COMPRESSORS DESIGN PRACTICES

COMPRESSION CALCULATIONS Section Page

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Changes shown by ç

CONTENTS
Section Page

SCOPE .................................................................................................................................................... 3

REFERENCES ......................................................................................................................................... 3
COMPUTER PROGRAMS................................................................................................................ 3
TECHNICAL LITERATURE............................................................................................................... 3

BACKGROUND ....................................................................................................................................... 3

DEFINITIONS........................................................................................................................................... 4

COMPRESSOR DESIGN FLOWCHART................................................................................................... 5

INTERSTAGE COOLER PRESSURE DROP ............................................................................................ 5

INLET VOLUME FLOW RATE.................................................................................................................. 5

COMPRESSOR EFFICIENCY ESTIMATES .............................................................................................. 6

DISCHARGE TEMPERATURE ESTIMATES ............................................................................................ 6

COMPRESSOR OUTLET TEMPERATURE LIMITATIONS ....................................................................... 7

COMPRESSOR HEAD, POWER, PRESSURE RATIO AND VOLUME RATIO........................................... 7

POLYTROPIC HEAD........................................................................................................................ 7
COMPRESSOR GAS POWER.......................................................................................................... 8
PRESSURE RATIO .......................................................................................................................... 8
VOLUME RATIO .............................................................................................................................. 9
COMPRESSOR SHAFT AND DRIVER POWER................................................................................ 9
CENTRIFUGAL COMPRESSORS .................................................................................................... 9
AXIAL COMPRESSORS................................................................................................................... 9
RECIPROCATING COMPRESSORS................................................................................................ 9
DRY HELICAL SCREW COMPRESSORS ........................................................................................ 9

SPECIAL CALCULATION CONSIDERATIONS - RECIPROCATING COMPRESSORS............................10

VOLUMETRIC EFFICIENCY............................................................................................................10
POTENTIAL FOR DRIVER OVERLOADING ....................................................................................10

PHYSICAL CHARACTERISTICS OF A COMPRESSOR SECTION..........................................................10

COMPUTER PROGRAMS.......................................................................................................................11

NOMENCLATURE ..................................................................................................................................11

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CONTENTS (Cont)
Section Page

FIGURES
Figure 1 Compressor Calculations Flowchart ............................................................................ 12
Figure 2A Estimated Polytropic Efficiency of Uncooled Centrifugal Compressors (Customary
Units) ......................................................................................................................... 13
Figure 2B Estimated Polytropic Efficiency of Uncooled Centrifugal Compressors (Metric Units) .... 13
Figure 3A Estimated Polytropic Efficiency of Uncooled Axial Compressors (Customary Units) ...... 14
Figure 3B Estimated Polytropic Efficiency of Uncooled Axial Compressors (Metric Units).............. 14
Figure 4 Typical Reciprocating Compressor Efficiency .............................................................. 15
Figure 5 Typical Mechanical Efficiency of Reciprocating Compressors....................................... 15
Figure 6 Generalized Schultz Compressibility Derivative Function ............................................. 16
Figure 7 Mechanical Efficiency of High Speed Gearboxes at Full Load ...................................... 17
Figure 8A Estimated Mechanical Losses of Centrifugal Compressors (Customary Units) .............. 18
Figure 8B Estimated Mechanical Losses of Centrifugal Compressors (Metric Units) ..................... 18
Figure 9A Estimated Mechanical Losses of Axial Compressors (Customary Units) ....................... 19
Figure 9B Estimated Mechanical Losses of Axial Compressors (Metric Units) .............................. 19

Revision Memo
12/98 Page 3: Note 1 added.
Page 11: COMPUTER PROGRAMS updated.
Page 11: NOMENCLATURE added.

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SCOPE
This section presents the procedures and calculation methods necessary to determine the process design requirements of a
compression service. The information in this section is generally applicable to all compressor types commonly applied in
process plants although some calculation methods and information specific to a particular compressor type are also included.(1)
This section includes:
1. Compressor calculation flowchart.
2. Methods to determine the number of process stages required for a compression service.
3. Compressor inlet volume flow rate calculation (at condition).
4. Information to estimate the efficiency of various compressor types.
5. Calculations to estimate the inlet and outlet pressures for each process compression stage.
6. Calculations for process compression stage outlet temperature.
7. Outlet temperature limits for various compressor types and services.
8. Calculations for head, efficiency, power, pressure ratio and volume ratio.
9. Information to estimate the characteristics of a process compression stage.
10. Information about computer programs to automate and improve the compression calculations.

REFERENCES

COMPUTER PROGRAMS
CPEE-41 CompCalc - PC Program for Compressor Network Simulation and Design
O2666 Reciprocating Compressor Selection

TECHNICAL LITERATURE
ASME Performance Test Code 10, Compressors and Exhausters, 1965, Reaffirmed 1987.
Schultz, J. M., The Polytropic Analysis of Centrifugal Compressors, ASME J. of Engineering for Power, January 1962, p. 69-82.
Huntington, R. A., Evaluation of Polytropic Calculation Methods for Turbomachinery Performance, ASME J. of Engineering for
Gas Turbines and Power, October 1985, p. 872-878.

BACKGROUND
A variety of compressor types may be applied within process plants. However centrifugal, reciprocating, axial, and helical
screw compressors are the most common. These types include both dynamic compressors (centrifugal and axial) and positive-
displacement (reciprocating and helical screw) compressors which require somewhat different methods to calculate or predict
their performance. However, each of these compressors and their calculations share common considerations, as follows:
• Each compressor type raises the pressure of a gas by adding energy to the gas. This energy is known as Head and has
units of energy per unit mass of gas (e.g., ft-lb/lbm or kJ/kg).
• The capability of a compressor to raise gas pressure is dependent on the volume of gas entering the compressor at its
current inlet conditions. This volume rate is known as its Actual Inlet Volume Flow rate and has common units of ACFM
(actual cubic ft per minute) and ACMH (actual cubic meters per hour).
• The Efficiency of a compressor is measured by the ratio of the head found for a reversible (idealized) compression
process between the same pressure levels and the enthalpy change of the gas for the actual compression process.
• The Gas Power of a compression stage is the product of total work done (reversible work/efficiency) to raise the gas
pressure and the mass flow rate of gas being compressed. Gas Power includes all thermodynamic losses such as internal
leakage, gas friction within the compressor gas path but excludes mechanical losses.
The complexity of the compressor calculations ranges from very simple where the compressed gas acts as a Perfect Gas to
difficult for non-ideal gases or those that condense at cooling steps within the compression process. The more difficult cases
are better suited to partial or full solution via computer.

ç Note:
(1) API compressor data sheets specify pressure in psi, bar, and kPa. In this section, bar is the metric unit used for
pressure. See Section XI-A, Nomenclature, for parameter symbols and units not defined in text.

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DEFINITIONS

Head
Reversible work necessary to raise the pressure of a gas.

Ideal Gas
A gas for which the relation between pressure, temperature and volume can be expressed as:
PV = RT
over the range of interest of pressure and temperature.

Isentropic Efficiency, η S
Ratio of Isentropic Head vs. the enthalpy rise from the initial pressure and temperature to the final pressure and temperature.

Isentropic Head, HS
Head calculated along an isentropic path (reversible adiabatic) from the initial pressure and temperature to the desired
pressure as follows:
Hs = h2s - h1
where: h1 = h (P1, T1), enthalpy at inlet conditions
h2s = h (P2, T2s), enthalpy at discharge conditions
T2s = The temperature at which s (P2, T2s) = s (P1, T1)
T1 = Inlet temperature
P1 = Inlet pressure
P2 = Discharge pressure
s = Entropy

Perfect Gas
A gas which conforms to the ideal gas relationship between pressure, temperature and volume and which has a constant
specific heat over the range of interest of pressure and temperature.

Polytropic Efficiency, ηpoly

Ratio of polytropic head vs. the enthalpy rise from the initial pressure and temperature to the final pressure and temperature.

Polytropic Head, Hpoly

Head calculated along a reversible path along which reversible head and reversible heat are added in constant proportions to
raise the pressure and temperature of the gas from the initial values to the desired pressure and actual outlet temperature. A
polytropic path is described for all gas conditions by the differential equation: dHpoly = ηpolydh. For perfect gases, this is
simplified to the familiar: PVn = constant along the polytropic path where n is a constant known as the polytropic volume
exponent.

Pressure Ratio, r
The ratio of the absolute outlet pressure vs. the absolute inlet pressure of a compression stage.

Volume Ratio, V1 / V2
The ratio of the inlet volume flow rate or inlet specific volume of the gas vs. the outlet volume flow rate or outlet specific volume
of the gas.

Volumetric Efficiency, ηV
The ratio of the inlet volume flow rate of a reciprocating compressor stage vs. the piston displacement of that stage. Piston
displacement is the product of the cylinder swept volumes and the compressor speed in revolutions per unit time (e.g., RPM).
Swept volume of a cylinder is the product of piston area and stroke for each acting end of the cylinder.

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COMPRESSOR DESIGN FLOWCHART

A flowchart to complete the process design calculations for a new compressor service is illustrated in Figure 1. This flowchart
describes the overall steps to determine characteristics of the compression equipment for the new service including: the
number of process stages, the efficiency, head and power of each stage, the overall power of the compression equipment, and
the physical characteristics of the compressors. This Compressor Calculations Flowchart must be used in conjunction with
Section XI-B, Compressor Type Selection and Sections XI-E, XI-F, XI-H, and XI-I for the particular type of compressor to be
used.
For each of the steps described in the flowchart, a section follows that details the information required, sources for that
information and necessary calculations to complete the step. In some cases, the steps will be repeated as the information is
refined. In other cases, it may become necessary to re-evaluate the compressor type selection and repeat the process in total.
These are expected and normal aspects of the compressor design process.

INTERSTAGE COOLER PRESSURE DROP

Interstage cooling of compressed gas streams is necessary or desired for two primary reasons: 1) to limit the temperature of
the gas to some specified maximum, and 2) to reduce the compression power necessary for a service based on an economic
evaluation by reducing the head requirement through the lowering of the mean temperature of the compressed gas and/or by
reducing the mass flow rate of gas by removing condensable material. Interstage equipment generally consists of an air-fin or
shell-and-tube heat exchanger, a knock-out drum fitted with a crinkle-wire-mesh screen (CWMS) and interstage piping that may
include a flow meter.
A typical value of pressure drop for the interstage system described above is 7 to 10 psi (0.5 to 0.7 bar). Use other values
based on the calculated pressure drop for the interstage equipment, if known. This may especially be required for low-pressure
applications [cooler inlet pressure less than 50 psig (3.5 barg)]. However, in other cases use 7 psi (0.5 bar) as an
approximation.

INLET VOLUME FLOW RATE

The inlet volume flow rate refers to the actual volume flow rate at the inlet flange of the compressor section. This volume rate
may be calculated based on the weight, molar or standard volume flow rate plus gas properties at the inlet pressure and
temperature at the flange of the compressor; a nominal pressure drop for an inlet throttle valve (if installed) should be
subtracted from the upstream pressure prior to evaluation of the inlet conditions. A typical pressure drop for an inlet throttle
valve should be based on a line-size butterfly valve that is 80% open at the design flow rate to the compressor.
Use the following calculations to determine the inlet volume flow rate to the compressor:

CUSTOMARY METRIC
SCFM SCMH
Q1 = ⋅ MW ⋅ V1 (ACFM) Q1 = ⋅ MW ⋅ V1 (ACMH)
378.7 23.65
Q1 = Mol ⋅ MW ⋅ V1 (ACFM) Q1 = Mol ⋅ MW ⋅ V1 (ACMH)

Q1 = W ⋅ V1 (ACFM) Q1 = W ⋅ V1 ⋅ 3600 (ACMH)

where:

Z1 R T1 Z1 R T1
V1 = (ft3/lb) V1 = (m3/kg)
144 P1 100 P1

1545.31  ft ⋅ lbf  8.31427  kJ 

R =   R =  
MW  lb ⋅ o R  MW  kg ⋅ oK 
 m   

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COMPRESSOR EFFICIENCY ESTIMATES

Figures 2 to 4 provide estimates for the polytropic efficiency of uncooled centrifugal and reciprocating compressors. For
cooled reciprocating compressors, which include most applied to process services, multiply the value from Figure 4 by 1.05 to
account for the cylinder cooling effectiveness. For Helical Screw compressors, use a polytropic efficiency estimate of 75%
unless a specific efficiency is available from a vendor quotation.

DISCHARGE TEMPERATURE ESTIMATES

The discharge temperature of any compressor section is predicted based on the pressure rise of the section, the efficiency of
the compressor section, and the properties of the compressed gas. The discharge temperature may be estimated as:
m
P 
T2 = T1  2 
 P1 

where: T1 and T2 are absolute temperatures in either °R or °K.

P1 and P2 are the absolute inlet and outlet pressure of the compressor section.
and m is the Polytropic Temperature Rise Exponent.
The Polytropic Temperature Rise Exponent is exactly given by the following formula at a known pressure and temperature:

Z R  1 
m= + X

Cp  η poly 


T  ∂Z 
where: X =   which is one of the Schultz compressibility derivative functions.
Z  ∂T  p

The values of Z, Cp and X can be calculated with the CompCalc PC program Gas Properties section. Z and Cp may also be
obtained from a flow sheet program calculation (PRO/II, ASPEN, COPE, etc.) with X estimated based on the generalized chart
included in PTC-10 (1965) and reproduced as Figure 6.
For Real Gases, the value of m will change along the compression path and therefore an average value should be calculated at
the inlet and roughly estimated outlet conditions to more accurately predict the compressor section discharge temperature.
m1 + m 2
mavg =
2

mavg
P 
T2 = T1  2  (o R or oK )
 P1 

Repeat the evaluation of m2 at the calculated value of T2 and repeat the discharge temperature calculation as necessary to
achieve the desired accuracy.
Ideal and Perfect Gases: For compressed gases that may be approximated as Ideal or Perfect Gases, the evaluation of the
Polytropic Temperature Rise Exponent may be simplified. For Ideal Gases, the compressibility factor is constant. Therefore,
the value of X is zero and the temperature rise exponent may be expressed as:
Z R
m = For Ideal Gases only
Cp η poly

For Perfect Gases, Cp is also constant and is equal to ZR + Cv. By substitution and re-arrangement, this expression becomes:
k −1
m = For Perfect Gases only
k η poly

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COMPRESSOR OUTLET TEMPERATURE LIMITATIONS

The following outlet temperature limitations are generally applied to compressor applications:

TEMPERATURE LIMIT, TEMPERATURE LIMIT,

COMPRESSOR AND SERVICE DESCRIPTION °F °C

Centrifugal Compressor, Non-fouling Process Gas 350 175

Centrifugal Compressor, Fouling Process Gas 250 120

Centrifugal Compressor, Air or Nitrogen, No Oil Seals 400 205

Axial Compressor, Air or Nitrogen 400 205

Reciprocating Compressor, Process Gas Service, MW > 12 300 150

Reciprocating Compressor, Process Gas Service, MW ≤ 12 275 135

Reciprocating Compressor, Air or Nitrogen 300 150

Dry Helical Screw Compressor, Non-Fouling Process Gas 350 175

Dry Helical Screw Compressor, Air or Nitrogen, No Oil Seals 350 175

COMPRESSOR HEAD, POWER, PRESSURE RATIO AND VOLUME RATIO

The following calculations may be used to identify the key characteristics and/or design restrictions of various compressor
types.

POLYTROPIC HEAD
This is a measure of the pressure raising capability of a compressor stage. Generally, the performance capabilities of dynamic
compressors such as centrifugal and axial compressors are given in terms of polytropic head. It is a useful term to calculate
the enthalpy rise of the compressed gas and the gas power of a compressor section.
Polytropic head is defined by the following integral along a polytropic compression path:
P2
H poly =
∫ VdP
P1

However, this integral is difficult to calculate exactly for all but Perfect Gases, for which the relationship
(PVn = constant) allows the simplification of the integral and its exact solution. The polytropic head may also be calculated
exactly if the polytropic efficiency is known (i.e., from a vendor, test or the estimation curves in Figures 2-4) and the enthalpy
rise of the compressed gas is also known.
The calculation of polytropic head based on enthalpy rise is:
H poly = η poly (h2 − h1) For All Gases (ft-lb/lbm or kJ/kg)

If the enthalpy rise of the gas is not known beforehand, then the polytropic head may be estimated by the following equation,
which is based on the Perfect Gas assumption described above. The results of this equation are accurate to within 1 percent
for most process applications but can understate or overstate the head by 2-3% for some services including high pressure and
refrigeration services.
 n −1 
 n   P  n 
H poly ≅ Z1 R T1     2
− 1 Exact for Perfect Gases (ft-lb/lbm or kJ/kg)
 
 n −1    P1  
 
log (P2 / P1)
where: n= For all Gases
(1 − mavg ) ⋅ log (P2 / P1) − log ( Z2 / Z1)

1
n = For Ideal or Perfect Gases
(1 − mavg )

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COMPRESSOR HEAD, POWER, PRESSURE RATIO AND VOLUME RATIO (Cont)

The uncertainties of the head calculation are rooted in the Perfect Gas assumptions used to derive the equation above and the
non-constancy of n for many compressed gases (see Schultz reference for more information). To ensure the best accuracy for
the polytropic head calculation, use the CompCalc PC program Solver section for all gases. This program uses the method
described in the Huntington reference to improve the head calculation accuracy for non-ideal gases.

COMPRESSOR GAS POWER

The gas power of a compressor section is equal to the rate of energy added to the gas stream plus the energy rejected to
cylinder cooling jackets and similar integral compressor cooling systems.
For uncooled compressor sections, the gas power is:

CUSTOMARY METRIC
W H poly H poly
GHP = (HP) GkW = W (kW)
33000 η poly η poly

For cooled compressor sections (e.g., typical reciprocating compressors), the gas power must be increased by an additional
factor to account for the energy rejected to the integral compressor cooling system (e.g., cylinder cooling jackets). Based on
the recommendations included in Figure 4 for cooled reciprocating compressor, this factor may be estimated to be 1.05. With
this value, the gas power for a cooled compressor, such as a reciprocating compressor is:

CUSTOMARY METRIC
1.05 H poly 1.05 H poly
GHP = W (HP) GkW = W (kW)
33000 η poly η poly

Use other factors as appropriate for other cooled compressor types but ensure that the same factor is used for both the initial
ηpoly estimate for the discharge temperature prediction as well as the gas power estimates above.

PRESSURE RATIO
The pressure ratio of a compressor section is:
P2
r =
P1

The following pressure ratio limitations are generally applied to single compressor sections of various compressor types:

COMPRESSOR AND SERVICE DESCRIPTION PRESSURE RATIO LIMIT PER STAGE

Centrifugal Compressors Refer to DP Section XI-B, Table 2 for Head Limits

Axial Compressors, Air or Nitrogen 12

Reciprocating Compressors, P1 ≤ 1000 psig (70 barg) 5

Reciprocating Compressors, P1 > 1000 psig (70 barg) 2.5

Dry Helical Screw Compressors 5

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COMPRESSOR HEAD, POWER, PRESSURE RATIO AND VOLUME RATIO (Cont)

VOLUME RATIO
This is the ratio of the inlet volume flow rate vs. the outlet volume flow rate for a compressor section. It is also equal to the ratio
of the specific volume of the compressed gas evaluated at the inlet conditions of the compressor section vs. the outlet
conditions. Since the outlet volume should be less than the inlet volume for a practical compressor, the volume ratio must
always be greater than 1.0 and may be predicted as follows:
1− mavg
V1 Z T P Z  P2 
Volume Ratio = = 1 1 2 ≅ 1   For All Gases
V2 Z 2 T2 P1 Z2  P1 

COMPRESSOR SHAFT AND DRIVER POWER

The compressor shaft (or brake) power equals the sum of the Gas Power for each compressor section in the compressor
casing plus the mechanical losses of the compressor. The Driver Power equals the sum of the Shaft Powers for each of the
casings in the compressor string plus the mechanical losses of the drive gearbox, if any. The following formulas may be used
to estimate the Shaft Power and Driver Power for the major compressor types:

CENTRIFUGAL COMPRESSORS
Shaft Power = Σ (Gas Power for each compressor section in a casing) + (Mechanical Losses)
Refer to Figure 8A or 8B for estimates of mechanical losses for centrifugal compressors.
Σ (Shaft Power for each casing)
Driver Power =
Gearbox Efficiency

Refer to Figure 7 for typical gearbox efficiencies.

AXIAL COMPRESSORS
Shaft Power = Σ (Gas Power for each compressor section is a casing) + (Mechanical Losses)
Refer to Figure 9A or 9B for estimates of mechanical losses for axial compressors.
Σ (Shaft Power for each casing )
Driver Power =
Gearbox Efficiency

Refer to Figure 7 for typical gearbox efficiencies.

RECIPROCATING COMPRESSORS
Σ (Gas Power for each section in the compressor )
Shaft Power =
Mechanical Efficiency

Refer to Figure 5 for an estimate of the mechanical efficiency of a reciprocating compressor.

Driver Power = Shaft Power

DRY HELICAL SCREW COMPRESSORS

Gas Power for the compressor section
Shaft Power =
Mechanical Efficiency

Use 96% (0.96) for the Mechanical Efficiency unless a specific value is available from a vendor quotation.
Σ (Shaft Power for each casing )
Driver Power =
Gearbox Efficiency

Refer to Figure 7 for typical gearbox efficiencies.

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SPECIAL CALCULATION CONSIDERATIONS - RECIPROCATING COMPRESSORS

VOLUMETRIC EFFICIENCY
The volumetric efficiency of a reciprocating compressor stage is the ratio of the inlet volume flow rate vs. the piston
displacement of that stage. This value is used to compute the actual capacity of a compressor, based on geometry.
Volumetric efficiency may be estimated by the following formula:
1
ηv = (100 − L ) − c (r k − 1)

where: ηv = Volumetric Efficiency, %

c = Cylinder Clearance, %. Cylinder Clearance Volume / Swept Volume X 100.
See Section XI-H for definitions of Clearance Volume and Swept Volume.
L = Loss factor, %. The Loss Factor may be estimated by the following formula for
lubricated
reciprocating compressors.

[
L = 3.0 + 0.016 + 0.78 Patm0.2 r ]
For non-lubricated compressors, double this value. Patm is the stage inlet pressure in
atmospheres.

POTENTIAL FOR DRIVER OVERLOADING

Either an increase or a decrease in the inlet pressure of a reciprocating compressor (at constant discharge pressure) has the
potential to result in an overload of the driver. With a constant discharge pressure, a critical pressure ratio generally exists at
which the compressor power is a maximum. Therefore, if the design pressure ratio is greater than this critical ratio, a decrease
in the pressure ratio (i.e., increasing inlet pressure) will result in an increase in compressor power. Conversely, if the design
pressure ratio is less than this critical value, a decrease in the inlet pressure will result in an increased compressor power. The
resulting power increases can, in some circumstances, exceed the driver rating factors normally applied to reciprocating
compressors. Therefore, if alternative operating conditions require significantly different pressure ratios than the design value,
then in addition to considering the compressor power requirements at the design and alternate operating points individually,
several operating points in between should be evaluated to ensure that a peak power requirement is not overlooked.
The critical pressure ratio described above can be determined theoretically by re-writing the compressor power formula to
replace the mass flow term as given below:

CUSTOMARY METRIC
  n−1    n−1 
D ηv   n  n  D ηv   n  n 
GHP = P1    r − 1  (HP) GkW = P1    r − 1 (kW)
22917 η poly   n − 1   3600 η poly   n − 1  
     

This expression can then be evaluated (after expansion of the volumetric efficiency term using the formula given previously) to
determine a theoretical critical pressure ratio (i.e., peak power point). In practice, use of the CompCalc PC computer program
is suggested to evaluate alternate and off-design operating points for their potential to overload the driver.

PHYSICAL CHARACTERISTICS OF A COMPRESSOR SECTION

Based on the volume flow, pressure ratio, head and/or volume ratio predicted for each compressor section, refer to the Section
XI-B, Compressor Type Selection and Sections XI-E, XI-F, XI-H and XI-I to determine the specific physical characteristics of
the compressor.

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ç COMPUTER PROGRAMS
For centrifugal compressors, the CompCalc PC computer program is available to design a complete compressor string based
on Design Specification or Heat and Material Balance Information. In addition, SIM/SCI PROII / PROVISION includes a
compressor design module useful for screening. CompCalc may also be used to simulate an existing centrifugal, axial or
reciprocating compressor for new operating conditions based on performance characteristic curves and machine design details.
Reciprocating compressors may be designed based on Design Specification or Heat and Material Balance information with the
mainframe program, O2666, Reciprocating Compressor Selection.
No computer tools are available to design or select helical screw or axial compressors and the designer is referred to the hand
calculations supplemented with specific vendor quotations as necessary. Contact the Machinery Engineering Section for
assistance.

ç NOMENCLATURE
See Design Practice Section XI-A.

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FIGURE 1
COMPRESSOR CALCULATIONS FLOWCHART

Start

Estimate dp at Interstage

Calculate Inlet Volume Flow to 1st Stage

Estimate Efficiency of 1st Stage

Estimate No. of Stages

Estimate Inlet and Outlet Pressures for Each Stage

Calculate Inlet Volume Flow to Stage

Estimate Efficiency of Stage

For
Calculate Discharge Temperature
Each
Stage

Discharge Too High Increase

Temperature No. of Stages
OK?

Yes
Calculate Head, Power, Pressure
Ratio for Each Stage

Estimate Characteristics
of Compression Stage

DP11Df01

EXXON RESEARCH AND ENGINEERING COMPANY - FLORHAM PARK, N.J.

 COMPRESSORS DESIGN PRACTICES
COMPRESSION CALCULATIONS Section Page
EXXON XI-D 13 of 19
ENGINEERING Date
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FIGURE 2A
ESTIMATED POLYTROPIC EFFICIENCY
OF UNCOOLED CENTRIFUGAL COMPRESSORS
(CUSTOMARY UNITS)
82

80

78
Polytroplic Efficiency (%)

76

74

72

70

68

66
100 1000 10000 100000
Inlet Volume Flow Rate, ACFM
DP11Df2a

FIGURE 2B
ESTIMATED POLYTROPIC EFFICIENCY
OF UNCOOLED CENTRIFUGAL COMPRESSORS
(METRIC UNITS)

82

80

78
Polytropic Efficiency (%)

76

74

72

70

68

66
100 1000 10000 100000 1000000

Inlet Volume Flow Rate, ACMH

DP11Df2b

EXXON RESEARCH AND ENGINEERING COMPANY - FLORHAM PARK, N.J.

 DESIGN PRACTICES COMPRESSORS
Section Page COMPRESSION CALCULATIONS
XI-D 14 of 19 EXXON
Date ENGINEERING
December, 1998 PROPRIETARY INFORMATION - For Authorized Company Use Only

FIGURE 3A
ESTIMATED POLYTROPIC EFFICIENCY
OF UNCOOLED AXIAL COMPRESSORS
(CUSTOMARY UNITS)

88.5

88.0
Polytropic Efficiency (%)

87.5

87.0

86.5

86.0
10000 100000 1000000
Inlet Volume Flow Rate, ACFM
DP11Df3a

FIGURE 3B
ESTIMATED POLYTROPIC EFFICIENCY
OF UNCOOLED AXIAL COMPRESSORS
(METRIC UNITS)

88.5

88.0
Polytropic Efficiency (%)

87.5

87.0

86.5

86.0
10000 100000 1000000
Inlet Volume Flow Rate, ACMH
DP11Df3b

EXXON RESEARCH AND ENGINEERING COMPANY - FLORHAM PARK, N.J.

 COMPRESSORS DESIGN PRACTICES
COMPRESSION CALCULATIONS Section Page
EXXON XI-D 15 of 19
ENGINEERING Date
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FIGURE 4
TYPICAL RECIPROCATING COMPRESSOR EFFICIENCY

100

M=2
Isentropic Efficiency, η /s, %

90
M = 10 0
=2
M

M = 30
80

70
1.0 2.0 3.0 4.0 5.0 6.0

Stage Pressure Ratio

Note: Multiply the efficiency value from this chart by 1.05 for cooled reciprocating compressors, which are the norm,
to account for cylinder cooling effectiveness. DP11Df04

FIGURE 5
TYPICAL MECHANICAL EFFICIENCY OF RECIPROCATING COMPRESSORS

100
Mechanical Efficiency η m, %

90

80
0 to 75 100 125 150 175 200 and up

DP11Df05
Horsepower per Cylinder

EXXON RESEARCH AND ENGINEERING COMPANY - FLORHAM PARK, N.J.

 DESIGN PRACTICES COMPRESSORS
Section Page COMPRESSION CALCULATIONS
XI-D 16 of 19 EXXON
Date ENGINEERING
December, 1998 PROPRIETARY INFORMATION - For Authorized Company Use Only

FIGURE 6
GENERALIZED SCHULTZ COMPRESSIBILITY DERIVATIVE FUNCTION

2.8 0.95
12
2.4
11
2.0
10
0.90
1.6 1.00
9 X
1.2
8 T = 0.85 1.05
Compressibility Function X

0.8 1.10
7 Reduced 0.80 1.15
Temperature, T = 1.00 1.20
0.4 0.70 1.30
6 1.50
1.05 0.60 2.00
0 5.00
0 0.1 0.2 0.3 0.4 0.5 0.6
5
1.00 P
1.10
4
1.05
1.15
3 1.10 1.20
1.15
1.20
1.30
2
1.30
1.50
1 1.50
2.00
0 5.00
0 0.2 0.4 0.6 0.8 1.0 1.2 1.4 1.6 1.8 2.0 2.2 2.4 2.6 2.8 3.0
Reduced Pressure, P

where:
T  ∂Z 
X =  
Z  ∂T  p

P
Pr =
Pc

T
Tr =
Tc DP11Df06

EXXON RESEARCH AND ENGINEERING COMPANY - FLORHAM PARK, N.J.

 COMPRESSORS DESIGN PRACTICES
COMPRESSION CALCULATIONS Section Page
EXXON XI-D 17 of 19
ENGINEERING Date
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FIGURE 7
MECHANICAL EFFICIENCY
OF HIGH SPEED GEARBOXES AT FULL LOAD

99
4000 rpm
8000 rpm
98
12000 rpm

16000 rpm
97
20000 rpm
Gear Efficiency, %

24000 rpm
96
Pinion Speed

95

94

93
10 100 1000 10000
Driver Horsepower, BHP
DP11Df07

EXXON RESEARCH AND ENGINEERING COMPANY - FLORHAM PARK, N.J.

 DESIGN PRACTICES COMPRESSORS
Section Page COMPRESSION CALCULATIONS
XI-D 18 of 19 EXXON
Date ENGINEERING
December, 1998 PROPRIETARY INFORMATION - For Authorized Company Use Only

FIGURE 8A
ESTIMATED MECHANICAL LOSSES
OF CENTRIFUGAL COMPRESSORS
(CUSTOMARY UNITS)
200

180

160

140
Mechanical Loss, HP

120

100

80

60

40

20

100 1000 10000 100000

DP11Df8a Inlet Volume Flow Rate, ACFM

FIGURE 8B
ESTIMATED MECHANICAL LOSSES
OF CENTRIFUGAL COMPRESSORS
(METRIC UNITS)
160

140

120
Mechanical Loss, kW

100

80

60

40

20

100 1000 10000 100000 1000000

DP11Df8b Inlet Volume Flow Rate, ACMH

EXXON RESEARCH AND ENGINEERING COMPANY - FLORHAM PARK, N.J.

 COMPRESSORS DESIGN PRACTICES
COMPRESSION CALCULATIONS Section Page
EXXON XI-D 19 of 19
ENGINEERING Date
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FIGURE 9A
ESTIMATED MECHANICAL LOSSES
OF AXIAL COMPRESSORS
(CUSTOMARY UNITS)

350

300

250
Mechanical Loss, HP

200

150

100

50
10000 100000 1000000

DP11Df9a
Inlet Volume Flow Rate, ACFM

FIGURE 9B
ESTIMATED MECHANICAL LOSSES
OF AXIAL COMPRESSORS
(METRIC UNITS)

240

220

200

180

160
Mechanical Loss, kW

140

120

100

80

60

40
10000 100000 1000000
DP11Df9b Inlet Volume Flow Rate, ACMH

EXXON RESEARCH AND ENGINEERING COMPANY - FLORHAM PARK, N.J.