RECIPROCATING COMPRESSOR CALCULATION SHEET
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- ĒΔανιήλ Αγγελίδης
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1 RECIPRCATING CMPRESSR CALCULATIN SHEET WITH INTERCLER Gas properties, flowrate and conditions 1 Gas name Air 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 C 4 Ts 308 K p CR bar A 5 MW 28.4 kg/kgmol T CR K 6 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 ( Sheet : 1. f 3.) 13 Preliminary Calculation (General method) 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) Check number of stage due to max. temp 21 Max. temperature t MAX C 150 See Chapter VI. 22 T MAX K Max. pressure ratio r MAX -T Equation (11) 24 Is r > r MAX or need intercooler? Yes 25 Total Hydrodynamic head H TTAL m Eq Expected minimum adiabatic vol. eff Max. clearance space vol. % Eq. A.3. If need intercooler, use r = r max-t, otherwise use r Total 28 Clearance space volume c % 10 Fill < max.at expected eff. 29 Volumetric efficiency η V Eq. A.3 and A.4.
2 Item Symbol Unit Quantity Note ( Sheet : 2. f 3.) 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 Mechanical efficiency BHP Frame BHP selection at first stage Casing I 9 No. of compression acting 2 Fig. A.3 10 Stroke length, L 430 Fig. A.3 11 No. of throw at first stage, z 2 Fig. A.3 12 Crankshaft speed, N 360 Fig. A.1 13 Max. diameter, Dmax (= L / 0.4 ) No. of frame 1 15 Calculated frame BHP/throw, 0.11 Qp1 929 Chapter A Max. H per throw 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) # 45.0 # 45.0 # #VALUE! #VALUE! 24 Ts ( K) # # # #VALUE! #VALUE! 25 Max. disch arge temp., td max. ( C) # 140 # 140 # Chapter 6 26 Td max. ( C) # # # MW # 28 # 28 # Rs = 8.314/MW p CR # 47.9 # 47.9 # T CR # # # p R = p RED = p / p CR #VALUE! #VALUE! #VALUE! Appendix B 32 T R = T RED = T / T CR #VALUE! #VALUE! 33 Z S MCp S (kj/kgmol.k) # 29.1 # 29.1 # k = MCp Cp S = R.k /(k-1), (kj/kg.k) DSs = 100.ps / (Z.R.Ts), (kg/m3) # 15.7 # 39.1 #VALUE! #VALUE! #VALUE! Eq. 3 up to 7 38 Q S = G / DSs, (m3/hr) # 4109 # # #VALUE! #VALUE! #VALUE!
3 15 Preliminary Piston speed (m/s) Stroke length, ( ) # 430 # 430 # ( Sheet : 3. f 3..) 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! #VALUE! Eq. 11, Eq. A.10 6 Due to max. frame BHP 7 Max. r' due to max. frame BHP # # # #VALUE! #VALUE! 8 Selected r' # # # # #VALUE! # #VALUE! # #VALUE! 9 Discharge pressure, pd (bara) # # # #VALUE! #VALUE! #VALUE! 10 Cylinder exh p # # #VALUE! #VALUE! #VALUE! Eq. A8 11 Clearance space vol ume, c (%) Volumetric efficiency, η V # # #VALUE! #VALUE! #VALUE! Eq. A4 13 Supply efficiency, λ/η V # # #VALUE! #VALUE! #VALUE! Eq. A5 14 Required pist on capacity, Qp ( m3) # # # #VALUE! #VALUE! #VALUE! Eq. A7 17 No. of compression acting No. of throw st z Fill for D < Dmax 19 Crankshaft d, # 360 # 360 # Adjust if U > 6 m/s 20 Piston speed, (m/s) # 5.2 # 5.2 # Eq. 12, max. 6 m/s 21 Piston displacement vol./strok e, m # # # #VALUE! #VALUE! #VALUE! 22 Piston di t ( ) # # # #VALUE! #VALUE! #VALUE! Max.(mm)= Hydrod ic d, H m) # # # #VALUE! #VALUE! #VALUE! Eq GHP Eq Exhaust t ef l 131 # 140 # 140 # 140 # 52 #VALUE! # #VALUE! # #VALUE! Eq Need intercooler? Yes Yes Yes Yes No If "Yes", outlet gas temp. ( C) 45 # 45 # 45 # 45 # # 45 # Pres. drop at inter/stg cooler (bar) 0.10 # 0.10 # 0.10 # # # # Compression continue? Continue Continue Continue Continue Finish 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) # 61.2 # 61.2 # For Δt water = 10 C 35 Total C.W. required (ton/hr) 244.7
4 Gas properties, flowrate and conditions RECIPRCATING CMPRESSR CALCULATIN SHEET WITH INTERCLER 1 Gas name Dry Air Item or symbol Quantity Unit Item or symbol Quantity Unit 2 Suction pressure, ps bar A Discharge pressure, pd 45 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 6000 kg/hr G mol 212 kgmol/hr 11 Q S 5382 m 3 /hr Q N 4770 Nm 3 /hr 12 Compressor Calculation Sheet Item Symbol Unit Quantity Note K ( Sheet : 1. f 3.) 13 Preliminary Calculation (General method) 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) Check number of stage due to max. temp 21 Max. temperature t MAX C 150 See Chapter VI. 22 T MAX K Max. pressure ratio r MAX -T Equation (11) 24 Is r > r MAX or need intercooler? Yes 25 Total Hydrodynamic head H TTAL m Eq 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 28 Clearance space volume c % 10 Fill < max.at expected eff. 29 Volumetric efficiency η V Eq. A.3 and A.4.
5 Item Symbol Unit Quantity Note ( Sheet : 2. f 3.) 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 kw Mechanical efficiency η M BHP BHP kw Frame BHP selection at first stage Casing I 9 No. of compression acting 2 Fig. A.3 10 Stroke length, L L mm 300 Fig. A.3 11 No. of throw at first stage, z z 1 Fig. A.3 12 Crankshaft speed, N N RPM 520 Fig. A.1 for U near 5 m/s or using graphical method below 13 Max. diameter, Dmax (= L / 0.4 ) Dmax mm No. of frame 1 15 Calculated frame BHP/throw, 0.11 Qp1 BHP/throw kw 456 Chapter A Max. H per throw H STG-MAX m 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) # 6000 # 6000 # 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) # 45.0 # 45.0 # #VALUE! #VALUE! #VALUE! 24 Ts ( K) # # # #VALUE! #VALUE! #VALUE! 25 Max. disch arge temp., td max. ( C) # 150 # 150 # Chapter 6 26 Td max. ( C) # # # MW # 28 # 28 # Rs = 8.314/MW # 0.30 # 0.30 # p CR # 37.7 # 37.7 # T CR # # # p R = p RED = p / p CR #VALUE! #VALUE! #VALUE! #VALUE! Appendix B 32 T R = T RED = T / T CR #VALUE! #VALUE! #VALUE! 33 Z S MCp S (kj/kgmol.k) # 29.1 # 29.1 # k = MCp Cp S = R.k /(k-1), (kj/kg.k) DSs = 100.ps / (Z.R.Ts), (kg/m3) # 22.1 # #VALUE! #VALUE! #VALUE! #VALUE! Eq. 3 up to 7 38 Q S = G / DSs, (m3/hr) # 733 # # #VALUE! #VALUE! #VALUE! #VALUE!
6 15 Preliminary Piston speed (m/s) Stroke length, ( ) # 300 # 300 # ( Sheet : 3. f 3..) 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) # 4770 # 4770 # (k-1)/k # # # k/(k-1) # # # Due to max. temperature 5 Pressure rati r o # # # #VALUE! #VALUE! #VALUE! #VALUE! Eq. 11, Eq. A.10 6 Due to max. frame BHP 7 Max. r' due to max. frame BHP # # # #VALUE! #VALUE! #VALUE! 8 Selected r' # # # # #VALUE! #VALUE! # #VALUE! # #VALUE! 9 Discharge pressure, pd (bara) # # # #VALUE! #VALUE! #VALUE! #VALUE! 10 Cylinder exh p # # # #VALUE! #VALUE! #VALUE! #VALUE! Eq. A8 for 3 % loss 11 Clearance space vol ume, c (%) Volumetric efficiency, η V # # # #VALUE! #VALUE! #VALUE! #VALUE! Eq. A4 13 Supply efficiency, λ/η V # # # #VALUE! #VALUE! #VALUE! #VALUE! Eq. A5 14 Required pist on capacity, Qp ( m3) # # # #VALUE! #VALUE! #VALUE! #VALUE! Eq. A7 17 No. of compression acting No. of throw st z Fill for D < Dmax 19 Crankshaft d, # 520 # 520 # Adjust if U > 6 m/s 20 Piston speed, (m/s) # 5.2 # 5.2 # Eq. 12, max. 6 m/s 21 Piston displacement vol./strok e, m # # # #VALUE! #VALUE! #VALUE! #VALUE! 22 Piston di t ( ) # # # #VALUE! #VALUE! #VALUE! #VALUE! Max.(mm)= Hydrod ic d, H m) # # # #VALUE! #VALUE! #VALUE! #VALUE! Eq GHP Eq Exhaust t ef l 150 # 150 # 150 # 127 # #VALUE! #VALUE! # #VALUE! # #VALUE! Eq Need intercooler? Yes Yes Yes No If "Yes", outlet gas temp. ( C) 45 # 45 # 45 # 45 # # 45 # Pres. drop at inter/stg cooler (bar) 0.10 # Compression continue? Continue Continue Continue Finish Total Adiabatic Compression GHP (kw) Adiabatic eff, when isn' t fully adiabatic 0.90 See figure below 31 Mechanical efficiency 0.93 Fig. A4 32 Total BHP (kw) C.W. each cooler (ton/hr) # 15.6 # 0.0 # For Δt water = 10 C 34 Total C.W. required (ton/hr) 48.2
7 Example : Blue dot line To find N (RPM) at expected overall efficiency ,300x 6,000 H10 T = = 39, 180m 10,000
8 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 )
RECIPROCATING COMPRESSOR CALCULATION SHEET
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,
RECIPROCATING COMPRESSOR CALCULATION SHEET ISOTHERMAL COMPRESSION Gas properties, flowrate and conditions. Compressor Calculation Sheet
RECIPRCATING CMPRESSR CALCULATIN SHEET ISTHERMAL CMPRESSIN Gas properties, flowrate and conditions 1 Gas name Air Item or symbol Quantity Unit Item or symbol Quantity Unit Formula 2 Suction pressure, ps
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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A BALANCE Proses = 120 / 31 391 t/h T Gun = 29 T Gun = 31 [38oC] A-101-JCA 443 / 2.46 10" TG = 31 05 November 2012 Rate 102.075% Proses = 0 / 33 349 t/h T Gun = 29 T Gun = 37 [38oC] A-101-JCB 261 / 1.42
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