In-House Controls Services
FOX In-House Controls Services
FOX provides specialized in-house controls services built on deep application knowledge, proprietary methodologies, and real-world turbomachinery experience.
From anti-surge engineering to system validation and performance analysis, our team supports the full lifecycle of control system design, verification, and optimization.
Support Driven by Internal Know-How and Cross-Functional Expertise
Anti-Surge Engineering Services
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ANTI-SURGE WRITE-UP
Define the Surge Limit Line (SLL) and configure Anti-Surge Controller (ASC) settings tailored to the specific compressor and operating envelope.
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ANTI-SURGE SIZING
Determine the required capacity and performance characteristics of the recycle system to ensure safe and stable compressor operation
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ANTI-SURGE VERIFICATION
Validate recycle system capacity and performance under expected and transient operating conditions to confirm proper anti-surge protection.
FOX Anti-Surge Control Systems
FOX Control Solutions designs and integrates advanced anti-surge control systems engineered to protect centrifugal compressors from damaging surge conditions while maximizing reliability and process performance.
Our OEM-independent approach allows seamless integration with both legacy and modern control architectures, including DCS, PLC, and SCADA platforms. Each system is tailored to the compressor’s performance map and process dynamics, ensuring fast, stable, and energy-efficient operation across all load conditions.
From algorithm development and dynamic modeling to commissioning and lifecycle support, FOX delivers complete turnkey anti-surge solutions that enhance safety, reduce downtime, and extend the operational life of your rotating equipment.
Do you have an anti-surge control systems & services project we can help with?
Flow Element Engineering
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FLOW ELEMENT SIZING
Define the geometry and performance characteristics of flow measurement devices to ensure accurate and reliable process feedback.
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FLOW ELEMENT VERIFICATION
Verify installed flow elements against design requirements to confirm measurement accuracy and system compatibility.
Performance Evaluation & Diagnostics
In-depth turbine and compressor performance analysis, root cause investigation, and vibration diagnostics — powered by decades of rotating equipment expertise.
Turbine & Compressor Performance
Comprehensive performance analysis and consultancy for turbomachinery — identifying efficiency losses, degradation patterns, and optimization opportunities.
Root Cause Analysis
Systematic investigation of unexpected events — identifying the origin of failures, trips, and anomalies through structured diagnostic methodology.
Machine Vibration Diagnostics
Advanced vibration analysis and diagnostics — detecting imbalance, misalignment, bearing faults, and structural resonance in rotating machinery.
Reverse Engineering & Revamping Services
Complete reverse engineering and revamping services covering both hardware and software — breathing new life into legacy systems or upgrading to modern platforms.
Hardware Revamping
Complete hardware reverse engineering — from legacy panel documentation and wiring analysis to modern platform migration, component replacement, and cabinet redesign. Full traceability from the existing system to the upgraded architecture.
Software Revamping
Full software reverse engineering — logic extraction from legacy controllers, algorithm migration, application code modernization, and re-commissioning on new PLC/DCS platforms with complete functional verification.
Smart Testing & Validation
Rigorous UCP testing programs combining hands-on inspection with advanced Software-in-the-Loop simulation — ensuring every system is field-ready before deployment.
UCP General Testing
Visual inspection of wiring, components, and panel build
Loop checks — verifying signal integrity end-to-end
Functional tests — validating logic, interlocks, and I/O mapping
Software-in-the-Loop Testing
Dedicated Dynamic process Simulation tailored to the application
Real-time controller response validation against process model
Edge-case and failure scenario testing in a simulated environment
Surge Protection for Centrifugal Compressors
Using dynamic modeling, real-time performance data, and proprietary control algorithms, our engineers deliver stable, responsive surge protection for centrifugal compressors in process, petrochemical, and energy applications. Each system is engineered for precise valve response, smooth recovery, and optimal compressor performance under all load conditions.
Our comprehensive control solutions include:
Anti-Surge Control – For compressors up to 4 stages, ensuring reliable operation under all load conditions.
Anti-Surge Control (with Side Flows) – Handles complex configurations and varying process dynamics effectively.
Choke Controller – Prevents compressor overload by managing flow at high operating limits.
Performance Controller – Regulates efficiency through inlet guide vanes (IGV), speed, and suction/discharge pressure acceleration control.
Load Distribution Control – Balances operating points across compressors in parallel or series arrangements for maximum efficiency.
Quench Controller – Manages inter-stage cooling in refrigeration compressors to maintain optimal thermodynamic conditions.
Steam Turbine Speed Governor – Provides stable and responsive speed control for turbine-driven compressors.
Centrifugal Compressor Anti-Surge Control
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OEM-Independent Design
Flexible control solutions engineered for all major compressor OEMs.
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Advanced Surge Control
Proprietary algorithms for precise surge detection and prevention.
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Dynamic Modeling & Tuning
Real-time simulation ensures optimal stability across operating ranges.
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Seamless System Integration
Easily integrates with existing DCS, PLC, or SCADA platforms.
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Optimized Performance
Fine-tuned control loops improve reliability and energy efficiency.
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Global Field Support
Comprehensive commissioning, validation, and lifecycle service worldwide.
We have in-depth experience with the industry’s most common control platforms, ensuring seamless integration, reliable performance, and optimized system operation. Our algorithms can be embedded in the main control platforms on the market:
Rockwell / Allen Bradley
RX3i
Siemens
Triconex
Schneider
Yokogawa
Micronet
HIMA
We are OEM Agnostic
Rolls Royce
Baker Hughes
Elliott
MAN Turbo
Solar Turbines
General Electric
Mitsubishi Compressor (MHI)
Dresser-Rand
Delaval
Anti-Surge Control Services
Fox provides field-proven anti-surge control services — from retrofit design and hardware installation to on-site tuning and commissioning. Whether upgrading legacy systems or fine-tuning an existing control loop, our specialists bring decades of compressor controls experience to every project.
Our team configures and validates anti-surge systems for reliable compressor operation across all OEMs. We handle valve actuation tuning, pressure and flow instrumentation calibration, and real-time system verification to ensure smooth, surge-free performance.
Our Anti-Surge Control Services Offering Include:
Installation & Commissioning
Seamless system integration and performance validation.
Upgrades & Retrofit
System upgrades and retrofit implementation.
Anti-Surge Valve Installation
Anti-surge valve installation & calibration
Tuning & Testing
On-site loop tuning and compressor performance testing.
Operator Training
Operator training and knowledge transfer.
Troubleshooting
Quick diagnosis and resolution to minimize downtime & improve reliability.
FOX Anti-Surge Control Systems
Decades of Experience in Compressor Control Integration.
With decades of experience in designing centrifugal compressor anti-surge control systems, FOX Innovation & Technologies delivers robust, field-proven solutions that integrate seamlessly with Distributed Control Systems (DCS), Programmable Logic Controllers (PLC), and supervisory control and data acquisition (SCADA) networks.
Our engineers combine advanced modeling, simulation, and tuning methodologies to ensure each control system maintains peak compressor efficiency and safety — from design to commissioning.
How FOX Anti-Surge Control Systems Work:
Monitoring: A system of precision sensors continuously measures suction and discharge pressure, temperature, and process flow rate.
Calculation: A dedicated anti-surge controller determines the compressor’s current operating point and calculates its distance from the surge limit line on the compressor map, taking into account process flow property changes.
Actuation: When the operating point approaches the surge line, the controller sends a signal to a fast-acting anti-surge valve.
Recirculation: The valve opens, routing a portion of the discharge gas back to the compressor inlet. This increases the inlet flow and shifts the operating point away from the surge limit.
Optimization: The controller continuously modulates the valve to maintain a stable, efficient operating range—preventing surge without excessive recirculation.
Anti-Surge System Design, Installation, and Field Tuning Services — From Retrofit to Commissioning
FOX provides custom-engineered anti-surge control systems designed to maximize compressor reliability, performance, and efficiency.
Our solutions:
Prevent surge conditions by dynamically adjusting minimum flow setpoints.
Improve compressor longevity by reducing mechanical stress and vibration risks.
Ensure real-time monitoring for precise flow and pressure regulation.
Seamlessly integrate with existing automation systems for cost-effective upgrades.
With decades of compressor anti-surge control expertise, FOX offers flexible, retrofit-ready, and cost-effective solutions that enhance protection, performance, and safety across all compressor applications.
Contact SSE for on-site anti-surge control expertise — from design validation to commissioning support.