IAETSD JOURNAL FOR ADVANCED RESEARCH IN APPLIED SCIENCES, VOLUME 4, ISSUE 1, JAN-JUNE /2017

ISSN (ONLINE): 2394-8442

Experimental Analysis of Multi Cylinder Horizontal Opposed Piston

Compressor Used in Process Industry
1
Mr. Patan Imran Khan, 2Dr. G.V.Patil
1 2
PG Student, Associate Professor, Dept. Of Mechanical Engineering, Pillai College of Engg. & Tech, Rasayani ,Mumbai University, India.
1
pathanimrankhan09@gmail.com, 2gpatil@mes.ac.in

ABSTRACT.

In this work, Ingersoll Rand IHE-5-NL type Horizontal opposed piston reciprocating
compressor is analyzed both experimentally as well as through numerical simulations. To perform design
check aimed at an excessive vibration problem of Compressor. The process plant comes across dynamic
vibration problems, if process plants arise across dynamic vibration problem through their operation, before
they need to be addressed as critical then should be analyzed cutting-edge detail. These vibrations are
mostly induced by the rotating or reciprocating machines like compressor, pump and turbo machine. With
reliable and robust method for solution of vibration problems without the means of experimentation.
Experimentally vibration response is captured in terms of velocity, displacement and accelerations along
with corresponding frequencies .It has been observed that thrusting of air causes axial vibrations to go to
level of 55 m/s2.Vibrations are also at peak for back end but are within limit at driving end . As FEM
approach is required to back up the results, simulations were run on compressor by identifying conditions
observed from experiments with harmonic analysis in the appropriate frequency range captured from
experiments .Stresses at critical locations worked out .It has been observed that level of vibrations should be
cut down and modifications required in compressor to improve performance of compressor and reduce
maintenance.

Keywords Ingersoll Rand IHE-5-NL type Horizontal opposed piston reciprocating, experimentally, simulations, vibration problem, Von Mises
Stresses, harmonic analysis.

INTRODUCTION
The Ingersoll Rand IHE-5-NL type Horizontal opposed piston reciprocating Compressor is used in process Industry. Only 10-30% of energy reaches
to the end user, and remaining energy is lost [1-4]. The Compressor comes under vibration frequencies while operating. In the Industry, where the
compressor work for 24*7 time period the compressor needs the predictive maintenance time to time. To predict the maintenance time is quite
difficult, if it is done early compressor has to be stop and result into unproductively and if it is done later the compressor parts can be damaged and
whole setup can be damaged. The vibration frequencies changes as day by day and tell the compressor health. And through frequency, predictive
maintenance can be predicted. This paper tell the effect of the Experimental frequency and displacement , velocity , acceleration at different critical
location on the compressor and the stresses generated in term of Von Misses stress for individual parts. The Harmonic analysis is preformed and the
frequency range and acceleration is used to find the Stress.

To Cite This Article: Mr. Patan Imran Khan and Dr. G.V.Patil,. Experimental Analysis of Multi Cylinder
Horizontal Opposed Piston Compressor Used in Process Industry. Journal for Advanced Research in Applied
Sciences ;Pages: 516-523
517. Mr. Patan Imran Khan and Dr. G.V.Patil,. Experimental Analysis of Multi Cylinder Horizontal Opposed Piston
Compressor Used in Process Industry. Journal for Advanced Research in Applied Sciences; Pages: 516-523

As Von Misses stress is considered to be a safe haven for design engineers. And by using the Resonance transmissibility curve the maximum stresses
came is predicted. Using this information an engineer can say his design will fail at current scenario or not. And this tells which parts are sensitive to
the maintenance [5-7]. And in later time at different time interval the different frequency range can be used in time to time to check the compressor
health and the maintenance time. It is used in current trends to optimize the compressor compact and free from vibration; therefore, it is very
important to be able to successfully reduce and prevent harmonic response of Compressor components.

OBJECTIVE -

To measure the excessive vibration frequencies at different locations of Compressor.

To observe and note down the excessive vibrations frequencies at different locations on a Compressor at starting of the engine and at steady
state.

To identify critical Locations in a Compressor.

With a reliable and robust method for solution of vibration problems with use of experimental data for avoiding repeated use for
experimentation for maintenance and optimization.

Experimental Investigation -

Displacement ,velocity ,acceleration are recorded at critical locations of compressor of Non Driving End OF compressor ,Middle housing Right hand
side of Compressor , Driving End of Compressor ,HP Side ,Motor side . Driving End of Compressor are critical as stresses and frequency response
are difficult to get , these are having higher frequency range and acceleration range of 55m/s2.They are obtained by HTC company based VB-8205
micrometer pick up device .

Non Driving End of Compressor values are :

Horizontal side Vertical side

Frequency vs. Acceleration Frequency vs. velocity

Frequency (Hz) Ace. (m/sec2) Frequency (Hz) Velocity (m/sec)

1648 56.1 1547
1026 32.1 1243 11.7
2461 33.5 1215 20.4
1121 48.7 1779 13.2
1026 25.9 1446 13.3
1225 22.9 1450 10.4
1691 36.1 2783 21.9
1846 45.1 2325 10.6
930 33.7 1447 13.7
1251 31.7 2052 20.6

Fig 1 Frequency vs. Acceleration Fig 2 Frequency vs. velocity

518. Mr. Patan Imran Khan and Dr. G.V.Patil,. Experimental Analysis of Multi Cylinder Horizontal Opposed Piston
Compressor Used in Process Industry. Journal for Advanced Research in Applied Sciences; Pages: 516-523

And Driving End of Compressor values are:

Frequency vs. Displacement Frequency vs. velocity

Frequency (Hz) Displacement (m) Frequency (Hz) Velocity (m/sec)

1887 0.08 1887 1.89
1469 0.07 1469 0.83
1981 0.08 1981 0.9
1849 0.07 1849 1.41
2331 0.1 2331 2.1
1815 0.07 1815 1.19
1456 0.05 1456 0.81
1290 0.06 1290 1.03
1080 0.05 1080 1.11
1387 0.05 1387 1.27

HP Side:
Frequency vs. Displacement Frequency vs. velocity

Frequency (Hz) Displacement (m) Frequency velocity (m/sec)

2680 0.47 2680 4.57
2606 0.08 2606 4.14
2830 0.08 2830 4.03
2619 0.07 2619 4.47
2288 0.07 2288 4.07
3764 0.06 3764 4.71
2959 0.08 2959 4.49
2691 0.07 2691 4.19
2617 0.06 2617 4.45
3189 0.08 3189 4.15

Fig 5 Frequency vs. Displacement Fig 6 Frequency vs. velocity

519. Mr. Patan Imran Khan and Dr. G.V.Patil,. Experimental Analysis of Multi Cylinder Horizontal Opposed Piston
Compressor Used in Process Industry. Journal for Advanced Research in Applied Sciences; Pages: 516-523

Acceleration vs. Frequency

Frequency
(Hz) 2680 2606 2830 2619 2288 3764 2959 2691 2617 3189
2
Ace. (m/sec ) 107 118 117 100 91.3 18.4 99.3 99.6 90 104

Fig 7 Acceleration vs. Frequency

RESULTS & DISCUSSIONS

The experimental data is then used with software package for creation of stress and frequency response for the compressor parts like, outer frame ,
Crank Shaft , piston ,connecting rod , Outer covering of Piston [8-10] . The analysis software used is Ansys Workbench. The different materials
selected for compressor are as:

Head: Cast Iron, Cylinder liner: Stainless Steel, Piston: Forged Aluminum alloy, Crank shaft: Forged carbon steel, Disc/Relief valves internals:
Stainless steel.

Model of Horizontal opposed piston compressor

Fig 8: Model of in Ansys compressor

520. Mr. Patan Imran Khan and Dr. G.V.Patil,. Experimental Analysis of Multi Cylinder Horizontal Opposed Piston
Compressor Used in Process Industry. Journal for Advanced Research in Applied Sciences; Pages: 516-523

Equivalent stress and Frequency Responses

Fig 9: Von Misses Stress on outer cover.

The Maximum Von Misses Stress is 10.643 MPA near the crankshaft and the minimum Von Misses Stress is 5.85*e -5 MPA near the outer cover of
the piston , taking the frequency Range of 1000-6000 Hz , acceleration as 55 m/sec2 and Phase angle of 0 as the initial condition.

Fig 10: Von Misses Stress in Crank Shaft

The Maximum Von Misses Stress is 2.46 MPA near the lobe of the crankshaft and the minimum Von Misses Stress is 3.06*e-4 MPA near the outer
end of crankshaft , taking the frequency Range of 1000-6000 Hz , acceleration as 55 m/sec2 and Phase angle of 0 as the initial condition.

Fig 11: Von Misses stress in Piston

521. Mr. Patan Imran Khan and Dr. G.V.Patil,. Experimental Analysis of Multi Cylinder Horizontal Opposed Piston
Compressor Used in Process Industry. Journal for Advanced Research in Applied Sciences; Pages: 516-523

The Maximum Von Misses Stress is 2.06*e-1MPA near the hole in piston and the minimum Von Misses Stress is 2.51*e-3 MPA near piston ring ,
taking the frequency Range of 1000-6000 Hz , acceleration as 55 m/sec2 and Phase angle of 0 as the initial condition.

Fig 12: Frequency Response of Piston

The stress Amplitude with the frequency showing the critical frequencies matching the given frequencies Range of 1000-6000 Hz , acceleration as 55
m/sec2 and Phase angle of 0 as the initial condition.

Fig 13: Von Misses Stress in Outer covering of Piston

The Maximum Von Misses Stress is 2.9857*e-1 MPA near outer edge of piston cover and the minimum Von Misses Stress is 3.27*e-4 MPA near the
outer cover of piston , taking the frequency Range of 1000-6000 Hz , acceleration as 55 m/sec2 and Phase angle of 0 as the initial condition.

Fig 14: Frequency Response of Outer covering of Piston

522. Mr. Patan Imran Khan and Dr. G.V.Patil,. Experimental Analysis of Multi Cylinder Horizontal Opposed Piston
Compressor Used in Process Industry. Journal for Advanced Research in Applied Sciences; Pages: 516-523

The stress Amplitude with the frequency showing the critical frequencies matching the given frequencies Range of 1000-6000 Hz , acceleration as 55
m/sec2 and Phase angle of 0 as the initial condition.

Fig 15: Von Misses Stress in Connecting Rod

The Maximum Von Misses Stress is 1.2698 MPA near outer edge of piston cover and the minimum Von Misses Stress is 1.5113*e-2 MPA near the
outer cover of piston , taking the frequency Range of 1000-6000 Hz , acceleration as 55 m/sec^2 and Phase angle of 0 as the initial condition.

Harmonic analysis has been run for a frequency range of 1000Hz to 6000Hz which is consistent with experimental observations and picked up
accordingly. Acceleration levels used in analysis are consistent with experimentally observed facts.

o The joint section of crankshaft is experiencing more stress level. Maximum Von Misses Stress is observed to be 2.46 MPA so at 10th order
resonance transmissibility level as compared to current 55 m/sec^2, the stress will be equal to 246 MPA which is still within the range of
allowable designed stress but alarming as along as vibration levels are considered.

o Frame stress is observed to be 10.64 MPA so at 10th order resonance transmissibility level as it is linear with respect to vibration order and
stress level of 100.64 MPA so it is more safe from vibration point of view.

o Connecting rod stress levels are around 1.2698 MPA so at 10th order resonance transmissibility level as it is linear with respect to vibration
order and the stress level of 12.698 MPA so it is more safe from vibration point of view.

o Similarly, Outer cover of the piston stress levels are around 2.98 MPA so it is more safe from vibration point of view

o Similarly, Piston stress levels are around 2.062 MPA so it is more safe from vibration point of view.

CONCLUSION
In this study the joint section of crankshaft is experiencing more stress level. The analytical results by simulating various parts of compressor have
compared with experimental data which had collected using micrometer during its working conditions. This article includes yield limit of stress at
different parts of compressor before it causes major damage to system. The design check aimed at an excessive vibration problem of the Compressor.
The process plant comes across dynamic vibration problems, if process plants arise across dynamic vibration problem through their operation, before
they need to be addressed as critical then should be analyzed cutting-edge detail.

These vibrations are mostly induced by the rotating or reciprocating of the compressor with reliable and robust method for solution of vibration
problems without the means of experimentation for maintenance and optimization. And in later time at different time interval the different frequency
range can be used in time to time to check the compressor health and the maintenance time. It is used in current trends to optimize the compressor
compact and free from vibration; therefore, it is very important to be able to successfully reduce and prevent harmonic response of Compressor
components.
523. Mr. Patan Imran Khan and Dr. G.V.Patil,. Experimental Analysis of Multi Cylinder Horizontal Opposed Piston
Compressor Used in Process Industry. Journal for Advanced Research in Applied Sciences; Pages: 516-523

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