An Engineering Selection Guide for Compressor Protection Systems
Applicable to: Natural Gas Compressor Stations / Gas Pipeline Networks / Chemical Plant Compressors / LNG Plants / FCC Units
Introduction
For design institute engineers, EPC project engineers, plant equipment procurement managers, and compressor OEM engineers, anti-surge valves are a vital control component in centrifugal compressor systems. These valves respond rapidly when a compressor approaches surge conditions by opening a bypass route to reduce differential pressure and protect the compressor from damage.
This article explores the working principles of anti-surge valves, examines their application in various compressor systems, and compares the top 10 global anti-surge valve manufacturers. Special attention is given to the technical advantages and application cases of THINKTANK anti-surge valves. We also provide selection recommendations and invite interested engineers to fill out our contact form to receive detailed technical support.
Difference Between Anti-Surge Control Valve Vs. General Control Valve？
These valves are mostly the same, the main difference is that anti-surge valves have a fast opening time, so surge can be avoided.
| Feature | Anti-Surge Control Valve | General Control Valve |
| Purpose | Specifically protects compressors from surge | General flow, pressure, or temperature control |
| Response Speed | Extremely fast (typically <1 sec full open) | Standard (1–4 sec or more, not always emergency-rated) |
| Opening Characteristics | Often Fail-Open, full stroke required rapidly | Modulating control, typically slower |
| Cv Range | Very wide Cv range for surge relief and blow-off | Sized for stable control at target setpoint |
| Trim Design | May include multi-stage trim, noise reduction, cavitation control | May include trim, but optimized for regulation not relief |
| Actuator Type | High-thrust, spring-return pneumatic or electro-hydraulic | Pneumatic, electric, or hydraulic (less emphasis on speed) |
| Integration | Tightly integrated with Anti-Surge Controller (e.g., CCC, Triconex) | Integrated with DCS/PLC for process loop control |
| Criticality | Safety-critical — failure may damage compressor | Generally process-critical, but less catastrophic risk |
| Common Applications | Compressors in LNG, ASU, refineries, gas pipelines | Process units, tanks, pipelines, steam/utility services |
| Valve Types | Fast globe valves, axial valves, T-ball valves | Globe, V-ball, rotary plug, butterfly, etc. |
How Anti-Surge Valves Work & Applications
Anti-Surge Valves Working Principle
Centrifugal compressors operating at low flow conditions are prone to surge, a phenomenon where discharge pressure exceeds inlet pressure, causing backflow and flow instability. This leads to severe vibration, elevated temperatures, and even damage to bearings or impellers.
An anti-surge valve (ASV), also known as an anti-surge control valve, is typically installed in a bypass line connecting the compressor discharge and suction. During normal operation, the valve remains closed. When surge conditions are detected, the ASV quickly opens to route part of the high-pressure gas back to the inlet, relieving differential pressure, stabilizing flow, and preventing surge.
The anti-surge valve is governed by an anti-surge controller that monitors the compressor’s operating point in real time. Once thresholds are exceeded, the valve actuates almost instantly to prevent damage.
Anti-Surge Valves Applications
Natural Gas Booster Stations
Compressors in long-distance pipelines increase gas pressure. Anti-surge valves are placed at the discharge of each centrifugal compressor to prevent surge during load drops or valve transitions. For example, in one gas station, the ASV reliably opens to bypass excess gas to the inlet, protecting the booster system.
Gas Transmission Pipelines
Including systems transporting natural gas, hydrogen, nitrogen, etc. Intermediate compressors may face low-flow conditions during downstream shutdowns or demand drops. ASVs unload pressure quickly to prevent surge.
Chemical Plant Compressor Systems
Used in units like ethylene crackers or ammonia synthesis, where compressors operate under complex, fluctuating conditions. ASVs help each unit maintain stability even during transitions. For example, in a large integrated refinery, both hydrogen recycle compressors and propylene chillers use ASVs to avoid surge during load shifts.
LNG Liquefaction Plants
LNG facilities have multiple high-power centrifugal compressors handling liquefaction and cooling. Due to the cryogenic nature of LNG (down to -162°C) and large compressor sizes, any surge event can be catastrophic. Therefore, each compressor loop is equipped with specially designed ASVs for cryogenic service. Key requirements: material must withstand -162°C, and valve must fully open in ≤1 second. International manufacturers like IMI CCI and Mokveld have proven ASV solutions for such conditions, often with SIL3 certification.
FCC Units in Refineries
Fluid catalytic cracking units use large compressors (main air blowers) to feed regenerators. When air demand drops (e.g., emergency turndown), surge can occur quickly. ASVs in this setting provide immediate relief by recycling excess air to prevent vibration damage. FCC dry and wet gas compressors also require ASV protection.
Air Separation Units (ASU)
Main air compressors and nitrogen recycle compressors in ASUs are also equipped with ASVs. A stable airflow is critical for downstream processes. If flow drops too low, surge affects operations like distillation. ASVs quickly vent or recycle gas to keep compressors operating safely. In one large ASU project, nitrogen compressors use ASVs that automatically open during demand drops to bypass gas, preventing surge.
Now we know ASVs are indispensable across critical compressor systems. Due to the varying demands across industries (high pressure, high temp, cryogenic conditions, corrosive gases), each manufacturer offers distinct design advantages. The following section compares 10 globally recognized anti-surge valve brands and their key specifications.
Comparison of the World’s Top 10 Anti-Surge Valve Manufacturers
In the global industrial valve market, several well-known manufacturers supply high-performance anti-surge valves. We have selected ten leading international brands for comparison, including Emerson, Flowserve, IMI CCI, SAMSON, Baker Hughes (GE), Mokveld, Metso (Neles), Cameron, Japan KOSO, and UK-based Severn. Each of these brands has its own technical strengths, offering various types of anti-surge valves—such as straight-through control valves, axial flow control valves, and rotary ball valves. They differ slightly in terms of opening speed, control method, applicable working conditions, lead time, and certifications. The table below summarizes the key parameters of these brands:
| Manufacturer | Product Page Link |
| Emerson (Fisher) | Compressor Anti-Surge Control Valves |
| KOSO Kent Introl – UK/Japan | Anti-Surge Valves |
| IMI CCI | DRAG® Compressor Recycle Anti-Surge Valve |
| Cameron (Schlumberger) – USA | Valves Products |
| SAMSON – Germany | Anti-Surge Valves (Types 3595 and 3599) |
| Mokveld | Highly Reliable Fast-Acting Anti-Surge Control Valves |
| Baker Hughes (Masoneilan/Becker) | Becker™ Anti-Surge Valves |
| Flowserve (Valtek) | Linear Globe Compressor Anti-Surge Valve |
| Metso (Neles) | Neles™ Top Entry Rotary Ball Valve Series T5 |
| Severn (UK) | Anti-Surge Actuator |
* Ranking in no particular order.
NO 1. Emerson (Fisher)
Fisher offers globe-style anti-surge valves with multi-stage low-noise trims and FIELDVUE digital positioners. Fisher™ anti-surge control valves provide excellent dynamic response and reliability for applications such as LNG, refining, chemical, and natural gas pipelines, especially where precise control and integration with DeltaV/DCS systems are required. You can download the Fisher anti-surge valve brochure here.
NO.2 KOSO Kent Introl – UK/Japan
This brand delivers cage-guided or angle valves with special fast-open trims. A frequent choice for OEM compressor skids and chemical plants where high-pressure hydrogen or toxic gas demands tight control and reliability.
NO.3 IMI CCI
Known for its DRAG® multi-stage trim technology, IMI CCI supplies high-pressure, fast-acting valves for severe service. Ideal for hydrogen compression, high-pressure recycle, and refineries with tight surge margins.
NO.4 Cameron (Schlumberger) – USA
Cameron supplies large-diameter ball and butterfly valves integrated into full compressor protection packages. Trusted in oil and gas gathering systems and LNG terminals, especially where turnkey surge protection systems are required.
NO.5 SAMSON – Germany
SAMSON’s axial flow control valves support fast opening and modular actuation. Preferred in large flow applications such as ethylene plants, LNG cold loops, and air separation units requiring SIL3-certified response under cryogenic conditions.
NO.6 Mokveld
Mokveld specializes in axial anti-surge valves for pipeline booster stations, offshore platforms, and large compressors. Their valves offer high reliability, full-bore flow paths, and extremely fast opening (<2 sec), even under deep cryogenic conditions.
NO.7 Baker Hughes (Masoneilan/Becker)
Becker’s T-Ball quarter-turn design delivers fast response, high Cv, and minimal clogging. Popular in natural gas compressor stations and dusty gas conditions where quick isolation and zero-leakage are critical.
NO.8 Flowserve (Valtek)
Flowserve’s globe and angle anti-surge valves are widely adopted in petrochemical plants. Known for high thrust pneumatic actuators and the Logix digital positioner, they ensure fast and accurate flow modulation under high ΔP.
NO.9 Metso (Neles)
Neles offers high-rangeability Q-Ball and top-entry control valves that are compact and efficient. Suitable for refinery recycle gas and skid-mounted compressor systems with space constraints and dynamic load profiles.
NO. 10 Severn – UK
Severn focuses on custom-engineered surge valves and silencers for high-vibration applications such as FPSOs, BOG compressors, and LNG trains. Their valves are built for extreme reliability, with proven references in offshore and subsea markets.
Comparison of the World’s Top 10 Anti-Surge Valve Manufacturers
| Manufacturer | Valve Type / Structure | Opening Speed (Full Open) | Typical Applications | Certifications |
| Emerson (Fisher) | Globe valve, multi-stage low-noise trim | ≤ 1 sec (with booster) | LNG, refining, gas pipelines | CE, PED, ATEX, SIL3 |
| IMI CCI | Globe valve, DRAG® multi-stage severe service | < 1 sec | Hydrogen, recycle, refineries | CE, SIL3, API |
| SAMSON (with Ringo) | Axial flow valve, modular design | ≤ 1 sec (emergency), 2 sec (normal) | Ethylene, LNG, air separation | CE, PED, ATEX, SIL |
| Mokveld | Axial flow, full-bore low ΔP | < 2 sec | Pipeline compressors, cryogenic gas | CE, PED, SIL3 |
| Baker Hughes (Masoneilan / Becker) | Quarter-turn T-Ball valve | < 2 sec | Gas stations, dusty or sour gas | API 6D, ISO, CE, SIL3, NACE |
| Flowserve (Valtek) | Globe/angle valve, high Cv | ~ 1 sec | Petrochemical, high ΔP control | PED, ISO9001, ASME |
| Metso (Neles) | Q-Ball, top-entry rotary control valve | ~ 1 sec | Refinery recycle gas, compact skids | PED, ATEX, SIL, FE certified |
| KOSO Kent Introl | Cage-guided / angle valve, fast-open trim | ~ 1 sec | Chemical, hydrogen, OEM compressors | ISO9001, CE, SIL, Japan Gas Act |
| Cameron (Schlumberger) | Large ball/butterfly valves, integrated systems | 1–2 sec | Oil & gas gathering, LNG | API 6A/6D, ISO 15848, CE |
| Severn | Custom-engineered valves with silencer | Custom (< 1 sec possible) | FPSO, LNG BOG, offshore | PED, API 6D, UKCA |
THINKTANK Anti-Surge Valves: Technical Highlights and Product Advantages
THINKTANK (part of Taiwan’s STONE Valve Group) is a rising industrial control valve brand offering high-performance, cost-effective solutions to global clients. For anti-surge applications, THINKTANK integrates advanced international technology with proprietary R&D to deliver a product line that combines rapid response, wide Cv range, and high reliability—suitable for gas transmission, petrochemical, and air separation systems.
Key Features and Advantages
a. Ultra-Fast Response Time
THINKTANK utilizes large-diameter pneumatic piston actuators combined with high-capacity solenoid valves and air reservoirs to ensure emergency full-stroke opening within 0.5 ~ 1 second (adjustable based on size/stroke). Its valve positioners support high-speed air charge/discharge, enabling full open/close cycles within 2 seconds during normal modulation—comparable to leading international brands and fully meeting the speed demands of surge control systems.
b. Wide Cv Range
By optimizing internal flow paths and offering multi-stage trim options, THINKTANK anti-surge valves cover a broad Cv spectrum—from just a few dozen to over 10,000. From DN50 (2″) to DN600 (24″) and beyond, mature designs are available.
- For high-flow systems, high-performance butterfly valves or eccentric rotary ball valves are available.
- For high ΔP, low-flow scenarios, specialized multi-stage pressure-reducing trims ensure stable low-end control and effective surge relief. This flexibility allows engineers to select valves that operate in ideal control ranges across varying load conditions.
c. Control System Compatibility
THINKTANK prioritizes seamless integration with compressor control systems. Its anti-surge valves come standard with smart digital positioners (HART, Profibus, Foundation Fieldbus optional) and accept standard 4–20mA signals. They are compatible with common anti-surge controllers (CCC, Triconex, Yokogawa, etc.). For hazardous environments, intrinsic safety and explosion-proof versions are available, certified under ATEX/IECEx. Redundant solenoids and position feedback options are supported for reliable DCS/SIS interfacing.
d. Customization Capability
THINKTANK follows an “engineered-to-fit” philosophy. Whether it’s special body materials (316L, cryogenic stainless steel, Hastelloy), custom end connections (ANSI, DIN, large flanges, butt weld), or non-standard actuators (e.g., hydraulic assist, ultra-high thrust), all configurations are flexible.
- For cryogenic service, dedicated -196°C trim and packing systems ensure long-term sealing integrity.
- For high-pressure toxic media, dual sealing systems and packing leak monitoring options enhance safety and environmental compliance. This customization ensures optimal valve design for each client’s operating conditions.
e. Certified to International Standards
THINKTANK anti-surge valves meet a full range of global certifications:
- CE/PED (Pressure Equipment Directive, EU)
- SIL3 functional safety approval (for safety loop applications)
- ISO 9001:2015 quality system
- Optional compliance with API, ANSI, DIN standards
- NACE MR0175 options for H2S/corrosive services These ensure buyers can trust the quality and reliability of THINKTANK solutions.
f. Fast Delivery & Full Service
Unlike many global brands with extended lead times, THINKTANK supports delivery in 10–12 weeks for standard anti-surge valves. For urgent projects, expedited builds are possible. With stocked components and local assembly/testing capacity, THINKTANK ensures rapid production and QA. An experienced technical team offers support from early-stage specification to on-site commissioning, helping EPCs and end users reduce project delays and communication gaps.
Proven Case Studies
- Case 1: In a major air separation project in China, THINKTANK provided a 16-inch Class 600 globe-type anti-surge valve for a nitrogen compressor. It successfully replaced an imported brand and delivered reliable performance under -50°C and large flow swings.
- Case 2: In a gas plant retrofit project in the Middle East, THINKTANK supplied 20-inch high-speed ball valves with electro-hydraulic actuators for two booster compressors. Opening time was verified at 0.8 seconds, winning client approval.
- Case 3: In a refinery hydrocracking unit revamp, THINKTANK replaced legacy single-stage anti-surge valves with modern multi-stage trims, solving previous instability and frequent surging issues. Compressor operation is now smoother and more reliable.
Study on turbo compressor anti-surge system(learn from KOSO)
1. Typical compressor anti surge bypass system shown alternative anti surge ventilation system
2. Anti-surge control system isolated from process control
3. Anti-surge control system integrated with process control
Final Thoughts
Anti-surge valves are not just control components—they’re the first line of defense against costly compressor failures. This article introduced the top 10 global manufacturers shaping the anti-surge valve industry, covering their technical strengths, valve types, certifications, and application experience across industries like LNG, refining, air separation, and gas transmission.
While these brands lead the global market, it’s important to recognize that performance, responsiveness, and long-term support matter just as much as brand reputation—especially for EPC contractors, design engineers, and plant operators working under strict timelines and budgets.
THINKTANK may not be among the global Top 10 anti-surge valve brands—yet. But we are your most cost-effective partner, delivering international quality and performance without compromise. With rapid delivery, wide Cv coverage, SIL3-certified safety design, certified with CE, PED, ATEX and engineering-level customization, THINKTANK valves have already proven themselves in challenging compressor systems across Asia and the Middle East.
For engineers and project managers seeking reliable, responsive solutions with full technical support and flexible integration—THINKTANK is the choice you can trust.
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