Technical Seminars 2012 Industrial Compressor Controls Standard Custom CONTROLLING the power of ENERGY 1 TM
2 Woodward Compressor Controls
Small Steam Turbine Driven Compressors (ITCC) 3
Simple Compressor Control Options 505 CC-2 Controller User configurable Turbine Controller Single Valve Turbines Single Extraction Turbines Compressor Controller 1 or 2 Loop Performance Control included Suction Pressure Discharge Pressure Plant DCS Compressor Controller Operator Control Station (Optional) Engineering Work Station Simple Compressor Train 4
505CC-2 Turbine & Compressor Control AO DO AI Two RS232 Serial Modbus Ports 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 T&T Valve A Recycle Valve No. 1 Recycle Valve No. 2 Suction Flow No. 1 Suction Pressure No. 1 Side stream Flow Side stream Pressure Discharge Pressure No. 2 Compressor Compressor 505CC-2 Application PT PT FT PT 5 FT
6 6 EWS Screen Turbine Configuration
7 7 EWS Screen Compressor Config
OCP Screen - Overview Configured for both turbine and compressor 8 8
9 9 OCP Screen Turbine Performance Map
OCP Screen Compressor Performance Map 10
11 OCP Screen - Compressor Control
12 OCP Screen - Compressor Control
Small Motor Driven Compressors 13
Vertex-Pro Compressor Controls 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 Vertex-Pro Compressor Controller VFD Touchscreen (153 mm) Configuration Tool Simple Compressor Train 14
15 EWS Screen Compressor Config
16 EWS Screen Compressor Config
17 EWS Screen Compressor Config
18 18 OCP Screen Turbine Performance Map
19 OCP Screen Turbine Performance Map
20 Compressor Operation Screen
Custom Compressor Controllers 21
Custom Compressor Controls Fault Tolerant Controller Plant Control Compressor Controls Motor Drive Turbine drive Parallel & Series compressors Surge Anticipation Technology VFD Compressor Island 22
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 Single, Dual or Triplicated I/O As Required To Meet Availability Goals Recycle Valve No. 1 Recycle Valve No. 2 Suction Flow No. 1 Suction Pressure No. 1 T&T Valve PT Side stream Flow Side stream Pressure Discharge Pressure No. 2 Compressor Compressor PT PT PT FT PT FT 23
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 PT FT FT PT PT FT FT 24
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 25 OEM Qualified / Field Proven Software Logic
26 Global Experience
Dushanzi Chooses Woodward Dushanzi Chooses Woodward Woodward was selected as the control of choice for all three of Dushanzi s new critical compressor trains (cracked gas, ethylene, and propylene) due to Woodward s 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 Dushanzi s, Linde s, and Siemens stringent system control, protection, and plant interface requirements. 27
Compressor Control Overview 28
Compressor Control Functions Surge Prevention 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 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 29
Polytropic Head (H P ) Compressor Operating Point Calculation Standard Compressor Performance Map Surge Region Surge Line BOOST Line Surge Control Line Operating Point N2 N3 X-axis (Flow) Represented by Actual Volumetric Flow Referenced to Suction Conditions Y-axis (Head) Represented by Polytropic Head Online Calculations Compensate for Varying Molecular Weights, Pressures, and Temperatures N1 Volumetric Inlet Flow (Q A ) 30
Compressor System Limits Pressure Surge Limit Pressure Limit Speed Limit Power Limit Stonewall % Flow Operating Envelope 31
Compressor Control Block Diagram Anti-Surg Accel To Recycle Valve Suction Discharge 32
33 Compressor Control Block Diagram
34 Compressor Operation Screen
Compressor Control Basics 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 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 35
Compressor Surge Prevention 36 Closed Loop Actions (Modulated Output to Recycle Valve) Anti-Surge PID The Main Anti-Surge Routine Compares S_PV to 100 Dynamics Compensated With Operating Conditions Rate PID Acts on Derivative of S_PV Acts to Open Recycle Valve Earlier Than Anti-Surge PID Useful For High Rates of Surge Onset Open Loop Actions (Opens Recycle Valve by Fixed Amount) BOOST Opens Recycle Valve if Surge Control Line is Exceeded Includes Pre-Pack to Adjust for Piping Lags
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) 37
Compressor Surge Capture Recursion Rate 40 Milliseconds The compressor is unloaded. The control response returns the compressor operating point to a safe condition. Operating Point Closed-loop controls begin to open the Anti-Surge Valve as the operating point moves below setpoint. Anti-Surge Valve Demand The primary closed-loop controls cannot prevent the operating point from reaching the Surge Limit Line A surge occurs. Raw Flow Input Flow Element dp 38
Compressor Surge Capture Recursion Rate 160 milliseconds 39
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 ST PT TT PT TT FT PT PIC SIC UIC FY 40
NetSim Simulation Software Complete Package Simulation Control Software Emulation Control Hardware Emulation Compressor Package Emulation Control Logic Start Sequencing Communications CPU Scan Rate I/O delays I/O Resolution 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 Motor Actual Compressor Control 41
Why Operators Choose 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) 42
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 43
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 44
Industrial Turbomachinery Systems Improve Reliability Enhance Performance 45 TM