mr s k deshmukh
TRANSCRIPT
-
7/28/2019 Mr S K Deshmukh
1/14
1KIRLOSKAR PNEUMATIC CO. LTD.
Presentation on,
DEVELOPMENTS IN RECIPROCATINGCOMPRESSOR
S. K. Deshmukh
DGM-ACD (R & E)
9/12/2008
2KIRLOSKAR PNEUMATIC CO. LTD.
Back Ground
1940s Low speed 180 rpm, f irst generation of reciprocating
compressors developed
In last 10 y ears, predictions were made that Recip will be tapered
down.
However, Recip compressors hav e ov ercome the past concerns ofcertain weaknesses through technological advancements.
It is a f av ored selection by all industries General purpose, Power, Oil,
Gas, Petrochemical and Air separation etc.
It can handle v irtually all gases and do compression from v acuum to
3500 bar (Hy per compressor f or LDPE ethy lene) with power rating up
to 30 MW of single compressor.
-
7/28/2019 Mr S K Deshmukh
2/14
3KIRLOSKAR PNEUMATIC CO. LTD.
Reciprocating Compressor Advancements
(Latest Design Features)
a) Valve design f or low noise (environment f riendly ) & high energy
eff iciency (low v alv e losses)
b) Piston ring materials Lif e enhancements & low friction
c) Synthetic lubricants Bio degradable - env ironment f riendly.
d) Condition monitoring for health of Compressor web based
e) Digital Pulsation analysis
f) High speed designs
g) Air cooled packages
h) Integrated packages
i) Engine driven direct coupled high speed compressorj) Uncooled cy linder f or gases of lower adi abatic exponents (Jacketless)
4KIRLOSKAR PNEUMATIC CO. LTD.
Reciprocating Compressor Advancements(Latest Design Features)
k) Special Metallurgy compatible f or gases inv olv ed
l) Life enhancements
m) Use of jacket & intercooler / aftercooler heat f or building heating as
low grade heat
n) Compact design (Low weight to capacity ratios energy packed
machines )
o) Env ironmentally f riendly materials f or construction i.e. Asbestos free
p) Use of recy clable materials
q) High pressure engineered compressors
r) Conf ormance to the international standards such as API618, API 11P
etc.
s) Electricals & Instrumentation: Suitable f or specif ied area classif ication
/ Gas group / Temperature Class
t) Integrated Engine Compressor.
-
7/28/2019 Mr S K Deshmukh
3/14
5KIRLOSKAR PNEUMATIC CO. LTD.
Reciprocating Compressor Advancements
(Latest Design Features)u) Env ironmental Awareness : EMS (ISO 14001) & OHSAS 18001- ref lecting in
design specif ications e.g. compliance to Bharat Stage II I (Euro 3),
Residential type silencers, Spark Arrestor (I.S. specif ied)
v ) Saf eties compliance (e.g. API RP-520 / API 526 / API 527), CCOE approv ed
cy linders etc.
w) Use of Computational Fluid Dy namics (CFD), Finite Element Analysis (FEA),
Thermal / Thermody namic Simulation study etc.
x) Use of Energy Eff icient Motors matching with National Electric Manufacturers
Association's (NEMA's) MG1-1993 publicat ion / BIS 12615.
y ) VFD f or v ariable demand cycles and multiple units installations.
z) Silenced versions Canopy f or noise lev el of 75 dB.
6KIRLOSKAR PNEUMATIC CO. LTD.
Compressor suction & Discharge Valves play important role of
heart of Compressor
Important components
a) Valve seats
b) Valve guard
c) Mov ing / sealing element Valve plate , channel etc.
d) Springs / cushion plates
Valve Design Enhancing the Valve Life &Reliability
-
7/28/2019 Mr S K Deshmukh
4/14
7KIRLOSKAR PNEUMATIC CO. LTD.
Valve Design Valve Dynamics
8KIRLOSKAR PNEUMATIC CO. LTD.
Valve Design Enhancing the Valve Life &Reliability
Use of material adv ancements such as PEEK.
Design criterion for optimization (Characteristics of Ideal valv e)
a) The minimum clearance v olume.
b) Low impact v elocity (low lif t).
c) The largest possible f low area & f low coeff icient.
d) Light weight combined with low lif t with quick act ion.
e) Robust construction f or long lif e.
f ) Low price.
-
7/28/2019 Mr S K Deshmukh
5/14
9KIRLOSKAR PNEUMATIC CO. LTD.
Valve Design Enhancing the Valve Life &Reliability
10KIRLOSKAR PNEUMATIC CO. LTD.
Torsional Vibration Analysis
The natural f requencies of torsional v ibration of the idealized complete
drives train system comprising of motor, coupling, and compressor
calculated using Torsional Critical Speed computer program.
The equiv alent mass elastic diagram f or the complete driv es train will be
used in determination of torsional (mechanical) natura l f requencies / critical
speeds where a potential f or resonant behav ior exists.
Interference / Campbell Diagram developed to identify & av oid harmf ul
resonant behav ior f or the operating speed range.
Determination of v ibratory torque & stresses on the components of the
drive t rain to ensure such torque & stresses v ariations are within the saf e
limits of the components with adequate separation margin as per API
Standard 618.
-
7/28/2019 Mr S K Deshmukh
6/14
11KIRLOSKAR PNEUMATIC CO. LTD.
Torsional Vibration Analysis
12KIRLOSKAR PNEUMATIC CO. LTD.
Compressor Design PhilosophyCompressor Design Philosophy
Utilization of s tandards, serv ice proven designs components and with
indiv idual compressor designed to cater to precise needs
Lube oil sy stem, Pulsation dampeners, Saf eties, Instrumentation and
Controls as per API-618 with minor deviations
Gas Cooler designs generally per TEMA R / B and also as per API-660& API-661
Pressure Vessel design as per ASME section-VIII
15 Years of serv ice lif e and 2 Years without a major ov erhaul.
ARM Theme
Av ailability , Reliability & MaintainabilityAv ailability , Reliability & Maintainability
-
7/28/2019 Mr S K Deshmukh
7/14
13KIRLOSKAR PNEUMATIC CO. LTD.
Compressor Packages
A wide range of auxiliary equipment on Process gas compressor
packages includes:
Forced lubrication systems and waterconsoles comply ing with
API -618 standards.
Capacity control systems including suction v alv e unloaders,
v olume clearance pockets (manually or pneumatically operated),
automatic by -pass sys tems and step less capacity control sy stems.
Pulsation dampeners designed to attenuate pressure pulsations in
process pipe work.
Digital and Analogue computer analysis of the acoustic and
mechanical interaction of t he v essels and associated piping sy stems.
Gas intercoolers and aftercoolers of shell and tube, air blast,
plate type or other design.
14KIRLOSKAR PNEUMATIC CO. LTD.
Natural Gas Compressor
-
7/28/2019 Mr S K Deshmukh
8/14
15KIRLOSKAR PNEUMATIC CO. LTD.
Advancements in Pulsation Control Technology
Department of Energy (DOE) and the Gas Machinery Research Council
(GMRC) spo nsored program terme d as the Advanced Reciprocating
Compressor technology (ARCT) program.
Necessity of Advanced Pulsation Control technique due to high speed of
compressor with high horse power requirements.
This design tool leads to
a) Filtering pulsations.
b) Reduced equipment, piping v ibrations & noise.
c) Increased sy stem reliability.
d) Improved compressor eff iciency .
e) Enhancing compressor v alv e lif e. Design approaches 1, 2 or 3 as per API 618 used as per applications
The rapid advancements of digital computer aided Design Systems
enables to analyze the f luid dy namics to predict attenuation
characteristics, pass bands, pulsation lev els, acoustic simulation etc.
Simple solutions giv e substantial power consumption sav ing.
16KIRLOSKAR PNEUMATIC CO. LTD.
Advancements in Pulsation Control Technology
-
7/28/2019 Mr S K Deshmukh
9/14
17KIRLOSKAR PNEUMATIC CO. LTD.
Inertia Balanced with Zero Couple BOPs
Latest Balanced Opposed Compressor v ersions are prov ided with
crankshaf ts with zeroing couple feature wherein crank throws are exactly
aligned thereby eliminating most v ibrations generally associated with
reciprocating ty pe compressors.
Inertia f orces balanced within 1%
Enables use in v ibration sensitiv e application such as off shore platf orms
and trailer mounted units.
Permits the compressor to run at high speed of 1800 rpm
18KIRLOSKAR PNEUMATIC CO. LTD.
Truck Mounted High Pressure ReciprocatingCompressor (200 Bar) - ONGC
-
7/28/2019 Mr S K Deshmukh
10/14
19KIRLOSKAR PNEUMATIC CO. LTD.
CNG Packages
20KIRLOSKAR PNEUMATIC CO. LTD.
Advantages of Natural Gas Driven Air Compressors
Natural gas engine-driven air compressors offer many
potential benefits, inc luding:
Lower cost of producing compressed air
Lower cost for providing steam and hot water for heating or
cooling needs
Lower life-cycle cost
Attractive return on i nvestment
Lower cost of emergency backup power equipment
Secured capability for supplying compressed air during
power disruptions
-
7/28/2019 Mr S K Deshmukh
11/14
21KIRLOSKAR PNEUMATIC CO. LTD.
Focus on Life Enhancement
Fig. Primary causes of unscheduled reciprocating compressor shutdowns
22KIRLOSKAR PNEUMATIC CO. LTD.
From Concept ( 3-D) to Manufacturing (2-D Drawing)
-
7/28/2019 Mr S K Deshmukh
12/14
23KIRLOSKAR PNEUMATIC CO. LTD.
Design optimisation for weight reduction
(Resultant Deformation plot)
24KIRLOSKAR PNEUMATIC CO. LTD.
Effective visualization(Compresso r House )
-
7/28/2019 Mr S K Deshmukh
13/14
25KIRLOSKAR PNEUMATIC CO. LTD.
Energy Efficient Motors
Energy-eff icient motors, also called premium or high- eff iciency motors or
EFF1, are 2 to 8% more eff icient than standard motors.
Motors qualify as "energy-eff icient" if they meet or exceed the efficiency lev els
listed in the National Electric Manuf acturers Association's (NEMA's) MG1-1993
publication.
Energy-eff icient motors generally have longer insulation and bearing lives,
lower heat output, and less v ibration.
In addition, these motors are of ten more tolerant of ov erload conditions andphase imbalance.
This results in low f ailure rates, which has prompted most manufacturers to
off er longer warranties f or their energy-eff icient lines.
26KIRLOSKAR PNEUMATIC CO. LTD.
Energy Efficient Motors
The ef f iciency of a motor sy stem depends on several f actors, including:
a) motor ef f ic iency
b) motor speed control
c ) proper s izing
d) power supply quality
e) distribution losses
f) mechanical transmission
g) maintenance practices
h) end-use mechanical eff iciency (pump, f an, compressor, etc).
The non-energy benefits of higher eff iciency sy stems are better process
control, reduced disruption and improved product quality .
Energy-eff icient motors should be considered for all new installations,
replaceme nt of failed motors, or as spares.
-
7/28/2019 Mr S K Deshmukh
14/14
27KIRLOSKAR PNEUMATIC CO. LTD.
VFD
VFD- VARIABLE SPEED DRIVE
The synchronous speed of an inducti on motor is d etermi ned by the following equation.
N s = 120 f / p ( rpm)
The only way to chang e th e speed, for a gi ven pole numb er is to vary th e freque ncy
VFD B ASIC PRINCIPLE -
The process of transfor mi ng the stable power line frequency i nto a variabl e
frequency i s basi cally done in two steps:
1. The sinusoi dal voltag e is rectifi ed into an DC voltage.
2. The DC vol tag e is chopped up to an DC vol tag e of the desired fr equency
VFD- VARIABLE SPEED DRIVE
By Providing VFD in compressor control we can vary th e C ompr essor R PM depending
on req uirement. This c ompl etely avoids unloading and saves unl oad powerconsumption which is n or mall y 25- 35% of the full l oad consumpti on.
Major advantage of variable speed drive is that i f 4 to 5 c ompr essor are connected
to a commo n header, then by i nstalling VFD in on e compressor, th e energ y savi ng due
to pr essure reduction is achieved i n all the compressor.