Compressor surge control remains one of the most popular topics here on the blog. I took an inventory of many of the Emerson products used to control surge conditions. These include valves and related components, actuators and boosters, controllers and software, and sensors and transmitters.

Valves and Related Components

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  Fisher™ Optimized Anti-surge control valve is a key component of an anti-surge system.

  Fisher Optimized Antisurge Control Valves. Specialized valves that quickly open when the compressor is close to surging, letting excess gas flow back to the inlet to boost the flow rate and keep the compressor running smoothly without damage.

• Fisher FB Fabricated Angle Valves. Used in the recycle loop, it detects a near-surge and opens to send discharge gas back to the inlet, increasing flow to stabilize the compressor, much like releasing pressure to prevent an overload.
• Fisher WhisperFlo Aerodynamic Noise Attenuation Trim. Shapes the gas flow through the valve to reduce noise and vibration during high-speed operation, helping the system stay quiet and stable while preventing surge without extra wear.

Actuators and Boosters

• Fisher 685 Series Piston Actuators. Power the valve to open or close rapidly in both directions; in surge control, they stiffen the response to quickly adjust gas recycle, stopping surge by reacting fast to flow changes.
• Fisher SS-263 and Fisher 2625 Volume Boosters. Amplifies the air signal to the actuator for quicker valve movement, ensuring the valve responds instantly to surge risks by maintaining proper flow through the compressor.

Controllers and Software

• Fisher FIELDVUE DVC6200 Digital Valve Controller. Tracks and adjusts the valve position in real time, helping prevent surge by precisely controlling the recycle valve based on compressor conditions for stable operation.
• Fisher FIELDVUE ValveLink Software. Analyzes valve health (e.g., checking for leaks) without stopping the process, ensuring the anti-surge valve operates reliably to prevent compressor instability.
• DeltaV DCS and DeltaV PK Runs control strategies to monitor flow and pressure, automatically adjusting valves to prevent surge while optimizing energy use and balancing multiple compressors.
• SmartProcess Compressor Solution by DeltaV. A software application within DeltaV that provides antisurge strategies, stabilizes process parameters, and minimizes recycle flow to prevent surge with minimal energy waste.
• AMS 6500 ATG System. A safety monitoring tool that detects surge conditions or faults instantly, and stops surge events by triggering protections, ensuring the compressor doesn’t get damaged during upsets.

Sensors and Transmitters

• Rosemount 4051S Pressure Transmitter. Measures pressure and flow differences accurately and quickly to signal the control system to open valves when a surge condition is near, allowing safe operation nearer to the limit.
• Micro Motion Gas Specific Gravity Meter. Measures gas density and composition in real time and accurately adjusts the surge limit for varying gases, reducing the safety margin required and improving efficiency without causing surge.

Visit the links above to learn more about these technologies to help you operate more efficiently without entering surge conditions.