Condition Monitoring Of Reciprocating Air Compressor
Reciprocating compressors are vital for production processes in the oil & gas, chemical industries & petrochemical. They must operate 24*7, 365 days per year without interruption, and must maintain a high degree of efficiency. Unexpected breakdowns frequently have serious consequences, such as risks for production loss and plant safety, environmental damage, even expensive consequential damages, etc.
The easiest way to resolve the problem is online condition monitoring which will prevent machine breakdowns and consequential damage.
Condition monitoring is the process of checking the parameters like Vibration, Temperature, Noise, Alignment and Oil etc. In a reciprocating air compressor, the rotating motion is converted to reciprocating motion, which produces vibrations in the compressor. Machine Health monitoring is required to check the condition of the air compressor. In this work, an FFT analyzer is used to perform the vibration test on an old set-up of a reciprocating air compressor to find out the root cause. Beside, Belt alignment tool, Oil check monitor and Belt tension gauge is used to check the alignment, oil and belt condition to minimize the vibrations and noise created by the machine. Noise level readings are recorded by Noise level meter and overall bearing vibrations are tabulated by using the machine condition advisor device in this paper. It is observed that faults like belt misalignment, pulley unbalance, looseness of mounting bolts and oil contamination are present. This leads to high noise and vibration level. Subsequently, the faulty parts are replaced or repaired. Finally, significant improvement is achieved in NVH of the air compressor.
After a certain amount of time, reciprocating air compressors have some major problems like excessive noise in operation and vibration of the compressor. In this article, Compressor related problem and solution toward the journey is specified. A reciprocating air compressor is monitored to find the mechanical or other faults present in it by performing noise and vibration tests. Here two test is performed:
- Vibration Signature Analysis
- Noise Harshness Level Check
After these tests, the faulty performance part of the compressor was replaced and the same test was performed again.