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Ji# Old#ich 177

VARIABLE COMPOSITION GAS CENTRIFUGAL COMPRESSOR
ANTISURGE PROTECTION

Ing. Ji# Old#ich, CSc.
KD NOV ENERGO, a.s.,
Kle#kova 1947, 190 02 Praha 9, Czech Republic
jiri.oldrich@ckdenergo.cz





1. SUMMARY

The contribution deals with experience with thermodynamic design of a centrifugal compressor for
compression of variable composition gas and with development of antisurge protection algorithm
for this compressor.
Surge is an unstable operation state of centrifugal compressors witch begins when the operating
point of the compressor crosses the surge line. Surge line is the stability limit of the compressor
performance map.
Because surge limits for gases of variable composition are not the same, traditional methods cannot
be used. The new method was developed with goal to fit antisurge protection to different gas
mixtures. Second goal is to display performance curves of compressor and operating point for
actual gas mixture and for actual operating parameters. This method is based on mathematical
model of above-mentioned centrifugal compressor.



2. PREFACE

Thermodynamic design of the compressor that has to compress gas with a variable composition is
more complicated than design of the compressor that compresses constant composition gas. As the
principle of centrifugal compressor consists in exploitation of centrifugal forces, a molecular weight
of compressed gas is one of main parameters that must be taken into consideration.
Very important characteristic of centrifugal compressor is performance curve, pressure versus
capacity. From this curve, designer or user of the compressor can determine for example operating
range at constant pressure or a point of intervention of antisurge control.
Our task was to design centrifugal compressor for compression of light gases mixture. Main
compound of that mixture was hydrocarbon. Its molar fraction was in range from 77 to 83 percent.
Compressor was driven by electric motor with constant speed. Our customer required regulation of
capacity at constant pressure at range from 60 to 110 percent. Compressor reached discharge
pressure approximately 26 bars and the capacity in design point was approximately 30000 Nm
3
/hr it
means that on discharge of the last compressor stage was approximately 1150 m
3
/hr. Second
requirement was that the compressor must be able to compress another gas, nitrogen, without
change of its rotating speed as well. Required pressure and capacity was also given.
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Four stages centrifugal compressor with impellers with diameter 440 mm and with relatively high
rotating speed 21000 rpm was designed for this parameters. The compressor was manufactured and
delivered to our costumer. Now this compressor works without any difficulties.
Mathematical model of the centrifugal compressor, which enables to approximate behavior of the
compressor with chosen accuracy, was developed on requirement to find surge line in case when the
gas changes its molecular weight during the compression.
When we apply standard method for determination of surge line, we cannot use the whole operating
range with the all compressed gas mixture. To guarantee safety operation the antisurge control must
be set on the worst case. It is operation with the heaviest gas that means operation with gas that
contains the smallest quantity of hydrogen. The operating range is smaller as we can see on figure1.
Difference between the lightest and the heaviest gas surge line is approximately 10 percent. In case
of light gas the distance of antisurge control intervention line from the surge line must be 20 %. The
operating range is very contracted in this case.
The method used is based on isentropic model compression, with generalization of all known
performance maps calculated for gas mixtures with various content of hydrocarbon. The result of
above mentioned generalization is one dimensionless performance curve that is valid for the whole
considered working range and for all chosen gas mixtures.
Using this dimensionless curve together with several correction equations and considering behavior
of the real gas, it is not difficult to reconstruct dimension performance curve for every gas mixture
that contains hydrocarbon in considered boundaries. So, it is very easy to generate virtually
indefinite number of the performance curves. This property can be used to visualization of
operating state of the compressor. The screen of control system shows an operating point, updated
performance curve and surge line. Operator can observe how far is operating point from surge line
and where the operating point lies. He also can see the allowed operation field on the screen and
actual location of the operating point.
This model is suitable for study of behavior of the compressor in operating field for which the
compressor has not been designed. So, this model also allows predicting of behavior of the
compressor in non-design conditions.
This model was created and verified by software that was realized in language Visual Basic for
Applications in environment of MS EXCEL. Screenshots of this model are shown on figures 9 and
10.


3. TRANSFORMATION OF THE PERFORMANCE CURVE INTO DIMENSIONLESS
CURVES

Surge is an unstable operation regime of centrifugal compressors, which usually occurs when the
operating point of the compressor is on the left side of the surge line (Fig. 1). This line is the
stability limit on the compressor performance curve. The surge line, surge point and operating point
are shown on the Figure 1. Dashing line highlights unstable part of compressor performance curve.
When the working point crosses the surge line, the operation of the compressor becomes unstable.
Role of the antisurge control is to prevent surge and ensure stable operation of the compressor even
in case of smaller capacity. Surge control line is the second line on the Figure 2.

This line is on the right side of the surge line and it is set usually 10% from surge line. In case when
composition of compressed gas is variable, the surge line changes its location, depending on density
of compress gas. In such case, we must set surge control line according to the worst gas. It means
according the heavier gas (77%H
2
) in our case.
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Assume we know the characteristics of
the compressor working in specified
range of composition as a relation of
discharge pressure on volume flow
(capacity) suction conditions. These
characteristics are limited by point of
minimal flow; this point is on the surge
line, and by point with maximal flow
rate.
In case that the capacity is determined
as mass flow, we can use next equation
to calculate volume flow




1 1
v G Q where
1
1 1
1
p
RT z
v .

Now we can determine circumferential speed of the first stage impeller

60
2
2
n D
u

.

Using the known volume flow Q
1
, diameter of the first stage impeller D
2
and its circumferential
speed u
2
the flow coefficient can be determined for each point of the characteristic

2
2
2
, 1
4
u D
Q
i
i

.

p
2

Surge
line
A
F
C
E
P
Surge
point
Operating
point
Q
p
2

Q
Surge line
Surge control line
Operating
point
d
Fig. 1 Stable and instable part of characteristic
Fig. 2 Surge line and surge control line
1.6
1.8
2
2.2
2.4
2.6
2.8
3
3.2
14000 19000 24000 29000 34000
QN [Nm3/h] (0C, 101325 Pa)
p
2

[
M
P
a
]
77%H2 83%H2
Fig. 3 Surge lines of the centrifugal compressor for
2 different gas mixtures
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Isentropic specific work is calculated for each point of this characteristic too. This work is used for
increasing of gas pressure from pressure p
1
on pressure p
2

1
1
1
]
1

,
_

1
1
1
1
, 2
1 1 ,
k
k
i
i s
p
p
T R z
k
k
H
and isentropic pressure coefficient is
2
2
,
,
u
H
i s
i s

.
Now we have k points of n characteristics that are transformed into one characteristic in
dimensionless coordinates (Figure 4). Equation of this new characteristic is ) ( f
s
. It can be
substituted by polynomial of third order

D C B A
s
+ + +
2 3
.

















If the variable composition gas is compressed, we get for each gas slightly different curve after
transformation (Figure 5).

) , (
2 H s
x f .

These differences must be corrected. In the first step one of gas mixtures is selected as a reference
gas

( ) 0
2 3
,
+ + + D C B A F
ref ref ref ref s
.

Correction coefficients was established for correction of pressure and flow coefficients

i a s
ref s
i s
K
, ,
,
,

and
i a
i ref
i
K
,
,
,

.



p
2

G

s


=>

surge line
surge
point
Fig. 4 Transformation of several dimensions characteristics into one dimensionless curve
and transformation of surge line into surge point
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chi=f(fi)
0.3
0.5
0.7
0.9
1.1
1.3
1.5
1.7
1.9
0.01 0.015 0.02 0.025 0.03
fi
c
h
i
77%H2 83%H2



Instead of correction coefficient K

we can use shift of point of characteristic

i ref i a i , ,
.

















Value of both correction coefficients depends on composition of the gas mixture. Because the
hydrogen is main part of compressed gas mixture and because according information of our
customer only contents of hydrogen can be measured, the correction coefficients was established
like coefficients that depend only on content of the hydrogen. Inaccuracy of such solution is not too
big.


4. RECONSTRUCTION OF CHARACTERISTIC OF THE COMPRESSOR

Equations above derivated were used for setting of surge control line and for visualization of actual
performance curve for real working point on the screen in operating room.
To set intervention of antisurge control must be real operating point recalculated into dimensionless
coordinates. Then this point can be shown on the reference dimensional performance curve.

s

Reference gas
Heaviest gas

Surge point
Surge control
point
Operating
point
Reference
characteristic
Fig. 5 Differences between dimensionless
characteristics for two extreme contents of
hydrogen
Fig. 6 Dimensionless curve of reference gas
and the heaviest gas
Fig. 7 Significant points on reference dimensionless
characteristic
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Correlation between this point and surge point on dimensionless characteristic is important for
setting up when the antisurge control must intervene.
In second step the characteristic in coordinates, Q
st
- p
2
is calculated for actual operating state
(suction pressure, suction temperature, discharge pressure, volume flow rate on suction and content
of hydrogen) by using the dimensionless characteristic. By this way all necessary information
concerned with real operating state of the compressor are prepared. Operator can watch all these
parameters on the screen (Fig. 8).
Computer model was prepared for demonstration of this method. This model allows to change all
input parametrs including composition of the gas. Appropriate performance characteristic is painted
on the screen. When the input parametrs are changed, this characteristic is set up into new location
and its form is changed too. Simultaneously with this the surge line changes and antisurge control
line is set up into new position (Fig. 3, 9 and 10).

























5. CONCLUSION

The method described above depends very much on accordance of the design performance curves
with actual characteristic of the centrifugal compressor. Accuracy of this method also depends on
accuracy of determination of thermodynamic properties of real gases. Same inaccuracy can appear
due to errors in determination of gas composition. This gas mixture is defined by content of
hydrogen only. Because the hydrogen forms main and decisive part of mixture, these errors are
small.
This method was designed to better utilize operating range when the compressed gas changed its
molecular weight. But this method is so simple and so general that can be used in another cases. It
can be for example for refrigeration compressor, which compresses gas with constant composition
but whose thermodynamic properties must be calculated by using real gas equation of state. This
method can be useful also for compressors with variable rotating speed.
Fig. 8 Reconstructed characteristic, characteristics for operating range 60% to 100%, surge line and
antisurge control line prepared for view on operator display.
p
2

60 %
100 %
110 %
Surge line
Antisurge control line
Operating point
Q
st

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Fig. 9 Screenshot Model of control of the centrifugal compressor 4RSA32. Displaying of gas with 77% H
2
.
Green line (located more left) is surge line, red line (parallel, right) is the surge control line, its distance from the
surge line can be optional changed by user. Location of operating point can be changed too. It enables to simulate
capacity control or pressure control.
Fig. 10 Screenshot Model of control of the centrifugal compressor 4RSA32. Displaying of gas with 83% H
2
.
Operating point is on surge control line. In the top right window dimensionless curve with operating point, surge
point and surge control point is displayed.
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6. REFERENCES



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