The document discusses different types of compressors used to compress air or gas, including centrifugal, rotary, and reciprocating compressors. It then describes the operation and analysis of centrifugal and reciprocating compressors. Multistage compression is discussed as a way to increase pressure to over 300 KPa using multiple compressor stages separated by intercoolers to reduce temperature and save power compared to a single stage. The analysis shows that for ideal multistage compression with perfect intercooling, the work is equal at each stage and the total work is equal to the number of stages times the work of one stage.
A compressor is a type of machine that increases the pressure of a gas by reducing its volume. An air compressor is a specific type of gas compressor. Compressors helps to transport the fluid through a pipe maintaining the high pressure conditions. It is convers power (using and electrical motor, diesel or gasoline engine, etc.) into potential energy stored in pressurized air. The main and important types of gas compressors are illustrated and discussed below.
A compressor is a type of machine that increases the pressure of a gas by reducing its volume. An air compressor is a specific type of gas compressor. Compressors helps to transport the fluid through a pipe maintaining the high pressure conditions. It is convers power (using and electrical motor, diesel or gasoline engine, etc.) into potential energy stored in pressurized air. The main and important types of gas compressors are illustrated and discussed below.
Centrifugal Compressors
SECTION ONE - ANTI-SURGE PROTECTION AND THROUGHPUT REGULATION
0 INTRODUCTION
1 SCOPE
2 MACHINE CHARACTERISTICS
2.1 Characteristics of a Single Compressor Stage
2.2 Characteristic of a Multiple Stage Having More
Than One Impeller
2.3 Use of Compressor Characteristics in Throughput
Regulation Schemes
3 MECHANISM AND EFFECTS OF SURGE
3.1 Basic Flow Instabilities
3.2 Occurrence of Surge
3.3 Intensity of Surge
3.4 Effects of Surge
3.5 Avoidance of Surge
3.6 Recovery from Surge
4 CONTROL SCHEMES INCLUDING SURGE PROTECTION
4.1 Output Control
4.2 Surge Protection
4.3 Surge Detection and Recovery
5 DYNAMIC CONSIDERATIONS
5.1 Interaction
5.2 Speed of Response of Antisurge Control System
6 SYSTEM EQUIPMENT SPECIFICATIONS
6.1 The Antisurge Control Valve
6.2 Non-return Valve
6.3 Pressure and flow measurement
6.4 Signal transmission
6.5 Controllers
7 TESTING
7.1 Determination of the Surge Line
7.2 Records
8 INLET GUIDE VANE UNITS
8.1 Application
8.2 Effect on Power Consumption of the Compressor
8.3 Effect of Gas Conditions, Properties and Contaminants
8.4 Aerodynamic Considerations
8.5 Control System Linearity
8.6 Actuator Specification
8.7 Avoidance of Surge
8.8 Features of Link Mechanisms
8.9 Limit Stops and Shear Links
APPENDICES
A LIST OF SYMBOLS AND PREFERRED UNITS
B WORKED EXAMPLE 1 COMPRESSOR WITH VARIABLE INLET PRESSURE AND VARIABLE GAS COMPOSITION
C WORKED EXAMPLE 2 A CONSTANT SPEED ~ STAGE COMPRESSOR WITH INTER-COOLING
D WORKED EXAMPLE 3 DYNAMIC RESPONSE OF THE ANTISURGE PROTECTION SYSTEM FOR A SERVICE AIR COMPRESSOR RUNNING AT CONSTANT SPEED
E EXAMPLE OF INLET GUIDE VANE REGULATION
FIGURES
2.1 TYPICAL COMPRESSOR STAGE CHARACTERISTIC PLOTTED WITH FLOW AT DISCHARGE CONDITIONS
2.2 TYPICAL COMPRESSOR STAGE CHARACTERISTIC PLOTTED WITH FLOW AT INLET CONDITIONS
2.3 PERFORMANCE CHARACTERISTICS OF A COMPRESSOR STAGE AT VARYING SPEEDS
2.4 SYSTEM WORKING POINT DEFINED BY INTERSECTION OF PROCESS AND COMPRESSOR CHARACTERISTICS
2.5 DISCHARGE THROTTLE REGULATION
2.6 BYPASS REGULATION
2.7 INLET THROTTLE REGULATION
2.8 INLET GUIDE VANE REGULATION
2.9 VARIABLE SPEED REGULATION
3.1 GAS PULSATION LEVELS FOR A CENTRIFUGAL COMPRESSOR
3.2 REPRESENTATION OF CYCLIC FLOW DURING SURGE OF LONG PERIOD
3.3 TYPICAL WAVEFORM OF DISCHARGE PRESSURE DURING SURGE
3.4 MULTIPLE SURGE LINE FOR A MULTISTAGE CENTRIFUGAL COMPRESSOR
3.5 TYPICAL MULTIPLE SURGE LINES FOR SINGLE STAGE AXIAL-FLOW COMPRESSOR
4.1 GENERAL SCHEMATIC FOR COMPRESSORS OPERATING IN PARALLEL TO FEED MULTIPLE USER PLANTS
4.2 ILLUSTRATION OF SAFETY MARGIN BETWEEN SURGE POINT AND SURGE PROTECTION POINT AT WHICH ANTISURGE SYSTEM IS ACTIVATED
4.3 ANTISURGE SYSTEM FOR COMPRESSOR WITH FLAT PERFO ..........
Engineering Thermodynamics-second law of thermodynamics Mani Vannan M
This file consists of content which covers the basics of second law of thermodynamics,heat reservoir,heat source ,heat sink,refrigerator, heat pump,heat engine,carnot theorem,carnot cycle and reversed carnot cycle
ABSTRACT
Heat/light/electrical energy is out today’s necessity and has scarcity also. Energy conservation is key requirement of any industry at all times.
In general, industries use heat energy for conservation of raw material to finished product. The source of heat energy is generally saturated or super heated steam. The steam generation is common use one boiler with carity of fuels. Whatever may be the fuel the generation should be as economy as possible which adds to the product cost. Further the usage of steam and recycling steam condensate back to boiler is an art depending on plant layouts.
In this project the steam generator is water tube boiler fired with rice husk. The steam is transferred to the tyre/tube moulds where tyres/tubes are cured while the heat is rejected to the tyres the condensate forms and this condensate is put back to the boiler. While doing so the steam is also stopped back to boiler without rejecting complete heat to the product. This gets flashed into atmosphere at feed water tank. The science of separation of condensate from steam saves energy. Better the separation more the fuel conservation.
In the steam generator the fuel is burnt to heat the water and form steam. This fuel burnt flue gas carries lot of energy, out through chimney. Prior to exhausting through the heat left in flue need to be recovered, through heat recovery mechanisms’. In this project an air-preheater condensate heat recovery unit is the major energy consuming station.
Design Considerations for Plate Type Heat ExchangerArun Sarasan
A plate heat exchanger is a type of heat exchanger that uses metal plates to transfer heat between two fluids. This has a major advantage over a conventional heat exchanger in that the fluids are exposed to a much larger surface area because the fluids spread out over the plates. This facilitates the transfer of heat, and greatly increases the speed of the temperature change. Plate heat exchangers are now common and very small brazed versions are used in the hot-water sections of millions of combination boilers. The high heat transfer efficiency for such a small physical size has increased the domestic hot water (DHW) flowrate of combination boilers. The small plate heat exchanger has made a great impact in domestic heating and hot-water. Larger commercial versions use gaskets between the plates, whereas smaller versions tend to be brazed.
Centrifugal Compressors
SECTION ONE - ANTI-SURGE PROTECTION AND THROUGHPUT REGULATION
0 INTRODUCTION
1 SCOPE
2 MACHINE CHARACTERISTICS
2.1 Characteristics of a Single Compressor Stage
2.2 Characteristic of a Multiple Stage Having More
Than One Impeller
2.3 Use of Compressor Characteristics in Throughput
Regulation Schemes
3 MECHANISM AND EFFECTS OF SURGE
3.1 Basic Flow Instabilities
3.2 Occurrence of Surge
3.3 Intensity of Surge
3.4 Effects of Surge
3.5 Avoidance of Surge
3.6 Recovery from Surge
4 CONTROL SCHEMES INCLUDING SURGE PROTECTION
4.1 Output Control
4.2 Surge Protection
4.3 Surge Detection and Recovery
5 DYNAMIC CONSIDERATIONS
5.1 Interaction
5.2 Speed of Response of Antisurge Control System
6 SYSTEM EQUIPMENT SPECIFICATIONS
6.1 The Antisurge Control Valve
6.2 Non-return Valve
6.3 Pressure and flow measurement
6.4 Signal transmission
6.5 Controllers
7 TESTING
7.1 Determination of the Surge Line
7.2 Records
8 INLET GUIDE VANE UNITS
8.1 Application
8.2 Effect on Power Consumption of the Compressor
8.3 Effect of Gas Conditions, Properties and Contaminants
8.4 Aerodynamic Considerations
8.5 Control System Linearity
8.6 Actuator Specification
8.7 Avoidance of Surge
8.8 Features of Link Mechanisms
8.9 Limit Stops and Shear Links
APPENDICES
A LIST OF SYMBOLS AND PREFERRED UNITS
B WORKED EXAMPLE 1 COMPRESSOR WITH VARIABLE INLET PRESSURE AND VARIABLE GAS COMPOSITION
C WORKED EXAMPLE 2 A CONSTANT SPEED ~ STAGE COMPRESSOR WITH INTER-COOLING
D WORKED EXAMPLE 3 DYNAMIC RESPONSE OF THE ANTISURGE PROTECTION SYSTEM FOR A SERVICE AIR COMPRESSOR RUNNING AT CONSTANT SPEED
E EXAMPLE OF INLET GUIDE VANE REGULATION
FIGURES
2.1 TYPICAL COMPRESSOR STAGE CHARACTERISTIC PLOTTED WITH FLOW AT DISCHARGE CONDITIONS
2.2 TYPICAL COMPRESSOR STAGE CHARACTERISTIC PLOTTED WITH FLOW AT INLET CONDITIONS
2.3 PERFORMANCE CHARACTERISTICS OF A COMPRESSOR STAGE AT VARYING SPEEDS
2.4 SYSTEM WORKING POINT DEFINED BY INTERSECTION OF PROCESS AND COMPRESSOR CHARACTERISTICS
2.5 DISCHARGE THROTTLE REGULATION
2.6 BYPASS REGULATION
2.7 INLET THROTTLE REGULATION
2.8 INLET GUIDE VANE REGULATION
2.9 VARIABLE SPEED REGULATION
3.1 GAS PULSATION LEVELS FOR A CENTRIFUGAL COMPRESSOR
3.2 REPRESENTATION OF CYCLIC FLOW DURING SURGE OF LONG PERIOD
3.3 TYPICAL WAVEFORM OF DISCHARGE PRESSURE DURING SURGE
3.4 MULTIPLE SURGE LINE FOR A MULTISTAGE CENTRIFUGAL COMPRESSOR
3.5 TYPICAL MULTIPLE SURGE LINES FOR SINGLE STAGE AXIAL-FLOW COMPRESSOR
4.1 GENERAL SCHEMATIC FOR COMPRESSORS OPERATING IN PARALLEL TO FEED MULTIPLE USER PLANTS
4.2 ILLUSTRATION OF SAFETY MARGIN BETWEEN SURGE POINT AND SURGE PROTECTION POINT AT WHICH ANTISURGE SYSTEM IS ACTIVATED
4.3 ANTISURGE SYSTEM FOR COMPRESSOR WITH FLAT PERFO ..........
Engineering Thermodynamics-second law of thermodynamics Mani Vannan M
This file consists of content which covers the basics of second law of thermodynamics,heat reservoir,heat source ,heat sink,refrigerator, heat pump,heat engine,carnot theorem,carnot cycle and reversed carnot cycle
ABSTRACT
Heat/light/electrical energy is out today’s necessity and has scarcity also. Energy conservation is key requirement of any industry at all times.
In general, industries use heat energy for conservation of raw material to finished product. The source of heat energy is generally saturated or super heated steam. The steam generation is common use one boiler with carity of fuels. Whatever may be the fuel the generation should be as economy as possible which adds to the product cost. Further the usage of steam and recycling steam condensate back to boiler is an art depending on plant layouts.
In this project the steam generator is water tube boiler fired with rice husk. The steam is transferred to the tyre/tube moulds where tyres/tubes are cured while the heat is rejected to the tyres the condensate forms and this condensate is put back to the boiler. While doing so the steam is also stopped back to boiler without rejecting complete heat to the product. This gets flashed into atmosphere at feed water tank. The science of separation of condensate from steam saves energy. Better the separation more the fuel conservation.
In the steam generator the fuel is burnt to heat the water and form steam. This fuel burnt flue gas carries lot of energy, out through chimney. Prior to exhausting through the heat left in flue need to be recovered, through heat recovery mechanisms’. In this project an air-preheater condensate heat recovery unit is the major energy consuming station.
Design Considerations for Plate Type Heat ExchangerArun Sarasan
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Compressor
1. Air or Gas Compressors: A steady-state, steady flow machine that is used to compressed air or gas to final pressure exceeding 241.25 Kpa gage. Types of Compressor: 1. Centrifugal Compressors: For low pressure and high capacity applications. 2. Rotary Compressors: For medium pressure and low capacity application. 3. Reciprocating Compressors: For high pressure and low capacity application. Uses of compressed air: 1. Operation of small engines 2. Pneumatic tools 3. Air hoists 4. Industrial cleaning by air blast 5. Tire inflation 6. Paint Spraying
2.
3. Where: m – mass flow rate in kg/sec C p – constant pressure specific heat in KJ/kg- C or KJ/kg- K
5. 3. Isothermal Compression: PV = C Analysis of Reciprocating Type Compressor (Piston-in-cylinder type): piston Valves cylinder Piston rod P V P 2 P 1 PV = C
6. Pressure-Volume Diagram (PV) HE – head end CE – Crank end L – length of stroke P 1 – suction pressure P 2 – discharge pressure V 1’ – volume flow rate at intake V D – displacement volume CV D – clearance volume CV D = V 3 V D L HE CE P V 1 2 3 4 P 2 P 1 V 1’ V D CV D
7. 1. Isentropic Compression: PV k = C Where: V1’ – volume flow rate at intake, m 3 /sec m – mass flow rate corresponding V 1’ P 1 – suction pressure, Kpa P 2 – discharge pressure, Kpa T 1 – suction temperature, K T 2 – discharge temperature, K W – work, KW 2. Polytropic Compression: PV n = C
8. 3. Isothermal Compression: PV = C Percent Clearance : Ratio of the clearance volume to the displacement volume. Note: For compressor design values of C ranges from 3 to 10 percent.
9. Pressure Ratio: Ratio of the discharge pressure to suction pressure. Volumetric Efficiency: Ratio of the volume flow rate at intake to the displacement volume. 1. For Isentropic Compression and Expansion process: PV k = C
10. 2. For Polytropic Compression and Expansion process: PV n = C 2. For Isothermal Compression and Expansion process: PV = C Actual Volumetric Efficiency : Ratio of the actual volume of air drawn in by the compressor to the displacement volume.
11. For an air compressor handling ambient air where pressure drop and heating of air occurs due to fluid friction and irreversibilities of fluid flow, less amount of air is being drawn by the cylinder. The actual volumetric efficiency is: Where: P O – ambient air pressure in Kpa T O – ambient air temperature in K Displacement Volume: Volume of air occupying the highest stroke L of the piston within the cylinder. The length of stroke L is the dis- tance from the HE (head end) to the CE (crank end).
12.
13. Where: D – diameter of piston in meters d – diameter of piston rod in meters N – no. of RPM n’ – no. of cylinders Piston Speed : It is the linear speed of the piston. Compressor Performance Factor: 1. Compression Efficiency: Ratio of Ideal Work to Indicated Work.
14. 2. Mechanical Efficiency: Ratio of Indicated Work to Brake or Shaft Work. 3. Compressor Efficiency: Ratio of Ideal Work to Brake or Shaft Work.
15. MULTISTAGE COMPRESSION: Multi staging is simply the compression of air or gas in two or more cylinders in place of a single cylinder compressor. It is used in reciprocating compressors when pressure of 300 KPa and above are desired, in order to: 1) Save power 2) Limit the gas discharge temperature 3) Limit the pressure differential per cylinder 4) Prevent vaporization of lubricating oil and to prevent its ignition if the tem- perature becomes too high. It is a common practice for multi-staging to cool the air or gas between stages of compression in an intercooler, and it is this cooling that affects considerable saving in power.
16. For an ideal multistage compressor, with perfect inter-cooling and minimum work, the cylinder were properly designed so that: a) the work at each stage are equal b) the air in the intercooler is cooled back to the initial temperature c) no pressure drop occurs in the intercooler 2 Stage Compressor without pressure drop in the intercooler : 1 2 3 4 Suction Discharge Qx Intercooler 1 st stage 2 nd stage
17. Work of 1 st stage cylinder ( W 1 ) : Assuming Polytropic compression on both stages. Work of 2 nd stage cylinder ( W 2 ) : Assuming Polytropic compression on both stages.
18. For perfect inter-cooling and minimum work: W 1 = W 2 T 1 = T 3 W = W 1 + W 2 W = 2W 1 P 2 = P 3 = P x therefore P 1 V 1’ = P 3 V 3’ Where: Px – optimum intercooler pressure or interstage pressure P V P 4 P 1 P x 1 4 3 2 5 6 7 8 PV n = C W 1 W 2 S T 4 3 2 1 P 4 P x P 1 Q x
19.
20. With pressure drop in the intercooler: T 1 T 3 and P 2 P 3 W = W 1 + W 2 P 1 V 1’ P 3 V 3’ 2 Stage Compressor with pressure drop in the intercooler : 1 2 3 4 Suction Discharge Qx Intercooler 1 st stage 2 nd stage
21. P V P 4 P 1 P 3 1 4 3 2 5 6 7 8 PV n = C W 1 W 2 S T 4 3 2 1 P 4 P 1 Q x P 2 P 2 P 3 3 Stage Compressor without pressure drop in the intercooler : 1 2 3 4 Suction Discharge Qx LP Intercooler 1 st stage 2 nd stage 3 rd stage 5 6 Qy HP Intercooler
22. S T 4 3 2 1 P 6 P x P 1 Q x P y 5 6 Q y For perfect inter-cooling and minimum work: T 1 = T 3 = T 5 P x = P 2 = P 3 W 1 = W 2 = W 3 P y = P 4 = P 5 W = 3W1 P 1 V 1’ = P 3 V 3’ = P 5 V 5’ mRT 1 = mRT 3 = mRT 5 Therefore: r P1 = r P2 = r P3 P V P 6 P 1 P x 1 4 3 2 5 6 7 12 PV n = C W 1 W 2 P y 9 10 11 8 W 3
23. Work for each stage: 1 st Stage: 2 nd Stage: 3 rd Stage: Intercooler Pressures:
24.
25. For multistage compression with minimum work and perfect inter-cooling and no pressure drop that occurs in the inter-coolers between stages, the following conditions apply: 1. the work at each stage are equal 2. the pressure ratio between stages are equal 3. the air temperature in the inter-coolers are cooled to the original temperature T 1 4. the total work W is equal to Where: s – is the number of stages. Note: For multistage compressor with pressure drop in the intercoolers the equation of W above cannot be applied. The total work is equal to the sum of the work for each stage that is computed separately.