Module 2.
Rotary Compressors
Centrifugal compressor: Velocity diagrams, work input, Efficiency, Effect
of blade shape, Slip factor, Types of casings, Impeller and diffuser system
and design aspects
Axial flow compressors: Velocity triangles and calculation of work input and
efficiency
Losses in Compressors: Choking, Surging and Stalling
Compressor:
In the previous chapter, we have discussed the reciprocating
compressors, in which the pressure of the air is increased in its cylinder
with the help of a moving piston. But in a rotary air compressor, the air is
entrapped between two sets of engaging surface and the pressure of air
is increased by squeezing action or back flow of the air.
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Comparison of Reciprocating and Rotary Air Compressors
No. Reciprocating air compressors Rotary air compressors
1. The maximum delivery pressure may be as The maximum delivery pressure is 10 bar
high as 1000 bar. only.
2. The maximum free air discharge is about The maximum free air discharge is as high
300 m3/min. as 3000 m3/min.
3. They are suitable for low discharge of air at They are suitable for large discharge of air
very high pressure. at low pressure.
4. The speed of air compressor is low. The speed of air compressor is high.
5. The air supply is intermittent. The air supply is continuous.
6. The size of air compressor is large for the The size of air compressor is small for the
given discharge. same discharge.
7. The balancing is a major problem. There is no balancing problem.
8. The lubricating system is complicated. The lubricating system is simple.
9. The air delivered is less clean, as it comes The air delivered is more clean, as it does
in contact with the lubricating oil. not come in contact with the lubricating oil.
10. Isothermal efficiency is used for all sons of Isentropic efficiency is used for all sorts of
calculations. calculations.
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TYPES OF ROTARY AIR COMPRESSORS
Though there are many types of rotary air compressors, yet the following are
important from the subject point of view :
Roots blower compressor;
Vane blower compressor;
Centrifugal blower compressor and
Axial flow compressor.
The first two compressors are popularly known as positive displacement
compressors, whereas the last two as non-positive displacement.
Note:
The positive displacement compressors (i.e. roots blower and vane blower) are not very
popular from the practical point of view.
However, they have some academic importance.
The only important rotary compressor is the centrifugal blower compressor.
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Centrifugal Compressor
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Static and Total Heads
The velocities encountered in centrifugal Assuming no external heat and work transfer.-
compressors are very large compared with to the system, SFEE for one kg of air flow.
the air velocity in reciprocating compressors V
2
V
2
and therefore total head quantities should be u p v 1 u p v 2
taken into account in the analysis used for 1 1 s1 2 2 2 s2 2
centrifugal compressors. 2 2
The total head quantities take into account V V
the kinetic energy of the air passing through h 1 h 2
1 2 2 2
the compressor.
Consider a horizontal passage of varying V
2
V
2
area as shown in Fig. through which air is C T 1 C T 2
p 1 2 p 2 2
flowing.
2
V
C T Cons tan t
p 2
Temperature 'T’ is called the static
temperature or the temperature of the air
measured by the thermometer when the
thermometer is moving at the air velocity.
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Static and Total Heads (contd…)
If the moving air is brought to rest under V2
reversible adiabatic conditions, the total T0 T
kinetic energy of the air is converted into heat 2C p
energy, increasing the temperature and
2
pressure of the, air. V
h h
0 2
This temperature and pressure of the air is
known as "stagnation" or "total head" For finding the total head pressure,
temperature and pressure. apply the equation
The total head temperature and pressure are
p T0 1
denoted by a suffix notation '0'. 0
p T
V2
CpT CpT0 Where p and T are static pressure
2 and temperature and p0 and T0 are
where To is known as total head or total head or stagnation pressure and
stagnation temperature. temperature.
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Velocity Diagrams and Theory Of Operation of
Centrifugal Compressors
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025
Work done by Impeller
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025
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025
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Work done by Impeller (Contd…)
Assuming the heat transfer during the flow of
air through the impeller is zero
and considering the steady flow at the inlet and
outlet of the impeller
V12 V22
h1 W h2
2 2
---3
Where Rp0 is the pressure ratio based
on stagnation pressures.
In most practical problems, V1 = V2 then
equations (2) and (3) are reduced to
---2
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Work done by Impeller (Contd…)
Now from the equations 20.64 and 3 Thus the power input to the compressor
as per the equation 3 depends upon the
following factors :
Mass flow of air through the
compressor.
Total temperature at the inlet of the
compressor.
Total pressure ratio of the compressor
which depends upon the square of the
impeller tip velocity.
If Cbl1 = Cbl2 In the above analysis, p01, p02, T01 and T02
are head pressures and temperatures at
the inlet and outlet of the impeller and p1,
p2, T1 and T2 are the static pressures and
temperatures at the inlet and outlet of the
compressor.
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P01 = Stagnation pressure at inlet of the compressor
T01 = Stagnation temperature at inlet of the compressor
P02 = Stagnation pressure at outlet of the compressor
T02 = Stagnation temperature at outlet of the compressor
P1 = Static pressure at inlet
T1 = Static temperature at inlet
P2 = Static pressure at outlet
T2 = Static temperature at outlet
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•Width of Blades of Impeller and Diffuser
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Width of Blades of Impeller and Diffuser
The height or width of the blades at inlet of the impeller, outlet of the impeller and
outlet of the diffuser are calculated considering the constant mass flow through the
system.
Where; Ri = Radius of impeller at inlet ; vsi = Specific volume of air at inlet
n = Number of blades on impeller ; t = Thickness of the blade
bi = Width or height of the blade
Similarly for the outlet condition of impeller
Suffix '0' represents the quantities at the outlet of impeller. The width or height of the
impeller blades at the outlet and height of diffuser blade at the inlet should be same
theoretically. The width or height of the diffuser blades at the outlet, is given by
where suffix 'd' represents the
quantities at the outlet of diffuser.
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Losses and Isentropic Efficiency of the
Compressor
Some of internal losses during the flow of air
through the impeller are.
Friction between the air layers moving with
relative velocities and friction between the air
and flow passages.
Turbulence caused in the air, and
Shock at entry.
The actual work required for the same
increase in pressure ratio is more due to
these irreversibility's. The actual and
isentropic compression for the same pressure
ratio is shown in Fig
If Cbl1 = Cbl2, then
provided specific heat at constant
pressure remains constant.
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Slip Factor and Pressure Coefficient
In the analysis, it has been assumed that
Vw2 = Cbl2 but this condition is not satisfied The actual work done per kg of air as
in actual practice due to secondary flow per equation (5) is given by
effects and therefore in actual compressors
Vw2 < (Cbl2 = U2).
---6
The difference (Cbl2 – Vw2) is known as
slip. The actual work done per kg of air by the
Slip factor is defined as the ratio of actual
whirl component to ideal whirl component compressor is always greater than U2Vw2
and it is denoted by s
due to fluid friction and windage losses,
---4 therefore the actual work is obtained by
The total head pressure ratio is given by
multiplying U2Vw2 by a factor known as
---5 work factor or power input factor w
Cp T02 T01 wU 2Vw 2 ---A
Substituting the value of
from isentropic
T02 T1
efficiency
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wU 2Vw 2
T02 T01 ---7
Cp
Substitute eq. 7 in eq. 6
•Substitute the value cw2 from eq. 4
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Using eq.4 and assuming the vanes of the impeller are radial and counter flow of
fluid is neglected.
Using eq.A
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Compressor Characteristics - Surging and Choking
In the compressor where the flow is
against the pressure gradient the
incidence loss due to incorrect fluid angles
relative to the blades becomes more
important and pressure ratio (Vp) falls
sharply at conditions away from the design
point.
This loss, added to the friction loss which
will increase with increase of mass flow
rate, gives a pressure ratio-mass flow rate
relation as shown in Fig.
At point N, the compressor is choked and
is passing the maximum mass flow
rate.
A fall in mass flow rate will be accompanied
by a fall in pressure ratio. In this situation any
On the section MN of the curve the flow is
small disturbance causing a check in, mass
stable. On the section LM of the curve, flow will cause a fall in pressure ratio and the
the flow is not stable. flow may reverse at some point.
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Compressor Characteristics - Surging and Choking (Contd…)
When the temporary disturbance is
removed, the flow will pick up and it is
found that small disturbances cause the
flow to oscillate rapidly.
The oscillation is noisy and can, cause
structural damage in the compressor and
is called 'surge' and the point M on the
curve marks the limit of useful operation
of the compressor.
If a compressor is running normally at the
point where surge usually commences it It is found that compressor efficiency
is possible to induce surge merely by is highest at point adjacent to M
passing the hand across the inlet. and it is therefore advisable to able to
operate as close to M as possible.
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•Stallin
g
It is the break away of the flow from suction
side of the blade aerofoil .
It may be due to lesser flow rate than the
designed value or non uniformity in the
blade profile or angle of attack is not
proper.
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•Axial Flow Compressors
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Velocity Diagrams for Axial Flow Air Compressors
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Comparison
Sr. Centrifugal Compressor Axial Flow Air
No Compressors
1 Flow of air is perpendicular to the axis Flow of air is parallel to the
of compressor axis of compressor
2 It has a low manufacturing and It has a high manufacturing
running cost and running cost
3 It requires low starting torque It requires high starting
torque
4 It is not suitable for multi staging It is suitable for multi staging
5 It requires large frontal area for given It requires lesser frontal area
rate of flow for given rate of flow. Due
this it is suitable for air crafts
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