Anti Surge

Nuovo Pignone
CLIENTE - CUSTOMER
QATAR FERTILISER COMPANY
LOCALITA' - PLANT LOCATION
FIRENZE
MESAIEED STATE OF QATAR
COMMESSA - JOB
IMPIANTO - PLAN
QAFCO 5 PROJECT
1102339 - 40
TITOLO - TITLE
QATAR FERTILISER COMPANY (S.A.Q.)
Job No.
Doc. ID code
Q5-PT-C900-01004
Q5-SH-T151.32000-022
Job No.
Doc. No.
317300
51-MA-E-32022
Plant
QAFCO 5 PROJECT
A company of Saipem
Category Code:
Acceptance Code:
Rev.
Status
Sh. 1 of 13
00
(Flow Element installed at compressor suction)
TAGGING RULE
Instrument to be wired (transmitter, limit switch, ecc)
st
351.5xxx07yyyZ (1 UNIT JOB 110.2339/190.0550)

nd
361.6xxx07yyyZ (2 UNIT JOB 110.2340/190.0551)
Where
xxx is instrument ID (ex. PIT for pressure instrument)
yyy is a progressive number starting from 251 to 305
This Functional Description is revised according to P. & I.D. (rev. 1)
TOTAL SHEET : 13
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EMESSO - ISSUED
DESCRIZIONE - DESCRIPTION
EA
Nardi G.
Mannucci S.
CONT-CHK'D
APP-APPR'D
PREP'D
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Il presente documento di propriet NUOVO PIGNONE. A termine di legge ogni diritto riservato.
SOSTITUISCE IL - REPLACES
This document is the property of NUOVO PIGNONE. All rights are reserved according to law.
SOSTITUITO DA - REPLACED BY
Electronically approved draw. GE NuovoPignone Internal DT-'N'
ANTISURGE WRITE-UP
for
AMMONIA SYNTHESIS COMPRESSOR
Nuovo Pignone
FIRENZE
INDEX
SECTION 1 : GENERAL DESCRIPTION
1.1 - GENERAL FEATURES
1.2 - SYMBOLS LEGEND
1.3 - ANTISURGE CONTROL LAW
1.4 - ANTISURGE CONTROL ALGORITHM
page 3/4
page 4/5
page 5/6
page. 7/8
SECTION 2 : ANTISURGE PROTECTION

2.1 - ANTISURGE CONTROL
2.2 - ANTISURGE CONTROL LINE (SCL)
page 8/9
page 9/10
SECTION 3 : ANTISURGE CONTROLLER

3.1 - ANTISURGE CONTROLLER OPERATION
3.2 - AUXILIARIES CONTROLLER OPERATION
page 11/12
page 12/13
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SECTION 1
1.1 GENERAL FEATURES
For each compressor speed, its possible to determine, on the plane SUCTION FLOW
COMPRESSION RATIO, a curve that describes all compressor operating points. Each obtained
curve meets its limits on the surge point, corresponding to the maximum polytropic head. All
surge points, defined for different speeds represent the limit line, on the left of this line (called
SURGE LIMIT LINE SLL) the compressor operates in an unstable area.
The purpose of the ANTISURGE CONTROL SYSTEM is to avoid that the operating point
A reaches the SLL. To achieve this objective, its defined, on the right of the SLL, a
protection line where (point B) the control system will operate opening the antisurge valve.
This line is called SURGE CONTROL LINE (SCL). The opening of the antisurge valve
increases the suction flow moving the operating point along the speed characteristic curve, from
the critical condition to the stable operating area (fig. 1).
Fig. 1
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1.2 SYMBOLS LEGEND

N
compressor speed
K1,K2,K3,K4
constants
QS
volumetric flow
Hp
polytropic head
Pd
discharge pressure
Ps
suction pressure
compressibility factor
gas constant
gas absolute temperature
polytropic head exponent
characteristic orifice constant
hs
p across the orifice
suction gas density
PSD
design suction pressure
deviation margin
SLL
surge limit line
SCL
surge control line
PV
process variable (compressor operating point)
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1.3 ANTISURGE CONTROL LAW

Considering a mono-stage centrifugal compressor, it is possible to verify the following relations,
varying the compressor speed, for each surge point:
(1) QS = K1* N
(2) Hp = K2 * N2
From (1) and (2) we obtain
Qs
(3) Hp K 2
K1
where
K2
K 1
K 3 = constant .So :
Hp K 3 Q s 2
being
n 1
n
Pd
n
(4) Hp ZRT
1
n 1 Ps
from (3) and (4) we obtain
n Pd
ZRT

n 1 Ps
(5)
n 1
1 K 3 Q s 2
If Qs is measured through a flow element installed at the compressor suction, we can express it
related to the measured p
Qs
(6)
since s
Ps
the (6) becomes
RZT
hs
s
Qs
hs * RZT
(7)
Ps
n Pd
so we can describe the (5) as : ZRT

n 1 Ps
n 1
h ZRT
1 K 3 2 s
Ps
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Simplifying ZRT in the expression, the obtained equation, that represents all the surge points in
function of the orifice p; we can demonstrate how the surge phenomenon is not influenced by
the gas condition and composition.
n Pd
hs

K 3 * 2 n 1 Ps
n 1
Ps
(8)
Moreover for small compression ratios, using series expansion at first order m 1 m 1
we have:
n Pd

n 1 Ps
hs
n 1
P
1 d 1 ;
Ps
Pd
K 3 * Ps
Ps
where
so the (8) becomes :
1
K3 * 2
hs Ps * K 4 * d 1
Ps
(9)
K 4 is a constant
hs
1
Pd
1 * Ps * K 4
Ps
The equation (9) defines the SLL shape, on the plane of compression ratio () versus flow (Q),
represented by a parabola which has the minimum located in = 1 and Q = 0 , Fig 1a .
SLL
SCL
SLL
SCL
Fig.1a
Fig.1b
The fig. 1a represents a theoretical performance characteristic for a single stage compressor (one
impeller only), while the Fig. 1b represents a typical characteristic for a multistage compressor.
As we can see in the latter conditions the antisurge control line can not be realized utilizing a
parabola without cutting a large zone of compressor operability .
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In order to avoid this inconvenient, the Surge Control Line is calculated by a eight break lines
P Ps
that permits to realize the SLL and consequently the relevant SCL.
function generator f d
Ps
The SCL will be positioned at a pre-set percentage margin (K), to the right of the first one .
SLL
SCL
1.4 ANTISURGE CONTROL ALGORITHM

In order to meet the described requests, the control algorithm will be developed inside the
controller is the follows :
hs *
Psd
Ps
P Ps
f d
Ps
K2
Where :
hs = differential pressure on calibrated orifice at compressor suction (Eng. unit).

Pd = compressor absolute discharge pressure (eng. unit).
Ps = compressor absolute suction pressure (eng. unit).
Psd = compressor absolute suction pressure at design conditions
The controller set-point is K2 . It represents the deviation margin between SLL and SCL . In
the Antisurge Control Line configuration sheet , the margin is expressed in percentage of flow.
The algorithm takes in account the P measured across the flow element (indicated by hs) that
is proportional to square suction flow (hs = Q2) .
The controller algorithm compensates continuously the hs signal according to the suction
pressure variation, taking in account the suction pressure measured and comparing it with the
design suction pressure PSD.
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SECTION 2
2.1 ANTISURGE CONTROLLER
The picture 2 shows the antisurge system diagram. With reference to the picture, the instruments
range will be :
INSTRUMENT
PT-278
PT-280
FT-258
MEASURED VARIABLE
SUCTION PRESSURE
DISCHARGE PRESSURE
FLOW ELEMENT DIFFER. PRESSURE
RANGES
0 6 Mpa(g)
0 25 Mpa(g)
0 25 Kpa
Fig. 2
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2.2 ANTISURGE CONTROL LINE

The picture 3 shows the SLL and SCL line on the plane COMPRESSOR RATIO ORIFICE
P.
Units
for all
tables
m3/h
mBar
FLOW ELEMENT
Volumetric flow
Differential pressure
Molecular weight
Absolute suction pressure
Absolute suct. temperature
Compressibility
FE calc.
values
FE values @
refer.conditions
Flow
Margin %
15642.0
250.00
8.702
31.40
290.2
1.012
15643.3
250.00
8.702
31.40
290.2
1.012
10
bara
K
Surge values @ reference conditions

N
Q surge
(Pd/Ps)-1 hs(SLL)
hs(scl)
0.000
31.54
1
5556
38.16
2.551
31.54
2
5556
38.16
3.118
37.24
3
6037.857
45.06
3.685
43.42
4
6519.714
52.54
4.316
50.08
5
7001.571
60.60
5.018
57.21
6
7483.429
69.23
5.721
64.82
7
7965.286
78.43
6.516
72.90
8
8447.143
88.20
7.331
81.45
9
8929
98.55
hs_safe
81.45
PSD
Point N (normal point)

Q(N) @ ref.con.
9445.0
Abs.disch.press.
187.100
hs(N) @ ref.con.
91.13
(Pd/Ps)-1 (N)
4.959
Point R (real point)
FE diff.pressure
91.13
Mol. weight
8.702
Abs.suct.press.
31.40
Abs. suct. temp.
290.2
Compressibility
1.012
Abs.disch.press.
187.10
Q(R) vol. flow
9443.9
hs(R) @ ref.con.
91.11
(Pd/Ps)-1 (R)
4.959
98.55
Antisurge curve
10.0
9.0
8.0
(Pd/Ps)-1
7.0
6.0
5.0
4.0
3.0
hs(SLL)
hs(SCL)
N
R
2.0
1.0
140
120
100
80
60
40
20
0.0
Differ. Press. across suction FE at refer. conditions (mBar)
Fig. 3
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-Surge Limit Line

2
Qsurge
Diff . press.span
hs ( sll )
Vol. flow.span @ ref .cond .
-Surge Control Line
Flow.mar. 100
hs ( scl ) hs ( sll )
100
-Point R (real point)

This portion of values could be use for verify the operating point position during compressor running.
-Point N (normal point)
Represents the compressor operating point @ performance curve reference conditions
-FE calc. values
Values used for the design of flow element (data from FE calculation sheet) .
-FE values @ refer. condition
FE design values converted to the compressor reference condition.
-Surge value @ reference condition
Surge values expressed by volumetric suction flow and (Pd/Ps)-1 at compressor reference
condition.
-hs_safe
Represent the antisurge controller setpoint in case of one or more pressure and temperature
transmitters in fault.
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SECTION 3
3.1 ANTISURGE CONTROLLER OPERATION
Controller Operation; Cascade PI control by direct action with the following signals:
Inputs :
a) Suction pressure (Ps)
b) Discharge Pressure (Pd)
c) Differential pressure on suction orifice Suction Flow (hs)
d) HIC Antisurge valve manual opening/closing command.
e) Safety Protection/Correction disabling.
f) External protection (EP)
g) L4AS (min. control speed) antisurge controller enable / disable.
h) External Transient.
i) PURGE command.
j) Zero Speed.
k) Solenoid Reset push button.
l) External override controller.
Outputs :
a) Antisurge valve control signal (ASVC)
b) Solenoid Valve Command.
c) Transmitter Failure indication.
d) Safety Protection/Correction disabling indication.
e) A/S Solenoid Valve de-energize indication.
f) A/S Controller Manual Control indication.
g) Feedback to external override controller.
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3.2 AUXILIARIES CONTROLLERS OPERATION
Pressure
Ratio
Surge Limit Line

Safety Protection Line
Safety Correction Line
Surge Control Line
Compressor
Operating
Point
Suction Flow
a) Dead band function :

If the difference between measure and set is included between imposed value, the controller
output does not change. This function permits to make the controller less sensitive to the noise of
flow transmitter.
b) Transient Absorption :
If the measure decreases very fast, to anticipate the controller response, the controller set point is
incremented by a fixed value.
When the condition resets, the set point return to the previous value following a pre-set ramp .
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c) Safety Correction :
When the measure is lower of the Safety Correction Line (SLL + 5% in term of flow) the
antisurge controller output decreases following fixed steps in fixed time gaps until the measure
goes back to a value higher than Safety Correction Line.
d) Safety Protection :
When the measure is lower of the Safety Protection Line (SLL + 2% in term of flow) the
antisurge controller output decreases following quick opening ramp until the measure goes back
to the right of the Safety Correction Line .
e) Rate limiter function :

Its used to avoid instability phenomenon on antisurge control introducing an output limit of
variation. Quick rate is used in opening, slow rate in closing.
f) Safety disabling function :

Allows disabling the safety protection and safety correction functions. Password protected.
A typical application of this function is the compressor surge points test, using the controller in
manual mode.
g) Manual operation override function :

Allows the automatic disabling of manual control in case measure reaches the Safety
Correction limit.
h) Controller Enabling/Disabling
When the controller is disabled the antisurge valve is forced to open position. Controller is
generally enabled when min. control speed is reached.
i) Purge function :
Allows the complete closing of the antisurge valve when the compressor is stopped .
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Anti Surge

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Anti Surge

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Nuovo Pignone

QATAR FERTILISER COMPANY

LOCALITA' - PLANT LOCATION

MESAIEED STATE OF QATAR

QATAR FERTILISER COMPANY (S.A.Q.)

(Flow Element installed at compressor suction)

351.5xxx07yyyZ (1 UNIT JOB 110.2339/190.0550)

This Functional Description is revised according to P. & I.D. (rev. 1)

Electronically approved draw. GE NuovoPignone Internal DT-'N'

SECTION 2 : ANTISURGE PROTECTION

SECTION 3 : ANTISURGE CONTROLLER

1.2 SYMBOLS LEGEND

gas absolute temperature

polytropic head exponent

characteristic orifice constant

p across the orifice

suction gas density

design suction pressure

surge limit line

surge control line

process variable (compressor operating point)

1.3 ANTISURGE CONTROL LAW

from (3) and (4) we obtain

so the (8) becomes :

1.4 ANTISURGE CONTROL ALGORITHM

hs = differential pressure on calibrated orifice at compressor suction (Eng. unit).

2.2 ANTISURGE CONTROL LINE

Surge values @ reference conditions

Point N (normal point)

Differ. Press. across suction FE at refer. conditions (mBar)

-Surge Limit Line

-Surge Control Line

-Point R (real point)

3.2 AUXILIARIES CONTROLLERS OPERATION

Surge Limit Line

a) Dead band function :

e) Rate limiter function :

f) Safety disabling function :

g) Manual operation override function :

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