Proceedings of the National Conference on Emerging Trends In Mechanical Engineering 2k13
372 NCETIME 2k13
ALTERNATIVE DESIGN FOR RECIPROCATING COMPRESSOR DRIVEN BY USING A FLUID PISTON TO OVERCOME LIMITATIONS
[1] R.Ayyappan, [2] C.Srinivasan
[1] Sr. Assistant Professor, Department of Mechanical Engineering, Aksheyaa College of Engineering, Pulidivakkam, Kancheepurm-District e-mail: Prof.ayyappan@gmail.com
[2] Assistant Professor, Department of Mechanical Engineering, Aksheyaa College of Engineering, Pulidivakkam, Kancheepurm-District e-mail: c.srinivasan86@gmail.com [*] corresponding author Abstract: In this paper alternative design of a reciprocating compressor driven by a fluid piston drive is presented and its advantages are discussed. The compressor, which is 100 mm in diameter and 300 mm stroke length has a simple structure consisting of two compressor chamber, a gear pump driven by a electric motor, self acting check valve, and two 3/2 DC valves. Using oil as working medium, the simple fluid system enables a variable compression ratio. With a working voltage of 230V for the control system as a preliminary work, the device gives flow rates of 0.2m 3 / min. The investigational efforts have done and the performance analysis was done.
INTRODUCTION The investigation of compressor is brought upon by the need for an improved power source for fluid power industries. Current industries utilize rotary compressors for larger mass flow rate and lesser pressure applications. But in the case of high pressure application and lesser mass flow rate reciprocating compressors are the middle ground. But the existing systems have strong limitations on the work output and the life of the machineries. A more appropriate energy source of fluid power automation could be coupled to a linear pneumatic actuator to provide greater energy density than rotary devices. [1, 4]
The goal of the project is to reduce the maintenance cost, noise, unexpected failure and increase the performance of the system. 1. Size and Weight The total volume of the device should be able to fit on any irregular shape Due to the flexibility of compression chamber, lighter in weight casing and frictionless fluid piston is desired to Increase the maneuverability and efficiency of the system.
2. Low Noise Noise is a form of energy loss and is therefore a factor that should be minimized in order to increase the efficiency of the compressor system. Also, noise in the system is an environmental hazard in some cases. Because the inertia driven device decreases the pressure of the outlet, the Proceedings of the National Conference on Emerging Trends In Mechanical Engineering 2k13
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discharge of these gasses creates minimal noise when exiting. Flexibility of the fluid is also becomes important to reduce the noise. Compression along with a flexibility in movement causes the device to remain stationary, reducing frictional and noise losses. Another source of noise is the collision of the free piston striking against a wall and friction created while running against the wall.
3. I nertia Driven The Fluid piston Compressor is driven by a fluid piston that is not rigidly attached to a crankshaft. It uses the kinetic energy of a fluid mass to compress air. A free piston allows the entire energy for compression created by the fluid pump. The potential energy in the form of high pressure incompressible fluid compresses the compressible gaseous fluid. Whereas, a kinematic device would have wasted energy in the form of friction due to the crankshaft link pulling the piston back into place. Also, the inertia driven device allows for the compression of gasses to discharge at lesser than reciprocating compressors, allows for minimized discharge noise.
4. Maintenance Cost In the higher pressure applications the force acting on the crank shaft, push rod, journal bearings, piston pin, and cylinder walls are more due to the unbalanced forces acting on it. It cause uneven wear and rapid wear of mating surfaces leads to the failure of the consecutive parts in a linkage or mechanisms. This will leads to increase the maintenance cost of the entire operating environment. By the exertion the maintenance cost of the entire system is almost reduced.
5. Automatic Cooling The fluid piston compressor must allow the compression chamber to cool, in order to provide for the most efficient compression. In many compressors this is brought about by some type of separate cooling device, and therefore increases the weight and complexity of the design. In order for automatic cooling to exist, the pressure inside the combustion chamber must decrease to lower than atmospheric pressure, and cool ambient air is drawn into the chamber through a check valve. This cooling of the compression chamber allows more volume of air into the next stroke of the compressor to push out a greater amount of air out of compressor than if the chamber was hot.
6. Valve losses The actual indicated horsepower is built upon the base of ideal horsepower and includes the thermodynamic losses in the cylinder. These thermodynamic losses (fluid losses) are summed up under the general term compression efficiency. The major factor involved in determining the compression efficiency is the valve loss or pressure drop through the inlet and discharge valves. These fluid losses are a function of gas density and valve velocity. The suction and discharge pressures and the molecular weight establish the density. The valve velocity is fixed by the valve area available in the selected cylinders and by the piston speed. Valve velocity is normally stated in feet per minute; it is the ratio of piston area to valve area per cylinder end, multiplied by feet per minute piston speed.
In the fluid piston compressor the opening and valve closing are done in a prolonged time, so that the frictional turbulence during opening and closing of valve in various operating speeds are eradicated. The existing compressors are operated beyond the rated speed the malfunction and there is no pumping of the working fluid. Proceedings of the National Conference on Emerging Trends In Mechanical Engineering 2k13
374 NCETIME 2k13
7. Volumetric efficiency By adopting the said methodology the volumetric efficiency is increased and achieved by introducing the control systems and sensors in the appropriate place of work. The expansion volume and the impact of piston on the wall due to clearance are decreased by the adopting proposed methodology.
8. Mechanical efficiency The friction in-between the walls and piston rings and linkages are entirely eliminated by means of the fluid piston the performance of the entire system is increased.
9. Flexibility of proposed system; In the physical exertion it is observed that the above problems were eradicated and the improvement in the said efficiencies by adopting the precision sensing elements with controlling devices. In examination of the past studies and proposed work results indicates prolonged life and eco-friendly machinery in the middle ground with higher pressure can be obtained by adopting the said methodology.
Figure 1 Load force for various machineries
10. Reduction of pressure pulsation:
In the existing system the pulsation of pressure inside the valve body and discharge pipe produces more losses and can be accompanied by an increase in shaking forces (or unbalanced forces) [14]. It illustrates that shaking forces shall be determined and controlled and piping and vessels properly supported. The margin of separation between the mechanical natural frequency (MNF) of system (including piping and bottles) and excitation frequency is 20% and MNF shall be greater than 2.4 times maximum run speed [16,18]. If not meet limits, the force response (including stress analysis) is required. The cylinder gas forces (also called frame stretch or cylinder stretch force) can be significant source of excitation (can cause high frequency vibration on the bottles and piping close to the compressor) and lead to excessive pulsation bottle vibration even if the pulsation shaking forces meet limits. Flow induced pulsation is rarely seen [14]. API 618 Design Approach 3 and less rigorous analysis, to control pulsation and shaking (unbalanced) force levels and avoiding mechanical resonance can result in an optimized design [14]. Pulsation and vibration analysis report shall include Time Domain (TD) and Frequency Domain (FD) simulations, Time Domain (TD) plots of key forces and pressure pulsation, dynamic pressure drop, models including mounting details (mounting plate, bolts, localized skid, etc) and shell flexibility (nozzle connection flexibility), calculated cylinder stretch forces, mode shape of bottles and piping and compressor stiffness assumption compressor frame modelled as flexible support) [18].
11. Main bearing monitoring Proceedings of the National Conference on Emerging Trends In Mechanical Engineering 2k13
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Abnormal loading conditions of reciprocating machines cause increase in temperature that overheat all sliding parts. Continuous heating leads to wear and tear of moving parts rapidly and unevenly this leads to produce noise and vibrations after a prolonged time of usage these shaking forces causes damage to the main bearings . considering all the above factors are acquired and compared with the existing design and normal operating specifications inorder to reduce potential malfunctions the design changes were made. 12. Design changes : Sometimes due to the process requirements, reciprocating compressor shall be operate at low suction pressures and full design flow at normal discharge. It can have the strong effect on compressor sizing especially frame rating and motor capacity (more than 35 % of increase in power due to 20 % drop in pressure). Latest experiences recommended respecting this condition as design point in basic design to avoid costly future changes. The fluid piston compressor is proposed to obtain the variable mass flow rate at the constant running speed to eliminate the design changes and power losses due to offload conditions.
13. Noise reduction: It is important to note the simplicity of this Fluid piston compressor while meeting the design criteria. It has eliminated discharge noise problems by discharge high -pressure gasses, has no leakages were found in compressors, can start and stop at will, has an automatic cooling process, small in design, and is an inertia driven device. However, this device does create some problems of its own through fixing conventional type of reciprocating machineries.
The force with which they hold by the spring pressure of the inlet and outlet valve opening and closing of chamber is lesser and in a gradual manner so the impact on the valve seats and valve can be minimised and pitting and valve flutter can be reduced drastically. The problem of turbulent exit at the discharge and wall friction due to turbulent exit were minimised by the valve at gradual discharge of air.
14. Elimination Rod drop: The piston rod assembly drops during operation due to normal rider band wear sometimes due to dirt or liquid in the gas stream ,cylinder valve problem , insufficient lubrication , cylinders running unloaded over prolonged periods of time can cause drastic and sometimes sudden reduction in rider band life rider bands must therefore be changed periodically to prevent contact between the piston and Figure 2 Snap Shot of Fluid Piston Compressor Proceedings of the National Conference on Emerging Trends In Mechanical Engineering 2k13
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cylinder , as this would seriously damage both components and results in expensive repair. Replacement of rider bands solely an hour of operation is not the most efficient method. By replacement of the above mechanisms by means of the fluid piston the above problems were minimized and the replacement costs of the components are null and void. Results and Discussion:
From the experimental results the improved volumetric efficiency for the given input shows the better performance at lesser pressure ratio and higher mechanical efficiency for the given input. The various problems faced and the remedial alternative design for the above problems and the alternative methodology and its benefits are addressed in this paper.
Conclusion From the past studies of the problems and remedial solutions it is arrived and concluded that the fluid piston compressor plays a vital role in the middle ground of the linear pneumatic device in the Morden technological world. By defeating the limitations of the micro controlled devices to sense the level of the fluid in position and controlling of the position of the fluid may give the most efficient and economic compression in all the aspects. These types of compressors are suitable for compressing the hazardous and flammable gaseous without any maintenance, if needs to be safely done by servicing valves provided in the compression chambers. The only moving part in the fluid piston compressor is valves and fluid pump. It does not require adequate maintenance because it is an inertia driven machinery. By introducing the accurate and cheaper sensing technology leads to the better energy efficient maintenance free compressors in the future market.
Refrences
1. Dr.T.Rajesh Kanna and R.Ayyappan, Design Of Fluid Piston Compressor For Reliability And Repeatability ,National Conference on Advances In Mechanical Engineering AME - 2011; PP 111-121.
2. Dr.T.Rajesh Kanna and R.Ayyappan, Design of Fluid Piston Compressor Variable Compression Ratio And Reduced Frictional Losses, Recent Trends In Aeronautics And Mechanical Engineering, NCRTAME11 ;PP 10.
3. Amin ALMASI Advanced technologies in reciprocating compressor with Respect to performance and reliability International Advanced Technologies Symposium (IATS09), May 13-15, 2009, Karabuk, Turkey.
4. Eric J. Barth and Jose Riofrio, Dynamic Characteristics of a Free Piston Compressor, Accepted to the 2004 ASME International Mechanical Engineering Congress and Exposition (IMECE).
5. JoseRiofrio and Eric J. Barth, Experimental Operation and Characterization of a Free Piston Compressor, Accepted to the 2005 ASME International MechanicalEngineering Congress and Exposition (IMECE). Proceedings of the National Conference on Emerging Trends In Mechanical Engineering 2k13
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