Prevent surge, limit recycle losses and maintain process stability.
Comprehensive Anti-surge Compressor Control Systems
Flexible, Efficient Compressor Control and Protection for Air and Process Applications
Compressors—whether centrifugal, reciprocating, or rotary screw—often operate under dynamic conditions involving high compression ratios, rapidly shifting flowrates, changing discharge pressures, and varying gas compositions. These factors demand advanced compressor control methods to ensure stable, efficient operation, minimize recycle losses, and prevent costly surge events.
Petrotech offers advanced compressor control systems that enhance energy efficiency, optimize throughput, and enable precise control across a wide variety of industrial applications. Our flexible solutions are designed to integrate seamlessly with compressed air systems, pneumatic networks, and gas processing environments. Whether managing multiple compressors or a single high-value asset, our controls offer unmatched adaptability and performance.
A Comprehensive Anti-Surge Compressor Control System Consists of Four Primary Parts:
Instrumentation and Redundant Hardware
High-performance instrumentation—such as pressure transmitters, flow meters, and temperature sensors—feeds real-time data to the compressor control system. These inputs form the basis for surge detection, pressure control, and airflow optimization. Redundant hardware ensures continuous compressor operations by improving system reliability and availability. It also supports safe shutdown sequences in fault scenarios.
Calibration and Surge Detection Algorithms
The calibration algorithm identifies where the compressor is operating relative to its surge limit. Petrotech’s adaptive surge detection technology recalibrates the surge line automatically in response to real-time system conditions, ensuring robust protection across a variety of load profiles and ambient conditions. This is critical for compressors handling variable molecular weight gases, fluctuating inlet pressures, and modulating air demand.
Petrotech’s control systems support:
Suction or discharge flow measurement
Operation with variable inlet guide vanes
High or low compression ratio operation
Control Algorithms
Our advanced control algorithms dynamically adjust final control elements such as recycle valves or blow-off valves to maintain the system above the surge limit. Key features include AUTO/MANUAL/SAFE-MANUAL operation, PURGE/RUNUP/RUNDOWN sequencing, and unload control strategies.
We support integration with multiple control methods, including:
Speed control via electric motor or variable speed drive (VSD)
Throttling or modulating valve actuation
Adaptive and predictive control based on load profiles and setpoint tracking
ASC Final Control Elements (Recycle and Blow-off Valves)
The final control elements receive setpoint-adjusted commands to steer the compressor operating point safely away from surge. These include high-performance pneumatic or electric actuated valves. Petrotech’s RVAM Recycle Valve Assembly is purpose-built for precise, fast-acting anti-surge operation. These elements work under full load conditions and provide efficient operation with minimal wear.
Maximizing Energy Efficiency and Reducing Operating Costs
Our systems help plants realize substantial energy savings by reducing unnecessary recycling and keeping compressors running at optimal efficiency. By intelligently managing unload control and matching compressor output to actual air demand, Petrotech helps customers minimize energy waste while ensuring performance continuity. We also support load-sharing across multiple compressors, which balances production while avoiding over-capacity operation.
Seamless Integration and Lower Cost of Ownership
Our control systems integrate directly into your plant’s preferred DCS or PLC platforms, eliminating the need for proprietary hardware. This open architecture approach reduces capital and lifecycle costs and simplifies control panel configurations and maintenance planning. When direct integration isn’t ideal, we offer proven standalone or retrofit solutions that can be deployed with minimal disruption.
Available Features:
Surge anticipation and detection algorithms
Adaptive control and asymmetrical control
Backup high-gain proportional controller
Loadshare controller for multiple compressors
Recycle, transfer control, and modulating valve logic
Capacity control and flow control
Discharge pressure control and suction pressure management
Power override control and speed control (VSD compatible)
Support for centrifugal and reciprocating compressors
Compressor shutdown sequencing
Auto/Manual/Safe Manual modes
Fallback strategies for sensor failure
Performance monitoring and system optimization display
Retrofit capability for legacy compressed air systems
Petrotech Markets
Compressor OEMs
- Borsig
- MAN Diesel & Turbo
- Solar
- Delaval
- Mafi Trench
- Sulzer
- Elliott Turbo
- Nuovo Pignone
- Worthington
- Ingersoll Rand
- Siemens