Reciprocating Comp.

RECIPROCATING COMPRESSORS
March 29, 2014
COURSE OBJECTIVES
1. Describe the functions of a compressor 2. Classification of positive displacement Compressors 3. The working principle of a reciprocating compressor and its components 4. Reciprocating compressor classification 5. Rotary positive displacement compressors 6. The components of each type and how it works? 7. Capacity control systems 8. Instrument air system (air dryers)
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COMPRESSOR CLASSIFICATION
Compressors Dynamic Axial Flow Positive Displacement Reciprocating
Rotary positive Dis.
Centrifugal
Screw Lobe
Sliding Vanes
Liquid ring
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POSITIVE DISPLACEMENT COMPRESSORS CLASSIFICATION

It can be divided into two subgroups: 1. Reciprocating positive displacement compressors 2. Rotary positive displacement compressors
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Working principle of reciprocating compressor

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ROTARY POSITIVE DISPLACEMENT
COMPRESSORS
Rotary positive displacement compressors include: 1. Screw compressors 2. Lobe compressors 3. Sliding vane compressors 4. Liquid ring compressors
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RECIPROCATING COMPRESSORS-BASIC COMPONENENTS
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HOW IT WORKS? 1. Suction stroke
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2. DISCHARGE STROKE
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ONE COMPLETE CYCLE
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TRUNK COMPRESSORS AND CROSS HEAD DESIGN COMPRESSORS

Trunk compressor design: The piston head is direct connected to the connecting rod to the crank shaft. Trunk compressor always single acting it never be double acting. Cross head design compressor: The piston head is connected to the piston rod to cross head to connecting rod to crank shaft. Cross head design compressor could be single acting or double acting. Most of the time is double acting.
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DOUBLE ACTING COMPRESSOR
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DOUBLE ACTING COMPRESSOR COMPONENTS

Connecting rod Cross head
Piston rod
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ROTATING AND OSCILLATING COMPONENTS
1. Crankshaft and the connecting rod converts the rotary motion of the crankshaft into reciprocating motion of Crosshead. 2.Piston rod transmits this reciprocating motion to the piston head. The piston head reciprocate in the cylinder
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CRANKSHAFT
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CRANKCASE
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CROSSHEAD AND CONNECTING RODS
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MULTI- STAGE COMPRESSION

1. If the discharge pressure of single stage compressor is not enough, we move to multistage design. 2. In multi-stage the same amount of gas recompressed again and again until we get the required pressure. 3. Cooling of the gas after each stage and before it enters the next one is essential (intercooler).
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MULTI-STAGE RECIPROCATING COMPRESSOR
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Single-stage
two-stage compressor
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The effect of multi-staging on consumed power

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ADVANTAGES OF MULTI- STAGING

1- The saving in power achieved by two-stage compression is illustrated by the shaded area in figure before.
2- The temperature of the gas increases continuously during compression. Multi-staging with cooling of the gas (or air) between stages reduces the maximum gas temperature in the cylinders thereby easing or eliminating difficulties with lubrication, carbon deposits and thermal stresses. 3- The reduction of the pressure differential across each cylinder; this lightens the load and stresses imposed on valves and piston rings and correspondingly increase the life of these parts. 4- Multi-staging reduces the size and sometimes the number of cylinders which must operate at the final discharge pressure.
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OIL LUBRICATION SYSTEMS

The function of oil system in positive displacement compressors: To provide clean, high grade lubricating oil with suitable pressure and temperature. There are two lubrication systems: 1. Oil splash system: suitable for small machines. 2. Forced feed system (forced circulation system): suitable for big machines.
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OIL LUBRICATION SYSTEMS
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OIL SPLASH LUBRICATION SYSTEM
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THE COMPRESSION CYLINDER COMPONENTS
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THE COMPRESSION CYLINDER COMPONENTS

Compression cylinder contains: 1. Piston head 2. Piston rings (compression rings and rider rings) 3. Piston rod 4. Piston rod packing 5. Suction valve (s) 6. Discharge valve (s)
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PISTON-TO- PISTON ROD CONNECTIONS

There are three methods commonly used to fasten the piston to the piston rod: Taper Fit: The end of the piston rod is machined with a tapered bore in the piston. The end of the piston rod is threaded, and a nut draws the piston to the rod and holds it securely. Interference Fit: The piston bore is machined to accept the piston rod with an interference. No threaded connection or nut is used to hold the piston to the rod, and the piston is "peened" at the rod end. Single Nut: The piston bore is closely fitted to the piston rod, and the piston is held to a shoulder or collar machined on the rod. The piston is held to the rod by a nut which is torqued to the proper value dependent on material, diameter, and number of thread. This is the most common fastening arrangement.
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Segmented piston with rider band (ring)

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Taper fit piston rod connection
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Multi-bolt piston attachment allowing removal of piston without having to unscrew the piston rod from the crosshead
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Interference fit piston rod connection for small compressors
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Single nut, one-piece piston arrangement

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PISTON HEAD DESIGNS AND COMPONENTS

Single piece piston head
Three pieces piston head

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PISTON HEAD DESIGNS AND COMPONENTS
Three-piece piston design
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PISTON HEAD AND PISTON ROD
The function of:

piston head: displace the gas outside the cylinder on discharge stroke. Piston rod: drive the piston head back and forth
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NON METALLIC PISTON RINGS
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NON METALLIC PISTON RINGS

The function of compression rings: Prevent internal leakage around the piston head from high pressure area to low pressure area Rider rings (guide rings): Carry the weight of the piston head and piston rod.
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NON-METALLIC PISTON RINGS
Guide ring
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Segmented carbon ring as compression ring

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METALLIC PISTON RINGS IN CASE OF OIL LUBRICATED COMPRESSOR
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PISTON ROD PACKING
The function of piston rod packing: Prevent leakage of gas around piston rod in double acting compressors.
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TANGENT- CUT SEALING RINGS
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SEALING RING ALIGNMENT WITH VARIATIONS IN BORE FIT
Packing ring joints remain in contact despite variations in bore fit
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COMPRESSOR PACKING CASES
Ring design and advanced materials combine to form the most effective gas sealing solution.
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NON-METALLIC PACKING ASSEMBLIES
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NON-METALLIC PACKING ASSEMBLIES

1. The packing case consists of a flange and a series of cups with packing rings. 2. Rings are available in various types of materials from cast iron to teflon, depending on the applications. 3. Case material is normally cast iron or steel to withstand higher pressures (>2,000 psig).
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COMPRESSOR PACKING RINGS
Piston rod oil wiper rings
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COMPRESSOR PACKING RINGS
Piston rod packing
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RECIPROCATING COMPRESSOR COOLING SYSTEMS

Sources of heat: 1. Due to compression of gas. 2. Due to friction between the piston rings and the cylinder wall. This heat must removed adequately to protect the compression cylinder components.
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Cylinder cooling fins
Air cooled compressor
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Compression cylinder cooling jacket

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WATER COOLED INTERCOOLER
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AIR COOLER INTERCOOLER
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RECIPROCATING COMPRESSOR VALVES

What is a compressor valve? Compressor valves are devices placed in the cylinder to permit one-way flow of gas either into or out of the cylinder. There must be one or more valves for inlet and discharge in each cylinder end.
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Basic requirements of a compressor valve: Basically, an automatic compressor valve requires only three components to do the job it is required to do: 1. Valve seat 2. Sealing element 3. A stop to contain the travel of the sealing element
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Compressor valves must have the following: 1. Large passage area and good flow dynamics for low throttling effect (pressure drop) 2. Low mass of the moving parts for low impact energy. 3. Quick response to low differential pressure 4. Small outside dimensions to allow for low clearance volume. 5. Low noise level. 6. High reliability factor and long life 7. Ease of maintaining and servicing
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Plate valve
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Valve cover
Valve plate
Valve springs
Valve seat
The plate valve components

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Channel valve Channel valve components
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The poppet valve
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Finger valve - for small compressors
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VALVE FAILURE ANALYSIS

When valve failure analysis is under taken, component appearance must first be investigated to determine causes of failure. Valve failures can be classified as resulting from three general causes: 1. Wear and fatigue 2. Foreign materials 3. Abnormal mechanical action
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1. Wear and fatigue: Wear cannot be completely eliminated. It can be minimized by proper lubrication, design, and selection of materials Fatigue is the result of repeated cyclic stress. 2. Foreign materials Foreign materials may be: 1. liquid carryover 2. Dirt gas 3. Carbon formation 4. corrosive elements
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3. Abnormal mechanical action: There are four causes of abnormal operation: 1. Slamming 2. Fluttering 3. Resonance or pulsation 4. Flow pattern
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COMRESSOR CAPCITY CONTROL

There are seven methods of varying the pumping capacity of a reciprocating compressor: 1. Throttling of the suction pressure. 2. By-pass line from discharge to the suction line. 3. By-pass line from mid-stroke position to the suction manifold. 4. A pocket in the cylinder head. 5. Unloading system which keeps the suction valve open all the time. 6. Changing the compressor running speed. 7. Shut down the compressor periodically (start-stop operation).
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Un-loader
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Throttling of the suction pressure
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By-pass system
Bypass discharge gas back to the suction
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A pocket in the cylinder head

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CLASSIFICATION OF RECIPROCATING COMPRESSORS
Vertical compressor
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Two stage vertical cylinders compressor
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Horizontal, multi-stage compressor back to back arrangement

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V-shape arrangement
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W-shape arrangement
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W-shape arrangement
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W-shape arrangement
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L-shape arrangement
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RECIPROCATING COMPRESSOR PRESSURE PULSATION DRUMS
Gas scrubber and pressure pulsation drum on the suction side and pressure pulsation dampener on discharge side
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GAS SCRUBBERS ON THE SUCTION SIDE
The function of gas scrubber is to remove any liquid droplets or solid particles from March 29, 2014 the gas before it enter the compressor
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ROTARY POSITIVE DISPLACEMENT COMPRESSOS
Lobe compressors (lobed blowers)

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The two lobes in the lobe compressors

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Screw compressor
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SCREW COMPRESSORS
Rotor profiles of the four lobe male and six-lobes female
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OIL FLOODED ROTARY SCREW COMPRESSOR
Oil/ gas flow The function of the oil: Lubricate, seal and cool all internal components.
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OIL FLOODING SYSTEM
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Sliding vanes compressor

Sliding vane Compressor rotor Coupling Cooling jacket Compressor casing
Seal
Sliding vane compressor components

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SLIDING VANES COMPRESSOR

The rotor
Sliding vane
The rotor of sliding vanes compressor

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Liquid ring compressor
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Liquid ring compressor
The liquid distribution inside the compressor casing when it rotates

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Two throw frame and running gear
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Reciprocating Comp.

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RECIPROCATING COMPRESSORS

March 29, 2014

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POSITIVE DISPLACEMENT COMPRESSORS CLASSIFICATION

March 29, 2014

Working principle of reciprocating compressor

ROTARY POSITIVE DISPLACEMENT

March 29, 2014