# RECIPROCATING COMPRESSOR CALCULATION SHEET

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1 Gas properties, flowrate and conditions 1 Gas name Air RECIPRCATING CMPRESSR CALCULATIN SHEET WITH INTERCLER ( Sheet : 1. f 4.) Item or symbol Quantity Unit Item or symbol Quantity Unit 2 Suction pressure, ps bar A Discharge pressure, pd 38.2 bar A 3 Suction temperature, ts 35 4 Ts 308 C K p CR bar A 5 MW 28.4 kg/kgmol T CR k S p R = p / p CR R S kj/kg. K T R = T / T CR DSs kg/m3 Z S MCp kj/kgmol. K Cp S kj/kg 10 G kg/hr G mol 917 kgmol/hr 11 Q S m 3 /hr Q N Nm 3 /hr 12 Compressor Calculation Sheet Item Symbol Unit Quantity Note 13 Preliminary Calculation 14 Check whether need intercooler 15 First Stage Volume flow Qs m3/hr Cylinder intake pressure ps' bara Cylinder exhaust pressure pd' bara Pressure ratio (p D / p S ) r' TTAL (k-1)/k k/(k-1) Total Hydrodynamic head H TTAL m Eq Check number of stage due to max. temp 23 Max. temperature t MAX C 150 See Chapter VI. 24 T MAX K Max. pressure ratio r MAX -T Equation (11) 26 Is r > r MAX or need intercooler? Yes 27 Expected minimum adiabatic vol. eff. η V-A Max. clearance space vol. c MAX % Eq. A.3. If need intercooler, use r = r max-t, otherwise use r Total 29 Clearance space volume c % 10 Fill < max.at expected eff. 30 Volumetric efficiency η V Eq. A.3 and A.4. K

2 Item Symbol Unit Quantity Note ( Sheet : 2. f 4.) 1 Supply efficiency λ/η V Eq. A.5. 2 Required piston capacity Qp m3/hr Eq. A.6 and A.7. 3 Max. hydr. Head for each stage H STG-MAX m Eq. A.6. 4 Preliminary number of stage i CAL 5 = Htotal / Hstg-max 5 GHP GHP Mechanical efficiency η M BHP BHP Frame BHP selection Casing I 9 Selected frame BHP 5100 See frame BHP table near preliminary BHP in line 7 10 No. of frame 1 Frame BHP data 11 No. of throw per frame 8 Frame BHP data 12 Stroke length 400 Frame BHP data 13 No. of compression acting 2 Frame BHP data 14 Crankshaft speed 500 Frame BHP data 15 Max. diameter 1000 Frame BHP data 16 Max. H per throw 6791 Eq.A Detail calculation CASING I Note 18 Stage 1 Stage 2 Stage 3 Stage 4 Stage 5 Stage 6 Stage 7 Stage 8 19 G (kg/hr) # Max. H per stage for parallel throws # = line Last cylinder exhaust press. (bara) # Cyl. intake pressure, ps ' (bara) Eq. A8 23 Suction temperat ure, ts ( C) 35.0 # #VALUE! 24 Ts ( K) # #VALUE! 25 Max. di ( C) 140 # Chapter 6 26 Td max. ( C) # MW # Rs = 8.314/MW p CR 37.7 # T CR # p R = p RED = p / p CR #VALUE! #VALUE! Appendix B 32 T R = T RED = T / T CR #VALUE! 33 Z S MCp S (kj/kgmol.k) # k = MCp/( Cp S = R.k /(k-1), (kj/kg.k) DSs = 100.ps / (Z.R.Ts), (kg/m3) #VALUE! #VALUE! Eq. 3 up to 7 38 Q S = G / DSs, (m3/hr) # #VALUE! #VALUE!

3 15 Preliminary Piston speed (m/s) Stroke leng, ( ) 400 # No. of compression acting No. of throw st z Max. = 8 19 Crankshaft d, 450 # Adjust if U > 6 m/s 20 Piston speed, (m/s) Eq. 12, max. 6 m/s 3 21 Piston displacement vol./strok e, m #VALUE! #VALUE! 22 Piston di t ( ) # #VALUE! #VALUE! Max.(mm)= Hydrod ic d, H m) # #VALUE! #VALUE! Eq Compression continue? Continue nti Continue nti Continue nti Continue nti Continue nti Finish # - - ( Sheet : 3. f 4.) Detail calculation (cont) CASING I Note Stage 1 Stage 2 Stage 3 Stage 4 Stage 5 Stage 6 Stage 7 Stage 8 1 Q N (Nm3/h) # (k-1)/k k/(k-1) Due to max. temperature 5 Pressure rati r o #VALUE! #VALUE! Eq. 11, Eq. A.10 6 Due to max. frame BHP 7 Max. r' due to max. frame BHP #VALUE! 8 Selected r' # #VALUE! #VALUE! 9 Discharge pressure, pd (bara) #VALUE! #VALUE! 10 Cylinder exh p #VALUE! #VALUE! Eq. A8 for 3 % loss 11 Clearance space vol ume, c (%) 10 # Volumetric efficiency, η V #VALUE! #VALUE! Eq. A4 13 Supply efficiency, λ/η V #VALUE! #VALUE! Eq. A5 14 Required pist on capacity, Qp ( m3) # #VALUE! #VALUE! Eq. A7 24 GHP Eq Exhaust t ef l 100 # 110 # #VALUE! - #VALUE! Eq Need intercooler? Yes No Yes No Yes No Yes No Yes No No # If "Yes", outlet gas temp. ( C) Pres. drop at inter/stg cooler (bar) Total Adiabatic Compression GHP (kw) Adiabatic eff, when isn' t fully adiabatic 0.90 See figure below 32 Mechanical efficiency 0.94 Fig. A4 33 Total BHP (kw) C.W. each cooler (ton/hr) 41.5 # For Δt water = 10 C 35 Total C.W. required (ton/hr) 207.7

4 Compressor Calculation Sheet (Cont.) ( Sheet : 4. f 4.) Frame Power Data Frame Max. dia. Max. no. Stroke Crank Power Frame Max. dia. Max. no. Stroke Crank Power power Dmax throw length, L max. speed per throw power Dmax throw length, L max. speed per throw (kw) (mm) Z (mm) N (RPM) (kw) (kw) (mm) Z (mm) N (RPM) (kw)

5 Interpretation of adiabatic efficiency from literature (0.65 for small, 0.80 for medium, 0.85 and higher for large reciprocating compressor) when the compressor doesn't work in fully adiabatic compression. Qs is suction flow at first stage of the compressor. When intercoolers and water jacket are applied, adiabatic efficiency higher than above figure. BHP = GHP /( η A. η M )

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v R = c v 2 v P = R v = v 3 v n P = n 3 v 1 v = n 1 n P 1 P = c 1 c P 1 P = n 1 c 1 n 3 c = v 1 v 3 3 3 c P P = c v 4.5 P = c v 4 P = c v 3.5 v 1 = 24 v 2 = 18 c 1 c 1 4.5 = v 1 c 2 v 4.5 2 = 244.5 = 3.65

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