CMMS Implementation for Reciprocating Compressors

We design the asset hierarchy with the compressor frame as the parent equipment, cylinders as sub-equipment with stage and end attributes, and maintainable components (valves, packing, pistons, rider bands, crosshead assemblies) as sub-components or BOM items with position identifiers. Equipment records capture frame data (manufacturer, model, number of throws, RPM, driver type) and cylinder data (bore, stroke, stage, service gas, operating pressures). Valve records include position identification (cylinder, end, suction/discharge), valve type, plate material, spring configuration, and run-hour tracking for life analysis. Failure coding follows ISO 14224 with compressor-specific extensions: failure modes (leaking, broken, abnormal noise, reduced output) by component position, failure mechanisms (fatigue, erosion, fouling, wear), and failure causes. PM task libraries generate work orders at the appropriate hierarchy level — frame-level tasks (oil analysis, alignment), cylinder-level tasks (valve temperature monitoring, performance testing), and component-level tasks (packing leak rate measurement). KPI dashboards track valve MTBF by position, packing life by stage, and overall compressor availability.