Troubleshooting Checklist for Reciprocating Compressors

Trouble
Compressor will not start

Motor will not synchronize

Low Oil Pressure

Noise in Cylinder

Excessive Packing Leakage

Packing Over-Heating

Excessive Carbon on Valves

Relief Valve Popping

High Discharge Temperature

Frame Knocks

Crankshaft Oil Seal Leaks

Piston Rod Oil Scraper Leaks

Prepared by:

g Checklist for Reciprocating Compressors

Check Points
1. Power Supply Failure
2. Problem in switchgear or MCC
3. Low oil pressure shutdown interlock is active
4. Control Panel problem
1.
2.
3.
4.

Low Voltage
Excessive Starting Torque
Incorrect Power Factor
Excitation Voltage failure

1. Oil Pump unable to start or trips when started

2. Oil foaming from counter-weights striking oil surface
3. Oil temperature low (cold oil)
4. Dirty or plugged oil filter
5. Interior frame oil leaks
6. Excessive leakage at bearing shim tabs and/or bearings
7. Low oil pressure switch calibration disturbed or improperly set
8. Low setting of oil gear pump bypass control or relief valve
9. Defective relief valve (stuck-open)
10. Local Oil pressure gauge is defective
1.
2.
3.
4.
5.
6.
7.

Loose Piston
Piston hitting outer head or frame end of cylinder
Loose crosshead lock-nit
Broken or leaking valves(s)
Worn or broken piston rings or expanders
Valve improperly seated / damaged seat gasket
Free air unloader plunger chattering

1.
2.
3.
4.
5.
6.
7.
8.
9.

Worn Packing Rings

Improper lube oil and/or insufficient lube rate (blue rings).
Dirt in packing.
Excessive rate of pressure increase.
Packing rings assembled incorrectly.
Improper ring side- or end-gap clearance.
Plugged packing vent system.
Scored piston rod.
Excessive piston rod run-out.

1. Lubrication failure.
2. Improper lube oil and/or insufficient lube rate.
3. Insufficient cooling.
1. Excessive lube oil.

2. Improper lube oil (too light, high carbon residue).

3. Oil carryover from inlet system or previous stage.
4. Broken or leaking valves causing high temperature.
5. Excessive temperature due to high pressure ratio across
cylinders.
1. Faulty relief valve.
2. Leaking suction valves or rings on next higher stage.
3. Obstruction (foreign material, rags), blind or valve closed in
discharge line.
1. Excessive compression ratio on cylinder due to leaking inlet
valves or rings on next higher stage.
2. Fouled intercooler / piping.
3. Leaking discharge valves or piston rings.
4. High inlet temperature.
5. Fouled water jackets on cylinder.
6. Improper lube oil and/or lube rate.
1.
2.
3.
4.
5.
6.

Loose crosshead pin, pin caps or crosshead shoes.

Loose/worn main, crankpin or crosshead bearings.
Low oil pressure.
Cold oil.
Incorrect oil.
Knock is actually from cylinder end.

1. Faulty seal installation.

2. Clogged drain hole.
1.
2.
3.
4.

Worn scraper rings.

Scrapers incorrectly assembled.
Worn/scored rod.
Improper fit of rings to rod/side clearance.

Ankur Srivastava
Chemical Engineer
ankur_2061@hotmail.com

Troubleshooting Checklist for Centrifugal Compressors

Trouble
Low Discharge Pressure

Compressor Surge

Low Lube Oil Pressure

Shaft Misalignment

High Bearing Oil Temperature

Note:
Lube oil temperature
leaving bearings should
never be permitted to
exceed 82C.

Excessive Vibration
Note:
Vibration may be

transmitted from the

coupled machine. To
localize vibration,
disconnect coupling and
operate driver alone. This
should help to indicate
whether driver or driven
machine is causing
vibration.

Water in Lube Oil

g Checklist for Centrifugal Compressors

Check Points
1. Compressor not up to speed.
2. Excessive compressor inlet temperature.
3. Low inlet pressure.
4. Leak in discharge piping.
5. Excessive system demand from compressor.
1. Inadequate flow through the compressor.
2. Change in system resistance due to obstruction in the discharge
piping or improper valve position.
3. Deposit buildup on rotor or diffusers restricting gas flow.
1. Faulty lube oil pressure gauge or switch.
2. Low level in oil reservoir.
3. Oil pump suction plugged.
4. Leak in oil pump suction piping.
5. Clogged oil strainers or filters.
6. Failure of both main and auxiliary oil pumps.
7. Operation at a low speed without the auxiliary oil pump running
(if main oil pump is shaft-driven).
8. Relief valve improperly set or stuck open.
9. Leaks in the oil system.
10. Incorrect pressure control valve setting or operation.
11. Bearing lube oil orifices missing or plugged.
1.
2.
3.
4.
5.

Piping strain.
Warped bedplate, compressor or driver.
Warped foundation.
Loose or broken foundation bolts.
Defective grouting.

1. Inadequate or restricted flow of lube oil to bearings.

2. Poor conditions of lube oil or dirt or gummy deposits in
bearings.
3. Inadequate cooling water flow lube oil cooler.
4. Fouled lube oil cooler.
5. Wiped bearing.
6. High oil viscosity.
7. Excessive vibration.
8. Water in lube oil.
9. Rough journal surface.
1. Improperly assembled parts.
2. Loose or broken bolting.
3. Piping strain.

4. Shaft misalignment.
5. Worn or damaged coupling.
6. Dry coupling (if continuously lubricated type is used).
7. Warped shaft caused by uneven heating or cooling.
8. Damaged rotor or bent shaft.
9. Unbalanced rotor or warped shaft due to severe rubbing.
10. Uneven build-up of deposits on rotor wheels, causing
unbalance.
11. Excessive bearing clearance.
12. Loose wheel(s) (rare case).
13. Operating at or near critical speed.
14. Operating in surge region.
15. Liquid slugs striking wheels.
16. Excessive vibration of adjacent machinery (sympathetic
vibration).

1. Condensation in oil reservoir.

2. Leak in lube oil cooler tubes or tube-sheet.