Reciprocating compressor

A reciprocating compressor or piston compressor is a positive-displacement compressor that

uses pistons driven by a crankshaft to deliver gases at high pressure. [1][2]

The intake gas enters the suction manifold, then flows into the compression cylinder where it gets
compressed by a piston driven in a reciprocating motion via a crankshaft, and is then discharged.
Applications include oil refineries, gas pipelines, chemical plants, natural gas processing plants
and refrigeration plants. One specialty application is the blowing of plastic bottles made
of polyethylene terephthalate.
In the ionic liquid piston compressor many seals and bearings were removed in the design as the
ionic liquid does not mix with the gas. Service life is about 10 times longer than a regular diaphragm
compressor with reduced maintenance during use, energy costs are reduced by as much as 20%.
The heat exchangers that are used in a normal piston compressor are removed as the heat is
removed in the cylinder itself where it is generated. Almost 100% of the energy going into the
process is being used with little energy wasted as reject heat.

Reciprocating Compressor basic parts

Reciprocating compressors play a major role in the chemical, petrochemical, gas, and general industry
processes. It is best known and most widely used compressors of the positive displacement type. In this
article, we will learn about the reciprocating compressor basic parts.

1 Cylinder
2 Pistons
3 Piston Rod
4 Distance Piece
5 Rod Packing
5.1 Tangent Ring
5.2 Radial Ring or Pressure Breaker Ring
5.3 Backup Ring
6 Crankshafts
7 Bearing:
8 Connecting Rod
9 Cross Head
10 Valves
10.1 Poppet Type Valve
10.2 Plate Type Valve
10.3 Ring Type Valve
11 Lubrication Systems
Cylinders:
Cylinders of the reciprocating compressor are used in the process industries are separable from the
frame. They are attached to the frame by way of an intermediate part known as the distance piece. The
cylinder will accommodate the both suction and discharge valve plates.

Normally most of the cylinders used in the process are equipped with replaceable liners. The purpose of
the liner is to provide a renewable surface to the wearing portion of the cylinder. This saves the cost of
replacing a complete cylinder once the bore has been worn or scored. In the larger, more complex
compressors, this feature is standard or readily available as an option. On the smaller frames, particularly
the single-stage models, the smaller cylinder size is such that the replaceable liner is not economical and
may not be available.

The cylinders are equipped for cooling to reduce the temperature during the compression cycle. This is
usually by means of a water jacket. If water jacketing in the cylinder is not feasible than fins are provided
in the cylinder for air cooling. The latter method is limited to either small or special purpose machines.

The most common material used in cylinder construction is cast iron for the larger, low-pressure cylinders
and steel for the smaller, high-pressure cylinders. In some cases, nodular or ductile iron can be used in
lieu of cast iron. For hydrocarbon service, steel is most desirable, although not universally available.

For capacity control, clearance pocket included in the cylinders. In the case of multi-stage compressors,
the clearance pocket is used in the first stage cylinder.

Piston:
The piston is the heart of the reciprocating compressor. The piston translates the energy from the
crankcase to the gas in the cylinder. In order to avoid the leakage of compressed gas between the piston
and cylinder, the piston is equipped with a set of sliding seals called as piston rings. Usually, the rings are
made of a material, that having self-lubricating property to reduce the slide friction force between the
cylinder and the piston. This to avoid the wear in the cylinder wall and also increase efficiency by
reducing the friction force.

Different types of rings are used for lubricated or non-lubricated service. In the case of non-lubricated
service, the rings shall have good self-lubricated property. Usually, this type of piston ring is made up of
PEEK and other fluorocarbon compounds.
For lubricated service, metallic rings such as cast iron or bronze as well as non-metallic materials such as
filled nylon are used. Nowadays the compressor manufacturer preferred non-metallic materials because
of less weight when compare with metallic rings.

In the case of horizontal cylinder piston, along with piston rings, an additional ring is used to reduce the
avoid the wear between cylinder and piston it is called as wear band or rider ring. The rider ring is one
piece configuration, to accommodate the rider ring the piston is segmented construction. As per API 618
one-piece rider rings are a required. Rider band life can be extended by rotating a piston 120° to 180° at
each overhaul.

Normally the piston is made up of lesser weight materials such as aluminium and aluminium alloys, this is
to reduce the reciprocating compressor shaking forces and Rod load. In the case, piston diameter larger
piston diameter hollow pistons are also used to reduce the weight.

Piston Rod:
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). Rod loading
must be kept within the limits set by the compressor vendor 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.

Distance Piece:
The distance piece is a separable housing that connects the cylinder to the frame. The distance piece
may be open or closed and may have multiple compartments. It may be furnished as single, double, or
extra long.

The purpose of a longer distance piece is to isolate that part of the piston rod entering the crankcase and
receiving lubrication from the part entering the cylinder and contacting the gas. This prevents lubricant
from entering the cylinder and contaminating the gas, particularly necessary in non-lubricated cylinders. It
can also keep a synthetic lubricant in a cylinder.

Compartments in the distance piece collect and control packing leakage when the gas is toxic or
flammable. The leakage can be directed to a flare or buffer inert gas is used to prevent the toxic gas
leakage to atmosphere.

Rod Packing:
Rod packing is required to prevent the gas leakage along the piston rod where it passes through the
crank end cylinder closure.

If cooling packing is required, the stuffing box may be jacketed for liquid coolant.

The packing rings are the heart of rod packing assembly. The main packing rings types are
  Tangent Ring
 Radial Ring or Pressure Breaker Ring
 Backup ring

Tangent Ring
The tangent ring is cut into three segments so that each cut lies on the side of an equilateral triangle. The
cuts of this ring maintain sealing contact regardless of variations of the ring’s inside diameter. As wear
occurs, the ring segments will close radially to compensate while still maintaining sealing contact at the
tangential joints by mean of Garter Spring.

Radial Ring or Pressure Breaker Ring

The radial ring or pressure breaker rings are cut into three segments so that each cut lies on the side of a
radial direction of the ring. The cuts of this ring are used to break down the pressure act on the ring.
Usually, a radial ring is the first packing ring face the cylinder pressure.

Backup Ring
This type of ring construction is similar to radial ring. As the name indicate this type of ring is used to
backup all the rings when using in the high-pressure application.

CrankShaft:
Larger compressors, normally above 150 kW(200 hp), have forged steel crankshafts. for compressor less
than or equal to 150kW machines ductile iron crankshaft. Crankshafts should have removable balance
weights to compensate for rotary unbalance as well as reciprocating unbalance. The crankshaft should be
dynamically balanced when above 800 rpm.

When force lubrication is used, the crankshaft oil passages should be drilled. The Figure shows a drilled
crankshaft. In the case of machines above 150kW,

Bearing:
The main and connecting rod bearings should be split-sleeve, steel-backed, babbitted insert type.
Antifriction bearing shall be used for compressor rating less than 150kW. As per API 618 trapper roller
bearings are used as the main bearing for compressor rating less than 150kW.

The cross head pin should have a replaceable bush bearing.

Connecting Rod:
For reciprocating compressor of above 150 kW(200 hp), have forged steel connecting rod are used and
for compressor less than or equal to 150kW machines ductile iron material is used. Like Crankshafts, the
connecting rod should have drilled hole for oil passage. The connection rod is used to connect the
crankshaft and the crosshead. The connecting rod converts the rotary motion into reciprocating motion.
The connecting rod bolts and nuts shall be securely locked with cotter pins or wire after assembly.

Cross Head:
All industrial reciprocating compressors are equipped with Crosshead. The crosshead is used to guide
the piston in the cylinder bore. The following are the advantage of crosshead

 The compressor can use a narrow piston, due to the use of narrow piston larger valve area for
greater efficiency.
 Permits a longer stroke and greater capacity.
 Separates crankcase from the cylinder, allowing control of oil carryover into the cylinder.
 Gives greater stability to piston, eliminating piston “slap” and reducing ring wear
 Permits stronger piston design and higher operating pressures.

Valve:
The reciprocating compressor cylinder valves are of the spring-loaded, gas-actuated type. Reciprocating
compressors generally use one of three types of valve configurations:

 Ring Type valve

 Poppet Type valve
 Plate Type valve

Poppet Type Valve

The poppe t valve (see Figure) consists of multiple, same-size

ports and sealing elements. The advantage of the valve is that has a high flow efficiency due to the high
lift used and the streamlined shape of the sealing element. The disadvantage is that the valve is not
tolerant of uneven flow distribution. The valve is most commonly used in medium pressure range.
Nowadays these types of valves are used in hydrocarbon service because of easy maintenance.
Poppet valves are recommended up to 15 Mpa differential pressure or 30 Mpa discharge pressure and
600rpm.

Plate Type Valve

The plate valves, as shown in Figure, are similar to the concentric ring valve except that the rings are
joined into a single element. The advantage is that the va

lve has a single element making flow control

somewhat easier. Because of the single element, the number of edges available for impact is reduced.
The valve may be mechanically damped, as this design permits the use of damping plates. It has the
disadvantage that because of the geometry used, the stress is higher due to the potential of higher stress
concentrations. These valves are mostly used in the industrial process compressor.

Plate valves are recommended up to 20 Mpa differential or 40 Mpa discharge pressure and 1800 rpm.

Ring Type Valve

As the name implie s the ring type valve consisting of concentric ring
valve uses one or more relatively narrow rings arranged concentrically about the center line of the valve
(see Fig ). These valves have the advantage of a low-stress level due to the lack of stress concentration
points. The disadvantage is that it is difficult to maintain uniform flow control with the independent rings.

Ring valves are recommended up to 30 Mpa differential or 60 Mpa discharge pressure and 600 rpm.

Lubrication System:
Force type lubrication is use for medium and heavy duty compressor. The main component of the force
type lubrication is the main oil pump, dual oil filter, lube oil cooler, pressure regulating valve, lube oil tank,
and its associated accessories.

Splash type lubrication is use for a small compressor of 100kW. This type of system lubricating oil by
splashing of crank-throw moving through the lubricant in the sump.
ist of Important Parts of Reciprocating Air Compressor
Frame/Crankcase

Crankcase which is also known as Frame is a heavy, rugged housing containing all the
rotating parts. A cylinder and crosshead guide is also mounted on the crankcase.
Bearing housing is fitted on a crankcase with accurately bored to fit main bearings. So,
misalignment or eccentricity is avoided.

This is a totally enclosed rigid cast iron body in square or rectangle shape, often work as oil
sump.

Crank Shaft
High-grade S.G. Iron crankshaft in one piece in design, dynamically balanced with
counterweights, avoid any twisting.
Crank pin & journals duly ground & polished ensure the long life of bearings. A flywheel is
fitted on the crankshaft.

Cylinders

Graded cast iron cylinders designed with a water jacket in water-cooled air compressor to
remove heat generated during compression.
Designed for streamlined air passage & maximum numbers of valves, cylinder provides a
smooth flow of air, thereby minimizing the pressure drop.
Pistons
Special Aluminum alloy pistons for non-lubricated air compressor and graded cast iron
pistons are used for lubricated models. Piston Rings are used for sealing to a cylinder.
Connecting Rod

Forged alloy steel connecting rod is duly normalized, are designed to provide minimum
thrust on cross head bearing surface.

Main Bearings & Big End Bearings

Copper lead alloy designed for long life. It gives perfect rigidity to running gear.
Cross Slide & Cross Head

Manufactured from high-grade S.G. Iron material. Its low inertia along with low friction cross
slide ensure the perfect running of the crosshead.

Suction & Discharge Valves

Stainless Steel plate type or spring type valves are arranged symmetrically in suction &
discharge provides longer life.
Oil Pump

It feeds oil to main bearings, connecting rod bearings & to cross slides. The oil pump
regulates the oil pressure by pressure regulating screw.
Along with above parts some other small parts as like oil seal ring, small end bushing,
Suction filter element, crosshead pin, heads, belts nut, and bolt, gaskets etc. are used.