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International Compressor Engineering Conference School of Mechanical Engineering
1984
Khan, M. O., "Basic Practices in Compressors Selection " (1984). International Compressor Engineering Conference. Paper 509.
http://docs.lib.purdue.edu/icec/509
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BASIC PRACTICES IN COMPRESSORS SELECTION
VA = Ps Vs Za Ta
Q = In3et CFM at actual P, T,
ft /min. or ACFM
ZT
s s Pa
N = Speed, RPM
Where Va = Actual Volume @ Pa, Ta ACFM
Ps = Standard Referen ce Pressur e, psi D = Impelle r Diamete r, inches
Vs = Standar d Volume, SCFM
Zs = Compre ssibility factor at For centrifu gal compres sors, the flow coeffic ient
standard conditio ns ranges between .01-0. L The minimum discharg e
Za = Compre ssibility factor at actual flow coeffic ient is around .008- .01. The peak
conditio ns efficien cy occurs around mid range 0.04 -.05.
Head Coeffic ient Mach Number
The head coeffic ient is a dimensi onless factor Mach number is a ratio of velocity of gas to the
which relates the adiabat ic head capabil ity of a velocity of sound in,-the gas at operatin g
wheel with its periphe ral velocity requirem ent. pressur e and tempera ture. The Velocit y of Sound
It is defined as: in a gas is calcula ted thus:
lf = gcH us =JKgc R T
u2
Where: us = Velocity of sound in gas,
Where: )? = Head Coeffic ient, non- ft/sec
dimensi onals
H = Adiabat ic Head i~
K = Specifi c heat ratio c~v
lbm
R = Gas Constan t ~
gc = Gravity constan t 32.2
OR lbmf
lbm ft
~Sec 2 T = Gas Temperature 0 R
U = Periphe ral Velocity of the g;c = Gravity Constan t,
impelle r ft/sec.
32.2 .!!!! ft 2
= DN lbf Sec
60
For simplic ity, the velocity of gas is referred
N = Rotatio nal Speed RPM to as the v~locity of the impelle r at the tip.
It should be noted that the absolut e velocity of
D = Impelle r diamete r, ft. gas leaving the impelle r is differe nt fl"om the
tip speed.
The head coeffic ient is also called pressure
coeffic ient, and it can be analyti cally shown to u
Mach Number is defined as M= U
combine all blade angle, slip and efficien cy
s
619
Where U is the impeller,veloc ity at a given 12,000 ft.lbf/lbm and the total head demands
station e.g., a tip or eye. more than 10-12 impellers per casing.
For turbonmachiner y, the Mach Number presents the d. For capacity turndowns below 40% at constant
aerodynamic stability of flow. It is mandatory speed. Below these flows, centrifugal
to render the inlet flows subsonic i.e. Mach compressors have limitation due to surge and
Numbers less than unity (0.6-0.7) to avoid power loss due to excessive recycle.
choking of compressors.
e. When the intended service requires unloaded
compressor operation for extended periods
AERODYNAMIC PARAMETERS FOR COMPRESSORS SELECTION with nominal power loss e.g. refrigeration.
It is not the intent of this paper to delve into k. When two or more separate process streams
the details of such analytical aerodynamic are to be compressed independently by the
treatment. However, for purpose of utilizing same compressor frame. Use multi-throw
Balje's rationalized approach, reference is made reciprocating compressor to meet such
to R. F. Neerken's comprehensive paper requirement,
"Compressor Selection for the Process
Industries". In this article, the use of Balje's
analysis as a tool to check a given selection is WHEN NOT TO USE POSITIVE DISPLACEMENT
demonstrated through Figure 4. COMPRESSORS:
Table 1 provides a summary of Compressor a. Large inlet flows in excess of 3000 ACFM.
performance limits.
b. Process does not permit cylinder lubricant
Following are the basic guidelines in compressor carryover and non lubricated cylinders are
selection. not compatible to process.
c. When gas flow rates render valve velocities
WHEN TO USE POSITIVE DISPLACEMENT COMPRESSOR unsatisfactory for valve operation due to
lack of momentum.
a. Low inlet flow rates below 500 ACFM, below
which the centrifugal compressor selection d. When process does not permit any pressure
becomes difficult due to smaller wheels and fluctuations, even below API permissible
narrow flow passages. Reciprocating values.
compressors usually range up to 3000 ACFM
capacity. Note that some manufacturers When the gas turbine driver RPM are too high
offer small centrifugal compressors up to in low HP range, say 1000-2000, rendering
350 ACFM. unrealistic gear ratios, say 5:1 and above.
Higher gear ratios impose double reduction,
b. When discharge pressures are in excess of higher pinion velocities and noisier
5000 psig. operation.
c. When the adiabatic head per impeller exceeds f. Space restraints and structural requirements
620
demand compact machiner y with no out-of WHEN TO USE AXIAL COMPRESSORS
balance forces on the foundatio ns, e.g.
offshore platform s. Axial flow compress ors are generally used in air
service e.g.: Fluid Catalytic Cracker (FCC)
g. Higher pressure ratios above 5:1 per casing units, blast furnace, sewage aeration , etc.
restrain rotary compress or selection due to
rotor deflectio ns, low volumetr ic efficienc y An Axial flow compress or is recommended:
and speed limitatio ns.
a. When large inlet capacitie s (50,000) ACFM
h. When larger capacitie s dictate higher piston and above render the centrifu gal
velocitie s above normally accepted limits. configur ation uneconom ically bulky.
i. When use of cast-iron is prohibite d in the b. When higher compress ion efficien cies (5-10%)
process plant for fire hazard reasons, and above centrifug al configur ation are a
the use of steel cylinder s and casing is not deciding factor in driver selection and
economic al. running costs.
j. When the tip speeds exceed the following It can be explained that the aerodynamic design
criteria : of axial blades, straight axial flow path and
adjustab ility of stator guide vanes contribu te to
Helical Screw MACH NO: 0.3-0.4 axial compress or's efficien t operation over a
Spiral Axial Screw MACH NO: 0.12 wide capacity range with a constant speed driver.
Lobe MACH NO: 0.05
c. When the aerodynamic paramete rs i.e.,
specific speed and specific diameter fall in
WHEN TO USE CENTRIFUGAL COMPRESSORS
(1,000-10 ,000) and (0.3-2.0) range,
respectiv ely. Refer to Figure 4.
a. When equipment reliabil ity is prime and no
spare train of equipment is allowed. d. When a mechanic al seal is not required and
b. For Specific Speed range 30-3000, Specific nominal compressed air or gas leakage across
Diameter range (0.3-6.0) and flow the labyrinth is acceptab le.
coefficie nt (.01-0.1 ). e. When the compress ion temperat ures/casi ng
exceed 45QOF, dry labyrinth seals with
WHEN NOT TO USE CENTRIFUGAL COMPRESSORS buffer gas permit compress ion temperat ures
up to 700F, whereas the non-meta llic
a. Below 500 inlet ACFM. components of mechnica l seals such as 11 0 11
Check design with rings and the seal oil, limit compress ion
caution.
temperat ure to 400-4500F,
b. When the discharg e volume rate reduces to f. When part-load efficienc y (below 40% being
300-400 ACFM range rendering very narrow
impeller s and diffuser gas passages usual centrifu gal compress ion limitatio n) is
difficul t to produce. a premium, as multi-sta ge stator blading can
be adjusted with effective capacity control
c. Capaciti es in excess of 50,000 ACFM and even at constant speed.
discharg e pressure s less than 100 psig which
are in axial range. Larger inlet flows Note that after first 5-6 stages, variable
demand proportio nately larger inlet area (to stator blading has diminish ing effect of
keep inlet Mach Number low hence bigger volume control as increased density in later
impeller eye and the resultan t wheel stages demands excessiv ely wide angle
diameter ), turning of blades for throttlin g the flow.
621
design is not readily adaptable to ACKNOWLEDGEMENTS
intercooler connections or for additional
side process loads. Exceptions to this may The author wishes to thank Brown & Root, Inc.
be found in the custom-built European Houston for the permission to publish this
designs of axial compressors. article. Most of the material covered herein is
based on a Basic Practice (BP) developed by the
author,
WHEN TO USE AXIAL-CENTRIFUGAL COMPRESSORS
b. The centrifugal impellers placed at the tail 2. "Compressor Selection For The Chemical
end of axial compression stages optimize the Process Industries"
low flow-high head capability of the R. F. Neerken, Chern Eng. Jan. 20, 1975
centrifugal stage, thereby reducing the
overall length of the rotor. 3. "Basic Practice in Compressors Selection"
M. 0. Khan, Brown & Root BP-00-01 May 1984
622
COMPRESSORS
&
BLOWERS
POSITIVE
DISPLACEMENT
I
CYLINDER CYLINDER
LUBED NONLUBED
~ ~
CRANK CROSS CROSS DIA-
CASE HEAD HEAD PHRAGM
TYPE TYPE CYL.
I
OIL SLIDING OIL OIL STRAIGHT HELICAL SCREW
FLOODED VANE FLOODED FLOODED LOBE LOBE
SINGLE ECC. HELICAL OR
VANE (ROOTS J ( LYSHOLM J SP I RAX I AL
LOBE !.
SLIDING
VANE
~---------------------------------------
-------------~
623
100.000 RECIPROCATING
\ CENTRIFUGAL
10.000
,-1--\-l
I I
(')
Ul
Q_ 1000 -
I
w
a:
I I AXIAL
-------------t-------- 01~---1
::::J
Ul
Ul
w
a:
Q_
UJ 1
(') ROTARY SCREW I 1 I
~
0:::
<C 100
:r::
u
Ul
-SlriilNG-VANE ___ i---; j l_l
......
0
7 I I I
10
-LOBE------l----~- ---~
I I I
j
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I
I I I I
I I I I
I I I I
I I I I
I I I I I I
I I I il I
I I I I
I
I
10 100 1000 10,000 100,000 1.000.000
INLET CAPACITY-ACFM
624
('\
FOUNDATION
~
r::
\ uco's"rC
_J
or:
t-
("{
!NSTALLAT ION
\J
OPERf\TING
COST
6
VARIAT!ON S
\J
625
c;
6
j"
'g 3
t
en
0.6
Specific Opeed. N,
626
w TABLE 1 - SUMMARY OF COMPRESSOR LIMITS
<l...
>
1-
0::
PERFORMANCE LIMITSl
a
V'l
Approx.
Vl Approx. Range Of Max.
w
0:: Range Of Min. Max. Surge Pressure Disch. Typical
a..
:;::: Aerodynamic Parameters2 Flow Flow Limit Ratio/
a Spec. Speed Ns Temp/ Adiabatic BHP RPM
u Sp. Dia Ds Flow Coeff 0 ACFM ACFM % Rated Casing Casing Efficienc y Max Range