Compressor Anti-Surge

Valve

V.E.S TOYO India

Agenda

Surge Mechanism

Surge Impacts

Surge Control

Anti-Surge Valve Issues

Fisher CCC Agreement

Invitation for Jemima Show

Surge Mechanism



Surge is an inherent phenomenon in compressors

Surge limit is determined from compressor performance
curve - a plot between discharge pressure and flow
through the compressor at a given speed for a particular
gas at an inlet temperature
There is a curve plotted for each speed and their
compilation is called wheel map

Surge Mechanism


Impeller has to be coupled to the

load
This depends upon a flow
through the impeller
While flow is sufficient
impeller keeps grip on the
gas
There is a transfer of energy
from impeller to gas
This needs a minimum flow
rate

Surge Mechanism


Surge is characterized by fast flow reversals through a

compressor, and is caused by a large scale breakdown of
flow patterns within the compressor.
It occurs when flow decreases below a certain minimum
point.
The flow pattern in the compressor becomes unstable
and fluid move back through the compressor from high
pressure side to the low pressure side.
Flow reversals are only temporary and forward flow
quickly re-established.

Surge Mechanism
Compressor Discharge Press

Compressor Wheel Map

Design point
XXX RPM
XXX RPM
XXX RPM
XXX RPM

Compressor Inlet Flow

Forward

XXX RPM

Surge Mechanism
Compressor discharge press

Backward

Forward
Compressor Inlet Flow

Impeller is at constant speed

Head (discharge press) varies with Downstream load (flow)

Normal
operating point

Surge Mechanism
Compressor discharge press

Backward

Operating point

Forward
Compressor Inlet Flow

Sudden decrease in gas demand

Increases head (discharge press)
Flow decreases

Surge Mechanism
Compressor discharge press

Backward

Max pressure head

or Surge point

Forward
Compressor Inlet Flow

As flow continues to decrease

Head increases until it reaches max for that speed

Surge Mechanism
Compressor discharge press

Backward

Operating point

Forward
Compressor Inlet Flow

Flow is a minimum where the impeller can maintain its grip on the gas.

Impeller becomes decoupled from load

Gas in the impeller is no longer pushed forward and spins with the impeller

Gas stops moving and operating point moves to zero flow

Surge Mechanism
Compressor discharge press

Backward

Operating point

Forward
Compressor Inlet Flow





Downstream compressed gas leaks back around the impeller

Downstream head reverses gas flow
Flow moves into negative flow regime

Surge Mechanism
Compressor discharge press

Backward

Operating point

Forward
Compressor Inlet Flow




This flow reversal pushes impeller to opposite side of the housing

The head bleeds to the minimum maintained by the impeller by
centrifugal force

Surge Mechanism
Compressor discharge press

Backward






Operating point

Compressor Inlet Flow Forward

The impeller picks up the load, pushing the gas forward to new
operating point
If line flow remains low for the speed, the cycle repeats
Cycle time approx 1 sec
Causes catastrophic damage to compressor

Surge Mechanism
Compressor discharge press Compressor Surge Line

XXX RPM
XXX RPM
XXX RPM
XXX RPM

Backward


Compressor Inlet Flow

Forward

Surge Point is a point on each curve where discharge

pressure is maximum as flow is reduced progressively
A line joining surge points from each curve is called Surge
Line

XXX RPM

Surge Impacts


Can lead to damage of seals, bearings, impellers, shaft, casing,

pedestal, etc.
Cost of replacing Seals in a 3,000 hp compressor can easily
exceed US$ 20,000
Bearings US$ 10,000
New rotor assembly US$250,000

Reduce compressor life span

Typical life span is 30 years or more if operated and
maintained properly

To prevent surge from happening it is required to ensure that the

flow through the compressor never falls below the surge line

Surge Control


Not easy and not efficient to adjust compressor speed

to control surges
Surge control system opens recycle valve
Opening recycle valve too soon will result in
wastage of fuel / energy and capacity
Therefore valve should be opened only when the
operating point is very close to surge and closed
immediately after it exceeds the surge limit

Surge Control


Surge prevention is achieved by a dedicated control

system, separate from compressors other controls
because of high speed of response requirements
A surge relief valve, also referred as anti-surge valve, is
the final control element in the surge control
The valve function is to open very quickly when
demanded and re-circulate the gas from discharge to
suction and ensure that minimum flow goes through the
compressor when it is running

Antisurge Valve Issues



Protect the Compressor

Reliability (3 years between maintenance cycles)
Fast Stroke Ability (< 2 seconds closed to open)
Accurate Step Response (Fast acting, no hunting,
minimal hysterisis)
Ease of Tuning (Ability to easily tune in the field)
Eliminate Noise & Vibration

Antisurge Valve Performance - Fisher

& CCC agreement

CCC Guidelines for Antisurge Valves

Valve Actuation
- Stroking time with Solenoid Trip = Less than 1 second
- Stroking time with Positioner Control = Less than 2 seconds
- Positioner should be used
- Stroking time should be roughly equal in the opening and
closing directions
- Quick exhaust valves should be avoided. Volume boosters
should be used instead.
Valve Sizing
- Linear valve trim should be used
- 1.8 ~ 2.2 x (Cv @ max perf. curve and surge limit line)