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Technical Seminars 2012

Industrial Compressor Controls Standard Custom

CONTROLLING the power of ENERGY


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Compressor Application Challenges

Hydrogen Separation Application


One component in a complex process

Naphtha Cracker Application


1st Stage 2nd Stage 3rd Stage 4th Stage

MPU MPU MPU

PT TT FY PT FY PT TT FT PT TT

PT TT FT PT TT

PT TT FT PT TT

FT

PT TT

PT

Stage to stage connections Many failure points Turbine part of process


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FY

FY

Acetylene Vacuum Compressors

Parallel compressor connections Starting/stopping challenges


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Liquid Natural Gas Process

Stage to Stage Relationships


Multi-stage anti-surge controls
Stage to Stage decoupling Each stage controller benefits from a decoupling signal from the before or after stage controller. Each stages flow has a direct effect on the attached stage flow, control and protection.

Compressor Control Overview

Compressor Control Functions


Surge Prevention
Anti-Surge Control (PID) Rate Control (PID) BOOST

Compressor-Based
Process Limiting Aux Functions
Sequence Positioning Surge Control Line Biasing Manual Control modes Auto Gain Compensation HSS Auxiliary Inputs Surge Counter Valve Freeze Logic

Surge Recovery
Surge Detection Surge Recovery Routines Surge Min Position

Speed Bias Logic


Min Speed Valve to Valve Decoupling

Compressor Operating Point Calculation

Standard Compressor Performance Map


X-axis (Flow) Represented by Actual Volumetric Flow Referenced to Suction Conditions Y-axis (Head) Represented by Polytropic Head
Operating Point
Lin e
Lin e e

Polytropic Hea ad (HP)

Surge Region

Online Calculations Compensate for Varying Molecular Weights, Pressures, and Temperatures

rge Su

Li n BO OS T

Co nt r ol

Su

rge

N3

N2 N1

Volumetric Inlet Flow (QA)


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Compressor Control Basics


Anti-Surge Control Modes
Automatic
Full Surge Prevention & Surge Recovery Control

Starting, Shutdown &


Purging
Sequence Position Feature
Provides Fixed Position Control

Manual with Backup


Operator Can Open Recycle Beyond the Value Set by the Automatic Demand Cannot Close Beyond the Value Set by the Automatic Demand

Support Functions
On-Line Detection Surge Detection
Captures Surge Signature via Derivatives of Pressure & Flow

Full Manual
Total Manual Control of Recycle Valve Position Bypasses Automatic Controls (Surge Recovery can be Enabled) Deactivates Decoupling Routines
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Surge Counter
Number of Surge Cycles Since Last Reset

Freeze Mode
Stops Unnecessary Valve Movement During Steady State Operation

Compressor AntiAnti-Surge Control


The open- and closed-loop surge prevention and
recovery routines act together as a comprehensive control strategy throughout the compressor performance map.
Backup Line SCL PID Controller Rate PID Controller Surge

Backup Line SCL PID Controller Rate PID Controller 12 Decoupling

Decoupling

Compressor Control Block Diagram


Anti-Surg

Accel

To Recycle Valve

Suction

Discharge

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Process / 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

PT ST PT TT TT

FT

PT

PIC

SIC

UIC

FY

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Other Controller Functions


Control capability
Parallel or Series Compressors Load Sharing Incipient Surge Detection Performance Controller Dynamic Compressor Surge Limit Line Backup Strategies for Signal Failures

Auxiliary Controls
Bearing Temperature Monitoring Turbine Lube Oil Compressor Gas Seals Load Limiting (power limit and/or compressor choked flow)
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Compressor Control Block Diagram

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Compressor Operation Screen

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Compressor Surge Capture


Recursion Rate 10 Milliseconds

The compressor is unloaded.

The control response returns the compressor operating point to a safe condition.

Operating Point

Anti-Surge Valve Demand


Closed-loop controls begin to open the Anti-Surge Valve as the operating point moves below setpoint.

Raw Flow Input Flow Element dP The primary closed-loop controls cannot prevent the operating point from reaching the Surge Limit LineA surge occurs.

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Compressor Surge Capture


Recursion Rate 160 milliseconds

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Woodward Solutions

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Woodward Compressor Controls

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Simple Compressor Control Options 505 CC-2 Controller


User configurable Turbine Controller
Single Valve Turbines Single Extraction Turbines
Plant DCS Operator Control Station (Optional)

Compressor Controller
1 or 2 Loop
Compressor Controller
Engineering Work Station

Performance Control
included
Suction Pressure Discharge Pressure
Simple Compressor Train
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505CC505CC -2 Turbine & Compressor Control


Two RS232 Serial Modbus Ports
AO DO AI

6 Configurable Analog Outputs Turbine/Comp Shutdown, Turbine/Comp Alarm, 10 Configurable Discrete Outputs 10 Configurable Analog Inputs ESD, Reset, Raise/Lower Speed, Open/Close Recycle Valves, 16 Configurable Inputs

24 Vdc

Turbine Speed Actuator Demand Signal


Recycle Valve No. 1 Recycle Valve No. 2 Suction Flow No. 1 Suction Pressure No. 1 Side stream Flow Side stream Pressure

T&T Valve

Discharge Pressure No. 2

Compressor

Compressor

505CC-2 Application
PT FT PT FT

PT

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OCP Screen Turbine Performance Map

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VertexVertex -Pro Compressor Controls


Motor Drive Apps. MicroNet platform
Simplex or Redundant
Plant DCS

User Configurable Compressor Controller


Software
1 or 2 Loop Compressors
Vertex-Pro
Compressor Controller

Touchscreen (153 mm)

Performance Control
included Compressor Load Sharing Optional - HMI Touch Panel
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Configuration Tool

VFD

Simple Compressor Train

EWS Screen Compressor Config

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OCP Screen - Overview

Configured for both turbine and compressor

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OCP Screen Turbine Performance Map

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OCP Screen Compressor Performance Map

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OCP Screen - Compressor Control

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OCP Screen - Compressor Control

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Custom Compressor Controllers

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Custom Compressor Controls

Fault Tolerant Controller Plant Control

Compressor Controls
Motor Drive Turbine drive Parallel & Series compressors Surge Anticipation Technology
VFD

Compressor Island

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Custom MicroNet System Overview


Ethernet, RS232, RS422, RS485 Ports
AO DO AI

Programmable Analog Outputs Programmable Discrete Outputs Programmable Analog Inputs Programmable Discrete Inputs Exhaust Pressure Signal Turbine Speed Inlet Pressure Signal Actuator Demand Signal

Recycle Valve No. 1

Single, Dual or Triplicated I/O As Required To Meet Availability Goals

Recycle Valve No. 2 Suction Flow No. 1 Suction Pressure No. 1 Side stream Flow Side stream Pressure

T&T Valve

Discharge Pressure No. 2


PT

Compressor

Compressor

PT PT

PT FT PT FT

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Compressor Train 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
Compressor Train Controller

Compressor

Compressor

Compressor

Compressor

PT PT PT

PT FT

PT FT

PT FT

PT FT

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CORE 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 Five Stage Industrial Compressor 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 Software


Complete Package Simulation
Control Software Emulation
Control Logic Start Sequencing Communications

Control Hardware Emulation


CPU Scan Rate I/O delays I/O Resolution

Compressor Package Emulation


Compressor Recycle Valve Package Aux

SIMULATION PACKAGE
( MatrixX, Matlab, Simulink, ACSL )

Debug Software in the Office Import & Use OEM Models Reduce Commissioning Time Reduce Commissioning Risk
Actual Compressor Control
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Motor

Why Operators Choose Woodward? Woodward?


Reliable Hardware
Long MTBF periods Field proven hardware and software Global Support

Advanced control algorithms developed


specifically for industrial compressors

Smart-PID algorithms for bumpless mode


transfers and load response anticipation

Adaptive Speed and analog anti-aliasing filters Advanced load rejection and decoupling routines
to increased stability

Simulation Tools (used for training & validation)


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Why Woodward?
Faster scan rates:
5 10 milliseconds

Faster compressor control point acceleration


sensing
WGC = 100 microseconds

Hardware reliability
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?
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
(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
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Dushanzi Chooses Woodward

Dushanzi Chooses Woodward Woodward was selected as the control of choice for all three of Dushanzis new critical compressor trains (cracked gas, ethylene, and propylene) due to Woodwards 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 Dushanzis, Lindes, and Siemens stringent system control, protection, and plant interface requirements.

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Industrial Turbomachinery Systems


Improve Reliability Enhance Performance
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