CHAPTER SEVEN

SELECTING A RECIPROCATING
COMPRESSOR

Chapter 7 – Selecting a Reciprocating Compressor

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 SELECTING A RECIPROCATING COMPRESSOR

7.1 Construction Standard

In selecting a reciprocating compressor for oil field production

applications, it is necessary to determine if the proposed service requires
features conforming to API 618, or AN 11P or if the compressor is built to
manufacturer standards and modifications for a proposed oil field usage are
satisfactory.

7.2 Process Design D a t a

When selecting a reciprocating compressor the process design data

required is necessary for the calculations needed. The input data required
is:
Qg = Gas flowrate, MMSCFD
Ps = Stage suction pressure, psia
Pd = Stage discharge pressure, psia
Ts = Stage suction temperature, °F

Gas properties - it is best to know the composition of the gas to be

compressed, but as a minimum the manufacturer will need to know the
specific gravity of the gas and the amount of H2S or CO2 present.

Chapter 7 – Selecting a Reciprocating Compressor

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 7.3 Choosing High-speed vs. Slow-Speed

When selecting a reciprocating compressor, the engineer must decide

whether to use a high-speed or a slow-speed unit. Advantages and
disadvantages of each type are discussed in chapter one (Introduction to
reciprocating compressors). Other factors affecting the decision are:
• Foundation considerations (Dirt, Gravel, Shell, Limestone, Concrete,
Barge or Offshore Platform).
• Transportation and/or lift equipment available to transport, install, and
service the unit.
• Duration of unit service.
• Delivery and timing of start-up (Integral units typically have longer
manufacturing lead time).
• Existence of similar or like units which can share spare parts,
maintenance training, special tools, etc.
• Preference and experience of operational staff.

7.4 Process Considerations

If a packaged compressor is desired, a flowsheet should be. Included

showing those items discussed in Section 5 which are required.

In some small field applications it may be acceptable to purchase a

standard package from a manufacturer. However, in most instances it will be
beneficial to specify the quality desired in fabrication, choice of materials,
and coating systems. Often the project engineer will want to specify scrubber
size and cooler size, and specify process Instrumentation, etc.

Chapter 7 – Selecting a Reciprocating Compressor

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 7.5 Construction Details

Construction details are best left to the manufacturer, who can

choose among the number and type of cylinders, etc.

A compressor data sheet, such as the example in Table 7.1, could be

used. Along with the compressor data sheet, an engine data sheet as
shown In Table 7.2 could also be used for the compressor driving
mechanism. Data for which there is a known value or preference can be
completed by the project engineer. The manufacturer completes the rest of
the data sheet, which can be used by the project engineer to evaluate
alternatives.

Chapter 7 – Selecting a Reciprocating Compressor

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 Example Compressor Data Sheet
I. General
Flowrate --------------- MMSCFD
Gas Specific Gravity ---------------
Suction Pressure --------------- psia
Discharge Pressure --------------- psia
No. of Stages ---------------
No. of Cylinders ---------------
Speed --------------- rpm

II. Cylinders 1 2 3 4 5 6
Suction Pressure, psia ---- ---- ---- ---- ---- ----
Discharge Pressure, psia ---- ---- ---- ---- ---- ----
Suction Temperature, °F ---- ---- ---- ---- ---- ----
Discharge Temperature, °F ---- ---- ---- ---- ---- ----
Cylinder Material ---- ---- ---- ---- ---- ----
Bore, in. ---- ---- ---- ---- ---- ----
Stroke, in. ---- ---- ---- ---- ---- ----
MAWP, psig ---- ---- ---- ---- ---- ----
Hydrostatic Test Pressure, psig ---- ---- ---- ---- ---- ----
Single or Double Acting ---- ---- ---- ---- ---- ----
Cylinder Weight ---- ---- ---- ---- ---- ----
Cylinder Volume
Fixed Head End, in3 ---- ---- ---- ---- ---- ----
Fixed Crank End, in 3
---- ---- ---- ---- ---- ----
Variable Head End, in 3
---- ---- ---- ---- ---- ----
Variable Crank End, in 3
---- ---- ---- ---- ---- ----
Number of Pockets per Cylinder ---- ---- ---- ---- ---- ----

III. Piston and Rod 1 2 3 4 5 6

Rod Diameter, in. ---- ---- ---- ---- ---- ----
Rod Packing
Type ---- ---- ---- ---- ---- ----
Manufacturer ---- ---- ---- ---- ---- ----
Piston Rings
Type ---- ---- ---- ---- ---- ----
Manufacturer ---- ---- ---- ---- ---- ----
Maximum Rod Load
Compression, lbs. ---- ---- ---- ---- ---- ----
Tension, lbs. ---- ---- ---- ---- ---- ----
Allowable Rod Load
Compression, lbs. ---- ---- ---- ---- ---- ----
Tension, lbs. ---- ---- ---- ---- ---- ----

Chapter 7 – Selecting a Reciprocating Compressor

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 IV. Valves 1 2 3 4 5 6
Number, Suction
Suction ---- ---- ---- ---- ---- ----
Discharge ---- ---- ---- ---- ---- ----
Size & Type
Suction ---- ---- ---- ---- ---- ----
Discharge ---- ---- ---- ---- ---- ----
Total Free Lift Area
Suction, in2 ---- ---- ---- ---- ---- ----
Discharge, in 2
---- ---- ---- ---- ---- ----
Valve Velocity
Suction, ft/min , ---- ---- ---- ---- ---- ----
Discharge, ft/min ---- ---- ---- ---- ---- ----

V. Actual Dimensions 1 2 3 4 5 6
Actual
Width, ft ---- ---- ---- ---- ---- ----
Length, ft ---- ---- ---- ---- ---- ----
Height, ft ---- ---- ---- ---- ---- ----
Minimum Req. for Maintenance
Width, ft ---- ---- ---- ---- ---- ----
Length, ft ---- ---- ---- ---- ---- ----
Height, ft ---- ---- ---- ---- ---- ----
Total Weight, lbs ---- ---- ---- ---- ---- ----
Max. Component Weight ---- ---- ---- ---- ---- ----
Component ---- ---- ---- ---- ---- ----

VI. Inlets and Outlets 1 2 3 4 5 6

Stage
Suction: Nominal Size, in. ---- ---- ---- ---- ---- ----
Rating ---- ---- ---- ---- ---- ----
Type(RF or RT) ---- ---- ---- ---- ---- ----
Discharge: Nominal Size, in. ---- ---- ---- ---- ---- ----
Rating ---- ---- ---- ---- ---- ----
Type (RF or RTJ) ---- ---- ---- ---- ---- ----

Table 7.1 - Example Compressor Data Sheet

Chapter 7 – Selecting a Reciprocating Compressor

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 Example Engine Data Sheet
I. General Data
Make and Model -----------------------
BHP @------ ft. Alt. & -------°F, -----------------------
Max. and min. speed, rpm's -----------------------
Critical Speeds, rpm's -----------------------
No. of Cylinders or Throws -----------------------
Bore and Stroke, in. -----------------------
Compression Ratio -----------------------
Peak Cyl. Firing Press. Max. Load, psig -----------------------
BMEP Max. Load, psi -----------------------
Exhaust Temp. Max. Load, °F -----------------------
Fuel Consumption Btu/Bhp/hr (LHV) -----------------------
Oil Pump gpm at max. and min. rpm -----------------------
Heat Rejection to Oil, Btu/hp-min. -----------------------
J.W. Pump gpm at max. and min. rpm -----------------------
Heat Rejection to Water, Btu/hp-min. -----------------------
Heat Rejection to Exhaust Btu/hp-min. -----------------------
Fuel Introduction Method -----------------------
Piston Material/Cooling -----------------------
Weight, lb (without radiator) -----------------------

II. Engine Valve and Cylinder Head Data

No. of Intake Valves per Cyl. -----------------------
Valve Port I.D., in. -----------------------
Valve Lift, in. -----------------------
Stem, Solid or Filled -----------------------
No. of Exhaust Valves per Cyl. -----------------------
Valve Port, I.D., in. -----------------------
Valve Lift, in. -----------------------
Stem, Solid or Filled -----------------------
Hydraulic Valve Lifters, Yes-No -----------------------

III. Frame and Running Gear Data

Crankshaft Mtl. -----------------------
Connecting Rod Mtl. -----------------------
Piston or Crosshead Pin Mtl./Hardness -----------------------
Main Bearing Mtl. -----------------------
Support Method (Bottom or Underslung) -----------------------
Main Bearing Diameter, in. -----------------------
Main Bearing No. and Length, in. -----------------------
Total Projected Area, sq. in. -----------------------
Cam Shaft Bearing Mtl. -----------------------

Chapter 7 – Selecting a Reciprocating Compressor

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 Con Rod Bearing Mtl. -----------------------
Con Rod Bearing Diameter, in. -----------------------
Con Rod Bearing Length, in. -----------------------
Projected Area, sq. in. -----------------------
Piston or Crosshead Pin Bearing Mtl. -----------------------
Piston or Crosshead Pin Diameter, in. -----------------------
Piston or Crosshead Bearing Length, in. -----------------------

IV. Unbalance Forces and Couples

Forces Horizontal, lb
Primary -----------------------
Secondary -----------------------
Forces Vertical, lb
Primary -----------------------
Secondary -----------------------
Couples Horizontal, lb ft.
Primary -----------------------
Secondary -----------------------
Couples Vertical, lb ft.
Primary -----------------------
Secondary -----------------------
Critical Speeds of Unit, rpm's -----------------------

Table 7.2 - Example Engine Data Sheet

Chapter 7 – Selecting a Reciprocating Compressor