RECIPROCATING

COMPRESSORS
BASICS
PRESSURE

• Absolute & Gage

– Actual pressure → Absolute pressure
– Gage reading → Gage pressure
– Pabs = Pg + Patm (1.013 bar)
– Liquid calculations → gage pressure
– Gas calculations → absolute pressure
• Bar and Psi
– 1 bar = 14.5 psi
– 100 psi = 7 bar
– P = 50 psia = 3.5 bara
– P = 300 psig = 21 barg
TEMPERATURE

– Celsius & Kelvin (absolute)

• T(K) = T(C) + 273
• All calculations → Kelvin
– Fahrenheit & Rankin (absolute)
• T(R) = T(F) + 460
• T(F) = T(C) × 9/5 +32
• T(F) ≈ 2 × T(C)
IDEAL GAS LAW

𝑷∙𝑽=𝒎∙𝑹∙𝑻
𝐽
3
𝑃𝑎 𝑚 𝑘𝑔 𝑘𝑔 ∙ 𝐾 𝐾
÷ 𝑻𝒊𝒎𝒆

𝑷 ∙ 𝑸 = 𝒎ሶ ∙ 𝑹 ∙ 𝑻

𝑚3 𝑘𝑔
𝑠 𝑠
FLOW RATE

𝒎ሶ ∙ 𝑹 ∙ 𝑻
𝑸=
𝑷

V (Q) V (Q)

Compressor capacity → suction (inlet) flow rate

Qcompressor = 200 LPM → Qsuction (inlet)

STANDARD FLOW RATE

𝒎ሶ ∙ 𝑹 ∙ 𝑻𝒔 25o C
𝑸𝒔 =
𝑷𝒔 1.013 bar
STANDARD FLOW RATE: EXAMPLE

𝑨𝒊𝒓 𝑹 = 𝟐𝟖𝟕 𝑱/𝒌𝒈 ∙ 𝑲

𝑸𝒂𝒄𝒕𝒖𝒂𝒍 = 𝟐𝟎𝟎 𝑳𝑷𝑴
𝑷 = 𝟕 𝒃𝒂𝒓𝒂
𝑻 = 𝟐𝟕𝒐 𝑪

𝑷∙𝑸 𝑷𝒔 ∙ 𝑸𝒔
= 𝒎ሶ =
𝑹∙𝑻 𝑹 ∙ 𝑻𝒔

𝟐𝟎𝟎
𝟕 × 𝟏𝟎𝟓 ∙ 𝟓
𝟔𝟎 × 𝟏𝟎𝟎𝟎 = 𝟎. 𝟎𝟐𝟕𝟏 𝒌𝒈/𝒔 = 𝟏. 𝟎𝟏𝟑 × 𝟏𝟎 ∙ 𝑸𝒔
𝟐𝟖𝟕 ∙ 𝟐𝟕 + 𝟐𝟕𝟑 𝟐𝟖𝟕 ∙ 𝟐𝟓 + 𝟐𝟕𝟑

𝑸𝒔 = 𝟏𝟑𝟕𝟑 𝑺𝒕𝒂𝒏𝒅𝒂𝒓𝒅 𝑳𝑷𝑴

𝟔𝟎 𝒎𝒊𝒏/𝒉
×
𝟏𝟎𝟎𝟎 𝑳/𝒎𝟑
𝑸𝒔 = 𝟖𝟐. 𝟑𝟕 𝑺𝑪𝑴𝑯
COMPRESSION PROCESS

P2
h Enthalpy
𝑇ℎ𝑒𝑜𝑟𝑒𝑡𝑖𝑐𝑎𝑙 𝑃𝑊 ℎ2𝑠 − ℎ1
= 𝜂𝑖𝑠𝑒 =
𝐴𝑐𝑡𝑢𝑎𝑙 𝑃𝑊 ℎ2 − ℎ1
h2
h2s
ℎ = 𝑐𝑝 ∙ 𝑇

Theoretical

power
Isentropic

Actual
𝑇2𝑠 − 𝑇1 P1

power
𝜂𝑖𝑠𝑒 =
𝑇2 − 𝑇1
T2
𝛾−1
𝑇2𝑠 𝑃2 𝛾
= h1 Entropy
𝑇1 𝑃1
s
SELECTION OR
SIZING
Selection

Sizing
 Selection
&
Sizing
Selection

Sizing
Cylinder bore, number of stages, number of cylinders per
stage
RC MANUAL
SELECTION
 PROBLEM

❖ JOB:
❖ Compressing H2 from 10 bara & 47o C to 120 bara at a rate of 0.4 kg/s.
❖ REQUIRED:
o Select the suitable RC frame and size the cylinders in each stage.
❖ DATA:
o H2 (R = 4124 J/kg-K & γ = 1.4)
o Use the following brochure of Dresser-Rand

Stroke In. Number of Nominal Rated Max. Allowable Rod

Model Rated rpm
(mm) Cylinders Power hp (kW) Load lbs. (kN)
5D-VIP2 5 (127) 2 1875 (1398) 45,000 (200) 1500
5D-VIP4 5 (127) 4 3750 (2797) 45,000 (200) 1500
5D-VIP6 5 (127) 6 5625 (4195) 45,000 (200) 1500
6D-VIP2 6 (152.4) 2 1500 (1119) 45,000 (200) 1200
6D-VIP4 6 (152.4) 4 3000 (2237) 45,000 (200) 1200
6D-VIP6 6 (152.4) 6 4500 (3356) 45,000 (200) 1200
7D-VIP2 7 (177.8) 2 1800 (1343) 45,000 (200) 1000
7D-VIP4 7 (177.8) 4 3600 (2685) 45,000 (200) 1000
7D-VIP6 7 (177.8) 6 4800 (3580) 45,000 (200) 1000
NUMBER OF STAGES: CRITERIA
Prevent
lubricant breakdown
Maximum temperature < 150o C And hence:
Piston ring wear
Valve failure

P2
T

T2
T2s

𝑇𝑑 ≈ 𝑇2𝑠 P1

𝛾−1
𝑇𝑑 𝑃𝑑 𝛾
=
𝑇𝑠 𝑃𝑠 T1

s
 47o C 378o C
10 bara 120 bara

NUMBER OF STAGES: DECISION

Assume a single-stage compressor

(𝒓𝒑 = 𝟏𝟐𝟎/𝟏𝟎 = 𝟏𝟐)

𝑇𝑑 1.4−1 183o C 47o C

= 12 1.4 Td = 651 K = 378o C 34.64 bara 34.64 bara
47 + 273
Intercooler
Assume a two-stage compressor
(𝒓𝒑 = 𝟏𝟐 = 𝟑. 𝟒𝟔𝟒) 47o C 183o C
10 bara 120 bara
1.4−1
𝑇𝑑
= 𝟏𝟐 1.4 Td = 183o C
47 + 273
132o C
Assume a three-stage compressor 120 bara
𝟑
(𝒓𝒑 = 𝟏𝟐 = 𝟐. 𝟐𝟖𝟗)

1.4−1
𝑇𝑑 𝟑 1.4 47o C
= 𝟏𝟐 Td = 132o C
47 + 273 10 bara
 COMPRESSOR STAGES

47o C
52 bara
47o C 132o C
10 bara 52 bara

132o C
120 bara

132o C 47o C
23 bara 23 bara

Note: the number of

cylinders per stage is
undefined yet
INLET (SUCTION) FLOW RATES
𝑷𝟏 ∙ 𝑸𝟏 𝑷𝟐 ∙ 𝑸𝟐 𝑷𝟑 ∙ 𝑸𝟑
𝒎ሶ = = =
𝑹 ∙ 𝑻𝟏 𝑹 ∙ 𝑻𝟐 𝑹 ∙ 𝑻𝟑
𝟏𝟎 × 𝟏𝟎𝟓 ∙ 𝑸𝟏 𝟐𝟑 × 𝟏𝟎𝟓 ∙ 𝑸𝟐 𝟓𝟐 × 𝟏𝟎𝟓 ∙ 𝑸𝟑
𝟎. 𝟒 = = =
𝟒𝟏𝟐𝟒 ∙ 𝟒𝟕 + 𝟐𝟕𝟑 𝟒𝟏𝟐𝟒 ∙ 𝟒𝟕 + 𝟐𝟕𝟑 𝟒𝟏𝟐𝟒 ∙ 𝟒𝟕 + 𝟐𝟕𝟑
𝒎𝟑 𝒎𝟑 𝒎𝟑
𝑸𝟏 = 𝟎. 𝟓𝟐𝟖 , 𝑸𝟐 = 𝟎. 𝟐𝟑 , 𝑸𝟑 = 𝟎. 𝟏
𝒔 𝒔 𝒔
0.1 m3/s

0.528 m3/s

0.23 m3/s
SHAFT POWER

𝐶𝑜𝑚𝑝𝑟𝑒𝑠𝑠𝑖𝑜𝑛 𝑝𝑜𝑤𝑒𝑟 = 𝑚ሶ ℎ𝑜𝑢𝑡 − ℎ𝑖𝑛 = 𝑚𝑐

ሶ 𝑝 𝑇𝑜𝑢𝑡 − 𝑇𝑖𝑛

𝜸−𝟏
𝜸 𝒓𝒑 𝜸
−𝟏
𝑷𝒔𝒉 = 𝑷𝒊𝒏 ∙ 𝑸𝒊𝒏
𝜸 − 𝟏 𝜂𝑖𝑠𝑒 ∙ 𝜂𝑚𝑒𝑐ℎ

𝜂𝑖𝑠𝑒 ∙ 𝜂𝑚𝑒𝑐ℎ ≈ 0.82

𝟏.𝟒−𝟏
𝟏. 𝟒 𝟐. 𝟐𝟖𝟗 𝟏.𝟒 −𝟏
𝑷𝒔𝒉,𝟏𝒔𝒕 = 𝟏𝟎 × 𝟏𝟎𝟓 ∙ 𝟎. 𝟓𝟐𝟖 = 𝟔𝟎𝟏. 𝟔 𝒌𝑾
𝟏. 𝟒 − 𝟏 0.82

𝟏.𝟒−𝟏
𝟏. 𝟒 𝟐. 𝟐𝟖𝟗 𝟏.𝟒 −𝟏
𝑷𝒔𝒉,𝟐𝒏𝒅 = 𝟐𝟑 × 𝟏𝟎𝟓 ∙ 𝟎. 𝟐𝟑 = 𝟔𝟎𝟏. 𝟔 𝒌𝑾
𝟏. 𝟒 − 𝟏 0.82

𝟏.𝟒−𝟏
𝟏. 𝟒 𝟐. 𝟐𝟖𝟗 𝟏.𝟒 −𝟏
𝑷𝒔𝒉,𝟑𝒓𝒅 = 𝟓𝟐 × 𝟏𝟎𝟓 ∙ 𝟎. 𝟏 = 𝟔𝟎𝟏. 𝟔 𝒌𝑾
𝟏. 𝟒 − 𝟏 0.82

𝑷𝒔𝒉 = 𝑷𝒔𝒉,𝟏𝒔𝒕 + 𝑷𝒔𝒉,𝟐𝒏𝒅 + 𝑷𝒔𝒉,𝟑𝒓𝒅 = 𝟏𝟖𝟎𝟓 𝒌𝑾

 FRAME SELECTION

𝑷𝒔𝒉 = 𝟏𝟖𝟎𝟓 𝒌𝑾

Model Stroke In. Number of Nominal Rated Max. Allowable

Rated rpm
(Frame) (mm) Cylinders (throws) Power hp (kW) Rod Load lbs. (kN)
5D-VIP2 5 (127) 2 1875 (1398) 45,000 (200) 1500
5D-VIP4 5 (127) 4 3750 (2797) 45,000 (200) 1500
5D-VIP6 5 (127) 6 5625 (4195) 45,000 (200) 1500
6D-VIP2 6 (152.4) 2 1500 (1119) 45,000 (200) 1200
6D-VIP4 6 (152.4) 4 3000 (2237) 45,000 (200) 1200
6D-VIP6 6 (152.4) 6 4500 (3356) 45,000 (200) 1200
7D-VIP2 7 (177.8) 2 1800 (1343) 45,000 (200) 1000
7D-VIP4 7 (177.8) 4 3600 (2685) 45,000 (200) 1000
7D-VIP6 7 (177.8) 6 4800 (3580) 45,000 (200) 1000

So use frame 5D-VIP4

 COMPRESSOR SPEED

As the compressor speed increases, the shaking forces, friction

between piston and cylinder and valve wear increase
Criteria: piston speed
𝑁 𝑚
𝑃𝑆 = 2 × 𝐿 × ≤ 3.5 , 𝑓𝑜𝑟 𝑙𝑢𝑏𝑟𝑖𝑐𝑎𝑡𝑒𝑑 𝑐𝑦𝑙𝑖𝑛𝑑𝑒𝑟
60 𝑠
𝑚
≤ 3.0 , 𝑓𝑜𝑟 𝑛𝑜𝑛 − 𝑙𝑢𝑏𝑟𝑖𝑐𝑎𝑡𝑒𝑑 𝑐𝑦𝑙𝑖𝑛𝑑𝑒𝑟
𝑠
Depends on manufacturing technology
Model Stroke In. Piston speed
Rated rpm
(Frame) (mm) (m/s)
5D-VIP2 5 (127) 1500 6.4
5D-VIP4 5 (127) 1500 6.4
5D-VIP6 5 (127) 1500 6.4
6D-VIP2 6 (152.4) 1200 6
6D-VIP4 6 (152.4) 1200 6
6D-VIP6 6 (152.4) 1200 6
7D-VIP2 7 (177.8) 1000 5.9
7D-VIP4 7 (177.8) 1000 5.9
7D-VIP6 7 (177.8) 1000 5.9
 NUMBER OF CYLINDERS PER STAGE

𝑷𝒔𝒉,𝟏𝒔𝒕 = 𝟔𝟎𝟏. 𝟔 𝒌𝑾, 𝑷𝒔𝒉,𝟐𝒏𝒅 = 𝟔𝟎𝟏. 𝟔 𝒌𝑾, 𝑷𝒔𝒉,𝟑𝒓𝒅 = 𝟔𝟎𝟏. 𝟔 𝒌𝑾

Model Stroke In. Number of Nominal Rated Max. Allowable

Rated rpm
(Frame) (mm) Cylinders (throws) Power hp (kW) Rod Load lbs. (kN)
5D-VIP4 5 (127) 4 3750 (2797) 45,000 (200) 1500

𝑷𝒔𝒉 𝒑𝒆𝒓 𝒄𝒚𝒍𝒊𝒏𝒅𝒆𝒓 = 𝟕𝟎𝟎 𝒌𝑾 > 𝑷𝒔𝒉,𝒔𝒕𝒂𝒈𝒆

So use one cylinder per stage

CYLINDER DIAMETER: INLET (SUCTION) FLOW RATE

𝑁
𝑄𝑖𝑛 = 𝜂𝑣𝑜𝑙 ∙ 𝑉𝑑 ∙
60

𝜋 2
𝑉𝑑 = 𝐷 𝐿 × 2 × 𝑁𝑐𝑦𝑙
4
𝜸−𝟏
𝜂𝑣𝑜𝑙 = 1 − 0.03 − 0.03 − 𝒓𝒑 𝜸 −𝟏 ∙𝐶

P decrease &
T increase
inside cylinder
Slip (0.03→0.05)
P
Vstroke
Vloss

V
CYLINDER DIAMETER
1500
𝑄𝑖𝑛 = 𝜂𝑣𝑜𝑙 ∙ 𝑉𝑑 ∙
60
𝜋 2
𝑉𝑑 = 𝐷 𝐿 × 2 × 𝑁𝑐𝑦𝑙
4
𝜋 2
= 𝐷 0.127 × 2 × 1
4
𝜸−𝟏
𝜂𝑣𝑜𝑙 = 1 − 0.03 − 0.03 − 𝒓𝒑 𝜸 −𝟏 ∙𝐶
𝟏.𝟒−𝟏
= 1 − 0.03 − 0.03 − 𝟐. 𝟐𝟖𝟗 𝟏.𝟒 − 𝟏 × 0.12
= 0.9

𝑚3
𝑄1 = 0.528 → 𝐷1 = 0.34 𝑚 ≅ 14"
𝑠
𝑚3
𝑄2 = 0.23 → 𝐷2 = 0.225 𝑚 ≅ 9"
𝑠

𝑚3
𝑄3 = 0.1 → 𝐷3 = 0.15 𝑚 ≅ 6"
𝑠
RC SELECTION
USING
SOFTWARE