A Practical Guide to Compressor Technology (Second Edition)

PREFACE xiii

ACKNOWLEDGMENTS

xv

PART I POSITIVE DISPLACEMENT COMPRESSOR TECHNOLOGY 1

1 Theory 3

1.1 Symbols 3

1.2 How a Compressor Works 4

1.3 First Law of Thermodynamics 8

1.4 Second Law of Thermodynamics 8

1.5 Ideal or Perfect Gas Laws 9

1.5.1 Boyle’s Law 9

1.5.2 Charles’ Law 9

1.5.3 Amonton’s Law 9

1.5.4 Dalton’s Law 9

1.5.5 Amagat’s Law 10

1.5.6 Avogadro’s Law 10

1.5.7 Perfect Gas Formula 10

1.6 Vapor Pressure 11

1.7 Gas and Vapor 11

1.8 Partial Pressures 11

1.9 Critical Conditions 13

1.10 Compressibility 13

1.11 Generalized Compressibility Charts 14

1.12 Gas Mixtures 15

1.13 The Mole

1.14 Specific Volume and Density 16

1.15 Volume Percent of Constituents 16

1.16 Molecular Weight of a Mixture 16

1.17 Specific Gravity and Partial Pressure 17

1.18 Ratio of Specific Heats 17

1.19 Pseudo-critical Conditions and Compressibility 18

1.20 Weight-Basis Items 18

1.21 Compression Cycles 19

1.22 Power Requirement 20

1.23 Compressibility Correction 21

1.24 Multiple Staging 22

1.25 Volume References 23

1.26 Cylinder Clearance and Volumetric Efficiency 24

1.27 Cylinder Clearance and Compression Efficiency 27

Reference 27

2 Reciprocating Process Compressor Design Overview 29

2.1 Crankshaft Design 33

2.2 Bearings and Lubrication Systems 37

2.3 Connecting Rods 37

2.4 Crossheads 38

2.5 Frames and Cylinders 39

2.6 Cooling Provisions 45

2.7 Pistons 47

2.8 Piston and Rider Rings 47

2.9 Valves 48

2.10 Piston Rods 51

2.11 Packings 55

2.12 Cylinder Lubrication 55

2.13 Distance Pieces 56

2.14 Reciprocating Compressor Modernization 

2.14.1 Cylinder Upgrades 59

2.14.2 Design for Easy Maintenance 59

2.14.3 Crosshead Designs and Attention to Reliable Lubrication 61

2.14.4 Materials

A Practical Guide to Compressor Technology (Second Edition) by Heinz P. Bloch is a well-regarded reference book that provides a detailed and comprehensive overview of compressor technology. It is designed for engineers, technicians, plant operators, and industry professionals who are involved in the selection, operation, and maintenance of compressors in various industrial applications. This second edition is updated with the latest advancements in compressor technology, making it an essential resource for understanding modern practices in the field.

Overview of the Book

Heinz P. Bloch, a seasoned expert in machinery and reliability engineering, presents this guide as a practical, hands-on resource for tackling real-world issues in compressor systems. The book focuses on practical solutions and provides in-depth knowledge on various types of compressors, operational considerations, troubleshooting, and maintenance strategies. It aims to bridge the gap between theoretical concepts and field applications, offering insights that are valuable for optimizing compressor performance and reliability.

Key Topics Covered

1. Compressor Fundamentals and Principles

   • The book begins with an introduction to the basic principles of compression, including an explanation of the thermodynamics behind the compression process. Key concepts such as isentropic efficiency, adiabatic compression, and polytropic processes are discussed to help readers understand how compressors work and the factors that influence their performance.

2. Types of Compressors

   • Positive Displacement Compressors:
     • The guide covers positive displacement compressors like reciprocating, rotary screw, and vane compressors. It explains their design features, operating principles, advantages, and common applications. The differences between single-acting and double-acting reciprocating compressors are highlighted, along with maintenance practices specific to each type.
   • Dynamic Compressors:
     • The section on dynamic compressors includes centrifugal and axial compressors. These types are commonly used in high-capacity, continuous-flow applications. The book delves into the mechanics of how these compressors work, their performance characteristics, and how they differ from positive displacement types in terms of pressure and flow rate handling.
   • Specialty Compressors:
     • The book also examines specialized compressors such as scroll, diaphragm, and liquid ring compressors, which are used in niche applications. It explains their unique features, operation, and suitability for specific industrial processes.

3. Selection and Application of Compressors

   • Choosing the right compressor for a specific application is a critical decision that affects both performance and cost. The guide provides a detailed approach to selecting compressors based on factors like flow rate, pressure requirements, gas composition, and environmental conditions.
   • It offers practical advice on evaluating compressor efficiency, reliability, and cost-effectiveness. The author also discusses key considerations such as compressor capacity control, safety requirements, and environmental regulations.

4. Design and Installation Best Practices

   • This section provides detailed guidance on designing and installing compressor systems. Topics include foundation and mounting, piping layout, vibration control, and noise reduction. It also covers considerations for site preparation and equipment placement to minimize issues like pressure drops and energy losses.
   • The importance of auxiliary equipment, such as aftercoolers, intercoolers, filters, and moisture separators, is highlighted to ensure efficient operation and extended equipment life.

5. Operation, Control, and Optimization

   • Efficient operation and control are crucial for maximizing compressor performance. The book discusses various control strategies, including constant speed, variable speed, and on-off control, as well as capacity modulation techniques.
   • It also covers modern advancements in control systems, such as the use of PLC (Programmable Logic Controllers) and DCS (Distributed Control Systems) for real-time monitoring and process optimization.

6. Maintenance, Reliability, and Troubleshooting

   • Maintenance is a major focus of the guide, with an emphasis on strategies for ensuring long-term reliability and minimizing downtime. It provides detailed maintenance schedules and practices, including lubrication, inspection, filter replacement, and alignment checks.
   • The troubleshooting section helps users diagnose and address common issues, such as vibration, excessive noise, oil carryover, and overheating. The book offers practical solutions and preventive measures to avoid recurring problems.

7. Energy Efficiency and Cost Reduction

   • Given the high operational costs associated with compressors, the book emphasizes the importance of energy efficiency. It provides tips for optimizing energy use, such as regular maintenance, reducing air leaks, proper system design, and using variable frequency drives (VFDs).
   • The guide also discusses methods for conducting energy audits and implementing energy recovery systems, which can help reduce overall operating costs.

8. Emerging Technologies and Trends

   • The second edition includes updates on the latest trends and innovations in compressor technology. It explores topics like advanced materials, digital monitoring systems, and the integration of smart technologies for predictive maintenance and enhanced performance monitoring.

Features and Tools

The A Practical Guide to Compressor Technology is designed to be a user-friendly and accessible reference. It includes:

• Illustrations and Diagrams: Clear visuals to help explain complex concepts and components of compressor systems.
• Formulas and Calculation Examples: Practical examples that guide users through sizing and selecting the right compressor for specific applications.
• Case Studies: Real-world examples that illustrate successful implementation and troubleshooting of compressor systems, offering insights into best practices.
• Checklists and Maintenance Guides: Handy tools for ensuring that all aspects of operation and maintenance are covered thoroughly.

Who Should Read This Book?

This guide is suitable for:

• Mechanical and Process Engineers: Seeking to deepen their understanding of compressor technology for system design and optimization.
• Maintenance Technicians: Looking for detailed guidance on maintaining and troubleshooting compressor systems effectively.
• Plant Operators and Facility Managers: Needing practical insights to improve system reliability and efficiency while managing costs.
• Students and Educators: As a comprehensive textbook on compressor technology, it provides a solid foundation for those studying mechanical engineering or industrial maintenance.

Conclusion

A Practical Guide to Compressor Technology (Second Edition) by Heinz P. Bloch is an authoritative resource that covers the full spectrum of compressor technology, from basic principles to advanced applications. Its emphasis on practical, hands-on solutions, coupled with its detailed coverage of both traditional and emerging technologies, makes it an indispensable tool for anyone involved in the design, operation, or maintenance of compressor systems. The book's comprehensive approach ensures that readers can effectively optimize performance, improve reliability, and reduce operating costs in their industrial applications.

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