MEL 344

Refrigeration and
Air Conditioning

Refrigerant Compressors
Abhay Deep Singh 2007ME10466
Kishor Kumar 2007ME10498
Danish Sharma 2007ME10483
 Classification of Compressors
Compressors

Positive Displacement Aerodynamic

Reciprocating Rotary Centrifugal

Piston One shaft Two shaft Three shaft Axial

Sliding
Diaphragm Roots Ejector
vane

Liquid ring Twin screw

Stepped
Scroll
rotor

Tooth
 Positive Displacement
• Positive admission and delivery ,no flow
reversal, (valves , etc. used)
• Intermittent operation
• Necessary discharge pressure can be
developed by the application of force.
• ‘Surge’ does not take place here.
• Reciprocating and Rotary compressors
come under this category Bicycle pump
 Aerodynamic compressors
• Also called dynamic or non positive
displacement compressor
• Continuous operation
• Pressure developed depends on the
kinetic energy of the inlet fluid
• Flow reverses when pressure
developed is less than discharge
pressure
• Surge may occur.
• Axial , centrifugal are some of the
examples.
 Reciprocating compressors
I. Piston II. Diaphragm

•W = 1∫2 pdV +
3 4
2∫ pdV + 3∫ pdV
+4∫1 pdV
= Area 1-2-3-4

• V1 – V4 = Vp

• V1 – V3 = Vs
 Piston Compressor Types

• Single acting

• Double acting
 Piston Compressor types

• Trunk piston compressors

• Crosshead piston
compressors
 Thermodynamics of Compression
• w = f(T1,p2/p1,n)
• isothermal work (n=1) :
P1v1 ln(p2/p1)
• Isentropic work (n=γ) :
(γ/(γ-1))p1v1[(p2/p1)(γ-1)/γ – 1]
• Polytropic work : (n=n)
• Isothermal Efficiency : ηt =
Isothermal work / actual work
• Adiabatic Efficiency : ηa =
Isentropic work / actual work
 Volumetric Efficiency
• ηv = Vs/Vp = 1+c-c(p2/p1) 1/n
• P2/pmin = (1/c + 1)γ

Effect of valve pressure drops:

ηv = (1+c)(ps/p1)1/n - c(pd/p1)1/n

Leakage loss
Overall efficiency
ηv = (1+c)(ps/p1)1/n - c(pd/p1)1/n
+ 0.015r
Performance characteristics
 Capacity Control
I. Speed variation

Power %
100
• discharge pressure

80
independent of speed hence

60
power consumption reduces
at reduced capacity

40
• Efficient for reciprocating

20
compressors.
0 0 20 40 60 80 100
capacity %
 Contd..
II. Valve Lifting
• Method of unloading the cylinders
• depressors or fingers are used
Single acting:
single cylinder 100% and 0%
Double cylinder 100% , 50%and 0%
Double acting:
Single cylinder 100% ,50% and 0%
And so on
 contd…

Valve Lifting
• Suction valve opened during compression stroke
with depressors or fingers .
• No work is involved except the friction work
during idling
• Finger type unloading there is a series of fingers
housed in an assembly
that are actuated by a push rod from an outside
actuator
• Fingers are lowered that depress the valve sealing
components and hold the valve in open position
• It directly acts on the valve sealing components so
it might damage them
• Plug and Port type are also used.
 Contd…
III. Clearance Pockets
• Volumetric efficiency depends upon clearance
• higher the clearance – lower the volumetric efficiency and hence lower the
mass flow rate
• We can have stepped clearance pockets for variable capacity control
 Contd..
III. Clearance pockets
• expansion and compression processes

60 80 100
power %
have efficiency less
than 100% which results in
off -load power to be a
substantial value. ideal

40
20
0

0 20 40 60 80 100
capacity %
 Contd.
IV. Compressor by-passing
• When evap pressure falls below a certain value, bypass
valve opened , hot discharged refrigerant flowing back into
suction
• the capacity of the compressor can be regulated quite
closely
• little or no reduction in compressor power consumption at
reduced refrigeration capacities
• excessive superheating of the suction gas resulting in
overheating of the compressors.
• Only for small compressors
• Overheating of the compressor can be reduced by sending
the hot bypass gas to the evaporator inlet - two advantages
Contd..
 Contd…
V. Cyclic on-off operation
• A gas receiver is at the end of discharge line
• When the receiver reaches pre-set level of pressure the
compressor power supply is cut off.
• It saves power but it is generally used in small scale applications as
continuous on-off leads to motor heating
• In large applications , it is limited to the number of starts per hour
– typically 3 to 4.
Compressor temperature and pressure
limitations
Temperature
• Discharge temperature should be low so that suction volume
is larger for maximum compressor performance.
• The compressor should be covered by cooling jacket to avoid
temperature distortions (especially gases with high γ)
• Excessive temperature can cause piston seizure
• Synthetic lubricants can be used
• Typical maximum temperature is 150⁰ C (302⁰F)
Pressure
These can be used for a wide range of discharge pressures
varying from 1 bar to 1000 bars.
 Other parameters
Piston Speed
The materials of construction and the type of lubricants
determine the reliable maximum speed.
Typical piston speed limitations :
maximum speed (m/s)
Lubricated cylinder in vertical , ‘V’ or ‘W’ configuration 4.3
Lubricated cylinder in horizontal configuration 3.8
Non-lubricated cylinders in vertical , ‘V’ or ‘W’ configuration 3.5
Non –lubricated cylinder in horizontal configuration 3.0
Compressor Size
Generally they come under the range 3000-5000 m³/hr
Some of them also available at 20000 m³/hr
 Scroll
Compressors
 Scroll Compressors
• Scroll compressors are orbital
motion, positive-displacement
machines that compress with
two inter fitting , spiral-shaped
scroll members (ASHRAE 2004).
• Structure – fixed scroll and
orbiting scroll
• Two types : compliant design &
Non-compliant design
 Compression Process
• Built-in pressure ratio = (Built-in volume ratio) (cp/cv)
 Efficiencies
• Compared with equivalent up-to-date reciprocating
designs of similar sizes.

Volumetric efficiency %
20 40 60 80 100
0

1 2 3 4 5 6
pressure ratio
 Capacity control
I. speed variation
Good method – wide range of speeds
Standard frequency inverters are available foe small power
inputs which will provide a wide range of speeds from a
standard AC motor
In compliant design there may be minimum speeds below which
effective sealing may be lost.
No difficulty with non-compliant design
 Contd…
II. Variable-Displacement
• Porting holes in the fixed scroll member. The control
mechanism disconnects or connects compression chambers
to the suction side by respectively closing or opening the
porting holes.
• When all porting holes are closed, the compressor runs at full
capacity; opening all porting holes to the suction side yields
the smallest capacity..
 Summary
• Used in wide variety of refrigeration and HVAC applications
• Manufactured in variety of sizes up to 25 tonnes
Advantages
• High efficiency no clearance volume as compared to
reciprocating compressors
• Few moving parts , low vibration
• Low noise levels
Disadvantages
• Difficult to disassemble in field for maintenance
Centrifugal Compressors
 Centrifugal compressors
• They are called “dynamic” machines because they
continuously exchange angular momentum between a
rotating mechanical element and a steadily flowing fluid.
• Because their flows are continuous, turbomachines have
greater volumetric capacities, size for size, than do positive-
displacement devices
• Ability to produce a high pressure ratio(upto 8:1) and
mass flow rates of upto 15m3/sec
• Can be single or multi stage( for process refrigeration)
 Centrifugal compressor
Main components:
i. Inlet casing
ii. Impeller
iii. Diffuser
iv. Volute casing
Work done in compression =
(outlet ang. Momentum-inlet ang. Momentum)*ω
 Reaction of an impeller
• The ratio of pressure-producing work to total
work is known as the impeller reaction. Some
of work increasing the velocity of flow.
• Ψ varies from about 0.4 to about 0.7.
 Isentropic analysis

W = (h2o – h10 ) = (h4 – h1) + (c42 – c12)/2

• ήs varies from about 0.62 to about 0.83, depending on the
application. The same compressor produces different
adiabatic results with different refrigerants and with the same
refrigerant at different suction conditions. A compressor’s
overall adiabatic efficiency does not completely indicate its
individual stage performance.
• This efficiency cannot be used in case we have multistaging.
Compressor characteristics
Surging

Suppose we are operating at

point D. We decrese the mass
flow rate , pressure decreses at
compressor outlet .In case the
pressure in discharge tube
downstream doesn’t fall quickly
enough. The flow tends to
reverse due to adverse pressure
gradient. The pressure ratio
keeps on decreasing. No
stability in region where slope of
this curve is positive.
 Surging
• Part-load range is limited (on the left side of the performance map) by a
surge envelope.
• In surging refrigerant alternately flows backward and forward through the
compressor, accompanied by increased noise, vibration, and heat.
• Prolonged operation under these conditions can damage the compressor.
• Surging can be distinguished from other kinds of noise and vibration by
the fact that its flow reversals alternately unload and load the driver.
Motor current varies markedly during surging.
 Characteristic curve

ηp = ∆hois/∆ho ∆ho = h40 – h10 = (h4 + c42/2) - h10

∆hois = h40is – h10 = (h4is + c4is2/2) - h10
Pressure ratio developed in a centrifugal stage

• Overall, polytropic work and efficiency are

more consistent from one application to
another because they represent an average
stage aerodynamic performance.
 System balance and capacity
control
• Normally refrigerant compressors are designed to
take care of the most severe operating conditions
cooling load is high and heat sink temperature.
• However, when the operating conditions are not so
severe, i.e., when the cooling load is low and/or the
heat sink temperature is low, then the compressor
becomes oversized.
• If no control action is taken, then the compressor
adjusts itself by operating at lower evaporator
temperature, which may affect the refrigerated space
temperature.
• Operating at low evaporator temperature may
lead to other problems such as
1. Low air humidity,
2. frosting of evaporator coils
3. freezing of the external fluid
Besides affecting the temperature of
refrigerated space
• In order to maintain almost the same evaporator
outlet conditions and condensor conditions with
decreasing load , we need to control the mass flow
rate of refrigerant, or the volume flow rate and
decrease the work input also

• Capacity control is done by 2 ways-

1. Variable Speed drive(VSD)
2.Variable inlet whirl vanes
System characterstics
 Hot gas bypass
• E, F,G,H are non attainable points beyond surge
envelope.
• ADD hot gas from the compressor discharge to
the evaporator, or compressor suction piping.
When hot-gas bypass is used, no further power
reduction occurs as load decreases. The
compressor is artificially loaded to stay out of the
surge envelope. The increased volume caused by
hot-gas recirculation performs no useful
refrigeration.
 Variable inlet whirl vanes
• Prerotation vanes modulate capacity by
altering the direction of the fluid flow entering
the impeller relative to the impeller blade
leading edge.
.
Compressor characterstics
1.The theoretical curve of a compressor can be
derived from the velocity triangles.
2. A spin-free inflow is to be present.
3.Furthermore we take the assumption of
equal c m (which is characterizing for the flow
rate) at entry and exit.
Assuming ϐ1= 0 Assuming cr1=cr2

W= ∆angular momentum * ω
W= (u2 * (u2 - cr1cotϐ2)) - (u12) (1)
V=A1*cr1 (2)
W= (u2 2 - u2 *V/A1/cotϐ2)) - (u12) (3)
W=a - b*V
• Above expression can be
written as
• W= c * r(n-1)/n - d (4)
• Comparing (3) and (4) we get
• A - B*V = r(n-1)/n
The straight line , which is derived by this, is only correct for an infinite number
which means it is a theoretical straight line. If you look upon a limited number o
lift of delivery is reduced.
• If you look upon a limited number of blades the lift of
delivery is reduced about Δyz.
• The friction losses Δyr cause a further sinking of the
characteristic curve, which becomes the larger, the
higher the flow rate is.
• The collision losses, which result from an unfavourable
incident flow of the profile nose, are considered by
Δyst. The collision losses become the larger the further
away by the design point the machine is operated.
• Finally the clearance losses cause a further shift of the
characteristic around ΔV, which causes an additional
waste of the efficiency.
 Rotary compressors
• These are used primarily for lower
refrigeration capacities ( e.g 1 ton).
• Small and compact in size
• They are of two types
1. Rolling pisten/fixed vane
2. Rotary vane types
• Consists of a roller mounted on the eccentric
of a shaft with a single vane or blade suitably
positioned in the non rotating cylindrical
housing, generally called the cylinder block.
• Produces large torsional vibrations.
• Rotary compressors have a high volumetric
efficiency
 Rotary vane compressor
• Rotary-vane compressors have a low mass-to-
displacement ratio, which, in combination with compact
size, makes them suitable for transport application.
• Capacity of order of 2 to 40 kW
• The eight discrete volumes are referred to as cells. A
single shaft rotation produces eight distinct compression
strokes. Although conventional valves are not required
for this compressor, suction and discharge check valves
are recommended to prevent reverse rotation and oil
logging during shutdown
• Built in compression ratio.
Rotary Screw Compressors
 Rotary screw compressors
• Use a rotary type positive displacement mechanism.
• One rotating or two counter rotating intermeshed
helical screw elements housed within a specially
shaped chamber.
• As the mechanism rotates, the meshing and rotation of
the two helical rotors produces a series of volume-
reducing cavities. Gas is drawn in through an inlet port
in the casing, captured in a cavity, compressed as the
cavity reduces in volume, and then discharged through
another port in the casing
 Rotary screw compressors
• The effectiveness of this mechanism is
dependent on close fitting clearances
between the helical rotors and the chamber
for sealing of the compression cavities.
 Twin screw compressors
• The twin-screw type compressor or twin-screw blower is a
positive displacement type device that operates by pulling
air through a pair of meshing high-tolerance screws similar
to a set of worm gears.
• The intake is located at one end of the two screws, which
overlap, but not completely, leaving a small pocket open.
• As the air moves axially through the housing, space
becomes smaller and the screw continues to pressurize the
air charge. This air gets released via the built in pressure
ratio discharge, which holds the compressed air to a
specified pressure before exiting the compressor
Twin screw compressors
Twin screw compressors
A twin-screw
compressor consists
of accurately
matched rotors (one
male and one
female) that mesh
closely when rotating
within a close
tolerance common
housing. One rotor is
driven while the other
turns in a counter-
rotating motion.
 Single screw compressors
• A single-screw compressor uses a single main
screw rotor meshing with two gate rotors with
matching teeth. The main screw is driven by the
prime mover, typically an electric motor
• The screw-like grooves gather vapors from the
intake port, trap them in the pockets between
the grooves and compressor housing, and force
them to the discharge port along the meshing
point path. This action raises the trapped gas
pressure to the discharge pressure.
Single screw compressors

Screw
compressor
s have the
capability
to operate
at pressure
ratios
above 20:1
single
stage
Single screw compressors
 Oil-flooded screw compressors

• Oil is injected into the compression cavities to aid

sealing and provide cooling sink for the gas charge.
• The oil is separated from the discharge stream,
then cooled, filtered and recycled.
 Oil-flooded screw compressors
• It is usual for some entrained compressor oil to carry over
into the compressed gas stream downstream of the
compressor. In some applications, this is rectified by filter
vessels.[2]
• In other applications, this is rectified by the use of receiver
tanks that reduce the local velocity of compressed air,
allowing oil to condense and drop out of the air stream to
be removed from the compressed air system via
condensate management equipment.
• Standard oil-flooded compressors are capable of achieving
output pressures over 200 psig, and output volumes of over
1500 cubic feet per minute (measured at 60 °C and
atmospheric pressure).
 Oil-free screw compressors

• the air is compressed entirely through the action

of the screws, without the assistance of an oil
seal.
• They usually have lower maximum discharge
pressure capability as a result. However, multi-
stage oil-free compressors, where the air is
compressed by several sets of screws, can
achieve pressures of over 150 psig, and output
volume of over 2000 cubic feet per minute
(measured at 60 °C and atmospheric pressure).
 Under compression

• If the internal volume ratio is too low for a

given set of operating conditions, the gas
pressure in the trapped volume remains
below the desired discharge pressure.
• the discharge port opens The high pressure
gas from the discharge line flows back into the
flute space, equalizing the flute pressure that
must be compressed again
Under compression

Extra work
is required
to
compress
the same
gas twice.
 Over compression
• If the internal volume ratio of the compressor is
too high for a given set of operating conditions
the discharge gas remains trapped longer, leading
to pressure rise above the discharge pressure .
• In this case, the gas is compressed to a value
above the discharge pressure and when the
discharge port opens, the high pressure gas in the
screw flutes expands out of the compressor into
the discharge line.
Over compression
This takes more
energy than that
required if the
compression had
been stopped
sooner when the
internal pressure
was equal to the
system discharge
pressure.
 Capacity control
• Compressors that have only axial ports will have
fixed volume ratios. The built-in volume ratio can
be changed by changing the size or location of
the discharge port.
• Another way to change the volume ratio is with
the help of a slide valve. For these compressors,
the volume ratio can be varied according to
requirements while the compressor is in
operation, to get better part-load efficiency.
 Capacity control
• Capacity is controlled with slide valves. The design uses a slide
valve that opens to vent some gas back to the suction port,
reducing both the net gas flow and power input .
Capacity control
A slide valve for
capacity control
of a screw
compressor:
(a) its position
relative to the
rotors,
(b) slide at full-
capacity position,
and
(c) slide at
reduced-capacity
position.
Capacity control

It can be seen that

for a given built-in
volume ratio, the
efficiency reaches a
peak at a particular
optimum pressure
ratio. The value of
this optimum
pressure ratio
increases with built-in
volume ratio
 References
• www.google.com
• www.wikipedia.org
• Refrigeration Handbook ASHRAE
• Industrial Compressors – P.A. O’Niell
• Refrigeration and Air-Conditioning – C.P. Arora