In Operation 34 Years
Offices Worldwide +/- 400 Employees 8300+ Installations 200 Major Retrofit Projects/Year Worlds Largest GT Retrofitter
1974
2008 Next
Series 3+ Products
Multi-loop controllers for speed, extraction,
Series 5 Products
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Status Indicators
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Class 1, Div 2 / Class 1 Zone 2 ATEX Group 2 Class 3 Simplex or hot backup redundant All AOs have built-in feedback loops to identify hardware or wiring problems On-board temperature monitoring On-board power supply voltage monitoring Wired Ethernet version Completely backward compatible with S3+
Upstream
improved control strategies for load sharing, expanders, integration of networks across platforms
Midstream
improved control strategies for Boil Off Gas networks, intense focus on all primary LNG services
Downstream
broader approach to process control, rather than just Turbomachinery control. Advanced control strategies for Ethylene, FCCU and PTA Plants. (Next focus is Ammonia).
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PT. Pupuk Iskandar Muda PT. Pupuk Sriwidjaya PT. Pupuk Kujang PT. Pupuk Kalimantan Timur PT. DSM Kaltim Melamine Indonesia PT. Amoco Mitsui PTA PT. Polysindo Eka Perkasa PT. Chandra Asri Pertamina / Refinery (WGC Exor Project) ConocoPhillips Indonesia ExxonMobil Oil Indonesia Total Indonesie PT. Kangean Energi Indonesia BP Tangguh LNG PT. Badak LNG PT. Arun LNG PT. Indonesia Power (PLN) Etc.
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RSP
Train A
Section 1 out
LSIC
Section 2
UIC 1A
Serial network
UIC 1A
PT
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Compressor Refresher
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Compressor Type
Compressors
Positive Displacement Compressor Dynamic Compressor
Reciprocating Compressor
Centrifugal
Rotary Compressor
Axial
Membrane Compressor
Screw Compressor
CCC Focus
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Axial Compressor
Centrifugal Compressor
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Stator
Stator Blades
Rotor Blades
Shaft
Casing
Stator Blades
Rotor Blades
Casing
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Rotor blades
Adjustable guide vanes Thrust bearing Compressor inlet nozzle Compressor outlet nozzle
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Barrel (Centrifugal)
Bullgear (Centrifugal)
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Thrust bearing
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Single-Section, Three-Stage
What is the function of this cooler? Intercooling reduces energy consumption but results in having multiple compressor maps which need separate antisurge protection Next
Series Network
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Surge Phenomenon Why Compressor Surge and what happens when they do
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Pd
B A D C
Pd = Compressor discharge pressure Pv = Vessel pressure Rlosses = Resistance losses over pipe
Pressure builds Resistance goes up Compressor rides the curve Pd = Pv + Rlosses Electro motor is started Machine accelerates to nominal speed Compressor reaches performance curve
Note: Flow goes up faster because pressure is the integral of flow
Qs,
vol
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TIME (sec.)
1 PRESSURE
Rapid pressure oscillations with process instability Rising temperatures inside compressor
TIME (sec.) 1 2 3
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severity to seals, bearings, impellers, shaft Increased seal clearances and leakage Lower energy efficiency Reduced compressor life
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Startup Shutdown Operation at reduced throughput Operation at heavy throughput with: - Trips - Power loss - Operator errors - Process upsets - Load changes - Gas composition changes - Cooler problems - Filter or strainer problems - Driver problems
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Pressure
stonewall or choke limit Actual available operating zone stable zone of operation minimum speed
Flow
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Pressure
stonewall or choke limit Actual available operating zone stable zone of operation minimum speed
Flow
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CCC Control
Base Ingredients: - Advanced algorithms - Rate of change feed forward signals - Fast hardware
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Antisurge Controller
FT 1
PsT 1
PdT 1
Suction
UIC 1
Process
Compressor
F 1 T
PsT 1
PdT 1
Suction
UI 1 C PIC 1
Process
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VSDS Compressor
Performance Controller
Load
ST 1 FT 1 PsT 1 TsT 1 PdT 1 TdT 1 PIC 1 HIC 1
Suction
UIC 1
Process
Serial network
The control system objective is to keep the process on its Primary Process Variable (PV) set-point, and to return it to set-point as quickly as possible after a process disturbance The control system has to keep the process on/return to set-point while operating within compressor operating envelope limits, including protection against surge and surge damage
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z z
An algorithm that can accurately locate the operating point and its corresponding surge limit A controller execution speed that will allow a digital controller to emulate immediate analog control Control responses that allow different margins of safety for different operating conditions Advanced control strategies that can avoid the negative effects of loop interaction A quick acting, correctly sized antisurge control valve The elimination of unnecessary dead time or lag time within the system Valid load sharing strategies
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CCC
Compressor
Suction
Process
P 1 I C S T1 F 1 T P s1 T T s1 T U I1 C P d1 T T d1 T P I1 C
Load
H I1 C
Suction
Process
Serial network
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Standard
z z z
CCC
z z
z z
15% surge margin Quick opening valves No control of process variable via recycle No invariant coordinates Concentrating on Protection
Typically 8% surge margin Linear valves with positioners for control across 100% range Control of primary process variable by recycle when speed limit is reached Can handle varying molecular weight gases Concentrating on Control and Protection
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VSDS Compressor
Rc
Rprocess Rprocess+valve
FT 1
PsT 1
PdT 1
Suction
UIC 1
Discharge
qr
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B A
When the operating point crosses the SCL, PI control will open the recycle valve PI control will give adequate protection for small disturbances
qr
2
PI control will give stable control during steady state recycle operation Slow disturbance example
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Antisurge Controller Operation Protection #2 Moving The Surge Control Line (SCL)
Rc
When the operating point moves quickly towards the SLL = Surge Limit Line SCL = Surge Control Line SCL, the rate of change (dS/dT) can be used to dynamically increase the surge control margin. B
A
This allows the PID controller to react earlier. Smaller steady state surge control margins can be used w/o sacrificing reliability. Fast disturbance example
Q
2
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Benefits:
OP
Output to Valve
Reliably breaks the surge cycle Energy savings due to smaller surge margins needed Compressor has more turndown before recycle or blow-off Surge can be prevented for virtually any disturbance
PI Control Step Change
+
To antisurge valve
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Input
Speed Inputs
Antisurge Inputs
(Field Transmitter)
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1. When operating at Point A, process encounters a large disturbance, operating point will move to Point B
B C A
PIC-SP
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If Operating Point crosses the Safety On Line the compressor is in surge The Safety On response shifts the SCL and the RTL to the right
Pressure axis
Additional safety or surge margin is added PI control and Recycle Trip will stabilize the machine on the new SCL
Flow axis
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Compressor networks
Compressors are often operated in parallel and sometimes in series The purposes of networks include: z Redundancy z Flexibility z Incremental capacity additions Often each compressor is controlled, but the network is ignored Compressor manufacturers often focus on individual machines A network view of the application is essential to achieve good surge protection and good performance control of the network.
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Load Sharing
Control system objectives for compressors in parallel:
z
Maintain the primary performance variable (in this case suction pressure), and then: Optimally divide the load between the compressors in the network, while: Minimizing risk of surge Minimizing energy consumption Minimizing disturbance of starting and stopping individual compressors Operating within limits
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Load Sharing
1. Base and Swing Load Sharing system 2. Equal Flow Load Sharing system 3. CCC Equidistance Load Sharing controls system
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Base and Swing Load Sharing Flow Diagram for Control Process
VSDS Compressor 1
UIC 1
Swing machine
PIC 1 HIC 1
Suction header
Process
VSDS Compressor 2
UIC 2
Base machine
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Compressor 1
Swing machine
Rc,2
Compressor 2
Base machine
PIC-SP
qr,2
Notes:
Base loading is inefficient Base loading increases the risk of surge since compressor #1 will take the worst of any disturbance Base loading requires frequent operator intervention Base loading is NOT recommended
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out
UIC 1 FIC 1
RSP
out
PIC 1
out
UIC 2 FIC 2
P RS
Notes Performance controllers act independent of antisurge control Higher capital cost due to extra Flow Measurement Devices (FMD) Higher energy costs due to permanent pressure loss across FMDs Next
Compressor 1
Rc,2
Compressor 2
PIC-SP
Equal flow
QP,1 = QP,2
qr,1
QP,1
2
Equal flow
qr,2
QP,2QC,2
where: QP = Flow to process QC= Total compressor flow QC - QP = Recycle flow
Notes:
Requires additional capital investment in FMDs Requires additional energy due to permanent pressure loss across FMDs Poor pressure control due to positive feedback in control system (see next) Equal flow division is NOT recommended
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RSP Compressor 1
UIC 1
Serial network
out
LSIC
Serial network
MPIC
Suction header
VSDS
Process
RSP Compressor 2
out
UIC 2
Serial network
LSIC
Notes All controllers are coordinating control responses via a serial network Minimizes recycle under all operating conditions
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Compressor 1
SCL = Surge Control Line 0.1 0.2 0.3
Rc,2
Compressor 2
DEV = 0 0.1 0.2 0.3 PIC-SP
Dev1 = Dev2 Q1 = Q2 N1 = N2
q2 r,1
DEV1 DEV2
2 qr,2
Notes:
Maximum turndown (energy savings) without recycle or blow-off Minimizes the risk of surge since all machines absorb part of the disturbance Automatically adapts to different size machines CCC patented algorithm Next
Average
Master Controller
Analog Inputs
DEV DEV PV PI RT Primary response SP Load balancing Primary response
FA Mode
DEV
DEV
+ Loadsharing Controller
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ANTISURGE CONTROLLER
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End Slides Thank You very much for your kind attention and cooperation
PT Putranata Adi Mandiri Jl Kartini VIII No. 9 Jakarta 10750 Tel: (021) 6007850 Fax: (021) 6007846 Email: pamccc@cbn.net.id