial compressor is more efficient
than a centrifugal compressor.
Major Parts
The major parts of the axial compressor are the:
o Suction Inlet
o Stator
o Rotor Assembly/Shaft
o Discharge Outlet
o Bearings
o Labyrinth Seals
An axial compressor is shown in figure 51.
SUCTION DISCHARGE
INLET OUTLET
INLET STATOR BLADES

VOLUTE DISCHARGE
VOLUTE
SHAFT
LABYRINTH
SEALS
BEARINGS BEARINGS
INLET
VOLUTE ROTOR ASSEMBLY
SUCTION
INLET
Figure 51
FigureCompressor
Axial 51
Axial Compressor
PCST
Module 3.1

INFORMATION SHEET
Suction Inlet
A feeder gas line is connected to the suction inlet.
Stator
The stator has rows of stationary discs located in

front of each rotor disc. This is shown in figure 52.
ROTORS
SHAFT
STATORS
Figure 52
Figureand
Stator 52 Rotor Discs
Rotor Discs
PCST
Module 3.1
Some stator discs have fixed blades. The blades can
be turned to different angles to adjust the amount
of gas that flows into the compressor.

INFORMATION SHEET
Rotor Assembly/Shaft
The rotor assembly contains blade discs and is

mounted on a shaft. A motor or engine turns the
rotor assembly.
Discharge Outlet
The discharge outlet bearings and labyrinth seal are

shown in figure 53. The discharge outlet connects
to a line to carry compressed gas away.
DISCHARGE
OUTLET
LABYRINTH JOUNAL
SEAL BEARING
Figure 53
Discharge
Figure 53 Outlet Bearings and Labyrinth Seals
Disharge Outlet, Bearing Labyrinth Seal
PCST
Module 3.1
Bearings
Journal bearing are used in axial compressors. The

bearings need a continuous supply of lube oil. A
lube oil system lubricates the bearings.

INFORMATION SHEET
Labyrinth Seals
The seals are used to prevent lube oil leakage from

the bearings along the shaft. They also prevent
leakage of high pressure along the shaft.
Operation
Axial compressors are designed for specific operating

conditions. They are not designed for wide
variations in the flow rate. The operation of an axial
compressor is shown in figure 54.
1. Gas is sucked into the compressor by the rotor

assembly.
2. Stator blades interrupt the flow of gas and

reduce its velocity. The reduced velocity causes
a small increase in pressure. The rotor blades
speed up the flow again.
DICHARGE 4
1 INLET SUCTION OUTLET
3
2
Figure 54
Figure 54 of an Axial Flow Compressor
Operation
Operation of an Axial Compressor
PCST
Module 3.1

INFORMATION SHEET
Gas flows through the alternate rows of stator

and rotor blades. Each row of stator blades
interrupts the flow of gas, reducing the
velocity. Each time this happens, the pressure
is increased. Each row of stator and rotor
blades is smaller than the row before it. The
gas is compressed into a smaller and smaller
area as it flows through the compressor.
3. At the output of the row of blades, the gas is

at a high pressure and is hot because of
compression.
4. The gas leaves the compressor through the

discharge outlet.
Aftercoolers, cool the hot gas. When gas is cooled,

its pressure drops.

INFORMATION SHEET
exercise E
1. Compressors are used to increase the pressure

of .
a. water
b. crude oil
c. salt water
d. gases
2. Centrifugal compressors operate at high speeds

and may have many .
a. cylinder heads
b. pistons
c. stages
d. inlets
3. The volute in a centrifugal compressor is a

passageway that gradually .
a. increases in size
b. tapers at the top
c. squeezes liquids
d. meets the eye

INFORMATION SHEET
4. In a multistage centrifugal compressor, the

diaphragm is a disc shaped part located
between each .
a. stage
b. volute
c. impeller
d. suction inlet
5. Labyrinth seals consist of a series of thin

.
a. lubricating pads
b. films of oil
c. diaphragms
d. fins or teeth
6. In a reciprocating compressor, the uploader is a

.
a. exhaust valve
b. discharge valve
c. relief valve
d. connecting pipe
7. When gas is cooled, its pressure will

.
a. increase
b. remain the same
c. trip the relief valve
d. drop

INFORMATION SHEET
SUMMARY
In this part, you learned that compressors increase

the pressure of gases and that compressors are very
similar to pumps and they operate the same. Pumps
move liquids and compressors compresses gas. You
learned that centrifugal compressors operate at high
speeds and may have many stages, that in a
reciprocating compressor the piston compresses the
gas in the cylinder, and that there are single-stage
and two-stage compressors, the single-stage
compressor compresses gas one stroke of the piston
and discharged it on the return stroke.
You also learned that in an axial compressor, gas

flow is along the axis of the shaft and the axial
compressor is more efficient than the centrifugal
compressor. You learned that gas flows through the
alternate rows of stator and rotor blades and each
time this happens pressure is increased. Each row of
stator and rotor blades is smaller than the row
before and gas is forced into a smaller and smaller
area as it flows through the compressor.
This completes the information for this module. If

you have any questions, ask the instructor.

GLOSSARY
Bearing(s)
A part that supports a shaft and allows it
to rotate freely and smoothly.
Centrifugal force
The spinning force that tends to move a
body away from the center of a circle.
Governor
A device that controls the speed of an
engine.
Inject
To force a fluid into a chamber.
Stator
The stationary part of an electric motor.
The stationary blades in a turbine or
compressor.


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Trainee Handbook

Training & Development

Unit 3: Describe the Operation of Plant Equipment

Describe the Operation of Rotating Equipment

Module 3.1 January 2012 1

This module introduces four drivers that are

Lubrication is a vital part of the operation of

2 January 2012 Process Control Systems Technician

PART I OBJECTIVE 3.1.1

Identify the Major Parts, and Describe the

Electric motors are the most commonly used drivers

In this part, you will learn the major parts and

MAJOR PARTS OF AN ELECTRIC MOTOR

The major parts of an electric motor are shown in

Module 3.1 January 2012 3

The motor housing is normally made of cast iron.

When an electric motor is running, it generates

Electrical connections between the motor and

4 January 2012 Process Control Systems Technician

The stator is stationary, which means it does not

Module 3.1 January 2012 5

The rotor is the rotating part of the motor. The

BALL The ball bearings hold the shaft in

The shaft is made of steel and transfers the rotation

A magnet produces magnetic lines of force. One end

If you place the north pole of one magnet close to

If you pass electric current through a coil of wire, a

Electricity flowing through a coil generates a

With dc (direct current), the magnitude and V

direction remains the same over time. This is shown

You will learn more about ac and dc in later units. Figure 8

An alternating current (ac) is an electrical current

and then in the other. It reverses many times each

The sine wave is a representation of ac voltage and

negative alternation. Figure 9

If coil A is connected to an alternating current (ac),

Note: Only an alternating current applied to one coil can

Electromagnetic induction is a basic principle in the

COIL A (STATOR) COIL B (STATOR)

10 January 2012 Process Control Systems Technician

The ac applied to the stator produces a rotating

Almost all electric motors are protected by circuit

Module 3.1 January 2012 11

1. The most common type electric motor is the

2. In an electric motor, the stator does not

a. have coils of copper wire

3. The rotor consists of copper bars embedded in

12 January 2012 Process Control Systems Technician

4. In a motor, ball bearings are used to reduce

5. If the north pole of one magnet is placed close

6. Only an alternating current applied to one coil

7. When ac is connected to the stator winding, it

Module 3.1 January 2012 13

8. Almost all electric motors are protected by

9. When a circuit breaker trips, the electrical path

14 January 2012 Process Control Systems Technician

In this part, you learned that electric motors are the

You learned that the stator does not rotate and it is