ABU QAIR PETROLEUM

compressor Anti Surge

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control
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What is Surge?
 Developing the Surge Cycle
• As pressure builds, resistance goes up,
operating point “draws” the perf curve
• Compressor reaches surge point A
Pd
• At this point the potential energy in the vessel
exceeds the capability of the compressor
• Because Pv > Pd(max) , the flow reverses
• Pressure drops and forward flow is Pv
reestablished

Pd
B A Pd = Compressor discharge pressure
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Pv = Vessel pressure

D
C
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• From A to B….20 - 50 ms…….. Drop into surge

• From C to D....20 - 120 ms…… Jump out of surge
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• A-B-C-D-A….0.3 - 3 seconds…… Surge cycle

Qs,
2010

vol
 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
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• Temperature rises
• “Whooshing” noise
• Trips may occur
• Conventional instruments and human
operators may fail to recognize surge
 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
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• Reduced compressor life

 Major Process Parameters
during Surge
FLOW

• Rapid flow oscillations

• Thrust reversals
• Potential damage
1 2 3
TIME (sec.)
PRESSURE
• Rapid pressure
oscillations with
process instability
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1 2 3
TIME (sec.)
TEMPERATURE
• Rising temperatures
inside compressor

1 2 3
TIME (sec.) Operators may fail to
recognize surge
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Surge
Calculating
Distance from
 Distance From Surge Calculation

SLL (Surge Limit Line)

The controller continuously
hr calculates:
Performance Curve
Operating The ratio of the slope of the
Point Surge Limit Line & the slope of
the Operating point line:

SlopeOPL
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Ss =
OPL (Operating SlopeSLL
Point Line)
The distance between the
operating point and the surge
2
limit:
qr
Variable Ss defines the relative slope d = 1 - Ss
of a line from the origin to the
operating point
 Controller Deviation

The controller
calculates deviation
from the SCL as:
hr DEV = d - b1
Where:
d = 1 – SS
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b1 = the relative distance

between the SLL &
the SCL

DEV represents the

distance between the
operating point and the
2
qr surge control line
 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
VSDS
Rprocess+valve
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Compressor

FT PsT PdT
1 1 1

Suction Discharge
UIC 2
1 qr
Surge parameter based on invariant
coordinates Rc and qr
– Flow measured in suction (DPo)
– Ps and Pd transmitters used to calculate Rc
 The Surge Control Line (SCL)
Rc SLL = Surge Limit Line
SCL = Surge Control Line

• When the operating

B
point crosses the SCL,
A PI control will open
the recycle valve
• PI control will give
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adequate protection
for small disturbances
2
qr

• PI control will give stable control during steady

state recycle operation
• Slow disturbance example
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Surge Event