Surge
Phenomenon
Hp
B1
-Q 6000 10000
1
HAPPENS
ONLY TO :
CENTRIFGAL
COMPRESSORS
AND AXIAL FLOW
COMPRESSORS
But Does not Happen to
Reciprocating
2
2 Compressors
Surge Description
1-This phenomenon is an internal phenomenon
2-The discharge flow stops completely (Flow rate=0)
3-All the flow return back to the suction
4-This action convert the compressor to Turbine
5- The turbine produces a power equal to the motor power but in the
reverse direction the rotor direction
6- This action creates a sever torsion force on the compressor rotor
7- When the flow return back to the suction the machine now has the
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).
8- This action repeated from 5 to 20 times per second
COMPRESSOR
SURGE CYCLE
If the enough
flow rate in
the suction is
not enough to
build up the
required
design
pressure
22 April 2024
4
FLOW BACK
AVAILABLE
FLOW RATE
22 April 2024
5
FLOW BACK
AVAILABLE
FLOW RATE
Compressor Performance Envelope
Rolls Royse
The area of desired compressor
operation is bounded on the left
by the surge line, on the right by
the choke line, on the top by the Surge
Region
maximum speed line, and on
the bottom by the minimum Normal
speed line. Head Operation
Operation of the machine in this
region will allow the machine to Choke
Region
meet the process requirements
with safe and reliable
performance.
Flow
7
Developing the Compressor Map
process limit
Rc
adding control
margins
maximum speed
surge limit
power limit
stonewall or
choke ‘limit’
stable zone
Actual available
of operation
operating zone
minimum speed
Qs, vol
8
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
Developing the Surge Cycle on the Compressor Curve
• From A to B 20 - 50 ms Drop into surge
• From C to D 20 - 120 ms Jump out of surge
•
Wrong
A-B-C-D-A 0.3 - 3 seconds Surge cycle
Pd
• Compressor reaches surge point A
• •
Compressor loses its ability
Compressor to build
starts to makepressure Pv
pressure
• Compressor “rides” curve towards surge Rlosses
• Suddenly
• Pd drops
Point and thus Pv > Pd
A is reached
• Plane• goes
Thetosurge
stall -cycle
Compressor surges
is complete
Pd Pd = Compressor discharge pressure
BB AA Pv = Vessel pressure
Rlosses = Resistance losses over pipe
•Pressure builds • System pressure is going down
Wrong • D
Resistance goes
• up
Compressor is again able to overcome Pv
C •Compressor “rides”
• the curve “jumps” back to
Compressor
•Pd = Pv + Rlosses performance curve and goes to point D
• Because Pv > Pd the flow reverses • • Forward
Driver flow
is started
is re-established
• • Result of flow reversal is that pressure
Compressor operating point goes to point Bgoes • Machine accelerates to nominal
down speed
• Pressure goes down => less negative flow • Compressor reaches performance
• Operating point goes to point C curve
• Note: Flow goes up faster because
pressure is the integral of flow
Machine shutdown Qs, vol
no flow, no pressure
10
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
11
Factors Leading to the Onset of Surge
* Startup
* Shutdown
* Filter or strainer problems
* Due to a process upset .
12
Some Surge Consequences
Unstable flow and pressure – process upsets
Rotor vibration – predominantly axial but can be radial
Damage compounded with increasing severity to seals,
bearings, impellers, shaft
Increased seal clearances and leakage
Lower efficiency due to increased internal recirculation
Reduced time between overhauls
13
Honeywell
SURGE PHENOMEN
The surge region, located on the left-hand side of the compressor map
(known as the surge line), is an area of flow instability typically caused
by compressor inducer stall.
Compressor surge is when the air pressure after the compressor is
actually higher than what the compressor itself can physically
maintain.
This condition causes the airflow in the compressor wheel to back up,
build pressure, and sometimes stall.
In cases of extreme surge, the thrust bearings of the turbo can be
destroyed, and will sometimes even lead to mechanical failure of the
compressor wheel itself.
This is wrong explanation
The surge region, located on the left-hand side of the compressor
map (known as the surge line), is an area of flow instability typically
caused by compressor inducer stall.
Compressor surge is when the air pressure after the
compressor is actually higher than what the
compressor itself can physically maintain.
The correction
Compressor surge at the moment when the
airflow in the suction is not enough to build up
the required pressure for continuous flow then
stall occurred, followed immediately by surge
SURGE 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
16
SURGE 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
17 horizontal portions of the performance curve
NO SURGE IF
INLET FLOW RATE Q IS ENOUGH
IN OUT
18
IF INLET FLOW RATE Q
IS NOT ENOUGH
COMPRESSOR
IS SURGING
IN OUT
5 to 20 cycles per second
19
SURGE PHENOMENON
B
H A
p
6000 10000
Q M³/ hr
20
THRUST
BEARINGS
COMPRESSOR
SURGE WILL DAMAGE THE
COMPRESSOR THRUST BEARINGS
21
EFFECT OF SURGE ON
CENTRIFGAL COMPRESSOR ROTOR
THRUST
BEARINGS
SURGE WILL DAMAGE THE COMPRESSOR
THRUST BEARINGS
22
SURGE CYCLE
Hp
B1
-Q 6000 10000 Q M³/ hr
5 to 20 cycles per second
23
ANTI-SURGE METHODS
1- BY PASS WITH ANTI - SURGE VALVE
THIS METHODS IS COMONLY
USED FOR GAS COMPRESSORS
2 –BLOW OFF VALVE
THIS METHODS IS COMONLY
USED FOR AIR COMPRESSORS
24
ANTI-SURGE METHODS
1- BY PASS WITH ANTI - SURGE VALVE IN CASE OF
COMPRESSOR
SURGING
COMRESSOR
FT P,T
COOLER
UIC
FY ANTI-SURGE
VALVE WILL
OPEN
25
1- BY PASS WITH ANTI - SURGE VALVE
COMRESSOR
3 3 3
6000 M 10000 M 6000 M
3
3 4000 M
4000 M FT P,T
COOLER
UIC
FY ANTI-SURGE
VALVE
UIC = ANTI- SURGE INTEGRATED CONTROLER
26 FY = TRANSDUCER
BY PASS WITH ANTI - SURGE VALVE
GRAPHICALLY
B
H
p C A
SURGE CONTROL LINE
RECYCLE TRIP LINE
SURGE LIMIT LINE
27 Q M³/ hr
2 –BLOW OFF VALVE
AIR
COMRESSOR
33
10000
6000MM
Air
F P,T
BLOW
T OFF
FY VALVE
UIC
UIC = ANTI- SURGE INTEGRATED CONTROLLER
FY = TRANSDUCER
28
2 – BLOW OFF VALVE
GRAPHICALLY
Hp B
A
B1
Q M ³/ hr
29
IN CASE OF GAS TURBINE
AIR COMPRESSOR SURGE
BLEED VALVE WILL OPEN
BLEED VALVE
COMPRESSOR TURBINE
30
Mokveld Anti-Surge Valve Spring Loaded during
normal operation
Valve Disk Valve Seat
moves LHS
31
to open
a
webs
a
Section a-a
32
