SIEMENS
AD353-121
Procidia™ Control Solutions
Compressor Surge Control
This application data sheet describes implementing
compressor surge control in a Siemens 353
controller 1.
Centrifugal and axial compressors cannot be allowed
to operate in the surge area, see Figure 1. Operating
in the surge area will result in unstable compressor
operation, exposing the machine to destructive stress
and vibration. If the flow requirements of the process
are such that the compressor operates in the surge
area, a portion of the discharge flow must be vented,
or recycled to the inlet, to keep the flow through the
machine below the surge area.
Figure 1 “h” vs. ∆P Surge Control Line
The performance map of a compressor, typically
supplied by the compressor manufacturer, is a plot of
head vs. capacity over the full range of operating
conditions. The map also shows the location of the
surge line, which separates the region of safe
operation from the surge area.
Surge control generally requires a method of inferring
the point at which the compressor is operating
relative to the surge line using variables that
1
See Application Support at the back of this publication for
a list of controllers.
APPLICATION DATA
Rev 1
October 2005
represent compressor head and capacity. The most
common method of surge control uses compressor
∆P to represent head and the differential pressure
across an inlet orifice (called “h”) to represent
capacity.
It is important to realize that the “h vs. ∆P” method of
surge control uses the “raw” differential (h), rather
than a flow signal (Q) that has been compensated for
pressure and temperature and characterized with a
square root extractor. When h is used, there is a
fairly linear relationship between h and ∆P at the
surge line, and the relationship is nearly immune to
changes in compressor inlet conditions: such as
temperature, pressure, and gas composition.
Figure 1 shows a plot of h vs. ∆P at the surge limit for
various operating capacities. These points can be
determined by empirical testing of the compressor or
by analyzing the compressor performance map.
Depending on the type of compressor and the
method of manipulating its capacity, each point on
the surge line represents a different speed, inlet
guide vane position, or inlet pressure.
In the case of a variable speed compressor, for any
given speed, there is a maximum ∆P the compressor
can generate. If a decrease in flow demand causes
the pressure in the discharge piping to exceed the
value that can be supported by the maximum
compressor ∆P, a temporary flow reversal will occur
to relieve the excess pressure. After the flow
reversal relieves the downstream pressure, the
compressor will restore flow in the forward direction.
However, if no action is taken to increase the flow
demand, these flow reversals will continue to occur.
This unstable operation is called “surge” and it can
cause serious damage to the compressor.
To prevent surge, it is necessary to keep the
compressor operating to the right of the surge line
shown in Figure 1. The surge control strategy shown
in Figure 2 uses a characterizer to plot the surge line
as a function of the inlet orifice differential (h). After
applying a bias to the surge line to provide a margin
AD353-121
of safety, the resultant control line represents the
surge controller setpoint. If a decrease in flow
demand drives the compressor ∆P above the
setpoint, the surge controller opens the recycle valve
to create an artificial flow demand that maintains safe
operation.
.
SP
Bias PID
PV
Surge Line f(x)
L H
DPT DPT
Compressor
Inlet Flow
Inlet
Orifice
"h"
Turbine
Compressor
Figure 2 Compressor Surge Control Strategy
Design
The configuration for the surge controller is shown in
Figure 3. Characterizer function block CHR1 and
Bias function block BIAS provide the control setpoint,
which varies with the operation of the compressor.
Under normal operating conditions, compressor ∆P
will remain below the setpoint, and the PID controller
function block will “windup” to hold the recycle valve
closed. Should the compressor approach a surge
condition, the setpoint will tend to decrease and the
∆P will tend to increase. Whenever the ∆P crosses
the setpoint, the controller will open the recycle valve
as much as required to maintain the ∆P at the surge
control setpoint.
The batch switch (BATSW) is an anti-reset windup
device that manipulates the reset feedback signal
when controller output is off scale. This helps to
minimize overshoot when ∆P approaches the control
line.
The Auto/Manual function block A/M, in combination
with low signal selector SEL1, provides conditional
manual operation. The operator can open the
recycle valve further but cannot close the recycle
valve any further than the surge controller permits.
2
The low signal selector allows the controller to
override the manual value if necessary to open the
valve.
For “fail safe” operation, the recycle valve should be
an “air-to-close” valve (fails open). Therefore, the
CO
< Conditional Manual
.
Lo Select
Recycle
Valve
Fail Open
P
Discharge Flow
.
valve display signal is inverted in Gain & Bias
function block GB1 to correspond with the CLOSE
and OPEN markings on the faceplate of the 353.
Likewise, the adjusting knob is configured to operate
counterclockwise during manual operation.
The Rate Limiter function block RLM1 is configured
to slow the closing of the recycle valve. This allows
the surge controller to be tuned for faster response
than would be possible without this limit. The RLM
should be set so as not to impede the opening of the
recycle valve.
The compressor status signal (Run/Shutdown) is
used to force the recycle valve fully open whenever
the compressor is shutdown. This prevents surge on
a compressor “trip” and also holds the valve in a fully
open position for startup.
Applications
This surge control strategy is applicable to both
variable speed and constant speed compressors. It
is also applicable to axial and centrifugal
compressors.
 AD353-121

Figure 3 Surge Control Configuration (CF353-121)

Application Support Software. Those with CF353 in parenthesis in the

Other Application Data sheets in this series can be
found at the Siemens public Internet site. Detailed
information about function blocks mentioned in this
publication can be found in the User’s Manual for
each controller.
Siemens sales representatives in the United States
and globally are available to provide additional
application support.
Figure title are available on the Siemens public
Internet site.
The configuration(s) in this publication can be created
in Model 353 Process Automation Controller, Model
353R Rack Mount Process Automation Controller
(i|pac™ Internet Control System), Model 352Plus™
Single-Loop Digital Controller, Model 354 Universal
Control Station, and Model 354N Universal Loop
Controller (model series 354 discontinued).

The configuration(s) shown in this publication were

created in Siemens i|config™ Graphical Configuration

Procidia, i|pac, i|config, and 352Plus are trademarks of Siemens Energy & Automation, Inc. Other trademarks are the property of their
respective owners. All product designations may be trademarks or product names of Siemens Energy & Automation, Inc. or other supplier
companies whose use by third parties for their own purposes could violate the rights of the owners.

Siemens Energy & Automation, Inc. assumes no liability for errors or omissions in this document or for the application and use of information
in this document. The information herein is subject to change without notice.

Siemens Energy & Automation, Inc. is not responsible for changes to product functionality after the publication of this document. Customers
are urged to consult with a Siemens Energy & Automation, Inc. sales representative to confirm the applicability of the information in this
document to the product they purchased.

Control circuits are provided only to assist customers in developing individual applications. Before implementing any control circuit, it should
be thoroughly tested under all process conditions.

Copyright © 2005, Siemens Energy & Automation, Inc.