Standard instrumentation

used on reciprocating
compressors
Gaia Rossi – Thorsten Bickmann
GE Measurement & Control

EFRC training on
Condition monitoring and diagnostics 26 September 2012
 Contents
Introduction
• Recommended measurements for protection and diagnostic

Vibration and position

• Frame and Crosshead Vibration: transducer selection, purpose, technology
• Piston Rod Drop and Vibration, transducer technology, examples
• Installation pitfalls
• Ultrasonic measurements

Pressure
• Purpose and derived parameters, installation pitfalls, examples

Temperature
• Locations, purpose and available technologies, examples

EFRC training on
Condition monitoring and diagnostics 26 September 2012
 Reciprocating Compressor
Measurements
Design, malfunction modes determine measurements types:

Compressor Valves Displacement

Piston rods Velocity
Rider Bands Acceleration
Pressure Packing Pressure
Piston Rings Temperature
Crosshead pin ...

EFRC training on
Condition monitoring and diagnostics 2026
October 2010 2012
September
 Standard measurements for
reciprocating compressor
Limited information from standards on measurements for Condition Monitoring.

• API 618 mentions frame vibration as alarm and shutdown parameter

• API 670 mentions also rod drop and casing velocity as protection parameters
• Generic indications in ISO standards for vibration validation of recip
machinery.

Technology developments and practical experience over recent years lead to

additional recommended measurements for monitoring and diagnostics:

• Crosshead and cylinder vibration

• Piston rod runout, rod vibration
• Cylinder pressure

EFRC training on
Condition monitoring and diagnostics 26 September 2012
Casing Vibration Measurements

Frame Vibration
Crosshead Vibration Cylinder Vibration
 Typical Frequency Ranges
Seismic Transducers

Accelerometer: Highest frequency

response. Used for crosshead and
cylinder impulse/impact monitoring
Accelerometer
Piezovelocity Sensor: Lower high
frequency response, but less noise
than using an external integrating
amplifier with an accelerometer,
used for frame vibration Piezovelocity Sensor

Moving Coil Sensor: Limited

frequency response, no requirement
for an external power supply. Widely
used before piezo sensors perfected Moving Coil Sensor

EFRC training on Typical Frequency Ranges

Condition monitoring and diagnostics
 Crosshead and Cylinder
Vibration (Acceleration)
Accelerometer is suitable for monitoring
impact events at crosshead guide and valve
signatures at cylinder.
Accelerometers

• Units: meters per second2 (m/s2), inches per second2 (in/s2), or Gravity (g)
• High frequency response (up to ~20 kHz)
• Typical Scale Factor 100mv/g (p-p) 26 September 2012
 Accelerometer Specifics
case charge amplifier case
charge amplifier

preload band

preload screw mass mass

element element

mounting stud mounting stud

compression type sensor shear type sensor

Piezoelectric Accelerometer
EFRC training on
Condition monitoring and diagnostics 26 September 2012
 Frame Vibration (Velocity)
Frame vibration is the response of the system to dynamic
loads: gas load, inertial load, gas unbalance.
Many years of analysis and study of velocity data before
perfecting piezo-sensors has resulted in vibration monitoring
guidelines (such as ISO standards) that include
recommended severity levels based on units of velocity.

Excess or unbalanced load,

inertial imbalance, loose
foundation can be detected by
frame vibration measurement.

Units: millimeters per second (mm/s) or

inches per second (ips)
Typical Scale Factor: 100mv/in/s (p-p).
Frame vibration installation
 Velocity Sensor Specifics
charge amp. & case
magnet integration circuit

preload band

moving coil
Sensitive
mass
Axis

crystal

mounting stud

Traditional Moving-Coil Sensor Piezo-Velocity Sensor

(self-powered) (Accelerometer with onboard integrating circuit)

Integration within the sensor minimizes signal noise

EFRC training on
Condition monitoring and diagnostics 26 September 2012
 Ultrasonics: Acoustic Emission
for Valve Leakage Detection
High frequency signatures generated by leaks in valves, piping and other
process systems can be identified using ultrasonics. Measurements are
usually made as snapshots with portable systems.
Suction Valve Suction Valve Discharge Valve
Opening Closing Opening
Discharge
Valve
Closing

High frequency vibration (AE)

generated by the turbulent flow of gas
leaking from a suction valve when the
valve is supposed to be closed.
26 September 2012
 Mounting considerations
To ensure accurate and consistent readings, transducer mounting is key.
Accelerometers are extremely sensitive to the method of attachment.

Permanently installed stud-mounted transducers need flat surface

meeting specified tolerances and mounting torque.
Signal noise can also be produced by badly tied or loose cabling.

Mounted natural frequency

EFRC training on
Condition monitoring and diagnostics 26 September 2012
 Piston Rod Displacement
• Eddy current proximity transducer
• Units: microns (m) or 1/1000 of an inch (mil)
• Measuring rod drop and rod or plunger vibration
• Calibrated to target material

Pitfalls:
• Wrong material calibration
• Bracket vibration / resonance
• Improper application (rod drop)

Rod Drop trend Frequency Response down to 0 Hz

Typical Scale factor -200 mv/mil (p-p)
Rod vibration waveform
EFRC training on
Condition monitoring and diagnostics 26 September 2012
 Cylinder Pressure
• Used to identify leaks at valves, rings, packing case
• Used to determine rod load and load reversal degrees
• Dynamic pressure by piezoresistive transducers
• Absolute pressure for performance calculation
• Isolation valve required for safety
• Snapshot or permanent mount

Pitfalls:
• Channel resonance due to unproper
mounting design
• Overpressure damage due to wrong
pressure range selection
EFRC training on
Condition monitoring and diagnostics 26 September 2012
 Pressure Sensor Installation
Pressure sensors should be mounted as close to the chambers as possible with straight,
short and constant diameter gas passage

Cylinder Indicator Taps

Isolation
Valves
Crank End Head End Pressure
Pressure Transducer
Transducer
26 September 2012
Pressure Sensor Installation
Pressure
Support Sensor
Bracket

Isolation
Valve

EFRC training on
Condition monitoring and diagnostics 26 September 2012
 Installation Pitfalls: Channel
Resonance
Improper installations leading to channel resonance

Isolation valve

Protective conduit (A) covering transducer and

field wiring, isolation valve (B), and 90-degree
elbow (C).

EFRC training on
Condition monitoring and diagnostics 26 September 2012
 Acoustic Resonance Noise
Discharge Process
800 Resonance? Valve
Expansion Process Flutter?
700 Apparent
Resonance
600
Pressure (PSIG)

500
Measured resonance
400 frequency = number of
pulsations / time.
300
Compression
200 Suction Process Process Apparent
Resonance? Valve Resonance
100 Flutter?
0
0 30 60 90 120 150 180 210 240 270 300 330 360
Crank Angle (degrees)

EFRC training on
Condition monitoring and diagnostics 26 September 2012
 Temperature measurements
• Main Bearing

• Valve

• Packing Case

• Connecting Rod bearing

and Crosshead Pin

EFRC training on
Condition monitoring and diagnostics 26 September 2012
 Valve Temperature
• Valve leaks cause gas recompression and
temperature increase
• Monitoring with Thermocouple or RTDs
• Tradeoff between installation effort and benefit
• Also performed with portable instruments Valve cover temperature

Valve cover skin temperature

EFRC training on Internal valve temperature

Condition monitoring and diagnostics 26 September 2012
 Wireless connecting rod big and
small end bearing temperature
A low energy / high frequency Radar
Pulse is generated by the Signal
Processing Unit (SPU)
Transmission to the wireless passive
sensor via the stationary antenna
Reflection of a pulse back to the SPU
modified in function of the temperature

Connecting
rod big and
small end /
crosshead pin
 Backup

EFRC training on
challenging environments 20 October 2010
 Proximity Transducer System
RF signal

To
CONDUCTIVE Monitoring
MATERIAL System

Eddy currents

EXTENSION
CABLE PROXIMITOR
AND PROBE

DEMODULATOR

OSCILLATOR

EFRC training on
Condition monitoring and diagnostics 26 September 2012
 Observed vibration
RF signal output, V

Probe closer to 0
target

Probe away from

target 0

Oscillating
0
distance from
target

Target vibration causes the oscillator signal amplitude to be modulated at the same
frequency as the vibration.
 Output values
0
RF SIGNAL

Demodulator extracts the

signal from the RF signal
0V
Transducer output:
• Time-varying (AC)
value: vibration signal.
• Average (DC) value:
gap voltage.
0V
DC Gap Voltage

AC Vibration Signal
(peak to peak)

EFRC training on
Condition monitoring and diagnostics 26 September 2012
 Probe Response Curve
Operational Verification
24
22
CHANGE IN GAP
20
18
OUTPUT IN VOLTS - DC

16

CHANGE IN VOLTAGE
14
12

10

8
6

2
0
mils 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140
PROBE GAP
EFRC training on
Condition monitoring and diagnostics 26 September 2012
 Shaft Surface Material
24
22

20

18
OUTPUT IN VOLTS - DC

16

14

12

10

6 4140 STEEL
TUNGSTEN
ALUMINUM
4
COPPER
2

0
mils 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140
EFRC training on PROBE GAP
Condition monitoring and diagnostics 26 September 2012