Compressor at 100% capacity

[Kandan]

Hi everybody,

a simple question
Can a compressor be run at 100% capacity in a continuous operation

 

[quark]

Yes, but it is a bad design.

 

[25362]

To quark, could you expand or qualify your answer ?
Many process units I know of, work at full capacity on a continuous basis without unexpected or unusual consequences thereof.

 

[Samiran]

May I say that it can be okay to run over 100% capacity of a compressor. You really ought to look at the right parameters instead only capacity. The parameters to look is potential increase in vibration, stonewall proximity, PRV available capacity on the discharge etc. This assumes you have enough power to drive the compressor at high rates.

Samiran

 

[pmover]

kandan,

for further assistance, what type (i.e. recip, centrifugal, etc) of compressor?

what are the compressor's design conditions?

what are the compressor's actual operating conditions?

comments by 25362 & Samiran are valid.

-pmover

 

[johngerhart]

agree with previous notes , not enough info to answer your question . need service, type of machine -- what is 100%-- head , flow ?

 

[quark]

IMHO, a compressor running at full flow capacity can't be able to reach the maximum pressure that it was designed for(I still doubt about the pressure building techniques during startup). But there are fair chances that it may be running just below the maximum pressure thus cosuming maximum energy at any point of time.

Further, power consumption will be low for a cyclic compressor when compared to a fully loaded compressor.

Finally as a maintenance guy I would prefer intermittent operation of equipment for better life.

Regards,

 

[25362]

I have the feeling quark refers to centrifugal (dynamic types) rather than the displacement type of units.

 

[quark]

No. Reciprocating

 

[25362]

My thoughts: is the machine inherently unreliable or should we look to those who operate and maintain it to locate the culprit ?

There are indeed hydrogen reciprocating compressors that can operate continuously for 25,000 hours (3 years!) without a shutdown.

Of late original spare hydrogen reciprocating compressors are being brought online without spares. There is a demand for reciprocating compressors that are capable of running consistently at full capacity (volume- and pressure-wise) from turnaround to turnaround without a shutdown.

It appears that the reliability of these units is strongly dependent (given a good OEM's job for the purpose, a proper installation, good lubrication and instrumentation) on the good working relationships between the maintenance/reliability group and the production group.

Of course, good maintenance procedures (including organized documentation) carried by knowledgeable personnel is considered by many an important factor in getting reliable compressors.

It is, in the end, the operations department who answers the question: which will cost more in the long run, taking a short-term cut in production and fixing a "problem" or letting the compressor run even though there is the potential for further equipment damage and a longer shutdown. On these grounds I understand quark's comments.