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LP
HP Disch. Volute
LP First Impeller
HP First Impeller
HP
HP Inlet
Di
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LP Discharge
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LP Inlet
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Jo
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Co
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H
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Blade
Hub
Eye
Bore
Cover
Exit
Suction
Pressure
Discharge
Pressure
Suction
Pressure
Discharge
Pressure
Suction
Pressure
Discharge
Pressure
Balance
Piston
Suction
Pressure
Discharge
Pressure
P (1/2 U22)
gas density
U =Impeller Tip Speed
Frequency = 1/2 to 2 Hz
Stall Cells
Incipient Surge
Compressor Performance
Equations
Hp =
P2 (
P1
[( )
k-1
k
k ZRT1
-1 (k-1) MW
h Z R T1
Q1 = MW P
1
Readily Measureable
Variables
Hp =
P2 (
P1
[( )
k-1
k
k ZRT1
-1 (k-1) MW
h Z R T1
Q1 = MW P
1
Simplification of Head
Factor
Hp =
P2 (
P1
[( )
Q
2
1
k-1
k
k ZRT1
-1 ( k-1)
MW
h Z R T1
MW P1
Simplification of Flow
Factor
P2 (
P1
[( )
k-1
k
k
-1 ( k-1)
h
P1
P2
P1 - 1
( )
h
P1
Determining the
Surge Limit Point
A Surge Limit Point, in terms of
Pd
ho
&
, is determined
Ps
Ps
by testing the compressor in the field or from using the predicted curves
supplied by the manufacturer. The compressor should be tested for
at least three surge points if possible, one at minimum speed, one at maximum
speed, and one at 50% of the speed range. This establishes the
relationship of speed vs. surge limit.
N1
N2
N3
Q2 (ICFM)
If the controller is unable to prevent a compressor surge, it is
desirable to automatically increase the surge margin so that
the compressor does not continue to surge. The controller
must detect a surge, increment the margin and alarm.
Instrumentation
Considerations
Flow Measurement is the most important signal for proper surge control. Close
attention should be given to selecting and locating the flow device and transmitter.
Location: Preferred in compressor suction for simplifying algorithm. Commonly
found in compressor discharge piping and is compensated to inlet conditions. MUST
be located to measure TOTAL COMPRESSOR FLOW inside the recycle loop.
Size: The flow measuring device and transmitter must be sized for maximum
compressor flow. The required pressure differential corresponding to maximum flow
should be 10 WC or greater.
Instrumentation
Considerations (cont.)
Flow Transmitter: The length of tubing between flow device
and the transmitter should be minimal. The transmitter must
be reliable, repeatable, and have a speed of response (rise time)
of 100 msec or less.
Pressure Transmitters: These transmitters should be located as
close to the compressor as possible. For constant speed
compressors with suction throttling valves, the suction pressure
must be measured downstream of the valve.
Temperature Transmitters: Location is not as critical but
should be located to provide correct temperature.
Instrumentation
Considerations (cont.)
Flow Measurement for Load Control
The flow measuring device for load control must be located to measure "user" flow
and not compressor flow. It must therefore be located outside the recycle loop.
Also, most flow control applications are "mass flow", requiring temperature and
pressure readings as well as flow.
FIC
SIC
ST
FT
PT
PT
TT
TT
UIC
FY
FT
Flow Measurement
Need to have a sufficient signal to noise ratio.
Accuracy of the flow coefficient is not critical. Must be
repeatable.
Venturi Tube- best device- most costly
Orifice Plate- good characteristics- unrecoverable pressure loss- less
costly
Annubar - widely used, least costly, least desirable - poor signal-tonoise ratio.
Transmitters
Flow transmitters- Rosemount 1151 analog
and 3051 digital are most widely used for
surge control.
Pressure transmitters- Acceptable to use
smarts.
Temperature transmitters- Acceptable to use
smarts.
Avoid Honeywell Smarts
Control Valve
Typically actuated with pneumatics.
Some axials may be hydraulic.
Size and Speed are the two most critical
factors.
Linear Valves are preferred. Others can
be characterized.
Valve Actuation
Piping/Tubing for pneumatic actuator and volume booster.
SV
1:1
Out
Supply
In
Air
Supply
SV
I/P
Control Features
Proportional Function
Closed
0%
rPROPTM
Open
100%
rSUCLN
Pdischarge
Psuction
rSULIN
7
r MAR
0
h orifice
P suction
Control Setpoint
Current Operating Point
PD/PS
Hover Setting