Axial

Compressor
Control
Technical Product Guide Single Stage

Inter-cooled

Refrigeration

1
 Compressor Control
Technical Product Guide

COPYRIGHT
by Triconex Systems, Inc.
La Marque, Texas, U.S.A.

All rights reserved. No part of this work covered by the copyright hereon may be
reproduced or copied in any form or by any means—graphic, electronic, or
mechanical—without first receiving the written permission of
Triconex Systems, Inc., La Marque, Texas, U.S.A.

Printed in U.S.A.
1999

NOTE: Triconex Systems, Inc. reserves the right to make improvements in the design, construction,
and appearance of its products without prior notice.

3
 Table of Contents
What is Surge? ....................................................................................... 7
Performance Curves ............................................................................. 7
µ Curve .................................................................................................. 7
Compressor Map ................................................................................... 8
A Universal Surge Curve .................................................................. 13
Determining HP/A02 .................................................................................................................................. 13
Determining (Q/A0)2 .................................................................................................................................. 14
Plotting the Surge Line ...................................................................... 14
Summary of Features ......................................................................... 21
Choice of Pressure Rise or Pressure Ratio Algorithms ............... 22
Safety Margin Recalibration ............................................................ 22
Setpoint Hover .................................................................................... 22
Dynamic Adaptive TuningTM ...................................................................................................... 23
Non-symmetrical Valve Response .................................................. 23
Purge and Start-up Logic................................................................... 24
Manual Control ................................................................................... 24
Proportional Function ........................................................................ 24
Valve Prep ............................................................................................ 25
Dump Output ...................................................................................... 25
Valve Linearization and Reversal ................................................... 25
Compensated Recycle Temperature Controller ........................... 25
Process Pressure Control ................................................................... 29

5
 Compressor Surge
This document describes the in work done per unit mass of the A0; that is, for a given compressor
implementation of a centrifugal fluid. Foot pounds per pound (ft-lbf/ speed, there is only one valid set of
lb) and kilojoules per kilogram (kj/kg) gas properties (MW, Z and k) and
compressor surge control in the
are the common English and Metric suction temperature (Ts). If the gas
TRISENTM digital governor or units. For a given impeller design, composition and/or suction tempera-
control system. diameter, and rotational speed, the ture is variable, multiple curves must
amount of work energy expended is be provided to show the performance
What is Surge? dependent on the volume flow at the of the stage. See the previous figure.
suction.
Surge occurs in a turbo compressor
when discharge head cannot be The polytropic head developed for a
sustained at the available suction flow. given fluid (gas) and inlet conditions
µ Curve is proportional to the pressure
Surge occurs at specific combinations
of head and flow, as defined by the coefficient "µ," as defined by equation
Compressor manufacturers use "µ"
compressor manufacturer's perfor- (1).
curves to define the performance of
mance curves. One or more of the
following can result from surge:
1.4
• Unstable operation
• Partial or total flow reversal
1.2
through the compressor 2 1
3 µ
• Disrupted process
1.0 100
• Mechanical damage to the
compressor
.80 80
Pressure
Surge is usually accompanied by the coefficient ηp Polytropic
Efficiency
following: " µ" .60 60
2 3 η
p
1 2 3
• Increase in discharge .40 40
1
temperature
• Reduction in discharge .20 20
pressure
• Increase in vibration
0 10 20 30 40 50 60 70 80
• Sharp rise in inlet tempera-
ture % Q / N

Figure 1- µ”
Impeller “µ
Performance Curves
A turbo compressor imparts energy to individual impeller stages. A typical
the gas by accelerating it through a "µ" curve is shown in Figure 1. Equation (1)
rotating impeller to increase its U2
velocity and pressure. This kinetic "µ" indicates the polytropic head Hp = µ ⋅
energy is then converted to a higher provided by the stage for a given g
pressure in a diffuser. The amount of volume flow at the suction. Each where:
energy imparted to the gas is defined "µ" curve is specific for a given N/

7
Compressor Surge
Hp = Polytropic head
µ = Pressure coefficient of
the impeller for the
specific gas
U = Impeller peripheral
velocity ft/sec
g = Gravitational constant
32.17 ft/sec2
In the Figure 1 example, the two sets
of three curves indicate the perfor-
mance of the impeller for three
different gas conditions. The term
“A0” is used to define the sonic
velocity of the gas at the suction
conditions and is determined by
equation (2).
Equation (2)
1545 ⋅ k ⋅ Z s ⋅ Ts ⋅ g
A0 =
MW
where:
A0 = Sonic velocity of the
gas at the inlet condi-
tions (ft/sec)
k = Ratio of specific heats
Cp/Cv
Zs = Compressibility factor
Ts = Inlet temperature °R
g = Gravitational Con-
stant, 32.17 ft/sec2
The upper set of curves, in conjunc-
tion with equation (1), relate Hp to Q/
N (inlet flow (acfm)/speed (RPM)).
The lower curves relate Q/N to
polytropic efficiency hp. Curves 1
through 3 show performance for
heavy, medium, and light gases,
respectively. The left extreme of each
line indicates the surge point.
Compressor Map
While the "µ" curves are a tool used
in the design stage, the final com-
pressor characteristic is defined by a
performance curve, or compressor
map. This is a series of impeller "µ"
curves combined as a multistage
compressor. An example is shown in
the next figure.
NOTE: The Hp versus Q curve is
good for one set of gas conditions
(A0) only.
80
Surge Line
60
Hp
Polytropic
Head 40
(1000 Ft lbf/lb)
20
0
0 500
Q - Inlet Flow (acfm)
Figure 2
Compressor Performance Map
The Surge Line is not linear with
respect to flow. In a low head, single
impeller machine, compressing a light
gas such as air, the surge line tends to
follow the fan law. This law states the
following:
• Capacity is proportional to
rotating speed.
• Head is proportional to the
inlet flow squared.
• Power required is propor-
tional to the speed, cubed.
Multi-impeller high head machines
can have surge lines which have
8
significant deviations from this ideal
curve. As the speed increases, surge
moves to later impeller stages, due to
volume reduction by the initial stages,
and consequent lower suction volume
flow available to the later impeller
inlets. The next figure is an example.
Compressor performance maps are
presented in various forms. Most
provide a basic performance plot, as
shown in Figure 3, but with additional
curves, relating inlet temperature,
molecular weight, pressure ratio,
suction pressure, and driver horse-
105%
100%
90%
Constant
Speed
80% Lines
1000 1500 2000 2500
power. Design gas conditions, such as
compressibility factor (Z), and specific
heat (k) are usually noted. If Ts and/or
MW are variable, several surge curves
may be plotted, showing surge limits
for different gas compositions and
suction conditions.
From a surge control standpoint, the
challenge is to keep the compressor
out of surge without wasting energy
on excessive recycling. This requires
that the surge point be precisely
computed from measurable, compres-
 Compressor Surge
sor-operating conditions. This goal
will be addressed in the construction
of the Surge Line. First, we will
describe how the TRISENTM system
uses the recycle valve to avoid surge.

80

60
Surge Line
Hp
105%
Polytropic Speed
Head 40 100%
(1000 Ft lbf/lb) Speed
90%
Speed
20 80%
Speed

0
0 500 1000 1500 2000 2500
Q - Inlet Flow (acfm)

Figure 3
Multi-Impeller, High Head Performance Curve

9
Compressor Surge

NOTES
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10

In the gas compressor section
(Figure 4), surge can be avoided by
recycling a controlled portion of the
discharge flow back to the suction
through a recycle valve. Recycling
raises the suction pressure and
lowers the discharge pressure, which
increases flow and moves the
operation away from surge. Raising
speed also moves the compressor
away from surge. This is a tempo-
rary solution because it also raises
Pd and lowers Ps, which tends to
drive the machine back towards
surge.
Avoiding Surge
In the air compressor section (Figure
5), a blowoff valve is used to vent
the compressor discharge to atmo-
sphere. This does not affect the
suction conditions, but it reduces
discharge pressure and increases
flow, which moves the operating
point away from surge.

Gas
Compressor

Discharge
Suction

Recycle
Valve

Figure 4
Gas Compressor Anti-Surge Valve

Blowoff
Valve

Air
Compressor

Suction Discharge

Figure 5
Air Compressor Anti-Surge Valve

11
Avoiding Surge

NOTES
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12
 The Surge Line
The problem with both "µ" and are directly measurable by conven- ity factor (Zs + Zd)/2
performance curves is that they both tional instruments. The challenge is Ts = Suction temperature
show the compressor surge character- to define and implement this curve in (degrees absolute)
istics for specific conditions only. terms of variables that we can measure MW= Molecular weight
Ideally, a curve and a method which reliably, economically, quickly, and Rc = Compression ratio
accurately defines surge for all gas and accurately. This is a formidable task at (Pd/Ps)
suction conditions, is needed. first look. σ = Polytropic exponent

A Universal Surge Curve Determining HP/A02 where:

k −1
As stated earlier, the surge and Let us first examine the Head σ = k ⋅ ηp
performance characteristics of the variable Hp/A02:
compressor change the function of A0
or the sonic velocity of the gas at the where:
suction. An intuitive analysis of the k = Ratio of specific heats
Equation (3)
"µ" curve reveals that if Hp/A02 (head) (Cp/Cv)
is plotted against (Q/A0)2 (capacity), a σ ηp = Polytropic efficiency
1545 ⋅ Z a ⋅ Ts ⋅ ( R c − 1)
curve which defines surge for all gas Hp = (%)
conditions, suction conditions, and MW ⋅ σ
speeds results. Furthermore, if
performance lines are plotted as N/A0, where:
rather than simply speed alone, these Hp = Polytropic head in ft- We have already defined A0:
lines are also valid for all conditions.
lbs/lb
None of the variables Hp, A0 , or Q Za = Average compressibil-
Equation (4)

1545 ⋅ k ⋅ Z s ⋅ Ts ⋅ g
A0 =
MW
Surge Line
where:
A0 = Sonic velocity of the
Hp gas at the inlet condi-
105%
A0 2 tions , ft/sec
100% k = Ratio of specific heats
90%
Cp/Cv
N Zs = Compressibility factor
80%
% Ts = Inlet temperature °R
A0
g = Gravitational con-
2
stant, 32.17 ft/sec2
Q
( )
A0 Therefore:

Figure 6 Equation (5)

Universal Surge Curve

13
The Surge Line
σ
Ts = Suction temp (°R) Because Q2 is proportional to h, the
Z a ⋅ T s ⋅ ( R c − 1) MW = Molecular Weight new curve no longer follows the fan
Hp
= MW ⋅σ Ps = Suction Press law. A classic low head application
A0
2
k ⋅ Z s ⋅ Ts (psia) will have a surge line that is closer to
a straight line. At high heads, the surge
MW So Q/A0 can be written as: often moves to a different impeller.
Za/Zs increases predictably with Therefore, high head applications will
increasing head so it can be accommo- still exhibit non-linearity.
h ⋅ Z s ⋅ Ts
dated in the surge line. So by cancella- 2
tion:  Q MW ⋅ Ps A typical surge curve may now look
  = like Figure 7.
 A0  k ⋅ Z s ⋅ Ts ⋅ 1545
Equation (6)
MW Some applications can use a simpler
σ
variation of this surge computation
Hp Rc - 1 technique. If both the head term (Pd/
=
A0
2
k ⋅ σ Simplifying and canceling: Ps-1) and the capacity term (h/Ps) are
multiplied by Ps, these terms reduce to
2 Pd-Ps for the head and simply h for the
k −1  Q h
And substituting: σ =   = capacity.
k ⋅ ηp  A0  Ps ⋅ k ⋅ 1545
However, there is a disadvantage of
Equation (7)
the Pd-Ps method, or “Pressure Rise”
Plotting the Surge Line method. If the surge line is nonlinear
k−1 and the suction pressure is variable,
k ⋅ ηp
Hp R c - 1 Because k appears in the denominator then errors will result when operating
then: 2
= of both terms of Hp/A02, and Q2/A02, its on a section of the curve that does not
A0 k - 1
effect is further minimized. If changes pass through the origin. If the surge
ηp in k are ignored, the surge curve can line is linear or if the suction pressure
be plotted as a function of Pd/Ps and h/ is reasonably constant, this method is
An analysis of equation (7) with
Ps. The relationship h/Ps is another perfectly acceptable and can be used
actual compressor data shows that Hp/
way of saying h compensated for with confidence.
A02 is minimally affected by minor
changes in Ps.
variations in k and ηp, and is predomi-
nantly affected by Rc.
100
Recall that Rc=Pd/Ps and the chal-
lenge has been met. The variables Pd
and Ps are readily measured by 75
SURGE LINE
conventional pressure transducers.
Pd/Ps 105%
2
Determining (Q/A0) 50
100%

If flow is measured by a conventional 90%

% Speed
orifice or venturi device, then: 25
80%
h ⋅ Z s ⋅ Ts
Q2 =
MW ⋅ Ps
0
where: 0 20 40 60 80 100
Q = Flow (acfm) h/Ps (%)
h = Orifice differen-
tial
Zs = Compressibility Figure 7
Typical Surge Curve
14
 The Surge Line

Compressor

Suction
Discharge

PT
FT
∆p
h

SC I
P

Recycle
or
Blowoff

Figure 8
Pressure Rise Method

Compressor

Discharge
Suction

PT PT
FT
Ps Pd
h

SC I
P

Recycle
or
Blowoff

Figure 9
Pressure Ratio Method
15
The Surge Line

NOTES
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16

To prevent surge, the system must
accurately predict surge and begin to
open the recycle valve before surge
can occur. The safety margin
between the predicted surge point,
and the point that recycle flow is
initiated, is called the surge margin.
The surge margin is implemented by
modifying the surge line to produce
a "Control Line." Referring to
The Surge Control Line
Figure 10, the Control Line lies to safety margin to determine the
the right of the surge line by an control flow.
amount equal to the safety margin.
Depending on the application, either The control line provides the
a constant (parallel), or progressive setpoint to the surge controller,
(meeting at the origin), characteris- which opens the recycle valve to
tic can be configured. prevent flow from falling below the
Control Line.
For a given Pd/Ps (or Pd-Ps), the
system computes the surge flow
from the surge line, then applies the

100
Safety
Margin
Surge Line

Progressive
75
Surge Control
Area Line
Pd Safe
Ps 5 0 Area

Constant
Control
25 Line

0
0 20 40 60 80 100
h%
c

Figure 10
Typical Control Line

17
The Surge Control Line

NOTES
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18
Surge Control Block Diagram
The TRISENTM surge control
system can be best described in the
form of individual modules. Each
S urge
1 Line 4 Line
module has a readily defined output signals, which are given tag
functionality, and interacts with names.
other modules through input and
In the next section, the features of
the system will be examined and
each of the blocks will be readily
identified with an associated
C ontrol C ontroller function.
5 S etpoint

h hx

SU LIN
hx
Dp

or SU C LN C O N SP 9
AD M AR 6 H igh
C ontroller S elector
Pd

Ps S SU C O N
P ID
hx M V alve
S ignal
3 S elector
P roportional (if necessary)
R ecalibrate 7 Term S peed
10 B ias
PR O TM
S peed
M AR G IN
SP DU P
R eference
B ias
(internal)
V alve
hx P rep 12
SU VLV
11
2 S urge VA PR EP A uto/M an
D etect A /M
hx O pen
D um p (D O ) C lose
DUMP
S tartup 8 VA

E nable (D I)
STU P
R ecycle
V alve
vV 2 (A O )
T yp ica l fo r E a ch C o m p re sso r S e c tio n
13
V alve
Linearize/
F ro m A d d itio n a l C o m p re sso r S e c tio n s R everse
(if applicable)

Figure 11
Surge Block Diagram
19
Surge Control Block Diagram

NOTES
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20
 TRISEN TM Surge Controller Features
Summary of Features • Linearization function for recycle valve when operating
equal percentage valves. close to the surge line.
Because surge can occur very quickly, • A Valve Prep function bleeds • A solenoid contact output
special control techniques must be overpressure from the “dumps” the recycle valve if
used to ensure that the recycle valve
opens in time to prevent surge.
6 x4 = 92.6
The TRISENTM Controller is ideally
y4 = 5.80
suited to perform surge prevention
because of its fast processing speed x 3 = 60.8
5
y3 = 5.18
and ability to efficiently perform the
complex algorithms required. The Pd x2 = 46.2
TRISENTM controller also performs 4
Ps y2 = 4.2
the turbine speed control function. It
can internally implement interactive x1 = 40.5
3
y1 = 3.3
coupling between surge and speed
control algorithms to improve
response and stability. 2

Standard features that can be enabled 1

in the surge prevention strategy are: 0 20 40 60 80 100
• Choice of Pd/Ps vs. h/Ps or
h/Ps %
∆p vs. h algorithms.
• If a surge occurs, the surge Figure 12
safety margin automatically Surge Curve - Pressure Ratio
readjusts.
• Setpoint Hover function
opens the recycle valve on a
100 x4 = 92.6
sudden movement toward
y4 = 98.5
surge.
80 x 3 = 60.8
• Special surge controller with y 3 = 86.8
adaptive gain and fast
opening/slow closing ∆P 60 x 2 = 46.2
y2 = 62.2
response.
• Proportional function 40 x 1 = 40.5
"forces" recycle valve open y 1 = 44.9
independent of controller
20
tuning.
• Speed setpoint is coupled to
surge control. 0
• Flexible enable logic for 0 20 40 60 80 100
start-up and shutdown. Orifice Differential (h)
%
• Manual control options aid
setup, troubleshooting, and
Figure 13
testing.
Surge Curve - Pressure Rise

21
TRISENTM Surge Controller Features
surge is imminent, or if
turbine trips.
NOTE: If the application requires it,
any of the above features can be
enabled. Features not required are
simply not configured and have no
effect.
Choice of Pressure Rise
or Pressure Ratio
Algorithms
As discussed previously, either of two
surge computing algorithms can be
configured, depending on the applica-
tion.
The surge line can be configured with
up to ten line segments. The examples
depicted in figures 12 and 13 display
four segments.
the right) by a calibrated amount.
Entering a new safety margin sets the
transition counter to zero, and sets the
recalibrated margin to equal the
entered value.
The system can be configured to
increment by a fixed amount (i.e.,
2%), or by a progressive amount (1, 2,
4, 8%, etc.), on each transition. The
maximum number of times that
recalibration occurs is also
configurable.
The system displays the following:
• Number of surge occurrences
(number of calibrations)
• Initial safety margin
• Current recalibrated safety
margin
Setpoint Hover
In most applications, the compressor
will not operate continuously, or for
extended periods on the Surge Control
Line. When operation is to the right of
the control line (safe area), the
setpoint to the Surge Controller is
ramped (at a configurable rate) to
within a configurable percent of the
current h value.
The following occurs after a small,
quick movement toward surge, past
the hover setpoint:
• Immediate opening of the
recycle valve
• Hover setpoint is then
ramped down (at the same
rate) until the recycle valve
closes.
• New operating point is
established.

Safety Margin If the setpoint reaches the Surge

Recalibration
If the system detects a transition of the
operating point across the Surge Line,
indicating that surge has occurred, it Control Line
Surge Line rSUCLN
automatically readjusts the Surge rSULIN
Control Line to the right to add 6
additional safety margin.
5 Controller Setpoint
Some conditions which can result in rSUCSP
surge are:
4 Current Operating Point
• Shifting of the Surge Line hx
Pd/Ps
due to compressor wear
3
• Transmitter out of calibra-
tion Hover Setting
• Insufficient safety margin 2 kHOVER
• Drastic changes in process Hover Ramp Rate
conditions kHOVRR
1
• Incorrect surge line used
0 20 40 60 80 100
• Improper tuning or set up of
the surge prevention system hx

Each time a surge transition is Figure 14

detected, the safety margin is Setpoint Hover
incremented (control line moved to

22

Control Line, the system will
maintain recycle flow to operate on
the Surge Control Line.
Dynamic Adaptive
TuningTM
The Surge Controller is available with
an adaptive tuning feature that varies
TRISENTM Surge Controller Features
the gain and integral values based on
the margin to the surge line.
Dynamic Adaptive Gain - reduces
the proportional action when opera-
tion is to the right of the Surge
Control Line and increases it as the
operation moves to the left of the
Surge Control Line. The result is a
unique gain value for any operating
point. Normal gain is applied when
the operating point is on the control
line. As the operating point decreases
to the left of the control line, a
nonlinear increasing function is
applied to the gain. As the operating
point increases to the right of the
control line, the gain will decrease to
a minimum at the Setpoint Hover
line.

Dynamic Adaptive Integral - allows

M ax a minimum amount of integration
when operating on the Surge Control
Line. The Integral value increases non-
linearly as the operating point move
away from the control line (either
increasing flow or decreasing flow).
N orm al
G ain This technique allows the surge
controller to operate near its setpoint
with primarily proportional action, yet
when the operating point moves away
from the normal control line, the
restoring affect of the integral action
M in increases.

h/P S Non-symmetrical Valve

Response
N orm al The recycle valve opens, based on the
Surge Line C ontrol Line proportional and integral responses,
but a straight ramp function limits the
6
closing of the recycle valve. This
feature allows the valve to respond
5 C ontroller Setpoint quickly to prevent surge. After
operation is safely to the right of the
surge control line, the valve is ramped
4 C urrent O perating Point closed at a slow (configurable) rate to
Pd/Ps allow the turbine driver and the
performance controller to adjust to the
3
new operating conditions.
H ov er Setting
2
A nonlinear ramp function can also
be applied that will cause the valve to
close more quickly if the margin is
1 high, yet preserves the slow response
0 20 40 60 80 100 as the control line is approached. This
feature is useful if the valve moves
h/P S nearly wide open in response to a
severe system transient, thus shorten-
Figure 15 - Dynamic Adaptive Gain ing the time that the operator must
TRISENTM Surge Controller Features
allowing Surge Controller interven-
M ax
tion as necessary.

Manual Control
Integral
Two manual control options are
M in available.

The first option provides full-

authority manual control. It allows the
valve to be closed, regardless of the
h/P S action of the Surge Controller. This
option is useful for testing and setup,
but should not be configured for
N orm al normal operation. If the system is left
S urge Line C ontrol Line in manual operation, the Surge
Controller will not be able to open the
valve to prevent surge.

The second option provides limited-

C ontroller S etpoint
C urrent O perating P oint
Pd/Ps
authority manual control. This option
sets a minimum recycle valve limit,
allowing the operator to open the
recycle valve, but not close it if the
controller needs to open it to avoid
surge.

H ov er S etting Proportional Function

0 20 40
h/P S
Figure 16 - Dynamic Adaptive Integral
wait for the system to return to
normal.
Purge and Start-up Logic
Prior to starting the compressor, the
recycle valve can be configured to stay
closed for purging the compressor
case and the inlet and outlet piping.
Once purging is finished, the Surge
Control opens the valve. The Surge
Control can be enabled at anytime, but
60 80 100
is typically configured for one of the
following:
• Always enabled
• Enabled at minimum governor
• Enabled by a remote contact or
flag from the DCS
Before the Surge Controller is
enabled, the valve is held at the start-
up limit. When the Surge Controller
is enabled, the start-up signal is
ramped closed at a configurable rate
The system has a proportional-only
term, which forces the recycle valve to
open, independent of normal P+I
controller action. This occurs, due to a
severe process upset, if the operating
point moves to the left of the Surge
Control Line, and the normal control-
ler tuning provides insufficient
response. This term begins to open the
valve at a specified margin, to the left
of the Surge Control Line, and fully
opens the valve as the operating point
reaches the Surge Line.
In other words, the valve is opened
proportional to the instantaneous
operating margin, less the initiation
value. The proportional term is
applied through a signal selector, and
the anti-windup action of the control-
ler forces the controller output to
track the proportional term.

Closed
0%
rPROTM
100%
Open
Py%
rSULIN
hx%
Figure 17
Proportional Function
This feature will protect the machine,
even if the Surge Controller is poorly
tuned.
Valve Prep
In some applications, the recycle valve
is not equipped with a positioner. A
positioner fully loads the valve
diaphragm or cylinder on closed over-
travel. This is undesirable because it
takes too much time to bleed off the
excess pressure to open the valve.
The Valve Prep feature is designed to
improve the speed of operation of
these applications by the following:
• When operating away from
the Surge Control Line, fully
load or unload the diaphragm
to positively close the valve.
• When operation moves
within a specified distance of
the Surge Control Line, set
the loading to "poise" the
valve to open.
If the valve is air fail-closed, this
TRISENTM Surge Controller Features
rSUCLN
Proportional
Initiation
7
rMAR
0
feature requires a special I/P calibra-
tion for 6-20 mA input range. The 4-6
mA portion is used to under-pressure
the valve closed.
If the valve is air fail-open, this
feature requires a special I/P calibra-
tion for 4-18 mA input current range.
The 18-20 mA portion of the range is
used to overpressure the valve closed.
Dump Output
When a specified excursion to the left
of the Surge Control Line occurs, a
contact output can be configured to
open a high-volume solenoid to
quickly open the recycle valve.
This feature is useful on large valves
which have slower stroking times. As
the system moves back from surge, the
solenoid will close. This restores
normal proportional control of the
valve to the Surge Controller.
25
Valve Linearization and
Reversal
The TRISENTM Surge Controller
provides for linearizing the output for
an equal percentage trim recycle
valve. This tends to produce a more
linear overall system gain. Possible
instability is avoided when the system
operates at a different point than at
which it was tuned.
Most applications have a recycle valve
with an air-fail open action (AFO),
requiring reversal of the recycle valve
output. The system is configurable for
either direct, or reverse, output
operation.
Compensated Recycle
Temperature Controller
For single component refrigeration
compressors utilizing a liquid
quench, Triconex offers a variable
temperature controller setpoint that
changes with the refrigerant pres-
sure. These systems take “hot”
discharge gas through a recycle
control valve back to the suction and
side streams to satisfy the minimum
volume flow demands of the com-
pressor sections. A liquid quench
line provides cooling for this gas in
order to maintain the suction
temperature (and pressure). Figure
18 is a schematic of a typical system.
The liquid quench flows are regu-
lated by a temperature controller
referencing the compressor suction or
sidestream temperature. As long as
the gas pressure remains within a
narrow range, the controller will
provide adequate temperature
regulation.
When the gas pressure rises to the
point that the temperature controller
setpoint is less than the saturation
TRISENTM Surge Controller Features

temperature (at that pressure), the
controller will open the quench valve
fully, even though that amount of
liquid is not required for controlling
the gas temperature. This situation
can result in excessive liquid refriger-
ant consumption, high suction drum
liquid levels and liquid carry-over into
the compressor.
Figure 19 shows the a typical
pressure-enthalpy diagram for a
single component refrigerant. Point
A is the intersection of the gas
pressure (P1) and the temperature
controller setpoint temperature line.
If the pressure rises to P2, the
intersection of P2 and the tempera-
ture controller
setpoint is Point B, which is in the
subcooled liquid section of the
diagram. Since this temperature
cannot be achieved, the controller
will open the valve fully.
Also shown on Figure 19 is a line in
the superheat region that parallels the
saturated vapor line. This line

FT

PT

TT

PT PT PT

TT TT TT

FT FT

Recycle
Valve

Liquid
Quench
Valve

Figure 18
Typical Refrigeration System

26
 TRISENTM Surge Controller Features
represents the Compensated Recycle
Temperature Controller setpoint.
Instead of using a fixed temperature
for the controller setpoint, the
equations of state of the refrigerant
are used to calculate the saturation
temperature at the gas pressure. The
setpoint of the controller is the
saturation temperature plus an
incremental amount of superheat.

Compensated
Temperature
Controller Setpoint

Tem
P2
Pressure

per
atu
re
P1 Conventional
Temperature
A Controller
Setpoint (fixed)
py
tro
En

Enthalpy

Figure 19
P-h Diagram for Refrigerant

27
TRISENTM Surge Controller Features

NOTES
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28

Process Pressure Control
In variable speed applications,
compressor capacity is controlled by
varying the speed to meet process
requirements of flow, suction pres-
sure, suction temperature, discharge
pressure, etc. This controller can be
internal to the system, or it can be
external and applied as a remote input.
For a given head, compressor speed
produces flow, as defined by the
manufacturer's performance curves.
Because both the capacity controller
(sometimes called the process
controller or performance controller),
and the surge controller influence
flow, there is interaction between
them. Depending on the type of
capacity control, this interaction can
cause system instability and make
surge protection extremely difficult.
Consider the following situation:
The system is configured as a
suction pressure controller
cascading to the speed controller.
If the suction pressure falls, the
controller slows the turbine down
to maintain the suction pressure.
Conversely, it raises the speed if
the pressure rises.
An upstream process upset
drastically reduces the available
gas at the suction. Because the
suction pressure is falling (pres-
sure ratio rising) and the flow is
falling, the operating point moves
rapidly towards the surge line.
The Surge Controller begins
opening the recycle valve. How-
ever, due to valve stroking and the
Dynamic Process Control Decoupling
volume of piping, intercoolers,
etc., there can be several seconds
delay before the recycle flow
reaches the suction of the com-
pressor.
Meanwhile, the suction pressure
controller sees only suction
pressure falling and responds by
slowing down the machine. This
reduction in speed further reduces
the flow and drives the compres-
sor even faster into surge.
If the process controller was control-
ling discharge pressure, then the
scenario would have been different.
The discharge pressure would have
dropped and the controller would have
raised speed to correct it. This would
be a desirable response, as it would
move the operation away from surge.
In some applications, the cycle
described in the suction pressure
control example above can continue
indefinitely. To prevent this occur-
rence, the Triconex capacity controller
is designed to open the recycle valve
once operation is decreased to the
point where the
compressor is on
the surge control 100%
line. A separate set
of tuning con-
stants for the
Station Recycle
Valve Output
process controller
are provided
depending whether
speed is being
controlled or the
0 0
recycle valve is
0 50%
being opened.
Compressor
capacity control is
29
achieved by adjusting the speed of the
compressor and opening the recycle
valve. Maximum capacity is reached
when the turbine reaches its maximum
operating speed and the recycle valve
is fully closed. Minimum capacity is
reached when the compressor is
operating on the recycle line and the
recycle valve is fully open.
In effect, the Triconex Dynamic
Process Control Algorithm is a special
split-range controller with a variable
breakpoint. The point at which the
capacity control switches from
controlling the speed to controlling
the recycle valve opening is called the
Dynamic Breakpoint. This point is
dynamic because it is variant depend-
ing on the process flow and pressure
demands.
A conventional split range controller
is shown in Figure 20. This type of
controller does not take into account
the slope of the surge control line. In
effect, the split line must be based on
the highest operating pressure ratio.
The turbine minimum speed is based
100%
Controller Output
Turbine Speed
Turbine Min.
Speed
100%
Load Sharing Controller
Output
Figure 20 - Conventional Split Range
Process Control
Dynamic Process Control Decoupling
on the maximum operating pressure
ratio rather than the minimum
governor speed.
Triconex incorporates the slope of the
compressor curves into the determina-
tion of the break point for the split
range controller. The lower the
pressure ratio, the greater the turn-
down available to the speed-control
portion of the controller. Figure 21
shows how the compressor surge line
relates to the determination of the
Dynamic Break Point TM. As the
compressor pressure ratio increases,
the minimum speed at which surge
100%
Valve Output
Recycle
0 0
X-50
P 2 /P 1
Figure 21 - Process Decoupling using Dynamic Break Point
occurs also increases. The break
point for the split range controller
will shift to the right to assure that
the recycle valve is opened based on
the process flow demand rather than
the surge controller requirements.
The decoupling exit line will be set
2% to the right of the surge control
line. In other words, the process
controller decoupling algorithm will
operate the recycle valve whenever the
process controller output drops below
the surge controller control line flow,
but does not start closing the valve
until the process controller output is
Minimum Break Dynamic Break Point (X')
Point (Xm )
Turbine Min.
50%
Process Controller
Output
Flow 2
30
2% greater than the surge controller
control line. As the operating point
increases above the surge control line,
the process controller will first
increase speed until the its output is
2% greater than the surge control line;
further increases in the process
controller output will cause the
recycle valve to close. This approach
assures that the valve will not close at
the same time that an increase in the
pressure ratio is taking place.
Another feature of the capacity
controller is that if load is quickly
reduced, the speed setpoint of the
100%
Controller Output
Turbine Speed
Speed
100%
 Dynamic Process Control Decoupling
turbine is initially reduced a small gradually, the load on the compressor
amount and then ramped down slowly, is maintained which aids in maintain-
as required to satisfy the capacity ing process stability. Note that this is
controller. While the speed setpoint is only a transitory situation; at steady
ramping down, if further reduction in state the recycle valve is only opened
capacity is required, the recycle valve the amount that is required to main-
is opened. This provides superior tain the recycle line.
control to the traditional method of
reducing speed and finding too late
that operation has crossed to the left
of the surge control line, requiring the
recycle valve to open quickly. Another
advantage is that since the recycle
valve is opened sooner and closes

S urge Line
Pd PT

Ps PT

h FT Speed
Controller

S
P ID
M

D ecoupling G ov ernor
V alv e

S
P ID Process
M Controller
Surge
Controller

S
P ID
M
Proportional
Term
>

Startup
R ecycle
V alv e
ST U P

Figure 22 - Process Controller Decoupling Block Diagram

31
Dynamic Process Control Decoupling

NOTES
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32
 Nomenclature

ACFM Actual Cubic Feet Per Minute at flowing conditions

C Constant
Cp Specific heat of gas at constant pressure
Cv Specific heat of gas at constant volume
FE Primary flow element, orifice, flow tube, etc.
G Gas specific gravity = MW/28.966
h Differential head produced by flow element, usually “H20
differential
hc h corrected for suction pressure = h/Ps
Ha Head, Adiabatic, Foot-lbs/Pound
Hp Head, Polytropic, Foot-lbs/Pound
k Ratio of specific heats, Cp/Cv
M Mass flow rate, e.g., Lbs/Minute, Kg/Hr.
MW Molecular Weight, Lbs/mole volume
N Rotative Speed, Revolutions Per Minute, RPM
P Pressure, Pounds per square inch absolute, psia
Pb Pressure at base conditions, usually 14.7 psia
Pd Pressure (absolute) compressor discharge
Pf Pressure (psia) at flowing conditions used to
specify/calculate primary flow element
Ps Pressure (absolute) at compressor suction
Q Gas volumetric flow rate at flowing conditions (e.g.,
ACFM,
SCFM, m3/h, etc.)
R Gas Constant = 1545.3/MW
Rc Compression Ratio, Pd/Ps
T Temperature, °R = °F + 459.67 or °K = °C + 273.15
Tb Temperature at Base Conditions, usually 60°F
Td Gas Temperature (°R or °K) at compressor discharge
Tf Temperature (°R or °K) at flowing conditions used to
specify/calculate primary flow element
Ts Gas Temperature (°R or °K) at compressor suction
Z Compressibility factor to correct for the deviation from the
ideal gas flow.
ρ Density, lbs/Ft3
P ⋅ MW
ρ=
10.73 ⋅ T ⋅ Z

33
Nomenclature

SYMBOL C ρ P T Z
VARIABLE CONSTANT DENSITY PRESSURE TEMPERATURE COMPRESSIBILITY
FACTOR
SYSTEM UNITS
ENGLISH 10.73125 Lbs/Ft3 psia °R = °F + 459.67 Dimensionless
METRIC 0.084784 kg/M3 kg/cm2 °K = °C + 273.15 Dimensionless
S.I. 8.3145 kg/M3 kPa °K = °C + 273.15 Dimensionless

σ Exponent of Compressions, adiabatic or polytropic

(k − 1)
Adiabatic σ=
k

(k − 1)
Polytropic σ= where η p = Polytropic efficiency
k ⋅ ηp

34
 Technical Product Guide Notes

NOTES
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35