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1. INTRODUCTION
2. ANTISURGE CONTROL SYSTEM
3. WGC CONTROL SYSTEM
4. MODIFICATIONS
5. CONCLUSIONS
6. ANNEXURE
INTERLOCKS
FALL BACK
STARTUP /SHUTDOWN SOP
A. INTRODUCTION :
The wet gas compressors (WGC) are manufactured by Mitsubishi Heavy
Industries , Ltd. The compressor system consists of two trains, each train is a two – stage
centrifugal compressors driven by steam turbine and with interstage coolers,. The two
trains are operating in parallel with antisurge control on each stage, loadsharing between
the two trains, and performance control for the compressor system .The antisurge controls
and the load sharing controls are by CCC. This project concentrates on understanding the
existing CCC logics in a better way and to incorporate new controls / logics for better
operational reliability.
SLL
SOL SCL
Operating
point
Tdo*dS/dt = 1
(fast)
Tdo*dS/dt = 0
(slowt)
b1 b2 Q, Q2
Operating point (OP) ; The point on the compressor map that represents the current operating
location of the compressor.
PI response ; The closed loop response of the antisurge controller.
Recycle trip line (RTL) ; the line of the compressor map where the open loop RT response is
triggered.
Recycle trip (RT); The distance between (RTL) and (SCL).
Surge control line (SCL) ; The line on the compressor map where DEV has a zero value. If the
OP is left of the SCL then the recycle valve opens. If the OP is right of the SCL then the recycle
valve closes.
Surge limit line (SLL) ; the line on the compressor map which represents the where surge
happens. If the OP is left of the SLL surge occurs.
Safety on (SO) ; The distance between the SLL and the SOL.
Safety on line (SOL);– The line on the compressor map where the controller recognizes surge and
the safety on response is triggered
Anti surge PI response : A proportional – integral response of the antisurge controller to
manipulate the recycle valve based on the Deviation.
Derivative response : A response of the antisurge controller where the (SCL) moves to meet the
operating point. How far the line moves is dependent on the speed of approach of the operating
point (Tdo*dS/dt) multiplied by the value (b3). This is done so the the recycle valve can open
sooner for a fast disturbance.
Recycle trip response - an open loop response where the recycle valve is stepped open in
response to crossing the recycle trip line (RTL), causing the operating point (OP) to go back to
the surge control line (SCL)
Safety on response : A response where the (SCL) and (RTL) are moved to a safer location (by the
amount b2). The operator should determine the cause of the safety on response and “RESET“ the
Safety on.
Deviation (DEV) : The distance between the SCL and the OP. A positive value indicates the OP is
to the right of the SCL. A negative value indicates the OP is to the left of the SCL
Width of safety margin (b) : The distance between the SCL and SLL based on the equation :
b = b1 + (b2 n) + (b3*T dO*dS/dt)
Where
b1 is initial safety margin – minimum distance between SCL and SLL
b2 is safety on bias – distance added to SCL each time surge is detected.
b3 – Derivative response – a response of the antisurge controller where the SCL moves to meet the
operating point.
Falback : An alternate operational strategy to maintain the same level of surge protection in the
event of a required input failure.
Limit : A response of the antisurge controller that can override the normal PI control based on a
secondary variable (Ps), (Pd) or (Rc).
If the operating point of the compressor crosses a surge control line, the antisurge controller
will employ advanced closed loop and open loop surge control responses to modulate the recycle
valve. The surge surge control line is biased from the surge limit line in a dynamic manner that is
designed to provide adequate surge control with the minimum amount of necessary recycle.
In addition the antisurge controller will participate with its Master performance controller to
modulate the compressor’s throughput based on the latter’s load sharing response when the
compressor is recycling.
When process conditions dictate that both compressors of the same stage in each train operate
with continuous recycle , then the antisurge controllers will coordinate their control responses so
that the recycle rates of both compressors will be equalized. This feature can be disabled by
energizing the Disable recycle balancing discrete input.
Note :During commissioning , it was noticed that reverse rotation on the compressor
occurred during shutdown. Thus in order to prevent the above situation, a purge request is added
via hardwired discrete input to the first stage antisurge controllers whenever shutdown occurs.
During purge mode, the antisurge controller will keep its antisurge valve at fully closed position
during shutdown mode.
RUN state :
The RUN operating state maintains automatic control of train throughput using its PID
algorithm. The controller PID error and set point are initialized to values that provide bumpless
transfer into the RUN state.
When in the RUN state, the following control functions are performed
Main column receiver pressure control
Limiting control
Load sharing
Load balancing
Automatic fall back
MANUAL state :
The MANUAL operating state allows the operator to directly control the output of the
controller, thereby allowing the operator to “manually” increase or decrease overall train
throughput via the load sharing controllers (not available from DCS). When toggled into the
MANUAL state , the MANUAL target parameter is initially set to the current controller output to
provide a bumpless transfer. The operator may then change the manual target parameter value by
asserting the UP or down discrete inputs. When in the Manual state, the controller’s set point
tracks the control variable to allow bumpless transfer back into the RUN state.
SHUTDOWN state ;
The controller assumes its shutdown state when the stopping sequence is ended. In the
shutdown state the output of the controller is held at the pre-configured stop output parameter
value, corresponding to the steam turbine’s minimum governor speed (3200 RPM)
STARTING state :
The controller goes from its shutdown state into the starting state when the following
conditions are satisfied;
The stop discrete is cleared
The compressor speed is higher than the run threshold parameter value for a configured
number of seconds.
When in the starting state , the controller ramps up its output (increasing steam turbine speed from
its stop output value at a rate specified by the configurable start rate 1 parameter value. This ramp
up continues until the following conditions are satisfied;
D. MODIFICATIONS SUGGESTED :
Present startup :
At present while ramping up WGC during startup , the main column overhead receiver
pressure ( suction pressure ) drops suddenly as the compressor automatically ramps up to 3200
rpm As a result we are continuously flaring from the main column receiver ( during WGC ramp
up ) to maintain the suction pressure .
This has three distinct disadvantages
1. Wastage of money as a result of hydrocarbon flaring
2. Reactor – Regenerator pressure balance upset.
3. Sudden decrease in fuel gas export upsetting the other units
Recommendations :
Provide a face plate in the DCS where the operator can key in the RPM up to which the
compressor should ramp up - From 1000 rpm to 3200 rpm . (Pl. note the automatic ramp up
crossing the critical speeds still holds good ).
Reconfigure the “ Speed Increase “ / “Speed Decrease “ PB on the local control panel to
ramp up from 1000 rpm. Pl. note right now this facility is available only after 3200 rpm.
D.5 RELIABILITY :
Install a spare interstage cooler bundle with isolation valves to be used if there is any leak in
the existing bundles. This will prevent the unit from going down in case of exchanger tube
bundle leak.
Feasibility study of laying a separate line from the available 12 kscg condensate header at
utilities to be carried out. At present we are dropping the pressure by a let down valve into a
tank and again pumping into the system using separate pumps .With this modification 414
P02A/B may not be required.
Structure strengthning for avoiding the lines vibrations.
D.6 HSE :
Install silencers on startup line vents for avoiding noise pollution.
Extend the seal leak line outside the compressor house from safety point of view
Extend the Nitrogen purge line outside the compressor house from safety point of view
E. CONCLUSION ;
CCC logics pertaining to load sharing and anti surge controls have been thoroughly
discussed in this project for better understanding.
The present start up procedure for WGC has been reviewed and the scope for improvement
pointed out
Modification in the present start up procedure has been proposed for better operational control
and unit profitability
New infra structural modifications have been proposed for better unit reliability