A literature review of a reciprocating compressor is a comprehensive examination and interpretation

of literature relating to this specific type of compressor, widely used in various industrial applications
for its ability to compress gases at high pressures. Undertaking such a review involves navigating
through an extensive array of technical documents, research papers, and case studies. This task is
inherently challenging due to the technical complexity of the subject matter, the vast amount of
literature available, and the need to synthesize and critically analyze information from multiple
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The difficulty in writing a literature review on reciprocating compressors stems from several factors.
First, understanding the intricate technical details and operational principles of reciprocating
compressors requires a solid background in mechanical engineering and fluid dynamics. Second, the
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Reciprocating Compressors The reciprocating air compressor, illustrated in Figure 1, is the most
common design employed today. Larger reciprocating compressors, over 1000 HP, are commonly
found in large industries and petroleum applications. Out of some other types of dynamic air
compressors, the commonest is the centrifugal compressors. According to this the common
compressors are the reciprocating compressors, rotary screw compressors, rotary centrifugal
compressors. The overall reliability of the compressor depends on the piston material and design. We
use cookies to create the best experience for you. The size of compressor is very large for a given
capacity. The studs that connect the cylinder head to the cylinder body are made of temperature
resistant materials. Reciprocating compressor is mainly used in the refrigeration cycle. Fig.2.
Components of a reciprocating air compressor. Generally, electric motor, internal combustion engine
or steam engine, turbine etc. P M V Subbarao Professor Mechanical Engineering Department. Learn
more here. What is the difference between the pricing plans. The suction filter in the input side
filters the dirt particles from the inlet air and provides clean air for compression. A recognized
subject-matter-expert on plant equipment and failure avoidance, he is the author of numerous books
and articles, and continues to present at technical conferences around the world. Dr. Margaret Bailey
Faculty Guide Garry Studley Project Manager Dave Rigolo Lead Engineer Alec Jarvie Industrial
Systems Engineer Chris Neitz Computer Engineer Kiernan French Mechanical Engineer. Also the
major components of the compressor along with the design criteria, methods of manufacture have
also been discussed. At constant speed, the air flow remains essentially constant with variations in
discharge pressure. Thus these types of compressors could be widely used. Rotary types are
primarily specified in compressed air applications, though other types of compressors are also found
in air service. The concept was adapted to the heat engine and ultimately the steam engine.
Reciprocating Compressors Reciprocating Compressor has piston cylinder arrangement
Reciprocating Compressor Reciprocating Compressor has piston, cylinder, inlet valve, exit valve,
connecting rod, crank, piston pin, crank pin and crank shaft. The compressing element, consisting of
air cylinders, heads and pistons, and air inlet and discharge valves. For the 300 mm liner bore
example, this capacity capability reduction is on the order of 35 percent for 76 mm (3 inches) stroke.
This is exactly the type of success being achieved with this 21ST-century technology.Although the
basic design of a reciprocating compressor has not changed much over the years, manufacturing,
design capabilities, non-metallic materials, and performance modeling have. There are two types of
reciprocating compressors are for a general purpose. The manner in which they work is very similar to
that of an internal combustion engine but more or less in a reverse manner (they were classified, in
many classifications, in a separate category of piston type compressors). They operate on the same
principle as the old, familiar bicycle pump, that is, by means of a piston in a cylinder. This skid
serves as a platform on which to mount all the previously mentioned equipment, but also, in many
instances, the compressor's foundation. ASTM A395 happens to be a very poor material for use in an
application that subjects the material to rubbing wear, as is the case in a cylinder bore where the
piston and piston rings, or the wearbands and piston rings, are rubbing against it.
The results advocate the optimal time for starting each stage of the two-stage compressors. The chart
assumes a compression ratio of 2.5 and a gas adiabatic exponent of 1.4. Assumed liner thickness is
9.5 mm (0.375 inches) up to 254 mm liner bore (10 inches) and 12.5 mm (0.500 inches) 254 mm bore
(10 inches) and larger following API Standard 618 guidelines. In the graph, the can is subjected to a
progressive force, which is increased evenly. Moreover, this market report also covers regional and
country market in detail. Condition Monitoring can achieve substantial savings in maintenance cost
and in increased run time. We have over one million books available in our catalogue for you to
explore. The overall reliability of the compressor depends on the piston material and design. Non-
cooled cylinder body castings are of significantly higher quality due to the fact there is no cooling
jacket complicating the casting. A diffuser section converts the velocity energy to pressure energy.
The flow will continue until the piston reaches the Bottom. Invalid email address You've successfully
subscribed. Compressors could be classified under two categories, namely positive displacement type
and dynamic type. Due to this piston movement from TDC to BDC suction pressure is created
causing opening of inlet valve. If only one side of the piston is used for compression, then it is called
as single acting. Splitting the main bearing along the vertical plane relieves the surface discontinuities
in the loaded areas. Not responding to this cause will lead to an overheated cylinder and ultimately
to such events as piston seizure, ring breakage, and piston cracking. Both valves are designed to
quick and leak-free operation. So, the piston continues its motion towards BDC till. The prime
mover powers the compressor and the treatment. Engineering Failure Analysis, Engineering Failure
Analysis 17 (2010), pp.150-157. On P-V diagram process 4-1 shows the suction process followed by
compression during 1-2 and discharge through compressor is shown by process 2-3. When piston
starts to move downward from TDC to the bottom side of the cylinder BDC (Bottom dead center)
the residual gas (refrigerant) from the previous cycle in the cylinder gets expanded which reduce the
pressure inside the cylinder. Don't Miss Our Updates Be the first to get exclusive content straight to
your email. Storage can be used to protect critical pressure applications from other events in the
system. Axial-flow compressors are dynamic rotating compressors types that use arrays of fanlike
airfoils to progressively compress the air or gas. These suction filters are placed in a detachable
casing. As the piston continues upward, air is compressed until the pressure in the cylinder becomes
great enough to open the discharge valve against the pressure of the valve springs and the pressure of
the discharge line (Figure 2E). Steel material is used for the design of crossheads. When looking for
an air compressor, there are different types of compressor like Reciprocating compressor, Vane
Compressor, Screw Air Compressor, Diaphragm Compressor, Centrifugal Compressor. Let us
consider piston to be at top dead centre (TDC) and move towards bottom dead centre (BDC).
The report encompasses data regarding market share and recent developments by key players. The
piston has many grooves that serve the purpose of scraping and sealing. The overall reliability of the
compressor depends on the piston material and design. The studs that connect the cylinder head to
the cylinder body are made of temperature resistant materials. Generally, the sub-systems and
equipment of compressed air systems are organized as air compressor followed by coolers, separator,
air dryers, and air storage tank. Based on principle of operation: Based on the principle of operation
compressors can be classified as. Creating this type of imagery takes someone that enjoys
communicating with scientists, physicians, engineers, executives, sales personnel, marketing
specialists, advertising teams, and most importantly the audience. For a single acting reciprocating
compressor both suction and compression stroke of completed in one revolution of the crankshaft. ??
Work done by reciprocating compressor without clearance volume with PV and TS diagram. In
single-acting type, the compressor cylinder usually arranged in the vertical position while in double
acting the compression cylinders are normally arranged in horizontal. ?? Single Stage and Multi Stage
Compressor Advantages and Limitation Construction and working of reciprocating compressor
Figure shows the line drawing of the simplest form of a reciprocating compressor. A current
industrial compressor is a system composed of several sub-systems and many components. A
compressor package is a complete gas compression system module having the compressor with its
driver, coupling, all process gas, and utility piping, lubrication systems, and all the instrumentation
and control systems mounted on a structural steel skid. Over time the rotating and average piston
speed increased as the sealing technology for piston rod packing and piston rings improved. The
capacity capability has been reduced from that of a 325 mm bore cylinder to that of a 300 mm. The
piston is also designed foe air compression hence the fluid flow analysis is as follows; The Piston
crown design influences the characteristics of the fluid flow field depending on the different shapes
of the piston crowns. Disadvantages One of the drawbacks of the reciprocating compressor is that it
cannot self-regulate its capacity against a given output pressure, it will continue displacing the gas
until told not to do. Further, the market has been bifurcated into sub-segments with regional and
country market with in-depth analysis. Here fluid is not contained in definite volume and subsequent
volume reduction does not occur as in case of positive displacement compressors. For this the
mechanism is derived to maintain constant temperature during compression process. Also, the
addition of the liner has increased the fixed clearance volume, which reduces the volumetric
efficiency, further reducing the capacity capability. The design and main functions of the automatic
acquisition and testing system for air compressor performance was introduced. Area on p-V diagram
shows that work requirement shall be minimum with isothermal process 1-2”. Experiment addressed
some factors that led to the inefficient performance of the compressed air system and cause energy
losses. That excitement tempered with an objective and analytical approach based on more than 20
years of experience leads to seamless integration with your team and an easy working relationship.
Reciprocating compressors may also be single acting compressor or double acting compressor. Many
large snowmaking operations (like ski resorts) use this type of compressor. Storage can be used to
protect critical pressure applications from other events in the system. The cooling jackets will be used
to heat the cylinders prior to startup to avoid liquid condensing out of the gas stream (warm
saturated gas contacting cold metal) and causing damage to the compressor valves or other
components when the compressor starts. It is still significant for a 457 mm (18 inches) stroke at
about a 17 percent reduction. To eliminate the limitations of single stage, the air is. Finally a
comparison of the reciprocating compressor with the other types has been done in terms of the
capacity, pressure levels, efficiency, maintenance, noise level and other parameters.
Single acting reciprocating compressor and double acting reciprocating compressor. The experiment
addressed some factors that led to the inefficient performance of the compressed air system and
cause energy losses. The wear of expensive components can be alleviated by the use of materials like
polytetrafluoroethylene (PTFE). In general the manufacturing the reciprocating compressors with
hyper ethylene would be capable enough of delivering pressures up to 3500 bar. This work, in
addition, may give the insight for the development of the design of multi- stage compressors and
presents some key design parameters. The first industrial compressor was simple, a reciprocating
piston-driven machine powered by a water wheel. This causes the valve opening allowing the gas to
flow. Subsystems include prime mover, controllers and accessories, treatment equipment, and
distribution unit. Work required for increasing pressure of air is available from the prime mover
driving the compressor. When looking for an air compressor, there are different types of compressor
like Reciprocating compressor, Vane Compressor, Screw Air Compressor, Diaphragm Compressor,
Centrifugal Compressor. The roto-dynamic compressor which is also called centrifugal or turbo
compressor, is classified as radial flow and axial flow types according to the flow arrangement. The
chart assumes a compression ratio of 2.5 and a gas adiabatic exponent of 1.4. Assumed liner
thickness is 9.5 mm (0.375 inches) up to 254 mm liner bore (10 inches) and 12.5 mm (0.500 inches)
254 mm bore (10 inches) and larger following API Standard 618 guidelines. Dynamic compressors
are available in two main types: centrifugal and axial. Compressors are invariably used for all
applications requiring high pressure air. Thermodynamic Analysis Compression of air in compressor
may be carried out following number of thermodynamic processes such as isothermal compression,
polytropic compressor or adiabatic compressor. If only one side of the piston is used for
compression, then it is called as single acting. These modern designs are packaged into complete
compression system modules contributing to reduced capital cost through reduced installation time
and therefore cost. The results advocate the optimal time for starting each stage of the two-stage
compressors. As the piston continues upward, air is compressed until the pressure in the cylinder
becomes great enough to open the discharge valve against the pressure of the valve springs and the
pressure of the discharge line (Figure 2E). A regulation or control system designed to maintain the
pressure in the discharge line and air receiver (storage tank) within a predetermined range of
pressure. The following chart, Figure 4, will help to explain. Table of contents Reciprocating
compressors and their applications. Microstrip Bandpass Filter Design using EDA Tolol such as
keysight ADS and An. The compressor types could be classified as two main types: positive-
displacement and dynamic. Reciprocating compressors work by pumping air into an air chamber then
reducing this chamber's volume. Single acting compressor has one delivery stroke per revolution
while in double acting there are two delivery strokes per revolution of crank shaft. In the example to
the left the reciprocating motion of the piston is converted to the rotary motion in the crank. They
are the most widely used type of positive displacement compressor. What is Perlego? We are an
online textbook subscription service, where you can get access to an entire online library for less than
the price of a single book per month. Don't Miss Our Updates Be the first to get exclusive content
straight to your email.
Generally, the sub-systems and equipment of compressed air systems are organized as air compressor
followed by coolers, separator, air dryers, and air storage tank. Upload Read for free FAQ and
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fluid is not contained in definite volume and subsequent volume reduction does not occur as in case
of positive displacement compressors. The compressor types could be classified as two main types:
positive-displacement and dynamic. Moreover, this market report also covers regional and country
market in detail. In the example to the left the reciprocating motion of the piston is converted to the
rotary motion in the crank. The report encompasses data regarding market share and recent
developments by key players. Affiliations and expertise Consulting Engineer, Montgomery, TX,
USA JH John J. Sustainable Energy Development Office, (200), Government of Western Australia.
Diaphragm compressors are a less common type and are used for compressing hydrogen and natural
gas as well as in a number of other applications. After piston reaching BDC it reverses its motion and
compresses the air inducted in previous stroke. These included the two-stage compressor, the piston,
a separate dynamometer, analogue meters, the two industrial compressors, the air receiver and the
intercooler which is located between the first and second stages. The efficiency of this reciprocating
compressor has been found to be high compared to other types of compressors. For the 300 mm liner
bore example, this capacity capability reduction is on the order of 35 percent for 76 mm (3 inches)
stroke. Definitions. Saw Tool for cutting Serrated blade Worked either by hand or other power
Reciprocating Saw Straight blade mounted on gun-like body. The discharge valve lets the
compressed air outside when the cylinder pressure is greater than the discharge pressure. Again
comparing the cost of a 125 psi reciprocating compressor with 1000 psi reciprocating compressor, it
can be seen that the 1000 psi reciprocating compressor costs much more than the 125 psi
reciprocating compressors. For this purpose, a performance characteristic evaluation of a two- stage
reciprocating compressor is carried out in this paper. The concept was adapted to the heat engine and
ultimately the steam engine. If both sides of the piston are used, then it is called as double acting.
Troubleshooting compressor problems. Preventive maintenance of reciprocating compressors. At
BDC of stroke, the suction valve again gets closed. Moreover, this market report also covers regional
and country market in detail. The compressor uses spring loaded valves that operate when the
differential pressure across the valve is proper. Advantages and disadvantages of reciprocating
compressor Advantages Used to produce high-pressure gas. Many find it difficult to understand how
a higher speed reciprocating compressor can have equal reliability to a low speed, but it is possible
and being proven every day. Like liners, cooling is not required for a compressor cylinder to
compress the gas. First Options. Back to Reality. Lets Brake It Down. They have pistons, valves,
cylinders, housing blocks and crankshafts. Further, the market has been bifurcated into sub-segments
with regional and country market with in-depth analysis.
Their application can be from 100 horsepower (HP) to thousands of horsepower. Based on this
simple mechanism, these compressors are capable of producing a large amount of energy which can
be used for many purposes; consequently, reciprocating compressors are the most common types
available in the market today. In the example to the left the reciprocating motion of the piston is
converted to the rotary motion in the crank. Offer details Home Books Engineering and technology
Reciprocating Compressors: Reciprocating Compressors: Operation and Maintenance 1st Edition -
October 8, 1996 Authors: Heinz P. Now the piston moves from BDC to TDC (compression stroke),
the cylinder volume decreases, pressure increases and the gas get compressed. In the graph, the can
is subjected to a progressive force, which is increased evenly. Normally maximum compression ratio
of 5 is realized in single stage compressors. A compressor using both sides of the piston is considered
as double acting. Since his retirement from Exxon, he has been in demand throughout the world as a
consultant and trainer in the areas of failure avoidance, root cause failure identification, and
reliability improvement. The cost wise comparison of the various compressors shows that the
reciprocating compressors (125 psi) are more costly compared to the centrifugal and rotary
compressors of same specifications. Isothermal efficiency is defined by the ratio is isothermal work
and actual indicated work in reciprocating compressor. As the piston continues upward, air is
compressed until the pressure in the cylinder becomes great enough to open the discharge valve
against the pressure of the valve springs and the pressure of the discharge line (Figure 2E).
Theoretical cycle is shown neglecting clearance volume but in actual cycle clearance volume can not
be negligible. The report provides key statistics on the market status of the Reciprocating
Compressor manufacturers and is a valuable source of guidance and direction for companies and
individuals interested in the industry. Again referring to the 300 mm example, a 76 mm stroke
compressor would have to be about 35 percent larger if equipped with a liner. Ease of use is very
important to a consumer, here are some good design aspects of the saw. Three types of designs
include Reciprocating compressor, Rotary compressor, Centrifugal air compressors. This report
intends to discuss the Reciprocating air Compressor in terms of product description, method of
operation including the health and safety aspects. Inadequate clearance will ultimately lead to piston
failure or rod breakage with attendant damage to the crosshead. The efficiency of this reciprocating
compressor has been found to be high compared to other types of compressors. These compressors
dominate the upstream and midstream oil and gas industries and are becoming more common and
gaining wider acceptance downstream. The material selection for casing is plastic or metals of less
weight or sometimes aluminum. Figure 1 Reciprocating Air Compressor The reciprocating
compressor normally consists of the following elements. This is actually a 325 mm (12.8 inches)
diameter bore cylinder with a 12.5 mm (0.5 inches) thick liner installed. Health and safety aspects in
the reciprocating compressor need to concentrate on efficient cooling arrangements to maintain the
temperatures during the compression process. The overview of these components are shown in the
following Fig.2. These reciprocating find critical applications in production facilities like refineries,
gas transmission systems, petrochemical plants and many other similar industries. Reciprocating
compressors generally, employ piston-cylinder arrangement where displacement of piston in cylinder
causes rise in pressure. What is Perlego? We are an online textbook subscription service, where you
can get access to an entire online library for less than the price of a single book per month. The
cylinder head is connected to the compressor body by proper nuts and studs.
Advancements have taken us from punch cards to medical computers that can be swallowed. There is
no cylinder jacket water system to operate or maintain. Many find it difficult to understand how a
higher speed reciprocating compressor can have equal reliability to a low speed, but it is possible and
being proven every day. The following chart, Figure 4, will help to explain. One proven hardening
method uses the ion-nitride heat treat process. The crankcases need to be provided with large
openings so as to reduce cost of maintenance and time required for maintenance. He is the former
chief engineer of Worthington Service Corporation. Website language selection impacts menus and
navigation. Both valves are designed to quick and leak-free operation. P M V Subbarao Professor
Mechanical Engineering Department. This arrangement transfer the rotation of the engine to
reciprocating motion of piston. Reciprocating compressors can be either stationary or portable, can
be single or multistage, and can be single acting, double acting or diaphragm. Use of inter stage and
after coolers helps in maintaining proper temperature of the fluid being compressed. The difference
between the observed and calculated temperatures should be more or less constant from day to day.
Each type has a completely different working principle than the other. Storage tank has many
functions; it represents the available air that can be released or replenished at any time as required. In
the example to the left the reciprocating motion of the piston is converted to the rotary motion in the
crank. The report encompasses data regarding market share and recent developments by key players.
Due to this piston movement from TDC to BDC suction pressure is created causing opening of inlet
valve. In general the manufacturing the reciprocating compressors with hyper ethylene would be
capable enough of delivering pressures up to 3500 bar. The operation can be made smooth by using a
flywheel. The above report has dealt in detail the reciprocating compressors. Many large
snowmaking operations (like ski resorts) use this type of compressor. The dirt particles are attracted
towards the filter by a slight coating of lube oil. In diaphragm compressor type (also known as a
membrane compressor) the compression of gas occurs by the movement of a flexible membrane
instead of an intake element. Generally, the sub-systems and equipment of compressed air systems
are organized as air compressor followed by coolers, separator, air dryers, and air storage tank. The
system can give real-time process monitoring on test data and compile test reports of the
reciprocating two stages compressor. It can also be useful for reciprocating compressors. Since his
retirement from Exxon, he has been in demand throughout the world as a consultant and trainer in
the areas of failure avoidance, root cause failure identification, and reliability improvement. Both
inlet valve and exit valves are of plate type and spring loaded so as to operate automatically as and
when sufficient pressure difference is available to cause deflection in spring of valve plates to open
them.