By

SYED ASGHAR ABBAS NAQVI

CLASSIFICATION
COMPRESSOR
INTERMITTENT FLOW

POSTIVE DISPLACEMNT

ROTARY

SLIDING VANE
LIQUID PISTON
HELICAL LOBE
SCREW
LOBED BLOWER

RECIPROCATING

MECHANICAL
PISTON

CONTINOUS FLOW

DYNAMIC

EJECTOR

RADIAL

MIXED

FLOW

FLOW

CENTRIFUGAL

MIXED
FLOW

AXIAL
FLOW

AXIAL

Reciprocating Compressor
In a reciprocating compressor, a volume of gas is
drawn into a cylinder, it is trapped, and
compressed by piston and then discharged into
the discharge line. The cylinder valves control the
flow of gas through the cylinder; these valves act
as check valves. There are two types of
reciprocating compressor.

Reciprocating Compressor
Types
Single Acting compressor
It is a compressor that has one discharge per
revolution of crankshaft.

Double Acting Compressor

It is a compressor that completes two
discharge strokes per revolutions of crankshaft.
Most heavy-duty compressors are double
acting..

Reciprocating Compressor

Reciprocating Compressor
Different parts of double acting compressor
are listed below.
Suction valve.
Suction gas jacket.
Piston.
Cylinder.
Discharge valve.
Discharge gas jacket

Reciprocating Compressor

Construction of Reciprocating
Compressors
Reciprocating compressors can be divided into
two main groups.
1.
2.

Gas end.
Power end.

Cylinder & Liner

Piston reciprocates inside a cylinder. To provide for reduced

reconditioning cost, the cylinder may be fitted with a liner or
sleeve. A cylinder or liner usually wears at the points where
the piston rings rub against it. Because of the weight of the
piston, wear is usually greater at the bottom of a horizontal
cylinder. A cylinder liner is usually counter bored near the
ends of the outer ring travel i.e. counter bores are made just
ahead of the points where the end piston rings stop and
reverse direction. Shoulders may form in the liner where the
rings travel stops unless counter bores are provided.

Piston
For low speed compressors (upto 330 rpm)
and medium speed compressors (330-600
rpm), pistons are usually made of cast iron.
Upto 7 diameter cast iron pistons are made
of solids. Those of more than 7 diameters
are usually hollow
(to reduce cost).
Carbon pistons are sometimes used for
compressing oxygen and other gases that
must be kept free of lubricant.

 As the compressor reaches operating temperature,

the piston and rod expand more than liner/cylinder
does. In order to prevent seizure adequate clearance
should be provided, at the same time clearance must
be close enough to permit adequate support of piston
rings. Similarly end clearance is also important.

A cold piston is usually installed with one third of its

end clearance on the crank end and two third of its
end clearance on the head end.

PISTON ROD AND PISTON

Generally, the piston rod is fastened to the
piston by means of special nut that is
prevented from unscrewing. The surface of the
rod has suitable degree of finish designed to
minimize wear on the sealing areas as much
as possible. The piston is provided with
grooves for piston rings and rider rings.

Piston rod packing

Piston rod packing ensures sealing of the compressed gas.
The piston rod packing consists of series of cups each
containing several seal rings side by side. The rings are
built of three sectors, held together by a spring installed in
the groove running around the outside of the ring.
The entire set of cups is held in place by stud bolts. Inside
channels are there for cooling, gas recovery and lubrication
of the piston rod packing.

Piston rod packing

Piston rod packing

Piston rod packing

Piston rod packing

Oil Seal
An arrangement of scraper
rings serves to keep the oil,
entrained by piston rod, from
leaking out of the crankcase.
The oil scraped is returned to
the crankcase reservoir.

Oil Seal
An arrangement of scraper rings serves to keep the oil,
entrained by piston rod, from leaking out of the crankcase. The
oil scraped is returned to the crankcase reservoir.

Piston Rings
Piston rings provide a seal that prevents or minimizes
leakage through piston and liner. Metal piston rings
are made either in one piece, with a gap or in several
segments. Gaps in the rings allow them to move out
or expand as the compressor reaches operating
temperature. Rings of heavy piston are sometimes
given bronze, Babbitt or Teflon expanders or riders.
Lubrication is a must for metallic rings. Teflon rings
with Teflon rider bands are sometimes used to support
the piston when the gas do not permit use of a
lubricant.

Piston Rings

Head

The ends of cylinder are equipped with removable heads,

these heads may contain water/liquid jacket for cooling.
One end is called head-end head and other crank-end
head. The crank-end contains packing (a set of metallic
packing rings) to prevent gas leakage around piston rod.
Valves
There are normally three types of valves, these are
1.
Plate valve.
2.
Channel valve.
3.
Poppet valve.

Plate Valve
Heavy-duty compressors use a form of plate valve. The part that
closes against a valve seat is a flat metal plate. The plates are
held tightly against the seat by a set of springs.

Channel Valve
These valves use channel shaped plates instead of flat plates.
Above each channel is a bowed, steel tension spring. Spring
pushes from the stop plate and channels cover the slots in the
valve seat.

Poppet Valve
These are shaped like the
valves in an automobile
engine. These are separate,
round poppets to seat against
holes in the valve seats.
Poppets are made of low
friction
material
(e.g.
Bakelite), they provide a lowpressure drop and are often
used
when
ratios
of
compression are low and also
for high flow rates.

Valves
The valves are of automatic type. They open due to the effect of the
differential pressure between cylinder and the suction or discharge
chambers, and close due to the force of springs acting on the plates plus
the differential pressure across the valves.

Major Components of Valves

Seat

The main body of valve that withstands the differential

pressure when the valve is closed

Power End

Parts of reciprocating compressor that assist in transferring power and

converting rotary motion into reciprocating motion are grouped in this category.

Crank Case
Crank case supports the crankshaft. All bearing
supports are bored under setup condition to ensure
perfect alignment. Crankcase is provided with easy
removable covers on the top for inspection and
maintenance. The bottom of the crankcase serves
as the oil reservoir. A main pump for lubrication of
the crank mechanism is placed on the shield
mounted on the side opposite the coupling and is
driven by compressor.

Crankshaft
The crankshaft is built in a single piece. On the inside of the
shaft are holes for passage and distribution of lube oil.
Main Bearings
The main bearings
are built in two
halves, made of
steel, with inner
coating of
antifriction metal.

Connecting Rods
The connecting rod has two bearings. The big end
bearing is built in two halves. It is made of metal with
inner coating of antifriction metal. The connecting rod
small end bearing is build of steel, with inner coating of
antifriction metal. A hole runs through the connecting
rod for its entire length, to allow passage of oil from the
big end to the small end bush.

Connecting Rods

Connecting Rods

Crosshead
Crosshead fastens piston rod to the connecting rod. The
sliding surfaces of crosshead are coated with antifriction
metal i.e. babbited shoes. These are of interchangeable type.
That permits it to slide back and forth within the crosshead
guides. The shoes have channels for the distribution of lube
oil. The lubrication is obtained under pressure; it comes out
from the two guides of the crosshead slide body.
Connection between connecting rod and crosshead is
realized by means of a gudgeon pin. The piston rod is
connected to the crosshead by nut arrangement, tightened by
means of hydraulic device.

Crosshead

Crosshead

Lubrication
Lubricants reduce friction and therefore wear between
moving compressor parts. Lubricant also serves as a
coolant.

Lubrication Systems
Generally, two types of systems are uses to lubricate the positive
displacement compressors.
SPLASH SYSTEM
It is used in older machines. A supply is maintained in the
crankcase. Oil is splashed up by the rotation of the crank and the
counter weight into the collecting ring. Centrifugal force throws the
oil outward through an oil passage to the crank pin.

Splash Lubrication

Forced Feed System

Oil is pumped under pressure to the required parts.
Following are the main parts of system:
STRAINER
Oil from the crankcase first passes through a coarse strainer.
The strainer is removable so that chips or broken off pieces
can be cleaned out of the strainer.

Bypass Relief Valve

The compressor will be completely
damaged if the oil flow is appreciably
reduced or stopped by a plugged filter.
In order to prevent this damage, forced
feed system is fitted with a bypass relief
valve, a low-pressure alarm and bypass
shutdown.
If this filter becomes plugged, inlet
pressure to the filter increases. If the
inlet pressure exceeds spring pressure,
the bypass valve opens allowing oil to
return to the crankcase. Oil pressure in
the system falls, the low-pressure alarm
causes the compressor to shutdown.

Oil Circulation System

To keep bearings lubricated,
oil is supplied under pressure
to the bearings. The
lubrication system keeps a
supply of cool and clean oil
flowing to the system. A
sufficient quantity of oil is
stored in a reservoir.

Oil Cooler
Oil flows from the pump to cooler. The oil in the cooler flows
through the tubes. The cooling water on the shell side
absorbs heat from the oil. Generally, oil temperature is kept
between 40 50C. Oil cooler than 40C can lead to
condensation of water inside the crank case. Moisture can
promote sludging of oil. Temperature of oil higher than 50 C
can decrease strength of bearing materials (Babbitt), that
can lead to premature failure.
In order to maintain the desired temperature range, the oil
system has a bypass valve upstream the cooler that is
controlled by a thermostat.

Oil Cooler

Interstage Cooler

Cylinder Cooling

Lubricated Piston/Packing

Outboard Bearing

Clearance Pocket

Packing Lubrication

Piston Lubrication

Maintenance Procedure
Periodic Maintenance (Every 4000 hours of
operation)
Lubrication system

Change the oil. Clean filters and oil sump.

Gudgeon pins of
crosshead

Check and tighten the fastening screws, if

necessary.

Lock nuts of crosshead Check and tighten if necessary.

Piston rings & rider
rings

If compressor operation shows deterioration,

proceed for replacement.

Rod packing

If the behavior of the compressor indicates

deterioration proceed for replacement.

Compressor valves

Check the seats, springs, rings and lift.

Replace if necessary.

Note:

After 8000 hours of operation it is advisable to replace all parts in

movement.

Maintenance Procedure

Every 16000 hours of Operation

Main bearings &
connecting rod bearings

Check wear and clearances.

Crosshead

Check clearances between shoes and

guides.

Crankshaft

Inspect for any scoring caused by dirt in

oil. Check tightening of counterweight.

Cylinder liner

Check for wear and ovalizing.

Piston rod

Check for wear, and tightening of nut.

Maintenance Procedures &

Safety (contd.)

After maintenance, machine shall be rotated slowly for at

leas on revolution to ensure no interference.
Whenever a component is disassembled. Make sure of the
absence of defects before re-using.
The person responsible for maintenance should ensure
that all parts installed are perfectly clean.
After, maintenance on cylinders and sealing rings ensure
that all the lube oil pipes are filed with oil. This could be
checked by loosening the pipefitting. Tighten the pipe fitting
again.

Maintenance Procedures &

Safety (contd.)
Do not use a chisel to remove gaskets attached to the
surface. Carefully slide a blade between gasket and surface.
Damaging to the compressor-sealing surface can be avoided
in this way.
If the bearings are found damaged, perform thorough
cleaning to avoid further damage due to contamination of oil
by metallic particles.

Problems & Troubleshooting

Trouble

Excessive
noise or
abnormal
noise.

Possible Cause

Remedy

Misalignment
and looseness.

Restore correct tightening of flywheel

Check support bearings.
Correct alignment.
Perform correct tightening of foundation.

Excessive
press
pulsation.

Restore compressor design operating

conditions.

Excessive
entrainment of
condensate

Restore the minimum condensate level in

knock out drum.
Increase frequency of drawing clean
separators.
Add drain valves at points where liquid
accumulates.

Incorrect
assembly

Repeat assembly, following the correct

order.

Loosening of
cylinder valves

Restore their fastening.

Correct position of the valves.
Restore the surfaces on which the valve
rests.

Problems & Troubleshooting

contd.
Trouble

Abnormal
temperature
gas discharge

Gas flow rate

not at required
value.

Possible Causes

Remedy

Insufficient cooling

Increase cooling fluid rate.

Clean the cooling system.
Utilize a fluid that gives lower deposits.

Leakage of gas
from gaskets

Apply adequate tightening torque.

Replace damaged gaskets.
Restore sealing surface.

Inadequate piston
ring seal.

Restore clearances between piston

rings and their grooves.
Replace worn out rings.

Excessive leakage
of gas from
packing.

Correctly install packing seal.

Restore proper clearance.
Restore / replace piston rod.