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Franz O.,PROGNOST Systems GmbH | Vigants J.,PROGNOST Systems Inc.
American Society of Mechanical Engineers, Pressure Vessels and Piping Division (Publication) PVP | Year: 2015

The high pressure (Hyper) Compressor is one of the most critical assets within a LDPE production line. Failures starting off with simple valve leakage may lead into interstage pressure variation, load increasing and loss of load reversal and finally a main bearing failure resulting into multiple days' downtime. This paper describes some of the challenges and a proven effectively method for monitoring Hyper compressors and its individual components. Using a series of short real-life case studies, it will be illustrated how a state-of-the-art monitoring technology helps to detect impending failures at an early stage to eliminate consequential damages and avoids to be caught off-guard. One case study describes the early indication of a developing valve failure; another provides understanding how a packing failure is detected reliably. The third case study covers aspects of a safety relevant damage resulting into an automatic compressor shutdown, which otherwise would have likely resulted into significant and costly production loss. The session will be concluded with hands-on guidance on recommended Safety Protection analysis. Copyright © 2015 by ASME.

Anderhub J.,PROGNOST Systems GmbH
Hydrocarbon Engineering | Year: 2011

Several measures that need to be considered when choosing monitoring and diagnostic technologies for reciprocating sensors are presented. Systems should be functionally scalable, allowing new or additional capabilities, such as measuring loops, to be added to an installed system without inordinate cost or difficulty and system should offer a means to expand monitoring to additional machines. A monitoring system should warn the user about problems and provide an accurate diagnosis with specific component identification, location and indication of the extent of damage. A monitoring system should continuously acquire and diagnose machine vibrations for each crank revolution and then segment signals into crank angle related portions. The vibration signals must be evaluated using the most accurate mathematical analysis. The most effective monitoring systems incorporate rod position measurement in conjunction with analyses of other parameters to identify impending failures in drive train integrity.

Drewes E.,Prognost Systems GmbH | Anderhub J.,Prognost Systems GmbH
Hydrocarbon Engineering | Year: 2011

An insight into the basic techniques and challenges associated with the application of automatic diagnosis of reciprocating compressors, is provided. The techniques include technical diagnosis, signal based methods, and automated diagnosis and pattern recognition methods. Compared to other rotating equipment, reciprocating compressors involve greatly varying stress levels for many components. To deal with the challenges, PROGNOST Systems GmbH developed an automatic feature in their PROGNOST®-NT automatic diagnosis system for detecting operating conditions that affect the measurement data used for diagnosis. Based on the available information for cylinder four, the system diagnosis module can detect a fault in the sticking suction valve category. The rate of coincidence with all the patterns available for the sticking suction valve category determined using fuzzy logic methods is 61%; for damaged discharge valve it is 60.3%.

Drewes E.,Prognost Systems GmbH | Anderhub J.A.,Prognost Systems GmbH
Hydrocarbon Engineering | Year: 2010

Eike Drewes and JostA Anderhub, PROGNOST Systems GmbH, Germany, discuss how the use of modern, specialized monitoring systems can have a positive effect for operators. All companies that operate process critical machines must set themselves the task of evaluating the risks when operating the equipment. The result is a certificate that is valid worldwide and documents the safety requirements met by the monitoring system Safety Integrity Level (SIL). A SIL awarded for overspeed protection in turbomachinery is useless in ensuring safety in reciprocating machinery. Due to the rapid development of some types of damage, a gapless transient record of as much data as possible is crucial in the post mortem analysis in order not to miss any important elements when securing evidence for understanding the events. Operators with high costs for a small number of reciprocating machines should, through targeted retrofitting, take the step into the 21st century so as to not expose themselves to accusations of backwardness.

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