Anti Surge Protection in Action For Compressors

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"Antisurge Protection in action" for Compressors
Presentation · September 2022

DOI: 10.13140/RG.2.2.21560.21766
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Prem Baboo
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“Antisurge Protection
rotection in action” for Compressors
By
Prem Baboo
T The Fellow of Institution of Engineers (India)
Abstract increase yield, save energy, reduce downtime
In any centrifugal compressor the Antisurge and enhance ce plant safety & security. These
protection in action interlock is given for optimization services are technology-agnostic
technology
compressor safety. This logic is very typical and and automation provider can serve your needs
related to much input. Each input is very better with local support and a legacy of proven
important for compressor life and internals. This results. These devices surging can load
paper intended how to work this logic. This decreases, the amount of discharge flow and an
paper explains surge protection in action pressure drop, and a limit is exceeded, possibly
phenomena and explains why the anti anti-surge destroying the compressor.
protection system is a very important part of a Keywords- Antisurge, protection, flow, CCC
compressor? The multi stage compressor has pressure, temperature.. Compressor,
Compressor
many stages for developing pressure and high Description
rpm which is generated
ated with steam turbine. When the head in the system increases beyond
Numbers of companies are available for the maximum head developed by the compressor
controlling surging of compressor like CCC it will no longer be able to deliver gases to the
(Compressor Controls Corporation), USA USA. system. At this stage, gases will try to flow back
Woodward and Yokogawa,, Turbo machinery into the impeller where as the impeller tries to
control system etc. are provider solutions for blow the gases out. This will results in unsteady
compressor flow control device with software state of the system and cause heavy vibration.
vibration
and hardware. These expertises are executed in a Sometimes resulting in damage to Compressor.
comprehensive platform of hardware, software The head developed by compressor is denoted
and consulting services that optimize turbo by following equation.
machinery to improve process performance,
Fig-Compressor Antisurge control
1
This is an open access article, Research Gate is a European commercial social networking site for scientists and researchers
speed of soundnd shocks is produced that limits the

flow and in order to increase flow, it is necessary
In a centrifugal compressor, to maintain its to increase the speed. Anti-surge
Anti protection
speed at required, there is a certain capacity system is a very important part of compressor
below which the operation is unstable. This but it is not presented in anti--surge valves only
breakdown
own point is called “Surging” is a term but it contains a several devices that integrate all
associated with low flow. It is the phenomena, together to give an output which is the safe
resulting from the inability of the turbo protection set-point
point for machine. Anti-surge
Anti
compressor impeller to produce the amount of protection system has several points of control in
required energyy that the process system requires other words its degree differs according to
.In above equation, Lower Ts means Pd/Ps number of parameters measured and integrated
integrate
should increase, i.e. Pd increase &/or Ps processed data together to obtain the final result
decrease. Lower MW means Pd/Ps should which will be applied as an action. These actions
decrease i.e. Pd decrease & /or Ps increase. will take place before steam turbine reach
Lower Pd means Pd/Ps should decrease i.e. Ps maximum speed and over- speed trip where after
increase. Similarly higher Pd means/Ps should over-speed
speed trip the turbine will under come high
increase i.e. Ps increase. Surge is a high
high-speed thermal stresses es and can reach higher critical
phenomenon, surge flow reversals can occur in speeds that should be overcome with an extra
less than 150 milliseconds. Pressure rapidly flow of steam which will not be found as boiler
fluctuates, noise is generated. Temperature capacity will not cover it. Also to overcome
increases can be very rapid and mech mechanical choking of compressor due to huge rise of
damage can occur. The anti-surge surge control rotating speed.
system is designed to determine the surge Choking or Stonewall
condition in the compressor and to operate the The Choke
hoke point is the maximum rate of flow
anti-surge
surge control valve in an efficient and that a compressor can give at a given speed. At
speedy manner to protect the centrifugal this point the machine can no longer assure a
compressor from the surge. Blow ooff causes discharge head. This is not a dangerous
waste of expensive process fluid, therefore, phenomenon. The Centrifugal compressor’s
recycle is preferred and mostly carried out by operating range between Surge & Choke is
through 4-2020 mA electronic operated control reduced
educed as the pressure ratio per stage is
valve which is termed as “Anti-surgesurge Control increased or the number of stages is added. This
Valve .The anti-surge
surge control controller (FIC) is caused by the gas exceeding the speed of
provides the compressor against the surge by sound.
opening the recycle valve. Speed of Sound -When the maximum velocity
The Choke point is the maximum rate of flow reaches the speed of sound shocks are produced
that a compressor can give at a given speed. At that limits the flow and in order to increase flow,
this point the machine can no longer assure a it is necessary to increase the speed.
discharge head. This is not a dangerous Critical Speed -TheThe speed of the shaft at which
phenomenon. The Centrifugaltrifugal compressor’s frequencies of stationary parts (casing) and
operating range between Surge & Choke is rotating parts (shaft and impeller) become equal,
reduced as the pressure ratio per stage is a sudden heavy vibration is experienced which
increased or the number of stages is added. This can cause damage to both. The speed at which
is caused by the gas exceeding the speed of this phenomenon occurs is called Critical Speed.
sound. When the maximum velocity reaches the
2
Types of Anti Surge Control System Advanced dedicated Anti Surge Controller
Dedicated controller System (CCC, Woodward, system
Triconex V), Yokogawa, Turbo machinery In the advanced controller, the control action is
Control system etc. Programmable Logic split into two actions.
Controller (Siemens, Allen Bradley PI action, Recycle Trip Action.
Fig- Compressor PFD with antisurge control. valve in such a way to maintain the volumetric
Anti Surge Controller flow above a safe level.
The anti surge controller system consists of a Function of CCC
controller which monitors the relative distance d Recycle Trip open loop controller response
= (1-S) between the operating point of which prevents operating point of the
compressor and its Surge control line and compressor from crossing the surge limit line.
provide:- Safety On response which adds extra static
Proportional & Integral response to prevent this margin of safety to surge control line thus
distance d from decreasing below the set point. reducing the possibility of future cycles and
Increasing the margin of safety when the counts the actual number of surge cycle the
operating point rapidly approaches its surge compressor has experienced since the controller
control line & slow decreasing when operating was rest. Limiting the discharge pressure of final
point moves away from the surge control line. stage. Communication with DCS & service
Objective of Antisurge Controller computer. RT : Recycle trip, SO : Safety ON,
To prevent surge induced compressor damage & DEV: Deviation (d), d =1-S, RT- Recycle trip,
process upsets without sacrificing energy It is open loop control response which prevents
efficiency. To maintain selected process limiting compressor operating point crossing surge limit
variable within safe range .To achieve these line (SLL). When ‘RT’ appears, controller
objective the CCC controller position the recycle jumps to auto & will open 10 % wait for ‘1 sec’,
if flow is established it will stop otherwise it will
3
continue to open the ASV in steps of 10 % at It is open loop control response which adds extra
time interval of 1 sec, SO – Safety on safety to surge control line and hence reducing
possibility of future surge cycle and also counts
Actual No. of surge cycles from last manual
reset. When ‘SO’ appears one surge cycle is
completed and controller jumps into auto and
opens ASV fully to avoid further surge cycles
immediately.DEV – Deviation (d)= 1-S, It is
relative distance between operating point of
compressor and surge control line (SCL).
Negative deviation (DEV) means recycle flow
rate needs to be increased and Positive deviation
(DEV) means recycle flow can be decreased.
Zero deviation
(DEV-0) means operating point of compressor is
on surge control line (SCL).
Each controller receives four analog
rd
1. Ps-3- Suction pressure of 3 stage PT.
2. N -Speed of compressor.
inputs. Two inputs are required for indication only
Diff. Pressure across flow orifice of 3rd suction 1. Discharge temperature of 4th stage
FE,Pd-4- Discharge pressure of 4th stage PT.
Suction temperature of 3rd stage.
Ccompressor Anti Surge Control Systems energy saving, for saving of energy the antisurge
Surge is a potentially dangerous phenomenon valve opening of 10%, 20%....100% the flow of
that can occur in centrifugal and axial compressor is not achieved within 10 seconds
compressors. Compressor surge can cause consequently tripping of the machine occurs. For
mechanical damage to the internals of a a typical surge controller the CCC use following
compressor. Surging can also cause the input.
compressor to overheat to the point where the 1. Q2 = Discharge Flow;
maximum allowable temperature of the unit is 2. 2. P1 = Suction Pressure;
exceeded causing damage to seals. Further, 3. P2 = Discharge Pressure;
4. T1 = Suction Temperature;
surging can cause damage to the thrust bearing
5. T2 = Discharge Temperature;
due to the rotor shifting back and forth from the Above synchronized with both stages HP &
active to the inactive side due to the high forces LP. And the Q2 (Flow of Antisurge) when
induced by flow reversal. For axial compressors, reaches the surge line Antisurge will open
the damage may be measureable after only a few 10%, 20% ….100%, we have observed when
surge cycles. Compressor surge can occur in a “Antisurge protection in action” alarm
fraction of a second so a fast acting Antisurge appeared the antisurge valve of compressor
open fully for avoid machine damage and
control system is required to avoid surge and
energy saving. If the flow not achieved within
expensive compressor damage. 11 second then machine will trip.
Compressor is having CCC (compressor Control
Corporation) for better control of surge line &
4
Graph-Compressor Antisurge Flow Vs Pressure Head (Pd/Ps)

Anti Surge Control System at once, what happens?, then the suction
Surge happens quickly, and conventional temperatures will come down immediately then
instruments, control loops, and actuated control pressure of suction also will come down, then
valves usually fail to recognize the onset of Pd/Ps , Ps come down then Head will be
surge and react to it quick enough. Therefore increases then flow of the compressor will come
axial and centrifugal compressors are usually down before surging point the controller will
fitted with a dedicated Antisurge control system. give signal to antisurge and open 10% to achieve
Typical components in an anti-surge control the flow if not recovers then further will open
system include inlet flow transmitter, inlet and 10% means 20% , if fail the process goes to
outlet pressure and temperature transmitters, further 20-30-40….. % etc. If not recovers at all
antisurge controller, and anti-surge control valve within 11 seconds (whatever timing given to
as described below. your machine) then the machine will be tripped.
For Example- Your system is running normal
and no deviation suppose if start the raining all
5
Fig- Antisurge Control system

Antisurge control systems detect when a to the inlet of the compressor via a suction
compression
ssion stage is approaching surge and cooler. The resulting increase in compressor
rapidly take action to reverse the movement of inlet volume flow moves the operating point
the operating point towards the surge line. This away from surge. The specialist components in
is normally achieved by opening a fast acting the antisurge control system are the antisurge
control valve (an Antisurge control valve) in a controller,
er, and the antisurge control valve.
recycle line, thereby returning
ng the discharge gas
Graph-Head
Head Vs Suction flow with variable rpm
As discussed above, an anti-surge
surge controller which is fast acting (faster than a typical DCS)
modulates the anti-surge
surge valve to prevent the and contains special surge detection algorithms.
compressor’s operating point from reaching the The controller will have an inbuilt closed and
surge limit while maintaining other process open loop control responses; this helps minimize
variables within safe or acceptable limits. The the control margin and gas recycling without
antisurge controller is a specialized controller
6
Unnecessary upsets to the process. The more advanced antisurge controllers can automatically
compensates for changes in gas molecular compressor operates to its surge limit. Since
weight, temperature, compressibility, pressure, recycling gas from the discharge back to the
and compressor rotor speed. This antisurge suction of compressor wastes energy, the most
control loop also requires fast acting antisurge economic operation is to keep the recycle flow
valves and differential pressure transmitters, as low as possible, thus operating closer to the
because the overall control response is a surge line. A second consideration is that any
function of the response time of the antisurge antisurge system is providing closed-loop
valve, measurement devices and control regulatory control only before compressor goes
algorithm relative to the dynamics of the into surge. When a compressor is surging, the
compressor parameters. The system speed-of- system only needs to detect this condition and
response becomes more critical the closer the keep opening the antisurge valve in steps until
the compressor stops surging.
These types of Compressors are low flow
compressors and installed in parallel to avoid
surge control and equal flow following methods
are used as shown in figures.
1. Base Load Method.

2. Suction Side – Speed Control Method.
3. Equal Flow Balance Method.
4. Equidistant to Surge Line Method
1. Base Load Method
During periods of low process

demand, Compressor B (Swing Machine) can be
recycling & sometimes even close enough to
the Surge Control Line (SCL) causing the Swing
Machine to Trip. Hence an inefficient
configuration. Base Load Operating Style
requires frequent operator intervention. A
configuration that is not in vogue anymore & not
recommended.
Suction Side – Speed Control Method.

How to Control Surge for Parallel Gas
Compressors?
Fig- Surge Control with reference of power Both Compressors would not necessarily operate
saving at the same speed/flow during a recycle since
No Base Load Exists, but instead the Master UIC A/B is acting independently of each other.
Pressure Controller (PIC) is shifted to the 2. Equal Flow Balance Method
suction side. Master Pressure Controller (PIC) The Master Pressure Controller (PIC) on the
provides set point (SP) to speed controller (SC). common discharge header determines the total
7
load demand and alters Compressors A & B the total load demand (Bias A & Bias B) to the
speeds (SC). The individual flow control signal individual flow controller (FC) on
to each speed controller is achieved by scaling
Each compressor. Both Compressor Operations Dev2 (i.e., Dev = Distance between Operating
are independent of the Anti-surge Valve Point & Surge Line).
(ASV) Operation. Both UIC A/B (Anti-surge Controller) & LSIC
3. Equidistant to Surge Line Method A/B (Load sharing Controller) would coordinate
Based on the principle –The Deviation/Distance their responses in Real time. Applicable also
between the operating points & the surge control for parallel compressors that have dissimilar /
(SCL) line in both trains is equidistant. For this asymmetrical performance curves.
configuration N1 ≠ N2 & Q1 ≠ Q2, but Dev1 =
Fig-Anti surge control for parallel compressors
8
Theory of Compression Following changes takes place during

Compressors are mechanical devices used to compression:
increase the pressure of air / gas mixtures such Volume is reduced, Pressure is increased,
as fuel gas , ammonia, air, hydrogen, CO2 etc. Temperature of gas increases as a result of heat
depending on the process requirement. of compression, Density increases as the volume
Compressors are either Dynamic or Positive decreases.
displacement type. In Conventional Centrifugal Compressor,
Centrifugal Compressors Kinetic Energy is converted into Pressure
When gas molecules are forced close together, energy. Gas enters Axially at the center of the
the result will be increase in pressure. The Impeller and passes through the tip of the wanes,
molecules get squeezed into smaller volume which are rotating at high speed. The gas picks
because of the force acting upon them. The up the velocity, and high pressure is achieved,
above process is known as compression. when it expands at discharge.
Fig-Head H -explain
PV = NRT the periphery of impeller at high velocity, flow
PVk = Constant =Adiabatic compression thru the annular diverging passage called
PVn = Constant=Polytropic Compression diffusers between inlet wall & diaphragm
γ= (k-1/k) / (n-1/n) Polytrophic Efficiency converting velocity head into pressure head. The
(n-1/n)
Td= {(Pd/Ps) Ts} = {(Pd/Ps)[(k-1) / (k x g)]Ts} temperature rise in the recycle loop during start
H = (ZRTs/MW) (n/n-1) {(Pd/Ps)(n-1/n) –1} up when antisurge is full or maximum open is
Where, H= Polytropic head the function of the turbine power more recycle
MW=Molecular weight, Z=Compressibility more power. Low pressure ratio compressors
factor, Principle of a Centrifugal compressor. often do not require after coolers there are
Basically a simple Dynamic machine, Gas several strategies that can be employed to avoid
travels essentially radically. Rotor impellers overheating the un-cooled compressor during
impart Kinetic Energy to gas entering thru the start up. The Polytropic is what happens in a real
suction volute, Inlet Guide vanes direct the gas situation. When gas is compressed, some of the
to the Eye of the impellers, Gas is charged from heat stays within the gas, while some of it
9
accumulates in the metal casing (that's why using Polytropic compression methods is a more
surfaces get hot) and some of it escapes to the realistic approach.
surroundings. Therefore making calculations
Fig- Compressor sealing system
Fig- Compressor oil Diagram
10
Fig Compressor internals
Fig- Turbine sealing system
11
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Conclusion-You have seen the surging loop for any variation in detail and thoroughly so as not
compressors is very typical and multi loop to happen. Compressor antisurge logic is the
system, any variation in the system internals and huge gland. The antisurge controller should
outer (weather conditions rains etc) may reflect choose only reliable and international company.
the flow of compressor. We have to check the
************************************************************************************
12

Anti Surge Protection in Action For Compressors

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See discussions, stats, and author profiles for this publication at: https://www.researchgate.

"Antisurge Protection in action" for Compressors

Presentation · September 2022

Industrial Process View project

Comparison Stamicarbon Saipem View project

The user has requested enhancement of the downloaded file.

Fig-Compressor Antisurge control

speed of soundnd shocks is produced that limits the

Graph-Compressor Antisurge Flow Vs Pressure Head (Pd/Ps)

Fig- Antisurge Control system

1. Base Load Method.

During periods of low process

Suction Side – Speed Control Method.

Fig-Anti surge control for parallel compressors

Theory of Compression Following changes takes place during

Fig- Compressor sealing system

Fig- Compressor oil Diagram

Fig Compressor internals

Fig- Turbine sealing system

www.researchgate.net 22 nd Sept, 2022

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