APPLICATION DATA

AD353-121
Rev 2
April 2012

Procidia Control Solutions

Compressor Surge Control
This application data sheet describes implementing represent compressor head and capacity. The most
compressor surge control in a Siemens 353 common method of surge control uses compressor
controller 1 . ∆P to represent head and the differential pressure
across an inlet orifice (called “h”) to represent
Centrifugal and axial compressors cannot be allowed capacity.
to operate in the surge area, see Figure 1. Operating
in the surge area will result in unstable compressor It is important to realize that the “h vs. ∆P” method of
operation, exposing the machine to destructive stress surge control uses the “raw” differential (h), rather
and vibration. If the flow requirements of the process than a flow signal (Q) that has been compensated for
are such that the compressor operates in the surge pressure and temperature and characterized with a
area, a portion of the discharge flow must be vented, square root extractor. When h is used, there is a
or recycled to the inlet, to keep the flow through the fairly linear relationship between h and ∆P at the
machine below the surge area. 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
Figure 1 “h” vs. ∆P Surge Control Line to relieve the excess pressure. After the flow
reversal relieves the downstream pressure, the
The performance map of a compressor, typically compressor will restore flow in the forward direction.
supplied by the compressor manufacturer, is a plot of However, if no action is taken to increase the flow
head vs. capacity over the full range of operating demand, these flow reversals will continue to occur.
conditions. The map also shows the location of the This unstable operation is called “surge” and it can
surge line, which separates the region of safe cause serious damage to the compressor.
operation from the surge area.
To prevent surge, it is necessary to keep the
Surge control generally requires a method of inferring compressor operating to the right of the surge line
the point at which the compressor is operating shown in Figure 1. The surge control strategy shown
relative to the surge line using variables that in Figure 2 uses a characterizer to plot the surge line
1 as a function of the inlet orifice differential (h). After
See Application Support at the back of this publication for applying a bias to the surge line to provide a margin
a list of controllers.
AD353-121

of safety, the resultant control line represents the The low signal selector allows the controller to
surge controller setpoint. If a decrease in flow override the manual value if necessary to open the
demand drives the compressor ∆P above the valve.
setpoint, the surge controller opens the recycle valve
to create an artificial flow demand that maintains safe For “fail safe” operation, the recycle valve should be
operation. an “air-to-close” valve (fails open). Therefore, the
.

SP CO
Bias PID < Conditional Manual
.
PV Lo Select
Surge Line f(x)

L H Recycle
DPT DPT Valve
Fail Open
Compressor P
Inlet Flow Discharge Flow

Inlet
Orifice
"h"

Turbine
Compressor
.
Figure 2 Compressor Surge Control Strategy

valve display signal is inverted in Gain & Bias

Design function block GB1 to correspond with the CLOSE
and OPEN markings on the faceplate of the 353.
The configuration for the surge controller is shown in Likewise, the adjusting knob is configured to operate
Figure 3. Characterizer function block CHR1 and counterclockwise during manual operation.
Bias function block BIAS provide the control setpoint,
which varies with the operation of the compressor. The Rate Limiter function block RLM1 is configured
Under normal operating conditions, compressor ∆P to slow the closing of the recycle valve. This allows
will remain below the setpoint, and the PID controller the surge controller to be tuned for faster response
function block will “windup” to hold the recycle valve than would be possible without this limit. The RLM
closed. Should the compressor approach a surge should be set so as not to impede the opening of the
condition, the setpoint will tend to decrease and the recycle valve.
∆P will tend to increase. Whenever the ∆P crosses
the setpoint, the controller will open the recycle valve The compressor status signal (Run/Shutdown) is
as much as required to maintain the ∆P at the surge used to force the recycle valve fully open whenever
control setpoint. the compressor is shutdown. This prevents surge on
a compressor “trip” and also holds the valve in a fully
The batch switch (BATSW) is an anti-reset windup open position for startup.
device that manipulates the reset feedback signal
when controller output is off scale. This helps to Applications
minimize overshoot when ∆P approaches the control
line. This surge control strategy is applicable to both
variable speed and constant speed compressors. It
The Auto/Manual function block A/M, in combination is also applicable to axial and centrifugal
with low signal selector SEL1, provides conditional compressors.
manual operation. The operator can open the
recycle valve further but cannot close the recycle
valve any further than the surge controller permits.

2
 AD353-121

Figure 3 Surge Control Configuration (CF353-121)

Application Support Utility. Those with CF353 in parenthesis in the Figure

title are available using the above navigation, then
User manuals for controllers and transmitters, click Software Downloads > 353 Compressor
addresses of Siemens sales representatives, and Surge Control (Reference AD353-121).
more application data sheets can be found at
www.usa.siemens.com/ia. To reach the process The configuration(s) can be created and run in a:
controller page, click Process Instrumentation and • Model 353 Process Automation Controller
then Process Controllers and Recorders. To select • Model 353R Rack Mount Process Automation
the type of assistance desired, click Support (in the Controller*
right-hand column). See AD353-138 for a list of • i|pac™ Internet Control System*
Application Data sheets. • Model 352Plus™ Single-Loop Digital Controller*
* Discontinued model
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 Industry, Inc. Other trademarks are the property of their respective owners.
All product designations may be trademarks or product names of Siemens Industry, Inc. or other supplier companies whose use by third
parties for their own purposes could violate the rights of the owners.

Siemens Industry, 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 Industry, Inc. is not responsible for changes to product functionality after the publication of this document. Customers are urged to
consult with a Siemens Industry, 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 © 2012, Siemens Industry, Inc.