TL;DR
Compressor surge is a severe reversal of flow that can damage compressor internals. Check the anti-surge valve, operating point, and gas composition after any surge event.
What you might see
- audible banging or coughing from the compressor
- suction and discharge pressure oscillating rapidly
- vibration spike during the surge event
- compressor tripping on high vibration
Likely causes
Anti-surge valve failing to open quickly enough during a load reduction
Operating point driven past the surge line by a gas composition change
Compressor fouling from lube oil carryover increasing stage pressure drop
Suction throttle valve moving faster than the anti-surge system can respond
Required tools
- Anti-surge valve response timer
- Gas composition analyzer
- Vibration monitoring system access
- Oil sample kit
Safety first
- High-pressure hydrocarbon gas is present at the compressor suction and discharge during surge. Confirm gas containment before approaching after a surge event.
- Compressor surge on H2S-containing gas service requires gas detection before any work around the compressor.
- Do not restart after a surge event without a vibration check and an oil analysis to rule out bearing damage.
Procedure
- 1
After a surge event, stop the compressor per the emergency procedure and inspect for damage before restarting.
Warning: Compressor surge can cause impeller blade damage or bearing damage. Do not restart a compressor after a severe surge without an inspection. - 2
Review the surge event data from the control system. Confirm the anti-surge valve response time matches the design specification.[1]
- 3
Check the anti-surge valve stroke and response. A slow or stuck anti-surge valve cannot prevent surge during a rapid load shedding.[1]
- 4
Review the suction gas composition and molecular weight. A lighter gas shifts the surge line toward the operating point.
- 5
Inspect the anti-surge recycle piping and cooler for blockage.
- 6
After a surge event, take a lube oil sample from the compressor bearings and send for particle analysis to assess bearing condition.
- 7
Increase the anti-surge controller margin if the operating point is close to the surge line under normal conditions.
Sources
Solar Turbines (Caterpillar) Solar Mars 100 / Titan 130 / Centaur 50 Centrifugal Gas Compressor / Turbine general technical documentation, Solar Turbines (Caterpillar)
Solar Turbines Mars 100 / Titan 130 / Centaur 50 general compressor surge diagnosis and anti-surge system procedures (general)
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