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Discussion Points
Basic Terminology Rod (Pin) Load Rod (Pin) Reversal Area Classifications NEMA Enclosures Wire Separation Intro to PV Card
COMPRESSION SYSTEMS
TERMINOLOGY
(Jargon) Gas Compressor Industry Language
Compression = Compressor = pressure. The act of pressing or compacting into a smaller space. A machine which converts gas from low pressure to a higher
COMPRESSION SYSTEMS
COMPRESSION SYSTEMS
The System
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Terminology
= = = = = = = = = = =
ratio of compression suction pressure discharge pressure suction temperature discharge temperature ambient temperature horse power head end crank end volumetric efficiency ratio of specific heats of a particular natural gas - a thermal dynamic value
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COMPRESSION SYSTEMS
Terminology
Ratio of Compression (RC) RC = Discharge Pressure(Pd)psig + 14.7 = ??? psia Suction Pressure (Ps)psig + 14.7 = ??? psia Note: Elevation or Barometric pressure must be taken into account when figuring Rc.
COMPRESSION SYSTEMS
Terminology
Note: If we had not converted to psia the ratio would have been 30:1.
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Terminology
Finding Approximate HP Requirement: To find the HP required for a single stage unit (example 1): Approximating HP Formula using Example #1 HP = 21 x Rc x S x Q Where:
HP 21 Rc S Q = Horse Power = Standard (Constant) = Ratio Of Compression = # of Stages = Quantity in MMCFD
Terminology
SA = Single Acting - The act of compressing on one end of the compressor cylinder. = Double Acting - The act of compressing on both ends of the compressor cylinder. = Two compressor cylinders either bolted together or cast as one casting, using a common piston rod with two piston sizes.
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DA
Tandem
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SCRUBBER
RELIEF VALVE
GAS DEFLECTOR
OUTLET CONNECTION
MESH FILTER GAS HIGH LIQUID LEVEL SHUTDOWN SWITCH CONTROL PRESSURE
MANUAL DRAIN
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SCRUBBER MOUNTING
3-POINT OK
SCRUBBER MOUNTING
4" CHANNEL
SINGLE BEAM NO
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4" CHANNEL
FIELD MODIFICATION
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Terminology
Clearance Volume = The volume remaining in the compressor cylinder at the end of the discharge stroke. Normally expressed as a % of piston displacement. Displacement = Area of piston X length of stroke X # of strokes per minute. For DA compressors, the displacement on the CE is less than the HE due to the rod area. Normally expressed in cubic feet per minute or CFM.
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COMPRESSION SYSTEMS
Terminology
Capacity
(or flow rate) Volume of gas compressed and delivered at specified conditions of temperature & pressure measured at the compressor inlet. Usually expressed as volume/unit of time - cubic feet per minute or cubic feet per day. Refers to the heat exchanger design 30F approach means the cooler will cool the gas to 130when ambient temperature is 100F.
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Approach
COMPRESSION SYSTEMS
Terminology
Swept Volume = The volume swept by the piston during the forward and/or backward stroke. = Compressor speed is not a factor. = Normally expressed in cubic inches and calculated as follows:
Swept Volume HE = Area of Piston X Stroke in Inches Swept Volume CE = (Area of Piston - Area of Rod) X Stroke in Inches Total Swept Volume = (2 X Area of Piston - Area of Rod) X Stroke In Inches
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Terminology
Total Swept Volume Example (DA): 6 Diameter x 7 Stroke 2.5 Piston Rod Diameter Total Swept Volume = (2 X 28.274 - 4.909) X 7 = (56.548 - 4.909) X 7 = 51.639 X 7 = 361.473 cu. In.
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COMPRESSION SYSTEMS
Terminology
Units of Measure: PSI PSIG PSIA MMCFD MMSCFD = pounds per square inch = pounds per square inch gauge = pounds per square inch absolute = gauge + atmospheric pressure = million cubic feet per day = million cubic feet per day @ the standard conditions of 14.65psia & 60F
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Terminology
In-Hg
= inches of mercury pressure = can be a manometer or mercury filled gauge, used where pressures are low & extreme accuracy is desired = 1 Hg = .491 PSI = inches of water pressure = usually a manometer filled with water = used for measuring very low pressure = 1/13.6 as heavy as mercury 13.6 of H2O = 1 of Hg = .491 PSI
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In-H2O
COMPRESSION SYSTEMS
Terminology
Temperature Scales: Temperature = A measure of molecular energy the higher the temperature the more molecular energy. Degrees Fahrenheit (F) = Temperature scale where, at sea level, the freezing point of water is 32 & the boiling point is 212. The distance between these two points is 180.
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Terminology
Temperature Scales: Degrees Centigrade or Celsius (C) = A scale used worldwide which relates to the metric system. At sea level, the freezing point of pure water is 0 & the boiling point is 100. The distance between these two points is 100.
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Terminology
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V Inline
Configuration Configuration
Horizontal Opposed
Configuration
Separable Engine
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In In-Line 4
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V - Six
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Horizontal 4
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Click Here
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Compressor
Engine
Coupled Separables
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Left Bank
Right Bank
Sheave
3 LH
1L 2L 3L
1R 2R 2 3R 1 RH
4L
4R
Flywheel
5L 5R
Flywheel
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INTEGRAL ENGINECOMPRESSORS
COMPRESSION SYSTEMS
ERL Compression
Area of piston in square inches times discharge pressure, minus area of piston, minus area of rod times suction pressure.
2.5
Pd=814.7 PSIA
Ps=214.7 PSIA
= 28.274 x 814.7 - (28.274 - 4.909) x 214.7 = 23,035 - (23.365 x 214.7) = 23.035 - 5016 = 18,019 #
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ERL Tension
Area of piston in square inches, minus area of rod times discharge pressure, minus area of the piston times suction pressure.
2.5
Ps=214.7 PSIA
Pd=814.7 PSIA
= (28.274 - 4.909) x 814.7 - (28.274 x 214.7) = 23.365 x 814.7 - (28.274 x 214.7) = 19,035 - 6070 = 12,965 #
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Crank Pin
Oil
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Data needed for Compressor Sizing Operating Conditions Gas properties Approximate HP per application Suction Pressure (PS) Discharge Pressure (Pd) Quantity of gas in MMCFD Conditions Assumed: Suction Temp (TS) = 80F Ambient Temp (Ta) = 100F Discharge Temp (Td) required approach = 20F Altitude = < 1500 Atmospheric Pressure = 14psi Specific Gravity = 0.64 N value = 1.26 Sweet Gas
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COMPRESSION SYSTEMS
Any Questions?
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Area Classification
Class I: Flammable gases and vapors Within this class are four groups in order of explosive potential This is where most gas compression will be found. Group A: Acetylene Group B: Hydrogen and other gases Group C: Ethylene and other gases Group D: Acetone, Butane, Ethane, Methane, and other gases Class II: Combustible dusts Group E: Metallic dusts Group F: Carbonaceous dusts (e.g.coal) Group G: Agricultural, Chemical, and Plastic dusts Class III: Combustible filings and fibers
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COMPRESSION SYSTEMS
Area Classification
The NEC(National Electric Code) and CEC(Canadian Electric Code) recognize two further divisions distinguished by the likelihood of the material being Present Division 1: Areas where hazardous materials may be present under normal operating conditions. Intrinsically Safe: A system comprising of equipment and interconnecting wiring in which any spark or thermal effect in any part of the system intended for use in the hazardous location is incapable under prescribed conditions of causing ignition of the test gas mixture. Division 2: Areas where hazards arise only as the result of leaks, ventilation, or other unexpected breakdowns. As a rule of thumb the probability of the presence of explosive materials must be less than 1% for an area to be assigned to Division 2. Non-incendive Circuit: A circuit in which any spark or thermal effect, that may occur in normal use, is incapable of causing an ignition of the test gas mixture.
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NEMA 7 enclosures are for indoor use in locations classified as Class I, Groups A, B, C, or D, as defined in the National Electrical Code. NEMA 7 enclosures shall be capable of withstanding the pressures resulting from an internal explosion of specified gases, and contain such an explosion sufficiently that an explosive gas-air mixture existing in the atmosphere surrounding the enclosure will not be ignited. Enclosed heat generating devices shall not cause external surfaces to reach temperature capable of igniting explosive gas-air mixture in the surrounding atmosphere. Enclosures shall meet explosion, hydrostatic, and temperature design tests. Note: If the NEMA 7 enclosure will be used in an outdoor environment a NEMA 7, 4 enclosure can be specified for weather proof.
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Wire Separation
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DISCHARGE VOLUME
PRESSURE
RE-EXPANSION
COMPRESSION
STROKE OR VOLUME
MINIMUM CYLINDER VOLUME MAXIMUM CYLINDER VOLUME
USEFUL WORK
LOSS DUE TO SUCTION VALVE
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Pressure
Volume
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Pressure (psig)
400
Poor Pv Trace
350
300
250
200
25
75 250
100
225
Acceptable Pv Trace
175
150
125
100
25
75
100
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