3.

0
Failure Analysis -
Predicting Maintenance
(Reciprocating Compressor Packages)
Dave Simonar
Field Operations Engineer
Universal Compression Inc.

The following presentation briefly describes a number of common procedures used when conducting failure
analysis and when initiating a predictive/preventative maintenance program on a typical compressor package.
Failure analysis and predicting maintenance are two distinct topics, but each one impacts the other. With
respect to a specific failure, the most effective approach in conducting a successful failure analysis involves;
the accumulation of good statistical data for similar units/packages, documentation of previous and existing
operations, obtaining failure history of the unit, and extensive use of good technical/field experience of the
unit/s. There are a number of monitoring and diagnostic tools available for operations and service supply
personnel to use to pinpoint or prove the cause of a given failure. Once enough pertinent data is collected and
all of the facts are evaluated, a solution or a number of solutions are usually decided upon.
With respect to future maintenance on a unit, the best starting point is from using manufacturers’
recommended practices, procedures and maintenance intervals. The next step is to establish comprehensive
failure analysis and to establish a preventative maintenance schedule for the operating equipment.
 3.1

Failure Analysis
(Reciprocating Compressor Packages)

- Accumulate as much Pertinent Data as Possible

-Understand the Operation of Subject Equipment
-Confirm that the Unit is Properly Designed for
Required Operating Conditions
 3.2

Use of Specialized Services

(Establish possible causes of failure)

-Manufacturers’ of Failed Components

-Laboratories and Equipment Specialists
-Vibration Analysis and Inspection Companies
-Instrumentation and Mechanical Troubleshooters
-Foundation/Civil Specialists
 3.3

Document Equipment/Operating Data

(usually supplied by operating company)

-Routine Recording of Operating Conditions

-Electronic Real Time Capture of Operating Conditions
-Real Time Vibration Monitoring
-Real Time Monitoring of Compressor Dynamics
-Design Drawings, As-Builds, Models, Photographs
 3.4

Engine
Data

1 2 3 4 5 6
Date
Location
Unit#
Time
Engine Hours
Performance Data
Speed RPM
Torque %
Max. Torque %
Ignition Timing BTC
EAR %
Pilot %
Main Fuel Flow (SCFM)
Air Flow (FT3/SEC)
Pilot % Output
A/F Ratio
Supply Volts
MW DT (ms)
Cylinder Temperatures
RB Cyl #1 Temp DegF
RB Cyl #2 Temp DegF
RB Cyl #3 Temp DegF
RB Cyl #4 Temp DegF
RB Cyl #5 Temp DegF
RB Cyl #6 Temp DegF
LB Cyl #1 Temp DegF
LB Cyl #2 Temp DegF
LB Cyl #3 Temp DegF
LB Cyl #4 Temp DegF
LB Cyl #5 Temp DegF
LB Cyl #6 Temp DegF
Temperatures
Manifold Temperatures
JW Temp DegF
Oil Temp DegF
TIT Right Temp DegF
TIT Left Temp DegF
Fuel Gas Temp Deg F
MW Gas Temp DegF
Air Inlet Temp DegF
JW in Temp Deg F
JW out Temp Deg F
AuxW in Temp Deg F
AuxW out Temp Deg F
Ambient Deg F
 3.5
Engine Sheet 2
Data 2412G

Pressures 1 2 3 4 5 6
Oil Pressure, psig
JW Pressure, psig
I/C Pressure, psig
Manifold Pressure, psig
Main Gas Pressure, psig
Pilot Gas Diff. Pressure, psig
Main Gas Diff. Pressure, psig
Pilot Gas Diff. Pressure, psig
Barometer, psi
Prelube Pressure, psig
Control Loops
RPM Setpoint
Actual RPM
Main Fuel Setpoint
EAR % Desired
EAR %
Wastegate Output %
Main Fuel Setpoint
Fuel Flow %
Main Fuel Output %
Pilot Fuel Setpoint %
Pilot Fuel %
Pilot Fuel Output %
Process Variables - Metric
Units
Suction Pressure, kPag
Suction Temperature, Deg C
Discharge Pressure, kPag
Discharge Temp., Deg C
Miscellanous Data
Compressor Oil Press., kPag
Compressor Oil Temp., Deg C
Comp. Vibration, mm/s
Cooler Vibration, mm/s
Engine Vibration, mm/s
After Cooler Temp. Deg C
Fuel Gas Specific Gravity
LHV
NBN
CO2 %
N2 %
C1 %
C2 %
C3 %
iC4 %
nC4 %
 3.6

Reporting of Failures
(Warranty Considerations)

-Data Collection Key to Failure Analysis

-Warranty Work Must be Performed by Approved
Companies/Personnel and with Warranty Approved
Replacement Parts
-Proper Information to Manufacturer
 3.7
Engine Data
Performance
RPM:_______________________________________ Timing BTDC:_______________________________
Torque %:___________________________________ Torque % Max:_______________________________
EAR Actual:_________________________________ EAR Setpoint:________________________________

Main Fuel Flow:______________________________ Main Fuel Valve Output %:____________________

Pilot %:_____________________________________ Pilot % Setpoint:______________________________
Pilot Fuel Flow-#/min:_________________________ Pilot fuel Valve Output %:______________________
Wastegate Valve Output %:____________________ Air Flow-lb/sec:_______________________________
A/F Ratio – lb/lb:_____________________________ Stoich. A/F Ratio:_____________________________

Vol. Eff. %:__________________________________ Battery Volts:________________________________

Fuel S.G.:___________________________________ LHV – btu/scf:________________________________
MW Fuel:___________________________________ Vol % of Inerts:_______________________________

Pressures
Lube Oil:___________________________________ Jacket Water:________________________________
Intercooler Water:___________________________ Air Manifold:_________________________________
Main Fuel:__________________________________ Main Fuel Delta:______________________________
Pilot Fuel:__________________________________ Pilot Fuel Delta:_______________________________
Barometric:_________________________________ Crank Case:__________________________________
Exhaust:____________________________________

Temperatures
Turbine Inlet:_______________________________ Manifold:____________________________________
Intake Air:__________________________________ Jacket Water:________________________________
Intercooler:_________________________________ Oil:_________________________________________
Fuel:_______________________________________ MW Gas:____________________________________

Cylinder Temperatures: Compression Tests:

1R_______________ 1L_______________ 1R_______________ 1L_______________
2R_______________ 2L_______________ 2R_______________ 2L_______________
3R_______________ 3L_______________ 3R_______________ 3L_______________
4R_______________ 4L_______________ 4R_______________ 4L_______________
5R_______________ 5L_______________ 5R_______________ 5L_______________
6R_______________ 6L_______________ 6R_______________ 6L_______________
7R_______________ 7L_______________ 7R_______________ 7L_______________
8R_______________ 8L_______________ 8R_______________ 8L_______________

(Attach Operations Data For Day of Failure If Available)

 3.8

Compressor Data

Series Size

Frame Oil Pr. Oil T. RPM CLEARANCE UNLOADED

Cyl#1 PS1 PD1 TS1 TD1

Cyl#2 PS2 PD2 TS2 TD2

Cyl#3 PS3 PD3 TS3 TD3

Cyl#4 PS4 PD4 TS4 TD4

Cyl#5 PS5 PD5 TS5 TD5

Cyl#6 PS6 PD6 TS6 TD6

Cyl#7 PS7 PD7 TS7 TD7

Cyl#8 PS8 PD8 TS8 TD8

Replaced Parts
Qty. Part Number Description

CompleteAllAvailable Data
 3.9

Compressor Performance and Predicting Failures

Theoretical calculations (compressor performance runs):

-Mechanical Limitations, Compressor, Driver and Entire

Package
-Process Limitations, Gas Rates and Pressures
-Operating Limitations Set by Operating Company
 3.10
CUSTOMER: Generic Compressor Run QUOTE #: Gas Compression
Quote
LOCATION: Somewhere DATE: 02-14-2002
ELEVATION(FT):2500 ATMOS. PR.(PSIA):13.404 AMB.TEMP(DEG F):90
Tc(DEG R):374.0 Pc(PSIA):670.9 PISTON SPEED (FPM): 900
DRIVER: Caterpillar COMPRESSOR: GEMINI STROKE (IN): 3.000
MODEL: G3408TA MODEL: H304 ROD DIA (IN): 1.125
MAX BHP: 400 MAX BHP: 400.0 R/L TENSION: 10000
MAX RPM: 1800 MAX RPM: 1800 R/L COMPR.: 10000
DRIVER LOAD(%): 100.0 DESIGN RPM: 1800 R/L COMB.: 20000
----------------------------CYLINDER DATA----------------------------
CYLINDER #.......... 1 2 3 4
STAGE #............. 1 1 2 2
CYL. BORE.......(IN) 8.000 8.000 5.000 5.000
M.A.W.P. .....(PSIG) 300 300 1250 1250
CYL. ACTION .(DA/SA) DA DA DA DA
PISTON DISPL...(CFM) 311.1 311.1 119.6 119.6
----------------------PRESSURES AND TEMPERATURES----------------------
INLET PRES....(PSIG) 60.0 60.0 181.0 181.0
DISCH. PRES...(PSIG) 186.5 186.5 500.0 500.0
COMP. RATIO .(Pd/Ps) 2.8 2.7
Ts...........(DEG-F) 60 60 120 120
Td (ADIAB)...(DEG-F) 180 180 250 250
Td (INTERNAL)(DEG-F) NVD NVD NVD NVD
--------------------FLOW CONDITIONS AND HORSEPOWER--------------------
CAP.PER CYL.(MMSCFD) 1.52 1.52 1.52 1.52
STAGE CAP...(MMSCFD) 3.04 3.04
SP. GRAVITY..(Air=1) .650 .650 .650 .650
K VALUE .....(Cp/Cv) 1.260 1.260 1.260 1.260
ZS.................. .986 .986 .975 .975
ZD.................. .982 .982 .972 .972
CYL. IHP ..(PER/CYL) 89 89 94 94
CYL. BHP ....(TOTAL) 379
TOTAL UNIT BHP ..... 379 + 20(AUX. HP) = 399
----------------------------CLEARANCE DATA----------------------------
H.E. BASE CLR....(%) 14.10 14.10 19.00 19.00
C.E. BASE CLR....(%) 15.00 15.00 19.50 19.50
ADDED CLR H.E....(%) 15.0 15.0 .0 .0
PKT.TRAVEL......(IN) .55/18 .55/18 .00/ .00/
H.E.VSPCS USED/AVAIL 0/4 0/4 0/2 0/2
H.E. TOTAL CLR...(%) 29.10 29.10 19.00 19.00
ADDED CLR C.E....(%) .0 .0 .0 .0
C.E.VSPCS USED/AVAIL 0/4 0/4 0/2 0/2
C.E. TOTAL CLR...(%) 15.00 15.00 19.50 19.50
H.E. VOL. EFF....(%) 59.85 59.85 72.72 72.72
C.E. VOL. EFF....(%) 76.27 76.27 72.16 72.16
------------------------ROD LOADS AND REVERSALS----------------------
VLV.VEL. INLET.(FPM) 6577 6577 6574 6574
VLV.VEL. DISCH.(FPM) 6577 6577 6574 6574
ROD LOAD TENS...(LB) 6196 6196 5848 5848
ROD LOAD COMPR..(LB) 6467 6467 6557 6557
3.11
 3.12

Compressor/Engine Fluids and Oil Analysis

-Importance of Monitoring Fluid quality

-Recommended Oil Change Frequencies

-What is Meant by Useful Fluid Life

 3.13
SPINNER F ILTER INSPECTION
____________________________________________________________________
mg./Kg. mg./Kg.

Silver : 0 Manganese : 0
Aluminum : 268 Molybdenum : 66
Arsenic : 0 Sodium : 840
Boron : 0 Nickel : 0
Barium : 0 Phosphorous : 19010
Calcium : 98480 Lead : 181
Cadmium : 0 Selenium : 0
Chromium : 105 Silicon : 232
Copper : 179 Tin : 0
Iron : 437 Titanium : ---------
Mercury : --------- Vanadium : 0
Potassium : 4729 Zinc : 21260
Magnesium : 345 Cobalt : 4078
_____________________________________________________________
% Oil : 24.10% Loss on Ignition: 61.90%
Residue wt : 523.07 g. Acid Insolubles: 0.02%
______________________________________________________________________________________
 3.14

Predicting Maintenance
(Routine and Scheduled Maintenance on Compressor
Package Components)

-Prime Movers
-Compressors
-Associated Equipment
 3.15

Predicting Maintenance
(Routine and Scheduled Maintenance on Prime Movers)

-Internal Combustion Engines

-Electric Drives
-Turbine Drives

Maintenance schedules on all package components

are dictated by manufacturers’ recommendations
and from extensive field experience
 3.16
Superior Engine(s) Maintenance Schedule
(based on field experience)

Job Description 1706G 1712G 2406GTL 2408GTL 2412GTL

Oil Change 1000 hrs 1000 hrs 1500 hrs 1500 hrs 1500 hrs
Change Spark Plugs 500 hrs 500 hrs 1500 hrs on LC 1500 hrs on LC 1500hrs on LC
500hrs on HC 500hrs on HC 500hrs on HC
Valve Lash 1500 hrs 1500 hrs 1500 hrs 1500 hrs 1500 hrs
Oil Samples 500 hrs 500 hrs 500 hrs 500 hrs 500 hrs
Pre Chambers As required as required, up to 8,000 hrs
Bearing Inspections MAINS-8000 MAINS-8000 MAINS-8000 MAINS-8000 MAINS-8000
Cylinder Heads As required 10,000 or as required
Major Overhauls 24,000 hrs 24,000 hrs 25,000 hrs 25,000 hrs 20,000 hrs
Turbo Chargers Every 10,000 hours using clean dry fuel (Varies on operation and condition of unit)
Air & Fuel Filters 1500 hrs 1500 hrs 1500 hrs 1500 hrs 1500 hrs
Compression Test 4000 hrs 4000 hrs 4500 hrs 4500 hrs 4500 hrs
Hot Alignments 8000 hrs 8000 hrs 8000 hrs 8000 hrs 8000 hrs
Boroscope 12,000 hrs 12,000 hrs 12,000 hrs 12,000 hrs 12,000 hrs
Vibration Balancer 24,000 hrs 24,000 hrs 24,000 hrs 24,000 hrs 24,000 hrs
HP 500 800 1200 1600 2400
RPM 1200 1200 1200 1200 1200
Cost N/A N/A N/A N/A N/A
$/HP N/A N/A N/A N/A N/A

Total hours based on 100% load with clean dry fuel

 3.17

Caterpillar 3400 Series Maintenance Schedule

(based on field experience)

Job Description G3406NA G3406TA G3408TA G3412TA

Oil Change 750 hrs 750 hrs 750 hrs 750 hrs
Change Spark Plugs 750 hrs 750 hrs 750 hrs 750 hrs
Valve Lash 1500 hrs 1500 hrs 1500 hrs 1500 hrs
Oil Samples 750 hrs 750 hrs 750 hrs 750 hrs
Bearing Inspections 8000 hrs 8000 hrs 8000 hrs 8000 hrs
Cylinder Heads AT O/H -OR AS REQUIRED
Major Overhauls 16,000 hrs 16,000 hrs 16,000 hrs 16,000 hrs
Turbo Chargers Every 8,000 hours using clean dry fuel
Air & Fuel Filters 750 hrs 750 hrs 750 hrs 750 hrs
Compression Test 4000 hrs 4000 hrs 4000 hrs 4000 hrs
Hot Alignments 8000 hrs 8000 hrs 8000 hrs 8000 hrs
Boroscope 8000 hrs 8000 hrs 8000 hrs 8000 hrs
Vibration Balancer Inspect every 750 hrs
HP 215 325 400 600
RPM 1800 1800 1800 1800
Cost N/A N/A N/A N/A
$/HP N/A N/A N/A N/A

Total hours based on 100% load with clean dry fuel

 3.18

Waukesha VHF (High) Series Maintenance Schedule

(based on field experience)

Job Description L7042GL/GSI L7042GSI P9390GL/GSI

Oil Change 1500 hrs 1500 hrs 1500 hrs
Change Spark Plugs
Valve Lash 2500 hrs 2500 hrs 2500 hrs
Oil Samples 720 hrs 720 hrs 720 hrs
Bearing Inspections 8000 hrs 8000 hrs 8000 hrs
Cylinder Heads AT O/H -OR AS REQUIRED
Major Overhauls 32,000 hrs 32,000 hrs 32,000 hrs
Turbo Chargers Clean and inspect annually
Air & Fuel Filters As required by indicator
Compression Test 8000 hrs 8000 hrs 8000 hrs
Hot Alignments 8000 hrs 8000 hrs 8000 hrs
Boroscope 16,000 hrs 16,000 hrs 16,000 hrs
Vibration Balancer 32,000 hrs 32,000 hrs 32,000 hrs
HP 1478 1680 1970
RPM 1200 1200 1200
Cost N/A N/A N/A
$/HP N/A N/A N/A

Total hours based on 100% load with clean dry fuel

 3.19

Predicting Maintenance
(Routine and Scheduled Maintenance on Compressors
and Associated Equipment)

As with prime movers, the maintenance schedules for

the above components are dictated by manufacturers’
recommendations and from extensive field experience.
 3.20

Failure Reports
and
Product Service Incident Reports

Failure Database/s

Improvements in Design and Manufacturing

 3.21
Failure Report
Site Contact Name/Number:_______________________________________/(_____)___________________
Mechanics Name/Number:_______________________________________/(_____)____________________
Customer: ______________________________________ Work Order Number:____________________
Unit Number:____________________________________
Model:__________________________________________ Below Items For Administration
Serial Number:___________________________________ Date Submitted _____/_____/_____
Location:________________________________________ Submitted By____________________________
Date of Repair:___________________________________ Warranty Claim#__________________________
Unit Hours:______________________________________ Date Parts Received_____/_____/_____
Hours on Failed Part:______________________________ Parts Received By_________________________
Part Number:_____________________________________ Date Failure Report Received_____/_____/_____
Part Name:_______________________________________ Report Received by________________________
Serial Number of Failed Part:_______________________ Date Parts shipped _____/_____/_____
Serial Number of New Part:_________________________ (Above must be completed and signed)

Customer Complaint:_______________________________________________________________________
__________________________________________________________________________________________
__________________________________________________________________________________________

Possible Reason(s) for Failure________________________________________________________________

__________________________________________________________________________________________
__________________________________________________________________________________________
__________________________________________________________________________________________

Observations During Repair(Liquids, broken in pieces, etc.)______________________________________

_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________

Possible Prevention:________________________________________________________________________
__________________________________________________________________________________________
__________________________________________________________________________________________
__________________________________________________________________________________________

Was this a Call Out † yes † no Were replacement parts available † yes † no
Estimated Downtime:___________ Delivery time of parts:_____________________

When Completed Fax Copy to Number Below. Also send copy with All Replaced Parts
 3.22

LOG #:

PRODUCT/SERVICE INCIDENT REPORT

/UNIT #: LOCATION: DATE:

Please fill out your personal information below. This information will help us contact you so that we may follow
up on this issue.

Customer Name: Customer Contact:

Telephone (or cell) #: Fax #:

Please give a detailed description of the incident.

Description of Incident:

Please give a brief description of the equipment that was involved in the incident. Serial and model numbers of
specific equipment should be included.

Equipment Involved:

If you believe that any other factors were involved, please list them below.

Additional Factors:

Please describe the action that you have already taken as well as any actions you would like to see happen in
order to resolve this issue.

Corrective Actions Already Taken:

Suggested Actions to be Taken:
Problem Solved at Local Level? Yes No

For office use only.

Corrective Action to be taken:

Date Answer Needed: Who Should Investigate:

Initiated By: Manager:
Routed To:

*If you require more room, please attach another page GEN-QA-004.1
 3.23

Keys for Successful Failure Analysis and

Effective Predicting of Maintenance
-Knowledge of all Operating Conditions Prior to Failure
-Involve Appropriate Manufacturing/Operating Personnel
-Know What is Expected of the Equipment and Ensure
That Equipment is Properly Sized/Designed
-Accurate Record Keeping and Adherence to
Recommended and Recognized Maintenance Schedules
 3.24
Biographical Sketch
Author: Dave Simonar
Education, Affiliations, Experience and Personal Info:
-Bachelor of Science in Geological Engineering, University of Saskatchewan, 1981
-P.Eng., (current member of APEGGA)
-12 years experience in Oil and Gas Resource Companies as a Production Engineer
(for, Dome Petroleum, Amoco Canada Petroleum and Albert Energy Company)
-3 years experience in Oil and Gas Resource Companies as an Exploitation Engineer (for
Dome/Amoco)
-3 years experience consulting for Oil and Gas Resource Companies as a Production
Engineer (mainly for, Morrison Petroleum and Fletcher Challenge Energy Canada)
-3 years experience with an Oil and Gas Compression Services Companies as a Field
Operations Engineer (for Weatherford Global Compression/Universal Compression Inc.)
-Living in Edmonton, and Married with 3 children (16, 14 and 11 years of age)