GE Energy

Integrated Turbine Compressor Controls - ITCC

Agenda
History of Compressor Controls Integration Fundamentals Rotating Stall & Incipient Surge OptiComp BN

Our jobs
Its not all about design..

It takes proper execution

Our Responsibility
We must get it right
Or operations might have a bad day

GE Energy

Advanced OptiCompTM Antisurge Control Technology What is Integration?

What is Integration?
Machinery
Centrifugal Compressors Axial Compressors Hot gas Expanders Cryogenic Expanders Drivers (GT, ST, VFD, Motor) Power Recovery Train

Process
Oil & Gas Production Pipeline Liquefied Natural Gas Refining Petrochemical Power Generation

Controls
Speed / Extraction Antisurge Load /Capacity Loadsharing Quench Discharge Pressure Limiting Current Limiting

OptiComp

Protection
Vibration / Condition monitoring Machine Emergency Shutdown Sequencing Seal System Lube oil / Control oil

GE Energy

Advanced OptiCompTM Antisurge Control Technology What is Surge?

Definition of Surge
Large and self-sustaining pressure and flow oscillations in the compression system Rotating speed or motor current is affected Interactions between the compressor and the process system Fluid aerodynamic phenomena Flow reduction (light surge) Flow reversal (hard surge)

Motor Driven Gas Compressor on Offshore platform

Consequences of Surging Compressor

Potential mechanical damage: Labyrinth, Mechanical, Dry Gas Seals Thrust Bearings Consequences of damaged seals: Thrust changes can wear seals Worn seals allow gas paths Internal recycling Reduced efficiency Surge can damage associated equipment: Valves Piping/Pipe Hangers Mechanically connected equipment
Turbine

P
S
Suction KO

Pv Pd
Vessel

Next Steps on the Platform

Immediate Response
What happened ?

Is the compressor damaged ?

How badly how do you know? Can I start up or need to inspect ?

Do I need to look for another job ??

I hear GE Control Solutions are hiring !

GE Energy

Advanced OptiCompTM Antisurge Control Technology Rotating Stall and Incipient Surge

Compressor Aerodynamics Stall & Surge

Stall & Surge Rotating Stall: instability around the circumference of the compressor, due to boundary layer separation cannot be detected by existing control systems, due to high frequency

extended operation in this region may reduce efficiency and damage the machine
well developed rotating stall = incipient surge

Surge Detection
Current methods rely solely on process measurements
Compressor must be surged for accurate mapping of surge points Compressor surge detected only after full surge event Cannot detect stall (precursor to surge) Can give false indication and response to surge event Cannot be analyzed for severity of surge event

Incipient surge
Incipient Surge ? Incipient Surge ? Surge

Suct. P Disch. P

Flow dP

Speed Valve

GE Energy

Advanced OptiCompTM Antisurge Control Technology OptiComp BN

Integrated OptiComp BN

Process vs. vibration correlation

First fluid measurement indicators of stall

Fluid measurements

Mechanical radial vibration

First mechanical indicators of stall Surge

Developing Stall (incipient surge)

Surging Spectrum Identified @ 12:26:02

Developing Incipient Surge Signal

1x vibration at running speed of the compressor

Thrust Vibration Data

Waveform Signal

Compressor Stall and Surge Axial Movement

Flow Re-attachment and Compressor Recovery

Surge Cycle Counting

Surge, Incipient Surge, Rotating Stall

Performance Map, Disch. Pd vs Volume Flow, Qa
80 70 60 50
Pd (bar a)

Surge Limit Line (SLL) Surge Control Line (SCL) High Subsync Alarm, DE

40

Op. Point
30 20 10 0 0 5000 10000 Qa (m 3/hr) 15000

Power Limit

20000

25000

Algorithms Radial & Axial Vibrations

Benefits
Lower risk when field testing to establish accurate surge limit detect stall pre-cursor to surge vs. full surge of compressor More precise location of surge limit used in controller Detect stall and surge when compressor characteristics change gas composition, degradation or malfunction Ability to alarm re: unstable area of compressor map Option to adjust surge margin when stall is detected Identify/highlight unstable areas of performance map on HMI More reliable surge detection and appropriate recovery response Assess potential mechanical damage resulting from compressor surge