“ai-11-1997 @2:65PM = COMPRESSOR Ciineeee Tilflow control valves have a characteristic relation resuting flow rate. Figure 1 illust ‘common valva flow characteristics: = Avalve exhibiting linear flow provides excellent response throughout is range of tavel. This is the prefered characteristic for antsurge contol. + An equal-percentage valve provides less effec {ive control when only slightly open, a point where cltettive action is often most needed. However, ‘Such valves are sometimes adequate for epplica tions such as small packaged alr compressors. «+ Aquick-opening valve is en exceltent choise oF ppack-up protection, However, installing such 2 valve ina primary, closed-loop surge protection fem wil present many dificuties when fine- tuning the foop dynamics. when selecting a nev’ antisurge valve, itis best to 5 the following ing compressor wilh an equelperaantage oF quick. compensete for such valves. Series 4 systems also ‘culated by squaring the intended flow rate. ‘On the other hand, a controler set up for an equal square of tha valve opening (Ior ‘The contro! signal is than calculated as the square root of the intended flow rate, Sizing Antisurge Valves ‘Toingure comprossor and process safety, an ant surge valve must be big enough to prevent the com pressor from surging even i all other flow paths are Completely blocked, yet small enough to provide responsive contro) under less severe carcilions. i Selecting and Sizing Antisurge Valves Ship betwen the vals positon (stem travel) and he pect one with a linea flaw characteristic. Hovis ityou ave rotting a new contra system ton exist | To size the antsuree ‘valve, you should frst calculate ‘opening antisurge valve, you do not need 10 replace it | yleids the highest costiciont value This s usually the Pocause our Series 3 Plus Antisurge Gontrolers c89 | intersection of the ‘surge limit ine (SLL) and the maxi- cameo resa deine a custom vENE NOW OharCLTe8. | sever! points and uss the highest ei. iineconteris set vo fr aquck-onering anisuege | Then age tis How oetlent into thato te p pro- Nave t assumes tne normalized fowis proportional) posed valve (G,y)-An adequately sized valve will yield Joins square root of the fractional valve opaning. FOr, | a rato in he range ‘example, If the valve is 1/4 open, the flow: would be 1/2 fs maximum rate. The velve contro! signal is ten cal- 185G,,,/C, 822 tage valve assumes flow is Propane Pe Tit exceads 2.2, dynamic adjustment o! the system , might prove cifficult and he operating point could SZ open, the fiow would be 1/4its maximum rate). | approach ‘he compressa’ choko (stonewall mitt Flow Position (% Open) Figure 1 Valve characteristics the flow coafticlent (C,) for the operating point that mum performance curve. fn doubt, calculate O, for ‘this ratio is less than 4.8, he proposed valve may be too small and would yield marginal surge protection. the valve were fully opened. Note that thage are"empirics! limits based on Our: ‘experiance with thousands of compressors. In Fave cases, 2 larger ratio might be needed, while @ smaller ratio might prove adequate in ofhers. This is espocially {tue I! theve are other signlficant flow restrictions in the > recycle toop. Individual customers may wish 10 ontact Us for recommendations for particuler applications. February 24, 1897 Page 1082 "AN 17 (4.0)41-11-1997 @2:@erM = COMPRESSOR CLIN ee Valve Characteristic «== —~—«‘LInear Flow Response : | Z 2 5 5 é 5 g 3S | a/ i i Control Response: ‘Valve Position intended Flow Equal-Percentage Valve 3g 2 z } i : : g g ‘Control Response: ‘Valve Position Intended Flow: | ( Quick-Opening Valve Figure 2 Non-linear valve compensation Some contol eystem designers size tho vana ovhat | ALE Ome, ‘extreme, there Is 3 tendancy to oversize por opan tow rate corresponds fo apointon the | | the vave, ‘that itcen decrease the compressor performance map eighty tothe ight of tne surge con | PrENTE tfarential to eimost zero. The compressor artormerccause avon the best contol system might | might then be damaged by reaching the choke or tbe unable to prevent surge under thase conditions, ‘stonewall regon, end shutting down the system could ‘hat approach could lead to compressor damage. be ditfcutt ; "Agystom with an undersized valve woutd be Incapable ‘of preventing surge when a large or fast cisturbsnce Scburred while operating on the surge controlling with + the valve partly open. The remaining flow capacity ‘might then be Insufficient to compensate for changing process | conditions. “The antisurge contol loop shoukd also be capable OF ‘Compensating for a combination of disturbances (fr ‘example, simultaneous increase of system resistance {nd deorease of speed, or simultaneous increase of — sysiem resistance ‘and decrease of inlet density). This (CONMAND i a trademark, and the Impeter loge, TTC 10g0, raopires alerge: valve. Sete Irn. Stel On Alraise. TTC, ane Toa Ten Control [ip rogstoreciadamarks of Comaressor Contoss Corparaton AN 17 (4.0) Page 2012 T= February 24, 1997 COMPRESSOR CONTROLS CORPORATION {11959 AUROBK AVENUE DES MOINES, IOWA 50922, U.S.A. © PHONE 515-270-0857 » FAX 515-270-1394ii-t4-1997 e7PM © COMPRESSOR CONTROLS Con's - Project Error! Cannot open file., Errori Cannot open fil Antisurge Valve Calculations , | 2.14 Scope -The cater for selecting antisurge valves is based upon Compressor . Cantrols Corporation's (CCC) lengthy experience in he design and peraon of compressor control systems. There are five pray certideratione for propery selecing and applying anfisurge valves: © stroking time + location + characteristic ‘+ actuator, positioner, and electro-pneumatic transducer + size tach ofthe sbove considerations Is discussed seperately in the following sections, . 2.4.1 Stroking Time “jransients Inthe region close to surge can be extremely fast sue to the on { rjatve ftress of the compressor performance eurve inthis region. For . texample, the duration of typical surge cycle Cam. be fess than one ‘protect the compressor from surge, the sacond. Therefore, to adequately Sa00e speed of responce must be aay fast_As a guideline, the ‘troking time should pe two (2) seconds orlees. Aso. should have Faking tes roughly equal n both the opening and closing directions. erosive with a dosing svoke ime of more than 1.5 mes the opening ‘roko te (or an opening soe time cf more than 1.6 mes the toslig Toke Sime) wil resutin the vale conibutng unequal components fo the overal loop gain, ‘This uneven valve action wil inhibit optim : dynamic tuning of the compressor control system. «volume booster Installation = reduction of tubing length : “The use of a quick release solencid valve instead ‘of a vole booster is ‘not recommended. The quick release solenoid valve only increases: the: Vols string speed inthe opencdrebton. Tbe volume boosie however, increases the speed in bolh the open ‘nd closing directions. ‘iso, since a quick release solencis valve dass. ‘not provide modulating ‘control, itean be detrimental to antisurge. and process control when ‘operating in steady state recycle. eeeeete u FORT CannOT OPEN FILE, FOR ERROR] CANHOT OPEN PLE: 7di-i4-1997 82:67PM Project Error! Cannot open fil BRE Rer ae eee eee Eee 0 _Antisurge Valve Calculations : 2.1.4.1 Volume Boosters “To increase the stroking speed of the antisurge valve, volume boosters, (Fiehersype 2625, for example) ere used on the valve actuators. On Jolume booster is required fora diaphragm actuated valve. Two volume tboosters ae required for a piston actuated valve. The volume booster delivers a high volume output forcing @ repid stroking of the actuator. Therefore, when signaled by the anfsurge control, the valve not only Tencte immaciately but also the posion of the valve keeps up with the signal recelved from the antisurge controler, 2.4.1.2 Tubing Length ~~ Antisurge valve: ‘components can also affect stroking speed. Toreduce ‘component eects on valve stroking speed, the length of tubing between tho slocro-pneumatio transducer, valve postione, valume booster, and valve actuator should be kept toa minimum. Itis also necessary to property select the maximum diameter of ubing between these devices to provide the desired speed of response and valve stability, Valve vendorimanufacturer | ‘recommendations should be followed. ee "ERROR! CANNOT: “OPEN FILE, FOR ERROR] CANNOT OPEN FILE.Seis rier eee eee eee eee Project Error Cannot oper fite., Errort Cannot oF _-. Intisurge Valve Calculations, 2.1.2 Location ‘Gc recommends locating the enisurge valve as close as possible fo the discharge flange of the compressor. Volume between the discharge ofthe compressor, the check valve inthe discharge (downstraam of he Snlisurge takoof fine), end the antisurge valve should be kept to & rrinimum, See figure 2-1. ic Frinimize discharge / & COMPRESSOR Figure 2-4 Discharge Piping Conolderations. tnmostceses, the valve must be located upstream from the disehsrge Shuck valve. A check valve located inthe inmediate discharge ofthe ompressor, between te compressor discharge and the anisurge fakeot ine, can be detrimental to the compressor. Tis piping configuration may allow the compressor fo be cut off from the actions of the valve and could possibly inhibit adequate antsurge conte for the ‘compressor. However, In cases where the valves slow in responding or Gore ea large discharge volume, a check valve located inthe immediate discharge of e compressor can be beneficial ‘The discharge check valve [s an important component ofthe antsurge Control system. It helps protect the compressor under ditfielt and dynam condens. The use of a discharge check vawve downstream from the antsurge takeoff ine is recommended. Wantisurge gas cooling is necessary. 2 separate antisurge cooler is ‘recommended, tt shouk! be located DOWNSTREAM of the antisurge Valve, This wil reduce the posslllty of hydration and valve foutng or arnege, or both, dus to condensate, See figure 2:f. fz separate cooler is not ‘econorically justified, proper placement of the discharge EGROAT GhiNOT OPEN FILE, FOR ERROR! CANNOT OPEN FILE,Ti-t1-1997 @2:gePM = COMPRESSOR Coin Project Error) Cannot open: Error! Cannot op! fil > Antisurge Valve Calculations, | check valve and minimization of discharge volume are factors that take ‘ona higher level of ‘importance. _ 2.4.3 Characteristic “The antisurge valve: characteristic is the relationship between the travel ofthe restricting element and the resulting Gow rate. Figure 22 Twustrates the following common velve characteristics: + finest, © equalpercentage, + _quickopening. %OPEN Figure-2-2 Valve Characteristics. ‘Avalve exhibiting a linear fiow characteristic provides excalient response ftroughowt is entre range of evel, The inear fw characte is me preferred characterisic fr most compresscr contol systems, TOOLBAR- “SECTION 2” exist, val or salectina new vel 2.1.4 Actuator, Positioner, and Electro-Pneumatic Transducer : ‘pneumatic daphragm or pneumatic Fston-ype achat provides the psary mechanical power to operate the valve, Should the valve Setuaton system fll loss of mA signe, oss of alr syppiy), COC C4 reeommends the valve fall open. a 7m ERROR] CANNOT OPEN FILE. we TERROR! CANNOT OPEN FILE14-11-1997 82:26PM COMFRESSUR Sere Project Error! Cannot open file. Error! Cannot open file > Bntisurge Valve Calculations , 2.1.5 Sizing ‘positioner fs required in oder to ensure the vate position is always: ireely proportional tothe velue ofthe controter ‘output—regardiess of packing box fiction, actuator hysteresis, of off-balance, forces. In etton to its primary furclon, the postioner afords adjustability for ~ valve travel. ‘an eleco-preumati transducer (Fisher-ype G46, for exemple) Is used ee Savor the electrical signal of te controler fo @ proportions pneumatic signal received by the posttoner. The Best location for the ‘transducer is on the valve. -To encure compressor end process safely, he valve must be lae enough to prevent the compressor from surging even if all other flow paths are completly blocked. Howover the valve must algo provide responsive control under less severe conditions. An oversized valve may tead to process instabiities due to the relatively large affect on compressor fw with 2 reatvely eral eontal input, Hence, coversizing ‘he valve must be avoided. : “There ate many diferent views on how to size antisurge valves. Ato end ofthe sizing spectrum is the phiosophy of sizing the valve such that tie paraeteritiais located on the performance map only elght the right ofthe surge conteal ne when the vai I uly oper ‘Atihe other Forme is the pnlosophiy of sizing the valve auch that fs pablo of ‘decreasing the compressor pressure differential to almost 2ero. “The fist aerate coud lead to surge induced compressor damage, A compressor control system using 2 valve sized for Surge control line flow ‘will not provide adequate antigurge contro! regardless of the control strategy used. Even the very best control strategy will be uneble, in surtegy Tarmstancos, to provent compressor surge. This is duet the semvely smal flow capscty ofthe vale compared to the fw capac of the compressor. When a process upset causes the compressors: peratng point to move towards surge, the compressor CORO! system ‘will command the valve fo open. ‘This will reduce the compressor discharge pressure while increasing compressor flow. However, time consuming event and many geeoqds may pass before the discharge pressure is reduced enough ‘and the fow of the compressor is increased enough to avold surge. A systemwith an. undersized valve Is never capable of preventing surge under large oF fast disturbances when the coripressors operating point is: pormanenily.tocated close to or on the carge contrel ine. Underiing te antsurge vale js especialy dangerous If the compressor frequently ‘operates on the Surge control “ERRONT CaniOF OPEN FILE, FOR EnORI CANNOT OPEN FILE. 25Be eR etna Ree ieee eer Ree eee eee Project Error! Cannot open file. Error Cannot oper, Antisurge Valve Calculations “Avelve wth Gy,y = Cy max may make the dynamic adjustment of the system more difficult and the valve’s stroke may need to be limited. Note: For Fisher Control valves, replace the ebdve Cy with Cg. 2.3 Compressor Applications With Multiple Compressor Maps Per Recycle Or Blowoff Path; Multicase and Sidestream Compressors 2.3.1 Calculation Method ‘There are dfeules in selecting entisurge valves for sidestream compressors which recteulate gas from the compressors discharge to | 7 Sach compressor section's respectve Inlet drum, rather than recirculating i ‘gas from the discharge of each compressor ‘section to each respective \ Hotaru. Toerofore, the design discharge pressure of the last section, land the design discharge temperature of the last section after the Gioonarge covler, ae used 2s the entisurge vale's inlet conditions for calculating the recommended vaive Now coafficient. For sidestream compressors, as long es the compressor Is not surging, each compressor section (except the first ‘seotion} receives some flow from tne section immediately upstream from tself. For sizing sidesteam entisurge valves, the flow {used for caloulating ‘the valve flow coefficient) fhrough any sidestream should equal the Surge Limit Line flow through the compressor caso immediately downstream from the sidestream less, the Suige Limit Line low through the compressor case immediately from the sidestream, “The Surge Limit Line flow is determined af the design discharge pressure of the compressor section. Ina eimiar fashion, mulicase nonsidestream compresstre are reviewed. “The design discharge pressure of the lsst section, and the design discharge temperature ofthe last section aftar the discharge coaler, are ‘ysed as the antisurge valve's inlet cdndifions for ealovieling the tesommended valve flow coeticient. The indviduel compressor section's Surge Lintit Line flow is determined the design discharge pressure oF the respecte compressor section, Allnormsized flows are compared “ERROR! CANNOT OPEN FILE, FOR ERROR! CANNOT OPEN FILE. 27PEen Ree Perea eee ee eet not open file., Error! Cannot open fl Project Brrort _- ‘Rntisurge Valve Calculations Teoommended antisurge valve flow coeficient. ‘Based upon CCC's | experiance, the most effective method for: ‘selecting. antisurge valves for these applications is as folows: i | | and the lrgestis chosen, Tis ow valves used for determining the i + Using the compressor’ performance curved. define a pelt Diareeetion between the Surge Linst Line and the horizontal ing aevening the design discharge conditions forthe comprassor section. «Calculate flow coefficient Cy for tis point Multiply Gy by 18 fo find the minimum value ofthe required ffow ‘coefficient Cy min- . 4 Multply Cy by 2.2 find the maximum value of the required Nov coefficient Cymax + Compare the flow coefictont af the existing valve Cy,y f0 valves Cymin 305 Cymax: Foran adequately sized valve: Cy,min § yy $ Cv,max ro ‘Avalve with Oy & Gy min may be too smal fr effective eurce 3 protection and makes the enisurge loop marginal valve with G2 Gy max may make tha dynamic ecjustment oe system more diffcut an the vaive's stroke may need to be limited. ; a ERROR] CannOT OPEN PLE., FOR ERROR] CAHNOT OPEN FILE. 28 TOTAL P.1441-11-1997 82:89PM = CUNERESse ee sort Cannot open file. Project Error! Cannot open _~ Entisurge Valve Caiculations, fine, The low capacity of the valve is already partially used to satisty ‘lendy state concons leaving very tle margin to compensate for any system dynamic. inthe second sizing teria, the compressor might be damaged by the vTrests of compressor choke or other high fow rate related Instabities. ‘aso, con! system tuning may be dificult due tothe large gain ofan fveteized vaWve. The stroke of an oversized valve can be limited, which til raduce the maximum flow capacity. However, the valve wil ail present tuning diffculties. “To ensure compressor and process safely es well as to decrease the amount of recireulation, the ‘valve should have a flow coefficient that is higher than the ‘coefficient calculated for the ‘compressor’s operating point when the operating point Is located on the surge lirrit line, 2.2 Compressor Applications With One (Overall) Compressor Map Per Recycle Or Blowoff Path; Single And Multicase Compressors : 2.2.1 Calculation Method esed upon COC's experience, the most effective method for selecting ‘antisurge valves for these applications Is as follows: + Using the compressor’s performance curves, define a polnt Intersection between the Surge Limit Line and the maximum performance curve. ; «© Galeulate flow cosfficient Cy for this point a Multiply Cy by 1.8 fo Find the minimum value ofthe required flow coeticiant Cy min 4 ullipty Gy by 2.2 to find the maximum value ofthe required flow coefficient Cy mare «= Compare the flow ooetticient of the existing valve Cy,y fo values Gyjmin and Cy max: Foran adeauatly sized valve: jx S Cymax Cumin’ € “Avalue with Cy,y S Cyymin May b2 100 ‘sinall for effective surge protection and makes the entsurge foop marginal. : “Ganon! 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