49th IEEE Conference on Decision and Control

December 15-17, 2010

Hilton Atlanta Hotel, Atlanta, GA, USA

Control of Compressor Surge with Active Magnetic Bearings

Se Young Yoon †, Zongli Lin† , Chris Goyne‡ and Paul E. Allaire‡

Abstract— The design of an active surge controller, which also applicable for centrifugal compressors. After this, many
employs Active Magnetic Bearings (AMBs) to stabilize the flow improved and advanced models for axial and centrifugal
in the compressor, is presented in this paper. The axial tip compression systems were presented by different researchers
clearance of an unshrouded centrifugal impeller from a single
stage compressor is modulated relative to the static shroud to in [6]–[12], and stability of compression systems for various
induce a pressure variation in the compressor output pressure. configurations of the inlet and the exhaust piping was studied
This fast-response, high-precision control of the output pressure in [13], [14] and [15]. However the original Greitzer model is
is employed to stabilize the compressor operating in surge still generally preferred in designing active surge controllers
condition. The control law for the tip clearance is derived due to its low order and simple implementation of the
based on a recently introduced mathematical model, and the
performance of the controller is tested through simulation. controller designed based on it.
Efforts to develop reliable model based surge controllers
I. I NTRODUCTION have been ongoing, fueled by the increasing need of boosting
Surge is a dynamics instability in compressors, charac- productivity and improving the safety of the workspace.
Surge suppression and control methods rely on accurate
terized by large-amplitude axisymmetric flow oscillations.
Surge instability can cause extensive damage to the system, plant models to design a surge control law that is able
to stabilize the compression system pass the surge point.
especially during the reversal of the flow in deep surge
Passive surge controllers rely on passive systems, that react
condition, when the impeller and the casing are subject
to high loads and temperatures. Two different approaches to environmental changes in the compressor and suppress the
surge oscillations. On the other hand, active surge controllers,
exist to deal with the surge instability in turbomachineries.
The most common approach in industry is surge avoidance, which were first proposed by Epstein et al. in [16], employ
where the compressor is operated in a conservative way actuators to perturb the compression system according to
feedback measurements from sensors in the flow path. A
within a predetermined stable operating region, and safety
mechanisms “reset” the compressor back to the stable op- brief review of published works on model based surge
control, with both active and passive systems, were presented
eration if surge occurs. This leads to a significant drop in
by Arnulfi et al. in [17]. An important point to consider
compressor efficiency by limiting the compressor output. The
second approach is surge control, where an active or passive in designing a surge control system is the selection of
the appropriate actuator. Simon et al. presented in [18] an
surge controller is implemented such that it compensates
for the disturbances of surge, and stabilizes the flow in the overview of commonly employed actuators for surge control,
compression system. More details on surge avoidance and and demonstrated the complexity of selecting an accessible
actuator with sufficient control authority on the compressor’s
control can be found in [1].
unstable modes and bandwidth to stabilize the flow dynamics
The modeling of compression systems for the active
during surge. Common actuators for passive control systems
control of surge instabilities has been investigated intensively
are the movable plenum wall and the hydraulic oscillator,
over the years, motivated by the potential benefits from
which induce a pressure variation in the compression system
expanding the stable operating region of these machineries.
by changing the plenum volume. On the other hand, and
Reviews of modeling techniques for compression systems
common actuators in active control schemes are the close-
can be found in [1] and [2]. Emmons et al. presented in [3]
coupled valve [11], and the throttle valve [19].
one of the first stability analysis for a compression system
A less considered but also promising actuator for the
using a linearized model, where the initiation of the surge
control of compressor surge is the Active Magnetic Bearing
oscillations was captured by employing the analogy between
(AMB). The use of AMBs for the control of other compres-
the compression system and a self-excited Helmholtz res-
sor instabilities was proposed in [20]. On the other hand,
onator. Using the same principle, Greitzer [4] later intro-
the use of the AMB for the control of surge in single-
duced a two-state nonlinear lumped-parameter model of a
stage centrifugal compressors with unshrouded impeller was
compression system. This model was first derived for axial
proposed by Sanadgol in [21]. The study was based on results
compressors, but it was later demonstrated in [5] that it is
by Senoo [22] and Senoo and Ishida [23] on the change
† S. Y. Yoon and Z. Lin are with Charles L., Brown Department of of the compressor efficiency versus the axial impeller tip
Electrical and Computer Engineering, University of Virginia, Charlottesville, clearance. Sanadgol proposed axially modulating the com-
VA 22904-4743, USA pressor impeller to induce a pressure variation to stabilize
‡ C. Goyne, and P. E. Allaire are with the Department of Mechanical and
Aerospace Engineering, University of Virginia, Charlottesville, VA 22904- surge, and the AMBs were employed as servo actuators to
4746, USA control the axial clearance between the impeller and the static

978-1-4244-7746-3/10/$26.00 ©2010 IEEE 4323

shroud. A mathematical model describing the compression
system with AMBs was introduced by Sanadgol, although
no experimental results were available. Later, experimental
validation of the theoretical model was presented by Yoon
et al. in [24] and [25].
In this paper we address the design and implementation
of the active surge controller for a compression system with
active magnetic bearings. A surge controller for a compres-
sion system with variable impeller axial clearance is derived
and implemented in an experimental setup described in [24].
Additionally, issues encountered during the implementation
of the surge controller are also discussed here.
The remainder of the paper is organized as follows. A
description of the experimental setup is given in Section Fig. 1. Experimental compressor setup.
II. The mathematical model describing the dynamics of the
test rig, including the effects of varying the impeller axial
clearance on the compressor output, is presented in Section
III. In Section IV we derive the control law for the impeller
tip clearance to stabilize the compression system in surge
condition, and the controller is tested in simulation. Finally,
Section V discusses the preliminary observations on the
implementation of the surge controller and draws a brief
conclusion to the paper.
II. E XPERIMENTAL S ETUP
An experimental setup for the study of the active control
of compressor surge was developed and commissioned by
the Rotating Machinery and Controls (ROMAC) Laboratory
at the University of Virginia. The setup shown in Fig. 1
consists of a single-impeller centrifugal compressor with Fig. 2. The single stage centrifugal compressor in the experimental
an unshrouded impeller and a vaneless diffuser, a modular setup operates with an unshrouded impeller and a vaneless diffuser. The
exhaust piping system that forms the plenum volume, and rotor is radially supported by two radial AMBs, and a single thrust AMB
provides the axial support.
a throttling device that controls the flow rate through the
compressor. An innovative feature of this experimental setup
is the implementation of AMBs, which not only provide The layout of the experimental setup is shown in Fig. 3.
radial and axial support of the compressor rotor, but they A modular exhaust piping system forms the plenum volume,
also induce a pressure variation in the compression system and a pneumatic throttling device controls the flow rate
by changing the axial clearance between the rotating impeller through the compressor. The size of the plenum volume
and the static shroud. The final objective of this setup is to can be varied by moving the throttle valve to one of the
develop an active surge controller that uses the AMBs to cre- three predetermined locations along the exhaust piping. By
ate pressure waves by changing the impeller tip clearance for modifying the plenum volume this way, we can change the
the active control of compressor surge. A detailed description intensity of the observed surge in the compressor. Pressure
of the experimental setup can be found in [24]. measurements are recorded using high-bandwidth pressure
A cut-section drawing of the compressor is given in Fig. 2. transducers along the inlet and the exhaust piping, together
The compressor has an overhung design, with two radial with thermocouples to provide temperature measurements
AMBs located near each end of the compressor to levitate at the same locations. The steady state mass flow rate
and center the rotor about its rotating axis. The axial support is given by an orifice flow meter installed in the return
of the rotor is provided by a thrust AMB located at the mid- section of the exhaust piping. For the initial testing of the
section of the compressor, which also controls the clearance compressor, the throttle valve is located at the position closest
between the impeller tip and the shroud with high bandwidth to the compressor, and the operating speed is selected to be
and precision. The rated load capacity for the thrust AMB 16290 RPM.
is 6600 N. The maximum end-to-end displacement of the
AMBs is 20 mils (0.508 mm) on each axis, and it is limited III. C OMPRESSION S YSTEM M ODEL
by the auxiliary bearings protecting the internal components The derivation of the mathematical model describing the
of the compressor. The compressor is powered by a prototype dynamics of our experimental setup is described in detail
induction motor from KaVo, which is rated to produce 95 kW in [21]. Here we present a brief overview for the purpose
of power at the design speed of 23000 RPM. of deriving a surge controller. A lumped parameter model

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 experimental
curve fit
1.4

1.35

Exhaust Pressure (kPa)

1.3

1.25

1.2

1.15

1.1

Fig. 3. Layout of the experimental setup, including the compressor, 1.05

−0.2 0 0.2 0.4 0.6 0.8 1
instrumentations, and the movable throttle valve. Possible throttle valve Mass Flow (kg/sec)

locations are at 2.2 m, 7.1 m and 15.2 m along the exhaust piping
measured from the compressor. Fig. 5. Fitted characteristic curve of the compressor at 16290 RPM.

curve where a further restriction of the flow would force the

compressor into surge. The stable region is to the right of the
surge point, and the curve can be interpolated from steady
state pressure and flow rate measurements using a 3rd order
polynomial fitting
Φeq = a1 Ψ3eq + b1 Ψeq2 + d1 . (2)
Equilibrium pressure and mass flow measurements in the
Fig. 4. Schematic drawing of a compression system described by the unstable region, or to the left of the surge point, are difficult
Greitzer model. to obtain, and the characteristic curve is extrapolated from
the curve fitting in the stable region. A correction term
for the pressure at zero mass flow rate is added based on
for a compression system composed of the compressor, the
observations. Details on determining the characteristic curve
plenum volume and the throttle valve was derived by Greitzer
of a compressor can be found in [1]. The characteristic curve
in [4] for the study of flow instabilities in turbomachineries.
for our model is given in Fig. 5.
This models adds the transient dynamics of the compres-
The model in Eq. (1) makes some assumptions on the
sion system over the steady state characteristics given by
geometry and the operating conditions of the compression
the compressor characteristic curve. Assuming quasi-steady
system. First of all, it assumes that the compression system
behavior of the compressor and the throttle valve, the states
operates with low inlet Mach numbers and small pressure rise
of the Greitzer compression system are the non-dimensional
values compared to ambient pressure. Also, the flow in the
compressor mass flow rate Φ c and the non-dimensional
duct section is taken to be one-dimensional and incompress-
plenum pressure rise Ψ p and are governed by
ible. In the plenum, isentropic compression process is as-
Φ̇c = BωH (Ψc − Ψp ), (1a) sumed with uniform pressure distribution, and fluid velocities
ωH are considered to be negligible. Finally, plenum dimensions
Ψ̇p = (Φc − Φth ), (1b) are taken to be much smaller than to the wavelength of the
B

Φth = cth uth Ψp . (1c) acoustic waves related to surge.
Selecting a proper actuator that perturbs the compression
The non-dimensional throttle mass flow rate Φ th is computed system with enough bandwidth and control authority to
as a function of the throttle percentage opening u th and Ψp . stabilize surge is a difficult task, and it is the topic of research
The throttle valve constant c th is determined experimentally for many published works in compression systems ( [17],
and is specific to each valve. Finally, B and ω H are the [18], [26], [27]). Here, we take advantage of the AMBs
Greitzer stability parameter and the Helmholtz frequency, levitating the rotor to servo control the impeller axial position
respectively. A schematic drawing of a compression system with high precision, and thus changing the axial clearance
as represented by the Greitzer model is given in Fig. 4. between the impeller and the static shroud.
The steady state performance of the compressor is given The variation of the axial impeller tip clearance in the
by its characteristic curve. This curve gives the equilibrium compressor is the input perturbation for the compression
pressure output for the compressor operating at different system. Senoo in [22] and Senoo and Ishida in [23] studied
mass flow rates. The curve is generally divided into two the relationship between the axial impeller tip clearance
region by the surge point, which is the critical point in the and operating efficiency of turbomachineries, and Senoo

4325
 TABLE I
where the gain k is a function of the compressor pressure
S YSTEM MODEL PARAMETERS
ratio ψc,ss
Parameter Value
 
γ k0 γ1 γ−1
γ
B .5246 k=− ψc,ss 1 − ψc,ss ,
ωH (rad/sec) 50.25 γ−1 b
Po1 (Pa) 101,325 1 2
2 ρU

ρ (kg/m3 ) 0.833 ψc,ss = Ψc,ss + 1 .
γ 1.4 Po1
U (m/sec) 213.24
It was demonstrated in [21] that the linearization error
introduced by the above approximation is small for the
allowed range of δ cl .
introduced a simple mathematical expression relating the By defining the states χ and ξ as the variation of the
average impeller tip clearance to the change in the efficiency nondimensional plenum pressure rise and compressor mass-
for a single-stage unshrouded centrifugal compressor. The flow rate from their respective equilibrium values
mathematical expression introduced by Senoo was here ad-
justed to match our observations in the measurements taken χ = Ψp − Ψeq , ξ = Φc − Φeq , (7)
from the experimental setup, such that a variation of 2% in the state equations for the compression system can be
the ratio between the axial impeller clearance cl over the rewritten as the following
blade height b, induces a changes of 1% ratio between the
change of efficiency from its zero-clearance value ∆η, and ξ˙ = BωH (Ψc,ss + kδcl − χ − Ψeq ), (8a)
the current efficiency η. ωH
χ̇ = (ξ − Φth + Φeq ), (8b)
B
∆η cl
− ≈ . (3) and the surge control problem becomes the stabilization of
η 2b the system (8) at the origin (ξ, χ) = (0, 0).
Define δcl = cl0 − cl to be the variation in the tip An H∞ surge controller is derived from a linear approxi-
clearance from the nominal clearance value cl 0 , and the mation of system (8). A linear controller is preferred in this
impeller clearance coefficient k 0 to be case because the tracking limitation of the AMB actuator
can be included into the controller derivation employing
0.5 linear robust control methods. The linearized model for the
k0 = . (4)
1 + 0.5cl
b
0
compression system at a nominal throttle valve opening
uth0 = .28, corresponding to the experimentally observed
Assuming we have isentropic compression and perfect gas surge point, is given by
properties, Ψ c can be expressed as a function of the steady   
ξ˙ BωH 1PρU 2k
  
state compressor pressure rise Ψ c,ss , which is itself is a ξ o1

=A + 2 δcl , (9)
function of the compressor mass flow rate Φ c and obtained χ̇ χ 0
from the compressor characteristic curve at the nominal tip
clearance cl0 , and the variation in the tip clearance δ cl , where the matrix A is defined as

BωH (3a1 Φ2eq + 2b1 Φeq )

γ −BωH
A= . (10)
 γ−1 
1 2
γ−1 ωH
− ωBH cth0 uth a2
ρ
2 o1 U γ
B
po1  Ψc,ss +1 − 1 
Ψc = 1 1+ po1
  − 1 . (5) The constants a1 and b1 are the coefficients from the polyno-
2 δ
2 ρo1 U

 1 − k0 bcl  
mial fit of the characteristic curve, and a 2 is obtained from
the linear approximation of the square root
The density ρo1 is given at the inlet condition, γ is the


Ψeq = a2 Ψeq + b2 . (11)
specific heat ratio, and the impeller tip velocity U is obtained
from the compressor operating speed. Thus, Eqs. (5) and The 2-input 2-output interconnection system shown in
(1) are the state equations representing the dynamics of the Fig. 6 is employed to synthesize the linear controller, where
compression system. Table I gives the values for the dif- GC (s) is the linearized compression system and K C (s) is
ferent model parameters corresponding to the experimental the surge controller. The weighting function W 2 (s) contains
compressor test rig. information on the AMB servo tracking performance, and
weights on the control input to the plant. The benefit of
IV. C ONTROLLER D ESIGN AND S IMULATION this method is that in addition to incorporating a limit to
the actuator bandwidth, it also consider the steady state
In order to simplify the system equations for the derivation tracking error introduced by the dynamics of the closed
of the surge controller, a linear approximation of Eq. (5) is loop AMB, as well as the error from overshoot and other
introduced. By keeping the first order terms of the Taylor transient dynamics. We define W 2 (s) = 4s/(s + 400), such
expansion, the equation for the compressor pressure rise can that it upper-bounds the sensitivity function of an acceptable
be written as AMB dynamics.The function W 4 (s) weights the added noise
Ψc ≈ Ψc,ss + kδcl , (6) to the plant output, and contains the information of noise

4326
 90

80

Magnitude (dB)
70

60

50

40 Experimental
Model w/ throttle piping
30
−1 0 1
10 10 10

50

Phase (Deg)
−50
Fig. 6. Interconnection system for the synthesis of H∞ controller
−100

−150

characteristics in the sensor measurement signal. For the 10

−1
10
0 1
10
Frequency (Hz)
remaining weighting functions, W 1 (s) is set to be 1, and the
value of W3 (s) is iterated to obtain a satisfactory controller. Fig. 7. Comparison between simulated frequency response of the
One issue that needs to be considered before the above mathematical model vs. experimental Bode plots. Throttle valve at 32%
controller can be practical is the availability of the sen- open.
sor measurements. High-bandwidth pressure transducers are
35
common in industrial applications and readily available. 34

Throttle opening (%)

On the other hand, transient flow rate measurements are 33

not reliable, especially for larger industrial compressors. 32

31
Therefore, a nonlinear mass-flow rate observer is derived 30
from the system equations (1) as presented in [28]. The state 29

equation for the observer are given as 28

0 0.5 1 1.5 2 2.5 3 3.5 4
 
P o1
ż = BωH Ψ̂c,ss + 1 2 kδcl −Ψp −cΦ̂c +cΦth , (12a) 1.6

2 ρU
1.4
Φ̂c = z + B 2 cΨp . (12b)
Ψp

1.2

where Φ̂c is the estimated non-dimensional compressor mass

1
flow rate, Ψ̂c,ss is the non-dimensional steady-state compres-
sor pressure rise at Φ̂c , and c = 5 is the observer constant. 0.8
0 0.5 1 1.5 2 2.5 3 3.5 4
Time (s)
It was demonstrated in [28] that the estimation error for the
above observer approaches to zero for c ≥ 2(∂ Ψ̂c,ss /∂ Φ̂c ). Fig. 8. Throttle valve opening uth and plenum pressure rise Ψp for the
The stability of the compression system with the derived uncontrolled system simulation
observer and surge controller was tested through simulation.
In order to further improve the fidelity of the numerical
simulation to the experimental observations, the acoustic compression system enters the surge cycle.
effects in the plenum piping was included to the state Some simulation results of the compression system with
equations in (1) as described in [25]. Fig. 7 compares of active surge control are shown in Fig. 10 for the same
the simulated Bode plots of the extended model from small changes in the throttle valve opening as above. The variation
perturbations in the tip clearance to the output pressure, and in the impeller tip clearance is shown in the figure, and we
the equivalent plots from measurements in the experimental can see that the plenum pressure rise follows the equilibrium
setup. A good match is observed between the two responses, Ψeq and remains stable beyond the stable region.
which give us confidence in the simulated results.
Fig. 8 shows the simulated response in surge condition V. C ONCLUSIONS
for the uncontrolled system. The throttle valve opening is The design and implementation of an active surge con-
reduced from 34% to 29%, crossing the surge point at 31.5% troller for an unshrouded centrifugal compression system
open into the unstable region. The compression system with AMBs was studied in this paper. Employing the com-
becomes unstable, and the surge oscillations can be observed pressor bearings to servo control the impeller position, the
in the plenum pressure signal. The characteristic curve and compressor output pressure was modulated to control surge.
the simulated operating point of the compression system An H∞ controller was designed based on a previously
is plotted in Fig. 9. During stable operation, the states of validated model of the compressor, taking into account the
the compression system would approach the characteristic tracking performance of the AMB.
curve. Instead, the uncontrolled system becomes unstable in We are currently in the preliminary stage of implementing
the positive-slope region of the characteristic curve, and the the surge controller. Initial observations show high noise-to-

4327
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