Reciprocating compressors unloaders

Motor-driven reciprocating compressors above about 75 kW (100 hp) in size are usually equipped with a step control. This is in reality a variation of constant-speed control in which unloading is accomplished in a series of steps, varying from full load down to no load. Three-step eontrol (full load, one-half load, and no load) is usually accomplished with inlet-valve unloaders. Five-step eontrol (fuU load, three-fourths load, one-half load, one-fourth load, and no load) is accomphshed by means of clearance pockets (see Fig. 10-91). On some machines, inlet-valve and clearance-control unloading are used in combination. 

If turndown is a consideration, again the reciprocating compressor, with its many unloading options, does meet the challenge. This flexibility is difficult to achieve reliably in the dynamic machine and may require the compressor to operate at an unfavorable point on its characteristic curve. 

Reciprocating compressor capacity may easily be adjusted by changing compressor speed, changing compressor cylinder clearance, unloading compressor cylinder inlet valves, recycling gas from unit discharge to unit suction, or a combination of these methods. All these methods may be accomplished either manually by the operator or automatically by the control panel. 

Figure 11-21D. Helical rotors refrigerant compressors. (1) Cutaway of a 100-ton intermediate compressor. The intermediate Helirotor compressor has only three moving parts the two rotor assemblies and the capacity controlling slide valve. The general purpose Helirotor compressor has only four moving parts two rotor assemblies, the variable unloader valve, and the step unloader valve. Unlike reciprocating compressors, the Trane Helirotor compressor has no pistons, connecting rods, suction and discharge valves, or mechanical oil pump.

Motor-driven reciprocating compressors above about 75 kW (100 hp) in size are usually equipped with a step control. This is in reality a variation of constant-speed control in which unloading is accomplished in a series of steps, varying from full load down to no load. 

In the plant, we use the term unloading to indicate various ways of reducing the volumetric efficiency of a reciprocating compressor. There are two sorts of unloaders ... 

The second way to unload a reciprocating compressor is with valve disablers. Most of the unloaders you have on your compressors are likely of this inferior type. They typically consist of steel fingers, which are pressed down through the valve-cap assembly. The fingers prevent the valve plate from moving. These valve disablers are far less costly than an adjustable clearance pocket. They may be used on both the crank and head ends of the cylinder. They can reduce the gas flow through a cylinder to zero. 

Figure 3.24. Control of positive displacement compressors, rotary and reciprocating, (a) Flow control with variable speed drives, (b) Pressure control with bypass to the suction of the compressor, (c) Reciprocating compressor. SC is a servomechanism that opens some of suction valves during discharge, thus permitting stepwise internal bypass. The clearance unloader is controllable similarly. These built-in devices may be supplemented with external bypass to smooth out pressure fluctuations.

Many reciprocating compressors come equipped with unloading pockets. This is an open area at the end of the cylinder whose length is adjustable. The compressor piston cannot compress the gas in the unloading pockets. The purpose of the pockets is to allow the operator to decrease compressor capacity without wasting horsepower. If you are looking for maximum capacity, make sure these adjustable pockets are closed. 

Most large reciprocating compressors are equipped with pneumatically operated, automated unloaders. A malfunctioning unloader remains in an open position and thus reduces the capacity of the compressor. To identify this problem, proceed as follows ... 

The best way to unload a reciprocating compressor is to increase the cylinder clearance. When the piston completes the end of its stroke, the space between the piston face and the cylinder head is called the clearance. Increasing the clearance reduces the scfd flow of gas to a compressor running at a constant speed and a fixed suction pressure. The effect of adjusting the cylinder clearance is proportional to the suction stroke volumetric efficiency (Evs). Evs is calculated as follows ... 

For a constant speed driver such as motor, capacity of a reciprocating compressor can be controlled by Unloading inlet valve and/or unloaditig pockets or reservoirs at the cylinder. Lift suction valve (suction valve unloading) will prevent compression and open pocket to cylinder (clearance unloading) will increase cylinder clearance volume. Either action will reduce compressor capacity. If gas demand is intermittent, on-ofT control of motor can be used to control capacity. 

The first method is used most frequently. The next preference is for the last method, mostly used in small compressors due to problems with speed control of electrical motors. Other means of capacity control are very seldom utilized due to thermodynamic inefficiencies and design difficulties. Energy losses in a compressor, when capacity regulation is provided by lifting the suc tion valves, are due to fric tion of gas flowing in and out the unloaded cylinder. This is shown in Fig. 11-84 where the comparison is made for ideal partial load operation, reciprocating, and screw compressors. 

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