DRAWING TITLE
ANTI-SURGE SYSTEM DESIGN
TURBOMACHINERY SYSTEMS PROVIDER
ENGINEERING
CUSTOMER
PROJECT NAME
DRIVER
Mars 100 CS
EQUIPMENT
CFE Tuxpan Tula
C453
LOCATION
Mexico
REV
A
A1
DESCRIPTION
Initial Submittal
Revised submittal / Changed ASV type & removed Hot Bypass Valve per customer request
APPROVED
Franklin Enriquez
CHECK
Gus Mendez
ERCC
DRAWING NO.
PROJECT MANAGER
Fernando Lopez
DESIGN
DATE
7 Mar 16
25 Mar 16
3X231 - 149653
"THIS COPYRIGHTED WORK AND THE INFORMATION HEREIN IS PROPRIETARY TO
CATERPILLAR INC., SOLAR TURBINES INCORPORATED, AND/OR SUBSIDIARIES OF
EITHER. WITHOUT EXPRESS WRITTEN PERMISSION FROM CATERPILLAR INC. OR
SOLAR TURBINES INCORPORATED. ANY COPYING, DISCLOSURE, OR USE EXCEPT
THAT FOR WHICH IT IS LOANED, IS PROHIBITED."
COMP REV FSCM NO
B0
66195
PROJECT SHORT NAME
TC-CR4
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TABLE OF CONTENTS
INTRODUCTION .......................................................................................................................................................... 3
Document Purpose & Scope ................................................................................................................................... 3
General Design Notes ............................................................................................................................................. 3
Project Specific Notes .............................................................................................................................................. 4
Information and Data Requirements ........................................................................................................................ 4
Abbreviations / Definition ......................................................................................................................................... 5
References............................................................................................................................................................... 5
RECYCLE SYSTEM ..................................................................................................................................................... 6
ANTI-SURGE VALVE ................................................................................................................................................... 7
Anti-Surge Valve Sizing Information ........................................................................................................................ 7
Anti-Surge Valve Assembly ..................................................................................................................................... 9
Valve Schematic (Globe) .................................................................................................................................... 9
Recommended Accessories .................................................................................................................................. 10
Anti-Surge Valve Evaluation .................................................................................................................................. 11
Fast Stop Analysis ................................................................................................................................................. 12
System Volumes ............................................................................................................................................... 12
Anti-Surge Valve ............................................................................................................................................... 12
Valve Performance (Reference: Solar ES2451) .............................................................................................. 13
Deceleration Rate ............................................................................................................................................. 16
Head and Flow vs Time .................................................................................................................................... 17
Anti-Surge Control System ...................................................................................................................................... 18
Anti-Surge System Software Constants ................................................................................................................ 18
Flow Measuring Element .......................................................................................................................................... 20
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ANTI-SURGE SYSTEM DESIGN
"THIS COPYRIGHTED WORK AND THE INFORMATION HEREIN IS PROPRIETARY TO
CATERPILLAR INC., SOLAR TURBINES INCORPORATED, AND/OR SUBSIDIARIES OF
EITHER. WITHOUT EXPRESS WRITTEN PERMISSION FROM CATERPILLAR INC. OR
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INTRODUCTION
Document Purpose & Scope
The purpose of this document is to define the recommended anti-surge valve(s) and related accessories, and
components necessary for effective operation of the anti-surge control system to avoid surge during all phases of
compressor operation. This includes valve sizing data, criteria, accessories, performance evaluation and fast stop
analysis, transmitter ranges, and flow element data. This also includes the constant values that are required to
program the anti-surge control system software.
This document applies on all compressor packages that utilize Solar® Turbines proprietary compressor anti-surge
control system.
General Design Notes
1. Refer to ISA standard instrument symbols and identification (ANSI/ISA-S5.1) for symbols not identified.
2. For flow measurement using orifice plates: Meter run sizing criteria shown are for compressor packages
requiring accurate performance calculations. Upstream and downstream meter-run requirements are described
in AGA REPORT #3, Part 2.
3. For restricted travel or restricted trim valves, relief valve flow capacity must not exceed the maximum flow
normally associated with an identical valve with full travel or trim.
4. The customer is responsible for keeping the recycle line free of debris that could impair valve capability.
Periodic inspections are recommended.
5. Instrument air is preferred over natural gas for valve actuation media. If natural gas must be used, proper care
needs to be taken during conduit/interconnect installation on the valve positioner to ensure that gas does not
leak to the control panel (reference: Solar Service Bulletin 5.3/102).
6. Instrument air to be clean and oil-free. Refer to ISA-S7.0.01-1996, “QUALITY STANDARD FOR
INSTRUMENT AIR” for detailed specifications.
7. If a temporary or permanent suction line strainer is installed between the suction flow measuring element and
the compressor, the pressure drop across it must be monitored by the unit control system to ensure proper
operation of the surge protection system. This may be accomplished by installing a second pressure transmitter
downstream of the strainer, or delta-p transmitter across the strainer.
8. Design of the piping and the selection, and placement of instruments significantly affect the performance of an
anti-surge control system. The benefits of a good piping & instrumentation design cannot be over emphasized.
The cost of correcting a poor design once the equipment is in operation can be very expensive.
9. Guidelines to help ensure proper operation of the anti-surge control system are available in Solar’s Gas
Compression Control Systems document (Drawing # SPGCCS). The entire document is available upon
request.
10. Anti-surge control system designs are joint venture between the compressor supplier, the controls provider, and
the piping contractor. It is important that communication between these parties be given the highest priority to
facilitate an effective and efficient compressor controls design.
11. For effective anti-surge control system, all customer furnished data (e.g. suction pipe size, flow-meter data,
suction & discharge system volumes, etc) that are used on the design must be verified and confirmed by the
customer.
DRAWING TITLE
PROJECT SHORT NAME
ANTI-SURGE SYSTEM DESIGN
"THIS COPYRIGHTED WORK AND THE INFORMATION HEREIN IS PROPRIETARY TO
CATERPILLAR INC., SOLAR TURBINES INCORPORATED, AND/OR SUBSIDIARIES OF
EITHER. WITHOUT EXPRESS WRITTEN PERMISSION FROM CATERPILLAR INC. OR
SOLAR TURBINES INCORPORATED. ANY COPYING, DISCLOSURE, OR USE EXCEPT
THAT FOR WHICH IT IS LOANED, IS PROHIBITED."
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Project Specific Notes
1. Fast stop analysis revealed that an additional hot bypass valve is recommended to avoid compressor surge on
fast stop shutdowns however, the customer has decided not to install this valve and therefore has not been
included on the Unit Control Balance of Plant design.
2. In Solar fast stop analysis, process and operating conditions are modeled based on compressor design data
point, but may not be sufficient to simulate the actual field conditions. To validate Solar’s findings, it is highly
recommended that a full dynamic analysis/simulation be performed by the customer.
Information and Data Requirements
The table below shows the required information and data to complete and finalize the Anti-Surge System design
document.
Item
1
2
3
4
5
Description
Project Specific Process P&ID
Action By
EPC/Customer
DRAWING TITLE
PROJECT SHORT NAME
ANTI-SURGE SYSTEM DESIGN
"THIS COPYRIGHTED WORK AND THE INFORMATION HEREIN IS PROPRIETARY TO
CATERPILLAR INC., SOLAR TURBINES INCORPORATED, AND/OR SUBSIDIARIES OF
EITHER. WITHOUT EXPRESS WRITTEN PERMISSION FROM CATERPILLAR INC. OR
SOLAR TURBINES INCORPORATED. ANY COPYING, DISCLOSURE, OR USE EXCEPT
THAT FOR WHICH IT IS LOANED, IS PROHIBITED."
Status
Open
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Abbreviations / Definition
ASV
=
Anti-surge Valve
FSV
=
Fast Stop Valve
HBV
=
Hot Bypass Valve
HPC
=
High Pressure Compressor
IPC
=
Intermediate Pressure Compressor
LPC
=
Low Pressure Compressor
K50
=
Gas Specific Heat Ratio @ 50 deg F
K300
=
Gas Specific Heat Ratio @ 300 deg F
PCP
=
Pseudo-Critical Pressure
PCT
=
Pseudo-Critical Temperature
SG
=
Specific Gravity
Turndown =
Ratio @ Constant Head of the difference between Actual Flow & Surge Line Flow, to the
Actual Flow, expressed in %
X
=
Ratio of Actual Pressure Drop to Absolute Inlet Pressure of Valve
Cv
=
Flow Coefficient or Flow Capacity Rating of Valve
Xt
=
Ratio of Terminal Pressure Drop to Absolute Inlet Pressure of Valve
Lin
=
Linear Valve Characteristic
Eq%
=
Equal Percentage Valve Characteristic
Q Open =
Quick Opening Valve Characteristic
NGP
=
Gas Producer Speed
NPT
=
Power Turbine Speed
ASC
=
Anti-surge Control
Ki
=
Integral Gain
Kp
=
Proportional Gain
KCL
=
Control Line Constant
KDB
=
Dead Band Line Constant
C’
=
C-Prime or Flow Element Coefficient
References
The following documents were used as references for this specification.
Document Title
Drawing No.
DRAWING TITLE
Rev / Date
PROJECT SHORT NAME
ANTI-SURGE SYSTEM DESIGN
"THIS COPYRIGHTED WORK AND THE INFORMATION HEREIN IS PROPRIETARY TO
CATERPILLAR INC., SOLAR TURBINES INCORPORATED, AND/OR SUBSIDIARIES OF
EITHER. WITHOUT EXPRESS WRITTEN PERMISSION FROM CATERPILLAR INC. OR
SOLAR TURBINES INCORPORATED. ANY COPYING, DISCLOSURE, OR USE EXCEPT
THAT FOR WHICH IT IS LOANED, IS PROHIBITED."
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RECYCLE SYSTEM
10
9
8
6
7
3
4
5
2
1
Suction Volume
E
E
Discharge Volume
D
D
ANTI-SURGE
(FO)
C
C
Suction to
Eye
B
PT
S
V
LV
TE
FT
TE
DV
Suction
Volume
Mars 100
C453
B
Discharge
Volume
PT
V
V
A
A
10
9
8
7
6
4
5
3
Figure 1 – Recycle System Schematic
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ANTI-SURGE SYSTEM DESIGN
"THIS COPYRIGHTED WORK AND THE INFORMATION HEREIN IS PROPRIETARY TO
CATERPILLAR INC., SOLAR TURBINES INCORPORATED, AND/OR SUBSIDIARIES OF
EITHER. WITHOUT EXPRESS WRITTEN PERMISSION FROM CATERPILLAR INC. OR
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2
1
ANTI-SURGE VALVE
Anti-Surge Valve Sizing Information
The following figures provide the data and information necessary for sizing the valve.
DESIGN ENGINEER:
Franklin Enriquez
PROJECT DEFINITION NUMBER (PD):
3X231
REV AB
COMPRESSOR PERFORMANCE CURVE # I-37204
VALVE MAXIMUM FLOW COEFFICIENT (Cv):
810
DATE: 25-Mar-16
COMPRESSOR CONFIGURATION: HP Body
K50
K300
PCP
PCT
S.G.
1.306
1.235
4684.9888
199.4
0.5928
KPA
K
CONSTANT VALVE OUTLET PRESSURE
5410.3175
KPA
MAXIMUM VALVE INLET TEMPERATURE
119
°C
RECYCLE VALVE SIZING
0.60
0.50
0.40
X
(∆P/P1)0.30
0.20
0.10
0.00
0.00
5000.00
10000.00
15000.00
20000.00
25000.00
SM3/d-e3
Figure 2 – Anti-Surge Valve Sizing Graph
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PROJECT SHORT NAME
ANTI-SURGE SYSTEM DESIGN
"THIS COPYRIGHTED WORK AND THE INFORMATION HEREIN IS PROPRIETARY TO
CATERPILLAR INC., SOLAR TURBINES INCORPORATED, AND/OR SUBSIDIARIES OF
EITHER. WITHOUT EXPRESS WRITTEN PERMISSION FROM CATERPILLAR INC. OR
SOLAR TURBINES INCORPORATED. ANY COPYING, DISCLOSURE, OR USE EXCEPT
THAT FOR WHICH IT IS LOANED, IS PROHIBITED."
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DESIGN ENGINEER: Franklin Enriquez
REV AB
PROJECT DEFINITION NUMBER (PD):
3X231
COMPRESSOR PERFORMANCE CURVE # I-37204
DATE: 25-Mar-16
KPA
TBD
RECYCLE LINE PRESSURE RELIEF VALVE SETTING
VALVE ANSI CLASS RATING (Must match Recycle Pipe rating):
900
COMPRESSOR CONFIGURATION: HP Body
22 / 24
RECOMMENDED RECYCLE PIPE SIZE (Upstream/Downstream) INCHES
GAS CHARACTERISTICS
K50
1.306
K300
1.235
PCP
4684.9888
PCT
199.4
S.G.
0.5928
CONSTANT VALVE OUTLET PRESSURE
SURGE PROTECTION MARGIN:
KPA
K
5410.3175
KPA
10%
TURNDOWN
THROTTLING CONDITIONS (Note relief valve setting above):
N
Q
RPM
SM3/d-e3
P1
P2
T1
D-P
K1
Z1
Power
KPA
KPA
°C
KPA
N
Q
RPM
SM3/d-e3
P1
P2
T1
D-P
K1
Z1
Power
KPA
KPA
°C
KPA
8,000
9080.15
7,000
7570.68
6,000
6305.49
9770.85
5410.32
97.87
4360.54
1.26
0.93
10820.86
8559.07
5410.32
85.37
3148.75
1.26
0.93
6875.70
7619.03
5410.32
74.49
2208.71
1.27
0.92
4201.42
5,700
5943.63
7378.49
5410.32
71.51
1968.17
1.27
0.92
3572.45
Figure 3 – Anti-Surge Valve Sizing Data
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ANTI-SURGE SYSTEM DESIGN
"THIS COPYRIGHTED WORK AND THE INFORMATION HEREIN IS PROPRIETARY TO
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EITHER. WITHOUT EXPRESS WRITTEN PERMISSION FROM CATERPILLAR INC. OR
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Anti-Surge Valve Assembly
Valve Schematic (Globe)
4
6
3
FREE FLOW
7
1
5
C2
4-20 MA
CLOSED LIMIT SW.
OPEN LIMIT SW.
4-20 MA
S
8
AIRSET
2
Figure 4 – Anti-Surge Valve Assembly, Globe Valve - Typical
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ANTI-SURGE SYSTEM DESIGN
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EITHER. WITHOUT EXPRESS WRITTEN PERMISSION FROM CATERPILLAR INC. OR
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Recommended Accessories
SOLAR TURBINES
REFERENCE
DRAWING NUMBER
CALL OUT
Note 1
N/A
1
Fisher 67CFR
N/A
2
Note 3
N/A
3
Fisher 289RC
1033516-1
4
Note 1
N/A
5
Needle Valve
ASCO V022A1
1041929
6
Check Valve
SS-CHSS-1/3
N/A
7
Headline, 360AFI70C
1043229-1
8
DESCRIPTION
VENDOR P/N
Electro-Pneumatic Positioner
Pressure Regulator
Three-Way 24 VDC Solenoid
Valve
Exhaust Booster
Position Transmitter
Coalescing Filter
Table 1 - Recommended Anti-Surge Valve Accessories
NOTES:
1. Electro-Pneumatic Positioner - Smart Type Positioner with 4-20mA feedback position signal and open/closed limit
switches suggested.
2. Pressure Regulator, For larger actuators a larger capacity regulator may be required to achieve desired closing speeds
(Fisher 64R /1041930).
3. Three-Way 24 VDC Solenoid Valve - Explosion/Flame-proof with necessary certification and protection to meet specific
application requirements (BIFOLD Model FP06P, VERSA Model VSG-3321, or ASCO Series NF8327).
4. Exhaust Booster - For smaller actuators the 289RC may be too large (Cv=21). May use Humphrey QE4 or QE5.
5. Position Transmitter (required if not available with positioner in Note #1), 4-20 mA Proportional to 0-100%
Close with full open and full closed relay outputs.
6. For larger actuators a needle valve with greater free flowing capacity may be required to achieve desired closing
speeds.
7. Stainless steel check valve
8. High efficiency or equivalent coalescing filter
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ANTI-SURGE SYSTEM DESIGN
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EITHER. WITHOUT EXPRESS WRITTEN PERMISSION FROM CATERPILLAR INC. OR
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Anti-Surge Valve Evaluation
The figure below shows the valve position/travel of the recommended valve superimposed on the compressor
curve. This provides the expected valve travel to recycle the compressor to avoid surge during normal operation,
and helps evaluate the valve for controllability at partial recycle condition.
DESIGN ENGINEER:
PROJECT DEFINITION NUMBER (PD):
COMPRESSOR PERFORMANCE CURVE #
DATE:
COMPRESSOR CONFIGURATION:
VALVE MANUFACTURER:
BODY TYPE
BODY SIZE
PORT DIAMETER
TOTAL TRAVEL
CAGE CHAR:
MAX RATED Cv:
Franklin Enriquez
3X231
I-37204
3/25/2016
HP Body
Dresser
41335
304.80 mm
247.65 mm
101.60 mm
LINEAR
810
Connected at Compressor Discharge
REV AB
ISA RECYCLE VALVE EVALUATION
LINEAR CHARACTERISTIC
2.40
100%
2.20
R
A
T
I
O
P
2
/
P
1
50%
40%
2.00
30%
1.80
1.60
1.40
1.20
1.00
0
5000
10000
15000
M3/hr
20000
25000
30000
Figure 5 – Anti-Surge Valve on Compressor Map
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ANTI-SURGE SYSTEM DESIGN
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EITHER. WITHOUT EXPRESS WRITTEN PERMISSION FROM CATERPILLAR INC. OR
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THAT FOR WHICH IT IS LOANED, IS PROHIBITED."
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Fast Stop Analysis
The following is a model of a PLC initiated fast stop shutdown of a compressor set. The model predicts the
pressures in the volumes on either side of the compressor and how these pressures compare to the compressor
surge limit. The model begins (time T0 ) when the fast stop is initiated. Simultaneously signals are sent to the fuel
valve to close, and to the anti-surge valve(s) to open. The model incrementally predicts the flow through the antisurge valve(s), the flows in and out the suction and discharge volumes, the flow through the compressor and the
effect of these flows on pressures in the volumes. For initial condition, the simulation assumes that the compressor
is operating at design pressures, temperatures and head, and 25% turndown with fully closed anti-surge valve.
(Reference: PIL 216).
System Volumes
The following volumes were used in the shutdown analysis, and are the maximum volumes that the valve(s), shown
below can handle to avoid surge during a fast stop shutdown.
NOTE: The suction volume is assumed to be infinite (very large volume) when no check valve is installed at the
suction line that can define the boundary of the suction volume.
Suction
Discharge
30000
3
m3
m3
Table 2 - Suction and Discharge Systems Volume
Anti-Surge Valve
The table below shows the type and fully open Cv of the anti-surge valve used in the model. The anti-surge valve
is opened though the solenoid during fast stop shutdown. This valve is also used for surge protection during normal
operation, and therefore sized for optimum controllability at partial recycle condition.
Cv
810
Xt
0.74
Valve Port Size
9.75
inches
Valve Characteristic Globe Lin
Valve Body Size
12
inches
Table 3 – Anti-Surge Valve CV
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Valve Performance (Reference: Solar ES2451)
The valve shall meet or exceed the opening speed/time requirements from fully closed position.
Opening time requirement as a result of the solenoid being de-energized as follows:
Anti-Surge Valve: The valve must reach 63.2% open in 100 + 100 inches of port size (milliseconds)
Fast Stop/Hot Bypass Valve: The valve must reach 63.2% open in 70 + 70 inches of port size (milliseconds)
With positioner command step change from 20 to 12 mA:
Anti-Surge Valve:
The valve must reach 50.0% open in 300 + 100 inches of port size (milliseconds) = maximum half opening time.
Example:
A 4” valve, 4.375” port, must reach 50% open in less than 509 milliseconds.
The valve shall not overshoot by more than 60% and have a maximum excursion not to exceed 80% open.
% Overshoot = (Maximum Excursion – Final Position) / Final Position – Starting Position) X 100
Example:
Valve goes to 80% travel from closed position and return to 50%.
Starting Position = 0% (closed), Maximum Excursion = 80%, Final Position = 50%
% Overshoot = (80-50) / (50-0) X 100 = 60%
After the overshoot the valve shall return to its ultimate position (50% open) in less than 10 times its maximum half
opening time.
Example:
A 4” valve, 4.375 port, at maximum overshoot, must return to its ultimate destination in 5.09 seconds, and
at maximum recovery time, must have no more than 30% overshoot.
The area beyond the ultimate destination (overshoot triangle) shall be less than 1.5.
Where:
Area = B X (H/2)
B = Recovery Time (X2) divided by Maximum Half Opening Time
H = % Overshoot (Y)
If there is a second “ring” returning from the overshoot, it shall not exceed 2.5% of the total valve travel.
Valve minimum resolvable position (stick & slip) shall not exceed 2% of the total travel.
The valve can go over 60% overshoot given the area is less than 1.5 and travel is less than 90%.
Two 20% step changes shall be performed. The overshoot, recovery time and overshoot triangle shall be
calculated and included in the test results. There are no pass/fail criteria guidelines for this test. This is to gather
data and record valve performance on small step changes.
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ANTI-SURGE SYSTEM DESIGN
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20 ma
Closed
12 ma
50% travel
Overshoot Area
(<1.5)
X1
X2
X1: Opening Time
X2: Recovery time
Figure 6 – Acceptable Positioning at Maximum Recovery Time
20 ma
Closed
12 ma
50% travel
Overshoot Area
(<1.5)
Y
X1
X1: Opening Time
Y: Overshoot travel
Figure 7 – Acceptable Positioning at Maximum Overshoot
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ANTI-SURGE SYSTEM DESIGN
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EITHER. WITHOUT EXPRESS WRITTEN PERMISSION FROM CATERPILLAR INC. OR
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20 m a
C lo s e d
O v e rs h o o t A re a ,A 2
2 0 % tra v e l
1 7 .6 m a
O v e rs h o o t A re a ,A 3
X3
2 0 % tra v e l
15 m a
X4
X3
X4
X 1 ,X 3 : O p e n in g T im e
X 2 ,X 4 : R e c o v e r y tim e
Figure 8 – Positioning at 20% Step Change and Recovery Time
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EITHER. WITHOUT EXPRESS WRITTEN PERMISSION FROM CATERPILLAR INC. OR
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Deceleration Rate
The figure below illustrates the power turbine speed (NPT), which is also the compressor speed modeled
deceleration during the first two seconds of shutdown. During the first 0.3 seconds the power turbine decelerates
linearly with a deceleration rate of 5% speed per second. This is the amount of time it takes the flame to go out
once the fuel valve is commanded closed, and can vary between turbine models. After 0.3 seconds the power
turbine is expected to decrease speed by 30% in a second with a relationship inversely proportional to time.
Also shown in the figure is the valve Cv(s) used in the model with respect to time as the valve opens.
90.00%
900
80.00%
800
70.00%
700
60.00%
600
50.00%
500
40.00%
400
30.00%
300
20.00%
200
10.00%
100
0.00%
Cv
% NPT
Compressor Deceleration
0
0
0.5
1
1.5
2
2.5
Time (sec)
NPT Deceleration Curve
Recycle Valve Opening
Figure 9 – NPT/Compressor Deceleration
DRAWING TITLE
PROJECT SHORT NAME
ANTI-SURGE SYSTEM DESIGN
"THIS COPYRIGHTED WORK AND THE INFORMATION HEREIN IS PROPRIETARY TO
CATERPILLAR INC., SOLAR TURBINES INCORPORATED, AND/OR SUBSIDIARIES OF
EITHER. WITHOUT EXPRESS WRITTEN PERMISSION FROM CATERPILLAR INC. OR
SOLAR TURBINES INCORPORATED. ANY COPYING, DISCLOSURE, OR USE EXCEPT
THAT FOR WHICH IT IS LOANED, IS PROHIBITED."
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Head and Flow vs Time
The graphs below illustrate how the actual head and flow compare to the head and flow at surge condition during
the first 2 seconds of a fast stop.
In order to keep the units out of surge:
1) The actual head must be lower than the head at surge.
2) The actual flow must be greater than the flow at surge.
HP Unit, Surge Margin
6000
Surge
5000
Actual
Flow (ACFM)
4000
3000
2000
1000
0
0
0.5
1
1.5
2
2.5
Time (sec)
HP Unit, Head Rise To Surge
35000
Isentropic Head (ft lbf/lbm)
30000
Surge
25000
Actual
20000
15000
10000
5000
0
0
0.5
1
1.5
2.5
2
Time (sec)
Figure 10 – Head and Flow vs Time
DRAWING TITLE
PROJECT SHORT NAME
ANTI-SURGE SYSTEM DESIGN
"THIS COPYRIGHTED WORK AND THE INFORMATION HEREIN IS PROPRIETARY TO
CATERPILLAR INC., SOLAR TURBINES INCORPORATED, AND/OR SUBSIDIARIES OF
EITHER. WITHOUT EXPRESS WRITTEN PERMISSION FROM CATERPILLAR INC. OR
SOLAR TURBINES INCORPORATED. ANY COPYING, DISCLOSURE, OR USE EXCEPT
THAT FOR WHICH IT IS LOANED, IS PROHIBITED."
TC-CR4
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ANTI-SURGE CONTROL SYSTEM
Anti-Surge System Software Constants
DATE
ENGINEER
CUSTOMER
PROJECT PD or SALES NO.
STATION NAME
LOCATION
DRIVER
DRIVEN EQUIPMENT
COMPR. PERF. MAP NO.
COMMENTS
3/4/2016
Franklin Enriquez
TCPL
3X231
TUXPAN
Mexico
Mars 100
C45-3
I-37204
Need Air Test B-Factor
CONFIGURATION
FLOW DESIGN HEAD
Specific Gravity
SPEC. HEAT RATIO (K1)
CPSR P1
CPSR P2
COMPRESSOR T1
COMPRESSOR T2
CPSR Z1
CPSR Z2
CRIT. PRESSURE
CRIT.TEMPERATURE
PAGE 1 OF 2
Rev AH
HP BODY
(KPA)
172.3648356
0.5928
1.285
5410.32
9305.9
43.40
91.2
0.9150
0.9290
4684.99
199.4
(KPA)
(KPA)
(°C)
(°C)
(KPA)
(K)
FLOW TRANSMITTER RANGE
SPECIFIC GRAVITY
RATIO OF SPECIFIC HEAT (K=Cp/Cv)
COMPRESSOR SUCTION PRESSURE
COMPRESSOR DISCHARGE PRESSURE
COMPRESSOR SUCTION TEMPERATURE
COMPRESSOR DISCHARGE TEMPERATURE
SUCTION GAS COMPRSBLTY FACTOR
DISCHARGE GAS COMPRSBLTY FACTOR
GAS CRITICAL PRESSURE
GAS CRITICAL TEMPERATURE
SOLAR'S SURGE CONTROL SYSTEM
K-VALUES TABLE
DESCRIPTION
KT_HPC_ASC_Fast_Kp
KT_HPC_ASC_Fast_Ki
KT_HPC_ASC_Slow_Kp
KT_HPC_ASC_Slow_Ki_Yn.Val[0]
KT_HPC_ASC_Slow_Ki_Yn.Val[1]
KT_HPC_ASC_KCL
KT_HPC_ASC_KDB
HPC_ASC_Flow_DP
Hp_Suc_Press
Hp_Dis_Press
KT_HPC_ASC_Surge_Line_ A_Coef
KT_HPC_ASC_Surge_Line_ B_Coef
KT_HPC_ASC_Surge_Line_ C_Coef
KT_HPC_ASC_Surge_Line_ D_Coef
KT_HPC_ASC_Surge_Pulse_ROC
KT_HPC_ASC_X_Max
KT_HPC_ASC_Y_Max
KT_HPC_ASC_Y_Min
KT_HPC_ASV_Manual_Rate
KT_Npt_Min_At_Idle
KT_Npt_Min_At_On_Load
TT4
4.00
75.00
0.40
20.00
75.00
10.0000
2.0000
692.00
See Hydros
See Hydros
2.5672E-05
-4.7477E-03
7.1576E-01
7.4550E+00
334.17
1.000000
1.000
32.593
2.00
44.00
60.00
%
Verify Minimum Compressor
Speed!
Table 4 – Surge Design Data
DRAWING TITLE
PROJECT SHORT NAME
ANTI-SURGE SYSTEM DESIGN
"THIS COPYRIGHTED WORK AND THE INFORMATION HEREIN IS PROPRIETARY TO
CATERPILLAR INC., SOLAR TURBINES INCORPORATED, AND/OR SUBSIDIARIES OF
EITHER. WITHOUT EXPRESS WRITTEN PERMISSION FROM CATERPILLAR INC. OR
SOLAR TURBINES INCORPORATED. ANY COPYING, DISCLOSURE, OR USE EXCEPT
THAT FOR WHICH IT IS LOANED, IS PROHIBITED."
TC-CR4
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18 OF 20
DATE
ENGINEER
CUSTOMER
PROJECT PD or SALES NO.
STATION NAME
CONFIGURATION
DATA
POINT
9500
9000
8000
7000
6000
5700
FLOW
(ACFM)
4868.5
4484.0
3776.5
3148.7
2622.5
2472.0
3/4/2016
Franklin Enriquez
TCPL
3X231
TUXPAN
PAGE 2 OF 2
Rev AH
HP BODY
P2
(PSIA)
1774.8
1643.7
1421.2
1244.5
1107.4
1072.3
D ATA
TAB LE
FLOW
H(SURGE)
(MMSCFD)
(INCHES H2O)
372.3941
216.59
342.9835
183.73
288.8664
130.32
240.8457
90.59
200.5964
62.84
189.0846
55.84
ANTISURGE PROTECTION IS:
SUCTION FLOWMETER C'
H(CONTROL)
(INCHES H2O)
267.39
226.82
160.89
111.85
77.59
68.94
Disch. T
(°F)
246.6
233.2
208.2
185.7
166.1
160.7
10.0 % TURNDOWN
37637.86
Flow transmitter range (for surge control):
Max flow transmitter range (if needed):
T2 transmitter range:
P1 transmitter range:
P2 transmitter range:
(INCHES H2O, PSIA, SCFH)
692.00
N/A
See Hydros
See Hydros
See Hydros
(INCHES H2O)
(INCHES H2O)
(°F)
(PSIG)
(PSIG)
(DAMPING = 0.0)
Table 5 – Surge Design Data (Cont’d)
NOTE: Above data are used for anti-surge control system software testing. Software is designed to use English
units only.
DRAWING TITLE
PROJECT SHORT NAME
ANTI-SURGE SYSTEM DESIGN
"THIS COPYRIGHTED WORK AND THE INFORMATION HEREIN IS PROPRIETARY TO
CATERPILLAR INC., SOLAR TURBINES INCORPORATED, AND/OR SUBSIDIARIES OF
EITHER. WITHOUT EXPRESS WRITTEN PERMISSION FROM CATERPILLAR INC. OR
SOLAR TURBINES INCORPORATED. ANY COPYING, DISCLOSURE, OR USE EXCEPT
THAT FOR WHICH IT IS LOANED, IS PROHIBITED."
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FLOW MEASURING ELEMENT
DATE
ENGINEER
CUSTOMER
PROJECT PD or SALES NO.
STATION NAME
LOCATION
DRIVER
DRIVEN EQUIPMENT
COMP. PERF. MAP
COMMENTS
ORIFICE LOCATION
Suction to Eye
DESIGN HEAD
MAX FLOW RANGE
FLOW
(m^3/hr)
3.7E-07
B Factor:
Single Flow Coefficient
FLOWMETER CALCULATION
METHOD
Specific Gravity
SPEC. HEAT RATIO (K1)
CPSR P1
CPSR P2
COMPRESSOR T1
COMPRESSOR T2
CPSR Z1
CPSR Z2
CRIT. PRESSURE
CRIT.TEMPERATURE
PAGE 1 OF 1
Rev AH
3/4/2016
Franklin Enriquez
TCPL
3X231
TUXPAN
Mexico
Mars 100
C45-3
I-37204
Need Air Test B-Factor
(KPA)
(K)
0.59
1.29
5410.32
9305.86
43.40
91.20
0.9150
0.9290
4684.99
199.39
SPECIFIC GRAVITY
RATIO OF SPECIFIC HEAT (K=Cp/Cv)
COMPRESSOR SUCTION PRESSURE
COMPRESSOR DISCHARGE PRESSURE
COMPRESSOR SUCTION TEMPERATURE
COMPRESSOR DISCHARGE TEMPERATURE
SUCTION GAS COMPRESSIBILITY FACTOR
DISCHARGE GAS COMPRESSIBILITY FACTOR
GAS CRITICAL PRESSURE
GAS CRITICAL TEMPERATURE
(KPA)
(KPA)
172.365
N/A
FLOW TRANSMITTER RANGE FOR SURGE (DAMPING = 0.0)
MAX FLOW TRANSMITTER RANGE
(KPA)
(KPA)
(°C)
(°C)
DESIGN POINT
9756.98
MINIMUM FLOW
4199.95
MAXIMUM FLOW
14530.28
FLOW
(SM3/hr)
517790.15
222886.16
771103.11
FLOW
(KG/MIN)
6272.63
2700.10
9341.32
C'
37637.86
37637.86
37637.86
75.06
13.91
166.47
5410.32
5410.32
5410.32
(INCHES H2O, PSIA, SCFH)
DELTA-P, h
(KPA)
PRESSURE at Flowmeter
(KPA)
Table 6 – Flow Measuring Element Data
DRAWING TITLE
PROJECT SHORT NAME
ANTI-SURGE SYSTEM DESIGN
"THIS COPYRIGHTED WORK AND THE INFORMATION HEREIN IS PROPRIETARY TO
CATERPILLAR INC., SOLAR TURBINES INCORPORATED, AND/OR SUBSIDIARIES OF
EITHER. WITHOUT EXPRESS WRITTEN PERMISSION FROM CATERPILLAR INC. OR
SOLAR TURBINES INCORPORATED. ANY COPYING, DISCLOSURE, OR USE EXCEPT
THAT FOR WHICH IT IS LOANED, IS PROHIBITED."
TC-CR4
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