entrifugal Compressor Failure Analysis Case Study

Problem A petrochemical plant had experienced multiple failures of an open-faced impeller on a multistage centrifugal compressor. A blade or a portion thereof would break loose causing major damage to the compressor and resulting in significant down time. KHE was contracted to perform an independent study of the latest failure. Solution KHE conducted an in depth study of the process, process controls, upstream and downstream equipment, and the compressor itself. Field Measurements were taken to determine dynamic conditions for vibration, pressure pulsation and natural resonant frequencies of the compressor and impeller. It was determined that under specific process conditions and rotor speeds, the 2nd mode natural frequency of the impeller the acoustic natural frequency of the suction volute and the blade passing frequency all matched up resulting in catastrophic failure of the impeller. Results The compressor was immediately lmiited in speed to avoid the conditions. KHE designed a new impeller to allow increased process throughput at lower speeds and moved the 2nd mode natural frequency higher and away from any running speeds or blade passing frequencies.