Reciprocating Compressor Cylinder Pressure Patterns Bently NevadaAsset Condition Monitoring

GE
Measurement & Control
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Bently Nevada, Keyphasor and System 1 are trademarks of General Electric Company.
Copyright 2012 General Electric Company. All rights reserved.
Packing Vent
Temperature
Packing Case
Temperature
Rod Position
Cylinder
Pressure
Cylinder
Acceleration
Suction
Temperature
Cylinder Valve
Temperature
Multi-Event
Keyphasor
System
Main Bearing
Temperature
Frame
Vibration
Connecting Rod
Bearing
Temperature
Crosshead
Vibration
Single-Event
Keyphasor
System
Instrumentation Layout Components and Nomenclature
Connecting Rod
Multi-Event Wheel
Timing Details
Isolation Valve
(should not induce
channel resonance
reference GER-4273)
Mechanical Bracing
To Protect Cylinder
Pressure Transducer
Cylinder Pressure
Transducer
(-/+ 0.5% accuracy
for 1+ billion cycles)
Leak to Low Pressure Side
(often suction valves)
Leak to High Pressure Side
(discharge valves)
Inter-Chamber Leak
(usually piston rings)
Red is Theoretical Pressure Curve
Black is Indicated Pressure Curve
Leak to Low Pressure Reservoir
(crank end shown, head end similar)
Leak from High Pressure Reservoir
(crank end shown, head end similar)
Red is Theoretical Pressure Curve
Black is Indicated Pressure Curve
Supporting Evidence
Is flow balance greater than 1.05?
Does the trend of a particular suction valve temperature indicate a rise compared to the other suction valve covers?
Does valve cover acceleration/ultrasonic show high amplitude when suction valves are closed?
Supporting Evidence
Is flow balance less than 0.95?
Does the trend of a discharge valve temperature indicate a rise compared to the other discharge valve covers?
Does valve cover acceleration/ultrasonic show high amplitude when discharge vavles are closed?
Red is Crank End Theoretical Pressure Curve
Black is Crank End Indicated Pressure Curve
Inter-Chamber Leak
Supporting Evidence
Is flow balance on both chambers greater than 1.05?
Is discharge temperature elevated compared to adiabatic discharge temperature?
Does acceleration/ultrasonic show high amplitudes when chamber pressures different and low amplitudes
when chamber pressures are equal?
Pressure Versus Volume Log Pressure Versus Log Volume Pressure Versus Volume Log Pressure Versus Log Volume Pressure Versus Volume Log Pressure Versus Log Volume
Indicated pressure
crosses theoretical pressure
(both chambers)
Cylinder Pressure
Installation Details
1. Drill and tap three 3/8-24 UNF 2B thread 1.00 in. deep 120
degrees apart on 3.00-inch diameter bolt circle.

1
2
3

1. Direction of rotation
2. Falling edge
3. Divided notch
4. Trailing narrow notch
1
2

1. Direction of rotation
2. Minimum negative voltage output
1
2

1. Direction of rotation
2. Maximum negative output voltage
1
2

1. Direction of rotation
2. Keyphasor output equals halfway value
38.1 mm (1.500 in.)
radius
120 120
3/8-24 UNF 2B
25.4mm (1.00 in.) deep
3 places
2. Install the guiding stud of the recip multi-event wheel.
3. Slide the recip multi-event wheel over the guiding stud and
align the falling edge of the divided notch with the Keyphasor.
The second narrow notch should trail the first one in the
direction of rotation. Loosely install 3/8 24 bolts to hold the
wheel in place.
4

Recip Multi-Event Wheel
(Part No. 145732-01)
Recip Multi-Event Stud and Pilot
(Part No. 146622-01)
Recip Mulit-Event Wheel Kit
(Part No. 146973-01)
4. You can precisely align the edge by measuring the voltage from
the Keyphasor probe-proximitor combination when the probe is
located over the notch, and then when it is over the protrusion.
Rotate the wheel to obtain the minimum negative Keyphasor
voltage over the protrusion and record this value.
5. Rotate the wheel to obtain the maximum negative Keyphasor
voltage over the notch and record this value. Average the two
voltage values to get the precise edge value.
6. Rotate the wheel back to the edge. When the Keyphasor
output equals the calculated halfway value, secure the
wheel into place
Maximum Allowable Continuous Combined Rod Load (MACCRL)

A value determined by the Original Equipment Manufacturer (OEM) based on
design limits of the various components in the compressor frame and the
running gear (bearings, crankshaft, connecting rod, crosshead assembly,
zpiston rod, piston assembly).
Maximum Allowable Continuous Gas Load (MACGL)

A value determined by the OEM based on the design limits of the static
components (frame, distance piece, cylinder, and bolting).
Rod Reversal
The shortest distance, measured in degrees of crank revolution, between
each change in sign of force in the combined rod-loading curve.
Gas Force Synch
Crank Angle
Compressor Train From 29APR2003 12:36:39 To 29APR2003 12:36:39 Historical MACHINE SPEED: 276 rpm
Inertial Load
Crank Angle
Compressor Train Historical
Combined Force
Crank Angle
Compressor Train Historical
-100
-50
0
50
100
0 100 200 300
10k lbf/div
20 Degrees/div
Crank Angle
<--COMPRESSION FORCE TENSION-->
TDC
0 Degrees
-105746.2 lbf (-470382.5 N)
0 Degrees
43951.9 lbf (195508 N)
0 Degrees
-61794.3 lbf (-274875 N)
10k N/div
<--COMPRESSION FORCE TENSION-->
0
-220
-440
440
220
Rod Reversal
Green is Head End Theoretical Pressure Curve
Blue is Head End Indicated Pressure Curve
5 %/div
Displaced Volume
IN
D
ICATED
PRESSU
RE
TDC
Indicated Suction Pressure (Toe Pressure)

Cylinder pressure when the piston is at bottom-dead-center for
head-end chamber or at top-dead-center for crank-end chamber.
Indicated Discharge Pressure (Heel Pressure)

Cylinder pressure when the piston is at top-dead-center for head-end
chamber or at bottom-dead-center for crank-end chamber.
Compression Ratio
Indicated discharge pressure divided by the indicated
suction pressure.
Indicated Suction Pressure
Indicated
Discharge Pressure
Minimum Pressure

Smallest indicated pressure value that occurs over the entire
pressure-volume cycle.
Maximum Pressure
Largest indicated pressure value that occurs over the entire
pressure-volume curve cycle.
Maximum
Pressure
Minimum
Pressure
Reciprocating Compressor
Operating Cycle
Indicated pressure compression
and expansion strokes not
parallel in log-log format.
Indicated pressure rises
faster than theoretical
on compression stroke.
Indicated pressure falls
slower than theoretical
on expansion stroke
(if theoretical curve
uses cylinder
nameplate clearance).
Indicated pressure rises
slower than theoretical
on compression stroke.
Indicated pressure compression
and expansion strokes not
parallel in log-log format.
Rounded Toe
Indicated pressure falls faster
than theoretical on expansion
stroke (if theoretical curve
uses cylinder nameplate clearance).
Rounded Heel
Crosshead
Crosshead Pin
Bushing
Lubricating
Passage
Crosshead
Pin
Connecting
Rod
Piston Rod
Cooling Water
Suction Valve Cage
Discharge Valve
Pressure Packing Case
Chamber (Frame End or Crank End)
Crosshead Pin
Discharge Valve Cage
Valve Cover
Cylinder Head
(Outer End or
Head End)
Wear Bands (Rider Rings)
Cylinder
Piston
Piston Rings
Suction Valve
Chamber (Outer End or Head End)
Cylinder Head (Frame End or Crank End)
Distance Piece
Intermediate Partition Packing
Oil Wiper Packing
Piston Rod Locknut
Crankpin Bearings
Main Bearings
Crankshaft
Frame
Crosshead
Shoe
Crosshead Assembly
Nomenclature
Discharge
Temperature
API-618 (Fifth Ed.)
Protection Solution
Management Solution
Channel Resonance on Pressure Versus Displaced Volume Curve
Pressure Operated Valves Mechanically Operated Valves
Typical Pressure Versus Displaced Volume
A A
A
A typical indicated cylinder
pressure curve will have some
pressure fluctuation when the
suction and discharge valves
are opened. The areas labelled
A and indicated by braces
show these pressure
fluctuations. When the valves
are closed, the pressure shows
a smooth line.
A pressure transducer
installation suffering from
channel resonance will show
pressure fluctuations when
the suction and discharge
valves are closed as well as
when the valves are opened.
The frequency of this resonance
remains nominally constant
throughout the cycle.
1 2
P2
P1
PRESSU
RE
VOLUME
Stroke
CLEARAN
CE
VO
LU
M
E
OUTLET
INLET
1 2
3
P2
P1
PRESSU
RE
VOLUME
Stroke
CLEARAN
CE
VO
LU
M
E
OUTLET
INLET
1 2
3 4
P2
P1
PRESSU
RE
VOLUME
Stroke
CLEARAN
CE
VO
LU
M
E
OUTLET
INLET
1 2
3 4
5
P2
P1
PRESSU
RE
VOLUME
Stroke
CLEARAN
CE
VO
LU
M
E
OUTLET
INLET
1 2
3 4
5
P2
P1
PRESSU
RE
VOLUME
Stroke
CLEARAN
CE
VO
LU
M
E
OUTLET
INLET