Compressors: Selection and Sizing

Royce N. Brown0884151646, 9780884151647, 9780585470467

This practical reference provides in-depth information required to understand and properly estimate compressor capabilities and select proper designs. Engineers and students will gain a thorough understanding of compression principles, equipment, applications, selection, sizing, installation, and maintenance. The many examples clearly illustrate key aspects to help readers understand the “real world” of compressor technology.This second edition is completely updated with new API standrard. It presents the latest technology in the areas of efficiency, 3-D geometry, electronics, CAD, and the use of plant computers. The critical chapter on negotiating the purchase of a compressor now reflects current industry practices for preparing detailed specifications, bid evaluations, engineering reviews, and installation. A new chapter compares the reliability of various types of compressors.

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Table of contents :
Contents……Page 6
Preface……Page 14
Acknowledgments……Page 16
1. Overview……Page 18
Compression Methods……Page 19
Reciprocating Compressors……Page 21
Rotary Compressors……Page 22
Ejectors……Page 26
Dynamic Compressors……Page 27
2. Basic Relationships……Page 31
Perfect Gas Equation……Page 32
Generalized Compressibility Charts……Page 34
Specific Heat Ratio……Page 35
Specific Gravity……Page 36
Humidity……Page 37
Flow……Page 38
Equations of State……Page 43
First Law of Thermodynamics……Page 44
Second Law of Thermodynamics……Page 46
Theoretical Work……Page 47
Real Gas Exponent……Page 51
Power……Page 52
Velocity Head……Page 53
Intercooling……Page 58
Isothermal Compression……Page 59
Description……Page 65
Classification……Page 67
Arrangement……Page 68
Drive Methods……Page 69
Pistons and Rods……Page 84
Valves……Page 86
Rod Packing……Page 90
Crankshaft and Bearings……Page 91
Frame Lubrication……Page 94
Cooling……Page 95
Pulsation Control……Page 101
Common Features……Page 110
Arrangements and Drivers……Page 111
History……Page 112
Operating Principles……Page 113
Displacement……Page 116
Dry Compressors……Page 117
Flooded Compressors……Page 126
Flooding Fluid……Page 128
Appendix D—Labyrinth and Carbon Ring Seal Leakage Calculations……Page 0
Rotors……Page 132
Bearings and Seals……Page 133
Timing Gears……Page 134
Straight Lobe……Page 138
Sizing……Page 141
Mechanical Construction……Page 142
Sliding Vane……Page 143
Operation……Page 147
5. Centrifugal Compressors……Page 149
Restrictive Seals……Page 228
Liquid Buffered Seals……Page 229
Dry Gas Seals……Page 232
Capacity Control……Page 237
References……Page 239
Historical Background……Page 241
Blades……Page 243
Compression Cycle……Page 245
Reaction……Page 246
Stagger……Page 249
Curve Shape……Page 253
Stators……Page 264
Rotor……Page 265
Biading……Page 267
Seals……Page 269
Maintenance……Page 270
7. Drivers……Page 273
Electric Motors……Page 274
Voltage……Page 275
Totally Enclosed Motors……Page 276
Division 1 Enclosures……Page 277
Insulation……Page 278
Service Factor……Page 280
Synchronous Motors……Page 281
Brushless Excitation……Page 283
Motor Equations……Page 284
Selecting Compressor Motors……Page 285
Starting Characteristics……Page 287
Starting Time……Page 290
Enclosure Applications……Page 292
Variable Frequency Drives……Page 294
Motor……Page 295
Steam Turbines……Page 299
Steam Temperature……Page 301
Operation Principles……Page 303
Steam Turbine Rating……Page 307
Gas Turbines……Page 309
Gas Turbine Types……Page 310
Gas Turbine Economics……Page 312
Types……Page 313
Power Recovery……Page 314
Refrigeration……Page 315
Condensation……Page 316
Expander Applications……Page 317
8. Accessories……Page 319
Lubrication Systems……Page 320
Reservoir……Page 323
Pumps and Drivers……Page 326
Startup Control……Page 330
Check Valves……Page 331
Coolers……Page 332
Transfer Valves……Page 333
Accumulators……Page 334
Seal Oil Overhead Tank……Page 336
Lube Oil Overhead Tank……Page 337
Seal Oil Drainers……Page 338
Degassing Drum……Page 339
System Design Considerations……Page 340
Dry Gas Seal System Control……Page 343
Dry Gas Seal System Filters……Page 344
Gears……Page 345
Gear Design and Application……Page 347
Rotors and shafts……Page 348
Housing……Page 350
Pressure……Page 359
Temperature……Page 360
Flow……Page 362
Torque……Page 363
Rod Drop Monitor……Page 365
Vibration Sensors……Page 366
Seismic Sensors……Page 367
Proximity Sensors……Page 369
Axial Shaft Motion……Page 371
Radial Shaft Vibration……Page 370
Control……Page 373
Pressure Control at Variable Speed……Page 374
Volume Control at Variable Speed……Page 376
Pressure Control at Constant Speed……Page 378
Weight Flow Control at Constant Speed……Page 379
Anti-Surge Control……Page 380
9. Dynamics……Page 385
Basics……Page 386
Unbalance……Page 388
Balance Methods……Page 391
Shop Balance Machine……Page 392
High Speed Balancing……Page 393
Field Balancing……Page 394
Reciprocating Shaking Forces……Page 395
Rotary Shaking Forces……Page 399
Rotor Dynamics……Page 401
Damped Unbalance Response……Page 404
Torsionals……Page 407
Torsional Damping and Resilient Coupling……Page 413
10. Testing……Page 420
Operational Tests……Page 424
Objectives of Centrifugal Compressor Mechanical Tests……Page 425
Rotor Dynamics Verification……Page 428
String Testing……Page 429
Reciprocating Compressor Test……Page 430
Static Gas Test……Page 431
Testing of Lubrication Systems……Page 432
Shop Performance Test……Page 433
Test Codes……Page 434
Loop Testing……Page 437
Sidestream Compressors……Page 440
Test Correlation……Page 442
Abnormalities in Testing……Page 443
Field Testing……Page 445
Planning……Page 447
Flow Meters……Page 448
Location……Page 449
Power Measurement……Page 450
Speed……Page 451
Conducting the Test……Page 452
11. Negotiation and Purchasing……Page 455
Preliminary Sizing……Page 457
Operations……Page 458
Specification Outline……Page 460
Basic Design……Page 461
Materials……Page 464
Bearings……Page 465
Lube and Seal System……Page 466
Gear Units……Page 467
Mounting Plates……Page 468
Controls and Instrumentation……Page 469
Inspection and Testing……Page 470
Guarantee and Warranty……Page 471
Bid Evaluation……Page 472
Pre-Award Meeting……Page 473
Coordination Meeting……Page 474
Engineering Reviews……Page 475
Tests……Page 476
Shipment……Page 478
Commissioning the Compressor……Page 479
Commissioning the Lube Oil System……Page 480
Successful Operation……Page 481
General……Page 483
Robust Design……Page 485
Foundations……Page 487
Suction Drums……Page 488
Piping……Page 490
Type Comparison……Page 491
Positive Displacement Rotary Compressors……Page 492
Centrifugal Compressors……Page 493
Axial Compressors……Page 494
Lubrication……Page 502
Couplings……Page 503
Methodology……Page 504
Manufacturing Tolerances……Page 505
Summary……Page 506
A……Page 560
C……Page 561
E……Page 562
H……Page 563
M……Page 564
P……Page 565
R……Page 566
S……Page 567
T……Page 568
W……Page 569