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HP First Impeller

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HP Inlet LP Inlet
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Suction Discharge
Pressure Pressure
 Discharge
Suction Pressure
Pressure

Normal Pressure Profile

 Discharge
Suction Pressure
Pressure

Surge Pressure Profile

 Balance
Piston

Suction Discharge
Pressure Pressure
 ∆P  (1/2 ρ U22)

ρ = gas density

U =Impeller Tip Speed

Frequency = 1/2 to 2 Hz

Pressure Pulsations Associated with Surge

Stall Cells

Incipient Surge
 ∆P = 0.05 (1/2 ρ U22)

ρ = gas density

U =Impeller Tip Speed

Frequency = 0.3N to 0.6N

Pressure Pulsations Associated with Incipient Surge

 Surge Control Basics

Opening the Recycle Valve accomplishes two things

which helps the compressor avoid surge:

• Recirculates flow back to the compressor

inlet
• Relieves resistance in compressor discharge
network, allowing flow to increase
 Surge Control Application
The following factors make surge control a unique
and difficult control application.

• Accurately defining the compressor operating point

• Locating and defining the surge limit of the compressor
• Acceleration of surge due to compressor curve shape
near surge
• Interaction with other control loops
• Special requirements for load sharing between multiple
compressors
Compressor Performance
Equations
k-1
P2 ( )
Hp = [( )
P1
kη
] kη ZRT1
-1 (k-1) MW

h Z R T1
Q1 = MW P
1
Readily Measureable
Variables
k-1
P2 ( )
Hp = [( )
P1
kη
] kη ZRT1
-1 (k-1) MW

h Z R T1
Q1 = MW P
1
Simplification of Head
Factor
k-1
P2 ( )
Hp = [( ) P1
kη
] kη ZRT1
-1 ( k-1)
MW

h Z R T1
Q1 2
= MW P1
 Simplification of Flow
Factor

k-1
P2 ( )
[( )
P1
kη
] kη
-1 ( k-1)

h
P1
 The Universal Surge Curve

P2
( )
P1 - 1

h
P1
 Determining the
Surge Limit Point
ho Pd
A Surge Limit Point, in terms of & , is determined
Ps Ps
by testing the compressor in the field or from using the predicted curves

supplied by the manufacturer. The compressor should be tested for

at least three surge points if possible, one at minimum speed, one at maximum

speed, and one at 50% of the speed range. This establishes the

relationship of speed vs. surge limit.

Increasing Surge Margin
Auto Increase of Surge Margin
Surge Limit Line Open Loop Response or High Gain
Hp Surge Control Line
New Surge Control Line

2 1

N2 N3
N1

Q2 (ICFM)

If the controller is unable to prevent a compressor surge, it is

desirable to automatically increase the surge margin so that
the compressor does not continue to surge. The controller
must detect a surge, increment the margin and alarm.
 Instrumentation
Considerations
Flow Measurement is the most important signal for proper surge control. Close
attention should be given to selecting and locating the flow device and transmitter.

• Location: Preferred in compressor suction for simplifying

algorithm. Commonly found in compressor discharge
piping and is compensated to inlet conditions. MUST be
located to measure TOTAL COMPRESSOR FLOW
inside the recycle loop.
• Size: The flow measuring device and transmitter must be
sized for maximum compressor flow. The required
pressure differential corresponding to maximum flow
should be 10” WC or greater.
 Instrumentation
Considerations (cont.)
• Flow Transmitter: The length of tubing between flow
device and the transmitter should be minimal. The
transmitter must be reliable, repeatable, and have a speed
of response (rise time) of 100 msec or less.
• Pressure Transmitters: These transmitters should be
located as close to the compressor as possible. For
constant speed compressors with suction throttling valves,
the suction pressure must be measured downstream of the
valve.
• Temperature Transmitters: Location is not as critical but
should be located to provide correct temperature.
 Instrumentation
Considerations (cont.)
Flow Measurement for Load Control
The flow measuring device for load control must be located to measure "user" flow
and not compressor flow. It must therefore be located outside the recycle loop.
Also, most flow control applications are "mass flow", requiring temperature and
pressure readings as well as flow.

FIC

ST FT
SIC
FT
PT
TT
PT TT

UIC

FY
 Flow Measurement
Need to have a sufficient “signal to noise” ratio.
Accuracy of the flow coefficient is not critical. Must be
repeatable.

• Venturi Tube- best device- most costly

• Orifice Plate- good characteristics-
unrecoverable pressure loss- less costly
• Annubar - widely used, least costly, least
desirable - poor signal-to-noise ratio.
 Transmitters
• Flow transmitters- Rosemount 1151 analog
and 3051 digital are most widely used for
surge control.
• Pressure transmitters- Acceptable to use
“smarts.”
• Temperature transmitters- Acceptable to use
“smarts.”
• Avoid Honeywell Smarts
 Control Valve
• Typically actuated with pneumatics.
Some axials may be hydraulic.
• Size and Speed are the two most critical
factors.
• Linear Valves are preferred. Others can
be characterized.
 Control Valve (cont.)
• Size- Valve size should be checked at all
operating conditions along the surge line
• Speed: Stroking speed of 1 sec. for 6" and
smaller valves. Stroking speed of 2 sec. for
8" and larger valves. Normally requires a
volume booster in air supply
 Valve Actuation
Piping/Tubing for pneumatic actuator and volume booster.

SV
Large Cv Volume Booster
1:1

Out Air
Supply
SV
Supply
In I/P
Control Features
 Proportional Function
Closed
0%

rPROPTM

100%
Open rSUCLN
Pdischarge
Psuction rSULIN
7
r MAR
0

h orifice
P suction
 Setpoint Hover Feature
Control Line

Surge Line
Control Setpoint
Pressure Ratio

Current Operating Point

PD/PS

Hover Setting

Suction Flow (hx)