16 EG-600 Compressor Surge Control Systems

ULSD Project

Approved Feb 94

Engineering Guides and General Specifications

16 EG-600 Compressor Surge Control Systems

Table of Contents
1. Introduction .................................. 2 2. References.................................... 2
2.1 Industry Documents............................ 2 2.2 Shell Oil Company Documents .......... 2 3.2 Definition of Terms ............................. 4 3.3 Surge Control Line.............................. 4 3.4 Surge Control Primary Measurement...................................... 4 3.5 Surge Control Valves.......................... 5 3.6 Compressor Piping Arrangement ....... 8

3. Technical Discussion .................. 2

3.1 General ............................................... 3

Appendix 1 - Definition of Terms ... 9

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16 EG-600 Compressor Surge Control Systems

ULSD Project

Approved Feb 94

1.

Introduction
This Engineering Guide (EG) provides assistance in using the associated General Specifications (GSs): 16 GS-600. This EG includes background and philosophy type information on instrumentation design but not requirements. The Shell Instrument Engineer shall be consulted for approval on any proposed designs by the contractors, or others, which are based on this section if such designs may deviate from requirements of any EGGS GS sections. This EG is not a stand-alone document; the user must refer to the associated GSs for related requirements.

2.

References
The latest edition of the reference documents cited below provide related background information. References cited in the associated GSs are not listed again below but may be referred to in the body of this EG.

2.1

Industry Documents
API 617 Centrifugal Compressor for General Refinery Service

2.2

Shell Chemical Company/Shell Oil Products Company Documents

11 EG-612 11 EG-617 16 EG-110 16 EG-120 16 EG-140 16 EG-150 Special Purpose Steam Turbines Centrifugal Compressors Pressure Measurement Temperature Measurement Flow Measurement Actuated Valve Application

3.

Technical Discussion
The following technical discussion provides guidance for the design of centrifugal and axial compressor surge control systems covered in the associated GS.

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16 EG-600 Compressor Surge Control Systems

ULSD Project

Approved Feb 94

3.1

General
The purpose of the compressor process control system (PCS) is to control flow or suction/discharge pressure to meet required process conditions. However, for each performance curve, there is a point of minimum flow and maximum head, which is known as the surge limit point. Surge occurs when the network (piping, valves, exchangers, etc.) resistance becomes too high for the compressor to overcome (i.e. flow too low). Surge can be induced by low suction pressure (e.g. suction valve too far closed), high discharge pressure, or reduction of speed of the compressor. The obvious way to prevent surge is to decrease network resistance whenever the operating point moves too close to the surge limit line. This is accomplished by an auxiliary control system which opens a surge control valve to recycle or discharge a portion of the total flow. The chief drawback of this approach is the efficiency penalty that it entails. The energy that was used to compress the recycled gas will go to waste. Thus, the control system should be tailored to open the surge control valve only when and as far as necessary to stop surge. On the other hand, 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. All centrifugal and axial compressors should have a surge control system. The system may be very simple with a fixed or operator adjustable set point for a minimum flow controller as shown in Shell drawing 16 DC-6005. Some compressors may require a very complex system with multiple process variables being measured and the minimum flow requirement being calculated by the control system. Justification of the more complex system is based on cost (e.g., cost to installed and maintain) and complexity versus savings by reducing wasted energy to compress the process fluid and then having it vented to atmosphere (i.e., air compressors only) or recycled back to suction. Any time the surge control valve is open, energy is being wasted. Therefore the control system should ensure that the surge control valve is only open the minimum amount required to stop compressor surging. System design must consider the process and the machine; some machines are more sensitive to surge (axial machines) and some processes are more sensitive. Each compressor section in a machine should have a surge control system. Compressor sections are defined as one or more compressor stages (i.e., wheels) that work together without cooling or liquid knockout; see Shell drawing 16 DC6003. Though all rotors are on the same shaft and therefore operate at the same speed, each case has its own unique set of operating variables and transient disturbances. Variables such as polytropic efficiency, composition, specific heat ratio and compressibility all figure into the problem, yet vary from section to section. Individual compressor sections can and will surge independently and should be protected as if each was a separate machine. Communication may be provided between the surge control system on each section to prevent control action by one control system from forcing the other section(s) into surge.

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16 EG-600 Compressor Surge Control Systems

ULSD Project

Approved Feb 94

3.2

Definition of Terms
For definition of terms refer to Appendix 1.

3.3

Surge Control Line

The surge control line should be determined as described in Shell specification 16 GS-600. However variations in molecular weight cause performance of the compressor to change. Molecular weight variations also affect the response of the inlet flow device and therefore flow transmitter output. For small fluid molecular weight variations, changes in flow measurement and compressor performance tend to cancel out and have little affect on the surge limit line. Larger changes in molecular weight will require compensation of the surge control line to prevent compressor surge. A more complex surge control algorithm possibly with temperature input is necessary. (See 16 DC-6004 for Typical Compressor delta Pc vs. Inlet Flow delta Po.) The curves (derived from actual plant data) indicate that molecular weight extends the curve along the line to higher values of delta Pc and delta Po and that suction pressure variations tend to change the surge limit line with regard to required flow.

3.4

Surge Control Primary Measurement

The transmitters used to transmit information to the surge controller must be properly ranged, fast and repeatable. Absolute accuracy is not as important since surge tests will be conducted in the field using the actual instruments. Since surge is a rapid pulsation of forward and reverse flow, pressure and differential pressure transmitters must be very fast to detect surge. NOTE: Smart transmitters are not acceptable due to the slow sample rate relative to the process. 3.4.1 Flow Transmitters The low loss venturi is the preferred device for compressor suction flow measurement due to its low permanent pressure loss. Orifice plates are not acceptable in low suction pressure (e.g., less than 50 psig) compressors because of the following: 1. Permanent pressure loss (Increased power requirement). 2. Orifice straight run length requirements. But remember, repeatability, not accuracy, is the main concern. Therefore, orifice plates without adequate straight run length can be used if repeatability and power loss are evaluated. It is preferred to locate the surge control primary measurement in the compressor suction. This is because the surge limit point is invariant to changes in the compressor suction and discharge temperatures when determined from a suction flow measurement. The surge limit point

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16 EG-600 Compressor Surge Control Systems

ULSD Project

Approved Feb 94

may be determined using a discharge flow measurement. However, this method usually requires correcting the discharge flow measurement for changes in the ratio of discharge to suction temperature. 3.4.2 Pressure Transmitters The surge controller requires the pressure measurement as an absolute value (i.e., psia), however, pressure transmitters should be specified as gauge pressure transmitters above 20 psi. Gauge pressure transmitters are more common and much easier to calibrate than absolute transmitters. The conversion to absolute units can be done by the surge controller. Absolute pressure transmitters are used when the pressure is less than 20 psi because of the effects of atmospheric pressure changes. All pressure transmitters on a machine shall be the same type. With high suction and low compression ratio applications, use differential pressure transmitters due to accuracy. Note that a suction pressure transmitter is still needed. 3.4.3 Temperature Transmitters Temperature transmitters are generally not required in surge control systems except when used for correcting for variable fluid molecular weights. When temperature transmitters are required, smart transmitters are used. Due to the relatively slow changes in process temperature, speed of transmitter response is not a factor.

3.5

Surge Control Valves

3.5.1 Surge Control Valve Sizing It is important not to make the surge control valve too large or too small. If the compressor would operate just to the left of the surge control line, shown on Shell drawing 16 DC-6001, to meet process operating requirements, the surge control valve will only be open a small amount. A valve that is too large will open and move the operating point too far to the right of the surge control line, resulting in controller action to close the valve. The valve will oscillate between open and closed which can cause process upsets. Surge control valves should be sized for each of the following points shown on Shell drawing 16 DC-6001: 1. Point A on the surge control line at minimum speed. (minimum governor speed and total recycle) 2. Point B on the surge control line at maximum speed. (maximum governor speed and total recycle)

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16 EG-600 Compressor Surge Control Systems

ULSD Project

Approved Feb 94

3. Point C on the surge control line at normal operating pressure and/or relief valve pressure setting. 4. Point D, the design capacity of the machine. The surge control valve is not typically required to pass the total design capacity of the machine (i.e., the valve is designed to control/stop surge not perform a capacity test on the machine). However, the valve should be checked to see if it will pass this flow. If a valve that will pass this capacity is available, without being too large for conditions A, B, and C, the larger valve should be selected (i.e., use this in final valve selection criteria). Normally, the surge control valve is required to function due to a reduction or total elimination of forward flow (sudden closure of valve to user). The machine is still operating therefore producing pressure. The surge control valve must open quickly but there is a driving force to get flow through the valve. When the machine is tripped this driving force is lost. If the surge control valve is not large enough to pass the capacity of the compressor, it will probably surge as it is stopping. Normally point A is the governing case (i.e., lowest flow but also lowest delta P) and the valve will usually pass flow at point D. An item that is often overlooked is start-up conditions (slow roll and idle speeds). Often the compressor is tested or commissioned with material that is different (molecular weight, temperature, pressure, etc.) than the process material it will normally process. These conditions can have a big impact on valve selection and must be considered. 3.5.2 Valve Characteristics The installed characteristics of the surge control valve should be linear. This can be accomplished by either buying a linear trim characteristic control valve or line arising an equal percentage valve in the surge controller. There are some advantages of using an equal percentage valve. The surge control valve typically has two very different operating positions. It is either slightly open (e.g., the process operating point is just to the left of the surge control line which may require less than 10% of the capacity of the valve) or it is midrange or greater (i.e., no flow to the user). The stability of an equal percentage valve at low Cv requirements is much better than a linear valve. The surge controller electronics can make very small changes in output signals but valve may not respond. Equal percentage valves require more "lift" vs. Cv change near the seat (when compressed with linear trim). Valve failure position must also be determined by the Project Team. A fail open valve will protect the machine but will probably result in a process upset. A fail closed valve may prevent the process upset but can not be opened on loss of air supply. It is also very difficult to determine air supply has failed to a fail closed valve since the valve is

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16 EG-600 Compressor Surge Control Systems

ULSD Project

Approved Feb 94

usually closed during normal operation conditions. If a fail closed valve is used, consideration should be given to installing a volume tank that will force the valve open when the machine is tripped (i.e., solenoid valve actuated, not part of normal valve position control, but trip actuated). All application should have solenoid on the air to the surge control valve to force the valve open when the machine is shutdown. (See section 3.5.1., item 4.) Both piston and diaphragm operated valves are used. First choice should be diaphragm with piston operated valves used only when required. Volume boosters are used to increase the stroking speed of piston operated valves. The use of dual, parallel boosters is not recommended since they are difficult to adjust. Quick exhaust valves have been used with success but should be avoided. Quick exhaust valves on piston operated valves tend to produce nonlinear and unstable valve action. On diaphragm operated valves, precision, instrument signal quality quick exhaust valves are used by some vendors. Design of the valve and operator must be coordinated with the surge control system vendor. Whisper/noise trim valve should not be used. These valves have very small openings that will plug very easily making the valve useless. A high noise for a short period of time is acceptable (remember, the surge control valve is not normally open). Noise trim may be required in some applications since noise level may be so high that it will cause physical damage to the valve. Always make sure the holes are as large as possible. Coordinate with Process Engineer to determine minimum hole size. 3.5.3 Local Manual Control Local manual control is generally not required, but is justified for maintenance of system hardware. Car-sealing of the selector is required since this defeats the automatic surge control system. Installation of a hand indicating controller (HIC), for local manual control, should be as close as possible to the surge control valve; best location is to mount directly on the valve. The selector switch (i.e., three-way valve) should be installed between the I/P and the HIC, therefore if the HIC is not close to the valve, the amount of tubing between the I/P and the surge control valve positioner will cause lag in the valve response. Typically 3/8" or 1/4" tubing will give the best results. Keep the tubing as short as possible and test the system response in the field. Even with boosters, the I/P must have a relatively high volume. This HIC is only for maintenance of the surge controller and I/P. It shall not be used by operations unless surge control system hardware problems have definitely been identified. Selector switch shall not be located on the field panel or other place that would have easy access for operator use.

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16 EG-600 Compressor Surge Control Systems

ULSD Project

Approved Feb 94

3.6

Compressor Piping Arrangement

Lag and dead time in the compressor recycle loop must be minimized. In addition to using fast valves and transmitters, the volume of gas between the discharge port of the compressor, the discharge check valve and the recycle valve should be as small as possible. The compressor vendor and the surge control system vendor should provide data on the maximum volume for this piping system. Large volumes of gas act as filters with excessive time constants slowing recycle response. Recycle gas must be cooled. The best arrangement is to route the gas back through the suction cooler. Some existing installations may not have suction coolers or may have flow measurement in the discharge. Acceptable surge control can still be achieved but requires special considerations.

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16 EG-600 Compressor Surge Control Systems

ULSD Project

Approved Feb 94

Appendix 1 - Definition of Terms

Some of the following definitions of terms are taken from "API Standard 617-Centrifugal Compressors for General Refinery Service''.1 (See drawings 16 DC-6001 and 16 DC-6007) Legend: Ti P Sg k = = = =

R
psia specific gravity specific heat ration

V W G v

= = = =

volume of gas weight of gas gas constant specific volume

Compressibility - Relationship of specific volume to pressure and temperature for a perfect gas is defined by the equation Pv = RT. However, many gases do not obey this perfect-gas law exactly. The deviation from the perfect-gas law is referred to as compressibility and is stated as a ratio of actual gas volume at a given pressure and temperature to the volume calculated by the theoretical law, in which case Pv = ZRT, where Z is the compressibility factor. Compressor Rated Point - Point on the 100-percent-speed curve at the highest capacity of any specified operating point. Gas Constant - as constant, R, is equal to the universal gas constant divided by the gas molecular weight, or 1544/M. Head - Work in a compressor is commonly called head, and the equation is usually stated in terms of specific gravity, as follows:

Head =

53.34Ti k k -1 Sg

)[(

Pf Pi

)(k - 1 / k)-1 ]

(EQ 1)

Isentropic Process - If heat is neither added to nor removed from the gas during the compression, the process is reversible; the process is then called adiabatic. (In the compressor industry, the terms isentropic and adiabatic are generally used interchangeably.) The relationship between pressure and volume follows the law PVk = a constant. The total work done on a unit mass of gas is

________
1.

The subscripts i and f indicate respectively the initial and the final condition of the gas.

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16 EG-600 Compressor Surge Control Systems

ULSD Project

Approved Feb 94

Work = Cp (Tf - Ti) = ViPi

or

( )[ (
Pf Pi

k k -1

Pf Pi

)(k - 1 / k)-1 ]

(EQ2)

Work = RTi

( )[(
Pf Pi

k k -1

)(k - 1 / k)-1 ]

(EQ3)

Isothermal Process - By abstracting heat from the gas during compression, the temperature may be held constant; this process is called isothermal. The relationship between pressure and volume is PV = a constant. The work done, or head, is

Head = P1V1 loge

) = RTi ( loge

Pf Pi

Ti ( loge ) 53.34 Sg

Pf Pi

`(EQ4)

Maximum Continuous Speed - In revolutions per minute (RPMs), for compressors driven by variable-speed prime movers, is the speed at least equal to 105 percent of the highest speed required by any of the specified operating conditions. Maximum continuous speed for constantspeed drivers shall be equal to 100-percent speed. Minimum Allowable Speed - Lowest speed in RPMs at which the manufacturer's design will permit continuous operation. Normal Operating Point - Point at which usual operation is expected and optimum efficiency is desired. This point is usually the point at which the vendor certifies that performance is within the tolerances stated in the API Standard 617. Normal Speed - Speed corresponding to the requirements of the normal operating point. One-Hundred-Percent Speed - Highest speed required for any specified operating point above the normal speed curve. If there are no specified operating points that require greater than normal speed, the 100-percent speed shall be the normal speed. For motor driven compressors, the 100percent speed shall be equal to the gear ratio (if any) times the full-load speed of the motor being furnished. Polytropic Process - Actual compression path seldom follows either the isentropic or the isothermal process but is generally of the foam PVn = a constant. In such cases the work, or head, is given by

Head =

n 53.34 Ti ( n - 1 Sg

)[ (

Pf Pi

)(n-1/ n) - 1 ]

(EQ5)

where n is the exponent of polytropic compression. This factor may be found from the equation

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16 EG-600 Compressor Surge Control Systems

ULSD Project

Approved Feb 94

k - 1 n k n - 1

(EQ6)
p

where p is the polytropic efficiency. Also, the relation between final pressure and temperature can be stated as

Tf = Ti

( (P ) P
f i

n-1/n)

(EQ7)

Specific-Heat - Amount of heat required to raise the temperature of one unit mass of gas one degree. If the volume of the gas is kept constant while the heat is added, all the heat is used in increasing the internal energy, i.e., in raising the temperature. This specific heat at constant volume is denoted Cv - If the pressure is kept constant and the volume is allowed to vary while the heat is added, more heat will be required. In addition to raising the temperature, the gas expands, and external work equal to Pdv is done. This specific heat at constant pressure is called Cp. Specific Heat Ratio - Ratio of the specific heat at constant pressure to the specific heat at constant volume is known as k; hence k = Cp/Cv. Stability - Difference in capacity (in percentage of rated capacity) between the rated capacity and the surge point at rated speed (and rated gas properties). Trip Speed - Speed in RPMs at which the independent emergency overspeed device operates to shut down the prime mover. Turndown - Percentage of change in capacity (referred to rated capacity) between the rated capacity and the surge-point capacity at the rated head when the unit is operating at rated suction temperature and gas composition.

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