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FMDS0795
FMDS0795
COMPRESSORS
Table of Contents
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7-95 Compressors
Page 2 FM Global Property Loss Prevention Data Sheets
List of Figures
Fig. 1. Main types of compressors .............................................................................................................. 12
Fig. 2. Vortices acting on an airfoil .............................................................................................................. 15
List of Tables
Table 1. Sprinkler Protection for Compressors With a Lube-Oil Hazard ....................................................... 4
Table 2. Summary of Recommended Alarms and Trips for Protective Systems for Dynamic Compressor .. 6
Table 3a. Recommended Protective Devices, Alarms, and Trips for Reciprocating Compressors ............... 8
Table 3b. Recommended Protective Devices, Alarms, and Trips for Rotary Screw Compressors ............... 8
1.0 SCOPE
This data sheet provides loss prevention recommendations for dynamic and positive displacement
compressors. The recommendations are intended to prevent or minimize the effects of equipment failures,
fires, and explosions involving compressor units.
Other data sheets that address specific compressor applications are:
• DS 7-35, Air Separation Process
• DS 13-26, Internal Combustion Engines (addresses integral engine-compressor units; reciprocating units)
For the purposes of this data sheet, a compressor unit includes the following sections: casing(s) and
associated utility and support systems including lube oil, seal oil (when included), shaft couplings, shafts,
increaser/reduction gears, intercoolers, separators, filters, etc.
1.1 Changes
January 2022. Interim revision. Minor editorial changes were made.
2.2 Occupancy
2.2.1 Locate air compressor intakes away from sources of flammable vapor, gas, steam, dust, cooling tower
exhaust, or other contaminants. Provide suitable intake-air filters to remove suspended solids.
2.2.2 Provide basements or below-grade spaces containing flammable gas piping with continuous positive
ventilation of 0.5 cfm/ft2 (0.15 m3/min/m2) of ceiling area. This ventilation is not needed where only welded
piping is used (no leakage points such as valves, fittings, etc.).
2.2.3 Where flammable gas compressors are installed, provide grated tops with at least 50% open area for
piping in trenches and tunnels. Alternatively, provide positive exhaust ventilation of 1 cfm/ft2 (0.3 m3/min/m2)
of ceiling area throughout flammable gas pipe trenches and tunnels located indoors.
2.2.4 Limit ordinary combustibles in the compressor area to the minimum required for routine operation and
maintenance. Store oil, spare parts, filters, etc. in a separate storage room or warehouse.
2.3.1 Detection
2.3.1.1 Provide an FM Approved combustible gas detection system for flammable gas compressors (including
natural gas compressors), designed as follows:
A. Establish alarm and trip “set points” below 25% of the lower explosive limit (LEL) of the fuel, and at
least the lowest feasible gas concentration to avoid spurious trips.
B. Interlock the detection to shut down the compressor system upon reaching the trip “set point,” including
closure of all inlet and discharge gas lines and opening of all blowdown valves in the compressor building.
2.3.1.2 Provide FM Approved flame or heat detectors arranged in accordance with Data Sheet 5-48, Automatic
Fire Detection, for flammable gas compressors (including natural gas compressors). Arrange the fire
detection system to shut down the compressor system upon actuation. Arrange all inlet and discharge gas
lines to close, and all blowdown valves in the compressor building to open upon shutdown. This fire detection
system is not necessary where automatic sprinkler protection is provided and interlocked to shut down the
compressor system upon actuation.
2.3.1.3 Design detection systems to transmit an alarm to a constantly attended location.
B. Where sprinklers are not necessary for the compressor or lube-oil hazard, but are needed to protect
another hazard in the area (e.g., the building or adjacent occupancy is combustible), design automatic
sprinkler protection for the surrounding occupancy. At a minimum, design the protection for a Hazard
Category 2 (HC-2) occupancy in accordance with Data Sheet 3-26, Fire Protection for Nonstorage
Occupancies.
2.3.3.3 Insulate any surface with temperatures approaching the autoignition temperature of the lubricating
oil to prevent ignition of escaping oil. Provide insulation that is impervious to oil or cover it with sheet metal.
2.3.3.4 Provide a means, in a safe location (accessible), for remotely stopping the oil pumping equipment
during a fire or other emergency.
2.3.3.5 Provide hinged covers for oil tanks associated with seal oil for flammable gas compressors to minimize
damage from an internal flammable gas-air explosion. Provide vents on the flammable gas seal oil system,
flammable gas detraining tanks, with pipes venting to a safe location.
Table 2. Summary of Recommended Alarms and Trips for Protective Systems for Dynamic Compressor
Protective Function Alarm Trip
Surge Protection X
High differential pressure across process gas inlet filter X [1]
Low process gas intake pressure for each stage X X
High process gas intake temperature for each stage X
High discharge temperature from each stage and/or compressor X X
High vibration (installed instrumentation) X
High temperature in thrust bearings pads or high axial deflection X [2]
(reduced thrust-bearing clearance)
High temperature at bearing oil drain or in journal bearing metal X [2] [3]
Bearings & Lube Oil System
High differential pressure across lube-oil filter X
Low lube-oil pressure at lubricated equipment bearing X X
Low level in lube oil reservoir X
High oil temperature leaving oil cooler (to bearings) X [3]
Low lube-oil rundown tank level (gravity or pressurized tank) X
Seal Oil System (if system installed)
High differential pressure across seal-oil filter X
Low seal oil pressure at equipment seal X
Low level in oil reservoir (if separate from lube oil reservoir) X
Low level for each seal-oil overhead tank or low seal oil differential X X
pressure for each seal oil level.
Notes:
[1] A reduction in load or unit trip is acceptable depending on the process and operating limits, or a runback condition also possible. May
result in collapsing ductwork, failing expansion joints, or FOD.
[2] Trip in accordance with standard operating procedure (see Section 2.4.2.6). An automatic trip is expected when axial clearances have
exceeded limits designated by the OEM.
[3] In some cases, thrust trip may be interlocked to trip with a high Babbitt temperature alarm.
2.4.2.2 Provide an automatic anti-surge system to prevent operating in unstable regions that may cause
damage to the compressor. The specific system used is process- and OEM-dependent. Surge protection lines
should be directed to intrinsically safe areas for the process involved. Piping supports should be inspected
for cold and operational settings.
2.4.2.3 Provide lube-oil, seal-oil (if required) and oil-purification systems in accordance with the OEM’s
recommendations. The lube and seal oil system may be combined or separate, depending on the application.
These systems may service either a single component or a train of components. A compressor train includes
components such as a steam turbine or gas turbine drivers, compressors, gearbox, coupling, etc. If there
is a common lube-oil system for these components, ensure the oil and systems used are compatible with all
of the components serviced.
2.4.2.4 Provide a separate source of oil for each train (or component) supplied.
2.4.2.5 Ensure the lube-oil system configuration, including electrical and mechanical support systems, are
inherently resilient (i.e., no single failure can result in a loss of equipment lubrication).
2.4.2.6 Lube-oil temperature is a critical operating parameter and if the compressor operates for an extended
period of time at elevated temperatures the bearings can be damaged. Provide high lube-oil or bearing metal
temperature trips as follows:
A. For an attended unit: Provide an alarm on high lube-oil or bearing metal temperature and have a
procedure in place for the operator to respond promptly to diagnose the source of the high temperature.
If the high temperature condition cannot be corrected and the oil temperature reaches the design limit,
direct the operator to trip the unit, or have the unit automatically trip when the temperature reaches the trip
set point.
B. For an unattended unit: If the oil or bearing metal temperature reaches the design set point, have the
unit automatically trip.
Table 3a. Recommended Protective Devices, Alarms, and Trips for Reciprocating Compressors
Protective Function Alarm Trip
Reciprocating Compressor
High vibration (installed instrumentation) [1] X X
High gas discharge pressure for each cylinder X X
High-temperature at compressor or stage discharge X X
High differential pressure across process gas inlet filter X
Cooling water jacket, high-temperature (if cooling jacket present) X X
Low lube-oil pressure downstream of pressure regulator X X
High lube-oil temperature [2] X X
Low level in lube oil reservoir X
Cylinder lube-oil, failure X
High Level in separator X X
Seal Oil System (if system installed)
High differential pressure across seal-oil filter X
High or low seal oil pressure X X
High or low seal oil temperature [2] X X
High or low level in seal oil reservoir (if separate from lube oil reservoir) X
Low level for each seal-oil overhead tank or low seal oil differential X [3]
pressure for each seal oil level.
Notes:
[1] Refer to Section 2.5.2.1 for additional guidance on unmonitored units.
[2] Trip in accordance with operational procedure (see Section 2.4.2.6).
[3] May not be required by OEM.
Table 3b. Recommended Protective Devices, Alarms, and Trips for Rotary Screw Compressors
Protective Function Alarm Trip
Rotary Screw Compressor
Axial Position Movement X
Overspeed X X
Unit Shutdown X X
Operation of Spare lube oil/seal oil pump X
High winding temperature X
High vibration (installed instrumentation) [1] X X
High bearing temperature X
High inlet-air-filter differential pressure X
High lube oil filter differential pressure X
High-temperature at compressor or stage discharge X X
High gas differential pressure X
High thrust bearing drain temperature X
High temperature to compressor jacket (if cooling jacket present) X X
High Level in separator X
High or low lube-oil temperature [2] X X
High or low level in lube oil reservoir X [3]
Low coolant flow to compressor jacket (if cooling jacket present) X
Low lube-oil pressure downstream of pressure regulator X X
Low buffer gas pressure X
Seal Oil System (if system installed)
High differential pressure across seal-oil filter X
High or low seal oil pressure X
High or low seal oil temperature [2] X
High or low level in oil reservoir (if separate from lube oil reservoir) X
Low level for each seal-oil overhead tank or low seal oil differential X X
pressure for each seal oil level.
Notes:
[1] Refer to Section 2.5.2.1 for additional guidance on unmonitored units.
[2] Trip in accordance with operational procedure (see Section 2.4.2.6).
[3] May not be required by OEM.
2.4.5 Separators
2.4.5.1 When an air filter/separator is specified by OEM, provide an alarm and differential pressure indicator
across the filter(s).
2.4.5.2 Ensure that solids are being removed by an inlet separator and do not pass through the screw
compressor. It is possible to damage the rotor, rotor housing, and oil pump due to the collection of particles
in the discharge separator.
2.4.7 Expanders
Refer to Data Sheet 13-3, Steam Turbines.
2.5.1 Operations
2.5.1.1 Operate the unit within the limits specified by the OEM. Ensure operations personnel have adequate
knowledge of equipment operation and the ability to acknowledge adverse conditions to prompt a process
of analysis and/or investigation for excursions of key operating parameters.
2.5.1.2 Monitor the gas properties to ensure it is delivered in accordance with the compressor manufacturer’s
recommendations for the unit.
2.5.2.2.4 Base performance and surge-margin calculations on the inlet pressure, defined as downstream of
the inlet filter if one is installed.
A. The condition of the inlet filter is important in avoiding axial-flow compressor blade failures. Monitor
condition of the inlet filter by the differential-pressure sensor as recommended in Table 2.
B. If the alarm level established by the filter manufacturer is exceeded, clean or replace the filter as
indicated.
C. Do not permit pressure drop through the filter to exceed 2 in. H2O (0.5 kPa).
B. Processes and procedures needed for removal, dismantling, transportation, availability, and installation
of a compressor unit and/or components
C. Review of any service contracts with the OEM and/or vendors to identify the duration of delivery of
the compressor unit and/or components. Review compressor repair/replacement options/sources strategy,
focusing on rotors/impellers, blading and stationary elements.
D. OEM and/or third-party vendor review to determine the optimum spare part strategy
2.8.2 Sparing
Sparing can be a mitigation strategy to reduce the downtime caused by a compressor breakdown depending
on the type, compatibility, availability, fitness for the intended service, and viability of the sparing. For general
sparing guidance, see Data Sheet 9-0, Asset Integrity.
Dynamic compressors, also known as turbocompressors, use centrifugal or axial force to accelerate the gas
and convert the velocity of the gas to pressure. Centrifugal and axial-flow compressors are the main types
of dynamic compressors.
In centrifugal compressors, the fluid flows radially through the compressor. The compressor impeller is used
to force the fluid to the rim of the impeller, increasing the velocity. Stationary diffuser/guide vane/diaphragms
between impeller sections direct and convert the velocity energy to pressure energy. Centrifugal compressors
have lower volume (flow rate) and higher pressure ratios (discharge pressure/suction pressure) compared
to axial compressors so they are used in applications where those performance parameters are required.
In axial compressors, the fluid flows straight through the compressor (parallel to the compressor shaft) through
blade airfoils set in rows as pairs - One compressor (rotor) and one stationary (vanes). The compressor
airfoils accelerate the fluid. The stationary airfoils turn and decelerate the fluid to prepare and redirect the
flow for the rotor blades of the next stage. Axial compressors have higher volume (flow rate) and lower
pressure ratios (discharge pressure/suction pressure) compared to centrifugal compressors. Axial
compressors also offer a higher efficiency, speed capability and higher capacity for a given size compared
to a centrifugal compressor. However, axial compressors have a relatively low pressure capability and a
narrower operating range so they are used in applications where those performance parameters are
required.
Positive-displacement compressors physically reduce the initial volume of the gas in a closed chamber to
increase the pressure. These compressors may use screws, sliding vanes, lobes, gears, or a piston to trapping
a set amount of gas and with each stroke force it into a smaller volume. The two main types of displacement
compressors are reciprocating and rotary.
Compressor trains may contain several compressors along with drive unit(s), coupling(s), gear set(s) and
clutch(s). These components are addressed in the following data sheets:
Drivers:
• DS 5-17, Electric Motors
• DS 13-3, Steam Turbines
• DS 7-101, Fire Protection for Steam Turbines and Electrical Generators
• DS 13-17, Gas Turbines
• DS 7-79, Fire Protection for Gas Turbines and Electrical Generators
• DS 13-26, Internal Combustion Engines
Other components:
• DS 13-7, Gears
• DS 13-18, Industrial Clutches and Clutch Couplings
Ideally, pressure or velocity of the flow entering an impeller stage would be uniform (i.e., there would be no
flow distortion), but a vane would encounter average conditions as it rotates through one revolution of the
rotor. However, there is always some distortion, which can be represented as a non-uniform velocity around
the flow path from 0° to 360°.
3.1.1.8 Surge
Surge is behavior in axial and centrifugal compressors in which the pressure at the compressor inlet drops
to the extent that the flow through the compressor reverses. For surge to occur the inlet flow is reduced to
the point where the compressor head cannot overcome the discharge pressure. This results in flow
instabilities, causing reversal of flow in the compressor, significant reduction in discharge pressure and
increase in internal temperatures. The resulting axial forces/stress on compressor internal and external
components, including impellers, blades, vanes, shafts, bearings, housings, casings and piping systems can
result in component damage and failures. The increased internal temperatures can result in rub damage
due to different expansion rates of the compressor components.
Surge can be avoided with properly designed control systems. These systems prevent compressor operation
in unstable ranges where damage can occur. Surge avoidance (“anti-surge-control”) consists of a recycle
loop that can be activated by a fast-acting valve (“anti-surge valve”) when the control system detects that the
compressor is approaching its designed surge limit. The anti-surge valve recycles gas from the discharge
to the suction when low flow is detected. Typical control systems use suction and discharge pressures and
temperatures, together with the flow through the compressor to calculate the relative distance (“turndown”)
of the present operating point to the predicted or measured surge line of the compressor. The surge control
system must protect the compressor without causing fluctuations or disruptions in the process. Control
system sizing must account for both steady state operations to meet process demand requirements (including
normal startup and shutdown) and emergency shutdown conditions where reducing the pressure differential
across the compressor to an acceptable range is required.
Surge systems require adequate inspection, testing and maintenance to verify operational integrity.
Performance deterioration of the compressor should be corrected before it becomes excessive, since a
deteriorated compressor may have a reduced surge margin.
3.1.1.8.1 Surge Hazards in Centrifugal Compressors
In centrifugal compressors the impellers act as the rotating aerodynamic components. A significant hazard
from surge in centrifugal compressors is the impeller inlet and outlet surfaces (shrouded impellers) and blade
surfaces (open impellers) are subjected to large stresses. These forces can cause impeller cracking and
fracture, damaging internal components.
3.1.1.8.2 Surge Hazards in Axial-Flow Compressors
Axial compressors are designed to a certain airflow and blade velocity. Surge in axial compressors results
in flow instability in the blade rows and is characterized by high-speed reversals of flow. At a given rpm,
reversal occurs at low flows and may originate about midway along the compressor (i.e., the blade row that
first becomes unstable is usually not in one of the early stages).
A significant hazard from surge in axial-flow compressors is that the blades are subjected to oscillating forces
and deflection stresses which can cause blade cracking or failure and/or contact with the preceding row of
stator vanes. This phenomenon is known as “clashing,” and it is characterized by distinctive triangular imprints
of the rotating blades on the stationary vanes at their outer ends. This can result in blade liberation and the
resulting upstream and downstream damage.
case, a shower of sparks was seen at the compressor just prior to the fire. Thus, ignition may have been
the result of a severe internal rub following a spark-producing thrust-bearing failure. Another incident also
involved a severe thrust-bearing failure.
A break or leak in the system piping downstream of the compressor could result in an intense fire involving
combustibles in an oxygen-rich atmosphere.
4.0 REFERENCES
4.1 FM Global
Data Sheet 1-44, Damage-Limiting Construction
Data Sheet 3-26, Fire Protection for Nonstorage Occupancies
Data Sheet 5-1, Electrical Equipment in Hazardous Locations
Data Sheet 5-48, Automatic Fire Detection
Data Sheet 7-13, Mechanical Refrigeration
Data Sheet 7-14, Fire Protection in Chemical Plants
Data Sheet 7-32, Ignitable Liquid Operations
Data Sheet 7-35, Air Separation Process
Data Sheet 7-43, Process Safety
Data Sheet 7-45, Instrumentation and Control in Safety Applications
Data Sheet 7-79, Fire Protection for Gas Turbines and Electric Generators
Data Sheet 7-83, Drainage and Containment Systems for Ignitable Liquids
Data Sheet 7-101, Fire Protection for Steam Turbines and Electric Generators
Data Sheet 9-0, Asset Integrity
Data Sheet 12-2, Vessels and Piping
Data Sheet 12-43, Pressure Relief Devices
Data Sheet 13-3, Steam Turbines
Data Sheet 13-7, Gears
Data Sheet 13-17, Gas Turbines
Data Sheet 13-18, Industrial Clutches and Clutch Couplings
Data Sheet 13-26, Internal Combustion Engines
4.2 Others
American Petroleum Institute (API). API 617, Axial and Centrifugal Compressors and Expander-Compressors
American Petroleum Institute (API). API 614, Lubrication, Shaft-Sealing and Oil-Control Systems and
Auxiliaries
American Petroleum Institute (API). API 618, Reciprocating Compressors for Petroleum, Chemical, and Gas
Industry Services
American Petroleum Institute (API). API 619, Rotary-type Positive Displacement Compressors for Petroleum,
Petrochemical, and Natural Gas Industries