Download - Fs Intro Tipos
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COMPRESORES CENTRIFUGOS Y SU IMPLICACION EN EL AHORRO
DE LOS COSTOS OPERATIVOS
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INTRODUCCION
• Normalmente no se le da la importancia al aire comprimido como se le llegase a dar a la electricidad y al agua.
• Compresores centrífugos como la mejor opción de generación de aire comprimido a partir de 200 HP hacia arriba .
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TIPOS DE COMPRESORES
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Compresor de PistCompresor de Pistóónn
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Compresor de Tornillo
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Compresor de Tornillo
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Compresor Centrifugo
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SCFM Vs. ACFM Vs. ICFM
Figura 1. Un (1) Pie Cúbico (Volumen)
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Masa Vs. Volumen Constante Vs.Altura Sobre el Nivel del Mar
ICFM, ACFM, CFM = Medidas Volumétricas
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Masa Constante Vs. Volumen Vs. Altura Sobre el Nivel del Mar
SCFM*, Nm3/Hr*, lb/hr*, kg/min*, FAD* = Medidas Masicas
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Variación de la densidad Vs. Altura Sobre el Nivel del Mar
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Formula para el cambio de SCFM a ICFM
( )( ) Pa
Pb
Ts
Ta
PVaRHaPb
PVsRHsPsSCFMICFM ××
×−×−×=
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TALLER
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Datos requeridos para seleccionar un compresor
• Flujo: (ICFM, ACFM, SCFM, Nm3/Hr….)• Presión de Descarga: (PSIA, PSIG, BAR..)• Presion Barometrica o altura sobre el nivel del mar• Temperatura Ambiental:
– Máxima y Mínima (deg. F, deg. C..)
• Humedad Relativa Máxima: (%)• Temperatura Agua de Enfriamiento:
– Máxima (deg. F, deg. C..)
• Electricidad Disponible– Frecuencia (60 o 50 Hz) y Voltaje.
• Encerramiento del motor electrico.
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Historia del PAP
• 1962 Elliott Co. crea la Division de Compresoresde Aire en Jeannette, Pa USA
• El primer producto fue el Compresor de AireCentrifugo con engranes integrados de cortevertical PAP de 3 piñones.
• In 1974 el modelo fue redisenado a carcaza de corte horizontal para facil mantenimiento.
• Desde sus inicios dentro del mercado, han sidoinstalados mas de 5,000 unidades queactualmente estan en operacion.
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Historia del PAP• En 1985 Elliott establecio un acuerdo de
ventas y servicio con FuSheng en Taiwan.• El 1 de Octubre de 2003, la Division de
Compresores de Aire (PAP-PLUS) de Elliott Company fue adquirido por FushengIndustrial Co.
• Se adquiere una nueva propiedad en Export, PA. solo a 5 minutos en auto de Jeannette, PA.
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Historia del PAP
• Durante 2006 se duplican las unidades vendidasasi como las ventas en un año.
• Se hace una fuerte inversion en lasinstalaciones de Export, PA. por cerca de $50 Millones de Dolares lo cual tambien incluye un nuevo centro de maquinado “State of the Art”.
• El PAP-PLUS continua siendo, hasta la fecha, el Compresor de Aire Centrifugo Libre de Aceitepreferido para los mercados de la Industria del Petroleo & Gas,, Refinacion y Petroquimica en el mundo entero.
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• EE.UU.:Export, PA
o Mellon
o Enterprise
• China:• Shanghai
• Taiwan: • Taipei
USA
ChinaTaiwan
Historia del PAP Instalaciones de Manufactura y Empaquetado
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FS-Elliott Co.
Oficina Principal y Fabrica en Mellon Road
• Direccion• Legal• Mercadotecnia• Ingenieria /R&D• Contaduria• Planeacion• Control de Calida• Centro de Pruebas
Historia del PAP de Elliott
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Planta en Mellon - Export, PA
Maquinado de Difusor
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Planta en Mellon - Export, PA
Remocion de rebaba Difusor
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Planta en Mellon - Export, PA
Ensamble cabezal de compresion
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Planta en Mellon - Export, PA
Balanceo de Rotor
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Planta en Mellon - Export, PA
Ensamble del Paquete Completo
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Productos FS-Elliott
• Mercados TipicosIndustria:– Electronicos– Acero / Aluminio– Alimentos & Bebidas– Automotriz– Farmaceutica– Mineria– Industria Textil– Industria Manufacturera en
General
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Productos FS-Elliott• Unidades para la
Industria– 200 HP ~ 4,000 HP– 700 ICFM ~ 18,000
ICFM– Unidades de 1, 2 & 3
Pasos– Accionamiento por
Motor Electrico y Turbina de Vapor
– Presion de Descarga –30 psig ~ 175 psig
– Sistemas de Control Digital
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Productos FS-Elliott
• Mercados Tipicos paraAPI 672 :– Refinerias– Petroquimicas– LNG– Produccion de Petroleo y Gas– Separacion de Aire– Servicio de Nitrogeno
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Configuracion EstandarVs.
Productos de Ingenieria
PaquetesPaquetes IngenieriaIngenieriaAPI 672API 672
PaquetePaquete Industrial, Industrial, PrePre--ingenieriaingenieria
RequerimientosRequerimientos con con EspecificacionesEspecificaciones
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FS-ElliottDescripcion del Compresor
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Entrada del aire
FlujoFlujo del del AireAire ComprimidoComprimidoEl aire es comprimido por el 1er paso del compresor
El calor y condensado esremovido en el 1er intercambiador de calor
El aire vuelve a ser comprimido en el 2o paso del compresor
Nuevamente el calory condensado son removidos
El aire escomprimido a supresion final en 3er paso
Salida del aire al postenfriador y airede planta
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Air System
- Filter elements remove airborne particles from air.
- Two stages of filtration.
- Requires maintenance.
Inlet AirInlet Air
FilterFilter
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Air System- Filter assembly is shipped
loose on larger air compressor packages.
- Filter should be located outside at source of cool, clean, dry air.
- Should be mounted at least 6 feet (2 m) above floor or roof.
- Inlet piping should be constructed of stainless steel, aluminum, or rigid plastic.
- Pressure drop across piping should be minimized.
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Air System
Two Stage Air FilterTwo Stage Air Filter
Pre-Filter Element
Final Filter Element
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- Regulates air flow into compressor.
- Guide vanes or butterfly valve.- Electric or pneumatic.
Inlet ValveInlet Valve
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Air System
- Cools the hot air from the impeller.
- Water makes several passes through the intercooler.
- Air makes one pass through intercooler.
IntercoolersIntercoolers
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Air System- Water makes several passes through the intercooler tube bundle.
- Return channels at each end of tube bundle redirect the water flow.
- Gaskets prevent water leaks.- The air makes one pass through the
tube bundle.- Rubber sealing strips prevent the
bypass of hot air.- Require periodic maintenance.
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Air System
- As the air is cooled, water vapor in the air will condense.
- Water exits the intercooler via a notched drain valve.
- Water traps can be used but must be closely monitored.- Mufflers are available to attenuate the noise.
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Air System
- The tube bundles inside the intercoolers require periodic maintenance.
- Typically, only the front cover needs to be removed for access to the tubes.
- The tube bundles can be removed for more involved cleaning.
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Air System
- Interior of intercooler shells is coated with Plasite.
- Prevents corrosion.
PlasitePlasite
CoatingCoating
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Air System
- Minimizes stress on compressor casings.
- Shipping bars are removed after piping is completed.
Expansion JointExpansion Joint
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Air SystemDischargeDischarge
Expansion JointExpansion Joint
- Compensates for thermal growth.- Allows for angular and lateral
movement.
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Air System
Inlet Inlet
ExpansionExpansion
JointJoint
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Air System
DischargeDischarge
Check ValveCheck Valve
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Air System
- The check valve prevents the reversal of air flow when the compressor is shut down.
- Requires periodic maintenance.
Check ValveCheck Valve
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Air System
- Cools the air prior to entering the plant air system.
- Requires maintenance.
AftercoolerAftercooler
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Air System
CYCLONE SEPARATORCYCLONE SEPARATOR
- Aftercooler is installed separately on larger air compressor models.
- Requires maintenance.
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Air System
- Regulates discharge air pressure.
- Unloads compressor during surge.
- Vents air to atmosphere.- Electric or pneumatic.
Unloading ValveUnloading Valve
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Air System
- Pneumatic valve.- Normally open / Air to close.- Sometimes equipped with positioner.- Regulates discharge air pressure.- I/P transmitter required.
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Air System
- Attenuates noise from unloading valve.
- Vents air to atmosphere.
Unloading SilencerUnloading Silencer
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Air System
- On larger compressor models, must be mounted in the field.
- Attenuates the noise from the unloading valve.
Unloading SilencerUnloading Silencer
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Aerodinamica“State of the Art”Minimo numero de partes en movimientoDiseno para 20 años de vidaComponentesconfiablesMantenimiento de rapido acceso
Corazon del Corazon del CompresorCompresorCentrifugoCentrifugo FSFS--ElliottElliott
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Corte horizontalEngranePrincipalPiñonesChumacerasSellos
““ CajaCaja EngranesEngranes((ExtremoExtremoAireAire))””
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Calidad AGMA 13
Toleranciascerradas
Tipo simple helicoidalAleacion de acerode calidadaeronautica
““ EngraneEngranePrincipal y Principal y PiPiññonesones””
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Corte horizontalChumaceras con 5 zapatasbasculantesChumacera de empujeEstabilidad superior y capacidadasoporte de carga a condiciones de diseno y extremas
““ ChumacerasChumaceras””
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Corte horizontalChumacera de MangaChumacerasde empujeplanas
““ ChumacerasChumacerasEngraneEngranePrincipalPrincipal””
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Corte horizontalDoble anillo de carbonAmortiguamientode aireBaja perdida de aire
““ SellosSellosde de AnilloAnillo de Carbonde Carbon””
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Piñón (acero al carbon calidadaeronautica)Impulsores (17-4PH SS)Balanceadosdinamicamente
““ EnsambleEnsamblede Rotorde Rotor””
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Inclinacion haciaatrasAlta EficienciaProlongadaelevacion al SurgeMayor rangooperacion17-4PH SS
““ ImpulsoresImpulsores””
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DisminuyevelocidadIncrementa presionAletas fabricadas o fundidas (aluminio)
““ DifusorDifusor””
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INTERCAMBIADORESDE
CALOR
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Tubo de aguaTubos rectosRemovibles sin perturbar tuberiade aireFacil limpieza de tubos varillado
““ IntercambiadoresIntercambiadores””
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Cubierta inferiorBaja velocidadSeparacionefectivaDrenes en VRecubrimientoespecialFacil acceso
““ IntercambiadoresIntercambiadores””
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Opciones en Materiales
CobreAdmiralty90/10 CuNiAc. Inox.
““ IntercambiadoresIntercambiadores””
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SISTEMADE
LUBRICACION
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Tanque de Aceite
Bomba auxiliarBomba principalFiltro aceiteEnfriador aceiteValvula alivioEliminador de niebla de aceite
““ SistemaSistemaAceiteAceiteLubricacionLubricacion””
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Cubierta ampliaFacil accesoIndicador de nivelRecubrimientoFacil limpieza
““ TanqueTanquede de AceiteAceite””
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Motor TEFCA plenacapacidad30-35 psigOperacion plenaen emergenciaMontaje vertical u horizontal
““ BombaBombaauxiliarauxiliar de de aceiteaceite””
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Accionamientodirecto en flechaPlena capacidad30-35 psig
““ BombaBombaPrincipal de Principal de AceiteAceite””
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Filto sencillo (std) Filtro Dual o Duplex filter (opcional)10 micron
““ FiltrosFiltros de de AceiteAceite””
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Enfriador simple (std) Doble enfriador(opcional)Tipo tubos de aguaValvula de control de temperatura aceite
““ EnfriadorEnfriador de de AceiteAceite””
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TABLERODE
CONTROL
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TableroTablero de Control de Control
RegulusRegulus
�� ArrancadorArrancador de Motor de Motor
IntegralIntegral
�� Display a color de 6Display a color de 6”” LCDLCD
�� Areas Areas separadasseparadas parapara
circuitoscircuitos AC y DCAC y DC
�� OpcionalOpcional con con cabinacabina
acusticaacustica
FS-Elliott Polaris Modelo P-300
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• Transmisoresmontadosdentro del panel de control
• Monitoreoproporcionadoen paquetes
• Desarrollografico
““Panel de Control IndustrialPanel de Control Industrial””
Regulus RRegulus R--200200 ((basadobasado en en sistemasistema PLC)PLC)
FS-Elliott Controls
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Panel Industrial Regulus R-200
Proteccion / Monitoreo Alarma DisparoLectura
Temperatura del aire interetapas X X X
Baja temp. aceite X XAlta temperatura aceite X X
XBaja presion de aceite X X XAlta vibracion – Pinon baja velocidad X X XAlta vibracion – Pinon alta velocidad X X XSurge del compresor X XFalla microprocesador X XFalla de transmisor (6) X XAlta carga de accionador X
X
FS-Elliott Controls
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Estatus Pantalla
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Pantalla 1 ajustes
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Pantalla Aceite
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Pantalla Modo Op.
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Air CompressorAir CompressorControl TheoryControl Theory
Objective: Objective: To explain centrifugal compressor To explain centrifugal compressor
control theory.control theory.
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Surge Surge
Control Modes Control Modes
Control Theory Control Theory
Typical Compressor Curve Typical Compressor Curve
Control SystemControl System
Functions Functions
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Control System Functions Control System Functions
- Start/Stop air compressor
- Operate the control valves (inlet & unloading)
- Provide safety functions
- Stores data in memory
- Communicates with remote devices (DCS)
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PAP Air System
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Typical Centrifugal
CompressorPerformance
Curve
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PAP Air System
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Controlled CompressorAmbient Temperature Change
WinterWinter-- High DensityHigh Density
SummerSummer-- Low DensityLow Density
Inlet ValveInlet Valve
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Base Mode Control
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Suction Throttle Control
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Adaptive Increment Control
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Intermittent Mode
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Auto Dual Mode
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FS-Elliott…y un futuro cercano
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Electra “Oil-Free”Compresor con motor integral
Objectivos• Compresor centrifugo libre
de aceite• Chumaceras magneticas
• Fuente de alimentacion• Motor integral (estator y
rotor)
• Controlador del compresor• Cabina acustica
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Electra “Oil-Free”Compresor con motor integral
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FS-Elliott Electra “Oil-Free”Compresor con motor integral
• 2010 presentacion al mercado• Verdaderamente “libre de
aceite” / diseno con menosaceite– Sin aceite en ductos de aire– Sin aceite en carcaza –
Chumaceras magneticas• Variacion de velocidad – 90,000
RPM• Impulsores en Titanio• 100 bhp – 400 ICFM @ 125 psi• Compacto y sencillo• Competitivo con el tipo tornillo
seco
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Electra “Oil-Free”Compresor con motor integral
��DisenoDiseno compactocompacto
��CabinaCabina parapara recuccionrecuccion de de ruidoruido
��Panel de control Panel de control basadobasado en en
RegulusRegulus
��CostoCosto efectivoefectivo –– EnfocadoEnfocado al al
mercadomercado de de compresorcompresor de de tornillotornillo
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Comparacion de Compresor Centrifugo de Aire FS-Elliott con
Compresor de tornillo seco
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FS-Elliott Centrifugo Vs. TornilloSeco
“simplemente elegante por diseño…”
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FS-Elliott Centrifugo Vs. TornilloSeco
“diseno complicado!”
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FS-Elliott Centrifugo Vs. TornilloSeco
•Complicado• Simple
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Comparacion
• Comparemos lo basico
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Comparacion
� Centrifugo– Poco mantenimiento
– Facil acceso
– Mntto. En sitio
– Larga vida rotor
– Mayores flujos
– Presion constante, min ajuste
� Tornillo seco– Reemplazo cabezal
compresion
– Dificil acceso
– Mntto. en fabrica
– Corta vida rotor
– Menores flujos
– Ajustes Min/Max aprox107% HP
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Comparacion
• Comparemos los detalles
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FS-Elliott Centrifugo Vs. Tornillo Seco
16 jgo de rodamientosbolas (vida esperada -50000 Hrs)
2 jgo chumaceras zapatasvasculantes + 2 jgo de chumaceras manga – vidaprolongada (ilimitada)
Chumaceras
8 juegos de selloscontacto
3 juegos de sellosflotantes
SellosFlecha
7 engranes, disenocomplejo
3 Engranes, disenosimple
Engranes
AGMA 11 o 12AGMA 13GradoEngrane
4 RotoresVida esperada – 40,000 Hrs Costo reemplazo aproxSesenta porciento (60 %)
2 PinonesLarga vida (ilimitada)
Pinones / Rotores
Tornillo rotatorio secoFS-Elliott Centrifugo
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FS-Elliott Centrifugo Vs. Tornillo Seco
Paquete grande - menorcfm / espacio ocupado
Paquete compactopequeno - mayor cfm / espacioocupado
Consideraciones de espacio
Los elementos deben ser reconstruidos en fabrica
Componentesreemplazables en campo
Reacondicionamiento
1 inter & 1 post enfriamiento
2 inter & 1 post enfriamiento
Intercambiador
Si, para alcanzar claroscriticos
No requiereRecubrimientoRotor
Acero forjado o al carbonImpulsor 17-4 ph SSMaterial Rotor
Tornillo rotatorio secoFS-Elliott Centrifugo
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FS-Elliott Centrifugo Vs. TornilloSeco
Conclusion
Una magnifica opcion debido a su diseño simple, sin partes de desgaste y comportamiento confiable
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Accesorios y Auxiliares
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Secadores de Aire
• Tipos de Secadores.– Refrigerativos
• Punto de Rocío 3 deg. C• Gas refrigerante (R-22, R-134…)
– Regenerativos• Libre de Calor (Purga 15%)• Calentador (Purga 7%)• Purga por soplador externo (Purga 0%)
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El porque de los secadores
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Filtros de Aire
• Tipos de filtros– Coalescentes
• Grado 11 a Grado 6– Humedad y Partículas
• Grado 5 a Grado 3– Remoción de aceite (99.99%)
– Carbón Activado• Grado 1
– Remoción de Aceite (99.999%)
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Tanques Pulmon