Filosofia de Control

Data Book Solar Surge Control for
Centaur T4500 Gas Turbine-Driven Compressor Set Aquasay Plant, Corpoven S.A. - Venezuela
GlTERPILLARe
SolaiTurbines
•••• 'T •• I •• lI ••••. iIM P.O. Box 85376
San Diego. CA 921 86-5376
The Iwords Solar. Mara,
ncorporated. Centaur
CAT and and Satum
Caterpillar ere Irademarks
ere lrademarks of Solar Turblnes
01 Caterplllar Inc.
SpecIllcatIonS subject lo change wtthout notlc8. Pl1nted In U.SA
PUSLlCATION NUMBER: DS 92-01481B 03/92
1.1 GENERAL
The centrifugal gas compressor is a device that converts input torque energy to fluid
energy through a dynamic process. This process involves accelerating gas as it is drawn
into the compressor. Gas enters (or is induced into) the center, or eye, of a rotating
impeller (Figure 1 .1.1) and exits at the periphery, or the impeller tip. Energy is imparted
by the impeller blades, which increases the gas velocity and the static pressure. The eye of
the compressor impeller is small; the tip is larger. The difference in surface area causes the
gas to speed up in order to exit the larger diameter. The final energy change occurs when
the gas enters the diffuser, either vaned or vaneless, at a high velocity. The diffuser then
slows the gas, which converts most of the kinetic energy into additional static pressure.
1.1.1 Centrifugal Gas Compressor Impeller
Gas enters the impeller eye. The blades extending forward in the axial region of the
impeller are referred to as the inducer. The inducer guides the flow into the radial region,
increasing the angular momentum. The inlet edge of a blade is the leading edge, while the
exit edge, at the outer diameter, is the trailing edge (impeller tip). The face of the blade in
the direction of rotation (pushing the flow) is the driving face (pressure side), while the
opposite surface is the trailing face (suction side).
The minimum opening of each impeller channel is the window perpendicular to the flow,
between the leading edge of a blade and the side of the adjacent one, and it is referred to as
the inducer throat or impeller throat. Often shorter blades, called splitter vanes, are used in
between the regular ones to provide better guidance to the flow without reducing the
inducer throat.
Fig. 1.1.1 Compressor impeller

1.1.2 Gas Flow through a Centrifugal Gas Compressor
Gas enters the suction flange and is then directed into the inlet guide vane (Figure 1 o 1.02)
o The inlet guide vane routes the gas into the rotating impeller. The guide vane angular
relationship to compressor rotation (Figure 1.1.3) is selected at the initial sale or at restage.
Fig 1.1.3 centrifugal Compressor Internal components
The gas then enters the diffuser. The diffuser can be either vane less, (Figure 1.1.4) or
vaned (Figure 1.1.5). The diffuser slows down the gas slightly and directs it into the next
inlet guide vane. This action is repeated for as many stages as are installed in the
compressor.
1.1.3 Compressor Pressure

1.1.3 Compressor Pressure
Absolute pressure measurements are based on a zero reference point--the perfect vacuum.
Measured from this reference, the standard atmospheric pressure at sea level is
approximately 14.7 psi (101.35 kPa); however, local pressures may deviate from this
standard value because of weather conditions and distance above sea leve!. Figure 1.1.6
shows the relation of various pressure terms.
1.1.4 Compressor Performance
Only two factors affect the performance of a centrifugal compressor; the head (or enthalpy
rise) produced and the capacity (or actual inlet volumetric flow rate). Head and capacity
cannot be measured directly, but can be calculated from the known values of gas
composition, pressures, suction temperature, and standard volumetric flow rate (or mass
flow).
To determine the number of stages required within the chosen compressor, divide the total
head required by the maximum head per stage as defined below:
Round the number of stages required (m) to the next highest integer. To estimate the actual
operating speed, use the Fan Law total head requied
N actual = N max
m x head max/ stage
1.1.5 Compressor Performance Calculations
Performance calculations for a centrifugal compressor require the following information.

For the gas to be compressed:
• Specific gravity (SG), the ratio of molecular weight of the gas to that of air
• Ratio of specific heats (k), Cp/Cv

• Temperature at the compressor suction (T1) in degrees F (degrees C)
• Compressibility factor (Z1), the ratio of actual volume occupied by the gas at
suction conditions (P1' T1, and SG) to the volume occupied by an ideal gas at
the same conditions
• Average compressibility (Zave) is the compressibility factor at the average

suction and discharge pressure and temperature
For the compression job to be accomplished (any three of the following):
• Suction pressure (P1) psia (kPa abs)
• Discharge pressure (P2) psia (kPa abs)

• Standard volumetric flow rate (Qstd) in mmscfd
(sm3/hr)
• Compressor power consumption in hp (kW) this information is then used in the
following equations:
1 . Isentropic Exponent, σ
k −1
σ=
k
2. Isentropic Head, Head, ft-Ibf/lbm (J/kgm)
c (t1 + c 2 ) Z ave ⎡⎛ p ⎞
σ
⎤
head = 1 ⎢⎜⎜ 2 ⎟⎟ − 1⎥
σ SG ⎢⎣⎝ p1 ⎠ ⎥⎦
3. Capacicity, Qact actual inlet volumetric flow rate),

cfm (m3/seg.)
CFM= C3 QSTD Z1 (T1+C2)/P1
4. Efficiency Effy (Expressed As %)

Effy = nisen nmech
(isentropic efficiency from chart; mechanical efficiency is aproxmately 098).
5. Power consumption, PWR, Hp (Kw)
Hp = C4 head Qstd SG/EFFY
6. TEMPERATURE RISE, ∆T (across the compressor)
t1 + c 2 ⎡⎛ p 2 ⎞
σ
⎤
∆T = ⎢ ⎜⎜ ⎟⎟ − 1⎥
η isen ⎢⎣ ⎝ p 1 ⎠ ⎥⎦
7. Compressor suction flow, Qstd (at specified pressure ratio)
Qstd = PWR EFFY / C4 Head SG
8. Pressure ratio, p2/p1 (at specified throughput)
p2 ⎡ c PWR EFFY σ ⎤ 1
= 1+ ⎢ 5 ⎥
p1 ⎣ Q std (T1 + C 2 ) Z AVE ⎦ σ
9. COMPRESSOR SUCTION FLOW, QSTD by following AGA Report # 3
To
Q std = C1 x hw x P1 x
T1
The amount of gas flow in a compressor can be expressed in terms of either its mass
(weight) or its volume. Volumetric flow is expressed as a unit of volume per a unit of time;
cubic feet per minute (cfm) or cubic meters per minute (m3/min). For example; at standard
conditions of pressure and temperature, a physical cubic foot would contain one standard
cubic foot of gas (or a physical cubic meter would contain one standard cubic meter of gas
Note
It should be clearly understood that all parameters selected as examples in the following
are arbitrary. Consequently, actual performance and parameters will depend on (and
possibly be Limited by) the rating of the equipment selected. These examples do not
necessarily reflect actual performance at your installation
By
Comparing engine performance curves to the calculations in equations 2 through 5, it can

be determined which compressor and engine type is required. As calculated in equation 6,
the minimum number of stages may be determined
It is possible to apply Solar's centrifugal compressor line to many different conditions by

using these equations. Two or more units may be operated in parallel or in series. When
operated in series, a cooler is usually placed between the compressors to achieve more
efficient compression. It is important to realize that these calculations select the optimum
staging configuration for a single design point. Once the staging configuration is
determined, Solar's application engineers can produce typical multi-stage performance
curves for that particular compressor. For example, reducing the speed to 90 percent of
design speed while maintaining suction conditions will reduce the capacity to 90 percent of
design capacity. The head will be reduced to 81 percent of design head and the power
consumption will be reduced to 73 percent of design.
Good efficiencies may be achieved over a wide range of flow and head. Compressor
staging can be selected to give a maximum operating range. To estimate compressor
performance other than design conditions, use the Fan Laws (Figure 1.1.7):
2.1 DESCRIPTION OF SURGE
For every speed in a centrifugal compressor, there is a certain capacity below which the
operation is unstable. This breakdown point is called the surge point. The unstable,
pulsating operation after passing this point is called surge.
A typical compressor impeller (with backward curved van es) is illustrated in Figure 2.1.1
This type of impeller is used for most industrial and process applications. A vector diagram
has been constructed at the impeller exit. The head developed in a stage of a centrifugal
compressor is a function of the product of the tangential component of the absolute
velocity leaving the impeller and the hydraulic efficiency at a given relative speed. As the
capacity of the stage is reduced from the design value at constant speed, the value of the
relative velocity leaving the impeller is reduced very nearly in proportion to the reduction
in stage capacity. The angle of this relative velocity remains almost constant, except for the
effect of "slip" which results from a circulation effect at the impeller tip. As the capacity is
reduced at constant speed, the value of the velocity leaving the impeller increases and at a
much greater rate than the hydraulic efficiency is reduced. The result is an increase in head
developed by the stage as the capacity is progressively reduced below the design value,
and a typical centrifugal compressor head flow characteristic develops.
As the capacity is reduced, the impeller flow channel is not completely filled (Figure
2.1.2). Actually, some localized recirculation occurs in the flow channel and the greater the
reduction in flow, the larger this circulation effect becomes.
At approximately 60% of the stage design capacity, the flow pattern in the impeller
resulting from this circulation effect collapses and the unit then surges. The actual
percentage is dependent on the level of speed, Mach number and molecular weight.
FLOW UNES
Figure 2.1.2 Impeller Flow Path

At the instant that flow pattern collapses, the impeller is no longer able to maintain the
pressure rise which it had been developing. The pressure level in the receiver downstream
of the compressor is higher than that at some intern allocation and the flow reverses locally
to follow the pressure gradient. This means that the capacity continues to reduce until the
downstream reservoir pressure is low enough for the impeller to overcome it. This is
indicated by points (3) in Figure 2.1.3. When the downstream pressure has dropped to a
level corresponding to point (3), the impeller can again begin to deliver, and it immediately
handles a capacity corresponding to point (4).
If the condition which has caused surge has not been eliminated, the compressor capacity
will again be progressively reduced along the constant speed curve through point (1) to
point (2), and the surge cycle will be repeated.
The frequency of the surge is a function of the time required for the compressor capacity to
change from point (2) through point (3) and point (4), and finally back to point (2). Ifthe
downstream receiver capacity is large, the frequency of the surge will be low and the
violence.of it audible. If the downstream receiver capacity is small, the frequency will be
high and the violence considerably reduced and perhaps just barely audible. This also
dependent on the pressure involved. The higher the pressure, the greater the energy.
Although a centrifugal compressor stage, operating at constant speed, will surge at

approximately 60% of the design capacity, the stability of multi-stage units is much lower.
This follows from the basic characteristic of each compressor stage, since at capacities less
than the design; a greater volume reduction is obtained. Thus, if each stage of a multi-stage
compressor surges at 60% of design capacity, the overall unit may surge at 70% of design
capacity of the inlet of the unit. This flow corresponds to 60% of the design capacity of the
last impeller because of the increased volume reduction encountered in the earlier stages.
If the molecular weight of the gas being handled increases above the molecular weight for
which the compressor was designed, the stability of the compressor is decreased for a
given speed. Stability here is defined as the difference between design capacity and the
capacity at surge point at design speed divided by the design capacity and is given as a
percent of the design capacity.
2.2 CONDITIONS THAT MAY CAUSE SURGE
Conditions that reduce flow through the compressor or increase the head requirement
cause the compressor to be more susceptible to surge. These conditions include:
• Clogged inlet screens which increase the ratio while reducing the
suction throughput
• Upstream flow conditions which reduce system usage and cause the discharge
pressure to rise
• Inadequate or clogged recycle valve
• Internal (interstage) flow leakage
• Clogged impeller passages
• • Different gas specific gravity
Examples of reduced flow sources include:
• Operator or automatic process controller reduces engine power
• Recycle valve and/or piping is undersized
• Recycle line injection opposes process gas thereby reducing process

gas flow
• Interstage seals worn which allows interstagegas recirculation
• Foreign object adhering to the impeller passages which reduces flow area
• Failed or improperly installed check valve(s) in series/parallel compressors
2.2.1 Rise in Discharge Pressure
If suction pressure (P1) and revolutions per minute (rpm) are held constant, a rise in
discharge pressure (P2) results in a fall in flow ultimately reaching the surge limit. The
process condition that causes discharge pressure to rise is a decline in flow-acceptance of
the load.
2.2.2 Fall in Suction Pressure
If discharge pressure (P2) and rpm are held constant, a fall in suction pressure (P1) results in
a fall in flow, ultimately reaching the surge Iimit.
2.2.3 Loss of Upstream Compressor
In an application with compressors operated in series, the loss of an upstream compressor

may affect engine performance and trigger a surge condition.
2.2.4 Fall in rpm
If suction and discharge pressure are held constant, a fall in rpm can very quickly drop the
flow to the surge limit. In fact, sud den reduction in rpm is the most serious upset that a
surge control system has to handle. By comparison, suddenly closing the discharge or
suction valve is usually an easier upset to control.
2.3 SYMPTOMS OF SURGE
Surge can be mild and almost undetectable, or it can be violent.

2.3.1 Mild Surge
Surge does not necessarily occur simultaneously in all areas of the compressor. Because
gas velocity varies as it flows through the compressor, surge conditions may develop in
one area, while the gas in other are as ofthe compressor is still flowing forward. This
partial or mi Id surge may be indicated by the following conditions:
• Momentary fluctuations in flow rate
• Significant increase in discharge temperature
• Rapid pulsation of flow and discharge pressure
• Increased axial and radial vibration levels
2.3.2 Violent Surge

Violent surge is easily recognized by the following symptoms:
• Loud c1attering noise from the compressor
• Successive slamming of the discharge check valve
• Significant increase in discharge temperature

• • Rapid pulsation of flow and discharge pressure
Eventual package shutdown will result from Vibration, Overspeed, or after a duration,
from High Discharge Temperature.
Note
Violent surge is typically repetitive
2.4 EFFECTS OF SURGE
The effects of surge can vary widely, depending on the seriousness of the surge condition.
Mild surge may only produce decreased performance efficiency and the associated
increase in discharge temperature, whereas violent surge can produce high frequency
reversals in the axial thrust on the compressor shaft. At the first sign of surge, corrective
action should be taken immediately to get the compressor out of surge.
The effects of surge can seriously damage the compressor. The following is a Iist of some
results of surge conditions:
• Thrust and/or radial bearing failure
• Compressor overheat
• Bent shafts
• Cracked or ruptured casings
• Damaged bearings and impellers
2.5 METHODS OF CONTROLLlNG SURGE
What may be done to bring a compressor out of surge is dependent upon what can be done
with the process involved. If the speed remains constant, then the flow in the compressor
must be increased, or the pressure ratio across the compressor should be reduced.
Several steps may be taken to bring a compressor out of surge.
1. Increase the flow from the process to the compressor suction.
2. Increase the flow through the compressor by by-passing some of the gas being
pumped from the compressor discharge through a cooler, back to the suction of the
unit.
3. Decrease the pressure ratio across the compressor by decreasing the discharge
pressure, or increasing the suction pressure, or both, if the flow is to remain constant.
If the process requires a higher pressure ratio than the compressor is able to develop at a
given speed, an increase in pressure ratio may be obtained by increasing the speed of the
compressor. This speed increase will be limited by the maximum allowable operating
speed of the compressor and driver.
If the process requires a lower capacity than the compressor can develop at a given speed,
the speed may be reduced if the pressure ratio can be reduced. When the speed is lowered,
the first critical speed of the compressor and driver may be the Iimiting factor.
3.1 GENERAL DESCRIPTION
The Solar surge control system cO'nsists of a differential pressure transmitter in the suction
and discharge Hnes of the cOmpressor, a flow transmitter across the suction orifice plate, a
control algorithm in the control system, and a valve with corresponding accessories to keep
the compressor from going into surge.
Surge at a given speed is caused by an excessive differential pressure across the

compressor (isentropic head) for a given flow rate to the suction side. Therefore, surge in
the compressor may be controlled by either decreasing the differential pressure across the
compressor or by increasing the flow rate of the gas to the suction side of the compressor.
When the turbine package Programmable Logic Controller (PLC) detects conditions that
could cause the compressor to go into surge, a signal is sent to open the recycle val ve and
surge is prevented. When the condition that created the temporary instability disappears,
then the PLC will order the valve to close as required in order to minimize recycle.
3.2 FUNCTIONAL DESCRIPTION
The surge control system consists of two interrelated systems; a control system with
Proportional and Integral (P + 1) actions and a surge detector system.
The surge control loop is disabled until the engine speed is greater than a preset value
(typically 90 percent Ngp). Below this preset value, the recycle valve will be fully open to
allow maximum flow of gas through the compressor.
Above the preset value, the pressure differential across the compressor is sensed by a
transmitter in the suction and discharge Iines. Suction flow to the compressor is
determined by measuring the differential pressure across a flow orifice in the suction line
to the compressor. The information from these transmitters is analyzed by the controller
(PLC). If PLC analysis indicates the compressor is approaching surge, a signal is sent to
the electro-pneumatic converter. Depending on the amplitude of the signal, the converter
will cause the recycle valve to open partially or entirely. When opened, a portion of the gas
from the discharge side of the compressor is routed back to the suction side so that gas
flow through the compressor is increased.
In the PLC, the differential pressure across the flow orífice is used to compute the rate-of-
change of flow to the compressor and compared to a preset value. If the
1k computed value is greater than the preset value (typically 15 to 25 percent per second),
one pulse is counted and the recycle valve is opened 15 percent. If five of these pulses
occur within ten seconds, the engine is shut down and the message COMPRESSOR IN
SURGE appears on the display terminal.
In MANUAL mode, the recycle valve opening and c10sing is controlled at the turbine
control panel. If the compressor is approaching the "DEADBAND" area near the surge
limit line, control of the recycle valve automatically reverts back to the microprocessor.
When this occurs, the message "MANUAL MODE INHIBIT" is displayed on the package
control system surge control screen (Figure 3.2.1).
A position transmitter attached to the valve stem of the recycle valve sends a signal back to
the PLC corresponding to the percentage that the valve is open.
3.3 COMPONENT DESCRIPTION
For settings and system normal or operating design values not discussed in the following
paragraphs, refer to vendor data supplied in Section 6, Supplementary Data or Section 7,
Reference Drawings.
Major components that make up the surge control system are shown in Figure 3.3.1 and are
Iisted in Table 3.3.1. These include the surge control recycle valve and supporting system
transmitters.
GENERAL
Solar’s basic surge control system is designed around the flow /∆P scheme (Figure 5.1 .1).
This approach uses the following equation for control purposes:
∆P = Kc * h + Bias (1)
Where:
∆P= diferential pressure across the compressor, Psid

Kc= surge control line slope
h= diferencial pressure across the flowmeter, in. W.C.
Bias= Surge control line offset
This equation is the basis for the majority of applications. Some applications require more
parameters (P1 orT1) to be monitored in order to compensate for their effect over the actual
compressor surge line position
5.2 SYSTEM FEATURES
Solar's surge control software has been designed with enough flexibility to be easily
configured either at the factory or in the fieldo The control loop includes the following
features:
• Special Proportional and Integral (P + 1) algorithm for fast response
• Controller P + I function includes anti-reset windup
• Adaptive P + I tuning constants for asymmetric output
• Control loop transmitter failure detection logic
• Adjustable surge control loop enable speed
• Compressor surge margin real-time calculation
• "SURGE DETECTOR" circuit as a function of the compressor suction flow rate-of-
change
• AUTO/MANUAL control with bumpless transfer
• Automatic interaction with the process control loop (Optional)
• Automatic manual mode override when the compressor operating

condition is approaching the surge controlline
In addition, the surge control display screen (Figure 5.2.1) provides the following
information to the user.
• X-Y display of compressor ..6.P (psid) versus Flow ("H20) showing surge
control and deadband lines along with the actual compressor operating
point
• Compressor..6.P (psid)
• Compressor suction flow ("H20)
• Control loop setpoint
• Control loop output to valve
• Valve position feedback
• Gas producer and power turbine speed
• Compressor surge margin (%)
• Compressor mass flow in MMSCFD (optional)
5.2.1 P + I Algorithm
Solar's surge control P + I algorithm is based on the following equation:
Ot = Ot-1 + et(Kp + kI t/2) + et-1(kI T/2 - Kp) ;
Where;
Ot= surge controller output at time “t”
Ot-1= surge controller out at time “t-1”
et= error (sp-pv) at time t
et-1= error (sp-pv) at time t-1
kI= integral gain
T= Scan time in seconds
Kp= proportional again
This algorithm will produce a fast response of the surge control loop when sudden load
changes move the compressor operating point toward the surge control line.
5.2.2 P + I Anti-Reset Windup
This function stops the P + I controller output from changing when it reaches the
maximum orthe minimum Iimits (4 or 20 mA). This will provide a fast response ofthe
required control action and eliminate the possibility of overshoots or undershoots. The
anti-windup function acts mainly over the integral portion of the P + I controlling the
stopping of the integration of the "Error" when a Iimit has been reached.
5.2.3 Adaptive P + I Tuning Constants for Controller Asymmetric Output
This function allows the control loop to open the recycle valve fast (Iess than 2 seconds),
and c10se it slowly (between 30 to 45 seconds). The asymmetric response is achieved by
detecting the direction of the compressor operating point (toward or away from surge). If
the compressor is approaching surge, the P + I controlleris set with fast tuning constant
(high gain). If the compressor operating point is getting away from the controlline, then
the P + I controller is set with the low tuning constants (Iow gain).
5.2.4 Control Loop Transmitter Check
The surge control software will verify that compressor suction flow and differential
pressure transmitters are working within range. If any one ofthe transmitters is not within
range, (Iess than 4 mA, typically 2 to 3 mA setting), the engine will shut down (cooldown
stop on Centaur and Mars applications) and the message "ANTISURGE CONTROL
TRANSMITTER FAILURE" will be displayed on the package control system alarm
display screen.
5.2.5 Surge Control Enable Speed
The surge control loop is enabled when engine speed is greater than a preset value
(typically 90% Ngp). Below this preset value, the recycle valve will be 100% open. When
engine speed is greater than the preset value, the surge controller will open or close the val
ve as required by the process. The enable speed can be entered using the package control
system K-value screen.
5.2.6 Compressor Surge Margin
The Solar surge control software computes the proximity of the compressor operating point
to the surge line in real time (one per sean about 70 ms). The output value of this
calculation is shown as percent of flow. This parameter can be used in some applications as
the process variable to control a station recycle valve or to trigger a remote alarm. The
equation that computes surge margin is as follows
5.2.7 Surge Detector

Solar's antisurge control system is furnished with a "SURGE DETECTOR" function
(Figure 5.2.2). This function will compute the compressor suction flow rate-of-change and
compare it with a preset value (typically 15 to 25% per second). Ifthe computed value is
greater than or equal to the preset value, one pulse is counted and the P + I controller
output is overridden. This reducesthe outputby 10to 15%, so thevalve will open 10to 15%
more regardless what the P + I controller tells the output to do.
If five (5) of these pulses are detected in less than 10 seconds, the engine is shut down and
the message "COMPRESSOR IN SURGE" is displayed on the package control system
surge control display screen.
5.2.8 Auto/Manual Function
The auto/manual function enables the operator to place the antisurge control loop in
manual mode and operate the recycle valve. However, if the control loop is in MANUAL
mode and the compressor is approaching the antisurge controlline and eventually hits the
controlline DEADBAND, then the loop is automatically set back to auto and the message
"MANUAL MODE INHIBIT" is displayed on the surge control screen (Figure 5.2.1).
In order to provide bumpless transfer when going from auto to manual, the manual output
tracks the P + I (auto) output while the loop is in AUTO mode. From manual to auto mode,
the valve position is changed (closed) at arate of above 7% per second until the valve
output reads the P + I controller output.
5.2.9 Surge and Process Controllnteraction

These two controlloops tend to be stable with Iittle interaction. However, a greater degree
of interaction between capacity (pressure) and antisurge control may be expected with high
static loads (reducing the slope of the load line) or steep speed lines. In such a case, the
recycle valve may have more effect on pressure, and speed may influence the surge
calculation to a greater degree. To avoid this interaction, Solar's antisurge control/process
control system provides "decoupling" of the two loops by telling the process control P + I
controller not to change engine speed when the compressor operating point is between the
surge controlline and its deadband line.
This decoupling function between the antisurge control and process control guarantees
compressor and process stability.
5.3 ALGORITHMS
5.3.1 Standard Surge Control Algorithms

Solar has developed a series of antisurge control algorithms for the package
microprocessor-based control system. These algorithms (used as schemes) are designed to
accommodate the majority of applications, although there will be cases' in which the
standard schemes will require modification in order to accommodate process transients.
The standard algorithms are listed in Table 5.3.1.
5.3.2 Sales Order Special Algorithms

Other available algorithms that can be implemented as "specials" are listed below:
• Flow/ AP with flowmeter on discharge side
• Flow/ AP scheme for a variable IGV compressor (other than Solar
• compressor)
• Flow/AP scheme for compressor with side stream line
• Flow/ AP scheme for series/parallel compressors • Flow (CFM)/compressor speed
scheme
For more information, contact Solar Turbines Customer Services
5.3.3 Flow/ ~p Algorithm (SCA-1)

The Flow/∆P algorithm used in surge control scheme SCA-1 (Figure 5.3.1) is based on the
Flow/∆P equation, and is more suitable when process transients are slow. Gas
transmission, gas injection, and gas lift applications are examples where this algorithm can
be applied. The main advantage of this algorithm is that the compression efficiency is
maintained at the maximum possible level under operating conditions. This is
accomplished by recirculating the exact amount of gas required to keep the compressor
operating point at the control line during transient conditions with little waste.
The controller is equipped with proportional, integral, and batch reset functions. The batch
reset function is very important because it prevents controller wind-up during normal
operating conditions. Wind-up can delay the controller response during transient
operations, and the compressor may go into surge before the controller is able to respond
(unwind).
This algorithm is also equipped with "Asymmetric Output" action which ensures
compressor and process stability.
5.3.4 Flow/∆P Algorithm with Suction Pr~ssure Compensation (SCA-2)
The main effects of changes on the compressor suction pressure are over the surge line
offset bias. Although there is an effect over the slope of the surge line, it is almost
insignificant when compared with the offset (bias).
The flow/∆P suction pressure compensation (Figure 5.3.2) option should be considered
when the expected suction pressure changes are greater than 300 psia (2068 kPa abs)
5.3.5 Flow/~P Algorithm with Suction Temperature Compensation
Thermodynamic analysis assumes that compressor suction gas temperature and specific
gravity are constant. This assumption is true in a majority of the centrifugal compressor
applications. Under this condition, SCA-1 can be used. In some applications, it is
necessary to determine the effect of these variables over the surge line. For these
applications, alternate algorithms would apply as iIIustrated in schemes SCA-3 and SCA-4
(Figures 5.3.3 and 5.3.4)
The effect of suction temperature over the surge line is shown in Figure 5.3.5. When the
inlet temperature increases, the surge line swings down to the right and the compressor is
mor~ likely to go into surge. In order to maintain a constant protection margin, the "Kc"
value for the controlline must be a function of the suction temperature as indicated in the
following equation
5.3.6 Logic Block Diagram

Figure 5.3.6, Sheets 1 through 6, illustrates the logic flow of the Solar Surge Control
software.
5.4 SOFTWARE CONFIGURATION
The surge control software has been designed for easy configuration either at the factory ,
or in the field. The variables that can be configured through the package control system K-
values screen are listed and described in Table 5.4.1.
Notes
While the PLC function address and description will remain constant, PLC symbols may
change from sales order to sales order. Later versions of software may also reflect
variations in symbols.
Refer to the Solar Surge Control System Drawing No. 149653 or Software Drawing No.
149741 for specific K-values and system normal settings.

Filosofia de Control

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Filosofia de Control

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Data Book Solar Surge Control for

Data Book Solar Surge Control for

1.1.1 Centrifugal Gas Compressor Impeller

Fig. 1.1.1 Compressor impeller

1.1.2 Gas Flow through a Centrifugal Gas Compressor

Fig 1.1.3 centrifugal Compressor Internal components

1.1.3 Compressor Pressure

1.1.3 Compressor Pressure

1.1.4 Compressor Performance

1.1.5 Compressor Performance Calculations

Performance calculations for a centrifugal compressor require the following information.

• Ratio of specific heats (k), Cp/Cv

• Average compressibility (Zave) is the compressibility factor at the average

For the compression job to be accomplished (any three of the following):

• Suction pressure (P1) psia (kPa abs)

• Discharge pressure (P2) psia (kPa abs)

3. Capacicity, Qact actual inlet volumetric flow rate),

4. Efficiency Effy (Expressed As %)

5. Power consumption, PWR, Hp (Kw)

Hp = C4 head Qstd SG/EFFY

6. TEMPERATURE RISE, ∆T (across the compressor)

7. Compressor suction flow, Qstd (at specified pressure ratio)

Qstd = PWR EFFY / C4 Head SG

8. Pressure ratio, p2/p1 (at specified throughput)

9. COMPRESSOR SUCTION FLOW, QSTD by following AGA Report # 3

Comparing engine performance curves to the calculations in equations 2 through 5, it can

It is possible to apply Solar's centrifugal compressor line to many different conditions by

2.1 DESCRIPTION OF SURGE

Figure 2.1.2 Impeller Flow Path

Although a centrifugal compressor stage, operating at constant speed, will surge at

2.2 CONDITIONS THAT MAY CAUSE SURGE

• Recycle line injection opposes process gas thereby reducing process

In an application with compressors operated in series, the loss of an upstream compressor

Surge can be mild and almost undetectable, or it can be violent.

• Significant increase in discharge temperature

• Rapid pulsation of flow and discharge pressure

• Increased axial and radial vibration levels

2.3.2 Violent Surge

• Loud c1attering noise from the compressor

• Successive slamming of the discharge check valve

• Significant increase in discharge temperature

2.4 EFFECTS OF SURGE

3.1 GENERAL DESCRIPTION

Surge at a given speed is caused by an excessive differential pressure across the

3.2 FUNCTIONAL DESCRIPTION

3.3 COMPONENT DESCRIPTION

∆P= diferential pressure across the compressor, Psid

5.2 SYSTEM FEATURES

• Automatic manual mode override when the compressor operating

5.2.2 P + I Anti-Reset Windup

5.2.3 Adaptive P + I Tuning Constants for Controller Asymmetric Output

5.2.7 Surge Detector

5.2.8 Auto/Manual Function

5.2.9 Surge and Process Controllnteraction

5.3.1 Standard Surge Control Algorithms

5.3.2 Sales Order Special Algorithms

5.3.3 Flow/ ~p Algorithm (SCA-1)

5.3.4 Flow/∆P Algorithm with Suction Pr~ssure Compensation (SCA-2)

5.3.5 Flow/~P Algorithm with Suction Temperature Compensation

5.3.6 Logic Block Diagram

5.4 SOFTWARE CONFIGURATION

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