RECIPROCATING COMPRESSORS

Reciprocating compressors use pistons to "compress" high pressure gas. These systems are common in the handling of natural gas and other high pressure systems.

Source: Presentacin de compresores. Prof Manuel E. Cabarcas

RECIPROCATING COMPRESSORS
Operate with the adiabatic principle by which the gas is introduced into the cylinder through the inlet valves, is retained and compressed in cylinder and exits through the discharge valves against the discharge pressure.

Source: Presentacin de compresores. Prof Manuel E. Cabarcas

RECIPROCATING COMPRESSORS

Start of cycle at point A. Piston has reached end of stoke and moves to the right. Suction and discharge valves closed. Cylinder filled with gas at discharge pressure.

As piston moves to the right, the gas in the cylinder at the start begins to expand and its pressure drops. At point B, pressure in cylinder equals suction pressure and suction valve opens.

Source: CAMPBELL M John,Gas conditioning processing Vol 2, pag 214

RECIPROCATING COMPRESSORS

Suction valve reminds open, and gas flows into cylinder. When piston starts to move to the left, the pressure in the cylinder rises and the suction valve closes.

Piston moves from C to D, pressure in cylinder rises. At pint D, pressure reaches discharge pressure and discharge valve opens.

Piston moves from D to A, gas flows out of the cylinder into the discharge line. At point A, cycle starts over.

Source: CAMPBELL M John,Gas conditioning processing Vol 2, pag 214

RECIPROCATING COMPRESSORS DESIGN

PISTON DISPLACEMENT It can be calculated from: Head end displacement: ( 2 )()() = 2200 Crank end displacement: ( 2 2 )()() = 2200 PD: piston displacement, cfm S: stroke lenght, in rpm: compressor speed, rpm dc:diameter of cylinder,in dr: diameter of rod, in

RECIPROCATING COMPRESSORS DESIGN

VOLUMETRIC EFFICIENCY The flow rate is not directly equal to the piston displacement. Volumetric efficiency is the ratio of actual volumetric flow at inlet temperature and pressure conditions to piston displacement. It is given by:
1

: 96

Ev: stage volumetric efficiency, % R: compression ratio (Pd/Ps) C: cylinder clearance, percent of piston displacement Zs: compressibility factor at suction, psia K: ratio of specific heats, Cp/Cv

RECIPROCATING COMPRESSORS DESIGN

CYLINDER THROUHPUT CAPACITY Using a known piston displacement and efficiency, the gas throughput can be calculated from: = qa: gas througput at suction conditions of temperatura and pressure, ft3/min Ev: volumetric efficiency PD: piston displacement, ft3/min = 35.4

= 0.051

qg: gas throughput at standard conditions, scfm Ps: suction pressure, psia Ts: suction temperatura, R Zs: compressibility at suction conditions

Qg: gas throughput, MMscfd

RECIPROCATING COMPRESSORS DESIGN

ROD LOAD It depends on rod diameter and material, and will be quoted by the manufacturer Single-acting cylinder, head end = + = Single-acting cylinder, crank end = + = Double-acting cylinder RLc: rod load in compression, lb RLt: rod load in tensin, lb ap: cross-sectional rea of piston, in2 Pd: discharge pressure, psia Ps: suction pressure, psia Pu: pressure in unloadead rea, psia ar: cross-sectional rea of rod, in2

= + =

RECIPROCATING COMPRESSORS DESIGN

GAS DISCHARGE TEMPERATURE The discharge temperature it neglects heat from friction, irreversibility effects, etc., and may be somewhat low, but the values obtained from this equation will be reasonable field estimates.

Pd: discharge pressure, psia Ps: suction pressure, psia K: ratio of specific heats

RECIPROCATING COMPRESSORS DESIGN

HORSEPOWER REQUIRED 1 = . 0857 ( ) 1 1

+ = ( ) 2

BHP: brake horsepower Qg: gas flow rate, MMSCFD Ts: suction temperatura, R Zav: Z average Zs: suction compressibility factor Zd: discharge compressibility factor E: overall efficiency K: ratio of specific heats Ps: suction pressure, psia Pd: discharge pressure

EXAMPLE
Field downstream of the separator from 800 psig at 100F to 1,000 psig. An engine-driven separable compressor is available from surplus. The engine is rated for 1,600 hp at 900 rpm. Horsepower is proportional to speed. The compressor frame has six 7-in. bore by 6.0-in. stroke double-acting cylinders with a minimum clearance of 17.92%, a rod load limit of 25,000 Ib, and rod diameter of 1.75 in. Assume k = 1.26, Zs = 0.88, and Zd = 0.85. Calculate: Compute discharge temperature Volumetric efficiency Required clearance Rod load Required horsepower for the given conditions Calculate the lowest suction pressure at which this unit can compress 100 MMscfd.

EXAMPLE
Calculate the gas discharge temperature:

1015 = 560 815

1.261 1.26

= 586 R =126F

EXAMPLE
Calculate the volumetric efficiency

: 96

1015 = = 1245 815 : 96 1245 17.92 : . % 1245

1 1.26

0.88 1 0.85

EXAMPLE
Calculate the requires clearance

(2 2

2200

2 )()()

(2 72 1.752 )(6)(900) = 2200

= 233

= 6 233
=

EXAMPLE
Gas troughput

= = 0.906 1398 =

= 0.051 1267 815 = 0.051 560 0.88 = .

EXAMPLE
Calculate required rpm to give desired throughput:

815 100 = 0.051 560 0.88 = = 0.906

2200 = 6 (2 2 2 ) 218 2200 6 (2 72 1.752 )

= = .
= =

EXAMPLE
Calculate the clearance that would be needed to reduce the throughput from 106.9 MMscfd to 100 MMscfd:

1186 = = 1398

= .

Now back calculate for the clearance that must be added to produce this volumetric efficiency.
84.8: 96 1.245 1.245
1 1.26

0.88 1 0.85

= %

EXAMPLE
Calculate the size liner required to reduce piston displacement:

1186 = = 1309 0.906

1309 2 2 1.752 6 900 = 6 2200 = .

EXAMPLE
Calculate the rod load
2 = 7.52 1015 815 + (1.75 2 ) 815

= .

2 = 7.52 1015 815 (1.75 2 ) 1015

= .

EXAMPLE
Calculate the required horsepower needed for the given conditions: 1 = . 0857 ( ) 1 1 = 0.88 + 0.85 = 0.865 2

E= E= . . = . 100 560 1.26 1015 1.261 = . 0857 0.865 ( ) 1.26 1 0.83 1.26 1 815 =1.137 hp

EXAMPLE
Calculate the lowest suction pressure

Using the minimum clearance

100 560 0.88 0.051 1267

= 0.051

=747.9 psig

CONCLUSIONS
In a gas plant before use is necessary to subject it to a compression process to raise its energy level, the main function compressors is increase the pressure of gas, so the gas submits the compressor even work so that increase the total energy of the same. In compression facilities, must be installed a primary separation equipment or slug catcher upstream suction manifold to avoid the possibility that any liquid can reach the compressor.

BIBLIOGRAPHY
ENGINEERING DATA BOOK. Gas Processors Suppliers Association. Volumen I. Edicin FPS. 2004. SURFACE PRODUCTION OPERATIONS. Volumen 2. Design of Gas-Handling Systems and Facilities. Ken Arnold, Maurice Stewart. Segunda Edicin. 1999.

CAMPBELL M John,Gas conditioning processing Vol 2.

HERRERA F. BLADIMIR, SALAZAR M. LAURA C Estudio de los problemas asociados con el proceso de separacin flash en las plantas tpicas de compresin de gas natural, TESIS DE GRADO UNIVERSIDAD DE ORIENTE.

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