Cases with PROGNOST®-NT

Condition Monitoring on a reciprocating compressor in a shale oil plant

2020-11-10T07:47:40+01:00Customer Case Studies, Cases with PROGNOST®-NT, Online Condition Monitoring, Published Articles, Reciprocating Machinery|

Reciprocating compressors are often used to handle very dirty and corrosive gases that have a negative impact on component lifetime and affect on the plant productivity. Due to this fact there are several ways to handle this problem, a few plants are using a identic machine as backup and in case of failure they are using the twin machine to keep the process running. But maybe this is not the best way. Efficient plants are asking for a condition monitoring system, this is where PROGNOST Systems comes to the play. A installation of a condition monitoring system like PROGNOST®-NT brings several benefits to the operator. Starting at the maintenance planning because he sees the development of his wearing parts and [...]

Company (LDPE industry) avoided costs, by trusting Machine Monitoring System

2020-07-03T08:47:48+02:00News, Cases with PROGNOST®-NT, Customer Case Studies, Featured, Hyper Compressor, Knowledge Hub, Online Condition Monitoring, Reciprocating Machinery, Vibration Monitoring|

Detection of various valve failures on LDPE hyper compressor within the six weeks of operation saved 250 million USD in production loss

Timely trip of a LDPE hyper compressor

2020-09-04T07:33:39+02:00Customer Case Studies, Cases with PROGNOST®-NT, Featured, Hyper Compressor, News|

Monitored Machine The monitored machine is a secondary LDPE Hyper Compressor (high pressure compressor) in Ethylene service of LDPE production line. What happened? Sequence of events On March 29, the PROGNOST System tripped the Hyper compressor in consequence of high plunger vibration on cylinder 2AVertical position lead LDPE unit for total shut downThe Maintenance group of the customer, started the root cause analysis with assistance of the PROGNOST Systems Customer Support team, they analyzed the data and finally recommended to open the cylinder for inspection Trend over 60 minutes of plunger position Peak-to-Peak values Findings As a result of the cylinder opening the following findings where detected. In the plunger path way they found Chips of packing ring material.The packing [...]

Detection of a damaged crankshaft bearing

2020-06-05T09:47:36+02:00Customer Case Studies, Cases with PROGNOST®-NT, Hyper Compressor, News, Online Condition Monitoring|

Information about monitored Machine Hitachi-Buckhardt Hyper Compressor F10 10 cylinders, 2 stages, in Ethylene service for LDPE production Speed: 189 rpm Power: 11 186 kW (15000 hp) Inlet pressure: 250 bar (3,626 psi) / Outlet pressure: 3.165 bar (45,904 psi) Hitachi-Buckhardt Hyper Compressor F10 Used Monitoring equipment and sensor positions Monitoring sensor positions What happened (Sequence of events)? Development of vibration increases over a time of 6 months. Long term trend over 6 months of the crosshead slide vibration of cylinder B1 in 3D plot Since May 30, for segments 31 and 32, vibration values increase from 2,5 m/s² (0.25 g) to over 10 m/s² (1 g) Segmented vibration plot Shutdown of [...]

Lube oil in compression chamber

2020-06-05T09:52:26+02:00Customer Case Studies, Cases with PROGNOST®-NT, News, Reciprocating Machinery, Vibration Monitoring|

Machine data NEA (Neumann Esser) horizontal reciprocating compressor with 4 throws. 1 stage in Natural gas service. The Pressure for Inlet is 33 bar (479 psi) for Outlet 75 bar (1088 psi). NEA horizontal reciprocating compressor Used Monitoring Software Modules of PROGNOST®-NT Machine Protection Early Failure Detection Wear Monitoring Performance Optimization Process Data Integration Sequence of events PROGNOST Systems received a call from the customer. The compressor was shut down by the PROGNOST system shortly after start up. This was a result of protection limit violations on two measuring points. In detail the shutdown was triggered by increased vibrations at the crosshead guides 3 and 4, this affected segment 20 of crosshead slide (CHS) 3 and segment 19 [...]

Early detection of rider ring damage on a Free Floating Piston

2020-06-05T09:49:02+02:00Knowledge Hub, Cases with PROGNOST®-NT, Customer Case Studies, Reciprocating Machinery|

Application Thomassen piston compressor2 throws, 2 stagesMedium: HydrogenCapacity control: HydroCOM The compressor has a „Free Floating Piston“ system with non-lubricated cylinder (for lifetime optimization of rider rings) and a mini-lube stuffing box seal. This machine combines the Free Floating Piston system with a Hoerbiger HydroCOM flow regulation. Since the initial compressor start, the piston rings of both stages reached only short operation lifetimes of 1,500 hours and with a decreasing tendency: Lifetimes before replacement of piston rings of the 1st stage 1,850 hrs   707 hrs   891 hrs   801 hrs1,607 hrs Lifetimes before replacement of piston rings of the 2nd stage 3,773 hrs4,006 hrs Preliminary PROGNOST® data analysis: Detection and location of the problem Expansion and compression lines of the p-V diagrams of [...]

Babbitt metal wear on crosshead

2020-06-05T09:44:14+02:00Customer Case Studies, Cases with PROGNOST®-NT, Cases with PROGNOST®-SILver|

Machine data Manufacturer: ArielDrive power: 6150 kW (8636 hp)Speed: 700 rpm6 cylinderDouble acting, 2 stagesSuction pressure: 40 barDischarge pressure 240 bar Sequence of events: 3:45 AMPROGNOST®-SILver Protection hardware shut down the monitored compressor. Initiated because of piston rod position of cylinder 1. 5:02 AMPROGNOST®-SILver tripped the compressor again during start-up. Again due to rod position cylinder 1. 9:45 AMPROGNOST Customer Support recommends to make no restart, cause of high piston rod movement Screenshots from Online Condition Monitoring system PROGNOST®-NT 2 months 3D-trend of rod position 2 months 3D-trend of crosshead slide vibration Evaluation No long term indications on crosshead slide (CHS) and rod position (RP)No changing pressure gradientHigher dynamic in RP signalCHS peak nearly 2nd rod load reversal point decreasesCHS [...]

Early detection of rider band and piston ring failure

2020-06-05T09:48:58+02:00Customer Case Studies, Cases with PROGNOST®-NT, Online Condition Monitoring|

Shutdown due to high values of Peak-To-Peak and Piston rod position of the Booster cylinder. Monitored compressor Booster Primary, Burckhardt Compression B5C 1.654 cylinders, 5 stagesSuction pressure (0,6 bar)Discharge pressure (245 bar) Trend November 2015 Rod position values October - November 2015 Meaningful analysis and display Segmented piston rod position in 3D trend view Root cause analysis Findings

Consequential damages of failed lubrication

2020-06-05T09:46:58+02:00Customer Case Studies, Cases with PROGNOST®-NT, Machine Protection, Online Condition Monitoring|

PROGNOST® successfully detected irregularities during the supply of lube oil at the crosshead. Based on two case studies, the following text illustrates the necessity of appropriate monitoring. The operation mode of a reciprocating compressor requires the continuous supply of lubrication. This is due to the multitude of moving parts that are required to convert the rotating into an oscillating movement. This movement is implemented by the crosshead. This component moves between two contact surfaces and is continually subject to high forces, i.e. compression and tension, as well as friction. At the centre of the crosshead, a ‘crosshead pin’ connects the crosshead to the piston, onto which, facing the side of the cylinder, the piston rod is bolted. The crosshead pin [...]

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