RECIPROCATING COMPRESSOR

TABLE OF CONTENT

I.

Purpose

II.

Units and Symbols

III.

Unit Conversion

IV.

Main Component of Reciprocating Compressor

V.

Operating Range of Reciprocating Compressor

VI.

Gas Compression

VII. Intercooler and Aftercooler

VIII. Compressor Control

IX.

Calculation Formula

Appendix A. Size, Efficiency and Losses

11

Appendix B. Gas Properties

14

Appendix C. Compressor Control

19

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RECIPROCATING COMPRESSOR
I.

PURPOSE
To be used for selection, application into the system, power and cooling water estimation. This
manual does not for designing reciprocating compressor and the related parts.

II.

SYMBOLS AND UNIT

Designation

Symbol

Unit

Pressure
Pressure ratio
Temperature
Absolute Temperature
Capacity (volume flow)
Piston displacement volume
Volumetric efficiency
Mechanical Efficiency
Power
Brake horse power
Gas horse power
Speed
Head
Gas Constant
Molecular Mass

p
r
t
T
Q
VP
V
M
P
BHP
GHP
N
H
R
MW

Mole
Density
Specific Gravity
Specific volume
Specific Heat
Mass Flowrate
Adiabatic Exponent
Polytropic Exponent
Isentropic exponent
Compressibility Factor
Gravity
Heat Capacity
Enthalpy
Enthalpy different
Entropy
Piston diameter
Piston speed
No. of stage
No. of throw
Power loss

MM
DS
SG
v
Cp
G
k
n
m
Z (capital)
g
MCp
h
h
s
D
U
i
z
PLOSS

bar A
C
K
m3 / hr
m3
kW
kW
kW
RPM
m
kJ/kg.K
kg/kgmole (=lb/lbmole )
kgmole ( kgmole/h or kmol/h )
kg/m3
m3/kg
kJ/kg.K
kg / hr
m/s2 (9.81)
kJ/kgmole
kJ/kg
kJ/kg
kJ/kg.K
mm
m/s
Integer number
Integer number
kW

a
p
1, 2 etc.
I, II etc.
N
MAX, max

Adiabatic process
Polytropic
Position
Stage No.
Normal condition ( 0 O C , 1.013 bar A )
Maximum

Subkrip (Subscript)
cr atau CR
red atau R
s atau S
d atau D
G
V
STG

Critical
Reduced
Suction
Discharge
Gas/GHP
Volumetric
Stage, throw

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III.

UNIT CONVERSION

Designation

Unit to be converted

Factor

Unit to be used

Length

ft
inch

304.8
25.4

mm
mm

Pressure

psi
kg/cm2 (at.)
atm.
Pa (Pascal)

0.06897
0.981
1.013
10-5

bar
bar
bar
bar

Temperature

F (Fahrenheit)
K (Kelvin)
R (Rankin)

(t-32) x (5/9)
T - 273
(5/9)

C
C
K

Velocity

ft/s
ft/min (fpm)

0.3048
0.00508

m/s
m/s

Volume flow

GPM (US)
Cfm

0.227
1.699

m3/hr
m3/hr

Mass

lbm

0.4536

kg

Power

HP

0.7457

kW

Head

ft

0.3048

Enthalpy

kcal/kg
BTU/lbm

4.1868
2.326

kJ/kg
kJ/kg

Gas constant

kcal/kg.K

4.1868

kJ/kg.K

Specific heat
& Entropy

BTU/lbm.R

4.1868

kJ/kg.K

Specific mass
lbm/ft3
or density
Specific volume ft3 /lbm

16.0185

kg/m3

0.06243

m3/kg

N.s/m2
lbf.s/ft2

1000
47880.3

cP
cP

Viscosity

Note : American Standard State at 1.013 bar A and 15.5 C. In volume common written as SCF.
Normal condition at 1.0132 bar A and 0 C. In volume common written as Nm3

IV. MAIN COMPONENT OF RECIPROCATING COMPRESSOR

Figure 1 and figure 2 show components of reciprocating compressor.
1. Crankshaft
2. Connecting rod
3. Crosshead
4. Piston rod

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RECIPROCATING COMPRESSOR
5. Piston and their rings
6. Packing rings or seal rings
7. Check valves
8. Suction unloader and clearance pocket
9. Distance pieces

Figure 1. Cross Section of Typical Reciprocating Compressor

Figure 2. Cross Section of Typical Reciprocating Compressor

V.

OPERATING RANGE OF RECIPROCATING COMPRESSOR

Figure 3 shows operating range of reciprocating compressor base on suction volume flow against
speed (RPM). Comparing to the other compressor types, reciprocating compressor has lowest
operating speed where below 1000 RPM.
Compression ratio of reciprocating compressor is up to more than 500 where is highest
compression ratio compared to the other compressor types.

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RECIPROCATING COMPRESSOR

Figure 3. Operating Range of Reciprocating Compressor.

VI. GAS COMPRESSION

Gases to be handled by compressor are both single component (pure gas) and mixed gas. This
manual also describes physical properties of mixed gas. In the next equations and calculations,
gas is assumed as ideal gas but then corrected by correction factors and so ever is assumed equal
to actual physical properties of the gas.
Figure 4 shows typical gas flow diagram in reciprocating compressor. Due to the discontinuity of
gas flow of reciprocating compressor, gas pulsation will occur if excitation frequency is near or
equal to natural frequency of gas column in the system. Pulsation dampener is made from pressure
vessel and orifice. Pulsation dampeners usually can be designed and supplied by compressor
manufacturer.

Figure 4. Flow Diagram of Gas at around Reciprocating Compressor

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RECIPROCATING COMPRESSOR

There is pressure drop at suction side and discharge side of reciprocating compressor due to inlet /
outlet and check valve constructions. Ps is system suction pressure, Ps is intake pressure of
compressor cylinder, Pd is outlet pressure of compressor cylinder and Pd is discharge pressure to
the system.
Gas compression process in reciprocating compressor can be expressed such in figure 5. In the
way back from point 1 to point 3, gas flows or gas induced to cylinder is only from point 2 to 3,
because from point 1 to 2 there is only gas expansion of residual gas in clearance space. Ratio of
effective stroke (Le) by physical stroke (Lp) named volumetric efficiency.

Figure 5. Idealized Gas compression Process in Piston Displacement and Pressure

VII. INTERCOOLER AND AFTERCOOLER

Intercooler is required when compressed gas temperature to the next compression will higher than
permitted temperature during or after compression. Permitted gas temperature during
compression is depending to the weakest of constructed components, cooling media or gas
compressed properties itself. The following are typical permitted temperature in reciprocating
compressor.

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RECIPROCATING COMPRESSOR
Designation

Permitted temperature ( C)

Oil lubricated air compressor

160 for multi stage

200 for single stage
120
200

Pure oxygen and pure chlorine

Dry cylinder with Teflon seals

Other typical standard give maximum temperature 150 C for any gas based on adiabatic process
calculation.
If intercooler is cooling water media type, differential temperature between inlet cooling water
and exhaust gas from intercooler shall be not so close, i.e. higher than 5 oC or 8 to 10 oC is most
used.
Aftercooler is required when discharge system temperature of compressor is limited or to be
cooled due to process requirements.

VIII. COMPRESSOR CONTROL

There are some ways to control reciprocating compressor capacity such as speed for turbine
driver, suction valve unloader or clearance pocket or bypass control or combination of these
controls for constant speed driver (i.e. electric motor). See also Appendix C.
Figure 6 shows gas process in clearance pocket control. When residual gas space is larger, intake
volume will decrease. Figure 7 shows gas process in suction valve unloader. Suction valve unloader
controls pressure drop between suction pressure and cylinder suction pressure ( Ps) and by itself,
volume flow is also controlled because given energy by driver is constant or equal.
Figure 8 shows gas process in bypass control system. Effective volume will reduced when bypass
volume is become parts of total volume.

Figure 6. Volume Control by Clearance Pocket

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Figure 7. Volume Control by Suction Valve Unloader

Figure 8. Gas Process in Bypass Controller.

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RECIPROCATING COMPRESSOR
IX.

CALCULATION FORMULA
All following calculation formula are related to required power, required cooling water, number of
stage and gas condition for each stage of gas in reciprocating compressor.
Brake horse power,
BHP =

GHP / M

(kW)

(1)

where M is mechanical efficiency, see Appendix A.

Gas horse power

G.H .g .10 6
GHP =
3.6 (V )

(kW)

(2)

where G is induced mass flow and V is volumetric efficiency, see Appendix A.

G = DSS . Qs

(kg/h)

(3)

DSS is density of gas in kg/m3 and Qs is induced volume flow in m3/hr

For perfect gas,

Ts.Qn
269.69( ps )

Qs =

and

Qd =

Td .Qn
269.69( pd )

(m3/hr)

(4)

Where Qn is volume flow at normal condition ( 0 C and 1.013 bar A)

DSS =

101.3
DSs.Ts. pd
100( ps )
, DSN =
and DSD =
273( R)
Td . ps
Rs.Ts

(m3 /hr)

(5)

For actual gas with compressibility correction,

Ts.Qn.Zs
269.69( ps )

Qs =

DSS =

and

Qd =

Td .Qn.Zd
269.69( pd )

100( ps )
DSs.Ts. pd .Zs
, and DSD =
Rs.Ts.Zs
Td .Zd

(m3/hr) where ZN 1

(6)

(m3 /hr)

(7)

(m)

(8)

Hydrodynamic head in adiabatic process,

H=

pd ' (
1000( Zs )( R )(Ts ) k
{
}{(
)
g
k 1
ps '

k 1
)
k

1}

With substitution, GHP can be rewritten as the following equation,

k 1

0.02778 x ps ' x Qs k pd ' k

1
GHP =

V ( / V )
k 1 ps '

Where (pd/ps = r ) is compression ratio. pd and ps are in absolute pressure (bar A) and

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(9)

RECIPROCATING COMPRESSOR
k is adiabatic exponent. Following figure 9 shows relation between compression process and the
exponents.
Isothermal compression is where gas always in constant temperature during compression.
Adiabatic compression is where gas always in constant entropy during compression. There is no
heat loss or heat addition and no friction that potentially produce heat.
Polytropic compression is where during gas compression there is heat loss and friction as an actual
compression process.

GHP in equation (1) can be written

Figure 9. Gas Compression Process and Their Exponents

Practically, n is almost equal with k for reciprocating compressor without special cooling process.
R = Ro / MW

(kJ/kg.K)

Ro = 8.314

(kJ/kgmole.K)

See Appendix B for R, MW, k and Z for several gas.

Discharge Temperature

pd ' (
Td = Ts . (
)
ps '

k 1
)
k

(10)

If discharge temperature is limited at Tdmax, then maximum pressure ratio become

k

pd '
Td max ( k 1 )
) MAX = (
)
ps '
Ts

(11)

Average piston speed (also piston rod and crosshead),

U=

0.002 x L x N
60

m/s

(12)

Where L is piston stroke in mm, N crankshaft speed in RPM. Several data shows U is in the range of
2 up to 6 m/s.

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RECIPROCATING COMPRESSOR
APPENDIX A. SIZE, EFFICIENCY, LOSSES AND MAXIMUM FRAME BHP
A.1. VOLUMETRIC EFFICIENCY
Piston displacement volume,
VP = 7.8675 x 10-10 x D2

(m3)

(A.1)

Piston displacement volume flow / acting,

QP = 4.7205 x 10-8 x D2 x N

(m3/hr)

(A.2)

Adiabatic volumetric efficiency,

VO = 1 r ' k 1 x (0.01 c ) and c <

100(1 v 0 EXP )
1
k

, VO-EXP , c >2 %

(A.3)

(r ' 1)

k is adiabatic exponent, r is pressure ratio (pd/ps) and c is clearance volume divided by total
volume of cylinder in %. VO-EXP is expected efficiency but c must be approximately > 2 %.
Correction factors due to the actual compression process are given such as the following
equations,

V = 0.96 x VO or

V = VO 0.05 . In this manual, V is taken as :

V = 0.95 x VO

(A.4)

During compression there is heating effect during suction stroke, gas leak through valves, piston
rings and piston rod seals. Actual delivered of gas become smaller than induced gas at intake.
Defined Supply efficiency, .
= V . ( /V )
Typical of /V is given in the following equation,
/V = 1.03 0.03116 r + 0.001 r2 , r within the range of 1 up to 5

(A.5)

Required piston capacity,

Qp = Qs /

(m3/hr)

(A.6)

or
Qp =

Qs
( / V ).V

(m3/hr)

(A.7)

A.2. INTAKE AND EXHAUST LOSSES

Pressure drop at intake and exhaust is (see also figure 4),
0.08 x p at low pressure stage and 0.03 x p for other stage
ps = 0.92 x ps for low pressure and ps = 0.97 x ps for high pressure
pd = 1.08 x pd for low pressure and pd = 1.03 x pd for high pressure
A.3. HEAD AT EACH STAGE

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(A.8)

RECIPROCATING COMPRESSOR

When temperature is limited during compression, maximum head for each stage is
HSTG-MAX =

k 1
pd '
1000( Zs )( R)(Ts ) k
(
)
{
}{(
) max k 1}
g
k 1
ps '

(A.9)

where (pd/ps)max = rSTG-MAX-T = (

Td max ( k 1 )
Td max ( k 1 )
or pdSTG-MAX-T = ps (
bar A
)
)
Ts
Ts

(A.10)

r is also limited by maximum frame power of compressor.

Substitute equation 1, 2 and A.9,
HSTG-MAX =

3.6 BHPframe m V .10 6

g .G.z

and rSTG-MAX-P =

k 1
)
k
+1
1000.Z .R.Ts
H .g .(

}( k 1)

(A.11)

If so, maximum r is selected whichever is lower.

A.4. PISTON CAPACITY, PISTON SPEED, STROKE LENGTH AND MAXIMUM FRAME BHP
In this article, maximum piston speed is defined at 6 m/s. Figure A.1 shows relation between N
(RPM), stroke length L (mm) at several average piston speed, U based on equation (12). When
there is no data for frame BHP, maximum frame BHP is defined at 0.11 Qp1. z kW, where Qp1 is
piston displacement capacity for each stroke in m3/hr (4.721.10-8.D2.L.N where D is maximum
diameter in mm, L in mm and N in RPM) and z is number of throw.

Figure A.1. Typical Stroke Length for Reciprocating Compressor

Available maximum diameter in this manual is decided at 1130 mm based on manufacturers
data. Figure A.2 and A.3 show relation between stroke length L and piston volume flow at defined
L/D = 0.4 for varies number of throw. Manufacturers are available to produce reciprocating
compressor with number of throw, z up to 12 at one casing. In general, stroke length 430 mm and
shorter are available. Figure A.2 for single acting and figure A.3 for double acting compression.

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Figure A.2. Stroke length Against Piston Capacity Chart for Single Acting Compression

Figure A.3. Stroke length Against Piston Capacity Chart for Double Acting Compression
A.5. MECHANICAL EFFICIENCY
The following figure shows mechanical efficiency, m

Figure A.4. Mechanical Efficiency of Reciprocating Compressor

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APPENDIX B. GAS PROPERTIES

B.1. SINGLE GAS
The following table presents single gas properties. There are MW (molecular weight), k (adiabatic
exponent), pcr (critical pressure ), Tcr (critical temperature) and MCp (=MW x Cp).

Table 1. Pure Gas Properties

Gas constant (R), specific heat (Cp) and k

Gas constant R =

8.314
MW

(B.1)

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RECIPROCATING COMPRESSOR

Specific heat Cp =

R.k
k 1

(B.2)

Value of k is constant for dry gas, see table above.

Compressibility factor (Z)
Z determined by gas compressibility chart using reduction temperature (Tred) and pressure (pred)
as the variables. Tred = T/Tcr and pred = p/pcr. See following figure A.1

Figure B.1. Gas compressibility chart for pred < 1

Figure B.1 presents Z factor for pred = 1 and lower. For pred higher than 1 see figure B.2.
Density of gas,
DS =

100( p )
R.T .Z

(B.3)

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RECIPROCATING COMPRESSOR

Figure B.2. Gas compressibility chart for pred higher than 1.

B.2. MIXED GAS
Gas constant (R), specific heat (Cp) and k of mixed gas
Subscript (i) indicates partial of pure gas.
i

MW =

{0.01(%Mi)(MWi)}

(B.4)

Where %Mi is partial mole of each individual gas in %

% Mi =

100( MMi)
MMi

(B.5)

Where MMi is molal mass of each gas in kgmole or mols

MMi =

Mgi
MWi

(B.6)

Where Mgi is mass of each gas in kg

k=

0.01(MCpi)(%Mi)

(B.7)

0.01(MCpi)(%Mi) 8.314

Gas constant R =

8.314
MW
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RECIPROCATING COMPRESSOR

Specific heat Cp =

R.k
k 1

Compressibility factor (Z)

pcr =

0.01(%Mi)( pcri)

(B.8)

Tcr =

0.01(%Mi)(Tcri)

(B.9)

Z factor determined using figure A.1 and A.2.

Density of mixed gas,
DS =

100( p )
R.T .Z

(B.10)

B.3. WET GAS

Gas shall be dry in centrifugal compressor to prevent internal parts and impeller from erosion due
to liquid particles. Gas condition shall be kept at little far from wet condition. Following table
presents vapor pressure for some gases.

B.4. WET AIR

Following steps describes how to determine properties of wet air.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.

Relative humidity RH in %
Dry bulb temperature tdb in C and then Tdb = 273 + tdb in K
Atmospheric pressure patm at bar A
From psychometric chart, determine wet bulb temperature twb and Twb = 273 + twb
From H2O saturated pressure table, determine saturated pressure at twb, pg
Partial pressure of H2O
pw = 0.01 (%RH)(pg)
Partial pressure of dry air
pa = patm pg
Mole fraction of dry air
Xa = pa / patm
Mole fraction of H2O
Xw = pw / patm
Molal mass of wet air
MW = (MWdry air)(Xa) + (MWH2O )(Xw)
MCp of wet air
MCp = (MCp dry air)(Xa) + (MCp H2O)(Xw)
Gas constant
R = 8.314 / MW
k
k = MCp / (MCp-8.314)
Density
DS = 100.patm / (R.Tdb)

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RECIPROCATING COMPRESSOR

Table 2. Saturated pressure of H2O

From % RH and tdb determine twb from following typical psychometric chart

Figure B.3. Psychometric chart for air at 1 atm.

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RECIPROCATING COMPRESSOR
APPENDIX C. COMPRESSOR CONROL
The following figures are typical reciprocating controller diagram and capacity charts. Figure C.1 up to
C.3 for constant speed driver and C.4 for variable speed driver.

Figure C.1. Bypass Pressure Controller and Clearance Pocket Controller for Constant Speed

Figure C.2. Suction Valve Unloader and Clearance Pocket Controller

Figure C.3. Bypass Capacity Controller and Clearance Pocket Controller

Figure C.4. Variable Speed Controller

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