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ENGINEERING
YPFB
CUSTOMER
PROJECT NAME
DRIVER
M100 CS
EQUIPMENT
C452
LOCATION
Tarija, Bolivia
REV
A
B
DESCRIPTION
DATE
30 Apr 12
20 Aug 12
Initial Submittal
Approved for construction
APPROVED
DRAWING NO.
PROJECT MANAGER
F. LOPEZ
DESIGN
J.SANCHEZ
CHECK
G. MENDEZ
ERCC
3N041 - 149653
"THIS COPYRIGHTED WORK AND THE INFORMATION HEREIN IS PROPRIETARY TO
CATERPILLAR INC., SOLAR TURBINES INCORPORATED, AND/OR SUBSIDIARIES OF
EITHER. WITHOUT EXPRESS WRITTEN PERMISSION FROM CATERPILLAR INC. OR
SOLAR TURBINES INCORPORATED. ANY COPYING, DISCLOSURE, OR USE EXCEPT
THAT FOR WHICH IT IS LOANED, IS PROHIBITED."
REV
B
SHEET
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TABLE OF CONTENTS
INTRODUCTION ..........................................................................................................................................................3
Document Purpose & Scope ...................................................................................................................................3
General Design Notes .............................................................................................................................................3
Project Specific Notes..............................................................................................................................................4
Information and Data Requirements........................................................................................................................4
RECYCLE SYSTEM .....................................................................................................................................................5
ANTI-SURGE VALVE...................................................................................................................................................6
Anti-Surge Valve Sizing Information........................................................................................................................6
Anti-Surge Valve Assembly .....................................................................................................................................8
Valve Schematic (Globe)....................................................................................................................................8
Recommended Accessories ....................................................................................................................................9
Anti-Surge Valve Evaluation ..................................................................................................................................10
Fast Stop Analysis .................................................................................................................................................11
System Volumes...............................................................................................................................................11
Anti-Surge Valve...............................................................................................................................................11
Fast Stop Valve ................................................................................................................................................11
Valve Performance ...........................................................................................................................................12
Deceleration Rate.............................................................................................................................................13
Head and Flow vs Time....................................................................................................................................14
Anti-Surge Control System ......................................................................................................................................15
Anti-Surge System Software Constants ................................................................................................................15
Flow Measuring Element..........................................................................................................................................17
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INTRODUCTION
Document Purpose & Scope
The purpose of this document is to define the recommended anti-surge valve(s) and related accessories, and
components necessary for effective operation of the anti-surge control system to avoid surge during all phases of
compressor operation. This includes valve sizing data, criteria, accessories, performance evaluation and fast stop
analysis, transmitter ranges, and flow element data. This also includes the constant values that are required to
program the anti-surge control system software.
This document applies on all compressor packages that utilize Solar Turbines proprietary compressor anti-surge
control system.
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Description
Process P&ID ( TJ-E144-IC-00-03-01 de 04)
Suction Pipe Inside Diameter (ID)
Action By
EPC/Customer
EPC/Customer
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Status
Closed,
Open
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RECYCLE SYSTEM
10
Suction Volume
E
Discharge Volume
FAST STOP
(FO)
ANTI-SURGE
(FO)
FT
S
V
PT
TT
Mars 100
LV
TT
Discharge
Volume
PT
DV
C452
V
V
Suction
Volume
10
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ANTI-SURGE VALVE
Anti-Surge Valve Sizing Information
DESIGN ENGINEER:
Jose Sanchez
PROJECT DEFINITION NUMBER (PD): 2-3N041 REV AB
COMPRESSOR PERFORMANCE CURVE # P-34978
VALVE MAXIMUM FLOW COEFFICIENT (Cv):
508
DATE: 23-Apr-12
COMPRESSOR CONFIGURATION: HP Body
K50
K300
PCP
PCT
S.G.
1.283
1.214
680.9
383.2
0.6643
PSIA
R
1094.7
PSIA
120
500.00
600.00
0.50
0.40
X
0.30
(
P/P1)
0.20
0.10
0.00
0.00
100.00
200.00
300.00
400.00
700.00
MMSCFD
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PSIA
R
1094.7
PSIA
10%
TURNDOWN
RPM
MMSCFD
P1
P2
T1
D-P
K1
Z1
Power
PSIA
PSIA
F
PSID
N
Q
RPM
MMSCFD
P1
P2
T1
D-P
K1
Z1
Power
PSIA
PSIA
F
PSID
9,500
245.21
9,000
240.87
8,000
227.78
7,000
208.78
6,000
189.05
1091.11
555.23
120.00
535.88
1.26
0.86
9295.70
1091.33
590.76
120.00
500.57
1.26
0.86
8190.04
1091.85
664.04
120.00
427.81
1.26
0.86
6124.94
1092.43
739.14
120.00
353.29
1.26
0.86
4313.02
1092.93
814.27
120.00
278.66
1.26
0.86
2873.00
5,000
173.72
3,990
150.87
1093.27
887.13
120.00
206.14
1.26
0.86
1822.10
1093.67
954.83
120.00
138.84
1.26
0.86
1002.84
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6
3
COMM
N.O.
N.O.
FREE FLOW
7
C2
4-20 MA
CLOSED LIMIT SW.
OPEN LIMIT SW.
4-20 MA
AIRSET
35 - 50 PSIG
2
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Recommended Accessories
SOLAR TURBINES
REFERENCE
DRAWING NUMBER
CALL OUT
Note 1
N/A
Fisher 67CFR
N/A
Note 3
N/A
Fisher 289RC
1033516-1
Note 1
N/A
Needle Valve
ASCO V022A1
1041929
Check Valve
SS-CHSS-1/3
N/A
Headline, 360AFI70C
1043229-1
DESCRIPTION
VENDOR P/N
Electro-Pneumatic Positioner
Pressure Regulator
Three-Way 24 VDC Solenoid
Valve
Exhaust Booster
Position Transmitter
Coalescing Filter
NOTES:
1. Electro-Pneumatic Positioner - Smart Type Positioner with 4-20mA feedback position signal and open/closed limit
switches suggested.
2. Pressure Regulator, For larger actuators a larger capacity regulator may be required to achieve desired closing speeds
(Fisher 64R /1041930).
3. Three-Way 24 VDC Solenoid Valve - Explosion/Flame-proof with necessary certification and protection to meet specific
application requirements (BIFOLD Model FP06P, VERSA Model VSG-3321, or ASCO Series NF8327).
4. Exhaust Booster - For smaller actuators the 289RC may be too large (Cv=21). May use Humphrey QE4 or QE5.
5. Position Transmitter (required if not available with positioner in Note #1), 4-20 mA Proportional to 0-100%
Close with full open and full closed relay outputs.
6. For larger actuators a needle valve with greater free flowing capacity may be required to achieve desired closing
speeds.
7. Stainless steel check valve
8. High efficiency or equivalent coalescing filter
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Jose Sanchez
2-3N041
P-34978
23-Apr-12
Fisher
EWD/EWT
8X6
7
2
EQ%
508
Downstream of After-Cooler
REV AB
2.20
R
A
T
I
O
2.00
1.80
1.60
P
2
/
P
1
1.40
100%
70%
60%
1.20
1.00
0
2000
4000
6000
8000
10000
ACFM
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Anti-Surge Valve
The table below shows the Cv used in the model. This is the minimum required Cv to keep the unit from surging
during a fast stop shutdown. This valve is also used for surge protection during normal operation, and therefore
sized for optimum controllability at partial recycle condition.
EWD/EWT
Cv
508.0
ANSI 600
Xt
0.684
Valve Port Size
7
inches
Valve Characteristic Globe Eq%
Valve Body Size 8 X 6
inches
ED/ET
ANSI 600
Cv
863.0
Xt
0.827
Valve Port Size
8
inches
Valve Characteristic Globe Q. Open
Valve Body Size
8 inches
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Valve Performance
Valve performance is based on Solars required opening time as a result of the solenoid being deactivated as
follows:
Anti Surge Valve: The valve must reach 63.2% open in
Fast Stop Valve: The valve must reach 63.2% open in
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Deceleration Rate
The figure below illustrates the power turbine speed (NPT), which is also the compressor speed modeled
deceleration during the first two seconds of shutdown. During the first 0.3 seconds the power turbine decelerates
linearly with a deceleration rate of 5% speed per second. This is the amount of time it takes the flame to go out
once the fuel valve is commanded closed, and can vary between turbine models. After 0.3 seconds the power
turbine is expected to decrease speed by 30% in a second with a relationship inversely proportional to time.
Also shown in the figure is the anti-surge valve Cv(s) with respect to time as the valve opens.
100.00%
90.00%
80.00%
70.00%
60.00%
50.00%
40.00%
30.00%
20.00%
10.00%
0.00%
1000
900
800
700
600
500
400
300
200
100
0
0
0.5
1.5
Cv
%NPT
Compressor Deceleration
2.5
Time (sec)
NPT Deceleration Curve
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Surge
Flow (ACFM)
3500
Actual
3000
2500
2000
1500
1000
500
0
0
0.5
1.5
2.5
Time (sec)
25000
20000
Surge
Actual
15000
10000
5000
0
0
0.5
1.5
2.5
Time (sec)
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Mars 90
C452
P-34978
B factor 0.000000338
CONFIGURATION
BORE SIZE
PIPE I.D.
BETA RATIO
FLOW DESIGN HEAD
Specific Gravity
SPEC. HEAT RATIO (K1)
CPSR P1
CPSR P2
COMPRESSOR T1
COMPRESSOR T2
CPSR Z1
CPSR Z2
CRIT. PRESSURE
CRIT.TEMPERATURE
PAGE 1 OF 2
Rev AG
Jose Sanchez
YPFB
2-3N041
CAMPO
HP BODY
(INCHES)
(INCHES)
(INCHES H2O)
(psia)
(psia)
(F)
(F)
(psia)
(R)
#DIV/0!
200
0.6643
1.269
663.70
1094.7
90.00
163.9
0.8929
0.8986
680.90
383.2
KT_HPC_ASC_Fast_Kp
KT_HPC_ASC_Fast_Ki
KT_HPC_ASC_Slow_Gain_Kp
KT_HPC_ASC_Slow_Ki_Yn.Val[0]
KT_HPC_ASC_Slow_Ki_Yn.Val[1]
KT_HPC_ASC_KCL
KT_HPC_ASC_KDB
HPC_ASC_Flow_DP
Hp_Suc_Press
Hp_Dis_Press
KT_HPC_ASC_Surge_Line_ A_Coef
KT_HPC_ASC_Surge_Line_ B_Coef
KT_HPC_ASC_Surge_Line_ C_Coef
KT_HPC_ASC_Surge_Line_ D_Coef
KT_HPC_ASC_X_Max
KT_HPC_ASC_Y_Min
KT_HPC_ASC_Y_Max
KT_HPC_ASC_Surge_Pulse_ROC
KT_Npt_Min_At_Idle
KT_Npt_Min_At_On_Load
KT_HPC_ASV_Manual_Rate
TT4
4.00
75.00
0.40
20.00
75.00
10.0000
2.0000
200.00
See Hydros
See Hydros
2.1095E-05
-3.3096E-03
5.3062E-01
6.2493E+00
1.000000
17.407
0.80
327.80
44.00
42.00
2.00
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DATE
ENGINEER
CUSTOMER
PROJECT PD or SALES NO.
STATION NAME
CONFIGURATION
DATA
POINT
9500
9000
8000
7000
6000
5000
3990
FLOW
(ACFM)
3910.8
3588.6
2981.3
2423.8
1967.1
1639.2
1308.1
PAGE 2 OF 2
Rev AG
Jose Sanchez
YPFB
2-3N041
CAMPO
HP BODY
P1
(PSIA)
555.2
590.8
664.0
739.1
814.3
887.1
954.8
DATA
TABLE
FLOW
H(SURGE)
(MMSCFD)
(INCHES H2O)
224.8388
105.55
219.5173
95.14
204.9900
74.74
185.5052
55.70
165.8546
40.93
150.5747
31.34
129.3301
21.72
H(CONTROL)
(INCHES H2O)
130.31
117.46
92.27
68.76
50.53
38.69
26.82
Disch. T
(F)
196.2
186.3
167.7
150.9
135.6
122.1
110.7
10.0 % TURNDOWN
38340.14
200.00
692.00
See Hydros
See Hydros
See Hydros
(INCHES H2O)
(INCHES H2O)
(F)
(PSIG)
(PSIG)
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Mars 90
C452
P-34978
B factor 0.000000338
ORIFICE LOCATION
Suction to Eye
FLOWMETER CALCULATION
METHOD
Specific Gravity
SPEC. HEAT RATIO (K1)
CPSR P1
CPSR P2
COMPRESSOR T1
COMPRESSOR T2
CPSR Z1
CPSR Z2
CRIT. PRESSURE
CRIT.TEMPERATURE
DESIGN HEAD
MAX FLOW RANGE
PAGE 1 OF 1
Rev AG
Jose Sanchez
YPFB
2-3N041
CAMPO
B Factor:
3.38E-07
(psia)
(R)
0.66
1.27
663.70
1094.70
90.00
163.90
0.8929
0.8986
680.90
383.20
SPECIFIC GRAVITY
RATIO OF SPECIFIC HEAT (K=Cp/Cv)
COMPRESSOR SUCTION PRESSURE
COMPRESSOR DISCHARGE PRESSURE
COMPRESSOR SUCTION TEMPERATURE
COMPRESSOR DISCHARGE TEMPERATURE
SUCTION GAS COMPRESSIBILITY FACTOR
DISCHARGE GAS COMPRESSIBILITY FACTOR
GAS CRITICAL PRESSURE
GAS CRITICAL TEMPERATURE
(INCHES H2O)
(INCHES H2O)
200.000
692.000
(psia)
(psia)
(F)
(F)
DESIGN POINT
5566.77
MINIMUM FLOW
1308.10
FLOW
(MMSCFD)
382.57
135.79
655.44
FLOW
(LBS/MIN)
13496.57
4790.37
23123.23
C'
38340.14
39285.35
38659.60
FLOW
(acfm)
MAXIMUM FLOW
8179.10
260.44
21.72
655.60
PRESSURE at Flowmeter
(psia)
663.70
954.83
761.18
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