AbuDhabi.comprControl Overview.n.technology_R.kamphaus Feb2012

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Industrial Compressor Controls

• Standard

Technical SeminarsTechnical SeminarsTechnical SeminarsTechnical Seminars –––– 2012201220122012

1

TM

• ustom

CONTROLLING the power of ENERGY



Compressor ApplicationCompressor Application

2

a engesa enges



Hydrogen Separation ApplicationHydrogen Separation Application

One component in a

complex process

3



MPU MPUMPU

1st

Stage

2nd

Stage

3rd

Stage4th

Stage

PT

FY

FY

FT

PT

TT

TT

PT

FT PT

TT

TT

PT

FT PT

TT

TT

PT

FTPT TTTTPT

Naphtha Cracker ApplicationNaphtha Cracker Application

4

FY

FY

PT

• Stage to stage connections

• Many failure points

• Turbine part of process



Acetylene Vacuum CompressorsAcetylene Vacuum Compressors

5

• Parallel compressor connections

• Starting/stopping challenges



Liquid Natural Gas ProcessLiquid Natural Gas Process

6



Stage to Stage RelationshipsStage to Stage Relationships

• Multi-stage anti-surge controls

Stage to Stage decoupling

Each stage controller benefits from a decouplingsignal from the before or after stage controller.

Each stage’s flow has a direct effect on the attachedstage flow, control and protection.

7



Compressor ControlCompressor Control

8

OverviewOverview



Compressor Control FunctionsCompressor Control Functions

• Surge Prevention

Anti-Surge Control (PID)

Rate Control (PID)

BOOST

• Surge Recovery

• Compressor-BasedProcess Limiting

• Aux FunctionsSequence Positioning

Surge Control Line

9

urge e ec on

Surge Recovery Routines

Surge Min Position

• Speed Bias Logic

Min Speed

Valve to Valve Decoupling

Manual Control modes

Auto GainCompensation

HSS Auxiliary Inputs

Surge Counter

Valve Freeze Logic



Compressor Operating Point CalculationCompressor Operating Point Calculation

d

( H P

) SurgeRegion

Standard CompressorPerformance Map

O eratin

X-axis (Flow) Represented by ActualVolumetric Flow Referenced to SuctionConditions

Y-axis (Head) Represented by PolytropicHead

10

P o l y t r o p i c H

e

Volumetric Inlet Flow (QA)

S u r g

e L

i n e

S u r g e

C o n t r o

l L i n

e

N1

N2

N3

Point

B O O S T

L i n

e

Online Calculations Compensate for

Varying Molecular Weights, Pressures, andTemperatures



Compressor Control BasicsCompressor Control Basics

• Anti-Surge Control Modes Automatic

Full Surge Prevention & Surge

Recovery Control

Manual with Backup

Operator Can Open RecycleBeyond the Value Set by the

• Starting, Shutdown &Purging

Sequence Position Feature Provides Fixed Position Control

• Support Functions On-Line Detection

11

Cannot Close Beyond the ValueSet by the Automatic Demand

Full Manual

Total Manual Control of RecycleValve Position

Bypasses Automatic Controls(Surge Recovery can beEnabled)

Deactivates DecouplingRoutines

Captures Surge Signature via

Derivatives of Pressure & Flow

Surge Counter Number of Surge Cycles Since

Last Reset

Freeze Mode Stops Unnecessary Valve

Movement During Steady StateOperation



Compressor AntiCompressor Anti--Surge ControlSurge Control

• The open- and closed-loop surge prevention andrecovery routines act together as a

comprehensive control strategy throughout thecompressor performance map.

SCL PIDController

BackupLine

12

Rate PID

Controller

Decoupling

Surge

Backup

Line

Decoupling

Rate PIDController

SCL PIDController



Compressor Control Block DiagramCompressor Control Block Diagram

Anti-Surg

Accel

To RecycleValve

13

Suction

Discharge



Process / Performance ControlProcess / Performance Control

• Typical performance or process control variables:

Compressor suction pressure

Compressor discharge pressure

Compressor flow

Another process dependent upon one of the above

FY

14

PT

ST

FY

FT

PT

TT

PIC SIC UIC

PT

TT



Other Controller FunctionsOther Controller Functions

• Control capability Parallel or Series Compressors

Load Sharing

Incipient Surge Detection

Performance Controller

Dynamic Compressor Surge Limit Line

15

Backup Strategies for Signal Failures

• Auxiliary Controls Bearing Temperature Monitoring

Turbine Lube Oil

Compressor Gas Seals

Load Limiting (power limit and/or compressor chokedflow)



Compressor Control Block DiagramCompressor Control Block Diagram

16



Compressor Operation ScreenCompressor Operation Screen

17



Compressor Surge Capture

Recursion Rate – 10 Milliseconds

Operating Point

The control response returns thecompressor operating point to a safe

condition.

The compressor is unloaded.

18

Anti-Surge Valve Demand

Raw Flow Input – Flow

Element dP

The primary closed-loop

controls cannot prevent

the operating point from

reaching the Surge LimitLine—A surge occurs.

Closed-loop controls begin to open the

Anti-Surge Valve as the operating point

moves below setpoint.



Compressor Surge CaptureCompressor Surge Capture

Recursion Rate – 160 milliseconds

19



20

oo war o u onsoo war o u ons



Woodward Compressor ControlsWoodward Compressor Controls

21



Simple Compressor Control OptionsSimple Compressor Control Options

505 CC-2 Controller• User configurable

• Turbine Controller

Single Valve Turbines

Single Extraction Turbines

OperatorControl Station

(Optional)

Plant DCS

22

• Compressor Controller 1 or 2 Loop

• Performance Controlincluded

Suction Pressure

Discharge Pressure

Compressor Controller

Engineering Work Station

Simple Compressor Train



24 Vdc

Suction Flow No. 1

Recycle Valve No. 2

Recycle Valve No. 1

Turbine Speed

Actuator Demand Signal

ESD, Reset, Raise/Lower Speed, Open/Close Recycle Valves, 16 Configurable Inputs

10 Configurable Analog Inputs

Turbine/Comp Shutdown, Turbine/Comp Alarm, 10 Configurable Discrete Outputs

6 Configurable Analog Outputs

AI

AO

DO

Two RS232 Serial Modbus Ports

505CC505CC--2 Turbine & Compressor Control2 Turbine & Compressor Control

23

T&TValve

Compressor Compressor

PT

PT

FT

PT

FT

Discharge Pressure No. 2

Side stream Pressure

Side stream Flow

.

505CC-2 Application

A



OCP ScreenOCP Screen – – Turbine Performance MapTurbine Performance Map

2424



VertexVertex--Pro Compressor ControlsPro Compressor Controls

Motor Drive Apps.

• MicroNet platform

Simplex or Redundant

• User Configurable

• Compressor Controller

Touchscreen(153 mm)

Plant DCS

25

Software 1 or 2 Loop Compressors

• Performance Controlincluded

• Compressor Load Sharing

• Optional - HMI Touch Panel

Vertex-ProCompressor Controller

Configuration Tool

Simple Compressor Train

VFD



EWS ScreenEWS Screen – – Compressor ConfigCompressor Config

2626



OCP ScreenOCP Screen -- OverviewOverview

2727

Configured for

both turbine and

compressor



OCP ScreenOCP Screen – – Turbine Performance MapTurbine Performance Map

2828



OCP ScreenOCP Screen – – Compressor Performance MapCompressor Performance Map

29



OCP ScreenOCP Screen -- Compressor ControlCompressor Control

30



OCP ScreenOCP Screen -- Compressor ControlCompressor Control

31



Custom CompressorCustom Compressor

32

on ro erson ro ers



Plant Control

Fault Tolerant

Controller

Custom Compressor ControlsCustom Compressor Controls

Compressor Controls

33

Compressor Island

VFD

•Turbine drive

•Parallel & Series compressors

•Surge Anticipation Technology



Custom MicroNet System OverviewCustom MicroNet System Overview

Suction Flow No. 1

Recycle Valve No. 2

Recycle Valve No. 1

Inlet Pressure Signal

Exhaust Pressure Signal

Turbine Speed

Actuator Demand Signal

Programmable Discrete Inputs

Programmable Analog Inputs

Programmable Discrete Outputs

Programmable Analog Outputs

AI

AO

DO

Ethernet, RS232, RS422, RS485 Ports

“Single, Dual or

Triplicated I/O AsRequired To Meet

”

34

T&TValve


PT

PT

FT

PT

FT

Discharge Pressure No. 2

Side stream Pressure

Side stream Flow

uc on ressure o.

PT

PT



Compressor

Train Controller

CompressorCompressor Train Control FunctionalityTrain Control Functionality

Compressor Control Functionality• Anti-Surge protection for all loops

• Start/Stop sequencing (valve positioning)

• Suction/Discharge pressure control

• Loop-to-Loop performance control• Loop-to-Loop decoupling action

• Compressor load sharing

35

PT


PT

FT

PT

FT

PT


PT

PT

FT

PT

FT



CORE Software ModulesCORE Software Modules

•Single Stage Industrial Compressor

•Dual Stage Industrial Compressor

•Dual Stage Industrial Compressor with Side Stream

•Three Stage Industrial Compressor•Three Stage Industrial Compressor with Side Streams

•Four Stage Industrial Compressor

•Four Stage Industrial Compressor with Side Streams

36

• ve age n us r a ompressor

•Five Stage Industrial Compressor with Side Streams•Parallel compressors (3 max)

•Series compressors (2 max)

•API-611 Steam Turbine

•API-612 Single Valve Steam Turbine•API-612 Single Extraction Steam Turbine

•API-612 Double Extraction Steam Turbine

OEM Qualified / Field Proven Software Logic



NetSim Simulation SoftwareNetSim Simulation Software

• Compressor

• Recycle Valve• Package Aux

CompressorPackageEmulation

• CPU Scan Rate

• I/O delays• I/O Resolution

ControlHardwareEmulation

ControlSoftware

Emulation

• Control Logic

• Start Sequencing• Communications

Complete Package Simulation

37

• Debug Software in the Office

• Import & Use OEM Models• Reduce Commissioning Time• Reduce Commissioning Risk

Actual Compressor Control

SIMULATION PACKAGE( MatrixX, Matlab, Simulink, ACSL )

Motor



WhyWhy Operators Choose WoodwardOperators Choose Woodward??

• Reliable Hardware

Long MTBF periods

Field proven hardware and software

Global Support

• Advanced control algorithms developed

38

• Smart-PID algorithms for bumpless modetransfers and load response anticipation

• Adaptive Speed and analog anti-aliasing filters

• Advanced load rejection and decoupling routinesto increased stability

• Simulation Tools (used for training & validation)



Why Woodward?Why Woodward?

• Faster scan rates: 5 – 10 milliseconds

• Faster compressor control point accelerationsensing WGC = 100 microseconds

39

DR or TMR offerings

• True System Determinism Synchronized Software & I/O

• Better Service MHI, Ebara, Conoco Phillips, Dresser Rand, BP,

Chevron



Why Woodward?Why Woodward?

• Easier Software Changes

Changes can easily be made and tested at site

(KBR report)

Woodward NetSim Simulation package

• Better Control stability

Automatic PID dynamics selections makes starts easier

40

(BP report)

• Faster Flow signal filtering

Woodward uses 4 point filter – 20 milliseconds

• Better Service Tools

Woodward = 5 millisecond

• Safety Certified Products

MicroNetTMR, MicroNet-Plus, ProTech203

D h i Ch W d dD h i Ch W d d



Dushanzi Chooses WoodwardDushanzi Chooses Woodward

Dushanzi Chooses Woodward

Woodward was selected as the control of choice

for all three of Dushanzi’s new

41

and propylene) due to

Woodward’s highly reliable control platforms,advanced compressor protection algorithms, and

ability to control very difficult ITCC applications.

The Woodward MicroNet TMR® control platform

met all of Dushanzi’s, Linde’s, and Siemens’

stringent system control, protection, and plant

interface requirements.



42

TM

Industrial Turbomachinery SystemsImprove Reliability●Enhance Performance

Documents

AbuDhabi.comprControl Overview.n.technology_R.kamphaus Feb2012