“R G Compressor – B PH-2 Maintenance”

JOB CARRIED OUT ON 22.05.2023 TO 25.05.2023

LPG TR-12 Recovery Unit.
GAIL(India) Limited.
VIJAIPUR, MP.

Prepared By-
Mr. SURAJ LODHA

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Activities and Observations: -
The following components M6 PM of RG compressor-B to be inspected
and activities to be undertaken
1. Piston
2. Piston Rings
3. Rider Band
4. Piston Rod
5. Cylinder Liner
6. Loaders
7. Lube Oil Filters
8. Suction Strainer
9. Cylinder Jackets
10. Plate Valve
11. Ring Valve

Work Permit Details: -

HOT WORK PERMIT – RG Compressor Phase 2
Work Permit No. : 2849283
Maintenance Order No. : 22830350

Maintenance & Action Taken: -

Job carried out: Job was started at 22.05.2023 and completed at
25.05.2023 and clearance was given to the operations department for
starting the unit as per requirement.

1. RG compressor overhauling
The compressor was overhauled and observations are as follows:

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S No. Component Observation(s) Action(s) Taken

1 Piston The piston was also found in good piston was properly cleaned by
condition. cleaner and diameter 277 mm

2 Piston rings The piston rings were also found The outer diameter of the piston
in good condition. (No. of rings 3 rings was checked and found to
one side) be 278 mm.

3 Rider Band Both rider band were also found both rider bands are being
in good condition. checked and found to be width
80mm and thickness 10mm.

4 Piston Rod Both piston rods were also found The piston rods were properly
in good condition. cleaned by a cleaner, and their
diameters were measured to be
74.90mm and 74.80mm.

5 Cylinder Liner cylinder liner was found in almost cylinder liner was properly
good condition cleaned and inner dia. 280.10mm

6 Loaders All loaders ware found in good All loaders were properly cleaned
condition. by a cleaner

7 Lube Oil The lube oil filters were in good filters were properly cleaned.
Filters
condition.

8 Suction Suction strainer was in good Suction strainer was properly

Strainer condition.
cleaned.

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9 Cylinder cylinder jackets were in good cylinder jackets were in good
Jackets condition. condition.

10 Plate Valve All plate valves were found to be
in good condition. (Plate valves
are used in the suction line.)
11 Ring Valve One ring valve was found to be
damaged, while three valves were
in good condition. (Ring valves are
used in the discharge line.)
All plate valves were properly
cleaned.
One ring valve was replaced, and
the other three valves were
properly cleaned and put back
into use.

2. Clearances Between Cylinder & Piston: -

Piston, Cylinder is clearance to measure feeler gauge.

1.40mm 0.85mm

1.60mm 1.75mm 1.40mm 1.85mm

2.05mm 2.35m
m

WEST SIDE (LEF GTC SIDE) EAST SIDE (CHILLER SIDE)

3. The runout of the piston rod was measured and the following
readings were obtained:
East Side Reading:
• Left Side: 0.08mm
• Top Side: 0.09mm

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 West Side Reading:
• Left Side: 0.05mm
• Top Side: 0.08mm
4. The Cylinder Head was bolted to the cylinder. The distance
between Cylinder and piston at TDC (Outer Dead Centre) and BDC
(Inner Dead Centre) were measured.
East Side Reading
TDC- 4.44 mm, BDC-2.93 mm
West Side Reading
TDC- 4.27 mm, BDC-3.03 mm
5. The unloaders were mounted on the cylinder.

Reading of the Loader 1 Loader 2 Loader 1 Loader 2

Load and unload (East) (East) (West) (West)
Valve Length
126.3mm 124.4mm 126.1mm 126mm
(without load)
Valve Length
131.1mm 127mm 131.3mm 131mm
(with load)
Depth of Loader 4.8mm 3.2mm 5.2mm 5mm

NOTE: During installation, the lever of unloaders should be in a vertical

position. However, afterwards, it should be turned to a horizontal
position to manually unload the valve.

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 Piston Rod

Liner

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OIL SEAL

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Conclusion: -
The maintenance work on the R G Compressor - B PH-2 at the LPG
TR-12 Recovery Unit was carried out successfully. Components
such as the piston, piston rings, rider bands, piston rods, cylinder
liner, loaders, lube oil filters, suction strainer, cylinder jackets, plate
valves, and ring valves were inspected. Necessary cleaning and
replacements were done as required. Measurements were taken
for runout of the piston rod and distances between the cylinder and
piston. The unloaders were properly installed. Overall, the
compressor is in good condition and ready for operation.