ANTI-SURGE CONTROL

SYSTEM

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 CONTROL PHILOSOPHY
I n c a s e o f a P r o c e s s U n its t h e
e m p h a s is is o n s a f e o p e r a t io n a n d
p r e c is e c o n t r o l

In c a s e o f R o ta ry M /C s th e
e m p h a s is is o n s a f e o p e r a t io n a n d
m o n it o r in g .

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Measurements :
Health of a Rotary machine is best monitored
by measuring and monitoring the following
machine parameters :
 Vibration levels of casing and / or shaft
 Shaft RPM
 Relative location of the shaft with respect to a
predetermined mark ( e.g.-Key phasor )
 Axial shift of shaft

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Measurements ( CONTINUED):

 Temperature of thrust bearing pads

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Major control system
 Auto start of stand by lube oil pump.
 Lube Oil / Seal Oil back up system
 Sequential start / stop (speed ramping of
turbines) to avoid human error
 Capacity control
 Surge control system

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What is “Surge” ?

SURGING IS AN UNSTABLE
OPERATING CONDITION THAT
CAUSES ERATIC
COMPRESSOR PERFORMANCE

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WHERE AND WHEN SURGE
OCCURS ?
EVERY AXIAL AND CENTRIFUGAL
COMPRESSOR WILL EXPERIENCE A
DAMAGING PHENOMENON KNOWN
AS SURGE WHEN THE FLOW
THROUGH THE COMPRESSOR
DROPS BELOW A CERTAIN LEVEL

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Why surge Occurs ?

Surge can be induced by low

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How Compressor is affected due
to Surging ?
 Compressor damage results from
repetitive or frequent surging
 During Surge momentary flow reversal
takesplace, this leads to a very rapid
pulsating flow backward and forward
through the internals of compressor,
resulting in SEVERE VIBRATION and
consequent damage

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What happens during Surge ?
 Flow reverses in 20 to 50 milliseconds
 Surge cycles at a rate of 0.3 s to 3 s per cycle
 Compressor vibrates
 Temperature rises
 “Whooshing” noise
 Trips may occur
 Conventional instruments and human operators
may fail to recognize surge

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Some surge consequences
• Unstable flow and pressure resulting in process
upset
• Damage in sequence with severity to
seals,bearings,impellers, shaft
• Increased seal clearances and leakage
• Lower energy efficiency
• Reduced compressor life

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 Anti-Surge control system
 To prevent Surge, Surge protection systems are
required
 If adequate protection against Surge is not provided,
there is a risk of machine damage and downtime costs
 Adequate protection is defined as protecting the
compressor but not at the cost of unnecessary upset to
the process
 The job of the antisurge system is to detect the
potential upset and automatically compensate for it by
maintaining a flow through the compressor in excess of
the surge condition

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Anti-surge Control system-(contd)
 The chief drawback of this approach is
the efficiency penalty
 The energy that was used to compress the
recycled will go to waste
 So, the control system should be tailored
to open the surge control valve only when
and as far as necessary to stop surge

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ASPECTS OF SURGE CONTROL
SYSTEM
 Compressor Flow path has probability of
sudden flow reduction
 Is the Compressor provided with Variable
Speed Drive?
 Is the Compressor provided with IGV ?
 Molecular Weight Changes
 Manufacturer’s Surge curve and tested surge
Points
 Safety Margin
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 REQUIREMENTS FOR ANTI-SURGE CONTROL
 API asks for 10% safety distance between Surge line and
control line, referred to surge flow
 This corresponds to 4 to 8% referred to full range flow
 This safety distance need to cover:
- Anti surge controller response time
- Limited stroke speed of Blow-off valve
- Transmitter accuracy and drift
- Measuring errors when the location of the surge line
is determined
- Compressor fouling and changes in gas composition
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SURGE DETCTION METHODS

 DCS-Minimum Flow controller(On spill back)

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Compressor Performance Map

For any operating curve the point of

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Surge control Diagram:
The diagram below shows the performance map of a compressor with the
surge control lines .
SKETCH - 3

1 2

3
Pd
------
Ps
4

FLOW

1. SURGE LIMIT LINE 2. SURGE CONTROL LINE

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Effect of Gas composition on Surge
2
1.8
1.6
1.4
M7.8
1.2 M4.6
1 M2
0.8 new
0.6 M28

0.4
0.2
0
0 0.2 0.4 0.6 0.8 1

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Antisurge Control System
Anti surge system achieve this By manipulating the positions of Recycle
valve (Normally for Hazardous Gas) By using a Blow off valve (Normally for
Air or Non hazardous applications) in order to maintain the volumetric flow
rate above a safe, minimum level.

Compressor

Antisurge Valve

FT PT PT FT
TT TT
FY

ANTI SURGE
CONTROLLER

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Surge Control Techniques :
 Calculate and Monitor the "Operating
Point " of the Compressor.
 Open the vent or Blow off valves in a
controlled way .
 Open the recycle valve( Between the
discharge and suction of the compressor)
in a controlled way.
 In variable speed machines , reduce the
speed.
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Surge Control Valve
 SURGE CONTROL VALVE SIZING
Surge control valves should be sized for
each of the following
1. Surge control line at minimum speed and total recycle
2. Surge control line at maximum speed and total recycle
3. Surge control line at normal operating pressure
4. The design capacity of the machine
Normally point 1 is the governing case (i.e.
lowest flow and lowest delta P) and the valve usually
pass flow the machine design capacity

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Surge control Valve(contd..)
 VALVE CHARACTERISTICS
The installed characteristics of the surge
control valve should be linear. This can be
accomplished by either a linear trim characteristic
control valve or line arising an equal percentage valve
in the controller
 SPEED OF RESPONSE:
The Valve is designed to “Open fully” from “full close”
with in 2 seconds. This is accomplished by proper
punematic accessories with Valve Actuator

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References
 Shell Dep 16ES-600 - Compressor surge
control systems
 Shell Dep 16GS-600 - Design requirements
for compressor surge control systems
 CCC Publication for Accurately defining
surge control line
 GHH-BORSIG - Turbolog operation manual

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THANK YOU

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