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Compressor operation
Centrifugal compressors
Axial compressors
Compressor system classifications
Developing the compressor curve
The surge phenomena
Compressor control
Acrobat
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20,000 hp
Axial air blower
Seals
$20,000
$50,000
Bearings
$10,000
$25,000
$200,000
$750,000
Rotor Assembly
Compressors
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$457,000
$1,830,000
$18,300,000
Assumes power at $.07 per kilowatt hour or $457 per horsepower per year.
Energy costs vary due to local conditions.
Compressors
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Compressor
application
Compressor
shaft power
Actual achieved
savings
Actual Energy
Savings Result
From
Propylene
refrigeration
40,000
hp ( 29 MW)
$1,200,000
Improved Antisurge Protection and Capacity Control
FCCU air blower
Centac air compressor
$155,000
$78,000
Compressors
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9
8
7
Pay-back less than 6
Months with 15% Reduction
6
5
1000 HP
4
3
3,500 HP
Pay-back approximately 1
Month with 15% Reduction
2
1
20,000 HP
0
10
15
20
25
30
35
Reduced Recycle
(Per Cent of Maximum Compressor Flow)
*Assumes electro motor power At $0.05 US per kilowatt hour or turbine power at $327
per horsepower per year. Tax consequences are not considered in pay-back period
due to varying tax policies around the world.
Energy Saving Examples
Compressors
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60,000 BPD Cat Cracker: $90,000 per hour, lost sales plus
fixed expenses. The biggest units are twice this size!
Natural Gas Production, 100 MMSCFD: $12,500 per hour
lost sales plus fixed expenses.
Consequences of downtime: Lost profit, lost customer
goodwill, repair costs, attention of top management.
Compressors
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Process
Start-up Cost Per Day
100 MMSCFD
Natural Gas Plant
$375,000
60,000 BPD
Cat Cracker
$2,300,000
Compressors
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Putting it in perspective
30-year life cycle costs for a 20,000 hp compressor
Maintenance Costs
$4.5 Million
Initial Cost
$1.5 Million
97%
of total costs
Energy Costs
$180 Million
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Putting it in perspective
30-year cost per 1,000 hp
$ Millions
15.0
Controllable
5.0
0.0
Initial Cost
Maintenance
Energy
Lost
Production
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Centrifugal compressors
Centrifugal Impeller
Compressors
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Impellers
Casing
(horizontally split flange)
Thrust bearing
Centrifugals
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Centrifugals
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Centrifugals
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Centrifugals
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Journal bearing
Pinion shafts
Gear casing
Compressor volutes
Centrifugals
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Centrifugals
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Centrifugals
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Axial compressors
Efficient
Stator Blades
Shaft
Rotor Blades
Casing
Rotor
Blades
Stator
Blades
Casing
Picture of Axial
Compressors
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Labyrinth seals
Compressor rotor
Rotor blades
Picture of Axial
Axials
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Axials
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Single-Section, Three-Stage
Parallel Network
Series Network
Compressors
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DischargeRatio
Differential
Pressure
Polytropic
Pressure
Head
Pressure
(Pd/P(P
) 2or
) -(P
PR
)process,2
or
s(P
d
s/P
2
1) (P2 - P1)
Rprocess,1
Rc2
Rc1
Compressor curve
for a specific
speed N1
Q2
Q1
Compressors
Qs,
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mass
vol
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Rc
adding control
margins
maximum speed
surge limit
power limit
stonewall or
choke limit
Actual available
operating zone
stable zone
of operation
minimum speed
Qs,
Compressors
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v1, p1
v2, p2
Bernoullis law
Lift
As a result there is Dp or
lift
And the plane can
fly
Compressors
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Lift
Lift
Lift
Lift
The air no longer sticks to the wing and the lift is lost
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Compressor
pressure
pressure
From
Cto DCompressor
20 - 120rides
ms
Jumptowards
out of surge
curve
surge
Suddenly
P
drops
and
thus
P
>
P
d
v
d
Point
A
is -reached
A-B-C-D-A
0.3
3
seconds
Surge
cycle
Plane goes
tosurge
stall -cycle
Compressor
surges
The
is complete
Pv
Rlosses
Pd
Pd
= Compressor discharge pressure
Pv
= Vessel pressure
Rlosses = Resistance losses over pipe
Pressure builds
Compressor
performance curve and goes to point D
Pd = Pv + Rlosses
Electroflow
motor
is started
Forward
is re-established
Result
of
flow
reversal
is
that
pressure
goes
Machine shutdown
no flow, no pressure
Qs,
vol
Compressors
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2
TIME (sec.)
2
TIME (sec.)
2
TIME (sec.)
TEMPERATURE
PRESSURE
Compressors
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Surge description
Compressor vibrates
Temperature rises
Whooshing noise
Compressors
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Compressors
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Startup
Shutdown
Trips
Operator errors
Load changes
Cooler problems
Driver problems
Power loss
Process upsets
Gas composition changes
Filter or strainer problems
Compressors
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Compressor control
Objectives
Performance control
Compressor networks
Antisurge control
Other topics
Fall-back strategies
Limiting control
Output linearization
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Compressor control
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Compressor control
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Typical compressor maps include: (Qs, Hp), (Qs, Rc), or (Qs, pd)
coordinates, where:
Qs = Suction flow and can be expressed as actual
or standard volumetric flow
Hp = Polytropic Head
Rc = Compressor Ratio (pd / ps)
pd = Discharge pressure of the compressor
ps = Suction pressure of the compressor
ks = Exponent for isentropic compression
These maps are defined for (1) specific set of inlet conditions:
Compressor control
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Fundamental variables
characterizing compressor
operation
Hp = f0(Q, w, m, r, a, d, a)
Invariant coordinates
Set 1
Set 2
hr
qr
Ne
a
jr
Re
Rc
qr
Ne
a
jr
Re
Dimensional analysis
or Similitude
J = f1(Q, w, m, r, a, d, a)
where:
Hp
J
Q
w
m
r
a
d
a
= Polytropic head
= Power
= Volumetric flow rate
= Rotational speed
= Viscosity
= Density
= Local acoustic velocity
= Characteristic length
= Inlet guide vane angle
where:
hr
qr
Ne
a
jr
Re
Rc
Compressor control
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= Reduced head
= Reduced flow
= Equivalent speed
= Guide vane angle
= Reduced power
= Reynolds number
= Pressure Ratio
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(hr, qr2)
Invariant coordinates
where:
Hp
Qs
hr
qr2
= Polytropic head
= Volumetric suction flow
= Reduced head
= Reduced flow squared
Compressor control
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(Rc, qr2)
Invariant coordinates
qr2
where:
Rc
Qs
qr2
= Pressure ratio
= Volumetric suction flow
= Reduced flow squared
Compressor control
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where:
Rc
jr
Ne2
(Rc, jr)
(Rc, Ne2)
Invariant coordinates
Invariant coordinates
= Pressure ratio
= Reduced power
= Equivalent speed squared
Compressor control
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Hp
hr
(ZRT)s
and
qr
Qs
( ZRT)s
Hp
hr
(ZRT)s
and
2
Q
s
qr2
( ZRT)s
hr
2
qr
Design
Nitrogen Off-gas
MW
MW
MW
Ps
Ps
Ps
Ts
Ts
Ts
ks
ks
ks
Compressor control
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qr
2=
Qs 2
(ZRT)s
where:
R
Ru
R
MW
ps
K
Dpo,s
Ts
Zs
K . Zs . Ru . Ts Dpo,s
.
MW
ps
=
(ZRT)s
Dpo,s
=
ps
= Ru / MW
= Universal gas constant
= Specific gas constant
= Molecular Weight of the gas
= Suction pressure
= Orifice plate constant
= Differential pressure across orifice plate
= Temperature of the gas in suction
= Compressibility of gas in suction of compressor
Compressor control
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hr =
Hp
(ZRT)s
Zs . Ru . Ts
Rcs-1
.
MW
s
=
(ZRT)s
Rcs-1
=
s
log(Rt)
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f1(hr )
Ss 2
qr ,op
The function f1 returns the value of qr2 on the SLL for input hr
hr
hr
qr,SLL
qr
Compressor control
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As a result:
Ss =
q2r,SLL
q2r,op
hr
Ss > 1
Ss < 1
Ss = 1
Ss > 1
surge region
OP
hr
Ss < 1
2
qr,SLL
2
qr,op
qr
OP = Operating Point
Compressor control
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Step 1:
Introduce parameter
d = 1 - Ss
Step 2:
Introduce parameter
hr
d =0
Ss = 1
Benefits:
d <0
DEV = 0
No operator confusion:
Ss > 1
DEV < 0
Ss < 1
DEV > 0
Good
d >0
DEV = 0
Recycle line
DEV > 0
DEV < 0
Bad
Surge margin
qr
Compressor control
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Ss =
f1(Rc)
2
qr,op
2
Compressor control
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The parameter Ss =
f1(Rc)
2
qr
qr
Rc - 1
= Dp
o
ps
(
=
pd
-1
ps
Dpo
ps
pd - ps
=
Dpo
Dpc
Dpo
Compressor control
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qr
Compressor control
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Compressor control
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1
Dpo,1
P1
T1
3
Dpo,2
P2
T2
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Reduced flow
Step 2:
Equivalent speed
.
m
ZRT
qr
p
N
Ne
ZRT
.
Step 3:
Combine qr and Ne
where:
.
Ne
qr
= mass flow
= Compressibility
= Gas constant
= Equivalent speed
= Reduced flow
= Rotational speed
= Pressure
= Temperature
qrNe m ZRT .
p
Compressor control
mN
N
=
ZRT
p
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1
Dpo,1
p1
.
T1 m1
q3 Ne,3
3
Dpo,2
p2
.
m2 T2
p
p
1
2
N
A1 Dpo,1
.
.
.
A
D
p
2
o,2
.
T1
m3 . N
T2 (m1 + m2 ) N
=
=
p2
p2
p3
Compressor control
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Compressor control
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1 SEC.
100%
Qs
Pd
100%
ABC
D
DPo
0
100%
AB C
DPc
Compressor control
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100%
DPo
0
1 sec.
100%
DPc
0
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Opening of the recycle valve lowers the resistance felt by the compressor
Rc
Rprocess+valve
VSDS
Compressor
FT
1
PsT
1
PdT
1
qr
Discharge
Suction
UIC
1
Compressor control
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Rc
B
A
qr
Compressor control
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Adaptive Gain
Enhancing the effectiveness of the PI controller
Rc
B
A
qr
Compressor control
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Rc
Total response
Disturbance
When
Operating
the
OP hits
operating
point
arrives
SCL
of
keeps
Moves
controller
the
the
point
PI
moving
back
Operating
controller
hits
is
tothe
the
the
Pointside
opens
towards
Recycle
safe
sum
of(OP)
valve
the
Trip
surge
ofmoves
PIthe
based
Line
control
and
RTL
(RTL)
towards
on
hits
and
proportional
Recycle
the
Recycle
the SCL
and
conclusion
Trip
integral
LineRT(RTL)
action
is:
actiondecays out the
The
function
step
response
We are
close to surge
PI
controller
integrates
to stabilize
The
PI controller
is too slow
to
Benefits:
OP
on
SCL
catch the disturbance
Get
Energy
due to smaller
out savings
of the dangerous
zone
surge margin
An open loop response is
Compressor has more turndown
triggered
before recycle or blow-off
Surge can be prevented for
virtually any disturbance
Output
to Valve
qr
Recycle Trip
Action
PI Control
Total Response
PI Control Response
Time
Compressor control
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Open loop corrections of a fixed magnitude (C1) are often either too
big or too small for a specific disturbance
Compressor control
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C = C1Td
where:
C
C1
Td
d(Ss)/dt
Output
to valve
Benefits
Maximum protection
No surge
No compressor damage
d(Ss)
dt
Medium disturbance
Output
to valve
Large disturbance
100%
Total
PI Control
Total
PI Control
Recycle Trip
Recycle Trip
0%
Time
Time
Compressor control
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Output
to valve
Output
to valve
100%
Total
PI Control
Total
PI Control
Recycle Trip
0%
Time
C2
Recycle Trip
Time
C2 C2 C2
Compressor control
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Rc
Recycle
will
Additional
PI
The
If Operating
control
Safetyand
safety
On
Point
response
or
crosses
surge
Trip
shifts
margin
the
Safety
theis
SCL
added
stabilize
RTL
to the
onright
the
new
SCL
On and
Linethe
themachine
compressor
is in
surge
New SCL
New RTL
Additional surge margin
2
qr
Compressor control
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Pd
0%
1 TO 2 SECONDS
100%
DPo
0%
20 to 50
milli-seconds
Compressor control
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Over 75% of the problems are in the field and not in the controller
The CCC control system has fall-back strategies to handle these field
problems
Benefits
Avoids nuisance trips
Alarms operator of latent failures
Increases machine and process availability
Compressor control
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Antisurge controller
If a pressure transmitter fails, a minimum q2r algorithm is used
If a temperature transmitter fails, hr is characterized as a function
of compression ratio
If the speed transmitter fails, a conservative speed setting is used
If the flow transmitter fails
Redundant transmitter is used
Output is driven to:
Last value OR
Last Value selected: If Last Value >Pre-selected fixed value OR
Pre-selected fixed value selected: If Pre-selected fixed value>Last
Value
Performance controller
Switches to redundant transmitter upon primary transmitter
failure
Output goes to pre-selected value if all transmitters fail or is
frozen
All transmitter failures are alarmed
Compressor control
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Output linearization
Controller
Dynamic
Existing
Linear
For antisurge
valve
valve
flow
output
gives
control
response
hasisthe
equal
quick
characterized
asame
linear
becomes
percentage
opening
valveas
as
linear
trim
dynamic
is preferred
mirror
mirror
image
flow
image
in
response
the
in the
linear
linear
over
valve
valve
its line
line
complete stroke
Flow rate
through
valve
Controller output
Valve trim
quick opening
Valve trim
Controller
output
equal percentage
Controller
output
Notes
Used to improve controllers operation when non-linear valves are
used
Used on retrofits to avoid additional investment in new valve
Works well with equal percentage characteristics
Works less satisfactory with quick opening characteristics
Compressor control
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Controller
output
PI Control
Controller
output
Low clamp on controller output
0% to the valve
Rc
SCL
TSL = Tight Shut-off Line
B
A
Time
At
CCC
The
For
When
Many
the
dynamic
5%
controller
antisurge
antisurge
the
low
oroperating
controller
low
clamp
control
is
clamp
controller
valves
now
value
point
crosses
we
value
ready
have
the
want
has
isvalve
represents
to
the
the
to
to
a the
Tight
go
use
TSL
Shut-off
the
right
following
when
closed
range
output
of
the
the
Line
operating
characteristic:
5%
of
position
TSL
the
-(TSL)
100%
the
controller
for
controller
points
that
on
control
the
eliminates
hits
jumps
valve
closes
theto
Usually
still
leaks
which
results
the
purposes
SCL
disadvantages
valve
low
- energy
point
clamp
at C
0%
value
- point
- point
A value
B the
in
from
0%
towaste
low
clamp
This
flow
is below
rate
the low the
clamp
valve
value
is
Makes
anthrough
annoying
noise
Benefits
(almost) zero and does not
Typical
for worn
valveswhen
and valves
No leakage
and noise
controller
change
with
Teflon
seat
is far
away
from
point
A
Once
the
lowsurge
clamp- is
reached
Eliminates
noise and energy
the characteristic
is linearwaste
Eliminates
time in
the response
Typical dead
low clamp
value
can be
of the
valve
when
thethe
5%antisurge
- we will use
the
5% as
operating
point is close
to the
SCL
value throughout
in this
example
qr
Compressor control
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Also called:
Throughput control
Capacity control
Process control
Compressor control
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Rprocess
Process
Rprocess + Rvalve
PIC - SP
PT
1
Curve 1
PIC
1
Curve 2
Shaft
power
P1
P2
Notes
2
Q
Compressor
Pressure
Point
Required
Power
represents
B2
loss
represents
is
power
is
controlled
operates
P1 energy
in
-P
point
the
by
point
waste
A
B
point
blow-off
is that
P1A
loss
2 in
2
Most
inefficient
control
method
qr
Curve
represents:
would deliver the pressure for Rprocess
Qloss
Regularly
foundon
in plant
air speed
systems
Lower speed
variable
systems
Rare
in other systems
Curve 1
IGVs
closed on variable geometry
Not
recommended
compressors
Curve 2
Inlet throttle valve closed on fixed
speed compressors
2
qr
Compressor control
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Rprocess + Rvalve
Rprocess
Process
PIC - SP
PT
1
Curve 1
Curve 2
PIC
1
Shaft
power
qr
P1
P2
Curve 1
Curve 2
Notes
Power
Compressor
Required
Pressure
Opening
Lower
resistance
loss
of
is
power
is
valve
controlled
operates
P1 is
-would
would
PP21 in
byreduce
require
point A
Curve
2 represents:
pressure
resistance
less
speed
drop
to
and
Rover
power
valve
process
Lower speed on variable speed
Notes
systems
Extremely inefficient (consumes
IGVs closed on variable geometry
approx. the same power for every load)
compressors
Rarely used
Inlet throttle valve closed on fixed
Not recommended
speed compressors
qr
Compressor control
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Process
A
PIC - SP
PT
1
PIC
1
Shaft
power
qr
P1
qr
Required
Inlet
Changing
Pressure
Compressor
valveis
power
suction
manipulates
controlled
operates
is pressure
P1 in
by
suction
point
inlet A
pressure
generates
valve
for
given
position
Raprocess
family of curves
Notes
Common on electric motor machines
Much more efficient than discharge
throttling
Power consumed changes proportional
to the load
Throttle losses are across suction valve
Compressor control
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A
PIC - SP
amin
aOP
PT
1
amax
PIC
1
Required
Different
Pressure
Compressor
geometry
is
power
controlled
operates
is
Pmeans
by
point
inletaA
Change of
guide
vanes
angle
1 in
different
guide
for
given
vane
Rdifferent
positioncompressor
curve
results
inperformance
process
Notes geometry
Improved turndown
More efficient than suction throttling
Power consumed is proportional to the
load
Power loss on inlet throttling is
eliminated
Shaft
power
qr
P1
qr
Compressor control
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Pd
Rprocess
Process
A
PIC - SP
PT
1
Nmax
NOP
PIC
1
Nmin
Shaft
power
qr
P1
qr
Required is
Changing
Pressure
Compressor
power
speed
controlled
operates
is
generates
P1 in
bypoint
speed
a A of
family
rotation
for
given
of curves
Rprocess
Notes
Most efficient (Power f(N)3)
Steam turbine, gas turbine or variable
speed electric motor
Typically capital investment higher than
with other systems
No throttle losses
Compressor control
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CONTROL
Discharge Pressure
Suction Pressure
Net Flow
Suction Pressure
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Power limit
R1
R2
R3
PIC-SP
However
Primary
Limiting
Compressor
Machine
Process
PIC
will speed
would
variable
variable
resistance
hits
power
like
operates
power
machine
tolimiting
PPower
speed
changes
limit
inup
loop
point
to
d decreases
A
from
N
further
machine
takes
in R
order
control
to
atup
RR
Nto
to
and
control
N4 and
controls
pressure
operate
Compressor
operates
in point
2for
11to
32
1
P
in
machine
point
atNspeed
N3
Bdfor
R2 D
at
2
Compressor will operate in
point C for R3 at N3
N4
N
N2 3
N1
Benefits
Maximum protection
No machinery damage
Qs,
vol
Maximize production
Machine can be pushed to the
limits without risk of damage
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FT
1
Suction
PsT
1
PdT
1
UIC
1
Discharge
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Interaction starts at B
Performance controller on
discharge pressure reduces
performance to bring
pressure back to setpoint
Results of interaction
Rc
B
C
DPo
Ps
PIC-SP
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Compressor control
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Menu
Compressor control
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Section 2
UIC
1
UIC
2
PIC
Disturbance
Rc,1
R
R
Rc,2
qr,1
qr,2
The
system
is oscillating
of controller
recycle
on
section
Antisurgeofcontroller
Opening
recycle
valve
UIC-1
on
will
section
open
2 Opening
Disturbance
Antisurge
comesvalve
from
UIC-2
the
will
open1
caused
Pd,1side
= Ps,2 lead
to decrease
caused
the
recycle
Ps,2 valve
= Pd,1to
to
protect
increase
section
1 controller
discharge
the
recycle
valve
protect
Slowing
down
the
tuning
would
to: section 2
Pd,2 increases
Increased risk of surge
against
against
surge
Result:
Result: surge
Compressor damage
P
decreases
Pd,1
d,1 increases
Process trips
P
increases
Ps,1
s,1 remains constant
Bigger surge margins
R
decreases
Rc,1
c,1 increases
surge
Energy
Section
from
surge waste
Section 1
1 moves
moves away
towards
remains
constant
Ps,2s,2
decreases
PP
d,2decreases
increases
c,2remains
Pd,2
increases
PR
constant
s,2
Section
2
moves
towards surge
R
decreases
Rc,2c,2increases
Section22moves
movestowards
away from
surge
Section
surge
Compressor control
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Section 2
Serial
network
UIC
2
Serial
network
PIC
How much section 1 is driven towards surge depends on how much the
recycle valve on section 2 is opened
Compressor control
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VSDS
Section 1
Section 2
Serial
network
UIC
1
Analog Inputs
UIC
2
Each
controller
itshas
PI
and
its
own
Recycle
values
gain
to
M
toPI
Antisurge
UIC-2
UIC-1
Loop
decoupling
reports
is protecting
controller
PI
and
block
value
values
section
UIC-2
Recycle
is
multiplies
ofadded
opens
other
1decoupling
against
TripTrip
to
controllers
its
reported
output
output
valve
surge
to
to
PI
using
UIC-1
protect
and
nUIC-2
Avoids
control
system
oscillations
allow
for
tuning
relative
loop
between
section
and
Recycle
antisurge
(performance
Recycle
2Trip
against
valve
Trip
and
values
1ofsurge
antisurge)
with
aregains
added
gain
to output
M2
to
Same
decoupling
takes
place
Allows
faster
tuning
ofdecoupling
control
system
different controllers
antisurge
valve 1
Reduced risk of surge
Allows closer operation to surge limits
without taking risk
From other
controllers
FA
Mode
FA
Mode
DEV1
PI
From other
controllers
Analog Inputs
RT
PIn . Mn
+
RTn . Mn
+
Antisurge
Controller 1
To antisurge valve 1
PI2 . M2
+
RT2 . M2
DEV2
PI
RT
+
Loop
Decoupling
PI1 . M1
+
RT1 . M1
PIn . Mn
+
RTn . Mn
+
Loop
Decoupling
Antisurge
Controller 2
To antisurge valve 2
Compressor control
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Compressor networks
Compressor control
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Compressor control
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Swing machine
UIC
1
PIC
1
Suction
header
HIC
1
Process
VSDS
Compressor 2
UIC
2
Base machine
Notes
All controllers act independently
Transmitters are not shown
Compressor control
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Compressor 1
Rc,2
Compressor 2
Swing machine
Base machine
PIC-SP
qr,1
qr,2
Notes
Load
Machines
Base
Swing
load
machine
could
machine
operate
one
be is
or
re-divided
can
fully
more
atbe
same
loaded
running
compressors
toReliminate
since
with
runs
suction
recycle
and
recycle
without
letand
therecycle
discharge
other(s) absorb
of both
the
c and
Base loading is inefficient
machines
load
swings
are tied together
Base loading increases the risk of surge since
compressor #1 will take the worst of any disturbance
where:
QP
= Flow to process
Base loading requires frequent operator intervention
QC
= Total compressor flow
Base loading is NOT recommended
Q -Q
= Recycle flow
C
Compressor control
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RSP
Compressor 1
out
UIC
1
FIC
1
RSP
out
PIC
1
Suction
header
Process
VSDS
RSP
Compressor 2
out
UIC
2
FIC
2
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
Compressor control
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Compressor 1
Rc,2
Compressor 2
PIC-SP
QP,1 = QP,2
Equal flow
Equal flow
2
qr,1
QP,1
qr,2
QP,2QC,2
Notes
Machine
Equal
Machines
Bias
relay
flow
2are
operate
on
operates
division
remote
never
atmight
with
identical
same
setpoint
recycle
work
Rc except
since
would
ifin
while
both
suction
by
only
machines
machine
coincidence
work
andif1discharge
are
curves
still-identical
different
hashave
turn
of both
Requires
additional
capital
investment
FMDs
machines
down
resistance
same
steepness
are
duetied
to piping
together
arrangments
Requires additional energy due to permanent pressure
loss across FMDs
where:
Poor pressure control due to positive feedback in
QP
= Flow to process
QC
= Total compressor flow
control system (see next)
QC - QP = Recycle flow
Equal flow division is NOT recommended
Compressor control
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Rc
R2
C
R1
B
D
PIC-SP
disturbance
isthe
amplified
Pressure
The
In
Process
As
Since
Only
aatypical
FIC
PIC
machine
result
as
the
the
provides
reacts
is
disturbance
controller
PIC
the
the
master-slave
PIC
is
is
master
fast
machine
operating
starts
slow
and
(PIC)
causes
RSP
itand
todoes
will
moves
control
reduce
in
provides
for
the
try
point
the
not
the
FIC
to
toitsis
A
Remote
speed
the
scheme
resistance
point
move
maintain
output
slave
B
its
controller,
toSetPoint
the
output
its
control
toslave
SP
change
yet
suction
pressure
needs
(RSP)
which
from
for
to
throttle
is
R
the
be
Flow
the
toFICR
FICPositive
feedback
system
This
is the
intersection
of 4 1lines:2
controller
valve
approx.
SP comes
or 5guide
times
(FIC)
down
vanes
faster
and the
than
pressure
the
is
The
FIC will speed
the machine to
Resistance
line Rup
1
master
restored
point
C at speedcurve
N 3 N1
Performance
PIC-SP
FIC-SP = Output of PIC
N3
N1
N2
FIC-SP
PIC OUT
1
Master
RSP
FIC
1
OUT
Slave
RSP
SIC
1
qr
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
Equal flow division is NOT
recommended
Compressor control
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RSP
Compressor 1
out
UIC
1
Serial
network
LSIC
Serial
network
MPIC
Suction
header
Process
VSDS
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
Compressor control
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Compressor 1
Rc,2
Compressor 2
DEV = 0
.1
.2
.3
.3
PIC-SP
Dev2
Q1 Q2
N1 N2
2
Dev1
qr,1
qr,2
DEV1
DEV2
Notes
Since
The
Machines
DEV
DEV
isare
operate
is
a dimensionless
kept at
at same
the same
Rcnumber
all
since
relative
sorts
suction
representing
ofdistance
machines
and discharge
to the
can
the distance
be
Surge
mixed:
of Control
both
between
small,
Line
the
Maximum turndown (energy
savings) without recycle or blow-off
machines
operating
(SCL)
big,
axials,
point
are
centrifugals
tied
and
together
thewhen
Surge
Line
Recycle
will
only
start
allControl
machines
are on their SCL
Minimizes the risk of surge since all machines absorb part of the
Lines
This
The
DEV
means
of equal
willinbe
practice
DEV
the can
same
the
befor
plotted
same
all machines
DEV
on the
for both
performance
but machines
they willcurves
operateasatshown
disturbance
different
speeds and
flow rates
Automatically
adapts
to different size machines
CCC patented algorithm
Compressor control
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If DEV
Master
The
In
When
the
output
primary
the
<=
controller
0machine
of
apply
the
response
loadsharing
controls
master
is close
block
controller
the
to the
gain
main
the SCL
controller
PID
Process
the
goes
Variable
to
checks
master
the primary
controller
if(PV)
the machine
via
response
its
will
PID
no
iscontrol
block
close
longerin
toblock
reduce
the
the SCL:
Output goes to antisurge valve
loadsharing
performance
controller
to
control
the primary
variable
Yes: to
dont
reduce
capacity
- keepisoutput
In order
check
if the
machine
close
to
constant
the
the controller
primary response
needs
TheSCL
master
will startblock
to open
the
No:
reduce
capacity
as
necessary
the
DEV
recycle valve to control the primary variable
Apply loadsharing gain M0
The DEV is reported by the antisurge
The
output of the master controller goes via
controller
the primary response block directly to the
performance control element
Master Controller
PV
PID
SP
Analog Inputs
Dont change
output
FA
Mode
No
DEV <
>0
DEV
DEV
DEV
Yes
PI
Apply loadsharing
gain
Primary
response
RT
Primary
response
x
+
Antisurge
Controller
Primary response
To
Toantisurge
performance
valve
control element
Loop
Decoupling
Loop
Decoupling
To antisurge valve
Compressor control
Loadsharing
Controller
To performance
control element
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This
In
Other
The
order
fast
antisurge
loadsharing
master
average
loadsharing
to
master
balance
controller
DEV
controller
controller
controller
is
controllers
the
sent
calculates
machines
reports
out
controls
reports
to
also
all
the
the
they
this
report
the
actual
need
The
load
balancing
block
is
a
slow
primary
to
DEV
their
average
loadsharing
bePV
to
DEV
kept
the
also
process
ofPV
at
all
load
controllers
the
to
to
reported
the
the
balancing
same
variable
master
master
DEV
DEV
toby
block
become
controller
controller
PVs
directly
in the SP
controller
that
will
equalize
all
DEVs
for all
manipulating
loadsharing
for
all load balancing
controller
the finalblocks
control elements
parallel compressors
This reported DEV becomes the Process
Its
output(PV)
is added
the balancing
total output
to
Variable
for thetoload
PID
the
loopperformance control element
DEV from other
loadsharing controllers
Master Controller
PV
PID
SP
Average
Analog Inputs
DEV
FA
Mode
DEV
DEV
DEV
PV
PI
Primary
response
RT
SP
Load
balancing
Primary
response
Antisurge
Controller
Loop
Decoupling
Loop
Decoupling
To antisurge valve
Compressor control
Loadsharing
Controller
To performance
control element
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Rc
PV
PID
PV
SP
PI
(One-Sided)
SP
Average
Analog Inputs
Relief valve
setting
POC-SP
DEV
Master Controller
operating
happen
pressure
valve
Override
faster
the
POC-SP
setting
than
that
Control
rises
point
aline
the
reduction
and
sharply
on
performance
the
(POC)
trip
the
antisurge
the
PIC-SP
in
mode
process
speed
control
that
line
valves
willstart
open
Fast
response
during
fast
upsets
element
the
to
close
antisurge
again
(e.g. valve
speed)
toisget
toothe
slow
disturbance
to keep the
Avoid process trips due to lack of
pressure
under
control
under
quickly
control
response in performance control elements
Allows closer operation to process limits
without taking risk
FA
Mode
DEV
DEV
DEV
PIC-SP
PV
PI
Primary
response
RT
SP
Load
balancing
Primary
response
Antisurge
Controller
Loop
Decoupling
Loop
Decoupling
Loadsharing
Controller
qr
To antisurge valve
Compressor control
To performance
control element
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RSP
Train A
Section 1
Section 2
out
UIC
1A
Serial
network
UIC
2A
Serial
network
LSIC
Serial
network
MPIC
Suction
Header
VSDS
Process
RSP
Train B
Section 1
Section 2
out
UIC
1B
Serial
network
UIC
1B
Serial
network
LSIC
How
Select
By
Share
selecting
tothe
per
operate
load
train
the--equidistant
--section
equal
in theDEVs
loadsharing
closest
from
forto
the
both
the
controller
Surge
trains
SCL Control
it--ison
--guaranteed
the
the
Line
section
section
(SCL)
that
closest
closest
when
the other
there
totothe
theis
more
section
SCL
than
on one
the same
section
train
perismachine
not in recycle
???
Compressor control
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PV
SP
PI
Both
The selected
lowest
antisurge
DEV
DEV
controllers
is is
selected:
report
the section
reported
their
to:closest
DEV to the
to the
loadsharing
SCL
Primarycontroller
control
response blocks
(One-Sided)
SP
DEV from other
loadsharing controllers
Master controller
averaging block
Average
Analog Inputs
FA
Mode
FA
Mode
DEV1
DEV1
PI
PV
RT
Primary
response
To antisurge valve-1
DEV2
DEV2
SP
Load
balancing
Primary
response
+
Antisurge
Controller
<
PI
+
Loop
Decoupling
Loop
Decoupling
Primary
response
RT
+
Loadsharing
Controller
To performance
control element
Compressor control
Antisurge
Controller
Loop
Decoupling
To antisurge valve-2
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Orifice plates
Venturis
Pitot tubes
etc.
Compressor control
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minimum possible
minimum possible
Suction
Discharge
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1 SEC.
100%
Ps
100%
ABC
D
DPo
Actual
pressure
Transmitter
output
63% response
100%
AB C
1- (1/e)
DPc
Time
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Flow 50
t = 16.0 s
t = 1.70 s
t = 0.03 s
t = 0.20 s
Actual Flow
-50
1.25
2.50
3.75
Time (seconds)
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Rc
Qvol
Compressor control
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Rc
A
Qvol
Compressor control
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Open to close
< 3 seconds
< 5 seconds
< 10 seconds
Closing time needs to be the same order of magnitude to assure the same
loop gain in both directions
Normally control valves are selected to be open 80% to 90% for design
conditions
In order to have an equal loop-gain over the whole operating range a linear
valve is required
This will allow for the fastest tuning leading to smaller surge margins
Compressor control
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Install positioner
Minimize tubing length between I/P and valve positioner
Install volume booster
Minimize volume and resistance between volume booster and actuator
Increase air supply line to 3/4 or more
Increase size of air connection into the actuator
Drill additional holes in actuator - avoids pulling a vacuum
Compressor control
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VSDS
Compressor 1
volume to be
minimized
Compressor control
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Section 2
Compressor control
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Section 1
Section 2
Small volume
Result
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Increased
volume due
to cooler
Compressor 2
Minimum
volume
Result
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Section 1
Section 2
Section 3
Suction
Process
Minimum
volume
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Section 2
Section 3
Suction
Process
Section 2
Section 3
Suction
Process
When selecting
lay-out
the most
residence
time
of
the
gas
in
the
surge
volume
Lay-out
These
two
#1
#2 piping
has
requires
minimum
lay-outs
one#2
cooler
volume
are
less
between
common
and thus
thefor
the
flanges
antisurge
capital
and
investment
is
control
the
bestislay-out
lower
should
be verified
to purposes
check acceptable time delays are not exceeded
for
antisurge
control
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Analog controller
100%
SCL
SLL
Operating
point
0%
Time
100%
Controller
output
0%
Time
Compressor control
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Digital controller
(2 executions per second)
100%
100%
SCL
SLL
Operating
point
0%
SCL
SLL
Operating
point
0%
Time
100%
Time
100%
Controller
output
0%
Time
Controller
output
0%
Tuning same as analog controller
Compressor surged
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Digital controller
(3 executions per second)
100%
100%
SCL
SLL
Operating
point
0%
SCL
SLL
Operating
point
0%
Time
100%
Time
100%
Controller
output
0%
Time
Controller
output
0%
Tuning same as analog controller
Compressor surged
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Fwd
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Digital controller
(10 executions per second)
100%
100%
SCL
SLL
Operating
point
0%
SCL
SLL
Operating
point
0%
Time
100%
Time
100%
Controller
output
0%
Time
0%
Tuning same as analog controller
Time
Controller
output
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100%
100%
SCL
SLL
Operating
point
0%
SCL
SLL
Operating
point
0%
Time
100%
Time
100%
Controller
output
0%
Time
0%
Tuning same as analog controller
Time
Controller
output
Adding Recycle Trip to PI control will allow even smaller surge margins
Compressor control
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Load
FT
1
PsT
1
TsT
1
PdT
1
Td T
1
PIC
1
HIC
1
UIC
1
Suction
Process
Serial
network
MODBUS
Start simulation
Compressor control
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RSP
Compressor 1
out
UIC
1
Serial
network
LSIC
Serial
network
Load
MPIC
HIC
1
Process
VSDS
RSP
Compressor 2
out
UIC
2
MODBUS
Serial
network
Start simulation
LSIC
Compressor control
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