Reciprocating compressor testing involves rigorous assessments, ensuring the equipment meets operational standards and can handle specified pressure loads without failure. This testing typically includes performance evaluations, durability tests, and safety checks to detect potential issues before placing the units in industrial settings. Following are some of the tests performed on a reciprocating compressor.
Reciprocating Compressor Tests
- The Reciprocating Compressor Mechanical Running Test is done during and before assembly and takes four hours. During this time, regular checks occur of lube oil pressure, lube oil temperature, bearing temperature, lube oil viscosity, power consumption, rotor speed, and vibration. The unit is operated at the rated speed for 30 minutes, allowing the bearing temperatures, lube oil temperature, vibration amplitudes, and oil viscosity to stabilize.
- The Reciprocating Compressor Aerodynamic Performance Test verifies measured values with the manufacturer’s table/curves of power and capacity versus suction pressure, ensuring measured values are in the acceptable range.
- The Reciprocating Compressor Hydrostatic Test involves testing the piping system, cooling water jacket, and cylinder. Complete this test after installing the valve covers, heads, fasteners, and clearance pockets. A pressure gauge is used (preferable range = 2 X the test pressure, not less than 1.5 X nor more than 4 X).
- The Reciprocating Compressor Gas Leakage Test takes place after hydrostatic testing is complete. The test pressure should be the same as the compressor’s maximum allowable working pressure.
- The Reciprocating Compressor Bar-Over Test involves measurements of piston rod vertical/horizontal runout and piston end clearance using a feeler gauge and dial indicator. Complete this test during assembly after all mechanical running tests are complete.
- The Piston End Clearance is done after mechanical running tests and during assembly using a lead wire and filler gauge.
- The Piston Rod Horizontal Runout Measurement is performed after the mechanical running tests and during the assembly using a dial gauge.
- The Piston Rod Vertical Runout Measurement requires a dial indicator on top of the piston rod. It measures the amount of runout (should be more than + or – 0.015% of stroke value.
- The Reciprocating Compressor Vibration Test measures vibration limits at the cylinder, compressor skid, crankcase, cylinder flange, and distance pieces.
Does your compressor need maintenance or overhaul? Would you like to modify an existing compressor system? Need a new reciprocating compressor (single or two-stage, sweet or sour) that passes all relevant tests? Contact GASPRO Compression Corp, a leading provider of compression packages.
