Reciprocating Compressor Optimum Design and Manufacturing With Respect To Performance, Reliability and Cost
Reciprocating Compressor Optimum Design and Manufacturing With Respect To Performance, Reliability and Cost
compressing almost any gas mixture in wide range of pressure, can high suction pressure. If not tolerate-able, additional clearance
generate high head independent of density, and have numerous
pocket on first stage cylinder and part load operation
applications and wide power ratings. These make them vital
component in various units of industrial plants. In this paper inhabitation by the controlling logic, can be studied. Generally
optimum reciprocating compressor configuration regarding inter- it is compromise to fix PRV-Pressure Relief Valve set points
stage pressures, low suction pressure, non-lubricated cylinder, speed (and inter-stage facility design pressure accordingly) based on
of machine, capacity control system, compressor valve, lubrication worst case of part load operation and process variations (such
system, piston rod coating, cylinder liner material, barring device, as high suction pressure). For common design cases (50% and
pressure drops, rod load, pin reversal, discharge temperature,
75% part load steps and around 5%-7% suction pressure
cylinder coolant system, performance, flow, coupling, special tools,
condition monitoring (including vibration, thermal and rod drop variation), PRV pressure set points will be around 10-15%
monitoring), commercial points, delivery and acoustic conditions are higher due to part load operation and suction pressure
presented. variations.
B. Low Suction Pressure with Full Flow
Keywords—Design, Optimum, Reciprocating compressor.
Sometimes, due to process requirements, reciprocating
I. INTRODUCTION compressors shall be capable to operate at lowest suction
pressure and full design flow at normal discharge pressure. It
R ECIPROCATING compressors are the most common
type of compressors found in industrial applications [1]-
[4]. Worldwide installed reciprocating compressor
can have strong effect on electric motor sizing as well as
compressor sizing and machine frame rating (for example
more than 35% electric motor power increase for 20% suction
horsepower is approximately three times that of
below normal). It is absolutely necessary to respect this
centrifugal compressors and maintenance costs of
condition for motor and compressor sizing. It is optimum to
reciprocating compressors are approximately three and half
respect them in basic design and design stage to avoid costly
times greater than those for centrifugal compressors [3].
changes.
Design and manufacturing of a reciprocating compressor shall
be involved optimization process with respect to full array of C. Minimum Speed Lubricated Cylinder
compressor data. Otherwise, it may end up with equipment Reliable machine is involved low speed (around 350 RPM)
that may not be suitable over the full operating cases, and lubricated cylinder. Optimum piston speed is 3-4.4 m/s.
reliability level, commercial terms or power requirement for Optimum configuration: horizontal cylinder(s), discharge
which the manufacturer and client expect. nozzle on the bottom side. For small compressor selection, it
may be necessary to deviate lubricated cylinder or low speed.
II. MACHINE DESIGN Optimum option is lubricated cylinder with available
lowest speed machines. Probably less than 20% of all
A. Inter-stage Design Pressures
reciprocating compressors are designed for non-lubricated
Discharge pressure of each stage is normally protected by operation just because of process demands (oxygen, high
pressure relief valves, high pressure discharge switches are pressure air, down stream facilities sensitive to oil such as
seldom seen [2]. Optimum inter-stage pressures can be some catalysts, etc) [2].
obtained by formulation and optimization of performance and
investment for compressor and inter-stage facilities. Inter- D. Unloader and Capacity Control System
Step-less capacity control system uses finger type unloader,
A. Almasi is with the Tecnicas Reunidas S.A., Madrid 28050, Spain is pneumatically actuated, and unloads the suction valve for
(phone: +34 91 409 8254; fax: +34 91 750 4165; e-mail: aalmasi@trsa.es only a portion of compression cycle to achieve adjusted
amin_almassi@yahoo.com).
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capacity [2]. Finger type unloaders have potential for lower the valve pressure drop, less consumed power, higher
damaging the valve sealing elements and require more care for moving elements impact velocities and lower valve durability.
maintenance [2]. Valves and unloaders cause around 44% of Acceptable compromise should be found. Optimum valve
unscheduled reciprocating shut down [5], [6] and this spring stiffness is also important. Too stiff spring can lead to
selection has a strong effect on reliability [5]-[8]. For small valve flutter (more compressor power and considerable wear
machine, 100% spill back is optimum solution, because rate) or early closing of valve (reduce capacity). Too light
power is low. For big machine optimum configuration is spring cause valve late closing and the reverse flow (higher
selection of part load steps based on plug/port unloader velocity, less reliability and reducing capacity). Nonlinear
and clearance pocket. partial differential equations describing the valve differential
pressure and the valve element motion (such as [14]) can be
E. Condition Monitoring
used in optimization process to estimate optimum valve lift,
Condition monitoring [9]-[13] shall be particularly cost spring stiffness and gas velocity for each machine and
effective and include necessary items to identify malfunctions application.
at an early stage (lower maintenance costs and risk of
accidents). Optimum vibration monitoring: 1- Vibration – G. Piston Rod Coating
continuous monitoring (Shut down). Velocity transducers Piston rod seal is second important area for reliability of
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are preferred over accelerometers due to better signal to reciprocating compressor and most likely path for potentially
noise ratio [9]. The optimum configuration: each end of the hazardous process gas leakage [8]. Packing life could be
crankcase about halfway up from the base plate in line with a improved three times by adding the proper tungsten carbide
main bearing [9]. 2- Each cross head accelerometer (Alarm). piston rod coating [10]. It is optimum selection.
3- Electric motor vibration (Shut down). Optimum
H. Cylinder Liner Material
temperature monitoring: 1- High gas discharge temperature -
each cylinder (Alarm and Shutdown). 2- Pressure packing Cylinder liner is used to provide a renewable surface to the
case - piston rod temperature (Alarm). 3- High cross head pin wearing. The liners made by Ni-Resist cast iron (high Nickel
temperature (Alarm). 4- High main and motor bearing content) are not recommended due to problems such as
temperature (Alarm). 5- Valve temperature (Monitoring). 6- permanent distortions. Optimum selection is grey cast iron
Oil temperature out of frame (Alarm). 7- High jacket water [8] except very high pressure or extremely high corrosive
temperature - each cylinder (Alarm). Optimum applications.
implementation is properly set trip levels that are just high I. Passive Vibration Reduction System
enough over the normal operating levels to reach to Sometimes odd number of cylinders is not avoidable. In this
mechanical failures, but not so high as to miss the failure prior case dummy crosshead shall be used to reduce vibration. Also
to catastrophic release [9]. Proximity probes are typically spring-mass-spring system shall be studied for passive force
located under the piston rods [9] and used to measure the rod counter balance and more reduction in vibration, where
position and determine wear of the piston and rider bands, dummy crosshead is, on the one hand, flexibly attached to a
malfunction e.g. cracked piston rod attachment, a broken movable piston assembly and on the other hand, to the
crosshead shoe, or even a liquid carryover to a cylinder. stationary compressor casing using auxiliary mechanical
Optimum figure: just for alarm and not for shut down. springs.
Optimum cold run outs and normal conditions operating run
outs are about 50 micrometers (2 mils) and on the order of 50 J. Future Expansion
to 150 micrometers (2 to 6 mils) peak to peak, respectively Future expansion planning can save money and time if
[9]. process changes (capacity increase, molecular weight increase
due to catalyst change, etc) are foreseen [12]. Optimum
F. Valve Selection
selection is sizing cylinders for economical operation at the
Cylinder valves are the most critical components of present rate. The frame can be sized for future
reciprocating compressors and strongly influence the applications. When the future conditions become a reality,
reliability and efficiency [5]-[8], [10]. Valve defects are the cylinders can be changed while keeping the same frame.
obviously responsible for most of the unscheduled Generally it is optimum to over size the journal diameter
maintenance events [5]-[8], [10]. Three main valve types: ring include margins for future development, thus ensuring that
type, ported plate and poppet. For big machines (generally crankshaft size would never become the first important
low speed and high pressure ratios) and small machines limitation of the design [15].
(relatively higher speeds) ring type valves and plate type
valves are optimum choice respectively. Optimum valve III. COMMERCIAL OPTIMUM CONDITIONS
size shall be obtained with respect to efficiency, reliability and
performance requirements including minimum clearance A. Commercial Conditions
volume. Lift is the distance travelled by the valve moving It is absolutely necessary to receive at least three proposals
elements. The higher the lift, the higher the valve flow area, and have minimum two technically accepted offers for main
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components and equipment. It is completely justified to to be equal to or greater than the compressor crankshaft
extend proposal dead time, clarification time, accept optimum diameter.
configuration, reasonable deviations and attend extensive Generally coupling shall be capable to allow continuous
clarification meetings to have at least two clarified and operation with twice the estimated cold-to-hot thermal growth.
technically accepted proposals. The coupling to shaft connection shall usually be rated for a
minimum of 125% of the maximum driver power. Numerous
B. Delivery
torsional vibration problems continue to occur in compressor
Small and medium machines shall be delivery fully trains. Main reasons are lack of comprehensive torsional
fabricated as one skid mounted package. For very big vibration analysis and study, improper application and
machine, optimum figure is to deliver machine maintenance of coupling (mainly flexible couplings) and lack
prefabricated (including crankcase, distance pieces, etc) of monitoring.
while cylinders are dismantled. Assembled cylinders are Shaft materials should be high strength steel. If welds are
delivered to site separately and installed. Sometimes it is required on shaft, a weld-able shaft material should be used.
required to offer all site supervision work for cylinder Proper weld procedures and material compatibility must be
installation as closed price. considered. Fabrication details such as the electric machine
pole bolt torque, etc should consider loads due to torsional
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IV. AUXILIARIES AND ACCESSORIES vibration. Avoid full load shutdowns for compressor
especially in train with torque sensitive equipment. Some
A. Lubrication System
designers offer to use stiff system with short flanged
API 614 is typically applied only to reciprocating connection (no coupling) and single bearing electric machine.
compressor trains involving a large turbine driver and gear These designs have much lower damping however higher
unit [11]. Optimum oil system shall include two oil pump, natural frequencies (more rugged, less elasticity and
both sized at least 20% over (Two motor driven identical with damping). These designs may be acceptable after careful
run down tank, or well known crankshaft driven main oil review of torsional analysis including all possible operating
pump, supplying UPS power for one pump is not acceptable steady state and transient torsional situations.
alternative), dual removable bundle shell and tube oil coolers It is important to measure and verify torsional vibration
(TEMA C) and double oil filters with removable element and during performance test. Based on site observations following
stainless steel piping. transient events are critical and shall be respected in details:
B. Coupling and Torsional Analysis start up, short circuit, machine possible malfunctions (such as
Usually the potential exits for torsional resonance and valve failure in reciprocating compressors) and loaded shut
torsional fatigue failure [2]. Coupling is best available option down. A train which passes through a torsional natural
for modification to tune the system. Coupling option: 1- High frequency during start up may produce significant transient
torsional stiffness coupling (it is optimum if allowed by shaft stresses. If the system is started on a frequency basis, a
torsional analysis). 2- Flexible coupling (more elasticity and start up analysis should be performed to determine if low
damping and more maintenance). 3- Direct forged flanged cycle fatigue is a potential problem. Coupling torque is
rigid connection (no coupling), with single bearing motor. usually chosen on the basis of mean requirements for full
Coupling for special purpose machines shall be as per API load. It must have a sufficient service factor to handle and
671. likely overload (such as electrical faults). Minimum
Typically, for reciprocating compressor, lateral natural recommended service factor for special purpose units is"1.75".
frequencies will be positioned well above significant torsional C. Coolant System
natural frequencies, so lateral critical studies are not Liquids should never form inside the cylinder [10]-[12].
required. A stress analysis shall be performed if the torsional Liquid contributes to poor reliability, can cause high impact
excitation falls close to the torsional natural frequency to velocities, can lead to stressing of valve moving elements
ensure that the resonance will not be harmful for the system. (slugging) and reduce the lubrication effectiveness. For any
The torsional vibration analysis report shall include data used application, a good sized suction drum with a drain provision
in mass elastic system, display of force vs. speed, torsional shall be included [12]. It may be a part of pulsation control, if
critical speeds, deflection (mode shape diagram), worst case properly done. Cylinder cooling system must be monitored
design, upset condition results (such as start up, short circuit, and controlled. Coolant inlet temperature between 6 ºC and
electrical network faults, etc) and how the input data variance 16 ºC above inlet gas temperature [12]. For exotic gases or
will affect the results (sensitivity analysis). Continuous operations near critical areas, much care needs to be taken also
operation at torsional resonance shall be avoided. Changing make sure the thermodynamic model is proper.
the load sequence could help reduce torsional vibration.
Synchronous motor or system started on a frequency basis D. Pulsation Control
need more care (definitely need a transient torsional start up Optimum technique trends to dissipate less energy than
analysis). As a rue of thumb, electric motor shaft diameter reliance on special solutions such as orifices to control
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World Academy of Science, Engineering and Technology
International Journal of Economics and Management Engineering
Vol:3, No:4, 2009
pulsation levels [16]. Acoustic reviews shall be performed for this analysis is strongly influenced by the design of the
design and guarantee points as well as all other operating foundation especially for pile installation [18]. It is even more
cases and combinations of pressures, speeds and load steps important for packages mounted on offshore platforms, FPSO
[13]. Pulsation can also alter the timing of the valve motion (Floating Production Storage Offloading Vessels), modules
and decrease efficiency and reliability [5]. Preliminary mounted on steel structure, new and unproven skid design and
optimum value for maximum allowable peak to peak is where the local soil conditions are suspect. Skid lifting study
recommended as (1), in SI units, where "P1" and "PL" are (including lifting lug details and calculations review) is
percentage of average absolute pressure (%) and line pressure necessary. Transit study and environmental loading analysis
(Bara), respectively. are also recommended [18].
H. Barring Device
P1 (% ) =
6 (1)
(PL ) 3
1
When compressor stopped for an extended time, turn it
around a quarter turn every week by barring device. Manual
E. Pulsation Shaking Forces barring device is for small compressor. Pneumatic barring
Reduction of pressure pulsation can be accompanied by an device is for compressor rated over 750 KW, without area
increase in shaking forces (or unbalanced forces) [17]. It classification problem or intermittent power availability and
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illustrates that shaking forces shall be determined and preferred technically [11].
controlled and piping and vessels properly supported. The I. Special Tools
margin of separation between the mechanical natural Optimum check list for special tools [11] for big machines:
frequency (MNF) of system (including piping and bottles) and 1- bearing extractor 2- piston extractor 3- valve extractor 4-
excitation frequency is 20% and MNF shall be greater than piston fit up tool 5- hydraulic tightening system 6- crosshead
2.4 times maximum run speed [11], [18]. If not meet limits, assembling tool, 7- special lifting tools 8- partition plate
the force response (including stress analysis) is required. The assembling tools 9- mandrels for wear bands. For special
cylinder gas forces (also called frame stretch or cylinder tools, tool boxes required and they shall be delivered with
stretch force) can be significant source of excitation (can main machines, in separate and tagged boxes.
cause high frequency vibration on the bottles and piping close
to the compressor) and lead to excessive pulsation bottle J. Package General Arrangement
vibration even if the pulsation shaking forces meet limits. Layout is often complex and compromise must be made
Flow induced pulsation is rarely seen [17]. API 618 Design between the support requirements, process requirements,
Approach 3 and less rigorous analysis, to control pulsation vibration/pulsation conditions, access and maintenance.
and shaking (unbalanced) force levels and avoiding Optimum configuration is to install local panel near
mechanical resonance can result in an optimized design [17]. compressor package (around 200 mm away from package)
Pulsation and vibration analysis report shall include Time but on separate skid (frame) which is installed on
Domain (TD) and Frequency Domain (FD) simulations, Time foundation, to avoid vibration damage. For maintenance,
Domain (TD) plots of key forces and pressure pulsation, consider spool removal and avoid support removal. Access
dynamic pressure drop, models including mounting details required in front of cylinder for cylinder piston
(mounting plate, bolts, localized skid, etc) and shell flexibility dismantling and non-drive end of compressor. Pay
(nozzle connection flexibility), calculated cylinder stretch attention to minimum elevation requirement of pulsation
forces, mode shape of bottles and piping and compressor bottle suction flange to keep suction line "No Pocket".
stiffness assumption (compressor frame modeled as flexible
K. Piping Analysis
support) [18].
The thermal piping design often requires that flexibility be
F. Coolers added to the system which is counter to requirement for more
Inter stage cooler and after cooler shall be sized carefully. support and increase stiffness to meet vibration design. These
Undersized cooler can cause excessive pressure drop and analyses shall be conducted by same party to optimize design
power loss. Pulsation and shaking force studies are necessary iteration and result in an overall optimized system. Piping
to avoid vibration problem in cooler. Increased cooler cross thermal analysis is necessary [18] especially when the coolers
section area to decrease pressure drop can cause significant are off-skid, multiple compressors on a common header,
increase of shaking force and cooler vibration. Secondary extremely cold ambient temperature, or operation over a very
volumes may be studied to reduce this vibration however in wide range of conditions.
some cases it can not reduce it and modification of recycle
L. Cylinder Lubrication System
line are required to significantly lower shaking [17].
Using the proper type of lubricant as well as establishing
G. Dynamic Package Analysis the proper lubricant rates to the cylinder and packing can be
The dynamic package analysis shall include modeling and most important for machine reliability [10]. The life of the
simulation of the foundation at the same time. The accuracy of compressor valves, piston rings, rider bands, and pressure
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Vol:3, No:4, 2009
packing can all be significantly affected by the type and G. Machine Shop Run Test
quality of lubrication used. Too much or wrong type of Shop mechanical run test [11] is the first test after
lubrication can increase the effects of valve stiction (viscous manufacturing of machine and last test before delivery. Shop
adhesion) and reduction in reliability. Reliable lubrication test results, including vibration, may seem to have limited
system with optimum type and rate of lubrication shall be usefulness because supporting structure and operating
selected [10]. condition of the machine are different with final site
installation. However this test is a unique opportunity to find
V. PERFORMANCE defects in design and manufacturing phases while machine is
still in fabrication shop. Generally the lager the power per
A. Expected Pressure Drops
compressor throw leads to higher the dynamic forces and 370
Preliminary optimum pressure drop values: pulsation KW per throw or more is a high risk machine [20]. It is
dampeners and suppression devices: totally less than 1% justified and optimum to record and analyze shop run test
pressure, intercooler: 0.70 bar. The use of orifice plates, measurements (Kalman Filter can be used to optimally
especially on high-speed single-act compressor, can contribute evaluate machine dynamic characteristics based on measured
to significant pressure drops [13].
data).
B. Rod Load and Pin Reversal Details
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International Scholarly and Scientific Research & Innovation 3(4) 2009 247 scholar.waset.org/1307-6892/136
World Academy of Science, Engineering and Technology
International Journal of Economics and Management Engineering
Vol:3, No:4, 2009
International Scholarly and Scientific Research & Innovation 3(4) 2009 248 scholar.waset.org/1307-6892/136