POL

Petroleum Open Learning

Petroleum Gas
Compression
Part of the
Petroleum Processing Technology Series

OPITO
THE OIL & GAS ACADEMY

4
 Petroleum Open Learning
Petroleum Gas Compression – Unit 4 - Other Types of Compressor
(Part of the Petroleum Processing Technology Series)

Contents Page

• Training Targets 4.2 Visual Cues

training targets for you to achieve

• Introduction 4.3 by the end of the unit

• Section 1 – Other Types of Positive Displacement Compressor 4.4

test yourself questions to see how
much you understand
Rotary Screw Compressors
Lobe Compressors
Sliding Vane Compressors
Liquid Ring Compressors
check yourself answers to let you
see if you have been thinking along
the right lines
• Section 2 – Other Types of Continuous Flow Compressor 4.11

Axial Flow Compressors
Mixed Flow Compressors activities for you to apply your new
Fluidic Compressors knowledge
Ejectors

• Check Yourself - Answers 4.18 summaries for you to recap on the

major steps in your progress

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Training Targets

When you have completed Unit 4 of the Petroleum Gas Compression series you will be able to :

• List the main types of compressor used in the petroleum industry other than centrifugal and
reciprocating compressors

• Describe the construction and operation of four types of rotary positive displacement compressors

• Describe the construction and operation of the axial and mixed flow of dynamic compressors

• Describe the construction and operation of the ejector type fluidic compressor

• Explain the principal uses of the compressors listed

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Petroleum Gas Compression – Unit 4 - Other Types of Compressor
Introduction
In Units 2 and 3 of this compressor programme we
concentrated on two types of compressor :
• reciprocating
• centrifugal
These are the common types of compressor found in
petroleum production operations.
However, they are by no means the only cornoressors
in use. You will remember from Unit 1 that we
classified compressors into a number of different
categories and represented this as a family tree
Check your recall of Unit 1 now by trying the following
Test Yourself question.
Test Yourself 4.1
Test a typical compressor family tree, naming the
types of compressor in each main branch.
You will find the answer in Check Yourself 4.1 on
page 4,18
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From the family tree you can see that we must
consider a few more machines to complete our study
of compressors.
In this Unit, therefore, we will tie up the loose ends in
the programme on compression by taking a brief look
at these other types.
I do not intend to go into nearly so much detail as I did
in Units 2 and 3. In fact, we will limit ourselves to just
two sections.
In Section 1 we will look at the basic construction
and operating principles of another type of positive
displacement compressor, namely the rotary
compressors. (In the family tree, we also included the
diaphragm type of reciprocating machine. However,
I do not intend to say anything further about this
compressor.)
Section 2 will concentrate on the other continuous
flow machines. These are the axial and mixed flow
dynamic and the fluidic types.
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Petroleum Gas Compression – Unit 4 - Other Types of Compressor Petroleum Open Learning

Section 1 - Other Types of Positive Dislacement Compressor

You will remember from the family tree that the two Take a look at Figures 1(a) and 1(b) which show, in Figure 1(a) is a plan view and Figure 1(b) is a
branches of the positive displacement arm led to the simplified form, a rotary screw compressor simplified end view of the machine.
reciprocating machines and the rotary machines. In
this section we will be having a look at the rotary
types. These include:

• screw type

• lobe type

• vane type

• liquid ring type

Let’s now look at each of these in turn.

Rotary Screw Compressors

The double rotary screw type of compressor is the
most common form of rotary compressor used in the
oil and gas industry. In this machine, two intermeshing
screws are used to trap and compress a gas in the
space between the screws.

The double rotary screw compressor is a positive

displacement machine which delivers a constant
volume at variable pressures. It has a single stage
compression ratio of approximately 4 to 1.

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The compressor casing contains two precision The incoming gas is trapped between the compressor
machined, helical screw rotors. One of these rotors has casing and the tips of the lobes. As the lobes are fitted
splines, giving it a male profile. These splines mesh close together, no gas can escape backwards between
with grooves in the other, female, rotor. The rotors are the lobes themselves. The trapped mass of gas is
usually of small diameter. This small diameter allows then pushed forwards towards the delivery end of the
shaft speeds of up to 20 000 rpm. compressor, with no reduction in volume.

The screws rotate together in opposite directions.

The splines and grooves mesh to form a series of
pockets which travel one following the other, towards Think for a moment about this process and then do the
the discharge end of the machine, The volume in each following Test Yourself
pocket reduces, thereby increasing the pressure. as it
moves from suction to discharge,

In most designs the rotors require no lubrication within

the compressor chamber and can produce an oil free
compressed gas,
Test Yourself 4.2
Rotary screw compressors are often found in
compressed instrument air service,
What is the fundamental difference in method of
compression, between a lobe type compressor and
Lobe Compressors the other two positive displacement compressors
we have looked at up to now, ie, the reciprocating
type and the screw type rotary?
Lobe compressors are often used where large volumes
of relatively low pressure gas are required,

Figure 2 shows how a twin lobe compressor works

and how the gas flows through the compressor.
The casing of the compressor encloses two rotors,
each of which has a Figure of eight shape. At each
end of the figure of eight is a lobe. These specially
shaped rotors are geared together externally to You will find the answer in Check Yourself 4.2
ensure correct meshing. They rotate in opposite on page 4.19
directions within the casing.
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From the answer to this Test Yourself you can see that
the back pressure in the delivery pipework determines
the outlet pressure of this compressor.

The machine we have just been looking at is a two

lobe compressor. However, lobe compressors may be
found with two, three or four lobes per rotor.

Because of these low pressure applications often

referred to as blowers.

Lobe compressors can be found on petroleum

croductlon installations as Fuel Gas compressors, or
as Booster compressors and other lower pressure
applications.

Sliding Vane Compressors

Sliding vane compressors are designed to supply a
constant volume and pressure of gas.

Figure 3 shows the basic construction of a sliding

vane compressor. Familiarise yourself with the
components, then go through the following description
of how the machine works.
Within the casing of the compressor is mounted a rotor or drum. The drum is designed to rotate eccentrically
within the casing.

The drum carries a number of vanes. These are free to slide back and forth within slots machined into the rotor.
As the drum rotates. the vanes are thrown out by centrifugal force so that they contact the casing. Sometimes
spring loading assists in this.

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The sliding vane compressor operates by trapping
the gas in a succession of pockets whose volume is
gradually reduced. The pockets are formed by the
inside of the casing, the outside of the drum and a
pair of sliding vanes.
Gas enters the casing through the inlet nozzle and
is trapped in a pocket where the vanes are at their
maximum extension. As the drum rotates the
vanes are pushed back into the drum as the
distance between casing and drum decreases. This
then reduces the volume of the pocket. The
pressure of the gas within the pocket increases until
the volume of the pocket is at its minimum. At this
point the gas is discharged through the delivery
nozzle.
Sliding vane compressors are very prone to damage
and breakdown if any liquids or solid particles enter
the gas stream. The vane tips erode and gas can
then leak backwards, past these tips.
They are occasionally found in Heating, Ventilation
and Air Conditioning (HVAC) Systems, In this
service are used both as air blowers and as
refrigerant compressors.
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Liquid Ring Compressors
The liquid ring compressor is more commonly
called a vacuum pump, It is used extensively in
injection water treatment plants, It is capable of
creating a vacuum which assists in the
de-oxygenation of water.
The unit consists of a cast iron casing which
contains a multi-bladed impeller. The impeller is
mounted on a shaft supported at each end on
bearings. The shaft is fitted eccentrically to the
casing so that the blades of the impeller are nearer
to the casing at one point of the rotation.
Figure 4, on the next page, shows diagramatically
the construction of a liquid ring compressor.
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The liquid ring compressor operates in a similar

manner to the sliding vane type of compressor. The
essential difference is the way in which the reduction
in volume of the pockets is achieved.
Summary of Section 1
You will remember that this reduction in pocket
volume is accomplished, in a sliding vane
compressor, by the vanes being pushed back into
the drum. The liquid ring compressor uses an In this section you have seen how a selection of rotary compressors work. These were:
advancing ring of water to create the same effect.
• screw type
Look at Figure 4 and see how this works.
• lobe type
Water is injected into the unit and centrifugal force
causes it to form a liquid ring which is pinned to the • vane type
inside of the casing.
• liquid ring type
Air is drawn a pocket formed between the
impeller blades and the inner surface of the water You saw the lobe type of compressor was the only one which did not trap gas and then reduce its volume. In
ring. This occurs where the blades are furthest from fact the trapped gas in such a machine is pushed towards the discharge at an almost constant volume.
the casing and the pockets have their greatest
volume. As the impeller rotates, the blades get
nearer to the casing wall. The ring of water We did not go into a great deal of detail regarding the construction of rotary compressors. However, Section 1
advances into the pocket, and pocket volume is should have given you an idea of how these machines work and what their main applications are.
reduced. This increases the pressure of the air in
the pocket The compressed air / water mixture is
then ejected at the discharge port.

Have a look at Figure 4 again, and try to visualise

what is going on inside the compressor, Before moving to Section 2, have a go at the following Test Yourself to check your
understanding of Section 1.

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Test Yourself 4.3

Which type of positive dlsplacernent compressor do the following statements refer to?

1. The male splines mesh with the female grooves.

2. Springs assist in throwing the vanes outward

3. These compressors are for low pressure applications and are sometimes called blowers

4. The piston moves back and forth within a cylinder

5. The drum is mounted eccentrically within the casing.

6. This compressor is more commonly called a vacuum pump.

7. The two rotors have a figure of eight shape.

8. The small diameter of the rotors allows shaft speeds of up to 20 000 rpm.

You will find the answers in Check Yourself 4.3 on page 4.19

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Petroleum Gas Compression – Unit 4 - Other Types of Compressor
Section 2 - Other Types of Continous Flow Compressor
The continuous flow branch of the family tree
was divided into dynamic machines and fluidic
machines. Unit 2 of the Compressor Series
concentrated on one of the dynamic machines, namely
the centrifugal compressor. In this section we will have
a brief look at the other dynamic types of compressor,
the axial flow and mixed flow compressors.
Finally we will consider just one type of fluidic machine,
that is the ejector.
Once again we will not go into any great detail but
will only cover the basic construction and operation of
each unit.
Axial Flow Compressors
Like centrifugal compressors, axial flow compressors
are dynamic machines. They impart kinetic energy to
the gas by increasing its velocity. This kinetic energy
is then converted into pressure energy by allowing the
gas to slow down.
In the case of an axial flow compressor, the flow of
gas stays parallel (axial) to the shaft. The simplest type
of axial flow compressor is the propeller. Air is drawn
into the propeller from the front and thrown backwards
through the propeller.
In the case of an axial flow compressor a large number
of blades, called rotor blades, are attached to an
impeller. There may be as many as fifteen or more
impellers attached to a shaft. The impellers and the
shaft are contained within a casing.
The rotor blades run between fixed blades, called
stators, mounted inside the compressor casing.
Figure 5 shows the component parts of an axial flow
compressor
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As the impellers rotate, the shaped rotor blades induce
the gas to flow across them, parallel to the shaft.
The rotor blades accelerate the gas towards the
stator blades. The shape of these stationary blades
causes them to act as diffusers, and slow down the
gas. This converts kinetic energy into pressure
energy. The stator blades then direct the gas
towards the next set of rotor blades. and so on.
The most common use for axial flow compressors in
the oil and gas is as inlet air compressors
on gas turbines. In this service they are ideally suited
to provide the large amounts of low pressure air which
are required to enable the engine to function.
Figure 6 : On the next page shows the Axial
Compressor, in a Gas Turbine layout
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Mixed Flow Compressors

Mixed Flow compressors utilise both centrifugal and

Test Yourself 4.4

axial flows within the same compressor casing,

All centrifugal compressors have an

element of mixed flow. In these machines, the gas
flows axially along the shaft into the inlet of each
impeller before being accelerated by centrifugal List 5 errors which appear in the following sentences.
force.
Axial flow compressors are dynamic machines. They impart potential energy to the gas by increasing
Mixed flow compressors utilise a form of axial flow it’s velocity. This energy is to converted pressure energy as the gas is slowed down. The flow of gas
blades called inlet guide vanes installed upstream stays parallel to the shaft. A number of stator blades are attached to the impeller. They rotate between
of the first centrifugal impeller. These guide the gas fixed blades mounted inside the compressor casing. Rotor blades act as diffusers to slow down the gas
into the eye of the first impeller in the most efficient after it has been accelerated. Axial compressors are often used as inlet air compressors on gas turbine
direction. The inlet guide vane often has a variable installations.
pitch facility which allows the operator to control the
direction of this inlet flow.
Mixed flow compressors utilise axial flow and reciprocating flow within the same machine. Compressors
Before we move on to have a look at Fluidioc which are designated mixed flow utilise inlet guide vanes to guide the gas into the axial flow impeller,
compressors, try the following Test Yourself question
about dynamic compressors of the axial and mixed
flow types.

You will find the answers in Check Yourself 4.4 on page 4.19

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Fluidic Compressors
In Fluidic compressors, a carrier fluid is accelerated in
order to transfer its energy to another fluid.

Fluidic compressors have no pistons, valves, rotors or

any other moving parts.

They are relatively inefficient but are often favoured

for use with corrosive materials or in inaccessible
situations,

Ejectors (also called Eductors) and Diffusion

Pumps are the two most common types of fluidic
compressor. However, because diffusion pumps are
seldom found in petroleum producing operations, we
will not be considering them in this Unit.

Ejectors
Ejectors (or Eductors) are names used to describe
equipment which operates to the Bernoulli Principle.

Bernoulli was a scientist who discovered that there is a

relationship between pressure and velocity of a fluid as
it flows across a restriction.

Take a look at the two diagrams in Figure 7.

Figure 7(a) shows fluid flowing across a restriction.

Figure 7(b) illustrates this relationship in the form of a As the fluid enters the the pressure falls At the exit from the restriction, the reverse
graph. and the velocity increases. This occurs as occurs, as you can see.
pressure energy is converted kinetic energy.

4.14

Figure 8 shows a restriction built a of equipment called an ejector
This restriction, similar to the one shown in Figure 7, is called a venturi tube.
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A fluid, called the driving fluid, is pumped, at high
velocity, through the venturi tube of the ejector via
an inlet nozzle. The underside of the ejector is
connected to the gas inlet. As the driving fluid enters
the venturi tube, its velocity increases and its pressure
falls. This reduction in pressure pulls gas from the gas
inlet and entrains it in the driving fluid.
This can create a vacuum at the gas inlet and, in fact
this type of equipment can also be called a vacuum
pump.
As the mixture of driving fluid and gas leaves the
venturi tube, its velocity falls again and the pressure
increases to that of the discharge pipework.
Ejectors have many applications in petroleum
production. For example:
• To increase the vacuum which is applied to
the de-aeration tower of a water treatment
facility (in conjunction with a liquid ring
compressor)
• To pull gas into a water stream in order to
create a foam in water clean-up facilities
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Summary of Section 2

In this short section we have had a look at some of the other compressors which fall into the
continuous flow category. These were:

• axial flow compressors

• mixed flow compressors

• ejectors

You saw that the first two were dynamic machines. They work in a similar manner to the centrifugal
compressor which we considered in Unit 2 of this Compression Series

The axial flow compressor uses rotor blades which act as impeller blades, and stator blades which act as
diffusers. The flow of gas through such a machine is parallel to the shaft, hence the name axial flow.

The ejector, however, works in a different way and has no moving parts. It relies on a driving fluid creating a
low pressure zone. This type of equipment is often used in water injection and produced water applications.
Further units in the Petroleum Processing Technology Series will explore these applications more fully.

Now, before leaving the Unit, try the final Test Yourself question.

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Test Yourself 4.5

Decide to which type of compressor and which branch of the family tree (positive displacement or continuous
flow) the following compressor components belong. I have done the first one as an example.

1. piston rod reciprocating compressor positive displacement

2. splined rotors ............................................. .......................................

3. inlet guide vane ............................................. .......................................

4. crosshead ............................................. .......................................

5. venturi tube ............................................. .......................................

6. water ring ............................................. .......................................

7. figure of 8 rotor ............................................. .......................................

8. drum and vanes ............................................. .......................................

9. dry gas seal ............................................. .......................................

10. stator blades ............................................. .......................................

You will find the answers in Check Yourself 4.5 on page 4.20

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Check Yourself 4.1

Sketch a typical compressor tree, naming the types

of compressor in each main branch.

Your sketch will look something like the family tree

shown opposite.

(You will remember that you first saw this diagram in

Unit 1 on Page 1.26).

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Check Yourself 4.2 Check Yourself 4.3 Check Yourself 4.4

With the piston and screw types, the 1. screw type 1. Kinetic energy is imparted not potential
compressor traps a mass of gas and reduces energy
its volume, to achieve compression, The lobe 2. vane type
type compressor simply pushes a fixed volume 2. Rotor blades not stator blades are attached
of gas into a higher pressure discharge. 3. lobe type to the impeller

4. reciprocating type 3. Stator blades act as diffusers, not rotor

blades
5. vane type
4. Mixed flow compressors use axial flow and
6. liquid ring type centifrugal flow, not axial and reciprocating.

7. lobe type 5. Inlet guide vanes guide the gas into the
first centrifugal impeller not the axial flow
8. screw type impeller.

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Check Yourself 4.5

1. piston rod reciprocating compressor positive displacement

2. splined rotors screw type positive displacement

3. inlet guide vane mixed flow continuous flow

4. crosshead reciprocating positive displacement

5. venturi tube ejector continuous flow

6. water ring liquid ring positive displacement

7. figure of 8 rotor lobe type positive displacement

8. drum and vanes sliding vane positive displacement

9. dry gas seal centrifugal continuous flow

1O. stator blades axial flow continuous flow

4.20