Module 05 Centrifugal Compressors Trouble Shooting

Module
05
Centrifugal Compressors
Trouble Shooting

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Module 05 Centrifugal Compressors Trouble Shooting

Large dynamic compressors are commonly the heart of various petrochemical and
industrial processes. The plant output as well as the power consumption is controlled by the
compressor performance. Reduced compressor efficiency will not only cause increased utility
bills, but may also limit plant production rates. Maximization of compressor efficiency is
therefore most crucial in assuring maximization of plant profits.

Correction of compressor performance deficiencies can be very complex, and a very

methodical procedure is necessary in pinpointing the root cause of the situation. The
following outline is a starting point.

1. Define the problem.

a. What exactly is the problem?
b. What should the performance be?
c. What is the performance now?

2. Outline the history of the compressor.

a. How long has it been operating?
b. When was the last overhaul?
c. What changes were made at that time?
d. When did the problem start?
e. Was it a quick or gradual change?
f. Note the trend of various parameters.
g. What else changed, what other problems occurred at this time
i. on the compressor?
ii. in the process?
iii. in operation and control?

3. Verify all data.

a. Have instruments been calibrated?
b. Do cross checks agree?
A thorough performance test should be the first step. Follow as closely as possible
ASME PTC10 test procedure. If possible get several operating points at one speed so a full
curve can be plotted. This can be a big help in determining corrective measures.

Refer to guide in Table 5.1 for help in trouble shooting aerodynamic problems.

• Define problem—what, where, when.

• Outline history of operation—trend data.
• Verify data.

Test data
Complete power balance.
Check pressure taps: location, size, and condition.
Is there liquid in pressure lines?
Note the temperature probe insertion depth, and heat transfer.
Calibrate instruments.
Inspect flow meter: wear and sludge build up.
Are there condensates in gas analysis?
Is there a vortex or undeveloped velocity profile upstream of flow meter?
Conduct a mass flow balance.

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Equipment problems
Vortex or undeveloped velocity profile upstream of compressor suction
Internal leakage across diaphragm splitline
Recirculation from rubbed interstage seals or balance piston seals, casing drains,
other areas
Foreign object damage or blockage
Liquids in process
Dirt accumulation or polymer buildup
Erosion of impeller blades and diffuser passages
Proper direction of rotation
Balance line sleeve

Economics
Per diem cost to operate as is
Associated risks
Cost for repairs
Cost for down time to complete repairs
Safety concerns

Common Sources of Test Error

In order to trouble shoot any problem, it is important to have correct information on the
subject. Aerodynamic performance is very involved and data errors can rapidly mushroom,
thereby misleading the problem solver. It is therefore essential that accurate data be obtained.

Before trouble shooting the compressor, trouble shoot the testing procedure. The best
way to do this is a power balance. If it is not feasible to do a power balance, or if there is a
significant error (7%) between the compressor power and the driver power, a thorough
analysis of the test procedure is necessary.

Gas Analysis
To have good test results, it is critical to have an accurate gas analysis. This can be a bit
complex on high pressure, high mole weight gas. If the sample is taken at high temperatures,
some of the heavy gas may condense on the walls of the sample container when it cools. If the
sample is taken at the inlet, there may be some liquids in the gas stream that will remain in the
sample container. When testing the gas, this condensed liquid will remain in the bottle unless
heated.
For best results, take samples at both the inlet and discharge points. Check for
condensable and compensate by heating the sample before testing.

Liquids in the System

If there is liquid anywhere in the system, it is possible that some may carry over into the
compressor. Knockout drums and demister pads do not always work the way they should.
This liquid carryover will give erroneous results on the performance test.
Another liquid problem is liquid in pressure tap lines. Be sure all lines are properly
sloped and drained. If lines are too small (less than 1/2 inch), capillary action will hold liquid
in the lines.
Be sure to open drain valves at low spots in process piping and instrument lines before,
during, and after test.

Pressure and Temperature Measurement

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Be sure that a proper pressure tap is installed. Inspect the inside edge of the hole to see
that it was deburred and that it has not been eroded, corroded, or plugged with dirt.
Check thermocouple installations. Thermocouples should be inserted into the pipe one-
third to one-half the pipe diameter. Use graphite paste in the thermo-well to assure good heat
transfer between the thermo-well and thermocouple.
Be sure to only use instruments that have recently been calibrated.

Cleaning Centrifugal Compressors

Sometimes dirt, polymer build up, or other substances can clog the compressor
internally and seriously degrade performance. Very small amounts of dirt on axial blades alter
the blade profile and degrade performance. Cleaning a compressor may be all that is required
to regain ‘‘like new’’ performance.
A centrifugal compressor can be easily cleaned during normal operation (design speed)
by using mild abrasives such as cooked rice or walnut shells. More common is the use of
liquid cleaning agents sprayed into the process and into the return channel areas of the
compressor.

Velocity Profile
A major source of compressor performance problems can be attributed to an incomplete
velocity profile or a vortex upstream of the compressor or process flow meter. Either situation
will seriously alter the compressor and/or flow meter performance.
A flow straightener device is required when flow swirl or a vortex is present. This can
occur when there are two or more adjacent elbows in different planes. A flow straightener can
be a tube bundle or an ‘‘egg crate’’ as shown in the flowing two figures.

The vortex or flow swirl shown is caused by two elbows in

different planes. The vortex can be corrected by installation of a
simple vane flow straightener. Length of vanes should be two
times the pipe diameter. A flow straightener may be more

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effective without a flow equalizer due to the high pressure drop

associated with the flow equalizer.

Mitered, vaned elbow. A flow equalizer can be used, but at the

price of a significant pressure drop.

A flow equalizer is required when the velocity profile is not uniform. This can be caused
by flow hugging one side of a pipe due to flow around an elbow or flow through a partly
closed butterfly valve. This situation is best corrected by an equalization plate which is
essentially a perforated plate. Think of it as parallel orifices in a flow path. At high velocities,
the resistance (pressure drop) is greater. The higher velocity side of the velocity
profile is restricted more than the lower velocity side, causing a shifting
and equalization of the velocity profile as shown in the previous figures.

When designing a flow equalizer, it is important to realize that

pressure drop can be significant, especially if the plate becomes plugged
with debris. The best method for calculating pressure drop is to add the
area of all the holes in the plate and determine an equivalent single hole
orifice while calculating pressure drop accordingly. Be sure to note the
effect of the recovery factor.

Make a schematic diagram of the compressor and adjacent piping.

Note the length of straight runs of pipe, elbows, flow meters, valves,

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suction strainers, knockout drums, silencers, flow straighteners,

instrumentation, etc. This will help in resolving system-related problems.
If possible, a flow meter should be installed in each inlet and
discharge pipe so a mass flow balance in the system can be carried out.
This is done by simply comparing the total mass inflow to the total mass
outflow. The difference is the accuracy of the flow meters.
ASME ‘‘Fluid Meters’’ provide comprehensive guidelines on the
straight run required upstream of an orifice or flow nozzle.

Inlet Piping
Compressor performance is very dependent on obtaining a uniform flow distribution to
the impellers. Great pains are taken by the compressor designer to assure proper flow
distribution to intermediate impellers. Although inlet guide vanes may exist on a compressor,
this alone does not assure proper flow distribution to the first stage impeller. Compressors are
designed assuming a relatively uniform velocity profile at the compressor inlet flange.

Although ASME goes to some detail in describing upstream straight-run requirements

for orifice meters, the requirement for compressors is very simply stated. The straight-run
requirement for axial inlet compressors is 10 pipe diameters and for non-axial inlets, 3
diameters. Additionally, if the velocity pressure exceeds 1% of the static pressure, a flow
equalizer must be used at the exit of the elbow upstream of the compressor inlet flange.

Values for Pv /P1 _ .01 are shown in the following figure. Note that for 100oF air (MW=
29), the maximum inlet velocity for a three-diameter straight run without an equalizer is 140
fps. For propane (MW =44) at 0oF, the maximum velocity would be 100 fps.

According to Hackel and King17 the ASME guideline is adequate but could be modified
to call for a reduced straight run for lower Pv /P1 values, and greater straight run for larger Pv
/P1 values. Also, additional length of straight run should be required for compound piping
arrangements.

For a base case of one elbow in a plane parallel to the compressor axis and for a radial
inlet with 50oF gas, the following figure gives the minimum straight run required.
To correct for other suction temperatures, use the following equation to find the
equivalent velocity for 50oF. First calculate the actual velocity V1.

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For axial inlets and/or other inlet piping arrangements, use The following figure along
with the multipliers provided in the following Table 5.2

Maximum velocity allowed at the suction flange.

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Straight pipe run requirements for the base case

Table (5.2) Multipliers for Various Inlet Piping Arrangements

Double Flow Compressors

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A common method of increasing capacity of a system is using two or more compressors

in parallel. However it is feasible, since the ‘‘identical’’ units are always somewhat different
and system resistance varies, that both units will not be operating at the same point on the
performance curve. It is therefore always recommended that each unit have a separate anti-
surge system. For a double flow compressor this is not very simple due to the common
discharge nozzle. The design of the inlet piping must be such to achieve a well-balanced,
distortion-free flow into each inlet of the compressor. Otherwise, as with the parallel
compressors, the flow rates to each side may not be balanced and premature surging will
occur.

The most reliable inlet piping design for a double flow compressor utilizing a drum to
split the flow is shown in Fig. 4.72. While a Y with a proper upstream straight run of pipe may
seem like a good design, it should be noted that even the smallest disturbance in the piping
upstream of the Y will cause the flow to shift to one leg of the Y or the other.

More often than not, some type of trimming device (orifice plate, butterfly valve, or
others) is used in one or both legs of double flow compressors to equalize the flow. For this
reason, the most economical method may be to simply install a butterfly valve upstream of a
Y connection (Fig. 4.72).

Suggested piping for double flow compressor (left). D3 and D1 sized according to Fig.
4.69. Size D2 to achieve a velocity 1/4 of that in Fig. 4.69. Note that antisurge line should
be fitted to the knockout drum further upstream and not to this distribution drum.
Piping legs from the drum to each inlet must be identical mirror image of each other.
For a Y type splitter (right) note the large radius at the dividing point. A mitered type

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joint with a sharp, pointed dividing geometry could cause flow separation and uneven
distribution. A minimum of 10 pipe diameters is required upstream of the Y joint. Low
velocity (relative to Fig. 4.69) will help assure equal flow distribution.

Compressors Troubleshooting Guide

We must consider at the commission the following:
1. The correct assembly of the parts and the connections of the according to the
international standards.
2. The systems of the compressor must include the developed and accurate
instruments for best monitoring and protection.
3. We must take care during the commission tests in all cases of operating and
stopping of the compressor.

- All this factors lead to improve the operating efficiency of the machine troubles
free, and also decrease dangerous and the period of shutdown and emergency
cases.
- Otherwise when any troubles were happen it is important to consider all the
possible causes, and their suggested remedies.

* The following table lists the most common troubles, their possible causes, and the
suggested remedies.
Turbo compressor trouble shooting guide
Trouble Possible cause Correction
1. Low
lube oil Faulty lube oil pressure gage or Calibrate or replace.
pressure switch

Low oil level. Add oil.

Oil pump suction plugged Clean pump suction.

Leak in oil pump suction Tighten leaking connection

piping. Replace gaskets.

Clogged oil strainer / filter. Clean or replace oil strainer

or filter cartridge.

Relief valve improperly stuck Adjust relief valve.

Recondition or replace
or open. relief valve.
Incorrect pressure control Check control valve for
valve setting or operation. correct setting and
operation.

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Tighten flanged or threaded

Oil leakage. connections
Replace defective gaskets
or parts.

Check to see that lube oil

orifices are installed and
Bearing lube oil orifices are not obstructed. Refer to
missing or plugged. the lube system schematic
diagram for orifice
locations.
Clogged or restricted oil Clean or replace cooler.
cooler.

Failure of both main and Repair or replace pumps.

auxiliary oil pumps.

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Trouble Possible cause Correction

2) Excessive Temp. Gage (s) are faulty.
bearing oil Replace oil temp. gage (s)
Drain temp.
and/or Lower lube oil pressure.
Inadequate
bearing wear bearings. flow of lube oil to If pressure is satisfactory, check
for restrictions to flow of lube oil
to the affected bearings
Note:
Lube oil Change oil.
temp. Inspect and clean lube oil
leaving Poor condition of oil or dirt or strainer or filter.
Bearing gummy deposits in bearing. Inspect and clean bearings.
must not Check with oil supplier to see if
correct oil is being used.
exceed 95 C
Oil cooler is not receiving Clean or replace lube oil cooler.
adequate cooling water.
Replace bearing
Wiped bearing Determine and correct cause of
wiped bearing

Excessive oil viscosity Check oil requirements with oil

supplier.

Vibrations Refer to No. 3 in trouble column.

Water in lube oil Refer to No. 5 in trouble column.

Stone or chrome-plate journals.

Rough rotor shaft in journal Replace the shaft.
surface

Possible cause Correction

Shut down, dismantle, inspect

and correct, if any changes are
Improperly assembled parts made to the rotor, the rotor
should be balanced Perrier to
operation.
Check bolting at support
assemblies
Loose or broken bolting Check base plate bolting,
tighten or replace.

Piping strain. Inspect piping arrangement and

proper installation of pipe
hangers, springs, or expansion
joints.

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Sympathetic vibrations.
Shaft. Misalignment.
Worn or damaged coupling.
Bent rotor (caused by uneven Straighten or replace shaft.
heating or cooling).
Operating in critical speed range. Operate
Build up of deposits on rotor
Unbalanced rotor.
Damaged rotor.
Excessive bearing clearance.
Liquid slugs striking rotor.
Loose rotor parts.
Operating in surge region.
Centrifugal Compressors Trouble Shooting
Adjacent machinery can cause
vibration even the unit is shut
down, or at certain speeds due
to foundation or piping
resonance. A detailed
investigation is required in order
to take corrective measures.
Check shaft alignment operating
temperatures. Correct any
misalignment.
Replace the coupling.
speed
at other than the critical
Clean deposits from rotor
Check balance.
Inspect rotor for singes of
rubbing
Check rotor for concentricity,
cleanliness, looses parts.
Rebalance.
Replace or repair rotor
Rebalance rotor
Replace bearings.
Locate and remove the source
of liquid
Drain the casing of any
accumulated liquid.
Repair or replace the loose
parts.
Reduce speed until vibration
stops. Refer to No. 6 in trouble
column.
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Trouble Possible cause Correction

4) Units do Inspect for proper
not stay in installation of pipe hanger’s
alignment. springs and expansion
Piping strain. joints.
Inspect the piping
arrangement and correct as
necessary.
Check for possible setting
of the foundation support.
Warped foundation or base Correct
Check
footing as required.
for uneven temp.
plate. Surrounding the foundation
or base plate causing
distortion.
During operation, maintain
5) Water in a minimum lube oil
Lube oil. reservoir temp. of 50 OC to
permit separation of
Condensation in oil reservoir entrained water to avoid
excessive oil vaporization,
do not exceed a reservoir
temp. of 81 C.
Cooling water in oil Check and test tube oil
cooler.
Inadequate flow through the Refer to compressor surge.
compressor
Change in system resistance Properly position inlet or
6) due to obstruction or
Comp improper inlet or discharge discharge valves.
Remove obstructions.
ressor valve position.
surge.
Deposit build upon rotor or Mechanically clean the
diffusers restricting gas flow. rotor and diffusers.
7) Loss of
compressor Compressor not ups to Increase the required
discharge speed. operating speed
Pressure.
Correct cause of the
Excessive compressor inlet excessive
temp. Compressor inlet
temperature.
Leak in discharge. Repair leak.

Excessive system demand Reduce demand until

compressor discharge
from compressor. pressure returns to normal

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Trouble Possible cause Correction

8) Bearing
failure. Make sure that the oil used is as
Improper lubrication. prescribed. Check periodically
that there is no water or dirt in
the oil.

Misalignment. Check alignment, if necessary

correct.

Clearance of bearings beyond Check clearance, if necessary

allowable. correct.

Unbalancing of compressor See relative section under

coupling. vibrations.
9) Thrust
bearing Make sure that the coupling is
failure and mounted so as not to
Excessive axial thrust. transmit excessive thrust to the
compressor from the coupled
driver

Improper lubrication. Refer to section under bearing

failure.
10) Oil seal Refer to section under
ring failure. Misalignment and vibrations. vibrations.

Dirt in oil. Check conditions of filters and

replace dirty cartridges.

Clearance of rings not as Check clearance if necessary

prescribed. corrects.

Check that the reference gas

Insufficient oil pressure. pressure does not go below
minimum value.

11) Seal oil

pressure too Control valve for seal oil pressure Examine oil system beginning at
high incorrectly set or blocked. oil tank

Check temperature, pressure

Suction pressure of the
and flow; if the normal values
compressor or seal gas pressure
have changed, correct these to
changed
desired values.

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Trouble Possible cause Correction

12) Seal oil
Examine oil system, beginning
is aged in oil level in oil tank too low at oil tank
extent of the
normal.
Pumps suck in air.

Main or auxiliary oil pump

defective

Oil filter is fouled; differential

pressure at indicator is too high.

Drain or vent cooler or filter open Check temp., pressure and flow.

Seal oil control valves jammed in

open position or open bypass.

Level control valve of overhead

tank not in order.

Viscosity of the oil dropped due to

gas condensate.
13) Seal oil
Check oil supply plant, check oil
temperature Defects in the oil supply. pressure.
too high
Seal oil pressure too low, seal oil
Check oil flow.
flow too small.

Insufficient cooling of oil cooler. Check oil cooler.

14) Auxiliary
oil pump
does not
Operating voltage or control
start voltage for motor failing.
Check the control voltage
automaticall
y at dropping
oil pressure.
Defect in the electric system of Check the electric system of the
the pump automatics. pump automatics.

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Trouble Possible cause Correction

15) Oil Non-return devices in discharge
pumps lines jammed.
working
poorly Pumps and piping not vented
Check the pump system.
Coupling damaged.

Blow-off pressure of pump safety

valves set too low
16) Bearing
Examine oil system starting with
temperature Defects in the oil supply unit. the oil reservoir.
too high
Check the bearing clearances, if
Bearing damage due to fouling.
necessary, replace bearings.

Bearing clearance too small.

17) Bearing Oil level too low in the oil

Examine oil system starting with
oil pressure reservoir, pumps are sucking in the oil reservoir.
too low air.

Main and auxiliary oil pumps Check temp., pressure and flow
defective. through the bearings.

oil filter fouled, differential

pressure at indicator too high

Drain or vent of cooler or filter

open

Control valve jammed in open

position or by-pass open.
18) Oil
Cooler fouled. Check cooler
temperature
downstream
of oil cooler Not enough cooling water Check cooling water circuit
too high
19) Oil level
too low in Check oil supplies unit for
Leakage in the oil system.
the oil leakage.
reservoir

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Trouble Possible cause Correction

20)
Discharge The compressor is sucking in gas
Check cooling water flow.
temperature whose temperature is too high.
too high.
Check whether by-pass valve
By-pass valve (surge limit control)
must be open, check surge limit
is open.
control.

Insufficient cooling in after-cooler

inter cooler or condenser.

21) Surging
of the Check surge limit control
compressor Compressor is operated within an consisting of valve, controller,
unstable operating range. impulse transmitter and
electrical equipment.

Check valve position of the

Incorrect setting of surge limits surge limit control in the by-pass
control. or blow-off discharge line and
open the valve if necessary.

By-pass valve or blow-off valve of

the surge limit control is jammed

By-pass valve or blow-off valve of

the surge limit control is closed.

Valve in the discharge line of the

compressor is closed

No gas or not sufficient gas of the

delivered flow is carried off.

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