4 and 5 are used to calculate displacement of single-acting cylinders. reciprocating compressor maintenance checklist date of inspecion: model number: (hp): customer name: serial number: ... compressor type: work order number: general inspections - (check and record, if … Condensation The fans take over as they blow cold air over the coil thereb… The AC cord is also quite short, which makes it challenging to use. Clearance volume is the space remaining in the compressor cylinder at the end of the stroke. Ingersoll Rand is one of the biggest air compressor manufacturers and produces high-quality air compressors. Displacement is commonly expressed in actual cubic feet per minute (Acf/min). The cranks are arranged so that the motion of each piston is balanced by the motion of an opposing piston. The poppet style uses separate, round poppets to seat against holes in the valve seat. (See the section on Rod Load below). Oil migrates between the cylinder and the crankcase. Double-acting cylinders compress gas in both directions of piston travel (see Fig. We have provided 79+ years of industry leadership in reciprocating compressors for air conditioning and refrigeration applications. Integral compressors typically have compressor and engine-power cylinders mounted on the same frame and are driven by the same crankshaft. Reciprocating compressors have been … Divider blocks are used to distribute the flow of oil between the cylinders and the packing. Fixed volume also can be added by a side-passage clearance plug consisting of a flange with a variable length plug inserted into a passage built into the side of the cylinder. They have the highest initial installation cost. The American Petroleum Institute (API) has produced two industry standards, API Standard 11P and API Standard 618, which are frequently employed to govern the design and manufacture of reciprocating compressors. Concrete should be poured into a "neat" excavation without formed side faces. Care must be taken to avoid condensation that can result from excessive cooling. The set of inlet (suction) valves admits gas into the cylinder. Cylinders are frequently supplied with liners to reduce reconditioning costs. Thermoplastic wear (or rider) bands often are fitted to pistons to increase ring life and reduce the risk of piston-to-cylinder contact. However, cylinder liners increase the clearance between the valve and the piston, diminish the effectiveness of jacket cooling, and decrease compressor capacity from a given diameter. You must log in to edit PetroWiki. The incoming air goes through all these components and comes out cool and comfortable. These vendors have not been evaluated directly by this website, only the manufacturers have been listed here, which they have … 13 is a typical process flow diagram for a reciprocating compressor installation. Variable clearance pockets allow a variable amount of clearance to be added to the cylinder and can be attached to either the head end or crank end of the cylinder. The compressor process gas piping must be properly designed and installed to avoid problems associated with excessive vibration. Cleanliness and corrosion resistance are important considerations. Safety instrumentation should include a crankcase low oil level switch, a low oil pressure shutdown switch, and a high oil temperature switch. If too much clearance is present, no gas will be discharged. The packing consists of a series of non-metallic rings mounted in a case and bolted to the cylinder. With concentric ring-type valves, it is possible to place a plug unloader in the center of a suction valve for unloading. As the piston passes the lubricator feed hole in the cylinder wall, the piston ring gathers oil and distributes it over the length of the stroke. This assures that the bearings are not dry at startup. Reciprocating compressors are positive displacement machines in which the compressing and displacing element is a piston having a reciprocating motion within a cylinder. A reciprocating compressor or piston compressor is a positive-displacement compressor that uses pistons driven by a crankshaft to deliver gases at high pressure. The components are well coordinated and universal. The tank must be sized to provide oil until the compressor has completely shut down. Most often, variable clearance pockets are attached to the head end, as shown in Fig. When speed reduction is used for capacity control, care must be taken to ensure that this pump provides adequate lubrication at the minimum operating speed. For this reason, an adequately sized suction scrubber with provisions for draining is required. Piston displacement is defined as the actual volume of the cylinder swept by the piston per unit of time. Either an engine or an electric motor usually drives a separable compressor. Dippers may be attached to the crankshaft to enhance the effect. 9—Valve-in-piston design (courtesy of Dresser-Rand). Splash lubrication systems distribute lubricating oil by the splashing of the crank through the lubricant surface in the pump. While the quantity is small, the oil pressure necessary to supply oil at the packing and cylinders is high. Universal and environmentally friendly: ECOLINE reciprocating compressors offer high cooling capacity with minimal energy requirements and are optimised for HFC, HFO and low-GWP refrigerants. SAHARA AIR CONDITIONING & REFRIGERATION TRADING L.L.C, ECOLINE compressor with horizontal liquid receiver, ECOLINE Tandem compressor with horizontal liquid receiver, 2nd generation compressor with horizontal liquid receiver. The overhead tank provides oil to the bearings if a pump fails. Unloading both ends of the same cylinder may cause the cylinder to overheat; thus, it is best to unload only one end of a double-acting compressor cylinder. The compression process in reciprocating compressors is nearly isentropic, so the energy required to compress the gas in the clearance space is recovered when the gas expands at the end of the compression stroke. Reliability and easy maintenance have made them popular options for years. In the single-compartment design, the space between the cylinder packing and the diaphragm is lengthened so that no part of the rod enters both the crankcase and cylinder stuffing box. They are easy to install, offer a relatively small initial cost, are easily moved to different sites, and are available in sizes appropriate for field gathering—both onshore and offshore. Click on the Brochures, Drawings and Manuals sections, in order to see the available documents for Reciprocating Compressors range. They manufacture both reciprocating piston compressors and rotary screw compressors (and other types too). Fig. 3 is a cross section of a typical integral compressor. Approved Reciprocating Compressor Manufacturers. The 5 Types of Air Conditioning Compressors Reciprocating Air Conditioner Compressor. These are: compressor, condenser and an evaporator. 1 is a cross section of a typical separable compressor. The oil from the overhead tank is gravity-fed to the bearings. The auxiliary pump is usually driven by an electric motor and is designed to start automatically when oil supply pressure falls below a specified level. 13—Compressor process flow diagram with integral (pulsation vessel) separator (courtesy of Dresser-Rand). Rapid overheating can occur because no cool suction gas enters the cylinder. The highly reliable semi-hermetic series is designed to be robust and suitable for a variety of refrigerants. Use soil bearing for a design that is less than 50% of that allowable for static conditions. The crankshaft rotates around the frame axis and drives the connecting rod, piston rod, and piston (see Fig. The main oil pump is driven by the crankshaft or may be separately driven. Air conditioners house three components which play a crucial role in the entire process of air conditioning. This can be assured by maintaining the cylinder jacket coolant temperature at least 10°F above the suction gas temperature. 6—Double-acting cylinders (courtesy of Dresser-Rand). Because this function is provided by the auxiliary pump, a prelube pump is required only when the system does not have an auxiliary pump. The valve-in-piston design (Fig. Part numbers, images and logo of this organization is used for cross reference and interchange purposes only. The term “separable” is used because this category of reciprocating compressors is separate from its driver. Cast steel is usually used for pressures between 1,500 and 2,500 psi. Because each pair of rings accommodates a limited amount of pressure differential, multiple pairs are required depending on the pressure required by the application. Depending on the sealing plate material, plate valves are capable of handling pressures as high as 15,000 psi, differential pressures to 10,000 psi, speeds to 2,000 rpm, and temperatures to 500°F. Transfer valves allow switching from one filter to the other so that the filters can be cleaned without shutting down the compressor. Relief valve setting should never exceed the cylinder maximum allowable working pressure (see the section on cylinders above). Cylinder cooling reduces losses in capacity and power caused by suction gas preheating. Depending on the molecular weight of the gas, both port and plug unloaders reduce BHP/MMscf/D and significantly improve the reliability of the unloading system. The increase in compression ratio caused by reduction in suction pressure results in an increase in discharge temperature. Often a gearbox is required in the compression train. A reciprocating compressor is a positive-displacement compressor that uses a cylinder and piston mechanism to compress the gas. Fig. The compressor compresses the refrigerant, which flows to the condenser, where it gets cooled. Fig. Use this section for citation of items referenced in the text to show your sources. If the suction valve is held open with finger depressors during the compression stroke, gas will flow through the open valve back into the suction gas passage, and no gas will be discharged from the end of the cylinder containing the unloaded suction valve. The set of discharge valves is used to evacuate compressed gas from the cylinder. Scroll air conditioning compressors, like this LG compressor, are newer on the scene. A pressurized lubrication system consists of the components discussed next. In horizontal arrangements, cylinder wear is greatest at the bottom because of piston weight. slippage of gas past piston rings, % (1% for high-speed separable, 5% for nonlubricated compressors and 4% for propane service). The cylinder is a pressure vessel that contains the gas in the compression cycle. An auxiliary pump is provided to back up the main pump. This page lists the Approved Reciprocating Compressor Manufacturers (vendors), also provides inspection and test advice to the Reciprocating Compressor purchasers buying from vendors, suppliers and distributors.. Metallic poppets work well at: Thermoplastic poppets can be applied to applications with: Most compressors have valves mounted in the cylinders. Separable units are skid mounted and self-contained. Fig. allowance for losses because of pressure drop in valves. It also removes heat from the gas, thereby lowering the discharge temperature of the gas. The intake gas enters the suction manifold, then flows into the compression cylinder where it gets compressed by a piston driven in a reciprocating motion via a crankshaft, and is then discharged. Fig. Forged steel is selected for cylinder operating pressures greater than 2,500 psi. 7—Two-compartment distance piece showing packing and buffer gas arrangement (courtesy of Dresser-Rand). Piston rod connects the crosshead to the piston. The flow capacity of a given cylinder is a function of piston displacement and volumetric efficiency. The piping system should be designed to avoid any pockets in which dirt or debris could accumulate. They are commonly used in gas plants and pipeline service where fuel efficiency and long life are critical. Bearings located throughout the compressor frame assure proper radial and axial positioning of compressor components. The discussion on the this page on reciprocating compressors includes a description of process configuration for multistage units, as well as an explanation of the concepts of: ... Reciprocating Air Compressors. A Reciprocating Compressor uses piston cylinder to compress the refrigerant gas. Scroll Compressors are More Efficient Scroll compressors run quieter and smoother than reciprocating compressors because they only have two moving parts: a fixed and orbital scroll. inlet capacity of the cylinder at actual inlet conditions, Acf/min. 7 illustrates API Standard 11P and API Standard 618 distance pieces. 8—Crankshaft assembly (courtesy of Dresser-Rand). In most cases, it is preferable to remove the suction valve when unloading the head end of a cylinder to assure load reversal in the rods. Integral compressors offer high efficiency over a wide range of operating conditions and require less maintenance than the separable units. Ingersoll Rand provides products, services and solutions that enhance our customers' energy efficiency, productivity and operations. Poppet valves are widely used in pipeline, gas conditioning, and processing facilities. As a result, part of the piston displacement occurs before the suction valve opens. If oil contamination is a concern, an oil slinger can be provided to prevent packing lube oil from entering the compressor frame. To safely vent gas leakage through the packing, the vent port is usually located between the two outer ring assemblies (see the section on Distance Piece above). Jacket cooling water in a shell and tube heat exchanger is often used to cool the lubricating oil. For compressors with integral engine drivers, it is recommended that the compressor and driver be lubricated with separate systems so that combustion gases from the engine do not contaminate the lube oil. Crosshead bearings are located at the top and bottom of each crosshead. The 2-stage reciprocating compressors are designed for an extensive application range and boast an optimised drive gear and efficient motor. Fig. Sort By. Removing some of this heat is beneficial to the performance and reliability of the compressor in several ways. Single-acting cylinders can have either head-end or crank-end displacement. Insufficient cooling can lead to reduced capacity and fouling of the cylinders. Some systems are equipped with dual, full-flow oil filters with transfer valves. For installations in very cold environments, immersion or in-line heaters and special lubricating oils should be considered. The compressor is the heart of the machine. An actuator control allows the clearance pocket to be opened or closed from outside the cylinder while the compressor is in operation. The gas in the inlet section is compressed by the reciprocating motion of the pistons. Due to the open drive design, standard motors can be attached to the compressor via coupling housing or belt drive. Each compressor should be equipped with a separate vent and drain system for distance pieces and packing. Reciprocating Compressor : A reciprocating compressor is a positive-displacement machine that uses a piston to compress a gas and deliver it at high pressure. Separable compressors are usually arranged in a balanced-opposed configuration characterized by an adjacent pair of crank throws that are 180 degrees out of phase and separated by only a crank web. Single-acting cylinders compress gas in only one direction of piston travel. At very low ratios, the power may actually decrease with increasing suction pressure. Integral compressors may be equipped with two to ten compressor cylinders with power ranging from 140 to 12,000 hp. Compared with the process gas piping must be of sufficient magnitude to provide lubrication to performance. 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