AIF Product Presentation India - July 2000

AIF Product presentation India - July 2000
AGENDA
 COMPRESSOR TYPES
 WORKING PRINCIPLES
 CHARACTERISTICS
 CONTROL SYSTEMS
 STAGING
 GENERAL INFORMATION

AGENDA
 CHARACTERISTICS
 CONTROL SYSTEMS
 STAGING

COMPRESSOR TYPES
The basic principals of air or gas compression

COMPRESSOR TYPES
Two Basic Principals of Air or Gas Compression
Compressors
Positive Displacement Dynamic Compression

AGENDA
 CHARACTERISTICS
 CONTROL SYSTEMS
 STAGING

WORKING PRINCIPLES
Compressors

WORKING PRINCIPLES
Positive
displacement
principle
Reducing the volume of

a gas increases its pressure

WORKING PRINCIPLES
Oil Free Rotary Screw Element Design

WORKING PRINCIPLES
The Positive Displacement

Principle As
Applies To Screw
The volume of the air or gas is

progressively reduced along the length of
the screw,causing a pressure increase.

WORKING PRINCIPLES
Compressors

WORKING PRINCIPLES
DYNAMIC COMPRESSOR
 Dynamic Principle
Velocity (Kinetic Energy)

1/2 mv 2
converted to pressure

WORKING PRINCIPLES
CENTRIFUGAL COMPRESSORS
RADIAL DIFFUSERS
PRESSURE CUTS
FLOW CUTS
VANES
INDUCER
PRESSURE INCREASE FOLLOWS THE PRINCIPLE OF BERNOULLI
2
P V

WORKING PRINCIPLES
A CENTRIFUGAL IMPELLER

WORKING PRINCIPLES
WORKING PRINCIPLE
Blade
 Wheel turns
 Speed of the ball increases
 Speed suddenly reduced to
create pressure increase
DIFFUSER

CENTRIFUGAL COMPRESSOR GENERAL
ARRANGEMENT

THE RIGHT CHOICE
 CHARACTERISTICS
 CONTROL SYSTEMS
 STAGING
GENESIS OF SCREW COMPRESSORS
 IN THE 1930S COMPRESSED AIR AND GAS USERS HAD TWO MAIN OPTIONS RECIPS AND CENTRIFUGALS
• RECIPS WERE POSITIVE DISPL. M/CS WHICH WERE :
– THERMODYNAMICALLY STABLE AND POWER SAVING BUT
– REQUIRED EXPENSIVE INSTALLATION AND FOUNDATIONS
– WERE MAINTENANCE INTENSIVE - EXPENSE/DOWNTIME
– CAPACITY FELL WITH USE
– LIMITED USE WITH DIRTY GASES
• CENTRIFUGALS WERE LESS MAINTENANCE INTENSIVE BUT
– REQUIRED EXPENSIVE INSTALLATION AND FOUNDATIONS
– WERE THERMODYNAMICALLY UNSTABLE
– OPERATING BAND WAS LIMITED
– SENSITIVE TO DUST AND UNSUITABLE FOR DIRTY GASES
– CAPACITY FELL EVEN WITH A FEW MICRON DUST BUILDUP

GENESIS OF SCREW COMPRESSORS II
PROFESSOR LYSHOLM OF THE ROYAL SWEDISH INSTITUTE OF SCIENCE DOING

RESEARCH ON COMPRESSORS SET ABOUT FINDING AN IDEAL SYSTEM ON THE FOLLOWING
HYPOTHESIS :
 TO OVERCOME WEAKNESSES OF THE RECIPS HIS DREAM MACHINE HAD TO BE A ROTARY

WITH NO METAL CONTACT
 TO OVERCOME DISADVANTAGES OF CENTRIFUGALS IT HAD TO BE A POSITIVE DISPLACEMENT

MACHINE
THUS WAS BORN THE IDEA OFTHE ROTARY SCREW WHICH COMBINED THERMODYNAMIC AND
OPERATIONAL STABILITY AND LOW POWER CONSUMPTION
WITH UN PARALLELED RELIABIITY

GENESIS OF SCREW COMPRESSORS III
 ATLAS COPCO DREW ON THIS BASIC IDEA AND AFTER INTENSIVE RESEARCH COMMERCIALLY
INTRODUCED THE U SERIES IN 1957. MANY OF THESE MACHINES ARE STILL OPERATING THE
WORLD OVER
 IN THE 1970S THE ATLAS COPCO RESEARCH CENTRE THE CERAC I NSTITUTE IN GENEVA
DESIGNED AND PATENTED A REVOLUTIONARY ASSYMETRIC SCREW PROFILE WHICH IS CURRENTLY
USED IN THE G AND Z SERIES MACHINES
 IN THE WORLD TODAY 9 OUT OF 10 MACHINES PRODUCED AND SOLD IN THEIR RANGE ARE ROTARY
SCREWS

COMPRESSOR CHARACTERISTICS
Performance
curves
PRESSURE
DYNAMIC
COMPRESSOR
POSITIVE
DISPLACEMENT
COMPRESSOR
CAPACITY

Centrifugal and Screw compressor characteristics
OIL FREE SCREW

P
R SURGE LIMIT SURGE CONTROL LINE
E
AT 25°C 1 BAR A
S
S
BLOW OFF RANGE
U
R AT 40°C 0.97 BAR A
E
60 85 100 FLOW
P
O
W OIL FREE SCREW
E
R
FLOW

Inlet throttle valve

DYNAMIC MACHINES- OPERATING BAND
Pressure
Surge
Stonewall
Flow

COMPRESSOR CHARACTERISTICS- DYNAMIC MACHINES
A DYNAMIC COMPRESSOR OPERATES IN A BAND

BETWEEN
SURGE
Breakdown of airflow due to high back pressure
(oscillation flow)
AND
STONE WALL (choke)

Maximum flow a compressor can handle at a given speed

COMPRESSOR CHARACTERISTICS-Displacement compressors
Variables influencing compressor performance

n-1
n
P n
Power P = P1 . V1 . {( 2 ) -1 }
P1 n-1
Inlet air temperature and weight flow (density) have no effect on power
Where: P : Power
P1 : Inlet pressure
V1 : Inlet volume Variables influencing power:
n : Adiabatic factor P1 = Inlet pressure
P2/P1 : Pressure ratio V1 = Volume flow (not mass!)
P2/P1 = Pressure ratio

COMPRESSOR CHARACTERISTICS-Dynamic compressors
Variables influencing compressor performance
Hp . m
Power P = h
is
There are three variables that affect
Where: Hp : Head pressure the power:
m : Mass flow T : Inlet temperature
his : Isentropic efficiency m : Mass flow
P2/P1 : Pressure ratio
Mass flow in winters increases and hence high power consumption

Dynamic machines - Effect of speeds
A Dynamic machine develops pressure proportional to the square of the velocity reduction
It follows that
Reduced impeller speeds cause pressure reduction according to
2
P S
Hence due to a frequency drop of 3% outlet pressure reduces by 6% per stage
(18% for a 3 stage machine)

Thermodynamic instability - Dynamic machines
Thermodynamic instability can hence be interpreted as :
 Pressure and volume are inversely related.Pressure increase reduces volume
 Lower air inlet temperature :
- Same volume flow with higher power
- Higher mass flow
- Higher pressure possibilities
 Lower speeds cause very low pressures.
 The machine operates in a narrow band ( Between surge and stone wall)
 The system is prone to surge due to pressure drops

THE RIGHT CHOICE
 CHARACTERISTICS
 CONTROL SYSTEMS
 STAGING
Compressor Control
Most industrial processes require a varying amount of air

The changes in air demand can be due to:
•Extent of plant utilization
-Time of the day or the day of the week
-Degree of maturity of the process
•Large consumers of air with intermittent demands (Forging hammers,Presses,etc)
•Mass dependent processes such as air separation
•Or simply because the air demand is over-estimated
The compressor therefore requires a control system to regulate the air

generation of the compressor in direct relation to the demand

TYPICAL AIR DEMAND PATTERNS
MONDAY
TUESDAY
WEDNESDAY
THURSDAY
FRIDAY
AIR DEMAND
SATURDAY
SUNDAY
HOURS

Screw Compressor Controls-Modulation Control
In a modulation control a butterfly valve regulates the intake
Full load Part load
•Butterfly valve is fully open with full flow of air •Restriction at the inlet (Vacuum)
•Compressor operates at the built-in pressure ratio •Outlet pressure remains the same(air net pressure)
Vacuum prevails
Intake 1 Bar A Intake 0,5 bar A *
SCREW
ELEMENT
Outlet 8 Bar A Outlet 8 Bar A
Pressure ratio = 8 Pressure ratio = 16 Higher than the

BIPR,hence inefficient at part loads
* Figures are used for concept demonstration only

Screw Compressor controls
Load-no load regulation
•In a load-no load control the machine runs either fully loaded or unloaded
•In the loaded condition,the intake valve is fully open and hence the machine
operates at the BIPR
•In the unloaded condition,the intake valve is fully closed and the element is isolated
from the Air-net.
•Hence part load power comes down dramatically and the machine operates
efficiently even at part loads

Screw Compressor Controls
Variable speed drives
In a variable speed control the speed of the machine is continuously adjusted in line with the demand
Schematic:
MOTOR VSD P/ I convertor
Compressor
C Outlet
•P to I convertor senses pressure and generates a proportional 4-20 mA signal

•This current signal is used by the VSD to alter the frequency to the electric motor
•The electric motor speed varies as a function of the frequency
•Variable speed drives constitutes the most efficient compressor control

Screw Compressor Controls
A Comparison
VARIABLE SPEED
CONTROL

Dynamic Compressor Control
P SURGE LIMIT SURGE CONTROL

R
E
S
S
U
R
E
60 85 100 FLOW
DEMAND FALLS BELOW DEMAND IS ABOVE

SURGE CONTROL SURGE CONTROL
2 SCENARIOS:
•CONTROL ABOVE SURGE CONTROL
•CONTROL BELOW SURGE CONTROL

Dynamic Compressor Controls
Control above surge control line
Inlet Throttle Valve Inlet Guide Vane

ZH-series
Efficient centrifugal compressors
Adjustable inlet guide vanes
provide a pre whirl to the air
150
or gas,smoothly controlling
capacity without any
Pressure %
turbulence unlike the

throttle valve
100
Plant demand
Inlet throttle valve

100 at 100% pressure
9%energy
90 Inlet guide vanes
savings at part load
at 100% pressure
80
Power %
Energy savings
70
60 70 80 90 100 110
Capacity %
Dynamic Compressor Controls
Control below Surge control line
Auto Dual control Modulated Blow-Off Control

Pressure
Volume flow
Re-loading time is long,calling for huge Entails blow-off at partial loads,thus

stored capacities to protect the process wasting energy

BEARING CONFIGURATIONS
DYNAMIC MACHINES
JOURNAL SHAFT
SIMPLE TILTING PAD TILTED PAD
•Turbo machines operate above critical speeds and hence need sleeve bearings,which support the
rotating shaft on an oil film.Starting and stopping,frequent load changes and vibrations cause
thinning of the oil film (Film Dispersion)
•Hence Loading Unloading cycles have to be strictly controlled and spaced out for effective
protection of the compressor.

THE FLEXIPAD BEARINGS
Tilting pad or flexi pad bearings

offer better dampening
characteristics as compared to
the fixed geometry bearings

THE RIGHT CHOICE
 CHARACTERISTICS
 CONTROL SYSTEMS
 STAGING
Staging of turbo machines
Safety Considerations
THE NUMBER OF STAGES IS DEDUCED AS FOLLOWS :
 With17-4 PH SS as impeller material,the max.tip speed is 450 m/s
 When using 45 Deg impellers,this is attained at a PR of 2,1 per stage.
 Hence a 2 stage machine should not run beyond 3,4 bar.
 And a 3 stage can achieve upto 8,2 bar upto the safe limits.
 Exceeding maximum tip speeds entail serious risks of impeller breakage

Staging of turbo machines
Efficiency Considerations
mechanical
efficiency
aerodynamic
efficiency
total efficiency
FACTORS DETERMINING
AERODYNAMIC EFFECIENCY ARE
SPECIFIC SPEEDS
MACH NUMBERS
number of stages REYNOLDS NUMBERS
CURVE CORRESPONDS TO 7-8 BAR OPERATION

THE RIGHT CHOICE
 CHARACTERISTICS
 CONTROL SYSTEMS
 STAGING
Impeller performance
characteristics
90° 70° 45°

Impeller
performance
characteristics 45°
90°
% RELATIVE PRESSURE
70°
50°
At the same relative

tip speed, each impeller
will have a basic operating
characteristic as shown
% RELATIVE FLOW 100%

Impeller
performance C2
characteristics W2
ß2
U2
Cu2

Impeller C2
performance ß2 W2
U2
characteristics
Cu2


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AIF Product presentation India - July 2000