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SEMINAR REPORT
Submitted by
VISHNU VIJAYAN
Reg No: 12428066
to
The University of Kerala
in partial fulfillment of the requirements for the award of
B.Tech Degree in Mechanical Engineering
ATTINGAL
CERTIFICATE
Certified
that
this
report
entitled
FRICTIONLESS
COMPRESSOR
Mr. HARISANKAR.U.S
Seminar Guide
Mechanical Department
RIET, Attingal
Prof. S. SIVAKUMAR
Staff coordinator
Mechanical Department
RIET, Attingal.
Head of Department
Mechanical Department
RIET, Attingal
ACKNOWLEDGEMENTS
Finally I thank my parents and friends near and dear ones who directly and
indirectly contributed to the successful completion of my seminar.
ATTINGAL
VISHNU VIJAYAN
ABSTRACT
Traditional centrifugal compressors use roller bearings and hydrodynamic bearings,
both of which consume power and require oil and lubrication system. This can be overcome by
the introduction of new compressor technology called frictionless compressor technology. The
frictionless compressor technology is compressor with the application of magnetic bearings and
permanent magnet synchronous motor. In frictionless compressor instead of roller bearings
and hydrodynamic bearings, magnetic bearings are used. Magnetic bearings consume less
power and there is no need for oil and lubrication systems. Permanent magnet brushless
synchronous motor has permanent magnet instead of copper windings.
After 10 years of development, magnetic bearing compressors offer economic, energy,
and environmental benefits. Chief among them are increased energy efficiency, the elimination
of oil and oil management and considerable less weight, noise, and vibration. This is initial midrange package offers centrifugal compression efficiencies previously reserved for large tonnage
systems only. This compressor has high reliability, efficiency, less maintenance cost and staff.
With the help of digital control system the controlling and monitoring of work is very easy. The
frictionless compressor technology makes new revolutions in the field of air conditioning,
refrigeration etc
CONTENTS
1. INTRODUCTION ..................................................................................................................... 1
2. GAS COMPRESSOR ................................................................................................................. 2
2.1 Types of Compressors ......................................................................................................................... 2
2.1.1 Centrifugal compressors .............................................................................................................. 3
2.1.2 Diagonal or mixed-flow compressors .......................................................................................... 3
2.1.3 Axial-flow compressors ................................................................................................................ 3
2.1.4 Reciprocating compressors .......................................................................................................... 4
2.1.5 Rotary screw compressors ........................................................................................................... 5
2.1.6 Rotary vane compressors............................................................................................................. 5
2.1.7 Scroll compressors ....................................................................................................................... 6
2.1.8 Diaphragm compressors .............................................................................................................. 6
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1. INTRODUCTION
A new compressor technology introduced during the 2008 International AirConditioning Heating Refrigerating Exposition (AHR Expo), held last January in Chicago, may
have a significant effect on the future of mid-range chillers and rooftop applications in watercooled, evaporative cooled, and air-cooled chilled water and direct-expansion (DX) systems.
Designed and optimized to take full advantage of magnetic-bearing technology, the compressor
was awarded the first AHR Expo Innovation Award in the energy category, as well as Canadas
Energy Efficiency Award for its potential to reduce utility-generated greenhouse-gas emissions.
The compressor is key to a new water cooled centrifugal-chiller design, with Air Conditioning
and Refrigeration Institute (ARI) tests indicating integrated part-load values (IPLVs) not normally
seen with conventional chillers in this tonnage range.
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2. GAS COMPRESSOR
A gas compressor is a mechanical device that increases the pressure of a gas by reducing
its volume. Compressors are similar to pumps: both increase the pressure on a fluid and both
can transport the fluid through a pipe. As gases are compressible, the compressor also reduces
the volume of a gas. Liquids are relatively incompressible, so the main action of a pump is to
transport liquids.
Types of Compressors
The main types of gas compressors are illustrated and discussed below:
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Centrifugal compressors
Centrifugal compressors use a rotating disk or impeller in a shaped housing to force the
gas to the rim of the impeller, increasing the velocity of the gas. A diffuser (divergent duct)
section converts the velocity energy to pressure energy. They are primarily used for continuous,
stationary service in industries such as oil refineries, chemical and petrochemical plants and
natural gas processing plants. Their application can be from 100 hp (75 kW) to thousands of
horsepower. With multiple staging, they can achieve extremely high output pressures greater
than 10,000 psi (69 MPa).
Many large snow-making operations (like ski resorts) use this type of compressor. They
are also used in internal combustion engines as superchargers and turbochargers. Centrifugal
compressors are used in small gas turbine engines or as the final compression stage of medium
sized gas turbines.
Axial-flow compressors
Axial-flow compressors are dynamic rotating compressors that use arrays of fan-like
aero foil to progressively compress the working fluid. They are used where there is a
requirement for a high flows or a compact design.
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The arrays of aero foil are set in rows, usually as pairs: one rotating and one stationary. The
rotating aero foils, also known as blades or rotors decelerate and pressurize the fluid.
The stationary aero foil is, also known as a stators or vanes, turn and decelerate the fluid;
preparing and redirecting the flow for the rotor blades of the next stage. Axial compressors are
almost always multi-staged, with the cross-sectional area of the gas passage diminishing along
the compressor to maintain an optimum axial Mach number. Beyond about 5 stages or a 4:1
design pressure ratio, variable geometry is normally used to improve operation.
Axial compressors can have high efficiencies; around 90% polytrophic at their design
conditions. However, they are relatively expensive, requiring a large number of components,
tight tolerances and high quality materials. Axial-flow compressors can be found in medium to
large gas turbine engines, in natural gas pumping stations, and within certain chemical plants.
Reciprocating compressors
Reciprocating compressors use pistons driven by a crankshaft. They can be either
stationary or portable, can be single or multi-staged, and can be driven by electric motors or
internal combustion engines. Small reciprocating compressors from 5 to 30 horsepower (hp)
are commonly seen in automotive applications and are typically for intermittent duty. Larger
reciprocating compressors up to 1000 hp are still commonly found in large industrial
applications, but their numbers are declining as they are replaced by various other types of
compressors. Discharge pressures can range from low pressure to very high pressure (>5000 psi
or 35 MPa). In certain applications, such as air compression, multi-stage double-acting
compressors are said to be the most efficient compressors available, and are typically larger,
noisier, and more costly than comparable rotary units.
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Scroll compressors
A scroll compressor, also known as scroll pump and scroll vacuum pump, uses two interleaved
spiral-like vanes to pump or compress fluids such as liquids and gases. The vane geometry may
be involutes, Archimedean spiral, or hybrid curves. They operate more smoothly, quietly, and
reliably than other types of compressors in the lower volume range.
Often, one of the scrolls is fixed, while the other orbits eccentrically without rotating, thereby
trapping and pumping or compressing pockets of fluid or gas between the scrolls.
Diaphragm compressors
A diaphragm compressor (also known as a membrane compressor) is a variant of the
conventional reciprocating compressor. The compression of gas occurs by the movement of a
flexible membrane, instead of an intake element. The back and forth movement of the
membrane is driven by a rod and a crankshaft mechanism. Only the membrane and the
compressor box come in touch with the gas being compressed.
Diaphragm compressors are used for hydrogen and compressed natural gas (CNG) as
well as in a number of other applications.
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5. MAIN COMPONENTS
The components in Frictionless Compressor can be mainly classified into two categories as
Mechanical components and Electrical components
MECHANICAL COMPONENTS
FIG 1
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3. Touchdown bearings
Carbon-lined radially and axially located bearings support the rotor when the
compressor is not energized
Prevents contact between the rotor and other metallic surfaces
5. Compressor cooling
Liquid refrigerant flow is controlled electronically, cooling electronic, mechanical and
electromechanical compressor components to assure maximum efficiency and safe
operation
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ELECTRICAL COMPONENTS
FIG 2
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4. Rectifier
Converts AC line power into a high-voltage DC power source for motor, bearings and
control operations
5. Capacitors
Energy storage and filter for smooth DC voltage
Provide power to the magnetic bearings, along with motor
rotation, to ensure rotor shaft levitation through
compressor coast down in the event of an external power
loss
6. DC-DC converters
Supplies and electrically isolates the high and low DC voltages required for the control
circuits
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7. Controls connection
Network connection for external control and monitoring
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6. THE BEARINGS
FIG 3
When the magnetic bearings are energized, the motor and impellers, which are keyed
directly to the magnetic shaft, levitate. Permanent-magnetic bearings do the primary work,
while digitally controlled electromagnets provide the fine positioning. Four positioning signals
per bearing hold the levitated assembly to a tolerance of 0.00002 in. As the levitated assembly
moves from the center point, the electromagnets intensity is adjusted to correct the position.
These adjustments occur 6 million times a minute. The software has been designed to
automatically compensate for any out-of-balance condition in the levitated assembly
P a g e | 16
8. OIL-FREE DESIGN
Oil management, particularly as it pertains to the lubrication of compressor bearings, is a
critical issue in refrigeration system design. But with magnetic bearings, this issue is avoided.
Only a very small amount of oil is required to lubricate other system components, such as seals
and valves; often, however, experience shows that even this small amount of oil is not needed.
Avoiding oil-management systems means avoiding the capital cost of oil pumps, sumps,
heaters, coolers, and oil separators, as well as the labor and time required to perform oil
related services. Reports indicate that for many installations, compressor-maintenance costs
have been cut by more than 50 percent..
Magnetic bearings eliminate the need for these systems and oil management in general.
In fact, the only required regular maintenance of the compressor is the quarterly tightening of
the terminal screws, the annual blowing off of dust and cleaning of the boards, and the
changing of the capacitors every five years. Complete service agreements and extended
maintenance contracts can be provided by the manufacturer.
P a g e | 17
9. THE MOTOR
Most hermetic compressors use induction motors cooled by either liquid or suction-gas
refrigerant. Induction motors have copper windings that, when alternating current is run
through them, create the magnetic fields that cause the motor to turn. These copper windings
are bulky, adding size and weight to the compressor. Two-pole, 60-Hz induction motors operate at
approximately 3,600 rpm. A higher number of revolutions per minute can be obtained by
increasing the frequency. Compressors that require higher shaft speeds tend to use gears. While
gears are a proven technology, they create noise and vibration, consume power, and require
lubrication. The magnet-bearing compressor features a synchronous permanent-magnet brushless
DC motor with a completely integrated variable-frequency drive (VFD). The stator windings
found conventional induction motors are replaced with a permanent-magnet rotor.
Alternating current from the inverter energizes the armature windings. The stator (excitation) and
rotor (armature) change places. The motor and key electronic components are internally refrigerant
cooled, so no special cooling is required for the VFD or the motor.
The use of permanent magnets instead of rotor windings makes the motor smaller and
lighter than induction motors. Using magnetic-bearing technology, a 75-ton compressor weighs
265 lbabout one-fifth the weight of a conventional compressor. A variable-speed drive (VSD) is
required for the motor to operate.
The VSD varies the frequency between 300 and 800 Hz, which provides a compressor-speed
range from 18,000 to 48,000 rpm. This avoids a gear set. The VSD is integrated into the
compressor housing, avoiding long leads and allowing key electronic components to be
refrigerant-cooled. The VSD also acts as a soft starter; as a result, the compressor has an
extremely low startup in-rush current: less than 2 amps, compared with 500 to 600 amps for a
traditional 75-ton, 460-v screw compressor with a cross-the-line starter. With the integration of
the motor, VSD, and magnetic-bearing system, the capacitors required for the motor and
drive can be used as a backup power source for the bearings in the event of a power outage
or emergency shutdown
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12. ADVANTAGES
Easy to work with
It features the same standard suction, discharge and economizer ports as conventional
compressors. It mounts in the standard way. It can use the same power wiring with a single control and
monitoring connection.
Easy on product cost
This frictionless magnetic bearing design needs no oil management system. And because theres
no oil to coat the heat transfer surfaces, the units high efficiency can be maintained over the lifetime of
the product. The outstanding efficiency of the compressor gives equipment manufacturers the option
to offer the highest efficiency/lowest emissions, cost effective performance in its tonnage range.
Easy on the ears
A sound level less than 70 dB, with virtually no structure-borne vibration, eliminates the
need for expensive attenuation accessories.
Easy to handle
265 pounds (120 kg) is less than 20% of the weight of competitive compressors with an
approximate 50% smaller footprint.
Easy refrigerant choice
Since the compressors are optimized for HFC -134a, a well-known, environmentally
responsible, refrigerant.
Easy to control
Onboard digital electronics make the compressor the compressor with a brain. Inside,
the compressor is totally self-correcting and incorporates a system of sophisticated selfdiagnostics, monitoring and control. Outside, you can tap into this intelligence by using control
outputs in various for including web-enabled monitoring and control.
Easy on energy
The compressor enables chiller and rooftop manufacturers to achieve the necessary product
efficiency levels to meet and exceed ASHRAE 90.1 and the California Title 24 requirements for energy
efficiency.
P a g e | 20
13. APPLICATIONS
1 Water-cooled chiller applications
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14. CONCLUSION
P a g e | 22
15. REFERENCES