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Control & Protection Systems

SPS Surge Protection System

SPS is IPC's advanced control and protection system for centrifugal compressors, designed to provide full protection across real operating conditions, including off-design scenarios and changing process variables.

Anti-Surge Protection in Action

Real-time detection and control to prevent compressor surge and ensure safe operation.

Video Introduction

Understanding Compressor Surge

Compressor surge is a critical instability that can cause severe damage if not properly controlled. This video gives an intuitive introduction to the phenomenon and to the need for robust protection logic.

Why This Matters

Surge is not simply a loss of performance. It is an unstable operating condition that may involve strong oscillations, flow reversal and potentially severe mechanical stress on the compressor train.

While simplified, this visualization highlights why accurate protection requires engineering-based models and control logic, as implemented in SPS.

SPS System Architecture Overview

Integrated protection logic, thermodynamic modelling and real-time data processing interact to provide a complete and adaptive surge protection strategy.

Overview

Advanced Protection for Centrifugal Compressors

The SPS brochure presents the system as an advanced surge protection solution for centrifugal compressors, emphasizing full protection, thermodynamic modelling, surge detection and diagnostic capabilities.

What SPS Brings

  • Full protection for centrifugal compressors
  • Protection under every possible compressor operating condition
  • Embedded thermo-mechanical engine for performance and surge prediction
  • Expected performance evaluation and diagnostic tasks
  • Integration potential with compression station control systems

SPS combines a gas thermodynamic engine, a compressor thermo-mechanical model, protection logic, surge detection and diagnostic functions in one integrated system.

Protection
Full protection strategy
Model
Thermo-mechanical engine
Detection
Surge detection and override logic
Diagnostics
Support for maintenance decisions
Main Features

Engineering-Based Anti-Surge Protection

The brochure highlights SPS as more than a standard anti-surge controller: it is described as a platform that predicts compressor behaviour and updates protection logic on the basis of expected and measured conditions.

Thermodynamic Engine

  • Hydrocarbons properties database
  • Gas mixture composition setting
  • Implementation of recent thermodynamic theories
  • Results validated against academic research and available technical data

Thermo-Mechanical Model & Protection

  • Compressor characterization as per OEM specifications
  • Performance prediction for off-design gas mixtures
  • Real-time surge limit evaluation update
  • Anti-surge valve control and emergency action
  • Automatic surge condition detection and protection update
Diagnostic & Architecture

System Layout and Functional Architecture

SPS is presented as a layered solution involving application server, PLC, local HMI and field devices, with a clear split between business/application level and field execution level.

Diagnostic & Surge Detection

  • Incoming mechanical surge detection and override action
  • Hardware for mechanical surge detection already prototyped and tested
  • Matching between expected performances and measured ones
  • Diagnostic messages for maintenance decision support
  • Advanced logic for difficult operating environments

Architecture

  • Application layer for web, data mining and enterprise reporting
  • Access data layer
  • PLC for sequences, alarms and protections management
  • Local HMI for performance display and operator supervision
  • Field layer for devices, actuators and machinery interaction
Control Station

Part of a Wider Compression Station Control Strategy

According to the brochure, SPS can be embedded into IPC modular software for compression station control, enabling coordinated action across station load control and machine protection systems.

Control Station Integration

  • Applicable to compression stations with variable speed drives or fixed speed drivers
  • Suitable for working groups in series or parallel configurations
  • Synchronized interaction with machine protection systems
  • Case-by-case customization for optimal control strategy

Development Status

  • Thermodynamic software validated
  • Mechanical surge detection hardware prototyped and field tested
  • More than thirty years of application experience referenced in the brochure
Downloads

Brochure and Technical Resources

SPS marketing material can be made directly available, while more advanced technical documentation can be accessed through the technical papers section.

SPS Brochure

Download the brochure for a visual introduction to the system, its features, architecture and positioning.

SPS Technical Papers

For deeper technical content, application notes and specialist papers, use the IPC technical papers section.

Contact

Discuss Your Compressor Protection Needs

Contact IPC to explore how SPS can support compressor protection strategies, integration with station control logic and operational reliability improvement.