Introduction to Positive

displacement compressors
Petroskill course

Hector Nguema Ondo Perez

Positive Displacement compressors
Table of contents

• Reciprocating compressors

 Basic parts of reciprocating compressors

 P-V Diagrams
 Controlling a compressor
• Type of clearance
 Overhead Stabilizer Compressor #5

• Rotary compressors
• Type of rotary compressors
• Design of rotary compressors
• Operation of rotary compressors
• Constructing Reciprocating compressors
 Valves
 Pistons
 Rod packing
• Lubrication

• Cooling and safety controls

• Operating Compressor Procedures

• Pre-start up
• Start up
• Shutdown
• Normal Operations
Reciprocating compressors
Reciprocating compressor basic parts

Frame: convert rotary motion into linear motion

• As the shaft turns motion is transferred to a

throw on the crankshaft connected to the
crosshead. Crosshead slides transferring motion
to the piston rod.
Reciprocating compressors
Reciprocating compressor basic parts

Distance Piece: provide isolation between the process side (cylinders) and the frame

• Crosshead guide end of the piston rod is isolated from

the crankcase by a packing, which provides seal to
prevent leakages.

Cylinder: creates internal passages for the gas flow and access to the suction and discharge valves

• Cylinder is cast with an outer wall and main bore at the

center.
• Cylinder must match the stroke of the frame and the
selected bore diameter required for the pressure and
flow condition
 Reciprocating compressors
Reciprocating compressors
Double-acting
Single-acting

• In the single-acting compressor, the • Forward stroke

forward stroke is the compression stroke.
• Crank end Suction Valve
• The backstroke is the suction stroke.
• Head End discharge valve

• Backstroke
Reciprocating compressors
Interpreting P-V diagrams
Overhead Stabilizer
A: Piston reaches head-end of the cylinder Compressor #5 D: Discharge valve opens
Compressed gas
leaves cylinder

Discharge

Expansion of Expansion Compression Gas inside

clearance gas
P cylinder is
compressed

Suction

V
Fresh Gas
enters cylinder

B: Suction valve opens C: Piston reaches crack-end of the cylinder

 Reciprocating compressors
Controlling a compressor

Throttling: Change capacity or rate of flow through the Clearance Pockets: Varying clearance pocket increase
compressor or decrease amount of gas entering the compressor

Excessive clearance volume → Shutoff

Compressor ratio (R)

• R is low (2.0) increase HP

• R is between 2 and 2.5

minimum impact

• R is above 2.5 decrease HP

• Cylinder capacity and Volumetric efficiency are 0
 Reciprocating compressors
Types of clearance pockets

HOFV Fixed-volume

The hand wheel opens a valve which allows for a fixed It is always in use and cannot be adjusted by
amount of clearance when needed. operators.

Screw or flanged Variable

Once installed, these types of pockets have a fixed The hand wheel makes it possible to adjust the amount of
volume. The amount of clearance may be changed by clearance as needed.
changing the size of the pocket
 Reciprocating compressors
Controlling a compressor

Unloading: An unloaded compressor compresses less Controlling speed: Reducing speed reduces fuel used
gas, uses less horsepower in the motor, and will be more and decrease operating costs.
efficient

• Unload one end of a single cylinder.

• To reduce the pressure and temperature of the
packing, unload the crank end.
• Unload all of the crank-end suction valves at one
end of a multi-cylinder.
• As gear trains and belt drives reduce
speed from the driver, they increase the
torque delivered to the compressor shaft
Rotary compressors
Rotary compressors
Lobed blowers
A rotary-type lobed blower
has two impellers that trap
and transfer gas. Because of
the clearance space, some
gas could leak backwards.
Screw compressors
Gas is displaced by
helically-lobed rotors. The
reduction in volume
increases the pressure of
the gas.
Sliding-Vane Compressors
As the rotor turns, the pocket gets
smaller while the vanes move into
the rotor, compressing the
gas. At maximum compression,
the gas is released out of the
discharge port.
Liquid-piston compressors
As the rotor turns, gas enters
from the two inlets in the
stationary port chamber. The
blades displace the gas toward
the discharge ports in the
stationary port chamber
Rotary compressors
Operation of rotary compressors

• Gas is drawn between the top side of rotors and • As rotors rotate the inlet port is sealed
the lobes

• Rotation reduce the gas volume increasing • When the gas is exposed to the outlet port the
pressure gas is discharged
Rotary compressors

Propane refrigerant compressor

• Compression is achieved by the meshing of the two helical

rotors on parallel shafts

• Capacity control is achieved by means of a slide valve in the

casing
Positive Displacement Compressors
Compressor valves

Plate Valves Poppet Valves

• Capable of handling large flows by • These valves provide a low pressure drop
moving a sealing plate to open or and are often used when compression
close a flow path ratios are high.

Channel Valves

• The springs push from the

stop plate and the channels
cover the slots in the valve
seat
Positive Displacement Compressors
Pistons and Piston Rings

Piston Rings
The rings seal by a
close fit against the
cylinder and against
the flat sides of the
grooves

Rod Packing Rider Bands

Positive Displacement Compressors
Bores, Liners, Crosshead and bearings
Cylinder Bore and Liner Crossheads

If breakage occurs between

the piston and the crosshead:

• Faulty alignment
• Improper rod Material
• Operating above the max
load

If there is excessive wear in the cylinder bore, the entire

body does not have to be replaced. Only the worn liner
needs to be replaced

Bearings

A film of oil separates the crosshead pin and the crankshaft from
the bearings.

The oil is supplied under pressure through holes in the bearing

surfaces.
Positive Displacement Compressors
Lubrication systems

Splash system
• Supply of oil is maintained in the crankcase
and splashed up by the rotation to lubricate
the bearings and the crosshead

• Centrifugal force is used to lubricate the

crank pin. The oil is forced up to the
crank pin through an oil passage.

• Oil is pumped under

Force-Feed system pressure to the
required parts.
Positive Displacement Compressors
Filters & Relief Valves

Self-cleaning filters • The self-cleaning filter is designed to be cleaned by turning a

wiper so that it sweeps over the holes in a cylindrical screen.

Bypass Relief Valves

• Opening the bypass when the filter is blocked allows oil from
the pump to return to the crankcase. In this system, the
compressor shuts down when the bypass valve is open to
protect against the failure of lube oil pressure and supply
Positive Displacement Compressors
Oil Flow

• Oil enters passages drilled in the crankshaft. The

passages lead to the crank pin. The oil lubricates
the crank pin and enters the passages drilled in the
connecting rods.
Positive Displacement Compressors
Cooling system
• A compressor's cooling system is designed to remove some of the heat of compression.

• An intercooler cools the gas between the

stages, and an aftercooler cools the gas
after it leaves the compressor.
Positive Displacement Compressors
 Positive Displacement Compressors
Overhead Stabilizer Compressor #5

Engine Exhaust silencer Lube oil tank

exhaust

Compressor Engine

Reciprocating Gas Compressor Frame

Suction bottle
2nd Suction Scrubber

Gas cooler
Intake
 Positive Displacement Compressors
Safety Controls
Spring Loaded Safety Valve
• The pressure needed to open the valve
depends on the compression of the spring.
Rupture Disc
• Safety valves or rupture discs prevent excessive
pressure from building up in the compressor
• Safety valves discharge the gas to a vent or flare
line. Safety valves must be installed between the
cylinder outlet nozzle and the first valve in the
discharge line.
 Positive Displacement Compressors
Safety Controls

Governor Overspeed Trip

• Keep the engine running at a constant speed

• Control the amount of fuel or fuel-air mixture by

opening and closing the engine's throttle or mixing
valve

Mechanical governor

• Connected to the engine crankshaft through the gears

• The trip pin is held in its recess
Hydraulic governor by a compression spring. When
the engine overspeeds,
centrifugal force pushes the trip
• Hydraulic fluid is used to control the operating pin out of its recess in the
mechanism of the governor driveshaft and trips the shut-
down switch.
Positive Displacement Compressors
Safety control

Oil Pressure Control Water Temperature Control

• The low oil pressure shutdown device • Activate if the cooling water temperature
shuts off the compressor when the oil rises dangerously high.
pressure is low.
• Monitor the engine jacket water pressure
• Some devices cut off the fuel supply and
also shut down the ignition
 Positive Displacement Compressors
PLC Cause & Effect Chart

Total Trips

1st Stage

2nd Stage

Vibration &
Speed
Oil & Lubrication

Water Level
Positive Displacement Compressors
Pre-start up procedure

• All compressor parts are in good operating condition

• Vent Valves are open and compressor block valves are closed

• The incoming gas is clean and free of liquid

• The lubrication and cooling system are operating or are ready to

operate

• Safety Valves and other automatic control devices are properly set
Positive Displacement Compressors
Start-up procedure

• Open the suction equalization valve for 30 seconds

• Open the suction block valve and close suction equalization valve

• Open discharge block valve

• Engine Fuel system block Valve is opened

• ENGINE START Sequence is initiated

• Engine starts and compressor is an unloaded condition during warm-up

• After Lube Oil temperature is above SP, manual LOAD becomes

enabled. It is recommended to load slowly in incremental steps.

• Sidestream supply is made available to the compressor.

Positive Displacement Compressors
Shutdown procedure

• LEVEL ONE S/D: Close process side stream block valve, open the process
recycle/bypass valves to unload the compressor, stop the drive engine, close engine
fuel system block valve, close discharge block valve, close process suction block valve
and close process suction equalization valve.

• LEVEL TWO S/D: Similar to LEVEL ONE S/D, but without delays

• LEVEL THREE S/D: Similar to LEVEL TWO S/D but opens the Blowdown valve
until pressure is less than 50Psig
Positive Displacement Compressors
Maintenance Activities

• Check Oil Levels Daily (Operator Rounds)

• Inspect lube oil for contaminants (MEGPL LAB)
• Check Lube oil Pumps ( Operator Rounds)
• Change Oil Filter cartridges (Maintenance)
• Calibrate instruments daily ( I&E PMR)
• Replace pneumatic filter regulator filters every 6 months
(Maintenance)
• Open drains on all pneumatic filter regulator for 10 sec every week
ANY QUESTIONS??

Thanks for coming!

Hector Nguema Ondo Perez