What is Compressor ?

– Compressors are machines required for

transportation /movement of gases in the
system.
– Purpose of these machines is to increase the
pressure of a gas from one level to another
level.
– Trouble free and smooth operation of
compressors is vital for process plants.
– Interruption results in huge production loss.
 Type of Compressors
• Two principle methods are used to
compress gases.
1. To trap a volume of gas and displace it by
the positive action of a piston or rotating
member. Positive Displacement
Compressor
2. Dynamic compression which uses action
of contoured blades to increase velocity
and then convert in pressure Dynamic
Compressor
 COMPRESSOR TYPES
COMPRESSORS

POSITIVE DISPLACEMENT DYNAMIC FLOW

Reciprocating Axial
Rotary Screw Centrifugal
Rotary Vane
Dynamic Type Compressors
A. Centrifugal Compressors - The machine in
which velocity and pressure are imparted to
the gas in a redial direction by one or more
impellers- diffuser combination.

B. Axial Compressors – The machine in which

velocity and pressure are imparted to the gas
in an axial direction by one or more sets of
moving and stationary rows of blades.
 Positive Displacement
Compressors
A. Reciprocating Compressors - The machine
in which the compressing element is a piston
following a reciprocating motion in a
cylinder.
B. Rotary lube Compressors – The machine in
which two mating lobe impellers revolve
within a cylinder and are prevented from
making contact with each other by timing
gears mounted outside the cylinder. The gas is
trapped by the lobes, which displace it from
intake to discharge.
 Positive Displacement
Compressors
A. Reciprocating Compressors - The machine
in which the compressing element is a piston
following a reciprocating motion in a
cylinder.
B. Rotary lube Compressors – The machine in
which two mating lobe impellers revolve
within a cylinder and are prevented from
making contact with each other by timing
gears mounted outside the cylinder. The gas is
trapped by the lobes, which displace it from
intake to discharge.
 Positive Displacement
Compressors
C. Liquid Ring Compressor -
– Liquid ring compressors are frequently used
in applications where the compression ratio is
less than 5:1.
– A flow of liquid for removing heat of
compression.
– Absence of close clearances and the flow of
flushing liquid permits liquid ring compressor
to tolerate liquid and solid carry over to
suction.
 Fans & Blowers
– Though they belong to the same family of
compressors, they are differentiated from
compressor in nomenclature.
– This is most likely due to the fact that the
pressure development is marginal and does
not affect much of volume reduction..

1. FANS : Delivery pressure is less than 0.5 psi.

2. Blowers : Delivery pressure is up to 1.65 psi.
 Selection of Compressor
– Selection of compressor depends on
following factors.
A. Capacity
B. Pressure ratio requirement
C. Duty – Intermittent or Continuous
D. Criticality of service
E. Operating variations
 Selection of Compressor
- Centrifugal compressors are essentially a variable capacity
constant pressure machine.
- Axial compressor and positive displacement compressors are
essentially a constant capacity, variable pressure machines.
Axial
Centrifugal

Pressure

Positive
displacement
Capacity
 Selection of Compressor
Capacity :
• As a general rule, positive displacement machines are for
smaller capacities, centrifugal compressors for medium
capacity and Axial compressors for larger capacities.
• However, there is considerable overlap of capacity range
between these different types of compressors.
• Broadly, Below 3000 m3/hr  Positive displacement
Above 30000 m3/hr  Axial Compressor
3000-12000 m3/hr Overlap between positive
displacement and Axial
12000-120000 m3/hr  Overlap between
Centrifugal and Axial
 Comparison

• Centrifugal • Reciprocating
– Low Maintenance – Highest Maintenance
– Low Civil Work – Complex Installation
– Pulsation free – Need Air Receivers
– Higher Flows – Low Flow/Large Size
– Newer Technology – Old Technology
– Low Unit Power – High Wear
 Comparison

  Oil Free Screw

Centrifugal
– Low Maintenance – Air End Replacement
– Easy Access – Difficult Access
– Site Maintenance – Shop Maintenance
– Long rotor life – Limited rotor life
– Large clearances – Small clearances
– Higher Flows – Lower flows
 Centrifugal Compressor
1. Horizontal Split :
• Permits easy removal of rotor
• Permitted up to 70 bar internal pressure
• For erection and dismantling, the top half of the casing,
complete with the associated stationary components, can be
handled as a single unit.
• Possible to have all types of drives like motor, steam turbine,
gas turbine etc.
2. Side stream Compressors :
• In multistage refrigeration processes, different mass flows pass
through various levels of refrigeration.
 Centrifugal Compressor
• These requires injection of refrigerant vapors to compressor at
intermediate stages where it gets mixed with discharge of
previous stage before feeding to next stage.
3. Vertically Split (barrel Type):
• Preferred for high pressure application or for compression gases
rich in hydrogen.
• Cylindrical casing ensures good stress distribution and
extremely good gas tightness.
 Axial Compressor
• A massive rotor with several rows of blades rotating in a casing
containing rows of stationary blades.
• Energy is provided from driver through rotor to axial blades.
• Typically, energy transfer is arranged to provide 50% of the
pressure rise in the rotating row and the other 50% of the
pressure rise in the stationary rows. This type of design is called
50% reaction design.
• Axial compressors are more suited for higher capacity and
comparatively lower pressure application.
• These offers high efficiency and smaller foundation
requirement.
 Reciprocating Compressor
• Reciprocating compressors are the best known and most widely
used compressors of the positive displacement type.
• They operates on the principal of reducing the volume (increase
in pressure), of specified quantity on trapped gas in an enclosure
and then compresses gas is pushed out of the enclosure.
• Advantages :
1. High Compression ratio : Due to positive displacement action,
they are capable of extremely high compression ratios and
pressure levels.
2. Delivers fairly constant volume over wide pressure range.
3. Molecular weight flexibility : Whether a low MW gas such as
hydrogen or extremely high MW gas can be compressed.
 Reciprocating Compressor
• Disadvantages :
1. Pulsating flow : Due to pulsation on the suction and discharge of the
machines, pulsation suppression device are required to dampen the
pressure wave amplitudes.
2. Poor reliability : Due to reciprocating motion the parts are subjected
to more wear and tear, this requires opening of machine periodically.
3. More plot area requirement compared to centrifugal machines.
4. More maintenance cost
 Classification of Reciprocating
Compressors
• Cylinder Lubrication :
1. Lubricated Compressors : Generally big compressor cylinders are
lubricated to avoid wear and tear of liner, piston etc. Lubricants are
injected in drops and are lost with the process.
2. Non-Lubricated Compressors : There are many services in which oil
in any form in the compressed gas, is not acceptable such as
instrument air compressors etc. In such cases, oil is not injected in
the cylinders, instead wear parts are made of soft material with low
co-efficient of friction such as PTFE etc.
In short, process requirement and gas to be compressed dictate
whether to use compressor with lubricated or non-lubricated
cylinder.
 Classification of Reciprocating
Compressors
• Cooling Type :
1. Air cooled type : This type of compressors has fins cast as part of
the cylinder to dissipate some of the heat generated by the
compression of the gas. Generally used in small portable
compressors.
2. Water cooled type : Water cooled compressors are most commonly
used in industry as it is impossible to sustain cooling with air in big
compressors, where heat generation is very high. Water is circulated
in cylinder jacket from some external source.
 Classification of Reciprocating
Compressors
• Loading Type :
1. Single Acting : In single acting cylinder, compression takes place
only on one side of the piston and valves are installed only on that
side.
2. Double acting : In double acting cylinder compression takes place on
both sides of the piston. When one side is in compression, the other
is in suction.
 How to decide no. of stages of Cent.
compressor

• Ideal process in isothermal

• Economic trade off between operating cost
vs. capital cost.
• Maximum discharge temperature limits of
compressor (200-250 deg C)
• Division with equal power. Compression
ratio will change with flow & properties.
 Compressor Drivers
• For centrifugal & Axial Compressor first preference  Turbine
drive.
A. Variable speed and no opening of min. flow valves
B. Large capacity means large power requirement which makes
capital investment economical
C. Possibility of efficient steam system design
D. Better turn down
• Reciprocating machines are almost motor driven,
A. No incentive for capacity control using speed as it can be
controlled using unloaders
B. Turbine / reciprocating compressor combination has poor
reliability.
 Compressed Air System
Inlet
Filter Control Valves
Bypass Throttling and
Unloading Valve
Inlet Throttling
Valve

Compressor System
Typical Compressed Air System
CICB
Compressor Performance Curve
115
Surge

105
Discharge Pressure (PSIG)

Design

100
Turndown

95
Stonewall

85
1100 1200 1300 1400 1500 1600

Volumetric Flow (ACFM)

CICB
Power Curve
325

Design
300
Shaft Horsepower (SHP)

Surge
Stonewall
250

225

Turndown
200
1100 1200 1300 1400 1500 1600

Volumetric Flow (ACFM)

CICB
Compressor Operating Point
C
A B

C’
Discharge Pressure

A’

B’

Volume Flow
CICB
Performance
“In general”
• The more stages, the more efficient the
compressor.
• Centrifugals are more efficient, at full and
part load, than oil free rotary screws.
Inlet Guide Vanes A Misconception

• Do Inlet Guide Vanes Really Save Energy

As Claimed By Manufacturers??
• When Does A Inlet Guide Vane Effective??
• Inlet Guide Vanes (IGVs) can save money
at part load: The greater the throttle, the
greater the savings. IGVs pre-swirl the air
on its way to the impeller.
 Parameters Which Effect The
Performance
• Relative Humidity
• Inlet Air temperature
• Cooling Water Temperature.
• Electrical Voltage And Frequency
 COMPRESSOR PERFORMANCE CURVE
7.0
Surge
Discharge Pressure (KG/CM²G)

6.5

Rated
6.0
Turndown
5.5

Stonewall
5.0
12000 12500 13000 13500 14000 14500 15000 15500 16000 16500 17000
Volumetric Flow (M3/Hr)

Performance Curve is fixed for a constant speed

 FAN LAWS

• V2/V1 = N2/N1 V = Volumetric Flow Rate

H = Differential Head
• H2/H1 = (N2/N1)2
N = Speed
• K2/K1 = (N2/N1 )3
K = Power
f = frequency (50 Hz)
P = No. of Poles
• N = 120f / P
Compressor Speed is directly proportional to electrical frequency.
A reduction in frequency of 5% reduces the speed by 5%.
 PERFORMANCE VARIATION
(for single stage machine)
V
P
COMP
K
MOTOR
N
Effect of 5% reduction in speed on other parameters
V = 0.95 V
P = 0.9025 P
K = 0.857 K
 EFFECT OF SPEED VARIATION
Discharge Pressure (Kg /cm2 G)
9.5
9.0
8.5
8.0
48Hz
7.5
7.0
6.5
47.5 Hz48.5 Hz 50Hz
6.0
16 17 18 19 20 21 22 23 24 25
Volumetric Flow ( Thousand M3/Hr)

Surge Control (3 psi)

Surge
 PERFORMANCE AT DIFFERENT FREQUENCIES
Reliance, Hazira (existing)
Discharge Pressure (Kg /cm2 G) 9.5
9.0
8.5
8.0
48Hz
7.5
7.0
6.5
47.5 Hz48.5 Hz 50Hz
6.0
16 17 18 19 20 21 22 23 24 25
Volumetric Flow ( Thousand M3/Hr)
Rated Conditions
V= 23780 M3/hr, P = 8.09 kg/cm²G, Speed at 50 Hz
Safe operation at 48.5 Hz
 OPTION 1 : RELIANCE HAZIRA
RERATED AEROS

Discharge Pressure (Kg /cm2 G)

11.0
50Hz (Unthrottled)
10.0 50Hz (Throttled)
49Hz
9.0

8.0

7.0 47.8 Hz
48.5 Hz
6.0
16 17 18 19 20 21 22 23 24 25
Volumetric Flow ( Thousand M3/Hr)
Rated Conditions
V= 23780 M3/hr, P = 8.09 kg/cm²G, Speed at 49 Hz
Safe Operation at 47.8 Hz
PERFORMANCE AT DIFFERENT FREQUENCIES

Discharge Pressure (Kg /cm2 G)

Reliance Refinery, Jamnagar
12.0
50Hz
11.0
50Hz
10.0
47.8 Hz
9.0

8.0

7.0
18 20 22 24 26
Volumetric Flow ( Thousand M3/Hr)

Speed at 50 Hz, Effect of frequency not considered

Speed at 50 Hz, Safe Operation at 47.8 Hz
 CONCLUSION
• Compressor tends to surge at low frequencies
• Both flow and pressure reduce with frequency
• Compressor performance curve changes

• Compressor selection depends on limits of the

frequency between which compressor operates
• Power consumption is dependent on above
compressor selection
ELECTRICAL FREQUENCY VARIATION IS
AN IMPORTANT DESIGN SPECIFICATION
 Problem Reasons
1 Compressor fails to Discharge pressure set point
develop design is low.
pressure Unloading Control valve is
open and in manual control
Defective discharge pressure
Transmitter
Pneumatic Air Supply to
control valve improper.
Improper Control Signal
Excessive System Demand
Compressor Operating On
Intermittent or dual mode.
Worn out internals
 What To Check & When ??
Problem Reason
2 Frequent Surging •Drastic variation in
Consumption
•Choked inlet filters.
•Unloading valve malfunction
•Inlet valve malfunction
•E/P or I/P malfunctioning
•High Interstage Air Temp.
•Wrong Control Setting.
•Inadequate Control Air
Supply
•Operation at Lower Electrical
Frequency
•Check Valve wrongly fitted
 Problem Reason
3 Excessive Vibration •Dirt Build up on
impellers
•Water in the air
/gas stream
•Piping strain
•Vibration from near
by Equipment
•Coupling
Misalignment
•Dry Coupling
•Impeller Rub
•Excessive bearing
wear
 Problem Reasons
4 Rotor •Rotor Unbalance due to
Vibrations Excessive surging
Impeller not mounted
properly
Poor balance of rotor
Dirt Build up
•Defective Vibration System
Out of Calibration
Oil Splashing on probe.
Electrical Noise
Loose Connection
 Problems Reasons
5 Bearings •Inadequate oil supply
damaged/ •Excessive compressor surge
Abnormal •Excessive oil temperature
Bearing
wear •Dirty Oil Temperature
•Dirty Oil
•Thrust bearing failure
•Water in lube oil
6 Seal Rub •Seals Installed incorrectly
•Non concentric back plate
•Seals assembled incorrectly
 Problem Reason
7 Impeller •Foreign debris entering the
damage inlet of compressor
•Insufficient impeller
clearance
•Back plate deflection/ piping
strain
•Water / condensate carryover
•Excessive compressor surge
 Problem Reasons
8 Oil Mist •Oil Mist eliminator is
Eliminator bypassing the elements
smoking •The oil in the reservoir is
excessively foaming.
•Motor of the oil mist
eliminator is not
operating.
 Problem Reasons
9 High Motor •Low Supply voltage
Amps •Voltage unbalance
•Incorrect Control set points
10 High •Inadequate lubrication
bearing •Excessive lubrication
temperature
11 Motor •Uneven air gap in the
Humming circumference of the rotor
Noise and stator
•Fan Unbalance
 Problem Reasons
12 Driver  Motor Current set point
overloads too high.
/trips Inlet Guide vanes is in
manual control
Defective Analog Signal to
inlet control valve.
Defective motor current
transmitter.
Motor starter set points
are improperly set
Inlet Air temperature
below Design
 Problem Reasons
13 High Lube oil Low cooling water flow to
Temperature oil coolers.
High Cooling water inlet
temperature
Dirty / choked oil cooler
Defective Oil Temperature
Transmitter
 Problem Reasons
14 Low Lube oil Main /AOP pump
Pressure defective
Defective / improperly
adjusted relief valve
Oil pump suction
obstructed
Air leak in the oil pump
suction line.
Dirty oil filter cartridge.
Defective oil pressure
transmitter.
 Incorrect Analog Signal
Oil Leakage
 Problem Probable reasons
15 Inlet valve fails  Leak / Obstruction in the the
to operate/ air line to inlet valve.
Erratic Defective inlet valve actuator.
Operation Low Air Supply Pressure.
Defective inlet valve I/P
transducer
Defective / improperly adjusted
current transmitter
Improper proportional band or
reset options chosen
Inlet valve is not in desired
control mode.
Incorrect analog signal
 Problem Reasons
16 Unload Valve  Leak / obstruction in the
does not air line to unloading valve.
operate/ erratic Defective unloading valve
operation actuator
Low Air supply pressure
Defective unloading valve
I/P Transducer
Incorrect Analog Signal
Defective / Improperly
adjusted discharge
pressure transmitter.
Unloading valve is not in
the desired control mode.
Problem Reasons
Water in lube Leak in oil cooler
oil Condensation in oil
reservoir
Low bearing Excessive water flow
oil through cooler
temperature AMOT malfunctioning
Monitoring of centrifugal
compressors
 Centrifugal compressor monitoring
Why to monitor
• They are generally single line equipment and any deterioration
in performance directly affects the plant throughput /
performance.
• These are among the largest consumers of utilities in the plant
and thus affect the utility bill significantly if health is poor.
• Maintenance is extremely expensive
• Monitoring presents the only tool available to detect this
deterioration, correct online if possible or attend successfully
in a turnaround.
• Opportunities for a turnaround in plants are very few.
 Theory of compression
• A centrifugal compressor is like a turbine operating in reverse
• We get back to our favourite equation for open systems
[(H+u2/2+zg)m] = Q - W

1 2

Generally very small Q W

• Here on the treatment of compressors is slightly different
• Gas compression is modeled either as an adiabatic process or a
polytropic.
 Theory of compression - adiabatic
processes
• An adiabatic process is one which is similar to the turbine and
thus we end up as in a turbine
[(H)m] = + W (note change in sign)
• Thus if the change in the enthalpy of the fluid is known the
work required for compression can be calculated
• The lower is the change in enthalpy for a given discharge
pressure, the lower is the work required for compression
• As in a turbine, the minimum amount of work required to raise
the pressure of the gas in a adiabatic process is done if the
compression is reversible (process called isentropic)
• This minimum work is called ideal or isentropic work required
for the compression
 Performance of real compressors
• Unfortunately like turbines real compressors don’t run
isentropically.
• Their performances is however judged by how closely they
approach the adiabatic reversible curve.
• The thermodynamic performance evaluation of the compressor
is in terms of the adiabatic efficiency which is defined as
adia = Wisen / Wreal
• If the assumption of an adiabatic process (Q = 0) is valid
adia =  Hisen /  Hreal
• Adiabatic compressor efficiencies are in the range of 70 to 85 %
 Adiabatic Compressor - example
• H2S is compressed from 100 F and 14.7 psia to 65 psia.
• The compressor discharge temperature is 440 F
The problem is to find the adiabatic reversible(isentropic efficiency.
From mollier charts
Hinlet = -86 Btu/lb Sinlet = 1.45 Btu/lb/F
Hout = -1.7 Btu/lb Sout = 1.48 Btu/lb/F
Houts = -27 Btu/lb Souts = 1.45 Btu/lb/F
adia =  Hisen /  Hreal = (-1.7 - (-86))/( -27 - (-86))
= 70%
• The outlet temperature in the adiabatic process would have been 345 F
 Adiabatic compressor
• For single components which have mollier charts or
property databases (giving enthalpy variation), this method
is the best to follow (steam , ethylene, propylene etc)
• If enthalpy data is not available the estimation of  Hreal
should be done from the Cp data from the thermodynamic
PVT relations
• These calculations can now be easily, quickly and
accurately done on any commonly available software such
as ASPEN, HYSIS, CHEMCAD.
• If software are not available the procedure for efficiency
estimation needs to be suitably simplified.
 Adiabatic compressor - ideal gas
• For ideal gases undergoing reversible and adiabatic compression (isentropic) it is known
that the final pressure temp. are related to the initial conditions by
P (1-  ) / T = constant. (k) is the ratio of the specific heats of the gas
 =Cp / Cv
• From this the work done for reversible compression of an ideal gas for an open system
can be estimated as
Wisen =  / (-1)* RT1[ (P2/P1)(-1 ) /  -1] per mole of the gas
• The derivation of this equation assumes that  is constant over the range of temperatures
involved
• The adiabatic ideal gas efficiency we saw was
adia = Wisen / Wreal
If the heat capacities of the ideal gas are assumed to be constant over the compression then it
can be shown that
T2r = T1 + (T2isen - T1) / adia
 Adiabatic compressor - ideal gas
• Thus
T2r = T1[1+(1/ adia)*((P2/P1)(-1) /  -1))]
• In operation all the temperatures and pressures are known and the adiabatic ideal gas
efficiency can be calculated from the above equation
• For the solution  needs to be known.  is a fairly strong function of temperature and so a
average value of  at the inlet and outlet temperatures should be taken
• e.g. An ideal gas undergoes an adiabatic compression with P2 / P1 = 3 T1 = 35 C and T2 is 195
C. avg. = 1.4
If the compression had been reversible the outlet temperature would be T2isen = T1(P2/P1) (  -
1)/ 
= 148.7 C. (Use T in deg K for calc)
From above adia = 71 %
Adiabatic compression- ideal gas
• A more accurate way to handle ideal gases is to use
adia =  Hisen /  Hreal where both subscripts refer to ideal
gases but in reversible and irreversible processes
• The  H and  S for an ideal gas are
 H =  Cp dT  S =  Cp / T dT - Rln (P2 / P1)
• Using the equation for ( S=0) the final temperature in the
isentropic process can be estimated by trial and error
• Using this temperature and the relation for  H we can estimate 
Hisen .
  Hreal can be estimated from the equation directly since T2r is
known.
• Thus efficiency can be estimated
 Adiabatic compressor - ideal gas
example
• We will take the same example of the H2S solved earlier accurately using mollier
chart
Conditions are 100 F and 14.7 psia to 65 psia and 440 F
Cp data is available as
Cp = 7.629 + 3.431*10-4*T +5.809*10-6*T2- 2.81*10-9 *T3
T is in deg K. Objective is to find adiabatic efficiency
• We solve  S = 311 Cp / T dT - Rln (P2 / P1) = 0
By trial and error Tisen is obtained so that  S is 0
• We get Tisen = 441 K = 335 F ( Compare with 345 F from mollier chart).
• Using this temperature we solve for  Hisen =  Cp dT = 58 BTU/lb (59)
• Using the same equation for  H we solve for  Hreal = 83.1 Btu/lb
Thus the efficiency is adia = 69.8 % (compare with 71 earlier)
Here since the pressures involved are relatively low ideal gas
assumption gives very good results
 Adiabatic compression - real gases
• Again, no gas is ideal. At higher pressure and low temperatures
the assumption gives erroneous results
• However we can model most gases by the equation PV = ZRT to
account for the non-ideality. Z is called compressibility
• The work equation can then be suitably modified as
Wisen = (Z1+Z2)/2*  / (-1)* RT1[ (P2/P1) (  -1) /  -1] per mole of the gas
• The Z values can be found from standard compressibility charts
• The  if not available, can be estimated as in the case of an ideal gas
(Cp / Cv and Cp - Cv = R)
• For estimating Cp for mixtures mole weighted value should be used
• More accurate methods which take into account the variation of Cp
with pressure and calculate  H are available in standard textbooks on
thermodynamics
 Estimation of compressibility
• Thermodynamic compressibility charts are available
in any standard textbook
• These chars plot Z against the reduced pressure (P r =
Pact / Pc) with reduced temperature Tc as a parameter
• For mixtures (Pc)mix =  xiPci and (Tc)mix =  xiTci
should be use to find Z
• Since both Pact and Tact are available the
compressibility Z can be read of these charts
 Standard compressibility Chart

Z
Gas compression -Polytropic process
• The compression can also be modeled by a reversible polytropic
process.
• This process is modeled by a work effect (W) and a heat effect
(Q) to reach the final state of the gas.
• In a reversible polytropic process the PV relation of the gas can
be depicted by PVn = constant.
• n is called the polytropic coefficient.
• The reversible work required to be done for an real gas is
Wpoly = Zavg*n / (n-1)* RT1[ (P2/P1) (n -1) / n -1] per mole of gas
• The compressibility factors are determined from standard
compressibility charts.
 Estimation of polytropic efficiency
• The polytropic coefficient is calculated from P(1-n) /n ZT = constant
using values of P and T from the operating compressor
• After n is estimated, the polytropic work is calculated as
Wpoly = Zavg*n / (n-1)* RT1[ (P2/P1) (n -1) / n -1]
• then W real is calculated from the enthalpy difference between the
suction and discharge states.
• Finally the efficiency is calculated from
poly = Wpoly / W real
• If the gas is ideal then the equation for poly can be simplified as
poly = n /(n-1)
avg. / (avg.-1)
• Typical range of Polytropic efficiencies is between 75 - 88 %
• If the compressor is multistage, similar estimates are done for each
stage
 Advantages of Polytropic
efficiency
• Polytropic process model is preferred to the adiabatic model for
two main reasons
– The Polytropic efficiency is independent of the
thermodynamic state of the gas undergoing compression
whereas the adiabatic efficiency is a function of the pressure
ratio
– The sum of the Polytropic heads for each stage in a
multistage compressor equals the Polytropic head to get
from state 1 to 2. This is not true of the adiabatic heads
• Hence we should monitor the compressors
performance using the polytropic efficiencies
 Types of Polytropic efficiency
• There are two types of Polytropic efficiencies that compressors vendors
generally refer to
– Internal - This refers to the efficiency associated with the process of
raising the gas from the conditions at the eye of the impeller to the
discharge conditions.
– External or flange to flange - This refers to the efficiency in raising the
gas from conditions at the inlet flange to the conditions at the
discharge flange.
• The external efficiency has the advantage that it takes into account
– The inlet flange pressure drop
– Effects of balance piston leakage
– Effects of mechanical losses on the efficiency
– The total power for compression can be directly calculated from the
plotted Polytropic head, efficiency versus flow curves
Thus the external curves should be used for monitoring
whenever available
 Polytropic compressor - example
• Gas mixture with composition
5 % ethane 80 % propane 15% n-butane from 2 bara 15.5 C to 6.9 bara and 70.5
C
• Objective is to find the Polytropic efficiency and the required power
MW = 45.4, Pc = 42.1bara, Tc = 66 C, avg. = 1.126
• From the Pc and Tc and the actual temperature and pressure data we find that Z1 =
0.955 and Z2 = 0.925 Zavg = 0.94
• To estimate the Polytropic coefficient new use the relation for ideal gases as an
approximation
T2real = T1(P2/P1) ( n -1)/ n n = 1.17 (Use T in deg K)
Then poly = n /(n-1) = 77 %
avg. / (avg.-1)
 Polytropic compressor - example
• To estimate the work done we use

Wreal = n / (n-1)* ZavgRT1[ (P2 / P1) ( n -1) / n -1]

poly
= (6.88*0.94*8.314J/mol/K*288.7K*0.197)/0.77)
= 3975 J/ mol
• The power require by the driver should also include losses
in the bearings and seals. These are added to the above
• Approximate mechanical losses as a percentage of of Gas
power Power KW Losses %
0-2500 3
2500-5000 2.5
5000-7500 2
7500+ 1.5
Polytropic compressor calculations
• The method used in the earlier example to calculate poly can
sometimes lead to serious errors as the equation is true for ideal gases
only poly = n /(n-1)
avg. / (avg.-1)
• Here avg corresponds to the ideal gas value
• The error is introduced because of the way value of  (K) is defined
in the compressor data sheet
• If the  value in the data sheet, is the value estimated for the process
fluid as if it were an ideal gas,( no effect of pressure on Cp) the
efficiency results match the design Polytropic efficiency very closely
• However, if the compressor vendor reports the true value of  in the
data sheet it results into huge errors
• Let us look at an example
 Polytropic efficiency calculations -
Discrepancies
• We look at cracked gas compressor at NC / GC.
• The design data is for the NC CG compressor fourth stage is
P1 = 12.26 kg/cm2a, P2 = 26.83 kg/cm2a, T1= 314 K, T2 =376 K
Z1=0.97, Z2=0.969 ( avg)ideal gas = (1.244+1.219)/2 = 1.232
• We estimate n from T2real= T1(P2/P1) ( n -1)/ n gives n=1.3
(assumption of ideal gas)
poly = n /(n-1) = 1.3 / (0.3)
avg. / (avg.-1) 1.232 / (0.232)
poly = 81.2 %
The design value is 82.2 %. The match is very good (1.2% off)
Let us look at the Gandhar design
 Polytropic efficiency discrepancies
• The design data is for the Gandhar CG compressor fourth stage is
P1 = 12.68 kg/cm2a, P2 = 26.94 kg/cm2a, T1= 314 K, T2 = 369 K
Z1=0.975, Z2=0.973 ( avg ) datasheet = (1.271+1.255)/2 = 1.263
• We estimate n from T2real= T1(P2/P1) ( n -1)/ n gives n=1.263 (assumption of
ideal gas)
poly = n /(n-1) = 1
avg. / (avg.-1)
poly = 100 % impossible !!
The design value is 89.6 %.
The design composition for the cracked gas fourth stage at GC and NC are
nearly the same. Since the pressure and temperatures are similar we will
take ( avg)ideal gas = 1.232 as at NC
We get poly = 90.4 %. Match is very good !
 Estimation of  ideal
• For a pure component  ideal is easy to determine
• Cp data is generally available for components
as a function of temperature at a constant
pressure
• Cp is evaluated at the desired temperature from
this data and used to estimate  ideal (cp/(cp-R))
• For mixtures Cp =  xi* Cpi i.e. molar average
 Polytropic efficiency- calculation
summary
• From the PT plant data estimate the Polytropic coefficient n
• Estimate cp for the individual components
• Calculate the molar average Cp
• Calculate  ideal
• Calculate Polytropic efficiency
• The power can then be determined from
Wreal = n / (n-1)* ZavgRT1[ (P2 / P1) ( n -1) / n -1]
poly
• The most accurate value of efficiency is determined
by calculating Wreal from the enthalpy difference of
the gas - the manner in which the software does it
 Reasons for loss of efficiency
• Compressors loose efficiency due to three
main reasons
– Fouling of the gas path due to deposits resulting
in higher pressure drops
– increased leakage through the shaft seals as a
result of which gas from the discharge of a
stage recirculates back to its suction
– increased leakage through the seals of the
balance piston which results in recirculation
from the final discharge to the suction
Sectional view - centrifugal compressor
Seal leakage
 Effect of Wash oil /Wash water
• Wash oil is sometimes added to compressors to dissolve
the polymer deposits formed due to the high
temperatures.
• Wash water is added to reduce the temperature rise in
the compressor to reduce the polymer formation
tendency.
• The effect of these has to be taken into account while
estimating the efficiency
• This is best done by estimating the new base case design
efficiency with the wash water / wash oil added so that
a consistent design case is achieved
 Compressor performance
monitoring - Summary
• Estimate design values from compressor data sheets (may
not match exactly with vendor numbers if different software
is used or if estimated manually by described method.
• Estimate the Polytropic efficiently over a regular period.
Once a week / fortnight. Samples for measuring the gas
composition will be needed
• For compressor (like C3R , C2R) where interstage
temperatures are not available, a average efficiency will
have to be used between stages which have indications
• Trend these values against the design estimated above to
monitor performance
 Assignment
• Make an excel spread sheet for estimating
the Polytropic efficiency and the real power
of a stage of the Cracked Gas Compressor
– Clearly list the inputs required
– Data required for estimation of Cp is available
– Analysis required to be done