Aspen HYSYS

Compressor Surge Analysis Feature: A Quick

Tutorial
Version Number: V8.6
May 2014
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Compressor Surge Analysis
Feature: A Quick Tutorial

This is a brief introduction to the Compressor Surge Analysis feature of HYSYS

V8.6 and higher. This tutorial describes the methodology to follow in the
analysis of two steady-state cases, each featuring only one compressor: cases
K-100.hsc and K-101.hsc.

Test Case K-100.hsc

Activating the Dynamic Compressor
To activate the dynamic compressor:
1 Open the case K-100.hsc.
Note: This test case corresponds to a turbine driven, 500kg compressor
with a radio of gyration of 1m, which you can view by selecting the
Inertia page of the Rating tab on the compressor property view.
2 On the Home ribbon tab, from the Analysis group, select Compressor
Surge . The Compressor Surge form appears.
3 Select the arrow next to the Add button, and, from the drop-down list,
select Dynamic Compressor. The Compressor Surge: Dynamics
dialog box appears.
4 On the Compressor Surge: Dynamics dialog box, next to the Unit field,
click the Select Unit button to select the compressor. The Select Target
Unit Op dialog box appears. On the Select Target Unit Op dialog box,
select K-100, and then click OK.
In this example, you will test several templates and equipment
configurations.

Note: For this case, you will discard the Cooler on Discharge side template
since the dew point temperature of the stream on the outlet side of the Cooler
is significantly lower than 43°C. This means that condensation cannot take
place, so there is no need of a downstream scrubber.

Compressor Surge Analysis Feature: A Quick Tutorial 1

 Testing the Cooler on discharge side, no
downstream scrubber Template
The Cooler on discharge side, no downstream scrubber template
includes two sets of degrees of freedom with a single criterion to pass four
scenarios.
The degrees of freedom are for:
 the surge controller and anti-surge valve side
 the hot-bypass valve size and overall discharge volume size

To select the Cooler on discharge side, no downstream

scrubber template:
1 From the Template drop-down list, select the Cooler on discharge
side, no downstream scrubber template type.
2 Click the Enter Flowsheet button to create the dynamic sub-flowsheet. A
Compressor Surge entry appears in the navigation pane with sub-nodes
listing the different dynamic flowsheets that were created. The
Compressor Surge: Dynamics-K-100 window appears.

Notes:
 The scrubbers will be sized from the following two equations. These
equations determine the minimum vessel diameter and a convenient
height. The computed diameter is the minimum to prevent the entraining
of liquid into the compressor from the vessel through the vapor line due to
an excessively high vapor velocity. This equation was originally developed
to set the percentage of flooding by vapor in distillation columns and
applies to systems at dew point conditions and far away from the critical
point [1], [2].
These formulas are only valid for the units given below and that their
conversion to the English system of measures is not straightforward [2].
Also, if the compressor suction stream or the Cooler outlet stream are too
far away from dew point conditions, considerably oversized scrubber
vessels are a possible result.

D  2.12 Q  g0.5

H  1. 5 D
where
 g : mass density of the vessel vapor outlet stream (kg/m3)
Q : mass density of the vessel vapor outlet stream (m3/s)
D : minimum vessel diameter (m)
H : vessel height (m)
 The flowsheet is in steady state. Make sure that it is converged before
proceeding with the rest of this example.

2 Compressor Surge Analysis Feature: A Quick Tutorial

 Running Scenarios
From the ribbon, you can access the Summary button on the Dynamics tab
to view and, if necessary, modify the default settings from the Summary view
before running scenarios.
 On the Summary property view, select the Run Controls tab. You can
view a Run Time length of 30 minutes = 1,800 seconds and a Step Size of
50 milliseconds = 0.05 seconds.
 Select the Compressor Curves tab. The Compressor Curve Status
appears as Input Complete. If you select the Edit Curves button, the
Curves page of the Rating tab of the compressor property view appears.
The single criterion for success or failure is based on the trail of the
compressor operating point in the compressor map that is generated
during the particular test scenario. Select the Plot Curves button to show
the map. The recommended settings are those in Figure 1 below. You can
also access the Flow Limits page of the Rating tab from the compressor
property view to verify your selections. You should clear all the check
boxes for preliminary studies, as shown below in Figure 2.

Figure 1. Default settings and appearance of the compressor curve

profiles at steady-state (or initial time).

Compressor Surge Analysis Feature: A Quick Tutorial 3

 Figure 2. Default settings of the compressor flow limits options.
 Select the Strip Charts tab of the Summary view. For consistency with
the graphical display settings in Figure 1, the settings of the strip charts
are 20,000 samples every 100 milliseconds.

To run the Discharge Valve Failure scenario:

1 On the Dynamics ribbon tab, from the Select Scenario drop-down list,
select Discharge Valve Failure.
Note: You can select the Event Scheduler button on the Dynamics tab
of the ribbon to view further details regarding this scenario.
2 On the Dynamics ribbon tab, click the Run button. Make sure that the
Real Time option is cleared.
The test does not need to be run until completion of the 30 minute
setting. You can manually stop it after 5 minutes by selecting the Stop
button on the Dynamics ribbon tab.

4 Compressor Surge Analysis Feature: A Quick Tutorial

 Figure 3. Compressor map indicating that the default settings do not lead
compressor K-100 into surge
This test has passed, since the operation point did not go beyond the
surge curve boundary. A real compressor crossing into the surge region,
on the left side of the surge curve, is at potential risk of severe damage.
Note: For this scenario, only the surge compressor and anti-surge valve
settings are used to avoid this situation.

To run the Emergency Shutdown scenario:

1 The Emergency Shutdown scenario relies mostly on the Cv value of the
anti-surge valve. The surge controller plays no role, since the anti-surge
valve will fully open manually as the compressor power is shut down. The
Event Scheduler is also set to open the hot-bypass valve. In a first pass,
you want to avoid the interaction of both valves, so select the Dynamics
ribbon tab, select Summary, and then select the Equipment Sizing tab.
Set the conductance of the hot-bypass valve to zero, as shown below in
Figure 4.
2 On the Dynamics ribbon tab, from the Select Scenario drop-down list,
select Emergency Shutdown.
3 On the Dynamics ribbon tab, click the Run button.

Compressor Surge Analysis Feature: A Quick Tutorial 5

 Figure 4. Setting to zero the Cv of the hot-bypass valve will result in no
flow recirculation through it.

Figure 5. Trail at the default anti-surge valve conductance, and on the

right side, at Cv= 720 USGPM
4 To test the impact of a larger Cv, adjust the anti-surge valve Cv to 720
USGPM and run the scenario again. The larger Cv moves the operating
point trail closer to the stonewall region.

6 Compressor Surge Analysis Feature: A Quick Tutorial

 Figure 6. The red curve indicates that the flow through the hot-bypass
valve has been zero during the Emergency Shutdown test if setting a zero
Cv value for the hot-bypass valve.
Figure 6 verifies that the flowrate through the hot recycle path is zero; the
hot-bypass valve is blocking the hot recycle flow when its Cv is equal to
zero.

Figure 7. Operating point trail for the Cv=720 USGPM at the anti-surge valve
Figure 7 now shows the impact of this larger Cv on the Discharge Valve
Failure scenario. Notice that the minimum compressor flow is now slightly
higher than the one in Figure 3. In conclusion, a larger Cv will avoid surge,
but you can only increase it to some maximum value before stonewall takes
place. This test case does not require the hot bypass valve to handle these
two scenarios.

To run the Controlled Shutdown scenario:

This scenario takes the compressor towards a minimum-of-governability
compressor speed, which is usually accepted as equal to 70% of the speed at
steady-state conditions. After this goal is met, the anti-surge valve is fully

Compressor Surge Analysis Feature: A Quick Tutorial 7

 opened and the compressor power is shut down. Both final actions occur at
the same time for electric motor driven compressors. For the case of turbine
driven compressors, such as the current case, a 1 second delay between the
valve opening and the compressor shutdown is the norm. Occasionally, when
these two events take place simultaneously, a sudden power shutdown may
take the compressor into surge.
1 Leave the anti-surge valve Cv value as 720 USGPM.
2 On the Dynamics ribbon tab, from the Select Scenario drop-down list,
select Controlled Shutdown.
3 On the Dynamics ribbon tab, click the Run button.
With your settings, the results are satisfactory, as shown in Figure 8. You can
view how the surge controller is overridden after the angular speed of the
compressor has reached 70% of its initial value. This is done by means of the
speed controller SC which is set into Auto mode from the Event Scheduler and
then back into Man at the end of the compressor trip.

Figure 8. Successful controlled shutdown with no hot bypass required

To run the Total Power Loss scenario:

1 On the Dynamics ribbon tab, from the Select Scenario drop-down list,
select Total Power Loss.
Note: The main differences between the Emergency Shutdown scenario
and the Total Power Loss scenario are that the Total Power Loss
scenario entails the loss of coolant at the Cooler and the switching to a
higher actuator speed at the anti-surge valve resulting in a shorter
opening time of 2 seconds.
2 On the Dynamics ribbon tab, click the Run button.

8 Compressor Surge Analysis Feature: A Quick Tutorial

 The trail in Figure 9 below indicates that the test passes without surge or
stonewall issues.

Figure 9. Successful total power loss when using the previously found
overall settings
As you can see with Figure 10 (below), the loss of coolant does not represent
a serious inconvenience. The compressor suction stream temperature slightly
exceeds 70oC. For the still rotating shutdown compressor, the discharge
temperature is almost the same as the suction temperature.

Figure 10. Evolution of the compressor suction side temperature during

the total power loss scenario
In conclusion, none of the four selected scenarios represent a threat to the
compressor.

Compressor Surge Analysis Feature: A Quick Tutorial 9

 Testing the Cooler on suction side Template
With regards to K-100, the original “suction” stream temperature equals
41.3oC, so you can use this template, since a Cooler approach temperature of
9.3oC is not too low when compared to the nominal 11oC.

To select the Cooler on suction side template:

1 From the Template drop-down list, select the Cooler suction side
template type.
2 Click the Enter Flowsheet button to create the dynamic sub-flowsheet. A
Compressor Surge entry appears in the navigation pane with sub-nodes
listing the different dynamic flowsheets that were created. The
Compressor Surge: Dynamics-K-100 window appears.

Note: The flowsheet is in steady state. Make sure that it is converged before
proceeding with the rest of this example.

Running Scenarios
There are two sets of degrees of freedom to modify and a single criterion to
pass four scenarios.
The degrees of freedom are for:
 the surge controller and anti-surge valve side
 the hot-bypass valve size and overall discharge volume size
All scenarios have been set to convenient default values, so only minor
changes are involved. The single criterion for success or failure is based on
the trail of the compressor operating point in the compressor map that is
generated during each particular test scenario.

10 Compressor Surge Analysis Feature: A Quick Tutorial

 To run the Discharge Valve Failure scenario:
1 From the compressor property view, select the Rating | Flow Limits
page, and select the options shown below.

Figure 11. Setting at the compressor property view, Rating/Flow Limits

page used during the course of the simulation for all four scenarios
presented below.

2 On the Dynamics ribbon tab, from the Select Scenario drop-down list,
select Discharge Valve Failure.
Note: You can select the Event Scheduler button on the Dynamics tab
of the ribbon to view further details regarding this scenario.
3 On the Dynamics ribbon tab, click the Run button. Make sure that the
Real Time option is cleared.
The test does not need to be run until completion of the 30 minute
setting. You can manually stop it after 5 minutes by selecting the Stop
button on the Dynamics ribbon tab.
See Figure 12 below to view the operating point trail on the compressor
map for the default settings of the surge controller parameters and the
anti-surge recycle valve.

Compressor Surge Analysis Feature: A Quick Tutorial 11

 Figure 12. Discharge valve failure test

To run the Emergency Shutdown scenario:

1 On the Dynamics ribbon tab, from the Select Scenario drop-down list,
select Emergency Shutdown.
2 On the Dynamics ribbon tab, click the Run button.
See Figure 13 below to view the operating point trail for the Emergency
Shutdown scenario. This scenario requires the hot bypass recycle to avoid
surge. Using the default Cv value of the hot bypass valve, the result is an
important incursion into stonewall, which is not very serious for a
shutdown scenario. It is preferable to use two valves in this case rather
than a single one that would end up being too large.

12 Compressor Surge Analysis Feature: A Quick Tutorial

 Figure 13. Emergency shutdown. Very close to the limit of surge using the
hot bypass valve in combination with the anti-surge one. Since it gets into
stonewall, additional anti-surge capacity to avoid surge would take it
deeper into stonewall.

To run the Controlled Shutdown scenario:

1 On the Dynamics ribbon tab, from the Select Scenario drop-down list,
select Controlled Shutdown.
2 On the Dynamics ribbon tab, click the Run button.

Figure 14. Controlled shutdown test (left side) and total power loss (right
side). Both recycle valves are used at their default Cv values and simulate
surge and stone wall conditions.

Compressor Surge Analysis Feature: A Quick Tutorial 13

 Note: Regarding the overall setup temperature resulting from the loss of
coolant during the total power loss scenario, Figure 15 indicates we do not
reach 60oC on the suction side.

Figure 15. Evolution of the compressor suction side temperature during the
total power loss scenario
For K-100, the Cooler on discharge side, no downstream scrubber
template seems to be a more reasonable one, since it only requires the anti-
surge recycle valve with moderate Cv and the operating point trails found
were acceptably close to either the surge or the stonewall limits. This
completes your study of the first compressor case.

Test Case K-101.hsc

Activating the Dynamic Compressor
To activate the dynamic compressor:
1 Open the case K-101.hsc.
2 On the Home ribbon tab, from the Analysis group, select Compressor
Surge . The Compressor Surge form appears.
3 Select the arrow next to the Add button, and, from the drop-down list,
select Dynamic Compressor. The Compressor Surge: Dynamics
dialog box appears.
4 On the Compressor Surge: Dynamics dialog box, next to the Unit field,
click the Select Unit button to select the compressor. The Select Target
Unit Op dialog box appears. On the Select Target Unit Op dialog box,
select K-101, and then click OK.
In this example, you will test several templates and equipment
configurations.

14 Compressor Surge Analysis Feature: A Quick Tutorial

 Note: You will not test the Cooler on discharge side, no downstream
scrubber template in this example, since this particular compressor has
condensation at the downstream scrubber, so you will try to avoid sending
two-phase flow through the recycle valves.

Testing the Cooler on discharge side

Template
To select the Cooler on discharge side template:
1 From the Template drop-down list, select the Cooler on discharge side
template type.
2 Click the Enter Flowsheet button to create the dynamic sub-flowsheet. A
Compressor Surge entry appears in the navigation pane with sub-nodes
listing the different dynamic flowsheets that were created. The
Compressor Surge: Dynamics-K-101 window appears.

Note: The flowsheet is in steady state. Make sure that it is converged before
proceeding with the rest of this example.

Running Scenarios

To run the Discharge Valve Failure scenario:

1 On the Dynamics ribbon tab, from the Select Scenario drop-down list,
select Discharge Valve Failure.
2 On the Dynamics ribbon tab, click the Run button.
The test passes without surge or stonewall issues, as shown in the image
below. Figure 16 shows the operating point trails on the compressor map
for the default settings of the surge controller parameters and
conductance of the anti-surge valve.

Compressor Surge Analysis Feature: A Quick Tutorial 15

 Figure 16. Discharge valve failure test without surge or stonewall issues

To run the Emergency Shutdown scenario:

1 On the Dynamics ribbon tab, from the Select Scenario drop-down list,
select Emergency Shutdown.
2 On the Dynamics ribbon tab, click the Run button.
The test passes without surge or stonewall issues, as shown in the image
below. Figure 17 shows the operating point trails on the compressor map
for the default settings of the surge controller parameters and
conductance of the anti-surge valve.
Note: During the Emergency Shutdown Scenario, the conductance of the
hot-bypass valve was set to zero, so no hot-recycle is required.

16 Compressor Surge Analysis Feature: A Quick Tutorial

 Figure 17. Emergency Shutdown test without surge or stonewall issues

To run the Controlled Shutdown scenario:

1 On the Dynamics ribbon tab, from the Select Scenario drop-down list,
select Controlled Shutdown.
2 On the Dynamics ribbon tab, click the Run button.
The test passes without surge or stonewall issues, as shown below.

Figure 18. Controlled Shutdown test

To run the Total Power Loss scenario:

1 On the Dynamics ribbon tab, from the Select Scenario drop-down
list, select Total Power Loss.

Compressor Surge Analysis Feature: A Quick Tutorial 17

 2 On the Dynamics ribbon tab, click the Run button.
The test passes without surge or stonewall issues, as shown below.

Figure 19. Total Power Loss test

You have determined that this template is a good candidate for all four
scenarios, with no need for a hot-bypass valve.

Testing the Cooler on suction side

Template
The temperature of the suction stream of compressor K-101 is 47.5 °C, so
you can still use cooling water with an exchanger approach temperature of
15.3 °C (or 27.5 °F) in order to have reasonable heat transfer rates.
The default valve settings for K-101 are as shown below.

Figure 20. Default valve sizing and conditions for “Cooler on suction side”
template, compressor K-101

18 Compressor Surge Analysis Feature: A Quick Tutorial

 Running Scenarios

To edit settings before running scenarios:

1 On the PFD, double-click the Compressor: Surge Controller.
2 On the Surge Control page of the Parameters tab, in the Control Line
[%] field, type 20.
3 In the Backup Line [%] field, type 2.
4 On the PFD, double-click the Antisurge Valve.
5 On the Specs page of the Dynamics tab, in the Conductance field, type
200 USGPM.
6 On the PFD, double-click the Hotbypass Valve.
7 On the Specs page of the Dynamics tab, in the Conductance field, type
0.
Next, you can run the scenarios.

To run the Discharge Valve Failure scenario:

1 On the Dynamics ribbon tab, from the Select Scenario drop-down list,
select Discharge Valve Failure.
2 On the Dynamics ribbon tab, click the Run button.
The test passes without surge or stonewall issues, as shown below.

Figure 21. Discharge valve failure test for compressor K-101 in template
“Cooler on suction side”

To run the Emergency Shutdown scenario:

1 On the Dynamics ribbon tab, from the Select Scenario drop-down list,
select Emergency Shutdown.
2 On the Dynamics ribbon tab, click the Run button.

Compressor Surge Analysis Feature: A Quick Tutorial 19

 The test passes without surge or stonewall issues, as shown below.

Figure 22. Emergency Shutdown test for compressor K-101 in template

“Cooler on suction side”

To run the Controlled Shutdown scenario:

1 On the Dynamics ribbon tab, from the Select Scenario drop-down list,
select Controlled Shutdown.
2 On the Dynamics ribbon tab, click the Run button.
The test passes without surge or stonewall issues, as shown below.

Figure 23. Controlled Shutdown for compressor K-101

20 Compressor Surge Analysis Feature: A Quick Tutorial

To run the Total Power Loss scenario:
1 On the Dynamics ribbon tab, from the Select Scenario drop-down list,
select Total Power Loss.
2 On the Dynamics ribbon tab, click the Run button.
The test passes without surge or stonewall issues, as shown below.

Figure 24. Total Power Loss for compressor K-101

After the minimal changes that you performed to the default settings, the
compressor performance in the Cooler on suction side configuration was
similar to that of the Cooler on discharge side configuration. In real life
situations, you will select your template based on a variety of other factors in
order to obtain the best control system and shutdown system to meet your
design needs.
You have now completed your study of the K-101 example case.

References
[1] Douglas, James M. “Conceptual Design of Chemical Processes.” McGraw-
Hill, Inc., 1988.
[2] Luyben, William L. “Plantwide Dynamic Simulation in Chemical Process
and Control.” Marcel Dekker, 2002, Chapter 2.

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