A QUICK ESTIMATION METHOD TO DETERMINE HOT RECYCLE REQUIREMENTS FOR CENTRIFUGAL COMPRESSORS

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A QUICK ESTIMATION METHOD TO
DETERMINE HOT RECYCLE
REQUIREMENTS FOR
CENTRIFUGAL COMPRESSORS
Turbomachinery Engineers often conduct studies to
determine if a hot gas bypass is required for a given
centrifugal compressor system. This would mean
building a process model and simulating it for
Emergency Shutdown conditions (ESD) & Normal
Shutdown conditions (NSD) to check if the compressor
operating point crosses the surge limit line (SLL). A
quick estimation method that uses dimensionless
number called the inertia number can be used to
check prior to the study, if a Hot gas bypass (a.k.a. Hot
Recycle) is required in addition to an Anti-surge line
(ASV or a.k.a Cold Recycle).
Figure 1. Typical Compressor Loop with HGB
The decision to employ a short recycle around the
compressor unit during ESD depends on,
1. Effective compressor/driver rotor inertia defined at
the compressor end (I) (kg.m
2
)
2. The delay time before the first crack-opening of the
recycle valve opening stroke plus time taken for the
first pressure wave to arrive at the compressor
outlet or inlet () (milliseconds)
3. The maximum fluid energy extracted from the
power train & the compressor speed which can be
approximated by the product smH (Subscript ‘s’
refers to the surge point at max speed (N) (rpm).
The inertia number is calculated from the total energy
balance by neglecting the windage & frictional losses,
    












dt
dN
NJ
dt
dN
NJmH M
MM
C
CCS
22
22  (1)
Where, m = Mass Flow at Surge point [kg/s]
MJ = EM Inertia [kg-m
2
] ; CJ = CC Inertia [kg-m
2
]
N = Rotational speed [rps] ; SH = Head at Surge [J/kg]
Using the gear ratio (GR) relationship between the
electric motor & the centrifugal compressor,
  MC
M
C
NGRN
N
N
GRRatioGear  (2)
Substituting Eq. (2) in Eq. (1) & rewriting,
 
 
02 2
2
























dt
dN
GR
N
J
dt
dN
NJmH CC
M
C
CCs  (3)
 
 
02 2
2









dt
dN
N
GR
J
JmH C
C
M
Cs  (4)
Taking,
 
J
GR
J
J M
C 







 2
(5)
Where, J = Total Inertia [kg-m
2
]
Substituting Eq. (5) in Eq. (4) & taking NNC  ,
  02 2

dt
dN
JNmHs  (6)
 
 
NdNdt
J
mH
dt
dN
JNmH s
s  2
2
2
2

 (7)
As the compressor operating point traverses towards
the surge point at max flow, the delay time of the cold
recycle ( dt ) during ESD is taken as ‘’.
(8)
When ESD occurs, it is assumed that the motor power
goes to zero instantaneously & the time delay between
coast down initiation & cold recycle valve crack
opening is of the order of few milliseconds. Here
speed decay is approximated to begin when the cold
recycle valve cracks open while the operating point
reaches the surge flow point along the same operating
speed. Therefore at steady state,
(9)
Substituting Eq. (8) & Eq. (9) in Eq. (7), the ratio
termed as inertia number is arrived as,
 
2
2
2
N
J
mHs



 Ratio called
 


s
I
mH
JN
N
22
2
 (10)
Converting back to ‘rpm’, we get,
     

















sec
sec
.
3600
2 2222
kg
Jkg
rpmmkg
mH
NJ
NNumberInertia
s
I

 (11)

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An IN < ~30 would require a hot gas recycle to
prevent the compressor unit from experiencing surge,
while for IN > ~100 would mean the conventional
recycle system (Anti-Surge system) would be
adequate. For 10030  IN , a detailed dynamic
simulation is required to check if a hot recycle is
necessary. Based on industrial data obtained for 24
industrial centrifugal compression systems (Ref [1, 2])
as described in Table 1, whether only a cold recycle or
a combination of both hot & cold recycle is required
can be estimated.
Table 1. Inertia Numbers for Various Industrial Compression Systems [Ref 1, 2]
Notes:
1. The derivation must also include the gearbox and coupling inertia. However considering their contribution in
comparison to the Driver and Compressor inertia is much smaller; they are neglected in deriving the
relationship for inertia number.
2. The compressor polytropic efficiency & driver mechanical efficiency though contributes during operating point
migration; they are neglected considering the short duration of the cold recycle delay time in opening.
3. It is assumed that the driver power was set to zero instantaneously at the instant of ESD. This is applicable for
electric motors but not absolutely correct for gas turbines since there is residual fuel in the supply manifold
that causes the compressor to run for a few 100s of milliseconds & also the gas generator’s rotor inertia will
continue to provide hot gas to the power turbine even at a decreasing temperature
[2]
.
Inferences:
For a given compressor speed, high discharge pressure & volume flow compressors whose cold recycle valve’s
opening time is high, are more prone to quickly experience surge & are likely contenders for a Hot Recycle Valve
(a.k.a Hot Gas Bypass) in addition to Cold Recycle Valve (a.k.a Anti-Surge Valve).
References:
[1] 'Dynamic Instabilities in Industrial Compression Systems with Centrifugal Compressors', Kamal K. Botros,
S.T. Ganesan, Proceedings of the Thirty-Seventh Turbo machinery Symposium, 2008
[2] 'A New Approach to Designing Centrifugal Compressor Surge Control Systems', Kamal K. Botros, Steve Hill,
Jordan Grose, Proceedings of the 44th Turbo machinery 31st Pump Symposia, USA, Sep 2015

A QUICK ESTIMATION METHOD TO DETERMINE HOT RECYCLE REQUIREMENTS FOR CENTRIFUGAL COMPRESSORS

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A QUICK ESTIMATION METHOD TO DETERMINE HOT RECYCLE REQUIREMENTS FOR CENTRIFUGAL COMPRESSORS