MSE (Consultants) Ltd. - Performance Testing & Trouble Shooting

Gas Compressor Performance Testing

MSE has carried out performance testing of a wide range of gas compressors operating in the field. This testing is performed, using ASME PTC 10 Class I procedures, which use the actual gases for which the machines were initially designed. Although it is not possible to duplicate the exact design compositions, flows and pressures, however, operating pressures and flows are similar to the original design which allows the Class I test procedures to be applied. MSE determines non-dimensional performance of the machine which allows for performance corrections required and ascertain the underlying compressor performance.

Field Tests Vs. Factory Tests

Factory performance tests are carried out by the manufacturer, in accordance with ASME PTC 10 Class II procedures, using simulated gases at very low pressures and speeds to conserve compression power and fuel costs for the test. These factory test results determine the aerodynamic performance of the compressors which is then applied to field operating conditions using corrections for Reynolds Numbers which has the effect of increasing efficiency.

Field testing of compressors is quite different from factory testing. Factory tests are performed on new as built machines while the compressors operating in the field are invariably old and have been in service over a number of years. Therefore it is reasonable to assume the field performance would differ from the factory test and would be generally lower as a result of wear and fouling etc.

However, MSE's experience of testing a very large number of compressors in the field has shown that the compressor performance in the field can be very different from the factory tests. MSE has carried out extensive research on this subject and published papers in professional publications: Determining the Real Performance of Centrifugal Compressors Operating in Oil and Gas Production Facilities.

Joint Industry Project

The field testing was also carried out under a Joint Industry Project which was supported by five oil companies. They included at that time the following names Centrica, BG-Group, Lasmo, bp and Conoco- Phillips. More than 50 compressors were tested as part of the JIP where field data was collected using the DCS or SCADA historians and analysed with performance analysis tools developed specially for the project. The compressor performance analysis tools developed during the JIP project have been further refined and are now extensively used by MSE.

Compressor Field Performance Database

MSE has created a large database of compressor performance which compares the design with the field performance. The database has grown over the years and provides an unrivalled resource for our clients and operating companies to benchmark their own machinery and compare it with the industry norms. This database also helps in providing reasons for performance deviations and can point to corrective measures which have been tried in the field such as compressor washing techniques and blade coatings etc.

Compressor Performance Testing Services

	Planning a performance test and procedure
	Conducting the performance tests and data analysis
	Benchmarking compressor performance operating in the field
	Assisting during compressor surge testing provided by the OEM
	Building computer models of the compressor and gas turbines
	Witnessing factory performance testing on behalf of the client

MSE services are used extensively by operating companies that are experiencing performance shortfalls or where there are recurrent equipment failures which are resulting in very low availability of the plant.