Antisurge NpL3 ENG

g
GE
Oil & Gas
Nuovo Pignone
Anti-Surge
© Nuovo Pignone S.p.A., all rights reserved

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SUMMARY
1 INTRODUCTION ................................................................................................................. 3
2 CONTROL OVERVIEW ...................................................................................................... 6
2.1 ANTISURGE CONTROL LAW ..................................................................................... 10
2.2 FLOW ELEMENT IN SUCTION ................................................................................... 14
2.3 FLOW ELEMENT IN DISCHARGE .............................................................................. 15
2.4 FLOW ELEMENT INTERSTAGE ................................................................................. 17
2.5 ANTISURGE CONTROL LINES................................................................................... 19
2.6 AUXILIARIES CONTROLLERS OPERATION ............................................................. 21
3 INPUT AND OUTPUT ....................................................................................................... 24
3.1 CONTROL INPUT ........................................................................................................ 24
3.2 CONTROL OUTPUT .................................................................................................... 27
4 COMMUNICATIONS ......................................................................................................... 28
5 DIAGNOSTIC .................................................................................................................... 29
6 VIDEO PAGES.................................................................................................................. 31
6.1 LIST OF GRAPHIC INTERFACES............................................................................... 32
6.2 BASE FUNCTIONALITIES ........................................................................................... 34
6.2.1 HEADING............................................................................................................ 34
6.2.2 CONTROL BANNER........................................................................................... 34
6.2.3 SET-POINT CONTROL ...................................................................................... 35
6.2.4 ALARMS & TRIPS WINDOWS ........................................................................... 37
6.3 ESA SCREENS ............................................................................................................ 39
6.3.1 LOG AND MAIN MENU ...................................................................................... 39
6.3.2 LIST OF GRAPHIC INTERFACES ..................................................................... 40
6.3.3 ESA SCREEN HIERARCHY............................................................................... 41
6.4 HMI VIDEO PAGES ..................................................................................................... 45
7 PARAMETERS CONFIGURATION................................................................................... 50
7.1 INSTRUMENTS RANGES ........................................................................................... 50
7.2 ANTISURGE CONTROL .............................................................................................. 51
7.3 SURGE CONTROL LINE ............................................................................................. 55
7.4 SETTING EXAMPLE .................................................................................................... 56
SYMBOL LEGEND ..................................................................................................................... 57
© Nuovo Pignone S.p.A., all rights reserved 2

UNICOS Anti-surge Controller rev. 1.01 March 2005
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1 INTRODUCTION
Compressor surge is a low-flow phenomenon known to exist in dynamics, i.e.

centrifugal and axial compressors found in petrochemical plants, liquefied natural
gas (LNG) facilities and pipeline compressor stations. A simplified definition would
describe surge as a series of rapidly occurring reversals of the pressurized gas flow.
Transient surge vibration will develop when the steady state fluid velocity is
suddenly altered, increasing and forward flow through the compressor can no longer
be maintained. Fig. 1-1 shows how control surge is done in a 4:1 pressure ratio
centrifugal compressor, operating at 80 percent of design speed.
Fig. 1-1 Surge Control.
A simple description of the surge phenomenon can be given, having a look at the
flow - differential pressure plane, as shown in Fig. 1-2 Centrifugal-compressor
performance curve, where is illustrated a compressor curve for a constant speed.
Differential pressure Surge line
Surge point
D C B for this speed
A
F
E Compressor’s characteristic
curve as determined by speed,
inlet temperature, pressure
and composition
Backward Forward
Inlet Flow
Fig. 1-2 Centrifugal-compressor performance curve

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Suppose there is a steady state at point A and there comes a sudden decrease in
gas demand, experienced by the compressor as a differential pressure increase.
Since speed changes of heavy rotating mass as compressors, require a great lag
time such as several minutes. Therefore, on a shorter term, speed may be
considered constant.
At a constant speed the compressor cannot keep up as much flow against a higher
pressure, so flow goes down toward the SCL to point B, as reflected in the curve
and called surge point. The locus of the surge points for all compressor speeds,
above and below the characteristic curve, is then called surge limit line. The flow
here has fallen to the least the impeller can handle without losing grip on the gas.
From the surge line on, any further decrease in downstream demand no longer
result in increased differential pressure. Instead, the impeller suddenly loses its
effectiveness as a motive element and immediately the gas begins spinning around
with the impeller. As the pipeline gas coasts to a stop, the operating point falls to
zero flow at point C.
Gas begins leaking backwards as a flow reversal and is shown in the picture Fig.
1-2 as a continuation of the jump past point C to point D, lying on a theoretical
extension of the normal characteristic (point B) into negative flow.
Then, within a short time the differential pressure goes down to the minimum the
impeller, decoupled by the gas, can maintain with centrifugal force only, point E.
There, the impeller suddenly gains grip on the gas and push it forward to point F on
the normal characteristic curve. If line flow is still restricted below the surge point for
the given speed, the described cycle B-C-D-E-F repeats at regular intervals, typical
on the order of one second.
The consequences of surge are severe. Surge is a powerful process disturbance

that can disrupt or trip the process. It can also damage the compressor. Damage to
seals and bearings are common. Seal clearances will be increased as a result of
surge, lowering compressor output and efficiency. Even one cycle can have
unwanted consequences in terms of compromise operations, altering internal
clearances and overstressing seals. The costs alone of replacing the compressor
seals are in order of €20K to €50K, thus applying a suitable and effective control
strategy must prevent surge. Catastrophic surge incidents can result in complete
destruction of the rotor.

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In order to prevent such economic losses an effective antisurge control system is

required, for every turbo-compressor. Fig. 1-3 shows a piping and instruments
schematic, where is depicted the dedicated digital controller which is the heart of an
advanced antisurge control system.
DIFFERENTIAL PRESSURE
FLOW
DP
FT
USERS
CHECK
VALVE
CENTRIFUGAL
COMPRESSOR
STEAM OR GAS
TURBINE
ELECTRICAL MOTOR
PC
PRESSURE CONTROLLER
Fig. 1-3 Antisurge Piping and Instruments schematic
In typical antisurge systems, a quick-acting valve recycles a portion of the

compressor discharge flow, back to the compressor suction. Sufficient gas volume,
to ensure forward flow of the gas, is thus always provided to the compressor.

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2 CONTROL OVERVIEW
The preventive antisurge action is provided by a dedicated surge-control system that

is separate from the compressor’s other controls because of response speed
requirements.
The other compressor controls attempt to stay reasonably clear of the surge line, but
only on a relatively long time horizon. Surge events tend to be transient
disturbances. It would be both impractical and inefficient to slow and then accelerate
a large turbine-driven compressor as every potential surge comes and goes. If the
compressor has variable inlet vanes, the control system typically manipulates them
to optimise fuel efficiency, not to avoid every threat of a surge.
Instead, the action provided by the surge-control system is to open the recycle valve
to an appropriate degree. The past dominant strategy was to begin opening the
recycle valve well before the operating point reached the surge line. This approach
led to long operation times with a consequent and appreciable waste of compressor
fuel as well as capacity.
Nowadays antisurge control philosophy is to avoid opening the recycle valve until
absolutely necessary, move away from surge as quickly as possible and then shut
the valve again.
USERS
ANTI-SURGE
VALVE
CHECK
FLOW VALVE
CENTRIFUGAL OR
AXIAL COMPRESSOR
Fig. 2-1 Simplified P&I diagram of a compressor installation
The piping and instrument diagram shown in, represents a compressor provided of
antisurge valve. The energy produced by a turbine or an engine moves compressors

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shaft and process gas sucked up in the inlet. Finally the line users shared out the
gas, compressed to the desired pressure ratio.
The outlet gas is also feed-backed to the antisurge valve. If the recycle valve is not
closed, the process gas is allowed to get back to the compressor inlet, reducing the
compression ratio. In a system of this type, the dedicated digital controller, heart of
an advanced surge-control system, receives inputs:
Inlet pressure
Temperature
Flow
Head across the compressor
Compressor speed.
If gas composition is subject to appreciable change, an indication of that variable,

such as density, may be included. Characteristic curves for various temperatures
and various inlet pressures and compositions are available to the control algorithm
as equations or look-up tables, see chapter 2.
The advanced controller’s reaction time may be well under 50 milliseconds. The
algorithm attempts to duplicate the action of an experienced human operator having
an eye on the instruments, a hand on the manual valve control and a wish to
minimize energy waste resulting from prolonged recycling. This requires a
combination of closed-loop (feedback) and open-loop (prearranged) control. The
system keeps the recycle valve closed as long as the operating point is well away
from the known surge line. As the operating point approaches the surge line, the
control algorithm becomes more sensitive to its motion. Getting too close or moving
too suddenly toward the line causes the valve to open by an appropriate amount to
halt progress toward surge smoothly without triggering control oscillations. Should
extraneous circumstances continue to force the operating point toward the surge
line, the recycle valve opens all the way. If a load reduction persists, then after a
relatively long time (perhaps a few minutes), speed typically is reduced by the
compressor control system.
Consequently, unless the reduced flow is beneath the capability of the compressor,
the operating point and the surge point move away from each other, and the surge
controller gradually shuts the recycle valve. The compressor has kept a firm grip on
the gas.
The control features are all based on PID, Proportional-Integrative-Derivative
controller, that is a type of feedback controller whose output, a control variable (CV),

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is generally based on the error (e) between some user-defined set point (SP) and
some measured process variable (PV). The PID controller computations are
addressed in cutting the error down and anticipating the system response.
The PID implemented grant bumpless control mode transfer, avoiding unwanted
disturbance in the control loop.
The characteristic of PID controller:
o Proportional control; reduces the rise time and reduces, but never eliminate, the
steady-state error.
o Integral control; eliminates the steady-state error, worsening the transient

response.
o Derivative control; increases the stability of the system, reducing the overshoot,
and improving the transient response.
The PID controller is provided of tracking Anti-Windup, in order to avoid any limit
cycling or even instability, that integrator windup may cause.
Surge Limit Line SLL

Differential pressure
Pd
Ps Surge Control Line SCL
Compressor
Operating
B Point
SPEEDn
A
SPEED2
SPEED1
SPEED0
Backward Forward
Suction Flow QS
Fig. 2-2 Suction Flow-differential pressure plane
All compressors operating points are described on the suction flow - differential
pressure plane. There is a different curve for each speed, altogether forming the
compressor’s wheel map (Fig. 2-2). In each line is possible identifying the so-called
“surge point”, corresponding to the maximum differential pressure that limits the
stable area of the speed constant curves. The locus of surge point for all
compressor speeds, above and below the characteristic curve in question, is called

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surge limit line (SLL). The flow here has fallen to the minimum impeller can handle,
without losing its grip on the gas and represents the limit after which corresponds to
an unstable behaviour of the compressor.
The antisurge control (ASCV) system main goal is to avoid the compressor
operating point (A) to reach SLL. This purpose is obtained defining a protection line
on the right side of SLL. This safety line is called surge control line (SCL).
The ASCV system will act opening the antisurge valve. This action increases the
suction flow therefore the operating point moves backwards along the speed
characteristic curve, from the critical condition to the stable operating area.

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2.1 ANTISURGE CONTROL LAW
Considering a mono-stage centrifugal compressor, it is possible to verify the

followings relations for each surge point, varying the compressor speed N, where Qs
is the suction volumetric flow and Hp the polytropic head:
QS = K1 ∗ N Eq. 2-1
H P = K2 ∗ N 2 Eq. 2-2
From Eq. 2-1, Eq. 2-2 we obtain
Hp = K 3 (QS )
2
Eq. 2-3
K2
K3 =
Where
(K1 )2
Since polytropic head Hp is defined as:
⎡ ⎛ n −1 ⎞
⎜ ⎟ ⎤
⎛ n ⎞ ⎢⎛ Pd ⎞⎝ n ⎠ ⎥
Hp = ZRT ⎜ ⎟ ⎜ ⎟ − 1 Eq. 2-4
⎝ n − 1 ⎠ ⎢⎝ Ps ⎠ ⎥
⎢⎣ ⎥⎦
From Eq. 2-3, Eq. 2-4 we obtain
⎡ ⎛ n −1 ⎞
⎜ ⎟ ⎤
⎛ n ⎞ ⎢⎛⎜ Pd ⎞⎝
− 1⎥⎥ = K 3 (Q s )
n ⎠
ZRT ⎜ ⎟ ⎟⎟ 2
⎝ n − 1 ⎠ ⎢⎜⎝ Ps
Eq. 2-5
⎠
⎣⎢ ⎦⎥
If QS is measured through a calibrated orifice mounted on the compressor suction,
we can express it related to the measured Δp
hs
Qs = β Eq. 2-6
γs
Ps
Eq. 2-6 with the perfect gas equation γ s = , leads to Eq. 2-7
RZT
hs * RZT
Qs = β Eq. 2-7
Ps
Introducing this equation into Eq. 2-5, Eq. 2-8 is obtained representing all the surge
points in function of the orifice differential pressure Δp. It is possible demonstrate
how the surge phenomenon is not influenced by the gas condition and composition.

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⎡ ⎛ n −1 ⎞
⎜ ⎟ ⎤
⎛ n ⎞ ⎢⎛⎜ Pd ⎞⎝
− 1⎥⎥
Ps n ⎠
hs = ⎜ ⎟ ⎟⎟
K 3 * β 2 ⎝ n − 1 ⎠ ⎢⎜⎝ Ps
Eq. 2-8
⎢⎣ ⎠ ⎥⎦
Therefore, for small compression ratios and small n variations, the terms:
⎡ ⎛ n −1 ⎞
⎜ ⎟ ⎤
n −1 ⎛ n ⎞ ⎢⎛⎜ Pd ⎞⎝
− 1⎥⎥ ≅ d − 1
n n ⎠ P
and become roughly 1 and so ⎜ ⎟ ⎟⎟
n −1 n ⎝ n − 1 ⎠ ⎢⎜⎝ Ps ⎠ Ps
⎢⎣ ⎥⎦
Eq. 2-8 becomes:
Ps ⎡ Pd ⎤ 1
hs = ⎢ − 1⎥ where = K 4 is a constant
K 3 * β ⎣ Ps
2
⎦ K3 *β 2
⎡P ⎤ hs
h s = Ps * K 4 * ⎢ d − 1⎥ ⇒ =1
⎣ Ps ⎦ ⎛ Pd ⎞ Eq. 2-9
⎜⎜ − 1⎟⎟ * Ps * K 4
⎝ Ps ⎠
1
Where = K4
K3 *β 2
The Eq. 2-9 defines the SLL shape, on the plane of compression ratio (ρ) versus
flow (Q) and is represented by a parabola which has the minimum located in ρ = 1
and Q = 0, see Fig. 2-3.
SLL SCL SLL

SCL
ρ ρ
Q Q
Fig. 2-3 Single stage compressor Fig. 2-4 multistage compressor
Fig. 2-3 highlights a theoretical wheel map, characteristic for a single stage
compressor (one impeller only), while the Fig. 2-4 shows typical multistage
compressor behaviour. The multistage compressor surge limit line puts in evidence
that the surge control line cannot be realized using a parabola, since this
approximation excluding a large part of compressor operating area.

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SLL SCL
ρ
Fig. 2-5 Surge limit and control step line
Fig. 2-5 shows the solution to this lost of operability. The SLL is evaluated by a ten-
break lines function generator f(Pd-Ps/Ps) and consequently the relevant SCL,
moving the SLL right side of a pre-set percentage margin (K). The following section
illustrates the algorithm used to evaluate the surge control line.
The control algorithm developed from Eq. 2-9 and used inside the controller requires
as process variables, suction, discharge and design pressures and the differential
pressure evaluated at a calibrated orifice positioned at compressor suction
Psd
hs *
Ps
= K2 Eq. 2-10
⎛ P − Ps ⎞
f ⎜⎜ d ⎟⎟
⎝ Ps ⎠
Where:
hs = differential pressure on calibrated orifice at the compressor suction (Eng. unit).
Pd = compressor discharge pressure (Eng. unit).
Ps = compressor suction pressure (Eng. unit).
Psd = compressor suction pressure at design conditions
The controller set point is K2. It represents the deviation margin between “SLL” and
“SCL”. In the “Antisurge Control Line configuration sheet”, the margin is expressed
in percentage of flow.
The algorithm takes in account the ΔP measured across the flow element (indicated
by “hs”) that is proportional to square suction flow (hs = Q2).

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The controller algorithm compensates continuously the hs signal according to the

suction pressure variation, taking in account the suction pressure measured and
comparing it with the design suction pressure.
NOTE: the same algorithm is applied for pipeline compressors where the flange to
eye characteristic instead of a traditional flow element is used.

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2.2 FLOW ELEMENT IN SUCTION
The antisurge controller with the orifice placed in the compressor suction is the basic
configuration to which all the previous calculations refer. See Fig. 2-6 where is
shown the antisurge control loop and the relevant instruments.
COMPRESSOR
SUCTION DISCHARGE
PT
FT PT
ANTISURGE
CONTROLLER
PY
Fig. 2-6 Antisurge control loop, suction orifice
The orifice placed in the compressor inlet provides the suction flow and with suction
and discharge pressure is sufficient to build up surge calculations, applying directly
Eq. 2-10. The instruments involved in the antisurge controller are listed in the
following Table 2-1.
INSTRUMENT MEASURED VARIABLE

PT SUCTION PRESSURE
FT FLOW ELEMENT DIFFERENTIAL PRESSURE
PT DISCHARGE PRESSURE
Table 2-1 Instrument list

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2.3 FLOW ELEMENT IN DISCHARGE
The second displacement of the calibrated orifice is in discharge, it is typical for low
suction pressure cases and needs more instrument measure to reconstruct the
suction flow, see Fig. 2-7.
COMPRESSOR
SUCTION DISCHARGE
TT
PT
TT PT FT
ANTISURGE
CONTROLLER
PY
Fig. 2-7 Antisurge control loop, discharge orifice
The orifice placed in discharge needs more process variables than suction, as seen
in Table 2-2.

PT SUCTION PRESSURE
TT SUCTION TEMPERATURE
TT DISCHARGE TEMPERATURE
The increase of signal necessary for the control provides the analog inputs useful to
build up Eq. 2-10, through the differential pressure evaluated at a calibrated orifice
placed at compressor discharge.

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The differential pressure can be reproduced through Eq. 2-11 that, as seen in
chapter 2.1 ANTISURGE CONTROL LAW is proportional to flow squared (hs = Qs2).
Pd Ts Z s
hs = hd ∗ ∗ ∗ Eq. 2-11
Ps Td Z d
Replacing the differential pressure calculated with the previous equation in Eq. 2-10
is possible to control the deviation margin percentage between SLL and SCL, basic
antisurge control algorithm, the following Eq. 2-12.
⎛ P T Z ⎞ P
⎜⎜ hd ∗ d ∗ s ∗ s ⎟⎟ * sd
⎝ Ps Td Z d ⎠ Ps
= K2 Eq. 2-12
⎛ Pd − Ps ⎞
f ⎜⎜ ⎟⎟
⎝ Ps ⎠
Where:
hd = differential pressure on calibrated orifice at the compressor discharge (Eng.
unit).
Td = compressor discharge temperature (Eng. unit).
Ts = compressor suction temperature (Eng. unit).
Zd = compressor discharge gas compressibility at design conditions
Zs = compressor suction gas compressibility at design conditions
The controller set point variable is K2. It represents the deviation margin between
“SLL” and “SCL”. In the “Antisurge Control Line configuration sheet”, the margin is
expressed in percentage of flow.


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2.4 FLOW ELEMENT INTERSTAGE
An other interesting case regards the displacement of the calibrated orifice in

between two compressor stages and more instrument measure to reconstruct the
suction flow are needed, see Fig. 2-8.
1ST COMPRESSOR 2ND COMPRESSOR

SUCTION INTERSTAGE DISCHARGE
FT
TT PT TT PT PT
ANTISURGE
CONTROLLER
PY
Fig. 2-8 Antisurge control loop, inter-stage orifice
The inter-stage orifice displacement requires the largest number of instruments to

build up the antisurge control low. Refer to Table 2-3 for the instrument list.

PT SUCTION PRESSURE
PT INTERSTAGE PRESSURE
TT INTERSTAGE TEMPERATURE
Like the previous case, whit the orifice placed in discharge, the differential pressure
can be reproduced through Eq. 2-13 that, as seen in chapter 2.1 ANTISURGE
CONTROL LAW is proportional to flow squared (hs = Qs2).

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Pi Ts Z s
hs = hi ∗ ∗ ∗ Eq. 2-13
Ps Ti Z i
Replacing the differential pressure calculated with the previous equation in Eq. 2-10
is possible to control the deviation margin percentage between SLL and SCL, basic
antisurge control algorithm, the following equation.
⎛ P T Z ⎞ P
⎜⎜ hi ∗ i ∗ s ∗ s ⎟⎟ * sd
⎝ Ps Ti Z i ⎠ Ps
= K2 Eq. 2-14
⎛ P − Ps ⎞
f ⎜⎜ d ⎟⎟
⎝ Ps ⎠
Where:
hi = differential pressure on calibrated orifice at the compressor intermediate phase
(Eng. unit).
Pi = compressor intermediate phase pressure (Eng. unit).
Ti = compressor intermediate phase temperature (Eng. unit).
Ts = compressor suction temperature (Eng. unit).
Zi = compressor intermediate phase gas compressibility at design conditions
Zs = compressor suction gas compressibility at design conditions
The controller set point is K2. It represents the deviation margin between “SLL” and
“SCL”. In the “Anti-surge Control Line configuration sheet”, the margin is expressed
in percentage of flow.


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2.5 ANTISURGE CONTROL LINES
An example of surge safety and control lines construction is given in Fig. 2-9,
together with the relevant graphic.
Units
FE calc. FE values @ Flow
FLOW ELEMENT for all
values refer.condition Margin %
tables
Volumetric flow m3/h 11844.0 11844.0 10
Differential pressure mBar 100.00 100.00
Molecular weight 8.720 8.720
Absolute suction pressure bara 31.41 31.41 Ps Design
Absolute suct. temperature °K 313.0 313.0
Compressibility 1.012 1.012
Surge values @ reference conditions Point N (normal point)

N° Q surge (Pd/Ps)-1 hs(SLL) hs(scl) Q(N) @ ref.con. 8172.0
1 8000 8.000 45.62 55.20 Abs.disch.press. 200.000
2 7750 7.750 42.82 51.81 hs(N) @ ref.con. 47.61
3 6800 6.480 32.96 39.88 (Pd/Ps)-1 (N) 5.367
4 6600 6.000 31.05 37.57 Point R (real point)
5 6250 5.000 27.85 33.69 FE diff.pressure 47.56
6 5800 4.250 23.98 29.02 Mol. weight 8.720
7 5200 3.450 19.28 23.32 Abs.suct.press. 31.41
8 5000 2.980 17.82 21.56 Abs. suct. temp. 313.0
9 4600 2.000 15.08 18.25 Compressibility 1.012
10 4600 0.000 15.08 18.25 Abs.disch.press. 200.00
11 4600 0.000 15.08 18.25 Q(R) vol. flow 8168.1
hs(R) @ ref.con. 47.56
hs_safe 35.00 42.35 (Pd/Ps)-1 (R) 5.367
Antisurge curve
8.0
7.5
7.0
6.5
6.0
5.5
5.0
(Pd/Ps)-1
4.5
4.0
3.5
3.0
2.5
2.0
hs(SLL)
1.5 hs(SCL)
1.0 N
0.5 R
0.0
0
10
20
30
40
50
60
70
80
90
100
Differ. Press. across suction FE at reference conditions (mBar)
Fig. 2-9 Example of surge lines construction
The wheel plane, differential pressure minus one vs. suction volumetric flow, shown
in the picture above is the result of interpolation of the input values inserted in the
table.
The following list reports and illustrates the quantities taken in consideration to build
the table shown in Fig. 2-9.

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Surge Limit Line

2
⎛ Qsurge ⎞
hs( sll ) = ⎜⎜ ⎟⎟ Diff . press.span
⎝ Vol. flow.span @ ref .cond . ⎠
Surge Control Line
⎡ (Flow.mar. + 100) ⎤
2
hs( scl ) = hs( sll ) ⎢ ⎥⎦

⎣ 100
Point R (real point)

this portion of values could be use for verify the operating point position during
compressor running.
Point N (normal point)

represents the design operating point of the compressor.
FE design values
Values used for the design of flow element.
FE values @ refer. Condition

FE design values converted to the compressor reference condition.
Surge value @ reference condition

Surge values expressed by volumetric suction flow and (Pd/Ps)-1 at
compressor reference condition.

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2.6 AUXILIARIES CONTROLLERS OPERATION
Surge Limit Line SLL
Differenial pressure
Pd
Safety Protection Line
Ps
Safety Correction Line
Surge Control Line SCL
Compressor
Operating
Point
SPEEDn
SPEED2
SPEED1
SPEED0
Suction Flow QS
Fig. 2-10 Antisurge auxiliaries control operation
ADDITIONAL CONTROL CAPABILITY
UNIT STOP: The valve is in open position by setting to minimum the control
signal.
PURGE: When the unit is at zero speed, it is possible to close the valve by a
digital command in order to allow purging of the centrifugal compressor.
START UP: The valve is forced in open position by setting to minimum the
control signal, until the minimum operating speed is reached.
NORMAL RUNNING: The valve is under automatic control. In this conditions

also all the following auxiliary functions are active:
a) Dead Band:
If the difference between measure and set is included between imposed values,

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the controller output does not change. This function permits to make the
controller less sensitive to the noise of flow transmitter.
b) Transient Absorption:
If the measure decreases very fast, to anticipate the controller response, the
controller set point is incremented by a fixed value. When the condition resets,
the set point return to the previous value following a pre-set ramp.
c) Safety Correction:
When the measure is lower of safety correction line (SLL plus 5% in term of
flow) the antisurge controller output decreases following fixed steps in fixed time
gaps until the measure goes back to a value higher than safety correction line.
d) Safety Protection:
When the measure is lower of safety protection line (SLL plus 2% in term of
flow) the antisurge controller output decreases following quick opening ramp
until the measure goes back at the right of the safety correction line.
e) Control Output Rate Limiter:
It's used to avoid instability phenomenon on antisurge control introducing an
output limit of variation. Quick rate is used in valve opening, slow rate in valve
closing.
f) Safety Protection/Correction Disabling:
Allows disabling the safety protection, the safety correction and the manual
operation override functions. Password protected. A typical application of this
function is the compressor surge test, using the controller in manual mode.
g) Manual operation override function:
Allows the automatic disabling of manual control in case measure reaches the
"Safety Correction" limit.
NORMAL STOP: The valve remains under automatic control until the unit drops
below the minimum operating speed. At this point the valve is forced in fully
open position.
EMERGENCY STOP: The valve is forced immediately in fully open position.

Solenoid valve on actuator is also de-energized in order to reduce the valve
opening time.

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EXTERNAL CONTROL OPTIONS
To control from remote the valve, the following features are provided:
EXTERNAL OVERRIDE: Analog input that opens the valve more than anti-surge
controller action. Anti-surge controller current output is available for feedback
purpose. This can be useful when the anti-surge valve is used also for load
control.
EXTERNAL PROTECTION: Digital input that opens the valve with the fast ramp.
This signal can be used in case of series compressors to drive all anti-surge
valves in open position when one stage reaches the safety protection level. The
safety protection signal is available at controller output too.
EXTERNAL TRANSIENT: Digital input that activates the transient absorption

function, so the controller set point is incremented by a fixed value. When the
condition resets, the set point return to the previous value following a pre-set
ramp.
FALLBACK STRATEGY
TRANSMITTER FAULT: In case of a fault is detected in an analog input connected

to a field transmitter, the antisurge controller switch to a simplified control mode
where the measure become the real Dp across the orifice (h) and the set become
the predefined safe value (h_safe). The control transition is managed in order to
avoid bumps at the output. The normal control mode is restored when the analog
input fault is cleared.

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3 INPUT AND OUTPUT
This chapter illustrates all inputs and outputs involved in the examined control.
Starting from control I/O, a brief look at the communications mode is given in the last
section.
3.1 CONTROL INPUT
Control inputs can be divided into digital and analog inputs; the first ones are listed
in the table below, where is also shown a small description:
Digital Input DESCRIPTION

DI 1 SAFETY PROTECTION/CORRECTION DISABLING
DI 2 ZERO SPEED
DI 3 "L3" RUN/STOP ANTISURGE CONTROLLER
DI 4 EXTERNAL TRANSIENT
DI 5 PURGE COMMAND
DI 6 EXTERNAL PROTECTION (E.P.)
Table 3-1 Digital inputs
The DI 3, run/stop antisurge controller command is a settable delay of minimum

operating speed MOS reached signal. The delay is due to system recovery times
from any instability caused by speed control ramp.
For what concerns analog inputs, Suction and discharge are the key points of the
control. Instruments are placed respectively at the compressor inlet and outlet to get
the analog inputs for the control loop.
Four different set of signals are taken in consideration, depending on where is
placed the calibrate orifice and its presence, as seen in chapter 2.
The set of signals are depicted in the following units and in chapter ANTISURGE
CONTROL LAW are given the antisurge algorithms necessary to the control. In all
cases, analog inputs for feedback signals are included.

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A. FLOW ELEMENT IN SUCTION
The orifice placed in the compressor inlet provides the suction flow and with suction
and discharge pressure is sufficient to build up surge calculations, as seen in
section 2.1. The instruments are listed in the following Table 3-2.
PT SUCTION PRESSURE
B. FLOW ELEMENT IN DISCHARGE
The compressors displacement in the orifice outlet needs more instrument signals,
see in Table 3-2, this is due to the reconstruction of the suction flow as shown in
section 2.1.
PT SUCTION PRESSURE
TT DISCHARGE TEMPERATURE

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C. FLOW ELEMENT INTERSTAGE
The largest number of instruments is required in the interstage orifice displacement

case, refer to unit 2.4. All the instruments involved in the control are listed in Table
2-3.
PT SUCTION PRESSURE
PT INTERSTAGE PRESSURE
TT INTERSTAGE TEMPERATURE

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3.2 CONTROL OUTPUT
Antisurge control output signals have a dual effect on the antisurge valve:
The analog output provides the control variable that converted is the valve
open/close value.
The digital output commands the open/close solenoid valve, controlling the
valve inlet circuit. The safety approach to the antisurge valve is the failure
open type.
A schematic if the output control is given in Fig. 3-1, where are shown the two
different type of signals coming out of the antisurge controller and their different
action. The analog provides the control value for the recycling valve, while the digital
secure the compressor against surge in the failure mode.
ANTISURGE
CONTROLLER
ANALOG
DIGITAL
SOLENOID
CONTROL
VALVE
VARIABLE
SIGNAL
ELECTRO
PNEUMATIC
TRANSDUCERS
FAILURE
ANTI-SURGE OPEN
VALVE
SUCTION DISCHARGE
LINE FEEDBACK
Fig. 3-1 Control output schematic

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4 COMMUNICATIONS
One, two or more serial ports, used as control interface, grant communication to and
from control system. These ports support the following types of communication:
Hardwire connection
RS-232
RS-485, 2/4 wires
RJ-45 (Ethernet)
Communication protocols used are:
• MODBUS RTU on TCP/IP
• MODBUS RTU
A computer port can be used to load the configuration program.

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5 DIAGNOSTIC
The device is provided of a Human/Machine Interface HMI system, which offers a

toolbox to cope with system analysis, trouble shooting, data logging and reports
publishing. The main features are:
Trouble shooting:
a. Automatic generation of cause–effect tips in case of alarms.
b. Video or photos to help the operator to solve the problem.
Data logging in case of trip: the last hours of the analog signals, the events for
the digital signals and the alarm history are stored automatically or manually
when required. Data logging help the operator to determine trip causes or find
correlation out of a particular subset of signals. Signals cross analysis is
possible.
Database storing and restoring: the HMI archives can be exported as Excel
files and externally viewed by the customer with his software tools, to perform
statistic reports, production analysis, etc.
HMI commissioning video pages: on line video page builder allows the
operator to visualize all those elements, useful in the commissioning phase.
These pages can be stored and are protected by a password.
HMI I/O diagnostic video pages: according to the control panel I/O list some
HMI pages are dedicated to raw signals visualization. All the digital input are
represented by a LED, all the analog input by a graphic bar. The data
exchanged with the DCS is shown as well. This pages help during pre-
commissioning and are a useful tool for troubleshooting.
Privilege management. The following users are defined:

a. View - only read privilege.
b. Operator - base privileges.
c. Supervisor - diagnostic and settings privileges.
d. Engineer - configuration privileges.
e. Super user - application and operating system access.
Trend plotting tool: configurable signals sets can be represented as 2D plots.

These combinations can be stored and recalled by a meaningful name.

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Automatic reports generation. By selecting the sample time, the report rate
and the signals subset, an automatic report can be generated. This report is
stored in the database and then in can be compared with the previous ones
and exported.
Multi-language video-pages. A particular keystroke combination switches the

text language, without any service loss.
Load and Restore parameters setting. The running parameters can be stored
and recalled if needed (a password is required). Many parameters sets can be
stored with different names and a default setting is always present.
Video Pages on hand held computer. A wireless connected Hand held

computer run the video pages, allowing the operator to control both the
process in the field and the video pages: this can help some maintenance
tasks where two operators are needed.
Alarm messages and data via SMS or Email. Temporal or alarm events can
trigger a message to be sent via SMS or Email to a configurable team. The
message will contain all those information previously selected during a
configuration session.

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6 VIDEO PAGES
The touch-screen on board or an external device acquires data from the control
using Human/Machine Interface HMI software. The link is internal or made through
Ethernet or TCP/IP connection architecture.
All the data are stored in a database, providing all the necessary data to the
operator allowing control and diagnostic of the system.
Features available are:

Control pages
Diagnostic pages
Video pages have the following functionality:

• Faceplates for mode signalling of all auxiliary components (I.E. oil lubrication
pump etc.)
• Continuous indication of all process variables (temperature, pressures etc.)
• Display and modification of all calibration SET POINTS and eventually present
logic timers. Access to above mentioned functions by means of a mechanical
or electronic key.
• Display and modification of engineer unit for all the acquire measure. Access
to above-mentioned functions is allowed by means of a mechanical or
electronic key.
• Historical logging of all analog measures for minimum 3 months. The system
will use a standard relational database. At least two different historical tables
are created, the first one indicating data types and the other the data storage
times. The first table is for a detailed analysis and reports the data sampled
with a minimum period of two seconds during at least one day. The second
table is for production analysis and it reports the data averaged during a
maximum period of five minutes and acquired during at least three months.
The following units illustrate in detail video pages graphics interfaces, base
functionalities and screen samples.

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6.1 LIST OF GRAPHIC INTERFACES
Graphic interfaces are devised to interact with the HMI system and following
functions are adopted in order to protect the system:
Video pages can be opened one at a time and cannot overlap.
The video page format cannot be changed.
The user can interact with the resources available (active areas) through either
the mouse pointer or the keyboard (Tab key).
The user cannot use any other Windows applications except those of the same
application.
The colours on video pages identify the occurrence of an event.
To briefly describe alarms under way, a message box on the bottom of the page
is used.
The user’s functions vary according to the login type (type of user).
Generally, the icons used in an HMI system are:
Push buttons are used to perform various

actions, they can be recognised by their
light grey background colour, black text
and projecting shape.
Generally (when not above an active
zone) the mouse cursor looks like a
leaning small white arrow.
When the mouse cursor is on a push-

button (or any active zone) it turns into a
black vertical arrow.
The selected push-button (or active zone)
is highlighted by a double black outline.
A push-button not available or not
selectable can be recognised either by its
dark grey background colour and black
text or by the fact that when the mouse
cursor is positioned on it the push-button
does not change.

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This icon shows the scrolling object if several

pages are linked (to the right), and if a video
page has no other pages linked to it (to the
left).
The left-hand number represents the video
page number currently displayed; the right-
hand number represents the total number of
linked pages.
This object displays one video page at a time.
To increase or decrease the page number,

position the mouse cursor (which changes as
described above) on the upward or downward
arrows.
By clicking the mouse left-button, the left-hand
number changes as well as the video page
displayed and the head banner title.
Positioning the cursor on this icon it is possible

to go back to the previous page.
Clicking on this icon it is possible to go to the

video page defined as Home (usually the Main
Page)
This object is displayed in the alarm banner

with yellow background colour and black text.
to acknowledge any alarm or trip occurred: if
the alarm or trip is still active, the background
colour will get black and the text yellow.
Please note that the number in brackets
means that also pressing F2 on the keyboard
can perform the operation.
to reset any alarm or trip previously
acknowledged; this means that the alarm or
trip acknowledged in the alarm banner
disappears from this banner if reset.
means that also pressing F3 on the keyboard
can perform this operation.
to enlarge the alarm banner to full page in
order to view more than the usual 4 alarms or
trips.
means that pressing F4 on the keyboard can
also perform this operation; by pressing F5 the
banner goes back to its normal format.
Fig. 6-1 Video page icons review

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6.2 BASE FUNCTIONALITIES
Each video page is composed of five different and separated sectors, divided per
functionality:
• Heading
• Control Banner
• Right-hand Toolbar
• Point Control Object
• Alarms & Trips window
6.2.1 HEADING
On top the page a banner is featured showing: the company name and possible
logo, the system name, the machine item, the title of the video page displayed and
the T&T Sistemi logo.
Video page title

Company
Logo T&T Logo
System type
Fig. 6-2 Video page upper banner
6.2.2 CONTROL BANNER
On the bottom of each video page a dialogue banner of the general control system
is displayed. This banner is divided into the following zones:
Acknowlegment push-buttons (ACK) and Trips and Alarms reset push-buttons
(RESET);
Zooming push-button (ZOOM);
Window reporting existing alarms and trips, date and time of occurance, whether
they have been acknowledged and the alarm message description

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Leds for the main signallings such as: PLC active, allarm common, trip common ,
MOS active, and so on.
Display of PLC date and time.
Previous and Home Page push-buttons
General signal
PLC Date&Time
Alarm and Trips

Previous page
Acknowledgement
Alarm and Trips Home-page

RESET Alarm and Trip
Alarm and Trip list display
list zoom
Fig. 6-3 Video page lower banner
The user can employ the various graphic interfaces by positioning the mouse arrow
on the desired push-button and pressing the mouse left-button. Some push-buttons
feature hotkeys (e.g. F2, F3 or F4) which allow the use of functions by pressing on
the corresponding hotkey with no need to use the mouse.
Note: when the mouse arrow icon moves onto an active area (e.g., push-buttons or
setpoints), the mouse icon turns from a skew arrow into a vertical one and the active
area is highlighted by an outline.
6.2.3 SET-POINT CONTROL
The access to the HMI control is possible as two kinds of users. The first level is the
view mode, while the second level one is the maintenance mode. Positioning the
mouse cursor on the active area and clicking once with the mouse left-button, a
password request window is displayed.
The connection as viewer is possible If user enters the level 1 password (np) in
the appropriate text box and presses “OK”, so that a new window appears, see Fig.
6-4.

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Fig. 6-4 First level password
The user is now in view mode and is only allowed to change the Set-point value in a
preselected range and press “OK” to confirm the choice.
Fig. 6-5 Second level banner
Fig. 6-5 shows the set-point window if connected as maintenance; If user enters the
Level 2 password (np1) in the appropriate text box and presses “OK”. This second
level configuration allows user to change the Set-point value of the range selected
(HH,H,L,LL) as well as the related Min and Max thresholds, and then press “OK” to
confirm.
In this case the user can change the measure Set-point values and press “OK” to
confirm.
Any mistake done entering the password an error window pops up, as shown in Fig.
6-6 below.
Fig. 6-6 Error window

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6.2.4 ALARMS & TRIPS WINDOWS
The existing alarms and trips are shown in the control banner (see Fig. 6-7),
displayed in the bottom of all video pages. The alarm window can be enlarged to full
screen by pressing the zoom push-button (seeFig. 6-3) and this operation will open
the alarm historical report.
Fig. 6-7 Alarms and trips
The acknowledgement sequence (ACK) and the alarm sequence is the following:
The alarm occurs and is displayed in the related banner (Fig. 6-7) with a
yellow background and black text.
The user must acknowledge the alarm by pressing the ACK push-button (see
Fig. 6-3); if the alarm remain active it is still displayed in the control banner (Fig. 6-7)
with black background and yellow text and shall automatically disappear when it is
no longer active.
If once the alarm has been acknowledged and is no longer active, the alarm
automatically disappears without changing coulor.
ISA-A sequence is used for alarms as shown in the following Table 6-1:
Alarm status Text Background

Alarm not active Not shown Not shown
Alarm active not acknowledged Black Yellow
Alarm active acknowledged Yellow Black
Alarm not active reset Not shown Not shown
Table 6-1 ISA-A Alarm sequence
The trip acknowledgment (ACK) and reset (RESET) sequences are as follows:
The trip occurs and is displayed in the related banner (Fig. 6-7) with red
background and black text.
The user must first acknowledge the trip by pressing the ACK push-button
(see Fig. 6-3); if the trip is still active it is displayed in the control banner (Fig. 6-7)
with black background and red text.
The user must reset the trip by pressing the RESET push-button (see Fig.
6-3), then the trip disappears from the alarm and trip list.

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ISA-F1A sequence is used for trips, see the table below.
Trip status Text Background

Trip not active Not shown Not shown
First trip active not acknowledged Black Red
Second trip active not acknowledged Red Black
First trip active acknowledged Red Black
Second trip active acknowledged Red Black
Trip not active reset Not shown Not shown
Table 6-2 ISA-F1A Trip sequence
The following tables report text and background colours for the signal status and in
the control banner.
Signals Text Background

Run Black Red
Stop Black Green
Fault Black Fuchsia
Available Black Green
Signal off Black Dark grey
Table 6-3 Status Colors
Signal Type Text Background

PLC Run or OK Black Green
PLC Error Black Red
PLC Stand BY Black Yellow
Communication Error Black Red
Alarm Black Yellow
Shoutdown Black Red
Running Black Green
Stop Black Red
Idle Black Aqua
rated Black Aqua
No Load Black Aqua
Island Black Aqua
Parallel Black Aqua
MOS Active Black Red Blink (*)
Signal off Dark grey Dark grey
Table 6-4 Signal Colors on the Control banner

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6.3 ESA SCREENS
This section offers a general review or ESA screens, followed by a more detailed of
the single features appearing in the screen, starting with the log and main menu
page and continuing with a brief look at hierarchy, concluding with the whole set of
screens.
6.3.1 LOG AND MAIN MENU
Fig. 6-8 and Fig. 6-9 show respectively the log and main screens of ESA monitor.
Fig. 6-8 LOG page
Open main menu screen.

Log in with administrator privileges to modify all PLC
parameters.
Touch to close administrator privilege.
Touch to change administrator password.
Fig. 6-9 Main menu
Return to LOG Page.
Alarms and Trips Acknowledgment.

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6.3.2 LIST OF GRAPHIC INTERFACES
The functions adopted to protect the system are listed below:

Screens can be opened one at a time and cannot overlap.
The user can interact with the resources available (active areas) touch the screen.
To briefly describe alarms under way, an icon on the left of the page is used. The
icons used in an ESA system are shown in the following description:
Push buttons used to perform

different actions.
Number of the actual screen / Pages

total number.
Increase or decrease one page at a

time, touching the right or left arrow.
Display and monitor value tags,

touching the screen and shows the
value.
Return to Home page (usually the

Main Page), by touching this icon.
Alarm or trip occurred acknowledge

touch button.

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6.3.3 ESA SCREEN HIERARCHY
Screens are organized according to the hierarchy structure reported below; it can be
noted that there are three main video page classes:
LOG page
MAIN
MENU
P&I Antisurge
1. Analog Range 1. Antisurge cintrol

2. P&I 2. Setpoint
configuration
3. FIC control
Fig. 6-10 ESA screen hierarchy
In this section these three typical video page classes are described, explaining in
detail the page use for supervision purposes.
1.1) ANALOG RANGE

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1.2) P&I
2.0) Main antisurge

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2.1) Antisurge control
2.2) Set pint configuration

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2.3) FIC 08102 Control

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6.4 HMI VIDEO PAGES
Fig. 6-11 Main menu
Fig. 6-12 Set-points

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Fig. 6-13 Antisurge 1/3

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Fig. 6-16 Control P&ID

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Fig. 6-17 Trips & Alarm History
Fig. 6-18 Event History

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Fig. 6-19 Time setting
Fig. 6-20 Step 1 Fig. 6-21 Step 2 Fig. 6-22 Step 3

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7 PARAMETERS CONFIGURATION
This chapter intends to offer a useful worksheet for antisurge controller

configuration. The first unit provides the instrument table where insert instruments
tags and ranges. The second unit is dedicated to list all parameters involved in
antisurge control, finally unit 1 SURGE CONTROL LINE provides the worksheet
useful to reconstruct the antisurge segment lines for the control calculation.
7.1 INSTRUMENTS RANGES
INSTRUMENT MEASURED VARIABLE RANGES
PT- SUCTION PRESSURE ÷
PT- DISCHARGE PRESSURE ÷
PT- INTERSTAGE PRESSURE ÷
TT- SUCTION TEMPERATURE ÷
TT- DISCHARGE TEMPERATURE ÷
TT- INTERSTAGE TEMPERATURE ÷
FLOW ELEMENT DIFFERENTIAL

FT- ÷
PRESSURE

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7.2 ANTISURGE CONTROL
1. Margin K
2. Absolute Pressure Constant (KPA) (Block A/B):

Converts suction and discharge pressure measured from the gauge to
absolute pressure as the following low: PSA=PS+KPA. Generally 1.013 Bar
3. Absolute Temperature Constant (KTA) (Block C1/C2):
Converts inter-stage and discharge temperature measured from the gauge
to absolute pressure as the following low: PTA=PT+KTA. Generally 273K
4. Gas Compressibility Ratio (KZ) (Block C3):
Provides the gas compressibility ratio KZ=ZS/ZD: where ZS and ZD are the
gas compressibility constant in suction and discharge.
5. Flow Filter Time (FFT) (Block D):
First order filter applied to suction flow measure, with transfer function
1/(1+τS).
5.1 Max FFT:
Maximum time for the flow filter.
5.2. Min FFT:
Minimum time for the flow filter
6. Design Pressure (PSD) (Block E):
It compensates the compressor suction flow, considering the measured
suction pressure.
7. Conroller Paramiter Rate Limiter (Block H):
Output changing according to a rate limiter, temporary enabled if the transmitter failure
occurs, with PARF as minimum output value.
7.1. Fast Rate:
Rate occuring when the valve is steady or closed.
7.2. Slow Rate:
Rate occuring when the valve is opening.
7.3. PARF:
Minimum output value.
7.4. Rate Limiter Enabling Time (RLET) (Block M):
In case of pressure failure it changes, the controller parameter
rate limiter will be enabled for a fixed time.
7.4.1. RLET Min
RLET lower range value.
7.4.2. RLET Max
RLET upper range value.
8. Failure Surge Set Point:
Set surge set point in case of pressure transmitter failure.

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9. Transient Absorption Derivate Parameter (TAKd) (Block Q):

Derivate parameter threshold to determine the transient absorption.
9.1. Min TAKd:
Minimum derivative parameter.
9.2. Max TAKd:
Maximum derivative parameter.
10. Signal Ramp (Block R):
Ramp used to enlarge the margin between the SLL and SCL, up to a maximum
limit value, see parameter 11 preset value and 15 incremental value:
10.1. Rate Up:
10.2. Rate Down:
10.3. Min Limit:

Minimum limit when ramp is disabled.
11. Signal Preset value (Block S):
Signal value kept during normal conditions, necessary in case of transient
absrption.
11.1. Min Preset Value:
11.2. Max Preset Value:
12. Safety Correction (SCM) (Block T):

5% safety correction, corresponding to the value obtained as
(1+5/100)2.
13. Output Cycling Status (Block U):
While the “1” status in , the “0” status is the scanning cycle.
13.1. Min Cycling Status Time:
13.2. Max Cycling Status Time:
14. Triggering Logic (Block V):

(COR) The existence of logic input “1” causes the logic output existence for
“t” time. It enables point 11 (block W)
15. Incremental Value (Block W):

Increasing value for the output signal, see 10.

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16. Safety Protection Set Value (Block Z):

2% safety protection, corresponding to the value obtained as
(1+2/100)2.
16.1. Min Safety Protection Set:

1% safety protection.
16.2. Max Safety Protection Set:
Safety correction percentage minus 1.55%.
17. Reset Safety Protection Value (Block Z):

5.50% safety protection, corresponding to the value obtained as
(1+5.50/100)2.
17.1. Min Safety Protection Reset:
Safety correction percentage plus 0.2%.
17.2. Max Safety Protection Reset:
The maximum corresponds to the Margin.
18. Purge Valve (Block X):
Antisurge valve while purging the piping before start-up.
19. Flow Internal Controller (FIC):
19.1. FIC Proportional Gain (Kp):
19.1.1. FIC PG Min

Proportional gain lower range value.
19.1.2. FIC PG Max
Proportional gain upper range value.
19.2. FIC Integral Time (IT):
19.2.1. FIC IT Min

Integral time lower range value.
19.2.2. FIC IT Max
Integral time upper range value.
19.3. FIC Derivative Time (DT):
19.3.1. FIC DT Min

Derivative time lower range value.
19.3.2. FIC DT Max
Derivative time upper range value.
19.4. FIC Action:
PID action 0 direct or 1 inverse.

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19.5. FIC Dead Band:
19.5.1. Dead Band Lower Limit (DBLL) (Block A4)
19.5.1.1. Lower DBLL

Lower limit for the lower dead band
19.5.1.2. Upper DBLL
Upper limit for the lower dead band
19.5.2. Dead Band Upper Limit (DBUL) (Block A5)
19.5.2.1. Lower DBUL

Lower limit for the upper dead band
19.5.2.2. Upper DBUL
Upper limit for the upper dead band
20. Solenoid Valve Preset Time (Block A1):
If safety protection is still on, after this preset time, the solenoid valve is de-
energized until the reset manual command is operated.
20.1. Min Preset Time:

Minimum solenoid valve preset value.
20.2. Max Preset Time:
Maximum solenoid valve preset value
21. Antisurge Manual Ramp Rate (Block A2):
Valve opening and closing rate in case of manual operation.
21.1. Min Manual Rate:
Minimum manual rate value
21.2. Max Manual Rate:
Maximum manual rate value

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7.3 SURGE CONTROL LINE
FLOW ELEMENT Eng. Unit FE design values

Volumetric Flow @ Discharge Conditions Nm3/h
Flow element Differential Pressure mmH20
Molecular weight
Absolute discharge pressure Bara
Absolute discharge Temp. K
Compressibility @ Discharge Condition
Flow Element Data @ Suction Condition FE val. @ refer. Con. Flow Margin %
Volumetric Flow @ Suction Condition
DP @ Suction Condition
Molecular Weight
Absolute Suction Pressure Design Pressure
Absolute Suction Temp.

Compress. @ Suction Conditions
Surge values @ reference conditions

Surge line
Q surge (Pd/Ps)-1 Bar hs(SLL) mmH2O hs(SCL) mmH2O
segment
1
2
3
4
5
6
7
8
9
10
11

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7.4 SETTING EXAMPLE
In this chapter is shown a typical video page representing antisurge constants and
underneath are listed the setting constants position in the worksheet.
B
C
D
E
F
G
H
I
Fig. 7-1 Video page setting example
Constants:
A, I and Surge Lines can be found in unit 7.3.
B are placed respectively in unit 7.2 point 12, 16 and 17.
C, unit 7.2 points 9 and 8.
D, unit 7.2 points 5.4, 13, 14 and 20.
E, unit 7.2 point 5.
F, unit 7.2 point 11 and 15.
G, unit point 19.1 and 19.2.
H, unit point 5.1 and 5.2
FIC parameters can be found in unit 7.2 point 19.

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SYMBOL LEGEND
PT = PRESSURE TRASMITTER
FT = FLOW TRASMITTER
TT = TEMPERATURE TRASMITTER
PSD = DESIGN SUCTION PRESSURE
SCL = SURGE CONTROL LINE
SLL = SURGE LIMIT LINE
N = COMPRESSOR SPEED
K1,K2,K3,K4 = CONSTANTS
Qs = VOLUMETRIC FLOW
Hp = PRESSURE HEAD
Pd = DISCHARGE PRESSURE
Ps = SUCTION PRESSURE
Z = COMPRESSIBILTY FACTOR
R = GAS CONSTANT
T = GAS ABSOLUTE TEMPERATURE
n = POLYTROPIC HEAD EXPONENT
β = CHARACTERISTIC ORIFICE CONSTANT
hs = ΔP BETWEEN SUCTION PIPE AND 1ST COMPRESSOR EYE
γs = SUCTION GAS DENSITY
Κ = DEVIATION MARGIN


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Compressor surge is a low-flow phenomenon known to exist in dynamics, i.e.

Fig. 1-1 Surge Control.

Differential pressure Surge line

Fig. 1-2 Centrifugal-compressor performance curve

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The consequences of surge are severe. Surge is a powerful process disturbance

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In order to prevent such economic losses an effective antisurge control system is

Fig. 1-3 Antisurge Piping and Instruments schematic

In typical antisurge systems, a quick-acting valve recycles a portion of the

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The preventive antisurge action is provided by a dedicated surge-control system that

Fig. 2-1 Simplified P&I diagram of a compressor installation

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If gas composition is subject to appreciable change, an indication of that variable,

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o Integral control; eliminates the steady-state error, worsening the transient

Surge Limit Line SLL

Fig. 2-2 Suction Flow-differential pressure plane

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2.1 ANTISURGE CONTROL LAW

Considering a mono-stage centrifugal compressor, it is possible to verify the

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Eq. 2-8 becomes:

SLL SCL SLL

Fig. 2-3 Single stage compressor Fig. 2-4 multistage compressor

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Fig. 2-5 Surge limit and control step line

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The controller algorithm compensates continuously the hs signal according to the

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2.2 FLOW ELEMENT IN SUCTION

Fig. 2-6 Antisurge control loop, suction orifice

INSTRUMENT MEASURED VARIABLE

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2.3 FLOW ELEMENT IN DISCHARGE

Fig. 2-7 Antisurge control loop, discharge orifice

INSTRUMENT MEASURED VARIABLE

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The controller algorithm compensates continuously the hs signal according to the

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2.4 FLOW ELEMENT INTERSTAGE

An other interesting case regards the displacement of the calibrated orifice in

1ST COMPRESSOR 2ND COMPRESSOR

Fig. 2-8 Antisurge control loop, inter-stage orifice

The inter-stage orifice displacement requires the largest number of instruments to

INSTRUMENT MEASURED VARIABLE

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The controller algorithm compensates continuously the hs signal according to the

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2.5 ANTISURGE CONTROL LINES

Surge values @ reference conditions Point N (normal point)

Differ. Press. across suction FE at reference conditions (mBar)

Fig. 2-9 Example of surge lines construction

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Surge Limit Line

Surge Control Line

hs( scl ) = hs( sll ) ⎢ ⎥⎦

Point R (real point)

Point N (normal point)