Proceedings of GT2007

ASME Turbo Expo 2007: Power for Land, Sea and Air
May 14-17, 2007, Montreal, Canada

GT2007-28270
Gas Turbine Compressor System Design Using Dynamic Process Simulation

Norman A. Samurin, PE George. C. Talabisco

Dresser-Rand Company Dresser-Rand Company
[email protected] [email protected]

ABSTRACT ESD Emergency shut down

Almost all petrochemical processes are modeled as steady state H Head
to establish the required sizes of pipe, vessels, compressors, HAZ-Op Hazardous Operation Review
pumps, and valves. A dynamic simulation study of the process LNG Liquefied natural gas
compressor system design can now be done as part of the initial N Rotating speed
plant design activity. The system piping design and proper NGL Natural gas liquids
placement of the anti-surge valves (ASV) along with Overload High flow region beyond the compressor map
preliminary valve sizing can be evaluated. Additional control Q Volume flow
strategies may be evaluated for emergency shut down (ESD). Surge A point where the flow within the compressor
This will confirm the system design to safely shutdown a becomes unstable.
compressor without surge. Many of the issues that may be
uncovered during study execution can save time and expense Gas Turbine Compressor Applications
before the initial commissioning of the process. For a plant • Gas pipeline applications usually have relatively constant
start up, the driver capability, compressor loading, positions of gas composition with variations in slow changing upstream
valves, and control philosophy may be tested before the and downstream pressure variations caused by the large
components are committed to hardware. volume of gas.
• Gas reinjection applications can have variations of gas
INTRODUCTION composition with potential for rapid changes in flow
New advances in computer computation speed and because of process upsets. There also could be slugs of
improvements in simulation programs now make it possible to liquid that cause flow disturbances in the compression
provide simulation modeling as part of the initial plant/process system. They usually are high pressure ratio applications
design. The requirements to accurately model the major that have discharge gas conditions greater than 5000 PSIG.
components of the simulation are discussed in this paper. The • Gas gathering applications collect untreated gas to make it
dynamic analysis of the process can be done up front because suitable for transfer to transmission pipelines. This type of
the programs have become less complex to set up and run. Skill compression system can have variations in gas
and knowledge are still required to properly create a simulation composition and system transients caused by dehydration,
model, interpret the data and recognize valid results. The lead filtration and sweetening system upsets. They are
times to do such an analysis have been dramatically reduced. somewhat similar to reinjection applications. Discharge
The system modeling may start with some basic simple pressures are usually under 3000 PSIG.
assumptions. This initial model can then grow, as more details • Processing plant applications cover a broad spectrum that
become known. Additional components may be added to the could include NGL removal, LNG facilities, and refinery
model and evaluated as an integral part of the system. Issues of & hydrocarbon processing plants. The plant transients
startup and shut down may point to system changes that would include variations in gas composition along with
not readily be understood from the normal steady state process upstream/downstream processing upsets.
flow diagrams. The DYFLO program (1) by QMC Corporation
was the simulation software package used in the evaluation of Requirements for a dynamic study
several actual case studies that this paper is based on. As mentioned above, the dynamic simulation requires
some components to be specified or approximated. The
compressor flow map is needed for estimating the performance.
NOMENCLATURE The volumes at the inlet and the discharge of the compressor
ASV Anti-surge valve are critical to evaluate the dynamic response of the system. It is
Cv Valve flow capacity important to note that the volumes determine the mass

1 Copyright © 2007 by ASME

contained in the process system. The compressor is used to • Rotating inertia of the gas turbine component mechanically
move mass from inlet to discharge. The time to move this mass connected to the load (i.e., power wheel)
is determined by the volumes and the given flow capability of • Control system response time to a transient condition
the compressor. The time it takes to fill a volume determines including:
the rate of increase in discharge pressure (head build up). A 1. fuel shutoff and control valve inherent time lag
compressor operating at full speed may operate in overload and response characteristics
until the pressure in the discharge volume builds up. During 2. stored energy of the fuel between the last fuel
start up, the compressor will accelerate and move gas mass shutoff valve and turbine combustor(s)
from inlet to discharge. Thus there can be a significant lag in 3. Turbine unloading through variable geometry or
the build up of discharge pressure. However, the compressor blowoff
power will follow its overload curve for flow and head These all combine to define the power decay
internally even though the external system head may be much characteristics of the rotating equipment.
lower. Some turbine manufacturers have test stand and or field
The calculations for a system are based on mass data to accurately determine response characteristics. When
distribution, pressure and temperature. The compressor is these are not available, assumptions have to be made which
operating between two volumes at different pressures. The may affect accuracy of results. The customary assumption of
volume head is fixed and at a given speed the compressor flow instantaneous loss of power production in response to a
is the resultant and not the driving element. To effect a change transient event can lead to an over design of components with
in the flow, the pressure and/or compressor speed must be associated commercial impact. Dynamic simulation can
modified. Therefore, the head and speed determine the flow for therefore provide a tool to gauge the validity of the design.
a dynamic simulation. Intentional time delay of the turbine trip has been utilized
successfully to prevent compressor surge in response to the
Piping Geometry and Equipment Layout rapid deceleration. See discussion below
The location of components in a compressor Other gas turbine characteristics that need to be
installation is critical to a plant design. This should be reviewed considered for upset conditions include maximum load
during the initial plant design to help prevent operational acceptance and rejection rates. These define the acceleration
problems. Some of the important points to consider are: and deceleration rates for safe and continuous equipment
• Large volumes located between the compressor discharge operation. Sometimes these maximum rates may not be
flange and the recycle valve should be avoided or satisfactory for connected equipment or stable process
minimized. operation. A dynamic simulation will help determine the best
• Cooling of the recycle gas is required for operation in operational rate of change characteristics required for a specific
continuous recycle. plant equipment design.
• Liquid separation vessels should be located upstream of Gas turbine start up characteristics and sequences may
compressors and downstream of cooling elements in a also impose some additional limitations. These include turbine
compressor system. warm up at minimal speed and power producing capabilities for
• Separate and independent recycle loops should be provided heat soak requirements. These are outside the normal operating
for multiple sections of compression connected in series. envelope of compressors and could have special requirements.
Placement of check valves and recycle take off and return Gas turbine restart with high compressor settle out
lines is critical to achieving separate loops of compression. pressure conditions may impose excessive load at low speed
• Parallel compressor units must have check valves installed This should be considered in equipment and start up control
to isolate each unit. sequence design to prevent an undesirable operating condition.
Dynamic simulation can be used to determine safe operating
The volume of the piping, vessels and coolers determines parameters for plant and equipment start up.
the system response to a change. The change may be to move
from one operating point to another or a system trip of the Turbine Trip Delay
compression train. The dynamic simulation determines the Some gas turbine compressor applications can and have used a
mass inventory of each component at a given time. As the mass trip delay feature to prevent compressor surge during an
inventory changes, the specific component pressure and equipment shutdown event. This delay allows anti-surge valves
temperature will change. and optional hot gas bypass valves time to respond prior to
terminating the fuel source to the gas turbine. Compressor
Turbine Modeling surge on trip can cause equipment damage and should be
For a process simulation the gas turbine is simply avoided or minimized as much as possible. The use of this
modeled as a power producing component along with its control strategy requires the categorization of all the turbine-
transient response capability to load change. The elements of compressor equipment trips into two categories. These trips can
the gas turbine are not modeled in detail as compressor, be classified as either critical requiring immediate shutdown or
combustor and turbine. non-critical where a delay of 1 to 3 seconds can be tolerated.
The knowledge of gas turbine operational sequences The definition of a critical shutdown is any malfunction that
along with other physical characteristics of the gas turbine could pose a threat to equipment, personnel or environment. A
compression system are the essential requirements for HAZ-OP study should be conducted with participation by
developing an accurate model for dynamic process simulation. various parties including the owner/operator, engineering
These characteristics include the following: contractor, equipment suppliers and possibly consultants. This

2 Copyright © 2007 by ASME

HAZ-Op study could be used to help categorize the trips. Some
examples of critical type shutdowns are over-speed, low oil
Compressor Map
pressure and fire or gas detection. Some examples of non
Actual Vs Fan Law
critical shutdowns are high bearing temperature, high process
scrubber level or high process gas temperature. The results of 180000
this categorization are then incorporated into the control system 160000
logic. This control strategy would not totally eliminate 140000

Head Ft LB/LB
compressor surge during trip but rather minimize the number of 120000
shutdown events that could cause a surge on trip. A careful 100000
80000
evaluation should be made to determine if this control strategy
60000
could be utilized on a specific application. 40000
20000
Compressor Modeling 0
The modeling of a compressor may be as simple as 0 500 1000 1500 2000 2500 3000 3500
using classical fan laws defined by the normalized parameters ACFM

of head divided by the square of the rotational speed (H/N2 ) as Figure 1

a function of flow divided by rotational speed (Q/N) and 100% RPM 90% RPM 80% RPM
70% RPM 60% RPM Fan Law 90% RPM
efficiency as a function of flow divided by rotational speed
Fan Law 80% RPM Fan Law 70% Fan Law 60%
(Q/N). This approach works well for single compressor stages
and some multistage arrangements. However, this can lead to
Figure 1 Comparison of fan laws to actual compressor flow
significant error in determining surge depending on the number
Map
of compression stages in series in the compressor body and the
resulting overall compressor performance map especially below
design speed.
Compressor Map
Predicted head and flow data for multiple stages in Overlay of Fan Law
series are derived from individual stage performance. The
combined performance prediction may be accurate over a very 180000

limited range of speed range. Extrapolating this data to a larger 160000

140000
speed range can lead to errors of 25% at overload and surge. A
Head Ft-lb/lb

120000
more accurate compressor map must be generated at multiple 100000
speeds especially for start up and shutdown studies. During an 80000
ESD the shape of the surge curve is critical. Many systems 60000
model the surge limit as a linear relation between flow and 40000
20000
differential pressure developed across the compressor. The
0
surge curve for each compression system is unique and may 0 500 1000 1500 2000 2500 3000 3500
not be linear in many applications. Modeling the system must ACFM
try to be as accurate as possible. The same is required for Figure 2

overload operation. Many compressor systems are started in Surge Overload Fan Law Surge Fan law Overload
overload. As multiple sections of compression are part of many
processes the accuracy of the curves used modeling become Figure 2 Comparison of fan law estimation to actual
even more important. performance showing the shift of the overall compressor
The practice of normalizing the head flow curve from performance map
the Q/N vs. Head /N^2 relationship to represent the entire curve
from low to high speed will lead to modeling errors. As shown overload. The consequences of this could limit the equipment
in Figure 1, the performance prediction by the compressor life and process operating range.
manufacturer’s extended performance curves does not match Continuous operation in overload is not recommended
the extrapolated Q/N based on the normal design speed curve. by some compressor manufactures (3). While not as
As can be seen the Q/N speed curves have a much different detrimental as operating in surge, the mismatch between
shape as the speed decreases. The change in shape will cause components can cause damage to the internal parts of the
erroneous results for the dynamic simulation. Figure 2 shows compressor.
the overlay of the surge and overload lines. The Q/N predicted
overload at the end of the curve will be greater than is actually
available at lower speed based on the manufacturers data. The
Anti-Surge Valve Requirements
The proper protection of a compressor requires
surge points will also not be estimated correctly and could lead
analysis of steady state online requirements and transient
to inaccurate conclusions. The conclusions drawn from a
requirements of the valve capacity. Steady state requirements
system that is not modeled accurately can lead to either over
can be determined from compressor performance data.
design or under design of the compression system components.
Traditional sizing uses an over sizing factor that multiplies
Over design could restrict operating range, reduce efficiency,
surge flow by the sizing factor to determine a required Cv for
and provide poor control system response. Under design may
the anti-surge valve. This method does not accurately predict
lead to predicting safe operation in an area of the extrapolated
specific compressor requirements for surge protection during a
compressor performance map that is actually in surge or
high-speed transient event such as an emergency shutdown

3 Copyright © 2007 by ASME

(ESD) of the compressor. These transient requirements are not and load sharing which optimize throughput and plant
as easily determined. The transient requirement must be able to efficiency.
handle the compressor flow along with rapid depressurization The battery limits of a dynamic study must be clearly
of the discharge volume to match the compressor head established to meet the objectives defined for the study. The
producing capability as it decelerates. Traditional valve sizing specification of the known parameters and their expected
procedures may select a valve capacity that is too large to variations need to be clearly spelled out to the simulation
provide stable control when operating near the surge control models. The model can be simplified by using lumped volume
line. Over sizing may allow the compressor to operate in parameters to model piping and vessels. The model may also
overload if the valve goes to full open position during normal be complex to include modeling of 2-phase flow in the piping
operation. Dynamic simulation is a predictive tool, which and specific equipment such as separators.
provides more accurate sizing to account for the transient
behavior of the system. This may indicate the use of two Evaluation of Settleout
valves that have different anti-surge protective functions. One Settleout of the system is usually determined by
valve would be used for traditional on line modulating anti- evaluating the mass and pressure for given volumes and
surge protection and the other valve would be used only for assuming the mass contained in the total volume and estimating
shutdown in a discrete open/close mode to handle the transient the pressure. The temperature does not solve as easily. It must
flow. Dynamic simulation may also identify other valve be noted that the settle out of a system is a dynamic process.
characteristics that can be used to optimize system response. Gas is in circulation through the system as the compressor is
These include valve trim characteristics and valve stroke time. slowing in speed. The rate of gas flow through the cooler in the
Start-up or on-line operation for extended periods on system is decreasing. The temperature rise developed across
partial or full recycle may dictate a requirement for low noise the compressor is also decreasing. Since this change is
trim on a modulating valve. Noise requirements versus occurring in a matter of seconds the cooler thermal controls do
cleanliness of gas may also necessitate special design not normally react to match the rapid decrease in flow. The
considerations. High speed transients like a compressor ESD flow exiting the cooler will, therefore, approaches the coolant
event are of short time duration and may not necessarily have temperature. The average temperature at initial settleout will
the same noise requirement as required by continuous then be closer to the coolant temperature for the above reasons.
operation. If low noise trim is used extra consideration to
system cleanliness must be required. Noise attenuation
techniques used in valves can require small openings that act Example 1: ESD Prediction
like a filter to collect debris from the piping system. Initial An ESD requires the compressor to shut down with
start up may warrant the use of a valve start up trim or trash the power cut off. A single compressor process simulation
screen installed upstream of the valve. model generated with the DYFLO program is shown in Figure
Some systems may require a hot gas bypass valve to 3. The elements of this model are essentially the compressor
assist in rapid depressurization of the compressor discharge and inlet and discharge process components.
volume to keep the compressor out of surge. This is
accomplished by separating some of the hot discharge volume
from the compression total discharge volume, i.e. installation of
a bypass and check valve in the discharge piping following the
compressor discharge flange. The size of the volume and the
selection of the valve become a specifically tuned system,
which can be optimized through dynamic simulation.

Plant Modeling and Multiple Unit Simulation

Typical gas turbine compressor applications can have
multiple units operating in either a parallel or series
configuration. Some applications allow switching operating
configuration between series and parallel.
Transients caused by trip or start up of individual turbine
compressor units can be utilized to determine effective control
strategy along with determining overall plant response to upset
conditions. The impact on upstream and downstream Figure 3 Example of DYFLO flow sheet model.
conditions external to the unit boundary will also be identified.
Load sharing schemes can be analyzed for response to The simulation of an equipment train ESD event
transients. requires the depiction of the rotating components and the
Tuning of control system response to imposed interaction with the total modeled system. The rotor speed
transient can be analyzed for providing optimized response. decays as a function of the residual power absorption in the
Troubleshooting plant performance and operational problems compressor, the inertia (WR^2) of the rotor system and the
can be analyzed to provide solutions that resolve or mitigate driver power decay. As the compressor decelerates, the
the effect of an undesirable operating condition. pressure in the discharge volume and the pressure in the inlet
Real time equipment performance evaluation can be embedded volume determine the head. The rate at which the discharge
within a control system to fine tune control system response pressure decreases and the head developed by the rotating rotor

4 Copyright © 2007 by ASME

will determine if surge will occur. If the rotor developed head deceleration. Figures 6 and 7 depict the same compressor
is less than the system volume head, the discharge mass system response with the larger valve. These are the results of
attempts to back flow through the compressor creating the an actual case study.
instability called surge.
Compressor Map
The mass of gas contained in the discharge must be Revised Valve Size
reduced so that the discharge pressure decays. The ASV is
45000
commanded open as fast as possible to reduce the discharge
mass which will lower the discharge pressure. Figure 4 depicts 40000

the effects of an ESD event has on a compressor. Shown is the 35000

30000
Compressor Map
105% RPM

Head Ft
25000
45000 100%
20000

40000 90%
15000
80%
35000 10000 70%
60%
30000 5000 50%
40%
105% RPM 0
Head Ft

25000
0 500 1000 1500 2000 2500 3000 3500 4000
100%
ACFM
20000
Figure 6
90%
15000
80% Figure 6 Compressor Flow Head map with operating path
10000 70% in response to an ESD event, no surge is encountered
60%
5000 50%
40%
0
Revised Valve Size
0 500 1000 1500 2000 2500 3000 3500 4000
ACFM 3000
Figure 4

Figure 4 Compressor Flow Head map with operating path 2500

in response to an ESD event, surge is encountered.

2000
Flow ACFM

path of the compressor operation as a function of volume flow

1500
versus head. This is superimposed on the compressor map with
lines of constant speed. The surge limit is the left most point on 1000
each speed line. As can be seen the path of the deceleration
crosses the surge limit line. Figure 5 shows the same flow data 500
on a time line along with the surge flow limit line. The
compressor flow drops below the surge limit line into surge in 0
about one second and does not recover until six seconds into 0 2 4 6 8 10
Time Sec
Figure 7
ACFMvs Time
Compressor Flow Surge Flow
3000
Figure 7 Flow vs. time map for the ESD event showing
2500
surge limit line and compressor operating path during ESD
2000
Flow ACFM

1500
The total deceleration of the rotating components is shown in
Figure 8.
1000 The estimation of the required size of the valve to
500 avoid surge and prevent possible equipment damage during an
ESD event can be accurately predicted though the use of
0 dynamic simulation.
0 2 4 6 8 10
Time Sec
Figure 5 Example 2
Compressor Flow Surge Flow
Sudden discharge blockage with ASV system for pressure
Control
Figure 5 Flow vs. time map for the ESD event showing A Sudden blockage of the discharge side of a
surge limit line and compressor operating path during ESD compression system can be controlled by several methods. The
anti-surge system could open the recycle valve when it senses a
the event. A larger anti-surge valve capacity will be required to reduction of inlet flow. This causes the compressor operating
prevent this excursion into surge. An 80% larger ASV was point to move away from surge hence reducing discharge
selected after a number of iterations. This resulted in the pressure. The control system can also be configured with a
compressor staying out of the surge region during the discharge pressure override control. This system will sense a

5 Copyright © 2007 by ASME

 Rotor Deceleration Volum e Flow
Revised Valve Size
40000
12000
35000
10000
30000

8000
25000
Speed

ACFM
6000 20000

4000 15000

10000
2000
5000
0
0
0 5 10 15 20 25
Time Sec 0 10 20 30 40 50 60

Figure 8 Tim e S ec
Figure 10

Figure 8 Rotor Speed vs. time response to an ESD.

Figure 10 Flow vs. time response to a discharge blockage
rise in discharge pressure and open the recycle valve to control
the discharge pressure. A variable speed gas turbine driver may Example 3 Sudden discharge blockage for relief valve sizing
also be used to control the discharge pressure by reducing the A sudden blockage on the discharge of a compression
operating speed. Control system algorithms can be system is an event that can cause the compressor operating
implemented to provide a coordinated response in multiple point to move towards surge and result in a rise of the discharge
section compression systems. The control system algorithm can pressure. If the rise in pressure is sufficiently fast or there is not
be a simple Proportional Integral Derivative control loop or proper pressure control then the discharge pressure could
more sophisticated to include control action based on rate of approach design limits where a pressure relief valve would
pressure change, adaptive gain or other parameters as deemed operate to control the pressure. Proper sizing of the relief valve
necessary. would prevent pressure from exceeding equipment design
A sudden blockage of the discharge system event is limits. An undersized relief valve will not protect the system to
depicted in Figures 9 and 10. Figure 9 shows pressure versus defined pressure limits. Over sizing of a relief valve may
time response for pressure control valve to operate. There is a provide over pressure protection but could also cause rapid
swings in pressure that may be detrimental to equipment and
cause disturbances to the connected process external to the
Pressure compressor. Dynamic Simulation allows verification of sizing
to confirm peak pressures do not exceed design limitations.
350 Figures 11 and 12 show an under sized relief valve response.
345
340
Mass Flow
335
Pressure Psia

Small Relied Valve

330
325 35000
320 30000
Mass Flow Lb/min

315 25000
310 20000
305 15000
300 10000
0 10 20 30 40 50 60
5000
T ime Sec 0
Figure 9
0 5 10 15 20 25 30
Time Sec
Figure 9 Pressure vs. time response to a discharge blockage Figure 11
Compressor Flow Relief Valve Flow
small increase in pressure and recovery to set point in 10
seconds. Figure 10 shows the reduction in flow to a minimum Figure 11 Flow vs. time for undersized relief valve
value to maintain the discharge pressure for this event. While
the pressure recovery was quick (10 seconds) the time required The valve goes through a number of open close cycles due to
for the flow to stabilize took longer due to the system volume. the volume of the compressor discharge and the flow supplied
by the compressor. The flow through the relief valve, when
open, may allow the pressure in the discharge volume to

6 Copyright © 2007 by ASME

 Pressure Pressure
Sm all Relief Valve Design Relief Valve

400
450
350
400
350 300

Pressure Psia
Pressure Psia

300 250
250 200
200
150
150
100 100
50 50
0 0
0 5 10 15 20 25 30 0 5 10 15 20 25 30
T ime Sec T ime Sec
Figure 12 Figure 14

Figure 12 Pressure vs. time for an undersized relief valve Figure 14 Pressure vs. time design relief valve.

decrease and thus the valve will close. This is purely a mass
imbalance relationship. The control limit is 360 psia however
the relief settle out was over 422 psia. The 422 psia was the Appendix
pressure where the compressor flow and the relief valve flow Simulation Requirements
matched. Figure 13 and 14 demonstrate the response of the 1. Process and Instrument Diagram
properly sized relief valve. Once full open the valve allowed 2. Process Flow Diagram
the pressure to reach 362 psia. 3. Gas analysis
4. Volumes of piping , coolers, and vessels
Mass Flow
5. Control valve design including Cv, and stroke time
Design Relief Valve 6. Block valve design including Cv and stroke time
7. Compressor map for flow, pressure , temperature and
35000 speed
30000
8. Design operating point for compressor system
9. Driver characteristics, power, speed, rate of change, startup
Mass Flow Lb/sec

25000
speed torque data
20000 10. Inertia of the rotating shaft system
15000 11. Specific conditions at process boundaries
10000
12. Definition of relief valves
5000

0
0 5 10 15 20 25 30
Time Sec
ACKNOWLEDGMENTS
Figure 13 The authors thank Dresser-Rand Company for providing
the opportunity to present this document. Also Quality
Compressor Flow Relief Valve
Monitoring and Control Company for providing training and
insight into dynamic process simulation..
Figure 13 Flow vs. time design relief valve.
REFERENCES
1. Quality Monitoring and Control Corporation; DYFLO
Conclusion Users Manual
Dynamic process simulation is a valuable tool that can 2. Franks. Roger G.E.; Modeling and Simulation in
be used to validate process design to ensure trouble free Chemical Engineering, R. , John Wiley & Sons, 1972
operation from initial start up. It can also assist in the 3. Sorokes, J.; Miller, H.; Koch J.; The Consequences Of
resolution of existing plant operational problems. This tool has Compressor Operation in Overload, Texas A&M
evolved from a complex computer program, involving many Turbomachinery Conference, September 2006
hours to set up and run, to the point where it can now be 4. McKee, R.J.; Blodgett, L.L.; Transient Gas Flow &
effectively used as part of initial design of petrochemical Control System Modeling for the Design of
processes. Compressor Surge Control Systems for Trips &
Upsets, Gas Machinery Resource Council 2004

7 Copyright © 2007 by ASME