Page 223 - Practical Machinery Management for Process Plants Major Process Equipment Maintenance and Repair

Reciprocating Gas Engines and Compressors 205

spections that require a minimum of downtime and disassembly. Most
can be done while the unit is on the line and require few and inexpensive
instruments. Some are only observations. They are elementary and well
known and have been used by the old-timers for many years. If used with
judgment, these simple indicators can be used to maintain any modern
installation.
The modern trend, however, is to forget these basic items and to deal
only with exotic instrumentation for maintaining engines, and it is not
only a trend that can damage the equipment but can also be quite expen-
sive in terms of operational downtime. Instruments such as the ignition
analyzer, balance pressure indicator, etc., are here to stay and are highly
recommended as a part of the basic maintenance equipment for any in-
stallation.
There is also a tendency for some engine-builder field representatives,
as well as operators, to make field design changes before making sure of
correct installation and basic adjustments. The redesign approach is
healthy, as it keeps the engine builder on his toes and does give him valu-
able information. However, when overdone it deters from necessary ba-
sic maintenance procedures, and the equipment will not function as in-
tended.

Reclprocatlng Compressor Component Overhaul and Repair

Usually we will try to inspect the reciprocating compressor whenever
the opportunity arises. Each plant has its favorite “hours elapsed” which
would indicate that it is time to do an inspection. The box at right shows a
typical checklist used during a reciproacting compressor inspection. This
checklist would be used in conjunction with an appropriate maintenace data
sheet similar to the one shown later in Figure 5-17.
While there could be a substantial or near endless array of possible repair
procedures we would like to concentrate on three important activities around
our reciprocating compressors:

1. hlve repairs
2. packing replacement
3. Cylinder honing

Wve repairs are likely to occur most around reciprocating compres-
SOTS. The following is a typical example of a procedure used to remove,
repair, test, and reassemble compressor valves.