Field-based Control for Compressor Anti-Surge

John Rezabek Process Control Specialist ISP Lima LLC

2009 General Assembly Yokohama, Japan

Objectives

Provide efficient and reliable surge g control to:

Prevent e e t su surge ge a and d co consequent seque t equ equipment p e t damage Prevent p process downtime Improve process stability Decrease blow off Reduce power consumption
2009 General Assembly Yokohama, Japan

1999 2009 Fieldbus Foundation

Introduction

Compressor Antisurge requires speed and reliability Can field-based control improve reliability and performance? How fast can we go with ith newer offerings?
2009 General Assembly Yokohama, Japan

1999 2009 Fieldbus Foundation

What is Surge?
P Surge Line
B

Point where the flow pattern collapses Design Operating point

A Speed D

105 % 100 % 95 %

Flow
2009 General Assembly Yokohama, Japan

1999 2009 Fieldbus Foundation

Deep Surge!
P
C

Surge Line
B

Cycle lasts 300 ms to 3 s s, depending on speed, compressor characteristics

A

Reverse flow finds blades resistance

Speed

100 %

Flow
2009 General Assembly Yokohama, Japan

1999 2009 Fieldbus Foundation

Surge path

If the throughput is reduced from A, the compressor will follow the curve back to B. In B the flow collapses, going to zero at point C. With the head falling below the head capability of the compressor, a new flow is produced (D). If the system y load is the same, , the compressor p will go through A, B, C and back to D on and on. Each compressor speed has a point B, where the flow collapses The collection of these points is called Surge Curve.
2009 General Assembly Yokohama, Japan

1999 2009 Fieldbus Foundation

What is Surge?
P Surge Line
B

Point where the flow pattern collapses Design Operating point

A Speed

Surge Area

105 % 100 % 95 %

Flow
2009 General Assembly Yokohama, Japan

1999 2009 Fieldbus Foundation

Consequences of Surge

During surge, the flow variation produces prominent axial oscillation. The frequency and displacement of this oscillation depends on the compressor speed speed, among other factors. The oscillation can damage the bearings, impellers and labyrinth seals, causing parts of the rotor and stator to touch each other, resulting in serious damage or destruction. Internal temperature can raise to dangerous levels. Compressor life is shortened
2009 General Assembly Yokohama, Japan

1999 2009 Fieldbus Foundation

Factors leading to Surge

Load changes, start/stop Gas Molecular Weight change Upstream p or downstream pressure p changes g Gas temperature changes

2009 General Assembly Yokohama, Japan

1999 2009 Fieldbus Foundation

Surge control
P Surge Line
FTS TTS PTS

B'

Driver
A Speed

Compressor

FIC

TTD

Discharge Flow PTD

105 %

Calculated Setpoint Line

100 % 95 %

Flow
2009 General Assembly Yokohama, Japan

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1999 2009 Fieldbus Foundation

Process Blower Simpler with milder consequences

Keeping the Blower out of the surge region i means a more stable t bl flow fl More stable flow allows running closer to constraints Running closer to constraints means less fuel CO2 fuel,

2009 General Assembly Yokohama, Japan

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1999 2009 Fieldbus Foundation

Inside peak peak pressure pressure line, line flow is unstable

Desired Operating Point Peak Pressure

2009 General Assembly Yokohama, Japan

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1999 2009 Fieldbus Foundation

Field-based control of blow-off valve

Controls total flow Allows operation close to low-flow BMS trip p point p Saves fuel costs and reduces CO2 emissions

2009 General Assembly Yokohama, Japan

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1999 2009 Fieldbus Foundation

Surge Control Scheme

Discharge Pressure Blow-off Flow Flow to Burner Inlet Louvers
2009 General Assembly Yokohama, Japan 1999 2009 Fieldbus Foundation

SGCR

SP FIC C (Total Flow) Blow-off ff Valve

FIC
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Blower Anti-surge scheme

Flow to Burner

Total Flow Setpoint

Total Flow Controller

2009 General Assembly Yokohama, Japan

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1999 2009 Fieldbus Foundation

Macrocycle Schedule
Discharge Pressure Flow to Burner Blow-off Flow Calculate SP Sum Flows Burner Flow FIC
Fast PID / AO would reduce Burner Flow Valve required macrocycle to 325 ms or less
2009 General Assembly Yokohama, Japan

Total Flow FIC

Blow-off Valve
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1999 2009 Fieldbus Foundation

10,000 HP Turbine / Blower Anti Anti-surge surge

Large critical un spared un-spared asset Typically yp y runs at 5000 to 7000 RPM Expensive to repair; lost production d ti even more expensive
2009 General Assembly Yokohama, Japan 1999 2009 Fieldbus Foundation

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Discharge Flow / Pressure / T Temperature t Measurement M t Venturi Flow meter on discharge Pressure and Temperature p Compensation Discharge and suction converted to ACFM

2009 General Assembly Yokohama, Japan

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1999 2009 Fieldbus Foundation

Control Scheme FF for IO only

2009 General Assembly Yokohama, Japan

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1999 2009 Fieldbus Foundation

Control Scheme FF for IO only

2009 General Assembly Yokohama, Japan

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1999 2009 Fieldbus Foundation

Control Scheme FF for IO only

CALC Block 2: 1) Calculates CALC Block: Surge Theoretical 1) Curve Corrects SCFM 2) C corrected d 2) Converts Calculates % Over SCFH Surge to Suction Discharge g 3) and Adds 5 10% ACFM Bump when surge 3) is Converts PSIG to approached PSIA

2009 General Assembly Yokohama, Japan

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1999 2009 Fieldbus Foundation

Control Scheme FF for IO only

2009 General Assembly Yokohama, Japan

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Macrocycle Schedule no FF control

2009 General Assembly Yokohama, Japan

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1999 2009 Fieldbus Foundation

With Core Calculations in Field:

Keep same look and feel for operator Percent over Surge calculation does not fit nicely in standard FF blocks CALC blocks will not run in H1 card

2009 General Assembly Yokohama, Japan

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1999 2009 Fieldbus Foundation

With Core Calculations in Field:

Converts Mass Flow to ACFM at Suction Conditions

New DP cell does Mass Flow internally

2009 General Assembly Yokohama, Japan

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1999 2009 Fieldbus Foundation

With Core Calculations in Field:

Derives Discharge ACFM Asynchronously

2009 General Assembly Yokohama, Japan

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1999 2009 Fieldbus Foundation

With Core Calculations in Field:

TRK_VAL TRK VAL is a constant 100%

HOST still calculates surge 27 curve

ARTHM calculates % over Surge

Sets TRK TRK_IN_D IN D if Suction Flow < Surge Flow

2009 General Assembly Yokohama, Japan 1999 2009 Fieldbus Foundation

Macrocycle Schedule FF control

Discharge Di h P Pressure Suction Temperature 1 Discharge Flow Disch. Press. Push ISEL doing ISELs d i H Hot t Bup B

Disch. Temp. Push

Calc % Over Surge Check if < 0%

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Blow-off Valve

2009 General Assembly Yokohama, Japan 1999 2009 Fieldbus Foundation

Business Results Achieved

Data from CCC talks about 100K yearly energy savings for a compressor about the same size used in process air. Control in the field responds within the macrocycle whereas in the DCS takes longer. Proven availability and fault tolerance with physical layer diagnostics.

2009 General Assembly Yokohama, Japan

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1999 2009 Fieldbus Foundation

Summary

Anti-surge control is of great benefit, if not a necessity Unless there is great economic benefit for running close to surge, extraordinary cycle times are not required Intelligent devices and field-based deterministic control can be superior to hostsolved schemes Newer devices have increasingly fast and efficient function blocks
2009 General Assembly Yokohama, Japan 1999 2009 Fieldbus Foundation

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About the Presenter

John Rezabek, Process Control Specialist, ISP Lima LLC Began with Standard Oil and later BP, working in refineries and chemical plants. After 27+ years, still pulls into a process plant and sits at DCS engineering console nearly every day.

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1999 2009 Fieldbus Foundation