Royal Belgian Institute of Marine Engineers

Surge Detection And Surge

Control Systems For Centrifugal
Compressors -- Part 1
Fundamentals include dynamic centrifugal compressor map, operating
envelope, surge cycle
BY NEETIN GHAISAS AND TODD REITSMA

Abstract
Surge detection and surge control of centrifugal
compressors is complex. It requires specialized
knowledge and experience of machinery, controls
and processes to develop advance algorithms,
tailback strategies and dedicated, purpose-built
systems that are capable of high-speed execution of
algorithms for optimized turbomachinery controls.
This paper presents fundamentals such as
dynamic centrifugal compressor map, operating
envelope, surge cycle and surge detection. The
paper will also describe antisurge and performance
controllers and their importance to an overall
control strategy, antisurge control responses,
advance control features including loop decoupling,
load sharing, performance override control, limiting
loops and tailback modes. Recycle piping and valve
sizing considerations, hot gas bypass valve (HGBV)
requirements and instrumentation considerations
are also discussed.

Dynamic Compressor Map

Centrifugal compressors convert energy imparted
by the driver into potential and kinetic energies in
the gas being compressed. Figure 1 shows a
representative dynamic compressor map. It explains
energy conversion in two dimensions. The
horizontal coordinate of the map is for volumetric
inlet capacity Q and the vertical coordinate
represents pressure ratio Rc.
Characteristic operating envelope of a centrifugal
compressor is shown in Figure 2. It illustrates how
the stable operating zone was determined after
adding control margins within the boundaries of
surge limit, stonewall, minimum and maximum
speeds and any additional process or compressor
train constraint.
Surge Cycle And Surge Detection
Figure 3 shows propagation of a surge cycle. As
pressure builds up, system resistance increases, and
the operating point draws the performance curve.
At point A, the potential energy in the discharge
vessel exceeds the capability of the compressor.
With Pv > Pd(max), the flow in the system reverses.
As a result, the pressure downstream of the
compressor drops, and that allows the compressor
to reestablish forward flow. If corrective action is not
initiated, the surge cycle repeats.
Surge can be experienced during the startup and shutdown of a compressor, during operation at low flow
rates (inlet volumetric flow in the proximity of surge limit line) or when a centrifugal compressor operates at
high flow rates with sudden process variations, such as changes in pressures and gas composition, fouled
aftercoolers, plugged inlet filters or strainers and loss of driver power.
Surge cycle times typically range from 0.3 to 3.0 s/cycle.
Consequences of a surge include rapid oscillations in flow and pressure, exponential rise (severity based) in the
temperature of the gas, process instability, potential machine/ process trips and possible damage to
compressor seals, bearings, impellers and shaft depending on the energy level associated with surge and the
compressor design.
Surge detection is an inherent feature of the surge control system. It is used to alarm plant operators, engage
the surge system controller's adaptive action (i.e., increase the margin to surge) and, if necessary, shutdown
the compressor to prevent damage. Various methods are used for surge detection, including setting thresholds
on rate of change in pressure, rate of change in flow, rise in temperature compared to upstream gas
temperature, rate of change in driver power and/or a combination of all of these parameters.

Compressor Map With Invariant Coordinates

Compressor inlet volumetric flow (Qs) and polytropic head (Hp) are commonly used map coordinates. These are
expressed by the following equations:
In these equations, not all parameters can be
measured directly. Real-time measurement of
molecular weight is not suitable for antisurge control.
Accurately defining the interface between stable
operation and surge in all possible conditions is
essential to protect a compressor from surge.
Invariant coordinate systems contain only the
variables, which are measured directly. Normalizing
the above equations will produce a compressor map
in reduced flow and reduced head coordinates that
are invariant to changes in gas properties such as gas
density and molecular weight. This creates a reliable
coordinate system for better surge protection and
control. The following equations are for reduced flow
(qsr2) and reduced head (hpr),
Defining The Distance To Surge
An antisurge controller must accurately determine
where the operating point is on the coordinate
system and accurately calculate the distance to surge.
Due to the dynamic nature of turbocompressors and
the process in which they operate, a surge control
line (SCL) must be added to the performance curve to
allow the control system to respond and avoid surge.
The distance between the operating point and the
SCL is called deviation. It is shown in Figure 4.
Deviation infers how far the operation point is from
recycling or opening the blow off valve (air
compressors). Zero deviation means that the
operating point is located on the surge control line
(recycle valve begins to engage). Deviation greater
than zero indicates that the operating point is in
normal zone (recycle is closed) while deviation less
than zero signifies that the operating point has
crossed the surge control line (recycle is taking place
to prevent surge).
Many users expect surge margin (b1) to be 10% of
the flow at SLL. This is a good target that is
appropriate for some cases, but not for others. The
surge margin of a system must take into account
many factors, such as uncertainty of SLL (surge tested
or theoretical); performance curve shape (steep or
flat curves); accuracy and response of transmitters;
size, speed and response of the recycle/blow off
valve; volume of the discharge and recycle
piping/system; type, size and frequency of process
disturbances; robustness of the compressor design;
and criticality of the compressor service to the
operation.
With all factors considered, it is impossible to predict
the right amount of surge margin tor a specific
system. Only final site testing and operating
experience can determine the right amount.
Recycling gas is a waste of energy so take the time to
optimize surge margin and reduce operating costs.
Performance Control
The primary control objective of a performance
controller is to maintain a process variable at its
desired set point. Output of the performance
controller is the set point for the compressor
throughput. Plant production can be optimized by
precise control of the process variable. Typical
process variables include suction pressure, discharge
pressure, compression ratio or process volumetric or
mass flow.
 Figure 5 shows various throughput control
methods, such as suction throttling, inlet guide vanes
and variable speed drive options. The throughput
control method selected must consider factors such
as electrical costs, cost and availability of steam or
fuel gas and process system efficiency. Constant
speed electric motor drives with throttling used for
control is the simplest method to start and operate,
but it is not likely the most energy efficient.
Throughput control method has a significant impact
on the antisurge control system. For example, it inlet
guide vanes are used, the guide vane position signal
may need to be fed back to the antisurge control
system so a specific characterizer can be
implemented and adjust the SCL accordingly. It
turbine speed or suction throttling is controlled, then
the antisurge control needs to be integrated to avoid
control loop interactions.
In every case, the antisurge and throughput control
are interrelated because they both influence the
same process variables and, in turn, the position of
the operating point on the compressor map. Highly
integrated antisurge and throughput controls will
maximize the compressors stable zone of operation,
prevent design limit excursions, provide more
effective surge protection, provide more precise
control of the process variable and enable smoother
and repeatable automated start-up and shutdown
procedures.
Loop Decoupling
Control loops are coupled when the control action of
one loop causes the process variable of another loop
to change. Dedicated recycle loops on multisection
compressors are highly coupled (often referred to as
interactive). Opening either recycle valve in the two-
section compressor example will improve the
location of the operating point in that section, but
can negatively affect the location of the operating
point in the other section. The reaction of the two
recycle loops can quickly become unstable.
Feed forward loop decoupling between the recycle
controllers (UIC) is essential to minimize the
interaction. Feed forward action preemptively opens
the other recycle valve and very effectively stabilizes
each loop.
Load Sharing
Often, multiple compressors will work in parallel to
meet the process needs of the plant. This gives plants
the flexibility to do maintenance on one of the
machines and typically not affect plant production
and also the ability to manage large process flow
ranges. Significant energy savings can be realized by
taking machines online or offline as required.
Controlling parallel compressors efficiently and
effectively to meet the process goals, however, can
be a challenging task.
The primary control objectives of parallel
compressor networks include:
• Precise control of the primary process variable to
maximize plant production.
• Maintain all compressor trains within their design
operating limits.
• Optimally divide the responsibility of maintaining
the primary process variable between the
compressors in the network, while at the same time:
o Minimizing the risk of machines tripping due
to surge, vibration, over-speed and process
disturbances.
o Minimizing compressor network energy
consumption.
o Avoid introducing disturbances to the process
when bringing machines online and offline.
There are many ways to control parallel
compressors and some are more effective than
others at achieving the control objectives above.
Typical control strategies include:
• Base load and swing machines, which can result in
recycling gas with the swing load machine. Only the
swing machine handles process disturbances, which
increase the risks of trip and increase wear and
maintenance on swing machines.
• Independent performance controllers on each
train. Flow oscillations can occur between trains
when multiple controllers are used to maintain a
common process parameter. To avoid oscillations,
controller tuning is dampened or control loops are
switched to manual mode. These reactions severely
compromise the main process variable control and
increase the risk of trips during process disturbances.
• Master controller for load balancing. A master
controller is added to maintain the primary process
variable. A master controller provides the set point
for each train performance controller (also referred
to as load-sharing controllers). This control
architecture guarantees that both compressor trains
move in the same direction to meet the main process
goal. This control method requires all compressor
performance maps to be the same. Since no two
compressors are exactly alike, and suction and
discharge piping in the network can influence
individual compressor performance, they will handle
flow differently. The result is trains are not balanced,
so in low flow conditions, some compressors may go
into recycle while others will not.
• Master controller for distance to surge balancing.
In this control architecture, the load share response
of the master takes into account the distance to the
surge control line (SCL) calculated by each antisurge
controller in the parallel network. Equalizing the
relative distance from surge (deviation), is the best
means for distributing flow among parallel
compressors. This strategy guarantees minimum
overall recycle of the group of compressors, providing
the most efficient operation and also the most
effective antisurge control. In the case of a process
disturbance, all compressors in the parallel system
begin to open their recycle valves at the same time.
Neetin Ghaisas is a senior fellow - rotating
equipment, With Fluor.
Todd Aeitsrna is a senior account manager With
Compressor Control Corp
Source: COMPRESS0Rtech2 JULY 2016
http://dieselpub.com/compressortech2