Bridging the Field Gap in Compressor Surge Testing: A Semi-Automated Supervisory Framework for Surge Limit Verification

Reliable determination of the surge limit of an installed centrifugal compressor cannot rely solely on OEM performance maps, theoretical predictions, or previously configured surge lines. The actual field boundary is influenced by installation-specific characteristics, including piping volumes, recycle-system dynamics, valve response, and instrumentation, all of which affect compressor behavior as surge is approached. At the same time, field surge testing is inherently demanding, because it is a safety-critical procedure that requires careful execution and often depends on the experience of specialist personnel. This paper presents a semi-automated supervisory framework for field surge limit verification intended for use by trained site engineers under operator supervision. The framework guides the testing process through readiness checks, instrumentation verification, recycle-valve assessment, gradual reduction of surge margin, real-time monitoring, surge-event identification, recovery actions, and structured data logging. Because early surge precursors are not consistently visible using standard plant instrumentation, the proposed approach relies on a practical signal-based event-recognition method derived from installed measurements and referenced to a pre-event baseline. The paper also introduces a structured method for tuning staged Recycle Trip® recovery actions following surge limit verification using a limited number of field tests. The field evaluation included seven industrial compressor records: five independently confirmed surge cases, one shutdown/non-surge transient, and one confirmed no-surge case. Using a record-specific baseline threshold, all five confirmed surge events were recognized, with reported detection delays of 0–0.1 s. The supporting dynamic simulation environment was used for logic development and qualitative assessment of the supervisory and recovery-tuning concepts. Overall, the proposed approach provides a more structured and repeatable basis for supervised field surge limit verification while preserving operator authority.