Compresor Reciprocante

Basic Elements of
Reciprocating
Compressors
Reciprocating Compressor
Condition Monitoring
© 2010 General Electric Company. All rights reserved.

Topics
We will be discussing the following reciprocating

compressor concepts:
• Components & Nomenclature

• Capacity Control
• Lubrication Systems
• Compressors Types

Components & Nomenclature
Crosshead Guide
/ Distance Piece
Cylinde
r
Cylinde Fram
r e
Cylinde
r
Cylinde
r

Driver
Distance Piece
Frame
Cylinder
Crosshead
Guide

Frame
Spacer Blocks Main Bearing Cap

Tie Rods
Crosshead Guide
Crankshaft
Main Bearing
Support Web
Oil Sump
Soleplate Mounts

Main Bearing
Thermocoupl
e
Bearing
Cap
Bearing
Nuovo Pignone S.p.A.
Insert
Bearing
Support

Running Gear
Describes the moving

parts of the compressor
including:
•Crankshaft
•Connecting Rod
•Crosshead
•Piston Assembly
8-Throw_080406.wmv

Crankshaft
Primary Function of Crankshaft:

• Convey power from driver to
connecting rod
Secondary
Function:
• Provide passages
for lubricating other
components

Crankshaft
Crankshaft Flange
Web
Web
Assembly
Main Bearing Journal
Crank Pin
Main Bearing Journal

Crankshaft
Fixed Angle
Crankshaft
Web
Drive Flange
Crank Pin
Journal Journal
Crank Pin
Web Web
Fixed Angle Crankshaft:

• Adjacent crank pins exactly 180
degrees apart,
•Not separated by a main journal
bearing.
10

Crankshaft
• Fixed Angle Crankshaft
• Four (4) throw

• Horizontal,
Balanced & Opposed
11

Crankshaft
• Fixed Angle
Crankshaft
• Six throw
• Horizontal, Balanced
& Opposed
12

Crankshaft
Variable Angle Crankshaft
120 degrees 120 degrees

Crank Pin
Journal Journal
Crank Pin
Crank Pin
Variable Angle Variable Angle
Crankshaft (end view) Crankshaft (side view)
Variable Angle Crankshaft:
• Main bearing between each web assembly,
• Angles between any throws can be whatever
is required by design.
13

Crankshaft
• Variable Angle Crankshaft
• Three (3) Throw

• Not balanced & Opposed
14

Crankshaft
• Variable Angle Crankshaft
• Five (5) Throw

• Not Balanced &
Opposed
15

Crankshaft Main Bearing
Cap
Thrust Shoe
16

Main Bearing
Crankshaft Cap
Thrust Shoe
17

Flywheel
Flywheel
18

Reciprocating Compressor Throw
• The term “throw” is often used to • This example shows two throws
refer to a connecting rod, driven by a single crankpin & web
crosshead, piston rod & piston assembly.
assembly.
Single Throw
WebAssembly_Angle.wmv
19

Connecting Rod
Crank Pin Bearing
Crosshead Pin Bushing
Connecting Rod
Bolts
Crosshead
Pin
20

Connecting Rod
Oil Passage to
Lubricate Crosshead
Pin
21

Connecting Rod
• Rod load reversal is the periodic shifting of piston rod load

between tension and compression during a complete
stroke.
– Important for adequate crosshead pin & bushing lubrication.
Crosshead
Crosshead Pin Bushing
Lubricating Oil
Crosshead Pin
Crosshead Assembly
Cross-Section
22

Connecting Rod
Connecting rod big end

bearing insert (bearing cap
removed)
Small end bushing

Nuovo Pignone S.p.A. (with oil distribution
grooves)
23

Crosshead
Shoe
Piston
Rod
Shoe
Crosshead
Shoe Pin
Piston
Rod
Shoe Nuovo Pignone S.p.A.

24

Crosshead Assembly
Nuovo Pignone, S.p.A.
Crosshead extension
with crosshead and
connecting rod
Nuovo Pignone, S.p.A.
Installing crosshead extension on compressor frame
25

Crosshead Assembly
Upper Crosshead
Guide
Upper Crosshead Pin
Shoe (hidden from
view)
Locknut
Crosshea
Piston Rod d
Lower
Shoe Lower Crosshead
Guide
26

© 2007 General Electric Company. All rights reserved. Nuovo Pignone S.p.A.
Cylinder Components
Suction Port
Pressure
Tap (crank- Suction
end) Valve (head-
end)
Discharge
Valve (crank- Unloade
end) r
Discharge 28
Port
Cylinder Assembly
Distance
Piece
Suction
Valve
Cooling Water
Cylinde
r
Piston
Rod
Buffer Gas Purge
Pressure Packing
Case
Chambe
r Piston
Discharge 29
Valve
Cylinder Assembly (Tandem)
Distance
Piece
Distance
Piece
Piston
Rod
Pressure Packing
Case
Inner Cylinder
Outer Cylinder
30

Cylinder Assembly (Tandem)
Distance
Piece
Distance
Piece
Piston
Rod
Pressure Packing
Case
Inner Cylinder
Outer Cylinder
31

Cylinder Assembly (Tail Rod)
Distance
Suction
Piece
Valve
Cylinder
Crank End Pressure

Packing Case
Head End Pressure

Packing Case Tail Rod
32

Piston Assembly (Compound)
Piston Rod Locknut
(Crosshead nut)
Piston Rod
Piston Washer
Frame End Piston Half
Piston Rings
Ring Carrier
Wear Bands
(Rider Bands)
Head End Piston Half
Piston Nut Washer
Piston Nut
Exploded View
Compound Piston
Assembled View
Compound Piston
33

Piston Assembly (Integral)
Piston Rod Locknut

(Crosshead nut)
Piston Rod
Piston Rings
Wear Bands
(Rider Bands)
Assembled View
Cross Sectional View
Integral Piston
Integral Piston
34

Valve
Plate Valve Concentric Ring Valve
PlateValveDescription.wmv ConcRingValveDescription.wmv
Seat
Gas Flow
Plate
Buttons
Spring
s
Guard
35

Suction Valve Assembly
Suction valve
with finger-
type unloader

36

Packing Sets
Oil Wiper
Oil Wiper Packing
•Prevents frame oil from
Packing
migrating into the distance pieces
Intermediate •Sometimes referred to as
Partition Packing “scraper packing.”
•Intermediate Partition
Packing
•Prevents process gas that
leaked through the pressure
packing case from entering
Piston frame.
Rod •Sometimes referred to as
Pressure “intermediate packing.”
Packing
•Pressure Packing
•Prevents process gas from
entering the distance piece.
37

Pressure Packing – Assembled
Nose Cup Gasket
Packing
Rings
Packing assembly installed

Tie in crank-end cylinder head.
Bolts Packing
Cups
Packing
Case
Flange
38

Pressure Packing – Components
Nose Cup Gasket Packing case flange
includes ports for coolant,
lubricating oil, vent, and
buffer gas purge lines – as
appropriate.
Tie Bolts
Packing
Cup
Packing
Rings
Packing Case
Flange 39

Packing Rings
Radial Tangentia
Packing l Packing
Ring Ring
Radial and tangential rings are most

effective when used together in a packing
set.
40

Purged Pressure Packing
Cylinder Head
Buffer Gas Purge
Process
Buffer Gas
Gas Leakage
Leakage Piston
Rod
Vent to Disposal Packing

System (flare) Cups &
Packing Rings
Case
Flange
41

Capacity Control
• Starting and Stopping Compressors
• Clearance Pockets
• Suction Valve Unloaders
• Variable Speed Drivers
• Recirculation or Bypass
42

Starting and Stopping
Compressors
Capacity Control
In general, the procedure is the following:
• Clear compressor and process lines
• Start compressor
• Open the gas cut-off valve on the final stage discharge line.
• Gradually load the various stages, starting from the last one
and working back to the first.
• Gradually close the overall by-pass (if there is one).
• Reverse procedure to shutdown
43

Capacity Control
• Starting and stopping compressors
• Clearance pockets
• Suction valve unloaders
• Variable speed drivers
44

Clearance Pocket
Capacity Control
Suction
Valve
Fixed-
Volume
Pocket
Piston PV Curve - Loaded
Plug
PV Curve – Reduced
Capacity
Discharge Actuator
Valve
45

Clearance Pocket Actuators
Capacity Control
Example: Head-end clearance pockets with hydraulic actuators.
46

Variable Clearance Pocket
Unloader Head End
Head
Capacity Control
Control
Piston
Control Piston Motion
Additional Clearance
Hydraulic Cylinder Volume
(Actuator)
47

Variable Clearance Pocket
Unloader Process Gas Line
Capacity ControlControl Unit Electrical Line
Mechanical Link
Pressure Transducer
PT Hydraulic Line
Position Discharge
Transducer
Directional Valve With

Manual Override
Suction
Hydraulic
Cylinder
Hydraulic Console 48

Plug-Type Valve Unloader
Capacity Control
Actuator
Plug
PV Curve - Unloaded PV Curve - Loaded
Suction Piston
Valve
49

Finger-Type Valve Unloader
Capacity Control
Actuator
Finger
Assembly
Suction Piston
Valve
50

Active Valve Control
Capacity Control
Electroni
c
Circuitry
High-
Speed
Hydraulic
Actuator
Finger
Assembly
Suction Piston
Valve
51

Active Valve Control
Capacity Control
High-speed Actuator
Electronics
Unloader Finger
Assembly PV Curve - Unloaded
Suction Valve
(Hoerbiger Corporation)
PV Curve - Loaded
52

Valve Unloader Actuators
Capacity Control
Example: Suction valve unloaders with hydraulic actuators.
53

Capacity Control
• Starting and stopping compressors
• Clearance pockets
• Suction valve unloaders
• Variable speed drivers
54

How does the BY-PASS operate?
Recirculation or Bypass
Compress
or Control system in operation
Capacity 100 %
55

Compressor Lubrication
Main functions of lubrication:
• Minimize wear, avoid contact between parts in relative
motion
• Remove heat induced by friction
• Remove impurities from the outside or produced internally
by wear
• Protect metal parts from corrosion
Components that require lubrication in a reciprocating
compressor:
• The crank-gear (bearings and crosshead shoes)
• The cylinders (piston, piston rings, valves and packing) if
lubricated type
Large machines always have separate systems for crank-gear and cylind
56

Frame lubrication
Nuovo Pignone Type HG

57

Frame and Cylinder Lube Systems
Frame
lubrication
Cylinder
lubrication
58

Frame and Cylinder Lube Systems
59

Cylinder Lubrication
60

Lubrication System Monitoring
4-20 mA signal to data acquisition
/ monitoring system to monitor
decrease of lubrication frequency
Lubrication to cylinder/packing
gland usually with a “divider Main line
block” system Lubrication
Proximity switch
monitor
Flow monitor and shutdown

devices are used, usually thisTo control panel
goes to PLC directly, it is alsoshutdown relay
possible to have measurement
to monitoring system
To cylinder and
packing glands
injection points
61

Compressor Types
• Separable (typical)
• Integral
• Overhung
• Vertical
• Hyper
62

Separable Compressor
Compressor Types
Outboard
Bearing
Motor Rotor
Rigid Coupling
Main Bearing
Crankshaft
63

Integral Compressor
Compressor Types
Integral Compressor: Driven by

internal combustion engine that
shares a common crankshaft
with the compressor.
With vertical power cylinders
With vee power cylinders and articulated connecting rods
64
WebAssembly_Angle.wmv
Overhung Motor-Compressor
Compressor Types
Auxiliary Motor
Support Bearing
Clark Compressor With Overhung Motor
Motor Rotor
Main Bearing
Crankshaft 65

Vertical Compressor
Compressor Types
Valve Cover
Cylinder
Frame
Vertical Sulzer Compressor

(Oil Pump End) 66

Hyper Compressors
Compressor Types
Crossheads and
guide tracks inside
frame
“Packed-plunger”
cylinders
67

Single-Acting Design
Compressor Types-Hyper
Plunger
Connecting Rod
• Smaller machine size than
double-acting design
Journal Bearing
• Permanent factory
alignment of compressor
components
Crankshaft
• Simplified maintenance
compared to double-acting Crosshead
design. Crosshead Pin
Guide Tracks
Plunger
Nuovo Pignone
S.p.A.
68

Double-Acting Design
Main
Crosshead
Crank- Guide
End
Cylinder Fram
Tie Rods e
(stationary) Auxiliary
Crosshea
Plunger d Guide
Crankshaft &
Connecting
Main Rods
Crosshea Double-Acting design
d
uses traditional
Auxiliary Push crankshaft, frame,
Head- Crosshea Rods
End connecting rods & main
d (moving)
Cylinder crossheads.
69

Double-Acting Design
Plungers
Pushrods
Cylinder Cylinder
Main
Auxiliary Crosshead
Crosshea
d
Hyper_Compressor_Animation.gif Crankshaft
70

Summary
• Components & Nomenclature

• Capacity Control
• Lubrication Systems
• Compressors Types
71

72

Compresor Reciprocante

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Compresor Reciprocante

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Basic Elements of

© 2010 General Electric Company. All rights reserved.

We will be discussing the following reciprocating

• Components & Nomenclature

© 2010 General Electric Company. All rights reserved.

© 2010 General Electric Company. All rights reserved.

© 2010 General Electric Company. All rights reserved.

Spacer Blocks Main Bearing Cap

© 2010 General Electric Company. All rights reserved.

© 2010 General Electric Company. All rights reserved.

Describes the moving

© 2010 General Electric Company. All rights reserved.

Primary Function of Crankshaft:

© 2010 General Electric Company. All rights reserved.

Main Bearing Journal

Main Bearing Journal

© 2010 General Electric Company. All rights reserved.

Fixed Angle Crankshaft:

© 2010 General Electric Company. All rights reserved.

• Fixed Angle Crankshaft

• Four (4) throw

© 2010 General Electric Company. All rights reserved.

© 2010 General Electric Company. All rights reserved.

Variable Angle Crankshaft

120 degrees 120 degrees

© 2010 General Electric Company. All rights reserved.

• Variable Angle Crankshaft

• Three (3) Throw

© 2010 General Electric Company. All rights reserved.

• Variable Angle Crankshaft

• Five (5) Throw

© 2010 General Electric Company. All rights reserved.

© 2010 General Electric Company. All rights reserved.

© 2010 General Electric Company. All rights reserved.

© 2010 General Electric Company. All rights reserved.

© 2010 General Electric Company. All rights reserved.

Crank Pin Bearing

Crosshead Pin Bushing

© 2010 General Electric Company. All rights reserved.

© 2010 General Electric Company. All rights reserved.

• Rod load reversal is the periodic shifting of piston rod load

Crosshead Pin Bushing

© 2010 General Electric Company. All rights reserved.

Nuovo Pignone S.p.A.

Connecting rod big end

Small end bushing

© 2010 General Electric Company. All rights reserved.

Shoe Nuovo Pignone S.p.A.

© 2010 General Electric Company. All rights reserved.

Nuovo Pignone, S.p.A.

Nuovo Pignone, S.p.A.

Installing crosshead extension on compressor frame

© 2010 General Electric Company. All rights reserved.

© 2010 General Electric Company. All rights reserved.

© 2010 General Electric Company. All rights reserved.

© 2010 General Electric Company. All rights reserved.

Crank End Pressure

Head End Pressure

© 2010 General Electric Company. All rights reserved.

Frame End Piston Half

Piston Nut Washer

© 2010 General Electric Company. All rights reserved.

Piston Rod Locknut