What would you do if you knew you had 60 hours to go before your multistage compressor was going to shut down?
The drive to improve the operational efficiency of multistage compressors cannot be successful if maintenance issues are not recognised. What is critical to profitability is not only reducing operating cost through better efficiencies but also to reducing significant maintenance costs through the use of a good online monitoring system coupled with a supporting workflow.
Measure to manage
In many cases the causes of performance issues are unknown and the old adage of no management without measurement applies.
Matrikon Moore’s advanced condition-based monitoring systems provide both the measurement and the realtime analyses required to implement an effective maintenance management strategy. Multistage compressors form complex systems where individual compressor efficiencies, cooler efficiencies, lube oil system efficiencies as well as bearing condition need to be monitored and maintained.
By translating these complex systems into thermodynamic and statistical models based on manufacturers’ design specifications and then benchmarking the actual performance of the overall system, Matrikon Moore is able to combine process, vibration, performance and design conditions into a comprehensive package that provides immediate problem identification and root cause analysis.
Tell-tale signs
Internal deterioration of a compressor will result in discharge temperature change, suction flow change, bearing temperature change, or vibration amplitude and frequency change. Internal fouling of coolers will also create a change in the overall efficiency. The impact of these internal changes will also show up in the performance of lube oil systems and oil qualities.
The system also checks highly sensitive readings for performance degradation to pick up problems such as heat exchanger or intercooler fouling. That way maintenance can prepare for shutdowns and prepare for the required activities to be carried out during the shutdown.
Key performance indicators
The Matrikon Moore solution translates these various conditions into high level key performance indicators (KPI) to provide a useful interface for operators, engineers and maintenance personnel. If a performance incident, deterioration or impending problem is detected the analysis and root causes are instantly available. This maximises the time available to make appropriate repairs and/or modify the running conditions to prevent catastrophic failure.
The result is a comprehensive predictive maintenance system that ensures complex multistage compressor systems are monitored 24/7 and advance notifications of problems are given to the appropriate people to take action.
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