AIF Product presentation India - July 2000

AGENDA

 COMPRESSOR TYPES

 WORKING PRINCIPLES

 CHARACTERISTICS

 CONTROL SYSTEMS

 STAGING

 GENERAL INFORMATION

AIF Product presentation India - July 2000

AIF Product presentation India - July 2000
 AGENDA

 COMPRESSOR TYPES

 WORKING PRINCIPLES

 CHARACTERISTICS

 CONTROL SYSTEMS

 STAGING

 GENERAL INFORMATION

AIF Product presentation India - July 2000

 COMPRESSOR TYPES
The basic principals of air or gas compression

AIF Product presentation India - July 2000

 COMPRESSOR TYPES

Two Basic Principals of Air or Gas Compression

Compressors

Positive Displacement Dynamic Compression

AIF Product presentation India - July 2000

 AGENDA

 COMPRESSOR TYPES

 WORKING PRINCIPLES

 CHARACTERISTICS

 CONTROL SYSTEMS

 STAGING

 GENERAL INFORMATION

AIF Product presentation India - July 2000

 WORKING PRINCIPLES

Two Basic Principals of Air or Gas Compression

Compressors

Positive Displacement Dynamic Compression

AIF Product presentation India - July 2000

 WORKING PRINCIPLES

Positive
displacement
principle

Reducing the volume of

a gas increases its pressure

AIF Product presentation India - July 2000

 WORKING PRINCIPLES

Oil Free Rotary Screw Element Design

AIF Product presentation India - July 2000

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.

AIF Product presentation India - July 2000

 WORKING PRINCIPLES

Two Basic Principals of Air or Gas Compression

Compressors

Positive Displacement Dynamic Compression

AIF Product presentation India - July 2000

 WORKING PRINCIPLES

DYNAMIC COMPRESSOR

 Dynamic Principle

Velocity (Kinetic Energy)

1/2 mv 2
converted to pressure

AIF Product presentation India - July 2000

 WORKING PRINCIPLES

CENTRIFUGAL COMPRESSORS

RADIAL DIFFUSERS
PRESSURE CUTS

FLOW CUTS
VANES

INDUCER

PRESSURE INCREASE FOLLOWS THE PRINCIPLE OF BERNOULLI

2
P V

AIF Product presentation India - July 2000

WORKING PRINCIPLES

A CENTRIFUGAL IMPELLER

AIF Product presentation India - July 2000

 WORKING PRINCIPLES

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

DIFFUSER

AIF Product presentation India - July 2000

CENTRIFUGAL COMPRESSOR GENERAL
ARRANGEMENT

AIF Product presentation India - July 2000

 THE RIGHT CHOICE

 COMPRESSOR TYPES

 WORKING PRINCIPLES

 CHARACTERISTICS

 CONTROL SYSTEMS

 STAGING

 GENERAL INFORMATION
AIF Product presentation India - July 2000
 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

AIF Product presentation India - July 2000

 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

AIF Product presentation India - July 2000

 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

AIF Product presentation India - July 2000

 COMPRESSOR CHARACTERISTICS

Performance
curves

PRESSURE
DYNAMIC
COMPRESSOR

POSITIVE
DISPLACEMENT
COMPRESSOR

CAPACITY

AIF Product presentation India - July 2000

 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

AIF Product presentation India - July 2000

Inlet throttle valve

AIF Product presentation India - July 2000

DYNAMIC MACHINES- OPERATING BAND

Pressure
Surge

Stonewall

Flow

AIF Product presentation India - July 2000

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

AIF Product presentation India - July 2000

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

AIF Product presentation India - July 2000

 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

AIF Product presentation India - July 2000

 COMPRESSOR CHARACTERISTICS
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)

AIF Product presentation India - July 2000

 COMPRESSOR CHARACTERISTICS
Thermodynamic instability - Dynamic machines

Thermodynamic instability can hence be interpreted as :

 Pressure and volume are inversely [Link] 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

AIF Product presentation India - July 2000

 THE RIGHT CHOICE

 COMPRESSOR TYPES

 WORKING PRINCIPLES

 CHARACTERISTICS

 CONTROL SYSTEMS

 STAGING

 GENERAL INFORMATION
AIF Product presentation India - July 2000
 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

AIF Product presentation India - July 2000

 TYPICAL AIR DEMAND PATTERNS

MONDAY
TUESDAY
WEDNESDAY
THURSDAY
FRIDAY
AIR DEMAND

SATURDAY
SUNDAY

HOURS

AIF Product presentation India - July 2000

 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

AIF Product presentation India - July 2000

 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

AIF Product presentation India - July 2000

 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

AIF Product presentation India - July 2000

 Screw Compressor Controls
A Comparison

VARIABLE SPEED
CONTROL

AIF Product presentation India - July 2000

 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

AIF Product presentation India - July 2000

 Dynamic Compressor Controls
Control above surge control line

Inlet Throttle Valve Inlet Guide Vane

AIF Product presentation India - July 2000

 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

AIF Product presentation India - July 2000

 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 [Link] 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.

AIF Product presentation India - July 2000

THE FLEXIPAD BEARINGS

Tilting pad or flexi pad bearings

offer better dampening
characteristics as compared to
the fixed geometry bearings

AIF Product presentation India - July 2000

 THE RIGHT CHOICE

 COMPRESSOR TYPES

 WORKING PRINCIPLES

 CHARACTERISTICS

 CONTROL SYSTEMS

 STAGING

 GENERAL INFORMATION
AIF Product presentation India - July 2000
 Staging of turbo machines
Safety Considerations

THE NUMBER OF STAGES IS DEDUCED AS FOLLOWS :

 With17-4 PH SS as impeller material,the [Link] 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

AIF Product presentation India - July 2000

 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

AIF Product presentation India - July 2000

 THE RIGHT CHOICE

 COMPRESSOR TYPES

 WORKING PRINCIPLES

 CHARACTERISTICS

 CONTROL SYSTEMS

 STAGING

 GENERAL INFORMATION
AIF Product presentation India - July 2000
Impeller performance
characteristics

90° 70° 45°

AIF Product presentation India - July 2000

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%

AIF Product presentation India - July 2000
Impeller
performance C2
characteristics W2
ß2
U2

Cu2

AIF Product presentation India - July 2000

Impeller C2
performance ß2 W2
U2
characteristics

Cu2

AIF Product presentation India - July 2000

AIF Product presentation India - July 2000