+2(5%,*(5

MONITORING

Tools and services to increase

performance and availability of
reciprocating compressors

Monitoringe.ppt
MC&S +2(5%,*(5
MC&S - M MC&S - C MC&S - S
Monitoring Controls Service

REPORT

PSI

sec.

RECIP-TRAP
K101 450 297 Once
1HPT5 Level RPM Per Turn
TRAP UNIT TRAPDEF SNAP ON/OFF TRAP

Monitoringe.ppt
 Monitoring General +2(5%,*(5
Maintenance Concepts :
In general there are different ways to operate and service
reciprocating compressors:

» Disaster - or “run to failure”

– Euipment is operated as long as it will operate and repairs are only
carried out when the unit fails.
– Minor problems are neglected as long as they become complete
failures
» Time based - Scheduled or preventiv
– Nowadays common for most compressors, programs based on:
› Manufacturer’s recommandation
› Past experience
» Condition based - Predictive
– Various indicators are used to determine the condition and
performance in order to perform only necessary repairs.
– Predictive maintenance allows the operator to know the exact
condition of the units all the time.

Monitoringe.ppt
Monitoring History +2(5%,*(5

Monitoring started in the

United States, where a large
number of reciprocating
compressors is used for gas
transport. During the winter
period maximum throughput
and reliability is required.
Time based maintenance was
to expensive, so condition
based maintenance has been
introduced.

Monitoringe.ppt
Monitoring Principles +2(5%,*(5

To evaluate the mechanical condition and performance

of the compressor with snap-shot (periodic) or online
(continuous) measurement and the analysis of:

» Cylinder indicated pressure

» Vibrations

» Ultrasonic

» Temperature

» Rod drop,......

Monitoringe.ppt
Alliance Dynalco - Hoerbiger: +2(5%,*(5

DYNALCO
CONTROLS

» 29 years of compressor
monitoring experience
» State of the art electronics and
software
» Experience of 400 Recip-Trap
users
»Wide range of products for
snap-shot analysis, online
monitoring, data handling,....

Monitoringe.ppt
Recip-Trap 9240 +2(5%,*(5
The new Recip-Trap
9240 features 4
channel data
acquisition with the
possibility to take up
to 60 readings for
each channel.

Monitoringe.ppt
Recip-Trap Hardware +2(5%,*(5

The Recip-Trap is a compact, mobile and easy to maintain

analyzer in conjunction with calibrated sensors , the following
measurements are provided:

700
B

Pressure
A
R 0

2.0
G
-2.0

700
B
A
R
0

G
2.0

-2.0
Vibration
RECIP-TRAP 9240

ESC
K101A
1H PT5
623
AVE
33
DEV
672
MAX
587
MIN
331
RPM
10
PRDS
20
STAT MENU Ultrasonic
TRAP GROUP POINT START SCALE ZOOM POWER TRAP

Temperature

Option
Rod drop

PC with RTwin-software
Monitoringe.ppt
Pressure Measurement +2(5%,*(5

Only pressure measurement per cylinder end evaluates:

» Thermodynamic Characteristics of the cylinder
» Valve, piston ring and packing leakage
» Valve dynamics
» Power losses
» Pulsation
» Capacity and power

Monitoringe.ppt
Vibration Measurement +2(5%,*(5
Vibration readings are taken at different locations for specific
frequency ranges:
» Valve covers 5.6 kHz - 27 kHz
aim: Analysis of the valve dynamic

» Cross head 5 Hz - 5 KHz

aim: Detect cross head problems

» Frame, base µm, Fourier-analysis

aim: Analyse resonance, clearance,...

Monitoringe.ppt
Ultrasonic Measurements +2(5%,*(5

Ultrasonic readings are taken at the valve covers and at the

cylinder to evaluate leakage in early stages:

»Valve cover 35 kHz - 40 kHz

aim: In combination with the
pressure patterns it is
possible to detect leaks and
related energy losses

Monitoringe.ppt
Temperature Measurement +2(5%,*(5

Infrared Temperature readings at the valve covers and at suction

and discharge flanges are taken to:

» Verify leakage shown in pressure

patterns and ultrasonic traces
» Show theoretical PV- diagramm
to support analysis

Monitoringe.ppt
Recip-Trap Software +2(5%,*(5

» Data handling and storing

» Extensive comparative analysis
tools and different graphs
» Pressure pattern processing:
» Power
» Capacity
» Power losses
» “Flow Balance”
» Piston rod loading
» Trend of levels
» Automatic Anomaly Detection
» Additional functions as:
Simulation, Cursor, Zoom, Fourier-
analysis,..

Monitoringe.ppt
Analysis +2(5%,*(5
Preparing the report by analyzing the measured data, trending
levels, establishing alarm conditions and comparing results to
similar compressors.

Monitoringe.ppt
Pressure Pattern Analysis +2(5%,*(5
A comparison of the two PV-patterns measured on the same
headend cylinder shows, how a leaking suction valve affects the
pressure-volume curve.

35.00
Before Service After Service

30.00

25.00
Pressure abs. [bar]

20.00

15.00

10.00

5.00

0.00
0.00 0.20 0.40 0.60 0.80 1.00
Displaced Volume [%]

Monitoringe.ppt
Vibration Pattern Analysis +2(5%,*(5
The Vibration Readings on the valve covers show opening and
closing events, thus valve motion can be evaluated.
Vibration Traces

CE-DV

CE-SV

HE-DV

HE-SV

Pressure versus Time

35.00 Headend Crankend

30.00

25.00
Pressure [bara]

20.00

15.00

10.00

5.00

0.00
0 30 60 90 120 150 180 210 240 270 300 330 360
Crank Angle [°CA]

Monitoringe.ppt
Analysis report +2(5%,*(5
The report established after measurement contains a short
summary, the graphs and the results from analysing the
measured data regarding:

» Mechanical condition analysis MC&S MONITORING

» Piston rings RHBC\GQBC

CONTROLS
SERVICES

Compressor technology

» Valves
Kompressoranalyse - Report
» Packings
» Crosshead Kunde:

Kompressor:
OMV Wien

KSB G9815

» Bearings Datum: 16.10.1996

» Clearance
» Performance analysis
» Indicated power
» Capacity
» Power and valve losses HOERBIGER VENTILWERKE AG
Braunhubergasse 23; A-1110 VIENNA; AUSTRIA
Phone ++431 74 004 Fax ++431 74 94 376 Telex 131119 hoerb a

» Clearance volumes
» Piston rod loading

Monitoringe.ppt
 RTWin: Example I +2(5%,*(5
Single Stage Natural Gas Compressor:
First Analysis June 97, PV-Diagram Crankend

Ideal CE PV-Curve
Measured CE
Pressure [psi]

PV-Curve

Displaced Vol. [%]

Discharge Valve Leakage !

Monitoringe.ppt
 RTWin: Example I +2(5%,*(5
Single Stage Natural Gas Compressor:
Second Analysis August 97, PV-Diagram Crankend

Ideal CE PV-Curve
Measured CE
Pressure [psi]

PV-Curve

Displaced Vol. [%]

O.K. !
Monitoringe.ppt
 RTWin: Example II +2(5%,*(5
Multistage Hydrogen Compressor:
8% Capacity is missing !
PV-Diagram Crankend, 1st Stage

Ideal CE PV-Curve
Measured CE
PV-Curve
Pressure [psi]

Re- expansion is starting

too late, capacity drops!

Displaced Vol. [%]

Late closure - Oil stiction!

Monitoringe.ppt
RTWin: Example II +2(5%,*(5
Multistage Hydrogen Compressor:
PV-Diagram Crankend, 1st Stage

Ideal CE PT-Curve Vibration Trace

Discharge valve 1

Measured CE
PT-Curve
Vibration Trace
Discharge valve 2
Druck [psi]

Vibration Trace
Suction valve 1

Best valve closing moment! Vibration Trace

Suction valve 2

Actual valve closing moment!

Crank Angle [°KW]

Monitoringe.ppt
Causes for unscheduled shutdowns +2(5%,*(5
Results of a reliability study of reciprocating hydrogen
compressors:

Percentage [%] 0 10 20 30 40

Compressor Valves
Pressure packings
Process problems
Piston rings
Rider rings
Unloaders
Lube system
Instrumentation
Other
Piping
Frame
Foundation
Coolant system
Partition packings

Monitoringe.ppt
Benefits +2(5%,*(5

about 50 % of the problems causing

unsheduled breakdowns of the compressor
can be detected in early stages.

Cost reduction is accomplished by:

Reducing downtime

Planned order for replacement parts

Reducing overtime and “emergency repairs”

Avoiding major failures

Avoiding trouble shooting

Monitoringe.ppt
Benefits +2(5%,*(5
Performance analysis evaluates the efficiency
of the compressor and thus expensive energy
losses can be avoided.

Cost reduction is accomplished by:

Minimizing power losses, example:

Caused by a leaking discharge 25000

valve the regarding cylinder
(indicated power 300 kW) 20000

pumps 10 % less gas thus

Costs [DM]
15000
wasting about 30 kW. In the
next three months this damage 10000
leads to additional costs of
6.500 DM 5000

Note: 0,10 DM / kWh 0

0 20 40 60 80 100
Power losses [kW]

Monitoringe.ppt
Benefits +2(5%,*(5

Extending overhaul periods by introducing

condition based maintenance.

Cost reduction is accomplished by:

Reduced parts costs

» Perform only required maintenance
» Less general “overhaul maintenace”
» Scope of work is specific
Reduced labor costs
» Especially under the ongoing trend, “less employees,
same amount of equipment to maintain”.

Reduction of production interruptions

Monitoringe.ppt
Benefits +2(5%,*(5

Providing data for engineering and optimizing

the components.

Cost reduction accomplished by:

Reducing energy losses

» Optimizing valve springs and design
» Optimizing piston rings
» Avoiding piping losses

Increased reliability accomplished by:

Design check
» Eliminate overload
» Evaluate pulsations

Monitoringe.ppt
MC&S-M Services and products +2(5%,*(5
Services:
» Single time analysis
» Performance
» Trouble-shooting
» Testing

» Periodic mechanical condition analysis

in general 2-3 compressors per day
»Training “data analysis”
Analyzers and accessories:
» Analyzer Recip-Trap 9240
B
A
R
700

2.0
» Hardware
»
G

Training (Basics, software, analysis)

-2.0

700
B
A
R 0

»
2.0

On-site training
G
-2.0

»
RECIP-TRAP 9240

ESC

TRAP
K101A
1H PT5

GROUP POINT
623
AVE
33
DEV
672
MAX

START SCALE
587
MIN

ZOOM
331
RPM

POWER
10
PRDS
20
STAT MENU

TRAP
Accessories
» Indicator valves, TDC-Sensors, Adapters,...

Monitoringe.ppt
Requirements +2(5%,*(5
The compressor has to meet a few requirements, before the
first analysis can be carried out:

» Indicator valves on all cylinder ends

Indicator Adapter
valve

» TDC-Mark on the flywheel

» TDC-Sensor or Encoder

TDC-Sensor Encoder

Monitoringe.ppt
MONITORING - Requirements +2(5%,*(5

Cylinder indicated
pressure is the most
important measurement on
a reciprocating cylinder, if
the cylinder is not
equipped with “Indicator
Passages” and there is no
possibility to drill the
cylinder, Hoerbiger offers
you an easy way to
measure pressure by going
through the center bolt of
the compressor valves.

Monitoringe.ppt
Adapter Kit +2(5%,*(5
Cylinder Pressure

Discharge Valve
Center Bolt M20x1.5
Adapter M20x1.5

Glyd-Ring Seal
Nut
Pipe dia 10 mm

Nut 761L
Double Clamp Ring

Valve Cover
Adapter G1”

Indicator Valve

Monitoringe.ppt
Nadelventil.ppt
Adapter Kit - Technical Details +2(5%,*(5

• Pressure Range up to 340 bar *

• Temperature Range up to 200°C *
• Pipe and Adapter Material stainless steal
• Pipe chrome-plated
• Sealing Material Turcon and Viton
• Special Glyd-Ring Seal for axial displacement

Adapter

NUT

Pipe

* Obey max. pressure and temperature ratings of the indicator valve!

Monitoringe.ppt
Adapter Kit - Assembling +2(5%,*(5

• Discharge valve with drilled

center bolt and mounted adapter is
inserted into the valve nest.

• Valve cover with 1” tapping hole

• Valve, cage and valve cover are
mounted as usual.

• The length of the pipe can be

adjusted at site

• Finally the indicator valve is

mounted

Monitoringe.ppt
Periodic Snap-shot Analysis +2(5%,*(5
How the goals can be accomplished
systematically:
» Preparation
» Tailored analysis program for the
specific demands and problems of the
compressor.
» 1st. Analysis
» Evaluate present condition
» Performance analysis
» Detect problems
» Baseline for following measurements
» following analysis
» Trending data over baseline
» Early detection of problems
» Mech. condition analysis provides
information for planning maintenance
activities
Monitoringe.ppt
Monitoring benefits +2(5%,*(5

“Maximum throughput for minimum costs”

» Reduction of downtime and lost

production
» Full utilization of installed power
and capacity
» Increased reliability and availability
» Extend overhaul periods and thus
reduce maintenance costs
» Lower power and energy losses by
optimizing components

Monitoringe.ppt
 +2(5%,*(5

MC&S - M

The End

Monitoringe.ppt