Customer's Challenge
A critical compressor system at a refinery began logging an increasing running temperature trend, specifically showing excessive wear on the inter-connecting shaft between the compressor and gearbox. The wear was more severe than on the shaft connecting the motor to the gearbox. This uneven wear raised concerns with the Operations and Safety departments, who had to decide on the next course of action.
To maintain safe operating temperatures in the compressor gearbox, the team considered adjusting the unit’s loading, which would reduce plant output. However, continued wear could still cause the compressor to overheat, posing a significant safety risk. Faced with the decision between extending operations and addressing the safety hazard, the client opted for a thorough investigation to diagnose the root cause and resolve the issue during a planned shutdown.
Solution
To maximize efficiency during the shutdown, multiple teams of experts were involved in assessing the gearbox’s condition. Metal Machines was entrusted with conducting dimensional checks on the gearbox housing, gathering Geometric Dimensioning & Tolerancing (GD&T) data, including flatness, straightness, and parallelism.
For this, the API laser tracker was selected due to its battery-powered design and compact form factor, making it suitable for use in confined spaces. The upper and lower gearbox housings were dismantled, and two separate surveys were conducted on each half of the housing. The data collected was processed using Spatial Analyzer software to verify that the GD&T measurements were within acceptable limits, ruling out the possibility that overheating was due to any deformation in the casing.
Benefits
The laser tracker captured a large number of precise measurement points quickly, even on large components, with temperature compensation for outdoor conditions. By integrating Spatial Analyzer software into the process, the data analysis and reporting were completed in less than two days. This streamlined approach ensured that the investigation was both thorough and timely, allowing the client to take swift corrective action and minimize downtime while ensuring the safety and reliability of the compressor system.
