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Reciprocating Compressor Diagnostics

Periodic monitoring of reciprocating compressors through diagnostic analyses allows issues to be identified early and corrective actions to be taken, improving machine performance and availability. SINT Technology provides diagnostic services including measuring and analyzing absolute pressure vs. piston displacement, vibration, and torsional vibration to detect problems like excessive valve leakage or pressure loss. These analyses help determine mechanical conditions and pinpoint any undesired behaviors in reciprocating compressors.

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Chandra Shekar
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© Attribution Non-Commercial (BY-NC)
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Download as PDF, TXT or read online on Scribd
299 views

Reciprocating Compressor Diagnostics

Periodic monitoring of reciprocating compressors through diagnostic analyses allows issues to be identified early and corrective actions to be taken, improving machine performance and availability. SINT Technology provides diagnostic services including measuring and analyzing absolute pressure vs. piston displacement, vibration, and torsional vibration to detect problems like excessive valve leakage or pressure loss. These analyses help determine mechanical conditions and pinpoint any undesired behaviors in reciprocating compressors.

Uploaded by

Chandra Shekar
Copyright
© Attribution Non-Commercial (BY-NC)
Available Formats
Download as PDF, TXT or read online on Scribd
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RECIPROCATING COMPRESSOR DIAGNOSTICS

Periodic monitoring of reciprocating compressors makes it possibile to check the condition of the machines and to pinpoint impending trouble or changes in behavior. Preventive fault diagnosis provides the following benefits: Better programming of maintenance services Reduced risk of forced outages Improved machine performance

Periodic monitoring therefore results in superior machine availability and efficiency. Diagnostic analyses on reciprocating compressors can be conducted right from the outset of operational problems to find the causes and to take the most appropriate corrective action.

SINT Technology can provide a wide range of diagnostic services for reciprocating compressors, including: measurement and analysis of abs. pressure vs. piston displacement measurement and analysis of vibration measurement and analysis of torsional vibration

MEASUREMENT AND ANALYSIS OF ABS. PRESSURE VS. PISTON DISPLACEMENT


Analysis of absolute pressure versus piston displacement is one of the main techniques for checking reciprocating compressor efficiency and for promptly detecting undesired behavior, such as: excessive valve pressure loss packing and piston ring leakage gas leakage to the suction and discharge valves faulty valve behavior (flutter, excessively stiff spring system, etc.) suction and discharge pressure pulsations

Data acquisition and analysis


SINT Technology has developed a portable system (hardware plus software) specifically for monitoring reciprocating compressors that enables absolute pressure vs. piston displacement to be displayed in real time, recorded and analyzed. The thermodynamic cycle is determined by measuring pressures inside the cylinder with transducers fitted on pressure taps on the machine. These pressures are then related to the angular position of the shaft by means of a sensor that measures the speed of rotation.

The software can also overlap the ideal cycles formed on the basis of the operating conditions of the machine (knowing the thermodynamic properties of the gas), record process parameters versus time (static temperatures and pressures upstream and downstream from the cylinder), and calculate the main parameters characteristic of the cycle.

Automatic dead center calculation


Since it is important that measured pressures be correctly related to the real position of the piston within the cylinder, SINT Technology has perfected a procedure for checking key phasor positioning on the machine, making it possible to calculate the angular phase displacement between the key phasor signal and the position of the crankgear dead center.

Measurements on compressors for high pressure service

In high pressure applications (eg, polyethylene) where sensors cannot be fitted on cylinder pressure taps, the thermodynamic cycle can only be determined indirectly. For this type of compressor, SINT Technology can measure the cycle by strain gage analysis of cylinder tie rod deformation.

VIBRATION MEASUREMENT AND ANALYSIS


Vibration analysis of reciprocating compressors and reciprocating compressor components is an important instrument for identifying undesired machine behavior in good time. The analysis is usually done by comparing measured values with set threshold values and/or with the results of previous measurements. The points where vibration is measured are the cylinders, valve covers, crankcase, skid, pulsation dampers, piping and any other component that can provide significant data, according to the application concerned.
Allowable Piping Vibration Level
80.0

70.0

not allowable
60.0

Amplitude (mm/s 0-Pk)

50.0

40.0

30.0

allowable

20.0

10.0

0.0 0 20 40 60 80 100
Frequency (HZ)

120

140

160

180

200

As a rule, an analysis of vibration versus frequency and an analysis of overall vibration values are sufficient to obtain useful information on machine operation. In the event of particular requirements, more complex analyses can be conducted

Modal analyses, generally on piping, can be performed to identify the natural frequencies and thus establish the cause of improper behavior while a machine is operating.

MEASUREMENT AND ANALYSIS OF TORSIONAL VIBRATION

SINT Technology has developed a telemetric acquisition system for measuring torque and torsional vibration. These analyses are performed in start-up and coast-down transients as well as in steady-state operating conditions. Unique features of the system are accuracy in signal transmission and the fact it is quick to install (it can fit any size of diameter).

R1 Mt R4

R2

Mt

R3

Time and waterfall analyses can be performed by the software, which was specially developed for the system by SINT Technology.

30000

20000

10000

Second part

Time analysis

Torque [Nm]

-10000

-20000

-30000

-40000 0 0.2 0.4 0.6

First part
0.8 1 1.2 1.4 1.6 1.8 2 2.2 2.4 2.6 2.8 3 3.2 3.4 Time [sec]

2 1 5

4 1

The 3-D waterfall analysis, which can either be in the time or velocity domain, makes it possible to display the harmonics of the system, the natural frequencies and any resonance phenomena during transient periods, automatically calculating the damping factor .

Waterfall analysis

FIELD OF APPLICATION
Reciprocating compressors Reciprocating compressors

DESCRIPTION
Measurement and evaluation of mechnical vibrations of reciprocating piston engines and piston compressors Measurement on reciprocating compressors (Internal procedure)

REFERENCE STANDARD
VDI 2063 ISO 10816 SINT F08

Via Giusti 229 - 50041 Calenzano (FI) tel +39 055 8826302 fax +39 055 8826303 e-mail: [email protected] www.sintechnology.com

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