Compressor presentation

1. BASIC COMPRESSOR’S WORKING
AND
OPERATION

2. COMPRESSOR
A device which convert low pressure low temperature air/gas into high pressure high temperature air/gas
COMPRESSOR TYPES
Basic two types of compressor
1)SECREW COMPRESSOR
2)RECIPROCATING COMPRESSOR
1)SECREW COMPRESSOR
Rotary Screw compressors use two meshing helical screws known as rotors to compress the air/gas
TYPES OF SECREW COMPRESSOR
1) SINGLE STAGE
2) TOW STAGE OR MULTISTAGE
Further divide screw compressor in more three type
a)Air cooled
b)Water cooled
c)Oil cooled

3. SECREW AIR COMPRESSOR PARTS
Compressor Elements 5:6
Air Filter (6micron)
Inter and After cooler

4. GEA SCREW COMPRESSOR PARTS
AXIAL BEARING
MECHANICAL SHAFT SEAL
Gas strainer
Inlet valve
Discharge valve
Screw
Oil sump
Oil strainer
Oil filter
Oil pump
Oil regulator
Mechanical seal
capacity control
bearing
etc.

5. RECIPROCATING COMPRESSOR
In reciprocating compressor piston is use to compress the air/gas
TYPES OF RECIPROCATING COMPRESSOR
Basic tow types of reciprocating compressor
( 1) Single stage (2) Tow stage or Multistage
further divide reciprocating compressor into two more types
a) Single acting reciprocating compressor (b) Double acting reciprocating compressor

6. RECIPROCATING COMPRESSOR PARTS
Gas strainer
Inlet valve
Discharge valve
Buffer spring
Cylinder
Cylinder liner
Cylinder head
Crank shaft
Big end bearing
Connecting rod
Small end bearing
Piston
Oil strainer
Oil filter
Oil pump
Oil regulator
Mechanical seal
Cylinder capacity
control
etc.

7. SPECIFICATION OF AIR COMPRESSOR
Model ZR-250 ZT-250 ZR-250 VSD
Capacity (Nm3/hr) 2400 m3/hr. 2400 m3/hr. 2400 m3/hr
Cooling media for air coolers Circuit water Air Circuit water
Cooling media for circuit water Chilled water Glycol water/child water
Pumps Motor Power capacity Head Pressure
Circuit water pump 1 ZR 3.0 kW 36 m3/hr. 16.3 m 1.63 bar
Circuit water pump 2 ZR 3.0 kW 24 – 54 m3/hr. 26.3 – 14.5 m 2.63 – 1.45 bar
Company: ATLAS COPCO
Type: 2-stage screw compressors
.

8. ZR-250 Air water and oil Circuit
(water cooled)
Ambient Air
Suction
(1 bar, 30 C)
Air filter
(dp<0.044 bar)
1st Element
Compression
(2 bar, 180 C)
Inter-Cooler
(1.9 bar, 30 C)
2nd Element
Compression
(8 bar, 160 C)
Post Cooler by
pass
(8 bar, 160 C)
Air Dryer
XD 1400 G
To process
Oil sump capacity : 80 liters
Oil temperature: 40 C
Oil pressure: 2bar (1.5 to3bar)

9. ZT-250
Air cooled/oil cooled
Ambient Air
Suction
(1 bar, 30 C)
Air filter
(dp<0.044 bar)
1st Element
Compression
(2 bar, 180 C)
Inter-Cooler
(1.9 bar, 30 C)
2nd Element
Compression
(8 bar, 160 C)
Post Cooler
(8 bar, 30 C)
Air Dryer
XD 1400 G
To process

10. AIR FLOW
Air drawn through filter (AF) is compressed in low-
pressure compressor element (El).
On ZR compressors, the compressed air is discharged
to intercooler (Ci).
The cooled air is further compressed in high-pressure
compressor element (Eh) and discharged through
silencer (AS) and after cooler (Ca).
On discharge line of high pressure compressor element
check valve (CV) is fitted downstream of the silencer.
The compressed air leaves the compressor via the air
outlet (AO).
NOTE: The regulator keeps the net pressure within
programmable pressure limits by automatically loading
and unloading the compressor depending on the air
consumption
1st compression
element
2nd compression
element

11. Cooling system for ZR compressors
The cooling water flows through oil cooler (Co), the
cooling jackets of high-pressure compressor element (Eh)
and low-pressure compressor element (El), as well as
through intercooler (Ci) and after cooler (Ca).
Condensate drain
Two moisture traps are installed: one downstream of
the intercooler (MTi) to prevent condensate from
entering in high pressure compressor element
and other downstream of the aftercooler (MTa) to
prevent condensate from entering the air outlet pipe.
 These moisture traps are connected to an EWD
(Electronic Water Drain).
Inter-cooler
after-cooler
Oil cooler
(brazed PHE)

12. OIL SYSTEM
Oil is circulated by pump (OP) from the sump of the
gear casing through cooler (Co). (PHE)
The oil passes through oil filters (OF) towards the
bearings and timing gears.
Bypass Valve (BV) opens if the oil pressure should rise
above a given value.
Oil pump
Oil filter

13. SAFETY TRIPPING
Condition action
Dp of suction air filter > 0.044
bar
Service required
Oil pressure drops to 1.5 bar Shutdown
Element 1 outlet temperature
 235 C
Shutdown
Element 2 inlet temperature 
80 C
Shutdown
Element 2 outlet temperature
 235 C
Shutdown
Oil temperature  80 C Shutdown
Low pressure safety valve (at 1st
element)
Opens at 3.7 bar
High pressure safety valve (at
2nd element)
Opens at 9.3 bar
GENERAL OPERATING PARAMETER

14. AIR COUSTOMER

15. GEA GRASSO RECIPROCATING COMPRESSOR
Model No. = Grasso V1400
No. of Cylinders = 8
Type of Compressor = Single Stage Reciprocating
Crank shaft rpm =1200
Maximum pressure =23~25 bar
Working medium=NH3(ammonia vapor)
Swept volume = 1273 M3/h
Capacity =948 kw =2844
Compressor drive pully dia =650 mm
Manufacturer = Grasso
Lubrication oil = MOBIL ARTIC 300
GEA FES SECREW COMPRESSOR
MODEL No M-5 Serial No M 0755
Hydraulic Test Pressure 620 psig Rotation C.W.
Max Design Working PR 23~27 bar
Type of compressor=single stage screw
Max RPM =4500rpm
swept Volume at 490cfm
working medium = NH3 (ammonia vapor)
capacity = 600kw+740 kw=1340 kw
Suction Line DN 125mm
Discharge line DN 80mm
Liquid injection ¾”
Lubrication oil = reflo XL
REFRIGERATION UNIT IN FCEPL SAHIWAL PLANT
The refrigeration unit in Utility section uses ammonia (NH3) as refrigerant and the
process is done according to the Vapor Compression Cycle of Refrigeration. The ice
water leaving this unit is at temperature of 1c~3c as per load

17. REFRIGERATION CYCLE
Actual Cycle
The actual vapor compression cycle practical vapor compression cycle
Compressor
Condenser Compressor
expender Condenser
evaporator High Pressure Tank
Expender
Low Pressure Tank
Ice Bank
Practical Cycle
Condenser
High Pressure Tank
Low Pressure
Tank
Ice Bank Compressor
Practical Vapors Compression Cycle
Condenser
Compressor
Expander
Evaporator
Actual Vapor Compression Cycle

18. FLOW DIAGRAM OF REFRIGERATION CYCLE
MOTOR
Motor power =250kw
Motor rpm =1485
Motor pulley diameter =500mm
COMPRESSOR
Compressor type =Grassov1400
Compressor crank shaft rpm = 1200
Maximum pressure=23to25bar
Working medium = NH3(vapors)
Swept volume = 1273 m3/h
Mechanical seal =85mm( bellow)
Seal id is =85mm
Seal od is =105 mm
Seal o ring size is =85x4mm
Compressor pulley diameter=650mm
V belt for transmission
power=XPB3750

19. ANY QUESTION
?
THANK YOU