Centrifugal Compressor Commissioning

11/12/2019 Centrifugal Compressor Testing
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provides information about the centrifugal
compressor aerodynamic testing,
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mechanical running test, impeller overspeed
test, casing inspection and casing
hydrostatic testing, impeller and rotor
GENERAL I4I Academy -
dynamic balancing, vibration testing and
Video Training
Pre-Shipment analysis and gas leakage test. You may want
Inspection to review the centrifugal compressor
inspection procedure and corresponding
Third Party inspection and test plan.
Inspection
Vendor
Inspection
Centrifugal Compressor
Commodity
Aerodynamic Testing
Inspection API 510 Training -
The centrifugal compressor aerodynamic
Exam Prep Course
Inspection and testing is performed after completion of the
Test Plan assembly. The API Std. 617 requires that the
aerodynamic testing being conducted based
Factory
on the requirements of ASME PTC-1997.
Acceptance Test
Based on the centrifugal compressor testing

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Industrial
Inspection
Quality Control
Plant Inspection
Coating
API 510 Exam
Inspection
Questions Package
I4I
ACADEMY
I4I Academy
Courses
requirement minimum 5 datapoints including
API 510 Training
surge and choke points shall be taken, and
- Prep Course API 570 Training -
isentropic head vs. volumetric flow be
Exam Prep Course
API 510 Exam plotted. The test shall be repeated for
Questions different shaft speed, and similarly, the surge
Package points shall be identified.
API 570 Training

The plotted aerodynamic performance curve
- Prep Course
shall be verified aginst approved compressor
API 570 Exam datasheet and procedures to make sure is
Questions meeting the acceptance range for the
Package isentropic head, surge points, efficiency and API 570 Exam
power consumption. Questions Package
CWI
Endorsement
Course
ASME Training Mechanical Running
Course
Test
ASME IX
Training Course The mechanical running test is performed
after Aerodynamic performance test. In the
CWI Endorsement
mechanical running test, we are testing
FIX mechanical operation of the compressor.
Training - Prep
EQUIPMENT The test shall be done based on approved

test procedure.
Pressure Vessel The centrifugal comressor testing procedure

or approved datasheet shall be used for
Heat Exchanger
acceptance criteria. The test starts with
Piping System minimum speed almost at 1000 rpm to
identify any abnormal issue and then
Industrial Valve
increased to 100 % of MCS (maximum
Steam Boiler continuous speed) at the rate increment of ASME Training
10%. Course
Storage Tank
Process Heater 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
ROTARY speed for a while and then is increased to
EQUIPMENT the 2400 rpm, and this process continues
until reaches to 12000 rpm.
Centrifugal
ASME IX Training
Pump
Course
Centrifugal
Compressor
Reciprocating
Compressor
Gas Turbine
Steam Turbine
Fan & Blower

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
E&I speed for a while and then is increased to
EQUIPMENT the 2400 rpm, and this process continues
until reaches to 12000 rpm.
Electric
Generator Subsequently, the rotor speed shall be
Electric Motor increased to the trip speed and run for 15
min. The trip speed is 115% of MCS speed,
Power
and MCS speed is the highest rotor speed
Transformer which designed and tested and capable of
Control Panel continuous operation.
Switchgear
Power Cable After this 15 min, the rotor speed is reduced

to the 100 MCS and compressor runs for 4
hours. When the compressor reached to
GET IN MCS speed shall run for 30 minutes to get all
variables such as oil temperature, pressure,
TOUCH
bearing metal temperature and vibration
About Me levels stabilized.
Contact fter stabilization, the test technician starts the

I4I Academy collection of measurements in each 10 or 15
Contact minutes. At the end of the test, the
mechanical running test result is provided in
Services the tabulated format.
Blog
The bearing metal temperature, lube oil
Privacy Policy
temperature and pressure, seal oil
temperature and pressure, cooling water
temperature and pressure, bearing housing
We will be updating vibration, shaft vibration, and power
and growing this consumption are the parameters that are
site with more and measured in the mechanical running test.
more of industrial
inspection related
As per API 617, the job bearings, job
articles.
vibration probes and job seals shall be used
for the mechanical running test.
Please subscribe to
my monthly
newsletter so you The collected measurements are provided to
don't miss a thing. the inspector at the end of the test, and it is
the responsibility of the inspector to verify
the measurement aginst acceptance criteria.
Email
As mentioned the acceptance criteria could

be found in the approved procedure or
Enter Your First compressor datasheet. For vibration
Name (optional) acceptance criteria the test procedure or API
617 directly might be used depending on the
project specification.
I am at least 16
years of age. During the mechanical running test, the
inspector shall make a visual inspection and
walk around of compressor and make sure

I have read
and accept the there is no leak from piping joints or
privacy policy. compressor connections, and there is no
abnormal noise, etc.
I understand
that you will use
my information to
send me a
newsletter. Impeller Overspeed Test
Subscribe
(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.
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.

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

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.

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
Return to Inspection for Industry Home
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11/12/2019 Centrifugal Compressor Testing

Home General I4I Academy Fix Equipment Rotary Equipment

E & I Equipment Get in Touch

Did you find this Centrifugal Compressor Follow on

Based on the centrifugal compressor testing

API 570 Training

EQUIPMENT The test shall be done based on approved

Pressure Vessel The centrifugal comressor testing procedure

Process Heater For example, if the rotor speed (MCS) is

Fan & Blower

Power Cable After this 15 min, the rotor speed is reduced

About Me levels stabilized.

Contact fter stabilization, the test technician starts the

As mentioned the acceptance criteria could

walk around of compressor and make sure

In the second step, the impeller mounted in

In the third Step, a second dimensional

providing acceptance range and refers that

In the fourth step, the impeller is subjected

The heat treatment type, holding time and

hardness value in the MTR, and the value is

The API 617, contrary to the API 610 (for

You should check approved inspection and

API 617 requires the PT test be performed

The above mentioned ASTM standards are

covers all above tests e.g. PT, MT, RT, and

If you refer to this appendix, you will notice

These 3 standards have adjunct comparator

You should review the NDE test report and

acceptable imperfection based the other

The acceptance criteria for welded

After successful completion of the Material

You as inspector or customer representative

approved compressor datasheet. The test

The chloride content shall be less than 50

The preferable pressure range gage is two

Gas Leakage Test

The compressor end seals (contract seals)

Household detergent shall not be used for

Vibration Test & Analysis

The API 617 only requires the centrifugal

You may also review the Third Party

You may also need a sample centrifugal

The following content provides a sample

Applicable Standards @ Centrifugal

The applicable standards for centrifugal

API Standard 617; Centrifugal

Required Data for Centrifugal

Following data need to be extracted for

Specified Operating Speeds

Normal Operating Speed

Maximum Continuous Speed

Maximum Shaft Vibration

At Maximum Continuous Speed

Lube Oil Data

Oil Viscosity Class

Preparation for Centrifugal Compressor

Typically a checklist is used to ensure all

The following components are used from

Drive unit (Electric motor)

The following components are used from

Coupling (poss. with adapter) X

Note: The coupling and instruments are used

Centrifugal Compressor Testing -