Performance and Condition Assessment

BETA provides performance assessments on:

1. Reciprocating Compressor/Engine

2. Turbine/Centrifugal Compressors, and other rotating equipment

See below for descriptions of each of these services.

1. Performance of Reciprocating Compressors / Engines
For maximum reliability of reciprocating compressor packages, customers will implement periodic performance and condition assessments (for the compressor and engine). The performance analysis is typically a one day site visit with additional time for set-up and post-processing of data. A portable compressor/engine analyzer is used to collect performance data, including the pressure/volume card data.

Scope

• The customer provides information of the unit (to set-up our analyzer and investigation).
• The operator/mechanic will install valves on compressor cylinders prior to the visit.
• During the site visit, BETA captures mechanical and performance data. Comparing the actual operating results to the theoretical performance model is used for early indication of problems.
• Performance and condition indicators include:
• Power and load
• Capacity
• Efficiency
• Leaking valves and rings
• Improper valve dynamics
• Crosshead and rod knocks
• Power cylinder combustion
• Accessories and Frame Vibration
• A detailed performance report is prepared for the unit. This baseline is valuable for comparing to future assessments

Reciprocating compressor performance analysis

Fast inspection identifies condition of bearings, wrist pin and internal condition

Option: Engine Bearing Assessment

• A non-invasive method to assess the wear on internal bearing and components. This avoids expensive (and often un-necessary) engine overhauls.
• Operators can avoid excessive maintenance costs and potential crashes by checking:
• Wrist pin and rod bearing clearances (wear and trend)
• Cylinder leakage rates
• Power cylinder condition & wear: liners, rings, ports, head, valves
• Valve sink and train setting
• Cylinder condition rating (borescope)
• The internal inspection requires only a short shutdown to collect this valuable data (typically, a 4 hour shutdown is required). This is a fraction of the cost of an unnecessary overhaul.
• The assessment uses BETA’s patented B-Probe (which is sold under license by Dynalco Controls and called the DynaProbeTM).

Results
Here are some example savings:

• A US gas transmission company saved over $3 million by postponing overhauls of 7 units (during a one year inspection)
• Prevented failures that would have resulted in >$1 million damage
• Identified significant performance improvement opportunities because of valve dynamics problems. Incremental production exceed $millions/year.
• Allowing more targeted engine overhauls resulted in 80% cost reduction
• Extended the period between overhauls and identified overhaul requirements based on the unit’s condition

BETA Advantages

• The inventors of Recip-Trap™and technology leaders still remain at BETA. This experience is utilized in our field and monitoring groups.
• The integrated service of coordinated performance inspections with pulsation/vibration assessments is only offered by BETA.

Examples
Contact us for examples of performance and optimization studies.

2. Performance Assessment of Turbine / Centrifugal Compressors
Example: A gas field was projected to be depleted within 18 months and the client wanted to avoid replacement or overhaul of the gas turbine. BETA conducted a detailed performance and vibration assessment of the complete gas turbine and centrifugal compressor system. The gas turbine was in acceptable shape to last the required time as long as it was regularly washed. The analysis did point out that the power turbine was in poor shape and that the compressor system needed booster compression to avoid surge. As a result, the client conducted an overhaul of the power turbine and installed additional compression for the remainder of the area’s production life.
> More examples