Distributor / authorized representative that deals with supply & delivery of axial vane compressors to industrial enterprises of Russia
Engineering company ‘Intech GmbH’ LLC (ООО «Интех ГмбХ»), Russia, has been successfully working with a number of Russian industrial enterprises at the local market for more than 20 years. Since the company’s founding, it has acquired immense engineering experience, market reputation, and has realized more than a hundred large-scale projects at the industrial plants in Russia. Our company is continuously in search of new business partners, who consider Russian market investment-attractive and want to boost their sales in the region, as well as expand their field of activities and enter a new international level.Contents:
We are interested in cooperation with the manufacturers of axial vane compressors, who are looking for an official and reliable distributor that deals with supply & delivery of their equipment to the industrial plants in Russia.
The company’s top management and sales team are well acquainted with the Russian market, its mentality and laws; they also understand industrial specifics of the financial and economic activities of the Russian customers. All our sales managers have a large customer database, extensive experience of successful sales and well-established connections with the potential buyers of your axial vane compressors. This allows our managers to promptly set out the most promising directions for promotion and to ensure a rapid entry of the products into the promising Russian market. Our employees, who are fluent in English and German, are focused on working at the international market with the supplies of foreign equipment.
Our team of experienced engineers, who can handle the most serious technical problems, constantly keeps in touch with the Russian customers, holds meetings and delivers presentations regarding the latest achievements of our manufacturing partners. They point out the engineering challenges and actively communicate with all the departments at Russian plants. That is why the specifics of doing a business in the Russian Federation are well-known to us, and we also know the equipment of the local industrial plants and their up-to-date modernization needs.
Once we become your authorized representative in Russia, our marketing staff will carry out a market research in order to check the demand for axial vane compressors, will submit a market overview for axial vane compressors that you offer and evaluate the needs for this type of equipment at local plants. Our specialists will also estimate the potential and capacity of this market at local industrial plants. Our IT-team will start developing a website for your products in Russian. Our experts will assess the conformity between your axial vane compressors and customer needs as well as analyze the common reaction to the new goods in general. We will look into the categories of potential customers, and pick out the largest and the most promising plants.
Upon becoming your authorized agent on the territory of Russia, ‘Intech GmbH’ LLC (ООО «Интех ГмбХ»), will obtain certificates, if required, for a batch of the goods, for various types of axial vane compressors in compliance with Russian standards. We can also arrange the inspection in order to obtain TR TS 010 and TR TS 012 Certificates. These certificates provides permission to operate your equipment at all industrial plants of the EAEU countries (Russia, Kazakhstan, Belarus, Armenia, Kyrgyzstan), including the hazardous industrial facilities. Our company is eager to assist in issuing Technical Passports for axial vane compressors as per Russian and other EAEU countries’ requirements.
Our engineering company ‘Intech GmbH’ LLC (ООО «Интех ГмбХ»), collaborates with several Russian design institutes in various industrial segments, which allows us to conduct preliminary design as well as subsequent design works according to the standards, construction rules and regulations that are applicable in Russia and other CIS countries. It also enables us to include your axial vane compressors into the future projects.
The Company has its own logistics department that can provide packing service, handling as well as the most efficient and cost effective mode of transportation of the goods (incl. over dimensional and overweight goods). The goods can be delivered on DAP or DDP-customer’s warehouse basis in full compliance with all the relevant regulations and requirements that are applicable on the Russian market.
Our company has its own certified specialists who will carry out installation supervision and commissioning of the delivered equipment, as well as further guarantee and post-guarantee maintenance of axial vane compressors. They will also provide necessary training and guidance for the customer’s personnel.
Overview: axial vane compressors
Vane type compressors are dynamic machines, which working elements - vanes - increase the gas pressure in a continuous flow. When rotating, vanes transfer the kinetic energy to the gas, which then converts into the potential energy. The increment of energies, kinetic and potential, of the pumped gas occurs as follows: gas interacting with the rotating grate, which houses the vanes of the blade wheel (one of which rotates and the other is fixed) generates a suitable constant pressure, without producing pulsations. It is a unique feature in this type of compressors. Leaving the blade wheel, the gas goes into the withdrawal device. The increase in the gas flow energy in the flow part of the compressor results in the gas compression without altering the thermodynamic state.
There exist the following types of vane compressors or, as they are also called, turbocompressors:
- Centrifugal (radial)
- Radiaxial (diagonal)
There is a functional relationship between all the elements in the flow part of the compressor. This means that if, for example, the blade wheel has good aerodynamic characteristics, the required unit efficiency will not necessarily be provided.
The compressor stage of this type includes:
- Supplying device
- Blade wheel
- Withdrawal device.
Let us imagine the work of the intermediate stage by the example of a centrifugal compressor. The reverse guide vanes and the inlet guide vanes, which create the necessary turbulence of the flow at the inlet of the blade wheel, perform the role of the supplying device. The blade wheel (in this case of the closed type) is fixed on the shaft. Leaving the wheel, the gas enters the vaneless ring diffuser, and then the reverse guide vanes of the next stage.
Labyrinth seals are used between stages to minimize the overflow of the gas between the rotating wheel and the fixed stator system. This helps to achieve a high efficiency level of the stage and affects the energy characteristics of the stage itself.
Components of the stage can be roughly divided using the control sections, and their gas-dynamic parameters will reflect the process of the gaseous medium flow in the flow part of the compressor stage. The funnel at the blade wheel inlet has a radial section defining the flow parameters when the flow enters the blade wheel. The transfer of the gas flow on the vanes is also characterized by a certain section located parallel to the leading edge of the blade. At the inlet and outlet, you also select sections that are arranged parallel to the rotation axis of the rotor. In centrifugal compressors, the withdrawal device can be configured as the scroll of the vaneless ring diffuser or as a withdrawal device with vanes. The end seals are mounted at the junction of the shaft and the compressor housing.
Vane compressors along with other positive displacement compressors are most widely used for boosting in internal combustion engines.
Vane compressors are devices in which the gas is moved from the low-pressure zone to the high-pressure zone under the continuous impact of the vanes on the flow, thus causing compression and increased kinetic energy of the gas. The kinetic energy received by the gas is converted into pressure in the diffuser located next after the blade wheel.
Vane compressors were chosen for their application in industries with low or medium pressure and high efficiency. In the compressor, gases, not fluids, pass through the wheel, and due to changes in the gas density with changes in the gas pressures, the compression process becomes more complicated. However, since the difference in pressures within the wheel is insignificant, all the calculations of the compressor are carried out based on the specific gas density. The higher the peripheral velocity of the gas while leaving the wheel, the greater the head produced by the compressor and the ber the material of the blade wheel should be. The wheel of alloy steel can provide a compression ratio ξ = 1,25...1,5.
If you need a higher compression ratio, the gas should be compressed consecutively in several wheels. The gas velocity at the outlet of the blade wheels is very high and can reach 160...170 meters per second, which indicates the high kinetic energy of the gas.
If the gaseous medium is moved by centrifugal forces radially, this is a centrifugal compressor of the vane type (radial). If the gaseous medium moves along or parallel to the axis of the blade wheel, this is an axial compressor of the vane type. Both types of vane compressors resemble types of pumps of the same name in terms of their arrangement principle, but compressors have structural features associated with a b decrease in the gas volume and increase in the temperature.
Let us consider some design versions of vane type compressors:
1) Centrifugal compressor. The main unit of this compressor is a set of blades having a complex shape and equally spaced from one another on the rim of the disc. The blades (see fig. below) suck in the incoming air, driving it to the outlet pipe. The air is compressed under the effect of centrifugal force. Before the release, the air can be driven further through the diffuser designed to reduce pressure losses.
During the compressor operation, rotating parts (blade wheel, shafts) rub against the pumped gas and get slightly worn. Bearings and end seals of the compressor are also exposed to friction. To overcome this friction you need additional power expenditures, therefore, to calculate the effective power it is necessary to subtract from the power intake expenditures used to overcome the losses. The complex design of the compressor flow part makes it difficult to estimate losses, but the use of the computer allows you to calculate the losses related to power expenditures accurately due to the friction in the compressor. All the losses in the compressor stages are summed.The compressor power is not completely consumed in compressing the gas - as with any mechanism - the compressor has power losses. During the gas movement in the flow part, the gas-dynamic losses cause a decrease in the head, which means that the actual pressure in the compressor is always less than the estimated value. A part of the compressor power is used to overcome these losses. Similarly, the effective power of the blade wheels is always less than the estimated one.
The following losses occur in the compressor stages:
a) gas-dynamic losses associated with changes in the flow rate and its direction in the flow part;
b) additional losses associated with the impact inleakage of the flow on the blades, with flow separation and vortex formation of the gas flow;
c) losses in the blade wheel;
d) volume losses (leakage of the gas);
e) mechanical losses: internal mechanical losses due to the friction of the outer rotating elements against the pumped gas and external mechanical losses due to the friction in bearings and end seals of the compressor.
The following equation will be correct for centrifugal compressors:
Ws = u2CΘ2 – u2CΘ2,
Ws — input power on the shaft
u — speed of the blade tip
Cθ — tangential components of the rates of the flow which rebounds from the blades at the inlet and outlet, respectively.
Drives for compressor centrifugal machines:
- Electric motors of the standard design with a simple drive circuit and easy-to-use features
- Gas turbines with good self-containment, higher than that of a conventional electric motor, with the rotation speed of 5,500 – 6,000 rpm and the possibility of an efficient control system
- Air and steam turbines (for refrigerating compressor units) with the high rotation speed up to 100,000rpm.
Main disadvantages of the centrifugal compressor include the fact, that to operate it requires a very high rotation speed of the impeller. The pressure generated by the compressor is equal to the square of the speed of the impeller, therefore, the basic compressor speed is at least 40,000rpm, and however, it can reach 200,000rpm. This leads to a very high rotation speed of the drive mechanism belt, which causes excessive noise during operation, and rapid wear of the compressor parts. The problem of noise is sometimes eliminated with the help of an additional device, multiplier, which causes the loss of a part of the compressor efficiency.
At low speed, the efficiency of such compressor is very low, but when increasing the number of revolutions the power increases quite rapidly, too. For this reason, centrifugal compressors are mounted on machines, where there is a need in high power and speed, and the low intensity of acceleration is not taken into account.
Advantages of centrifugal compressors: low price, simple installation. This made centrifugal compressors popular in the automotive industry.
If the flow rate of the centrifugal compressor and the size of the blades reduce, the decrease in the efficiency of these compressors is not very significant; therefore, the main field of application of centrifugal compressors is gas turbine units with insignificant flow rates of the actuating medium and parameters of compression ratios. In this field of application, centrifugal compressor units are superior to axial compressor units in terms of efficiency and weight while having the same degree of compression.
Obvious advantages of centrifugal compressors include simple structure, small number of component parts, better characteristics of the pumping process, low sensitivity to operating conditions.
A disadvantage of this type of compressors is a lower level of efficiency compared to the axial type due to the complexity of the multi-stage compression. In the simple arrangement of the centrifugal compressor, its dimensions grow in direct proportion to the airflow passing through it. Disadvantages can also include low frontal performance.
The main advantage of the centrifugal compressor in comparison with the axial one is its ability to produce higher degrees of compression per one stage - it exceeds 5...6, and in advanced aircraft compressors it can reach even 12. The efficiency of the centrifugal compressor stage can reach 0.85, which is less than that of the axial compressor. Efficiency values close to the above are typical for compressors of aircraft gas turbine engines having relatively high performance.
2) Rotary or rotary-vane compressor. In this compressor, the compression process is carried out by means of a massive round rotor that rotates eccentrically in a special round housing. The rotor has grooves or slits intended for the vanes of rectangular shape. The blades during rotation are pressed to the walls by centrifugal force.
Rotary-vane compressor layout
During the operation of compressors with two- and three-bladed rotors, the gas is completely sucked in, enters the zone between the blades and the housing, enters the discharge cavity and then is completely displaced through the discharge pipe. The generating lines of the blades are usually executed in the form of a screw, which provides a continuous flow of the gas and is one of the advantages of this compressor. These compressors are usually compact, but the complexity of the kinematic system of this type is a disadvantage and complicates the design concept as a whole, which limits their widespread use. For this reason, there is an aim to expand functionality for practical use. This aim can be reached by installing two blades along one rotation axis in the housing of the rotary-vane compressor and binding them kinematically with the central gears connected to the satellite row. The satellite is equipped with a carrier containing an additional planetary gear train fitted with a central pinion and fixed central wheel. The carrier, if there is a retainer or stopper, has the ability to brake, and the satellite itself is connected to the rack through the gear transmission. It is characteristic that both the satellite row and central gears are not round, but for example, elliptical.
Work processes of the rotary-vane compressor are similar to those of the reciprocating compressor, which allows calculations based on theoretical estimates used for the classical calculation of reciprocating compressors. At the same time, one should not forget about the special characteristics of the rotary-vane compressor. Special attention here is required by the losses arising due to the overflow of the working medium in the compressor itself, which affect its performance. They are caused by the pressure differential between the closely spaced working chambers in the rotary-vane compressor, separated by movable blades.
Speaking of the advantages of these compressors, we should mention the following:
The use of the non-round satellite row and central gears in the described compressor is not accidental, since it excludes the axial impact on the walls of the housing, and thus allows using non-contact seals, omitting the use of many bearings, valves at the inlet and the outlet, and seals. This allows you to expand the application functionality of rotary-vane compressors, for example, to use them in refrigerating machines.
Powerful compressors widely used due to the low price and very high reliability. The low price is caused by the simplicity of manufacture, and the high reliability - by the design features: the rotors do not come into contact with each other, and their synchronization is achieved by the synchronizing gears, the gear ratio of which is equal to one. It ensures a low load level of the device, which provides for efficiency: the service life of the gears determines the service life the compressor. Such compressors are used in industries with high consumption and low pressures, while providing for long service life and extremely reliable operation; they are almost insensitive to the dust content of the sucked air in contrast to compressors, the working chamber of which contains friction couples. Rotary-vane compressors have a wide range of performance. The losses of oil are excluded (in case of oil-flooded compressors) due to the oil return system. The filter set at the outlet filters the discharge gas. The oil is prevented from entering back into the system due to the check valve set on the air inlet.
This type of compressors has a large variety of applications: they are applicable for aeration of treatment facilities and reservoirs; in the food industry; in the production of vacuum packages; in the textile industry; in the automotive industry; in central heating systems; in chemistry, laser production, and pharmacy; in metallurgy and mechanical engineering, as well as in research.
3) Axial compressors. They represent one of the varieties of turbocompressors. The operating principle of the axial compressor resembles that of the axial pump: the gas moves mainly along the rotation axis, and in contrast to dynamic compressors or turbocompressors, the air compression in the axial compressor takes place, like the movement of the gaseous medium itself, along the shaft axis. The particles of the gas flow have trajectories close to the cylindrical or conical planes.
Structurally, axial compressors are divided into single-stage and multi-stage.
The axial compressor consists of the rotor with alternating moving grates with vanes fixed to the shaft and called the blade wheels, and the stator with fixed vane grates called the guide vanes. The rotary shaft is connected to the turbine shaft and rests on the ball and roller bearings. The cylindrical unit of the housing represents a set of cylindrical sections which are joined together axially by means of screw connections. The housing can consist of two elements also connected axially with screws. This design ensures the disposition of the compressor housing around the rotor.
The gas-dynamic behavior of vane compressors is excessively inert because the compressor rather slowly gains momentum in the operation process. Turbines usually drive vane compressors. The turbines themselves rather slowly reduce their speed, so turbocompressors need a lot of time to switch to another mode of operation. The problem was solved by dividing the compressors into:
a) low pressure compressor equipped with its own separate turbine mounted on the shaft,
b) high pressure compressor with its own separate turbine.
Such devices are referred to as two-shaft. This solution improved the operation of the compressors when switching from mode to mode, and also improved their gas-dynamic behavior and ensured its sustainability.
Axial compressors differ from each other in the type of vanes, and are widely used in aircraft; in industrial processes requiring very high efficiency and low pressure; as a part of the compound compressor as the initial stage.
Typically, axial compressors are designed multi-stage. The design possibility to create multi-stage axial compressors, the airflow rate of which can be controlled, reduces losses of the compressor and increases its efficiency and, therefore, reduces the fuel consumption. This is an advantage over centrifugal compressors, as these conditions are almost impossible to achieve during the operation of centrifugal compressors.
The axial compressor stage structurally differs from the centrifugal compressor stage by its less complicated design. The vanes can be fixed on the blade wheel or can be turned at a certain angle, but only when the compressor is stopped. The guide vanes can also be mounted fixed or with the possibility of turning both on the stopped and on the running compressor.
Below, see the appearance of the axial compressor vane:
Axial compressor vane
Advantages of axial compressors:
- Easy-to-manufacture components (except for the vanes)
- Compact design
- Allow reaching higher levels of efficiency (in perfect structures - 90-94%) and high supply values at low pressure
- Have high performance
- The axial compressor rotor has high speed, consistent with the GT speed.
Disadvantages of axial compressors include the complexity of the manufacture of a large number of vanes, their susceptibility to contamination, failure of the vanes when suspended particles, water, and other foreign bodies enter the flow part.
Axial compressors are usually used in air-breathing engines for airplanes and helicopters.
Siemens and Elliott can be named among the manufacturers of axial compressors.
4) Axial-centrifugal compressors. Sometimes in turbine machines, where the flow rate of the actuating medium is not very significant, axial-centrifugal multi-stage compressors can be used to increase the efficiency of the compressor. They are a combination of axial and centrifugal stages, whereby the centrifugal stage is always the last one. It is set instead of multiple axial stages, the vanes of which have a very low altitude. Such vanes very sharply react to the effect of radial clearances and secondary flows. Compressors of this combined type, despite the slight loss of efficiency, have much smaller linear dimensions and weight when compared with axial compressors with the same compression ratio values.
This type of compressors is now at the development stage.
5) Diagonal compressors (radiaxial). In terms of operation principle and design parameters, the diagonal compressor is not very different from the radial compressor and represents an intermediate type. This is confirmed by the discharged medium outlet direction - at a certain angle in the axial-radial direction.
Vane type compressors may vary in the number of rotary devices:
- Single-rotor turbocompressor, equipped with only one rotor;
- Multi-rotor turbocompressor, has two or more rotors (double-, triple-rotor, etc.).
By the number of housings, vane compressors are divided into:
- Single-housing compressors structurally implemented in a single housing
- Multi-housing compressors can have two, three housings, etc.
By the flow type, vane compressors are divided into:
- Centripetal compressors, representing the compressor of the radial type, where during the rotation of the vane grates in the meridional plane the actuating medium flow goes from the periphery to the center
- Vortex compressors, representing centrifugal compressors, where the compressed gas repeatedly circulates through the rotating vane grate
- Jet compressors are dynamic compressors, where the compressed air flow is affected by the flow with greater energy density
- Centrifugal-centripetal compressors represent a combined type of turbocompressors having the stages of the centrifugal and centripetal type.
In addition, we should once more highlight the benefits of the vane-type compressor equipment, which reveal themselves during the compression of large amounts of gas:
a) the compressor shaft is connected to the motor shaft directly, without any intermediate conversion speed devices;
b) the supply of the actuating medium is uniform and continuous, so there is no need to install large tanks on the discharge side;
c) inertial forces are minimal, so you can use a lighter foundation;
d) no suction or discharge valves, which increases the reliability of the unit;
e) during the supply, the gas is not contaminated with lubricants from the working elements.
A few words should be said on the choice of the compressor unit. The most important aspect when choosing a compressor is its performance. Units of its measurement: l/min or m3/min, if it has sufficient power characteristics. This value should be calculated taking into account all the technical parameters of pneumatic devices.
The following table shows the calculation formulas for the characteristics of vane compressors:
Recalculation of the vane compressor characteristics:
|Characteristics||Performance, P||Pressure ratio, λ||Power, N|
|Rotation speed change||P2/P1 ≈ n2/n1||λ2 ≈ [1 + (n2/n1)²·(λ1[(k-1)/k]-1)][k/(k-1)]||N1/N2 ≈ [ρ12/ρ11]·[n2/n1]3|
|Change of the gas properties||P1 ≈ P2||λ2 ≈ [1 + (T11/T12)(λ1[(k-1)/k]-1)][k/(k-1)]||N1/N2 ≈ ρ1/ρ2|
|The formulas are applicable for the range of rotation speed relations from 0.5 to 2 and geometric dimensions from 0.5 to 2|
When choosing a compressor unit, the certainty with the power source is of great importance. Usually a single-phase network is used, but large industries require three phases. If the operation is remote, i.e. the unit is located far from power grids, it is necessary to use a compressor unit equipped with the autonomous petrol or diesel engine.
There are certain initial data, which need to be considered when choosing a compressor:
1) flow rate of the inlet gas;
2) required final pressure of the unit;
3) temperature, suction pressure, relative humidity of the inlet gas;
4) molar composition, pollution of the pumped gas, its harmfulness, ability to polymerize;
5) drives (type, requirements);
6) special list of requirements (no lubricant in the gas path, limited weight of the equipment, requirements to dimensions, vibration, noise, seals to provide tightness).
The main parameters of the fabricated compressor are final pressure (Pk) and flow rate of the inlet gas (VH). They determine the type and the model of the compressor.
Some background information on the average characteristics of vane compressors is shown in the following table:
Average characteristics of vane compressors:
|Pressure ratio within one stage, λ1||not more than 1.4||1.1… 1.3|
|Adiabatic efficiency, ηad||0.8… 0.9||0.85… 0.95|
|Mechanical efficiency, ηmech||0.96… 0.98||0.98… 0.99|
The correct choice of a particular compressor type determines its service life. When buying a compressor, it is necessary to provide for the margin of performance and operation intensity.
The service life of any compressor is associated with a variety of factors:
- Ambient temperature: most types of compressors are operated in the temperature range from + 5 to + 45 degrees. Temperature below these values causes an increase in the viscosity of the refrigerant oil, thereby increasing the load on the compressor; temperature above the given values facilitates liquefaction of the oil, leading to the wear of the working planes
- The premises, the compressor and the inlet air must be clean, which contributes to the better cooling. The cleanliness makes it easier to control and locate faults and leaks
- Fluctuations in voltage, phase losses or imbalances adversely affect the condition of the compressor, reduce its service life
Timely and high quality maintenance is necessary for any compressor, irregular and poor preventive maintenance shortens the service life of the
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Upon becoming the official distributer of axial vane compressors, our company ‘Intech GmbH’ LLC (ООО «Интех ГмбХ»), carries out the following: finds the buyers of your products on the market, conducts technical and commercial negotiations with the customers regarding the supplies of your equipment, concludes contracts. Should a bidding take place, we will collect and prepare all the documents required for the participation, conclude all the necessary contracts for the supply of your equipment, as well as register the goods (axial vane compressors) and conduct customs clearance procedures. We will also register a certificate of transaction (Passport of Deal) required for all foreign trade contracts in the foreign currency control department of the authorized Russian bank so that currency transaction could be effected. If required, our company will implement an equipment spacing project in order to integrate your equipment into the existing or newly built production plant.
We are convinced that our company ‘Intech GmbH’ LLC (ООО «Интех ГмбХ»), will become your reliable, qualified and efficient partner & distributor in Russia.
We are always open for cooperation, so let’s move forward together!