Gas Compression

Principle + Applications

Surge Prevention in the Centrifugal

Compressor

Lesson # 9
 Lesson Objectives

• Define the terms “Choke” and “Stonewall” as they

apply to the centrifugal compressor
• Define the term “surge” and the symptoms related to
surge condition
• State the purpose of the anti-surge control system
• Identify the major components of the anti-surge
control system
• Describe the action of the anti-surge control system
• Describe the operation of the major components of
the system
 Choke or Stonewall

• Solar prevent choke under

• The terms Choke and normal operating conditions by
Stonewall, describe a high limiting compressor speed and
flow, low head, and low power – (Ngp, Npt and T5
efficiency area of compressor topping)
operation • However choke can occur under
abnormal conditions such as
• The conditions occurs when the – Very high suction pressures
gas pathway within the – Very low discharge pressure
compressor is to small to
handle the volume of gas
• In other words the gas passing
through the compressor has
reached its maximum velocity
• Prolonged operation in choke is
not harmful to the compressor
 Choke or Stonewall

• Area of choke or stonewall

• The compressor can be compared to an orifice at full flow
• Further increase in operating speed or power will not alter the operating point
 Surge

• Surge - is the point at

which the compressor
cannot add enough
energy to overcome the
system resistance.
• Surge occurs when the
impellers cannot lift the
gas from suction to
discharge pressure
• This occurs locally at
each impeller
• As a results flow within
the compressor stops
Stall, and then reverses
in direction Surge
 Compressor Performance Map

Surge is the unstable area of flow to the left

side of the performance map
 Example Head vs. Capacity Map

Surge Limit Line

Unstable Operation
Surge Region

Stable Operation
 Example Head vs. Capacity Map

• Surge within the compressor

occurs when added system
resistance reduces flow
• As the flow reduces the
operating point move towards
the left of the curve towards the
surge limit line
• If unchecked the operating point
will cross over into this unstable
are of operation
• Flow initially stops – Stall as the
impeller looses the ability to
impart energy to lift the gas
forward
• Flow then reverses in direction –
Surge
 Impeller and Surge

• As the gas flows through the

Reduced exit due
impeller, the layer of gas next to
to boundary layer
the surface is subject friction
• (Between the impeller wall and
the gas)
• This causes this layer to move
slower than the gas at the center
of the impeller
• This layer is known as the
Boundary Layer
• The thickness of this layer
determines the effectiveness of
the impeller
• Thicker boundary layer reduce
the area of impeller exit
 Impeller and Surge

• As flow reduces, Head increases

• Operating point moves towards
the surge limit line
• The boundary layer near the
impeller tip begins increase in
thickness
• Adding more resistance to the
system and further reducing the
effectiveness of the impeller • As the impeller is the only
component that adds energy to
• As this effectively reduces the
the gas
impeller diameter, eventually flow
will Stall and Surge • Without flow, this energy needs to
dissipate somewhere
• The Boundary layer eventually
– High Temperature
breaks down allowing the impeller
– Noise
to push gas forward
– Vibration – Axial and Radial
• If not corrected the cycle will
begin once again
 Performance and Surge

Surge Limit Line

As the flow decreases the operating is initially operating at

Compressor
point moves toward B point A
Head continues to increase,System
System resistance increases, Head
resistance increasesIncreases, Flow Reduces,
Operating
If not corrected the Operating point point moves to left
towards
will move towards the Surge Limit the Surge Limit Line
Line

Surge is cyclic in nature


Surge Limit Line
System recovers, pressure
equalize, flow increases
Operating point moves from point D
to E
System recovers, pressure
equalize, Flow Increases
Surge is cyclic in nature
Cycle begins again
Performance and Surge
At point C, the compressor is at its
surge limit point
To the left of the point lies the surge
area
If unchecked the operating point will
move into this area
As the operating point moves
towards D
Head Decreases, Flow increases,
The boundary layer collapses
 Signs and Symptoms

• Surge can be classified as either Mild or Violent

– Not that it really matter both are bad

• Mild (Incipient) • Violent Surge

– Momentary fluctuations in
flow rate
– Rapid pulsations in P2
– Increases axial and radial
vibration
– Loud noise
– Slamming of discharge
check valve
– Rapid increase in T2
– Pulsation of flow, and P2
 Causes and Effect of Surge
• Surge may be caused by many factors
• The most common is process disturbances that rapidly reduce flow

• Causes of Surge • Effects of Surge

– Loss of power – The cyclic nature of surge subjects the
compressor to large mechanical forces
• Operator or controller action – Typical damage
that reduces engine power • Thrust bearing damage and failure
• Automatic shutdown of • Radial bearing damage
• Excessive temperature
engine
• Damaged interstage seals
– Restricted Flow • Damage to impellers
• Clogged inlet screens • Bent shafts
• Under extreme conditions shaft rotating can stop
• Inadvertent valve closures
– Process conditions very
different than design
• This tend to happen more
slowly – operating point
moves closer to surge line
– Loss of compressor
performance
• Clogged impellers
• Damaged / worn interstage
seals
 Surge Control Basic Principles

• The compressor can be

brought out of surge in several
ways
– Reducing Head (Lowering
discharge pressure)
– Increasing Flow
– Increasing Power (Ngp Inc)
– The simplest and most
common method is to
– Reduce Head, and Increase
Flow using a Anti-Surge
Control Valve (ASCV)
– The ASCV is located in the • This arrangement allows for
bypass line that connects the increase in Flow while
suction and discharge header simultaneously decreasing Head
piping
ASCV Piping Layout
 System Purpose

• The purpose of the Anti-Surge Control System

(ASCS) is to protect the compressor from the effects
of Surge
• The ASCS actively monitors and compares the
compressor operating point to a set of predefined
limits
• If exceeded the ASCS takes corrective action
• The operation of the ASCS can be divided as
following
– Surge Detection
– Surge Avoidance
 Elements of the Anti-Surge System

• The ASCS is comprised of the following components

– HMI Operator display (TT2000 / TT4000)
– Turbotronic Controller (TT4/TT3/TT2)
– Flow measurement device (Orifice Plate, impeller eye)
– Anti-Surge Bypass Valve
– Pressure / Temperature sensing devices
Anti-Surge System Overview
 Surge Control Display Screen

• The integrated Surge Control

Display Screen consists of a
modified Head vs Capacity
• Horizontal (X) axis plots
Actual Flow expressed as a
%
• Vertical (Y) axis plots
Polytropic Head expressed
as a %
• Expressing both X and Y
values as a percentage
– Simplifies calculation
– Allows flexibility (one map fits
all)
 Surge Control Display Screen

Surge Limit Line (Red)

This line represents the predicted operating limit
of the compressor
Position of the line depends on
Compressor Staging
Gas Properties

Surge Control Line (Yellow)

Dead Band Line (Green)
This line is the minimum point at which the
compressor is allowed to operate This line is set 2% to the right of the Control line

The Control line is offset from the Limit line by a Once crossed, it prevents the ASCV from
safety margin closing until the Operating Point move back to
the right
(Surge Margin 10%Flow)
If the compressor operating point crosses this
line
The ASCV will open a proportional amount
Surge Control Display Screen

Set Point
Min allowable flow at which the ASCV will begin
to close

Process Variable
Current flow factor expressed as %

Anti-Surge Valve
Select Auto / Manual Control
Manual permitted above Loading Speed
Disabled if operating point crosses Dead Band
Line

Command / Position
Valve position command expressed as a % of
Closed
Valve Position feedback expressed as a % of
Closed
Surge Control Display Screen

Suction
Compressor P1 and T1

Discharge
Compressor P2 and T2

Suction Flow Meter (Orifice) Dp

Surge Margin
The distance as a %Flow to the surge limit line
from current operating point at a constant speed
 Control System Action

• As stated earlier in this lesson, the ASCS is

comprised of
– Surge Detection
– Surge Avoidance
 Surge Detection

• The detection function of the

ASCS
• Monitors inlet flow, and
responds to detected surge
pulses by opening the ASCV
by 15% of current position
• Each successive pulse will
cause the valve to open
another 15%
• A surge pulse is a 25%
change in flow
• A cooldown stop is initiated if
5 or more pulses are detected
within any 10 second period
 Surge Avoidance

• The avoidance function of the

ASCS, prevents the compressor
from operating in the surge region
• The system uses a P+I algorithm to
modulate the position of the Anti-
Surge Control Valve (ASCV)
• The algorithm is asymmetrical, in
using slow gains to close the • However if the Error(e) is positive,
ASCV, with fast gains to open the the ASCV is allowed to close
ASCV
• The ASCV compares the values of
the current Flow (PV), to the
predicted Flow (SP) at surge for
the current Head
• If this comparison of PV to SP plus
Surge Margin yields a negative
Error(e) than the ASCV is
commanded open
What is Compressor Surge Margin?

Surge Control Line

Design
Maximum
B Speed
Continuous
Speed

e
rg
Su
HEAD

A
Design
Point

QB QA

Surge Margin (%) = (QA - QB)/QA

CAPACITY (Q)
 Anti-Surge Recycle Valves

• The ASCV is the final element of the anti-surge control system

• The valve regulates the recycle of gas from the discharge to the
suction of the compressor
• Valve sizing is critical
– If the valve is to small the compressor will not be protected and
surge
– If too large recycling will causes undesirable process upsets
• Solar use two different types of control valve
– Globe Valve
– Ball Vales
• Ball valves are typically used where noise is a consideration
 Anti-Surge Valve Sizing

• Valve are typically sized to handle full recycle at 70% of full open
• In the event of a shutdown the valve must be capable of reaching 2/3 of its
full open position in less than 100 ms/inch of port size
• Fast valve action is needed as the most likely time for the compressor to
surge is on loss of power (immediately after a shutdown)
 Globe Valve Assembly

• The term anti-surge valve,

actually refers to an
assembly consisting of
• Valve body
• Actuator – (Pneumatic)
• Valve Accessories
– Electro-pneumatic
positioner
– Position feedback
transmitter
– Exhaust booster
– Pressure regulator
– Needle Valve
– Enable solenoid
 Student Activity

Complete the activity questions at

the end of this lesson
 Activity Question # 1

• Define the term choke as it applies to the

centrifugal compressor
• ____________________________________
Choke describes the high flow low efficiency are of operation

____________________________________
 Activity Question # 2

• Operating the compressor in a choke

conditions is prevented by
– Limiting the size of the passages within the
compressor
– Limiting the flow of gas to the compressor
– Limiting the operating speed of the compressor
– It is impossible to achieve a choked condition
 Activity Question # 3

• Define the term surge as it applies to the

centrifugal compressor
• ____________________________________
Surge is an area of unstable compressor operation, where
the impellers are unable to produce enough head to
____________________________________
overcome the required pressure ratio
 Activity Question # 4

• State the purpose of the anti-surge control

system
• ____________________________________
The purpose of the anti-surge control system is to protect the
compressor from the effects of unstable operation by, preventing
____________________________________
operation of the compressor in the surge region. The anti-surge
control system actively monitors and compared the operating
point of the compressor to a set of pre-defined limits and takes
corrective action if these limits are exceeded
 Activity Question # 5

• Which of the following best describes the

dual action of the anti-surge control system
– Monitoring and detection
– Detection and regulation
– Avoidance and monitoring
– Detection and avoidance
 Activity Question # 6

• Identify the primary method of avoiding

compressor surge
– Increase operating speed
– Increase flow through the compressor
– Decrease operating speed
– Increase discharge pressure
 Activity Question # 7

• Identify from the list given, the main

components of the anti-surge control system
– Plc Controller
– Anti-Surge Valve
– Flow Meter
– All of the above
 Activity Question # 8

• Surge margin is defined as the distance from

the operating ___________
Flow factor to the flow factor
at the __________________
Surge limit and is
expressed as a_____________________
Percentage
 Activity Question # 9

• Which of the following best describes suction

to impeller eye flow measurement
– Available on all compressor models
– Accurate, inexpensive, no permanent losses
– Available on new generation three compressors
– A and B
– B and C
 Activity Question # 10

• State the purpose of the enabling solenoid

fitted to the anti-surge control valve assembly
• ____________________________________
The enabling solenoid is energized to allow the pneumatic
control signal to modulate the postion of the recycle valve. In the
____________________________________
event of a package shutdown or PLC failure the solenoid is
automatically de-energized causing the control valve actuator to
vent, fully opening the recycle valve