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7/28/2019 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
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Compressor ApplicationCompressor Application
2
a engesa enges
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Hydrogen Separation ApplicationHydrogen Separation Application
One component in a
complex process
3
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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
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Acetylene Vacuum CompressorsAcetylene Vacuum Compressors
5
• Parallel compressor connections
• Starting/stopping challenges
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Liquid Natural Gas ProcessLiquid Natural Gas Process
6
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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
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Compressor ControlCompressor Control
8
OverviewOverview
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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
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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
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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
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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
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Compressor Control Block DiagramCompressor Control Block Diagram
Anti-Surg
Accel
To RecycleValve
13
Suction
Discharge
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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
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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)
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Compressor Control Block DiagramCompressor Control Block Diagram
16
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Compressor Operation ScreenCompressor Operation Screen
17
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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.
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Compressor Surge CaptureCompressor Surge Capture
Recursion Rate – 160 milliseconds
19
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20
oo war o u onsoo war o u ons
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Woodward Compressor ControlsWoodward Compressor Controls
21
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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
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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
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OCP ScreenOCP Screen – – Turbine Performance MapTurbine Performance Map
2424
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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
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EWS ScreenEWS Screen – – Compressor ConfigCompressor Config
2626
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OCP ScreenOCP Screen -- OverviewOverview
2727
Configured for
both turbine and
compressor
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OCP ScreenOCP Screen – – Turbine Performance MapTurbine Performance Map
2828
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OCP ScreenOCP Screen – – Compressor Performance MapCompressor Performance Map
29
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OCP ScreenOCP Screen -- Compressor ControlCompressor Control
30
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OCP ScreenOCP Screen -- Compressor ControlCompressor Control
31
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Custom CompressorCustom Compressor
32
on ro erson ro ers
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Plant Control
Fault Tolerant
Controller
Custom Compressor ControlsCustom Compressor Controls
Compressor Controls
33
Compressor Island
VFD
•Turbine drive
•Parallel & Series compressors
•Surge Anticipation Technology
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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
Compressor Compressor
PT
PT
FT
PT
FT
Discharge Pressure No. 2
Side stream Pressure
Side stream Flow
uc on ressure o.
PT
PT
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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
Compressor Compressor
PT
FT
PT
FT
PT
Compressor Compressor
PT
PT
FT
PT
FT
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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
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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
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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)
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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
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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
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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.
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42
TM
Industrial Turbomachinery SystemsImprove Reliability●Enhance Performance