APPLICATION DATA
AD353-120
Procidia Control Solutions
Compressor Capacity Control
This application data sheet describes implementing
compressor capacity control in a Siemens 353
controller 1 .
All compressors are equipped with a mechanism for
manipulating flow capacity. For turbine-driven
compressors, this is usually accomplished by varying
the speed. For motor-driven compressors, the speed
is generally constant, and the capacity is manipulated
by an inlet throttle valve or by inlet guide vanes.
Figure 1 shows the effect of an inlet throttle valve on
the capacity of a constant speed compressor;
decreasing the inlet pressure causes a significant
decrease in the flow capacity of the compressor.
Figure 1 Characteristic Curves for Constant
Speed Compressor
The primary objective of capacity control is to
manipulate the flow capacity of the compressor to
match the flow required by the process. This is
usually accomplished by controlling the discharge
pressure of the compressor at a constant value.
Since a change in pressure is caused by an
imbalance between the supply and demand for flow,
manipulating the capacity of the compressor to
1
See Application Support at the back of this Publication for
a list of controllers.
Rev 2
April 2012
control the pressure will maintain the desired
balance. In some cases, inlet pressure is controlled
instead of discharge pressure, and occasionally the
primary objective is simply to maintain a constant
capacity, which is accomplished with a flow
controller.
Without additional constraints, however, the demands
of the process can cause the capacity controls to
drive the compressor beyond safe operating limits.
On low flow demand, centrifugal and axial
compressors can be damaged by surge. On high
flow demand, motor-driven compressors can be
damaged by excessive motor current.
To prevent surge, a separate control loop is required
(such as the one described in AD353-121). On low
flow demand, the surge controller opens a recycle
valve to keep the flow through the compressor above
the surge limit. Unfortunately, when the surge
controller becomes active, it often interacts with the
capacity controller to cause unstable operation. The
surge controller disturbs the discharge pressure
controller because the inlet valve affects both flow
and pressure. The two loops acting simultaneously
may produce a sustained oscillation that is
characteristic of closely coupled loops that have
similar dynamic characteristics.
Figure 2, on the next page, shows a capacity control
strategy for a motor-driven compressor with an inlet
throttle valve. A pressure controller manipulates the
inlet control valve to maintain a constant discharge
pressure. The adaptive gain function of the pressure
controller is used to minimize interaction with the
surge controller. A current override controller
reduces the risk of overloading the motor.
AD353-120
High Current
Override Controller
IC < PID
Surge Controller
Output
Lo Select
.
f(x)
Recycle
Valve
Fail Open
Control Valve
Fail Closed
IT
Motor
Compressor
Figure 2 Capacity Control Strategy
To reduce the interaction between the pressure and
surge controllers, the pressure controller is detuned
whenever the surge controller is active. This allows
the surge controller to come to balance before the
pressure controller produces any significant
response. The adaptive gain of the pressure
controller is switched from a normal to a “low” value
whenever the recycle valve is open. The “low” gain
reduces the response of the pressure controller
whenever the surge controller is active.
If the load on the compressor tends to exceed the
safe operating limit, the current controller overrides
the pressure controller to reduce the load. The
current controller closes the inlet valve as much as
required to hold the motor current at the high limit.
Although this prevents the pressure controller from
maintaining the discharge pressure, it is usually
preferable to keep operating at a lower pressure
rather than risk a high current “trip” that shuts down
the compressor completely.
Design
The capacity control configuration is shown in
Figures 3 and 4. The discharge pressure controller
(PIDAG) in Figure 3 manipulates the inlet valve to
control the pressure at the setpoint from the SETPT
function block. The controller is the adaptive gain
version of the PID algorithm. The error signal in the
PID block is multiplied by the adaptive gain (AG)
input.
A Comparator function block CMP1, set for reverse
action, will provide a logic “1” signal when the recycle
valve begins to open. Since the recycle valve will be
“air-to-close” (fail open), the surge controller output
Discharge Pressure will be decreasing from 100% as the valve
Controller
begins to open. The trip point of the
CO
comparator should be set as close as
AG
PV possible to 100%, but low enough that the
output of the comparator is “0” when the
recycle valve is closed. The actual setting
will depend on the calibration of the recycle
PT
valve positioner and the adjustable dead-
band of the comparator function block.
Transfer Switch function block TSW1
switches the adaptive gain input between
high (normal) and low values. The output of
the comparator controls the position of the
transfer switch. It also is connected to the
initialization input (I) of the controller.
Whenever the comparator changes state, the
controller is initialized. This will prevent the
controller from bumping its output when the
controller gain is changed. When the comparator
output goes high (1), the transfer switch will change
the adaptive gain signal from 1.0 to 0.25. This
provides a 4 to 1 reduction in controller gain. The
setting of the Hold block HLD2 can be adjusted
higher or lower depending on the severity of the
control interaction problem.
The current controller in Figure 4 overrides the
pressure controller to control the motor current at the
high current limit. Override Selector ORSL1 (Figure
3) selects the lower of the two controller output
signals to manipulate the inlet valve. The actual
valve loading signal provides external reset feedback
to both controllers. The reset component of the
inactive controller tracks the output signal of the
active controller to prevent reset windup, aligning the
output of both controllers when the inactive variable
crosses setpoint. This allows the inactive controller
to take control of the valve as soon as its variable
exceeds setpoint.
The Auto/Manual function block is located upstream
of the override selector to provide overload protection
in both manual and automatic modes of operation. If
unconstrained manual operation is desired, the order
of the ORSL1 and A/M function blocks can be
reversed. The A/M function block for the current
override controller has been set to auto only. The
compressor status signal (RUN/SHUTDOWN) is
used to force the inlet valve closed whenever the
compressor is shut down. This unloads the
compressor on a “trip” and holds the valve in the
unloaded position for startup.
2
 AD353-120

Figure 3 Capacity Control Discharge Pressure Configuration (CF353-120)

Figure 4 Capacity Control Motor Current Override (CF353-120)

3
AD353-120

Applications right-hand column). See AD353-138 for a list of

The interaction prevention technique shown in this
publication is applicable to all axial and centrifugal
compressor designs. The motor current override is
not applicable to turbine-driven compressors.
However, override control should still be considered if
it is necessary to enforce a constraint based on a
measured or calculated load variable for safe
operation of the turbine.
Application Support
User manuals for controllers and transmitters,
addresses of Siemens sales representatives, and
more application data sheets can be found at
www.usa.siemens.com/ia. To reach the process
controller page, click Process Instrumentation and
then Process Controllers and Recorders. To select
the type of assistance desired, click Support (in the
Application Data sheets.
The configuration(s) shown in this publication were
created in Siemens i|config™ Graphical Configuration
Utility. Those with CF353 in parenthesis in the Figure
title are available using the above navigation, then
click Software Downloads > 353 Compressor
Capacity Control (Reference AD353-120).
The configuration(s) can be created and run in a:
• Model 353 Process Automation Controller
• Model 353R Rack Mount Process Automation
Controller*
• i|pac™ Internet Control System*
• Model 352Plus™ Single-Loop Digital Controller*
* Discontinued model

Procidia, i|pac, i|config, and 352Plus are trademarks of Siemens Industry, Inc. Other trademarks are the property of their respective owners.
All product designations may be trademarks or product names of Siemens Industry, Inc. or other supplier companies whose use by third
parties for their own purposes could violate the rights of the owners.

Siemens Industry, Inc. assumes no liability for errors or omissions in this document or for the application and use of information in this
document. The information herein is subject to change without notice.

Siemens Industry, Inc. is not responsible for changes to product functionality after the publication of this document. Customers are urged to
consult with a Siemens Industry, Inc. sales representative to confirm the applicability of the information in this document to the product they
purchased.

Control circuits are provided only to assist customers in developing individual applications. Before implementing any control circuit, it should
be thoroughly tested under all process conditions.

Copyright © 2012, Siemens Industry, Inc.