An Introduction To Compression Equipment

AN INTRODUCTION TO
COMPRESSION EQUIPMENT
An Introduction to Compression Equipment
From the earliest

recorded times, man
has used the air
around him to drive
his sailing ships and
turn the blades of his
windmills.
Sailors and shipbuilders knew

through countless years of
trial and error how to cut and
set a sail for maximum
efficiency. Why the pressure
and flow of air made one
shape better than another was
of little interest to them.
Early Egyptian writings tell of Priests using simple bellows

to compress air.
The air was then made to "magically open and close"
temple doors to the wonderments of the assembled rulers
and common people. Here again the why was no practical
value in the eyes of these people, and therefore did not
particularly interest them.
It wasn't until the early to mid 17th century that man

started to recognize the importance of the world around
him. At this time his knowledge of the air around him
began to increase significantly.
Spurred by the scientific awakening of the Renaissance,
"natural philosophers" as scientists were then called,
began to dispel the errors and superstitions which for the
centuries had been divine truths.
The Flemish Alchemist, Van Helmont,

suspected from his study from the vapors
given off by fermenting fruit juices that the air
was not composed of a single element, but
that it might be a compound or mixture of
substances.
Henry Cavendish, was among the first to
establish that air was indeed a mixture of at
least 4 chemically different gases. In the
process, he discovered hydrogen.
Robert Boyle, an English physicist in the later

half of the 17th century, discovered the laws
governing the relationship between air
pressure to volume
The great Frensh chemist, Antoine
Lavoisier was set the proportions of oxygen
to nitrogen in air, and proved that the oxygen
content was essential to animal life.
Alexandre Charles discovered the laws governing the

relationship of air pressure and temperature.
Evangelista Torricelli in about 1630

discovered the principle of the barometer by
being the first to measure the weight of the
atmosphere. In an elegant experiment, he
found it to be equivalent to a column of
mercury 30 inches high.
Air, when compressed, represents a

potential energy that can be used in a
tremendous variety of ways.
Man began to compress air and apply it
to a widespread and diverse uses about
100 years ago.
Early compressors were steam driven, but in other respects
were essentially the same as today's models, differing only
in refinement of materials and tolerances.
What is a compressor?
A compressor is a device used to increase the pressure of a

compressible fluid.
+ High level
Discharge pressure
Inlet pressure
0
Compressor Atmospheric
- Sub atmospheric
Compressor
The fluid can be any compressible fluid;

either gas or vapor and can have a wide
molecular weight range.
What does this mean?

It means that, to selection and design of any

compressor, the fundamental is a knowledge of the basic
properties of the gas or gases being compressed.
352 Uranium hexafluoride
Molecular weight rang
2 Hydrogen
Compressor
Station
Compressor
Station
Compressor
Station
Production Processing Transmission & Storage Distribution

32,000 Compressors 5,000 Compressors 8,500 Compressors 0 Compressors
For comparison, the different types of compressors can

be subdivided into two broad groups based on
compression mode.
There are two basic modes:
•Intermittent .
•Continuous.
An Introduction to Pumping Equipment
COMPRESSORS
Intermittent flow Continuous flow
Positive displacement
Dynamic Ejector
Reciprocating Rotary
Radial Mixed Axial

Mechanical •Helical lobe flow flow flow
piston
•Straight lobe
•Sliding vans
• Liquid piston
COMPRESSORS
Intermittent
Positive mode
displacement of Continuous compression
compression is cyclic mode Dynamic
is one in which the
Ejector
in nature, inRotary
Reciprocating that a gas is moved into
specific quantity of Radial
compressor,
Mixed
is acted
Axial
gas is ingested
Mechanica by
•Helical lobe flowupon, moved
flow through
flow the
l piston
compressor, acted
•Straight lobe compressor and
upon and discharged,
•Sliding vans discharged without
before the cycle
• Liquid pistonis interruption of the flow at
repeated. any point in the process.
200
Multistage
Pressure ratio
Reciprocating
20
Single stage
Recip. Multistage
Centrifugal Multistage Axial
Rotary
compressors
2 .Single S Cen
102 103 104 105 106

(Flow rate (CFM
General Performance Curve
140
Positive
Percent Pressure Ratio
Centrifugal Displacement
120 Compressors Compressors
or Head
100
Design Point
80
Axial-Flow
Compressor
60
50 60 70 80 90 100 110 120
Percent Flow
COMPRESSORS
Dynamic Ejector
Radial Mixed Axial

piston
•Straight lobe
•Sliding vans
• Liquid piston
Intermittent mode compressors

Reciprocating compressors

It is a piston and
cylinder device with
(automatic) spring
controlled inlet and
exhaust valves the
reciprocating motion is
transmitted to a piston,
which is free to move in
a cylinder.

Delivery is usually to a receiver.
The receiver is effectively a store
of energy used to drive (eg)
compressed air tools.
Pressure can be developed on one
or both sides of the piston ( double
acting ).

When a single cylinder
is used or when multiple
cylinders on a common
frame are connected in
parallel, the
arrangement is referred
to as a single-stage
compressor.

When multiple cylinders
on a common frame are
connected in series,
usually through a cooler,
the arrangement is
referred to as a
multistage compressor.

For large volumes of
compressed gas, they
are usually the most
expensive to buy and
install, and require
greater maintenance,
however, they may be
lower cost at small
capacities.

Due to their size and the
vibrations caused, they
require large foundations
and may not be suitable
where noise emissions are
an issue.
Nevertheless, they are the most energy efficient, both at full
and part loads.

It is generally in the lower
flow end of the compressor
spectrum. Inlet flows range
from less than 100 to
approximately 10,000 cfm /
cylinder.
It is particularly well suited for high-pressure service.
The reciprocating compressor is one of the most efficient of
all the compressors.
COMPRESSORS
Dynamic Ejector
Radial Mixed Axial

piston
•Straight lobe
•Sliding vans
• Liquid piston

Rotary Compressors
Sliding Vane Compressors
It consists of a single rotor
mounted eccentrically in a
cylinder slightly larger than
the rotor.
The rotor has a series of
radial slots, which hold a set
of vanes.

Rotary Compressors
Sliding Vane Compressors
The vans are free to move
radially within the rotor slots.
They maintain contact with
the cylinder wall by
centrifugal force generated
as the rotor turns.
COMPRESSORS
Dynamic Ejector
Radial Mixed Axial

piston
•Straight lobe
•Sliding vans
• Liquid piston

Rotary Compressors
Liquid Piston Compressors
It performs its compression
by use of liquid ring acting
as a piston.
The single rotor is located
eccentrically inside a
cylinder or stator.
COMPRESSORS
Dynamic Ejector
Radial Mixed Axial

piston
•Straight lobe
•Sliding vans
• Liquid piston

Rotary Compressors
Helical Lobe or Screw Compressors

Rotary Compressors
Oil Injected
Screw (or rotary) compressors
use two meshing helical screws,
rotating in opposite directions to
compress air.
These compressors are usually the lowest cost to install, for
large volumes of compressed gas.

Rotary Compressors
Oil Injected
Variable output and variable
speed drives are usually available
from most suppliers.

Rotary Compressors
Oil free
Carry the same benefits as oil
injected screw compressors but
compress in two stages and have
no lubricant in contact with the
gas during its passage through
the compressor.

Rotary Compressors
Oil free
Water injected screw
compressors are also available
where oil free air is required.
COMPRESSORS
Dynamic Ejector
Radial Mixed Axial

piston
•Straight lobe
•Sliding vans
• Liquid piston

Rotary Compressors
Straight Lobe Compressors
They are commonly called
blowers, and they are low-
pressure machines.
The feature unique to these
compressors is that the machines
do not compress the gas
internally as do most of the other
rotaries.

Rotary Compressors
The straight lobe compressor
uses two rotors, which inter-mesh
as they rotate.

Rotary Compressors
The features rotary compressors
have in common are:
They impart energy to the gas being
compressed by way of an input shaft
moving a single or multiple rotating
elements.
They perform the compression in an
intermittent mode.
They do not use inlet and discharge
valves.
COMPRESSORS
Dynamic Ejector
Radial Mixed Axial

piston
•Straight lobe
•Sliding vans
• Liquid piston
Continuous compression compressors

Ejectors
The ejector can first be identified as having no moving parts .

it is used primarily for that feature as it is not as efficient as
most of the mechanical compressors.

Ejectors
The ejector is operated directly by a motive gas or vapor

source. Air and steam are probably the two most common of
motive gases.

Ejectors
The ejector uses a nozzle to accelerate the motive gas into

the suction chamber where the gas to be compressed is
admitted at right angles to the motive gas direction.

Ejectors
In the suction chamber, also referred to as the mixture

moves into a diffuser where the high velocity gas is gradually
decelerated and increased in pressure.

Ejectors
The ejector is widely used as a vacuum pump, where it is

staged when required to achieve deeper vacuum levels.

Ejectors
If the motive fluid pressure is sufficiently high, the ejector can

compress gas to a slightly positive pressure.

Ejectors
Ejector are used both as subsonic and supersonic devices.

The design must incorporate the appropriate nozzle and
diffuser compatible with the gas velocity.

Ejectors
The ejector is one of the few compressors immune to liquid

carryover in the suction gas.
COMPRESSORS
Dynamic Ejector
Radial Mixed Axial

piston
•Straight lobe
•Sliding vans
• Liquid piston

Dynamic compressors
In dynamic compressors energy is transferred from a moving
set of blades to the gas.
The energy takes the form of velocity and pressure in the
rotating element, with further pressure conversion taking
place in the stationary elements.
Because of the dynamic nature of these compressors, the
density and molecular weight have an influence on the
amount of pressure the compressor can generate.

Dynamic compressors
The dynamic compressors are further subdivided into three
categories, based primarily on the direction of flow through
the machine.
These are radial, axial and mixed flow.
COMPRESSORS
Dynamic Ejector
Radial Mixed Axial

piston
•Straight lobe
•Sliding vans
• Liquid piston

Dynamic compressors
Radial flow or centrifugal compressor

Dynamic compressors
It is a widely used compressor and is
probably second only to the reciprocating
compressor in usage in the process
industries.
The compressor uses an impeller consisting
of radial or backward-leaning blades and a
front and rear shroud.

Dynamic compressors
The front shroud is optionally rotating or
stationary depending on the specific design.
As the impeller rotates gas is moved between
the rotating blades from the area near the
shaft and radially outward to discharge into a
stationary section, called a diffuser.

Dynamic compressors
Diffuser
Impeller

Dynamic compressors
Another feature of the centrifugal is its ability
to admit or extract flow to or from the main
flow stream, at relatively close pressure
intervals, by means of strategically located
nozzles.
COMPRESSORS
Dynamic Ejector
Radial Mixed Axial

piston
•Straight lobe
•Sliding vans
• Liquid piston

Dynamic compressors
Axial compressors

Dynamic compressors
Axial compressors
Axial compressors are large-volume
compressors that are characterized by the
axial direction of the flow passing through the
machine, .
Typically, the rotor consists of multiple rows of
unshrouded blades. Before and after each
rotor row is a stationary (stator) row.

Dynamic compressors
Axial compressors
A gas particle passing through the machine
alternately moves through a stationary row,
then a rotor row, then another stationary
blades row, until it completes the total gas
path.
Pair of rotating and stationary blades rows
defines a stage.

Dynamic compressors
Axial compressors
Stage Stage Stage


Dynamic compressors
Axial compressors
One common arrangement has the energy
transfer arranged to provide 50% of the
pressure rise in the rotating row and the other
50% in the stationary row. This design is
referred to as 50% reaction.
Axial compressors are smaller and are
significant more efficient than centrifugal
compressors when a comparison is made at
an equivalent flow rating.

Dynamic compressors
Axial compressors
The axial compressor, because of a low
pressure rise per stage, is exclusively
manufactured as a multistage machine.
Axial compressors are an integral part of
large gas turbines where the pressure ratios
normally are much higher. In gas turbine
service, discharge pressures up to 50 psi are
utilized.

Dynamic compressors
Mixed flow compressor

Dynamic compressors
A bladed impeller is used, but
the flow path is angular in
direction to the rotor; that is, it
has both radial and axial
components .
Because the stage spacing is wide, the compressor is used
almost exclusively as a single-stage machine.

Dynamic compressors
The compressor size is flexible
and covers the centrifugal
compressor flow range, generally
favoring the higher flow rates.
The head per stage is lower than available in the centrifugal.

An Introduction To Compression Equipment

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AN INTRODUCTION TO

From the earliest

Sailors and shipbuilders knew

Early Egyptian writings tell of Priests using simple bellows

It wasn't until the early to mid 17th century that man

The Flemish Alchemist, Van Helmont,

Robert Boyle, an English physicist in the later

Alexandre Charles discovered the laws governing the

Evangelista Torricelli in about 1630

Air, when compressed, represents a

A compressor is a device used to increase the pressure of a

The fluid can be any compressible fluid;

What does this mean?

It means that, to selection and design of any

352 Uranium hexafluoride

Molecular weight rang

Production Processing Transmission & Storage Distribution

For comparison, the different types of compressors can

Radial Mixed Axial

102 103 104 105 106

General Performance Curve

50 60 70 80 90 100 110 120

Radial Mixed Axial

Intermittent mode compressors

Intermittent mode compressors

Intermittent mode compressors

Intermittent mode compressors

Intermittent mode compressors

Intermittent mode compressors

Intermittent mode compressors

Intermittent mode compressors

Radial Mixed Axial

Intermittent mode compressors

Intermittent mode compressors

Radial Mixed Axial

Intermittent mode compressors

Radial Mixed Axial

Intermittent mode compressors

Intermittent mode compressors

Intermittent mode compressors

Intermittent mode compressors

Intermittent mode compressors

Radial Mixed Axial

Intermittent mode compressors

Intermittent mode compressors

Intermittent mode compressors

Radial Mixed Axial

Continuous compression compressors

The ejector can first be identified as having no moving parts .

Continuous compression compressors

The ejector is operated directly by a motive gas or vapor

Continuous compression compressors

The ejector uses a nozzle to accelerate the motive gas into

Continuous compression compressors

In the suction chamber, also referred to as the mixture

Continuous compression compressors

The ejector is widely used as a vacuum pump, where it is

Continuous compression compressors

If the motive fluid pressure is sufficiently high, the ejector can

Continuous compression compressors

Ejector are used both as subsonic and supersonic devices.

Continuous compression compressors