…Where Flexibility Meets Best

Fit Technology

Advanced Control Valve Technology

Compressor Anti-Surge Capabilities

Page 1
Agenda …Where Flexibility Meets Best
Fit Technology

•What is compressor surge?

•Anti-surge valve requirements
•Traditional
•Latest generation
•Additional benefits
•Control valve solutions
•Actuation solutions
•Unique benefits from Masoneilan

Page 2
Modern Dynamic Compressor …Where Flexibility Meets Best
Fit Technology

• Designed to operate between 50-100% of rated

capacity
• Flow below 50% causes physical phenomenon
called surge
• Surge:
– When compressor impellers cannot generate
enough head to keep discharge pressure
above downstream piping pressure. The gas
flows backwards through the compressor
due to the open vane construction. These
flow reversals occur very rapidly and cause
damage to the compressor.

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Compressor Anti-Surge System Example …Where Flexibility Meets Best
Fit Technology

Anti-Surge Valve

Anti-Surge Valve

Cooler

Suction
1.1 Bar,g Discharge
KO KO 18-19 Bar,g
5-7 Bar,g

1st 2nd
Stage Stage

Page 4
What is Compressor Surge? …Where Flexibility Meets Best
Fit Technology

Suction

Discharge

Page 5
What is Compressor Surge? …Where Flexibility Meets Best
Fit Technology

Compressor Surge Line

Head
Compressor Speeds

Backward Compressor Flow Forward

Page 6
What is Compressor Surge? …Where Flexibility Meets Best
Fit Technology

Compressor
Head
I

Backward Compressor Flow Forward

Page 7
What is Compressor Surge? …Where Flexibility Meets Best
Fit Technology

II:Downstream
I: Net Flow = Zero
Demand Drops
Flow To The
Compressor Surge Point
Head
II I

Backward Compressor Flow Forward

Page 8
What is Compressor Surge? …Where Flexibility Meets Best
Fit Technology

Flow Reverses
Due to Higher
Downstream
Compressor Pressure
Head
II I

Backward Compressor Flow Forward

Page 9
What is Compressor Surge? …Where Flexibility Meets Best
Fit Technology

IV: Maximum
III: Head Drops To
Reverse
The PointFlow
Where
Point Is No Flow
There
Compressor
Head
III II I

IV

Backward Compressor Flow Forward

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What is Compressor Surge? …Where Flexibility Meets Best
Fit Technology

V: Compressor
Reengages With
Flow and Throws
Compressor Gas Forward
Head
III II I

IV V

Backward Compressor Flow Forward

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Anti-Surge System …Where Flexibility Meets Best
Fit Technology

Surge Controller

Suction

Discharge

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Anti-Surge System …Where Flexibility Meets Best
Fit Technology

Surge Controller

Suction

Discharge

Compressor Open Loop Control Zone

(Solenoid)
Closed Loop Control Zone
(Positioner)
Head
Surge Line

Backward Compressor Flow Forward

Page 13
 Anti-Surge Control …Where Flexibility Meets Best
Fit Technology

• Designed for Super-Response

– Microcycle <30 Milliseconds

• Recovery Time “Cold Start”

• With Position Control
– < 250 Milliseconds
• Average reaction time
• Includes micro-processor execution Plus pneumatic/mechanical response
– 150 Milliseconds
• Auto-Tuning
– With Volume Boosters & Quick Exhaust

250 Ft.
A

COMPONENTS LIST
1 Masoneilan SVI-IIAP Smart Positioner
2 ¾” Volume Booster (Qty. 4 )
3 Hi-Capacity 1” Filter Regulator
4 Volume Tank (Remote Mount)
5 ½” Check Valve
6 Pressure Gauge
7 Air Bleed Valve
8 **Isolation Manual Valves (Customer Supply)
Page 14
0in 12 in 24 in 48 in
SVI-IIAP Characterized Behavior …Where Flexibility Meets Best
Fit Technology

Adaptive Response

Auto-Tune Level +9 Auto-Tune Level 0 (Normal) Auto-Tune Level -9

377 m/s 935 m/s 1.348 m/s

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 SVI-IIAP Characterized Behavior …Where Flexibility Meets Best
Fit Technology

• Super Response Requirements

• Fast Stroke to open @ 50% (Typically less then 1 Seconds)
• Fast Stroke to open @ 100% (Typically less then 2 Seconds)
• Control Stability to large step changes
• Control Resolution to small step changes
• Minimum Overshoot
• Total Recovery Time to overshoot
• Stroking Speed with Solenoid (EsTop)
• Heavy Cycling
• Reliability

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 SVI-IIAP Characterized Behavior …Where Flexibility Meets Best
Fit Technology

• The time required to stroke the valve open or closed.

• Dependent on:
– Actuator size • Super Response Time-Line
– Spring range
– Supply pressure
• Execution Micro-Cycle
– Stroke length • Execution Absolute-Cycle
– Accessories

100% Valve Stroke

0 602

Positioner Execution/Reaction Lag Actuator Pneumatic/Mechanical Lag 0- 50% Stroke 50-100% Stroke

10 m/s 140 m/s 28 m/s 199 m/s 225 m/s

Displacement Lag
Control Signal Dead Time

Mechanical Response

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Masoneilan Advantage: SVI II AP …Where Flexibility Meets Best
Fit Technology

The only Smart Valve Positioner in the market designed for “Surge Control”

Integral programmable Close/Open switches & Position Feedback

150 millisecond average reaction time
Includes micro-processor execution Plus pneumatic/mechanical response
Auto-Tunes with Volume Boosters and Quick-Exhaust Valves highly gained.
User Selectable “Auto-Tune” aggressiveness level (-9 to +9)
Minimum “Over-Shoot” and “Recovery” to large step changes.
Can meet stroking speed requires below 1 Second
Auto-Tunes to Symmetrical Super Response
Auto-Tunes to Asymmetrical Super Response

Page 18
Control Valve Solutions …Where Flexibility Meets Best
Fit Technology
•2” globe & rotary to 48”+ angle valves
•ANSI 150 – API 10000 (ANSI 4500)
•Multiple Trim Offerings
•Standard trim
•Single stage Lo-dB drilled hole Best Fit for each application
•Multi-stage Lo-dB drilled hole - Cost
- Performance
•V-LOG stacked-disc trim - Application requirements

•Optimized combinations
•NACE capabilities
•Offshore suitable designs
•High performance actuation
•Fast pneumatics (<1 second available)
•Accurate (minimal overshoot)
•Modulating signal
•Solenoid trip
•Easy tuning in the field Page 19