Engine Losing Power / Lost Production

What Happened?
The site had a 2370 HP, 1000 rpm engine with a two stage reciprocating gas compressor. The engine control system was performing as it was designed; however, the operations personnel were not fully aware of the system’s capabilities. Their response was to unload the gas compressor, which restored the engine to its full rated rpm. However, a production foreman noticed the metered gas sales reduction and initiated an investigation from their area office.

What Was the Underlying Cause?
The production foreman graphed the engine intake air temperature in Productivity Optimizer and noticed that the trend line confirmed that there was a temperature rise over time. He added ambient temperature to the plot and immediately recognized the correlation. He called the field tech to investigate and the tech found that the engine air intake air diverter actuator linkage had failed which, directed preheated air into the engine rather than the cooler ambient air.

What Was the Value to the Customer?
Having the ability to compare a wide range of data points greatly enhances the diagnostic process. In this case knowledge of the ambient temperatures variances provided the information needed to make repairs and increase production. The production foreman saved having to travel to the field, the fault was easily repaired, and the production level restored.