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Surge

The document discusses compressor surge, an unstable phenomenon causing gas flow to alternate, leading to potential damages such as shaft vibration and bearing seizure. It outlines factors contributing to surge, the function of antisurge systems to prevent it, and the control algorithms used to maintain safe operating conditions. Additionally, it addresses choking, which occurs when flow rates exceed a certain threshold, resulting in pressure drops and reduced efficiency.

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Ahmed Abdulla
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12 views17 pages

Surge

The document discusses compressor surge, an unstable phenomenon causing gas flow to alternate, leading to potential damages such as shaft vibration and bearing seizure. It outlines factors contributing to surge, the function of antisurge systems to prevent it, and the control algorithms used to maintain safe operating conditions. Additionally, it addresses choking, which occurs when flow rates exceed a certain threshold, resulting in pressure drops and reduced efficiency.

Uploaded by

Ahmed Abdulla
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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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 OIL & GAS CUSTOMER TRAINING CENTER

MAJOR PROCESS PARAMETERS


FLOW DURING SURGE
PRESSURE

TIME (sec)

Rapid flow oscillations TIME (sec)

Rapid pressure oscillations


TEMPERATURE
with process instability

Rising temperatures
inside compressor
TIME (sec)
g 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
g 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
g OIL & GAS CUSTOMER TRAINING CENTER
g OIL & GAS CUSTOMER TRAINING CENTER
g OIL & GAS CUSTOMER TRAINING CENTER
g OIL & GAS CUSTOMER TRAINING CENTER
g 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 joins the
compressor discharge to the suction.
g OIL & GAS CUSTOMER TRAINING CENTER

As a consequence a part of the flow outgoing from


the machine is recirculated.

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.
g OIL & GAS CUSTOMER TRAINING CENTER
g OIL & GAS CUSTOMER TRAINING CENTER

It is possible to demonstrate that to evaluate if


a compressor, with a single impeller, works in
safety condition for the surge, must be:
h
>K
P -P
D S

h= Inlet flow index

PD = Pressure discharge

PS = Pressure suction

K = Set-point that corresponds to the antisurge control line


g OIL & GAS CUSTOMER TRAINING CENTER

SLL
ρ
speed SLL FOR A COMPRESSOR
WITH ONE IMPELLER

ρ SLL
speed
SLL FOR A COMPRESSOR WITH
MORE THAN ONE IMPELLERS

Q
g OIL & GAS CUSTOMER TRAINING CENTER

CONTROLL ALGORITHM

P sd
hs *
Ps
= K 2
 Pd − P s 
f  
 Ps 

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.
g OIL & GAS
CONTROLL CURVES
CUSTOMER TRAINING CENTER
This
This curve
curve
This curve isisdrawing
isdrawing
drawing
atat2%
at5%
10%
ononthe
on
theright
the
rightof
Pressure
of right
SLL. SLL.
Whenof
When
SLL.
the OP the
When
OP reach
thethis
reach OPthis
reach
line line
the this
the line
controller
Ratio Surge Limit Line controller
the antisurge
generatecontroller
a “Step-Opening”
generate a “Quick-Opening” signal to the valve.
signal
is activated
to the valve.
Safety Protection Line o Recicle trip line

Safety Correction Line

Surge Control Line

Compressor
Operating
Point

Speed Line

Suction Flow
g OIL & GAS CUSTOMER TRAINING CENTER
g 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.

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