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Case study: Centrifugal compressor failure analysis

BY CLIFF KNIGHT, OWNER/PRESIDENT, KNIGHTHAWK ENGINEERING JANUARY 6, 2023 12:01 PM

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During a petrochemical plant shutdown for a scheduled turnaround, a two-stage compressor suffered a catastrophic
failure.

The compressor ripped into more than 180 metal shards, some of which were recovered as far as 100 feet away. KnightHawk Engineering (KHE)
performed a root cause analysis to determine the cause of the explosion.

Process

The analysis began with an onsite assessment, disassembling the compressor, preserving the evidence and inspecting the components and
machinery. KHE then analyzed the processes of the system. The process data was examined in conjunction with KHE’s metallurgical lab analysis.
KHE discovered an imbalance between the stages of the compressor, presumably caused by inaccurate reporting of Annubar ows from the
detection systems. This nding suggested a leak occurred between the two stages, however, metallurgical analysis revealed no evidence of leaks
prior to the incident. Despite the absence of leaks, the inaccurate readings proved problematic. The incorrect molecular weight measurements
utilized by the controls systems were signi cantly higher than reasonable values, considering the system was being switched to a nitrogen purge for
shutdown. The reported molecular weight was an estimated weight rather than a live reading for the calculations. Unfortunately, this reported
molecular weight became inaccurate during the dynamic shutdown process. In addition to the mass ow differential between stages one and two,
KHE discovered a rising discharge temperature in relation to inlet temperature, strongly suggesting a loss of ef ciency in the compressor. KHE
considered the cause to be internal seal failure allowing for back ow, but further analysis determined this was the result of a surge.
Close
The lab also studied the microscopic structures of the metal to determine the origin and propagation of the fractures. After nding no signs of
impact damage, KHE collected 20 of the samples for metallurgical analysis.

The lab review of compressor pieces found no evidence of historical wear, impact damage or casting defects. However, the inlet guide vane revealed
signs of corrosion. Chemical testing identi ed the residue and corrosive element present at the time of the failure. Structural failures were
thoroughly examined and determined to be recent, eliminating pre-existing defects as the cause of the catastrophic failure. Hardness tests and
tensile strength tests were also performed to identify yield stresses.

KHE used data obtained from the metallurgical and process analyses and the onsite assessments to create an FEA model of the compressor. The
model, which incorporated the locations of stresses, was used to determine whether the process or design may have caused the failure of the unit.
The model showed, under normal conditions, the unit operated well within design and expected tolerances, and the areas of high stress did not
coincide with fracture locations.

KHE reviewed the controls system assessment and the recorded data focusing on the unit’s surge controllers for stage 1 and 2. Although stage 2 did
not appear to have entered surge leading up to the incident, it appeared that stage 1 entered surge a number of times in the hours leading up to the
failure. Valve data revealed the system was still responding to the surge controller, although the system response time was too slow to avoid surge.
It appeared the recycle system controller was insuf ciently designed to fully recover the compressor back to the desired conditions.

Solution

The cause of the failure was a combination of factors which contributed to the bypass of an insuf cient surge control system, causing compressor
surge and compressor failure. The spillback valve was fully open, contributing to rapidly rising temperatures inside the compressor and making
surge recovery dif cult. To correct the problem, KHE recommended implementing faster response time systems in the compressor controls
systems and including polytropic discharge temperature data collection inside the compressor. KHE also recommended the computerization of the
compressor performance curve for operator clarity, and the installation of vent lines valves to prevent accidental valve control during the
compressor’s operation.

For more information, visit knighthawk.com or call (281) 282-9200.

TAGS
CURRENT ISSUE KNIGHTHAWK ENGINEERING

BY CLIFF KNIGHT, OWNER/PRESIDENT, KNIGHTHAWK ENGINEERING JANUARY 6, 2023 12:01 PM

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