Experimental Investigation and Simulation of Surge Instability in Turbo-Compressors of the Refrigeration Units at Sarkhun and Qeshm Gas Refinery: Development of a Monitoring Tool and Identification of Safe Operating Limits

Hasanzade, Yasha; Hamzavi, Foad; Ghobadi, Ali; Niazi, Saeed; Ansarinasab Minabi, Abdolhamid; Rahimi, Amirreza; Mostaghisi, Omid; Razavizadeh, Seyed Amir; Saadat, Ali; Ghafari, Samad

doi:10.22034/ijche.2026.552907.1561

Experimental Investigation and Simulation of Surge Instability in Turbo-Compressors of the Refrigeration Units at Sarkhun and Qeshm Gas Refinery: Development of a Monitoring Tool and Identification of Safe Operating Limits

Articles in Press

Document Type : Original Article

Authors

yasha hasanzade ¹

foad hamzavi ²

ali ghobadi ³

Saeed Niazi ⁴

Abdolhamid Ansarinasab Minabi ⁵

amirreza rahimi ³

omid mostaghisi ³

seyed amir razavizadeh ³

ali saadat ³

samad ghafari ⁶

¹ sarkhoon gas refinery

² CEO of Sarakhoun Gas Refinery

³ Sarakhoun and Qeshm Gas Refinery

⁴ Department of Mechanical Engineering, Faculty of Engineering, University of Hormozgan

⁵ Instructor, Mechanical Engineering Department, Faculty of Engineering, University of Hormozgan

⁶ Mechanical Engineering, Larstan Higher Education Complex

10.22034/ijche.2026.552907.1561

Abstract

The reduction in feed gas supplied to the Sarkhun and Qeshm Gas Refinery caused the refrigeration unit compressors to operate considerably below their design capacity, thereby increasing the risk of process instabilities, particularly compressor surge. In this study, the refrigeration cycle of the refinery was simulated using Aspen HYSYS software in conjunction with the Peng–Robinson thermodynamic equation of state, based on real operating data. Model accuracy was assessed through the sum of squared errors, yielding deviations of 1.516 kmol/h in flow rate, 0.176 kPa in pressure, and 2.861 °C in temperature. To overcome the limitations associated with the unavailability of compressor characteristic curves, operational performance tests were conducted for the first time at three distinct compressor rotational speeds, enabling a realistic evaluation of surge onset conditions. Furthermore, vibration sensors were implemented to continuously monitor dynamic compressor behavior and accurately detect surge events. The experimental findings and simulation outcomes were subsequently integrated into an Excel-based decision-support tool, enabling real-time operational monitoring, enhancing decision-making efficiency, and improving overall process safety.

Keywords

Surge phenomena

Simulation

Refrigeration unit

Compressor

Process unit

Subjects