NAME-409

Marine Engineering -II

Conducted by:
Cdr Tasnuva

Blowers and Compressors

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 GENERAL APPLICATIONS OF COMPRESSOR
COMPRESSORS HAVE MANY USES, SUCH AS IN :
❑REFRIGERATION

❑AIR CONDITIONING

❑AIR COMPRESSION FOR PNEUMATIC SYSTEMS

❑AIR COMPRESSION FOR INDUSTRIAL MANUFACTURING

❑AIR COMPRESSION FOR STEAM TURBINE

❑AIR COMPRESSION FOR GAS TURBINE/JET ENGINE

❑AIR COMPRESSION FOR WEAPONRY

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 ONBOARD APPLICATIONS OF COMPRESSED AIR
COMPRESSED AIR IS USED ONBOARD FOR THE FOLLOWING PURPOSES:

❑ENGINE/TURBINE STARTING AND RUNNING.

❑CHARGING OF BREATHING APPARATUS.
❑CHARGING OF DIVING SETS.
❑SERVICE AIR FOR GUNS, TORPEDOES AND MISSILES.
❑CONTROL AIR FOR ENGINES, CPP ETC.
❑DECK SERVICES LIKE WINCH, CAPSTAN, DAVIT, DERRICK ETC.
❑AUXILIARY SERVICES LIKE PNEUMATIC HAMMER, SIREN, HYDROPHORE
SYSTEM ETC.
❑PRESSURE TESTING OF CYLINDER HEAD, CONDENSER, COOLER,
WATERTIGHT COMPARTMENT ETC. 3

❑CLEANING
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What are compressors?
Compressor is a mechanical device that increases the pressure
of a gas. Compressors are closely related to pumps: both
increase the pressure on a fluid, and both can transport the fluid
through a pipe. As gases are compressible, the compressor
also reduces the volume of a gas. Liquids are generally
incompressible, so the main result of a pump is to move the
liquid elsewhere without affecting its volume
How they are different from blowers?
Basic difference between blower and compressor is the
pressure to which they can compress air. Blowers are
designed to provide large volumes of air at low pressure.
Blower simply can operate against a back pressure of up to 1
bar. Compressors are used to create high pressures in the
range of 5 to 500 bar
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 Classification of Compressors

Rotodynamic Positive Displacement

Compressors of Compressors

Centrifugal Axial
Compressors Compressors Reciprocating Rotory
Compressors Compressors
Mixed
Compressors
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 Blowers
Centrifugal type

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Compressors
Reciprocating /Piston
type

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Compressors Reciprocating /Piston type

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Compressors
Rotary vane type

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Compressors
Screw type
Helix of male and female
rotor screw is designed to
permit complete charging of
the inter lobe space before
the re-mesh.

On completion of the filling

operation the inlet end of
male and female lobes
begins to re-engage thus
reduces the volume of air
continuously.

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 Compressors
Screw type
Thus compression begins and air is discharged at the end of other side.

There is no contact between male and female rotors and casing. Hence, no lubrication is
required but oil may be injected for the purpose of sealing and cooling.

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 TWO-STAGE COMPRESSION

Discharge Discharge

Suction

14.7 psi /1 bar 20 bar 200 bar

FIRST STAGE SECOND STAGE

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Two stage reciprocating compressor

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 TWO STAGE RECIPROCATING COMPRESSOR

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 BASIC OPERATION OF A
RECIPROCATING COMPRESSOR

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Suction valve
closed Discharge valve
closed
Pressure in the
cylinder is equal to
the discharge
pressure

Piston is at Top Dead Centre (TDC)

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Suction valve
open Discharge valve
closed
Pressure in the
cylinder is equal to
the suction Suction gas is
pressure pulled into the
compression
cylinder

Piston is moving downward in the cylinder

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Suction valve
closed Discharge valve
closed

Volume is
decreasing,
compression
begins

Piston is moving up in the cylinder

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Suction valve
closed Discharge valve
open
Pressure in the
cylinder crosses
the discharge Discharge gas is
pressure pushed out from
the cylinder

Piston is moving up in the cylinder

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 COMPRESSION PROCESS - DISCHARGE

• WHEN THE CYLINDER PRESSURE RISES ABOVE DISCHARGE PRESSURE,

THE DISCHARGE VALVE OPENS AND THE SUCTION VALVE REMAINS
CLOSED
• AS THE PISTON CONTINUES TO MOVE UPWARDS, THE GAS IS
DISCHARGED FROM THE COMPRESSOR
• DISCHARGE CONTINUES UNTIL THE PISTON REACHES TOP DEAD
CENTER (TDC)

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Compression
Theory

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 Compression Practical

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Referring to the diagram, at point 4, when the clearance air has reduced to
the atmospheric pressure, the inlet valve will not open immediately. The
pressure drops lower than the atmospheric pressure and the inertia of the
valves are overcome by the pressure difference. Thus the valve is forced open
by the atmospheric air and it rushes into the cylinder chamber. There is a
“valve bounce" and the pressure does not remain constant inside the cylinder.
The pressure slightly increases and then decreases after which reaches
somewhat steady intake of air. This negative pressure difference is called as
the “Intake Depression".
The same occurs at the point 2, where the delivery valve delays to open. The
compressed air pressure inside the cylinder of compressor reaches a pressure
slightly more than the air receiver pressure. The delivery valve then opens
causing a slight decrease in pressure but always above the air receiver
pressure enabling the compressor to deliver air. Then it reaches a stable point
after some “Valve Bounce" and then reaches point 3 where the delivery valve
closes to continue its cycle. Thus in practice, the compressor requires more
power to compensate for the additional work done due to the depressions in
delayed opening of the valves.
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 ISENTROPIC WORK OF COMPRESSION
As a first approximation, a compressor without any internal
cooling can be assumed to be adiabatic. If the process is also
assumed to be reversible, it will be isentropic.
 −1
 p2  
p = p1 = const. T2
= 
 
1

T1 
 1
p 

Solve for  and integrate.

 −1
 
p1  p2  
Wˆ S =0 =   − 1
Upon Integration:
1 ( − 1)  p1  
 

This is the isentropic (adiabatic) work of compression.

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The quantity p2/p1 is the compression ratio.

 COMPRESSOR WORK
Actually, compression is not reversible. Deviations from ideal
behavior must be accounted for by introducing an isentropic
compressor efficiency such that the true work of compression is
given by.

Wˆ S =0
Wˆc =
ad
How can ad be found?

Wˆc = C p (T2 − T1 )
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 ISOTHERMAL COMPRESSION
If sufficient cooling is provided to make the compression process
isothermal, the work of compression is simply:

ˆ RT1 p2
WT =0 = ln
M p1
For a given compression ratio and suction condition, the work
requirement in isothermal compression is less than that for
adiabatic compression. This is the reason why cooling is very
useful in compressors

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 POLYTROPIC COMPRESSION
In reality, the S = 0 path assumed for expression p/ = const. is
not the true thermodynamic path followed by gases in most large
compressors, and the compression is neither adiabatic nor
isothermal. So, a polytropic path is a better representation:
p p
= 1 = const.
 n
 n
1
Here n depends on the nature of the gas and details of the
compression process.
 n −1
 where Ŵp is the work for
p1n  p2 
  − 1
n
ˆ
Wp = polytropic compression
1 (n − 1)  p1  
 
Wˆ p
Again,
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the calculated work and: p
 POLYTROPIC COMPRESSION
The polytropic efficiency p is often the efficiency quoted by
manufacturers. From this efficiency useful relations can be stated
to convert from polytropic to adiabatic results:

To get n the polytropic exponent:

 p n 
n= = p
1 +  p −  or n −1  −1

To get relationships between T or  and compression ratio simply

replace  with n. n −1
T2  p2  n
e.g. =  
T1  p1 
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 COMPRESSION EFFICIENCY
The volumetric efficiency

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 MULTISTAGE COMPRESSION
Consider a two stage compression process p1→px→p2 with
perfect intercooling (temperature reduced to T1 after each
compression)

 n −1
  n −1

n RT1  p x  nRT1  p2 
   − 1
n n
Wˆ S =0 =   − 1 +
n − 1  p1   n − 1  p x  
   

Now find px which will minimize work, differentiate wrt px

p xopt = p1 p2
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 MULTISTAGE COMPRESSION
1
p2 p3  p3  2
= =  
p1 p2  p1 
So the compression ratio that minimizes total work is such that each stage has
an identical ratio.
This can be generalized for n stages as:
1
p2 p3  pn +1  n
= =  =  
p1 p2  p1 
 −1
 pi +1   pi +1
When T is not cooled to T1: Ti   = const. Ti  
 pi  pi
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Multistage Compression: Intermediate pressure
 Multistage Compression: Intermediate pressure

For a fixed P1, T1 and P2, we can have the optimum Pi that gives us
minimum total work by
Multistage Compression: Intermediate pressure
 Multistage Compression: Intermediate pressure

1
Generalized pressure ratio for N  pn +1  n
p2 p3
stages : = =  =  
p1 p2  p1 

 n −1

Total work for N   p2 
 − 1
Nn Nn
WTotal = mRT1 
stages : n −1  p1  
 

n −1
 pi +1  n pi +1
When T is not cooled to T1: Ti   = const. Ti  
 pi  pi
Problem 1: A two stage air compressor takes in air at a rate of 0.2 cubic meter /
sec. Intake pressure is 1 bar and 16 oC . Final pressure is 7 bar the intermediate
pressure is ideal with perfect intercooling. The compression takes place according
to law PVn=Constant, where the compression index is 1.25. The compressor runs at
600 RPM. Neglecting clearance determine a)The intermediate pressure b) Volume
of each cylinder c) cylinder power

(a) (b)

(c)
 MULTISTAGE COMPRESSION
Requirement of Multistage Compressor

1. Maximum temperature is reduced and thus there is little change

of lubrication troubles

2. Leakage loss is minimum due to better cylinder lubrication and

reduced pressure difference across the two sides of the piston and
valve

3. There is gain in volumetric efficiency with increase in number of

stages

4. When air is being compressed in one cylinder. There is suction

in the other cylinder

5. The machine has a lighter construction further since the

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operating temperature is lower, cheaper material can be used for
50
construction
Problem 1: Gas is compressed in a reciprocating compressor from 1
bar to 6 bar. The FAD is 13 dm3/s. The clearance ratio is 0.05. The
compression and expansion of cycle follows PV1.2=Constant. The
shaft speed is 360 rpm. Calculate swept volume and volumetric
efficiency.

Problem 2: Find the power required to compress and deliver 2 kg/min

air from 1 bar and 200 C to a delivery pressure of 7 bar by a single
stage compressor. Compression follows PV1.4=Const. Neglect clearance
volume. Take R=287 J/kg K.

Problem 3: A single stage reciprocating air compressor takes air at 1

bar and 150 C. The conditions at the end of suction are 0.97 bar and
300 C. The discharge pressure is 6 bar. The compression and
expansion
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Problem 4: A single acting reciprocating compressor having L/D =
1.5 has the cylinder diameter of 200 mm and it operates at 100
rpm. The compressor compresses air at 1 bar 300 k to a presser of
8 bar according to PV1.25=Constant law. Find the indicated power
of the compressor, mass of air delivered, and temperature of air
delivered. Also calculate the power required to drive the
compressor if mechanical efficiency is 80%. Neglect clearance
volume.
Problem 5: A two stage single acting compressor compresses air to
delivery pressure of 20 bar from atmospheric condition of 1 bar
and 200 C. The condition of air at the inlet of compression stroke is
0.98 bar and 320 C . Take perfect intercooling of air between
stages. The size low pressure cylinder is 400 mm bore with 500 mm
stroke. The clearance ratio of both cylinders are 0.04. Shaft speed
is 240 rpm. Compression index is 1.33 and Cp =1.005 kJ/kg K.
Find the power required to run the compressor for having
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mechanical efficiency 98 percent and heat rejection by intercooler.

 Compressor Problems:
• COMPRESSOR INSTABILITIES:

ROTATING STALL AND SURGE MAY DEVELOP. THESE MUST BE CONTROLLED

AT HIGH PRESSURE RATIOS, ESPECIALLY AT LOW MASS FLOW RATES.

• LIQUID IN THE COMPRESSION CYLINDER:

IF LIQUID ENTERS THE CYLINDER, DAMAGE WILL OCCUR. LIQUIDS CANNOT
BE COMPRESSED. LIQUID SLUGGING CAN CAUSE IMMEDIATE DAMAGE
TO THE COMPRESSOR COMPONENTS

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 COMPRESSOR PERFORMANCE MAP
Desired
Lines of
Extension of
Constant
Operating
Efficiency
Range

Lines of
Total Pressure Rise

Constant
Rotational
Speed

Volumetric Flow Rate

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Surge
The surge limit defines the flow at which, for a given speed, the
operation of the compressor becomes unstable. At flow rates below the
surge limit the characteristic curve actually drops toward zero flow after
having reached its maximum point at the surge limit.
Surging usually creates a clearly audible noise. Prolonged operation in
this unstable mode can cause serious mechanical damage to the
compressor.
A compressor can be brought out of surge in a number of ways.
✓The most obvious is to increase flow by using Antisurge Valves.
✓Decreasing discharge pressure and/or increasing speed are other
ways to move out of a surge condition.

Compressor manufacturers usually perform an aerodynamic

performance
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test before delivering the compressor. Determination56of the
compressor’s actual surge limit is a very important aspect of the
manufacturer’s shop testing program.
 SURGE
It is an “axisymmetric” phenomenon that causes periodic variations
in mass flow rate and pressure rise. Deep surge can create a
reversed flow in the entire compression system.

Mean Peak
Limit Cycle Pressure Performance
Pressure Operating Oscillations Rise
Rise Point

Flow Flow
Rate Rate
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Mild Surge Deep Surge

Stonewall (choke)
The stonewall limit of the performance curve defines the flow at
which the gas velocity at one of the impellers approaches the
velocity of sound for the gas at the conditions within the compressor
where this sonic condition is first encountered.
At the stonewall (or choke) flow the pressure vs. volume curve
becomes essentially vertical, and it is not possible to develop head or
pressure at any greater flow. When the required operating flow
exceeds the stonewall limit, the only remedy is to reconfigure the
compressor with impellers (For centrifugal compressor) designed for
larger flow rates.

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 ROTATING STALL
Rotating Stall is a local separation pattern that rotates at a
fraction of the spool RPM

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 STRATEGIES FOR COMPRESSOR CONTROL

Guide
Bleed
Vanes
Valves
Bleed Air
Controller Unit

Pressure
Sensors
Air
Injection Steady
Blowing

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Walls
 RELIEF VALVE
• USED TO CONTROL OR LIMIT THE PRESSURE IN A SYSTEM OR VESSEL
• THE PRESSURE IS RELIEVED BY ALLOWING THE PRESSURIZED FLUID
TO FLOW FROM AN AUXILIARY PASSAGE OUT OF THE SYSTEM
• DESIGNED OR SET TO OPEN AT A PREDETERMINED SET PRESSURE

Margin pressure for relief valves:

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 AIR COMPRESSOR MAINTENANCE
• DRAIN THE WATER OUT OF THE STORAGE TANK DAILY BY
OPENING THE DRAIN VALVE IN THE BOTTOM OF THE TANK.
ALSO DRAIN THE WATER OUT OF THE LINE DAILY.

• CHECK THE OIL LEVEL IN THE AUTOMATIC LUBRICATOR WEEKLY.

• THE BELTS NEED TO BE CHECKED ON A MONTHLY BASIS, AND

REPLACED AS NEEDED.

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How to Select a Particular
Type of Compressor ?

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 ADVANTAGES AND DISADVANTAGES OF
DIFFERENT TYPE COMPRESSORS
Compressor Advantages Disadvantages
Type
Centrifugal •Wide operating range •Instability at reduced flow
•High reliability •Sensitive to gas composition
•Low Maintenance change
Axial •High Capacity for given size •Low Compression ratios
•High efficiency •Limited turndown
•Heavy duty
•Low maintenance

Reciprocating •Wide pressure ratios •Heavy foundation required

•High efficiency •Flow pulsation
•High maintenance

Screw
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•Wide application •Expensive 64
•High efficiency •Unsuitable for corrosive or
•High pressure ratio dirty gases
OPERATING REGIONS OF VARIOUS COMPRESSORS

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 Operating conditions of various compressors

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 Selection Considerations
Economics
a. Life-cycle cost
b. User and vendor capabilities and facilities for maintaining
equipment
c. Expected equipment reliability

Safety
a. Limiting gas properties (e.g., decomposition, flammability,
toxicity).
b. Compatibility of process gas with materials of construction
c. Over-pressure protection

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Selecting the proper compressor
Knowledge of the gas, required capacity, suction pressure, suction
temperature, and discharge pressure will enable the proper compressor to
be sized. The basics steps involved are:

1. Calculate the compression ratio.

2. Choose between a single-stage or multi-stage compressor.
3. Calculate the discharge temperature.
4. Determine the volumetric efficiency.
5. Determine the required piston displacement.
6. Select the compressor model.
7. Determine minimum RPM required for selected compressor.
8. Select an actual RPM.
9. Calculate the actual piston displacement.
10. Calculate the power required.
11. Identify prime mover.
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12. Select appropriate options.
Factors for Compressor Selection

The most influential factors to be considered in the selection are:

1. Duty cycle
2. Flow rate
3. Type of gas
4. Pressure ratio
5. Temperature limits
6. Head
7. Power consumption
8. Sealing method
9. Lubrication method
10. Control system and safety protection
11. Maintenance facility
12. Expected equipment reliability
13. Costs
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 Selecting a Compressor
❖Understand the Application: What is the purpose.
❖Find Out the Details of requirements such as Gas,
pressures, temperatures, etc.
❖Determine the consumption rate.
❖Identify the size: available space where to be installed
❖Determine Compressor Type.
❖Determine compressor horse power.
❖Identify prime mover type and power.
❖Determine accumulator capacity.
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❖Select control system and accessories.