COURSE OVERVIEW:

Anti-surge and surge relief systems are critical safety and operational components designed to protect high-value centrifugal compressors and liquid pipelines from catastrophic damage. This course provides a high-level technical analysis of the aerodynamic instability known as "surge" in gas compressors and the hydraulic transients known as "water hammer" in liquid lines. Understanding the physics of flow reversal and pressure spikes is essential for configuring the control loops and mechanical valves that mitigate these risks.

The scope of this training involves the detailed study of surge control philosophy, including the calculation of the surge limit line and the implementation of safety margins. Participants will explore the mechanics of anti-surge valves, actuators, and the high-speed controllers required to respond to rapid flow fluctuations. The coverage extends to surge relief systems in liquid service, focusing on the sizing and testing of fast-acting relief valves and the design of nitrogen-loaded or spring-loaded protection skids.

Furthermore, the course addresses the rigorous testing and tuning protocols required to ensure system reliability. It delves into the use of "surge testing" to validate compressor maps and the maintenance of instrumentation such as transmitters and positioners. By focusing on both the control logic and the mechanical hardware, the course equips professionals with the expertise to prevent machinery destruction, reduce downtime, and ensure the safety of the process plant and pipeline infrastructure.

COURSE OBJECTIVES:

After completion of this course, the participants will be able to:

1. Explain the physics of compressor surge and its mechanical consequences.
2. Define the Surge Limit Line (SLL) and Surge Control Line (SCL).
3. Tune anti-surge control loops for rapid and stable response.
4. Calculate the required capacity and stroke time for anti-surge valves.
5. Analyze the impact of gas composition changes on surge margins.
6. Perform "live" surge testing to verify compressor performance maps.
7. Troubleshoot faults in high-speed anti-surge controllers.
8. Design and maintain surge relief systems for liquid pipelines.
9. Test and calibrate nitrogen-loaded surge relief valves.
10. Evaluate the performance of recycle valves and hot-gas bypass systems.
11. Interpret pressure and flow trends to identify incipient surge.
12. Implement maintenance protocols for surge protection instrumentation.
13. Assess the risks of "stonewall" or "choke" conditions in compressors.
14. Manage the integration of anti-surge systems with the overall DCS.

TARGET AUDIENCE:

This course is intended for instrumentation and control engineers, rotating equipment specialists, pipeline operations managers, and senior maintenance technicians involved in the protection of compressors and piping networks.

TRAINING COURSE METHODOLOGY:

A highly interactive combination of lectures, discussion sessions, and case studies will be employed to maximise the transfer of information, knowledge, and experience. The course will be intensive, practical, and highly interactive. The sessions will start by raising the most relevant questions and motivating everybody to find the right answers. The attendants will also be encouraged to raise more of their questions and to share in developing the right answers using their analysis and experience. There will also be some indoor experiential activities to enhance the learning experience. Course material will be provided in PowerPoint, with necessary animations, learning videos, and general discussions.

The course participants shall be evaluated before, during, and at the end of the course.

COURSE CERTIFICATE:

National Consultant Centre for Training LLC (NCC) will issue an Attendance Certificate to all participants completing a minimum of 80% of the total attendance time requirement.