• Surge control basics.

• Series 3+ Antisurge controller

basics.
• Series 3+ Emergency Anti-Surge
detector (EAS) basics.
 What is Surge?
The Phenomenon of
surge is a characteristic
of any compressor ….
 What is Surge?
The Operation of a compressor
can become unstable due to
changes in many operating
conditions such as flow rate,
pressure and molecular weight
of gas. This causes rapid
pulsations in flow, and this is
called SURGE.
 Surge Definition
Surge is defined as “Self oscillations of
Pressure and Flow, often including flow
reversal

Compressor flow chart

Typical Surge Cycle

 The Surge Phenomena
Flow

Rapid flow oscillations

usually with thrust reversals
Sec.
/ mechanical damage
1 2 3
Press

Rapid pressure oscillations

Sec. with process instability
1 2 3
Temp

Sec.
Rising temperature
3 inside compressor
1 2
 Surge Description
 Flow reversals in 20 to 50 Milliseconds.
 Surge cycles at a rate of 0.3s to 3s per
cycle.
 Compressor vibrates
 Temperature rises
 “Whooshing” Noise
 Trips may occur
 Conventional instruments and operators
fail to detect the surge.
Surge consequences
 Unstable flow and
pressure
 Damage in sequence with
increasing severity to seals,
bearings, impellers and
shaft
 Increased seal clearances
and leakage
 Lower energy efficiency
 Reduced compressor life
Factors leading to onset
of surge
 Start-up
 Shutdown
 Operation at reduced
throughput
 Operation at heavy
throughput with: Trips /
Operator errors / Load
changes / Cooler problems /
driver problems /Power loss /
Process upsets / Gas
composition changes / Filter
or strainer problems
 Surge can happen any time
Compressor Map

HEAD

N1

N2

N3

MASS FLOW
Reduction in flow
Surge Cycle PRESS Surge zone Operating zone

A Operating
C point
B

D E

FLOW
- +
VE VE

1. Due to a reduction in load, operating point moves from stable operating Point A to
Point B. Highest pressure (Head) at Surge point “B”.
2. Operating point moves from Point B to Point C – Flow Reverses.

3. Discharge pressure falls from C to D

4. Operating point moves from Point D to Point E to increase flow & pressure.
5. Again due to reduced load, the operating point moves through the curve to
Point B
6. This completes one surge cycle – Typical duration: 0.3 to 3 seconds.
Antisurge Control basics
To prevent a compressor from experiencing
surge, one need to know where the Surge
Limit Line is located. This information is
determined from extensive surge
tests, and is downloaded to a controller
that controls the recycle valve. If the
controller knows theSurge Limit Line
and the Location of Operating point
with respect to this line, then the Recycle
valve can be opened when required.
 Antisurge Control basics
Hr SLL

OP
Rc + Slope of the line
α K = Tan α = Qr²/Hr

Qr²
(Qr²)SLL (Qr²)OP

CCC Uses Reduced Head (Hr) Versus reduced

Suction flow Squared (Qr²) to develop Surge
control map. Hr is measured in KJ/Kg, m/ft
lbf/lbm etc. Qr² is measured in ft3/hr, m3/hr,
Tons /day etc.
 Antisurge Control basics
The SURGE PARAMETER Ss
Surge parameter (Ss) is the most important
parameter used in CCC controllers.

Ss is a function of Head and mass flow

calculations. These calculations takes into
account the factors such as flow, pressure,
compressibility, molecular weight, temperature
etc.

In several applications in DPC, this value is

derived, without use of Temperature and Speed
values considered in calculations.
 Surge Concepts
Smaller
Value of Surge Limit
K Line SLL

Large
Value of
K

Value of K and the correct location of SLL is determined

through actual surge tests on the compressor by CCC
Engineers
 Antisurge Control basics

Hr
Ss = 1
Ss > 1 on SLL
OP
Hr +
α Ss < 1 Ss < 1 : Stable Operation
Ss = 1: Surge Limit Line
Ss > 1: Surge Region
(Qr²)SLL (Qr²)OP
 Antisurge Control basics
The surge Limit line is an unstable limit,
Hr SLL
which, if crossed by operating point, will
SCL cause compressor to experience at least
b1 one surge cycle. The continual surge
+ cycles might cause compressor damage,
OP along with shutdowns.
The only way to prevent this from
happening is to keep the operating point
at a safe distance from surge limit line.
(Qr²)

This Minimum distance is called as “Safety Margin” and is visualized in

operating map by drawing a line in front of the Surge Limit line. This line
is called as “SURGE CONTROL LINE” (SCL)..
The distance between SLL and SCL is determined by the constant b1.
Recycle valve will be closed as long as operating point is towards the
right of the SCL. When operating point reaches SCL or crosses to the left
of SCL, it enters the Surge Control Zone and Recycle valve will be
Opened.
 Antisurge Control basics
Hr SLL
SCL
b1
+
OP

Surge control Zone

(Qr²)

The FIRST control action that opens valve when operating point is in
SURGE CONTROL ZONE IS P+I action.
The “S” Value for is calculated for Surge Control Line:
S = K X[ f(Rc)/ (Qr²)OP] + b1 X 1/ΔPo
Note that S=1 when operating point is on SCL.
Thus the control action that opens recycle valve uses this S-value as its
process variable ……………………
 Antisurge Control basics
……. As long as S < 1, the output of Antisurge controller will keep
Recycle valves closed. When S > 1, the P+I action of Antisurge
valve will open the Recycle valve.
Operator interface of the controller does not show the S Value.
Instead it shows the derived value, DEV (deviation).

Deviation: DEV = 1 - S
DEV = 0 When Operating point is on SCL
DEV > 0 When Operating point is to the “Right” of SCL –
Stable compressor operation
DEV < 0 When Operating point is to the “Left” of SCL –
The compressor is operating at Surge Control Zone.
P + I control will give adequate protection for small disturbances
and the control will be stable for steady state Recycle operation..
 Antisurge Control basics
Margin of Safety
The width of the margin of Safety is the distance between the SLL and OP.
It is represented by parameter “b” which is defined as:

b = (b1) + (b2 x n) + (b3 x Td0 x ds/dt), where

b1 = minimum margin of safety (SCL LOCATION)
(b2 X n) = Safety on response (distance added when safety on
response is triggered), where “n” is the surge counts.
Initially n = 0 and starts counting in increments each
time, a surge is detected and/or operating point
crosses safety on line.
(b3 X Td0 X ds/dt) = The derivative control response where:
b3 = maximum derivative response.
Td0 = derivative response time constant and
ds/dt = derivative of Ss with respective to time.
When ds/dt is moving left (+ve), the magnitude of
response reflects the rate of change of derivative.
…………………..
Antisurge Control basics
Margin of Safety
…….
When ds/dt is negative, that is operating point is
moving to right, then the derivative response is
ramped to zero at a rate set by the ramp rate
constant. (CONSTANT G IN PARAMETERS)
Also, the derivative action is suspended if the
Operating point crosses Recycle trip line.
 Antisurge Control basics
Enhancement to P+ I control: Adaptive gain

When OP moves Hr SLL

SCL
towards SCL fast, the
Adaptive gain moves
the SCL towards OP. op
This allows P+I
control to react earlier
(Qr²)
Hence small steady
surge control margin
can be achieved
without sacrificing
reliability
 Surge Concepts: Recycle Trip Line
Recycle Trip Line RTL
Recycle
Hr SLL
SCL Trip Action
P+I

Recycle Valve
Qr²

Recycle Trip (SECOND CONTROL ACTION FROM ANTISURGE CONTROLLER)

For normal or small surge conditions the PI action is enough for control.
However for large disturbances, PI action alone is not enough and operating
point crosses SCL rapidly.

To control this disturbance, a Recycle Trip line is set between SCL and SLL.
The Recycle Trip Line is determined for each compressor by means of Surge
Testing process.
 Surge Concepts: Recycle Trip Line
Recycle Trip Line RTL
Hr Recycle
SLL Trip
SCL P+I Action

+
OP

Recycle
Qr²
Valve

Valve
Total response

P + I control

Recycle Trip

Time
 Surge Concepts: Recycle Trip Response

1. Disturbance arrives, the OP moves towards SCL.

2. When OP hits SCL, the P+I action opens valve as per
PI settings.
3. OP keeps moving towards surge and hits RTL
4. When OP hits RTL, then the conclusion is:
• We are close to surge
• PI control action is slow to control disturbance
• Need to be out of danger zone fast
5. An open loop response is triggered
………………………………….
 Surge Concepts: Recycle Trip Response
………………………..
6. OP moves back to safe side of RTL
The RT function decays out the step response
PI controller integrates to stabilize output on SCL
7. Total response of controller is the sum of PI control
and RT action

Benefits:
Energy savings due to smaller surge margin
Compressor has more turndown before recycle or
blow off
Surge can be prevented for virtually any disturbance
Surge Concepts: Recycle trip Response
Improving Recycle Trip response
1. Open loop control lacks accuracy needed to
precisely position Recycle valve.
2. Open loop corrections of a fixed magnitude C1 are
often too big or too small for a specific disturbance
3. Hence the actual response of the RT function is the
rate of change of OP or dSs/dt.
Recycle trip response calculation:
C = C1 X Td X d(Ss)/dt
Where
C = Actual step to the valve
C1 = Constant which defines max. step
Td = Scaling constant
d(Ss)/dt = Rate of change of OP
Surge Concepts: Recycle trip Response
Valve
Total response

P + I control

Recycle Trip

Time

Small disturbance

Valve

Total response

P + I control

Recycle Trip
Larger disturbance

Time
Surge Concepts: Recycle trip Response
ONE STEP RESPONSE
After Time delay C2, controller checks
if the OP is back to safe side of RTL
Valve
Position • If yes : Exponential decay of RT
Response
• If No : Another Step added to RT
Response

C1

C2 Time
Surge Concepts: Recycle trip Response
MULTI- STEP RESPONSE

Valve
Position

C1

C2 C2 Time
 Surge Concepts: Safety ON (SO)
1. Safety On is the THIRD LEVEL of protection of a
compressor from surge.
2. The SO Line is a line to the left of SLL and again its
position is usually determined through calculations
after Surge tests.
3. Compressor can surge severely due to:
 Transmitter Calibration shift
 Sticky or blocked Recycle valve
 Blocks in Recycle line
 Large process upsets.
4. Benefits of SO response:
 Continuous surge avoided
 Operators get alarms about surge.
Surge Concepts: Safety ON
SLL SCL
Hr RTL

Safety On
Line (SOL)

Qr²
b2

Safety ON (SO) Line

 Surge Concepts: Safety ON
NEW NEW
SLL RTL SCL RTL SCL

Additional Surge Margin

The Safety On Function increases margin between SLL and SCL

when surge is detected. Note that RTL follows SCL
 Surge Concepts: Safety ON
Safety ON (SO)
1. If Operating point cross SO Line, then the compressor is in
surge.
2. SO response shifts the SCL and RTL to the right
3. Additional safety margin is added.
Surge detector:
In series 3 + controller,
1. Surge signature is recorded during surge tests
2. Rate of change of flow / pressure is determined.
3. Thresholds are configured.
4. Surge is detected when actual rates of change are exceeded in
configured thresholds.
5. When surge is detected a SAFETY ON response is triggered
6. Digital outputs are triggered upon a configurable number of surge
cycles
 Transmitters used in Surge control
measurements
Flow Transmitters:
This transmitter is critical for Surge control system.
1. Main selection criteria:
 Repeatability and Sufficient signal to noise
ration
2. Very fast response to changes in flow.
3. Transmitter to be ranged for maximum compressor
flow.
4. Should not be damped as any delay in flow
measurement can be disastrous for surge control
system.
5. Preferred location is to Suction piping of
compressor / As close to inlet flange as possible
 Transmitters used in Surge control
measurements

1. Generally Electronic transmitters with measurement lag of not

more than 0.0200 secs are used in surge controls for pressure
and flow measurements.
2. These transmitters should not be “Heavily” damped that the
compressor dynamics are not reported to the controller.
3. The transmitter taps & sensors should be located as close to the
compressor piping, to prevent signal lags.
4. The transmitter taps should be “above” the upper half of pipe
works – this prevents the condensation build-up
5. The transmitter should be mounted at a level above its impulse
tubing taps. The tubing should be routed with a gradual slope.
6. The length of impulse tubing should be minimized to avoid
measurement lags.
 Surge control Instruments &
Valves
How fast should the response of Antisurge control system should be?
Certain operating conditions such as Jammed check valves, process
parameters, ESD (equipment shutdowns caused by protective
systems) etc. cause upsets that are very fast and large.
Conventional pneumatic Instruments are too slow to detect these fast
changes that cause surge.

CCC Series 3+ controllers

provide Highly advanced,
specialized, fast
Microprocessor based
control functions
 Recycle Valves
 For Effective Surge control, the recycle valves must be large
and fast acting. It should be capable of recycling 100% of
design flow rate. Larger the valve, greater will be the effect of
its opening.
 When Suction flow decreases and compressor operation is
moving close to Surge, it is necessary to effect a quick increase
in flow. The rate at which flow can be increased depends upon
the response of Recycle valve and its size.
 Typically, the duration of a surge cycle can be one second.
Hence the speed of response of recycle valve should be very
fast. Field tests have shown that the full stroke of the Recycle
valve should be achieved within 2 Seconds. This speed is
achieved by using devices such as Volume Boosters along with
Valve positioners etc. These work by increasing the volume of
pneumatic signal to the valve actuator.
 Recycle Valves
 Use of Solenoid instead of Volume booster is not
recommended as Volume booster provides modulating control
along with speed.
 Also, to maintain required speed of valve operation, the
length of pneumatic tubing between components are kept at
minimum possible and proper tubing size is necessary to be
selected.
 Quick Exhaust increase speed in only one direction. (Typically
from full close to full open). Volume boosters increase speed
in both directions. Hence, Volume boosters are used with
recycle valves
 Recycle Valves
Minimize the
discharge pipe
Compressor volume

Check
Valve
Suction.
Drum
Recycle
valve

Cooler

Piping consideration and location

Series 3+
Antisurge
Controller
Face
Alpha Numeric Display:
1. DEV Displays the distance from
surge (DEV = 1-S)
2. ALT Displays surge count (when
display surge count is
pressed
3. OUT Displays the output to
Valve
4. AUX Auxiliary display window
 1. Auto Lit when Automatic Op mode
2. Manual Lit when Manual Op Mode
3. RT Lit when Recycle Trip is in effect
due to close prox. to surge
4. SO Lit when Safety On has detected
one or more surge cycles
5. Limit Lit when Limiting variable is at or
beyond threshold
6. Tracking Lit when in redundant tracking
mode. Flashes in o/p track mode
7. Tran Fail Lit when any analog input is
outside its alarm limits
8. Fall back Lit when input or communication
failure triggers a Fallback
Status LED’s 9. CommErr Lit when expected message fail to
arrive on port 1 or 2
10.Fault Lit when controller has failed
(redundant units switch to
backup
 Toggle between auto and manual modes
Zeroes SO surge count, Returns surge control
line to initial position. Temporary display of
numerator/denominator in ALT and DEV
windows OF S VALUE
Temporary display of SO surge count in ALT
window

Used to select AUX window display

In Auto mode – NO effect

In Man mode – Changes out put signal

Temporary display of disch. & Suct press.

And its limiting set point in DEV and ALT
windows (AUX tells which)

Scroll Keys Used to select AUX window display

Antisurge controller AUX display:
Operating status menu: (Does not scroll – operating status
of compressor selected by analog or discrete input)
1. Status RUN
2. Status STOP
3. Status Purge

Measured Variable Menu:

(Default labels)
1. dP0 ##.#
Calculated Variable menu
2. D Press ##.#
1. Sigma .###
3. S Press ##.#
4. Speed ##.#
2. Rc #.##

5. D Temp ##.# 3. Rt #.##

6. S. Temp ##.# 4. Speed #####
7. Chan 7 ##.#
8. Chan 8 ##.#
 SERIES 3+ SURGE CONTROLLER INPUT/OUTPUTS

Analog inputs
CH-1 dP0 (Flow)
Analog out
CH-2 Pd (Disch)
to EAS
CH-3 Ps (Suct)

CH-4 Speed

CH-8
Discrete outputs
(CR1) To IN-8 of EAS
Discrete inputs
(CR2) AIC Fault/OP Fail
ESD (D2) status to EAS
PURGE (D3) (CR3) SAFETY ON

RUN/STOP (D6) (CR4) TRANS FAIL

(CR5) EXCESSIVE SURGE

 SERIES 3+ EAS DETECTOR

RUN
EAS EAS detector
_______________
Surge Detector
0.05 % and
Manual Loading
is configured
Station
As
IN TAKE

Auto/Manual
CONTROL CONTROL

ALARM 1 RETURN
TO

ALARM 2
ANALO
Loading station
RESET CON-

(AMS) in DPC
ALARMS FIGURE
FAULT

SCROLL ENTER

Compressor
Controls
Corporation
SERIES 3+ EAS DETECTOR

FT - B FT-A AIS

EAS FY
 SERIES 3+ EAS DETECTOR: Input / Output

Analog inputs
RUN
EAS Valve Out 4-20 MA
_______________
CH-1 Flow Tx.
Surge Detector
0.05 % and
CH-2 Manual Loading
Station Discreet Outputs
REMOTE IN (4-20
MA from AIS IN TAKE (CR-1) EAS FAULT
CONTROL CONTROL
Controller)
(CR-2) SURGE COUNT – 1
ALARM 1 RETUR ALARM
N TO
ANALO

Discreet inputs ALARM 2 (CR-3) SURGE COUNT – 2

RESET CON- ALARM
ALARMS FIGURE
FAULT (CR-4) SURGE COUNT – 3
(IN-8) From CR-1 of Emergency Shutdown
AIS CONTROLLER SCROLL ENTER

Compressor (CR-5) EAS IN CONTROL

Controls
Corporation
 SERIES 3+ EAS DETECTOR
 EAS is configured as Auto Manual Loading station (AMS) Mode.
 Compressor Surging can be detected by using CH-1 Flow
transmitter.
 CH-2 Analog input is used to track the output of Antisurge
controller.
 Each time a surge is detected, two counters are incremented – the
“EVENT SURGE COUNT” and the ACCUMULATED SURGE COUNT.
 The Event Surge Count is the number of surges detected since the
Surge Alarms were last manually or automatically reset.
 The accumulated Surge Count is menu variable that can be set to
any desired value. Thus its interpretation depends on when it was
last reset and what value it was given. If the original value was
Zero, then its value indicates how many times surge has occurred
 The EAS is manually tuned after Surge testing the compressor to
determine the parameters for surge detection thresholds.
 The Event Surge Counter is configured to drive the Alarms (4) and
its associated digital outputs.
 SERIES 3+ EAS DETECTOR
 The EAS “Tracks” the output of Antisurge controller.
 In event of Antisurge controller failure, the EAS takes over the
surge control function, in a limited way. (IN CONTROL of EAS is lit).
 When Antisurge controller is fixed, the control can be transferred
back to AIS, in bump less transfer mode. Same holds true when
Control is transferred to EAS.
 In most applications, the EAS operates normally in its
tracking state (TRK displayed in the display). This mode
is active when the fault relay of AIS controller is
normal. Only when the AIS is faulted, then the EAS will
take control (RUN displayed in display). The EAS will
also, take control if the “TAKE CONTROL” key on its face
is pressed.
 Causes ESD of the unit if 3 surge counts are detected in
a minute.
 SERIES 3+ EAS DETECTOR

RUN
EAS Operator interface
_______________
Surge Detector
0.05 % and
Manual Loading
Station

IN TAKE
CONTROL CONTROL

ALARM 1 RETURN
TO
ANALO

ALARM 2
RESET CON-
ALARMS FIGURE
FAULT

SCROLL ENTER

Compressor
Controls
Corporation
 EAS Operator interface
LED’s: These flash to indicate conditions as follows:
IN CONTROL The Green “in control” LED is lit when the EAS is its RUN mode
and flashes in the Return state.

The Yellow Alarm 1 LED flashes when Event surge count

ALARM1 exceeds the Alarm 1A threshold. It lights continuously, if
that count equals or exceeds the 1B threshold

The Yellow Alarm 2 LED flashes when Event surge count

ALARM2 exceeds the Alarm 2A threshold. It lights continuously, if
that count equals or exceeds the 2B threshold

The Red Fault LED lights if CPU crashes or the voltage for
FAULT internal circuitry falls too low.
When the fault LED is lit, the value of the output signal and
the state of the output selection relay are unpredictable.
Process disruptions or equipment damage can result unless
that relay is deenergized by powering down EAS.
 EAS Operator interface
KEYS ON THE EAS FACE

TAKE If EAS is operating in its Tracking or Return state, Pressing the TAKE CONTROL
CONTROL
Key selects the RUN state. If it is already in RUN state and if MANUAL is
enabled in configuration, then the key toggles between RUN and MAN state

If EAS is operating in its RUN or MAN state then pressing RAISE key
increases intended valve position by 1% and pressing LOWER key decreases
the intended valve position by 1%. These keys have no effect when the EAS
is in TRK or RET state

RETURN
Pressing the RETURN ANALOG key while EAS is operating in RUN state initiates
TO
ANALOG
the sequence for returning control to PRIMARY CONTROLLER. Provided discreet
IN 8 is satisfied and Local Return Analog method is enabled in Software

Pressing the RESET ALARMS Key sets the Event Surge Count to Zero and cancels
RESET
ALARMS any active Surge Alarms. But this action does not return the intended valve flow
to its initial value.
 EAS Operator interface
KEYS ON THE EAS FACE
Pressing the CONFIGURE key initiates a procedure for invoking the
CON- configure state, in which you can view or Change variable and
FIGURE
parameters and execute various tests

Pressing the SCROLL key cycles the Digital readouts through the
SCROLL available operating variables

Pressing the ENTER key has no effect other than restoring the
ENTER default variable readout
 EAS Operator interface
EAS READOUTS:

EAS is provided with two 4-Character LCD readouts. When not operating in its
configuration state, the upper readout displays the name of operating variable
and lower readout displays its value.
Pressing the SCROLL key cycles these readouts through the list of variables
available for display.
An EAS normally displays its operating state and intended valve position. If you
scroll to another variable, then you can restore back to default by pressing the
ENTER KEY

Upper display

Lower display
 EAS Operator interface
EAS READOUTS:

Operating state: Shown in Upper display

1. The upper display reads TRK then the EAS is in Tracking state. The intended
valve position/flow are calculated from the output of Antisurge Controller
2. The upper display reads RUN then EAS is in RUN state. The intended valve
flow can be raised by closed loop response or the intended valve position
can be changed by operator.
3. If the upper display reads MAN then EAS is in MAN state (if enabled in
configuration). The Closed loop response is disabled.
4. If upper display reads RTN, the EAS is operating in its return state. The
intended flow is being ramped to match the output signal of the primary
controller for Bump less transfer.
In all above cases the lower readout displays Intended Valve Position.
 EAS Operator interface
EAS READOUTS:

INTENDED VALVE FLOW (LOWER READOUT)

IF the EAS is in RUN STATE, then depending on how it is
configured, EAS can raise its intended valve flow (VFLO) as each
surge alarm (TOTAL = 4) is tripped (This response never decreases
the VFLO).
Each Surge alarm (1A/1B/2A/2B) is set to ramp the VFLO to the
absolute value set by corresponding alarm response parameter (in
an increasing direction only)

Pressing the RAISE or LOWER KEY will immediately abort any

ramped change in VFLO.
 EAS Operator interface
EAS READOUTS:

Also, pressing the SCROLL KEY, one can display following:

1. EVENT SURGE COUNT (CNT) – How many times EAS detected surge
since last reset
2. Analog input CH-1
3. Output of Primary controller CH-2
4. Accumulated Surge Count (ACCL) the net total number of surge
detected since installation/commissioning
5. Discrete input 1 to 8 (As four binary digits 0 or 1)
6. Discrete output 1 to 4 (As four binary digits 0 or 1)
7. Discrete output 5 through test