COMPRESSORS

Compressor is a mechanical device that increases the pressure of a gas by reducing its volume.

Compressors are similar to pumps both increase the pressure on a fluid and both can transport the fluid through a pipe. As gases are compressible, the compressor also reduces the volume of a gas. Liquids are relatively incompressible, while some can be compressed, the main action of a pump is to pressurize and transport liquids.

Working
Air compressor consists of two major components y Compressing mechanism y Power source The compressing mechanism can be a piston, rotating impeller or vane, whereas the power is supplied by an electric motor or other energy sources

Working
The basic working principle of an air compressor is to compress atmospheric air, which is then used as per requirements. In the process, atmospheric air is drawn in through an intake valve; more and more air is pulled inside a limited space mechanically by means of piston, impeller or vane. Since the amount of pulled atmospheric air is increased in the receiver or storage tank, pressure is raised automatically.

Compressor Classification
o By principle of operation o By construction type o By staging o By service duty o Lubricated/ non lubricated

Principle of Operations
Type of compressor

Positive displacement

Dynamic

Reciprocating

Rotary

Centrifugal

Axial

Positive Displacement
(Increase pressure by reducing volume) Types are y Reciprocating y Rotary - Screw, Vane , Liquid Ring & Lobe y Diaphragm

Dynamic or Turbo Compressors

By imparting K.E. to air/gas and then converting it into pressure Types are y Centrifugal or Radial Compressors y Axial Flow Compressors

Reciprocating Compressor
Used for air and refrigerant compression Works like a bicycle pump: cylinder volume

reduces while pressure increases, with pulsating output

Many configurations available Single acting when using one side of the piston,

and double acting when using both sides

y Advantages:

- simple & open in construction - site repairs possible -do not require specialist at site y Disadvantages: -Maintenance prone mainly valves, piston/rider rings -Large bulky foundation -Long installation time

Rotary Compressor
Rotors instead of pistons: continuous discharge Benefits: low cost, compact, low weight, easy to

maintain
Sizes between 30 200 hp

Types

Lobe compressor Screw compressor Rotary vane / Slide vane

y Advantages:

- fewer components - compact design, very good for portable applications -package skid mounted concept y Disadvantages: -Not very reliable. Mainly anti-friction bearings used and these have limited life -Close tolerances between screw elements -Site repairs not possible

Diaphragm Compressors
y A diaphragm compressor (also known as a

membrane compressor) is a variant of the conventional reciprocating compressor. The compression of gas occurs by the movement of a flexible membrane, instead of an intake element. The back and forth movement of the membrane is driven by a rod and a crankshaft mechanism. Only the membrane and the compressor box come in contact with the gas being compressed

Centrifugal Compressor
Rotating impeller

transfers energy to move air

Continuous duty Designed oil free High volume

applications > 12,000 cfm

Advantages: - reliable and suitable for uninterrupted operation without standby - no wearing parts, compact design, easy installation -consistent performance Disadvantages: -Sensitive to changing ambient conditions -Special protection system against surge -Change in gas mol. wt. limits the operation

y Axial compressors are rotating, airfoil based

compressors in which the working fluid principally flows parallel to the axis of rotation. This is in contrast with other rotating compressors such as centrifugal, axi-centrifugal and mixed-flow compressors where the air may enter axially but will have a significant radial component on exit.

Advantages: - Highest efficiency - no wearing parts -consistent performance Disadvantages: y High noise level. y -Special care to be taken for the variation in frequency

Classification by staging of compressors

y Single Stage ( compression of gas in one stage) y Multi-stage ( compression of gas in more then one

stage )

Lubricated or Non Lubricated Compressors

y Lubricated Compressors : Where the gas is mixed

with lubricant
y Non Lubricated Compressors: Where process gas or

air remains uncontaminated by the the lubricant during the compression process

Significant inefficiencies of Compressors

Compressors: 5 to > 50,000 hp 70 90% of compressed air is lost

Benefits of managed systems

Electricity savings: 20 50% Maintenance reduced, downtime decreased,

production increased and product quality improved

Applications
y In petroleum refineries, natural gas processing

plants, petrochemical and chemical plants, and similar large industrial plants for compressing intermediate and end product gases. y In gas turbine systems to compress the intake combustion air y In many various industrial, manufacturing and building processes to power all types of pneumatic tools