COURSE OVERVIEW:

The Anti-Surge Controller course provides a deep technical focus on the specialized control systems used to protect centrifugal and axial compressors from the destructive phenomenon of surge. This course examines the aerodynamic principles of surge and the rapid response requirements of the control loop to prevent mechanical damage and process instability. Participants will explore the mathematical algorithms used to define the surge limit line and how to configure safety margins that maximize the compressor's operating envelope without compromising safety.

The scope of this training includes a detailed analysis of the hardware and software components that constitute an anti-surge system, including high-speed controllers, fast-acting recycle valves, and precision transmitters. Attendees will learn the procedures for mapping the compressor performance curve and translating physical characteristics into controller parameters. The course covers advanced features such as derivative response, loop decoupling, and fallback strategies that ensure continuous protection even during instrument failure or rapid process fluctuations.

This coverage also emphasizes the practical aspects of testing and tuning the anti-surge loop in a live or simulated environment. Participants will master the methodologies for performing surge tests to validate the Surge Limit Line (SLL) and the Surge Control Line (SCL). The program provides hands-on guidance on tuning the PID constants for the recycle valve to ensure high-speed opening while avoiding oscillation. By focusing on the integration of the anti-surge controller with the overall machine control system, the course ensures that participants can provide comprehensive protection for critical rotating assets.

COURSE OBJECTIVES:

After completion of this course, the participants will be able to:

• Explain the aerodynamic and mechanical consequences of compressor surge.
• Identify the key components and architecture of an anti-surge control system.
• Map compressor performance curves using pressure, flow, and temperature data.
• Configure Surge Limit Lines (SLL) and Surge Control Lines (SCL) in the controller.
• Select and size high-speed anti-surge recycle valves and actuators.
• Implement derivative and "Tight-Shut-Off" logic within the anti-surge algorithm.
• Tune anti-surge control loops for rapid response and minimal overshoot.
• Perform safe and controlled surge testing to validate compressor characteristics.
• Integrate anti-surge logic with load-sharing and speed control systems.
• Troubleshoot controller alarms and instrument malfunctions affecting surge protection.
• Apply fallback strategies to maintain protection during transmitter failures.
• Evaluate the impact of gas molecular weight changes on surge margin accuracy.

TARGET AUDIENCE:

This course is intended for Control System Engineers, Rotating Equipment Specialists, Maintenance Engineers, and Senior Operators responsible for the protection and optimization of large compressors in the oil, gas, and petrochemical sectors.

TRAINING COURSE METHODOLOGY:

A highly interactive combination of lectures, discussion sessions, and case studies will be employed to maximize the transfer of information, knowledge, and experience. The course will be intensive, practical, and highly interactive. The sessions will start by raising the most relevant questions and motivating everybody to find the right answers. The attendants will also be encouraged to raise more of their questions and to share in developing the right answers using their analysis and experience. There will also be some indoor experiential activities to enhance the learning experience. Course material will be provided in PowerPoint, with necessary animations, learning videos, and general discussions.

The course participants shall be evaluated before, during, and at the end of the course.

COURSE CERTIFICATE:

National Consultant Centre for Training LLC (NCC) will issue an Attendance Certificate to all participants completing a minimum of 80% of the total attendance time requirement.