KAPITA SELEKTA

Pompa & Kompressor

By: Thomas Putradi Nurwaskito

PT. Trimassive Indonesia
INTRODUCTION TO PUMPS &
COMPRESSORS
THERE IS NO SINGLE PUMP THAT CAN
HANDLE ALL APLICATION
• The Basic things how to select the pumps
1. The total head or pressure against which it must
operate
2. The desired flow rate
3. The suction lift
4. Characteristic of fluid
THE TOTAL HEAD
pumps increase the mechanical Devices used to
energy of the liquid, increasing transport/move liquids
its velocity, pressure, or through pipes & channels.
elevation-or all three.

PUMPS

Positive-Displacement Centrifugal
Pumps Pumps

Reciprocating Pump Rotary Pump

Vane
Diaphragm
Piston Gear Lobe

Plunger Screw
Spur-GP
Internal-GP
Positive-Displacement Pumps
• 2 subclasses: reciprocating pumps & rotary pumps.
• Reciprocating pumps: the chamber is stationary cylinder that
contains a piston or plunger.
• Rotary pumps: the chambers moves from inlet to discharge and back
to the inlet.
discharge chamber

inlet discharge

chamber
gear
inlet
Reciprocating pumps Rotary pump
 Positive-Displacement Pumps:
Reciprocating Pumps
• Piston pump:
 liquid is drawn through an inlet check valve into the cylinder by the withdrawal of
a piston.
 then the liquid is forced out through a discharge on the return stroke.

discharge Piston Check valve

chamber
inlet Single-acting
Piston pump:
 Positive-Displacement Pumps:
Reciprocating Pumps
 most piston pumps are double-acting with liquid admitted alternately on each
side of the piston so that one part of the cylinder is being filled while the other
is being emptied.
 the piston may be motor-driven through reducing gear or a steam cylinder
may be used to drive the piston rod directly.
 max. discharge pressure for commercial piston pumps is about 50 atm.

discharge

chamber
inlet Piston Check valve
Double-acting
Double Acting Piston Pump:
Positive-Displacement Pumps:
Reciprocating Pumps
• Plunger pump:
 are used for higher pressures.
 instead of using pistons and piston rings, they make use of finely machined
plungers of very small clearances in order to seal the liquid to be pumped.
 the plungers are highly polished and made relatively long so that only very
little liquid can escape through the clearances.
 at the limit of its stroke, the plunger fills nearly all the space in the cylinder.
 are single-acting and usually are motor driven.
 they can discharge against a pressure of 1500 atm or more.

discharge

chamber

inlet
Plunger pump:
Positive-Displacement Pumps:
Reciprocating Pumps
• Diaphragm pump:
the reciprocating member is a flexible diaphragm of
metal, plastic & rubber.
diaphragm pumps handle small to moderate amounts of
liquid, up to about 100 gal/min, can develop pressures in
excess of 100 atm.
Positive-Displacement Pumps:
Reciprocating Pumps
Diaphragm pump:
Positive-Displacement Pumps:
Rotary Pumps

• Unlike reciprocating pumps, rotary pumps contain no check valves.

• Minimize leakage from the discharge space back to the suction
space; they also limit the operating speed.
• Rotary pumps operate best on clean, moderately viscous fluids such
as light lubricating oil.
• Discharge pressures up to 200 atm or more can be attained.

chamber

inlet discharge

gear

Rotary pump
Positive-Displacement Pumps:
Rotary Pumps
• Spur-gear pump
 Intermeshing gears rotate with close clearance inside the casing.
 Liquid entering the suction line at the bottom of the casing is caught in the
spaces between the teeth & the casing & is carried around to the top of the
casing & forced out the discharge.
 liquid cannot short-circuit back to the suction because of the close meshing of
the gears in the center of the pump.

chamber

inlet discharge

gear

Spur-gear pump
Positive-Displacement Pumps:
Rotary Pumps
• Internal-gear pump
 A spur gear or pinion meshes with a ring gear with internal teeth.
 Both gears are inside the casing.
 The ring gear is coaxial with the inside of the casing, but the pinion, which is
externally driven, is mounted eccentrically with respect to the center of the casing.
 A stationary metal crescent fills the space between the two gears.
 Liquid is carried from inlet to discharge by both gears, in the spaces between the
gear teeth and the crescent.

Internal-gear pump
• Internal-gear pump
Positive-Displacement Pumps:
Rotary Pumps
Lobe pump
Vane pump
Positive-Displacement Pumps:
Rotary Pumps
Screw pump
 Centrifugal pumps
• The second major class of pumps, where mechanical energy of the liquid is
increased by centrifugal action.
• The liquid enters through a suction connection concentric with the axis of a high-
speed rotary element called the impeller which carries radial vanes integrally cast in
it.
• Liquid flows outward in the spaces between the vanes and leaves the impeller in
greater velocity with respect to the ground than at the entrance to the impeller.

 In a properly functioning pump, the space between the vanes is completely filled
with liquid flowing without cavitation.
 The liquid leaving the outer periphery of the impeller is collected in a spiral
casing called the volute and leaves the pump through a tangential discharge
connection.
 In the volute, the velocity head of the liquid from the impeller is converted to
pressure head.
Centrifugal pumps
• The power is applied to the fluid by the impeller and is transmitted to the
impeller by the torque of the driveshaft, which usually is driven by direct-
connected motor at constant speed, commonly at 1750 or 3450 r/min.
• Centrifugal pumps constitute the most common type of pumping machinery
in ordinary plant practice.
• A common type uses a double-suction impeller, which accepts liquid from
both sides.
Centrifugal pumps

Single-suction centrifugal pump

Centrifugal Pumps
Multistage Pumps Axial Split Case Pump
Centrifugal Pump
Type of Impeller Range of Duty
Performance Curve
Centrifugal Pump Positive Displacement
 CAVITATION
• Cavitation is the formation and accumulation of bubbles
around a pump impeller.
• NPSHa > NPSHr
• Cavitation makes:
- Decreased Flow or Pressure
- Unexpected Vibrations
- Impeller Erosion/ eroded
- Seal/Bearing Failure
- Erratic Power Consumption
- Noise
CAVITATION
 CAVITATION
NPSHa calculation
Impeller Cavitation
THE SUCTION LIFT

Negative Suction Positive Suction

Pump for negative suction
application
Downhole Pump Vertical Turbine Pump
THE CHARACTERISTIC OF LIQUID
Mechanical Damaged Chemical Damaged

• Scratch • Corrosivities
• Abrassive
• Phase Transition
CHARACTERISTIC OF FLUID
Mechanical damage Chemical damage
MATERIAL SELECTION
Mechanical damage Chemical damage
Slurry Chemical Pump
Metal or Rubber Liner Thermo Plastic Pump
COMPRESSORS
Compressors & Blowers, Fans
• are machines that move & compress gases.
1. Fans discharge large volumes of gas (usually air) into spaces
or large ducts
-are low-speed machines that generate very low pressures,
on the order of 0.04 atm.
2. Blowers: are high-speed rotary devices (using either positive
displacement or centrifugal force) that develop a max.
pressure of about 2 atm.
3. Compressors: are also positive-displacement or centrifugal
machines, discharge at pressure from 2 atm to several
thousand atmospheres.
Differences between fans, blowers
& compressors
Ratio of discharge pressure
over suction pressure

Equipment Specific Ratio Pressure rise

(mmWg)

Fans Up to 1.11 1136

Blowers 1.11-1.20 1136-2066

Compressors
More than 1.20 -
Definition of Compressor
Compressors are mechanical devices that compresses gases.
It is widely used in industries and has various applications
What are its applications?
Compressors have many everyday uses, such as in :

• Air conditioners, (car, home)

• Home and industrial refrigeration

• Hydraulic compressors for industrial machines

• Air compressors for industrial manufacturing

What are its various types?
Compressor classification can be described by following
flow chart:
 Dynamic Compressors
The dynamic compressor is continuous flow
compressor is characterized by rotating
impeller to add velocity and thus pressure to
fluid.

It is widely used in chemical and petroleum

refinery industry for specific services.

There are two types of dynamic compressors

 Centrifugal Compressor
 Axial Flow Compressor
 Centrifugal Compressor
Achieves compression by applying inertial
forces to the gas by means of rotating impellers.
It is multiple stage ; each stage consists of an
impeller as the rotating element and the
stationary element, i.e. diffuser
 Fluid flow enters the impeller axially and
discharged radially
 The gas next flows through a circular chamber
(diffuser), where it loses velocity and increases
pressure
 Centrifugal Compressors

Interior of centrifugal compressor

Axial Flow Compressor
Working fluid principally flows parallel to the
axis of rotation.
 The energy level of air or gas flowing through it
is increased by the action of the rotor blades
which exert a torque on the fluid
Have the benefits of high efficiency and
large mass flow rate
Require several rows of airfoils to achieve
large pressure rises making them complex
and expensive
Why multistage compressor?
Discharge temperature shall not exceed 150ºC and should
not exceed 1350C for hydrogen rich services
High temp rise leads into limitation for the maximum
achievable pressure rise.
A multistage centrifugal compressor compresses air to the
required pressure in multiple stages.
Intercoolers are used in between each stage to removes
heat and decrease the temperature of gas so that gas could
be compressed to higher pressure without much rise in
temperature
Positive Displacement Compressors
Positive displacement compressors causes movement by trapping
a fixed amount of air then forcing (displacing) that trapped
volume into the discharge pipe.

It can be further classified according to the mechanism used to

move air.
Rotary Compressor
Reciprocating compressor
 Rotary compressors
The gas is compressed by the rotating action of
a roller inside a cylinder.

The roller rotates off-centre around a shaft so

that part of the roller is always in contact with the
cylinder.

 Volume of the gas occupies is reduced and the

refrigerant is compressed.

High efficient as sucking and compressing

refrigerant occur simultaneously.
 Reciprocating Compressor
It is a positive-displacement compressor that

 Uses pistons driven by a crankshaft to

deliver gases at high pressure.

The intake gas enters the suction manifold,

then flows into the compression cylinder

It gets compressed by a piston driven in a

reciprocating motion via a crankshaft,

Discharged at higher pressure

Reciprocating Compressors
Graph showing operating regions of various compressors
Advantages and Disadvantages of dynamic compressors
Advantages and disadvantages of positive displacement type compressor
 Selection Considerations
Safety
Limiting gas properties (e.g., decomposition, flammability, toxicity).

Compatibility of process gas with materials of construction

Over-pressure protection

Economics
Life-cycle cost

User and vendor capabilities and facilities for maintaining equipment

Expected equipment reliability

RECIPROCATING COMPRESSORS
Block diagram of reciprocating compressor
Construction of Reciprocating Compressors
• Reciprocating compressors can be divided into two main
groups.

1. Gas end.
2. Power end.
 Different Parts Of Gas End
Various parts of gas end are:
• Cylinder & liner
• Piston
• Piston rod
• Piston rod packing
• Piston rings
• Valves
 Different Parts of Power End
Various parts of power end are
• Crank and Crankshaft
• Connecting rod
• crosshead

Crank and crankshaft

 Relief Valve
• Used to control or limit the pressure in a system or vessel
• The pressure is relieved by allowing the pressurized fluid
to flow from an auxiliary passage out of the system
• Designed or set to open at a predetermined set pressure
Table showing margin pressure for relief valves
Cycle Analysis

process
1->2 compression
2->3 discharge
3->4 expansion
4->1 induction
Thermodynamic Process in Compressor
• Isothermic Compression
Temperature tetap pada setiap proses
Kerja Kompressor paling rendah
• Polytropic Compression
kompresi politropik temperature gas setelah kompresi lebih tinggi
dari pada temperature pada awal langkah kompresi.
Kerja yang diperlukan untuk kompresi politropik lebih besar
daripada untuk kompresi ishotermal, tetapi lebih rendah dari
pada untuk kompresi adibatik.
• Adhiabatic Compression
kompresi adiabatic adalah proses kompresi tanpa perpindahan
kalor dari gas dan sekitarnya, yaitu dengan jalan memberikan isolasi
panas secara sempurna pada dinding silinder. Dengan kompresi
adiabatic, temperature gas akan naik dan lebih tinggi dari pada
kenaikan yang terjadi dengan kompresi politropik.
Disamping itu, dengan kompresi adiabatic kerja yang diperlukan
untuk kompresi akan lebih besar, tetapi akan diperoleh kenaikan
tekanan yang tinggi.
 Various types of efficiencies
Adiabatic efficiency Mechanical efficiency

Isothermal efficiency Overall efficiency

 Vibration
• Gerakan bolak-balik dalam suatu interval waktu
tertentu.Getaran berhubungan dengan gerak osilasi benda
dan gaya yang berhubungan dengan gerak tersebut. Semua
benda yang mempunyai massa dan elastisitas
mampu bergetar, jadi kebanyakan mesin dan struktur rekayasa
(engineering) mengalami getaran sampai derajat tertentu dan
rancangannya.
 Vibration
Type of Vibration.
1. Getaran bebas
Getaran bebas terjadi jika sistem berosilasi karena bekerjanya gaya yang ada dalam
sistem itu sendiri (inherent), dan jika ada gaya luas yang bekerja. Sistem yang
bergetar bebas akan bergerak pada satu atau lebih frekuensi naturalnya, yang
merupakan sifat sistem dinamika yang dibentuk oleh distribusi massa dan
kekuatannya. Semua sistem yang memiliki massa dan elastisitas dapat mengalami
getaran bebas atau getaran yang terjadi tanpa rangsangan luar.

2. Getaran Paksa
Getaran paksa adalah getaran yang terjadi karena rangsangan gaya luar, jika
rangsangan tersebut berosilasi maka sistem dipaksa untuk bergetar pada frekuensi
rangsangan. Jika frekuensi rangsangan sama dengan salah satu frekuensi natural
sistem, maka akan didapat keadaan resonansi dan osilasi besar yang berbahaya
mungkin terjadi. Kerusakan pada struktur besar seperti jembatan, gedung ataupun
sayap pesawat terbang, merupakan kejadian menakutkan yang disebabkan oleh
resonansi. Jadi perhitungan frekuensi natural merupakan hal yang utama
 Vibration
Parameter of Vibration
a. Amplitudo
Amplitudo adalah ukuran atau besarnya sinyal vibrasi yang dihasilkan
makin tinggi amplitudo yang ditunjukkan menunjukkan makin besar ganguan yang
terjadi besarnya amplitudo tergantung pada tipe mesin yang ada.

b. Frekuensi
Frekuensi adalah banyaknya periode getaran yang terjadi dalam satu
putaran waktu.Besarnya frekuensi yang timbul saat terjadinya vibrasi dapat
mengindikasikan jenis jenis ganguan yang terjadi.Frekuensi biasanya ditunjukkan
dalam bentuk Cycle Per Menit (CPM) yang biasanya disebut dengan
instilah Hertz(Hz).

c. Phase Vibrasi
Phase adalah penggambaran akhir dari pada karakteristik suatu getaran
atau vibrasi yang terjadi pada suatu mesin.Phase adalah perpindahan atau
perobahan posisi pada bagian bagian yang bergetar secara relatif untuk
menentukan titik referensi atau titik awal pada bagian lain yang bergetar.
THANK YOU