Documenti di Didattica
Documenti di Professioni
Documenti di Cultura
Review basics of centrifugal compressors Explore key terminology Understand parameter relations Performance capabilities of different compressor technologies
Basics of Compressors
The principles of increasing pressure for pumps and compressors are the same. A PUMP moves an incompressible fluid - a liquid. The volume of a liquid does not change with pressure and temperature. A COMPRESSOR moves a compressible fluid - a gas. The volume of a gas changes with pressure, temperature, and gas composition.
Surge
Head
Stonewall
Flow (ACFM)
Los Angeles, June 1, 2007
-1
Flow
Process Engineers are trained to calculate mass balances and therefore work in MASS flow (lbm/hr, kgm/hr). Centrifugal compressors are designed to handle a given VOLUME flow. Difference between Standard volume flow, and Actual volume flow
Flow
Standard Conditions = 0 psig, 60 F Normal Conditions = 0 BAR g, 0 C Example: 1,000 lb/min of pure Methane @ 1,000 psia & 100 F correspond to 339.2 acfm, or 23,616 SCFM; 1,000 lb/min of pure Methane @ 500 psia & 50 F correspond to 632.7 acfm, or 23,616 SCFM
Key Terminology
Volume Flow Headrise (adiabatic and polytropic)
Specific heat ratio (k) Compressibility (z)
Specific Speed Mass Flow Power Mach Number Surge, Stonewall or Choke
Headrise
Head is the energy in ft-lbf (N-m) required to compress and deliver one lbm (kgm) from one energy level to another. Head H = ft-lbf / lbm (N-m/ kgm)
Headrise
Reversible thermodynamic paths
Isentropic (adiabatic) = no heat loss Polytropic = heat loss Adiabatic and polytropic virtually the same for single stage. Much different for multistage
Headrise Calculation
Required Headrise = z* R*T1(r m-1)/m
z = Compressibility Factor (approx. 1.0) R = Universal Gas Constant (1545/MW) T1 = Absolute Suction Temperature of Gas r = Pressure Ratio m = [(k-1)/kLA k = Specific Heat Ratio of Gas (Cp/Cv) L= Polytropic Efficiency
Headrise
The amount of energy required to compress a volume to the same pressure for a gas is much higher because the gas is at a much lower density than the liquid.
(n-1)/n
Lp = k-1 * n k n-1
Had = Hp Lad Lp
Headrise
LIQUID
HEAD = 2.311 X P (Ft.) S.G. Water P = 100 PSI HEAD = 231 Ft. P1 - 14.7 PSIA 1T1 = 100F HEAD 1545 (T1) (Ft.) = M. W.
GAS
K K-1
( )
P2 P1
K-1 K
-1
Nitrogen P = 100 PSI HEAD = 86,359 Ft. P1 = 14.7 PSIA 1T1 = 100F
231 Ft.
114.7 PSIA
86,359 Ft.
114.7 PSIA
Pump
Compressor
Volume Flow
Actual Flow volume flow rate entering the suction flange acfm, m3/hr Standard Flow volume flow rate referenced to an established set of P, T conditions scfm, Nm3/hr, MMSCFD
Specific Speed
Ns = N * Q1/2 H 3/4
N = speed Q = flow H = headrise
Impeller Efficiency
Full Emission Impellers
EFFICIENCY - (%)
SPECIFIC SPEED - Ns
Los Angeles, June 1, 2007
Power
Gas Horsepower (GHP)
GHP = Head * Mass Flow 33,000 * Eff
Mach Number
Acoustic Velocity a = 223 * T1 * Z1 * k MW Relative Mach Number MnRel = Inlet Velocity a Machine Mach Number MnMachine = U = D * N a 229*a Affects curve shape and range. Practical limit = 1.3
Los Angeles, June 1, 2007
Head
Stonewall
Flow (ACFM)
Los Angeles, June 1, 2007
Surge
Surge is a system phenomena that is the result of flow separation caused by low gas velocity anywhere in a compressor stage. Surge is an oscillation of backflow and forward flow. Left to continue, Surge is a bad thing!
Stonewall or Choke
Stonewall or choke flow is the maximum flow a given stage can handle. This value occurs when the ratio of the relative gas velocity to the acoustic velocity of the process gas is equal to 1.0, or Mach 1.
Parameter Relations
Had (ft-lbf/lbm) = z * 1545 * T1 (R) * k * P2 M.W. k-1 P1 Q (acfm) =
(lb/min)
(k-1)/k
-1
BHP (hp) = GHP + losses = Had (ft-lbf/lbm) * (lb/min) + losses 33,000 * Lad
Los Angeles, June 1, 2007
Parameter Relations
Assuming No Hardware Changes Assuming Hardware Can Be Altered
No Hardware Changes
VARIABLE P1 CONSTANT ACFM, T1, H, MW CHANGED CONDITIONS P2 , T2 , w , HP
MW
P2 , T2 , w , HP
T1
P2 , T2 , w
, HP
ACFM
P1, T1, MW
H , P2 , T2 , w , HP
MW
H , T2 , w , HP
T1
H , T2 , w
, HP
ACFM
w , HP
Affinity Laws
Q 2 = N2 Q1 N1 GHP2 = N2 3 GHP1 N1 GHP (hp) = * Had (ft-lbf/lbm) = 33,000 * Lad
(lb/min) (lb/min)
H 2 = N2 H1 N1
* Hp (ft-lbf/lbm) 33,000 * Lp
Compressor Technologies
Positive Displacement Reciprocating (piston & diaphragm) Screw (oil flooded and dry) Rotary (liquid ring, sliding vane, lobe) Dynamic (Turbo) Centrifugal Regenerative Axial
Los Angeles, June 1, 2007
Compressor Types
200
PRESSURE RATIO
Multi-st. Recip.
20
Single Stage Recip.
Sundyne
Multistage centrif Multi-st. Axial
Rotary
2
102 103 104 105 106
VOLUME FLOW
Pressure
Pressure
Volume
Los Angeles, June 1, 2007
Volume
Types Include
Reciprocating Screws Sliding Vane & Liquid Ring Rotary Lobe
Reciprocating Compressor
Similar to an automobile engine Compresses a given volume of gas through the use a reciprocating piston Positive displacement compressors increase the pressure of a gas by operating on a fixed volume in a confined space.
Los Angeles, June 1, 2007
EXTERNAL VALVES
CRANKCASE LUBRICATION
Diaphragm Compressor
Reciprocating Performance
Piston Type: flow to 3,000 cfm, pressure to 30,000 psi, compression ratio to 20:1 (3:1) per stage , power to 15,000 HP, efficiency +/90% special designs to nearly 20,000 cfm at low suction pressures Diaphragm Type: flow to 100+ cfm, pressure to 30,000 psi, compression ratio 20:1 per stage, power to 150 HP
Los Angeles, June 1, 2007
SCREW COMPRESSORS
Oil Free Oil Flooded
Dry
Liquid Injected
Screw Compressor
Top View
Screw Compressor
Side View
Four distinct pockets of gas are moved from the suction to discharge in each revolution of the driving shaft.
Los Angeles, June 1, 2007
Pressure to 350 psid, 4:1 compression ratio dry, 15:1 compression ratio flooded, flow to 10,000 cfm, max efficiency 75%
Liquid Ring
Pressure to 175 psig (29 Hg Vacuum), 5:1 compression ratio, flow to 17,000 cfm, max efficiency 50%
Sliding Vane
Pressure to 50/100 psid, 4:1 compression ratio, flow to 6,000 cfm, max efficiency 70%
Lobe (Roots Type)
Pressures to 20 psid, 2+:1 compression ratio, flow to 25,000 cfm, max efficiency 70%
Los Angeles, June 1, 2007
Centrifugal Compressors
Dynamic Machines Impeller uses centrifugal force to add velocity to gas Diffuser reduces the velocity changing the energy from velocity to pressure
Dynamic Compressors
Variable volume delivery Fixed head capacity (for a certain flow) Self limiting Flow is sensitive to pressure ratio
9000 8000 7000 6000 5000 4000 3000 2000 1000 Head 0 0
Los Angeles, June 1, 2007
Regenerative Compressor
Axial Compressor
Axial Compressors
140 120 Percent Design Pressure Rise
Su r
100
ge
Li ne
% 100 N
N 95%
80
N 90%
60
N 80%
N 85%
40 20 60 70
80
90
100
110
Competitors
Centrifugal
AC, Atlas Copco, Cooper, Demag, Dresser-Rand Man Turbo (Sulzer + Borsig), York
Reciprocating
Ariel, Dresser, GE, Neuman & Esser, Sulzer Burckhardt
Diaphragm / Regenerative
Burton-Corblin (Periflow)
Screw
Mycom, Howden, Kobelco, Roots
Los Angeles, June 1, 2007
Centrifugal Compressors
Dynamic Machines Impeller uses centrifugal force to add velocity to gas Diffuser reduces the velocity changing the energy from velocity to pressure
Dynamic Compressors
Variable volume delivery Fixed head capacity (for a certain flow) Self limiting Flow is sensitive to pressure ratio
9000 8000 7000 6000 5000 4000 3000 2000 1000 Head 0 0 Flow 500 ACFM 1000