Rotating Equipment Reliability Management
Compressors, pumps, turbines — reliability strategies, common failure modes, and condition monitoring for rotating assets.
Why Rotating Equipment Drives Production Risk
Rotating equipment — centrifugal and reciprocating compressors, pumps, gas turbines, steam turbines — is often the single largest driver of unplanned production loss. Unlike static equipment, rotating equipment can fail suddenly with minimal warning. The top 5-10 most critical machines in a gas processing plant may account for 80%+ of total rotating equipment production loss risk.
Common Failure Modes
Centrifugal Compressors: Surge, impeller fouling, bearing and seal failures.
Reciprocating Compressors: Valve failures (most common — fatigue of valve plates), piston/rod wear, cylinder liner damage.
Centrifugal Pumps: Cavitation (NPSH), mechanical seal failures (most common pump failure), bearing failures.
Gas Turbines: Hot section blade creep, compressor fouling, combustor liner cracking.
Condition Monitoring Strategy
Vibration monitoring is the cornerstone of rotating equipment CBM. Online continuous monitoring for critical machines; periodic portable routes for less critical items. Lube oil analysis provides early warning of bearing and gear wear. Performance monitoring tracks efficiency vs. design curves.
Key Takeaways
Critical rotating equipment is the leading cause of unplanned production loss
Match condition monitoring technique to failure mode: vibration for mechanical faults, oil analysis for wear
Performance monitoring detects efficiency degradation that precedes mechanical failure
FMECA is the analytical foundation for selecting the right maintenance task for each failure mode
Apply this knowledge to your assets
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