Synopsis

• Gas End Maintenance

• Packing Maintenance
• Power End Maintenance
• Troubleshooting Chart
• Running Clearances
• Preventive Maintenance Schedule
 Gas End Maintenance
Removal of valves (Suction/Discharge) /
Unloading devices

Checking of piston end and side

clearances

Disassembly of piston rod from cross

head

Removal of complete piston rod

assembly from cylinder

Inspection of piston rod, rider rings,

piston rings, piston and cylinder liner
Step-1:Removal of Valves
Checking and restoring valve components
• Seat
– Check for signs of hammering-in on the sealing surface with the
cylinder and on the plane of contact with the cage and for signs
of passage of gas to the outside of the valve seat. These
abnormalities could be caused by loosening of the fastening
system fixing the valve and cage to the cylinder.

– Check the sealing surface with the plates. If deformation or

signs of hammering-in exist with consequent loss of planarity, it
will be necessary to restore the surface by finish grinding or
hand lapping using very fine lapping compound.
Checking and restoring valve components
• Plates
– In general, these elements are reutilize on condition that:
• Seal side hammering do not exceed 0.2mm in depth
• The impressions made by the coils of the springs or spider finger do not
exceed 0.2mm in depth
• The planarity of the plates does not exceed the value of 0.05mm

• Springs
– In general, these elements are reutilize on condition that:
• Verification of absence of wear
• Verification of the free height of the spring is equal to that of the new spring
• Nut
– Verify that the reutilizing nut has not lost its property of elasticity.
– Ensure that tapered and notched part offers resistance when
tightened onto the stud bolt
– Verify that self locking nut has been tightened to the specified
torque
 Lapped components

Valve Seat

Valve Plate
 Checking valve lift
Lift Washers

Nut

Pins

Stop Plate

Springs

Damping Plates

Valve Plate

Valve Seat
Valve testing
 Piston end clearance
• Crank and head end clearance is adjusted in
relation to cross head

• Head end clearance is kept more to accommodate

expansion during operation

• The head end clearance is kept 2/3 of the total while

the crank end clearance is kept 1/3
• Remove the suction valve and by using lead
wire/feeler gauge end clearance can be measured
Piston end clearance
Measurement piston end clearance

Step-2: Measuring piston end clearances using lead wire

Measuring piston to liner clearance

Step-2: Measuring Cylinder to liner clearance on all sides after

removing head flange
Disassembly of piston rod from cross
head

Step-3: Measuring distance between lock nut and cross head

for reference
Removal of piston rod assembly

Step-4: Removal of piston rod Assembly

Assembly of single nut one piece piston
arrangement

Angle of rotation of nut: α

Rod Piston lengthening: ∆L

 Inspection of piston rod

• Wear is measured in the central section of the length

subjected to sliding of the piston rod packing
• Wear that can allow satisfactory behavior of the piston
rod packing seal rings may reach the value of 0.2% of
the nominal diameter of the rod
• Beyond the limit specified above, rod will have to be
ground and use of under size packing rings is
recommended
• Reduction in diameter beyond limit specified by the
vendor, rod needs to be replaced/refurbished
Worn out piston rod
 Piston rod run out

• Is measure how compressor internal (piston, rod,

cross head) are lined up or frame and cylinder
combination.

• Run out check and adjusted in cold condition during

erection.

• Oil and gas packing should be loosened.

• Measuring Procedure
– Piston set at max. HE side
Procedure to measure Piston rod run out

• Set the dial indicator on the piston rod for horizontal

or vertical measurement.

• Piston is then moved towards crank end side and

measure the reading.
– A negative reading indicate piston is low and expansion
during operation is accommodated.
– A positive reading indicate piston is high in relation to
cross head.

• Adjustment to be made as per OEM reading

 Piston rod run out
When the piston is moved
towards crank side a
negative reading is obtained

A negative vertical reading is preferred as it accommodates the

piston expansion during operation
Measuring piston rod run out
Inspection of Piston & Rider rings
 Inspection of rider rings
• Open type rider ring should be mounted on the piston so
that it can not rotate during operation.

• Rider ring can be utilized after having reached maximum

wear after having turned it 180°.

• Rings should not be enlarged excessively during

assembly to avoid breakage.
 Inspection of rider rings
• The axial clearance between the rider ring and its
housing on the piston and end gap of the ring should be
as per assembly drawing of the piston.

• Wear on the rider ring is determined by

– Rod Drop
– Measuring the projection of the ring from piston or Piston to liner
clearance

– Measuring the run out on the rod between piston rod packing
and cross head in vertical and horizontal direction
Measuring rider ring axial clearance
Rider Ring axial clearance
Measuring Rider ring end gap
 Inspection of Piston rings
• Measure
– End Gap
– Axial Clearance in housing
 Inspection of cylinder liner
• Replacement of liner is to be proceeded as it reaches
the maximum value of wear and ovalization.
• Liner fitted without interference
– Remove cylinder head and pull out the liner using appropriate
pullers
– Prior to reinstalling, carefully check the o-ring placed between
liner and cylinder
– While inserting the liner, ensure that the dowel enters into its
housing
– For cylinder of the lubricated type, check that the lubrication
holes between cylinder and liner coincide with each other
– In liner with spacer, shim is used to recover the clearance
between cylinder head, spacer and liner
Cylinder liner
Gas End Maintenance
 Inspection of Piston Rod Packing
• Excessive leakage of gas from packing case is generally
caused by;
– Worn out seal rings.
– Poor condition of piston rod.
• Axial clearance between seal rings and cups should be
within the limits specified by OEM.

• Maintain position of the rings inside the cups and

position of the cups in the packing as per packing
assembly drawing.
 Inspection of Piston Rod Packing
• For cooled piston rod packing, check and carefully
reassemble the O-ring seal elements.

• After assembly check the various passages (oil, water,

vents) with air.

• The flange should be tightened by operating gradually on

the bolts. Defects in parallelism at assembly of the flange
are possible causes of rubbing between rod and cups
and of leakage.
Packing Rings Axial Clearance
 Inspection of Oil Scrapper Rings
• Assemble scrapper rings following the order specified on
the assembly drawing.

• Ensure that the scrapper ring lip is always positioned

toward the cross head slide body.

• Ensure that the oil drainage holes in the cups are

positioned downward.

• Check that the clearance between ring and cup is within

limits specified by the assembly drawing.
Packing ring Maintenance
 Power End Maintenance
Inspection of cross head

Inspection of connecting rod

Inspection of crank shaft

Inspection of crack shaft bearings

 Inspection of cross head
• Remove the stop screw between cross head and rod.
• Measure the distance between the locknut and cross
head which is used as reference for piston head
clearance.

• Measure the clearance between cross head shoes and

their guides.

• If wear on the antifriction metal is not excessive, the

clearance can be restored by shimming the shoe.
Measurement of big end bearing clearance
 Web deflection

Any movement of crank web from ideal position during entire rotation 360 degree
of crank shaft. Above depiction where crank centerline is curved due to any
reasons .The induce cyclic stresses can lead to fatigue failure
Measurement of web deflection
Measurement of web deflection
 Cause of web deflection
Compressor support

Alignment of compressor

Rod run out, frame alignment

Main bearing clearance

Compressor loading
 Main bearing axial positioning
• Both the main bearings present a shoulder which, at the
time of assembly is positioned toward the inside of the
frame.

• Between these shoulders and the outside surfaces of the

end webs, there is a clearance within which the shaft is
allowed small axial displacement.

• When it is observed that the clearance does not comply

with the values specified by OEM, it is necessary to
replace one or both bearings.
Measurement of main bearing clearance

Reading is noted after jack shaft is completely tightened and loosened

 Troubleshooting chart
Trouble Probable cause Remedies

1. Excessive ratio on 1. Repair valve or rings

cylinder due to leaking 2. Clean inter cooler
High discharge of inlet valves or rings 3. Clean jackets
2. Fouled inter cooler 4. Clean inter cooler
temperature
3. Fouled water jacket
4. High inlet temperature

1. Loose / worn main, crank 1. Check bearing

pin or cross head clearance
Frame knocks bearings 2. Increase oil pressure
2. Low oil pressure 3. Replace loose parts
3. Loose cross head pin or
shoes
 Trouble Probable cause Remedies

Noise in cylinder 1. Broken or leakage 1. Measure valve temp.

valves and fluctuation in
2. Worn or broken piston/ pressure also occurs
rider rings replace valves.
3. Moisture carry over 2. Replace rings
4. Valves improperly 3. Open head side drain
seated/ damage seat valve
gasket 4. Replace gasket
Excessive packing 1. Worn packing rings 1. Replace packing rings
leakage 2. Improper lube oil or 2. Use correct lube oil
insufficient pressure and increase lube rate.
3. Rings assembled 3. Assemble as per
incorrectly instruction
4. Scored piston rod 4. Replace rod
5. Excessive piston run out 5. Correct run out . Re-
6. Improper packing cup end shim cross head
clearance
 Trouble Probable cause Remedies
Packing over 1. Lubrication failure or 1. Replace lubricator or
heating insufficient lube rate increase lube rate
2. Insufficient cooling 2. Clean coolant passage
or reduce coolant
temperature
Suction discharge 1. Liquid carry over 1. Proper removal from
valve leakage 2. Worn valve seat / damage separators
(inlet temperature plates or sealing elements 2. Lap seat/ replace parts.
rise /pulsation in
discharge flow
valve temperature
differ)
Insufficient 1. Suction valve leakage 1. Replace faulty valves
capacity 2. Valves seat gasket 2. Replace damage
damage gasket
3. Un loader stuck 3. Isolate instrument air
4. Head gasket leak and rectify sucking
5. Worn or broken piston problem
rings 4. Replace rings
Rule of thumb for general running clearance

• Piston (cast iron) to cylinder bore or liner:

– .00125" per inch of bore diameter
– Example: 20" diameter cylinder
– 20 x .00125 " = .0250“=0.635mm clearance

• Main bearing and crankpin bearing to journal

clearance:
[Link] iron or steel-backed shells
• 00075" per inch of journal diameter=0.019mm
Rule of thumb for general running clearance

• Aluminum bearing shells

– .001“(.025mm) -.0015“(.0375mm) per inch

• Crosshead pin to bushing clearance:

– .0005“(.012mm) - .0015“(.038mm) per inch of pin
diameter

• Crosshead pin to crosshead clearance

– .0005“(.012mm0 - .002“(.05mm) per inch of pin diameter
Rule of thumb for general running clearance

• Minimum clearance between rider ring and cylinder

bore in middle of piston adjacent to piston rings:
–Cast iron piston -.00125" - .0015" per inch of cylinder
diameter

–aluminum piston -.002" per inch of cylinder diameter

 Preventive maintenance

COMPONENT MAINTENANCE INTERVAL

compressor valves 6 mos.
piston rod packing 9 mos.
piston ring 9 mos.
rider ring 2 yrs.
piston rods 3 yrs.
compressor cylinder 5 yrs.
 Relative maintenance costs

COMPONENT % of Total Maintenance Cost

compressor valves 50%
piston rod packing 20%
piston ring 20%
wear bands 7%
piston rods 2%
compressor cylinder 1%