COMPRESSOR

Gas Compressor is a mechanical equipment used to transport fluids from one place to another
place by increasing the gas pressure with reducing its volume. This process of increasing the
pressure of a gas naturally followed by the increasing of gas temperature.

Types of gas compressor :

1. Positive Displacement
Positive displacement compressors work with a constant flow regardless of outlet
pressure. In positive displacement compression, the air flow in into one or more of its
compression chambers, which are then closed from the inlet. Then the air is compressed
internally until the pressure reaches its targeted pressure ratio. Then, the valve opens
and the air is discharged into the outlet system.

- Reciprocating
Reciprocating compressor is one of positive displacement compressor type. Use psiton
driven by the crankshaft to compress the gas entering the chamber and deliver the gas
at high pressure. Reciprocating Compressor itself is divided into two types of
compressor:

Separable Compressor (High Speed)

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Separable term is used due to the installation of the reciprocating compressor is

installed separately with its driver either an engine or an electric motor. Typically
operated at 900-1800 rpm.
Separable units self-contained and skid mounted. They are easy to install, relatively
small initial cost, easily moved to different sites, and are available in sizes appropriate
for field gathering both onshore and offshore. However, separable compressors have
relatively higher maintenance costs comparing than integral compressors.

Separable compressor best used when:

- High fuel Cost

- No waste heat required
- Minimum initial cost required
- Maximum operating flexibility
- Relocation may be required
- Medium Project life is required

Integral Compressor (Low Speed)

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The integral term is used because the driver (power cylinder) that drive the compressor
are mounted integrally with the frame containing the compressor cylinders. Integral
units run at speeds of between 200 and 600 rpm (lower than the separable). They are
commonly used in gas plants and pipeline service where fuel efficiency and long life are
critical.

Integral compressors offer high efficiency over a wide range of operating conditions and
require less maintenance than the separable units. However, integral units usually must
 be field-erected and require heavy foundations and a high degree of vibration and
pulsation suppression. They have the highest initial installation cost.

Separable compressor best used when:

- Less maintenance needed for the project

- Have a long lifetime project period
- Maximum operating flexibility
- Have a good fuel efficiency

- Rotary
Rotary Screw Compressor

https://www.quora.comcompressor

Rotary compressors are the another type of famous compressors that belongs to
reciprocating type. .It uses two Asymmetrical rotors that are also called helical screws to
compress the air. The rotors are covered by cooling jackets. Two shafts on the rotors are
placed that transfer their motion with the help of timing gears that are attached at the
starting point of the shafts/compressor

The equipment starts to work when Air sucked in at one end and gets trapped between the
rotors( helical screws) and get pushed to other side of the rotors .The air is pushed by the
rotors that are rotating in opposite direction and compression is done when it gets trapped
in clearance between the two rotors. Then it pushed towards pressure side. Rotary screw
compressors are of two types oil-injected and oil-free. Oil-injected is cheaper and most
common than oil-free rotary screw compressors.
 The advantages of using Rotary Screw Compressor:

1. Less noisy.
2. Supply large amount of compressed air, called work-horses
3. More energy efficient than piston type compressors
4. Having continuously air supply comparing to the reciprocating type
5. Have a relatively low end temperature of compressed air.

The disadvantage of using Rotary Screw Compressor:

1. Expensive then piston-type compressors.

2. More complex design.
3. The maintenance is very important

Scroll Compressor(Spiral Compressor)

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One of the best compressor in types of rotary . The air is compressed using two spiral elements.
One element is static and not doing any movement and the other one moves in small eccentric
circles inside the spiral. Air gets trapped inside the spiral way of that element and get
transported in small air-pockets to the center of the spiral.

then air gets trapped at the outer edge and get compressed due to reduction of the area as it
travels from outer edge to inner edge . It takes 2 to 3 turns for the air to reach the pressure
output in the center.
The Advantages of using Rotary Scroll Compressor

1. Very quiet.
2. Compact in size
3. Not need to many parts
4. Low maintenance

The Disadvantages of using Rotary Scroll Compressor

1. Low output capacity

2. Relatively expensive
3. You have to buy a new scroll element with the failure of it even if there is not any big
problem.
4. The temperature of compressed air is too much high.

Vane Type Compressor(Spiral Compressor)

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This is an another type of rotary compressor.There is a fixed casing in Vane type compressor in
which a rotary rotor disc is placed which has slots that are used for holding the sliding plates.

Whenever rotor rotates the disc also rotates thus allowing the sliding plates to slide as the
inner surface of casing is eccentric.Whenever the plates moves away from the center a huge
amount of air get trapped inside it and with the rotation the sliding plates converge due to its
shape and the trapped air get compressed.This results in compression of air.

Lobe Type Compressor

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In this compressor there is no complicated moving part.There are two lobes attached to the
driving shaft by the prime mover.These lobes are displaced with 90 degrees to one
another.Thus if one of the lobe is in horizontal direction the other lobes will be exactly
positioned at 90 degree i.e in vertical direction.

The air gets trapped from one end and as the lobes rotates the air gets compressed. The
compressed air is then delivered to delivery line.
 2. Dynamic

- Axial Compressor

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An axial-flow compressor is a type of dynamic compressor in which the working fluid, such as
air, is compressed in a series of stages as it flows axially (parallel with the axis of rotation),
through a decreasing tubular area. Axial compressors are widely used in gas turbines, such as
those in jet engines, high speed ship engines, and small scale power stations.

An axial-flow compressor compresses its working fluid by first accelerating the fluid and then
diffusing it to obtain a pressure increase. The fluid is accelerated by a row of rotating airfoils
(blades) called the rotor, and then diffused in a row of stationary blades (the stator). The
diffusion in the stator converts the velocity increase gained in the rotor to a pressure increase.

Several Stage of an axial compressor:

1) A combination of a rotor followed by a stator make-up a stage in a compressor;

2) An additional row of stationary blades are frequently used at the compressor inlet and are
known as inlet guide vanes to ensue that air enters the first-stage rotors at the desired flow
angle, these vanes are also pitch variable thus can be adjusted to the varying flow requirements
of the engine; and

3) In addition to the stators, another diffuser at the exit of the compressor consisting of another
set of vanes further diffuses the fluid and controls its velocity entering the combustors and is
often known as the exit guide vanes.

- Centrifugal
Overview

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The basic principle of how centrifugal compressor work is increasing the velocity of fluid coming
through the inlet part, then gradually decreasing the velocity of the fluid by using diffuser and
convert it to static pressure force. The fluid’s flow from the diffuser is being collected by using
the volute casing and deliver to the outlet part.
Components
Casing and Inlet/ Suction Port

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As the first entrance for the gas before being processed by the impeller. Usually shaped as a
simple pipe. Sometimes several additional devices being added to this part such as sensors,
valves, stationary vane which can affect the control of the centrifugal compressor. A case house
consists of number of bearings in order to provide radial and axial support of the rotor. The
case also contain nozzles along with inlets and discharge flow connections in order to introduce
and extract flow from the compressor.

Casing are of two types :-

a.) Horizontally split

b.) Vertically split

Centrifugal Impeller
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As an equipment responsible for generate kinetic energy for the fluid. There are blade attached
on rotating disk. The blade could be installed on several type of installation such as radial,
backward leaning, and forward leaning. This centrifugal impeller is assembled on steel shaft
which driven by electricity to give a kinetic force to the fluid.

For most applications, high-strength alloy steel is selected for the impeller material. Stainless
steel is often the material of choice for use in corrosive environments. Because the impellers
rotate at high speeds, centrifugal stresses are an important design consideration, and high-
strength steels are required for the impeller material. For gases containing hydrogen sulfide, it
is necessary to limit the impeller material’s hardness (and therefore strength) to resist stress
corrosion.

Diffuser

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Diffuser as one of the key parts for the compressor. Responsible for decreasing the velocity of
the gas produced by the impeller and converting the kinetic energy contain inside the gas into
static pressure as well. The diffuser usually formed two walls which form a radial channel.
Because of these arrangements the velocity of the gas decreases and dynamic pressure is
converted into static pressure.
Volute Casing

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Last stage, after the gas flowing through the walls and the velocity is decreased, the gas being
collected by the volute casing in order to direct the gas into discharge section.

Types of Centrifugal Compressor:

1. Single Stage Compressor

Single stage compressors consist of only a single impeller and it is use for moving the air or
other gases up to 3 to 1 compression ratio for either pressure or vacuum duty. In this type
of arrangement the impeller is at the non-driving end of the shaft. One major advantage of
it over the multistage compressor is that it provides high efficiency and the delivered gas is
totally oil and surge free.

2. Multi Stage Compressor

Multistage compressors consists of 1-10 impellers and it can be arranged in a variety of flow
path configurations. Throughout each and every stage the temperature and the
compression ratio are assumed to be constant. Multistage compressor can be arranged in
straight-through, compound, and double flow configurations.
Test Facilities Centrifugal compressors are carefully tested throughout the manufacturing process in
order to guarantee a perfect match to their design criteria and to assure long lasting, continuous
operation. The following tests are typically carried out on components and assembled machines: -
casing: hydraulic pressure test - impellers: ultrasonic and dye penetrant liquid tests; over speed testing -
impellers/rotors: over-speed testing - mechanical run test Optional tests may be performed based on
the specific job requirements. For example: - performance tests (with air or other gases in an open or
closed loop) - full load - performance tests (including flammable gases) to check rotor stability and the
performance of the machine - mechanical string test. Numerous indoor and outdoor test beds together
with a sophisticated system for data acquisition and processing of test results distinguish the Florence,
Massa and Le Creusot facilities. We have the largest and most complete testing capability in the industry
to perform tests under actual load and pressure conditions (including LNG and re-injection) for trains
driven by gas turbines or electric motors.