g

OIL & GAS

CUSTOMER TRAINING CENTER

SURGE

Compressor surge is an unstable phenomenon

where the gas flow forward and backward across
the machine alternatively. This phenomenon
occurs at certain conditions of flow, pressure ratio
and rotational speed.
As a consequence some damages can occur:
shaft vibration
instability in axial thrust
bearings seizure
seals damage

g
FLOW

OIL & GAS

CUSTOMER TRAINING CENTER

MAJOR PROCESS PARAMETERS

DURING SURGE
PRESSURE

TIME (sec)

Rapid flow oscillations

TEMPERATURE

TIME (sec)

Rapid pressure oscillations

with process instability

Rising temperatures
inside compressor
TIME (sec)

OIL & GAS

CUSTOMER TRAINING CENTER

SURGE FEATURES

FLOW REVERSES IN 20 TO 50 MILLISECONDS

SURGE CYCLES AT A RATE OF 0.3 sec TO 3 sec PER CYCLE

COMPRESSOR VIBRATES

TEMPERATURE RISE

WHOOSHING NOISE OR CLANKING NOISE

CONVENTIONAL INSTRUMENTS AND HUMAN

OPERATORS MAY FAIL TO RECOGNIZ SURGE

OIL & GAS

CUSTOMER TRAINING CENTER

OIL & GAS

CUSTOMER TRAINING CENTER

FACTORS LEADING TO ONSET OF SURGE

DURING NORMAL OPERATION WITH:
- High discharge pressure ( Increase of plant resistance )
- Reduction of suction pressure
- Increase of suction temperature
- Gas composition changes (Decrease molecular weight)
START-UP
SHUTDOWN

OIL & GAS

CUSTOMER TRAINING CENTER

OIL & GAS

CUSTOMER TRAINING CENTER

OIL & GAS

CUSTOMER TRAINING CENTER

ANTISURGE SYSTEM
An antisurge system avoids that the machine
operating point falls on the surge line.
Substantially the protection consists in the
opening of a control valve that put in
connection the compressor discharge to the
suction.

OIL & GAS

CUSTOMER TRAINING CENTER

As a consequence the resistance curve become the

antisurge valve resistance itself.
This causes an increase in the suction flow and so
the operating point moves away from the critical
condition.
On the right of the surge line a protection curve,
called antisurge line, is defined.

OIL & GAS

CUSTOMER TRAINING CENTER

OIL & GAS

CUSTOMER TRAINING CENTER

A compressor with a single stage, or, if

multistage, realizing a limited compressor
ratio and where the surge is determined by
the first stage, can be regulated by a law of
this simple type: h
>
K
P -P
D

h= Inlet flow index

PD = Pressure discharge
PS = Pressure suction
K = Set-point that corresponds to the antisurge control line

OIL & GAS

CUSTOMER TRAINING CENTER

SLL
speed

SLL FOR A COMPRESSOR

WITH ONE IMPELLER

SLL
speed

SLL FOR A COMPRESSOR WITH

MORE THAN ONE IMPELLERS

OIL & GAS

CUSTOMER TRAINING CENTER

CONTROLL

ALGORITHM

Psd
hs *
Ps
Pd Ps
f
Ps

K2

The controller set-point is K2. It represents the deviation margin beteween SLL and SCL. The
margin is expressed in percentage of flow. The algorithm takes in account the deltaP measured
across the flow element (indicated by hs that is proportional to square suction flow (hs =
Q2).
The controller algorithm compensates continuously the hs signal according to the suction
pressure variation, taking in account the suction pressure measured and comparing it with the
design suction pressure.

OIL & GAS

CUSTOMER TRAINING CENTER

THE SURGE LIMIT LINE (SLL) IS NOT A

FIXED LINE.
IT CHANGES DEPENDING ON THE
COMPRESSOR INLET CONDITIONS:
T

MW

THE ANTISURGE CONTROLL MUST

PROVIDE A DISTANCE TO SURGE
CALCULATION THAT IS INDEPENDENT
OF ANY CHANGE IN INLET CONDITIONS

OIL & GAS

CONTROLL CURVES

Pressure
Ratio

Surge Limit Line

CUSTOMER TRAINING CENTER

This curve is drawing at 2% on the right of
SLL. When the OP reach this line the controller
generate a Quick-Opening signal to the valve.
curve
is drawing
Safety Protection Line o This
Recicle
trip line

at 5%
right of SLL. When the OP
Safety Correction Line
line the controller generate
Surge Control
Line
Opening
signal to the valv
Compressor

This curve is drawing

at 10% on the
Operating
Point
right of SLL. When
the OP reach
this line
the antisurge controller
is activated
Speed Line

Suction Flow

OIL & GAS

CUSTOMER TRAINING CENTER

OIL & GAS

CUSTOMER TRAINING CENTER

CHOKING
When the flow rate increases beyond a certain
value it may happen that in some ducts is
achieved the speed of the sound.
This phenomenon determine the pressure drops
due to the friction and high incidence of the
flow on the fixed and mobile ducts.
As a consequence there is an enormous
reduction in efficiency.

OIL & GAS

CUSTOMER TRAINING CENTER

SOME DEFINITIONS ABOUT

PERFORMANCE CURVES
ACCORDING TO
NORM API 617

OIL & GAS

FIELD
CUSTOMER
OF OPERATION
TRAINING CENTER
COMPRESSOR
RATED
POINT:
MAXIMUM
CONTINUOUS
SPEED:
NORMAL
MINIMUM
STABILITY:
NORMAL
OPERATING
ALLOWABLE
SPEED
The
difference
:
POINT:
SPEED:
in
100 PERCENT SPEED: is the
capacity
The
intersection
(in
onequal
the
of
rated
100
percent
capacity)
TURNDOWN:
The
percentage
of
The
speed
least
to any
105
percent
The
highest
Is
the
The
point
lowest
speed
speed
atatpercent
which
speed
corresponding
required
usual
at
which
for
to
thethe
between
speed
corresponding
rated
and
totoby
the
the
change
inthe
capacity
(referred
rated
of
the curve
highest
speed
required
any of
operation
specified
manufacturers
requirements
operating
is
expected
design
ofcapacity
the
point
and
normal
willabove
permit
surge
highest
point
capacity
atpoint.
rated
ofcurve.
any
speed.
specified
capacity
atefficiency
the
rated
the
specified
operating
condition.
optimum
the
continuous
operating
normal
speed
operation.
ishead).
desired.
operating point.