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    Rotary Screw Compressors: Online Condition Monitoring of

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    fazzlie
    ScrewCompressors

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    Rotary Screw Compressors: Online Condition Monitoring of

    Uploaded by

    fazzlie
    406 views3 pages
    ScrewCompressors

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    ScrewCompressors

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    ScrewCompressors

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    406 views3 pages

    Rotary Screw Compressors: Online Condition Monitoring of

    Uploaded by

    fazzlie
    ScrewCompressors

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
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    At a glance
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    The key takeaways are that screw compressors are used to compress air and process gases in industries like refineries and plastics production. Their availability is critical so condition monitoring helps prevent failures and maximize component life.

    According to VDI 3836, screw compressors can be classified into 4 groups based on their bearing and gear configurations - Group 1 with plain bearings and synchromesh gears, Group 2 with roller bearings and synchromesh gears, Group 3 without synchromesh gears, and Group 4 being roots-type superchargers.

    The VIBNODE online monitoring system monitors the main and secondary rotors, step-up and synchromesh gears, roller bearings, charge compression, and the drive machine components like couplings using vibration and sound monitoring.

    Application

    Online Condition Monitoring


    of Rotary

    Screw Compressors

    Increased system availability


    Predictive maintenance
    Service programs with remote monitoring

    Process assurance and availability increase in rotar


    Rotary screw compressors
    In rotary screw compressors, the
    medium is compressed by means
    of two rotors. Due to their cyclical
    operation, screw compressors are
    grouped between reciprocating
    compressors and turbo compressors. Their vibration behavior is
    dominated by the discharge frequency of the charge output.

    VDI 3836 differentiates screw


    compressors into four machine
    groups:
    Group 1
    Screw compressors with plain
    bearings and synchromesh
    gears (usually for compressing
    process gases)
    Group 2
    Screw compressors with roller
    bearings, or roller and plain
    bearings, and synchromesh
    gears (usually oil-free compressors for generating compressed air)
    Group 3
    Screw compressors without
    synchromesh gears (usually oilflooded screw compressors)
    Group 4
    Roots-type superchargers with
    roller bearings and synchromesh gears (usually for generating compressed air at high
    volumes).

    Screw compressor in a plastics plant

    Secondary rotor

    Suction

    Discharge

    Shaft seal
    Radial bearing

    Main rotor
    Synchromesh gear

    Axial bearing

    Step-up gear
    Cooling fan

    Dry-running screw compressor (Group 2 as per VDI 3836)

    High availability requirements


    The availability demands placed on
    screw compressors are extremely
    high for many production processes. Failure of non-redundant machines can result in the standstill of
    an entire production line, with lossof-production costs quickly reaching six-digit figures per hour.
    Screw compressors are frequently
    used for compressing air and refrigerant. Another major field of

    application is process gas compression in refineries and in oil and gas


    production. Machine protection
    also plays an important role. Unrecognized unallowably high machine vibrations, bearing damage
    and lubrication problems can lead
    to catastrophic failure of compressor units.
    Condition monitoring during operation helps prevent faults, enables

    the early detection of wear processes and lets operators take full
    advantage of the component service life.
    VIBNODE provides reliable and
    cost-effective online condition
    monitoring for screw compressors.

    ry screw compressors
    Reliable monitoring with the
    VIBNODE online monitoring system
    For the following components,
    condition monitoring is performed
    using frequency-selective monitoring of the specific machine vibrations and of structure-borne sound
    in roller bearings. These values are
    tracked in combination with operating parameters such as operating
    pressure, speed, output and temperatures:
    Main rotor / secondary rotor with rotor mesh
    Step-up and synchromesh
    gears
    Roller bearings
    Compression of charge
    Drive machine with coupling / belt drive
    The condition information is automatically transmitted to the higher
    level system of the operator or to a
    service partner via a network connection or via eMail.

    Monitoring with the VIBNODE online monitoring system

    Vibration sensor on bearing of main and secondary rotors

    OMNITREND diagnosis software


    Discharge
    Step-up gear

    Synchromesh gear

    Rotors

    Level 1

    Overall value monitoring


    VIBNODE tracks the trend of
    the characteristic vibration values along with the operating
    parameters. On the basis of a
    rise in the trend, predictions
    can be made on how other
    condition parameters will develop. An alarm is output if a
    limit value is exceeded.

    Frequency-selected monitoring with 8 alarm bands.

    Monitoring band of rotational frequencies of the main and secondary rotors

    Level 2

    In-depth diagnosis
    The possible causes for condition deterioration are narrowed down using in-depth diagnosis functions. This permits
    condition-based and cost-optimized planning of maintenance measures.

    Monitoring band of discharge

    Discharge

    Monitoring band of main rotor roller bearing

    Multidiagram

    Waterfall diagram

    LUDECA, INC. (305) 591-8935 www.ludeca.com

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