TC3: Day 3

Rotating Equipment Efficiency

Calculations

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 Contents
▪ Day 3: Rotating Equipment Efficiency
➢ Compressors Efficiency Calculations
➢ Pumps Efficiency Calculations
➢ Electric Motors Efficiency Calculations

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Compressor Efficiency Calculations

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 Basic Concepts and Definitions
• Compressor efficiencies vary with compressor type, size, and
throughput.
• They can only be determined (afterward) by a compressor test,
although compressor manufacturers can usually provide good
estimates.
• For planning purposes, the following values for the overall
efficiencies are provided:
Compressor Type Overall Efficiency
Centrifugal 0.70 – 0.85
High Speed Reciprocating 0.72 – 0.85
Low Speed Reciprocating 0.75 – 0.90
Rotary Screw 0.65 – 0.75 4
• Efficiencies
Isentropic Efficiency
(𝜼𝒊𝒔 )
Drive Efficiency
(𝜼𝒅𝒓𝒊𝒗𝒆 )
Mechanical
Efficiency (𝜼𝒎 )

Gas Power
Overall Efficiency: o =  drive mis =
Shaft Power 5
• Enthalpy-Entropy Diagram (h-s Diagram)

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Discretization of the Compression Process

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• Isentropic Efficiency

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• Effective Air Delivery (for Reciprocating
Compressors)

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 Compression Ratio

• Compression Ratio: Used for Estimation of Number of

Compression Stages

where:
Rc: Overall compression ratio
Pf: Final discharge pressure (kg/㎠A) (psia)
Pi: Inlet pressure (kg/㎠A) (psia)
• The compression ratio per stage shall be under 5-6 (for
reciprocating) 10
 Discharge Temperature
• The discharge temperature, based on isentropic
compression, is given by:

where:
TO : Outlet temperature (0K) (0R)
Ti : Inlet temperature (0K) (0R)
PO : Outlet pressure (absolute pressure)
Pi : Inlet Pressure (absolute pressure)
K : Cp/Cv at the mean inlet and outlet conditions 11
 Operating Temperature

Reciprocating Compressors
▪ Any hydrocarbon-lubricated compressor handling air or
other oxygen shall not exceed 177 ℃
▪ Hydrocarbon-lubricated compressors handling gases
shall not exceed 191 ℃
▪ Non-lubricated compressors shall not exceed 204 ℃
Centrifugal Compressors
▪ The operating temperature should not exceed 232 ℃
(450 ℉) at any point in the operating range
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 Specific Heat Ratio (K)

K is normally
determined at the
average suction and
discharge
temperatures.

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 Estimating Compressors Efficiency
• The isentropic efficiency is defined by

where
• h1 = Suction enthalpy calculated at P1, T1, and composition (zi)
• h2 = Discharge enthalpy calculated at P2, T2, and composition (zi)
• h2Isen = Isentropic discharge enthalpy at P2 (or T2), S2Isen =S1, and
composition (zi)
• 𝑚ሶ = Mass flow rate 14
• The actual discharge temperature based on a polytropic path
can be estimated by

where
• n = Polytropic index
• P2 = Discharge pressure
• P1 = Suction pressure

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 Polytropic Efficiency of the Compression Process

• The basic definition of the polytropic efficiency is

provided by:

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 Isentropic and Polytropic Heads

• The isentropic head is calculated by:

[kJ/kg]

• Similarly, the polytropic head is calculated by

[kJ/kg]

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 Absorbed Power
• For an isentropic (reversible and adiabatic) process the power is
calculated by

• Or for a polytropic process the power is calculated by

• Alternatively:

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 Compressor Affinity Laws

• The affinity laws express the relationship between the

head, capacity, speed and size of centrifugal
compressors.
• In general these relations can be applied to inlet volume
conditions for good preliminary designs, but all final
designs apply these laws to the actual discharge
volumes from the impeller.

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• (1) Speed (Constant Impeller)

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• (2) Impeller Diameter (Similar Impellers)
• For two geometrically similar, same family, wheels with
the same specific speed and operated at the same rpm:

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• (3) Impeller Diameter (Changed)
• When an impeller diameter is reduced, but the speed is
held constant:

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• (4) Effect of Temperature
• The effect of changing compressor inlet temperature is
given by:

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• Compressor Operating with Variable
Speed Drive

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• Case Study: Electric Motor Driven
Compressor Calculation Sheet (Group Work)
Input Sheet:

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• Case Study: Electric Motor Driven
Compressor Calculation Sheet (Group Work)
Output Sheet:

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• Case Study: Turbine Driven Compressor
Calculation Sheet (Group Work)
Input Sheet:

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• Case Study: Turbine Driven Compressor
Calculation Sheet (Group Work)
Output Sheet:

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Pump Efficiency Calculations

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 Basic Concepts and Definitions

• Pump efficiency is the “water horsepower” divided by

the “brake horsepower”.
• Water horsepower is a system design tool and is the
power that the pump would require to accomplish the
hydraulic conditions if it was 100 percent efficient.
• The efficiency of the pump is not a factor in the water
horsepower equation.
• Water horsepower defines the lowest boundary for the
power requirements.

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 Pressure Heads in Pumping Systems
• The rated, design or manometric head of any pump
depends on
❑The pressure (gauge) inside the suction vessel Ps
(from which the liquid is pumped),
❑The pressure inside the delivery vessel Pd
❑The total friction and secondary losses in suction and
delivery piping Σhf,s and Σhf,d
❑The static suction and delivery heads Hs and Hd and
❑Kinetic energy of water in the piping.
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• Open Reservoirs

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• Pressure Reservoirs

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• Head Calculations
ps Cs2
H ms = − H ss − − h f , s
g 2
p
H md = d + H sd + h f ,d
g
pd − ps Cs2
H m = H md − H ms = + H s + h f , s +  h f , d +
g 2g
H s = H ss + H sd

 Cd2   Cs2  Cd2

H t =  H md +  −  H ms +  = H s + h f , s +  h f , d +
 2g   2g  2g
total suctionhead total delivery head
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 Pump Efficiencies
Pin − Ploss ,m
m = Mechanical Efficiency
Pin
Q
v = Volumetric Efficiency
Q + Qleak
wis gH
h = = Hydraulic Efficiency
w w
Q = Volumetric flow of the process fluid
H = “Head” of the system
ρ = the density of the fluid
g = gravity acceleration (constant value)
w = pump specific work 38
 Overall Efficiency

• The pump overall efficiency is given by:

 gHQ
o = mvh =
Pin
(without Drive Efficiency)

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 Pump Affinity Laws

• The affinity laws are to be used to estimate the

relationships between the performance and a change in
RPM or in the impeller diameter.

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• (1) Change in RPM
• If the speed is changed, with the impeller design
(diameter and efficiency) fixed, the following conditions
and characteristics will vary:

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• (2) Change in Impeller Diameter
• When the impeller diameter is to be changed, with the
speed and efficiency fixed (without changing any other
points in the design), the calculations can be conducted
by the following equations:

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• Pump Operating with Variable Speed
Drive
PC: Pump curve
SC: System curve

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• Example: Grundfos Pump SPE 17-12

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• Pump Motor: MS6000P QXT60

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• Relative Power Consumption

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• Case Study: Pump Efficiency Calculation
Sheet (Group Work)

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Electric Motor Efficiency
Calculations

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• The Motor System

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Induction Electric Motor Performance Charts

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Induction Electric Motor Starting Charts

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• Estimation or Calculation of Motor Load

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Case Study: Load Estimation Using Tachometer

• Measured speed: 1490 rpm

• Measured voltage: 390 V

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• Load Estimate

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 Case Study: Load Estimation Using Ammeter

• Measured current: 188 A

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 Case Study: Load Estimation Using Ammeter &
Voltmeter
• Measured current: 188 A
• Measured voltage: 390 V

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• Premium Efficiency Motor Retrofit Energy
Saving Calculations

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Activity
 Activity : 10 minutes
▪ Split into groups A, B, and C
▪ Each group select a topic of Activity
the 3 covered today
(Compressors, Pumps,
Motors, …. )
▪ Discuss with your group
some proposed techniques A C
to improve energy
efficiency in the selected
equipment.
▪ List down your suggestions
▪ Present your group work in
B
front of the whole
audience.
 Day 3 Assessment

➢ 10 MCQ to be solved online in 10 minutes.

➢ Link:

Purpose:
➢ Measure the learning objectives of Day 3
➢ Pinpoint the strengths and weaknesses

Results and Conclusions

Conclusion of Day 3
Thank You.

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