Impact of condition monitoring on reciprocating compressor efficiency

Abstract

Purpose Reciprocating compressors offer an efficient method of compressing almost any gas composition in a wide range of pressures and have numerous applications. Condition monitoring of critical rotating machinery is widely accepted by operators of centrifugal compressors. However, condition monitoring of reciprocating machinery has not received the same degree of acceptance. An earlier study (Townsend et al., 2016) was conducted on temperature monitoring. The purpose of this paper is to examine the impact of continuous pressure monitoring on electric-driven compressors. Design/methodology/approach This research analyzes the impact of continuous pressure monitoring on a fleet of 14 compressors transporting CO2 for enhanced oil recovery. The reliability and efficiency data on 14 reciprocating compressors over a three-year period were analyzed for failures detectable by the condition monitoring technology. The engineering economic analysis is presented to determine the impact this technology will have on the productivity of the compressors. Findings The study considers utilizing condition monitoring technology to analyze the pressure of the swept volume of the compressor cylinders. The results of the study indicate that continuous pressure monitoring technology has a strong impact on the productivity of the compressor fleet. The internal rate of return not only exceeds the operators hurdle rate, but the payback period is also dramatic. Pressure monitoring was found to be economically better than temperature monitoring. Originality/value The study reveals the economic benefits of implementing condition monitoring in the form of continuous pressure monitoring on reciprocating compressors.

Improving periodic maintenance performance: a grouping and heuristic approach

“…On top of reliability and cost analysis, Abbasinejad et al (2021) applied expected utility theory and proposed an ABPM policy to determine the optimal maintenance interval for equipment with variable and constant failure rates, respectively. It is worth mentioning that for certain critical components, reliability and cost analysis results suggest the use of condition monitoring, which further reduces failure rate and increases productivity comparing to periodic maintenance (Townsend et al, 2016;Townsend and Badar, 2018). As for routine inspections, Guo et al (2015) provided an analytical approach to optimize inspection intervals to achieve minimum maintenance costs, taking both short-and long-term cost rates into account.…”

“…It is worth mentioning that for certain critical components, reliability and cost analysis results suggest the use of condition monitoring, which further reduces failure rate and increases productivity comparing to periodic maintenance (Townsend et al. , 2016; Townsend and Badar, 2018). As for routine inspections, Guo et al.…”

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“…Amaçları sürekli basınç izlemenin güvenilirliğini, verimliliğini ve mühendislik ekonomisini incelemektir. Sonuç olarak sürekli basınç izleme teknolojisinin kompresör filosunun verimliliği üzerinde güçlü bir etkiye sahip olduğunu gösterdiler [9].…”

Problem-solving by total productive maintenance swift teams: communication network structure, media choice and team effectiveness

“…In a second step, typical of TPM and of normally much longer duration than the first, the team seeks to carefully find and solve the underlying causes of the problem or “root cause” (Macduffie, 1997; Khan et al , 2020) in order to develop a cost-effective (Townsend and Badar, 2018), permanent solution that will help prevent the OE from happening again in the future. This problem-solving process's two stages may have different priorities, different time constraints and different access to resources.…”