FM Global

Property Loss Prevention Data Sheets

7-95
September 1990
Revised May 2000
Page 1 of 17

COMPRESSORS

Table of Contents
Page
1.0 SCOPE ................................................................................................................................................... 3
1.1 Changes .......................................................................................................................................... 3
2.0 LOSS PREVENTION RECOMMENDATIONS ....................................................................................... 3
2.1 General ............................................................................................................................................ 3
2.1.1 Protection .............................................................................................................................. 3
2.1.2 Equipment and Processes .................................................................................................... 5
2.1.2.1 Compressor Safeguards ............................................................................................ 5
2.1.2.2 Intercoolers ................................................................................................................ 5
2.1.2.3 Lubrication Systems .................................................................................................. 5
2.1.2.4 Drivers ........................................................................................................................ 5
2.1.2.5 Electric Motor ............................................................................................................. 5
2.1.2.6 Internal Combustion Engines .................................................................................... 5
2.1.2.7 Turbine Drivers .......................................................................................................... 6
2.1.2.8 Miscellaneous ............................................................................................................ 6
2.1.2.9 Fuel Supplies ............................................................................................................. 7
2.1.3 Ignition Source Control .......................................................................................................... 7
2.1.3.1 Filters ......................................................................................................................... 7
2.1.4 Operation and Maintenance .................................................................................................. 8
2.1.5 Construction and Location .................................................................................................... 8
2.2 External Lubrication Systems .......................................................................................................... 8
2.2.1 Introduction ............................................................................................................................ 8
2.2.2 Equipment and Processes .................................................................................................... 8
2.2.3 Construction and Location .................................................................................................... 8
2.2.4 Ignition Source Control .......................................................................................................... 9
2.2.5 Contingency Planning ........................................................................................................... 9
2.2.6 Occupancy ............................................................................................................................. 9
2.3 Air Compressors .............................................................................................................................. 9
2.3.1 Construction and Location .................................................................................................... 9
2.3.2 Equipment and Processes .................................................................................................... 9
2.3.3 Human Element ..................................................................................................................... 9
2.3.4 Operation and Maintenance .................................................................................................. 9
2.4 Oxygen Compressors ...................................................................................................................... 9
2.4.1 Construction and Location .................................................................................................... 9
2.4.2 Equipment and Processes .................................................................................................... 9
2.5 Flammable Gas Compressors ....................................................................................................... 10
2.5.1 Construction and Location .................................................................................................. 10
2.5.2 Equipment and Processes .................................................................................................. 10
2.5.3 Ignition Source Control ........................................................................................................ 10
2.5.4 Operation and Maintenance ................................................................................................ 10
2.6 Natural Gas Compressor Stations ................................................................................................. 10
2.6.1 Introduction .......................................................................................................................... 10
2.6.2 Construction and Location .................................................................................................. 10
2.6.3 Equipment and Processes ................................................................................................... 11
2.6.4 Utilities ................................................................................................................................. 11
2.6.4.1 Electric Power and Lighting ..................................................................................... 11
2.6.5 Protection ............................................................................................................................. 11

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stored in a retrieval system, or transmitted, in whole or in part, in any form or by any means, electronic, mechanical,
photocopying, recording, or otherwise, without written permission of Factory Mutual Insurance Company.

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3.0 SUPPORT FOR RECOMMENDATIONS .............................................................................................. 11

3.1 Comments ...................................................................................................................................... 11
3.1.1 Fire and Explosion Hazards ................................................................................................ 11
3.1.2 Lubrication System Hazards ................................................................................................ 11
3.1.3 Gas Turbine Fire Hazards ................................................................................................... 12
3.1.4 Internal Combustion Engine-Driven Compressors .............................................................. 12
3.1.5 Motor-Driven Compressors ................................................................................................. 12
3.1.6 Air Compressors .................................................................................................................. 12
3.1.7 Oxygen Compressors .......................................................................................................... 12
3.1.8 Flammable-Gas Compressors ............................................................................................. 13
4.0 REFERENCES ..................................................................................................................................... 13
4.1 FM Global ...................................................................................................................................... 13
4.2 NFPA Standards ............................................................................................................................ 13
4.3 Others ............................................................................................................................................ 13
APPENDIX A GLOSSARY OF TERMS ..................................................................................................... 14
APPENDIX B DOCUMENT REVISION HISTORY ..................................................................................... 14
APPENDIX C SUPPLEMENTAL INFORMATION ...................................................................................... 14
C.1 Scope ............................................................................................................................................ 14
C.2 General Information ...................................................................................................................... 14
C.3 Types of Compressors .................................................................................................................. 14
C.3.1 Centrifugal Compressors .................................................................................................... 14
C.3.2 Axial-Flow Compressors ..................................................................................................... 14
C.3.3 Reciprocating Compressors ................................................................................................ 14
C.3.4 Rotary Compressors ........................................................................................................... 14
C.4 Drivers ........................................................................................................................................... 15
C.5 External Lubrication Systems ....................................................................................................... 15
C.6 Air Compressors ........................................................................................................................... 15
C.7 Oxygen Compressors ................................................................................................................... 15
C.8 Flammable-Gas Compressors ...................................................................................................... 15
C.9 Natural Gas Compressor Stations ................................................................................................ 15

List of Figures
Fig. 1. Automatic Sprinkler Decision Tree. .................................................................................................... 4
Fig. 2. Combined lube-oil/seal-oil system. ................................................................................................... 16
Fig. 3. Natural Gas Compressor Station Arrangement. ............................................................................... 17

List of Tables
Table
Table
Table
Table
Table
Table

1.
2.
3.
4.
5.
6.

Automatic Sprinkler Systems Design Specifications ....................................................................... 3

Recommended Compressor Interlocks ............................................................................................ 6
Recommended Intercooler Interlocks .............................................................................................. 6
Recommended Driver Interlocks ...................................................................................................... 6
Protective Devices for Internal Combustion Engines ...................................................................... 7
Recommended Lubrication and Control-oil Interlocks ..................................................................... 7

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FM Global Property Loss Prevention Data Sheets

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1.0 SCOPE
This data sheet provides recommendations to prevent or minimize the effects of fires and explosions involving
compressor systems. This data sheet applies to internal and external fires and explosions involving positivedisplacement compressors and external fires involving dynamic compressors.
Guidelines for protecting internal fires and explosions involving dynamic compressors are provided in Data
Sheet 7-100/13-16, Dynamic Compressors.
1.1 Changes
January 2000. This revision of the document has been reorganized to provide a consistent format.
2.0 LOSS PREVENTION RECOMMENDATIONS
2.1 General
2.1.1 Protection
2.1.1.1 Provide automatic sprinkler protection for compressors if any of the following conditions exist (see
Fig. 1):
a) Room or building construction is combustible;
b) Adjacent occupancy is combustible, or;
c) Compressor has an external lubrication system with a capacity greater than 100 gallons (378 l) or a
flowrate exceeding 25 gpm (95 l/min). (If there are multiple compressors, the capacity should be considered the aggregate total for all compressors within 25 ft [8 m]).
Exception: Where the probability of an oil fire is low due to the lack of any hot surface ignition source, the compressor installation, including lubrication system, may be protected by hose streams with spray nozzles if
there is available personnel and good accessibility for manual fire fighting. In addition, all piping and connections should be metallic.
If sprinkler protection is omitted, consideration should be given to providing heat actuated detectors interlocked to an automatic shutdown for high value units or areas.
2.1.1.2 Design automatic sprinkler systems in accordance with Table 1.
Table 1. Automatic Sprinkler Systems Design Specifications1
Type
of
Sprinkler System
Wet

Wet

Dry

Dry
1

Sprinkler
Temp. Rating
F (C)
High
286
(141)
Ord.
160
(71.1)
High
286
(141)
Ord
160
(71.1)

Density
gpm/ft2
(mm/min)

Area of
Demand
ft2 (m2)

0.20
(8)

3000
(278.7)

0.20
(8)

4000
(371.6)

0.20
(8)

5000
(464.7)

Hose stream demand: 500 gpm (1900 dm3/min). Duration of demand: 60 min

2.1.1.3 Outdoor compressors needing sprinkler protection, according to Figure 1, should be protected with
either a deluge or water spray system.

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Compressors
FM Global Property Loss Prevention Data Sheets

Fig. 1. Automatic Sprinkler Decision Tree.

2.1.1.4 Ceiling sprinklers should extend 20 ft (6 m) beyond the compressor and any part of the oil system.
2.1.1.5 Provide 1-12-in. (3.8 cm) small hose stations on maximum 100 ft (33 m) spacing in compressor buildings or areas.
Train and drill employees on all shifts in incipient fire fighting methods.

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Page 5

2.1.2 Equipment and Processes

2.1.2.1 Compressor Safeguards
2.1.2.1.1 Equip compressors with the protective devices listed in Table 2. Additional interlocks are recommended in applicable sections of this data sheet.
Exception: Protective devices are optional for compressors below 100 hp (75 kW).
2.1.2.1.2 Provide pressure-relief devices on the discharge line between the compressor and any shutoff
valves, between stages of compressors having two or more stages, on all pressure containers, air compressors and positive-displacement compressors. Set the relief valves to open at slightly above normal operating conditions. Test valves annually.
Exception: These devices may be omitted if the maximum pressure obtainable by any element in the system cannot exceed 110% of its maximum allowable working pressure. Pressure relieving devices should
be provided between positive displacement compressor discharge and block valves without exception.
2.1.2.1.3 Pressure-relief devices should discharge to a safe location if flammable gas may be released. On
new installations, the relief valve should preferably discharge to a safe location without manifolding.
2.1.2.1.4 Provide a check valve on the discharge connection of the compressor system.
2.1.2.1.5 Provide at least one remote station in an accessible location for stopping the compressor and shutting the supply line in an emergency.
2.1.2.2 Intercoolers
2.1.2.2.1 On air compressors, provide intercoolers between stages and an aftercooler following the last stage.
Intercooler water supply should be adequate and reliable.
2.1.2.2.2 Equip intercoolers with the protective devices listed in Table 3.
2.1.2.2.3 Provide an open drain or other visible water discharge for water jackets, intercoolers, and
aftercoolers.
2.1.2.3 Lubrication Systems
2.1.2.3.1 Use the correct quantity and quality of lubricating oil as recommended by the compressor manufacturer and as confirmed by satisfactory performance. Carbon formation may occur in compressors designed
to operate at unusually high discharge temperatures, even if chemically stable oils are used.
2.1.2.3.2 Special oils, which form a soft fluffy carbon that will not adhere strongly to metal surfaces, should
be used. Such oils should also have high film strength and high adhesive properties to resist the washing
action of moisture.
2.1.2.4 Drivers
2.1.2.4.1 Provide the protective devices listed in Table 4 on all drivers. Additional protective devices for specific
drivers may be recommended in applicable sections.
Exception: Protective devices are optional for drivers below 100 hp (75 kW).
2.1.2.5 Electric Motor
2.1.2.5.1 Provide overload protection on the compressor drive motor.
2.1.2.5.2 Arrange and protect synchronous motors in accordance with applicable Data Sheet 5-13/14-14,
Synchronous Motors.
2.1.2.6 Internal Combustion Engines
2.1.2.6.1 Provide the protective devices listed in Table 5.
Exception: Protective devices are optional on units below 100 hp (75 kW).

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FM Global Property Loss Prevention Data Sheets

2.1.2.6.2 Provide Factory Mutual Research Approved explosion vents on the crankcase of internal
combustion engines that have a cylinder bore of 8 in. (200 mm) or greater, or a crankcase volume of 21 ft3
(0.6 m3). The vents should provide a minimum vent ratio of 1.5 in2/ft3 (345 cm2/m3).
2.1.2.6.3 Vent gas-engine crankcases to outdoors.
2.1.2.6.4 Provide a three-way cock on the fuel-gas line supply line to gas engines. Vent the piping on the
engine side to atmosphere to prevent gas from entering the air-intake system while the engine is shut down.
2.1.2.6.5 Supply combustion air for gas engines from outdoors. Provide explosion vents on air-intake manifolds and air filters to prevent damage in event of an explosion caused by gas leakage into the air-intake system while the engine is shut down.
2.1.2.6.6 Provide a purging period for the intake systems on gas engines by turning the engine over a specified number of times before ignition is turned on. The number of turnovers depends upon the manufacturers instructions and the volume of the intake system.
2.1.2.7 Turbine Drivers
2.1.2.7.1 Provide the protective devices listed in Table 4.
Exception: Protective devices are optional on units below 100 hp (75 kW).
Refer to Data Sheets 7-79, Fire Protection for Gas Turbines, and 7-101, Fire Protection for Steam Turbines
and Electric Generators, for additional protection recommendations for large, valuable turbines.
2.1.2.7.2 Provide complete fuel burner safety controls for gas-fired turbines as specified in Data Sheet 7-79,
Fire Protection for Gas Turbines.
2.1.2.8 Miscellaneous
2.1.2.8.1 Install electrical equipment in accordance with the National Electrical Code (or equivalent in non-US
locations).
Table 2. Recommended Compressor Interlocks
Condition
Compressor or Stage Discharge Line:
high pressure
high temperature

Alarm

Trip

X
X

Table 3. Recommended Intercooler Interlocks

Condition
Intercoolers:
high water temperature
or
water supply valve

Alarm

Trip

Table 4. Recommended Driver Interlocks

Condition
overspeed
excessive vibration
high cooling water temperature
excessive axial thrust (turbine)
exhaust temperature (gas turbine)

Alarm
X
X
X
X
X

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Trip
X
X
X
X
X

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Table 5. Protective Devices for Internal Combustion Engines

Condition
high cooling water jacket temperature
low oil pressure
high oil temperature (2500 hp [1865 kW])
high vibration amplitude (1000 hp [745 kW])
Engine Running indicator (emergency generators and
all emergency engines that start automatically)
engine overspeed actuator
high exhaust gas temperature (1000 hp [745 kW])
auxiliary oil pump (2500 hp [1865 kw])

Alarm
X
X
X
X

Trip
X
X
X
X

X
X

1. Protective devices should have separate alarm and trip settings and not the time-delay type. Also, all engines greater than or equal to
2500 hp (1865 kW) should have both air shutoff valves and fuel shutoff valves, to provide redundant protection and to prevent engines from
continuing to run when there are volatile fumes in the air.
2. All engine protective systems should be designed to shut the engine off in the event that there is either an electrical short, or an opening
of the circuit in the shutdown system (i.e., all protective devices should be fail-safe).
3. All protective devices should transmit to monitors at a permanently attended station if the engine operates unattended.
4. The following protective devices are available and may be designed to initiate an alarm and/or trip. Installation of these devices is optional,
though strongly advised if the loss potential is large enough to warrant the cost of their installation.
Oil metal detector
Oil mist detector
High crankcase pressure
High exhaust gas temperature (1000 hp [745 kW])
Low coolant level
High bearing temperature
Auxiliary oil pump (2500 hp [1865 kw])
Low coolant flow
High oil pressure

Table 6. Recommended Lubrication and Control-oil Interlocks

Condition
Lube Oil:
low pressure
low reservoir level
high temperature
Seal Oil:
low pressure
low reservoir level

Alarm

Trip

X
X
X

X
X
X

X
X

X
X

2.1.2.9 Fuel Supplies

2.1.2.9.1 Locate and arrange fuel equipment and piping in accordance with applicable Factory Mutual
Research standards.
2.1.3 Ignition Source Control
2.1.3.1 Filters
2.1.3.1.1 Activated charcoal filters are subject to spontaneous heating if contaminated by oily residues and
should not be used as suction filters with air compressors that require oil lubrication.
2.1.3.1.2 Use filters of activated alumina, glass fiber or stainless steel or monel-metal wool for oil-lubricated
compressors. Clean such filters periodically to prevent oil accumulations (the frequency of cleaning should
be at least as often as recommended by the manufacturer).
2.1.3.1.3 Ordinary steel wool is subject to spontaneous heating caused by oil residues and should not be
used.

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FM Global Property Loss Prevention Data Sheets

2.1.4 Operation and Maintenance

2.1.4.1 Post detailed operating and maintenance instructions, including emergency procedures, at compressor buildings or areas.
2.1.4.2 Establish and maintain high standards of housekeeping in the compressor area. Unnecessary combustibles, flammable gases or liquids should not be stored in the area.
2.1.4.3 Establish an inspection and cleaning program to keep safety devices, valves and other compressor
components in good condition and prevent formation of excessive deposits in the compressor system. This
inspection and cleaning program must include cylinders, discharge valves, air piping, water jackets, receivers, intercoolers and aftercoolers, and air filters.
This program should also include the following actions:
a) Replace worn or broken parts, install new shaft packing and conduct maintenance work promptly when
needed.
b) Blow out piping receivers and aftercoolers low points regularly to remove oil residues and sludge.
Periodic introduction of a suitable cleaning solvent or solution into the lubrication system as recommended by the manufacturer can remove oily residues and help prevent carbon formation. Kerosene or
other flammable solvents should not be used for this purpose.
2.1.4.4 Inspect drive belts regularly and take necessary corrective measures.
2.1.4.5 Install piping, preferably aboveground, without low spots, where moisture or condensate can collect.
Provide access openings in air piping for inspection and cleaning. Provide means of preventing liquid
carryover.
2.1.5 Construction and Location
2.1.5.1 Locate and arrange liquid-fuel storage facilities in accordance with Data Sheet 7-88, Storage Tanks
for Flammable Liquids.
2.2 External Lubrication Systems
2.2.1 Introduction
2.2.1.1 Provide protection as specified below for external lubrication systems with a capacity exceeding 100
gallons (378 l) or with a flowrate greater than 25 gpm (95 l/min).
2.2.2 Equipment and Processes
2.2.2.1 Provide the protective devices listed in Table 6.
2.2.2.2 Provide hinged covers for oil tanks associated with hydrogen seal oil equipment to minimize damage from an internal hydrogen-air explosion. Provide vents on the hydrogen seal oil system, hydrogen detraining tanks, with pipes venting to outdoors.
2.2.2.3 Provide a means, in a safe location, for remotely stopping the oil pumping equipment in an emergency.
2.2.3 Construction and Location
2.2.3.1 Concrete or concrete-on-protected-steel should be used for a compressor system supporting structure exposed by an oil fire hazard or any adjacent process equipment handling combustible materials.
Exposed steel construction is acceptable if protected by standard automatic or deluge-system sprinklers.
2.2.3.2 Provide means of confining lubricating oil in event of a pipe break or other accident at the oil reclaiming equipment in the compressor building. Relief valves on the oil pump should discharge to a safe location.
Oil lines under pressure should preferably be installed inside drain or return lines or inside separate enclosures designed to return any oil leakage to the reservoir. High- pressure steel-welded pipes and fittings are
preferable. Lines and gauges should be substantially supported and braced, and guarded against mechanical damage (new installations).
2.2.3.3 Provide containment for any floor area where an oil spill, leak or overflow could occur so that oil
cannot flow to other areas.

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Page 9

2.2.4 Ignition Source Control

2.2.4.1 For steam-turbine drives, oil and steam lines should be separated from each other as far as practicable by distance or by noncombustible baffles to prevent escaping oil from contacting the hot pipe surfaces. Wherever possible, locate the oil piping below steam lines (new installations).
2.2.4.2 Surfaces with temperatures approaching the auto-ignition temperature of the lubricating oil should
be insulated to prevent ignition of escaping oil. The insulation should be covered with sheet metal or be impervious to oil.
2.2.5 Contingency Planning
2.2.5.1 Provide a reliable emergency source of power for oil pumping equipment.
2.2.6 Occupancy
2.2.6.1 Limit the amount of oil storage to a practical minimum consistent with efficient operation of the
compressor system.
2.3 Air Compressors
2.3.1 Construction and Location
2.3.1.1 Preferably locate air compressors in noncombustible buildings or cutoff rooms.
2.3.1.2 Rotary-screw compressor air-receiver vents should discharge to a safe location because the vented
air/oil mixture may be flammable.
2.3.1.3 Locate air intakes away from sources of flammable vapors, gas, steam, dust, or other contaminants. Provide intake-air filters to remove suspended solids.
2.3.2 Equipment and Processes
2.3.2.1 Install a pressure-relief valve on the air receiver set to open at slightly above normal operating
pressure and below the maximum allowable working pressure as stamped on the receiver.
2.3.2.2 Use air receivers fabricated in accordance with the latest revisions of Section VIII rules for construction of unfired pressure vessels of the American Society of Mechanical Engineers (ASME) Boiler and
Pressure Vessel Code.
2.3.3 Human Element
2.3.3.1 Remove interior deposits before performing cutting or welding operations on the system.
2.3.4 Operation and Maintenance
2.3.4.1 Contaminants cause excessive wear and erosion and contribute to the formation of hazardous
deposits. Inspect and clean air filters regularly to prevent clogging and reduction of air flow.
2.4 Oxygen Compressors
2.4.1 Construction and Location
2.4.1.1 Locate oxygen compressors outdoors or in dedicated noncombustible buildings. Flammable-gas
compressors should not be located in the same area or building with oxygen compressors.
2.4.2 Equipment and Processes
2.4.2.1 If there is a possibility that combustible gases could be introduced into the oxygen compressor,
provide an Approved continuous combustible gas-analyzer arranged to sound an alarm and shut down the
compressor upon detection of combustible gases.

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FM Global Property Loss Prevention Data Sheets

2.5 Flammable Gas Compressors

2.5.1 Construction and Location
2.5.1.1 Locate flammable-gas compressors outdoors or in lightweight, noncombustible detached buildings
of damage-limiting construction, well separated from other process equipment or occupancies.
2.5.1.2 Provide separation between compressors to prevent interexposure. Approximately 40 ft (12 m) should
provide adequate separation.
2.5.1.3 Provide natural-draft ventilation in all buildings containing gas piping by installing continuous-ridge
or amply sized unit ventilators in the roof and louvers at the floor level. Provide positive ventilation of 0.5 cfm/
ft2 (0.15 m3/min/m2) of ceiling area at unventilated belowgrade areas, such as those in the compressor
building.
2.5.1.4 Provide ventilation for pipe trenches by grating tops and for tunnels by installing grating over 50%
of the area or by installing continuously operated fans having a capacity of 1 cfm/ft2 (0.30 m3/min/m2) of ceiling area.
2.5.2 Equipment and Processes
2.5.2.1 If a leak of flammable gas could expose important buildings or equipment, provide a combustiblegas detection system. The system should alarm upon detection of 10% lower flammable limit (LFL) and shut
down the compressor upon detection of 25% LFL.
2.5.2.2 Provide Approved explosion vents on reciprocating compressor crankcases.
2.5.2.3 If a potential process upset may introduce oxygen or air into the flammable gas feed stream, provide a continuous gas analyzer to simultaneously sound an alarm and shut down the compressor system in
the event of unsafe operating conditions. Arrange the system to be automatically vented and purged upon
shutdown.
2.5.2.4 Provide a low pressure interlock on the suction line to shut down the compressor if a negative pressure is developed.
2.5.2.5 Pipe relief valve outlets to the compressor suction side or to a safe location.
2.5.2.6 Vent piston-rod housing on positive-displacement compressors and the seals on centrifugal compressors to a safe location.
2.5.2.7 For refrigerants and refrigerating systems, follow guidelines as outlined in Data Sheet 7-13,
Mechanical Refrigeration.
2.5.3 Ignition Source Control
2.5.3.1 Install electrical equipment in compressor buildings or areas as specified in the National Electrical
Code (or equivalent in non-US locations) for Class I, Division 2 locations.
2.5.4 Operation and Maintenance
2.5.4.1 Purge all piping to a safe location with inert gas after completing any work on piping that may have
admitted air.
2.6 Natural Gas Compressor Stations
2.6.1 Introduction
Follow recommendations in Section 2.5. In addition, provide protection as recommended in the following
sections.
2.6.2 Construction and Location
2.6.2.1 Eliminate all unventilated basement areas in plant buildings.

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2.6.2.2 Locate auxiliary buildings such as warehouses, construction buildings, boiler houses, garages and
repair shops at least 50 ft (15 m) from the compressor building. Locate general offices farther away if space
and operating conditions permit.
2.6.3 Equipment and Processes
2.6.3.1 Provide two or more isolated stations to shut down the compressors, close all inlet and discharge
gas lines and to open the station-piping blowdown valve. The emergency controls should operate independent of the line pressure. Test controls and valves monthly.
2.6.3.2 Provide means of releasing the gas pressure in the compressor suction and discharge lines between
the shutoff valves and compressor to a safe location when the compressor is not operating.
2.6.3.3 Locate high-pressure gas piping in or near the compressor building aboveground and arrange it in
accordance with American National Standard B31.8, Gas Transmission and Distribution Piping Systems.
2.6.3.4 Protect buried piping against corrosion by coating with protective material and/or by cathodic
protection.
2.6.3.5 Provide relief valves on the discharge side of the pressure regulators for the gas-service supply for
the plant. These valves should have ample capacity to prevent excessive pressures in the piping if the valve
opens as the result of regulator diaphragm failure.
2.6.3.6 Provide protection for industrial heating equipment, such as boilers and heaters on dehydrating equipment, in accordance with Data Sheet 6-0/12-1, Elements of Industrial Heating Equipment.
2.6.4 Utilities
2.6.4.1 Electric Power and Lighting
2.6.4.1.1 Ground all buildings and equipment.
2.6.4.1.2 Provide emergency power-generation equipment to supply power in event of a power supply failure.
2.6.5 Protection
2.6.5.1 Provide an Approved combustible-gas detection system interlocked to sound an alarm upon detection of a methane concentration of 10% of the LFL and shut down the system upon detection of 25% of the
LFL. The shutdown should include closing all inlet and discharge gas lines and opening all blowdown valves
in the compressor building.
2.6.5.2 Provide an Approved heat detection system interlocked to shut down the compressor system upon
actuation. The shutdown should include closing all inlet and discharge gas lines and opening all blowdown valves in the compressor building.
The heat-detection system may be omitted if automatic sprinkler protection is provided and interlocked to shutdown the compressor system as indicated.
2.6.5.3 Provide yard hydrants if a water supply is available.
3.0 SUPPORT FOR RECOMMENDATIONS
3.1 Comments
3.1.1 Fire and Explosion Hazards
The fire- and explosion-hazard potential of a compressor installation is a function of the size and type of
compressor, driver, lubrication system and the type of gas being handled. Other important factors are the temperature and pressure of the gas being handled and external exposures to the compressor system.
3.1.2 Lubrication System Hazards
External lubrication oil systems, commonly found in turbine-driven compressors, present a severe fire hazard. They contain large quantities of combustible oil under pressure. In the absence of fixed automatic protection, such fires may damage equipment and the building and cause prolonged business interruption.

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FM Global Property Loss Prevention Data Sheets

Turbines normally operate at temperatures far above the autoignition temperature of lubricating oils. A fire
will occur if oil under pressure escapes and the atomized spray is ignited by hot surfaces or from open flames,
sparks, friction or electrical equipment. The ensuing fire is often difficult to control with manual fire fighting.
The most common sources of ignition are steam pipes, hot parts of the turbine or other hot surfaces. Oil
leaks can occur near the turbine governor, at machine bearings, at the oil-pressure-actuated regulator valve
that controls the auxiliary oil pump, at oil piping, at oil pressure and temperature gauges and at other similar locations.
Typically, a turbine/compressor unit cannot be quickly stopped and the oil supply cannot be completely shut
off while the machines are still rotating. A considerable amount of oil can then be fed to a fire when accidental leakage occurs.
Severe oil fires have resulted from accidental overspeeding, excessive vibration and other mechanical failures of the compressor system causing the oil piping to fracture and release large quantities of oil under pressure. When these oil fires occur indoors, heat and smoke may interfere with effective fire fighting. They can
result in extensive physical damage to the building and equipment and prolonged business interruption.
In addition to the lube-oil fire hazard, there is a possibility of overpressurizing the oil reservoir through the
seal oil system. Failure of the seals may result in the gas overpressurizing the oil reservoir with a sudden
release of the oil content and probable ignition of the oil and gas (if flammable).
3.1.3 Gas Turbine Fire Hazards
Compressors driven by gas turbines present a fuel fire or explosion hazard in addition to the oil fire hazard.
3.1.4 Internal Combustion Engine-Driven Compressors
Internal-combustion type engine drivers present a fuel fire or explosion hazard. Explosions may occur in
crankcases or combustion-air intake systems of internal combustion engines.
3.1.5 Motor-Driven Compressors
Motors driving compressors can overheat and cause ignition of the windings.
3.1.6 Air Compressors
Many air compressor explosions and fires originate from oil and carbon deposits in the compressor systems. Excessive deposits in the system are the result of overlubrication, use of unsuitable lubricants or dirty
or chemically contaminated suction air.
Under conditions of high temperature and pressure, contaminants and oily carbon deposits may oxidize and
ignite spontaneously, creating an ignition source for vapors and residues. Glowing particles may be carried to a point in this system where there is a combustible or explosive mixture. Localized heating may weaken
the equipment walls to the point of failure.
Another important cause of air compressor fires and explosions is excessively high discharge temperatures.
Abnormal temperatures are caused by recompression due to leakage through faulty valves or to blow-by
in double-acting cylinders, by inadequate cooling water jackets and after-coolers, by high cylinder pressure
due to severe restriction of discharge lines by deposits, or by mechanical friction or broken compressor parts.
Other air compressor fires and explosions have originated in the compressor drive motor, controls or associated electrical equipment. A few fires have been caused by friction due to slippage of drive belts or pulleys;
by external ignition sources that involved oily residues; by solvent cleaners or combustibles in the vicinity of
the compressor that in some cases heated the compressor system to a point where internal carbon deposits ignited; and by oily lint or other combustibles in contact with outside surfaces of hot compressor parts.
The frequency of fires in oil-flooded rotary-screw compressors is much greater than other air compressors.
Currently, the cause of this increased frequency is not entirely understood. Oil overheats and ignites within
the compressor or the receiver. Complete, well maintained interlocks are essential.
3.1.7 Oxygen Compressors
Compressor components can burn in an oxygen atmosphere. An internal fire, regardless of origin, could
work its way through the system causing extensive damage to the compressor.

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If any flammable gases or liquids enter the system, an explosion and/or fire could result. Petroleum-base lubricating oils form explosive mixtures with oxygen; they are also highly susceptible to spontaneous ignition in
an oxygen atmosphere. Although petroleum-base lubricating oils are not used directly in contact with oxygen, accidents have occurred when oil from reciprocating compressor crankcases leaked along the piston
rod into the compressor cylinder.
A break or leak in the system piping downstream of the compressor could result in an intense fire involving
combustibles in an oxygen-rich atmosphere.
3.1.8 Flammable-Gas Compressors
The hazards of a flammable-gas compressor system are internal and external explosions and torch fires
caused by rapid ignition of gas escaping from a leak or break.
An internal explosion is possible if air is drawn into the system through leaking packing glands, fittings or
valves under conditions of negative pressure produced by a suction line obstruction. These explosions
frequently lead to external fires.
An external explosion can occur from failure of piping or equipment under pressure, with delayed ignition
of escaping gas.
Hydrocarbons such as butane, propane, propadiene, methane and natural gas reduce the viscosity of lubricating oils by going directly into solution or by condensing on cylinder walls as pressure increases, washing away the film of lubricant and mixing with it. A heavier oil may be used to prevent excessive wear and
possible overheating.
Failure of high-pressure piping inside or immediately outside a compressor building may result in an explosion and/or fire.
A severe flammable-gas fire can best be extinguished by shutting off the gas supply and immediately venting the gas piping to a safe location. Plants with sufficient separation and provision for promptly shutting
off the gas flow and blowing down the high-pressure piping from a safe remote control station have received
significantly less damage from such an incident.
4.0 REFERENCES
4.1 FM Global
Data Sheet 5-13/14-14, Synchronous Motors.
Data Sheet 6-0/12-1, Elements of Industrial Heating Equipment.
Data Sheet 7-13, Mechanical Refrigeration.
Data Sheet 7-79, Fire Protection for Gas Turbines.
Data Sheet 7-88, Storage Tanks for Flammable Liquids.
Data Sheet 7-100/13-16, Dynamic Compressors.
Data Sheet 7-101, Fire Protection for Steam Turbines and Electric Generators.
4.2 NFPA Standards
NFPA 70, National Electrical Code, 1996.
4.3 Others
American National Standard B31.8, Gas Transmission and Distribution Piping Systems.
American Society of Mechanical Engineers (ASME) Boiler and Pressure Vessel Code.

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APPENDIX A GLOSSARY OF TERMS

Approved: references to Approved in this data sheet means the product and services have satisfied the
criteria for Factory Mutual Research Approval. Refer to the Approval Guide for a complete listing of products
and services that are Factory Mutual Research Approved.
APPENDIX B DOCUMENT REVISION HISTORY
This document does not have any revision history.
APPENDIX C SUPPLEMENTAL INFORMATION
C.1 Scope
This appendix discusses compressors, compressor uses and lubrication systems.
C.2 General Information
Compressors are used for a variety of purposes or services such as process air or gas, process refrigeration, gas transmission and storage, gas separation processes and general plant service air. They are used to
transport compressible fluids such as air, natural gas, oxygen, nitrogen, carbon dioxide, ammonia synthesis
gas, propane, ethylene, hydrogen and hydrocarbon mixtures.
C.3 Types of Compressors
Compressors are classified as either positive-displacement or dynamic machines.
Positive-displacement machines compress gases by physically reducing the initial volume of gas in a closed
chamber to the terminal volume. Reciprocating and rotary compressors are positive-displacement machines.
Dynamic compressors compress gases by changing gas velocity. Centrifugal and axial-flow compressors
are dynamic machines.
C.3.1 Centrifugal Compressors
Centrifugal compressors are variable-capacity and constant-pressure-ratio machines. Centrifugal compressors are either horizontally (axially) or vertically (radially) split.
Centrifugal compressors are driven mainly by a steam turbine, gas turbine or electric motor. A common
arrangement is the centrifugal compressor train (more than one centrifugal compressor driven by one or more
drivers, all connected in series). Multiple driver arrangements are used where economics demand low utility consumption and flexibility in operation. Otherwise, optimum performance efficiencies are obtained with
speed-changing gears.
C.3.2 Axial-Flow Compressors
Axial-flow compressors were developed for gas turbines. They have found wide use in blast furnace, gas
booster and wind tunnel applications.
C.3.3 Reciprocating Compressors
Reciprocating compressors are constant-capacity and variable-pressure-ratio machines. They are capable
of transporting gases to pressures as high as 50,000 psi (3500 bar).
Reciprocating compressors are driven mainly by an internal-combustion engine, steam engine or electric
motor. Some reciprocating compressors are turbine driven.
C.3.4 Rotary Compressors
Rotary compressors are medium-volume and low-pressure machines. The most common type of rotary
compressor, a rotary-screw compressor can transfer up to 20,000 cfm (6,000 m3/min/m2) of gas to pressures as high as 300 psi (21 bar). Rotary compressors are adaptable to motor drive, turbine drive and internalcombustion engine drive.

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C.4 Drivers
Compressors are driven by electric motor, internal-combustion engine, and by turbines (gas or steam). Gas
turbines may be either combustion-gas turbines or hot-gas expander turbines. The driver is connected directly
or through speed-changing gears with the compressor or compressors depending upon the effective operating speed of the driver and compressor(s), respectively.
Many large compressors are high-speed, turbine-driven multistage centrifugal compressor trains with external lubrication systems (Fig. 2). These compressor systems may be used in single-line processes with a
high business interruption loss potential and represent a large capital investment.
C.5 External Lubrication Systems
Lubrication-oil systems include an oil reservoir, pumps, coolers, filters, regulators and supply and drainage
piping between the oil reservoir and the compressor system. Lube-oil systems serve two main functions: lubrication of the compressor and driver bearings and gears where used, and operation of the turbine governor.
Oil pressures up to 250 psi (17 bar) are used for the turbine controls and pressures of 15-25 psi (1-2 bar)
for the various components of the turbine and compressor.
Lubrication-oil systems are either integral to the compressor subbase or are a separate console. Oil reservoirs for large indoor installations are frequently located below the operating floor. Pumps, regulators, oil coolers and most of the other associated equipment are usually located at the oil reservoir.
Many centrifugal compressor systems have a seal-oil system (Fig. 2) that is frequently incorporated into the
lubrication system. The seal-oil system takes suction from the lubrication oil pump and further pressurizes
the oil (normally keyed to the inlet pressure of the process gas).
The pressurized seal oil is fed to an overhead seal-oil tank to maintain a sufficient quantity of oil with a 5
psi (0.3 bar) pressure differential across the oil seal. The oil seal is used to prevent the escape of gas from
the compressor, particularly at higher pressures where a mechanical seal alone is not practical.
C.6 Air Compressors
Air compressors provide process air and plant-service air. Plant-service air may be as vital as electricity,
gas or water.
Activated charcoal filters are commonly used in fermentation and pharmaceutical air compressors to purify
air from lubricants.
Oils suitable for air compressor service are those which are of high quality, well refined, and possess high
chemical stability to resist oxidation and formation of gum and carbon deposits. They also have carefully controlled viscosities to assure effective distribution, adequate film strength, anti-rust properties and waterseparating ability to prevent emulsions.
C.7 Oxygen Compressors
Oxygen compressors are used extensively in air separation plants and at facilities using oxygen as a process
gas.
C.8 Flammable-Gas Compressors
Flammable-gas compressors are used for many applications such as cylinder filling, gas storage, process
refrigeration, chemical processes and gas transmission.
C.9 Natural Gas Compressor Stations
Gas compressor stations are used:
a) to collect natural gas from wells or nearby refineries, compress it to approximately 1,800 psi (124 bar),
and discharge it into transmission piping;
b) as a pressure-booster or relay station in a cross-country gas-transmission system, and;
c) to pump gas back into underground storage areas at depleted gas fields as a reserve supply.
A typical compressor station arrangement is shown in Figure 3.

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Fig. 2. Combined lube-oil/seal-oil system.

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Fig. 3. Natural Gas Compressor Station Arrangement.

FM Engr. Comm. July 1990

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