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Figure 1. Process flow diagram for a 3-stage compression Uncategorized
Table 1. Measured temperature and pressure for the three stages of compression Water and Corrosion
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Table 2. Gas analysis and flow rate for the three stages of compression
* Calculated
The process flow diagram shown in Figure 1 was simulated by ProMax software [5] to perform the rigorous calculations
using the SRK EOS. The program calculated polytropic and isentropic efficiencies, heads, and compression power. The
program also calculated the isentropic path exponent (k), and polytropic path exponent (n). These calculated results are
presented in Table 2 for all three stages under SRK headingings. The calculations performed by ProMax are very similar
to the step-by-step of a through h described in the rigorous section. Table 2 also presents the shortcut caculation results
for the corresponding values under the shortcut heading. The shortcut calculations are based on the step-by-step of a
through f described in the shortcut method section. The error percent between the rigrous method and the shortcut
methods for each stage are presented in Table 2, too. Table 2 indicates that excellent agreements are obtained for stages
1 and 2. However, larger deviations are obseved for the isetropic and polytropic exponents of stage 3 due to high pressure
operation which deviated too far from ideal gas state conditions.
Conclusions
Table 2 indicates that there are good agreements between the shortcut and the rigorous results. The differences between
the rigorous and shortcut method results for facilities calculations and planning purposes are negligible. For stage 3, due
to high-pressure operation and deviating too far from the ideal gas state condition, a larger error is observed for the
isentropic exponent (k).
The calculated isentropic exponent (k) in the ProMax [5] is not the ideal gas state heat capacity (CP/CV) ratio. It is the
value of the isentropic exponent that is required to yield an isentropic path from inlet to outlet. Its value is calculated as an
integration of that path. Thus it is somewhat of an “average” value representing the true isentropic path. For ideal gases,
the value would be equal (CP/CV) ratio.
This error in ‘k’ also illustrates the importance of specifying which correlation is to be used when ordering a performance
test (ie, refer to ASME PTC-10 for additional details), so that client and vendor are on the same agreement moving
forwards with regard to molecular weight (MW) and k for the test fluid. For further detail refer to reference [6] and August
and September 2010 TOTMs [7, 8].
It may also be worth noting that when trending ‘n’ and the polytropic efficiency to evaluate machine condition, the relative
accuracy of measurement instrument/equipment (temperature and pressure transducers) and mapping of compressor
performance to the original performance curve (actual gas volume flow rate vs speed), introduces many potential
erroneous sources into this daily evaluation.
Note that the accuracy of the shortcut methods is dependent on the values of k and n. The definition of average
temperature in the shortcut method was adjusted to obtain a better match between the isentropic path exponent (k)
calculated by rigorous method.
To learn more about similar cases and how to minimize operational problems, we suggest attending our G4 (Gas
Conditioning and Processing), PF4 (Oil Production and Processing Facilities), ME46 (Compressor Systems–
Mechanical Design and Specifications) and ME44 (Fundamentals of Pump and Compressors Systems), courses.
PetroSkills offers consulting expertise on this subject and many others. For more information about these services, visit
our website at http://petroskills.com/consulting, or email us at consulting@PetroSkills.com.
Reference:
1. Maddox, R. N. and L. L. Lilly, “Gas conditioning and processing, Volume 3: Advanced Techniques and Applications,”
John M. Campbell and Company, 2nd Ed., Norman, Oklahoma, USA, 1990.
2. Campbell, J.M., Gas Conditioning and Processing, Volume 2: The Equipment Modules, 9th Edition, 2nd Printing, Editors
Hubbard, R. and Snow–McGregor, K., Campbell Petroleum Series, Norman, Oklahoma, 2014.
3. Soave, G., Chem. Eng. Sci., Vol. 27, pp. 1197-1203, 1972.
4. Peng, D. Y., and Robinson, D. B., Ind. Eng. Chem. Fundam., Vol. 15, p. 59, 1976.
5. ProMax 3.2, Bryan Research and Engineering, Inc, Bryan, Texas, 2014.
7. Honeywell, J. “Important Aspects of Centrifugal Compressor Testing-Part 1”, Tip of the Month, August 2010
8. Honeywell, J. “Important Aspects of Centrifugal Compressor Testing-Part 2”, Tip of the Month, September 2010
23 comments
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2. Francis says:
December 28, 2015 at 9:30 am
Please may I know the equation seven. I cannot find the formula for calculating the polytropic path exponent(n).
Please can u write the formula for calculating polytropic path exponent
Laurent says:
February 25, 2016 at 8:37 am
Laurent:
You are correct, both temperature and pressure ratios should have been ln(T2/T1) and ln(P2/P1).
Thanks.
3. Daniel says:
April 22, 2016 at 3:51 am
Hello, used these equations with preos… did not work, gave me an efficiency of 4000…
CAE350 compressor analyzing system is a low cost portable system to test the capacity,power efficiency and unit
air consumption of the compressor
5. Panos says:
June 17, 2016 at 4:19 pm
Here is the link of a new article, which describes the rigorous calculation of the polytropic efficiency based on
thermodynamics of real gases. A comparison with data shown on this website (!) can also be found, under:
http://www.degruyter.com/view/j/tjj.ahead-of-print/tjj-2016-0029/tjj-2016-0029.xml?format=INT
Arif says:
November 2, 2016 at 12:55 pm
Arif says:
November 2, 2016 at 12:56 pm
Compressor efficiency is very important factor for any business. Thanks for sharing this detailed calculations.
http://www.zahroofvalves.com
I built an air compressor with a quick return mechanism and a bike pump. So obviously it is a single stage
compressor. But for the calculation of efficiency should I follow these equations? If I want to neglect the
temperature change(too low) which equations should I follow?
M. Azarakhshi says:
July 1, 2017 at 8:30 am
Would these equation work for an oil injected twin rotary screw compressor?
when I try to calculate the polytropic exponent with the T1 = 40.6, T2 = 129.4, P1 = 793.1, P2 = 2275.9 the n =
1.808666. but in the table the value is n = 1.3097. Please clarify me why i am getting wrong.
I tried using the same formulas for calculating the compressor efficiency but results are good in one case but in
other cases error is more than 20 %.
Efficiency was calculated for high pressure compressor with suction pressure 60 kg/cm2.
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for you? Plz reply as I’m looking to create my own blog and would like
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can anyone please help that how to calculate the efficiency of rotary screw air compressor..????
The correlation of heat capacity ratio (Eq 3) is valid for light hydrocarbon mixtures. It is not valid for air. Air
heat capacity ratio is about 1.4 in the range of -40 deg F to 200 deg F.