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Module
01
Compressor Overview
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Module 01 Compressors Overview
Types of Compressors
Some rotary machines are suitable only for low-pressure ratio work, and are
applied to the scavenging and supercharging of engines, and the various applications
of exhausting and vacuum pumping. For pressures above 9 bar the vane-type rotary
machine can be used to supply boost pressures, but for sustained high-pressure work
up to 500 bars and above, for special purposes, the reciprocating type is used.
Both basic types exist in many different forms each having its own
characteristics. They may be single or multistage, and have either air or water cooling.
The reciprocating machine is pulsating in action which limits the rate at which fluid
can be delivered, but the rotary machine is continuous in action and does not have this
disadvantage. The rotary machines are smaller in size for a given flow, lighter in
weight and mechanically simpler than their reciprocating counterparts. The treatment
and scope of the following sections is fundamental and is not exhaustive. Many
compressors are designed to overcome the deficiencies of the basic machines and to
satisfy special requirements. For descriptions of these machines the excellent
literature supplied by the manufacturers concerned should be consulted.
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Module 01 Compressors Overview
b) Types of compressors
The following figure shows the compressor types.
c) Centrifugal compressors
The centrifugal compressors use a vane rotating disk or impeller in a shaped
housing to force the gas to the rim of the impeller, increasing the velocity of the gas. A
diffuser (divergent duct) section converts the velocity energy to pressure energy. They
are primarily used for continuous, stationary service in industries such as oil
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Module 01 Compressors Overview
refineries, chemical and petrochemical plants and natural gas processing plants. Their
application can be from 100 hp (75 kW) to thousands of horsepower. With multiple
staging, they can achieve extremely high output pressures greater than 10,000 psi (69
MPa).
d)
Axial- Flow
Compressors
Axial flow compressors use a series of fan-like rotating rotor blades to
progressively compress the gas flow. Stationary stator vanes, located downstream of
each rotor, redirect the flow onto the next set of rotor blades. The area of the gas
passage diminishes through the compressor to maintain a roughly constant axial Mach
number. Axial-flow compressors are normally used in high flow applications, such as
medium to large gas turbine engines. They are almost always multi-staged. Beyond
about 4:1 design pressure ratio, variable geometry is often used to improve operation.
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Screw
Compressor
Gas and Oil Diagram of a Rotary Screw Compressor
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Module 01 Compressors Overview
This type has untwisted or straight lobe rotors which intermesh as they rotate,
they use a timing gears to phase the rotors. Gas is trapped in the open area between
the lobes and the casing as the lobe pair crosses the inlet port. There is no
compression as the gas is moved to the discharge port it is compressed by the back
flow from the discharge port.
The pressure range is about 1 bar.
Sliding vane compressor uses a single rotating element, the rotor is mounted
eccentric to the center of the cylinder portion of the casing, it is slotted and fitted with
vanes. The vanes are free to move in and out within the slots as the rotor revolves.
Gas is trapped between a pair of vanes as they cross the inlet port; gas is moved and
compressed circumferentially as the vane pair moves toward the discharge port.
This compressor is widely used as a vacuum pump as well as a gas
compressor, the compressor rating pressure is about 3.5 bar.
Outlet
rotor
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Module 01 Compressors Overview
h) Scroll Compressor
A scroll compressor, also known as scroll pump and scroll vacuum pump, uses
two interleaved spiral-like vanes to pump or compress fluids such as liquids and
gases. The vane geometry may be involute, archimedean spiral, or hybrid curves.
They operate more smoothly, quietly, and reliably than other types of compressors.
Often, one of the scrolls is fixed, while the other orbits eccentrically without
rotating, thereby trapping and pumping or compressing pockets of fluid between the
scrolls.
Scroll Compressor
i) Diaphragm Compressor
A diaphragm compressor (also known as a membrane compressor) is a variant
of the conventional reciprocating compressor. The compression of gas occurs by the
movement of a flexible membrane, instead of an intake element. The back and forth
movement of the membrane is driven by a rod and a crankshaft mechanism. Only the
membrane and the compressor box come in touch with the gas being compressed.
Diaphragm compressors are used for hydrogen and compressed natural gas
(CNG) as well as in a number of other applications.
j) Reciprocating Compressor
Reciprocating compressors use pistons driven by a crankshaft. They can be
either stationary or portable, can be single or multi-staged, and can be driven by
electric motors or internal combustion engines. Small reciprocating compressors from
5 to 30 horsepower (hp) are commonly seen in automotive applications and are
typically for intermittent duty. Larger reciprocating compressors up to 1000 hp are
still commonly found in large industrial applications, but their numbers are declining
as they are replaced by various other types of compressors. Discharge pressures can
range from low pressure to very high pressure (>5000 psi or 35 MPa). In certain
applications, such as air compression, multi-stage double-acting compressors are said
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Module 01 Compressors Overview
to be the most efficient compressors available, and are typically larger, noisier, and
more costly than comparable rotary units.
Reciprocating Compressor
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Work done on the air per unit time is equal to the work done per cycle times
the number of cycles per unit time. The rate of mass flow is more often used than the
mass per cycle; if the rate of mass flow is given the symbol m, and replaces m in
equation, then the equation gives the rate at which work is done on the air, or the
indicated power.
The working fluid changes state between a and b in the figure, from P1 and Ti
to P2 and T2. The delivery temperature, T2, is given by ;
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Module 01 Compressors Overview
n 1
P n
T2 T1 2
P1
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The pressure force and flow forces acting on the individual impellers lead to a
resultant axial thrust.
To calculate these axial forces, knowledge of the pressure progression in the
wheel chambers must be as well as the way this progression is influenced by the
leakage flow across the labyrinths at the shrouded hub ends of the impellers. At the
shroud, the labyrinth leakage flows from the out side to the inside (delivery to
suction) and in the hub disk from the inside to the out side (inlet of second stage to the
suction of the first one).
This results in a differing pressure distribution on the shroud and hub disks.
The pressure differential is directly proportional to the density of the gas and rises
with increasing labyrinth leakage
The axial force developed can be calculated from the simple equation:
The resultant forces are in the direction from the discharge side to the suction
side. This for is large enough to be accomplish by a large thrust bearing area, So a
balance piston takes a place here to reduce the axial force acting and the thrust
bearing and the met force only that action the thrust bearing so small thrust bearing
areas can by used.
The force exerted in the balance piston be determined by the equation
Fb.piston = Psuc * Ab.piston
And its direction is from the suction side to the delivery side opposite to the
axial thrust
So the net force acting on the thrust bearing
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