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Compressors

Introduction:
Compressors are machines designed for compressing air or gas from an initial intake
pressure to a higher discharge pressure.
Applications:
Compressors are used in wide variety of applications as follows:

For operating instruments


For operating pneumatic tools, gates, damper through
Pneumatic cylinder
It is substitute for steam, electricity in operating tools, drills etc.
For agitation of liquids in tanks
For burner firing through atomization.
Classification of compressors:
Type:

1.
2.
3.
4.
5.

Reciprocating
Rotary Vane
Screw
Turbine
Centrifugal
Single acting, Double acting, Single stage, Multi Stage, Two Stage, Single Cylinder,
Multi Cylinder, Water Cooled, Air Cooled, Electrical, Diesel, Gas, and Steam.

Air Flow In Reciprocating Compressor

Main Parts Of Reciprocating Compressors:


Crank Case: Heavy Duty grain cast iron frame. It also serves as lubricating oil reservoir.
Crank Shaft: Made of forged steel is provided with bolted counter weights.
Connecting Rod: Made of nodular gray iron or forged alloy steel and are provided small
and big end bearing.
Cross Head: Made of nodular gray iron and is designed to ensure true running of piston
rod.
Cylinder: Made of graded close grain cast iron. These are provided with water jackets to
ensure efficient cooling of the surface that comes in contact with hot compressed air.
Piston: Made of nodular gray iron or high grade aluminium alloy and having the same
weight i.e. L.P. Piston hollow and H.P. Piston Solid.
Oil Pump: Gear pump is driven from the free end of crank shaft for lubrication of all
parts.
Inter Cooler: It is device for removing the Heat Of Compression of the air between
consecutive stages of multistage compressors.
After Cooler: These are meant for removing the heat of compression of the air after is
compression is completed. These are also used for removing moisture from compressed
air.
Air Receiver: It is used to store the air and help to eliminate pulsation in the discharge
line.
Valves: Each cylinder is provided two suction and two delivery valves for the upper and
lower compression. The valve is opened and closed by the means of the pressure
difference occurring in the cylinder.

Reciprocating Compressor

Clearances for a Typical Reciprocating Compressor:

Main Bearing and Crank shaft = 0.66d to 0.0015d


Thrust collar and Crank shaft lateral = 0.008 to 0.004
Cross head and guide = 0.006 to 0.016
Cylinder and Piston per 100 mm = 0.004 to 0.012
Piston ring gaps in plates 0.2 to 0.3% dia. Of cylinder or 0.20 to 0.024 per 100 mm dia.
Side gap between rings and piston grooves 0.002 to 0.008
Piston groove depth piston rings thickness 0.01% to 0.2%d
Lateral clearance of big end between connecting rod and crank shaft = 0.008 to 0.025
Piston / Piston rod and outer cover is 1/16 to 3/16

Piston / Piston rod and inner cover is 3/64 to 1/8


Diametrical clearance between big end baring 0.0008 d to 0.0012 d.

Centrifugal Compressors

Make: Ingersoll Rand


Type: Centac Integrally Geared, centrifugal air compressors
Model: C 55 MX3
Capacity: 6092 cfm
Speed: 2975 rpm
Discharge pressure (after cooler outlet): 7kg/cm2
Suction pressure (Barometric Pressure): 0.995 kg/cm2
Inlet air temperature: 50-degree c/ 35-degree c
Shaft Power: 828.2 kw / 880.81
Motor BHEL make: 950 kw, 3.3 kV, 3 Ph., 50 Hz, and squirrel cage induction motor.
Specific Power kw/cfm: 0.131/0.144
Cold Water Consumption: 3400 LPM
Suction Filter: 2 no (2stage)
No. Of stage at compressor: 3
Impellers: 3ss impellers mounted on separate pinion
Maximum allowable pressure drop across suction filter: 0.02kg/cm2
Lubricating Oil: Servo prime-32
Oil pressure: 2kg/cm2 max.

Principle:
The Centac compressor is a dynamic centrifugal type compressor. The air being
compressed enters the compressor through the machine mounted inlet control device and
flows to the the first stage where the impeller imparts velocity to air.
The air proceeds through the stationary diffuser that converts velocity to pressure. The
built-in inter cooler removes the heat of compression, which improves efficiency. The air
then passes through a stainless steel moisture separator in a low velocity zone to remove
condensate. Entrained moisture in the air is reduced when the air is forced through
stainless steel moisture separators. This sequence repeats in each succeeding stage until
the compressor achives the desired operating pressure.

Description:
The Centac compressor is a centrifugal compressor driven by an electric motor. The
compressor and driver are not directly coupled.
The compressor contains:

A main driver that directly drives a bull gear that is common to all stages.

Compression stages consisting of an impeller mounted on its own shaft, enclosed


within a common cast iron casing.
Rotors consisting of an integral pinon gear driven at its optimum speed by a common
bull gear.
An intercooler that is mounted after stage of compression.
A moisture separator and a moisture removal system are fitted after each cooler to
remove condensate.

Compressors Parts:

Rotor Assemblies
Bearing
Seals
Diffusers
Intercoolers
Moisture Separators
Vibration Probes
Casing
Compressor Driver
Lubrication System
Diffusers:
A diffuser, located between each impeller and cooler, converts velocity energy in pressure
energy.
Intercoolers and After coolers: The Coolers are donut types with the water over tubes and
oil in shell.

Moisture Separators: The moisture separator is a SS mesh screen type construction


located at points in the air compressor where air velocities are relatively low permitting
efficient moisture separation.
Vibration Probes: A non contacting vibration probe is mounted on each stage next to the
plain bearing to measure vibration of each rotor assemblies. Each probe is connected to a
vibration transmitter.
Casing: The gear case consists of a casing and casing cover jointed vertically by bolted
assembly which is opened for servicing the bull gear and its bearings.
Rotor Assemblies: Each rotor consists of an SS impeller and a removable thrust collar
mounted on a helical geared pinion shaft each secured to the shaft by a polygon spline,
eliminating the need of keyways.
Bearings: Each rotor assembly is equipped with a thrust bearing near impeller and a plain
journal bearing, Babbitt lined, near bull gears for radial loads.
Seals: A single cartridge seal is mounted in the plain bearing housing behind each
impeller. Each cartridge consists of three, one piece, fully floating non-contact carbon

rings. One ring is used as an air seal and the remaining two as oil seals. Buffer air is
supplied to the oil a seal assuring that lube oil is not drawn past the seals, thus ensuring
oil free air.

Compressors Efficiency:
Factors effecting the compressors efficiency:

Leaky Valve
Too large piston ring gaps
More clearance between cylinder and piston
Leakage at piston rod
Inadequate Inter stage cooling (inter cooler plugged)
High Inlet Air temperature
Low water Pressure
High inlet water temperature
Speed is less (Prime Mover)
Choking of Suction filter
After Cooler ineffective
Moisture separator is not working properly (Moisture in Air)
Air conservation / Efficient Air System:

Inter cooler and after cooler must be perfect and to be cleaned periodically.
Threaded connections are to be avoided in air system.
Tapping in air lines, receiver outlet should be from top to avoid water moisture carry
over.
Auto drains are to provide for drain.
Global valves should be used in air system as pressure drop is very high. In 1 gate
valve pressure drop is 1.14ft of used pipe whereas in 1 global valve is 30ft of used
pipe.
Hydraulic testing of receiver should be done on every year at 1.5 times the safety of valve
setting.
Flow meters are to provide in air lines to control air consumption.
The colour coding of air lines are essential.
Cleaning operation should be done with 30-40 psi air pressure only to save air
consumption. Pressure regulations are to be provided.
pipe releases 308 cfm at 70 psi
pipe releases 200 cfm at 40 psi
Efficiency, flow measurement of compressors.
Ratio of Compression: The rates of initial volume to final volume.
Cylinder Ratio: r = P3/P
Where r = Ratio of Compression
P3 = Absolute discharge pressure in psi

P = Atmospheric pressure in psi


Inter Cooler Pressure: p1 = P*P3/P P
Piston Speed: (2 * Stroke length * rpm)/ 12 ft./min
Displacement: It is volume swept through by the piston with proper deduction for the
piston rod, Unit- CFM

Normal Velocity in compressed air piping = 20 ft. /sec max

Effect of Comparative pressure on power Cost: Cost of air generation is 7% less at 6


kg/cm2 than at 7 kg/cm2

Unloading Power of Compressors in comparison to full load:


Unloading Power consumption should be 15% to 18% of full load.

Cost of air generation in Alumina Plant Rs. 5.20 aprrox. (Calculated)


Intake air temperature decreases 3deg C and due to this increase in volume delivered by
1%.

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