Professional Documents
Culture Documents
Compressor Analysis
Techniques
Azonix-Dynalco
Kathy Boutin, B.Sc.
Ben Boutin, P.Eng.
1
Short Course Outline
! Analysis Programs
! Characterizing engines and compressors
! Data types
! Testpoint Locations
! Sequence of events
! 2-stroke engines
! 4-stroke engines
! Compressors
! Analyzing Engine Faults
! Analyzing Compressor Faults
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© 2002 DYNALCO CONTROLS SHORT COURSE: BASIC ENGINE & COMPRESSOR ANALYSIS TECHNIQUES 3
Analysis Programs
! Objectives
! Types of analysis
! Analysis process
2
Analysis Programs
Objectives of analysis programs
Analysis Programs
Types of machinery analysis
! Maintenance Analysis
! Identifies incipient failure so that you can turn unscheduled
maintenance into scheduled maintenance
! Helps avoid in-service failures
! Goal is to reduce maintenance cost
! Performance Analysis
! Characterizes the engine/compressor operating potential
! Efficiency
! Fuel consumption
! Horsepower
! Throughput
3
Analysis Programs
The analysis process
! Data Types
! Testpoint Locations
4
Characterizing Engines and Compressors
Special data types
! Process data
! Tell about the process
! Examples: suction temperature and pressure
! Phase-marked data
! Data is referenced to the flywheel
! Example: pressure versus time data
! Non-phased data
! Sampling is a function of time only
! Example: acceleration data from a
turbocharger bearing
! Once-per-degree
! Shaft encoder
! 360 pulses per
revolution
! Better accuracy
! Once-per-turn
! Magnetic, active or
optical pickups are
common
! 1 pulse per revolution
! Usually permanently
mounted
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5
Characterizing Engines and Compressors
Example of phase-marked pressure (PT)
1700
1600
1500
1400
Head and
1300
crank end
pressure
Pressure (psig)
1200
traces on a
1100
compressor
1000
cylinder
900
800
700
600
500
! Common applications:
! Structural vibration
! Supports, foundations
! Turbochargers
! Oil and water pumps
! Pressure pulsation
6
Characterizing Engines and Compressors
Example of free-running, non-phased, spectrum data
UNIT #4-E Testpoint OPEH 7/17/2002 10:51:55 AM
1.0
0.122 at 652.5
0.110 at 487.5
0.6 0.098 at 1627.5
0.079 at 2932.5
bolts. Mils peak-
0.073 at 1357.5
0.061 at 1140.0
peak, oil pump
0.5
0.061 at 1020.0
0.061 at 975.0
end, horizontal
0.4 direction.
4 times
0.3 run speed Engine speed
323 RPM
0.2
0.1
0.0
0 500 1000 1500 2000 2500 3000
cpm
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Engine Data
Ignition secondary
• Inductive connection to unshielded
Cylinder pressure
spark plug cable
• Pressure transducer
• Multi-period sampling statistics
• Time domain data phased to
• Ignition secondary patterns
crankshaft position
• Peak pressure statistics
Ignition primary (not shown)
• Connection to primary box
• Ignition primary firing patterns
TDC Reference
• Shaft encoder Frame vibration (displacement)
• Magnetic pickup • Tri-axial accelerometer (H, V, A)
• Phased data taken at opposite corners of
• RPM engine frame
• Frequency domain data
© 2002 DYNALCO CONTROLS
7
Characterizing Engines and Compressors
Typical 2-stroke engine PT/VT
350 -
0 --------------
900
VT -
800
- 2L VT4
Pressure (psig)
700
-
600
- Scale 5.0
500
-
400
-
300
200 -
PT
100 -
0 --------------
0 45 90 135 180 225 270 315 360 405 450 495 540 585 630 675 720
Angle (deg)
8
Crosshead Vibration
• Standard accelerometer
Compressor Data
• Time domain data phased to
crankshaft position
• Relate to rod load
Valve cap temperatures
TDC Reference • Infrared temperature wand
• Shaft encoder • thermocouples, RTDs
• Magnetic pickup
Suction/discharge temperatures
• Phased data
• Infrared temperature wand
• RPM
• thermocouples, RTDs
CE PT --------------
600 -
-
- 4HD1 VT1
-
- Scale 3.0
550 - 145 DGF
-
-
-
HE PT ---------------
-
-
Pressure (psig)
9
Sequence of events
10
Sequence of events
for a 2 stroke engine
0
90 180 270 360
Crank Angle (Deg)
11
Sequence of events for a 2-stroke engine
PT: combustion
Pressure
• Speed of propagation is critical
•Too fast, detonation
•Too slow, soft fire
0
0 90 180 270 360
• Combustion is complete
• Pressure drives piston down
• As volume increases, pressure decreases
Pressure
0
0 90 180 270 360
12
Sequence of events for a 2-stroke engine
PT: exhaust blowdown
Pressure
0
0 90 180 270 360
0
90 180 270 360
Crank Angle (Deg)
13
Sequence of events for a 2-stroke engine
PT: scavenging
Pressure
0
0 90 180 270 360
0
0 90 180 270 360
14
Sequence of events for a 2-stroke engine
PT: compression
Pressure
• Temperature rises
0
0 90 180 270 360
0
0 90 180 270 360
15
Sequence of events for a 2-stroke engine
PT: end of cycle
Pressure
0
0 90 180 270 360
0
0 25 50 75 100
16
Sequence of events for a 2-stroke engine
PV: combustion
Pressure
• Speed of propagation is critical
•Too fast, detonation
•Too slow, soft fire
0
0 25 50 75 100
• Combustion is complete
• Pressure drives piston down
• As volume increases, pressure decreases
Pressure
0
0 25 50 75 100
17
Sequence of events for a 2-stroke engine
PV: exhaust blowdown
Pressure
0
0 25 50 75 100
0
0 25 50 75 100
18
Sequence of events for a 2-stroke engine
PV: scavenging
Pressure
0
0 25 50 75 100
0
0 25 50 75 100
19
Sequence of events for a 2-stroke engine
PV: compression
Pressure
• Temperature rises
0
0 25 50 75 100
0
0 25 50 75 100
20
Sequence of events for a 2-stroke engine
PV: end of cycle
Pressure
0
0 25 50 75 100
0
0 90 180 270 360
Crank Angle (deg)
21
Sequence of events for a 2-stroke engine
Cylinder vibration: combustion
126 234 Intake
108 252 Exhaust
Fuel 225 310
Pressure
VT4
0
0 90 180 270 360
Crank Angle (deg)
Ring clip
ULT
Pressure
VT4
0
0 90 180 270 360
Crank Angle (deg)
22
Sequence of events for a 2-stroke engine
Cylinder vibration: exhaust blowdown
126 234 Intake
108 252 Exhaust
Fuel 225 310
ULT
Blowdown
Pressure
VT4
0
0 90 180 270 360
Crank Angle (deg)
ULT
Pressure
VT4
0
0 90 180 270 360
Crank Angle (deg)
23
Sequence of events for a 2-stroke engine
Cylinder vibration: fuel intake
126 234 Intake
108 252 Exhaust
Fuel 225 310
ULT
Fuel
injection
Pressure
VT4
0
0 90 180 270 360
Crank Angle (deg)
ULT
Fuel valve
closure
Pressure
VT4
0
0 90 180 270 360
Crank Angle (deg)
24
Sequence of events for a 2-stroke engine
Cylinder vibration: ignition
126 234 Intake
108 252 Exhaust
Fuel 225 310
ULT
Pressure
VT4
0
0 90 180 270 360
Crank Angle (deg)
ULT
Pressure
VT4
0
0 90 180 270 360
Crank Angle (deg)
25
Sequence of events
for a 4 stroke engine
2 1
0
0 180 360 540 720
Crank Angle (deg)
1 Combustion 2 Exhaust 3 Intake 4 Compression
26
Sequence of events for a 4-stroke engine
PT/VT: peak firing pressure
137 417 Exhaust
Intake 300 565
Fuel 502 611
Pressure
su
re
P
2 1
0
0 180 360 540 720
Crank Angle (deg)
1 Combustion 2 Exhaust 3 Intake 4 Compression
su
re
P
2 1
0
0 180 360 540 720
Crank Angle (deg)
1 Combustion 2 Exhaust 3 Intake 4 Compression
27
Sequence of events for a 4-stroke engine
PT/VT: exhaust blowdown
137 417 Exhaust
Intake 300 565
Fuel 502 611
Pressure
2 1
0
0 180 360 540 720
Crank Angle (deg)
1 Combustion 2 Exhaust 3 Intake 4 Compression
Exhaust valve
closure
Pressure
4 3
0
0 180 360 540 720
Crank Angle (deg)
1 Combustion 2 Exhaust 3 Intake 4 Compression
28
Sequence of events for a 4-stroke engine
PT/VT: fuel intake
137 417 Exhaust
Intake 300 565
Fuel 502 611
Intake valve
closure
Pressure
4 3
0
0 180 360 540 720
Crank Angle (deg)
1 Combustion 2 Exhaust 3 Intake 4 Compression
Fuel valve
closure
Pressure
4 3
0
0 180 360 540 720
Crank Angle (deg)
1 Combustion 2 Exhaust 3 Intake 4 Compression
29
Sequence of events for a 4-stroke engine
PT/VT: end of cycle
137 417 Exhaust
Intake 300 565
Fuel 502 611
Pressure
su
re
P
2 1
0
0 180 360 540 720
Crank Angle (deg)
1 Combustion 2 Exhaust 3 Intake 4 Compression
P1 0
-2 672
2
P2 0
-2 192
2
P3 0
-2 432
2
0
P4
-2 72
2
P5 0
-2 552
2
P6 0
30
Sequence of events for a 4-stroke engine
PV: top dead center
2 1
0
0 25 50 75 100
3 COMBUSTION 4 EXHAUST 1 INTAKE 2 COMPRESSION
2 1
0
31
Sequence of events for a 4-stroke engine
PV: fuel intake & compression
2 1
0
0 25 50 75 100
3 COMBUSTION 4 EXHAUST 1 INTAKE 2 COMPRESSION
2 1
0
32
Sequence of events for a 4-stroke engine
PV: top dead center
4 3
0
4 3
0
33
Sequence of events for a 4-stroke engine
PV: power stroke
• Combustion is complete
• Pressure drives piston down
• As volume increases, pressure decreases
4 3
0
4 3
0
34
Sequence of events for a 4-stroke engine
PV: exhaust
4 3
0
4 3
0
0 25 50 75 100
3 COMBUSTION 4 EXHAUST 1 INTAKE 2 COMPRESSION
35
Sequence of events
for a double acting
reciprocating compressor
HE
Discharge
Pressure
2-3
Clearance Volume
Compression
Expansion
u
s
re
P
HE
Expansion
m
u
o
V
c
rn
a
le
C
3-4
1
Ps
4 Suction
Swept Volume HE
Suction
Volume
4-1
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36
Sequence of events in a reciprocating compressor
CE compression cycle
CE
Compression
Discharge 1-2
2
Pd 3
CE
Clearance Volume
Discharge
Pressure
2-3
Compression
Expansion
u
s
re
P
CE
Expansion
m
u
o
V
c
rn
a
le
C
3-4
1
Ps
Suction 4
Swept Volume
CE
Volume Suction
4-1
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Clearance Volume
Compression
Cylinder Pressure (Pcyl)
is above Ps and increasing to Pd.
Discharge valve opens when Pcyl
is greater than Pd (2).
Ps
1 Discharge AP
closed
AD
37
Sequence of events in a reciprocating compressor
PV: HE discharge event
Clearance Volume
Compression
Cylinder Pressure (Pcyl)
is above Pd and decreasing to Pd.
Discharge valves closes when Pcyl
equals Pd (3) at TDC.
Ps
1 Discharge
open AP
Clearance Volume
Compression
Cylinder Pressure (Pcyl)
is below Pd and decreasing to Ps.
Expansion
Suction valve opens when Pcyl is
less than Ps (4).
Ps
1 Discharge AP
4 closed
AD
38
Sequence of events in a reciprocating compressor
PV: HE suction event
Clearance Volume
Compression
Cylinder Pressure (Pcyl)
is below Ps and increasing to Ps.
Expansion
Suction valve closes when Pcyl is
equal to Ps (1) at BDC.
Ps
1 Discharge AP
4 Suction closed
AD
600
550
500
Pressure (psig)
450
400
350
300
250
0 25 50 75 100
Percent swept volume
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39
Sequence of events in a reciprocating compressor
PT: HE and CE
2 D
Discharge A 3 A
Pressure
CE PT
HE PT
su
re
P
su
re
P
Suction
Pressure 1 B
C 4 1
0 180 360
Crank Angle (Deg)
Head End: Expansion (A-B) Suction (B-C) Compression (C-D) Discharge (D-A)
Crank End: Compression (1-2) Discharge (2-3) Expansion (3-4) Suction (4-1)
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HE Discharge 4 5 6
0 180 360
Gas blowing noise is loudest at valve
opening and gradually diminishes as
gas velocity through the valve decreases.
40
Sequence of events in a reciprocating compressor
CE valve vibration
CE Discharge
CE Suction
0 180 360
HE Discharge
CE Discharge
CE Suction
HE Suction
0 180 360
41
Sequence of events in a reciprocating compressor
Typical HE PT/VT signature
K200 - C cylinder 4 9/23/1998 9:52:15 AM HE Period 5, CE Period 7
--------------
600 -
-
- 4HD1 VT1
-
- Scale 3.0
550 - 145 DGF
-
-
-
---------------
-
-- 4HD2 VT1
Pressure (psig)
500
-
- Scale 3.0
- 146 DGF
-
450 -
-
---------------
-
-
- 4HS1 VT1
400 -
- Scale 3.0
- 84 DGF
-
-
350 -
---------------
-
-
- 4HS2 VT1
-
300 - Scale 3.0
- 84 DGF
-
-
---------------
250
0 45 90 135 180 225 270 315 360
Crank Angle (deg)
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Quick Recap
42
Analyzing Engine Faults
! Combustion
! Mechanical
43
Combustion
Combustion
Chemical equation of combustion
44
Combustion
If only it was that simple…
Combustion
Why is combustion so variable?
45
Combustion
Results of poor combustion
Combustion
Typical faults
! Unbalance
! Dead cylinders
! Early firing
! Soft firing
! Detonation
! Pre-ignition
46
Engine balance
Engine Balance
Cylinder pressures (balanced engine)
Unit2 4/15/2002 9:21:55 AM
All cylinders - In Bank Order
800
700
P2 P8
600 P1 P4 P5 +10%
P3 P6
P7
Pressure (psig)
+2%
500 -2%
-10%
400
300
200
100
47
Engine Balance
Pressure rise rate (balanced engine)
Unit2 4/15/2002 9:21:55 AM
All cylinders - In Bank Order
35 P2
P4 P8
P5
30
P3 P6
25
P1
20 P7
Pressure (dp/dθ)
15
10
-5
-10
-15
Engine Balance
Cylinder pressures (unbalanced engine)
C2B-E 6/6/2001 7:22:02 AM
All cylinders - In Bank Order
700
600 2 7
3 8
500 +10%
4 5
Pressure (psig)
+2%
1 -2%
-10%
400 6
300
200
100
48
Engine Balance
Pressure rise rate (unbalanced engine)
C2B-E 6/6/2001 7:22:02 AM
All cylinders - In Bank Order
20 2 7
Highly variable
3
15
8
1 4 5
Pressure (dp/dθ)
10
6
5
-5
-10
Detonation
49
Detonation
Engine pressure signature comparisons
K203 - E 11/21/1996 2:13:03 PM
All cylinders - In Bank Order
600
550
500 P3 – Detonating
450 Cylinder
Pressure (psig)
400 P1
350
300 P2 P4
+10%
250 +2%
-2%
200 -10%
150
100
50
0
Detonation
Multiple PT cycles for a power cylinder (P3)
K203 - E - P3 PT3 11/21/1996 2:13:03 PM
550
500 Detonation Detonation Detonation
450
400
350
300 Misfire Misfire
250
200
150
100
50
0
500 1000 1500 2000 2500 3000 3500
Samples
50
Soft Firing
Soft Firing
Engine pressure signature comparisons
1A - E 5/22/1997 10:34:26 AM
All cylinders - In Bank Order
800
700 P1R
600
P3R P5R
P4R
Pressure (psig)
P1L P3L
500 P4L
P2R P5L
400 P2L
300
200
100
51
Soft Firing
PT: comparison to normal
20905-E Cylinder P8 7/14/1999 6:46:53 AM Period 3
550
137 223 Intake
500 118 242 Exhaust
Fuel 213 273
450
400
350 Normal
Pressure (psig)
300
250
200
Soft (Late)
150 Fire
100
50
Soft Firing
PV: comparison to normal
20905-E cylinder P8 7/14/1999 6:46:53 AM Period 3
550
500
450
400
350
Pressure (psig)
300
Normal
250
200
150
100
50
Soft (Late)
0 Fire
0 25 50 75 100
% swept volume
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52
Soft Firing
Another example comparing engine PTs
C402 - E 9/9/1998 12:02:53 PM
All cylinders - In Bank Order - CRC is corrected
1000
900
P4L P4R
P3L P1R P3R
800 P2R
Pressure (psig)
500
P2L
400
300
200
100
0
0 45 90 135 180 225 270 315 360
Crank Angle (deg)
Early Firing
53
Early Firing
engine pressure comparison
1A - E 5/22/1997 10:34:26 AM
All cylinders - In Bank Order
800
700 P1R
600 P3R
P4R P5R P1L P3L
Pressure (psig)
P4L
500
P2R
P5L
400 P2L
300
200
100
Dead Cylinders
54
Dead Cylinders
Cylinder comparisons of peak pressures
C402 - E 9/9/1998 12:02:53 PM
All cylinders - In Bank Order - CRC is corrected
1000
900
P4L P4R
P3L P1R P3R
800 P2R
Pressure (psig)
500 P2L
400
P1L
300
200
100
0
0 45 90 135 180 225 270 315 360
Crank Angle (deg)
Dead Cylinders
Cylinder comparisons of pressure shape & timing
C402 - E 9/9/1998 12:02:53 PM
All cylinders - To Center of Plot - CRC is corrected
1000
900
800
700
Pressure (psig)
600
500
P2L soft fire
400
300 P1L
Dead Cylinder
200
100
55
Dead Cylinders
Cylinder comparisons of pressure rise rate
C402 - E 9/9/1998 12:02:53 PM
All cylinders - To Center of Plot - CRC is corrected
35
30
Normal
25
20
Other cylinders
Pressure Rise Rate (dP/dθ)
15
10
P2L Soft Fire
5
-5
-10
P1L – Dead Cylinder
-15
-20
Dead Cylinders
Pressure and pressure rise rate relationship
C402 - E Cylinder P1L 9/9/1998 12:02:53 PM Period 4
CRC is corrected
-103 EXHAUST PORT 100
1000
-123 INTAKE PORT 119
900 -125 -65 FUEL VALVE
800
700 Normal PT
Pressure (psig)
600
500 ∂P
∂θ PT
400
300
200
100
56
Dead Cylinders
PV comparison to normal
C402 - E cylinder P1L 9/9/1998 12:02:53 PM Period 4
CRC is corrected
1000
900
800
700
600
Normal
500
400
300
100
0 25 50 75 100
% swept volume
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Pre-ignition
57
Pre-ignition
Sketch of pre-ignition (not actual data)
-103
103 EXHAUST PORT 100
1000
123 INTAKE PORT 119
900 -125 -65 FUEL VALVE
800
Pre-ignition
700 Normal
Pressure (psig)
600
500
400
300
200
100
0
Combustion
Analysis summary
Observation Characteristics
Normal " All cylinder average PFPs fall within 10-15% of the engine
average PFP
" Low cycle-to-cycle deviation in cylinder PFP
" PFP angle consistent and at expected location
" Similar exhaust temperatures among power cylinders
58
Combustion
Analysis summary (cont.)
Observation Characteristics
Soft Firing " Type of misfire
" Average PFP lower than normal
" PFP angle later than normal
" Low pressure rise rate when compared to other cylinders (or
history)
" May be followed by detonation
" Increased exhaust temperature
Combustion
Analysis summary (cont.)
Observation Characteristics
Dead Cylinder " Average PFP at running compression – exhibits no cycle
variation, low PFP deviation
" Maximum pressure = running compression pressure
" Low pressure rise rate when compared to other cylinders (or
history)
" Consumes horsepower
" Wastes fuel ($100-$200/day/cyl)
" Fuel in exhaust manifold is a backfire risk
" Low exhaust temperature
59
Combustion
PT for a dead cylinder, soft fire, and detonation
K203 - E Cylinder P3 11/21/1996 2:13:03 PM Period 1
109 251 EXHAUST VALVE
600 126 234 INTAKE VALVE
FUEL VALVE 206 307
550
500
450
400
Pressure (psig)
Detonation
350
300
250
200
150
Soft (Late) Fire
100
50 Dead
0 Cylinder
Combustion
PV for a dead cylinder, soft fire, and detonation
K203 - E cylinder P3 11/21/1996 2:13:03 PM Period 1
550
500
450
400
350
Pressure (psig)
300
Detonation
250
200
150 Soft (Late) Fire
100
Dead Cylinder
50
0 25 50 75 100
% swept volume
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60
Analyzing the mechanical
condition of engines
! Valves
! Liners
! Rods and wrist pins
! Rings
! Ignition systems
Valve Train
Rocker Arm
Valve Lifter
Push Rod
Valve Springs
Valve Stem
Exhaust Port
Valve Seat
Cam Follower
Cam Lobe
61
Valve Train
Common problems
Mechanical Leakage
! Loose/worn rocker arm ! Burnt valves
! Improper lifter clearance ! Deposits on valve seat
! Broken springs ! Damaged seat
! Incorrect spring tension ! Bent valve stem
! Worn valve guide
! Worn or mis-timed cam
! Excessive cam gear lash
Valve Train
Incorrect clearance
wrong time
Lift
62
Valve Train
Hydraulic lifters
Valve Train
Excessive exhaust valve clearance (solid lifter)
K1F - E 12/13/1994 11:19:43 AM
Engine Cylinders: Phased Vibration VT4:
2.5 2.5
P
P1 0.0 0.0 P7
-2.5 -2.5
2.5 2.5
P2 0.0 0.0 P8
P
-2.5 -2.5
2.5 2.5
P3 0.0 0.0 P9
P
-2.5 -2.5
2.5 2.5
-2.5 -2.5
P
2.5 2.5
2.5 2.5
0 90 180 270 360 450 540 630 720 90 180 270 360 450 540 630 720
63
Valve Train
Vibration comparison for a leaking exhaust valve
2.5 2.5
P1 0.0 0.0 P7
-2.5 -2.5
2.5 2.5
P2 0.0 0.0 P8
-2.5 -2.5
2.5 2.5
P3 0.0 0.0 P9
-2.5 -2.5
2.5 2.5
2.5 2.5
2.5 2.5
0 90 180 270 360 450 540 630 720 0 90 180 270 360 450 540 630 720
Valve Train
PT and PV: leaking exhaust valves
300 300
2 2
250 250
200 200
150 1 150
100 100
50 50
1
3 3
0 0
0 45 90 135 180 225 270 315 360 405 450 495 540 585 630 675 720
Angle (deg) 0 25 50 75 100
% swept volume
64
Valve Train
Worn rocker arms
K1D - E 2/3/1997 10:52:37 AM
Engine Cylinders: Phased Vibration VT4:
2.5 2.5
0.0 0.0
P1 -2.5 -2.5
P7
2.5 2.5
0.0 0.0
P2 P8
-2.5 -2.5
2.5 2.5
0.0 0.0
P3 P9
-2.5 -2.5
2.5 2.5
0.0 0.0
P4 P10
-2.5 -2.5
2.5 2.5
0.0 0.0
P5 -2.5 -2.5
P11
2.5 2.5
0.0 0.0
P6 -2.5 -2.5
P12
0 90 180 270 360 450 540 630 720 0 90 180 270 360 450 540 630 720
Valve Train
Worn cam gear
NO-4 - E 2/28/1995 1:38:59 PM
Engine Cylinders: Phased Vibration VT4:
2 2
P1 0 0 P7
-2 -2
2 2
P2 0 0 P8
-2 -2
2 2
P3 0 0 P9
-2 -2
2 2
P4 0 0 P10
-2 -2
2 2
P5 0 0 P11
-2 -2
2 2
P6 0 0 P12
-2 -2
0 90 180 270 360 450 540 630 720 0 90 180 270 360 450 540 630 720
65
Valve Train
Worn cam gear
800 800 -
Pressure (psig)
Pressure (psig)
600 600 -
400 400 -
300 300 -
200 200 -
100 100 -
0 0
0 45 90 135 180 225 270 315 360 405 450 495 540 585 630 675 720 0 45 90 135 180 225 270 315 360 405 450 495 540 585 630 675 720
Angle (deg) Angle (deg)
Valve Train
Leaking fuel valve
5 5
1F 0 0 5F
-5 -5
5 5
Hard closures
2F 0 0 6F
-5 -5
5 5
3F 0 Leakage 0 7F
-5 -5
5 5
4F 0 0 8F
-5 -5
0 45 90 135 180 225 270 315 3600 45 90 135 180 225 270 315 360
66
Valve Train
Leaking fuel valve
C2A-E Cylinder 8 10/10/2001 6:28:53 AM Period 9
130 230 Intake
700 110 250 Exhaust --------------
Fuel 213 283 -
-
- 8FV ULT
600 -
-- Scale 4.0
-
-
500 -
- Leak as
---------------
-
P rises
-
400
Pressure (psig)
- 8 ULT
-
-- Scale 4.0
-
300 -
-
-
---------------
200 -
-
- 8 VT4
-
-- Scale 2.0
100
-
-
-
-
0 --------------
Valve Train
Analysis summary
Fault Characteristics
Normal ! Valve opening events are quiet or absent
! Valve events are similar across the entire engine
! Closing events are at expected crank angle, single
impact of short duration
! No leakage occurs after valve closure
67
Valve Train
Analysis summary (cont.)
Fault Characteristics
Broken ! Impact noises on opening and closure
! Valve may close late
valve spring
Worn valve ! Roughness seen in vibration pattern as valve opens
and closes
guide
! Valve may hang up in the guide and not close at the
correct time
! May see gas leakage if valve does not seat properly
Cam gear ! Impacts in the vibration as gear teeth pass each other
! May cause excessive wear on the cam lobe leading to
faults
rough vibration pattern
! When troubleshooting, be prepared to move the
vibration transducer around
Valve Train
Analysis summary (cont.)
Fault Characteristics
Leaking ! Blowby pattern appears when pressure rises in the
cylinder
valves
Improper ! Multiple impacts on valve closure as valve finds the
seat
valve
! Look for differences in valve closure across the engine
seating ! Can be caused by beat-out seat, worn/broken/incorrect
spring, worn guide, loose rocker arm, bent valve stem
! May see blowby pattern when pressure is high in the
cylinder
68
Pistons, Rods, Rings and Liners
Piston slap
69
Piston Slap
Low frequency vibration showing piston slap
C2A-E 6/5/2001 8:23:09 AM
Engine Cylinders: Phased Acceleration VTL:
5 5
1 0 0 5
-5 -5
5 5
2 0 0 6
-5 -5
5 5
3 0 0 7
-5 -5
5 5
4 8
0 0
-5 -5
0 45 90 135 180 225 270 315 360 0 45 90 135 180 225 270 315 360
Piston Slap
Low frequency vibration showing piston slap
C2A-E Cylinder 3 6/5/2001 8:23:09 AM Period 6
130 230 Intake
700 110 250 Exhaust --------------
Fuel 213 283 -
Not always visible -
- 3FV ULT
in ultrasonic -
600 -- Scale 20.0
--
-
--
Pressure (psig)
--------------
500 --
- 3 ULT
-- Scale 4.0
400 --
-
-
--------------
-
-
300 -
- 3 VTL
-- Scale 6.0
-
-
200 -
-
-
--------------
--
- 3 VT4
100 -- Scale 2.0
--
-
0 -
--------------
70
Piston Rods
Piston Rods
Wrist pin load for a 2-stroke engine
Wrist pin load in a 2 stroke engine
250000
Gas force
Vibration occurs
200000 around BDC
where load is minimal Total force
150000
Force (lbs)
Inertia
100000
50000
-50000
0 45 90 135 180 225 270 315 360 405 450 495 540 585 630 675 720
Degrees
71
Piston Rods
Wrist pin load for a 4-stroke engine
Wrist pin load in a 4 stroke engine
250000
Gas force
200000 Vibration occurs
around TDC
Total force where load reverses
150000
Force (lbs)
Inertia
100000
50000
-50000
0 45 90 135 180 225 270 315 360 405 450 495 540 585 630 675 720
Degrees
Piston Rods
Excessive wrist pin clearance (4 stroke)
K200 - E Cylinder P6 1/16/1996 9:39:11 AM Period 6
137 417 EXHAUST VALVE
INTAKE VALVE 300 565 --------------
FUEL VALVE 502 611
700
-
600 -
- P6 VT4
500
Pressure (psig)
-
400
- - Scale 2.0
300 -
-
200
-
100
-
0 --------------
0 45 90 135 180 225 270 315 360 405 450 495 540 585 630 675 720
Angle (deg)
GMRC 2002 GAS MACHINERY CONFERENCE
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72
Piston Rings
Worn or improperly loaded rings
Liners
Scuffing and scoring
73
Liners
Liner groove (P2, 10 rotations)
NO-6 - E 12/21/1995 8:14:16 AM
Engine Cylinders: Phased Vibration VT4:
2 2
P2 (MMM) 0 0 P2 (6)
-2 -2
2 2
P2 (1) 0 0 P2 (7)
-2 -2
2 2
P2 (Med 2) 0 0 P2 (8)
-2 -2
2 2
P2 (3) 0 0 P2 (9)
-2 -2
2 2
P2 (4) 0 0 P2 (10)
-2 -2
2 2
P2 (5) 0 0
-2 -2
0 90 180 270 360 450 540 630 720 0 90 180 270 360 450 540 630 720
Liners
Liner groove
NO-6 - E Cylinder P2 12/21/1995 8:14:16 AM Period 2
151 403 EXHAUST VALVE
1000 INTAKE VALVE 345 560 --------------
FUEL VALVE 504 610
900 -
Symmetric angle cursors
800
reveal liner groove
-
700 - P2 VT4
600 -
Pressure (psig)
400 -
300 -
200 -
100 -
0 --------------
20 340 380 700
0 45 90 135 180 225 270 315 360 405 450 495 540 585 630 675 720
Angle (deg)
74
Liners
Liner groove
NO-6 - E 12/21/1995 8:14:16 AM
Crosstalk from P1
Engine Cylinders: Phased Vibration VT4:
exhaust blowdown
P2 (MMM) 0 0 P2 (6)
-2 -2
2 2
P2 (1) 0 0 P2 (7)
-2 -2
2 2
P2 (Med 2) 0 0 P2 (8)
-2 -2
2 2
P2 (3) 0 0 P2 (9)
-2 -2
2 2
P2 (4) 0 0 P2 (10)
-2 -2
2 2
P2 (5) 0 0
-2 -2
0 90 180 270 360 450 540 630 720 0 90 180 270 360 450 540 630 720
Liners
Crosstalk from exhaust event on P3
NO-6 - E 12/21/1995 8:14:16 AM
Engine Cylinders: Phased Vibration VT4:
2 2
P1 0
0 P7
422
-2 17
-2
2 2
P2 0
0 P8
662
-2 257
-2
2 2
P3 0
0 P9
182
-2 497
-2
2 2
P4 0 0P10
542 137
-2 -2
2 2
P5 0 0P11
-2
302 Unphased cursor indicates 617
-2
2 crosstalk from other cylinders 2
P6 0 0P12
62 377
-2 -2
0 90 180 270 360 450 540 630 720 0 90 180 270 360 450 540 630 720
75
Liners
Liner wear
NO-6 - E 3/19/1996 1:28:36 PM
Engine Cylinders: Phased Vibration VT4:
2 2
P1 0 0 P7
-2 -2
2 2
P2 0 0 P8
-2 -2
2 2
P3 0
Chatter as loaded 0 P9
rings pass over wear -2
-2
2 2
P4 0 0 P10
-2 -2
2 2
P5 0 0 P11
-2 -2
2 2
P6 0 P12
0
-2 -2
0 90 180 270 360 450 540 630 720 0 90 180 270 360 450 540 630 720
Liners
Liner wear
NO-6 - E Cylinder P7 3/19/1996 1:28:36 PM Period 2
151 403 EXHAUST VALVE
1000 INTAKE VALVE 345 560 --------------
FUEL VALVE 504 610
900 -
800 -
700 - P7 VT4
Pressure (psig)
600 -
400 -
300 -
200 -
100 -
0 --------------
0 45 90 135 180 225 270 315 360 405 450 495 540 585 630 675 720
Angle (deg)
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76
Liners
Liner wear confirmed by symmetric cursor
NO-3 - E Cylinder P5 5/1/1995 8:06:19 AM Period 2
161 410 EXHAUST VALVE
1000 INTAKE VALVE 325 575 --------------
FUEL VALVE 536 621
900 -
800 -
700 - P5 VT4
Pressure (psig)
600 -
400 -
300 -
100 -
0 45 90 135 180 225 270 315 360 405 450 495 540 585 630 675 720
Angle (deg)
GMRC 2002 GAS MACHINERY CONFERENCE
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Liners
Liner wear
NO-3 - E 5/1/1995 8:06:19 AM
Engine Cylinders: Phased Vibration VT4:
1 1
P1 0 0 P7
-1 -1
1 1
P2 0 0 P8
-1 -1
1 1
P3 0 0 P9
-1 -1
1 1
P4 0 0 P10
-1 -1
1 1
P5 0 0 P11
-1 -1
1 1
P6 0 0 P12
-1 -1
0 90 180 270 360 450 540 630 720 0 90 180 270 360 450 540 630 720
77
Liners
Port bridge wear
C2A-E 10/10/2001 6:28:53 AM
Engine Cylinders: Phased Ultrasonic ULT:
10 10
1 5
0 0
-10 -10
10 10
2 0 0 6
-10 -10
10 10
3 0 0 7
-10 -10
10 10
4 0 0 8
-10 -10
0 45 90 135 180 225 270 315 360 0 45 90 135 180 225 270 315 360
Liners
Port bridge
C2A-E Cylinder 4 10/10/2001 6:28:53 AM Period 6
130 230 Intake
700 110 250 Exhaust --------------
Fuel 213 283 -
Excessive -
- 4FV ULT
ring clip
600 -
- - Scale 10.0
-
-
-
500
-
---------------
-
Pressure (psig)
-
400 - 4 ULT
-
- - Scale 10.0
-
300 -
-
-
---------------
200 -
-
- 4 VT4
-
100 - - Scale 2.0
-
-
-
-
0 --------------
78
Ignition Systems
Ignition Systems
Ignition Primaries
Zener C402 - E Cylinder P1L 07/03/1997 8:07:43 AM
Gates
5.5
P4L P5L P2L P3L P6L P1L
5.0 P1R P4R P5R P2R P3R P6R
4.5
4.0
Voltage (V)
TDC 3.5
3.0
Voltages should 2.5
be similar
2.0
1.5
1.0
0.5
0.0
0 45 90 135 180 225 270 315 360
Crank Angle (deg)
79
Ignition Systems
Ignition secondaries
Secondary Voltage
Plug Stops Firing
Arc Duration
Indication of
ionization voltage
0 1 2 3 4 5
Time (ms)
Ignition Systems
Typical ignition secondary patterns
C402 - E 09/09/1998 12:02:53 PM
0 0
P4LL P5LR
(Med 1) (Med 1)
Ignition timing angle = 5.7 Ignition timing angle = 5.9
0 0
P4LR P6LL
(Med 1) (Med 1)
Ignition timing angle = 5.9 Ignition timing angle = 5.9
0 0
P5LL P6LR
(Med 1) (Med 1)
Ignition timing angle = 6.3 Ignition timing angle = 6.1
0 1 2 3 4 5 0 1 2 3 4 5
80
Ignition Faults
Timing
Ignition Faults
Typical spark plug problems
81
Ignition Faults
Cables
Ignition Faults
Coils
82
Ignition Faults
Two bad coils – spark did not fire
C402 - E 9/9/1998 12:02:53 PM Secondary Ignition (Y Axis: mV -- X Axis: ms)
0 0
P1LL -250 Ignition timing angle = 5.5 P1RL Ignition timing angle = 5.7
-250
0 0
P1LR -250 P1RR
Ignition timing angle = 6.4 -250 Ignition timing angle = 5.9
0 0
P2LL -250 Ignition timing angle = 5.4 P2RL Ignition timing angle = 5.6
-250
0 0
P2LR P2RR
-250 Ignition timing angle = 5.1 -250 Ignition timing angle = 5.5
0 0
P3LL -250 Ignition timing angle = 5.7 P3RL Ignition timing angle = 5.9
-250
0 0
P3LR P3RR
-250 Ignition timing angle = 5.9 -250 Ignition timing angle = 5.4
0 1 2 3 4 5 0 1 2 3 4 5
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Ignition Faults
Reversed coil
10JVGE-E 4/24/2001 7:34:26 AM 10JVGW-E 4/24/2001 10:55:35 AM
Secondary Ignition (Y Axis: mV -- X Axis: ms) Secondary Ignition (Y Axis: mV -- X Axis: ms)
200
200
100
P1C 0 P1C -0
-100
-200
200
200
100
P2C 0 P2C -0
-100
-200
200
200
100
P3C 0 P3C -0
-100
-200
200
200
100
P4C 0 P4C -0
-100
-200
0 1 2 3 4 5 0 1 2 3 4 5
83
Analyzing Compressor Faults
84
Characterizing the machine
800 --------------
-
-
- 4HD1 VT1
750 -
- Scale 7.0
-
- 150 DGF
700 -
-
---------------
-
650 -
- 4HD2 VT1
-
Pressure (psig)
- Scale 8.3
- 152 DGF
600 -
-
-
---------------
550 -
-
- 4HS1 VT1
-
500 - Scale 7.9
- 91 DGF
-
-
-
450 ---------------
-
-
- 4HS2 VT1
400 -
- Scale 8.7
- 91 DGF
-
350 -
-
--------------
85
Characterizing the compressor
Leaking HE discharge valve: PT/VT
K200 - C cylinder 4 8/29/1996 10:52:08 AM HE Period 9, CE Period 8
800 --------------
-
-
- 4HD1 VT1
750 -
- Scale 7.0
- 150 DGF
-
700 -
-
---------------
-
650 -
- 4HD2 VT1
-
Pressure (psig)
- Scale 8.3
-
600 - 152 DGF
-
-
---------------
550 -
-
- 4HS1 VT1
-
500 - Scale 7.9
- 91 DGF
-
-
-
450 ---------------
-
-
- 4HS2 VT1
400 -
- Scale 8.7
- 91 DGF
-
350 -
-
--------------
800 --------------
-
-
- 4HD1 VT1
750 -
- Scale 7.0
-
- 150 DGF
700 -
-
---------------
-
650 -
- 4HD2 VT1
-
Pressure (psig)
- Scale 8.3
- 152 DGF
600 -
-
-
---------------
550 -
-
- 4HS1 VT1
-
500 - Scale 7.9
- 91 DGF
-
-
-
450 ---------------
-
-
- 4HS2 VT1
400 -
- Scale 8.7
- 91 DGF
-
350 -
-
--------------
86
Characterizing the compressor
Leaking Rings: PT/VT
K200 - C cylinder 4 8/29/1996 10:52:08 AM HE Period 9, CE Period 8
800 --------------
-
-
- 4HD1 VT1
750 -
- Scale 7.0
- 150 DGF
-
700 -
-
---------------
-
650 -
- 4HD2 VT1
-
Pressure (psig)
- Scale 8.3
-
600 - 152 DGF
-
-
---------------
550 -
-
- 4HS1 VT1
-
500 - Scale 7.9
- 91 DGF
-
-
-
450 ---------------
-
-
- 4HS2 VT1
400 -
- Scale 8.7
- 91 DGF
-
350 -
-
--------------
700
VEd
650
Pressure (psig)
600
Theoretical
550 PV
500
450
VEs
400
350
0 25 50 75 100
Percent swept volume
87
Characterizing the compressor
Leaking HE suction valve: PV
K200 - C cylinder 4 8/29/1996 10:52:08 AM HE Period 9, CE Period 8
800
750
700
VEd
650
Pressure (psig)
600
550
500
450
VEs
400
350
0 25 50 75 100
Percent swept volume
750
700
VEd
650
Pressure (psig)
600
550
500
450
VEs
400
350
0 25 50 75 100
Percent swept volume
88
Characterizing the compressor
Leaking rings
K200 - C cylinder 4 8/29/1996 10:52:08 AM HE Period 9, CE Period 8
800
750
700
650
Pressure (psig)
600
550
500
450
400
350
0 25 50 75 100
Percent swept volume
ne = 1.26 nc = 1.26
n ratio = 1.00
n ratio = 1.00
End 4C Step 1 = 31.2%
Crank End
nc = 1.25
ne = 1.24
89
Characterizing the compressor
Leaking HE suction valve: LogP-LogV
K200 - C cylinder 4 8/29/1996 10:52:08 AM
HE ratios calculated using geometry. CE ratios calculated using geometry.
Head End
ne = 1.35 nc = 1.10
n ratio = 1.23
Normal n ratio = 1
n ratio = 1.00
End 4C Step 1 = 31.2%
Crank End
nc = 1.25
ne = 1.24
ne = 1.35 nc = 1.23
n ratio = 0.85
Normal n ratio = 1
n ratio = 1.00
End 4C Step 1 = 31.2%
Crank End
nc = 1.25
ne = 1.24
90
Characterizing the compressor
Leaking rings: LogP-LogV
K200 - C cylinder 4 8/29/1996 10:52:08 AM
HE ratios calculated using geometry. CE ratios calculated using geometry.
Head End
ne = 1.26 nc = 1.26
n ratio = 1.00
n ratio = 1.00
End 4C Step 1 = 31.2%
Crank End
nc = 1.25
ne = 1.24
91
Characterizing the compressor
Discharge temperature delta (DTD)
175 Discharge
Usually less
150 than Td
Usually warmer
Temperature (F)
125 than Ts
100
Suction
75
50
25
0
S2 S1 D2 D1 S2 S1 D2 D1
Head End (Stage# 1) Crank End (Stage# 1)
92
Compressor Faults
! Pressure Leaks
Pressure Leaks
Sources of leaks and analysis tools
93
Pressure Leaks
CE suction valve leak: PT/VT
1250
--------------
-
1200 -
-
- 3CD4 ULT
-
1150 - Scale 30.0
-
-
-
126 DGF
1100 -
- --------------
-
1050 -
-
3CD3 ULT
Pressure (psig)
-
-
1000 - Scale 30.0
-
-
-
148 DGF
950 -
- --------------
-
900 -
-
- 3CS2 ULT
850 -
- Scale 30.0
-
-
-
86 DGF
800
-
- --------------
750 -
-
-
- 3CS1 ULT
700 -
- Scale 30.0
-
650
-
-
78 DGF
-
--------------
600
Pressure Leaks
HE Suction valve leak: PT/VT
Unit1-C cylinder 4 1/22/2002 8:35:12 AM HE Period 4, CE Period 7
--------------
1000 -
-
- 4HD3 VT1
-
- Scale 8.0
- 95 DGF
950 -
-
-
---------------
-
900 -
- 4HD4 VT1
-
Pressure (psig)
- Scale 8.0
- 94 DGF
-
850 -
-
---------------
-
-
- 4HS1 VT1
800 -
- Scale 8.0
- 61 DGF
-
-
750 -
---------------
-
-
- 4HS2 VT1
-
700 - Scale 8.0
- 73 DGF
-
-
-
650 --------------
94
Pressure Leaks
HE Suction valve leak: PV
Unit1-C cylinder 4 1/22/2002 8:35:12 AM HE Period 4, CE Period 7
1000
950
900
Pressure (psig)
850
HE PT
800 HE
theoretical
750 PT
700
650
0 25 50 75 100
Percent swept volume
Pressure Leaks
HE Suction valve leak: LogP-LogV
ne = 1.14 nc = 0.73
n ratio = 1.02
End 4C Step 9 = 66.3%
Crank End
nc = 1.34
ne = 1.36
95
Pressure Leaks
HE Suction valve leak: Valve Cap Temps
High
temperature
Unit1-C Cylinder 4 1/22/2002 8:35:12 AM
100
90
Discharge
80
70
Temperature (F)
60
50 Suction
40
30
20
10
0
S1 S2 D3 D4 S1 S2 D3 D4
Head End (Stage# 1) Crank End (Stage# 1)
GMRC 2002 GAS MACHINERY CONFERENCE
© 2002 DYNALCO CONTROLS SHORT COURSE: BASIC ENGINE & COMPRESSOR ANALYSIS TECHNIQUES 191
Pressure Leaks
HE suction valve leak: Health Report
96
Pressure Leaks
Leaking rings
C-140 cylinder 4 07/26/2002 11:55:03 AM C-140 cylinder 4 07/26/2002 11:55:03 AM
End 4H Step 4 = 27.5%
1800
nc = 1.45
Head End
1700
ne = 1.48
1600 n ratio = 1.02
Pressure (psig)
1500
1400
End 4C Step 4 = 30.0%
1300
Crank End
1200
n ratio = 0.86
nc = 1.51
1100
ne = 1.30
1000
0 25 50 75 100
Percent swept volume
!The bulging beyond the expansion
!Minor ring leak in a hydrogen and compression lines indicates a
compressor. minor ring leak.
!Iron oxide was coming through the
pipeline wearing the rings down.
!Filters were installed in the suction inlet
to solve the problem.
Pressure Leaks
Severely leaking rings
PV curve for a severe ring leak Log P - Log V plot for a severe ring leak
1000
End 2H Step 1 = 115.9%
n ratio = 2.57
nc = 1.62
Head End
950 ne = 4.17
900
Pressure (psig)
nc = 1.73
800
ne = 3.37
750
0 25 50 75 100
Percent swept volume
97
Pressure Leaks
Analysis summary
Observation Typical characteristics
Suction valve leak ! Gas passing vibration pattern when the differential pressure across the valve
is high. Vibration leak pattern is highest in the leaking valve.
! Flow balance > 1.05
! n ratio for LogP-LogV > 1.03
! Elevated discharge temperature delta. Elevated valve cap temperature.
! Rounded discharge toe on the PV. Discharge toe pressure drops.
! Cylinder end capacity drops
! Expansion and compression lines on PT and PV below theoretical
Discharge valve ! Gas passing vibration pattern when the differential pressure across the valve
leak is high. Vibration leak pattern is highest in the leaking valve.
! Flow balance < 0.97
! n ratio for LogP-LogV < 0.98
! Rounded suction toe on the PV
! Suction toe pressure rises
! Abnormal discharge temperature delta and valve cap temperature.
Expansion through the discharge valve may actually lower the valve cap and
discharge temperature.
! Cylinder end capacity drops
! Expansion and compression lines on PT and PV above theoretical
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Pressure Leaks
Analysis summary (cont.)
Observation Typical characteristics
Packing leak ! All packing leaks a small amount. Excessive leakage looks similar to a
leaking suction valve.
! Leakage pattern in crank end valves. Move the vibration sensor closer to the
packing to confirm.
! Packing temperature increases. Check packing vent flow rate if so equipped.
! Expansion and compression lines on PT and PV below theoretical
! Gas passing vibration pattern near crank end when the pressure in the crank
end is higher than atmospheric.
! Flow balance > 1.05
! n ratio for LogP-LogV > 1.03
Ring leak ! Gas passing vibration pattern in all valves when the differential pressure
across the rings is high.
! Flow balance generally increases.
! Rounded suction and discharge toes on the PV
! Suction toe pressure rises and discharge toe pressure falls.
! Increase in discharge temperature delta.
! Expansion and compression lines on PT and PV do not follow the ideal gas
law: PVn=constant.
98
Compressor Faults
! Valve Dynamics
Valve Dynamics
Some causes of valve failures
99
Valve Dynamics
Approach to analysis
Valve Dynamics
Slamming … leading to leakage
Unit2-C cylinder 1 11/13/2001 6:07:57 AM HE Period 8, CE Period 3
Channel Resonance is corrected
--------------
-
950 -
- 1CD3 VT1
-
- Scale 4.0
-
-
-
900 -
---------------
-
-
- 1CD4 VT1
-
- Scale 4.0
850 -
Pressure (psig)
-
-
-
---------------
-
Channel Resonance is corrected
-
- 1CS1 VT1
800 -
- Scale 4.0 --------------
- -
- -
1000 - - 1CD3 VT1
- -
--------------- - Scale 6.4
750 - -
- - 106 DGF
- 1CS2 VT1 -
- -
950 - Scale 4.0 ---------------
- -
- -
700 - - 1CD4 VT1
- -
-------------- - Scale 2.5
900 -
- 105 DGF
Pressure (psig)
-
0 45 90 135 180 225 270 315 360 -
---------------
Crank Angle (deg) -
850 -
- 1CS1 VT1
-
- Scale 6.9
-
- 73 DGF
800 -
-
---------------
-
-
- 1CS2 VT1
750 -
- Scale 5.3
-
- 73 DGF
-
-
--------------
700
100
Valve Dynamics
Multiple opening events
RTC10002 - C cylinder 2 8/6/1992 11:27:32 AM HE Period 1, CE Period 1
Channel Resonance is corrected
200 --------------
-
-
- 2HD3 VT1
-
175 - Scale 2.0
- 172 DGF
-
-
-
---------------
150 -
-
- 2HD4 VT1
Pressure (psig)
-
- Scale 2.0
- 177 DGF
125 -
-
-
---------------
-
-
100 - 2HS1 VT1
-
- Scale 2.0
- 86 DGF
-
-
-
75 ---------------
-
-
- 2HS2 VT1
-
- Scale 2.0
50 - 85 DGF
-
-
-
--------------
Valve Dynamics
Flutter
JC1A cylinder 5 1/29/2001 10:18:56 AM HE Period 9, CE Period 6
2250
--------------
-
-
2000 - 5CD2 ULT
-
- Scale 10.0
-
1750 - 183 DGF
Pressure (psig)
-
-
1500 ---------------
-
-
- 5CS1 ULT
1250 -
- Scale 10.0
-
- 85 DGF
1000 -
-
--------------
101
Valve Dynamics
Analysis summary
Valve Dynamics
Analysis summary (cont.)
102
Valve Dynamics
Analysis summary (cont.)
Compressor Faults
! Losses
103
Compressor Losses
Calculating HP
Compressor Losses
Pressure drop
104
Compressor Losses
No-loss IHP
K200 - C cylinder 4 8/29/1996 10:52:08 AM HE Period 9, CE Period 8
800
Actual
750 PV
700
Theoretical
650 PV
Pressure (psig)
600
No-loss indicated
power (IHP).
550
Minimum IHP
500 required to move
the gas
450
400
350
0 25 50 75 100
Percent swept volume
Compressor Losses
Total IHP
K200 - C cylinder 4 8/29/1996 10:52:08 AM HE Period 9, CE Period 8
800
Total discharge
750 loss, IHP
700
650
Pressure (psig)
400
350
0 25 50 75 100
Percent swept volume
105
Compressor Losses
Magnitude of losses
Pulsation
106
Pulsation
Nozzle Pressure Trace
RTC21000 - C cylinder 1 4/28/1994 8:18:32 AM
Channel Resonance is corrected
Pressure in ---------------
850 --- 1HD1 VT1
discharge - Scale 2.0
-- 91 DGF
nozzle --
----------------
800 -- 1HD2 VT1
-- Scale 2.0
-- 92 DGF
--
750 ----------------
Pressure (psig)
-- 1HD3 VT1
-- Scale 2.0
- 91 DGF
--
700 ----------------
--
Pressure in --- 1HS1 VT1
Scale 2.0
650 suction - 76
-- DGF
nozzle --
--------------
-
-- 1HS2 VT1
-- Scale 2.0
600 -- 50 DGF
----------------
--
-- 1HS3 VT1
550 -- Scale 2.0
-- 74 DGF
----------------
500
0 45 90 135 180 225 270 315 360
Crank Angle (deg)
Pulsation
Total HE Power
RTC21000 - C cylinder 1 4/28/1994 8:18:32 AM HE Period 1
Channel Resonance is corrected
850
800
750
Pressure (psig)
700
600
550
0 25 50 75 100
Percent swept volume
107
Pulsation
No-loss HE Power
RTC21000 - C cylinder 1 4/28/1994 8:18:32 AM HE Period 1
Channel Resonance is corrected
850
800
750
Pressure (psig)
700
No-loss IHP
650
600
550
0 25 50 75 100
Percent swept volume
Pulsation
Total losses
RTC21000 - C cylinder 1 4/28/1994 8:18:32 AM HE Period 1
Channel Resonance is corrected
850
800
750
Total Discharge loss = 104 IHP, or 20%
Pressure (psig)
700
650
600
Total Suction loss = -11 IHP, or -3%
550
0 25 50 75 100
Percent swept volume
108
Pulsation
Valve and Passage loss
RTC21000 - C cylinder 1 4/28/1994 8:18:32 AM HE Period 1
Channel Resonance is corrected
850
800
750
Discharge valve and passage loss = 24 IHP
Pressure (psig)
700
650
550
0 25 50 75 100
Percent swept volume
Pulsation
Effect on HP
Compressor Horsepower And Capacity Report
Unit Name: RTC21000 - C Model: TCV10 Date: 4/28/1994 8:18:32 AM
Location: FLL Unit Mfr: DRESSER RAND Serial No.:
Load Step: 3
Clearance Indicated Brake Total; Loss Valve & Pass; Loss Total Loss Calculated Capacity bhp/mmscfd
Cyl % of Swept Power Power (ihp) (ihp) (%) (mmscfd) Flow
End Volume (ihp) (bhp) Suction Disch. Suction Disch. Suction Disch. SVE* DVE** Balance Calc. Theor.
1H 158 514 541 -10.67 103.52 30.56 23.79 -2.08 20.13 32.00 35.05 0.913 16.9 14.0
1C 92 565 595 14.04 58.39 42.59 30.47 2.48 10.33 39.82 38.49 1.035 15.5 14.6
3H 132 546 575 29.33 28.31 36.02 32.57 5.37 5.18 37.00 35.27 1.049 16.3 15.5
3C 87 587 618 28.89 58.15 31.82 17.08 4.92 9.91 40.93 38.80 1.055 15.9 14.1
5H 127 609 641 27.22 101.62 32.76 38.29 4.47 16.70 36.86 38.90 0.948 17.4 14.1
5C 94 592 623 33.22 51.00 33.20 28.36 5.61 8.61 40.72 38.98 1.044 16.0 14.6
Stage Totals: 3413 3593 122.04 400.99 206.95 170.57 3.58 11.75 227.34 225.49 16.3 14.5
109
Horsepower
Cost of horsepower loss
Engine And Compressor Economic Condition Report
Unit Name: RTC21000 - C Model: TCV10 Date: 4/28/1994 8:18:32 AM
Location: FLL Unit Mfr: DRESSER RAND Serial No.:
Load Step: 3
Percent Load: 86.4 %
UNIT COSTS
Fuel Cost: 1673.37 $/day
Brake Power from the load: 3654.50 bhp
Cost of Each BHP: 0.46 $/bhp-day
ENGINE COSTS
Percent of Fuel Cost
Actual Fuel Consumption: 8675.17 BTU/BHP - hr
Predicted Fuel Consumption: 7434.80 BTU/BHP - hr
Deviation From Predicted: 1240.36 BTU/BHP - hr
Cost of Deviation: 239.26 $/day 14.3 %
7282.35 $/month
87388.25 $/year
110
Compressor Rods
Compressor Rods
Forces
111
Compressor Rods
Gas force
Gas ForceCE = PCE ∗ AreaCE
PCE = CE cylinder pressure
AreaCE =
π
4
2
[(
piston diameter − (piston rod diameter ) )
2
]
Gas ForceHE = PHE ∗ AreaHE
PHE = HE cylinder pressure
AreaHE =
π
4
[(
2
)
piston diameter − ( tailrod diameter )
2
]
Compression Tension
(PHE ∗ AreaHE ) > (PCE ∗ AreaCE ) (PHE ∗ AreaHE ) < (PCE ∗ AreaCE )
Compressor Rods
Gas force
K200 - C cylinder 1 9/23/1998 9:52:15 AM HE Period 9, CE Period 9
60000 Maximum Rodload Tension: 60000
600
50000
40000 550
30000
20000 500
Pressure (psig)
Rod Load (lbs)
10000
450
0 Zero Rodload
-10000 400
-20000
-30000 350
-40000
300 Gas force
-50000
Maximum Rodload Compression: 60000
-60000 250
0 45 90 135 180 225 270 315 360
Crank Angle (deg)
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112
Compressor Rods
Inertial force
Displacement
! Inertial Force = (mass of recip components)
x (instantaneous acceleration)
! Differentiate piston displacement (top
graph) with respect to time to derive the
0 90 180 270 360
velocity (middle), then the differential of
velocity with respect to time gives
Velocity
acceleration (bottom)
! Rod load due to inertia takes the form of the
acceleration curve
0 90 180 270 360
Acceleration
! high mass piston and rod assemblies
! high speed compressors
! low compression ratio services
0 90 180 270 360
Compressor Rods
Inertial force
K200 - C cylinder 1 9/23/1998 9:52:15 AM HE Period 9, CE Period 9
60000 Maximum Rodload Tension: 60000
600
50000
40000 550
30000
20000 500
Pressure (psig)
Rod Load (lbs)
10000
450
0 Zero Rodload
-10000 400
-20000
-30000 350
Inertia
-40000
300
-50000
Maximum Rodload Compression: 60000
-60000 250
0 45 90 135 180 225 270 315 360
Crank Angle (deg)
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113
Compressor Rods
Total rod load force
K200 - C cylinder 1 9/23/1998 9:52:15 AM HE Period 9, CE Period 9
60000 Maximum Rodload Tension: 60000
600
50000
40000 550
30000
20000 500
Pressure (psig)
Rod Load (lbs)
10000
450
0 Zero Rodload
-10000 400
-20000
-30000 350
Inertia
-40000
300 Gas force
-50000
Total
Maximum Rodload Compression: 60000
-60000 250
0 45 90 135 180 225 270 315 360
Crank Angle (deg)
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Compressor Rods
Tension only
301C - C cylinder 4 7/17/1997 8:23:05 AM HE Period 5, CE Period 6
75000 Maximum Rodload Tension: 75000
1000
Rod is in
900 tension
50000 throughout the
800 cycle
25000 700
Pressure (psig)
Rod Load (lbs)
600
0 Zero Rodload
500
-25000 400
300
Inertia
-50000
200 Gas force
Total
100 Maximum Rodload Compression: 75000
-75000
0 45 90 135 180 225 270 315 360
Crank Angle (deg)
114
Compressor Rods
Compression only
RTC13003 - C cylinder 2 11/9/1992 8:08:46 AM HE Period 1, CE Period 1
50000 Maximum Rodload Tension: 50000
1100
40000
Rod is in
1050 compression
30000
throughout
1000 the cycle
20000
Pressure (psig)
Rod Load (lbs)
950
10000
0 900
Zero Rodload
-10000 850
Unloaded CE
-20000 800
Compressor Rods
Crosshead pin knock
RTC13002 - C cylinder 3 12/4/1991 7:43:52 AM HE Period 1, CE Period 1
60000 Maximum Rodload Tension: 60000
1100 --------------
50000 Knocks near rod
reversal points -
1050
40000
-
30000 1000
- 3T VT1
20000 950
Pressure (psig)
Rod Load (lbs)
10000 -
900
0 Zero Rodload - Scale 0.5
850
-10000 -
800
-20000
-
-30000 750
Inertia -
-40000 700
Gas force
-
-50000
650 Total
Maximum Rodload Compression: 60000 --------------
-60000
0 45 90 135 180 225 270 315 360
Crank Angle (deg)
115
Compressor Rods
Excess load
C-47 cylinder 1 07/26/2001 7:24:05 AM HE Period 9, CE Period 1
Channel Resonance is corrected
-
250
-
Zero Rodload --------------
-
0 -
-
200 1XA
- VT1
-
-5000 - Scale
- 1.0
Inertia -
150 -
Gas force
-
Total
-
-10000 Maximum Rodload Compression: 11000 --------------
100
0 45 90 135 180 225 270 315 360
Crank Angle (deg)
Compressor Rods
Crosshead knock
C-47 cylinder 1 07/26/2001 7:24:05 AM HE Period 9, CE Period 1
Channel Resonance is corrected
-
250
-
Zero Rodload --------------
-
0 -
-
200 1XA
- VT1
-
-5000 -
- Scale 1.0
Crosshead Inertia -
150 -
Knock Gas force
-
Total
-
-10000 Maximum Rodload Compression: 11000 --------------
100
0 45 90 135 180 225 270 315 360
Crank Angle (deg)
116
Compressor Rods
Analysis summary
Observation Typical characteristics
Rod load is above ! The crosshead pin, crosshead, piston, linkages and rod are stressed above
limit the manufacturer’s specified limit.
! Adjust the loading on the compressor.
! Change the line pressures.
Insufficient rod ! API 618 (June 1995) says:
load reversal “…the duration of this reversal shall not be less than 15 degrees of crank
angle, and the magnitude of the peak combined reversed load shall be at
least 3 percent of the actual combined load in the opposite direction.”
! Unloading crank end suction valves can lead to insufficient reversal.
! Adjust the loading on the compressor.
Knock at reversal ! Check the low frequency vibration reading types. Look for knocks when the
rod load changes from tension to compression and vice versa.
117
Rod Motion
Why is it important?
Rod Motion
Cylinder rod runout and history (at 240 degrees)
2 ROD RODOUT cylinder 2-RR Top Probe Rod Motion 6/4/2002 9:48:02 AM
3.5
Current
3.0
2.5
Rod Motion (mil)
2.0
1.5
1.0
0.5
-0.0
-0.5
-1.0 Previous
-1.5
-2.0
118
Rod Motion
Rod runout
2 ROD RODOUT cylinder 2-RR 6/4/2002 9:48:02 AM
-2
-3
-4 Top probe
sees rod
-5
dropping
-6
0 45 90 135 180 225 270 315 360
Rod Motion
Analysis summary
Observation Typical characteristics
Trend of rod motion over ! Check for signs of rider band and liner wear.
time drops ! Examine the PV and LogP-LogV for signs of ring leakage.
! It is possible that the crosshead shims are wearing out. Check
shims and crosshead lubrication.
The top and bottom probes ! The probes see the rod dropping most at 90 and 270 degrees
follow a W path from 0 to appearing to rise at TDC and BDC. The most common type of liner
360 degrees. wear has a barrel shape, more in the center than at the ends.
The top and bottom probes ! The liner is tapered, with most wear occurring in the crank end.
form a V shape from 0 to ! Check for excessive packing wear.
360 degrees ! Check cylinder alignment.
The top and bottom probes ! The liner is tapered, with most wear occurring in the head end.
form an inverted V shape ! Check for excessive packing wear.
from 0 to 360 degrees ! Check cylinder alignment.
Patterns for top and bottom ! The rod is worn where the separation occurs. If this is around BDC,
probes separate on the rod check the rod for wear near the packing.
runout plot. Top drops and
bottom rises.
119
Compressor Faults
120
Main and crank bearings
Vibration
UNIT #4-E 7/17/2002 10:51:55 AM UNIT #4-E 7/17/2002 10:51:55 AM
Engine Vibration: Phased Vibration VT4: Engine Vibration: Phased Vibration VT4:
1.0 1.0
0.0 0.0
-0.5 -0.5
-1.0 -1.0
1.0 1.0
UNIT #4-EBRG2 (Med 1)
0.0 0.0
-0.5 -0.5
0.5 0.5
0.0 0.0
-0.5 -0.5
-1.0 -1.0
0 90 180 270 360 450 540 630 720 0 90 180 270 360 450 540 630 720
121
Compressor Faults
Foundation
Trend of frame vibration: broken anchor bolts
9 Horizontal displacement,
oil pump end, mil-p-p
8 High
5
Gradual increase
4 High Vertical displacement,
oil pump end, mil-p-p
3
2 High
1
Low Axial displacement, oil After repair
0 Low
pump end, mil-p-p
-1
4.5
122
Foundation
Spectrum: Normal frame vibration
K101P-V Testpoint OPEV 11/19/1997 2:01:47 PM
0.150 at 277.5
0.150 at 247.5
1.25 0.106 at 202.5
0.081 at 217.5
0.075 at 390.0
0.075 at 495.0
1.00 0.069 at 172.5
0.056 at 405.0
0.050 at 660.0
0.75
0.50
0.25
0.00
0 500 1000 1500 2000 2500
cpm
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123