Basic Reciprocating Compressor Analysis

Windrock, Inc. Qualification Exam AQC1

2018

Version 6

Name: _________________________________________

Title: _________________________________________

Company: _________________________________________

Email: _________________________________________

Mailing Address _________________________________________

_________________________________________

_________________________________________

Work Phone: _________________________________________

Test Date: _________________________________________

Test Administrator: _________________________________________

Available Points: 75

Minimum Passing Score: 60

Number Missed: _________________________________________

Percent Right: _________________________________________

DIRECTIONS: Circle the letter of the most correct response:

1. The atmospheric pressure measured at the test site should 1 pt

a. Be corrected to sea level

b. Not be corrected to sea level

2. The gas compressibility factor is used to? 1 pt

a. compensate for the variable compression characteristics of the gas

b. modify the measured horsepower
c. modify the measured temperature
d. all of the above

3. The suction toe pressure can be measured at? 1 pt

a. Bottom Dead Center on the head-end

b. Crank-angle degree 0 on the head-end
c. Crank-angle degree 180 on the crank-end
d. Bottom Dead Center on the crank-end

4. Absolute pressure is? 1 pt

a. discharge toe pressure + internal cylinder differential pressure

b. atmospheric pressure + gauge pressure
c. gauge pressure + standard pressure
d. discharge pressure - suction pressure

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 A  B  C  D  E F

5. Identify the components labeled in the above figure: 6 pts

A. __________________________
B. __________________________
C. __________________________
D. __________________________
E. __________________________
F. __________________________

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 G  H  I  J  K L

6. Identify the components labeled in the above figure: 6 pts

G. __________________________
H. __________________________
I. __________________________
J. __________________________
K. __________________________
L. __________________________

7. To calculate the compressor compression ratio: 1 pt

a. Divide discharge gauge pressure by suction gauge pressure

b. Divide discharge volume by suction clearance volume
c. Divide discharge absolute pressure by suction absolute pressure
d. Divide cylinder displaced volume by total cylinder volume

8. To calculate compressor brake horsepower: 1 pt

a. Divide compressor indicated horsepower by the compression efficiency

b. Add compressor indicated horsepower to accessory IHP
c. Multiply compressor indicated horsepower by compression efficiency
d. Divide compressor indicated horsepower by the compressor mechanical efficiency

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 9. An example of friction horsepower is: 1 pt

a. Ring and liner friction horsepower

b. Wrist pin and bushing friction horsepower
c. Connecting rod bearing and crankshaft friction horsepower
d. All of the above

10. What is the primary function of the springs in the suction or discharge valve? 1 pt

a. Close the valve plates / poppets

b. Dampen the plate opening
c. Decrease flow velocities
d. Keep the valves from closing too early

DIRECTIONS: Fill in the blank with the correct responses:

11. During the walk around inspection, list 4 items that should be checked with the ultrasonic leak
detector? 4 pts

__________________, __________________, _____________________, _________________

12. During the walk around inspection, list 4 items that should be checked visually? 4 pts

__________________, __________________, _____________________, _________________

DIRECTIONS: Circle the letter of the most correct response:

13. What sensors would normally be used for crank-angle traces for a compressor? 1 pt

a. Accelerometer, velocity probe, pressure transducer

b. Accelerometer, ultrasonic, pressure transducer
c. Accelerometer, pressure transducer
d. Velocity probe, pressure transducer, ultrasonic

14. What crank-angle related test points would the accelerometer normally be used for on 1 pt
any reciprocating compressor assembly?

a. Cylinder head, packing gland, main bearings

b. Cylinder head, compressor valves, crosshead, bearings,
c. Cylinder head, oil cooler, cylinder liner, main bearings
d. Cylinder head, cylinder liner, main bearings, base bolts

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 15. What crank-angle related test points would the ultrasonic normally be used for? 1 pt

a. Cylinder body, valve caps, packing area, pocket un-loaders

b. Cylinder head, crosshead, wiper packing
c. Cylinder body, cylinder liner, main bearings
d. Cylinder head, cylinder liner, main bearings, base bolts

16. What crank-angle related sensor points are normally used for testing main bearings? 1 pt

a. High frequency vibration, ultrasonic

b. High frequency vibration, raw vibration
c. Ultrasonic, raw vibration
d. Displacement

The following questions refer to the above trace. Write in the correct choice.

17. What is the approximate discharge line pressure (230, 45, 265)?____________________ 1 pt

18. What is the approx. head-end discharge toe pressure?________________ 1 pt

19. What is the approximate crank-end suction toe pressure?______________ 1 pt

20. From degree 180 to 360 is the piston moving toward or away from TDC?_____________ 1 pt

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21. The crank-end discharge valve is opening between degree: 1 pt

a. 90 and 135
b. 170 and 190
c. 225 and 270
d. 270 and 315

22. The head-end discharge valve is opening between degrees: 1 pt

a. 90 and 135
b. 170 and 190
c. 225 and 270
d. 270 and 315

23. The head-end suction valve is opening between degrees: 1 pt

a. 225 and 270

b. 170 and 190
c. 45 and 90
d. 180 and 225

24. The crank-end suction valve is opening between degrees: 1 pt

a. 225 and 270

b. 170 and 190
c. 45 and 90
d. 180 and 225

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The following questions refer to the above trace. Write in the correct choice.

25. The cylinder is only loaded on the head-end or crank-end?________________________ 1 pt

26. Is the deactivated end unloaded at suction or discharge pressure?____________________ 1 pt

27. At what degree does the crank-end suction valve open? 1 pt

Circle the letter of the most correct response:

a. About 240 degrees

b. About 20 degrees
c. Does not open
d. About 180 degrees

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 B

A  C

The following questions refer to the above trace. Write in the correct choice.

28. Is this head-end or crank-end pressure?____________________________ 1 pt

29. When following the trace from 0% to 100% is the piston moving toward the head-end or crank-end?
___________________ 1 pt

30. What is the approximate suction volumetric efficiency % (78, 33, 86, 14)?__________ 1 pt

31. What is the approximate discharge volumetric efficiency % (67, 33, 40, 14)?__________ 1 pt

32. Identify each event (place the letters from the previous graph on the lines below): 4 pts

Compression ____________
Expansion ____________
Discharge ____________
Suction ____________

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The following questions refer to the above trace. Circle the letter of the correct response.

33. What kind of leakage is most represented? 1 pt

a. suction valve leakage

b. packing leakage
c. ring leakage
d discharge valve leakage

34. The actual flow rate will? 1 pt

a. increase
b. decrease
c. stay about the same
d none of the above

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The following questions refer to the above trace. Circle the letter of the correct response.

35. What kind of leakage is most represented? 1 pt

a. suction valve leakage

b. packing leakage
c. ring leakage
d discharge valve leakage

36. The actual flow rate will? 1 pt

a. increase
b. decrease
c. stay about the same
d none of the above

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The following questions refer to the above trace. Circle the letter of the correct response.

37. What kind of leakage is most represented? 1 pt

a. suction valve leakage

b. packing leakage
c. ring leakage
d discharge valve leakage

38. The actual flow rate will? 1 pt

a. Increase
b. Decrease
c. Stay about the same
d. None of the above

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 A  B  C  D  E  F 

The following questions refer to the above trace.

39. Identify by letter from the above plot, the following events. Some letters may be used more than
once: Write the appropriate letter in the spaces provided.

Head-end suction valve opening ____________

Head-end discharge valve opening ____________
Head-end discharge valve closing ____________
Head-end suction valve closing ____________
Crank-end suction valve opening ____________
Crank-end discharge valve opening ____________
Crank-end discharge valve closing ____________
Crank-end suction valve closing ____________ 8 pts

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The following question refers to the above plot. Circle the letter of the correct response.

40. Trace 9 indicates what possible problem or problems? 1 pt

a. Head end suction valve leak only

b. Head end discharge valve leak only
c. Crank-end suction valve leak only
d. Crank-end discharge valve leak only
e. Head-end suction or crank-end discharge leak
f. Crank-end suction or head-end discharge leak

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The following question refers to the above plot. Circle the letter of the correct response.

41. Trace 5 indicates what kind of possible problem? 1 pt

a. Head end suction valve leak only

b. Head end discharge valve leak only
c. Crank-end suction valve leak only
d. Crank-end discharge valve leak only
e. Head-end discharge or crank-end suction leak
f. Crank-end discharge or head-end suction leak

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 Not corrected for channel 
resonance 

42. What kind of leakage is most represented? 1 pt

a. suction valve leakage

b. pressure packing leakage
c. ring leakage
d discharge valve leakage

43. The actual flow rate will? 1 pt

a. increase
b. decrease
c. stay about the same
d none of the above

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The following question refers to the above plot. Circle the letter of the correct response.

44. What kind of leakage is most represented? 1 pt

a. Head-end discharge valve leakage

b. Crank-end discharge valve leakage
c. Head-end suction valve leakage
d. Ring leakage

45. What kind of temperature problems may be noticed? 1 pt

a. Suction cavity temperature increase

b. Discharge cavity temperature increase
c. Suction and discharge cavity temperature increase
d. None of the above

DIRECTIONS: In the following questions, circle the letter of the correct response

46. Packing leakage showing up in the PV trace looks similar to what other defect? 1 pt

a. Ring leakage ______

b. Suction valve leakage ______
c. Discharge valve leakage ______

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Circle the letter of the correct response.

47. Flow balance is calculated by Dividing: 1 pt

a. Calculated suction flow rate by the calculated discharge flow rate

b. Calculated discharge flow rate by the calculated suction flow rate
c. Calculated suction flow rate by the actual flow rate
d. Average flow rate by the discharge calculated flow rate of the above

48. A flow balance of 1.08 would normally indicate: 1 pt

a. Suction valve leakage, or packing leakage, or ring leakage

b. Discharge valve leakage
c. Suction valve leakage and discharge valve leakage
d. Ring leakage

49. A flow balance of 0.95 would normally indicate: 1 pt

a. Suction valve leakage or packing leakage or ring leakage

b. Discharge valve leakage
c. Suction valve leakage and discharge valve leakage
d. Ring leakage

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