Posted on: 06. 18. 26
Your business depends on your industrial gas infrastructure running as much as possible. But keeping pressure equipment running at all times isn’t always feasible, especially when regulations prevent it. When you’re installing new compressors or regulators in an industrial facility, the care you take at installation dictates how well they’ll run for the life of the system. Cutting corners can lead to sudden pressure losses, accelerated wear on critical components, and expensive shutdowns. Take steps to ensure your system is installed correctly the first time to avoid pressure problems and keep systems running smoothly.
To ensure efficiency and reliability throughout the life of your equipment, consider each piece not just on its own, but how it works within the facility as a whole. Here are a few tips to avoid headaches when working with your industrial gas infrastructure.
Finding Pressure Problems & Velocity Increases
Pipeline systems experience pressure losses whenever there is a high degree of friction or a sudden increase in velocity. If your system is designed to handle a certain average volume of gas flow but doesn’t account for peak usage periods, you can experience serious pressure issues. If downstream demand increases, gas velocity will rise in smaller-diameter lines. This increase in velocity can cause pressure to plummet, starving your equipment of needed pressurization.
Look for areas in your pipeline that cause gas to slow down. Any time you have a 90-degree elbow in your piping, it causes added resistance equivalent to adding more straight pipe to your system. Opting for longer radius elbows can help reduce turbulence within your pipes. You should also check to ensure piping dimensions are consistent throughout your headers. Variances can cause gas to pool or become restricted before it reaches your regulator manifold.
Another culprit for pressure losses can be found in your filter cartridges. Just like a pipe will restrict flow when dirty, your filters can cause your upstream compressors to work harder if debris is allowed to build up. Performing routine checks on the differential pressure across your filters can help alert your team when it’s time to service them. Many facilities will install sensors on each filter vessel to monitor for pressure changes across each filter media.
System Optimization & Troubleshooting Tips
Maintenance Hint: Tune your controller settings and routinely audit your infrastructure for weak points. Advanced AI-powered software can alert your team to restrictions in your compression assets up to 72 hours before your flow sensors detect an issue, allowing your team to make adjustments and avoid unexpected downtime.
Correctly spec-ing your valves is also important to prevent wear and tear on your system. Selecting heavier-duty regulators with a balanced plug can help decrease system hunting. Regulator hunting is when your regulator tries to adjust, causing your pressure to bounce above and below your setpoint. Rapid cycling of your regulator wears out piping joints and seals.
Step-by-Step Installation Guide
Proper installation of your equipment is essential to ensuring it functions correctly down the road. Many issues discovered in gas systems can be traced back to installing new hardware too quickly. Take your time and follow these steps to ensure your system operates correctly.
Step 1 | Ensure Pipes Are Clean
Make sure all connecting pipes are cleaned out before connecting your new hardware. Any debris, water, or slag left inside a pipe can cause high-velocity damage to your regulator seats and compressors when turned on. Using nitrogen to blow out your lines is a great way to ensure your piping is debris-free.
Step 2 | Align Pipes With Proper Technique
When connecting your pipes to hardware, never force them into place. Pushing your pipes will cause high stress to the housing of your equipment, which could cause deformation, misalignment of compressor shafts, and gaskets blowing out prematurely. Always hand-tighten your bolts first before using a torque wrench. Double-check that your piping is perfectly parallel by using a dial indicator or laser measurement tool. Then, slowly torque your bolts in a star pattern.
Step 3 | Testing For Leaks
Once you’ve installed your hardware, it’s important to verify integrity before pressurizing your lines. Close off your system and perform a hydrotest or pneumatic test to ensure everything is safe to put under pressure. Many countries have industrial standards set by ASME that must be followed when pressure testing your equipment. After your pressure test, apply a leak detection spray or ultrasonic leak detector to every joint, flange, and nut. Catching microscopic leaks now will save you from major gas losses later.
Step 4 | Operational Testing
Once you’ve completed your leak test, slowly bring your system up to pressure. Bring your inlet gas flow up slowly to prevent pressure surges from causing shock to your system. Ensure all of your control loops are set to the correct setpoints. Perform a few test strokes on your emergency shutdown system. Ensuring your IOG valves shut off within their required timeframe is critical to the safety of your facility.
Use Software To Track Performance
While many companies install new hardware and hope for the best, proactive facilities take advantage of software technology. Implementing sensors throughout your system allows you to track temperature, vibrations, and flow rates at all times. This level of detail allows you to spot micron-level deviations in performance before they are caught during a routine maintenance inspection.
For example, by tracking the heat signature of your compressor cylinders, you could identify a leaking valve or worn piston ring. If there is a leak in your compression stage, the gas escaping will be compressed again, causing that area to heat up. By catching this defect early, you allow your maintenance team to schedule repairs when it best suits your downtime schedule. Catching issues before they cause a system failure saves your facility from significant losses.
Another benefit of tracking vibration data is that you can catch otherwise hidden issues with your rotating equipment. If your vibration signature changes, it could be an indicator of shaft misalignment, bearing failures, or even structural loosening. Use this data to reverse engineer what could be causing your equipment to lose stability.
Trust The Experts At Pro Gas LLC For Consultation
Installing new hardware into your system can be tricky. Pro-Gas LLC offers industrial clients specialized expertise when it comes to your industrial gases. The company offers services to help you eliminate bottlenecks and reduce downtime on your systems. They pride themselves on offering technical guidance that many consultancies don’t provide. From correct piping layout to specifying the right hardware for your operating parameters.
Whether you need help retrofitting an existing system to eliminate pressure restrictions or you need help spec-ing new hardware for an expansion, Pro-Gas has the knowledge and experience to guide you. Their team of experts will work with your team to design a configuration that will meet your needs and keep your facility running. Give Pro-Gas LLC a call today and see how they can help keep your systems running smoothly.
Industrial Gas Infrastructure FAQ
Q. Why does my system experience pressure drops?
- Pressure issues are usually caused by sudden increases in velocity. This can be caused by undersized pipes, too many 90-degree elbows, or dirty filter elements. You can reduce friction by ensuring your pipes are sized correctly and installing long radius elbows.
Q. How does predictive maintenance reduce O&M costs?
- Predictive software can alert your team to anomalies in your equipment’s performance using real-time sensor data. This allows your team to schedule maintenance when it best fits your schedule rather than waiting for something to break. Predictive maintenance has been shown to reduce maintenance costs by up to 20%.
Q. How do I prevent damage to regulators/seats when installing compression equipment?
- When installing new compression equipment, make sure to purge your lines with dry nitrogen. This will clear your lines of any moisture, debris, or slag from cutting. Preventing debris from entering your system upstream is also key. Utilizing high-efficiency filters will keep particles away from your regulator seats and compressors.
