5 COMPRESSOR MAINTENANCE
5.1 Preventive Maintenance
This schedule of maintenance, in general terms, is a preventive maintenance guide and running service necessary for our range of reciprocating compressors. However, it does not cover for any eventualities, which could occur from neglect or incorrect operation by the customer or adverse environmental conditions.
Before carrying out any preventive maintenance work related to this equipment it is a requirement that you read and work in accordance with the Safety Precautions given in Chapter 2 of this Instruction Manual. Also, for your own protection, be sure to read and obey WARNING and CAUTION notices and observe any special notes you find in this Chapter and any associated literature.
When working on the compressors rotational parts you MUST fit piston rod clamps to prevent possible uncontrolled movement of the crankshaft and motion work. Refer to Maintenance Procedure Job No. 002 Fitting Piston Rod Clamps.
On plants with two or more compressors the opportunity should be taken during the early weeks of running, following commissioning, to vary the service hours of the compressors so that no two machines reach their maintenance interval at the same time. A gap of about 200 hours between machine running times is recommended.
When 'running-in' a new compressor the crankcase oil MUST be renewed after the first 500 hours of operation and thereafter change in accordance with the intervals laid down in the following maintenance schedule.
5.1.1 Maintenance Schedule
The following schedule, lists recommended maintenance tasks which are designed to both prevent unplanned machine breakdowns and to help the maintenance teams to plan maintenance activities. Where a maintenance activity requires greater explanation than that given in the schedule a reference to the relevant associated maintenance instruction is given.
All materials used for scheduled maintenance and repair MUST COMPLY with Gardner Denver Belliss & Morcom standards and the standards laid down by associated equipment manufacturers. Only approved spares may be used.
When a system component associated with a mechanical or electrical device is changed or renewed, the system must undergo a functional test before the equipment is returned to service.
OPERATION & MAINTENANCE MANUAL
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CHAPTER 5 - COMPRESSOR MAINTENANCE
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Date: May 2002 Page: 52 of 145
EACH DAY
A shutdown of the compressor is not normally required for a Shift inspection.
Tasks Supplementary Information
Check all temperature and pressure gauge readings are normal.
Report immediately any abnormality.
Note: Observe operation of moisture trap drains.
Check for undue noise, oil leakage, vibration or
heat. Report immediately any abnormality.
Note: Ensure that load control equipment is operating correctly.
Test protection circuits annunciator lamps. All
lamps MUST illuminate The 'Test' push-button is normally located on the compressor control panel. If a lamp fails, renew the bulb. If the new bulb does not illuminate report failure to the Supervisor.
Check the crankcase oil level. Oil level should be halfway up the window nut.
Use the breather aperture in the top of the crankcase to top-up the oil. Refer to the table of lubricants for oil type.
Note: Where vee belts are fitted check tension and adjust if necessary.
Any aspect of the Shift inspection requiring further attention MUST be reported for action as required.
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MONTHLY - INSPECTION
A shutdown of the compressor is not normally required for a monthly inspection.
Tasks Supplementary Information
Carry out a running examination to ensure satisfactory operation of all compressor and ancillary equipment.
Record all temperatures, pressures and hours run on compressor log sheet.
Note: Check air inlet filter element cleanliness - renew if necessary.
Check the cleanliness and ensure correct operation of drain traps on compressor and ancillary equipment where applicable.
Clean drains and renew worn or damaged parts, as required.
Check all external bolts and nuts on the compressor including the holding down nuts for tightness.
Re-tighten or renew any missing nuts and bolts.
Tighten nuts to appropriate torque.
Check air pressure supplied to compressor
unloaders and note pressure drop. Pressure should be 7 bar minimum at unloader.
Any aspect of the Monthly inspection requiring further attention MUST be reported for action as required.
OPERATION & MAINTENANCE MANUAL
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Date: May 2002 Page: 54 of 145
SIX MONTHLY - SERVICE
The compressor is required to be shutdown for two days to perform this service schedule.
Tasks Supplementary Information
Carry out a running examination to ensure satisfactory operation of all compressor and ancillary equipment.
Record all temperatures, pressures and hours run on compressor log sheet. A copy of this form is provided in Appendices located at the end of this manual. Check cooling water flow rate (If flow recorder is fitted).
Check the cleanliness and ensure correct operation of drain traps on compressor and ancillary equipment where applicable.
Clean drains and renew worn or damaged parts, as required.
Check all external bolts and nuts on the compressor including the holding down nuts for tightness.
Re-tighten or renew any missing nuts and bolts.
Tighten nuts to appropriate torque.
Visually examine (through the valve pockets) the general surface condition of cylinder bores for evidence of ring wear or scoring.
Replace worn or damaged parts, as required
Check valve unloaders & interconnecting small bore pipework for defects.
Clean and service as necessary. Replace worn or damaged parts as required.
Examine piston rods along gland travel to
ensure no scoring is present. Clean and service as necessary. Renew worn or damaged parts as required.
Check that inlet filter is clean Clean and service as necessary.
Check that inter and aftercooler moisture drains are operational and that the diffusers on the blowdown valves are clear and clean..
Clean and service as necessary
Check one suction and one delivery valve from
each stage for cleanliness or fouling. Clean and service as necessary. Renew worn or damaged parts as required.
Renew third stage piston rod packing, piston
rings and rider rings. Renew worn or damaged parts as required.
Check integrity of all flexible air and water
pipes. Record condition. Renew worn or damaged parts
as required.
CRANKCASE INSPECTION
Examine crossheads and main guide slipper
paths, condition and clearances. Clean and service as necessary. Renew worn or damaged parts as required.
Check connecting rod bottom end bolts are
pinned. Rectify as required.
Check that lubrication oil suction strainer is clean and all pipework to main pump is in good order and that unions are tight.
Clean and service as necessary. Tighten unions and renew worn or damaged parts as required.
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SIX MONTHLY - SERVICE (Cont)
Tasks Supplementary Information
Check that crankcase oil is clean and no foreign particles are present. Ensure that oil delivery filter is clean and that oil pressure is satisfactory.
If dirty renew crankcase oil and delivery filter element. If necessary investigate source of any foreign particles. Refer to table of lubricants for oil type and quantity.
The crankcase oil and the delivery filter are renewed as a matter of course during the Annual Service.
Any aspect of the Six Monthly service requiring further attention MUST be reported for action as required. On completion of the service, re-commission the compressor and recording all operating pressures and temperatures. Ensure that the working area is left in a clean and tidy condition.
ANNUALLY - SERVICE
- (or as stipulated by local regulations)The compressor is required to be shutdown for five days to perform this service schedule. All Six Monthly tasks are to be undertaken as part of this schedule.
Tasks Supplementary Information
Remove all air valves and replace with factory refurbished units.
Renew crankcase oil and delivery filter
element. Refer to table of lubricants for oil type and
quantity.
Inspect connecting rod bottom end shells, crankpin, top end bearing and gudgeon pin.
Check motion work clearances.
Clean and service as necessary. Renew worn or damaged parts as required.
Withdraw pistons and piston rods and examine wear. Gauge cylinder bores and piston rods for wear and record readings.
Renew piston rings, piston rod packings, and piston rod scrapers.
Check condition of water jacket spacers for fouling from lime deposits.
Report condition.
Check cleanliness of motor ventilation fan and that air flow paths are clean. Carry out an insulation resistance check on motor windings and record readings.
Clean and service as necessary. Renew worn or damaged parts as required.
Check all system protection devices and circuits for correct operation.
Use a calibrated test rig to test the protection devices. Alternatively the devices can be tested
OPERATION & MAINTENANCE MANUAL
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Date: May 2002 Page: 56 of 145
TABLE OF LUBRICANTS
Lubricant Supplementary Information Crankcase Oil
Oil Capacity 91 Litres
Recommended Lubricant SAE 30 oil (ISO VG 100) (Ambient temperature 0oC to 45oC)
Approved Brands:-
BP Vanellus M30 Esso Essolube HDX 30 Mobil Delvac 1330 Shell Rimula X30
Alternatively:- The oil MUST be a good quality mineral oil having a flash point (open test) of not less than 210o C and within a viscosity range (Centistokes) of 110 at 40o C to 12.5 at 100o C, the oil should also contain rust and oxidation inhibitors and anti-foam additives.
If the site is particularly hot (over 45oC) then use an SAE 40 oil (ISO VG 150)