PRESENTATION ON

RECIPROCATING COMPRESSOR

BY : S.G. Arekar
 What is compressor
 Gas compressor is a mech. Device that
increases pressure of gas by reducing its
volume
 Compressor are similar to pump that
increases the pressure of fluid and both
can transferred the fluid through pipe.
 Asgases are compressible the compressor
also reduces the volume of gas.
Two Basic Compressor Types

Type of
compressor

Positive
Dynamic
displacement

Reciprocating Rotary Centrifugal Axial

RECIPROCATING COMPRESSOR

 In positive displacement compressor successive

volume of gases are confined within a close
space and pressure is increased by reducing
volume of space

Reciprocating
 Positive displacement comp.
Rotary
 Principal element of reciprocating comp. are
1) Cylinder, Head , Piston, Inlet and outlet valves.

2)Power transmitting parts are such as Crank

shaft, Cross head Connecting rod and fly wheel.

3)Lubricating system
Reciprocating comp. are uses automatic spring
loaded valves which open only when the proper
DP exists across valve.
Reciprocating compressors are also
available in variety of types:

􀂃 Lubricated and non-lubricated

􀂃 Single or multiple cylinder
􀂃 Water or air-cooled.
􀂃 Single or multi stage

In the case of lubricated machines, oil

has to be separated from the discharge
air. Non-lubricated compressors are
especially useful for providing air for
instrumentation and for processes which
require oil free discharge. However non-
lubricated machines have higher specific
power consumption (kW/cfm) as
compared to lubricated types.
Capacity of a compressor is the full rated volume of
flow of gas compressed and delivered at conditions of
total temperature, total pressure, and composition
prevailing at the compressor inlet. It sometimes
means actual flow rate, rather than rated volume of

Inter-stage Coolers: Reduce the temperature of

the air before it enters the next stage to reduce
the work of compression and increase efficiency.
They are normally water-cooled.

􀂃 After Coolers: The objective is to remove the

moisture in the air by reducing the temperature
in a water-cooled heat exchanger
 19K3A SYNTHESIS GAS COMPRESSOR

14L62A : FROM
14P35 A : 14V61A
14L62B : 14V61B
14P35B :

CW

I II
I III
19I03A

COOLING WATER

TO
12T2A1
2T2B
 Function of 19K3 compressor

The non-condensable synthesis gas is collected

in 14V61 and
recycled back to 12T2 by the oil free
reciprocating compressor 19K3.

It is also useful in transfering deuterium from

one plant to another :
14 P35 of D2 rich plant is taken in line &
compressor is diverted to D2 lean plant
What is the type of the 19K3 compressor
 It is reciprocating non lubricated type of
compressor. Because its cylinder & piston
are not lubricated by oil. They are made up
of special Teflon material
 There are three stages in 19 K3 compressor
 Type of coupling V’ belt over fly wheel
 working pressure/temp of first, second and
third stage
 First stage : 50Kg/cm2 Temp. 1150C
 Second stage : 85Kg/cm2 Temp 900C
 Third stage : 120Kg/cm2 Temp 750C
 19 K3 A/B
 Rating : 110KW
 Type/Model : INDUCTION MOTOR
 Manufacturer : FUJI ELECTRIC
 Speed : 1000RPM
 Voltage : 415 V
 RPM motor/Comp. : 975/400
 Water requires at
Inter stage cooler
Rod packing
Oil cooler
Cylinder jacket
 Sealing & its gas pressure
From 26 unit syn. Gas header @29
kg/cm2 ,pressure lowered to 20Kg/cm2 for use
as seal gas.
 19K3A SYNTHESIS GAS COMPRESSOR ALARMS AND TRIPS
-------------------------------------------------------------------------------------------------------------------------------------------------------------------
TAG NO. DESCRIPTION ALARM TRIP
SETTING SETTING
--------------------------------------------------------------------------------------------------------------------------------

19 PAL 101A 1st STG SUCT PRESS LOW 12 KG/CM2 ---

19 PHA 103A 3rd STG DISCH PRESS HI 145 KG/CM2 ---

19 PHH 105A 3rd STG DISCH PRESS HI HI --- 155 KG/CM2

19 TAH 101A 1st STG DISCH TEMP HI 1600C ---

19 TAL 103A 2nd STG SUCT TEMP LO 370C ---

19 TAH 105A 2nd STG DISCH TEMP HI 1600C ---

 --------------------------------------------------------------------------------------------------------------------------------------
--
TAG NO. DESCRIPTION ALARM TRIP
SETTING SETTING
----------------------------------------------------------------------------------------------------------

19 TAL 107A 3rd STG SUCT TEMP LO 370C ---

19 TAH 109A 3rd STG DISCH TEMP H 160 0C ---

19 FAL 802A LOW CYL CW FLOW ALARM ---

19 PAL 602A LUBE OIL PRESS LOW 1.4 KG/CM2 ---

19 PLL 604A LUBE OIL PRESS LO LO --- 1.0 KG/CM2

14 LHA 33A/B 14V61 A/B LEVEL HI HI --- TRIP

 19K3 COMPRESSOR START- UP CHECK LISTDATE:

 1Check oil level  

 2 Vent valve Close 
 3 Suction valve from A-plant Open 
 4 Suction valve from B-plant Open
 5 Discharge Valve towards A/B plant Open 
 6 Bypass valve Open 
 7 Cooling water i/l and o/l valves Open 
 8 Manually develop oil pressure   Ok
 9 Compressor ready for start OK 
 10 Start after electrical clearance 
 11Oil separator drain valves Close 
 12Bypass valve Close 
1. 19K3 seal gas is taken from – 26 Unit Header

2. 19K3 having suction gas from - 14V61

What is the capacity of 19K3 - 329 Kg / hr

19K3 motor having electrical supply from - 415 V

Which oil used in 19K3 crank case - 220

 How the loading of 19K3 is done?
Ans:- When comp. is started the bypass v/v & clearance pocket v/v
are open, disch v/v kept close to avoid ingress of high pressure due
to check v/v passing possibility into LP side of compressor. First
bypass v/v is closed & when disch press is rising (just below final
disch. Pressure 115 kg/cm2 then open disch v/v. and bypass v/v
kept closed

Why second stage and third stage suction temperature should be

maintained slightly above than 40 degree centigrade and 50
degree centigrade respectively?
Ans:- Because at this temp the ammonia in the gas will condense at
the operating pressure because of saturation which will not desired.

What are the things you should ensure before stopping 19K3?
Ans:- Before stopping compressor ensure that clearance pocket &
bypass v/v is open i.e. comp is unloaded.
Discharge pressure is coming down but suction pressure is
constant. What is the reason and what is your action?
--:Tube leak is suspected in interstage cooler, Start stand by
compressor & stopped running compressor to attend job if leak is
confirmed.

Suction pressure of 19K3 is increasing, what may be the reason?

--:-1)Suction strainer is choke 2)bypass v/v is passing /crack
open ,3)seal gas pressure is high,4) over all 14 unit pressure was
increased 5) v/v plates of compressor stage 6) d/s of SV may be
passing & stage is not compressing 7) Malfunctioning of 14PCV
35A/B.

Relief valve in 19K3 circuit started blowing. What is the reason

and what is your action?
--: 1) Disch v/v not sufficiently open 2)V/V plates of comp. may be
passing 3)SV may be passing 4) Stage is not compressing 4)
Malfunctioning of 14PCV 35A/B
Action :- Stop compressor/ stop s/b compressor
 As soon as started 19K3 a knocking sound started, what is your
action?
Ans:- Stop comp. immediately sound may be because of liq. Carry over
from plant, if liq is there flush the liquid & restart. Or sound may be due
to mech. damage of any part, Do barring check free operation & restart.
Cylinder temperature is in increasing trend, what may be the
reason?
Ans ;- 1) CW flow to cylinder is less clean i/l strainer 2)Very high comp.
ratio 3) Check for cylinder v/v passing 4) Adjust suc. Temp by adjusting
CW flow in inter stage cooler.
Pressure of motion work lubrication is too low. What may be the
cause?
Ans:- 1) Check oil lvl 2) Strainer in oil circuit may be chocked 3) Oil SV
passing
25.Oil level in crankcase is rising on draining a small sample is it
found water, what is the reason?
Ans:- Oil cooler is leaking.
26. How is the suction pressure controlled for 19K3?
Ans:- Suction pressure is controlled by use of 14PCV35 which is installed
on 12V2 to 14V61 line.
26.What are the faults on which 19K3 will trip for safety purpose?
Ans:- 1) Disch press too high 2) LO press. Very low 3)14V61 lvl very hi
4)Motor over load
27.Where is the down stream of safety valves of 19K3 discharge
connected?
Ans:- The down stream of safety valves of 19K3 discharge is connected to
suction of compressor at 1st stage.

28.What is the function of 19K3 compressor & its Operating press. Temp
Ans:- The uncondensed syn gas collected in 14V61 is taken to self lubricated
reciprocating compressor 19K3 & disch. Tower 12T2.It is also useful in
transferring deuterium from one plant to other by taking 14P35 of D2 rich
plant is taken in line & comp. disch diverted to D2 lean plant .

29. Why nitrogen is given to distance piece?

Ans:- To maintain inert atmosphere in distance piece compartment where rod
packing leak is coming.

26. How is the suction pressure controlled for 19K3?

Ans:- Suction pressure is controlled by use of 14PCV35 which is installed on
12V2 to 14V61 line.
26.What are the faults on which 19K3 will trip for safety purpose?
Ans:- 1) Disch press too high 2) LO press. Very low 3)14V61 lvl very hi 4)
Motor over load

27.Where is the down stream of safety valves of 19K3 discharge

connected?
Ans:- The down stream of safety valves of 19K3 discharge is connected to
suction of compressor at 1st stage.

28.What is the function of 19K3 compressor & its Operating press.

Temp
Ans:- The uncondensed syn gas collected in 14V61 is taken to self
lubricated reciprocating compressor 19K3 & disch. Tower 12T2.It is also
useful in transferring deuterium from one plant to other by taking 14P35 of
D2 rich plant is taken in line & comp. disch diverted to D2 lean plant .

29. Why nitrogen is given to distance piece?

Ans:- To maintain inert atmosphere in distance piece compartment where
rod packing leak is coming.
Function Of 20K4 Compressor

 Function of 20K4 comp. is to compress the

crack gas from 12T2 top (MP loop) pressure
@115Kg/cm2 to 12 T1 bottom (HP loop)@
200Kg/cm2 .
 There are 3 reciprocating 20K4 compressor are
provided
 20K41A for A plant
 20K41B for B plant
 20K42C can coupled to both A/B plants.
 Supply voltage of 20K4 compressor is 11KV.
 Induction motor :- Its RPM varies with as per
load

 Synchronous:-The synchronous motor runs

at consatant speed in synchronous with
stator speed & there is no slip
OR
Its RPM remain constant it will not vary with
power
 20K4 compressor
 What is the type of compressor

20K4 compressor is balanced type apposed ,

single stage two cylinder reciprocating
lubricated compressor .

Compressor max. capacity of 16.8 T/HR.

(SYNTHESIS GAS SATURATED WITH AMMONIA).
Compressor has pressure ratio of 2.11.
Compressor is having SYNCHRONOUS MOTOR
and it is electrically driven . Compressor is
having two lube oil pump, One shaft driven and
another electric motor driven auxiliary oil pump.
COMPRESSOR RATING : 11000 V, 1.45 MW

CURRENT : 83.5 AMPS

RPM : 333 RPM

TYPE : SYNCHRONOUS

L.O.PUMP RATING : 3.7 KW

L.O.PUMP SPEED : 1500 RPM

L.O.PUMP TYPE : INDUCTION MOTOR

CRANK-CASE : SS 220

HEAD TANK : SS 320

 20K4 ALARM & TRIP SETTINGS

TAG NO. DESCRIPTION ALARM TRIP

SETTING SETTING
--------------------------------------------------------------------------------------------------
-------------------
20 PSL104B SUCTION PRESS LOW 95 KG/CM2 ---

20 PSH107B DISCHARGE PRESS HI 270 KG/CM2 ---

20 PSHH101B DISCHARGE PRESS HI HI --- 280 KG/CM2

20 PSL601B LUBE OIL PRESS LOW 1.4 KG/CM2 ---

20 PSLL604B LUBE OIL PRESS LO LO --- 1.0KG/CM2

20 FSL801B CYL CW FLOW LOW ALARM ---

20 LSLL601B LUBE OIL H/TANK LVL LO --- TRIP

20 LSH101B 1st STG OIL SEPERATOR LVL HI ALARM ---

20 VSH601B CRANK CASE VIBRATION HI ALARM ---

 20K4 ALARM & TRIP SETTINGS

EXCITATION FAILURE --- TRIP

EXCITATION CUBICLE FAULT --- TRIP

20 TSH101-1B 1st CYL DISCH TEMP HI 1000C ---

20 TSH101-2B 2nd CYL DISCH TEMP HI 1000C ---

20TSH201.1-6B MOTOR WINDING TEMP HI 1200C 1300C

20 TSH 201.7B MOTOR AIR TEMP HI 1000C ---

20 TSH 201.8B MOTOR BEARING NDE TEMP HI 750C 850C

20 TSH 201.9B MOTOR BEARING DE TEMP HI 750C 850C

 .What is the function of unit 20K4 ? Why three compressors
are provided ?
Ans:- Comprssor is used for compressing the main Cr. Gas from MP
pressure to HP pressure . 20K4 compressor is balanced type apposed ,
single stage two cylinder reciprocating lubricated compressor . 20K41A is
used for Plant -A and 20K41B is used for Main plant -B. 20K42C can be
used for any plant. Compressor max. capacity of 16.8 T/HR. (SYNTHESIS GAS
SATURATED WITH AMMONIA). Compressor has pressure ratio of 2.11.
Compressor is having SYNCHRONOUS MOTOR and it is electrically driven .
Compressor is having two lube oil pump, One shaft driven and another
electric motor driven auxiliary oil pump.

How is the capacity controlled in 20K4

Ans:- By use of 20P01 control v/v
By use of loading /unloading of v/v of A/B cylinder & clearance pocket
v/v.

Why after coolers are provided?What is the temp. being maintained?

:- After cooler is provided in disch of 20K4 so as to bring down gas temp up to
value above saturation temp. this will reduce refrigeration load in plant too.

What is the material used to remove oil in20K4?

Ans:- activated carbon in felt baskets.
 Explain the start up &
subsequent transfer of control operation to control room.
Ans :- Capacity can control by 1) Use of 20P01 CV 2) By loading / unloading
v/v of A/B cylinder 3)clearance pocket v/v
Take clearance from electrical dept.
Start main motor of the compressor once starting its current gets
normalised, load the compressor as per instruction.
(Compressor loading - 25%, 50%, 75%, 87.5% OR 100%)
(Compressor should be loaded by opening wheels of suction v/v mounted on
compressor head and closing clearance pocket as per sequence given )
L: LOAD (N2- OUT FROM UNLOADER)
U: UNLOAD (N2-IN TO UNLOADER)
After loading the compressor, put auxiliary lube oil pump in auto mode.
While loading the compressor ,position loader/unloader knob on L.
After proper loading transfer control of bypass CV (20PCV01C)to control
room by positioning the switch on remote.

What is barring? What is its purpose? What is the frequency of barring?

:- A. keeping compressor in standstill condition for long time after
changeover, it is recommended to do the barring beacause some parts of
sliding & bearing areas are in dry condition even if lube oil pump is ON.
Rotate the compressor for a while by using barring gear to confirm nothing
wrong in all parts & t lubricate all sliding parts. After barring confirm
disengaged barring gear from crank shaft drive system Freq. of barring ones
in 48 hrs
What is the function of 20A01? What are the content in it?
Ans:-The purpose of 20A01A is to remove traces of oil in gas leaving 20K4,by absorbing
on activated charcoal.

Why there is no stand by for 20A01A?

Ans :- As life of activated charcoal is quite long as compared to the traces of oil carried
over, hence there is no s/b for 20A01,material are replaced periodically.

9.Why small amount of leakage gas from 20K4 is collected and recompressed to feed
back to the system.?
Ans:-Because loss of D2 rich gas is not affordable.

system.
 What are the oils used for 20K4 compressor?
 Ans;- Cylinder lubrication – Servo system 320
 Crank case – servo system 220
 Motor bearing – servo system 68
 What is your action when you see the discharge pressure is going high in 20K4?
 Ans :- The discharge pressure of 20K4 floats with the pressure of the HP loop. If HP loop
is rising then 20K4 pressure will increase. this may be happened due to closure of one
of the motorized v/v in the HP loop. Or restriction in discharge i/v of 20K4.
 Action:- Unload compressor to avoid tripping of compressor on high discharge pressure.
 What is function of pulsation dampener at suction and disch. Of 20K4?
 Ans:- As 20K4 is reciprocating compressor the pulsation dampener are provided to avoid
the pulsation in flow and therby giving constant flow. It also reduces the vibration in the
 Write the detail start up of 20K4?

:--Oil in cc (crank Case) level (Min.60%).

-Take cooling water in line
- Co- ordinate with control room for clearance
- check whether barring has been done in 48 hrs, if not barring
to be done.
- Turn on N2 gas to the distance piece.
- Pressurise the compressor by equaliser of suction i/v (at 60
KG/CM2 )
- Once compressor get pressurised (Full pressure is 110-120
Kg/CM2), Open suction/discharge v/v of compressor (Two
Each).
- Start auxiliary lube oil pump.
- Check oil supply pressure (2.5-3.5 Kg/CM²). Also check oil
filter DP (Should be <1 KG/CM²G).
 - Take clearance from electrical dept.
 - Start the main motor of the compressor once starting current get
normalised, load the compressor as per the instruction.
 (Compressor loading - 25%, 50%, 75%, 87.5% OR 100%)
 - After loading the compressor, put auxillary lube oil pump in auto mode
pump will automatically stop.
 - While loading the compressor loading the compressor position loader /
unloader knob on L’.
 - After loading transfer control of bypass CV (20PPCV01) to control room
by positioning the switch on remote.
 - Check the machine for any abnormality.
 - After ½ rs of running, take all readings and report abnormality if any.
 20K5C-LEAKAGE GAS COMPRESSOR

MANUFACTURER : FUJI ELECTRIC

RATING : 200 KW

TYPE : INDUCTION MOTOR

SPEED : 490RPM

L.O.PUMP SPEED : 1500RPM

L.O.PUMP RATING : 1.5KW

 20K5 ALARM & TRIP SETTINGS
TAG NO DESCRIPTION ALARM TRIP
SETTING SETTING

--------------------------------------------------------------------------------------------------------------
----
20 PSL 210C 1ST STG SUCT PRESS LOW 0.033 KG/CM2 ---

20 PSH 210C 1ST STG SUCT PRESS HI 0.7 KG/CM2 ---

20 PSH 207C 4TH STG DISCH PRESS HI 140 KG/CM 2 ---

20 PSHH 208C 4TH STG DISCH PRESS HI HI --- 145 KG/CM2

20 PSL 707C LUBE OIL PRESS LOW 1.4 KG/CM2 ---

20 PSLL 708C LUBE OIL PRESS LO LO --- 1.0KG/CM2

TAG NO DESCRIPTION ALARM TRIP
SETTING SETTING

20 FSL 904C CYL CW FLOW LOW ALARM ---

20 LSH 204C 1ST STG SUCT SEP LVL HI ALARM ---

20 LSLL 704C LUBE OIL H/TANK LVL LO --- TRIP

20 TSH 204C 4TH STG DISC TEMP HI 1850C ---

20 TAH 30 1.1C to 6C MOTOR WIND. TEMP HI 1200C 1300C

20 TAH 301.7C MOTOR AIR TEMP HI 1000C ---

20 TAH 301.8C MOTOR BEARING NDE TEMP HI 750C 850C

20 TAH 301.9C MOTOR BEARING DE TEMP HI 750C 850C


What is the purpose of 20V6?
Ans :-It is vessel before 1st suction of 20K5 bypass PCV
o/l,all SV release come back to it & mainly gas coming from
various D2 rich leakage point come into 20V6 & oil is
separated from gas in this vessel.

What are the pressure control arrangement installed on

20V6?
Ans :- Split control is provided.If pressure of 20V6 increases
above set point by pass v/v close up to 0-50%range of
controller,at 50% it closes full. If pressure is still increasing
vent v/v start opening from 50% onwards of controller range
.
What is the design & operating pressure of 20V6
Ans:- Operating 0.03Kg/cm2 min
Design 5Kg/cm2 max

What is the normal amperage of 20K5 motor?

Ans:- 50Amps
 What will happen to 20K5 leakage gas while 20K4is running and
20K5 is shut down.?
Ans –It will be vented from 20V6 vent.

Can 20K5 run with N2 without any modification

Ans –Yes we can run.

What is your action when temp. of any particular stage is rising

in case of 20K5?
Ans:- Check for v/v plate passing, Check inter stage cooler
performance &cooling water flow.

What are the trips of 20K5?

Ans;- 1st stage suction pressure lo lo,
Lube oil head tank level lo,
Motor overload
LO pressure lo lo
Disch. Press hi hi

What is oil used in 20K5?

Ans:- Cylinder lubrication – Servo system 320
Crank case – servo system 220