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Rotating Equipment
CHAPTER 5
RECIPROCATING COMPRESSORS
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Rotating Equipment
CHAPTER 5
RECIPROCATING COMPRESSORS
CONTENTS
Page Number
SECTION - 5.1
Reciprocating Compressor Working Principle & Components
5.1.1 Compressor component ...
5.1.2 How does it work .
5.1.3 Compressor cycle in the pressure volume diagram .
5.1.4 Single acting compressor and double acting
5.1.5 Trunk compressor and cross head compressor .
5.1.5.1 Trunk design
5.1.5.2 Crosshead design .
5
6
7
8
9
9
10
SECTION - 5.2
Reciprocating Compressor Component
5.2.1 Drive end group ..
5.2.2 Compression cylinder group ..
5.2.2.1 Cylinder & cylinder liner
5.2.2.2 Valves and unloading system .
5.2.2.3 The piston and piston rings
5.2.2.4 Piston rod and piston rod packing .
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13
13
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18
SECTION - 5.3
Reciprocating Compressor Cooling Systems
5.3.1 Cylinder cooling .
5.3.2 Cooling methods
5.3.2.1 Air cooling method
5.3.2.2 Water cooling method
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20
21
21
SECTION - 5.4
Multi Stage Compression
5.4.1 Theory of multi staging ..
5.4.2 Advantages of multi staging ...
5.4.3 Cooling systems for gas between stages and after the last stage
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SECTION - 5.5
Reciprocating Compressor Lubrication
5.5.1 Function of lubricants .
5.5.2 Methods of lubricant distribution
5.5.2.1 Forced circulation system ...
5.5.2.2 Splash lubrication system ...
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25
25
SECTION - 5.6
Classification of Reciprocating Compressors
5.6.1 Classification of compressors into single or double acting
5.6.2 Classification into single stage or multi stage
5.6.3 Classification into trunk type and compressor with crosshead ..
5.6.4 Classification with respect to cylinder layout .
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SECTION - 5.7
Prim Movers for Reciprocating Compressors
5.7.1 Function of a driver .
5.7.2 Driver selection
5.7.2.1 Electric motor driven compressors .
5.7.2.2 Internal combustion engine driven compressors
5.7.2.3 Reciprocating steam engine and steam turbine driven
compressors
5.7.2.4 Gas turbine driven compressors .
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SECTION - 5.8
Reciprocating Compressor Operation
5.8.1 Starting a new reciprocating compressor .
5.8.2 Cleanliness of the suction line .
5.8.3 Break in period
5.8.4 Preparation for extended shut down
5.8.5 Routine checks
5.8.6 Air cooled compressor routine checks
5.8.7 Troubleshooting ..
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38
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SECTION - 5.9
Reciprocating Compressor Maintenance
5.9.1 Strip down the compressor .
5.9.2 Piston rod maintenance ..
5.9.3 Cylinder & cylinder liner maintenance (inclued water jackets)
5.9.4 Reciprocating compressor valves maintenance
5.9.5 Driving end maintenance ..
5.9.6 Inspection and maintenance of auxiliary equipment .
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CHAPTER 5
RECIPROCATING COMPRESSORS
Introduction
Chapter 4 was an overview of different types of compressors and centrifugal
compressors. In this chapter further details of reciprocating compressors will be
covered.
This chapter is nine sections, they are:
1- Reciprocating compressor working principle.
2- Reciprocating compressor components.
3- Reciprocating compressor cooling systems.
4- Multi stage compression.
5- Reciprocating compressors lubrication.
6- Classification of reciprocating compressors.
7- Prime movers for reciprocating compressors.
8- Reciprocating compressor operation.
9- Reciprocating compressor maintenance.
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SECTION 5.1
RECIPROCATING COMPRESSOR WORKING PRINCIPLE &
COMPONENTS
5.1.1 Compressor Component
The basic reciprocating compressor consists of:
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Piston (s).
Piston rings.
Cylinder (s)
Valves (suction valve & discharge valve).
Driving mechanism (crank shaft, connecting rod, cross head and piston
rod).
6- Suitable frame.
Figure 5.1 shows these components
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1- Suction Stroke
1- The piston moves from position (A) to position (B). This create vacuum
inside the cylinder. The differential pressure exists across the suction
valve (inlet valve). Inlet valve open.
2- Gas (or air) is drawn into the cylinder via (through) the suction valve.
In the suction stroke the suction valve is open, the discharge valve is
closed, the piston movement from (A) to (B).
3- When the piston reach position (B) it stop before change the direction of
movement from (B) towards (A). At this moment both valves (suction
and discharge) are closed.
2- Discharge Stroke
1- The gas is trapped in the cylinder.
2- The piston moves from (B) to (A). The volume of gas decrease and its
pressure increases and the temperature also.
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3- When the gas pressure inside the cylinder becomes higher than the
pressure of the gas in the discharge manifold, the discharge valve open
and the gas passes through the discharge valve to outside the cylinder.
4- The piston keep going pushes the gas outside the cylinder until it reaches
again position (A). When the piston reaches position (A), it completes
one complete cycle.
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4- At point (3) both valves (suction & discharge) are closed, the
compression stroke from point (3) to point (4). Until point (4), the
compression stroke still going.
5- At point (4) the discharge valve opens, the gas leaves the cylinder via
discharge valve and the piston keep going pushing away the gases to
point.
At point (1) the compressor complete one complete cycle.
The area 1 2 3 4 represent the power consumed to perform compression.
(a)
(b)
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S. No.
Number of valves
Number of
compression strokes
in one crank shaft
revolution
Double acting
compressor
One set of valves on
One set of valves
each side of the piston
(suction valve (s) and
head.
discharge valve (s)) on
(one set on head end
one side of the piston
& one set on crank
head (head end)
end.)
one
Two
once
Power consumption
per unit volume
Higher
Less
Mechanical
construction
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SECTION 5.2
RECIPROCATING COMPRESSOR COMPONENT
In this section further details of reciprocating compressor components will be
covered.
The common parts of all reciprocating compressors are grouped into two
groups:
1- Drive end group.
2- Compression cylinder group.
Drive end group (some times called crank mechanism) consists of:
Crank shaft & crank shaft bearings
Connecting rod
Crosshead.
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The liners are pressed or shrunk into place. It must be sufficiently thick enough
to withstand the pressure load during the compression stroke.
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Valve seat.
Moving sealing element (valve disc).
Certain sort of spring force.
A cage (or guard) to contain the travel of the moving sealing elements.
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Valve Designs
There are several designes are commonly used to day. The most common types
are:
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Piston rings provide a seal that prevent or minimize leakage between the piston
and the liner. During operation, the pressure of the gas between the piston ring
and the piston pushes the piston ring against the wall of the cylinder (liner).
In some other designs, there is a spring ring between the piston and the piston
ring to keep the contact between the piston ring and the wall of the cylinder.
The function of rider rings (or guide rings) are to carry the weight of the piston
(in horizontal cylinders) and to guide the piston during its movement (in vertical
cylinders).
In non-lubricated compressors (oil free compressors) the piston rings and rider
rings are made from low friction materials like Teflon (figure 5.9)
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Figure 5.10 Exploded view of non lubricated piston & piston rings
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SECTION 5.3
RECIPROCATING COMPRESSOR COOLING SYSTEMS
5.3.1 Cylinder Cooling
Heat in a cylinder comes from:
1- Compression of the gas being compressed.
2- Friction of piston and piston rings on cylinder wall, and the rod packing
on the rod.
Heat can be considerable, particularly when moderate and high compression
ratios are involved. This heat must be removed for the following reasons:
1- Lowering cylinder wall and cylinder head temperature reduces losses in
capacity and horse power per unit volume due to suction gas preheating
during inlet stroke.
2- Reducing cylinder wall and cylinder head temperature will remove more
heat from the gas during compression, lowering its final temperature and
reducing power required.
3- A reduction in gas temperature and in that of the metal surrounding the
valves provides a better operating temperature for these parts, giving
longer valve service life and reducing the possibility of deposit formation.
4- Reduced cylinder wall temperature promotes better lubrication, resulting
in longer life and reduced maintenance.
5- Cooling, particularly water cooling, maintains a more even temperature
around the cylinder bore and reduces warpage or going out of round
(thermal distortion).
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Water jacket around the cylinder (s). The cooling water is circulated in the
water jacket to absorb the heat from the cylinders. The hot water is
pumped to the radiator.
Radiator it is air cooler. The hot water enter the radiator. The cooling
fan push the air across the radiator tubes. The water in the radiator become
cooled.
Water pump to circulate the water from the cylinder jackets to the radiator
and back again.
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SECTION 5.4
MULTI STAGE COMPRESSION
5.4.1 Theory of Multi Staging
4.
Two stage compression the compression process begins at point (3). In the
first stage to compression is carried only up to point (3 a). At point (3 a) the gas
is withdrawn from the cylinder and is cooled, reducing its volume back to point
3b. Compression in the second stage then occurs along the line 3b 4a.
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5.4.3 Cooling System for Gas Between Stages and After the Last
Stage
The cooling of gas (or air) between different stages is done by entercoolers.
The cooling of gas (or air) after the last stage is done by after cooler.
The same cooling method which is used to cool the cylinder, is used also for
enter coolers and after coolers (i.e. air cooling or water cooling).
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SECTION 5.5
RECIPROCATING COMPRESSOR LUBRICATION
The most important operational item in compressing gases is proper lubrication.
Proper lubrication includes:
1- Selection of high quality lubricants suited to the particular service
conditions.
2- Cleanliness in storage and dispensing.
3- Application in correct quantities in a way that permits effective
performance.
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SECTION 5.6
CLASSIFICATION OF RECIPROCATING COMPRESSORS
There are several ways to classify the reciprocating compressors. It could be
classified with respect to;
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SECTION 5.7
PRIME MOVERS FOR RECIPROCATING COMPRESSORS
5.7.1 Function of a Driver
A driver (together with any connecting medium between it and the compressor
such as a gear and/or coupling) must do more than just drive the compressor at a
rated condition. It must first start the compressor from rest, accelerate it to full
speed, and then keep the unit operating under any design condition of capacity
and power.
Following are six important factors should be taken into consideration
1.
2.
3.
4.
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SECTION 5.8
RECIPROCATING COMPRESSOR OPERATION
Reciprocating compressor operation covers five main areas:
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Also, see that the suction and discharge lines are unobstructed and that all
valves therein are properly set. Be sure intake filters and screens are in
place and charged with oil as necessary.
On multi-stage units it may be advisable, if the unit has been in storage or
subjected to questionable handling during the shipment to remove the
tube bundles from the inter coolers to make certain that the shell and
tubes are thoroughly cleaned and free from foreign material.
The suction ports of the cylinders should also be thoroughly cleaned,
removing any material that may have accumulated therein during the
erection of the unit.
Check the valves in the cylinders making sure that the valves are placed
properly in the cylinder ports, suction and discharge, and securely
tightened in place.
A valve or two (dependent on the cylinder size) should be left out of the
cylinder during the initial running period. This will allow a light load on
the unit during this period and permit ready observation of the lubrication
and wearing in of the cylinder bores.
Before starting the compressor, turn on the cooling water to the cylinders
and to coolers used with the compressor. Check to insure that the cooling
system is filled and that flow is indicated at the outlets. Adjustment of the
amount of cooling water should be made after the compressor has
warmed up.
Check the direction of rotation of the primover. This check must be done
on the primover separately, i.e. disconnect the primover from the unit and
then make this check.
Open proper valves in unloader, discharge, and regulator lines. Be sure
the unit is unloaded as necessary for starting.
After the correct rotation is established (motor driven or otherwise) the unit
should be started and run for a period of several minutes. Immediately upon
starting the unit, note that the lubricator is feeding properly and that all parts are
being lubricated. Also, note that the unit operates without any noise or knocks.
After this short run stop the unit and feel all bearings to make sure that there is
no tendency of parts to heat too rapidly and that the lubrication to all parts is
adequate.
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During the speed and load build-up, observe at frequent intervals the bearings
and the piston rod temperatures to make certain that these elements are
operating properly and are not overheating. It is recommended during the breakin run (except on non-lubricated compressors) that oil be applied to the piston
rod to facilitate the running in of the packing. This is specially true when
metallic packing is used.
The additional time taken to run in the unit to insure that it is operating properly
will be compensated for by the increased satisfaction resulting in the subsequent
performance of the unit.
In the running in of an I.C. engine or turbine-driven compressor, this same
procedure as outlined for a motor driven compressor should be allowed.
However, in this case, the advantage of the variable speed feature should be
utilized by running the unit at the start at slow speeds and gradually building up
to full rated speed as the pressure and load is built up.
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Air-Cooled Compressor
The crankcase should be drained and refilled with a preservative oil.
Such oil contains more inhibitor than normal inhibited oil. The machine
should then be operated a minimum of 15 minutes at no pressure for
thorough distribution and the driving off of any crankcase condensate. At
the same time, fog some of this oil into the compressor intake (in oil
lubricated compressors only).
All openings then should be taped or plugged to exclude moisture.
Relieve V-belt tension.
Drain the receiver and after-cooler. Drain after-cooler cooling water, if
used.
The driver should be treated in accordance with the manufacturer's
instructions.
This will permit storage for a year. However, if the unit can be run for 30
minutes every two or three weeks at full load and followed by 15 minutes at no
pressure, these precautions may not be necessary. Be sure operational periods
are scheduled and that the machine is actually run.
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For a shutdown of several weeks, do the same, then remove the piston rod
packing and the oil wiper rings from the rod, coat the rod with grease,
grease rings, and warp them in waterproof paper. Leaving the packing
rings on the rod may result in a ring of corrosion that will injure the
packing when the unit is re-started.
When a unit is to be shutdown for a lengthy period, write to the
manufacturer for complete instructions.
If freezing is possible during shutdown, all water must be drained from
jackets, inter-coolers, after-coolers, separators, drain traps, and oil
coolers. If this is neglected, cylinder jackets or cooler tubes might burst
and major repairs will result.
When putting the unit back into service, go through every check and
procedure required for first starting a new machine.
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Weekly check
Intake filters for cleanliness. If conditions are bad, clean them. A biweekly schedule may be found adequate later.
Drain air receiver and inter-cooler. In humid weather, it may be necessary
to drain more frequently. On larger units, this should be a daily
procedure.
Check the crankcase oil level. Replenish as necessary (toping).
Operate all safety valves manually.
Monthly
Clean the machine and driver externally.
Check time required to pump up the receiver with its outlet shut. A record
kept of the time required to increase the pressure from, say, 30 psig to
100 psig, will provide a check on machine efficiency. Any serious
difference may indicate leaky or broken valves. Run a pipe leakage
check. During the lunch hour, or any other time when the surroundings
are quiet, follow closely all distribution lines beyond the receiver while
the compressor is shutdown but pressure is still high. Listen for leaks. Fix
those found.
Two to three months
Change crankcase oil. For definite recommendations, read the instruction
book. Tighten all bolts and check V-belt tightness.
Six months maximum
Remove and clean all valves. Do this first after only two to three months,
then as needed up to six months maximum. Check air ports, pistons, and
head for deposits and remove any found.
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Check cylinder and packing lubricator feeds. Make sure each feed is
pumping oil and that reservoir is filled with correct oil.
Check and record inter-stage and discharge pressures. If any substantial
change is noted, find and correct the trouble immediately. Inter-stage
pressure is normally almost constant for a given discharge. Any
abnormality in reading probably indicates leaking valves.
If frame oil filter can be cleaned manually, operate it as directed.
Weekly
Pop all safety valves manually.
Operate regulator manually throughout entire load range to keep free any
unloader that may not normally be in regular operation.
Keep the compressor and its surroundings clean.
Check crankcase oil level and add proper oil as needed.
Check cleanliness of intake air filters.
Operate safety shutdown or alarm devices where possible.
After first week, tighten foundation bolts and all other nuts and bolts on
the unit to recommended torque. Re-check alignment if there is
foundation bolt take-up.
Semi-Annually
Change crankcase oil (on some machines more often). See instruction
book.
Check condition of water side of coolers and jackets.
Tighten all foundation bolts and nuts and machine bolts. Re-check
alignment if there is any foundation bolt take-up.
Annually
Check clearance in all bearings.
Adjust crosshead or replace parts to restore piston rod alignment as
necessary due to wear on crosshead shoe or piston.
As experience dictates (at least annually) check condition of all valves.
Check condition of cylinder bore through valve opening.
Check effectiveness of lubrication by observing the degree of oiliness on
the cylinder bore and valves.
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CAUTION:
If for any reason the compressor is operated without water and cylinders
become overheated, do not turn on cooling water until they have cooled. A
sudden application of cool water may crack the cylinder.
5.8.7 Troubleshooting
Pages following present charts designed to tip off the maintenance man where
to look for the cause of some difficulty. These charts, although designed mainly
for 100 psiG compressors of all types, apply quite generally. Some items apply
only to the vertical air-cooled units, some to water cooled only and some to twostage only.
Many categories in the chart refer to normal conditions. There is no way to
know what normal conditions are except to keep a record of temperatures and
pressures. Other items should also be recorded in certain cases.
1- Temperatures recorded a minimum of twice a day could well include the
ambient on air-cooled units a few feet from the compressor and the air
discharge temperature. On larger two-stage units, the discharge
temperature of the first stage cylinders should be added. Water
temperature in and out is desirable on water-cooled compressors.
2- Pressures recorded should include those taken at discharge or receiver
and, on a two stage compressor, always at the inter-cooler. It is a
particularly valuable norm to have. On smaller compressors operating
either start-and-stop or constant-speed, make a one hour study (at least
once a month) of the number of starts or full load periods and the total
running time. Do this at the same hour each time and select the hour
when maximum demand is apt to exist. The purpose of making this study
is to discover any trend in operating time that would render a change in
control advisable. Also, if the operating time is increasing steadily, there
is either increasing system leakage, some compressor deficiency, or an
increased demand. The correct reason should be determined, the proper
remedy applied.
3- Valves problems are apt to be the predominant maintenance item.
Leaking and broken valves and gaskets should be discovered and repaired
quickly. As previously discussed, these lead to many added problems and
even to dangers if neglected.
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4- A defective inlet valve can generally be found by feeling the valve cover.
It will be much warmer than normal.
Discharge valve leakage is not as easy to detect since the discharge is
always hot. Experienced operators of water-cooled units can usually tell
by feel if a particular valve is leaking. This is not for those who
frequently check their units.
The best indication of discharge valve trouble is the air discharge
temperature. This will rise, sometimes rapidly, when a valve is in poor
condition or breaks. This is one very good reason for keeping a record of
the air discharge temperature from each cylinder.
It must be remembered that there will be seasonal variations in
temperature, all temperatures rising in summer and falling in winter.
5- The recording of inter-cooler pressure on multi-stage units is valuable
because any variation, when operating at a given load point, indicates
trouble in one or the other of the two stages. If the pressure drops, the
trouble is in the low pressure cylinder. If it rises, the problem is in the
high pressure cylinder.
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