GE

Energy

Is Rod Drop the Right

Measurement for My
Reciprocating Compressor?

Roger Hala
Applications Engineer
Bently Nevada™ Asset Condition Monitoring
What is Rod Drop? • Is L/D < 30?
Is the ratio of the piston rod length (L) to the piston rod diameter
Rod drop is the indication of the vertical piston movement inside
(D) less than 30? The L/D ratio is an indication of stiffness of the
the cylinder, calculated from the measurement of piston rod
piston rod. Rod drop measurements may not work properly due
movement at the pressure packing case.
to excessive flexing of the piston rod on machines with an L/D

Applicability ratio greater than 30.

Inferring piston movement from the measurement of rod • Is Correction Factor at Top Dead Center < 2.0?
movement at the pressure packing case is based on a number of The correction factor is defined as the ratio of the piston rod
assumptions. In some compressor configurations these length to the distance between the center of the crosshead and
assumptions are not valid. The applicability must be evaluated on a the center of the probe when the piston is at top dead center. On
case-by-case basis. This document and the decision flow diagram machines with a correction factor greater than 2, the rod drop
shown in Figure 1 pertain specifically to rod drop measurements, measurements may not work properly due to excessive
and are intended to assist users in determining whether the crosshead influence.
measurement will provide value for their application.
• Is Discharge Pressure < 1500 psig (10.2 MPa)?
Is the cylinder discharge pressure less than 1500 psig (10.2
Using the Diagram
MPa)? Rod drop measurements may not work properly due to
To use the diagram, begin at the start location and answer each
high-pressure packing case influence on the rod with cylinder
question in order. To aid in interpreting the questions in the
pressure greater than 1500 psig.
diagram, additional detail is provided in the following list:
• Is Piston Diameter > 20 Inches (508 mm)?
• Is Rider Band Non-Metallic?
Pistons are usually constructed of either cast iron or aluminum,
Rider bands were originally made from babbitt alloy material
depending on diameter. Larger pistons are made from aluminum
similar to standard journal/sleeve bearings. Although there are
to reduce the reciprocating mass. With the high coefficient of
some reciprocating compressors that still use metallic rider
thermal expansion of aluminum, piston rise becomes very
bands, non-metallic rider bands are now much more common.
noticeable on pistons with a diameter greater than 20 inches
However, rod drop measurements should not be used on
(508 mm). Users should be aware of this expected rise and use
cylinders that incorporate metallic rider bands since the exposed
11 mm probes to accommodate this added movement.
babbitt thickness is very small.
• Is it a Non-lubed Cylinder?
• Is HP > 600 (447 kW)?
If any answer to the above questions is no, and if the cylinder is
Is the reciprocating compressor frame rating greater than 600
not lubricated, experience has shown that the rod drop
horsepower (447 kW)? Rod drop may not work properly due to
measurement may provide erratic results. It is recommended
excessive flexing of running gear and compressor components
that users consult with GE regarding their expectations for the
on lightweight machines of less than 600 hp.
measurement to ascertain whether the installation of rod drop
• Is RPM < 500? monitoring will provide value.
Is the operating speed of the compressor less than 500
revolutions per minute? Experience indicates that rod drop
measurements may not work properly on machines with RPM
greater than 500.

GE Energy | GER-4274 (08/06) 2

Rider Band Wear vs. Other Rod Drop Applications
This flow diagram was developed specifically to ascertain whether the rod drop measurement will provide a useable indication of rider band
wear. However, it is not the only machine condition detectable by measurement of the piston rod motion at the pressure packing case. If the flow
diagram indicates that the compressor is a poor rod drop application, consider installing the rod position measurement instead. This measurement
uses two orthogonally mounted proximity probes in an X-Y configuration, rather than the single-plane measurement used for rod drop. It can
provide supporting evidence for diagnosing other machine or process conditions. Your local GE sales professional or field applications engineer
can assist you in assessing whether your proposed application can be adequately addressed by a rod drop measurement.

Rod Drop Channel Type Decision Flow

Start

Is Rider Band No
Non-Metallic?

Yes
Rod Drop may
Is Cylinder or may
No Non-Lubed? Yes
not provide value
Is HP > 600?
No
Yes
Confirm Customer
No
Expectation
No
Is RPM < 500?

Yes
No

Is L/D < 30?

L is Piston Rod No
Yes Length and Rod Drop
D is Piston Channel Type Customer to
Rod Diameter. Acceptable be notified
Is Correction of thermal
Factor < 2.0? expansion
during start
up and
Correction Factor unloading.
Yes is Piston Rod Length
divided by distance Is Piston
from crosshead Diameter > 20"?
to probe.
Is Pressure No Yes
< 1500 psig?

Yes
8 mm Transducer 11 mm Transducer

Figure 1. Decision flow diagrams

GE Energy | GER-4274 (08/06) 3

GE Energy
Optimization and Control
1631 Bently Parkway South
Minden, NV 89423

+1 775.782.3611

www.ge-energy.com/oc

©2006, General Electric Company. All rights reserved.

GER-4274 (08/06)