Refrigeration

Reciprocating Compressors

Reciprocating Compressor Features

Common in 2 through 16 cylinder configurations. Individual step unloading

Liquid resistant safety head protection

Reciprocating Compressor

Reciprocating Compressor

Efficient Compression
Piston rings provide positive sealing and
minimal leakage

Valve springing allows compressor to

operate at any pressure ratio
Valve plate inertia is function of speed Throttling losses function of effective flow area

Capacity Control
Reduce power and energy consumption Reduce compressor cycling

Decrease the starting load

Provide good oil return

Capacity Control

More continuous operation of the

compressor

Minimizing electrical problems

Improving lubrication.

Capacity Control
Variable speed compressors Hot gas bypass with or without liquid
injection

Unloading Simple on/off compressor operation on

multiple compressor setups.

Unloading Suction Port Blocking

Discharge Pressure

Solenoid Operated Needle Valve

Suction

Blocking Valve

Suction Port

Unloading Lifting Suction Valve

Consists of piston actuated unloading

mechanism

Mechanism uses spring-loaded pins to raise the

suction valve plate from its seat

Can be actuated with either high pressure gas or

oil

Compression

Maximum Efficiency
Efficient at Full Load Operation
Efficient at Part Load Operation Greater than Rotary Screw Compressor

8 Steps of Unloading

4 Steps of Unloading

Hot Gas Bypass

Recommended where normal compressor
cycling or the use of un-loaders may not be satisfactory.

System of bypassing the condenser with

compressor discharge gas to prevent the compressor suction pressure from failing below a desired setting. All hot gas bypass valves operate on a similar principle.

Hot Gas Bypass to Suction

Hot Gas Bypass

Requires an additional refrigerant line, which
also increases the likelihood of refrigerant leaks and oil/refrigerant logging.

Reduces operating efficiency because the

bypassed vapour does no useful cooling.

Costs more to operate. As the load fluctuates,

the compressor consumes more energy because its forced to operate at a compression step that is likely one stage higher than necessary.

Hot Gas Bypass

Prevent excessive compressor cycling
Match system capacity to load

Reciprocating Compressor Advantages

Efficient at part and full load

Instantaneous unloading

Simple controls
Direct and belt drive
adjust capacity by speed

Safety Head

Valve Problems
High Discharge Temperature Low Discharge Temperature

Low Discharge Pressure High Suction Pressure

Damaged Valves
High Discharge Temperature: Refrigerant leaking back into cylinder Hot refrigerant being recompressed
Low Temperature: Progressive damage to valves
Lack of refrigerant flow

Damaged Valves
Low Discharge Pressure:

Short cycling of refrigerant Low flow rate to condenser Reduced heat load

Damaged Valves
High Suction Pressure

Refrigerant leaking past suction valve on

compression stroke

Damaged Valves
Reduced refrigerant flow
Reduced load on compressor Reduced amps on motor

Two Stage Compression

Two-Stage Compression
Intercooler reduces suction temperature

and discharge temperature of high stage

Very low evaporator temperatures require

high discharge pressure at high stage or deep vacuum at suction of low stage