Sl.No.

Parameter Symbol Units Value Remarks / Formula

Compressor Selection

1 Design Basis

Type of Compressors Integrally Geared Multi-Stage Centrifugal Compressor

1.1 No of Compressors nos 1 Working + 1 Standby
1.2 Volume Flowrate, Dry Basis Q Nm3/h 40,000.00
1.3 Ambient Pressure Pa ksca 1.0332
1.4 Design Relative humidity RH % 88
1.5 Ambient Temperature ta o
C 37.8
1.6 Pressure Drop in Suction filter ∆Pf ksc 0.02 Assumed
1.7 Compressor Discharge Pressure Pd ksca 9.73 Pressure drops in Intercooler and after cooler has been added
1.8 Compressor Discharge Temperature td o
C 42.00
1.9 Average Molecular Weight of Air MWa 28.84
1.10 Average Molecular Weight of Water MWw 18
1.11 Compressibilty factor at suction conditions Zs 1
1.12 Ratio of Cp/ Cv k 1.4
1.13 Critical Pressure Pc ksca 38.46
1.14 Critical Temperature Tc o
C -140.5
1.15 Universal gas constant R J/kmol-K 8314.3
1.16 Accelaration due to Gravity g m/s2 9.81
1.17 Cooloing water Inlet Temperature twi o
C 33
1.18 C.W Temperature Rise ∆tw o
C 10
1.19 Enthalpy of Water Vapour(steam)@ 315K hs 315K kJkg 2577.1
1.20 Enthalpy of Water Vapour(steam)@ 385K hs 385K kJkg 2694.1
1.21 Enthalpy of Water Vapour(steam)@ 390.0K hs 390K kJkg 2701.5
1.22 Specific Heat Capacity of Dry Air Cp kJkg-K 1.000693
 Power Calculation

2.1 Molar Flowrate of air, Dry Basis Na kmol/h 1,785.71

2.2 Mass Flowrate of air, Dry Basis ma kg/h 51,500.00
2.3 Water Vapour Pressure @ amb. temp. pv ksca 0.0673 From Steam Table
2.4 Partial Pressure of W.V. @ amb temp & RH pp ksca 0.0592 pp=pv x RH / 100
2.5 Compressor suction Inlet Temp. Ti K 310.93 Ti = ta + 273.13
2.6 Compressor suction Inlet Pressure Pi ksca 1.0132 Pi = Pa - ∆Pf
2.7 Molar Flowrate of Water Vapour Nw kmol/h 110.859 pp / Pi = Nw / { Na + Nw)
2.8 Mass Flowrate of Water Vapour mw kg/h 1995.47
2.9 Total Molar Flow rate of wet air Na + Nw kmol/h 1896.57
2.10 Total Mass Flow rate of wet air ma1 + mw1 kg/s 14.86
2.11 Compressor suction inlet Volume flowrate Vi Am /h
3
49326.95 Vi = Q x {Ti / 273.13 } x {1.0334 / ( Pi - pp ) }
2.12 Overall Compression Ratio CRov 9.60
2.14 Polytropic efficiency ƞp % 73 Assumed
2.15 Polytropic Exponent n 1.643 n / { n-1} = { k / (k -1)} x ƞp
2.16 Polytropic Function n-1/ n 0.391
> than 463K hence not okay. Hence Multi stage with inter cooling
2.17 Discharge Temperature Td K 753.53 machine required
2.18 Reduced Pressure @ discharge conditons Pr ksca 0.25 Pr = P / P c
2.19 Reduced Temperature @ discharge conditons Tr K 5.68 Tr =T / T c
2.20 Compressibilty factor at Discharge conditions Zd 0.982 From graph using Pr and Tr
2.21 Avg Compressibilty factor Zavg 0.991
2.22 Adiabatic Head Had m 28785.95 Had = Zavg x R x T1 x {(P2/P1)
(k-1)/k
- 1} / {g x MWa x (k-1) / k}
2.23 Maximum allowable impeller tip speed U2 m/s 274.32 As per manufacturer Standard
2.24 Maximum Adiabatic Head per Stage Had/stg kg-m/kg 7670.89 Had/stg = U22 / g
2.25 No of Stages s no 4.0 Rounded off to nearest integer
2.26 Compression ratio of each stage CRs 1.760 CRs = ( CRov )1/s
 Stage Wise Power Calculation
1st Stage
2.27 1st Stage Discharge Pressure P1d ksca 1.783
2.28 1st Stage Discharge Temp exit intercooler Ts2 K 315.13
2.29 Polytropic Function n-1 / n 0.375 From graph and k value of 1.4
2.30 Polytropic efficiency ƞp % 76.190
2.31 1st Stage Discharge Temp T1d K 384.4
2.32 Reduced Pressure @1st stage discharge Pr ksca 0.05
2.33 Reduced Temperature @ 1st stage discharge Tr K 2.90
2.34 Compressibilty factor at 1st stage Discharge conditions Zd 0.999 From graph using Pr and Tr
2.35 Avg Compressibilty factor Zavg 0.9995
2.36 1st Stage Polytropic Head Hpoly1 m 5829.92 Hpoly1 = Zavg x R x T1 x {(P2/P1)
(n-1)/n
- 1} / {g x MWa x (n-1) / n}
2.37 1st Stage Brake kilowatt BKW1 kW 1115.44 BKW1 = (ma1 + mw1) x Hpoly1 x g / { 1000 x ( ƞp /100) }
2nd Stage
2.38 Pressure Drop in !st Stage Intercooler ∆Pa1 ksc 0.02 Assumed
2.39 2nd Stage Suction Pressure P2s ksca 1.763
2.40 2nd Stage Discharge Pressure P2d ksca 3.104
2.41 2nd Stage Discharge Temp exit intercooler T3s K 315.13
2.42 Water Vapour Pressure @ 1st stage exit inter cooler pv ksca 0.0836 From Steam Table, Satd at exit inter cooler conditions
2.43 Partial Pressure of W.V. @ 2nd stage inlet pp ksca 0.0836
2.44 Molar Flowrate of Water Vap to 2nd stage Nw2 kmol/h 88.870 pp / Pt = Nw / { Na + Nw)
2.45 Mass Flowrate of Water Vap to 2nd stage mw2 kg/h 1599.66
2.46 Condensed water in 1st Stage inter cooler kg/h 395.812
2.47 Total Mass Flow rate of wet air to 2nd Stage inlet ma2 + mw2 kg/s 14.75
2.48 2nd Stage Discharge Temp T2d K 389.6
2.49 Reduced Pressure @2nd stage discharge Pr ksca 0.08
2.50 Reduced Temperature @ 2nd stage discharge Tr K 2.94
2.51 Compressibilty factor at 2nd Discharge conditions Zd 1.001 From graph using Pr and Tr
2.52 Avg Compressibilty factor Zavg 1.0000
2.53 2nd Stage Polytropic Head Hpoly2 m 5832.84
2.54 2nd Stage Brake kilowatt BKW2 kW 1107.74
2.55 Heat Load due to dry air in 1st stage inter cooler kW 991.18
2.56 Heat Load due to water vapour in 1st stage inter cooler kW 348.20
2.57 Total Heat Load in 1st stage inter cooler ∆Qic1 kW 1339.38
2.58 Cooling Water Flow in inter cooler wic1 kg/s 31.99
3rd Stage
2.59 Pressure Drop in 2nd Stage Intercooler ∆Pa2 ksc 0.02 Assumed
2.60 3rd Stage Suction Pressure P3s ksca 3.084
2.61 3rd Stage Discharge Pressure P3d ksca 5.428
2.62 3rd Stage Discharge Temp exit intercooler T4s K 315.13
2.63 Water Vapour Pressure @ 2nd stage exit inter cooler pv ksca 0.0836 From Steam Table, Satd at exit inter cooler conditions
2.64 Partial Pressure of W.V. @ 2nd stage inlet pp ksca 0.0836
2.65 Molar Flowrate of Water Vap to 3rd stage Nw3 kmol/h 49.756 pp / Pi = Nw / { Na + Nw)
2.66 Mass Flowrate of Water Vap to 3rd stage mw3 kg/h 895.61
2.67 Condensed water in 2nd Stage inter cooler kg/h 704.051
2.68 Total Mass Flow rate of wet air to 3rd Stage inlet ma3 + mw3 kg/s 14.55
2.69 3rd Stage Discharge Temp T3d K 389.6
2.70 Reduced Pressure @ 3rd stage discharge Pr ksca 0.14
2.71 Reduced Temperature @ 3rd stage discharge Tr K 2.94
2.72 Compressibilty factor at 3rd Discharge conditions Zd 1.002 From graph using Pr and Tr
2.73 Avg Compressibilty factor Zavg 1.0015
2.74 3rd Stage Polytropic Head Hpoly3 m 5841.59
2.75 3rd Stage Brake kilowatt BKW3 kW 1094.69
2.76 Heat Load due to dry air in 2nd stage inter cooler kW 1,065.50
2.77 Heat Load due to water vapour in 2nd stage inter cooler kW 559.28
2.78 Total Heat Load in 2nd stage inter cooler ∆Qic2 kW 1624.78
2.79 Cooling Water Flow in 2nd stage inter cooler wic2 kg/s 38.81
4th Stage
2.80 Pressure Drop in 3rd Stage Intercooler ∆Pa3 ksc 0.02 Assumed
2.81 4th Stage Suction Pressure P4s ksca 5.408
2.82 4th Stage Discharge Pressure P4d ksca 9.520
2.83 4th Stage Discharge Temp exit aftercooler Tac K 315.13
2.84 Water Vapour Pressure @ 3rd stage exit inter cooler pv ksca 0.0836 From Steam Table, Satd at exit inter cooler conditions
2.85 Partial Pressure of W.V. @ 3rd stage inlet pp ksca 0.0836
2.86 Molar Flowrate of Water Vap to 4th stage Nw4 kmol/h 27.931 pp / Pi = Nw / { Na + Nw)
2.87 Mass Flowrate of Water Vap to 4th stage mw4 kg/h 502.76
2.88 Condensed water in 3rd Stage inter cooler kg/h 392.844
2.89 Total Mass Flow rate of wet air to 4th Stage inlet ma4 + mw4 kg/s 14.45
2.90 4th Stage Discharge Temp T4d K 389.6
 2.91 Reduced Pressure @ 4th stage discharge Pr ksca 0.25
2.92 Reduced Temperature @ 4th stage discharge Tr K 2.94
2.93 Compressibilty factor at 4th Discharge conditions Zd 1.004 From graph using Pr and Tr
2.94 Avg Compressibilty factor Zavg 1.0030
2.95 4th Stage Polytropic Head Hpoly4 m 5850.33
2.96 4th Stage Brake kilowatt BKW4 kW 1088.11
2.97 Heat Load due to dry air in 3rd stage inter cooler kW 1,065.50
2.98 Heat Load due to water vapour in 3rd stage inter cooler kW 312.17
2.99 Total Heat Load in 3rd stage inter cooler ∆Qic3 kW 1377.67
2.100 Cooling Water Flow in 3rd stage inter cooler wic3 kg/s 32.90

2.101 Total BKW in Four Stages kW 4405.98

2.102 Mechanical losses % 2
2.103 Total BKW with Mechanical loss kW 4494.10
After Cooler
2.104 4th Stage Discharge Pressure P4d ksca 9.520
2.105 Pressure Drop in aftercooler ∆Pac ksc 0.02 Assumed
2.106 Compressed air Pressure at outlet of aftercooler Pd ksca 9.500
2.107 4th Stage Discharge Temp exit aftercooler Tac K 315.13
2.108 Water Vapour Pressure @ 4th stage exit after cooler pv ksca 0.0836 From Steam Table, Satd at exit after cooler conditions
2.109 Partial Pressure of W.V. @ 4th stage exit after cooler pp ksca 0.0836
2.110 Molar Flowrate of Water Vap exit 4th stage after cooler Nw4 kmol/h 15.854 pp / Pi = Nw / { Na + Nw)
2.111 Mass Flowrate of Water Vap exit 4th stage after cooler mw4 kg/h 285.38
2.112 Condensed water in 4th Stage after cooler kg/h 217.386
2.113 Total Mass Flow rate of wet air exit after cooler ma4 + mw4 kg/s 14.38
2.114 Heat Load due to dry air in after cooler kW 1,065.50
2.115 Heat Load due to water vapour in after cooler kW 172.99
2.116 Total Heat Load in after cooler ∆Qac kW 1238.50
2.117 Cooling Water Flow in after cooler wac kg/s 29.58

2.118 Total Cooling Water Flow to intercooler and after cool wt kg/s 133.28
2.119 Total water condensed in intercooler and after cooler kg/h 1710.09
 Compressor Disch. CA Dist. Dryer Inlet Dryer Inlet Dryer DCA Dist.
Sl.no. Parameter Symbol Units Header(CA) Header(CA) Header(CA) (CA) outlet(DCA) Header

1 Pipe Velocity Calculation

1.1 Volume Flowrate, Dry Basis Q Nm3/h 40,000 16,000 24,000 6,000 6,000 24,000
1.2 Operating Pressure Po ksca 9 9 9 9 8.5 8.5
1.3 Operating Temperature ta o
C 42 42 42 42 42 42
1.4 Water Vapour Pressure @ operating conditions pv ksca 0.0836 0.0836 0.0836 0.0836 0.00003 0.00003
1.5 Partial Pressure of W.V. @ operating conditions pp ksca 0.0836 0.0836 0.0836 0.0836 0.00003 0.00003
1.6 Average Molecular Weight of Air MWa 28.84 28.84 28.84 28.84 28.84 28.84
1.7 Average Molecular Weight of Water MWw 18 18 18 18 18 18
1.8 Molar Flowrate of air, Dry Basis Na kmol/h 1,785.71 714.29 1,071.43 267.86 267.86 1,071.43
1.9 Mass Flowrate of air, Dry Basis ma kg/h 51,500.00 20,600.00 30,900.00 7,725.00 7,725.00 30,900.00
1.10 Molar Flowrate of Water Vapour Nw kmol/h 16.743 6.697 10.046 2.511 0.001 0.004
1.11 Mass Flowrate of Water Vapour mw kg/h 301.37 120.55 180.82 45.21 0.02 0.07
1.12 Total Molar Flow rate of wet air Na + Nw kmol/h 1802.46 720.98 1081.47 270.37 267.86 1071.43
1.13 Total Mass Flow rate of wet air ma1 + mw1 kg/s 14.39 5.76 8.63 2.16 2.15 8.58
1.14 Actual Volume flowrate V Am3/h 5348.84 2139.53 3209.30 802.33 841.63 3366.53
1.15 Recommended Pipe Velocity v m/s 10 10 10 10 10 10
1.16 ID pipe based on recommeded velocity di mm 434.99 275.11 336.94 168.47 172.55 345.09
1.17 Selected Nominal Pipe Size NB mm 450 300 350 200 200 350
1.18 Pipe schedule STD STD STD STD STD STD
1.19 Pipe thickness t mm 9.53 9.53 9.53 8.2 8.2 9.53
1.20 Pipe Outside diameter OD mm 457.2 323.8 355.6 219.1 219.1 355.6
1.21 Pipe Inside diameter ID mm 438.14 304.74 336.54 202.7 202.7 336.54
1.22 Pipe Velocity based on selected pipe size va m/s 9.86 8.15 10.02 6.91 7.25 10.51
2.00 Pipe Pressure Drop Calculation

2.1 Compressibilty factor at suction conditions Zs 0.995 0.995 0.995 0.995 0.995 0.995
2.2 Ratio of Cp/ Cv k 1.4 1.4 1.4 1.4 1.4 1.4
2.3 Universal gas constant R J/kmol-K 8314.3 8314.3 8314.3 8314.3 8314.3 8314.3
2.4 Accelaration due to Gravity g m/s2 9.81 9.81 9.81 9.81 9.81 9.81
2.5 Density of Air kg/m3 9.685 9.685 9.685 9.685 9.179 9.179
2.6 Viscosity of Air N-s2/m 1.85E-05 1.85E-05 1.85E-05 1.85E-05 1.85E-05 1.85E-05
2.7 Sonic Velocity vs m/s 1910.4 1910.4 1910.4 1910.4 1910.4 1910.4
2.8 Mach Number Ma 0.00516 0.00427 0.00525 0.00362 0.00379 0.00550
2.9 Reynold's number NRe 2,260,717 1,300,138 1,765,931 732,988 728,725 1,755,661
2.10 Roughness factor Ɛ mm 0.04570 0.04570 0.04570 0.04570 0.04570 0.04570
2.11 ε/D 0.000104 0.000150 0.000136 0.000225 0.000225 0.000136
2.12 Friction factor 4f 0.01229 0.01324 0.01293 0.01445 0.01445 0.01293
2.13 1 / ( f )0.5 9.02110 8.69072 8.79361 8.31994 8.31994 8.79361
2.14 -2 x log10 { (ε /( D x 3.7))+2.51 / ( NRe x f 0.5 ) } 9.02102 8.69135 8.79388 8.32324 8.32265 8.79345
2.15 St Pipe length m 10 2500 20 6 6 2500
2.16 Pressure drop m of fluid 1.39 367.70 3.94 1.04 1.14 541.34
2.17 Equivalent length- K values
2.18 Gate Valve- Full open k1= 0.17 nos 1 1 1 1 1 1
2.19 Globe type Control Valve- 50% open k2= 36 nos 1 1 1 1 1 1
2.20 90o Elbow k3= 0.75 nos 3 3 3 3 3 3
2.21 Tee k4= 1 nos 2 2 2 2 2 2
2.22 Check Valve k5= 2 nos 1 1 1 1 1 1
2.23 Total K 42.42 42.42 42.42 42.42 42.42 42.42
2.24 Velocity head m of fluid 4.952 3.385 5.121 2.432 2.676 5.635
2.25 Pressure Drop in valves and fittings m of fluid 210.05 143.61 217.23 103.17 113.52 239.04

Total Presure in Pipe, valves and fittings m of fluid 211.44 511.31 221.17 104.21 114.67 780.38
Total Presure in Pipe, valves and fittings ksc 0.2048 0.4952 0.2142 0.1009 0.1052 0.7163
Percentage of Press drop with inlet pressure % 2.28 5.50 2.38 1.12 1.24 8.43