Control and Operation of Centrifugal Gas Compressors

ESD Simulation Training
Global Leaders in Training for the Process Industries
COURSE OUTLINE
Control and Operation of Centrifugal Gas Compressors

A Practical Introduction
ESD Simulation Training uses dynamic simulation models to deliver
hands-on training that will help you make better decisions in the
operation and maintenance of equipment and in the design of systems.
The capacity to create real scenarios in real time provides an engaging
learning environment and measurable results. Our courses are taught
by a highly qualified faculty of experienced engineers and operations
professionals and are broken into 40-minute sessions comprised of
lectures, simulation model exercises, videos, CBT, multi-media training
and group discussions. With a firm focus on hands-on training and
interaction, these courses will keep you engaged and result in a deeper
and more lasting understanding of process operations.
Summary: Intensive, three-day, hands-on course using dynamic simulation models to give
a practical introduction to centrifugal gas compressors, their performance characteristics
and their operation within a process plant. Topics will include compressor performance and
selection, control strategies for capacity and surge protection and compressor operations.
Pre-requisites: This course is designed for participants with no prior knowledge of
centrifugal gas compressors, and for those with experience who want to learn more.
Participant profile: Engineers, operations and maintenance personnel who are either
supervisors or who are responsible for the day-to-day operation or maintenance of
centrifugal compressors. Other professions which may be interested in this course include
process operators, technicians and engineers, including those responsible for the design or
modification of a process plant, as well as rotating machinery engineers seeking a deeper
understanding of the principles of operation and control of centrifugal compressors.
www.esd-simulation.com
COURSE OUTLINE
Learning Outcomes:
At the end of this course, delegates will:
Be able to identify the most common types of compressors in use today
Understand the thermodynamic and physical principles of compression systems
Be able to explain the purpose and function of the main compressor components
Appreciate the impact of suction condition variations (molecular weight/
composition, pressure, temperature) on compressor performance
Be familiar with the most commonly used capacity control systems
Appreciate how the design of an overall plant control scheme relates to the
compression system
Have a thorough understanding of surge and its consequences for the machine
Understand the principles of more complex anti-surge control systems
Be able to set-up simple anti-surge control systems for both fixed and variable
speed compressors
Be able to explore typical compressor operating scenarios (including start up) and
identify commonly encountered problems
Appreciate how to prevent a compressor surging on trip and the use of hot-gas
bypass valves
Course Curriculum:
This course will cover compressor performance and selection, instrumentation and control,
surge protection and compressor operation within the following sessions:
1. Compression Principles
Explore the differences between positive displacement (PD) and dynamic
compressors and how they influence the technical selection process
Understand the principles of the compression process and how they relate to the
laws which govern the performance of the machine
Learn how a centrifugal compressor raises pressure
2. Compressor Performance
Explore the ways in which compressor performance is mapped and identify the
important variables used (head, flow, efficiency and speed)
Study the effects on performance of changes to suction and discharge conditions,
primarily pressure and gas composition
Study the main differences in performance between fixed and variable speed
compressors
Explore compressor efficiencies and how they are defined and mapped
Hands-on: instructor gives a demonstration using a simulator to show how fixed
and variable speed compressors move on their curves/maps
Hands-on: using dynamic simulation, participants investigate the performance of
compressors (fixed and variable speed) against changing suction and discharge
conditions. They are encouraged to identify the suitability of using different
variables to define the performance map
COURSE OUTLINE
3. Capacity Control
The common methods of capacity control are explored for both fixed and variable
speed compressors
For each method, a summary based on applicability and efficiency is considered
a. Applications
b. Energy efficiency
c. Choice of controlled variable
d. Choice of manipulated variable
The concept of shared load control for parallel compressor configurations is
introduced
Hands-on: short dynamic simulation exercises are used to explore some typical
applications of capacity control
Hands-on: three case studies are presented showing typical control strategies and
delegates are encouraged to identify the strategies in question, identify potential
problem areas and summarise the operational characteristics of each
4. Simple Anti-Surge Control
Explore the phenomena of surge
a. How it occurs
b. Speed of onset
c. Consequences
Introduction to the basic principles and the theory of anti-surge control
Explore the significance of the safety margin and its magnitude
Explore the principles and design of a flow/deltaP anti-surge control system
Hands-on: dynamic simulation is used to allow delegates to investigate the
dynamics of the responses of an anti-surge control loop
Hands-on: dynamic simulation is used to allow delegates to investigate the structure
and tuning of typical anti-surge control systems
Hands-on: delegates carry out a surge test on a fixed speed compressor
5. Recycle Valve Sizing
Introduction to the theory of sizing valves, demonstrating the ways in which recycle
valves are used to protect compressors during run-down and normal operation
Hands-on: participants are given some practical methods to work out the size of a
recycle valve
COURSE OUTLINE
6. Complex Anti-Surge Control

Demonstration of the CCC (Compressor Control Corporation) anti-surge control
technology is used to explain the principles of complex anti-surge control
a. Explanation of the mapping technologies used to determine the position
of a compressor within its operating envelope
b. Defining the surge map
c. Explore the control safety margin
d. Explore how an anti-surge controller is configured to provide consistent
surge protection
e. Explanation of parallel compressor load share techniques
Hands-on: a dynamic model is linked to real CCC hardware to allow the tuning and
configuration of the system to be explained in detail
7. Compressor Operations
Developing a start up strategy for a pipeline compressor
Investigating multi-stage compressor operation
Hands-on: delegates are given the opportunity to conduct a start up of a compressor
using a dynamic simulation model
Hands-on: various exercises are performed on a multi-stage centrifugal compressor
8. Compressor Protection
Explore methods of protecting compressors from surge or damage on trip
a. Parallel recycle valves
b. Hot-gas bypass valves
Understand the principles to be adopted for the optimum design and layout of
equipment around the compressor
a. Non-return valves
b. Coolers
c. Scrubbers
d. Recycle lines/valves
Appreciate the impact of poor design on the performance of the anti-surge
control system
a. Coolers
b. Recycle lives/valves
9. Performance and Efficiency Monitoring
Introduction to factory testing (PTC10)
Methods for monitoring and tracking the performance of a centrifugal
compressor on a day to day basis
FACULTY
In addition to leading edge computer models and simulation tools, ESD Simulation Training
has a highly qualified faculty of experienced engineers and operations professionals
who have undergone extensive training within their areas of expertise. The depth of
their knowledge in the process industries has won the trust and respect of over 30,000
delegates over the past 20 years.
Mark Dixon, B.Sc. (Hons) C.Eng. MIChemE, MIGasE

Managing Director of ESD and a Chartered Chemical Engineer, Mark has been working as
a Chemical Engineer and delivering training courses for 28 years. He is a member of the
Institution of Chemical Engineers (IChemE) and the Institution of Gas Engineers.
Colin Baker, ONC Science

With 47 years experience in operation in the oil, gas, chemical and petrochemical
industries, Colin is one of the most knowledgeable simulator trainers in the world. His
expertise extends to the operation of ethylene plants, LNG production, oil refineries and
oil and gas production facilities.
Robert Hodder, MAIChE

Robert is a member of the American Institute of Chemical Engineers and has 45 years of
practical experience working as a Process Engineer, Operations Supervisor, and Training
Manager on oil refineries, LNG plants, offshore and onshore oil and gas production
facilities.
David Llewellyn, B.Sc. (Hons) C.Eng.

A fellow of the Institution of Chemical Engineers and the Institution of Gas Engineers,
David is a process engineer with 47 years experience in the energy industry with a wealth
of experience working in the production, storage and transportation of LNG, natural gas,
LPG and ammonia industries.
Peter Watson, B.Sc. (Hons), C.Eng

Peter is a fellow of the Institution of Chemical Engineers (Eur. Ing.MEI) and a Chartered
Engineer with 40 years experience in the oil and gas processing business, including many
senior management positions around the world.
FACULTY
Roger Edward, Power Engineer, First Class

Roger brings 36 years of training experience as a consultant to the industry in a wide
range of process facilities on several continents, specialising in implementing site-specific
training, safety and emergency response procedures.
Gareth Pemberton, B.Sc. (Hons) A.M.I. Mech.E

Gareth has over 35 years experience in the Rotating Equipment Industry as a design
engineer, project manager and general manager. He has worked principally in the oil and
gas, petrochemical and power generation sectors and most recently in the LNG industry
with direct involvement in many of the latest LNG projects.
Edward Dilley, B.Sc. (Hons) C.Eng.

A member of the Institution of Chemical Engineers with over 40 years of experience in
process control, process engineering and planning within the oil refining, petrochemical,
synthetic rubber and power industries. Edward brings a wealth of practical knowledge to
the classroom.
Mike Tolstyko, HNC MECH Eng., ONC Bus.

Mike has over 36 years of industry experience in drilling operations worldwide. He is fully
accredited by the IWCF, and is a member of the Society of Petroleum Engineers.
Ronald E. LeTard, P.E. BSChE, MEChE

Ron has been a professional engineer registered in Louisiana since 1976, and in Texas since
2005. Ron has 42 years total experience. For the last 12 years, Ron has taught courses on
installation and operation of rotating machinery at a major oil company and has also led
commissioning and troubleshooting efforts on numerous compression projects.

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ESD Simulation Training

Global Leaders in Training for the Process Industries