Basic Reciprocating Compressor

Analysis
AQC1

Knoxville, Tennessee 2012

 Course Agenda/Objectives
• Definitions
• Compressor physical characteristics
• Data collection safety
• Sensor point selection
• Visual inspection procedures
• Basic compressor theory
• Pressure vs. crank-angle
• Vibration vs. crank-angle
• Ultrasonic vs. crank-angle
• Pressure vs. displaced volume
• Determining toe pressures, compression ratio,
volumetric efficiencies, horsepower
• Performance report
• Panel report
• Field reporting
 Safety
Always complete your own personal Job Safety Analysis (JSA) before starting
each job and entering the work area. It should include but not limited to:
• A review of the possibility of a hazardous atmosphere.
• Possible low headroom.
• The presents of possible slips, trips, or fall hazards.
• Extreme temperatures.
• High pressures.
• Pinch points
• Rotation parts.
• Noise
• Toxic chemicals
• Flammable gases and liquids
• Overexertion
• Poor visibility
• Weather
• Required PPE
Detectable Malfunctions (Skid)

• Scrubber sizing
• Bottle & pipe sizing
• Plugged screens
• Instrumentation defects
• Leaking by-pass and recycle
valves
• Excessive vibration / support
deficiencies
 Detectable Malfunctions

• Valve & un-loader defects

• Improper clearances
• Pocket condition
• Piston / ring / rider condition
• Liner condition
• Mechanical looseness
• Rod loading / rod reversal / run-out
• Pulsation related problems
• Poor efficiency
Breakdown of Compressor Maintenance
Costs and Time Spent
• Valves - 50%
• Packing - 20%
• Piston rings - 20%
• Piston rider band - 7%
• Piston rods - 2%
• Cylinder liners - 0.5%
• Bearings - 0.5%
 Causes of Failures

• Overloading - 28%
• Liquid/foreign object ingestion - 18%
• Lubrication - (lack of rod reversal) - 12%
• Fatigue/excessive stress - 10%
• Freeze damage - 7%
• Other causes/undetermined causes - 25%
Purpose of Compressor Analysis
• Evaluate performance
• Maximize Compressor Efficiency
• Maximize Valve Life
• Maximize Throughput to Horsepower
Ratio
• Research and Development
• Economic Evaluation
• Evaluate mechanical condition
• On-Condition Maintenance
• Insure Reliability and Safety
• Evaluate PM program
• Reduction of Maintenance Costs
• Less Downtime and Lost Production
• Attempt to “Warrant” no Catastrophic
Breakdown Between Analysis
 The Reciprocating Machinery

• Integral types have a

common crankshaft shared
between the power cylinders
and compressor cylinders.
 The Reciprocating Machinery

Flywheel
Connecting Rod
Crosshead assembly
Wiper packing
Piston rod
Pressure packing
Piston
 The Reciprocating Machinery

Crosshead shoe
Distance Piece
Valve cap S/D
Suction cavity
Cylinder head
The Reciprocating Machinery

17 3 11 13
21 19 16 4
12 14 18 9
2 20 10 1
15 7 22
8 5 6

Component Identification
Large 4-Stroke Multi-Stage Integral
Separable Engine-Compressor
 The Analyst
The analyst is the most significant component in a successful predictive
maintenance program. Much of the actual data interpretation and analysis
is performed in the human mind. The analyst converts data into
information. Some key characteristics include:

• Mechanical, engine and operations knowledge

• Computer and electronics knowledge
• Leadership and teaching skills
• Competent in ability and confident in decisions
• Knows how to use the analysis equipment
• Knows the difference between good and bad data
• Deals with facts, not assumptions
• Collects and utilizes all the facts and avoids jumping to conclusions
• Objective attitude with a willingness to learn and evaluate new ideas,
procedures, and theories
• Ability to gain confidence of fellow employees and team members
Analysis Setup Procedures
(Pre-Analysis Information)
• Determine the type of
analysis to be performed
• Breakdown the machine
into sub-components
• Acquire machine
mechanical
specifications and
dimensions
• Determine Sensor
Points
• Perform Machine
Software Setup
• Perform Equipment
Setup
Compressor & Power Master Rods
Rotation not needed

Piston or
Crosshead

Master Rod Setup Requires:

1. Con Rod Length (in inches)
Stroke (in)
2. Stroke (in inches)
 Piston Motion (35 rod lgth-14 stroke-300 rpm)

25
20
15
displ(inch)/vel(ips)

10
5
DISP
0
VELOCITY
-5 0 45 90 135 180 225 270 315 360
-10
-15
-20
-25
degrees
Mechanical Specifications and
Dimensions (Compressor)
• Number of Compressor Cylinders
• Number of valves for each compressor
cylinder end
• Rated Horsepower and Speed
• Atmospheric Pressure
• Standard Pressure
• Cylinder Phase (TDC)
• Cylinder Bore Size
• Stroke
• Connecting Rod Length
• Piston Rod Diameter
• Rod Load Limits (Compression and Tension)
• Mass of Reciprocating Weights
• Accurate Gas Analysis
• Load Step Clearance Information
Pressure Sensor Points
(Compressor)
• DC Pressure Sensor
• Head end Pressure
• Crank end Pressure
• Suction Nozzle
• Discharge Nozzle
• Suction Pulsation Bottle
• Discharge Pulsation
Bottle
• Suction Valve Cavity
• Discharge Valve Cavity
Pressure Sensor Points
(Compressor)
• Head end and Crank end
Indicator Valves
• Pulsation Bottle Indicator
Valves

• Nozzle Indicator Valves

Compressor Vibration Sensor Points

• Vibration
• High Frequency
Vibration
• Head end
• Unloaders (optional)
• Crosshead
• Valve caps (optional)
• Raw Vibration
• Head end
• Crosshead
Compressor Vibration Sensor Points
Compressor Ultrasonic Sensor Points

Ultrasonic
probe
• Ultrasonic
• Cylinder Head end (optional)
• Cylinder Crank end (optional)
• Cylinder Side (optional)
• Suction Valves & Unloaders
• Discharge Valves &
Unloaders
• Gas Packing Area (optional)
Compressor Ultrasonic Sensor Points

Ultrasonic
probe
Frame Crank-angle Vibration Points

• Raw vibration
• Main bearings
• Accessories
• High frequency vibration
• Main bearings
Main Bearing Test Points

• Locate a good
vibration path
from the mains
to the outside of
the unit
or
• Crank-angle
related or FFT
Route Based FFT Accessories

• Oil pump
• Water pump
• Hydraulic pump
• Frame
• Cylinders
• Piping
• Horizontal
• Vertical
• Axial
Machine Software Setup Review
Reciprocating Compressor Design,
Theory and Sequence of Events
Typical Balanced-opposed Compressor

Side View - Double Acting Compressor

Suction System

• Block valves
• Pressure control
valves
• Scrubbers
• Volume/pulsation
bottles
• Screens
Discharge System

• Pulsation/volume
bottles
• Gas cooler
• Recycle lines
• Relief valves
• Check valves
Compressor Components

• BDC Crankshaft
– Fixed Design

©Copyright 2003, Dresser-Rand Company. All Rights Reserved

 Crosshead
Shoes

Crosshead Guides ©Copyright 2003, Dresser-Rand Company. All Rights Reserved

Compressor Cylinder Components

©Copyright 2003, Dresser-Rand Company. All Rights Reserved

 Compressor Valves

Cut-away of Poppet Exploded view of

valves channel valve
The primary
function of the
valve springs
is to close the
valve
©Copyright 2003, Dresser-Rand Company. All Rights Reserved
©Copyright 2003, Dresser-Rand Company. All Rights Reserved
 Compressor Pressure

• Compressor calculations use absolute pressure

• Absolute pressure = gauge pressure + atmospheric
pressure
• (100 psig + 14.7 = 114.7 psia)
• (200 psig + 14.7 = 214.7 psia)
• The atmospheric pressure at the test location is not
corrected to sea level
• Compression ratio = absolute discharge pressure
divided by absolute suction pressure
• (214.7 psia / 114.7 psia = 1.872 CR)
• Standard pressure or standard atmosphere is the
pressure of a standard cubic foot of gas
 Boyle’s 1st Law

• If temperature remains constant, the volume occupied by a

given weight of gas varies inversely with its absolute
pressure.

• As the volume of gas is reduced, its pressure increases.

• P1*v1 = p2*v2

• 20 psia * 10 cu. Ft. = 40 psia * 5 cu. Ft

• If the volume reduces to half of its original size, the absolute

pressure doubles (a 50% reduction in total volume will cause
a 100% increase in absolute pressure)
 P1 V1 = P2 V2

160.0
140.0
120.0
100.0
psia

80.0
60.0
40.0
20.0
0.0
0 5 10 15
volume
 P1 V1 = P2 V2

1000.0

100.0
log psia

10.0

1.0
1 10 100
log volume
 Compressor Temperature

• Theoretical compressor calculations use

absolute temperature (deg Rankin)

• Absolute temperature (R) = degrees F + 460

• (60 deg F + 460) = 520 deg R
 Boyle’s 2nd Law
• If the volume of a given quantity of gas is held constant, the
pressure varies directly with the absolute temperature.

• When the volume of gas remains the same and the absolute
temperature of the gas increases, the pressure increases
proportionately.

• P1/p2 = t1/t2

• 100 deg F = 560 deg R

• 200 deg F = 660 deg R

• 660 / 560 = 1.18

• 100 psia pressure raised from 100 deg F to 200 deg F will
cause the pressure to raise to 118 psia.
 P1/P2 = T1/T2

40.00
35.00
30.00
psia

25.00
20.00
15.00
10.00
500 700 900 1100 1300
absolute temp
 Charles’ Law
• If the absolute pressure remains constant, the
volume of a gas increases proportionately
with any increase in the absolute temperature.

• As the temperature of the gas increases, the

volume increases if the pressure remains the
same.

• V1/v2 = t1/t2

• V = cubic foot (cu. Ft.)

• T = degrees Rankin = degrees F + 460

 V1/V2 = T1/T2

24.00
22.00
20.00
volume

18.00
16.00
14.00
12.00
10.00
500 700 900 1100 1300
absolute temp
 Ideal or Basic Gas Law
• (P1*v1)/ t1 = (p2*v2)/ t2
• P = absolute pressure
• V = volume
• T = absolute temperature

• If this equation is not balanced, it means that:

• There is leakage.
• Internal (rings, valves, unloaders)
• External (packing, etc)

• There is temperature entering or leaving

the process.
 Critical Pressure & Temperature
• Gases can be liquified by raising the
pressure or lowering the temperature.

• The highest temperature at which a gas

can be liquified by increasing pressure
alone is referred to as the critical
temperature.

• The pressure required to liquify a gas at its

critical temperature is called its critical
pressure.
 Formulas

Displaced Volume – The volume the piston displaces as it move from Top
Dead Center (TDC) to Bottom Dead Center (BDC) of the cylinder.

Clearance Volume – The volume remaining in the cylinder when the

piston reaches Top Dead Center (TDC).
= Total Volume – Displaced Volume
 Formulas
Force = Pressure * Area

Work = Force * Distance (stroke)

Power = Work/Time

Compressor Cylinder Horsepower Relationships

Brake Horsepower = Indicated Horsepower + Friction Horsepower

Brake Horsepower = Indicated Horsepower / compressor mechanical efficiency

Friction Horsepower
Ring/Liner friction
Wrist pin/Bushing friction
Connecting rod bearing/ crankshaft friction
 Compressor Indicated Horsepower
• The horsepower measured at the compressor
piston face with an indicating device (eg: 100 IHP).

• Includes all thermodynamic losses

• Thermodynamic losses (15) are equal to indicated

horsepower (eg: 100) minus theoretical horsepower
(eg: 85)

• Thermodynamic or compression efficiency equals

theoretical horsepower (85) divided by indicated
horsepower (100) = .85 = 85%
 Indicated Horsepower
• The horsepower measured at the power
piston face with an indicating device
• Includes all thermodynamic losses
• PLAN/33,000
• P = IMEP
• L = STROKE
• A = AREA
• N = RPM
• 33,000 ft-lb/minute = 1 Horsepower
 Compressor

Crankangle Plots
Used for Performance Information
and Mechanical Condition
 Crank-angle Sweep

TDC
TDC BDC
Compressor (Press Vs Crank-Angle)

TDC BDC TDC

Toe Pressures from Pressure PT

Crank-end
Discharge Head-end
toe pressure Discharge
toe pressure

TDC BDC TDC

Head-end Crank-end
Suction toe Suction toe
pressure pressure
Toe Pressures from Pressure Vs. Crank-angle

Crank-end
Discharge Head-end
toe pressure Discharge
toe pressure

TDC BDC TDC

Head-end Crank-end
Suction toe Suction toe
pressure pressure
Pressure & Vibration Vs. Crank-Angle
 Compressor Volume Sweep

TDC PISTON OR PERCENT OF STROKE BDC PISTON

POSITION POSITION
 Compressor (PV Diagram)

In a double acting compressor cylinder, the same action is

taking place on the crank end of the cylinder as the head end
of the cylinder. Consider the crank end of the cylinder is filled
with gas at suction pressure (1) and the head end of the
cylinder is filled with gas at discharge pressure (2), having just
discharged a volume of gas. The piston is at top dead center.
 Compressor (PV Diagram)

As the piston moves toward the crank end, the gas in the
crank end cylinder volume is being compressed (1).
Immediately after compression begins, the suction valves
close because the pressure in the crank end is now slightly
higher than the pressure in the suction line. Simultaneously,
the gas in the head end is beginning to expand (2).
 Compressor (PV Diagram)

When the pressure in the head end drops below the pressure in
the suction line (1), the differential pressure causes the suction
valve to open, filling the head end with gas at suction pressure.
In the crank end, the pressure has increased. When the
pressure reaches a point slightly above discharge pressure (2),
the discharge valves open and the gas is discharged.
 Compressor (PV Diagram)

At this time, the piston has passed through TDC and his moving
back toward the head-end. The piston reaches the end of its
stroke compressing the gas in the head end to discharge
pressure (2),and expanding the gas in the crank end to suction
pressure (1).
 Compressor
(Head End PV Diagram)

A – Expansion B – Suction
C – Compression D – Discharge
 Compressor
(Crank End PV Diagram)

A – Expansion B – Suction
C – Compression D – Discharge
Compressor Volumetric Efficiencies
• Suction Volumetric Efficiency (VEs) is the
percent of the cylinder end's displacement
that the piston passes through after the
internal cylinder pressure drops to suction
pressure as measured at the end of the
stroke.

• Discharge Volumetric Efficiency (VEd) is the

percent of the cylinder end’s displacement
that the piston passes through after the
internal cylinder pressure reaches discharge
pressure as measured at the end of the
stroke.
 Compressor
(HE Volumetric Efficiencies)
 Compressor
(CE Volumetric Efficiencies)
 Compressor
(De-Activated Volumetric Efficiencies)
 Volumetric Efficiency Decreases When
the Compression Ratio Increases

The flow rate decreases with an increase in compression ratio

Volumetric Efficiency Decreases When Clearance
Volume Increases (Flow rate decreases)
 Theoretical Temperature

• Calculated from suction temperature,

k-value and compression ratio

• T2 = ((T1+460) * R^((K-1)/K))-460
T2 = Theoretical discharge temperature
T1 = Beginning temperature degrees F.
R = Absolute compression ratio
(absolute disch pr / absolute suct pr)
K = Ratio of specific heats
Theoretical Temperature Example
T1 = 60 deg F
R = 200 psia / 100 psia = 2
K = 1.28
T2 = ((T1+460)*R^((K-1)/K))-460
T2 = ((60+460)*2^((1.28-1)/1.28))-460
T2 = (520*2^(.28/1.28))-460
T2 = (520*2^(.21875))-460
T2 = (520*1.1637)-460
T2 = (605.124)-460
T2 = 145 deg F
 Capacity

• scfd = (dv * VE * rpm * 1440 * pressure correction *

temperature correction) / Z
• scfd = flow in std cu ft of gas/day
• dv = area*stroke/1728
• VE = volumetric efficiency
• rpm = compressor shaft revolutions per minute
• pressure correction = absolute pr / standard pr
• temperature correction = 520/absolute temperature
• Z = compressibility (compensates for the compression
characteristics of the gas)
• Calculated at suction and/or discharge conditions
• mmscfd = scfd/1000000
 Flow Balance

• The calculated suction flow rate divided by the

calculated discharge flow rate.

• A result greater than 1.0 indicates gas leaking

out of the cylinder into a low pressure area.

• A result less than 1.0 indicates gas leaking into

the cylinder from a high pressure area.

• FB = 1.9443 / 1.9198 = 1.013 (HE example)

 Application of Smoothing
• Smoothing is a method of correcting the collected pressure
data for inherent indicator passage resonance on different
types of compressors.
• The indicator passage from the cylinder surface to diaphragm
of the pressure sensor commonly changes diameter, length,
and physical geometry.
• These changes are the cause of the acoustical resonance
somewhere in the 360 degrees of crank-angle pressure data.
• This acoustical resonance typical does not effect the
horsepower measurement because it is sinusoidal in nature.
• If this acoustical resonance is present during the compression
and re-expansion portions of the pressure trace, it can
significantly effect the accuracy of the Toe pressure and
Volumetric Efficiency picks.
• Channel resonance correction needs to be applied correctly.
 Application of Smoothing

Crank-end
Discharge Head-end
toe pressure Discharge
toe pressure

TDC BDC TDC

Head-end Crank-end
Suction toe Suction toe
pressure pressure

Some pressure data requires little or no smoothing

Application of Smoothing

Some pressure data requires little or no smoothing

 Application of Smoothing

Some pressure data requires medium amounts smoothing

 Application of Smoothing

Some pressure data requires medium amounts smoothing

 Application of Smoothing

Some pressure data requires medium amounts smoothing (3 passes)

 Application of Smoothing

Some pressure data requires excessive amounts smoothing

 Application of Smoothing

Some pressure data requires excessive amounts smoothing

 Application of Smoothing

Some pressure data requires excessive amounts smoothing (11 passes)

Application of Smoothing

Be careful not to over-smooth and change the horsepower

 Application of Smoothing

Be careful not to over-smooth and change the horsepower

Application of Smoothing

This is an example of too much smoothing

Cylinder Pressure With Suction & Discharge Line Overlay
With Nozzle Traces Added
With Discharge Bottle Trace Added
Expanded Suction Events
Expanded Discharge Events
Typical Compressor Leakage
 Leakage Characteristics
• A leakage can only occur from a high pressure to a
low pressure.
• A valve only leaks when it is closed.
• If a valve ultrasonic pattern is noisier when the valve
is closed than when the valve is open, it is probably
leaking.
• Head end suction leakage can be very similar to
crank end discharge valve leakage.
• Crank end suction leakage can be very similar to
head end discharge valve leakage.
• Be careful with crosstalk from head end to crank
end.
Compressor HE Valve Leakage Patterns

Discharge leakage area

Suction leakage area

 5S
4S 6S

HE
3D 1D
2D
 5S
4S 6S

HE
3D 1D
2D
1S 2S

HE
4D 3D
Compressor CE Valve Leakage Patterns

Discharge leakage area

Suction leakage area

 5S
4S 6S

CE
3D 1D
2D
 5S
4S 6S

CE
3D 1D
2D
1S 2S

CE
4D 3D
 Before the Analysis
• Research the maintenance history of the unit.
• Review previous analysis reports.
• Talk to people closely associated with the unit
about potential problems.
• Verify TDC reference accuracy.
• Inspect indicator valves and passages.
• Verify pressure transducer performance.
 Initial Site Inspection

• Visual indicators of load

• Packing vent emissions
• By-pass, vent, blow-down, relief and recycle
valve leakage
• Pad, base, line, vessel and accessory
vibration
 Initial Site Inspection
Ultrasonic survey of external leaks (head
gaskets, valve caps, pockets, unloaders,
flanges, packing glands and rod packing,
pneumatic control lines and actuators)

Ultrasonic Leak Survey

 Initial Compressor Visual Inspection

• Temperature of valve caps, packing vents,

capacity control devices, recycle and vent
valves
• Feel and listen for knocks to identify
potential problems.
• Gather all manual panel, temperature and
IR sensor test point data if dynamic
pressure data is to be collected next.
Compressor End Manual Panel Points

• Suction reference pressure per stage

• Discharge reference pressure per stage
• Pocket position per cylinder end (load
step)
• Predicted or measured flow rate
• Predicted BHP/torque
• Pump and bearing oil pressure
(separable units)
Compressor Manual/IR Temp. Points

• Suction reference temperature

• Discharge reference temperature
• Valve cap temperatures
• Packing vent temperature
• Cooling water in and out temperatures
• Oil in and out (separable units)
• Scavenge/air cylinder suction and
discharge temperatures
 Compressor Sensor Points
• Head and crank end dynamic DC pressure
• Suction and discharge pressure overlays (optional)
• Head end high frequency and raw vibration
• Cross-head raw and high frequency vibration
• Valve cap ultrasonic and/or high frequency vibration
• Closed clearance pocket ultrasonic
• Dynamic rod run-out (optional)
• Scavenge cylinder suction and discharge ultrasonic
• Scavenge cylinder high, low and raw frequency
vibration
• Compressor frame main bearing raw & high
frequency vibration (for separable frames)
 Compressor End Analysis
• Collect all manual panel, manual temp and
infrared data just prior to or just after
collecting dynamic pressure information
• Gather all sensor point information while
holding the unit load as constant as possible
• Perform “dynamic” troubleshooting
(unloaders & pockets) using auto-scan
features
• View manual and performance reports to
determine if collected data is in memory and
if additional data collection or troubleshooting
is required
 Analyzer Equipment Setup (Encoder)

Crank-angle Encoder
• Mechanical or
friction drive
• No slippage
• Shaft properly
aligned
• Solid on floor
• Avoid excessive
tension
• Angular velocity
issues
 Analyzer Equipment Setup
(Once Per Turn/n-turn)

Magnetic Pickup
• Magnetic or
optical pickup
• Not tracking
crankshaft by
degree
• Works better
on electric
driven
compressors
• No angular
velocity data
 (TDC Identification and Synchronization)
TDC Marks
(accuracy rules!) • Reference mark
on flywheel lined
up with reference
mark on frame
• Couplings can
cause
synchronization
errors on
separable
machines
• Second stationary
mark on frame
eliminates
parallax errors
 TDC Accuracy

• Shifting the data 2 degrees to the right on a

KVS-48 in injection service caused:
• Power IHP to increase by 7%
• Compressor IHP to decrease by 8.6%
• Shifting the data 2 degrees to the right on a
low ratio pipeline compressor service caused:
• Compressor IHP to decrease by 4.2%
• The lower the VE, the greater the induced
error.
0 Offset on Compressor
+2 Offset on Compressor
 TDC Determination

• Cylinder obstruction method

• Dial indicator method
• Existing factory marks
• Determining from collected data
• Guess
 Verifying/Marking TDC (Positive Stop
Method)
• No dial indicator is required; however the cylinder head
or valve cap must be removed so the unit must be blown
down.
• The basis of this method is that TDC can be determined
from the midpoint of two cylinder positions marked on
the flywheel. These positions are determined by the
placement of the cylinder at a fixed distance from TDC.
This fixed distance is determined by the hard stop used.
• The first step in this process is to obtain the hard stop.
The stop can be inserted into the cylinder by removing
the valve cap or the cylinder head. If the cylinder head is
removed, obtain a stiff 1/4-inch rod and sharpen one end
to form a pointer. The length of the rod should be set,
such that the piston stops at 2 to 10 degrees below TDC.
 Verifying/Marking TDC (Positive Stop
Method)
• Attach pointer to a rigid strip of steel and drill appropriate
mounting holes in it. The strip must not deflect when the
piston contacts it. The strip is placed across the center of
the cylinder bore and bolted to secure it. If a valve cap is
removed, place the stop between the head and piston.
• Once the positive stop mechanism is installed, manually
rotate the crankshaft in the clockwise direction until the
piston end comes in contact with the stop. Mark this
position on the flywheel in reference to a fixed pointer.
• Rotate the crankshaft in the opposite direction until the
piston end comes in contact with the stop. Mark this
position on the flywheel. Using a highly accurate
measurement device, determine the middle between the
two marks. This is the location of TDC (+/- ½ degree
accuracy required).
 Verifying/Marking TDC (Dial Indicator
Method)
• Rotate the compressor crankshaft till the reference
cylinder is approximately at ODC.
• Install a dial indicator to measure crosshead movement.
• Position the dial indicator, such that the indicator is
touching the crosshead or crosshead shoe.
• Rotate the compressor until the piston is near TDC (the
dial indicator will stop moving). Zero the dial indicator.
• Rotate the crankshaft in the opposite direction until it
reaches 0.030”. Rotate the crankshaft back in the other
direction until the dial indicator reads 0.015”. Mark this
location on the flywheel in reference to a fixed pointer.
 Verifying/Marking TDC (Dial Indicator
Method)
• Rotate the crankshaft in the same direction until the dial
indicator reads 0.030” (the compressor will progress
through TDC and past it, so the dial indicator will read 0
and then go back to 0.030”).
• Rotate the crankshaft back the other direction until the
dial indicator reads 0.015”. Mark this location on the
flywheel in reference to the same fixed pointer used
above.
• Using an accurate distance measurement, mark the
center between these two marks on the flywheel. This is
the location of TDC (+/- ½ degree accuracy required).
• Rotate the crankshaft back to the marks made (using the
procedure above) and check the locations of the marks.
If the locations are repeatable, then the TDC marking is
satisfactory.
 On-Machine Analysis

• Analysis done at the machine

• Using all the capabilities of the Analyzer while at
the machine (Calculate, Zoom)
• Observing the Temperatures and Operating
parameters
• Analyzing real-time Pressure, Vibration and
Ultrasonic data in the Auto-Scan Mode
• Viewing the reports and plots for data
confirmation and integrity
• Knowing about 80% of the information that will
be reported before leaving the compressor
What You Should Know From the Compressor Test

• Determine the mechanical condition of each compressor

valve
• Identify flow restrictions or excessive pressure drops
• Find leaking rings
• Detect loose piston on the rod
• Determine if the pockets are leaking
• Evaluate the effectiveness of the capacity control and
unloader devices
• Locate external process leaks including packing
• Survey the bearings, pins and bushings for extra
clearance
• Measure the HP, capacity and efficiency of each cylinder
• Determine the effective operating clearance volume
• Other vibration related problems (looseness, alignment,
etc.)
 Reports

• Compressor Performance
• Manual Panel, Temperature/IR
• Economic
• Set-up Data
• Prioritized Deficiency List
 Compressor Performance Report

Without an accurate TDC, the report information has no value!

 Compressor Performance Report

Capacity is the average

of the calculated flow rate
at both suction and
discharge conditions.
This number is a good
indicator of the actual
capacity only when the
cylinder is healthy and all
collected data is accurate
IHP accuracy is not
dependent on the IHP/MMSCFD is
cylinder health;
however, the IHP/calculated average capacity
geometry, TDC
accuracy, and
sensor linearity must
be accurate.
 Compressor Performance Report

These items are used in the flow calculation at suction conditions. All 3 can be
affected by the mechanical condition of the cylinder. Even in a healthy cylinder,
the values could be wrong. The temperature at the cylinder valve port is difficult to
obtain. The pressure and volumetric efficiency accuracy can be affected by
channel resonance. The pressure can be affected by the sensor zero and
linearity.
 Compressor Performance Report

Absolute
compression ratio

These items are used in the flow calculation at discharge conditions. All 3 can be
affected by the mechanical condition of the cylinder. Even in a healthy cylinder,
the values could be wrong. The temperature at the cylinder valve port is difficult to
obtain. The pressure and volumetric efficiency accuracy can be affected by
channel resonance. The pressure can be affected by the sensor zero and
linearity.
 Compressor Performance Report

The minimum reversals in

degrees are calculated
using both the gas load
and inertia loading. The
mass in the setup data
should include all
reciprocating mass
except the connecting rod
weight. A “T” indicates
that the minimum reversal
These are the % of the
occurs in tension.
rod load limits in the
setup file and are
calculated from gas loads
only. Any values close to
100 would require
viewing of the actual rod
load plots.
 Compressor Performance Report

These are the average

calculated capacities for
each stage. They should
have a reasonable
agreement for the same
product stream. The
calculated capacities
have a tendency to
increase when there are
internal cylinder
leakages, while the actual
capacities are
diminishing.
These values are
extremely dependent on
the TDC accuracy.
 Compressor Performance Report

calculated Measured
difference (from page 1)
The Theoretical
discharge temperature
is calculated from the
The delta temperature will
measured suction
elevate as the cylinder leakage
temperature, the
rates increase.
compression ratio of the
toes and the K-value of
the gas.
 Compressor Performance Report

In a healthy cyl
end, the SWR
calculation will
normally agree
closely with the
set clearance if
the set
calculated clearance is an
accurate value.
difference

The Set value is used in These are the calculated clearances using
the creation of the the GPSA method. The actual clearance is
theoretical PV models, not needed to make this calculation. The
the log/log plots, and avg value should be used as the set
the polytropic values clearance for good diagnostic plots of
(n). It must represent theoreticals. In a healthy cylinder, with an
the actual clearances in accurate TDC, the Suc and Dis
the individual cylinders calculations will be close together.
ends.
 Compressor Performance Report

These values are calculated from the

supplied gas analysis information.
 Compressor Performance Report

If accurate gas The N ratio is These N values are

data is calculated from the
available and N comp/N Exp
slope of the
the cylinder And is compression and
end is healthy, comparable to re-expansion lines and
the Adiabatic K flow balance generally agree with
and the when all data is each other in a healthy
Polytropic N accurate. cylinder. Accurate
values will be clearance data is
very close. required.
Compressor Performance Report

The theoretical These are the

IHP and calculated capacities at
efficiency are suction and discharge
determined by conditions. Their
comparing the accuracy is dependent
measured IHP to on the health of the
the theoretical cylinder and the
HP. accuracy of the
collected data.
 Calculated Capacity
Is only valid for a healthy cylinder
Suction calculated capacity goes up with a
suction valve, packing or ring leak
Suction calculated capacity goes down with a
discharge valve leak
Discharge calculated capacity goes up with a
discharge valve leak
Discharge calculated capacity goes down with a
suction valve leak or ring leak
The average of the calculated suction and
discharge capacity goes up significantly with
ring leakage and generally up slightly for valve
and packing leakage
 Flow Balance

Accurate flow balance is dependent on the accuracy of the

TDC reference, toe pressures, suction and discharge
temperatures at the valve ports, gas compressibility, and
VE picks.

Flow balance by itself is not a reliable way to determine the

health of the compressor cylinder.

Do not adjust the TDC offset in an effort to improve flow

balance alone.
Let’s try out our new abilities
Double-Acting Cylinder with 4 Valves per End

• A Destroyed
discharge valve

• B Discharge valve in
suction port

• C Suction valve in
discharge port

• D Indicator passage
drilled into
discharge cavity

• E None of the above

Double-Acting Cylinder with 4 Valves per End
• A Excessive
discharge valve
leakage

• B Wrong reported
clearance

• C Excessive
suction valve
leakage

• D Rings leaking in
one direction

• E None of the
above
Double-Acting Cylinder with 4 Valves per End
• A Excessive
discharge valve
leakage

• B Excessive
suction valve
leakage

• C Excessive ring
leakage

• D All of the above

• E None of the
above
Double-Acting Cylinder with 4 Valves per End
• A Discharge
valve leakage
in both ends

• B Suction valve
leakage in
both ends

• C Suction
leakage in
head end &
discharge
leakage
in crank end

• D Ring leakage

• E None of the
above
Double-Acting Cylinder with 4 Valves per End
• A Head end
discharge
valve leakage

• B Crank end
suction valve
leakage

• C Moderate ring
leakage

• D Excessive
power losses

• E None of the
above
Double-Acting Cylinder with 4 Valves per End
• A Head end
discharge
valve flutter

• B Crank end
suction valve
flutter

• C Indicator
passage
channel
resonance

• D Ring leakage

• E All of the above

• F None of the
above
Double-Acting Cylinder with 4 Valves per End
• A Head end
discharge valve
flutter

• B Crank end
suction valve
leakage

• C Indicator
passage
channel
resonance

• D Ring leakage

• E All of the above

• F None of the
above
Double-Acting Cylinder with 4 Valves per End

• A Head end
suction valve
leakage

• B Crank end
suction valve
leakage

• C Ring leakage

• D None of the
above
Double-Acting Cylinder with 4 Valves per End
• A Slight crank
end suction
valve leakage

• B Slight crank
end discharge
valve leakage

• C Slight head
end discharge
valve leakage

• D Ring leakage

• E None of the
above
Double-Acting Cylinder • A Suction and
with 4 Valves per End discharge
valve leakage

• B Set clearance
volume is
smaller than
actual

• C Set clearance
volume is
larger than
actual

• D Ring leakage

• E None of the
above
 • A Head end suction
Double-Acting Cylinder valve leakage
with 6 Valves per End
• B Head end
discharge valve
leakage

• C Crank end
suction
valve leakage

• D Crank end
discharge valve
leakage

• E Ring leakage

• F None of the
above
Double-Acting Cylinder
• A Top valve
with 6 Valves per End indicates
leakage

• B Bottom valve
indicates
insufficient lift

• C Middle valve
indicates
restriction

• D Bottom valve
indicates
spring damage

• E Both A and D

• F Both A and C
 • A Top valve is a
Double-Acting Cylinder leaking
with 2 Valves per End suction valve

• B Top valve is
a leaking
discharge
valve

• C Top valve is
a suction
valve with a
sticking
component

• D Both A and C

• E None of the
above
 • A Cylinder has
Double-Acting Cylinder slight discharge
valve leakage
with 6 Valves per End
• B Cylinder has
moderate
discharge valve
leakage

• C Cylinder has
moderate suction
valve leakage

• D Cylinder has
slight suction
valve leakage

• E Top two valve

traces indicate
leakage

• F Both C and E
Unloaded Head End Cylinder
• A Loose piston
on rod

• B Piston hitting
crank end
head

• C Piston hitting
head end
head

• D None of the
above
 Atmospheric Pressure

The pressure of the atmosphere at your current location

corrected to sea level.

True or False? ______

 Standard Pressure

The pressure of the atmosphere at sea level and is the

same for every company at all locations.

True or False? ______

 Compression Temperature

Which of the following pure gases will get the hottest

when compressed to an identical compression ratio?

Methane ______
Nitrogen ______
 Packing Leakage

Packing leakage severe enough to show up in the PV

trace looks similar to what other crank-end defect? Check
all that apply.

Ring leakage ______

Suction valve leakage ______
Discharge valve leakage ______
 Unloader Leakage

Finger or plug unloader leakage severe enough to show

up in the PV trace looks similar to what other cylinder
defect? Check all that apply.

Ring leakage ______

Suction valve leakage ______
Discharge valve leakage ______
 Suction Valve Leakage

Suction valve leakage severe enough to show up in the PV

trace has what characteristics? Check all that apply.

Flow balance less than 1 ______

Suction cavity significant temp increase ______
Discharge temperature increase ______
Discharge VE increase ______
Calculated suction flow rate increase ______
Discharge delta temperature increase ______
 Discharge Valve Leakage

Discharge valve leakage severe enough to show up in the PV

trace has what characteristics? Check all that apply.

Flow balance less than 1 ______

Suction cavity significant temp increase ______
Discharge temperature increase ______
Discharge VE increase ______
Calculated suction flow rate increase ______
Discharge delta temperature increase ______
 Ring Leakage

Ring leakage severe enough to show up in the PV trace has

what characteristics? Check all that apply.

Flow balance greater than 1 ______

Suction cavity significant temp increase ______
Discharge temperature increase ______
Calculated average flow rate increase ______
Discharge delta temperature increase ______
 TDC Offset

Shifting the pressure trace to the right will result in ? Check all
that apply.

Lower compressor IHP ______

Lower power cylinder IHP ______
A rise in the apparent mech engine eff% ______
Higher calculated average flow rate ______
 IHP Measurement
Which of the following have an effect on the IHP
measurement? Check all that apply.

Bore ______
Stroke ______
Rod length ______
K-value ______
Compressibility ______
Measured RPM ______
Transducer 0 offset ______
Transducer linearity ______
 Flow Measurement
Which of the following have an effect on the calculated
flow rate? Check all that apply.

Bore ______
Stroke ______
Rod length ______
K-value ______
Compressibility ______
Measured RPM ______
Transducer 0 offset ______
Transducer linearity ______