Resolving Surge Phenomena on Centrifugal Compressor
Issue Identified:
Following the replacement of the control system for a centrifugal compressor in 2014, the client experienced surge phenomena—operational instabilities occurring before the activation point of the anti-surge curve configured in the control system.
This anomaly posed a significant threat to compressor safety, especially since the reference curve had been validated in 2011 and had proven adequate until then.
Solution:
During a field troubleshooting session, the Opus Automazione technical team observed anomalous compressor behavior related to the flow signal, which did not correspond to the actual process conditions.
Following an in-depth analysis, the team carried out the following actions:
Internal borescope inspection of the flow meter to assess its physical and functional state
Identification of internal seal damage, which compromised measurement accuracy
Restoration of flow measurement functionality by relocating the pressure transmitter to a different position on the flow meter, ensuring a more accurate reading of the actual flow rate
Results Achieved:
Resolution of the surge phenomenon:
The intervention restored stable compressor operation, eliminating machine risk conditionsIncreased plant safety:
The new pressure transmitter position ensured reliable and precise flow measurement, critical for system efficiency and safetyEffective and timely diagnostics:
Opus Automazione’s structured approach enabled rapid fault identification, preventing extended downtime and potential mechanical damage
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