REE Tutorial Gas Engine / Motor Drive

Retrofit of Reciprocating Compressors

Reliability. Efficiency. Environmental.
HOERBIGER Compression Technology
Gas Electric Conference Feb 7th 2014
Christean Kapp

Elements of the REE Audit

Rule No 1: Know what you are getting into, Gather Data!

Site
inspection

DCS
data

ESM
database

REE
Audit

Compressor
manual

Maintenance
records

Failure
history

Process
Customer
interview

Christean Kapp

Tutorial Gas Engine Electric Drive Revamp

Departments involved:
Maintenance
Operation, Production
Process
Projects
Reliability

Waukesha Engine to E-motor on

Dresser-Rand Natural Gas Compressor

Compressor and Engine data

Christean Kapp

Tutorial Gas Engine Electric Drive Revamp

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

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

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

HydroCOM vs Variable Speed Control

Low Speed
requires high
Moment of Inertia

Christean Kapp

Tutorial Gas Engine Electric Drive Revamp

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

Engineering
Check

Rod Load
Analysis

EC-Level 0
on-site
(mandatory)

Health Check and data collection:

Lifecycle experiences
Collection of monitoring data for pressure, temperatures, pulsation
& vibration
Actually installed control system
Piping and Instrumentation Check

EC-Level 1
(mandatory)

Rod load
magnitude and
reversal check

Engineering Checks (EC)

Christean Kapp

Torsional
Analysis

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

Analysis of
torsional effects of
the control system
onto the drive train
system: Change of
excitation torques
and frequencies

EC-Level 2
(optional in
case of
necessity)

Pulsation Study
based on an
acoustical analysis:
Damper Check

Natural frequency
Analysis within a
Campell Diagram

EC-Level 3
(optional in
case of
necessity

Full pulsation and

mechanical
vibration Analysis
according API618
Approach 3

Full Torsional
Vibration Analysis
according to
API618

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

Pulsation &
Vibration
Analysis

Tutorial Gas Engine Electric Drive Revamp

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

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

Rod Load Analysis 70 % load (both HE and CE)

OK
Christean Kapp

Tutorial Gas Engine Electric Drive Revamp

11

Torsional Analysis: Summary

Torsional Vibration Analysis with bigger coupling:
Reduction of maximum vibration torques about 6 times
OLD Situation:

Christean Kapp

New Situation:

Tutorial Gas Engine Electric Drive Revamp

12

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

Start up Curve,
Optimized Flywheel & Size Motor

14

Tutorial Gas Engine Electric Drive Revamp

Christean Kapp

Calculation of
Static and Dynamic foundation forces

Christean Kapp

Tutorial Gas Engine Electric Drive Revamp

15

Design of foundation and skid

Christean Kapp

Tutorial Gas Engine Electric Drive Revamp

16

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

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

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

P&ID
Gas, Water, Cylinder & Frame Lubrication

Christean Kapp

Tutorial Gas Engine Electric Drive Revamp

20

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

Driver Change / Waukesha Engine to E-motor on

Dresser-Rand Super CUB

Christean Kapp

Tutorial Gas Engine Electric Drive Revamp

22