Maintenance of Reciprocating Compressor

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- Components of Compressor CRANKSHAFT CROSSHEAD PISTON ROD PISTON

CROSSHEAD GUIDE

CONNECTING ROD

FRAME

CYLINDER

- Installation Flow Crankshaft Main Bearings Assemble Crosshead & Connecting Rod Coupling / Alignments Rod Packing Piston Bar-over Test Compressor Valves
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Disassemble

- Location of Bearings MAIN BEARING CRANK PIN BEARING CROSSHEAD PIN BEARING / BUSH

CROSSHEAD SHOE

- Disassembling of Main Bearings Disassemble frame tie rod

W ier Rope Eye Bo l t

Upper meta l

Remove the cap with upper metal

Set Scre w Lo wer Meta l

Install special tool into oil hole of crankshaft

D isasse mb l ing Too l

Crank Sha ft

To Tu rn

Turn the crankshaft and remove the lower metal

Lo wer Meta l

- Assembling of Main Bearings Assembling lower metal

Assembling crankshaft

Assembling upper metal with cap

Tighten the upper cap by torque wrench

(820 N-m)
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- Construction of Crosshead & Connecting Rod -

- Assembling of Connecting Rod Assembling of connecting rod can be done by the opposite flow of assembling. However, tightness of big end bolts are controlled by its elongation.

So, please measure its length before and after installation.

- Disassembling of Crosshead After disassembling of piston and connecting rod. Tilt the crosshead by 90 and take out crosshead from window of crosshead guide or compressor frame.

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- Assembling of Crosshead In case of assembling of crosshead, please take care that there are two type of crosshead shoes. One is Cshoe and the other is O shoe.

And after assembled to the crosshead guide, clearance between crosshead and crosshead guide to be recorded.
Planned clearance is 0.20 0.29mm and the using limit is 0.40mm.
O Shoe
C lea rance
Measu r ing Po in t

C Shoe

C Shoe

O Shoe

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- Measurement of Crank Arm Deflection 1. Set the deflection gauge (special dial gauge) between each crank arm at 0 position. Turn and measure the movement at 90, 180, 270. For example, if the measured deflection is 0 +0.06mm, jack up the turning gear at the half of the measured value of 0.03mm. Adjustment limit is 0.03mm and using limit is 0.06mm
0

2. 3.

90

180

4.

270

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- Construction of Cylinder PISTON ROD PACKING CYLINDER LINER SUCTION VALVE SUCTION VALVE UNLOADER

DISCHARGE VALVE

PISTON

CLEARANCE POCKET

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- Construction of Piston Rod Packing Piston rod packing Packing case

Tie bolt
Rod packing Gater Spring
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- Assembling of Piston Rod Packing There are three types of packing. Butt-cut type (a) Step-cut type (b) Backup ring (c) Please take special care for the direction & combination of packings. Incorrect direction or combination will cause the leakage of gas. After assembled to packing case, please measure the side clearance and record it.
F R A ME S I D E

(a)

R1 No .1 &2

T1

R0

R3 No .3 &4

T5

R0

(b)
T5 No .5 T5

(c)

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- Construction of Piston Piston ring Rider ring

Piston rod Piston nut

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- Assembling of Piston Assemble piston rod & piston rings to piston

R E M O V E T H EN YL O N SL I N G C H AI N BL O C K AF T E R I NS E RT I N GR O D C YL I N D E R

R O DP A C KI N GP R O T E C T O R

Set piston rod wrench to piston nut & set protector for the threaded portion of piston rod
L E N G T H PI S T O NR O DW R E N C H 1 S T A/ B : a 2145 W EI G H T 1 S T A/ B : 208 kg

Then, hoist the piston assembly and install into cylinder

Inserting the piston assembly, install the rider rings to piston Screw in the piston rod to crosshead

Protect ing Cap for P is ton Rod Pack ing

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- Assembling of Piston Adjust the screw travel by markings on piston rod and crosshead by using divider. Then, tighten cross nut. The reference length indicated on window of crosshead guide

Measure the clearances between piston & cylinder liner for four directions
Assemble cylinder cover Carry out bar-over test (End clearance, runout)
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- Assembling of Piston Rings (1) Two PPS ring form one set. In case of exchange exchange as set not one ring alone. (2) At installation, install the piston rings in the direction parallel with piston axis. Dont install from direction b. (3) After assembled to piston, measure and record the side clearance.

P iston R ing

P iston Body

D irect ion "a" D irect ion "b"

(4) When assembling, locate the two rings 180 apart each other.

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- Maintenance of Rings (1) Wear limit of piston rod packing is 3mm at the height of the ring. In case of replacement, do not replace one ring alone. The planed life of rod packing is 8000hrs, so maintenance required within 8000hrs.

In i t ia l

Wea r L m i it

(2) The planned life of piston ring is also 8000hrs however, only for initial operation, we recommend you to overhaul at 4000hrs to estimate the actual life.

P iston P iston R ing

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- Maintenance of Rings (1) The wear limit of rider ring is by the bottom clearance between piston and cylinder liner becomes 0.5mm. The planned life is 8000 hrs, however, for initial maintenance, we recommend you to carry out overhaul at 4000hrs to estimate the actual life. (2) To determine the life, please plot the clearance versus operation time like the below graph.
Gap

0 .5 m m Wear L m i it

Dm i en t ion

Tm i e L i fe Expec ted Next Check

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