Methods and systems for real-time monitoring and optimizing the performance of reciprocating compressors

Abstract

Disclosed are systems and methods for monitoring the performance of a plurality of reciprocating compressors having components made by at least two different manufacturers. A source of reciprocating compressor data associated with a plurality of reciprocating compressors and a source of reciprocating compressor component specifications associated with the plurality of reciprocating compressors are in communication with a computer processor. The computer processor obtains at least one measured value from the source of reciprocating compressor data and at least one specification value from the source of reciprocating compressor component specifications, performs at least one calculation using the at least one measured value and the at least one specification value to calculate at least one calculated performance value, compares the at least one calculated value to a user-defined calculated value limit selected from the group consisting of an upper alarm limit, a lower alarm limit, an upper deviation limit, a lower deviation limit, a maximum value, a minimum value and combinations thereof, and initiates an alert to a user of any calculated value exceeding the user-defined calculated value limit every user-defined period of time.

What is claimed is: 
     
         1 . A system for monitoring performance of a plurality of reciprocating compressors having components made by at least two different manufacturers, comprising:
 a. a source of reciprocating compressor data associated with a plurality of reciprocating compressors comprising reciprocating compressor components made by at least two different manufacturers;   b. a source of reciprocating compressor component specifications associated with the plurality of reciprocating compressors comprising reciprocating compressor components made by at least two different manufacturers; and   c. a computer processor in communication with the source of reciprocating compressor data and the source of reciprocating compressor component specifications;   wherein the computer processor:
 i. obtains at least one measured value from the source of reciprocating compressor data and at least one specification value from the source of reciprocating compressor component specifications; 
 ii. performs at least one calculation using the at least one measured value and the at least one specification value to calculate at least one calculated performance value; 
 iii. compares the at least one calculated value to a user-defined calculated value limit selected from the group consisting of an upper alarm limit, a lower alarm limit, an upper deviation limit, a lower deviation limit, a maximum value, a minimum value and combinations thereof; and 
 iv. initiates an alert to a user of any calculated value exceeding the user-defined calculated value limit every user-defined period of time. 
   
     
     
         2 . The system of  claim 1 , wherein in step (b)(i) the computer processor obtains at least two measured values from the source of reciprocating compressor data wherein the at least two measured values are associated with reciprocating compressor components made by at least two different manufacturers; and in step (b)(ii) the computer processor performs calculations using the at least two measured values and the at least one specification value to calculate at least two calculated performance values on an equivalent basis independent of manufacturer. 
     
     
         3 . The system of  claim 1 , wherein the at least one calculated performance value is stored in a historical database comprising calculated values retrievable by the computer processor. 
     
     
         4 . The system of  claim 1 , further comprising:
 c. a user input device in communication with the computer processor; and   d. a visual display in communication with the computer processor;
 wherein, in response to user input provided via the user input device, the computer processor generates at least one report, table, chart, diagram or graph on the visual display associated with the at least one measured value or the at least one calculated value. 
   
     
     
         5 . The system of  claim 1 , wherein the plurality of reciprocating compressors comprises from 10 to 200 reciprocating compressors; and the source of reciprocating compressor data comprises from 10 to 1000 sensors. 
     
     
         6 . The system of  claim 1 , wherein the reciprocating compressor components are selected from the group consisting of engines, crank shaft housings and cylinders. 
     
     
         7 . A method for monitoring performance of a plurality of reciprocating compressors having components made by at least two different manufacturers, comprising:
 a. obtaining at least one measured value from a source of reciprocating compressor data associated with a plurality of reciprocating compressors comprising reciprocating compressor components made by at least two different manufacturers;   b. obtaining at least one specification value from a source of reciprocating compressor component specifications associated with the plurality of reciprocating compressors comprising reciprocating compressor components made by at least two different manufacturers;   c. performing at least one calculation using the at least one measured value and the at least one specification value to calculate at least one calculated performance value;   d. comparing the at least one calculated value to a user-defined calculated value limit selected from the group consisting of an upper alarm limit, a lower alarm limit, an upper deviation limit, a lower deviation limit, a maximum value, a minimum value and combinations thereof; and   e. alerting a user of any calculated value exceeding the user-defined calculated value limit every user-defined period of time.   
     
     
         8 . The method of  claim 7 , further comprising storing the at least one calculated value in a historical database comprising calculated values such that the at least one calculated value is retrievable by the computer processor. 
     
     
         9 . The method of  claim 7 , further comprising generating at least one report, table, chart, diagram or graph associated with the at least one measured value or the at least one calculated value.