Automated fault diagnosis method and system for engine-compressor sets

• US 7,403,850 B1
• Filed: 09/29/2006
• Issued: 07/22/2008
• Est. Priority Date: 09/29/2005
• Status: Expired due to Fees

• Current Assignee: Windrock Incorporated (ChampionX Corporation)
• Original Assignee: Dynalco Controls Corp. (Crane Company)
• Inventors: Fernandez, Javier, Boutin, Benjamin J., Webber, Robert J. Jr., Oliva, Ferdinand G., Kealty, John F., Kitchens, Thomas J.
• Primary Examiner(s): Wolfe, Jr.; Willis R.
• Assistant Examiner(s): Hoang; Johnny H
• Application Number:
  US11/537,136
• Time in Patent Office: 662 Days
• Field of Search: 701/104, 701/107, 701/110, 701/113, 701/114, 73 3501- 3509
• US Class Current: 701/107
• CPC Class Codes: G01M 15/05 by combined monitoring of two or more different engine parameters

Abstract

The automated fault diagnostic system operates on engine-compressor sets with one vibration sensor per sub-group of engine cylinders and one sensor per compressor cylinder. Vibration signals linked to crankshaft phase angle windows (“VT”) mark various engine events and compressor events. In data-acquisition-learning mode, VT is stored for each engine and compressor event per operating load condition, statistical process control (SPC) theory identifies alarm threshold bands. Operator input-overrides are permitted. If no baseline data is stored, the system automatically enters the learn mode. To monitor, current VT are obtained and current load condition is matched to the earlier load set and alarms issue linking predetermined engine or compressor event to the over-under VT. Baseline data, SPC analysis, alarms and monitoring are set for crankcase flow, engine cylinder exhaust temperatures, ignition system diagnostic messages. Compressor performance alarms use suction and discharge temperatures and pressures.

Claims

1. An automated fault diagnosis method for a reciprocating, multiple cylinder engine driving a reciprocating, multiple cylinder compressor, said multiple cylinder engine having sub-pluralities of cylinders, an engine crankcase, a crankshaft and an engine cylinder exhaust, comprising:

on each of said sub-plurality of engine cylinders, sensing vibratory signals from a single location;

isolating pluralities of vibration signatures from each group of vibratory signals, each vibration signature correlated to an engine cylinder and further to a respective predetermined engine event of a corresponding plurality of predetermined engine events per engine cylinder, the isolation based upon concurrently obtained timing signals correlated to crankshaft angular positions for a corresponding one of said plurality of predetermined engine events and each said engine cylinder and;

establishing a plurality of engine load operating conditions other than start-up and shut-down operating conditions;

in a baseline data acquisition mode, calculating statistical characteristics for respective vibration signatures for each predetermined engine event per engine cylinder per each engine load condition and assigning engine event alarm thresholds for each engine event, engine cylinder and engine load condition;

sensing combustion gas flow through said crankcase and generating a representative crankcase flow signal;

in said baseline data acquisition mode, calculating statistical characteristics for respective crankcase flow signals for each engine load condition and assigning combustion gas alarm thresholds for each engine load condition;

sensing engine cylinder exhaust temperatures and generating representative signals therefor;

in said baseline data acquisition mode, calculating statistical characteristics for respective engine exhaust temperature signals and assigning engine exhaust temperature alarm thresholds for each engine load condition;

in a monitoring mode, matching a current engine load operating condition with one of said plurality of engine load conditions and concurrently monitoring respective vibration signatures, respective crankcase flow signals and respective engine exhaust temperature signals, and;

issuing a unique engine event alarm identified with the corresponding engine cylinder when said respective vibration signature exceeds said engine event alarm thresholds per predetermined engine event per engine cylinder and per each engine load condition;

issuing a combustion flow alarm when said respective crankcase gas flow signals exceeds said combustion gas flow alarm threshold; and

,

issuing a engine exhaust temperature alarm when said respective engine exhaust temperature signals for the matching operating condition exceed said engine exhaust temperature alarm thresholds.

2. An automated fault diagnosis method as claimed in claim 1 including determining the presence or absence of statistical characteristics for respective vibration signatures per predetermined engine event per engine cylinder and per each engine load condition, and for respective crankcase flow signals per each engine load condition and for respective engine exhaust temperature signals per each engine load condition, and, in the absence thereof, automatically entering the corresponding baseline data acquisition mode.

3. An automated fault diagnosis method as claimed in claim 2 in the monitoring mode and in the event of issuance of the alarm, logging chronologic data therefor corresponding to said engine event and current engine load condition.

4. An automated fault diagnosis method as claimed in claim 3 wherein said multiple cylinder compressor includes compressor valves having compressor valve events and the automated fault diagnosis method includes:

on each compressor cylinder, sensing compressor vibratory signals thereon;

isolating plurality of compressor vibratory signals correlated to each compressor cylinder and further to a respective predetermined compressor valve event of a corresponding plurality of predetermined compressor valve events per compressor cylinder, the isolation based upon concurrently obtained timing signals correlated to crankshaft angular positions for a corresponding one of said plurality of predetermined compressor valve events and each said compressor cylinder and;

establishing a plurality of compressor load operating conditions other than start-up and shut-down operating conditions;

in said baseline data acquisition mode, calculating statistical characteristics for respective compressor vibration signatures for each predetermined compressor event per compressor cylinder per each compressor load condition and assigning compressor valve alarm thresholds for each compressor event, compressor cylinder and compressor load condition;

in said monitoring mode, matching a current compressor load operating condition with one of said plurality of compressor load conditions and concurrently monitoring respective compressor vibration signatures, and;

issuing a unique compressor valve event alarm identified with the corresponding compressor cylinder when said respective compressor vibration signature exceeds said compressor valve event alarm thresholds per predetermined compressor event per compressor cylinder and per each compressor load condition.

5. An automated fault diagnosis method for a reciprocating, multiple cylinder engine driving a reciprocating, multiple cylinder compressor, said reciprocating, multiple cylinder engine having sub-pluralities of designated cylinders therein, comprising:

providing a plurality of vibration sensors wherein a single vibration sensor detects vibration for each sub-plurality of engine cylinders;

generating respective vibration signals from each vibration sensor of said plurality of vibration sensors;

detecting a plurality of predetermined phase angle windows about crankshaft angular positions for a corresponding plurality of predetermined reciprocating engine events;

in a baseline data acquisition mode, storing respective vibration signals for each phase angle window corresponding to said plurality of predetermined engine events for a plurality of engine load operating conditions other than start-up and shut-down operating conditions;

in said baseline data acquisition mode, calculating statistical characteristics for respective vibration signals per phase angle window corresponding to said predetermined engine events for each operating condition of said plurality of operating conditions;

assigning alarm thresholds for said respective vibration signals per phase angle windows corresponding to said predetermined engine events for each operating condition based upon the corresponding statistical characteristics therefor; and

,

in a monitoring mode, acquiring respective vibration signals for said corresponding phase angle window and matching a current operating condition of said engine with one of said plurality of operating conditions; and

,

in said monitoring mode, issuing an alarm unique to one of said plurality of predetermined engine events when said respective vibration signal corresponding to said engine event for the matching operating condition exceeds said alarm threshold.

6. An automated fault diagnosis method as claimed in claim 5 wherein the detecting for said plurality of predetermined phase angle windows generates a timing signal for said predetermined engine events.

7. An automated fault diagnosis method as claimed in claim 5 wherein assigning alarm thresholds for predetermined engine events for each operating condition includes manual and automatic assignment of said alarm thresholds.

8. An automated fault diagnosis method as claimed in claim 5 including transmitting the unique alarm to a remote location away from said engine.

9. An automated fault diagnosis method as claimed in claim 5 including storing the unique alarm and logging chronologic data therefor corresponding to said engine event and current operating condition of said engine.

10. An automated fault diagnosis method as claimed in claim 9 including displaying, upon operator command, said unique alarm and logged chronologic data therefor corresponding to said engine event and logged operating condition of said engine.

11. An automated fault diagnosis method as claimed in claim 10 including issuing an illuminated alarm near said engine upon issuance of the unique alarm.

12. An automated fault diagnosis method as claimed in claim 5 including generating a local alarm alert, near said engine, and transmitting the unique alarm to a remote location away from said engine.

13. An automated fault diagnosis method as claimed in claim 5 wherein said reciprocating, multiple cylinder engine includes a crankcase and the automated fault diagnosis method includes providing a crankcase gas flow measurement device mounted on said engine crankcase, said flow measurement device generating a crankcase flow representative signal;

in said baseline data acquisition mode, monitoring said crankcase flow signal during each operating condition of said plurality of operating conditions and calculating statistical characteristics for respective crankcase flow signals corresponding to each operating condition;

assigning combustion flow alarm thresholds for said respective crankcase flow signals for each operating condition based upon the corresponding statistical characteristics therefor; and

,

in a monitoring mode, acquiring respective crankcase flow signals and matching a current operating condition of said engine with one of said plurality of operating conditions; and

,

in said monitoring mode, issuing a combustion flow alarm when said respective crankcase flow signals for the matching operating condition exceeds said combustion flow alarm threshold.

14. An automated fault diagnosis method as claimed in claim 5 wherein said reciprocating, multiple cylinder engine includes an exhaust manifold and the automated fault diagnosis method includes

providing an engine exhaust temperature sensor mounted on or adjacent said engine exhaust manifold to sense cylinder exhaust temperature, the engine exhaust temperature sensor generating a representative engine exhaust temperature signal;

in said baseline data acquisition mode, monitoring said engine exhaust temperature signal during each operating condition of said plurality of operating conditions and calculating statistical characteristics for respective engine exhaust temperature signals corresponding to each operating condition;

assigning engine exhaust temperature alarm thresholds for said respective engine exhaust temperature signals for each operating condition based upon the corresponding statistical characteristics therefor; and

,

in a monitoring mode, acquiring respective engine exhaust temperature signals and matching a current operating condition of said engine with one of said plurality of operating conditions; and

,

in said monitoring mode, issuing a engine exhaust temperature alarm when said respective engine exhaust temperature signals for the matching operating condition exceed said engine exhaust temperature alarm thresholds.

15. An automated fault diagnosis method as claimed in claim 5 wherein said reciprocating, multiple cylinder compressor includes a suction manifold and a discharge manifold;

and the automated fault diagnosis method includes;

providing a plurality of suction and discharge temperature sensors mounted on said suction manifold for each compressor stage, a respective suction and discharge temperature sensor sensing the corresponding temperature for a respective compressor stage, each manifold suction and discharge temperature sensor generating a representative manifold suction and discharge temperature signal;

providing a plurality of suction pressure sensors and discharge pressure sensors respectively mounted on said suction manifold and said discharge manifold for each compressor stage, each suction pressure sensor and discharge pressure sensor sensing the corresponding suction pressure and discharge pressure for a respective compressor stage and generating a representative suction pressure and discharge pressure signals therefor;

sensing the speed of said compressor and generating a speed signal;

in said baseline data acquisition mode, monitoring;

manifold suction and discharge temperature signals for each stage,

suction pressure signals for each stage,

discharge pressure signals for each stage, and

speed signals;

calculating and storing baseline data for a plurality of operating compressor conditions other than start-up and shut-down operating conditions with respect to;

capacity per stage,

brake horsepower,

brake horsepower per unit volume throughput period per stage, and

total capacity and total brake horsepower per unit volume throughput period for said compressor,

based upon predetermined mathematical algorithms and compressor manufacturer'"'"'s loading curves, compressor models and preexisting data relative to said compressor and

said manifold suction and discharge temperature signals for each stage,

suction pressure signals for each stage,

discharge pressure signals for each stage, and

speed signals; and

,

logging chronologic data therefor corresponding to said each compressor operating condition of said plurality of operating conditions for said compressor.

16. An automated fault diagnosis method as claimed in claim 15 including

calculating statistical characteristics for compressor performance based upon said total brake horsepower per unit volume throughput period for each operating compressor condition of said plurality of operating conditions for said compressor;

assigning compressor performance alarm thresholds for compressor performance for each operating condition based upon the corresponding statistical characteristics therefor; and

,

in a monitoring mode, acquiring;

said manifold suction and discharge temperature signals for each stage,

suction pressure signals for each stage,

discharge pressure signals for each stage, and

speed signals, and,

matching a current operating compressor condition of said compressor with one of said plurality of operating conditions; and

,

in said monitoring mode, issuing a compressor performance alarm when said respective compressor performance for the matching operating compressor condition exceed said compressor performance alarm thresholds.

17. An automated fault diagnosis method as claimed in claim 15 wherein said reciprocating, multiple cylinder engine is supplied with fuel and said engine has a predetermined fuel consumption rate and data providing representative of cost of said fuel, and the automated fault diagnosis method includes:

providing a fuel flow sensor for said fuel supplied to said engine and generating fuel flow signals representative thereof,

calculating, storing and, upon operator input, displaying brake horsepower fuel consumption based upon a predetermined correlation between the total compressor brake horsepower and the fuel flow rate from said fuel flow signals.

18. An automated fault diagnosis method as claimed in claim 15 wherein said reciprocating, multiple cylinder compressor includes compressor valves having compressor valve events and the automated fault diagnosis method includes:

providing a plurality of vibration sensors for said compressor, a single vibration sensor mounted on a respective compressor cylinder of said reciprocating, multiple cylinder compressor for detection of compressor cylinder vibration;

generating respective compressor vibration signals from each vibration sensor mounted on the respective compressor cylinder;

detecting a second plurality of predetermined phase angle windows about crankshaft angular positions for a corresponding plurality of predetermined compressor valve events;

in a baseline data acquisition mode, storing respective compressor vibration signals for each phase angle window corresponding to said plurality of predetermined compressor valve events for said plurality of operating compressor conditions other than start-up and shut-down operating conditions;

in said baseline data acquisition mode, calculating statistical characteristics for respective compressor vibration signals per phase angle window corresponding to said predetermined compressor valve events for each operating compressor condition of said plurality of operating conditions;

assigning compressor valve alarm thresholds for said respective compressor vibration signals per phase angle windows corresponding to said predetermined compressor valve events for each operating compressor condition based upon the corresponding statistical characteristics therefor; and

,

in a monitoring mode, acquiring respective compressor vibration signals for said corresponding phase angle window and matching a current operating compressor condition with one of said plurality of operating compressor conditions; and

,

in said monitoring mode, issuing a compressor valve alarm unique to one of said plurality of predetermined compressor events when said respective compressor vibration signal corresponding to said compressor event for the matching operating compressor condition exceeds said compressor valve alarm threshold.

19. An automated fault diagnosis method as claimed in claim 5 wherein said reciprocating, multiple cylinder engine includes an ignition system controlling a spark plug firing for each cylinder in said engine and outputting a signal representative of ignition diagnostics, and the automated fault diagnosis method includes:

in a baseline data acquisition mode, storing respective ignition diagnostics signals for each engine cylinder for said plurality of engine operating conditions other than start-up and shut-down operating conditions;

in said baseline data acquisition mode, calculating statistical characteristics for respective ignition diagnostics signals for each engine operating condition of said plurality of engine operating conditions;

assigning ignition diagnostics alarm thresholds for said respective ignition diagnostics signals for each operating condition based upon the corresponding statistical characteristics therefor; and

,

in a monitoring mode, acquiring respective ignition diagnostics signals for each engine cylinder and matching a current engine operating condition with one of said plurality of engine operating conditions; and

,

in said monitoring mode, issuing an ignition diagnostics alarm when said respective ignition diagnostics signal corresponding to said matching engine operating condition exceeds said ignition diagnostics alarm threshold.

20. An automated fault diagnosis system for a reciprocating, multiple cylinder engine driving a reciprocating, multiple cylinder compressor, said multiple cylinder engine having sub-pluralities of cylinders, an engine crankcase, a crankshaft and an engine exhaust manifold, comprising:

a plurality of vibration sensors each generating respective vibratory signals for each engine cylinder group;

a phase angle sensory system for detecting a plurality of predetermined phase angle windows about crankshaft angular positions for a corresponding plurality of predetermined reciprocating engine events;

means for generating timing signals correlated to crankshaft angular positions for a corresponding one of said plurality of predetermined engine events and each said engine cylinder;

an isolation module, coupled to said plurality of vibration sensors and said means for timing, isolating pluralities of vibration signatures from each group of vibratory signals, each vibration signature correlated to an engine cylinder and further to a respective predetermined engine event of a corresponding plurality of predetermined engine events per engine cylinder;

a computerized diagnostic system, coupled to said isolation module, with a processor, memory stores, a display and an operator interface, said computerized diagnostic system having a baseline data acquisition operational mode and a monitoring operational mode both effective for a plurality of engine load operating conditions other than start-up and shut-down engine operating conditions;

a statistical characteristic calculator, as part of said computerized diagnostic system and in said baseline data acquisition mode, first storing respective vibration signatures for each predetermined engine event per engine cylinder per engine load operating condition, calculating statistical characteristics for respective vibration signature per predetermined engine event per engine cylinder and per engine load condition, and assigning engine event alarm thresholds for each engine event, engine cylinder and engine load condition;

crankcase gas flow sensor sensing combustion gas flow through said crankcase and generating a representative crankcase flow signal;

said statistical characteristic calculator having a combustion gas flow module calculating statistical characteristics for respective crankcase flow signals for each engine load condition and assigning combustion alarm thresholds for each engine load condition;

engine exhaust temperature sensor generating representative engine cylinder exhaust temperature signals;

said statistical characteristic calculator having an engine exhaust temperature module calculating statistical characteristics for respective engine exhaust temperature signals and assigning engine exhaust temperature alarm thresholds for each engine load condition;

a monitor determining a current engine load operating condition with one of said plurality of engine load conditions, said monitor coupled to said isolation module and receiving current pluralities of vibration signatures, said crankcase flow sensor and receiving current crankcase flow signals, and said engine exhaust temperature sensor and receiving current engine exhaust temperature signals;

an engine event alarm module issuing a unique engine event alarm identified with the corresponding engine cylinder when said respective vibration signature exceeds said engine event alarm thresholds per predetermined engine event per engine cylinder and per each engine load condition;

a combustion gas alarm module issuing a combustion gas alarm when said respective crankcase flow signals exceeds said combustion gas alarm threshold; and

,

a engine exhaust temperature alarm module issuing a engine exhaust temperature alarm when said respective engine exhaust temperature signals for the matching operating condition exceed said engine exhaust temperature alarm thresholds.

21. An automated fault diagnosis system as claimed in claim 20 including automatic means for entering the corresponding baseline data acquisition mode in the absence of statistical characteristics for respective vibration signatures per predetermined engine event per engine cylinder and per each engine load condition, and for respective crankcase flow signals per each engine load condition and for respective engine exhaust temperature signals per each engine load condition.

22. An automated fault diagnosis system as claimed in claim 21 including a logger for logging all alarm data with chronologic data corresponding to said engine event and current engine load condition.

23. An automated fault diagnosis system as claimed in claim 22 wherein said multiple cylinder compressor includes compressor valves having compressor valve events and the automated fault diagnosis system includes:

on each compressor cylinder, compressor vibration sensors sensing compressor vibratory signals thereon;

said isolation module including a compressor isolation module isolating the plurality of compressor vibratory signals correlated to each compressor cylinder and further to a respective predetermined compressor valve event of a corresponding plurality of predetermined compressor valve events per compressor cylinder;

said computerized diagnostic system, coupled to said compressor isolation module, and said baseline data acquisition operational mode and monitoring operational mode both effective for a plurality of compressor load operating conditions other than start-up and shut-down engine operating conditions;

said statistical characteristic calculator having a compressor valve module and in said baseline data acquisition mode, first storing respective compressor vibration signatures for each predetermined compressor event per compressor cylinder per compressor load operating condition, calculating statistical characteristics for respective compressor vibration signature per predetermined compressor event per compressor cylinder and per compressor load condition, and assigning compressor valve event alarm thresholds for each compressor event, compressor cylinder and compressor load condition;

said monitor determining a current compressor load operating condition with one of said plurality of compressor load conditions, said monitor coupled to said isolation module and receiving current pluralities of compressor vibration signatures;

a compressor valve event alarm module issuing a compressor valve event alarm identified with the corresponding compressor cylinder when said respective compressor vibration signature exceeds said compressor valve event alarm thresholds per predetermined compressor event per compressor cylinder and per each compressor load condition.

24. An automated fault diagnosis system for a reciprocating, multiple cylinder engine driving a reciprocating, multiple cylinder compressor, wherein the engine cylinders are sub-divided into groups each having a sub-plurality of cylinders therein, comprising:

a plurality of vibration sensors each generating respective vibration signals for each engine cylinder group;

a phase angle sensory system for detecting a plurality of predetermined phase angle windows about crankshaft angular positions for a corresponding plurality of predetermined reciprocating engine events;

a computerized diagnostic system, coupled to said vibration sensors and said phase angle sensory system, with a processor, memory stores, a display and an operator interface, said computerized diagnostic system having a baseline data acquisition operational mode and a monitoring operational mode both effective for a plurality of engine operating conditions other than start-up and shut-down engine operating conditions;

as part of said computerized diagnostic system, a statistical characteristic calculator first storing respective vibration signals for each phase angle window corresponding to said plurality of predetermined engine events for corresponding engine operating conditions, calculating statistical characteristics for respective vibration signals per phase angle window corresponding to said predetermined engine events for each engine operating condition, and assigning alarm thresholds for said respective vibration signals per phase angle windows corresponding to said predetermined engine events for each operating condition based upon the corresponding statistical characteristics therefor; and

,

as part of said computerized diagnostic system, a monitor acquiring respective vibration signals for said corresponding phase angle window and matching a current engine operating condition with one of said plurality of engine operating conditions; and

,

an alarm unit, coupled to said statistical characteristic calculator and said monitor and said memory stores, issuing an alarm unique to one of said plurality of predetermined engine events when said respective vibration signal corresponding to said engine event for the matching engine operating condition exceeds said alarm threshold and storing the unique alarm in said memory stores.

25. An automated fault diagnosis system as claimed in claim 24 wherein said alarm unit includes a display alarm and a lighted alarm.

26. An automated fault diagnosis system as claimed in claim 24 wherein said statistical characteristic calculator is coupled to said operator interface and includes means for manually assigning alarm thresholds for predetermined engine events for each engine operating condition.

27. An automated fault diagnosis system as claimed in claim 24 including a data transmission unit, coupled to said alarm unit, to send the unique alarm to a remote location away from said engine.

28. An automated fault diagnosis system as claimed in claim 24 wherein said computerized diagnostic system includes an alarm log to store said unique alarm with chronologic data and corresponding engine event data and current operating condition of said engine.

29. An automated fault diagnosis system as claimed in claim 28 wherein said display and operator interface includes a data retrieval unit for displaying, upon operator command via said operator interface, said unique alarm and logged chronologic data and corresponding engine event and logged operating condition of said engine.

30. An automated fault diagnosis system as claimed in claim 29 including a lamp, near said engine and coupled to said alarm unit, providing an illuminated alarm upon issuance of said unique alarm.

31. An automated fault diagnosis system as claimed in claim 24 wherein said statistical characteristic calculator and said monitor process respective vibration signals for each phase angle window via said processor and store, in said memory stores, the calculated statistical characteristics for respective vibration signals per phase angle window and the assigned alarm thresholds.

32. An automated fault diagnosis system as claimed in claim 24 wherein said reciprocating, multiple cylinder engine includes a crankcase and the automated fault diagnosis system includes:

a flow measurement device mounted on said engine crankcase, said flow measurement device generating a crankcase gas flow representative signal;

said statistical characteristic calculator, coupled to said flow measurement device and receiving said crankcase gas flow representative signal in said baseline data acquisition mode, calculating statistical characteristics for respective crankcase flow signals corresponding to each engine operating condition and assigning combustion flow alarm thresholds for said respective crankcase flow signals for each engine operating condition; and

,

said monitor coupled to said flow measurement device and acquiring, in said monitoring mode, respective crankcase flow signals and matching a current engine operating condition of said engine with one of said plurality of engine operating conditions; and

,

said alarm unit having a combustion flow alarm module issuing a combustion flow alarm when said respective crankcase flow signals for the matching engine operating condition exceeds said combustion flow alarm threshold.

33. An automated fault diagnosis system as claimed in claim 24 wherein said reciprocating, multiple cylinder engine includes a manifold and the automated fault diagnosis system includes:

an engine cylinder exhaust temperature sensor mounted on or adjacent said manifold and generating a representative engine exhaust temperature signal;

said statistical characteristic calculator, coupled to said engine exhaust temperature sensor, receiving said engine exhaust temperature signal, calculating statistical characteristics for respective engine exhaust temperature signals corresponding to each engine operating condition and assigning engine exhaust temperature alarm thresholds for said respective engine exhaust temperature signals for each engine operating condition based upon the corresponding statistical characteristics therefor; and

,

said monitor acquiring respective engine exhaust temperature signals and matching a current engine operating condition of said engine with one of said plurality of engine operating conditions; and

,

said alarm unit having an engine exhaust temperature alarm module issuing an engine exhaust temperature alarm when said respective engine exhaust temperature signals for the matching engine operating condition exceed said engine exhaust temperature alarm thresholds.

34. An automated fault diagnosis system as claimed in claim 24 wherein said reciprocating, multiple cylinder compressor includes a suction manifold and a discharge manifold;

and the automated fault diagnosis system includes;

a plurality of suction and discharge temperature sensors mounted on said suction manifold for each compressor stage, a respective suction and discharge temperature sensor sensing the corresponding temperature for a respective compressor stage, each manifold suction and discharge temperature sensor generating a representative manifold suction and discharge temperature signal;

a plurality of suction pressure sensors and discharge pressure sensors respectively mounted on said suction manifold and said discharge manifold for each compressor stage, each suction pressure sensor and discharge pressure sensor sensing the corresponding suction pressure and discharge pressure for a respective compressor stage and generating representative suction pressure signals and discharge pressure signals therefor;

a speed sensor for said compressor;

said statistical characteristic calculator, coupled to said suction and discharge temperature sensors, said suction pressure sensors and discharge pressure sensors and receiving said representative signals thereof in said baseline data acquisition mode, calculating and storing baseline data for a plurality of operating compressor conditions other than start-up and shut-down compressor operating conditions with respect to;

capacity per stage,

brake horsepower,

brake horsepower per unit volume throughput period per stage, and

total capacity and total brake horsepower per unit volume throughput period for said compressor,

based upon predetermined mathematical algorithms and compressor manufacturer'"'"'s loading curves, compressor models and preexisting data relative to said compressor and

said manifold suction and discharge temperature signals for each stage,

suction pressure signals for each stage,

discharge pressure signals for each stage, and

speed signals; and

,

a chronologic data log module, coupled to said statistical characteristic calculator and said memory stores, for storing at least;

brake horsepower,

brake horsepower per unit volume throughput period per stage, and

total capacity and total brake horsepower per unit volume throughput period for said compressor,

corresponding to said each compressor operating condition.

35. An automated fault diagnosis system as claimed in claim 34 including

said statistical characteristic calculator calculating statistical characteristics for compressor performance based upon said total brake horsepower per unit volume throughput period for each compressor operating condition and assigning compressor performance alarm thresholds for compressor performance for each compressor operating condition;

and,

said monitor acquiring;

said manifold suction and discharge temperature signals for each stage,

suction pressure signals for each stage,

discharge pressure signals for each stage, and

speed signals, and,

matching a current compressor operating condition with one of said plurality of compressor operating conditions; and

,

said alarm unit having a compressor performance alarm module issuing a compressor performance alarm when said respective compressor performance for the matching operating condition exceed said compressor performance alarm thresholds.

36. An automated fault diagnosis system as claimed in claim 35 wherein said reciprocating, multiple cylinder engine is supplied with fuel and said engine has a predetermined fuel consumption rate and data is provided representative of cost of said fuel, and the automated fault diagnosis system includes:

a fuel flow sensor for said fuel supplied to said engine generating fuel flow signals representative thereof,

said statistical characteristic calculator, in conjunction with said processor, memory stores, display and operator interface, calculating, storing and, upon operator input, displaying brake horsepower fuel consumption based upon a predetermined correlation between the total compressor brake horsepower and the fuel flow rate from said fuel flow signals.

37. An automated fault diagnosis system as claimed in claim 35 wherein said reciprocating, multiple cylinder compressor includes compressor valves having compressor valve events and the automated fault diagnosis system includes:

a plurality of vibration sensors for said compressor, a single vibration sensor mounted on a respective compressor cylinder of said multiple cylinder compressor, generating respective compressor vibration signals for each respective compressor cylinder;

a compressor phase angle sensory system for detecting a second plurality of predetermined phase angle windows about crankshaft angular positions for a corresponding plurality of predetermined compressor valve events;

said statistical characteristic calculator, coupled to the compressor vibration sensors and compressor phase angle sensory system and receiving said compressor vibration signals and plurality of predetermined phase angle windows for said compressor valve events, calculating statistical characteristics for respective compressor vibration signals per phase angle window corresponding to said predetermined compressor valve events for each compressor operating condition of said plurality of compressor operating conditions and assigning compressor valve alarm thresholds for said respective compressor vibration signals per phase angle windows corresponding to said predetermined compressor valve events for each operating condition based upon the corresponding statistical characteristics therefor; and

,

said monitor acquiring respective compressor vibration signals for said corresponding phase angle window and matching a current compressor operating condition with one of said plurality of compressor operating conditions; and

,

said alarm unit having a compressor valve alarm module issuing a compressor alarm unique to one of said plurality of predetermined compressor events when said respective compressor vibration signal corresponding to said compressor event for the matching compressor operating condition exceeds said compressor valve alarm threshold.

38. An automated fault diagnosis system as claimed in claim 24 wherein said reciprocating, multiple cylinder engine includes an ignition diagnostics system controlling said engine and outputting a signal representative of ignition diagnostics, and the automated fault diagnosis system includes:

said statistical characteristic calculator, coupled to the ignition diagnostics system and receiving said ignition diagnostics signal for each engine cylinder, calculating statistical characteristics for respective ignition diagnostics for each engine operating condition of said plurality of engine operating conditions and assigning ignition diagnostics alarm thresholds for said respective ignition diagnostics signals for each engine operating condition based upon the corresponding statistical characteristics therefor; and

,

said monitor acquiring respective ignition diagnostics signals and matching a current engine operating condition with one of said plurality of engine operating conditions; and

,

said alarm unit having an ignition diagnostics alarm module issuing an ignition diagnostics alarm when said respective ignition diagnostics signal corresponding to said matching engine operating condition exceeds said ignition diagnostics alarm threshold.