A surge in your air compressor has the potential to cause a lot of damage to the machine’s components. At Jaguar Air Compressors, we believe that effective control of a surge is essential for any owner of an air compressor. There are many ways in which to prevent and control an air compressor surge, and this article will discuss various ways in which to do so.
The majority of damage and strain to an air compressor usually occurs during the start-up period, a routing shut-down, or during an emergency shut-down. Other events that cause strain to the machine include a variation in production, a change to the composition of the gas, and discharge valve failure. All of these events have the potential of causing stress to the air compressor.
In the worst-case scenario, they can negatively affect air compressor operation due to a compressor surge that may (or may not) result in mechanical damage to the compressor itself. Generally speaking, a surge will be the result of a sudden and significant change in the compressors’ flow function.
To detect a surge, measurements of discharge pressure, inlet temperature, and compressor flow should be taken. The compressor’s suction pressure can also indicate a surge-based oscillation. The implementation of a surge detection system can go a long way in detecting the incidence of a surge. Your air compressor’s flow measurement is probably the most telling sign when trying to detect a surge. In addition to the flow measurement, other factors such as suction pressure, suction temperature, and discharge should also be evaluated, especially in cases where the flow measurement cannot be detected.
As long as the signal shows the production of a measurable surge signature, you will be able to use either the motor power or current in place of the flow measurement. Your surge detection system would then be able to accommodate any of these surge signals. Instrumentation can also be used to detect a surge. Such instruments would, therefore, need to located in very close proximity to the compressor’s flanges. This is so that you would be easily able to locate the process sensing points in order to provide the fastest and most informative information around the compressor’s condition.
Consideration of vibration at the installation point is another factor to consider when you are selecting the transmitter’s location. Care should be taken during the installation process as when it is placed close to the rotating components of the unit (or even onto a section of pipe that is affected by the vibration), this can negatively affect the transmitter and its parts. Finally, always ensure that the installation process is as perfect as possible. For example, if you do not accommodate enough straight run piping in any direction, you may have a signal that is too loud. Knowing how to control a surge is one of the most important factors to consider when you own an air compressor. How do you control your surges, and how does this work for your particular application?