Aerothermodynamic and rotordynamic performance evaluation to diagnose deposits accumulation in a gas lift centrifugal compressor

The paper presents a case study focusing on the assessment of the aerothermodynamic and rotordynamic performance to diagnose deposit accumulation on the internals of a centrifugal compressor. The case involves a four-stage gas lift centrifugal compressor powered by a 5.9 MW induction motor and utilizing a fluid coupling to regulate the compressor's rotational speed. The Huntington 4-point method was employed to evaluate the polytropic head and efficiency of the four compressor sections over a 20-month period, with pressure and temperature data sampled every 6 hours. The efficiency model was supported by the GERG-2008 equation of state, used to calculate the necessary thermodynamic properties at intermediate and endpoint states. The aerothermodynamic analysis identified a deterioration in polytropic efficiency in compressor section 3, accompanied by a pressure drop and an increase in discharge temperature. Simultaneously, the rotordynamic response was examined through various vibration plots. Although the increase in the vibration amplitudes was not significant, a notable phase shift was observed. This decline in polytropic efficiency and change in vibration patterns were attributed to severe fouling, which was confirmed during the overhaul of the HP compressor. Root cause investigations revealed the deposit as reactive, leading to the installation of an online washing system. Over a nine-month observation period post-maintenance, the compressor operation was stable with no degradation in its polytropic efficiency.