2/26/2019 Antisurge Control : Evalulating the Surge Line without Surge Testing – RMoore Controls

Antisurge Control : Evalulating the Surge Line

The Surge Line used for anti-surge control can be evaluated before the
compressor is commissioned.

The majority of anti-surge controllers are patterned after US Patent 5,195,875. That
patent makes the simplifying assumptions necessary to eliminate the use of gas
properties.  The unfortunate consequence of eliminating gas properties is the
inability to estimate and control volumetric flow rate.

These anti-surge controllers use a Surge Line rather than volumetric flow rate to
determine distance from surge.  The location and shape of the Surge Line is specified
by entering X-axis and Y-axis values.  Using correct X/Y values is critical to the
effectiveness of the anti-surge controller.  Incorrect values can lead to surge or
excessive false load.

There are two methods for determining Surge Line X/Y parameter values. The
conventional approach is to conduct surge test while recording the measurements
needed to estimate X/Y values.  A second, less exciting approach, is to calculate
parameter values directly from the performance curves without the need for surge
testing.

The two methods are illustrated below. Note that the specific calculations required
depend on the specific definitions of X and Y used by the anti-surge controller.

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SURGE TEST METHOD – Illustrated

The surge test involves intentionally surging the  compressor while recording the
values of Ps (suction pressure), h (inlet flow meter differential pressure output), and
Pd (discharge pressure).  The value of these measurements that existed immediately
prior to surge are used to calculation the Surge Line X/Y values.

Constant speed compressors need only one X/Y pair to specify the surge
line. Variable speed compressors require several X/Y pairs determined by surge
testing at several speeds.

Entering these values into the corresponding Anti-surge controller parameters,

CALCULATION METHOD – Illustrated

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If the gas composition is known, the Surge Line parameters can be calculated
directly from the performance curves.

Step 1: Note the value of Hp, Q, and Efficiency at surge for each curve provided.

Step 2: Calculate gas properties

Step 3: Calculate the Surge Line X/Y parameter values

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In this example the meter constant is calculated to indicate volumetric flow rate

OTHER DEFINITIONS for Surge Line

The specific calculations needed depend on the X-axis and Y-axis used to define the
Surge Line.   Shown below are several axis used and how each can be calculated off-
line.

Y-AXIS

X-AXIS  where the flow meter indicates volumetric flow rate

X-AXIS  where the flow meter indicates mass flow rate

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With the following Variable Definitions

Question & Answers

Will the two methods yield the same results?

Yes, the two methods should result in similar values

What benefit is there in using both methods if they give the same result?

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First, it is an indication that the measurements are consistent with the performance
curves. Second, it should give confidence in the ability to use the calculation to check
parameter values when operating conditions change.

What if the results differ?

That indicates that something is wrong somewhere and worth sorting out. The first
time it happens indicates the calculation method isn’t setup correctly.  If it happens
after the calculation has been validated, then the problem may be elsewhere.

What if gas composition is constant but unknown?

The value of mw/Z needed to calculate parameter values can be estimated from the
surge test.  Having that will enable use of the calculation later.

What if gas composition is unknown and variable?

That is a bad combination for compressors. The calculation method would enable
you to calculation and set parameter values based on the worst case gas
composition.

Would the calculation method be useful for new compressors?

New compressor installation may be the best opportunity to prepare the calculation.
Parameter values can be calculated as soon as the performance curves and estimate
gas composition is available. If you’ve set up the calculation correctly, the results
should match the surge test and then you’ll have a validated calculation that will be
useful if operating conditions change and there are questions about the anti-surge
controller.

Can the calculation method replace surge tests?

The calculation method is intended to augment rather than replace surge testing at
least until the calculations used are validated. Parameter values should only be
modified by someone that is very experienced with your Anti-surge Control system.

UPDATE :  An application that does these calculations for you will be developed and
available for downloading from SimsReady.com.  Please leave a comment listing
components you would like added to the list below.

Ammonia
Butane
Ethane

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Ethylene
Hydrogen
Methane
Nitrogen
Oxygen
Propane
Propylene
Water

Author :  Robert Moore

© 2016 RMoore Controls, LLC

RMooreControls.com / SimsReady.com

 August 18, 2015  rmoore  Uncategorized

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