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ENGINEERING FORUM
surge control strategies to mitigate
the risk.
Two critical cases identified by plant
operation were studied. The first case
was a propane compressor trip scenario,
which in several occasions had caused
the MR compressor to trip subsequently.
The second case was the emergency
shutdown operation, where surge events
had been observed during compressor
coast down.
Control system
The control system for the MR
compressors is supplied by Compressor
Control Corp. (CCC). The CCC control
system consists of three anti-surge
controllers, one for each stage, as shown
in Figure 2.
The locations for measuring devices
that supply analog inputs to the
controllers are also indicated in the
Figure. Based on the analog inputs, each
controller determines the position of the
compressor operating point and provides
one output to the recycle valve.
The anti-surge controllers use a
combination of closed- and open-loop
control responses to provide anti-surge
protection for the compressors [3]. The
primary anti-surge control responses
that are triggered depending on the
location of the compressor operating
point are:
1) Proportional Integral (PI) control
response: The anti-surge PI control
response is the normal first level
response serving to increase the recycle
rate when the operating point is on the
left side of the Surge Control Line (SCL),
and will reduce the recycle rate when the
operating point is on the right side of the
SCL.
2) Recycle Trip response: The anti-
surge Recycle Trip response provides a
2nd level correction to the normal PI
response by step increasing the recycle
rate when the operating point is on the
left side of the Recycle Trip Line. This is
an open loop response that is
implemented to prevent surge if the
normal PI response is not sufficient.
An illustration of the compressor
performance curve and major control
lines calculated by the CCC controller is
provided in Figure 3. The illustrated
compressor operating point is in the
stable operating region.
In case of an emergency shutdown, a
trip signal from the Central Control
System will directly initiate the opening
of all anti-surge valves.
In addition to the anti-surge valves,
the LP axial stage is also protected by a
hot gas bypass (HGBP) recycle loop. The
axial stage inter-stage bleed valve (IBV)
will also be opened to provide sufficient
flow to the compressor suction.
Dynamic Simulation Model: A rigorous
dynamic simulation model was developed
using Aspen Custom Modeler (ACM), an
advanced equation based software
licensed by AspenTech.
The simulation model covered the
entire MR circuit as shown in Figure 1,
with input data based on as-built
equipment and piping details. The
compressors were modeled on tested
compressor curves provided by the
compressor vendor.
The accuracy of the base model was
first validated in steady state against
plant operating conditions. Dynamic data
such as the axial stage Inlet Guide Vane
(IGV) closing speed, control and actuator
delay, valve stroke time, and other system
dynamics were based on available data
from the plant.
The dynamic model was further
validated dynamically against plant data
collected during actual transient events.
The dynamic validation of the simulation
results will be described in more detail.
Using the rigorous dynamic model,
compressor operating conditions were
generated according to plant operational
sequences.
Integrated Simulation Approach: To
ensure accuracy of the study results, a
CCC-supplied control emulator was used
to emulate the actual controllers.
Together with configuration files
downloaded from the plant CCC system,
the emulator is able to replicate the exact
control functions of the field-installed
controllers, and thus allow in-depth
analysis of the actual compressor and
control system in the field.
Figure 4 shows a schematic view of the
software-hardware assembly used in the
dynamic study. The system includes the
CCC emulator hardware and a single PC
on which the dynamic simulation
software and emulator operating
software were operated.
Data link between the simulation
model and emulator was accomplished
through OPC server interfaces. The
values of process variables calculated by
the dynamic model, such as flows (as
pressure differentials), pressures,
temperatures, valve positions and speed,
are supplied to the CCC emulator as
inputs.
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