Mod 4 - Recip Compressors

Module from the Rotating Equipment Training Curriculum curriculum.

RECIPROCATING COMPRESSOR OPERATIONS · Learning Objectives · 1. Identify key components and their failure modes 2. Monitor rod drop and packing wear indicators 3. Apply capacity control methods (unloaders, clearance pockets, speed) 4. Maintain compressor valves for reliability · Component Monitoring & Maintenance

Component	Function	Failure Mode	Monitoring	Maintenance Interval	API Reference
Suction Valve	Admit gas into cylinder on suction stroke	Plate/disc wear, spring fatigue, seat erosion	Valve temperature increase (>20°F above normal), P-V diagram	2,000-8,000 hrs or on condition	API 618
Discharge Valve	Release compressed gas on discharge stroke	Same as suction but more severe (higher ΔP, temperature)	Discharge temp rise, reduced capacity	1,500-6,000 hrs or on condition	API 618
Piston Rod Packing	Seal gas from escaping along piston rod	Ring wear, gas leakage, scoring	Packing case vent flow (>1% of capacity = worn)	8,000-16,000 hrs	API 618
Piston Rings / Rider Bands	Seal between piston and cylinder, support piston	Ring wear, scoring, blow-by	Rod drop increase (>0.030" change), capacity loss	8,000-16,000 hrs	API 618
Crosshead & Bearings	Convert rotary to linear motion	Bearing wear, crosshead pin bushing	Vibration, knock, metallic debris in oil	Inspect at major overhaul (4-6 years)	API 618
Crankshaft & Main Bearings	Provide rotary motion from driver	Fatigue, bearing wear	Vibration, oil analysis (wear metals), bearing temperature	Major overhaul (4-6 years)	API 618
Frame & Cylinder	Structure and compression chamber	Cracking (fatigue), corrosion (wet gas)	UT inspection, visual (dye penetrant on frame)	8-12 year inspection cycle	API 618
Source: FOS Chief Files — Training module on Multistage reciprocating compressors, Compressors ETS, IPE-EP-6-2-1

Source: Rotating_Equipment_Training_Curriculum_v1.xlsx · Sheet: Mod 4 - Recip Compressors

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