Prof.

Dr: nazih Noaman Bayomi


Egyptian Maintenance Company

Classification of Compressors
COMPRESSORS

Positive Displacement Compressors Rotary Compressors

Sliding Vane Screw

Dynamic Compressors
Centrifugal Compressors Axial Flow Path Radial Flow Path Mixed Flow Path

Reciprocating Compressors
Lope

Classification of Reciprocating Compressor

Types of Compressors

Maximum Pressures and Capacities of Air Compressors


Egyptian Maintenance Company


Egyptian Maintenance Company

Reciprocating Compressors

Reciprocating Compressors
Compressors are used to increase the pressure of a process gas, in order to drive it into a pipeline system to an onshore process plant, to use on the producing well as gas lift, to re-inject gas for reservoir pressure maintenance and for use as a fuel gas. Reciprocating compressors are used for High Pressure / Low Flow applications, where screw and centrifugal compressors cannot meet the duty.

 This document covers high pressure reciprocating compressors of Horizontal and Vertical types on process duties.

Materials of construction must be mechanically capable, and compatible with process fluids anticipated throughout the field lifetime.

 The major hazards relate to the inventory of flammable gas that can be released if there is an equipment failure. Hazard assessment must relate to the complete package and not just the compressor itself. There is an injury risk from a mechanical failure, heavy parts can be ejected at moderate speeds.

 Compressors have gas seals on moving drive shafts and piston rods. These are safety critical items when handling hazardous materials.

Reciprocating compressors can, under fault conditions, suffer internal explosions. The design must address prevention / containment / relief of such events.

Reciprocating Compressor
Four stage Intake Power Compression Exhaust

Reciprocating Compressor

Reciprocating Compressor

 Reciprocating compressor

Reciprocating Compressor
As the piston moves down, the vacuum created allows outside air to push open the inlet valve (left). During compression (right), the inlet valve shuts while air is pressed into tank.

Reciprocating Compressors
Reciprocating compressors use a conventional piston and cylinder arrangement to compress the gaseous refrigerant. As the crank arm pulls the piston down in the cylinder, the intake valve is opened, allowing gas to enter the cylinder.

Reciprocating Compressors
As the crank continues to turn further, the piston then begins to move upward, the intake valve is closed, the exhaust valve is opened, and the gas is compressed and discharged through the open exhaust port. The cycle then repeats.

Reciprocating Compressors

Reciprocating compressors are positive displacement machines, meaning that they increase the pressure of the air by reducing its volume.
This compressor has a crankshaft, connecting rods, and pistons. Single-stage and two-stage reciprocating compressors are commercially available.

Reciprocating Compressors

Single-stage compressors are generally used for pressures in the range of 70 psig to 100 psig.
Two-stage compressors are generally used for higher pressures in the range of 100 psig to 250 psig.

Reciprocating Compressors
A positive displacement compressor compresses air by reducing the size of the space that contains the air. In most cases, this achieved with a piston. is

Piston type and lubrication method are two variables that affect compressor design and application.

Reciprocating Compressor
The smaller pistons have oil grooves cut in them. This Figure illustrates a common piston connecting rod assembly.

Part Section of Reciprocating Gas Compressor

Normal Cylinder and Piston Assembly with Valves.

Static Parts Assembly with Crankcase Shown Inset. Crank shaft on Crane.

Oil system for reciprocating compressor

Process Diagram for Reciprocating Gas Compressor

Lubrication and Purge Gas Diagram

Four Cylinder Gas Compressor in Workshop Assembly

High Pressure Cylinder Arrangement (Plunger Piston)

Single Acting Reciprocating Compressor

Acting Double Reciprocating Compressor

Positive Displacement Performance Curve

Positive Displacement Performance Curve

A performance curve for a positive displacement machine is provided in this figure. It can be seen that despite compressor discharge pressure, load remains constant. Load reduction is achieved by unloading individual cylinders.

Positive Displacement Performance Curve

Typically, this is accomplished by throttling the suction pressure to the cylinder or bypassing air either within or outside the compressor. Capacity control is achieved by varying speed in engine-driven units through fuel flow control.

Main Components of the Reciprocating Compressor

Reciprocating Compressor Construction

Main Components of the Reciprocating Compressor

Cylinder Piston Connecting rod Crankshaft Piston Pin Piston Rings Valves

Piston & Connecting Rod

This figure illustrates a commercial type piston and connecting rod assembly. This one is fitted with piston rings.

Piston & Connecting Rod

Connecting Rod

Connecting Rod Assembly

Connecting Rod

Connecting Rod With Wedge Adjusting Bearings

Connecting Rod

Piston
The piston is designed to come as close as possible to the cylinder head without touching it. This is to press as much of the vapor into the highpressure side pressure side as possible. When the piston is at upper dead center of its stroke, the clearance between the piston and cylinder head is approximately 0.010 in. to 0.020 in. (0.254 mm to 0.508 mm). The volume of space created is called clearance space. There is a valve plate under the cylinder head with both he intake and exhaust valve located in it, see next figure.

Cross head

Every part, from cross head to crankcase, from bearings to crankshaft, is precision made to exact tolerances.
The cross head on larger frame sizes has been designed to eliminate the threaded connection between the piston rod and cross head.

 Compressor piston, cylinder and crankshaft arrangements. Piston, cylinder and crankshaft arrangements for two, four and eight cylinder compressors.

Piston rings
There are two types of piston rings. The upper ring or rings are known as compression rings and the lower is designed to control the oil "flow" past the piston. It is an oil ring. Piston rings are usually made of cast iron. Some bronze rings have been used. Rings should be fitted to the groove as closely as possible and still allow movement. A 45 degree tapered or angled ring gap permits the ring to push out against the cylinder wall. This gap should be about 0.001 in. (0.0254 mm) for each inch of piston diameter.

Piston Pins
Piston pins are made of case hardened high carbon steel accurately ground to size. They are hollow to reduce weight. Piston pins are usually of the full floating type. This means that the pin is free to turn in both the connecting rod bushing and the piston bushings.

Compressor Valves

1- Plate valve
The common overhaul procedure of a plate valve is:

Pre-cleaning of dirty valves. Some valves out of HPI compressors need special cleaning methods. Dismantling Visual inspection and dimensional check Cleaning sand blasting etc. if necessary Crack detection spot check Inspection of valve guard for further use.

Plate valve
Pre-cleaning of dirty valves. Some valves out of HPI compressors need special cleaning methods. Dismantling Visual inspection and dimensional check Cleaning sand blasting etc. if necessary Crack detection spot check

Plate valve

Typical compressor valve plate

A- Intake valve. B- Exhaust valve. Heavy springs on exhaust valve cage permit a greater valve lift to protect compressor in case of severe liquid refrigerant or oil pumping.

2- Ring Valve
The extent of work is comparable to that of the plate valves. The rework of the seats usually requires special tools and well trained personnel! The seal rings need to match perfectly the seat for proper sealing of the valve. Different thermal expansion of ring and seat material can lead to undesired leakage during operation. Ring materials are Nylon, PEEK and other thermoplastic materials.

Ring Valve

3- Poppet Valve
The job of the poppet valve is easier than it is for the plate and ring type valves. Wear in the bores for the poppets of the valve guard can limit its lifetime. Replacement of the wear parts: Poppets, springs and lift washers. For good sealing the poppets must correspond exactly to the seat. On this type of valve it is less difficult to achieve than on a ring type valve. Also, different thermal expansion of poppet and seat material is not critical.

Poppet valve details

4- COP Valve
The COP Valve is a poppet type valve that does not require any rework of the seat.
The actual valve seat is the seat plate that is replaced when worn. Therefore, the overhaul of a COP valve is very simple: Cleaning and replacing parts is all that is needed.

The wear parts, poppets, springs, lift washers and seat plates are easy to stock and not expensive.
The seat plate does not have to be replaced at each overhaul.

COP Valve

COP Valve design

The COP valve is a poppet valve of special design.

The valve guard, poppets, springs and wear shims are conventional. The valve seat on the other hand is made of two pieces.
A seat plate covers the seat body. This plate is a wear part.

COP Valve design

The new concept for the sealing area has significant advantages concerning maintenance.

Expensive overhaul with remachining of valve seats is no longer required.

The valve is field repairable without special tools. Materials: The valve guard, seat and seat plate are usually made of stainless steel and the poppets are made of PEEK. There are little limitations for the use of this valve.

COP Valve

Valve Selection
A reciprocating compressor operator should consider the following issues in order to make the best choice for his compressors valves:
What kind of suction -and discharge valves could be used? Are maintenance contracts in effect that limit the free choice? What materials can be used considering the gas composition, pressure, temperatures and compressor speed? How important is energy consumption? How critical are unscheduled shutdowns?

Valve Selection
Who provides support in case of a problem? Are valve overhaul intervals to be increased? Who is doing the valve overhauls? In house or external? What parts (complete valves and spare parts) have to be stocked? What is the on site spare parts inventory cost? What are the costs for new valves and spare parts?

Comparison between the valves

Performance comparison in natural gas compressors

Plate valves, Ring type valves and Poppet valves have been compared in natural gas compressors.
The gas engine driven machines of horizontal design operate between 320 and 400 rpm on a stroke of 300 mm.

The test results confirm the advantages of poppet valves regarding flow and power consumption.

Performance comparison in natural gas compressors

Compressor Valves

Valves are the most critical component in compressor reliability.

Dresser-Rand applied more than a century of design and manufacturing experience to create the Magnum valve shown here and make it compatible with all brands of reciprocating compressors. Gases ranging in molecular weight from 2 to 71, speeds from 327 to 1,000 RPM and discharge pressures ranging from 35 to 4,000 psig.

Valves Parts

Modern Valve Design Options.

Valve Selection
What kind of suction -and discharge valves could be used? Are maintenance contracts in effect that limit the free choice? What materials can be used considering the gas composition, pressure, temperatures and compressor speed? How important is energy consumption? How critical are unscheduled shutdowns?

Valve Selection
Who provides support in case of a problem? Are valve overhaul intervals to be increased? Who is doing the valve overhauls? In house or external? What parts (complete valves and spare parts) have to be stocked? What is the on site spare parts inventory cost? What are the costs for new valves and spare parts?

Piston Rod Gas Packing Cut-Away.

General guidelines
Use only original spare parts from the valve manufacturer Make sure that springs and stroke of suction and discharge valves are correct Do not mix if different. Do not grind valve plates. Do not change valve stroke and spring type without consultation of the manufacturer. Renew sealing surfaces. Install new sealing elements and rework the valve seats.

General guidelines
Follow the manufactures specs. for max. wear of parts. Consider dimensions that must not be changed especially on timed suction valves. If in doubt always replace parts. Premature failure of a valve is much more expensive than savings are possible by using worn parts. If valves are to be shipped to a repair shop pack them properly to avoid damage during transport.

Performance of the Reciprocating Compressors

The Relation between Volume & Pressure

The Theoretical & Actual Performance

Multi Stage Reciprocating Compressors

Two Stage, Double Acting, Differential Piston

Two Stage, Double Acting, Differential Piston

Two Stage, Single Acting, Differential Piston

Two Stage, Single Acting, Differential Piston

Three Stage, Differential Piston

Two Stage Reciprocating Air Compressor

Two Stage Reciprocating Air Compressor (Cut-away)

Two Stage Reciprocating Air Compressor

Two Cylinder, Two Stage, V Type Air Compressor

Two Stage Reciprocating Air Compressor

Two Stage Reciprocating Air Compressor each Stage in different Cylinder

Reciprocating Compressor
Many medium-pressure compressors have differential pistons, as shown in Figure. This type of piston provides more than one stage of compression on each piston.

Reciprocating Compressor
W-type compressors have two cylinders for the first stage of compression and one cylinder for the second stage.

Reciprocating Air Compressor Second Stage Cylinder.

Note protection over hot discharge pipe.

Supply compressor W Type

Reciprocating Very efficient Requires frequent maintenance Can be equipped for very efficient part loading Can be multistaged

Common problem areas

Air Leaks No heat recovery High pressure drop Insufficient air storage Ineffective control strategy Multiple compressor operation not optimized Base load vs. trim compressor Inappropriate end uses Poor record keeping Electric usage Air production

Cooling System of the Reciprocating Compressor

Cooling System

Cooling

Cooling
The use of inter-coolers and after-cooler are very important in the reciprocating compressors. They are simple heat exchangers in which heat is removed from the air after it has been compressed and its temperature has risen as a result of compression. A simple section showing the principles of construction is shown in the next figure.

Cooling
The coolant, which may be water or any other fluid, passes through the tubes secured between two end plates and the air circulates over the tubes through a system of baffles. The construction shown is for two-passes intercooler since the coolant passes through one set of tubes and again passes through another set of tubes before coming out. Baffles are provided to ensure intimate contact between the tubes and the air by passing the air in a circuitous path.

Cooling

Four Stage with Coolers

Cooling
In the reciprocating compressor may be cooled by water or air. In the system of watercooled a water jucket around the cylinder is built as shown in figure.

Cooling
In the system of aircooled a thin fins around the cylinder is built as shown in the figure.

Operation of a Reciprocating Compressor

Operation of a Reciprocating Compressor

A reciprocating compressor consists of a crankshaft (driven by either a gas engine, electric motor, or turbine) attached to a connecting rod, which transfers the rotary motion of the crankshaft to a crosshead. The crosshead travels back in forth in a crosshead guide.

The crosshead converts the rotating motion to a reciprocating motion.

Operation of a Reciprocating Compressor

The piton rod is attached to the crosshead and the piston (which is contained in a cylinder) is attached to the piston rod. The piston acting within the cylinder then compresses the gas contained within that cylinder.
Gas enters the cylinder through a suction valve at suction pressure and is compressed to reach desired discharge pressure.

Operation of a Reciprocating Compressor

When the gas reaches desired pressure, it is then discharged through a discharge valve.
Desired discharge pressure can be reached through utilization of either a single or double acting cylinder.

Operation of a Reciprocating Compressor

In a double acting cylinder, compression takes place at both the head end and crank end of the cylinder. The cylinder can be designed to accommodate any pressure or capacity, thus making the reciprocating compressor the most popular in the gas industry.

Different Types of Reciprocating Compressor

Reciprocating Compressor

Reciprocating Compressor
Horizontal tank Vertical tank

SINGLE & DOUBLE-ACTING COMPRESSORS applications 5-1000 HP, Pressure Range from 50 to 4000 PSIG

A Series

L-Series, High pressure Dependability

The L-Series Gardner Denver water cooled compressors are designed for 24 hours a day, 7 days a week continuous duty. Tough cast iron construction and pressure lubrication throughout provides complete dependability. Gardner Denver knows its L-Series compressors are high quality, and backs each one with a 2 year warranty.

Reciprocating Compressor

W-Series

JH "HORIZONTAL-OPPOSED" CONFIGURATION

The newest member of the J-Series family, our horizontal-opposed compressor has already proven itself in numerous process air & gas applications over the past five years.

Ideally suited for multistage, high pressure applications using tandem J-Series cylinder sets, the JH design has found universal acceptance because of its low cost, easily-packaged footprint, and smooth, dependable operation.

Opposed Cylinder Machine

Crankshaft Throws, Connecting Rods, Cross heads on Typical Opposed Cylinder Machine

JY "WYE" CONFIGURATION
In our two-cylinder Y-type design, primary and secondary forces are balanced by counterweights and cylinder arrangement for smooth operation. JY compressors are universally used in all industrial and process applications and are available as single-stage, lowpressure, high volume units and as 2-stage high-pressure machines.

JR "SEMI-RADIAL" CONFIGURATION
In this unique semi-radial design. A a logical progression from J-Series Y-type construction. 4 cylinders are spaced semiradially around the frame to balance forces for minimum vibration and smooth, quiet operation.

JR compressors are recommended for continuous heavy-duty conditions. They can be furnished as single or multistage units for low- and high-pressure service.

Advantage of J-SERIES compressors

Heavy-duty crankcase provides support for running gear and cylinders. Large, dust-tight, gasketed covers seal the crankcase and provide easy access to all internal parts. Precision machined and ground, accurately weighted crankshaft. Self closing type oil wiper ring(s).

Cylinder(s) designed with added clearance pocket(s) as application requires.

Tungsten-plated steel piston rod(s). Crankcase oil level sight gauge and drain. Contoured compression area, for maximum air flow and efficiency. Full flow cooling water jackets for efficient cylinder and head cooling.

Some common arrangements employed for multistage air compressors

Compressor Materials

 Compressor cylinders for external drive compressors are usually made of cast iron.
The cast iron must be dense enough to prevent the seepage of refrigerant through it.

Some nickel is usually added to give the casting this density.

Hermetic (sealed) compressors usually have cast iron cylinders. Some may be of aluminum or other materials. Small compressors usually have fins cast with the cylinders to provide better air-cooling.

Large compressors may have water jackets surrounding the cylinders for cooling.

 Pistons used in external drive compressors are usually made of cast iron, while in small high-speed hermetic compressors they are of die-cast aluminum. Smaller sizes do not have piston rings. There are two types of piston rings. The upper ring or rings are known as compression rings and the lower is designed to control the oil "flow" past the piston. It is an oil ring. Piston pins are made of case hardened high carbon steel accurately ground to size. They are hollow to reduce weight. Piston pins are usually of the full floating type. This means that the pin is free to turn in both the connecting rod bushing and the piston bushings.

 Connecting rods for external drive compressors are usually made of drop forged steel. The connecting rod attaches the piston to the crankshaft. Cylinder heads for both external drive and hermetic compressors are usually made of cast iron.

Compressor valves are usually made of high carbon alloy steel.

Crankshaft Seals use two rubbing surfaces. One surface turns with the crankshaft and is sealed to the shaft with an O ring of synthetic material. The other surface is stationary and mounted on the housing with leakproof gaskets. The surface materials are made of these different combinations: hardened steel and bronze, ceramics and carbon.

Compressor Control

Common methods of control are the following:

1- Throttle control. 2- Clearance control. 3- Blowing air to waste.

(1) Throttle control.

Typical arrangement for affecting throttle control is shown in the next figure. When the demand is less, there is build up of pressure in the receiver and the high-pressure air from the receiver is led to piston and cylinder at point (A). The movement of the piston is resisted by spring. With excessive pressure the piston depresses the spring, thus closing partly the suction valve (B). Thus during the suction stroke the air intake is partly throttled. The reverse action will take place when the pressure in the receiver falls due to increase in demand.

(1) Throttle Control Valve

(2) Clearance control.

The next Figure shows the typical arrangement or increasing and decreasing clearance by providing clearance pockets. The control by this device can be obtained in steps. In this method the volumetric efficiency is reduced in proper proportion to control the output. When the pressure exceeds the desired amount, a dead weight (not shown) is raised by the diaphragm (not shown) and releases air to a pressure chamber (A). Thus the spring (1) lifts the valve (2) and clearance space is put in communication with the cylinder. If the pressure still continues to raise, a second valve (B) puts another pocket of clearance space in communication till the supply and demand are balanced.

(2) Clearance control

(3) Blowing off to waste

In the next Figure shows a device in which there is a bypass valve from the high pressure cylinder delivering air direct to atmosphere in case of excessive pressure built up in the receiver due to decrease in demand. The high-pressure air operates a relay piston against a dead weight until the port through which (B) is connected is uncovered. Thus the high-pressure air forces the piston (B) downward and the air is released to the atmosphere. The check valve prevents the receiver air escaping to atmosphere. When the pressure in the receiver falls, the relay piston moves down by the dead weight and closes the communication between relay cylinder and cylinder (B).

(3) Blowing off to waste

Main Components of an Air Compressor Plant

 Thank you for your attention