REE Tutorial Gas Engine / Motor Drive Retrofit of Reciprocating Compressors Reliability. Efficiency. Environmental.

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1 REE Tutorial Gas Engine / Motor Drive Retrofit of Reciprocating Compressors Reliability. Efficiency. Environmental. HOERBIGER Compression Technology Gas Electric Conference Feb 7 th 2014 Christean Kapp

2 Elements of the REE Audit Rule No 1: Know what you are getting into, Gather Data! Site inspection ESM database Compressor manual DCS data Process REE Audit Customer interview Failure history Maintenance records Departments involved: Maintenance Operation, Production Process Projects Reliability Christean Kapp Tutorial Gas Engine Electric Drive Revamp 2

3 Waukesha Engine to E-motor on Dresser-Rand Natural Gas Compressor Compressor and Engine data Christean Kapp Tutorial Gas Engine Electric Drive Revamp 3

4 REE Overview and Report REE improvement potential Rating Current Situation REE savings potential with improvements Recommended enhancements Shortfall relative to a REE Index of 10 Christean Kapp Tutorial Gas Engine Electric Drive Revamp 4

5 Situation Engine Motor Drive Retrofit Checklist Complete Site Review Determine Control Options Check Vibration & Pulsation Check Rod Loads Check TORSIONALS Check Motor /Flywheel Check Foundation Check Cylinders & Bearings Package Engineering & Project Management Christean Kapp Tutorial Gas Engine Electric Drive Revamp 5

6 Control System Selection Key Criteria: Need to be evaluated Individually for Every Project: Control System Cost Attractiveness Automatic Energy Saving Reliability Applicability (control range, available space) Impact on valve reliability Reverse flow (HydroCOM) Medium High High High good Variable clearance pocket Medium High Medium High Medium good Variable Frequency Drive Low Medium Mediu m High Low Medium poor Christean Kapp Tutorial Gas Engine Electric Drive Revamp 6

7 HydroCOM vs Variable Speed Control Low Speed requires high Moment of Inertia Christean Kapp Tutorial Gas Engine Electric Drive Revamp 7

8 Control System Selection Safe and reliable system selection for existing compressor installation requires sound methods Compressor - Health Check, Monitoring Development of specific solutions Feasibility Study Depending on the required control range and the selected control system a more or less detailed engineering analysis is necessary. Besides product related engineering it is necessary to follow up with compressor and environmental related Engineering Checks (EC) Engineering Check EC-Level 0 on-site (mandatory) EC-Level 1 (mandatory) EC-Level 2 (optional in case of necessity) EC-Level 3 (optional in case of necessity Rod Load Analysis Pulsation & Vibration Analysis Torsional Analysis Health Check and data collection: Lifecycle experiences Collection of monitoring data for pressure, temperatures, pulsation & vibration Actually installed control system Piping and Instrumentation Check Rod load magnitude and reversal check Health Check and Damper size check: Evaluation of efficiency of the pulsation & vibration suppression devices for the new part load conditions based on calculation and pressure and vibration monitoring results of the existing installation Pulsation Study based on an acoustical analysis: Damper Check Full pulsation and mechanical vibration Analysis according API618 Approach 3 Analysis of torsional effects of the control system onto the drive train system: Change of excitation torques and frequencies Natural frequency Analysis within a Campell Diagram Full Torsional Vibration Analysis according to API618 Christean Kapp Tutorial Gas Engine Electric Drive Revamp 8

9 Situation Engine Motor Drive Retrofit Checklist Complete Site Review Determine Control Options Check Vibration & Pulsation Check Rod Loads Check TORSIONALS Check Motor /Flywheel Check Foundation Check Cylinders & Bearings Package Engineering & Project Management Christean Kapp Tutorial Gas Engine Electric Drive Revamp 9

10 Pulsation & Vibration Analysis Compressor applications in critical situation, where already high vibration levels are experienced and fatigue failures occurred frequently a full pulsation & mechanical vibration study according to API 618 Approach 3 has to be applied. Based on monitoring and inspection results of the existing installation a focus on critical parts of the installation is possible With the API618 method Approach 3 the system is evaluated and pulsation / vibration suppression devices like dampers, orifices and support structures have to be engineered new based on the collected results. Christean Kapp Tutorial Gas Engine Electric Drive Revamp 10

11 Rod Load Analysis 70 % load (both HE and CE) OK Christean Kapp Tutorial Gas Engine Electric Drive Revamp 11

12 Torsional Analysis: Summary Torsional Vibration Analysis with bigger coupling: Reduction of maximum vibration torques about 6 times OLD Situation: New Situation: Christean Kapp Tutorial Gas Engine Electric Drive Revamp 12

13 Situation Engine Motor Drive Retrofit Checklist Complete Site Review Determine Control Options Check Vibration & Pulsation Check Rod Loads Check TORSIONALS Check Motor /Flywheel Check Foundation Check Cylinders & Bearings Package Engineering & Project Management Christean Kapp Tutorial Gas Engine Electric Drive Revamp 13

14 14 Start up Curve, Optimized Flywheel & Size Motor Tutorial Gas Engine Electric Drive Revamp Christean Kapp

15 Calculation of Static and Dynamic foundation forces Christean Kapp Tutorial Gas Engine Electric Drive Revamp 15

16 Design of foundation and skid Christean Kapp Tutorial Gas Engine Electric Drive Revamp 16

17 Cylinder upgrade Re-machining cylinders New liner? Piston with ring bushing Hydraulic test New piston and rider rings New valve cages? New valve covers? Re-machining piston with rods Cylinder cover with internals New cylinder support design New cylinder lubrication lines New vibration monitoring New packing and OT wiper Christean Kapp Tutorial Gas Engine Electric Drive Revamp 17

18 Frame and running gear overhaul with re-engineered bearings Original crankshaft was designed without axial bearing. The fix point was in the engine drive Christean Kapp Tutorial Gas Engine Electric Drive Revamp 18

19 Situation Engine Motor Drive Retrofit Checklist Complete Site Review Determine Control Options Check Vibration & Pulsation Check Rod Loads Check TORSIONALS Check Motor /Flywheel Check Foundation Check Cylinders & Bearings Package Engineering & Project Management Christean Kapp Tutorial Gas Engine Electric Drive Revamp 19

20 P&ID Gas, Water, Cylinder & Frame Lubrication Christean Kapp Tutorial Gas Engine Electric Drive Revamp 20

21 Project Management All design, manufacturing and assembly steps have been placed in an overall time frame. Christean Kapp Tutorial Gas Engine Electric Drive Revamp 21

22 Driver Change / Waukesha Engine to E-motor on Dresser-Rand Super CUB Christean Kapp Tutorial Gas Engine Electric Drive Revamp 22