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

Section 1 Section 2 Section 3

Suction Process

Lay-out #2: Compressor with coolers upstream of recycle take-off

Section 1 Section 2 Section 3

Suction Process

• These two piping lay-outs are most common for antisurge control
• Lay-out #1 has minimum volume between the flanges and is the best lay-out for antisurge control
purposes
• Lay-out #2 requires one cooler less and thus the capital investment is lower
• When selecting lay-out #2 the residence time of the gas in the “surge” volume should be verified to
check acceptable time delays are not exceeded
• Lay-out #2 will require bigger surge control margins