Assignment – 009

Sheet 1 / 5
Answer 1:
The three types of rotary compressors normally used in Petro chemical industries are:
1. Screw 2. Lobe and 3. Sliding vane compressors.

Answer 2:
The three major advantages are:
1- The motion of the compressor is rotary, so it can be coupled by a motor and a higher speed can
be achieved.
2- Maintenance is less (wearing and tearing is reduced).
3- Flow is smooth and continues in the rotary compressors (No pulsation).

Answer 3:
In diffuser vanes, kinetic energy is converted into pressure energy.

Answer 4:
The four factors are:
1. Inlet Temperature of gas 2. Blade geometry, MOC, and surface finishing
3. Gas properties 4. Blade tip speed

Answer 5:
By adding inter cooler we are trying to make the compression process near to Isothermal thermo
dynamic process.

Answer 6:
In gas equation PV= ZRT, Z is called as Compressibility of gas.

Answer 7:
When the mass flow increases, the power required to drive the compressor increases.

Answer 8:
The inter section point of the system resistance curve and the head capacity curve is known as
Operating point.

Answer 9:
As the system resistance increases the operation moves towards the Surge line.

Answer 10:
The head output of the impeller depends only on the impeller’s tip speed and the impeller’s design
(geometry, type…etc).

Answer 11:
As the inlet pressure of a compressor decreases the operating point shifts downward on the curve.

Answer 12:
As the inlet temperature of a compressor decreases the operating point shifts upwards on the curve.
Answer 13:
If the Molecular weight of gas decreases the pressure ratio decreases and the discharge pressure
decreases and the power requirement increases. The increase of power will be because the RPM need to
be increased in order to maintain the same discharge pressure. This can be shown in the Polytropic
head equation: Hp= ZRT1 (n/ n-1) (rp(n-1/n) -1)

Answer 14:
Surging means reverse of flow.
 Assignment – 009

Sheet 2 / 5
Answer 1:
Balancing drum is used to balance the axial thrust force on the compressor rotor.

Answer 2:
There are two types of casing, vertically or barrel split and horizontally or axially split.

Answer 3:
Barrel type casings are used when the pressures are high.

Answer 4:
Labyrinths are used for inter stage sealing.

Answer 5:
When the balancing drum clearance increases there will be more load on the thrust bearing.

Answer 6:
1. Speeds can be optimized by selecting bull gear to pinion speed ratios
2. Smaller size impellers have less inertia and gives less force on bearings
3. Cooling arrangement after every impeller (inter stage cooling) is possible and thus the
compression process is near to isothermal.

Answer 7:
Most important property of lubricating oil to achieve proper lubrication is its viscosity.

Answer 8:
The five main components are:
1. Lube oil Tank (Reservoir): the lube oil will be stored in this tank to a certain level and also the
returned oil from the system will be collected in it.
2. Lube oil pump: it will circulate the lube oil through the system for lubrication at a designed
pressure.
3. Lube oil filter: it will prevent impurities (10 to 20 microns) in the oil from reaching to the
bearings and seals.
4. Lube oil coolers: it cools the oil in order to maintain the oil’s viscosity and temperature.
5. Pressure control valve: it is a self actuated valve which ensures that the oil is at an acceptable
pressure. If the pressure overcomes the pressure limit it will open and the excess oil will pass
through the bypass to the tank.

Answer 9:
The oil reservoir size should be such that the working capacity should be sufficient for at least five
minutes of normal oil flow.

Answer 10:
The size of heater provided in lubricating reservoir should be sufficient to heat entire oil in twelve
hours up to minimum recommended temperatures.

Answer 11:
Reservoir is provided with a proper vent sized connection to avoid over pressurization.
Answer 12:
Oil filters are provided on downstream side of the cooler and upstream side of compressors.

Answer 13:
Oil centrifuging is required to remove dirt, contaminants from oil and moisture (water) from oil.

Answer 14:
Labyrinths seal works on principle of increase in volume in successive stages thereby reducing leakage
pressure.

Answer 15:
The tapping which connects at top of overhead seal oil reservoir is taken from reference gas line.
 Assignment – 009

Sheet 3 / 5
Answer 1:
This is because the drained seal oil contains gas (sour/dirty oil); therefore this gas needs to be removed
by entering through gas traps and degassing tank. After that the seal oil can be returned to the seal oil
tank.

Answer 2:
The following are the steps of how the dry gas works:
1) The rotating ring -made up of silicon carbide or tungsten carbide- is having “spiral grooves”.
2) The stationary ring -made up of carbon- is spring loaded.
3) During rotation, the buffer gas supplied to seal, is scooped up at outer diameter and pushed towards
the ID of the groove and forms a sealing dam.
4) Due to pressurization of the gas, the rotating ring gets lifted away from the stationary ring forming a
gap of 3 to 5 microns size, and sealing is achieved without any contact between the two faces. The
sealing gas passing through seal is vented out through the “primary vent”.

Answer 3:
Three arrangements of dry gas seals are Single, Double and Tendem.

Answer 4:
Five advantages of dry gas seal are:
1) Reduced or zero emissions
2) Low power consumption (as the power required for seal oil pumps, heaters for oil degassing
tanks is eliminated)
3) Fire hazard is greatly reduced (since there is no contaminated oil)
4) Process fluid is free from oil
5) Low maintenance cost.

Answer 5:
This is because the process gas vented from the primary vent will pollute the air.

Answer 6:

Answer 7:
 Assignment – 009

Sheet 4 / 5
Answer 1:
Answer 2:
Answer 3:
Answer 4:
Answer 5:
The two methods are: suction valve unloaders and Clearance pocket capacity control

Answer 6:
The following are five points to minimize pulsation and shaking forces in a reciprocating compressors:
1) Knock out drum / separator shall be close to the compressor
2) Minimize points of generation of shaking forces such as – elbows, tees…etc
3) Locating normally closed valve on branch lines close to the branch point
4) Control maximum gas velocity to 10 to 20 m/sec to avoid gas turbulence
5) Maximum piping span between 2 consecutive supports to be calculated to control
resonances

Answer 7:
The common material of construction used for piston rods are: AISI 4140 , AISI 4340, 17-7 PH

Answer 8:
The most probable cause of frequent valve plate failures in the reciprocating compressors could be the improper
separation of moisture from the suction side knock out drum / separator.

Answer 9:
The most important considerations for the selection of air compressor suction filters are:
1) Amount or capacity of dust it can hold 2) Separation efficiency 3) Pressure drop generated
4) Filter media used.

Answer 10:
The function of a lubricator is to supply the reciprocating compressor with continuous lubricating oil needed for
the lubrication types. The lubrication types are “frame lubrication” and “Cylinder and packing lubrication”.

Answer 11:
The most two important safety devices in reciprocating compressors are:
 Pressure relief valve
 Low lube oil pressure switch.