Compressor

Compressor control menu
Cost of operating turbo compressors

Maintenance cost
Operating cost
Commissioning cost
Putting it in perspective
Compressor operation
Centrifugal compressors
Axial compressors
Compressor system classifications
Developing the compressor curve
The surge phenomena
Compressor control
Acrobat
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Repairs are expensive
Costs of repairs - materials and labor

3,000 hp
Process gas compressor
20,000 hp
Axial air blower
Seals
$20,000
$50,000
Bearings
$10,000
$25,000
$200,000
$750,000
Rotor Assembly
Compressors
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Operating costs are large
Cost to operate one turbo compressor per year:
Plant air compressor
1,000 HP (746 kW)
$457,000
Wet gas compressor
4,000 HP(2,984 kW)
$1,830,000
Propylene refrigeration comp.
40,000 HP(29,480 kW)
$18,300,000
Assumes power at $.07 per kilowatt hour or $457 per horsepower per year.
Energy costs vary due to local conditions.
Energy Saving Examples
Energy Savings Predictions
Compressors
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Energy savings examples

resulting from reduced recycle or blow-off
Compressor
application
Compressor
shaft power
Actual achieved
savings
Actual Energy
Savings Result
From
Propylene
refrigeration
40,000
hp ( 29 MW)
$1,200,000
Improved Antisurge Protection and Capacity Control
FCCU air blower
Centac air compressor
15,000 hp (11.2 MW)
$155,000
1,500 hp (1.1 MW)
$78,000
Energy Savings Predictions
Compressors
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Available energy savings can be predicted

Less than one year pay-backs* typical by reducing recycle of blow-Off
Pay-back 12
Period 11
(Months)
10
Pay-back less than 10

Months with 15% Reduction
9
8
7
Pay-back less than 6
Months with 15% Reduction
6
5
1000 HP
4
3
3,500 HP
Pay-back approximately 1
Month with 15% Reduction
2
1
20,000 HP
0
10
15
20
25
30
35
Reduced Recycle
(Per Cent of Maximum Compressor Flow)
*Assumes electro motor power At $0.05 US per kilowatt hour or turbine power at $327
per horsepower per year. Tax consequences are not considered in pay-back period
due to varying tax policies around the world.
Compressors
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Downtime costs can be enormous!
60,000 BPD Cat Cracker: $90,000 per hour, lost sales plus
fixed expenses. The biggest units are twice this size!
Natural Gas Production, 100 MMSCFD: $12,500 per hour
lost sales plus fixed expenses.
Consequences of downtime: Lost profit, lost customer
goodwill, repair costs, attention of top management.
Compressors
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Commissioning costs are large
Process
Start-up Cost Per Day
100 MMSCFD
Natural Gas Plant
$375,000
60,000 BPD
Cat Cracker
$2,300,000
Includes lost sales plus fixed operating expenses.
Most turbo compressor control system design problems are

discovered during commissioning.
Delays due to turbomachinery control problems are not unusual.
Startups are faster with a properly designed turbomachinery

control system.
Compressors
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30-year life cycle costs for a 20,000 hp compressor
Maintenance Costs
$4.5 Million
Initial Cost
$1.5 Million
97%
of total costs
Energy Costs
$180 Million
Costs in constant dollars

Source: Experiences in Analysis and Monitoring Compressor Performance
Ben Duggan & Steve Locke
E.I. du Pont, Old Hickory, Tennessee
24th Turbomachinery Symposium
Compressors
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30-year cost per 1,000 hp
$ Millions
15.0
What can we control?

10.0
Uncontrollable
Controllable
5.0
0.0
Initial Cost
Maintenance
Energy
Costs in constant dollars
Lost
Production
Source: Experiences in Analysis and Monitoring Compressor Performance

Ben Duggan & Steve Locke, E.I. du Pont, Old Hickory, Tennessee
24th Turbomachinery Symposium
Compressors
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Centrifugal compressors
Widespread use, many applications
Gas is accelerated outwards by rotating impeller
Can be built for operation as low as 5 psi, or operation

as high as 8,000 psi (35 kPa or 55,000 kPa)
Sizes range from 300 hp to 50,000 hp

DIFFUSERS
Cross Section of Horizontal Split
Picture of Horizontal Split

Cross Section of Barrel Type
Picture of Barrel Type
Cross Section of Integrally Geared
Picture of Integrally Geared
IMPELLERS
Single Case Compressor
Centrifugal Impeller
Compressors
Picture of Gear and Impellers
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Cross section of horizontal split

Discharge volutes
Impeller inlet labyrinth seals
Impellers
Shaft and labyrinth seal

Drive coupling
Journal bearing
Casing
(horizontally split flange)
Thrust bearing
Compressor discharge nozzle
Compressor inlet nozzle
Picture of Horizontal Split
Centrifugals
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Picture of horizontal split
Cross Section of Horizontal Split
Centrifugals
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Cross section of barrel type compressor
Picture of Barrel Type
Centrifugals
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Picture of barrel type compressor
Cross Section of Barrel Type
Centrifugals
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Cross section of bull gear compressor

Labyrinth seals
Drive coupling
Impellers
Main gear
Journal bearing
Inlet guide vanes
Pinion shafts
Gear casing
Compressor volutes
Centrifugals
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Picture of bull gear compressor
Centrifugals
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Picture of (bull) gear and impellers
Centrifugals
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Axial compressors
Gas flows in direction of rotating shaft
Can be built for lower pressures only

10 to 100 psi (0.7 to 6.8 Bar)
High flow rate
Efficient
Not as common as centrifugals
Stator Blades
Shaft
Rotor Blades
Casing
Rotor
Blades
Stator
Blades
Casing
Cross Section of Axial
Picture of Axial
Compressors
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Cross section of axial compressor

Guide-vane actuator linkage
Labyrinth seals
Compressor rotor
Rotor blades
Adjustable guide vanes

Thrust bearing
Compressor inlet nozzle
Compressor outlet nozzle
Picture of Axial
Axials
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Picture of axial compressor
Cross Section of Axial
Axials
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Compressor system classifications
Single-Section, Three-Stage
Parallel Network
Single-Case, Two-Section, Six-Stage
Two-Case, Two-Section, Six-Stage
Series Network
Compressors
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R
Pcdpc c
DP
R
H
DischargeRatio
Differential
Pressure
Polytropic
Pressure
Head
Pressure
(Pd/P(P
) 2or
) -(P
PR
)process,2
or
s(P
d
s/P
2
1) (P2 - P1)
Rprocess,1
Rc2
Rc1
Compressor curve
for a specific
speed N1
Q2
Q1
Compressors
Qs,
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normal
mass
vol
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process limit
Rc
adding control
margins
maximum speed
surge limit
power limit
stonewall or
choke limit
Actual available
operating zone
stable zone
of operation
minimum speed
Qs,
Compressors
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How an airplane wing develops lift
v1, p1
v2, p2
Bernoullis law
pstatic + 1/2rv2 + rgH = Constant
The term rgH is negligible for the wing
Then: pstatic + 1/2rv2 = Constant
Lift
Due to the shape of the

wing: v2 < v1 thus p2 > p1
As a result there is Dp or
lift
And the plane can
fly
Compressors
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How the airplane develops stall
Lift
Lift
Lift
Lift
As the wing tilts back the Dv changes and thus the Dp
This leads to more lift
When the wing is tilted too much the streaming profile

suddenly changes from laminar to turbulent
The air no longer sticks to the wing and the lift is lost
The plane starts to fall down

Compressors
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Developing the surge cycle on the compressor curve

Pd
Compressor reaches surge point A

From
A to B
20 - 50
ms
Drop
into surge
Compressor
looses
itsstarts
abilitytotobuild
make
Compressor
pressure
pressure
From
Cto DCompressor
20 - 120rides
ms
Jumptowards
out of surge
curve
surge
Suddenly
P
drops
and
thus
P
>
P
d
v
d
Point
A
is -reached
A-B-C-D-A
0.3
3
seconds
Surge
cycle
Plane goes
tosurge
stall -cycle
Compressor
surges
The
is complete
Pv
Rlosses
Pd
Pd
= Compressor discharge pressure
Pv
= Vessel pressure
Rlosses = Resistance losses over pipe
Pressure builds
System pressure is going down

D
Resistance
goes
up
Compressor is again able to overcome Pv

Compressor
rides
the curve jumps back to
C
Compressor
performance curve and goes to point D
Pd = Pv + Rlosses
Electroflow
motor
is started
Forward
is re-established
Because Pv > Pd the flow reverses
Result
of
flow
reversal
is
that
pressure
goes
Machine accelerates to nominal
Compressor operating point goes to point B

down
speed
Pressure goes down => less negative flow
Compressor reaches performance

curve
Operating point goes to point C
Machine shutdown
no flow, no pressure
Qs,
Note: Flow goes up faster because

pressure is the integral of flow
vol
Compressors
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Major process parameters during surge

FLOW
2
TIME (sec.)
2
TIME (sec.)
2
TIME (sec.)
Rapid pressure oscillations

with process instability
Rising temperatures inside

compressor
TEMPERATURE
Rapid flow oscillations

Thrust reversals
Potential damage
PRESSURE
Compressors
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Surge description
Flow reverses in 20 to 50 milliseconds
Surge cycles at a rate of 0.3 s to 3 s per cycle
Compressor vibrates
Temperature rises
Whooshing noise
Trips may occur
Conventional instruments and human operators

may fail to recognize surge
Compressors
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Some surge consequences
Unstable flow and pressure
Damage in sequence with increasing severity

to seals, bearings, impellers, shaft
Increased seal clearances and leakage
Lower energy efficiency
Reduced compressor life
Compressors
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Factors leading to onset of surge
Startup
Shutdown
Operation at reduced throughput
Operation at heavy throughput with:

-
Trips
Operator errors
Load changes
Cooler problems
Driver problems
Power loss
Process upsets
Gas composition changes
Filter or strainer problems
Surge is not limited to times of reduced throughput. Surge

can occur at full operation
Compressors
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Compressor control
Objectives
Performance control
Major challenges of compressor control
Loadsharing for parallel compressors
Location of the surge limit
Compressor networks
High speed of approaching surge
Base loading parallel compressors
Control loop interactions
Equal flow division system
Loadsharing of multiple compressors
CCCs equidistant Loadsharing system
Antisurge control
Other topics
Basic antisurge control system
Fall-back strategies
Protection #1: PI control
Limiting control
Protection #2: Recycle Trip
Pressure Override Control (POC)
Protection #3: Safety On
Flow Measuring Devices (FMDs)
Output linearization
Antisurge control valve
The tight shut-off line
Piping lay-out considerations

Influence of controller execution time
Dynamic simulation single compressor
Dynamic simulation parallel compressors
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Major control system objectives

(user benefits)
1. Increase reliability of machinery and process
Prevent unnecessary process trips and
downtime
Minimize process disturbances
Prevent surge and surge damage
Simplify and automate startup and shutdown
2. Increase efficiency of machinery and process
Operate at lowest possible energy levels

Minimize antisurge recycle or blow-off
Minimize setpoint deviation
Maximize throughput using all available
horsepower
Optimize loadsharing of multiple units
Compressor control
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Calculating the distance between the Surge

Limit Line and the compressor operating point
The Ground Rule
The better we can measure the distance to surge, the closer we can
operate to it without taking risk
The Challenge
The Surge Limit Line (SLL) is not a fixed line in the most commonly used
coordinates. The SLL changes depending on the compressor inlet
conditions: Ts, Ps, MW, ks
Conclusion
The antisurge controller must provide a distance to surge calculation that
is invariant of any change in inlet conditions
This will lead to safer control yet reducing the surge control margin which
means:
Bigger turndown range on the compressor

Reduced energy consumption during low load conditions
Compressor control
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Commonly used (OEM provided) coordinate

systems of the compressor map
Typical compressor maps include: (Qs, Hp), (Qs, Rc), or (Qs, pd)
coordinates, where:
Qs = Suction flow and can be expressed as actual
or standard volumetric flow
Hp = Polytropic Head
Rc = Compressor Ratio (pd / ps)
pd = Discharge pressure of the compressor
ps = Suction pressure of the compressor
ks = Exponent for isentropic compression
These maps are defined for (1) specific set of inlet conditions:
ps, Ts, MW and ks
Compressor control
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The problem with commonly used (OEM provided)

coordinate systems of the compressor map
These coordinates are NOT invariant to suction conditions as shown
For control purposes we want the SLL to be presented by a single

curve for a fixed geometry compressor
Compressor control
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Developing invariant coordinates
The following variables are used to design and to characterize

compressors
Through dimensional analysis (or similitude) we can derive two
sets of invariant coordinates
Fundamental variables
characterizing compressor
operation
Hp = f0(Q, w, m, r, a, d, a)
Invariant coordinates
Set 1
Set 2
hr
qr
Ne
a
jr
Re
Rc
qr
Ne
a
jr
Re
Dimensional analysis
or Similitude
J = f1(Q, w, m, r, a, d, a)
where:
Hp
J
Q
w
m
r
a
d
a
= Polytropic head
= Power
= Volumetric flow rate
= Rotational speed
= Viscosity
= Density
= Local acoustic velocity
= Characteristic length
= Inlet guide vane angle
where:
hr
qr
Ne
a
jr
Re
Rc
Compressor control
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= Reduced head
= Reduced flow
= Equivalent speed
= Guide vane angle
= Reduced power
= Reynolds number
= Pressure Ratio
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Coordinates (Hp, Qs) and (hr, qr2)

(Hp, Qs)
(hr, qr2)
NOT invariant coordinates
where:
Hp
Qs
hr
qr2
= Polytropic head
= Volumetric suction flow
= Reduced head
= Reduced flow squared
Compressor control
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Coordinates (Rc, Qs) and (Rc, qr2)

(Rc, Qs)
(Rc, qr2)
NOT invariant coordinates
qr2
where:
Rc
Qs
qr2
= Pressure ratio
= Volumetric suction flow
= Reduced flow squared
Compressor control
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Coordinates (Rc, jr) and (Rc, Ne2)
where:
Rc
jr
Ne2
(Rc, jr)
(Rc, Ne2)
= Pressure ratio
= Reduced power
= Equivalent speed squared
Compressor control
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Representing the SLL as a single curve

using reduced coordinates
A coordinate system that is invariant to suction conditions is:
Hp
hr
(ZRT)s
and
qr
Qs
( ZRT)s
Squaring the flow will still keep coordinates invariant:
Hp
hr
(ZRT)s
and
2
Q
s
qr2
( ZRT)s
hr
2
qr
Design
Nitrogen Off-gas
MW
MW
MW
Ps
Ps
Ps
Ts
Ts
Ts
ks
ks
ks
Compressor control
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Calculating qr2 (reduced flow squared)
qr
2=
Qs 2
(ZRT)s
where:
R
Ru
R
MW
ps
K
Dpo,s
Ts
Zs
K . Zs . Ru . Ts Dpo,s
.
MW
ps
=
(ZRT)s
Dpo,s
=
ps
= Ru / MW
= Universal gas constant
= Specific gas constant
= Molecular Weight of the gas
= Suction pressure
= Orifice plate constant
= Differential pressure across orifice plate
= Temperature of the gas in suction
= Compressibility of gas in suction of compressor
The antisurge controller calculates qr2 using ps and Dpo,s transmitters
Compressor control
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Calculating hr (reduced head)
hr =
Hp
(ZRT)s
Zs . Ru . Ts
Rcs-1
.
MW
s
=
(ZRT)s
Rcs-1
=
s
log(Rt)
For polytropic compression Rt = Rcs thus s =

log(Rc)
R
= Ru / MW
Rt
= Td / Ts
Temperature ratio
Rc
= pd / ps
Pressure ratio
where:
Ru
= Universal gas constant
R
= Specific gas constant
MW
= Molecular Weight of the gas
pd
= Discharge pressure
ps
= Suction pressure
Zs
= Suction compressibility
s
= Exponent for polytropic compression
The antisurge controller calculates hr using pd, ps, Td and Ts transmitters

Compressor control
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Building the Surge Limit Line

Any curvature of the Surge Limit Line can be characterized as a
function of the ordinate hr
The surge parameter is defined as:
f1(hr )
Ss 2
qr ,op
The function f1 returns the value of qr2 on the SLL for input hr
hr
hr
qr,SLL
qr
Compressor control
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The surge parameter Ss
The function f1 returns the value of qr on the SLL for input hr
As a result:
Ss =
q2r,SLL
q2r,op
hr
Ss > 1
Ss < 1
stable operating zone
Ss = 1
surge limit line (SLL)
Ss > 1
surge region
OP
hr
Ss < 1
2
qr,SLL
2
qr,op
qr
OP = Operating Point
Compressor control
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Introducing the distance between the operating

point and the Surge Control Line
Step 1:
Introduce parameter
d = 1 - Ss
Step 2:
Introduce parameter
DEV = d - surge margin
The parameter DEV is independent of the size of the compressor

and will be the same for each compressor in the plant
hr
d =0
Ss = 1
Benefits:
d <0
DEV = 0
One standard surge parameter

in the plant
No operator confusion:
Ss > 1
DEV < 0
Ss < 1
DEV > 0
Good
d >0
DEV = 0
Recycle line
DEV > 0
DEV < 0
Bad
Surge margin
qr
Compressor control
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Simplifying the surge parameter

by replacing hr with Rc
Reduced Head hr can be replaced by Rc while keeping the
coordinate system invariant to suction conditions
The surge parameter Ss now becomes
Ss =
f1(Rc)
2
qr,op
2
where the function f1( ) returns the value of qr,SLL

on the SLL for the input Rc
This eliminates the need for Td and Ts transmitters for control

Important Note: CCC still strongly recommends Td and Ts
transmitters as well as rotational speed N for compressor
monitoring purposes
Compressor control
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The simplest CCC surge parameter

An antisurge algorithm can be designed around two transmitters:
Dpo and Dpc
The parameter Ss =
f1(Rc)
2
qr
is invariant to inlet conditions and speed
For two transmitters choose the function f1 to be (Rc - 1)

f1(Rc)
Ss =
qr
Rc - 1
= Dp
o
ps
(
=
pd
-1
ps
Dpo
ps
pd - ps
=
Dpo
Dpc
Dpo
Selecting the specific function for f1(Rc) to be (Rc - 1) keeps the

map invariant to inlet conditions and speed
Compressor control
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Disadvantage of the Dpc /Dpo surge parameter

The SLL is rarely a straight line in the coordinates qr2 and Rc
The parameter Dpc /Dpo represents a straight line in the invariant
coordinates qr2 and Rc
The Dpc /Dpo approach results in loss of turn down and
unnecessary recycle
Rc
loss of operating envelope
Actual Surge Limit Line (SLL)
SLL calculated by antisurge

controller using
Dpc /Dpo = constant
2
qr
Compressor control
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Actual field data showing disadvantage of

Dpc /Dpo surge parameter
Compressor control
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Surge parameter for compressor with sidestream

Problem definition
1
Dpo,1
P1
T1
3
Dpo,2
P2
T2
q3 and T3 are internal to the compressor and cannot be measured

Compressor control
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Derive a new surge parameter for compressor with

sidestream: qrNe
Any combination of invariant parameters results in another

invariant parameter
Derive equation for surge parameter that does not require

measurement of T and qr at point 3
Step 1:
Reduced flow
Step 2:
Equivalent speed
.
m
ZRT
qr
p
N
Ne
ZRT
.
Step 3:
Combine qr and Ne
where:
.
Ne
qr
= mass flow
= Compressibility
= Gas constant
= Equivalent speed
= Reduced flow
= Rotational speed
= Pressure
= Temperature
qrNe m ZRT .
p
Compressor control
mN
N
=
ZRT
p
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Calculating the invariant parameter qrNe
1
Dpo,1
p1
.
T1 m1
q3 Ne,3
3
Dpo,2
p2
.
m2 T2
p
p
1
2
N
A1 Dpo,1
.
.
.
A
D
p
2
o,2
.
T1
m3 . N
T2 (m1 + m2 ) N
=
=
p2
p2
p3
Compressor control
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Developing invariant surge patameter

Rc vs. qrNe
Compressor control
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The approach to surge is fast

Pd
1 SEC.
100%
Qs
Pd
100%
Typically, performance curves are

extremely flat near surge
Even small changes in compressor

pressure differential cause large
flow changes.
The speed of approaching surge is

high. In only 0.4 seconds, DPO
dropped by 14%, with a 2% change
in DPc
ABC
D
DPo
0
100%
AB C
DPc
Compressor control
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The approach to surge is fast - another example
100%
DPo
0
1 sec.
100%
DPc
0
For a 2% increase in pressure differential

(DPc), flow rate DPo dropped 9% in 0.3 sec.
Compressor control
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Basic antisurge control system
The antisurge controller UIC-1 protects the compressor against surge by

opening the recycle valve
Opening of the recycle valve lowers the resistance felt by the compressor
This takes the compressor away from surge

Rprocess
Rc
Rprocess+valve
VSDS
Compressor
FT
1
PsT
1
PdT
1
qr
Discharge
Suction
UIC
1
Surge parameter based on invariant

coordinates Rc and qr
Flow measured in suction (DPo)
Ps and Pd transmitters used to
calculate Rc
Compressor control
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Antisurge controller operation

Protection #1: The Surge Control Line (SCL)
Rc
SLL = Surge Limit Line

SCL = Surge Control Line
When the operating point

crosses the SCL, PI control
will open the recycle valve
PI control will give adequate

protection for small
disturbances
PI control will give stable

control during steady state
recycle operation
Slow disturbance example
B
A
qr
Compressor control
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Adaptive Gain
Enhancing the effectiveness of the PI controller
Rc
When the operating point

moves fast towards the SCL,
adaptive gain moves the SCL
towards the operating point.
This allows the PI controller

to react earlier
As a result a smaller steady

state surge control margin
can be achieved without
sacrificing reliability
Fast disturbance example
B
A
qr
Compressor control
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Protection #2: The Recycle Trip Line (RTL)
Rc
RTL = Recycle Trip Line

Total response
Disturbance
When
Operating
the
OP hits
operating
point
arrives
SCL
of
keeps
Moves
controller
the
the
point
PI
moving
back
Operating
controller
hits
is
tothe
the
the
Pointside
opens
towards
Recycle
safe
sum
of(OP)
valve
the
Trip
surge
ofmoves
PIthe
based
Line
control
and
RTL
(RTL)
towards
on
hits
and
proportional
Recycle
the
Recycle
the SCL
and
conclusion
Trip
integral
LineRT(RTL)
action
is:
actiondecays out the
The
function
step
response
We are
close to surge
PI
controller
integrates
to stabilize
The
PI controller
is too slow
to
Benefits:
OP
on
SCL
catch the disturbance
Get
Energy
due to smaller
out savings
of the dangerous
zone
surge margin
An open loop response is
Compressor has more turndown
triggered
before recycle or blow-off
Surge can be prevented for
virtually any disturbance
Output
to Valve
qr
Recycle Trip
Action
PI Control
Total Response
PI Control Response
Recycle Trip Response

To antisurge
valve
Time
Compressor control
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Improving the accuracy of Recycle Trip

open loop control
Recycle Trip is the most powerful method known for antisurge

protection
But, open loop control lacks the accuracy needed to precisely

position the antisurge valve
Open loop corrections of a fixed magnitude (C1) are often either too
big or too small for a specific disturbance
The rate of change (derivative) of the compressor operating point

has been proven to be an excellent predictor of the strength of the
disturbance and the magnitude required from the Recycle Trip
response
Therefore, the magnitude of actual step (C) of the Recycle Trip

response is a function of the rate of change of the operating point
or d(Ss)/dt
Compressor control
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Recycle Trip based on derivative of Ss

Recycle Trip
Response calculation
C = C1Td
where:
C
C1
Td
d(Ss)/dt
Output
to valve
Benefits
Maximum protection
No surge
No compressor damage
d(Ss)
dt
Minimum process disturbance

No process trips
= Actual step to the valve

= Constant - also defines maximum step
= Scaling constant
= Rate of change of the operating point
Medium disturbance
Output
to valve
Large disturbance
100%
Total
PI Control
Total
PI Control
Recycle Trip
Recycle Trip
0%
Time
Time
Compressor control
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What if one Recycle Trip step response is not enough?
After time delay C2 controller checks if Operating Point is back to

safe side of Recycle Trip Line (RTL)
If Yes:
Exponential decay of Recycle Trip response
If No:
Another step is added to the Recycle Trip response
Output
to valve
Output
to valve
One step response
Multiple step response
100%
Total
PI Control
Total
PI Control
Recycle Trip
0%
Time
C2
Recycle Trip
Time
C2 C2 C2
Compressor control
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Protection #3: The Safety On Line (SOL)
Rc
SOL = Safety On Line

RTL = Recycle Trip Line
Recycle
will
Additional
PI
The
If Operating
control
Safetyand
safety
On
Point
response
or
crosses
surge
Trip
shifts
margin
the
Safety
theis
SCL
added
stabilize
RTL
to the
onright
the
new
SCL
On and
Linethe
themachine
compressor
is in
surge
Compressor can surge due to:

Transmitter calibration shift
Sticky antisurge valve or actuator
Partially blocked antisurge valve or
recycle line
Unusual large process upset
New SCL
New RTL
Additional surge margin
2
qr
Benefits of Safety On response:

Continuous surging is avoided
Operators are alarmed about surge
Compressor control
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Built in surge detector
Pressure and Flow Variations

During a Typical Surge Cycle
100%
Surge signature is recorded during

commissioning
Rates of change for flow and pressure
during surge are determined
Thresholds are configured slightly more
conservative than the actual rates of
change during surge
Pd
0%
1 TO 2 SECONDS
100%
DPo
0%
20 to 50
milli-seconds
Surge is detected when the actual rates of

change exceed the configured thresholds
The following methods can be used:
Rapid drops in flow and pressure
Rapid drop in flow or pressure
Rapid drop in flow only
Rapid drop in pressure only
When surge is detected a Safety On
response is triggered
A digital output can be triggered upon a
configurable number of surge cycles
Compressor control
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Increase compressor system reliability and

availability with fall-back strategies
Over 75% of the problems are in the field and not in the controller
The CCC control system has fall-back strategies to handle these field
problems
The controller continuously monitors the validity of its inputs
If an input problem is detected the controller ignores this input and

automatically switches to a fall-back mode
Benefits
Avoids nuisance trips
Alarms operator of latent failures
Increases machine and process availability
Compressor control
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Fall-back strategies for the antisurge and

performance controller
Antisurge controller
If a pressure transmitter fails, a minimum q2r algorithm is used
If a temperature transmitter fails, hr is characterized as a function
of compression ratio
If the speed transmitter fails, a conservative speed setting is used
If the flow transmitter fails
Redundant transmitter is used
Output is driven to:
Last value OR
Last Value selected: If Last Value >Pre-selected fixed value OR
Pre-selected fixed value selected: If Pre-selected fixed value>Last
Value
Performance controller
Switches to redundant transmitter upon primary transmitter
failure
Output goes to pre-selected value if all transmitters fail or is
frozen
All transmitter failures are alarmed
Compressor control
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Output linearization
Controller
Dynamic
Existing
Linear
For antisurge
valve
valve
flow
output
gives
control
response
hasisthe
equal
quick
characterized
asame
linear
becomes
percentage
opening
valveas
as
linear
trim
dynamic
is preferred
mirror
mirror
image
flow
image
in
response
the
in the
linear
linear
over
valve
valve
its line
line
complete stroke
Flow rate
through
valve
Controller output
Valve trim
quick opening
Valve trim
Controller
output
equal percentage
Controller
output
Notes
Used to improve controllers operation when non-linear valves are
used
Used on retrofits to avoid additional investment in new valve
Works well with equal percentage characteristics
Works less satisfactory with quick opening characteristics
Compressor control
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The Tight Shut-off Line (TSL)

Dynamic control range
Flow rate
through
valve
Controller
output
PI Control
Controller
output
Low clamp on controller output
0% to the valve
Rc
SOL SLL RTL
SCL
TSL = Tight Shut-off Line
B
A
Time
At
CCC
The
For
When
Many
the
dynamic
5%
controller
antisurge
antisurge
the
low
oroperating
controller
low
clamp
control
is
clamp
controller
valves
now
value
point
crosses
we
value
ready
have
the
want
has
isvalve
represents
to
the
the
to
to
a the
Tight
go
use
TSL
Shut-off
the
right
following
when
closed
range
output
of
the
the
Line
operating
characteristic:
5%
of
position
TSL
the
-(TSL)
100%
the
controller
for
controller
points
that
on
control
the
eliminates
hits
jumps
valve
closes
theto
Usually
still
leaks
which
results
the
purposes
SCL
disadvantages
valve
low
- energy
point
clamp
at C
0%
value
- point
- point
A value
B the
in
from
0%
towaste
low
clamp
This
flow
is below
rate
the low the
clamp
valve
value
is
Makes
anthrough
annoying
noise
Benefits
(almost) zero and does not
Typical
for worn
valveswhen
and valves
No leakage
and noise
controller
change
with
Teflon
seat
is far
away
from
point
A
Once
the
lowsurge
clamp- is
reached
Eliminates
noise and energy
the characteristic
is linearwaste
Eliminates
time in
the response
Typical dead
low clamp
value
can be
of the
valve
when
thethe
5%antisurge
- we will use
the
5% as
operating
point is close
to the
SCL
value throughout
in this
example
qr
Compressor control
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Compressor performance control
Also called:
Throughput control
Capacity control
Process control
Matches the compressor throughput to the load
Can be based on controlling:

Discharge pressure
Suction pressure
Net flow to the user
Compressor control
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Performance control by blow-off or recycle

Pd
Rprocess
Process
Rprocess + Rvalve
PIC - SP
PT
1
Curve 1
PIC
1
Curve 2
Shaft
power
P1
P2
Notes
2
Q
Compressor
Pressure
Point
Required
Power
represents
B2
loss
represents
is
power
is
controlled
operates
P1 energy
in
-P
point
the
by
point
waste
A
B
point
blow-off
is that
P1A
loss
2 in
2
Most
inefficient
control
method
qr
Curve
represents:
would deliver the pressure for Rprocess
Qloss
Regularly
foundon
in plant
air speed
systems
Lower speed
variable
systems
Rare
in other systems
Curve 1
IGVs
closed on variable geometry
Not
recommended
compressors
Curve 2
Inlet throttle valve closed on fixed
speed compressors
2
qr
Compressor control
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Performance control by discharge throttling

Pd
A
Pressure loss
across valve
Rprocess + Rvalve
Rprocess
Process
PIC - SP
PT
1
Curve 1
Curve 2
PIC
1
Shaft
power
qr
P1
P2
Curve 1
Curve 2
Notes
Power
Compressor
Required
Pressure
Opening
Lower
resistance
loss
of
is
power
is
valve
controlled
operates
P1 is
-would
would
PP21 in
byreduce
require
point A
Curve
2 represents:
pressure
resistance
less
speed
drop
to
and
Rover
power
valve
process
Lower speed on variable speed
Notes
systems
Extremely inefficient (consumes
IGVs closed on variable geometry
approx. the same power for every load)
compressors
Rarely used
Inlet throttle valve closed on fixed
Not recommended
speed compressors
qr
Compressor control
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Performance control by suction throttling

Pd
Rprocess
Process
A
PIC - SP
PT
1
Suction valve open

Suction valve throttled
PIC
1
Shaft
power
qr
P1
qr
Required
Inlet
Changing
Pressure
Compressor
valveis
power
suction
manipulates
controlled
operates
is pressure
P1 in
by
suction
point
inlet A
pressure
generates
valve
for
given
position
Raprocess
family of curves
Notes
Common on electric motor machines
Much more efficient than discharge
throttling
Power consumed changes proportional
to the load
Throttle losses are across suction valve
Compressor control
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Performance control by adjustable guide vanes

Pd
Rprocess
Process
A
PIC - SP
amin
aOP
PT
1
amax
PIC
1
Required
Different
Pressure
Compressor
geometry
is
power
controlled
operates
is
Pmeans
by
point
inletaA
Change of
guide
vanes
angle
1 in
different
guide
for
given
vane
Rdifferent
positioncompressor
curve
results
inperformance
process
Notes geometry
Improved turndown
More efficient than suction throttling
Power consumed is proportional to the
load
Power loss on inlet throttling is
eliminated
Shaft
power
qr
P1
qr
Compressor control
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Performance control by speed variation

SIC
1
Pd
Rprocess
Process
A
PIC - SP
PT
1
Nmax
NOP
PIC
1
Nmin
Shaft
power
qr
P1
qr
Required is
Changing
Pressure
Compressor
power
speed
controlled
operates
is
generates
P1 in
bypoint
speed
a A of
family
rotation
for
given
of curves
Rprocess
Notes
Most efficient (Power f(N)3)
Steam turbine, gas turbine or variable
speed electric motor
Typically capital investment higher than
with other systems
No throttle losses
Compressor control
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Limiting control to keep the machine in its stable

operating zone
While controlling one primary variable, constrain the

performance control on another variable
CONTROL
BUT DO NOT EXCEED
Discharge Pressure
Max. Motor Current
Suction Pressure
Max. Discharge Pressure
Net Flow
Min. Suction Pressure
Suction Pressure
Max. Discharge Temperature
Exceeding limits will lead to machine or process damage

Performance controller controls one variable and can limit
two other variables.
Compressor control
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Power limiting in the performance controller

an example
Rc
Power limit
R1
R2
R3
PIC-SP
However
Primary
Limiting
Compressor
Machine
Process
PIC
will speed
would
variable
variable
resistance
hits
power
like
operates
power
machine
tolimiting
PPower
speed
changes
limit
inup
loop
point
to
d decreases
A
from
N
further
machine
takes
in R
order
control
to
atup
RR
Nto
to
and
control
N4 and
controls
pressure
operate
Compressor
operates
in point
2for
11to
32
1
P
in
machine
point
atNspeed
N3
Bdfor
R2 D
at
2
Compressor will operate in
point C for R3 at N3
N4
N
N2 3
N1
Benefits
Maximum protection
No machinery damage
Qs,
vol
Maximize production
Machine can be pushed to the
limits without risk of damage
Note: Same approach for other variables (pressures, temperatures, etc.)

Compressor control
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Limiting Ps or Pd using the antisurge controller

VSDS
Compressor
FT
1
Suction
PsT
1
PdT
1
UIC
1
Discharge
The antisurge controller can be configured to limit:

Maximum discharge pressure (Pd)
Minimum suction pressure (Ps)
Both maximum Pd and minimum Ps
This does NOT conflict with antisurge protection
Compressor control
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Interacting antisurge and performance loops
Interaction starts at B
Performance controller on
discharge pressure reduces
performance to bring
pressure back to setpoint
Unless prevented, PIC can

drive compressor to surge
Antisurge controller starts to

operate at B
Even if surge is avoided,

interaction degrades pressure
control accuracy
Results of interaction
Rc
B
C
DPo
Ps
PIC-SP
Large pressure deviations

during disturbances
Increased risk of surge
Compressor control
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The performance controller interacts with

the antisurge controller
Both controllers manipulate the same variable - the

operating point of the compressor
The controllers have different and sometimes

conflicting objectives
The control action of each controller affects the other
This interaction starts at the surge control line - near

surge - and can cause surge
Compressor control
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Ways to cope with antisurge and

performance loop interactions
De-tune the loops to minimize interaction. Result is

poor pressure control, large surge control margins and
poor surge protection
Put one loop on manual so interaction is not possible.

Operators will usually put the Antisurge Controller on
manual. Result - no surge protection and often partially
open antisurge valve
Decouple the interactions. Result - good performance

control accuracy, good surge protection and no energy
wasted on recycle or blow off
Compressor control
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Interacting antisurge control loops

VSDS
Section 1
Section 2
UIC
1
UIC
2
PIC
Disturbance
Rc,1
R
R
Rc,2
qr,1
qr,2
The
system
is oscillating
of controller
recycle
on
section
Antisurgeofcontroller
Opening
recycle
valve
UIC-1
on
will
section
open
2 Opening
Disturbance
Antisurge
comesvalve
from
UIC-2
the
will
open1
caused
Pd,1side
= Ps,2 lead
to decrease
caused
the
recycle
Ps,2 valve
= Pd,1to
to
protect
increase
section
1 controller
discharge
the
recycle
valve
protect
Slowing
down
the
tuning
would
to: section 2
Pd,2 increases
Increased risk of surge
against
against
surge
Result:
Result: surge
Compressor damage
P
decreases

Pd,1
d,1 increases
Process trips
P
increases

Ps,1
s,1 remains constant
Bigger surge margins
R
decreases
Rc,1
c,1 increases
surge
Energy
Section
from
surge waste
Section 1
1 moves
moves away
towards
remains
constant
Ps,2s,2
decreases
PP
d,2decreases
increases
c,2remains
Pd,2
increases
PR
constant
s,2
Section
2
moves
towards surge
R
decreases
Rc,2c,2increases
Section22moves
movestowards
away from
surge
Section
surge
Compressor control
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Loop decoupling between multiple antisurge controllers

VSDS
Section 1
UIC
1
Section 2
Serial
network
UIC
2
Serial
network
All CCC controllers are connected on a serial network
This allows them to coordinate their control actions
When UIC-2 opens the recycle valve:
Section 2 will be protected against surge
Section 1 will be driven towards surge
PIC
How much section 1 is driven towards surge depends on how much the
recycle valve on section 2 is opened
The output of UIC-2 is send to UIC-1 to inform UIC-1 about the

disturbance that is arriving
UIC-1 anticipates the disturbance by immediately opening its valve
Note: The same applies when the antisurge

valve on section 1 is opened first
Compressor control
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Loop decoupling simplified block diagram

Benefits
VSDS
Section 1
Section 2
Serial
network
UIC
1
Analog Inputs
UIC
2
Each
controller
itshas
PI
and
its
own
Recycle
values
gain
to
M
toPI
Antisurge
UIC-2
UIC-1
Loop
decoupling
reports
is protecting
controller
PI
and
block
value
values
section
UIC-2
Recycle
is
multiplies
ofadded
opens
other
1decoupling
against
TripTrip
to
controllers
its
reported
output
output
valve
surge
to
to
PI
using
UIC-1
protect
and
nUIC-2
Avoids
control
system
oscillations
allow
for
tuning
relative
loop
between
section
and
Recycle
antisurge
(performance
Recycle
2Trip
against
valve
Trip
and
values
1ofsurge
antisurge)
with
aregains
added
gain
to output
M2
to
Same
decoupling
takes
place
Allows
faster
tuning
ofdecoupling
control
system
different controllers
antisurge
valve 1
Reduced risk of surge
Allows closer operation to surge limits
without taking risk
From other
controllers
FA
Mode
FA
Mode
DEV1
PI
From other
controllers
Analog Inputs
RT
PIn . Mn
+
RTn . Mn
+
Antisurge
Controller 1
To antisurge valve 1
PI2 . M2
+
RT2 . M2
DEV2
PI
RT
+
Loop
Decoupling
PI1 . M1
+
RT1 . M1
PIn . Mn
+
RTn . Mn
+
Loop
Decoupling
Antisurge
Controller 2
To antisurge valve 2
Compressor control
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Compressor networks
Compressors are often operated in parallel and, less

frequently, in series
The purposes of networks include:

Redundancy
Flexibility
Incremental capacity additions
Usually, each compressor is controlled, but the network is

ignored
Compressor manufacturers often focus on individual

machines
Control of the network is essential to achieve good surge

protection and good performance control of the network
Compressor control
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Control system objectives

for compressors in parallel
Maintain the primary performance variable (pressure or flow)
Optimally divide the load between the compressors in the

network, while:
Minimizing risk of surge
Minimizing energy consumption
Minimizing disturbance of starting and stopping individual
compressors
Compressor control
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Process Flow Diagram for base load control

VSDS
Compressor 1
Swing machine
UIC
1
PIC
1
Suction
header
HIC
1
Process
VSDS
Compressor 2
UIC
2
Base machine
Notes
All controllers act independently
Transmitters are not shown
Compressor control
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Parallel compressor control by base loading

Rc,1
Compressor 1
Rc,2
Compressor 2
Swing machine
Base machine
PIC-SP
QP,1 + QP,2 = QP,1 + QP,2

2
qr,1
qr,2
QP,1 QC,1 QP,1
QP,2 QC,2= QP,2
Notes
Load
Machines
Base
Swing
load
machine
could
machine
operate
one
be is
or
re-divided
can
fully
more
atbe
same
loaded
running
compressors
toReliminate
since
with
runs
suction
recycle
and
recycle
without
letand
therecycle
discharge
other(s) absorb
of both
the
c and
Base loading is inefficient
machines
load
swings
are tied together
Base loading increases the risk of surge since
compressor #1 will take the worst of any disturbance
where:
QP
= Flow to process
Base loading requires frequent operator intervention
QC
= Total compressor flow
Base loading is NOT recommended
Q -Q
= Recycle flow
C
Compressor control
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Process Flow Diagram for equal flow division

VSDS
RSP
Compressor 1
out
UIC
1
FIC
1
RSP
out
PIC
1
Suction
header
Process
VSDS
RSP
Compressor 2
out
UIC
2
FIC
2
Notes
Performance controllers act
independent of antisurge control
Higher capital cost due to extra
Flow Measurement Devices (FMD)
Higher energy costs due to
permanent pressure loss across
FMDs
Compressor control
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Parallel compressor control by equal flow division

Rc,1
Compressor 1
Rc,2
Compressor 2
PIC-SP
QP,1 = QP,2
Equal flow
Equal flow
2
qr,1
QP,1
qr,2
QP,2QC,2
Notes
Machine
Equal
Machines
Bias
relay
flow
2are
operate
on
operates
division
remote
never
atmight
with
identical
same
setpoint
recycle
work
Rc except
since
would
ifin
while
both
suction
by
only
machines
machine
coincidence
work
andif1discharge
are
curves
still-identical
different
hashave
turn
of both
Requires
additional
capital
investment
FMDs
machines
down
resistance
same
steepness
are
duetied
to piping
together
arrangments
Requires additional energy due to permanent pressure
loss across FMDs
where:
Poor pressure control due to positive feedback in
QP
= Flow to process
QC
= Total compressor flow
control system (see next)
QC - QP = Recycle flow
Equal flow division is NOT recommended
Compressor control
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Dynamic control problem with pressure to flow

cascade system
Rc
R2
C
R1
B
D
PIC-SP
disturbance
isthe
amplified
Pressure
The
In
Process
As
Since
Only
aatypical
FIC
PIC
machine
result
as
the
the
provides
reacts
is
disturbance
controller
PIC
the
the
master-slave
PIC
is
is
master
fast
machine
operating
starts
slow
and
(PIC)
causes
RSP
itand
todoes
will
moves
control
reduce
in
provides
for
the
try
point
the
not
the
FIC
to
toitsis
A
Remote
speed
the
scheme
resistance
point
move
maintain
output
slave
B
its
controller,
toSetPoint
the
output
its
control
toslave
SP
change
yet
suction
pressure
needs
(RSP)
which
from
for
to
throttle
is
R
the
be
Flow
the
toFICR
FICPositive
feedback
system
This
is the
intersection
of 4 1lines:2
controller
valve
approx.
SP comes
or 5guide
times
(FIC)
down
vanes
faster
and the
than
pressure
the
is
The
FIC will speed
the machine to
Resistance
line Rup
1
master
restored
point
C at speedcurve
N 3 N1
Performance
PIC-SP
FIC-SP = Output of PIC
N3
N1
N2
FIC-SP
PIC OUT
1
Master
RSP
FIC
1
OUT
Slave
RSP
SIC
1
qr
Notes
Requires additional capital
investment in FMDs
Requires additional energy due to
permanent pressure loss across
FMDs
Poor pressure control due to positive
feedback in control system
Equal flow division is NOT
recommended
Compressor control
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Process Flow Diagram for equidistant control for

parallel compressors
VSDS
RSP
Compressor 1
out
UIC
1
Serial
network
LSIC
Serial
network
MPIC
Suction
header
Process
VSDS
RSP
Compressor 2
out
UIC
2
Serial
network
LSIC
Notes
All controllers are coordinating
control responses via a serial
network
Minimizes recycle under all
operating conditions
Compressor control
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Parallel compressor control by equidistant operation

Rc,1
Compressor 1
Rc,2

.1
.2
Compressor 2
DEV = 0
.1
.2
.3
.3
PIC-SP
Dev2
Q1 Q2
N1 N2
2
Dev1
qr,1
qr,2
DEV1
DEV2
Notes
Since
The
Machines
DEV
DEV
isare
operate
is
a dimensionless
kept at
at same
the same
Rcnumber
all
since
relative
sorts
suction
representing
ofdistance
machines
and discharge
to the
can
the distance
be
Surge
mixed:
of Control
both
between
small,
Line
the
Maximum turndown (energy
savings) without recycle or blow-off
machines
operating
(SCL)
big,
axials,
point
are
centrifugals
tied
and
together
thewhen
Surge
Line
Recycle
will
only
start
allControl
machines
are on their SCL
Minimizes the risk of surge since all machines absorb part of the
Lines
This
The
DEV
means
of equal
willinbe
practice
DEV
the can
same
the
befor
plotted
same
all machines
DEV
on the
for both
performance
but machines
they willcurves
operateasatshown
disturbance
different
speeds and
flow rates
Automatically
adapts
to different size machines
CCC patented algorithm
Compressor control
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Compressors in parallel - the primary response
If DEV
Master
The
In
When
the
output
primary
the
<=
controller
0machine
of
apply
the
response
loadsharing
controls
master
is close
block
controller
the
to the
gain
main
the SCL
controller
PID
Process
the
goes
Variable
to
checks
master
the primary
controller
if(PV)
the machine
via
response
its
will
PID
no
iscontrol
block
close
longerin
toblock
reduce
the
the SCL:
Output goes to antisurge valve
loadsharing
performance
controller
to
control
the primary
variable
Yes: to
dont
reduce
capacity
- keepisoutput
In order
check
if the
machine
close
to
constant
the
the controller
primary response
needs
TheSCL
master
will startblock
to open
the
No:
reduce
capacity
as
necessary
the
DEV
recycle valve to control the primary variable
Apply loadsharing gain M0
The DEV is reported by the antisurge
The
output of the master controller goes via
controller
the primary response block directly to the
performance control element
Master Controller
PV
PID
SP
Analog Inputs
Dont change
output
FA
Mode
No
DEV <
>0
DEV
DEV
DEV
Yes
PI
Apply loadsharing
gain
Primary
response
RT
Primary
response
x
+
Antisurge
Controller
Primary response
To
Toantisurge
performance
valve
control element
Loop
Decoupling
Loop
Decoupling
To antisurge valve
Compressor control
Loadsharing
Controller
To performance
control element
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The load balancing response
This
In
Other
The
order
fast
antisurge
loadsharing
master
average
loadsharing
to
master
balance
controller
DEV
controller
controller
controller
is
controllers
the
sent
calculates
machines
reports
out
controls
reports
to
also
all
the
the
they
this
report
the
actual
need
The
load
balancing
block
is
a
slow
primary
to
DEV
their
average
loadsharing
bePV
to
DEV
kept
the
also
process
ofPV
at
all
load
controllers
the
to
to
reported
the
the
balancing
same
variable
master
master
DEV
DEV
toby
block
become
controller
controller
PVs
directly
in the SP
controller
that
will
equalize
all
DEVs
for all
manipulating
loadsharing
for
all load balancing
controller
the finalblocks
control elements
parallel compressors
This reported DEV becomes the Process
Its
output(PV)
is added
the balancing
total output
to
Variable
for thetoload
PID
the
loopperformance control element
DEV from other
loadsharing controllers
Master Controller
PV
PID
SP
Average
Analog Inputs
DEV
FA
Mode
DEV
DEV
DEV
PV
PI
Primary
response
RT
SP
Load
balancing
Primary
response
Antisurge
Controller
Loop
Decoupling
Loop
Decoupling
To antisurge valve
Compressor control
Loadsharing
Controller
To performance
control element
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The Pressure Override Control (POC) response

Benefits
The
When
There
Opening
As
soon
operating
CCC
primary
a
islarge
aas
of
master
high
the
PID
disturbance
point
antisurge
chance
operating
loop
controller
rides
will
to valve
point
stabilize
exceed
the
occurs
has
curve
is
drops
a Pressure
the
it
much
the
can
and
relief
under
the
DEV from other

Rc
PV
PID
PV
SP
PI
(One-Sided)
SP
Average
Analog Inputs
Relief valve
setting
POC-SP
DEV
Master Controller
operating
happen
pressure
valve
Override
faster
the
POC-SP
setting
than
that
Control
rises
point
aline
the
reduction
and
sharply
on
performance
the
(POC)
trip
the
antisurge
the
PIC-SP
in
mode
process
speed
control
that
line
valves
willstart
open
Fast
response
during
fast
upsets
element
the
to
close
antisurge
again
(e.g. valve
speed)
toisget
toothe
slow
disturbance
to keep the
Avoid process trips due to lack of
pressure
under
control
under
quickly
control
response in performance control elements
Allows closer operation to process limits
without taking risk
FA
Mode
DEV
DEV
DEV
PIC-SP
PV
PI
Primary
response
RT
SP
Load
balancing
Primary
response
Antisurge
Controller
Loop
Decoupling
Loop
Decoupling
Loadsharing
Controller
qr
To antisurge valve
Compressor control
To performance
control element
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Loadsharing for multi-section compressors

VSDS
RSP
Train A
Section 1
Section 2
out
UIC
1A
Serial
network
UIC
2A
Serial
network
LSIC
Serial
network
MPIC
Suction
Header
VSDS
Process
RSP
Train B
Section 1
Section 2
out
UIC
1B
Serial
network
UIC
1B
Serial
network
LSIC
How
Select
By
Share
selecting
tothe
per
operate
load
train
the--equidistant
--section
equal
in theDEVs
loadsharing
closest
from
forto
the
both
the
controller
Surge
trains
SCL Control
it--ison
--guaranteed
the
the
Line
section
section
(SCL)
that
closest
closest
when
the other
there
totothe
theis
more
section
SCL
than
on one
the same
section
train
perismachine
not in recycle
???
Compressor control
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Selecting the section closest to SCL for parallel operation

Master Controller
PV
PID
PV
SP
PI
Both
The selected
lowest
antisurge
DEV
DEV
controllers
is is
selected:
report
the section
reported
their
to:closest
DEV to the
to the
loadsharing
SCL
Primarycontroller
control
response blocks
(One-Sided)
SP
DEV from other
Load balancing block
Master controller
averaging block
Average
Analog Inputs
FA
Mode
FA
Mode
DEV1
DEV1
PI
PV
RT
Primary
response
To antisurge valve-1
DEV2
DEV2
SP
Load
balancing
Primary
response
+
Antisurge
Controller
<
PI
+
Loop
Decoupling
Loop
Decoupling
Primary
response
RT
+
Loadsharing
Controller
To performance
control element
Compressor control
Antisurge
Controller
Loop
Decoupling
To antisurge valve-2
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Flow Measuring Device (FMD) selection criteria
Main selection criteria for FMD in antisurge control system:

Repeatability
Sufficient signal-to-noise ratio
Accuracy of the FMD is not critical
FMD delays must be absolutely minimal
Present state-of-the-art limits the choice of FMD to head flow meters

or to other devices that are based on the principle of velocity
measurement:
Orifice plates
Venturis
Pitot tubes
etc.
Recommended flow range for FMD and transmitter is maximum

compressor flow
Recommended Dp corresponding to Qmax, compressor is 10 WC (250

mmH2O) or more
Compressor control
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Flow Measuring Device (FMD) location

VSDS
Compressor
minimum possible
minimum possible
Suction
The preferred location of the FMD:

Suction of compressor
As close to the inlet flange as
possible
Discharge
Less preferable location of the FMD:

Discharge of compressor
As close to the discharge flange as
possible
Selection of the location should be based on:

Necessity of surge detection
Often more difficult with flow measured in discharge
Capital cost of flow measuring device
Operating cost of the FMD (permanent pressure loss)
Compressor control
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Response time of the FMD transmitter
The speed of approaching surge is high
The transmitter type and brand should be

selected based on two major factors:
Reliability
Speed of response
Desired rise time for Dp (flow) transmitters

is 200 ms or less
Pressure step is 100%
The first order response (63%) is less
than 200 ms
1 SEC.
100%
Ps
100%
ABC
D
Desired rise time for pressure transmitters

is 500 ms or less
DPo
Actual
pressure
Transmitter
output
63% response
100%
AB C
1- (1/e)
DPc
In only 400 ms, DPO dropped by 14%,

with a 2% change in DPc
Time
t1 is less than 200 ms

Compressor control
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The effect of damping the Dpo (flow) transmitter
Knowing the flow is essential to determine the distance between the

operating point and the SCL
Damping the Dpo (flow) transmitter destroys essential information

Start of Surge
Flow 50
t = 16.0 s
t = 1.70 s
t = 0.03 s
t = 0.20 s
Actual Flow
-50
1.25
2.50
3.75
Time (seconds)
Damping the Dpo (flow) transmitter can paralyze the

complete antisurge control system!!!
Compressor control
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Sizing the antisurge control valve
Criteria for antisurge valve sizing based on CCCs experience

Provide adequate antisurge protection for worst possible disturbances
Provide adequate antisurge protection in all operating regimes
Sized to provide flow peaks greater than what is required in steady state to
operate on the Surge Control Line
Sized to avoid choke zone
Not be oversized from controllability point of view
Rc
Take point A at the intersection of the

maximum speed performance curve and
the Surge Limit Line (SLL)
Calculate Cv,calc (or equivalent) for point A
Select standard valve size using the

following criteria:
1.8 . Cv, calc < Cv,selected < 2.2 . Cv, calc
Qvol
Compressor control
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Sizing the antisurge control valve - alternative method
Rc
A
Qvol
An alternative method yielding

excellent results is:
Take design point of the compressor

point A
Draw a horizontal line through the design

point
Take point B at intersection of maximum

speed performance curve and the
horizontal line
Calculate Cv,calc in point B
Select standard valve size using the

following criteria:
0.9 . Cv, calc < Cv,selected < 1.1 . Cv, calc
Compressor control
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Stroke speed and characteristic of the antisurge valve

Antisurge valve stroke speed
Antisurge valve must have speed of response adequate for antisurge

protection for all disturbances
Recommended full stroke times:

Size
Close to open
1 to 4
1 second
6 to 12
2 seconds
16 and up
3 seconds
Open to close
< 3 seconds
< 5 seconds
< 10 seconds
Closing time needs to be the same order of magnitude to assure the same
loop gain in both directions
Antisurge valve characteristic
Normally control valves are selected to be open 80% to 90% for design
conditions
Antisurge valves can operate anywhere between 0% and 100%
In order to have an equal loop-gain over the whole operating range a linear
valve is required
This will allow for the fastest tuning leading to smaller surge margins
Compressor control
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Improving the performance of the antisurge valve
Most normal control valves can be made to perform as required for

antisurge control
The following steps help improve the performance of the valve
Install positioner
Minimize tubing length between I/P and valve positioner
Install volume booster
Minimize volume and resistance between volume booster and actuator
Increase air supply line to 3/4 or more
Increase size of air connection into the actuator
Drill additional holes in actuator - avoids pulling a vacuum
Compressor control
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Piping lay-out consideration when designing an

antisurge control system
Piping lay-out influences the controllability of the the total system
The primary objective of the antisurge controller is to protect the

compressor against surge
This is achieved by lowering the resistance the compressor is feeling
The resistance is lowered by opening the antisurge valve
Dead-time and time-lag in the system needs to be minimized
This is achieved by minimizing the volume between three flanges

Discharge flange of the compressor
Recycle valve flange
Check valve flange
VSDS
Compressor 1
volume to be
minimized
Compressor control
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Using a single antisurge valve increases recycle lag time

Large volume
Section 1
Section 2
In order to protect section 1 the antisurge valve needs to be opened

The volume between compressor discharge, check valve and
antisurge valve determines the dead time and lag time in the system
Large volume significantly decreases the effectiveness of the
antisurge protection
Result
Note
Poor surge protection

Large surge margins
Energy waste
Process trips because of surge
This specific piping layout is found on

many wet gas compressors in FCCUs
Compressor control
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Sharing recycle coolers degrades surge protection
Section 1
Section 2
Small volume
The piping lay-out for section 2 is excellent for surge protection

Minimum volume between the three flanges
The piping lay-out for section 1 is not ideal

Large volume to be de-pressurized decreases ability of the control system to
protect the machine against surge
Result
Poor surge protection

Large surge margins
Energy waste
Process trips because of surge
Compressor control
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Installing recycle valve upstream from

cooler improves control response
Compressor 1
Increased
volume due
to cooler
Compressor 2
Minimum
volume
Compressor 1 has ideal piping lay-out for surge protection

Minimum volume between the three flanges
The piping lay-out for compressor 2 is commonly found in the industry

The cooler creates additional volume and decreases the effectiveness of the
antisurge control system
The piping lay-out for compressor 2 can be acceptable if the additional

volume does not create excessive dead time and lag in the system
Result
Increased surge margins

Energy waste
Compressor control
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Recycle lines configured for optimum surge protection
Section 1
Section 2
Section 3
Suction
Process
Minimum
volume
Compressor has ideal piping lay-out for surge protection

Minimum volume between the three flanges for all sections
Compressor control
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Which antisurge piping configuration do you choose???

Lay-out #1: Compressor with recycle lines optimally configured for antisurge control
Section 1
Section 2
Section 3
Suction
Process
Lay-out #2: Compressor with coolers upstream of recycle take-off

Section 1
Section 2
Section 3
Suction
Process
When selecting
lay-out
the most
residence
time
of
the
gas
in
the
surge
volume
Lay-out
These
two
#1
#2 piping
has
requires
minimum
lay-outs
one#2
cooler
volume
are
less
between
common
and thus
thefor
the
flanges
antisurge
capital
and
investment
is
control
the
bestislay-out
lower
should
be verified
to purposes
check acceptable time delays are not exceeded
for
antisurge
control
Lay-out #2 will require bigger surge control margins

Compressor control
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Influence of controller execution time
Analog controller
100%
SCL
SLL
Operating
point
0%
Time
100%
Controller
output
0%
Time
Leading engineering contractor

performed evaluation of execution
time influence on ability to protect
compressor from surge
Dynamic simulation of compressor
was built
Digital controllers are compared
against analog controller on
simulation
Analog controller has no execution
time and is immediate
Analog controller tuned for minimum
overshoot
Digital controllers get exact same
tuning parameters
Digital controllers get exact same
disturbance
Compressor control
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Analog vs digital controller at 2 executions per second

Analog controller
Digital controller
(2 executions per second)
100%
100%
SCL
SLL
Operating
point
0%
SCL
SLL
Operating
point
0%
Time
100%
Time
100%
Controller
output
0%
Time
Controller
output
0%
Tuning same as analog controller
Compressor surged
Large process upset would have resulted

Compressor control
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Analog controller
Digital controller
100%
100%
SCL
SLL
Operating
point
0%
SCL
SLL
Operating
point
0%
Time
100%
Time
100%
Controller
output
0%
Time
Controller
output
0%
Compressor surged
Large process upset would have resulted

Compressor control
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Analog controller
Digital controller
100%
100%
SCL
SLL
Operating
point
0%
SCL
SLL
Operating
point
0%
Time
100%
Time
100%
Controller
output
0%
Time
0%
Time
Controller
output
Compressor almost surged
Control system would have to be set up with bigger surge margins

Compressor control
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Analog vs CCC controller at 25 executions per second

Analog controller
CCC antisurge controller

100%
100%
SCL
SLL
Operating
point
0%
SCL
SLL
Operating
point
0%
Time
100%
Time
100%
Controller
output
0%
Time
0%
Time
Controller
output
Response of CCC controller nearly indentical to analog controller
Adding Recycle Trip to PI control will allow even smaller surge margins
Compressor control
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Dynamic simulation single compressor

VSDS
Compressor
Note: Speed transmitter for

indicating purposes only
ST
1
Load
FT
1
PsT
1
TsT
1
PdT
1
Td T
1
PIC
1
HIC
1
UIC
1
Suction
Process
Serial
network
Compressor is controlled on Pd by PIC-1

HIC-1 controls the process load and can be used to create process disturbances
Controllers communicate via serial communication to computer running the
simulation
MODBUS
Start simulation
Compressor control
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Dynamic simulation parallel compressors

VSDS
RSP
Compressor 1
out
UIC
1
Serial
network
LSIC
Serial
network
Load
MPIC
HIC
1
Process
VSDS
RSP
Compressor 2
out
UIC
2
MODBUS
Serial
network
Start simulation
LSIC
Compressor control
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Compressor

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Compressor control menu

Cost of operating turbo compressors

Repairs are expensive

Costs of repairs - materials and labor

Operating costs are large

Cost to operate one turbo compressor per year:

Plant air compressor

1,000 HP (746 kW)

Wet gas compressor

4,000 HP(2,984 kW)

Propylene refrigeration comp.

40,000 HP(29,480 kW)

Energy Saving Examples

Energy Savings Predictions

Energy savings examples

15,000 hp (11.2 MW)

1,500 hp (1.1 MW)

Energy Savings Predictions

Available energy savings can be predicted

Pay-back less than 10

Downtime costs can be enormous!

Commissioning costs are large

Includes lost sales plus fixed operating expenses.

Most turbo compressor control system design problems are

Delays due to turbomachinery control problems are not unusual.

Startups are faster with a properly designed turbomachinery

Costs in constant dollars

What can we control?

Costs in constant dollars

Source: Experiences in Analysis and Monitoring Compressor Performance

Widespread use, many applications

Gas is accelerated outwards by rotating impeller

Can be built for operation as low as 5 psi, or operation

Sizes range from 300 hp to 50,000 hp

Cross Section of Horizontal Split

Picture of Horizontal Split

Single Case Compressor

Picture of Gear and Impellers

Cross section of horizontal split

Impeller inlet labyrinth seals

Shaft and labyrinth seal

Compressor discharge nozzle

Compressor inlet nozzle

Picture of Horizontal Split

Picture of horizontal split

Cross Section of Horizontal Split

Cross section of barrel type compressor

Picture of Barrel Type

Picture of barrel type compressor

Cross Section of Barrel Type

Cross section of bull gear compressor

Inlet guide vanes

Picture of Gear and Impellers

Picture of Integrally Geared

Picture of bull gear compressor

Picture of Gear and Impellers

Cross Section of Integrally Geared

Picture of (bull) gear and impellers

Picture of Integrally Geared

Cross Section of Integrally Geared

Gas flows in direction of rotating shaft

Can be built for lower pressures only

High flow rate

Not as common as centrifugals