RECIP TIPS

Valve Temperature Measurement for Reciprocating Compressors

eciprocating compressor users frequently report that valve failures rank among the leading causes of unplanned outages [1,2]. They apply a number of technologies to assess the condition of the valve to better manage their compressors. One technique that has been around for years perhaps decadesis valve or valve cover temperature [3,4]. Properly understood and applied, this measurement provides valuable insight into reciprocating compressor cylinder valve health. This article reviews the successes and limitations of this measurement and discusses the three primary methods of monitoring valve temperature, comparing the advantages and disadvantages of each.

Measurement Application
The reciprocating compressor valve is, in principle, a check valve. Figure 1 shows a cross-sectional schematic of a valve (the figure does not show valves springs and other internals). The valve operates on differential pressure. For a suction valve, when the pressure inside the cylinder falls below the suction manifold pressure, the valve opens and gas flows into the cylinder. The bottom illustration in Figure 1 shows how the sealing elements seat against the guard when the valve is open. When the pressure inside the cylinder rises above the suction manifold pressure the valve closes as shown in the top illustration. Discharge valves in a reciprocating compressor cylinder open when the cylinder pressure exceeds the discharge manifold pressure and close when the cylinder pressure falls below discharge manifold pressure.

When reciprocating compressor valves fail, they can no longer provide effective sealing. This allows small quantities of gas to escape the valve. In the case of the suction valve, compressed gas escapes into the suction manifold and in the case of the discharge valve, compressed gas escapes back into the cylinder. In both cases, the leak introduces the same gas back into the compression process where it is heated again. The re-compression results in a temperature increase near the valve. Industry has applied several different techniques to measure this local temperature increase. These include penetrating the valve cover to place the transducer near the valve, thermocouple washers underneath the cover nuts or secured to the cover with a small screw, penetrating the valve cover, penetrating the cylinder wall near the valve cover, etc. Although effectiveness differs somewhat across these techniques, all successfully provide an indication of increased temperature.

Brian Howard, P.E. Sr. Technical Manager Reciprocating Compressor Condition Monitoring GE Energy brian.howard@ge.com
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Relating Valve Temperature to Valve Condition

The rise in temperature of the valve or valve cover depends on the mass of re-compressed gas and the ratio of compression this gas experiences. So long as the compression ratio remains constant, an increase in mass flow results in more heat transfer to the cover and higher temperature. In a single cylinder arrangement with a control valve that controls only on pressure, the compression ratio remains relatively constant. In contrast, as valve failure progresses in a multi-stage arrangement, the compression ratio of the cylinder in distress drops as the other stages begin to pick up load. The decrease in compression ratio, even as leak mass flow increases due to deteriorating valve condition, results in less heat being available and a decrease in valve temperature.

WHEN RECIPROCATING COMPRESSOR VALVES FAIL, THEY CAN NO LONGER PROVIDE EFFECTIVE SEALING THE LEAK INTRODUCES THE SAME GAS BACK INTO THE COMPRESSION PROCESS WHERE IT IS HEATED AGAIN. THE RE-COMPRESSION RESULTS IN A TEMPERATURE INCREASE NEAR THE VALVE.

Figure 1. Reciprocating compressor suction valve. Top shows valve closed and bottom shows valve open.

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NA LP Stg 2 DischW Temperature Recip Compres From 12NOV2002 08:56:21 To 28NOV2002 08:56:21 NA LP Stg 2 Disch SW Temperature Recip Compres From 12NOV2002 08:56:21 To 28NOV2002 08:56:21 NA Temperature LP Stg 2 Disch SE Recip Compres From 12NOV2002 08:56:21 To 28NOV2002 08:56:21 NA LP Stg 2 Disch SE Temperature Recip Compres From 12NOV2002 08:56:21 To 28NOV2002 08:56:21 NA LP Stg 2 Disch Temp Temperature Recip Compres From 12NOV2002 08:56:21 To 28NOV2002 08:56:21
300
INVALID DATA

12NOV2002 08:56:20 Historical 12NOV2002 08:56:20 Historical 12NOV2002 08:56:20 Historical 12NOV2002 08:56:20 Historical 12NOV2002 08:56:20 Historical

177 deg F 170 deg F 184 deg F 175 deg F 213 deg F

NA NA NA NA NA

AMPLITUDE: 20 deg F/div

200

100

0 08:56 12NOV2002

08:56 14NOV2002

08:56 16NOV2002

08:56 18NOV2002

08:56 20NOV2002

08:56 22NOV2002

08:56 24NOV2002

08:56 26NOV2002

08:56 28NOV2002

TIME : 12 Hours /div

LP Stage 2 West (CE) Displaced Volume Recip Compressor Tra LP Stage 2 West (CE) Displaced Volume Recip Compressor Tra LP Stage 2 East (HE) Displaced Volume Recip Compressor Tra LP Stage 2 East (HE) Displaced Volume Recip Compressor Tra
1500

LP Stage 2 West (CE) Displaced Volume Recip Compressor Tra LP Stage 2 West (CE) Displaced Volume Recip Compressor Tra LP Stage 2 East (HE) Displaced Volume Recip Compressor Tra LP Stage 2 East (HE) Displaced Volume Recip Compressor Tra
1500

Synch From 12NOV2002 06:12:16 To 12NOV2002 06:12:16 Historical Reference Synch From 12NOV2002 06:12:16 To 12NOV2002 06:12:16 Historical 1385.3 psig 0% Reference MACHINE SPEED: 276 rpm MACHINE SPEED: 276 rpm MACHINE SPEED: 276 rpm MACHINE SPEED: 276 rpm

Synch From 24NOV2002 06:13:29 To 24NOV2002 06:13:29 Historical Reference Synch From 24NOV2002 06:13:29 To 24NOV2002 06:13:29 Historical 1099.6 psig 0% Reference MACHINE SPEED: 276 rpm MACHINE SPEED: 276 rpm MACHINE SPEED: 276 rpm MACHINE SPEED: 276 rpm

TDC

TDC

POUNDS PER SQUARE INCH GAUGE 100 psig/div

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POUNDS PER SQUARE INCH GAUGE 100 psig/div

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LP Stage 2 West (CE) Displaced Volume Recip Compressor Tra LP Stage 2 West (CE) Displaced Volume Recip Compressor Tra LP Stage 2 East (HE) Displaced Volume Recip Compressor Tra LP Stage 2 East (HE) Displaced Volume Recip Compressor Tra
TDC 1500

Synch From 13NOV2002 09:26:21 To 13NOV2002 09:26:21 Historical Reference Historical MACHINE SPEED: 276 rpm MACHINE SPEED: 276 rpm

Synch From 13NOV2002 09:26:21 To 13NOV2002 09:26:21

MACHINE SPEED: 276 rpm 1322.8 psig 0% Reference MACHINE SPEED: 276 rpm

LP Stage 2 West (CE) Displaced Volume Recip Compressor Tra LP Stage 2 West (CE) Displaced Volume Recip Compressor Tra LP Stage 2 East (HE) Displaced Volume Recip Compressor Tra LP Stage 2 East (HE) Displaced Volume Recip Compressor Tra

Synch From 18NOV2002 09:00:18 To 18NOV2002 09:00:18 Historical Reference Historical 1100.4 psig 0% Reference MACHINE SPEED: 276 rpm MACHINE SPEED: 276 rpm MACHINE SPEED: 276 rpm MACHINE SPEED: 276 rpm

Synch From 18NOV2002 09:00:18 To 18NOV2002 09:00:18

POUNDS PER SQUARE INCH GAUGE 100 psig/div

1500

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Figure 2. Failing discharge valve.

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For an example of this phenomena consider a highpressure hydrogen cylinder instrumented with cylinder pressure, discharge temperature, and valve cover skin temperatures. Figure 2 shows a valve failure progression timeline for this cylinder. The top left Pressure versus Volume (PV) curve shows the cylinder pressure profile on 12 November. The plot shows good agreement between the indicated cylinder pressures and theoretical curves. Referring to the trend plot across the top of Figure 2, it can be observed that on 12 November the discharge valve cover skin temperatures and the discharge temperature lie close to each other. Together, these observations indicate effective sealing by the piston rings and cylinder valves. On 13 November a leak develops in one of the crank end discharge valves. This can be seen in the PV diagram in the lower left of the plot where the actual pressure rises faster than the theoretical pressure. Valve cover skin temperature of the LP Stage 2 Disch W valve rises quickly from 180F to 208F. At this point, the failure has a minimal impact on compression ratio. The valve failure did not adversely impact rod loads or rod reversals, so the plant decided to continue with operations. By 18 or 19 November, the distressed valve cover skin temperature reaches a maximum of 255F. The PV curve, shown in the lower right of Figure 2, shows that the failure now begins to have a more noticeable impact on the compression ratio of the cylinder. The rod load and rod reversal of this cylinder and the other cylinders servicing the compression stream were still acceptable, so the plant continued to operate.

Over the next few days, the cover skin temperature of the distressed valve begins to drop. By 24 November, the distressed valve cover skin temperature has fallen to 215F. If valve temperature correlated accurately with valve condition, one would expect the condition of the valve to have improved. In fact, as the PV diagram in the top right shows, valve condition has further deteriorated resulting in a significant deviation between the indicated and theoretical curves as well as a further reduction in the compression ratio of the cylinder At this point, the rod load and rod reversals had dropped near the limits recommended by the compressor OEM. For this reason the plant shut the compressor down for overhaul.

Secondary Temperature Effects of Valve Failure

The previous example focused the relationship between the temperature of the distressed valve cover and valve condition. The recirculation of gas at a particular valve changes not only the temperature of the local valve cover, but also the temperature profile of other components of the cylinder. A failing suction valve provides a good example of the secondary effects introduced by a valve failure. Figure 3 shows the valve cover temperatures on the crank end in the left panes, and head end in the right panes. On all trends, temperatures group together until the morning of August 19th.

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ValveTempEffects - Trend Plot [Figure03] Company: None Job Reference:

LP STG 1 Suct NW 14AUG2008 11:01:38 100 d Recip Compress From 14AUG2008 11:01:38 To 25AUG2008 11:01:3 LP STG 1 Suct W 14AUG2008 11:01:38 98 de Recip Compress From 14AUG2008 11:01:38 To 25AUG2008 11:01:3 LP STG 1 Suct SW 14AUG2008 11:01:38 104 d Recip Compress From 14AUG2008 11:01:38 To 25AUG2008 11:01:3 LP STG 1 Suct Temp 14AUG2008 11:01:38 96 de Recip Compress From 14AUG2008 11:01:38 To 25AUG2008 11:01:3

Plot Number:__________ Enterprise: ValveTempEffects

LP STG 1 Suct NE 108 d 14AUG2008 11:01:38 Recip Compress From 14AUG2008 11:01:38 To 25AUG2008 11:01:3 LP STG 1 Suct E 114 d 14AUG2008 11:01:38 Recip Compress From 14AUG2008 11:01:38 To 25AUG2008 11:01:3 LP STG 1 Suct SE 103 d 14AUG2008 11:01:38 Recip Compress From 14AUG2008 11:01:38 To 25AUG2008 11:01:3 LP STG 1 Suct Temp 96 de 14AUG2008 11:01:38 Recip Compress From 14AUG2008 11:01:38 To 25AUG2008 11:01:3

300

300

AMPLITUDE: 20 deg F/div

200

AMPLITUDE: 20 deg F/div

11:01 11:01 18AUG2008 22AUG2008 TIME : 12 Hours /div

200

100

100

0 11:01 14AUG2008

0 11:01 14AUG2008

LP STG 1 Disch NW 14AUG2008 11:01:38 175 d Recip Compress From 14AUG2008 11:01:38 To 25AUG2008 11:01:3 LP STG 1 Disch W 14AUG2008 11:01:38 184 d Recip Compress From 14AUG2008 11:01:38 To 25AUG2008 11:01:3 LP STG 1 Disch SW 14AUG2008 11:01:38 186 d Recip Compress From 14AUG2008 11:01:38 To 25AUG2008 11:01:3 LP STG 1 Disch Temp 14AUG2008 11:01:38 208 d Recip Compress From 14AUG2008 11:01:38 To 25AUG2008 11:01:3

LP STG 1 Disch NE 172 d 14AUG2008 11:01:38 Recip Compress From 14AUG2008 11:01:38 To 25AUG2008 11:01:3 LP STG 1 Disch E 177 d 14AUG2008 11:01:38 Recip Compress From 14AUG2008 11:01:38 To 25AUG2008 11:01:3 LP STG 1 Disch SE 189 d 14AUG2008 11:01:38 Recip Compress From 14AUG2008 11:01:38 To 25AUG2008 11:01:3 LP STG 1 Disch Temp 208 d 14AUG2008 11:01:38 Recip Compress From 14AUG2008 11:01:38 To 25AUG2008 11:01:3

11:01 11:01 18AUG2008 22AUG2008 TIME : 12 Hours /div

300

SAMPLE FILTERING

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AMPLITUDE: 20 deg F/div

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AMPLITUDE: 20 deg F/div

11:01 11:01 18AUG2008 22AUG2008 TIME : 12 Hours /div

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11:01 11:01 18AUG2008 22AUG2008 TIME : 12 Hours /div

Figure 3. LP stage 1 valve cover temperature trends.

Page 1

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Optimization and Diagnostic Platform

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LP Stage 1 CE Crank Angle Recip Compressor Train LP Stage 1 CE Crank Angle Recip Compressor Train LP Stage 1 HE Crank Angle Recip Compressor Train LP Stage 1 HE Crank Angle Recip Compressor Train LP STG 1 Xhead W Crank Angle Recip Compressor Train LP STG 1 Xhead W Crank Angle Recip Compressor Train TDC 700

Synch From 19AUG2008 00:58:59 To 19AUG2008 00:58:59 Historical Reference Historical Reference Historical Historical

Synch From 19AUG2008 00:58:59 To 19AUG2008 00:58:59

Synch From 19AUG2008 00:58:59 To 19AUG2008 00:58:59 Filtered Sync From 19AUG2008 00:58:59 To 19AUG2008 00:58:59

358.3 psig 0 Degrees MACHINE SPEED: 276 rpm 358.3 psig 0 Degrees MACHINE SPEED: 276 rpm 655.8 psig 0 Degrees MACHINE SPEED: 276 rpm 655.8 psig 0 Degrees MACHINE SPEED: 276 rpm

LP Stage 1 CE Crank Angle Recip Compressor Train LP Stage 1 CE Crank Angle Recip Compressor Train LP Stage 1 HE Crank Angle Recip Compressor Train LP Stage 1 HE Crank Angle Recip Compressor Train LP STG 1 Xhead W Crank Angle Recip Compressor Train LP STG 1 Xhead W Crank Angle Recip Compressor Train TDC 700
4 2 G'S 0.5 g/div

Synch From 19AUG2008 06:09:20 To 19AUG2008 06:09:20 Historical Reference Historical Reference Historical Historical

Synch From 19AUG2008 06:09:20 To 19AUG2008 06:09:20

Synch From 19AUG2008 06:09:20 To 19AUG2008 06:09:20 Filtered Sync From 19AUG2008 06:09:20 To 19AUG2008 06:09:20

358.5 psig 0 Degrees MACHINE SPEED: 276 rpm 358.5 psig 0 Degrees MACHINE SPEED: 276 rpm 600.9 psig 0 Degrees MACHINE SPEED: 276 rpm 600.9 psig 0 Degrees MACHINE SPEED: 276 rpm

4 2 POUNDS PER SQUARE INCH GAUGE 20 psig/div 600 G'S 0.5 g/div G'S 0.2 g/div 0 100 20 Degrees/div Crank Angle 200 300 0 -2 -4 500 2 1 400 0 -1 300 -2

POUNDS PER SQUARE INCH GAUGE 20 psig/div

600

0 -2 -4

500 2 1 400 G'S 0.2 g/div 0 100 200 20 Degrees/div Crank Angle 300 0 -1 300 -2

Figure 4. Cylinder pressure and crosshead acceleration waveforms, before valve failure.

Figure 5. Cylinder pressure and crosshead acceleration waveforms, after valve failure.

Figure 4 shows cylinder pressure curves and crosshead accelerometer signals for this cylinder, typical for the time period prior to the morning of August 19th. The close agreement between the theoretical and indicated pressure signifies effective cylinder trim sealing. Further, the high frequency crosshead accelerometer signal shows only discrete events associated with normal valve opening and closing. Referring back to Figure 3, the consistency across the trend line ends on the morning of the 19th. At this point, the plots show relative changes in temperature trends. The LP STG 1 Suct NE trend line in top right pane displays the most significant change; however other points also show changes. For example, the LP STG 1 Suct E and valve cover temperature rises as do the head end discharge valve cover temperatures, LP STG 1 Disch NE/E/SE. The sudden change in relative temperature values indicates a change in the sealing ability of the cylinder trim components. As discussed above, this results in recirculation of gases and a local increase in valve cover temperature. Given the relatively high change in the LP STG 1 Suct NE temperature relative to the other changes, one can reasonably associate the valve failure

with this valve cover. The rise in the LP STG 1 Suct E temperature, adjacent to LP STG 1 Suct NE, results from the re-circulating gas heat effect spreading to other valve covers. The 20F plus rise in the head end discharge valve group, LP STG 1 Disch NE/E/SE deserves attention as well. Either one or more of the discharge valves has a leak, or there is something about the leaking suction valve that changed the operating conditions of the discharge valves. Figure 5 shows the indicated cylinder pressure curves and crosshead acceleration after the suction valve leak began. The slower rise in pressure during the compression stroke on the head end indicates a leak from the cylinder to a low-pressure reservoir, such as the suction manifold. The high frequency content crosshead accelerometer waveform, shown on the top, shows a rise in amplitude as the difference between internal cylinder pressure and suction valve manifold pressure increases. This rise in amplitude results from internal cylinder gas leaking across the valve into the suction manifold. The features of this plot confirm that only a suction valve leak exists at this time.

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With the possibility of a discharge valve leak eliminated, only the scenario of a leaking suction valve causing the rise in the discharge valve cover temperatures remains. At first glance, it seems unlikely that the suction valve could impact the performance of the discharge valves. The connection lies in the re-circulating gases underneath the suction valve cover. While some of this gas does stay local to the valve cover, large portions of the gas re-enter the cylinder to be compressed, resulting in a higher effective suction temperature for that end of the cylinder. Since the compression ratios remain the same on both ends of the cylinder, the discharge gas temperature for the head rises with respect to the crank end valve cover temperatures.

Review of Valve Temperature Installation Arrangements

Three main approaches in valve temperature monitoring have gained acceptance. These three approaches are: 1. Valve cover skin temperature 2. Valve cover temperature 3. Internal valve temperature The following sections describe the measurements in detail along with the advantages and disadvantages of each approach. Table 1 on the following page summarizes the discussion.

1. Valve Cover Skin Temperature

In this temperature arrangement, a small hole drilled and tapped in the valve cover provides anchorage for a fastener securing a washer-style thermocouple to the valve cover. Figure 6 shows this type of arrangement. Obviously, this arrangement provides ready access for maintenance and reduced retrofit effort. The approach does limit temperature sensor options as only thermocouple temperature sensors have been offered in this configuration. Further, it is not possible to install an explosion-proof housing around the element, if plant hazardous area requirements dictate such an arrangement. The impact of the ambient environment has the potential to reduce the effectiveness of the measurement. For example, consider the valve temperature mapping shown in Figure 7. This end of the cylinder has three discharge valves. Two of the valves, LP Stg Disch NE and LP Stg Disch NE, lay at an angle with respect to the true horizontal axis. The LP Stg Disch E valve is horizontal.

Relying on Valve Temperature Alone for Cylinder Condition

Valve temperature, combined with a trending tool, can provide a good indication of a failing valve at the onset of failure. As the failure progresses, valve temperature becomes a poor predictor of valve health. Valve leaks may also result in secondary temperature effects in other parts of the cylinder, making it difficult to confidently pinpoint the leaky valve. Further, it does not provide any insight into the forces acting on the compressor (i.e., rod load and rod reversal), making it difficult to understand the stress the failure places upon the compressor. Nor does cylinder pressure provide sufficient information to pinpoint which valve on a particular end of a cylinder has failed. For these reasons, valve temperature measurements primary value is as a supporting evidence tool in PV analysis, but is not sufficient by itself to fully understand and manage the cylinders condition.

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Figure 6. Valve cover skin temperature.

Table 1. Valve Temperature Installation Arrangement Comparisons. Valve cover skin temperature Installation effort Effect of variables other than valve condition on measurement Installation cost Allows explosion proof housings? Effort of removal for valve maintenance Temperature Sensor Minor Major Minor No Minor TC Valve cover temperature Moderate Moderate Minor-Moderate Yes Minor-Moderate TC/RTD Internal valve temperature Major Moderate Major Yes Minor-Moderate TC/RTD

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Neither radiative nor conductive heat transfer modes provide significant cooling for valve covers; however, convective cooling does provide noticeable heat transfer. The angled valves allow hot air near the surface of the valve cover to rise more easily than does the true horizontal surface of the LP Stg Disch E valve cover. This results in a higher temperature for those valve covers oriented in the true horizontal plane. For example, the 6-9 degree spread shown in Figure 8 for a cylinder in good condition is typical for discharge valve cover arrangements like that represented in Figure 7. The dependence of valve cover skin temperature on valve cover orientation adds uncertainty to the measurement. Skin temperature elements experience exposure to the elements. Figure 9 shows the valve cover skin temperature over a 48-hour period. This valve cover skin temperature data shows a high degree of variation around 8:00 am on the 3rd of July. As the Pressure versus Volume (PV) curves on the right show, cylinder condition remained good throughout this time period. The valve covers on the side show more variation as they receive more wind than does the valve on the bottom of the cylinder. The 10-15F variation in valve cover temperature over a short period of time due to elemental exposure is typical for most valve cover skin temperature installations. Figure 7. Valve cover skin temperature layout.

VALVE TEMPERATURE MEASUREMENTS PRIMARY VALUE IS AS A SUPPORTING EVIDENCE TOOL IN PV ANALYSIS, BUT IS NOT SUFFICIENT BY ITSELF TO FULLY UNDERSTAND AND MANAGE THE CYLINDERS CONDITION.

LP Stg 1 Disch NE LP Stg 1 Disch E LP Stg 1 Disch SE LP Stg 1 Disch Temp

NA NA NA NA

24JUN2006 04:45:03 24JUN2006 04:28:36 24JUN2006 03:18:43 24JUN2006 04:35:22

106 deg F 105 deg F 105 deg F 102 deg F

NA NA NA NA

LP Stage 1 East Synch Displaced Volume Recip Train From 02JUN2006 03:18:11 To 02JUN2006 03:18:11 LP Stage 1 East Displaced Volume Recip Train
TDC 800

Historical 697.0 psig 0%

MACHINE SPEED: 276 rpm MACHINE SPEED: 276 rpm

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INVALID DATA

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POUNDS PER SQUARE INCH GAUGE 20 psig/div

19:46 06JUN2006 19:46 13JUN2006 19:46 20JUN2006 19:46 27JUN2006 19:46 04JUL2006 19:46 11JUL2006

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300 0 20 40 60 80 100

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Figure 8. Head end head discharge valve temperature trends (left side) and cylinder PV curve (right side).

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LP Stg 1 Disch NE LP Stg 1 Disch E LP Stg 1 Disch SE LP Stg 1 Disch Temp

300

NA NA NA NA

03JUN2006 07:51:49 160 deg F NA 03JUN2006 07:59:37 177 deg F NA 03JUN2006 08:52:17 176 deg F NA 03JUN2006 07:48:54 207 deg F NA

LP Stage 1 East Synch Historical MACHINE SPEED: 276 rpm Displaced Volume From 03JUN2006 07:16:33 To 03JUN2006 07:16:33 Historical MACHINE SPEED: 276 rpm Recip Train 709.2 psig LP Stage 1 East 0% Displaced Volume Reference MACHINE SPEED: 276 rpm Recip Train

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Synch LP Stage 1 East Displaced Volume Recip Train From 03JUN2006 08:16:33 To 03JUN2006 08:16:33 Historical MACHINE SPEED: 276 rpm 713.1 psig LP Stage 1 East 0% Displaced Volume Reference MACHINE SPEED: 276 rpm Recip Train

TDC

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POUNDS PER SQUARE INCH GAUGE 20 psig/div

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Figure 9. Valve cover skin temperature (left side) and cylinder PV curve (right side).

2. Valve Cover Temperature

The valve cover skin temperature installation approach can be modified slightly to allow explosion proof housings as well as to reduce the effects of exposure. Figure 10 shows two examples of this valve approach, referred to as valve cover temperature. In either case, a dimple or shallow hole receives the temperature-sensitive portion of the transducer. The installation shown in the top pane does not require explosion-proof fittings allowing a bayonet connector with an armored cable style temperature transducer to be used. In the case where the plant hazardous area classifications require explosion-proof fittings an explosion-proof head is installed into the bracket and flexible conduit run from this head to the junction box.

Valve cover temperature has the advantage of not requiring significant cover modification; however, the installationespecially in the case of the explosionproof fittingssomewhat complicates maintenance activities compared to valve cover skin temperature installations. Figure 11 shows a photo of a typical non-explosion proof installation. In this installation, a compression-style tube fitting threads into the valve cover and secures the temperature element rather than a bayonet connector. Although this installation requires more effort than the valve cover skin temperature approach, valve cover temperature typically experiences less influence from orientation and environmental effects. The reduced external influence can be demonstrated by considering the data provided by the sensor arrangement of Figure 11 on a large hydrogen booster compressor in a

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refinery. (Note: The controls on this compressor include hydraulically actuated stepless unloaders, so the PV curves will appear altered from those of conventionally operated compressor cylinder valves). Figure 12 shows the valve temperature map for throw 4. The cylinder has three (3) suction valves and three (3) discharge valves on each end. Stepless unloaders have been installed on the suction valves. Figure 13 shows the valve cover temperature trend for the head end discharge valves from 05 Dec to 09 Dec. Compared to Figure 8, it can be observed that plot shows closer agreement between the temperatures (~57F difference) for valve cover temperatures regardless of orientation. Note that the PV curves show a slight suction valve leak, which the temperature trends in Figure 14 confirm to be Valve #56.

Figure 10. Valve cover temperature (top) and valve cover temperature with explosion proof ttings (bottom).

Figure 11. Valve cover temperature installation.

Figure 12. Throw 4 valve cover temperature maps.

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POUNDS PER SQUARE INCH GAUGE 20 psig/div

Valve #50 N/A Valve #54 N/A Valve #55 N/A

300

90 Left Temperature 05DEC2006 10:00:13 From 05DEC2006 11:00:00 To 09DEC2006 11:00:00 90 Left Temperature 05DEC2006 09:48:59 From 05DEC2006 11:00:00 To 09DEC2006 11:00:00 90 Left Temperature 05DEC2006 09:53:56 From 05DEC2006 11:00:00 To 09DEC2006 11:00:00

187 deg F NA Historical 180 deg F NA Historical 185 deg F NA Historical

1stStage-HE4 Displaced Volume TRAIN K-20 1stStage-HE4 Displaced Volume TRAIN K-20 TDC 400

Synch 407.4 psig 0% From 05DEC2006 13:45:58 To 05DEC2006 13:45:58 Historical MACHINE SPEED: 360 rpm 407.4 psig 0% Reference MACHINE SPEED: 360 rpm

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1stStage-HE4 Displaced Volume TRAIN K-20 1stStage-HE4 Displaced Volume TRAIN K-20 TDC

Synch 399.8 psig 0% From 09DEC2006 10:06:13 To 09DEC2006 10:06:13 Historical MACHINE SPEED: 360 rpm 399.8 psig From 09DEC2006 10:06:13 To 09DEC2006 10:06:13 0% Reference MACHINE SPEED: 360 rpm

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TIME : 4 Hours /div

Figure 13. 1st stage head end valve temperature trend and head end PV curves.

Valve #49 N/A Valve #48 N/A Valve #56 N/A

150

90 Left Temperature From 05OCT2006 11:00:00 To 09DEC2006 11:00:00 90 Left Temperature From 05OCT2006 11:00:00 To 09DEC2006 11:00:00 90 Left Temperature From 05OCT2006 11:00:00 To 09DEC2006 11:00:00
SAMPLE FILTERING

05OCT2006 11:00:00 05OCT2006 11:00:00 05OCT2006 11:00:00

86 deg F NA Historical 90 deg F NA Historical 87 deg F NA Historical

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TIME : 48 Hours /div

Figure 14. Suction valve temperature trends, head end.

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3. Internal Valve Temperature

Re-circulating and re-compressing the gas gives rise to the higher temperature observed at the valve cover. The internal valve temperature design approach moves the sensor closer to the valve where the gas first returns to the manifold. Figure 15 shows a typical design for a non-explosion proof installation. A slight modification would be required to the thermowell to allow installation of an explosion-proof head. A penetration in the valve cover allows for a thermowell to be installed, close to the valve. Within the thermowell, an RTD or TC provides the actual temperature measurement and sensing. The proximity of the sensing element to the valve provides better response time compared to either valve cover skin temperature or valve cover temperature. In addition, in most cases the measurement provides data less influenced by environmental factors than either of the other two measurements. Figure 15. Internal valve temperature installation. For many installations, temperature data from this arrangement typically varies by 2-3F, better than either of the other two approaches. Figure 16 shows this data and how closely the two crank end discharge internal valve temperature trends track.
1st Stg CE Disch #3 45 Right 28DEC2006 21:43:13 79 deg F NA Recip Compress From 28DEC2006 10:11:41 To 22JAN2007 16:11:41 Historical 90 Left 28DEC2006 21:43:13 80 deg F NA 1st Stg CE Disch #4 Recip Compress From 28DEC2006 10:11:41 To 22JAN2007 16:11:41 Historical

In some cases, it has been observed that the sensitivity of the temperature sensor to transient conditions within the valve assembly (i.e., dirt, debris, etc.) creates changes in the valve temperature trend that do not correlate with the overall health of the valve. Figure 17 shows data from one such case. From 29

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December onward, the data shows the temperature of valve 1st Stg CE Suct #2 increases away from the other suction valve temperature. This usually indicates a leaking valve. The PV curves should show a deteriorating suction valve as well. The PV curve in the top right pane of Figure 17 shows the data at 29 December and the lower right shows the data 22 January 2007. Although
10:11 04JAN2007 10:11 11JAN2007 10:11 18JAN2007

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both curves do show a minor leak, the cylinder pressure curve does not change over the time period of the valve temperature trend plot, as would be expected for a leaking valve.

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Figure 16. Internal valve temperature trend.

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45 Right 28DEC2006 10:11:41 77 deg F 1st Stg CE Suct #1 Recip Compress From 28DEC2006 10:11:41 To 22JAN2007 16:11:41 90 Left 28DEC2006 10:11:41 76 deg F 1st Stg CE Suct #2 Recip Compress From 28DEC2006 10:11:41 To 22JAN2007 16:11:41
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Synch 1st Stg CE Pres Displaced Volume Recip Compressor Tra From 29DEC2006 06:43:02 To 29DEC2006 06:43:02 1st Stg CE Pres Displaced Volume Recip Compressor Tra

651.5psig 0% Historical MACHINE SPEED: 327 rpm 651.5psig 0% Reference MACHINE SPEED: 327 rpm

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Synch 1st Stg CE Pres Displaced Volume Recip Compressor Tra From 22JAN2007 11:23:43 To 22JAN2007 11:23:43 1st Stg CE Pres Displaced Volume Recip Compressor Tra

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Figure 17. Crank end suction internal valve temperature and PV curves.

References
[1]  Leonard, Stephen M. Increasing the Reliability of Reciprocating Compressor on Hydrogen Service, Hydrocarbon Processing, January 1996. [2]  Manurung, Togar MP, et. al. Reliability Improvement of a Reciprocating Compressor in an Oil Refinery. [3]  Smith, Tim. Quantum Chemical Uses Reciprocating Compressor Monitoring to Improve Reliability, Orbit Magazine, June 1996, pp. 13-16. [4]  Silcock, Don. Reciprocating Compressor Instrumented for Machinery Management, Orbit Magazine, June 1996, pp. 10-12.

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