Documenti di Didattica
Documenti di Professioni
Documenti di Cultura
Petroleum Gas
Compression
Part of the
Petroleum Processing Technology Series
OPITO
Contents
Page
Training Targets
2.2
Introduction
2.3
2.4
Operating Principles
Capacity and Compression Ratio
Compressor Performance
Cylindars
Pistons and Piston rings
Compressor Valves
Stuffing Box
Crankshaft, Connecting Rod, Crosshead and Piston Rod
2.29
2.17
Visual Cues
2.37
summaries for you to recap on the
major steps in your progress
2.44
2.
Introduction
Training Targets
When you have completed Unit 2 of the Petroleum Gas Compression series you will be able to :
Describe the layout and operation of the auxiliary systems associated with a reciprocating
compressor.
2.
Introduction
As I previously explained, the compressor requirements of an oil or gas production system are dependent upon
many variables.
Each system will have its own characteristics and show
detailed design differences.
2.
2.
2.
You can see from Figure 1 that the flow of gas through
the compressor is controlled by valves. These act as
non-return valves to permit flow in one direction only.
These valves are often called check valves. They are
positioned in the inlet (suction) and outlet
(discharge) of the compressor. Gas enters the
cylinder through the suction valve and leaves through
the discharge valve,
Suction valves open when the cylinder
pressure is lower than the pressure of the gas
to be compressed
Discharge valves open when cylinder pressure
is higher than the pressure of the system into
which the gas is to be discharged
Reciprocating compressors are classified as :
Single Acting
or
Double Acting
2.
2.
2.
2.
Activity
Take a bicycle pump and, without connecting it to a
bicycle tyre, pump it ten times.
Now put your hand on it and test the temperature.
What do you notice?
After you have done this, connect the pump to a
bicycle tyre and pump it another ten times.
2.10
2.11
Compressor Performance
The performance of a reciprocating compressor can
be represented by a pressure/volume (PV) diagram.
One of these is shown in Figure 5, which illustrates
the relationship between the cylinder pressure of a
compressor and the cylinder volume enclosed by the
piston, for a single-acting compressor.
2.12
2.13
1.
.... 1 ....
............
2.
............
............
3.
............
............
4.
............
5.
............
............
6.
............
7.
............
The answers to Test Yourself 2.3 will be found on Page 2.44
2.14
Summary of Section 1
In this first Section of Unit 2, we have looked at the basic theory of operation for positive displacement
compressors.
We started by looking at how a reciprocating
compressor operates, and compared this operation to
that of a bicycle pump.
The main components of a reciprocating compressor
were described, and you identified these on a simple
line diagram.
single acting,
or
double acting
2.15
Single-
Acting
Double-
Acting
1.
6.
2.
7.
3.
8.
4.
5.
Single-
Acting
DoubleActing
You will find the answers to Test Yourself 2.4 on Page 2.45
2.16
Cylinders
Pistons and piston rings
Compressor valves
Stuffing box and packing
Crankshaft, connecting rod, crosshead and
piston rod
Take another look at Figure 1 on Page 2.5. See how
many of the components listed above you can identifythey are not all labelled ! When you have done that, we
will look at each item on the list in turn.
Cylinders
You have seen in previous illustrations that the
cylinder in a reciprocating compressor is considerably
more substantial than a bicycle pump. However, it is
still basically a tube in which a piston slides back and
forth.
2.17
Cylinder Cooling
Cylinder Lubrication
In low pressure/low temperature applications, the
cylinders may not require lubrication. In this case, the
pistons may be fitted with self-lubricating piston
rings, made of nylon or teflon.
However, in most compressor applications, cylinder
lubrication is required to prevent excessive overheating
or wear. In such situations, a boundary layer
lubrication system is usually installed. This injects
small droplets of oil into the cylinder, to be distributed
by the movement of the piston rings. This type of
lubrication prevents the formation of an oil mist in the
gas leaving the compressor.
2.18
The coolant fluid is circulated to prevent localised hot spots and to take
away unwanted heat generated by compression. This removal of unwanted
heat improves compressor efficiency.
2.19
2.20
Compressor Valves
Stuffing Box
In order to prevent leakage of compressed gas from
the cylinder past the piston rod, some form of seal
is required. The most common type of seal is the
stuffing box.
The stuffing box consists of a series of seal elements
each containing a pair of seal rings. Figure 11, on the
next page, shows the arrangement of a seal element
with a type of seal ring known as the TR type.
2.
3.
4.
2.22
The TR type seal element consists of two rings which are distinguished from each
other as follows
the internal ring (T) is fitted first and has tangential cuts
the external ring (R) is fitted last and has radial cuts
The T ring haste function of preventing gas leakage. The R ring protects the T ring
and helps to dissipate heat.
The two rings are assembled with staggered cuts and a dowel (not shown) provides
for their correct positioning.
2.23
Crankshaft
The crankshaft is made of forgeable carbon steel,
machined throughout. It is provided with a single
crank and is suitably counterweighted to limit the
dynamic load on the foundation.
The crankshaft ends are equipped with bearings of the
bush type. They are fitted on the crankcase sidewalls.
2.25
2.26
Connecting Rod
Crosshead
Piston Rod
Piston rods are usually made of stainless steel.
They are accurately ground and have no taper
within their length of travel.
The piston rod screws into the crosshead and is
secured in place by a locking device.
A slinger ring prevents oil from the crankcase being
carried out by the piston rod and reaching the
cylinder. It is installed on the piston rod, as you can
see in Figure 14.
Summary of Section 2
1.
2.
You will have noted how the piston is lubricated and how the cylinders are cooled.
3.
4.
5.
6.
We saw how the space between the cylinder liner and the piston is sealed by the piston rings.
The construction of compressor valves was described, and how they operate to maintain the flow
of gas through the compressor.
We have looked at the different types of seal used in the stuffing box, and how the stuffing box
prevents gas from escaping from the compressor along the piston rod.
You saw how the crankshaft, crosshead and connecting rod convert the rotary motion of the driver to the
reciprocating motion required by the compressor.
In the next Section, we will take a look at the auxiliary systems which are used with reciprocating
compressors.
2.28
Cooling System
You saw earlier that, as gas is compressed, its
temperature increases. The compressors cooling
system removes some of the heat generated by
compression (heat of compression) and also protects
the piston and cylinder from becoming overheated.
Figure 16 is a simple line drawing of a compressor
cooling system, cooling the cylinder and stuffing box.
2.29
Lubrication System
2.30
2.31
2.32
2.33
Drive Coupling
2.34
2.
3.
4.
5.
Why is there always a liquid knockout drum installed in the suction piping ?
6.
7.
On a typical oil production platform where would you expect the compressor
vent line to lead to ?
8.
You will find the answers to Test Yourself 2.6 on Page 2.46
2.35
Summary of Section 3
In this Section on auxiliaries, we have looked at :
the compressor cooling system
the lubrication system
the suction and discharge piping system
the driver coupling
2.36
2.37
2.38
2.39
2.40
2.41
2.42
2.
3.
4.
5.
6.
Summary of Section 4
In the final Section of this Unit on reciprocating compressors, we have concentrated on the operation and
control of the system.
The Section was split into three parts :
8.
5.
20 bara
12.
6.
3.
10.
7.
2.44
Only the space at the head end of the cylinder is used for
compression.
2.
3.
4.
5.
6.
7.
8.
DoubleActing
a
a
a
a
a
a
a
a
a
1.
2.
3.
4.
5.
6.
1.
1.
2.
2.
3.
4.
3.
No. It is a major problem. If the level gets any higher, the liquid may
enter the compressor and cause damage. A shutdown and alarm
will be generated
5.
To remove any entrained liquid from the process gas and prevent the
possibility of serious damage due to liquids entering the compressor
4.
The beeper stops sounding and the light stops flashing but stays
alight to remind the operator that the problem still exists
6.
5.
7.
8.
6.
Inhibit alarms are fitted to prevent the compressor from being started
under certain conditions. Once the compressor is running, the
inhibit alarms will not stop the compressor
2.46