BCTB-201 SIZING AND SELECTING DIAPHRAGM COMPRESSORS

INTRODUCTION
When compressor selection can not be determined from a performance curve, sizing of
the compressor is necessary. This Technical Bulletin outlines the methods to be used for
the selection of frames (crankcases) and contour volumes for general purpose and spe-
cific customer applications related to the operating pressures and the flow rate.
DEFINITION OF TERMS
For the purpose of sizing a compressor, the primary interest is in the characteristics and
quantity of gas handled, the initial and final pressures, the temperature conditions, and the
power required. All too often the specified operating conditions may not be properly de-
fined and consequently, the compressor has not been adequately sized for the application.
FLOW RATE
Compressor flow rates may be expressed as volume per unit time or weight per unit time.
n each of these cases, the reference points of pressure and temperature are required.
Common flow rate terminology includes:
Standard cubic feet per minute, or SCFM - The volume is measured at 14.7 psiA at 60F
(STP or stp).
nlet cubic feet per minute, or CFM - The volume is measured at the suction pressure and
suction temperature.
Actual cubic feet per minute, or ACFM - The volume is measured at the discharge pressure
and the estimated discharge temperature.
Operating cubic feet per minute, or OCFM - The volume is measured at either the suction
pressure and suction temperature, or the discharge pressure and the estimated discharge
temperature.
Normal cubic meters per hour - The volume is measured at 1 atmA at 0C (STPM or stpm).
Pounds per minute, or hour (b/m or b/hr) - The dry weight is required and either the spe-
cific gravity, density, specific volume or molecular weight must be given along with the inlet
temperature.
Kilograms per minute or hour (kg/m or kg/hr) - The dry weight is required and either the
specific gravity, density, specific volume or molecular weight must be given along with the
inlet temperature.
Moles per minute - The dry weight is required along with the inlet temperature.
PRESSURE
Pressure is expressed as a force per unit area and is usually measured by a gauge which
registers the difference between pressure in a confined volume and the atmospheric pres-
BCTB-201: SIZING AND SELECTING DIAPHRAGM COMPRESSORS
- 2 -
sure. Therefore, a gauge pressure does not indicate the true total gas pressure. To obtain
true gas pressure, it is necessary to add the atmospheric or barometric pressure in the
proper units. The world wide standards used are 14.696 psi and 1.033 kg/cm. When the
atmospheric pressure is added to gauge pressure it is defined as the absolute pressure
and is identified as psiA and kg/cm(A). For all compressor calculations the absolute pres-
sure is required.
TEMPERATURE
Temperature can be expressed in several different but interrelated terms. The two temper-
ature scales are Fahrenheit and Centigrade. Like pressure, the absolute temperature is re-
quired for all compressor calculations.
CONVERSION OF TERMS
FLOW RATE CONVERSION
Since the calculations and performance tests are based on standard or normal conditions,
1 atmA at 0C or 14.7 psiA at 60F, conversion of the flow rate at other than standard con-
ditions is required.
SCFM from standard cubic feet at a different reference temperature.
Q
s
= SCFM( T
a
/T
s
)
SCFM from CFM.
Q
s
= CFM ( P
s
/14.7 )( T
a
/T
s
) ( 1/Z
s
)
SCFM from ACFM
Qs = ACFM ( P
d
/14.7 )( T
a
/T
d
)( 1/Z
d
)
SCFM from weight flow (bs/minute)
Q
s
= Q
w
( S
v
)( T
a
/T
d
) or,
Q
s
= Q
w
( 1 /S
w
) ( T
a
/T
d
) or,
Q
s
= Q
w
( 13.1 /S
g
)( T
a
/T
d
)
SCFM from mole weight flow
Q
s
= Q
m
( 379/M ) ( T
a
/T
d
)
PRESSURE AND TEMPERATURE CONVERSION
Sizing calculations are based on absolute pressure and temperature. Conversions to ab-
solute pressure and temperature are given
PSA from PSG
PSA = PSG + 14.7psi
kg/cm
2
A from kg/cm
2
G
kg/cm
2
A = kg/cm
2
G + 1.033kg/cm
2
BCTB-201: SIZING AND SELECTING DIAPHRAGM COMPRESSORS
- 3 -
R from F
R = F + 459.7
K from C
K = C + 273.2
COMPRESSOR SIZING - SINGLE STAGE
The sizing methods discussed in this section are accurate to within 5% provided that all
of the factors are properly applied. Since compressor speed can be increased or de-
creased 5%, for all practical purposes the methods outlined are satisfactory for well over
90% of the applications. Higher accuracy or BCNA design judgement will be required in
those cases involving gases having unusual compressibility characteristics. Examples of
such gases are carbon dioxide and the C
2
+ hydrocarbons.
COMPRESSION RATIO
The compression ratio for any application is:
R = ( P
d
/ P
s
) ( Z
s
/ Z
d
)
f the value calculated for R is greater than 10, then two or more stages of compression
may be required.
VOLUMETRIC EFFICIENCY
The efficiency will be estimated based on the compression ratio efficiency graph, Figure 1.
Using the value of R determine the estimated efficiency from the graph in figure 1 using
the closest discharge pressure given.
Figure 1, VoIumetric Efficiencies vs. Discharge Pressure
MINIMUM COMPRESSOR EFFECTIVE DISPLACEMENT
The flow rate from a single stage compressor is based on the volumetric efficiency and the
effective displacement. Volumetric efficiency is a function of the clearance volume. The ef-
fective displacement is the volume displaced by the piston during one revolution and is the
compressor displacement. The minimum compressor displacement per stroke is calculat-
ed using the volumetric efficiency from figure 1 and the specific operating pressure and
flow requirements .
BCTB-201: SIZING AND SELECTING DIAPHRAGM COMPRESSORS
- 4 -
V
pm
= ( Q
s
)( 1728 ) (14.7/P
s
) ( Z
s
)( T
s
/T
a
)( 1/N
s
)( 1/E )
The volume calculated by this equation is not the contour displacement; it is the minimum
displacement of the piston relative to the required gas flow. Most diaphragm compressors
are designed to have a "hydraulic pad" between the diaphragm set and the contour of the
hydraulic plate. This is accomplished by having a piston displacement slightly smaller than
the contour volume. The contour will only displace a volume equal to the piston displace-
ment.
ACTUAL COMPRESSOR EFFECTIVE DISPLACEMENT
Table 1 lists all of the standard contours and their effective displacement on the current
line of crankcases. Select a contour with an effective displacement and pressure rating
equal to or greater than V
pm
and the required discharge pressure. The selection is desig-
nated as V
pe
.
Therefore,
V
ce
= V
pe
> V
pm
, where V
ce
is the effective contour volume.
FLOW VERIFICATION
Using the actual effective contour volume (V
ce
) determine the gas flow rate by:
Q
s
= V
ce
N
s
E ( P
s
/14.7 ) (1/Z
s
) ( 1/1728 )
COMPRESSOR SIZING - TWO STAGE
The requirements for two stage compressors are virtually the same as single stage com-
pressors.
COMPRESSION RATIO
n the case of two stage compressors, the compression ratio for each stage of compres-
sion and the approximate flow rate for each stage must be calculated. The single stage
compression ratio calculation is restated as:
f the value of R
i
is greater than 10, then additional stages of compression may be required.
The n root is taken until stage compression ratios are less than 10. The interstage pressure
may then be approximated since the compressibility factor of the gas has yet to be consid-
ered. Refer to the section NTERSTAGE PRESSURE.
P
i
= (R
i
)(P
s
)
Using the estimated interstage pressure and the required final discharge pressure, read
R
i
P
d
P
s
-------
Z
s
Z
d
------
=
BCTB-201: SIZING AND SELECTING DIAPHRAGM COMPRESSORS
- 5 -
the estimated efficiency from figure 1.
MINIMUM COMPRESSOR EFFECTIVE DISPLACEMENT
The minimum compressor displacement per stroke for each stage of compression is cal-
culated using the volumetric efficiency from figure 1 and the estimated interstage pressure
and the specific discharge pressure and flow requirements.
V
pm1
= (Q
s
)(1728)(14.7/P
s
)(Z
s
)(T
s
/T
a
)(1/N
s
)(1/E). first stage and,
V
pm2
= (Q
s
)(1728)(14.7/P
i
)(1/N
s
)(1/E), second stage.
The volume calculated for the second stage does not account for the compressibility factor
at the interstage conditions and assumes that the intercooler reduces the discharge tem-
perature from the first stage to 60F (520R).
ACTUAL COMPRESSOR EFFECTIVE DISPLACEMENT
Table 1 lists all of the standard contours and their effective displacement on the current
line of crankcases. Select a contour with an effective displacement and pressure rating
equal to or greater than Vpm and the required discharge pressure. The selection is desig-
nated as Vpe.
Therefore,
V
ce1
= V
pe1
>= V
pm1
, where V
ce1
is the effective contour volume, first stage
V
ce2
= V
pe2
>= V
pm2
, where V
ce2
is the effective contour volume, second stage
INTERSTAGE PRESSURE
Before the effective contour volumes of a two stage compressor can be finalized, the in-
terstage pressure must be reasonably accurate. The interstage pressure as previously cal-
culated was an approximation and did not account for gas compressibility at the inlerstage
condition. Gas compressibility was accounted for when the overall compression ratio was
determined. The interstage pressure is a function of the gas compressibility and can be
restated as,
P
i
= (Z
i
) (psiA)
To approximate P
i
and its corresponding Z
i
refer to the original calculation for the inter-
stage pressure, Pi = (Ri)(Ps). Check the value for Z
i
at this pressure (P
i
). For example,
assume the compression of methane and a calculated interstage pressure of 1000 psiA:
P
i
= (Z
i
)( 1000 psiA ) From the compressibility curve for methane, Z
i
= 0.895
P
i
= ( 0.895 ) ( 1000 )
P
i
= 895 psiA
Since the compressibility factor of methane at 895 psiA is 0.889, this compressibility is then
substituted back into the equation.
P
i
= ( 0.889 ) ( 1000 )
P
i
= 889 psiA From the compressibility curve for methane, Z
i
= 0.890
BCTB-201: SIZING AND SELECTING DIAPHRAGM COMPRESSORS
- 6 -
This is good agreement and therefore the interstage pressure and the compressibility fac-
tor can be considered as 889 psiA and 0.890, respectively. Agreement between interstage
pressure and compressibility factor should be 5%. Depending on the results of this trail
and error method, the effective contour volumes must be reviewed and revised if required.
FLOW VERIFICATION
Using the original selection or revised selection of effective contour volumes determine the
gas flow rate for each stage:
Q
s1
= V
ce1
N
s
E1 ( P
s
/14.7 ) ( 1/Z
s
) ( 1/1728 ), first stage and,
Q
s2
= V
ce2
N
s
E2 ( P
i
/14.7 ) ( 1/Z
j
) ( 1/1728 ), second stage
Q
s1
does not necessarily have to equal Q
s2
. However, Q
s1
must be equal to or greater than
the specified flow rate since the first stage determines the overall volumetric rate. n most
cases, Q
s1
Q
s2
. f the flow from the first stage is greater than the second stage, the in-
terstage pressure will be forced higher than the theoretical pressure since the effective
contour volumes are not in perfect balance. The slightly higher interstage pressure will
cause the first stage to become less efficient; the second stage will become more efficient
since the inlet pressure (interstage pressure) is higher.
ACTUAL EFFICIENCY
n previous paragraphs the minimum compressor displacement was made based on esti-
mated efficiency from which an effective piston displacement and an effective contour vol-
ume were selected. The following paragraphs provide for methods to calculate the
theoretical efficiency by controlling clearance volumes in the gas plate.
The maximum theoretical efficiency of any stage of compression is determined by:
E = V
ce
- {V
d
[( P
d
Z
s
/ P
s
Z
d
) - 1 ]} / V
ce
Since the theoretical efficiency is maximum and does not account for pressure drops or
hydraulic losses within the compressor, the efficiency must be derated by a factor of 0.90.
Therefore, the equation above is redefined as:
E = ( V
ce
- {V
d
[( P
d
Z
s
/ P
s
Z
d
) - 1 ]} / V
ce
) 0.90
Should suction pressures to the compressor be less than 10 psiA, the factor shall be 0.75.
The term V
d
is the clearance volume . The value for V
d
may be taken from Table 1. n some
cases the clearance volume may be reduced, but in no case shall it be less than 3% of the
effective cavity volume. Clearance volumes may have to be increased for dense gases or
high molecular weight gases such as argon, C
2
+, Freons, or gases with compressibility
factors less than 0.85 at the specified suction and/or discharge conditions.
With a calculated efficiency, the contour volume may be smaller than that which was de-
termined in the previous paragraphs. The frame size and piston size should be reviewed
at this time if the theoretical efficiency from this equation is 5% of the estimated efficiency
taken from figure 1.
BCTB-201: SIZING AND SELECTING DIAPHRAGM COMPRESSORS
- 7 -
TEMPERATURE RISE - SINGLE OR TWO STAGE
When a gas is compressed, the temperature will increase since work or energy is imparted
to the gas. The amount of temperature increase is a function of the thermodynamic prop-
erties and the method of compression (thermodynamic work). From experimental data, it
has been shown that gas compressed by a diaphragm compressor does not increase in
temperature as much as positive displacement piston compressors. This is due to the
large surface area of the gas plate which transfers the heat of compression by convection;
the circulation of oil in the hydraulic system, which transfers the heat by conduction; the
cooling water circulating through the gas plate which transfers the heat by conduction.
The temperature rise of a gas due to compression is expressed by,
This expression holds true for gases whose ratio of specific heats (k) is < 1.3 and when
the compression ratio is < 2.25:1. When k is > 1.3 or when the compression ratio is > 2.25:1
polytropic constant (h) is used for calculating the temperature rise. The equation is rewrit-
ten for the polytropic constant in the form of,
Refer to Table 2 for polytropic constants.
TabIe 2 - PoIytropic Constants (h)
When performing the calculations, all temperatures must be in degrees absolute, R or K.
Note that compressibility factors are not used - the compression ratio is based on ideal gas
laws.
&2035(66,21 5$7,2 N ! N !
3:1 1.30 1.40
4:1 1.26 1.35
5:1 1.23 1.32
6:1 1.19 1.30
7:1 1.16 1.27
8:1 1.12 1.25
9:1-10:1 1.11 1.20
7 7 3 3
G V G V
N N
=

( / )
( / ) 1
7 7 3 3
G V G V
=

( / )
( / ) 1
BCTB-201: SIZING AND SELECTING DIAPHRAGM COMPRESSORS
- 8 -
NOMENCLATURE AND SYMBOLS
The following symbols and their definitions are used in this Technical Bulletin:
SYMBOL DEFNTON
ACFM Actual cubic feet/minute
E Efficiency, %
CFM nlet cubic feet/minute
M Molecular weight, dimensionless
N
s
Rotational speed, revolutions per minute (rpm)
0CFM Operating cubic feet/minute
P Pressure, psiA
P
d
Pressure, gas discharge, psiA
P
h
Pressure, hydraulic, psiG
P
i
Pressure, gas interstage, psiA
P
s
Pressure, gas suction, psiA
Q
a
Flow rate, actual cubic feet/minute
Q
o
Flow rate, inlet cubic feet/minute
Q
s
Flow rate, standard cubic feet/minute or normal cubic meters/hour
Q
m
Flow rate, moles/minute dry
Q
w
Flow rate, pounds/minute dry or kg/minute dry
R Compression ratio, overall, dimensionless
S
v
Specific volume of gas, cubic feet/lb
S
w
Specific weight (density) of gas, bs/cubic foot
S
g
Specific gravity of gas (Air=1)
SCFM Standard cubic feet/minute
T Temperature
T
a
Temperature, ambient, R (460 + 60F = 520R)
T
d
Temperature, discharge, R
T
i
Temperature, interstage, R
T
s
Temperature, suction, R
V
ca
Volume, actual contour, in
3
V
ce
Volume, effective contour, in
3
V
d
Volume, gas contour clearance, in
3
V
pe
Volume, effective piston displacement, in
3
V
pm
Volume, minimum piston displacement, in
3
Z Compressibility factor, gas
Z
d
Gas Compressibility factor, discharge pressure, dimensionless
Z
i
Gas Compressibility factor, interstage pressure, dimensionless
Z
s
Gas Compressibility factor, suction pressure, dimensionless
h Polytropic constant, dimensionless
a Ambient condition (subscript)
d Discharge (subscript)
k Ratio of specific heats, dimensionless
i nterstage (subscript)
n Number
o Operating Conditions (subscript)
s Suction (subscript)
R Temperature, absolute
ssue Date: November 26, 1990