Controller tuning
We assess stability, responsiveness, and equipment performance, then deploy practical tuning solutions aligned with real process dynamics.
Process Control
Anti-Surge Valve Optimisation
Structured commissioning, characterisation, and dynamic tuning improved gas compressor anti-surge valve response, strengthening machine protection and restart confidence.
The Challenge
Protection needed a better fit
A major oil and gas operator in the Netherlands required the tuning and optimisation of gas compressor anti-surge valves during a planned compressor outage.
Over time, operating conditions and equipment performance characteristics had changed, resulting in sub-optimal valve response and reduced control accuracy.
To ensure reliable machine protection and maintain compressor efficiency during restart and normal operation, a specialist programme of anti-surge valve commissioning, characterisation, and dynamic tuning was required.
ICSS was engaged to provide engineering and commissioning expertise to develop and execute the tuning programme, validate valve performance, and hand back the system to operations ready for immediate service.
Our Scope
Tuned, tested, proven offshore
ICSS delivered the full lifecycle of planning, execution, and performance verification needed to return the anti-surge control system to service with confidence.
Our team prepared detailed procedures defining the offline and dynamic test steps required to assess, accept, and tune anti-surge valve performance prior to compressor restart.
We then mobilised to site to commission, characterise, and dynamically tune the anti-surge control valves, ensuring optimal performance across the full operating envelope.
The work was closed out with comprehensive performance analysis and reporting, including valve response characteristics, tuning parameters, validation results from static and dynamic testing, and recommendations for future optimisation and maintenance.
The Result
Stronger compressor protection
The project delivered enhanced compressor protection, improved valve performance, and greater control stability across the operator's gas compression system.
By combining structured testing, disciplined tuning methodology, and close coordination with site personnel, the anti-surge control system operated at peak performance from the first day of restart.
All anti-surge valves successfully passed static and dynamic performance testing, confirming reliable and rapid response under expected operating conditions.
The control loops were tuned and validated to provide optimum compressor surge protection without excessive valve movement or instability, safeguarding critical rotating equipment and supporting sustained production reliability.
Process Control
Unlocking potential. Turning stability into value.
Our solutions are targeted, measurable, and impactful. Whether we are working on routine optimisation or resolving chronic control issues, we deliver tangible improvements to stability, operability, and bottom-line performance.
Advanced control
We apply the right technique in the right place, stabilising compression trains and optimising process performance without unnecessary complexity.
Start Here
Need help with process control performance or optimisation?
Tell us what you are trying to stabilise, tune, or optimise across greenfield projects, brownfield upgrades, or late-life assets. We will help shape the scope, de-risk the decision, and define a practical route to measurable performance improvement.