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Do your reciprocating compressors have sufcient protection?

Due to the increasing demands on availability and because of their special mode of operation,

reciprocating compressors require monitoring and protection systems designed specically for

this type of machines. These systems monitor the compressor around the clock, enable a more

efcient operation and avoid unscheduled downtimes and major damage.

Without appropriate monitoring, many problems are

detected too late or not at all

Loose or damaged mechanical connections Liquid carry-over damages valves, pistons and piston rings Clogged valves cause increased pressure in the cylinder

and poor compressor performance

Worn seals cause gas leakage and loss of efciency Damage due to piston rod overloading or loss of rod load

reversal

A compressor failure can have serious consequences for

your business

Major damage and resulting downtimes Loss of production Safety risk to workers Inefcient operation Unnecessary and unplanned maintenance work High costs for repairs, risk management and environmental

protection

Why monitoring and protection are a mustYour reciprocating compressors are at the heart of yourprocess. Inefcient operation and unplanned shutdowns canseriously harm your business. You cannot rely on conventionalmeasurement technology alone to guarantee the earlydetection of potential failures to prevent damages in time.Only through the use of RecipCOM it is possible to minimizefailures and high repair costs.

Crosshead failure

Piston damage

Clogged valve

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The benets are clear

Dependable protection against compressor failures -for increased operational safety and reliability

SIL certied protection of compressors, people and

environment Prevention of major compressor damage Reduction in the number of compressor failures

Improved maintenance planning and lower service costs Early and unambiguous fault detection Online condition monitoring

Precise root-cause analysis Condition-based maintenance

Lower operating costs and increased productivity Risk-free extension of maintenance intervals Provision of information to optimize compressor

performanceReduction of risk transfer costs and insurance premiums

Monitoring and protection systems ensure optimal and

protable operation of your compressor. If the systemprevents major compressor damage only once, or is ableto reduce the duration of a maintenance stoppage, theinvestment will have already paid for itself.

HOERBIGER's RecipCOM protects your compressor in realtime and ensures optimal and cost-efcient operation of yourplant.

RecipCOM continuously monitors critical equipmentparameters such as vibration, rod position, indicator pressure

and temperature. This allows you to exploit the full potentialof your compressor and gives you early warning of potentialfailures.

Compressor monitoring and protection is the bestinvestment you can make

Investing in RecipCOM pays off if even a single outage can be prevented or

compressor downtime shortened.

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... you invest only in the features you really need

Maximum exibility combined with deep technical know-how: choose the RecipCOM modules relevant

to your current compressor operation and upgrade your system when you need it.

Measurement vs fault detection

Modules Parameter measured

Fault detection

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Rod positionRod position

Rod run out

Vibration

Frame vibration

Crosshead vibration

Cylinder vibration

Bearing vibration

Indicator pressure Cylinder pressure

Static data

Suction / Discharge valvetemperature

Packing temperature

Leakage gas temperature

Bearing temperature

Performance Cylinder pressure

Damage prediction Vibration

Rod motion Rod position

RecipCOM Top Training andperformance optimization

RecipCOM Core: Detects and monitors gradually developing problems.

RecipCOM Pro: Protects your compressor from rapidly developing problems, with automatic shutdown to prevent severe damage.

RecipCOM Diagnostics: Advanced diagnostics, fault analysis and online condition monitoring.

RecipCOM Top: Training, optimization of performance and remote monitoring services by HOERBIGER experts.

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...you get better insight into your compressor's performance and can direc

Eddy current sensors in the distancepiece monitor rider ring wear andpiston rod run-out over each revolution.An increase in run-out indicates aloose connection between piston rod

and crosshead, a change in cylinderalignment or excessive crossheadclearance. Early detection of theseproblems can prevent major damage,help scheduling repair work and reducemaintenance costs.

Dynamic pressure sensors in theclearance spaces measure the gaspressure in the cylinders at a highfrequency. The RecipCOM hardware usesthe cylinder pressures and compressor

parameters to calculate the piston rodload, the load ratio and the durationof the load reversal. As a result, yourcompressors are protected againstexcessive stress on the oscillatingcomponents and insufficient lubricationof the crosshead pin. In addition,the system performs comprehensivethermodynamic analyses (pV).

CrossheadLoose connections, damage, excessivecrosshead clearance

Rider ringWear

Piston ringsBreakage

CylinderAlignment problems, liner wear

Piston rodLoose connections, cracks, breakage,excessive run-out

Piston rodRod load

Main packingsLeakage

Crosshead pinRod load reversal

ValvesLeakage, suction and discharge pressure loss, clogging, late closing

Suction lineDirty intake filter

Piston ringsLeakage

CylinderPerformance, efficiency, maximum cylinder pressure, pulsations, liquid

carry-over

RodPosition

IndicatorPressure

RodMotion

Performance

Protection

Protection

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retrieve health status data

CrossheadIncorrect assembly, crosshead pin

damage, excessive crosshead clearance,loose connection between crosshead andpiston rod

Piston rodBreakage

OthersLoose valves or cages, loose foundationbolts, major imbalance, failure of mainand connecting rod bearings

CylinderLiquid carry-over

PistonLoose connection between piston andpiston rod, cracked piston

Vibration sensors on the distance pieceand crankcase monitor the movingparts of the crank drive and check formechanical failure. The unique methodof vibration monitoring with a resolutionof 1 degree crank angle enables thedetection of malfunctions much earlierthan conventional systems. This allowsfor prompt initiation of the necessarymeasures to resolve the problem at anearly stage and prevent potential seriousdamage.

VibrationDamage

predictionProtection

RecipCOM Pro is certified by TÜVRheinland and complies with IEC61508/61511 (SIL). RecipCOM isa monitoring and protection system

developed specifically for reciprocatingcompressors. Because every singlerevolution is monitored in real time,the compressor can be shut downimmediately in the case of developingproblems. Thanks to the operatingcondition-based alarm limits, a smartalarm counter and continuous self-diagnosis, false alarms are reliablyeliminated.

StaticData Protection Protection

Temperature readings on components,leakage and lubricating oil lines areimportant maintenance parameters.The following applies to suction and

discharge valves: Temperature deviationsare a sign of wear on valves or pistonrings. Bearing temperatures can be usedto identify problems with lubrication,load or wear. Accurate trending showswhether a problem must be correctedimmediately or if it can wait until thenext scheduled shutdown.

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RecipCOM Diagnostics for advanced diagnostics and fault analysis

RecipCOM Top stands for training and performance optimization

Sophisticated pV-analysis allows RecipCOM to detect problemsat the suction and discharge valves, identify leaking rings andpacking or malfunctions on other cylinder-related components.At the click of a mouse, compressor performance tables can becalled up to evaluate critical equipment parameters which canbe used to assess compressor efciency and energy costs andto determine the impact of new operating conditions.

Where other monitoring systems use xed alarm limits,

RecipCOM monitors vibration levels and relates them to thecrank angle for reliable and robust fault detection. Comparingvibration signals with rod load and cylinder pressure diagramspinpoints events such as rod load reversal and valve openingand closing. The result is precise diagnosis of liquid carry-over,delayed valve closing and loose components.

Rod motion plots display the movement of the piston rod atthe main packing over a crank angle of 360 degrees. On thebasis of deviations from the normal operating conditions,changes in cylinder alignment, excessive crosshead clearance,as well as liner or rider ring wear can be detected as a functionof the crank angle. An XY-analysis of the rod position over a360° angle is also possible.

Get the winning edge: RecipCOM Diagnostics

With RecipCOM Diagnostics you can benet from HOERBIGER’s extensive

experience in the elds of reciprocating compressors and condition monitoring.

Performance

Damageprediction

RodMotion

System implementation , ranging fromthe assessment of existing monitoringequipment and failure history of individualcompressors to turnkey installations.

Monitoring services for increasedreliability and improved maintenanceplanning.

Support and training in using RecipCOMto its full potential and ensuring optimalperformance.

Customized upgrade solutions that makethe operation of your compressor moreefcient, reliable and environmentallyfriendly – on the basis of an integratedREE assessment.

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Powerful, compact, versatile

RecipCOM provides unmatched monitoring capabilities and reliable protection of your

reciprocating compressors. With only a small number of system interfaces, RecipCOM can be

integrated quickly and easily into both existing and new installations.

How does RecipCOM work?RecipCOM is a monitoring and protection system designedspecically for reciprocating compressors. It is certied to IEC61508/61511 and compliant with API 670.RecipCOM is reliable, versatile and fast: if necessary, it canimmediately shut down a compressor automatically. RecipCOMcombines the speed and robustness of its evaluationelectronics with a Windows®-based software for simple andpowerful data analysis.The new generation of Fast Transmitter Interface Modules(FTIM2s) enables a decentralized acquisition of the measuredsignals. Each of these FTIM 2s contains a power supply andbarriers for up to eight intrinsically safe transmitters. TheFTIM2s can be installed in explosion-proof areas.

Compared to conventional monitoring systems, the simplesystem architecture reduces planning, wiring, and installationfrom the compressor to the control cabinet. All themeasurements are made synchronously over each revolutionand the readings transferred over a secure and redundant high-speed communication link to the compressor interface unit(CIU²).The CIU2 receives and compares these data with the alarmthresholds set for the particular operating conditions. TheRecipCOM system immediately detects any limit violationand communicates this to the control system by means of arelay contact. To avoid false alarms , the CIU2 triggers the alarmrelays only if the alarm threshold is exceeded for a set numberof revolutions. The alarm signal is passed from the CIU 2 to adedicated safety system or the main DCS.

Ex-Zone

Electrical RoomDCS / PLC

Data & power supply

TDC signal

Sensor cabling

Modbus RS232/RS485/TCP

LAN

Hardwired

Detailed analysis with the built-in"Flight Recorder"RecipCOM is the only machineprotection system with integrateddynamic signal recording capabilities.The on-board "Flight Recorder" storesall dynamic signals during start-up,shutdown and alarms over a number ofrevolutions directly on the hardware ofthe CIU2. If required, these data canbe loaded onto a laptop or PC to carryout a detailed analysis. A separateRecipCOM server can also be used torecord and visualize all data collected bythe system. A comprehensive exchangeof information with the PLC or DCStakes place via standard interfaces. Theconnection over TCP/IP enables fullnetwork integration and remote access.

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This product brochure contains product specications based on research and development on the one hand and on manufacturing on the other. Since the individual parametersof the described product may change depending on operating conditions, place of installation and specications, HOERBIGER assumes no liability or warranty for the accuracyand completeness of the information covered in this brochure.

Benets of RecipCOM at a glance

RecipCOM offers more than other compressor monitoring systems . With more than 100 years ofexperience in the eld of reciprocating compressors, HOERBIGER has implemented over 1,300

mechatronic solutions for compressor monitoring and protection.

Take advantage of HOERBIGER's unmatched global technical support and contact your

local HOERBIGER branch or write to: compressor-mechatronics@hoerbiger.com.

Areas of application: natural gas, petrochemical industry, rening

Take advantage of HOERBIGER's expertise in the eld ofreciprocating compressors and condition monitoring

Specialists with expert knowledge of compressorcomponents, their operation and service.

Modular and customized monitoring solutions tailored toyour needs

Easy to use, with simple installation and quick integration Distributed data acquisition in hazardous areas: reduced

wiring costs, fewer terminal blocks, easier installation in

the control cabinet Digital communication: cable lengths of up to 500 meters

between compressor and CIU² possible (60% longer thanconventional systems)

Plug and work: Reduced installation and commissioningcosts

User-specic operating modes: "Basic" for plant operatorsand "Expert" for maintenance engineers

Online assessment of compressor condition On-board 'Flight Recorder'

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www.hoerbiger.com

HOERBIGER is active throughout the world as a leading player in the elds of compression technology, drive technologyand automation technology. In 2013, its 6,400 employees achieved sales of 1.05 billion euros. The HOERBIGER brand issynonymous with performance-dening components in compressors, industrial engines and turbines, automobile transmissions,and multifaceted mechanical engineering applications. Innovations in attractive technological market niches are the basis forcomponents and services that offer unique selling propositions and long-term benets for the customer.We set standards.

Highest precision and reliabilityFunctional safety certied by TÜV Rheinland, Germany

Extra-ne resolution of alarm limits: 1 degree crank angle Reliable and fault-resistant redundant digital data

transmission "Trust" function for internal fault detection and system

monitoringSmart alarm counter: envelope type alarming withoperating condition-dependent limits to prevent falsealarms