Oliver Franz and Alexander Harenkamp, PROGNOST Systems, Germany, question whether frame vibration offers effective machinery protection for reciprocating compressors. Se eaten seat eedu snes eeinthrstment sirens ice ea Re ue c) Tec erence eet eens Parnes eco een ere ee eee es eee ese However elty shows that ecprocating compressors have eee ete Cog ee eer ae und een ie cc! Pence ene ecard eer ties ties ferent cco) Prec ower niece) fore tee errr engineering stage. These standards were valid tthetimeof Baie rete ere ttn} theage ofthe reciprocating compressor population iis clear that mary ofthese are, critical machines hve never been ene eer ee ere eet oy rer. Even after numerous catastiophic reciprocating Pee eter acento ay pei a cece ba the history of applicable standards can help clarity the ere PN SREY) Sr erent ea mon See ca eres ere ceed pee ee ne enn eet cue enc) Seem eee ead Peer ence ene asa eee Maen one eee) eee ete ence aR ced sensor based machinery monitoring and was named: eee are teeter? Pee ee er eer k Pec ‘Asa consequence of evolving vibration rronitring technology, AP lowed up with a parallel standard covering teens lee ur Reena ees) Poni icineValnty Figure 1. Acceleration versus velocity signals Table I. Hisory of API standards 1875 APL670 edition Non-cantacting Viation and Axial “Postion Monitoring Systeri 1986 AP 670.2% edition 2000 AF 670-4" edition ‘Machinery rotection ystems’ “The 3 revision of API 670, released in1983 was more than an extension and update of the previous API6I0. It Incorporated and replaced the API 678 standbrd, which Focused ‘on accelerometer based monitoring, To better reflect Is safety relevant character, the API670 was renamed Machinery protection systems’ forits 4 edition, released 2000 and sti valid today. From its conception in}9%6 tots current ecition the API standards covering monitoring of tial machinery Focused very snuchon the technical requlrernents of centrfugal equipement {eg gas and steam turbines, centrifugal compressors), These require monitoring of a¥al and radial shaft postions, speed and surge,along with beating and frane vbration, ‘Until 2007 ~ 2008, when the APL 670 5® edtion task force ‘wat formed, reciprocating compressors had never been a focus ‘within APL 670, The 5* edition of API 670, tobe released in 202, will offer valuable information and guidance on how to effectively protect reciprceating comprestoss, ated on past ‘experience, wets in collaboration with machinery protection system verdors have made an important agreement to include Information on applying crosshead acceleration asa safety shut down parameter, ‘While the machine specific standards (AA 610, APL 61, APL (612. APL 613, APL 616, APL 617 and API 618) mainly deal with the aspocts of machinery desig, installation, pevormance and support systems, limited guldance for monitering and safeguarding is offered. AP 670 Is increasingly becoming the central document for all aspects for machinery protection. fs singular, concise standard and useful appendices cover a lot of ‘machinery with special needs, such as recirccating compressors. ston BU ereeaars Monitoring adoiprpcating, “This chort excursion into the histoveal background of API standards largely explains why numerous recprocating ‘compressoss are equipped with ‘machinery protectin systems originally designed for centrifugal machinery. Two commen approaches often found on aged reciprocating machinery ate: 1 Frame vibvation meatured as velocity. | ister rod position measurement. ‘Many compressor operators have confirmed the Inadequacy ofthese cutdated systems to protect against the most costly compressor damages, such as breaking piston rods, seling wrist pins and other fllure modes involving loss of containment. While older systems often miss developing catastrophic damages, users regularly report a story of nuisance trips due to transient process peaks or single time, on-critical impacts. Cansequertilly operators begin to corsider disarming their outdated protection system instead ‘wusting their proven maintenance practices and relying on sturdy machine decign Limitations and differences ‘To understand the limitations of the standard approach of ‘monitoring reciprocating machinery, itis important to derstand the difference between auniform rotating ‘movement of a turbine shaft in comparison to a reciprocating ‘movement. Machines with a uniforn rotation typically show ‘almost zero shaft deflection per cycle, along with a solid, stiff ‘connection to the ground and virtually no detectable frame vibration Incentrast, a reciprocating compressor exhibits very different behaviour requiring a different monitoring approach, Fistons are driven back and forth by crosshead type drive trains, Involving the reversal of piston rod forces frm tension into “compression, This makes the entire frame of the compressor, with alls components, shake and bend to a good degree ‘Suction and alscharge valves create opening and closing. Impacts, thus leaving vibration amplitudes on the entire ‘machine This s the ‘normal eperating condition’ ‘When comparing the working principles of a reciprocating, ‘compressor with a centrifugal machine, it becomes eminently clear that a reciprocating compresior requires amorededicated monitoring approach, designed to handle all the special challenges this machinery bears Looking atthe workrg principal of reiprcatng machines, the cosshead is early the focal pot Here the rteting rmovernent ofthe crank shaft is transformed intoa reciprocating linear) movement ofthe plston od. The crosshead the central compenent wher all he aor forces are transferred via the sophisticated crosshead pin/wist pin to the pistonred.A soll crosshead guide san integral part of each recprocating compresior ast failtatesthe movement ofthese forces inthe right rection. Thisis the most direct connection from the mening dive train tothe frame and is therefore the bast postion to inal vibration sensors 2 Figure shows, reciprocating machinery ypically demonstrates very smooth crosshead acceleration characteris with two deine impact around the tworod toad reversal pons. Changes ofthe acceleration signature and amplitudeimmedately indicate adiferent mechanical behavicur Thisallows modern machinery protection systems todetect type fllures and eliminate consequential damage Fallures include 1 Grosshead wrt pn fle Increased crosshead bearing clearance Figure 3. Compressor components and signals. sch (irermocomnes _soitaon MB erceemney Loote connection of piston rod (crosihead, peton} increased con rod bearing clearance Piston nut failure Linu slog Wen installing the sensor on the crosshead gullet is vwerth considering the rotating ection {lochwse/antilockwite ofthe crank shaft For the best rests, recommenced to rstall the sensor oa top for Up tuning crosshead shoes and on the bottom for down running crosshead shoes. This means the sereo willbe inline withthe effective direction of forces transmitted to the crosshead. “bref lookin the basic physics ofthe proces shows why many contemporary operators rely on crosshead ide acceleration asthe primary machinery protecton paramete. Acceleration should always be the fist parameter detectable For example tale a ear drive from location & to location. At te starting point A, the vehicle mass accelerates (acceleration mm/sec) utilthe desired speed isreached (velocity: m/sec)to ‘each (deplacement:m) location 8. Before any velocity can be ‘recorded, acceleration must be applied to the meses. Nevertheless, itis important to emohasise that frame vibration (velocity) can provide valusbleinfrmation fer some tare falure modes when applied and evaluated correctly. Frame velocity can reveal slowly developing foundation sues, as well as events involving high numberof impact. These high energy impacts agkate the equipment ints natural frequency Lange, developing a dangerous rate cf mechanical moverert ‘The installation of fram vibration traneducers involves voting schemes (eg.2 out of 3 to reduce nuisance trips by mounting two groups of three velocity transdcesson the drive end and on-crive end ofthe frame, Itshould be considered that solid reciprocating compressor construction including the heary foundation) requires ‘tremendous amount of kinetic energy, which is provided over rmtiple strong impacts to reach citical velocity limits. Yelocity transducers are typically installed anay from components that ae likely to fil This makes frame velocity an Inaccurate pararnter that should only be considered as a second layer of protection Moder monitoring systems have the capability to mathematically integrate the acceleration signal overtime, delivering a velocity analysis per acceleration sensor location, This reduces the value of adding frame velocity twanschcers to amonitoring sensor scope, ‘During its arly days of plementation piston rod postion measurement was considered a variation of shat peition ‘measurements on acentifugal machine, s the same harcware and signal analysis logic was applied. The major difference and ‘monitoring challenge sthata piston rod’ purpose isnot to rotate, butinstead topushard pull the piston. This can lead to significant bering ofthe rod and varying duo to different lead steps hence the enduring tad reputation of tod drop. These effects are not known from monitoring centrifugal machinery to this degree For ls ntendee purpose (namely the detection ofriderband wear ‘tesgnal must be phased and corectly analysed toelinate the rodbendng under different load conditions Ade tional value can be foundby analysing the dynamic component ofthe rod position sigral formachinery protection. Seginented signal analysis (segmenting the 360° crank angle Into portions) has preven to be highly reliable for detectinggeese fe loose connections in the drivetrain. These loose connections ‘can be piston rod crosshead and piston rod cylinder connections, as well as impending pston rod cracks The piston rod typically moves and bends even duirg normal operation, bur the behavicur of the piston red changes significantly when ‘mechanical damages and cracks are developing. These changes can be detected using an eight segmented analysis based on the dynamic rod postion signal (gure) Benefits Managers of different disciplines have different objectives, hence they wouldall rae the justification and value of equipment moritoring to their operation differently. There i no uriversal appreach that cuts all appeation, services and crtcaly levels, ‘Operators may appreciate the added machinery uptime, ‘eslting in increased production rates and move revere, while ‘maintenance managers may plan to utilsea monktoring systern 10 optimise maintenance spending by implementing condition based maintenance program that does not jeopardise machine integrity or health an safety aspects. The relability department may even consider incorporating costly largely preventable previous machinery damages in their justifcaticn approach. Allof the aforementioned tring the legal obligations {occupational safety and health adminitration hazaid and ‘operability study) in Ine with ecoromic interests of all parties involveciby definirg an acceptable damage /loss per process Lnit/piece of equiprrent. Mast users weuld agree that damages resulting from a seeing wrist pin or breaking piston rods are rot acceptable the technology is available to mitigate these. Users of old fully deprecated, recirocatirg compressors may considera costly replacerment ofthe asset for efferent reasons, They may alternatively employ ust fraction of the «capital required for replacement in ord to breathe a ‘ecard, Ife’ into the machinery. Upgrading the compressor with a ‘moder monitoring system and state ofthe at sealing elements can have ths effect, enabling the user to safely and reliably run the assat for years to came. Its pertinent to ask whether the petrochemical Industry ‘canafford to continue using inadequate monitoring anton (BM expracarzon Figure 4, Dynamic piston rod position and segmented analysis. technology in the competitive contemporary business ‘environment To answer this itis important to consider the Internal requirements for return on investment and imagine all catastrophic demages esting loss of production rulbance trips and safety aspects ofthe past 10 years. The ‘ast majorty of these issues would have been virtually eliminated with an effective machinery protection system. A significant amount can be invested into a machinery protection system. whilst staying within company RO! boundaties. With educated plant personnel becoming increasingly hard to fnd, companies cannot afford to shy ‘aay from investing in a plants future. Conclusion Looking backat he development ofthe API standards starting inthe 1970s itis possble to delineate the evolution of todays standard. The ence state ofthe art monitoring approach used cn centrfugal machines was adopted and applied on reciprocating machinery At thistime. fame vibration rmonitoringand rod postion menitorng made their way into the montring standard ofrecprocating compressors. Howeter. experience has shown that the former standards did ‘ot deliver the desired effet for monitoring reciprocating ‘machinery and eventually lec to the development of tedays ‘modem monitoring approach. ‘One ofthe main sspects is to make use ofthe working Principle ofa reciprocating compressor and to focus onthe crosshead guide in order to detect developing flores early and reliably Fame vibration measurement is imply too far sway from tre main factional components and the velocty type ‘measurement leads to rissing detections. Nevertheless frame velocity offers small but very limited machinery protection ‘value when lookingat the common failures experienced on Feciprocating compressors. Baced on the experience of more than 600 critical machines equipped itis esential to suppert the wets’ demand for adequate machiney protection systems tailor made for reciprocating compressors Employment of crosshead side acceleration as the prime protection parameter and application | oF dynamic piston rod position measurement asa reliable second layer of protection is recommended.