Reciprocating Compressor Condition Monitoring & Diagnostics (CMD)

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Participants learn about instrumentation used for protection and condition monitoring of a reciprocating compressor, interpret data plots, and identify reciprocating compressor malfunctions. The course includes hands-on workshops with actual case histories.

Duration:

28 hours

Schedule:

days

Delivery:

Audience:

Anyone who wants to learn about reciprocating compressor components and mechanics
Engineers seeking to understand reciprocating compressor performance theory
Engineers who interpret reciprocating compressor vibration and analyze malfunctions
Engineers who design, test, and maintain reciprocating machinery

Objectives:

Develop an understanding of the basic components and nomenclature of API-618 reciprocating compressors.
Learn reciprocating compressor mechanics, performance theory, and recip-specific diagnostic techniques.
understand the need for monitoring of reciprocating compressors and typical monitoring strategy corresponding to API-618 and API-670 guidelines.
Comprehend the importance of crank angle reference measurements in recip monitoring and diagnostics.
Develop a diagnostic strategy (understand plots for PV, rod load, performance indicators, frame vibration, crosshead vibration, cylinder vibration and piston rod monitoring) required for comprehensive monitoring and analysis of reciprocating compressors.Practice the knowledge while diagnosing real-time data from machines.
Several case studies will be presented throughout the course to visualize the typical malfunctions’ signatures.
Demonstration of Calibration, setup and maintaining Piston Rod Monitoring.

Required Prerequisites:

None

Recommended Prerequisites:

Machinery Diagnostics Methodology

Additional Requirements:

None

Program:

Day 1

Introduction to reciprocating compressors
Components, typical failures and condition monitoring of reciprocating compressors
Crankshaft timing – crank angle reference
Dynamic cylinder pressure monitoring (PV and performance monitoring)

Day 2

Recap from day 1
Workshop: case studies related to cylinder pressure monitoring
Cylinder pressure installation issues
Workshop: case study on instrumentation issues
Monitoring efficacy of capacity control types and case studies
Monitoring of multistage compression

Day 3

Rod Load forces, rod load reversal and vertical forces monitoring
Workshop: case study on rod load forces and rod reversal
Piston rod monitoring (rod drop and rod position)
Probe calibration demonstration
Workshop: case study on rod position data interpretation

Day 4

Compressor Vibration
Workshop: case study on compressor vibration
System 1 recip plots
Workshop: System 1 recip plots navigation
Knowledge check: case history
Introduction to Decision Support Analytics

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