Final Direct Surge Control Report

& GMRC Project Plan

Increased Flexibility of Turbo-Compressors
in Natural Gas Transmission Through
Direct Surge Control
October 2001 - December 2004
Prepared by
Robert McKee
Shane Siebenaler
Danny Deffenbaugh
of
Southwest Research Institute

Project Identification

This DOE project was directed and funded by

DOEs Office of Fossil Energy, the

National Energy Technology Laboratory, and the
Strategic Center for Natural Gas and Oil, in the
Delivery Reliability Program, as part of the
Natural Gas Infrastructure Program.

The Co-funders are the Gas Machinery Research

Council and Siemens Energy and Automation
Other participants were Duke and El Paso
Energy and Solar Turbines.
Conducted by Southwest Research Institute

Centrifugal Compressor Operating Map

Compressor Curve Showing Surge Line and Operational Boundaries

MAX SPEED/ MAOP/ POWER LIMIT
SURGE LINE

Surge is a
potentially
damaging
instability.
Surge limits
low flow
operations.
Current
controls
results in
unnecessary
recycle flow.

1.28
Discharge Pressure Ratio

1.32

1 0 0 % RPM
9 5 % RPM
9 0 % RPM
8 5 % RPM
Surge Line
Surge Cont rol

1.24

STONEWALL
MINIMUM SPEED LIMIT

LIMIT

1.2
15

30

45
Inlet Volume Flow

60

Objectives

To develop an internal surge control

sensor and an associated surge control
system that will allow reduced surge
margins, increased range and flexibility of
operation, and safe minimization of the
energy and costs of avoiding surge in
pipeline centrifugal compressors.
To meet the needs of the natural gas
industry for improved surge control.

What happens before and during surge?

In some, but not all cases, surge is preceded by

unsteady pulsation and vibrations due to stall.
In other cases, there are no vibrations, pulsation,
or warnings and surge occurs suddenly.
Surge is a complete collapse of compressor flow
and results in gas travelling backwards through a
forward spinning impeller.
Surge is energetic and can cause damage to
thrust bearings, seals, impellers, etc.
A flow re-circulation occurs at the impeller inlet as
identified by previous GMRC research

Industry Specifications - General

The sensor is to be simple, rugged,

sensitive, cost effective, manufacturable,
installable, and able to detect the
nearness of surge in a useful manner.
The controller is to use the nearness to
surge signal and incorporate algorithms
to control the compressor in a flexible
manner, with a minimum safe surge
margin, and increased efficiency in
response to the operating requirements.

Design Process and Typical Drag Probe

Size probe for max
and min velocity &
force
Size bending beam
for support & strain
sensitivity
Predict & avoid vortex
& mech. natural
frequencies
Design probe holder
& wire way
Iterate on design
until all is OK

Flow Test Results for a Drag Probe

30

Flow Test of Long Probe in 1-3

Direction at 84 and 130 Degrees

Strain microinches

25
20

Base84

15

Repeat

10

Rep2 130

5
0
-5

100

200

300

400

500

600

Flow Rate ACFM

One Direction Flow at Two Temperatures

700

Flow Test Results as Force vs. Strain

30

Flow Test of Long Probe in 1-3

Direction at 84 and 130 Degrees

Strain microinches

25
20

Base 84

15

Repeat
10

Rep2 130

5
0
0

10

20

30

40

50

60

70

80

90

-5

Force (Calculated)

Flow calibrations are not necessary for every probe

A Finding from the Test Program

Direct Surge Control in the present

implementation with a probe at the impeller
inlet is applicable for modern 3D impellers and
not for older units with 2D impellers where the
blades are recessed from the inlet.
It is estimated that between 66 and 80 percent
of pipeline centrifugal compressors in use are of
the modern 3D design.

Laboratory Compressor Test at Low Speed

Axial & Tangential Strain with Scaled Flow
30

Second Lab Test 13,100 RPM

25

Strain Axial

20
15
10
5
0
2:26

2:34

2:41

2:48

2:55

3:02

3:10

-5
-10

Time
AxialStr

ScFlow

TangSt4

3:17

3:24

Laboratory Compressor Test at High Speed

Axial & Tangential Strain with Scaled Flow
30

25

Second Lab Test 19,200 RPM

20

15

Strain

10

10:45

10:46

10:47

10:48

10:48

-5

-1 0

-1 5

-2 0

Time During Test

AxialStr

ScFlow

TangSt4

10:49

10:50

Increased Range on the Laboratory Unit

Map with Use of Direct Surge Detection
10000
9000
8000
LowS p

Head ft-lbf/lbm

7000

Me dS p
De signS p

6000

HighS p
13,100

5000

16,020
19,240

4000

21,865
S urge Line

3000
2000
1000
0
0

500

1000

1500

2000

2500

3000

Inlet Flow Q

Turndown by Surge Line = 47%, by Surge Probe = 68%

Plot of Axial Strain Changes as a Function

of Flow Coefficient for Laboratory Tests
30
25
20

Axial Strain

15
10
5
0
-5

0.2

0.4

0.6

0.8

1.2

1.4

-10
-15

Strain vs. Flow Coefficient

-20
-25

Flow Coefficient
13.1K

16.0K

19.2K

1.6

Diagram of Flow Vectors as Surge is

Approached with a Drag Probe Location

Requirements for Direct Surge Detection

The route of the wire within and leaving

the compressor must be protected and
secure. Solid core wires in a quality
compression fitting are needed.
The output of the strain gauge bridge from
the probe must be stable and repeatable.
The strain gauge circuit should
automatically balance when a compressor
is shut down for a period of time.

Long-Term Stability of Strain Signals

with Operational Changes
2

Axial & Tang Strain Volts

1.5

0.5
Axia l
Ta nge nt
Flow

0
8/ 10/ 04 0:00

8/ 12/ 04 0:00

8/ 14/ 04 0:00

8/ 16/ 04 0:00

8/ 18/ 04 0:00

-0.5

-1

-1.5

Tim e During Monitoring

8/ 20/ 04 0:00

8/ 22/ 04 0:00

8/ 24/ 04 0:00

Field Test B - Axial and Tangential

Strain at Low Pressure & Low Speed
80

Test B, approaching surge at low pressure & low speed

Strains & FlowRelated

60

40

Axial
Tang

20

Flow

0
14:05

14:12

14:19

14:26

-20

-40

Time

14:34

14:41

14:48

Field Test C - Axial and Tangential

Strain at Low Pressure & Low Speed
80

Test C, approaching surge at low pressure & low speed

60

Strains & Flow Related

40

Axial
20

Tang
Flow

0
16:26

16:33

16:40

16:48

16:55

-20

-40

Time

17:02

17:09

17:16

Field Test E - Axial and Tangential

Strain at Low Pressure & Low Speed
80

Approach Into Surge at Low Pressure (200 psia) and Low Speed
60

Surge Parameters

40

Flow DP
Axial St

20

Tangent St

-20

-40
15:00

15:07

15:14

15:21

15:28
Time

15:36

15:43

15:50

Plot of Strain Difference as a Function of

Nominal Flow for Lab and Field Tests
40

30

20

Strain Diff

10

13,100RPM

0
2

10

12

14

16

16,000RPM
19,200RPM
NG Test B

-10

NG Test C
NG Test E

-20

-30

-40

-50
Flow

Axial and Tangential Strain Changes During a

Rapid Approach to Surge
30

Rapid Approach to Surge July 29, 2004

Variable

20

Axial
Tangent
Flow Scal

10

0
14:57

14:58

14:59

15:00

-10
Time

15:00

15:01

Axial and Tangential Strain During a Moderate

Pressure Approach to Surge
400

350

300

250

Axial Strain

200

Scaled Flow Rate

150

100

Axial Strain
50

Tangential Strain

-50

-100
13:50

13:52

13:53

13:54
Time

13:56

13:57

Axial and Tangential Strain During a High

Pressure High Speed Approach to Surge
300

250

Scaled Flow Rate

Strains and Flow

200

150

100

Axial Strain
50

0
16:06

16:07

16:09

16:10

16:12

16:13

16:14

-50

Tangential Strain
-100

Time During High Speed Test

16:16

16:17

16:19

16:20

Trends is Strain as the Field

Compressor Approached Surge
100

80

60

40

Strains

20
Axia l S t

0
100

150

200

250

-20

-40

-60

Appro xim a te Vo lum e tric F lo w R a te s

-80

-100

Flow DP

300

350

400

Ta nge nt S t

Field Compressor Performance Map

with Direct Surge Control
1.16

1.15

1.14

1.13

Pressure Ratio

16K
17K

1.12

18K
19K
1.11

20K
Surge Limit
Data Points

1.1

SurgeControl
New Control

1.09

Data Points
1.08

1.07

1.06
0

200

400

600

800

1000

1200

Inlet Flow ACFM\

1400

1600

1800

2000

CFD Modeling of Impeller Inlet Flows

To determine if CFD analysis can be used

to predict re-circulation zones.
To explain the differences between 2D and
3D impeller results.
Undertaken as a result of improved
modeling capability and better
understanding of geometric and
operational flow effects on re-circulation.

Cross-Section of the Modeled

Impeller Inlet Flow Path

CFD Models of 3D and 2D Impellers

CFD Results at Design Flow (1037 ACFM)

CFD Results at Surge Line (685 ACFM)

CFD Results at Near Actual Surge

CFD Results for 2D Impeller at Low Flow

Steps for Implementation of Direct

Surge Control - Part 1
1. Determine that the compressor is a modern,
single-stage machine with a 3D impeller.
2. Calculate the flow velocity and gas density
ranges at the impeller inlet (area required).
3. Size the drag body (start of an iteration).
4. Calculate the forces acting on the drag body
for the full range of flows. (CD = 0.5)

5. Determine the probes bending beam width

(square) and length for strength and
sensitivity.

Steps for Implementation of Direct

Surge Control - Part 2
6. Calculate the strain expected from gauges due to
maximum and near surge flows.
7. Calculate the mechanical natural and vortex
shedding frequencies. Check that these do not
coincide with compressor or other frequencies.
8. Design the probe holder to secure the probe in
the correct location at the impeller inlet. Check
the location relative to the expected re-circulation
using a CFD analysis.
9. Check that the final design is properly sized,
rugged (strong), sensitive, and vibration free. If it
is not, return to Step 3 to adjust variables.

A Drag Probe Resulting from Design

Steps and Ready for Installation

Steps for Implementation of Direct

Surge Control - Part 3
10. Arrange for the signal wires to pass through
internal dividers, in conduits, and a pressure
fitting to the outside of the compressor case.
11. Connect the probe wires to an amplifier and a
surge controller to monitor axial and tangential
strain signals, filter (avg.), and process the
strain indications of approaching surge.
12. Tune the balance, gain, filter, and algorithms to
control the compressor to minimize recycle flow
and achieve stable, wider, and efficient
operation.

The Surge Controller should;

Accommodate two half bridge amplifiers for the strain

signals with 5 volt outputs.
Sample data at 80 to 240 Hz to follow flow changes
but not high frequency noise or disturbances.
Satisfy Class I, Div. 2, Group D in a NEMA panel.
Monitor compressor speed, pressure, temperature, &
flow as a convenience for display and recording.
Filter by short averaging and process the strain
signals through a selected algorithm such as the
difference of axial and tangential strain and provide
an output when the signal drops below a set limit.

Conclusions

Surge is a potentially damaging flow instability that

limits the low-flow operation of centrifugal
compressors and is usually avoided by wasteful and
inefficient recycling of flow.
Early GMRC research identified flow recirculation
along the outer wall of a compressor inlet as a
surge precursor and a potential control signal that
can be sensed with a drag type probe.
A step-by-step design procedure for direct surge
control drag probes and controllers is defined by
this research and given in the report.

Conclusions - continued a

Surge probes designed per the procedures and

fabricated per specifications need to be checked
functionally but not calibrated or flow tested.
Test results show that for sensitive near surge
detection, with the current methods the impellers
must be a modern 3D design.
Flow changes along the outer wall of a centrifugal
impeller inlet do produce re-circulating flows,
which cause axial and tangential strain changes on
a drag probe that indicate the approach of surge.

Conclusions continued b

A control algorithm based on comparing the

difference between the axial and tangential strains
is less sensitive in installation details and can be
used as a surge control method.
Operational tests show an increase in low flow
range of up to 25 percent for compressors with
direct surge control. A potential savings of 10 to 24
MSCF or $50 to $120 per hour of operation is
expected. The possible industry wide saving is $50
to $85 million per year.
CFD modeling can be used to check the location of
a direct surge control probe in the re-circulation.

Demonstration and Commercialization

of Direct Surge Control

The direct surge control system is successful as a

prototype but needs to be demonstrated as a
commercial product in a pipeline compressor.
SwRI, along with the GMRC advisors, will identify
and interview a number of potential application
contractors and will help to select one.
The interest of all parties, DOE, Siemens Energy &
Automation, Solar Turbines, others, and particularly
the user companies, will be considered.
A demonstration project led by an application
contractor will install a system in a members
pipeline compressor & operate it for all to see.

Tasks in the Demonstration and

Commercialization Project

Task A. Identify and select an application

contractor or contractor alliance.
Task B. Transfer the technology for design
and installation of direct surge probes and
controller interfaces to the application
contactor.
Task C. Conduct a field demonstration of
the commercial direct surge control system
led by the contractor with oversight from
SwRI & GMRC.

Companies to Consider as Potential

Application Contractors

Demag Delaval A compressor division of Siemens.

Petrotech Inc. An experienced control system supplier.
Alotronic - An experienced control system supplier.
Cooper Compressor A manufacturer of integral geared
compressors.
Solar Turbines A manufacturer of pipeline compressors.
Metrix An instrument manufacturer.
Compressor Controls Corp. A controls supplier.
Rosemount An instrument company.
Many Others

SwRIs Actions at the Start of the Project

Contact each company to discuss the technology

and needs and to determine who is interested
With the oversight committee, develop a selection
criteria and what we need from the contractor.
Request a proposal from the interested parties.
Evaluate the proposal and with industry select one.
Start the transfer of technology to the contractor.
Plan for and monitor the demonstration test.
Report to the GMRC at all stages in the project and
on the final report.