HydroCOM 4.

The Smart Control & Monitoring System

for Maximum Compressor Performance
Hoerbiger RecipCOM Online Monitoring

RecipCOM concentrates on the essential ...

Liquid carry over

Bolting to foundation Capacity control

Rod load & reversal

Run-out
Packings
Mechanical looseness

Piston & rider rings

Valves

Experience of operation and maintenance to be considered

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Concentrate on the essential ...

80 % of failures can be detected at an early stage ...

By on-line monitoring of wear

parts and gas-process

Stephen M. Leonard:
Increasing the Reliability of Reciprocating
Compressors on Hydrogen Services.
Presented at the NPRA Maintenance
Conference,
May 20-23, New Orleans, Louisiana (1997)

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Monitoring signals

Position of piston rod

Vibrations
Valve temperatures
Indicator pressure

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Monitoring signals

Position of piston rod

Vibrations

Valve temperatures

Indicator pressure

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Position of piston rod

Sensor bracket

Rod-position sensor

Main packings

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Position of piston rod

Monitored: On-line feeler gage

Rider ring wear

Piston rod run out
Loose x-head/piston connections
Broken piston rings
Alignment problems
Excessive crosshead clearance

On-line dial indicator

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Position of piston rod

Trend of rider ring wear:

0,5 mm change within 3 months.

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Monitoring signals

Position of piston rod

Vibrations

Valve temperatures

Indicator pressure

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Vibrations

Mechanical looseness detectors

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Vibrations

Transformation of
rotating to oscillating
movement:

Reciprocating
compressors require
specific monitoring
techniques compared to
pumps, turbines,
centrifugal compressors

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Vibrations

Monitored:

Crosshead assembly failures

Crosshead pin failure
Loose x-head/piston connections
Broken piston rods
Loose valves / cages
Liquid carry over

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Vibrations - Alarming

Acceleration signal over one revolution

recorded at the crosshead guide

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Vibrations

100
Good Condition
m/s² TDC BDC TDC

75

60

45
Crosshead guide vibration
30

15

-15

-30

-45

-60

-75
Indicator pressure
-90

0 20 40 60 80 100 120 140 160 180 200 220 240 260 280 300 320 340 360
Grad KW
Machine Measuring Point Dataname TAG-Name Value Unit
GB-7401 B KKB 1.O Vibration signal X74573 m/s²
GB-7401 B Zyl 1.O, KS Pressure signal P74576 bar
GB-7401 B Online 1ost_020200.onl 02.02.2000 08:19:55 , 207.3 U/min PROGNOST Systems GmbH

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Piston failure
100
Bad
m/s²TDC
Condition Piston failure BDC TDC

75
Rod Load Curve
60

45

30

15

-15

-30

-45

-60

Vibration Peaks at rod

-75
load reversals
-90

0 20 40 60 80 100 120 140 160 180 200 220 240 260 280 300 320 340 360
Grad KW
Machine Measuring Point Dataname TAG-Name Value Unit
GB-7401 B KKB 1.O Vibration signal X74573 m/s²
GB-7401 B Zyl 1.O, KS Pressure signal P74576 bar
GB-7401 B Zyl 1.O, KS ??? P74576 kN
GB-7401 B Online piston_crack.onl 02.07.2001 02:24:14 , 211.3 U/min PROGNOST Systems GmbH

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Monitoring signals

Position of piston rod

Vibrations

Valve temperatures

Indicator pressure

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Valve temperatures

Increase of valve nest gas temperature

indicates valve wear / failure at early
stage.

5 to 10°C temperature
increase!

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Monitoring signals

Position of piston rod

Vibrations

Valve temperatures

Indicator pressure

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Indicator-pressure

Monitored components:

Cylinder valves
Piston rings
Main packings
Control equipment e.g unloaders
Rod loading and rod load reversal
Clogging of suction strainer

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Indicator-pressure

Performance monitoring:
pV-diagram and analysis
Suction and discharge pressure
in cylinder
Indicated performance
Efficiency
Suction and discharge losses
Gas flow

Enhanced diagnostics:
Pulsations
Late closing of compressor valves
caused by oil sticktion
(excessive cylinder lubrication)
Valve clogging
Maximum cylinder pressure

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Indicator-pressure

Enhanced diagnostics:
Valve and Piston Ring Leakage Indication

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Indicator-pressure
Piston rod loading:
Maximum rod load (compression)
Maximum rod load (tension)
Start and end of rod load
reversal for sufficient lubrication
of crosshead-pin.

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 HydroCOM-CCM Systems Integration

LAN/ WAN
ISDN

Modbus / OPC

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CCM Software

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CCM Software

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 Reporting

Display and Flow of Information

Alarm Management:
Automatic information of user
- Network (LAN)
- e-mail, SMS, fax, pager
- DCS System

Advantage
No continuous observation
necessary by the user

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Benefits of on-line monitoring

1. Increase of Reliability

2. Reduction of Operating Costs

3. Improvement of Productivity

4. Increase of Safety

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Not just a monitoring system supplier

Use the monitoring information

to propose upgrades for
efficiency and reliability

Propose corrective actions

Assist User to identify problem

Remote diagnosis, Compressor service
system & maintenance
support Monitoring Information

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