OPERATION MONITORING

Presented by FS Engineer
Sundyne Corporation
 Type of DCS Events

Signals to the DCS are monitored for the following events

• Permissive start - Allowing the Compressor to be started,
based on permissive set point
• Alarm - Investigate the change and find the root cause,
based on alarm set point
• Controlled shutdown - Shutdown the Compressor within 3
hours, based on trip set point with specific signals
• Immediate shutdown - Emergency shutdown of
Compressor, based on trip set point with voting between
specific signals
IMMEDIATE SHUT DOWN
 SHUTDOWN

HIGH SUCTION KNOCK OUT DRUMP

= IMMEDIATE SHUTDOWN !
 ALARM/TRIP : SKID

ALARM/TRIP SETTING

UNIT
INSTRUMENT PART CALIBRATED
REV TYPE APPLICATION MANUFACTURER Model RANGEABILITY

Permissive to start
steady state (1)
Tag # NUMBER RANGE

Alarm Category
Alarm low/high

Trip low/high
Unit

Unit
(3)

(4)
Oil circuit
212-PI-212 F39-1174 0 Pressure gauge WIKA 233.50 - 0/1 MPa g 0.2 - MPa g - - - MPa g
Before gearbox

212-LG-201 GA01AA01 C Level indicator Gearbox SUNDSTRAND - - - - - - - - - - -

Oil circuit
212-PIT-209 F39-1173 0 Pressure transmitter EMERSON 3051 CG4 0.02 / 2.06 0/1 MPa g 0.2 - MPa g - - 0.08 / - MPa g
Before gearbox

Oil circuit
212-PIT-211 F39-1173 0 Pressure transmitter EMERSON 3051 CG4 0.02 / 2.06 0/1 MPa g 0. 0.12 MPa g 0.1 / - 1 - MPa g
Before gearbox

Differential pressure
212-DPI-234 F39-1178 0 Duplex oil filter WIKA 733.14 - 0 / 250 kPa 35 - kPa 100 2 - kPa
gauge

Gearbox
212-TT-064 F51-543 0 Temperature transmitter EMERSON 3144P (1) -60 / 120 -60 / 120 °C 65 - °C - / 100 1 - / 110 °C
upper thrust bearing

Gearbox
212-TT-066 F51-543 0 Temperature transmitter EMERSON 3144P (1) -60 / 120 -60 / 120 °C 65 - °C - / 100 1 - / 110 °C
upper journal bearing

Gearbox
212-TT-068 F51-543 0 Temperature transmitter EMERSON 3144P (1) -60 / 120 -60 / 120 °C 65 - °C - / 100 1 - / 110 °C
lower journal bearing

Oil circuit
212-TT-201 F51-544 0 Temperature transmitter EMERSON 3144P (2) -60 / 120 -60 / 120 °C 49 - °C - - - / 75 °C
Before gearbox

Oil circuit
212-TT-203 F51-544 0 Temperature transmitter EMERSON 3144P (2) -60 / 120 -60 / 120 °C 49 - °C - / 65 2 - °C
Before gearbox

Oil circuit
212-TI-205 F41-382 0 Temperature gauge WIKA S73.100 -60 / 100 - °C 49 - °C - - - °C
Before gearbox
 ALARM/TRIP : SKID

ALARM/TRIP SETTING

Permissive to start
steady state (1)

Alarm Category
Alarm low/high

Trip low/high
UNIT
INSTRUMENT PART RANGEABIL CALIBRATE
REV TYPE APPLICATION MANUFACTURER Model
Tag # NUMBER ITY D RANGE

Unit

Unit
(3)

(4)
212-VT-203A - - Radial probe X axis Lower bearing Gearbox BENTLY NEVADA 330980 0 / 100 0 / 100 µm pk-pk 20 - µm pk-pk - / 48 1 - / 64 µm pk-pk

212-VT-203B - - Radial probe Y axis Lower bearing Gearbox BENTLY NEVADA 330980 0 / 100 0 / 100 µm pk-pk 20 - µm pk-pk - / 48 1 - / 64 µm pk-pk

212-VT-201A - - Radial probe X axis Upper bearing Gearbox BENTLY NEVADA 330980 0 / 100 0 / 100 µm pk-pk 20 - µm pk-pk - / 48 1 - / 64 µm pk-pk

212-VT-201B - - Radial probe Y axis Upper bearing Gearbox BENTLY NEVADA 330980 0 / 100 0 / 100 µm pk-pk 20 - µm pk-pk - / 48 1 - / 64 µm pk-pk

- -

212-TCV-210 - - Thermostatic valve Oil circuit AMOT 3/4 CM - 49 °C 49°C - °C - - - °C

Main motor
212-TE-070 - - RTD probe EPHY-Mess M-OK/DSH/KH PT100 -50 / 180 - °C - - °C - / 135 1 - / 145 °C
winding

Spare Main motor

212-TE-071 - RTD probe EPHY-Mess M-OK/DSH/KH PT100 -50 / 180 - °C - - °C - / 135 1 - / 145 °C
Non connected winding

Main motor
212-TE-072 - - RTD probe EPHY-Mess M-OK/DSH/KH PT100 -50 / 180 - °C - - °C - / 135 1 - / 145 °C
winding

Spare Main motor

212-TE-073 - RTD probe EPHY-Mess M-OK/DSH/KH PT100 -50 / 180 - °C - - °C - / 135 1 - / 145 °C
Non connected Winding

Main motor
212-TE-074 - - RTD probe EPHY-Mess M-OK/DSH/KH PT100 -50 / 180 - °C - - °C - / 135 1 - / 145 °C
Winding

Spare Main motor

212-TE-075 - RTD probe EPHY-Mess M-OK/DSH/KH PT100 -50 / 180 - °C - - °C - / 135 1 - / 145 °C
Non connected Winding
 ALARM/TRIP : SKID

ALARM/TRIP SETTING

UNIT

Permissive to start
INSTRUMENT PART CALIBRATED

steady state (1)

Alarm Categorie
REV TYPE APPLICATION MANUFACTURER Model RANGEABILITY

Alarm low/high
Tag # NUMBER RANGE

Trip low/high
Note 3

Note 4
Unit

Unit
Main motor M-OK/DSH/KH
212-T-250 (251) - - RTD probe EPHY-Mess -50 / 121 - °C - - °C - / 110 1 - / 120 °C
Bearing PT100

Main motor M-OK/DSH/KH

212-T-252 (253) - - RTD probe EPHY-Mess -50 / 121 - °C - - °C - / 110 1 - / 120 °C
Bearing PT100

Oil circuit
212-PI-216 F39-1174 0 Pressure gauge WIKA 233.50 0/1 - MPa g - - MPa g - - - MPa g
Before gearbox

Buffer line inlet

212-PI-201 F39-1174 0 Pressure gauge WIKA 233.50 0/1 - MPa g 0.3 - MPa g - - - MPa g
Port 2

Differential pressure Buffer line inlet

212-DPI-230 F39-1175 0 WIKA 733.14.100 0/100 - kPa <5 - kPa 50 2 - kPa
gauge gas filter Port 2

Oil circuit
212-TI-207 F41-382 0 Temperature gauge WIKA S73.100 -60 / 100 - °C 49 - °C - - - °C
Before gearbox

212-LSH-203 F23-222 0 Level switch Oil trap EMERSON 2120D - - On/Off - - On/Off - - - On/Off

Seal buffer outlet

212-PIT-207 F39-1173 0 Pressure transmitter EMERSON 3051CG4 0.02 / 2.06 0.02 / 2.06 MPa g 0.3 - MPa g - - 1.5 MPa g
Port 7

Seal buffer outlet

212-PIT-205 F39-1173 0 Pressure transmitter EMERSON 3051CG4 0.02 / 2.06 0.02 / 2.06 MPa g 0.3 - MPa g 1 2 - MPa g
Port 7

212-PIT-214 F39-1176 0 Pressure transmitter Propylene flush gas EMERSON 3051CG5 0.14 / 13.79 0/6 MPa g 2.48 - MPa g 2 1 - MPa g

212-PI-203 F39-1174 0 Pressure gauge Flush line WIKA 233.50 0/6 - MPa g 2.6 - MPa g - - - -

Differential pressure Flush line

212-DPI-232 F39-1175 0 WIKA 733.14.100 0 / 100 - kPa <3 - kPa 30 2 - kPa
gauge gas filter

Flow transmitter
212-FIT-201 F27-223 0 Flush line EMERSON R050S 0 / 300 0 / 200 Nm3/h 132.0 - Nm3/h 85.7 2 - Nm3/h
(coriolis type)

212-ZSO-201 - Limit switch Compressor drain valve STAHL 8070 - - On/Off - - On/Off - - - On/Off

212-ZSC-201 - - Limit switch Compressor drain valve STAHL 8070 - - On/Off - - On/Off - - - On/Off

Integrated
212-LG-203 - Level indicator Oil trap SUNDSTRAND - - - - - - - - - - -
on oil trap
 SEAL FAILURES

PRIMARY SEAL FAILURE =

CONTROLLED SHUT DOWN FOR SEAL REPLACEMENT

LEAKAGE FLOW HIGH /FIH 53254A/B

SEAL LEAKAGE FLOWMETER
SEAL LEAKAGE
Compressor Monitoring
Compressor Monitoring
Compressor Monitoring
 Compressor Monitoring

Gearbox
• Radial bearing THERMOCOUPLE
– Alarm – 105°C
– Immediate shutdown – 110°C

• Active Thrust bearing THERMOCOUPLE

– Alarm – 105°C
– Immediate shutdown – 110°C
BEARING TEMPERATURE
BEARING TEMPERATURE
BEARING TEMPERATURE
BEARING TEMPERATURE
Compressor Monitoring
Compressor
Monitoring: System 1
Compressor Monitoring
COMPRESSOR MONITORING
Compressor Monitoring
Compressor Monitoring
VIBRATIONS
 WHAT IS VIBRATION?

A mechanical motion or oscillation about a reference point of

equilibrium

A periodic motion : the movement of a body about a reference

position which repeats itself after a certain interval of time.
 THE SOURCES OF VIBRATION

UNBALANCE
MISALIGNMENT
MECHANICAL LOOSENESS
BENT SHAFT
GEAR NOISE (MESH)
ELECTRICAL
DAMAGED BEARINGS (HIGH WEAR)
HYDRAULICS (BLADE PASS)
RESONANCE
 THE RESULTS OF VIBRATION

EXCESSIVE WEAR, REDUCED LIFE OF PARTS

INCREASED NOISE

INCREASED MAINTENANCE

INCREASED POWER LOSSES

DECREASED QUALITY

CAN AFFECT EQUIPMENT NEARBY

 HOW WE DECREASE VIBRATION

ROTATING ELEMENTS ARE BALANCED TO ELIMINATE OR REDUCE

UNEVEN MASS DISTRIBUTION

EACH PART IS BALANCED INDIVIDUALLY

THE RESULTANT UNBALANCING MASS OF THE ASSEMBLY IS THE SUM

OF THE MINIMUM UNBALANCING MASSES OF EACH ITEM
BALANCING PROCESS
BALANCING PROCESS
BALANCING PROCESS
BALANCING PROCESS
BALANCING PROCESS
BALANCING RECORDS
BALANCING RECORDS
BALANCING RECORDS
BALANCING PROCESS
BALANCING PROCESS
 BALANCING

UNBALANCE IN A ROTATING PART IS INDEPENDENT OF ROTATIONAL

SPEED

HOWEVER, THE EFFECT OF UNBALANCE (CENTRIFUGAL FORCE)

INCREASES WITH THE SQUARE OF THE SPEED

WE BALANCE TO ISO 2.5 (G2.5)

API 610 maximum unbalancing mass calculation:

UM=4*Weight / Output Speed
 COMPRESSOR – BALANCE EXAMPLE

Impeller
• N = Output Speed = 29,998 rpm
• W = Weight of Impeller = 5.71 lbm
• API Balance Specification:
– 4W/N = (4 * 5.71)/29,998 = 0.0008 oz.-inch

High Speed Shaft

• N = Output Speed = 29,998 rpm
• W = Weight of Shaft = 10.36 lbm
• API Balance Specification:
– 4W/N = (4 * 10.36)/29,998 = 0.0014 oz.-inch
 MEASURES OF VIBRATION

AMPLITUDE

FREQUENCY

PHASE
Vibration Measure Relation

Acceleration
(Energy Change)

Velocity
(Total Energy)

Displacement
(Movement)
Frequency
 PROPERTIES OF VIBRATION

DISPLACEMENT

VELOCITY

ACCELERATION
 DISPLACEMENT

DISPLACEMENT : MAGNITUDE OF THE MOTION OF VIBRATION

MEASURED IN INCHES OR MILS

PEAK TO PEAK
 VELOCITY

IS THE RATE OF CHANGE OF DISPLACEMENT PER UNIT TIME

MEASURED IN INCHES PER SECOND. (IPS)

RMS (root mean square)

O-PEAK
PEAK-TO-PEAK
 Amplitude, Frequency and Phase
360  t
Phase_ Shift 
T 1 1
Frequency  
Period T
T
t

XPEAK

XRMS
XAVE
 ACCELERATION

IS THE RATE OF CHANGE OF VELOCITY PER UNIT TIME

STATED IN TERMS OF GRAVITY OR “G’S”

 TYPES OF VIBRATION PROBES

DISPLACEMENT PROBES

VELOCITY PROBES

ACCELEROMETERS
• SINGLE INTEGRATION = VELOCITY
• DOUBLE INTEGRATION = DISPLACEMENT
 WHAT DOES THIS MEANS?

Overall vibration levels are measured and go/no go determination

made.

To determine a potential cause, a frequency or spectral analysis is

required.

These can be quantitative (vibration level) or qualitative (spectrum

analysis).
 DISPLACEMENT PROBES

MEASURE RELATIVE SHAFT MOTION DIRECTLY

VOLTAGE CHANGE INDICATES CHANGES IN GAP

PERMANENTLY INSTALLED
 VELOCITY PROBES

USED FOR SURFACE VIBRATION

LIMITED FREQUENCY RANGE

REQUIRE CALIBRATION

PORTABLE
 ACCELEROMETERS

MOST ACCURATE AND RUGGED

BROADEST APPLICATION RANGE

WEAK AT LOW FREQUENCY

SENSITIVE TO MOUNTING

PORTABLE
ACCELEROMETERS
 MOUNTING METHODS ACCURACY

Stud mounted – up to 10,000 Hz

Glue – up to 5,000 Hz

Adhesive – up to 2,000-4,000 Hz

Magnet – up to 2,000 Hz

Hand held – up to 500 Hz

 PREDOMINANT FREQUENCIES

INPUT SHAFT SPEED

INPUT GEAR MESH FREQUENCY

HIGH SPEED SHAFT SPEED

 Main frequencies
N= N= Input Shaft
53 120 2 973 RPM
49,55 Hz

Upper 356 760,00 RPM

gear mesh 5 946,00 Hz
Idler Shaft Lower 706 788,68 RPM
6 731 RPM gear mesh 11 779,81 Hz
112,19 Hz
N=
75 High speed shaft
9 424 RPM
N= 157,06 Hz
105
Blade pass
8 75 391 RPM
Gearbox Ratio blades 1 257 Hz
3,17 24 226 172,38 RPM
blades 3 769,54 Hz
 Harmonic frequencies
Input Shaft Idler Shaft High Speed Shaft
2973 50 6731 112 9424 157
5946 99 13463 224 18848 314
8919 149 20194 337 28272 471
11892 198 26925 449 37695 628
14865 248 33657 561 47119 785
17838 297 40388 673 56543 942
20811 347 47119 785 65967 1099
23784 396 53851 898 75391 1257
26757 446 60582 1010 84815 1414
29730 496 67313 1122 94238 1571
32703 545 74045 1234 103662 1728
PROBE CALIBRATION
VIBRATION PROBES
 Compressor Monitoring

Gearbox Vibration (BN 3300 RAM series probes)

Start up delay of 10 seconds for BN system
activating
• High speed shaft
– One keyphasor
– X & Y radial probes (Impeller & blind end bearings)
– Alarm – 48µ
– Immediate shutdown – 64µ
Compressor Monitoring
Compressor Monitoring
Compressor Monitoring
 Compressor Monitoring

MAIN MOTOR
Bearing temperature : Alarm:110°C /SD:120°C
Winding Temperature:Alarm:135°C/SD:145°C
 SUNDYNE REFERENCE POINT

UPPER IDLER
SHAFT
BEARING
INPUT SHAFT
BEARINGS

LOWER
IDLER
SHAFT
OUTPUT SHAFT BEARING
BEARINGS
 VIBRATION CRITERIA

VELOCITY TRANSDUCER

TEST ACCEPTANCE *ANTICCIPATED ALARM SHUTDOWN

LIMIT (FULL SPEED) FIELD LEVELS LIMIT LIMIT
MODEL IN/SEC IN/SEC IN/SEC IN/SEC
(MM/SEC) (MM/SEC) (MM/SEC) (MM/SEC)
FILTERED UNFILTERED FILTERED UNFILTERED FILTERED UNFILTERED FILTERED UNFILTERED
0.15 0.2 0.2 0.25 0.25 0.35 0.3 0.4
LMV/BMP (3.81) (5.08) (5.08) (6.35) (6.35) (8.89) (7.62) (10.16)
0.15 0.2 0.2 0.25 0.25 0.35 0.3 0.4
LMC/BMC (8.89) (7.62) (10.16)
(3.81) (5.08) (5.08) (6.35) (6.35)
SHAFT PROBES (HIGH SPEED SHAFT ONLY)

TEST ACCEPTANCE *ANTICCIPATED ALARM SHUTDOWN

LIMIT (FULL SPEED) FIELD LEVELS LIMIT LIMIT
MODEL MILS MILS
MILS MILS
(MICROMETERS) (MICROMETERS) (MICROMETERS) (MICROMETERS)
FILTERED UNFILTERED FILTERED UNFILTERED FILTERED UNFILTERED
LMV/BMP 1.5 2.0 1.5 2.0 2.0 2.5 2.5 3.0
(ALL) (38.1) (50.8) (38.1) (50.8) (50.8) (63.5) (63.5) (76.2)
1.4(1/REV) 1.4 1.4 1.4 1.9 1.9 2.5 2.5
LMC/BMC (35.56) (35.56) (35.56) (48.26) (48.26) (63.5) (63.5)
(35.56)
LMC/BMC 1.0(1/REV) 1.0 1.0(1/REV) 1.5 2.5
1.0 1.5 2.5
(SPECIAL (25.4) (25.4) (25.4) (38.1) (63.5)
(25.4) (38.1) (63.5)
GEARBOX)
HMP 1.7 2.0 1.7 2.0 2.5 2.5 3.0 3.0
(STANDARD) (43.18) (50.8) (43.18) (50.8) (63.5) (63.5) (76.2) (76.2)
HMP 1.0 1.3 1.0 1.3 2.5 2.5 3.0 3.0
(SPECIAL) (25.4) (33.02) (25.4) (33.02) (63.5) (63.5) (76.2) (76.2)

* Many units will run at levels below this value. When this is the case, it is recommmended that the user set the
alarm 0.5 mils (12 µm) above actual and shutdown 1.0 mil (25.4 µm) above actual.