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Procedia Engineering 152 (2016) 497 – 504

International Conference on Oil and Gas Engineering, OGE-2016

About the experience in operation of reciprocating compressors


under control of the vibration monitoring system
Kostyukov V.N.a, Naumenko A.P.a*
a
Dynamics SPC, 108/1 Rabinovicha st., Omsk 644007, Russian Federation

Abstract

The article presents the results of reciprocating compressors operation under the control of Vibration-Based Diagnostics
monitoring systems, dwells upon the issues of usage of reciprocating compressors valves by various vendors and their influence
on compressors’ vibroactivity. An adequate evaluation of vibroactivity of piston machines is provided by the Russian regulative
database on vibration parameters.
Main differences of Russian and global methods of reciprocating compressors health evaluation, particularly, used frequency
range, are presented in the article. It is shown that the approach laid in Russian standards on reciprocating compressors vibration
regulations, ensures true-to-life assessment of reciprocating compressors assemblies and details condition.
The examples given in the article confirm that the criteria of reciprocating compressors repair correctness assessment should be
the machinery health, including its vibroactivity, not just mindless usage of new components purchased from the global brands.
Practical examples of operation and monitoring of reciprocating compressors show that Russian developments and products,
particularly, scientific-methodological and standards base of Vibration-Based Diagnostics monitoring, reciprocating compressors
monitoring systems, reciprocating compressors valves are highly competitive with foreign ones, and sometimes even superior to
them in parameters and characteristics, which is a positive factor under the conditions of current economic situation and import
substitution policy.
© 2016
© 2016TheTheAuthors.
Authors.Published
Publishedbyby Elsevier
Elsevier Ltd.Ltd.
This is an open access article under the CC BY-NC-ND license
(http://creativecommons.org/licenses/by-nc-nd/4.0/).
Peer-review under responsibility of the Omsk State Technical University.
Peer-review under responsibility of the Omsk State Technical University
Keywords: reciprocating compressors, valve, vibration, monitoring, diagnostics, condition

* Corresponding author. Tel.: +7-381-225-4244; fax: +7-381-225-4372.


E-mail address: post@dynamics.ru

1877-7058 © 2016 The Authors. Published by Elsevier Ltd. This is an open access article under the CC BY-NC-ND license
(http://creativecommons.org/licenses/by-nc-nd/4.0/).
Peer-review under responsibility of the Omsk State Technical University
doi:10.1016/j.proeng.2016.07.635
498 V.N. Kostyukov and A.P. Naumenko / Procedia Engineering 152 (2016) 497 – 504

1. Introduction

Safe resource-saving operation of hazardous production machinery, particularly reciprocating compressors, is


impossible without their health monitoring in real time. The main parameter that helps to adequately and accurately
evaluate the state of machinery structural parameters is vibration [1, 2, 3]. Until recently, the procedure of
reciprocating compressors health evaluation according to vibration parameters was a challenge, since neither Russia
nor other countries had necessary regulatory and procedural base. ISO 10816-5:1995, the recently enacted ISO
10816-8:2014 and API 618 did not and still has not ensured true-to-life evaluation of piston machines health [4].
And only when GOST R 56233-2014 [5] was adopted there appeared vibration standards in Russia allowing not
only to conduct a reliable and adequate control of reciprocating compressors vibration, but to monitor piston
machines health. Since 2011 the industry standard [6] was being used in Russia. This standard is a prototype of the
national standard [5]. The standards contain the values of the specified vibration parameters and methods of
reciprocating compressors health evaluation according to vibration parameters. All these data are the result of more
than 20-years’ experience in Vibration-Based Diagnostics monitoring of dozens of reciprocating machines [1, 7].
The object of this article is to present statistics for faults of assemblies and details of reciprocating compressors,
and analyze vibroactivity of reciprocating compressor valves, as one of the most often failed components.

2. Estimation of statistics for faults of reciprocating compressors assemblies and details

The implementation of reciprocating compressor monitoring systems and the selection of assemblies for health
monitoring are based on the statistics of assemblies and details faults. The survey of consumers and manufacturers
of reciprocating compressors from the USA, Canada, UK, France, Belgium, Norway, Kuwait, Singapore, China and
UAE revealed the components that most frequently cause reciprocating compressor shutdowns [8].
The results of the survey [8] showed that five systems and components of compressors cause about 76.5% of all
unplanned compressors shutdowns. Faults of valves make up 36%, and the cost of their repair is 50% of the total
repair costs.
Analysis of distribution of reciprocating compressors failure causes [8, 9, 10] shows that one of the main reasons
for compressors failures, and in the first place valves, is overload that occurs due to changes of physicochemical
state of gas during compression. This fact is easy to exemplify by the compressors squeezing hydrogenous gas.
According to sources [9, 10, 11] failures of valves (mainly plates) cause up to 70-90% of shutdowns of mine and
factory compressors. Valve faults in compressors of 5G-100/8, 4M10-100/8 types can make up to 50% of the total
repaired assemblies [11].
The data regarding reciprocating compressors repair and data of compressors monitoring systems were analyzed
by statistical mathematics. The data were provided by one of the Russian oil refineries. The analysis results are
presented in Table 1 [9, 10].
The results here show that the statistics of valves and seals failures obtained at one of the Russian oil refineries
[9, 10] agree with research data of [8]. However, piston-cylinder units cause a significant percentage (over 30%) of
all faults, where the ring failures are more than 25% (according to [8] they are 14%). Failures in the slide-crank
mechanism (SCM) and cranking mechanism (CM) are very significant as well.

Table 1. Reciprocating compressors shutdowns caused by different components.

Percent, %
Assemblies and repair causes
Russian oil refinery [9, 10] Source [8]
Repair and replacement of valves 36.4 36
Repair and replacement of piston-cylinder units, including: 17.5.
packing 25.8 17.8
rings 5.0 13.9
others …
V.N. Kostyukov and A.P. Naumenko / Procedia Engineering 152 (2016) 497 – 504 499

Repair and replacement of SCM details 3.8


Repair and replacement of CM details 4.0 32,3
Other repairs 7.5
Total repairs, items 772 …

3. Problems of spare parts and components usage

Current trends to reduce expenses for design and manufacture of certain components of complex engineering
systems have led, on the one hand, to the development of standard and strict design and production technologies,
and on the other hand, have significantly complicated the use of machinery under particular operating conditions.
One of the problems in modern process plants of oil-gas-chemical complexes is to provide high quality spare parts
and consumables, which include, in particular, rolling bearings, piston compressor valves and others. It is
widespread practice that original components work long and reliably reaching the end of its assigned service life.
Installation of new valves in reciprocating compressors usually leads to a change in their technical condition, in
particular the machine vibroactivity changes. Most often this is due to the installation of the valves with parameters
unsuitable for the actual compression conditions.
Experience in operating of online monitoring systems for reciprocating compressors [12, 13] shows that in most
cases valves need to be aligned and adjusted for the particular conditions of use [12].

4. Experience in operating of RC monitoring systems

Trends of vibration parameters of type 4M16M-35/45-55 reciprocating compressors monitoring system (Fig. 1,
Section 1 – 10 months of operation before replacement of valves) have a large number of emissions that show
frequent increase in vibration level. It proves faults of valves and breakdowns of their details. To judge by the
trends, it comes as the operation and maintenance personnel has been continuously replacing the valves of this
cylinder and the actual maximum life of a particular valve was only a few operating shifts.
After installation of new valves 17 valve failures and repairs occurred within three months of the reciprocating
compressor operation (see. Fig. 1, Section 2). And only when the parameter “time-section” had been changed three
months before end of the observation (see Fig. 1, Section 3), vibration level dramatically decreased. Valve faults
stopped (see Fig. 1, Section 4). Thus, a significant reduction of valves vibroactivity was reached through the change
of parameter “time-section” by altering the height of plates moving.
A similar problem occurred in the operation of the hydrotreating recycle compressor for hydrogen bearing gas
(HBG) on “Isomerizatsiya” unit of 2GM2,5-6,2/38-46S type.
The compressor is reciprocating, horizontal, single stage on the 2M2,5 opposite base, without cylinders and seals
lubrication. It is driven by the motor with a speed of 750 min-1. The compressor was supplied with type VKT and
NKT valves. During the compressors operation with the original valves the machinery vibroactivity increased only
if the compression process was changed or violated.
500 V.N. Kostyukov and A.P. Naumenko / Procedia Engineering 152 (2016) 497 – 504

Fig. 1. Cylinder vibration trends in the valves area of type 4M16M-35/45-55 compressor.

At the same time attempts to use valves of different manufacturers and designs led to a substantial increase in the
compressor vibroactivity (Fig. 2) to the inadmissible levels given in sources [5, 6]. Another problem with the
application of non-original valves for different compressors is off-nominal behavior of a certain gas composition.
Due to this the parameter “time-section” that defines the valve capacity is usually violated. In this case, a turbulent
gas flow occurs in the compressor after the valve and its surge, which results in vibroacoustic oscillations of high
power.

Fig. 2. Vibration trends of the first cylinder discharge valve before replacement of the type 2GM2.5-6.2/38-46S compressor valves (the cursor is
hovered over the date of valve replacement: 06/03/2015).
V.N. Kostyukov and A.P. Naumenko / Procedia Engineering 152 (2016) 497 – 504 501

Selection of a valve with the parameter “time-section” suited to a particular compressor for a specific gas
composition is quite a serious problem for many operating companies. This is due to the fact that a valve
manufacturer should calculate and produce valves for the specified machine operating under the given conditions.
But it always is unprofitable. For “branded” valve manufacturers it is easier to hold in stock valves with average
performance and deliver them under the questionnaires, which actually regard average properties of compressed
gases, and disregard gas dynamics under specific conditions of compression.

5. Solution to valve vibroactivity problems

Special research in gas flow through the valves helped find solutions to form gas flows and control gas dynamics.
The specialists of KSK-Service, Ltd. have implemented the solution and designed a poppet springless valve. Well-
streamlined spherical surface of locking plates ensures laminar flow of gas through the valve. It significantly
increases the valve life and improves its vibroacoustic characteristics (Fig. 3) [14].

Fig. 3. Low vibroactivity valve designed by the specialists of KSK-Service, Ltd. (Omsk).

The prototypes of the valves (Fig. 3) were installed on the first cylinder of the compressor of 2GM2,5-6,2/38-46S
type in June 2015. At the same time valves of another manufacturer were installed on the second cylinder. After the
machine had been started the values of some controlled parameters on the first cylinder decreased almost 10 times
(Fig. 4), which significantly affected the overall vibroactivity of the compressor. While the values of vibration
parameters on the second cylinder, located oppositely to the first, remained virtually unchanged (see Fig. 4,
“Cylinder 2” parameter trend).
Trends of vibration parameters [mean square value (RMS) of acceleration] show that vibroactivity of the suction
and discharge valves has integrally declined almost 3 times (Fig. 5).
Causes of valves vibroactivity show vibration spectra (Fig. 6, 7). Valves with the parameter “time-section”
unsuitable for the particular compression gas and process give rise to vibration of high frequency ranging 8 to
10 kHz (Fig. 6). At the same time the valve properly selected for the actual compression process is a source of
almost “pink” noise without clearly defined resonances (Fig. 7).
It should be noted that the vibration-based diagnostics monitoring system [2, 10, 12, 13] classified the condition
of the valve, which spectrum is shown in Fig. 6, as impermissible according to the Russian regulative documents
[5, 6]. While according to ISO 10816-8-2014 and API-618 this valve was classified as fit for operation. The
fundamental difference between the approaches of reciprocating compressors health evaluation given in sources
[5, 6] and the other known approaches is the frequency range used for evaluation. All over the world vibration is
measured in the range up to 1 kHz. But as Fig. 5, 6 show the upper value of the frequency range should be increased
at least 10 times. This approach included in the Russian standards on reciprocating compressors vibration
regulations [5, 6] and ensures true-to-life health monitoring of reciprocating compressors components and details.
502 V.N. Kostyukov and A.P. Naumenko / Procedia Engineering 152 (2016) 497 – 504

Fig. 4. Vibration trends of the discharge valves of the first (new) and the second (old) cylinders.

Fig. 5. Vibration trends (RMS of vibration acceleration) of the first cylinder suction and discharge valves after the replacement of valves.

6. Conclusion

Thus, the usage of adequate Russian methodological and standards base [4, 5, 6, 15] on vibration-based
diagnostics monitoring of reciprocating compressors, as well as cutting-edge developments in online machinery
health monitoring and techniques of reciprocating compressors monitoring [2, 10, 12, 13] helped to implement safe
resource-saving operation of hazardous production reciprocating compressors. Operating personnel has an
opportunity to carry out repairs according to the real condition and use spare parts and components with low
machinery vibroactivity. It in turn allows extend the life of the machinery.
The examples given in the article show that the criteria of repair correctness assessment should be the machinery
health, including its vibration activity, not just mindless usage of new components purchased from the global
brands. Practical examples of operation and monitoring of reciprocating compressors show that Russian
V.N. Kostyukov and A.P. Naumenko / Procedia Engineering 152 (2016) 497 – 504 503

developments and products are highly competitive with foreign ones, and sometimes even superior to them in
parameters and characteristics, which is a positive factor under the conditions of the current economic situation and
import substitution policy.

Fig. 6. Vibration spectrum of the valve unsuitable for the compressor and compression process.

Fig. 7. Vibration spectrum of the valve suitable for the compression process.

References

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