ANTI-SURGE CONTROL

SYSTEM
M.S.MANI , CES-INSTS.

CONTROL PHILOSOPHY
I n c a s e o f a P r o c e s s U n it s t h e
e m p h a s is is o n s a f e o p e r a t io n a n d
p r e c is e c o n t r o l
In c a s e o f R o ta ry M /C s th e
e m p h a s is is o n s a f e o p e r a tio n a n d
m o n it o r in g .
2

Measurements :
Health of a Rotary machine is best monitored
by measuring and monitoring the following
machine parameters :

Vibration levels of casing and / or shaft

Shaft RPM
Relative location of the shaft with respect to a
predetermined mark ( e.g.-Key phasor )
Axial shift of shaft
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Measurements

( CONTINUED):

Temperature of thrust bearing pads

Temperature of bearing housing
Temperature of lube oil return line
Oil/gas flow/pressure to seals

Major control system

Auto start of stand by lube oil pump.

Lube Oil / Seal Oil back up system
Sequential start / stop (speed ramping of
turbines) to avoid human error
Capacity control
Surge control system

CONTROL SYSTEMS BLOCK DIAGRAM :

UCP
MCMS
B -N 3 3 0 0 /3 5 0 0
S E R IE S

ALLEN BRADLEY
P L C -5 /4 0

DCS
C C C /T U R B O L O G

FOXBORO
I/A S E R IE S

W OOD W ARD
505

BY
E L E C T R IC A L

(A S A P P L IC A B L E )

ESD

MCC

PROTECH
203

T R IC O N E X
TM R

LO CAL
IN D IC A T O R
(M T L M A K E )

LO CAL CO NTRO L
PANEL
(IN F IE L D )

What is Surge ?
SURGING IS AN UNSTABLE
OPERATING CONDITION THAT
CAUSES ERATIC COMPRESSOR
PERFORMANCE

WHERE AND WHEN SURGE

EVERY AXIAL AND CENTRIFUGAL
OCCURS
?
COMPRESSOR WILL EXPERIENCE A
DAMAGING PHENOMENON KNOWN
AS SURGE WHEN THE FLOW
THROUGH THE COMPRESSOR
DROPS BELOW A CERTAIN LEVEL

Why surge Occurs ?

Surge can be induced by
low suction pressure, high
discharge pressure and
reduction of speed of the
compressor

How Compressor is affected due

to Surging ?
Compressor damage results from
repetitive or frequent surging
During Surge momentary flow reversal
takesplace, this leads to a very rapid
pulsating flow backward and forward
through the internals of compressor,
resulting in SEVERE VIBRATION and
consequent damage

10

What happens during Surge ?

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
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Some surge consequences

Unstable flow and pressure resulting in process

upset

Damage in sequence with severity to

seals,bearings,impellers, shaft

Increased seal clearances and leakage

Lower energy efficiency

Reduced compressor life

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Anti-Surge control system

To prevent Surge, Surge protection systems are

required
If adequate protection against Surge is not provided,
there is a risk of machine damage and downtime costs
Adequate protection is defined as protecting the
compressor but not at the cost of unnecessary upset to
the process
The job of the antisurge system is to detect the
potential upset and automatically compensate for it by
maintaining a flow through the compressor in excess
of the surge condition

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Anti-surge Control system-(contd)

The

chief drawback of this approach is

the efficiency penalty
The energy that was used to compress the
recycled will go to waste
So, the control system should be tailored
to open the surge control valve only when
and as far as necessary to stop surge
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ASPECTS OF SURGE CONTROL

SYSTEM
Compressor Flow path has probability of
sudden flow reduction
Is the Compressor provided with Variable
Speed Drive?
Is the Compressor provided with IGV ?
Molecular Weight Changes
Manufacturers Surge curve and tested surge
Points
Safety Margin

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REQUIREMENTS FOR ANTI-SURGE CONTROL

API asks for 10% safety distance between Surge line and
control line, referred to surge flow
This corresponds to 4 to 8% referred to full range flow
This safety distance need to cover:
- Anti surge controller response time
- Limited stroke speed of Blow-off valve
- Transmitter accuracy and drift
- Measuring errors when the location of the surge line
is determined
- Compressor fouling and changes in gas composition
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SURGE DETCTION METHODS

DCS-Minimum Flow controller(On spill back)
Mechanical Minimum stopper on suction Valve
Operating Point proximity to Surge control
Line
Flow reversal detection - Diff. Pr and Diff
Temp.
Sudden Drop in Motor current

17

Compressor Performance Map

For any operating curve the point of
minimum flow and maximum pressure is
known as the Surge limit point. The locus
of all such points defines a curve known
as surge line

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Surge control Diagram:

The diagram below shows the performance map of a compressor with the
surge control lines .
SKETCH - 3

3
Pd
-----Ps
4
3

FLOW

1. SURGE LIMIT LINE

3.PERFORMANCE CURVES

2.SURGE CONTROL LINE

4.OPERATING POINT

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Effect of Gas composition on Surge

2
1.8
1.6
1.4

M7.8
M4.6
M2
new
M28

1.2
1
0.8
0.6
0.4
0.2
0
0

0.2

0.4

0.6

0.8

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Antisurge Control System

Anti surge system achieve this By manipulating the positions of Recycle
valve (Normally for Hazardous Gas) By using a Blow off valve (Normally for
Air or Non hazardous applications) in order to maintain the volumetric flow
rate above a safe, minimum level.

Compressor

Antisurge Valve

FT

PT

TT

TT

PT

FT

FY
ANTI SURGE
CONTROLLER

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Surge Control Techniques :

Calculate and Monitor the "Operating
Point " of the Compressor.
Open the vent or Blow off valves in a
controlled way .
Open the recycle valve( Between the
discharge and suction of the compressor)
in a controlled way.
In variable speed machines , reduce the
speed.
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Surge Control Valve

SURGE CONTROL VALVE SIZING

Surge control valves should be sized for each
of the following
1. Surge control line at minimum speed and total recycle
2. Surge control line at maximum speed and total recycle
3. Surge control line at normal operating pressure
4. The design capacity of the machine
Normally point 1 is the governing case (i.e. lowest
flow and lowest delta P) and the valve usually pass flow
the machine design capacity

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Surge control Valve(contd..)

VALVE CHARACTERISTICS
The installed characteristics of the surge
control valve should be linear. This can be
accomplished by either a linear trim characteristic
control valve or line arising an equal percentage valve
in the controller
SPEED OF RESPONSE:
The Valve is designed to Open fully from full close
with in 2 seconds. This is accomplished by proper
punematic accessories with Valve Actuator

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CONTROL SYSTEMS INSTALLED AT JG

CCC - COMPRESSOR CONTROLS

CORPORATION - SERIES 3+, SERIES 4
GHH- BROSIG - TURBOLOG
HARTMANN- BRAUN - PROTRONIC

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SURGE PROTECTION/CAPACITY
CONTROL FOR CRITICAL
COMPRESSORS IN JAMNAGAR
HEAT PUMP COMPRESSOR
MIN FLOW CONTROLLER IN DCS WITH
OPERATOR ENTERED SET POINT
MANUAL SPEED CONTROL THROUGH
DCS
PLAT FORMER/ISOMAR GAS
COMPRESSORS
MIN MECHANICAL STOP IN SUCTION
VALVES
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TAIL GAS COMPRESSOR

DEDICATED CONTROL SYSTEM "TURBOLOG"
FROM GHH BASED ON COMPRESSOR
PERFORMANCE MAP
SURGE CONTROL BY RECYCLE VALVE
MIN OPENING BY OPERATOR
SUCTION PRESSURE CONTROL BY IGV
IMPLEMENTED IN GHH
TRIP ON SURGE

27

COKER GAS COMPRESSOR

DEDICATED MULTI VARIABLE CONTROL CCC SEREIS 3+ CONTROLLER
SURGE CONTROL BY RECYCLE VALVE
SEPARATELY FOR FIRST AND SECOND
STAGE
ASC HAS PRESSURE OVERRIDE
CONTROL(POC) FOR THE FIRST STAGE
DISCHARGE PRESSURE
AUTO CAPACITY CONTROL BY SPEED
VARIATION BASED ON SUCTION
PRESSURE/COLUMN OVERHEAD PR.
DECOUPLING BETWEEN PERFORMANCE
AND ANTI SURGE CONTROLLER

28

VGO HT COMPRESSOR
DEDICATED CONTROL SYSTEM
"TURBOLOG" FROM GHH BASED ON
COMPRESSOR PERFORMANCE MAP
SURGE CONTROL BY RECYCLE VALVE
TO HASNDLE DIFFERENT PROCESS
CONDITIONS (MOL WT CHANGE)
SELECTION SWITCH IS PROVIDED IN THE
UCP. MOL WT-2.0,4.3,7.2 28
VISUALIZATION IS PROVIDED IN THE
PIB.
MIN OPENING BY OPERATOR
CAPACITY CONTROL IS BY SPEED
CONTROL BY OPERATOR.
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PRT
DEDICATED CONTROL SYSTEM FROM CCC
SERIES 4 SYSTEM
CONTROL SYSTEM IS DUAL REDUNDANT AND FAULT TOLERANT
FALL BACK STRATEGY IS IMPLEMENTED
PRT CONTROLS ARE VERY COMPLEX DUE TO MULTIPLE
INTERACTING CONTROLS SUCH AS
EXPANDER CONTROL
DELTA P CONTROL RX/RG
STEAM TURBINE CONTROLS
BLOWER CAPACITY CONTROL
LOAD SHARING CONTROL
M/G CONTROL( LIMIT CONROL)
GHH TURBOLOG CONTROL SYSTEM FOR START UP AND MACHINE
PROTECTION
GHH SPECIAL SURGE DETECTOR BASED ON DP REVERSAL/ 'T'
REVERSAL( FAST T/C) ACROSS SUCTION AND DISCHARGE OF THE
BLOWER

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Turbine / Compressor Control System Concept

31

References
Shell Dep 16ES-600 - Compressor surge
control systems
Shell Dep 16GS-600 - Design requirements
for compressor surge control systems
CCC Publication for Accurately defining
surge control line
GHH-BORSIG - Turbolog operation manual

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THANK YOU

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