AN AMERICAN NATIONAL STANDARD ASME PTC 10-1997 Performance Test Code on Compressors and Exhausters PERFORMANCE TEST CODESDate of Issuance: September 30, 1998 This document will be revised when the Society approves the issuance of a new edition, There will be no addenda issued to ASME PTC 10-1997. Please Note: ASME issues written replies to inquiries concerning interpretation of technical aspects of this document. The interpretations are not part of the document. PTC 10-1997 is being issued with an automatic subscription service to the interpreta- tions that will be issued to it up to the publication of the next edition. ASME isthe registered trademark of The American Society of Mechanical Engineers. ‘This code or standard was developed under procedures accredited as meating the erteria for ‘American National Standards. The Standards Committee that approved the code or standard ‘was balanced to assure that Individuals from competent and concerned interests have had an ‘opportunity to participate. The proposed code or standard was made available for public review ‘and comment which provides an opportunity for additional public input from industry, academia, regulatory agencies, and the publc-atlarge. "ASME does not “approve,” “rate,” or “endorse” any item, construction, proprietary device, ‘ASME does not take any positon with respect to the validity of any patent rights asserted in connection with any items mentioned inthis document, and does not undertake to insure anyone Utilizing @ standard against liability for infringement of any applicable Letters Patent, nor assume ‘any such lability. Users of a code or standard are expressly advised that determination of the ‘validity of any such patent rights, and the risk of infringement of such rights, is entirely their ‘own responsibly. PPantcipation by federal agency reprasentativels) or personis) affilated with industry is not to be interpreted as government of industry endorsement ofthis cade or standard. "ASME accepts responsibilty foronly those interpretations issuedin accordance with governing [ASME procedures and policies which preclude the issuance of interpretations by individual volunteers. No part of this document may be repraduced in any form, in an electronic retrieval system or otherwise, without the prior written permission of the publisher. ‘The American Society of Mechanical Engineers ‘Three Park Avenue, New York, NY 10016-5990 Copyright © 1998 by ‘THE AMERICAN SOCIETY OF MECHANICAL ENGINEERS All Rights Reserved Printed in U.S.A,FOREWORD (This Foreword is not a part of ASME PTC 10-1897.) PTC 10.was last revised in 1965 and it hs been reaffirmed many times in the intervening period. The PTC 10 Committee has been in various states of activity for approximately ‘the past 20 years. During that time the Cade has been completely rewritten to be far more explanatory in nature. The performance testing of compressors is complicated by the need in virtually every ‘case to consider and make correction for the differences between the test and specified conditions. The techniques used to do so are based upon the rules of fluid-dynamic similarity. Some familiarity with this fundamental technique will be a significant aid to the users of PTC 10. Compressors and exhausters come in all sorts of configurations. A very simple case is a single section compressor with one impeller, and single inlet and outlet flanges. Many more complex arrangements exist with multiple inlets, outlets, impellers, sections, in- tercoolers and side seams. Typical gases handled are air, its constituents, and various hydrocarbons. Tests are commonly run in the shop or in the field, at speeds equal to or different from the specified speed, and with the specified or a substitute gas. In order to handle this vast array of possibilities PTC 10 reduces the problem to the simplest element, the section, and provides the instructions for combining multiple sections to compute the overall results. Uncertainty analysis can play a very important role in compressor testing, from the design of the test to interpretation of the test results. in all but the very simplest of cases the development of an analytic formulation, ie. in simple equation form, for overall uncertainty computation is formidable. The test uncertainty will always be increasingly more complex to evaluate with the complexity of the compressor configuration, and by the very nature of the test will be a function of the performance curves. ‘The modem personal computer is readily capable of completing the calculations re- Quired. The Committee developed software and used it to perform both the basic code calculations and uncertainty analysis computations for a wide range of possible compressor configurations. ‘This Code was approved by the PTC 10 Committee on January 18, 1991. Itwas approved and adopted by the Council as a standard practice of the Society by action of the Board con Performance Test Codes on October 14, 1996, It was also approved as an American National Standard by the ANSI Board of Standards Review on April 22, 1997.NOTICE All Performance Test Codes MUST adhere to the requirements of PTC 1, GENERAL INSTRUCTIONS. The following information is based on that document and is included here for emphasis and for the convenience of the user of this Code. It is expected that the Code user is fully cognizant of Parts I and III of PTC 1 and has read them prior to applying this Code. ASME Performance Test Codes provide test procedures which yield results of the highest level of accuracy consistent with the’ best engineering knowledge and practice currently available. They were developed by balanced committees representing all concerned interests. They specify procedures, instrumentation, equipment operating requirements, calculation methods, and uncertainty analysis, ‘When tests are run in accordance with this Code, the test results themselves, without adjust- ment for uncertainty, yield the best available indication of the actual performance of the tested equipment. ASME Performance Test Codes do not specify means to compare those results to contractual guarantees. Therefore, itis recommended that the parties toacommercial test agree before starting the test and preferably before signing the contract on the ‘method to be used for comparing the test results to the contractual guarantees. [tis beyond the scope of any code to determine or interpret how such comparisons shall be made. Approved by Letter Ballot #95-1 and BPTC Administrative Meeting of March 13-14, 1995PERSONNEL OF PERFORMANCE TEST CODE COMMITTEE NO. 10 ON COMPRESSORS AND EXHAUSTERS (The following isthe roster of the Comminee atthe time of approval of this Code) ‘OFFICERS Gordon j. Gerber, Chair Richard |. Gross, Vice Chair fack H. Karan, Secretary COMMITTEE PERSONNEL Helmut 8. Baranek, Public Sewice Elecric & Gas Company John J. Dwyer, Consultant Gordon J. Gerber, Praxair Richard J. Gross, The University of Akron Jack H. Karin, ASME Robert E. Lawrence, Consultant Jack A. Lock, Lock Engineering Vincent J. Polignano, iMO Delaval Frank H. Rassmann, Eliott Company Norman A. Samutin, Dresser Rand Company Joseph A. Silvaggio, Ir, Altemate to Polignano, IMO DelavatBOARD ON PERFORMANCE TEST CODES ‘OFFICERS D.R. Keyser, Chair P.M. Gerhart, Vice Chair W. 0. Hay, Secretary COMMITTEE PERSONNEL RW. Henry 5.8. Scharp .R. Keyser 1. Siegmund 5.1. Korellis ILA, Silvagto, J 1. Milton RE, Sommerlad CH. Mitendort, W. G. Sele, J. 5. Nuspl 1.6 Wester RP. Perkins 1G. Yor ALL PlumleyCONTENTS Foreword «0.2... : i Committee Roster . v Board Roster... vi Section 1 Object and Scope . seeee 1 2 Definitions and Description of Terms. 3 3 ‘Guiding Principles. el u 4 Instruments and Methods of Measurement 2B 5 Computation of Results . : 39 6 Report of Test....... 55 Figures 31 Section Control Volumes... 6... 4 3.2 Typical Sideload Sectional Compressors. = 16 3.3 Allowable Machine Mach Number Departures, Centrifugal Compressors oe... eee cece ceeeeeeees le ee iG) 3.4 Allowable Machine Mach Number Departures, Axial Compressors. 9 3.5 Allowable Machine Reynolds Number Departures, Centrifugal Compressors... eee eee eeee seseees 20 3.6 Schultz Compressibility Factor — Function Y versus Reduced Pressure 21 3.7 Schultz Compressibility Factor — Function X versus Reduced Pressure 22 41 Inlet and Discharge Configuration pebuesonES , 24 42 Open inlet. . : 24 43 Vortex Producing Axial inlet . 25 44 Open Discharge 25 45 Diffusing Volute 26 4.6 Typical Closed Loop + 26 47 Typical Closed Loop With Sidestream 7 4.8 Straighteners and Equalizers. 29 43 Inlet Nozzle on an Open Loop |... 32 4.10 Discharge Nozzle on an Open Loop, Subcritical Flow 3B 4.11 Discharge Nozzle on an Open Loop, Critical Flow. 3 4.12 Typical Sidestream Inlet Area... feos 35 5.1 Specified Condition Capacity Coefficient for Specified Condition Capacity of Interest .. eee 49 Tables 3.1. Permissible Deviation From Specified Operating Conditions for Type 1 Tests... - oouBeea 232 33 34 3a 52 53 54 Permissible Deviation From Specified Operating Parameters for ‘Type 1 and 2 Tests. . Limits of Departure From ideal Gas Laws of Specified and Test Gases... o Permissible Fluctuations of Test Readings. Ideal Gas Dimensionless Parameters . Real Gas Dimensionless Parameters... Total Work input Coefficient, All Gases. Typical Conversion of Dimensionless Parameters Nonmandatory Appendices 8 c ct C2 C3 ca cs ce c7 ca ra7m™9 Use of Total Pressure and Total Temperature to Define Compressor Performance . : Properties of Gas Mixtures Sample Calculations . . . Type 1 Test for a Centrifugal Compressor Using an Ideal Gas. ‘Type 2 Test for a Centrifugal Compressor Using an Ideal Gas. leal Gas Applicaton to Selection of Text Speed and Tet Gas and Methods of Power Evaluation Treatment of Bracketed Test Points. Selection of a Test Gas for a Type 2 Test Using Ideal and Real Gas Equations. . f Type 2 Test Using Real Gas Equations for Data Reduction - Treament of a Two Section Compresor With Externally Piped Intercoolers, Condensate Removal : Application of Uncertainty Analysis References. Rationale for Calculation Methods . Reynolds Number Correction... . Refine Mthods for Calculating ‘otal Conditions - SII... ee eee cere bobseesee 2 B 4 40 4 48 50(COMPRESSORS AND EXHAUSTERS ‘ASME PTC 10-1997 SECTION 1 — OBJECT AND SCOPE 1.1, OBJECT The object of this Code is to provide a test procedure to determine the thermodynamic perform- ance of an axial or centrifugal compressor or ex- hhauster doing work on a gas of known or measurable Properties under specified conditions. This Code is written to provide explicit test proce- dures which will yield the highest level of accuracy consistent with the best engineering knowledge and practice currently available. Nonetheless, no single universal value of the uncertainty Is, or should be, expected to apply to every test. The uncertainty associated with any individual PTC 10 test will depend upon practical choices made in terms of instrumentation and methodology. Rules are pro- Vided to estimate the uncertainty for individual tests. 1.2 SCOPE 1.2.1 General. The scope of this Code includes instructions on test arrangement and instrumentation, test procedure, and methods for evaluation and reporting of final resuls. Rules are provided for establishing the following ‘quantities, corrected as necessary to represent ex- pected performance under specified operating condi- tions with the specified gas: (2) quantity of gas delivered (©) pressure rise produced (©) head (d) shaft power required (e) efficiency (0 surge point @ choke point Other than providing methods for calculating me- chanical power losses, this Code does not cover rotor dynamics or other mechanical performance parameters. 1.2.2 Compressor Arrangements. This Code is de- signed to allow the testing of single or multiple casing axial oF centrifugal compressors or combinations thereof, with one or more stages of compression per casing. Procedures are also included for exter- nally piped intercoolers and for compressors with interstage side load inlets or outlets. Internally cooled compressors are included pro- vided that test conditions are held nearly identical to specified conditions. Compressors, as the name implies, are usually intended to produce considerable density change aS a result of the compression process. Fans are ‘normally considered to be air or gas moving devices and are characterized by minimal density change. A distinction between the two at times may be unclear. As a very rough guide, either PTC 10 or PTC 11 may be used for machines falling into the approximate pressure ratio range of 1.05 to 1.2. ‘The methods of PTC 10, which provide for the pronounced effects of density change during com- pression, have no theoretical lower limit. However, practical considerations regarding achievable accu- racy become important in attempting to apply PTC 10 to devices commonly classified as fans. For example, the low temperature rise associated with fans may lead to large uncertainty in power require- ment if the heat balance method is chosen. Fans also may require traversing techniques for flow and gas state measurements due tothe inlet and discharge ducting systems employed. Refer to PTC 11 on Fans for further information. 1.3 EQUIPMENT NOT COVERED BY THIS CODE The calculation procedures provided in this Code are based on the compression of a single phase 85, They should not be used for a gas containing suspended solids or any liquid, when liquid could bbe formed in the compression process, or when a chemical reaction takes place in the compression process. This does not preclude the use of this Code on a gas where condensation occurs in a cooler provid- ing the droplets are removed prior to the gas entering the next stage of compression.ASME PTC 101997 1.4 TYPES OF TESTS ‘This Code contains provisions for two different types of tests. A Type 7 test must be conducted on the specified gas with a limited deviation between test and specified operating conditions. A Type 2 test permits the use of a substitute test gas and extends the permissible deviations between test and specified operating conditions. 1.5. PERFORMANCE RELATION TO GUARANTEE This Code provides a means for determining the performance of a compressor at specified operating conditions. It also provides a method for estimating the uncertainty of the results. The interpretation of the results relative to any contractual guarantees is beyond the scope of this Code and should be agreed upon in writing prior to the test by the participating partes. 1.6 ALTERNATE PROCEDURES Definitive procedures for testing compressors are described herein. if any other procedure or test ‘COMPRESSORS AND EXHAUSTERS configuration is used, this shall be agreed upon in writing prior to the test by the participating parties. However, no deviations may be made that will violate any mandatory requirements of this Code when the tests are designated as tests conducted in accordance with ASME PTC 10. The mandatory rules of this Code are characterized by the use of the word “shall.” if a statement is of an advisory nature it is indicated by the use of the word “should” or is stated as a recommendation. 1.7. INSTRUCTIONS The Code on General Instructions, PTC 1, shall be studied and followed where applicable. The instructions in PTC 10 shall prevail over other ASME Performance Test Codes where there is any conflict. 1.8 REFERENCES Unless otherwise specified, references to other Codes refer to ASME Performance Test Codes. Litera- ture references are shown in Appendix D.‘COMPRESSORS AND EXHAUSTERS ASME PTC 10-1997 SECTION 2 — DEFINITIONS AND DESCRIPTION OF TERMS 2.41, BASIC SYMBOLS AND UNITS Symbol Description Flow channel cross sectional area ‘Acoustic velocity Tip width Coefficient of discharge Molal specific heat (Appendix B only) Specific heat Specific heat at constant pressure Specific heat at constant volume Diameter Diameter of fluid meter Relative error Polytropic work factor Dimensional constant, 32.174 Molal enthalpy Humidity ratio Enthalpy Coefficient of heat transfer for casing and adjoining pipe Mechanical equivalent of heat, 778.17 Flow coefficient Ratio of specific heats, cp/cy ‘Common logarithm (Base 10) Naperian (natural) logarithm Molecular weight Machine Mach number Fluid Mach number Polytropic exponent for @ path on the p-T diagram Mass (Appendix B only) Rotative speed Polytropic exponent for a path on the p-v diagram n Number of moles (Appendix B only) ns Isentropic exponent for a path on the p-v diagram Pp Power Pp Pressure Pe Velocity pressure ex Other external heat losses Qn Total mechanical losses (equivalent) FTTIB PAOD ANA oeD mR =sg = : 5 523 3 Units fe ft/sec ft dimensionless Btu/lbm - mole °R Btu/lbm °R Btu/lbm °R Btu/lbm °R dimensionless dimensionless bm ful sec? Btu/lbm-mole bm H2O/lbm dry air Btu/lbm Btu/hr -f- °R ft Ibf/Btu dimensionless dimensionless dimensionless dimensionless Ibm/lbmole dimensionless dimensionless dimensionless bm ‘pm dimensionless Ib mole dimensionless hp psia psi Btu/min Buu/minASME PTC 10-1997 a Qu q R RA, RB, RC Re Rem RH Re R " ® fa SER RR SOW NXE gE CCE TIS poe epee Heat transfer from the section boundaries External seal loss equivalent Rate of flow Gas constant Machine Reynolds number correction constants Fluid Reynolds number Machine Reynolds number Relative humidity Reduced pressure Reduced temperature Pressure ratio across fluid meter Recovery factor Pressure ratio Flow rate ratio Temperature ratio Ratio of specific volumes Molar entropy Heat transfer surface area of exposed ‘compressor casing and adjoining pipe Entropy Absolute temperature Temperature Internal energy Blade tip speed Velocity Specific volume Work per unit mass Mass rate of flow Compressibility function Mole fraction Compressibility function Elevation head or potential energy Compressibility factor as used in gas law, 144 py = ZRT Diameter ratio of fui Isentropic exponent Partial derivative Efficiency Absolute viscosity Work input coefficient Polytropic work coefficient Isentropic work coefficient Kinematic viscosity Density ‘Summation Torque Surface roughness Total work input coefficient Flow coefficient meter, d/Dy ‘COMPRESSORS AND EXHAUSTERS Btu/min Bru/min f8/min ft Ibfflom « °R dimensionless dimensionless jimensionless percentage dimensionless ensionless dimensionless jimensionless dimensionless dimensionless Bru/lbm - mole « *R pes Btu/llbm - °R R F Btu/bm ft/sec fusec ffm ft Ibfflbm dimensionless dimensionless dimensionless dimensionless dimensionless fe/sec bent dimensionless ma‘COMPRESSORS AND EXHAUSTERS Subscripts a Ambient ,b,c,j Component of gas mixture (Appendix B ‘oniy) Average Casing Correction Fluid’s critical point value Compressor discharge conditions da Dryair db Dry-bulb des Design dg Dry ges g Gas hb Heat balance i Compressor inlet conditions lu Leakage upstream Id Leakage downstream m Gas mixture Pp Polytropic rotor Flow location reference 5 Isentropic sh Shaft 5p Specified conditions su sidestream upstream sd sidestream downstream sv Saturated vapor Test conditions wb Wet-bulb 1,1 Upstream of fluid meter 2,2n Downstream or at throat of fluid meter @ Compressor inlet conditions (static, ‘Appendix A only) 7 Compressor discharge conditions (static, ‘Appendix A only) static Static ‘meas. Measured Superscripts (Y Condition at discharge pressure with entropy equal to inlet entropy (Determined at static conditions 2.2 PRESSURES 2.2.1 Absolute Pressure. The absolute pressure is the pressure measured above a perfect vacuum. ‘ASME PTC 10-1997 2.2.2 Gage Pressure. The gage pressure is that pressure which is measured directly with the existing barometric pressure as the zero base reference. 2.2.3. Differential Pressure. The differential pres- sure is the difference between any two pressures measured with respect to a common reference (e4., the difference between two absolute pressures), 2.2.4 Static Pressure. The static pressure is the pressure measured in such a manner that no effect is produced by the velocity of the flowing fluid. 2.28. Total (Stagnation) Pressure. The total (stagna- tion) pressure is an absolute or gage pressure that would exist when a moving fluid is brought to rest and its kinetic energy is converted to an enthalpy rise by an isentropic process from the flow condition to the stagnation condition. in a stationary body of fluid the static and total pressures are equal. 2.2.6 Velocity (Kinetic) Pressure, The velocity (ki- netic) pressure is the difference between the total pressure and the static pressure at the same point in a fluid. 2.2.7 Inlet Total Pressure. The inlet total pressure is the absolute total pressure that exists at the inlet ‘measuring station (see para. 4.6.8). Unless specifi cally stated otherwise, this is the compressor inlet pressure as used in this Code. 2.2.8 Inlet Static Pressure. The inlet static pressure is the absolute static pressure that exists at the inlet measuring station (see para. 4.6.7). 2.2.9 Discharge Total Pressure. The discharge total pressure is the absolute total pressure that exists at the discharge measuring station (see para. 4.6.9). Unless specifically stated otherwise, this is the com- pressor discharge pressure as used in this Code. 2.2.10 Discharge Static Pressure. The discharge static pressure is the absolute static pressure that exists at the discharge measuring station (see para. 46.7). 2.3. TEMPERATURES 2.3.1. Absolute Temperature. The absolute temper- ature is the temperature measured above absolute zero, It Is stated in degrees Rankine or Kelvin. The Rankine temperature is the Fahrenheit temperature plus 459.67 and the Kelvin temperature is the Celsius temperature plus 273.15.[ASME PTC 10-1997 2.3.2. Static Temperature. The static temperature is the temperature determined in such a way that no effect is produced by the velocity of the flowing fluid. 2.3.3 Total (Stagnation) Temperature. The total (stagnation) temperature is the temperature that ‘would exist when a moving fluid is brought to rest and its kinetic energy is converted to an enthalpy rise by an isentropic process from the flow condition to the stagnation condition. In a stationary body of fluid the static and the total temperatures are equal. 2.3.4 Velocity (Kinetic) Temperature. The velocity etic) temperature is the difference between the total temperature and the static temperature at the measuring station. 2.3.5 Inlet Total Temperature. The inlet total tem- perature is the absolute total temperature that exists at the inlet measuring station (see para. 4.7.7). Unless specifically stated otherwise, this is the compressor inlet temperature used in this Code. 2.3.6 Inlet Static Temperature. The inlet static tem- erature is the absolute static temperature that exists at the inlet measuring station. 2.3.7 Discharge Total Temperature. The discharge total temperature is the absolute total temperature that exists at the discharge measuring station (see para. 4.7.8). Unless specifically stated otherwise, this is the compressor discharge temperature as used in this Code. 2.3.8 Discharge Static Temperature. The discharge static temperature is the absolute static temperature that exists at the discharge measuring station. 2.4 OTHER GAS (FLUID) PROPERTIES 2.4.1 Density. Density is the mass of the gas per Unit volume. It is a thermodynamic property and is determined at a point once the total pressure and temperature are known at the point. 2.4.2. Specific Volume. Specific volume is the vol- ume occupied by a unit mass of gas. Its a thermody- namic property and is determined at a point once the total pressure and temperature are known at the point. 2.4.3. Molecular Weight. Molecular weight is the weight of a molecule of a substance referred to that ‘of an atom of carbon-12 at 12.000. ‘COMPRESSORS AND EXHAUSTERS. 2.4.4 Absolute Viscosity. Absolute viscosity is that property of any fluid which tends to resist a shearing force. 2.4.8 Kinematic Viscosity. The kinematic viscosity of a fluid is the absolute viscosity divided by the fluid density. 2.4.6 Specific Heat at Constant Pressure. The spe- cific heat at constant pressure, (cj) = @h/@T)p is the change in enthalpy with respect to temperature at a constant pressure, 2.4.7. Specific Heat at Constant Volume. The spe- cific heat at constant volume, (c) = (@u/@T)y is the change in intemal energy with respect to temperature at a constant specific volume. 2.4.8 Ratio of Specific Heats. The ratio of specific heats, k, is equal to cp/cw. 2.4.9 Acoustic Velocity (Sonic Velocity). A pres- sure wave or acoustic wave of infinitesimal ampli- tude is described by an adiabatic and reversible (isentropic) process. The corresponding acoustic ve- locity for such waves in any medium is given by: 5%) 2.4.10 Fluid Mach Number. The Fluid Mach num- ber is the ratio of fluid velocity to acoustic velocity. 2.5 MACHINE CHARACTERISTICS 2.5.1 Capacity. The capacity of a compressor is the rate of flow which is determined by delivered mass flow rate divided by inlet total density. For an exhauster itis determined by the inlet mass flow rate divided by inlet total density. For sidestream machines, this definition must be applied to individ- val sections. 2.5.2 Flow Coefficient. The flow coefficient is a dimensionless parameter defined as the compressed mass flow rate divided by the product of inlet density, rotational speed, and the cube of the blade tip diameter. Compressed mass flow rate is the net, mass flow rate through the rotor. 2.5.3. Pressure Ratio. Pressure ratio is the ratio of the absolute discharge total pressure to the absolute inlet total pressure,(COMPRESSORS AND EXHAUSTERS 2.5.4 Pressure Rise. Pressure rise is the difference between the discharge total pressure and the inlet total pressure. 25.5 Temperature Rise. Temperature rise is the rence between the discharge total temperature and the inlet total temperature. 2.5.6 Volume Flow Rate. The volume flow rate as used in this Code is the local mass flow rate divided by local total density. Its used to determine volume flow ratio. 2.5.7 Volume Flow Ratio. The volume flow ratio is the ratio of volume flow rates at two points in the flow path. 2.8.8 Specific Volume Ratio. The specific volume ratio is the ratio of inlet specific volume to discharge specific volume. 2.5.9 Machine Reynolds Number. The Machine Reynolds number is defined by the equation Rem = Ub/v, where U is the velocity at the outer blade tip diameter of the first impeller or of the first stage rotor tip diameter of the leading edge, » is the total kinematic viscosity of the gas at the compressor let, and b is a characteristic length. For centrifugal compressors, b shall be taken as the exit width at the outer blade diameter of the first stage impeller. For axial compressors, b shall be taken as the chord length at the tip of the first stage rotor blade. These variables must be expressed in consistent units to yield a dimensionless ratio. 2.5.10 Machine Mach Number. The Machine Mach number is defined as the ratio of the blade velocity at the largest blade tip diameter of the first impeller for centrifugal machines or at the tip diameter of the leading edge of the frst stage rotor blade for axial flow machines to the acoustic velocity Of the gas at the total inlet conditions. NOTE: This isnot to be confused with local Fluid Mach number. 2.5.11 Stage. A stage for a centrifugal compressor is comprised of a single impeller and its associated stationary flow passages. A stage for an axial com- pressor is comprised of a single row of rotating blades and its associated stationary blades and flow passages. 2.5.12 Section. Section is defined as one or more stages having the same mass flow without external heat transfer other than natural casing heat transier. 2.5.13. Control Volume. The control volume is a region of space selected for analysis where the fiow ASME PTC 10-1987 steams entering and leaving can be quantitatively defined as well as the power input and heat exchange by conduction and radiation. Such a region can be considered to be in equilibrium for both a mass and energy balance. 2.5.14 Compressor Surge Point. The compressor surge point isthe capacity below which the compres- sor operation becomes unstable. This occurs when flow is reduced and the compressor back pressure exceeds the pressure developed by the compressor and a breakdown in flow results. This immediately ‘causes a reversal in the flow direction and reduces the compressor back pressure. The moment this happens regular compression is resumed and the cycle is repeated. 2.5.15 Choke Point. The choke point is the point where the machine is run at a given speed and the flow is increased until maximum capacity is atained. 2.6 WORK, POWER, AND EFFICIENCY ‘These definitions apply to a section. 2.6.1 Isentropic Compression. isentropic compres- sion as used in this Code refers to a reversible, adiabatic compression process. 2.6.2. Isentropic Work (Head). Isentropic work (head) is the work required to isentropically compress a unit mass of gas from the inlet total pressure and total temperature to the discharge total pressure. The total pressure and temperature are used to account for the compression of the gas and the change in the kinetic energy of the gas. The change in the gravitational potential energy of the gas is assumed negligible. 2.6.3. Polytropic Compression. Polytropic compres- sion is a reversible compression process between the inlet total pressure and temperature and the discharge total pressure and temperature. The total pressures and temperatures are used to account for the compression of the gas and the change in the kinetic energy of the gas. The change in the gravitational potential energy is assumed negligible. The polytropic process follows a path such that the polytropic exponent is constant during the process, 2.6.4 Polytropic Work (Head). Polytropic work (head) is the reversible work required to compress 8 unit mass of gas by a polytropic process from the inlet total pressure and temperature to the discharge total pressure and temperature.‘ASME PTC 10-1997 2.6.5 Gas Work. Gas work is the enthalpy rise of a unit mass of the gas compressed and delivered by the compressor from the inlet total pressure and temperature to the discharge total pressure and temperature. 2.6.6 Gas Power. Gas power is the power transmit. ted to the gas. It is equal to the product of the mass flow rate compressed and the gas work plus the heat loss from the compressed gas. 2.6.7. Isentropic Efficiency. The isentropic effi- ciency is the ratio of the isentropic work to the gas work. 6.8 Polytropic Efficiency. The polytropic effi- ciency is the ratio of the polytropic work to the gas work. 2.6.9 Shaft Power (Brake Power). The shaft power (brake power! is the power delivered to the compres- sor shaft. It is the gas power plus the mechanical losses in the compressor. 2.6.10 Isentropic Work Coefficient. The isentropic work coefficient is the dimensionless ratio of the isentropic work to the sum of the squares of the blade tip speeds of all stages in a given section. 2.6.11 Polytropic Work Coefficient. The polytropic ‘work coefficient is the dimensionless ratio of the polytropic work to the sum of the squares of the blade tip speeds of all stages in a given section. 2.6.12 Mechanical Losses. Mechanical losses are the total power consumed by frictional losses in integral gearing, bearings, and seals. 2.6.13 Work Input Coefficient. The work input coefficient is the dimensionless ratio of the enthalpy rise to the sum of the squares of the tip speeds of all stages in a given section, 2.6.14 Total Work Input Coefficient. The total work input coefficient is the dimensionless ratio of the total work input to the gas to the sum of the squares of the blade tip speeds of all stages in a given section. 2.7 MISCELLANEOUS 2.7.1 Fluid Reynolds Number. The Fluid Reynolds number is the Reynolds number for the gas flow in a pipe. It is defined by the equation Re = VD/v, where the velocity, characteristic length, and static kinematic viscosity are to be used as follows: velocity Vis the average velocity at the pressure measuring COMPRESSORS AND EXHAUSTERS station, the characteristic length D is the inside pipe diameter at the pressure measuring station and the kinematic viscosity, v is that which exists for the static temperature and pressure at the measuring station. The pressure and temperature measuring stations for flow metering calculations shall be speci- fied as in Section 4 and the accompanying illustra- tions. The variables in the Reynolds number must be expressed in consistent units to yield a dimen- sionless rat 2.7.2 Dimensional Constant. The dimensional con- stant, gc, is required to account for the units of length, time, and force. It is equal to 32.174 ftlbm/ Ibf sec, The numerical value is unaffected by the local gravitational acceleration. 2.7.3. Specified Operating Conditions. The speci- fied operating conditions are those conditions for which the compressor performance is to be deter- mined. Refer to paras. 6.2.3 and 6.2.4. 2.7.4 Test Operating Conditions. The test operating ‘conditions are the operating conditions prevailing during the test. Refer to paras. 6.2.7 and 6.2.8. 2.7.5 Equivalence. The specified operating condi- tions and the test operating conditions, for the put- pose of this Code, are said to demonstrate equiva- lence when, for the same flow coefficient the ratios of the three dimensionless parameters (specific volume ratio, Machine Mach number, and Machine Reynolds number) fall within the limits prescribed in Table 3.2. 2.7.6 Raw Data, Raw data is the recorded observa tion of an instrument taken during the test run, 2.7.7 Reading. A reading is the average of the corrected individual observations (raw data) at any given measurement station. 2.7.8 Test Point. The test point consists of three ‘or more readings that have been averaged and fall within the permissible specified fluctuation, 2.7.9 Fluctuation. The fluctuation of a specific ‘measurement is defined as the highest reading minus the lowest reading divided by the average of all readings expressed as a percent. 2.8 INTERPRETATION OF SUBSCRIPTS 2.8.1 Certain values for thermodynamic state and mass flow rate are used in the computation of the dimensionless performance parameters M, Re, fw 4, Hp Hu np and O. Unless otherwise specificallyCOMPRESSORS AND EXHAUSTERS ASME PTC 10-1997 stated, the thermodynamic total conditions are used. The subscripts used in these equations are interpreted as follows. 2.8.1.1. The subscript “i” on thermodynamic state variables denotes inlet conditions. For single entry streams it refers to conditions at the section inlet measurement station. For multiple inlet streams it refers to a calculated mixed state. See para. E.5 of Appendix E. 2.8.1.2 The subscript “d” on thermodynamic state variables denotes discharge conditions. it refers to conditions at the mainstream discharge measure- ‘ment station, 2.8.1.3 The subscript “rotor” is used on mass flow rate to denote the net mass flow rate compressed by the rotor. Its determination requires that all mea~ sured flows and calculated leakages are considered.‘COMPRESSORS AND EXHAUSTERS ASME PTC 10-1997 SECTION 3 — GUIDING PRINCIPLES 3.1. PLANNING THE TEST 3.1.1 Before undertaking a test in accordance with the rules of this Code, the Code on General instruc- tions, PTC 1, shall be consulted. It explains the intended use of the Performance Test Codes and is Particularly helpful in the initial planning of the test. 3.1.2 When a testis to be conducted in accordance with this Code, the scope and procedures to be used shall be determined in advance. Selections of Pipe arrangements, test driver, instruments, and test 82s, if applicable, shall be made. Estimates of the probable uncertainty in the planned measurements should be made. 3.1.3. The scope ofthe test shall be agreed to by the interested partes, This may be dictated in advance by contractual commitments or may be mutually agreed upon prior to the start of the test. This Code contains procedures for a single point performance test and Bives guidance on determining a complete perform- ance curve. 3.1.4 Specified conditions, that is, mass flow rate, inlet conditions of pressure, temperature, humidity, discharge pressure, cooling water temperature if ap- plicable, speed, gas properties, and input power expected shall be defined. 3.1.5 _A detailed written statement of the test objec- tives shall be developed prior to conducting the test. 3.1.6 A test facility shall be selected. Typically this is the manufacturer's test stand or the user's installation site. 3.1.7 The number of test personnel should be sufficient to assure a careful and orderly observation of all instruments with time between observations to check for indications of error in instruments ot ‘observations. 3.1.8 An individual shall be designated as responsi- ble for conducting the test. u 3.2. TYPES OF TESTS This Code defines two types of test which are based on the deviations between test and specified operating conditions. 3.2.1 Type 1 tests are conducted with the specified gas ator very near the specified operating conditions. Deviations in the specified gas and operating condi- tions are subject to the limitations imposed by Table 3.1. These limitations are subject to the further restriction that their individual and combined effects shall not exceed the limits of Table 3.2. 3.2.2 Type 2 tests are conducted subject to the limits of Table 3.2 only. The specified gas or a substitute gas may be used. The test speed required is often different from the specified operating condition speed. 3.2.3. The selection of test type shall be made in advance of the test. In the interest of maximizing accuracy of test results it is desirable that test condi- tions duplicate specified operating conditions as closely as possible. The limits in Table 3.1 provide maximum allowable deviations of individual param- eters for Type 1 tests, The limitations of Table 3.2 provide maximum allowable deviations of the fundamental dimensionless parameter groupings for both types. The emphasis in conducting either a ‘Type | or Type 2 test should be toward minimizing these deviations. The most reliable test results would bbe expected when the deviations in both tables are minimized. 3.2.4 Calculation procedures are given in Section 5 for gases conforming to Ideal Gas Laws and for Real Gases. Where the compressibility values depart from the limits prescribed in Table 3.3 the alternate calculation procedures provided for Real Gases shall bbe used. These alternate procedures apply to calcula- tions for either Type 1 or Type 2 tests. 3.3. LIMITATIONS 3.3.1. Compressors constructed with liquid cooled diaphragms, or built-in heat exchangers, shall beASME PTC 10-1997 ‘COMPRESSORS AND EXHAUSTERS TABLE 3.1 PERMISSIBLE DEVIATION FROM SPECIFIED OPERATING CONDITIONS FOR TYPE 1 TESTS Variable Symbol Units Deviation inlet pressure m ps % inlet temperature 7 R am Speed N ‘pm m Molecular weight mw lbevtomole % Cooling temperature R 5% diference Coolant flow rate gala 3% Capacity « iin a ‘GeNERAL NOTES: (@) Type | test are tobe conducted with the specified gas. Deviations ar based onthe specified values Where pressures and temperatures are expressed in absolve values {B) The combined effet of inlet pressure, temperature ard molecular weight shall not produce more than an 84% deviation i the inlet gas density. (ql The combined effect of the deviations shall not exceed the limited of Table 2.2. Cooling temperature diference is defined a5 inlet ges temperature minus inlet cooling water temperature. TABLE 3.2 PERMISSIBLE DEVIATION FROM SPECIFIED OPERATING PARAMETERS FOR TYPE 1 AND 2 TESTS nst of Test Values as Percent of Design Values Parameter Symbol Min Max Specific volume ratio va s 105 j Flow coeficient 6 9% t08 Machine Mach number CCentifugal compressors See Fig. 3.3 ‘Axial compressors Ma See Fig. 34 Machine Reynolds number Centrifugal compressors [Note (1] Rem See Fig. 35 ‘Asal compressors where the Machine Reynolds number at specified condi- tions is below 100,000 0 105 ‘Axial compeessors where the Machine UNote (i Reynolds number at specified condi- 10 tions is above 100,000 290 (0) Minimum allowable test Machine Reynolds number is 90,000. 2‘COMPRESSORS AND EXHAUSTERS. ASME PTC 101997 TABLE 3.3 LIMITS OF DEPARTURE FROM IDEAL GAS LAWS OF SPECIFIED AND TEST GASES ‘Maximum ‘Allowed Range for ‘Allowed Range for cm Function X Function Y Ratio maxima Min Max Min Max ~o388 0.279 0.925 v.07 0175 0167 0.964 1.034 0073 071 0.982 ion “00st 0.050 0988 oti 0.031 0.033 oset 1.008 ~0025 0.028 1.006 Bs ay = 2) ee gs a6 and3.71 (©) Maximum and mini Valves of k shall apply to both the specified and test gas over the complete range of conditions (©) When these limits are exceeded by either the specified gas or the tet gas at any point along the ‘compression path real gas calculation methods shall be used if these limits Se not exceeded, tested on the specified gas and at the operating conditions specified for the inlet pressure, inlet tem= erature and speed, and with the flow rate and the temperature specified for the cooling fluid. The fluctuations of the test readings shall be controlled within the limits of Table 3.4. The results shall be Computed by the methods provided for a Type 1 test, and reported “as run.” 3.3.2. The methods of this Code may be applied for conversion of test results to specified operating condition results for compressors which may be treated as one or more sections. A section is that Portion of a compressor where no intermediate stream leaves or enters between one impeller inlet and the same or another following impeller dis- charge. See Table 3.2. Heat exchangers are excluded from the interior of the section boundaries. Section boundaries are indicated diagrammatically in Fig. 3.1. The gas state and flow rate shall be established for each stream where it crosses the section bound- ary. The power absorbed and heat loss or gain by natural ambient heat transfer must also be deter- mined. 3.3.3 Compressors with externally piped intercool- ers may be given a Type 1 test or they may be tested by individual sections using a Type 2 test. 3.3.4 Compressors with inlet or outlet sidestreams may be tested using the procedures for a Type 1 ‘be used for that gas Ideal or real gas method may test providing all conditions, including those at the sidestream, meet the requirements of Table 3.1. Compressors with sidestreams may also be tested by Individual sections utilizing the criteria for a Type 2 test. 3.3.5 Where condensation can take place between compression sections; for example, intercooled com- pressors handling moist air; the capacity shall be measured at the compressor discharge. (For atmo- spheric exhausters the flow shall be measured at the inlet) Care shall be taken to assure that there is no liquid carry-over from the intercoolers. 3.3.6 Volume flow ratios may in practice differ between test and specified operating conditions due to leakage differences. For example, it is common to test at reduced inlet pressure and the reduced differential pressure across a seal to atmosphere could result in zero or negative leakage. As a result, volume flow ratio equality can not be achieved between test and specified conditions. Therefore, it shall be necessary to estimate the leakage ratio; that is, the leakage mass flow divided by the inlet mass flow for both test and specified conditions, Wf the leakage ratio difference between test and specified is significant, these effects shall be applied to the calculations of capacity and power.ASME PTC 10-1997 COMPRESSORS AND EXHAUSTERS TABLE 3.4 PERMISSIBLE FLUCTUATIONS OF TEST READINGS! Measurement Symbol Unis Fluctuation inlet presure Pe pala 7% Inlet temperature 7 ® 05%. Discharge pressure pe sia ro Nozze differential ap pressure ps m™% Nozzle temperature r 'R 05%. Speed N pm ost Torque + et 1% Electr motor input kw 1%. Molecular weight mw "bromole 025% Cooling water inlet T temperature "R 0.5% (Note (2 ‘Cooling water flow ate sg2limio m™ Line voltage vols % ‘GENERAL NOTES: {ay A fluctuation is the percent diference between the minimum and maximum test reading divided by the average of al readings (t) Permissible Ructuations apply to Type 1 and Type 2 tests. NoTEs: 1) See para. 5.4.23, (2) See para. 4.16 for futher restrictions. Test ‘Multiple ston — | at Boundary ‘streams cc Heat transfer FIG. 3.1. SECTION CONTROL VOLUMES 4COMPRESSORS AND EXHAUSTERS In many cases it is not practical to measure the leakage flow and it is permissible to use calculated values of leakage for test and specified conditions. 3.3.7 Where the efficiency is to be determined by shaft input power measurements the bearing and seal losses should not exceed 10 percent of the total test power. This will minimize the effect of Uncertainties in the bearing and seal loss determina- tion of gas power. 3.3.8 Evaluation of performance of components between sections, if any, such as heat exchangers, piping, valves, etc., is generally beyond the scope of this Code and shall be agreed upon by parties to the test. The specified operating condition per- formance of such components or the technique for correction of test results to specified operating conditions shall be agreed upon by parties to the test. 3.3.9 When power is to be determined by the heat balance method, the heat losses due to radiation and convection, expressed in percent of the total shaft power, shall not exceed 5 percent. 3.3.10 For, Type 2 tests, the inlet gas condition shall have @ minimum of 5°F of superheat. 3.4 TEST GAS AND SPEED 3.4.1 The physical and thermodynamic properties of the specified and test gas shall be known. The option of using tabulated data, an equation of state correlation, oF experimental determination as 2 source for these properties shall be agreed upon prior to the test. 34.2 The following physical properties of the test as throughout the expected pressure and tempera- tre range shall be known or accurately determined: (a) molecular weight (©) specific heat at constant pressure (cj) (6) ratio of specific heats (¢p/c,) (A) compressibility factor (Z) (e) dew point 0 viscosity ) isentropic exponent (h) enthalpy @ acoustic velocity 3.4.3 The test speed shall be selected so as to conform to the limits of Table 3.2. The test speed shall not exceed the safe operating speed of the compressor. Consideration should be given to critical ‘ASME PTC 10-1997 speeds of rotating equipment in selecting the test speed. Test pressures and temperatures shall not exceed the maximum allowable pressures and temperatures for the compressor. 3.5 INTERMEDIATE FLOW STREAMS 3.5.1 Section Treatment. Compressors having flows added or removed at intermediate locations between the inlet and final discharge are handled by treating the compressor by sections, The gas state and fiow rate shall be established for each stream where it crosses the section boundary. 3.5.2 It is necessary to maintain 2 consistency between specified volume flow rate ratio and test volume flow rate ratio for each section. Permissible deviations from these ratios are listed in Fig. 3.2. ‘AS an example, in the first section of a multisection compressor, the ratio of inlet volume flow rate to discharge volume flow rate for the specified and test conditions must be held to within =5 percent ‘which is the same as that required for conventional ‘compressors in Table 3.2. In addition, itis required that the ratio of first stage section discharge flow rate to second section inlet volume flow rate for the specified and test conditions be held to within 10 percent. This is required so that the total pressure determined at the sidestream flange will have the same relationship to the total pressure actually existing at the exit ofthe first section bound- ary for specified and test conditions. For the second and succeeding sections the re- quirements are similar. The ratio of inlet volume flow rate to discharge volume flow rate for specified and test conditions must be held to within *5 percent. Also, the preceding section discharge volume flow rate to sidestream inlet volume flow rate ratio for specified and test conditions must be held to +10 percent. Finally, the ratio of the discharge volume flow rate of the section being tested to the next sidestream volume flow rate must also be held to £10 percent. This requirement is most important in the second section of a three section machine where both inlet and discharge total pressures are being determined at the sidestream flanges and velocity similarities are necessary for test accuracy. Code requirements are also described in equation form in Fig. 3.2.‘COMPRESSORS AND EXHAUSTERS [ASME PTC 10-1997 SUOSSIYAWOD TVNOLLDAS GVOTGIS WIIGAL Z'E ‘D1 Guay wos 1 Zu0HeS = & weensepte 10yoq suewouneroul wip Prindwoo Bvey20p L uoweB =z won aSveyomp E Vong = @ Prindwoo eu pent YONDER = Ladvongne ue worse} L UoNEES =f adHoRGNE ‘atom dst) ay, sos tee 16‘COMPRESSORS AND EXHAUSTERS 3.5.3 Inward Sidestreams. When the sidestream flow is inward, the discharge temperature of the Preceding section shall be measured prior to the mixing of the two streams. This temperature measure- ‘ment shall be made in a portion of the discharge flow stream where the sidestream cannot affect the raw data. Raw data may be affected by heat transfer from a cold sidestream to a hot mainstream flow (or from recirculation which may occur within the flow passage. The discharge temperature is needed to compute the performance of the preceding section and to compute the reference mixed temperature for the next section inlet. {tis possible for internal total pressures to exceed flange total pressure due to the higher internal veloc ties. The higher internal velocities are accompanied by a lower static pressure which provides a pressure difference for inward flow. 3.5.4 Temperature Stratification. It is common for sideload sectional compressors to have temperature differences between the mainstream and sidestream. ‘When testing all sections of a multisection compres- sor (three or more sections) simultaneously, large differences between the sidestream and mainstream temperatures may occur. it is possible, due to these differences, for thermal flow stratification to exist within the compressor sections. This. stratification ‘may result in inaccurate measurements of internal temperatures in downstream sections. Under test conditions, the stream temperature differences should be maintained as close to specified as prac- tical. 3.5.5. Performance Definition, The sectional head, efficiencies, and pressures are defined flange to flange. The only internal measurements needed are the sectional discharge temperatures for computing the mixed temperature conditions and sectional per- formance. The pressure used for calculating the sectional performance is assumed to be equal to the sidestream flange total pressure. The internal mixed temperature should be com- puted on a mass enthalpy basis (real gas evaluation} for obtaining the inlet temperature for succeeding sections. Simplified mixing based on mass tempera- ture may be done for ideal gases with constant specific heat. For further information see para. E.5 of Appendix E. 3.5.6 Extraction Sidestreams. When the intermedi ate flows are removed [i.e,, bleed-off) from the compressor, they will cross a section boundary. 7 ASME PTC 10-1997 The Internal temperature and pressure can be assumed to be equal to the external flange tempera- ture and pressure of the primary intemal stream. The ratio of flow rate restrictions in Fig. 3.2 shall also apply to outward flowing sidestreams. 3.5.7 It is recommended that each section of a rmultisection machine have its own performance curve defined by a number of test points. This enables synthesis of the combined overall perform. ance curve and provides data on the interrelations of the individual sections. The ratios of Fig. 3.5 will apply at all points unless other specified operating ratios are identified. 3.6 SAFETY 3.6.1. The test gas used shall be in compliance with local regulations and prudent practice with regard to flammability and/or toxicity. 3.6.2 Test gases used in a closed loop shall be continuously monitored for composition and avoid- ance of combustible mixtures. Air or other oxidizing gases shall not be used in a closed loop. 3.6.3 The party providing the test site will be responsible for establishing the requirements of sys- tem protection. Consideration should be given to the need for relief valves for accidental overpressure. The requirement of alarms and/or automatic shut- down devices for such items as high temperature, loss of cooling water, low cil pressure, compressor overspeed, or other possible malfunctions should be reviewed. 3.7 PIPING 3.7.1 Piping arrangements required to conduct a test under the Code are detailed in Section 4. Permi sible alternates are described for convenience and suitability. A selection suitable for the prevailing test conditions shall be made and described in the test report. When the choke point is to be determined, care should be taken to assure that the compressor pressure rise shall exceed system resistance. 3.7.2 Minimum straight lengths of piping at the inlet, discharge, and on both sides of the flow device are specified in Section 4, When compressors are treated, as a number of individual sections, these piping requirements apply to each section. Such piping between sections may ‘not occur naturally in the design. When it doesASME PTC 10-1997 03 02 02 O48 COMPRESSORS AND EXHAUSTERS C8 a ets Mach No. Specified — Mmgp FIG, 3.3 ALLOWABLE MACHINE MACH NUMBER DEPARTURES, ‘CENTRIFUGAL COMPRESSORS not, the parties to the test should elect by mutual agreement to: (a) install additional piping between the sections (0) take measurements in the available space. Con- sideration shall be given to any compromise in mea- surement accuracy and its effect upon the final test objective. (C) remove components such as external heat ex- changers and replace them with the required piping. ‘When this alternate is selected it is important that the removal of the component have a negligible effect, upon the section entry or exit flowfield so as not to affect the section performance parameters. 3.7.3 Where extemal intercooler performance and pressure drop are known for the specified operating conditions, or determined on a separate test, the compressor may be tested as separate sections and the combined performance computed by the method described in Section 5. 3.7.4 Ifa closed loop test is to be performed, the ‘maximum pressure to be obtained and the maximum heat load shall be estimated. The piping and cooler from the compressor discharge to the throttle valve 18 shall be designed for the maximum pressure plus a suitable safety factor and the cooler shall be sized to dissipate the maximum heat load. Additional lengths of piping beyond the minimum prescribed may be required to provide additional system capa tance. Provisions may be necessary to allow for expansion of the piping and the piping design shall be of sufficient strength to withstand the stresses imposed during compressor surge. 3.8 INSTRUMENTATION Test instruments shall be selected, calibrated, and installed in accordance with the requirements of Section 4 3.9 PRETEST INSPECTION Pretest inspection may be of interest to either party. Refer to PTC 1 for guidance.COMPRESSORS AND EXHAUSTERS 020 0.18 00 Mam — Mmsp & 208 010 2p rosea ASME PTC 10-1997 oO Mach No. Specified — Mmep FIG, 3.4 ALLOWABLE MACHINE MACH NUMBER DEPARTURES, AXIAL COMPRESSORS 3.10 PRETEST RUN 3.10.1 The compressor shall be operated for sufi. cient time at the required conditions to demonstrate acceptable mechanical operation and stable values of all measurements to be taken during the test. Preliminary data shall be taken to familiarize test personnel, to determine if all instruments are func- tioning properly, and to ascertain if the reading fluctuations fall within the limits prescribed in Ta- ble 3.4, 3.10.2 All instrument observations pertinent to the test shall be taken during the pretest run, They commonly include the following: (a) inlet pressure (6) inlet temperature (6) relative humidity or wet bulb temperature, if atmospheric air isthe test gas (@) discharge pressure (e) discharge temperature and/or shaft power input (0 flow device pressures and temperatures, @) speed (hy cooler inlet and outlet temperatures, gas and coolant sides, if applicable @) lubricant temperatures, inlet and outlet of bear- ings, seals, and speed changing gear, if applicable @) coolant and lubricant flows, if applicable () barometric pressure () gas analysis, if atmospheric airis not the test gas. (m) time 3.10.3 A set of calculations shall be made using the preliminary test data to assure that the correct test speed has been selected, that the test pardmeters required in Tables 3.1 or 3.2, as applicable, were obtained and that the overall performance values are reasonable. 3.10.4 The pretest run may be considered as part of the test if it meets all requirements of the test. 3.11 TEST OPERATION 3.11.1 The compressor shall be operated at the required conditions for a sufficient period of time to demonstrate that all variables have stabilized. 3.11.2 When all variables have stabilized, the test personnel shall take the first set of readings of allASME PTC 10-1997 og ‘COMPRESSORS AND EXHAUSTERS 10 10! 10° Rem/Remyp ot 102 10 10 10 07 108 10? Machine Reynolds No. Specified — Remap 000 is eu FIG. 3.5 ALLOWABLE MACHINE REYNOLDS NUMBER DEPARTURES, CENTRIFUGAL COMPRESSORS essential instruments. Three sets of readings shall be taken during each test point. 3.11.3 The minimum duration of a test point, after stabilization, shall be 15 minutes from the start of the first set of readings to the end of the third set of readings. 3.11.4 When a testis only to verify a single speci- fied condition, the test shall consist of two test points which bracket the specified capacity within a range of 96 percent to 104 percent. 3.11.5 When performance curves are required to verify the complete compressor range of operation, multipoint test shall be performed. Each point selected along the curve shall be assumed to be a specified point and checked for equivalency. This may require a different equivalent speed for each test point. Usually five points should be used to complete a curve. A point shall be taken at approxi mately the specified capacity. The additional points should consist of one point near surge, two points between specified capacity and surge, and one point in the overload range (preferably 105 percent or 20 greater of specified capacity). When the compressor is used with a variable speed driver additional points may be run on selected speed lines, provided that an equivalent speed is generated for each operating point selected. 3.11.6 The flow at which surge occurs can be determined by slowly reducing the flow rate at the test speed until indications of unstable or pulsating flow appear. The severity of surge will vary widely as a function of pressure ratio, type of compressor, and capacitance of the piping system. Surge may be identified by noise, fluctuations in the differential pressure of the flow nozzle, or a drop and/or fluctua- tion of the pressure and/or temperature. ‘When the surge flow has been identified, the flow should be increased slightly until stable operation is restored so that a complete set of performance data may be taken. This process may be repeated a second time to demonstrate the reliability of the initial setting. It should be understood that a surge flow estab- lished ina shop test may not define the surge conditions which will occur in the field due to(COMPRESSORS AND EXHAUSTERS i Compressi 02 06 08 10 12 14 75 ASME PTC 10-1987 18 20 22 26 26 28 90 Reduced Pressure, P, FIG. 3.6 SCHULTZ COMPRESSIBILITY FACTOR — FUNCTION xX VERSUS REDUCED PRESSURE differences in piping configuration and system re- sponse. 3.11.7 The choke flow may be determined by gradually opening the discharge throttle valve while ‘maintaining speed and inlet pressure until the flow remains essentially constant with decreasing dis- charge pressure. VF the compressor is to be operated as an exhauster fr tested with an open discharge, the choke flow may be determined by gradually opening the inlet valve while holding speed and discharge pressure constant, If choke flow is to be determined, the facilites shall be designed so as not to limit maximum flow. 2 3.12 INCONSISTENCIES 3.12.1 Where four independent instruments are Used to measure a pressure or temperature value and one recorded observation is inconsistent due to measurement error, its value shall be discarded and the value determined from the average of the other three. Where fewer than four independent measuring devices are used, all values shall be used and averaged to determine the measurement value. 3.12.2. The three readings for each test point shall be within the fluctuation tolerances listed in Ta- ble 3.4[ASME PTC 10-1997 Compressibilty Function ¥ 0 02 04 08 08 10 12 14 18 ‘COMPRESSORS AND EXHAUSTERS i 1.0] 18 20 22 24 26 28 30 Reduced Pressure, F, FIG. 27. SCHULTZ COMPRESSIBIETY FACTOR — FUNCTION J VERSUS REDUCED PRESSURE 3.13 ERRORS AND UNCERTAINTIES 3.13.1. It should be recognized that the results of the test calculations are subject to error caused by the inaccuracies of the test instruments and/or procedures. It is recommended that an uncertainty analysis be made prior to the test to assure that the test objectives can be met. The detailed procedures are given in PTC 19.1 and are discussed in para. 5.7 of this Code. 3.13.2. The uncertainty is a measure of the quality of the test and should not be used as a measure of the quality of the machine. 2 3.14 TEST LOG SHEETS The test log sheet shall identify the compressor manufacturer, model, and serial number. Test loca- tion, driver identification, test instruments used, and test date shall be listed. Raw data for each test point shall be recorded as observed on the test log sheet as well as the time of each set of data. Corrections and corrected readings shall be listed separately in the test report. ‘At the completion of the test the log sheets shall be signed by the representatives of the interested parties. Copies of the complete log sheets shall be furnished to the interested parties. The test report shall be completed in accordance with the instruc- tions in Section 6,‘COMPRESSORS AND EXHAUSTERS ASME PTC 10-1997 SECTION 4 — INSTRUMENTS AND METHODS OF MEASUREMENT 4.1 METHODS 4.1.1 The choice of methods provided in this Code depend on the compressor, the specified gas, and the type of test selected. 4.2 INSTRUMENTATION 4.2.1 The Performance Test Code Supplements in the PTC 19 series on Instruments and Apparatus provide authoritative information concerning instru- ments and their use and should be consulted for such information. The selection of instrumentation shall be determined by the uncertainty limit require- ments of the test as well as suitability for the test site conditions. The instrument selection shall be justified by calculation that the uncertainty in results ‘meets the stated test objectives. Instrumentation is required to determine the inlet and discharge gas states, flow rate, and compressor speed. Depending upon the method selected, addi- tional instrumentation may be required to determine test power. 43° PIPING 4.3.1. The location of the pressure and temperature ‘measuring stations have specific relation to the com- pressor inlet and outlet openings. The pipe sizes shall match these openings. Minimum lengths of straight pipe are mandatory for certain pressure and temperature measurement stations and for cer flow devices. Pipe arrangements and allowable ex- ceptions are described in this Section. Appropriate selections shall be made and described in the test report. 4.3.2. Typical inlet piping required for compressors outlined in Fig. 4.1. The minimum straight length of inlet pipe is determined by what is upstream of the inlet opening. The four static pressure taps are a minimum of 24 in, upstream of the inlet opening, Downstream of the pressure taps are four temperature 23 taps displaced 45 deg. from them and at least 12 in. downstream. In special cases when atmospheric conditions sat- isfy the requirements, the compressor may be run without an inlet pipe as shown in Fig. 4.2. The inlet opening shall be protected with a screen and bellmouth suitably designed to eliminate debris and minimize entrance losses (see para. 4.4). The total inlet pressure is equal to atmospheric pressure. Tem- perature measuring devices shall be located on the screen to measure the temperature of the air stream at the compressor inlet. For compressors with an axial inlet, the impeller may, under some conditions, produce a vortex at the pressure station to cause substantial error in the measurement of inlet pressure. Users of this Code, by agreement, may use vanes suitably designed for low pressure loss to prevent rotation at the pressure taps. The static pressure stations shall not be less than four pipe diameters upstream of the compressor flange as shown in Fig. 4.3. 4.3.3. Typical discharge piping required for com- pressors are outlined in Fig. 4.1. The minimum Straight length of discharge pipe required before and after the instrumentation is specified. The four static pressure taps are a minimum of 12 in. downstream of the discharge opening. The pressure taps are followed by the four temperature taps displaced 45 deg. from them and at least 8 in. downstream, ‘An alternate arrangement may be used when a compressor operating as an exhauster on air has a discharge velocity pressure less than 5 percent of the total pressure. In this case the compressor can be run without a discharge pipe as shown in Fig. 4.4, The discharge temperature of the gas stream is measured at the compressor discharge. ‘When the compressor has a volute that produces unsymmetrical flow at the discharge opening the static pressure taps shall be a minimum of six diameters downstream as shown in Fig. 4.5. The ‘other minimum dimensions are specified in Fig. 4.1 Straightening vanes designed for low pressure loss,‘ASME PTC 10-1997 8 minimum ———+| Ansinimum op Win. mi COMPRESSORS AND EXHAUSTERS [-—_——aminimurn 12 in, minimum 1 }— Aminimum coe ee pS (alert sate Inlet temperature Discharge temperatu ressure "¢ measuring stations Discharge static ‘¢ measuring taps spaced taps spaced spaced 90 deg. apart pressure 90 deg, apart (45 de 90deg. part (45 deg. trom static measuring from state pressure) taps spaced 90 deg. apart Inlet Opening _Minimum Dimension Discharge Opening Preceded BY ae Followed By ‘Straight run 2 © 30 Straight run 2 (3D Elbow 2 30 Elsow re By Reducer 280 Reducer mC) Valve 30 100 Valve 2080 Flow device 3080 Flow device a 10 For open inlet, soe Fig. 6.2. For open discharge, s00 Fig. 4.4. For vortex producing axial inlet, For ditfusing volute with unsymmetrical flow, see Fig. 43. sea Fig. 45. Inlet Configuration Discharge Configuration FIG. 4.1. INLET AND DISCHARGE CONFIGURATION Inlet pressure Protecting sereen mesh tin. Inlet temperature “dmeasuring stations spaced 90 deg. apart FIG. 4.2 OPEN INLET 24‘COMPRESSORS AND EXHAUSTERS LL Inet static pressure ‘4 taps spaced $0 deg. apart NI ASME PTC 10-1997 2 Fig. 4.1 for 1um dimensions 10min, Intet temperature ‘4 measuring taps spaced 190 deg. apart (45 deg, from static pressure) FIG. 4.3 VORTEX PRODUCING AXIAL INLET Discharge temperature ‘4 measuring locations spaced 90 deg. apart o static pressure by barometer when discharge velocity pressure exceeds 54% of total pressure use discharge pipe arrangement, Fig. 4.1) FIG. 4.4 OPEN DISCHARGE as covered in para. 4.5, may be used by mutual agreement to minimize the effect of the unsymmeti- cal flow. 4.3.4 Figures 4.6 and 4.7 show a typical arrange- ment for testing with a general closed loop and closed loop with sidesteams. 4.4 PROTECTIVE SCREENS 4.4.1 Compressors operating with an open inlet shall be protected with a screen of filter, suitable 25 for the conditions. In general, a screen on the inlet must be strong enough to prevent collapse in the event of accidental clogging. The mesh of a screen shall be selected to prevent entry of foreign matter which might damage the compressor and impair its performance. Reliable tests cannot be made on atmospheric air laden with dust, oil-fog, paint spray, cr other foreign matter which may foul the flow passage of the compressor. Protective screens shall have an open area at least two times that of the ‘compressor inlet or the nozzle pipe. When screens with very small mesh or filters are used, inlet pressure‘ASME PTC 10-1997 Discharge static pressure {4 measuring taps spaced 90 deg. apart 1D min. ‘COMPRESSORS AND EXHAUSTERS See Fig. 4.1 for ‘minimum dimensions 3 Ate | Straightener (optional) See Fig. 48, para. 45 FIG. 45 Discharge temperature ‘4 measuring taps spaced 90 deg. apart (45 deg. ‘rom static pressure) DIFFUSING VOLUTE DISCHARGE WITH NONSYMMETRIC FLOW f i oo tt Cooling water init temp. Cooling water Discharge ee source — messing TE measuring ations ations Seer an || (See Fig. 1) ad AL — eo oe =. = ‘Drain Drain ae 1 ‘charging and venung ger Nozzle ae ae wneaeutng : ave arange Relet valve Flow equalizer Flow nozzle and straightener Drain pot [Hl Gauge FIG. 4,6 TYPICAL CLOSED LOOP 26COMPRESSORS AND EXHAUSTERS ‘ASME PTC 10~1997 Flow equalizer Nozzle ‘measuring arrangement (See PTC 135) SSSR Flow none Drain pot Draintank [I] Gauge : Tee Inlet ‘measuring. stations (Seo Fig. 4.1) Compressor Cooling water inlet temp, Discharge net meaning messing ato aoe tSaehig. 40 Seog. 40 cooing water dich tmp. pol oa Valves for : Drain 7 charging and a venta oat sotle wreauring ie trang Seo Fte ios) felt r ‘ave ‘SSE a Flow vane i Cl ‘and straight Drain pot Drain tank [I] Gauge tt FIG. 4.7 TYPICAL CLOSED LOOP WITH SIDESTREAM 7‘ASME PTC 10-1997 shall be measured by static taps as provided in Fig. 4.1 for straight pipe. Where screens or filters are used ina closed loop, precautions such as measurement of the differential pressure are recommended. 4.5 FLOW STRAIGHTENERS AND EQUALIZERS 4.5.1 Flow straighteners may be installed by mutual agreement of the parties to the test as shown in Figs. 4.3 and 4.5. These flow straighteners may be of the simple vane type, Fig. 4.8, sketch (a), where L/D will be equal to or greater than unity, or of the multitube type, Fig. 4.8, sketch (b), where the length-diameter ratio of the tube shall be equal to or greater than eight and a maximum tube diameter of 4D. 45.2 Flow equalizers shall be installed if required in PTC 19.5. See Fig. 4.8, sketch (c). Flow equalizers shall be a multihole plate, designed to produce a minimum static pressure drop of two times the calculated velocity pressure for the pipe section. The total area required of the holes may be deter- mined from the following formula An (ao) Ae” 40} (opep” where total area of holes in plate, sq in. area of cross section or pipe, sq in. let volume flow, cfm inlet density, bm’ per cu ft Dp= diameter of pipe, in. ‘Pp= density of gas in pipe upstream of plate, tbm per cu ft ‘p= pressure drop across plate, psi The plate should contain not less than 50 holes per square foot of area, uniformly spaced, but not less than 50 holes minimum. 4.5.3 A combined flow equalizer and flow straight- ener is used with flow nozzles where required by PTC 19.5. See Fig, 4.8, sketch (d). The flow str ner shall be the multitube type as shown in Fig. 4.8, sketch (b), preceded by a flow equalizer one- half pipe diameter upstream. Alternatively three flow equalizers spaced one pipe diameter apart may be used as shown in Fig. 4.8, sketch (e). 28 COMPRESSORS AND EXHAUSTERS 4.6 PRESSURE MEASUREMENTS 4.6.1. Reference should be made to PTC 19.2, for general information on instruments to measure pressure. For the range of pressures likely to be measured in compressor test, the manometer and the deadweight gage shall be used as standards. Pressure transducers and other pressure measurement devices can be used. These can be calibrated using deadweight testers or manometers. Deadweight test- ers shall be certified by a competent laboratory. Where gage lines are filled with liquids, means shall be provided to measure the liquid level, and a correction shall be applied for unbalanced liquid head. 4.6.2 Bourdon tubes or similar gages should be selected to operate in the mid-range of the scale, The diameters of the scales and the arrangement of the graduations shall permit easy reading. The temperature of the gage during calibration shall be within 40°F of the ambient temperature prevailing during the test. 4.6.3 Manometers can be either U-tube or single leg design. Small bore manometers are subject to appreciable error resulting from capillary forces, variable meniscus, and restricted separation of en- trained gas bubbles. These errors vary with the type ‘of fluid, the tube diameter, and the tube cleanliness. Single leg manometers shall be checked for zero position before and after test. Manometer fluid shall be chemically stable when in contact with the test gases and metal parts of the instrument. The specific gravity and the coefficient of tempera- ture expansion of the fluid shall be determined before the test. See PTC 19.2 for further guidance. 4.6.4 Deadweight gages and testers shall be se- lected to suit the pressure range. Deadweight gages cannot measure rapid pressure changes and where necessary they shall be installed in parallel with a Bourdon tube gage, transducer, or other instrument. 4.6.5 Transducers shall be selected with pressure ranges appropriate for the expected test pressures. They must be calibrated before and after each test. When automated data collection equipment is used with a pressure switching device, and a single transducer, that transducer shall be selected to cover the entire range of pressure. When using pressure switching devices, sufficient time between successive switch points shall be allowed so that the transducer pressure will reach equilibrium for the selected pres-‘COMPRESSORS AND EXHAUSTERS ct Pt OM (a) Simple-Vane Flow Straightener == a {b) Muti-Tube Flow Straightener {et Equalizer (Perforated Plate or Sereen} 2 nin 2 () Combination Equalizer and Straightener + ° Et (e} Mut-Tube Type Equalizer and Straightener FIG. 4.8 STRAIGHTENERS AND EQUALIZERS 29 ASME PTC 10-1997ASME PTC 10-1997 sure tap. Equilibrium should be verified as part of the measurement system operating procedures. 4.6.6 Velocity pressure shall be computed on the basis of average velocity. (See para. 5.4.3.) 4.6.7 Static pressure shall be taken as the average of individual raw data observations from four stations, spaced 90 deg. in the same plane of the pipe. The diameter of the static hole shall not exceed four-tenths of the pipe wall thickness and it should not be greater than "in. in normal circum- stances, The hole shall be drilled smooth and free of burrs. A preferred connection is obtained by welding a coupling to the pipe and then drilling the hole. Total pressure probes may be used to measure pressure at the same stations the static measurements are made. Where the absolute values from four stations differ by more than one percent, the cause shall be determined and the condition comected. See PTC 19.2 for further guidance, 4.6.8. Inlet pressure is the total pressure prevailing at the compressor inlet. It is the sum of the static pressure and the velocity pressure. Static pressure shall be measured as specified for inlet pipes in Figs. 4.1 or 4.3, Where no inlet pipe is used, as in Fig. 4.2, the inlet total pressure shall be measured by a barometer. Total pressure may be directly measured by the Use of total probes inserted into the flow stream (such probes shall be properly oriented or directionally Compensated to insure proper measurement), The measurement obtained by a total pressure probe can be influenced to varying extent by spatial location. In the event of significant unresolved differences from the total pressure deduced from the static pressure and average velocity, the static-pressure-based result shall prevail. 4.6.9 Discharge pressure is the total pressure pre- vailing at the compressor discharge. It shall be taken as the sum of the static pressure and the velocity pressure. Static pressure shall be measured as illus- trated in Fig. 4.1. When no discharge pipe is used, as illustrated in Fig. 4.4, the discharge static pressure shall be measured by a barometer. If the velocity pressure (based on discharge opening area) exceeds 5 percent of the static pressure, an open discharge shall not be used. Total pressure may be directly measured by the use of total probes inserted into the flow stream (such probes shall be properly oriented or directionally compensated to insure proper measurement). 30 ‘COMPRESSORS AND EXHAUSTERS The measurement obtained by a total pressure probe can be influenced to varying extent by spatial location. In the event of significant unresolved difer- ences from the total pressure deduced from the static pressure and average velocity, the static-pressure- based result shall prevail. 4.6.10 Barometer readings and the temperature at the instrument shall be recorded at the beginning and end of each test point, The instrument shall be located at the site of the test. It shall be protected from weather, direct sunlight, and fluctuating temper- ature changes. Precautions shall be taken to prevent negative pressures in the vicinity of the barometer which may be caused by strong winds, compressor intakes, or ventilating fans. The instrument elevation with respect to the compressor shall be determined and proper corrections applied. See PTC 19.2 for further guidance. 4.6.11. Internal pressure measurements are required only if the sectional performance is defined for internal conditions (as an alternative the Code defini- tion in para. 3.5.6). Due to the many configurations of the intemal passages in sidestream compressors, this Code cannot specify precisely where or how internal pressure instrumentation may be placed. Asa guide, four pressure probes (either static or dynamic) should be inserted in the mainstream flow. These probes should be located so the incoming sidestream does not affect the raw data (see Fig. 4.12). It is usually difficult to make accurate intemal pressure measurements at a stage discharge since this is normally a f high velocity with local varia- tions of velocity, flow angle, and pressure. This measurement uncertainty should be reflected in the error analysis and in the value of the uncertainty assigned to these stations. 4.7 TEMPERATURE MEASUREMENTS: 4.7.1 Reference should be made to PTC 19.3, Temperature Measurement, for guidance on instru- ments for temperature measurement. Temperature shall be measured by thermocouples or mercury-in- glass thermometers or other devices with equivalent accuracy. The range of their scales, the sensitivity, and the required accuracy shall be chosen for each of the significant measurements according to the particular need. The following general precautions are recommended when making any temperature ‘measurement: the instrument installation should as- sure that thermal conductance by radiation, convec-‘COMPRESSORS AND EXHAUSTERS tion, and conduction between the temperature sen: tive element and all external thermal bodies (pipe wall, external portions of thermometer wells and thermocouple, etc.) shall be negligible in comparison to the conductance between the sensor and the medium being measured. insulation of those parts of thermometer well, thermocouple sheath, etc., that extend beyond the pipe outside diameter may be a means of accomplishing this objective if necessary. In some cases, insulation of the pipe wall near the thermometer or possibly insulation of the section of the pipe upstream of the thermometer may be necessary. ‘The temperature measuring device shall extend a sufficient distance into the fluid stream to minimize Uunavoidable conduction of heat. They need not be Perpendicular to the wall. Oil or other heat conduct- ing fluid should be used in thermowells to improve heat transfer. Precaution shall be taken to avoid insertion of the temperature measuring device into a stagnant area when measuring the temperature of a flowing medium, 4.7.2 When selecting a liquid-in-glass thermometer there may be a need for an emergent stem correction. Refer to PTC 19.3 for further information. 4.7.3. Thermocouples shall have junctions silver brazed or welded. The selection of materials shall be suitable for the temperature and the gases being ‘measured. Calibration shall be made with the com- plete assembly, including the instrument, the refer- ence junction, and the lead wires. If the well is integral with the thermocouple, the well shall also be included in the calibration. 4.7.4 Thermometer wells shall be as small in diam- eter and with walls as thin as conditions will permit Wells shall be evaluated for the conditions of antici- pated use to determine the time lag and the correc- tions to be applied. Thermocouples should be welded to the bottom of a well to reduce or minimize the correction for well error. 4.7.5 Resistance temperature detectors or thermis- tors should be selected for the appropriate range. Caution should be taken because some of these devices have a relatively slow response time, 4.7.6 Total temperature is the sum of static temper- ature and velocity temperature. Where the Mach umber is lower than 0.11 for gases, or for ai where the velocity is below 125 ft/sec, the velocity temperature may be negligible. Normally, the actual 3 ASME PTC 10=1997 temperature measured is a value between static and total temperature. The velocity temperature is then corrected for the recovery factor and added to the ‘measured observation (see para. 5.4.4). Special tem- erature probes made to measure total temperature need little or no correction. 47.7. Inlet temperature is the total temperature prevailing at the compressor inlet. When the com- pressor is tested with an inlet pipe, four temperature taps shall be spaced 90 deg. apart and displaced 45 deg. from the static pressure sensors (see Figs 4.1 of 4.3). When machines are assembled with an open inlet as in Fig. 4.2, inlet total temperature is the atmospheric temperature, and it shall be measured by four instruments attached to the protecting screen. In general, when the 4 (four) raw data observations differ by more than 0.5 percent of the absolute temperature the cause shall be determined and cor- rected. For low temperature rise machines uncer- tainty analysis should be used to determine accept- able limits. Variations of more that 0.5. percent caused by factors other than instrument error such as design may require more than 4 (four) measuring stations. 47.8. Discharge temperature is the total tempera- ture prevailing at the compressor discharge. When a compressor is assembled for test with a discharge Bipe, the instruments shall be located as shown in 4.1 of 4.5 and spaced. 90 deg. apart and atiaces 45 deg. from the pressure taps. Where the compressor is operated without a discharge pipe, four instruments shall be anchored to the discharge ‘opening with a suitable projection into the gas stream. ‘When the four raw data observations differ by more than 0.5 percent of the absolute temperature, the cause shall be determined and corrected. Varia- tion of more than 0.5 percent caused by factors other than instrument error such as design may require more than four measuring stations. 4.7.9. For sidestream compressors, due to the many possible configurations of internal passages, this Code can not specify where or how internal tempera- ture instrumentation may be placed (see paras, 3.5.5 and 3.5.6). As a guide, four temperature probes should be inserted in the mainstream flow. These probes should be located so the incoming sidestream does not affect the raw data (see Fig. 4.12). It is Usually difficult to make accurate internal tempe ture measurements at a stage discharge since this normally a region of high velocity. This measurement‘ASME PTC 10-1997 Nozzle temperature ‘Ameasuring stations Protecting seroe ‘See para. 44 J FIG. 4.9 uncertainty should be reflected in the uncertainty analysis and in the value of the uncertainty assigned to these stations. The internal temperature measure- ment is always required when sidestream and main- stream flows mix internally. 4.8 CAPACITY MEASUREMENTS. 4.8.1 Flow may be measured by using an ASME flow nozzle, concentric square edge orifice, Herschel type venturi tube, or alternative devices of equal or beter accuracy. Reference shall be made to PTC 19.5, Flow Measurement, for general instruction and detailed description of the various primary elements and their applications. Other references are provided in Appendix O. The interested parties shall mutually agree upon the type of metering device to be used and the choice shall be stated in the test report. 4.8.2 The flow measuring device may be located on either the inlet or discharge side of the compressor. It shall be used to determine the net capacity delivered, for in the case of an exhauster, the net capacity exhausted, which excludes losses by shaft leakage, balancing pistons, condensation, and other normal leakage that may be inherent in the compressor design. Multiple devices are required for multiple inlet or discharge flow sections 4.8.3 The nozzle may be used with an open inlet. The nozzle arrangement shown in Fig. 4.9 may be used for the test of compressors as exhausters. The minimum length of straight pipe, following the noz- zle, shall be equal to five times the pipe diameter, and the pipe diameter shall be a minimum of 1.66 times the nozzle throat diameter. A protecting screen shall be used in accordance with the instructions of para. 4.4. Upstream total pressure is equal to the INLET NOZZLE ON AN OPEN LOOP 32 COMPRESSORS AND EXHAUSTERS Nome pressure i tape paced 90 dag. barometer pressure. Differential pressure is measured from two static taps located 0 downstream of the nozzle flange. Temperature is measured by sensors at the screen. 4.8.4 The nozzle may be used with an open dis- charge: Figs. 4.10 and 4.11 show optional arrange- ments of the flow nozzle on the outlet end of a Pipe for use where itis convenient to discharge the gas to atmosphere. For a subcritical flow, the nozzle differential pressure, 4 will be less than the baromet- shall be measured from impact Fig, 4.10. Where the available a5 pressures permit, the nozzle may be sized for ‘operation at critical flow. In this case the differential be greater than barometric pressure, and it shall be measured from static taps located 1D upstream of the nozzle as indicated in Fig. 4.11. In both cases the minimum length of straight pipe preceding the nozzle shall be 10D and the pipe diameter shall be a minimum of 1.66 times the nozzle throat diameter. Temperature measuring sta- tions shall be located 6D upstream. The flow straight. ener and/or flow equalizer, as described in para. 4.5, shall be used. Users of these arrangements are cautioned to observe the distinction between critical ‘and subcritical flow. it should be noted that the velocity of approach is included in measurements made with impact tubes. 4.8.5 Formulas for calculating mass flow for a variety of flow measuring devices as provided in PTC 19.5 shall be used. Methods are included for the determination of the discharge coefficient, fluid expansion factor, and metering element thermal expansion coefficient for various flow elements,COMPRESSORS AND EXHAUSTERS [ASME PTC 10-1997 Nozzle pressure 2 measuring stations One impact tube for d 8 in. spaced 90 deg. Two impact tubes for d> 5 in, Flow equalizer and ‘tighten See Fig, 43) reatertnan 2 ia Not reterthan [SPECIAL NOTE: dnot more than 0.6D for any nozzle arrangement FIG. 4.10 DISCHARGE NOZZLE ON AN OPEN LOOP, SUBCRITICAL FLOW Nozzle pressure 2 measuring stations spaced 90 deg. Nozzle temperature ‘2 measuring stations spaced 90 deg. 1 FIG. 4.11. DISCHARGE NOZZLE ON AN OPEN LOOP, CRITICAL FLOW 4.9 GAS COMPOSITION the compressor or the sampling points. This analysis shall consist of identifcation of the constituents, a 4.9.1" The test gas must be defined. At the mini, measure of mole percent of each and evaluation of mum, sampling will be taken atthe start and end the molecular weight. ifthe tet gas is air no samples are necessary. However, relative humidity or dew- 4.9.2 special precautions shall be taken when test- point shall be measured during each test point. ing with the closed loop to eliminate all liquids from the gas steam and static instrument lines. ‘When dealing with gas mixtures subject to variation, 4.9.3 Note that while the gas under test conditions samples shall be taken at each test point and be may not exhibit condensation, the gas inthe instruc analyzed by spectrographic, chromatographic, or ment lines will be cooler (i.e, room temperature) chemical methods. The sample shal be taken from and, under some conditions, condensation could the piping such that there is no condensation before occur. 3ASME PTC 10-1997 4.10 SPEED MEASUREMENT 4.10.1 instruments shall be selected to provide a continuous indication of speed fluctuation where variable speed drivers are used. Use of two indepen- dent instruments, one to provide a check on the other, is also recommended. 4.10.2 The speed of a compressor driven by syn- chronous motors may be determined from the numn- ber of poles in the motor and the frequency of the power systems. If gears are used between the measuring point and the compressor shat, the speed ratio shall be computed from a count of the number of teeth. 4.10.3 Detailed instructions on speed measuring instrumentation is given in PTC 19.13, Measurement of Rotary Speed. 4.11 TIME MEASUREMENT 4.11.1 The date and time of day at which test readings are taken shall be recorded on all data records. 4.12 METHODS OF SHAFT POWER ‘MEASUREMENT 4.12. The shaft power input at the compressor coupling or the drive shaft may be measured di- rectly by: (2) torque meters (@) reaction mounted drivers ‘or evaluated from: (©) measurement of electrical input to a driving motor (@) a heat balance method () heat input to a loop cooler 4.12.2 The precautions, limitations, and the permis- sible applications for each of these methods are described separately. Code users shall select the method best suited for the application. Detailed instruction on the measurement of shaft power will be found in PTC 19.7, Measurement of Shaft Power. 4.13 SHAFT POWER BY TORQUE MEASUREMENTS, 4.13.1 Torque may be directly measured by devices installed in a drive shaft interposed between the driver and the compressor. For tests under this Code, 34 COMPRESSORS AND EXHAUSTERS torque meters shall be of a type suitable for calibra- tion. The torsion member shall be selected for read- ability and accuracy at the speed and load prevailing during test. 4.14 SHAFT POWER BY ELECTRICAL MEASUREMENTS, 4.14.1 The shaft power input to a motor driven compressor may be computed from measurements of the electrical input to the motor terminals under certain conditions. The power requirement of the compressor should be above mid-point of the motor rating. The output of a motor shall be calculated by subtracting losses from the measured electrical input, or as the product of input and efficiency. Efficiency shall be determined by an input-output test where output is measured on a calibrated dyna- mometer or other appropriate device. For efficiency determination, the supply line voltage used for cali- bration shall be the same as that used for the compressor test. 4.14.2. Eficiency determination by input-output ‘measurements may not be practical for large motors. For large motors the loss method may be used. The segregated losses of an induction motor shall include friction and windage, core loss, FR loss of the rotor and the stator, and a load loss. These measurements shall be made in accordance with current ANSI standards, 4.14.3. The electric power input to the motor shall be measured by the instruments connected at the motor terminals. The detailed instructions for the measurement of electrical power are as in (EEE 120. The indicating electric meters should be selected to read above one-third of the scale range. 4.144. Calculations of electrical power shall in- clude calibration corrections for the meter and cur- rent transformers. The transformers shall be measured for ratio and phase angle at the load conditions prevailing during the test. 4.15 SHAFT POWER BY HEAT BALANCE MEASUREMENTS 4.15.1 When it is not possible or practical to measure shaft power by direct means, it may be computed from measured values of the capacity, a8 properties at inlet and discharge, heat exchange‘COMPRESSORS AND EXHAUSTERS Location A Location B ASME PTC 10-1997 L— Location ¢ VA Sidestream nozzle GENERAL NOTE: Mainstream instrumentation to be located between stations A and 8. FIG. 4.12 TYPICAL SIDESTREAM INLET AREA through the casing, mechanical losses, and gas leak- age loss from the shaft seals. 4.15.2 Methods to account for mechanical losses are discussed in para. 4.18. External heat loss from the casing may be evaluated in accordance with para. 4.17, 4.15.3 The heat balance method shall be used with the following precautions and limitations. (a) The inlet and discharge temperatures shall be measured with instruments suitably selected and ap- plied to provide combined accuracy within 1 percent of the temperature rise. When the rise is less than 50°F, consideration should be given to direct mea- surement of the temperature rise (such as with differ- ential thermocouples), Evidence of nonuniform tem- perature distribution more than 2 percent of the temperature rise at either the inlet or the discharge ‘measurement station, may require one of the follow- ing procedures be used at the offending measurement station: (1) Apply insulation to the piping upstream of the temperature measurement station in an effort to minimize thermal gradient. successful, the tempera- ture measurement installation need not be changed. (2) Move the temperature measurement station away from the compressor and add pipe insulation, ‘This might be particularly effective when temperature 35ASME PTC 10-1997 stratification causes the problem at a compressor dis- charge. (3) Perform a temperature traverse using 10 loca~ tions along each of two diametral traverse lines spaced 90 deg. apart at the same pipe cross section, The 10 sensing locations along each traverse line should correspond closely to the average radii of five annular regions of equal area which comprise the entire pipe cross section. (The central region actually would be a circular rather than annular area.) The measured ‘temperature would be the average of the 20 individual measurements. (b) In sidestream machines, where internal temper- ature measurements are to be made, ideally four loca- tions should be used. However, this may not prove tobe practical. inal cases, the upstream temperatures of the two streams mixing internally should be mea- sured. A measurement of the downstream mixed tem- perature would be unreliable and should not be used for calculation purposes due to inherent poor internal mixing conditions in a machine. (c) Temperature equilibrium shall be established before starting the test reading. Acceptable equ rium will be demonstrated by six or more readings, Uniformly timed, for a period not less than 10 minutes, during which the temperature rise drift does not ex- ceed 5 percent of the temperature rise. (@) The heat losses due to radiation and convection ‘expressed in percent of total shaft power shall not exceed 5 percent, (See para, 4.17.) () The inlet gas conditions shall have a minimum of 5 deg. superheat for Type 2 tests. 4.16 SHAFT POWER BY HEAT EXCHANGER METHODS 4.16.1 When it is not possible or practical to measure shaft power directly or by a compressor heat balance, and a heat exchanger is incorporated in the test arrangement, the heat transferred to the cooling water may be used to determine the net compressor shaft power. 4.16.2 Methods to account for the mechanical losses are discussed in para. 4.18. External heat loss from the casing, piping, and cooler may be evaluated in accordance with para. 4.17. 4.16.3 The heat exchanger method shall be used with the following precautions and limitations. (2) The cooling fluid supply shall be stable in pres- sure and temperature so that the fluctuation of flow rates will not deviate more than 2 percent and the 36 ‘COMPRESSORS AND EXHAUSTERS fluctuation of the temperature rise by not more than 1 percent of the temperature rise. () The cooling fluid flow meter shall be selected and calibrated to maintain the uncertainty imit within 1/2 percent at test conditions. (c) The cooling fluid flow rate shall be regulated so that the temperature rise is not less than 20°F. (d) Two or more temperature measuring devices shall be used at each cooling fluid inlet and outlet. (e) Spinners or similar devices shall be used to in- sure thorough mixing of the outlet stream prior to temperature measurement. (9 The heat losses due to radiation and convection from the gas loop piping, the compressor, and the cooler shall not exceed 5 percent of the total shaft power. It is recommended that the piping between the compressor discharge flange and the cooler inlet be insulated. (@ Temperature equilibrium shall be established before starting the test reading. Acceptable equilib- rium will be demonstrated by six or more readings, uniformly timed, for a period not less than 10 minutes, during which the temperature rise drift does not ex- ceed 5 percent of the temperature rise. 4.17 HEAT LOSS. 4.17.1. When using either the heat balance or heat exchanger method for determining power, it is rec- ‘ommended that heat loss be minimized by the application of a suitable insulating material. If the compressed gas temperature rise is less than 30°F, the inlet piping, compressor casing, and exit piping shall be insulated at least to the measuring station. The extemal heat loss from the compressor casing and connecting piping may be computed with ac- ceptable accuracy from measurements of the ex- posed surface area, the average temperature of the surface, and the ambient temperature. Where a hot surface temperature varies widely, as in large multistage compressors, it is advisable to divide the ‘casing into arbitrary sections and determine the area and temperature of each separately, and thus obtain ‘an approximate integrated average temperature for the total surface. 4.17.2 Where cooling occurs between the inlet and ‘outlet measuring stations as part of the compressor design, measurement of temperatures and flow rates of the cooling fluids are required. Examples are compressors incorporating cooled diaphragms, in- terstage coolers, or aftercoolers as part of the com- pressor package being tested.‘COMPRESSORS AND EXHAUSTERS 4.18 MECHANICAL Losses 4.18.1. When practical, the heat equivalent of the mechanical losses (integral gears, bearings, and seals) shall be determined from the temperature rise of the cooling fluid. The quantity of fluid flowing shall be determined by calibrated flow meters. The heat equivalent of the extemal losses as well as the frictional loss in the mechanical seals, if used, shall be determined and included in the total mechanical losses. Where the mechanical losses are well known and documented, the calculated values or those values determined from prior testing may be used by agreement by test partes. 4.18.2 Where speed changing gears (not part of the compressor) are used between a driver and a ‘compressor, and shaft power is measured on the input side of the gear, it will be necessary to subtract the friction and windage loss of the gear to obtain the shaft power input to the compressor. The gear power loss to the lubricating fluid may be determined by measuring the flow rate and the temperature rise. The additional external loss to the atmosphere may be determined by the methods of para. 4.17. When gear loss measurements are made on an independent gear test, care should be taken to assure that the load, lubricating oil temperature, viscosity, and flow rates are similar to those for the compressor test. 4.19 INSTRUMENT CALIBRATION 4.19.1. All instruments used for measurement shall be currently certified by comparison with appropriate standards before the test. Those instruments subject to change in calibrations due to use, handling, or exposure to injurious conditions, shall be compared again with standards after the test. 37 ASME PTC 10-1997 4.19.2 Pressure measurement devices (Bourdon tube geges and transducers, etc.) shall be calibrated with a deadweight standard or manometer at approx: imately 3 percent intervals for the anticipated mea- surement range. Instruments affected by temperature shall be cali- brated in the same temperature range prevailing during their use. 4.19.3 Temperature measurement devices (thermo- couples, mercury-in-glass thermometers, RTDs, thermisters, etc.) shall be calibrated with certified standards at 20 percent intervals for the measurement range. The standard shall be suitable for the measure- ment range of the instruments to be calibrated. Procedures described in PTC 19.3, Temperature Measurement, shall be followed for checking the accuracy of temperature measuring instruments. ‘Thermocouple calibration checks shall include the hot junction, the lead wires, and the indicating instrument. RTDs and thermisters shall be calibrated with the total system. 4.19.4 Instruments for measuring electric power such as wattmeters, ammeters, and voltmeters shall be calibrated with primary standards. The zero ad- justments shall be checked. They shall be examined for pivot friction. Instruments showing pivot friction shall not be used. Dynamometer types may be calibrated on either ac or de current. Current trans- formers shall be measured for transformation ratio and phase angle at the range of burdens prevailing in the circuit during the test. The transformation ratio of potential transformers shall be measured at the approximate primary voltage and frequency prevailing during the test. 4.19.5 Torque meters shall be calibrated by applying torque with centfied standard weights, load cells, or other appropriate devices spaced to cover the working range. For strain gage types, the calibra- tion shall include the brushes, lead wires, and the indicating instrument.‘COMPRESSORS AND EXHAUSTERS. ASME PTC 10-1997 SECTION 5 — COMPUTATION OF RESULTS 5.1 FORMAT 5.1.1. The Calculation Procedure. The process of establishing compressor performance from test data involves a number of calculation steps. This Section is presented in the following chronological order: © Perfect or real gas treatment is selected. © The appropriate test speed is calculated if a Type 2 testis to be performed. © The raw test data is processed. © Test performance is calculated. © Test performance is expressed in dimensionless form, © Reynolds number correction is applied. © The corrected dimensionless expressions are used to predict performance at specified operating con- ditions. The important subject of uncertainty is treated separately. The section format is intended to guide the user in basic calculation procedure and to present the necessary equations. Appendix € is provided as a background theory source and further explanation of the equations. 5.2. COMPUTATIONAL METHODS FOR IDEAL AND REAL GASES 5.2.1 Choice of Methods. The test and specified gases may be treated as either perfect or real de- pending upon their respective thermodynamic be- havior. For the purposes of this Code ideal gases are those which fall within the limits of Table 3.3. Gases which exhibit deviations beyond these limits are considered real, Three distinct treatments of gases are recognized in the computational procedures. The appropriate choice will depend upon the selected gas, knowledge of its properties, and the desired accuracy. 5.2.1.1 Ideal Gas Method. The gas may be treated as an ideal gas when its properties satisty the limits imposed in Table 3.3. The table limits are defined so that the use of ideal gas laws will intoduce maximum uncertainty of approximately 39 fone percent in efficiency and two percent in dis- charge specific volume. The ideal gas equation of state, 144pv = RT, and the corresponding derived equations in Tables 5.1 and 5.4 may be used. For gases with variable specific heats, average properties are calculated at the arithmetic mean section temperature. 5.2.1.2 Schultz Method. The gas may be treated as a real gas using the method of Schultz [see Ref. (0.13)] when the compressibility functions are known. The real gas equation of state, 144pv = ZRT, and the corresponding derived equations of Tables 5.2 to 5.4 are used. The arithmetic mean between inlet and discharge conditions shall be used for evaluating compressibility, specific heat, X and Y, The Schultz method is normally used when the harge conditions are unknown and an estimate of the polytropic exponent, 1, is needed. Iteration is required to obtain the arithmetic mean conditions. The curves provided for X (Fig. 3.6) and Y (Fig. 3.7) are for reference. They were derived from the generalized compressibility charts. Specific values of X and Y may be developed for any test or specified gas composition 5.24.3 Tabulated Properties and Equation of State Methods. Pure gases and gas mixtures for ‘which tabulated data properties exist may be treated as real gases. There are many gas property correlation equations of state for pure components and gas mixtures. Many of the generalized equations of state provide sufficiently accurate predictions of gas properties to be used in conjunction with the calculation methods, The use of either of these methods will require iterative procedures to satisfy the equations in Tables 5.2 to 5.4, 5.3. TYPE 2 TEST GAS SPEED SELECTION 5.3.1 Test Gas Selection. The gas to be used in establishing the performance of the compressor to be tested can be the specified operating gas or aASME PTC 10-1997 ‘COMPRESSORS AND EXHAUSTERS TABLE 5.1 IDEAL GAS DIMENSIONLESS PARAMETERS ‘Mathveratical Description at Test Operating Parameter Conditions Eq. No. ‘Assumption Flow coefficient 5.73] bea br ‘Woxk input coetfcient (5.72) ly lal Isentropic work coefficient (1 31 iedap = Lede Remon Polytropic work coefcient (s.1T4) ade = ltl Remon (273) Isentropi efficiency (sat) ldap = ts Remain Polytropic efciency (s.1771 Unglee = (ngh: Remean Total work input coeficient See Table 5.3. For ideal gases with con- {s.173) stant specific heats and, sats} ‘GENERAL NOTE: Appropriate unis must be chosen to vende he parameters dimensionies. Further explanation of the equations available Jn Appendix 40‘COMPRESSORS AND EXHAUSTERS ASME PTC 10-1997 TABLE 5.2 REAL GAS DIMENSIONLESS PARAMETERS Parameter “Mathematical Description at Test Operating Conditions Eq. No. ‘Assumption Flow coeicient = [te sar n= or Ee og | Work input coficient a ft - “| ts2r2] Leal = lade ule = [ Tsu a), lsertzopic work cotficent 152-31 Uap = (ads Remeoy (5.214) 24s} Polyropic work coefictent 27) agl = UasleReon (sari tsentopic efficiency 15.218] (ml = Und Remon able continued 2 next pagel, a‘ASME FIC 10-1997 COMPRESSORS AND EXHAUSTERS TABLE 5.2 (CONT'D) REAL GAS DIMENSIONLESS PARAMETERS Parameter ‘Mathematical Description at Text Operating Conditions a. No, ‘Assumption Polyopic efficiency ‘Total work input coefficient See Table 5.3 (5279) Engl = (ngh Remar ‘GENERAL NOTE: Appropriate units must be chosen to render the parameters dimensionless. Further explanation ofthe equations is avaliable in Appendix {gas which allows for similarity testing at equivatent conditions. 5.3.2 Test Speed Selection. The volume ratio limi- tation of Table 3.2 may be met by controlling the test speed. The appropriate test speed is calculated from 5.3.1] where and, with the restriction that, Id = bedap 15.3.4] 2 (5.3.51 e- The Machine Reynolds number correction, Remon, is explained in para, 5.6.3. In order to apply these equations it is necessary to know the polytropic exponent, which is a function of polytropic efficiency. For any gas, ele inl 1 tsa (mi) For an ideal ges, 5371 For a real gas using the Schultz method, . u 83.81(COMPRESSORS AND EXHAUSTERS where 15.3.9] Both the test and specified operating condition effi Ciencies are known only approximately before the test. Where no better approximation is available, they may be estimated from the design value, Toes Remeor Toy aes 1% 3.3.3. Test Speed Validation. When the actual test conditions differ from the estimated values, the most appropriate test speed will depart from the previously calculated test speed. Some deviation is allowable. The test speed is acceptable when the deviation satisfies the limits of Table 3.2. 5.4 CALCULATIONS FOR TEST OPERATING CONDITIONS Performance at the test conditions is calculated by the following procedures. 5.4.1 Raw Data Acceptability. The observed data shall be checked for compliance with the limitations imposed in Sections 3 and 4. See PTC 19.1 for guidance on examining data for outliers. 5.4.2 Processing Raw Data. Acceptable raw data shall be processed to provide values to be used in the computation of results. 5.4.2.1. Calibrations and Corrections. Applicable instrument and system calibrations shall be applied to the raw data, The need for corrections and calibra- tions arises from both the indicating system compo- nents and measurement technique. Raw data shall be corrected as required based on: (a) instrument and instrument system calibrations (6) liquid legs in pressure measurement lines (c) temperature effects (d) thermometer emergent stem corrections (6) local gravitational variation 5.4.2.2 Data Conversion. The corrected raw data is then averaged from the total number of observa- tions (raw data) at each measurement station. This averaged data becomes the reading. The reading is then converted to absolute units of pressure, temperature, etc. 8 ASME PTC 10-1997, 5.4.2.3 Fluctuation. Three or more readings are used to obtain the test point, The allowable fluctua- tion of the readings is shown in Table 3.4. The fluctuation is computed by taking the differences of the highest reading and the lowest reading and dividing by the average of all the readings. ape OMA ay ley where ‘AF= fluctuation expressed in % (Table 3.4) ‘An highest reading ‘A= lowest reading ‘Am i reading ‘n= total number of readings UE the fluctuation values of Table 3.4 are satisfied, then the point is assumed to be valid. 5.4.2.4 Test Point Data. The individual readings are summed and divided by the total number of readings to establish an average. This average is then used as the test point data . 5.42.5 Total Conditions. Gas state static test point data shall be converted to total condition values for the computational procedure. This does ot preclude final presentation in terms of static conditions, but total values are used in the intermedi- ate computations. ‘The relationship between static and total properties is velocity dependent. Average total properties are estimated herein from the average velocity at the measurement station. The average velocity at the measurement station is given by Panic A Simplified methods for converting between static and total conditions at low Fluid Mach numbers are presented in the following paragraphs. A refined ‘method for higher Mach numbers is given in Appen- dix G. The Fluid Mach number for ideal gases is given by[ASME PTC 10-1997 5.4.3 Test Pressure 5.4.3.1 Simplified Method. For measurement sta- tion Fluid Mach numbers of 0.2 or less the effects ‘of compressibility are small. A good approximation of velocity pressure may be obtained by assuming incompressible flow at the measurement station and calculating an approximate density from the mea- sured static pressure and measured temperature. Thus p= 144 PraiclZRTne (5.4.21 Voy = w/60pA [5.4.3] + -eVhe P= Paste * Saat 15.44] 5.4.3.2 Refined Method. For cases where the measurement station Fluid Mach number exceeds 0.2, or when a better average velocity estimate is desirable, the refined method of Appendix G may be used. This method is based upon the assumption of uniform compressible flow at the measurement station, 5.4.4 Test Temperature 5.4.4.1 Recovery Factor. The temperature indi- cated by a sensing element is normally a value somewhere between the static and total temperature, depending upon the ability of the sensor to recover the converted kinetic energy of the gas stream. This ity is defined in terms of a recovery factor, Treas = Tac 0 TTrase 5.45) The recovery factor is primarily dependent upon ‘geometric configuration, orientation, and Fluid Mach number. Standardized Performance Test Code wells (PTC 19.3) used at velocities below 300 ft/sec have a recovery factor for air equal to 0.65. Recovery factors for various sensors may be available from the instrument manufacturer. (COMPRESSORS AND EXHAUSTERS The test total temperature is calculated from the measured temperature taking into account the effect of recovery factor. 5.4.4.2 Simplified Method. The difference be- tween total and static temperatures may be evalu- ated from Vis ma [5.4.6] T= Trae = This equation is accurate for ideal gases (using an average u,= Fz oF], = FS of] = 2983 x10 (0 The shaft power was measured by the shaft power method to be (Pi, = 1097 hp (shaft power method) The shaft power can also be determined using £q, [5.4.141: Pan = Py + Pest where Eqs. [5.4.17] and [5.4.18] show the parasitic losses to be mechanical losses (represented by the lubricating oil temperature rise) Also using Eq. [5.4.13] gives (Pade = (Pel Wo Cpe AT + Qe = (wep (Ta Tt Wo Gpo ATo + 0 (22.000 2) (02455 8) os -saom . (12410 BE) (60 0) 59.5 82) (nase (31.0 °R) ibm Bu (rae . = 1065 hp + 20.1 hp '= 1085 hp (heat balance method) 78(m) The gas power can be calculated from the heat balance method using Eq. [5.4.13] (Pile = bw cp (Ta = Ti # Qe ‘= 1065 hp (heat balance method) The gas power can also be calculated from the shaft power using the shaft power method. Using Eqs. (5.4.12), [5.4.17], and [5.4.18] (Pahi= (Pathe ~ Wo Go & To = 1097 hp = 20.1 hp 1077 hp (shaft power method) (a) The capacity is Check for a Type 1 Test The following calculations confirm that the test conditions meet the limits prescribed for a Type 1 test in Table 3.1. (@) Inlet pressure departure (pidsp — (pie 14.07 - 14.17 (ps giereu a eaiatrae x 100 = -0.71% ‘The test inlet total pressure is within the Table 3.1 limit of 5%. @) Inlet temperature departure (Tap = (Te 650.8 ~ $40.8 tie x 100 Soe 100 = 3.6% The test inlet temperature is within the Table 3.1 limit of 8%. (©) Speed departure (dap = (Ni 10,000 - 10,000 ie — 1 1099 = 10:000 10,008 5 100 = (We T0000 * 100 = 0% The test speed is within the Table 3.1 limit of 2%. (A) Molecular weight departure (Mi — (MWA 28, (MW) ep ee 28.36 x 100 = -1.02% The test molecular weight is within the Table 3.1 limit of 2%. 76(e) Capacity departure en» ete Be 36,000 __38,000 632” 0.06997 36,000 0.06632 x 100 = ~0.049% The test inlet capacity is within the Table 3.1 limit of 4%. (0 Density departure (oie (0dr 190 ie 100 = -5.5% The test inlet total density is within the Table 3.1 limit of 8%. The test coolant temperature difference and coolant flow rate were not checked with the specified values since there is no coolant at the specified condition. Since all the test parameters listed in Table 3.1 (excluding the coolant parameters) satisfy the Table 3.1 limits, the test is a Type 1 test. Computed Test Dimensionless Parameters (similar to para. 6.2.9) The dimensionless parameters which form the basis for the conversion ftom test data to specified operating conditions are calculated in this section. (2) Polytropic efficiency is found as follows: ‘Average specific heat ratio Bu 0.246 Eg (024 ga) (198 acie) (nes oe Polytropic exponent (see Eq. {5.1T-5]) 1.392 1.555 |” Ga.t7 pala) (631.3 °®) 7Polytropic efficiency (see Eq, [5.1T-9]) (ad = al (i, () Flow coefficient (see Eq. {5.17-1)) (som a = (—” = 0.03996 0° 0 - rB) (onn) Bgp (©) Polytropic work coefficient (see Eq. (5.1T-4) ial fais BA) soa BF (2909105) Gera tee) = 0.4734 (2) Total work input coefficient using the shaft power method (see Eqs. [5.4.18] and [5.3T-2)) (1097 hp = 20.1 hp (33,00 = * 2000 2) (2503 108 eae a (9 it S17 i) 0.6082 (e) Total work input coefficient using the heat balance method (see Eg. {5.3T-1)) 78[(o2us 2) sts -snaren +o] ZAIERE ee = 05996 (2903 055) Garr bios (9 Work input coefficient (see Eq. (5.2T-2)) @ Volume ratio at stagnation conditions (for information only) =e Computed Results for Specified Operating Conditions (similar to para. 6.2.11) The performance at the specified operating conditions is calculated from the test dimensionless parameters. These values apply directly since the Reynolds number corrections are negligible. (a) Discharge total pressure at specified conditions is obtained as follows: ‘Average specific heat Bu Bu eames lbm °R 250 Bu 2 ee Tom 247 2% oo Tom fee =( (The design discharge temperature has been used to estimate ¢p,) ‘Average specific heat ratio Buy ibm 0.250 = 1.389 Polytropic exponent is found assuming equality of the polytropic efficiency at test and specified conditions (see Eq. (5.4T-7]) 79ig = 2933 2 154 7.823 oe) Discharge pressure ratio is found using the definition of the polytropic work coefficient and assuming equality of the polytropic work coefficients at test and specified conditions to give (see £q. (5.5T-6)) (2.900 rot) ( m= a Temole* 1 bf, sat) 32.174 flbm 1 Tbmole) (eae Ee) 660.8 *R) 0.4734 | ey (es +1 = 3.196 0.549) (pap = 3.196 (pip = 3.196 (14.07 psia) = 44.97 pia () Capacity at specified conditions is found using the definition of the flow coefficient and equating the flow coefficients at test and specified conditions (see Eq. (5.47-1)). Gl. = 0.03996 (10,000 *) (2 22) 184)” = s0s1 bie (ND Ing = $AND ep 80(C) The inlet mass flow rate is wo (2), tote = (2051 2) (.0sss1 82) (50) an = 36,020 20 = 600.3 22 (d) The specific volume ratio based on total conditions is (for information only) ©), = [@)'], = 31968 = 207 (@) Discharge total temperature is found using Eq. [5.4T-18] 7 (2) 7], = sso. Ro.196) 75 = a46.s on pl” be Since this temperature is nearly equal to the design value of 844.1°R, the average specific heat chosen for the calculations is assumed appropriate. (® Gas power is found using the equality of the total work input coefficient between the test and the specified operating condition. Using the shaft power method and Eq, (5.47-20] gives 600.3 2 0.6052) (2.903 « 106) (1 sec) «cai tp (23,000 55) (038) Using the heat balance method, Eq. [5.4T-20] gives = 1011 hp (2.0 sp) @ Since the specified speed and the test speed are equal, the mechanical losses are assumed equal. The shaft power is then (Palen = (Psy + Qndp = 1021 hp + 20.1 hp = 1041 hp (shaft power method) (Pade = (Peyy + Qe = 1011 hp + 20.1 hp = 1031 hp theat balance method) (h) Static discharge temperature and pressure may be calculated from the mass flow rate, flow area, and total temperature and pressure. Since the flow Mach number is below 0.2, Eqs. [5.4.2], (5.4.3), [5.4.4], and [5.4.6] may be used. alWith a guessed velocity of 130.5 ft/sec, obtained by. trial and error, 2 A (130.57 2 HB (77017 SS (2.174 ABS) (0.25: Cratie diag = (Talap = eee ‘0.140 >) (130.5) (01005) = (paag = Peete ME 8 gg.g7 WEA eT sec (eave dle = (Pay - PRETES = 48.97 75 2 (are BER) (a4 ‘Checking. v-( (00.3 22) ( \Paaue Al (0.140 Bm) = (2002) ‘ome vastuede (RNG tn sane dee = R TTaaie dap (1545 BEE) (seg BE) saz em) o 2TABLE C.1.1 CALCULATION SUMMARY Quantity Symbol Units 1. Quantity of gas delivered w Toate 2, Pressure rze ap psi 3. Head total) 7 ft-lb 43,900 43,800 44,100 4, Shaft power (a) Shak method Pate he 11001040 1020 (6) Heat method Pada hp vos 1030 1020 5. Poltropic efficiency ™ 0790 079% 080 6, Flow coeficient . 0.0400 0.0400 7. Machine Mach no. Mm = - 8, Machine Reynolds no Rem S E E 9. Specific volume ratio total w/a ai zi 10, Specific heat ratio k 138139 11, Polyropic work coefficient — wy oars 0473 12, Work input coefcient sain 0.600 0.600 13, Total work input coefficient (a) Sha method Oe 0.605 0.605 (6) Heat method My 0.600 0.600 14. Capacity q= lwo) —fBimin 90509050, 15, Inlet gas sate (a) Static temperature t 540560 560 (@) Stati pressure 2 141140 149 (Tora temperature T *R a) 561 (Total pressure ? sia M200 14d 141 16. Discharge gas sate (a) Static temperature Tr "R 230885 243s (6) Satie presure e psa 47047 45.0 (2) Total temperawre a te a1 aa? mae (a) Tota pressure ° pala 73450 453 17, Cas power (a) Sha method Po hp 10801020 1000 (6) Heat method (phe hp 106010101000 18. Cooling condition Not applicable 18. Speed x om ¥0.000 19,000 10,000 20. Mechanical loses Qn be 21203 200 331100 12001300 1000 700 ty, wave) 180} syed eunsseig wersuog, g g ty, way wo} aypood§ 01 21g 1UeIEUOQ ‘200 +1000 ‘1100 1200 1300 ‘Steam Temperature CR) IDEAL GAS SPECIFIC HEAT FOR STEAM 700 FIG. C.1(b)SAMPLE CALCULATION C.2 TYPE 2 TEST FOR A CENTRIFUGAL COMPRESSOR USING AN IDEAL GAS This sample calculation is intended to demonstrate: @) Type 2 test (®) Test gas same as specified gas (6) Ideal gas (a) No heat loss to lubricating oil and to ambient {e) No flow leakages (9 Centrifugal machine @) No flexibility to change compressor speed (h) Single section machine The purpose of this calculation is to determine the quantity of gas delivered and the compressor head, pressure rise, efficiency, and shaft input power. Paragraph 3.11.4 of the Code requires that when a test is only to verify a single specified condition, the test shall consist of two test points which bracket the specified capacity. The calculations demonstrated in this sample calculation would be used on both of these bracketing poi Description of Test installation (see para. 6.2.2) (a) Type of compressor — centrifugal (1) type of impellers — shrouded (2) number of stages — single section, ten stages (3) arrangement of casing and piping — not applicable to this sample (4) pipe sizes; inlet and discharge — inlet pipe is 18 in., schedule 40(D; = 16.876 in.) discharge 0 in., schedule 40 (Oy = 10.020 in.) (5) arrangement of intercoolers, if used — no intercool (6) impeller diameter and blade tip widths — impeller diameters Dy = Dz = Dy = Dy = Ds = Dg = 20 in. Dy = Dy = Dy = Dio = 18.0 in, first stage impeller tip width = b = 1.5 (©) Description of lubricating system and lubricant properties — Lubricating system oil flow rate is 4 gpm per beating for a total flow rate of 8 gpm. Oil density is 55.6 lbm/t so the oil flow rate is 59.5 Ibm/min [8 gpm/(7.48 gal/t?) x 55.6 lbm ft]. Oil has constant pressure specific heat of cp = 0.462 Btu/lbm *R. (©) Type of shaft seals — Not applicable to sample (d) Type and arrangements of driver; turbine direct connected, motor direct connected, motor and gear, etc. — Not applicable to sample (e) Description of compressor cooling system and coolant properties — No cooling system Simplifying Assumptions for This Sample (2) The gas (ait) may be treated as an ideal gas with a constant specific heat (evaluated at the average of the inlet and discharge temperatures). Specified Operating Conditions (see para. 6.2.3) : (a) Air with constant pressure specific heats of dry air and water vapor given in Fig. C.1, MWay = 28.97 and MW. = 18.02 ©) Inlet gas state pipe 85(1) paaic 1 = 7.50 psia at inlet flange (2) Tua doi = 600.0 °R at inlet flange (3) inlet densities; to be calculated (4) Riel = 50.0 % (0) Gas flow rate (1) inlet mass flow rate = discharge mass flow rate = w = 17,300 lb/hr = 288.3 Ibm/min (2) inlet and discharge volume flow rates have to be determined (3) capacity has to be determined (@) Discharge static pressure = 48.00 psia at discharge flange (e) Compressor coolant not applicable (9 N = 10,000 rpm @ Compressor internal roughness = € = 0.00012 in. Expected Performance at Specified Operating Conditions (see para. 6.2.4) (a) Developed polytropic head = 88200 ft - Ibf/lbm (based on total conditions) (©) Efficiency (polytropic) = np = 0.82 () Power requirement = Pj, = 1025 hp (d) Discharge total temperature (The discharge s The following preliminary calculations establi form convenient for the Code calculations. (a) Partial pressure of water vapor is found using the steam tables: [Ref. (0.20)] ic temperature is assumed given as 1103°R.) the given specified operating conditions in a (wie * RH alos = 0.500 (2.912 psia) = 1.456 psia (6) Air humidity ratio ati let flange (Ref. (0.20)] (Hig = (05220 2) to) asp (06220 B22) os pin 7.50 ~ 1.456) pala tom w) (_tomole w_) (28.97 tom da [0.1489 aa) (Tab mw) (mae de) tomate w = o.24og mote w (c) Air molecular weight (Ref, (0.20)] mole da (MWe) + mole w (My) oe mole da + mole w 00 Tomole da > 2408 Tomole w tom = 6.06 86(2) Air specific heat at constant pressure is found using dry air and steam properties. The specific heat at constant pressure for both the dry air (da) and water vapor (w) are given in Sample Calculation CA. (Fig. C1) mass da (pga) + mass w (Cyn) (am = mass da + mass w 1.000 tam da (0.240 4) + 0.1498 hm w (0.0 gE w= T1000 Tom da O58 Tw 0.267 = 0267 om R 1.000 thm da (0.251 ;-=Pee a) + 0.1498 om w (0.400 EE (nde = 000 Tom da + OTA58 sw ow 020 ge (@) Air specific heat ratio 267 et kip = = 1,383 Bua [moe (0297 arse) (1986 sate) Gero (hig = ny (020m) ("296 iotea) (sere (The inlet lange kinetic viscosity is found from Ref. (0.20) and is assumed to be that of dry air at the inlet pressure and temperature (og = 4.00% 104 a7(@) Static specific volume at inlet and discharge flanges is found using the ideal gas law (icing = (Tee) | (SeS sR) (sere) (000 (ase Dip = Gat ia 23198 ine) (4 Fe EERO ete dig = ROSIE R26. 84 Bee 8 5.106 he (o.oo (448 (h) Average fluid velocity at inlet and discharge flanges (see para. 5.4.3.1) vB) (ca, Why (1 hey 7, gs eam i a) (94 Bal sae £ IAL)() Fluid Mach number at inlet and discharge flanges (see para. 5.4.2.5) v Me (Teme 98.94 (Map = = a mae = 0.0798 1.383, (324 74 are) =) (0 545 eae) (sear Ten) (000.0 °R) & zor (Malo = sec = 0.0484 1357 (22176 FBR) (i505 AE) ERE) cr03.0% () Total temperature at inlet and discharge flanges is found using the energy equation for an adiabatic process (see Eq. [5.4.6]) (o09«) 2 (77037 2 (an74 EEE (ozer (Tig = 600.0 °R + (cos: 2) 2 (7707 22) (ans74 BBE) (one PE) (Talip = 1103.0 °R + = 1103.46 °R (K) Since the Fluid Mach number is less than 0.2, the total pressure may be calculated according to the simplified Eq, [5.4.4] 9Po = uncle (a), (oo)! (ip = 7.50 psia +, __ BY (szrz4 EO) (140) 53 psia apr c ® (Pay = 48.00 psia + 3.08 pi 2 ore iB) (2174 ree) (14493) () Total density at the inlet and discharge flanges is found using the ideal gas law (739m) (4) bon (1545 tere) Gea toe) ie a)” (ea.00 MY) (144 2) i” Ge a Tbmole °R/ \26.84 Ibm Gao = Bee) oasm) (m) The sum of the squares of the blade tip speeds is Sul -lFSal 6 cin + 4 (8 i (2 eH ‘Mean Observations Derived from Test Data The test is to be run with air at atmospheric pressure and temperature as the inlet pressure and temperature. These give (Duasc dr = 14.10 psia and (Trac obi): = 560.0 °R. Both the specifi gas and the test gas are assumed ideal gases. Assuming equality of the (total) volume ratio between the test and specified operating conditions gives 2 = 7.037 x 108 ec 90([email protected]@,-1 Assuming equality of the polytropic efficiencies between the test and specified conditions gives (ph = (ade or (AAG, Since the same gas is used in the test and atthe specified operating con 3s, assume k; = ky. Then, (oh, = (ah, and 48.0 psia o (Pd) i sia (pak = ton (E 140 psa ey bee = 900 pi ‘as the approximate (total) discharge pressure for the test. The test speed is found by assuming equality of the polytropic work coefficient between the test and the specified operating condition to give (ape = ade (ai) ( on Ti N= Nn [SE which can be obtained from equality of Machine Mach numbers. The numerical values give n= 190005 [SEE « 9841 opm as the approximate appropriate test speed. Not that no Reynolds number correction (as used later in converting the test data to the specified operating condition) is used in this estimation of the test speed. Also, note that the Code speed rule (para. 5.3.2) reduces to the equality of Machine Mach numbers between the test and the specified operating conditions for ideal gases with equal values of the specific heat ratios. See para. 6.2.7. () Test run number 4 () Duration of test = 40 minutes (€) Compressor speed = 9,500 pm (@) Inlet temperature = Tawic bs = 540.0 °R a(e) Barometer reading = 14.10 psia (9 Ambient temperature at barometer = $40.0 °R © Inlet static pressure = Pyaie = 14.10 psia (h) Dry bulb temperature at inlet flange = Taaic anv = 540.0 ° (@ Wet bulb temperature at inlet flange = Trac wei = 530.0 °R ) Dew point at intet flange = 525.1 °R () Gas density not measured ) MWg = 28.97 and MWy = 18.02 (m) Discharge static pressure = Panic a = 99.6 psia (n) Discharge static temperature = Taxicdid = 1042.2 °R (o) Mass flow rate = 36,500 lb/hr (p)t0 (w) Not applicable to this sample 6) Shaft power input = Py = 1851 hp (determined by measuring shaft input torque of speed) (7) Shaft torque = 1023 ft Ib (2) Lubricating system oil flow rate is 19.3 gpm. The oil density is 55.45 Ibm/ft? so the oil flow rate is 143.1 lbm/min (19.3 x $5.45/7.48). The oil has constant pressure specific heat cp = 0.462 Buu/lbm °R. (a) Lubricant inlet temperature (bb) Lubricant outlet temperature = Too (cc) to (ee) Casing heat loss = 6740 Btu/hr (ff) Not applicable Tein = 525.0 °R 68.5 °R Computed Results for Test Operating Conditions (similar to para. 6.2.8) The previous test data is converted into a form convenient for Code calculations. (2) The air humidity ratio of the inlet air is found using air and steam properties (Ref. (D.20)] Pag 70.3 °F (HRs = 0.6220 0.3667 psia tom w TaI0 pri - 9.3667 pata = °°" ibem da = 0.6220 = [= (Tan = Tai) + HR gb = Pa) rey bu tom) bu 240 gots gi00 5200) (noreer BEY) gosaa ~ 3039 ge wes83 303 (ootse Sra) (eas tem) (297 meatea Tomole w_ Tomole da 0.03024 92(b) Air molecular weight (Ref. (D.20)] mole da (MW) + mole w (MWe OM = Tame“, lm 1.000 timated (28.97 228) «0.3024 mele w(18.22 1-00 lbmole da + 0.03024 lomole w om w Temole wi Ibm = 2065 (©) Air specific heat is found using dry air and steam properties, Btu Tom da) 1.000 Ibm da + 0.01881 lam w + 0.01881 im (2447 BE 1200 om (0280 th a a eee eet se (020 att) 010m tm (nas Be at 1.000 Ibm da + 0.01881 Inm w ow = 0282 St Average specific heat Bu e249 2 ° ibm ® 93(A) Air specific heat ratio w= (8,* (Ca), Bw R (024 ara) ~ (04986 pase) (eae tom) 0.244 ie kar = = 1.397 Bw 0253 AR (01906 geet) Gas ie) (ka = ) ibm) ~ (€) The inlet flange kinematic viscosity is found from Ref. (D.20) and is assumed to be that of dry air at atmospheric pressure and the existing temperature + (oe = 1.70 104 0 Static specific volume at inlet and discharge flanges is found using the ideal gas law Pre (ase = [e#, e @) Fluid velocity at inlet and discharge flanges (see para. 5.4.3.1) 94na fm TCGE= A (20002) (ae 00) at 10.020 sec) sec IEPs) (00%) (h) Fluid Mach numbers at inlet and discharge flanges (see para. 5.4.2.5) ae = = (eras ft 93.60 = (Me = a + = 0.0818 1.397 (32.174 FOR) (1545 EP) (Go BR) 540.0) (Ma) = SS eee 0.0459 137722176 rae (155 apie) Gas em) 10822 0 (i) Total temperature at inlet and discharge flanges is found using the energy equation for an adiabatic process = (Tame 3), (e360 8° ) (87 Se) (174 ees) (Ty = 540.0°R+ = 540.7°R 2(e26 95(asec) (Fade = 1082.2 $8 + ——— = 1042.6 "8 2 (0289 EE) (7007 22) (sane BE) @) Since the Fluid Mach number is less than 0.2, the total pressure may be calculated according to the simplified method of Eq. [5.4.4] = unre (>) ; (os0-8)" chee (72304) (ok = 996 psa + = 99.74 pi 20919) (27 BEE) (144) (K) Total density at the inlet and discharge flanges is found using the ideal gas law (14:7 2 (saa) = = lg oa ton Ol Ca Ea efor) OP tote (rt) sas * (i545 EE) (Ge BS) (1002.68) 38.65 Tom () The sum of the squares of the blade tip speeds is i u- ee ale (2.500 =)" t6 eo passin (22S) eee +(29) (m) The shat power was measured by the shaft power method to be (Pip): = 1851 hp (shaft power rethod) me 96The shaft power can also be calculated from the gas power using the heat balance method and Eq. [5.5.14] (Parks = (Pele + Prarie losses to be mechanical losses. Also, using Equations [5.4.17] and [5.4.18] show the par &q. [5.4.13] gives (Pane = (wcghe Ta = The # Qe + Wo po ATo (oso 2) (ozas fe (1244 ire) (60 (140 22) (oa gt) 68s - 525.01" Be) (ras) = (1791.4 + 2.65 + 67.8) hp vons-sonn ero (eo ina) ( (Pah = + = 1862 hp (heat balance method) (n) The gas power can be calculated from the heat balance method as done above to get (Pe = (wr phe (Ta = The + Qe 1791 4 + 2.65) hp ‘= 1794 hp (heat balance method) The gas power can also be calculated from the shaft power using the shaft power method (Pp = Panhi= We Spe ATo (1862 ~ 67.8) hp 1794 hp (shaft power method) Check for a Type 1 Test The above test does not qualify as a Type 1 test due to the large differences in the inlet Pressures, To formalize this observation, the inlet pressure departure is (Pie - (pe 7.53 ~ 14.16 Pee NP 1099 = ZR A TANE 109 = - 28. te 100 i 100 = -88.0% which is outside the range of the Table 3.1 limit of 5%; therefore, the test is not a Type 1 tes. Therefore, we must conduct a Type 2 test; however, we will verify that this is a Type 2 test, ., satisfies the Table 3.2 requirements. 97Computed Test Dimensionless Parameters (similar to para. 6.2.9) The dimensionless parameters which form the basis for the conversion from test data to specified ‘operating conditions are calculated in this section. (@) Polytropic efficiency is found as follows: ‘Average specific heat ratio 0.249 tu caw wag * 188 (029 gina) ~ (199° act) (Se “to Polytropic exponent (see Eq. [5.1T-5]) 2apiND> toen) (_rev_) (_he_) (eee a aa (06500 8) (5500 5°) (222 4) 98(C) Polytropic work coefficient (see Eq, [5.1T-4]] Gr) (84 ae) (sos tow) 107 [Ca (¢38«00" 5) Gea eis) 4075, 1251 mp 67.8 (23,000 AL) (0 1 (265005) (63510 5) (os ee bw (0 Work input coefficient (see Eq. (5.2T-21) Br fll coens ~ 5405) (7.7 249 eo(Te~ 1) tom (gh = SET - Ey 7B 0.4927 ca (69500023) (son tes) 99( Volume ratio at stagnation conditions (for information only) Computed Results for Specified Operating Conditions (similar to para, 6.2.11) The performance at the specified operating conditions is calculated from the test dimensionless parameters. The effect of the difference between test and specified operating condition Reynolds fhumbers is estimated from the PTC 10 Reynolds number correction. (a) Discharge total pressure at specified conditions is obtained as follows: Average specific heat pos 0267 gitig 0201 it te (le = (74, = 0274 ee (The design discharge temperature has been used to estimate cpg) ‘Average specific heat ratio 0.274 oe ee ee es eae Or eS Polytropic efficiency correction is now used to account for the differences in the Machine Reynolds numbers. The Reynolds number limits for this correction are found using Eqs. [5.4.4] and [5.6.1] to [5.6.4] roe = 2.73 x 108 (2500) (2s) (io) Cia) * se) = 6.10 x 108 rfl 2 (170x104) (eo Bem = [sade w od FS] «arr 020 100or Rem: < 4.775 Remy = 4.775 (2.73 x 105) = 1.3 x 108 Rem, > 0.2094 Remy = 0.2094 (2.73 x 109) = 5.72 «104 Since the test Machine Reynolds number (6.10 x 108) falls in the above range, the following Reynolds number correction may be used. The corrected polytropic efficiency for the specified operating condition is related to the test polytropic efficiency by 1 = Ope = 0p eee 988 RemzP2? = 0,988 (2.73 x 105-928 = 0.04718 RCr= 0,988 Rem?" = 0,988 (6.10 x 10°28 = 0.03881 105), RAs 0066 + 0934 [AI le i) x 105) 00071 Bry 0.066 + 0.934 [SES x10 7 ons 4b 105) *, RAsp= 0.066 + 0.934 eee) (1.5 in) 105) 0081 npr cee + 0534S AIF as tg (0020125 + fog (000072 + D7 x18) RB, = tog (0000125 + = 0.9961 tog (000012 2 1011.0354 0.99940) (1 = 0.829) 1- (pe and (nuply = 0.822 The polytropic exponent is found from 3.042 or aoe (7.037 x 108 Vax pises) 32,174 fiom (Gs) (18 aca) (ase ea) 07") Discharge pressure is found using Eq. [5.4T-15] Pa = 6.400 (pil = 6.400 (7.53 psia) = 48.2 psia (©) Capacity at specified conditions is found using the definition ofthe flow coefficient and equating the flow coefficients at test and specified conditions (see Eq, (5.4T-1]) a= (Z), = Ful Oy = 44ND ny (228) 72a)" = o157 = 903148 (10.00 7 102(C) The inlet mass flow rate is wo (5), tale = (9157 £) (o.05136 22) (60. Ibm = 1723052 (d) The specific volume ratio based on total conditions is (€) Discharge total temperature is found using Eq. [5.47-18] i) Since this temperature is nearly equal to the design value of 1103.5°R, the average specific heat chosen for the calculations is assumed appropriate. (0 Gas power is found using the equality of the total work input coefficient between the test and the specified operating condition. Using the shaft power method, Eq. [5.4T-20], and Table 5.3 gives J, = 600-7 °R 6.400)" = 11.06 *R (Tae vn Onde (EE wilt (EE) ale = —syaag tale * — az 50 17,230 BE aaso) (7.037 x 108 2) (Sh : (22.000 58) («0 ) = 932.8 hp (shaft power method) Using the heat balance method, Eq. (5.4T-20}, and Table 5.3 gives, vr Ondo EZ) welt EA), @ = 3,000 33,000 (17.230 82) cana (7.0n7 «108 £3) (SE (om SED (co = 939.3 hp (heat balance method) 103(@) The shaft power is found by assuming the mechanical losses are proportional to a power of the rotational speed (see Eq. {5.6.8)) (Qmip = (Qul 2) 2771 hp ‘The shaft power is found using Eqs. [5.4.14], [5.4.17], and [5.4.18] (Parle = Pry + Ome += (932.8 hp + 77.1 hp) = 1010 hp (shaft power method) (Panlp = (Pay + Omse = (939.3 hp + 77.1 hp) = 1016 hp (shaft power method) (h) Static discharge temperature and pressure may be calculated from the mass flow rate, flow area, and total temperature and pressure. Since the flow Mach number is below 0.2, Eqs. [5.4.2], (5.4.3), (5.4.41, and [5.4.6] may be used. With a guessed velocity of 80.2 ft/sec, obtained by trial and error, Teac day = (Taig (eorr & see 27017 2) (a2174 £22) (0281 = 1106. - = 1105.5 °R (Pune ap = (pap = 220d 0V2 Ponte dig = (Palin ~ aT tom op pa 8 woe _ (0108 5) oar io = 102m i AO 2[saare EB (ue 104Checking (e037 FE) Ge) sec | 80.2 (oso) FGF) # 144 (peated RO alee (+4) (sua (1545 RG) (sete BEM) 05.5 + (Pame dip = 0.109 ca] rs Check for a Type 2 Test (2) Specific volume ratio (see Eq. (5.5.5)) % 100 = 1.049% ‘The test specific volume flow ratio is just within the Table 3.2 range of 95% to 105%. The difference is due largely to the assumption of equal gas properties between test and specified conditions made when determining the test speed. A retest at an adjusted speed would reduce this deviation. (b) Capacity — speed (flow coefficient) ratio (see Eqs. (5.2T-1] and [5.4T-4] x 100 = 99.6% (cana B3)(‘The test capacity — speed ratio is within the Table 3.2 range of 96% to 104%, (0) Test Machine Mach number (see para. 5.5.1) us DN. Mo = TERT ~ Ras ing = (19.00) (rei oe) ee 2a [rae (0568 ee) (ope BEE) oa 9 (ara RES) os (0,500 *) a seared oe 3e7 (i545 Ee) (a BE saz ow (s2170 ES) ‘The test Machine Mach number is within the Fig. 3.4 range of 0.625(0.710 - 0.085) to 0.815, {0.710 + 0.105). (d) Machine Reynolds number ratio (see Eq. (5.5.5)) = 273x108 rev) /,, fad) (20 senso On brie) i ae 2 (170x108) (0 Fat 100 = SIO2IE 5 100 = 223.4% ‘The test Machine Reynolds number is above the Table 3.2 lower limit of 90,000 and the Machine Reynolds number is between the Fig. 3.6 limits of 0.17 and 6.5. Since all the Table 3.2 requirements are satisfied, the test is a Type 2 test. 106TABLE C.2.1 CALCULATION SUMMARY Tet Conected Expected 0 a Specified Specified Test Operating Operating Quantity Symbol ___Units__Value Condon __ Condition 1. Quanity of gs delivered w br —36500 17,230 ~—«47,300 2 Presure ise ap pl 56407 406 3. Head ota % ‘t-tbffem 20,400 88,450 08,200 4, Shaft power (a) Shaf method Can hp yas1 101002 (©) Heat method Cae he 18821016025 5, Polyropicefciency ™ oss oa asa 6. Flow coeffcent * 00x15 0.0315 aoe 7. Machine Mach no. Me 0724 0703 oo 8. Machine Reynolds no, Rem 10000 273,000 273,000 9 Specific volume ratio total) ahd 433 aa 10. Specific heat ratio k fat ey tar 11, Polyropie wa coticient ay 0408 os = 12, Work input cooicient bn 04930493 = 13, Total work input coeficient (a) Shak method 0.490 0.490 S () Heat method 04s 0.494 = 14, Capacity 2700160 9190 15, tne gas ate (a) Static temperature Tr *R 50660 600 (@) Static pressure 2 pila 141750 750 (© Total temperate r *R sat cor ‘ot (@ Total pressure 2 psa 2753 753 16, Discharge gas sate a) Static temperature r "R tor 1106 1103 (©) Static presore e sia 36 a8. 480 (Total temperature T ‘R 1031106 1103 (eh Total pressure Pe pala 997 482 4a 17, Gas power (a) Shak method a be 1794933, = (@) Heat method Core bp 1794939 = 18. Casing heat loss @ bp 265 - = 19, Speed N pm 9500 10,000 10,000 20, Mechanical loses Qn bp oa 73 pled ee 107SAMPLE CALCULATION C.3 IDEAL GAS APPLICATION TO SELECTION OF TEST SPEED AND TEST GAS AND METHODS OF POWER EVALUATION This sample calculation is intended to demonstrate: {a) Test speed selection (b) The effect of substitute gas use on achievement of flow similarity (C) Methods of power evaluation The following information is given about the design: Number of stages = 6 ‘At an inlet flow of 3000 f’/min 1st stage diameter = 11.459 i Discharge pressure = 90 psia Impeller exit tip width = 0.5 in, Polytropic efficiency = 0.76 Shaft rotational speed = 16000 rpm Shaft power = 650 hp Gas — Methane Inlet pressure = 30 psia Inlet temperature = 570°R ahs EU2ge = 1.11006 x 108 felbf/bm us lao The data in the left hand column above indicate the specified operating conditions. This data describes the compressor geometry, the operational speed, and intet gas conditions. The data in the above right hand column describes the intended performance of the compressor at the specified operating conditions. it is the purpose of the test to verify these intended values or establish the actual values. It is assumed that circumstances prohibit testing with methane. Air is available at 14.7 psia, 520°R, and 50 percent relative humidity. The driver has variable speed capability. The following assumptions are made to simplify the calculation process so that focus may be made on demonstration points. (2) Both the test gas, air, and the specified gas, methane, will be treated as ideal gases with constant. specific heats. Average values will be used. (The alternative is to use actual gas thermodynamic data and the Type 2 calculation procedure. This would lead to slightly more accurate results.) () Leakages will be assumed negligible at both test and specifed conditions. The rotor mass flow rate is then the inlet mass flow rate. The test speed required to provide equivalence between test and specified conditions is obtained from the speed selection rule. For ideal gases,TABLE C.3.1 PRETEST CALCULATION SUMMARY Gas Methane be pala 30. Bm psia 30. We wd 570. R — felbtem’R 96.31 k 128 Ton 1078693 Ibm sec 0.768 x 10% N rpm 16000. Ue 200. Mm 0832 Rem Bait 1081583 x 108 » 076 076 (excludes Reynolds Number cor- ‘ection! pole 30 3st a 1 16, ie 219 219 é 0.00343 with ee . jz" 2 pl!” Np aa and Precise values of pressure ratio, efficiency, and polytropic exponent for both specified and test conditions are of course unknown before test. However, the appropriate test speed may be estimated by making the following assumptions: (2) The pressure ratio and efficiency at specified operating conditions are equal to the design values. (0) The efficiency at test conditions is also equal to the design value. While the Reynolds number effect might be taken into account here, it is small and the current calculation is only an estimate. {tis ignored simply for computational ease. The first assumption allows calculation of the specified condition polytropic exponent. The second allows calculation of the test polytropic exponent. With these a test pressure ratio estimate and a required test speed estimate may be calculated. This speed may be used to calculate Machine Mach and Reynolds numbers. The gas data used and results of the computations indicated above are summarized in Table 3.1. The values in this table may be used to determine if it is possible to accomplish the Proposed test within the allowable deviations in similarity parameters. ‘Mach Number Check: The test Mach number is = 6.6 percent greater than the design Mach number. This is an unavoidable consequence of gas selection with 0different k values when specific volume ratio equality is maintained, The deviation is, however, within the limits of Fig. 3.2. Reynolds Number Check: The test Reynolds number is =46 percent of the design Reynolds ‘umber. This is within the deviation limits of Fig. 3.4, and the correction relationship applies. The correction has riot been applied to the tabulated values, since the computations are preliminary. The compressor is run to obtain a bracketing point. A bracketing point lies within #4 percent Of the specified operating condition flow coefficient of interest, which is 3000 = 0.03427 2 (16000) The desired test inlet flow may be calculated from test and specified operating condition flow coefficient equality, which yields The test yields the following data: w= 2.9595 lbm/sec pie 147 If fin? T= 520 °R RHj= 50% 0.4 Ibf fin? 332 °R Qn= 20 hp (from lubricating oil temperature rise and flow rate) ‘Q-= 5574.5 Btu/hr (calculated casing heat loss) Pays 339. hp (shaft power, pethaps from a torquemeter) N= 12690 pm R= 53.53 felbf/lomR The next step is to compute the following dimensionless parameters from the test data. Specific Volume Ratio: = 2.14286 Flow Coefficient: os ran) umPolytropic Work Coefficient: He ~1] = 0.62702 Work Input Coefficient: n Hin, = 0.84317 Polytropic Efficiency: 1, = — = 0.746 J ta 1 +2 cea &e Total Work Input Coefficient: (Shaft power method) (SO 33000 Eu & 0.849 ‘Machine Mach Number: 5675 ‘Machine Reynolds Number: which have been evaluated using pulp; = 50.4/14.7 = 3.4286 112vilva = (palpif(TalT:) = 3.4266/(832/520) = 2.1429 fn = In (palpiiin(vifva) = In (3.4286)/In (3.1429) = 1.6167 1) = (2.9595 Ibm/sec) (60 sec/min) = 177.57 lbm/min N= 12690 rev/min D = 11.459 in, R = 53.53 felbilbmeR 520 °R Te = 832 °R &p = (5574.5 Btu/he) (1/60 r/min) = 1347 (2%) rae (3) a en eal me RT f ib asses (7) (a) oa mi 1 a.oreoer (82 Py = 339 hp fe tbe cong s3000(A-A) Qn = a = 048.2 2 0.0417 f The preliminary assumption is made that these coefficients with appropriate Reynolds number correction, also apply at specified conditions. The limits for allowable test Machine Reynolds umber are given by 4or 6A1 x 10 < Rem, s 1.81 x 108 The test Machine Reynolds number does fall within these limits and the efficiency correction may be used. Thus 0.97798 (0.99648) 1a rg = 0 Oe °F 01184 (0.99718) where 4.x tot bc wy = 0.066 +0924 (EIEN | gorng aa, = 0086 +0934 (EIEN a otte4 tg [oooors + 2) te = ossess wf ES) #[ + (rene) 1367 tos [ooooras « (222) RB, “— = 0.99718 an te[+ (rom) with RCip= 0.988 Remy 92? = 0.044696 988 Rem 22 = 0.053862 3 411 x 108 Rem;= 1.593 x 105 = 0000120 in, so, "ey _ 0.752 Mog = 07526 ad Rete = Ew 228 = 19 The Reynolds number correction is applied to both the polytropic efficiency and the polytropic work coefficient. usIn summary, the preliminary assumption is that the following dimensionless coefficient set applies at specified operating conditions. by = b= 0.3363 Bingg = Hin, = 0.84317 Dr, = Ane, = 0.84900 Oy, = en; = 0.84900 Tog = Te, Recor = 0.744 (1.0118) = 0.752 Bog = He, RE Mea = 0.627 (1.0118) = 634 This assumption is taken to be valid to the approximation involved i {a) the test specific volume ratio is within 5 percent of the specified condition volume ratio (Table 3.2). The specified operating condition volume ratio is calculated to determine if this requirement is ‘met. This is done by using the polytropic work coefficient and polytropic efficiency to calculate the specified condition discharge gas state, i., zur Be 1.11006 x 105 34095, (tates TOE) 5] = aso Saamsseai 67a) *'] wherewhich yields ng = 1.4099. The specific volume ratio is then ip = 2.975 Ta = 2.167 le (b) the test Machine Mach number is within the limits of Fig. 3.4, which is seen to be satisfied; (@) the test Machine Reynolds number is within the limits as already described; (@) the est flow coefficients within +4 percent ofthe specified operating condition flow coefficient of interest. It is concluded that the dimensionless coefficient set developed is valid for the specified ‘operating conditions. The following quantities of interest at the specified operating conditions are established from this set as follows. The section pressure fatio has already been established in the volume ratio calculation using the polytropic efficiency and polytropic work coefficient. The discharge gas state is then bt Bi, = 2.975 (30) = 69.25 1.373 (570) = 782.6 °R The flow is determined from the flow coefficient f 2944 — [arer(2))] = anaes 2 «24 on00 (Aa)! min (12 144 (30) 96.31 570) lbm w= pq = nz‘The power requirement at the specified operating conditions is determined from the total work input coefficient. zu wa ——| l Belg ryt 33000” 33000 62 eo SE 40 (1.1006 «108 8) (MP) 657.3 op Tam} \33000 f+ 16H where, Qe! Qed 125 16000)25 @ = 20hp(——) = 35.7 hp 33000 ~ 33000 (Wy, 7268 In this example both the shaft method and heat balance method give exactly the same power requirement. This may not always be true because of differences in the independent measurements which are used. This example was specifically constructed using values such that the powers would match. usCOMPRESSORS AND EXHAUSTERS ‘ASME PTC 10-1997 SAMPLE CALCULATION C.4 TREATMENT OF BRACKETED TEST POINTS This sample problem is an extension of Sample Calculation C.3. It demonstrates treatment of bracketing points. Suppose that a second data point for the compressor of Sample Calculation €.3 is available. The data is shown in the upper portion of the second column in Table C.4.1. Calculations were done for this data set following the same procedure as in Sample Calculation €.3. The results are summarized in the lower portion of column 2. The calculated efficiency and work coefficients are plotted as functions of flow coefficient in Fig. C.4.1, The flow coefficient of interest is for 3000 ft?/min at specified conditions, or = 0.03427 which falls about midway between the data points in Fig, C.4.1. The data points are valid bracketing points in that they are well within 4 percent of the flow coefficient of interest (Table 3.2). In the absence of additional data points, the values of the dimensionless coefficients at the flow coefficient of interest are determined by linear interpolation. Linear interpolation gives Hing 0.838, py = 0.629, np, = 0.750, Ors, = 0.8438, On, = 0.8232 ‘These values are used to calculate the compressor performance in dimensional terms as follows: Flow rate: 3000 f/min as above Discharge pressure: zur = a A wa) ar = 2.9497 ee = [say giatmee to] Gas09637670 *',, 19ASME PTC 10-1997 where and, TABLE C.4.1 Test Data its 1st Data Point 2nd Data Point nN ep 12680. 72650. w Ubrvisee} 2.9595 3.0799 a Ipsial 147 147 ti eR) 520. 520. aH, (6) 50. 50, pe Ipsial 50.4 494 Te (ra 332, 228, Qe {pl 20. 20. Pa (pl 339. 330.39 a (ctw 55745 5485. & (felon) 53.53 5353 k 1396 1396 Calaulation Summary: 1st Data Point 2nd Data Point Tet Specified Test Specified Operating Operating Operating, Operating Conditions Conditions Conditions Conditions 0034) ‘0034 0.035, 0035) 0883 0343 0.832 0.832 0627 0.634 ois 0.623 o7as 0752 0.739 0748 0.849 0849 0.838 0.84900 ‘0.84900 0794 0567s 0.5320 0.5674 1583 x 108 Batt x 108 15583 x 108 21429 21668 21105 n= 1.41145, Ps = (palpi) pr = (2.9497) 30 = 88.49 bin? 120 COMPRESSORS AND EXHAUSTERS‘COMPRESSORS AND EXHAUSTERS ‘ASME PTC 10-1997 . | 1 1 1 te ' 0.80 ! : Dey 1 1 1 eee aeeeeeere 1 1 1 070 ! ! 1 | 1 1 — » 1 0.099) 0.034 0.038 0036 FIG. C.4.1 Power requirement: Heat balance method: wD EU? Qn) Pee = 33000 “g. * 33000 (236.08)0.848(1.11006 x 10%) 33000 +.35.7 hp = 705.79 hp where pi qi = [(30)144(300011/(96.311(570)] = 236.08 Ibm/min 121ASME PTC 10-1997 COMPRESSORS AND EXHAUSTERS Shaft power method: wire EU2 | Onl Pew * 33000 g. * 33000 1006 x 10°) ie omeweell 435.7 hp = 689.43 hp "33000 Notice that the shaft power and heat balance methods yield two different results in contrast to Sample Calculation C.3. This is due to the contradictory measurements for the second data point, reflected in the two different values for total work input coefficient. One of the values is clearly in error, indicating an error in measurement. With mutual agreement by parties to the test, the options may include: {a) retest, eliminating the error; ©) neglecting the error should the difference in results be deemed negligible; (©) assuming one or the other measurement correct and ignoring the other; () comparison with other data points if available. {mn this case the error would appear quite large. Since only two data points are available it might well be prudent to retest for verification. As the methods agree for the first point, the second data point is questionable. Further, since the test shaft power is smaller for the second data point despite a larger mass flow rate, the shaft power measurement is especially suspect. ‘Assume that further investigation leads to disqualification of the shaft power measurement for the second data point. The final results from the bracketing data points may be summarized as. acer eee Speed tm) 716000 16000 Gas Methane Methane Tem 570. 570. Prigsiad 30, 30, qf) +3000. 3000, Pe 90. 8.09 » 076 0750 Po, 630. 708.79 ae 239 2.152 Comparison of the design and actual results indicates that the compressor falls short of meeting its design pressure goal at design flow. The implication of this fact to the parties involved are beyond the scope of this Code, as they would be also had the compressor exceeded its design goals. However, typical industrial reaction in lieu of mutual acceptance as tested is hardware ‘modification or specified condition speed adjustment. In the event of hardware modification the test must be repeated. For small speed adjustments the test results may remain valid. This is determined by conversion of the test results to the new specified condition speed and verifying that the limits in departure between test and specified conditions are not exceeded. 122SAMPLE CALCULATION C.5 SELECTION OF A TEST GAS FOR A TYPE 2 TEST USING IDEAL AND REAL GAS EQUATIONS This sample calculation is intended to demonstrate how to select a test gas and determine the test speed. A compressor designed for use on a hydrocarbon mixture is to be tested in the shop with a closed loop for an ASME test. Table C.5.1 gives the specified operating conditions and predicted performance for the point to be tested. Additionally, it gives mechanical design Tequirements of the equipment such as the maximum temperature, pressure, rotating speed requirements, the impeller design data needed for the evaluation of test equivalency, and the critical speeds of the compressor rotor system. The selection of the test gas and computation of the required compressor speed is a multi- step process. Table C.5.2 outlines the basic steps involved in flow chart form. The first step involves computation of the specified conditions; Reynolds number, Mach number, pressure ratios, volume ratios, etc. This data is contained in Table C.5.4. The next step is to select the possible test gases. In this problem nitrogen, carbon dioxide, refrigerant 134a (R134a) and reftigerant 22 (R22) have been selected as possible test gases.’ Knowing a closed loop is to be used, 20 psia and 100°F were used for a first estimate of inlet conditions. The selection of the 20 psia was to allow a loop with a positive pressure and therefore, no inward leakage of air as a contaminant would occur. Table C.5.3 lists the test gas inlet conditions for each of the gasses. The next step is the determination whether ideal gas or real gas calculation. methods should be used The X factor and Y factor of Schultz were computed for the specified gas as well as for each of the test gases. It was found that the specified gas required real gas calculations, nitrogen could be assumed to be ideal, and CO2, R134a, R22 required real gas calculations. From the X and Y factors, an estimate of the cp and the compressibility Z, the test polytropic exponent was computed. Since the specific volume ratio at test should equal the specific volume ratio at specified operating conditions, the test pressure ratio was computed along with the test discharge pressure and temperature; see Table C.5.4. Atthis point, a check with mechanical design conditions found that nitrogen and CO> test discharge temperatures were in excess of maximum allowed by the mechanical design and a further comparison of speeds also indicated extremely high rotational test speeds in excess of mechanical design. Further computation was not needed for nitrogen and COz, as these gases were eliminated. First estimates of temperature and speed for refrigerant 134a and refrigerant 22 (See Table C.5.4) indicated possible test gases since they did not exceed mechanical limitations. However, the rotative speed for the preliminary R22 selection was only 3 percent below the first critical speed and the rotative speed for the R134a selection was approximately 14 percent below the first critical speed. For the first pass, there was no Reynolds numbers correction, verification of specific volume ratio, efficiency, or an estimate of real gas correction factors. The final test speed should be checked so that it is not too close to a critical speed. The next step is the computation of the test head, discharge enthalpy, isentropic discharge condition, and the real gas correction polytropic work factor. Table C.5.5 has the computed data Tt recogized that thee i 8 pote enicrmartal problem of wing refigerant 22. The use hee nly to demonstrate the calculation method. ® * " 133TABLE C.5.1 SPECIFIED OPERATING CONDITIONS AND PREDICTED CONDITIONS trier Discharge Presure, pa 300 60 ‘Tenpersure"R 573 you Specie volume 0m a7sre 232802 z oars o7381 cory cenpive ooro2t oars Specie hen Brfbr"R oaase 08266 Specie heat rio ae 98 Some velcty fie 0 220, Enalpy Bult ree3 208.8 Envopy Buk 1577 is82 Gas properties: Hyrecarbon mire Coe! preeure:646.4 pi ital fempertue: 3772 °R Citcal speci volume 0.7943 76m ol weighs 35.67 Volume ow te: 22734 in as flow ate 30000 bmn Folopic eficieny. 0.781 Folepic heads 27310 fom Speed Gas 3600 rm Mechanic 109 hp echaniea design: Mae. femp 350 °F ax presse 900 pia ak peed 3775 pm 1st citeal sped: 2600 et 2nd crcl sped: 4700 tpn Impaler 1s 2d a cs af Diam, in. % 36 x 36 36 Sip wid in 2s 20 7s 13 tas en 800125 for R134a, The test specific volume ratio compared to specified indicated that the R134a gas conditions are very close (within the accuracy of estimated gas properties) to that of the specified. Further check on the assumed efficiency also indicated it was within 4 percent of specified. The polytropic head was computed along with Reynolds number correction factor and a new speed was also computed. Further check of this speed against the critical speed of the unit indicated a margin of 8.6 percent, which should be within a reasonable range for unit operation; therefore, R134a could be used. Table C.5.6 has the basic R22 check data. The test specific volume ratio is considerably off from that specified. The test speed is 2556 rpm which is too close to the first critcal speed. This problem demonstrated the extent of calculation necessary to come up with the test speed for a given unit. The final test power may be increased by changing the inlet pressure and then re-computing all the values. Effectively the temperature ratio should remain constant and test speed may vary slightly with increase of inlet pressure. ‘The test speed computed is only an estimate. Once the unit is on test, the q/N should be set land the specific volume ratio, r., checked from test data. If the volume ratio is not correct, the test speed should be adjusted and the q/N reset. 124TABLE C.5.2 GENERAL FLOW CHART FOR TEST GAS SELECTION rem qarieeee : Ferm, Mach No. a/N, eae is eres! Wi Mer ef i \Verify Mechanical Design Sai} +] “hein Aasumia net To Condens t a em Teeemavegea=] | mane] peemeboeee = Discharge Pressure ‘and Efficiency Convection ee a ane, 1 wena a inate T ‘Test Speed aaah ae ee ae . 4 ae eeeeonin Sere seo i a Sears eee Saeed at 125TABLE C5.3 TEST GAS INLET CONDITIONS ™ Oy Riad be pola 20 20 20 Te $60 560 560 ve fom 1073 6.778 28716 Zz 1.00 0.993 975 By centioise oor ons 0103 Gp Btu" 0.2499 0.2103 0.2088 K 1396 1273 1.098 3 lsec 1178 894 5388) Tok 274 5477 ore be psia 93, 1069.9 590.3 Mw 2801 “40 102. hy Brum = 123 a = x - 0.07 0.02 ¥ 1027 1.03 ‘GENERAL NOTE Iris recognized that there sa potenal environmental problem of using refigeant 22, The use here is only to demonstrate the calculation method. TABLE C5.4 FIRST PASS FOR GAS SELECTION Me C3 Rida 535 4309) 3.236 3551 2912 2912 2912 2912 1.226 1.40 1.495 a7 1261 10273, - azar 0781 07st 0781 0781 0.509/.056 = 01 0.08 0.02 Yow Yras 1.15071287 = Lot 1.03 1.03 Cale rype Real ‘deat Real Real Real ‘ 1.1027 1.574 1.366 1.116 1.185 We felbfim ——27310.0 rian 34860 10499) 13750 Rem 2.286 x 107 = 7 3473x108 Men 06st = 7 0.65 Ukisec 5655 = = 350 pa psia 1072 86.2 659 700 Tek 1030. 236.6 648 706 [Nowe (Note 1) ef? fom = s 0.983 Nepm 3600 sz 4067 2232 2554 Note (Note on (Nowe (3 Notes (1) Test values exceed the mechanical design limit forthe tested unit, (2) No Reynolds number cortecion or verfiation of volume ratio, efficiency, or real gas correction. (G) Test speed too close to rotor erica speed 126TABLE C.5.5 Poiytrople work factor 7 Rem/Rerie ‘Allowable range (minimum) ry check ‘ap check Wy flee Retreae Nepm Mn @ tp Supplement C5. Predicted Conditions Specified Gas Pressure Ratio fy = pa/p; = 650/200 = 3.25 Volume Ratio ry = v/va = 0.7578/0.2602 = 2.912 Kear 1.1283 /1.0975 = 1.028 qn = 2734/3600 = 6.315 Check Specified Gas for Type of Calculation Reduced Temperature = Rrnin = Ti/Tesx = 0.996 Remax = To/Torn = 1.221 Reduced Pressure = Rein = pilpern = 0.309 Remax = P/Pest = 1.006 From Schultz Charts = Xmin = 0.509 Yaa = 1.150 Xrnax = 0.056 Yopax = 1.287 Based on Table 3.3 kevax/kensx OK Xan Yosx NO Kesar Yann OK Use Real Gas Calculation Method for Specified Gas cpivige 14 Sonic Velocity a = /2PM 8c 138 [TEE ROOOTSTA SED AS = 830.2 A/sec, 127Tip Speed ON v= 70 7 (36) (3600) ft = TER = 565.5 Machine Mach Number ‘Mm = U/ai = 565.5/830.2 = 0.681 Machine Reynolds Number Rem = Uib/nv 4 = 0.01021 centipoise = 0,01021/(1488.2) = 6.86 x 10° lbm/it-sec (565.5) Fa) Rem = 56x 107 (0.7676) ~ 7266 10 Test Gas Nitrogen (N2) Estimate: Assume Ideal Gas Yet0 X=00 f= 10 Remon = 1.0 Compute Polytropic Exponent Pep = Mog = 0-781 1281_ 396-1) 0.7eia(s96 gmt my = 1.574 Compute Test Gas Pressure Ratio t= og = 3.257007 = 5.358 1, = fo, Pi, = 107.2 psia 1, = Mig)"F" 5.350202 = 1,840 Ta, = Ti, = my = 1O30R (570°) ) 600 7 = 10.725 129Test Polytropic Head 1.5704 (20) 10.725 (5.35892 ~ 1) 144 Wo T3708 = 71422 felbfflom Test Speed Wp, Recon N= Nop NOTE: Test temperature exceeds mechanical design limi. Test speed exceeds mechanical design limit. Test Gas CO, Initial Estimate: Tay = Aig —-ReMean = 1.0, fF 1.0 ‘Assume Nonideal Gas Use inlet conditions for initial calculations. Reduced Temperature = Ry = 7 /Tex Reduced Pressure = Rp = pi [pute DT eee ven ore 360/547.7 = 1.022 20/1069.9 = 0.0187 0.993 cp = 0.2103 130Compute Polytropic Exponent °" Vomit ex) m - came) _ 0.993 (1545) © F7ei7 (02109 (44.00, = 0.2749, Compute Test Pressure Ratio a 1.3655 foe logit = 22S ow 4.304 a, = Py, = 4.304 x 20 = 86.1 psia Compute Test Temperature Ratio n=l = (4,304)027 = 1,494 Ta, = 1 T; = 1494 (560 °R) = 836.6 °R 0.983 (288) co oo oor 131Test Head 1.3655 o> (Faas5=7) ) 20 carr e.304207 = 148 = 34860 fe-lbf/lbm Test Speed a = 3600, | 555 7 4067 pm NOTE: Test temperature is marginal. Test speed exceeds mechanical design. Test Gas R134a Initial Estimate Ao = pre Reman = 1.0, f = 1.0 ‘Assume Nonideal Gas Use Inlet Conditions for Initial Assumptions Reduced Temperature = Rr = Ti/Tet = 560/673.8 = 0.8311 Reduced Pressure = Ry = pi/pert = 20/590.3 = 0.0339 X=007 Y= 1.027 132Compute Polytropic Exponent zeit mah (ha) Temi Gy **) 75 (1545) 1 T7E7 3090) 005 (a7 *”) = 0.12215 i Yomi+o 1 Tony = Giz215 (1 + 0.07) = 1.1157 Compute Test Gas Pressure Ratio Pa * tp Pi = 3.2955 x 20 = 65.91 psia Compute Test Gas Temperature Ratio = (3.2955) = 1.1568 Ta = 4, Ty = 1.1568 x $60 = 647.8 °R (187.8 *F) 133Compute Test Head FF) 560) 144 (20) 1548) = 28716 wo (ise Compute Test Speed N= rp | ose Rares eg TOTO) Ne OTT = o959 3600 J = 2232 rpm Check Volume Ratio Ze = 0.951 vee ZRT_ 0.951 11545) 647.8 ¢° Ta pM W ~~ 144 (65.91) 102 fe = 2.8716/0.9832 = 2.921 Compute Polytropic Work (Real Gas) Factor Isentropic P= 65.91 psia 68.7 °F (628.7 °R) 9205 f'/lbm 35.46 Btu/lbm n= In pin ri f= Vid = 2.8716 10.9205 = 3.1196 y= In 3.2955/In 3.1196 = 1.0482 134(hg ~ hy) = (138.46 ~ 122.3) 778.17 = 10241 felbtfbm We (pe vi ~ prvi 144 10244 ae Toe TauaT ay 165-91 (0.9205) ~ 20 12.8716)) 14 TOE 165.91 (0.9205) - 20 2.8716)) 144 Compute Reynolds Number and Reynolds Number Correction Use Preliminary Test Speed Rem= Ub/pv Us 7DN/720 = w 36 (2232720 = 350.6 ft/sec. se = 373 x 108 7324 x 10 (2.8716) 0 Reynolds Number Ratio Rem, _ 3.473 x 108 Rem ~ 2.266% 10" = 0.153 Allowable Ratio Rem/Rem 2 0.1 Therefore, the Reynolds number ratio of 0.153 meets conditions. Compute Reynolds number conditions. Baw RB (~ nde =~ a Re t= 066 + o9ye 2x04 BME Re RB= log (0.000125 + 13.67/Rem)/log (e + 13.67/Rem) RC = 0.988/{Rem)922 135Rye 086 +0934 | | 1.548 Rigs 1, Remy aa = 002583 RAv= 0.66 +0934) a = 1.565 RB,= 1.0 o-oo ws C9 (1- np (1 = 78g (3) ) = 0.224 p= 0.7786 Remcan = 0.781/0.7786 = 1.003 ' vipa 1144 ane 01) (20) (2.8716) [3.295557 — 1] 144) = 10605 fbi Correct Prel inary Test Speed 051-003) N, = 3600 ja = 2247 rpm 136NOTE: Test speed within 8:1/2 percent of 1st rotor Ctcal Speed Calculate Mach Number Mm= U/a; Us #DN/720 = (736(2247/720 353 fifsec. Mm= 353/539 0.655 ‘Mach Number Ratio Difference Mmm ~ Meng = 0.655 - 0.681 = -0.026 Test Gas R22 (Chlorodifluoromethane) Initial estimate > Toy 0 Use real gas calculation Use inlet conditions for intial estimate Compute Polyropic Exponent X = 0.02 1.03 = 0.161 MW = 36.48 2 +002) = on WY =m +x) n= 1/{1.03 ~ 0.1821 (1 + 0.02)) ne 1.1845 Compute Test Pressure Ratio Pa = 5,2 137 Z = 0.982Compute Test Temperature Ratio Ta = 4, Ti = 1.259 (560) = 705°R(245°F) Compute Test Head = 13750 felbi/lbm Compute Test Speed 3600 [S700 - 27310 = 2554 rpm Test speed is too close to the first critical of 2600 rpm. 138SAMPLE CALCULATION C.6 TYPE 2 TEST USING REAL GAS EQUATIONS FOR DATA REDUCTION ‘A mixed hydrocarbon compressor which was set up in the Sample Calculation C.5 was tested ‘on refrigerant 134a using a Type 2 test. Table C.6.1 outlines the conditions for which this compressor was designed. It tabulates the inlet and discharge conditions, as well as the isentropic discharge conditions. Table C.6.2 shows the gas composition and critical properties for this hydrocarbon mixture. The molecular weight and the calculated gas constant are shown in this table. Table C.6.3 shows the derived design functions, specifically pressure ratio, temperature ratio, volume ratio, as well as polytropic exponent, volume flow, head, efficiency, and power. The test is supposed to verify these values. The calculation of these values is shown in Sample Calculation C. The unit was tested on reftigerant 134a.' The test data are shown in Table C.6.4. It was at a test speed of 2245 rpm. The inlet pressure was held at 20 psia at an inlet temperature of 100°F. Discharge conditions achieved were 67.5 psia and 187.4°F. The data shown is the average of the actual test data readings. It is assumed that all scatter was within the allowable test requirements for these data point positions. The derived test functions, pressure ratio, temperature ratio, volume flow ratio, etc., are shown in Table C.6.5. This is the reduced data from the test point of Table C.6.4. The calculations are shown in Supplement C.6.A for obtaining each of the individual items. TABLE C.6.1 SPECIFIC DESIGN CONDITIONS ‘Mass Flow 30,000 — lbmvmin Speed 3,600 — 1pm Inlet Discharge Tsentropic Pressure, pala ze 200. $50 650 Terperature T us mas 277 Specific volume, #?/Ibm ¥ 0.7578 0.2602 0.2465 Compressbility factor Zz 0.8768 07981 07749 Viscosity, centpoise # o.oro21 0.01373 Specific heat, Bevlom-"& & 04096 0.6266 Specific heat ratio F 1.3283 1.0975 Sonic velocity, fsec a 830 820 Enthalpy, Bruibm b 1649 209.84 199.05 Eneopy, Stub? ‘ 1877 1592 1577 | Ris ienpize ta there ba potential enviormenl problem of ung eigen. The use here is only to demonstrate ‘the calculation method. ar , sree 7 139TABLE C.6.2 GAS COMPOSITION AND PROPERTIES Compotition Methane 20% thane 25% Propane 50% Butane 5% Critical properties: Pe 646.4 psia Te S77.2°R ve (0.7943 8/6 Molecular weight = Ber Gas consant R = 43,31 fubitoen *R TABLE C.6.3 DERIVED DESIGN FUNCTIONS Pressure ratio 335, “Temperature ratio 1z2s Volume ratio 2912 nada 10281 ice 2734 IN, IEMipm 6315 Reduced temp minimax o.s96/t.221 Reduced pressure minimax 0.303/1.006 Schulte factors XenlXam 0.s0s/t.0s6 Yon!You 1.150/1,287 ‘st sage tip speed, fVse€ 565.5 Machine Mach no, 068 Machine Reynolds no 2.266 x 107 Polytropic exponent 0 1.1027 Isentropic exponent, 10495, Polytropie work factor f 1.008 Isentropic head, ftom 26570 Polytrpic head, fbb 27310 Polyropic efficiency 0781 Unit ga8 power, hp 31790 Table C.6.6 compares the test data and the test data converted to specified operating conditions with the predicted performance at the specified operating conditions. Supplement C.6.8 demon- strates the calculations for the conversion. The calcul of discharge conditions, pressure, temperature, and volume is shown in Supplement C.6.C, which also illustrates the use of an iterative procedure. ity for the converted test conditions was within 1 percent of and the head was within 2 percent. The converted specific volume ratio was within the specified 4 percent allowed. Supplement C.6.4 Calculations: Derived Test Functions 140TABLE C.6.4 TEST DATA Mass flow 4,923 — Ibeviin Speed 2.245 — pm tolet Discharge entropic Pressure, psla 2 20 ors as Temperature r 100 var 167.49 Specific volume, f?/bm ¥ 28716 03639 ‘09236 CCompressbility factor Zz 0975 0.955 ose Viscosity, centipcise * 0.0109 Specific heat, Btlom-“R & 0.2098 Specific heat ratio g 1.098 i 2 5308 h 1223 140.08 135.80 5 0.2539 0.2731 0.2639 Be 5903 pia Te 2138F TABLE C.6.5 DERIVED TEST FUNCTIONS Pressure ratio % 375 “Temperature ratio © Vase Volume ratio. 6 2380 ICM 1a QIN ICEMpm 63 ‘i sage tip speed (hisec) 3526 ‘Machine Mach no. ‘ose ‘Machine Reynolds. 349 108 Ibertrepic exponent Loma Polyropic work factor 1.0017 Polytropic exponent tana Polytropic head (bom) 107352 Polyropicefciency 0778 Unit gas powe thp) 2059 os Pressure Ratio tp = palpi = > 375 i (460 + 187.4) Temperature Ratio f= Ty = 647.4 560 1.156 vatTABLE C.6.6 DATA SUMMARY Tei bua coped Palace ‘ein apc etoaa ope Opting onions rn a tiem ort neo oe rat bs ioe is ‘ ta is na oe sant oa oa tuftm ul ve 1a 1545 0973 (55) sso let pei Vol o let pei Volume Nigro = zane 1345 gar, 0955 (88) er Discharge ‘fic Volume vg oS = hare SeciteVolume ve 28TH TOE oaeser ar16 Specified Volume Ratio saa new = 2.9805 Inlet Capacity q = mv = 4923 x 2.8716 = 14137 ICFM 14137 Capacity/Speed Ratio q/N = = = 6.297 142=DN _ 36.0 x 2245 Ist Stage Tip Speed U = 720 720 = 352.6 ftlsec 352.6 tachine Mach number Mm = U/a = 22 Machine Mach im = Ua = = 0.654 Machine Reynolds number Rem = Ub/uy 352.6 (2.5/121488.2) 0.0109 (2.8716) 3.493 x 10f Isentropic Exponent ny = In (pa/pi/in (w/vé) In (67.5/20) In @8716/0.9234) 07212 hon hi 7 (Pa vd ~ piv) Polytropic Work Factor f= — $0 ~ 122.3) 778.17, fa oo J = 1.002 [67.5 (0.9234) ~ 20 (2.8716)]144 o7aia 07212 t Polytrople Exponent a= In ifn) = = 1138Polytropic Head Wp = ({* ;) (pava ~ pvi) 1.4138 = 1.002 (SS) (67.5 (0.96347) - 20 (2.87169) 144 10736 f-lbs/lbm 10736 Bg hi” (140.04 = 122.3) 778.17 Polytropic Efficiency 0.7777 Wow _ 10737 (4923) neat f= mp 0.778 (33000) = 2059 hp Supplement C.6.8 Calculation: Conversion From Test to Specified Performance Inlet Capacity Reynolds Number Correction for Efficiency 8 Remaze RG = 0.988 Gas x roma = 0.0254 144ie (ozoras +282) fem 1387) Rem, RB, = ta(e* 3.493 x 10° oe Ree = emg ~ 566 x TPE z = 0.66 + 0.934 | ———_2 . 72.266 x 10° tad RBy = 1.0 Tog = =) Ra RB, 1.548 1.0 1565 7.0 Tag = (1 =0.7777) 1 = 49 = 0.2199 145Tey = 0-780 Remar = 1.003, Polytropic Head arse 289) yo aan Bl sar (2522) .03 = arena Power = 14137 54s) (aya) ~ 295 27690 (29915) 9.780 (33000) ~ ee Supplement €.6.C The conversion from test conditions to computed specified conditions involves an iteration to obtain the discharge pressure from the known head and discharge enthalpy. The iteration procedure and calculation involves assuming a discharge pressure at the known discharge enthalpy and finding the corresponding temperature and specific volume. The polytropic exponent and polytropic head is then calculated for the assumed discharge pressure. This polytropic head is then compared to the actual and, if not the same, then a new discharge pressure is assumed. The new assumed pressure is evaluation for properties at the known discharge enthalpy, and a new discharge volume is evaluated and polytropic exponent are computed. This iteration procedure is continued until the conditions match the required head. 14822,400 2000 27,800 3 7 . L 7 OF I 3 E 1 zg 27.400 F L : f| a 1 1 1 enthalpy «2105 Bun | Gascomposition L Methane 20% 1 Ethene 25% Propane oe E 1 Naviane ‘% 126,800 F- 1 I E 1 tae Lue frre 2me00 . 6 BIO ean Pressure, pla FIG, C.6.1 POLYTROPIC HEAD vs. PRESSURE, CONSTANT ENTHALPY Figures €.6.1 and C.6.2 are a plot of discharge conditions at a constant enthalpy of 210.5 Btu/lbm. The final point at 27,605 ft-lb/lbm is 659 psia, 246.5°F. This method can either be computerized or done graphically as shown in this example. Calculation Procedure: Known Wp= 27,680 ftlbt/lbm Piz 200 psia hy= 1643 Btu/lbm .7578 bm 147Temperature,*F Spoeifie Volume, 2b 29 28 a 28 25 | ma 23 0270 0.280 0.250) Enthalpy = 210.39 Btu Gas composition Methane 20% 2 Ethane 26% Propane 50% NBuane 5% oz0 u peu 620 40 650 ‘660 670 FIG. C.6.2 TEMPERATURE/SPECIFIC VOLUME vs. PRESSURE, Pressure, pia CONSTANT ENTHALPYp= 0.780 1.004 ‘Step 1 — Calculate discharge enthalpy. 27690 Buu = 16594 ee = 20s Be Step 2 — Assume a discharge pressure. Pox = 660.8 psa ‘Step 3. — For pg and hy, obtain the discharge volume for the properties. ve = 0.2562 f/lbm ‘Step 4 — Compute the polytropic exponent. n= In flit ty fp= 660.8/200 = 3.304 .7578/0.2562 = 2.958 In 3.25/ln 2.905 = 1.102 Step 5 — Compute the polytropic head, Wp = (4) fipevs - pw) 144 102 12) 004 (60.8 2562) - : $402) 0066608 asa) ~ 200107578) 14 of = 27705 ‘Step 6 — Compare the computed Wp to the actual. If they are within acceptable tolerance, then the discharge conditions are established. If they do not match, then a new discharge pressure must be assumed and the procedure repeated from step 2 thru 6. 149SAMPLE CALCULATION C.7 TREATMENT OF A TWO SECTION COMPRESSOR WITH EXTERNALLY PIPED INTERCOOLERS, CONDENSATE REMOVAL This sample calculation illustrates the computational procedure, at specified operating conditions, for_a multisection compressor having externally piped intercoolers. Consider a two stage air compressor equipped with one intercooler and an aftercooler. Incer Aner a Fina discharge Cooler Cooler ‘enditions Leakage Condensate Condensate Power requirements + Measurement stations lt is desired to calculate the compressor performance at the specified operating conditions shown. The compressor has been tested and the test data reduced to the following dimensionless form. The data was collected with pressure and temperature being measured at the inlet and outlet of each section. The flow coefficients were calculated based upon test rotor flow rates. The selection of test method and the means of establishing leakage and condensate flow rates ‘were subject to prior agreement by parties to the test. The first step in calculating the specified operating condition point of interest is to establish the first section performance, starting with the flow coefficient. Taking the saturation pressure of water vapor at 560°R to be approximately 0.949 Ibffin?, with the remaining specified operating conditions at the inlet, we obtain RHpyy = 0.60 (0.949) = 0.569 lbf/in? Pa = 14.7 0.560 = 14.131 Ibffin? and sm _ Ra Pu _ 53.34 0.569 tlm w ous = 0.0250 PO HR Ma Rw Pe 85.76 14.131 ue Tom da 181‘The gas constant for the mixture is R= (Réa + HR Ryl/ll + HR) = [53.34 + 0.25 (85.76)]/1.025 = 0.0250 Ibm + w/lbm + da ‘The rotor flow rate is the same as the inlet mass flow rate. The flow coefficient is then wT oo rae) inane) 6.5 (60) 54.13 (560) a ver 47 2 coon (222) = 0.0295 With the flow coefficient established the corresponding polytropic efficiency, polytropic work and total work input coefficient are read from the section 1 dimensionless curves 7.1). That is np = 0.83, xp = 0.599, and 0; = 0.722 at = 0.0295. To continue the calculations the properties of air at the specified operating conditions must be known. For the purpose of this example we assume that the air-water vapor mixture may be treated as an Section t Section 2 090 i 090 020 ; 020 1 I Ap 1 070 i nin 070 a oe ! ' tn 080 060 | 1 1 1 050 1 » 050 1 ! / Ye 1 I : \ Feerrer Ao Me 1 Bowe aaa ans 00a oon OTS az cas ° ° The Mm, Rem, k, and vj/vg for the data are assumed to match the specified operating conditions within Table 3.2 Limits. The Rem match is assumed sufficiently close so as to render the Reynolds number correction negligible. FIG. C7.1 182ideal gas with constant specific heat. k = 1.395 is used as being representative of the end result ‘which might be obtained by considering the properties of the constituent gases over the compression range. This value will be used for both sections for this example. The average constant pressure specific heat is Using the polytropic efficiency of np = 0.83 gives 2.931 on n= 15178 Using the polytropic work coefficient of pp = 0.599 gives we EUt } 1) ate The discharge pressure is Pa = tp pi = 2.166 (14.7) = 31.84 psia The temperature ratio and discharge temperature are 1 2.16627 = 1.302 and Te = tT) = 1.302 (560) = 729°R The power absorbed in the compressor section is obtained using the total work input coeffic O = 0.722. Zu? _60 Gas Power s wae sata = The shaft seal which is located downstream of the rotor leaks 0.03 lbm/sec for these conditions, so the mass flow rate at the intercooler entry is wfeooler entry = Wiser ~ Wak = 6.50 ~ 0.03 = 6.47 Ibm/sec ‘The intercooler is known to cool the flow to 560°R at the mass flow rate, gas entry state, and specified operating condition coolant temperature and flow rate. The air stream experiences a total pressure loss of 0.8 psi across the intercooler. it must now be determined if and how much 153condensation occurs in the cooler. Since the cooler exit velocity is assumed, very low stagnation values are used in the analysis. The saturation pressure of the vapor at S60°R is approximately 0.949 psia. If the exit air is at 100 percent relative humidity, the humidity ratio is lm + water 00196 ome da Ry _ Rea_Pov 3334 0.949, Rw P ~ Pw 85.76 (31.04 - 0.949) where p = 31.84 - 0.8 = 31.04 psia Since the saturated humidity ratio is less than the cooler entry humidity rat must occur. The difference between the two is the ratio of condensate to dry ai condensation Condehsate/way = HR; ~ HRs = 0.0250 ~ 0.0196 = 0.0054 Ibm = w/lbm + da The mass flow rate of dry air is given by Wau = will + AR) = 6.47/(1.025) = 312 Ibm/sec so, the condensate is Condensate = (condensate/wan) Way = 0.0054 (6.312) = Ibm/see The exit mass flow rate for the air ~ water vapor mixture is Wo = i= condensate = 6.47 ~ 0.0341 = 6.436 lbm/sec The intercooler exit conditions are the second section inlet conditions. ‘The previous calculation sequence is repeated for the second section, starting with calculation of the flow coefficient. The gas constant changes slightly due to the water vapor removal. R= (Rep + HR Ru)/\1 + HR) = [53.34 + 0.0196 (85.76)1/1.0196 = 53.96 ft-bf/lbm °R ‘And the flow coefficient is wT Taapi ea") (a) 6.436 (53.96) (560) “144 G04) 0.0197 Bm Reading “4p = 0.81, up = 0.560, and curves (see Fig, C.7.1) for ¢ .681 from the section 2 dimensionless performance .0197, and using 1847 yields yielding nek) ow 1001 = 1.228, (7) (Ti) = (1.228) (560) = 687.9 °R wae 1 £2 5g & as Power sae a 33000 = 285.1 hp. The shaft seal downstream of the rotor leaks 0.06 lbm/sec for these conditions, so the mass flow rate at the aftercooler entry is Weaaesenuy = 6.436 - 0.06 = 6.376 Ibm/sec The aftercooler is known to cool the flow to S80®R at this mass flow rate, gas state, and specified operating condition coolant temperature and flow rate. The aftercooler is 1 psi. Assuming a saturation pressure of 1.692 psia and following the intercooler condensation analysis scheme, 158Raa(_pw ) _ $334/ 1.692 bm w le ee 35.76 where p = 55.91 - 1 = 54.91 Since the saturated humidity ratio is greater than the entry humidity ratio, no condensation ‘occurs in the aftercooler. In summary, the final discharge pressure at the aftercooler exit is $4.91 psia, the final discharge temperature at the aftercooler exit is S80°R, and the total gas power requirement of the two sections is 667 hp. 156TABLE C.7.1 SUMMARY OF RESULTS Specified Conditions 6.500 Tomisee Inlet mase flow rate Inet total pressure 147 pais lnk totl temperature 560. *R Inlet celative humidity 60, % Gas constant, dry air 5334 foftbmer Gas constant, water vapor 35.76 feito sR 15 Section 20000 pm Rotational speed Tip diameter 13751 in 2nd Section: 20000 ‘pm Rotational speed Tip diameter 12208 in Intermediate Calculation Results 1s Seaion 2d Secon Gas constant for mire 56.13 53396 Specific heat fr mice 0.2457 0.2449 Flow coeficien Polyrope effcency 083 = Polyropie work coeficlent 0599 O56 = Work input coeficnt om ost = Taal work input coe oma ost = ent Patyrope exponent 15178 137 - Tip speed 1200 1165 five Inlet pressure 147 31.04 pa Pressure ratio 266 201 ' Discharge presure abe 5531 pia Inlet temperature 560 so. fe Discharge temperature 7 oar ay at power 3819 251 horsepower Inlet mass flow rte os e236 tome Leakage fw rate 003 2.06 lomiec Discharge flow rate ear 676 tome Coote condense ow on °. Tbmveec Cooler presice crop 08 10 pala Overall resus: Final discharge pressure 549 pala Fina discharge tempersue 580. Taal gas power 667 horsepower Delivered mass flow rte 628 tombe 137SAMPLE CALCULATION C.8 APPLICATION OF UNCERTAINTY ANALYSIS This sample problem highlights some of the features of uncertainty analysis as they apply to a PTC 10 test. The propagation of measurement error to final results is emphasized. ‘This particular case has been selected because of the relative simplicity of the equations involved. There is no intention to imply that it covers all uncertainties of interest. Nor is i intended to imply achievable or expected accuracy in general. It simply demonstrates the method. Suppose that test results which meet Code requirements are available. tt is desired to determine the uncertainty in shaft power for a given specified operating condition flow rate. Assume that the shaft power measurement method was used during the test. Uncertainty analysis is done following PTC 19.1, using the step-by-step calculation procedure given in that document. The steps, excluding final report, are: (1) Define the measurement process. (2) List the elemental error sources. () Estimate elemental errors. (4) Calculate the bias and precision errors for each parameter. (5) Propagate the bias and precision errors. (6) Calculate uncertainty. ‘Step 1 — Definition of the measurement process requires expression of the functional relationship involved. From Table 5.4 we obtain Leen My [=], + Pri oe 33000 ‘Assuming a single section and no leakage or sidestreams and, EUs a Pig = io Since the shaft power is being evaluated for a given flow and speed, wn and 22), se went a owns having 0 ero. 159The terms Oy, and Pheraiic,, are related to test conditions, from Table 5.3, as ng aNd Praasiesy (Pin ~ Poarasive) 33000 oy Be it Day, = Me, = Assuming that Qn is the only parasitic loss, (3300 Pn - J Qual 24, = Oe, eat e |, and 1.Q0 P= 33000] 1 Qn, nut | * 33000 Be : where JQmg 1 Qn [Uy # Poenig = Sark = sagas (GE) para. 5.7.4. {n general the procedure would now be to break down the individual variables in this equation in terms of independent measurements. For example, if the shaft power were determined from a torque meter, that power would be expressed as the product of measured torque and measured speed. Similarly, the rotor mass rate of flow might be expressed in terms of nozzle pressure drop, pressure, temperature, and gas composition. For brevity, in this example Pi, Qn,, Ur, and W, are teated as individually measured elemental quantities. Steps 2 thru 4 — Assume that the elemental error sources have been listed, the elemental errors estimated, and the corresponding bias and precision errors calculated. Many examples of this procedure may be found in PTC 19.1. This process depends upon the actual instrumentation system and data collection techniques used. The results may be expressed as follows. The bias limits and precision indices represent the combined effects of the independent measurements for each parameter. Absolute Bias Limi ‘Absolute Precision index ofthe Mean! we 0.01 w 5a, Bry. = 0.01 Pa, Sry, = 001 Pa, On, Qe! = 0.01 Qn, SQni = 0.01 Qa, u BU, = 0.01 UL; SU; = 0.01 U, a 026 "a" S, only in this section, is the Absolute Precision index of the mean = $/-VN. In every case a one percent value has been assigned to each bias limit and precision index for the measured quantities. This of course does not reflect what might be expected in reality, These values have been chosen to demonstrate the effect of unit variations. Step 5 — The individual errors are propagated into the result according to a Taylor series expansion. To do so it is necessary to determine sensitivity coefficients, the precision index of the result, and bias limit of the result, 160The sensitivity coefficients 4; are determined by partial differentiation, i. ifr = AP, Pa, Py, € Pi), then P; = ar/aP; So, 82m, ‘A bias error is assumed in the mechanical loss conversion equation’ due to an assumed unknown error in the exponent . It is estimated for this example as 0.2. The precision index for the result is the square root of the sum of the of sensitivity coeffi ares of the product iclents and average independent parameter precision indices. Thus Sta, = NOW SF Ory, Seg 0, 5a, + bo, PE for the result is the square root of the sum of the squares of the product of the sensitivity coefficients and average independent parameter bias limits, Thus NG= BT = Bry, Trg) (Oe, Bo) Fu, Bal + ep BP ‘Step 6 — Calculate uncertainty 16tUncertainty may be calculated according, by choice, to two models. The models combine the precision index and bias limits of the result differently, Uso, = Bry, + 55% Pang Mp "o Ving Tir F The value t is called the Student’s tt is assigned depending upon the degrees of freedom of the sample, which is usually one less than the number of points averaged. See PTC 19.1 for further explanation. Assuming a large sample, t = 2 may be used. Results In order to allow expression of the results of this example numerically, assume Qn) 33000 Up Fe |, 7 ONO TE = 105. = 1.20, and 6 = Pa ‘The sensitivity factors are ry = 1.20 (1.05)? = 1,323 20 (1.08% + (1.05925) 33000 0.00456 fey tao vaste ann (24) « 1 (1.05) In (1.05) Pay, = 0.008512 Pan, 162The precision index of the result is Sp, NG SPT, yt ey, San Te USP = {(-1.191 0.01 w)* a Pap, a 4 11.223(000 Pa} + 01999 00001 rap +[-2664 001 ul] = VTATEX TOTS 1.75 x 107 + 37ER TOFS TIOX 10% = 0.0320 Py, ‘The bias limit of the result is = Ge, OG) Brig, Big * BO, Bog + bu, Bu + Op Ba = VVATEX TOTS TIS X10% 574 x 1OFS TO TOFS TION TOF = 0.0325 Pep, ‘The uncertainties are @ Bry Usoo = 0.0325 + 2 (0.0320) = 0.097 Px, Urss = VOD3IS = [2 O.OSZO = 0.072 Pry, Discussion The Unoo and Urss uncertainties may be interpreted as follows. For Uso = 0.037 Puy, the ‘measurement Pyy, * 0.097 Py, will be expected to contain the true value 99 percent of the time, Similarly, for Usss = 0.072 Pa, the measured Pip, * 0.072 Pa, will be expected to contain the true value within 99 percent of the time, It is reasonable to assume that the uncertainty for this example is so large as to mask the objective of the test (recall that the numerical values for the independent measurement bias limits and precision indices were selected at 1. percent simply to demonstrate unit variations). It is a very simple matter to review the calculations to expose the major uncertainty source. Inspection of equations (a) and (b) for the largest terms immediately indicates the speed measurement, Thus, for example, if the bias limit and precision error for speed measurement could be reduced to By, = 0.001 U,, and Sy, = 0.001 U; the uncenainties become Unoo = 0.054 Pay, and Unss = 0.031 Pur, tis clear that such analysis is of great value in both planning a test and evaluating test results, 163on (0.2) (0.3) (0.4) (0.5) (0.6) (07) APPENDIX D REFERENCES (This Appendix is not a part of ASME PTC 10-1987.) ‘Maret, A, M. Giovannini, and P. Nava. “Shop Full Load Testing of Centrifugal Com- pressors.” December 1982 proceedings of the 1th Turbomachinery Symposium, Texas A& M. F. J. Wiesner. “A New Appraisal of Reynolds Number Effects on Centrifugal Compressor Performance.” Transactions of the ASME, pp. 384~ 395, Vol. 101, July 1979, Journal ofEngi- neering for Power. Huber, M. L,, and M. O, McLinden. “Thermo- dynamic Properties of R134a (1,1,1,2-Tetra- fluoroethane).” july 14-17, 1992 proceedings, Intemational Refrigeration Conference, Purdue University, West Lafayette, IN. ‘Simon, H., and A. Bulskamper. On the Evalua- tion of Reynolds Number and Related Surface Roughness Effects on Centrifugal Compressor Performance Based on Systematic Experimen- tal investigations, ASME paper no, 83 GT-118: Transactions of the Journal of Engineering for Power, presented March 27, 1983. Nathoo, N. S., and W. G. Gottenberg. “Mea- suring the Thermal Dynamic Performance of Multi-Stage Compressors Operating on Mixed Hydrocarbon Gases.” December 1981 pro- ceedings of the 10th Turbomachinery Sympo- sium, Texas A and M. Herd, T.C., and E. J. Hipp. “Accuracy Expecta- tions for Gas Turbine and Centrifugal Com- pressor Performance Testing,” Paper ASME 83- GT-128, Carter, A. D. S., C. E. Moss, G. R. Green, and G. G. Annear. “The Effects on Reynolds Num- ber on the Performance of a Single Stage Com- Pressor.” Aeronautical Research Council Re- Ports and Memorandum, 1960; memorandum. 3184, May 1957, U.K. 165 (0.8) (09) (0.10) (0.11) (0.12) (0.13) (0.14) (0.15) (0.16) Samurin, N.A., and M. A. Stite. “Equivalent Performance Testing of Multi-Section Com- pressors.” ASME 81-GT-150, March 9, 1961 Daugherty, R. L., and J. 8. Franzini. “Fluids Mechanics with Engineering Application." McGraw Hill Book Co.; 1977, Lee, J. F., and F. W. Sears. “Thermodynam- ics." Addison Wesley Publication Co.; 2nd edition, 1963. A. H. Shapiro. “Compressible Fluid Flow." The Weld Press Co., 1953. J. . Lay. “Thermodynamics.” Charles E. Mer- fill Books, Inc.; 2nd printing, 1964. J, M, Schultz. “The Polytropic Analysis of Centrifugal Compressors.” Transactions of the ASME, Series A. Vol. 84, Journal of Engi- neering for Power. January 1962, p. 69-82 and April 1962, p. 22. M. V. Casey. “The Effects of Reynolds Num- ber on the Efficiency of Centrifugal Compres- sor Stages.” Transaction of the ASME, April 1985, Vol. 107, p. 541-548. Journal of Engi- neering for Gas Turbine and Power. ‘A. Schaffler. “Experimental and Analytical In- vestigation of the Effects of Reynolds Number and Blade Surface Roughness on Multistage ‘Axial Flow Compressors.” Transactions of the ‘ASME, January 1980, Vol. 102, p.5~13, jour- nal of Engineering for Power. R. A. Strub, "Influence of the Reynolds Num- ber on the Performance of Centrifugal Com- pressors.” Final Repor of the Working Group of the Process Compressor Subcommittee of the International Compressed Air and Allied Machinery Committee (ICAAMC) Zurich, October 1982.(0.17) (0.18) (0.19) (0.20) Nathoo, W. S., and W. G. Gottenberg. “A New Look at Performance Analysis of Centrif- ‘ugal Compressors Operating with Mixed Hy- drocarbon Gases.” Transactions of the ASME, October 1983, Vol. 105, p.920-926, journal of Engineering for Power. Skoch, Gary J., and Royce D. Moore. NASA Technical Memorandum 1001/5 AJAA-87- 1745. AVSCOM Technical Report 87-C-21 “Performance of two 10 lb/sec centrifugal compressors with different blade and shroud thickness operating over a range of Reynolds Numbers.” 23rd Joint Propulsion Conference ‘cosponsored by the AIAA, SAE, ASME and ASEE, San Diego, CA, June 29-July 2, 1967. Moore, M. ., and H. S. Shapiro. Fundamen- tals of Engineering Thermodynamics. John Wiley & Sons, Inc., 1988. F. Kreith. Principles of Heat Transfer. intext Educational Publishers, 3rd edition, 1973. 166APPENDIX E RATIONALE FOR CALCULATION METHODS (Ttis Appendix is not a part of ASME PTC 10-1997) E.1 PURPOSE ‘The purpose of this Appendix is to describe the Code problem model, background theory, and simplifying assumptions. E2 PROBLEM MODEL The ultimate aim of a Code test is to determine compressor performance for a given set of conditions. That is, to determine relationships of the form Dependent parameter = F (many independent parameters) Examples of dependent parameters are discharge pressure, head, efficiency, etc. Among the independent parameters are geometry, speed, flow rate, inlet gas state, gas properties, etc. The functional relationship f is unknown. It is to be determined by the test. ‘The many independent parameters represent the specified operating conditions. Practical test situations are often such that one or more of these parameters is precluded from taking on the desired specified operating condition value. Means must then be sought to determine the effects of the departures. One method is to employ dimensional analysis. E21 Dimensional Analysis. The theory of dimensional analysis and similarity are discussed in PTC 19.23, Guidance Manual for Model Testing, and many fluid dynamics textbooks. In essen: it provides a means to reduce the number of parameters in a problem which is expressed in dimensional terms. This is done by appropriate grouping of dimensional terms in dimensionless groups. E22 Basic Model. Consideration of a simple mathematical model of compressor performance illustrates the general features of dimensional analysis as they are applied in this Code. A simple conventional set of dimensionless parameters often applied is given by 1p= Fi (g, Mm, Rem, gas properties expressed in dimensionless terms) p= Fa (gb, Mm, Rem, gas properties expressed in dimensionless terms) Hin= FF: The dimensionless parameters are defined in terms of dimensional variables, =with, 4 Rem = UL/y Mim= U/a 8S properties ... according to gas types It is presumed in performing a dimensional analysis that all of the variables affecting the thermodynamic and fluid dynamic performance of the compressor have been included. If so, different sets of dimensional variables which combine to form identical sets of independent dimensionless groups (g, Mm, Rem, gas properties) will have associated with them identical values for 7, tp, and ui This basic model is generally accepted to adequately describe the main features of compressor performance. It has the immediate advantage of reducing the number of parameters which must be considered in developing a test. But of at least equal importance it provides a means of accounting for unavoidable departures from desired specified operating conditions. For example, it may be used to establish an appropriate test speed to compensate for the effect of a test inlet temperature which differs from the specified operating condition temperature. E23. Allowable Departures. It often remains impractical to satisfy all the independent dimen- sionless parameter requirements. This situation may be addressed by allowing controlled departures in certain independent dimensionless groups. The assumption is that the limits placed upon these departures render the effects upon the dependent parameters either negligible or predictable. The following approach is taken in this Code. £2.3.1_ Mach Number. Mach number departures are assumed to be of increasing relative importance as the Machine Mach number increases. This is reflected in the allowable departures shown in Table 3.2 or Figs. 3.2 and 3.3. It is assumed that negligible effect is associated with departure within these limits. £.2.3.2 Gas Properties. Allowable departures from the the specified gases are given in Table 3.3. When these treated as real. feal gas laws for both the test and ts are exceeded the gas must be £.2.3.3 Reynolds Number. The allowable departures in Machine Reynolds number are given in Table 3.2 and Fig. 3.4. £2.34 Specific Volume Ratio. The preceding allowable independent dimensionless group departures may combine to alter the specific volume ratio between the compressor inlet and discharge. As a result an additional restriction is placed upon the volume ratio, ry, as shown in Table 3.2. The effects due to volume ratio departure are assumed to be negligible when these limits are observed. 168£24 Secondary Flow Streams. The basic compressor performance model assumes single entry and exit flow streams. in actual practice secondary flow streams may enter or leave a compressor section, Examples are sidestreams and leakages. These secondary streams give rise to a number of additional dimensionless groups. Each additional entry flow stream has associated with it a flow rate and gas state, or three additional independent variables. If we use volume flow rate, enthalpy, and density to define the streams we may form three additional independent dimensionless ‘groups by referencing mainstream values, (q/qdm (hd 3= (p/p,)m where x denotes the sidestream value, and m denotes the reference mainstream value. ‘The approach taken in this Code is to require that the ratio of sidestream to reference flow fates remain within the limits of Table 3.5 or leakages per para. 3.3.6. When these limits are observed it is assumed thatthe effects upon the dependent dimensioniess groups are negligible, No specific restriction is placed upon the density or enthalpy ratios. It is assumed that departures in these ratios will produce negligible effects upon the dependent dimensionless groups, Where thorough mixing of inlet streams before the compression is doubtiul, this assumption may not be valid. tn such cases the parties to the test may elect by mutual agreement to further restrict these ratios as well. Departures in these secondary dimensionless groups do affect results in the dimensi This is accounted for in the calculation procedure. = 5, Remean = Fi ($, 2, Mn, fo, dimensionles gas properties); Retcon ‘Mm, fv, dimensionles gas properties); Remon Yon » 0 Tap Oy = £5 (4, SM ta dimensiones popes) Remar For a given flow coefficient 4, certain departures are allowed in the remaining independent dimensionless groups. The volume ratio restriction serves to limit the effects of the combined Gepartures in the other dimensionless groups. The first three dependent groups have the same form as those in preceding issues ofthis Code. The fourth, Qyy is new to this issue as an explicit Parameter, it is a power coefficient which takes on different forms for energy balance and shaft Poway methods. it is related to the other dependent parameters, but is useful explicitly in a bookkeeping sense for complicated arrangements, 169£3 CODE DIMENSIONLESS PARAMETERS Appropriate units and dimensional constants are required for the system of units elected for computations. 3.1. Inlet and Exit Conditions. The structure of the problem model is such that to carefully define the inlet and exit conditions which are used in calculating the groups. The exit conditions are the stagnation condition at the discharge measurement station. The inlet condition is the stagnation state assigned to the flow stream entering the impeller, and is denoted by the subscript # on thermodynamic properties. For a simple single inlet flow stream this is the stagnation state at the inlet flange. For multiple inlet streams it is the stagnation state computed from the mixing of the individually determined streams. A standard calculation scheme is given in subpara. E. 3.2 Flow Coefficient. The flow coefficient is defined as naen( where Wroter= mass flow rate entering rotor (mass flow rate compressed) ‘im inlet total density N= rotor rotational speed Dis the blade tip diameter of the 1st impeller for centrifugal compressors Dis the diameter at the leading edge of the Ist stage rotor blade for axial compressors. ‘The mass flow rate entering the rotor is determined giving due consideration to all section inlet and outlet flow streams and leakages. E3.3_ Gas Properties. The physical properties of the gas are expressed in dimensionless form as the isentropic exponents, compressibility factors, and compressibility functions. £.3.4 Specific Volume Ratio. The specific volume ratio is the ratio of inlet to exit total specific volumes. The inlet specific volume is that assigned to the flow entering the rotor. The exit specific volume is that computed for exit total conditions where zat) 44 ple E3.5_ Ratio of Flow Rates. The ratio of flow rates is the ratio of flow rates at two points in the flow. It is given by 1702). “O, where w= local mass flow rate = local total density and x and y denote different points in the section. The flow rates so defined have the units of volume flow rate, but do not represent actual volume rates of flow since they are defined in terms of total densities. It is assumed that there is a constant relationship between these flow rates and actual volume flow rates between test and specified operating conditions. This is true when the test and specified operating condition local Fluid Mach numbers are equal, and the deviations are assumed negligible when the Code ‘Machine Mach number departure limits are observed. E3.6 Machine Mach Number. The Machine Mach number is given by Mm = Ufa where = first stage impeller blade or rotor blade tip velocity a= acoustic velocity at the inlet total conditions For ideal gases a= VERT For real gases aavoTpiE or, [EZ The Machine Mach number so defined is not an actual Fluid Mach number. It is nearly directly Proportional to actual Fluid Mach numbers when the Code departure limits are observed. The Code departure limits shown in Figs. 3.2 and 3.3 for centrifugal and axial compressors are also Biven in equation form in Table E.1. £3.7, Machine Reynolds Number. The Machine Reynolds number is given by Rem = Ub/y For centrifugal compressors, b is the exit width of the first stage impeller in the section of interest. For axial compressors, b is the chord length at the tip of the first stage rotor blade in the section of interest. The viscosity v is taken for inlet (stagnation) conditions, The Code departure limits shown in Fig. 3.4 for centrifugal compressors are given in equation form in Table 2. £.3.8 Isentropic Work Coeff The isentropic work coefficient is given byTABLE £1 MACHINE MACH NO. LIMITS ‘CENTRIFUGAL COMPRESSORS Specified Mach No. Range. Lower Limit Upper Limit ooze Ming ‘Zisimy = Ming) < (0.25 Mig + 0.288) 0215-0.86 (0.266 My ~ 0.271) -liirg = Meg) < (-0.25 Mg + 0.286) 086s My oer ‘Mim = Mig) < 0.07 [AXIAL COMPRESSORS Specified Mach No. Range Lower Lint Upoer Limit o-0.15 CM “ier, ~ Mg) < (-0.25 Mirig + 0.20) 0.16-0.6 (0.266Mmg - 0.19) tir, ~ Mong) <(-0.25 Mim + 0.20) 08s Mm, 003 thin, = Ming) € 0.05 TABLE E.2 REYNOLDS NUMBER APPLICATION LIMITS FOR CENTRIFUGAL COMPRESSORS" UPPER LIMIT Application Range Equation 9% 108 < Remy < 1x 107 RempRermyy = (1O0P 1 107 < Remy, Rem/Remy = 100 Lower uit RemiRemy <1 x= Remy ication Ran Equation 3104 < Remy < 1x1 RemfRemy = (001 1x10 < Rem Rem/Rem = 0.1 Nowe (1 See Fig. 3.2. 72where Ws isentropic work per unit mass IU?= sum of rotor tip speeds Zhe isentropic work for the purposes of this Code is the work done in an isentropic process between the inlet stagnation state and the discharge stagnation state. The isentropie work per Pound mass for an ideal gas is given by @ For any gas the isentropic work may be calculated from W, = (hg ~ hi) ‘The isentropic work for a real gas may also be calculated from the following: ® erie flO] Equation (a) differs from equation (b) by substituting a, for k and introducing f. For a real gas the isentropic volume exponent is not the same as k. On test, n, can be calculated from Substituting this 0, for k in equation (a) would produce a small error unless the isentropic ‘exponent were constant and equal to n, along the compression path. The polytropic work factor ‘Fcompensates forthe difference between n, and the actual isentropic exponent. tis computed from thé aM 4 lps =p) £3.9. Polytropic Work Coefficient. The polytropic work coefficient is given by WM Bue a be where Wor polytropic work per pound mass Z.U?/g2= sum of rotor tip speeds squared 2h Polytropic work for the purposes of this Code isthe polytropic work required to compress the gas from the inlet stagnation state to the discharge stagnation state. The gas properties are evaluated at the arithmetic mean between inlet and discharge conditions. 173For ideal gases For real gases where = Inipafp) / Intu/va) or 1 °" yma and tt is assumed here that a variation inn affects W, just as the varying n, affects W, The polytropic work factor f is assumed to have the same value as computed in para. £.3.8, 10 _ Efficiencies. Efficiencies are in general defined as the ratio of ideal to actual work required a given compression process. The standard ideal work chosen for this Code is the work required in a polytropic compression process occurring between the total pressure at the inlet reference stagnation state and the total pressure at the discharge stagnation state, The actual work is taken as the change in total enthalpy between these states. It represents the actual work in the process only in the absence of heat transfer and secondary flow effects. The discharge gas state calculated for specified operating conditions using this efficiency definition therefore assumes the same relative heat transfer and secondary flow effects as those prevailing at test. The polytropic efficiency is then = 7° haa had and the corresponding isentropic efficiency is the= had 74E3.11 Work Input Coefficient. The work input coefficient is defined in terms of the stagnation enthalpy rise. It is a dimensionless representation of the actual gas work not including the effect of heat transfer and secondary flow. The work input coefficient is given by (he= hid “yor Be bin The ideal work coefficients are related to the foregoing efficiencies through the work input coefficient Bin = Hpltp = wens £3.12. Total Work Input Coefficient. Relative differences in heat transfer and leakage or sidestream flow rates often will occur between test and specified operating conditions. It is assumed that these relative differences are suficiently small so as to produce negligible changes in the polytropic work coefficient and efficiency. The leakage and sidestream flow rate differences, however, can Produce relative differences in actual power requirement. The following model is presented to establish a method to account for these effects as they relate to power consumption. The method is based on relating the total work input to rotor mass flow rate. The problem model and nomenclature are shown in Fig. E.1. The dimensionless total work input coefficient is determined as follows. ‘The first law of thermodynamics for a control volume surrounding the rotor (in Fig. .1) is J wae be, + Qa sao The first law of thermodynamics for a control volume surrounding the section (in Fig. E.1) is Pe = La ha + Waa bs + wig hig + Wis fy ~ wi bi ~ Wau has + Q4 133000 From the conservation of mass Weatoe = Wit Waa = Wig = Wee Wee + Wd The only work done on the gas is that done by the rotor, so Pg = La ha Wad had + Wa e+ Yu a = = Wis hay + Qi 1733000 = Pres = (rome hey = We be, + Qh!) ae ™ (Ware, = We, + Ql $e 175station it (Possibly ‘multiple stages) Protoe Figure Nomenclature Wim mass flow rate at the inlet measurement station. hhi= enthalpy per unit mass at the inlet measurement station. wa= mass flow rate at the discharge measurement station. ‘ha= enthalpy per unit mass at the discharge measurement station, leakage mass flow rate for gas escaping before the rotor, i.e., upstream of the rotor. ‘hy= enthalpy per unit mass for escaping gas. When the gas does not escape, but inlet leakage occurs, hy is the enthalpy of the gas outside the seal. wa= leakage mass flow rate for gas escaping after the rotor, i., downstream of the rotor. ‘hua= enthalpy per unit mass of the escaping gas. For inward leakage, it is the enthalpy of the gas outside the seal. Wa= mass flow rate for sidestream flow entering after the measurement station but before the rotor. ha= corresponding enthalpy per unit mass. wig mass flow rate for sidestream flow exiting after the rotor but before the discharge measurement station. haa= corresponding enthalpy per unit mass. Queer net mass flow rate through rotor. hei = enthalpy per unit mass at rotor inlet. hea= enthalpy per unit mass at rotor exit. Qaier= heat loss rate from rotor. ‘Q= heat loss rate from section. work input rate excluding mechanical loss. FG. £4 176Rearranging and non-dimensionalizing with ZU? 33000 Py _ wa (he~ hi) J wos (hay - hi) wig (hg hi) J Wawy LL Mar BUF Wit EOE * Wwe SOE * & &e & tw the= hid Qed ww LUT ze i & Gi Pe)S Qa J 2 . & oe ge This equation represents the total work input to the gas in dimensionless form. It is called the total work input coefficient and is given the symbol O, ie., = 33000 Py oe Let a7 a jThis coefficient bears a close relationship to the work input coefficient, jz, but accounts additionally for the energy lost through heat transfer and secondary flow effects. Like the work input coefficient itis assumed to be invariant between test and specified operating conditions at the same flow coefficient. is purpose is to aid in properly accounting for heat transfer and secondary flow effects in power calculations. For heat balance method tests, wa tha~ hil) wee (hah) J wie (high) wir thie = hid} wer EUT wer EUT* Wes EU?” Winer EOP be & Be te thaw Qed a pt 7 a. For shaft power method tests, i. (= =P, Where Fomsie represents all power in the shaft power measurement which does not represent ‘work input to the gas in the compressor section of interest, for example, mechanical losces and Power input to other sections. wzEa SPEED SELECTION The process of structuring the Code performance model includes adding the volume ratio to the independent parameter list to serve as a limiting parameter for the effects of other dimensionless Parameter departures. The volume ratio at test may be controlled at a given flow coefficient and inlet conditions by controlling the compressor speed and flow rate. The appropriate speed may be determined by i the specific volume ratio requirement (es) =e, Hp, Remean = Hp which may be written as Ne [EON [Wp Rare Np V Be Weep where and -, These relationships may be used to estimate the appropriate test speed. It is an estimate in the sense that the appropriate test speed depends upon a prior knowledge of the test efficiency and gas properties, The anticipated test efficiency is estimated from the design value when available. The anticipated olytropic exponent may then be estimated for ideal gases from 178‘and for real gases from 1 me ES INLET STATE FOR MIXED STREAMS For compressor sections with multiple inlet it is necessary to establish the mixed inlet conditions. \deally this would be the mixed stagnation state. Its conceivable that this state might be measured by obtaining intemal pressure and temperature measurements where the compressor geometry allows. However, in practice these are very difficult measurements to obtain. in some cases an actual full mixed state may not even occur. The following development provides a standard method for calculation of the mixed conditions. ‘A number of simplify ns are made. The computed reference conditions are only an approximation to the stagnation state after mixing. The intent is simply to model the main features of the mixing process. It is presumed that the same model when applied to the test and specified ‘operating conditions will produce consistent results. Other mixing models may be appropriate for pantcular compressor geometries. These may also be used with mutual consent by the parties to the test. E5.1 Inlet Stagnation Enthalpy. The inlet stagnation enthalpy is deduced from the average total enthalpy of the mixed streams. In the absence of work and heat transfer in the mixing section, Wa ha + We hy he where the subscripts a and b designate the individual stream values before mixing. £5.2 Inlet Stagnation Pressure. The inlet pressure may be calculated by applying the linear momentum principle to a simplified mixing section model. The geometry under consideration is given in Fig. £2. The following simplifying assumptions are made. (@) The flow is one dimensional. Conditions at stations a, b, and c are described by constant average values for the cross section. The flows are thus treated as being fully mixed, (0) The flow velocity at stations a and cis assumed to be parallel to the x axis, (C) The flow velocity at station b is assumed to enter at an angle with respect to the x axis. (@ The static pressure at station b is assumed equal to the static pressure at station 2. (e} The wall shear stress is ignored. 179‘The subscript s in the following development refers to static conditions. With these assumptions the x-component of the linear momentum conservation equation for the control volume shown is 1 144 (04, Ae~ Pig Ae) = (We Ve~ ws Va = me Vo cos an) & Introducing the continuity of mass equation yields the mixed inlet static pressure seen [to SFE) GS) ft -(1+ 33) C5) CS) C9) i ol, The inlet stagnation pressure is obtained by adding the dynamic head deduced from the average Fluid Mach number at c. The actual form of the equations to be solved depends upon the choice of gas. The following set amenable to iterative solution may be written for ideal gases. Bo Gia) DE -0- 2 C3) 296 cou}A simpler formulation assuming incompressible flow may be written as mot ADC) Ea) 09 Ge cos ane 2 8) -(1 8) AY] where Az 144 Ps This formulation will yield similar results to the compressible solution for low Fluid Mach numbers and nearly equal mixing stream densities. Figure €.3 shows some typical results based upon the preceding equations. 18110! : Cd ad Ba My=0.4 + ose) mam = Tele 18 on 192 101 1.00 ose a” ys 0 2 40 6 80 107 My=0.1 ap=0 TlTa= 1.0 fet 1.96 108 108 us 193 ZZ ° 102 191 1.00 108 108 Pe 102 rot 1.00 029) FIG. £3 182APPENDIX F REYNOLDS NUMBER CORRECTION (his Appendix is not a part of ASME PTC 10-1997) The Reynolds number correction for centrifugal ‘compressors recommended in this Code has been changed significantly from the previous issue of PTC 10. The changes resulted from new references not Previously available. The old correction for centrifu- Bal compressors was adapted from work on axial compressors [Ref. (D.8)] since no centrifugal com- pressor data was available. The correction for axial ‘compressors remains unchanged from the previous issue of the Code. The method of correction, for centrifugal compres- sors, recommended in this Code is based on the work done by Weisner (Ref. (0.2)] but has been simplited for ease of application. The data presented by Weisner suggests that the Machine Reynolds umber at which a compressor operates has an effect not only on the efficiency, but on the flow Coefficient and work input coefficient as well. The corrections are all based on the departure from a Rominal Machine Reynolds number which may vary 183 from one manufacturer to another. The correct Used in this Code, for centrifugal compressors, simplified in that the correction is only applied to the efficiency and polytropic work coefficient. No correction is applied to the flow coefficient or the work input coefficient. Additionally, the nominal condition has been standardized to a Machine Reyn- olds number = 4.8 x 10 x b and the surface roughness t0 0.000125 in. ‘Another correction method has been documented by Simon and Bulskamper [Ref. (D.4)]. This method is developed by analogy with the turbulent flow in rough pipes. Semi-empirical correlations are derived for efficiency, flow coefficient, head coefficient, and ‘work coefficient. The equations developed include a correction to the head, work, and flow coefficients. Similar correction methods have been proposed by Casey {Ref. (0.14)] and Sub (Ref. (D.16)]. Test data supporting. Reynolds number corrections has been ‘published by NASA [Ref. (D.18)].APPENDIX G REFINED METHODS FOR CALCULATING TOTAL CONDITIONS (This Appendix is not a part of ASME PTC 10-1987,) Guidelines are presented for calculating total pres- sure and total temperature with accuracies that ex- ceed those determined by the simpler methods of Paras. 5.4.3 and 5.4.4. The details of thermodynamic property evaluations are not a part of this Code. The calculations outlined below for both ideal gases and real gases must be supplemented by the data and procedures needed to provide the required properties. Compressible flow and uniform velocity are as- sumed for the measurement station in question Static absolute pressure, Puasc, and measured abso- lute temperature, Tress, are the only local measure- ments. The mass flow rate, w, and pipe flow area, A, are known and thermodynamic properties are calculable as needed, The remaining key assumption is the recovery factor, 1, which is defined in para 5.44 in terms of temperature. G.1_ IDEAL GASES The following iterative procedure is appropriate: Step 1 — Let tate = teas be the initial estimate of static temperature. Step 2 — Calculate needed properties correspond ing t (Prac, tease): p= density (from p = 144 p/Rt) specific heat at constant pressure 14s k= ratio of specific heats Step 3 — Compute velocity (w/60\/pa ‘Step 4 — Compute Mach number v we Vee AR toate Step 5 — Compute total temperature (eave ner ‘Step 6 — Compute static temperature Step 7 — Compare taase from step 6 with the value used in previous steps. If agreement is unacceptable, Use taade from step 6 and repeat steps 2 through 7 Until the change in taxic is acceptable (for example, Ataaic < 0.05°F) Step 8 — Calculate total pressure P= Pact «ADA Should Fluid Mach numbers be unusually high, greater than 0.3 for example, accuracy could be Improved by evaluating ¢p and k at both t and taeand using average values of cp and k in the above calculations. G.2_ REAL GASES The term “real gas” normally suggests that the compressibility factor, Z, is not unity and must be included in p-v-T calculations according to py = ZRT. The purpose of an equation of state is to provide ‘a mathematical expression relating pressure, volume, and temperature which corresponds as closely as possible to known or expected p-v-t behavior. Most equations of state use temperature and spe- cific volume (or density) as independent variables, from which pressure may be calculated. That is, p= pie Rigorous thermodynamic procedures are available for evaluating all thermodynamic properties needed for compressor calculations even though only the equation of state and low pressure (ideal gas) specific heat correlations are known. Only the results of these calculations are referred to below, such as: (@) t(p,, temperature obtained from pressure and enthalpy ©) p (has, pressure obtained from enthalpy and en- ‘wopy The recovery factor, 17, will be defined in terms of enthalpy rather than temperature, This definition is the same as that given in para. 5.4.4 when applied to ideal gases. The above defini- tion is considered to be more appropriate for real 885 calculations, and 17 = 0.65 remains the best available value for typical applications. The following iterative procedure is appropriate: Step 1 — Let tease = teas be the inital estimate Of static temperature for the calculation of density. ‘Step 2 — Compute static density rave Prac, tate) Step 3 — Compute velocity V = WEO/A prane Step 4 — Compute kinetic energy a 26h Step 5 — Compute “measured” enthalpy Frans (Prac teas) ‘Step 6 — Compute static enthalpy raat = Pras ~ 0.65 ke ‘Step 7 — Compute static temperature ‘rate (Prater rate) Step 8 — Compare Tenic from step 7 with the value used in previous steps. If agreement is unac- ceptable, then use Taaic from step 7 and repeat steps 2 through 8 until the change in Taase is acceptable (for example, ATraic < 0.05 °R). ‘Step 9 — Compute total enthalpy h = haaie + ke Step 10 — Compute static entropy Site (Prats uate) Step 11 — Compute total pressure Ph, See) (Recall that static and total entropies are the same.) Step 12 — Compute total temperature tp, h 136,APPENDIX H SI UNITS (This Append is not a part of ASME PTC 10-1997) U.S. Customary Conversion Symbol Description Units X Factor = St Units A Flow channel cross e 0.0929 m sectional area a Acoustic velocity ftisec 0.3048 m/s b Tip width ft 0.3048 m c Coefficient of discharge dimensionless 1 dimensionless c ‘Molal specific Btuflbmole-*F 1 Nemn/kgmole - K ¢ Specific heat Btu/lbm » °F 4183 Nem/kg K & Specific heat at constant Btu/bm - *F 4183 No mikg +k pressure o Specific heat at constant Btu/lbm «°F 4183 No mikg-K volume D Diameter i 0.0254 m d Diameter of fluid meter i 0.0254 m e Relative error dimensionless 1 dimensionless Fa Thermal expansion factor dimensionless 1 dimensionless for fluid meter f Polytropic work factor dimensionless. 1 dimensionless g Acceleration of gravity —f/sec? 0.3048 m/s . ft-tbm m-kg Be Dimensional constant 32174 pe 0.031081 H Molal enthalpy Btu/Ibmole 2324 N+ m/kg - mole AR Humidity ratio tbm-w/lbm-da 1 kg -wikg- da h Enthalpy Btu/lbm 2324 N= meg h Coefficient of heat transfer Btu/hr-ft2-°F 0.06896.» N- m/s-m?-K per unit area (for combined convection and radiation) ‘Mechanical equivalent of ft- lof J hae 717 not used K Flow coefficent dimensionless 1 dimensionless k Ratio of specific heats, dimensionless. 1 dimensionless oles log Common logarithm (base dimensionless. 1 dimensionless 10) 187USS. Customary Conversion Symbol Description Units X Factor = SI Units in Naperian (natural) dimensionless 1 dimensionless logarithm Mw Molecular weight Ibmibmole 1 kg/kgmole Mm ‘Machine Mach number dimensionless. 1 dimensioniess M Fluid Mach number dimensionless 1 m Polytropic exponent fora dimensionless. 1 dimensionless path on the p ~T diagram m Mass (Appendix 8 only) Ibm 0.4536 kg N Rotative speed rpm 0.01667 Hz n Polytropic exponent for a dimensionless 1 dimensionless path on the p ~ v diagram n Number of moles Ibmole 0.4536 kgmole (Appendix 8 only) ™ \sentropic exponent for an dimensiones 1 dimensionless ‘isentropic path on a p= vdiagram Pp Power bp 0.746 kw Pp Pressure psi 6895 N/m4Pa) Pr Velocity pressure psi 6895 Nim*(Pa) Qn Total mechanical losses. Btu/min 0.01757 kW (equivalent) a Casing heat transfer Btu/min 0.01757 kw Qs External seal loss Btu/min 0.01757 kW ‘equivalent q Capacity f@/min 0.0004719 m/s q Volume flow rate f/min 0,0004719 m/s R Gas constant ft-Ibibm.°R 5.381 Ne m/kg-K RA, RB, RC Machine Reynolds number dimensionless 1 dimensionless correction constants Re Fluid Reynolds number dimensionless. 1 dimensionless Rem Machine Reynolds number dimensionless. 1 dimensionless RH Relative humidity dimensionless 1 dimensionless r Pressure ratio across fluid dimensionless. 1 dimensionless meter " Recovery factor dimensionless 1 dimensionless b Pressure ratio dimensionless 1 dimensionless tq Flow rate ratio dimensionless. 1 dimensionless h Temperature ratio dimensionless 1 dimensionless 8 Specific volume ratio dimensionless 1 dimensionless s Molal entropy Btu/lbmole-°R 4183, N- m/kgmole : kK Se Heat transfer area of fe 0.09294 mt ‘exposed compressor casing and adjoining Pipe a Entropy BTU/lbm -°R 4183 No m/kg-K T Temperature R 0.5556 kK t Temperature F 0.5556 k 188 (°F + 459.67)US. Customary. Conversion Symbol Units X Factor = SI Units U Blade tip speed fisec 0.3048 mis u Internal ene Btu/lbm 2324 N-mikg v Fluid velocity ‘tise 0.3048 m/s v Specific volume f€/lbm 0.06243 milkg w Work ft/bffom 2.989 N- mikg w Mass flow rate lbm/min 0.00756 is x Compressibility function dimensionless. 1 dimensionless x Mole fraction dimensionless 1 dimensionless ¥ Compressibility function dimensionless. 1 dimensiontess y Elevation ft 0.3048 m Zz Compressbility factor as dimensionless 1 dimensionless ‘used in ideal gas law, py = ZRT a Diameter ratio of fluid dimensionless. 1 dimensionless meter a Partial derivative dimensionless 1 dimensionless 7 Efficiency dimensionless 1 dimensioniess # Absolute viscosity lbmit- sec 1.488 kgim-s Hin Work input coefficient dimensionless i dimensionless Up Polytropic work coefficient dimensionless 1 dimensionless us Isentropic work coefficient dimensionless 1 dimensionless y Kinematic viscosity /sec 0.09294 mils 2 Density Norns 16.02 kgim? x ‘Summation dimensionless — dimensionless Y Torque ft Ibe 1.356 Nem € Surface roughness in 0.0254 m a Total work input dimensionless 1 dimensionless coefficient o Flow coefficient dimensionless 1 dimensionless 189ASME Services ASME is committed to developing and delivering technical information, At ASME's Information Central, we make G1 effort to answer your questions and expedite your orders. 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