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01

COMPRESSION & COMPRESSORS OPERATION

Md Mohiuddin
Chemist, OPTD

COMPRESSION:
The measure of volume change resulting from pressure is denoted by a word Compressibility.
Compressibility has to do with the change in density of the flow. Generally a fluid in which
significant density variations occur during its flow have to be considered as compressible fluid, as is
usually the case with vapors and gases. Compression is defined as increasing the pressure and density
of compressible fluid (either gas or vapor and can have a wide molecular weight range) by decreasing
the volume.

TYPES OF COMPRESSION
Adiabatic Compression
The Compression at which no heat is removed or added during the
process is called adiabatic compressor.

Isothermal Compression
The Compression at which heat is removed or reduced through inter
stage cooler is called isothermal compression.

THEORY OF COMPRESSION
The perfect gas equation derived from Charles’ and Boyle’s laws
makes it possible to determine the weight of a given gas as determined by the equation
PV = NRT

In reality, all gases deviate from the ideal gas laws to some degree. This deviation is defined as a
compressibility factor, z, applied as a multiplier to the basic formula. Therefore, including the
compressibility factor the relation is as shown next.
PV = zNRT

Where, p = pressure, v = volume, N = number of mole, R = molar gas constant, T = temperature

Gas compression can be expressed in terms of pressure and temperature variation as

PVK = constant, i.e., P1V1K = P2V2K

A compression process typically following this pressure volume relation is known as polytropic
process. In this case changes in gas characteristics during compression are considered. Here, K is
polytropic exponent. Under constant temperature with a unit value of K the process under ideal gas
law considered as an isothermal process. Generally dynamic compressors follow this relation.
The process considered ideal gas law and follow the relation, K = γ, is known as adiabatic process.
In adiabatic process, temperature rises. The expression form temperature rise is derived as follows:
T2/T1 = (P2/P1) γ -1)/γ

Where, suction temperature and pressure is T1 and P1 and same for discharge is T2 and P2.

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The ratio of the specific heats γ = CP/CV is a factor in adiabatic engine processes and in determining
the speed of sound in a gas. This ratio γ = 1.66 for an ideal monoatomic gas and γ = 1.4 for air, which
is predominantly a diatomic gas.
During compression, the speed of the gas molecule also increases which causes an increasing in gas
temperature. The amount of temperature increases depends on the nature of the gas (fluid), the suction
temperature and the amount of compression ratio.

Discharge pressure
__________________________________
Compression ratio =
Suction pressure

COMPRESSOR
Compressor is a mechanical device that does work to increase the pressure of compressible fluid (gas
or vapor) by reducing its volume. The inlet and outlet pressure are related corresponding with the
type of compressor and its configuration. Compressors are similar to pumps: both increase the
pressure on a fluid and both can transport the fluid through a pipe. As most gases are compressible,
the compressor also reduces the volume of a gas. Liquids are relatively incompressible.
Compressor are commonly used in the process industries and gas transport or distribution industries;
Typical application include:

• Ammonia plant : Feed gas, Synthesis gas, Refrigeration and Air compression
• Urea plant : CO2 compression
• Refining : Hydrocracking, Hydrogen make up, recycle, air services etc;
• Air separation : Nitrogen feed, recycle and air services
• Oil production : Gas lift and reinjection
• Gas production : Gathering, Liquid production, Pipe line boosting services.
• Refrigeration & AC: Apply constriction energy to refrigerant vapor

IMPORTANT TERM OF A COMPRESSOR SYSTEM:

• Driving unit as Motor or Turbine
• Source/Receive system
• Suction/Discharge
• Lube oil/seal oil system
• Inter-stage cooling system
• Seal/Bearing
• Casing
• Filtration system
• Control logic
• Startup/Shutdown Fig: Main parts of reciprocating Air Compressor
• Troubleshooting

Operation and Process Technology Department, Polash, Narsingdi-1611

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Fig: Schematic control logic of a Compressor system

WORKING PRINCIPLE: Compressors work on either any of the following principles :

Positive displacement principle : Pressure is increased by physically squeezing the volume of gas.
Compressors working on this principle are known as positive displacement compressors e.g.
Reciprocating compressor, Screw compressor, Rotary compressor etc.

Turbo / Hydrodynamic principle : Pressure is increased by increasing speed of gas molecules

applying inertial forces to the gas by means of rotating bladed impellers. Compressors working on
this principle are known as Dynamic compressor.

CLASSIFICATION OF COMPRESSOR:

Reciprocating-Piston/Plunger-Single/Double acting or Diaphram

Positive Displacement
Rotary: Lobe/Screw type-Single/Multi Rotor
Compressor

Dynamic-Centrifugal (Radial/Mixed/Axial)-Single/Multistage

CONSTRUCTION AND WORKING PRINCIPLE OF COMPRESSOR

ROTARY COMPRESSOR

A. Screw Compressor
❖ Main Components
― Casing
― Screws or Rotors
― Gear Timer
― Bearings
― Seals

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❖ Working Principle
 Due to the rotation of screws takes place, the fluid enters from the suction port and trapped
between the casing and screws.
 The rotating screws displace the fluid.
 When the discharge port becomes open, the working fluid becomes pressurized by the
backpressure of already discharged fluid.
 For further rotation of the screws and displacement of the fluid towards discharge port the
volume of the fluid is reduced and increase pressure.

B. Lobe Compressor

❖ Main Components
― Casing, Lobes or Rotors, Gear Timer
Bearings, Seals

❖ Working Principle
 Due to the rotation of lobes takes place, the fluid enters
from the suction port and trapped between the casing and lobes.
 The rotating lobes displace the fluid.
 When the fluid falls into the discharge port, it becomes pressurized by the backpressure of
already discharged fluid.
 For further rotation of the lobes and displacement of the fluid towards discharge port the
volume of the fluid is reduced and increase pressure.

C. Vane Compressor

❖ Main Components
― Casing, Rotor with sliding vane
Spring, Bearings, Seals

❖ Working Principle
 Eccentrically fitted rotor when rotates, the vane
moves outward due to centrifugal force.
 When a pair of vanes passes the suction port, the
fluid enters and is trapped between the casing and pair of vanes.
 The fluid is displaced to the discharge port by the rotation of the rotor.
 When the fluid falls into the discharge port, it becomes pressurized by the backpressure of
already discharged fluid.

❖ Sealing System
 Usually mechanical seal, Oil film seal, Labyrinth seal are used in rotary type compressors.

Operation and Process Technology Department, Polash, Narsingdi-1611

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❖ Lubrication System
 In rotary compressor, usually, manual lubrication system, bath lubrication system etc. are
normally used.
 But in oil-flooded screw compressor oil is injected directly into the compressor intake. (at a
rate of 0.25 to 0.50 gpm)
 The discharge gas stream is a mixture of oil and gas (at 185° to 200°F) flowing into a series
of separators and filters which reduces the oil content. ( to around 2 ppm).

RECIPROCATING COMPRESSOR

 To and fro motion of the piston in the cylinder plays vital role for compression of the fluid.
❖ Main Components
― Casing ― Crank Shaft
― Cylinder ― Cylinder Liner
― Piston ― Piston Ring
― Piston Rod ― Connecting Rod
― Cross Head ― Cross Head Guides
― Compressor Ring Oil Spacer Ring
― Gland ― Gland Packing
― Bearing ― Valves (Suction/Discharge)

❖ Working Principle
 It consists of a mechanical arrangement where reciprocating motion is transmitted to a piston.
 The piston is free to move within the cylinder.
 When intake cycle takes place, the discharge valve becomes closed, the suction valve
becomes open and fluid enters into the cylinder.
 When the piston moves back, suction valve gets closed and discharge valve remains closed,
the volume of the fluid within the cylinder is reduced and the pressure is increased.
 When discharge cycle takes place, the suction valve remains closed, the discharge become
open and fluid with increased pressure is discharged.

Sealing System
 Compressor packing ring:
❖ It consists of one or more rings contained within a case that is typically bolted to that
head. Packing may be as basic as one ring in a case, or it may be an assembly
consisting of a number of different type rings in a case that might have provision for
lubrication, venting, purging, cooling, static sealing, temperature and pressure
measurement.
Operation and Process Technology Department, Polash, Narsingdi-1611
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❖ A typical compressor packing consists of a series of seal rings in which each ring is meant
to stop or restrict flow of gas to atmosphere or out in to the distance piece. The rings are
held in separate grooves or cups within a packing case free to move laterally.

❖ Lubrication System
 Generally, two types of systems are uses to lubricate the positive displacement compressors.
➢ Splash lubrication system & Forced feed lubrication system

CENTRIFUGAL COMPRESSOR

 Due to rotation of the shaft/rotor

assembly, centrifugal force plays vital
role for compression of the fluid.

❖ Main Components
― Casing, Bearings, Seals
― Rotor Assembly
• Shaft, Impeller
• Thrust Collar, Balance Drum
• Axial vibration/ position measuring Disc
― Diaphragm with Diffuser

❖ Working Principle
 When rotation takes place, due to centrifugal force the impeller throws its fluid with a high
velocity to outward direction.
 After the impeller, the fluid passes through the diaphragm/ diffuser, which continuously
changes the direction of the fluid.
 As a result, kinetic energy (velocity) is converted into potential energy (pressure). At the same
time the impeller becomes empty, fluid gets into the impeller through the impeller eye.
❖ Sealing System
In centrifugal compressor sealing system is essential:
 For gland sealing (front and rear) usually labyrinth seal, oil film seal and dry gas seal used.
 For inter stage sealing, labyrinth seal is used.
 For impeller eye caller sealing, labyrinth seal is used.
 For balance drum seal, labyrinth seal is used.
❖ Lubrication System
All centrifugal compressors require lubrication system. It is a high speed machine so force
feed lubrication system is normally used.

Operation and Process Technology Department, Polash, Narsingdi-1611