Tech Transfer, Inc. Reciprocating Compressor Station

Predictive Maintenance Survey

TEXAS REGISTERED ENGINEERING FIRM REG # F-10678 12141 WICKCHESTER LANE # 700 TEL: (713) 462-3636 HOUSTON, TEXAS 77079 FAX: (713) 462-5454

Abstract

A comprehensive Preventative/Predictive Maintenance (PM) program is based on periodic monitoring of the vibration health of reciprocating gas compression equipment. Elevated levels of vibration over time can indicate looseness of bolted joints in piping, piping supports, vessels and major equipment. The purpose of periodic vibration monitoring is for evaluating vibration data and assessing what type of maintenance is required to prevent potential failures and unscheduled shutdowns. The goal is to provide solutions for reducing vibration levels to within or below acceptable industry and Tech Transfer vibration standards. The main sources of vibration are mechanical and acoustical unbalanced energy associated with the driver and compressor.

The first step in creating a comprehensive program is to perform an initial site visit where vibration and pulsation data is collected on the entire compressor package and associated off-skid process piping. The purpose of this baseline collection is to evaluate the overall vibration health of the compressor package and identify areas that may require modifications to supports or the need for additional supports. For new units, the best time to perform the initial site visit is immediately after commissioning has been completed. Vibration and pulsation data is collected at different speeds and operating configurations as determined by normal operating conditions. With a temporary shutdown, multiple natural frequency bump test data on major components and vessels will be recorded to determine the critical speeds of operation that can cause excitation and resulting elevated vibration levels. In order to provide a cost effective PM program for multiple identical units at one location, full data collection will be performed on one unit and spot checks will be performed on the other units to determine if the same or different vibration levels occur. If all units require more detailed analysis, the amount of data collection will be adjusted accordingly.

Following the initial data collection and analysis procedures, subsequent semi-annual “trending” data collection should be scheduled. The semi-annual data collection and analysis will be performed using specific target areas of the compressor package to confirm any overall changes in the levels of vibration, and will be compared to the previous data to identify where changes have occurred. As part of the trending program, alarm limits will be assigned to specific components and/or areas of the compressor package according to Tech Transfer specified allowable limits. Alarm limits consist of Alert, Warning, and Shutdown. The Alert alarm limit is to notify you that more detailed analysis may be required to evaluate the problem, while allowing the unit to operate normally, or possible at a lower speed that may reduce vibration levels. The Warning alarm is where a high vibration level is occurring that should immediately be investigated for means of reducing vibration levels. The Shutdown alert level is what we would recommend when vibration amplitudes have reached an unsafe condition where failure is eminent and maintenance action is due immediately.

Each report submitted will have a table defining the operating conditions at the time data was acquired as well as a list of walk through discrepancies. We will have recommendations to bring vibration levels within acceptable industry standards. In addition to the detailed recommendations, the report will include sample plots of spectrums related to the alarms. When all problematic areas are resolved we will have an abbreviated measurement summary with all overall amplitude vibration levels at each measurement location. Recommendations will be provided for bringing high levels of vibration to within acceptable industry and Tech Transfer standards. Recommendations may include general maintenance concerns such as loose pipe clamps and loose discharge bottle supports. If required, detailed support recommendation drawings will be included in the report where supports may require structural modifications or where additional supports may be required.

 

Basic Outline of Periodic Monitoring

Periodic Monitoring is used to assess the condition and changes in the condition of machines.

Measurements are selected that provided the greatest sensitivity to a change in machine condition with the least complexity and data processing.

Data collection routes are based on plant layout, machine train, machine type, or data type. Measurement points are selected for efficient collection of data pertaining to overall

condition of the equipment. Frequency spans used in measurement are based on the run speed of the compressor. Baseline data provide a reference for evaluating changes in condition. The frequency of data collection is based on mean time to failure of machine components,

cost of failure, available personnel, number of spares, and monitoring costs. Screening can be a low-cost method for detecting changes in machine condition. Trending provides the opportunity to compare data and the alarm settings that will initiate

analysis, more frequent monitoring or repair. Alarms are used in periodic monitoring to bring to the attention of the data collector that a

significant change in condition has occurred. The effect of process changes on a trended measure must be taken into account during

trending. Reporting is used to document case histories, record alarms, and recommend

maintenance action. Reports will provide the facts in a clear and understandable format. Baseline data provide a reference for evaluating changes in conditions.

With 30 years of field vibration analysis experience, our comprehensive evaluation techniques will locate and identify the sources of high energy that results in high vibration. Tech Transfer’s vibration team is supported by David Kordewick and Christopher Boggs.

David Kordewick has been working in the gas compression industry for over 25 years. David began his career designing compressor packages, and eventually managing the design department. In 2004 he began travelling to the field providing vibration analysis on gas compression equipment, and providing effective solutions for vibration and pulsation issues both domestically and internationally.

Christopher Boggs has been doing preventative maintenance on rotary equipment since 2006. He first started working on the LM2500 Main Propulsion Gas Turbines for the Navy. After being released in 2012 he began solving vibration problems on pumps, turbines, cooling towers, centrifugal compressors, screw compressors, reciprocating compressors and draw works.

David and Christopher have the knowledge and experience to identify and resolve vibration issues with rotating equipment.

 

 

 

 

TYPICAL VIBRATION DATA COLLECTION POINTS MEASUREMENT LOCATION BASELINE 6 MONTH ANNUAL

DRIVER OUTBOARD FRAME VERT DRIVER OUTBOARD FRAME HORZ DRIVER OUTBOARD FRAME AXIAL DRIVER OUTBOARD FOOT VERT DRIVER OUTBOARD FOOT HORZ DRIVER OUTBOARD PEDESTAL VERT DRIVER OUTBOARD PEDESTAL HORZ DRIVER INBOARD FRAME VERT DRIVER INBOARD FRAME HORZ DRIVER INBOARD FRAME AXIAL DRIVER INBOARD FOOT VERT DRIVER INBOARD FOOT HORZ DRIVER INBOARD PEDESTAL VERT DRIVER INBOARD PEDESTAL HORZ COMP INBOARD FRAME VERT COMP INBOARD FRAME HORZ COMP INBOARD FRAME AXIAL COMP INBOARD FOOT VERT COMP INBOARD FOOT HORZ COMP INBOARD PEDESTAL VERT COMP INBOARD PEDESTAL HORZ COMP OUTBOARD FRAME VERT COMP OUTBOARD FRAME HORZ COMP OUTBOARD FRAME AXIAL COMP OUTBOARD FOOT VERT COMP OUTBOARD FOOT HORZ COMP OUTBOARD PEDESTAL VERT COMP OUTBOARD PEDESTAL HORZ

TYPICAL VIBRATION DATA COLLECTION POINTS MEASUREMENT LOCATION BASELINE 6 MONTH ANNUAL

CYLINDER #1 VERT CYLINDER #1 AXIAL CYLINDER #1 HORZ CYLINDER #3 VERT CYLINDER #3 AXIAL CYLINDER #3 HORZ CYLINDER #5 VERT CYLINDER #5 AXIAL CYLINDER #5 HORZ CROSSHEAD #1 VERT CROSSHEAD #1 AXIAL CROSSHEAD SUPPORT #1 TOP VERT CROSSHEAD SUPPORT #1 TOP HORZ CROSSHEAD #3 VERT CROSSHEAD #3 AXIAL CROSSHEAD SUPPORT #3 TOP VERT CROSSHEAD SUPPORT #3 TOP HORZ CROSSHEAD #5 VERT CROSSHEAD #5 AXIAL CROSSHEAD SUPPORT #5 TOP VERT CROSSHEAD SUPPORT #5 TOP HORZ CYLINDER #2 VERT CYLINDER #2 AXIAL CYLINDER #2 HORZ CYLINDER #4 VERT CYLINDER #4 AXIAL CYLINDER #4 HORZ CYLINDER #6 VERT CYLINDER #6 AXIAL CYLINDER #6 HORZ CROSSHEAD #2 VERT CROSSHEAD #2 AXIAL CROSSHEAD SUPPORT #2 TOP VERT CROSSHEAD SUPPORT #2 TOP HORZ CROSSHEAD #4 VERT CROSSHEAD #4 AXIAL CROSSHEAD SUPPORT #4 TOP VERT CROSSHEAD SUPPORT #4 TOP HORZ CROSSHEAD #6 VERT CROSSHEAD #6 AXIAL CROSSHEAD SUPPORT #6 TOP VERT CROSSHEAD SUPPORT #6 TOP HORZ

TYPICAL VIBRATION DATA COLLECTION POINTS MEASUREMENT LOCATION BASELINE 6 MONTH ANNUAL

1ST SCRUBBER HORZ 1ST SCRUBBER AXIAL 1ST SUCTION BOTTLE LEFT END VERT 1ST SUCTION BOTTLE LEFT END HORZ 1ST SUCTION BOTTLE RIGHT END VERT 1ST SUCTION BOTTLE RIGHT END HORZ 1ST DISCHARGE BOTTLE LEFT END VERT 1ST DISCHARGE BOTTLE LEFT END HORZ 1ST DISCHARGE BOTTLE RIGHT END VERT 1ST DISCHARGE BOTTLE RIGHT END HORZ 2ND SCRUBBER HORZ 2ND SCRUBBER AXIAL 2ND SUCTION BOTTLE LEFT END VERT 2ND SUCTION BOTTLE LEFT END HORZ 2ND SUCTION BOTTLE RIGHT END VERT 2ND SUCTION BOTTLE RIGHT END HORZ 2ND DISCHARGE BOTTLE LEFT END VERT 2ND DISCHARGE BOTTLE LEFT END HORZ 2ND DISCHARGE BOTTLE RIGHT END VERT 2ND DISCHARGE BOTTLE RIGHT END HORZ 3RD SCRUBBER HORZ 3RD SCRUBBER AXIAL 3RD SUCTION BOTTLE LEFT END VERT 3RD SUCTION BOTTLE LEFT END HORZ 3RD SUCTION BOTTLE RIGHT END VERT 3RD SUCTION BOTTLE RIGHT END HORZ 3RD DISCHARGE BOTTLE LEFT END VERT 3RD DISCHARGE BOTTLE LEFT END HORZ 3RD DISCHARGE BOTTLE RIGHT END VERT 3RD DISCHARGE BOTTLE RIGHT END HORZ 4TH SCRUBBER HORZ 4TH SCRUBBER AXIAL 4TH SUCTION BOTTLE LEFT END VERT 4TH SUCTION BOTTLE LEFT END HORZ 4TH SUCTION BOTTLE RIGHT END VERT 4TH SUCTION BOTTLE RIGHT END HORZ 4TH DISCHARGE BOTTLE LEFT END VERT 4TH DISCHARGE BOTTLE LEFT END HORZ 4TH DISCHARGE BOTTLE RIGHT END VERT 4TH DISCHARGE BOTTLE RIGHT END HORZ