<p>At the gas spring manufacturing company Strömsholmen AB there is the needfor a way to make the load alleviating gas springs more robust, endurable andmaintenance free. A small high pressure compressor with a control systemshould solve these problems. The system would have to raise the pressure in the gas spring if it were to drop under a level and let some pressure out if it were to increase over a certain level. The construction of this Micro Compressor system is presented in this master's thesis. At first, a deeper understanding of the task at hand was gathered resulting in a design specification, followed by a concept study generated by the systematic design method. The evaluation of the concept study resulted in a chosen concept for prototype production. This prototype system consists of a control system with a pressure switch, a pressure reducing valve and a Micro Compressor that raises the pressure when needed. An electric system was also designed to work with the pressure switch, actuating the compressor when needed. Thoughts of converting the Micro Compressor system to pneumatic drive were also considered to increase the scope of use. The prototype system was tested to see that the requirements in the design specification were met and then the project was handed back to Strömsholmen AB for future development together with a list of suggestions of things that need improvement.</p>

At the gas spring manufacturing company Strömsholmen AB there is the needfor a way to make the load alleviating gas springs more robust, endurable andmaintenance free. A small high pressure compressor with a control systemshould solve these problems. The system would have to raise the pressure in the gas spring if it were to drop under a level and let some pressure out if it were to increase over a certain level. The construction of this Micro Compressor system is presented in this master's thesis. At first, a deeper understanding of the task at hand was gathered resulting in a design specification, followed by a concept study generated by the systematic design method. The evaluation of the concept study resulted in a chosen concept for prototype production. This prototype system consists of a control system with a pressure switch, a pressure reducing valve and a Micro Compressor that raises the pressure when needed. An electric system was also designed to work with the pressure switch, actuating the compressor when needed. Thoughts of converting the Micro Compressor system to pneumatic drive were also considered to increase the scope of use. The prototype system was tested to see that the requirements in the design specification were met and then the project was handed back to Strömsholmen AB for future development together with a list of suggestions of things that need improvement.

An analysis is developed for a compressible bulk-flow model of the leakage path between a centrifugal compressor's impeller shroud and housing along the front and back side of the impeller. This is an extension of analysis performed first by Childs (1989) for a shrouded pump impeller and its housing considering an incompressible fluid, and then later by Cao (1993) using a compressible bulk flow model for the shroud of a cryogenic fluid pump. The bulk-flow model is used to develop a reaction force and moment model for the shroud of a centrifugal compressor by solving the derived governing equations and integrating the pressure and shear stress distribution. Validation is done by comparing the results to published measured moment coefficients by Yoshida et al. (1996). The comparison shows that the shroud casing clearance flow and the fluid force moment can be simulated by the bulk flow model fairly well. An Iwatsubo-based labyrinth seal code developed by Childs and Scharrer (1986) is used to calculate the rotordynamic coefficients developed by the labyrinth seals in the compressor. Tangential force and transverse moment components acting on the rotor are found to have a destabilizing influence on the rotor for a range of precession frequencies. Rotordynamic coefficients are derived for a single stage of a multistage centrifugal compressor, and a comparison is made to stability predictions using Wachel's coefficient using the XLTRC (rotordynamic FEA code). For the model employed, Wachel's model predicts a slightly lower onset speed of instability. The results also show that leakage that flows radially inwards on the back shroud has a greater destabilizing influence than leakage flow that is radially outwards. Seal rub conditions are simulated by increasing the clearance and simultaneously decreasing the tooth height, which increased the leakage and the swirl tothe eye seal inlet; and therefore reduced stability. Calculated results are provided for different seal clearances and tooth height, for seal and shroud forces and moments.

The main objective of this study is to propose and to validate simplified models to simulate the performance of refrigeration systems. The proposed modelling approach of the system is modular: the compressor is modelled by a simple and physical model that takes into account the heat transfers and the un-matching of internal and external pressure ratio for the scroll compressors. The evaporator is modelled as a two zones heat exchanger on the refrigeration side (one for the two phases zone and the other one for superheated gas) and finally the condenser is assumed to be divided into three zones (de-superheating, two-phase and the sub-cooling). The compressor model was already developed by other author; here it is only validated using three scroll compressors and two reciprocating ones. The main differences are the conditions at which these compressors are tested: 20 bar at the supply and 40 at the exhaust. The condenser and evaporator models are the main contribution of this study. These models use the geometry and the correlation from the literature to calculate the global heat transfer coefficient on each zone. In the case of the condenser, a mean void fraction model is used to determinate the condenser subcooling as function of the refrigerant charge or vice-versa. The refrigeration system model is validated with experimental results obtained on each component and the whole system in five different test benches. The results show a very good agreement between the measured and predicted main outputs of the system.

Neste trabalho aplica-se um método semi-empírico que utiliza uma técnica de otimização não linear para determinação das eficiências volumétrica e combinada do compressor hermético alternativo. Relações para estimar aproximadamente o fluxo de massa e a potência elétrica do compressor também são propostas. Todas estas características do compressor são calculadas através das relações físicas do modelo, empregadas nos cálculos de otimização. O método é implementado no software EES (Engineering Equation Solver) e baseia-se nos trabalhos de Jahing (1999) e Jahing et al. (2000). No presente método, cinco medições experimentais do fluxo de massa e potência elétrica são suficientes para determinar os parâmetros de ajuste do modelo. Este procedimento permite a geração de mapas de compressores satisfatórios sem a necessidade de um maior número de dados experimentais como no caso da norma ARI 540. Estes resultados obtidos com o modelo podem ser usados para o projeto de novos compressores. / In the present work is applied a semi-empirical method that uses a non-linear optimization technique for determination of the volumetric and combined efficiencies of hermetic reciprocating compressor. Relations to approximately estimate the mass flow and the electric power of the compressor are also proposed. All these compressor characteristics are calculated through physical model relations, used in the optimization calculations. The method is implemented in the EES (Engineering Equation Solver) software and is based on the works of Jahing (1999) and Jahing et al. (2000). In the method, four experimental measurements of the mass flow and electric power are enough to determine the fitting parameters of the model. This procedure allows the generation of satisfactory compressor maps without the necessity of a higher number of experimental data, as in the case of norm ARI 540 application. The results obtained with the model can be used for the design of new compressors.

Neste trabalho aplica-se um método semi-empírico que utiliza uma técnica de otimização não linear para determinação das eficiências volumétrica e combinada do compressor hermético alternativo. Relações para estimar aproximadamente o fluxo de massa e a potência elétrica do compressor também são propostas. Todas estas características do compressor são calculadas através das relações físicas do modelo, empregadas nos cálculos de otimização. O método é implementado no software EES (Engineering Equation Solver) e baseia-se nos trabalhos de Jahing (1999) e Jahing et al. (2000). No presente método, cinco medições experimentais do fluxo de massa e potência elétrica são suficientes para determinar os parâmetros de ajuste do modelo. Este procedimento permite a geração de mapas de compressores satisfatórios sem a necessidade de um maior número de dados experimentais como no caso da norma ARI 540. Estes resultados obtidos com o modelo podem ser usados para o projeto de novos compressores. / In the present work is applied a semi-empirical method that uses a non-linear optimization technique for determination of the volumetric and combined efficiencies of hermetic reciprocating compressor. Relations to approximately estimate the mass flow and the electric power of the compressor are also proposed. All these compressor characteristics are calculated through physical model relations, used in the optimization calculations. The method is implemented in the EES (Engineering Equation Solver) software and is based on the works of Jahing (1999) and Jahing et al. (2000). In the method, four experimental measurements of the mass flow and electric power are enough to determine the fitting parameters of the model. This procedure allows the generation of satisfactory compressor maps without the necessity of a higher number of experimental data, as in the case of norm ARI 540 application. The results obtained with the model can be used for the design of new compressors.

A streamline curvature (SLC) throughflow numerical model was assessed and modified to better approximate the flow fields of highly transonic fans typical of military fighter applications. Specifically, improvements in total pressure loss modeling were implemented to ensure accurate and reliable off-design performance prediction. The assessment was made relative to the modeling of key transonic flow field phenomena, and provided the basis for improvements, central to which was the incorporation of a physics-based shock loss model. The new model accounts for shock geometry changes, with shock loss estimated as a function of inlet relative Mach number, blade section loading (flow turning), solidity, leading edge radius, and suction surface profile. Other improvements included incorporation of loading effects on the tip secondary loss model, use of radial blockage factors to model tip leakage effects, and an improved estimate of the blade section incidence at which minimum loss occurs. Data from a single-stage, isolated rotor and a two-stage, advanced-design (low aspect ratio, high solidity) fan provided the basis for experimental comparisons. The two-stage fan was the primary vehicle used to verify the present work. Results from a three-dimensional, steady, Reynolds-averaged Navier-Stokes model of the first rotor of the two-stage fan were also used to compare with predicted performance from the improved SLC representation. In general, the effects of important flow phenomena relative to off-design performance of the fan were adequately captured. These effects included shock loss, secondary flow, and spanwise mixing. Most notably, the importance of properly accounting for shock geometry and loss changes with operating conditions was clearly demonstrated. The majority of the increased total pressure loss with loading across the important first-stage tip region was shown to be the result of increased shock loss, even at part-speed. Overall and spanwise comparisons demonstrated that the improved model gives reasonable performance trends and generally accurate results, indicating that the physical understanding of the blade effects and the flow physics that underlie the loss model improvements are correct and realistic. The new model is unique in its treatment of shock losses, and is considered a significant improvement for fundamentally based, accurate throughflow numerical approximations. The specific SLC model used here is employed in a novel numerical approach — the Turbine Engine Analysis Compressor Code (TEACC). With implementation of the improved SLC model and additional recommendations presented within this report, the TEACC method offers increased potential for accurate analysis of complex, engine-inlet integration issues, such as time-variant inlet distortion. / Ph. D.

The purpose of this study is to analyze the behavior of a reversible two-cylinder refrigerant compressor manufactured by Bristol Compressor Incorporated. This compressor contains a specialized linkage that causes the compressor to transition from a two-cylinder compressor to a single-cylinder compressor when the direction of rotation of the crankshaft is reversed. The linkage accomplishes this by reducing the throw of one cylinder to zero. Of interest are the conditions to which this linkage is subjected when the direction of rotation is again reversed, causing the compressor to return to its two-cylinder functioning. When this reversal takes place, a collision occurs within the linkage. These repeated collisions are thought to be the cause of fatigue failure of the linkage in many of these compressors. To verify that this collision is the problem, an understanding of the stress state during the collision is needed. This thesis begins the work necessary to determine the dynamic stress state present within the system. A FORTRAN program was developed that modeled the kinematic behavior of the system under operating conditions. The program predicts the accelerations, velocities, positions, and internal forces present within the system during startup conditions. Also, a method has been developed to model rotary sliding contact between two cylindrical surfaces. This method is developed and investigated in hopes that it will facilitate the modeling of the behavior of the compressor linkage in a dynamic finite element analysis. / Master of Science

Compressed air makes up an important part of South African precious metal mining processes. Rising operational costs in the struggling mining sector increased the interest of the power utility, Eskom, and mine management in achievable electrical energy savings. Demand side management initiatives, funded by Eskom, realised a significant improvement in electrical energy efficiency of compressed air networks. Supply side interventions further aided optimisation by lowering operational costs. Previous research identified the need for integrating compressed air supply and demand side initiatives. Automated compressor control systems were needed in industry to realise missed opportunities due to human error on manual control systems. Automatic systems were found to be implemented in the industry, but missed savings opportunities were still encountered. This was due to the static nature of these control systems, requiring human intervention from skilled artisans. A comprehensive system is required that can adjust dynamically to the ever-changing demand and other system changes. Commercially available simulation software packages have been used by various mine groups to determine an optimal control philosophy. Satisfactory results were obtained, but the simulations were still based on static control inputs. No simulation system was found that could solve and optimise a system based on real-time instrumentation feedback. By combining simulation capabilities with dynamic control in real time, advanced optimisation could be achieved. Development was done on the theoretical design of the system, where mathematical calculations and the accuracy of the system were evaluated. This study proved that the new controller was viable and, as a result, the development of a fully dynamic control Automation of compressor networks through a dynamic control system iii system incorporating the verified mathematical models followed. All of this was done following a theoretical approach. Intricate control requirements on the supply side were evaluated to determine the impact of new intelligent compressor control strategies. It was found that improved compressor control realised an additional 6.2% electrical energy saving on top of existing savings initiatives. Practical limitations and human perception issues were also addressed. Financial cost-benefit analyses were used to evaluate the viability of using automated compressor control. Ample maintenance data obtained from two leading mining companies was used to evaluate the impact of increased stopping and starting of compressors. Financial cost savings from electrical energy efficiency control strategies were found to considerably outweigh the minimal increase in compressor maintenance. Savings potential on deep-level mines proved to be in the order of 5% of the baseline consumption. When these results are extrapolated to the remaining 22 South African deep-level gold and platinum mines already subjected to demand side management initiatives, potential savings of 12.67 MW can be realised. Based on the Eskom 2014/2015 Megaflex tariff structure, the financial cost saving from 12.67 MW is R61 million. / PhD (Electrical Engineering), North-West University, Potchefstroom Campus, 2015

Compressed air makes up an important part of South African precious metal mining processes. Rising operational costs in the struggling mining sector increased the interest of the power utility, Eskom, and mine management in achievable electrical energy savings. Demand side management initiatives, funded by Eskom, realised a significant improvement in electrical energy efficiency of compressed air networks. Supply side interventions further aided optimisation by lowering operational costs. Previous research identified the need for integrating compressed air supply and demand side initiatives. Automated compressor control systems were needed in industry to realise missed opportunities due to human error on manual control systems. Automatic systems were found to be implemented in the industry, but missed savings opportunities were still encountered. This was due to the static nature of these control systems, requiring human intervention from skilled artisans. A comprehensive system is required that can adjust dynamically to the ever-changing demand and other system changes. Commercially available simulation software packages have been used by various mine groups to determine an optimal control philosophy. Satisfactory results were obtained, but the simulations were still based on static control inputs. No simulation system was found that could solve and optimise a system based on real-time instrumentation feedback. By combining simulation capabilities with dynamic control in real time, advanced optimisation could be achieved. Development was done on the theoretical design of the system, where mathematical calculations and the accuracy of the system were evaluated. This study proved that the new controller was viable and, as a result, the development of a fully dynamic control Automation of compressor networks through a dynamic control system iii system incorporating the verified mathematical models followed. All of this was done following a theoretical approach. Intricate control requirements on the supply side were evaluated to determine the impact of new intelligent compressor control strategies. It was found that improved compressor control realised an additional 6.2% electrical energy saving on top of existing savings initiatives. Practical limitations and human perception issues were also addressed. Financial cost-benefit analyses were used to evaluate the viability of using automated compressor control. Ample maintenance data obtained from two leading mining companies was used to evaluate the impact of increased stopping and starting of compressors. Financial cost savings from electrical energy efficiency control strategies were found to considerably outweigh the minimal increase in compressor maintenance. Savings potential on deep-level mines proved to be in the order of 5% of the baseline consumption. When these results are extrapolated to the remaining 22 South African deep-level gold and platinum mines already subjected to demand side management initiatives, potential savings of 12.67 MW can be realised. Based on the Eskom 2014/2015 Megaflex tariff structure, the financial cost saving from 12.67 MW is R61 million. / PhD (Electrical Engineering), North-West University, Potchefstroom Campus, 2015