Despite their criticality and relevance, reciprocating compressors are frequently overlooked by condition monitoring professionals due to sufficient data not being available. A portable vibration analyzer, which is commonly used on rotating equipment, is not well suited for reciprocating machines and has been monitoring reciprocating compressors unsuccessfully for years. Reciprocating machines generate uneven forces, and the process normally is intermittent. Therefore, the overall vibration amplitude is relatively unaffected and provides little warning of serious faults while serious damage may exist. In light of the aforementioned, HPCL Visakh Refinery has introduced a crank angle referenced condition and performance monitoring system for 2 Nos of Net Gas Compressor (NGC) which are 2 stage, 4 cylinder, double-acting reciprocating compressor. The probes/sensors that are being used here are: 4 Nos cylinder acceleration probes, 4 Nos crosshead acceleration probes, 4 Nos rod drop probes, 8 Nos pressure sensors, 1 Nos key phasor sensor. All the sensors are connected to one common Single Enclosure Module (SEM) which uses a 4G network to transmit recorded data to a server. This paper elucidates how the modern-day technology is being used on real-time basis for monitoring of extremely critical reciprocating compressor, troubleshooting underperformance of compressor and allows one to do preventive maintenance before any major failure.

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Condition Monitoring of Reciprocating Compressors

  • Padmakar Jaiswal

摘要

Despite their criticality and relevance, reciprocating compressors are frequently overlooked by condition monitoring professionals due to sufficient data not being available. A portable vibration analyzer, which is commonly used on rotating equipment, is not well suited for reciprocating machines and has been monitoring reciprocating compressors unsuccessfully for years. Reciprocating machines generate uneven forces, and the process normally is intermittent. Therefore, the overall vibration amplitude is relatively unaffected and provides little warning of serious faults while serious damage may exist. In light of the aforementioned, HPCL Visakh Refinery has introduced a crank angle referenced condition and performance monitoring system for 2 Nos of Net Gas Compressor (NGC) which are 2 stage, 4 cylinder, double-acting reciprocating compressor. The probes/sensors that are being used here are: 4 Nos cylinder acceleration probes, 4 Nos crosshead acceleration probes, 4 Nos rod drop probes, 8 Nos pressure sensors, 1 Nos key phasor sensor. All the sensors are connected to one common Single Enclosure Module (SEM) which uses a 4G network to transmit recorded data to a server. This paper elucidates how the modern-day technology is being used on real-time basis for monitoring of extremely critical reciprocating compressor, troubleshooting underperformance of compressor and allows one to do preventive maintenance before any major failure.