"Avoiding surge is not an option—it's a guarantee: intelligent antisurge for critical compressors"
The Antisurge Control Package by CPC Engineering is a comprehensive solution to protect centrifugal and axial compressors against surge events. It combines preventive detection and advanced operational control to ensure stability, energy efficiency, and avoid damage or unplanned shutdowns.
This modular solution operates with high speed and accuracy, integrating predictive algorithms, bumpless logic, and full connectivity with PLC or DCS. It improves compressor availability, extends its lifetime, and reduces maintenance costs.
Its flexible design allows use in new installations or upgrades, either by integrating with existing controllers or replacing obsolete systems, reducing project execution times.
The package is composed of three solutions that can be implemented individually or combined for advanced compressor protection. These three solutions are:
Click the following menu to learn more about each component of the Antisurge Control Package and its function.
The antisurge protection loads the compressor’s surge curves, applies a safety factor, and sets a minimum flow based on the current operating point.
It also analyzes critical variables in real time such as flow, pressures, and temperatures to ensure the operating flow is above the minimum threshold. If this is not the case, it takes progressive actions on the antisurge valve to ensure the establishment of the minimum flow, guaranteeing safe operation of the compressor.
Detection – SD
The surge detector provides crucial support to the protection system in case the final control elements (valves) cannot dynamically follow the setpoints. This system has preloaded surge patterns that allow it to identify events and take progressive actions, including solenoid actuation or machine shutdown if necessary.
The operation controller coordinates the antisurge valve positioning with another load control variable (speed, IGV position, suction pressure, etc.), ensuring a dynamic and energy-optimized response at all times.
The Antisurge Control System (ASC) from CPC Engineering actively protects the compressor against surge events, preventing abrupt drops in flow that could cause mechanical damage. It ensures stable and safe operation, extends equipment life, and secures process continuity.
The ASC is part of an advanced protection architecture for centrifugal and axial compressors. It can be implemented in new projects or integrated into existing systems via DCS or PLC.
Its logic is designed to anticipate surge, performing real-time calculations and taking progressive actions on the antisurge valve. It complies with international standards as an effective and mandatory solution for protecting critical compressors.
The system begins with a detailed technical analysis of the compressor (manufacturer data, plant tests, and historical records), which is used to define the surge line. Based on this and safety margins, the minimum operational flow is determined.
During operation, the ASC monitors key variables like flow and pressure in real time. When nearing the surge line, it triggers progressive corrective actions such as opening the antisurge valve.
Its sampling rate (every 100 ms) and reactive logic ensure effective protection without oversizing safety margins, contributing to system energy efficiency.
The Surge Detector (SD) from CPC Engineering is a real-time monitoring system designed to detect surge events in centrifugal and axial compressors. It triggers alarms, activates protections, or may even initiate emergency shutdowns under critical conditions.
It provides an additional safety layer and can operate independently or integrated with the ASC (Antisurge Controller). It is ideal for compressors operating near their performance limits.
It detects sudden changes in variables such as flow, current, or pressure, responding within milliseconds to prevent mechanical damage and ensure process continuity.
The SD analyzes characteristic surge patterns using a continuous monitoring algorithm with 50 ms cycles. When it detects abnormal behavior, it executes configurable actions like triggering solenoids or emergency signals.
Combined with the ASC, it offers a coordinated solution of prevention, detection, and response, ensuring comprehensive protection against surge scenarios.
The Performance Controller (PRC) from CPC Engineering dynamically adjusts compressor operation according to process demand. It optimizes energy and operational performance while maintaining surge protection at all times.
It complements the ASC by adding intelligence based on compressor load. It adjusts the antisurge valve in coordination with variables such as IGV, suction, or speed, adapting to real system demand.
Its flexible architecture allows integration into new or existing systems, ideal for installations with parallel compressors or variable load cycles.
The PRC calculates the optimal operating point of the compressor and adjusts the antisurge valve position in combination with other key variables, ensuring safety, stability, and minimal energy consumption.
It can integrate with advanced systems (DMC, multivariable or plant-wide control), and when combined with ASC, it allows margin reduction without losing protection, achieving higher operational efficiency.