Process Equipment troubleshooting serial Tip summary • The objective of this serial is to provide engineers with easy to use root cause analysis maps that can help them to easily troubleshoot the plant equipment and restore the equipment quickly to the good operating condition to save energy & cost. • In this video we will talk about gas moving devices especially Reciprocating-piston compressors troubleshooting. • Reciprocating-piston compressors major problems root causes can be summarized in the following points 1. Valves and piston rings knocking possible causes: • Frame lubrication inadequate • Head clearance too small • Cross-head clearance too high 2. Vibration possible causes: • Pipe support inadequate • loose flywheel or pulley • valve LP unloading system defective 3 Discharge pressure high possible causes: • Instrument error • Valve LP unloading system defective • Required system discharge high 4 Discharge pressure low possible causes: • Instrument error • valve LP unloading system defective • LP valve worn • System leakage 5 Discharge temperature high possible causes: • instrument error • LP valve worn • Valve LP unloading system defective • Required system discharge pressure high. 6 Cooling-water temperature high possible causes: • Instrument error • Water flow rate low • Fouled area • LP valve worn. 7 Valve temperature high possible causes: • Instrument error • Required system discharge pressure high • Run unloaded too long. • LP valve worn 8 Cylinder temperature high possible causes: • instrument error • Required system discharge pressure high • LP valve worn • Wrong speed. 9 Flow low possible causes: • Instrument error • LP valve worn • Valve LP unloading system defective • Dirty suction filter. Tip video https://youtu.be/drJuV1YdmJY Link to download the troubleshooting map https://www.slideshare.net/MagdyAly2/centrifugal-compressor-troubleshooting-map Tip Arabic version https://youtu.be/U0Qi383NTPY My blog: www.360proactiveengineer.com #Energy #energyefficiency #energymanagement #steam #sustainable #sustainability #engineering #engineer #chemicalengineering #Environment #360practiveengineer #Energy savings #troubleshooting #fan #compressors #rootcauseanalysis #Reciprocatingcompressor

1. 1.4 Reciprocating-piston
compressors troubleshooting map

2. 1.4 Reciprocating-piston
compressors troubleshooting map
Common symptom
valves and piston rings Knocking Possible cause
frame lubrication inadequate
head clearance too small
cross-head clearance too high
Vibration Possible cause
pipe support inadequate
loose flywheel or pulley
valve LP unloading system defective
Discharge pressure high Possible cause
instrument error
valve LP unloading system defective
required system discharge high
Discharge pressure low Possible cause
Instrument error
valve LP unloading system defective
LP valve worn
system leakage
Discharge temperature high Possible cause
instrument error
LP valve worn
Valve LP unloading system defective
Required system discharge pressure high.
Cooling-water temperature high Possible cause
Instrument error
Water flow rate low
Fouled area
LP valve worn.
Valve temperature high Possible cause
Instrument error
Required system discharge pressure high
Run unloaded too long.
LP valve worn
Cylinder temperature high Possible cause
instrument error
Required system discharge pressure high
LP valve worn
wrong speed.
Flow low Possible cause
Instrument error
LP valve worn
Valve LP unloading system defective
Dirty suction filter.
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3. Common symptom

4. valves and piston rings Knocking Possible cause
frame lubrication inadequate
head clearance too small
cross-head clearance too high

5. Vibration Possible cause
pipe support inadequate
loose flywheel or pulley
valve LP unloading system defective

6. Discharge pressure high Possible cause
instrument error
valve LP unloading system defective
required system discharge high

7. Discharge pressure low Possible cause
Instrument error
valve LP unloading system defective
LP valve worn
system leakage

8. Discharge temperature high Possible cause
instrument error
LP valve worn
Valve LP unloading system defective
Required system discharge pressure high.

9. Cooling-water temperature high Possible cause
Instrument error
Water flow rate low
Fouled area
LP valve worn.

10. Valve temperature high Possible cause
Instrument error
Required system discharge pressure high
Run unloaded too long.
LP valve worn

11. Cylinder temperature high Possible cause
instrument error
Required system discharge pressure high
LP valve worn
wrong speed.

12. Flow low Possible cause
Instrument error
LP valve worn
Valve LP unloading system defective
Dirty suction filter.

13. Please share it with others and for more visit
www.360ProcativeEngineer.com