IIAR Ammonia Refrigeration Education and Training Program Lreri om UUM Cite siete Module 4 - Compressors CMBasic Ammonia Refrigeration Module 4 - Compressors Lesson 1 In previous modules we learned about some of the major components that make up induscrial refrigeration systems. rnd ‘Most industrial systems (Fig, 1) have a receiver that contains a supply of liquid ammonia necessary to operate the syscern ‘when needed upon demand ee : ir Od oe Liquid ammonia flows from the receiver through a king valve and 4 pressure reduction device, which in this case is an expansion valve, into a vessel. As ic passes esate through the valve, the pressure and temperature of the ammonia refrigerant are suddenly lowered. ‘A pump moves the cold ammonia from the vessel and through a metering valve into an evaporator ‘where the liquid ammonia converts to vapor as it absorbs heat. The ammonia vapor is drawn through the vessel from the evaporator by a compressor. The compressor increases the pressure and temperature of the ammonia vapor and delivers it co a condenser. In the condenses, the ammonia vapor rejects the heat picked up as it passed dhiough the evaporator and compressor. As the ammonia refiigerant rejects heat, ic condenses and returns t0 aliquid. The liquid ammonia flows out of the condenser and collects in the high pressure receiver where it’s held for couse in the system. In this moduk tee different compressors commonly found in ammonia refrigeration systems 1) reciprocating compressor (Fig. 2) 2) rotary vane compressor (Fig. 3) 3) screw compressor (Fig. 4). the focus is on compressors. There are Fig. 3 monia refrigeration system, all three are “open” compressors, either belt driven or direc generally drive, An open compressor has a drive shaft that extends ‘outide of the comprestor and connects directly or indirectly to a driver, such asa motor, turbine or engine. Fig. 1 Module 4 L[No matter what type of compressor is used in a system, it petforms exo basic asks 1) providing the force that moves ammonia ‘through the system % 2), creating the pressure difference between the low side and the high side of the system. Fig. 4 An incase inthe pressure and temperatuse, caused by a compressor, is essential ta cefigeraion proces. If this process does not eke place, the ammonia would be unable fo reject the heat in a condenser that was picked up in the eraporstoe By drawing the ammonia vapor from an evaporator, the compressor controls pressure and maintains the desired boiling temperature in the evaporator. Ifthe ammonia vapor is nor removed from the evaporator by the compres presse wil bud up in the eepentoy, preventing it fiom opering at the desired temperanute, ‘The process of compressing the ammonia vapor clevates vapor temperature, ‘An increase in pressure and temperature results from the “werk” of compression, allowing the ammonia to reject heat as it passes through the condenser. To Review: a © Thre iftete compra connety tal imursel wfipeaton ape reo haaiie infittt Dian) as coe Dee sation © Reciprocating, rotary vane and screw compressors are generally “open” ‘compressors and are either belt driven or ditect drive. © An open compressor has a drive shaft thac extends outside of the compressor connecting directly ot indizecly to a dever euch as a motor, urbine or engine. © Compressors. perform two basic rasks: 1) providing the focce that moves anunonia through the system 2) creating the pressure difference berween the low side and the high side of che syscem. © The increase in the pressure and temperature caused by the comprestor is essential 1 the refiigeation proces. Without an inctease in pressure and temperature, che ammonia would be unable co reject the heat in the condenser that was picked up in che evaporator. © The comprenor contol the rest and matin the dese boing remperatire in the evaporaor by drawing the ammonia vapor from the peg: onpenton ‘Bx2 © The increase in pressure and temperature, produced by the compressor, results from the “worl” of compression, 2 Module 4Lesson 2 sons se ‘The focus ofthis lesson isthe compression proces ‘ Positive displacement is the most commonly Used compression method in the ammonia refrigeration industry. A ‘omplessot, using positive displacement, ones increases pressure by physically squeezing sili ammonia vapor toa smaller volume. Reciprocating, rotary vane and screw ‘compressors ar all postive displacement compressor. re Peete [Before discussing the compression process in move detail, there are several erms that should be defined. Ammonia vapor flows from the evaporator through the euction fine (Fig. 5). The vapor in che suction line is often referred to as suction vapor. Suction vapor enters the compressor through the inlet port and flows into the compression area where the process actually occurs. The name for this area dlfiets wich differenc kinds of compressors. In reciprocating compressors its called the cylinder In rotary vane and screw compressor, its most often called the compression chamber ‘Compressed vapor exits che compression area through the discharge port and flows into the discharge line that connects the discharge port to the condenser. Ammonia vapor in the discharge line is referred to as discharge vapor. sure at which rhe ammonia vapor enters the arge pressure isthe pressure at which the ammonia vapor exts the comprestion aca Suction pressure is the p Here's how che compresion process works AA pressure less than the suction pressuce is frst created ia che compression area which allows low Jow temperature ammonia vapor to flow sion area from the suction line volume of the ammonia vapor is mechanically reduced, or compressed, increasing the pressure and cemperature of the ammonia vapor (Fig. 7). How ed differs with the type of compressor sion of these methode will be addressed in fare lessons. Afier the ammonia vapor is compressed, the high pressure, high temperature ammonia flows ou of the compression atea ro a condenser. As the high oressute, high temperature ammonia vapor exits the fompcession area itis replaced with more low pressure, low temperature ammonia vapor drawn Into the compression area from the evaporator and the cycle is repected. This continuous process Fig. 5 Fig. 6 Fig. 7 Modi4 Fig. 8 Module 4 ‘occurs rapidly and ecpeats several hundred times every minure, posible to compress liguid. If tiqu ammonia is present in a suction line and drawn into the compression area along with ammonia vapor, serious damage can result (Fig. 8). Ikis also importane to note chat all compressors must be cooled. Cooling. [prevents 2 compressor from over heating and prevents breakdown of the cil used to lubeicate a compressor Cooling also reduces the temperature of the discharge vapor. “Without cooling, heat generated during the compression process will ca _moving parts in a compressor to absorb an excessive amount of heat, causing them to expand and to fail prematurely. There ate several methods of cooling compressors. Reciprocating compressors use jacket cooling or head eooling and oil cooling, Rotary vane compressors xgencraly use jacket cooling. Screw compressors utilize oil to cool the compressor. The oil lows through the compression area with the ammonia Jacket cooling is the flow of a coolant, such as water or glycol, through passage ways char are cast in the compressor housing. Head coeling is the flow of a coolant through a compartment located abene the cylinder head or ambient ai” flowing over the eylinder head, iB & Icis important co note dati isnot 9 ¢ 3To Review: © Positive displacement compressors increase pressure by physically “squeezing ammonia vapor to a smaller volume. © Thicc commonly used positive displacement compressors are: 1) reciprocating compressor 2) rotary vane compressor 3) sctew compressor. © Section vapor flows from the evaporator through the suction line, and into the compression area through the inlet port. © The compression area in 2 reciprocating compressor is called the cylindes. © The compression area in rotary vane and serew compressor is clled the compression chamber. © Compressed ammonia vapor flows out of the compression atea through the discharge pore into the discharge line © Ammonia vapor in the discharge line is referred to as discharge vapor. © The pressure at which the ammonia vapor enters the compression atea is known as the suction pressure. © The presure at which the compressed ammonia vapor exits the compression area is known as the discharge pressutc. passing dhrough the compressor can cause extensive © Cooling prevents the compressor from over heating and causing breakdown in the oil used to lubricate the compressor. Cooling reduces the tempersture of the discharge vapor Reciprocating compressors use jacket cooling or head cooling, and vil © Rotary vane compressors generally use jacker cooling © Jacket cooling isthe flow of a coolant through passage ways that are cast in the compressor housing, @ Head cooling is the flow of a coolane through a compartment located above the cylinder head or Ambient ai flowing over the cylinder head © Screw compressors utlie oil flowing through the Compression area with ammonia vapor to cool the compressorLesson 3 smomemsanemmauenssnionmase: ‘This lesson examines the a ee ae Pees positive displacement machine. In a reciprocating compresor 4 piston is sed to reduce the Yolume ofthe compression area, Most industrial refrigeration reciprocating compressrs have several oflindess configured in a vaiery of ways: Generally, all reciprocating compeesors have de same basic pars (Fig 9), including cylinder, 2 piston with sealing rings, a cank shaft connecting rod, LCR nc a valve plate, somecimes referred t0 as a safety head on which the suction and discharge valves are loca rt The crank shaft turns, causing the connecting rod o pull the piston down to the bottom of the cylinder. As the piston moves to the borram end of ¢ stroke, pressure in the cylinder decreases until itis lower than the suction © presate, allowing the suetion valve o open. Low presure, low temperature ammonia vapor is drawn into the area in the jlinder lefe vacant by the downward movement of the piston. As the crank nnecting rod pushes the piston in an upward in vapot. AS a result the pressure in the cylinder shaft continues to earn, th motion, squeezing the ammo is increased and the vapor is compressed. ‘When the pressure in the cylinder is increased and the suction valve closed, the discharge valve opens because the pressure inside the oylinder exceeds the discharge pressure. As a result, the high pressure, high temperature ammonia vapor flows into the discharge line to the condenser. reduction ‘As the piston begins to move to the bortom of the cylinder agi in the eylinder pressure causes the dischasge valve to close and the process is repeated. It is important ro note that throughout che compression cycle, or stroke, the piston never completely reaches the top of the cylinder. Clearance berween the piston and the botcom of the valve plate is required to prevent physical damage fo the valves and pistons. The compressed vapor in this clearance area does not leave the cylinder, It remains end re-expands to suction pressure during the downwazd movement of the pi 6 ModuleTo Review: © A reciprocating compresior isa positive displacement machine. © Reciprocating compressors use «piston to compres the ammonia vapor. © Reciprocating compressors have the following basic part: 1) acylinder 2) a piscon with a sealing 3) acrank shaft 4) connecting rod 5) a valve plate, commonly referred to 2s a safety head 6) suction and discharge valves. © Throughou: the compression cycle, or stroke, the piston never completely reaches the top of the cyindee. © Clearance between the top of the piston and the bottom of the valve plate is required to prevent physical damage co the valves and piscons © Some of the compressed vapor remains inthe eylinder during each stroke of the piscon, @ The remaining vapor re-expands suction pressure dusing the downward movement of the piston and is compressed again during the next stroke of the piston. Module 48 Module 4 Fig. 10 rr Lesson 4 ——EEEEE This lesson exaraines the rocary vane ‘compressor. A rota ‘vane compressor is 3 positive displacement ‘compressor that uses an off-center 10.0r, rotating inside the compression chamber to compress the ammonia vapor. A rorary vane of the following parts Cereee (Cig, 10): 2 BM compression chamber, rotor, a suction port, acbacg pat od ‘vanes that are mounted in sors in the rocor. The vanes maintain close eontact with the compression chamber wall and ate held in place by cearifigal force. Low temperature, low pressure ammonia vapor flows into the compression chamber through the suerion port. As che off center roror turns, vapor is trapped berween the wall of the compression chamber and the vanes in the Because the rotor i off center inthe compression chamber, the space occupied by vapor becomes smaller and smaller as the rotor turns and the vanes withdave back into the str [As this takes place, the low press comprested, inereasing vapor pressure and temperacure. low temperature vapor is squeezed and When the vane reaches the discharge port, the high pressute, high temperature ammonia vapor lows out of the compression chamber through the discharge port and into the discharge line A rotary vane compressor has a small clearance between the vanes and the 19 chamber wall chat prevents the vanes and the chamber wall from. direct contact and eausing damage. compres coming. iil. injected into the compression chamber, seals the space berween the rotor vvanes and the walls lubricating the moving pars, Compressor, a rotary vane compressor does not have a Unlike the reciprocar suction valve or a discharge valve regulating the flow of the ammonia vapor in and out of the compression chamber However, rorary vane compressors must have a check valve in the dischaage line that prevents How of the discharge ‘vapor back into the compressor {When discharge vapor is :llowed ro low hack nto the compressor ts knows SE 4s back flow. Back flow shoukd never be permitted to occur because it can cas. severe damage to the compressorTo Review: ‘A rotary vane compressor is 2 positive displacement compressor, A rotary vane compressor uses an off-center rotor, rating inside the ‘compression chamber to compress ammonia vapor © A rorary vane compressor consists off 1) acompression chamber 5) vanes mounted in slots in the rotor © Ina rotary vane compressor, the suction vapor is trapped between the ‘compression chamber wall and the vanes in the rotor © Ac the off center rotor turns, the ammonia vapor is compressed between the rotor and ehe chamber wall © Rotary vane compressors have a small dearance becween the vanes and the compression chamber wall © The dearance space prevents the vanes and the chamber wall from com. ing in direct contact and causing damage. © Oi injeced into the compression chamber, scale the space between the rotor vanes and the walls, lubricating the moving pais © Rotary vane compressors have a check valve in the discharge line that prevents flow ofthe discharge vapor back into the compressor. Backflow is discharge vapor that flows back into the compressor Back flow can cause severe damage eo the compressor Module 4 9Fig.11 Fig. 12 10 Module 4 Interobes pee Lesson 5 == ‘This lesson focuses on screw compressors which are positive displacement comprestors. They compress vapor by physically squeezing it in a confined area which in this case is along a screw thread, Probably the best analogy to a screw compressor is an old fashion meat grinder where the meat is pulled along a screw like thread until i is squeezed through a hole in the housing at the end of the thread. ‘There are wo types of screw compressors: 1) win screw 2) single screw Ain sew ‘compressor has 680 serew-like, intermeshing, halical rotors (Fig. 11). However, the rorors are not identical. One has 2 set of lobes and is often referred ts the male rotor. The other has aset of interlobes and is, often referred to a the female rotor. Suction vapor from the evaporator flows a port (Fig. 12), filing an ¢ housing, into the compression chamber through 3 su intcrlobe beaween the unmeshed rotors and {As the rorors turn, ammonia vapor is trapped berween the lobes, interiobes and housing, towards the The meshing of the lobes and interlobes squeeres the ammon discharge end of the compressor which is sealed against the housing, nue co rotate, progressively “The vapor pressure is increased asthe rotors con reducing the space occupied by the vapor. ‘When the incerlobe is exposed Housing to a discharge port, the conipressed, h high tempera vapor flows through the discharge port and into the discharge line RO er¥ A single screw compressor differs mechanically from the ein screw Perel compressor however, the single compressor employs the same ba ple. ‘The single serew compressor (Fg. 13) consiws ofa single helical rotor with grooves that run the length of the rotor Laide the compression chamnbes the rotor is flanked by two “gearlike” wheels known as gate x ‘minnie ile wana ne feesien porto «pre te ae fd Kalen ise The puesto ish roots with the grooves on the screw, balancing the thrust of the ammonia vapor as it moves down the grooves. As the serew cums, a gate rotor tooth follows che groove towards the discharge tend which is sealed against the housing. Pressure increases because the groove filled with ammonia meshes with a tooth on the gate rotor, reducing the size of the arca occupied by the vapor. Eventually, the groove is expased to the discharge port and the high pressure, high temperature vapor eaves the compressor, Like the rotary yane compresior.sctew compresiors dot have valves ike chee inthe reciprocatitg compressor. Another similarity to the rotary vane compressor isthe clearance between the compression chamber wall, the rors andlor the gate rotors which is Lubricated with oil injected inca the ‘compression chamber. the rorors In addition to providing lubrication and scaling the space betw and/or gate rotors and compression chamber walls the oil also acts as 2 coolant absorbing much of the heat of compression. As a result, screw compressors have alow discharge gas temperature, The oil cooling process will be discussed in a furure module Module 42 To Review: Single screw and twin screw compressors are positive displacement compressors. A twin screw compressor has two screw-like helical rosors. Tn a twin screw compressor, one rotor has a set of lobes, often referred 10 as the male rotor, and the second rotor has interlobes, often referred to as the female rotor. Compression in a nin screw compressor is accomplished by tapping and squeezing ammonia vapor berween the lobes, interlobes and housing [A.single screw compressor consists of a single helical rotor flanked by ewo gate rorors that mesh with the screw. Compression in a single screw compressor is accomplished by trapping vapor and squeezing it along the screw thread, [A screw compressor does not have valves like those in the reciprocating compressor il in a screw compressor provides lubrication, seals the space between the rorors, gate rotors and compression area walls, and acts as a coolant, absorbing mutch of the heat of compression. Module 4Lesson & msnemsssmmnomcmarr Ee In this lesson, the volumetric efficiency, oF pumping efficiency of a compressor is examined. Volumetric efficiency isa chatacters of positive displacement compressors. For the purposes of this explanation, we will exrmine volumetric efficiency as i rates to reciprocating compressors. ‘Volumettic efficiency is the percentage of displacement that a compressor can actually pump at suetion eonditioes, Displacement is determined by the swept yolume of the cylinder ‘Swept volume refers to the atea of the cylinder multiplied by the length of the piston stroke muliplied by ehe rpms and is expressed 28 cubic fee pet minute (Fig. 14). Arca of Ero Sars ro Not all of the high pressure, Beg ery eed rea Cee ae Ee Fig. 14 high temperature ammonia vapor contained in the cylinder of eciprocating compressor is ‘expelled during a single compression stroke. The vapor that remains in the cylinder re-expands fon the down stroke of the piston, affecting the volumetsc efficiency of a compressor. In other word, the volumetric efficiency is ‘equal 10 the amount of ammonia vapor that is ‘actually expelled fiom the compressor, divided by the size of the elinder expressed in swept volume (Fig. 15). For example, a compressor has a swept volume, often efetsed to as displacement, of 20 elm. Howeves, the compressor actually pumps only 18 cubic fect of ammonia vapor per minute. ‘The volumettic efficiency of the compressor is ‘equal to the actual volume pumped divided by the swepr volume, or 18 divided by 20 (Eig, 16). In this example, the volumecriceffi- ciency of the compressor would be 90%. Pear cd ad i oa ee ci Cen cies Fig. 15 Moduled 13“4 To Review: © Volumetric efficiency is a characteristic of positive displacement ‘compressors. © Volumerric efficiency isthe percentage of displacement that the compres- sor can actually pump at suction conditions. © Displacement is determined by the swept volume ofthe © Swept volume is cylinder area multiplied by piston stroke lengrh multi- plied by rpm © Sep vohume is expressed as cubic feet per minute. © Volumetric effcieney isthe amount of ammonia vapor chat is actually capolled from the eylinder divided by the swept volume. Module 4 aLesson 7 co Compression ratio describes the relationship of Fig. 16 suction pressure to discharge pressure. [n other words, it indicates the number of times the Pee ammonia vapor pressure has been increased as res 2 result of being puraped or compressed by the x rae compressor. ara ie Icis important to note that compression ratio is always expressed in absolute pressure. To illuscrate, we will use a compressor operating at sea level with a suction pressure of 39 psig, and a discharge pressure of 178 psig Fig. 16). To decermine the compression rato, all gauge pressures must frst be converted to absolute pressure, Recall from a previous lesson that adding gauge pressure and atmospheric pressure equals absolute pressure, In this case, 38 prig is added to 14.7 psia, which is atmospheric pressure a sea level, to determine the absolute pressure of 53.7 psa Tollow the same formula to determine the absolute discharge pressure. That is 178 psig plus 14.7 psia equals 192.7 psia Tie oat uo nb shasta Ubehan psos by the absolute suction pressure. In this case 192.7 psia divided by 53.7 psia ‘equals 3.6 (Fig. 17). The ratio is capressed in the following manner 3.6:1 : 3 4 We fig.17 absolute discharge pressure = absolute suction pressure = compression ratio ea eae orl At this point itis very important to note that the same system operating at the same gauge pressures, except at 2 higher elevation, will havea different compression ratio. However, the temperature of a mixture of ammonia liquid and vapor measured ata given absolute pressure has a constant temperature that docs not vary with altiwde. That’ the reason that compression ratios are based on absolute pressure. Compression ratios do nor vary with aire 4 mixture of ammonia liquid and vapor According to standardized table ure of 25° E under a pressure of 53.7 psi, has a constant saturation temp In order ro maintain a constane temperacure of 25° F ‘operating at sea level, subtract the atmospheric pressure from the absolute pressure In this case 53.7 psia minus 14.7 psiay or atmospheric pressure at sea level, equals 39 psig. Therefore, in order to maincain a constant temperature of 25° F at sea level, the gauge pressure must be maintained ar a reading of 39 psig. (Fig. 18), Module4 15Fig. 18 BRA th AT Beate 9 9.7 psio 39 psig i ‘ CE Est sea level aK aco aa However, at an altitude of 10,000 feet above sea level, the difference in atmospheric pressure will impact the gauge pressuse. In this ccample, the absolute pressure is sil 53.7. Gauge pressure is therefore 53.7 psia minus 9.7 psia, which is atmospheric pressure t an elevation of 10,000 feet, or 44 psig (Fig. 18). According to this calculation, in onder to maintain a constant 25" F saturation temperature of ammonia ar an clevation of 10,000 fect above sea level, she gauge pressure must maincain a reading of 44 psig. To Review: © Compression ratio describes the relationship of suction pressure 10 discharge pressure © Compression tatio indicates the number of times the ammonia vapor presse has heen increased as 2 result of passing through the compressor. © Compression ratio is always expressed in absolute pressure © Before calculating compression ratio, gauge pressures must fist be converted to absolute pressures. © To determine the compression ratio divide the absolute discharge pressure by the absolute suction pressure. © Tivo similar refrigeration systems operating at the seme gauge pressures bur ar different altitudes have different compression ratios vo similar syscer ating at the sam different alticudes have the same compression racio. © The saturation temperature coresponding to a given gauge pressure varies ac diferent altudes « © The saturation temperature corzesponding to given absolute pressure does nor vaty a differen: aliudes. 16 Module 4Module 4 - Compressors ay ae 12