What Went Wrong?
BY W. NORM SHADE
No company, product, or individual is immune from
experiencing failures or shortcomings. The solution to
these problems can often result in new “best practices.”
By relating some of these real case histories, it is hoped
that the lessons learned will be educational to the read-
ers. In each case, a failure or incident is described and the
question is asked, “What went wrong?” In each case, the
answer (or at least the best speculation) and the solution
that was applied to the problem will be explained.
Figure 1. Pipeline centrifugal compressor with overhung rotor as
in Compressors 1 and 2 and similar to Compressors 4 and 5.1
A bout 40 years ago, a major gas transmission pipe-
line operator was experiencing problems with car-
bon deposits on bearings and seals in several of its large
centrifugal compressors. In some cases, bearing and seal
failures were resulting from the deposits. Oddly, in each
case, the machinery had run successfully for long periods
of time prior to encountering problems, and operating
conditions were essentially unchanged from past experi-
ences. Mechanical inspection revealed no misassembled
or deviated components. This left the pipeline operator
asking the question, “What went wrong?”!
Five of the compressors were investigated in detail and
smoking guns were discovered with the care and mainte-
nance of the lubricant in each case. All the gas turbine-driv-
en compressors were lubricated with synthetic phosphate
ester lubricants (SPELs). Several types of SPELs had been
widely used in gas turbines and centrifugal compressors
JSVHIGEHIWQEMRP]FIGEYWISJMXWWYTIVMSV½VIVIWMWXERGI
Compressor 1 was a large 29,100-hp (21.7-MW),
4950-rpm centrifugal compressor with an overhung ro-
tor design as shown in Figure 1.1 Under normal operating
conditions, the axial position monitor showed the rotor
thrust toward the inboard direction, carried by a 15-in.
(381-mm) direct-lubricated tilting pad thrust bearing. The
40 gascompressionmagazine.com | APRIL 2023
CASE N
What caused the carbon buildup
o
28
on the compressor bearings?
highest thrust pad temperature had been 217°F (103°C), but af-
ter about 13,000 hours of problem-free operation, the position
monitor showed the rotor was gradually moving away from the
inboard thrust bearing and the thrust pad temperature had ex-
cursions as high as 248°F (120°C) over a period of about two
weeks. The compressor thrust bearing was inspected and found
to have a 0.007-in. (0.18-mm) thick black carbonaceous deposit
on the inboard bearing thrust pads. The thrust disc had simi-
lar deposits on its inboard face. The outboard thrust bearing
pads and disc face were free of deposits. The axial clearance of
the thrust bearing had decreased from 0.021 in. (0.53 mm) to
0.007 in. The carbonaceous material was water-soluble and after
washing, both the pads and disc were reusable.
A review of maintenance records showed that the total acid
number (TAN) of the tertiary-butylphenyl diphenyl SPEL had in-
creased to 0.89 about three months before the problems began
and was even higher when the carbonaceous deposits were dis-
covered. The lubricant had received occasional activated alumina
½PXVEXMSR)\GIWWMZIEQSYRXWSJERXMJSEQEKIRXLEHFIIREHHIH
in the preceding six months to combat a foaming problem. Also,
some problems with lubricant cooling had occurred prior to the
unit’s shutdown.
8LIPYFVMGEXMSRW]WXIQ[EWXLSVSYKLP]¾YWLIHERHXLIPYFVM-
cant was replaced with new SPEL of the same type. The cleaned
thrust pads and disc were reinstalled. With the new lubricant,
the inboard thrust pad temperature was under 199°F (93°C) at
the design condition. After two months, the unit continued to
VYR[MXLSYXTVSFPIQWERHXLI¾YMH8%2[EWFIMRKQEMRXEMRIHMR
XLIXSVERKI[MXLGSRXMRYSYWEGXMZEXIHEPYQMRE½PXVEXMSR
and it was still operating without problems after accumulating an
additional 18,000 operating hours.
Compressor 2 was similar to Compressor 1, but was direct-
driven by a 5900-rpm, 16,360-hp (12.2-MW) gas turbine. The
unit used an isopropyl phenyl SPEL, with occasional Fuller’s earth
½PXVEXMSRERHRSETTEVIRXTVSFPIQWJSVQSVIXLERLSYVW
The compressor had no thrust pad temperature instrumenta-
tion, but some erratic axial rotor position and outer seal drain
temperature indications had been observed in the last few weeks
of the operating period. When the compressor was disassem-
bled to add bearing pad temperature instrumentation, the out-
FSEVHXLVYWXTEHW[IVIJSYRHXSLEZILIEZ][MTMRKERHWMKRM½-
cant Babbitt loss as shown in Figure 2.1 The inboard thrust pads
had 0.040 in. (1.02 mm) of heavy black carbonaceous deposits.
Similar deposits and some resulting Babbitt loss were found on
XLISMP½PQFYWLMRKWIEPWERHSRXLIMRFSEVHJEGISJXLIXLVYWX
disc. The compressor journal bearings and all turbine bearings
were discolored, but free of deposits. After the black deposits
were washed off the inboard pads, pitting and corrosion damage
was evident on four of the eight pads, as shown in Figure 3.1
Figure 2. Outboard thrust bearing was found
in Compressor 2 with heavy wiping and sig-
RM½GERX&EFFMXXPSWWEWEVIWYPXSJXLMGOHITSW-
its on the inboard pads that reduced running
GPIEVERGI1
Figure 3. Inboard thrust bearing from Com-
TVIWWSVEJXIV[EWLMRKE[E]XLIXLMGOFPEGO
HITSWMXWVIZIEPIHTMXXMRKERHGSVVSWMSRHEQ-
age on four of eight pads.1
Figure 4. Inboard thrust bearing from Compres-
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W]RXLIXMGTLSWTLEXIIWXIVPYFVMGERXLEHEXSXEP
EGMH RYQFIV SJ  4MXXIH ERH GVEGOIH &EF-
bitt was discovered after washing away 0.004 in.
QQ
SJFPEGOGEVFSREGISYWQEXIVMEP1

A new thrust disc, thrust bearing pads, and pad tem- ½PXIVIHXLVSYKLEGXMZEXIHEPYQMRE3TIVEXMRK[MXLGSRXMRYSYWEG-
perature instrumentation were installed. After startup, the XMZEXIHEPYQMRE½PXVEXMSRXLIYRMXVER[MXLSYXER]JYVXLIVFIEVMRK
thrust pad temperatures increased with time at comparable TVSFPIQWEJXIVEGGYQYPEXMRKEREHHMXMSREPSTIVEXMRKLSYVW
WTIIHW ERH XLVYWX PSEHW ;MXLMR ½ZI HE]W XLI XLVYWX TEH 'SQTVIWWSV[EWETMTIPMRIGSQTVIWWSV[MXLEFIEQWX]PIVS-
temperatures were limiting both the compressor speed XSV HVMZIR EX  VTQ F] E LT 1;  KEW XYVFMRI
ERHPSEHXSFIPS[VEXIHGSRHMXMSRWIZIR[MXLVIHYGIHPY- %JXIVEFSYX½ZI]IEVWSJVIPMEFPISTIVEXMSRHYVMRKEVITEMVSJE
FVMGERXWYTTP]XIQTIVEXYVI-RWTIGXMSRSJXLIGSQTVIWWSV Continued on page 42
XLVYWX FIEVMRK VIZIEPIH XLEX XLI MRFSEVH TEHW LEH EPVIEH]
accumulated a 0.004-in.- (0.1-mm)-thick black deposit near
the outer diameter of the bearing pads. The deposits were
washed off the undamaged pads, which were reinstalled.
2MRIX] LSYVW EJXIV VIWXEVXMRK XLI YRMX I\TIVMIRGIH XLI
same temperature problems that limited speed and load.
-RWTIGXMSREKEMRJSYRHEHITSWMXSJEFSYXMRSRXLI
inboard thrust pads, as shown in Figure 4.1 After washing the
TEHWWYFWYVJEGITMXXMRKERHEGVEGOIH&EFFMXX[IVIHMWGSZ- One source for precision, quality,
IVIHYRHIVXLIEVIESJLIEZMIWXHITSWMXW*MKYVIWLS[WSRI
SJXLITEHW[MXLXLIHITSWMX[EWLIHE[E]SRLEPJXLITEH and capability.
surface.1 Under a microscope, the Babbitt cracks had the
appearance of a stress corrosion attack. At this time, high
8%2[EWHMWGSZIVIHERHXLI¾YMH[EWGMVGYPEXIHXLVSYKL
EGXMZEXIHEPYQMREJSVX[SHE]WVIHYGMRKXLI8%2JVSQ
XS3XLIVPYFVMGERXTVSTIVXMIWWYGLEWZMWGSWMX][EXIV
content, foaming characteristics, metal content, etc. did not
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bearing was installed and, after the unit was restarted, some
initial foaming was controlled through the addition of an
ERXMJSEQ EKIRX %X EFSYX  LSYVW EJXIV VIWXEVXMRK XLI
YRMXI\TIVMIRGIHWYGGIWWMZIWLYXHS[RWHYIXSLMKLMRFSEVH
XLVYWXFIEVMRKXIQTIVEXYVIERHI\GIWWMZIE\MEPVSXSVQSZI-
www.hfwindustries.com
QIRX;LIRXLISTIVEXSVF]TEWWIHXLIXVMTWERHVIWXEVXIH
to keep the unit online during a critical pumping period, the HFW Industries, Inc.
MRFSEVHXLVYWXFIEVMRKERHXLVYWXHMWG[IVIHIWXVS]IH8LI 196 Philadelphia St.
outboard thrust bearing was in perfect condition as were all Buffalo, NY 14207-0008
the compressor and turbine journal bearings. Compressor
bushing seals had thin deposits of black carbonaceous ma- sales@hfwindustries.com
XIVMEP(YVMRKXLIGSQTVIWWSVVITEMVXLI¾YMHW]WXIQ[EW Ph: 716-875-3380 / Fax: 716-875-3385
¾YWLIH RI[¾YMH[EWEHHIHERHXLIVIQEMRMRK¾YMH

gascompressionmagazine.com | APRIL 2023 41


Figure 5. One of the pads from the bearing in Figure
4 after washing away the deposits on half the pad
surface. Under a microscope, the Babbitt cracks had
the appearance of stress corrosion attack.1
HEQEKIH FEPERGI WIEP WMKRM½GERX GSEXMRKW SJ
black carbonaceous material were discovered
on the non-drive-end journal bearing, the
bushing seals on both ends, and the outboard
speeds on mineral oil. After problem-free operation for about six months, the
non-drive-end journal bearing temperature began to increase. Fluid quality was
RSXGLIGOIHFYXJSYVXS½ZILSYVWSJEGXMZEXIHEPYQMRE½PXVEXMSRGSRXVSPPIHXLI
TVSFPIQ;MXLTIVMSHMGEGXMZEXIHEPYQMRE½PXVEXMSRXLIYRMX[EWWXMPPSTIVEXMRK
with minimal deposits 30 months later.
Compressor 4 was another single-stage, overhung pipeline booster driven by
a 12,300-hp (9.2-MW), 4950-rpm gas turbine. The compressor encountered in-
board bearing and seal problems after more than 50,000 hours of operation. The
synthetic lubricant had never been replaced during that time, although makeup
¾YMH LEH FIIR EHHIH 8LI XIVXMEV]FYX]PTLIR]P HMTLIR]P 74)0 LEH SGGEWMSREP
*YPPIV´WIEVXL½PXVEXMSRERHSYXIVFYWLMRKWIEPPMJILEHI\GIIHIHSRI]IEV,S[-
ever, major problems were encountered following a six-month idle period during
[LMGLXLIVIWIVZSMVLIEXIVW[IVIWSQIXMQIWIRIVKM^IH[MXLSYX¾YMHGMVGYPEXMSR
About 1000 hours of operation after this idle period, the compressor seal drain
XIQTIVEXYVIFIKERXSMRGVIEWIERHXLIWIEPHVEMR¾S[VEXIHIGVIEWIH[MXLXMQI
Inspection revealed black carbonaceous deposits on the inboard journal bearing
TEHWERHSRFSXLFYWLMRKWIEPW8LI¾YMH8%2SJ[EWVIHYGIHXSF]
*YPPIV´WIEVXL½PXVEXMSR%JXIVXLIFIEVMRKWERHWIEPW[IVIVITPEGIHMRERSXLIV
1000 hours of operation, the inboard journal bearing failed, scoring the shaft. The
bushing seal bores and shaft area under each seal were coated with black deposits.
8LI¾YMH8%2LEHMRGVIEWIHXSERHXLIRLEHFIIRVIHYGIHXSPIWWXLER
F]½PXVEXMSREXXLIXMQISJXLIJEMPYVI8LIVIFYMPXYRMX[MXLXLIPYFVMGEXMSRW]WXIQ
¾YWLIHERHVI½PPIH[MXLRI[XIVXMEV]FYX]PTLIR]PHMTLIR]P74)0VER½RIEKEMR
TEHWERHXLVYWXHMWGSJXLIMRQQ
 Compressor 5, with almost 73,000 operating hours, was virtually identical to
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RS &EFFMXX PSWW JVSQ ER] SJ XLI FIEVMRKW SV
seals. The damaged balance seal caused the
seal differential pressure to increase, causing
some lubricant ingestion into the gas stream
on the non-drive end. There, the lubricant had
migrated along the rotor shaft, leaving black
carbonaceous deposits and some evidence of
chemical attack on the labyrinth seals. The
XIVXMEV]FYX]PTLIR]P HMTLIR]P 74)0 LEH SG-
GEWMSREP½PXVEXMSRXLVSYKL*YPPIV´WIEVXLERH
generous doses of silicone antifoam agent
LEH FIIR EHHIH SZIV WIZIVEP ]IEVW 3RP]
310 hours after the compressor rebuild, the
compressor non-drive-end bearings and seals
were reinspected following an increase in
the journal bearing pad temperature. The in-
ner bushing seal had accumulated a buildup
of deposits in the bore, causing a diametral
clearance reduction of 0.002 in. (0.05 mm),
which was 40% of the design running clear-
ance. Analysis of the lubricant indicated that
XLI 8%2 [EW  XLI ZMWGSWMX] [EW  
LMKLIV XLER WTIGM½GEXMSR ERH JSEQMRK XIR-
dency was high. Waxy deposits were found
MRXLI½PXIVWERHXLIVIWIVZSMVLIEXIVWLEHE
thick black deposit of carbonaceous material.
The lubrication system was cleaned,
¾YWLIH ERH VI½PPIH [MXL RI[ 74)0 SJ XLI
Compressor 4. It experienced similar behavior at about the same time following
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XLIXMQISJXLITVSFPIQ,S[IZIVJSVXLITVMSVX[S]IEVWTIVMSHMG¾YMHEREP]WMW
VIGSVHWWLS[IHE8%2EWLMKLEW*YPPIV´WIEVXL½PXVEXMSRLEHFIIRYWIHSGGE-
WMSREPP]JSVQER]]IEVWFIJSVIW[MXGLMRKXSEGXMZEXIHEPYQMRE½PXVEXMSR3RXLVII
SGGEWMSRW[MXLMR½ZIQSRXLWFPEGOHITSWMXW[IVIJSYRHSRXLISYXIVFYWLMRKWIEP
FSVIJSPPS[MRKSFWIVZEXMSRWSJHIGVIEWMRKSYXIVWIEPSMP¾S[ERHMRGVIEWMRKSMP
HVEMRXIQTIVEXYVI3RSRISGGYVVIRGIHITSWMXW[IVIJSYRHEPWSSRXLIMRFSEVH
thrust bearing pads and the mating thrust disc face. Following reassembly after the
third occurrence, the inboard journal bearing and seals failed in only 30 hours of
operation, preceded by an increasing outer seal drain temperature. The bearing
failure also damaged the shaft. After rebuilding, another failure occurred in only
seven hours of operation. After this failure, the compressor was rebuilt with 20%
increased inboard journal bearing clearance, although original design clearance
had run successfully for more than a decade on this unit and on many other units.
8LISPH¾YMH[EWVITPEGIH[MXLRI[XIVXMEV]FYX]PTLIR]PHMTLIR]P74)08LIVIEJ-
XIVXLIYRMXVERWYGGIWWJYPP][MXLGSRXMRYSYWEGXMZEXIHEPYQMRE½PXVEXMSR
8,)713/-2++927
As a result of extensive investigations of the compressor problems, sev-
eral smoking guns were discovered that answered the question, “What went
wrong?”! All were related to the maintenance procedures and condition of
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ERHETTPMGEXMSRWLEHVITSVXIHTVSFPIQW[MXL74)0W)EVP]YWIVWHMWGSZIVIH
XLEXXLI¾YMHWEVII\GIPPIRXTEMRXVIQSZIVWERHEVIMRGSQTEXMFPI[MXLQER]
common elastomers such as polychloroprene or acrylonitrile polymer.2,3 As
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XIQTIVEXYVI PIH XS WMKRM½GERX ZMWGSWMX] ERH EGMHMX] MRGVIEWIW GSPSV GLERKI
from yellow to black, and formation of black brittle deposits.4 For example, at
same type. The inner seal bore geometry „*„'
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XLI
[EWQSHM½IHXSTIVQMXQSVI¾S[JSVGSSP-
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ing; however, the original seal design had
been successfully used for many years on well
over 100 units operating at up to 10% higher
42 gascompressionmagazine.com | APRIL 2023
YWIJYPPMJI[EWEJI[[IIOWERHEX„*„'
8LII\MWXIRGISJELMKL8%2GEYWIWEREYXSGEXEP]XMGVIEGXMSRXLEXWTIIHWYT
the oxidation of the lubricant at relatively low temperatures.5 For quite some
Continued on page 44

Figure 6. Pipeline centrifugal compressor with beam-type rotor as in Compressor 3.1
XMQIFIJSVIXLI½ZIMRGMHIRXWHMWGYWWIHLIVI[EWXLIQE\MQYQ8%2
VIGSQQIRHIHJSVXYVFMRIPYFVMGERXW-JEPPS[IHXSMRGVIEWIWMKRM½GERXP]
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JI[TVSFPIQWEVIYWYEPP]JSYRHXSLEZIPS[PIZIPWSJEGMHMX]68LIVIJSVI
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44 gascompressionmagazine.com | APRIL 2023
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EWGSTTIVYRPIWWTPEXIH[MXLEQE- are changing. Waukesha Engine offers reliance for
XIVMEPXLEXMWRSRVIEGXMZI[MXLXLI today and compliance for tomorrow.
74)0 'ERMWXIVX]TI LIEXIVW EVI
TVIJIVVIH • 90%+ lower methane emissions
Fluid Recognition: 8LIVI EVI HMJ- • 10-20% lower CO2e emissions
JIVIRX 74)0 JSVQYPEXMSRW ERH
XLI] QE] RSX FILEZI XLI WEQI • Lower NOx and VOC emissions
[E] MR HMJJIVIRX W]WXIQW 1M\MRK
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