GE

Oil & Gas

Centrifugal Compressor Antisurge

Course Description
The training course provides control Eng. with the fundamentals of compressor anti surge control
system. Basics of Load Sharing concepts will be provided.

Prerequisite:
Trainees must have already performed the Centrifugal Compressor Basic course.

Expected Audience:
Control (ENG, Nouveaux & Anciens)

Course Content:
1. GE OIL & GAS CENTRIFUGAL COMPRESSORS
Centrifugal compressor introduction

2. COMPRESSOR PERFORMANCE CURVES

Introduction to Thermodynamic planes
Performance and system resistance curves theory
Operating Point and Conditions

3. ABNORMAL OPERATING CONDITIONS

Centrifugal Compressor Unsteady Flows Overview
Choking or Stonewall
Rotating Stall
Surge

4. ANTISURGE CONTROL AND PROTECTION

Control system introduction
Antisurge valve description
Antisurge block diagram sequence description
Antisurge control and protection philosophy
Antisurge control and protection operation
 GE
Oil & Gas

5. ANTISURGE SCREENS - BASED ON SPEEDTRONIC MARK FAMILY

Main screen field description
Auto/manual operation
Antisurge control status description

6. LOAD SHARING AND BALANCING OVERVIEW

7. QUESTION AND ANSWER

Course Duration: 2 Days

 GE
Oil & Gas

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TRAINING MANUAL

Customized for: SONATRACH (ALGERIA)

GE Oil & Gas
 GE Oil & Gas

Customer Training Job: 0622457

Customer : SONATRACH (ALGERIA)

This manual contains proprietary information of GE Oil & Gas Nuovo Pignone
S.p.A. (GE Oil & Gas), and is furnished to its customers solely for customer
training courses purposes.

This manual shall not be reproduced in whole or in part nor shall its contents
be disclosed to any third party without the written approval of GE Oil & Gas.
The instructions and information contained in the manual do not purport to
cover all details or variations in equipment, or to provide for every possible
contingency to be met during installation, operation, and maintenance.

Should further information be desired or should particular problems arise that

are not covered sufficiently for the purchasers purpose, the matter should
be referred to GE Oil & Gas.

Reviewed Verified Validate

Vito Antonio Tondolo Sandro Fantini
Massimiliano Romizi Mechanical Customer Training
Manual Specialist Instructor Leader Manager
/1/2013 /2/2013 /2/2013
GE Oil & Gas
 GE Oil & Gas
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TRAINING MANUAL

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Customized for: SONATRACH (ALGERIA)

GE Oil & Gas
 GE Oil & Gas
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TRAINING MANUAL

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Customized for: SONATRACH (ALGERIA)

GE Oil & Gas
Oil & Gas Industry Applications

Centrifugal Compressor Antisurge

Centrifugal Compressor- Introduction

What is a compressor?

Driven machine
Rotating machine
Its duty is to increase the gas pressure

How it works?

Increase the kinetic energy throgh rotating components and converts it into static pressure through the stator
components, using the torque given by the driver

Why do I need to compress a gas?

Transport
Create chemical reactions
Gas storage
Enhance oil production

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Antisurge
Centrifugal Compressor- Introduction
Oil/Gas field Pipeline inspection device

Offshore production platform

Re-injection plant

Oil / gas processing plant

Gas boosting station
Subsea equipment

Power generation plant

Oil boosting station

Natural Gas storage plant

LNG liquefaction plant

LNG receiving plant

Refinery / Petrochemical /
fertilizer plant

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Antisurge
Centrifugal Compressor- Introduction
According to the section arrangement of a centrifugal compressor, the internal components can be resumed in different
sections.

This section nomenclature is used to identify the different areas where the gas passes and this is also called GAS PATH.

The gas flows through the compressor along the gas path.
A compression stage consists of the impeller, which is the rotating part, and the diffuser, which is the stationary part.
We can split a compressor gas path into different main sections:

Suction stage
Discharge stage
Intermediate stage/s (multistage compressors)

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Antisurge
Centrifugal Compressor- Introduction

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Antisurge
Centrifugal Compressor- Introduction

The gas flow from the pipe arrives at the suction stage traveling in a radial direction and must be reoriented into an axial
direction to enter the impeller.

The purpose of the suction stage is to convey the gas into the first impeller with low load losses and with uniform pressure
and velocity.
Usually, the suction stage has a fin positioned at the opposite side of the suction flange, which splits the flow of the gas to
avoid gas recycling in the inlet volute.

Fin
Casing
Shaft
Blade

Inlet Volute
Impeller
Suction Nozzle

Suction Pipe

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Antisurge
Centrifugal Compressor- Introduction
Gas inlet

Gas inlet

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Antisurge
Centrifugal Compressor- Introduction

The intermediate stages are the stages between the suction and the discharge; their number depends on how many
impellers are installed on the shaft.
Due to the fact that each compressor is fully customized, the geometry of the intermediate stages will change from
compressor to compressor, according to operating specifications.

Labirinth seals

Blades
Diffuser

Return
channel

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Antisurge
Centrifugal Compressor- Introduction

A compressor stage consists of the impeller, the diffuser and the return
P3,C3
channel.
The impeller rotates with the shaft, increasing both the velocity and
the pressure of the gas.
Regarding the pressure increase, we can say that it occurs within the
impeller and the diffuser, and that the magnitude of this increase
depends on the design of both of these.

P2,C2

P4,C4
P1,C1

Increased velocity and pressure

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Antisurge
Centrifugal Compressor- Introduction
Velocity

Pressure
Energy
4

1
Impeller Inlet Blade Diffuser Diffuser
Inlet Inlet Outlet 2
1 2 3 4

As shown in this diagram: in the impeller both the velocity and pressure increase; in the diffuser the pressure increases and
the velocity decreases due to the convergent design; and in the return channel there is no increase in pressure because the
convergent design is chosen only to avoid load losses.
The return channel is bladed in order to more effectively convey the gas toward the next impeller inlet, thus reducing load
losses, but there is no further increase of pressure downstream the diffuser outlet.
We can state that all the pressure increase realized within a compressor stage is made between the blade inlet and the
diffuser outlet.

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Antisurge
Centrifugal Compressor- Introduction

The discharge section of the gas path is the connection between the
inner parts of the compressor and the piping. The most important part
is the Discharge volute.
The discharge volute is installed after the last diffuser and convey the
gas into the discharge piping.
The volute has a variable section to impart low load losses to avoid
decreasing the pressure.
A fin is usually installed near the discharge flange to prevent gas
recirculation within the volute

Last impeller Discharge volute

11
Antisurge
Centrifugal Compressor- Introduction

The performance curves are a graphical way to display the perfomance parameters, always related to Inlet flow.
Each of the curves is related to a certain fixed speed.
The parameters shown are:

Polytropic Head
Polytropic Efficiency
Pressure Ratio
Power
Discharge Temperature
Discharge Pressure

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Antisurge
Centrifugal Compressor- Introduction
Maximum
continuous speed
(MCS)
Normal operating point

Discharge pressure (bar a)

105%

100%
98%

90%
80%
Minimum
operating speed 65%
(MOS)

Inlet capacity

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Antisurge
Centrifugal Compressor- Introduction

Operating range

Surge Limit
Line
105%

100%
98%

90%
80%

65% Choking Area

14
Antisurge
Centrifugal Compressor- Introduction

External system
resistance curve

The plot represents the envelope of all the

possible operating conditions relevant to
the given suction parameter.

The actual operating point is unique and

105%
it is always the intersection between the
compressor curve at the given speed
and the plant resistance curve. 100%
98%

90%
Operating
80% point

65%

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Antisurge
Centrifugal Compressor- Introduction

The plant resistance curve can change

during operation

105%

100%
98%

90%
80%

65%

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Antisurge
Centrifugal Compressor- Introduction

105%

100%
98%

90%
80%
Operating
65% stability

Turndown Range
17
Antisurge
Centrifugal Compressor- Introduction
Looking back at this performance curve diagram, the left and right limits for the perfomance map of a centrifugal
compressor are called: Surge limit line and Choking area.

To introduce the topic, choking is related to the maximum flow rate that the compressor can handle at a certain speed while
surge is related to fluid dynamic instabilities that will occur if the flow rates decreases over a certain threshold at a certain
speed.

Operating range

Surge Limit
Line
105%

100%
98%

90%
80%

65% Choking Area

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Antisurge
Centrifugal Compressor- Introduction

Choking rapresents the right limit of the perfomance curves.

It is the maximum flow that the compressor can handle at that speed, given by the geometry of the impellers.
Due to a change in system resistance, if the operating point reaches the choking limit, the flow remains constant but the
discharge pressure will rapidly drop.

Rapid decrease in performances and efficiency.

The increase of gas speed inside the compressor can lead to
high vibrations alarms.

19
Antisurge
Centrifugal Compressor- Introduction

Choking is a physical limit of the compressor but it will mostly affect only the output.
No detection or protection system is required to provide choking.

What happens if the compressor chokes:

The flow reaches M=1 at the inlet of the impeller (restricted section);
Shock wave causes a dicontinuity of p and T.
Maximum flow rate;
Flow rate remains constant
Discharge pressure will drop
Gas velocity will increase

Shock wave

20
Antisurge
Centrifugal Compressor- Introduction

What is it surge?

"Axis-symmetric stall", more commonly known as "compressor surge" or "pressure surge", is a complete breakdown in
compression resulting in a reversal of flow. This phenomenon occurs when the machine operates at a compression ratio close the
maximum that the compressor can furnish at the speed at which it is running.
What is it due to?

Its due to the compressor's inability to continue working against the already-compressed gas behind it.

What happens?

The compressor either experiences conditions which exceed the limit of its pressure rise capabilities or is highly loaded such
that it does not have the capacity to absorb a momentary disturbance, creating a rotational stall which can propagate in less
than a second to include the entire compressor.

Which are the main factors leading to Surge?

During the normal operation: Increase of discharge pressure, downstream the compressor; decrease of suction pressure;
increase of suction temperature.
Due to high plant resistance, during Start up and Shutdown theres a high risk of surge phenomenons.

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Antisurge
Centrifugal Compressor- Introduction

Surge is the left limit of performance curve, on the left of this line the compressor operates in unstable condition;

Represents the maximum polytropic head of the curve;

All surge points, defined for different speeds represent the Surge Limit Line SLL;

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Antisurge
Centrifugal Compressor- Introduction

P2

P2 > P1

P1

Axial thrust

23
Antisurge
Centrifugal Compressor- Introduction

P2

P1 > P2

P1

Axial thrust

24
Antisurge
Centrifugal Compressor- Introduction

Flow Pressure

Time Time

Rapid flow oscillations Rapid pressure oscillations with process instability

Temperature

Rising temperatures
inside the compressor

Time

25
Antisurge
Centrifugal Compressor- Introduction

Flow reverses in 20 to 50 milliseconds

Surge cycles at a rate of 0.3 sec to 3 sec per cycle

Compressor vibrates, shakes

Temperature rise

Whooshing noise or clanking noise

Conventional instruments and human operators may fail to recognize surge

26
Antisurge
Centrifugal Compressor- Introduction

Unstable flow and pressure

Damage increasing with severity to seals, bearings, impellers and shaft

Increased seal clearances and leakage

Lower efficiency

Trips

Reduced compressor life

27
Antisurge
Centrifugal Compressor- Introduction

The purpose of the antisurge control system is to keep the operating point, at each respective speed, from surpassing the
surge limit line SLL.
At the same time, the antisurge control system allows the compressor to maintain a safe working range.

The opening of the antisurge valve causes an increase of compressor suction flow that will reduce the slope of the external
system resistance curve, so the working point of the machine remains safely on the right of the critical surge flow.

External system
In order to maintain the compressor resistance curve
operation within a safe operating range, all
the centrifugal compressors are equipped Operating range
with an antisurge system.
Surge Limit
Line

105%

100%
98%
Operating
90% point
80%

65% Choking Area

28
Antisurge
Centrifugal Compressor- Introduction

The Antisurge System is composed by:

Antisurge Valve

Instrumentation:

Flow indicator trasmitter

Pressure indicator trasmitter

Electronic controller

Antisurge valve: Is a regulating valve, to avoid excessive recycles of flow that will reduce the output of the machine. Recycles
flow from discharge to suction in order to reduce system resistance. Cv of this valve, according to the stroke, is first
equiexponential, for smooth regulation, then linear, for protection. Is a Failure Open valve and is equipped with a solenoid
valve for quick opening. Antisurge valve fully open (ZSL XXX) is a permissive to start.

Instrumentation: The flow transmitter can be a rotameter, an annubar or, more commonly, a differential pressure transmitter
across a calibrated orifice. In the last case we need also to measure the gas temperature to calculate the right density of the
gas.

29
Antisurge
Centrifugal Compressor- Introduction
Antisurge valve: Is a regulating valve, to avoid excessive recycles of flow that will reduce the output of the machine. Recycles
flow from discharge to suction in order to reduce system resistance. Cv of this valve, according to the stroke, is first
equiexponential, for smooth regulation, then linear, for protection. Is a Fail to Open valve and is equipped with a solenoid
valve for quick opening. Antisurge valve fully open (ZSL XXX) is a permissive to start.

30
Antisurge
Centrifugal Compressor- Introduction
The goal of this system is to maintain the operating point within a safe operating area.
But we have to avoid to reach the SLL, surge limit line.
For this reason, inside the controller, is stored another curve called SCL, surge control line, directly related to SLL.
The relationship between SLL and SCL is the safety margin that we want to maintain, usually the points on SCL have 10% flow
more than the points on the SLL at the same rotational speed.

If the operating point remains on the right of the SCL, the antisurge valve will remain closed, otherwise it will start to open.

During the Start-up the antisurge valve remains fully open until the compressor reaches the MOS, once reached that speed
the valve turns in control, according to where the operating point is.
As soon as the Shutdown sequence begins, antisurge valve becomes immediately fully open to prevent surge.

31
Antisurge
Centrifugal Compressor- Introduction
AS control curves
The actual Surge Line is the place in which the machine surge, it can change its position because can change the
thermodynamic parameters of the gas. All the other curves are calculated using a specific thermodynamic condition so they
can not change .

SPL SCL
SL

32
Antisurge
Centrifugal Compressor- Introduction
AS control curves
It is possible to have that after some change in the thermodynamic parameters, the surge line has moved while the
surge protection line did not move (because set points must be inserted manually):

SPL SCL
SL

33
Antisurge
Control system wiring and communication ways
network
PDH command
feedback
HMI
UDH

COMPRESSOR
EXT. F&G PLC
POWER

SIS
Mark VI
MCC
BN

MP

AUXILIARY TURBINE GEAR BOX COMPRESSOR

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19/11/2013
Mark VI Hardware Panel introduction
Main parts Simplex

2 2
1. VME rack
r. Rack R
s. Rack S
1r 1 4 t. Rack T
2. Protection Module
3 3. Terminal Boards
4. PDM
1s
6 5. DACA1 (AC/DC)
6. Input filters

1t
5 35

19/11/2013
Mark VI Hardware Panel introduction
Simplex-TMR connections

I/O board
FIELD
I/O board

I/O board

I/O board

I/O board

I/O board

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19/11/2013
Mark VI Hardware Panel introduction
Simplex-TMR connections

I/O board
FIELD
I/O board

I/O board

I/O board

I/O board

IONet (ethernet) I/O board

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HMI Introduction

The toolbox is a software for configuration of various control equipment.

Therefore, each product package can consist of the toolbox, product files
toolbox for the controller or drive, Trend Recorder, Data Historian, and product files
for the System Database (SDB). To order the toolbox software and specific
product support files.

The Cimplicity is a software for the definition and visualization of the HMI
screens for real time control of power-plant, processes and equipment.
In addiction, throught the Cimplicity software the operator can issue cimplicity
commands to the selected turbine or driven devices.

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HMI Introduction

Mark VI

alarm
feedbacks
TCI
commands

EGD
cimplicity

toolbox
39

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Graphic pages - load

40

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Graphic pages - load

41

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Antisurge signals
TEMPERATURE
TRANSMITTER

TT

TT-715
PT-723: Surge pressure transmitter
PT-723

PT-721
FT-721

PT-721: Discharge pressure transmitter

FT-721: Surge diff-pressure transmitter

MKVI
TT-715: Surge temperature transmitter
FV-722

42

19/11/2013
Antisurge signals
Mark VI
ON/OFF signal

Command: a20as
Position H :

Position L
43

19/11/2013
AS Sequence in MKVI
Antisurge master enabling signal

L3: READY TO LOAD

L94X: NO SHOUT DOWN L4AS

Antisurge master enabling signal
L33CDMN: MIN. COMPRESSOR
OPERATIVE SPEED
L4: MASTER OPERATIVE SIGNAL
L14LS: MINIMUM OPERATIVE SPEED

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19/11/2013
AS Sequence in MKVI
Start/Purge sequence
stopped L4AS = 0
A20as = 0% (AS valve completely opened)

L1X = 1 (auxiliaries ON) Compressor A20as = 100% (AS valve completely

And: closed) to purge the compressor
No Water Wash purge
No AS manual control
No Compressor pressuruzed

AS purge a20as = 0% (AS valve completely opened)

to purge the AS line

From L14LR = 1 (shaft acceleration

revolution) Protection mode (a20as = 0% (closed)

L4AS = 1 (AS enabledl)

to L3=1 (ready to load) Load a20as = 0-100% (AS valve in control)

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19/11/2013
AS Sequence in MKVI
Antisurge control Loop

A20AS_MAR a20as

A20AS_PARM

A PI controller regulates antisurge valve

position in order to maintain the
operative point on the control line (SCL).

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19/11/2013
AS Sequence in MKVI
Antisurge control Loop

A20AS_MAR a20as

A20AS_PARM

DEAD BAND: to PI error is added to avoid

that measurement noise acts directly on
PI output when operative point is near
control line.
The dead band is defined by 2 constant
K20AS_DB_L and K20AS_DB_H.

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19/11/2013
AS Sequence in MKVI
Antisurge control Loop

A20AS_MAR a20as

A20AS_PARM

RATE LIMITER: PI controller output rate is limited by the rate limiter

function. Two ramps are defined:
Opening rate is limited K20AS_ARATO (30%/s)
Closing rate is limited by K20AS_ARATC (1.5%/s)

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AS Sequence in MKVI
Antisurge specific funtions

SLOW OPENING (L20AS_SO):

It is activated in case of engine
shoutdown.
The valve, starting from tha actual
position, is opened at a slow rate
(K20AS_ARASO = 0.5%/s). All other
comtrols remain active and, if
required, the valve can be opened
faster.
When the function is deactivated,
the valve is closed using the
automatic closing rate
(K20AS_ARRATC = 1.5%/s) until the
normal activation controller action
takes back the control.

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19/11/2013
AS Sequence in MKVI
Antisurge specific funtions

TRANSIENT ABSORPTION
(L20AS_TA):
It is activated in case of rapid
approaching to surge line.

Detection: threshold K20AS_TA

(5 10 ) is reached and
override by derivative parameter
A20AS_PARAM.

Action: the setpoint A20AS_MAR is

increased by multiplying factor
K20AS_TA_G (1.15).
The original setpoint is than
restored when the derivative
parameter returns below the slow
rate threshold K20AS_TA_R
(5 10 ).

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19/11/2013
AS Sequence in MKVI
Antisurge specific funtions

SAFETY CORRECTION (L20AS_COR):

It is activated if operating point
approches surge line more than
correction line (COR).

Detection: AS parameter <

K20AS_COR

Action: set point is increased at

fixed time (2.2s).
Integral time is divided for 4 to
uncrease integral action and, as
consequence, speeding the valve
opening.

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AS Sequence in MKVI
Antisurge specific funtions

SAFETY PROTECTION (L20AS_SPR):

It is activated if operating point
approches surge line more than
protection line (SPR).

Detection: AS parameter <

K20AS_SPR

Action: recycling valve fast opening

ramp is initiated. Than safety
protaction terminate when
operating point parameter is above
safety protection SPR line with
hysteresis K20AS_SPRH.
If the situation is not OK in 10s an
alarm indicates a problem in the AS
valve opening.

Safety protection is also active

during START/STOP sequence.

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AS Sequence in MKVI
Antisurge specific funtions

PROTECTIONS DISABLING
When unit is operative (L4AS = 1),
safety protection and correction
can be disabled (normally to allow
surge zone exploration) by the
override command L43AS_O_CMD.
In this case alarm L43AS_O_ALM is
generated.

DANGER !!!

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AS Sequence in MKVI
Antisurge specific funtions
MANUAL OPERATION (L43AS_CMD)
Manual operation can be selected if at least one of the following condition is verified:
Safety protection od safety correction not active
Antisurge master enabing signal disabled (L4AS = 0)
Protections disabled (L43AS_O_CMD)

If MANUAL OPERATION is selected, recycling valve positio n is

managed by five pushbuttons (with a ramp of 1%/s):
1. L5AS_C_CPB: AS valve close PB (fine tuning)

2. L5AS_O_CPB: AS valve ope PB (fine tuning)

3. L5AS_FC_CPB: AS valve close PB (latched till

valve completely closed or L5AS_S_CPB is
received)

4. L5AS_FO_CPB: AS valve open PB (latched till

valve completely closed or L5AS_S_CPB is
received)

5. L5AS_S_CPB: stop AS valve stroking

54

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Graphic pages - load

55

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Graphic pages - load

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Graphic pages - load

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Load sharing theory
Regulation of the operating point of a compressor

The operating point of a compressor can be changed (regulated)

by means mainly two ways:

Speed variation
The operating point can be
changed changing the shaft
speed.

105%

100%
98% NPT = Pout and Qin
90%
80% NPT = Pout and Qin
65%

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Load sharing theory
Regulation of the operating point of a compressor

The operating point of a compressor can be changed (regulated)

by means mainly two ways:

Cooled bypass
The operating point can be changed
throught the managing of the
antisurge valve.

105%

100%
98%
AS Closing = Pout and Qin
90%
80% AS Opening = Pout and Qin
65%

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Load sharing theory
Regulation of the operating points of 2 compressors in PARALLEL

Qin1 Pout
Pout1
The goal is to share the load in equal
DRIVER

Collector
1
C1 parts on the two compressor trains,
50% on C1 and 50% on C2.

Qin2
Pout = Pout1 = Pout2
Pout2

DRIVER
2
C2

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Load sharing theory
Regulation of the operating points of 2 compressors in PARALLEL

Train 1 Train 2

105% 105%

100% 100%
98% 98%

90% 90%
80% 80%
65% 65%

If Driver1 increases its rpm, Pout1 increases. Pout = Pout1 =Pout2, so also Pout2 increases changing the resistance
curve of the second compressor. For that reason the working point 2 goes closer the surge limit.
When a train in a parallel configuration changes its speed, also the speed of the other train must be changed in the
same way.

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Load sharing theory
Regulation of the operating points of 2 compressors in SERIES

Qin2 Pout
Qin1
Pout1 Pout2

Collector
DRIVER DRIVER
1
C1 2
C2

Pout = Pout1 + Pout2

The goal, in this configuration, is the managing of the requested Pout.

An increasing of te Pout is implemented increasing the revolution speed.

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Load sharing theory
Regulation of the operating points of 2 compressors in SERIES

Qin2 Pout
Qin1
Pout1 Pout2

Collector
DRIVER DRIVER
1
C1 2
C2

Pout = Pout1 + Pout2

If the Pout needs to be increased, Driver2 can increase the speed. But, if
only Driver2 increases the speed, this variation determines the lowering
of the resistance curve of the Compressor1 that generates a decresing
of Pou1; and finally the consequent new decreasing of Pout.
When a train of a series changes its speed, also the speed of the
other train must be changed in the same way.
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Load sharing theory
Regulation of the operating points of 2 compressors.

AS valve
Qin
Pout
Fine regulation through the
antisarge valve:
DRIVER C

Because the 2 compressors cannot be perfectly equal (for costruction tolerances, dirty...) even if they are revolving a
the same speed, they will work a little bit differently one by the other.

In consideration of that: speed regulation is not enoght .

A fine regulation of the load sharing, both for series and parallel configurations, needs to be
implemented by means of Cooled bypass method.

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Centrifugal Compressor- Introduction

65
Antisurge
 GE Oil & Gas
&HQWULIXJDO&RPSUHVVRU$QWLVXUJH
TRAINING MANUAL

SEZ . Drawings

Customized for: SONATRACH (ALGERIA)

 GE
Oil & Gas

Drawings Index

BCL505/N assembly drawing SOS9929211

Performancecurves SOS9983763

Piping and instrument diagram SOM5081477

Instrument list SOM6609947

Control system functional description SOM6670429

Antisurge Valve SOS7248866

Antisurge valve data sheet RV 28465

Antisurge write-up SOS9983403

Performance curves SOS9983763