Technical Seminars 2012

Industrial Compressor Controls

Standard
Custom

CONTROLLING the power of ENERGY

TM

Compressor Application
Challenges

Hydrogen Separation Application

One component in a
complex process

Naphtha Cracker Application

1st
Stage

MPU MPU MPU

PT

PT

TT

TT

FT

FY

2nd
Stage

PT

PT

3rd
Stage

4th
Stage

PT

FT

TT

FT

PT

TT

FT

PT

TT

PT TT

TT

FY
TT

PT

PT

Stage to stage connections

Many failure points
Turbine part of process
4

FY

FY

Acetylene Vacuum Compressors

Parallel compressor connections

Starting/stopping challenges
5

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

Compressor-Based

Anti-Surge Control (PID)

Rate Control (PID)

BOOST
Surge Recovery

Surge Detection

Surge Recovery Routines

Surge Min Position
Speed Bias Logic

Min Speed

Valve to Valve Decoupling

Process Limiting
Aux Functions

Sequence Positioning

Surge Control Line

Biasing

Manual Control modes

Auto Gain
Compensation

HSS Auxiliary Inputs

Surge Counter

Valve Freeze Logic

Compressor Operating Point Calculation

Standard Compressor
Performance Map

Volumetric Flow Referenced to Suction

Conditions

Surge
Region

Y-axis (Head) Represented by Polytropic

Head

Lin
e

Varying Molecular Weights, Pressures, and

Temperatures

Co
nt r
ol

Li n

Online Calculations Compensate for

N3

Su

rge

BO
OS
T

rge

Lin
e

Operating
Point

Su

Polytropic Hea
ad (HP)

X-axis (Flow) Represented by Actual

N2
N1

Volumetric Inlet Flow (QA)

10

Compressor Control Basics

Anti-Surge Control Modes

Automatic
 Full Surge Prevention & Surge
Recovery 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

Full Manual
 Total Manual Control of Recycle
Valve Position
 Bypasses Automatic Controls
(Surge Recovery can be
Enabled)
 Deactivates Decoupling
Routines
11

Starting, Shutdown &

Purging

Sequence Position Feature
 Provides Fixed Position Control

Support Functions

On-Line Detection

Surge Detection
 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 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

13

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

14

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)

15

Compressor Control Block Diagram

16

Compressor Operation Screen

17

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.

18

Raw Flow Input Flow

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

Compressor Surge Capture

Recursion Rate 160 milliseconds

19

Woodward Solutions

20

Woodward Compressor Controls

21

Simple Compressor Control Options

505 CC-2 Controller
User configurable
Turbine Controller

Plant DCS

Single Valve Turbines

Single Extraction Turbines
Compressor Controller

1 or 2 Loop
Compressor Controller
Performance Control
included

Suction Pressure

Discharge Pressure

Operator
Control Station
(Optional)

Engineering Work Station

Simple Compressor Train

22

505CC--2 Turbine & Compressor Control

505CC
Two RS232 Serial Modbus Ports
AO
DO
AI

24 Vdc

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

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

PT
FT
PT
FT

23

OCP Screen Turbine Performance Map

24

24

Vertex--Pro Compressor Controls

Vertex
Motor Drive Apps.
MicroNet platform

Simplex or Redundant
User Configurable
Compressor Controller
Software

1 or 2 Loop Compressors
Performance Control
included
Compressor Load Sharing
Optional - HMI Touch Panel

Plant DCS

Touchscreen
(153 mm)

Vertex-Pro
Compressor Controller

Configuration Tool

VFD

Simple Compressor Train

25

EWS Screen Compressor Config

26

26

OCP Screen - Overview

Configured for
both turbine and
compressor

27

27

OCP Screen Turbine Performance Map

28

28

OCP Screen Compressor Performance Map

29

OCP Screen - Compressor Control

30

OCP Screen - Compressor Control

31

Custom Compressor
Controllers

32

Custom Compressor Controls

Fault Tolerant
Controller
Plant Control

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

33

Compressor Island
VFD

Custom MicroNet System Overview

Ethernet, RS232, RS422, RS485 Ports
AO

Programmable Analog Outputs

DO

Programmable Discrete Outputs

AI

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

34

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

Compressor
Train Controller

Compressor

Compressor

Compressor

PT
PT

35

PT

PT

PT

FT

FT

PT

PT

FT

FT

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
36

NetSim Simulation Software

Complete Package
Simulation

Control
Software
Emulation

Control
Hardware
Emulation

Control Logic
Start Sequencing
Communications

CPU Scan Rate

I/O delays
I/O Resolution

SIMULATION PACKAGE
( MatrixX, Matlab, Simulink, ACSL )

Debug Software in the Office

Import & Use OEM Models
Reduce Commissioning Time
Reduce Commissioning Risk

Motor

Actual Compressor Control

37

Compressor
Package
Emulation
Compressor
Recycle Valve
Package Aux

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)

38

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

39

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
40

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
TM

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