METHODS AND SYSTEMS FOR REAL-TIME MONITORING AND OPTIMIZING THE PERFORMANCE OF RECIPROCATING COMPRESSORS

Abstract

Disclosed are systems and methods for monitoring the performance of a plurality of reciprocating compressors having components made by at least two different manufacturers. A source of reciprocating compressor data associated with a plurality of reciprocating compressors and a source of reciprocating compressor component specifications associated with the plurality of reciprocating compressors are in communication with a computer processor. The computer processor obtains at least one measured value from the source of reciprocating compressor data and at least one specification value from the source of reciprocating compressor component specifications, performs at least one calculation using the at least one measured value and the at least one specification value to calculate at least one calculated performance value, compares the at least one calculated value to a user-defined calculated value limit selected from the group consisting of an upper alarm limit, a lower alarm limit, an upper deviation limit, a lower deviation limit, a maximum value, a minimum value and combinations thereof, and initiates an alert to a user of any calculated value exceeding the user-defined calculated value limit every user-defined period of time.

Description

FIELD

The present disclosure relates to methods and systems for monitoring and optimizing the performance of a plurality of reciprocating compressors. The present disclosure further relates to systems and methods for displaying data related to the performance of a plurality of reciprocating compressors in a user interface.

BACKGROUND

An issue facing businesses which utilize equipment such as reciprocating compressors is how to monitor their performance in real time operation. A related issue is how to analyze the operational data to optimize performance of such reciprocating compressors. Currently operational data is gathered by sensors on the compressors or obtained manually by operators and engineers. This information can then be used to perform thermodynamic (performance) and force calculations. There is no system available which is capable of obtaining real-time operational data from a number of data sources related to a number of compressors manufactured by at least two different manufacturers and using the data obtained to perform configurations of the equipment, trending, reporting and ad hoc calculations for the various compressors regardless of the manufacturer.

It would be desirable to have a system which addresses the above deficiencies in the field. Furthermore, it would be desirable to have such a system which enables users to perform configurations, trending, reporting, ad hoc calculations and the like from a single user interface.

SUMMARY

In one aspect, a system is provided for monitoring performance of a plurality of reciprocating compressors having components made by at least two different manufacturers. The system includes a source of reciprocating compressor data associated with a plurality of reciprocating compressors, a source of reciprocating compressor component specifications associated with the plurality of reciprocating compressors comprising reciprocating compressor components made by at least two different manufacturers and a computer processor in communication with the source of reciprocating compressor performance data. The computer processor: obtains at least one measured value from the source of reciprocating compressor data and at least one specification value from the source of reciprocating compressor component specifications, performs at least one calculation using the at least one measured value and the at least one specification value to calculate at least one calculated performance value, compares the at least one calculated value to a user-defined calculated value limit selected from the group consisting of an upper alarm limit, a lower alarm limit, an upper deviation limit, a lower deviation limit, a maximum value, a minimum value and combinations thereof, and initiates an alert to a user of any calculated value exceeding the user-defined calculated value limit every user-defined period of time.

In another aspect, a method using the system is provided for monitoring performance of a plurality of reciprocating compressors having components made by at least two different manufacturers.

DESCRIPTION OF THE DRAWINGS

These and other objects, features and advantages of the present invention will become better understood with reference to the following description, appended claims and accompanying drawings where:

FIG. 1 is a schematic diagram illustrating one exemplary embodiment.

FIGS. 2 and 3 are flowcharts illustrating steps performed by a computer processor according to an exemplary embodiment.

DETAILED DESCRIPTION

A system has been developed which monitors real-time data associated with a number of reciprocating compressors and which incorporates a robust calculation engine (i.e., a computer processor) for performing calculations such as thermodynamic, rod load and rod reversal calculations related to the performance of the reciprocating compressors using the real-time data. The data and calculated values can be used to optimize the production efficiency of the compressors. The system further enables users including engineers and operators to customize calculations for a network of compressors, and standardize calculations regardless of the number of compressor manufacturers in the network.

The reciprocating compressors being monitored and/or optimized by the system make up a network of compressors. In one embodiment, the network of reciprocating compressors can include from 2 to 500 reciprocating compressors. The reciprocating compressors include components selected from engines, crank shaft housings and cylinders. The system includes a source of reciprocating compressor performance data associated with the plurality of reciprocating compressors. The system collects real-time measurements from compressors within the network which are instrumented with a variety of sensors. Each compressor may have many data sensors as determined by the compressor configuration, e.g., as determined by, for instance, the number of stages, cylinders and pumps. In one embodiment, the network of compressors includes from 10 to 1000 sensors.

A simplified schematic of the system 100 is illustrated in FIG. 1. A computer processor 4, also referred to herein as a calculation engine, is in communication with a source of reciprocating compressor performance data 2. In one embodiment, the computer processor 4 obtains at least two measured values from the source of reciprocating compressor performance data. In one embodiment, the at least two measured values are associated with reciprocating compressor components made by different manufacturers.

The computer processor is also in communication with at least one database of static information 6 used to store engine specifications, frame specifications, cylinder specifications and stage specifications specific to the equipment manufacturers having manufactured the compressors in the network.

The computer processor performs calculations to obtain results also referred to as calculated values based on the at least two measured values and information obtained from the static information. The calculated values can relate to compressor performance, including values related to cylinder, stage or compressor, or the calculated values can relate to rod load and rod reversal. Calculated compressor performance values can include, for example, thermal efficiency, equipment utilization, throughput, horsepower and the like.

The computer processor is configured for all manufacturers of the reciprocating compressor being monitored, thus enabling analysis and optimization of the performance of the compressors from a single user interface 10 in communication with the computer processor 4 regardless of the number of compressor manufacturers in the network.

The computer processor can perform configuration, trending, reporting and ad hoc calculations, to be described further herein. The computer processor can also produce graphs, reports, and calculated data points, to help engineers analyze and optimize compressor production efficiency.

The computer processor can compare the at least two measured values to a user-defined measured value limit selected from the group consisting of an upper alarm limit, a lower alarm limit, an upper deviation limit, a lower deviation limit, a maximum value, a minimum value and combinations thereof Such limits are stored in a threshold definition table 9 accessed by the computer processor.

In one embodiment, the computer processor 4 calculates at least one calculated value using at least one measured value obtained from the source of reciprocating compressor performance data 2. The computer processor compares the at least one calculated value to a user-defined calculated value limit from the threshold definition table 9 selected from the group consisting of an upper alarm limit, a lower alarm limit, an upper deviation limit, a lower deviation limit, a maximum value, a minimum value and combinations thereof Thresholds or user-defined calculated value limits on calculations such as horsepower and flow utilization can be created to alert the user when a compressor is not performing as well as desired.

The computer processor can further be utilized to determine modifications to a compressor's configuration that will result in increased production or reduced power requirements.

In one embodiment, a historical database 12 is used to store calculated values and/or measured values. The calculated values and/or measured values are retrievable by the computer processor or calculation engine 2.

The user interface 10 can include a user input device 11, e.g., a keyboard, mouse, touch screen, voice input device, etc. The user interface 10 can further include a visual display 13. In one embodiment, in response to user input provided via the user input device 11, the computer processor 4 generates at least one report, table, chart, diagram or graph on the visual display 13. In one embodiment, the computer processor generates at least one report, table, chart, diagram or graph for at least two reciprocating compressors.

The user interface 10 has a plurality of user-defined fields associated with the reciprocating compressor components selected from engines, crank shaft housings and cylinders.

In one embodiment, a method for monitoring performance of a plurality of reciprocating compressors having components made by at least two different manufacturers includes the following steps. At least two measured values from a source of reciprocating compressor performance data 2 associated with a plurality of reciprocating compressors is obtained by the computer processor 4 wherein the at least two measured values are associated with reciprocating compressor components made by at least two different manufacturers. The computer processor 4 performs calculations to normalize the at least two measured values to an equivalent basis independent of manufacturer. The computer processor compares the at least two measured values to a user-defined measured value limit selected from the group consisting of an upper alarm limit, a lower alarm limit, an upper deviation limit, a lower deviation limit, a maximum value, a minimum value and combinations thereof; and then the computer processor creates an alert of any measured values exceeding the user-defined measured value limit every user-defined period of time.

In one embodiment, when a user has an incomplete set of variables associated with performance of at least one reciprocating compressor, the system can be used to determine additional calculated, theoretical values associated with components of the at least one reciprocating compressor.

In one embodiment, the user interface 10 includes a main menu with which the user is able to navigate between various views and execute commands in the system. Each command is visible on the visual display 13 based on the current view. For example, if the current view has a data grid, then the grid view commands will be visible.

Any of a number of known methods and components or modules for displaying data on the visual display 13 can be used, including tree views, heat maps and tree maps. In one embodiment, the system includes tree views, heat maps and/or tree maps views. Tree view displays hierarchy data from a common reference data base (CRDB). The tree view enables users to select equipment for application context. In trending and fleet threshold administration, the tree view displays check boxes enabling the user to select multiple pieces of equipment. The tree view can include commands to expand or collapse all items in a hierarchical list. Heat map view can display data from a CRDB using colors assigned according to categories specified in a data point mapping table. Categories can include, for example, maintenance, optimization and set point. Each category can be expandable and collapsible, by double clicking on the category header plus or minus icon, to present easy viewing. Tree map view displays data from a CRDB as a set of nested rectangles. In one embodiment, the size of the rectangles can be determined by the horsepower of the compressor. Opportunities for engineers are highlighted in real time (e.g., this can be updated every hour or other user-defined period of time). For example, potential problems which may need follow-up include bad parameters, previously flagged results that have not been acknowledged, calculations that did not run, and the like. Such potential problems can be indicated by user-defined symbols or colors. An example of software known for use to generate such tree map views is commercially available from Telerik (Boston, Mass.).

In one embodiment, in the Heat map view, specific measurements which exceed alarm limits or other thresholds are displayed. In this view, each piece of equipment can have an alarm indicator icon to navigate to an exceptions log until all exceptions are acknowledged by an authorized administrative user. Substitute numbers can be shown on the heat map view and indicated with a user-defined color.

In one embodiment, trends for measured and calculated values can be visualized or plotted on the visual display 13 in the user interface 10. For example, horsepower utilization, actual throughput vs. theoretical throughput and flow utilization can be plotted. In one embodiment, measured values can be trended or visualized live (at 30 second intervals). Users can request trends of values and save the results. Multiple pieces of equipment can be visualized on the same trend plot. Users can request trends over specify date ranges. Raw data, daily average data or monthly average data can be trended. In one embodiment, the ability to zoom in is provided on the visual display 13. Default settings can be customized Groups of specific pieces of equipment can be saved for convenience. User can create groups of parameters for future trending. In one embodiment, users can drag any measurement or calculation from any view (e.g., the heat map or other hierarchy view) to a “trending basket” where the measured or calculated values can be collected to be plotted or trended. Values in the trending basket can be viewed on individual graphs or all on a single graph.

Calculations are performed by the computer processor 4 according to known equations. For example, cylinder-related calculations include suction pressure drop, flange suction pressure, discharge pressure drop, flange discharge pressure, compression ratio, piston speed, piston area (head end and crank end) and so forth. Sample stage-related calculations include stage horsepower, interstage compression ratio (head end and crank end) and so forth. Sample compressor-related calculations include compressor horsepower, compressor utilization, available horsepower, thermal efficiency and so forth. Sample rod load calculations include displacement, acceleration, reciprocating mass, inertial load and so on. Many other related calculations can be performed by the computer processor 4 as would be apparent to one skilled in the art. The computer processor further creates the alerts, flags, symbols, colored highlighting, etc. to indicate when an alarm limit or threshold is exceeded.

In one embodiment, the system 100 includes a Calculations Scheduler view to enable users or administrators to schedule calculations for all equipment in the network.

In one embodiment, the system is configured with OEM specifications and data on equipment including engines, frames (crank shaft housings) and cylinders. This information is configured as static information by an administrative user in the user interface in a view referred to as the Static Information tab. Static information for a compressor can include, for example, compressor manufacturer and model, load limit, rated RPM, rod diameter, number of stages and so forth. Many other specifications can be configured as would be apparent to one skilled in the art.

In one embodiment, the system can be configured with process definition information by a user in the user interface. This occurs in a Process Definition tab. Here the user can define the composition of the gas being compressed by selecting gas components from a list in the user interface and specifying the mole fraction of each. In this tab, the user can also select the equipment and specify the process conditions. For instance, the user can select the cylinder and a cylinder edit form will then open automatically to be completed by the user. Similarly, engine and frame edit forms will open automatically when engine and frame types are selected by the user. In this tab, stages and pumps can be added. In this tab, pressure or slipstream flow can also be defined.

In one embodiment, the system includes a number of databases. The application can utilize relational database management systems such as Microsoft SQL Server Compact (SQL CE) for the user interface and Microsoft SQL Server (available from Microsoft, Redmond, Wash.) for the storage of all data points, measured, calculated, or static, as well as all tables for calculations and configurations. Nonlimiting examples of such tables for calculations and configurations include:

Engine Specifications

Engine Specification Comments

Frame Specifications

Frame Specification Comments

Gas Components

Manufacturers

Cylinder Specifications

Cylinder Specification Comments

Frames

Gas Mixtures

Engines

Logging

Cylinders

Stages

Data Point Values

Calculation Bad Parameters

Data Points

Data Point Mappings

Side Streams

Data Point Average Values

Calculations

Scheduled Calculations

Cylinder Data Points

Engine Data Points

Stage Data Points

Trending Groups

Trending Data Points

Within a data point mapping definition table, data points utilized by the computer processor 4 are defined or mapped and categorized. The categories assigned by users enable display of the data in the various views of the user interface 10. Within a threshold definition table 9, limits and thresholds can be set for each data point type. Nonlimiting examples of such limits can include bad data high, bad data low, minimum warning, maximum warning, minimum alert and maximum alert.

In one embodiment, at least one archive database 12 is maintained of measured and/or calculated values. The archive(s) 12 can later be accessed by the computer processor 4.

Nonlimiting exemplary measured, static and calculated values utilized by the system 100 may include those listed in Tables 1, 2 and 3. These are partial lists, and additional measured, static and calculated values would be apparent to those skilled in the art.

TABLE 1
		Secondary	Tertiary
Parameter	Primary Source	Source	source
Suction Pressure	Measured	Static DB	User
			input
Discharge pressure	Measured	User input	—
Speed (Driver)	Measured	Static DB	User
			input
Suction Temperature	Measured	Static DB	User
			input
Discharge Temperature	Measured	Calculated	—
		Value
Ambient temperature	Measured	Static DB	User
			input
Ambient Pressure	Measured	Static DB	User
			input
Pump Suction Pressure	Measured	Static DB	User
			input
Pump Discharge Pressure	Measured	Static DB	User
			input
Fuel usage (Gas and	Measured	User input	—
Diesel engines)
Current drawn (Motor	Measured	User input	—
drives)
Interstage pressure	Measured	Calculated	User
		value	Input
Side stream flow	Measured	Calculated	User
		value	Input

	TABLE 2
	Parameter	Primary Source	Secondary Source
	Gas Specific Gravity	Static DB	User input
	Adiabatic Exponent	Static DB	User input
	Suction Compressibility	Static DB	User input
	Discharge	Static DB	User input
	Compressibility
	Gas analysis (Constituent	Static DB	User input
	gases in the mixture for
	analysis)
	Number of stages	Static DB	—
	Number of cylinders	Static DB	—
	Cylinder configuration	Static DB	—
	(cylinders per stages)
	Fuel Calorific value	Static DB	User Input
	Compressor Driver	Static DB
	Manufacturer
	Compressor Driver	Static DB
	Model
	Compressor Driver Rated	Static DB
	Speed
	Compressor Driver Max	Static DB
	Speed
	Compressor Driver Rated	Static DB
	Power
	Compressor Driver Max	Static DB
	Power

TABLE 3
Parameter                        Type
Stage Power                      S
Total Compressor HP              M
Stage Discharge Temperature      S
Overall volumetric efficiency    M
Pump losses (Indicated in terms of M
power loss)-Multiple pumps
Cooler losses (Indicated in terms of M
power loss)-Multiple coolers
Remaining BHP                    M
Interstage Pressures             S
Stage (Compression) Pressure ratios S
Max Capacity                     M
Max Capacity Power               M
Compressor Capacity              M
Total Compressor power           M
Gas Rod load                     C
Inertial Rod load                C
Combined Rod Load Tension        C
Combine Rod load Compression     C
Rod reversal                     C
Compressor Utilization           M
Head end valve velocity          C
Crank end valve velocity         C
Head end suction volumetric efficiency C
Head end discharge volumetric    C
efficiency
Crank end suction volumetric     C
efficiency
Crank end discharge volumetric   C
efficiency
Delta between actual and calculated S
discharge temperatures
Delta between actual and calculated S
interstage pressure
Crank pin load                   C
Head end suction valve loss HP   C
Head end discharge valve loss HP C
Crank end suction valve loss HP  C
Crank end discharge valve loss HP C
Delta in Temperatures between two C
cylinders on same stage (Number)
Delta in Pressures between two   C
cylinders on the same stage (Number)
Differential for actual and calculated S = AVRG C
pressures and temperatures
Thermal Efficiency               M
Derated driver power based on    M
elevation and site temperature
M = Machine | S = Stage | C = Cylinder

FIG. 2 illustrates a high-level flowchart for the steps performed by the computer processor 4. In step 202, the computer processor 4 obtains the configuration of the equipment from the static information database 6. In step 204, the computer processor 4 obtains measurements from a source of reciprocating compressor performance data 2 and/or user input from the UI 10 in the case of ad hoc calculations. In step 206, the computer processor 4 performs calculations related to the performance of the equipment. In step 208, the computer processor 4 performs calculations to determine the maximum theoretical capacity, i.e., the maximum theoretical amount of gas the compressor can move based on the compressor and available horsepower. In step 210, the computer processor 4 obtains the threshold measurements. In step 212, the computer processor 4 calculates threshold calculated values. In step 214, the computer processor 4 determines differentials between the threshold measurements and the threshold calculated values. In step 216, the computer processor 4 saves the calculated values to an archive 12. In the case of ad hoc calculations, steps 214 and 216 are not performed but rather the results are displayed on the visual display 13 in step 218.

FIG. 3 illustrates a high-level flowchart for the steps performed by the computer processor 4 in step 206 described above. In step 302, the computer processor 4 performs calculations to determine the theoretical capacity, based on pressure and temperature measurements utilizing an iterative process. In step 304, the computer processor 4 calculates the piston speed. In step 306, the computer processor 4 calculates the compressor horsepower, and in step 308, the computer processor 4 calculates the total horsepower. In step 310, the computer processor 4 calculates the fan cooler horsepower.

In one embodiment, the system can be configured with calculating parameters by a user in the user interface. This occurs in a Detailed Performance tab in the user interface 10. For each service/stage/cylinder combination, specific conditions can be input in this tab into a form, resulting in calculations being performed the results of which are then displayed on the visual display 13.

In one embodiment, the system allows the user to generate graphs on the visual display 13. In one embodiment, the system allows the user to select the graph style. For instance, standard performance curves (also referred to as curve sheet plots), multi-condition step curves, and multiple suction pressure-discharge pressure curves may be provided as options. Performance curves plot horsepower or capacity for one or more selected pieces of equipment. The tab for this in the user interface 10 is referred to as the Curve Sheet Plot Tab. Calculated values appear as data points on the graph, and can be colored according to their relation with respect to threshold criteria. In one embodiment, the user can manually input a range to be graphed. In one embodiment, the maximum and minimum speed curve can be graphed for a constant suction pressure or discharge pressure. The current operating condition can also be plotted. In one embodiment, the curve will stop plotting when a threshold is reached.

In one embodiment, the system allows the user to generate rod load plots graphically displaying rod loads for individual equipment. The computer processor obtains the maximum rod load (tension and compression) from the static information database and adds this to the plot for reference. The plot can include gas, inertial, and/or gas and inertial loads for every 1-degree increment from 0 to 360 as requested by the user.

In one embodiment, the system can generate a variety of reports at the request of a user. For example, in one embodiment, within the user interface 10, the user can request a calculations history report which includes all of the calculated values performed by the computer processor 4. The report can also include whether a warning or alert was indicated, whether the calculation was a success and the like.

In another embodiment, within the user interface 10, the user can request a report of exceptions, also referred to as the exceptions log. By exceptions is meant calculated values for which an alert was indicated, thus requiring acknowledgment and/or follow-up by a user. Exceptions are shown based on the selected equipment in the hierarchy tree view. Warnings of the same type can be grouped in the report. Individual records in the report can reflect when the exception was acknowledged by whom. If any record is not acknowledged, a symbol or color may be used to indicate to the user that an action is required. In some embodiments, users can acknowledge exceptions in the user interface from within this report.

In another embodiment, within the user interface 10, the user can request a report of measured and/or calculated values which exceed the alarm limits or predefined thresholds. Color coding can be used to indicate such values. The user can also request report comparing calculated, theoretical values to the corresponding actual measured values. Color coding can be used to indicate large differences or discrepancies which may indicate a potential problem needing investigation by engineers.

In another embodiment, within the user interface 10, the user can request a report of Bad Parameters which includes a list of bad calculation parameters for equipment selected from a hierarchy. By bad parameters is meant measured values which are clearly incorrect and require follow-up. Other reports can be created by the system as would be apparent to one skilled in the art.

In one embodiment, the user interface 10 includes an off-line/online component. The purpose of the off-line/online component is to enable the system to synchronize cached local data with the business unit database at predefined periods of time or when the system detects that a user has established a connection to the system. The system creates the synchronization tasks in the background so that the user can continue working with minimum disruption.

In one embodiment, the user interface 10 includes an off-line data access layer. The layer is a smart client that can provide full access to historical data for reporting when the system is online (i.e. connected to the network). If the system is offline (i.e. disconnected from the network), the layer will use thirty days cached data.

It should be noted that only the components relevant to the disclosure are shown in the figures, and that many other system components which could be included are not shown for simplicity.

Unless otherwise specified, the recitation of a genus of elements, materials or other components, from which an individual component or mixture of components can be selected, is intended to include all possible sub-generic combinations of the listed components and mixtures thereof. Also, “comprise,” “include” and its variants, are intended to be non-limiting, such that recitation of items in a list is not to the exclusion of other like items that may also be useful in the materials, compositions, methods and systems of this invention.

From the above description, those skilled in the art will perceive improvements, changes and modifications, which are intended to be covered by the appended claims.

Claims

1. A system for monitoring performance of a plurality of reciprocating compressors having components made by at least two different manufacturers, comprising:

a. a source of reciprocating compressor data associated with a plurality of reciprocating compressors comprising reciprocating compressor components made by at least two different manufacturers;

b. a source of reciprocating compressor component specifications associated with the plurality of reciprocating compressors comprising reciprocating compressor components made by at least two different manufacturers; and

c. a computer processor in communication with the source of reciprocating compressor data and the source of reciprocating compressor component specifications;

wherein the computer processor: i. obtains at least one measured value from the source of reciprocating compressor data and at least one specification value from the source of reciprocating compressor component specifications; ii. performs at least one calculation using the at least one measured value and the at least one specification value to calculate at least one calculated performance value; iii. compares the at least one calculated value to a user-defined calculated value limit selected from the group consisting of an upper alarm limit, a lower alarm limit, an upper deviation limit, a lower deviation limit, a maximum value, a minimum value and combinations thereof; and iv. initiates an alert to a user of any calculated value exceeding the user-defined calculated value limit every user-defined period of time.

2. The system of claim 1, wherein in step (b)(i) the computer processor obtains at least two measured values from the source of reciprocating compressor data wherein the at least two measured values are associated with reciprocating compressor components made by at least two different manufacturers; and in step (b)(ii) the computer processor performs calculations using the at least two measured values and the at least one specification value to calculate at least two calculated performance values on an equivalent basis independent of manufacturer.

3. The system of claim 1, wherein the at least one calculated performance value is stored in a historical database comprising calculated values retrievable by the computer processor.

4. The system of claim 1, further comprising:

c. a user input device in communication with the computer processor; and

d. a visual display in communication with the computer processor; wherein, in response to user input provided via the user input device, the computer processor generates at least one report, table, chart, diagram or graph on the visual display associated with the at least one measured value or the at least one calculated value.

5. The system of claim 1, wherein the plurality of reciprocating compressors comprises from 10 to 200 reciprocating compressors; and the source of reciprocating compressor data comprises from 10 to 1000 sensors.

6. The system of claim 1, wherein the reciprocating compressor components are selected from the group consisting of engines, crank shaft housings and cylinders.

7. A method for monitoring performance of a plurality of reciprocating compressors having components made by at least two different manufacturers, comprising:

a. obtaining at least one measured value from a source of reciprocating compressor data associated with a plurality of reciprocating compressors comprising reciprocating compressor components made by at least two different manufacturers;

b. obtaining at least one specification value from a source of reciprocating compressor component specifications associated with the plurality of reciprocating compressors comprising reciprocating compressor components made by at least two different manufacturers;

c. performing at least one calculation using the at least one measured value and the at least one specification value to calculate at least one calculated performance value;

d. comparing the at least one calculated value to a user-defined calculated value limit selected from the group consisting of an upper alarm limit, a lower alarm limit, an upper deviation limit, a lower deviation limit, a maximum value, a minimum value and combinations thereof; and

e. alerting a user of any calculated value exceeding the user-defined calculated value limit every user-defined period of time.

8. The method of claim 7, further comprising storing the at least one calculated value in a historical database comprising calculated values such that the at least one calculated value is retrievable by the computer processor.

9. The method of claim 7, further comprising generating at least one report, table, chart, diagram or graph associated with the at least one measured value or the at least one calculated value.