Section 06 Surge
Section 06 Surge
Index page
1 Definition of surge 2
1.1 Compressor surging 3
1.2 Anti surge system 5
1.2.1 Basic anti-surge system 5
1.2.2 Characteristics 7
1.2.3 Design of an anti-surge system 8
2 Rotating stall 11
3 Surge versus stall 13
4 How to delay surge and stall 13
5 Choke 16
Questionnaire Surge, stall and choke 18
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Section 06 Surge, Stall and Choke Power Generation Industrial Applications
Introduction
Choke can occur when the velocity of flow within the machines approaches
the velocity of sound.
1 Definition of surge
- impeller design,
- number of stages,
- shape of head-capacity curve,
- gas being compressed, etc.
The primary cause of the pumping lies in the fact that the characteristic
curve begins to drop toward the zero capacity regions after reaching a peak
of pressure. When the capacity is reduced below the peak, the pressure in
the discharge line exceeds that produced by the compressor and the flow
tends to reverse momentarily. However, as soon as the flow reverses, the
system discharge pressure drops and the compressor resumes normal flow.
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Pumping points are not guaranteed, but are closely determined by specific
test or prior knowledge. No dynamic unit should be operated at capacity
close to the surge limit line. The setting of surge prevention controls should
be based on field determination of surge points on each individual machine
as installed.
The next figure shows the characteristic curve of a compressor for a given
constant speed. The performance characteristics of compressors are often
plotted in diagrams called the Head Capacity diagram or Q-H diagram.
Figure 01
PD = discharge pressure compressor and
PS = suction pressure pipeline performance
Pi = inlet pressure characteristics
The figure also shows the characteristic curve of the downstream system.
The curve is typical of a pipeline; it is a function of:
The operating point A is the point where the compressor curve and the
pipeline curve intersect. If the flow rate at the outlet of the pipeline is
reduced, because the valve at the end of the line is closed, the pressure P’S
at the outlet of the line will gradually increase from P’S1 to P’S2.
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Changes in flow rate and pressure will occur in the pipeline section
between the closed valve and the compressor. The pressure at the inlet of
the line Pi will gradually rise. The compressor will adjust its work to change
in operating conditions. PD will increase and the flow coefficient will
decrease according to the performance curve for constant speed.
When the system has stabilised, different stationary conditions will prevail.
The new operating point A’ will be at the intersection of the compressor
performance curve and the characteristic pipeline curve shifted from P’S1 to
P’S2. If the flow rate in the downstream pipeline section increases, the
pipeline curve will be shifted in the opposite direction and the operating point
will move into the higher flow coefficient zone.
Figure 02
Erratic compressor flow
If the rate of flow at the end of the pipeline is reduced, the pressure Pi at the
inlet of the line will again rise. The compressor discharge pressure PD will,
however, drop on the compressor performance curve and gas will flow from
the pipeline back in the compressor. The operating point will jump from M to
B on the performance curve extended into the negative flow zone.
As gas is flowing from the pipeline back into the compressor, the pressure Pi
will gradually drop. The discharge pressure PD decreases accordingly and
the operating point moves from B to C. As negative flow conditions will
prevail at operating point C, the pressure Pi still tends to decrease. This is,
however, not feasible because of the upward slope of the performance
curve. As PD becomes greater than Pi, gas is pumped into the pipeline by
the compressor. The flow becomes positive and the operating point jumps
from C to D. The pipeline is again filled, because the compressor delivers
more gas than is taken at the end of the line. The pressures Pi and PD rise
again until the operating point M is reached and the cycle starts again. This
flow pattern is called compressor surge cycle. The smaller the pipe diameter
and the shorter the pipeline, the shorter each cycle.
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Section 06 Surge, Stall and Choke Power Generation Industrial Applications
Surge line
If the compressor has a variable speed, for example when driven by a
turbine, there is an infinite number of performance curves. For each speed a
surge limit point can be established on the corresponding performance
curve. The line connecting the operating points at the surge limit is called
surge line. In a compressor characteristic diagram, the surge line is always
to the left of the peak of each line of constant speed.
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Figure 04
Basic Anti-surge system
The primary device FE measures the flow through the compressor. The
device generates a differential pressure (h), which is translated into a
standard signal by the flow transmitter FT. The signal is an input of the
surge controller. The dPT will measure the differential pressure across the
compressor. The output of this transmitter represents a signal proportional
to PD-PS.
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When the anti-surge controller senses the beginning of the instability, or the
predicted surge flow value, it opens the recycle valve in the recycle line. The
recycle line connects the pipeline downstream of the compressor with the
suction to recycle some of the gas back to the suction. This way a minimum
flow above surge is maintained. The by-passed gas would be increasingly
heated by the compression. Mixing the hot gas from the recycle with the
fresh gas causes the temperature to increase. To avoid unacceptable high
temperatures the recycled gas should be cooled.
1.2.2 Characteristics
The surge line should first be approached on the maximum speed curve to
allow the accurate adjustment of the differential pressure transmitter range.
Apart from the differential pressure (PD-PS) the suction pressure and the
discharge pressure are recorded during the field test. The values of the
measured characteristics of this point on the surge line are computed and
entered into a diagram.
Figure 05
Characteristics
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Section 06 Surge, Stall and Choke Power Generation Industrial Applications
Figure 06
Surge line of single-stage
and three stage compressor
The anti-surge control system automatically opens the control valve before
the surge line is reached. To provide the necessary safety margin to keep
the compressor out of the surge area, the valve must be opened at the
control line shown in the next figure.
Figure 07
Surge and surge control
line
The distance between the surge line and the control line must be minimised
to obtain maximum operation flexibility, if major flow rate or compression
ratio changes have to be made during the operation of the compressor. On
the other hand, the distance must not be too small to take account of the
inaccuracies of the control equipment. In pipeline operations, for example,
the control line is, as a general rule, displaced by about 10 percent of the
surge line.
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formula 1
formula 2
This equation is parabolic and represents the surge limit of a single stage
centrifugal compressor. From fluid dynamics it is known that:
formula 3
formula 4
Combination of equation 1 and 4 means that along the surge line can be
derived:
formula 5
formula 6
formula 7
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Conclusion: for a single stage compressor and a low-pressure ratio, the ratio
mentioned in formula 7 is constant and also independent from:
- suction pressure
- suction temperature
- gas characteristic
- speed
Multi-stage compressor
A multi-stage centrifugal
compressor does not have
a surge limit, which can be
derived from equation 1.
This surge-line has a much
more complex form.
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2 Rotating stall
If the flow decreases with respect to the compressor design flow, the gas
flow increasingly tends to separate from the suction side of the blades. If
separation occurs, for example at blade 1 to erratic flow conditions, the
disturbances will reduce or even block the passage between blade 1 and
blade 2. The flow flows around this area towards blade 1 and blade 3. The
angle of attack on blade 3 increases and the flow separates from blade 3,
while it comes again in contact with blade 1. The point of separation moves
to blade 3 and will then move to the other blades.
Figure 10
Development of rotat-
ing stall
The next figure shows how rotating stall is initiated by flow separation on the
blade suction side, blocking off the discharge side and reversing the flow
direction in the passage (area 1). The flow moves out of the passage into
the inducer creating a separation on the downstream part pressure side
(area 2). The subsequent back flow is supported in its direction by the
passage vortex and together with the more favourable inlet conditions helps
to re-establish normal flow conditions (area 3), the suction side boundary
layer is then developing again (area 4) and the whole cycle is repeated.
Figure 11
Sequence of stall
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A rotating zone of gas flow separation from the blades occurs when the flow
is insufficient. If the rate of flow decreases even more, this zone becomes
larger and then breaks down into two, three or more zones. If the flow rate
then continues to decrease even more, flow will separate to all blades. A
fluctuating force accompanies this shift from blade to blade, which can lead
to blade failure. The cell moves around the circumference at a fraction of the
impeller speed. The pressure fluctuations have a low frequency of typically
between 5% and 20% of the rotational speed.
Figure 13
Surge line of multi-
stage compressor
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3. Surge velocity fluctuations vary between 10% and over 100%. The flow
fluctuations are in phase over the whole compressor. Rotating stall
fluctuations have lower amplitude then surge fluctuations and show a
variation over the compressor circumference.
4. Surge occurs when the slope of the pressure rise curve exceeds a
minimum positive value. Rotating stall is possible at positive and
negative values of the pressure rise curve. This can result in a gradual
or a discontinuous charge of the performance curve.
6. Also steady stall can be at the origin of surge in the way it influences the
shape of the pressure rise curve. Stall in the vane less space or in the
diffuser channel can result in a decrease in pressure rise resulting in a
discontinuous performance curve. The critical slope for surge can then
be exceeded resulting in compressor surge.
The following list contains a number of actions that allow to influence the
surge limit during the design or to correct for an eventual prediction fault.
However, most of them result in an efficiency decrease when the range has
to be increased. The main action therefore to avoid surge and stall is a safe
design of impeller and diffuser and correct matching of the components.
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Pre-rotation
A way to influence the compressor
Figure 15
operating range is by the use of pre- Anti surge with secondary
rotation. An aerodynamically induced pre- compressor
whirl system re-injects flow from the
exhaust into the inlet channel to create pre-whirl. The amount of pre-rotation
depends on the amount of flow which is re-injected, and the position and
inclination of the injection holes. A system controls the amount of pre-
rotation and allows for a wide range between surge and choke. However,
this involves a mechanical complication and a control surface.
In narrow diffusers, the critical zone for rotating stall is close to the diffuser
inlet. The reduction in diffuser width must therefore start at rotor exit. Once
the critical zone is passed, one could open the diffuser again. A narrow
diffuser exit results in a lower static pressure rise in the diffuser and a larger
radial velocity component at scroll inlet. Due to the larger friction losses in a
narrow diffuser the efficiency will drop rapidly with increasing mass flow.
In wide diffusers, the critical zone for flow reversal is further downstream. It
is therefore possible to use a gradual decrease of diffuser width until the
critical zone and from there one can use a parallel diffuser.
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Volute
The operating range of a centrifugal compressor is strongly influenced by
the volute, following the vane-less diffuser. A large scroll will result in a
larger operating range but the flow becomes unsteady for high-pressure
ratios. A smaller scroll has a stable flow at all pressure ratios but a smaller
range. Surge and choke occur now at much smaller mass flows.
Casing treatment
In analogy with axial compressors, casing treatment has also been used in
centrifugal compressors to extend the stable operating range. Shroud
casing treatment can be efficient to delay rotating stall if the stall is
associated with the boundary layer on the shroud casing and inefficient if
the rotating stall is due to blade suction side separation. This principle has
been confirmed by experimental results on two axial rotors, with and without
grooves in the casing.
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5 Choke
The choke effect occurs in the inlet region of the impeller or in the diffuser.
Choke, also called stonewall* is the maximum flow that the compressor can
handle at a given speed. At that point, the compressor is unable to produce
any net overall pressure ratio. All the energy supplied to the compressor is
dissipated in losses. Choke is not detrimental to the compressor. It simply
limits the maximum flow.
* The term stonewalling has been applied because the characteristic pressure/volume curve becomes
almost vertical as the capacity is increased and the velocity approaches the sonic value. In other
words, there is a “stonewall” limit to capacity.
· sonic velocity
· negative stalling incidence
Sonic velocity
When the flow handled by the compressor increases, the velocity increases
too. The gas velocity increases with its maximum value occurring:
The throat section is the window perpendicular to the flow direction. This is
situated between the leading edge of one blade and the side of the following
one.
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If the flow is sufficiently high it may cause sonic velocities. The shock
associated with it produces such high losses that it determines the
maximum flow. If choke occurs in the impeller increasing the operational
speed can increase the maximum volume flow.
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question 3 As more gas is delivered and the system fills, does the
capacity need of the system change? Explain in your own
words
question 7 If the system continues to use less gas than is delivered to it,
the system’s pressure keeps increasing and the head
required to maintain flow keeps ........
question 8 What does the flow do when the head needed to maintain
flow increases above the maximum head of the compressor?
question 9 When the flow stops, the pressure within the compressor
becomes less than the pressure in the system. How does the
gas flow?
question 10 How does the pressure of the system react after some gas
flows back into the compressor or is used by the system?
question 13 The system still uses less gas than is delivered to it, the
compressor reaches its maximum head. What does the flow
stoppage do?
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Section 06 Surge, Stall and Choke Power Generation Industrial Applications
question 14 The rapid flow of gas back and forth in the compressor is
called surge. When does surge occurs?
question 16 The flow of gas drops below the minimum stable level. Does
the compressor go into surge?
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