Development of a Surge and Energy Performance Monitoring Tool for a Centrifugal Compressor
Abstract
Energy performance and surging dominate the life cycle cost of centrifugal gas compressors. To optimize compressor performance and reliability, the operating point on the compressor performance map is always set far from the surge control line. This results in significantly increased energy consumption owing to the backflow of compressed gas into the inlet pipes. This study presented the development of a novel and robust tool that enables real-time energy performance and surge monitoring of compressors. In the methodology, the off-design performance of the compressor was evaluated on the performance map provided by the OEM and design data. Microsoft Excel was used to digitize compressor performance maps, including surge curves, because it is easier and less expensive than other software, and users have constant access to source code updates. The results showed that the maximum compressing production gas for the 1st stage was 2093.89m3/h, and 1413.53m3/h for the 2nd stage. The polytropic head obtained 130kJ/kg for the low-pressure and 100kJ/kg for the high-pressure stage. While energy consumption was obtained at 5340kWh for the 1st stage and 8000kWh for the 2nd stage, when the compressor was running at full load with 8950 rpm with a 10% surge control line, it showed that the compressor was not surging. According to the findings, the compressor performance deviates from the designed conditions. Therefore, this monitoring tool assists operators and maintenance engineers in tracking the actual health performance of centrifugal compressors, predicting maintenance needs, and reducing maintenance costs and accidental equipment failures.
Keywords: predictive maintenance, surge control, energy performance, compressor.
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