Section 3 - RECIPROCATING COMPRESSOR / OPERATING LOG SHEET
UNIT MAINTENANCE RECOMMENDATIONS - RECIPROCATING GAS COMPRESSOR
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SYSTEM MAINTENANCE
The unit will operate as designed with built in safety controls to protect the specific components of
the equipment in case of malfunction.
It requires only routine inspection and maintenance. However, the maintenance of an adequate log
will indicate small changes in performance and provide early warning of possible malfunction.
BASIC PREVENTIVE MAINTENANCE RECOMMENDATIONS
Please consult the vendor documentation section of the unit manual for recommended
maintenance intervals of the compressor and engine respectively.
1.
Maintain permanent logs of Pressure, Temperature and other pertaining data:
A. Pressure
1)
Compressor Discharge pressure
2)
Compressor Interstage Pressures
3)
Compressor Suction pressures
4)
Compressor Lube oil pressures
5)
Engine Lube oil pressures (if engine drive)
6)
Gear box Lube oil pressures (if applicable)
7)
Compressor Oil Filter differential pressure (if applicable)
B. Temperature
1)
Compressor Lube oil temperature
2)
Engine Lube oil temperature (if engine drive)
3)
Gear box Lube oil temperature (if applicable)
4)
Cooling water temperature – all systems
5)
Process Gas Compressor suction, interstage and discharge temperatures
6)
Ambient temperature (dry bulb and wet bulb)
C. Other
1)
Operating hours of each rotating piece of equipment
2)
Lube oil levels and oil consumption – all devices
3)
Water levels – all systems
4)
Chemical levels (50/50 Glycol etc)
5)
All repairs, changes or adjustments
D. As a minimum, analyse these recordings each day. When they differ from design or
established limits, determine the cause and make corrections as soon as possible.
2.
Valves
A. Observe bonnet type on any valve. Screw type bonnets must be wrench held when back
seating valve stem or loosening packing nut. DO NOT SERVICE ANY VALVE WHEN
THE SYSTEM IS PRESSURISED AND / OR OPERATING.
B. Ensure that all valves are in there normal operating position.
3.
Each safety control and relief valve should be tested at least once each year in accordance
with the manufacturer's recommendations and local codes.
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Section 3 - RECIPROCATING COMPRESSOR / OPERATING LOG SHEET
UNIT MAINTENANCE RECOMMENDATIONS - RECIPROCATING GAS COMPRESSOR
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4.
Any pipe or vessel showing rust should be cleaned and painted. Repair insulation as
required.
5.
Use machinery manufacturer's recommended lubricants.
6.
Maintain correct belt tension on all drives. Check couplings on direct driven units.
7.
Monthly oil analysis should be performed (Increase frequency under extreme conditions).
8.
Rotating equipment should be checked for wear by qualified personal as per the OEM
recommendations.
9.
Maintain correct water treatment as required.
10.
Maintain compressor lube oil levels, but do not fill above recommended level. Please consult
the operation and maintenance section for additional information.
11.
Safety guards must be in place after any service and before operating.
12.
Keep all equipment and the machinery room clean.
13.
Never close valves on pressure operated safety controls or "shunt out" electrical control
circuits. Repair or replace defective controls as soon as possible.
14.
Locate and repair all oil leaks promptly.
15.
High quality oil will ensure longevity and reliability. Oil quality will rapidly deteriorate in
systems containing moisture, air, H2S or other contaminates. Monthly oil analysis is to be
performed by a lab that specializes in this procedure as a minimum.
16.
The driver will require routine maintenance as listed in the manufacturer manual in the
driver section. An optional used oil storage tank is often provided in the outer edge of the
skid. This tank is normally sized to provide capacity for four oil changes.
It remains the Operator’s responsibility to continually monitor the package for harmful
vibration levels and to advise the necessary parties, for implementation of corrective actions,
as soon as possible.
The compressor and the unit should be routinely serviced by a qualified mechanic.
Natgas Global Resources Inc.
Section 3 - RECIPROCATING COMPRESSOR / OPERATING LOG SHEET
UNIT MAINTENANCE RECOMMENDATIONS - RECIPROCATING GAS COMPRESSOR
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LOG BOOK MAINTENANCE RECOMMENDATIONS
It is recommended that a maintenance log is kept, which will track the operation of this unit. An
adequate log will indicate small changes in performance and provide early warning of possible
malfunction.
For packages with multiple compressors, a log for each compression system and the each
compressor should be maintained.
The following section is for the Reciprocating Compressor Only. Refer to the manufacturers
recommended maintenance (contained in this manual) for other components of the system.
MAINTENANCE
Check Frame Oil Pressure
Check Frame Oil Level
Check Lubricator Block Movement
Check Primary and Secondary Packing vent for
blowing
Check for Oil Leaks
Check Operating Pressures and Temperatures
DAILY VERIFICATIONS
MONTHLY VERIFICATIONS
Confirm safety shutdown verifications
For High Pressure Cylinders
– Remove Cylinder head and verify lubrication
SIX MONTH (4000 HR) VERIFICATIONS
AND SERVICE
Change Lubricator box oil
Change Oil Filter
Change Oil
– With Oil drained, visually check for foreign
matter
Clean Oil Strainer
Check Fluid Level in Dampener
Retighten Hold Down Stud Nuts
For cylinders rate 3500 psig or greater, inspect
for piston ring end gap.
Natgas Global Resources Inc.
Section 3 - RECIPROCATING COMPRESSOR / OPERATING LOG SHEET
UNIT MAINTENANCE RECOMMENDATIONS - RECIPROCATING GAS COMPRESSOR
YEARLY (8000 HR)
VERIFICATIONS AND SERVICE
Check main bearing clearance
Check connecting rod clearance
Check crank thrust clearance
Check crosshead guide clearance
Inspect valves for broken or worn components
Inspect cylinder bore
Inspect piston ring end gap
Inspect piston rod
Rebuild cylinder packing cases
Inspect frame alignment and re-shim feet as
required
– realign coupling to tolerances
Confirm safety shutdown verifications
Check and record rod run out
Grease VVCP stem threads
Clean crankcase breather filter
Adjust drive chains
Pressure test distribution blocks
EVERY 2 YEARS (16000 HR)
VERIFICATIONS AND SERVICE
Inspect auxiliary and chain drive sprockets
Rebuild oil wiper cases
EVERY 4 YEARS (32000 HR)
VERIFICATIONS AND SERVICE
Verify main and connecting rod bearing
clearances
Check crosshead guide clearance
Check crosshead pin to crosshead pin bore
Check connecting rod bushing bore
Check for excessive wear in auxiliary end drive
chain tightener
Check excessive ring grove wear in pistons
EVERY 6 YEARS (48000 HR)
VERIFICATIONS AND SERVICE
Replace main and connecting rod bearing shells
and bushings
Replace lubricator distribution blocks
Replace crosshead bushings
Replace DNFT
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RECIPROCATING COMPRESSOR / OPERATING LOG SHEET
UNIT LOCATION
COMP TYPE
DATE
TIME
HOUR
AMBIENT TEMP (IN/OUT)
/
UNITS
COMPRESSOR
1st Stage
1st Stage
2nd Stage
2nd Stage
2nd Stage
2nd Stage
3rd Stage
3rd Stage
3rd Stage
3rd Stage
SUCTION PRESSURE
SUCTION TEMPERATURE
DISCHARGE PRESSURE
DISCHARGE TEMPERATURE
SUCTION PRESSURE
SUCTION TEMPERATURE
DISCHARGE PRESSURE
DISCHARGE TEMPERATURE
SUCTION PRESSURE
SUCTION TEMPERATURE
DISCHARGE PRESSURE
DISCHARGE TEMPERATURE
FRAME OIL PRESSURE
FRAME OIL LEVEL
LUBRICATOR BLOCK
MOVEMENT
PRIMARY PACKING VENT
BLOWING
SECONDARY PACKING
VENT BLOWING
VISIBLE OIL LEAKS
/
/
/
/
/
/
RECIPROCATING COMPRESSOR / OPERATING LOG SHEET
SEPARATORS
SEPARATOR
TEMPERATURE
LEVEL (% OF GLASS)
ELEMENT PRESS DROP
DRIVER
(If applicable)
AMPS
TEMPERATURE
GEAR BOX
(If applicable)
CASE OIL TEMPERATURE
CASE OIL PRESSURE
OIL COOLING H2O TEMP
ENGINE
FUEL PRESSURE
CRANKCASE OIL TEMP
CRANKCASE OIL LEVEL
TURBO WATER TEMP (HOT)
TURBO WATER LEVEL
JACKET WATER TEMP (HOT)
JACKET WATER LEVEL
REMARKS: