A

Project Report
On

Improving Inlet Conditions

Of

Centrifugal Air Compressor

At Hyundai Motors Limited India,
SriPerumbudur. SriPerumbu
July 2011.

Submitted by,

Sugan Durai Murugan V, ME09B056 Suram Srikanth, ME09B057

Department of Mechanical Engineering, IIT Madras, Chennai 36.

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BONAFIDE CERTIFICATE
This is to certify that the project trainees V.Sugan Durai Murugan and Suram Srikanth of INDIAN INSTITUTE OF TECHNOLOGY Madras have successfully completed their project on "Improving Inlet Conditions for Centrifugal Compressors" in the Utilities & Services Department, Hyundai Motors India Limited in July 2011.

Signature, Mr. S. Balan Project guide, Manager Utilities & Services, HMIL .

Signature, Mr. S. Thirumalai Nambi Manager, Utilities & Services, HMIL.

Signature, Mr. C.S. Lakshmi Narayan Deputy General Manager, Utilities and Services, HMIL.

*This document is property of HMIL, and is illegal to reproduce.

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ACKNOWLEDGEMENT
We deeply thank Hyundai Motors Limited India and Utilities and Services Department for providing an opportunity to do this project. We would like to deeply acknowledge the support and guidance of Mr.S.BALAN Manager, U&S Department, without whom the project would not been this successful. We also would like to thank heart fully Mr.THIRUMALAI NAMBI Manager, U&S Department and Mr.C.S.LAKSHMI NARAYAN General Manager- U&S Department. Our sincere thanks to all the staff members of U&S Department for support and help in the completion of project. We also would like to thank all the Technicians in Compressors, Water Treatment plant and Propane yard, who helped us in understanding of the processes involved in the plant.

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ABSTRACT
Energy conservation is the most important task that all the industries leaning for. Certain innovative methods which reduce energy consumption are considered as energy conservation methods. That includes all the new physically and chemically evolved processes, which pave their way for Energy Conservation. All of the processes do not result in positive manner, because each and every process does have their own problem of Investment, Environmental impacts, and Life span. They may or may not uplift the profit obtained in implementing them. Efficiency is a more suitable term used in this context. In energy competing society, getting the maximum efficiency for their machines is the main motto of all the Companies. In case of Centrifugal air Compressor; the term efficiency goes with different factors. Giving cooler and lighter air to compressor is one of the ways to save power consumption in Compressor Working and to improvise its efficiency. Many machines do that job. But we need that kind of machines which can cope up with compressor flow rate, withstanding the continuity of compressor, the changes in pressure. The basic principle behind the Cooled and dehumidified air is refrigerating the air. Nowadays Refrigeration comes in handy with lot of physical principles. This project elaborates about Centrifugal Compressor and some of the principles used in energy efficient context. This project report shows with theoretical assumptions and practical ways to find the energy savings, their respective annual savings on those Efficiency Optimizing principles to operate on HMILs Centrifugal Compressor.

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TABLE OF CONTENTS
HMIL and U&S Department. Report on Propane Yard. Report on Water treatment plant. Report on Boiler plant. Project on Centrifugal Compressor.
o About o Parts
Inlet Impeller Diffuser Coolers

o Working o Performance and Control o Centrifugal Compressor Instabilities.

o

Surge Rotating Stall Volumetric Efficiency Isentropic Efficiency Polytropic Efficiency Pre-cooled air intake Decrease in Humidity Evaporative Coolers Chiller Coils Comparison

o Efficiency

o Improving Inlet Conditions

o Achieving Better Inlet Conditions

Conclusion

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HMIL
Hyundai Motor India Limitedis a wholly owned subsidiary of the Hyundai Motor Company in India. It is the 2nd largest automobile manufacturer in India.

LOCATION:
HMIL is situated in Sriperumbudur in the Kanchipuram district of Tamil Nadu.Here HMIL has two manufacturing plants capable of producing 600,000 vehicles annually.

HYUNDAI LOGO(HISTORY AND DESIGN):

The Hyundai logo seen above is appears to be an oval shaped H (symbolizing Hyundai). It is also supposed to be symbolic of the company's desire to expand. The ovaloid shape indicates the company's global expansion and the slanted, stylized 'H' is symbolic of two people (specifically the company and customer) shaking hands. HYUNDAI MOTOR COMPANY: Hyundai Motors Company is a Korean automaker which along with Kia comprises the Hyundai Kia Automotive Group, the world's fourth largest automaker as of 2009. As of 2009, it is the world's fastest growing automaker. In 2008, Hyundai (without Kia) ranked as the eighth largest automaker. Headquartered in Seoul, South Korea, Hyundai operates the world's largest integrated automobile manufacturing facility in Ulsan, which is capable of producing 1.6 million units annually. The Hyundai Motor Company (HMC) is a South Korean company manufacturing automobiles. Their automobiles are available in many countries around the globe. In 2003 it was South Korea's largest car maker and the world's seventh largest car maker. Its slogan is "Drive your way". Hyundai Motor Company is a division of Hyundai Motor Group which also manages Kia Motors. The company employs about 75,000 persons around the world. Hyundai vehicles are sold in 193 countries through some 6,000 dealerships and showrooms worldwide. In 2010, Hyundai sold over 1.7 million vehicles worldwide.
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HISTORY: Chung Ju-Yung founded the Hyundai Engineering and Construction Company in 1947. Hyundai Motor Company was later established in 1967. The company's first model, the Cortina, was released in cooperation with Ford Motor Company in 1968. When Hyundai wanted to develop their own car, they hired George Turnbull, the former Managing Director of Austin Morris at British Leyland. He in turn hired five other top British car engineers. They were Kenneth Barnett body design, engineers John Simpson and Edward Chapman, John Crosthwaite ex-BRM as chassis engineer and Peter Slater as chief development engineer. In 1975, the Pony, the first Korean car, was released, with styling by Giorgio Giugiaro of Ital Design and power train technology provided by Japan's Mitsubishi Motors. Exports began in the following year to Ecuador and soon thereafter to the Benelux countries. In 1991, the company succeeded in developing its first proprietary gasoline engine, the four-cylinder Alpha, and transmission, thus paving the way for technological independence. In 1986, Hyundai began to sell cars in the United States, and the Excel was nominated as "Best Product #10" by Fortune magazine, largely because of its affordability. The company began to produce models with its own technology in 1988, beginning with the midsize Sonata. In May 6th1996, Hyundai Motors India Limited was established with a production plant in Irrungattukotai near Chennai, India. In 1998, Hyundai began to overhaul its image in an attempt to establish itself as a world-class brand. Chung Ju Yung transferred leadership of Hyundai Motor to his son, Chung Mong Koo, in 1999. Hyundai's parent company, Hyundai Motor Group, invested heavily in the quality, design, manufacturing, and long-term research of its vehicles. It added a 10-year or 100,000-mile (160,000 km) warranty to cars sold in the United States and launched an aggressive marketing campaign. In 2004, Hyundai was ranked second in "initial quality" in a survey/study by J.D. Power and Associates. Hyundai is now one of the top 100 most valuable brands worldwide. Since 2002, Hyundai has also been one of the worldwide official sponsors of the FIFA World Cup.
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HMIL Policy:
HMILS policy is always to be a stickler for quality. HMIL presently markets 16 variants of passenger cars in six segments. The Santro in the B segment, Getz in the B+ segment, the Sonata Embera in the E segment and the Tucson in the SUV segment. HMIL's first car, the Hyundai Santro was launched in 23 September 1998 and was a runaway success.

CARS MANUFACTURED BY HMIL:

HMIL presently markets 6 models of passenger cars across segments. The A2 segment includes the Santro, i10 and the i20. The A3 segment includes the Accent and the Verna. The A5 segment includes the Sonata Transform. The SUV segment includes the Santa Fe. Latest segment includes now the Fluidic Verna also.

HMILs fully integrated state-of-the-art manufacturing plant near Chennai boasts of the most advanced production, quality and testing capabilities in the country. To cater to rising demand, HMIL commissioned its second plant in February 2008, which produces an additional 300,000 units per annum, raising HMILs total production capacity to 600,000 units per annum. In continuation with its commitment to providing Indian customers with cutting-edge global technology, HMIL has set up a modern multi-million dollar research and development facility in the cyber city of Hyderabad. It aims to become a centre of excellence for automobile engineering and ensure quick turnaround time to changing consumer needs. As HMCs global export hub for compact cars, HMIL is the first automotive company in India to achieve the export of 10 lakh cars in just over a decade. HMIL currently exports cars to more than 110 countries across EU, Africa, Middle East, Latin America, Asia and Australia. It has been the number one exporter of passenger car of the country for the sixth year in a row. To support its growth and expansion plans, HMIL currently has a 307 strong dealer network and 627 strong service points across India, which will see further expansion in 2010.
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EXPORTS: HMIL currently exports vehicles to more than 110 countries across Europe, Africa, Middle East, Latin America and Asia. It has been the number one exporter of passenger cars for the sixth year in a row in India. ACHIEVEMENTS: HMIL has been the number one exporter of passenger car of the country for the sixth year in a row. Here are the achievements of HMIL over their period of time till today. 2010 2009

Fastest exports of 10 lakh cars Hyundai Motor India Ltd. receives the EEPC National Award for Export Excellence for 200708. Hyundai won the Gold Trophy in the Large Enterprise category. Hyundai Motor India honoured with EXIM Achieved Award for the year 2008 by Tamil Chamber of Commerce Hyundai Motor India conferred the Top Exporter of the Year for 2006-07in the category of Large Enterprises and received the Gold Trophy at the Southern Region Annual Award Presentation by the Engineering Export Promotion Council (EEPC). Hyundai Motor India awarded with the Niryat Shree Silver Trophy for the year 2005-06 by the Federation of Indian Export Organizations (FIEO). Hyundai exports its first batch of i20 to European market. The first export consignment comprised 2,820 units of i20. Fastest Export - Over One lakh units of i10 exported since its launch in Oct 31, 2007 Fastest Export of 5 lakh units Fastest Export of 4 lakh units Hyundai Motor India adjudged the Top
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2008

2007
HMIL Project Report

Exporter of the Year for 2005-06 in the category of Large Enterprises and received the Gold Trophy by the Engineering Export Promotion Council (EEPC) Hyundai Motor India ships out the first Getz Hyundai Motor India rolls out the fastest 300,000th export car No 1 Entry Midsize Car' by Accent Petrol. No 1 Entry Midsize Car' by Accent CRDi. Hyundai Getz became the 'Car of the Year' by BS Motoring. Hyundai Motor India Limited became the 'Company of the Year' by BS Motoring. Hyundai Getz became the 'CNBC Autocar Car of the Year.' Hyundai Elantra became the 'Best Value for Money Car' by CNBC. Hyundai Motor India adjudged as the 'Car Maker of the year' at the ICICI Bank Overdrive awards. Hyundai Santro topped the 'JD Power Asia Pacific Initial Quality Study (IQS)' that measures the product quality for three consecutive years (2000, 2001 & 2002). Hyundai Santro topped the 'JD Power Asia Pacific Apeal' study that measures customer satisfaction for three consecutive years (2000, 2001 & 2002). Hyundai Accent topped the 'JD Power Asia Pacific IQS' for 2002 and the APEAL study for 2001 & 2002.

2006

2005

2003

2002

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U & S DEPARTMENT
Utilities and Services Department is one of the main departments in HMIL. It controls the Needs for the whole plant. It maintains Propane Yard Water and Waste Water Treatment Plant Boilers Air Compressors Electricity power Air Conditioners Air Washers Mist Collectors etc.

And with control over these, the U&S department provides plant Propane gas as fuel, Supplying industrial and canteen water, Electricity, Steam, Compressed air, treatment in waste water, air conditioning. In fact, U&S Department is the fuel behind the working of plant. Because it takes control over all the main energy sources for engine shop, body shop, Paint shop, Aluminium foundry, even for Canteen. Therefore U&S Department is the steering wheel for Plant Production. This Project concentrates on some of the equipment in U & S Department controlled plants, which are Propane Yard Water Treatment plant Boilers Centrifugal Compressor

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PROPANE YARD
ABOUT PROPANE:
Propane is a gas derived from natural gas and petroleum. It is found mixed with natural gas and petroleum deposits. Propane is one of the many fossil fuels included in the liquefied petroleum gas (LPG) family. Propane is a very clean burning fossil fuel, which explains its use in indoor which settings. It was approved as an alternative fuel under the Clean Air Act, as well as the National Energy Policy Act of 1992. Propane undergoes combustion reactions in a similar fashion to other Alkanesi. In the presence of excess oxygen, propane burns to form water and carbon dioxide. C3H8 + 5 O2 3 CO2 + 4 H2O + heat Propane + oxygen carbon dioxide + water When not enough oxygen is present for complete combustion, incomplete combustion occur when propane burns and forms water, carbon monoxide, carbon dioxide and carbon. dioxide, 2 C3H8 + 7 O2 2 CO2 + 2 CO + 2 C + 8 H2O + heat Propane + Oxygen Carbon dioxide + Carbon monoxide + Carbon + Water

PROPANE IN HMIL:
HMIL Utilises propane fuel in gas form, in 24X7basis. The yard has two bullets of Propane tank, Vaporiser, and Compressor units. Each Propane bullet has a Capacity of 95 MT, storing propane in both liquid and gas form. On an average the plant utilizes around 23 MT of propane daily. The pressure level of the propane is seen through the pressure gauge. And only upto 70 to 75 percentage of volume is filled with propane, because propane is easily expandable with temperature increase. Also bullet tank is designed with huge h thickness to withstand any expansion or explosion.
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Propane has a physical property, that Liquefied1ml of Propane occupies 270 ml in Gaseous form, therefore all propane users use propane eithe either completely in liquid form or partly gas and partly liquid form, In HMIL propane bullet stores in both liquid form and gas form, because plane needs gaseous form, and it is expensive to boil liquid propane into gas continuously. The plant needs propane supply at a pressure of 3 kg/cm2 continuously. The pressure levels are maintained by PRV and By-Pass valves. Vaporiser is used to heat the liquid propane to its boiling point and vaporise it. It is done by heating the water up to 85oC and it heats the propane. Vaporiser is used only if the propane gas form goes insufficient in the bullet, which is compromised by the liquid propane. The yard has three modes of colour codes in piping arrangement. They are Plain Yellow. Plain Yellow with Red Band. th Plain Red. Plain Yellow carries propane in pure liquid form. Plain yellow with red band carries propane in vapour form, and the plain red carries fire water for emergency purposes. The yard gets its propane source from tankers which come regularly to load the Bullets. Initially, the tanker is at high pressure than the bullet. Hence, liquid propane unloads from the tanker into the bullet until the pressure in the tanker equals that of the bullet. Then the compressor pushes the vapour from the bullet to the tanker and he pressurises the remaining liquid propane into the bullet. Once the liquid propane is completely filled into the bullet, the compressor loads compressed air into the tanker to empty the vapour propane to the bullet. Thus unloading is done into the bullets. unloading Fire fighting is supposed to be very important in any industry and its importance is almost equal to the importance which is given to production and profit. There are several methods of fire fighting used at HMIL. Since, propane
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is an explosive gas, the yard has large amount of precautions in fire fighting process. The yard is planted with 24 sensors to notify the temperature and any propane leakage. Innumerable fire alarms and sprinklers are implanted in various parts of the Yard. Also at the top of the bullets, automated fire extinguisher is fixed to quench the fire at the top, in case fire cant be controlled manually. In addition to this, external Hydrant is in practise. All the activation of fire fighting systems are situated in separate portion, on water treatment plant part with Jockey, Spray, and Hydrant pumps for respective activation. All are automated pumps.

USES OF PROPANE:
Heat is produced when propane undergoes combustion, which is used for several parts of the HMIL. They are Drying paints Heat treatment in hardening of gears Melting aluminium ingots Canteen Boilers furnace pilot firing

PROPERTIES OF PROPANE:
1. Molecular weight 2. Specific Gravity 3. Specific Volume 4. Density 5. Specific Heat 6. Specific Heat Ratio 7. Gas Constant 8. Latent Heat of Evaporation 9. Flammable 10.Heat of Combustion 44.097. 1.52. 0.552 m3/kg. 580 kg/ m3. 1630 J/kg.K. 1.2 188 J/kg.C 428000 J/kg. Yes. 50340 kJ/kg.

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WATER TREATMENT AND SUPPLY

WATER TREATMENT PLANT:
HMIL meets its water requirements from the water treatment plant. The eets plant supplies treated water to all parts of the HMIL. At first, raw water storage tank gets water from outside sources and it stores it. The outside sources are Chembarambakkam Lake. Rain water storage. er The capacity of the raw water tank is 2000kL. The water from there is pumped for pre-treatment. The water passes through MGF (Multi Grade Filter) treatment. in which chemicals such as Sodium hydroxide and poly aluminium chloride are used to decrease the turbidity, and it is passed through layers of filters, which vary with their porosity and it filters out the dust and remains in the water. Thus the filters reduce the Turbidity. The r. filter must be cleaned with backwash method, to avoid blockage of water inside the filters. During the process of backwash, the outlet is closed, and inlet , is switched to outlet portion, and water flows in reverse, peeling the sediments out. The water from there is stored in two separate tanks, in which one is called treated water tank which is used for canteen purposes, and other is called recycled or industrial storage, used for industrial purposes.

DEMINERALIZATION PLANT: ERALIZATION

Water from industrial storage can be used for cleaning, cooling, etc.. But for boilers, the water must be de mineralized, because the minerals may cause de-mineralized, corrosion, scale formation, inside the boiler parts when the water boils. Therefore, De-Mineralization plant supplies demineralised water to boiler feed Mineralization supply.

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Ion exchange resins are the basic methodology used to demineralise the water. There are two types of resins called Anion exchange resin and Cation exchange resin. Anion resin removes all anions from water, such as Cl,I,Br,S etc..in exchange of OH ions, and Cation resin removes all cations from water , such as Ca,Mg,Na,Al etc...in exchange with H ions. It is done by insoluble,cross linked, long chained polymers with a micro porous structure and the functional groups attached to them in the resins ous which are responsible for the reaction and removal of ions from Water. The components in the DM plant are strong acid Cation (SAC),weak base anion(WBA), Degasser tower and the strong base anion (SBA). The outlet of the SBA is the DM water which is used in the boilers. The regeneration of SAC is being done with Hydrochloric acid, WBA,SBA is being done with Sodium hydroxide. The regenerated sludge is neutralized and proposed to waste wat water treatment plant for further treatment. The parameters that are changed by the DM plant are PH (alkaline). Hardness. Turbidity. Conductivity. TDS(Total dissolved solids).

FIRE PUMPS:
Besides treating water for Industrial purposes, it also pumps wat to all the water fire fighting system all around the plant in automated way. The Water Treatment plant has pumps for fire fighting system. They are Hydrant Pump Spray Pump Jockey pump

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Hydrant Pump: There are three pumps which is always kept in ON condition. In case of fire incidents there will be heavy pressure losses inside the pipe line. To increase the pressure all the three pumps are switched on automatically. This pump discharges 171 m3/hr. Spray Pump: Spray Pump builds pressure for water sprinklers and supplies water to them. In case of fire accidents, the quartzite bulb detects the temperature rise immediately and pump valves are opened automatically. The pump covers propane yard, substation, paint shop.

Jockey Pump: The main use of this pump is to maintain pressure in the fire fighting water pipes, which automatically detects the loss of pressure in the pipe and builds pressure automatically.

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BOILER PLANT
STEAM:
Steam is vaporised water, being part gas, part liquid. Steam itself is usually interspersed with minute droplets of water in its liquid state, which gives it a white, cloudy appearance. In industrial and process situations, steam is often generated using water boilers that are heated to create steam under controlled conditions. The energy generated is then transferred and used in s. many different ways.

BOILERS:
HMIL needs steam at high pressure for industrial purposes. There are two types of boilers in HMIL, they are Fire Tube Boiler (FTB). Water Tube Boiler (WTB).

FTB:
A fire-tube boiler is a type of boiler in which hot gases from a fire pass through one or more tubes running through a sealed container of water. The heat of the gases is transferred through the walls of the tubes by thermal conduction, heating the water , and ultimately creating steam steam.

WTB:
A water tube boiler is a type of boiler in which water circulates in tubes heated externally by the fire. Fuel is burned inside the furnace, creating hot gas which heats , waterin the steam-generating tubes. In generating smaller boilers, additional generating tubes are separate in the furnace, while larger utility boilers rely on the water water-filled tubes that make up the walls of the furnace to generate steam.

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PARTS OF BOILER:
Boiler contains innumerable parts associated in the process; the following are core machinery processes involved in the steam generation process. 1.DEAERATOR: Deaerator is an important component in production of steam. Dissolved gase such as oxygen gases and carbon dioxide are initially present in the feed water. If these gases are not removed, they can line the surfaces within the boiler and cause accelerated corrosion. Since these gases cannot be condensed out. A deaerator utilizes Henrys law to remove dissolved oxygen, carbon dioxide, and other non noncondensable gases from boiler feed water. The feed water is sprayed in thin films into a steam atmosphere allowing it to become quickly heated to saturation. Spraying feed water in thin films increases the surface area of the liquid in contact with the steam, which, ms in turn, provides more rapid oxygen removal and lower gas concentrations. This process reduces the solubility of all dissolved gases and removes it from the feed water. The liberated gases are then vented from the deaerator. In this ated process, addition of Hydrazine is done to improve the efficiency. 2.ECONOMIZER: Economizer is the core of the boiler, where the fire from oil heats up the water into steam. Latter, economizer is also employed to utilize the waste heat generated from the combustion process to improve overall efficiency in the boiler. Flue gas exiting the combustion chamber is still, Very hot and can be used as a pre heater for the feed water. The economizer used fo pre-heater for these boilers is a horizontal counter current shell and tube heat exchanger. Feed water enters finned tubes while hot flue gases pass over the outside. This allows for the recovery of energy which would otherwise be wasted.

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3.FURNACE and FLUE GAS: Flue gas is the main heating element of the boiler. It is formed in the e furnace by atomising the oil into particles with compressed air, and igniting them up to 1500oC. The oil is being pumped into finned tubes, where oil atomised and mixes with compressed air. The flue gas passes through a air. numerous no of thin tubes into the water tank, slowly temperature of the flue gas gets reduced to 350oC at the end of the economizer. 4.BLOW DOWN: Dissolved solids and particles entering a boiler through the make make-up water will remain behind when steam is generated. During operation the r concentration of solids build up and finally a concentration level is reached where operation of the boiler becomes impossible. Blowdown is a common procedure for a boiler to control the contaminants in the boiling ontaminants water. Two types of blowdown exist, manual and continuous. For a continuous blow down, a Calibrated valve continuously takes water from the top of the boiling surface in the steam drum. Manual blowdown is accomplished through tapings at the bottom of the boiler where solids settled tapings are removed. With manual blowdown water level control devices and cut off devices are kept clean of any solids interfering with their operation.

PRODUCTION OF STEAM:
The basic principle behind the production of steam, is that water is pre production preheated, heated, and post heated by fire, there exists two path ways in this production, one describes how water converts into steam, whereas another goes with how air becomes flue gas. Water Steam: From the De Mineralization plant water enters Feed water storage tank, eralization which primarily stores water required for steam formation, from there using raw water pump it is pumped to deaerator. From Deaerator water enters economizer to heat up, the hotter water passes into Bank tube, then to Bank muddrum and passing through rifer tube where it finally converts into steam, the steam gets stored at Steam Drum (Steam Receiver).

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AirFlue gas: The atmospheric air is compressed and passed through Forced Drafter and mixes with atomised oil particles and ignited at the inlet of economizer to give flue gas which heats water inside the Economizer, part of the flue gas is reused to its maximum efficiency, and then passed onto the chimney, from where it leaves outside.

OUTPUT and CONTROL OF BOILER:

The WTB provides steam at 198C and at 14 kg/cm2pressure, whereas FTB delivers steam at around 180C and at 10.54 kg/cm2pressure. Pressure Gauges are located at the inlet and at Steam drum to record the pressure of steam continuously. Safety valve and Stop valves are fitted in the boilers in case of emergency purposes. Air vent is a valve, which is opened to remove air from free air left in Boiler. The flue gas leaving the chimney contains a lot of heat energy, which could be reused; modern boilers are more efficient in utilising the heat energy to the maximum extent. The steam produced in the boiler is used in Paint Shop Canteen Engine Shop Waste Water evaporation Unit

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CENTRIFUGAL COMPRESSORS
ABOUT CENTRIFUGAL COMPRESSORS (CC):
A compressor is a piece of machinery that compresses a fluid, a liquid or a gas, that flows in the compressor into greater pressure. As the pressure of the fluid rises, the fluid flows through the compressor from lower pressure into higher pressure. Compressors working in a small pressure ratio can also be Compressors referred as blowers. Centrifugal compressors use the rotating action of an impeller wheel to exert centrifugal force on air inside a round chamber (volute). Air is sucked into the impeller wheel through a large circular intake and flows between the impellers. The impellers force the air outward, exerting centrifugal force on the air. The air is pressurized as it is forced against the sides of the volute. Centrifugal compressors are well suited to compressing large volumes of air to relatively low pressures. The compressive force generated by an impeller wheel is small, so chillers that use centrifugal compressors usually employ use more than one impeller wheel, arranged in series. Centrifugal compressors are desirable for their simple design and few moving part. Compressors are used in Hyundai Motor India limited to provide compressed air to meet their requirements in various fields. Compressed air acts like a heart in heart, an ultimate source of energy next to electricity in this industry. It is used for air filling, drying, for pneumatic applications, painting etc, to meet the compressed air requirements of the industry. At HMIL, ompressed air Ingersoll Rand Centrifugal Compressors are used.

PARTS OF THE CENTRIFUGAL COMPRESSOR:

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Inlet: The inlet to a centrifugal compressor is typically a simple pipe. It includes features such as a valve, stationary vanes and their respective instrumentation. All of these additional devices have important uses in the control of the centrifugal compressor. Centrifugal Impeller: The key component that makes a compressor centrifugal is the centrifugal impeller. It is the impeller's rotating set of vanes that gradually raises the energy of the working gas by imparting their kinetic energy. In many modern high-efficiency centrifugal compressors the gas exiting the impeller is travelling near the speed of sound. Impellers are designed in many configurations including open (visible blades), covered or shrouded, with splitters (every other inducer removed) and without splitters (all full blades). Most modern high efficiency impellers use back sweep in the blade shape.

Diffuser: The next key component to the simple centrifugal compressor is the diffuser. Downstream of the impeller in the flow path, it is the diffuser's responsibility to convert the kinetic energy of the gas into pressure by gradually diffusing the gas velocity. Diffusers can be vane less, vaned or an alternating combination Bernoulli's fluid dynamic principal plays an important role in understanding diffuser performance. Coolers: The Centrifugal Compressor is equipped with Water coolers and Oil coolers to absorb the enormous heat energy produced and stored in air when it is compressed. The coolers swirl around the air pipe and by indirect means of heat exchange, it cools down the air. The coolers are further classified into Inter Cooler and After Cooler, with name implying its meaning that inter cooler cools in between the stages of compressor, and after cooler cools after completion of all stages.

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Centrifugal compressor(Ingersoll-Rand) parameters Discharge pressure Discharge Flow Shaft power at coupling for FAD 132 NM3/min(dry) Shaft power at coupling for FAD 132 NM3/min Installed motor power in kW Actual turn down ratio 7.0 kg/cm2 132 NM3/min 753.5 kW 709.3 kW 900 kW Above 25%

Compressor Inlet Conditions Suction pressure Inlet pressure Inlet air temperature Relative humidity Cooling water temperature 1.013 bar 0.994 bar 45oC 80% 35oC

Compressed Air-Phase I Centrifugal Compressors Screw Compressors Total Capacity Present Consumption 4*132 NM3/min 5*50 NM3/min 778 NM3/min 580 NM3/min

Compressed Air-Phase II 5*132 NM3/min 1*60 NM3/min 1*50 NM3/min 1*60 NM3/min 720 NM3/min 446 NM3/min

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WORKING OF CENTRIFUGAL COMPRESSORS:

Atmospheric air is brought to the inlet of the CC by using suction inlets. The sucked air is passed through primary and secondary filters, to absorb the dust and particulates. The filtered air passes through three stages of the CC. In the first stage the air is passed to the impeller, in which the air is circulated and it gains Kinetic energy and goes through the diffuser to convert the kinetic energy into Pressure energy. The pressure rises from 0.994 bar to 1.5 bar. During this process, the temperature of air raises dramatically up to 150oC. Then the hot air passes through the Inter Cooler 1, in which the cooling water passes around the hot air, and cools it down, back to the Inlet Temperature without changing the pressure. In the second stage , the air goes through the second impeller and diffuser to raise its pressure from 1.5 to 3.5bar approximately, once again an Inter cooler is set up to bring back the temperature to its Inlet Point without changing the pressure. In the final third stage, pressurized air goes through the third impeller and diffuser and it goes through an After Cooler to cool down its temperature in similar to Inter Cooler, except that the final temperature from the After Cooler is slightly above than that of Inter Cooler. In this stage, the Pressure rises from 3.5 to 6.5bar, and reaches outlet. Apart from inter cooler and after cooler, there exists also Oil cooler which takes part in the cooling of compressed air. All the coolers in the centrifugal compressor do not make contact with the compressed air, so no contact with the coolants. The amount of water and oil flow in these coolers is TYPE OF COOLER Inter Cooler After Cooler Oil Cooler CONSUMPTION 78.8 M3/hr 27.3 M3/hr 17 M3/hr

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The cooling water is being purified and recycled and pumped back to compressor throughout the process, also the water is been added certain chemicals to reduce corrosion of materials inside the inter cooler, and to avoid any formation of algae inside the machinery which would be a lot difficult to clean manually. Atmospheric air contains a huge amount of moisture (around 80% relative Humidity). When air gets cooled at Inter and after cooler, the moisture gets condensed to water. Therefore both inter and after cooler condense a large amount of water during the compression process, which are drained to water treatment plant in HMIL.

Even after this, Compressed air contains a particular amount of moisture, which is needed to be removed. It is done by the use of Dryers. The basic principle behind the working of Dryers is that, when the dry air with moisture comes in contact with the cooled water, moisture condenses out as water droplets. There are two types of dryers in practise in HMIL. They are

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1.

Refrigeration Dryers. (Absorbs up to 90 percent of the moisture content)

Compressed Air Quality - Refrigeration Dryer outlet Pressure Dew Point Dust Size 5.8-6.2 kg/cm2 Below (-)20oC Less than 0.5 m (Oil free Air)

2. Adsorption Dryers. (Absorbs 99.9 percent of the moisture content, particularly used for compressed air to paint shops, where there is no compromise for moisture)
Compressed Air Quality Adsorption Dryer Outlet Pressure Dew Point Dust Size 5.8-6.2 kg/cm2 Below (-)40oC Less than 0.01m (Oil Free Air)

PERFORMANCE AND CONTROL OF CC.

To monitor the CC, it is to be designed with Pressure Ratio (the ratio between the Discharge pressure and inlet pressure), Flow rate which is either mass flow rate or volumetric flow. The primary source of power to run the CC is the Motor Input to the Centrifugal Impeller, the secondary sources include the inter and after cooler motor inputs, suction power supply and power for digitally recording operating parameters. Basically the capacity control is achieved by inlet throttling or inlet guide vane control. For a given impeller design and speed of operation, the pressure
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ratio varies with the volume. The power consumption increases as the volume increases. When the flow demand fluctuates, constant pressure has to be maintained at the discharge. When flow demand reduces, inlet valve is throttled; keeping the bypass valve closed and the air flow will follow the straight line, keeping the pressure constant. However, this throttling is done only up to the point which is only marginally above the surge limit. Any further reduction in flow will result in the compressor operating in the surge region. At this point, if the flow demand is still reducing, the bypass valve is kept open by the signal from the surge sensor. The compressor now blows off surplus air thorough the bypass valve for flow requirements. Evidently, this mode of control is not energy efficient although surging is avoided. This mode of operation is used when system demand is more than 50% of the compressor capacity and is fairly constant. Use of movable inlet guide vanes is a better method of capacity control in centrifugal compressors, the movable inlet guide vanes add pre-whirl to the gas stream entering the impeller. By modifying the inlet whirl component, drop in efficiency is very little. It may be noted that the specific power consumption remains essentially the same for flow variation from 100% to 70%. FAD of CC. FAD (Free Air Delivery) of an air compressor is the air sucked in by the compressor at standard condition. The specific power consumption (kW/100scfm) is a good figure of merit to evaluate the performance of compressors, It may be noted that centrifugal compressors are the most efficient Compressors compared to screw and Reciprocating. The formula for calculating FAD is =

The design value FAD of Centrifugal Compressor in HMIL is 132 .The difference between measured FAD and designed FAD should not exceed 20% of the value which is 26.4. If not, then compressor needs a check up.
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Where P2 final pressure of the receiver. P1 - inlet pressure of the compressor. V Volume of the receiver. T1 Inlet temperature in Kelvin. T2 Compressed air temperature in Kelvin. T time taken to fill the receiver at working pressure of the system.

CENTRIFUGAL COMPRESSOR INSTABILITIES:

Surge: Surge is an instability that affects the entire compression system. Surge is characterized by a limit cycle oscillation that results in large amplitude fluctuations of the pressure and ow rate. In contrast to rotating stall, during surge the average mass ow is unsteady but circumferentially uniform. In other words, surge is one dimensional system instability while rotating stall is two-dimensional compressor instability. Furthermore, surge only occurs in compressible ow systems whereas rotating stall occurs in both incompressible and compressible ow. As mentioned before, surge results in considerable loss of performance and efficiency. Furthermore, the power level of the pressure oscillations can approach that of the compressor itself, inducing large mechanical loads on the entire compression system. The main Reasons behind the formation of Surge are Low Inlet Pressure High Discharge pressure. High Inlet Temperature. Tear and worn of machinery parts. Improper functioning of machine parts. The basic techniques for surge avoidance are: Improved aerodynamic design in Air flowing paths. Reduction of variations in operating conditions. Inclusion of components that supporting the ow, not obstructing the flow Active suppression of aerodynamic instabilities (if any).

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Rotating Stall: Rotating stall is an aerodynamic instability confined to the compressor otating internals that is characterized by a distortion of the circumferential ow pattern. One or more regions of stagnant ow, so-called stall cells, travel called around the circumference of the compressor at 10 90% of the shaft speed. 1090% The stall cells reduce or completely block the ow, resulting in l large vibratory stresses and thermal loads on the compressor blades. While the effects of rotating stall are known, details of stalled ow, for example the number of stall cells, their size and speed relative to the impeller, are far from being completely understood. Given its distorting effect on the ow, rotating stall can result in a large ow, drop in performance and efficiency. Rotating stall introduces a gradual or abrupt drop of the pressure rise. Moreover, rotating stall can introduce hysteresis into the system, implying that the ow rate has to be increased beyond the stall initiation point in order to bring the compression system out of its stalled operating mode.

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EFFICIENCY OF THE CC:

The efficiency of the machine is how much output does it give related to our given input. In the case of Centrifugal Compressor, the efficiency is calculated in many ways. Volumetric Efficiency. Isentropic Efficiency. Polytropic Efficiency.

Volumetric Efficiency:
Volumetric Efficiency is the ratio of Net Volume flow into the compressor to the compressor design flow. Compressor Design flow is a function of the impeller design flow coefficient, its speed and diameter and is inclusive of all leakages. Volumetric efficiency can then be defined as follows, =

The Compressor design volume flow depends on Flow coefficient, Speed, and Diameter of the impeller. The equation follows as, = .

Net Volumetric Flow (or flange-to-flange flow) is Compressor design flow minus the internal leakages i.e. balance piston and centre seal leakages whichever is applicable. Design flow = 5525.0802cfm. Net flow = 5445.2580cfm. Leakages = 5525.0802cfm 5445.2580cfm = 120.778cfm Therefore =
. .

= 99.94%.

The volumetric efficiency will be close to 100 % in factory test and lower in the field depending upon application, operating pressures and sizes of the machine and pressure ratios etc. This concept can help to explain some of flow anomalies found during field tests and reconcile the differences in head, efficiency and power found in field tests.
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Isentropic Efficiency:
The isentropic efficiency expresses how much the compression process resembles an isentropic compression process. When the value of efficiency is one, the compression process is an ideal process, which has no losses. Isentropic efficiency is defined by calculating the change in specific enthalpy in the real compression process and comparing it to the change in specific enthalpy in an ideal compression process. Isentropic efficiency is calculated throughout the whole compressor system. Isentropic efficiency for a compression process can be calculated with the equation =

Where c1 is the specific heat capacity in average temperature of an ideal isentropic compression process, T2ideal is the outtake temperature in an isentropic compression process, T1 is the intake temperature, c2 is the specific heat capacity in constant pressure computed in average temperature of a real compression process and T2real is the outtake temperature in a real compression process. Applying, adiabatic conditions to the process, we get,

Theoretical Power (kW) =

Where S= no of stages. K=adiabatic constant of air. Ps=Suction pressure. Pd=Discharge pressure. Q=FAD. CALCULATION OF ISENTROPIC EFFICIENCY OF 3 DIFFERENT STAGES OF CENTRIFUGAL COMPRESSOR. *Motor input Power (kW) = 776.35 kW.

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*Motor Efficiency, *Real Power = 776.35 * *K 1.4

= 96.2%.
.

.= 746.85 kW.

*S = 1. (Since the formula is applicable for only compression process, cooling is not involved, we calculate the efficiency stage wise.). *Q = 132 * * /min. .

= 0.994

= 1.5 bar for stage 1, 3.5 bar for stage 2, 6.5 bar for stage 3.

Substituting the data to the above formula, we get Theoretical Power for Stage 1:

. .

. .

= 92.62 kW

Theoretical Power for Stage 2:

. .

. .

. .

= 287.8 kW

Theoretical Power for Stage 3:

. .

. .

. .

= 105.0 kW

Therefore, the corresponding Isentropic Efficiencies are

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Stage 1: =
. .

= 12%. Stage 2: =
. .

= 38.5% Stage 3: =
.

=14%

Polytropic Efficiency:
The Polytropic efficiency expresses how much the real compression process resembles an ideal compression process, but different from isentropic efficiency, the Polytropic efficiency is defined across a differential part in the system, and so calculated through the whole system. Polytropic efficiency can be calculated by assuming that in an ideal process the temperature ratio is relative to the pressure ratio according to equation = Where p2 is the outtake pressure,p1 is the intake pressure and R is the specific gas constant of the fluid. When calculating a real compression process, the Polytropic efficiency is included in the equation by adding it to the exponent "according to the equation,
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= The Polytropic efficiency is better for compressor comparison than the isentropic efficiency, because the value of the Polytropic efficiency does not change as much as the value of the isentropic efficiency does. It is possible to have the same value of Polytropic efficiency for two different compressors working in the same conditions. The greater the pressure ratio, the more the isentropic and Polytropic efficiency values differ. We can find the by substituting the values found out by experimentally observed. Consider Stage 1, where pressure increases from 1bar to 1.5 bar, and temperature raises from 300K to around 420K.On Substituting these values we get 1 " "(with K=1.4) as ln = 1 ln

ln

420 0.4 1.5 = ln 300 1.4 0.994 = . .

Likewise, Efficiency for stage 2 and 3 are calculated with its parameters. We get, = . . = . .

From both isentropic efficiency and polytrophic efficiency one could notice that, even though the value of efficiencies differ, the order of efficiency doesnt change i.e. Second stage is most efficient and first stage is least efficient, which depicts on the magnitude of Pressure Ratio.

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IMPROVING INLET CONDITIONS:

Improving Inlet conditions is basically increases the performance of the compressor and its efficiency. Efficiency is a ratio between ideal process value and its real process value, in every practical purpose the real value will be always less than the ideal value. Thats why the efficiency never be 100%. The efficiency of the centrifugal compressor depends on various parameters, and there are many methods which could increase the efficiency of the compressors. But the problem associated with that is that all methods wouldnt be suitable in either cost, space, energy, etc..Thats why optimizing efficiency means us the meaner and fitter methods of better performance to the compressor. We choose two basic methods to reduce the power usage of the compressor. They are Pre Cooled Air intake. Humidity Reduction. Both of the methods actually inter relate to each other in a complex way. In an approximate way, it can be said that, cooling of air takes place easier at low humidity.

PRE-COOLED AIR INTAKE:

In general, air at ambient conditions is sucked in for compression. Due to this the compressor had to work more particularly during summer and monsoon period, because of high temperature and moisture content of ambient air. By cooling the air entering the compressor, the efficiency of the compressor can be improved which will reduce the energy consumption for generating the same quantity of compressed air. This cooling is achieved by sucking the air though a refrigeration dryer unit. As the temperature of air is reduced, its volume also decreases per unit mass and a greater mass of air is available for the given compressor work. Therefore, due to pre cooling either more air is delivered for a given power input or the power input is reduced for a required volumetric flow rate. The moisture present in inlet air is condensed out giving dry air for compression and saving energy, which would otherwise be used for compressing water vapour. This will also reduce the wear and tear of the moving parts in the compressor. The dust present in the air is entrained in the ice during freezing. This acts as a filter eliminating the need for a conventional filter and its inherent flow resistance, leading to further energy as well as capital cost savings.
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The work for the coolers and dryers are also reduced in this case. This represents another capital cost saving as well as an additional energy-saving device. It is estimated that for every 3C drop in suction air temperature improves the compressor efficiency by 1%. Installing of exhaust fans could make the cooling part easier and fast. Assume the Temperature gets reduced by T, therefore savings in specific energy is = =

Neglecting changes in K and

due to change in temperature.

Calculations:Finding the Savings in specific energy for 1 degree change in temperature, = 1.03
.

We get specific energy for three stages, as = 1K * . = 1K * . = 1K * .

. . .

. . . . .

. . . . . . . . .

= 0.403 kJ/kg.

= 0.401 kJ/kg.

= 0.415 kJ/kg.

Annual Power Savings (theoretically) is = `[E * Mass flow rate(kg/hr) * Unit cost(per kW hour) * 24 * 365]. =`(0.401kJ/kg * 9420.71 =` 49,490 50,000
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] * 24 * 365.)

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Therefore reducing the inlet temperature by 1K, the annual savings is reduce `50,000. Up to 15K reduce in temperature, the savings can be approximated as `( `(50000 *

DECREASE IN HUMIDITY:
Humidity is nothing but the presence of water vapour in the air. Due to the presence of humidity in air, compared to dry air work, the work done for humid air is higher. It is because the water vapour in the air makes its heavy s (by means of increase in their molecular weight). Humidity is location dependent; Chennai has more humidity than T Trichy or Madurai, due to the sea shore in Chennai. Therefore on a whole humidity cannot be suppressed or removed, instead it can be reduced up to certain extent, for which the expense can be easily renewed in a smaller period with the power savings given by the compressor in sucking in air with lesser humidity. The calculations in this study are made considering the compressed fluid to be air, but the effects of air humidity have to be considered as well. Humid air can be considered to be a mixture of dry air and water vapour. In this study the water vapour is assumed to be near liquefying and humid air is treated as a sumed perfect gas. Air humidity influences the values of air molecular mass, the specific gas constant of air and the specific heat capacity of air. Relative Humidity: The amount of water vapour in air is defined by the pressure of the vapour in the air. The pressure of the vapour in the air cannot be greater than the pressure of saturated water vapour; otherwise the water is in liquid or solid state. Relative humidity states the relation between the pressure of the water vapour in essure the air and the pressure of saturated water vapour. /

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Where Pvap is the water vapour pressure in the air, Psat is the pressure of the saturated water vapour and is the relative humidity. Specific Heat Capacity : After calculating the water vapour humidity, the molecular mass and gas constant can be calculated for the air-water vapour mixture. The molecular mass for air-water vapour mixture M can be calculated with the mole fraction of Water vapour " given by, = = + 1

= 18,

= 29.

The gas constant for humid air can be calculated with the equation where the molecular mass M is now the molecular mass of air-water vapour mixture. = The specific heat capacity for water vapour can be calculated with the equation using the constants for water vapour. With the mole fraction of water vapour in humid air, the specific heat capacity for humid air can be calculated with the equation.
,

= 1.005

= 1.85

=
. .

Since , the specific heat capacity of vapour is higher than that of air, presence of humidity increases the net specific heat capacity, in other words more the humidity , more the net specific heat capacity. Therefore, the extra specific energy consumed for compressor,(theoretically) is = [
,

* T] - [

* T]
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=[ =[

From above, written equations, we get =

) * * T].

]T - [

* T].

Therefore, Running the Compressor plant at 70% relative humidity (average relative humidity in Chennai) . In fact, month wise June has the lowest relative humidity and October has the highest relative humidity, Therefore in June Compressor should consume lowest power, and in October it should consume highest power. And

= 420 300 for three stages.

= 4.2 X 10

= 1.005

= 1.85

. .

= 0.994 10

= 120 . An approximated Temperature difference

. . .

= [ (1.85-1.005) *

* 120 ] = ~

Therefore, its shows for 70%humidity decrease; the specific power consumption is 3kJ/kg, then for 10% humidity decrease. = * 10 = 0.428 kJ/kg.
.

Annual Power Savings is = ` [ cost(per kW hour) * 24 * 365]. =`(0.428kJ/kg * 9420.71 =`53,110 `53,000.
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* Mass flow rate(kg/hr) * Unit

.

] * 24 * 365.)

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An Annual Savings of `53,000 appears on 10%humidty decrease.

TOTAL POWER SAVINGS.

Assume, with 1C reduction of inlet temperature and humidity decreases from 70% to 60%, then the theoretically calculated specific energy and power savings will be Let, = = = `= , = , =

= =

. .

. 0.3494

The following calculation is made with only the First Stage of the compressor, because from the second stage the temperature may not be as same as in the first stage.

Calculations:
= =
,

[1 ] +
,

[1 `] +
,

[ `]

[1 `] +

` *

[
,

[ `]

] * .

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With at 60% rel humidity ` = 70% = 1 ,

. .
. .

= .02535

= .02957,

= 0.84

1.005[1 .02535] + 1.85[.02535] 1 = 1.005[. 02957 .02535] 1.85[. 02957 .02535] 300 *.4

1 = 0.4

Annual Power Savings is = `[ [ kW hour) * 24 * 365]. =`(0.84 kJ/kg * 9420.71 =`1,03,671.04 `1,00,000

.
.

] * Mass flow rate(kg/hr) * Unit cost(per [

.

] * 24 * 365.)

It is shown from this calculation that combining both methods sums up the savings approximately.

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ACHIEVING BETTER INLET CONDITIONS:

The above mentioned methods to increase compressor performance can be achieved only with implementing new machineries. The machine which does this function must reduce the inlet temperature and decrease the humidity level. Moreover the two methods are dependable on each other. Reducing the inlet temperature will also reduce the humidity ideally, but note that it is more difficult to reduce temperature of air at higher humidity than at lower humidity. Therefore whatever machine that is being implemented, that must be efficient enough to control both the parameters. The Machines that more the less perform our desired function are Evaporative coolers(Industrial use) Chiller Coils. In general, these are used for cooling in turbine functions and for house hold purposes in areas of desert. They can be used for Compressors with some primary changes involved in their fitting and functioning. They do not affect the working of the rest of the compressor in any way. Also its Safe and Environment friendly in their use.

EVAPORATIVE COOLERS:
What is Evaporative Cooling? An evaporative cooler (also swamp cooler, desert cooler and wet air cooler) is a device that cools air through the evaporation of water. Evaporative cooling differs from typical air conditioning systems which use vapourcompression or absorption refrigeration cycles. Evaporative cooling works by employing water's large enthalpy of vaporization. An evaporative cooler produces effective cooling by combining a natural process - water evaporation - with a simple, reliable air-moving system. Fresh outside air is pulled through moist pads where it is cooled by evaporation and circulated through a house or building by a large blower.

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Working of Evaporative Cooler: An evaporative cooler is essentially a large fan with water moistened pads in water-moistened front of it. The fan draws warm outside air through the pads and blows the now-cooled air cooled throughout the house. The pads can be made of wood shavings - wood from aspen trees is a traditional choice - or other materials that absorb and hold moisture while resisting mildew. Small distribution lines supply water to the top of the pads. Water soaks the pads and, thanks to gravity, trickles through them to collect in a sump at the bottom of the cooler. A small re circulating water pump sends the collected water back to the top of the pads. Since water is continually lost through evaporation, a float valve - much like the one that controls the water in a toilet tank - adds water to the sump when the level gets low. Under normal conditions, a swamp cooler can use between 3 to 15 gallons of water a day. A large fan draws air through the pads, where evaporation drops the temperature approximately 20 degrees. The fan then blows this cooled air. Small units can be installed in ventilation, blowing cooled air directly into a target. Implementation and Benefits of Evaporative cooler: Evaporative coolers are rated by the cubic feet per minute (cfm) of air that they deliver to the house. Most models range from 3,000 to 25,000 cfm. Manufacturers recommend providing enough air moving capacity for 20 air-moving 20 40 air changes per hour, depending on climate. The temperature of air coming out of an evaporative cooler obviously depends on the temperature and the humidity of the air going in.

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The chart shows that an evaporative cooler can deliver comfortable air under a wide variety of typical summertime temperature and humidity ranges. In addition to the dropping the temperature of the air, evaporative cooling offers an additional cooling benefit. The constant movement of the air created by the blower - the cooling breeze it creates, if you will - makes the room feel 4 to 6 degrees cooler than the actual temperature. r

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( * above mentioned air temperature is in Fahrenheit Scale) An added benefit of evaporative cooling is that it works best in the hottest time of the day. As the temperature outside increases as the sun climbs, the humidity normally drops. In the early morning, for example, the temperature may be 30C, with a relative humidity of 60 percent. By mid midafternoon, when the temperature has climbed to 40C, the humidity may well have dropped to 30 percent - conditions that make evaporative cooling work more effectively. Multi stage Evaporative coolers: Two stage evaporative coolers have been developed that pre cool air before it pre-cool goes through the moistened pad. The new coolers are reported to be as effective as air conditioning, but their initial cost is high, approximately the conditioning, same as air conditioning. The price may come down as more such systems are sold, but for the time being two stage systems are hard to find. two-stage Evaporative coolers are now on the market that uses photovolta photovoltaic panels to create the electricity used to run the blower and the water pump. For hot areas, the combination of evaporative cooling and solar power are a perfect match: the afternoon, when the most solar energy is available, is also the hottest part of the day, when cooling is most needed. And since swamp e coolers use a fraction of the energy of air conditioners, PV cells can provide enough electricity to run the system effectively.
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CHILLER:
What is a chiller? A chiller is a machine that removes heat from a liquid via a vapour vapourcompression or absorption refrigeration cycle. This liquid can then be cycle. circulated through a heat exchanger to cool air or equipment as required. Working of a Chiller. As airflow passes through the chilled coils, the air is cooled through an indirect heat exchange with the coo cooling fluid. The air then passes through drift eliminator media and into the turbine. The coils are cold and therefore condensation is created. Condensate droplets are directed downward and collected in pans, then directed out of the system. Typically, al Condensation is all eliminated this way, but to ensure air dryness, mist eliminator panels are in place to remove any stray condensate droplets. In the chiller, refrigerant flows through the coil that cools the chilled water. The chilled water is pumped through a piping loop to air handlers in the spaces to be

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cooled, where it absorbs heat from the air that flows over the air handling coil. The warmed up water then returns through the piping loop back to the chiller, where the heat it absorbed is released to the refrigerant flowing through the chillers evaporator. The chilled water circuit of a typical water chiller system will consist of a pump, cooling coils, expansion tank, and piping valves and controls, in a closed loop. The temperature of the chilled water supplied to the loop will depend on the set point of the chiller. The temperature in the spaces being cooled will be controlled by thermostats. Performance of a Chiller. The factors that affecting the operation of Chiller are total life cycle cost, the power source, chiller IP rating, chiller cooling capacity, evaporator capacity, evaporator material, evaporator type, condenser material, condenser capacity, ambient temperature, motor fan type. To maintain the chiller its fins and parts should stay clean enough to function well for many years. Using pre-filters to ensure the cleanliness and functionality of the coils will maximise its life span. For maximum performance, the design temperature of the air leaving the cooling system and entering the turbine is typically no less than 7C. The ambient air temp and the altitude at the site are the major factors used in sizing and designing a coil system. Cooling agents are usually either water or a water/glycol mix, depending on local ambient conditions.

Comparison between Chillers and Evaporative Coolers:

Evaporative cooler Advantages: Economical operation Uncomplicated System Chiller coils Advantages: Can cool the inlet air regardless of ambient humidity. Can be sized for small or large systems

Disadvantages: Disadvantages: Not preferred in areas with high Need source of chilled water humidity of air. Cause slightly higher Pressure Need source of make-up water. difference than an evaporative cooler does.
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CONCLUSION:
To increase the performance of CC, it can be provided with lighter air by reducing the humidity content in air, and cooler air by decreasing the inlet temperature. Machines that perform our desired function are Evaporative Coolers and Chillers. They do mild cooling with little humidity reduction (reduce air temperature by around 5C or so and dehumidify by around 10%). They also use lesser power than any other refrigeration equipment. In more humid conditions, Chiller coils are preferred to Evaporative coolers. Energy Savings comes in a noticeable amount for each method, and when combined it sums up. Therefore it is best for results when both the methods are in use simultaneously. This project elaborates about Centrifugal Compressor and Optimizing efficiency ways in a theoretical description and practical methods of implementation.

This report is Submitted by Sugan Durai Murugan and Suram Srikanth, and is illegal to copy and distribute.

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