All About Compressors
All About Compressors
1.
Energize to Safe State - Emergency Shutdown System - Safety PLC
Basics
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Table of Contents
• What is a Compressor?
• Types of Compressors
• Positive Displacement – Reciprocating – Single Acting
• Positive Displacement – Reciprocating – Double Acting
• Positive Displacement – Rotary – Lobe
• Positive Displacement – Rotary – Screw
• Positive Displacement – Rotary – Vane
• Positive Displacement – Rotary – Scroll
• Dynamic – Centrifugal
What is a Compressor?
Whenever you want to transmit air or gas with high pressure, then you
will need a device to do it. Because, if the pressure is low, then it will
not be able to achieve proper results.
This output of the discharge side will have a very high temperature.
Then, the refrigeration cycle which follows afterwards reduces the
temperature of liquid or air and also reduces its pressure. After that,
the cycle repeats.
Types of Compressors
Some of the basic types of compressors are mentioned below.
As each rotor passes the blower inlet, it traps a definite volume of gas
(the ‘displaced volume’) and carries it around the case to the blower
outlet. As each rotor passes the blower outlet the gas is compressed
to the system pressure there and expelled.
As the vane rotates, the media enters the highly-volume area and
moves out from a low-volume area; thus compressing it. Each blade
has a spring in it which rotates in conjunction with the outer circle; and
as the centre is not the exact midpoint, it provides a flexible volume
area from high to low.
When the variable scroll starts to rotate around the fixed scroll, the
area starts to decrease from inlet to outlet. This increases the pressure
on the media.
Dynamic – Centrifugal
Unlike positive displacement ones, which depend on the mechanical
working to impact the media pressure, dynamic ones directly impact
the media.
Before proceeding further, let us see all the instruments used for the
safety of the centrifugal compressor or the controlling/operation of
the centrifugal-type compressor.
Table of Contents
• Compressor Shutdown Job
• Control Valves and their Accessories
• Differential Pressure type Flow Meters
• Pressure Transmitters
• Temperature Transmitters and RTD/Thermocouple Sensors
• Level Transmitter
• Vibration Probes
• Pressure Gauges
• Temperature Gauges
• Pressure Switches
• Flow Switches
• Level Switches
• A Controller like PLC and its cards
Compressor Shutdown Job
The following instruments are installed in a centrifugal compressor:
Here one important thing to note is that the Blow-Off Valve or Anti-
Surge Valve is an equal percentage type of valve characteristics in
many compressors.
So, refer to any standard document before doing the job on Blow-Off
Valve or Anti-Surge Valve. Check the physical condition of the Air Filter
Regulator. Replace if necessary.
The calibration of the PSV is very important. Make sure that the PSV is
calibrated.
The flow of the gas is also used for calculating the Surge value. This
Surge value is used in Surge Control System for the protection of the
compressor. Inspect the orifice plate if any opportunity is available.
Pressure Transmitters
Pressure transmitters are used to know the pressure of suction,
individual stage pressure as well as discharge pressure.
The values of the pressure are also used for calculating the surge
value. Check the response of the pressure transmitters and do
calibration if needed.
Level Transmitter
Level transmitters are used for measuring the level of lube oil in the
lube oil reservoir.
Generally, differential pressure level transmitters are used for the lube
oil reservoir level measurement. Calibration of the level transmitter
should be done after proper isolation of the lube oil system.
Vibration Probes
Characteristic checking, resistance checking, and response checking of
the vibration monitoring system should be done in every shutdown.
Pressure Gauges
Pressure gauges are used for viewing the pressure of the lines on
which they are installed.
Temperature Gauges
Temperature gauges also function like pressure gauges. Hence
calibration of the temperature gauge is also necessary.
Pressure Switches
Pressure switches are installed in seal gas pressure or some other
important pressure parameter on which the compressor should
immediately trip.
Ensure that the contact used for the pressure switch remains closed
when the pressure is healthy.
Flow Switches
Flow switches are installed in the cooling water flow line. Cooling
water is one of the most important factors while the compressor is
running. Because during the compression of the gas, the temperature
of the gas increases.
Level Switches
Level switches are required to monitor the amount of water in case of
an air compressor in the intercooler.
Also, Cause & Effect checking and Interlock checking should be done
during the shutdown of a plant.
Centrifugal Compressor Start
Permissive and Interlocks
by Editorial Staff
Today in this article, you will learn about the centrifugal compressor
start permissive and interlocks used in the DCS and PLC automation
systems.
A compressor has a lube oil system for proper control and lubrication
of the gearbox and bearings. A seal gas system is used to provide
isolation between the process gas to be compressed and the oil
system.
Table of Contents
• Centrifugal Compressor Start Permissive
• Centrifugal Compressor Interlocks
Two lube oil pumps are present in any lube oil system of a centrifugal
compressor. If one pump cannot build sufficient pressure, then the
other pump starts automatically.
When the compressor is running, the main oil pump (MOP) runs which
is engaged with the gearbox. This pump maintains the lube oil
pressure. When the compressor is running, the auxiliary oil pumps will
be stopped automatically after some time delay.
For example, Say we have given the start command to the main motor,
and due to some problem the main motor got tripped immediately.
Now you can give second start command after some time delay only.
This time delay is maybe 5 minutes, 15 minutes, 30 minutes, 60
minutes, etc. The time delay will depend on your motor parameters or
as per your control philosophy. This is for the protection of the motor.
Table of Contents
• Turbine and Compressor Control System
• Vibration Monitoring System
1. Level Measurement using DP Transmi...
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The system has the facility to indicate the status of redundancy and
switch over messages from dual to single mode. It must be possible to
interface this status to DCS via a soft link. It has the facility to generate
the “First Out” alarm in the case where a group of parameters is likely
to trip the system.
• Turbine Startup
• Acceleration
• Run mode
Governor and steam control valve unit shall not increase the turbine
speed to the turbine tripping speed even if the rated output is thrown
off instantaneously.
Once process conditions are stabilized the operator can reset and the
valve will close normally until either the surge control line is reached
or fully closed. It shall be possible to initiate an alarm or a shutdown
based on the number of detected surges within configured time.
For example, Bentley Nevada Make Series 3500. The machine vibration
monitoring system shall consist of vibration sensors, transducer,
special cables, junction boxes; Microprocessor-based vibration
monitoring system (Power supply, input card, interface card, cables,
relay board, Key-phasor module, etc.) cabinets, etc. together with all
necessary equipment and accessories.
Thus, the above-mentioned things are essential for the operation and
maintenance of the turbine and compressor control system.
It uses the basic objective of reducing the volume of air to increase its
pressure. This pressurized air is then used for various applications.
Table of Contents
• Air Compressor
• Types of Air Compressors
• Positive Displacement Compressors
• Dynamic Displacement Compressors
• Modern Air Compressors
Air Compressor
Example Image
Due to this, highly compressed air is stored in the tank. When the
demand comes, the pressurized air is then passed through outlet
valves, which can then be used for various applications. When the
pressure decreases again, the compressor starts again and begins to
pressurize the incoming air again.
Types of Air Compressors
Basically, air compression is achieved by two methods –
• rotary screw,
• rotary vane and
• piston type.
The difference between all these techniques is just the equipment that
decreases the volume of air.
Rotary vanes have adjustable rotary arms fitted in the motor. Due to
adjustable arms, as the air passes between them, the volume of air
starts to decrease as it gets trapped and thus increasing the pressure.
The piston is an up-down motion type of equipment that traps the air
as it moves upwards and starts increasing the pressure.
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Dynamic Displacement Compressors
Dynamic displacement is a method of applying kinetic or centrifugal
energy to the air. This increases the pressure of the air.
So, basically, the difference between both these methods is that the
first one decreases volume while the second one impacts kinetic or
centrifugal energy on the air. The end result is the same – an increase
in pressure.
Modulation Technique
The variable speed technique for adjusting the speed of the motor. All
these methods give a more flexible control in pressurizing the air.