This document provides an overview of different types of compressors used in refrigeration systems. It discusses positive displacement compressors including reciprocating, rotary vane, screw, and scroll compressors. It also covers non-positive displacement or centrifugal compressors. Key aspects covered include characteristics, configurations, performance metrics like volumetric efficiency and compressor efficiency, and comparisons of different compressor types.
This document provides an overview of different types of compressors used in refrigeration systems. It discusses positive displacement compressors including reciprocating, rotary vane, screw, and scroll compressors. It also covers non-positive displacement or centrifugal compressors. Key aspects covered include characteristics, configurations, performance metrics like volumetric efficiency and compressor efficiency, and comparisons of different compressor types.
This document provides an overview of different types of compressors used in refrigeration systems. It discusses positive displacement compressors including reciprocating, rotary vane, screw, and scroll compressors. It also covers non-positive displacement or centrifugal compressors. Key aspects covered include characteristics, configurations, performance metrics like volumetric efficiency and compressor efficiency, and comparisons of different compressor types.
This document provides an overview of different types of compressors used in refrigeration systems. It discusses positive displacement compressors including reciprocating, rotary vane, screw, and scroll compressors. It also covers non-positive displacement or centrifugal compressors. Key aspects covered include characteristics, configurations, performance metrics like volumetric efficiency and compressor efficiency, and comparisons of different compressor types.
Associate of Science in Building Services Engineering
BST20532 HVAC Services 2
COMPRESSORS
AIMS & OBJECTIVES
After studying this lecture notes, students are expected to: • understand the compressor as one of the essential components in a refrigeration system; • distinguish the two main categories of compressor: positive displacement and non-positive displacement; • understand the characteristics and configurations of different types of compressors, including the reciprocating, rotary vane, screw, scroll and centrifugal compressors; • determine the performance of a compressor, especially according to volumetric efficiency and compressor efficiency.
Compressor is one of the important parts of the compression refrigeration system and serves both to provide the necessary increase in pressure of refrigerant vapour and as a refrigerant pump to circulate the refrigerant through the system in a continuous cycle. Refrigeration compressors can be divided broadly into two categories: • Positive displacement compressors • Non-positive displacement compressors or dynamic compressors
1. Positive Displacement Compressors
The increase in pressure is by reducing the internal volume of the compression
chamber through work applied to the compressor’s mechanism. In vapour compression refrigeration systems, the major types of positive displacement compressors includes reciprocating, rolling piston, rotary vane, single screw, double screw, and scroll.
1.1 Reciprocating Compressors
Most reciprocating compressors are single acting, using pistons drive directly through a pin and connecting rod from the crankshaft. Double acting compressors are not extensively used.
(a) Intake stoke (b) Compression and discharge stoke
Figure 1 Semi-hermetic Reciprocating Compressor
1.1.1 Drive and Motor Arrangement
The halocarbon compressor is the most widely used and is manufactured in 3 designs according to the motor and drive arrangement: open, hermetic and semi-hermetic. Ammonia compressors are manufactured only in the open design, in which the driveshaft extends through a seal in the crankcase for an external drive.
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1.1.1.1 Open compressor
The crankshaft extends through the compressor housing so that a motor can be externally coupled to the shaft. A seal is therefore required at the compressor housing to prevent leakage (i.e. either refrigerant gas leaking out of, or ambient air leaking into the compressor).
1.1.1.2 Hermetic compressor or welded-shell hermetic
The motor and the compressor are enclosed in the same pressure vessel; the motor shaft is integral with the compressor crankshaft, and the motor is in contact with the refrigerant. In many designs, cold suction gas is drawn across the motor to keep it cool. Since moisture can damage the motor, dehydration of the hermetic units before refrigerant charging (filling) is essential.
1.1.1.3 Semi-hermetic compressor or bolted hermetic
The compressor cylinder heads are removable so that the cylinder valves and pistons can be readily serviced.
Hermetic Semi-hermetic Open
Initial Cost Low Average High Leakage Minimum Average Shaft seal is required Maintenance Not accessible for Can be repaired Accessible repair Efficiency Average Average Higher
1.1.2 Key features of reciprocating compressors include:
- Size: range from fractional to hundred kW refrigeration capacities due to limitation on compression ratio. - Speed: range from 2 to 60 revolutions per second (120 to 3600 rpm). - Single or multi-cylinder(s). - Ammonia (R717), R22, R500, R502 & R134a can be used. - Larger capacity chiller up to 500TR with 2 or more compressors / multi-cylinder. - Capacity control by on/off mode, variable speed motor, cylinder unloader or hot- gas by-pass. - Relatively low rotation velocities and safe operation. - Simplicity of construction and relative ease of maintenance and repair. - Relatively low initial cost. - Capacity control is in steps and the hot-gas by-pass method is a wastage of compressor input. - Reliable, spare parts readily available. - Relatively noisy and lower efficiency.
When the motor, compressor and condenser are completely mounted on the same frame and they are located remotely from the expansion valve and evaporator, they form the “Condensing Unit”.
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1.2 Rotary Vane Compressors
Rotory compressor operate with a circular, or rotary, motion instead of reciprocating
motion. Their positive-displacement compression process is non-reversing and either continuous or cyclical, depending on the type of mechanism. Most are direct machines. The use of suction valve is not required in vane compressors. The suction gas enters continuously and so gas pulsation is at a minimum.
1.2.1 Rolling-piston or Single-vane Compressor
A spring-loaded divider separates the suction and the discharge chambers. The rotor is located eccentrically on the shaft. When it revolves, it makes contact with the cylinder and compresses the gas.
Figure 2 Rolling–piston Rotary Compressor
1.2.2 Multiple-vane Compressor
The rotor has 2 or more sliding vanes, which are held against the cylinder by centrifugal force.
(a) 2-vane (b) 4-vane
Figure 3 Multiple-vane Compressor
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The displacement rate D of a rolling position compressor is given by
π D= 4 ( A 2 − B2 )LN (1)
where A = cylinder diameter, m
B = roller diameter, m L = cylinder length, m N = rotating speed, revolution per second
Key features of rotary vane compressors:
- R22, R502 & R717 are used in rotary vane compressor - Up to 4TR for commercial use, up to 150TR for industry application - Relatively quiet. - Rolling piston compressor are used in window A/C unit up to 3 hp. - Capacity control is by on/off mode.
1.3 Rotary Screw Compressors
Single-screw and twin-screw compressors are two distinct types used in refrigeration and air-conditioning applications. Refrigerant vapour enters one end of the compressor housing at the top and leaves the other end at the bottom. Figure 4 shows a cross-sectional view of the 2 principal rotating elements: the screws, where the male rotor drives the female rotor. The rotation results in meshing of the male lobe with the female gully, gradually decreases the volume in the cavity and hence compresses the gas as it travels along the length of the screws. At a certain point the discharge port is uncovered and the compressed gas is discharged by further meshing of the lobe and the gully. - Operate at pressure ratios above 20:1 single stage. - Capacity range from 70 to 4600kW. - High isentropic and volumetric efficiencies. - Relatively quiet.
Figure 4 Cross-section of the screw compressor rotors
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1.3.1 Single Screw Compressor
Figure 5 Cross-section of a Single Screw Compressor
Sequence of compression process:
(a) Suction: During rotation of the main rotor, a typical groove in open communication with the suction chamber gradually fills with suction gas. The tooth of the gaterotor in mesh with the groove acts as an aspirating piston. (b) Compression: As the main rotor turns, the groove engages a tooth on the gaterotor and is covered simultaneously by the cylindrical main rotor casing. The gas is trapped in the space formed by the three sides of the groove, the casing, and the gaterotor tooth. As rotation continues, the groove volume decreases and compression occurs. (c) Discharge: At the geometrically fixed point where the leading edge of the groove and the edge of the discharge port coincide, compression ceases, and the gas discharges into the delivery line until the groove volume has been reduced to zero.
(a) suction (b) compression (c) discharge
Figure 6 Sequence of Compression Process in Single-Screw Compressor
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1.3.2 Twin Screw Compressor
Twin screw is the common designation for double helical rotary screw compressors. The twin screw compressor consists of two mating helically grooved rotors - male (lobes) and female (flutes or gullies) - in a stationary housing with inlet and outlet gas ports [Figure 7(a)]. - 50-1500 TR capacity - R22, R134a & R717 can be used - Capacity control by moving the sliding valve towards the discharge end. - Capacity control can be continuous / stepless. - Relatively quiet.
Compression process of twin screw compressor is shown in Figure 7.
(b)Twin Screw Compression Process
(a) Twin Screw Compressor
Figure 7 Twin Screw Compressors
1.4 Scroll Compressors
Scroll compressors are orbital motion, positive
displacement machines that compress with 2 interfitting, spiral-shaped scroll members of phase difference of 180o. The characteristics include: - R22 - Small numbers of component. - Capacity ranging from 3 to 50kW. - High compression ratio. - High efficiency and low noise. - Most suitable for heat pump and air-cooled units application. - COP in the range of 3.1 to 3.34.
Capacity control: - by on/off mode; - by variable speed scroll compressor; or - by variable displacement scroll compreesor. Figure 8 Figure 8 shows the sequence of suction, compression Scroll Compression Process and discharge phases.
The only type of non-positive displacement compressor which is widely adopted in
the HVAC field is the centrifugal compressor. The increase in pressure of refrigerant vapour by a continuous transfer of angular momentum from the rotating member to the refrigerant vapour followed by the conversion of this momentum into a pressure rise.
Figure 9 Cross Section of a Centrifugal Compressor
The construction is similar to a centrifugal pump. The incoming fluid enters the eye of the spinning impeller and is thrown by centrifugal force to the periphery of the impeller. From the impeller the gas flows either into the diffuser blades or into a volute, where some of the kinetic energy is converted into pressure head (Figure 10). The flows are continuous, turbomachines have greater volumetric capacities, size for size, than the positive displacement devices do. For effective momentum exchange, their rotative speeds must be higher, but little vibration or wear results because of the steadiness of the motion and the absence of contacting parts.
Figure 10 Impeller Exit Velocity Diagram
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They are multi-stage in general, as many as 8 or 9 stages can be installed in a single
casing and the adiabatic compressor efficiency can reach 70 to 80%. Almost any refrigerant can be used.
2.1 Characteristics of Centrifugal Compressor
The characteristics of centrifugal compressor include:
- Compression ratio can be increased by connecting impellers in series (multi-stage). - Range from 200 to 5000TR or even 10000TR, high voltage - 11kV input can be specified for 1000TR machine and above. - Refrigerant can be R22, R134a & R717. - R123 is currently replacing R11 but it has greenhouse effect problem. - Stepless capacity control by inlet guide vane, variable speed turbine drive, adjustable frequency controller, combination of vane and speed control. - Higher volume flow rate than the positive displacement compressor to suit large capacity application. - Higher initial cost. - Higher efficiency.
2.2 Advantages of Centrifugal Machines
The advantages of centrifugal refrigeration machines above 500TR include:
- Flexible under varying load condition. - Adaptable to a wide range of operating temperature. - Fewer moving parts than large multi-cylinder reciprocating machines. - Simplicity of the lubrication system. - Reasonably good efficiency at part load less than 40% of the design capacity.
Screw, centrifugal and vane compressors are rotary machines.
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2.3 Comparison of Differernt Compressors
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3. Performance
The 2 most important performance indicators in compressors are the refrigeration
capacity and the power requirement. These are mainly controlled by the suction and discharge pressures of the compressor when it runs at a constant speed. The effects of these 2 pressures can be visualized through the following analysis.
3.1 Volumetric Efficiency (ηv)
volume flow rate entering compressor
ηv = (2) displacement rate of compressor
where the displacement rate is the volume swept through by the pistons in their suction strokes per unit time.
There are 2 volumetric efficiency terms: “clearance” and “actual”. The clearance volumetric efficiency ηvc depends on the re-expansion of gas trapped in the clearance volume. See the pressure-volume diagram in Figure 11. If Vc is the clearance volume (minimum volume) and V3 is the maximum volume of the cylinder, then a term called percent clearance (m) is defined as:
Vc m= x100% (3) V3 − Vc
Figure 11 Pressure-volume Diagram of Reciprocating Compressor
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The amount of gas drawn into the cylinder depends on the instantaneous suction pressure.
V1 v suc Since = , where v represents the specific volume, therefore for isentropic Vc v dis expansion between Vc and V1,
⎛v ⎞ ηvc = 100 − m⎜ suc − 1⎟ (6) ⎝ v dis ⎠
For the extreme case when suction pressure = P3, then ηvc = 0 .
The actual volumetric efficiency ηva is less than ηvc owing to the following occurrences: i) pressure drop across valves, ii) refrigerant leakage, and iii) suction gas being warmed and expanded in cylinder before the compression.
3.2 Compressor Efficiency ηc
isentropic work of compression
ηc = (7) actual work of compression
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TUTORIAL
A R-22 refrigeration system operates with an evaporating temperature of 5oC and a
condensing temperature of 50oC. The vapour compression cycle is with 3oC liquid sub- cooling and 8oC superheating of suction gas. The 6-cyclinder compressor runs at 29 rev/s. The required power input is 28.9 kW and the refrigerating capacity is 96.4 kW.
Determine: (a) clearances volumetric efficiency if m= 4.8%, (b) actual volumetric efficiency, and (c) compressor efficiency.
Given: for all cylinders, stroke = 57 mm, bore = 67mm.
Solution: T1 = 5 + 8 = 13oC T3 = 50 - 3 + 47oC From R-22 tables
