Protecting and Managing

Reciprocating Compressors

Best Practices

2000 Bently Nevada Corporation

Reciprocating Compressor Best Practices

Data Subject to Change (September 2001)

Table of Contents
INTRODUCTION.................................................................................... 3
PROTECTION / MANAGEMENT................................................................... 3
TRANSDUCER SELECTION ......................................................................... 4
DRIVERS................................................................................................... 4
Electric Motors ...................................................................................................... 4
Gas Engines ........................................................................................................... 6
Integral Engine ...................................................................................................... 7

CRANKSHAFT / CRANKCASE .....................................................................7

Main Journal Bearing ........................................................................................... 7
Frame ..................................................................................................................... 9
Vibration................................................................................................................ 9

CROSSHEAD............................................................................................11
Shoe Temperature ............................................................................................... 13

PRESSURE PACKING ...............................................................................14

Case Temperature ............................................................................................... 14
Vent Line Temperature ...................................................................................... 14
Purge Flow........................................................................................................... 15
Purge Pressure ..................................................................................................... 16

PISTON AND ROD ....................................................................................17

Rod Position......................................................................................................... 17

CYLINDER ..............................................................................................19
Cylinder Pressure ................................................................................................ 19
Valve Temperature ............................................................................................. 20
Discharge Temperature ...................................................................................... 22

HYPER RECIPROCATING COMPRESSORS .................................................23

Plunger Position .................................................................................................. 24

2000 Bently Nevada Corporation

Reciprocating Compressor Best Practices

Data Subject to Change (September 2001)

Protecting and Managing Reciprocating Compressors

Introduction
This best practices document contains recommendations for the selection and installation
of Bently Nevada transducers, monitoring systems, and trending systems on reciprocating
compressors. These recommendations apply to both new and existing machines targeted
for retrofit installations.
Continuous collection and trending of the vibration, rod position, cylinder pressure, and
temperature data using a machinery management system such as Bently Nevada's System
1 is highly recommended. Bently Nevadas reciprocating compressor monitoring
systems are also compatible with Bently Performance. Use of these tools will
maximize the ability to diagnose problems and analyze the performance of reciprocating
compressors.

Protection / Management
Minimal Protection System The minimal recommended protection system for
reciprocating compressors include crankcase Velomitor and main bearing temperature
probes. See Crankshaft in the Transducer Selection Section.
Minimal Management Solution The minimal recommended management system for
reciprocating compressors include the minimal protection system with the addition of
crosshead accelerometers. See Crosshead and Crankshaft in the Transducer Selection
Section.
Recommended Management Solution The recommended management system for
reciprocating compressors includes the minimal management solution with the addition
of piston rod position, cylinder pressure, and temperature monitoring on compressor
valves, pressure packing, and crosshead shoes (slippers). Figure 1 shows the placement
of each transducer on a reciprocating compressor. Each item is discussed in detail in the
Transducer Selection section of the document.

Fully Instrumented Reciprocating Compressor

2000 Bently Nevada Corporation

Reciprocating Compressor Best Practices

Data Subject to Change (September 2001)

Transducer Selection
The following table summarizes the transducer selection for reciprocating compressors.

Component

Monitoring Point

Transducer

Driver

Stator Temperature
Bearing Temperature

RTD or Thermocouple
RTD or Thermocouple

Crankcase

Bearing Temperature
Crankshaft Position Reference
Frame Vibration

RTD or Thermocouple
Keyphasor / Multi-event Keyphasor
Velomitor

Crosshead

Machine Vibration
Shoe Temperature

Accelerometer
RTD or Thermocouple

Pressure Packing

Case Temperature
Vent Line Temperature
Purge Flow
Purge Pressure

RTD or Thermocouple
RTD or Thermocouple
Flow Transmitter
Pressure Transmitter

Piston and Rod

Rod Position

Horizontal and Vertical Proximity Probes

Cylinder

Internal Cylinder Pressure

Valve Temperature
Discharge Temperature

Pressure Transducer
RTD or Thermocouple
RTD or Thermocouple

Drivers
Electric Motors
Stator Temperature
System
3500

Monitor
3500/60 (No recorder output)
3500/61

Transducer
RTD / Thermocouple
RTD / Thermocouple

Benefits - Electric motor stator winding temperature can indicate problems

related to the stator, including unloaded balances between phases, low /
improper line voltage, short circuit in windings, and ground in winding.
System Description Six channel continuous temperature monitoring on
3500 systems.
Applications Can be used on both induction and synchronous motors.

2000 Bently Nevada Corporation

Reciprocating Compressor Best Practices

Data Subject to Change (September 2001)

Installation installation includes imbedding either a RTD or thermocouple

into each winding lead. Typically the OEM does this during manufacturing,
but motors can be retrofitted.
Filtering N/A
Alarm / Danger In the absence of actual engineering data the
recommended* initial alarm and danger set points are:
Alarm: 180 o F
Danger: 200 o F
*These should be adjusted based on actual operating conditions

Stator winding temperature is typically not a shutdown parameter.

Bearing Temperature
System
3500

Monitor
3500/60 (No recorder output)
3500/61

Transducer
RTD / Thermocouple
RTD / Thermocouple

Benefits -Electric motor main bearing temperature can indicate problems

related to fluid- filmed bearings, including overload, bearing fatigue or
insufficient lubrication. Measuring temperatures at the main bearing
temperature and correlating them with other process variables can assist in
determining the overall condition of reciprocating compressors.
System Description Six channel continuous temperature monitoring on
3500 systems.
Applications No known restrictions
Installation - Bently Nevada offers six cha nnel monitors for temperature
monitoring using either thermocouples or resistance temperature detectors
(RTD).
Main bearing caps may be drilled and tapped to accept temperature probes
during the manufacturing process. If not, the bearing caps can always be
removed and drilled to accept the temperature probes.
Filtering N/A
Alarm / Shutdown In the absence of actual engineering data the
recommended* initial alarm and danger set points are:
Alarm: 180 o F
Danger: 200 o F
*These should be adjusted based on actual operating conditions

Bently Nevada highly recommends that customers use bearing

temperature as a shutdown parameter.
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Dynamic Power

This Section Intentionally Left Blank

Gas Engines
Bearing Temperature
System
3500

Monitor
3500/60 (No recorder output)
3500/61

Transducer
RTD / Thermocouple
RTD / Thermocouple

Benefits - crankshaft main bearing temperature on gas engines can indicate

problems related to fluid-filmed bearings, including overload, bearing fatigue
or insufficient lubrication.
System Description Six channel continuous temperature monitoring on
3500 systems.
Applications No known restrictions.
Installation - Bently Nevada offers six channel monitors for temperature
monitoring using either thermocouples or resistance temperature detectors
(RTD). Measuring temperatures at the main bearing temperature and
correlating them with other process variables can assist in determining the
overall condition of reciprocating compressors.
Main bearing caps may be drilled and tapped to accept temperature probe
during the manufacturing process. The bearing caps can be removed and
drilled to accept the temperature probes after machine installation.
Filtering N/A
Alarm / Danger In the absence of actual engineering data the
recommended* initial alarm and danger set points are:
Alarm: 180 o F
Danger: 200 o F
*These should be adjusted based on actual operating conditions

Bently Nevada highly recommends that customers use bearing

temperature as a shutdown parameter.
Turbocharger
See Turbocharger Best Practices

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Data Subject to Change (September 2001)

Integral Engine

See Gas Engine and Crankshaft / Crankcase Sections

Crankshaft / Crankcase

Main Journal Bearing

Temperature
System
3500

Monitor
3500/60 (No recorder output)
3500/61

Transducer
RTD / Thermocouple
RTD / Thermocouple

Benefits - High crankshaft main bearing temperature can indicate problems

related to fluid- filmed bearings, including overload, bearing fatigue or
insufficient lubrication. Measuring temperatures at the main bearing
temperature and correlating them with other process variables can assist in
determining the overall condition of the engine.
System Description Six channel continuous temperature monitoring on
3500 systems.
Applications No known restrictions.
Installation - Bently Nevadas six channel monitors for temperature
monitoring using either thermocouples or resistance temperature detectors
(RTD).
Main bearing caps may be drilled and tapped to accept temperature probe
during the manufacturing process. The bearing caps can be removed and
drilled to accept the temperature probes after machine installation.
Filtering N/A
Alarm / Danger In the absence of actual engineering data the
recommended* initial alarm and danger set points are:
2000 Bently Nevada Corporation

Reciprocating Compressor Best Practices

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Alarm: 180 o F
Danger: 200 o F
*These shoul d be adjusted based on actual operating conditions

Bently Nevada highly recommends that customers use bearing

temperature as a shutdown parameter.
Keyphasor Transducer
System
3500

Monitor
3500/25

Transducer
Proximity probe

A Keyphasor transducer produces a voltage pulse for each turn of the

crankshaft. This voltage signal is used to measure crankshaft rotative speed
and serves as a reference for measuring vibration phase lag angle. The
Keyphasor transducer is typically a proximity probe (recommended for
permanent installations in which the probe observes a physical gap).
Benefits Provides a reference signal based on crankshaft position.
System Description The 3500/25 provides two channels of Keyphasor
signal conditioning for proximity probe input from either a single notch or
projection on the crankshaft or from a multi-event wheel (see Multi Event
Keyphasor System section).
Applications A Keyphasor is mandatory for use with the cylinder
pressure monitor and is highly recommended for use with rod position
measurements (see rod position). A Keyphasor is also essential for
diagnostic purposes since it provides the necessary reference signal, usually
based on the position of the #1 piston.
Installation The Keyphasor transducer is typically mounted on the
foundation at a 45 degree angle from true vertical. A notch is made on the
flywheel with reference to the #1 piston at Top Dead Center (TDC) of the
cylinder stroke.
Note: The #1 piston is normally the first from the oil pump end of the
machine, which is the non-drive end of the machine.
Filtering N/A
Alarm/Shutdown N/A
Multi Event Keyphasor System
System
3500

Monitor
3500/25

Transducer
Proximity probe

The multi-event Keyphasor system is a special variation of the standard

Keyphasor transducer system that produces a voltage pulse for every 30
2000 Bently Nevada Corporation

Reciprocating Compressor Best Practices

Data Subject to Change (September 2001)

degrees of shaft rotation. The signal produced is used by the 3500 compressor
monitoring systems as an accurate reference of crankshaft position. The Multi
Event Keyphasor transducer is typically a proximity probe (recommended
for permanent installations in which the probe observes a physical gap).
Benefits Provides a reference signal based on every 30 degrees of
crankshaft rotation in addition to a once per turn event to establish a once per
turn reference.
System Description The multi-event Keyphasor system is a special
configuration of the standard 3500/25 monitors.
Applications The multi-event Keyphasor system is required for the
cylinder pressure monitor, 3500/77M. The multi-event wheel is highly
recommended to attain the highest accuracy on the cylinder pressure
measurements and provide the most accurate pressure-volume (PV) curves
Installation The multi-event wheel is mounted to the shaft on the outboard
end of the driver. Drilling and tapping of the driver shaft is normally required.
The once per turn reference is normally aligned with the top-dead-center
position of the #1 cylinder.
Filtering N/A
Alarm/Shutdown N/A

Frame

Vibration
System
3500

Monitor
3500/42

Transducer
Velomitor XA

The cylinders on balanced-opposed compressors are physically offset, causing

moments to be generated on the crankshaft. The pressure forces across the
machine can become unbalanced due to process changes, valve unloading, or
damaged valve assemblies. These forces are transmitted through the bearing to
the frame, resulting in crankcase vibration at one or two times machine running
speed. Frequencies on the order of x to 2x the machine speed and their
harmonics can also occur on reciprocating compressors due to their layout.
Excessive amplitudes at these frequencies may indicate mechanical or operational
problems. Velomitor Piezo-velocity Sensors are ideal for detecting machinery
problems on reciprocating compressors where rotation-related vibration is
transmitted to the compressor frame. Velomitor Sensors eliminate the cross 2000 Bently Nevada Corporation

Reciprocating Compressor Best Practices

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axis sensitivity problems inherent to moving coil velocity sensors. At the same
time, they have a better signal-to-noise ratio at the low running speed (frequency)
of reciprocating machines when compared to standard accelerometers.
Benefits -Typical operational problems that the Velomitor sensor and monitor
can detect include:
Imbalance due to an unusual pressure differential or inertial imbalance.
Looseness in the foundation attachment (such as deteriorating grout or
shims).
High moments caused by excessive rod load.
System Description - Frame vibration detection system consists of two
components: the Velomitor XA Piezo-Velocity Sensor and the 3300 or 3500
Velocity Monitor. The Velomitor Sensor employs an accelerometer with a
piezoelectric crystal at its core along with a low noise amplifier /integrator that
provides an output in velocity units. The result is a small sensor with no moving
parts, integrated electronics, and a virtually unlimited lifespan. The transducer
provides a vibration signal in velocity units.
Applications - The Velomitor XA transducer is ideally suited for measuring
casing vibration on reciprocating compressors with a running speed above 270
rpm.
Installation - The best locations to mount Velomitor XA Sensors are on the
crankshaft frame in the horizontal axis between each pair of cylinders. Mounting
Velomitor XA transducers level with the bearing split line is preferred, as it
places the transducers in the direct path of the forces acting on the machine.
Filtering When used with accelerometers mounted above the crosshead, the
high and low bands filters should be set 4X and 1/2X, respectively. When used
without accelerometers mounted above the crosshead, no band bass filtering
should be used.
Alarm / Shutdown In the absence of actual engineering data the
recommended* initial alarm and danger set points are:
Alarm: 0.25 in/s pk
Danger: 0.5 in/s pk
*These should be adjusted based on actual operating conditions

Bently Nevada highly recommends that customers use frame vibration as a

shutdown parameter. It is a recommended shutdown parameter in API 618.
Limitations - When applying velocity measurements on reciprocating machinery,
it is important to understand the effect that the Timed OK/Channel Defeat and
latching have on the behavior of the alarms. This is particularly true when a
catastrophic failure occurs from an impact-type event. Impact-type events can
result in vibration many orders of magnitude greater than the typically rated 50
in/s pk for a Velomitor Sensor. This condition can force the transducer to
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operate well outside its linear range and will indicate to the monitoring system
that the transducer is in a fault condition (Not OK).
To prevent a false alarm due to an intermittent wire connection, Bently Nevada
monitors are shipped with Timed OK/Channel Defeat enabled. This means that if
there is a not OK fault condition, the channel is disabled and the alarms are
bypassed for 3 to 6 seconds. If the Timed OK/Channel Defeat is enabled and an
impact event occurs, the transducer may be driven outside its linear (OK) range.
The monitoring system will indicate a transducer failure, bypassing the alarms.
Therefore, you will not get the alarm annunciation you are expecting.
Furthermore, if the alarm relays are wired to shutdown the machine, the impact
event could prevent automatic shutdown of the machine from the velocity
monitor.
The above scenario may be an acceptable situation if accelerometers are installed
to complement the velocity measurement or if multiple velocity transducers are
installed. Even so, a large impact could cause all velocity transducers and
accelerometers to go Not OK. If you are using a stand alone velocity monitor
and a single input, this is certainly not a favorable situation.
To ensure machinery protection, the possibility of missed trips should be virtually
eliminated. To do this, disable the Timed /OK Channel Defeat feature simply by
changing the monitor configuration. With this feature disabled, an impact event
may still cause the transducer to operate outside its linear range, and the monitor
will still indicate a transducer failure. However, the monitor will also go into
alarm and the alarm relays will shut down the machine if they are wired for
shutdown.

Crosshead

Vibration
System
3500

Monitor
3500/42M

Transducer
330400 Accelerometer
and 37439-01 Mounting
Base

Placing accelerometers over each crosshead provides the best method to detect
machinery problems due to impact-type events. Impact-related events
characteristically cause free vibrations and are typically due to liquid ingestion
into the cylinder or mechanical problems such as looseness in the crosshead
and piston assembly.
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Acceleration can detect impact-type machinery problems better than a velocity

measurement due to the high frequency vibrations created by impact events.
Under normal conditions, the vibration level should be very small. As impacts
occur, the vibration level increases and the waveform will resemble the classic
impact ring-down response over each stroke, as shown in the figure below.
The large increase in amplitude should be readily apparent from looking at an
acceleration waveform generated by an impact.

Benefits - The benefits of monitoring free vibration using accelerometers

include the ability to detect the following machinery faults:
Liquid ingestion into the cylinder.
Excessive crosshead clearance.
Loose or cracked nuts or bolts.
Excessive clearance in the wrist pin bushing.
Detonation on power cylinders for integral engine compressors.
System Description - The 3500/42M Proximitor/Seismic Monitor is a 4channel monitor that accepts input from proximity and seismic transducers,
conditions the signal to make various vibration and position measurements,
and compares the conditioned signals with user-programmable alarms. Each
channel of the 3500/42M should be programmed for acceleration.
Applications - The 330400 Accelerometer transducer is ideally suited for
measuring free vibration events on reciprocating compressors.
Installation - To detect impact-type events, mount an accelerometer on each
cylinder over the crosshead, distance piece or cylinder. For best results with a
single accelerometer per throw, mount the accelerometer directly above the
crosshead in the vertical plane.
Filtering When used in conjunction with a case mounted Velomitor the
filtering should be set between 2k and 20k hertz. If the accelerometer is the
only monitoring or protection system then no filtering is recommended.

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Alarm / Danger In the absence of actual engineering data the

recommended* initial alarm and danger set points are:
Alarm: 2.0 gs
Danger: 5.0 gs
*These should be adjusted based on actual operating conditions

Bently Nevada recommends that customers use crosshead vibration as a

shutdown parameter.
Shoe Temperature
System
3500

Monitor
3500/60 (No recorder output)
3500/61

Transducer
RTD / Thermocouple
RTD / Thermocouple

Benefits Crosshead shoe (slipper) temperature can indicate problems

including overload, fatigue, or insufficient lubrication.
System Description Six channel continuous temperature monitoring on
3500 system.
Applications On reciprocating compressors there is an up running and a
down running crosshead. The up running side is on the left side of the
machine when viewing from driver to driven equipment with the machine
turning in the clockwise direction. If the machine were turning in the counter
clockwise direction then the up running side would be on the right side of the
machine. If only one temperature probe is requested it should be placed on
the active side (e.g. top on up running side and bottom on down running side).
Installation An RTD or thermocouple may be mounted either on the bottom
or top of the crosshead guide. Precise machining of the crosshead is required
to make the necessary provisions for the temperature probes.
Filtering N/A
Alarm / Danger In the absence of actual engineering data the
recommended* initial alarm and danger set points are:
Alarm: 180 o F
Danger: 200 o F
*These should be adjusted based on actual operating conditions

Crosshead shoe temperature is typically not a shutdown parameter.

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Data Subject to Change (September 2001)

Pressure Packing

Case Temperature
System

Monitor

3500

3500/60 (No recorder output)

3500/61

Transducer
RTD / Thermocouple
RTD / Thermocouple

Benefits Pressure packing temperature can indicate problems related to the

packing, including excessive wear, insufficient cooling or insufficient
lubrication.
System Description Two and six channel continuous temperature
monitoring on 3300 systems. Six channel continuous temperature monitoring
on 3500 systems.
Applications Applies to both high and intermediate pressure packing
glands.
Installation The RTD or thermocouple should be installed as close as
possible to the packing. Typically, provisions are made on the packing case
flange to insert a temperature probe into the case. API 618 requires
temperature monitoring on the high pressure packing case when discharge
pressures exceed 500 psi.
Filtering N/A
Alarm / Danger In the absence of actual engineering data the
recommended* initial alarm and danger set points are:
Alarm: 140 o F
Danger: 160 o F
*These should be adjusted based on actual operating conditions

Packing case temperature is not typically a shutdown parameter.

Vent Line Temperature
System
3500

Monitor
3500/60 (No recorder output)
3500/61

Transducer
RTD / Thermocouple
RTD / Thermocouple

Pressurized packing was originally designed to prevent corrosive gases from

leaving the cylinder and entering the distance piece and crankcase. With the
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increase in concern for the release of volatile organic compounds, pressurized

packing glands have grown in popularity. (See purge pressure and flow
sections)
Benefits As the purge packing begins to leak from the atmospheric side, the
leaking gas exits through the packing vent line to flare. With the increase in
process gas flow, the vent line becomes hotter. For years, operators have used
the subjective method of touching the line to see if gas is leaking.
System Description Two and six channel continuous temperature
monitoring on 3300 system. Six channel continuous temperature monitoring
on 3500 system.
Applications The application of vent line temperature monitoring is well
suited for all reciprocating compressor applications.
Installation A RTD or thermocouple may be embedded or affixed on the
packing case vent line. It is important to have only one packing case vent line
at each monitoring point. The placement of the temperature probe should be
as close to the packing vent discharge as practical.
Filtering N/A
Alarm / Danger In the absence of actual engineering data the
recommended* initial alarm and danger set points are:
Alarm: 140 o F
Danger: 160 o F
*These should be adjusted based on actual operating conditions

Vent line temperature is not typically a shutdown parameter.

Purge Flow
System
3500

Monitor
3500/62

Transducer
Flow Transducer

Pressurized packing was originally designed to prevent corrosive gases from

leaving the cylinder and entering the distance piece and crankcase. With the
increase in concern for the release of volatile organic compounds, pressurized
packing glands have grown in popularity.

Purge Flow should be used with Purge Pressure Monitoring

Benefits As the pressure packing begins to wear, leakage can occur at either
the atmospheric or the process sides. If the purge pressure decreases and the
purge flow increases then the atmospheric side packing needs replacement. If
the purge pressure increases and the purge flow decreases then the process
side packing needs replacement.
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System Description The 3500/62 Process Variable Monitors are well suited
for this application.
Applications The application of purge flow is applicable to any
reciprocating compressor packing gland which incorporates nitrogen purged
packing.
Installation The installation of the packing case purge flow requires a signal
from a flow transducer.
Filtering N/A
Alarm / Danger In the absence of actual engineering data the
recommended* initial alarm and danger set point are:
Alarm: N/A
Danger: N/A
*These should be adjusted based on actual operating conditions

Purge flow is not typically a shutdown parameter.

Purge Pressure
System
3500

Monitor
3500/62

Transducer
Pressure Transmitter

Pressurized packing was originally designed to prevent corrosive gases from

leaving the cylinder and entering the distance piece and crankcase. With the
increase in concern for the release of volatile organic compounds, pressurized
packing glands have grown in popularity. (See purge temperature and flow
sections).

Purge Pressure should be used with Purge Flow Monitoring

Benefits - As the pressure packing begins to wear leakage can occur at either
the atmospheric or the process sides. If the purge pressure decreases and the
purge flow increases then the atmospheric side packing needs replacement. If
the purge pressure increases and the purge flow decreases then the process
side packing needs replacement.
System Description - The 3500/62 Process Variable Monitors are well suited
for this application.
Applications - The application of purge flow is applicable to any
reciprocating compressor packing gland which incorporates nitrogen purged
packing.
Installation - The installation of the packing case purge pressure requires a
signal from a pressure transducer.
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Filtering N/A
Alarm / Danger In the absence of actual engineering data the
recommended* initial alarm and danger set point are:
Alarm: N/A
Danger: N/A
*These should be adjusted based on actual operating conditions

Purge pressure is not typically a shutdown parameter.

Piston and Rod

Rod Position
System
3500

Monitor
3500/72M

Transducer
X &Y Proximity Probes

Reciprocating compressors typically have rider bands to minimize wear of the

cylinder liner and damage due to contact between piston and cylinder. The
primary problem with rider bands is determining how much wear has occurred
while the machine is operating so the machine can be shut down prior to
contact between the piston and cylinder.
The 3500/72M monitor is designed to monitor the rod position from the ideal
center of the cylinder bore. Based on configuration data, a circular acceptance
region is defined. When the piston moves too close to the cylinder wall in any
direction, as defined by leaving the acceptance region, an alarm or danger
signal is generated.
The 3500/72M monitor also accommodates the special case of the hyper
compressor plunger position somewhat differently than the normal rod
position (see hyper compressor section).
Although not recommended as a Best Practice, the 3500/72M Rod Position
Monitor may also be configured with a single probe to provide rod position or
rod drop.
Benefits - The Bently Nevada Rod Position Monitoring System continuously
monitors the crosshead looseness, rod bow and rider band condition of each
cylinder in a reciprocating compressor. The monitor has the following
features:
Continuous online indication of maximum magnitude and direction of rod
movement along with the crank angle at which the maximum occurs. This
information points to the source of movement enabling you to schedule
maintenance to replace rider bands or repair the crosshead only when
required, maximizing the lifespan.
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Alert and Danger alarm level indications warn of potential cylinder

damage.

System Description - The 3500/72M monitor is a four-channel monitor

providing rod position measurements for two piston rods using an X-Y probe
pair on each rod. The monitor provides alarms on rod position and rod
position angle using data from the orthogonal probe pairs and position crank
angle, peak to peak amplitude, gap, 1X amplitude, 2X amplitude, and Not 1X
amplitude measurements for each of the horizontal and vertical probes.
Applications The 3500/72M monitor can be applied to any horizontal,
vertical, V-shaped, or hyper (see hyper compressor section) reciprocating
compressor.
Installation - X and Y proximity probes must be mounted in an orthogonal
arrangement. The probes should be mounted directly on the high pressure
packing gland. A Keyphasor sensor is required which is typically mounted to
read a notch in the flywheel.
Monitor configuration requires the following user supplied parameters:
Proximity probe pair calibration data, physical mounting location and
mounting angles
Cylinder and piston diameter
Cylinder to bottom of piston clearance (rider band effective thickness)
Cylinder to top of piston clearance (piston to cylinder effective
clearance)
Piston Material
Piston rod length and diameter
Operating temperatures
Filtering N/A
Alarm / Danger - In the absence of actual engineering data the
recommended* initial alarm and danger set points are:
Alarm: 70% of hot radial clearance.
Danger: 85% of hot radial clearance.
Alarm Time Delay should be set for its maximum value of 3 seconds.
*These should be adjusted based on actual operating conditions

Bently Nevada does not recommend that customers use rod position as a
shut down parameter. It is primarily a machinery management tool to
help customers determine when to replace rider bands.

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Cylinder

Cylinder Pressure
System
3500

Monitor
3500/77

Transducer
Cylinder Pressure
Transducer

.
The 3500/77M Cylinder Pressure Monitor is a four channel monitor with
provisions for inputs from up to four pressure transducers.
Benefits - The most effective method to determine the overall health of a
reciprocating gas compressor is through examination of the cylinder pressure
profile. The cylinder pressure monitor provides on- line access to the internal
pressure for each cylinder on the compressor. This enables continuous
monitoring of cylinder pressures, compression ratios, peak rod loads, and rod
reversal. This provides valuable information on the condition of suction
valves, discharge valves, piston rings, packing glands, and crosshead pin.
System Description Cylinder pressures are monitored through the use of
permanently mounted pressure transducers located on each chamber of the
cylinder. The cylinder chamber pressure along with crankshaft position is
used for both continuous monitoring data and also performance data. Separate
alarm and danger set points can be set for each continuous monitored point.
Continuous monitoring data includes the following
Discharge pressure
Suction pressure
Maximum pressure for each crankshaft revolution
Minimum pressure for each crankshaft revolution
Compression ratio
Peak rod load for both compression and tension
Number of degrees of rod reversal
With an interface to System 1tm , the following performance data is generated
from the cylinder pressure monitor data output:
Indicated horsepower
Capacity at suction conditions
Capacity at discharge conditions
Suction horsepower losses
Discharge horsepower losses
Theoretical clearance
Flow balance of suction to discharge
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Data Subject to Change (September 2001)

Median capacity between suction and discharge capacity

Theoretical flow balance between theoretical discharge and suction
flow
Power to median capacity
Displaced volume
Adiabatic discharge temperature

With an interface to System 1tm , the following software plots are generated
from the cylinder pressure monitor data output:
Pressure verses displaced volume (P-V Diagram)
Log pressure versus log volume (Log P Log V Diagram)
Force (rod load) versus crank angle
Force (rod load) versus displaced volume
Pressure versus crank angle
Pressure versus time
Applications The 3500/77M monitor is applicable to all reciprocating gas
compressors with either single or double acting cylinders in either single or
tandem arrangements. Due to the high pressures involved, the 3500/77M
cannot be used on hyper compressors or reciprocating compressors with
cylinder pressures greater than 5000 psig.
Installation Pressure ports are required on each chamber of the cylinder.
Per API 618, 4th Edition, Section 2.6.4.6, all compressor cylinders are to be
supplied with pressure ports. When retrofitting an existing cylinder,
machining of the cylinder and liner may be required. Special pressure
transducers are mounted on the cylinder pressure ports, which are connected
to the cylinder pressure monitor. A multi-event Keyphasor is required (see
multi-event Keyphasor).
Filtering N/A
Alarm / Danger In the absence of actual engineering data the
recommended* initial alarm and danger set points are:
Rod Reversal (per API option)
Alarm: Less than 25 degrees of rod reversal
Danger: Less than 15 degrees of rod reversal
*These should be adjusted based on actual operating conditions

Bently Nevada highly recommends that customers use rod reversal as a

shut down parameter. Rod reversal is a recommended shut down
parameter per API 618.
Valve Temperature
System
3500
2000 Bently Nevada Corporation

Monitor
3500/60 (no recorder output)
3500/61
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Transducer
RTD / Thermocouple
RTD / Thermocouple
Data Subject to Change (September 2001)

Suction and discharge valves are the highest maintenance items on a

reciprocating compressor. Faulty valves can significantly reduce the
efficiency of the compressor. The six channel valve temperature monitor
displays the temperatures of the compressor valves and can help you to
manage your valuable reciprocating equipment.
Benefits - The benefits of using a valve temperature monitor include the
following:
Detect bad or damaged valves at an early stage. Bad valves can result in
reduced capacity, reduced efficiency, and damage to the cylinder liner due
to valve parts falling into the cylinder.
Determine if gas leakage is occurring between the head and crank ends of
the piston due to damaged or worn piston rings.
System Description- During normal process conditions, an increase in the gas
temperature near a valve is a primary indication of a failing valve. The Bently
Nevada 3500/62 Temperature Monitor provides early warning of valve
temperature changes and allows the operator to identify the bad valve(s).
Applications - By recompressing the same gas, a leaky valve becomes hotter
than normal, causing the valve cover plate temperature to increase. Since the
normal operating temperature of each valve varies with changes in load, gas
stream and ambient temperature, it is necessary to compare the temperatures
of similar valves in the same process conditions. Measuring the differential
temperature between these valves provides an early and reliable indication of
a degrading valve. If a valve is unloaded, howeve r, it may affect the
temperature of that individual valve and can cause a wide variation in
temperature. In these instances, bypass that channel before unloading the
valve in order to minimize these effects on the group.
Leaking piston rings will cause the temperature of the entire cylinder to
increase through the reworking of gas between each side of the piston.
Therefore, detecting changes in absolute valve temperature is also important.
If a temperature increase for all valves in the same cylinder is not due to a
process change or lubrication problem, it is most likely due to piston ring
leakage. Both intake and discharge valves at the head end and crank end will
show an increase in temperature due to piston ring leakage. Similarly, a
temperature increase for all valves on only the crank end of a cylinder is an
indication of leakage in the cylinder packing.
Installation The thermocouple or RTD should be placed as close to the
valve as possible. With the older style cage type valve hold-downs, the
temperature probe will need to be mounted on the valve cover.
With the new o-ring type valve cover, installation of the probe into the gas
passage is possible. This is accomplished by mounting a thermowell directly
to the valve cover that enters the gas passage. The thermowell should extend
into the gas passage as far as possible allowing placement close to the valve.
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Under no circumstance should the valve jackbolt be altered in anyway

without review and specific recommendations from the OEM.
Filtering N/A
Absolute Alarm / Danger In the absence of actual engineering data the
recommended* initial alarm and danger set points are:
Alarm: 20 o F above suction or discharge temperature
Danger: 30 o F above suction or discharge temperature
*These should be adjusted based on actual operating conditions

Relative Alarm / Danger In the absence of actual engineering data the

recommended* initial alarm and danger set point are:
Alarm: 20 o F above other valves in same group
Danger: 30 o F above other valves in same group
*These should be adjusted based on actual operating conditions

Valve temperature is not typically a shutdown parameter.

Discharge Temperature
System
3500

Monitor

3500/60 (No recorder output)

3500/61

Transducer
RTD / Thermocouple
RTD / Thermo couple

Discharge temperature is one of the first parameters used to monitor the condition
of reciprocating compressors. Discharge temperature gives a good indication of
overall cylinder health.
Benefits - Monitoring of discharge temperature can give an indication of worn
valves, unloaders, piston rings, inadequate lubrication, excessive compression
ratio, or insufficient cooling water.
System Description Two and six channel continuous temperature monitoring
on 3300 system. Six channel continuous temperature monitoring on 3500 system.
Applications Should be standard on all reciprocating compressors.
Installation The temperature sensor should be mounted in the discharge line as
close as possible to the cylinder. This is typically in the neck of the discharge
nozzle.
Filtering N/A
Alarm / Danger In the absence of actual engineering data the recommended*
initial alarm and danger set points are:
Alarm: 20 o F above normal maximum
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Data Subject to Change (September 2001)

Shutdown: 30 o F above normal maximum

*These should be adjusted based on actual operating conditions

Bently Nevada highly recommends that customers use discharge temperature

as a shutdown parameter.

Hyper Reciprocating Compressors

The polyethylene and polypropylene polymerization processes require process pressures
in the range of 30,000 to 50,000 PSI. (Structural grade steel yields at 36,000 psi.) For
the majority of these applications, process plants choose a specially designed
reciprocating compressor to deliver these pressures. The industry refers to these
compressors as hyper compressors. Hyper reciprocating compressors typically have very
strong rigid running gear (connecting rod, crosshead and piston) designs to handle the
large loads generated by the high pressure gases. Hyper compressors also have a very
high strength piston, usually made from tungsten carbide. The piston has no compression
or rider rings. To differentiate this design from the more common piston design, these
hyper pistons are referred to as plungers. To reduce bending stress in the brittle plunger,
the overall length of the plunger is usually shorter than a typical reciprocating compressor
piston and piston rod assembly.
There are two major types of hyper-compressors as shown in the figures 1 and 2 below.
The first type was designed and constructed for hyper-compressor applications. The
second incorporates a standard reciprocating compressor frame with special cylinders
attached.

Figure 1 specifically design for hyper compressor service

Figure 2 Standard reciprocating compressor frame with special cylinders for hyper compressor service
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Data Subject to Change (September 2001)

Except for the difference in monitoring a plunger as contrasted to a piston rod,

monitoring of hyper compressors is identical to that for lower pressure reciprocating
compressors.
Plunger Position
System
3500

Monitor
3500/72M

Transducer
X &Y Proximity Probes

In a hyper reciprocating compressor the piston rod, piston, and piston rings are
replaced by a solid tungsten carbide plunger. These plungers are capable of handling
large compressive fo rces but are much weaker when exposed to tensile or bending
forces.
The plunger in each cylinder uses numerous rows of bronze packing rings to seal the
gas from atmosphere. Typically, the packing is monitored for leakage to determine
their condition.
Benefits Monitoring of both plunger position and vibration give a good indication
of the bending forces on the plunger, packing condition, and crosshead shoe wear.
System Description - The 3500/72M monitor has been designed for monitoring the
plungers on hyper compressors. The monitor provides alarms on gap and vibration
measurements for the horizontal and vertical probe. Since the plungers are generally
brittle, can shatter, and may destroy probe tips in the process, the monitor sets timedok/channel defeat as disabled. This configuration will cause a danger signal to be
issued if both probes enter the not OK condition.
Applications - The monitors provide a convenient place for gathering the dynamic
data from both the horizontal and vertical probe simultaneously. This will assist in
analysis of dynamic plunger motion. The access to these signals is also important
during commissioning.
Installation The X and Y probes must be mounted in the true vertical and
horizontal direction, respectively. The probes must be mounted on the pressure
packing gland. (Note typical proximity probe scale factor for the tungsten carbide
plunger is 290 mV/mil.) Custom calibrated proximitors can be specified to output the
standard 200 mV/mil for various plunger materials.
Filtering N/A.
Vibration Alarm / Danger In the absence of actual engineering data the
recommended* initial alarm and danger set points are:
Alarm: 6 mils
Danger: 8 mils
Alarm Time Delay should be set for its minimum value of 100 ms for danger.

*These should be adjusted based on actual operating conditions

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Data Subject to Change (September 2001)

Gap Alarm / Danger In the absence of actual engineering data the recommended*
initial alarm and danger set points are:
Alarm: +/- 6 mils
Danger: +/- 8 mils
Alarm Time Delay should be set for its minimum value of 100 ms for danger.
*These should be adjusted based on actual operating conditions

Bently Nevada highly recommends that customers use both plunger vibration and
position as a shutdown parameter

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Data Subject to Change (September 2001)