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sensor cali-
brated to the material, an in-situ
measurement of probe sensitivity
using a shaft calibrator kit will help
account for shaft curvature and rod-
to-rod variability. Error in the B
1
measurement is magnified when it
is multiplied by the correction fac-
tor and results in significant error
in the calculated value of B
2
.
Even if the measurement of B
1
is
perfect, any error in the measure-
ment of the dimensions L
1
and L
2
(the components of the correction
factor), will also produce an error
in B
2
. Since the correction factor is
always greater than 1, it amplifies
the errors in B
1
.
Configuration Mitigates Errors
in Assumptions
Configuration provides a way to
mitigate the effects of piston rod
flex and piston thermal growth. To
reduce the effects of piston rod flex,
the instantaneous rod drop reading
should be taken when the piston
rod is in tension. To help reduce the
effects of thermal growth as the load
changes, dc-coupled waveforms
should be collected at each load
step, and the trigger angle chosen
so that the change between load
steps is minimized. And, on large
pistons, the thermal growth may be
enough to move the rod out of the
range of the proximity probe if it is
under the rod, or damage the probe
if it is mounted above the rod.
These precautions must be
accounted for when installing the
probe and setting its gap.
Real World Example of a Rod
Drop Installation
A North American refinery oper-
ates three balanced-opposed, hori-
zontal reciprocating compressors in
recycle hydrogen service. Two of the
compressors were installed in the
Rod Drop - Northwest Cylinder
10
0
20
30
40
50
60
70
80
6-Jul-00 25-Aug-00 14-Oct-00 3-Dec-00 22-Jan-01
R
o
d
D
r
o
p
(
m
i
l
)
FIG. 4A
Rod Drop - Southwest Cylinder
10
0
20
30
40
50
60
70
80
6-Jul-00 25-Aug-00 14-Oct-00 3-Dec-00 22-Jan-01
R
o
d
D
r
o
p
(
m
i
l
)
FIG. 4B
M A C H I N E R Y M E S S A G E
1Q04 ORBIT 59
early 1970s and one in the mid
1980s, and all were manufactured
in the US. All compressors have a
rod drop transducer on each cylin-
der, two Velomitor
transducers on
the frame, and a Keyphasor
trans-
ducer. The rod drop system went
into service in the mid 1990s on all
three machines.
The customer found that the rod
drop system often reported actual
wear that differed from measured
wear by as much as 60 mils (1.5
mm). The customer asked Bently
Nevada to identify changes in the
rod drop system installation that
would improve its accuracy. We
started by examining the applica-
tion assumptions. First, the
machine needed more than 600 hp
and ran at less than 500 rpm. The
piston rod L/D was less than 30,
and the correction factor was less
than 2. Per the four assumptions
noted previously in this article,
these characteristics indicated that
a properly installed and configured
rod drop system would indeed pro-
vide reasonably accurate indica-
tions of rider wear.
During this review, one significant
process effect was also noted: For a
short period of time each month,
the process steam was changed
from hydrogen to nitrogen.
Rod Drop - Northeast Cylinder
0
10
20
30
40
50
60
70
80
6-Jul-00 25-Aug-00 14-Oct-00 3-Dec-00 22-Jan-01
R
o
d
D
r
o
p
(
m
i
l
)
FIG. 4C
Rod Drop - Southeast Cylinder
0
10
20
30
40
50
60
70
80
6-Jul-00 30-Jul-00 23-Aug-00 16-Sep-00 10-Oct-00 3-Nov-00 27-Nov-00 21-Dec-00 14-Jan-01 7-Feb-01
R
o
d
D
r
o
p
(
m
i
l
)
Periodic spikes in trend data show changes
in rod drop when process stream changes
from hydrogen to nitrogen
FIG. 4D
Measured versus indicated wear results for eight month period. All units in inches. | TABLE 1
NORTHWEST 21.744 21.644 21.938 0.147 0.107 0.040 0.030
SOUTHWEST 21.752 21.652 21.941 0.144 0.077 0.067 0.053
NORTHEAST 21.745 21.645 21.945 0.150 0.115 0.035 0.024
SOUTHEAST 21.759 21.659 21.944 0.143 0.100 0.043 0.029
CARRIER PISTON RIDER PISTON PISTON MEASURED INDICATED
OD OD OD TO BORE TO BORE WEAR WEAR
31-MAY-00 31-JAN-01 7 DAY AVG
M A C H I N E R Y M E S S A G E
60 ORBIT 1Q04
Because the compression character-
istics of nitrogen differ greatly from
those of hydrogen, the suction and
discharge pressures changed, and
the rod load and thermal growth of
the piston were very different. The
change in rod load also changed the
piston rod flex characteristics. As a
result, the rod drop readings
changed significantly when the
machines processed nitrogen.
Because the time the machines
processed nitrogen was very short
compared to the time they pro-
cessed hydrogen, we recommended
that the plant disregard the rod drop
readings during the nitrogen cycle.
When we looked at the configura-
tion of the monitor and probes, sev-
eral discrepancies were found. First,
the L
1
and (L
1
+L
2
) measurements
were found to be inaccurate. In
addition, the instantaneous rod
drop readings were taken when the
piston rod was in transition from
compression to tension rather than
when it was in tension. This was
determined from analytical models
because cylinder pressure-volume
(PV) data was not available. In
addition, the probes had not been
calibrated to the piston rod mate-
rial. Once the curves had been run
in the field, the data was then
entered into the monitor configu-
ration.
After making these corrections,
Data Manager