1 - Compressors and Surge Control Rev0 - C - S5

© Compressor Controls Corporation
Compressors and Surge

Types of Compressors
• Positive Displacement
• Rotating
Positive Displacement
• Reciprocating (Piston)
• Screw
• Lobe
Reciprocating (Piston)
Rotary Screw
Air Compressors
• Also Positive Displacement Machines
• Normally 200HP to 1000HP
Lobe Compressor
Source: hahnconsultinggroup.com
• Axial
• Centrifugal
Rotating
Cross section of horizontal split
Discharge volutes Impeller inlet
labyrinth seals
Impellers
Shaft and
Drive coupling labyrinth seal
Journal bearing
Casing Thrust bearing

(horizontally split
flange) Compressor
discharge nozzle
Compressor
inlet nozzle
Picture of axial compressor

Centrifugal compressors
• Widespread use, many applications
• Gas is accelerated outwards by
rotating impeller
• Can be built for operation as low as
5 psi, or operation as high as 8,000 psi
(550 Bar or 55,000 kPa)
• Sizes range from 300 hp to 50,000 hp
DIFFUSERS
Cross section of horizontal split
Picture of horizontal split
Cross section of barrel

type compressor
Picture of barrel
type compressor
Cross section of
bull gear compressor
Picture of bull
IMPELLERS gear compressor
Picture of (bull)
Single Case Compressor Centrifugal Impeller gear and impellers
Rotor and Stator damage due to
Surge
Broke
Horizontal split compressor
Picture of horizontal split

Cross section of barrel type
compressor
Picture of barrel type compressor on a
skid
Cross section of bull gear compressor
Labyrinth seals
Drive coupling
Impellers
Main gear
Journal bearing
Inlet guide vanes Pinion shafts
Gear casing
Compressor volutes
Picture of bull gear compressor

Axial compressors
• Gas flows in direction of rotating shaft
• Can be built for lower pressures only 10 to
100 psi (6.89 Bar or 689 KPa)
• High flow rate…Used in Gas Turbines and as blower
or upstream!
• Efficient (for high flow)
• Not as common as centrifugals
• Much more sensitive to Surge
Stator Blades
Rotor Blades Shaft
Casing
Rotor
Blades
Stator
Blades
Casing
Axial-Hybrid Compressor
Guide-vane
actuator linkage Labyrinth seals
Compressor rotor
Rotor blades
Adjustable guide vanes
Compressor Compressor
inlet nozzle Thrust bearing outlet nozzle
Compressor system classifications
Single-Section, Three-Stage Single-Case, Two-Section, Six-Stage
Two-Case, Two-Section, Six-Stage (LP & HP)

Parallel Network (More Q)
Series Network (for very high Rc)

Compressor Performance Curves
and Surge
Resistance Curve
Low
~
Resistance
5000 rpm
High
~
Resistance
5000 rpm
Load
Valve
Can model all system resistance

Compressor Maps
• The intersection of these two curves

– Performance Curve
– Resistance Curve
shows us the location of the

Operating Point
(OP)
of the Compressor
What is the compressor curve?
• The compressor provides us with pressure

and flow.
• The compressor curve shows the

relationship between pressure and flow.
• If we just measure the pressure (using a

pressure transmitter) and flow using a flow

transmitter) we can then determine the
curve shape…
• The Operating Point of a compressor is

determined by the intersection of process
resistance curve and its performance curve.
Developing the compressor curve
Hp Polytropic Head
Rc Pressure Ratio (Pd/Ps) or (P2/P1)
Pc Differential Pressure (Pd - Ps) or (P2 - P1)
Pd Discharge Pressure (P2) R process,2
Rc
Rprocess,1
The force that works
against the compressor.
(invisible line)
Rc2
Rc1
Compressor curve for a

1. specific speed N1
2. IGV angle, or
3. Inlet-valve opening
percentage
Q2 Q1 Qs, vol [m^3/hr]

Qs, mass (W) [Kg/hr] .
Used to define the driver
power.
Developing the compressor curve
Rc
Adding Process limit
Safety
Margins
Maximum speed
Surge Limit Line (SLL) or Performance
Surge Control Line (SCL) Power limit
Stonewall or
choke limit
Stable zone
of operation
Actual available Minimum speed
operating zone or Performance
(Operational Envelope)
Qs, vol
Efficiency Curves
• Appear as elliptical curves approximately

centered on the compressor map
• The inner-most curve represents the area

of highest efficiency
• This area will includes the compressor’s

Design Point
Efficiency Curves
Centrifugal
72% to 85% Design Point (Best Point)
Axial
88% to 92%
What is Surge?
Surge: Inability for the compressor

to sustain the forward flow. Flow
collapses ( )on the impeller.
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 A the potential energy in the vessel
exceeds the capability of the compressor
• Because Pv > Pd(max) , the flow reverses
• Pressure Pd drops and forward flow is Pv
reestablished
• Excessive surge, i.e. surge count ≥3
(within a specified time).
Pd
B A Pd = Compressor discharge pressure
Pv = Vessel pressure
D
C
• From A to B….20 - 50 ms…….. Drop into surge

• From C to D....20 - 120 ms…… Jump out of surge
• A-B-C-D-A….0.3 - 3 seconds…… Surge cycle
Qs, vol
API 670 reference

API 670 reference

Surge description
• Flow reverses in 20 to 80 milliseconds

• Surge cycles at a rate of 0.3 s to 3 s per
cycle
• Compressor vibrates
• Temperature rises
• “Whooshing” noise (as large volumes of

gases reverse)
• “Banging” noise (as check valve slams
shut and slams open)
• 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
• Reduced compressor life

Factors leading to onset of surge
• Startup
• Shutdown
• Operation at reduced throughput (production)
• Operation at heavy throughput with:
– Trips
– Power loss
– Operator errors
– Process upsets
– Load changes
– Gas composition changes
– Cooler problems (blockage…)

– Filter or strainer problems
– Driver problems
• Surge is not limited to times of reduced

throughput.
• Surge can occur at full operation
• Other reasons:
• Transmitter improperly calibrated
• Impulse lines are plugged or contain moisture
• ASV is sticky when opening/closing
Major Process Parameters
during Surge
FLOW
Using high speed

recorder/HMI:
1 2
TIME (sec.)
3
• Rapid flow oscillations
PRESSURE • Thrust (Push) reversals
• Potential damage
• Rapid pressure
oscillations with
1 2 3
TIME (sec.)
process instability
TEMPERATURE
• Rising temperatures
inside compressor
1 2 3
TIME (sec.) Operators may fail to
recognize surge
How far the Compressor is
away from Surge?
Commonly used (OEM provided)
coordinate systems of the compressor map
400 6
350
5 o
o o oo o
300 o
o oo o o
o 4 o
250
o ooo o o
o
200 3 o
oo oo o
o o
oo o o
150 o
o o 2 oo o
o
o o oo o
ooooo o o oo
100 o
o oooo o o oo o
o o o o
oo o o o
1
50
0 0
0 500 1000 1500 2000 2500 3000 0 500 1000 1500 2000 2500 3000
Qs
Qs
Different inlet conditions produce different SLL locations

Distance from Surge
Fact:
– The more accurately we can measure the distance to surge,
the closer we can operate to it without taking risk
Challenge:
– The surge limit line changes depending on the compressor
inlet conditions: Ts, Ps, MW, ks (gas const.)
Conclusion:
– Compressor maps based on only measurement of pressure

and flow are not invariant to changing inlet conditions. They
are provided for certain Suction conditions.
– The antisurge controller must provide a distance to surge

calculation that is invariant of any change in inlet conditions.
Commonly used (OEM provided)
coordinate systems of the compressor map
• Typical compressor maps include: (Qs, Hp),

(Qs, Rc), or (Qs, Pd) coordinates, where:
Qs = Suction flow and can be expressed as actual
or standard volumetric flow
Hp = Polytropic Head
Rc = Compressor Ratio (pd / ps)
Pd = Discharge pressure of the compressor
Ps = Suction pressure of the compressor
ks = Exponent for isentropic compression
• These maps are defined for (1) specific set

of suction conditions: Ps, Ts, MW and ks.
That’s why an invariant coordinate space should
be defined since it is not affected by the suction
conditions.
Deriving Invariant Coordinates
Where:
Zs,d = Compressibility in Suction, Discharge
Equations for Zs + Zd
Polytropic Head & Zavg = Average Compressibility =
Ts = Suction Temperature
2
Volumetric Flow2 : Rc = Compression Ratio =
Pd
Ps
Pd = Discharge Pressure

R 1 Ps = Suction Pressure
Hp  Z avg R Ts   c
R=
Ru
- Gas Constant
MW
 Pos MW = Molecular Weight

Qs  Z s R Ts 
2 Ru – Universal Gas Constant
Ps  k- 1
k = Specific Heat Ratio =
Cp
kp Cv
Cp = Specific Heat at Constant Pressure
Cv = Specific Heat at Constant Volume
p = Polytropic Efficiency
Polytropic head Hp = [Jule/kg] or [kgfm/kg]….
How much energy this compressor is giving to the gas.
Invariant Coordinates
Reduce each equation by a factor A:
A  Z s R Ts

Rc  1 Pos
Zavg R Ts . 2 Zs R Ts .
Hp  Qs

Ps
 q2s,red
A
  hp, red A Zs R Ts
Zs R Ts
R is Reynold const. From experience, we know

that the ratio of the compressibility Zavg/Zs
varies negligibly. Assuming it to be constant
over the compressor operating range:

h p,red Rc  1
  q2s,red  Pos
Ps
 Calculation
• The relationship between pressure &
temperature for polytropic compression
leads to a practical way to measure
polytropic constant  : 
Td Pd 
= = Rc
Ts Ps
log Td
Solving for :  =
Ts
log Pd
Ps
Another way to calculate 
• Another way to calculate sigma is to get the polytropic efficiency p (eta)

from compressor data sheet, then:
Cp= specific heat at constant pressure,

Cv= specific heat at constant volume.
ks= ratio of specific heats at suction
kd= ratio of specific heats at discharge
• For an ideal gas, the ratio of specific heats ks= (Cp/Cv) is the same as the
isentropic exponent (kavg). We normally use this way or the previous way.
ks=kavg=(Cp/Cv) 
• For real gases:
kavg=(Cp/Cv)/((Cp/Cv)-1) OR OR
Reduced coordinates
Advantage of Invariant Coordinates
Illustration (1)
NOT invariant (Hp, Qs) Invariant (hr, qr2)

CCC
400 10
9
350
8
o o oo o
300 o
o oo o o 7
o o
250 6
o ooo o o o
o 5
200
oo oo o
o o
oo 4
150 o
o
o o
o 3 oo
100 ooooo o
o oo
o
2 oo
o
oo
50 ooo
o
1 oooo
oo
oo
o
0 0
0 500 1000 1500 2000 2500 3000 0 1 2 3 4 5 6 7 8 9 10
q2r
Qs
Legend:
Hp = Polytropic head
Qs = Volumetric suction flow
hr = Reduced head
qr2 = Reduced flow squared
Advantage of Invariant Coordinates
Illustration (2)
NOT invariant (Rc, Qs) Invariant (Rc, qr2)

6 6
CCC
5 o 5 o
4 o 4 o
3 o 3 o
o o
o o oo
2 oo o
2 ooo
o o oo o o
ooo
o o oo ooo
o oooo o o oo o
o
o oo o o o oooo
oo ooo
1 1 o
0 0
0 500 1000 1500 2000 2500 3000 0 1 2 3 4 5 6 7
Qs q2r
Legend:
Rc = Pressure ratio
Qs = Volumetric suction flow
qr2 = Reduced flow squared
Advantage of Invariant
Coordinates Illustration (2)
Hydrogen Recycle Compressor Invariant Coordinates
Surge Points - Mode fA 65
1.2
Variant Coordinates
Actual Surge Plot 1 6
40
56
.8 5
4
36
6 4
35 35
.6
6
6 4
5 32
Reduced Head
2
36
45
5 .4 12
15
30 4
36
6 3 512
14
2
3
5 3 .2
21
1
6
25
Dis. Pressure Psig
3
0
6 3
5
5
20 6 3 -.2
5
3
-.4
-.4 -.2 0 .2 .4 .6 .8 1 1.2 1.4
15 Reduced Flow [none]
4 Curve 1: MW = 4.62; Ps = 6.033 kg/cm2 a

4
4
Curve 2: MW = 5.90; Ps = 6.800 kg/cm2 a
2
10 4 2
2 Curve 3: MW = 7.90; Ps = 14.900 kg/cm2 a
4
2
4
2
2
1
1 1 Curve 4: MW = 8.20; Ps = 6.800 kg/cm2 a
1 1 1
Curve 5: MW = 9.70; Ps = 14.900 kg/cm2 a
5
Curve 6: MW = 10.8; Ps = 14.900 kg/cm2 a
1500 2000 2500 3000 3500 4000 4500 5000
Vol. Inlet Flow - ACFM [ACMH]
Actual Cubic Feet per Minute
Distance From Surge
is a Moving Target
For Off-Gas • Most all process
compressors will also
For Nitrogen have to operate in off-
design conditions
• Automatic antisurge
control must be able to
2013 Compressor Controls Corporation
For Design stage operate under varying

operating conditions:
– Suction Temperature
Design Nitrogen Off-gas
– Suction Pressure
MW
Ps
MW
Ps
MW
Ps
– Gas Composition
Ts Ts Ts – Rotational Speed
ks ks ks
Replacing hr with Rc
• Reduced Head hr can be replaced by Rc (Rc=Pd/Ps)
while keeping the coordinate system less
dependant upon suction conditions
f (R )
• The surge parameter Ss now becomes Ss = 1 2 c
qr,op
where the function f1( ) returns
the value of qr,SLL
2 on the SLL for
the input Rc
• This eliminates the need for Td and Ts transmitters for

control
Important Note: Td , Ts , and rotational speed (N) are
still recommended inputs for your anti-surge control
system for monitoring and event archiving purposes
• FT should be connected to suction. If FT is measured at the
discharge then (in S3 we use a different fA mode, and in S5:
dpo_comp_mode = UNCOMPENSATED ....dpo at suction
dpo_comp_mode = DISCHARGE ....dpo at discharge
Antisurge Control
Working with Invariant Coordinates
The reduced coordinates

hr define a performance map
SLP (Surge Limit Point) which:
OPL (Operating Point Line) • is invariant to changing
OP (Operating Point) inlet conditions
• has one surge limit
point for a given
rotational speed and
compressor geometry
• permits calculation of
h p,red the operating point
Slope OPL= 2
q s,red without difficulty to
obtain molecular
2 weight and
qr compressibility
measurements.
Performance Curve Drawn in
σ
Reduced Coordinates
h p,red = Rc -
σ
1 q2s,red = Pos
Ps
Distance From Surge Calculation
The controller continuously
calculates:
SLL (Surge Limit Line)
The ratio of the slope of the
Surge Limit Line & the slope of
hr the Operating point line:
Performance Curve
Operating SlopeOPL
Point Ss =
SlopeSLL
When Ss = 1, Then we are

OPL (Operating surging.

Point Line)
Ss The : Angular distance
between the OP and the SLL
point (Proximity to Surge Limit
2
Line).
qr
• Variable Ss defines the relative slope of a line from The distance between the
the origin to the operating point. operating point and the surge
• Ss is calculated each 5ms and averaged each 40ms. limit:
• Ss= 0 to 1 (right side of the SLL)
• Ss=1 to 2 (left side of the SLL) d = 1 - Ss
Ss vs. Operating Point Distance
h r /q 2r,op
Ss 
h r /q 2r,SLL
Controller Deviation
DEV = (-)…Bad…PI action…A/S
valve will open proportional to the
error. The more Dev is -, the more
the valve will open. RT might be
needed (coming soon). The controller calculates
deviation from the SCL
as:
hr DEV = d - b1
Where:
d = 1 – SS
b1 = the relative distance
DEV = (+) Good

between the SLL &
the SCL
b1 = 0 – 100 (S3+/++)
b1 = 0 – 1 (S5/S6)
DEV represents the

qr
2 distance between the
• When the deviation is positive, the antisurge PI response will gradually
operating point and the
close the antisurge valve to minimize unnecessary recycling.
• When the deviation is negative, the PI response will open the antisurge
surge control line.
valve as needed to restore the desired surge control margin.
Distance From Safety Margin (SCL) Calculation
“Deviation” is the most important number the

Antisurge Controller calculates
A Deviation (DEV) of 0 is the setpoint for the

Antisurge Controller
The Antisurge Controller will not open the valve until

DEViation becomes 0 and continues to negative*
DEV > 0 Safe and no recycle

DEV = 0 Safe and some recycle
DEV < 0 Danger AND recycle
*(There are some exceptions like FB, LC, POC, Limit)

Example 1
Given b1=0.5, and DEV = +0.3 . Find the

value of Ss calculated by the controller?
hr
Solutions:
DEV = d – b1
=1 – Ss – b1
OP Ss = 1 – b1 – DEV
= 1 – 0.5 – 0.3
= 0.2 which is less than 1 (0 to 1) then
the operating point is to right of the SLL.
2 Distance from OP to SLL d= 1 – Ss = 0.8

qr
Example 2
Given b1=0.5, and DEV = -0.2 . Find the

hr
OP
Solutions:
DEV = d – b1
=1 – Ss – b1
Ss = 1 – b1 – DEV
= 1 – 0.5 +0.2
= 0.7 which is less than 1 (0 to 1) then the
operating point is to right of the SLL.
2 Distance from OP to SLL d= 1 – Ss = 0.3

qr
Example 3
Given b1=0.5, and DEV = -0.8 . Find the

hr
Solutions:
OP
DEV = d – b1
=1 – Ss – b1
Ss = 1 – b1 – DEV
= 1 – 0.5 + 0.8
= 1.3 which is more than 1 (1 to 2) then
we are in surge.
2 Distance from OP to SLL d= 1 – Ss = -0.3

qr
Basic Antisurge Control System
• The antisurge controller UIC-1 (User-defined A/S Indicating

Controller) 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
• A/S valve is chosen as fail-open. R process
Rc
VSDS
Rprocess+valve
Compressor
FT PsT PdT
1 1 1
Suction Discharge
UIC 2
1 qr
Surge parameter based on invariant
coordinates
– Flow measured in suction (Po)
– Ps and Pd transmitters used to calculate Rc
Recommended example of ASV
Locations
What affects the value of b1
(Distance from SLL to SCL)?
• Stroking speed of the valve. Closing time needs to be the

same order of magnitude to assure optimized loop gain works well in both directions.
• Capacity of the valve
• Discharge volume to upstream of

antisurge valve. This is determined by distance of

antisurge valve from the machine (piping) (diameter and
length of pipes…the longer the pipe is the slow the
response…so we need to increase our safety margin b1).
2
1
How close the lines should be?
The Surge Control Line (SCL)
The first defense line
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
adequate protection
for small disturbances
2
qr
• PI control will give stable control during steady
state recycle operation
• Kp: Proportional Gain, Kr: Integral reset.
• Slow disturbance example
• If PID is used, then the valve will keep oscillating
The Recycle Trip® Line (RTL)
the second defense line
Rc SLL = Surge Limit Line
RTL= Recycle Trip® Line • Disturbance arrives - the
SCL = Surge Control Line operating point moves past
the SCL initiating Proportional
& Integral (PI) control action
OP
• If the operating point hits the
RTL, the conclusion is:
– We are close to surge
– The PI controller was too
slow to catch the
disturbance
2 – Move the valve now!
Output Q
to Valve • An open loop response is
Recycle Trip® Response
triggered and the operating
(Step Response)
point moves to a stable
position
PI Control Response
• RTL is defined by RT distance

Time from SCL.
Output
to Valve • After the operating
point moves back to
the safe side of RTL,
PI Control Response the open-loop function
Recycle Trip® Response should be ramped out
– PI controller will stabilize
Time
the operating point on the
SCL until normal process
flow in re-established
• For large, short duration disturbances a fixed ramp out

of the open loop response may hold the antisurge valve
open too long
– Could result in an unnecessary loss of process flow
– Antisurge controller should utilize its distance from surge
calculation to accelerate the exponential decay
Output
to Valve
• Total response of the
controller is the sum of
Total Response
the PI control and the
PI Control Response Recycle Trip® action
Recycle Trip® Response
Time
Benefits:
– Energy savings due to smaller

PI Control
Recycle Trip® required surge margins
Action
– Compressor has more turndown
before recycle or blow-off
+ – Surge can be prevented for
virtually any disturbance
To antisurge valve
Improving the Accuracy of
Recycle Trip®
• Open loop response is the fastest way to
get the antisurge valve open
– But, open loop control lacks the accuracy
needed to precisely position the antisurge
valve
• By definition, open loop corrections of a
fixed magnitude are often either too big or
too small for any specific disturbance
– The rate of change of the position of the

compressor operating point has been proven
to be an excellent predictor of the strength of
the disturbance
– This derivative calculation can be used to
adjust the magnitude of the open loop
response
Recycle Trip® Based on
Recycle Trip
®
Derivative of Ss
Response calculation:
*Put RT_Td=1 and RT_min=0 to see the effect of dSs/dt.

Maximum RT_CR = RT_max.
*RT_test will test an RT_max step response on the process.

Output Output
to valve Medium disturbance to valve Large disturbance
100%
Total
PI Control
Total
PI Control
Recycle Trip® Recycle Trip®
0%
Time Time
Multiple Recycle Trip® Steps
After time delay C2 (RT_deadtime in S5) controller
checks if Operating Point is back to safe side of
Recycle Trip® Line
- If Yes: Exponential decay of Recycle Trip® response
- If No: Another step is added to the Recycle Trip® response
Output
to valve Multiple step response
Output
to valve One step response Total
100% PI Control
Recycle Trip®
Time
C2 C2 C2
Total
PI Control
Recycle Trip®
0%
Time
C2
Recycle Trip® LED in S5/S6
The Recycle_Trip discrete output (RT indicator on the AS faceplate) is set to
True when a Recycle Trip has occurred within the Antisurge controller. It is
reset to False if :
1. The controller output reaches the low clamp, or

2. Another control response opens the valve, (like PI, Limit, or POC) or
3. An internal five-minute timer expires or
4. Controller is switched to Manual
The RT_decay_time status variable gives the amount of time remaining in the
five-minute timer.
RT output is decayed using the
Integral part of the PI loop in
S5/S6
Multiple Recycle Trip® Steps
A/S
Rc Output
3 2
1
4
5 0
0 1 2 3 4 5 Time
Qs
Closed loop (PI) vs. Open loop
(RT) responses
This comparison makes PI response a closed loop:
-PI loop: The PV (DEV) is compared with the SP (DEV=0). When PV is below the SP (meaning that DEV becomes
negative) then we will have an error. This error will pass to our PI response block to generate a PI signal to the valve.
This will increase PV (DEV) to return it back to the SP (DEV = 0) to eliminate the error; accordingly the OP will stay
on SCL for this disturbance.
-RT loop: The RT response is a result of crossing the boundaries or RT_distance. RT response is added to the valve
without any SP to return to.
Safety On® Response (SOL)
the third defense line
SOL - Safety On® Line
SLL - Surge Limit Line • If Operating Point crosses the
RTL - Recycle Trip® Line Safety On® Line the compressor is
SCL - Surge Control Line
Rc in surge
• SOL is defined to overcome errors
when calculating SLL
• The Safety On® response shifts
the SCL and the RTL to the right
• Additional safety or surge margin
is added (b=b1+(b2 x n))
• PI control and Recycle Trip® will
New SCL stabilize the machine on the new

SCL
New RTL
Compressor can surge due to:
2 – Transmitter calibration shift
Additional surge margin (b2) qr – Sticky antisurge valve or
actuator
– Partially blocked antisurge
Benefits of Safety On® response: valve or recycle line
- Continuous surging is avoided – Unusually large process
- Operators are alarmed about surge upset
Quiz
Determine the lines on the invariant coordinates?
 Define SLL (from OEM)
SOL - Safety On® Line
SLL - Surge Limit Line  Adjust b1 = 0.2 (Safety Margin)
RTL - Recycle Trip® Line (Distance from C to A)
Hp red SCL - Surge Control Line  Adjust RT_distance=0.1
(Distance from A to B)
 Adjust SO_distance=0.1
D C
B A (Distance from C to D)
OP
 Then:
 @A, DEV=
0
 @B, DEV=
-0.10
2  @C, DEV=
qred
-0.20
 @D, DEV=
-0.30
 Distance A to OP is 0.15; DEV @OP=
+0.15
Antisurge Controller Standard
Faceplate
Multidimensional coordinate
system representation
In case of a Variable-Speed Compressor, the Surge Points for different Speed Curves will hardly
ever be located on a single straight line through the origin of the Operating Map. Same thing
will happed if there are IGVs.
For example, if the “F1(RC)” numerator and “DPO/PS” denominator modes are selected, the f2
characterizer is a function of speed (N), and the f3 characterizer is a function of guide vane
angle (alpha), Ss would be calculated as:
For fixed speed and no IGVs:

For variable speed and no IGVs:

SCL Derivative
Response Algorithm
• When the operating point moves quickly
towards the SCL, the rate of change
(dSs/dt) is used to dynamically increase
Rc the surge control margin (b=b1+b3x
Td0 x dSs/dt). (ex. Td0=5, b3=3)
B
• PI controller reacts earlier since OP will
be hitting SCL earlier
A
• The derivative response is used to avoid

large disturbances only (there is no

need to increase the safety margin
when there is no need to do so)
• If the process is stable, then dSs/dt =0.
2
Q • If the process is stable then we can set
(FC3 =OFF, b=b1) otherwise (FC3=ON,
The bigger the disturbance, the faster b=b1+b3x Td0 x dSs/dt) SCL will keep
the Operating Point moves, the more swinging. If we operate at the SCL in
margin is added and the sooner the this case, we will have unstable
valve is opened. operation.
The b equation
• b = (b1) + (b2 x n) + (b3 x Td0 x dSs/dt)

- b1: Defines the minimum distance of the SCL from the SLL (after defining the SLL
from the invariant coordinates)
- b2: SOL coefficient while n is the surge count.
- (b3…): SCL derivative response. It represents the maximum margin that could be
added due to derivative response. Td0 is the derivative time constant.
• dSs/dt is the velocity of the operating point. The bigger dSs/dt

means we are moving faster towards surge.
• dSs/dt is the measurement of the stability of the process

• -1 <= dSs/dt <= +1
• Positive then the OP is moving towards surge and SCL to the
right
• Negative then the OP is moving away from surge and SCL is
returning to the left.
What does Td0 do?
• b = (b1) + (b3 x Td0 x dSs/dt)

• Td0 acts like a multiplier for dSs/dt
• It simply makes the controller more or less sensitive to

changes or disturbances in the process.
•The higher Td0 (say 10 as an example) the smaller the

disturbance it takes to get all of our extra safety margin.

What does dSs/dt term do?
•If Td0 = 1, then

•Stable process
•Small disturbance
•Higher disturbance
• b3 maximum derivative response constant.

• In S5 b3 is called deriv_response_max
• Note: Typical values for tuning:
b1=20 to 35
RT=0.5*b1
b2= 0.05 (25% of b1)
deriv_response_max = b1
C1(RT_max)=10 to 25
C2 (RT_deadtime)= 1 to 1.5 Sec.
Pb = 0.8 to 1.3 (or slower 0.5)
Kr = 3 to 5
- Usually within 20 or 30 sec , if we have excessive surge ( n =3) then we send an ESD signal.
- The excessive surge output is closed (energized) when the compressor is not surging, and open to trip (fail safe).
SO Folder in S5
SO deadtime in S5
SO_deadtime
• When SO_deadtime is set to less than 1.0, the operating point

must move back to the right of the SOL after a surge event
before another Safety On response can be triggered.
• When SO_deadtime is set equal to or greater than 1.0, surge

detection is suspended after a surge event for the specified
period of time. This allows time for the operating point to move
back to the right of the SOL before another Safety On response is
triggered. If the operating point is still to the left of the SOL after
the SO_deadtime has expired, the surge count will be

incremented and another Safety On response will be triggered.
Units/Range: seconds
Safety On and Excessive Surge in
S5
• Each antisurge controller can have two outputs configured; one
Modbus output representing the 1st surge detected (Safety On)
and one hardwired digital output for compressor trip (Excessive
Surge).
- The first output is activated when the Safety On response is

triggered.
- The second output, Excessive Surge, is triggered when the Surge

Count parameter exceeds the value of the Excessive surge
Threshold parameter.
- The Excessive Surge output is closed (energized) when the

compressor is not surging, and open to trip (fail safe).
Surge counters in S5
Surge_count
This status variable gives the current number of
surge events detected by the Antisurge Controller
through the Safety On Response and EAS Surge
Detection functions. The surge_count is reset to
zero by asserting the SO_reset command, or when
the Shutdown_SO_reset parameter is set to True
and the Antisurge Controller enters the Stop State
and the stopping ramp is complete.
Example: If a surge event was detected and the

excessive_surge_time expired before reaching
excessive_surge_thresh then this counter will
overwrite what was detected before even if reset
SO was not reset manually; to be ready for
excessive surge detection. Both SCL and RTL
will maintain their shifting; b=b1+(b2 x n).

Reseting reset SO manually will reset this
counter and will return b=b1.
Surge_count_total
The surge_count_total status variable gives the total number of
surge events detected by the Antisurge Controller. It is
incremented each time a surge is detected. The
surge_count_total must be manually reset to zero using the
surge_count_total_reset command.
The Tight Shut-off Line (TSL)
Assuming a low clamp is
Dynamic control range implemented*. When OP crosses TSL from left to
Controller right it shuts the valve off.
Flow rate output
through A/S valve is fully closed since
Controller Output:
valve Shows how much
DEV is +tive OUT = 0%
the A/S valve is

open PI Control D
E
A Time
Controller B C
output
• TSL position = TSO_distance % (ex. 10% off SCL)
Low clamp on controller output
0% to the valve •Here we assumed a low clamp is implemented. If
there was no low clamp then the valve will ramp
SOL SLL RTL

Rc SCL open from 0 at point C.
TSL = Tight Shut-off
Line
•The Tight Shut Off response fully closes the control valve
C to 0% (it forces 20mA to the valve) when it is at its low
B clamp position and the operating point is safely to the right
of the surge control line.
A
E
D Benefits
• No leakage and noise when controller is far
away from surge - point A
• Eliminates noise and energy waste
2
• Eliminates dead time in the response of the
qr antisurge valve when the operating point is
close to the SCL
TSO Release line

Antisurge Control Lines

2
1
How close the lines should be?
Cold Recycle (S) Control

Manual Override - MOR
• MOR = “On” is called Hard Manual.
• MOR = “Off” is called Soft Manual.
• The correct setting of MOR is normally “Off”.
• With MOR = “Off”, controller will switch from Manual to
Auto when Operating Point crosses the RTL, and will
bring the Operating Point back to the SCL.
• With MOR = “On”, controller is nothing but an open-
and-close button for your antisurge valve. The
controller ignores the calculation of DEViation and
gives no surge protection whatsoever.
• Used in Maintenance only (when adjusting the valve for

example where we don’t want to see any recycle flow).
Put MOR to ON to replace the transmitter since you
don’t know what process changes are there during
replacement.
• If you want to open the A/S valve manually, just go to
“Manual” and increase the OUT by pressing the
designated buttons on the S3+/S++.
Manual Override in S5V
• hard_manual_enable= “On” is called Hard

Manual
• hard_manual_enable= “Off” is called Soft
Manual
• Putting MOR or hard_manual _enable to

ON doesn’t put the controller in Manual
mode. To put the controller in Manual you

need to press Man/Auto on S3+/++
Operator panel, faceplate on TV, or from
Con5 (under command).
Limiting Ps or Pd using the
- Here we control the A/S valve opening (OUT%).

- The Selector selects the highest “priority”.
- If we are limiting Pd; suppose it went up then we open
the A/S valve to reduce Pd even if the DEV is +tive.
Limiting Ps or Pd using the
VSDS
Compressor
FT PsT PdT
1 1 1
Suction UIC
Discharge
1
• The antisurge controller can be configured to limit:

- Maximum discharge pressure (Pd)
- Minimum suction pressure (Ps)
- Both maximum Pd and minimum Ps
• This does NOT conflict with antisurge protection. If we have
loop1 as A/S and loop2 as Pd, then the controller will give
whichever is max valve opening (OUT%) to protect the
compressor.
Loop Decoupling for
Multiple Antisurge Controllers
Section 1 Section 2
PIC SIC Disturbance

1 1
UIC UIC
1 2
Disturbance comes from the

discharge side
• Pd,2 increases
• Ps,2 remains constant R
• Rc,2 increases Rc,2
• Section 2 moves towards surge R
Antisurge controller UIC-2 will open

the recycle valve to protect Section 2
against surge
• Pd,2 decreases 2
• Ps,2 increases qr,2
• Rc,2 decreases
• Section 2 moves away from surge
Loop Decoupling for
Section 1 Section 2
PIC SIC
1 1
UIC UIC
1 2
Opening the recycle valve on Section 2

causes Ps,2 to increase / Result:
R
• Pd,1 increases
• Rc,1 increases Rc,1 R
• Section 1 moves towards surge
UIC-1 will open its recycle valve to

protect Section 1 against surge
2
• Pd,1 decreases qr,1
• Ps,1 increases
• Rc,1 decreases
• Section 1 moves away from surge
Loop Decoupling for
Section 1 Section 2
PIC SIC
1 1
UIC UIC
1 2
• The system is oscillating

Opening of recycle valve on Section 1 • Slowing down controller
caused Pd,1 to decrease / Result: tuning could lead to:
• Ps,2 decreases - Increased risk of surge
• Rc,2 increases • Compressor damage
• Process trips
• Section 2 moves towards surge
- Larger surge margins
• Energy waste
Loop Decoupling for
Section 1 Section 2
• Antisurge controllers need to communicate in real time to

coordinate their control actions
• When UIC-2 opens the recycle valve:
- Section 2 will be protected against surge
- Section 1 will be driven towards surge
• How much Section 1 is driven towards surge depends on how
much the recycle valve on Section 2 is opened. (Decoupling Coof.)
• The output of UIC-2 is sent to UIC-1 to inform UIC-1 about the
disturbance that is arriving
Note: The same applies when the antisurge valve on Section 1 is opened first
Loop Decoupling for
• A decoupling control algorithm is designed to reduce and

eliminate the interaction between the loops. Also called
Feedforward control.
• Decoupling is achieved by adding a portion of the output of

controller A directly to the output of controller B.
• As a result, controller B actually begins its control action

before it sees the disturbance caused by controller A output.

Ideally, this proactive, feed forward control action would be
just enough to cancel the upcoming disturbance caused by
controller A output.
• (ex. If A/S 1 changed its output by 40 and LD2 is set to 0.20,

then 20% of the 40 will be 8% added to A/S 2 output)
• The loop-decoupling response can only be positive, so it will

never decrease the recycle flow rate.
Loop Decoupling for
• Decoupling is used to fine-tune the process and avoid oscillations.
• In S5, set the corresponding Packet IDs.
LD 1-8 : Decoupling Gains. Enter a decoupling gain value along with the
appropriate sign (positive or negative) in the fields corresponding to the
Application number from which this controller should be decoupled.
It should be positive if this recycle rate should rise with that of the
companion. It should be negative if this recycle rate should rise when
the other is reduced.
The loop decoupling response (CRLD) will be added to the output of an Antisurge
controller only under all of the following conditions:
The CRLD serves to open the antisurge valve. It will not be added if it serves to close the antisurge valve.
The Antisurge controller is currently operating to the left of its SCL. However, if a sending loop-decoupling
Antisurge controller is currently in a Recycle Trip Response, its loop-decoupling control variable (CV) will
produce a CRLD in the receiving Antisurge controller, even if the receiving Antisurge controller is operating to
the right of its SCL.
Fallback Strategies
Fallback Strategies in S5
How to calculate Run-Freeze
value
Cv ,max surge po int
default_out  120
Cv ,valve
(120,110,100,...)
This method of calculating default_out assumes that the valve has a linear
flow characteristic. Since in some cases, opening the antisurge valve upon
transmitter failure may upset the process, it is the policy of CCC Systems
Engineering to calculate CONST 1 as:
default_out = 0.
Which, when enabled with a 0 value, will maintain the antisurge valve at
the current opening (controller output will stay at its last value before the
transmitter failure). It is the responsibility of the Field Engineer to discuss
this fallback strategy with the customer, and implement as appropriate.
Minimum Flow Fallback and
Constant Sigma Fallback
Minimum Flow Fallback.
• If enabled, the Minimum Flow Fallback is triggered when a
dynamic minimum flow limit cannot be calculated (loss of a
pressure signal). The controller then falls back to minimum flow
control using minimum_flow_level. Minimum_flow_level is
calculated as:
Minimum _ flow _ level  Po ,max
Constant Sigma Fallback.

• If enabled, the Constant Sigma Fallback is triggered when a
temperature input fails. Proximity to surge is then calculated

using the constant_sigma value. constant_sigma is calculated
as:
constant_sigma = avg (average  along the surge limit line)

For Minimum Flow Fallback
(More info)
• The minimum_flow_enable discrete parameter is set to True to

enable the Minimum Flow Fallback strategy. It is set to False to
disable this strategy (controller will Fallback to Run Freeze
Fallback instead).
• When the Minimum Flow Fallback strategy is enabled and active,

the minimum_flow_level parameter specifies the minimum flow
level through the compressor that will be maintained. The
2013 Compressor Controls Corporation
controller will calculate proximity to surge (Ss) as the ratio of a

specified minimum flow level (minimum_flow_level) and the
suction flow measurement (dPo at suction):
minimum flow set point (minimum_flow_level), in EU_calc

It will then raise the recycle flow rate as needed to keep the compliment of
this ratio above the desired surge control margin (b).
Where is my dpo located?
Dual Flow Transmitters ?
Means dpo at Suction. If DISCHARGE then dpo at discharge.
One transmitter or redundant transmitters (depends on the definition of

the Signal in PB). Only dpo1 is connected in the application.
 High/Low ranges transmitters (They can be redundant only as explained in

the next slide)
FMD in Compressor Discharge
Compressor
ST PT TT TT PT FT
UIC
dPo_comp_mode 
If Td and Ts don’t exist, then use:

dPo_comp_mode  This will use a constant sigma given in CCC
configurator. See help for more.
dpo1 OR dpo2
Dual Flow Transmitters
(Low/High ranges dpo1 & dpo2 in PB)
• In applications where there is no need for flow transmitters with different ranges, dPo1
should be the only input configured.
• When flow transmitters with different ranges are required in an application, dPo1 must
be configured as the larger range transmitter and dPo2 as the smaller range
transmitter.
• The proximity-to-surge calculation would then use the low flow process variable as its flow
measurement until its signal variable reached 90 percent. It would then use the high range
until the low flow signal variable fell back below 75 percent.
• If the dPo2 transmitter fails, the controller will switch to the dPo1 signal.
• If the dPo1 transmitter fails, one of the following will occur:
• If the level of dPo2 > 90 percent of the dPo2 span, the controller will go to the Run Freeze
Fallback strategy.
• If the level of dPo2 < 90 percent of the dPo2 span, the controller will continue normal
operation using dPo2 (Act as redundant to dPo1).
• The current value of the selected flow is given by the CalcVars.dPo variable.
- To replace dpo1 or dpo2, use
MOR method since they are not
redundant.
- For real redundancy to happen,
the two transmitters should be
dPo1 dPo2 segregated completely with only
the flow element being shared.
Split Range Flow Transmitters
Operating Case 1 Operating Case 2
Pd Pd
Po,max,surge
Po,min,surge
Qs Qs
May require split range flow transmitters
Selection Method
• MED LOW: The low median is always a member of the data set. When the number of data points is odd, the middle value is
returned. When it is even, the smaller of the two middle values is returned.
>>> median_low([1, 3, 5]) = 3
>>> median_low([1, 3, 5, 7]) =3
• MED HIGH: The high median is always a member of the data set. When the number of data points is odd, the middle value
is returned. When it is even, the larger of the two middle values is returned.
>>> median_high([1, 3, 5]) =3
>>> median_high([1, 3, 5, 7]) =5
• A multiple input block that accepts up to three Anlaog inputs, and reports their health and value via Input#_failure
and Input#_EU status variables. Input_failure and Input_selected_EU report the health and value of the selected
input, while and input_OK_N indicates the number of healthy inputs. An Input Spread alarm indicates the highest
and lowest inputs differ by more than a configured threshold.
The AlarmSpread parameter sets the maximum spread, beyond which a spread alarm is posted by the
corresponding ANI or FRQ block.
Operating States for S5V
See next….
Antisurge Controller Sequencing
• From the STOP state, the Antisurge Controller begins

automatic control when the controller’s Stop and ESD
discrete inputs are cleared, and all of the following
conditions are satisfied:
» the main flow signal rises above dPo_min for
more than 2 seconds
» the discharge pressure signal rises above Pd_min
for more than 2 seconds
» the rotational speed N rises above N_min for more
than 2 seconds
• Once all the above conditions are met, the controller will be
in START state and begins ramping its output at the

start_ramp_rate [percent per second] towards the fully closed
position. The controller will then transition to the RUN state
when any of the following conditions occur:
• the deviation (dev) is below a specified threshold (dev_threshold);
• the intended recycle flow (IRF) reaches the low clamp (low_clamp);
• a limit condition occurs;
• a Performance Override Control occurs;
• a Run Freeze Fallback is initiated;
• Manual Control is initiated; or
• a Safety On Response is triggered.
Shutdown sequence
Antisurge controller:
A normal shutdown is initiated whenever the STOP request is asserted. The antisurge
valve is then ramped open at a specified rate (stop_ramp_rate) until it reaches its output high clamp.
NOTE: The valve will jump open to the high clamp if the operating point of the compressor moves to the
left of the Recycle Trip Line while the compressor is being stopped.
If an ESD input is received, the Antisurge controller will enter the Stop state and the antisurge valve will
jump fully open.
The Run/Stop status of the Antisurge controller can be obtained from a Performance controller using
Stop_Status_PacketID parameter.
Performance controller:
when a Stop or input is received, the performance controller will then enter the Stop State and begin
ramping its output down at a specified rate (stop_ramp_rate1). If a check valve exists, the ramping
rate will change when the check valve closes (stop_ramp_rate2)...higher rate.
The Performance controller continues to ramp down its output until it reaches the specified shutdown or
idle level (stop_output or idle_output).
Valve-Sharing
• In a Series 5 Control System, the valve-
sharing function allows several Antisurge
controllers to share one Antisurge valve by
keeping the recycle rate (OUT) high enough
to protect the section closest to its surge
or process limit.
Valve-Sharing in S5V
The secondary valve-sharing controllers pass their
proportional, integral, and Recycle Trip responses
to the primary controller, which includes the
highest responses in the calculation of its valve-
sharing response:
• CRVS = CRP + CRI + CRRT

where,
CRVS = valve-sharing response
CRP = highest proportional control response
CRI = highest integral control response
CRRT = highest Recycle Trip response
Enter the companion controller(s) packet ID here
To enable Valve-Sharing
Set to False in the primary AS

Set to True in the Secondary AS
Valve Assist
ASC
Diagram
Block
Transmitter Selection
(Speed Of Response)
 The transmitter type and brand should be selected

based on two major factors:
 Speed of response
 Reliability
 Response times:
 Desired response time
for Dp transmitters is
between 100 to 150ms
and not more than
200ms (including
damping /dead time)
 Desired response time
for pressure
transmitters is 300 to
400ms or less.
Response Time
• The speed of approaching surge is
high
• The transmitter type and brand should 1 SEC.
be selected based on two major 100%
factors:
– Reliability
– Speed of response A C D
• Desired rise time for p (flow) Pd B
transmitters is 200 ms or less 0
– Pressure step is 100%
– The first order response (63%) is less 100%
than 200 ms (including damping /dead
time) Po A C
• Desired rise time for pressure B D
transmitters is 400 ms or less

0
Actual pressure
Transmitter output 100%
63% response
1- (1/e)
A C D
Pc
B
Time In only 400 ms, PO dropped by

14%, with a 2% change in Pc
1 is less than 200 ms
The Effect of Damping
the po (Flow) Transmitter
• Knowing the flow is essential to determine
the distance between the operating point
and the SCL…(is the rise time)
Start of Surge
Flow 50
 = 16.0 s (measured by
Digital
Transmitters)
 = 1.70 s
0  = 0.03 s
 = 0.20 s
Actual Flow
(measured by Analog transmitter)
-50
0 1.25 2.50 3.75 5
Time (seconds)
Damping the po (flow) transmitter can paralyze the

complete antisurge control system!
Transmitter Damping
• Damping is a setting that allow the customer to increase the dead

time of the transmitter. This is done to keep the transmitter from
“chattering”. Chattering is when the output signal (For ex.
Pressure) has small but rapid changes due to process variations.
The damping removes this noise by extending the response time.
• The EJA-E and EJX-A transmitters are designed to not allow the
damping to be set less than 0.5 sec unless the Quick Response
feature is turned on. With the feature enabled, the damping can
be set down to 0. To achieve the 90 msec response time, the

damping must be set to 0.
(Source: Yokogawa).
Piping
Layout
Considerations
Piping Layout Considerations
• Piping layout influences the controllability of the
the complete system
• The primary objective of the antisurge controller is
to protect the compressor against surge
• This is achieved by lowering the resistance to
compressor flow
• The resistance is lowered by opening the
antisurge valve
• Dead-time & lag-time should be minimized
• This is achieved by
volume to be
minimizing the minimized
volume between
three flanges
– Discharge flange of
the compressor
– Recycle valve flange
– Check valve flange
Improving Control Response
Increased
volume due
to cooler
Minimum
volume
• Compressor 1 has ideal piping configuration for surge

protection as the between the three flanges is minimized
• The piping layout for compressor 2 is common but not
optimum from an antisurge system response point of view
• The cooler creates additional volume and decreases the

effectiveness of the antisurge control system
Using a Single Antisurge
Valve
Large volume
Section 1 Section 2
• In order to protect section 1 the antisurge valve needs to be opened

• The volume between compressor discharge, check valve and
antisurge valve determines the dead time and lag time in the system
• Large volume significantly decreases the effectiveness of the
antisurge protection
Results:
– Poor surge protection
– Large surge margins
– Energy waste
– Process trips because of surge
Sharing Recycle Coolers
Large volume
Small volume
• The piping configuration for section 2 is excellent for surge

protection
• Minimum volume between the three flanges
• The piping configuration for section 1 is not ideal as there is a large
volume of process gas to be de-pressurized
Results:
- Poor surge protection
- Large surge margins
- Potential energy waste
- Potential process trips due to surge
Optimum Surge Protection
Minimum
Volume
• This compressor has ideal piping configuration for

surge protection as the process volume is minimized
between the three flanges for all sections
Which Piping Configuration Would
you Choose?
Piping Configuration #1
Piping Configuration #2
• Configuration #1 has minimum volume between the flanges and is the best
layout for antisurge control reaction time
• Configuration #2 requires one cooler less / capital investment is lower and
cooler maintenance costs are reduced
• Configuration #2 will require bigger surge control margins
Output Linearization
• Linear valve trim is preferred

Controller output for good controllability / same
dynamic flow response over the
Flow rate complete stroke
through
valve • If the valve has quick opening
trim or equal percentage,
controller output should be
Valve trim characterized as mirror image.
quick opening Valve trim We add a signal to the output
equal percentage to make it linear.
By enabling the corresponding

valve flow characterizing function
Controller output
dynamic flow response becomes
linear.
Config>Output>valve_mode: valve mode selector:
0 - LINEAR
1 - EQUAL PERCENTAGE
2 - QUICK OPENING
3 - CHAR
Sizing the Antisurge
Control Valve
• Criteria for antisurge valve sizing based on
CCC’s experience
– Provide surge protection for worst possible disturbances
– Provide surge protection in all modes of operation
– Sized to provide flow peaks greater than what is required
in steady state to operate on the Surge Control Line
– Sized to avoid choke zone
– Not be oversized from controllability point of view
• Take the points at the intersection

of the min. & max performance
curves and the Surge Limit Line
(SLL)
• Calculate Cv,calc (or equivalent) for
each point
• Select standard valve size using
the following criteria:
1.8 . Cv, calc < Cv,selected < 2.2 . Cv, calc
Compressor
Performance Map
Valve Sizing Boundaries

Valve CV Curves vs. Compressor Maps
 Plotting the VALVE CURVE (Flow vs. Press. Differential) For Different Cv
Values
Valve Sizing Method for shared
sections
For Cv selection here:

Section2 for ex. has a Cv of 200
Section3 for ex. has a Cv of 250
Then we select the highest (250) provided that this value is below the chock Cv condition
for each compressor
Dynamic and Accuracy
requirements of the A/S valve
• Full stroking time to open, under positioner control, of less than 2 seconds with
less than 0.4 seconds of time delay without significant overshoot and closing time,
also under positioner control, of no more than 8-10 seconds
• A linear trimmed valve is recommended in order to provide equal loop-gain over

the whole operating range of the valve
• This will allow for the fastest tuning, leading to smaller surge margin requirements
and more stable control
• Positioning accuracy 1 percent or better

• A/S valve is chosen as fail-open.

• OUT @4mA: Fully Open
• OUT @12mA: 50% Open
• OUT @20mA: Fully Closed
Position Feedback
• When the difference between the position of
the antisurge valve (pos ) and the
(connected in Project Builder)
output of the controller (out) exceeds a

specified maximum value (pos_delta_max) for
a specified amount of time (pos_delta_delay),
the Antisurge Controller will set the Pos_failure
output and pos_deviation variable to True.
• This function must be enabled
(pos_delta_enable set to True).

Units/Range: seconds (pos_delta_delay)
percent (pos_delta_max)
To replace a transmitter in S5
• After a transmitter fails, the A/S controller will Fallback into a
predefined strategy. In Run-Freeze Fallback the ASV will run
on the last good value or a predefined value (whichever is
higher). The compressor will run safe.
• Put hard_manual_enable ON and put the controller in Manual
(using TV or Con5). You can increase OUT more if needed (to
a safe position).
• Remove the old transmitter and install the new one. Specify
the new transmitter range under Config_IO.
• Monitor the signal coming from the new transmitter under
_In_2.
• When you see the correct value coming from field, make
sure that you are running on +tive DEV or zero DEV before
switching back the controller to Auto (using TV or Con5).
• Put hard_manual_enable OFF and the controller in Auto
Surge Testing
Is surge testing required?
• NO !
• But recommended for End-user/EPC
contractor benefits.
• CCC does not require surge tests to set-up
control systems
• For CCC field service engineers surge

testing is a daily routine
Surge Test
Procedure
Surge Test Demo

Surge Detection – Option (EAS)
To configure this method of surge detection, it is necessary to execute a surge test and record the rate
of change of pressure and flow at the moment of surge.
Pressure and Flow Variations • Surge signature should be recorded

During a Typical Surge Cycle during commissioning
• Rates of change for flow and pressure
100%
transmitters should be calculated
• Thresholds should be configured
Pd
slightly more conservatively than the
actual rates of change during surge
• Surge is detected when the actual
0%
1 TO 2 SECONDS rates of change exceed the
100% configured thresholds
• The following methods have been
used:
Po – Rapid drop in flow
– Rapid drop in pressure
– Rapid increase in temperature
0%
– Rapid drop in flow & pressure
20 to 50
milli-seconds
Surge Detection – Option in S5
• If EAS (Emergency Antisurge Station) Method is selected, the controller also

monitors the rate of change of flow and discharge pressure measurements for
indications of surge. If thresholds exceeded, the surge count is incremented and a
Recycle Trip Response and Safety On Response are triggered.
Discussion:
When can the A/S valve open?
1. PI
2. RT
3. Limit in AS (Even if DEV is +tive)
4. Fallback
5. Loop decoupling
6. POC (hitting POC-SP) (Even if DEV is +tive)
7. Filtered-POC (Even if DEV is +tive)
8. Primary Response (from Master) if DEV <=0.
9. LC (RLC).
10. In Manual Mode
11. ESD
12. STOP
13. Unload (specific% for specific time)
14. Recycle Balancing (Even if DEV is +tive)
15. Valve Assist
16. Controller power failure
Thank You!

1 - Compressors and Surge Control Rev0 - C - S5

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© Compressor Controls Corporation

Compressors and Surge

Casing Thrust bearing

Picture of axial compressor

Cross section of horizontal split

Picture of horizontal split

Cross section of barrel

Picture of horizontal split

Inlet guide vanes Pinion shafts

Picture of bull gear compressor

Adjustable guide vanes

Single-Section, Three-Stage Single-Case, Two-Section, Six-Stage

Two-Case, Two-Section, Six-Stage (LP & HP)

Series Network (for very high Rc)

Can model all system resistance

• The intersection of these two curves

shows us the location of the

• The compressor provides us with pressure

• The compressor curve shows the

• If we just measure the pressure (using a

pressure transmitter) and flow using a flow

• The Operating Point of a compressor is

Compressor curve for a

Q2 Q1 Qs, vol [m^3/hr]

Surge Control Line (SCL) Power limit

• Appear as elliptical curves approximately

• The inner-most curve represents the area

• This area will includes the compressor’s

Surge: Inability for the compressor

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

API 670 reference

API 670 reference

• Flow reverses in 20 to 80 milliseconds

• “Whooshing” noise (as large volumes of

• Unstable flow and pressure

• Reduced compressor life

– Cooler problems (blockage…)

• Surge is not limited to times of reduced

Using high speed

Different inlet conditions produce different SLL locations

– Compressor maps based on only measurement of pressure

– The antisurge controller must provide a distance to surge

• Typical compressor maps include: (Qs, Hp),

ks = Exponent for isentropic compression

• These maps are defined for (1) specific set

 Pos MW = Molecular Weight

Reduce each equation by a factor A:

R is Reynold const. From experience, we know

• Another way to calculate sigma is to get the polytropic efficiency p (eta)

Cp= specific heat at constant pressure,

• For real gases:

NOT invariant (Hp, Qs) Invariant (hr, qr2)

NOT invariant (Rc, Qs) Invariant (Rc, qr2)

4 Curve 1: MW = 4.62; Ps = 6.033 kg/cm2 a

For Design stage operate under varying

• This eliminates the need for Td and Ts transmitters for

The reduced coordinates

When Ss = 1, Then we are

OPL (Operating surging.

DEV = (+) Good

DEV represents the

“Deviation” is the most important number the

A Deviation (DEV) of 0 is the setpoint for the