Bengbu Aipu Compressor Manufacturing Co.,Ltd
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Common Faults and Solutions of Reciprocating Compressors

Common Faults and Solutions of Reciprocating Compressors

1. The load regulation mechanism of reciprocating compressor is jammed

The jam of the load regulation mechanism is mainly manifested as:


(1) The load adjustment indicator does not work;

(2) The temperature of the corresponding intake valve rises and the valve cover heats up;

(3) The corresponding exhaust valve temperature rises;

(4) The pressure rises between the valve's stage and the previous stage;

(5) The displacement of the reciprocating compressor decreases;

(6) The intake air temperature increases.


If the load regulation mechanism is stuck in the discharge position, it will cause the suction valve to leak; if it is stuck in the loading position, it will cause the load start of the reciprocating compressor, which will affect the service life of the transmission components.


2. The common faults of the piston ring of reciprocating compressor

(1) Piston ring is broken;

(2) The piston ring loses its elasticity, and cannot expand;

(3) The piston ring is excessively worn and the clearance increases.


The main manifestations that the piston ring cannot play a sealing role are as follows:


(1) The exhaust temperature of this stage increases;

(2) The exhaust pressure of this stage is reduced;

(3) The displacement of the reciprocating compressor decreases.


For double-acting reciprocating compressors, that is, when one side of the cylinder is compressed, the other side is sucking air. When the piston ring is damaged or swollen, it cannot play a sealing role, making the high-pressure and high-temperature gas compressed on the cover side or the shaft side escape into the low-temperature and low-pressure gas on the shaft side (or cover side) through the piston ring. It is mixed with the inhaled low-pressure and low-temperature gas. After the mixing, the temperature of the gas rises, and because the compressed gas flows through each other through the piston ring, the discharge pressure of this stage drops, and the displacement of the reciprocating compressor also drops.


3. The process medium of reciprocating compressor entrains particulate matter

On-site inspections sometimes find a large amount of deposits in the cylinder and packing seal cavity of the reciprocating compressor. These deposits are composed of fine solid dust or coked carbon particles entrained by the process medium, and their hardness is often very high. Its deposition in the seal cavity will inevitably cause serious wear of the seal packing, thereby greatly reducing the service life of the packing seal ring and the piston rod.


By adjusting the process, the parameters of the reciprocating compressor can meet the design requirements. If necessary, the gas-solid separator can be used to separate these particles and debris, which can avoid the wear caused by the friction between the cylinder and the piston ring, the piston rod and the packing.


4. The amount of oil injected at the packing seal of the reciprocating compressor is too small or too large

Too much oil injection will easily cause too much reciprocating compressor oil to emulsify and form deposits; if too small, the lubrication effect of the packing ring will not be good, the wear rate will increase, and the service life will be affected. In addition to the manufacturer's standard, the oil filling amount should be determined by checking the operation of the seal ring at the beginning of the test run to determine an appropriate amount. After the test run, open to check whether there is any carbon on the piston rod at the packing to judge the size of the oil injection.


5. The cooling water flow of the stuffing box of reciprocating compressor is too small

The temperature rise of the stuffing seal box is mainly caused by the violent friction between the packing ring and the piston rod, and this frictional heat should be taken away in time.


In fact, since the water for the stuffing box and the liner are basically in parallel, the pressure drop at the stuffing seal is large, which results in insufficient cooling water flow for the stuffing box, and frictional heat cannot be taken away in time, which affects the normal service life of the packing. Therefore, the circulating water pressure and flow rate should be appropriately increased so that the circulating water can take away the heat generated by the friction between the piston rod and the packing ring in time. Control the temperature at the stuffing box to not more than 60℃.


Aipu is one of the leading reciprocating natural gas compressor manufacturers, if you want to know more about reciprocating compressors, please have no hesitation to contact us.

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