002 - Reciprocating Compressor

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Reciprocating Compressor Concept By Gholam Reza Khajeh1

Good Morning

Welcome to Johnson Control Training Courses


Courses Subjects

1. Reciprocating compressors

2. Screw Compressors

3. Screw Chillers

4. Screw Chillers with Variable Speed Drive.

5. Centrifugal Compressor

6. Centrifugal Chillers

7. Industrial Refrigeration

Exam for each course

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Training Means

Training Means : System Training

All Detail should read from specific chiller manual.

After this training you might need to work with one of experienced Service Technician / Engineers to be a

professional.


Reciprocating Compressor

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Four Basic Components

�Compressor(s)

�Condenser

�Evaporator

�Expansion Device

Refrigeration System


Refrigeration

Compressor

Condenser

Expansion

Valve

Evaporator

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Refrigeration Cycle

High-Pressure Vapor

High-Pressure Liquid

Low-Pressure Mixture

Low-Pressure Vapor

Condenser

Evaporator


Introduction to Compressor Types

� Positive Displacement

� Non Positive Displacement

Positive displacement compressors use a piston or other device to reduce the

volume of refrigerant vapor in a compressor chamber.

PROCESS:

� Power is applied

� Chamber volume is reduced

� Refrigerant pressure is increased

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Introduction to Compressor Types� Definition: compression chamber reduces in volume to compress gas

� Reciprocating

� Scroll

� Screw

� Unlimited lift

� Centrifugal (non-positive displacement)

compressors have a fixed amount of lift for a given set of operating conditions.


Hermetic Scroll

Semi-Hermetic

Reciprocating

Compressors

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J COMPRESSOR

Crankshaft and Bearings

Piston

Motor Housing

SuctionStrainer

Suction ServiceValve

Terminal Box

Motor WindingsCylinder Head

DischargeService Valve

Oil Pump

Sight glass

Un- loaders

Reciprocating Compressor Parts


Suction

How does it work?

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Volume Enclosed

How does it work?


Refrigerant GasCompressed

How does it work?

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Discharge

How does it work?


J COMPRESSOR

Crankshaft and Bearings

Piston

Motor Housing

SuctionStrainer

Suction ServiceValve

Terminal Box

Motor WindingsCylinder Head

DischargeService Valve

Oil Pump

Sight glass

Un- loaders

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Compression ratio Cr = discharge Pressure/ suction Pressure

Volumetric efficiency = 1- 0.05 x Cr

Swept volume 2 to 2400 m³/h

Rotation speed : until 1800 rpm

Single stage until Cr ≅ 6

Double stage Cr > 10 Compound

Maintenance: valve check 5000h

Crankshaft assembly 10000h

Compressor Parameters


Pistons and Connecting Rods

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Suction and Discharge Valves


Gudgeon Pin and Oil Pump

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Reciprocating Compressor Disadvantage

�More rotating parts�Lower reliability and efficiency�More Complex refrigerant piping�Higher Maintenance


� Cleaning Crank Case annually

�Cleaning Oil Strainer annually

�Oil Change annually

�Oil Analysis annually

�Suction Valve , Discharge Valve each 5000 Hrs

�Crank Case assembly each 10000 Hrs

�Cylinder Liner, Piston and Segment check each 20000Hrs

�Crank Case Heater

Periodic Maintenance Reciprocating Compressor

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Capacity Control �Expantion valve is a device to Maintains constant superheat on the evaporator. ( EXP is not a capacity controller)

� Capacity is a parameter of Compressor and it should be control inside the compressor.

� It may called some times as LOADING / Un LOADING compressor.

� The compressor is loaded when the solenoid is de-energized, and unloaded when the solenoid is energized.

� Unloading is accomplished by lifting and holding the suction valve off in its seat.

� All cylinders equipped with un-loaders will remain unloaded on start-up until the oil pressure has built up to normal.


Loading / Unloading StepsLoading & Unloading the compressor is depended to the number of the cylinder in compressor and it should be balance unloading, otherwise it will create the noise in compressor and finally chiller. In JCI- York technology the sequence should be adjust from the Opti-View panel as per the no of compressor cylinders.

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Load / Unload Solenoid Valves


Chiller

There are so many different type of the chillers therefore there are so many different type of the compressor with different number of compressors which might use in chillers.

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Reciprocating compressor inside view


Lets look inside a Compressor Click Here.

Note : This pictures are not JCI- York Compressors.

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Chiller

How do we able to control the compressor in a chiller ??


Electrical Control Cabinet

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Component locations

Power Board(APB)

Micro Board(AMB)

Input/Output Board(AIOB)

S1 Dip Switches

EPROM

RS485 (ISN)RS232 (printer)Selector Pin

System switchesS2 - S5

Clock jump contact& RT clock/battery back up


Questions ?

�Any question on Reciprocating Compressor working principle ??

� We will talk about complete control procedure on next sessions.

Thank you for your attention.

002 - Reciprocating Compressor

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