Page 336 - Reciprocating Compressors Operation Maintenance

Troubleshooting Compressor Problems 321

TABLE 5-2 (CONTINUED)
TROUBLESHOOTING CHART

Trouble Probable Cause(s) Remedies

Excessive Packing 1 . Worn packing rings 1 . Replace packing rings
Leakage 2. Improper lube oil and/or 2. Use correct lube oil and increase
insufficient lube rate lube rate
(blue rings)
3. Dirt in packing 3. Clean piping/gas supply
4. Excessive rate of pressure 4. Reduce pressure and increase
increase at more gradual rate
5. Packing rings assembled 5. Reassemble per instructions
incorrectly
6. Improper ring side or end 6. Establish correct clearances
gap clearance
7. Plugged packing vent 7. Remove blockage and provide
system low point drains
8. Scored piston rod 8. Replace rod
9. Excessive piston rod 9. Correct run-out. Reshim
run-out crosshead
Packing 1 . Lubrication failure 1 . Replace lubricator check
Overheating valve/lubricator pumping unit
2. Improper lube oil and/or 2. Use correct lube oil and increase
insufficient lube rate lube rate
3. Insufficient cooling 3. Clean coolant passages/install water
filter/increase supply pressure
Reduce coolant inlet temperature
Excessive Carbon 1 . Excessive lube oil 1. Adjust lube supply
on Valves 2. Improper lube oil (too light, 2. Use lube oil per manufacturer's
high carbon residue) recommendations
3. Oil carryover from inlet 3. Install oil separators/drain system
system or previous stage
4. Broken or leaking valves 4. Repair/replace parts
causing high temperature
5. Excessive temperature due 5. Clean exchangers, valves and
to high pressure ratio correct cause of high pressure
across cylinders
Leaking Valves 1 . Faulty seat gasket 1 . Replace gaskets
2. Inadequate setscrew 2. Tighten setscrews
tightening
3. Worn valve seat, channels 3. Replace valves/lap seats
or plates.
4, Improper valve assembly — 4. Reassemble properly per
channels sticking in guides "VALVES" section
(Source: Compressed Air and Gas Handbook, 5th Edition, Published by The Compressed
Air and Gas Institute)