17-6020-compressor maintenance and operation.pptVIP

Rike Service, Inc. COMPRESSOR MAINTENANCE AND OPERATION Fundamentals Compressors are a large investment. They serve in the field, gasoline plants, refineries, pipeline transmission, chemical plants, and air compressors (control). Maintenance and operating cost per year Direct maintenance at 160 per installed investment Lube oil 1/1320 new installed investment Fuel = 15% new installed investment ($2.00 MCF discounted) Fundamentals Example: Field unit of 300 Bhp Installed cost ($750/Bhp) = $225,000 Maintenance/Yr. = $3,750 ($12.50/Bhp/yr) Lube Oil/Year = 700 ($2.33/Bhp/yr) Fuel/Year = 7,500 ($25.00/Bhp/yr) $11,950 ($40.00/Bhp/yr) A rule of thumb is 10% of the installed cost for maintenance, lube oil, and fuel. Fundamentals Efficient utilization requires that units be kept running, kept loaded. Maintenance is challenging to operations, maintenance, engineering, and management. A good maintenance program results in minimum downtime, parts and labor, fuel cost, and lube oil cost. Compressor Operations Routine procedures include starting-stopping (emergency), and loading-unloading. Safety during starting includes handling fuel gas and ignition switch. Before turning ignition “On”, clean power and compressor cylinders. For 2-cycle engines, crank them least one revolution: 4-cycle engines: two revolutions. Gas purge compressor cylinders. Safety during running includes monitoring lube oil pressure and temperature. Engines are loaded by exhaust temperature (670-700°F full load — 750°F overload or carbon in valve). Listen for noises and look for overheating of lube oil and jacket water. Inspection Routine Twice each tour for attended units and twice daily for attended units Critical temperatures and pressures such as suction and discharge on compressor cylinders and all on the engine. Listen for unusual noises, monitor operating levels of lube oil, lubricators, jacket water, and look for leaks (lube oil and water). Gas leaks could occur aro