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July 2023 1
What is the acceptable vibration in a centrifugal compressor?
(Ensure safe operation and plant reliability)

Anecdote: A very senior and experienced platform supervisor ordered, and the technician changed the vibration trip limit by ~15
microns on a production critical (gas lift) centrifugal compressor to allow its start-up. This compressor was tripping on high vibration,
on start-up, as it passed through the 1st critical speed. On my next visit to the platform, the platform supervisor asked me to approve
the change in the vibration trip setting, and put the paper work in front of me to sign, just before the chopper came for my flight to
the shore. I approved it, but casually mentioned the pressure to sign the change to my manager. The platform supervisor had a very
hard time explaining his position to this company’s management. The compressor casing was changed soon afterwards.

Safety culture comes when a company walks the talk. So what should be the alarm and trip levels on a centrifugal compressor?
Centrifugal compressor’s design differs based on the application and other design factors. The alarm and trip values can differ.
Following is an opinion which may help field / operating engineers make safer operating decision(s). Also refer API 617 (Centrifugal
& Axial Compressors) and API 670 (Machinery protection system)

What defines alarm & trip values:

I had approved the proposed changes to compressor vibration trip value for the following reasons:
• vibration trip value was exceeded only during the ramp up when the compressor passed the first critical speed; and
• during operation, at normal speed the vibration level of @30 microns was significantly lower than the alarm value.
This was an old compressor set and its vibration monitoring system did not have the facility of set point multiplication to prevent
its spurious trip when passing through the resonant speed on compressor start-up. In my earlier discussions with this particular
compressor supplier, they had mentioned that the minimum mechanical clearance between any corresponding rotor and stator
parts was @ 200 microns; and the new modified vibration trip level was significantly lower and no internal rub was expected.
Multistage centrifugal compressors are typically designed to operate beyond the first critical (resonance) speed, lateral & train
torsional. In API 617, the rotor critical speed is defined as the speed at which the rotor vibration response amplifies 2.5 times or
more than the normal vibration. See figure below for clarity.

Set point multiplier can be used to allow safe passage of the compressor past the resonant speed on its start-up.

www.gl-mach.com , E: m.saxena@gl-mach.com , T: +61 456 980 655

Global Machinery Consultants Pty. Ltd., A.C.N No. 094 649 699, A.B.N. 20 094 649 699. Perth, Melbourne, Australia
© This document is the property of Global Machinery Consultants Pty Ltd., Australia.
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Usually, the compressor supplier will define each machine’s set point multiplier. API 670 (Machinery Protection System) provides
guidelines on set point multiplier. In the latest API 670, 5th edition, a timer is combined with the set point multiplier for greater
safety. Set point multiplier could be digital (including software based) or hard signal. Check the logic diagram of your compressor
to understand it better.
API 617 rotor design requirement:
Compressor manufacturer has to ensure that the rotor’s peak to peak unbalance response from zero to trip speed must not exceed
75% of the minimum design diametrical running clearances throughout the machine, except at the floating ring seal location. This
is theoretically verified for 1 and 2 times the internal clearances of wearable parts in the rotor during rotor dynamics analyses.
Note, the running clearances are different from the assembly clearances. Hence, the importance of taking compressor supplier
design engineer’s input. The separation margin between the operating speed (range in the case of variable speed compressor) is
many times jointly agreed between the purchaser engineer and the compressor supplier. The plant maintenance and reliability
engineers should obtain a copy of compressor rotor dynamics report for their reference and understanding.
Take note:
Rotor response is complex and theoretical amplification could be different from field measurements. Among design engineers
there is much debate about the dampening values considered in the rotor dynamics study as they are generally empirical values
drawn from the experience of individual suppliers. As the compressor get older, the internal clearances and unbalance change.
The rotor response on start-up or during normal operation changes substantially due to increased clearances or unbalance.
Baseline your compressor vibration data:
While the vibration of the compressor including the drive train may be recorded during the testing in supplier shop; it is highly
recommended that the operating companies should establish base line vibration signature of their machine train when it is
commissioned for the first time. This can then be used to monitor the health of your production critical compressors, thus helping
ensure safe, and reliable operation. When a new compressor is commissioned or after its every major overhaul, on start-up
generate waterfall plot of vibration frequency vs time; if the necessary software tools are available.
Water fall plot is a three-dimensional graph that displays the vibration frequencies against time.
By-line:
Plant engineers (Operations / Maintenance / Reliability) should make an effort to fully understand the technical reasons behind the
allowable vibration, alarm and trip set points of their high speed / high energy plant machinery to ensure its safe operation. We
hope this little anecdote has helped you to understand the context of the vibration alarm and trip set points.

www.gl-mach.com , E: m.saxena@gl-mach.com , T: +61 456 980 655

Global Machinery Consultants Pty. Ltd., A.C.N No. 094 649 699, A.B.N. 20 094 649 699. Perth, Melbourne, Australia
© This document is the property of Global Machinery Consultants Pty Ltd., Australia.