Distributor / authorized representative that deals with supply & delivery of reciprocating (piston) compressors to industrial enterprises of Russia
Engineering company ‘Intech GmbH’ LLC (ООО «Интех ГмбХ»), Russia, has been successfully working with a number of Russian industrial enterprises at the local market for more than 20 years. Since the company’s founding, it has acquired immense engineering experience, market reputation, and has realized more than a hundred large-scale projects at the industrial plants in Russia. Our company is continuously in search of new business partners, who consider Russian market investment-attractive and want to boost their sales in the region, as well as expand their field of activities and enter a new international level.Contents:
We are interested in cooperation with the manufacturers of reciprocating compressors (reciprocating compressor lines), who are looking for an official and reliable distributor to supply their equipment to the industrial plants in Russia.
The company’s top management and sales team are well acquainted with the Russian market, its mentality and laws; they also understand industrial specifics of the financial and economic activities of the Russian customers. All our sales managers have a large customer database, extensive experience of successful sales and well-established connections with the potential buyers of your reciprocating compressors. This allows our managers to promptly set out the most promising directions for promotion and to ensure a rapid entry of the products into the promising Russian market. Our employees, who are fluent in English and German, are focused on working at the international market with the supplies of foreign equipment.
Our team of experienced engineers, who can handle the most serious technical problems, constantly keeps in touch with the Russian customers, holds meetings and delivers presentations regarding the latest achievements of our manufacturing partners. They point out the engineering challenges and actively communicate with all the departments at Russian plants. That is why the specifics of doing a business in the Russian Federation are well-known to us, and we also know the equipment of the local industrial plants and their up-to-date modernization needs.
Once we become your authorized representative for reciprocating compressor lines in Russia, our marketing staff will carry out a market research in order to check the demand for reciprocating compressor lines, will submit a market overview for reciprocating compressors that you offer and evaluate the needs for this type of equipment at local plants. Our specialists will also estimate the potential and capacity of this market at local industrial plants. Our IT-team will start developing a website for your products in Russian. Our experts will assess the conformity between your reciprocating compressor lines and customer needs as well as analyze the common reaction to the new goods in general. We will look into the categories of potential customers, and pick out the largest and the most promising plants.
Upon becoming your authorized agent on the territory of Russia, ‘Intech GmbH’ LLC (ООО «Интех ГмбХ»), will obtain certificates, if required, for a batch of the goods or for various types of reciprocating compressors (reciprocating compressor lines) in compliance with Russian standards. We can also arrange the inspection in order to obtain TR TS 010 and TR TS 012 Certificates. These certificates provides permission to operate your equipment at all industrial plants of the EAEU countries (Russia, Kazakhstan, Belarus, Armenia, Kyrgyzstan), including the hazardous industrial facilities. Our company is eager to assist in issuing Technical Passports for reciprocating compressors as per Russian and other EAEU countries’ requirements.
Our engineering company ‘Intech GmbH’ LLC (ООО «Интех ГмбХ»), collaborates with several Russian design institutes in various industrial segments, which allows us to conduct preliminary design as well as subsequent design works according to the standards, construction rules and regulations that are applicable in Russia and other CIS countries. It also enables us to include your reciprocating compressor lines into the future projects.
The Company has its own logistics department that can provide packing service, handling as well as the most efficient and cost effective mode of transportation of the goods (incl. over dimensional and overweight goods). The goods can be delivered on DAP or DDP-customer’s warehouse basis in full compliance with all the relevant regulations and requirements that are applicable on the Russian market.
Our company has its own certified specialists who will carry out installation supervision and commissioning of the delivered equipment, as well as further guarantee and post-guarantee maintenance of reciprocating compressors. They will also provide necessary training and guidance for the customer’s personnel.
Overview: reciprocating compressors
The reciprocating compression unit is a positive displacement compressor equipped with a reciprocating compression system. This type of compressors was one of the first to be used in industries. Now they are actively used both in industrial production and for semi-commercial and domestic purposes.
The reciprocating compressor compresses and supplies air or liquids, such as oils, coolant, etc. under pressure. Reciprocating compressors are most likely to be used in areas, where the application is associated with high pressure.
The basic design elements of the reciprocating compressor are the working cylinder, piston, valves (discharge and suction) located on the cylinder cover. The reciprocating motion of the piston creates the required pressure of the medium in the compressor of this type. The crank mechanism together with the crankshaft cause the piston to reciprocate.
Compressors of this type can be equipped with one or more cylinders arranged horizontally/vertically/V-/W-shaped. These units can be of single or double action (if the piston runs with both sides) and differ in the type of compression: single-stage or multi-stage.
This type of equipment is usually equipped with the automatic performance control system in order to ensure a constant level of the pipeline pressure. The easiest way of control is to change the compressor shaft speed.
Reciprocating compressor units have a great diversity of models. The market offers a variety of options for any industrial purposes. There are many situations, in which reciprocating compressors would be the optimal solution:
- Need for a small-size compressor
- Big differences in the volumes of the produced compressed air (reciprocating compressors successfully cope with such situations)
- Operation in severe environment, such as work in dirty conditions, high humidity, changes in temperature (in cement packing, in mills, coal warehouses)
- Compression of corrosive gases
- For injecting high pressure, reciprocating units can have the design equipped both with one piston and with two or more (up to 40 atmospheres).
- Relatively inexpensive
- Simple maintenance (the internal operation mechanism is easy to understand)
- Suitable for high pressures.
Disadvantages include a lower level of efficiency, breakdowns that are more frequent, and noise.
The operation principle of the reciprocating (piston) compressor
The operation principle of the reciprocating compressor unit is quite simple. The classical model of the machine consists of the housing (made of cast iron), cylinder (arranged horizontally/vertically/tilted), piston, and valves (suction and discharge).
Reciprocating compressors consist of the working cylinder and piston, and valves (discharge and suction) located on the cylinder cover. The crank mechanism and the crankshaft join the operation to make the piston reciprocate.
The piston is driven by the direct drive of the crank mechanism. When reciprocating, it compresses the atmospheric air, and then pushes it to the connected main line zone. Below you can see the operation scheme of the reciprocating compressor:
The free space formed in the cylinder cavity when lowering the piston discharges the air. The resulting differential pressure opens the inlet valve, allowing the air to enter the chamber, where it is compressed. When the piston crosses the pivotal point corresponding to the maximum volume of the compression chamber, the inlet valve closes, followed by the air pressure increase.One shaft revolution is generally accepted for two piston strokes. A full compressor cycle is performed per one revolution of the shaft in each cylinder. When the piston goes right, the underpressure forms in the condenser over the piston zone, and the refrigerant vapors are sucked through the valve into the cylinder. When the piston goes back, the vapors compress and the pressure increases. The suction valve closes, the compressed vapors are pushed into the condenser, and then through the discharge valve. The piston then changes its direction, the discharge valve closes and the compressor again sucks vapors from the evaporator. The entire work process repeats in cycles repeatedly.
The smaller the volume of the chamber, the higher the air pressure. The discharge valve opens upon reaching the prescribed limits. At this point, the compressed air leaves the chamber cavity.
To reduce the wear of the cylinder walls and the piston, the cylinder unit is supplied with oil, which leads to the poorer quality of the supplied air that is mixed with small oil particles. Therefore, if the manufacturing process uses clean air, it is necessary to install the oil separator in the supply line. The separator helps to remove oil particles from the airflow.
Reciprocating compressors used in factories and industrial plants are not intended to operate alone, usually they are bought in pairs. In the normal operating mode, one of them is in the reserve and may undergo maintenance or repairs, and the second one, of course, serves its industrial purpose.
Main components and design features of reciprocating compressors
Reciprocating compressor units are the most common type of equipment capable of compressing the air. Their operation principle is as follows: The cylinder sucks in a certain amount of air, which is then compressed by the piston in motion. For the compression, it is possible to use both sides of the piston (the so-called principle of double action). The two-stage reciprocating compressor unit produces air with high levels of quality and is massively used in industrial processes, where there are strict requirements for the technology compliance.
The key components of the reciprocating compressor design are the piston, cylinder, chamber, crankshaft, crank mechanism, valves (intake and exhaust), and the drive (electric, petrol or diesel).
The design of these compressors is simple; repair and replacement of spare parts are easy to perform. However, such equipment requires regular maintenance.
Types of reciprocating (piston) compressors
Currently, the market offers a wide variety of modifications of reciprocating compressors. There are many models of single-stage, multi-stage compressors, with single-side or two-side suction, open-type and semi-hermetic compressors, etc. Some reciprocating compressors have to be lubricated with mineral oils, others do not. The main models of reciprocating compressors can be classified by the drive type, final pressure level, number of compression stages, and the design version.
There are the following types of reciprocating compressors:
- Single-action (closed-crankcase) or double-action (open-crankcase)
- Oil-filled and oil-free (dry friction or dry compression)
- With horizontal, vertical or angular arrangement of cylinders
- By the number of stages - multi-stage or single-stage
- With different number of cylinders.
By the drive type, the compressors are divided into:
- Direct-drive units (ensure significant energy savings, show a lower noise level relative to belt-driven units, and have a higher level of efficiency)
- Belt-driven units (show lower dynamic loads at the startup due to the slippage of the belt drive).
By the outlet pressure level, reciprocating compressors are divided into low-pressure units (from 5 to 12 bar), medium-pressure units (from 2 to 100 bar) and high-pressure units (from 0 to 1000 bar).
By the number of compression stages reciprocating compressor units can be multi-stage, double-stage and single-stage. In the multi-stage compressors it is important to avoid an excessive increase of the compressed gas temperature (not more than 180°C), since there is a risk of explosion and fire.
By the design version, these machines are divided into stationary and mobile (portable) units.
By the arrangement of cylinders, reciprocating compressors can be vertical, horizontal and angular.
Multiple-step piston (differential)
|Double-action compressor (open-crankcase)|
Horizontal stepped pistons
With opposed cylinders
Angular arrangement. In some rows cylinders may be arranged vertically, while in others horizontally. In this case, we are talking about rectangular compressors. The arrangement of cylinders can be V-shaped and W-shaped (so, by the cylinder arrangement compressors can be of V-type and W-type, respectively)
- Compressors for air
- Single-stage refrigerating compressors (ammonia or freon)
- Double-stage refrigerating compressors (ammonia)
Vertical arrangement. Vertical units have vertically arranged cylinders. The number of cylinders determines the application of the compressor and the discharge pressure. The figure below shows the open-crankcase compressor of double action. The cylinders are fixed on the frame (material: cast iron, molded) in several rows. The number of rows corresponds to the number of cranks in the crankshaft located on the main bearings. The length of the crankshaft and distance between cylinders determine the required number of bearings. The motor drive via a coupling or the V-belt transmission. The flywheel is a half-coupling on the shaft. The drive pulley is mounted on the shaft end.
Horizontal arrangement. In horizontal compressor units, cylinders can be arranged on the crankshaft on one side and on both sides.
Opposed design (arrangement of cylinders on both sides of the crankshaft) of reciprocating compressors of medium and high performance is a result of technological progress. The pistons move towards each other. Such compressors are characterized by high dynamics and balance, compactness and lightweight.
Small and medium units are rectangular in design and have Y-arranged cylinders. Due to the improved performance, opposed compressors are more frequently used than standard ones.
Here is an example of the horizontal open-crankcase double action compressor with the opposed arrangement of cylinders. The pistons move in mutually opposite direction. Such structures are compact and have a greater speed of operation. The installation of such units is simple thanks to the convenient arrangement of the equipment between the stages and mains. When delivered the compressor parts can be supplied in preassembled units.
Types and designs of reciprocating compressors
Any type of compressor or compressor unit is intended to compress and supply air (any gas) under pressure. The reciprocating compressor is a compressor, the piston of which reciprocates while being in the cylinder.
Users in the CIS countries prefer reciprocating compressors as the most known among machines with a capacity of 100 cubic meters per minute.
There are reciprocating compressors of the following types:
Coaxial reciprocating compressors
Coaxial compressors are characterized by the fact that the coupling connects the crankshaft with the electric drive, which ensures the exclusion of power losses due to friction. The design of such compressors is quite compact. These compressor units differ in lubrication methods. The piston-cylinder group of oil-free compressors does not require lubrication. The compressed air at the outlet of such devices has no oil impurities. Devices of this type are popular in the food industry, pharmacy, and medical industries. Oil-filled coaxial compressors use mineral compressor oil as a lubricant. Due to this, this compressor has a quite long service life. Coaxial compressors operate in the periodic mode, i.e. 20 minutes in operation, and 40 minutes of break. The operating pressure in this case amounts to 8bar. The motor power is approximately 2.25kW, and the capacity can reach 200L/min. The main advantages of these compressing devices include small size, lightweight, and relatively low price. Coaxial compressors are subdivided into oil-free and oil-filled reciprocating compressors.
This type of compressors is suitable for systems, where the supply of clean air is necessary. The air should be free of oil emulsion impurities. The motor for oil-free compressor devices has a capacity of 1.1kW, and they are equipped with receivers of various sizes. This type of compressors has its own positive features:
- Small size
- Do not require frequent maintenance
- Can be transported and moved in any position.
The oil-free compressor differs from the oil-filled compressor because the air and the lubricant inside "exist separately". Additional purification contributes to the high quality of the outlet flow. Oil-free compressors in their turn are subdivided into the following types:
- Automobile oil-free compressor is a compact unit designed for tire inflation. Usually it is not equipped with the receiver and is powered by a rechargeable battery.
- Residential compressor used to work with pneumatic tools, for example, spray guns. Oil-free reciprocating compressors constitute a separate category, performing, for example, high-quality painting, and thereby achieving perfectly painted surface. When using compact dehumidifiers, the dew point of which should not exceed 70 °С, the moisture is completely removed from the compressed air, which prevents it from getting on the surface painted by the compressor.
This fact contributes to the corrosion resistance of materials for paint coatings. Most of the imported vehicles and some vehicles of Russian manufacturers are painted in factories using oil-free compressors with adsorption dehumidifiers.
- Semi-professional and professional oil-free compressor used in workshops, laboratories, manufacturing plants, where the supply of large amounts of clean air is a must. These compressors are popular in the pharmaceutical and food industries. However, the price of oil-free compressors of this type is high.
Direct-drive oil-filled compressors
The receiver of this compressor, if any, can hold up to 100L of air, and the motor power is approximately 1.1-1.8kW. In comparison to oil-free compressor units, their service life is much longer. Moreover, oil-free compressors require specific maintenance. A negative factor of these compressors is the air containing oil emulsion at the outlet, which requires refitting of the compressor with a filter. Oil-filled compressors equipped with direct drives are widely used in the manufacture of furniture, in the automotive service, and in the repair work associated with the reconstruction of facades.
Belt-driven oil-filled compressors
The receiver of this compressor, if any, can contain up to 25L of air, and the motor power is approximately 1.5-15kW. Due to the belt drive, the motor speed can be reduced while keeping the same performance. These compressors have two pistons of different size. The first piston pre-compresses the air, and the second one brings the air to the desired pressure. These compressors are used when the air is consumed in large amounts. The reliable cooling system prevents the motor from overheating and wearing. This allows using the compressor motor in continuous operation.
Belt reciprocating compressors
Belt reciprocating compressors are characterized by the fact that the belt drive connects the crankshaft with the electric drive, which ensures high performance and long service life. Compressors of this type can operate for several hours straight. They are most frequently used in construction, tire service shops, and at service stations. The motor power is approximately 2.25 - 5.5 kW. The compressor capacity can reach 500L/min, the operating pressure reaches 16bar, in some cases up to 30bar. A positive aspect is the compression of air up to the required significant parameters.
Closed-crankcase and open-crankcase compressors
Closed-crankcase and open-crankcase compressors are distinguished among the modern designs of reciprocating compressors.
They are compactIn closed-crankcase compressors the rotational motion of the drive converts into the linear motion of the piston differently when compared to open-crankcase compressors. Closed-crankcase compressors have many positive features:
- Have a relatively simple motion mechanism
- Light weight
- Single lubrication system.
Along with the positive features, these compressors have a significant disadvantage: gas leaking into the crankcase through the piston. As a result, the crankcase operates under pressure, and the oil therein meets the pumped oil. Closed-crankcase compressors can be only of single action. This makes it impossible to use the cylinder effectively.
Therefore, high power and high-pressure compressors, as well as horizontal compressors, are always manufactured as open-crankcase compressors.
In addition to the above described classification, let us group reciprocating compressors by certain characteristics.
1. According to the principle of operation, compressors are subdivided into compressors with cylinders of single and double action. Only multi-stage compressors are equipped with differential cylinders.
2. According to the number of stages - one-stage, two-stage, three-stage compressors, etc. Modern compressors usually have up to seven stages.
3. According to the number cylinder units - one-, two-, three-cylinder and more.
4. According to the number of rows with cylinders: single-row, double-row and multi-row.
5. According to the arrangement of cylinders in the plane - angular compressors and compressors with the U-type cylinder arrangement.
6. Opposed compressors: horizontal devices equipped with pistons making the opposing motions.
7. According to the cooling type: with water and air cooling. Compressors of high performance are usually equipped with the water cooling.
8. According to the performance – mini-compressors, compressors of low, medium and high performance.
9. According to the number of pistons: one -, two-, and three-piston compressor devices.
To date, reciprocating compressors remain the most acceptable and common type of compressors for refrigerating plants. They are also widely used in air conditioning systems. There are the following types of reciprocating compressors:
- Hermetic reciprocating compressors. In this type of compressors, the motor is paired directly with the compressor itself, while being in a sealed stainless steel housing made of sheet steel. The flow of the suction gas cools the electric motor.
- Semi-hermetic compressor devices. The motor is directly connected to the compressor; they are disposed in a cast iron housing with an access for maintenance or repair work. The sucked refrigerant gas cools the electric motor.
- Open compressor devices. The compressor is placed directly in the cast iron housing with the shaft intended to connect it to a separate motor. Such compressor is equipped with an electronic emergency sensor for determining the insufficiency of the lubricant.
Advantages and disadvantages of reciprocating compressors
Reciprocating compressor equipment with capacity of up to 100 cubic meters per minute is the most popular on the territory of the former Soviet area. This is due to a number of advantages over similar products. So, this equipment is characterized by efficiency, reliability, simple design and ease of repair. Reciprocating compressors cope well with frequent switching, they are ideal for operation with interruptions, and operation in adverse conditions (high humidity, dirty air, etc.). This type of compressors can be started from any level of the initial pressure, and at the same time can generate a discharge pressure up to 1,000bar and above. Reciprocating compression equipment is also able to compress all types of gases (including corrosive, toxic and explosive), and is the best solution for working on objects that require small amounts of compressed air.
- Low price
- Lightweight design concept
- Reparability and long service life after the repair
- Increase in performance by means of service maintenance after 500 hours in operation
- Economical operation
- Fairly high performance
- Ability to maintain relatively low performance for a long time at the same level
- Relatively easily operated in the periodic mode, with the unit being frequently switched on and off.
Disadvantages of the reciprocating compressor
- The reciprocating compressor is very noisy and vibrates during operation; to install it you need separate premises equipped with a solid concrete foundation
- Low capacity (up to five cubic meters of air per minute)
- Limited field of application due to the low performance
- High power consumption
- Frequent maintenance: the maximum maintenance interval is 500 hours of operation
- Maintenance or repair requires multiple specialists.
Application of reciprocating compressors
Reciprocating compressors are commonly used in both the professional field and everyday life. As air pumps, they ensure operation of pneumatic devices such as pneumatic wrenches, spray guns, etc. They are used for tire inflation at service stations.
The reciprocating compressor with its simple design is the most common type of compressor devices today. Due to their technical parameters, compressors of this type are used in many areas of industry: in mechanical engineering, food industry, chemical industry and other areas.
Reciprocating compressors are used for pneumatic equipment, which does not require high consumption of compressed air per minute. Compressors of this type are also indispensable for obtaining high levels of the compressed air pressure. They are convenient to use when the equipment is to be frequently stopped, and, therefore, frequently started. In other words, they are resistant to transition process both of starting/stopping the compressor equipment. Compressors of this type have proven themselves in adverse operating conditions (too low or too high temperature, dusty media). Their application on cement trucks and flour trucks has no alternatives.
Specifications of reciprocating compressors
Specifications of various modifications of reciprocating compressors are significantly different. Therefore, this section presents the specifications in simplified form for three main groups of units: industrial, gas and mobile stations.
Industrial compressor stations operate at a pressure of 50 bar. The performance of such units is 350 m3/h, their power amounts to 30 kW at a speed of 500 rpm. These units are actively used in power plants, steel mills, for military purposes, in hydraulic systems, for filling of balloons.
The main parameters of reciprocating gas compressor stations are the gas compressor capacity and power. Depending on the size, such units are divided into small, medium and large. Thus, the gas compressor capacity ranges from 83 to 8098 nm³/hour depending on the size. The power may vary from 30 to 600 kW and depends on the size of the compressor.
The main technical parameters of mobile compressors are the pressure range of about 50 bar, capacity (within 37m³) and the nitrogen purity (up to 99%). The operating temperature is not less than -40ºС and not more than +40ºС.
The most appropriate model should be chosen taking into account the industry, application purpose, and operation conditions.
Application of reciprocating (piston) compressors
Reciprocating compressors are widely used in various industries, as well as in everyday life.
Therefore, industrial reciprocating compressor stations are operated:
- In power plants
- In the steel and engineering industry
- In the textile industry
- At military facilities
- As a part of hydraulic, refrigeration and cryogenic systems
- Used for filling of balloons.
Reciprocating compressors are designed for private use. Their reliability is almost equal to that of expensive industrial models. This type of equipment is used for cars painting, walls, parts sandblasting and so on. Oil-free reciprocating compressor units are used in cases where the compressed air must meet the highest quality standards.
Oil-free compressors of this type are used in medicine for filling the respirator balloons, where the pumped air must be clean without additional impurities (moisture, hydrocarbons, and oils).
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Upon becoming the official distributer of reciprocating compressors (reciprocating compressor lines), our company ‘Intech GmbH’ LLC (ООО «Интех ГмбХ»), carries out the following: finds the buyers of your products on the market, conducts technical and commercial negotiations with the customers regarding the supplies of your equipment, concludes contracts. Should a bidding take place, we will collect and prepare all the documents required for the participation, conclude all the necessary contracts for the supply of your equipment, as well as register the goods (reciprocating compressors) and conduct customs clearance procedures. We will also register a certificate of transaction (Passport of Deal) required for all foreign trade contracts in the foreign currency control department of the authorized Russian bank so that currency transaction could be effected. If required, our company will implement an equipment spacing project in order to integrate your equipment into the existing or newly built production plant.
We are convinced that our company ‘Intech GmbH’ LLC (ООО «Интех ГмбХ»), will become your reliable, qualified and efficient partner & distributor in Russia.
We are always open for cooperation, so let’s move forward together!