ASK THE EXPERTS

Why Do Surge Testing?

• Why Do Surge Testing?

• How To Do Surge Testing?
B E Y O N D
• When Can Surge Testing Be Avoided?

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.

Sourced 31 Aug 2017:

https://www.cccglobal.com/sites/default/files/documents/IS01-Why%20Do%20Surge%20Testing.pdf
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 CCC’s
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 OEM’s 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 OEM’s 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 compressor’s 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.

3
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.

For more information our website at:

www.cccglobal.com