Valdel Engineers and Constructors, Ltd.

WELCOME TO THE WONDERFUL WORLD OF PIPING

COMPRESSORS
BY:

SAMI UR REHMAN
PIPING DEPARTMENT

INTRODUCTION OF COMPRESSOR

Compressors are machines which are used to increase the pressure of a gas by mechanically reducing its volume with in its casing. Closely related to the pumps. Pressure and temperature will increase. Gases are compressible fluid. Process, Chemical reactions that takes place at elevated pressure. Transportation or transmission of gases through pipelines.

CLASSIFICATION OF COMPRESSORS
Compressors can be further classified on its working principle Positive displacement compressors. Dynamic compressors.

Reciprocating Compressors

Reciprocating compressors are machine in which The compressing element is a piston following a reciprocating (linear) motion in a cylinder. Temperature is increase due to increase kinetic energy of the molecules. Generally used for small to medium volume and compress gas to extremely high pressure. Piston

Two Stage Horizontal Reciprocating Compressor

MOTOR

Lines Size 1 Stage 24to 18 2 Stage 18to 12 3 Stage 12to 10

Three stage Reciprocating Compressor

Compressor Driver
Generally Electrical motors are used for reciprocating compressors these are of two types Synchronous and Induction motor.
Synchronous

motor is exactly same as that of rotating magnetic field they are used for higher power and lower RPM. Efficiency of synchronous motor is 94-97 and is better than induction motor.

Electric Motor

Auxiliary Equipment
It is supplied by compressor vendor as a skid mounted package with equipments, its internal piping arrangements, controls and instruments. Generally skid consists of these two systems. Lubrication system Cooling system

Lubrication System
Lubrication is lifeline of any rotating machinery. the lube oil system Contains reservoir, a pair of circulation pump, shell tube coolers and a duplex filter arrangement . The main function of the lubrication are Minimize friction and to avoid contact between moving parts. Remove heat induced by friction Protect metal from corrosion.

Lube Oil Console

Lube oil console maintenance

9

Auxiliary Equipment

Lube Oil Skid

10

Use of Lubrication
Generally, two oil pumps are provided for lubrication, one driven by crankshaft is known as main oil pump (MOP) and other driven by separate elective motor is called auxiliary oil pump (AOP).

11

Cooling System
Heat is generated due to compression of the gas friction in the cylinder . The need to provide cooling can be performed with Air Water (open and close water cooling)
Its difficult to control these limits in open system the PH value range of 6.5 to 8. Hardness should be less than 200 ppm. Suspended solids less than 100 ppm. Its very easy to add additives in close circulation Water- glycol solution which has low freezing point and high boiling point with respect to water use in close circulation.
12

Accessories Suction Separator

Because compressors requires dry gas free of foreign particles, the inlet gas is passed through suction drum. Its function is to remove oil and condensates from the gas, the principles of operation are Gravity, Impingement, Centrifugal force and Filtration

Pulsation Dampener or Volume Bottle

Volume bottles accumulate sufficient volume(5-20 times of cylinder) of gas to render uniform flow of gas. Pulsation dampers are devices with the internal system capable of cutting off certain frequencies. The Pulsation dampers must be installed as close to the cylinder as possible to avoid the possibilities of acoustic resonance between cylinder and device.

13

Suction Separator

14

Pulsation Dampener or Volume Bottle

15

Location and Maintenance

When locating compressors, consideration must be given to Operability Safety Maintenance

RECIPROCATING COMPRESSORS
Reciprocating compressors must be mounted close to grade. Because of the extreme vibration in the piping system. Compressor foundation elevation depends on these steps

16

Setting Elevations of Reciprocating Compressors

Nozzle 3.Minimum Distance Required to enter the header

17

Well Ventilated

Proper Access To Valves

18

Reciprocating Compressors Arrangement

At Least Two Stairways

19

Reciprocating Compressors Arrangement

Well Ventilated To Prevent Gas Build Up From Leaks

20

Open Installation And Enclosed Structure

21

Planning For Cylinder Removal

22

Reciprocating Compressors Piping

23

Reciprocating Compressor Piping

Allowable nozzle load Eccentric Reducer with the flat side on the bottom of the pipe to prevent the accumulation of any liquids Isolation valve with spectacle blind shall be provided in the inlet and outlet piping Temporary strainers must be used in inlet. Branch connecting shall be minimized or located at near to the point where the header is anchored. Piping shall be routed as close to grade or to heavy concrete foundation as possible. Positive displacement machinery shall be equipped with a PRV. Pressure measurement connection complete with isolation valves shall be provided on the inlet and outlet piping.

24

Reciprocating Compressors Typical Piping

25

Compressors line branch

Reciprocating Compressor With all Components

26

Reciprocating Compressor Support

Pipe support must be given special consideration due to the pulsation. Rigid anchors, to provide lateral stiffness needed to restrain dynamic force Compressor piping should never be supported from shelter steel work or operating floor. And must be provided with independent foundation to avoid transmission of vibrations.

27

Reciprocating Compressor Support

28

Centrifugal Compressor

Dynamic type compressor are machine in which air or gas is compressed by the dynamic action of rotating vanes or impeller. Centrifugal compressors are used to handle large volume of gas to moderating high pressure. Gas enters the machines at the axis of high speed impeller and discharges radially into a peripheral chamber at high pressure. Centrifugal compressors may have horizontally split or vertically split casing .

29

Horizontal Split Case Compressor

Vertical Split Case Compressor

30

Centrifugal Compressor

31

Centrifugal Compressor With Lube Oil Console

Centrifugal Compressor

Lube Oil Console

32

COMPRESSOR DRIVES

Electrical motor Steam turbine Gas turbine

Steam Turbine

Back Pressure turbines are driven by high pressure steam and do not require surface condenser. Condensing turbines are usually driven by low pressure steam.

Gas Turbine
Usually employed in remote area, where gas is available for fuel.
33

Elevation for Centrifugal Compressors

34

35

36

Auxiliary Equipment For Centrifugal Compressors

Air

filters Waste heat system Lube oil seal oil console Surface condensers Condensate pumps

Maintenance & Location of Centrifugal Compressors

The oil console is located closely at the turbine end to facilitate a free draining lube oil return to the reservoir . Control panel is located On the operating floor at the driver end The size of the operating floor must be established by allowing clearance of 6 ft all around machine. An access road is required for mobile handling equipment.

37

Grade Mounted Centrifugal Compressor Open-Sided Structure

38

Grade Mounted or Elevated Centrifugal Compressor Open-Sided Structure

39

Grade Mounted Compressor Wall Shelter

40

Elevated Centrifugal Compressor No Shelter

41

Vertical Condensate Pump

Removes the condensate from the hot well in the surface condenser

Inlet Air Filter

Gas turbines require large amounts of clean filtered air for operation
42

Seal Oil Console

Reduce gas or vapor to a liquid by removing heat

43

Surface Condenser

Waste Heat System

Hot exhaust gas from gas turbines may be used to generate steam or heating the oil and may be used as a heating medium

44

ELEVATION OF COMPRESSORS

The operating floor elevation is next established by making the required headroom allowance beneath horizontal pipe run under the floor while allowing the lube oil return header to slope down To its connecting point on the reservoir. The major factor in setting the elevation of the minimum height that satisfy NPSH requirements of the condensate extraction pumps. The straight run requirements of the suction line its could be varies between 3D to 8D.

45

Surface Condenser Elevation

46

Elevated Compressor

47

CENTRIFUGAL COMPRESSORS PIPING & SUPPORT

Nozzle allowable loads. Straight run requirements 3D to 8D Suction and discharge piping on bottom

entry installations should

Preferably be run close to grade. Do not support compressor piping from the compressor foundation structure . Strainer must be installed. All Valves must be accessible ,preferable from grade. Additional flanges for maintenance. Alignment is more easily achieves if adequate field fit up welds are allowed in spools

48

Centrifugal Compressor Inlet & Outlet Nozzles

Lines Size Inlet 84 outlet 42

Outlet line
49

Inlet Line

Straight run requirements

50

Strainer Must Be Installed.

Additional Flanges For Maintenance

51

Valves Must Be Accessible

52

QUESTION ??

53