Reciprocating Compressors:: Operation and Maintenance
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Table of contents
- Cover
- Reciprocating Compressors: Operation & Maintenanceiii
- Copyright Pageiv
- Contentsv
- Acknowledgmentsvii
- Prefaceix
- Chapter 1. Reciprocating Compressors and Their Applications1
- Introduction1
- What Is a Compressor?1
- How Compressors Work3
- Methods of Compression6
- Types of Compressors7
- Compressor Definitions9
- Pressure11
- Pressure Definitions Associated with Compressors12
- Theory of Reciprocating Compressors13
- Characteristics of Reciprocating Compressors26
- Compressor Type Selection34
- Reciprocating Compressor Cylinder Arrangements42
- Chapter 2. Design and Materials for Reciprocating Compressor Components44
- Materials of Construction47
- Non-Lubricated or Oil-Free Cylinder Construction71
- Piston Rod Column or Frame Loading82
- Disturbing or Shaking Forces90
- Foundations for Reciprocating Compressors96
- Compressor Piping and Pulsation99
- Design Overview of Labyrinth Piston Compressors102
- Chapter 3. Operation and Maintenance of Reciprocating Compressors107
- Lubrication of Reciprocating Compressors107
- Operational Problems and Maintenance of Compressor Valves131
- Compressor Piston Rod Packing167
- Compressor Control Systems192
- Compressor Cylinder Cooling209
- Non-Lubricated Compressor Maintenance215
- Labyrinth- Piston Compressors217
- Chapter 4. Overhaul and Repair of Reciprocating Compressors227
- Rule of Thumb for General Running Clearances227
- Compressor Alignment230
- Web Deflection Measurements231
- Compressor Cylinder Alignment242
- Foundation Problems and Repairs247
- Compressor Bearing Maintenance and Replacement251
- Cylinder Repair and Maintenance256
- Compressor Piston Maintenance268
- Rebuilding Compressor Pistons282
- Installing Pistons on Piston Rods284
- Setting Piston End Clearances288
- Inspection and Reconditioning Piston Rods290
- Manufacture of Compressor Piston Rods294
- Other Compressor Component Repairs296
- Compressor Part Replication301
- Chapter 5. Troubleshooting Compressor Problems303
- Introduction303
- Compressor Problems304
- Typical Compressor Problems307
- Troubleshooting Lubrication Systems317
- Significance of Intercooler Pressures318
- Interstage Pressures325
- Belt Drives326
- Motor Controls326
- Diagnostic Tests326
- Evaluating Reciprocating Compressor Condition Using Ultrasound and Vibration Patterns329
- Compressor Service Technician Reports335
- Basic Air Compressor System Evaluation337
- Chapter 6. Preventive Maintenance for Reciprocating Compressors340
- Introduction341
- Compressor Maintenance341
- Emergency Repairs Should Be Minimized342
- Effectiveness of Preventive Maintenance343
- Compressor Preventive Maintenance Program346
- Spare Parts351
- Vendor Selection353
- Personnel Training355
- Maintenance Contractors356
- Predictive Maintenance359
- Integrated Condition Monitoring Systems362
- Chapter 7. Safety in Operation and Maintenance369
- Basic Safety Rules369
- Lock-Out/Tag-Out Program369
- Safe Maintenance Procedures Restated375
- Valve Installation376
- Fires and Explosions378
- Summary382
- Air Piping383
- Bibliography388
- Appendix: Reciprocating Compressor Calculations389
- Index408
For anyone responsible for purchasing, servicing, or operating reciprocating compressors, this book discusses the theory of operation and explains how to install, troubleshoot, overhaul, and repair all types of compressors.
This broad comprehensive text offers practical details on how to purchase, service, operate, and maintain compressors used in any of the process industries such as pulp and paper, mining, food processing, pharmaceuticals.
This broad comprehensive text offers practical details on how to purchase, service, operate, and maintain compressors used in any of the process industries such as pulp and paper, mining, food processing, pharmaceuticals.