Reciprocating Compressor

By: Sajjad Hussain

Contents
• Single Acting Compressor • CO2 COMPRESSOR
• Double Acting Compressor • Gas End
• Construction Details of Gas Eng
• Cylinder & Liner • Cylinder
• Piston • Liner
• Piston Rod • Piston Rod & Piston
• Rod Packing • Rod Packing
• Piston Rings
• Head • Piston Rings
• Valves • Head
• Construction Details of Power End. • Valves
• Crank Case • Power End
• Crank Shaft
• Main Bearing • Crank Case
• Connecting Rod • Crank Shaft
• Crosshead • Main Bearings
• Oil Seal
• Connecting Rods
• Splash Lubrication System
• Forced Lubrication System • Cross Head
• Strainer • Oil Seal
• Gear Pump • Maintenance Procedure (Periodic Maintenance)
• Oil Filter
• Maintenance Procedure & Safety
• Relief Valve
• Cooler • Problems & Trouble Shooting
• Case History
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.
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. Different parts of
double acting compressor are listed below.
– Suction gas jacket.
– Suction valve.
– Piston.
– Cylinder.
– Discharge valve.
– Discharge gas jacket.
Construction of Reciprocating Compressors

• Reciprocating
compressors can
be divided into
two main groups.
– Gas end.
– Power end.
• Gas End
– Parts of the
reciprocating
compressor that
handle process
gas are grouped
in this category.
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 ring’s travel stops
unless counter bores are provided. Liners are usually pressed or
shrunk into place so that they do not slip and produce knocking
or oil holes do not get plugged due to misalignment.
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.
Piston contd.

• 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.
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 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, babbit 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.
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
– Plate valve.
– Channel valve.
– 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 low-
pressure drop and are
often used when ratios
of compression are low
and also for high flow
rates.
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 it’s entire
length, to allow passage of oil from the big
end to the small end bush.
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.
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.
Lubrication
• Lubricants
reduce friction
and therefore
wear between
moving
compressor
parts.
Lubricant also
serves as a
coolant.
Lubrication Systems
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.
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 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 – 50°C. Oil cooler than 40°C 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
(babbit), 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.
CO2 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.
• The compressor, which has been selected, is used to
compress CO2 gas. It is driven by electric motor and is
manufactured by M/s Nuovo Pignone, Italy. It is a
multistage, double acting reciprocating compressor of four
stages.
• The crankshaft is directly coupled to the electric motor
and flywheel.
• GAS END
– Parts of the
reciprocating
compressor that
handle process
gas are grouped
in this category.
• CYLINDER
– Piston
reciprocates
inside a cylinder.
Liner
• 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.
• Liners are usually pressed or shrunk into place so that
they do not slip and produce knocking or oil holes do not
get plugged due to misalignment.
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.
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 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, babbit
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.
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
• 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
Major Components of Valves contd.

• Counter seat
– The valve component that limits the lift and contains
the springs.
• Rings
– The element that withstands the differential pressure,
ensuring gas seal.
• Spring
– The element that acts on the rings, causing valve closing.
• Shim
– The element that determines the valve lift.
• Stud bolt, nut & pin
– These elements fasten all the components together.
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
• Crack 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 it’s entire length, to allow passage of oil from
the big end to the small end bush.
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.
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.
Maintenance Procedure
Periodic Maintenance (Every 4000 hours of operation
• Lubrication system – Change the oil. Clean filters and oil sump.

• Gudgeon pins of – Check and tighten the fastening screws, if

crosshead necessary.
• Lock nuts of – Check and tighten if necessary.
crosshead
• Piston rings & rider – If compressor operation shows
rings 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.
Every 16000 hours of Operation

Main bearings & Check wear and clearances.

connecting rod
bearings
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
• Recommendations & Precautionary Measures
– Gather all tools necessary for service in a container
near the machine.
– Use the set of special tools and instruction supplied by
manufacturer.
– Isolate the compressor from the process gas.
– Make sure that the driver cannot be started.
– During assembly, fully comply with assembly drawings.
– Follow bolt torque sequence and torque values given in
instruction manual.
– When hoisting systems are used, ensure that they are
perfect.
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.
– 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 Possible Cause Remedy
Excessive noise • Misalignment • Restore correct tightening of flywheel
or abnormal and looseness. • Check support bearings.
noise. • Correct alignment.
• Perform correct tightening of foundation.

• Excessive press • Restore compressor design operating conditions.

pulsation.

• Excessive • Restore the minimum condensate level in knock

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

• Incorrect • Repeat assembly, following the correct order.

assembly
• Loosening of • Restore their fastening.
cylinder valves • Correct position of the valves.
• Restore the surfaces on which the valve rests.
CASE HISTORY
• Since this compressor was commissioned in the year 1992. It
has following brief history.
LOW FLOW CAPACITY
• This problem was resolved after modification in valve lift.
VALVE PARTS BREAKAGE
• We have observed failure of valve parts such as seat bolts,
springs and rings. This problem is due to the moisture ingress.
An additional knock out drum has been installed in the first
suction. Moreover, experimentation on valves of peek material
is also in progress.
SECOND STAGE PISTON BREAKAGE
• We have observed cracks in 2nd stage piston during preventive
maintenance during turnaround 1994. The exact cause has not
been established but the problem is mainly attributed to
moisture ingress.
Problems & Troubleshooting contd.
Trouble Possible Causes Remedy

Abnormal • Insufficient • Increase cooling fluid rate.

temperature cooling • Clean the cooling system.
gas discharge • Utilize a fluid that gives lower deposits.

• Leakage of gas • Apply adequate tightening torque.

from gaskets • Replace damaged gaskets.
• Restore sealing surface.

Gas flow rate • Inadequate • Restore clearances btween piston rings

not at required piston ring seal. and their grooves.
value. • Replace worn out rings.

• Excessive • Correctly install packing seal.

leakage of gas • Restore proper clearance.
from packing. • Restore / replace piston rod.