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All About Compressors

Instrumentation Engineering for Compressors

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100% found this document useful (1 vote)
171 views26 pages

All About Compressors

Instrumentation Engineering for Compressors

Uploaded by

Bulex Extensiom
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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In the refrigeration cycle, you must have seen the use of compressors

in it. It is a must in achieving refrigeration, without which cooling


cannot be achieved.

Auto Manual Water Pump Control - PLC Examples for Beginners


18:17

1.
Energize to Safe State - Emergency Shutdown System - Safety PLC
Basics
8:34
Play Video

Compressors come under various types and categories. It is important


to understand them, which helps in choosing the best one for your
refrigeration application.

In this article, we will learn what is a compressor and the types of


compressors used in HVAC.

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.

So, a compressor is used for this, which is a mechanical device which


increases the pressure of gas or air by reducing its volume. It is the
most important stage of the HVAC cycle. The compressor has a
suction and discharge side, similar to a pump, which gets low-pressure
input on the suction side and pumps a high-pressure output on the
discharge side.

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.

• Single-acting Reciprocating Compressor,

• Double-acting Reciprocating Compressor,


• Rotary Lobe Compressor,
• Rotary Screw Compressor,
• Rotary Vane Compressor,
• Scroll Compressor,
• Centrifugal Compressor
Positive Displacement – Reciprocating – Single
Acting
A single-acting reciprocating compressor, as the name implies, works
on the principle of a single stroke. It has a piston in it. The piston when
driven from the first stroke, sucks the air or gas inside the compressor.

When the piston is driven again by a second stroke, then the


compression happens. The cycle then repeats with the first stroke
letting the air or gas inside and the second stroke doing compression
activity.

Positive Displacement – Reciprocating –


Double Acting
A double-acting reciprocating compressor, as the name implies, works
on the principle of a double stroke.

In a single-acting one where the media was compressed in only one


stroke, the media here is compressed in both strokes; thus increasing
the capacity of refrigeration.

Positive Displacement – Rotary – Lobe


A rotary lobe compressor has two rotors mounted on a parallel shaft.
There are generally two types of lobes – two and three. In a twin-lobe
compressor, each rotor has two lobes (four lobes per compressor). In a
tri-lobe machine, each rotor has three lobes (six lobes per
compressor).
Now, imagine you have two rotors rotating in opposite directions with
each other. Because both are moving in different directions, the lobes
in each rotor are then able to trap the media every time and pass it on
as it rotates.

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.

Positive Displacement – Rotary – Screw


The rotary screw compressor is the most widely used type of
compressor. It is an extension of the lobe type of compressor. The
lobes are in the shape of a screw piston. This screw piston opens or
closes a sliding valve.

Based on the opening or closing of the valve, the media will be


compressed or decompressed. As the screw control can be done with
accurate high or low speeds, you have more control in this type for
refrigerating the media.

Positive Displacement – Rotary – Vane


Imagine a circle with 10 blades inside it, housed in a circular fashion.
The centre of the blades is not the exact midpoint of the circle but is
placed more at a left-side angle. These blades are called here as vanes.

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.

Positive Displacement – Rotary – Scroll


In the scroll compressor, you have two spiral-shaped pistons. One
spiral scroll is fixed in position and the other spiral scroll rotates in
conjunction with it.

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.

As the name implies, a centrifugal compressor increases the flow and


pressure of a media by applying centrifugal force to it. They increase
the pressure by adding kinetic energy to the media as it flows through
an impeller. The impeller rotates at such a high speed, that the
pressure discharged from the outlet is very high.

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In this article, we will learn the instrumentation engineer duties during
a compressor shutdown job of a plant.
Play Video

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:

1. Control valves and their accessories


2. Differential Pressure type flow meters
3. Pressure transmitters
4. Temperature transmitters and RTD/thermocouple
5. Level Transmitter
6. Vibration probes
7. Pressure gauges
8. Temperature gauges
9. Pressure switches
10. Flow switches
11. Level switches
12. Controller: PLC and its cards
Now let us discuss what jobs can be done during the shutdown on all
the above-mentioned instruments

Control Valves and their Accessories


Two types of control valves are used in a centrifugal air compressor.
One is Inlet Guide Vane (IGV) and the other is a Blow-Off Valve or
Anti-Surge Valve.

So, we should do the stroke checking of both control valves. If


any issue is found in the control valve during the stroke-checking
activity, then we can go for calibration of the control valves.

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.

Replace the pressure gauges if needed. If any Solenoid Valve is


present on the control valve, check the solenoid valve as per the
standard procedure.

If any other valve accessory is present, then check the same. If a


volume tank is present, then check the PSV of the volume tank.

The calibration of the PSV is very important. Make sure that the PSV is
calibrated.

Differential Pressure type Flow Meters


Differential pressure type flow meters are installed in the compressor
to measure the flow of the gas as well as one of the most important
parameters i.e. flow of the cooling water. Hence, during every
opportunity, the differential pressure type flow meters should be
calibrated.

Also, whenever cooling water is isolated and again normalized there


will be air trapped in the DP-type flow meter’s tubing. Hence, after
normalization of the cooling water circuit, the DP-type flow meter of
the cooling water should be flushed.

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.

Temperature Transmitters and


RTD/Thermocouple Sensors
Temperature transmitters are installed for suction gas, intercooler
inlet, intercooler outlet, and discharge gas temperature measurement.
The values of suction gas temperature and/or discharge gas
temperature are taken for calculation of the Surge value.

The response of the RTD/thermocouple as well as the temperature


transmitter should be checked. One important thing to note here is to
carry out the inspection as well as the hydro test of the thermowell
used for the RTD/thermocouple.

In most cases, thermowells are neglected.

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.

Calibration of the pressure gauges is necessary because, during


emergency conditions like a blackout, pressure gauges can be used to
know the pressure in the system or the line 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.

Due to increased temperature, the volume of the gas also increases,


and hence more energy is needed to compress the gas.

Hence intercoolers are given which have a cooling water flow to


reduce the temperature of the gas. When the flow is healthy, the
contact should be closed.

Level Switches
Level switches are required to monitor the amount of water in case of
an air compressor in the intercooler.

If there is a high level of condensation in the intercooler then the


compressor should trip. Here also, when the level switch is healthy, the
contact should be closed.

A Controller like PLC and its cards


All connection tightening, panel cleaning jobs, and power supply
checking in the PLC panel should be done during the shutdown of the
compressor.

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.

Compressors are installed in every industry. Without compressors, an


industry cannot run because Instrument Air, Nitrogen, and Plant Air
are obtained from Air Compressors only. In other gas plants
also, compressors play a very important role in increasing the pressure
of gases.

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

Centrifugal Compressor Start Permissive


Important Start Permissive in Centrifugal Compressor:

1) Most important permissive for starting the compressor is the seal


gas pressure permissive. A minimum seal gas pressure is required for
starting the lube oil system.
2) Lube oil supply pressure to the gearbox should be greater than
some defined pressure. For this auxiliary lube oil pumps (AOP) are
running in auto mode to keep this pressure steady.

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.

3) Lube oil supply temperature to gearbox should be maintained in


the defined range. Example temperature should be above 30 degrees
centigrade and below 65 degrees Centigrade.

3) No trip signal from Machine Condition Monitoring System (MCMS).


Generally, a contact is taken from the MCMS system for tripping the
compressor on high vibration or high temperature of the motor
winding. All should be healthy.

4) Inlet Guide Vane (IGV) should have a minimum opening (usually


3%-5% open) and Anti surge valve (ASV)/ Blow Off Valve (BOV) should
be fully open

5) We can give a limited number of start commands to the main motor


in a fixed time interval.

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.

6) Low suction pressure also won’t allow the Compressor to start in


case of a booster Compressor like HP Air Compressor.

7) Inter-cooler and after-cooler levels should not be high

Centrifugal Compressor Interlocks


Important Interlocks in Centrifugal Compressor

1) Tripping on low seal gas pressure

2) Tripping on high vibration

3) Tripping on low lube oil pressure


4) Tripping on high lube oil temperature

5) Compressor unload on high motor current

6) On high discharge pressure, IGV starts closing. If still high, discharge


pressure doesn’t come down, then ASV/BOV starts opening.

7) Tripping on low suction pressure

8) Tripping on individual stage inlet temperature high

9) Tripping on high condensate level in inter cooler and after cooler.


A level switch is installed in the inter-coolers and after-coolers.

10) Tripping due to surging (surging is calculated typically using


parameters like pressure, temperature, and flow. Sometimes motor
current is also taken for calculating the surging)
Turbine and Compressor Control System
Turbine and Compressor Control System comprises of Electronic
Governor Control System for Steam Turbine and Anti-surge Control
System for Air compressor, Lubrication Oil Control System, Hot well,
Seal oil control, Over Speed protection System and Vibration
Monitoring System.

Table of Contents
• Turbine and Compressor Control System
• Vibration Monitoring System
1. Level Measurement using DP Transmi...
Pause

Play Video

Turbine and Compressor Control System


In a steam turbine, we need to maintain its speed constant during the
normal operation against the continuous load change.

To achieve this, the system is designed to control the Pneumatic


Control valve to control the speed over the full operational range from
barring speed to over speed trip point and control of load around the
rated speed after synchronizing.

The system also provides control on Surge of Compressor operations.


Anti-surge protection does open a quick Exhaust Anti-surge
Valve within a maximum of 500 msec.

The steam turbine is equipped with an electro-pneumatic speed


governing system capable of controlling and regulating the speed of
the steam turbine in conformity with performance Characteristics
specified. It is included necessary speed, load, pressure, frequency
controllers, steam valve operating device, etc.

The control system is microprocessor-based, protected against cyber


security by suitable antivirus or firewall application, dual redundant is
considered at all applicable levels as a minimum to ensure system
availability and reliability.

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.

In a redundant communication system, on the failure of the device or


component, the redundant device shall take over automatically
without interrupting the system operation.
In redundancy systems, we can do a manual switchover between the
main system and standby system without disturbing the plant
operations.

The system has capabilities to perform the calibration


of governor control when a machine is under Shutdown. It is possible
to adjust minimum & maximum stops and to manually stroke the
Output of the actuator and valves from 0 to 100%.

During normal operation it is possible to view and adjust the following


parameters to run the turbine:

• Turbine shutdown mode


• Turbine Ready to Start

• Turbine Startup
• Acceleration

• Run mode

• Over speed trip & test

The controller automatically adjusts the energy entering into the


steam turbine in order to prevent its speed and output from
fluctuating continuously even in case of a change in load condition.

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.

On detection of the surge, the anti-surge valve must immediately


open by a fixed amount above the current position demand.

The surge cycles must be broken during surge detection irrespective


of the method used for surge detection or irrespective of the pattern
of surge detected.
During the closing phase of the Surge Recovery response, the anti-
surge valve should not be allowed to close back more than its position
at the surge event to prevent reentering the surge zone (repeated
surge).

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.

If enabled, the anti-surge valve can be set to a fully open position if a


consecutive surge alarm is detected. In the event of compressor
suction pressure falling too low, the antisurge controller shall limit the
minimum suction pressure by adjusting the opening of the anti-surge
valve.

The minimum suction pressure value shall be a preset value. In the


event of compressor discharge pressure rising too high, the antisurge
controller shall limit the maximum discharge pressure by adjusting the
opening of the anti-surge valve. The maximum suction pressure value
shall be a preset value.

Vibration Monitoring System


The Machine Vibration Monitoring System also provides a critical
analysis of the health of rotating machines and by using this data the
plant maintenance personnel shall identify incipient problems to take
care of predictive maintenance of the turbines and compressor.

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.

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Working of Air Compressor – Types
– Control Techniques
In this post, we will learn the working of the air compressor, types of
compressors, and their different control techniques used in industries.
Play

An air compressor is a mechanical device that is used to compress the


incoming air and provide a fast speed and compressed air on the
outgoing side. They are widely used in almost every industry.

Because the volume of air is decreased and the pressure/speed of air


is increased, they can be used to fill the air in small objects or supply
air power to any mechanical equipment. They can be used to fill tires
or used for powering devices like drills, nail guns, grinders, spray guns,
sanders, staplers, etc.

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

A typical air compressor consists of a motor, an inlet, and outlet


valve to intake and discharge air, a pump to compress the air, and a
storage tank.

The air is forced into a tank. Then, mechanical equipment driven by


a motor reduces the volume of air by pressing it. When the pressure of
air has reached a high value, the compressor is turned off
automatically.

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 –

1. positive displacement and


2. dynamic displacement.
Positive Displacement Compressors
Positive displacement is a method of forcing air in a chamber where
the volume is decreased to increase the pressure.

Positive displacement has various methods to compress the air.

The most used ones are –

• rotary screw,
• rotary vane and

• piston type.

The difference between all these techniques is just the equipment that
decreases the volume of air.

Rotary screw uses two internal screws that rotate in opposite


directions to trap and pressurize the air between them.

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.

https://youtu.be/KYedgjOIDxY
Dynamic Displacement Compressors
Dynamic displacement is a method of applying kinetic or centrifugal
energy to the air. This increases the pressure of the air.

The centrifugal force is generated by a rotary blade or impeller


powered by an engine. When a high centrifugal force is implied upon
the air, its pressure is increased.

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.

Modern Air Compressors


Modern air compressors come with various new techniques due to
advance in industrial automation in recent times. The below
mentioned different techniques.

Loading and Unloading Technique

The loading and unloading technique which automatically controls the


on-off of valves according to demand.

Modulation Technique

The modulation technique for adjusting the opening and closing of


the valve in an analog way.
Variable Speed Technique

The variable speed technique for adjusting the speed of the motor. All
these methods give a more flexible control in pressurizing the air.

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