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The reciprocating compressor testing article
provides information about reciprocating
compressor mechanical running test,
Home aerodynamic testing, hydrostatic testing,
gas leakage test, bar-over test and vibration
analysis and testing. You may want to
GENERAL review the reciprocating compressor
inspection procedure and inspection and
Third Party test plan. 
Inspection

Vendor
Inspection

Factory
Acceptance Test

Inspection and
Test Plan

Commodity
Inspection

Industrial
Inspection
Reciprocating
Quality Control
Compressor Mechanical
Plant Inspection
Running Test
Coating
Inspection The API Std. 618 requires that reciprocating
Pre-Shipment compressor to be subjected to the 4 hours
Inspection unloaded running test after successful
inspection and testing that are done before
Vendor List and during assembly. To perform an
unloaded running test, the reciprocating
compressor cylinder valves shall not be
FIX installed for the mechanical running test.
EQUIPMENT The mechanical running test is considered a
routine test in the reciprocating compressor
Pressure Vessel testing. 
Heat Exchanger
The test shall be performed based on
Piping System manufacturer approved test procedure. The
Industrial Valve compressor is brought to the rated speed
and then runs for 30 minutes to get lube oil
Steam Boiler temperature, viscosity, bearing temperatures
Storage Tank and vibration amplitudes stabilized.After
operating parameter stabilization, the test
Process Heater
technician records the parameters in each
10 or 15 minutes as per requirements. 
ROTARY
EQUIPMENT
Centrifugal Pump

Centrifugal
Compressor

Reciprocating
Compressor

Gas Turbine

Steam Turbine
The following parameter is recorded
Fan & Blower periodically in this 4 hours:

Lube Oil Pressure

E&I Lube Oil Temperature
EQUIPMENT Bearing Temperature 
Lube Oil Viscosity 
Electric Power Consumption
Generator Rotor Speed 
Vibration
Electric Motor
The recorded values are provided by test
Power
engineer at the end of the test in a tabulated
Transformer
format. It is the responsibility of inspector to
Control Panel verify the values to make sure all of them
Switchgear are within acceptance range. As mentioned
in above, the acceptance range is provided
Power Cable in the test procedure and compressor
datasheet. 

I4I As per API 618, the power consumption

ACADEMY shall not be more than 3% of the rate power
value indicated in the datasheet.
I4I Academy
Courses
Aramco API The API 618 also requires the trip speed
Classroom shall not be less than 110 % of the rotor
rated speed. 
API CPD Hours

API SIFE Training The crankcase vibration is measured in real-

time basis in X and Y axises. The cylinder
API 510 Training
vibration is measured in X, Y, and Z axises
API 570 Training (Horizontal, Vertical, and Axial). The
measured values shall be verified aginst
API 653 Training
acceptance criteria provided in API 618 or
API 571 Training approved test procedure. 

ASME Training
Course If specified, the lube oil and cooling water
consoles also shall be subjected to the 4
ASME IX Training hours mechanical running test as per
Quality Control requirements of API 614.
Training

CWI Reciprocating
Endorsement
Training
Compressor Aerodynamic
Performance Test
I4I Academy
Contact
The reciprocating compressor aerodynamic
performance testing is not routine test in
GET IN the reciprocating compressor testing and is
identified as an optional test in API 618. If
TOUCH the performance test was a purchase order
requirement, then is performed based on
About Us
ISO 1217 and with cylinder valves installed
Contact Us in the closed loop system. 

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The manufacturer shall provide tables or
Privacy Policy curves of power and capacity vs. suction
pressure with the parameter of discharge
We will be updating pressure at the end of the test. These curves
and growing this or tables shall be verified aginst estimated
site with more and curves or tables and make sure that
more of industrial measured values are within acceptance
inspection related range.
articles.
Please subscribe to Rod load and gas load charts and similarly
my monthly shall be checked against estimated values.
newsletter so you The starting torque Vs. Speed curve also
don't miss a thing. shall be verified and verified against
estimated value. 
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The efficiency value shall not be less than
specified value. The power consumption
also shall be checked not to be more than
Enter Your First 3% of rated value. 
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Reciprocating
I am at least 16 Compressor Hydrostatic
years of age.
Test
I have read and
As per API 618, the cylinder, cooling water
accept the privacy
policy. jacket and piping system shall be subjected
to the hydrostatic testing. The hydrostatic
I understand testing shall be than at 1.5 times maximum
that you will use allowable working pressure and the
my information to pressure shall be held for minimum 30
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The cylinder shall be hydrostatically tested

before installation of the cylinder liner.
Besides, cylinder shall be tested with heads,
valve covers, clearance pockets, and
fasteners being already installed. 
The filters and pressure vessel generally are
manufactured at pressure vessel
manufacturers and are tested there, So, it
might not be necessary to subject them to
hydrostatic testing at the compressor
manufacturer facility. 

The hydrostatic testing shall be done by

calibrated pressure gage, and the preferable
range is two times of the test pressure but
in no case shall be less than 1.5 times and
more than 4 times of the pressure test. 

Reciprocating
Compressor Gas Leakage
Test
The API 618, requires helium leak test if the
"service gas" molar mass equal or less than
12 or "service gas" has a mol percentage of
Hydrogen Sulfide  (H2S) equal or more than
0.1%.This information can be found in
reciprocating compressor datasheet. 

 
The helium leakage test shall be done after
hydrostatic testing, and the test pressure
shall be the same amount of compressor
maximum allowable working pressure.

Similar to hydrostatic testing, the cylinder

liner shall not be installed and shall be
tested with the heads, valve covers,
clearance pockets, and fasteners. 

The pressurized compressor with helium at

MAWP shall be submerged to the water
pool, and the test result will be considered
satisfactory if no bubble observed during
the test (Zero Leakage). During the helium
test, the internal pressure shall be
maintained and recorded. The test shall be
done based on manufacturer approved
procedure. 
The helium probe is the alternative test
which can be done in lieu submergence test.
The instrument sensitivity shall be agreed
between compressor purchaser and
manufacturer. Most of the manufacturers
sue the submergence test. 

Reciprocating
Compressor Bar-Over
Test
Reciprocating compressor bar-over test
includes measurements of piston end
clearance and piston rod vertical and
horizontal runout measurement.

The test shall be done during the assembly

and also after the mechanical running test
which is called final bar-over test. 
The piston end clearance is measured by
feeler gage, and piston rod runout is
measured by the dial indicator. The final bar-
over test is one of the important test in the
reciprocating compressor testing. 

Piston End Clearance

The piston end clearance measurement

shall be done during assembly and after the
mechanical running test as a final bar-over
test. 

The clearance can be measured by inserting

of filler gage or using a lead wire.
A lead wire is inserted from valve port, the
compressor is turned and compresses the
lead wire trapped between piston and
cylinder. The compressor lead wire
thickness can be measured and identify the
piston end clearance. 

Piston Rod Horizontal Runout

Measurement

Similarly, the piston rod horizontal runout

shall be performed during the assembly and
also after the mechanical running test at the
bar-over test. The runout test indicates the
piston rod sagging amount. Dial gage is
installed on the horizontal side of the piston
rod, and then the compressor is turned, and
the piston rod is moved from crank-end to
head-end.

Then the dial gage indication is recorded

and is checked against acceptance criteria.
As per API 618, the horizontal piston rod
runout shall not be plus or minus 0.00015
mm/mm (0.00015 in./in.) of stroke value
(±0.015% of stroke value) but in no case
shall be more than 0.064 mm or 0.0025 in. 
Piston Rod Vertical Runout
Measurement 

Similarly, the runout is measured by the dial

indicator. The dial indicator is mounted in
verticle side of the piston rod (top of piston
rod), the compressor turned, and the piston
rod is moved from one end to other end, and
the amount of runout is measured and
recorded. As per API 618, the vertical runout
shall not be more than plus or minus of
0.015% of stroke value. 

You need manufacturing drawing to be able

to witness this test. You need to have stroke
value and make a simple calculation and
obtain maximum allowed values and then
compare measured runout with your
calculated values. 

Reciprocating
Compressor Vibration
Analysis and Testing
The API 618, requires following vibration
limits at compressor skid, cylinder, distance
pieces, crankcase and cylinder flange
pressure pulsation vibration. The vibration
testing is one of important item in
reciprocating compressor testing that is
performed in mechanical running test part. 

Vibration Limit @ Compressor Skid

The manufacturer shall make analysis and

determine whether the vibration frequency
is going to be less than 10 Hz or higher than
10 Hz.   The manufacturer makes the
calculation for vibration that comes from
natural frequency of base plate and also
significant excitation frequencies. 

If the analysis indicates the vibration

frequency is going to be less than 10 Hz,
then magnitude of vibration shall not be
more than 4 mil 0 to peak value or 8 mil
peak to peak value.

If analysis indicates the vibration frequency

is going to be higher than 10 Hz, then
magnitude of vibration shall not be more
than 4.5 mm/s RMS value (0.175 in/s RMS)

As you see, we are using displacement

vibration probe (sensor) when vibration
frequency is less than 10 Hz and using
velocity vibration probe (sensor) when
vibration frequency is higher than 10 Hz. 

The API 618, requires that the reciprocating

compressor manufacturer makes necessary
calculations and provide the vibration limits
for the cylinder, distance pieces, and
crankcase. These amounts normally are
indicated in approved mechanical running
test procedure. The vibration testing is done
in 4 hour mechanical running test. 

The API 618 also requires that cylinder

flange pressure pulsation vibration shall not
be more than of 7% of average absolute line
pressure or 3R% whichever is lesser. (the R
is the stage pressure ratio). The vibration
amplitude should be measured by
displacement probe (proximitor sensor).

The standard also provides the piping

system vibration limit. The limit is 0.5 mm
peak to peak or 20 mil peak to peak when
vibration frequency is less than 10 Hz. The
limit is 32mm/s peak to peak or 1.25 in/s
peak to peak when vibration frequency is 10
thru 100 Hz.

The third party inspection for reciprocating

compressor article provides a sample
inspection instruction for inspection. You
may also need to review a sample
recirocating inspection and test plan. 

Following content provides some other

information about reciprocating compressor
testing:
Applicable Standards @ Reciprocating

Compressor Testing

The applicable standards for these tests

are:

API Standard 618; reciprocating

Compressor for Petroleum, Chemical
and Gas Service Industries
ASME PTC 10; Performance Test Code
on Compressors and Exhausters
BS EN ISO 5167-2; Measurement of
fluid flow by means of pressure
differential devices inserted in circular
cross-section conduits running full -
Part 2: Orifice plates
BS ISO 5389 Turbo compressors
Performance Test Code

Mechanical Running Test @  Reciprocating

Compressor Testing 

The following components are used from

Job equipment

Compressor main unit

Lube oil unit

The following components are used from

test stand

Motor
Pressure gauge
Temperature gauge

The following components are not used in

the test

Suction/Discharge Valves
Surge Drum
Gas Piping
 Drum/Piping Support
Instrument

The compressor is assembled in test stand

in manufacturer's shop. The the cylinder
valves would not be installed to perform
non-load continuous operation.

The compressor is operated at the specified

rotating speed for 4 hours continuously and
mechanical stability, temperature, pressure,
vibration and noise are checked.

After 4 hours continuous operation the

reciprocating compressor needs to be
stopped and bearing temperatures to be
measured.

Then the reciprocating compressor is

diassmbled and strip down inspection is
done based the requirement of inspection
and test plan.

Measurement items during Mechanical

running test

Rotating Speed  @  Reciprocating

Compressor Testing

The rotating speed is measured by a

tachometer every 30 minutes. The
measurement value to be an average value
of those indicated by the tachometer.

Rotating speed need to be be within of the

specified rotating speed.

Oil Temperature  @  Reciprocating

Compressor Testing
The supplied and discharged oil
temperature of crankcase is measured by
temperature gauges in the shop lube oil unit
every 30 minutes.

The supplied and discharged oil

temperature needs to be within specified
values.

Oil Pressure  @  Reciprocating Compressor

Testing

The supplied oil pressure of crankcase

(bearings)and discharged oil pressure of
lube oil pump are measured by pressure
gauges in oil unit every 30 minutes.

The obtained values need to be in within

specified values

.Vibration  @  Reciprocating Compressor

Testing

The vertical and horizontal vibrations of

crankcase are measured at two locations by
the use of a shop vibration meter. Also, the
vibration at cylinder is measured with
respect toaxial, horizontal and vertical
directions by the use of a shop vibration
meter. Vibration measurement needs to be
done once during test operation.

The vibration of crankcase (peak to peak)

needs to be within specified values.

Noise @ Reciprocating Compressor Testing

The noise is measured at a distance of 1 m

from the side of the main unit and four
directions by using a shop noise meter.
Noise measurement to be done once during
test operation.

The obtained noise value need to be within

specified value.

Bearing Temperature
Measurement @ Reciprocating Compressor
Testing

The temperature for each of following

bearings during the 4-hour continuous test
operation needs to be measured
periodically. 

Temperature of main bearing

Temperature of crank pin bearing
Temperature of cross head pin

The measured values need to be within

specified values.

Lube Oil Console Running

Test @ Reciprocating Compressor Testing

After completion of successful oil flushing

the lube oil console running test needs to be
done. Running test would be performed
based on the following conditions for 4
hours, and temperature and pressure shall
be measured every 30 minutes.

Oil grade as per design

Lube oil pressure as per design
Lube oil temp as per design
Motor speed as per design
Start up as per design (generally cold
condition)

No leakage must be seen during the test

and Pressure drop of filter element shall not
exceed a specified value at operating oil
temperature. No abnormal sound shall be
confirmed during the running test.

Tempered Cooling Water Console Running

Test @ Reciprocating Compressor Testing

After completion of successful cooling

water flushing the tempered cooling water
system running test needs to be done.
Running test would be performed based on
the following conditions for 4 hours, and
temperature and pressure shall be
measured every 30 minutes.

Fluid as per design (water with

inhibitor or etc.)
Pressure as per design
Temperature as per design
Motor speed as per design

No leakage must be seen during the test

and no abnormal Pressure drop must be
confirmed. No abnormal sound shall be
confirmed during the running test.

After checking of the above items at two

times, the water pump is changed to
another and the same items needs to be
checked.

Thermodynamic Performance Test

@ Reciprocating Compressor Testing

The reciprocating Compressor

thermodynamic performance test is similar
to the centrifugal compressor. You may
review Centrigugal Compressor Testing for
detail test instruction.
Following data need to be extracted from a
centrifugal compressor design book,
datasheet and operating manual and to be
available during the test.

Specified Operating Speeds

Normal Operating Spee

Minimum Operating Speed
Maximum Continuous Speed
Trip Speed

Maximum Shaft Vibration

At Maximum Continuous Speed

At Trip Speed

Lube Oil Data

Oil Viscosity Class

Oil Inlet Temperature
Oil Inlet Pressure
Maximum Oil Volume Flow Of
Compressor

Shaft Seals

Seal Type
Seal Medium

Related Articles:

TPI Inspection for Reciprocating

Compressor, TPI Inspection for Centrifugal
Pump, TPIInspection for Gas Turbine, TPI
Inspection for Steam Turbine, TPI Inspection
for Fan and Blower, TPI Inspection for
Centrifugal Compressor, Screw Compressor
Testing,Centrifugal Pump Performance Test,
Centrifugal Compressor Testing, Fan
Mechanical Running test, Fan Performance
Test
Return Home Inspection for Industry

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Mohammad Abdalwahed
very good article.
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Enzo Campeggio
helpful
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Hani Khattab
Excellent report
Dana Petroleum Field General Manager
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Vipin Tolia
Dear Respected sir ,

cid:[email protected]

We came to know that you are th

That we are the manufacture of

Introduction letter below so plea

Introduction Letter… See more

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Vipin Tolia
Dear Respected sir ,

cid:[email protected]

We came to know that you are the distrib

That we are the manufacture of compres

below so please have a look.

Introduction Letter… See more

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Mohammed Shamim Haye

Awesome!! It would be helpful if can be a
procedure.
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Eben Ezer Situmorang

good article
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Santosh Palekar
Very good & informative article.
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Getachew Habtewold
very nice article
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