DRAWING TITLE

ANTI-SURGE SYSTEM DESIGN

TURBOMACHINERY SYSTEMS PROVIDER

ENGINEERING

Gasoductos del Noreste CUSTOMER

PROJECT NAME DRIVER

T130 CS
EQUIPMENT
GAS-LR C652
LOCATION
Ramones Station
REV DESCRIPTION DATE ERCC
A Initial Submittal 17 Sep 18
B As Shipped 20 Dec 18

APPROVED DRAWING NO.

PROJECT MANAGER
Fernando Lopez 4A431 - 149653
DESIGN "THIS COPYRIGHTED WORK AND THE INFORMATION HEREIN IS PROPRIETARY TO
Ricardo Montes CATERPILLAR INC., SOLAR TURBINES INCORPORATED, AND/OR SUBSIDIARIES OF
EITHER. WITHOUT EXPRESS WRITTEN PERMISSION FROM CATERPILLAR INC. OR
CHECK SOLAR TURBINES INCORPORATED. ANY COPYING, DISCLOSURE, OR USE EXCEPT
Fernando Niño THAT FOR WHICH IT IS LOANED, IS PROHIBITED."
COMP REV FSCM NO PROJECT SHORT NAME REV SHEET
B0 66195 GAS-LR B 1 OF 20

Caterpillar: Confidential Green

 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 – Typical ................................................................................................................................. 9
Anti-Surge Valve Evaluation .................................................................................................................................. 10
Fast Stop Analysis ................................................................................................................................................. 11
System Volumes............................................................................................................................................... 11
Anti-Surge Valve ............................................................................................................................................... 11
Fast Stop .......................................................................................................................................................... 12
Valve Performance ........................................................................................................................................... 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

DRAWING TITLE PROJECT SHORT NAME

ANTI-SURGE SYSTEM DESIGN GAS-LR
"THIS COPYRIGHTED WORK AND THE INFORMATION HEREIN IS PROPRIETARY TO DRAWING NO. REV SHEET
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 4A431 - 149653 B 2 OF 20
THAT FOR WHICH IT IS LOANED, IS PROHIBITED."

Caterpillar: Confidential Green

 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
configure 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 GAS-LR
"THIS COPYRIGHTED WORK AND THE INFORMATION HEREIN IS PROPRIETARY TO DRAWING NO. REV SHEET
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 4A431 - 149653 B 3 OF 20
THAT FOR WHICH IT IS LOANED, IS PROHIBITED."

Caterpillar: Confidential Green

 Project Specific Notes
1) N/A

Information and Data Requirements

The table below shows the required information and data to complete and finalize the Anti-Surge System design
document.
Item Description Action By Status
1 Process P&ID EPC/Customer Open
2 Suction Pipe Inside Diameter (ID) EPC/Customer Open
3 Flowmeter Data sheet EPC/Customer Open
4
5

DRAWING TITLE PROJECT SHORT NAME

ANTI-SURGE SYSTEM DESIGN GAS-LR
"THIS COPYRIGHTED WORK AND THE INFORMATION HEREIN IS PROPRIETARY TO DRAWING NO. REV SHEET
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 4A431 - 149653 B 4 OF 20
THAT FOR WHICH IT IS LOANED, IS PROHIBITED."

Caterpillar: Confidential Green

 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. Rev / Date

DRAWING TITLE PROJECT SHORT NAME

ANTI-SURGE SYSTEM DESIGN GAS-LR
"THIS COPYRIGHTED WORK AND THE INFORMATION HEREIN IS PROPRIETARY TO DRAWING NO. REV SHEET
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 4A431 - 149653 B 5 OF 20
THAT FOR WHICH IT IS LOANED, IS PROHIBITED."

Caterpillar: Confidential Green

 RECYCLE SYSTEM

10 9 8 7 6 5 4 3 2 1

Suction Volume
E E
Cold Discharge Volume

Hot Di scharge Volume

D ANTI-SURGE D
(FO)

HOT BYPASS
(FO)
C C

B S
P DT TE PT P DT P DT
CPS R
S KI D TE PT
FE B
DV
V

L GT CPRS
V V
V

A Sucti on
Volume
A

10 9 8 7 6 5 4 3 2 1
Figure 1 – Recycle System Schematic

DRAWING TITLE PROJECT SHORT NAME

ANTI-SURGE SYSTEM DESIGN GAS-LR
"THIS COPYRIGHTED WORK AND THE INFORMATION HEREIN IS PROPRIETARY TO DRAWING NO. REV SHEET
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 4A431 - 149653 B 6 OF 20
THAT FOR WHICH IT IS LOANED, IS PROHIBITED."

Caterpillar: Confidential Green

 ANTI-SURGE VALVE
Anti-Surge Valve Sizing Information
The following figures provide the data and information necessary for sizing the valve.
DESIGN ENGINEER: R. Montes
PROJECT DEFINITION NUMBER (PD): 4A431 REV AB
COMPRESSOR PERFORMANCE CURVE # P-38254
VALVE MAXIMUM FLOW COEFFICIENT (Cv): 4655
DATE: 13-Jul-18
COMPRESSOR CONFIGURATION: HP Body

K50 1.297
K300 1.227
PCP 679.6 PSIA
PCT 367.6 °R
S.G. 0.6198

CONSTANT VALVE OUTLET PRESSURE 769.6 PSIA

MAXIMUM VALVE INLET TEMPERATURE 120 °F

RECYCLE VALVE SIZING

0.45

0.40

0.35

0.30

0.25
X
(DP/P1)
0.20

0.15

0.10

0.05

0.00
0.00 200.00 400.00 600.00 800.00 1000.00 1200.00 1400.00 1600.00 1800.00

MMSCFD

Figure 2 – Anti-Surge Valve Sizing Graph

DRAWING TITLE PROJECT SHORT NAME

ANTI-SURGE SYSTEM DESIGN GAS-LR
"THIS COPYRIGHTED WORK AND THE INFORMATION HEREIN IS PROPRIETARY TO DRAWING NO. REV SHEET
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 4A431 - 149653 B 7 OF 20
THAT FOR WHICH IT IS LOANED, IS PROHIBITED."

Caterpillar: Confidential Green

 DESIGN ENGINEER: R. Montes
PROJECT DEFINITION NUMBER (PD): 4A431 REV AB
COMPRESSOR PERFORMANCE CURVE # P-38254
DATE: 13-Jul-18
RECYCLE LINE PRESSURE RELIEF VALVE SETTING PSIG 1284.7
VALVE ANSI CLASS RATING (Must match Recycle Pipe rating): 600
COMPRESSOR CONFIGURATION: HP Body
RECOMMENDED RECYCLE PIPE SIZE (Upstream/Downstream) INCHES 34 / 34

GAS CHARACTERISTICS
K50 1.297
K300 1.227
PCP 679.6 PSIA
PCT 367.6 °R
S.G. 0.6198

CONSTANT VALVE OUTLET PRESSURE 769.6 PSIA

SURGE PROTECTION MARGIN: 10% TURNDOWN

THROTTLING CONDITIONS (Note relief valve setting above):

N RPM 7,000 6,000 5,000

Q MMSCFD 681.69 578.25 480.16

P1 PSIA 1050.74 968.39 903.30

P2 PSIA 769.60 769.60 769.60
T1 °F 120.00 120.00 120.00
D-P PSID 281.14 198.79 133.70
K1 1.27 1.27 1.27
Z1 0.89 0.90 0.90
Power 11411.04 7018.52 4004.35

N RPM 4,000 3,630

Q MMSCFD 384.13 348.60

P1 PSIA 853.00 837.75

P2 PSIA 769.60 769.60
T1 °F 120.00 120.00
D-P PSID 83.40 68.15
K1 1.27 1.27
Z1 0.91 0.91
Power 2034.16 1517.73

WHERE: P1 & T1 = Valve Inlet Pressure & Temperature, P2 = Valve Outlet Pressure
Figure 3 – Anti-Surge Valve Sizing Data

DRAWING TITLE PROJECT SHORT NAME

ANTI-SURGE SYSTEM DESIGN GAS-LR
"THIS COPYRIGHTED WORK AND THE INFORMATION HEREIN IS PROPRIETARY TO DRAWING NO. REV SHEET
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 4A431 - 149653 B 8 OF 20
THAT FOR WHICH IT IS LOANED, IS PROHIBITED."

Caterpillar: Confidential Green

 Anti-Surge Valve Assembly
Valve Schematic – Typical

Figure 4 – Anti-Surge Valve Assembly, Schematic - Typical

NOTES:
1. Smart Type Positioner with 4-20mA feedback position signal and open/closed limit switches suggested.
2. Three-Way 24 VDC Solenoid Valve - Explosion/Flame-proof with necessary certification and protection to meet specific
application requirements
3. Exhaust booster Type 289RC is commonly used for ASV application.
4. 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.
5. For larger actuators a needle valve with greater free flowing capacity may be required to achieve desired
closing speeds.
Above notes are some common recommendations that may be considered, however, the valve purchaser and
manufacturer have the final decision on the design to meet valve application and performance requirements.

DRAWING TITLE PROJECT SHORT NAME

ANTI-SURGE SYSTEM DESIGN GAS-LR
"THIS COPYRIGHTED WORK AND THE INFORMATION HEREIN IS PROPRIETARY TO DRAWING NO. REV SHEET
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 4A431 - 149653 B 9 OF 20
THAT FOR WHICH IT IS LOANED, IS PROHIBITED."

Caterpillar: Confidential Green

 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: R. Montes REV AB

PROJECT DEFINITION NUMBER (PD): 4A431
COMPRESSOR PERFORMANCE CURVE # P-38254
DATE: 7/13/2018
COMPRESSOR CONFIGURATION: HP Body
VALVE MANUFACTURER: Dresser
BODY TYPE T2-GS
BODY SIZE 12.00 IN
PORT DIAMETER 12.00 IN
TOTAL TRAVEL 90.00 deg
CAGE CHAR: EQ%
MAX RATED Cv: 4655
Downstream of After-Cooler

ISA RECYCLE VALVE EVALUATION

EQUAL PERCENTAGE CHARACTERISTIC

1.70

1.60
R
A 1.50
T
I
O 1.40
P
2
1.30
/
P 1.20 100%
1
70%
1.10
60%
1.00
0 5000 10000 15000 20000 25000 30000 35000
ACFM

Figure 5 – Anti-Surge Valve on Compressor Map

DRAWING TITLE PROJECT SHORT NAME

ANTI-SURGE SYSTEM DESIGN GAS-LR
"THIS COPYRIGHTED WORK AND THE INFORMATION HEREIN IS PROPRIETARY TO DRAWING NO. REV SHEET
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 4A431 - 149653 B 10 OF 20
THAT FOR WHICH IT IS LOANED, IS PROHIBITED."

Caterpillar: Confidential Green

 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 anti-
surge 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.

System Volumes
Suction 1000000 ft3
Cool Discharge 5000 ft3
Hot Discharge 2250 ft3

Table 1 - 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.

Surge Control Valve

Cv 4655.0
Xt 0.350
Valve Port Size 12 inches
Valve Characteristic Ball
Valve Body Size 12 inches

Table 2 – Anti-Surge Valve CV

DRAWING TITLE PROJECT SHORT NAME

ANTI-SURGE SYSTEM DESIGN GAS-LR
"THIS COPYRIGHTED WORK AND THE INFORMATION HEREIN IS PROPRIETARY TO DRAWING NO. REV SHEET
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 4A431 - 149653 B 11 OF 20
THAT FOR WHICH IT IS LOANED, IS PROHIBITED."

Caterpillar: Confidential Green

 Fast Stop
The table below shows the type and fully open Cv of the additional valve used in the model. This is the minimum
required Cv for the additional valve to keep the unit from surging during a fast stop shutdown. Valve can be
ON/OFF or controlled Fail Open (FO) valve.

Hot Bypass Valve

Cv 8500.0
Xt 0.100
Valve Port Size 10 inches
Valve Characteristic Full Ported Ball
Valve Body Size 10 inches

Table 3 – Fast Stop/Hot Bypass Valve

NOTE: The recommended valve size(s) above is the result of Solar analysis where process and operating
conditions are modeled based on compressor design data point, but may not be sufficient to simulate the actual
varying site conditions. To validate Solar’s results, it is highly recommended that a full dynamic analysis/simulation
be performed by a 3rd party or independent contractor.

DRAWING TITLE PROJECT SHORT NAME

ANTI-SURGE SYSTEM DESIGN GAS-LR
"THIS COPYRIGHTED WORK AND THE INFORMATION HEREIN IS PROPRIETARY TO DRAWING NO. REV SHEET
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 4A431 - 149653 B 12 OF 20
THAT FOR WHICH IT IS LOANED, IS PROHIBITED."

Caterpillar: Confidential Green

 Valve Performance
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.

DRAWING TITLE PROJECT SHORT NAME

ANTI-SURGE SYSTEM DESIGN GAS-LR
"THIS COPYRIGHTED WORK AND THE INFORMATION HEREIN IS PROPRIETARY TO DRAWING NO. REV SHEET
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 4A431 - 149653 B 13 OF 20
THAT FOR WHICH IT IS LOANED, IS PROHIBITED."

Caterpillar: Confidential Green

 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

DRAWING TITLE PROJECT SHORT NAME

ANTI-SURGE SYSTEM DESIGN GAS-LR
"THIS COPYRIGHTED WORK AND THE INFORMATION HEREIN IS PROPRIETARY TO DRAWING NO. REV SHEET
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 4A431 - 149653 B 14 OF 20
THAT FOR WHICH IT IS LOANED, IS PROHIBITED."

Caterpillar: Confidential Green

 20 ma
Closed
Overshoot Area,A2

20% travel
17.6 ma

Overshoot Area,A3

X3

15 ma 20% travel
X4

X3
X4

X1,X3: Opening Time

X2,X4: Recovery time

Figure 8 – Positioning at 20% Step Change and Recovery Time

DRAWING TITLE PROJECT SHORT NAME

ANTI-SURGE SYSTEM DESIGN GAS-LR
"THIS COPYRIGHTED WORK AND THE INFORMATION HEREIN IS PROPRIETARY TO DRAWING NO. REV SHEET
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 4A431 - 149653 B 15 OF 20
THAT FOR WHICH IT IS LOANED, IS PROHIBITED."

Caterpillar: Confidential Green

 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.

Compressor Deceleration

90.00% 9000
80.00% 8000
70.00% 7000
6000
60.00%
5000
50.00%
%NPT

4000

Cv
40.00%
3000
30.00%
2000
20.00% 1000
10.00% 0
0.00% -1000
0 0.5 1 1.5 2 2.5
Time (sec)

NPT Deceleration Curve Surge Valve Opening Hot Valve Opening

Figure 9 – NPT/Compressor Deceleration

DRAWING TITLE PROJECT SHORT NAME

ANTI-SURGE SYSTEM DESIGN GAS-LR
"THIS COPYRIGHTED WORK AND THE INFORMATION HEREIN IS PROPRIETARY TO DRAWING NO. REV SHEET
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 4A431 - 149653 B 16 OF 20
THAT FOR WHICH IT IS LOANED, IS PROHIBITED."

Caterpillar: Confidential Green

 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

12000
Surge
10000 Actual

8000
Flow (ACFM)

6000

4000

2000

0
0 0.5 1 1.5 2 2.5

Time (sec)

HP Unit, Head Rise To Surge

16000

14000
Surge
12000
Actual
Isentropic Head

10000

8000

6000

4000

2000

0
0 0.5 1 1.5 2 2.5
Time (sec)

Figure 10 – Head and Flow vs Time

DRAWING TITLE PROJECT SHORT NAME
ANTI-SURGE SYSTEM DESIGN GAS-LR
"THIS COPYRIGHTED WORK AND THE INFORMATION HEREIN IS PROPRIETARY TO DRAWING NO. REV SHEET
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 4A431 - 149653 B 17 OF 20
THAT FOR WHICH IT IS LOANED, IS PROHIBITED."

Caterpillar: Confidential Green

 ANTI-SURGE CONTROL SYSTEM
Anti-Surge System Software Constants
DATE 7/26/2018 PAGE 1 OF 2
ENGINEER R. Montes Rev AH
CUSTOMER GASO-LR
PROJECT PD or SALES NO. 4A431
STATION NAME Los Ramones
LOCATION
DRIVER
DRIVEN EQUIPMENT G6520325
COMPR. PERF. MAP NO. P-38254
COMMENTS B Factor 1.40E-07 As Tested
VARIABLE B FACTOR

CONFIGURATION HP BODY

FLOW DESIGN HEAD (INCHES H2O) 1385 FLOW TRANSMITTER RANGE

Specific Gravity 0.6198 SPECIFIC GRAVITY
SPEC. HEAT RATIO (K1) 1.284 RATIO OF SPECIFIC HEAT (K=Cp/Cv)
CPSR P1 (psia) 769.60 COMPRESSOR SUCTION PRESSURE
CPSR P2 (psia) 1030.6 COMPRESSOR DISCHARGE PRESSURE
COMPRESSOR T1 (°F) 86.00 COMPRESSOR SUCTION TEMPERATURE
COMPRESSOR T2 (°F) 129.8 COMPRESSOR DISCHARGE TEMPERATURE
CPSR Z1 0.8918 SUCTION GAS COMPRSBLTY FACTOR
CPSR Z2 0.8972 DISCHARGE GAS COMPRSBLTY FACTOR
CRIT. PRESSURE (psia) 679.60 GAS CRITICAL PRESSURE
CRIT.TEMPERATURE (°R) 367.6 GAS CRITICAL TEMPERATURE

SOLAR'S SURGE CONTROL SYSTEM

K-VALUES TABLE
DESCRIPTION TT4
KT_HPC_ASC_Fast_Kp 4.00
KT_HPC_ASC_Fast_Ki 75.00
KT_HPC_ASC_Slow_Kp 0.40
KT_HPC_ASC_Slow_Ki_Yn.Val[0] 20.00
KT_HPC_ASC_Slow_Ki_Yn.Val[1] 75.00
KT_HPC_ASC_KCL 10.0000
KT_HPC_ASC_KDB 2.0000

HPC_ASC_Flow_DP 1385.00
Hp_Suc_Press See Hydros
Hp_Dis_Press See Hydros
KT_HPC_ASC_Surge_Line_ A_Coef 5.3525E-05
KT_HPC_ASC_Surge_Line_ B_Coef -9.6923E-03
KT_HPC_ASC_Surge_Line_ C_Coef 8.9491E-01
KT_HPC_ASC_Surge_Line_ D_Coef 6.8169E+00
KT_HPC_ASC_Surge_Pulse_ROC 859.11
KT_HPC_ASC_X_Max 1.500000
KT_HPC_ASC_Y_Max 0.600
KT_HPC_ASC_Y_Min 14.635 %
KT_HPC_ASV_Manual_Rate 2.00
KT_Npt_Min_At_On_Load 40.99

Table 4 – Surge Design Data

DRAWING TITLE PROJECT SHORT NAME

ANTI-SURGE SYSTEM DESIGN GAS-LR
"THIS COPYRIGHTED WORK AND THE INFORMATION HEREIN IS PROPRIETARY TO DRAWING NO. REV SHEET
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 4A431 - 149653 B 18 OF 20
THAT FOR WHICH IT IS LOANED, IS PROHIBITED."

Caterpillar: Confidential Green

 DATE 7/26/2018
ENGINEER R. Montes PAGE 2 OF 2
CUSTOMER GASO-LR Rev AH
PROJECT PD or SALES NO. 4A431
STATION NAME Los Ramones
CONFIGURATION HP BODY

VARIABLE B FACTOR
s/n G6520325
TBD
Diameter = 23.15
GCE Input For Controls
Phi B-factor*10^6 Q/N B-factor
0.048 0.1000 0.8503 1.000E-07
0.060 0.1310 1.0629 1.310E-07
0.072 0.1450 1.2755 1.450E-07
0.085 0.1490 1.5058 1.490E-07
0.100 0.1520 1.7715 1.520E-07
0.120 0.1540 2.1258 1.540E-07
0.135 0.1550 2.3916 1.550E-07
D AT A T AB L E
DATA FLOW P2 FLOW H(SURGE) H(CONTROL) Dis ch. T
POINT (ACFM) (PSIA) (MMSCFD) (INCHES H2O) (INCHES H2O) (°F)
8856 10064.0 1263.1 808.8969 384.74 474.99 166.7
8000 8814.1 1159.4 708.4359 295.11 364.33 152.4
7000 7633.2 1055.9 613.5207 221.33 273.24 136.6
6000 6474.9 972.3 520.4220 159.25 196.61 123.0
5000 5376.6 906.2 432.1458 109.81 135.57 111.6
4000 4301.3 854.9 345.7182 70.28 86.76 102.4
3630 3903.4 839.3 313.7369 57.88 71.45 99.5

ANTISURGE PROTECTION IS: 10.0 % TURNDOWN

SUCTION FLOWMETER C' 61939.38 (INCHES H2O, PSIA, SCFH)

Flow transmitter range (for surge control): 1385.00 (INCHES H2O) (DAMPING = 0.0)
Max flow transmitter range (if needed): 2771.00 (INCHES H2O)
T2 transmitter range: See Hydros (°F)
P1 transmitter range: See Hydros (PSIG)
P2 transmitter range: See Hydros (PSIG)

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 GAS-LR
"THIS COPYRIGHTED WORK AND THE INFORMATION HEREIN IS PROPRIETARY TO DRAWING NO. REV SHEET
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 4A431 - 149653 B 19 OF 20
THAT FOR WHICH IT IS LOANED, IS PROHIBITED."

Caterpillar: Confidential Green

 FLOW MEASURING ELEMENT
DATE 7/26/2018 PAGE 1 OF 1
ENGINEER R. Montes Rev AH
CUSTOMER GASO-LR
PROJECT PD or SALES NO. 4A431
STATION NAME Los Ramones
LOCATION
DRIVER
DRIVEN EQUIPMENT =
COMP. PERF. MAP P-38254
COMMENTS G6520325
VARIABLE B FACTOR
ORIFICE LOCATION Suction Flow meter B Factor: 0.00000014 AS Tested

FLOWMETER CALCULATION Single Flow Coef ficient

METHOD

Specific Gravity 0.62 SPECIFIC GRAVITY

SPEC. HEAT RATIO (K1) 1.28 RATIO OF SPECIFIC HEAT (K=Cp/Cv)
CPSR P1 (psia) 769.60 COMPRESSOR SUCTION PRESSURE
CPSR P2 (psia) 1030.60 COMPRESSOR DISCHARGE PRESSURE
COMPRESSOR T1 (°F) 86.00 COMPRESSOR SUCTION TEMPERATURE
COMPRESSOR T2 (°F) 129.80 COMPRESSOR DISCHARGE TEMPERATURE
CPSR Z1 0.8918 SUCTION GAS COMPRESSIBILITY FACTOR
CPSR Z2 0.8972 DISCHARGE GAS COMPRESSIBILITY FACTOR
CRIT. PRESSURE (psia) 679.60 GAS CRITICAL PRESSURE
CRIT.TEMPERATURE (°R) 367.60 GAS CRITICAL TEMPERATURE

DESIGN HEAD (INCHES H2O) 1385.000 FLOW TRANSMITTER RANGE FOR SURGE (DAMPING = 0.0)
MAX FLOW RANGE (INCHES H2O) 2771.000 MAX FLOW TRANSMITTER RANGE

DESIGN POINT MINIMUM FLOW MAXIMUM FLOW

FLOW 10496.40 3903.40 21268.00
(acfm)

FLOW 843.65 313.74 1709.42

(MMSCFD)
FLOW 27769.36 10326.87 56266.78
(LBS/MIN)

C' 61939.38 61939.38 61939.38

(INCHES H2O, PSIA, SCFH)
DELTA-P, h 418.51 57.88 1718.21
(INCHES H2O)
PRESSURE at Flow meter 769.60 769.60 769.60
(psia)

Table 6 – Flow Measuring Element Data

DRAWING TITLE PROJECT SHORT NAME

ANTI-SURGE SYSTEM DESIGN GAS-LR
"THIS COPYRIGHTED WORK AND THE INFORMATION HEREIN IS PROPRIETARY TO DRAWING NO. REV SHEET
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 4A431 - 149653 B 20 OF 20
THAT FOR WHICH IT IS LOANED, IS PROHIBITED."

Caterpillar: Confidential Green