Date – 16th Oct 2019

SUBJECT: PROCESS ENGINEERING DESIGN MANUAL FOR RECIPROCATING

COMPRESSORS

TABLE OF CONTENTS

1. Compressors Types, Selection, and Sizing Guidelines

 Introduction
 Codes, Standards and References
 Nomenclature and Definitions
 General
 Types of Compressors
 Advantages and Disadvantages of Compressors
 Basic Principals and Methods of Compression
 Selection Considerations
 Factors to Be Considered When Selection of Compressors
 Lubrication Systems
 Seal Systems
 Ancillary Equipment
 Tables
 Figures
2. Steps to Compressors Sizing and Selection
3. Types of Industrial Application

 Types of Industrial Applications

 Upstream
 Midstream
 Downstream
 Upstream Compression Applications 4
 Introduction
 Gas Gathering
 Gas Lift/Reinjection
 Gas Processing Plant
 Midstream (Pipeline) Compression Application
 Downstream Compression Application
 Introduction
 Refinery Applications
 LNG Production
4. Design Calculations for Reciprocating Compressors
 Performance Evaluation
 Estimation of Compressor Horse Power (HP)
 Detailed Calculations
 Capacity
 Differential Head
 Volumetric Efficiency
 Net Capacity
 Allowable Discharge Temperature
 Detailed Horse Power Calculations (HP)
 Compressor Performance Characteristics
 Piston Displacement
 Compression Ratio
 Actual Capacity v/s of Actual Delivery
 Clearance Volume
 Percentage Clearance
 Cylinder Unloading and Clearance Pockets
 Volumetric Efficiency
 Compression Efficiency (Adiabatic)
 Mechanical Efficiency
 Piston Speed
 Horsepower
 Signal Stage (Theoretical , Loss Factor, and Break HP)
 Multi – Stage (Theoretical, Loss Factor, and Break HP
 Temperature Rise—Adiabatic
 Temperature Rise—Polytropic
 Altitude Conversion
 Example of Single Stage Compressor BHP and Discharge Temperatures
Calculations
 Example of Double Stage Compressor BHP and Discharge Temperatures
Calculations
5. Reciprocating Compressor Construction and Other Engineering Considerations
5.1 Nomenclature
5.2 Types of Reciprocating Compressors
 Separable compressors
 Integral compressors
5.3 Prime Movers
 Combustion Engines
 Electric Motors
  Turbines
5.4 Major Components
 Frame
 Cylinder
 Distance Piece
 Crankshaft
 Piston
 Bearings
 Compressor Valves
5.5 Material of Construction
5.6 Compressor Performance
 Piston displacement
 Clearance volume
 Application
 Fixed-volume Clearance Pockets
 Variable Clearance Pockets
 Split-valve Yokes
 Allowable Critical Speed
 Volumetric Efficiency
 Rod Load
 Single-acting Cylinder (head end)
 Single-acting cylinder (crank end)
 Double-acting Cylinder
 Other Performance Factors
 Performance Maps
5.7 Process Installation
 Recycle Valve
 Blowdown Valve
 Suction Scrubber
 Relief Valves
5.8 Pulsation
 Pulsation Control Devices
 Pulsation Design
5.9 Vibration Considerations
 Piping Vibration
 Foundation Design
5.10 Cylinder Cooling
 Cooling Systems
 Gas Engines
 Intercoolers and Aftercoolers
 Types of Coolers
  Water Cooled Shell and Tube
 Air Cooled Exchangers
5.11 Cooling Console
 Process Design of Cooling Water Circuit (Consoles) – Reciprocating
Compressors
 References
 Definitions and Terminology
 Symbols and Abbreviations
 Design
 Internal Combustion Engines, Cooling Systems
 Coolers
 Design Requirements and Features for Intercooling and Aftercooling Facilities
5.12 Lubrication
 Frame Lubrication
 Splash Lubrication
 Pressurized Lubrication
 Main Oil Pump
 Auxiliary Pump (optional)
 Pre-lube Pump (Optional)
 Oil Cooler
 Oil Filters
 Overhead Tank
 Piping
 Cylinder and Packing Lubrication
 Crank Case Lubrication
5.13 Pressure Vessels
 Separators
 Pulsation Suppression Devices
5.14 Piping and apparatus
 Piping Design Process Guidelines
 Piping Material and Sizes
 Lubricating Oil Piping Requirements
 Coolant Piping Requirements
 Instrument Piping Requirements
 Drain and Vent Piping
 Blowdown Piping
 Relief Valve Piping
6. Controls and Instrumentations
 General
 Control systems
 Instrumentation
  Alarms and Shutdown
 Vibration and Position Detectors
 Temperature Monitoring System
7. Capacity Control
 Method of Capacity Control
 Speed Variation
 Clearance Variations
 Bypass Systems
 Valve Removal and Unloading
 Suction Pressure Limitations
8. Shutdowns, Alarms and
 Required Shutdowns
 Alarms and Shutdowns
 Emergency Shutdown
 Shutdown and Alarm Settings
9. Typical Start-up Flow Logic Diagram
10. Typical Shutdown Flow Logic Diagram
11. Trouble Shooting Guide
12. Reciprocating Compressor Package Data Sheets
 API 618 Reciprocating Compressor Data Sheet
 ISO 13631 Reciprocating Compressor Data Sheet
13. ISO 13631 Package Reciprocating Compressors Data Sheet (Vendor or
Manufacturer Design)
14. ISO 13631 Package Reciprocating Compressor Purchaser Check List
15. Drawings and Documents Expected By Engineering Companies