ANTI-SUGRE CONTROL

COKER GAS COMPRESSOR)

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Surge definition
Self oscillations of pressure and flow, often
including a flow reversal in the centrifugal
and axial compressors is known as surging

Surge description
Flow reversal in 20 to 50 milli seconds
Surge cycles at a rate of 0.3s to 3 s per cycle
Compressor vibrates
Temperature rises
whooshing noise or Clanking noise
Trip may occur
Conventional instruments /human operators
may fail to recognise surge

CONDITIONS THAT CAN LEAD TO

SURGE
Rise in discharge pressure when suction pressure
and RPM held constant
Fall in suction pressure when discharge pressure
and RPM held constant
Fall in RPM, when suction and discharge pressure
held constant can quickly drop flow to surge limit
Other process changes like drop in molecular
weight or specific gravity of the gas
Start up, shutdown, reduced through put
Heavy throughput with trips, operator error,
load change, cooler problem, driver problem

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Surge leads to
Once surge is induced, the flow rate & pressure
will oscillate drastically until the cause is
removed or protective devices shut down the
machine or a failure occurs.
The excessive thrust bearing & impeller loads,
vibration & rising gas temperatures associated
with surge can produce process upsets &
severe compressor damage if more than a very
few surge cycles are experienced.
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Objective
of Surge Protection Systems
To prevent Compressor Damage due to surge or
Process Upset without sacrificing energy
efficiency or system capacity
To maintain selected process variables within
Safe or acceptable ranges

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VSDS

Compressor
TT

FT

PT

PT
TT

UIC

Discharge

Suction

Basic antisurge control system

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How to prevent

A Anti surge system achieve this

By manipulating the positions of Recycle
valve (Normally for Hazardous Gas)
By using a Blow off valve (Normally for Air
or Non hazardous applications)

Opening of recycle valve lowers the resistance

felt by the compressor
This takes the compressor away from surge

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The challenges
Location of operating point
Location of surge limit
High speed of approaching surge
Control loop interactions
Load sharing for multiple compressor
Co-coordinating control of compressor &

driver

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Hp
Surge Control Line
Surge Limit Line
Maximum Pressure
2

2
2

1
1

Surge Control
Zone

Q s
Antisurge Controller Actions

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Control Actions
For any given performance curve (Operating Curve)
the point of minimum flow & maximum pressure is
known as the surge limit point. The locus of all such
points defines a curve known as Surge Limit line.
The anti surge controllers task is to keep the
operating point to the right of the surge limit line.
This is accomplished by opening an anti surge
valve to recycle enough gas to maintain the
required minimum flow rate.

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Control Actions
However, because the dynamics of the system are
inherently slow, this control action must be started
before the operating point reaches the surge limit.
The point at which the controller starts to open the
valve is known as Surge Control Point. The locus of
all such points defines a surge control line. The
Distance between SCL& SLL is refereed as the
margin of safety. Region left to the SCL is known as
Surge Control Zone.
Anti surge Controller starts opening the recycle
valve, When ever the operating point is in the Surge
Control Zone
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Pressure:
Hp
Rc
Pd
Pc

SOL

SLL

RTL

New SCL
After SO

SCL

Operating Point

Rt

b1

b2

Flow: Q, Q2, kW, Po

COMPRESSOR SURGE CONTROL MAP

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Control Lines

SCL: Surge Control Line.. The line on the compressor map

where the open loop RT response is triggered.
RTL: Recycle Trip Line.. The line on the compressor map where
the open loop RT response is triggered.
SLL: Surge Limit Line.. The line on the compressor map which
represents where the surge happens. If the OP is left of the SLL,
surge occurs.
SOL: Safety On Line.. The line on the compressor map where the
controller recognises surge and the Safety On response is
triggered
Anti surge Controller calculates proximity to surge on the
distance between the operating point of the compressor & the
Surge Limit line (SLL). The Controller also calculates other
control lines on the compressor map which are used to
determine its control responses & actions. These lines are
determined relative to either the SLL or the Surge Control Line.
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Control Actions

Various Control actions are triggered when the operating

point of the compressor crosses the control lines :
The anti surge PI response increases the recycle rate when
the operating point is to the left of the SCL & reduces it
when the point is to the right of the SCL.
The recycle trip response steps the anti surge valve open
when the operating point is to the left of the Recycle Trip
Line (RTL).
The Safety on response moves SCL & RTL control lines to
the right if the operating point moves to the left of the safety
on line(SOL).
The tight shutoff response fully closes the anti surge valve
when the operating point is to the right of the Tight Shutoff
Line(TSL) & the control signal is at its minimum clamp.
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Why not on DCS

Surge Cycles occurs within 1 sec, This is very rapid. So

conventional Control System can not cope with it.
Disadvantages with DCS
Normally DCS scan cycle is 200 m sec which is not efficient to
take rapid control actions & to detect surge sometimes.
No special algorithm to calculate surge control line , surge limit
line & to consider changes in suction & discharge pressure,
temp. or changes in the gas composition.
No Special response available other than PID to take fast
action.

16/44

CCC Anti Surge Controllers

CCC is a high speed control system with precise control
algorithms provides safe & efficient surge protection with
stable & precise process control which has following
advantages over DCS system.

CCC scan cycle is 40 m sec which is fast enough to take

control action & surge detection.
Precise algorithms to locate the surge limit regardless of
compressor operating condition.
Special responses like Recycle trip, Safety on, Derivative
other than conventional PID.
Loop De coupling between anti-surge & process control
system to avoid control loop interactions.
Fall back strategies.
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CCC Anti Surge Controllers

CCC gives Anti Surge Controllers in Two Basic Models

Series 3 (Single loop Applications)
Series 4 (Advance Application Module, Several primary
loops)
Series 3 Anti surge Controller can be used to protect a
single-section centrifugal or Axial Compressor from Surge
or it can be combined with other Series 3 Controller to
protect multi section compressors or compressor
network.Series 3 is like a Single loop controller.
Series 4 Controllers are for more Complex Controls &
protection of machines (Like Reactor /Regenerator of a
FCC Unit) .Series 4 is more like a PLC with Main
Processor modules, Input /Output Modules with Simplex,
Duplex or triplex redundancy level.

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Series 3 Controllers

Redundant Control : Main Controller & its backup should

be installed & configured exactly alike & must be connected via
their serial port no.1
Redundant controller track the status of the Active controller
& automatically transfer control to the backup by the fault relay
of the main controller.
Manual Operation : The operator can directly control the
position of the anti surge valve by using front panel Auto/Man
key to control the position of anti surge valve. When controller is
in this mode, New Output value is calculated by incrementing or
decrementing its previous value whenever front panel up or
down key is pressed.
Automatic mode can be restores by pressing the Auto/Man key
second time. A Bump less transfer algorithm is used to prevent
sudden changes to the output which might upset the
compression system.
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Series 3 Controllers

Manual Override Mode : During configuration , If this

mode is set OFF , Controller Automatically switch to Auto mode
from Manual Mode if operating point moves into the surge
control zone.
When MOR is set to ON, Switching the controller to its
manual operating mode completely overrides the automatic
control algorithms.The Compressor would then be completely
unprotected against the possibility of surges.(MOR should not
be set to ON Mode).
Transmitter Alarm : A transmitter alarm is indicated
whenever one or more of the analog input signals is outside the
range defined in the transmitter alarm limits during
configuration.
This mode can alert the operator when transmitter
failure occurs.(Transmitter, Signal Wire)
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Series 3 Controllers
Serial Communication Features : Series 3 Anti Surge Controllers
are equipped with either a three or four port Serial PCB assembly.
With these ports controllers can communicate with other series 3
controller like performance controller/Load Sharing Controller &
also with Host Computer/DCS/PLC.
Port 1 & 2 are reserved for communication with other series 3
controller
Port 3 & 4 are used for communication with other control
systems using the Modicon Modbus communication protocol.On
these ports controller can be monitored or even controlled.
Series 3 Anti surge controller can be operated by DCS in much
the same fashion as an operator would control it from the front
panel.
The controller can be Switched between its manual & Automatics
modes from DCS by forcing the Automatic Coils. When Operating
in Manual ,The controller output signal can be set either from
front panel or from DCS by changing register value.
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22/44

Series 3 Controllers
DIGITAL DISPLAY : Front panel has three digital displays
DEV(Deviation)
DEV : Display how far the compressor operation is deviating from
the minimum acceptable margin of safety. The controller acts to
maintain deviation at values equal or greater than Zero.
STATUS : run = Normal Operation, stp : Stop or Shutdown ,prg =
Purge
Purge mode will close the recycle valve, Allowing Purge gases to
pass through compressor.
OUT : Indicate the intended output of the controller to the anti
surge valve. Operator can observe valve position by pressing Alter
Display Key.
Indicator Lights: As Shown in the diagram except computer inhibit
lamp which if yellow ,host communication have been inhibited, If
lamp is off host communication are fully enabled.
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Series 3 Controllers
CONTROL KEYS : There are seven active control keys on the front
panel.

: Toggles the controller between the automatics &

manual modes
INHIBIT/COMPUTER :Inhibits or enable certain type of
communication(Can be Configured) with host computer or DCS.
</> (Up/Down) : Use to raise or lower the controller output signal
when the manual operating mode is selected. Momentarily
pressing ^ will increment output by .1 %.
RESET : Used to reset the Safety on response after a surge.It
should only be pressed if the condition which caused the surge
have been determined & corrected.
Display Surge Count : Upon pressing causes Status Display to
show the no.of surge cycle the controller has recorded after the
last reset.
Alternate Display: Temporally display certain results of the
controller internal calculation. These keys can be pressed at any
time without disturbing the process
AUTO/MANUAL

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Label

Color

Meaning

What Can I do

Auto

Green

When lit, the controller is in the

Automatic mode of Operation

You can switch to the manual mode of

operation using the Auto/Manual switch

Manual

Yellow

When lit, the controller is in the Manual

Mode of Operation.

You can switch to the Automatic mode of

operation using the Auto/Manual Switch.

Remote

Green

When lit, the Remote set point has been

selected.

You can select the local set point by

using the Remote/Local switch if it has
been enabled.

Local

Yellow

When lit, the local set point has been

selected.
When flashing, the load sharing
Fallback has been enabled and the local
set point has been selected

If the local indicator is lit, you can select

the remote set point by using the
Remote/Local switch if it has been
enabled.
If the local indicator is flashing, then the
Fallback and ComErr indicators will be
lit. Check the serial inputs.

Limit

Yellow

When lit, the controller is in a limiting

condition because the Loop 2 and/or
Loop 3 limiting variables are beyond
their defined limiting threshold.

You can determine the value of the

limiting variables by pressing the Display
Loop 2 switch or the Display Loop 3
switch. If possible the process should be
adjusted to prevent the limiting
condition.

Tracking

Green

When lit, the controller is in a redundant

operating mode and is tracking the
active controller. When flashing, the
output of the controller is being used as
a rotational speed set point and is
tracking the speed.

If the tracking indicator is lit, you can

switch to the active operating mode by
selecting this controller on the
Redundant Control Selector. If the
tracking indicator is flashing, then the
speed governor is either in manual or
using a local set point.

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Label

Color

Meaning

What Can I do

TranFail

Red

When lit, one or more analog inputs are

outside AN IN limits. It is not unusual to
see the Fallback indicator lit as well.

You can determine which analog input(s)

triggered the TranFail alarm by using the
MODE: D AN IN (minus) key sequence
on the Engineering Keypad. Use the
scroll button to setp it through the
successive channels.

Fallback

Yellow

when lit, the controller has enabled a

Fallback control strategy due to the
failure of analog and/or serial input(s).

You can check to see if the TranFail or

CommErr indicators are lit. Then follow
the procedure to determine the failed
input for that indicator.

ComErr

Red

When lit, it indicates a serial

communication error. It is not unsual to
also see the Fallback indicator lit as
well.

You can determine which serial input(s)

triggered the ComErr alarm by using the
MODE:D COMM -2 (Serial Port 2) or
MODE:D COMM 3 (Serial Port 1) key
sequence on the Engineering Keypad.

Fault

Red

When lit, an electronic failure has been

detected within the controller.
Disconnect it from process.

The controllers output signal is totally

unpredictable when the Fault indicator is
lit. Process disruptions or compressor
damage can result if it is not immediately
disconnected from your process. You
can replace this controller with your
spare controller.

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Series 3 Controllers
Configuration Procedure : Catalog is to be referred.
Modes & Fall Back Strategies : Series 3 Anti surge controller offers
a wide variety of modes which allow you to tailor its surge
control algorithms to specific applications & no. of input s,
location of inputs like flow measurement at suction or
discharge, temp. measurement, pressure measurement, diff.
pressure measurement.
In most applications , the more complicated algorithms will
provide energy savings as they tune controller more
aggressively.But because they require additional input signals,
so more complicated algorithms are also more likely to succumb
to transmitter failures.
In many such cases it is feasible to provide continued
surge protection by substituting an approximate constant value
for the missing input. A fallback strategy defined will trigger the
algorithms upon transmitter alarm condition.
27/44

Series 3 Controllers

Output Relay : Series 3 Controllers comes with 4 relay (CR 0 to

CR 3) which can be independently configured . These rely can
draw operator attention in the control room upon undesirable
conditions.
CR 0 relay is normally configured as a fault relay, Other relay
can be configures for reporting Communication errors in the
Port 1 to 4, Safety ON, Auto/Manual mode,Operating Point to
the left of the recycle trip,Analog Input Out of
range(Transmitter Failure).

Other Series 3 Controller types:

Performance Controller
Dual Loop Controllers
Turbine Speed Controller
Fuel Controller
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Salient features of Anti surge controller

Output loop back test comparing actual output of

anti surge control loops with desired output, thus
determining the failure status of the outputs.
Control loop decoupling among the performance
and anti surge loops via serial port 1
Serial communications for data and alarm
transfer to the DCS.
ESD request
Automated loading and unloading of the
compressor train.
Fallback control strategies
Limiting maximum discharge pressure /
minimum suction pressure
29/44

Salient features of Anti surge controller

Actuator output conditioning
Valve flow characterisation
Valve dead band compensation
Output clamping
Remote low output clamp
Tight shut off feature
Output reverse
Output tracking
30/44

Fallback stretegies
Over 75%

of the problems are in the field and

not in the controller
The CCC control system has fall-back
strategies to handle these field problems
The controller continuously monitors the
validity of its inputs
If an input problem is detected the controller
ignores this input and automatically switches
to a fall-back mode

31

Fallback stretegies

Constant output : If the discharge flow

measurement fails, the antisurge valve opening will
be frozen -implemented in Coker
Minimum flow control : when flow measurement is
reliable but others are not, surge is prevented by
maintaining minimum flow - implemented in Coker
Default compression ratio : The controller can
substitute a default compression ratio if the
discharge pressure input fail, 1st stage = 4,89; 2nd
stage =4.18 - implemented in Coker
Assumed sigma : if either of the temperature inputs
fail, surge is protected by substituting a constant
value for sigma - implemented in Coker
32/44

Other Fallback strategies

(not implemented in Coker)

Assumed speed
Assumed vane angle
Assumed adjacent stage flow rate
Temperature based polytropic head
A second anti surge controller as on line
back up

33/44

Details of Coker gas compressor

Service
Stages
Flow 1st stg
Flow 2nd stg
Driver
Driver power
Input
Output
Speed
Vendor

: Coker wet gas

: Two stage
: 112527 Nm3 /hr
: 90000 Nm3/hr
: Steam turbine
: 12.125 MW
: 0.45 kg/cm2
: 14 kg/cm2
: 4850 RPM
:Seimens / Mannesmann Demag AG
34/44

ANTI SURGE CONTROLER 3PA-UIC001

1st stage
INPUTS
372-FT-001
372PT-004
372-PT-001
372-TT-002
372-TT-005

(0-2150 mmWC) DISCHARGE FLOW

(0-7.5 kg/cm2) DISCHARGE PRESSURE
(0-4 kg/cm2) SUCTION PRESSURE
SUCTION TEMPERATURE
DISCHARGE TEMPERATURE

OUTPUTS
FY-002 - signal 4-20mA for RECYCLE VALVE (FV-002)
UA-011 controller fault / output failure alarm to
annunciation panel

35/44

ANTI SURGE CONTROLER 3PA-UIC002

2nd stage
INPUTS
372-FT-003 (0-2500 mmWC) DISCHARGE FLOW
372PT-006 (0-24 kg/cm2) DISCHARGE PRESSURE
372-PT-005 (0-7.5 kg/cm2) SUCTION PRESSURE
372-TT-007 (-100 Deg C) SUCTION TEMPERATURE
372-TT-008 (0-300 Deg C) DISCHARGE TEMPERATURE
OUTPUTS
FY-004 - signal 4-20 mA for RECYCLE VALVE (FV-002)
UA-012 controller fault / output failure alarm to
annunciation panel
36/44

Serial links/ interfaces

1st Stage
Pressure override control from performance controller
Communication with DCS (MG07)
Decoupling with performance and second stage anti surge controller
2nd Stage
Communication with DCS (MG07)
Decoupling with performance and 1st stage anti surge controller
Fractionator's top pressure control with 1st stage anti surge controller
Output of 371PIC001 from DCS is given as remote low clamp
(4 to 20 mA signal) to the 1st stage anti-surge controller

37/44

HOW CONTROLLER KNOWS THE

SURGE LINE ?

SURGE TEST

38/44

CONDITIONS FOR SURGE TEST

done under different molecular weights

of the fluid
under different rpms

39/44

REASON FOR THE CONDITIONS

The compressor compresses recycle gas from

the start of run to the end of run conditions
The recycle gas undergoes change in the
composition during the run
As the compressor has to be under the safety
limit under all the conditions ,the surge test is
done under different molecular weights and
different rpms

40/44

PARAMETERS MONITORED

Suction Flow
Suction Pressure
Suction Temperature
Discharge Pressure
Discharge Temperature

41/44

Pressure:
Hp
Rc
Pd
Pc

SOL

SLL

RTL

New SCL
After SO

SCL

Operating Point

Rt

b1

b2

Flow: Q, Q2, kW, Po

COMPRESSOR SURGE CONTROL MAP

42/44

1.

Surge
test
Steps

Reduce the flow somewhat through the compressor with anti surge valve

closed
2. Hold the compressor at minimum performance level minimum speed
3. Put the anti surge controller in manual and open the recycle valve 100%
4. If possible, isolate the compressor with a discharge block valve
5. Disable derivative response - opening of recycle valve will be constant on
Recycle Trip and no shifting of Surge Control Line
6. Disable fall back strategy
7. Put b1 =0 , now SCL will be on the top of SLL
8. Put b2 =40, to ensure large Margin of Safety on Safety On response
9. Put RT=5 & SO= 10 to put RTL & SOL just to the left of SCL /SLL
10. Put C1=30 & C2= 0.4 to open recycle valve 30% for 0.4 sec
11. Put TL =200 recycle valve closure time for 63% closing
12. Put PI tuning constants to average conservative values
13. Put K= .999 this moves SCL & SLL to right as far as possible
14. Put controller in auto. DEViation will be +ve, valve will close, DEV will be 0
15. Reduce K by 0.01, DEV again will be +ve, valve will close and DEV will be 0
16. Repeat step 15 till K value will correspond to actual SLL location, then drop in
DEV will result in RT (crossing of RT & SOL line), valve will open , RT line will
shift 40% -- this is the point surge has occurred
17. Put the controller in manual , open the valve 100%, note the value of 43/44
K

?
Thank you

44/44