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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:
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.
Reciprocating Compressor
Centrifugal Compressors
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.
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.
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