Reciprocating Compressor & Engine Analysis

Windrock 6310/PA
Performance, Condition and Vibration
Analyzer
1/6/2015

Mission Statement
To produce the highest quality instrumentation and
software for monitoring and analyzing reciprocating
machinery and to provide our customers with
unparalleled customer support after the sale.

From a major customers perspective:

There are three main reasons we choose Windrockyour functionality,

your flexibility and your customer support.

Company History
Windrock founded in 1989

Acquired by Computational Systems Inc. (CSI) in 1990 as a

wholly-owned subsidiary

Originally the research and development arm of CSI

Leveraged buyout from CSI by three employees in 1996
Windrock has grown to 24 employees in 9 years

Products include Portable and On-Line condition and

performance monitoring products for reciprocating
compressors and engines

Services include multi-levels of training and analysis services

3

Types of Engine/Compressor Analysis

Periodic mechanical

Troubleshooting

condition and performance

Performance
- Critical machines
(700 hours)

- High speed machines

(1400 hours)

Acceptance testing
Emissions testing
Compressor valve testing
Load curve generation
Research and development

- Low speed machines

(2100 hours)

- Electric driven machines

Special purpose
- Pulsation
- Vibration

(2100 hours)

Typical Engine/Compressor Analysis

Power Cylinders

Ignition

Vibration &
Pulsation

Compressor
Cylinder End

Frame &
Running Gear
5

Compressor Test Results

Determine the mechanical condition of each compressor valve

Identify flow restrictions or excessive pressure drops
Find leaking rings
Detect loose piston on the rod
Determine if the pockets are leaking
Evaluate the effectiveness of the capacity control and unloader
devices
Locate external process leaks including packing
Survey the bearings, pins and bushings for extra clearance
Measure the HP, capacity and efficiency of each cylinder
Determine the effective operating clearance volume
Other vibration related problems (looseness, alignment, etc)
6

Engine Test Results

The mechanical condition of the intake and exhaust valves

The condition of the rings and cylinder surfaces
The mechanical condition of the fuel valve
The timing for all valve and port related events
The exhaust and intake ports are restricted or not
There is piston slap indicated or not
That there are external leaks or not
That the bearings, pins and bushings indicate extra clearance
The IHP and all peak pressure statistics of each cylinder
Other vibration related problems

Ignition Test Results

Ionization voltage characteristics for each spark plug

Arc duration for each spark plug
Arc voltage for each spark plug
Arc slope for each spark plug
Maximum ring down voltage for each spark plug
Ignition timing and variation for each cylinder
Ionization rise time for each secondary circuit
Primary voltage available for each cylinder
Misfire, no arc & fly-back count on each spark plug

Windrock 6310 Analyzer Family

Model 6310/CA Combustion Analyzer
Model 6310/VA Vibration Analyzer
Model 6310/MA Maintenance Analyzer
Model 6310/PA Performance Analyzer
Model 6310/PA/HA - Performance and Horsepower Test Analyzer
Model 6310/PA/VA - Performance and Vibration Analyzer

Windrock 6310/PA Performance Analyzer

10

Windrock 6310/PA Analyzer

11

Windrock 6310/PA Analyzer Package

6310/PA Performance Analyzer,

keyboard and carrying strap

Dual bay battery charger and
three (3) Lithium Ion batteries
Two (2) DC pressure sensors with
8-foot cables
Ultrasonic probe, rubber acoustic
tip, contact tip, and 6 foot cable
Accelerometer & velocity pickup,
magnetic bases and 6 foot cable
Infrared temperature sensor and
6 foot cable
Wireless crank angle transmitter
and cable
Secondary Ignition clip and lead
Primary Ignition lead (optional)
Carrying case with wheels
12

Windrock 6310 Encoder Kit (Optional)

Crankshaft angle encoder, also
with Magnetic pick-up input
connector

Timing light and 20 foot cable

Tripod
Drive shafts with tips & sockets
Kiene valve wrenches

Communications cable and

Users manual

Carrying case with wheels

13

Crankshaft Angle Encoder

The Crankshaft Angle Encoder
converts the rotational motion of
the crankshaft into electrical
signals

The encoder generates both a

pulse per degree (PPD) signal
and a pulse per revolution (PPR)
signal

The Windrock 6310 analyzer

calculates the exact location of
each cylinders piston from the
signals

14

Optical Pickup (Optional)

The synch light will flash at the
leading edge of the reflective
tape if proper setup is obtained

The optical pickup should be

positioned at the leading edge of
the reflective tape when the
flywheel is at exact TDC position

The direction of rotation should

be referenced to determine the
leading edge.

15

Strobe Light Operation

The strobe light is triggered by the one
pulse per revolution (PPR) signal
generated by the crank angle encoder.

This is used for synchronizing the

analyzer with the top dead center

reference mark (TDC of crank angle
phase) on either the power or
compressor cylinder.

The finger trigger initiates the strobe

operation. The momentary switch pad

buttons are for remote electronic TDC
adjustment when using the encoder
input shaft for synchronization.

Trigger
Connect to crankangle encoder or
multi-event encoder

This can also be used with the

Magnetic Pick-up option to verify the

cable polarity is correct. The pin or
hole will be lined up with the mag pickup if the cable polarity is correct.

16

Crank Angle Encoder Operation

Alternately, the encoder incorporates Mag Pickup and
Photo input connectors for once per turn inputs.
The Strobe connector connects the strobe light for
synchronization to a reference cylinder.
The connector marked to 6300 connects the encoder
cable to the 6310 analyzer.
The Stroke switch is for selecting either 2 or 4 stroke
operation.

Hole or pin switch for magnetic pickup input

To analyzer or wireless transmitter

The Phase switch is for sweep reset between

compression and exhaust top dead centers when
analyzing four stroke engines.

LED indicator for Once per turn (OPT) pickup signal

17

Optional Multi-event Encoder

Incorporates the same
features as the
encoder except with no
rotational input

LED for OPT pickup signal indicator

Provides two magnetic probe inputs. One for once per turn (OPT)
synchronization and the other for hole or tooth count
18

Wireless Crankshaft Angle Transmitter

The wireless encoder
transmitter allows the
encoder generated pulses or
magnetic pickup signal to be
transmitted to the Windrock
6310 analyzer via radio
frequency.

These signals are received by

the 6310/PA portable
analyzers built-in receiver

The encoder cable is

Connect encoder cable from
here to here for wireless
operation

connected between the

encoder and the wireless
transmitter.

19

Air-Cooled Compressor Pressure Sensor

Standard pressure sensor used with Windrock 6310 analyzer for compressor
cylinder end and suction/discharge nozzle pressure measurement for extended
periods of time.

4 to 20 ma electrical signal directed to the analyzer.

Connected to Kiene or other indicator valve type on the compressor cylinders
Standard sensors available in 300, 500, 1000, 2000, 3000, 5000 psig Pressure
Ranges
20

Pressure Sensor Points (Compressor)

Headend and Crankend Indicator
Pressure Sensor Point Locations

Valves
Pulsation Bottle Indicator Valves
(optional)
Nozzle Indicator Valves (optional)

21

Air-Cooled Engine Pressure Sensor

Standard pressure sensor used with Windrock 6300/6310 analyzer for

conditions of high temperature for extended periods of time

4 to 20 ma electrical signal that is directed to the analyzer

The pressure transducer is typically connected to Kiene or other
indicator valve type on the power cylinders

Available in 2000, 3000, and 5000 psig Pressure Ranges

22

Ultrasonic Sensor and Headphones

Optional head-set and battery pack

Ultrasonic translator converts Ultra-high frequency (35 KHz to 44 KHz)

acoustics and mechanical energy into a Sub-Sonic lower frequency

Signal is directed to the analyzer display and/or a audio headset

Ultrasonic Pick-up is placed on numerous test points of the machine to

detect leakage and mechanical events, and is also used for external leak
identification

23

Compressor Ultrasonic

Valve Cap Ultrasonic

Many analysts
have good results
from placing
rubber tip on top of
stud, on the flat of
the nut or bolt or
on the edge of the
valve cap.

24

Vibration & Ultrasonic Frequencies

.5 Hz

14 KHz

Accelerometer Frequency
5 KHz

Accel Upper Limit

High Frequency Vibration

2.5
KHz

1.25
.5 Hz KHz
312
Hz

1.25
KHz

5
KHz

Low Frequency Vibration

.5 Hz

10
Programmable to
KHz 312 Hz, 625 Hz,
1.25, 2.5, 5 and
10 KHz
10 KHz

Raw Vibration
35 KHz

44 KHz

Ultrasonic
25

Vibration Accelerometer
The accelerometer converts
mechanical or physical
movement of the accelerometer
into an electrical signal,
proportional to the actual
acceleration of the object

The sensitivity is 100 mV/g and

the frequency range is from .5
Hz to 14 KHz or higher

Do not drop or slap on the test

point!

26

Vibration Velocity Probe

The Velocity probes output is in
inches per second (ips) velocity

Its output can be accurately

integrated to displacement for
measurement of components
vibrating at relatively low
frequencies. (Frames, cylinders,
skids)

27

Infrared Temperature Sensor

Calibrated to 01000 deg F

Infrared Temperature Sensor measures surface temperatures on

various points on the machine (i.e. Suction, Discharge, Valve Caps,
Fuel Valves)

Measurement should be within 2 3 inches from the desired point

The sensor can also be used as a scanner in the direct channel read
function during the walk-around assessment.
28

Compressor Valve Cap Temperature

Valve Cap Infrared (IR)

The Raytek infrared can be
used in this manner or held
back several inches to a
couple of feet if necessary.

29

Secondary Ignition Capacitive Clip

The calibrated secondary
ignition capacitive clip is used to
accurately measure the
secondary ignition voltages.

The attenuation is 10,000 times

and the voltage range is 50 kilo
volts

The capacitive clip is clipped

around the spark plug wire.

30

Primary Ignition Pick-up (Optional)

The primary ignition pick-up is
used to accurately measure and
capture the primary ignition
voltages.

The attenuation is 100 times and

the voltage range is 500 volts

The primary ignition pick-up is

clipped to the positive N or

G or other lead in the junction
box depending on the type of
ignition system with the red
alligator clip

Black alligator clip is connected

to engine ground for zero
voltage reference.
31

Optional Displacement Probes

Non-contact eddy current
probe (proximity or
displacement probe)

Measures static and dynamic

displacement and relative
motion

Requires a stable mounting

Setup as a 4-20 ma sensor
point

32

Principles of Pattern Interpretation

(Suggested by Randy Anderson - ACTT a div of CECO)

33

Windrock 6310 Analyzer Displays

34

Pressure vs. Crank Angle

35

Compressor Cylinder End Calculations

36

Wind Wizards Indicate Leaking Valve

37

Pressure-Volume with Theoretical

38

Log P-Log V indicates Leaking Rings

39

Piston Rod Load and Reversal

40

Compressor Report - Page 1 Analyzer

41

Compressor Report - Page 2 Analyzer

42

Engine PT with Peak Pressure Stats

43

Engine Pressure - Volume

44

Secondary Ignition Voltage Pattern

45

Engine Report Page 1 Analyzer

46

Ignition Report on Analyzer

47

Win6310 Software Presentations

48

Pressure Curves with Passage Resonance

49

Pressure Indicator Passage Peak Frequency

50

Pressure Measurement with Smoothing On

51

Cylinder 2 Pressure vs. Crank Angle

52

Cylinder 2 with Suction & Discharge Nozzle

53

Pressure vs. Crank Angle - All 4 Cylinders

54

Compressor Report - Page 1

55

Compressor Report - Page 2

56

Cylinder 2 Pressure / Ultrasonic / Vibration

57

Cylinder 2 Pressure - Volume Curves

58

Cylinder 2 Calculations and Leak Index

59

Cylinder 4 Calculations and Leak Index

60

Cylinder 2 Rod Load & Low Frequency Vib.

61

Cylinder 2 - PT & VT, PV, Rod Load, Log P

62

The Best for Last The Analyst

...is the most significant component in a successful predictive maintenance
program. The majority of the data interpretation and analysis is performed in
the human mindthe analyst converts data into information.
Key characteristics include:

Mechanical knowledge
Engine and compressor

knowledge
Ignition system knowledge
Operations knowledge
Computer knowledge
Electronics knowledge
Communications knowledge
Leadership and teaching skills
Competent in ability
Confident in decisions

Know the difference between

good and bad data

Deal with facts, not assumptions
Collect and utilize all the facts
Never jumps to conclusions
Know how to use the tool
Objective attitude with a
willingness to learn and evaluate
new ideas, procedures, and
theories
Ability to communicate and gain
confidence in fellow employees
and team members
63

Questions?

Contact: akrawczak@windrock.com
64