TOM Training Centrifugal Compressors

Section 08 Trouble shooting Power Generation Industrial Applications

Troubleshooting

Introduction

Before we go into this section: troubleshooting, possible causes and their

corrections, we should like to highlight one essential point ; Manufacturer
support.

Besides assisting with technical information, the manufacturer is in a

position to furnish experienced service personnel for troubleshooting on site.
Another important point is that the manufacturer will look beyond the
immediate problem and, if advisable, recommend and carry out
modifications in line with advanced design knowledge in order to improve
compressor operation and prevent recurrence of the problem.
The same policy also applies to repairs and spare parts, whereby any new
design and material selection will be incorporated where possible. Although
interchangeability is retained, the quality of a spare may be superior to that
of the original part.

To troubleshoot any problem it is important to have a Methodical Procedure.

This is necessary to pinpoint the root cause of the situation. e.g. the
following outline:

1. Define the problem ( what , where, when )

a) What exactly is the problem ?
b) What is the expected situation ?
c) What is the current situation ?
d) What was the previous situation ?

2. Outline the history of the compressor or the components.

a) How long has it been operating ?
b) When was the last overhaul ?
c) What changes were made during the overhaul ?
d) When did the problem start ?
( after overhaul, after operating for a period of time )
e) Was it a quick or gradual change ?
f) Trend of the various parameters ( pressure, temperature, speed )
g) Is the problem ; increasing, decreasing, continuous, intermittent ?

3. Verify all data

a) Have instruments been calibrated ?
b) Are the readings correct ?

Aids for Troubleshooting

P&I Diagrams
Cross sectional drawings
Operating Instructions

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TOM Training Centrifugal Compressors
Section 08 Trouble shooting Power Generation Industrial Applications

TROUBLE POSSIBLE CAUSE CORRECTIVE ACTION

Compressor Inadequate flow through the Increase flow.

surges compressor
Change in system resistance
due to obstruction or improper
valve position
Deposit build up on rotor or
diffusers restricting gas flow
Control system defective.
Check the position of all valves.
(Bypass, Blow off, Suction, Discharge)
Clean the rotor and diffusers.
(Wash system installed ?)
Check whether the auxiliary energy and
controller impulse are effective.
Eliminate the trouble, further operation
inadmissible.

Compressor runs Non - return valve not Close block valves in gas line. Check non
in reverse functioning -return valve.

Loss of Excessive system demand Reduce demand until compressor

compressor dis- from compressor discharge pressure returns to normal.
charge pressure Leak in discharge piping Inspect piping for escaping gas.
High compressor inlet temp Investigate and correct it.

Compressor not up to speed Increase the required operating speed

Discharge pressure control Check transmitters and controllers. The

system defective energy supply may be defective.
Incorrect inlet guide vane unit Correct it.
adjustment

Discharge Impellers are fouled Clean impellers, then make balance test
temperature of and refit.
compressor Excessive discharge pressure Reduce gas intake temperature if high
increases Reduce opening position of inlet guide
vane unit. (geared type compressor).
Check delivery pressure controller.

Intake Insufficient intercooling Increase water throughput by opening the

temperature water valves.
increases in Check water inlet temperature.
individual stages Check coolers.
Thermometer defective Check it, replace as necessary.

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TOM Training Centrifugal Compressors
Section 08 Trouble shooting Power Generation Industrial Applications

TROUBLE POSSIBLE CAUSE CORRECTIVE ACTION

Maximum intake Intake temperature too high
volume drops
Intake filter is fouled
Impellers and/or volutes are
fouled
Climatic factor if medium is taken in from
atmosphere.
Clean or replace the filter cassettes.
Continuous strip filter is exhausted or
jammed.
Check automatic filter switching system.
Clean impellers and volutes, then check
balance and refit.

Process coolers Intertake temp. excessively Climatic factor if medium sucked from
excessive water high atmosphere.
consumption Cooling water inlet temp. is too Check it .
high
Cooler leaking Remove cooler, carry out pressure test.

Cooler fouled Remove cooler, clean gas and water side.

Compressor fouled Clean impeller and volute, then balance

check and refit.

Water in lube oil Condensation in oil reservoir
Leak in lube oil cooler
During operation, maintain a min. oil
temp. of ~ 50°C to permit separation of
entrained water. To avoid excessive oil
vaporisation, do not exceed an oil
temperature of ~ 65°C. When shutting
down, stop cooling water flow to the oil
cooler when bearing oil drain
temperature is equal to the lube oil cooler
outlet temperature
Hydrostatically test the cooler for leaks
and repair as necessary.

Low lube oil Faulty lube oil pressure gauge Calibrate or replace.
press., or, lube or switch
oil pressure
Low level in oil reservoir Add oil to bring the reservoir to proper
drops slowly
operating level.
Oil pump suction plugged Shut down, drain lube oil reservoir.
Inspect and clear the pump suction.
Leak in oil pump suction piping Tighten leaking connections if possible
and/or replace gaskets.

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TOM Training Centrifugal Compressors
Section 08 Trouble shooting Power Generation Industrial Applications

TROUBLE POSSIBLE CAUSE CORRECTIVE ACTION

Low lube oil Clogged oil strainer/filter Inspect and clean, or replace oil strainer
press., or, lube or filter cartridges.
oil pressure
drops slowly Failure of oil pumps Check the operation.
Relief valve improperly set or Check the valve for correct setting and
stuck open proper operation.
Incorrect pressure control valve Check the valve for correct setting and
setting or operation proper operation.
Leak in oil lines Repair leaks.
Bearing damaged Replace with new bearing.

Excessive Inadequate or restricted flow of Check oil pressure gauge, check sight
bearing oil drain lube oil to bearings flow indicators, check for restrictions in
temp. and/or flow of lube oil to the affected bearing.
bearing wear
Inferior grade of oil. Change oil.
Poor conditions of lube oil orPrevent emulsification of oil by increasing
dirt or deposits in bearing frequency of oil changes until conditions
have been cleared up. Inspect and clean
strainer or filters more frequently. Inspect
and clean bearings. Recondition of oil by
centrifugation.
Inadequate cooling water flow Increase cooling water flow. Check the
through lube oil cooler cooling water inlet temperature against
design conditions.
Fouled lube oil cooler. Inspect and clean the cooler.

Wiped bearing Inspect bearing pads and replace as

Rough journal surface.
Water in lube oil
required. Determine and correct cause of
bearing failure prior to operation.
If scoring is excessive and polishing or
chrome-plating is impractical, replace
shaft, or grind shaft down and use smaller
bearings.
See "Water in lube oil " column.

Vibration See " Excessive vibration " column.

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TOM Training Centrifugal Compressors
Section 08 Trouble shooting
TROUBLE POSSIBLE CAUSE
Excessive vibra- Shaft misalignment
tion
Oil supply to coupling
inadequate
Worn or damaged coupling
Operating in surge region
Operation at or near critical Operate at other than the critical speed.
speed
Uneven build up of deposits on Shutdown and inspect the rotor. Clean
rotor/impeller
Unbalanced rotor or warped
shaft due to severe rubbing
Excessive bearing clearances Check bearing clearances. Check for
Bent rotor
Liquid slugs striking the
impellers
Improperly assembled parts
Loose or broken bolting
Piping strain
Units do not stay Piping strain
in alignment
Distorted foundation
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Power Generation Industrial Applications
CORRECTIVE ACTION
Check shaft alignment at operating
temperature, correct any misalignment.
Inspect and restore the coupling.
Replace the coupling.
Refer to "Compr. surge " column
the parts. Check balance.
Shutdown, dismantle the unit and inspect
for signs of rubbing at all points where it
could come into contact with a stationary
part.
rough or uneven surfaces and evidence
of pounding. Replace the bearing, if
clearances are excessive.
Shutdown and disassemble the unit,
check run out, if excessive ,replace the
rotor.
Locate and remove the source of liquid.
Drain the casing of any accumulated
liquid.
Listen to rubbing noises, particularly at
seals. Locate source of noise, shut down,
dismantle, inspect and repair. Balance the
rotor !
Check bolting at support assemblies.
Check bedplate bolting. Tighten.
Compressor inlet and discharge piping
should be installed in such a manner as
to limit piping strain. Inspect for proper
installation and correct any deficiencies.
Compressor inlet and discharge piping
should be installed in such a manner as
to limit piping strain. Inspect for proper
installation and correct any deficiencies.
Check for possible settling of the
foundation support. Correct compressor
mounting and alignment as required.
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