Compressor Performance, Surge & Anti-Surge Control

Performance maps, polytropic head, surge line and margin, recycle valve sizing, controller tuning and testing
What you'll learn

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Read a compressor performance map and know what the operating point on it means
Explain what surge is, and separate it from rotating stall and from stonewall
Set a control line and select a surge margin you can defend
Size a recycle valve and specify the stroke time the trip transient actually requires
Predict how molecular weight, suction temperature and pressure move the whole map
Recognise the damage surge causes and the signatures that detect it early
Assess recycle line volume, cooler placement and check valve location as response problems
Tune an anti-surge controller and understand why feedback alone cannot handle a trip
Calculate polytropic head and efficiency from field data and trend it against the map
Investigate repeated surge events and build a credible diagnosis from real data
Requirements

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No prior compressor experience is required - the performance map is built up from the start
Any engineering, technical or operations background is enough to follow the course
Comfortable with basic algebra - the performance calculations are worked step by step
Helpful but not essential: access to a performance map or a compressor trend from your own plant
No software or purchases needed - no simulation package or licence is required
Description

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This course contains the use of artificial intelligence.
▸ A compressor gives you seconds. The protection either works or the machine is damaged.
Surge is not a slow degradation. It is a flow reversal that repeats several times a second, and the damage it does to thrust bearings, seals, impellers and diaphragms can be done in the time it takes to notice the alarm. Machines have been destroyed by a single event following a driver trip.
Yet most of the engineering around it is treated as somebody else's problem. The machine engineer owns the map, the control engineer owns the controller, the process engineer owns the recycle line volume, and the surge margin sits between them - a number nobody can point to a standard for, carrying an enormous consequence.
This course covers the whole chain. Reading a performance map and what moves it, what surge physically is and how it differs from stall and stonewall, how the surge line is determined and how much of it you should trust, and then the protection system itself - flow measurement, recycle valve sizing and stroke time, line volumes, controller response and trip logic.
▸ The system, not just the machine
Surge is a system phenomenon. A compressor with a perfectly good map will surge if the recycle volume is too large, the valve strokes too slowly, the flow transmitter is too slow, or the controller is tuned for steady operation and cannot handle a trip transient. The course treats the protection system as a piece of engineering with a response time that must be proven, not a loop that gets tuned at commissioning and never revisited.
Performance monitoring is covered honestly, because a map drawn on the day of the shop test is not the map the machine is running on five years later. Fouling moves the surge line, and a control line set against the original map is no longer where the engineer thinks it is.
Five focused sections, worked through in an afternoon.
▸ What you will master
• Read a compressor performance map - head and flow, speed lines, efficiency islands and the operating envelope
• Predict what a change in molecular weight, suction temperature or suction pressure does to the entire map
• Explain what surge physically is, and separate it from rotating stall and from stonewall or choke
• Recognise the damage surge causes and how quickly it is done, from thrust bearings to diaphragms
• Understand how a surge line is determined by test, and how much uncertainty sits behind the line you were given
• Set an anti-surge control line and select a surge margin, including why invariant coordinates matter
• Size and select a recycle valve for full recycle duty, and specify the stroke time the transient requires
• Assess recycle line volume, cooler placement and check valve location as control response problems
• Tune an anti-surge controller, and understand why pure feedback control cannot handle a trip transient
• Calculate polytropic head and efficiency from field data and trend real performance against the map
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Who this course is for

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Rotating equipment and machinery engineers responsible for centrifugal and axial compressors
Process engineers specifying compression duty, recycle systems and operating envelopes
Control and instrument engineers owning the anti-surge controller, valve and flow measurement
Commissioning and start-up engineers proving surge protection before first gas
Reliability and operations engineers investigating surge events or lost capacity
Graduate engineers entering rotating equipment, process or control roles
Homepage

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Code:

https://www.udemy.com/course/compressor-performance-surge-anti-surge-control

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