RECIPROCATING COMPRESSOR

BY SE RBA DINAMIK GLOBAL SKILL CE NTRE

OBJECTIVE
INTRODUCTION
 History of compressor
Earliest man-made of
compressor, originated from
Egypt, used in production of
precious metals seen in
ancient tombs.

1660-1830 Compressors evolved and started to be driven by steam and

water wheels.
1850-1900 Compressors used along pneumatic drills to cool the air inside
the tunnel that connect Italy and France as the miners made
their way deeper into the rock.
20th century Compressors continue to be use in automobile, aircraft and to
build skycrappers
 WHAT IS COMPRESSOR?
A device used for increasing the pressure of a gas by mechanically decreasing its volume
Gas compressed in compressor includes air, natural gas, oxygen, nitrogen, and other industrially important
gases
Compressor work with the principle of gas law of thermodynamics which relate pressure (P), volume (V), the
amount of gas in moles (N), and temperature (T) with a factor R called the universal gas constant and
allowing the deviations in gas behaviour, the compressibility factor z is added to the equation to obtain:
PV=zNRT
A positive-displacement machine that uses a piston to compress a gas and deliver it at high pressure
Typically used where high compression ratios (ratio of discharge to suction pressure) are required per stage
without high flow rates, and the process fluid is relatively dry
Various compressors are found in almost every industrial facility, including the following:
◦ Air for compressed tool and instrument air systems
◦ Hydrogen, oxygen, etc. for chemical processing
◦ Light hydrocarbon fractions in refining
◦ Various gases for storage or transmission
◦ Other applications
From the equation obtained, we can simply put, as the volume of a gas decreases, the pressure increases
proportionally in order to keep the ideal gas law equation equated.
In ideal condition, compression occurs under isentropic conditions, which means the process is both reversible
and adiabatic (a type of process which occurs without transferring heat or mass between the system and its
surrounding. An adiabatic process transfers energy to the surroundings only as work). Isentropic condition
refers to the condition when the entropy (a measure pf disorder and of the unavailability of energy to do work)
for the given state of point remains constant.
How a Compressor Works?
TYPE OF COMPRESSOR
 COMPRESSOR TYPES

Positive Displacement Dynamic

Centrifugal
Rotary Reciprocating

Axial
Lobe
Diaphragm
Vane

Screw Double Acting

Scroll

Single Acting
Liquid Ring
 Positive displacement compressors
Use physical force to displace gas into smaller volumes
Includes:
➢Diaphragm compressors
➢Ionic liquid piston compressors
➢Reciprocating compressors
➢Rolling piston compressors
➢Rotary screw compressors
➢Rotary vane compressors
➢Scroll compressors
 Dynamic compressors
Use a continuous flow to pass gas through an element to generate a higher pressure
Includes:
➢Air bubble compressors
➢Axial-flow compressors
➢Centrifugal compressors
➢Diagonal/mixed-flow compressors
APPLICATIONS OF COMPRESSORS
 APPLICATIONS OF COMPRESSORS
- Compression of gases in petroleum refineries and chemical plants
- Storage of gas in high pressure cylinders
- Cabin pressurization in airplanes
- Air storage for underwater activities
- Filling tires
- Refrigeration and air conditioners
- Rail vehicle operation
- Gas turbines
- Powering pneumatic tools
- Pipeline transport of natural gas
RECIPROCATING/PISTON COMPRESSOR
 RECIPROCATING/PISTON COMPRESSOR
Use pistons controlled by a crankshaft to deliver the gas at high pressure within a cylinder
The piston compresses the air/gas inside the cylinder
The compressed air/gas is then discharged through respective valves into the discharge port
The piston is made to reciprocate by a connecting rod that receives drives from a rotating crankshaft
arrangement
American Petroleum Institute (API) - API Standard 11P and API Standard 618
Types of reciprocating compressors:
◦ High speed (separable)
◦ Low speed (integral)

Primarily of 2 types:
◦ Trunk design
◦ Crosshead design
 Reciprocating compressor – separable
Separate from its driver
Either an engine or an electric motor usually drives a separable compressor
Often a gearbox is required in the compression train
Operating speed is typically between 900 and 1800 rpm
Skid mounted and self-contained
Easy to install, offer a relatively small initial cost, easily moved to different sites, available in sizes appropriate
for field gathering – both onshore and offshore
 Reciprocating compressor – integral
The power cylinders that drive the compressor are mounted integrally with the frame containing the compressor
cylinders
Run at the speeds of between 200 and 600 rpm
Commonly used in gas plants and pipeline service where fuel efficiency and long life are critical
May be equipped with two to ten compressor cylinders with power ranging from 140 to 12,000 hp.
 Reciprocating compressor – trunk design
Piston directly connected to a connecting rod which in turn receives drive from a crankshaft
Working principle of trunk design allows compression and discharge of air/gas only at one end of the cylinder
 Reciprocating compressor – crosshead
design
A crosshead is available that connects the piston and the connecting rod
Allows compression and discharge of air/gas at both ends of the cylinder if required
RECIPROCATING COMPRESSOR PARTS
RECIPROCATING COMPRESSOR PARTS
1. Frame
2. Cylinders
3. Distance piece
4. Piston
5. Piston rings
6. Cross head
7. Crankshaft
8. Connecting road
9. Valve
10. Bearings
Crankcase
Distance piece
Cylinders – arrangement, materials, liners
Piston – dismantling, materials, piston rod
connections
Piston rod – materials, crosshead connections
Piston rings
Piston rod packing
Wiper packing
Cross heads
Crankshaft
Parts of Reciprocating Compressor
Frame
Heavy and rugged frame which encloses all the rotating components such as the cylinder and
crosshead guide.
Also called a crankcase
Has a square or rectangle shape
To offer support to the crankshaft bearings
Provides support for the crosshead assembly
Cylinders
The pressure vessels that contain the gas that is to be compressed.
In large low-pressure cylinders – made up of cast iron, can be removed from the major frame
and connected to the frame through an intermediary known as a distance piece.
In small high-pressure cylinders – made up of steel and directly fixed to the main body of the
compressor
Support the discharge valve plates and suction valve
 Distance piece
Separates the compressor cylinder from the frame.
Prevents contamination of process gas
Prevents contamination of crankcase oil
Can either have a single, double or even an extra long compartment arrangement
Single design – uses a structure where the distance between the diaphragm and cylinder packing is extended
in order to prevent any part of the rod entering the crankcase and cylinder stuffing box
Double design – also uses the same structure where there is no part of the rod entering the compartment and
crankcase places adjacent to the gas cylinder
Long distance piece – helps to separate the part of the Piston rod that enters the crankcase.
Major classification of distance piece: type A, type B, type C, type D
 Piston
The component that compresses air
Must have weight, strength, and be compatible with the gas to
be compressed
Also moves the energy from the crankcase to the gas contained
in the cylinder in a bid to prevent the refrigerant from leaking
through the gap.
In between the Piston and cylinder walls, this component
usually covered with Piston rings
Can be made either from aluminium or cast iron
Moves upwards and downwards in the cylinder
The movement brings about the suction and compression of
the refrigerant
Piston rings
Wound on the Piston and come in contact with the walls of the cylinder when the Piston moves
up and down the cylinder
Have to be replaced frequently due to the amount of friction created during the reciprocating
motion to maintain the seamless operation
There are different type of rings can be used for the piston. Example:
◦ non-metallic rings – made up of fluorocarbon compounds, mostly employed in non-lubricated service, weigh less than metallic
rings
◦ Metallic rings – bronze or cast iron, used for lubricating service
Cross head
Enables the Piston to be inserted in the cylinder bore
Enables the compressor to use a narrow Piston and it enables longer strokes and higher
efficiency
 Crankshaft
The major shaft in the compressor
Revolves around the frame axis and it drives the piston, piston rod and connecting rod
Built as a forged steel crankshaft for compressor that operates above 150 kW (200 hp). Meanwhile, for less than
or equal 150 kW, a ductile iron crankshaft is used
Connected to the electric motor directly or indirectly with the use of a belt and pulley system
When the motor rotates, the crankshaft also performs a rotary motion which gives the Piston the ability to carry
out its reciprocating motion inside the cylinder
Connecting rod
Connects the crankshaft and the Piston
One side of the rod linked to the Piston using a piston pin
Other side of the rod is connected to the crankshaft using a connecting cap rod
Connecting rod changes the rotary motion to reciprocating motion
Valve
Function of valve: to allow gas to flow in the right direction while blocking those that may tend
to flow in an undesired direction
These valves are placed in each operating end of a cylinder
One end will have a set of inlet valves to allow gas into the cylinder while another end features
two discharge valves
Configurations of valves in reciprocating compressor:
◦ Ring valve
◦ Poppet valve
◦ Plate valve
Ring type valve
Uses one or more circular rings that have a narrow channel embedded in them
Can be placed on the center line of the valve seat through the stud
The advantage of ring type valve is they have a low-stress level since there are no stress
concentration points
Recommended to be used on 30 Mpa or 60 Mpa discharge pressure and 600 rpm
Disc (poppet) type valve
Consists of several sealing elements and ports of the same size
Employed in reciprocating compressors that operate at a medium pressure range
Recommended up to a differential pressure of 15 Mpa or 30 Mpa discharge pressure and 600
rpm
Plate type valve
Have the same concentric design of the rign valve
Recommended differential is 20 Mpa and the discharge pressure of 40 MPa
 Bearings
Ensure the other components in the compressor are properly positioned radially and axially

Main bearing • Between crankshaft and frame

• Support the crankshaft and enables
its rotation within the engine block
Crank pin bearing • Between the crankshaft and the
connecting rod
• To increase efficiency
Wrist pin bearing • Between the connecting rod and
cross head
• Oscillates while the crankpin bearing
rotates
Cross head bearing • Underneath the cross head
• To eliminate sideways pressure in
reciprocating compressors
COMPRESSOR ANALYSIS
Analysis of the compressor using a pressure-
volume (PV) diagram
PV sequences of events
Suction valve leak
Discharge valve leak
Piston ring leakage
General operation limits
Pulsation effects
Valve and cylinder gas passage losses
Excessively strong discharge valve springs
Excessively strong suction valve springs
PV Sequence of Events
PV Sequence of Events
This diagram will consider the head-end (HE) of a
compressor only, while all also applies to the crank-
end (CE) of a cylinder.
Line 4-1: suction valve opens at point 4. as the
piston travels toward BDC, the volume in the
cylinder is slightly less than suction line pressure.
This small differential allows the valve to open and
holds it open during the suction stroke
Line 1-2: suction valve closes as pressure across
the valve equalizes as the piston has reached BDC
and changes direction at point 1. the cylinder
volume decreases as the piston moves towards
TDC, raising the pressure inside the cylinder.
 PV Sequence of Events
Line 2-3: at point 2, the pressure inside the cylinder has
become slightly greater than discharge line pressure. The
resulting differential pressure across the discharge valve
causes the valve to open, allowing gas to flow out of the
cylinder. The volume continues to decrease toward point 3,
maintaining a sufficient pressure differential across the
discharge valve to hold it open.
Line 3-4: at point 3, the piston reaches TDC and reverses
direction. At TDC, as the piston comes to a complete stop
prior to reversing direction, the differential pressure across the
valve becomes equal. This allows the discharge valve to
close. The volume increases, pressure decreases. The gas
trapped in the cylinder expands as the volume increases
toward point 4. at point 4, the gas pressure inside the cylinder
becomes less than suction line pressure, creating a
differential pressure that opens the suction valves.
The cycle then starts over again.
LEAKAGE AND PV ANALYSIS
Suction Valve Leak
Line 1-2A: compression – gas leaks out through the
suction valve(s). Gas is pushed out of the cylinder during
compression stroke, hence the piston must travel
further to reach the discharge valve opening pressure. If
the leak severe enough, the pressure within the cylinder
will not reach discharge pressure. The cylinder volume
at point 2A is less than point 2, resulting in a shorter
effective discharge stroke or a loss in discharge
volumetric efficiency (DVE).
Line 2A-3B: during the discharge stroke, gas is exiting
through both suction and discharge valves. Should the
leak be severe enough, the discharge valve will close
prematurely at 3B instead of point 3.
Suction Valve Leak
Line 3B-3A: with the discharge valve prematurely closed,
the piston is still moving towards TDC as gas continues to
leak out of the cylinder through the suction valve. The
internal cylinder pressure at point 3A is less than
discharge line pressure at point 3.
Line 3A-4A: the cylinder’s re-expansion slope occurs
more quickly than normal due to the continuing gas
leakage through the suction valve(s), thus causing the
suction valve to open at point 4A.
Line 4A-1: the early opening of suction valves causes the
actual suction volumetric efficiency (SVE) to be greater
than the theoretical SVE.
 Symptoms might happen for leakage
through suction valves
1. Inlet temperature rises because of the re-circulation of the gas.
2. Leaking suction valve cap temperature will increase. Other valve cap temperatures may increase, but
not as significantly.
3. Actual discharge temperature will increase (actual discharge temperature compared to theoretical
discharge temperature).
4. Indicated horsepower may be lower than normal.
5. Compression ratio may decrease.
6. Calculated capacity based on the SVE will be higher than the calculated capacity based on the DVE,
resulting in a capacity ratio greater than 1.0.
7. Compression and re-expansion lines will not match the theoretical PV curve.
Discharge Valve Leak
Line 3-4A: re-expansion – the trapped gas in the cylinder is
expanded as gas leaks through the discharge valve(s) into the
cylinder increasing internal cylinder pressure. As the
pressure increase, it causes the piston to move further down
the stroke, re-expanding gas as it enters the cylinder through
the discharge valve until it reaches a point where pressure is
reduced, allowing suction valves to open at point 4A. The
result is a smaller effective suction stroke, thus reducing
suction volumetric efficiency
Discharge Valve Leak
Line 4A-1B: during the suction portion of the cycle, gas is
entering the cylinder through the open suction valve and
leaking discharge valves. The cylinder pressure can rise to a
point causing premature closure of the suction valves at point
1B.
Line 1B-1A: suction valve has closed, cylinder volume is
increasing, and the internal cylinder pressure is rising, results
in a higher pressure at point 1A than suction line pressure at
point 1.
Line 1A-2A: actual compression line will not match the
theoretical compression line since the pressure at 1A is not
the same as the pressure at 1, gas continues leaking into the
cylinder through discharge valves. The discharge valve opens
when cylinder pressure rises above discharge line pressure
 Symptoms might happen for leakage
through discharge valves
1. Actual discharge temperature will be higher than the discharge temperature observed in normal
operation, or as compared to the theoretical discharge temperature.
2. Measured cylinder capacity will be less than the design cylinder capacity.
3. Capacity calculations based on DVE will be greater than capacity calculations based on SVE, resulting in a
capacity ratio of less than 1.0.
4. Indicated horsepower may be lower than normal.
5. Actual compression and re-expansion lines will differ from a theoretical PV curve.
 Piston Ring Leakage

Line 1A-2A: piston travels from point 1A to 2A, gas is leaking from the
HE side of the piston into the CE, as would happen with a leaking
discharge valve.
Line 2A-3B: gas is exiting through the discharge valve and continues
to leak past the rings. Should the leakage be severe enough,
premature closing of the discharge valve could occur at point 3B.
Line 3B-3A: gas continues to leak past the ring as the piston slows
and continues towards TDC, resulting in internal cylinder pressure
drop to point 3A. This pressure at point 3A is lower than application
pressure at point 3.
Piston Ring Leakage
Line 3A-4A: re-expansion stroke – gas continues to leak past the
rings, the suction pressure drop quicker until pressure equalizes on
both sides, just like a leaking suction valve. After pressure equalizes
fairly far down the stroke, pressure is now higher on the crank-end
side of the cylinder, and gas starts leaking into the head-end side,
look like a leaking discharge valve.
Line 4A-1B: gas is entering the cylinder through the suction valves
and is leaking past the piston rings. This leakage results in
premature closing of the suction valves at point 1B.
Line 1B-1A: suction valves have closed and the cylinder volume is
increasing. Pressure in the cylinder increases due to continued
piston ring leakage into the cylinder. The pressure at point 1A is
higher than design pressure at point 1.
 Symptoms might happen for leakage
through piston ring
1. Measured capacity might be lower than the application capacity.
2. Discharge temperature will increase due to re-circulation of the gas. Compare actual discharge
temperature to a normal value or theoretical discharge temperature. With severe leakage, the
temperature may rise 80⁰F or more.
3. Usually show up as a capacity ratio of greater than 1 or less than 1.
4. Measured compression and re-expansion lines will not match theoretical compression and re-
expansion lines.
 General Operation Limits
Common operational problems grouped together are: pulsating effects, valve losses and cylinder gas passage
losses.
Pulsating effect – pressure variations resulting from the oscillatory flow patterns. The valve opening and closing
times can be affected. The average inlet and/or discharge pressure of the cylinder may be different than the
design pressures with the net result being horsepower and capacity values which are different than the design
values. These values may be greater or smaller, depending on the pulsation characteristics.
Valve horsepower loss – due to the pressure drop across the compressor valve.
Cylinder gas passage loss – pressure drop between the cylinder flange and the compressor valve
Excessively Strong Discharge Valve Springs
Strong discharge valve spring will be evident when evaluating a PV curve. Pressure will have to rise higher than
normal to open the valve. Pressure will have to rise higher than normal to open the valve. A single hump may
appear and then taper off until the cylinder reaches the end of the discharge stroke. With extremely stiff
springs, there may be oscillations above and below the discharge line throughout the discharge stroke.
Pressure pulsations can also show a similar pattern. In this case, it is necessary to look at the bottle pressure
trace for indications of pulsations. Horsepower may not increase much, but excessive valve hp losses will be
evident.
Excessively Strong Suction Valve Springs
Suction valve may have stiff valve springs.
For stiff springs, a single dip would appear at the beginning of the suction stroke.
SVE will probable stay the same or a little less, but computed valve losses would be much higher.
Excessively stiff springs – caused the valve hp losses are high
Weak or broken springs – caused the valve hp are low
COMPRESSOR ANALYSIS
 Compressor vibration analysis
Events that could cause normal vibration in compressor:
◦ Suction valve opening. This event should represent a sharp mechanical impact. A gas passage noise may be
present for a short period of time.
◦ Discharge valve opening. A sharp mechanical impact can be seen and a short period of flowing gas at the
opening of the valve.
◦ Discharge valve closing. Because of the pressure present in the discharge line, the valve will quickly close.
Therefore, there should be a small closing peak with a slight blow as the gas is being shut off.

Type of analysis can be use to analyse the vibration:

◦ Use of an analyser
◦ Normal vibration patterns
◦ Compressor cross talk
◦ Pressure reversal
◦ Normal vibration pattern wrap-up
 Systematic compressor analysis
This approach is to ensure a thorough compressor evaluation that consumes the least amount of time.
Following a guideline that could be utilized in a form:

VEs or VEd – volumetric efficieincy (suction or discharge)

CRC – channel resonance correction
Ps – pressure suction (suction terminal pressure)
Pd – pressure discharge (discharge terminal pressure)
MCA – marker correction angle
 Fault Detection
Principle Component Analysis (PCA) – reduce the number of variables of a data set while preserving as much
information as possible
This technique enables to create and use a reduced set of variables which are called principal factors. A reduced
set is much easier to analyse and interpret.
PCA is extended to be used for classification of variables and hence early identification of abnormalities in the
data structure.
Step by step of PCA:
◦ Step 1: standardization
◦ Step 2: covariance matrix computation
◦ Step 3: compute the eigenvectors and eigenvalues of the covariance matrix to identify the principal components
◦ Step 4: feature vector
◦ Step 5: recast the data along the principal components axes
PCA – for selecting vibration feature and detecting faults in a reciprocating compressor
Vibration datasets were collected from the compressor under baseline condition and five common faults: valve
leakage, inter-cooler leakage, suction valve leakage, loose drive belt combined with intercooler leakage and belt
loose drive belt combined with suction valve leakage
COMPRESSOR LUBRICATION
 Purpose of lubrication
Lubrication of compressors must be accomplish one or more of the following:
1. Reduce friction between moving parts
2. Carry heat away from bearing surfaces
3. Prevent corrosion both during operation and when compressor is stopped
4. Reduce gas leakage between seal faces and close clearances
5. Separate the rubbing parts
6. Flash away entering dirt
7. Minimize wear
8. Reduce friction loss
9. Minimize deposits
Reciprocating Compressor Crankcase
• The oil pump delivers a continuous flow of 40-45
psi oil to the main and connecting rod bearings in
order to reduce friction and carry away heat.
• Oil sump temperature is usually maintained at
135 to 160⁰F to prevent moisture condensation.
• The pump pricks up oil from the crankcase,
passes it through an oil filter and controlled
cooler and back into the main bearing header.
• High viscosity oil – reduce the oil flow to the
bearings causing hotter bearing surfaces
• Low viscosity oil – inadequate to lubricate the
compressor cylinders or packing in those units
using crankcase oil for the dual purpose.
Properties of lubricant
Have knowledge about the properties of the lubricants is important in determining which lubricant is best for
which situation.
They are:
◦ Viscosity – “internal resistance to flow”. Higher viscosity lubricants are thick and do not flow, and vice versa. Low
viscosity lubricants have a closer consistency to water and do flow.
◦ Viscosity index – the rate of change in viscosity with changes in temperature (how much viscosity changes as
temperature changes)
◦ Oxidation stability – high temperatures, water and acids will accelerate the rate of oxidation. The life of a lubricant is
reduced as temperatures increase, leading to varnish and sludge.
◦ Pour point – the lowest temperature at which a lubricant will flow or pour like a liquid. This can differ depending on test
conditions.
◦ Demulsibility – the ability of a lubricant to separate from water
◦ Flash point – the temperature at which a lubricant will ignite when heated and mixed with air, but a flame is not
sustained
◦ Thermal stability – ability of lubricants to resist the chemical combination with oxygen. It can result in the creation of
sludge deposits and increased viscosity.
◦ Fire point – the temperature at which the oil sparks and the flame is sustained. The fire point for lubricating oil is
typically 371⁰C or above.
◦ Oiliness – the ability of oil to spread over.
◦ Adhesiveness – ability of the oil particles to stick to the metal surface.
◦ Specific gravity – the measure of the density of oil.
Components that need lubrication
Frame
Main bearings
Connecting rod bearings
Cross head bearings
Motor bearings
Cylinder region
Rider bands
Compression rings
Packing
Valves
Methods use for lubrication
Splash lubrication systems
forced-feed systems/full pressure circulation/pressure lubrication system
Splash
 Splash lubrication system
Crankcase Use to store the oil which is passed through the oil galleries for the proper lubrication.
Oil strainer Use to filter the impurities present in the oil such there should not be any blockage at any
part.
Oil pump Use to transport the fluid from the crankcase to all parts of the engine.
Oil troughs Located below the scoop of piston. When the piston moves in reciprocating motion, the
scoop of piston lifts oil from the oil troughs.
Crankshaft The power obtained from the crankshaft will be transmitted to all part of the vehicle.
Scoop Connected at the end of the piston and the scoop of piston lifts the oil from oil troughs.
Piston Converts the reciprocation motion into rotory motion of the crankshaft.
Cam shaft Consists of cams which are used for operating the valves in the internal combustion engines.
Oil pressure gauge Use to measure the pressure of oil in the engine cylinder.
Working of oil is filled in the

splash crankcase

lubrication provides adequate

lubrication to piston
pins. piston rings,
oil strainer removed
any impurities
valve mechanisms present in the oil
and cylinder walls

oil is thrown oil pump supply the

upward either as oil to all parts
droplets or fine mist including oil troughs

oil is pslashed from

the oil trough in the
lower part of the
crankcase
Force-feed
Pressure lubrication system
Crankcase Use to store the oil which is passed through the oil galleries for the proper lubrication.
Oil strainer Use to filter the impurities present in the oil such there should not be any blockage at
any part.
Oil pump Use to transport the fluid from the crankcase to all parts of the engine.
Oil troughs Located below the scoop of piston. When the piston moves in reciprocating motion,
the scoop of piston lifts oil from the oil troughs.
Crankshaft The power obtained from the crankshaft will be transmitted to all part of the vehicle.
Oil galleries In the form of pipes. Better than scoop because there is no case of leakage and the oil
will be passed to all the parts of the engine for better lubrication.
Piston Converts the reciprocation motion into rotory motion of the crankshaft.
Cam shaft Consists of cams which are used for operating the valves in the internal combustion
engines.
Oil pressure Use to measure the pressure of oil in the engine cylinder.
gauge
Working of forced- oil drawn from

feed lubrication crankcase

through
strainer to the
oil pump
oil pump
back to pumped the
reservoir oil through oil
filter

then to the the oil filter

crank bin led the oil
bearing and under
to the pressure to
crosshead the crankshaft

oil was forced main bearings

to through in the
thecrankshaft crankshaft
then to were
connecting rod lubricated
COMPRESSOR MAINTENANCE
Benefits of Maintenance
Money savings – unmaintained compressors are bound to have performance issues and lead to
costly repairs and downtime
Maximum efficiency – when the compressor performs at full capacity without fail, all the tools
along the assembly can perform at maximum speed and keep the productivity flowing day in,
day out
Productivity – to perform functions at speeds and capacities at highest productivity
Longer service life – to reduce need for parts replacement and system repairs
 General maintenance notes
Pressure relief valve • It is an automatic pop valve.
• Do not readjust.
Tank drain valve • Located at bottom of tank.
• Open drain valve daily to drain condensation.
• Do not open the drain if tank pressure exceeds 25 PSIG.
• The automatic tank drain equipped compressor requires draining manually once a week.

Pressure switch • this switch is automatic and will start compressor at low pressure and stop when the maximum
pressure is reached. It is adjusted to start and stop compressor at the proper pressure for the unit on
which it is installed.
• Do not readjust.
Belts • Must be kept tight enough to prevent slipping.
• If belts slip or squeak, see V-belt maintenance procedure.
Compressor valve • remove valve and clean thoroughly, using compressed air and a soft wire brush.
• After cleaning, all parts are replaced in exactly the same position and joints must be tight or the
compressor will not function properly.
• When all valves are replaced, perform a timed pump-up test and check to see that it meets factory
satisfaction.
 Keys to maintaining an efficient
compressor
No. Key Maintenance Description
1. Preventive maintenance • Include partial or complete overhauls at specified periods, oil
changes, and lubrication.
• The equipment information and deterioration can be recorded to
know when to replace or repair worn parts before they can cause
failure.
• This is designed to preserve and restore equipment reliability by
replacing worn components before they actually fail.
2. Corrective maintenance • Conducted to get equipment working again or fix any problems
found during preventive maintenance.
• The goal is to avoid or reduce the consequences of failure of your
compressed air equipment
3. Assessing equipment • Things needed for assessing equipment:
1. Criticality
2. Age and history
3. Frequency of failure
4. Trust degree to perform as designed when scheduled to run
5. Need or not to change to more advance technology
4. Knowledge on what the equipment needs • Maintenance instructions
• Operations and parts manual
Guideline for
Maintenance Checklist
Suggested Frequency for Maintenance
Daily or before each operation • Check for oil leaks
• Check lubricant level. Fill as needed.
• Drain receiver tank condensate (if automatic draining device is not
provided).
• Check for unusual noise and vibration
• Ensure beltguards and covers are securely in place.
• Ensure engine is filled with fuel and lubricant according to the
manufacturer’s recommendations.
• Ensure area around compressor is free from rags, tools, debris and
flammable or explosive materials.
• Check system oil pressure on pressure lubricated models while
compressor is hot.
Suggested Frequency for Maintenance
Weekly • Observe operation of safety/relief valves while the compressor is running. Replace
safety/relief valves that do not operate freely.
• Inspect air filter element(s). clean if necessary.
• Check V-belts for tightness. The V-belts must be tight enough to transmit the
necessary power to the compressor. Adjust the V-belts as follows:
a. Remove bolts and guard to access compressor drive.
b. Loosen mounting hardware which secures motor to base. Slide motor within slots of
base plate to desired position.
c. Check the manufacturer’s specifications for correct belt tension. Apply pressure with
belt tension checker to one belt at midpoint span. Make further adjustments if
necessary.
d. Check the alignment of pulleys. Adjust if necessary.
e. Tighten mounting hardware to secure motor on base.
f. Re-install guard and secure with bolts.
WARNING: Never operate unit without belt guard in place. Removal will expose
rotating parts which can cause injury or equipment damage
 Suggested Frequency for Maintenance
Monthly • Inspect for air leaks. Squirt soapy water around joints during compressor
operation and watch for bubbles.
• Check tightness of screws and bolts. Tighten as needed.
• Inspect drive belts. Adjust if necessary.
• Clean exterior
Every three months (90 • Change crankcase oil. Use type and grade oil as specified.
days)
• Check entire system for air leakage around fittings, connections, and
gaskets, using an ultrasonic leak detector or using soap solution and brush.
• Tighten nuts and cap-screws as required.
• Check and clean compressor valves, replace gasket valve assembly when
worn or damaged.
CAUTION: Valves must be reinstalled in original position. Valve gaskets
should be replaced each time valves are serviced.
• Pull ring on all pressure relief valves to assure proper operation.
COMPRESSOR TROUBLESHOOTING
Guideline for troubleshooting:
Define the problem. 1. What exactly is the problem?
2. What should the performance be?
3. What is the performance now?
History of the compressor. 1. How long has it been operating?
2. When was the last overhaul?
3. What changes were made at that time?
4. When did the problem start?
5. Was it a quick or gradual change?
6. Note the trend of various parameters.
7. What else change, what other problems occurred at this time.
i. On the compressor?
ii. In the process?
iii. In operation and control?

Verify all data. 1. Have instruments been calibrated?

2. Do cross checks agree?
Troubleshooting checklist
Test data • Complete power balance.
• Check pressure taps: location, size, and condition.
• Is there liquid in pressure lines?
• Note the temperature probe insertion depth, and heat transfer.
• Calibrate instruments.
• Inspect flow meter: wear and sludge build up.
• Are there condensates in gas analysis?
• Is there a vortex or undeveloped velocity profile upstream of flow meter
• Conduct a mass flow balance.
Equipment problems • Vortex or undeveloped velocity profile upstream of compressor suction
• Internal leakage across diaphragm splitline
• Recirculation from rubbed interstage seals or balance piston seals, casing drains, other areas
• Foreign object damage or blockage
• Liquids in process
• Dirt accumulation or polymer build-up
• Erosion of impeller blades and diffuser passages
• Proper direction of rotation
• Balance line sleeve
Economics • Per diem cost to operate as is
• Associated risks
• Cost for repairs
• Cost for down time to complete repairs
• Safety concerns
Example of Problems and What To Do
Example of Problems and What To Do
COMPRESSOR FAILURE
 Factors of Failure
Failure of reciprocating compressor can cause system lags and affect the seamless operation
processes.
The major culprits of reciprocating compressor valve failure are:
Environmental Factors Mechanical Factors

• Improper lubrication – stale or acidic lubricants can • Spring failure – a wear down of the spring attached to
damage the metallic part of the valve the valve, due to stress could cause the improper
• Corrosive contaminants – corrosive elements that functioning of the valve
touch the valve can cause its metallic part to wear off • High-cycle fatigue – the compressor’s operation at high
• Foreign material – foreign material in the reciprocating cycles over a long time can lead to stress which could
compressor can affect the valve’s inner lining and block affect the valve
airflow • Off-design operation – reciprocating compressors are
of various models each suited to certain purpose,
hence, the use of a compressor beyond the operations
which it was designed for could wear down the valve
 Failure, Diagnosis & Repair
FAILURE Overly high suction Low discharge pressure Overly high discharge Quiet compressor
pressures temperature
DIAGNOSIS • The pressure • When the pressure appears • Air discharged re- • Operating at low
may be higher inadequate, the valve enter the cylinder volumes
than normal passage may have been through unsecured • The machine may
blocked valve seal be unable to
• Usually accompanied by operate at its full
excessive suction pressure capacity
REPAIR • Inspect the • Inspect the system for valve • Inspect the LP valve
unloading system wear, leakage, or instrument and unloading system
to determine the problems
cause
Effect of Failure of Reciprocating
Compressor