reciprocating comp
TRANSCRIPT
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RECIPROCATING COMPRESSORS
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COURSE OBJECTIVES
1. Describe the functions of a compressor
2. Classification of positive displacementCompressors
3. The working principle of a reciprocating
compressor and its components4. Reciprocating compressor classification
5. Rotary positive displacement compressors
6. The components of each type and how it works?
7. Capacity control systems8. Instrument air system (air dryers)
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COMPRESSOR CLASSIFICATION
Compressors
Dynamic Positive Displacement
Axial Flow Centrifugal Reciprocating Rotary positive Dis.
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
compressors2. Rotary positive displacement compressors
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RECIPROCATING COMPRESSORS
Working principle of reciprocating compressor
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ROTARY POSITIVE DISPLACEMENT
COMPRESSORS
Rotary positive displacement compressorsinclude:
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 stagecompressor is not enough, we move to multi-stage design.2. In multi-stage the same amount of gas re-compressed again and again until we get therequired pressure.3. Cooling of the gas after each stage and before itenters the next one is essential (intercooler).
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MULTI-STAGE RECIPROCATING COMPRESSOR
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MULTI-STAGE RECIPROCATING COMPRESSOR
Single-stage two-stage compressor
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MULTI-STAGE RECIPROCATING COMPRESSOR
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 isillustrated 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 tothe piston rod:
Taper Fit: The end of the piston rod is machined with a taperedbore in the piston. The end of the piston rod is threaded, anda nut draws the piston to the rod and holds it securely.
Interference Fit: The piston bore is machined to accept thepiston rod with an interference. No threaded connection ornut 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 onthe rod. The piston is held to the rod by a nut which istorqued to the proper value dependent on material, diameter,and number of thread. This is the most common fasteningarrangement.
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PISTON-TO- PISTON ROD CONNECTIONS
Segmented piston with rider band (ring)
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PISTON-TO- PISTON ROD CONNECTIONS
Taper fit piston rod connection
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PISTON-TO- PISTON ROD CONNECTIONS
Multi-bolt piston attachment allowing removal of piston without
having to unscrew the piston rod from the crosshead
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PISTON-TO- PISTON ROD CONNECTIONS
Interference fit piston rod connection for small compressors
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PISTON-TO- PISTON ROD CONNECTIONS
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
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
S G G G
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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 seriesof cups with packing rings.2. Rings are available in various types of materialsfrom cast iron to teflon, depending on theapplications.3. Case material is normally cast iron or steel towithstand 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
RECIPROCATING COMPRESSOR COOLING
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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 heatmustremoved adequately to protect the
compression cylinder components.
RECIPROCATING COMPRESSOR COOLING
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RECIPROCATING COMPRESSOR COOLING
SYSTEMS
Air cooled compressorCylinder cooling fins
RECIPROCATING COMPRESSOR COOLING
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RECIPROCATING COMPRESSOR COOLING
SYSTEMS
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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RECIPROCATING COMPRESSOR VALVES
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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RECIPROCATING COMPRESSOR VALVES
Compressor valves must have the following:
1. Large passage area and good flow dynamics forlow 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 lowclearance volume.
5. Low noise level.6. High reliability factor and long life
7. Ease of maintaining and servicing
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RECIPROCATING COMPRESSOR VALVES
Plate valve
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RECIPROCATING COMPRESSOR VALVES
The plate valve components
Valve cover
Valve plate
Valve springs
Valve seat
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RECIPROCATING COMPRESSOR VALVES
Channel valve
Channel valve components
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RECIPROCATING COMPRESSOR VALVES
The poppet valve
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RECIPROCATING COMPRESSOR VALVES
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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VALVE FAILURE ANALYSIS
1. Wear and fatigue:Wear cannot be completely eliminated. It can beminimized by proper lubrication, design, andselection of materials
Fatigue is the result of repeated cyclic stress.2. Foreign materials
Foreign materials may be:
1. liquid carryover
2. Dirt gas3. Carbon formation
4. corrosive elements
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VALVE FAILURE ANALYSIS
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 pumpingcapacity 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 thesuction manifold.4. A pocket in the cylinder head.
5. Unloading system which keeps the suction valveopen all the time.
6. Changing the compressor running speed.7. Shut down the compressor periodically (start-stopoperation).
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COMRESSOR CAPCITY CONTROL
Un-loader
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COMRESSOR CAPCITY CONTROL
Throttling of the suction pressure
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COMRESSOR CAPCITY CONTROL
By-pass system
Bypass discharge gas back to the suction
COMRESSOR CAPCITY CONTROL
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COMRESSOR CAPCITY CONTROL
A pocket in the cylinder head
CLASSIFICATION OF RECIPROCATING
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CLASSIFICATION OF RECIPROCATING
COMPRESSORS
Vertical compressor
CLASSIFICATION OF RECIPROCATING
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CLASSIFICATION OF RECIPROCATING
COMPRESSORS
Two stage vertical
cylinderscompressor
CLASSIFICATION OF RECIPROCATING
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CLASSIFICATION OF RECIPROCATING
COMPRESSORS
Horizontal, multi-stage compressor
back to back arrangement
CLASSIFICATION OF RECIPROCATING
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C SS C O O C OC G
COMPRESSORS
Horizontal, multi-stage compressor
back to back arrangement
CLASSIFICATION OF RECIPROCATING
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COMPRESSORS
Horizontal, multi-stage compressor
back to back arrangement
CLASSIFICATION OF RECIPROCATING
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COMPRESSORS
V-shape arrangement
CLASSIFICATION OF RECIPROCATING
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COMPRESSORS
W-shape arrangement
CLASSIFICATION OF RECIPROCATING
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COMPRESSORS
W-shape arrangement
CLASSIFICATION OF RECIPROCATING
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COMPRESSORS
W-shape arrangement
CLASSIFICATION OF RECIPROCATING
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COMPRESSORS
L-shape arrangement
RECIPROCATING COMPRESSOR PRESSURE
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PULSATION DRUMS
Gas scrubber and pressure pulsation drum on the
suction side and pressure pulsation dampener on
discharge side
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PULSATION DRUMS
RECIPROCATING COMPRESSOR PRESSURE
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PULSATION DRUMS
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PULSATION DRUMS
GAS SCRUBBERS ON THE SUCTION 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
the gas before it enter the compressor
ROTARY POSITIVE DISPLACEMENT
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COMPRESSOS
Lobe compressors (lobed blowers)
ROTARY POSITIVE DISPLACEMENT
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COMPRESSOS
The two lobes in the lobe compressors
ROTARY POSITIVE DISPLACEMENT
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COMPRESSOS
Screw compressor
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OIL FLOODED ROTARY SCREW
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COMPRESSOR
Oil/ gas flow
The function of the oil: Lubricate,seal
and coolall internal components.
OIL FLOODING SYSTEM
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OIL FLOODING SYSTEM
Sliding vanes compressor
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g p
Sliding vaneCompressor
rotor
CouplingCooling
jacket
Compressor
casing
Seal
Sliding vane compressor components
SLIDING VANES COMPRESSOR
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SLIDING VANES COMPRESSOR
The rotor
Sliding vane
The rotor of sliding vanes compressor
Liquid ring compressor
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Liquid ring compressor
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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