EVALUATING PUMP
FIELD PERFORMANCE TESTS
Note: The source of the technical material in this volume is the Professional
Engineering Development Program (PEDP) of Engineering Services.
Warning: The material contained in this document was developed for Saudi
Aramco and is intended for the exclusive use of Saudi Aramco’s employees.
Any material contained in this document which is not already in the public
domain may not be copied, reproduced, sold, given, or disclosed to third
parties, or otherwise used in whole, or in part, without the written permission
of the Vice President, Engineering Services, Saudi Aramco.
Section Page
INFORMATION ............................................................................................................... 3
INTRODUCTION............................................................................................................. 3
VIBRATION MONITORING EQUIPMENT ...................................................................... 5
Vibration Monitoring.............................................................................................. 5
Basic Vibration........................................................................................... 5
Transducers for Vibration Variables......................................................... 11
Seismic Probes........................................................................................ 24
Requirements for Positive-Displacement Compressors........................... 28
Temperature Monitoring ..................................................................................... 28
Temperature-Monitoring Probes .............................................................. 28
MAJOR CONCERNS OF CONDITION MONITORING, MALFUNCTION
DIAGNOSIS, AND PREDICTIVE MAINTENANCE ....................................................... 36
Dynamic Compressors ....................................................................................... 40
Vibration................................................................................................... 40
Axial Position ........................................................................................... 41
Bearing Temperatures ............................................................................. 43
Seal Fluid Flow ........................................................................................ 44
Seal Fluid Leakage .................................................................................. 45
Balance Line Differential .......................................................................... 45
Performance ............................................................................................ 45
Oil Analysis .............................................................................................. 47
Positive-Displacement Compressors.................................................................. 48
Vibration................................................................................................... 48
Rod Drop ................................................................................................. 49
Packing .................................................................................................... 50
Bearing Temperatures ............................................................................. 50
Cooling Jacket Temperature.................................................................... 50
Performance ............................................................................................ 51
GLOSSARY .................................................................................................................. 53
LIST OF FIGURES
LIST OF TABLES
INFORMATION
INTRODUCTION
A vibration, axial position and bearing temperature monitoring
system consist of the following equipment:
• Probes
• Accelerometers
• Temperature Sensors
• Signal Conditioning Devices
• Interconnecting Cables
• Power Supplies
• Monitors
• Communication Devices
As defined by Saudi Aramco Engineering Standard SAES-J-
604, “Vibration, Axial Position and Bearing Temperature
Monitoring System” will be referred to as the “Vibration
Monitoring System.”
Vibration and axial position information is acquired by
transducers and proximity probes positioned at optimal locations
on a compressor. Transducers convert mechanical responses
to electric signals that are conditioned and processed by
electronic instruments.
Bearing and compressor temperature information is acquired by
temperature detectors that are positioned at the compressor
bearings and/or gas flow paths.
The vibration monitoring system provides the information
necessary to monitor compressor condition, to verify perform-
ance, and to diagnose faults. Vibration monitoring systems
provide the electrical signals to the Rotating Machinery
Protection System (RMPS) and the condition monitoring
system. The RMPS automatically sends shutdown commands
to the rotating equipment train if compressor vibration, axial
position, or monitored temperature exceeds a specified limit.
The condition monitoring system is a computer-based data
collection system that communicates directly to the vibration
monitoring system. The condition monitoring system will also
accept process data from communication links to the Distributed
Control System (DCS) or directly from process instruments. The
Vibration Monitoring
Vibration monitoring is a monitoring method and process.
Vibration monitoring measures the condition of the machine
from the initial vibration signature after installation and then at
periodic intervals throughout the machine’s life. This monitoring
method and process enables an accurate accrual or trend of
information by which equipment may be diagnosed before any
problems occur.
AMPLITUDE
FREQUENCY
TIME
AMPLITUDE
AMPLITUDE
TIME FREQUENCY
Besides sine waves, which are pure tones, there are random
vibrations. Random vibrations look similar to a complex
vibration signal except that the vibrations do not repeat regularly
or on a cycle. It is difficult to assign a frequency to random
vibrations. Random vibrations can occur in gas compressors
when the moving gas encounters stationary objects in the gas
stream and creates vortices and turbulence. Friction can also
cause random vibrations.
Transducers for
Vibration
Variables
There are two general applications for vibration sensors that are
used on rotating equipment. Both applications are used by
Saudi Aramco.
PROXIMITY
PROBE
SHAFT
12,000
Allowable shaft vibration in mils peak-to-peak =
rpm
(along the x axis of the X/Y plot) from a pulse mark to the first
positive peak in the waveform.
PROBE VIEWING
END OF ROTOR
Figure 7. API 670 Axial-Position Probe Installation for a Shaft with an Integral
Thrust Collar
Seismic Probes
The alarm level is set at one and a half times the acceptance
level. The shutdown level is set at two times the acceptance
level.
OUTPUT
TERMINALS
DAMPER
MASS
WIRE COIL
MAGNET SPRING
PICKUP CASE
PIEZOELECTRIC
MASS DISKS (QUARTZ)
OUTPUT
TERMINALS
BASE
Requirements for
Positive-
Displacement
Compressors
Temperature Monitoring
Temperature monitoring systems are primarily used to monitor
bearing conditions on compressors and compressor drivers.
These temperature detectors are sometimes used as protective
instrumentation to actuate a compressor shutdown and to
prevent compressor damage. Temperature monitoring systems
are also used to predict failure or wear of compressor
components, such as interstage valves and piston rings on
reciprocating compressors.
Temperature-
Monitoring Probes
the wire shields. T/C wires must never run in the same conduit
with electric power wires.
Magnetic noise may be induced into a T/C circuit any time the
extension wires are subjected to a magnetic field and a current
is produced to oppose the magnetic field. Magnetic noise can
be minimized by twisting each pair of T/C extension wires.
Cross talk noise between adjacent wire pairs in the same
conduit may also occur. Cross talk can be avoided by shielding
each pair of extension wires.
The monitor must provide a fault alarm for open or short circuits
in the control wiring between the detector and the monitor.
Monitor relays that are used for pre-alarm and shutdown output
functions must be the hermetically sealed, plug-in type. The trip
settings must be in accordance with the recommendations of
the compressor manufacturer.
Dynamic Compressors
Condition monitoring, malfunction diagnosis, and predictive
maintenance for dynamic compressors are concerned with
vibration, axial position, bearing temperatures, seal fluid flow,
seal fluid leakage, balance line pressure differential,
performance, and oil analysis. These factors can be the
indicators of a problem or a potential failure during dynamic
compressor operation.
Vibration
Bearing
Temperatures
In the case of oil film seals, seal oil is injected between two
collars or bushings (sleeves) that run at close clearance to the
shaft. For oil film type seals, seal oil is supplied as a controlled
differential pressure of 5 psid above the internal gas pressure.
The seal oil flow towards the gas stream of the system through
the gas-side bushing. The oil and system gas mix and
discharge through the contaminated oil drain line to be
reclaimed or discarded. An oil film seal bushing will have a seal
leakage of 10 to 20 gallons per day; larger compressors will
have even more flow. The oil that does not flow across the gas-
side bushing returns to the oil reservoir for reuse.
In addition, the oil provides the cooling and lubrication. The seal
oil flow toward the gas stream is a direct function of the
pressure difference between oil and gas. The static pressure
from an overhead tank, combined with the system gas stream
pressure, provide the necessary flow pressure.
Seal Fluid
Leakage
Seal oil leakage can result in significant operating costs during
the life of the equipment. Such costs can result from both the
replenishment and the disposal of discarded oil. An extreme
case is where compressors are located offshore, and
contaminated oil is shipped onshore for disposal.
Seal oil leakage rates should be thoroughly evaluated before
order placement and then enforced on the test stand prior to
equipment acceptance. Stated shop test leakage rates may
vary slightly from guaranteed field leakage rates due to different
seal clearance and differential pressure on the test stand. The
shop test and field leakage rates may differ due to the
adjustment of seal clearances for the shop test conditions. Oil
replacement costs and the cost of disposing of contaminated oil
can be significant on an offshore platform. The life of that oil
can be extended through use of a reclamation system. The
type of system will depend upon the volume of oil and the
contaminants that are present.
Balance Line
Differential
Because a labyrinth seal is utilized, a certain amount of leakage
occurs across the balance piston. This leakage is normally
routed back to the compressor suction, which creates a
differential pressure across the balance piston. Because the
balance piston seal must seal the full compressor pressure rise,
integrity of the seal is crucial to efficient performance and thrust
bearing load. A damaged seal results in higher leakage rates,
higher horsepower consumption, and greater thrust loads. A
balance line differential pressure increase is an indication that
the balance drum labyrinth clearance has increased.
Performance
Compressor performance degradation is expected over time.
However, degradation beyond the expected amount
unnecessarily reduces efficiency and performance. Identification
of these abnormal operations requires accurate trend analysis.
Through the use of a properly established baseline and the plot
of percentage change of a parameter, the initial and current
performance curves can be compared.
The initial curve may be predicted by the manufacturer, but the
curve should be adjusted in accordance with established field
data. Inlet conditions, discharge conditions, gas analysis, inlet
volume flow, and speed must be taken into consideration and
Oil Analysis
Positive-Displacement Compressors
Condition monitoring, malfunction diagnosis, preventive
maintenance, and predictive maintenance for positive-
displacement compressors are concerned vibration, rod drop,
packing, bearing temperatures, cooling jacket temperature,
performance, and oil analysis. These factors can be the
indicators of a problem or a potential failure during positive-
displacement compressor operation.
Vibration
Rod Drop
Cooling Jacket
Temperature
Performance
GLOSSARY
non-contact A sensor that detects the gap between its tip and a shaft surface.
proximity probe
thermocouple A junction of two dissimilar metals that has a voltage output that
is proportional to the difference in temperature between the hot
junction and the cold junction.
velocity transducer A transducer that senses velocity of vibration and that produces
an electrical output signal (in mV) that is proportional to velocity.