Reciprocating Compressor Analysis Procedures Purpose of One-Time Analysis + Determine overload or under-utilization, + Identify significant mechanical and/or performance deficiencies (on-condition + Determine effective clearances, osses and ‘compression efficiencies of healthy cylinders, Purpose of Routine Analysis + Efficient utilization of available horsepower + Reduced energy requirements + Reduction of downtime and lost production + Reduction of maintenance costsAnalysis Types + Troubleshooting + Detailed Performance Testing = Valve Compacison Load Curve Geseraton ~ Research and Development + Special = Pulsation, Vibration + Routine Mechanical Condition & Performance "| Before the Test + Gather required information to setup the analysis equipment Geometry ~ Process gas analysis ~ Exped operating conditions during the test + Research the maintenance history of the unit + Verify TDC reference accuracy, + Inspect indicator valves and passage geometry. + Verify Pressure transducer performance. + Talkto people closely associated with the nit Initial Site Inspection ‘+ Gas cooler condition (cleanliness, vibration) + Jacke. vater cooler condition + Visual indiestore of load + Packing vent essions + By-pass, vent, blow-down, relief and recycle valve leakage + Pad, base, line, vessel and aecesspry vibration mhInitial Compressor Visual Inspection + Ultesonio survey of extemal leks (Head pasts, ‘Valve caps pockets, unloaders, anges, packing glands | snd rod packing, pneumatic contol fines end atustors) + Temperature of vale caps, pecking vents capacity contol devices, syle and vet valves + Feel and ston for knocks to identify potential problems entity coolant and il oaks + Goer all mania! panel temperature and I sensor test point data if dynamic presse data so be collected ext Compressor End Manual Panel Points + Suction reference pressure per stage 7 + Discharge reference pressure per stage + Pocket position pe eylindr end + Predicted or measured flowrate + Predicted BHP/Torque + Pump and bearing ol pressure (Separable | uit) Compressor Manual/IR Temp. Points + Suction reference temperature + Discharge reference temperature + Valve cap temperatures + Packing vent temperature | * Cooling water in and out temperatures + Oilin and out (separable units) * Scavenge/Air eylinder suction and discharge temperatures,‘Compressor End Sensor Points (2 avg.) + Head and crankend dynanic DC pressure + Sveton and discharge pressure overlays (optional) + + Head and ern nd high frequency vibeation oad ond and crocehead low fequeny witation valve cap ultsonio | Closed cease pocket ulsonio ‘Dynamic rod run-out (optional) Scavenge evn sunonand discharge lmsonis | Scavege cinder high and low Sequeey vibration Compreso fame main betring low freqensy vibration (fr spate Exes) Compressor End Analysis + Collect ll manual panel, manual temp od Tnffared data just pir to or just after collecting sfynamie pressure information + Gather all sensor point information while holding the unit ead as constants possible 4 + Uszo-s20pe or monitor modesto perform "dynamic" troubleshooting (loaders & pockets) + View manual and performance reports to determine if collected data isin memory and if additional data colloton or troubleshooting is required Reports cisadou) + Compressor Performance Report + Manual Panel, Temperature and IR Report «| + Sct-up Data Report + Priotitized Deficiency List mnDeficiency Priority A/1 + Identifies a severe mechanical or performance deficiency. + Repair immediately or as soon as | possible to reduce the possibility of personnel injury or to prevent probable catastrophic failure of the defective and or related components. Priority A/1 Examples + Bice vin of oremsksinpreszed ‘components (ines, veools,eylinders) x + Combustible pas eis in ponmity ta potest ignition source. + Brose lotens of sposating components + Exoeing dame rod canine joel ods. + nner verso exosiveovroed. + Excessive tempers + Exceding MAW, + Bearing ard coterwight efits. + inopeaive sity devices and st downs. Deficiency Priority B/2 + Identifies an excessive mechanical or performance deficiency. + Repair in a timely manner to prevent | possible failure of the defective component and/or related components or to prevent reduction of capacity 4 below minimum requirements. mAPriority B/2 Examples + cessive valve leakage + Excessive ring leakage + Excessive packing leakage + Non-operative capacity control devices ‘causing unit overload. + Slight to moderate piston looseness on rod, + Correction level vibration amplitudes related to piping, vessels, eylinders and skids. y Deficiency Priority C/3 + Identifies a slight to moderate ‘mechanical or performance deficiency. + Schedule with other repairs or services to improve reliability and/or efficiency. Priority C/3 Examples + Slight to moderate valve seat leakage, + Slight ring leakage. + Slight pocket seat leakage, + Delayed valve closures without unacceptable failure history. + Excessive power losses not causing driver overload or rod-toad problems. + Other mTDeficiency Priority D/4 + Identifies a potential or minor ‘mechanical or performance deficiency. + No action is required at this time, + Tem of interest thatthe analyst will invostigate further at the next scheduled analysis. + Alerts operating personnel toa possible developing problem. Priority D/4 Examples + Minor valve opening and closing deficiencies without valve failure history. + Slight to moderate component vibration and Jooseness. + Instrumentation deficiencies (non contol related), + Minor non-combustible Mid and sir eaks. + Other ‘Affier The Report is Done + Discuss findings with technicians and supervisors + Follow-up to lam results of accomplished inspeations and repairs + Ipossibl, participate in the inspection and repair process. mT