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Note: The source of the technical material in this volume is the Professional
Engineering Development Program (PEDP) of Engineering Services.
Warning: The material contained in this document was developed for Saudi
Aramco and is intended for the exclusive use of Saudi Aramcos employees.
Any material contained in this document which is not already in the public
domain may not be copied, reproduced, sold, given, or disclosed to third
parties, or otherwise used in whole, or in part, without the written permission
of the Vice President, Engineering Services, Saudi Aramco.
Chapter : Mechanical
File Reference: MEX-212.01
Engineering Encyclopedia
Compressors
Classifying Compressors by Type
Section
Page
INTRODUCTION............................................................................................................. 4
CLASSIFYING DYNAMIC COMPRESSORS BY TYPES ............................................... 6
Centrifugal ............................................................................................................ 7
Barrel ......................................................................................................... 9
Axially Split .............................................................................................. 12
Integrally Geared ..................................................................................... 14
Single-Stage Blower ................................................................................ 17
Axial.................................................................................................................... 18
Multi-Stage............................................................................................... 18
Single-Stage (Fans) ................................................................................. 21
CLASSIFYING POSITIVE-DISPLACEMENT COMPRESSORS BY TYPE................... 23
Reciprocating...................................................................................................... 24
Single-Acting............................................................................................ 25
Double-Acting .......................................................................................... 27
Dry/Lubricated ......................................................................................... 28
Rotary................................................................................................................. 29
Screw....................................................................................................... 30
Lobe......................................................................................................... 33
Liquid-Ring............................................................................................... 34
Sliding-Vane ............................................................................................ 35
WORK AIDS.................................................................................................................. 37
WORK AID 1: ILLUSTRATIONS USED TO CLASSIFY DYNAMIC
COMPRESSORS BY TYPE ................................................................... 37
WORK AID 2: DISPLACEMENT COMPRESSORS BY TYPE
ILLUSTRATIONS USED TO CLASSIFY POSITIVE-.............................. 43
GLOSSARY .................................................................................................................. 48
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Classifying Compressors by Type
LIST OF FIGURES
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LIST OF TABLES
Table 1. Advantages and Disadvantages of Centrifugal and Axial Compressors............ 7
Table 2. Advantages and Disadvantages of Reciprocating and Rotary PositiveDisplacement Compressors ............................................................................ 24
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INTRODUCTION
A compressor is defined as a device that causes a reduction in
volume and an increase in the pressure of a gas. A compressor
moves a gas through a process system by increasing the
energy and the density of the gas. Because the action of a
compressor is similar to a pump, a compressor can be
considered a gas pump. One of the most important effects of
an increase in gas energy is pressure. The amount of pressure
increase above the pressure of the incoming gas depends on
the design and size of the compressor that is used. Because
gas is compressible, its volume will decrease as its energy is
increased. As the gas is compressed, the absolute pressure
and volume vary inversely. If the temperature of a gas remains
constant, which is an ideal situation, and if the volume of that
gas is reduced by one half, the pressure will double.
The use of compressors had expanded widely in industrial
applications. Figure 1 is an application range chart for the
various specific types of compressors, which shows discharge
pressure (psig) versus inlet flow (ACFM). Refer to Figure 1 for
the discussions of the various compressors. With many
manufacturers developing new and more efficient compressors,
the Mechanical Engineer must understand the types, the usage,
and the limitations that are placed on the different varieties of
compressors. Because Saudi Aramco uses both dynamic and
positive-displacement compressors, this module focuses on the
different compressor designs that are available. This module
describes the following topics that are pertinent to classifying
compressors by type:
Classifying Dynamic Compressors by Types
Classifying Positive-Displacement Compressors by Types
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Classifying Compressors by Type
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Classifying Compressors by Type
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Classifying Compressors by Type
Compressor Type
Centrifugal
Advantages
Disadvantages
Low Maintenance
Moderate efficiency
High Reliability
Axial
High efficiency
Centrifugal
Centrifugal compressors are the most common type of dynamic
compressors. Centrifugal compressors operate on the principle
of imparting velocity to a gas stream and then converting this
velocity energy into pressure energy. Centrifugal compressors
are designed as single or multi-staged and are driven directly by
a prime mover or through gearing.
An operational description of a simple centrifugal compressor
illustrates the relationship between gas pressure and flow.
Figure 2 shows a single-stage, single-flow centrifugal
compressor with the impeller overhung on a motor. This singleflow unit consists of the inlet nozzle, the impeller, the diffuser,
the volute, the discharge nozzle, and the driver (not shown).
The gas enters the compressor through the inlet nozzle, which
is proportioned to permit the gas to enter the impeller with
minimum shock and turbulence. The impeller receives the gas
from the inlet nozzle and dynamically compresses it. The
impeller also sets the gas in motion and gives it a velocity that is
slightly more than the tip speed of the impeller. The diffuser
surrounds the impeller and serves to gradually reduce the
velocity of the gas (kinetic energy) into pressure (potential
energy). The volute casing surrounds the diffuser and collects
the gas. From the volute, the gas exits the compressor through
the discharge nozzle. Some discharge nozzles act as conical
diffusers, and they further reduce the velocity of the gas to the
Saudi Aramco DeskTop Standards
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Classifying Compressors by Type
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Classifying Compressors by Type
Single-Stage Blower
Barrel
A typical, multi-stage, barrel-type centrifugal compressor is
shown in Figure 3. Barrel compressor casings can be of either
forged steel, cast steel, or fabricated steel; however, if the
relative molecular mass specified is less than 14, or if the
maximum allowable working pressure exceeds 1000 psig, Saudi
Aramco requires that the casing be made of forged steel. The
compressor casing is constructed as a complete cylinder, but at
least one end of the compressor is removable to allow access to
internal components. Barrel-type centrifugal compressors are
also referred to as radially split centrifugal compressors.
Sufficient space must be allowed at the rear of the compressor
for the removal of internal components.
Major Components - The following major components, which are
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Classifying Compressors by Type
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Applications - The application range chart that was shown
previously in Figure 1 shows discharge pressure (psig) versus
inlet flow (ACFM) for centrifugal compressors. Because of the
barrel design, barrel compressors, instead of axially split
centrifugal compressors, are normally selected for higher
pressure applications or for certain lower mole gas compositions
(hydrogen gas mixtures). Examples of Saudi Aramco
applications where barrel compressors are used are as follows:
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Operation - The operation of an axially split compressor is the
same as the operation of the barrel compressor pertaining to the
gas flowpath and gas velocities. The incoming gas is
accelerated through the inlet nozzle to the impeller. A diffuser
surrounds the impeller; the diffuser serves to gradually reduce
the velocity of the gas as the gas leaves the impeller, and it
converts the velocity energy to pressure. In a multi-stage,
axially split compressor, the gas exits the diffuser and enters
return channels. The return channels direct the gas into the
impeller of the next stage.
Applications - The application range chart that was previously
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Each impeller has its own volute casing which contains the
diffuser and the discharge volute and that is bolted to the gear
casing. To allow access to the gears, the gear casing may be
horizontally or vertically split.
Major Components - The following major components, which are
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Single-Stage
Blower
A single-stage blower, which is shown in Figure 6, contains an
impeller that is located inside a housing. The impeller is
mounted on a shaft (not shown) and rotates inside the blower
housing. The impeller is turned either by a direct drive system
or by a pulley and belt drive system if the horsepower is below
125. A single-stage blower is commonly called a centrifugal fan.
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shaft through the inlet to the impeller. The impeller moves the
gas stream in a rotary motion, which results in an outward
velocity due to centrifugal forces. The movement of the gas
stream outward creates a low-pressure area at the center of the
impeller (inlet). The low pressure at the center of the impeller
causes the gas stream to flow into the inlet of the blower. The
rotary motion of the gas stream is transformed to pressure by
means of a volute. The volute is a gradually widening section of
the housing that surrounds the impeller and that gradually
reduces the tangential or radial velocity of the gas stream as the
stream leaves the impeller. The volute converts the velocity to
pressure and directs the flow to the compressor outlet, where
the gas exits in a stream perpendicular to the axis of the blower
impeller.
Applications. Single-stage blowers are preferred for high
Axial
Axial compressors accelerate the gas in a direction that is
parallel to a rotating shaft and to pairs of moving and stationary
blades. The combination of a row of moving blades (rotating
vanes) and a row of stationary blades (stator vanes) forms a
stage. The pressure rise per stage in an axial compressor is
small compared to the pressure rise per stage of a centrifugal
compressor; therefore, the axial compressor contains more
stages than does a centrifugal compressor that operates in the
same pressure range. Roughly three axial stages are required
for one centrifugal stage.
Multi-Stage
An axial compressor that consists of more than one stage is
classified as a multi-stage axial compressor. As the volume or
pressure requirements of the process increases, the number of
axial compressor stages increases. A typical, multi-stage, axial
compressor is shown in Figure 7.
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Major Components - The following major components, which are
discussed in detail in Module 212.03, are noted for the purposes
of identification:
Shaft Seals
Thrust Bearing
Radical Bearings
Inlet Nozzle
Inlet Volute
Rotor Shaft
Stator Vanes
Adjustable Stator Vanes
Fixed Stator Vanes
Rotating Vanes
Tapered Cylindrical Casing
Discharge Volute
Discharge Casing
Operation. A multi-stage axial compressor consists of a rotor
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Applications - The application range chart that was previously
shown in Figure 1 shows discharge pressure (psig) versus inlet
flow (ACFM) for axial compressors. Multi-stage axial
compressors are used for high flow applications with relatively
low pressure ratios (80,000 - 800,000 inlet ACFM at 2 - 100 psig
discharge pressure). Multi-stage axial compressors are mostly
used to provide combustion air to gas turbines and are also
used to supply air to the regenerator in fluid catalytic cracking
units.
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Compressors
Classifying Compressors by Type
Single-Stage
(Fans)
Single-stage axial compressors or axial flow fans, as shown in
Figure 8, typically draw on an atmospheric pressure, and they
have discharge pressures up to only a few psig. A single-stage
axial compressor moves the gas stream parallel to the
compressors drive shaft. Single-stage axial compressors
consist of one row of blades that is attached to a shaft. When
process requirements vary significantly, the blades may have a
variable pitch control system to vary the discharge pressure and
volume.
Major Components - The major components associated with a
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Compressor Type
Reciprocating
Rotary
Advantages
Disadvantages
Higher efficiency
Pulsation
Higher maintenance
requirements
No pulsation
Lower efficiency
Lower maintenance
requirements
Reciprocating
A reciprocating compressor is a positive-displacement,
constant-volume, variable-pressure compressor. A
reciprocating compressor is the most common type of positivedisplacement compressor.
Reciprocating compressors are available in single and multistaged designs. Single-stage reciprocating compressors are
typically rated at discharge pressures of 25 to 100 psig, with
some units rated as low as 2 psig. Multi-stage reciprocating
compressors are typically rated at discharge pressures of 80 to
30,000 psig, with specially designed units rated in excess of
50,000 psig. As already mentioned, a reciprocating compressor
is a positive displacement device. Unlike centrifugal
compressors, the reciprocating compressor cannot self-regulate
its capacity against a given discharge pressure. The inlet and
outlet air flow of a reciprocating compressor is a function of
compressor speed and cylinder volume.
Some advantages of a reciprocating compressor over a
centrifugal compressor are:
Greater flexibility in capacity and pressure range.
Higher compressor efficiency and lower power cost.
Capability for delivering higher pressures.
Capability for handling lower flowrates.
Less sensitivity to gas composition, molecular weight, and
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density.
Because the design of a reciprocating compressor is such that
the produced gas pressure is not affected by the molecular
weight of the gas (as in the case with dynamic compressors),
reciprocating compressors are used for most low molecular
weight applications. Some Saudi Aramco applications that use
reciprocating compressors are as follows:
Refinery Off-Gas Compressors
Hydrocracker Make-Up Compressor (H2-Rich Gas)
Low-Flow Plant and Instrument Air Compressors
Nitrogen Compressors
Refinery Low-Flow Recycle Compressors (H2-Rich Gas)
Single-Acting
Figure 9 is an illustration of a single-acting reciprocating
compressor. Single-acting refers to the action that takes place
during a stroke of the piston.
A single-acting reciprocating compressor compresses gas on
only one side of the piston. The reciprocating motion of a
single-acting compressor is defined by a suction stroke and a
discharge stroke (also called a compression stroke).
Major Components - The major components of a single-acting
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Operation - The compression cycle of a single-acting
reciprocating compressor consists of two strokes of the piston:
the suction stroke and the compression stroke. The suction
stroke begins when the piston moves away from the inlet port of
the cylinder. The gas that is in the space between the piston
and the inlet port expands rapidly until the pressure decreases
below the pressure on the opposite side of the suction valve.
The pressure difference across the suction valve causes it to
open and admit gas into the cylinder. The gas flows into the
cylinder until the piston reaches the end of its stroke. The
compression stroke starts when the piston starts its return
movement. When the pressure in the cylinder increases above
the pressure on the opposite side of the suction valve, the
suction valve closes to trap the gas inside the cylinder. As the
piston continues to move toward the end of the cylinder, the
volume of the cylinder decreases and the pressure of the gas
increases. When the pressure inside the cylinder reaches the
design pressure to overcome the pressure that is exerted by the
discharge valve and the downstream piping, the discharge valve
opens and discharges the contents of the cylinder.
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Double-Acting
Double-acting also refers to the action that takes place during a
stroke of the piston. A double-acting reciprocating compressor
draws a suction on one side of the piston as it discharges on the
other side of the piston. The double action of a double-acting
reciprocating compressor reduces discharge pressure pulsation
and increases the output volume for a given cylinder design.
Double-acting pistons are standard for most process gas
compressor cylinders.
Major Components - The major components of a double-acting
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Dry/Lubricated
The design of the dry and lubricated reciprocating compressors
are relatively similar. The lubricated type is provided with oil
injection ports, and, typically, it has a force-feed lubrication
system that is separate from the lubrication that is provided to
the crankshaft. The dry compressor only lubricates the
crankshaft and crosshead. The lubricated type normally uses
two or three single-piece, diagonal-cut, Teflon rider rings on the
compression piston or possibly a three-piece bronze segmental
ring. Dry reciprocating compressors use Teflon, special
plastics, or high-performance polymer rings as the sealing
medium between piston and cylinder. Because the sliding
surfaces are lubricated on lubricated compressors, harder
piston and rider ring materials, such as glass and/or
molybdenum-filled Teflon, can be used.
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Rotary
The following types of rotary compressors are discussed in this
section:
Screw
Lobe
Liquid Ring
Sliding-Vane
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Screw
Screw compressors are positive-displacement, constantvolume, variable-pressure compressors. The application range
chart that was shown previously in Figure 1 shows discharge
pressure (psig) versus inlet flow (ACFM) for screw compressors.
Screw compressors are available up to an inlet flow from 300 to
60,000 ACFM with discharge pressures up to 580 psig. Screw
compressors are available in lubricated or dry and in single-,
two-, or three-stage designs.
Major Components - Figure 11 shows the basic construction of a
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Lubricated Screw Compressor - The screw compressor can be
motor-driven or engine-driven by direct, belt, or gear drive.
Typically, the male rotor is connected to the driver; however,
female rotor drive is possible in some designs. The female rotor
is driven by the male rotor without metal-to-metal contact
through the oil film developed between the rotors. In some
lubricated designs, timing gears are used to keep the two
counterrotating screws in the proper mesh. In a single-stage
design, the air inlet is usually located at the top of the cylinder
near the drive shaft end. The discharge port is located at the
opposite end of the cylinder. Compression begins as the rotors
unmesh at the air inlet port. Gas is drawn into the cavity
between the male rotor lobes (thread) and the female rotor
grooves. As rotation continues, the rotor threads pass the
edges of the inlet ports and trap the gas in a cell formed by the
rotor cavities and the cylinder wall. Further rotation causes the
male rotor thread to roll into the female rotor groove, which
reduces the volume and raises the cell pressure. Oil is injected
after the cell is closed to the inlet to seal the clearance between
the male thread and female groove and to absorb the heat of
compression. Compression continues until the rotor threads
pass the edge of the discharge port and release the
compressed gas and oil mixture.
Dry Screw Compressor - Similar to the lubricated screw
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GAS INLET
CASING
ROTOR
CHAMBER
MULTI-BLADE
ROTOR
GAS INLET
PORTS
GAS
DISCHARGE
PORTS
CASING
KEY:
ROTOR, ONE MOVING PART
LIQUID COMPRESSANT
CAST-IRON BODY
Sliding-Vane
A sliding-vane compressor, which is shown in Figure 15, is a
positive-displacement, constant-volume, variable-pressure
compressor. Sliding-vane compressors are available in singleand multi-stage arrangements. Typical single-stage capacities
range through 3200 cubic feet per minute and 50 psig; twostage sliding-vane compressors can deliver pressures from 60
to 150 psig and flows up to approximately 1800 cubic feet per
minute. The application range chart (Figure 1) graphically
compares the sliding-vane compressor capacity to the
capacities of other styles of compressors.
Sliding-vane compressors are typically found in applications
such as air blast hole drilling, pneumatic conveying, chemical
and petroleum vapor recovery, gas transmission, and small
plant air systems.
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WORK AIDS
WORK AID 1:
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WORK AID 2:
GAS INLET
CASING
ROTOR
CHAMBER
MULTI-BLADE
ROTOR
GAS INLET
PORTS
GAS
DISCHARGE
PORTS
CASING
KEY:
ROTOR, ONE MOVING PART
LIQUID COMPRESSANT
CAST-IRON BODY
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GLOSSARY
balance piston
casing
clearance volume
crankshaft
cross-head
cylinder
diffuser
discharge volute
dynamic compression
impeller
intercooler
piston
positive-displacement
compression
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