Control of Compressors

NAME : ASHIK JACOB OOMMEN

ROLL:03
EN.NO: R670211003
SAP : 500015111
M.TECH PROCESS DESIGN ENGINEERING

Contents
Introduction
Types of Compressors
Polytropic Head
Compressor Performance
Process Symbols
Control in Turbo-Machines
Control in Reciprocating Machines
Other Control Parameters
Anti-Surge Control
Conclusion

Introduction
Compressors are gas handling machines .
Performs the function of increasing gas pressure.
Done by Confinement or by Kinetic energy conversion.
Major ticket items in the capital cost of a chemical or

petroleum plant.
Eg : Large centrifugal compressor with a gas turbine is an

investment of many millions.

Types of Compressors

Positive
Displacement

Rotary
Blowers
Reciprocating
Compressors

Compressors
Axial
Turbomachines

Centrifugal
Compressors

The range of flow capacities and discharge pressures

that different compressor design can handle.

Polytropic Head
Performance of Compressor expressed in terms of

Polytropic head.

ZsRTs
H p p
1 MW
Where

p = Polytropic Efficiency
= Adiabatic Index
Pd=Discharge Pressure
Ps = Suction Pressure
Zs = Compressibility Factor

Pd

Ps

1
p

Compressor Performance
Compressor performance curves

should strictly be plots of

polytropic head Hp against
Suction flow
Performance curve of a

centrifugal compressor terminates

before the flow reaches zero.
At too low a flow, the compressor

will surge.
Upper limit of Performance curve

is Stonewall

Process Symbols

Control in Turbo-Machines

Introduction
The pressure drop

through the process

increases in proportion to
the square of the flow.
The exit of the process is

constant so that we can

add the process curve to
the compressor
performance curve.
Compressor operated

where the two line cross.

To adjust the flow, either the process curve or the

compressor curve has to move.

Also has to remove the conditions that the discharge and
the process inlet pressures are equal or that the flows are
equal.
There are different schemes that are possible for
controlling the flow. They are as follows :

Discharge Throttling
Suction Throttling
Speed Control
Variable inlet Guide Vanes
Recycle Manipulation

Discharge Throttling
Placing a control valve

between the compressor

and the process.
The pressure are no

longer equal.
Process curve will move

as we change the valve

opening

Due to the non-linear behavior of both the

compressor and the process, the relationship between

the flow and valve Pressure drop is highly non-linear.
But since we are expending energy to raise the

pressure of the gas to partially reduce it again across

the valve, the scheme is not energy efficient.
Range is limited since the process curve approaches

the end of the compressor curve as we close the valve,

resulting in Surge.

Suction Throttling
Control valve is relocated to

the suction of the compressor.

The compressor curve moves

when we change the suction

pressure.
More energy efficient than

Suction throttling due to

involvement of lower
pressures.
Has greater range because

surge point reduces as suction

pressure is reduced.

It is possible for the suction pressure to fall below

the atmospheric pressure.

Any leaks in the pipe-work would permit air to enter

into the compressor.

If compressing a flammable gas, will result in

explosion inside the machine.

Speed Control
Used if the compressor is

of variable speed type.

By changing the speed we

move from one

compressor curve to
another.
This is energy efficient.
However variable

frequency drives (VFD) for

large electric motors are
costly.

Variable Inlet guide vanes

Uses a set of adjustable

guide vanes on the inlet

to one or more of the
compressor stages.
Converts the inlet gas

forward momentum into

rotational momentum
Angle of the guide vanes

is adjustable.

Pre-rotation increases the compressor efficiency

permitting it to deliver a greater flow at the same

discharge pressure.
Since the guide vanes are present inside the compressor,

adjusting them changes the geometry of the machine

itself.
Another family of compressor curves will exist for each

guide vane angle, each with a different surge point.

Mechanically guide-vanes are more complex and more

costly to maintain.

Recycle Manipulation
Partially recycling gas

through the compressor

Thereby removing the

condition that flow through

the machine must equal to
the flow through the process.
Offers the greatest range

since the surge point is never

approached.
However, costly to install

and operate.

In reality, the system is more complex than drawn.

For example, the recycle must be cooled.
It is the least energy efficient approach.
It can however be used to increase the range of the

other schemes described, by recycling just enough to

avoid the surge.

Control in Reciprocating
Machines

Introduction
Reciprocating

compressor is a constant
volume, variable
discharge pressure
machine.
The volumetric

inefficiency is a result of
the clearance between
the piston end and the
cylinder end on the
discharge stroke.

Schemes used for the turbo-machines can also be

applied for reciprocating machines.

Suction throttling reduces the suction pressure and so
less gas enters the cylinder and less gas will be
discharged.
Discharge throttling has little effect on the flow.
Some other methods of capacity control is listed as
follows :

On-Off Control
Constant Speed unloading
Speed Control

On-Off Control
If the compressor wastes power when run continuously, the

capacity can be controlled by starting or by stopping the

motor.
Example shows an air mix blender uses a rapid series of highpressure air blasts when the mixer becomes full.
The high pressure air for this purpose is stored in the reciever.

Constant Speed Loading andUnloading

The driver operates continuously, at constant speed.
One varies the capacity in discrete steps by holding the

suction valves open on the discharge stroke or opening

clearance pockets in the cylinder.
The most common scheme are the three and the five-

step unloading techniques.

The large number of steps saves the horsepower because

it more closely matches the compressor output to

demand.

Three-Step Unloading

Five-Step Unloading

Capacity increment are 100%, 50% pr 0% of

maximum flow.
Method is accomplished by the use of valve
unloading in the double acting piston
Three steps include Suction, Discharge and
Blowdown.

Capacity increment are 100%, 75% , 50%

, 25% or 0%.
At 100%, both the suction valves and the
clearance pocket are closed.
Five Steps include Suction, Discharge,
Blowdown , Bypass and Purge.

Other Control Parameters

Control of Auxiliary items on the compressor

Package :

Oil, water and gas temperature

Oil, water and scrubber liquid level.
Fuel and starting gas pressures

Control of Compressor safety

Safety shutdown controls to be provided in case of harmful

temperatures, pressures, speed , vibration , engine load and liquid
levels.

Anti-Surge Control
Objective is to minimize

the recycling without

damaging the machine.
To do this, we need to
predict that surge is
about to occur.
Complexity of surge
avoidance depends much
on the machine and its
duty.
Example is as shown on
side

 This scheme causes the

recycle to open if the

discharge pressure is
exceeding the Suction
pressure.
Pressure must change

significantly as surge is
approached.
Better for Steep

Compressor Curves.

Anti-Surge Controller

Conclusion

Control of compressors plays a major role in a

chemical industry.
Temperature control can also be taken into

consideration.

References
A Real time Approach to Process Control , Second Edition;

William.Y.Svrcek, Donald.P.Mahoney, Brent.R.Young, John

Wiley and Sons Ltd.
Process Control a Practical Approach;Myke King; John

Wiley and Sons Ltd.

Compressor Handbook,;Paul.C.Hanlon;Mc-Graw Hill

Publishers.
Industrial Engineers Handbook: Process Control ; Third

Edition; Bela.G.Liptak; Chilton Book Company

THANK YOU!!!