Field surge test procedure

The anti-surge control system for this compressor utilizes an algorithm based on a relationship between inlet nozzle
differential pressure and machine discharge pressure at surge. Inlet nozzle pressure drop provides a repeatable,
relative indication of flow. The compressor capacity is controlled with the IGV. As shown on the typical performance
curve, the surge point occurs at lower flows and discharge pressures at more closed IGV positions. A surge line can
be established based on flow vs. discharge pressure, or inlet nozzle differential pressure vs. discharge pressure, in
this case. The anti-surge control line is used by the control system to keep the compressor out of surge and stall, and
establishes the minimum normal stable operating flow that the compressor can operate at for continuous duty. A
typical anti-surge control line is 5-10 percent higher in flow than the actual surge line. If the compressor approaches
the surge control line, the discharge vent valve is automatically opened to increase flow and move the machine away
from the surge. Due to instrumentation differences, the measured surge line in the field can be somewhat different
than the surge line based on predicted or shop test performance. It is therefore typically necessary to perform a surge
test in the field to establish an accurate surge line for the final installed configuration. The field surge test procedure
that was followed for the subject compressor consisted of the following steps:
1.

Compressor started with compressor discharge blocked, IGVs closed and the discharge vent valve 100
percent open.

2.

IGV adjusted to a fixed, partly closed position.

3.

Discharge vent valve slowly closed while monitoring inlet nozzle differential pressure, discharge pressure,
motor amps and compressor radial vibration. The surge point was identified when there was either a loud
squealing or low frequency booming noise and/or a significant increase in radial vibration and/or the flow
and discharge pressure started to rapidly oscillate. The last stable inlet nozzle differential pressure and
discharge pressure point was the surge point.

4.

Once the surge point was established, the discharge vent valve was quickly opened to get the machine out
of surge to prevent machine damage.

5.

IGV adjusted to another fixed position and surge test repeated.

6.

This procedure was repeated until a surge line using inlet nozzle differential pressure and discharge
pressure was determined. In this case, 4 surge points were taken and the surge line was a straight line.
Note that there are other cases where the surge line is a parabolic shape. The shape depends on the
machine characteristics.

7.

This type of surge test can be referred to as an audible test. The compressor will only momentarily surge,
provided the vent valve is quickly opened when the surge condition is detected. This short surge test will not
cause mechanical damage in most centrifugal compressors. However, the compressor manufacturer should
be consulted before performing this test.

8.

9.

Field surge test

The rotor in the subject compressor was changed out in September 2012. The new rotor used a modified 1st
stage impeller and a new diffuser design. Following the rotor change, the machine was surge tested. Due to
a prior issue, the compressor vibration controls were modified to add axial vibration indication in addition to
axial position. This information also was available during the surge test.
The anti-surge control system is configured in the plant DCS. During the surge test the inlet nozzle pressure
drop, discharge pressure, compressor radial vibration, axial vibration and axial position were carefully
monitored by the operators and engineers performing the

10. test. Four surge points were measured and recorded. The radial and axial vibration changes were similar for
all 4 surge points. The NDE radial vibration normal baseline vibration at stable operating conditions was

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around 1.0 mils. At audible surge, the vibration did not show measureable increase at two of the surge
points and increased to about 1.4 mils and 1.9 mils at the other two surge points. The DE X and Y radial
vibrations remained stable at surge at around 0.5 mils. The axial vibration increased from a normal baseline
value of 2.4 mils peak to peak, to about 3.5 to 4.0 mils at surge. Note the 2.4 mils baseline includes
electrical and mechanical runout because the target surface was not specifically prepped for vibration
measurement, and might not be indicative of the true rotor axial vibration. What is important is the relative
change. The axial position remained stable at surge and did not change from the normal base line value.
11. Discussion
The compressor DE radial vibrations and the axial position were insensitive to surge based on the results of
the audible surge test and are not useful parameters for detecting surge in this compressor. There was a
change in the NDE vibrations at some of the surge points and the vibrations might have increased if the
machine was run in surge for an extended period of time, but this would risk a machine failure. The
compressor manufactures recommended vibration alarm and trip points for radial vibration were 3.5 mils
and 4.3 mils, and clearly these values are too far away from the normal baseline values to be useful to
detect surge or provide adequate warning of a progressive problem. The NDE alarm values were lowered to
1.8 mils, which should provide a warning if a mechanical problem develops, while not being too low as to
cause nuisance alarms. Transient operating conditions and changes in load/operating conditions do have a
modest effect on the radial vibration levels, which prevent setting the alarm set points much lower. As a

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result,
12. the NDE vibrations arent really sensitive enough to provide a consistent, reliable indication of surge based
on the audible surge test. And, the DE radial vibration and axial position did not measurably change at
surge, making these measurements also unreliable for surge indication.
13. The compressor manufacturer had no comments on axial vibration indication. This was a change developed
and implemented by the end user as a potential means of detecting surge. Since adding this feature, longterm trends show that the axial vibration is very stable at different loads and transient operating conditions,
so a high alarm and/or high shutdown set point could potentially be used for surge indication and surge
protection.
14. It also is possible that rapid changes in discharge pressure and/or motor power could be used for surge
indication and protection. Some compressor suppliers have successfully used this strategy, which typically
requires a cycle rate of the measuring instruments in the range of 50-100 msec and is not practical in a
typical plant DCS.
15. There is no definitive answer to the question of whether or not a method of surge indication is required for
safe, reliable operation of centrifugal compressors. For compressors that operate at a constant speed and
compress a gas with a fixed composition, operate at steady operating conditions and are not prone to fouling
and/or erosion, the simple anti-surge control system described above can and has been a reliable method
for preventing surge. However, if the compressor performance degrades appreciably, the surge line can
change. If this happens and the compressor is operated at a turndown condition, there is risk the
compressor could drift into surge without the operator knowing about it, which could lead to a machine
failure. Monitoring compressor performance is therefore important to not only ensure efficient compressor
operation, but also to protect against operating the machine in surge.
16.
Conclusions
If surge indication is required or desired for a centrifugal compressor control/protection system, radial

vibration might or might not work. For the compressor that was the subject of this article, radial rotor
vibration was really not sensitive enough for reliable surge indication. There are other compressors that
show very high radial vibration sensitivity at surge. Many integral gear compressors exhibit this. But this is
not always the case, and depends on the specific compressor. Axial vibration, as described above, or
installing a control system that can measure rapid changes in flow or discharge pressure might work better.

SUBJECT: The most asked questions about mechanical seals 10-2

What is considered good life for a mechanical seal?

The only part of a mechanical seal that is supposed to be sacrificial is the carbon face.
The seal should run leak free until the carbon face is worn away. If the seal leaks for any
other reason we consider it a premature failure and always correctable.

Two hard faces are selected when carbon is not acceptable in the application and you
have run out of options. You are then trying to get the longest life you can.

The only variable in seal life should be the lubricating quality of the product you're
sealing. Hot water, many gases and most solvents are typical non-lubricants.

With all of that said, the fact is that in excess of eighty-five percent of mechanical seals
fail prematurely. When seals are removed from the running pump most of the carbon face
is still intact. Little face wear is the rule not the exception.

Why do most seals fail prematurely?

One of the seal components becomes damaged.

The seal faces open.

What are the most common causes of component damage?

Corrosion of one of the seal components.

Physical damage that includes the affects of high heat or excessive pressure

What are the most common causes for the lapped seal faces to open?

The seal was set screwed to a hardened shaft.

Solids in the product you are sealing are clogging the moveable components.

The product changed state and interfered with the free movement of the seal. It:
o Crystallized.

o Became viscous.
o Solidified.
o Built a film on the sliding components and the lapped faces.
o The product vaporized across the lapped faces blowing them open.
Do seal faces have to be lubricated? Can they run dry?

The graphite in the carbon/graphite face is a natural lubricant. In operation the graphite
separates from the mixture and transfers to the hard face. This means that the seal face
combination you are normally running is carbon on graphite. The hard face is just some
place to put the graphite.

Moisture must be present for the graphite to separate from the carbon/graphite mixture.

Running dry means higher heat at the faces. If you are using a good unfilled
carbon/graphite (and you should be) the faces are not going to be your problem. The
elastomer and the product you are sealing can be very sensitive to a temperature change
in the stuffing box, or an increase of temperature at the seal faces.

Do seal faces have to be kept cool?

Most carbons and hard faces can tolerate a lot of heat. The elastomers (rubber parts) are
the parts you have to watch. They are the most sensitive to a change in stuffing box
temperature, especially if they are positioned in the seal face.

Hydraulically balanced seals generate very little heat between the faces.

Unbalanced seals usually require cooling because of the excessive heat they can generate.

Some face combinations generate more heat than others. Two hard faces as an example.

Some seal materials conduct heat better than others. Ceramic is a poor heat conductor and
carbon is not much better. Tungsten carbide and silicone carbide are excellent conductors
of heat.

When should you use two hard faces?

With any of the oxidizing agents.

When sealing any of the halogens.

If the product tends to stick the faces together.

If you are sealing hot oil and you have to pass a fugitive emission test.

Some de-ionized water will attack carbon in any form.

When you are not allowed anything black in the system because of the possibility of
color contamination.

Any time carbon/graphite will not work for some reason.

If the specifications call for two hard faces.

Why not standardize on two hard faces?

They generate higher heat than the carbon/ hard face combination.

They are not very forgiving. If the faces are not dead flat at installation, they seldom lap
them selves flat in operation.

Do seals have to leak.?

Any good quality mechanical seal should run without visible leakage.

Single, stationary, (the springs do not rotate) hydraulically balanced mechanical seals can
pass a fugitive emission test as long as the rotating portion of the seal is designed to be
located square to the shaft.

Rotating seals (the springs rotate with the shaft) seldom can pass a fugitive emission test.
They are too sensitive to various forms of misalignment.

Cartridge mounted stationary seals usually fail fugitive emission testing because the set
screwing of the cartridge to the shaft prevents the rotating face from positioning its self
square to the shaft. Some seal companies offer some type of a self aligning design to
solve this problem.

Why do most original equipment seal designs frett and damage the shaft under the dynamic
elastomer or spring loaded Teflon.?

Corrosion resistant shafts and sleeves protect themselves from corrosion by forming a
protective oxide (ceramic) layer on the metal surface. The dynamic elastomer in the seal
polishes this layer away as the shaft slides through the elastomer because of shaft
vibration, pipe strain, misalignment etc.

The ceramic protective oxide that is removed by the polishing action imbeds its self into
the elastomer causing it to act as a grinding wheel that increases the sleeve or shaft
damage.

Do you have to flush most slurry applications?

It depends upon the percentage of solids. Most fluid with entrained solids can run without
flush if you have met the following conditions:
o The packing stuffing box has been replaced with a larger inside diameter version.
Centrifugal force will throw the solids away from the lapped seal faces.
o You are using a hydraulically balanced seal that generates low heat.
o The seal springs are not located in the fluid.
o The fluid is at the seal outside diameter.
o The dynamic elastomer moves to a clean surface as the carbon wears.
o You are using suction recirculation to get flow in the stuffing box.

I am looking for a simple solution to a difficult problem. Do discharge recirculation filters or

cyclone separators installed between the pump discharge and the stuffing box make sense in
slurry applications?

I wish they did! Filters clog and then there is no circulation in the stuffing box.

Cyclone separators were never intended to be a single pass devise. The also require a
substantial difference in pressure between the discharge and the clean liquid connections.
In a pump application these pressures are too close together.

If I put a higher fluid pressure barrier fluid between dual seals, shouldn't that keep the faces
clean?

No, the clean fluid always takes the path of least resistance. That is the same reason that
higher pressure air does not keep dry solids from penetrating the lapped faces.

Centrifugal force will pack solids in front of the inboard seal face and restrict its
movement.

Do you need a higher pressure barrier fluid between dual seals?

Higher pressure is called barrier fluid; lower pressure is called buffer fluid.

The only dual seals that require a barrier fluid are the "back to back" rotating, unbalanced
versions, and you shouldn't use them any way.

Balanced tandem seals (one behind the other) use a buffer fluid that will not dilute your
product if the inner seal fails. They also put the pumping fluid at the inner seal outside
diameter where it belongs.

Dual seals should be hydraulically balanced in both directions so that they will stay shut
regardless of the direction of the fluid pressure.

How does seal hydraulic balance work?

There are two forces closing the seal faces.

o A spring force caused by the spring, springs, or bellows pushing on the seal face.
o A hydraulic force caused by the pressure of the fluid acting on the closing area of
the seal faces.

There are three forces opening the mechanical seal:

o A hydraulic force caused by fluid or vapor trapped between the lapped faces.
o Centrifugal force that is causing the rotating portion of the seal to try and become
perpendicular to the rotating shaft.
o Hydrodynamic forces generated between the seal faces because for all practical
purposes liquids are not compressible.

We balance these forces by reducing the closing area of the seal faces and thereby reduce
the closing force. This is usually done by a small sleeve inserted into the seal or as step
machined into the shaft. Metal bellows seals have an effective diameter measured through
the bellows to accomplish the same thing.

Is it O.K. to have a third party rebuild my mechanical seals?

Not really. If you're happy with your seal have the manufacturer, or the company that sold
it to you do the rebuilding. Here are a couple of reasons why:
o Carbon/graphite has to be molded in a sintering process and the third party doesn't
own the molds for your carbon/graphite face. Machined carbons don't have the
density required for good seal faces.
o There are many grades of elastomers. How do you insure you have the right
grade. You can't tell by looking at the part.

o Lapping is a real art. The temperature has to be closely controlled to get the right
flatness.
Should I be using split mechanical seals?

There are places where they are the only logical solution:
o Double ended pumps. If one seal is leaking why take the pump apart and change
both? Change only the one that is leaking.
o Large vertical pumps. Sometimes you have to take the roof off the building to
remove the solid mechanical seal.
o Large size shafts are a natural for split seals.
o Changing a seal means doing a re-alignment. Why go through that again?
o If you have to remove a lot of pump insulation to get to the seal.
o If the pump is in an awkward location, split seals make sense.

Many split seal designs can run with no visible leakage, but they seldom can pass a
fugitive emission test that calls for leak rates in the order of parts per million.

If I touch the lapped faces, are they ruined?

Not at all. Touching seal faces seldom causes problems. We are trying to keep solids from
penetrating between the lapped faces, so the less you handle them the less likely solids
will be deposited on the faces.

Why should you not use stainless steel springs or stainless steel bellows in mechanical seals?

Chloride stress corrosion is the problem and chlorides are every where. Use hastelloy "C"
springs and metal bellows and you'll never have this problem.

Why not standardize on Teflon as the preferred rubber part in a mechanical seal?

Teflon is not an elastomer, it doesn't have a memory and has to be spring-loaded to the
sleeve or shaft. This spring loading interferes with the flexibility of the seal and prevents
the elastomer part from flexing and rolling to compensate for minor shaft movements.

Why not mount the seal outside the stuffing box and then dirt and solids will not get into the
springs and sliding parts of the mechanical seal?

The sealing fluid will be at the inside diameter of the lapped faces where centrifugal force
will throw solids into the faces.

Solids will pile up in front of the seal preventing the faces from moving forward when the
sacrifical carbon wears.

What is a cartridge seal?

The rotating portion of the seal is mounted on a cartridge sleeve and this assembly is
connected to the stationary portion of the seal along with the seal gland to form a
cartridge assembly. Cartridge seals simplify the installation process and allow you to
make impeller adjustments without upsetting the seal face loading.

Do I need the new gas seals if I want to seal fugitive emissions?

Not really. Rotating seals do not pass fugitive emission tests because of their sensitivity
to misalignment. Stationary seals usually do not have this limitation.

The difficulty arises when you try to install a stationary seal on a cartridge sleeve. When
you tighten the sleeve set screws to the pump shaft you introduce misalignment between
the rotating seal face and the rotating shaft. Hysteresis (delay or lag) problems take over
and the result is the stationary seal design fails to pass the fugitive emission test. Any
good cartridge mounted self aligning seal can resolve this problem.

Although a single seal can pass the test, a dual seal is recommended with a low pressure
buffer fluid between the seals to act as a back up when the first seal wears out or fails.
The buffer fluid will prevent unwanted product dilution and simplify the installation
because there is no need for a compatible high pressure barrier fluid that is often hard to
find.

Why does my outside mounted seal make a whistling sound?

The seal faces are running dry. The product you are trying to seal is not a lubricant.

Every time I remove a rubber bellows seal from my pump it is stuck to the shaft. Why?

It is supposed to vulcanize its self to the shaft so that it can drive the rotating face. If you
can remove it easily something is wrong. You probably used the wrong lubricant on the
rubber during installation. This is a case where the lubricant we use is supposed to attack
the rubber and make it swell.

When my metal bellows seal fails because of breakage at the plates, the break is always near the
end fittings and never in the middle of the bellows. How is that explained?

This is the common mode of failure for excessive vibration. Metal bellows seals need
some type of vibration damping to stop harmonic and "slip-stick" vibration problems.