4-Gas Compressors

RECIPROCATING COMPRESSORS
Peru Talara
November, 2012
Copyright of INSERT COMPANY NAME HERE
1/6/16
SECTION OBJECTIVES
Overview of various compressor types
Picture or diagram of a reciprocating compressor, identify
the location and function of each part

Lubricated parts and Recommended Lubricants
1/6/16
GAS ENGINE + RECIPROCATING

COMPRESSOR
Gas Engine
The combination of gas
engine and reciprocating
compressor is the most
prevalent configuration in
the gas industry.
In most situations, a reciprocating

compressor driven by a gas
engine is the most economical
means to perform the required
compression.
Of course, a gas engine makes

perfect sense as a prime mover
because it is fueled by natural gas
a fuel that does not have to be
transported to the site because it
is already there!
Reciprocating
Compressor
1/6/16
Reciprocating Compressors
Compressor Types
Operation and Components
Lubrication
1/6/16
COMPRESSOR TYPES
Compressors are divided into
two major types, positive
displacement and dynamic.
STRAIGHT LOBE
ROTARY ROTARY SCREW
POSITIVE DISPLACEMENT
COMPRESSORS
Direct Increase in pressure

by reducing the volume of the
chamber in which a gas is
confined
ROTARY VANE
RECIPROCATING
CENTRIFUGAL
DYNAMIC
Increases gas pressure
by increasing the gas's
velocity
AXIAL FLOW
1/6/16
STRAIGHT LOBE
ROTARY
ROTARY SCREW
Positive displacement
compressors move a fixed
COMPRESSORS
volume of gas. For example, a
piston displaces a set volume
on each stroke. As a rotary
screw turns, it moves a set
volume of gas.
ROTARY VANE
RECIPROCATING
CENTRIFUGAL
DYNAMIC
AXIAL FLOW
1/6/16
DYNAMIC COMPRESSORS
STRAIGHT LOBE
ROTARY
ROTARY SCREW
Dynamic compressors use

velocity to move gas, much
COMPRESSORS
as a fan blows air. The
different types require
different lubrication.
ROTARY VANE
RECIPROCATING
CENTRIFUGAL
DYNAMIC
AXIAL FLOW
1/6/16
POSITIVE DISPLACEMENT ADVANTAGES

STRAIGHT LOBE
ROTARY
ROTARY SCREW
Reciprocating
High pressure / Multi-Stage /
COMPRESSORS
Portable
Straight Lobe & Helical Lobe
Portable / Easy to Lubricate
ROTARY VANE
RECIPROCATING
CENTRIFUGAL
Sliding Vane
DYNAMIC
Efficient / Small
Liquid Piston
High Volume / Easy to Lubricate
AXIAL FLOW
1/6/16
DYNAMIC ADVANTAGES
STRAIGHT LOBE
ROTARY
Centrifugal
Large volumes at low pressures at

high speeds.
COMPRESSORS
Axial Flow
ROTARY SCREW
ROTARY VANE
RECIPROCATING
Direct connected to turbines and

rotors with high volumes.
CENTRIFUGAL
DYNAMIC
AXIAL FLOW
1/6/16
Separable
Integral
1/6/16
10
Compressor Types
Operation and Components
Lubrication
1/6/16
11
RECIPROCATING COMPRESSORS
Reciprocating compressors take
rotary motion from the driver and
convert it into reciprocating motion
in the form of the motion of the
compressor's pistons.
The motion of the pistons reduces the volume of the gas and
therefore increases its pressure.
In contrast, a gas engine uses reciprocating motion to make
rotary motion.
Since both the gas engine and reciprocating compressor convert
between reciprocating and rotary motion, they each use many
similar components, including pistons, cylinders, valves,
crankshaft, crankcase, and connecting rods.
1/6/16
12
RECIPROCATING COMPRESSOR
Take a look, one by one, at the major components of a
reciprocating compressor.
1/6/16
13
The
Theconnecting
connectingrod
rod
transmits
power
transmits powerfrom
fromthe
the
crankshaft
crankshaft(input
(inputshaft)
shaft)to
to
the
thecrosshead.
crosshead.
Connectin
g Rod
1/6/16
14
Suction Line
Crosshead &
Crosshead
Guides
The
Thecrosshead
crossheadtransmits
transmitspower
powerfrom
from
the
theconnecting
connectingrod
rodto
tothe
the
compressor
compressorrod.
rod.Transfers
Transfersrotating
rotating
motion
motionto
tolinear
linearmotion.
motion.
The
Thecrosshead
crossheadisissupported
supportedby
bythe
the
crosshead
crossheadguide.
guide.
Connecting
Rod
1/6/16
15
Crosshead &
Crosshead
Guides
The
Thecompressor
compressorrod
rod
gives
givespower
powerto
tothe
the
piston.
piston.
Connecting
Rod
Compress
or Rod
1/6/16
16
Crosshead &
Crosshead
Guides
The
Thepistons
pistonstake
takepower
powerfrom
fromthe
the
compressor
compressorrod
rodand
andmove
movein
inthe
the
cylinder
cylinderto
toreduce
reducethe
thegas
gasvolume,
volume,
Connecting
which
whichcompresses
compressesthe
thegas.
gas.
Rod
The
Therings
ringswrap
wraparound
aroundthe
thepiston
piston
and
andare
arewhat
whatactually
actuallycontact
contactthe
the
cylinder.
cylinder.
Compressor
Piston &
Rings
Compresso
r Rod
1/6/16
17
Suction Line
Crosshead &
Crosshead
Guides
Gas
Gasto
tobe
becompressed
compressed(the
(the
suction
gas)
enters
the
suction gas) enters the
cylinder
cylinderthrough
throughthe
thesuction
suction
valves
valveswhen
whenthey
theyopen.
open.The
The
valves
valvesopen
openwhen
whenthe
thesuction
suction
line
linepressure
pressurebecomes
becomesgreater
greater
than
the
cylinder
pressure.
Suctio than the cylinder pressure.
Connecting
n
Rod
Valves
Compressor
Piston &
Rings
Compresso
r Rod
1/6/16
18
Suction Line
Discharg
e Valves
Crosshead &
Crosshead
Guides
Compressor
Piston &
Rings
The
Thecompressed
compressedgas
gas(discharge
(discharge
gas)
leaves
the
cylinder
gas) leaves the
Connecting
cylinderthrough
through
the
valves
thedischarge
dischargeRod
valveswhen
whenthey
they
open.
open. The
Thevalves
valvesopen
openwhen
whenthe
the
cylinder
cylinderpressure
pressurebecomes
becomes
greater
greaterthan
thanthe
thedischarge
dischargeline
line
pressure.
pressure.
1/6/16
19
Suction Line
Crosshead &
Crosshead
Guides
Suction
Valves
Pressure packing" is sometimes called "rod packing"
and
"oil wiper packing" is sometimes just called "wiper
packing".
Pressure
Packing
Compressor
Piston &
Rings
The
Thepressure
pressurepacking
packingisisaa
seal
the
sealthat
thatprevents
prevents
thegas
gas
Compresso
in
from
inthe
thecylinder
cylinder
from
r
Rod
entering
enteringthe
thecrankcase
crankcase
through
throughthe
thecompressor
compressor
rod
rodopening.
opening.
The combination of the "pressure packing" and the

"wiper packing" is called the "compressor packing" or
just the "packing."
1/6/16
20
Suction Line
Crosshead &
Crosshead
Guides
Suction
Valves
Oil Pressure
Wiper Packing
Packing
Compressor
Piston &
Rings
IsIsan
anoil
oilseal
sealthat
thatkeeps
keepscrankcase
crankcase
lubricant
lubricantfrom
fromgetting
gettinginto
intothe
the
pressure
pressurepacking.
packing.
ItItgets
getsits
itsname
namebecause
becauseititwipes
wipes
excess
excessoil
oiloff
offof
ofthe
thecompressor
compressorrod.
rod.
1/6/16
21
Suction Line
Crosshead &
Crosshead
Guides
Oil Pressure
Wiper Packing
Packing
Cylind Suction
Connecting
er Valves
Rod
Coolan
t Area Can you find the coolant area
Can you find the coolant area
under
underthe
thecompressor
compressor
cylinder?
cylinder?
Compressor
Piston &
Rings
Compresso
r Rod
1/6/16
22
RECIPROCATING COMPRESSOR 8
Suction Line
Crosshead &
Crosshead
Guides
Oil Pressure
Wiper Packing
Packing
Compressor
Piston &
Rings
Compresso
Cylinde Suction
r Rod
Connecting
r Valves Compressor
Frame
Rod
Coolant
Footings or
Area
nottorqued
torqued
Anchor IfIfnot
correctly,
correctly,
misalignment
misalignmentcan
can
result.
result.
1/6/16
23
Suction Line
Crankcase
Crosshead & Breather
Oil Pressure
Crosshead
Wiper Packing
Guides
Packing
Compressor
Piston &
Rings
The
Thecrankcase
crankcasebreather
breatherallows
allows
excess
air
in
the
crankcase
excess air in the crankcaseto
toescape
escape
and
andavoid
avoidcrankcase
crankcasepressure
pressurebuildbuildup
upthat
thatwould
wouldotherwise
otherwiserupture
rupture
seals.
seals.
Cylinde Suction
Compressor
r Valves
Frame Footings
Coolant
or Anchor
Area
Connecting
Rod
Compresso
r Rod
1/6/16
24
ANIMATION OF RECIPROCATING
COMPRESSOR
Horizontally opposed compressor
COMPRESSOR WITH INTERCOOLER
This is a two-stage compressor with intercooler.

Reciprocating compressors can have different shapes, but
the components are the same as in the previous slides.
1/6/16
26
COMPRESSOR WITH INTERCOOLER
An intercooler is necessary for good efficiency because

gas temperature increases when it is compressed. The
hotter the gas is, the more work it takes to compress
it.
The
Intercooler
cools
the gas between stages of
Copyright
of INSERT COMPANY NAME
HERE
compression so it will take less work in the next
1/6/16
27
STAGES & PISTON DIAMETERS

What is a 2-stage, 3-stage, or 4-stage compressor?
A 2-stage compressor raises the pressure of the gas twice (in 2
stages), while a 3-stage compressor raises the pressure of the
gas 3 times (in 3 stages), and so on.
In a 2-stage compressor, for instance, the gas will be
compressed in the 1st stage from one pressure to another
pressure, cooled in the intercooler and then compressed in the
2nd stage to a higher pressure. Multiple stages are used to
compress gas to higher pressures.
A compressor's number of stages can be determined by noting
the number of different piston diameters it has. If the
compressor uses pistons with three different piston diameters
then it's a 3-stage compressor.
(Note: The number of pistons a compressor has is not indicative
of whether a compressor is multi-stage.)
1/6/16
28
CAN YOU FIND THESE?
Can you find these?

Suction Valves
Crosshead & Crosshead
Guides
Connecting Rod
Piston & Rings

Compressor Packing
Compressor Rod
1/6/16
29
LUBRICATION AREAS
Reciprocating compressors have three distinct areas for
lubrication:
Crankcase (bearings, bushings, timing gears, crosshead

guides, etc.)
Packing (oil wiper packing and pressure packing)
Cylinders (cylinder walls, piston rings, and valves)
Although most compressors use the same oil to

lubricate all three (usually a gas engine oil), some
applications require that a different lubricant be
used to lubricate the packing and cylinders.
Many hydrocarbon compressors are moving toward
dry or non-lubricated packing. Cylinders are
sometimes lubricated by the material being
compressed.
1/6/16
30
CIRCULATION LUBRICATION
The 3 areas that need lubrication (crankcase, packing &
cylinders) are lubricated by two separate systems.
The first system is an oil circulation system that lubricates the

crankcase area. The oil circulation system uses an oil pump to
circulate oil from the pool of lubricant that fills the compressor
crankcase to the various lubricated components in the crankcase
(main bearings, rod bearings, crosshead guides, etc.).
1/6/16
31
FORCE FEED LUBRICATION
Force Feed
Lubricator
The second system is a force feed lubrication system that

lubricates the packing and cylinders (the other two areas) via
tubing. The force feed lubrication rate can be adjusted by the
operator to deliver more or less oil to the packing and
cylinders.
1/6/16
32
LUBRICATION
For the majority of compressors driven by gas engines, the oil
used in both the compressor crankcase (oil circulation system)
and in the force feed lubrication system (for the cylinders &
packing) will be the same as the oil used in the gas engine.
Of course, since integral compressors share their crankcase
with the engine, engine oil must be used in the circulation
system as there is no separate compressor crankcase.
If a separable compressor is turned by a gas engine, the
compressor crankcase will almost always use the same gas
engine oil the engine uses. However, if turned by an electric
motor or another driver, the compressor crankcase may be
filled with a circulating oil like? Mineral, PAO, PAG, compounded.
Reciprocating compressor crankcases typically use an SAE 30
(ISO VG 100) or an SAE 40 (ISO VG 150-220).
1/6/16
33
GAS ENGINE OILS

Gas engine oils are formulated for the engine rather than
the compressor.
The engine's operating conditions dictate the type of gas
engine oil recommended.
Once the engine oil
recommendation has been made,
the compressor's operating
conditions are analyzed to
determine whether the engine oil
can also be used to lubricate the
compressor.
In the majority of cases, the same
gas engine oil used to lubricate
the engine can also lubricate the
reciprocating compressor.
Gas Engine Oil is NOT THE
PRIMARY lubricant OEM
1/6/16
34
LUBRICATION
The force feed lubrication system (for packing and

cylinders) will usually use the same oil as the
compressor crankcase (usually gas engine oil, but
sometimes circulating oil).
The exception to this is when the gas will be
compressed above 1,000 psig (pounds per square inch
gauge) in pressure or when the gas is not pipeline
quality natural gas. In these cases, the TA and OEM
recommendation should be consulted to provide the
proper product recommendation*.
Lubricant selection is gas quality and discharge
pressure dependent
1/6/16
35
ALL LOSS SYSTEM

The force feed lubrication system to the packing and cylinders is
an
all loss system. This means that all oil supplied to the packing
and cylinders mixes with the gas and leaves with the discharge
gas into the pipeline.
Shell Technical Advisors can do compressor cylinder feed rate
studies (*) to:
a) Reduce oil usage
b) Improve valve life
c) Reduce problems down stream of the compressor due to
excessive oil
feed
Valve
(too much feed)
tosticking
cylinders.
Valve wear (not enough feed)
Improper feed rates can cause numerous problems, including:
High oil consumption (too much)
Problems downstream even flash fires
1/6/16
36
ARIEL CIGARETTE PAPER TEST METHOD

Checking cylinders for the proper lubrication rates, the cigarette
paper test method can provide a practical indication.
Remove a head end suction valve and position piston at inner
center, for the cylinder to be checked. Use two layers of regular
unwaxed commercial cigarette paper, together. Wipe the
cylinder bore at top with both papers using light pressure in
circumferential motion through about 20. The paper
next to the bore should be stained (wetted with oil), but the
second paper should not be soaked through.
Repeat the test at both sides of the bore at about 90 from the
top, using two new clean papers for each side. When the paper
next to the bore is not stained through, it may be an indication of
under lubrication. When both papers are stained through, it may
be an indication of over lubrication.
LUBRICANT GUIDANCE
Ariel Reciprocating Compressors
90% Market Share
10% Market Share

Cylinder Discharge Pressure
Gas Stream
<1000 PSIG
<(70 bar-g)
1000 to 2000
PSIG
(70 to 140 bar-g)
2000 to 3500
PSIG
(140 to 240 bar-g)
3500 to 5000
PSIG
(240 to 345 bar-g)
>5000 PSIG
>(345 bar-g)
Pipeline Quality
natural Gas
Including CNG
(Dry)
ISO 150
(R&O, Syn)
Morlina S2 B 150
Morlina S4 B 100 (PAO)
ISO 150-220
(R&O, Syn)
Morlina S2 B 150-220
(PAO)
ISO 220
(Compounded, Syn)
Gas Compressor Oil S3
PSN 220
ISO 320-460
(Compounded, PAG)
Omala S1 W 460
Omala S4 WE 150 (PAG)
ISO 460-680
(Compounded, PAG)
Omala S1 W 460-680
Natural Gas
(Water Saturated
and/or Heavy
hydrocarbons
Methane<90%
Propane>8%
SG>0.7)
ISO 150-220
(R&O, Syn)
(PAO)
ISO 220-320
(Compounded, PAG)
Omala S1 W 460
ISO 460-680
(Compounded, Syn)
Omala S1 W 460-680
(PAO)
ISO 680
(Compounded, PAG)
Omala S1 W 680
ISO 680
(Compounded, PAG)
Omala S1 W 680
Gas Compressor Oil S4 PN
220 (PAG)
Natural Gas
(Water Saturated
and Carbon
Dioxide
>2% to 10%)
ISO 150-220
(R&O, Syn)
(PAO)
ISO 150-320
(Compounded, Syn)
Omala S1 W 460
(PAO)
ISO 460-680
(Compounded, PAG)
Omala S1 W 460-680
ISO 680
(Compounded, PAG)
Omala S1 W 680
ISO 680
(Compounded, PAG)
Omala S1 W 680
220 (PAG)
Natural Gas
(Water Saturated
and Carbon
Dioxide
>10%)
ISO 150-220
(R&O, Syn)
(PAO)
ISO 150-320
(Compounded, Syn)
Omala S1 W 460
(PAO)
ISO 460-680
(Compounded, PAG)
Omala S1 W 460-680
ISO 680
(Compounded, PAG)
Omala S1 W 680
ISO 680
(Compounded, PAG)
Omala S1 W 680
220 (PAG)
Consult your Shell LTA for actual product recommendation
38
LUBRICANT GUIDANCE
Ariel Reciprocating Compressors
90% Market Share
10% Market Share

Cylinder Discharge Pressure
Gas Stream
<1000 PSIG
<(70 bar-g)
1000 to 2000
PSIG
(70 to 140 bar-g)
2000 to 3500
PSIG
(140 to 240 bar-g)
ISO 150
(Compounded, Syn)
ISO 150-220
(Compounded, Syn)
PSN 220
(PAO)
ISO 220
(Compounded, Syn)
PSN 220
Natural Gas
(Water Saturated
and H2S
>30%)
ISO 150
(Compounded, Syn)
ISO 150-220
(Compounded, Syn)
PSN 220
(PAO)
ISO 220
(Compounded, Syn)
PSN 220
Air or gas mixtures with

>4% oxygen
ISO 100
(Diester or Polyol ester)
Corena S4 P 100
ISO 150
Nitrogen
(Bone Dry - Contact Ariel)
ISO 150
(R&O, Syn)
Morlina S2 B 150
ISO 150-220
(R&O, Syn)
Natural Gas
(Water Saturated
and H2S
>2% to 30%)
3500 to 5000
PSIG
(240 to 345 bar-g)
>5000 PSIG
>(345 bar-g)
ISO 320
(Compounded, Syn)
Omala S1 W 460
ISO 460-680
(Compounded, Syn)
Omala S1 W 460-680
Morlina S4 B 220-320 (PAO)
220 (PAG)
ISO 320
(Compounded, Syn)
Omala S1 W 460
ISO 460-680
(Compounded, Syn)
Omala S1 W 460-680
220 (PAG)
ISO 150
ISO 150
ISO 150
ISO 220
(R&O, Syn)
Morlina S2 B 220
ISO 320
(R&O, Syn)
Morlina S2 B 320
ISO 460-680
(Compounded, Syn)
Omala S1 W 460-680

39
COMPARING VISCOMETRICS @ 300F

Shell product
Corena S4 P 100
Corena S2 P 150
Morlina S4 B 100
Morlina S2 B 150
Gas Compressor Oil S3 PSN
220
Morlina S2 B 220
Morlina S4 B 150
Morlina S2 B 320
Morlina S2 B 460
Omala S4 WE 150
Morlina S4 B 220
Omala S1 W 460
Omala S1 W 680
Morlina S4 B 320
Omala S4 WE 220
220
Morlina S4 B 320
Gas Compressor Oil S4 PV
220
Omala S4 WE 320
Omala S4 WE 460
Base
Fluid
Diester
Mineral
PAO
Mineral
Syn
Blend
Mineral
PAO
Mineral
Mineral
PAG
PAO
Ariel Type
Diester
Compressor
Syn
R&O
R&O
R&O
Syn
R&O
R&O
PAG
Syn
Compounde
Mineral
d
Compounde
Mineral
d
PAO
Syn
PAG
PAG
VI
78
52
130
95
cSt @ 149 C
(300F)
3.8
4.1
5.0
5.4
40C VG Class @
300F
(undiluted)
<150
<150
150
150
17.9
18.3
19.8
25
30
22.5
25.9
92
92
149
96
94
188
149
6.0
6.1
7.6
8.0
9.0
9.2
9.4
220
220
320
320
460
460
460
460
31.2
98
9.4
460
680
320
220
680
320
222
35.2
33.8
34.4
83
148
203
9.8
11.6
13.5
680
680
1000
ISO
100
150
100
150
cSt @
40C
100
155
100
150
cSt @
100C
10.2
12.1
12.8
15
220
220
150
320
460
150
220
211
220
150
320
460
136
220
460
PAG
PAO
PAG
Syn
220
460
198
460
34.8
45.5
223
155
14.3
15.0
1500
1500
PAG
PAG
PAG
PAG
PAG
PAG
220
320
460
190
321
460
36
52.7
73.2
200
230
239
15.2
20.6
27.9
1500
2200
>2200

40

4-Gas Compressors

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RECIPROCATING COMPRESSORS

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the location and function of each part

GAS ENGINE + RECIPROCATING

In most situations, a reciprocating

Of course, a gas engine makes

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ROTARY ROTARY SCREW

Direct Increase in pressure

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Dynamic compressors use

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POSITIVE DISPLACEMENT ADVANTAGES

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Large volumes at low pressures at

Direct connected to turbines and

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Copyright of INSERT COMPANY NAME HERE

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The combination of the "pressure packing" and the

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COMPRESSOR WITH INTERCOOLER

This is a two-stage compressor with intercooler.

COMPRESSOR WITH INTERCOOLER

An intercooler is necessary for good efficiency because

STAGES & PISTON DIAMETERS

CAN YOU FIND THESE?

Can you find these?

Piston & Rings

Crankcase (bearings, bushings, timing gears, crosshead

Packing (oil wiper packing and pressure packing)

Cylinders (cylinder walls, piston rings, and valves)

Although most compressors use the same oil to

The first system is an oil circulation system that lubricates the

Copyright of INSERT COMPANY NAME HERE

FORCE FEED LUBRICATION

The second system is a force feed lubrication system that

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GAS ENGINE OILS

The force feed lubrication system (for packing and

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ALL LOSS SYSTEM

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ARIEL CIGARETTE PAPER TEST METHOD

10% Market Share

Consult your Shell LTA for actual product recommendation

10% Market Share

Air or gas mixtures with

Consult your Shell LTA for actual product recommendation

COMPARING VISCOMETRICS @ 300F

Consult your Shell LTA for actual product recommendation

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