Is a compressor surge bad? Possibly the most common question that new air compressor owners have is whether or not a surge is a good or bad thing. Here at Jaguar Air Compressors, we endeavour to help you make the most of your machine, and this article will discuss how harmful a compressor surge really is. The quick answer to this question is, yes, a surge is harmful as it is the leading cause of air compressor failure. That being said, if you have an isolated surge incident, it is not the end of the world.
An air compressor surge usually happens when a back-up occurs, and the unit will back up on its curve to such an extent that it can no longer deliver any further flow downstream. The flow in the system will then flow back into the air compressor, resulting in a surge. If you have repeated surges, your air compressor could overheat, and this is where a surge becomes harmful to the machine. The reason for this is that the unit will overheat after continued surges, and this will result in the rotors expanding, which, in turn, cause internal rubs and even over-stressing of the thrust bearing.
If this happens, the rotor will shift and will eventually rub the casing’s stationary components. This could result in damage to the blades, which might obstruct the unit’s gas pathway and could tear off other blades in the process. The good news is that many modern air compressors have anti-surge systems, and this prevents much of the damage that a surge can cause. A surge in your air compressor will always affect its performance, and you can often tell when a surge is happening by the loud noises.
In addition, a surge can often damage the solid structure of your air compressor. This is due to the consistently rough surge flows that are constantly hitting the unit’s blades. Eventually, your machine’s blades will become fatigued, and the air compressor could also even experience a total mechanical failure. In many cases, damage as a result of a surge is because of the unbearable, transverse loads on the unit’s blades and casings. Often, a chain reaction can occur, and this will cause the unit, as a whole, to simply burn out. This happens because there is limited air intake, resulting in large quantities of unburnt fuel in its combustion chamber. This unburnt fuel will ultimately ignite, and a flameout will take place near the exit. A surge within your air compressor is also accompanied by a wild fluctuation in pressure, and the RPM rate is increased. The effect of this pressure fluctuation can do a lot of damage to the compressor’s bearings and compressor wheel.
We recommend putting measures in place so that a surge can be prevented or avoided at all costs. By consulting your user manual and following the operating instructions carefully, you can help prevent any surges from happening as much as possible.
What has been your experience with surges, and how do you try and avoid them?
