WHITEPAPER

Monitoring
mechanical behaviour of
reciprocating compressors

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Table of contents
1. Why monitor reciprocating compressors?................................................... 3

2. Which parameters should be monitored? ................................................... 4

3. The API 670 about reciprocating compressors.......................................... 5

4. API 670 - Protective measures........................................................................ 6

5. API 670 - Condition measures......................................................................... 7

6. Four important parameters for reciprocating compressors.................. 8

Impact.................................................................................................................................... 8

Temperature........................................................................................................................ 9

Vibration.............................................................................................................................11

Rod drop measurement.................................................................................................. 13

7. Transmitter-based systems versus centralised systems ......................14

8. A deeper insight into rod drop monitoring...............................................16

9. Istec RecipSys 200............................................................................................19

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Why monitor reciprocating

compressors?
Reciprocating compressors are often called the workhorses of the industry.
These compressors fulfil critical parts of industrial processes and add an
important value to production. But there is a significant downside to these
heavy and powerful machines: high maintenance costs.

Reciprocating compressors are among the as a result, the maintenance costs of reciprocating
most critical machinery in industrial processes. compressors are often (unnecessarily) high; up to
Their unique capabilities make reciprocating five times higher than the maintenance costs of
compressors indispensable to the industry. Due similar-sized centrifugal compressors.
to their mechanical behaviour, these machines
require advanced monitoring systems to ensure To address this issue, advanced monitoring systems
proper operation and timely fault detection. must be implemented to continuously monitor
various parameters of reciprocating compressors
The increasing demands of machine directives and (table 1). Periodic and reactive maintenance should
standards (like API 670) on sufficient monitoring make place for predictive and condition-based
and protection confirm the importance of the maintenance, to improve the reliability, availability
subject. But in reality, only few compressors are and safety of reciprocating machinery. ■
equipped with sufficient monitoring systems and

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Which parameters
should be monitored?
In this whitepaper we focus on the mechanical health and behaviour
of reciprocating compressors with four important indicators; impact,
temperature (valves and bearings), vibration and rod drop. Table 1 shows
the typical measurements for reciprocating compressors. It covers each
of these measurement types and provides an in-depth description of rod
drop / displacement monitoring.

maintenance-demanding components of
APPLICATION MEASUREMENT TYPE
reciprocating compressors. Monitoring valve
COMPRESSOR CYLINDERS
IMPACT
CROSSHEAD and bearing temperatures allows for the early

TEMPERATURE
VALVES detection and repair or replace components before
BEARINGS
the machines’ efficiency decreases.
CASING (FRAME) VIBRATION
VIBRATION
CROSSHEAD VIBRATION Read more on page 9 →
PISTON ROD DISPLACEMENT
ROD DROP (INDIRECTLY: RIDER BAND
WEAR) Vibration
Table 1 Vibration monitoring on reciprocating compressors
should be done for both casing (frame) vibration
Impact and crosshead vibration as these are crucial
Impact measurements detect mechanical mechanical indicators for this type of machinery.
looseness in mechanical joints and are generally Read more on page 11 →
used to shut down the machine when limit values
are exceeded. Impacts produce high amplitude Rod drop
spikes of short duration which can’t be measured Rod drop measurements for reciprocating
by traditional vibration measurements. compressors provide accurate information on rider
Read more on page 8 → band wear, allowing the predictive scheduling of
rider band replacements.
Temperature Read more on page 13 →
Suction and discharge valves are the most

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The API 670 about

reciprocating compressors
The API 670 machine directive demands certain protective and condition
monitoring measures. The tables on the next pages show the recommended
combination of parameters, measurement types, sensor types and sensor
specifications that are required to operate conform the API 670. Table
2 provides information about the parameters that require protection.
Table 3 provides information about the parameters that require condition
monitoring.

Note that only the mechanical health indicators within the scope of Istec are in the tables, including vibration, speed and

temperature. For a full overview of protection and condition monitoring guidelines for reciprocating compressors, please

refer to the newest version of the API 670.

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 API 670 - Protective measures
APPLICATION MEASUREMENT TYPE SENSOR TYPE ALARM / SHUTDOWN FUNCTIONS

GAS DISCHARGE (FOR EACH CYLINDER) TEMPERATURE RTD / THERMOCOUPLE ALARM RECOMMENDED

JACKET COOLING SYSTEM TEMPERATURE RTD / THERMOCOUPLE ALARM RECOMMENDED

MAIN BEARING TEMPERATURE RTD / THERMOCOUPLE OPTIONAL

CRANK PIN BEARING TEMPERATURE RTD / THERMOCOUPLE OPTIONAL

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CROSSHEAD PIN BEARING TEMPERATURE RTD / THERMOCOUPLE OPTIONAL

FRAME / CASING VIBRATION ACCELEROMETER / VELOCITY SENSOR ALARM AND SHUTDOWN RECOMMENDED

CROSSHEAD GUIDE VIBRATION ACCELEROMETER ALARM AND SHUTDOWN RECOMMENDED

CYLINDER VIBRATION ACCELEROMETER ALARM RECOMMENDED

CYLINDER VALVES VIBRATION ACCELEROMETER OPTIONAL

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ACCELEROMETER / VELOCITY SENSOR /
MAIN DRIVER VIBRATION ALARM AND SHUTDOWN RECOMMENDED
DISPLACEMENT PROBE

PISTON ROD DROP DISTANCE DISPLACEMENT (PROXIMITY) PROBE ALARM AND SHUTDOWN RECOMMENDED

Table 2. Typical protective measures for reciprocating compressors according to the API 670

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 API 670 - Condition measures
APPLICATION MEASUREMENT TYPE SENSOR TYPE RECOMMENDED / OPTIONAL

PROCESS PARAMETERS

SUCTION AND DISCHARGE NOZZLE TEMPERATURE RTD OR THERMOCOUPLE RECOMMENDED

FRAME AND RUNNING GEAR

OIL HEADER SUPPLY TEMPERATURE RTD OR THERMOCOUPLE RECOMMENDED

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VALVES AND PRESSURE PACKING

SUCTION AND DISCHARGE VALVE TEMPERATURE RTD OR THERMOCOUPLE RECOMMENDED

PRESSURE PACKING (VENT) TEMPERATURE RTD OR THERMOCOUPLE RECOMMENDED

MAIN DRIVE MOTOR

MOTOR STATOR TEMPERATURE RTD RECOMMENDED

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MOTOR BEARING(S) TEMPERATURE RTD OR THERMOCOUPLE RECOMMENDED

FRAME LUBE OIL SYSTEM

OIL PUMP SUPPLY TEMPERATURE RTD OR THERMOCOUPLE RECOMMENDED

HEAT EXCHANGER – WATER INLET/OUTLET TEMPERATURE RTD OR THERMOCOUPLE OPTIONAL

JACKET WATER SYSTEM (IF APPLICABLE)

MAIN SUPPLY HEADER TEMPERATURE RTD OR THERMOCOUPLE RECOMMENDED

RETURN LINE TEMPERATURE AT EACH CYLINDER TEMPERATURE RTD OR THERMOCOUPLE RECOMMENDED

NON-TEMPERED WATER TEMPERATURE TO PRESSURE PACKING TEMPERATURE RTD OR THERMOCOUPLE RECOMMENDED

RETURN LINE TEMPERATURE FROM EACH PACKING TEMPERATURE RTD OR THERMOCOUPLE OPTIONAL

RESERVOIR TEMPERATURE RTD OR THERMOCOUPLE OPTIONAL

HYDRAULIC VALVE CONTROL SYSTEM (IF APPLICABLE)

HYDRAULIC OIL SUPPLY HEADER TEMPERATURE RTD OR THERMOCOUPLE RECOMMENDED

RESERVOIR TEMPERATURE RTD OR THERMOCOUPLE RECOMMENDED

Table 3. Typical condition monitoring applications for reciprocating compressors according to the API 670

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Four important parameters

for reciprocating compressors
Impact
Impact measurements are used as a reliable method reciprocating compressors at an early stage of
to monitor excessive mechanical movements of development.
reciprocating compressors. As the piston moves
through the cylinder, impacts are caused, which Excessive mechanical clearance can develop
produce high amplitude spikes of a very short quickly, which is why impact measurements are
duration. used for monitoring and, if necessary, shutting
down the compressor. Automatic shutdowns or
Traditional vibration measurement sensors are trip functions are activated based on pre-set alarm
not reliable to monitor these impact signals as values, which are related to the intensity of the
impacts do not affect the vibration signal by much. impact and the amount of impacts above a defined
Impact sensors (or transmitters) are suitable to threshold, within a certain timeframe.
detect mechanical clearance and looseness on ►

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An impact sensor can be placed on the distance efficiency of reciprocating compressors.

piece, perpendicular to the direction of movement
of the piston rod in the compressor cylinder. An RTD or thermocouple sensors are used to measure
impact sensor can also be placed on the crosshead. valve temperatures. There are two common
methods of positioning these sensors:
Temperature
Valve temperature 1. Sensor positioning in the valve through a

The suction and discharge valves are typically thermowell

the most maintenance-demanding parts of When the temperature sensor is mounted in a sleeve

reciprocating compressors. Faulty valves are that is installed in the valve pocket, the quality of the

considered the main cause for unplanned measurement is higher than measurements on the

shutdowns. The monitoring of valve temperature valve cover. There are no environmental conditions

offers insight into the condition of the valves. that influence the measurement using this type of

If a leak occurs at one of the valves the valve sensor positioning. The sensors that are installed in

temperature changes. By monitoring valve the valve pocket also provide a faster detection of

temperature, a defect at the valves can be detected changing temperatures and valve leaks. However,

quickly. Monitoring valve temperatures is a must, the valve design is not always suitable for the

as defective valves can significantly decrease the installation of thermowells. ►

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2. Sensor positioning on the valve cover crankshaft and the connecting rod
Mounting the temperature sensor directly to the 3. Wrist pin bearings are located between the

valve cover makes the sensor vulnerable to be connecting rod and crosshead pin
influenced by environmental conditions. It also has 4. Crosshead bearings are located at the top and

a slight delay on detecting valve leaks compared to bottom of the crosshead

the aformentioned method.

Pressurized oil is supplied to the bearings through

Bearing temperature grooves on the bearing surface in order to prevent
The bearings of reciprocating compressors overheating. If the oil supply is failing or friction
assure the proper running of the compressor. It is increases the bearing temperatures will increase
important to monitor the temperatures on the to a point where damage is likely to occur.
bearings as overheating could lead to bearing
failure, which may in turn lead to damage or RTD or thermocouple sensors are used to monitor
downtime. Various types of bearings are fitted on the temperature of main bearings, crank/wrist
different locations of the reciprocating compressor. pin bearings and crosshead bearings. They are
externally mounted and include a conduit head to
1. Main bearings are located in the frame to be able to access the sensor and cabling. ►
position the crankshaft properly
2. Crank pin bearings are located between the

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Vibration include gas load forces, inertial load forces,

Vibration measurements on reciprocating reciprocating and rotating unbalance forces and gas
compressors can be difficult due to the natural unbalance forces. It’s important to note that even
mechanical movement of reciprocating machinery. when in good condition, reciprocating compressors
However, there are some important parts that vibrate much more than their rotating equivalents.
should be monitored for changes in vibration
behaviour. To measure casing vibration on reciprocating
compressors, velocity measurements are used.
Casing vibration (frame vibration) Typically, these are integrating piezoelectric
Casing vibration results from various forces and accelerometers or moving coil velocity sensors,
movements inside the machine and are part of as the vibration frequencies for this application
normal running conditions. Due to the pistons usually include components below 10 Hz. The
being driven back and forth the entire frame with sensors are used to detect defects like unbalance,
all its components continuously vibrate, move and mechanical looseness and structural or foundation
deform. Moreover, suction and discharge valves issues. One sensor should be positioned at the
create impacts due to opening and closing during drive end side and one at the non-drive end side.
every revolution of the crankshaft. Every force ►
during a revolution has its impact and affects the
vibration behaviour of the machine. Such forces

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Crosshead vibration Accelerometers are typically used to measure

The crosshead slides on a lubricated surface and crosshead vibration due to their ability to monitor
moves back and forth (reciprocating). When the high frequency components. These sensors can
clearance between the crosshead and the surface detect problems related to excessive crosshead
increases, the crosshead vibration level will also clearance, excessive clearance in the crosshead pin
increase. Monitoring crosshead vibration allows bushing and loose or cracked nuts, bolts or pistons.
the operator to schedule maintenance in time and
make sure the clearance between the surface and Two sensors should be placed on the crosshead of
the crosshead stays within acceptable limits. which the positioning depends on the direction of
rotation. ►

Clockwise shaft rotation

One accelerometer should be mounted vertically

above the crosshead guide on the left and one

vertically below the crosshead guide on the right.

Counter clockwise shaft rotation

One accelerometer should be mounted vertically

below the crosshead guide on the left and one

vertically above the crosshead guide on the right.

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Rod drop measurement The proximity sensor must be vertically mounted

Rider bands are critical components that support (90 degree angle) above or below the piston rod,
the piston while moving through the cylinder of as close to the cylinder as possible. Optionally,
the reciprocating compressor. They are used to a second proximity sensor can be mounted
secure the piston positioning inside the cylinder, horizontally to the piston rod. This enables the
to protect the piston from scraping and damaging measurement of horizontal piston rod movement,
the cylinder wall. These rider bands wear down which may indicate piston float or rod flexing.
over time, which manifests itself in a vertical
displacement of piston and piston rod. To prevent Phase reference sensors are used to provide
damage to the piston and cylinder wall, the wear of a reference point to measure the position of
these rider bands should be monitored. the piston and piston rod. The sensor is a crucial
addition for reliable rider band wear monitoring as
Proximity sensors are used to monitor rider rod displacement should be measured at a specific
band wear. It is difficult to monitor the piston in point during the cycle. ■
the cylinder due to high pressure in the cylinder
chamber, so the vertical displacement of the piston Learn more about rod drop
rod is monitored instead. The piston rod drops
See page 16 for deeper insights into rod
proportional to the piston as a result of rider band
drop monitoring!
wear and is therefore a reliable monitoring method.

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EDITORS REVIEW;

Transmitter-based systems
versus centralised systems
Reciprocating compressors are often critical to industrial processes.
However, the prevailing idea that this type of machinery needs complex
centralised monitoring and protection systems, appears to be without
technical foundation.

There are a lot of components and parameters that monitor and integrate several parameters. These
can be monitored and protected, but that doesn’t solutions require large investments that should
necessarily mean you have to measure each of be proportional to the criticality and size of the
them. Smaller and/or less critical reciprocating machine. This is why rack-based solutions are rarely
compressors require monitoring and protection suitable for smaller and less critical reciprocating
too, but the costs of these complex centralised compressors, which need a low-entry solution
systems can be out of balance with the criticality rather than a complete system.
or value of the machine. Therefore, the investment
that is required to implement such systems cannot Market needs
always be financially justified. A growing demand for better and more data of the
condition of reciprocating machinery is emerging
Rack-based approach alongside the general increasing industrial
Rack-based systems offer great solutions for large demands. The imbalance between the criticality
machinery or machine trains that require advanced of the machine and the costs of the required
monitoring and protection on multiple parameters. monitoring solution has created a need for less
These complex systems feature a higher channel complex and more affordable solutions to provide
density and offer a more complete solution to monitoring and protection on various parameters
for reciprocating compressors.

“Rack-based solutions are rarely suitable

Transmitter approach
for smaller and less critical reciprocating
Recent transmitter developments allow for more
compressors, which need a low-entry
financially accessible solutions for advanced
solution rather than a complete system.“
monitoring and protection of parameters ►

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such as impact, temperature, vibration and rod and less critical reciprocating compressors. A
drop. A transmitter-based approach enables users strong advantage of a transmitter approach is the
to monitor only the parameters the application scalability and modularity that comes inherently
requires, with a small technical footprint. with their architecture. Transmitter-based systems
Transmitter solutions feature less measurement are often scalable to expand the amount of
channels, often focus on just one parameter (i.e. measurement channels, making them suitable
vibration), and are the ideal solution for smaller for larger applications. As for modularity, these
systems are often integrable with other systems
“Transmitter-based systems are often that monitor different parameters. For example,
scalable to expand the amount of vibration and temperature may affect each other,
measurement channels, making them which can be only seen in the parallel data output of
suitable for larger applications. “ both a vibration transmitter and the temperature
transmitter. ■

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A deeper insight into

rod drop monitoring
Rod displacement is a key mechanical indicator for reciprocating
machinery, to detect and trend rider band wear. Monitoring rider band
wear contributes to the maintenance efficiency and process efficiency of
reciprocating compressors.

Rider band wear “Instead of measuring the actual drop of

A rider band is the component that supports the the piston, the drop of the piston rod is
piston while it is moving through the cylinder measured, which is way more accessible“
chamber and prevents it from damaging the
cylinder wall. Over time these rider bands wear out. replacement of these rider bands during a
By monitoring the piston rod displacement (rod turnaround/standstill that was already scheduled,
drop), it can be determined when the rider bands instead of having to shut down the machine just
need to be replaced before damage occurs. Rod to inspect or replace the rider bands. Moreover,
drop monitoring contributes to a condition based early detection of rider band wear provides the
maintenance (CBM) or predictive maintenance opportunity to shut down the machine before
strategy. excessive damage and machine failures occur.

As traditional monitoring methods such as To detect wear on the rider bands the position
vibration measurements proved to be insufficient (relative to the reference point) of the piston
to accurately monitor rider band wear, different needs to be monitored. However, measuring the
methods were developed. Rod drop monitoring is actual drop of the piston is very difficult because of
the most reliable way to accurately monitor rider the high pressure in the cylinder chamber. Instead
band wear. of measuring the actual drop of the piston, the
drop of the piston rod is measured, which is way
Rod drop measurements more accessible (see image on the next page). Rod
Monitoring rider band wear is crucial to avoid drop monitoring provides information about the
major damage and improve maintenance planning. condition of the rider bands by monitoring changes
It allows operators to efficiently schedule the in the position of the piston rod. ►

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Rod drop measurement methods

Generally, two primary methods are used for rod effectively schedule maintenance.
drop monitoring:
A phase trigger can be used to determine the phase
Method 1; Digital measurements with proximity of the compression cycle. By using a phase trigger,
probes the rod displacement signal can be filtered to a
With proximity measurements the sensor is specific position in the cycle to eliminate phase
mounted vertically above or below the piston rod, related signal distortions from the measurement
as close as possible to the cylinder. A proximity and allows for accurate and reliable determination
probe works by using eddy current technology, of vertical rod displacement.
and measures the distance between the sensor
tip and a metal object. In the case of a rod drop Method 2; Mechanical measurements
measurement it measures the distance to the Generally, two mechanical methods are used for rod
piston rod. When the piston rod moves vertically, drop monitoring. The first method uses a block of
relative to the sensor, the change in distance is abrasive material with a space inside that contains
detected. These measurements make it possible to nitrogen. This block is placed directly under the
determine the vertical displacement of the piston piston rod. When the piston rod drops as a result
rod. This signal indicates the rider band wear and of wear on the rider band, the block will wear ►

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down until a point where nitrogen escapes. This Periodic and reactive maintenance is making place
nitrogen leak will cause a decrease in the pressure for predictive maintenance, which requires online
supply, leading to an alarm or machine shutdown. systems to provide accurate data and insights.

The second mechanical method for rod drop As for digital solutions, rod drop monitoring is
monitoring involves a type of roller that is mounted often part of larger systems that were developed to
under the piston rod. When the rider band wears monitor various parameters. Such systems are too
down, the piston rod drops gradually till a point expensive for smaller and less critical reciprocating
where it touches the roller. Upon contact between compressors. A more accessible solution is required
the piston rod and the roller, the roller will start for these applications. Istec has developed the
to rotate which allows nitrogen to escape from RecipSys 200; a scalable and modular transmitter-
a resevoir below. This nitrogen leak will cause a based rod drop monitoring system. ■
decrease in the pressure supply, leading to an
alarm or machine shutdown.

Mechanical versus proximity

The main disadvantage of mechanical rod drop
systems is the inability to do measurements, and
use these measurements for trending. The only
thing these mechanical systems provide is an alarm
that is triggered when the rider bands are worn
out. There is no indication of the extent to which
the rider band is worn out. A digital measurement
can trend the actual displacement of the piston
rod, and therefore the extent of the rider band
wear. Using the proximity sensor measurements
a trend can be monitored over time, allowing for
better maintenance planning (CBM).

Rod drop monitoring solutions

There are several solutions for rod drop monitoring,
both mechanical and digital. With data and insights
becoming more important in the current industrial
era, mechanical systems are becoming less suitable
as they do not comply to this demand for data.

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Istec
RecipSys 200
RecipSys 200 is a transmitter-based
monitoring- and protection system
for reciprocating machinery, that
offers advanced rod displacement
measurements for rod drop and rod
flex applications.

The 2-channel system provides essential monitoring or temperature, creating cost-effective, suitable
on key mechanical indicators of rider band wear monitoring systems.
and can be used as a stand-alone system or as an
add-on to advanced vibration monitoring systems. Cost-effective solution
The module offers simple and effective monitoring
Triggered rod drop measurements rod displacement monitoring system for key
RecipSys 200 indicates the vertical movement mechanical behaviour of reciprocating machinery.
of a piston inside a cylinder by measuring the The cost-effectiveness and scalability of a
vertical rod displacement, which provides crucial transmitter layout makes the system suitable for
information on rider band wear. By using a phase every monitoring need.
trigger the position of the rod is measured at a
specific point in the cycle, for an accurate and Simplicity over complexity
reliable measurement. The RecipSys 200 is the answer to the market
need for a financially accessible, simple solution
Scalable and modular to monitor a single mechanical indicator: rod
The RecipSys 200 is designed with a DIN-rail displacement. No need for an expensive and
transmitter layout and offers excellent scalability complex system, but simple stand-alone rod
and integrability. Multiple modules can be used drop monitoring with extensive scalability and
for 3 or more cylinder applications. Its modularity modularity options. ■
allows the integration with other transmitter
systems, like crosshead / casing vibration, impact Learn more: www.istec.com/recipsys-200

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