Page 357 - Reciprocating Compressors Operation Maintenance

342 Reciprocating Compressors: Operation and Maintenance

2. Routine maintenance. This maintenance includes lubrication and
proactive repair.
Lubrication should be done on a regular schedule.
Proactive repair is an equipment repair based on a higher level of
maintenance. This higher level determines that, if the repair does
not take place, a breakdown will occur.
3. Corrective maintenance. This includes adjusting or calibrating of
equipment. Corrective maintenance improves either the quality or the
performance of the equipment. The need for corrective maintenance
results from preventive or predictive maintenance observations.
4. Preventive maintenance. This includes scheduled periodic inspec-
tion. Preventive maintenance is a continuous process. Its objective
is to minimize both future maintenance problems and the need for
breakdown maintenance.
5. Predictive maintenance. This maintenance predicts potential prob-
lems by sensing operations of equipment. This type of maintenance
monitors operations, diagnoses undesirable trends, and pinpoints
potential problems. In its simplest form, an operator hearing a
change in sound made by the equipment predicts a potential prob-
lem. This then leads to either corrective or routine maintenance.

Similarly, a predictive maintenance expert system can monitor
machine vibrations. By gathering vibration data and comparing these
data with normal operating conditions, an expert system predicts and pin-
points the cause of a potential problem.
Traditionally, industry has focused on breakdown maintenance, and
unfortunately, many plants still do. However, in order to minimize break-
down, maintenance programs should focus on levels 2 through 5.

EMERGENCY REPAIRS SHOULD BE MINIMIZED

Plant systems must be maintained at their maximum level of perfor-
mance. To assist in achieving this goal, maintenance should include regu-
lar inspection, cleaning, adjustment, and repair of equipment and sys-
tems. On the other hand, performing unnecessary maintenance and repair
should be avoided. Breakdowns occur because of improper equipment
operation or failure to perform basic preventive functions. Overhauling
equipment periodically when it is not required is a costly luxury.