Reciprocating
Compressors
Condition Monitoring &
Diagnostics
Presentation Contents
Fundamentals
Instrument Settings
Determining Trigger Angle
Probe Calibration
2
2007 General Electric Company. All rights reserved.
Fundamentals
Over time, soft rider bands
wear away especially in
non-lubricated cylinders.
Piston
Ring
Rider Band
Cylinder Liner
3
2007 General Electric Company. All rights reserved.
Piston Damage
Fundamentals
Scuffing
Wear
4
2007 General Electric Company. All rights reserved.
Roller Valve
Fuse Metal Plug
(pressurized chamber)
(pressurized chamber)
Eddy Current
Proximity Probe
7
2007 General Electric Company. All rights reserved.
Measurement Geometry
Fundamentals
P IS T O N
M ID P O IN T
P R O B E P O S IT IO N
L1 L1 L 2
B1
B2
L1 L 2 B1
B2
L1
PR O BE
V IE W
PLA N E
L1
C L
L2
B1
N EW
B2
A C T U A L R ID E R
BA N D W EA R
W O R N
P IS T O N R O D L E N G T H
8
2007 General Electric Company. All rights reserved.
Assumptions
Fundamentals
10
2007 General Electric Company. All rights reserved.
(animation)
11
2007 General Electric Company. All rights reserved.
Instrument Settings
Installation dimensions (L1 &
L2)
Once-per turn reference
signal
Trigger angle (if collecting
one instantaneous sample
per crankshaft rotation)
Transducer scale factor
P IS T O N
M ID P O IN T
P R O B E P O S IT IO N
PR O BE
V IE W
PLA N E
L1
C L
L2
B1
N EW
B2
A C T U A L R ID E R
BA N D W EA R
W O R N
P IS T O N R O D L E N G T H
Compressor
Monitoring
Instruments
12
2007 General Electric Company. All rights reserved.
Required Measurements
Instrument Settings
13
2007 General Electric Company. All rights reserved.
Signal Processing
Instrument Settings
Average Value
Instantaneous Value
15
2007 General Electric Company. All rights reserved.
40
120
240
40
120
240
tensio
n
compressi
on
16
40
120
60
tensio
n
tensio
n
Piston rod displacement is ~46 mil for both Full & Part loads at 60
crank angle.
17
2007 General Electric Company. All rights reserved.
Rod Displacement
(Oscilloscope)
Determining Trigger Angle
360
360
360
360
18
2007 General Electric Company. All rights reserved.
Probe Calibration
Verify probe calibration to the actual piston rod
surface to reduce errors caused by the following
factors:
Specific composition of the piston rod alloy
Surface treatments, coatings, or contamination
Roundness of the cylindrical piston rod surface
19
2007 General Electric Company. All rights reserved.
22
20
18
16
14
12
10
8
4140 Steel
Tungsten
Aluminum
Copper
6
4
2
0
0
10
20
30
40
50
60
70
80
20
2007 General Electric Company. All rights reserved.
Micrometer Kit
Probe Calibration
Micrometer kit
accommodates creating a
probe calibration curve for
the actual piston rod.
21
2007 General Electric Company. All rights reserved.
Practice Exercises
Rod Drop
Fundamentals
Instrument Settings
Determining Trigger Angle
Probe Calibration
22
2007 General Electric Company. All rights reserved.