ASK THE EXPERTS Why Do Surge Testing?

Why Do Surge Testing? How To Do Surge Testing? When Can Surge Testing Be Avoided?

B E Y O N D

Why Do Surge Testing?

The main purpose of surge testing is to establish the surge points of a compressor under conditions approximating some, or even better, most of the zone in which surge might be encountered. Surge testing a compressor under conditions that will not be encountered during the operation of the unit in which the compressor is installed may be useful, but only to a limited degree. When deciding upon the performance of the surge test, it is important to remember that the surge control systems are operating on a principle of an inferential control system. That is, the exact position of the surge point is never known to the control system, and the control system must infer the position of the surge point for a given set of positions. In other words, the surge control system must have a model of the Surge Limit Line (SLL) of a given compressor in order to be able to avoid it during normal operation. As a result, the operation of the surge control system is always based on two sets of data: one representing the SLL of a given compressor, and the second representing the current position of the operating point (OP) on the compressor map. The controller then calculates the distance between the SLL and OP and must take actions based on this distance.

The main purpose of surge testing on site is to eliminate, or reduce as much as possible, errors in both of these sets of data. The main purpose of surge testing on site is to eliminate, or reduce as much as possible, errors in both of these sets of data. Listed below are the most frequently observed sources of error, based on the experience of CCC and others. The source of the first possible error is in the origin of the set of data representing the SLL. The data for the SLL can be obtained analytically from compressor maps submitted with the compressor by the OEM. Unfortunately, in our experience, the accuracy of the map data overall, and of the SLL especially, is not high enough for accurate implementation within the surge control system. In CCCs experience there have been cases when the SLL data on the compressor map was off by more than 20%, in an unpredictable direction. In many cases this inaccuracy is fully explainable: the tests performed by the OEM are often performed using a gas and conditions that are different from the gas that will flow through the compressor in actual operating conditions, with subsequent re-computation to operating conditions. (It is worth noting that the accuracy of such re-computations is limited, and actually is defined and can be predicted as per PTC-10 Compressor Testing Code.) Sometimes the compressor may not be tested at all, and compressor maps from other, similar compressors are used to create the Predicted Map. This error may be magnified further by the actual piping system that is used to connect the compressor to the process. Piping differences between the actual installation and the test stand of the OEM introduces additional errors, due to the pressure losses between measurement points of suction and discharge pressures and flows, and the actual values in the inlet and discharge of the compressor. On the OEMs stand the losses between points of measurement are minimal, but these are typically larger when the compressor is operating at the actual installation. As a result, compressor operation at the process unit for the same OP may produce different pressures and flows as compared to measurements taken at the OEMs test stand. A second source of error is in the nature of the flow measurement that typically is at the heart of the surge control system. The flow measuring devices are sometimes manufactured with insufficient accuracy to reproduce the calibration parameters used to calculate the pressure differential signal based on the flow through the compressor. In many cases, the flow measuring devices are installed in a way that does not meet the recommendations and standards for Gas Flow Measurement. This may result in a pressure differential signal different from what should be expected for a given gas flow. It is worth mentioning that, in a majority of cases, manufacturing inaccuracies and non-compliant installation practices do not result in disqualifying the flow measurement from the application. Rather, they result in some reduction of accuracy and in changes of the calibration constants of the flow measuring device, meaning that the flow measuring device is still able to produce a flow measurement accuracy sufficient for the needs of the surge control system. Surge testing in the field allows this unknown error to be zeroed-out in calibration by detecting the surge points directly, as observed by the flow measuring device in its actual installed position. The next reason for surge testing is to observe and acquire the surge signature of a given compressor in the actual installation. As a result of continuous operation over time, the position of the SLL may shift. Often, this shift may occur in a direction which reduces the margin of safety of the compressor, with the result that the compressor may now surge in a location that was previously considered safe within the surge controller. 2

Similar surge incidents may occur as a result of a number of other factors affecting the operation of the surge control system, such as: drift of instrumentation, causing an error in the representation of the OP within the controller; leak, obstruction, or accumulation of liquids or solids at the FE, caus- ing additional errors; poor dynamic performance of the recycle valve, resulting in inade- quate response speed when compressor protection is needed; erroneous action of the operator or the system, causing the compressor to surge; behavior of the compressor driver not present previously; etc. In any of these situations the compressor may surge, with the cause of the surge not due to the inaccuracy of the control system, but rather to one of the factors listed above. However, since the surge control system operates inferentially, it is only able to protect the compressor using the SLL that was based on the conditions that were present at the time of the last system testing. Regardless, the surge control system should be able to detect the surge as it happens, and obviously, should stop the surge cycling. The purpose of the additional adaptive feature of the surge control sys- tem is to increase the margin of safety so that, after the compressor is successfully returned from surge back into operation, the surge control system would return to a new, more conservative steady state condition and continue operation with a new, increased, safer surge margin. To accomplish these functions it is necessary to observe the surge signature in actual conditions, and to set the surge detection part of the controller using this observation, so that it would be able to detect the surge as it happens. If the compressor is not surge tested, these settings may not be able to provide the necessary safety of operation.

How To Do Surge Testing?

Surge testing of any centrifugal or axial compressor is a high-stress event for the compressor, the surrounding equipment, and for all the personnel involved. The surge testing must be organized in a way that reduces the possible consequences of undesirable outcomes. First, it is not always necessary to surge the compressor through a complete surge cycle. Often, an incipient surging of the compressor or some other feed forwarding signal may be recognized early enough to allow the parameters of the surge point to be obtained in near proximity to the SLL. Often this is sufficient to confirm that the compressor can be operated safely within the desired zone of operation. In essence, it proves that the compressors SLL is located to the left of the expected position, and therefore it is not necessary to pursue the surge testing further. (It may still be necessary to induce surge to obtain the surge signature for the purposes of reliable surge detection). To reduce stress, surge testing should always be performed with a gradual change in position of the compressor OP. Surge testing performed by imposing drastic changes in the OP position may result in unpredictable outcomes to the process, and such tests typically do not produce accurate surge test data. Gradually approaching the SLL allows for better monitoring of multiple variables that need to be maintained within limits, and for possible testing course changes, as required. During surge testing, it is of prime importance that a clear communication path be established between all testing participants, to assign their roles if a critical situation rises, and to pre-test the equipment responsible for taking the compressor out of surge so that it will perform free of error.

When Can Surge Testing Be Avoided?

Based on experience with compressors for many years and in many different installations, CCC always proposes that a compressor be surge tested to satisfy the above requirements. Obviously, the need to perform the surge test is always balanced against the wishes of the customer. If a particular installation, type of process, operating procedures, etc. dictate that surge testing be avoided, CCC will do its best to set up the surge control system based on any and all other data that is available. Surge testing a compressor can sometimes be avoided if the data obtained on the test stand of the compressor OEM is sufficiently accurate for setting up the surge controller data base. Typically this is possible when test gases which closely approximate the actual performance on site were used (Air Compressor, CO2 Compressor, Closed Cycle Refrigeration Compressor, etc.), and when the performance test itself was of high enough quality that the compressor was run through operation at pressures and temperatures closely approximating actual site conditions. As stated above, the additional condition that also needs to be satisfied is the verification of the actual flow measuring device in its actual installed position. If both of these conditions are met, surge testing of the compressor on site can be avoided. However CCC would still recommend testing the capability of the compressor to operate in vicinity of the SLL without surging.

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