Surge

Phenomenon
Hassan Mohamed A. M. Hassan
Lead Mechanical Engineer
.Worley Parsons Engineers Egypt Ltd
Cairo Egypt 01223190213
Tel.: +2-02-22706178
Email hasmonem@gmail.com
1
1
 HAPPENS
HAPPENS
::ONLY
ONLYTO
TO
CENTRIFGAL
COMPRESSORS

AND AXIAL FLOW

COMPRESSORS
But
But Does
Does not
not Happen
Happen to
to
Reciprocating
Reciprocating
2
2 Compressors
Compressors
 Surge Description
This phenomenon is a centrifugal and axial compressor internal-1
phenomenon
The discharge flow stops completely (Flow rate=0)-2
All the flow return back to the suction-3
This action convert the compressor to Turbine-4
The turbine produces a power equal to the motor power but in the -5
reverse direction the rotor direction
This action creates a sever torsion force on the compressor rotor -6
When the flow return back to the suction the machine now has the -7
enough flow rate in the suction to build up the required pressure,
then it send back gas to the discharge side again.(we call this one
.complete surge cycle)
This action repeated from 5 to 20 times per second -8
COMPRESSOR
COMPRESSOR
SURGE
SURGE CYCLE
CYCLE

If the flow
rate in the
suction is
Enough to
build up the
required
design
pressure

Tuesday, May 26, 2020

4
COMPRESSOR
COMPRESSOR
SURGE
SURGE CYCLE
CYCLE

If the flow
rate in the
suction is
not Enough
to build up
the required
design
pressure

Tuesday, May 26, 2020

5
 FLOW
FLOWBACK
BACK

AVAILABLE
AVAILABLE
FLOW
FLOWRATE
RATE

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6
 FLOW
FLOWBACK
BACK

AVAILABLE
AVAILABLE
FLOW
FLOWRATE
RATE
 Compressor Turbine

MOTION
MOTION

HYDRAULIC HYDRAULIC
ENERGY ENERGY
 Surge
Surge is the point of minimum stable flow
and maximum head condition for the
centrifugal compressor.
The surge region is to the left of the
surge line.
Operation in this region is highly
undesirable and can be very destructive
for the machine since a repeated, almost
instantaneous flow reversal takes place.

9
 Surge Description

• Flow reverses in 20 to 50 milliseconds

• Surge cycles at a rate of 0.3 s to 3 s per cycle
• Compressor vibrates
• Temperature rises
• “Whooshing” noise
• Trips may occur

• Conventional instruments and human

operators may fail to recognize surge
• 1
0
Factors Leading to the Onset of Surge

Startup *
Shutdown *
Filter or strainer problems *
. Due to a process upset *

11
SURGE
SURGE PHENOMEN
PHENOMEN
It is the flow back of gases from the outlet of the
Last stage of the compressor towards the suction and
return again to discharge

IN OUT

12
 IF INLET FLOW RATE Q
IS NOT ENOUGH

COMPRESSOR
IS SURGING

IN OUT

to 20 cycles per second 5

13
 SURGE PHENOMENON

If design Flow =10000 m3

Minimum Flow= 6000 m3

B
Hp A

6000 10000
Q M³/ hr
14
 THRUST
BEARINGS

COMPRESSOR

SURGE
SURGE WILL
WILL DAMAGE
DAMAGE THE
THECOMPRESSOR
COMPRESSOR
THRUST
THRUSTBEARINGS
BEARINGS
15
 Effect Of Surge On
Centrifugal Compressor Rotor
THRUST
BEARINGS

SURGE
SURGE WILL
WILL DAMAGE
DAMAGE THE
THECOMPRESSOR
COMPRESSORTHRUST
THRUSTBEARINGS
BEARINGS

16
Surge Cycle

Hp
B1

NE
LI
E
RG
SU

Q- Q+ Q M³/ hr

to
to 20
20 cycles
cycles per
per second
second 55
17
 SURGE
SURGE PHENOMEN
PHENOMEN
Why
1. FLOW-RATE IS NOT ENOUGH
This will happen at starting and shutdown,
also at abnormal conditions.

2. GAS PROPERTY
Gas is compressible but liquid is not.

3. COMPRESSOR PERFORMANCE
Centrifugal and Axial compressors are pumping gas
continuously but reciprocating is not.

4. FLATENESS OF P.C. AT LOW Q

Gas pressure has the same energy at
18 horizontal portions of the performance curve
 Surge Prevention

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19
 Basic Surge Control System
• The anti-surge controller UIC-1 protects the compressor against
surge by opening the recycle valve
• Opening of the recycle valve lowers the resistance felt by the
compressor
• This takes the compressor away from surge
Rprocess
Rc
VSDS Rprocess+valve

Compressor

F PsT PdT
T
1 1 1

Suction Discharge 2
qr
UIC
1
Surge parameter based on invariant
coordinates Rc and qr
Flow measured in suction (DPo)
Ps and Pd transmitters used to
calculate Rc Tuesday, May 26, 2020
20
 Surge Cycle

Hp
B1

NE
LI
E
RG
SU

Q- Q+ Q M³/ hr

to
to 20
20 cycles
cycles per
per second
second 55
21
 Anti-surge
Anti-surge Methods
Methods

By Pass With Anti - Surge Valve -1

This Methods Is Comonly

Used For Gas Compressors

Blow Off Valve– 2

This Methods Is Comonly

Used For Air Compressors
Tuesday, May 26, 2020
22
 Anti-surge
Anti-surge Methods
Methods
By Pass With Anti - Surge Valve -1 In Case Of
Compressor
Surging
COMRESSOR

FT P,T
COOLER

UIC
FY ANTI-SURGE
VALVE WILL
OPEN
23 Tuesday, May 26, 2020
23
By Pass With Anti - Surge Valve -1
If design Flow =10000 m3
Minimum Flow= 6000 m3 COMRESSOR

3 3 3
M 6000 M 10000 M 6000

3
M 4000
3 M 4000
FT P,T

COOLER

UIC

FY ANTI-SURGE
VALVE

UIC = ANTI- SURGE INTEGRATED CONTROLER

24 Tuesday, May 26, 2020
FY = TRANSDUCER
24
 By Pass With Anti - Surge Valve
Graphically

B
H
p C A

SURGE CONTROL LINE

RECYCLE TRIP LINE

SURGE LIMIT LINE

Q
25 Tuesday, May 26, 2020
25
M³/ hr
Blow Off Valve– 2

AIR
COMRESSOR

33
10000
MM 6000

Air
F P,T
BLOW
T OFF
FY VALVE
UIC

UIC = ANTI- SURGE INTEGRATED CONTROLLER

FY26 = TRANSDUCER
26
Tuesday, May 26, 2020
Blow Off Valve– 2

Graphically

Hp B

A
B1

Q M ³/ hr

27 Tuesday, May 26, 2020

27
 IN CASE OF GAS TURBINE
AIR COMPRESSOR SURGE
BLEED VALVE WILL OPEN

BLEED VALVE

COMPRESSOR TURBINE

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28
Mokveld Anti-Surge Valve Spring Loaded during
normal operation

Valve Disk Valve Seat

moves LHS
29
to open
 a

webs
a
Section a-a

30