ReciprocatingCompressorTesting

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Thefollowingparameterisrecordedperiodicallyinthis4hours:

AsperAPI618,thepowerconsumptionshallnotbemorethan3%oftheratepowervalueindicatedinthedatasheet.

Ifspecified,thelubeoilandcoolingwaterconsolesalsoshallbesubjectedtothe4hoursmechanicalrunningtestasperrequirementsofAPI614.

Themanufacturershallprovidetablesorcurvesofpowerandcapacityvs.suctionpressurewiththeparameterofdischargepressureattheendofthetest.Thesecurvesortablesshallbeverifiedaginstestimatedcurvesortablesandmakesurethatmeasuredvaluesarewithinacceptancerange.

AsperAPI618,thecylinder,coolingwaterjacketandpipingsystemshallbesubjectedtothehydrostatictesting.Thehydrostatictestingshallbethanat1.5timesmaximumallowableworkingpressureandthepressureshallbeheldforminimum30minutes.

Theheliumleakagetestshallbedoneafterhydrostatictesting,andthetestpressureshallbethesameamountofcompressormaximumallowableworkingpressure.

Reciprocatingcompressorbar-overtestincludesmeasurementsofpistonendclearanceandpistonrodverticalandhorizontalrunoutmeasurement.

Theclearancecanbemeasuredbyinsertingoffillergageorusingaleadwire.

Similarly,thepistonrodhorizontalrunoutshallbeperformedduringtheassemblyandalsoafterthemechanicalrunningtestatthebar-overtest.Therunouttestindicatesthepistonrodsaggingamount.Dialgageisinstalledonthehorizontalsideofthepistonrod,andthenthecompressoristurned,andthepistonrodismovedfromcrank-endtohead-end.

VibrationLimit@CompressorSkid

Iftheanalysisindicatesthevibrationfrequencyisgoingtobelessthan10Hz,thenmagnitudeofvibrationshallnotbemorethan4mil0topeakvalueor8milpeaktopeakvalue.

Ifanalysisindicatesthevibrationfrequencyisgoingtobehigherthan10Hz,thenmagnitudeofvibrationshallnotbemorethan4.5mm/sRMSvalue(0.175in/sRMS)

TheAPI618alsorequiresthatcylinderflangepressurepulsationvibrationshallnotbemorethanof7%ofaverageabsolutelinepressureor3R%whicheverislesser.(theRisthestagepressureratio).Thevibrationamplitudeshouldbemeasuredbydisplacementprobe(proximitorsensor).

Thestandardalsoprovidesthepipingsystemvibrationlimit.Thelimitis0.5mmpeaktopeakor20milpeaktopeakwhenvibrationfrequencyislessthan10Hz.Thelimitis32mm/speaktopeakor1.25in/speaktopeakwhenvibrationfrequencyis10thru100Hz.

Followingcontentprovidessomeotherinformationaboutreciprocatingcompressortesting:

Theapplicablestandardsforthesetestsare:

ThefollowingcomponentsareusedfromJobequipment

Thefollowingcomponentsareusedfromteststand

Thefollowingcomponentsarenotusedinthetest

Thecompressorisassembledinteststandinmanufacturer'sshop.Thethecylindervalveswouldnotbeinstalledtoperformnon-loadcontinuousoperation.

Thecompressorisoperatedatthespecifiedrotatingspeedfor4hourscontinuouslyandmechanicalstability,temperature,pressure,vibrationandnoisearechecked.

After4hourscontinuousoperationthereciprocatingcompressorneedstobestoppedandbearingtemperaturestobemeasured.

Thenthereciprocatingcompressorisdiassmbledandstripdowninspectionisdonebasedtherequirementofinspectionandtestplan.

MeasurementitemsduringMechanicalrunningtest

Therotatingspeedismeasuredbyatachometerevery30minutes.Themeasurementvaluetobeanaveragevalueofthoseindicatedbythetachometer.

Rotatingspeedneedtobebewithinofthespecifiedrotatingspeed.

Thesuppliedanddischargedoiltemperatureofcrankcaseismeasuredbytemperaturegaugesintheshoplubeoilunitevery30minutes.

Thesuppliedanddischargedoiltemperatureneedstobewithinspecifiedvalues.

Thesuppliedoilpressureofcrankcase(bearings)anddischargedoilpressureoflubeoilpumparemeasuredbypressuregaugesinoilunitevery30minutes.

Theobtainedvaluesneedtobeinwithinspecifiedvalues

Theverticalandhorizontalvibrationsofcrankcasearemeasuredattwolocationsbytheuseofashopvibrationmeter.Also,thevibrationatcylinderismeasuredwithrespecttoaxial,horizontalandverticaldirectionsbytheuseofashopvibrationmeter.Vibrationmeasurementneedstobedoneonceduringtestoperation.

Thevibrationofcrankcase(peaktopeak)needstobewithinspecifiedvalues.

Thenoiseismeasuredatadistanceof1mfromthesideofthemainunitandfourdirectionsbyusingashopnoisemeter.Noisemeasurementtobedoneonceduringtestoperation.

Theobtainednoisevalueneedtobewithinspecifiedvalue.

Themeasuredvaluesneedtobewithinspecifiedvalues.

Aftercompletionofsuccessfuloilflushingthelubeoilconsolerunningtestneedstobedone.Runningtestwouldbeperformedbasedonthefollowingconditionsfor4hours,andtemperatureandpressureshallbemeasuredevery30minutes.

NoleakagemustbeseenduringthetestandPressuredropoffilterelementshallnotexceedaspecifiedvalueatoperatingoiltemperature.Noabnormalsoundshallbeconfirmedduringtherunningtest.

Aftercompletionofsuccessfulcoolingwaterflushingthetemperedcoolingwatersystemrunningtestneedstobedone.Runningtestwouldbeperformedbasedonthefollowingconditionsfor4hours,andtemperatureandpressureshallbemeasuredevery30minutes.

NoleakagemustbeseenduringthetestandnoabnormalPressuredropmustbeconfirmed.Noabnormalsoundshallbeconfirmedduringtherunningtest.

Aftercheckingoftheaboveitemsattwotimes,thewaterpumpischangedtoanotherandthesameitemsneedstobechecked.

ThereciprocatingCompressorthermodynamicperformancetestissimilartothecentrifugalcompressor.YoumayreviewCentrigugalCompressorTestingfordetailtestinstruction.

Followingdataneedtobeextractedfromacentrifugalcompressordesignbook,datasheetandoperatingmanualandtobeavailableduringthetest.

SpecifiedOperatingSpeeds

MaximumShaftVibration

LubeOilData

ShaftSeals

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