Compressor

Compressor control menu
Cost of operating turbo compressors

Maintenance cost
Operating cost
Commissioning cost
Putting it in perspective
Compressor operation
Centrifugal compressors
Axial compressors
Compressor system classifications
Developing the compressor curve
The surge phenomena
Compressor control
Acrobat Previous Rew Fwd Help Main Menu

Repairs are expensive
Costs of repairs - materials and labor
3,000 hp 20,000 hp
Process gas compressor Axial air blower
Seals $20,000 $50,000
Bearings $10,000 $25,000
Rotor Assembly $200,000 $750,000
Compressors Previous Rew Fwd Help Menu

Operating costs are large
Cost to operate one turbo compressor per year:
Plant air compressor 1,000 HP (746 kW) $457,000
Wet gas compressor 4,000 HP(2,984 kW) $1,830,000
Propylene refrigeration comp. 40,000 HP(29,480 kW) $18,300,000
Assumes power at $.07 per kilowatt hour or $457 per horsepower per year.
Energy costs vary due to local conditions.
Energy Saving Examples Energy Savings Predictions Compressors Previous Rew Fwd Help Menu
Energy savings examples
resulting from reduced recycle or blow-off
Compressor Compressor Actual achieved

application shaft power savings
Actual Energy
Propylene Savings Result
refrigeration From
40,000 hp ( 29 MW) $1,200,000
Improved Antisurge Protection and Capacity Control
FCCU air blower 15,000 hp (11.2 MW) $155,000
Centac air compressor 1,500 hp (1.1 MW) $78,000
Energy Savings Predictions Compressors Previous Rew Fwd Help Menu

Available energy savings can be predicted
Less than one year pay-backs* typical by reducing recycle of blow-Off
Pay-back 12
Period 11 Pay-back less than 10
(Months) Months with 15% Reduction
10
9
8
7
Pay-back less than 6
6
Months with 15% Reduction
5
1000 HP
4
3 3,500 HP
Pay-back approximately 1
2 Month with 15% Reduction
1
20,000 HP
0 5 10 15 20 25 30 35
Reduced Recycle
(Per Cent of Maximum Compressor Flow)
*Assumes electro motor power At $0.05 US per kilowatt hour or turbine power at $327
per horsepower per year. Tax consequences are not considered in pay-back period
due to varying tax policies around the world.
Energy Saving Examples Compressors Previous Rew Fwd Help Menu

Downtime costs can be enormous!
• 60,000 BPD Cat Cracker: $90,000 per hour, lost sales plus
fixed expenses. The biggest units are twice this size!
• Natural Gas Production, 100 MMSCFD: $12,500 per hour

lost sales plus fixed expenses.
• Consequences of downtime: Lost profit, lost customer

goodwill, repair costs, attention of top management.

Commissioning costs are large
Process 100 MMSCFD 60,000 BPD

Natural Gas Plant Cat Cracker
Start-up Cost Per Day $375,000 $2,300,000
• Includes lost sales plus fixed operating expenses.
• Most turbo compressor control system design problems are

discovered during commissioning.
• Delays due to turbomachinery control problems are not unusual.
• Startups are faster with a properly designed turbomachinery

control system.

30-year life cycle costs for a 20,000 hp compressor
Maintenance Costs
$4.5 Million
Initial Cost
$1.5 Million
97%
of total costs
Energy Costs
$180 Million
Costs in constant dollars

Source: Experiences in Analysis and Monitoring Compressor Performance
Ben Duggan & Steve Locke
E.I. du Pont, Old Hickory, Tennessee
24th Turbomachinery Symposium

30-year cost per 1,000 hp
$ Millions
15.0
What can we control?
10.0
Uncontrollable
Controllable
5.0
?
0.0
Initial Cost Maintenance Energy Lost
Production
Costs in constant dollars
Source: Experiences in Analysis and Monitoring Compressor Performance
Ben Duggan & Steve Locke, E.I. du Pont, Old Hickory, Tennessee
24th Turbomachinery Symposium

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 (35 kPa 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
Picture of Barrel Type
Cross Section of Integrally Geared
Picture of Integrally Geared

IMPELLERS
Single Case Compressor Centrifugal Impeller Picture of Gear and Impellers

Cross section of horizontal split
Discharge volutes
Impeller inlet labyrinth seals
Impellers
Shaft and labyrinth seal
Drive coupling
Journal bearing
Casing Thrust bearing

(horizontally split flange)
Compressor discharge nozzle
Compressor inlet nozzle
Picture of Horizontal Split Centrifugals Previous Rew Fwd Help Menu

Picture of horizontal split
Cross Section of Horizontal Split Centrifugals Previous Rew Fwd Help Menu
Cross section of barrel type compressor
Picture of Barrel Type Centrifugals Previous Rew Fwd Help Menu

Picture of barrel type compressor
Cross Section of Barrel Type Centrifugals Previous Rew Fwd Help Menu
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 Gear and Impellers Picture of Integrally Geared Centrifugals Previous Rew Fwd Help Menu
Picture of bull gear compressor
Picture of Gear and Impellers Cross Section of Integrally Geared Centrifugals Previous Rew Fwd Help Menu
Picture of (bull) gear and impellers
Picture of Integrally Geared Cross Section of Integrally Geared Centrifugals Previous Rew Fwd Help Menu
Axial compressors
• Gas flows in direction of rotating shaft
• Can be built for lower pressures only
10 to 100 psi (0.7 to 6.8 Bar)
• High flow rate

• Efficient
• Not as common as centrifugals
Stator Blades
Rotor Blades Shaft
Casing
Rotor
Blades
Stator
Blades
Casing
Cross Section of Axial Picture of Axial Compressors Previous Rew Fwd Help Menu
Cross section of axial compressor
Guide-vane actuator linkage
Labyrinth seals
Compressor rotor
Rotor blades
Adjustable guide vanes
Thrust bearing
Compressor inlet nozzle

Compressor outlet nozzle
Picture of Axial Axials Previous Rew Fwd Help Menu

Picture of axial compressor
Cross Section of Axial Axials Previous Rew Fwd Help Menu

Compressor system classifications
Single-Section, Three-Stage Single-Case, Two-Section, Six-Stage
Parallel Network Two-Case, Two-Section, Six-Stage
Series Network

DP
R
Pcdpc c
R
H DischargeRatio
Differential
Pressure
Polytropic Pressure
Head
Pressure
(Pd/P(P
s(P
) 2or
d PR
) -(P s/P
2)process,2
or
1) (P2 - P1)
Rprocess,1
Rc2
Rc1
Compressor curve
for a specific
speed N1
Q2 Q1 Qs, normal
mass
vol

process limit
Rc
adding control
margins
maximum speed
surge limit
power limit
stonewall or
choke limit
stable zone
Actual available
of operation
operating zone
minimum speed
Qs, vol

How an airplane wing develops lift
v1, p1
v2, p2
Bernoulli’s law
• pstatic + 1/2rv2 + rgH = Constant
• The term rgH is negligible for the wing Lift
• Then: pstatic + 1/2rv2 = Constant
• Due to the shape of the

wing: v2 < v1 thus p2 > p1
• As a result there is Dp or
lift
• And the plane can
fly

How the airplane develops stall
Lift
Lift
Lift
Lift
• As the wing tilts back the Dv changes and thus the Dp

• This leads to more lift
• When the wing is tilted too much the streaming profile
suddenly changes from laminar to turbulent
• The air no longer “sticks” to the wing and the lift is lost
• The plane starts to fall down

Developing the surge cycle on the compressor curve
Pd
• Compressor reaches surge point A
• • From A to B 20 - 50 ms Drop into surge Pv
•
Compressor looses
Compressor itsstarts
abilitytotobuild
make pressure
• pressure
From C•to DCompressor
20 - 120“rides”
ms curve
Jumptowards surge
out of surge Rlosses
• Suddenly
• P
Point
d drops
A and thus
is -reached P v > P d
• • A-B-C-D-A
Plane• goes 0.3
tosurge 3 seconds
stall -cycle
Compressor Surge cycle
surges
The is complete
Pd Pd = Compressor discharge pressure

B A Pv = Vessel pressure
Rlosses = Resistance losses over pipe
•Pressure builds • System pressure is going down
• D
Resistance goes up
• Compressor is again able to overcome Pv
C •Compressor “rides”
• the curve “jumps” back to
Compressor
•Pd = Pv + Rlosses performance curve and goes to point D
• Because Pv > Pd the flow reverses • • Forward
Electroflow
motor is started
is re-established
• • Result of flow reversal is that pressure
Compressor operating point goes to point Bgoes • Machine accelerates to nominal
down speed
• Pressure goes down => less negative flow • Compressor reaches performance
• Operating point goes to point C curve
• Note: Flow goes up faster because
pressure is the integral of flow
Machine shutdown Qs, vol

no flow, no pressure

Major process parameters during surge
FLOW
• Rapid flow oscillations
• Thrust reversals
• Potential damage
1 2 3
TIME (sec.)
PRESSURE
• Rapid pressure oscillations
with process instability
1 2 3
TIME (sec.)
TEMPERATURE • Rising temperatures inside

compressor
1 2 3
TIME (sec.)

Surge description
• Flow reverses in 20 to 50 milliseconds
• Surge cycles at a rate of 0.3 s to 3 s per cycle
• Compressor vibrates
• Temperature rises
• “Whooshing” noise
• Trips may occur
• 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
• Operation at heavy throughput with:
- Trips - Power loss

- Operator errors - Process upsets
- Load changes - Gas composition changes
- Cooler problems - Filter or strainer problems
- Driver problems
• Surge is not limited to times of reduced throughput. Surge

can occur at full operation

Compressor control
Objectives Performance control
Major challenges of compressor control Loadsharing for parallel compressors

Location of the surge limit Compressor networks
High speed of approaching surge Base loading parallel compressors
Control loop interactions Equal flow division system

Loadsharing of multiple compressors CCC’s equidistant Loadsharing system
Antisurge control Other topics

Basic antisurge control system Fall-back strategies
Protection #1: PI control Limiting control

Protection #2: Recycle Trip Pressure Override Control (POC)
Protection #3: Safety On Flow Measuring Devices (FMD’s)
Output linearization Antisurge control valve
The tight shut-off line Piping lay-out considerations
Influence of controller execution time

Dynamic simulation single compressor
Dynamic simulation parallel compressors
Previous Rew Fwd Help Menu

Major control system objectives
(user benefits)
1. Increase reliability of machinery and process

• Prevent unnecessary process trips and
downtime
• Minimize process disturbances
• Prevent surge and surge damage
• Simplify and automate startup and shutdown
2. Increase efficiency of machinery and process Energy Saving Examples
• Operate at lowest possible energy levels

• Minimize antisurge recycle or blow-off
• Minimize setpoint deviation
• Maximize throughput using all available
horsepower
• Optimize loadsharing of multiple units
Compressor control Previous Rew Fwd Help Menu

Calculating the distance between the Surge
Limit Line and the compressor operating point
The Ground Rule

– The better we can measure the distance to surge, the closer we can
operate to it without taking risk
The Challenge
– The Surge Limit Line (SLL) is not a fixed line in the most commonly used
coordinates. The SLL changes depending on the compressor inlet
conditions: Ts, Ps, MW, ks
Conclusion
– The antisurge controller must provide a distance to surge calculation that
is invariant of any change in inlet conditions
– This will lead to safer control yet reducing the surge control margin which
means:
• Bigger turndown range on the compressor
• Reduced energy consumption during low load 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 inlet conditions:
ps, Ts, MW and ks

The problem with commonly used (OEM provided)
coordinate systems of the compressor map
• These coordinates are NOT invariant to suction conditions as shown
• For control purposes we want the SLL to be presented by a single

curve for a fixed geometry compressor

Developing invariant coordinates
• The following variables are used to design and to characterize
compressors
• Through dimensional analysis (or similitude) we can derive two
sets of invariant coordinates
Fundamental variables Invariant coordinates

characterizing compressor
operation Set 1 Set 2
hr Rc
Dimensional analysis qr qr
Hp = f0(Q, w, m, r, a, d, a)
or Similitude Ne Ne
a a
J = f1(Q, w, m, r, a, d, a) jr jr
Re Re
where: where:
• Hp = Polytropic head • hr = Reduced head
• J = Power • qr = Reduced flow
• Q = Volumetric flow rate • Ne = Equivalent speed
 w = Rotational speed  a = Guide vane angle
 m = Viscosity • jr = Reduced power
 r = Density • Re = Reynolds number
• a = Local acoustic velocity • Rc = Pressure Ratio
• d = Characteristic length
 a = Inlet guide vane angle Compressor control Previous Rew Fwd Help Menu
Coordinates (Hp, Qs) and (hr, qr2)
(Hp, Qs) (hr, qr2)

NOT invariant coordinates Invariant coordinates
where:
• Hp = Polytropic head
• Qs = Volumetric suction flow
• hr = Reduced head
• qr2 = Reduced flow squared
Coordinates (Rc, Qs) and (Rc, qr2)
(Rc, Qs) (Rc, qr2)
NOT invariant coordinates Invariant coordinates
qr2
where:
• Rc = Pressure ratio
• Qs = Volumetric suction flow
• qr2 = Reduced flow squared
Coordinates (Rc, jr) and (Rc, Ne2)
(Rc, jr) (Rc, Ne2)
Invariant coordinates Invariant coordinates
where:
• Rc = Pressure ratio
• jr = Reduced power
• Ne2 = Equivalent speed squared
Representing the SLL as a single curve
using reduced coordinates
• A coordinate system that is invariant to suction conditions is:

Hp Qs
hr  and qr 
(ZRT)s ( ZRT)s
• Squaring the flow will still keep coordinates invariant:

2
Hp Q
hr  and qr2  s
(ZRT)s ( ZRT)s
hr
Design Nitrogen Off-gas

MW MW MW
Ps Ps Ps
Ts Ts Ts
ks ks ks
2
qr

Calculating qr2 (reduced flow squared)
K . Zs . Ru . Ts Dpo,s
.
Qs2 MW ps Dpo,s
qr 2= = =
(ZRT)s (ZRT)s ps
• where:
• R = Ru / MW
• Ru = Universal gas constant
• R = Specific gas constant
• MW = Molecular Weight of the gas
• ps = Suction pressure
• K = Orifice plate constant
 Dpo,s = Differential pressure across orifice plate
• Ts = Temperature of the gas in suction
• Zs = Compressibility of gas in suction of compressor
• The antisurge controller calculates qr2 using ps and Dpo,s transmitters

Calculating hr (reduced head)
Zs . Ru . Ts Rcs-1
.
Hp
MW s Rcs-1
hr = = =
s
(ZRT)s (ZRT)s
log(Rt)
• For polytropic compression Rt = Rcs thus s =
log(Rc)
• R = Ru / MW
• Rt = Td / Ts Temperature ratio
• Rc = pd / ps Pressure ratio
where:
• Ru = Universal gas constant
• R = Specific gas constant
• MW = Molecular Weight of the gas
• pd = Discharge pressure
• ps = Suction pressure
• Zs = Suction compressibility
 s = Exponent for polytropic compression
• The antisurge controller calculates hr using pd, ps, Td and Ts transmitters

Building the Surge Limit Line
• Any curvature of the Surge Limit Line can be characterized as a

function of the ordinate hr
f1(hr )
• The surge parameter is defined as: Ss  2
qr ,op
• The function f1 returns the value of qr2 on the SLL for input hr
hr
hr
2 2
qr,SLL qr

The surge parameter Ss
2
• The function f1 returns the value of qr on the SLL for input hr
q2r,SLL
• As a result: Ss =
q2r,op hr
Ss > 1
OP
hr
• Ss < 1 : stable operating zone
Ss < 1
• Ss = 1 : surge limit line (SLL)
• Ss > 1 : surge region 2

2 2
qr
qr,SLL qr,op
OP = Operating Point

Introducing the distance between the operating
point and the Surge Control Line
• Step 1: Introduce parameter d = 1 - Ss
• Step 2: Introduce parameter DEV = d - surge margin
• The parameter DEV is independent of the size of the compressor

and will be the same for each compressor in the plant
d =0
Ss = 1 Benefits:
hr d <0 DEV = 0 • One standard surge parameter
Ss > 1 in the plant
DEV < 0 • No operator confusion:
Ss < 1 • DEV > 0 Good

d >0 • DEV = 0 Recycle line
DEV > 0
• DEV < 0 Bad
2
Surge margin
qr

Simplifying the surge parameter
by replacing hr with Rc
• Reduced Head hr can be replaced by Rc while keeping the

coordinate system invariant to suction conditions
f1(Rc)
• The surge parameter Ss now becomes Ss = 2
qr,op
2
where the function f1( ) returns the value of qr,SLL
on the SLL for the input Rc
• This eliminates the need for Td and Ts transmitters for control

Important Note: CCC still strongly recommends Td and Ts
transmitters as well as rotational speed N for compressor
monitoring purposes

The simplest CCC surge parameter
• An antisurge algorithm can be designed around two transmitters:

Dpo and Dpc
f1(Rc)
• The parameter Ss = 2 is invariant to inlet conditions and speed
qr
• For two transmitters choose the function f1 to be (Rc - 1)
pd
Ss =
f1(Rc) Rc - 1
= Dp =
( ps
-1) . ps
=
pd - ps
=
Dpc
2
qr o Dpo Dpo Dpo
ps
• Selecting the specific function for f1(Rc) to be (Rc - 1) keeps the

map invariant to inlet conditions and speed

Disadvantage of the Dpc /Dpo surge parameter
• The SLL is rarely a straight line in the coordinates qr2 and Rc
• The parameter Dpc /Dpo represents a straight line in the invariant

coordinates qr2 and Rc
• The Dpc /Dpo approach results in loss of turn down and

unnecessary recycle
Rc
loss of operating envelope

Actual Surge Limit Line (SLL)
SLL calculated by antisurge

controller using
Dpc /Dpo = constant
2
qr
Actual field data showing disadvantage of
Dpc /Dpo surge parameter

Surge parameter for compressor with sidestream
Problem definition
1 2 3
Dpo,1 Dpo,2
P1 P2
T1 T2
q3 and T3 are internal to the compressor and cannot be measured

Derive a new surge parameter for compressor with
sidestream: qrNe
• Any combination of invariant parameters results in another
invariant parameter
• Derive equation for surge parameter that does not require
measurement of T and qr at point 3
.
qr  m ZRT
Step 1: Reduced flow p
N
Step 2: Equivalent speed Ne 
ZRT
. .
N mN
Step 3: Combine qr and Ne qrNe  m ZRT . =
p ZRT p
where:
.
• m = mass flow
• Z = Compressibility
• R = Gas constant
• Ne = Equivalent speed
• qr = Reduced flow
• N = Rotational speed
• p = Pressure
• T = Temperature
Calculating the invariant parameter qrNe
1 2 3
Dpo,1 Dpo,2
p1 p2
. .
T1 m1 m2 T2
 p  p   
  A1 Dpo,1 1
 A Dp  2
 N . . .
  T1 2 o,2 
 T2    (m1 + m2 ) N
. m3 . N
q3 Ne,3  = =
 p2  p2 p3
 
 

Developing invariant surge patameter
Rc vs. qrNe

The approach to surge is fast
1 SEC. Pd D
100%
A
0 Qs
Pd
100%
• Typically, performance curves are
ABC extremely flat near surge
D
• Even small changes in compressor
0 pressure differential cause large
DPo flow changes.
100%
• The speed of approaching surge is

AB C
high. In only 0.4 seconds, DPO
dropped by 14%, with a 2% change
0 in DPc
DPc

The approach to surge is fast - another example
100%
DPo
0
1 sec.
100%
DPc
For a 2% increase in pressure differential

(DPc), flow rate DPo dropped 9% in 0.3 sec.

Basic antisurge control system
• The antisurge controller UIC-1 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
Rprocess
Rc
Rprocess+valve
VSDS
Compressor
FT PsT PdT
1 1 1 2
qr
Suction Discharge
UIC • Surge parameter based on invariant
1
coordinates Rc and qr
– Flow measured in suction (DPo)
– Ps and Pd transmitters used to
calculate Rc

Antisurge controller operation
Protection #1: The Surge Control Line (SCL)
Rc SLL = Surge Limit Line • When the operating point

SCL = Surge Control Line crosses the SCL, PI control
will open the recycle valve
B
• PI control will give adequate
A
protection for small
disturbances
• PI control will give stable

control during steady state
recycle operation
2 • Slow disturbance example

qr

Adaptive Gain
Enhancing the effectiveness of the PI controller
Rc • When the operating point

moves fast towards the SCL,
adaptive gain moves the SCL
B towards the operating point.
A
• This allows the PI controller
to react earlier
• As a result a smaller steady

state surge control margin
can be achieved without
sacrificing reliability
2
qr
• Fast disturbance example

Protection #2: The Recycle Trip® Line (RTL)
SLL = Surge Limit Line
• Total response
Disturbance
When
Operatingthe
OP hits
operating
pointarrives
SCL
of
keeps
Moves
controller
the
the
point
PI
moving
back
Operating
controller
hits
is
tothe
the
the
RTL = Recycle Trip® Line
Rc Pointside
opens
towards
Recycle
safe
sum of(OP)
valve
the
Trip
surge
ofmoves
PIthe
based
Line
control
and
RTL
(RTL)
towards
on
hits
and
proportional
Recycle
the
Recycle
the SCL
SCL = Surge Control Line
and
conclusion
Trip integral
LineRT(RTL)
action
– The is:
actiondecays out the
function
– step
We areresponse
close to surge
– PI
Thecontroller integrates
PI controller to stabilize
is too slow to
• Benefits:
OP on SCL
catch the disturbance
– Get
– Energy
out savings due to smaller
of the dangerous zone
surge margin
• An open loop response is
– Compressor has more turndown
triggered
before recycle or blow-off
– Surge can be prevented for
virtually any disturbance
2
qr
Output Recycle Trip®
PI Control
to Valve Action
Total Response
PI Control Response
+
Recycle Trip® Response

To antisurge
Time valve

Improving the accuracy of Recycle Trip®
open loop control
• Recycle Trip® is the most powerful method known for antisurge

protection
• But, open loop control lacks the accuracy needed to precisely
position the antisurge valve
• Open loop corrections of a fixed magnitude (C1) are often either too
big or too small for a specific disturbance
• The rate of change (derivative) of the compressor operating point
has been proven to be an excellent predictor of the strength of the
disturbance and the magnitude required from the Recycle Trip®
response
• Therefore, the magnitude of actual step (C) of the Recycle Trip
response is a function of the rate of change of the operating point
or d(Ss)/dt

Recycle Trip® based on derivative of Ss
Recycle Trip® Benefits
Response calculation • Maximum protection
– No surge
d(Ss) – No compressor damage
C = C1Td
dt • Minimum process disturbance
where: – No process trips
• C = Actual step to the valve
• C1 = Constant - also defines maximum step
• Td = Scaling constant
• d(Ss)/dt = Rate of change of the operating point
Output Medium disturbance Output Large disturbance

to valve to valve
100%
Total
PI Control
Total
PI Control
Recycle Trip® Recycle Trip®
0%
Time Time

What if one Recycle Trip® step response is not enough?
• After time delay C2 controller checks if Operating Point is back to

safe side of Recycle Trip® Line (RTL)
– If Yes: Exponential decay of Recycle Trip® response
– If No: Another step is added to the Recycle Trip® response
Output One step response Output Multiple step response

to valve to valve
100%
Total
PI Control
Total
PI Control
Recycle Trip®
0% Recycle Trip®
Time Time
C2 C2 C2
C2
Protection #3: The Safety On® Line (SOL)
SOL = Safety On® Line •• Additional

PI
The
If Operating
control
Safetyand ®Recycle
safety
OnPoint
response
or
crosses
surge
Trip ® will
shifts
margin
the Safety
theis
SLL = Surge Limit Line
RTL = Recycle Trip® Line
SCL
added
stabilize
On® and
Linethe
themachine
RTL to the
onright
compressor the new
is in SCL
surge
SCL = Surge Control Line
Rc
Compressor can surge due to:

• Transmitter calibration shift
• Sticky antisurge valve or actuator
• Partially blocked antisurge valve or
recycle line
New SCL
• Unusual large process upset
New RTL
2 Benefits of Safety On® response:

Additional surge margin qr
• Continuous surging is avoided
• Operators are alarmed about surge

Built in surge detector
• Surge signature is recorded during

Pressure and Flow Variations commissioning
During a Typical Surge Cycle
• Rates of change for flow and pressure
100% during surge are determined
• Thresholds are configured slightly more
conservative than the actual rates of
Pd change during surge
• Surge is detected when the actual rates of
0%
change exceed the configured thresholds
1 TO 2 SECONDS • The following methods can be used:
100%
• Rapid drops in flow and pressure
• Rapid drop in flow or pressure
DPo • Rapid drop in flow only
• Rapid drop in pressure only
• When surge is detected a Safety On®
0%
response is triggered
20 to 50
milli-seconds
• A digital output can be triggered upon a
configurable number of surge cycles

Increase compressor system reliability and
availability with fall-back strategies
• Over 75% of the problems are in the field and not in the controller
• The CCC control system has fall-back strategies to handle these field
problems
• The controller continuously monitors the validity of its inputs
• If an input problem is detected the controller ignores this input and
automatically switches to a fall-back mode
• Benefits
– Avoids nuisance trips
– Alarms operator of latent failures
– Increases machine and process availability

Fall-back strategies for the antisurge and
performance controller
• Antisurge controller
– If a pressure transmitter fails, a minimum q2r algorithm is used
– If a temperature transmitter fails, hr is characterized as a function
of compression ratio
– If the speed transmitter fails, a conservative speed setting is used
– If the flow transmitter fails
• Redundant transmitter is used
• Output is driven to:
– Last value OR
– Last Value selected: If Last Value >Pre-selected fixed value OR
Pre-selected fixed value selected: If Pre-selected fixed value>Last
Value
• Performance controller
– Switches to redundant transmitter upon primary transmitter
failure
– Output goes to pre-selected value if all transmitters fail or is
frozen
• All transmitter failures are alarmed

Output linearization
Flow rate • Controller

Dynamic
Existing
Linear
For antisurge
valve
valve
flow
output
gives
control
response
hasisthe
equal
quick
characterized
asame
linear
becomes
percentage
opening
valveas
through as
linear
trim
dynamic
is preferred
mirror
mirror
image
flow
image
in
response
the
in the
linear
linear
over
valve
valve
its line
valve line
complete stroke
Controller output
Valve trim
quick opening
Valve trim
Controller output
equal percentage
Controller
output
Notes
• Used to improve controllers operation when non-linear valves are
used
• Used on retrofits to avoid additional investment in new valve
• Works well with equal percentage characteristics
• Works less satisfactory with quick opening characteristics

The Tight Shut-off Line (TSL)
Dynamic control range
Flow rate Controller
through output
valve
PI Control
Controller A B C Time
output
Low clamp on controller output

0% to the valve • At
CCC
The
For
When
Manythe
dynamic
5%
controller
antisurge
antisurge
the
low
oroperating
controller
low
clamp
control
is
clamp
controller
valves
now
value “ready
point
crosses
we
value
have
the
want
has to
isvalve go”
represents
to
the
the
to
a the
Tight
use
TSL
Shut-off
the
right
following
when closed
range
output
of
the
• Usually the
Line
operating
characteristic:
5%of
position
TSLthe
-(TSL)
still 100%
the
controller
leaksfor
controller
points
that
on control
the
eliminates
which hits
jumps
valve
closes
theto
results
SOL SLL RTL the
purposes
SCL disadvantages
• invalve
low
- energy
frompoint
clamp
at C
0% 0% value
- point
towaste
low - point
clampA value B the
Rc SCL
• This flow
is below
rate
TSL = Tight Shut-off Line • Makes
Benefits anthrough
the low the
annoying clampvalve
noise valueis
(almost) zero and does not
•• Typical
No leakage
changefor worn
and noisevalveswhenand valves
controller
C with Teflon seat
B is• far away
Once thefrom
lowsurgeclamp- is point
reachedA
A • Eliminates noise and energy
the characteristic is linearwaste
• Eliminates
• Typical dead low clamp time in the response
value can be
of the5%antisurge
- we will use valvethe when
5% as thethe
operating point is close
value throughout to the
in this SCL
example
2
qr Compressor control Previous Rew Fwd Help Menu
Compressor performance control
• Also called:
– Throughput control
– Capacity control
– Process control
• Matches the compressor throughput to the load
• Can be based on controlling:
– Discharge pressure
– Suction pressure
– Net flow to the user

Performance control by blow-off or recycle
Pd
Rprocess
Rprocess + Rvalve Process

B A
PIC - SP PT
1
Curve 1
PIC
1
Curve 2
Notes
qr
2 • •Q
Compressor
Pressure
Point
Required
Power
Most
Curve
loss represents
B2
loss
represents
is
power
is
controlled
operates
P1 energy
inefficient in
represents:-Ppoint
the
2 inby
point
controlwaste
A
B
point
blow-off
is that
P1A
method2
Shaft
power Qloss would deliver the pressure for Rprocess
• Regularly
• Lower speedfoundon in variable
plant air speed
systems
P1 systems
• Rare in other systems
Curve 1
P2 • Not• IGVs closed on variable geometry
recommended
Curve 2 compressors
• Inlet throttle valve closed on fixed
speed compressors
2
qr

Performance control by discharge throttling
Pd
Rprocess + Rvalve
A
Rprocess
Pressure loss Process
across valve
PIC - SP PT
1
Curve 1
Curve 2
PIC
1
Notes
• Power
Compressor
Required
Pressure
Opening
Lower resistance
loss
of
is
power
is
valve
controlled
operates
P1 is
-would
would
PP21 in
byreduce
require
point A
2
Shaft qr • Curve 2 represents:
pressure
resistance
less speeddrop
to
andRover
powervalve
process
power
• Lower speed on variable speed
P1 Notes
systems
P2 Curve 1 • Extremely inefficient (consumes
• IGVs closed on variable geometry
Curve 2 approx. the same power for every load)
compressors
• Rarely used
• Inlet throttle valve closed on fixed
• Not recommended
speed compressors
2
qr

Performance control by suction throttling
Pd
Rprocess
Process
A
PIC - SP PT
Suction valve open 1
Suction valve throttled

PIC
1
• Required
Inlet
Changing
Pressure
Compressor
valveis
power
suction
manipulates
controlled
operates
is pressure
P1 in
by
suction
point
inlet A
2 pressure
generates
valve
for given
position
Raprocess
family of curves
Shaft qr
power Notes
• Common on electric motor machines
P1 • Much more efficient than discharge
throttling
• Power consumed changes proportional
to the load
2
qr • Throttle losses are across suction valve

Performance control by adjustable guide vanes
Pd
Rprocess
Process
A
PIC - SP PT
1
amax PIC
aOP 1
amin
•Required
Different
Pressure
Compressor
Change of geometry
is
power
controlled
operates
guide is Pmeans
1 in
vanes by inletaA
point
angle
2 different
guide
for given
vane
Shaft qr results inperformance
Rdifferent
positioncompressor
process curve
power Notes geometry
• Improved turndown
P1 • More efficient than suction throttling
• Power consumed is proportional to the
load
• Power loss on inlet throttling is
2
qr eliminated

Performance control by speed variation
SIC
Pd 1
Rprocess
Process
A
PIC - SP PT
Nmax 1
NOP PIC
1
Nmin
• Required is
Changing
Pressure
Compressorpower
speed
controlled
operates
is
generates
P1 in
bypoint
speed
a A of
2 family
rotation
for given
of curves
Rprocess
Shaft qr
power Notes
• Most efficient (Power  f(N)3)
P1 • Steam turbine, gas turbine or variable
speed electric motor
• Typically capital investment higher than
with other systems
2
qr • No throttle losses

Limiting control to keep the machine in its stable
operating zone
• While controlling one primary variable, constrain the

performance control on another variable
CONTROL BUT DO NOT EXCEED
Discharge Pressure Max. Motor Current
Suction Pressure Max. Discharge Pressure
Net Flow Min. Suction Pressure
Suction Pressure Max. Discharge Temperature
• Exceeding limits will lead to machine or process damage

• Performance controller controls one variable and can limit
two other variables.

Power limiting in the performance controller
an example
Power limit • However
Primary
Limiting
Compressor
Machine
Process
PIC will speed
would variable
variable
resistance
hits
power
like
operates
power
machine
tolimiting
PPower
speed
d decreases
changes
limit
inup
loop
point
to
Rc
R1 • A
from
N
further
machine
takes
2for
in R
order
control
11to
Compressor to
atup
RR
Nto
to
32
1 and
control
N4 and
controls
operates pressure
operate
in point
P
in
machine
point
Bdfor R2 D atNspeed
at 2
N3
R2
• Compressor will operate in
R3
A point C for R3 at N3
D PIC-SP
B
C
N
N4 Benefits
N2 3
• Maximum protection
N1
– No machinery damage
• Maximize production
– Machine can be pushed to the
Qs, vol limits without risk of damage
Note: Same approach for other variables (pressures, temperatures, etc.)

Limiting Ps or Pd using the antisurge controller
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

Interacting antisurge and performance loops
• Interaction starts at B
• Performance controller on
discharge pressure reduces
Rc
performance to bring
pressure back to setpoint
• Unless prevented, PIC can
B drive compressor to surge
C A • Antisurge controller starts to
PIC-SP
operate at B
• Even if surge is avoided,
interaction degrades pressure
control accuracy
• Results of interaction
– Large pressure deviations
DPo during disturbances
Ps
– Increased risk of surge

The performance controller interacts with
the antisurge controller
• Both controllers manipulate the same variable - the

operating point of the compressor
• The controllers have different and sometimes

conflicting objectives
• The control action of each controller affects the other
• This interaction starts at the surge control line - near

surge - and can cause surge

Ways to cope with antisurge and
performance loop interactions
• De-tune the loops to minimize interaction. Result is

poor pressure control, large surge control margins and
poor surge protection
• Put one loop on manual so interaction is not possible.

Operators will usually put the Antisurge Controller on
manual. Result - no surge protection and often partially
open antisurge valve
• Decouple the interactions. Result - good performance

control accuracy, good surge protection and no energy
wasted on recycle or blow off

Interacting antisurge control loops
VSDS
Section 1 Section 2
UIC UIC PIC

1 2 1
Disturbance
R R
Rc,1 Rc,2
R R
2 2
qr,1 qr,2
• • The
Antisurgeofcontroller
Opening recycle valvesystem
UIC-1on
will
section
open 2 •• Opening
is oscillating of controller
Disturbance
Antisurge recycle
comesvalve
from on
UIC-2
thesection
will open1
caused
the recycle = P•d,1to
Ps,2 valve toprotect
increase
Slowing section
down caused
1 controller
the Pd,1side
discharge
the recycle
tuning = Ps,2 lead
valve
would to decrease
protect
to: section 2
against • Increased risk of surge • Pd,2 increases
• Result:
• Result: surge against surge
•• P
Pd,1 decreases
d,1 increases • ••
• Compressor damage PP
Ps,2s,2 remains constant
decreases
d,2decreases
•• P
Ps,1 increases
s,1 remains constant
• Process trips • •• PR
Pd,2
s,2
increases
increases
c,2remains constant
•• R
Rc,1 decreases • Bigger surge margins • •• Section
R 2 moves
decreases
Rc,2c,2increases towards surge
c,1 increases
•• Section
Section 1 1 moves
moves away • surge
from
towards Energy
surge waste •• Section22moves
Section movestowards
away from surge
surge

Loop decoupling between multiple antisurge controllers
VSDS
Section 1 Section 2
UIC Serial UIC Serial PIC

1 network 2 network 1
• All CCC controllers are connected on a serial network

• This allows them 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
• The output of UIC-2 is send to UIC-1 to inform UIC-1 about the
disturbance that is arriving
• UIC-1 anticipates the disturbance by immediately opening its valve
Note: The same applies when the antisurge
valve on section 1 is opened first Compressor control Previous Rew Fwd Help Menu
Loop decoupling simplified block diagram
VSDS Benefits
Section 1 Section 2
• Each controller
Antisurge
UIC-2
UIC-1
Loop decoupling
reports
• Avoids itshas
is protecting
controller
PI
control PI
and and
its
block
values
value own
Recycle
section
UIC-2
Recycle
is 1decoupling
TripTrip
multiplies
system ofadded
opens
other ®
against
to values
gain
controllers
its
reported
output
output
oscillationsvalve
surge to
toto
PIM nUIC-2
using toPI
UIC-1
protect
and
• allow
section
and
Recyclefor
antisurge tuning
(performance
Recycle
2Trip ®
against
valve
Trip
and1ofsurge
®
values relative
antisurge)
with loop
aregains between
Serial Same decoupling
• Allows takes ofdecoupling
place added gain
to output
M2 to
UIC UIC
1 network 2 faster tuning control system
different controllers
antisurge valve 1
• Reduced risk of surge
• Allows closer operation to surge limits
without taking risk
From other From other

Analog Inputs controllers Analog Inputs controllers
FA FA
Mode Mode
DEV1 PIn . Mn PI2 . M2 DEV2 PI1 . M1 PIn . Mn

+ + + +
PI RT RTn . Mn RT2 . M2 PI RT RT1 . M1 RTn . Mn
+ + + +
Loop Loop
Antisurge Decoupling Antisurge Decoupling
Controller 1 Controller 2
To antisurge valve 1 To antisurge valve 2

Compressor networks
• Compressors are often operated in parallel and, less

frequently, in series
• The purposes of networks include:
– Redundancy
– Flexibility
– Incremental capacity additions
• Usually, each compressor is controlled, but the network is
ignored
• Compressor manufacturers often focus on individual
machines
• Control of the network is essential to achieve good surge
protection and good performance control of the network

Control system objectives
for compressors in parallel
• Maintain the primary performance variable (pressure or flow)

• Optimally divide the load between the compressors in the
network, while:
– Minimizing risk of surge
– Minimizing energy consumption
– Minimizing disturbance of starting and stopping individual
compressors

Process Flow Diagram for base load control
VSDS
Compressor 1 Swing machine
UIC
1
PIC
1
HIC
1
Suction
Process
header
VSDS
Compressor 2 Base machine

Notes
UIC • All controllers act independently
2
• Transmitters are not shown

Parallel compressor control by base loading
Compressor 1 Compressor 2
Rc,1 Rc,2
Swing machine Base machine
PIC-SP
QP,1 + QP,2 = QP,1 + QP,2

2 2
qr,1 qr,2
QP,1 QC,1 QP,1 QP,2 QC,2= QP,2
Notes
• Load
Machines
Base
Swing load
machine
could
machine
operate
one
be is
or
re-divided
can
fully
more
atbe
same
loaded
running
compressors
toReliminate
c and
since
with
runs
suction
recycle
and
recycle
without
letand
therecycle
discharge
other(s) absorb
of both the
• Base loading is inefficient
machines
load swingsare tied together
• Base loading increases the risk of surge since
compressor #1 will take the worst of any disturbance where:
• Base loading requires frequent operator intervention • QP = Flow to process
• QC = Total compressor flow
• Base loading is NOT recommended • Q -Q = Recycle flowC P

Process Flow Diagram for equal flow division
RSP
VSDS
Compressor 1
out
UIC FIC RSP
1 1
out
PIC
1
Suction
Process
header
RSP
VSDS Notes
Compressor 2 • Performance controllers act
independent of antisurge control
out
UIC FIC • Higher capital cost due to extra
2 2
Flow Measurement Devices (FMD)
• Higher energy costs due to
permanent pressure loss across
FMD’s

Parallel compressor control by equal flow division
Rc,1 Rc,2
PIC-SP
Equal flow QP,1 = QP,2 Equal flow
2 2
qr,1 qr,2
QP,1 QP,2QC,2
Notes
• •Requires
Machine
Equal
Machines
Bias relay
flow
2are
operate
on
operates
division
remote
never
additional atmight
with
identical
same
capital setpoint
recycle
work
Rc except
since
would
investment ifin
while
both
suction
by
only
machines
machine
FMD’scoincidence
work
andif1discharge
are
curves
still-identical
different
hashave
turn
of both
machines
down
resistance
same steepness
are
duetied
to piping
togetherarrangments
• Requires additional energy due to permanent pressure
loss across FMD’s where:
• Poor pressure control due to positive feedback in • QP = Flow to process
control system (see next) • QC = Total compressor flow
• QC - QP = Recycle flow
• Equal flow division is NOT recommended
Dynamic control problem with pressure to flow
cascade system
• disturbance
Pressure
The
In
Process
As
Since
Only
aatypical
FIC
PIC
machine
result
as
the the
provides
reacts
is
disturbance
controller
PIC
the
theis isthe
master-slave
PIC
ismaster
fast
machine amplified
operating
starts
slow and
(PIC)
causes
RSP
itand
todoes
will
moves
control
reduce
in
provides
for
thetry
point
the
not
the
FIC
to
toitsis
A
Rc Remote
speed
the
scheme
resistance
point
move
maintain
output
slave
Bits
controller,
toSetPoint
the
output
its
control
toslave
SP
change
yet
suction
pressure
(RSP)
needs
which
from for
tothrottle
is
R
the
be
Flow
the
toFIC-
RFIC-
R2 • Positive
This is the feedback
intersectionsystem of 4 1lines:2
controller
valve
approx.
SP comes
or 5guide
times
(FIC)
down vanes
faster
and the thanpressure
the is
• The FIC will speed
– Resistance line Rup 1
the machine to
C R1 master
restored
point C at speedcurve
– Performance N 3 N1
B
– PIC-SP
D
PIC-SP – FIC-SP = Output of PIC
A
N3
N1 Notes
N2 • Requires additional capital
investment in FMD’s
• Requires additional energy due to
2 permanent pressure loss across
qr FMD’s
FIC-SP
• Poor pressure control due to positive
PIC OUT
RSP
FIC OUT
RSP
SIC feedback in control system
1 1 1
• Equal flow division is NOT
Master Slave recommended
Process Flow Diagram for equidistant control for
parallel compressors
RSP
VSDS
Compressor 1
out
UIC Serial LSIC Serial
1 network 1 network
MPIC
1
Suction
Process
header
RSP
VSDS
Notes
Compressor 2
• All controllers are coordinating
out control responses via a serial
UIC Serial LSIC
2 network 2 network
• Minimizes recycle under all
operating conditions

Parallel compressor control by equidistant operation
Rc,1 Rc,2
SCL = Surge Control Line DEV = 0
.1
.1
.2
.2
.3
.3
PIC-SP
Dev1  Dev2
Q1  Q2
N1  N2
2 2
qr,1 qr,2
DEV1 DEV2
Notes
• Since
The
Machines
DEV
DEVisare
operate
is
a dimensionless
kept at
at same
the same
Rcnumber
all
since
relative
sorts
suction
representing
ofdistance
machines
and discharge
to the
can
the distance
be
Surge
mixed:
of Control
both
between
small,
Line
the
• Maximum turndown (energy savings) without recycle or blow-off
• machines
operating
(SCL)
big, axials,
Recycle point
are
centrifugals
will tied
onlyandtogether
thewhen
start SurgeallControl
machinesLineare on their SCL
• Minimizes the risk of surge since all machines absorb part of the
• Lines
This
The DEV
means
of equal
willinbe
disturbance practice
DEV
the can
same the
befor
plotted
same
all machines
DEV
on the
for both
performance
but machines
they willcurves
operateasatshown
different speeds and
• Automatically flow rates
adapts to different size machines
• CCC patented algorithm

Compressors in parallel - the primary response
• If DEV
Master
The
In
Whenthe
output
primary
the
<=
controller
0machine
of
apply
the
response
loadsharing
controls
master
is close
block
controller
the
to the
gain
main
the SCL
controller
PID
Process
the
goes Master Controller
Variable
to
checks
master
the primary
controller
if(PV)
the machine
via
response
its
willPID
no
iscontrol
block
close
longerintoblock
reduce
the
the SCL: PV
• Output goes to antisurge valve
• loadsharing
performance
In– order
Yes: to
don’t controller
to control
reduce
check the primary
capacity
if the variable
- keepisoutput
machine close to PID
the constant
• TheSCLmasterthe controller
primary response
will startblock needs
to open the SP
–
the No:
DEV reduce capacity as necessary
recycle valve to control the primary variable
• Apply loadsharing gain M0
• The DEV is reported by the antisurge
• The output of the master controller goes via
controller
the primary response block directly to the
performance control element
Analog Inputs
FA
Mode
Don’t change
DEV <
>0 DEV DEV DEV
output No
Yes
Primary Primary
PI RT response response
Apply loadsharing
gain
x
+ +
Primary response Antisurge Loop Loop Loadsharing
Decoupling Decoupling
Controller Controller
To
Toantisurge
performance
valve To antisurge valve To performance
control element control element

The load balancing response
• This
In
Other
The order
fast
antisurge
loadsharing
master
average
loadsharing
to
master
balance
controller
DEV
controller
controller
controller
is
controllers
the
sent
calculates
machines
reports
out
controls
reports
toalso
all
the
the
they
this
report
the
actual
need Master Controller
• The load
average
primary
to
DEV
their
loadsharing
bePV
to
DEV
kept balancing
ofPV
the all
also
process
at
loadreportedblock
controllers
the
to
to the
the
balancing
same
variableDEV
master
master
DEVis
toby a
blockslow
PV’s
become
controller
controller
directly
in the SP PV
controller
manipulating
loadsharing
for that will
all load balancing equalize
controller
the finalblocks all DEV’s
control elements for all
PID
parallel compressors
• This reported DEV becomes the Process SP
• Its output(PV)
Variable is added
for thetoload
the balancing
total output to
PID
the
loopperformance control element
DEV from other Average
loadsharing controllers
Analog Inputs
DEV
FA
Mode
DEV DEV DEV
PV SP
Primary Load Primary
PI RT response balancing response
+ +
Antisurge Loop Loop Loadsharing
To antisurge valve To performance

control element

The Pressure Override Control (POC) response
• The
Benefits
When
There
Opening
As soon
operating
CCC
primary
a
islarge
aas
of
master
high
the
PID
disturbance
point
chance
antisurge
operating
loop
controller
rides
will
to valve
point
stabilize
exceed
the
occurs
has
curve
is
drops
a Pressure
the
it
much
the
can
and
relief
under
the
Master Controller
• operating
happen
pressure
valve
Override
faster
the
FastPOC-SP
setting
than
that
Control
rises
point
responsealine
the
reduction
and
sharply
on
performance
the
(POC)
trip
duringthe
antisurge
the
PIC-SP
in
mode
fast process
speedcontrol
that
line
valves
upsets willstart
open PV
element
the
to close
antisurge
again
(e.g. valve
speed) toisget
toothe
slow
disturbance
to keep the
• Avoid process trips due to lack of PID
pressure
under control
under quickly
control PV
response in performance control elements PI SP
• Allows closer operation to process limits (One-Sided)
SP
without taking risk
Rc
Analog Inputs
Relief valve
DEV
FA
setting Mode
POC-SP DEV DEV DEV
PIC-SP PV SP
Primary Load Primary
+ +
Antisurge Loop Loop Loadsharing
2
qr To antisurge valve To performance
control element

Loadsharing for multi-section compressors
RSP
VSDS
Train A
Section 1 Section 2
out
UIC Serial UIC Serial LSIC Serial
1A network 2A network A network
MPIC
1
Suction
RSP Process
Header VSDS
Train B
Section 1 Section 2
out
UIC Serial UIC Serial LSIC
1B network 1B network B
• How
Select
By
Share
selecting
tothe
per
operate
load
train equal
in theDEV’s
the--equidistant
--section forto
loadsharing
closest
from both
thethe trains
controller
Surge
SCL Control
it--ison
--guaranteed
the
the
Line
section
section
(SCL)
that
closest
closest
when
the other
there
totothe
theis
more
section
SCL than
on one
the same
section train
perismachine
not in recycle
???

Selecting the section closest to SCL for parallel operation
Master Controller • Both

The selected
lowest
antisurge
DEV
DEV
controllers
is is
selected:
PV report
the section
reportedtheir
to:closest
DEV to theto the
PID loadsharing
SCL
• Primarycontroller
control
PV
SP response blocks
PI
(One-Sided) • Load balancing block
SP
• Master controller
averaging block
Analog Inputs
FA FA
Mode Mode
DEV1 DEV2
DEV1
< DEV2
PV SP
Primary Load Primary Primary
PI RT response
+ + +
Antisurge Loop Loop Loadsharing Antisurge Loop
Decoupling Decoupling Decoupling
Controller Controller Controller
To antisurge valve-1 To performance To antisurge valve-2

control element
Flow Measuring Device (FMD) selection criteria
• Main selection criteria for FMD in antisurge control system:

– Repeatability
– Sufficient signal-to-noise ratio
• Accuracy of the FMD is not critical
• FMD delays must be absolutely minimal
• Present state-of-the-art limits the choice of FMD to head flow meters
or to other devices that are based on the principle of velocity
measurement:
– Orifice plates
– Venturi’s
– Pitot tubes
– etc.
• Recommended flow range for FMD and transmitter is maximum
compressor flow
• Recommended Dp corresponding to Qmax, compressor is 10” WC (250
mmH2O) or more

Flow Measuring Device (FMD) location
VSDS
Compressor
minimum possible minimum possible
Suction Discharge
• The preferred location of the FMD: • Less preferable location of the FMD:
• Suction of compressor • Discharge of compressor
• As close to the inlet flange as • As close to the discharge flange as
possible possible
• Selection of the location should be based on:

• Necessity of surge detection
• Often more difficult with flow measured in discharge
• Capital cost of flow measuring device
• Operating cost of the FMD (permanent pressure loss)

Response time of the FMD transmitter
• The speed of approaching surge is high
1 SEC.
• The transmitter type and brand should be 100%
selected based on two major factors:

– Reliability
– Speed of response
• Desired rise time for Dp (flow) transmitters 0
is 200 ms or less Ps
100%
– Pressure step is 100%
– The first order response (63%) is less ABC
than 200 ms D
• Desired rise time for pressure transmitters 0

is 500 ms or less DPo 100%
Actual
pressure
Transmitter AB C
output
63% response
1- (1/e)
0
DPc
• In only 400 ms, DPO dropped by 14%,
with a 2% change in DPc
Time
t1 is less than 200 ms
The effect of damping the Dpo (flow) transmitter
• Knowing the flow is essential to determine the distance between the
operating point and the SCL
• Damping the Dpo (flow) transmitter destroys essential information
Start of Surge
Flow 50
t = 16.0 s
t = 1.70 s
0 t = 0.03 s
t = 0.20 s
Actual Flow
-50
0 1.25 2.50 3.75 5
Time (seconds)
Damping the Dpo (flow) transmitter can paralyze the

complete antisurge control system!!!
Sizing the antisurge control valve
• Criteria for antisurge valve sizing based on CCC’s experience

– Provide adequate antisurge protection for worst possible disturbances
– Provide adequate antisurge protection in all operating regimes
– 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
A
Rc
• Take point A at the intersection of the
maximum speed performance curve and
the Surge Limit Line (SLL)
• Calculate Cv,calc (or equivalent) for point A
• Select standard valve size using the
following criteria:
1.8 . Cv, calc < Cv,selected < 2.2 . Cv, calc
Qvol
Sizing the antisurge control valve - alternative method
• An alternative method yielding

excellent results is:
Rc • Take design point of the compressor

point A
A B • Draw a horizontal line through the design

point
• Take point B at intersection of maximum

speed performance curve and the
horizontal line
• Calculate Cv,calc in point B
Qvol
• Select standard valve size using the
following criteria:
0.9 . Cv, calc < Cv,selected < 1.1 . Cv, calc

Stroke speed and characteristic of the antisurge valve
Antisurge valve stroke speed
• Antisurge valve must have speed of response adequate for antisurge
protection for all disturbances
• Recommended full stroke times:
– Size Close to open Open to close
– 1” to 4” 1 second < 3 seconds
– 6” to 12” 2 seconds < 5 seconds
– 16” and up 3 seconds < 10 seconds
• Closing time needs to be the same order of magnitude to assure the same
loop gain in both directions
Antisurge valve characteristic

• Normally control valves are selected to be open 80% to 90% for design
conditions
• Antisurge valves can operate anywhere between 0% and 100%
• In order to have an equal loop-gain over the whole operating range a linear
valve is required
• This will allow for the fastest tuning leading to smaller surge margins

Improving the performance of the antisurge valve
• Most normal control valves can be made to perform as required for

antisurge control
• The following steps help improve the performance of the valve
– Install positioner
– Minimize tubing length between I/P and valve positioner
– Install volume booster
– Minimize volume and resistance between volume booster and actuator
– Increase air supply line to 3/4” or more
– Increase size of air connection into the actuator
– Drill additional holes in actuator - avoids pulling a vacuum

Piping lay-out consideration when designing an
antisurge control system
• Piping lay-out influences the controllability of the the total system
• The primary objective of the antisurge controller is to protect the
compressor against surge
• This is achieved by lowering the resistance the compressor is feeling
• The resistance is lowered by opening the antisurge valve
• Dead-time and time-lag in the system needs to be minimized
• This is achieved by minimizing the volume between three flanges
– Discharge flange of the compressor
– Recycle valve flange VSDS
– Check valve flange
Compressor 1
volume to be
minimized

Using a single antisurge valve increases recycle lag time
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
• Result Note
– Poor surge protection • This specific piping layout is found on
– Large surge margins many wet gas compressors in FCCU’s
– Energy waste
– Process trips because of surge
Sharing recycle coolers degrades surge protection
Section 1 Section 2
Small volume
• The piping lay-out for section 2 is excellent for surge protection

• Minimum volume between the three flanges
• The piping lay-out for section 1 is not ideal
• Large volume to be de-pressurized decreases ability of the control system to
protect the machine against surge
• Result
• Poor surge protection
• Large surge margins
• Energy waste
• Process trips because of surge
Installing recycle valve upstream from
cooler improves control response
Compressor 1 Compressor 2 Increased

Minimum volume due
volume to cooler
• Compressor 1 has ideal piping lay-out for surge protection

• Minimum volume between the three flanges
• The piping lay-out for compressor 2 is commonly found in the industry
• The cooler creates additional volume and decreases the effectiveness of the
antisurge control system
• The piping lay-out for compressor 2 can be acceptable if the additional
volume does not create excessive dead time and lag in the system
• Result
• Increased surge margins
• Energy waste

Recycle lines configured for optimum surge protection
Section 1 Section 2 Section 3
Suction Process
Minimum
volume
• Compressor has ideal piping lay-out for surge protection
• Minimum volume between the three flanges for all sections

Which antisurge piping configuration do you choose???
Lay-out #1: Compressor with recycle lines optimally configured for antisurge control
Suction Process
Lay-out #2: Compressor with coolers upstream of recycle take-off
Suction Process
• When selecting
Lay-out
These two
#1 one#2
lay-out
#2 piping
has
requires
minimum
lay-outs the
coolerresidence
volume
are most
less
between time
common
and thus of
thefor
the the
flangesgas in
antisurge
capital
and the “surge”
investment
is
control
the volume
bestislay-out
lower
should
for be verified
antisurge to purposes
control check acceptable time delays are not exceeded
• Lay-out #2 will require bigger surge control margins
Influence of controller execution time
• Leading engineering contractor

Analog controller
performed evaluation of execution
100%
time influence on ability to protect
compressor from surge
SCL Operating • Dynamic simulation of compressor
SLL point was built
• Digital controllers are compared
against analog controller on
0% simulation
Time
• Analog controller has no execution
100% time and is immediate
• Analog controller tuned for minimum
overshoot
Controller
output • Digital controllers get exact same
tuning parameters
0% • Digital controllers get exact same
Time
disturbance

Analog vs digital controller at 2 executions per second
Analog controller Digital controller
(2 executions per second)
100% 100%
SCL Operating SCL Operating

SLL point SLL point
0% 0%
Time Time
100% 100%
Controller
output
Controller
output
0% 0%
Time Tuning same as analog controller
Time
• Compressor surged
• Large process upset would have resulted


100% 100%

SLL point SLL point
0% 0%
Time Time
100% 100%
Controller
output
Controller
output
0% 0%
Time
• Compressor surged
• Large process upset would have resulted


100% 100%

SLL point SLL point
0% 0%
Time Time
100% 100%
Controller
output
Controller
0% 0% output
Time
• Compressor almost surged

• Control system would have to be set up with bigger surge margins

Analog vs CCC controller at 25 executions per second
Analog controller CCC antisurge controller

100% 100%

SLL point SLL point
0% 0%
Time Time
100% 100%
Controller
output
Controller
0% 0% output
Time
• Response of CCC controller nearly indentical to analog controller

• Adding Recycle Trip® to PI control will allow even smaller surge margins

Dynamic simulation single compressor
VSDS
Compressor
Note: Speed transmitter for

Load
indicating purposes only ST FT PsT TsT PdT Td T PIC HIC
1 1 1 1 1 1 1 1
UIC
Suction 1
Process
Serial
network
• Compressor is controlled on Pd by PIC-1

• HIC-1 controls the process load and can be used to create process disturbances
• Controllers communicate via serial communication to computer running the
simulation
MODBUS Start simulation Compressor control Previous Rew Fwd Help Menu
Dynamic simulation parallel compressors
RSP
VSDS
Compressor 1
out
UIC Serial LSIC Serial
1 network 1 network
Load
MPIC HIC
1 1
Process
RSP
VSDS
Compressor 2
out
UIC Serial LSIC
2 network 2
MODBUS Start simulation Compressor control Previous Rew Fwd Help Menu

Compressor

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Compressor

Uploaded by

Copyright:

Available Formats

Compressor control menu

Cost of operating turbo compressors

Compressor system classifications

Developing the compressor curve

The surge phenomena

Acrobat Previous Rew Fwd Help Main Menu

Costs of repairs - materials and labor

Bearings $10,000 $25,000

Rotor Assembly $200,000 $750,000

Compressors Previous Rew Fwd Help Menu

Cost to operate one turbo compressor per year:

Plant air compressor 1,000 HP (746 kW) $457,000

Wet gas compressor 4,000 HP(2,984 kW) $1,830,000

Propylene refrigeration comp. 40,000 HP(29,480 kW) $18,300,000

Compressor Compressor Actual achieved

Centac air compressor 1,500 hp (1.1 MW) $78,000

Energy Savings Predictions Compressors Previous Rew Fwd Help Menu

Less than one year pay-backs* typical by reducing recycle of blow-Off

Energy Saving Examples Compressors Previous Rew Fwd Help Menu

• Natural Gas Production, 100 MMSCFD: $12,500 per hour

• Consequences of downtime: Lost profit, lost customer

Compressors Previous Rew Fwd Help Menu

Process 100 MMSCFD 60,000 BPD

• Includes lost sales plus fixed operating expenses.

• Most turbo compressor control system design problems are

• Delays due to turbomachinery control problems are not unusual.

• Startups are faster with a properly designed turbomachinery

Compressors Previous Rew Fwd Help Menu

Costs in constant dollars

Compressors Previous Rew Fwd Help Menu

What can we control?

Compressors Previous Rew Fwd Help Menu

• Widespread use, many applications

• Gas is accelerated outwards by rotating impeller

• Can be built for operation as low as 5 psi, or operation

• Sizes range from 300 hp to 50,000 hp

DIFFUSERS Cross Section of Horizontal Split

Picture of Horizontal Split

Cross Section of Barrel Type

Picture of Barrel Type

Cross Section of Integrally Geared

Picture of Integrally Geared

Compressors Previous Rew Fwd Help Menu

Casing Thrust bearing

Compressor inlet nozzle

Picture of Horizontal Split Centrifugals Previous Rew Fwd Help Menu

Picture of Barrel Type Centrifugals Previous Rew Fwd Help Menu

Inlet guide vanes Pinion shafts

• High flow rate

Adjustable guide vanes

Compressor inlet nozzle

Picture of Axial Axials Previous Rew Fwd Help Menu

Cross Section of Axial Axials Previous Rew Fwd Help Menu

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

Parallel Network Two-Case, Two-Section, Six-Stage

Compressors Previous Rew Fwd Help Menu

Compressors Previous Rew Fwd Help Menu

Compressors Previous Rew Fwd Help Menu

• Due to the shape of the

Compressors Previous Rew Fwd Help Menu

• As the wing tilts back the Dv changes and thus the Dp

Compressors Previous Rew Fwd Help Menu

Pd Pd = Compressor discharge pressure