Elliott EDS Plus

(PLC Based)

Anti-Surge

Instruction Manual

Elliott Shop Order E598018

March 19, 2007

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 Table of Contents

Page

1.0 Introduction 3

2.0 Screen Description 4

2.1 Performance Screen 4
2.2 Anti Surge Loop Configuration 6
2.3 Anti surge controller 9

3.0 Control System as Supplied by Elliott 11

3.1 Anti Surge System 11
3.2 Surge Line 11
3.3 Surge Map 12

4.0 Specialized Code for the Crack Gas String 13

5.0 Commissioning of Anti Surge System 14

5.1 Pre-Start Operation 14
5.2 Start-up 14
5.3 Compressor Surge Verification 14
5.4 Anti-surge Control Tuning 15
5.5 General Tuning Guidelines 16

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1.0 Introduction
The primary function of the anti surge controller is protection of the compressor from
operation in an unstable region known as surge. Surge is a sudden flow reversal that occurs
when a centrifugal compressor’s throughput is reduced below a minimum value. Continued
operation in the surge region can result in a mechanical failure. The anti surge controller
prevents surge from occurring by maintaining a minimum flow rate through the compressor.
The flow rate is maintained by modulation of a control valve on the compressor discharge,
which either vents gas to the atmosphere or recycles gas back to the compressor suction. To
implement anti surge control, various parameters on the compressor must be monitored. The
quantity of variables measured depends on the type of compressor and the service conditions.

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 2.0 Screen Descriptions
The anti surge controller requires several screens to display all of the pertinent data, as
well as for configuration. The following sections detail the screens and their functions.
2.1 Performance Map Description

The anti surge performance map displays the operating point of the compressor in
relation to the control parameters of the compressor. By viewing this screen, one can
dynamically see the operating point of the compressor in relation to the control
parameters (See Sample Graph Below).

Anti Surge Performance Map

50

45

40
Compressor Delta Pressure

Surge Line
Feed Forward Point
High Gain Point
35
Control Point
Variable Control Point
Operating Point

30

25

20

1300 1600 1900 2200 2500 2800 3100 3400 3700 4000 4300
Compressor Inlet Flow

The X-axis of the graph normally displays compressor flow in respective units. The
Y-axis of the graph can display different compressor parameters such as head,
pressure ratio, or delta pressure in this case. A series of terms which apply to the anti
surge performance screen are defined below.

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Surge Line – The surge line is a graphical representation of points at which the
compressor will surge. The compressor operating point must be on or to the right of
this line at all times. The anti surge controller is shipped with the calculated surge
line configured. This line should be verified at commissioning.

Control Line – The control line is to the right of the surge line, which functions as
the setpoint to the controller. The controller attempts to keep the operating point of
the compressor on or to the right of this line by opening the anti surge or blow off
valve. This line is adjustable and normally set between five and fifteen percent to the
right of the surge line. The distance from the surge line to the control line is known
as the control margin. The control line will automatically move to the right an
adjustable amount when a compressor surge is detected. The present control line is
displayed under the conditions menu in actual flow units.

High Gain Line – The high gain line is between the surge line and the control line.
If the operating point of the compressor crosses the control line and high gain line the
gain to the controller is increased an adjustable amount. This action will open the anti
surge valve faster in an attempt to keep the operating point to the right of the surge
line. The purpose of the high gain line is to handle very fast flow transients. The
high gain line is displayed under the conditions menu in actual flow units.

Feed Forward Line - The feed forward line or ratchet line is between the surge line
and the high gain line. If the operating point of the compressor crosses the feed
forward line standard control is bypassed and the anti surge valve is directly
commanded to open a percentage proportional to the distance the operating point
crossed the feed forward line. The feed forward point is displayed under the
conditions menu in actual flow units.

Variable Control Line – The variable control line is an adjustable line that resides
between the operating point and the control line. This line always stays some
percentage (Normally 50%) between the operating point and the control line. This
line will move to the right as fast as the operating point moves to the right. When the
operating point moves to the left the variable control line will move to the left at an
adjustable slower rate to a maximum distance equal to the control line. If the
operating point crosses the variable control line the anti surge valve will begin to
open. The purpose of this line is to handle rapid flow transients. This line will have
no effect on a very slow movement of the operating point back to the control line.
The variable control line is displayed under the conditions menu in actual flow units.

ACL – The ACL is the distance in actual units from the operating point to the control
line. If the operating point is on the control line the ACL will equal zero. ACL will
be positive if the operating point is to the right of the control line. ACL will be
negative if the operating point is to the left of the control line.

VCL – The VCL is the distance in actual units from the operating point to the
variable control line. If the operating point is on the variable control line the VCL will
equal zero. VCL will be positive if the operating point is to the right of the variable

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control line. VCL will be negative if the operating point is to the left of the variable
control line.

2.2 Anti Surge Loop Configuration Screen

The loop configuration screen is used to enter all the control parameters. This
password protected screen can only be accessed by utilizing the MAINTENANCE
username or higher.

Surge Detection - The top part of the screen is the surge detection area. The surge
detection area is used to set up the surge detection method and parameters. Three
methods of surge detection can be enabled. The first and most common is flow surge
detection. To enable or disable a surge detection method just click on the enable “E”
or the disable “D” button in the respective method box. Normal numbers for flow or
discharge pressure detection are half scale in 0.5 seconds. For instance, if compressor
rated flow is 2000 CFM then delta flow would be set for 1000 and delta time 0.5
seconds. A surge count is also on this screen which can be reset by the surge count
reset push-button.

The lower part of the screen has a list of all the control parameters that can be
changed by clicking on the respective number to the left of each parameter. Each
item on the screen is explained below.

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Control Margin – The control margin is the distance from the surge line to the
control point. If the control margin is one the control point is on the surge line.
Values of 1.05 to 1.3 are normal values for the control margin, which is
approximately 105 to 130 percent of the surge line. Surge control point = control
margin * surge line.

Maximum Control Margin – The maximum control margin is an upper limit on the
control margin. The control margin will auto increase on a surge by the valve of the
adaptive control margin to a maximum, which is set by the maximum control margin.

Adaptive Control Margin – The adaptive control margin is the amount added to the
control margin in the event of a surge. Each time a surge is detected the value of the
adaptive control margin will be added to the control margin. A normal number for
the adaptive control margin is .05 or 5 percent.

Compressor maximum and minimum flow – Scale valves set during factor
configuration. These values should not require field modification.

Variable Control Line Setpoint – The variable control line setpoint fixes the
variable control point somewhere between the control point and the operating point.
A valid range for this set point is between 0 and 1. If 0 is entered this places the
variable control point on the control line. If 1 is entered this places the variable
control line on the operating point.

Variable Control Line Decay Constant – The variable control line decay constant
sets the rate at which the variable control point moves toward the left or toward the
surge line. The greater the number the faster the variable control point will move.
This parameter is used to keep the compressor out of surge during rapid flow
transients.

High Gain Control Margin – This parameter sets the position of the high gain
control point. The high gain control point should always be between the surge line
and the control point. This parameter is a percentage of the surge margin. For
example if the surge margin is 1.1 and the high gain control margin is .95 the high
gain control point would be at 1.045 times the surge line. The controller has a built in
safety that keeps the high gain control point between the surge line and the control
point.

Antisurge Valve Slow Close – This parameter controls the rate that the antisurge
valve is allowed to close. The parameter is in percent per second and should be set no
higher than 5.

System Trip A/S Valve Position – This parameter is the command anti surge valve
position on a compressor trip. This parameter is normally set to 100 percent.

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Delta Pressure Surge Valve Position – This parameter is specifically for a Delta
Pressure vs. Time surge detection. It allows a for a smaller valve response. All other
safeties are still valid.

PID High Proportional Gain - This parameter is the high gain proportional gain of
the PID loop that controls the anti surge valve. If the operating point of the
compressor crosses the high gain point the proportional gain of the PID will be
switched from the normal gain to this high gain. The units of this parameter are
hundredths. This parameter is normally set two to five times greater than the normal
PID proportional gain.

PID Low Proportional Gain – This parameter is the low proportional gain of the
PID loop that controls the anti surge valve. The units of this parameter are
hundredths. This parameter is normally factory set but may need adjustment is the
field.

PID Integral Gain – This parameter is the integral gain of the PID loop that controls
the anti surge valve. The units of this parameter are in repeats per 1000 seconds. This
parameter is normally factory set but may need adjustment is the field.

PID Derivative Gain - This parameter is the derivative gain of the PID loop that
controls the anti surge valve. The units of this parameter are in hundredths of
seconds. This parameter is normally factory set to zero but may need adjustment is
the field.

Ratchet Control Margin (Feed forward) – This parameter sets the position of the
feed forward control point. The feed forward control point should always be between
the surge line and the high gain control point. This parameter is a percentage of the
surge margin. For example if the surge margin is 1.1 and the high gain control
margin is .93 the high gain control point would be at 1.023 times the surge line. The
controller has a build in safety that keeps the high gain control point between the
surge line and the control point. If the operating point crosses the feed forward
control point the anti surge valve is commanded opened proportional to the distance
the operating point crossed the feed forward control point.

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2.3 Anti surge controller Screen
The anti surge controller screen is used to monitor and control the anti surge valve.
See the screen below.

There are several general modes of operation of the anti surge controller. When the
compressor is tripped, the anti surge valve is always commanded 100 percent open.
Once the driver is started, the anti surge controller receives a contact from the
governor or motor starter to enable the anti surge controller. After enabled, the anti
surge controller will modulate the anti surge valve to keep the compressor out of
surge. When the motor or turbine is tripped or shut down, the anti surge controller
will command the anti surge valve 100 percent open. No manual or operator
intervention is required to enable or disable the anti surge controller.

Safe manual mode is active any time the compressor is running and in the auto mode.
The anti surge valve can be manually opened by clicking on the up arrow under the
safe manual mode on the screen. The valve position can also be entered directly
under the arrows. This feature allows the anti surge valve to be opened manually.
When using the safe manual mode the anti surge valve can only be closed as far as
the controller will allow by clicking on the down arrow. In short, safe manual allows
opening of the anti surge valve and closing only as far as the control algorithm will
allow.

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The compressor must be reset to enter manual mode. In order to enter manual mode,
the user must be logged in at the MAINTENANCE level or higher. To enter manual
mode, click on the manual push-button on the left side of the screen. Manual controls
will appear similar to the safe manual controls on the upper right side of the screen.
As long as the compressor is operating, the manual command will manually control
the anti surge valve. This mode should only be used by experienced personnel
with CAUTION, because the control algorithm is overridden in the manual mode. If
the anti surge valve is manually closed when the valve needs to be open, a
compressor surge may result. The manual commands function the same as the safe
manual commands. To switch modes back to the automatic mode simply click on the
auto push-button or log in as OPERATOR.

Three bar graphs are displayed on the top center of the screen. ACL is the distance
from the actual control point to the operating point in actual units. VCL is the
distance from the variable control point to the operating point in actual units. The
valve position is the command position to the anti surge valve, 0 = closed and 100 =
open.

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3.0 Anti Surge System

Elliott Company has provided a complete compressor anti surge system for the compressor
string. Specific compressor control equipment supplied by Elliott is identified on the Elliott
P&I diagram. The anti surge controller has been configured by Elliott based on predicted
performance characteristics of the compressor.

3.1 Anti Surge System

The P&I diagram illustrates the components of the anti surge control system. The
anti surge controller receives pressure data from a transmitters located in the process
piping of the compressor. Compressor flow is measured by a flow element located in
the suction line of the compressor. For anti surge control, a recycle valve is routed
from the discharge to the suction.

3.2 Instrument Data Sheets

In the event that Elliott supplies the anti surge instrumentation, the pertinent data will
be provided in the ISA Data sheets supplied by Elliott. The anti surge is configured
with this data during testing.

3.3 Surge Line

The compressor flow values for surge flow at the off design, alternate point, normal,
and minimum cases were calculated to define the surge line of each compressor
section. Using this information, an appropriate control algorithm was selected. For
the selected algorithm, the compressor flow at surge is defined as a function of the
differential pressure across the compressor. The compressor flow versus compressor
differential pressure is input into a characterizer in the controller configuration. The
characterizer output is the value of compressor flow at surge for that pressure ratio.
The surge line and control line are shown on the surge map below. The control line
shown is based on 10% surge margin. Elliott has configured the EDS controller
based on the predicted compressor performance. During initial commissioning of the
system, compressor surge must be confirmed.

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3.4 Surge Map
The surge map is displayed below.

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4.0 Specialized Code for the Crack Gas String
Due to the design of the Crack Gas string, specialized control is needed to protect each section
of the compressor. The first anti surge valve is responsible for the protection of the first three
compressor sections, which are contained in two separate bodies. The last two sections, which
are contained in a third body, are protected by the second anti surge valve.
Using the available instrumentation and the known properties of the compressors, re-scaled
performance maps are implemented on each section. In the event that one of the first three
sections approaches surge, the controller will open the first anti surge valve to alleviate the
surge condition.
Additionally, if either of the last two sections approaches surge, the controller will open the
second antisurge valve. This approach will adequately protect each section of the compressor
string with the available instrumentation.
Since any one of the compressor sections that are protected by a specific valve may open that
valve, operating points are shown for all five compressor sections.

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5.0 Commissioning of the Anti-surge System
The Anti surge controller was configured and tested at Elliott prior to shipment. However final
adjustments with respect to loop tuning and surge line verification can only be done when the
compressor is actually running. This section describes the basic pre-start checks and then
details the steps required to identify the location of surge. Finally the procedure for tuning the
controller is described.

5.1 Pre-Start Operations

The following pre-start operations for the compressor anti-surge control system are
required.
1. Make all electrical connections to the anti surge controller that are identified in
the interconnection wiring diagram.
2. Apply supply power to the controller. Check signals from the suction and
discharge pressure transmitters and the flow transmitters.
3. Operation of the compressor anti-surge bypass valves must be confirmed.
Obtain a reset on the control system. From the anti surge controller screen
place the controller in manual mode. Adjust the valve command signal to
stroke the valve verify the valve is functioning correctly.

5.2 Start-up
The state (Run or Shutdown) of the anti surge controller is determined by the status of a
discrete input. This input is wired to a contact from the motor starter or turbine
governor. When the motor or turbine is started, the anti surge controller will go into the
run state after a short delay to allow for motor or turbine acceleration. If a trip
condition occurs, the anti surge controller is placed in the shutdown state. The anti-
surge valve is held at the full open position when the controller is in the shutdown state.
Anti-surge control commences when the anti surge controller is in the Run state and the
controller outputs are in the auto mode.
After attaining the run state, the anti-surge valve is permitted to close to the extent
permitted by the anti-surge control algorithm. This means that the anti-surge valve will
modulate to maintain a safe minimum flow through the compressor. The amount of
recirculation required depends on the amount of forward flow (to the process).
For start-up, it is recommended to place the anti-surge valve control in manual until the
location of compressor surge is confirmed. Selecting manual mode at start-up will hold
the valve to the manual command position regardless of the controller state.

5.3 Compressor Surge Verification

The anti surge controller should be placed in manual mode until the location of
compressor surge is confirmed. As noted in Section 3 of the manual, the controller was
configured based on the compressor performance maps provided by Elliott. The
following is a general procedure that is recommended to determine the actual location
of compressor surge. The following procedure assumes that there is no forward flow to
the process (i.e. all compressor flow is recycled). Note that sidestream compressors

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may require manipulation of more than one anti-surge valve to create a surge for a
particular stage. Furthermore the operator is cautioned to assure that recycled flow is
being cooled before returning to the inlet stage.
• Set anti-surge controller to manual mode. Slowly close the anti-surge valve until
the compressor surges. Constantly watch real time trend on anti surge controller
screen. Note: The surge detection function may fully open the valve when surge
occurs if settings are correct. If the anti surge controller does not detect that a surge
has occurred the anti-surge valve must be manually opened following a surge
occurrence.
• For the surge line surge detection method, the operating point must cross the surge
line as it is defined in the factory configuration. If the compressor surges and the
anti surge controller does not indicate that a surge has occurred or if the compressor
does not surge and the anti surge controller indicates that a surge has occurred, then
the configured surge line must be modified.
• At the completion of the surge testing the data must be compared to that configured
in the controller (i.e., Characterizer). The surge history data will have to be
scrutinized to determine when surge actually occurred.
• Upon completion of revisions (if necessary) to the controller configuration the anti-
surge control stability must be tested.

5.4 Anti-surge Control Tuning

After completing the surge testing and revision of surge line data in the controller, the
anti-surge loop tuning must be checked. The following procedure is recommended to
evaluate and optimize the tuning. Note that it is necessary that the governor speed
control be placed in local control during this phase of the testing. The following
procedure assumes that there is no forward flow to the process (i.e. all compressor flow
is recycled).
1. With the controller in manual mode, adjust output until ACL value for the loop
being tested is approximately 0.
2. Switch the controller to the auto mode.
3. Observe the valve command and ACL fluctuation.
4. Switch the controller back to manual mode.
5. Manually adjust the valve position so that the anti-surge valve is fully open.
6. Switch the controller back to the auto mode.
7. Valve should close down and modulate to hold ACL value at 0.
8. If output or ACL value show excessive fluctuation or if surge occurs then the
tuning constants must be adjusted.
9. Adjust tuning as defined in Section 4.5 and repeat steps 5 through 8.

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5.5 General Tuning Guidelines
Always tune Proportional Band first with the integral gain set to a minimum value, say
5 repeats / minute.
Start with the Proportional Band at a high value, say 20.
Upset the system and observe the control response. The easiest way to introduce an
upset is to put the controller in manual and change the controller output such that the
process variable moves away from the setpoint. Then switch the control back to auto
and observe how quickly the output moves to the required value and the degree of
process variable or controller output cycling.
Double the proportional band setting and upset the system. When cycling just begins,
decrease the proportional band setting by 50%. For example, if cycling begins when
the proportional band is set at 50, decrease the proportional band to 25.
With the proportional band set at its new value, double the integral value and upset the
system. For example, with the integral at the starting value of 5, increase to 10 and
upset the system. Observe control stability as was done when the proportional band
setting was increased.
Continue to double the integral value until cycling begins. Now decrease the integral
value by 50% of the last incremental increase. For example, if cycling starts when the
integral value is doubled from 20 to 40, then decrease the integral to 30.

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