Retrofit of Reciprocating Compressors - Hoerbiger Electric

7/24/2019 Retrofit of Reciprocating Compressors - Hoerbiger Electric

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REE Tutorial Gas Engine / Motor DriveRetrofit of Reciprocating CompressorsReliability. Efficiency. Environmental.

HOERBIGER Compression Technology

Gas Electric Conference Feb 7th 2014

Christean Kapp



Elements of the REE Audit

2

REE Audi t

ESMdata-base

Com-pressormanual

Mainte-nance

records

Failurehistory

Custo-mer

interview

Process

DCSdata

Siteinspec-

tion

Rule No 1: Know what you are getting into, Gather Data!

Departments involved:

Maintenance

Operation, Production

Process Projects

Reliability

Christean Kapp Tutorial Gas Engine Electric Drive Revamp



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Compressor and Engine data

Waukesha Engine to E-motor on

Dresser-Rand Natural Gas Compressor

Tutorial Gas Engine Electric Drive Revamp



REE Overview and Report

4

Current

Situation

Recommendedenhancements

Shortfall

relative to aREE Index of10

Rating

REE improvement potential

REE savings potential wi th

improvements

Christean Kapp Tutorial Gas Engine Electric Drive Revamp



Situation Engine – Motor Drive Retrofit Checklist

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Complete Site Review

Determine Control Options

Check Rod Loads

Check Vibration & Pulsation

Check TORSIONALS

Check Motor /Flywheel

Check Foundation

Check Cylinders & Bearings

Package Engineering & Project Management




Christean Kapp Tutorial Gas Engine Electric Drive Revamp 6

Control System Selection

• Key Criteria: Need to be evaluated Individually for Every Project:

Control

System

Cost

Attract iveness

Automatic Energy

Saving

Reliability Appl icabi li ty

(control range,

available

space)

Impact on valve

reliability

Reverse flow

(HydroCOM)

Medium High High High good

Variable

clearance

pocket

Medium High Medium

High

Medium good

Variable

FrequencyDrive

Low

MediumMediu

m

High Low

Mediumpoor




HydroCOM vs Variable Speed Control

Low Speed

requires high

Moment of Inertia




Control System Selection

• Safe and reliable system selectionfor existing compressor installation

requires sound methods Compressor - „Health Check“, Monitoring

Development of specific solutions„Feasibility Study“

• Depending on the required control

range and the selected controlsystem a more or less detailedengineering analysis is necessary.

Besides product related engineering it isnecessary to follow up with compressorand environmental related

Engineering Checks (EC)

Engineering

Check

Rod Load

Analysis

Pulsation &

Vibration

Analysis

Torsional

Anal ysi s

EC-Level 0

on-site (mandatory)

Health Check and data collection:

Lifecycle experiences Collection of monitoring data for pressure, temperatures, pulsation& vibration

Actually installed control system

Piping and Instrumentation Check

EC-Level 1

(mandatory)

Rod load

magnitude and

reversal check

Health Check and

Damper size

check:

Evaluation of

efficiency of the

pulsation &

vibration

suppression

devices for the newpart load

conditions based

on calculation and

pressure and

vibration

monitoring results

of the existing

installation

Analysis of

torsional effects of

the control system

onto the drive train

system: Change of

excitation torquesand frequencies

EC-Level 2

(optional in

case ofnecessity)

Pulsation Study

based on anacoustical analysis:

Damper Check

Natural frequency

Analysis within aCampell Diagram

EC-Level 3

(optional in

case of

necessity

Full pulsation and

mechanical

vibration Analysis

according API618 – Approach 3

Full Torsional

Vibration Analysis

according to API618




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Check Rod Loads


Check TORSIONALS


Check Foundation







Pulsation & Vibration Analysis

• Compressor applications in cr itical situation,

where already high vibration levels are

experienced and fatigue failures occurredfrequently a full pulsation & mechanical

vibration study according to API 618 –

Approach 3 has to be applied.

• Based on monitoring and inspection results of

the exist ing installation a focus on critical parts

of the installation is possible

• With the API618 method Approach 3 the system

is evaluated and pulsation / vibration

suppression devices like dampers, orifices andsupport structures have to be engineered new

based on the collected results.




Rod Load Analysis 70 % load (both HE and CE)

OK




Torsional Analysis: Summary

Torsional Vibration Analysis with bigger coupling:

Reduction of maximum vibration torques about 6 times

OLD Situation: New Situation:




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Check Rod Loads


Check TORSIONALS


Check Foundation





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Start up Curve,

Optimized Flywheel & Size Motor




Calculation of

Static and Dynamic foundation forces




Design of foundation and skid




Cylinder upgrade

Re-machining cylinders

New liner ?Piston with ring bushing

Hydraulic test

New piston and rider rings

New valve cages ?

New valve covers ?

Re-machining piston with rods

Cylinder cover with internals

New cylinder support design

New cylinder lubrication lines

New vibration monitoring

New packing and OT wiper




Frame and running gear overhaul with

re-engineered bearings

Original crankshaft was designed without axial bearing.

The fix point was in the engine drive




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Check Rod Loads


Check TORSIONALS


Check Foundation







P&ID

Gas, Water, Cylinder & Frame Lubrication



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Driver Change / Waukesha Engine to E-motor on

Dresser-Rand Super CUB


Retrofit of Reciprocating Compressors - Hoerbiger Electric

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