Applications: Reciprocating Compressors

About Reciprocating Compressors Reciprocating compressors utilize crankshaft driven pistons to compress gases for use in various processes. Much like internal combustion engines, an offset crankshaft causes rotary motion of a piston rod which is converted to linear motion via a crosshead. The crosshead can only move in a linear motion so that the rotary motion of the crankshaft is transformed into linear motion of the piston. As the piston moves to and fro, it takes in low pressure gas and increases its pressure. Unlike an internal combustion engine, the gas is not ignited. It is allowed to leave the compressor cylinder at a higher level of pressure than when it went in. The majority of applications for reciprocating compressors are in the oil and gas industries. Oil refineries use these compressors for processes that require high pressure delivery of essential gases. The natural gas industry also utilizes reciprocating compressors to transport gas via cross country pipelines. These compressors can also be found in chemical plants, refrigeration plants, air compressors for tooling, etc. Reciprocating compressors are unique pieces of equipment as they contain active components that are moving in rotary as well as linear directions. They also play a vital role in any process that

they are employed in. Therefore, a reciprocating compressors health must be monitored, but in order to do so, you must do more than follow the usual vibration monitoring rules.

Equipment for Recips IT6810 Impact Transmitter ST5484E Vibration Transmitter 8978-111 Cable

IT6810 Traditional vibration analysis focuses primarily on the steady tones generated by rotating equipment. However, this is not sufficient for a reciprocating compressor because their vibration characteristics have signals that typically dont constitute a significant portion of the total energy within the overall signal sensed by a vibration transducer. Thus the spiking/spurious signals that are so critical to monitor wont appear in a conventionally detected level displayed on a vibration monitor. Its the same problem you experience while attempting to converse with the person sitting next to you during a rock concert their presumably intelligent speech constitutes a miniscule portion of the overall sound level. These signals are created by a reciprocating compressor due to its multitude of moving parts. While the crankshaft is going round and round, rods are going back and forth reversing on every stroke. Squeaks, ticks, knocks and other assorted periodic impact type sounds are generated as components move. As these moving parts wear, the clearance between them increases and as a result, the gaps between the parts will click (and sometimes bang) as each part goes through its forward and reverse motion. For example, if you have a loose cross head pin, then every time the crosshead changes direction the crosshead will bang into the crosshead pin causing an impact event. Examples of anomalies that are manifested as impact or spike type transients are knocks

from loose parts and liquids in gas, clicks as cracks come together and open, and hissing flow noise through closed valves and squealing gasket leaks. All are embedded in the busy transient sounds of a reciprocating machine in action.

From this simplified description, one can see that in terms of vibration and sound, a reciprocating machine is a quite different animal and far more complex compared to a rotating machine. For this reason, conventional vibration monitoring and analysis techniques, employed very successfully on rotating machines, dont work very well on reciprocating machines. There is simply too much din and transient activity in a sound or vibration signal to accurately identify what a single component is attempting to say. If the vibration system is set to a high sensitivity in order to recognize small changes, you are likely to experience false trips. If the sensitivity is set too low, the monitored machine may suffer extreme damage without a trip from the vibration monitoring system. However, when ignored, these conditions identified by impacts only get worse and cause catastrophic damage very quickly. A traditional vibration sensor measures the vibratory energy over a broad spectrum. Anything within this spectrum will be added to an overall reading. The impact transmitter does not concern itself with a broad spectrum of frequencies because, while measuring overall values to detect mechanical looseness is a valid technique, by itself it is not enough. The Impact Transmitter, on the other hand, is designed to detect mechanical looseness, not vibration. To increase the reliability of this measurement a technique was developed which qualifies the impacting events. Within the Impact Transmitter, special peak detection circuitry captures and counts impact events above a threshold value

during a specified length of time. In this way, transient conditions where impact events appear and go are differentiated from mechanical flaws where impact events appear and stay such as looseness, cracks and leakage. The qualification of the measurement is based on both amplitude and whether or not the events are single events or repeated events. Upon detection, and meeting level threshold requirements, the events are counted within a time window. The time window, or reset time, is set based on running speed. The transmitter sets an output current level based on the registered number of events that occurred within the time window. Metrix calls this a measurement of impact severity. An output of 4mA indicates no events occurred over the threshold level, within the time window. An output of 6mA indicates 2 events, 8mA indicates 4 events, etc., up to 20mA for 16 events. The PLC, or other recording instrument, determines the alarm and trip action based on impact severity. This system offers significantly improved protection compared to conventional vibration monitoring. The impact measurement was originally developed as a reliable means of protecting reciprocating compressors. Impact monitoring has proven to be a sound measurement for detecting mechanical looseness at early stages of development on compressor cylinders. This measurement takes advantage of advantage reciprocating machine failure modes. They effectively utilize the inherent dynamic characteristics of a reciprocating machine to warn and trip in the event of defects such as:

Loose and cracked parts Valve and gasket leaks Bolts or fits loosening and internal leakage Catastrophic rod failure Increased valve lash Bent pushrods Broken valve keepers Cracked crankshaft Loose rod nut

Excessive slipper clearance Worn pins Liquid in the process Loose cylinder liners Other shocks or impacts

Mounting The Impact Transmitter is typically mounted on the crosshead or distance piece (doghouse) perpendicular to rod motion. It should be mounted where it will be out of the way of maintenance requirements and should not be mounted on access panels or removable covers because rattle noise from loose external parts can be mistaken for internal loose parts.

ST5484E The ST5484E is a precision vibration sensor and signal conditioner in a single package built to provide years of reliable service. It is the ideal solution for sensing vibration on most plant equipment. A simple two-wire loop signal proportional to velocity is generated for transfer to a programmable logic controller (PLC), distributed control system (DCS) or other 4-20mA input devices. Simply mount the transmitter on the machine case,

connect the 2-wire loop and read and/or record the vibration. While the impact transmitter will pick up on problems that traditional vibration measurements cannot see, it is not a replacement for those traditional methods. The purpose of the application of an ST5484E on a reciprocating compressor is to monitor the rotating elements of the compressor. This measurement will pick up the vibration of the machine and alert you to problems that the impact transmitter will ignore such as bearing, or gear problems. Mounting The ST5484E should be mounted on opposite ends of the compressor and in opposite orientations. The mounting should be parallel with the direction of piston travel and as close as possible to a solid internal structure so that the vibratory forces will have a direct path to the vibration sensor. They should be mounted out of the way of maintenance requirements and should not be mounted on access panels or removable covers.