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Many compressor operators often find difficulty in comprehending compressor behavior with respect to system
changes, particularly when coupled with other operational changes. An example is how to predict possible flow
increase when there is still some room for a speed increase. Where will the new operating point be if a change
is made will it shift along the constant pressure line to the right, along the system curve or along the
compressor curve itself? How are power consumption and efficiency predicted in such cases? For the benefit of
operators, compressor behavior with respect to the connected systems and related problems are presented for
common operating scenarios.
Fig. 1 shows a typical arrangement of a compressor operating in a process system. The compressor is taking
suction from a source, point A at pressure P1, and discharging at pressure P2 at point B into a process system
consisting of pipelines, valves and equipment. The gas is transported through this system to be delivered to
point C at pressure P3. The line pressure drop, (P2 P3), is usually denoted as P (delta P) of the system.
As shown in Fig. 2b, centrifugal compressors have continuously falling pressure-flow characteristics. A family of
parallel curves represents compressor operation at different speeds. For a compressor operating at a constant
speed, the pressure increases as the flow decreases and vice versa. If reduction in flow continues, at one point
compressor operation becomes unstable and a momentary flow reversal takes place. This leads to a very rapid
pulsating flow backward and forward through the compressor internals, resulting in severe vibration and
consequent damage. This phenomenon is known as surge and the flow at which surge occurs is the surge
point for that particular speed. The surge point shifts to the right as speed increases (Fig. 2b). The line joining
the surge points of curves at different speeds is the compressor surge line. To avoid surge, compressors are
always operated at flows greater than surge point, i.e., at a reasonable distance to the right of the surge line.
As flow increases, a point is reached at the right-hand extreme of the compressor curve after which the flow
can not increase no matter what changes are made on the outlet side. This point is known as stonewall for the
compressor for that particular speed. Like the surge point, the stonewall point also shifts to the right as speed
increases (Fig. 2b). However, unlike surge, no adverse effect occurs to the compressor at the stonewall point.
Therefore, the operating regime of a compressor is confined between these two limits, i.e., surge and stonewall.
The set of curves including the limit lines is also known as the compressor operating map.
Relationship between compressor and system curves. When a compressor is connected to a system, the
operating point can be obtained by superimposing the system curve (Fig. 2a) on the compressor curve (Fig.
2b), resulting in Fig. 2c. The point at which the compressor curve for a particular speed meets the system curve
represents the compressor operating point for that speed. That means the compressor would deliver flow and
pressure corresponding to the intersection point in Fig. 2c. Under no circumstances can the compressor deliver
any other flow or pressure (at that speed), unless a change is made in the system. Only when some change is
made in the connected system (say, change in valve opening, pipe size, length, etc.), does the operating point
shift along the compressor curve. Otherwise, the compressor will continue to operate at that fixed flow and
pressure.
Compressor behavior in common applications. The figures shown later are only schematics of the most
common compressor configurations. They are neither complete in all details, nor do they represent all possible
configurations. Several variations and different control system arrangements are also possible, although not
shown here.
1. Single-speed compressor drive with suction / discharge pressure control. Fig. 3 shows the typical
arrangement of a single-speed (motor-driven) compressor. In this configuration, a compressor operates
similarly to a motor-driven pump. The compressor takes suction from the suction drum and discharge into the
piping system.
Fig. 4a. As the control valve closes, the system curve shifts
to the left.
Consequently, the operating point (a) also shifts to the left along the compressor curve to the point of
intersection (b) with the modified system curve, where the compressor flow equals the reduced incoming flow.
So, in this type of arrangement, compressor capacity control is achieved by shifting the system curve along the
compressor curve backward and forward, as shown by arrows in Fig. 4a.
Scenario 1.2: Incoming flow drops below surge control point. As incoming flow drops, the compressor will try to
find the operating point in the way described in scenario 1.1. If, however, flow drops below the surge control
point, the compressor surge control system sends a signal to the recycle valve (also called antisurge valve
(ASV), a quick-acting control valve) to open. Part of the outlet flow is then returned back to the suction side via
the ASV. Thus, the inlet flow (incoming + recycle) is never allowed to fall below the surge control point to avoid
surge (Fig. 4b).
Fig. 4b. Inlet flow is never allowed to fall below the surge
control point.
In this case both the ASV and pressure control valves mounted on the compressor discharge line take action
simultaneously, i.e., the former opens and the latter closes.
Scenario 1.3: Gas demand decreases at the consumer end. In most of these cases, the online valve at the
consumer end is throttled, either manually or through the process control system, to achieve the desired flow
reduction. For example, in case of gas supply to a boiler, heater or gas turbine, the control valve at the inlet of
the equipment is throttled matching the equipment load. The valve may even close if the equipment trips. This
event in effect changes the system curve, shifting the operating point to the left until the desired lower flow is
achieved (similar to scenarios 1.1 and 1.2). The control valve on the compressor outlet line will, however, open
instead of closing, in contrast with scenarios 1.1 and 1.2. The reverse phenomenon follows when gas demand
increases. The same control sequence would also follow when gas is to be delivered to a consumer at a
constant pressure.
In summary, for all single-speed compressors, variation in flow is achieved only by varying the system curve
position backward and forward. The operating point shifts along the compressor curve, as shown in Figs. 4a to
c.
Fig. 6b. The operating point starts to shift down along the
system curve.
system curve.
It should be noted that under certain circumstances like this, the ASV might open even when the discharge flow
is higher than the surge flow at the minimum speed. However, this sequence of control takes place only if the
speed controller and the driver are fast enough to respond and rectify the changing condition. If the flow change
is very rapid, the fast-acting antisurge control system acts through the ASV ahead of the speed controller to
save the compressor from surging.
Scenario 2.3: Gas demand decreases at the consumer end. As in the case of a single-speed compressor, the
system curve also moves to the left due to throttling of the consumer valve(s) to achieve flow reduction. The
suction pressure controller now starts sending a signal for the driver to slow down. The operating point moves
horizontally from point a to be along the fixed-pressure line until it meets the compressor curve at a speed that
corresponds to the reduced flowrate (Fig. 6c). If the flow increases the reverse phenomenon takes place.
protection systems fail to detect such instability. The compressor map provided in the control system no longer
holds good as the flow-pressure-speed relationship is altered by the change in MW.
This, however, should not give an impression that compressors can operate only at a fixed (rated) MW.
Compressor design normally allows operation over a certain MW range without running into surge in any stage
(usually, there is enough distance between the surge and normal operating points). In case of a substantial
change in MW, compressor performance and stability should be reassessed, preferably with the assistance of
the compressor vendor.
4. Compressor flow increases beyond rating. If the driver (motor, steam or gas turbine) is sufficiently large
and sufficient inlet gas is available, it may often be possible to derive somewhat higher throughput from a
compressor without being unduly overloaded. The throughput is increased automatically by the control system
for reasons described earlier. MW change is one main reason; the other being actual system pressure drop
lower than estimated in design. Lower destination pressure or higher suction pressure may also cause a flow
increase, often to the operators benefit. In all these cases, the system curve shifts to the right to meet the
compressor curve at a higher flowrate. This is true for both single- and variable-speed compressors.
If all other compressor and driver operating parameters are within acceptable limits (below alarm and trip
points) and MW variation is within the specified design range, such operation at increased flowrate is not
expected to cause any instability or mechanical problem in the compressor. The operating point in this case is
well within the compressor design operating regime.
Barring the question of efficiency, a centrifugal compressor like a centrifugal pump can be operated
anywhere on its curve between surge point (or surge control line, SCL) and stonewall by shifting the system
curve, provided the driver is adequately sized. However, if the increase is due to a change in MW where the
compressor curve itself shifts, this should be limited to the specified MW variation range. In fact, during a
factory acceptance test (FAT), compressors are actually operated at varying flowrates within the compressor
map range to verify the developed pressure and other parameters.
Besides the above many other scenarios are possible. It is not possible to identify and discuss them all
separately. However, some of the common scenarios and problems presented will help to understand and
interpret the behavior of many others not described here.
BIBLIOGRAPHY
Compressor Handbook for the Hydrocarbon Processing Industries, Gulf Publishing Co., Book Division.
Lapina, Ronald P., Estimating Centrifugal Compressor Performance, Volume-1.
Pichot, Pierre, Compressor Application Engineering, Volume-1.