Maintenance And Trouble Shooting

of Reciprocating compressor
 Definitions - Compressor
• Compressor – A mechanical device that is used to increase
the pressure—or Compress—a gas.
• Compressor Types
• Centrifugal Compressor – Machines that use centrifugal
force to compress gas by feeling it into a wheel with radial
vanes. The wheel is then seal inside of a cylinder and spun.
When the wheel rotates, the gas is thrown away from the
wheel center. The outward spinning motion compresses the
gas.

Reciprocating Compressor – Machines in which the

compressing element is a piston having a reciprocating
motion in a cylinder.
• Rotary Compressor – Machines in which the compressing
element is a set of rotating elements (often “screws” or
“lobes”). Also a type of compressor belonging to the group
of dynamic compressors characterized by having its flow in
an axial direction.
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 Positive Displacement Reciprocating
Compressors
• Most common type of compressors.

• Work by trapping and compressing specific volumes

of gas between a piston and a cylinder wall.

• The back and forth motion incorporated by a

reciprocating compressor pulls gas in on the suction
(or intake) stroke and discharges it on the other.

• Spring-loaded suction and discharge valves

open/close automatically as the piston moves up
and down in the cylinder chamber.

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 Positive Displacement Reciprocating
Compressors

• Basic Parts of are:

– Piston
– Connecting Rod
– Crankshaft
– Diver
– Piston Rings
– Suction Line
– Discharge Line
– Spring -Loaded Suction and Discharge Valves

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 Positive Displacement:Reciprocating
Compressors

• Can have 1 to 4 cylinders. One shown only has one cylinder.

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 Mulitstage Compressors

• Discharge from Stage 1 is suction for Stage 2.

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 Reciprocating Compressor.
• Reciprocating compressors are positive displacement machines,
meaning that they increase the pressure of the air by reducing its
volume.
• The relationship between pressure and volume is illustrated in the
figure below.
• This compressor has a crankshaft, connecting rods, and pistons.
Single-stage as well as multi-stage reciprocating compressors are
commercially available.
• A performance curve for a positive displacement machine is
provided in the figure next.
• It can be seen that despite compressor discharge pressure, load
remains
• constant. Load reduction is achieved by unloading individual
cylinders.
• Typically, this is accomplished by throttling the suction pressure to
the cylinder or bypassing air either within or outside the
compressor.
• Capacity control is achieved by varying speed in engine-driven/
Turbine units through fuel flow control. 8
9
Reciprocating Compressor

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Reciprocating Compressor

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 MagnumTM Compressor Valve
• Features:
– Rigid and tough (low mass)
non-metallic sealing element
for maximum impact
resistance
– Minimal tensile loading in
sealing elements

– Minimized fixed clearance

– Large (effective) flow area at minimum lift

– Available, low cost sealing element eases reconditioning and

reduces inventory
– Can be used in conjunction with port, plug and finger type
unloaders

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 MagnumTM Compressor Valve
Gas flow High-strength,
low mass,
Locating pins PEEK sealing
for precision element
alignment

Advanced valve
element
geometry

Precision-guided
valve elements
and springs

Streamlined flow path with balanced seat, guard and lift areas
optimize EFA; good tolerance for liquids and particulates in the gas
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 Reciprocating Compressor Rod Packing
• A series of flexible rings fit around the shaft to
prevent leakage
• Leakage may still occur through nose gasket,
between packing cups, around the rings, and
between rings and shaft

Two Rings
(In Three Segments) Lubrication
High Pressure
Gas Piston Rod Gas Inside
Leakage
Cylinder
Flange
Cylinder Wall
Packing Cup

Springs (Side View, Cut in Half) 14

 Reciprocating Compressors

• Reciprocating compressor rod packing leaks

some gas by design
– Newly installed packing may leak 60 cubic feet per
hour (cf/hour)
– Worn packing has been reported to leak up to 900
(Side View, Cut in Half) Cylinder
cf/hour
Suction
Distance Piece
Piston Rod
Piston

OIL Discharge
Rod Packing Case
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Pressure Packings - Controlling Fugitive
Emissions

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Rod Packings and Packing Rings
• DuraWearTM Performance Parts
– Registered D-R trademark
– Packing case designs:
• Meet (or exceeds) API 618 standards
• Available in a variety of materials
including cast iron, alloy steels, and
stainless steels
– Packing rings
• Available in a variety of blended
thermoset and thermoplastic materials
including PTFE, PEEK, Nylon and
VESPEL.
– OEM application expertise at
competitive cost and delivery

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 Three Piece Piston; Stretch on Rider
Bands
• Stretch-on rider bands
located outboard of piston
rings

• Piston disassembles;
riders stretch directly
into ring grooves

• Thicker rider bands result in increased

band strength and extended service life

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 Single Piece Piston; Inboard Rider
Bands
• Rider bands protected
from direct exposure to
differential pressures

• Allows the use of split

rider bands

• Desirable for higher

pressure applications

• Use of this design can be limited by

the length and construction of cylinder

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 Single Piece Aluminum Piston
With Integral Steel Ring Carrier
• Design similar in weight to
an aluminum piston

• Rings located in integral

steel ring carrier

• Provides maximum
resistance to ring groove
wear (wallowing)

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 Piston Rings and Rider Bands
• DuraWearTM Performance Parts
– Registered D-R trademark

– Piston rings and rider bands

• Available in a variety of blended
thermoset and thermoplastic materials
including PTFE, PEEK, Nylon and VESPEL

– OEM application expertise at

competitive cost and delivery

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Upgrades for Improved Reliability and
Reduced Maintenance
Compressor valves
Pressure packings and rings
Piston rings, rider bands and compressor
pistons
• Cylinder unloaders

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 Cylinder Unloaders

• Ranked as #6 cause of unscheduled shutdowns

• Historical unloader problems

– Sticking / seizure
– Seal leakage (fugitive emissions)
– Seat leakage (capacity reduction / overheating)
– Vibration / chattering
– Alignment / adjustment

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 Unloader Design Features
(Port, Plug & Clearance Pocket Type)
• Corrosion resistant operator
piston & housing - reduces seizing
in corrosive ambient conditions

• Operator spring out of process

gas - increases spring life/
reliability

UNLOADER
ROD

• Unloader gland - provides

positive sealing to minimize
fugitive emissions

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 Unloader Design Features
(Port, Plug & Clearance Pocket Type)
• Guided unloader valve - ensures
positive alignment

• Sleeve unloader valve - minimizes

area exposed to differential
pressures to prevent “chatter” at
normal operator air pressures

UNLOADER
• Shoulder bolt - enables automatic ROD

minor adjustments if unloader and

seat are not perfectly aligned

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Upgrades for Improved Reliability and
Reduced Maintenance
Compressor valves
Pressure packings and rings
Piston rings, rider bands and compressor
pistons
Cylinder unloaders
• Cylinder valve covers

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 Compressor Cylinder Valve Covers
• Threaded “setscrew” or
“centerbolt” style valve
covers can require frequent,
periodic tightening
(especially in higher
pressure applications).

• Valve covers should not

Setscrew Style Valve Cover Design
be tightened while the
compressor is running.
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Compressor Cylinder Valve Covers
• Modern valve cover designs can increase reliability &
safety and decrease maintenance:

RAM Cover Design O-Ring Cover Design

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 RAM Valve Cover Design Features
• Patented design

• Ram O-ring seal

• Stepped Ram design

• Multiple Ram cover studs

• Easy retrofit

• May incorporate valve

cover gasket upgrade (flexible graphite)

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O-Ring Valve Cover Design Features
• API 618 4th edition

• Single O-ring seal

• Used in conjunction with

barrel-type valve cage

• Remachining of existing cylinders necessary to incorporate o-

ring cover design

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Thermodynamic cycle

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 TROUBLE SHOOTING
➢Regardless of which maintenance system is used,
machinery has potential to fail over a period of
operation ,hence it is necessary to troubleshoot
the problem at innocence stage.

➢Records of daily operation are very important.

Reason being, first, an analysis of these records
may direct you toward the source of your failure,
and second, if that pattern has not been
documented as an indication or prediction of a
particular failure, you gain experience that may be
useful in the future.
 Daily Monitoring & Measures
Check & record drive motor ampere hourly & while
changing load conditions.
Check crankcase oil level & top up if required. Keep
record of amount of oil added.
Check & record crankcase oil temperatures & pressures
hourly.
Check oil level in lubricator & top up as required. Record
oil used daily.

Check lubricator pump units for operation & correct flow

hourly.
Visually inspect packing rings for blow-by & scrapper
rings for excessive oil leakage.
 DAILY Monitoring & measures
Check & record cooling water pressure, temperature &
flow hourly.
Check for proper operation of liquid level controllers in
suction scrubbers hourly.
Check & record compressor cylinder suction & discharge
pressures & temperatures hourly & with every change
in load conditions.
Inspect for unusual noises or vibration and air, oil, water
& gas leaks at every opportunity & investigate and
correct discrepancies.
Review all log sheet data to determine unusual
operating conditions & investigate or correct as
required.
 Predictive Checks & Measures
Check bolt tightness. Cause for bolts that are found
repeatedly loose or excessively loose should be
investigated.
Analyze crankcase lube oil.
Check lube oil filter elements for excessive pressure drop
(>20 psi) & change if needed.
Analyze cooling water condition & clean, descale cylinder
water jackets, lube oil cooler, gas cooler as indicated by
analysis results. Also, clean sight flow indicators as
required.
Check main bearing saddle alignment (bottom bearing
clearances) & correct if required.
Check piston rod alignment (rod run-out) & correct if
required.
 Predictive Checks & Measures
Check main bearing clearances & adjust / correct
if required.
Check crankshaft deflections & correct if required.
Check connecting rod bearing clearances & correct
if required.
Check crosshead shoe clearance & correct if
required.
Check piston to bore clearances (for compressors
with rider or combo rings) & change rings if
required
Inspect compressor valves and service them.
Clean & inspect valve un-loaders.
 Overhauling Checks & Measures
Inspect drive motor and regrease at greasing
points.
Check crankshaft thrust clearance & correct if
required.
Check compressor piston rings & rider rings for
wear (actual time interval for this inspection has
to be established by the maintenance
personnel).
Check oil scrapper and pressure packing rings for
wear & cleanliness.
Clean & inspect frame oil breathers.
Clean & inspect the cylinder lubricator & feed
pumps & put new oil.
 OTHER MAINTENANCE
WEEKLY OFF COMPRESSOR
Check & blowdown condensate from
instrument air filters & pressure regulators.
Blow down dead legs of gas pressure sensing
lines to gauges & pressure transmitters.
BI-ANNUALLY OFF COMPRESSOR
Check calibration of all temperature &
pressure devices & indicators.
Function test all alarm & shutdown control
loops
 TROUBLE SHOOTING
COMPRESSOR WILL NOT START
PROBABLE CAUSES REMEDIES

1)Power supply failure 1)Correct voltage / power

supply
2)Switchgear or starting panel 2)Check circuitry, interlocks,
relays, etc.
3)Low oil pressure shutdown 3. a-Check switch setting.
switch b-Adjust timer if there is no
A.O.P.
c-Check A.O.P., if provided
4)Control panel
4)Check connections &settings
of all devices
 TROUBLE SHOOTING
MOTOR WILL NOT SYNCHRONIZE
PROBABLE CAUSES REMEDIES

1) Low Voltage 1) Correct voltage supply

2) Excessive starting torque 2) Unload compressor

during starting
3) Incorrect power factor 3) Adjust excitor filled
rheostat
4) Excitation voltage failure 4) Check field excitation
system
 TROUBLE SHOOTING (LOW OIL PRESSURE)
PROBABLE CAUSES REMEDIES

1) Oil pump failure 1) Check oil pumps/power

supply
2) Oil foaming from counter 2) Reduce oil level
weights striking oil
surface 3) Use frame oil heater and/or
steam trace exterior piping
3) Cold oil
4) Service filter. Replace
4) Dirty oil filter elements
5) Interior frame oil leakage 5) Check oil piping
6) Excessive leakage at
bearing shim tabs and/or 6) Set shim tabs and bearing
bearings clearances
 TROUBLE SHOOTING (LOW OIL PRESSURE)

PROBABLE CAUSES REMEDIES

7) Improper low oil 7) Reset low oil
pressure switch setting pressure switch setting
8) Low gear oil pump by- 8) Reset valve
pass/ relief valve setting
9) Defective pressure gauge 9) Replace gauge
10) Plugged oil sump 10) Clean strainer

11) Defective oil relief valve 11) Repair or replace

valve
 TROUBLE SHOOTING (NOISE IN CYLINDER)
PROBABLE CAUSES REMEDIES

1) Loose piston 1) Disassemble and tighten

piston
2) Piston hitting outer head
2) Adjust piston rod for
or frame head of cylinder
proper end clearances
3) Loose Crosshead lock nut
3) Tighten jam nut
4) Broke or leaking valves
4) Repair/replace parts
5) Worn/broken piston rings
5) Replace rings
6) Valve improperly seated/
6) Replace gasket and
damaged seat gasket
reassemble properly
7) Free air unloader plunger
7) Replace worn or broken
chattering
unloader springs
 TROUBLE SHOOTING (EXCESSIVE PACKING LEAKAGE)
PROBABLE CAUSES REMEDIES
1) Worn packing rings 1) Replace packing rings
2) Improper Lube oil and/or 2) Use correct lube oil and
insufficient lube rate lube rate
3) Dirt in packing 3) Clean piping /gas assembly
4) Excessive rate of pressure 4) Reduce pressure and
increase increase at more gradual rate
5) Incorrect packing ring
5) Reassemble correctly
assembly
6) Plugged packing vent 6) Remove blockage and
provide low point drains
7) Scored piston rod
8) Excessive piston rod run- 7) Replace piston rod
out 8) Correct rod run-out
 TROUBLE SHOOTING (PACKING OVER HEATING)

PROBABLE CAUSES REMEDIES

1) Lubrication failure 1) Replace lubricator check

valve / lubricator pumping
unit

2) Improper lube oil 2) Use correct lube oil and

and/or insufficient increase lube rate
lube rate
3) Clean coolant passages /
3) Insufficient
install water filer / increase
cooling
supply pressure. Reduce
coolant inlet temperature
 TROUBLE SHOOTING (EXCESSIVE CARBON ON VALVES)
PROBABLE CAUSES REMEDIES
1) Excessive lube oil 1) Adjust lube supply
2) Improper lube oil 2) Use correct lube oil
3) Oil carry over from 3)Install oil
Inlet system or previous separators/drain system
Stage
4)Broken or leaking valves 4) Repair /Replace parts
causing high temperature
5) Excessive temperature 5) Clean heat exchanges,
due to high pressure ratio valves and correct cause of
across cylinders high pressure
 TROUBLE SHOOTING (RELIEF VALVE POPPING)
PROBABLE CAUSES REMEDIES
1) Faulty relief valve 1) Test and reset
2) Leaking suction valves 2) Repair / replace
or piston rings on next defective parts
higher stage

3) Obstruction (foreign 3) Relieve obstruction

material, rags), blind or
valve closed in discharge
line
 TROUBLE SHOOTING(HIGH DISCHARGE TEMPERATURE)
PROBABLE CAUSES REMEDIES
1) Excessive ratio on cylinder 1) Repair / Replace
due to leaking inlet valves or valves/piston rings
piston rings on next higher
stage 2) Clean inter cooler /
2) Fouled inter cooler / piping piping. Reduce lube rates

3) Leaking discharge valves or 3) Repair/replace parts

piston rings
4) Clean inter cooler
4) High inlet temperature
5)Fouled water jacket on cylinder 5) Clean jackets
6) Improper lube oil and/or lube 6) Use correct lube oil
rate and correct lube rate
 TROUBLE SHOOTING(FRAME KNOCKS)
PROBABLE CAUSES REMEDIES
1) Loose cross head pin, 1) Tighten/replace loose parts
pin caps or cross head
shoes 2) Tighten/replace bearing, check
2) Loose/Worn main, clearance
crank pin or cross head
bearings
3) Increase oil pressure, repair
3) Low oil pressure leaks

4) Cold oil 4) Warm oil before loading unit.

Reduce water supply to oil cooler
5) Incorrect oil 5) Use proper oil
6) Knock is actually from 6) Refer to “TROUBLE NOISE IN
cylinder CYLINDER”
 TROUBLE SHOOTING(CRANKSHAFT OIL SEAL LEAKS)

PROBABLE
CAUSES REMEDIES

1) Faulty seal 1) Reset seal

installation

2) Clogged drain 2) Clear obstruction

hole
 TROUBLE SHOOTING(PISTON ROD OIL SCRAPPER LEAKS)

PROBABLE CAUSES REMEDIES

1) Worn scrapper rings 1) Replace rings

2) Scrappers incorrectly 2) Assemble

assembled correctly

3) Worn / scored piston 3) Replace piston

rod rod

4) Improper fit of rings 4) Replace rings

to rod / side clearance
Start Up Procedure for reciprocating compressors
• Check the oil level in the frame sump, so
as to ensure the level greater than 50%.
• When restarting an overhauled
compressor, manually turn the
compressor 1 round.
• Turn on the CW supply and check the
return line to ensure proper flow
• Ensure that the compressor is in Unloaded
condition
• Start the AOP and check its oil pressure. 52
Start Up Procedure for reciprocating compressors
• Start the driver and run the compressor
with no load for a few minutes
• Check the lubrication oil pressure. It
should be between 1.5 – 3.0 kg/cm2
• Listen for unusual noises during the warm
up period.
• When the compressor seems to be
running satisfactorily, then it can be
loaded
• After the compressor starts running on
load, check for any pressure and flow
deviation from the design parameters 53
Shut Down Procedure for reciprocating compressors
• Unload the compressor
• Ensure that the compressor is in no load
condition by checking the current,
pressure and flow of the compressor
• Then stop the driver (motor)
• Ensure that the AOP starts after the driver
has been stopped
• Stop the CW supply
• Prepare the unit, so that it can be
54
restarted in short notice
 Daily checks for the reciprocating compressors
• Check the oil level in the frame and add if
required
• Keep a log of gas temperatures, pressures and
CW temperatures once in a shift
• Check the inter-stage pressure and temperature
to detect any abnormal condition
• Inspect piston rod packing vents for excessive
blow by or overheating.
• Listen for any unusual noises and investigate
immediately if there are any.
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