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compressors . All excel in their own operational niche within the world of industrial gas transfer , whether it be the ability to produce high flow at high pressure , high flow at low pressure , low flow at low pressure or low flow at high pressure . Again , the operational parameters of the process will provide a roadmap to the best compressor technology . Another significant factor is cost – especially in today ’ s world of highly scrutinised and controlled capital investment and operating budgets . Generally speaking , reciprocating piston compressors are among the most cost effective technologies available to the market . That being said , the operation ’ s process parameters and requirements will play a large role in the final cost of the equipment required for the application . Machines that must meet API-618 design requirements , for instance , will have a much higher purchase price than a non-API-618 design . While many systems will be able to use a ‘ standard ’ machine ‘ as is ’, once the proper one has been selected , there will always be some applications in which a specially designed or configured machine is required . In this case , there are bound to be added system costs as the compressor and / or system are modified to fit the unique needs of the operation .

Narrowing the focus

Even when it has been determined that a reciprocating piston compressor is the best choice for the operation , there are still other considerations to be made before making a final decision . Within the family of reciprocating piston compressors there are oil-free , non-lube , lubricated and oil-less designs . Again , knowing the operational parameters and requirements will create a path that leads to the selection of the proper technology . For example , the transfer of crude natural gas may not require an oil-free compressor because there are already impurities in the gas itself so that any small amounts of oil carryover from the compressor that enters the gas stream will not harm the product or the process . Emission compliance requirements , however , could mean that an oil-free design might still be the best solution due to its leak-control capabilities . In other words , why offer the customer a technology he doesn ’ t need ? Also , oil-free compressors are normally more expensive due to the elevated technical requirements of the oil-free design . An oil-free machine will usually always be required if the gas purity of the customer ’ s process gas must not be contaminated by the compressor . In these kind of application requirements , an oil-free

The different types of reciprocating piston compressors – oil-free , non-lube , lubricated and oilless – give the user options

compressor is usually an excellent choice . Another growing environmental consideration that may lead to the use of an oil-free compressor design is a fugitive emissions requirement that will require more comprehensive leakage control . Some lubricated compressor designs that require oil lubrication in the upper cylinder and valve area do not have a gas sealing section ( distance piece ). This design can be prone to significantly higher leakage rates , which can be an environmental hazard . With the increased scrutiny being given by regulatory agencies to fugitive emissions and leaks , operators must be aware of the repercussions . These can include significant fines and , in the worst-case scenario , shutdowns if their operations continue to fall foul of any regulatory mandates . So , if the choice is an oil-free reciprocating piston compressor the actual environmental operating conditions must also be considered . Oil-free designs have very specific discharge-temperature limitations . In this instance , the top end of the machine is designed to operate without lubrication , so it has non-metallic wear parts ( eg , piston rings , packing seals , etc ) that become sacrificial wear parts because they operate without any lubrication . By design , those parts will need to be serviced and replaced on a regular basis . Typically this is done as an annual ‘ preventative maintenance ’ programme . That ’ s the nature of the beast . In some applications where operating temperatures are low , and operating pressures and compressor rpms are in a moderate range , a user can see the compressor operate for a few years without any need for significant maintenance . In other applications where temperatures are high and pressures more demanding , the operator may only get 2,000 hours of service out of the compressor before it needs to have those top-end wear parts serviced . Note that this situation typically occurs in applications that have very high discharge temperatures that are driven by the overall compression ratio of the application . The bottom line here is that these possibilities must be communicated to the operator on the front end of the selection process in order to minimise complaints or recriminations on the back end . Finally , and most importantly , the performance of the reciprocating piston compressor must meet or exceed the requirements of the process that it is operating in . Often , this can mean that the compressor manufacturer will need to reach out to other professionals in the field – distributors , fabricators , system integrators , etc – for assistance in completing a turnkey gas compressor system for the application . In the end , everyone involved has the same end result in mind – getting the job done reliably , efficiently , safely and cost-effectively .

Conclusion

In the end , reciprocating piston compressors – like any comparable technology – are only effective in performing their duties if they are put in a position to be successful . Reaching a state of ideal operation can be attainable if the proper legwork is done to ensure that the compressor can satisfy the many unique and varied needs of the application . By asking the right questions , performing the required research and working closely with the customer and other channel partners the unknowns will be removed from the compressor-selection process , resulting in an optimized operation and contented clients .

Glenn Webb is the business development manager – Blackmer Compressors for Blackmer and PSG . For more information on Blackmer ’ s full line of pumps and compressors , visit www . blackmer . com

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