Compressors

DELIVERING KNOWLEDGE. DEVELOPING COMPETENCE.
Compressors
Section 7
2011 Dr. Omar Barkat & PetroSkills, LLC. All rights reserved.
Field Compression Station
Compressors
Increase Pressure of Gas
By Decreasing Volume
|
+
T
V
P

T
P
V
Compression Ratio
R
T
= Overall Compression Ratio
P
d
= Discharge Pressure, psia
P
s
= Suction Pressure, psia
r = Compression Ratio Per Stage
(Sometimes Denoted as R or R
s
)
n = Number of Stages
T d s
R = P / P
( )
1/n
d s
r = P / P
Temperature Increase
k = Isentropic Coefficient (Heat Capacity Ratio)
T
d
= Discharge Temperature R
T
s
= Suction Temperature R
MC
p
= Molar Heat Capacity
Constant Pressure, BTU / # mol / R
a - Depends on the Type of Compressor
a = 1.0 for Reciprocal (Positive Displace)
a = 1.25 for Centrifugal
( )
( ) a k-1

k
d s
T = T r
( )
p
p
MC
k =
MC - 1.99
Thermodynamic
Property of Gas
Molar Heat Capacity: MC
p
Gas
Chemical
formula
Mol
wt 0F 50F 60F 100F 150F 200F 250F 300F
Methane CH
4
16.042 8.233 8.414 8.456 8.651 8.947 9.277 9.638 10.010
Ethyne (Acetylene) C
2
H
2
26.036 9.683 10.230 10.330 10.710 11.130 11.540 11.880 12.220
Ethene (Ethylene) C
2
H
4
28.052 9.324 10.020 10.160 10.720 11.400 12.080 12.750 13.140
Ethane C
2
H
6
30.068 11.44 12.170 12.320 12.950 13.770 14.630 15.490 16.340
Propene (Propylene) C
3
H
6
42.078 13.63 14.690 14.900 15.750 16.800 17.850 18.870 19.890
Propane C
3
H
8
44.094 15.64 16.880 17.130 18.170 19.520 20.890 22.250 23.560
1-Butene (Butylene) C
4
H
8
56.104 17.96 19.590 19.910 21.170 22.710 24.250 25.700 27.150
cis-2-Butene C
4
H
8
56.104 16.54 18.040 18.340 19.540 21.040 22.530 24.000 25.470
trans-2-Butene C
4
H
8
56.104 18.84 20.020 20.500 21.610 22.990 24.370 25.720 27.060
iso-Butane C
4
H
10
58.120 20.40 22.150 22.500 23.950 25.770 27.590 29.390 31.110
n-Butane C
4
H
10
58.120 20.80 22.380 22.710 24.070 25.810 27.540 29.230 30.900
iso-Pentane C
5
H
12
72.146 24.93 27.160 27.610 29.420 31.660 33.870 36.030 38.140
n-Pentane C
5
H
12
72.146 25.64 27.610 28.010 29.700 31.860 33.990 36.070 38.120
Benzene C
6
H
6
78.108 16.41 18.380 18.750 20.460 22.460 24.460 27.080 29.710
n-Hexane C
6
H
14
86.172 30.17 32.780 33.300 35.360 37.910 40.450 42.910 45.360
n-Heptane C
7
H
16
100.198 34.96 38.000 38.610 41.010 43.970 46.930 49.770 52.600
Ammonia NH
3
17.032 8.516 8.5180 8.519 8.521 8.523 8.525 8.527 8.530
Air 28.966 6.944 8.9510 6.952 6.960 6.973 6.990 7.009 7.033
Water H
2
O 18.016 7.983 8.0060 8.010 8.033 8.075 8.116 8.171 8.226
Oxygen O
2
32.000 6.970 6.9970 7.002 7.030 7.075 7.120 7.176 7.232
Nitrogen N
2
28.016 6.951 6.9540 6.954 6.956 6.963 6.970 6.984 6.998
Hydrogen H
2
2.016 6.782 6.8560 6.871 6.905 6.929 6.953 6.965 6.977
Hydrogen sulfide H
2
S 34.076 8.000 8.0910 8.109 8.180 8.270 8.360 8.455 8.550
Carbon monoxide CO 28.010 6.852 6.9570 6.958 6.963 6.975 6.986 7.007 7.028
Carbon dioxide CO
2
44.010 8.380 8.6980 8.762 9.004 9.282 9.559 9.810 10.050
Too Hot is Too Bad
Pressure Rating of Steel Derated at T > 250F
Non-Metallic Compressor Parts (Packing /
Seals) Fail at 250 to 300F
Steel in Compressor OK to 350F
Limit Temperature to < 300F
Fin Fan Cooler
T
IN
T
OUT
t
IN
t
OUT
Fin Fan Coolers
T
i
= Gas Inlet Temperature T
o
= Gas Outlet Temperature
t
i
= Ambient Air Temperature t
o
= Outlet Air Temperature
Approach Temperature: Discharge Gas Temperature Versus
Inlet (Ambient) Air Temperature
Designed to Get Within 10F
Usually Can Reach Within ~ 20
If Air Temp < 100F, Gas can be Cooled to 115 120F so Comp Ratio 3.5
OK
Sophisticated Coolers
Variable Air Exhaust Vanes (Louvers)
Operated Manually or Pneumatically Based on T
o
Water Cooling Towers Sometimes Added
Hot Climates: T
air
> 105F to 140F: Consider Limiting
Compression Ratio to 2.5 3.0
Suction Scrubbers and Interstage Scrubbers
Liquid Must be Removed Prior to
Compression
Close Clearance Between Piston and Cylinder
Cooling Liquids: Add Scrubber
Scrubber:
Single Phase Separator
No Internal Devices
First Scrubber: Suction Scrubber
Others: Interstage Scrubbers
Compressor Flow Diagram
Solution: Compressors Exercise
Produced Gas Compressed from Suction P of 25 psia
to a Sales Line Pressure of 1000 psia.
Determine Number of Stages Required
Compress Ratio of Each Stage = (40) 1/n
for 1 stage: n = 1 (40) 1 = 40
for 2 stages: n = 2 (40) = 6.32
for 3 stages: n = 3 (40) 1/3 = 3.42
1000 psia
Overall Compression Ratio = 40
25 psia
Compressor Flow Diagram: Shrinkage
Using a 2.2 compression ratio results in the following pressures if No AP between Stages:
(50 psig) 64.7 psia 142 psia 313 psia 689 psia 1515.7 psia (1500 psig)
If Shrinkage Due to Cooling and Scrubbing Decreases Volume 3% between stages:
(50 psig) 64.7 psia 142 psia 138 304 295 648 629 1383 1341 (1327 psig)
Final Pressure Too Low: Therefore INCREASE Compression Ratio ~ + 3%
Illustrate Your Compression Flow Scheme:
Compressor Skid
Types of Compressors
Positive Displacement
Type
Dynamic Type
Continuous Flow
Thermal
Type
Reciprocating Ejectors Rotary Axial Flow
Radial Flow
(Centrifugal)
Mixed Flow
HIGH VELOCITY
JET
Entrains
Inflow Gas
PISTON - CYLINDER CASE Rotating Element
HIGH SPEED
SLOW SPEED
Straight Lobe
Helical Lobe
(Screw)
Sliding Vane
Liquid-Ring
Diaphragm
Type
Dynamic Type
Continuous Flow
Thermal
Type
Radial Flow
(Centrifugal)
Mixed Flow
HIGH VELOCITY
JET
Entrains
Inflow Gas
HIGH SPEED
SLOW SPEED
Straight Lobe
Helical Lobe
(Screw)
Sliding Vane
Liquid-Ring
Diaphragm
Reciprocating Compressor
POSITION 1 POSITION 2
POSITION 3 POSITION 4
Two Stage Compression
Volume Reduction due to
Cooling and Scrubbing
between stages
Integral Reciprocating Compressor
(Usually Slow Speed: 200 to 600 rpm)
Slow Speed Reciprocating Compressors
Slow Speed (200 to 600 rpm) Integral
Size:
Common 2000 to 4000 BHP (Up to 15,000)
(Very Slow Speed: 140 to 360 BHP Skid Mounted)
2 to 10 Cylinders are Common
Flowrates up to 5 Mmacfd
20 psi to 30,000 + psi
( > 5000 psi Requires Special Design)
Advantages:
Reliability 99% Up Time
Efficient Over Wide Range (90%)
Long Operating Life 10 yrs Without Overhaul
30 to 40 +Year LIFE
High Flowrates and Pressures
Cheaper than Centrif if BHP < 2000
Disadvantages:
High Initial Cost
Large, Difficult to Move
Large, Solid, Heavy Foundation
Vibration and Pulsation Dampening
Cannot Handle Liquids
Commonly Used in Plants and on Transmission Lines
High Speed Reciprocating Compressors
High Speed: 900 to 1200 RPM Separable
Size:
1 to 2000 BHP
2, 4, 6 Cylinders are Common
0 psi to 2000 psi P
d
Rates up to 5 MMacfd
Advantages:
Can be Skid Mounted
Self Contained, Easily Moved
Lower Initial Cost
Flexible Capacity Range
Disadvantages:
Only 95% Up Time
Daily Maintenance
4 to 6 Years Between Overhauls
25 Year Life
Separable: Compressor Frame Coupled to Driver
Type
Dynamic Type
Continuous Flow
Thermal
Type
Radial Flow
(Centrifugal)
Mixed Flow
HIGH VELOCITY
JET
Entrains
Inflow Gas
HIGH SPEED
SLOW SPEED
Straight Lobe
Helical Lobe
(Screw)
Sliding Vane
Diaphragm
Straight Lobe Rotary Compressor
Suction Pressure Discharge Pressure
Screw Compressor
Screw Compressor
Screw Compressor
Sliding Vane Rotary
Sliding Vane Rotary
No Valves
Ports Sized When Made
Size: 50 to 500 BHP
Mostly < 125 BHP
P
d
Up to 400 psi
Usually < 200 psi)
Rates Up to 4 Mmacfd
Advantages:
Good Vacuum Service
No Pulsation
Smaller Space / Weight
Inexpensive for Vapor Recovery
Disadvantages:
Clean Gases Only
Uses 10 x Oil vs. Reciprocating
(Use After Cooler and Separator to Recycle)
Sliding Vane Rotary Compression
Excellent for Vapor Recovery Unit
Type
Dynamic Type
Continuous Flow
Thermal
Type
Radial Flow
(Centrifugal)
Mixed Flow
HIGH VELOCITY
JET
Entrains
Inflow Gas
HIGH SPEED
SLOW SPEED
Straight Lobe
Helical Lobe
(Screw)
Sliding Vane
Liquid-Ring
Diaphragm
Axial Flow Dynamic Compressor
Gas Flow through the
Stators and Rotors
Axial Compressors Blades
SINGLE STAGE BLADES
MULTI-STAGE BLADES
Axial Flow Dynamic Compression
Gas Flows Parallel to Shaft
Energy Transferred by Row of Blades
One Set Rotates
One Set Stationary
High Flowrate High Speed
(No Vortex Action)
Rates Up to 1 BaCFD
Low P
d
< 100 psig
Axial Flow Dynamic Compressor
Type
Dynamic Type
Continuous Flow
Thermal
Type
Radial Flow
(Centrifugal)
Mixed Flow
HIGH VELOCITY
JET
Entrains
Inflow Gas
HIGH SPEED
SLOW SPEED
Straight Lobe
Helical Lobe
(Screw)
Sliding Vane
Liquid-Ring
Diaphragm
Centrifugal Compressors
Radial Flow
G
a
s

O
U
T
Gas IN
Compressor
Electric Motor
Gear Box
Single-Stage Centrifugal Compressor
Centrifugal Surge
Centrifugal Choked Flow
Type
Dynamic Type
Continuous Flow
Thermal
Type
Radial Flow
(Centrifugal)
Mixed Flow
HIGH VELOCITY
JET
Entrains
Inflow Gas
HIGH SPEED
SLOW SPEED
Straight Lobe
Helical Lobe
(Screw)
Sliding Vane
Liquid-Ring
Diaphragm
Ejector Compressors
Forces High Pressure Gas Through Nozzle
Creates High Pressure Jet Across Suction
Kinetic Energy (Velocity) Converted to
Pressure Inside Diffuser
Main Use: Compress from Vacuum to Small
Positive Pressure
MAIN USE: Compress from Vacuum to Small Positive Pressure
Capacity Control Reciprocating
Problem: Less Gas Available than Required
Control Mechanisms
Reduce Driver Speed
Recycle a Portion of the Gas
(Often Used on Start-up)
Valve Lifters (Unloaders)
Alter Clearance
Variable Clearance Cylinder Heads
Cylinder Head Pocket (with Fill Plug)
Clearance Unloaders
Auto Pockets
Mechanical Adjustment
Automatic StartStop Control: < 100 BHP
Step Control: > 100 BHP
Reciprocating Compressor Control
Problem: Capacity More than Needed
Variable Volume
Clearance
Reciprocating Compressor Control
Auto-
Pocket
Volume Bottle Sizing Methods
1. Consult Manufacturer or Design Engineering Firm
2. Estimate by Following Rule of Thumb:
a) Calculate Displacement Volume of Single Stroke = V
d
b) Choose Suction Bottle Volume = (V
d
) x (Suction Multiplier)
c) Choose Discharge Bottle Volume = (V
d
) x (Discharge Multiplier)
Estimate Multipliers from Chart below
If More than One Cylinder is Connected to a Single Bottle: Sum
the Displacement Volumes
Compressor Brake Horsepower
Rule of Thumb Method
BHP = 22 (R Per Stage) (# of Stages) (MMsCFD) F
F Corrects for Interstage Cooling
= 1.00 for Single Stage
= 1.08 for Two Stage
= 1.10 for Three Stage
Centrifugal Compressors: Add ~ 18%
High Speed Compressors May Require Up to 20%
More BHP
(Check with Manufacturer)
r < 2.5 and SG
g
> .65 Will Require Less BHP
Use 20 vs. 22 if SG > .8
Use 17 vs. 22 if r < 2.0
Compressor Selection Guide
Centrifugal Advantages
Lower Installed Cost
Lower Maintenance Expense
Great Dependability and Uptime
Less Operating Attention
Greater Capacity for Size and Weight
Can Couple with High Speed Low
Maintenance Drivers
Not for Low Q and High P
Reciprocating Advantages
Greater Range of Capacities and Pressures
Low Q even with High P
More Efficient
Lower Power Cost
Can Deliver Higher Pressure
(30,000 psi vs. 10,000 psi)
Can Handle Low Flowrate
Flexible with Changing Gas Compositions
Appendices 7
Section 7
Appendix 7A
Reciprocal Compressor
Parts and Valves
Other Considerations
Reciprocating Compressors: TroubleShooting
Trouble Probable Cause(s) Trouble Probable Cause(s)
Compressor Will Not
Start
1. Power supply failure.
2. Switchgear or starting panel.
3. Low oil pressure shut down switch.
4. Control panel.
Packing
Overheating
1. Lubrication failure.
2. Improper lube oil and/or insufficient lube rate.
3. Insufficient cooling.
Excessive Carbon
on Valves
1. Excessive lube oil.
2. Improper lube oil (too light, high carbon residue).
3. Oil carryover from inlet system or previous stage.
4. Broken or leaking valves causing high temperature.
5. Excessive temperature due to high pressure ratio
across cylinders.
Motor Will Not
Synchronize
1. Low voltage.
2. Excessive starting torque
3. Incorrect power factor.
4. Excitation voltage failure.
Low Oil Pressure 1. Oil pump failure.
2. Oil foaming from counterweights striking oil
surface.
3. Cold oil.
4. Dirty oil filter.
5. Interior frame oil leaks.
6. Excessive leakage at bearing shim tabs and/or
bearings.
7. Improper low oil pressure switch setting.
8. Low gear oil pump by-pass/relief valve setting.
9. Defective pressure gauge.
10. Plugged oil sump strainer.
11. Defective oil relief valve.
Relief Valve
Popping
1. Faulty relief valve.
2. Leaking suction valves or rings on next higher
stage.
3. Obstruction (foreign material), rags), blind or valve
closed in discharge line.
High Discharge
Temperature
1. Excessive ratio on cylinder due to leaking inlet
valves or rings on next higher stage.
2. Fouled intercooler/piping.
3. Leaking discharge valves or piston rings.
4. High inlet temperature.
5. Fouled water jackets on cylinder.
6. Improper lube oil and/or lube rate.
Noise in Cylinder 1. Loose piston.
2. Piston hitting outer head or frame end of cylinder.
3. Loose crosshead lock nut.
4. Broken or leaking valve(s).
5. Worn or broken piston rings or expanders.
6. Valve improperly seated/damaged seat gasket.
7. Free air unloader plunger chattering.
Frame Knocks 1. Loose crosshead pin, pin caps or crosshead
shoes.
2. Loose/worn main, crankpin or crosshead bearings.
3. Low oil pressure.
4. Cold oil.
5. Incorrect oil.
6. Knock is actually from cylinder end.
Excessive Packing
Leakage
1. Worn packing rings.
2. Improper lube oil and/or insufficient lube rate (blue
rings).
3. Dirt in packing.
4. Excessive rate of pressure increase.
5. Packing rings assembled incorrectly.
6. Improper ring side or end gap clearance.
7. Plugged packing vent system.
8. Scored piston rod.
9. Excessive piston rod run-out.
Crankshaft Oil Seal
Leaks
1. Faulty seal installation.
2. Clogged drain hole.
Piston Rod Oil
Scraper Leaks
1. Worn scraper rings.
2. Scrapers incorrectly assembled.
3. Worn/scored rod.
4. Improper fit of rings to rod/side clearance.
Gas Processors Suppliers Association Courtesy of Ingersoll-Rand Co.
Centrifugal Compressors: Trouble Shooting
Trouble Probable Cause(s) Trouble Probable Cause(s)
Low Discharge
Pressure
1. Compressor not up to speed.
2. Excessive compressor inlet temperature.
3. Low inlet pressure.
4. Leak in discharge piping.
5. Excessive system demand from
compressor.
High Bearing Oil
Temperature
Note:
Lube oil temperature
leaving bearings
should never be
permitted to exceed
180F.
1. Inadequate or restricted flow of lube oil to
bearings.
2. Poor conditions of lube oil or dirt or gummy
deposits in bearings
3. Inadequate cooling water flow lube oil
cooler.
4. Fouled lube oil cooler.
5. Wiped bearing.
6. High oil viscosity.
7. Excessive vibration
8. Water in lube oil.
9. Rough journal surface.
Compressor Surge 1. Inadequate flow through the compressor
2. Change in system resistance due to
obstruction in the discharge piping or
improper valve position.
3. Deposit buildup on rotor or diffusers
restricting gas flow.
Excessive Vibration
Note:
Vibration may be
transmitted from the
coupled machine. To
localize vibration,
disconnect coupling
and operate driver
alone. This should help
to indicate whether
driver or driven
machine is causing
vibration.
1. Improperly assembled parts.
2. Loose or broken bolting
3. Piping strain.
4. Shaft misalignment.
5. Worn or damaged coupling.
6. Dry coupling (if continuously lubricated
type is used).
7. Warped shaft caused by uneven heating or
cooling.
8. Damaged rotor or bent shaft.
9. Unbalanced rotor or warped shaft due to
severe rubbing.
10. Uneven build-up of deposits on rotor
wheels, causing unbalance.
11. Excessive bearing clearance.
12. Loose wheel(s) (rare case).
13. Operating at or near critical speed.
14. Operating in surge region.
15. Liquid slugs striking wheels.
16. Excessive vibration of adjacent machine
(sympathetic vibration).
Low Lube Oil
Pressure
1. Faulty lube oil pressure gauge or switch.
2. Lowlevel in oil reservoir.
3. Oil pump suction plugged.
4. Leak in oil pump suction piping.
5. Clogged oil strainers or filters.
6. Failure of both main and auxiliary oil
pumps.
7. Operation at a low speed without the
auxiliary oil pump running (if main oil pump
is shaft-driven).
8. Relief valve improperly set or stuck open.
9. Leaks in the oil system.
10. Incorrect pressure control valve setting or
operation.
11. Bearing lube oil orifices missing or plugged.
Shaft Misalignment 1. Piping strain.
2. Warped bedplate, compressor or driver.
3. Warped foundation.
4. Loose or broken foundation bolts.
5. Defective grouting.
Water in Lube Oil 1. Condensation in oil reservoir.
2. Leak in lube oil cooler tubes or tube-sheet.
Gas Processors Suppliers Association
Comparison of Characteristics of Compressors
for Oilfield Service
TYPE OF COMPRESSOR -- >> ROTARY
VANE
ROTARY
SCREW
RECIPROCATING CENTRIFUGAL
1 STAGE MULTI STAGE 1 STAGE MULTI STAGE
COMMON APPLICATIONS VAPOR
RECOVERY
VAPOR
RECOVERY
GENERAL
HIGH PRESSURE
GENERAL
HIGH VOLUME
DISCHARGE PRESSURE, PSIG
COMMON 5 TO 50 < 100 < 2,000 (a)
MAXIMUM < 400 < 250 < 200 < 15,000 < 1,500 < 8,000 (b)
ACTUAL CUBIC FEET < 1,000 < 20,000 < 1,000 < 2,000 < 100 < 500
PER MINUTE < 1,000 < 20,000 (b)
< 100,000 (a)
HORSEPOWER
COMMON < 125
MAXIMUM < 500 < 400 < 12,000 < 20,000
SMALL for HC 50 TO 150 TO 350 STARTS AT 500
LARGE < 250 2,000 TO 4,000 PARITY AT 2,000
CAN HANDLE LIQUIDS MODERATE ABSOLUTELY NOT
CAN HANDLE DIRTY GAS NO YES
LUBRICATION COOLER YES YES
EFFICIENT -20% DP < 50 STANDARD FOR EFFICIENCY LOWER EFFICIENCY
FLEXIBLE LOW TO OPERATING CHANGES LIMITED FLEXIBILITY
Reciprocating Compressor Gas Throughput
E
V
=Volumetric Efficiency (%)
PD =Piston Displacement (cfm)
Where C =Cylinder Clearance (%)
Piston Displacement: One of the Following
(Configuration)
Single Acting Cylinder (Head End Displacement)
Single Acting Cylinder (Crank End Displacement )
Double Acting Cylinder (E Crank and Head Ends)
Where d
c
=diameter of cylinder, inches
d
r
=diameter of rod, inches
( )
MMCF v s s s
Q = .051 E PD P / T Z
| | ( ) ( )
(

1/k
v d s d s s d
E = 96 - P / P - C P / P Z / Z -1
2
c in rpm
PD = d L S / 2200
( )
2 2
c r in rpm
PD = d - d L S / 2200
| |
2 2
c r in rpm
PD = 2d - d L S / 2200
Appendix 7B
Compressor Exercises and Calculations
Discharge Temperatures
Volume Bottle Sizing
Number of Stages
Approximate Heat Capacity Ratios
of Hydrocarbon Gases
(MW = 28.96
Specific Gravity)
(MW = 28.96 x
Specific Gravity)
What is the
heat-capacity ratio (k)
for 0.69 gravity
Natural gas at 250
o
F?
(MW = 28.96 x
Specific Gravity)
What is the heat-
capacity ratio (k) for
0.69 gravity Natural
gas at 250
o
F?
MW = 28.96 x 0.69 = 20
k = 1.21
Most Oilfield Applications
Compressor Discharge Temperature: Exercise #1
Overall Problem:
Methane is Compressed from 250 psig to 600
psig, using a reciprocal compressor.
If the Suction Temperature is 100F, What is
the Discharge Temperature?
( )
( ) a k-1 /k
d s
T = T r
Compressor Discharge Temperature #1
Methane Compressed: 250 psig to 600 psig. T
s
= 100F
What is the T
d
?
Problem Broken Down Into Steps:
What is the Comp Ratio? (Remember: psia = psig + 14.7)
Determine k from k vs. Mol Wt Graph: FIGURE A page 10 2
(Mol Wt of Methane = 16.042)
Alternate Method: Determine k from Formula (MC
p
= 8.651)
What is (k-1) / k?
What is Suction Temperature in R?
Finally, Calculate Discharge Temperature if (2.32)
.23
= 1.21
( )
( ) a k-1 /k
d s
T = T r
( )
p p
k = MC / MC - 1.99
Step 1: Discharge Temp Calc Compression Ratio
Methane Compressed: 250 psig to 600 psig.
T
s
= 100F
What is the T
d
?
What is the Comp Ratio? (Remember: psia =
psig + 14.7)
T
Pd 600 + 14.7
R = = =
Ps 250 + 14.7
2.32
( )
( ) k-1 /k a
d s
T = T r
Step 2: Determine k (from Chart)
T
s
= 100F
What is the T
d
?
Comp Ratio = 2.32
Determine k: From Chart
From k vs Mol Wt Graph: Figure A (page 10 2)
Using MW = 16.042 and T = 100F:
Find k = ??
( )
( )
k-1 /k a
d s
T = T r
Approximate Heat Capacity Ratios of
Hydrocarbon Gases
Mol Wt of C
1
= 16.042
T
s
= 100F
Approximate Heat Capacity Ratios of
Hydrocarbon Gases
Mol Wt of C
1
= 16.042
T
s
= 100F
1.3
Compressor Discharge Temperature #1
T
s
= 100F
What is the T
d
?
Comp Ratio = 2.32
Determine k: From Chart
From k vs Mol Wt Graph: Figure A (page 10 2)
Using MW = 16.042 and T = 100F:
Find k = 1.3
( )
( ) k-1 /k a
d s
T = T r
Alternate Step 2: Determine k (from Equation)
T
s
= 100F
What is the T
d
?
Comp Ratio = 2.32
Determine k: from Equation
Find k = ? ?
( )
( ) k-1 /k a
d s
T = T r
Alternate Step 2: Determine k (from Equation)
T
s
= 100F
What is the T
d
?
Comp Ratio = 2.32
Determine k: from Equation
8.651
k = =
8.651-1.99
1.3
( )
( )
p p
p
k = MC / MC - 1.99
MC = 8.651 from TABLE
( )
( ) k-1 /k a
d s
T = T r
Molar Heat Capacity: MC
p
Gas
Chemical
formula
Mol
wt 0F 50F 60F 100F 150F 200F 250F 300F
Methane CH
4
16.042 8.233 8.414 8.456 8.651 8.947 9.277 9.638 10.010
Ethyne (Acetylene) C
2
H
2
26.036 9.683 10.230 10.330 10.710 11.130 11.540 11.880 12.220
Ethene (Ethylene) C
2
H
4
28.052 9.324 10.020 10.160 10.720 11.400 12.080 12.750 13.140
Ethane C
2
H
6
30.068 11.44 12.170 12.320 12.950 13.770 14.630 15.490 16.340
Propene (Propylene) C
3
H
6
42.078 13.63 14.690 14.900 15.750 16.800 17.850 18.870 19.890
Propane C
3
H
8
44.094 15.64 16.880 17.130 18.170 19.520 20.890 22.250 23.560
1-Butene (Butylene) C
4
H
8
56.104 17.96 19.590 19.910 21.170 22.710 24.250 25.700 27.150
cis-2-Butene C
4
H
8
56.104 16.54 18.040 18.340 19.540 21.040 22.530 24.000 25.470
trans-2-Butene C
4
H
8
56.104 18.84 20.020 20.500 21.610 22.990 24.370 25.720 27.060
iso-Butane C
4
H
10
58.120 20.40 22.150 22.500 23.950 25.770 27.590 29.390 31.110
n-Butane C
4
H
10
58.120 20.80 22.380 22.710 24.070 25.810 27.540 29.230 30.900
iso-Pentane C
5
H
12
72.146 24.93 27.160 27.610 29.420 31.660 33.870 36.030 38.140
n-Pentane C
5
H
12
72.146 25.64 27.610 28.010 29.700 31.860 33.990 36.070 38.120
Benzene C
6
H
6
78.108 16.41 18.380 18.750 20.460 22.460 24.460 27.080 29.710
n-Hexane C
6
H
14
86.172 30.17 32.780 33.300 35.360 37.910 40.450 42.910 45.360
n-Heptane C
7
H
16
100.198 34.96 38.000 38.610 41.010 43.970 46.930 49.770 52.600
Ammonia NH
3
17.032 8.516 8.5180 8.519 8.521 8.523 8.525 8.527 8.530
Air 28.966 6.944 8.9510 6.952 6.960 6.973 6.990 7.009 7.033
Water H
2
O 18.016 7.983 8.0060 8.010 8.033 8.075 8.116 8.171 8.226
Oxygen O
2
32.000 6.970 6.9970 7.002 7.030 7.075 7.120 7.176 7.232
Nitrogen N
2
28.016 6.951 6.9540 6.954 6.956 6.963 6.970 6.984 6.998
Hydrogen H
2
2.016 6.782 6.8560 6.871 6.905 6.929 6.953 6.965 6.977
Hydrogen sulfide H
2
S 34.076 8.000 8.0910 8.109 8.180 8.270 8.360 8.455 8.550
Carbon monoxide CO 28.010 6.852 6.9570 6.958 6.963 6.975 6.986 7.007 7.028
Carbon dioxide CO
2
44.010 8.380 8.6980 8.762 9.004 9.282 9.559 9.810 10.050
5
5
Step 3: Calculate (k-1) / k
T
s
= 100F
Comp Ratio = 2.32 k = 1.3
Calculate (k-1) / k:
(1.3 1) / 1.3 = 0.23
( )
( ) a k-1 /k
d s
T = T r
Step 4: Calculate T
d
T
s
= 100F
What is the T
d
?
R = 2.32 k = 1.3 (k-1) / k = 0.23
Calculate T
d
( )
( ) a k-1 /k
d s
T = T r

(k-1)/k .23
s
d
T = T (r) = ( 560 )( 2.32 )
= ( 560 )( 1.21 ) = 678 R = 218 F
Compressor Discharge Temperature: Exercise # 2
If this same gas was compressed to 1600
psia (In a Single Stage) what would be the
Discharge Temperature?
Compressor Discharge Temperature: Solution #2
If this same gas was compressed to 1600
psia (In a Single Stage) what would be the
Discharge Temperature?
T
d
= T
s
(r)
a(k-1)/k
T
d
= 560 (6.04)
.23
T
d
= 847R = 386F
Pd 1600
r = = = 6.04
Ps 250 + 14.7
Compressor Discharged Temperature: Exercise #3
For a compression ratio of 3.5 (good operating practice), what is the
maximum suction temperature that assures that the discharge
temperature remains below 250F?
k = Isentropic Coefficient (heat capacity ratio)
T
d
T
s
MC
p
constant pressure, BTU / lb-mol / R
a Depends on the Type of Compressor
a = 1.0 for reciprocating (positive displacement)
a = 1.25 for centrifugal
( )
( ) a k-1 /k
d s
T = T r
Compressor Discharged Temperature: Solution #3
For a compression ratio of 3.5 (good operating practice), what is the
maximum suction temperature that assures that the discharge
temperature remains below 250F?
k = Isentropic Coefficient (heat capacity ratio)
T
d
T
s
MC
p
constant pressure, BTU / lb-mol / R
a Depends on the Type of Compressor
a = 1.0 for reciprocating (positive displacement)
a = 1.25 for centrifugal
( )
( ) a k-1 /k
d s
T = T r
( ) ( )
( ) 1.0 1.26-1 /1.26
s
s
250 + 460 = T 3.5
T = 548R = 88F
Compressor Volume Bottle

Sizing Exercise
1. Consult Manufacturer or Design Engineering Firm
a) Calculate Displacement Volume of Single Stroke = V
d
b) Choose Suction Bottle Volume = (V
d
) x (Suction Multiplier)
c) Choose Discharge Bottle Volume = (V
d
) x (Discharge Multiplier)
Estimate Multipliers from Chart below
If More Than One Cylinder is Connected to a Single Bottle: Sum
the Displacement Volumes
Exercise: Volume Bottle Sizing
P
s
= 500 psia
P
d
= 1500 psia
Cylinder Bore = 6 inches Diameter
Cylinder Stroke Length = 18 inches
Choose: Suction and Discharge Bottle Size
Solution: Volume Bottle Sizing
P
s
= 500 psia P
d
= 1500 psia
Displacement Volume = V
d
= t r
2
L = t 3
2
(18)
= 509 Cubic Inches
Suction Multiplier from Chart at 500 psia?
Discharge Multiplier from Chart at 1500 psia?
509 Cubic Inches
Suction Multiplier from Chart at 500 psia? ?
Discharge Multiplier from Chart at 1500 psia? ?
Estimate Multipliers from Chart Below
509 Cubic Inches
Suction Multiplier from Chart at 500 psia? ? 7
Discharge Multiplier from Chart at 1500 psia? ? 9.5
Estimate Multipliers from Chart Below
Solution: Volume Bottle Sizing
P
s
= 500 psia P
d
= 1500 psia
Displacement Volume = V
d
= t r
2
L = t 3
2
(18)
= 509 Cubic Inches
Suction Multiplier from Chart at 500 psia ~ 7
Discharge Multiplier from Chart at 1500 psia
~ 9.5
Suction Bottle Size = 509 x 7 = 3563 cubic in.
Discharge Bottle Size = 509 x 9.5 = 4836
cubic in.

BHP
Calculate: Compressor Brake Horsepower
1. Rule of Thumb
2. Katz et al Equation
3. Charts and Figures Method
4. Computer
Rule of Thumb Method
BHP = 22 (R per Stage) (# of Stages) (MMCFD) F
F Corrects for Interstage Cooling
= 1.00 for Single Stage
= 1.08 for Two Stage
= 1.10 for Three Stage
Centrifugal Compressors: Add ~ 18%
High Speed Compressors May Require Up to 20%
More BHP
(Check with Manufacturer)
r < 2.5 and SG
g
> .65 Will Require Less BHP
Use 20 vs 22 if SG > .8
Use 17 vs 22 if r < 2.0
Equation Method: KATZ et al
Equation for Low Speed Recip Compressors
Add 4% for High Speed Reciprocating
Add 18% for Centrifugal
( ) ( )
( )
(

k-1 /k
MMCF s s d s
BHP =
.124 Q T Z k / k -1 P / P -1
Chart and Figure Method
1. Determine K of Mixture: Use Figure A page 10 2
Guess T
avg
Based on T
s
2. Determine T
d
for First Stage: Use Figure B page 10 3
Check T
guess
by Averaging T
s
and T
d
If Too Much Error, Repeat Steps 1 and 2
Repeat Steps 1 and 2 for Each Stage
3. Determine Z
s
for Each Stage: Charts 1 and 2 pp 10 8 and 10 9
4. Determine BHP/MMCF: Figs BHP1A and BHP1B pp 10 6 and 10 7
Repeat for Each Stage
Multiply by the Flowrate in MMCFD
5. If Needed, Correct for LOW P
s
Figure C page 10 4
6. If Needed, Correct for High Speed Table page 10 4
7. If Needed, Correct for Low P
d
/P
s
(<2.2) Fig D page 10 5
Exercise: Compressor BHP Chart Method
From Figure A (Heat Capacity) page 11-2, Determine K (guess avg. Temp = 150F)
From Figure B page 11-3, Determine discharge Temperature from first stage:
read r to K to t
s
to t
d
If interstage cooling lowers t
s
for second stage to 120F, what is t
d
for second stage?
Extra Given Bit Of Information Obtained From These Temperatures:
First Stage avg. Z ~ .975
Second Stage avg. Z ~ .940
Z given here, but you could have obtained them from Chart 1 page 11-8 and Chart 2 page 11-9
From Figure BHP 1A page 11-6 or BHP 1B page 11-7 Determine BHP / MMscfd for each Stage:
BHP / MMscfd for Stage 1 = ______________ Stage 2 = _____________
Do we need to correct for Low P
s
(Figure C)? page 11- 4
Do we need to correct for High Speed and S.G. (Table below Figure C)? page 11- 4
Do we need to correct for Low Comp Ratio vs. S.G. ( Figure D )? Page 11- 5
How much Horsepower do we require (Total)?
NOTE:
Tables were prepared using Volume at 14.4 psia and intake Temp (T
s
).
Sales contract is for volumes calculated at 14.65 psia AND 60F.
We have BHP for 2MMCF at 14.4 psia, Z
avg
and T
s
of each stage. We want @ 14.65 psia, 60F and Z=1
Correct the BHP For These Changes:
BHP
ACTUAL
= ( BHP
CHARTS
) (14. 4 / P
CONTRACT
) ( T
CONTRACT
/ T
CHART = Ts
) (1 / Z
CHART
)
Compare Your Answer With This Rule of Thumb:
BHP = (22 BHP) (Ratio / Stage) (Stages) (MMcfd) (F)
Where F corrects for interstage cooling = 1.00 for single-stage
1.08 for 2 stages
1.10 for 3 stages
Exercise: Compressor BHP Chart Method
What total horsepower is required to compress 2 MMscfd of
gas measured at 14.65 psia and 60F into a 900 psia sales line
from an intake pressure of 100 psia, and intake temperature of
100F?
The gas has a Specific Gravity of 0.8
Overall compression ration is:
Number of stages required is:
Increase the compression ratio, r , by 3% for interstage
cooling:
Calculate first stage P
d
:
Calculate second stage P
s
:
Solution: Compressor BHP Chart Method
From Figure A (Heat Capacity) page 11-2, Determine K (guess avg. Temp = 150F)
Convert Specific Gravity into Mol Wt: .8 x 28.96 = 23.2
From Fig A at MW of 23.2 and T = 150F: Read k = 1.215
(We are guessing that the average Temperature will be about 150F during Compression)
From Figure B page 11-3, Determine Discharge Temperature from first stage:
(read r to K to t
s
to t
d
)
r = 3.09, K = 1.215, t
s
= 100F: Read t
d
~ 223F
(Actual Average Temperature ~ 161.5 which doesnt change K enough to matter; so, our guess of using 150
F to determine K from Chart A was alright)
If interstage cooling lowers t
s
for second stage to 120F, what is t
d
for second
stage?
Using Fig B page 11-2 again with r = 3.09 t
s
= 120F, K = 1.215: Read t
d
~ 248F
Extra Given Bit of Information Obtained from these Temperatures:
First Stage avg Z ~ .975
Second Stage avg Z ~ .940
Z given here, but you could have obtained them from Chart 1 page 11-8 and
Chart 2 page 11-9
From Figure BHP 1A page 11-6: Determine BHP / MMscfd for each Stage:
BHP / MMscfd for Stage 1: ~ 65.7 BHP / MMscfd Stage 2: ~ 65.7 BHP / MMscfd
Do we need to correct for Low P
s
(Figure C) page 11-4? NO
Correct for High Speed and S.G. (Table below Figure C) page 11-4? NO
Correct for Low Comp Ratio vs. S.G. (Figure D) page 11-5 ? NO
How much Total Horsepower do we require?
Stage 1: 65.7 BHP / MMscfd x 2.0 MMscfd = 131.4 BHP
Stage 2: 65.7 BHP / MMscfd x 2.0 MMscfd = 131.4 BHP
Total: 131.4 + 131.4 = 262.8 BHP
Note: Tables were prepared using Volume at 14.4 psia and intake Temp (T
s
).
We are measuring volumes calculated at 14.65 psia AND 60F.
We have BHP for 2MMCF at 14.4 psia, Z
avg
and T
s
of each stage. We
want at 14.65 psia, 60F and Z = 1
Correct the BHP for these Changes:
BHP
ACTUAL
= (BHP
CHARTS
) (14.4 / P
CONTRACT
) (T
CONTRACT
/ T
CHART = Ts
) (1 / Z
CHART
)
Stage 1: (131.4) (14.4 / 14.65 ) (520R / 560R) (1/ .975) = 123.0
Stage 2: (131.4) (14.4 / 14.65 ) (520R / 580R) (1/ .940) = 123.3
Total BHP needed: 123.0 + 123.2 = 246.2 BHP
Compare Your Answer With This Rule of Thumb:
BHP = (22 BHP) (Ratio / Stage) (Stages) (MMcfd) (F)
Where F corrects for interstage cooling = 1.00 for single stage
1.08 for 2 stages
1.10 for 3 stages
BHP = (22) (3.09) (2) (2) (1.08) = 294 Total BHP
What total horsepower is required to compress 2 MMscfd of
gas measured at 14.65 psia and 60F into a 900 psia sales line
from an intake pressure of 100 psia, and intake temperature of
100F?
The gas has a Specific Gravity of 0.8.
Overall compression ration is: r = P
d
/ P
s
= 900 / 100 = 9
Number of stages required is: The square root of 9 is 3, which
is an acceptable compression ratio; therefore 2 Stages are
sufficient .
Increase the compression ratio, r, by 3% for interstage cooling:
3 x 1.03 = 3.09
Calculate first stage P
d
= 100 x 3.09 = 309 psia
Calculate second stage
P
s
= 309 psia x 97% (cooling, liquid removal) ~ 300 psia
Determination of Heat Capacity Ratio, K
(MW = 28.96 x
Specific Gravity)
Reciprocating Compressors
Theoretical Discharge
Temperatures
Single State Compression
Read r to k to t
s
t t
d
Super Compressibility Factor: Z
BHP Required Per MMSCFPD
Brake Horsepower Correction Factors
Table: BHP Correction for High Speeds
GAS SPECIFIC
GRAVITY
PERCENT HORSEPOWER INCREASE
FOR HIGH SPEED UNITS
0.5 0.8 4
0.9 5
1.0 6
1.1 8
1.5 and propane
refrigeration units
10
Bottom of Page 10 - 4
Compressors Number of Stages

Exercise
Compressors: Number of Stages Excercise
Produced gas is to be compressed from a Suction
Pressure of 50 psig to a Sales Line pressure of 1500
psig.
Assume ambient air temperatures reach > 140F
so the Compression Ratio should not exceed 2.5
Determine Number of Stages Required
(maintain the same compression ratio in each stage)
Compressors: Number of Stages Solutions
Produced gas is to be compressed from a Suction Pressure of 50 psig
to a Sales Line pressure of 1500 psig.
Compression Ratio should not exceed 2. 5
Determine Number Of Stages Required
(maintain the same compression ratio in each stage)
Overall Compression Ratio = (1500 + 14.7) / (50 + 14.7) = 23.4
Compression ratio of each stage = (23.4)
1/n
for 1 stage: n = 1 (23.4)
1/1
= 23.4
for 2 stages: n = 2 (23.4)
1/2
= 4.89
for 3 stages: n = 3 (23.4)
1/3
= 2.86
for 4 Stages: n = 4 (23.4)
1/4
= 2.2
THEREFORE: Need 4 compressor stages, 3 interstage-coolers plus 1
after-cooler, 1 suction scrubber and 3 interstage-scrubbers
Solution: Number of Stages
Compressor Flow Diagram
What is the Overall Compression Ratio?

Compressors

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Compressors

Uploaded by

Copyright:

Available Formats

DELIVERING KNOWLEDGE. DEVELOPING COMPETENCE.

Compressor Volume Bottle

Compressor Brake Horsepower

Compressors Number of Stages

You might also like