Reciprocating Compressor - Part 1

RECIPROCATING COMPRESSORS
Description
The reciprocating compressor
is a positive displacement,
intermittent-flow machine and
operates at a fixed volume.
One method of volume
variation, however, is by
speed modulation. Another,
more common method is to
use clearance pockets with or
without valve unloading.
Description
ith clearance pockets, the
cylinder performance is
modified.
ith valve unloading, one or
more inlet valves are
physically open.
Capacity may be regulated in a single- or double- acting
cylinder with single or multiple configurations.
A unique feature of the reciprocating compressor is the
possibility of multiple services on one compressor frame.
Description
On a multistage frame, each
cylinder can be used for a
separate gas service.
Lubrication of compressor
cylinders can be tailored to the
application.
The cylinders may be designed for normal hydrocarbon
lubricants or can be modified for synthetic lubricants.
The cylinder may also be designed for self lubrication,
generally referred to as nonlubed.
Description
A compromise lubrication
method which uses the
nonlubed design but requires
a small amount of lubrication
is referred to as the mini-lube
system.
Description
An unusual nonlubed compressor is a labyrinth piston
compressor.
Description
The piston does not touch
the sides of the cylinder
because it is equipped with a
series of circumferential by
labyrinths operating with a
close clearance to the
cylinder wall.
What is the effect of that?
Description
The piston does not touch
the sides of the cylinder
because it is equipped with a
series of circumferential by
labyrinths operating with a
close clearance to the
cylinder wall.
Efficiency is sacrificed (due to gas by-pass) in order to
obtain a low maintenance cylinder. This design is mentioned
primarily due to its being unique, as it is not widely
manufactured.
Description
Another feature necessary to the reciprocating compressor
is cylinder cooling. Most process compressors are furnished
with water jackets as an integral part of the cylinder.
Alternatively, particularly in the smaller size compressors,
the cylinder can be designed for air-cooling.
CIassification
#eciprocating compressors can be classified into several
types.
One type is the trunk or
automotive piston type .
The piston is connected to a
connecting rod, which is in
turn connected directly to the
crankshaft.
CIassification
This type of compressor has a single-acting cylinder and is
limited to refrigeration service and to smaller air
compressors.
Most of the smaller packaged
refrigeration system
compressors are this type.
CIassification
The more common type of compressor used in process
service is the .rosshead type .
CIassification
The piston is driven by a fixed piston rod, which passes
through a stuffing or packing box and is connected to a
crosshead.
CIassification
The crosshead, in turn, is connected to the crank-shaft by a
connecting rod. n this design, the cylinder is isolated from
the crankcase by a distance piece.
CIassification
A variable length or double distance piece is used to keep
crankcase lubrication from being exposed to the process
gas.
CIassification
This design has obvious advantages for hazardous
materials. The cylinder can be either single or double acting.
CIassification
Except for very small compressors, most reciprocating
compressors furnished to the process industry use the
double acting configuration.
Arrangement
Most multicylinder arrangement is in pairs in the form of a V
usually at 45
o
from the vertical.
The few single-acting crosshead compressors are normally
single-stage machines with vertical cylinders.
The more common double-acting type, when used as single-
stage, has horizontal cylinders. The double-acting cylinder
compressor is built in both the horizontal and the vertical
arrangement.
Arrangement
rom a ring wear consideration the more logical orientation
is vertical, however, taking into account size and the
ensuring physical location as well as maintenance
problems, most installations normally favor the horizontal
arrangement.
The most common multistage configuration being the
horizontally opposed. Other variations include V, Y angle or L
type.
Arrangement
Arrangement
PrincipIe of work
Compression
2 3
1 4

4
3
ith the piston moving towards
the closed end (compression
stroke), the original volume of
air is reduced and the
pressures increases until the
cylinder pressure exceeds the
receiver discharge pressure.
PrincipIe of work
Discharge
At this time, the cylinder
pressure exceeds the receiver
pressure forcing the discharge
valve to open to pass gas to
the receiver. The flow
continues until the piston
reaches the end of the stroke
at point 3 and the pressure
declines as the piston reverses
its direction. The inlet valve is
closed during discharge.
2 3
1 4
4
3
PrincipIe of work
Expansion
The gas expansion takes place
during the next part of the stroke.
Both the inlet and exhaust valves
are closed, the piston is moving
towards the point of beginning
and the pressure is decreasing to
the inlet pressure. During the
expansion stroke, the
compressed gas left in clearance
volume area from the discharge
expands to the cylinder inlet
pressure.
2 3
1 4
3
4
PrincipIe of work
Intake
During this time, the inlet valve is
open and the piston completes
the intake stroke to a fully
expanded position. The piston
movement creates a partial
vacuum causing the inlet valve to
(loaded) for the next cycle.
2 3
1 4
4
3
PrincipIe of work
Intake
The effectiveness is influenced by
numerous factors such as clearance
volume, inlet pressure, receiver
pressure, valve performance, piston-
cylinder leakage, nature of gas,
temperature, etc.
2 3
1 4
4
3
The mass flow will remain constrant
for dry gas although pressure,
volume and temperature will change.
f condensate is removed from the
gas the mass flow will reduce.
PrincipIe of work
ActuaI capacity
s the quantity of gas actually
compressed and delivered to the
discharge system by the machine at
rated speed and under rated inlet
and discharge conditions (and under
rated inter-stage conditions in a
multi-stage machine). Actual capacity
is usually expressed in cfm or m3/hr
referred to first stage inlet
temperature and pressure.
PrincipIe of work
ActuaI capacity
!iston displacement
Actual Capacity
VE=
ActuaI Capacity
Piston dispIacement
Compressor make-up
Cylinder - serves as a container for the gas. t must be
strong enough to withstand whatever pressures are to be
generated.
!iston - a circular object usually made of metal, which fits
inside the cylinder. t causes the cylinder volume to change
when moved, (compression).
Inlet valve - !ermits gas to enter the cylinder on the intake
stroke and closes when the piston starts compression.
Several inlet valves may be needed.
Compressor make-up
ischarge valve - Opens at the early part of the
compression stroke allowing the gas to pass out of the
cylinder into a discharge vessel. The discharge pressure
keeps the valve open until the pressure drops at the end of
the stroke.
Other essentials include provision for lubrication, removing
heat from compressor and power to move the piston.
Compressor make-up
CyIinders
Compressor make-up
CyIinders
Separable
Distance piece
rame
Cylinder
Distance piece
!iloting
Cooling (ater or Air)
Steel for the smaller,
high pressure cylinders
Nodular or Ductile iron
Compressor make-up
CyIinders
On larger cylinders, there is
normally enough space for
clearance pockets. An
additional location is the
head casting on the
outboard end of the
cylinder .
On smaller cylinders, this
feature must be provided
external to the cylinder.
Compressor make-up
CyIinders
Clearance volume is the
volume present in one
compressor cylinder or one
compressor in excess of the
net volume displaced by the
piston during one cycle.
Compressor make-up
CyIinders
hen applied to double
acting piston compressor,
the volumes are referred to
both the head end (HE) and
the cylinder end (CE) .
t may not be the same for
the two ends in a double
acting cylinder. An average
is usually used.
Compressor make-up
Piston and rods
Compressor make-up
Piston and rods
The piston must translate
the energy from the
crankshaft to the gas in the
cylinder.
The piston is equipped with a set of sliding seals referred
to as piston rings. #ings are made of a material, which
must be reasonably compliant for sealing, yet slide long
the cylinder wall with minimum wear.
Compressor make-up
Piston and rods
Different rings are used for
lubricated or nonlubricated
service, with the rings in the
nonlubed cylinders needing
good dry lubricating
qualities.
or lubricated service, metallic rings such as cast iron or
bronze as well as nonmetallic materials such as filled
nylon are used.
Compressor make-up
Piston and rods
or nonlubricated service,
the ring material is
nonmetallic, ranging from
carbon to an assortment of
fluorocarbon compounds.
Compressor make-up
Piston and rods
Horizontal cylinder pistons feature
the addition of a wear band,
sometimes referred to as a rider
ring .
!iston may be of segmented
construction to permit the use of
one piece wear bands.
Compressor make-up
Piston and rods
eight in a piston contributes
directly to the compressor
shaking forces and must be
controlled.
or this reason aluminum pistons are often found in large
low pressure cylinders.
Hollow pistons are used but can pose a hazard to
maintenance personnel if not properly vented. f trapped,
the gas will be released in an unpredictable and dangerous
manner when the compressor is dismantled.
Compressor make-up
Piston and rods
The piston rod is threaded to the
piston and transmits the
reciprocating motion from the
crosshead to the piston.
The piston rod is normally constructed of alloy steel and
must have a hardened and polished surface particularly
where it passes through the cylinder packing (double-
acting cylinders).
Compressor make-up
Piston and rods
#od loading must be kept within
the limits set by the compressor
vender because overloading can
cause excess run out of the rod
resulting in premature packing
wear. This in turn leads to
leakage, reduced efficiency and
increased maintenance expense.
Compressor make-up
Piston and rods
n unloaded or part load
operation, rod reversals must be
of sufficient magnitude to provide
lubrication to the crosshead
bearings.
The bearings are lubricated by the pumping action of the
opening and closing of the bearing clearance area.
Compressor make-up
Piston and rods
Tail rods are dummy rods, which protrude from the head
end of the cylinder .
Compressor make-up
Piston and rods
The purpose of the rod is to pressure-balance a piston or to
stabilize a particular piston design.
Compressor make-up
Piston and rods
n a tandem cylinder arrangement, the outboard cylinders
are driven with a rod similar to the tail rod.
Compressor make-up
VaIves
Compressor make-up
VaIves
Of all the many components in a
reciprocating compressor, none
works harder nor serves a more
important compressor component
function than the suction and
discharge valves. n fact,
compressor efficiency is
determined by the performance of
the valves more than any other
component.
Compressor make-up
VaIves
The compressor cylinder
valves are of the spring
loaded, gas actuated type
in all but a limited number
of portable compressors.
This kind of valve is used in contrast to the cam actuated
poppet type normally found in piston engines.
Compressor make-up
VaIves
The reciprocating compressor
uses automatic spring loaded
valves that open only when
differential pressure exists
across the valve.
nlet valves open when the pressure in the cylinder is
slightly below the intake pressure.
Discharge valves open when the pressure in the cylinder
is slightly above discharge pressure.
Compressor make-up
VaIves
#eciprocating compressors
generally use one of three basic
valve configurations:
PIate
ChanneI
Feather type
Compressor make-up
VaIves
PIate vaIve
Compressor make-up
VaIves
PIate vaIve
This type of valves employs two
additional spring-loaded discs, which
effectively reduce flutter and cushion
the impact of opening and closing .
Compressor make-up
VaIves
PIate vaIve
The built-in dampening action of these
valves makes them particularly suitable
for compressors operating at high
speeds (750 rpm or more), and in
applications with either a high pressure
differential (greater than 7 atm
differential) or varying pressure
conditions within the same compressor.
Compressor make-up
VaIves
ChanneI vaIve
n operation, gas trapped between the
spring and channel provides a
cushioning or dampening effect to
minimize pounding and wear, and
permits a somewhat larger lift than
other types.
Compressor make-up
VaIves
ChanneI vaIve
n operation, gas trapped between the
spring and channel provides a
cushioning or dampening effect to
minimize pounding and wear, and
permits a somewhat larger lift than
other types.
Each channel and spring operates
individually as an independent valve
Compressor make-up
VaIves
ChanneI vaIve
Channel valves are good for
medium to low pressure
service, with a maximum
pressure differential of 34 atm.
They are tolerant of dirty
environments, and offer a
particularly advantageous flow
pattern in sizes up to 33 mm
diameter.
Compressor make-up
VaIves
ChanneI vaIve
Compressor make-up
VaIves
Feather vaIve
The feather valve is most common on
the higher speed compressors because
of its light weight .
Due to the valve design and the fact that
there are no springs, these valves also
provide a good flow pattern through the
centre of the valve. eather valves are
normally used with a maximum pressure
differential of up to 5.0 atm.

Reciprocating Compressor - Part 1

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Reciprocating Compressor - Part 1

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RECIPROCATING COMPRESSORS

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