PROCEDURE NO.

PAGE OF
PTD-DGS-125 1 9

PREPARED BY DATE
PROCESS TECHNOLOGY PROCEDURES Edited from existing April 30, 2000
doc by J.R. Barnhart
APPROVED BY
DEPARTMENT: PROCESS ENGINEERING JRB
SUBJECT: COMPRESSOR HEAD CALCULATIONS DESIGN GUIDE REVISION DATE REV.
11/01/02 1
1.0 SCOPE

This design guide1 describes the method used to calculate compressor circuit hydraulics.
Refer to the Rotating Equipment Engineering Manual for a detailed description of
compressor design and operation.

2.0 RESPONSIBILITIES

The process engineer determines the hydraulic requirements for compressor circuits.

3.0 CODES AND STANDARDS

American Petroleum Institute (API)

STD 617 Centrifugal Compressors for General Refinery Service
STD 618 Reciprocating Compressors for General Refinery Service

4.0 DEFINITIONS

Listed below are the definitions of terms associated with calculations for centrifugal and
reciprocating compressors using traditional U.S. units.

4.1 Centrifugal Compressors

The API STD 617 definitions are shown below and in Figure 1.

1. Normal operating point is the point at which usual operation is expected and
optimum efficiency is desired. This point is usually the point at which the Supplier
certifies that performance.
2. Normal speed is the speed corresponding to the requirements of the normal
operating point.
3. One-hundred-percent speed is the highest speed required for any specified
operating point above the normal speed curve. If there are no specified operating
points that require greater than normal speed, the 100-percent speed shall be the
normal speed.
4. Compressor rated point is the point on the 100-percent-speed curve at the highest
capacity of any specified operating point.
5. Maximum continuous speed (in revolutions per minute) for compressors driven by
variable-speed prime movers is the speed at least equal to 105 percent of the
highest speed required by any of the specified operating conditions. Maximum
continuous speed for constant-speed drivers shall be equal to the 100-percent
speed.
6. Minimum allowable speed (in revolutions per minute) is the lowest speed at which
the manufacturer's design will permit continuous operation.

1
Rev. 0 of the Design Guide was adapted with minimal changes from a Pasadena document, DSG-MP4, 9/92
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7. Trip speed (in revolutions per minute) is the speed at which the independent
emergency overspeed device operates to shut down a prime mover (see Table 1).
8. Stability is the difference in capacity (in percentage of rated capacity) between the
rated capacity and the surge point (and rated gas properties).
9. Turndown is the percentage of change in capacity between the rated capacity and
the surge-point capacity at the rated head when the unit is operating at rated
suction temperature and gas composition.
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Source: API STD 617

Figure 1 – Centrifugal Compressors - Definitions

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Table 1 - Driver Trip Speeds

Trip Speed
(percent of maximum
Driver Type continuous speed)

Steam turbine
NEMA Class A 115
NEMA Classes B, C, D 110
Gas turbine 105
Variable-speed motor 110
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Constant-speed motor 100

Reciprocating engine 110

10 Maximum allowable working pressure is the maximum continuous pressure for

which the manufacturer designed the equipment (or any part to which the term is
referred) when it is operating at the maximum allowable temperature.

11 Maximum sealing pressure is the highest pressure expected at the seals during any
specified static or operating conditions and during startup and shutdown.
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12 Maximum allowable temperature is the maximum continuous temperature for which

the manufacturer designed the equipment (or any part to which the term is
referred).

13 Settling-out pressure is the pressure of the compressor system when the

compressor is shutdown.
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14 Inlet cubic feet per minute (ICFM) refers to the flowrate determined at the
conditions of pressure, temperature, compressibility, and gas composition,
including moisture, at the compressor inlet flange.

15 Actual cubic feet per minute (ACFM) refers to the flowrate at flowing conditions of
temperature and pressure at any given location. Because this term describes flow
at a number of locations, it should not be used interchangeably with ICFM.

16 Standard cubic feet per minute (SCFM) refers to the flowrate at any location
corrected to a pressure of 14.7 pounds per square inch absolute (1.01 bar) and a
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temperature of 60 degrees F (15.56 degrees C) with a compressibility factor of 1.0

and in a dry condition.

4.2 Reciprocating Compressors

The API STD 618 definitions are shown below.

1. Rated discharge pressure is the highest pressure required to meet the specified
conditions.
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2. Rated discharge temperature is the highest predicted operating temperature

resulting from a specified operating condition.
3. SCFM is an abbreviation for capacity in standard cubic feet per minute at 14.7
pounds per square inch absolute (psia) and 60 degrees Fahrenheit.
4. ICFM is an abbreviation for inlet cubic feet per minute determined at suction
(compressor inlet flange) conditions of pressure, temperature, compressibility, and
moisture. ICFM and ACFM (actual cubic feet per minute) are identical in meaning
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(at the inlet conditions). To determine ICFM, allowance shall be made for pressure
drop across pulsation suppression devices and for interstage knockout.
5. Minimum Allowable Suction Pressure for each stage is the lowest pressure at the
inlet flange below which the combined rod loading, or gas loading, or discharge
temperature, or crank shaft torque loading will exceed the maximum allowable
during operation at the setpoint pressure of the discharge relief valve and other
specified gas conditions for the stage.

5.0 CALCULATION PROCEDURE - CENTRIFUGAL AND RECIPROCATING

COMPRESSORS
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Using the Compressor Circuit Calculation form, complete the data section as follows:

5.1 Service Conditions

Enter service conditions and state the tag number and stage number.

5.2 Flow Sketch

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Using the Circuit Pressure Drop form, (Exhibit 2), construct a flow sketch identifying
pertinent equipment by item/tag number and showing orifices, control valves, and
alternate flow routes. Include dimensions for compressor center line from datum, line
sizes, static head, relief valve set pressures, and block valves. Show elevations of
equipment.

5.3 Line Sizing

Complete the line size calculations using the project specified method. Use actual routing,
if known, or the estimated route, using coordinates of equipment and allowing for change
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of elevation, pipe fittings, and valving. Particular care should be taken in estimating the
suction line equivalent length.

5.4 Compressor Differential Head Calculations

The compressor differential head calculations shall be performed as follows:

1. Enter line DP as calculated above.

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2. DPs of flow measurement devices shall be actual values obtained from the
instrumentation and controls supervising engineer. Be sure to consider the use of
low-pressure-drop devices for compressor circuits.
3. Identify the exchanger or equipment and the DP across the unit. These values
should be realistic and should be obtained from the heat transfer supervising
engineer. Use only fouled values (allowable DP).
4. R dynamic DP is the sum of dynamic losses listed above.
5. For control valve DP, consult with the instrumentation and controls supervising
engineer to obtain the minimum value that will ensure proper control of the
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compressor circuit. Generally, these values will be approximately 15 percent of the

total dynamic losses.
6. Compressor suction pressure is obtained by subtracting the total dynamic loss and
the control valve DP from the suction vessel pressure, allowing for static head
difference.
7. Terminal pressure is the pressure at the end point of the compressor system. This
is generally a vessel, the junction with another system, or the battery limit.
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8. Discharge pressure is the pressure at the discharge nozzle of the compressor. It is

the sum of the dynamic DP, the control valve DP, the static head, and the terminal
pressure.
9. Compressor differential pressure is the pressure the compressor must add to the
fluid to allow it to flow to its required destination. It is the difference between the
compressor suction pressure (step 6) and the discharge pressure (step 8).

6.0 COMPRESSOR TEAM

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The compressor team is an organization of members from the technical engineering

organization whose function is to agree on and to fix information pertinent to the design
and procurement of compressor-driver units. On a specific project, this team may be
formal or informal.

The process engineer is responsible for compressor hydraulics and participates in

establishing compressor-driver type and number.

7.0 EXHIBITS
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The following exhibits are referenced in this design guide.

Exhibit Title

1 PTD-FRM-111 - Compressor Circuit Calculation Form

2 PTD-FRM-110 - Circuit Pressure Drop Form
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Exhibit 1 - Compressor Circuit Calculation Form

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Exhibit 2 – Circuit Pressure Drop Form

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Exhibit 2 – Circuit Pressure Drop Form (Cont’d)