The reciprocating compressor testing article provides information about reciprocating compress

mechanical running test, aerodynamic testing, hydrostatic testing, gas leakage test, bar-over test a
vibration analysis and testing. You may want to review the reciprocating compressor inspect
procedure and inspection and test plan. 
Reciprocating Compressor Mechanical Running Test
The API Std. 618 requires that reciprocating compressor to be subjected to the 4 hours unloaded runni
test after successful inspection and testing that are done before and during assembly. To perform
unloaded running test, the reciprocating compressor cylinder valves shall not be installed for t
mechanical running test. The mechanical running test is considered a routine test in the reciprocati
compressor testing. 
The test shall be performed based on manufacturer approved test procedure. The compressor is broug
to the rated speed and then runs for 30 minutes to get lube oil temperature, viscosity, beari
temperatures and vibration amplitudes stabilized.After operating parameter stabilization, the te
technician records the parameters in each 10 or 15 minutes as per requirements. 

The following parameter is recorded periodically in this 4 hours:

Lube Oil Pressure

Lube Oil Temperature

Bearing Temperature 

Lube Oil Viscosity 

Power Consumption

Rotor Speed 

Vibration

The recorded values are provided by test engineer at the end of the test in a tabulated format. It is t
responsibility of inspector to verify the values to make sure all of them are within acceptance range.
mentioned in above, the acceptance range is provided in the test procedure and compressor datasheet
As per API 618, the power consumption shall not be more than 3% of the rate power value indicated
the datasheet.

The API 618 also requires the trip speed shall not be less than 110 % of the rotor rated speed. 
The crankcase vibration is measured in real-time basis in X and Y axises. The cylinder vibration
measured in X, Y, and Z axises (Horizontal, Vertical, and Axial). The measured values shall be verifi
aginst acceptance criteria provided in API 618 or approved test procedure. 
If specified, the lube oil and cooling water consoles also shall be subjected to the 4 hours mechanic
running test as per requirements of API 614.
Reciprocating Compressor Aerodynamic Performance
Test
The reciprocating compressor aerodynamic performance testing is not routine test in the reciprocati
compressor testing and is identified as an optional test in API 618. If the performance test was
purchase order requirement, then is performed based on ISO 1217 and with cylinder valves installed
the closed loop system. 
The manufacturer shall provide tables or curves of power and capacity vs. suction pressure with t
parameter of discharge pressure at the end of the test. These curves or tables shall be verified agin
estimated curves or tables and make sure that measured values are within acceptance range.
Rod load and gas load charts and similarly shall be checked against estimated values. The starti
torque Vs. Speed curve also shall be verified and verified against estimated value. 
The efficiency value shall not be less than specified value. The power consumption also shall be check
not to be more than 3% of rated value. 

Reciprocating Compressor Hydrostatic Test

As per API 618, the cylinder, cooling water jacket and piping system shall be subjected to the hydrosta
testing. The hydrostatic testing shall be than at 1.5 times maximum allowable working pressure and t
pressure shall be held for minimum 30 minutes.
The cylinder shall be hydrostatically tested before installation of the cylinder liner. Besides, cylinder sh
be tested with heads, valve covers, clearance pockets, and fasteners being already installed. 
The filters and pressure vessel generally are manufactured at pressure vessel manufacturers and a
tested there, So, it might not be necessary to subject them to hydrostatic testing at the compress
manufacturer facility. 
The hydrostatic testing shall be done by calibrated pressure gage, and the preferable range is two tim
of the test pressure but in no case shall be less than 1.5 times and more than 4 times of the pressu
test. 
Reciprocating Compressor Gas Leakage Test
The API 618, requires helium leak test if the "service gas" molar mass equal or less than 12 or "serv
gas" has a mol percentage of Hydrogen Sulfide  (H2S) equal or more than 0.1%.This information can
found in reciprocating compressor datasheet. 
The helium leakage test shall be done after hydrostatic testing, and the test pressure shall be the sam
amount of compressor maximum allowable working pressure. 
Similar to hydrostatic testing, the cylinder liner shall not be installed and shall be tested with the head
valve covers, clearance pockets, and fasteners. 
The pressurized compressor with helium at MAWP shall be submerged to the water pool, and the te
result will be considered satisfactory if no bubble observed during the test (Zero Leakage). During t
helium test, the internal pressure shall be maintained and recorded. The test shall be done based
manufacturer approved procedure. 
The helium probe is the alternative test which can be done in lieu submergence test. The instrume
sensitivity shall be agreed between compressor purchaser and manufacturer. Most of the manufacture
sue the submergence test. 
Reciprocating Compressor Bar-Over Test

Reciprocating compressor bar-over test includes measurements of piston end clearance and piston r
vertical and horizontal runout measurement.
The test shall be done during the assembly and also after the mechanical running test which is call
final bar-over test. The piston end clearance is measured by feeler gage, and piston rod runout
measured by the dial indicator. The final bar-over test is one of the important test in the reciprocati
compressor testing. 

Piston End Clearance

The piston end clearance measurement shall be done during assembly and after the mechanical runni
test as a final bar-over test. The clearance can be measured by inserting of filler gage or using a le
wire.
A lead wire is inserted from valve port, the compressor is turned and compresses the lead wire trapp
between piston and cylinder. The compressor lead wire thickness can be measured and identify t
piston end clearance. 

Piston Rod Horizontal Runout Measurement

Similarly, the piston rod horizontal runout shall be performed during the assembly and also after t
mechanical running test at the bar-over test. The runout test indicates the piston rod sagging amou
Dial gage is installed on the horizontal side of the piston rod, and then the compressor is turned, and t
piston rod is moved from crank-end to head-end.
Then the dial gage indication is recorded and is checked against acceptance criteria. As per API 618, t
horizontal piston rod runout shall not be plus or minus 0.00015 mm/mm (0.00015 in./in.) of stroke val
(±0.015% of stroke value) but in no case shall be more than 0.064 mm or 0.0025 in. 

Piston Rod Vertical Runout Measurement 

Similarly, the runout is measured by the dial indicator. The dial indicator is mounted in verticle side of th
piston rod (top of piston rod), the compressor turned, and the piston rod is moved from one end to othe
end, and the amount of runout is measured and recorded. As per API 618, the vertical runout shall not b
more than plus or minus of 0.015% of stroke value. 
You need manufacturing drawing to be able to witness this test. You need to have stroke value and ma
a simple calculation and obtain maximum allowed values and then compare measured runout with your
calculated values. 
Reciprocating Compressor Vibration Analysis and Testing
The API 618, requires following vibration limits at compressor skid, cylinder, distance pieces, crankca
and cylinder flange pressure pulsation vibration. The vibration testing is one of important item
reciprocating compressor testing that is performed in mechanical running test part. 

Vibration Limit @ Compressor Skid

The manufacturer shall make analysis and determine whether the vibration frequency is going to be le
than 10 Hz or higher than 10 Hz.  The manufacturer makes the calculation for vibration that comes fro
natural frequency of base plate and also significant excitation frequencies. 
If the analysis indicates the vibration frequency is going to be less than 10 Hz, then magnitude
vibration shall not be more than 4 mil 0 to peak value or 8 mil peak to peak value.
If analysis indicates the vibration frequency is going to be higher than 10 Hz, then magnitude of vibrati
shall not be more than 4.5 mm/s RMS value (0.175 in/s RMS)
As you see, we are using displacement vibration probe (sensor) when vibration frequency is less than
Hz and using velocity vibration probe (sensor) when vibration frequency is higher than 10 Hz. 
The API 618, requires that the reciprocating compressor manufacturer makes necessary calculations a
provide the vibration limits for the cylinder, distance pieces, and crankcase. These amounts normally a
indicated in approved mechanical running test procedure. The vibration testing is done in 4 ho
mechanical running test. 
The API 618 also requires that cylinder flange pressure pulsation vibration shall not be more than of 7
of average absolute line pressure or 3R% whichever is lesser. (the R is the stage pressure ratio). T
vibration amplitude should be measured by displacement probe (proximitor sensor).
The standard also provides the piping system vibration limit. The limit is 0.5 mm peak to peak or 20
peak to peak when vibration frequency is less than 10 Hz. The limit is 32mm/s peak to peak or 1.25 in
peak to peak when vibration frequency is 10 thru 100 Hz. 
The third party inspection for reciprocating compressor article provides a sample inspection instruction
inspection. You may also need to review a sample recirocating inspection and test plan. 

Following content provides some other information about reciprocating compressor testing:
Applicable Standards @ Reciprocating Compressor Testing

The applicable standards for these tests are:

API Standard 618; reciprocating 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
circular cross-section conduits running full - Part 2: Orifice plates

BS ISO 5389 Turbo compressors Performance Test Code

Mechanical Running Test @ Reciprocating Compressor Testing 

The following components are used from Job equipment

Compressor main unit

Lube oil unit

The following components are used from test stand

Motor

Pressure gauge
Temperature gauge

The following components are not used in the test

Suction/Discharge Valves

Surge Drum

Gas Piping

Drum/Piping Support

Instrument
The compressor is assembled in test stand in manufacturer's shop. The the cylinder valves would not
installed to perform non-load continuous operation.
The compressor is operated at the specified rotating speed for 4 hours continuously and mechani
stability, temperature, pressure, vibration and noise are checked.

After 4 hours continuous operation the reciprocating compressor needs to be stopped and beari
temperatures to be measured.
Then the reciprocating compressor is diassmbled and strip down inspection is done based t
requirement of inspection and test plan.

Measurement items during Mechanical running test

Rotating Speed @ Reciprocating Compressor Testing

The rotating speed is measured by a tachometer every 30 minutes. The measurement value to be
average value of those indicated by the tachometer.

Rotating speed need to be be within of the specified rotating speed.

Oil Temperature @ Reciprocating Compressor Testing

The supplied and discharged oil temperature of crankcase is measured by temperature gauges in t
shop lube oil unit every 30 minutes.

The supplied and discharged oil temperature needs to be within specified values.

Oil Pressure @ Reciprocating Compressor Testing

The supplied oil pressure of crankcase (bearings)and discharged oil pressure of lube oil pump a
measured by pressure gauges in oil unit every 30 minutes.

The obtained values need to be in within specified values.

Vibration @ Reciprocating Compressor Testing

The vertical and horizontal vibrations of crankcase are measured at two locations by the use of a sh
vibration meter. Also, the vibration at cylinder is measured with respect toaxial, horizontal and verti
directions by the use of a shop vibration meter. Vibration measurement needs to be done once duri
test operation.

The vibration of crankcase (peak to peak) needs to be within specified values.

Noise @ Reciprocating Compressor Testing

The noise is measured at a distance of 1 m from the side of the main unit and four directions by using
shop noise meter. Noise measurement to be done once during test operation.

The obtained noise value need to be within specified value.

Bearing Temperature Measurement @ Reciprocating Compressor Testing

The temperature for each of following bearings during the 4-hour continuous test operation needs to
measured periodically. 

Temperature of main bearing

Temperature of crank pin bearing

Temperature of cross head pin

The measured values need to be within specified values.

Lube Oil Console Running Test @ Reciprocating Compressor Testing

After completion of successful oil flushing the lube oil console running test needs to be done. Runni
test would be performed based on the following conditions for 4 hours, and temperature and pressu
shall be measured every 30 minutes.

Oil grade as per design

Lube oil pressure as per design

Lube oil temp as per design

Motor speed as per design

Start up as per design (generally cold condition)

No leakage must be seen during the test and Pressure drop of filter element shall not exceed a specifi
value at operating oil temperature. No abnormal sound shall be confirmed during the running test.
Tempered Cooling Water Console Running Test @ Reciprocating Compressor Testing

After completion of successful cooling water flushing the tempered cooling water system running te
needs to be done. Running test would be performed based on the following conditions for 4 hours, a
temperature and pressure shall be measured every 30 minutes.
Fluid as per design (water with inhibitor or etc.)

Pressure as per design

Temperature as per design

Motor speed as per design

No leakage must be seen during the test and no abnormal Pressure drop must be confirmed.
abnormal sound shall be confirmed during the running test.
After checking of the above items at two times, the water pump is changed to another and the sam
items needs to be checked.

Thermodynamic Performance Test @ Reciprocating Compressor Testing

The reciprocating Compressor thermodynamic performance test is similar to the centrifugal compress
You may review Centrigugal Compressor Testing for detail test instruction.
Following data need to be extracted from a centrifugal compressor design book, datasheet and operati
manual and to be available during the test.

Specified Operating Speeds

Normal Operating Spee

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
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