RECIPROCATING COMPRESSOR - OVERHAULING PROCEDURE FOR RECIPROCATING COMPRESSOR

 OVERHAULING PROCEDURE FOR RECIPROCATING COMPRESSOR

• Disconnect all auxiliary lines like discharge, air inlet, loader air, cooling lines

• Decouple coupling to disconnect with driver and remove crank case foundation bolts to transfer total unit to workshop for carrying overhaul.

• Remove the both suction valves with loader and discharge valve from head.

• open all inspection doors provided and loose the nut connects cross head and piston an takeout piston assembly with rod through head side. while removing care should be take about piston rings falling.

• dismantle piston plates, piston rings, expander rings, wear band and rod.

• Remove cylinder house with crank case with distance piece and disconnect distance piece dismantle wiper packings and gland. 

• Remove wrist pin and take out cross head

• Dismantle connecting rod big end and bearing cover and remove split big end bearing and take connecting rods outside

• Remove coupling hub and flywheel

• Remove lube oil pump connected with outboard of crank shaft and inboard cover

• Remove main bearings of connecting rod top half and take out crank shaft outside 

• Remove bottom half of main bearings

• Now complete dismantling is over. perfect inspection of each and every parts to be done while and after dismantling of any damage, score, break and etc.,

• Better is changing new one instead of reconditioning damaged parts

• assembly is the reverse procedure of dismantling.

• When assembling the following factors should be considered are main bearing radial and thrust clearances, connecting rod big end bearing and small end pin clearance, web deflection, rotor runout, wear band clearance, piston plate clearance with cylinder bore, bore surface finish, piston ring end and side clearance, piston end clearance,  oil tubes condition, valve lift an passing, loader piston freeness action, wiper packing clearance, free rotation and alignment. 

CHECKING THE CLEARANCE DURING OVERHAUL PROCEDURE:

1. PISTON END CLERANCE
2. PISTON RING SIDE CLEARANCE
3. PISTON RING END CLEARANCE
4. DIAMETRICAL CLEARANCE BETWEEN PISTON WITH CYLINDER / LINEAR, 
5. RIDER RING DIAMETRICAL CLEARANCE
6. WEB DEFLECTION 
7. PISTON ROD RUNOUT
8. CONNECTING ROD BIG & SMALL END BEARING CLEARANCE
9. CRANK SHAFT MAIN BEARING CLEARANCE
10. CRANK SHAFT THRUST ALLOWANCE
11. CROSS HEAD WITH CROSS SIDE CLEARANCE
12. GAS AND OIL WIPER PACK CLEARANCE