Compressor
- 2. T w o B a s ic P r in c ip a ls o f A ir o r G a s C o m p r e s s io n P o s it i v e D i s p l a c e m e n t D y n a m ic C o m p r e s s i o n C o m p r e s s o r s Compressor Types
- 3. reducing the volume of a gas increases its pressure positive displacement principle
- 4. Velocity (Kinetic Energy)Velocity (Kinetic Energy) converted to pressureconverted to pressure Dynamic principleDynamic principle
- 6. Working Principal •Wheel turns •Air molecules are accelerated through the wheel •Air molecules are discharged at a high velocity Blade ZH Compressor Fundamentals
- 8. blade barrier wheel turns speed of the ball increases speed suddenly reduced to create pressure increase WORKING PRINCIPLES
- 9. WORKING PRINCIPLES inducer vanes centrifugal compressor radial diffusers pressure increase follows the principle of Bernoulli PP V² P2 = d ( C1 2 - C2 2 ) + P1 2
- 10. WORKING PRINCIPLES Variables influencingVariables influencing compressor performancecompressor performance • Positive displacementPositive displacement compressorscompressors Where: P : Power P1 : Inlet pressure V1 : Inlet volume n : Adiabatic factor P2/P1 : Pressure ratio Variables influencing power: P1 = Inlet pressure V1 = Volume flow (not mass!) P2/P1 = Pressure ratio Inlet air temperature andInlet air temperature and mass flow (density) havemass flow (density) have no effect on powerno effect on power P = P1 . V1 . . {( ) -1 } n n-1 P2 P1 n-1 n
- 11. WORKING PRINCIPLES Variables influencingVariables influencing compressor performancecompressor performance • DynamicDynamic compressorscompressors Where: H : isentropic Head R : real Gas constant T1 : Inlet temperature k : Spec heat ratio cp/cv P2/P1 : Pressure ratio H = R . T1 . . {( ) -1 }k k-1 P2 P1 k-1 k Inlet air temperature andInlet air temperature and mass flow (density) havemass flow (density) have direct effect on powerdirect effect on power
- 14. CENTRIFUGAL COMPRESSOR STAGE SCROLL VOLUTE IMPELLER DIFFUSER
- 15. CENTRIFUGAL COMPRESSOR STAGE Discharge Volute collector Diffuser Impeller Inducer RotationInlet plenum or nozzle
- 17. Inlet flange Impeller eye Impeller rim Diffuser outlet Pressure rise in impeller Pressure rise in diffuser Suction pressure Discharge pressure PRESSURERISE Pressure risePressure rise CENTRIFUGAL COMPRESSOR STAGE
- 18. Pressure depends on the speed at which the air leaves the impeller Pressure cut: • reduced wheel diameter • only last stage Pressure variantsPressure variants STAGING
- 19. Flow cut: • reduced blade height • each stage Flow variantsFlow variants STAGING
- 21. Upstream Process or Reservoir Compressor Down stream Process Compressor delivering gas into a downstream process Measuring a characteristicMeasuring a characteristic performance curveperformance curve THEORY
- 22. The centrifugal compressor characteristic curve Surge Choke / Stonewall Flow Pressure THEORY
- 23. SURGESURGE Breakdown of gasflow due to high back pressure (oscillation flow) STONE WALL (choke)STONE WALL (choke) Maximum flow a compressor can handle at a given speed THEORY
- 24. What is surge ??? A dynamic instability that occurs in a compressor causing a momentary flow backwards It happens when the combination of flow and velocity is not large enough to develop the required discharge pressure The unit produces a loud screaming noise and Causes severe stresses Generates excessive heat THEORY
- 25. Surge control Control system tries to avoid that unit operates in the surge area. Surge protection If the unit surges, it is detected and the unit is switched to unload. THEORY
- 26. ZH-series Complete and ready to use • easy, low cost installation • no special foundation • no anchor bolts • minimal floor space
- 27. ZH Flow Diagram
- 28. Integrated design • short connections between components • aerodynamically designed components • less external piping • Reduced maintenance • Smaller pressure drops ZH Core
- 29. Integrated design Two stages on one pinion shaft Easy low cost maintenance
- 30. Drive shaft and bull gear Stage #2 Bearings , seals Pinion Stage #1 Volute Shroud IGV’s Oil pump ZH Stages and Drivetrain
- 31. Greater operating flexibility with turndown ratio up to 35% Power savings at fluctuating air demand Longevity in operation with stainless steel impellers Ensured reliable operation Impellers are tested at 115% of max. speed Exclusive backward lean impeller design Control line % Flow %DischargePressure Surge limit By-pass Turn-down range ZH Design
- 32. Smaller Machining Tolerances higher reliability reduced mechanical losses lower sound level ZH Design
- 33. Reliable horizontally split Tilt Pad pinion shaft bearings provide • easy inspection • extended lifetime • high reliability Pinion Bearings
- 34. Stage 1&2 Assembly Balanced as an assembly. If a rotor wheel needs to be replaced the shaft must be balanced with new rotor wheel
- 35. IGVCore Motor Discharge Water connections Blow off valveBase frame Oil reservoir Oil heater Cubicle Oil cooler Aftercooler ZH Layout
- 36. Easy access low maintenance cost filter elements 3 Nos Air Filter Box
- 37. Horizontally split Easy access • gears • bearings • seals Contains : • drive shaft + bull gear • 2 pinions • bearings and seals • main oil pump Gearbox
- 39. Improved resistance against poor water quality Cooler Tube Bundles Stainless steel bundle tubes and end plates stainless steel tubes for higher resistance to corrosion tubes with aluminium fins for extended exchange surface thus low air approach temperature
- 40. High efficiency intercoolers Intercoolers separated from the compressor core unit for higher reliability and easier maintenance low air approach temperature and pressure drop thanks to optimized air flow pattern through the shells and bundles Air Circuit: Intercoolers
- 41. Intercooler shells full epoxy coating inside the shells for enhanced resistance to corrosion flexible connections to the interstage piping for easy inspection & maintenance High efficiency condensate separation, up to 99% low velocity leaving the cooler bundle and optimized outlet port shape lead to natural condensate separation Air Circuit: Intercoolers
- 42. Condensate drain traps • mounted on intercoolers and aftercooler with manual by-pass valves • drains with bigger fluid reservoir for dirt sedimentation Water Circuit: Condensate Drain Traps
- 43. Compressor/motor coupling • maintenance free • reliableFlexible disk type Coupling
- 44. Oil reservoir • Complete scope • Reliable Standard with • oil heater 1,9 - 2,5 kW • low oil level warning / shut down • temperature sensor with thermo well • level sight glass • strainer • inspection openings • fill and drain connection Oil Reservoir
- 45. Oil pumps Mechanic driven (main oil pump) Oil Pump
- 46. Oil Filter Dual Oil filters
- 47. Environmentally friendly motorized oil demister prevents oil fumes leaking to the atmosphere Low energy consumption +/- 90 W Easy for maintenance Oil Demister
- 49. ZH Capacity Regulation There are three different modes of regulation available on the ZH series compressors Full Load – No Load - 100% or 0% output Auto Dual - 100% - 65% or 0% output Modulating Control - 100% - 65% then modulating blow off down to about 10%
- 50. IGV’s IGV’s are cycled by a 4- 20mA signal send from the PLC The valve must be adjusted on start-up and should be check on an annual 4mA = Valve Closed 20mA = Valve fully open When the valve is closed the hole in center allows the compressor to have a small amount of air flow that is blown off.
- 51. Inlet Guide Vanes Blow off valve Valves
- 53. Inlet pressure Inlet air temperature Cooling water temperature Humidity (molecular weight) INFLUENCE OF OPERATING PARAMETERS
- 54. Discharge Pressure % 100 Power at Coupling % 100 Inlet flow (weight/volume) percent 100 Decrease in inlet pressure reduces flow Decrease in inlet pressure reduces power required Inlet pressure influenceInlet pressure influence INFLUENCE OF OPERATING PARAMETERS
- 55. Inlet air temperature influenceInlet air temperature influence Discharge Pressure % Power at Coupling % Inlet flow (weight/volume) % 100 Decrease in air temperature increases flow Decrease in air temperature increases power Increase in air temperature reduces flow Increase in air temperature reduces power Surge line Design point 100 100 INFLUENCE OF OPERATING PARAMETERS
- 56. Discharge Pressure % 100 Power at Coupling % 100 Inlet flow (weight/volume) % 100 Colder water increases flow Colder water increases power requirement Warmer water decreases flow Warmer water decreases power requirement Surge line Cooling water temperature influenceCooling water temperature influence INFLUENCE OF OPERATING PARAMETERS
- 57. Discharge Pressure % Power at Coupling % Inlet flow (weight/volume) % 100 Increase in mole weight increases flow Increase in mole weight increases power Decrease in mole weight reduces flow Decrease in mole weight reduces power Surge line Design point Molecular weight influenceMolecular weight influence 100 100 INFLUENCE OF OPERATING PARAMETERS
- 58. ELEKTRONIKON
- 61. Elektronikon® a superior electronic control and communication system
- 62. The hardware compact electronic controller, microprocessor based, with a real time operating system stabilized 24 V AC, wide voltage band power supply (-30% to + 40%) ergonomic user interface (3xLEDs, easy to read alfa- numeric display, high quality push buttons) Elektronikon
- 63. Energy efficiency precise pressure control as standard the energy saving running mode DSS (Delayed Second Stop) is preprogrammed DSS avoids the unload time to the maximum extent by anticipating on pressure fluctuations in the system energy savings up to 10% are feasible Elektronikon 0 Sunday Monday Tuesday Wednesday Thursday Friday Saturday
- 64. Reliability controls and monitors compressor and integrated ancillaries - protects compressor and surroundings via automatic shut-down in case of a fault in a vital function - gives warnings well before shut- down, so proactive measurements can be taken Elektronikon®
- 65. Service friendliness - monitors service intervals - generates service ‘WARNING’ messages - easy troubleshooting and fault- diagnosis Elektronikon®
- 67. TOTAL LIFE CYCLE COST OF COMPRESSOR energy maintenance investment > 70%
- 72. Flow system header multi turbo installation Important: staggered entry of units directly opposite each other on header required PipingPiping Piping
- 73. PipingPiping Turbo downstream of air receiver * connection to system header with - long radius elbow - or angle in flow direction Recip Screw Turbo Turbo or Air receiver * * or Flow Piping
- 74. x compressor discharge connection to header Flow Header from compressor Not connectedNot connected to the bottomto the bottom but from compressor header Flow or header Flow from compressor PipingPiping Piping
- 77. THANK YOU
Editor's Notes
- #70: WHY IS ENERGY SO IMPORTANT? In the depiction of the life cycle costs in the diagram above,we see that energy constitutes the major portion, where as investments and maintenance occupy less than 30% of the costs. Consequently savings in energy bring about a large difference in the overall life cycle costs of the machine