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    Compressor GATE Mechanical Engineer

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    sap2279
    Compressors are mechanical devices that compress gases. There are two main types - dynamic compressors that use rotating impellers like centrifugal and axial compressors, and positive displacement compressors that use rotating screws or reciprocating pistons to compress gases. Compressors have many applications including air conditioners, refrigeration, industrial machinery, and manufacturing. Centrifugal compressors accelerate gas outward using a rotating impeller while axial compressors use parallel gas flow along the axis of rotation. Positive displacement compressors trap fixed volumes of gas and increase pressure. Surging can damage centrifugal compressors and occurs when flow reverses due to high outlet pressure.

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    Compressor GATE Mechanical Engineer

    Uploaded by

    sap2279
    503 views45 pages
    Compressors are mechanical devices that compress gases. There are two main types - dynamic compressors that use rotating impellers like centrifugal and axial compressors, and positive displacement compressors that use rotating screws or reciprocating pistons to compress gases. Compressors have many applications including air conditioners, refrigeration, industrial machinery, and manufacturing. Centrifugal compressors accelerate gas outward using a rotating impeller while axial compressors use parallel gas flow along the axis of rotation. Positive displacement compressors trap fixed volumes of gas and increase pressure. Surging can damage centrifugal compressors and occurs when flow reverses due to high outlet pressure.

    Original Description:

    compressor details , classification and working for mechanical engineers

    Original Title

    Compressor GATE mechanical engineer

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    Compressors are mechanical devices that compress gases. There are two main types - dynamic compressors that use rotating impellers like centrifugal and axial compressors, and positive displacement compressors that use rotating screws or reciprocating pistons to compress gases. Compressors have many applications including air conditioners, refrigeration, industrial machinery, and manufacturing. Centrifugal compressors accelerate gas outward using a rotating impeller while axial compressors use parallel gas flow along the axis of rotation. Positive displacement compressors trap fixed volumes of gas and increase pressure. Surging can damage centrifugal compressors and occurs when flow reverses due to high outlet pressure.

    Copyright:

    © All Rights Reserved
    Download as PPTX, PDF, TXT or read online from Scribd
    Download as pptx, pdf, or txt
    503 views45 pages

    Compressor GATE Mechanical Engineer

    Uploaded by

    sap2279
    Compressors are mechanical devices that compress gases. There are two main types - dynamic compressors that use rotating impellers like centrifugal and axial compressors, and positive displacement compressors that use rotating screws or reciprocating pistons to compress gases. Compressors have many applications including air conditioners, refrigeration, industrial machinery, and manufacturing. Centrifugal compressors accelerate gas outward using a rotating impeller while axial compressors use parallel gas flow along the axis of rotation. Positive displacement compressors trap fixed volumes of gas and increase pressure. Surging can damage centrifugal compressors and occurs when flow reverses due to high outlet pressure.

    Copyright:

    © All Rights Reserved
    Download as PPTX, PDF, TXT or read online from Scribd
    Download as pptx, pdf, or txt
    of 45

    What are

    compressors?
    Compressors are mechanical devices that
    compresses gases. It is widely used in
    industries and has various applications

    How they are different from pumps?

    Major difference is that compressors handles the gases and pumps handles
    the liquids.
    As gases are compressible, the compressor also reduces the volume of gas.
    Liquids are relatively incompressible; while some can be compressed

    Centrifugal pump

    What are its applications?


    Compressors have many everyday uses, such as in :
    Air conditioners, (car, home)
    Home and industrial refrigeration
    Hydraulic compressors for industrial machines
    Air compressors for industrial manufacturing

    Refrigeration compressor

    What are its various types?


    Compressor classification can be described by following flow chart:

    What are dynamic


    compressors?
    The dynamic compressor is continuous flow compressor is characterized by rotating
    impeller to add velocity and thus pressure to fluid.
    It is widely used in chemical and petroleum refinery industry for specific services.
    There are two types of dynamic compressors
    Centrifugal Compressor
    Axial Flow Compressor

    Centrifugal Compressor
    Achieves compression by applying inertial forces to the gas by means of
    rotating impellers.
    It is multiple stage ; each stage consists of an impeller as the rotating
    element and the stationary element, i.e. diffuser
    Fluid flow enters the impeller axially and discharged radially
    The gas next flows through a circular chamber (diffuser), where it loses
    velocity and increases pressure.

    Axial flow compressor


    Working fluid principally flows parallel to the axis of rotation.
    The energy level of air or gas flowing through it is increased by the
    action of the rotor blades which exert a torque on the fluid
    Have the benefits of high efficiency and
    large mass flow rate
    Require several rows of airfoils to achieve
    large pressure rises making them complex and
    expensive

    What are positive displacement


    compressors?
    Positive displacement compressors causes movement by trapping a fixed amount of
    air then forcing (displacing) that trapped volume into the discharge pipe.
    It can be further classified according to the mechanism used to move air.
    Rotary Compressor
    Reciprocating compressor

    Rotary compressors
    The gas is compressed by the rotating action of
    a roller inside a cylinder.
    The roller rotates off-centre around a shaft so
    that part of the roller is always in contact with the
    cylinder.
    Volume of the gas occupies is reduced and the
    refrigerant is compressed.
    High efficient as sucking and compressing
    refrigerant occur simultaneously.

    Rotary compressors
    These compressors use rotors in place of pistons,
    giving a pulsating free discharge air. These rotors
    are power driven. They have the following
    advantages over reciprocating compressors:
    o They
    o They
    air
    o They
    o They
    have

    require a lower starting torque


    give a continuous, pulsation free discharge
    generally provide higher output
    require smaller foundations, vibrate less, and
    lesser parts, which means less failure rate

    Subtypes:
    Depending on the action and geometry of
    the rotors, these are classified as follows:
    Rotary
    compresso
    rs
    Lobe
    compressors

    Screw
    compresso
    rs

    Vane
    compresso
    rs

    Scroll
    compresso
    rs

    Lobe compressor
    Also called the roots blower, its essentially a low pressure
    blower and is limited to a discharge pressure of 1 bar in a
    single-stage and 2.2 bar in two stage-design.

    12

    Rotary screw compressors:


    Rotary screw compressors use two meshed
    rotating positive-displacement helical screws
    to force the air into a smaller space (see
    figure).
    These are usually used for continuous
    operation in commercial and industrial
    applications and may be either stationary or
    portable.
    Because of simple design and
    few wearing parts, rotary screw
    air compressors are easy to
    install, operate, and maintain.

    13

    Rotary vane compressors:


    One of the oldest compressor technologies,
    rotary vane compressors consist of a rotor
    with a number of blades inserted in radial
    slots in the rotor.

    14

    The rotor is mounted offset in a larger housing that


    is either circular or a more complex shape. As the
    rotor turns, blades slide in and out of the slots
    keeping contact with the outer wall of the housing.
    Thus, a series of decreasing volumes is created by
    the rotating blades
    They can be either stationary or portable, can be
    single or multi-staged, and can be driven by electric
    motors or internal combustion engines. They are
    well suited to electric motor drive and is
    significantly quieter in operation than the equivalent
    piston compressor. They can have mechanical
    efficiencies of about 90%
    15

    Scroll compressors:
    A scroll compressor, also known as scroll pump
    and scroll vacuum pump, uses two interleaved
    spiral-like vanes to pump or compress air.
    Often, one of the scrolls is fixed, while the other
    orbits eccentrically without rotating, thereby
    trapping and pumping or compressing pockets of
    fluid or gas between the scrolls (see figure).

    16

    Due to minimum clearance volume between


    the fixed scroll and the orbiting scroll, these
    compressors have a very high volumetric
    efficiency. They operate more smoothly,
    quietly, and reliably than other types of
    compressors in the lower volume range.

    17

    Reciprocating
    compressor
    It is a positive-displacement compressor that
    Uses pistons driven by a crankshaft to deliver
    high pressure.

    gases at

    The intake gas enters the suction manifold, then flows into
    the compression cylinder
    It gets compressed by a piston driven in a reciprocating
    motion via a crankshaft,
    Discharged at higher pressure

    RECIPROCATING
    COMPRESSORS
    Detailed Analysis

    Block diagram of reciprocating


    compressor
    It is a piston and cylinder
    device with (automatic)
    spring controlled inlet and
    exhaust valves

    There is a clearance
    between the piston crown
    and the top of the
    cylinder.

    Centrifugal compressors

    Widespread use, many applications


    Gas is accelerated outwards by
    rotating impeller
    Can be built for operation as low
    pressure requirement 0f 4 to 6 bar
    Sizes range from 300 hp to 50,000 hp
    DIFFUSERS

    Cross section of horizontal split


    Picture of horizontal split
    Cross section of barrel
    type compressor
    Picture of barrel
    type compressor
    Cross section of
    bull gear compressor

    IMPELLERS

    Single Case CompressorCentrifugal Impeller

    Picture of bull
    gear compressor
    Picture of (bull)
    gear and impellers

    Cross section of horizontal split


    Discharge volutes
    Impellers

    Impeller inlet
    labyrinth seals
    Shaft and
    labyrinth seal

    Drive coupling

    Journal bearing

    Casing
    (horizontally
    split flange)

    Thrust bearing
    Compressor
    discharge nozzle
    Compressor
    inlet nozzle

    Picture of horizontal split

    Axial compressors
    Gas flows in direction of rotating shaft
    Can be built for higher pressures ratio of 10 to
    12.
    High flow rate
    Efficient
    Not as common as centrifugals
    Stator Blades

    Shaft

    Rotor Blades

    Casing

    Rotor
    Blades

    Stator
    Blades
    Casing

    Cross section of axial compressor


    Guide-vane
    actuator linkage

    Labyrinth seals

    Compressor rotor

    Rotor blades

    Adjustable guide vanes


    Compressor
    inlet nozzle

    Thrust bearing

    Compressor
    outlet nozzle

    Picture of axial compressor

    Advantages and Disadvantages of


    dynamic compressors
    Advantages

    Disadvantages

    Centrifugal

    Wide operating range


    High reliability
    Low Maintenance

    Instability at reduced flow


    Sensitive to gas composition
    change

    Axial

    High Capacity for given size


    High efficiency
    Heavy duty
    Low maintenance

    Low Compression ratios


    Limited turndown

    Dynamic
    Compressors

    Advantages and disadvantages of


    positive displacement type
    compressor
    Advantages
    Disadvantages
    Positive displacement compressor
    Reciprocating

    Wide pressure ratios


    High efficiency

    Heavy foundation required


    Flow pulsation
    High maintenance

    Diaphragm

    Very high pressure


    Low flow
    No moving seal

    Limited capacity range


    Periodic replacement of diaphragm

    Screw

    Wide application
    High efficiency
    High pressure ratio

    Expensive
    Unsuitable for corrosive or dirty
    gases

    Developing the compressor curve


    Rc
    Process limit

    Adding
    control
    margins
    Surge limit

    Maximum speed
    Power limit

    Stonewall or
    choke limit

    Actual available
    operating zone

    Minimum
    speed

    Stable zone
    of operation

    Qs,

    vol

    Developing the compressor curve


    P
    Differential
    Pressure
    PR
    )process,2
    or
    R
    P
    R
    H
    DischargeRatio
    Pressure
    Pressure
    Head
    (Pd/P(P
    or
    (P
    cd
    cp c Polytropic
    s)(P
    2)d 2s/P
    1) (P2 P1)
    R

    process,1

    Rc2
    Rc1

    O.P.
    Compressor
    curve for a
    specific speed
    N1

    Q2

    Q1

    Qs,

    normal
    vol
    mass

    Surges in centrifugal
    compressors
    What are surges?
    o Surge is defined as the operating point at which centrifugal
    compressor peak head capability and minimum flow limits are
    reached.
    o When the plenum pressure behind the compressor is higher than
    the compressor outlet pressure, the fluid tends to reverse or
    even flow back in the compressor.
    o As a consequence, the plenum pressure will decrease, inlet
    pressure will increase and the flow reverses again.
    o This phenomenon, called surge, repeats and occurs in cycles
    with frequencies varying from 1 to 2 Hz.
    39

    Effects on performance
    o Surging can cause the compressor to overheat to the point at
    which the maximum allowable temperature of the unit is
    exceeded.
    o Also, surging can cause damage to the thrust bearing due to
    the rotor shifting back and forth from the active to the inactive
    side. This is defined as the surge cycle of the compressor.

    Surge points for centrifugal compressors running at varying spee

    40

    Surge description
    Flow reverses in 20 to 50 milliseconds
    Surge cycles at a rate of 0.3 s to 3 s per cycle
    Compressor vibrates
    Temperature rises
    Whooshing noise
    Trips may occur
    Conventional instruments and human operators
    may fail to recognize surge

    Some surge consequences


    Unstable flow and pressure
    Damage in sequence with
    increasing severity to seals,
    bearings, impellers, shaft
    Increased seal clearances and
    leakage
    Lower energy efficiency
    Reduced compressor life

    Major Process Parameters during


    Surge
    FLOW

    2
    TIME (sec.)
    PRESSURE

    2
    TIME (sec.)

    Rapid pressure
    oscillations with
    process instability
    3

    TEMPERATURE

    2
    TIME (sec.)

    Rapid flow oscillations


    Reversal flow leads to
    reversal thrust
    Potential damage

    Rising
    temperatures
    inside compressor
    which can be seen
    at the Discgarge

    Operators may fail


    to recognize surge

    Graph showing operating regions


    of various compressors

    Table showing operating conditions


    of various compressors

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