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Centrifugal Compressor Testing

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The centrifugal compressor testing article provides information about the centrifugal
compressor aerodynamic testing, mechanical running test, impeller overspeed test,
casing inspection and casing hydrostatic testing, impeller and rotor dynamic balancing,
vibration testing and analysis and gas leakage test. You may want to review the
centrifugal compressor inspection procedure and corresponding inspection and test
plan.

Centrifugal Compressor Aerodynamic Testing

The centrifugal compressor aerodynamic testing is performed after completion of the
assembly. The API Std. 617 requires that the aerodynamic testing being conducted
based on the requirements of ASME PTC-1997.

Based on the centrifugal compressor testing requirement minimum 5 datapoints

including surge and choke points shall be taken, and isentropic head vs. volumetric flow
be plotted. The test shall be repeated for different shaft speed, and similarly, the surge
points shall be identified.

The plotted aerodynamic performance curve shall be verified aginst approved

compressor datasheet and procedures to make sure is meeting the acceptance range
for the isentropic head, surge points, efficiency and power consumption.

Centrifugal Compressor Mechanical Running

Test
The mechanical running test is performed after Aerodynamic performance test. In the
mechanical running test, we are testing mechanical operation of the compressor. The
test shall be done based on approved test procedure.

The centrifugal comressor testing procedure or approved datasheet shall be used for
acceptance criteria. The test starts with minimum speed almost at 1000 rpm to identify
any abnormal issue and then increased to 100 % of MCS (maximum continuous speed)
at the rate increment of 10%.

For example, if the rotor speed (MCS) is 12000 rpm, in the first stage the rotor speed is
brought to 1200 rpm and then stays at this speed for a while and then is increased to
the 2400 rpm, and this process continues until reaches to 12000 rpm.

For example, if the rotor speed (MCS) is 12000 rpm, in the first stage the rotor speed is
brought to 1200 rpm and then stays at this speed for a while and then is increased to
the 2400 rpm, and this process continues until reaches to 12000 rpm.

Subsequently, the rotor speed shall be increased to the trip speed and run for 15 min.
The trip speed is 115% of MCS speed, and MCS speed is the highest rotor speed which
designed and tested and capable of continuous operation.

After this 15 min, the rotor speed is reduced to the 100 MCS and compressor runs for 4
hours. When the compressor reached to MCS speed shall run for 30 minutes to get all
variables such as oil temperature, pressure, bearing metal temperature and vibration
levels stabilized.

fter stabilization, the test technician starts the collection of measurements in each 10 or
15 minutes. At the end of the test, the mechanical running test result is provided in the
tabulated format.

The bearing metal temperature, lube oil temperature and pressure, seal oil temperature
and pressure, cooling water temperature and pressure, bearing housing vibration, shaft
vibration, and power consumption are the parameters that are measured in the
mechanical running test.

As per API 617, the job bearings, job vibration probes and job seals shall be used for
the mechanical running test.

The collected measurements are provided to the inspector at the end of the test, and it
is the responsibility of the inspector to verify the measurement aginst acceptance
criteria.

As mentioned the acceptance criteria could be found in the approved procedure or

compressor datasheet. For vibration acceptance criteria the test procedure or API 617
directly might be used depending on the project specification.

During the mechanical running test, the inspector shall make a visual inspection and
walk around of compressor and make sure there is no leak from piping joints or
compressor connections, and there is no abnormal noise, etc.

Centrifugal Compressor Impeller Overspeed Test

(Spin Test)
The compressor impeller overspeeding test is performed before rotor assembly.

In the first step, The impeller is subjected to the thorough dimensional inspection
before the test. The inside diameter (bore), outside diameter and eye seal are measured
and documented.

In the second step, the impeller mounted in the machine in a vacuum chamber (to
avoid windage) and then is rotated at the speed of 115% of the MCS for 1 minutes. The
impeller is subjected to the strong centrifugal force during this 1 minutes.

In the third Step, a second dimensional inspection shall be performed and checked
against first dimensional inspection. The change in the dimension is inevitable, but the
change shall be within the acceptance range.

API 617 is not providing acceptance range and refers that to the manufacturer
specification. The inspector shall review before and after dimensional inspection reports
and check that aginst manufacturer acceptance criteria and make sure the change in
dimension fall within acceptance range.

In the fourth step, the impeller is subjected to the dye penetration or magnetic particle
test to make sure no crack developed during impeller overspeeding test.
Centrifugal Compressor Casing Inspection
The compressor casing "material test report (MTR)" shall be reviewed. The casing either
is made by casting or forging. The material test report shall be verified aginst assigned
ASTM material standard and make sure the chemical composition, mechanical
properties e.g. tensile strength, yield strength, elongation and reduction of area are
within acceptance range.

The heat treatment type, holding time and temperature also shall be verified. In some
material type, the hardness value shall be measured by Brinell or Rockwell technique.
You should make sure you can locate the hardness value in the MTR, and the value is
less than maximum allowed value.

The API 617, contrary to the API 610 (for pumps) is not addressing the required visual
inspection and the nondestructive testing amount in compressor casing. The amount of
the testing depends on the agreement between compressor manufacturer and customer
but addresses the test methods and acceptance criteria for NDE testing.

You should check approved inspection and test plan to see what NDE testing being
considered for casing inspection and make sure you can locate those tests in the
casing MTR.

API 617 requires the PT test be performed by test method addressed at ASTM E165,
MT based on ASTM E709, UT based on ASTM A609 (casting) and ASTM A388
(forging) and RT based on ASTM E94.

The above mentioned ASTM standards are the test procedures, and you can not find
acceptance criteria there. The API 617 requires the test interpretation be performed
based on ASME Code Section VIII Div. 1 Appendix 7 (for Casting). This appendix
covers all above tests e.g. PT, MT, RT, and UT.

If you refer to this appendix, you will notice this appendix in some tests refers you to
some other ASTM standards. The most important ones are ASTM E446, ASTM E 186
and ASTM E280 for RT film interpretation.

These 3 standards have adjunct comparator radiographs that shall be used in film
interpretation. The RT technician shall match the actual compressor RT films with these
reference radiographs and decide about acceptability or unacceptability of the films.

You should review the NDE test report and make sure the NDE tests being interpreted
and reported aginst correct assigned standard. As you might know, an indication might
be a defect in one standard and be an acceptable imperfection based the other
standard.

The acceptance criteria for welded components such as nozzles and attachments are
referenced to ASME Section VIII Div.1 UW 51 and 52 for RT and Appendix 6 and 8 for
PT and MT and appendix 12 for UT.

After successful completion of the Material Test Report Review (NDE reports included),
you need to witness the hydrostatic testing.
Casing Hydrostatic Testing @ Centrifugal
Compressor Testing
The compressor casing shall be subjected to the hydrostatic testing, similar to the other
rotating equipment; the casing shall be tested at 1.5 times of maximum allowable
working pressure.

You as inspector or customer representative do not need to calculate the test pressure.
The test pressure should be read from approved hydrostatic test procedure or approved
compressor datasheet. The test result shall be considered satisfactory if no leak or
seepage observed in 30 minutes (minimum time that compressor casing shall be under
pressure).

The chloride content shall be less than 50 ppm if the casing material is the stainless
steel. The pressure gage shall be calibrated, and you should verify calibration and
expiration dates on the gage label and gage certificate.

The preferable pressure range gage is two times of the test pressure but in no case
shall be less than 1.5 times and more than 4 times of the test pressure.

Gas Leakage Test @ Centrifugal Compressor

Testing
The centrifugal compressor gas leakage test shall be performed after successful
completion of the mechanical running test. The compressor shall be pressurized with
inert gas to the maximum sealing pressure for 30 minutes. The test can be considered
as the last test which is performed in centrifugal compressor testing.

The compressor end seals (contract seals) shall in the installed condition. The
compressor shall be subjected to soap water bubble test. The bubble test can be done
based on the requirement of the ASME Section V - Article 10 - Leak testing.

Household detergent shall not be used for soapy water solution. The specific leak test
solution shall be purchased and used for the test. The test result would be satisfactory
if no bubble development observed from joints, connections, etc.

Vibration Test & Analysis @ Centrifugal

Compressor Testing

The API 617 only requires the centrifugal compressor vibration test and analysis being
performed at shaft adjacent to the bearings during the aerodynamic performance test
and in the mechanical running test. The proximitor probe is used for measurement and
usually is handled by 4 probes, two for suction bearings X and Y axises and two for
discharge bearing same X and Y axises.

You may also review the Third Party Inspection for Centrifugal Compressor article which
can be considered a inspection instruction for centrifugal compressor testing and
inspection.

You may also need a sample centrifugal compressor inspection and test plan.
The following content provides a sample general centrifugal compressor testing
procedure which might be useful. The acceptance criteria have not been addressed in
this test procedure. This is a very brief and general procedure.

Applicable Standards @ Centrifugal Compressor Testing

The applicable standards for centrifugal compressor testing are:

API Standard 617; Centrifugal Compressor for Petroleum, Chemical and Gas
Service Industries
ASME PTC 10; Performance Test Code on Compressors and Exhausters
BS EN ISO 5167-2; Measurement of fluid flow by means of pressure differential
devices inserted in circular cross-section conduits running full - Part 2: Orifice
plates
BS ISO 5389 Turbo compressors Performance Test Code

Required Data for Centrifugal Compressor Mechanical Running Test

Following data need to be extracted for centrifugal compressor testing from design
documents, datasheet and operating manual and to be available during the test.

Specified Operating Speeds

Normal Operating Speed

Minimum Operating Speed
Maximum Continuous Speed
Trip Speed

Maximum Shaft Vibration

At Maximum Continuous Speed

At Trip Speed

Lube Oil Data

Oil Viscosity Class

Oil Inlet Temperature
Oil Inlet Pressure
Maximum Oil Volume Flow Of Compressor

Shaft Seals

Seal Type
Seal Medium
Preparation for Centrifugal Compressor Mechanical Running Test

Typically a checklist is used to ensure all items are based on design and actual
operating condition.

The following components are used from Centrifugal Compressor Testing Stand (Not
Contract Items)

Drive unit (Electric motor)

Gear box
Coupling (poss. with adapter)
Intercooler
Oil unit
Process gas piping
Instruments
Vibration monitoring system
Data acquisition equipment

The following components are used from centrifugal compressor (original)

Coupling (poss. with adapter) X

Seal gas panel
Instruments
Shaft vibration measurement equipment

Note: The coupling and instruments are used from both systems i.e. test stand and
original components of compressor

Centrifugal Compressor Testing - Mechanical Running Test

The mechanical running test is done with the following sequence:

1. The speed increase from standstill up to minimum driver control speed.

2. Speed increase in steps of approx. 10% of maximum continuous speed up to
maximum continuous speed (MCS) under consideration of the lateral natural
frequencies.
3. Continuations of operation until lube oil and bearing temperatures have stabilized.
4. Speed increases up to trip speed. Test runs for 15 minutes at trip. Babbitt metal
temperatures, oil inlet and outlet temperatures and pressures and the overall oil
volume flow are measured and recorded once. Shaft vibrations are measured and
recorded once at all contact measuring locations.
5. Speed deceleration to MCS. Test runs for 4 hours at MCS. Babbitt metal
 temperatures, oil inlet and outlet temperatures and pressures and the overall oil
volume flow are measured and recorded in intervals of about 20 minutes. Inlet and
outlet temperatures and pressures of the handled fluid are measured and
recorded. Shaft vibrations are measured and recorded at all existing measurement
points in intervals of about 20 minutes. A vibration spectra analysis is carried out
approximately in the middle of the 4 hours test run.
6. Speed increase up to trip speed.
7. Speed deceleration to final standstill.

Unfiltered and filtered displacement amplitudes and the corresponding phase angles will
be recorded and plotted vs. speed during coast down. Bode plots during coast down.

After completion of the mechanical running test and after sufficient cooling-down the
compressor will be checked according to the inspection and test plan.

Centrifugal Compressor Testing - Vibration Measurements & Analysis

Shaft vibrations and axial displacements are measured. Vibration measurements are
carried out with the vendor measuring system. All other necessary instrumentation for
vibration analysis needs to be available by centrifugal compressor vendors.

For assessment of the allowable amplitudes of the shaft vibrations according to design
the monitoring systems installed in the test stand are used. For visualization and
preparing plots a mobile diagnostic system are used.

Run out is determined and recorded. Only these values are binding for the machine. At
low speed the shaft vibration monitor only indicates the slow-roll-signal.

If the measured slow-roll-signal values during the test run exceed distinctly the specified
run out values, run out are controlled and, if necessary, refurbished after completion of
the test run without repeating the test run.

Required Data for Thermodynamic Performance Test

Following data need to be extracted from a centrifugal compressor design book,

datasheet and operating manual and to be available for calculations.

Operating Conditions

Gas Type
Mass Flow, Wet

Inlet conditions
 Pressure
Temperature
Relative Humidity
Inlet Volume, Wet

Discharge Conditions

Pressure
Temperature

Performance

Shaft power at compressor coupling (incl. losses)

Compressor speed
Polytropic head
Polytropic efficiency

Similarly the centrifugal compressor testing medium and related operating parameter
need to be identified. N2 normally is used as the test medium. Following also need be
specified:

Test Meduim Inlet Condition

Pressure
Temperature
Relative Humidity
Gas Constant X Compressibility Factor
Inlet Volume Flow, Dry

Test Meduim Discharge Condition

Pressure
Temperature

Performance

Gas Power
Compressor Speed

Centrifugal Compressor Testing - Thermodynamic Performance Test Procedure

Before starting the thermodynamic performance test the compressor is operated for a
sufficient period of time at the calculated test conditions to demonstrate acceptable
mechanical operation and stable values of all measurements.
All instruments are inspected separately and the measured variables in identical
measuring planes are compared to each other.

The duration of the test is depending on the time needed to reach steady-state test
conditions. This condition is insured by steady-state values of pressures and
temperatures.

An automated data acquisition system is used. The data are recorded, processed and
displayed online.

Centrifugal Compressor Testing - Measuring and Analysis

Previous to the test all measuring instruments for pressure and temperature are
calibrated. On customer's request the calibration can be redone after the test for one
instrument each for pressure and temperature at the inlet and discharge port.

The inlet and discharge pressures and temperatures are measured on centrifugal
compressor testing on the basis of the applicable documents.

The mass flow is measured according to BS EN ISO 5167-2

The shaft power will be calculated with the heat balance method.

For the mechanical power losses the design value is used.

The Reynolds Number correction is done in accordance to ICAAMC.

Measuring uncertainty per BS ISO 5389

Related Articles:

TPI Inspection for Reciprocating Compressor, TPI Inspection for Centrifugal Pump, TPI
Inspection for Gas Turbine, TPI Inspection for Steam Turbine, TPI Inspection for Fan
and Blower, Screw Compressor Testing, Centrifugal Pump Performance Test,
Reciprocating Compressor Testing, Fan Mechanical Running test, Fan Performance
Test

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