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M/s. Nuovo pignone, Italy.
COMPRESSORS
1.1. INTRODUCTION
A simple definition of compressor is a device used to pressurize a fluid
including liquids and gases. There are many different kinds of compressors, but the
main purpose of using a compressor is to raise the pressure of a gas.
A compressor converts shaft power to raise the enthalpy of the gas. The gas
enters the compressor at a low pressure and exits at a high pressure. The rotating shaft
is attached to a blade assembly; the rotating blades push on the gas and increase the
pressure and thereby increasing the enthalpy. Compressors can be either Positive
displacement type or Dynamic type.
COMPRESSORS
POSITIVE DISPLACEMENT
(COMPRESSING FLUID BY
REDUCING
VOLUME OF COMPRESSION
CHAMBER)
RECIPROCATING
HELICAL
SCREW
ROTARY TYPE
SPIRAL
AXIAL
DYNAMIC TYPE
(ACCELERATION AND
DECLERATION OF FLUID)
CENTRIFUGAL
COMPRESSORS
STRAIGHT
LOBE
AXIAL
COMPRESSORS
SLIDE
VANE
Not too many years ago, it was common practice to use reciprocating
compressors when high pressures were required. Dynamic-type machines were used
only where larger volumes and lower pressures were involved. Dynamic compressors
were usually called blowers when air or gas was compressed to about 40 psig. The term
compressor was applied to any such machine where air or gas was compressed to a
final pressure over 50 psig. In recent years, this differentiation has become
meaningless. Industry now uses the term compressor for all types of machines
compressing air or gas.
Centrifugal compressors are machines in which velocity and pressure are given to
the air or gas in a radial direction by one or more impeller-diffuser combinations
2.
Axial compressors are the machines in which velocity and pressure are given to
the air or gas in an axial direction by one or more sets of moving and stationary
rows of blades
2.
3.
Rotary lobe compressors are machines in which two mating lobed impellers
revolve within a cylinder and are prevented from making a contact with each
other by timing gears mounted outside the cylinder
4.
Rotary liquid-piston compressors are machines in which water or other liquids are
used, usually in a single rotating element, to displace the air or gas handled.
Although each of the positive-displacement types will vary from the other
somewhat, they can be grouped together as single class of machines for the purpose of
comparison with dynamic-type compressors. Figure shows the basic pressure-capacity
constant-speed characteristics of positive displacement, dynamic-type and centrifugal
compressors. The centrifugal compressor is essentially a variable-capacity, constantpressure machine, the axial compressor and the positive-displacement compressors are
essentially constant-capacity, variable-pressure machines.
These basic characteristics, however, represent only part of the problem of
choosing the type of compressor best suited to a specific application. Equally important
is the capacity range that can be built into a single machine. As a general rule, positivedisplacement machines are for small capacities, centrifugals are for medium capacities
and axial machines are for large capacities. As in all other general statements, however,
it must be realized that there is considerable overlap of capacity range between these
different types of compressors.
Although flow limits for centrifugal are dictated somewhat by the specific
conditions involved and design philosophy of different manufacturers, general range of
compressor selection goes as below
Positive displacement machines below 3000 m / hr.
Axial compressors above 30,000 m / hr.
Flow regions between 3000 - 12,000 m / hr. can be considered over-lapping between
positive displacement and centrifugal compressors
Flow regions between 30,000 - 1, 20,000 m / hr. can be considered over-lapping
between centrifugal and axial compressors.
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105
104
103
Centrifugal
102
101
Axial
Reciprocating
102
103
104
105
106
D
is
c
h
a
r
g
e
P
r
e
s
s
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P
si
a
b
CENTRIFUGAL COMPRESSORS
2.1. INTRODUCTION
Centrifugal Compressor is one of the most critical equipment in process
industry. As these machines are highly power intensive, efforts towards improving their
efficiencies and reliabilities has been the goal of the designer. Considerable
improvement in efficiencies of these machines has been possible by incorporating new
design concepts and state-of-art technologies in the product and the associated systems.
Following are the developments in the centrifugal compressors field
1. Optimal design of impeller geometry adapted for low flow conditions
2. Standard Stage Concept
3. Design of three dimensional impellers
4. Use of dry flexible couplings
5. Use of dry gas seals
6. Use of Low solidity diffuser vanes
Optimal design of impeller geometry adapted for low flow conditions:
Considering the requirement of impellers handling low flows especially for high
pressure compressors a new chapter in manufacturing is thus opened. This has
incidentally helped in extending the range operation of impellers. The basic fact in the
design of impellers is that higher the outlet vane angle higher the head coefficient and
higher flow handling capacity. This means we have to employ low outlet angles for
impeller vanes handling low flows. Generally for vane angles less than 37.5 degrees,
we require long channel passages. It is difficult to manufacture these impellers by any
traditional methods. The efficiency and head realized in this case are definitely low.
External welded impeller manufacturing technology has over come the above
difficulties. In this the design of impeller geometry can be aimed for low flows with
low vane angles without any sacrifice in efficiency. The operating range with these
impellers is more than the impeller employed with a compromise due to manufacturing
constraint. Impellers calling for the design with outlet vane angles in the range of 15-18
degree, result in long channel passages, hence appreciably better guidance for the flow.
VERTICALLY
VERTICALLY
SPLIT
SPLIT
SPLIT
MCL
(PROCESS)
BCL
(PIPE LINE)
PCL
2MCL
2BCL
SRL
3MCL
DBCL
DMCL
2.2.1. MCL Compressor
These are multistage compressors with horizontally split casing, for pressure up
to 40kg/cm2 and capacities up to 3, 60,000m3/hr at suction condition. These are mainly
used in
2.2.2.
Ethylene plants
Refrigerating services
2MCL Compressor
These are multi-stage compressors which group two compression stages in
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BCL
They are multi stage compressors with vertical split casing for pressure up to
350Kg/cm2 and capacities of 50,000m3/hr at suction conditions. They are mainly used
in:-
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12
Low noise.
High rigidity boxed base incorporating the lube oil tank and gearbox.
13
14
Steel castings
Cast iron
15
16
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CASINGS
END COVERS
DIAPHRAGMS
MCL TYPE
Horizontally split
No
Generally cast type
BCL TYPE
Vertically split
Yes
Cast and fabricated type
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2.5. IMPELLERS
Impeller is the vital rotary part in the functioning of the compressor. The fluid
(gas or air) enters the impeller axially at the eye of the impeller and then flows radially
out of the impeller. The gas goes through the diffuser to the return channel and further
goes into the next impeller. It is one of the most stressed components of the compressor,
demanding highly precise manufacturing methods. Each impeller is dynamically
balanced and subjected to over speed test. They are mounted, shrink fitted and keyed
on the shaft, which is coupled to an external source (generally electric motor). This
source imparts the required energy and makes it to rotate.
In an impeller, the energy transferred is in the form of kinetic energy, which is
then converted into pressure energy in the diffuser.
compressor depends mainly on the impeller diameter, rotational speed and volume flow.
2.5.1 Types of Impellers
There are three types of impellers:
Open type: These are used for high heads and for small to large flow, in single
compressors only. In this type of impeller, the flow of gas is least controlled.
Semi-enclosed type: These are used for large flow usually in single stage
compressors or first stage in multi stage compressors.
Closed type: These are made of special forged steels and these are used mainly
in multistage compressor. It consists of a disc and counter disc. The grooves
are milled on the disc and vanes on counter disc.
The vanes are radial or backward curved depending on the head required. The
disc and counter disc are clamped and welded together along the vanes. The impellers
are the most stressed components; in fact there is a tendency to exploit them to a
maximum so as to reduce the number of stages.
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21
22
23
C12 C 02
h
andT
2 g 427
Cp
At this point the fluid enters the first impeller, which transfers a certain
quantity of energy to it, bringing it to the final condition V1, P1, and T1 Volume,
pressure, and temperature at inlet.
According to the Eulers theory, the energy given to a unit weight of fluid
passing through the channel between the two vanes of the impeller is equal to the
change of its momentum.
hu
1
u 2 C 2 cos 2 u1C1Cos 1
g
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DIFFUSER
RETURN CHANNEL
LSD VANE
IMPELLER
ON IMPELLER SEAL
INTER STAGE SEAL
25
The three velocity vectors C1, U1, W1 forms the inlet triangle.
Since in general 1= 90 (radial inlet) the expression becomes:
hu
1
C 2 u 2 Cos 2
g
c 2 Cos 2
u2
c2 u
u2
Therefore
hu
1
2 u 22 Where u 2
g
nd e
60
= C2u / u2
According to Eulerian equation,
Heff = u2/g
b) Flow coefficient at the impeller outlet (2)
Depends on 2 value and on flow rate Q1 explicit, it is expedient to introduce
the ratio between C2r and u2.
2 = C2r / u2 = Q1/b2D2u2
This second parameter is called flow coefficient at the impeller outlet.
Two are particularly important for sizing and characterizing the impeller.
The two dimensionless coefficients and 2 allow to completely identifying the
velocity triangle at outlet both is dimensionless form and dimensional form, u 2 being
known.
and 2 are not independent to each other.
C2u=u2- C2r /tg2
=1- 2 /tg2 = 1- 2 cot g2
Thus depends on 2 by angle 2.
v m=
hu =
C 2 u 2 Cos 2
g
= 2/ 2theoritical
=0.86
2=0.86(1- 2 cot 2)
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Heff =hu
Adiabatic head
Ha=Z0RT0(k/k-1) ((k-1/k)-1)
A= Ha/ Heff
(kw)
The mechanical losses and the thrust bearing losses must be added.
Finally politropic efficiency is calculated
p =(k-1/k)/(n-1/n)
A = ((k-1/k)-1)/ ((n-1/n)-1)
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Application
Power
Drive
Blast furnace
Bessemer converter
Cupola
Coke oven
Mining and
metallurgy
Power
Furnace
Natural gas
Production
Distribution
Processing
Service or process
Typical gas
handled
Compression
Compression
Combustion
off gas
Oxidation
Combustion
Compression
Air
Air
Air
blast furnace gas
Air
Air
Coke oven gas
Air
Air
Air
Natural gas
Natural gas
Natural gas
Refrigeration
Chemical
Various processes
Air conditioning
Utilities
Industrial and
commercial
Steam generators
Propane and
methane
Butane, Propane,
Ethylene, ammonia,
special refrigerants
Special refrigerants
Soot blowing
Combustion
Cyclone furnace
Manufacturing
Distribution
Air
Air
Air
Fuel gas
Fuel gas
Air
Air
Paper making
Agitation
Power for tools and
machines
fourdrinier vacuum
Material handling
Gas engines
Conveying
Supercharging
Air
City gas
Miscellaneous
Sewage treatment
Industrial power
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Rotor balance
32
Absence of oil leakage and restriction in the lube and seal oil
channels in the compressor casing.
Noise level.
power consumption and temperature rise during the test run. The compressor
discharge hood temperature will shoot up, if discharge pipe of the compressor is
connected to atmosphere instead of the vacuum line.
During the test rum, the bearings are supplied with oil form a centralized
lube oil console. Which will pump oil at the required pressure and temperature. The
system consists of twin coolers, high-grade duplex filters and control valves.
The compressor is started from stand still and the speed is increased in 10%
increments till the maximum continuous speed is reached. The compressor is kept at
this speed for 4 hours. After this period, the compressor is made to over speed at
110% of maximum continuous speed for 15 minutes. During the deceleration, the
first critical speed is located and vibrations due to shaft run-outs are recorded.
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Gas leak test is conducted after assembling of end seals to the casing. Then
compressor casing is pressurized for 30minutes upto rated discharge pressure is
obtained. After acquiring the rated discharge pressure total casing and all casing
joints are checked for leakages with soap solution/leak detector.
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CONCLUSION
Hence the study of centrifugal compressor is performed in B.H.E.L. with the
help of the guide allocated to us. In this process we had studied the way the design is
selected according to the need of the customers. After the selection of the design all
the parts of centrifugal compressor such as impellers, diaphragm, rotor, oil seals,
casing and many other parts are prepared. Each parts is further classified in many
types each having its specification. The next step is the assembly of all the parts
according to the layout. During assembly some minor tests are carried out such as
hydraulic test and balancing test and after assembly of the centrifugal compressors
all the major tests such as no load test, full load test, seal test and many more are
being carried out .these test are carried out so that there is no malfunctioning of the
components during the delivery of the compressors. During the production of the
centrifugal compressor the main aim of the industry is the better quality and service
with a better efficiency.
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REFERENCES
1.
2.
R.Yadav, Steam and Gas turbines, Central Publishing House Ltd., Allahabad.
3.
4.
5.
Balje, O.E. Turbo machines-A Guide to Design, Selection and Theory, Wiley
& Sons, New York.
6.
7.
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