GER 0088 CGER 0088 Compressor Surge Controlompressor Surge Control

Global Engineering Reference
GER 0088
Revision: 0
Compressor Surge Control

Supersedes PTN-10
Rolls-Royce plc 2007

The information in this document is the property of Rolls-Royce plc and may not be copied, communicated to a third party, or used for any purpose other than for which it is supplied, without the express written consent of Rolls-Royce plc. While this information is given in good faith based upon the latest information available to Rolls-Royce plc, no warranty or representation is given concerning such information, which must not be taken as establishing any contractual or other commitment binding upon Rolls-Royce plc or any of its subsidiary companies
Rolls-Royce Power Engineering plc Atlantic Industrial Complex Dunnings Bridge Road Bootle, Merseyside L30 4UZ England www.rolls-royce.com
Rolls-Royce Energy Systems Inc. 105 North Sandusky Street Mount Vernon Ohio 43050 USA
GER 0088 Revision 0 Page 2 of 11
EXECUTIVE SUMMARY This Global Engineering Reference (GER) defines surge control as it applies to a typical pipeline or multi-stage centrifugal compressor, while the unit is coming on line during the start sequence.
POINT OF EMBODIMENT Applies to all new equipment tenders, initiated after issue of this revision; it should not be applied retrospectively to production or legacy projects unless affected equipment overhaul or replacement is required.
Revision History Revision 0 Revision Description Initial Issue per ECR 15501 Author M. Vaughan R. H. Marshall Approval Signature, Date
Peter Rainer 2008.01.04 15:09:12 Z APPROVED
TABLE OF CONTENTS
1 2 3 4
SCOPE ...................................................................................................................................4 SURGE DEFINITION..............................................................................................................4 REFERENCE DOCUMENTS AND SPECIFICATIONS ..........................................................4 COMPRESSOR START-UP ...................................................................................................4 4.1 4.2 4.3 4.4 Unit Pre-Start.................................................................................................................. 4 GG-PT Start Sequence................................................................................................... 5 Opening of Discharge Check Valve ................................................................................ 5 Surge Valve Control........................................................................................................ 5
SURGE CONTROL ................................................................................................................7 5.1 5.2 Surge Prevention ............................................................................................................ 7 Pressure Ratio and Flow Measurement.......................................................................... 7
THEORY.................................................................................................................................8 6.1 6.2 6.3 6.4 Pressure-Flow Diagram .................................................................................................. 8 Theory of Control Operation ........................................................................................... 9 Approaching Surge ......................................................................................................... 9 Leaving Surge ................................................................................................................ 10
APPLICATION NOTES ..........................................................................................................10 7.1 7.2 7.3 Recycle/Surge Control Valve Sizing ............................................................................... 10 Suction Pressure Compensation .................................................................................... 10 Suction Temperature Compensation .............................................................................. 10
SCOPE
1.1 This GER describes the compressor start-up activity and provides a summary of those functions, which either promote a unit start or cause a start abort. 1.2 Good anti-surge control system design is complex and encompasses the proper sizing, selection and location of the following elements: piping that comprises the recycle loop, the recycle valve, volumes of vessels in the recycle path, check valves, and the anti-surge controller. 1.3 All surge control/management is achieved through the surge controller acting on either the recycle valve or on a dedicated surge control valve that is installed in parallel with the recycle valve. 1.4 For the purposes of this document only, the term "Rolls-Royce" shall be construed as meaning and / or referring to "Rolls-Royce Power Engineering plc." and "Rolls-Royce Energy Systems Inc." either jointly or individually. NOTE: This document is an Engineering Standard. No deviations are permitted to instructions or specifications herein other than those approved in writing by the PCB (Product Change Board).
SURGE DEFINITION
2.1.1 Surge is a condition, which results when the centrifugal compressor impeller blades cannot impart sufficient energy to overcome the pressure differential across the compressor. The resulting surge or flow reversal tends to create severe gas flow pulsations which can cause bearing damage and rotor stator rubbing. This phenomenon begins to occur when, at a given flow, the differential pressure between the compressor suction and discharge pressure has reached a certain level. Interactions through multi-unit operation, in both series and parallel configurations may occur.
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3.1 3.2
REFERENCE DOCUMENTS AND SPECIFICATIONS

Surge Control Description and Application Manual. Doc. No. ZS524-002L-0103 BS EN 60079-10 - Electrical apparatus for explosive gas atmospheres. Classification of hazardous areas.
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4.1
COMPRESSOR START-UP
Unit Pre-Start
NOTE: Refer to Figure 2 when reading Section 4.1. 4.1.1 Before initiating the GG-PT (Gas Generator Power Turbine) start sequence, purge and pressurise the compressor from the main process line by opening the pressurising valve and surge control/recycle valve.
4.1.2 Vent valve is open and Check valve No. 2 is closed (ensure Check Valve no 2 is closed by higher downstream pressure in the process line, if this is not the case then close the discharge valve); as a result the gas then passes through the surge valve and out through the vent valve, the path of least resistance (path C-B on Figure 2). This occurs through the duration of the piping purge timer. Once the piping purge timer has timed out, the surge valve is forced closed in order to route gas through the compressor for compressor purge (path C-D-A-B). Once the compressor purge timer has timed out, the vent valve is closed to allow pressurisation of the compressor. When the differential pressure across the suction valve reduces to an acceptable value, both the suction and discharge valves will open. Once the suction valve is proven open, the pressurising valve will close. To enable start of the gas turbine, the surge control valve must be re-opened. Once re-opened, all valves are n in position to enable a start of the gas turbine. NOTE: The piping and compressor purge times are dependent on the piping configuration. 4.1.3 Vent valve positioning and discharge pressurization flow rates need to be fully understood and suitable risk assessments carried out to ensure that the hazardous area created during venting does not lead to a potentially dangerous condition. The size of the hazard zone shall be shown on the hazardous area drawing, and calculated in accordance with BS EN 60079-10. Also, the rate of depressurisation must be limited to 5 psi/SRC for clean and 3psi/SRC for sour gas, to protect O-ring seal life. 4.2 GG-PT Start Sequence
4.2.1 Begin GG-PT start sequence and ramp up to (N3) PT idle. Surge valve is opened and stays open. When warm-up is complete, unit is ready to load. When the load command is issued the surge valve will begin to close and the unit will ramp up to PT minimum speed on N1 (Gas Generator speed) control. NOTE: Minimum speed is identical to minimum governor speed. 4.3 Opening of Discharge Check Valve
4.3.1 If the discharge check-valve is open at PT minimum speed, the unit will remain at minimum speed and manual control is enabled. 4.3.2 If the discharge check-valve is closed at PT minimum speed, the PT is ramped up on N3 medium rate until the check valve is sensed open. At this time, the PT speed increase and medium rate commands are removed. The unit then remains at its achieved speed, and a standard unit start sequence is complete. The unit is now loaded. 4.3.3 If the discharge check valve does not open, the unit will finally shut down on either high discharge temperature or pressure. 4.4 Surge Valve Control
4.4.1 The surge valve provides a control loop which re-inserts compressed gas into the suction line to temporarily increase the flow across the compressor. This temporary increase relieves any overly high-pressure differential across the compressor, promoting higher flow. The surge loop thus assists the compressor to improve efficiency of operation as the dynamic operating point (point X in Figure 1) moves away from the surge region toward a desired (design) steady state high-flow region.
Key To Figure 1
A = Actual Surge Line B = Surge Trip Line C = Safety Valve Open Line
E = Surge PI-Control Line F = Approaching Surge Alarm Line G = Surge Anticipating Line
PD/PS = Compressor Discharge Pressure (abs)/ Suction Pressure(abs) Q = Actual Volume Flow through Compressor Figure 1. Compressor Pressure Ratio vs Q Diagram
4.4.2 Under normal conditions in the main process line, the compressor operates in a high efficiency region on the Pressure Ratio-Q diagram far from the surge zone. In this situation the surge valve is inactive and closed. 4.4.3 However, during start-up, and any time the surge valve is being controlled to move the compressor operation away from incipient surge, the initial effect of closing the surge valve is to decrease flow across the compressor. (Note that the flow at point Qc on Figure 2 drops to zero when the surge valves closes). This is true even though flow through the number 2 check valve is increasing. This condition is temporary and expected, and the surge controller senses and corrects for the transient pressures and flows.
Suction Check valve No.1 Discharge Valve Purge / Pressurisation Valve Suction Valve
I P
Main Process Line
PdA
Check valve No.2
B Vent Valve Qc Surge Control Valve
D Compressor
Figure 2. Compressor Surge Control Layout
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5.1
SURGE CONTROL
Surge Prevention
5.1.1 In the surge control system, surge is prevented by enabling a portion of the gas, from the compressor discharge to be re-circulated back to the suction line. The amount of re-circulated gas is dependant upon the compressor characteristics. A recycle/surge control valve, installed in this line controls the re-circulated flow and is actuated by the control system. For more information, refer to Figure 3, Surge Control Schematic. 5.1.2 Figure 1 illustrates the use of the universal surge control map (Pressure Ratio vs Q diagram). The compressor flow set point is provided by the control line. The location of the control line in comparison with the surge line depends on the slope of the speed lines on the map. The control line is positioned to the right of the surge line, which provides a safety margin for the surge controller PI (Proportional and Integral) algorithm. 5.1.3 The PI control loop is used to compare the control set point to the operating point of the compressor and provides an output to the surge valve to prevent the flow from decreasing below the control line. When a safe relationship between the control line and the surge line is determined, this relationship is configured into the surge controller. 5.2 Pressure Ratio and Flow Measurement
5.2.1 This ratio is the result of the absolute discharge pressure divided by the absolute suction pressure across the compressor. 5.2.2 The flow may be measured using any one of the following methods: Annubar or pilot static type device An orifice plate in the suction line The P from the suction flange to the impeller eye of the compressor divided by suction pressure (abs) -- suitable for surge control only, not performance evaluation Any other reliable flow measurement device.
5.2.3 NOTE: ECR.
Flow measurement by the P method is illustrated in Figure 3. Future revisions to paragraph 5.2.3, Figure 3, and Section 6 are required per upcoming
PDischarge(abs)/PSuction(abs)
PSuction Eye/PSuction(abs)
Figure 3. Surge Control Map
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6.1
THEORY
Pressure-Flow Diagram
6.1.1 In order to appreciate the relationship between surge and the combined characteristics of other influencing factors, a study should be made of the Pressure-Flow Diagram (Figure 1). 6.1.2 The vertical and horizontal coordinates shown in Figure 1, represent PDischarge/PSuction and Flow (Q). Lines of constant compressor speed determine the relationship between PD/PS and Q for any constant speed where: PD/PS = Differential Pressure across the compressor
Q = Actual Volume flow through the compressor
6.1.3 Theoretically, for any given speed, variations between PD/PS and Q result from the dynamic operating point moving along the speed line. An increase in differential pressure, with a consequential drop in flow, will cause the operating point to move along the speed line toward the "surge" region. "Surge" occurs at the intersection between the speed and surge lines. The relationship between pressure ratio and flow is similar to head and flow. 6.2 Theory of Control Operation
6.2.1 The concept of the Surge Control System can best be explained by following the course of Point x along the speed curve, shown in Figure 1. 6.2.2 The theoretical lines B, C, E, F, and G are parallel to the datum surge, Line A. The parallel distances of lines B, C, E, F, and G from the Surge Datum Line A are easily programmed in engineering units. Surge Datum Line A is shown here as two (2) segments a-y and y-z. Based on compressor manufacturer data, these line segments are defined by the user. The user enters the ordinate and abscissa of each line segment using engineering units. A maximum of five (5) line segments may be entered allowing for maximum use of the compressor envelope. The following points describe the surge control operation in further detail: A - Actual Surge Line at which the Compressor theoretically goes into surge B - Surge Trip Line at which surge is imminent and generates "Surge Failure" which indicates a failure to recycle sufficient flow. Typically, this is set at 4% of Point a. C - Safety Valve Open Line at which surge control safety function overrides any other control and instantaneously opens the valve. Typically, this is set at 6% of Point a. E - Surge PI-Control Line at which surge is controlled according to PI Control action if opening has not already been initiated through surge anticipation. Typically, this is set at 10% of Point a. F - Approaching Surge Alarm Line is the point at which a pre-alarm for approaching surge is initiated. This point is adjusted to the customer's preference. G - Surge Anticipating Line is the earliest point at which the system can anticipate surge, depending upon fluid dynamic characteristics. Typically, this is set at 20% of Point a. x - Dynamic Operating Point a, y+z - a maximum of six (6) programmable control line break points in engineering units (a total of five line segments).
6.3 NOTE:
Approaching Surge Please refer to Figure 1 while reading Sections 6.3 and 6.4.
6.3.1 If Point x is moving left, passing Line G at a slow rate, no action is taken until Point f is reached. This is the point at which indication is provided by an "Approaching Surge" contact output, which can be used for station control or other unit control. If Point x continues to move to the left, no action is taken until it reaches Point e. 6.3.2 If Point x is moving left between Points g and e, at a rate greater than the predetermined value, the controller will anticipate surge and cause the Recycle/Surge Control Valve to start opening. If the movement of Point x stabilizes, while in this region, the Recycle/Surge Control Valve will begin to close at a preset time rate. 6.3.3 If Point x reaches Point e, the Recycle/Surge Control Valve starts to be modulated according to the set PI Control function and surge flow, ie, process inlet flow and recycled flow will be kept stable at any valve status between closed and open. If the flow continues to decrease, the action of the PID Controller will increase the valve opening to prevent reaching surge conditions. If flow continues to decrease, an additional safety action will force the valve to proportionally open when Point c is reached. If flow continues to decrease below Line B, the "Surge Failure" contact will open and latch until the reset signal is received. 6.4 Leaving Surge
6.4.1 The Recycle/Surge Control Valve may be fully open or fully closed, depending upon the unit requirements, while Point x is on Line E. As the unit flow increases, the Recycle/Surge Control Valve will begin to close under the slow integral closing rate. 6.4.2 When the Recycle Surge Control Valve reaches its fully closed position, Point x will begin to move to the right as the flow continues to increase. 6.4.3 Derivative action, safety action, and high speed integral action have no influence on the valve closing as flow increases. This feature ensures a stable transition to normal conditions in order to avoid sudden changes to existing flow patterns, which would consequently effect other interconnected units in the process.
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7.1
APPLICATION NOTES
Recycle/Surge Control Valve Sizing
7.1.1 The Recycle/Surge Control Valve should be sized to handle a minimum of 120% of the maximum surge line flow. This will keep the unit out of surge, at the highest compressor speed, on the surge line. 7.2 Suction Pressure Compensation
7.2.1 Suction pressure compensation, on pipeline compressors, is not normally required. The surge line should be established for the worst case conditions, which is the flow condition with the highest suction pressure. On high ratio compressors, where larger suction pressure variations occur, compensation is not required if the compression ratio is used as a control parameter in compensating for changes. Using the compressor ratio as a surge control parameter, will also tend to compensate for changes in gas mole weights for mole weights less than 32. 7.3 Suction Temperature Compensation
7.3.1 On systems where suction temperature is not an input, the surge line should be set at the lowest suction temperature. A suction temperature change of 10C (18F) effects the surge line by approximately 1-2%.
Figure 4. Surge Control Schematic

GER 0088 CGER 0088 Compressor Surge Controlompressor Surge Control

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GER 0088 CGER 0088 Compressor Surge Controlompressor Surge Control

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Global Engineering Reference

Compressor Surge Control

Rolls-Royce plc 2007

GER 0088 Revision 0 Page 2 of 11

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REFERENCE DOCUMENTS AND SPECIFICATIONS

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Main Process Line

Check valve No.2

B Vent Valve Qc Surge Control Valve

Figure 2. Compressor Surge Control Layout

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5.2.3 NOTE: ECR.

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Q = Actual Volume flow through the compressor

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Figure 4. Surge Control Schematic

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