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Compressor Performance Test Procedure Shaybah Rev.2 Borsig
Compressor Performance Test Procedure Shaybah Rev.2 Borsig
Table of content:
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1. General
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5. Test procedure
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1 ...:
13. February 2013 / Rev. 1: 04. June 2013 / Rev. 2: 20. June 2013
1. General
This specification describes the in-house performance test-procedure, applicable to the below
referenced compressor order.
Client: Samsung / Korea
Project/Location: NGL Recovery Facilities SHAYBAH / Saudi Arabia
Type: Regeneration Gas Compressor and Driver
Job No.: SG-2420
Item Number: B90-K-0102 and B90-K-0202
BZM Compressor model: T-Jet 30
Compressor arrangement: Single stage integrally geared compressor
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unit performance-tested
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- Verification that also all additionally specified operating points, other than the guarantee-point,
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In order to obtain above data, the compressor will be inhouse-tested in a closed loop test-cycle filled
with Nitrogen as test-gas. Details will be presented in this report.
All specified operating conditions are being listed in the official compressor data sheet, document no.
BE-758125. The requested operating conditions are extracted from the data sheet and are shown in
attachment 1 of this report.
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13. February 2013 / Rev. 1: 04. June 2013 / Rev. 2: 20. June 2013
- All five specified operating points shall be fulfilled with no negative tolerances regarding mass
flow and discharge pressure.
- Additionally and according to API 617 7th Edition, the Normal-operating point “Summer 2018”
shall be achieved with a coupling power not higher than 1% in excess of the specified value.
The shop performance test is conducted following ASME PTC 10, release 10/1997 with some
modifications, as listed in chapter 7 of this report.
The test-gas and conditions are chosen so that certain key-parameters according to ASME PTC 10 are
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Table 1:
Permissible deviations from parameters derived from specified operating conditions for type 1 and
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type 2-tests
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Machine Mach number M u2 See figure 3.3, PTC 10 See figure 3.3, PTC 10
Machine Reynolds number Re See figure 3.5, PTC 10 See figure 3.5, PTC 10
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Note: The minimum allowable Machine Reynolds number for specified conditions is 90'000,
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As it has been found in the actual case as most appropriate, the compressor will be tested with
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Table 2:
Operating point: Normal (Guarantee) ASME Test-Point
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82'190.51 13'202.4
M
2)
Discharge pressure (bar abs) : 66.258 8.781
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1)
Coupling power (kW) : 566.3 acc. to conversion
Motor speed (rpm): 1'774 1'605.4
Speed of pinion with impellers 1 and 2 (rpm): 22'658.8 20'505.9
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13. February 2013 / Rev. 1: 04. June 2013 / Rev. 2: 20. June 2013
5) The surge capacity at Normal-operating point shall not exceed 530 ACFM without positive
tolerance.
Table 3:
ASME-conditions versus actual conditions :
Conclusion:
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All ASME-criteria can be fulfilled with high accuracy with the chosen test gas and properly adjusted
speed as shown above.
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After the compressor and its piping is connected, the closed loop is subsequently depressurized from
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enclosed ambient air by the use of a vacuum-pump. After reaching the targeted vacuum conditions,
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the closed loop is filled with test gas up to the required settle out pressure. The settle out pressure
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for the closed loop is predicted prior to the test for conditions to reach the desired suction pressure
at compressor inlet as shown in table 2 of this report.
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5. Test procedure
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Pressure, temperature and flow corresponding to pre-defined test-conditions will be monitored and
adjusted by setting the throttle-position of the test bed-throttle-valve, upstream of section 1. Before
taking test records, roughly one hour warm-up period shall be awaited. The actual appearing suction
pressure and temperature might be somewhat different from pre-defined test-conditions. However,
the ASME PTC10-conditions and the allowable tolerance-bands will be continuously monitored. In
case of unavoidable deviations of suction pressure and temperature due to test cycle-constraints, the
speed will be adjusted until the applicable ASME PTC 10 tolerance-bands are met for the guarantee-
point measurement of this section.
Flows, suction- and discharge pressures and temperatures along the curve including surge are
monitored and recorded in sequence as described under chapter 5.2.
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13. February 2013 / Rev. 1: 04. June 2013 / Rev. 2: 20. June 2013
5.2 Test data processing
(1) The setting angle of the IGV will be constant during the measurement of the first
performance curve. The IGV-angle is set so that the guarantee-point gets located on this
curve. After this IGV-position is determined, a minimum of five measuring points will be
taken, starting from choke-conditions towards the left side of the curve near surge. The third
point of the measurement is for the verification of the guarantee-point and this point will be
carefully adjusted so that the ASME-criteria are met as described in table 3 of this
procedure.
(2) The location of the surge point for that IGV-position will be detected directly near the
compressor by means of notification of the first surge-pulse (surge noise or flow meter-
fluctuations), occurring after careful gradual throttling of the flow.
(3) After the curve-data for the guarantee-point IGV-position are completely recorded, the IGV
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will be adjusted to a new, more closed position. The selected new IGV-angle will be about
60°. It is important that the new IGV-position allows the determination of the compressor-
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surge line shape and the turndown-capability of the measured section. For this IGV-position,
a minimum of three measuring points from choke to near surge will be recorded.
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(4) After the second curve is recorded, the IGV will be closed further to about 80°. Subsequently,
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at least three measuring points including the verification of the corresponding surge-point
are recorded.
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(5) Finally the curve with counter-preswirl will be taken. Thus, the IGV-position will be adjusted
to an angle which obtains maximum flow capacity of the compressor combined with
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sufficient compressor-head (most probably this angle will be around -25°). As before, the
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measurement of this third IGV-angle goes from choke to near surge and contains at least
three measuring points.
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When the pressures and temperatures reach stability, which is typically after about 10 minutes of
flow-adjustment, the data of all instruments will be taken three times during a duration of minimum
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15 minutes. Each item shall be within the limits of fluctuation as per ASME PTC 10, shown in table 4
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below.
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Note: According to observations during previous testings, the allowable fluctuation-ranges may not
be met for measuring points near surge or within the overload-range of the compressor. Under this
circumstances, also deviations of permissible fluctuations shall be discussed and mutually agreed.
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13. February 2013 / Rev. 1: 04. June 2013 / Rev. 2: 20. June 2013
Polytropic Head Guarantee Point
Measuring Point
Guarantee-Point-IGV-Position
Max-IGV-Position
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Table 4:
M
AT
pd
p
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pressure
Flow measurement T1 K 0.5%
device temperature
Speed N rpm 0.5%
Molweight test gas M kg/kmol 0.25%
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13. February 2013 / Rev. 1: 04. June 2013 / Rev. 2: 20. June 2013
6. Performance evaluation and conversion
An interactive computer-system is employed to take and to evaluate the test data, containing the
following functions:
The evaluation-procedure is programmed according to ASME PTC 10 and consists of the following
major formulas, herewith presented in SI-units (the corresponding ASME PTC10 formula-designations
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ln( p d / pi )
n
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ln( p d / pi )
M
h ' d hs
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ns 1
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n 1
n
Polytropic head [5.3.2]: hp fp i vi [( p d pi ) n
1]
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n 1
!
Vi
Flow coefficient:
d 22 u 2
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13. February 2013 / Rev. 1: 04. June 2013 / Rev. 2: 20. June 2013
hp
Polytropic work coefficient [5.2T-6]: p
u
(i )
2
2 ,i
hp
Polytropic efficiency [5.2T-9]: p
hd hi
p
Work input coefficient: o
p
Note: A Reynolds-Number will be not applied for the actual performance test. Anyway, for
reference reason the conversion-method will be presented below:
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Before converting the test-results to original conditions, a Reynolds-number correction will apply.
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The Reynolds-number correction will be performed using the set of formula according to ICAAMC
(International Compressed Air and Allied Machinery Committee).
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sp
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0.3 0.7
cr
M
(1 p , sp ) (1 p ,t )
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0.3 0.7 t
cr
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p ,sp 1 p.sp
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1
p ,t 2 p ,t
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sp p , sp
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t p ,t
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1 ks
1.74 2 log 10
cr b2
ks
1.74 2 log 10
1 18.7
sp b2 Re sp
sp
1 ks 18.7
1.74 2 log 10
t b2 Re t
sp
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13. February 2013 / Rev. 1: 04. June 2013 / Rev. 2: 20. June 2013
u 2 b2
Reynolds-number defined as: Re
dyn,i vi
Dynamic gas viscosity at inlet: dyn,i
ks Rm / 2
The non-dimensional parameters per each measuring point will be converted to specified conditions
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as follows:
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sp
sp t
t
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sp
sp t
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t
N
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sp
sp t
t
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After the non-dimensional performance curves are determined containing above parameters, the
gas and coupling power of the compressor will be calculated for the specified conditions.
In addition to the guarantee-point evaluation, the entire performance map will be generated for
original conditions including the surge-line.
10 ...:
13. February 2013 / Rev. 1: 04. June 2013 / Rev. 2: 20. June 2013
Off-design operating points, such as
- Rated,
- Winter 2018,
- Summer 2014,
- Winter 2014,
will be evaluated by interpolation between the measured and converted four as-tested performance
curves.
6.6 Nomenclature
Pressures: p
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Temperatures in Kelvin: T
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Specific Volume: v
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Enthalpy: h
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Mass flow: w
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M
Diameter: d
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Rotational speed: N
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Power: P
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Molweight: M
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Compressibility factor: Z
Subscripts:
Suction (Inlet): i
Discharge: d
Isentropic: s
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13. February 2013 / Rev. 1: 04. June 2013 / Rev. 2: 20. June 2013
7. Exceptions to ASME PTC 10 10-1997
(1) Power measurement (para. 4.12 to 4.15, 4.17, 4.18, 5.4.7.2, 5.4.7.4, 5.4..7.5)
Gas power will be calculated using the heat balance method as described in chapter 4.2.
The shaft power is not measured.
External heat loss by heat transfer through the compressor casing is minimized by test setup,
since the casing is equipped with insulation material and resulting heat transfer to
atmosphere can be neglected in this case.
The mechanical losses of bearings and seals are obtained by calculation out of oil flow, oil-
inlet and outlet temperature tested at 100%-speed during the mechanical running test of the
compressor.
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The operating conditions of the performance test will be displayed on a monitor, located next to the
tested compressor. The displayed data on the screen contain inlet and outlet conditions, specified
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The raw data of the test will be handed over to the purchaser during the test.
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The final test report with the conversion of the test results to specified conditions will be issued after
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the performance test and as-tested performance curves based on original specified conditions will be
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issued.
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Attachment 3 shows the expected performance curves including all specified operating points.
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N
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13. February 2013 / Rev. 1: 04. June 2013 / Rev. 2: 20. June 2013
Attachment 1: Data Sheet with
Specified Process Data
SPECIFICATION NO.
CENTRIFUGAL COMPRESSOR REVISION NO. D DATE 2011-11.21
CERT.
31-SAMSS-001 PAGE 4 OF 24 BY
SMART DATASHEET Plant No B90 Index K Drawing No BE-758125
1 APPLICABLE TO: PROPOSAL PURCHASE AS BUILT B
CHKD.
10 (ALL DATA ON PER UNIT BASIS) Summer2018 Winter2018 Summer2014 Winter 2014
DESCRIPTION
11 GAS HANDLED ALSO SEE PAGE 2 OF 10 Hydrocarbon Hydrocarbon Hydrocarbon Hydrocarbon Hydrocarbon
12 MMSCFD (14.7 PSIA & 60 °F DRY) (NOTE 1) 80.49 80.27 80.49 80.27 80.49 x 1.1
IN
13 WEIGHT FLOW, #/MIN (WET) (DRY) 3'020 2'977 3'060 3'003 3,020 x 1.1
14 INLET CONDITIONS
15 PRESSURE (PSIA)
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22 DISCHARGE CONDITIONS
23 PRESSURE (PSIA) 961 961 961 961 961
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27 BHP REQUIRED (ALL LOSSES INCLUDED) (BHP) 759.4 747.2 769.5 754.4 D 831.6
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64
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62
R
IN
60
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58 Compressor Choke
80 70 60 40 0 -25
R
M
56
20 40 60 80 100 120 140
AT
M. [1000 kg/h]
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800 Rated
-25 M = 90409.6
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Pk = 620.1
N
700 Normal
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0 M = 82190.5
Pk = 566.3
600
!
500 40
60
400 70
80
300
200
20 40 60 80 100 120 140
M. [1000 kg/h]
10
R
5
IN
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0 80 70 60 40 0 -25
R
M
-5
20 40 60 80 100 120 140
AT
M. [1000 kg/h]
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Polytropic Efficiency
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1 Rated
M = 90409.6
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Eta-p = .7975
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.8 Normal
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M = 82190.5
Eta-p = .7942
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.6
.4
.2
80 70 60 40 0 -25
0
20 40 60 80 100 120 140
M. [1000 kg/h]
70
Winter 2018
68 M = 81020.2
Pd = 66.26
66
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64
R
62
IN
60
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58 Compressor Choke
80 70 60 40 0 -25
R
M
56
20 40 60 80 100 120 140 160
AT
M. [1000 kg/h]
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900
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-25
N
M = 81020.2
Pk = 557.2
700 0
!
600
40
500
60
70
400
80
300
20 40 60 80 100 120 140 160
M. [1000 kg/h]
20 Winter 2018
M = 81020.2
Hp = 16.46
15
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10
R
5
IN
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0 80 70 60 40 0 -25
R
M
-5
20 40 60 80 100 120 140 160
AT
M. [1000 kg/h]
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Polytropic Efficiency
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1
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N
.8 Winter 2018
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M = 81020.2
Eta-p = .7377
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.6
.4
.2
70 40 0 -25
80 60
0
20 40 60 80 100 120 140 160
M. [1000 kg/h]
68
Summer 2014
M = 83279.1
66 Pd = 66.26
64
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62
R
IN
60
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58 Compressor Choke
80 70 60 40 0 -25
R
M
56
20 40 60 80 100 120 140
AT
M. [1000 kg/h]
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900
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800
N
M = 83279.1
700 Pk = 573.8
!
0
600
500 40
60
400 70
80
300
200
20 40 60 80 100 120 140
M. [1000 kg/h]
20 Summer 2014
M = 83279.1
Hp = 17.84
15
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10
R
5
IN
FO
0 80 70 60 40 0 -25
R
M
-5
20 40 60 80 100 120 140
AT
M. [1000 kg/h]
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Polytropic Efficiency
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1
O
N
.8 Summer 2014
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M = 83279.1
Eta-p = .7954
!
.6
.4
.2
80 70 60 40 0 -25
0
20 40 60 80 100 120 140
M. [1000 kg/h]
70
Winter 2014
68 M = 81727.8
Pd = 66.26
66
FO
64
R
62
IN
60
FO
58 Compressor Choke
80 70 40 0 -25
R
60
M
56
20 40 60 80 100 120 140 160
AT
M. [1000 kg/h]
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900
O
-25
N
M = 81727.8
0 Pk = 562.6
700
!
600
40
500
60
70
400 80
300
20 40 60 80 100 120 140 160
M. [1000 kg/h]
20 Winter 2014
M = 81727.8
Hp = 16.53
15
FO
10
R
5
IN
FO
0 80 70 60 40 0 -25
R
M
-5
20 40 60 80 100 120 140 160
AT
M. [1000 kg/h]
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Polytropic Efficiency
N
1
O
N
.8 Winter 2014
LY
M = 81727.8
Eta-p = .7393
!
.6
.4
.2
80 70 60 40 0 -25
0
20 40 60 80 100 120 140 160
M. [1000 kg/h]