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LP Inlet

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Blade

Hub

Eye
Bore

Cover

Exit

Suction
Pressure

Discharge
Pressure

Suction
Pressure

Discharge
Pressure

Normal Pressure Profile

Suction
Pressure

Discharge
Pressure

Surge Pressure Profile

Balance
Piston

Suction
Pressure

Discharge
Pressure

P (1/2 U22)
gas density
U =Impeller Tip Speed
Frequency = 1/2 to 2 Hz

Pressure Pulsations Associated with Surge

Stall Cells

Incipient Surge

P = 0.05 (1/2 U22)

gas density
U =Impeller Tip Speed
Frequency = 0.3N to 0.6N

Pressure Pulsations Associated with Incipient Surge

Surge Control Basics

Opening the Recycle Valve accomplishes two things
which helps the compressor avoid surge:

Recirculates flow back to the compressor

inlet
Relieves resistance in compressor discharge
network, allowing flow to increase

Surge Control Application

The following factors make surge control a unique
and difficult control application.

Accurately defining the compressor operating point

Locating and defining the surge limit of the compressor
Acceleration of surge due to compressor curve shape near surge
Interaction with other control loops
Special requirements for load sharing between multiple
compressors

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

The Universal Surge Curve

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.

Increasing Surge Margin

Hp

Surge Limit Line

Auto Increase of Surge Margin

Open Loop Response or High Gain
Surge Control Line
New Surge Control Line
1

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.

Control Valve (cont.)

Size- Valve size should be checked at all
operating conditions along the surge line
Speed: Stroking speed of 1 sec. for 6" and
smaller valves. Stroking speed of 2 sec. for
8" and larger valves. Normally requires a
volume booster in air supply

Valve Actuation
Piping/Tubing for pneumatic actuator and volume booster.

Large Cv 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

Setpoint Hover Feature

Control Line
Surge Line
Pressure Ratio

Control Setpoint
Current Operating Point

PD/PS

Hover Setting

Suction Flow (hx)