Surge control basics.

Series 3+ Antisurge controller

basics.
Series 3+ Emergency AntiSurge detector (EAS) basics.

What is Surge?
The Phenomenon of
surge is a
characteristic of any
compressor .

What is Surge?
The Operation of a compressor
can become unstable due to
changes in many operating
conditions such as flow rate,
pressure and molecular weight
of gas. This causes rapid
pulsations in flow, and this is
called SURGE.

Surge Definition
Surge is defined as Self oscillations
of Pressure and Flow, often including
flow reversal

Compressor flow chart

Typical Surge Cycle

The Surge Phenomena

Flow

Rapid flow oscillations

usually with thrust
Sec.
reversals / mechanical
damage

Pres
s

Tem
p

Rapid pressure
Sec. oscillations with process
instability

Sec.
1

Rising temperature
inside compressor

Surge Description

Flow reversals in 20 to 50 Milliseconds.

Surge cycles at a rate of 0.3s to 3s per
cycle.
Compressor vibrates
Temperature rises
Whooshing Noise
Trips may occur
Conventional instruments and
operators fail to detect the surge.

Surge consequences
Unstable flow and
pressure
Damage in sequence
with increasing severity
to seals, bearings,
impellers and shaft
Increased seal
clearances and leakage
Lower energy efficiency
Reduced compressor life

Factors leading to
onset of surge
Start-up
Shutdown
Operation at reduced
throughput
Operation at heavy
throughput with: Trips /
Operator errors / Load
changes / Cooler problems
/ driver problems /Power
loss / Process upsets / Gas
composition changes /
Filter or strainer problems
Surge can happen any
time

Compressor Map
HEAD

N1

N2

N3

Reduction in flow

MASS
FLOW

Surge
Cycle

PRESS

Surge zone

Operating zone

B
D

A Operating
point
E
FLOW

VE

VE

1. Due to a reduction in load, operating point moves from stable operating

Point A to Point B. Highest pressure (Head) at Surge point B.
2. Operating point moves from Point B to Point C Flow Reverses.
3. Discharge pressure falls from C to D

4. Operating point moves from Point D to Point E to increase flow &

pressure.
5. Again due to reduced load, the operating point moves through the

curve to Point B
6. This completes one surge cycle Typical duration: 0.3 to 3 seconds.

Antisurge Control basics

To prevent a compressor from
experiencing surge, one need to know
where the Surge Limit Line is
located. This information is determined
from extensive surge tests ,
and is downloaded to a controller that
controls the recycle valve. If the controller
knows the Surge Limit Line and
the Location of Operating point
with respect to this line, then the Recycle
valve can be opened when required.

Antisurge Control basics

Hr

SLL

Rc

OP

Slope of the line

K = Tan = Qr/Hr

Qr
(Qr)SLL

(Qr)OP

CCC Uses Reduced Head (Hr) Versus reduced

Suction flow Squared (Qr) to develop Surge
control map. Hr is measured in KJ/Kg, m/ft
lbf/lbm etc. Qr is measured in ft3/hr, m3/hr,
Tons /day etc.

Antisurge Control
basics
The SURGE PARAMETER Ss
Surge parameter (Ss) is the most important
parameter used in CCC controllers.
Ss is a function of Head and mass flow
calculations. These calculations takes into
account the factors such as flow, pressure,
compressibility, molecular weight,
temperature etc.
In several applications in DPC, this value is
derived, without use of Temperature and
Speed values considered in calculations.

Surge Concepts
Smaller
Value of
K

Surge
Limit Line
SLL
Large
Value
of K

Value of K and the correct location of SLL is

determined through actual surge tests on the
compressor by CCC Engineers

Antisurge Control
basics
Hr

Hr

Ss >
1

Ss =
1 on
SLL

OP

Ss < 1 : Stable
Operation

Ss <
1

(Qr)SLL

(Qr)OP

Ss = 1:

Surge Limit Line

Ss > 1:

Surge Region

Antisurge Control
basics
The surge Limit line is an unstable
Hr

SLL

SCL

b1
O
P

limit, which, if crossed by operating

point, will cause compressor to
experience at least one surge cycle.
The continual surge cycles might
cause compressor damage, along
with shutdowns.

The only way to prevent this from

happening is to keep the operating
(Qr)
point at a safe distance from surge
limit line.

This Minimum distance is called as Safety Margin and is

visualized in operating map by drawing a line in front of the
Surge Limit line. This line is called as SURGE CONTROL LINE
(SCL)..
The distance between SLL and SCL is determined by the
constant b1.
Recycle valve will be closed as long as operating point is
towards the right of the SCL. When operating point reaches SCL
or crosses to the left of SCL, it enters the Surge Control Zone

Antisurge Control
basics
Hr

SLL

SCL

b1
OP

Surge control Zone

(Qr)
The FIRST control action that opens valve when operating point is
in SURGE CONTROL ZONE IS

P+I action.

The S Value for is calculated for Surge Control Line:

S = K X[ f(Rc)/ (Qr)OP] + b1 X 1/Po
Note that S=1 when operating point is on SCL.
Thus the control action that opens recycle valve uses this S-value
as its process variable

Antisurge Control
basics

. As long as S < 1, the output of Antisurge controller

will keep Recycle valves closed. When S > 1, the P+I
action of Antisurge valve will open the Recycle valve.
Operator interface of the controller does not show the S
Value. Instead it shows the derived value, DEV
(deviation).

Deviation: DEV = 1 - S
DEV = 0

When Operating point is on SCL

DEV > 0

When Operating point is to the Right of SCL

Stable
compressor operation

DEV < 0

When Operating point is to the Left of SCL

The compressor is operating at Surge
Control Zone.
P + I control will give adequate protection for small
disturbances and the control will be stable for steady

Antisurge Control
basics
Margin of Safety
The width of the margin of Safety is the distance between the SLL
and OP.
It is represented by parameter b which is defined as:

b = (b1) + (b2 x n) + (b3 x Td0 x ds/dt), where

b1 =

minimum margin of safety (SCL LOCATION)

(b2 X n) =
safety on
surge counts.
increments each
operating point

Safety on response (distance added when

response is triggered), where n is the
Initially n = 0 and starts counting in
time, a surge is detected and/or
crosses
safety on line.

(b3 X Td0 X ds/dt) = The derivative control response where:

b3 = maximum derivative response.
Td0 = derivative response time
constant and
ds/dt = derivative of Ss with
respective to time.
When ds/dt is moving left (+ve),
the magnitude of
response reflects the rate of

Antisurge Control
basics
Margin of Safety
.
is

When ds/dt is negative, that is operating point

moving to right, then the derivative response is
ramped to zero at a rate set by the ramp rate
constant. (CONSTANT G IN PARAMETERS)
Also, the derivative action is suspended if the
Operating point crosses Recycle trip

line.

Antisurge Control
basics
Enhancement to P+ I control: Adaptive
gain
When OP moves
towards SCL fast,
the Adaptive gain
moves the SCL
towards OP.
This allows P+I
control to react
earlier
Hence small steady
surge control
margin can be
achieved without

Hr

SLL

SCL

op

(Qr)

Surge Concepts: Recycle Trip Line

Hr

SL
L

Recycle Trip Line

RTL

SC
L

Recycle
Trip
Action

P+I

Qr

Recycle
Valve

Recycle Trip (SECOND CONTROL ACTION FROM ANTISURGE

CONTROLLER)
For normal or small surge conditions the PI action is enough for
control. However for large disturbances, PI action alone is not
enough and operating point crosses SCL rapidly.
To control this disturbance, a Recycle Trip line is set between SCL
and SLL. The Recycle Trip Line is determined for each compressor by

Surge Concepts: Recycle Trip Line

Recycle Trip Line RTL

Hr

SLL

SCL

Recycle
Trip
Action

P+I

+
OP
Recycle
Valve

Qr

Valv
e

Total
response
P + I control
Recycle Trip
Time

Surge Concepts: Recycle Trip

Response
1.Disturbance arrives, the OP moves towards SCL.
2.When OP hits SCL, the P+I action opens valve as
per PI settings.
3.OP keeps moving towards surge and hits RTL
4.When OP hits RTL, then the conclusion is:
We are close to surge
PI control action is slow to control
disturbance
Need to be out of danger zone fast
5.An open loop response is triggered

Surge Concepts: Recycle Trip Response

..
6. OP moves back to safe side of RTL
The RT function decays out the step response
PI controller integrates to stabilize output on
SCL
7. Total response of controller is the sum of PI
control and RT action

Benefits:
Energy savings due to smaller surge margin
Compressor has more turndown before recycle
or blow of
Surge can be prevented for virtually any

Surge Concepts: Recycle trip

Response

Improving Recycle Trip response

1.
Open loop control lacks accuracy needed to
precisely position Recycle valve.
2.
Open loop corrections of a fixed magnitude
C1 are often too big or too small for a
specific disturbance
3.
Hence the actual response of the RT function
is the rate of change of OP or dSs/dt.
Recycle trip response calculation:
C = C1 X Td X d(Ss)/dt
Where
C
= Actual step to the valve
C1
= Constant which defines max. step
Td
= Scaling constant
d(Ss)/dt
= Rate of change of OP

Surge Concepts: Recycle trip

Response
Valv
e

Total response
P + I control
Recycle Trip

Time

Small disturbance
Valve
Total response

P + I control

Larger disturbance

Recycle Trip

Time

Surge Concepts: Recycle trip

Response
ONE STEP
RESPONSE
Valve
Positio
n

After Time delay C2, controller

checks if the OP is back to safe
side of RTL
If yes
: Exponential decay
of RT
Response
If No : Another Step added to RT
Response

C1
C2

Time

Surge Concepts: Recycle trip

Response
MULTI- STEP RESPONSE
Valve
Positio
n

C1
C2

C2

Time

1.

Surge Concepts: Safety ON (SO)

Safety On is the THIRD LEVEL of protection of

a compressor from surge.
The SO Line is a line to the left of SLL and
again its position is usually determined
through calculations after Surge tests.
Compressor can surge severely due to:

2.

3.

Transmitter Calibration shift

Sticky or blocked Recycle valve
Blocks in Recycle line
Large process upsets.

Benefits of SO response:

4.

Continuous surge avoided

Operators get alarms about surge.

Surge Concepts: Safety

ON
SLL
RTL

Hr

SCL

Safety On
Line (SOL)

b2

Safety ON (SO) Line

Qr

Surge Concepts: Safety ON

SLL

RTL

SCL

NEW NEW
RTL SCL

Additional Surge Margin

The Safety On Function increases margin between SLL and
SCL when surge is detected. Note that RTL follows SCL

Surge Concepts: Safety ON

Safety ON (SO)
2.

If Operating point cross SO Line, then the compressor

is in surge.
SO response shifts the SCL and RTL to the right

3.

Additional safety margin is added.

1.

Surge detector:
In series 3 + controller,
1.
2.
3.
4.

5.
6.

Surge signature is recorded during surge tests

Rate of change of flow / pressure is determined.
Thresholds are configured.
Surge is detected when actual rates of change are exceeded
in configured thresholds.
When surge is detected a SAFETY ON response is triggered
Digital outputs are triggered upon a configurable number of
surge cycles

Transmitters used in Surge control

measurements
Flow Transmitters:
This transmitter is critical for Surge control
system.
1.
Main selection criteria:
Repeatability and Sufficient signal to
noise ration
2.
Very fast response to changes in flow.
3.
Transmitter to be ranged for maximum
compressor flow.
4.
Should not be damped as any delay in flow
measurement can be disastrous for surge
control system.
5.
Preferred location is to Suction piping of
compressor / As close to inlet flange as

Transmitters used in Surge

control measurements
1.

2.

3.

4.

5.

6.

Generally Electronic transmitters with measurement lag of

not more than 0.0200 secs are used in surge controls for
pressure and flow measurements.
These transmitters should not be Heavily damped that the
compressor dynamics are not reported to the controller.
The transmitter taps & sensors should be located as close to
the compressor piping, to prevent signal lags.
The transmitter taps should be above the upper half of
pipe works this prevents the condensation build-up
The transmitter should be mounted at a level above its
impulse tubing taps. The tubing should be routed with a
gradual slope.
The length of impulse tubing should be minimized to avoid
measurement lags.

Surge control Instruments &

Valves
How fast should the response of Antisurge control system
should be?
Certain operating conditions such as Jammed check valves,
process parameters, ESD (equipment shutdowns caused by
protective systems) etc. cause upsets that are very fast and
large.
Conventional pneumatic Instruments are too slow to detect
these fast changes that cause surge.

CCC Series 3+
controllers provide
Highly advanced,
specialized, fast
Microprocessor based
control functions

Recycle Valves

For Efective Surge control, the recycle valves must be

large and fast acting. It should be capable of recycling
100% of design flow rate. Larger the valve, greater will
be the efect of its opening.
When Suction flow decreases and compressor operation
is moving close to Surge, it is necessary to efect a
quick increase in flow. The rate at which flow can be
increased depends upon the response of Recycle valve
and its size.
Typically, the duration of a surge cycle can be one
second. Hence the speed of response of recycle valve
should be very fast. Field tests have shown that the full
stroke of the Recycle valve should be achieved within 2
Seconds. This speed is achieved by using devices such
as Volume Boosters along with Valve positioners etc.
These work by increasing the volume of pneumatic
signal to the valve actuator.

Recycle Valves

Use of Solenoid instead of Volume booster is not

recommended as Volume booster provides modulating
control along with speed.
Also, to maintain required speed of valve operation,
the length of pneumatic tubing between components
are kept at minimum possible and proper tubing size is
necessary to be selected.
Quick Exhaust increase speed in only one direction.
(Typically from full close to full open). Volume boosters
increase speed in both directions. Hence, Volume
boosters are used with recycle valves

Recycle Valves

Compresso
r

Minimize the
discharge
pipe volume
Chec
k
Valve

Suction
. Drum

Recycle
valve

Cooler

Piping consideration and

location

Series 3+
Antisurge
Controller
Face

Alpha Numeric Display:

1. DEV
distance from
= 1-S)
2. ALT
(when
count is

Displays the
surge (DEV

Displays surge count

display surge
pressed

3. OUT
output to

Displays the
Valve

4. AUX

Auxiliary display

1. Auto
mode

Lit when Automatic Op

2. Manual

Lit when Manual Op Mode

3. RT
efect
surge

Lit when Recycle Trip is in

due to close prox. to

4. SO
detected
cycles

Lit when Safety On has

one or more surge

5. Limit
at or

Lit when Limiting variable is

beyond threshold

6. Tracking
Lit when in redundant
tracking
mode. Flashes
in o/p track mode

Status
LEDs

7. Tran Fail

Lit when any analog input is

outside its alarm limits

8. Fall back
Lit when input or
communication
failure triggers
a Fallback
9. CommErr

Lit when expected message

Toggle between auto and manual modes

Zeroes SO surge count, Returns surge
control line to initial position.
Temporary display of
numerator/denominator in ALT and DEV
windows OF S VALUE
Temporary display of SO surge count in
ALT window
Used to select AUX window display
In Auto mode NO efect
In Man mode Changes out put signal
Temporary display of disch. & Suct
press. And its limiting set point in DEV
and ALT windows (AUX tells which)

Scroll Keys

Used to select AUX window display

Antisurge controller AUX display:

Operating status menu: (Does not scroll operating
status
of compressor selected by analog or discrete input)
1. Status RUN
2. Status STOP
3. Status Purge

Measured Variable Menu:

(Default labels)
1. dP0

##.#

2. D Press

##.#

3. S Press

##.#

4. Speed
5. D Temp

##.#

6. S. Temp

##.#

7. Chan 7

##.#

8. Chan 8

##.#

Calculated Variable menu

1. Sigma

.###

2. Rc

#.##

##.# 3. Rt

#.##

4. Speed

#####

SERIES 3+ SURGE CONTROLLER INPUT/OUTPUTS

Analog
inputs
CH-1 dP0
(Flow)
CH-2 Pd
(Disch)
CH-3 Ps (Suct)

Analog out
to EAS

CH-4 Speed
CH-8

Discrete
inputs
ESD (D2)

Discrete outputs
(CR1) To IN-8 of EAS
(CR2) AIC Fault/OP Fail
status to EAS

PURGE (D3)

(CR3) SAFETY ON

RUN/STOP
(D6)

(CR4) TRANS FAIL

(CR5) EXCESSIVE SURGE

SERIES 3+ EAS DETECTOR

EAS

RUN
0.05 %

_______________

Surge Detector
and
Manual Loading
Station

IN
CONTROL
ALARM 1

TAKE
CONTROL

RETURN
TO
ANALO

Corporation

As
Loading station

RESET
ALARMS

CONFIGURE

SCROLL

ENTER

FAULT

Controls

is configured
Auto/Manual

ALARM 2

Compressor

EAS detector

(AMS) in DPC

SERIES 3+ EAS DETECTOR

FT - B FT-A

AIS

EAS

FY

SERIES 3+ EAS DETECTOR: Input /

Output
Analog inputs
CH-1 Flow Tx.
CH-2
REMOTE IN (4-20
MA from AIS
Controller)

EAS

RUN
0.05 %

_______________

Surge Detector
and
Manual Loading
Station

IN
CONTRO
L
ALARM
1

Discreet
inputs
(IN-8) From CR-1
of AIS
CONTROLLER

ALARM
2

TAKE
CONTROL

CONFIGURE

FAULT
SCROLL
Compressor
Controls
Corporation

Discreet
Outputs
(CR-1) EAS FAULT
(CR-2) SURGE COUNT 1
ALARM

RETUR
N TO
ANALO

RESET
ALARMS

Valve Out 4-20

MA

ENTER

(CR-3) SURGE COUNT 2

ALARM
(CR-4) SURGE COUNT 3
Emergency Shutdown
(CR-5) EAS IN CONTROL

SERIES 3+ EAS DETECTOR

EAS is configured as Auto Manual Loading station (AMS) Mode.

Compressor Surging can be detected by using CH-1 Flow
transmitter.
CH-2 Analog input is used to track the output of Antisurge
controller.
Each time a surge is detected, two counters are incremented
the EVENT SURGE COUNT and the ACCUMULATED SURGE
COUNT.
The Event Surge Count is the number of surges detected since
the Surge Alarms were last manually or automatically reset.
The accumulated Surge Count is menu variable that can be set
to any desired value. Thus its interpretation depends on when
it was last reset and what value it was given. If the original
value was Zero, then its value indicates how many times surge
has occurred
The EAS is manually tuned after Surge testing the compressor
to determine the parameters for surge detection thresholds.
The Event Surge Counter is configured to drive the Alarms (4)
and its associated digital outputs.

SERIES 3+ EAS DETECTOR

The EAS Tracks the output of Antisurge controller.

In event of Antisurge controller failure, the EAS takes over
the surge control function, in a limited way. (IN CONTROL
of EAS is lit).
When Antisurge controller is fixed, the control can be
transferred back to AIS, in bump less transfer mode. Same
holds true when Control is transferred to EAS.

In most applications, the EAS operates normally

in its tracking state (TRK displayed in the
display). This mode is active when the fault relay
of AIS controller is normal. Only when the AIS is
faulted, then the EAS will take control (RUN
displayed in display). The EAS will also, take
control if the TAKE CONTROL key on its face is
pressed.
Causes ESD of the unit if 3 surge counts are
detected in a minute.

SERIES 3+ EAS DETECTOR

EAS

RUN
0.05 %

_______________

Surge Detector
and
Manual Loading
Station

IN
CONTROL
ALARM 1

TAKE
CONTROL

RETURN
TO
ANALO

ALARM 2
RESET
ALARMS

CONFIGURE

SCROLL

ENTER

FAULT

Compressor
Controls
Corporation

Operator interface

EAS Operator interface

LEDs: These flash to indicate conditions as
follows:
The Green in control LED is lit when the EAS is its
IN CONTROL

ALARM1

ALARM2

FAULT

RUN mode and flashes in the Return state.

The Yellow Alarm 1 LED flashes when Event surge

count exceeds the Alarm 1A threshold. It lights
continuously, if that count equals or exceeds the 1B
threshold
The Yellow Alarm 2 LED flashes when Event surge
count exceeds the Alarm 2A threshold. It lights
continuously, if that count equals or exceeds the 2B
threshold
The Red Fault LED lights if CPU crashes or the voltage
for internal circuitry falls too low.
When the fault LED is lit, the value of the output
signal and the state of the output selection relay are
unpredictable. Process disruptions or equipment
damage can result unless that relay is deenergized by
powering down EAS.

EAS Operator interface

KEYS ON THE EAS FACE
TAKE
CONTROL

If EAS is operating in its Tracking or Return state, Pressing the TAKE

CONTROL Key selects the RUN state. If it is already in RUN state and
if MANUAL is enabled in configuration, then the key toggles between
RUN and MAN state
If EAS is operating in its RUN or MAN state then pressing RAISE key
increases intended valve position by 1% and pressing LOWER key
decreases the intended valve position by 1%. These keys have no
effect when the EAS is in TRK or RET state

RETURN
TO
ANALOG

RESET
ALARMS

Pressing the RETURN ANALOG key while EAS is operating in RUN state
initiates the sequence for returning control to PRIMARY CONTROLLER.
Provided discreet IN 8 is satisfied and Local Return Analog method is
enabled in Software
Pressing the RESET ALARMS Key sets the Event Surge Count to Zero
and cancels any active Surge Alarms. But this action does not return
the intended valve flow to its initial value.

EAS Operator interface

KEYS ON THE EAS FACE
CONFIGURE

SCROLL

ENTER

Pressing the CONFIGURE key initiates a procedure for

invoking the configure state, in which you can view or
Change variable and parameters and execute various tests

Pressing the SCROLL key cycles the Digital readouts

through the available operating variables

Pressing the ENTER key has no effect other than restoring

the default variable readout

EAS Operator interface

EAS READOUTS:
EAS is provided with two 4-Character LCD readouts. When not
operating in its configuration state, the upper readout displays the
name of operating variable and lower readout displays its value.
Pressing the SCROLL key cycles these readouts through the list of
variables available for display.
An EAS normally displays its operating state and intended valve
position. If you scroll to another variable, then you can restore back
to default by pressing the ENTER KEY

Upper
display
Lower
display

EAS Operator interface

EAS READOUTS:
Operating state: Shown in Upper display
1. The upper display reads TRK then the EAS is in Tracking state. The
intended valve position/flow are calculated from the output of
Antisurge Controller
2. The upper display reads RUN then EAS is in RUN state. The
intended valve flow can be raised by closed loop response or the
intended valve position can be changed by operator.
3. If the upper display reads MAN then EAS is in MAN state (if enabled
in configuration). The Closed loop response is disabled.
4. If upper display reads RTN, the EAS is operating in its return state.
The intended flow is being ramped to match the output signal of
the primary controller for Bump less transfer.
In all above cases the lower readout displays Intended Valve Position.

EAS Operator interface

EAS READOUTS:
INTENDED VALVE FLOW (LOWER READOUT)
IF the EAS is in RUN STATE, then depending on how it is
configured, EAS can raise its intended valve flow (VFLO) as
each surge alarm (TOTAL = 4) is tripped (This response
never decreases the VFLO).
Each Surge alarm (1A/1B/2A/2B) is set to ramp the VFLO to
the absolute value set by corresponding alarm response
parameter (in an increasing direction only)
Pressing the RAISE or LOWER KEY will immediately abort
any ramped change in VFLO.

EAS Operator interface

EAS READOUTS:
Also, pressing the SCROLL KEY, one can display following:
1. EVENT SURGE COUNT (CNT) How many times EAS
detected surge since last reset
2. Analog input CH-1
3. Output of Primary controller CH-2
4. Accumulated Surge Count (ACCL) the net total number of
surge detected since installation/commissioning
5. Discrete input 1 to 8 (As four binary digits 0 or 1)
6. Discrete output 1 to 4 (As four binary digits 0 or 1)
7. Discrete output 5 through test