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Surge Control System Overview

The basic surge control system uses differential pressure transmitters to measure compressor flow and pressure. It calculates a control line signal proportional to flow squared and compares it to the measured pressure differential to determine if the compressor is operating near or past the surge limit. If near the limit, a surge controller opens a recycle valve to maintain operation along the control line and prevent surge. Devices like low selectors and lag controllers provide stability to the system and prevent the surge controller from overreacting.

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30 views2 pages

Surge Control System Overview

The basic surge control system uses differential pressure transmitters to measure compressor flow and pressure. It calculates a control line signal proportional to flow squared and compares it to the measured pressure differential to determine if the compressor is operating near or past the surge limit. If near the limit, a surge controller opens a recycle valve to maintain operation along the control line and prevent surge. Devices like low selectors and lag controllers provide stability to the system and prevent the surge controller from overreacting.

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ankur2061
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© All Rights Reserved
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Basic Surge Control System

Reference: Compressor Handbook by Paul C Hanlon

FCV

COOLER
LX

HIC
LAG
RECYCLE
FLOW
SUCTION
FZ
FIC
FX

FT
DPT

DISCHARGE FLOW
FE

SURGE
LINE
P
CONTROL
LINE

P  C  h  (  b )
C

h
b

FT—The flow transmitter is a differential pressure transmitter which measures the pressure drop across
the flow element and transmits a signal that is proportional to flow squared.

DPT—The differential pressure transmitter measures the differential pressure across the compressor and
transmits an output signal that is proportional to the measured pressure differential.

FX—The ratio station receives the signal from the flow transmitter and multiplies the signal by a constant.
This constant is the slope of the control line.

FZ—The bias station receives the signal from FX, the ratio station, and biases the surge control line.

The ratio station must have both ratio and bias adjustment to enable the control line to be placed
as parallel to the compressor surge line as possible.

   
P  C  h  b
where:
P = calculated compressor differential pressure signal
C= Control line slope (ratio signal)
h= inlet orifice differential pressure signal measured by FT (square of flow)
b= Control line bias (could be zero)

FIC—The surge controller is a flow control device which compares the calculated ouput of FZ to the
measured ΔP output of the DPT with ΔP as defined above

When the calculated P is greater than the measured P, the compressor is operating to the right
of the control line. When the calculated P is equal to or less than the measured P,
the compressor is on or to the left of the control line, and the surge controller functions
as a flow controller and opens the anti-surge valve as necessary to maintain operation
of the compressor on this surge control line.

For rapid flow changes, the response of the control system must be rapid to prevent surge.

LAG—This device functions to enable the surge controller to open the recycle valve quickly,
while providing a slow closure rate. This feature provides stability between the anti-surge control
system and the process by minimizing the hunting effect between control system and recycle valve.

LX—The low signal selector is set up for two inputs and one output. The inputs are a 100% signal
value and the surge controller output signal. The output of the low selector is sent to the recycle
valve as well as back to the surge controller in the form of a feedback signal. This prevents the
surge controller from winding up. Windup of the controller penalizes the reaction time of the
anti-surge control system

FCV—The anti-surge recycle valve functions to prevent surge by recycling flow from the compressor
back to the compressor inlet. Sizing of the anti-surge should be at 105% of design flow at design
differential pressure.

Q: Who provides the surge line for a given compressor?


A: Surge line also called the surge limit line is provided by the compressor vendor as part of the
compressor map or chart. Refer the figure below.

Prep'd by: Ankur Srivastava


Chemical Engineer
Email: ankur_2061@[Link]

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