Professional Documents
Culture Documents
Authors:
Jihong Wu - KBR, USA
Jeffrey Feng - KBR, USA
Surajit Dasgupta - KBR, USA
Ian Keith - Woodside Energy, Australia
Publication / Presented:
LNG journal
Date:
October 2007
p23-30:LNG 3 12/10/2007 12:16 Page 5
ENGINEERING FORUM
ENGINEERING FORUM
ENGINEERING FORUM
ENGINEERING FORUM
and the recycle valves were ramped open Table 1: Dynamic Parameters for Compressor Trip-Coast Down Acknowledgment
to 50 percent and 30 percent for the low, The authors wish to express sincere
medium and high-pressure stage Study Range Desired Operating Range thanks to Nikhil Dukle and Wayne
respectively over 10 seconds. Delay Stroke time based on study Jacobson of Compressor Control Corp. for
With these settings, the recycle flow Opening of anti-surge valves 0 – 2 sec 1 – 3 sec As fast as possible technical support and review of control
rates appeared to be sufficient to Opening of hot gas bypass valve 0 – 2 sec 1 – 3 sec As fast as possible strategies, Martyn Blanchard of
Closing of axial compressor IGV 0 sec 7 – 35 sec No delay, 25 – 35 sec
maintain the MR compressor operating AspenTech for valuable comments during
closing
points in the stable region. the course of the study, and Ming Yan of
Opening of inter-stage bleed valve 0 – 2 sec 2 – 10 sec 5 - 10 sec
The adequacy of the feed forward KBR for technical assistance with the
Trip of gas turbine driver 0 – 3 sec - 2 – 3 sec
setting was verified for the full assembly of software-hardware used in
compressor operating range. Once the the study.
system is stabilized, the imposed feed The possible operating range for each provide an additional safety factor to
forward logic can be released and the dynamic variable and study results are avoid the surge of the compressors during Jihong Wu is a senior process engineer
with KBR in Houston, Texas, specialized
CCC controller will take over the control. summarized in Table 1. coast down.
in dynamic simulation. Her experience
Based on the study results, it was The simulation results revealed two
also includes process design and
concluded that a feed forward strategy important variables that might have Implementation optimization of LNG, olefins and other
combined with the CCC control system contributed to the surge problem. One The feed forward strategy studied in large-scale processing facilities. She
would provide a predictable and reliable was the LP stage IGV closing speed. Field Case Study 1 was incorporated into the graduated from Tokyo University with a
PhD in Chemical Engineering.
way to achieve continuous operation of data from actual events indicated that plant control logic and the benefits have
the MR compressors. the IGV closing time was in the range of been observed in several plant events
The use of the controls emulator in the 7 to 10 seconds. since the implementation. Jeffrey Feng is a process leader with KBR,
study allowed fine-tuning of the feed The other important variable is the To solve the surge on coast down, in Houston, Texas. He has been with KBR
forward settings realistic to the actual opening time of the LP stage bleed valve. which had been previously considered since 1995 after graduating from Texas
plant. Analysis of plant data indicated that the unsolvable by the vendor, field A&M University with a PhD in Chemical
Engineering. He is responsible for the
stroke time of this valve could possibly be modifications were made based on the
technical execution of dynamic
Train trip as fast as 2 seconds. findings from Case Study 2. Plant simulation and other transient analysis
The objective of this case study was to Conceptually, fast responses of the operation has demonstrated safe in LNG, refining, olefins, ammonia and
investigate the existing system and IGV and inter-stage bleed valve might be compressor coast downs since the offshore in domestic and international
projects.
improve anti-surge strategies to protect considered desirable as they help unload implementation and proved the accuracy
the compressors from surge during coast the compressor quickly. However, results of the dynamic simulation results.
down. The plant history has also from the dynamic simulations indicated Surajit Dasgupta is the Manager of
identified that emergency shutdown, or that the fast closing of the IGV as Conclusions Chemical Engineering Technology and
compressor trip, represents a high-risk observed in the plant could actually drive It was only through the use of rigorous Advanced Process Automation at KBR, in
case for possible surge of the the compressor toward surge. dynamic simulations that the Houston, Texas. He supervises all
projects in the area of dynamic
compressors, in particular, the LP stage. Based on the simulation results, it is permutations and combinations of
simulation, advanced process control,
The plant control sequence of suggested that the IGV stroke time be various system variables could be safely operator-training simulators and real-
operation in the event of a train trip is as modified to close the IGV at a moderate tested to derive the solution. time optimization. He graduated from
follows: rate over 25 to 35 seconds. As for the The studies proved the accuracy and Columbia University, NY, in 1977 with a
Close the axial stage IGV inter-stage bleed valve, an optimum effectiveness of such modeling and Doctoral degree in Engineering and
Science.
immediately window for the opening time appeared to provided useful results to diagnose and
Trip-open the anti-surge recycle exist to avoid surge in either section of improve field operation.
valves and hot gas bypass valve the axial stage. The combination of the dynamic Ian Keith is the Chief Process Control
Open the axial stage bleed valve A typical logic is to open the bleed valve simulation modeling with control vendor Engineer at Karratha Gas plant in
Stop heavy and light MR flow by when speed is reduced down to 95 percent, supplied hardware significantly enhanced Australia. He has been with Woodside and
Shell since 1998 and was the Senior
closing the MR flow control valves which in this case is equivalent to a delay the precision, capability and credibility to
Process Engineer for Karratha LNG plant
In this case study, the dynamic behavior of approximately 1 second. Overall, a valve develop realistic and reliable solutions for
prior to his current position.
and effectiveness of anti-surge elements stroke time between 5 to 10 seconds the actual plant system.
were thoroughly reviewed. In addition to appeared to be the optimum range.
reviewing the size and
characteristics of the recycle valves, the
flow The anti-surge recycle valves and the
hot gas bypass valve are required to open References
impact of various dynamic variables such as quickly as possible to reduce the risk of
as control signal and actuator delays, surge during coast down. [1] Omori H., Konishi, H., Ray, S., de January/February, 2004.
valve stroke time, IGV closing speed and Typical requirements for these valves la Vega, F. and Durr, C., “A New [3] Compressor Control Corporation,
Tool-Efficient and Accurate for Series 5 Antisurge Control
the timing for tripping the turbine driver are less than two seconds [4]. In the
LNG Plant Design and Application for Centrifugal and
were investigated. actual plant, the response time of these
Debottlenecking”, 13th Axial Compressors, Publication
In this scenario, the CCC calculation valves had limitations for significant
International Conference & UM5411, October 2005.
algorithm is bypassed upon the initiation improvements.
Exibition on Liquefied Natural [4] Wilson, J. and Sheldon, A.,
of a train trip. Therefore, the dynamic To compensate for any delay in the Gas, May, 2001. “Matching Antisurge Control
study was performed without using the responsiveness of these valves, the effect [2] Valappll J., Mehrotra, V., Valve Performance with
CCC control emulator. The LP axial stage of introducing a delay on turbine trip was Messersmith D and Bruner, P., Integrated Turbomachinery
was modeled as two stages with flow studied. Based on the simulation results, “Virtual Simulation of LNG Control Systems”, Hydrocarbon
take-off from between stages to the inter- it was concluded that delaying the Plant”, LNG Journal, Processing, August 2006
stage bleed valve. turbine trip by 2 to 3 seconds would