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Volute
t Inle LP
lute Vo
HP First Impeller
LP First Impeller
HP
Di sc ha rg e
LP Discharge
HP Inlet
LP Inlet
H P Fi rs t
LP La st W he el Fi rs tW he el
LP
Sh Be af ar t in g Jo ur na l
st ru Th
sk Di
W he el W he el
H P La st
Co up lin g H ub
Blade
Hub
Eye Bore
Cover
Exit
Suction Pressure
Discharge Pressure
Suction Pressure
Discharge Pressure
Suction Pressure
Discharge Pressure
Balance Piston
Suction Pressure
Discharge Pressure
Stall Cells
Incipient Surge
P = 0.05 (1/2 U22) = gas density U =Impeller Tip Speed Frequency = 0.3N to 0.6N
Recirculates flow back to the compressor inlet Relieves resistance in compressor discharge network, allowing flow to increase
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
[( )
P2 ( P1
k-1 k
k ZRT1 -1 (k-1) MW
h Z R T1 Q1 = MW P 1
[( )
P2 ( P1
k-1 k
k ZRT1 -1 (k-1) MW
h Z R T1 Q1 = MW P 1
[( )
Q1
2
P2 ( P1 =
k-1 k
k ZRT1 -1 ( k-1) MW
h Z R T1 MW P1
[( )
k -1 ( k-1) h P1
( )
P2 P1 - 1
h P1
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.
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.
SIC
ST
FT PT PT TT TT FT
UIC
FY
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 characteristicsunrecoverable pressure loss- less costly Annubar - widely used, least costly, least desirable - poor signal-to-noise 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.
Valve Actuation
Piping/Tubing for pneumatic actuator and volume booster.
SV
Out Supply In
Air Supply
SV
I/P
Control Features
Proportional Function
Closed 0% rPROPTM 100%
Open
rSUCLN
Pdischarge Psuction
rSULIN 7 r MAR 0
h orifice P suction
PD/PS
Hover Setting