Reciprocating Compressor Condition Monitoring
Reciprocating Compressor Condition Monitoring
by
Steven M. Schultheis
Senior Engineer
Charles A. Lickteig
Senior Engineer
Shell Global Solutions (US) Inc.
Houston, Texas
and
Robert Parchewsky
Principal Engineer
Shell Global Solutions International
Calgary, Alberta, Canada
ABSTRACT
Technology for reciprocating compressor condition monitoring
has been around since the 1950s. However until the last 15 years or
so it seemed that only the pipeline companies spent much effort on
this activity. Technology has advanced, and there are very effective
approaches to monitoring and protecting reciprocating compressors
on the market today. While pipeline operations are pulling out their
reciprocating compressors, this machine is still the workhorse of
refineries, chemical plants, and oil production facilities. As a result
a new generation of interest has developed in effective condition
monitoring of reciprocating compressors. This paper will discuss
risk-based decision making in regard to measurements and
protective functions, online versus periodic monitoring, proven and
effective measurement techniques, along with a review of both
mechanical- and performance-based measurements for assessing
machine condition. Case histories will also be presented to
demonstrate some of the concepts.
INTRODUCTION
Each year at the Turbomachinery Symposium in the reciprocating
compressor discussion group the focus of the discussion is
primarily on condition monitoring. With all the other technical
issues related to reciprocating compressors that could be discussed,
this is usually the topic that generates the most interest. Past
topics have included vibration monitoring, rod drop monitoring,
pressure-volume analysis, and temperature measurements. In
these discussions there are several thematic questions that have
come out:
108
AN OVERVIEW OF PROVEN
MEASUREMENT TECHNIQUES
For centrifugal compressor trains there is good agreement
across industry on how to effectively monitor machine condition.
These approaches are summarized in American Petroleum
Institute (API) Standard 670 (2000), and there is little question as
to what suite of instrumentation will be used to monitor centrifugal
machines. When it comes to reciprocating compressors in
process plants, there is much less agreement on which monitoring
techniques should be standard but at least API 618 (1995)
contains some basic requirements. For an ISO 13631 high speed
reciprocating compressor, particularly in oil field service, there
is even less agreement in the industry on applicable monitoring
systems. API Standard 618 (1995) monitoring and protection
requirements include high discharge temperature, low frame
lube-oil pressures and level, cylinder lubricator system failure,
high oil filter differential pressure, high frame vibration, high
level in the separator, and jacket water system failure. API
Standard 670 (2000) describes the requirements for installing
proximity and casing transducers on reciprocating compressors,
but the details of what measurements to make, and how to
apply those measurements are left to the original equipment
manufacturer (OEM) and the purchaser to decide. The following
are some techniques that have been proven effective across a
wide range of applications.
Vibration
There are two primary vibration measurements that have been
proven effective; measurement on the crankcase, and measurement
on the crosshead/distance piece. This is due to the way forces are
applied in reciprocating machines. The most common machine
design is a balanced opposed configuration and in this configuration
the reaction forces in the cylinders are balanced across the machine
by the opposing cylinder. Since the cylinders are offset, moments
are also set up in the crankcase, and these moments are balanced as
much as possible by cylinder placement and cylinder timing. The
balance of forces and moments is fine-tuned by designing the
weight of reciprocating parts and by applying counterweights on
the crankshaft. But it is rare for the balance to be perfect and if a
malfunction occurs that upsets this balance of forces and moments,
the result is high vibration at 1 or 2 running speed. The flip
side is that if the machine support stiffness is reduced, for
instance due to grout deterioration or the loosening of foundation
bolts, then even in the presence of normal forces and moments
the vibration will increase. Catastrophic events such as breaking
a piston rod or losing a counterweight result in a sudden increase
in unbalanced forces and moments, and may result in very high
crankcase vibration.
109
Temperature
Machine temperatures are a valuable indication of machine
condition and are a primary tool for reciprocating compressor
condition monitoring. The primary temperature measurements
include cylinder discharge temperature, valve temperature, packing
temperature, crosshead pin/big end bearing temperature, and main
bearing temperature. Cylinder discharge temperature is one of the
protection parameters recommended by API 618 (1995) since leaks
in rings and valves result in recompression of gas that will raise the
110
A RISK-BASED APPROACH
TO CONDITION MONITORING
The most common objections to condition monitoring on
reciprocating compressors include: We never needed it before,
why now? We dont have problems with these machines, why
monitor them? Monitoring is too expensive. All of this may
be true, it may not be necessary, the machine may not have
problems, and a complete system may be expensive. However if the
compressor is moving hydrocarbon gas, it becomes easy to justify
at least a simple accelerometer-based vibration system costing on
the order of $1000 USD, to shut down the machine in the event of
a catastrophic event and to install a performance calculation
tool using existing instrumentation and databases. Unfortunately
purchasing a condition monitoring system is much like buying an
insurance policy. If there is never a failure then there is really no
need to have it. One thought to consider is that at least 10 percent
to 20 percent of all reciprocating compressors (based on the
authors experience) suffer a catastrophic failure or a failure that
could have been catastrophic if protection systems did not stop the
event from progressing. In buying insurance, or in buying
condition monitoring, the first step is to assess the risk, and then
purchase what is appropriate to mitigate the risk specific to the
machine and the service. The outcome of the risk assessment
should be a list of parameters that will be used to protect the
machine, as well as parameters for determining machinery
condition. The approach to risk assessment is usually a risk matrix
that includes aspects of safety, business impact, environmental
impact, and reputation impact. Figure 9 is an example of such a
risk matrix. The outcome from this kind of analysis can be either a
level of criticality, a safety integrity level, or a standard monitoring
approach. One of the ways this type of analysis can be used is to
determine if monitoring should be online or periodic. Machines
with high criticality ranking will typically require online monitoring
and protection. Machines that are spared, and thus represent
significantly less risk, may only require minimal protection with
periodic monitoring. Machines with high criticality ratings may not
only justify a complete set of monitoring and protection instruments,
it might also make sense to establish the information technology (IT)
infrastructure for remote monitoring and diagnostics.
111
CASE HISTORIES
Case History 1
A 1500 kW compressor was installed in 2002 that was
deemed critical enough to justify an advanced monitoring and data
acquisition system with remote monitoring and diagnostic capability.
After 3000 running hours a failure occurred at the crosshead for
cylinder 1. The machine had experienced a four-hour shutdown
after a power failure and when this was resolved a restart was
initiated. Shortly after startup a trip occurred due to
vibration/impact at the accelerometer sensor for cylinder 1. The
weather was cold and stormy (0F), and after examination of the
crosshead the failure was obviously a matter of poor lubrication.
This compressor had one common oil supply line to the top and
bottom crosshead guides and based on the design there was
certainly a preference in the oil supply to the top. That issue, in
combination with the low temperature and associated viscosity
changes in the oil along with startup conditions, resulted in a lack
of oil supply to the crosshead and the resultant failure (Figure 10).
The compressor tripped on impact level set in the online monitoring
system, which prevented the machine from more extensive damage
and longer outage time. However, the system showed a change
earlier in both vibration and temperature. Unfortunately no
response was taken to this change in vibration level and temperature
increase until the failure occurred (Figures 11 and 12).
112
Figure 17. Broken Piston Rings Laid out on the Cylinder Support
Pedestal During Disassembly.
113
REFERENCES
Figure 18. Pressure Time and Ultrasonic Trace Showing Crank End
Discharge Valve Leak.
Case History 5
Again crosshead acceleration measurement saves the day as it
tracks the development of a loose piston nut. The acceleration
trace (Figure 19) changed significantly between the May and June
measurements, and there is a distinct impact/ring down pattern
present after top dead center (TDC) and bottom dead center
(BDC) indicating an impact as the load shifts from tension to
compression and back.
BIBLIOGRAPHY
Leonard, L., June 1996, The Value of Piston Rod Vibration
Measurement in Reciprocating Compressors, Orbit Magazine,
pp. 17-19.
Schultheis, S., June 1996, Vibration Analysis of Reciprocating
Compressors, Orbit Magazine, pp. 7-9.
Schultheis, S. M. and Howard, B. F., 2000, Rod Drop Monitoring,
Does it Really Work, Proceedings of the Twenty-Ninth
Turbomachinery Symposium, Turbomachinery Laboratory,
Texas A&M University, College Station, Texas, pp. 11-20.
Figure 19. Crosshead Acceleration Traces Showing the
Development of a Loose Rod Nut. Crosshead Knocks after TDC
and BDC (Ring Down).
CONCLUSIONS
ACKNOWLEDGEMENTS