Knowledge-based Tool Development and Design for Reciprocating Compressors

Condition monitoring data collection capabilities have grown over the last decade in large part due to advances in integrated circuits (IC). These advances now permit real time thermodynamic and process calculations on desktop computing platforms. With these capabilities, the sophistication and amount of data available to the users of rotating and reciprocating equipment has grown exponentially. In particular, online reciprocating compressor monitoring systems generate significant amounts of real time data beyond the traditional values of pressure, temperature, vibration, and speed. With the growth in the amount and manipulation of data, it has become imperative to assist the engineer or operator in quickly locating indications of a potential problem. Many users and condition-monitoring suppliers have designed, developed, and tested knowledge-based tools to achieve this goal. The intent of this paper is to describe the knowledge-based tool design and development process for reciprocating compressors, including the basic assumptions that must be considered and the design features that can make an effective knowledge-based system. A discussion of basic research into reciprocating compressor knowledge-based tool development will be presented in an effort to help those who undertake this development effort understand potential obstacles. The important aspects of an effective system will be described. Finally a series of case histories from operating process plants will show instances where the system worked, as well as instances where problems occurred and how they were addressed.