Best Practice

SABP-G-004 Centrifugal Compressors Dynamic Analysis Factory Acceptance Test Document Responsibility: Consulting Services Dept. 31 October, 2004

Saudi Aramco DeskTop Standards

Table of Contents 1 2 3 4 5 6 7 8 Introduction.................................................... 2 References.................................................... 2 General.......................................................... 3 Definitions...................................................... 3 Vibration Detectors........................................ 4 Shop Verification of Unbalanced Response Analysis ...... 4 Tests Procedure............................................ 5 FAT Acceptance Criteria.................................6

Previous Issue: New Next Planned Update: 1 November, 2009 Revised paragraphs are indicated in the right margin Primary contact: Khaleel M. Al-Hussain on 873-0311

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Document Responsibility: Consulting Services Dept. Issue Date: 31 October, 2004 Next Planned Update: 1 July, 2009

SABP-G-004 Centrifugal Compressors Dynamic Analysis Factory Acceptance Test

Introduction 1.1 Purpose The purpose of this Practice is to establish guidelines in reviewing the dynamic analysis of centrifugal compressors during Factory Acceptance Test (FAT). 1.2 Scope This Best Practice gives general guidelines for reviewing vibration instrumentation requirements, test procedure and acceptance limits during the Factory Acceptance Test and does not include performance test criteria. 1.3 Disclaimer This Best Practice is being provided for the general guidance and benefit of Saudi Aramco engineers attending centrifugal compressors Factory Acceptance Test (FAT). The use of this Best Practice during factory acceptance test, however, does not relieve the manufacturer from his responsibility or duty to confirm or to verify the accuracy of any information presented or from his contractual liability to perform an accurate FAT that conforms to Mandatory Saudi Aramco Engineering Requirements. The use of the information or material contained herein will not guarantee that the resulting product satisfies the applicable requirements of Saudi Aramco Standards. Saudi Aramco assumes no responsibility or liability whatsoever for any reliance on the information presented herein or for FAT performed by manufacturer in accordance with this Best Practice document. Moreover, this Best practice is intended only to provide guidelines for Saudi Aramco engineers attending the Factory Acceptance Test and shall not be considered as a replacement for the Mandatory Saudi Aramco Engineering Requirements. Saudi Aramco is a registered trademark of the Saudi Arabian Oil Company. Copyright, Saudi Aramco, 2004. 1.4 Conflicts with Mandatory Standards In the event of a conflict between this Best Practice and other Mandatory Saudi Aramco Engineering Requirement, the Mandatory Saudi Aramco Engineering Requirement shall govern.

References This Best Practice is based on the below referenced standards: 2.1 Saudi Aramco References

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Document Responsibility: Consulting Services Dept. Issue Date: 31 October, 2004 Next Planned Update: 1 July, 2009

SABP-G-004 Centrifugal Compressors Dynamic Analysis Factory Acceptance Test

Saudi Aramco Engineering Standard SAES-K-402 Centrifugal Compressor (30 July, 2003)

Saudi Aramco Materials System Specifications 31-SAMSS-001 34-SAMSS-625 2.2 Centrifugal Compressor (30 September, 2003) Machinery Protection Systems (30 June, 2002)

Industry Codes and Standards American Petroleum Institute (API) API STD 617 API STD 670 Centrifugal Compressors for Petroleum, Chemical and Gas Services Industries, 6th Edition Machinery Protection Systems, 4th Edition

General This best practice gives general guidelines for the vibration instrumentation requirements, test procedure and acceptable limits during centrifugal compressors factory acceptance test. The attendee should review the rotordynamic analysis prior the test. The Vendor shall submit written test procedures for all tests through the Company or Buyer Representative for approval by the Coordinator, Rotating Equipment Division, Consulting Services Department, Saudi Aramco at least 10 weeks prior to scheduled test (31-SAMSS-001 /P 4.3.1.2). The vendor shall notify the purchaser not less than five working days before the date the equipment will be ready for testing. If the testing is rescheduled, the vendor shall notify the purchaser not less than five working days before the new test date (API STD 617/ P 4.3.1.3). However, it is suggested that the vendor send notification six weeks prier any witness test.

Definitions Factory Acceptance Test (FAT): A performance/mechnical running tests conducted at the factory to check the integrity of the machine. Acceptance Vibration Level: This is the vibration level (displacement) at which a machine can run indefinitely without inducing vibration related maintenance. Normal Speed: The speed corresponding to the requirements of the normal operating point (API STD 617/ P 1.4.14).

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Document Responsibility: Consulting Services Dept. Issue Date: 31 October, 2004 Next Planned Update: 1 July, 2009

SABP-G-004 Centrifugal Compressors Dynamic Analysis Factory Acceptance Test

Normal Operation point: The point at which usual operation is expected and optimum efficiency is desired. This point is usually the point at which the vendor certifies that performance is within the tolerances stated in this standard (API STD 617/ P 1.4.13). Minimum Allowable Speed (in revolutions per minute): The lowest speed at which the manufacturer's design will permit continuous operation (API STD 617/ P 1.4.12). Maximum Continuous Speed (in revolutions per minute): The speed at least equal to 105% of the highest speed required by any of the specified operating conditions (for compressors driven by variable-speed prime movers). Maximum continuous speed for constant-speed drivers shall be equal to the 100% speed (API STD 617/ P 1.4.10). 5 Vibration Detectors Vibration detection equipment shall be provided as per the below Table-1(for more detail see 31-SAMSS-001 paragraph 3.4.1): Table-1: Required Vibration Instrumentation for Centrifugal Compressors
Machine Train Centrifugal Compressor Applicable Standard 31-SAMSS-001 (Sec. 3.4.7.1) Relative Measurement Radial X&Y Thrust Key Dual Yes Seismic Measurement Reading at the monitor Velocity Acceleration

Vibration detectors shall be provided, installed and calibrated in accordance with 34-SAMSS-625. 6 Shop Verification of Unbalanced Response Analysis 6.1 Shop verification of unbalanced response analysis shall be performed as part of the mechanical running test and the results shall be used to verify the analytical model (API STD 617 /P 2.9.3.1). The method to conduct the shop verification test is described in API STD 617 & 31-SAMSS-001 section 2.9.3. The results of the verification test shall be compared with those from the original analytical model. The vendor shall correct the model if it fails to meet any of the following criteria (API STD 617 /P 2.9.3.2.2): a) b) c) The actual critical speeds shall not deviate from the predicted speeds by more than 5%. The predicted amplification factors shall not deviate from the actual teststand values by more than 20%. The actual response peak amplitudes, including those are critically damped, shall be within 50% of the predicted amplitudes.
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6.2

Document Responsibility: Consulting Services Dept. Issue Date: 31 October, 2004 Next Planned Update: 1 July, 2009

SABP-G-004 Centrifugal Compressors Dynamic Analysis Factory Acceptance Test

6.3

When the test data does not meet the requirements of API STD 617, paragraph 2.9.3., additional more stringent testing is required as per API STD 617 and 31-SAMSS-001, paragraph 2.9.3.4. The purpose of this additional testing is to determine on the test stand that the machine will operate successfully.

Tests Procedure 7.1 All purchased vibration probes, transducers, oscillator-demodulators, and accelerometers shall be in use during the test. If vibration probes are not furnished by the compressor vendor, or if the purchased probes are not compatible with shop readout facilities, then shop probes and readouts that meet the accuracy requirements of API STD 670 shall be used (API STD 617/ P 4.3.4.1.8). Vendor shall prove compatibility between the contract probes and his test stand readout equipment. Contract radial vibration and axial position probes and oscillator- demodulators shall be used during the shop test. Calibration of the vibration probe and monitor circuits to be used shall be verified immediately prior to the test, utilizing a wobulator or equivalent device or method (31-SAMSS-001 / P 4.3.4.1.8). Shop test facilities shall include instrumentation with the capability of continuously monitoring and plotting revolutions per minute, peak-to-peak displacement and phase angle. Presentation of vibration displacement and phase marker shall also be by oscilloscope (API STD 617 / P 4.3.4.1.9). As a minimum, the FFT spectra range shall cover a frequency range from 0.25-8 times the maximum continuous speed but not more than 1500 hertz (API STD 617/ P 4.3.4.3.2). Plots showing synchronous vibration amplitude and phase angle versus speed for deceleration shall be made before and after the 4-hour run. Plots shall be made of both the filtered (one per revolution) and unfiltered vibration levels. Polar plots from the testing shall be furnished to the Purchaser immediately following the testing. The speed range covered by these plots shall be zero to the specified driver trip speed (API STD 617 & 31-SAMSS-001 / P 4.3.4.3.3). The combined total electrical and mechanical runout is presented in Table-2 (for more detail refer to API STD 617 paragraph 2.6.5):

7.2

7.3

7.4

7.5

7.6

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Document Responsibility: Consulting Services Dept. Issue Date: 31 October, 2004 Next Planned Update: 1 July, 2009

SABP-G-004 Centrifugal Compressors Dynamic Analysis Factory Acceptance Test

Table-2: Allowable Total Runout

Probes Location Radial Applicable Standard Allowable Total Runout (TR) whichever is greater TR 0.25 x maximum allowed pk-pk vibration amplitude TR 0.25 mils pk-pk

API STD 617 (Sec. 2.6.5)

API STD 617 Axial (Sec. 2.6.5)

whichever is greater TR 0.25 x maximum allowed pk-pk vibration amplitude TR 0.5 mils pk-pk

Note:

If the vendor can demonstrate that electrical or mechanical runout is present, a maximum of 25% of the maximum allowed pk-pk vibration amplitude, or 6.4 micrometers (0.25 mil), whichever is greater, may be vectorially subtracted from the vibration signal measured during the factory test (API STD 617/ P2.9.5.7).

7.7

Electrical and mechanical runout shall be determined and recorded by rolling the rotor in V-blocks at the journal centerline while measuring runout with a noncontacting vibration probe and a dial indicator at the same shaft location (API STD 617 / P 2.9.5.6). The mechanical running test shall verify that lateral critical speeds conform to the requirements of API STD 617 paragraph 2.9.2 and 2.9.3. Actual critical speed shall be determined on the test stand. The results of the balance and unbalance response test shall be plotted on the calculated curves for confirmation of analysis validity (API STD 617 & 31-SAMSS-001/ P 4.3.4.3.4). The equipment shall be operated at speed increments of approximately 10% from zero to the maximum continuous speed and run at the maximum continuous speed until bearings, lube-oil temperature and shaft vibrations have stabilized (API STD 617/ P 4.3.4.2.1). The speed shall be increased to trip speed and the equipment shall be run for a minimum of 15 minutes (API STD 617/ P 4.3.4.2.2).

7.8

7.9

7.10

FAT Acceptance Criteria While the equipment is operating at maximum continuous speed and at other speeds within the specified operating speed range, sweeps shall be made for vibration amplitudes and frequencies. The measured vibration shall not exceed the limits in Table-3. The below steps 1 to 3 specify the FAT vibration values that need to be checked.

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Document Responsibility: Consulting Services Dept. Issue Date: 31 October, 2004 Next Planned Update: 1 July, 2009

SABP-G-004 Centrifugal Compressors Dynamic Analysis Factory Acceptance Test

1.

The peak-to-peak amplitude of unfiltered vibration in any plane, measured on the shaft adjacent and relative to each radial bearing, at the maximum continuous speed or at any other speed within the specified operating speed range shall not exceed the overall limit specified in Table-3 (API STD 617 /P 2.9.5.5). The frequency spectrum at the maximum continuous speed and at other speeds that may have been specified in the test agenda should be checked to identify the highest amplitude (excluding the runing speed) and ensure that it does not exceed the maximum limit for discrete frequency amplitude specified in Table-3. At any speed grater than the maximum continuous speed, up to and including the trip speed of the driver, the vibration should not exceed 150% of the maximum value recorded at the maximum continuous speed (API STD 617/ P 2.9.5.5). Table-3: Vibration Limits for Centrifugal Compressor
Location of vibration Measurement Item

2.

3.

Compressor Shaft (adjacent to bearing)

(i) Maximum continuous speed or at any other speed within the specified operating speed range

Overall

whichever is less Au (7.74X106 /N)05 m pk-pk 05 ((12000/N) mils pk-pk)

Au 25 m pk-pk
(1.0 mils pk-pk) Discrete frequencies (other than N) 20% of the above allowable overall limit Af 0.2 x Au (API STD 617 / P 4.3.4.3.2)

(ii) Vibration limits at any speed greater than the maximum continuous speed, up to and including the trip speed

150 % of the recorded value at maximum continues speed

Where: Au = unfiltered displacement determined by FFT. Af = discrete frequencies, non-synchronous, displacement

N = rotational speed (RPM).

determined by FFT.

31 October, 2004

Revision Summary New Saudi Aramco Best Practice.

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