One does not must do an excessive amount of analysis to determine how previous reciprocating compressor know-how actually is. If steam generators ushered in die Industrial Revolution over 200 years in the past, reciprocating compressors could not have been far behind. On a go to to an Iowa-based gear producer in 1989, I used to be amazed to see how a 1908-vintage reciprocating compressor happy their around-the-clock plant air necessities dependably and effectively. Eighty years with nothing however routine, albeit conscientious, “tender loving care” upkeep!

What an endorsement of the talent of the unique designers, machine builders, and generations of upkeep craftsmen. It is solely honest to say that the previous turn-of-the-century compressor was designed with better margins of security, or power, or capability to outlive abuse than at present’s larger rotating pace and larger linear piston velocity reciprocating machines. A lot of at present’s compressors are more likely to have been designed with the emphasis on lowered weight, much less ground area and, let’s face it, least value. The ideas of maintainability, surveillability, and true life cycle value are too new to be taught in modem universities and engineering faculties.

The reward system for venture managers, course of design contractors, and venture engineers is essentially based mostly on capital value financial savings and fast schedules. Regrettably, even the dedication to upkeep excellence of lots of at present’s managers and mechanic/technicians is just not all the time as sound, or as rigorous and constant, because it maybe was just a few a long time in the past. Right now, everybody speaks of reliability, however many of those well-meaning people appear to be “forgetful hearers” as a substitute of “doers.” There are valuable few situations the place the upkeep or reliability technician is given both the time or the coaching to find out the true root causes of kit failures. Scores of employees are instructed to search out the faulty half, change it with a brand new one, and get the machine again in service.

However the half failed for a purpose, and if we do not discover the rationale for its failure, we’re sure to set ourselves up for a repeat occasion. Every time we rush a upkeep job, we’re more likely to omit taking the sorts of measurements which are critically vital to the achievement of ran size extensions and elevated reliability and security. What is required is extra consideration to element; the notion that gear reliability could be upheld by fixing solely these parts which are visibly faulty might not all the time be appropriate. There could also be compelling causes to name for a restoration of all suits, clearances, and dimensions to as-designed values.

This takes time and planning. It requires entry to authoritative knowledge and a elementary shift away from business-as-usual, quick-fix, or big-picture attitudes. Time and once more we now have seen reciprocating compressor house owners/customers have interaction within the seek for the excessive know-how resolution. When a succession of damaged valves is encountered, the hunt concentrates on higher valve supplies as a substitute of the elimination of moisture condensation and flowinduced liquid slugging. When piston rods put on erratically, some customers pursue superior metallic coatings, however shut their ears to the potential of tolerance stackup being the actual offender.

This progressive transfer in the direction of out-of-roundness or not-so-perfect perpendicularity of mating components may effectively be the foundation trigger of kit misery and must be rectified earlier than it makes financial sense to put in parts with superior configurations or metallurgical compositions/And we would add that it would not damage if somebody took the time to rigorously learn and implement the unique gear producer’s upkeep handbook.

Download Reciprocating Compressors Operating and Maintenance by Heinz P. Bloch and John J. Hoefner simply in PDF format without spending a dime.