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The effect of inlet parameters on surge limit line

Article  in  World Pumps · November 2016

DOI: 10.1016/S0262-1762(16)30318-2

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34 Feature
WORLD PUMPS November 2016

Research & development

The effect of inlet

parameters on
surge limit line
entrifugal compressors anti-surge protection systems
C are based on the Surge Limit Line (SSL). SSL is the
description of the surge points locus and, in the current
practice, it’s assumed to be invariant with centrifugal
compressor inlet conditions. This study looks at the
effect of inlet conditions on the SLL.

Surge is a well-known instability
phenomenon that consists of a rapid
oscillation of the mass flow elaborated
by the compressor, accompanied by a
characteristic noise and high vibrations.
Current protection methods have been
designed with the intention of running
the compressor safely, far away from
surge points. Today state-of-the-art anti-
surge systems provide a protection
action which involves the opening,
either partially or totally, of a special
control valve (anti-surge valve) located
on a line that recycles the gas from the
discharge to the compressor suction. In
this way the control system reduces the
overall line resistance and increases the
elaborated flow, moving the compressor
operative point to the right of the char-
acteristic curve corresponding to the
actual operative speed (Figure 1).
The anti-surge valve is directed by a
dedicated PID controller, usually
embedded in the protection system
PLC. The surge protection logic embeds

Compressor

Delivery
Suction

PT PT
PT

Ps Pd
ANTISURGE
hs CONTROLLER

PY

Figure 1. The control system reduces the overall Figure 2. The surge protection logic embeds the Surge Limit Line (SSL) and the correlated Surge
line resistance and increases the elaborated flow. Control Line (SCL).

www.worldpumps.com 0262 1762/16 © 2016 Elsevier Ltd. All rights reserved


WORLD PUMPS November 2016
the Surge Limit Line (SLL) and the
correlated Surge Control Line (SCL)
(Figure 2).
Using field readings, the protection logic
calculates the actual operative compres-
sion ratio (β) and uses the stored SCL
data to determine the corresponding
actual flow limit parameter. This value
is then used as set point for the anti-
surge valve PID controller. The process
variable instead is the actual flow
parameter also ∆ p / p1 obtained from
the field readings.
It’s evident that surge protection
systems rely on the SLL concept which
is the central element of the system’s
protection action. The SLL is a simplified
correlation between the compression
ratio b and the flow parameter ∆ p / p1
that identifies the surge points. This
simplified correlation is derived by
applying:
a) hydraulic affinity laws (fan laws)
b) t he expression of Polytrophic Head for
perfect gas
c) t he expression of the volumetric flow
rate through the suction flow meter
d) the real gas state equilibrium
Introducing a simplifying approximation
it’s possible to obtain the SLL final
expression as correlation between the
flow parameter ∆ p / p1 and the
compression ratio β:
Eq. 1
∆ p / p1 = K * (β - 1)
This expression of the SSL seems to be
invariant with gas inlet conditions (hence
it’s sometimes called the Universal Surge
Line) and this enables it to be easily
Case 1 low pressure suction condition
Operative conditions p1 [bar a]
DC 67,5
ODC 1 67,5
ODC 2 67,5
ODC 3 83,0
ODC 4 67,5
ODC 5 83,0
Table 1. The surge line has been calculated based upon a changing molecular weight (ODC 1 &ODC 2), pressure (ODC 3), temperature (ODC 4) and both
properties (ODC 5)
implemented on process computers. This
seemed to be an advantage in the early
stages of anti-surge applications in the
1960s when engineers were looking for
a simple surge locus formulation to be
implemented with a modest calculation
capability. For this reason it has been
extensively used in the past and is still
used today on actual surge protection
systems.
Although it is still currently in use, it
does have some limitations. It is possible
to argue that:
1) The Hp - Q flow curve depends on
the gas suction condition.
2) The affinity law is valid for liquid flow,
and can be considered applicable to
gas for low compressibility flows.
3) When applicable the affinity law is
valid in a small range around a refer-
ence point and cannot be used to
describe the overall range of
compressor surge point without
violating the applicability limits of the
hypothesis.
Based upon these considerations, it can
be seen that the SSL depends on inlet
suction conditions.
Numerical investigation
A better equation to calculate the surge
points is:
д (Pd / Ps) / д V = 0
Where
Pd = Discharge pressure
Ps = Suction pressure
V = Volume flow
For off design inlet conditions, a
compressor performance map can be
calculated using the Cmap software
T1 [°C]
38,5
38,5
38,5
38,5
23,0
23,0
(*) Gas mix has been obtained modifying the gas mix design composition.
Feature 35
which is not based on the affinity law or
any other approximation but on the
availability of a non-dimensional model
of the compressor using correlations of
work and flow coefficient parameterized
by the Mach number. The surge line is
then calculated from the compressor
performance map with reference to inlet
off design conditions.
Consequently, two surge lines, Design
Condition and Off Design Condition (DC
and ODC) can be drawn having the ratio
between Dp across the orifice and the
suction pressure (Ps) on the x-axis, and
the compression ratio (Pd / Ps) on the
y-axis.
Case studies
Two real cases are presented here:
• C
 ase study 1: Compressor working
with low pressure suction
• C
 ase study 2: Compressor working
with high pressure suction
In both cases, this study will show how
the limit surge line changes when inlet
conditions move from design values to
off-design values.
Low pressure suction
In this case study a centrifugal compressor
was running at various inlet conditions.
Starting from DC, the surge line has been
calculated based upon a changing molec-
ular weight (ODC 1 and ODC 2), pressure
(ODC 3), temperature (ODC 4) and both
properties (ODC 5). (See Table 1).
The following graph shows the surge
limit lines obtained with different inlet
conditions
It should be noted that for various ODC
points, the maximum error calculated is
M [g/mole] GAS mix (*)
16,04 Mix design
19,24 Mix 1
23,79 Mix 2
16,04 Mix Design
16,04 Mix Design
23,79 Mix 2
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WORLD PUMPS November 2016

The following table compares the design conditions (DC) versus the off design conditions (ODC)
Case 1 low pressure suction condition
Comparison Dp % DT [°C] DM % Pd / Ps error %
DC - ODC 1 0 0 +20 2,5-3,5 - 1,1
DC - ODC 2 0 0 +48 2,5-3,5 - 2,6
DC - ODC 3 23 0 0 2,5-3,5 +1,7
DC - ODC 4 0 -15,5 0 2,5-3,5 +0,9
2,5 +4,0
DC - ODC 5 23 -15,5 +48
3,5 +7,0

Table 2. Comparison of the design conditions (DC) versus the off design conditions (ODC).

The following graph shows the surge limit lines obtained with different inlet conditions 2.6%. If however, the variation on the
inlet conditions is applied simultane-
ously on pressure, temperature and mix,
the maximum error calculated is 7%
(with a compression ratio of 3.5).

High pressure suction

Starting from the DC condition the surge
line has been calculated based upon
changing molecular weight (ODC 1 and
ODC 2), pressure (ODC 3), temperature
(ODC 4) and both properties (ODC 5),
(Table 3)

It should be noted that for ODC the

maximum error calculated is 18.6%. If
the variation on the inlet conditions is
applied simultaneously on pressure,
temperature and mix, the maximum
error calculated is 31.2% (compression
Figure 3. The surge limit lines obtained with different inlet conditions (low ratio of 2.7). It is interesting to note that
pressure compressor). the correct surge flow line moves to
right with respect to the design surge
line. This implies that the control system
is underestimating the surge flow, and
then the compressor could be poten-
tially exposed to surge events

Conclusions
The analysis developed here indicates
that in a low pressure compressor if
the inlet conditions change it doesn’t
create a problem with the surge but
instead a reduction in the operating
efficiency.

The analysis proposed and described in

this paper confirm that the actual centrif-
ugal compressors protection systems
based on simplified hypothesis such as
the ideal gas law, and the validity of
Figure 4. The surge limit lines obtained with different inlet conditions (high pressure compressor). hydraulic affinity laws are valid only within
a certain range of application. For a high
pressure compressor, if the inlet condi-
tions vary then the errors calculated are

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 Feature 37
WORLD PUMPS November 2016

Case 2 high pressure suction condition

Operative conditions p1 [bar a] T1 [°C] M [g/mole] GAS mix (*)
DC 267,5 60 16,04 Mix design
ODC 1 267,5 60 19,24 Mix 1
ODC 2 267,5 60 23,79 Mix 2
ODC 3 285,0 60 16,04 Mix Design
ODC 4 267,5 45 16,04 Mix Design
ODC 5 285,0 45 23,79 Mix 2

Table 3. The surge line has been calculated based upon a changing (*) Gas mix has been obtained modifying the gas mix design composition.
molecular weight (ODC 1 &ODC 2), pressure (ODC 3), temperature (ODC 4)
and both properties (ODC 5)

The following table compares the design conditions (DC) versus the off design conditions, (ODC)
Case 2 high pressure suction condition
comparison Dp % DT [°C] DM % Pd / Ps error %
1,5 5,5
DC - ODC 1 0 0 +20
2.7 6,8
1,5 16,2
DC - ODC 2 0 0 +48
2.7 18.6
1,5 1,5
DC - ODC 3 +6,5 0 0
2.7 2,1
1,5 3,4
DC - ODC 4 0 -15 0
2.7 4,1
1,5 27,6
DC - ODC 5 +6,5 -15 +48
2.7 31.2

Table 4. Comparison of the design conditions (DC) versus the off design conditions (ODC).

greater than safety margin. Consequently the protection

become inefficient and can potentially cause damage to
the compressor. Ultimate Pump
The Cmap software developed by IPC allows prediction of
the performances of a centrifugal compressor under Control
varying thermodynamic conditions of the inlet gas. The One complete integrated solution
prediction of compressor performances is accurate even
at high pressures, whereas the ideal gas theory, which is l Intelligent pump control l Level measurement
commonly used, introduces considerable errors and l Remote telemetry l Flow measurement
implements advanced protection from surge, overcoming l Asset management data l Predictive maintenance
limits of the current technology.

All calculations in this study have been carried out

using a dedicated software tool (Cmap), developed at
the IPC research lab. Cmap has been designed to
New
predict easily and quickly a centrifugal compressors
performance under different inlet conditions and with
variable hydrocarbons and gas mixtures composition. •
Authors Contact
A.
Massimiliano Di Paganini Pasquale
ur DN
Febo & Paganini Industrial Plants Consultants (IPC)
t ’ s in o
on. I
Pasquale Via delle Violette 12,
In novati
70026 Modugno BA
Italy
Phone: +39 0805 833101
Malvern, Worcs WR14 1JJ, UK
Email: pasquale.paganini@ipc-eng.com
Tel: +44 (0) 1684 891 371
info@pulsar-pm.com
Web: www.ipc-eng.com
www.pulsar-pm.com

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