CCC Turbomachinery Controls System -...

CCC CCC TurbomachineryTurbomachineryControls SystemControls System

Who is the CCC?Who is the CCC?Who is the CCC?

CCC is a CCC is a Controls CompanyControls Company dedicated to dedicated to making the operation of Turbomachinery making the operation of Turbomachinery

SafeSafe and and EfficientEfficient

Safe = No Missed CommissioningNo Production Loss

Efficient = Minimum Power

The CCC Product is Control SolutionsNext

1974 2008

• Offices Worldwide• +/- 400 Employees• 8300+ Installations• 200 Major Retrofit Projects/Year• World’s Largest GT Retrofitter

In Operation 34 YearsIn Operation 34 Years

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MTBF of Series 3 Plus controllers is 43.4 years, or 2.5 failures per million hours of operation

MultiMulti--loop controllers for speed, extraction, loop controllers for speed, extraction, antisurge, & performance control antisurge, & performance control

Serial communications for peer to peer Serial communications for peer to peer and host system communicationsand host system communications

Series 3+ ProductsSeries 3+ Products

Series 5 ProductsSeries 5 Products

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Vanguard Duplex ChassisVanguard Duplex Chassis

Power Supplies

IOC-555

MPU-750

Extended Card

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Series 5 Reliant DuplexSeries 5 Reliant Duplex

Switching Module

Connector for Remote Switch Module

Status Indicators

Manual Switchover

Pushbuttons

Same Electronics Assembly and Terminations as Reliant SN

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GuardianGuardian®® Overspeed Trip SystemOverspeed Trip System

• API-670 Compliant

• 2oo3 Voting of Speed Modules

• Redundant Power Supplies

• Hot-Swap Speed Modules

• ModbusComms

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VantageVantage®® Steam Turbine GovernorsSteam Turbine Governors

• Vantage GPfor API-611 General Purpose Turbines

• Vantage GDfor Generator Drive Turbines

• Local HMI for Configuration and Maintenance

• Reliant inan IP-54 Enclosure

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• NEMA 4 enclosure • Touch Screen Color

Graphics Operator Interface – Parameter monitoring – Alarms (visual and audible)– Events and data logging– Real-time trending of process

data– Control loop tuning and

maintenance screens– Remote network and web data

access• Optional Instrumentation

and Value Packages

Air MiserAir Miser®®TL EnclosureTL Enclosure

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Class 1, Div 2 / Class 1 Zone 2Class 1, Div 2 / Class 1 Zone 2ATEX Group 2 Class 3ATEX Group 2 Class 3Simplex or Simplex or ““hot backuphot backup”” redundantredundantAll AOAll AO’’s have builts have built--in feedback loops to identify in feedback loops to identify hardware or wiring problemshardware or wiring problems

Series 3++ ControllersSeries 3++ Controllers

OnOn--board temperature board temperature monitoringmonitoringOnOn--board power supply board power supply voltage monitoringvoltage monitoringWired Ethernet versionWired Ethernet versionCompletely backward Completely backward compatible with S3+compatible with S3+

Raising the Bar Advanced Raising the Bar Advanced Constraint ControlConstraint Control

UpstreamUpstreamimproved control strategies for load sharing, expanders, improved control strategies for load sharing, expanders, integration of networks across platformsintegration of networks across platforms

MidstreamMidstreamimproved control strategies for Boil Off Gas networks, improved control strategies for Boil Off Gas networks, intense focus on all primary LNG servicesintense focus on all primary LNG services

DownstreamDownstreambroader approach to process control, rather than just broader approach to process control, rather than just Turbomachinery control. Advanced control strategies for Turbomachinery control. Advanced control strategies for Ethylene, FCCU and PTA Plants. (Next focus is Ammonia). Ethylene, FCCU and PTA Plants. (Next focus is Ammonia).

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CCC Installations CCC Installations -- IndonesiaIndonesia

PT. Pupuk PT. Pupuk IskandarIskandar MudaMudaPT. Pupuk PT. Pupuk SriwidjayaSriwidjayaPT. Pupuk PT. Pupuk KujangKujangPT. Pupuk Kalimantan PT. Pupuk Kalimantan TimurTimurPT. DSM PT. DSM KaltimKaltim Melamine IndonesiaMelamine IndonesiaPT. Amoco Mitsui PTAPT. Amoco Mitsui PTAPT. PT. PolysindoPolysindo EkaEka PerkasaPerkasaPT. Chandra PT. Chandra AsriAsriPertaminaPertamina / Refinery (WGC / Refinery (WGC ExorExor Project)Project)ConocoPhillipsConocoPhillips IndonesiaIndonesiaExxonMobilExxonMobil Oil IndonesiaOil IndonesiaTotal Total IndonesieIndonesiePT. PT. KangeanKangean EnergiEnergi IndonesiaIndonesiaBP BP TangguhTangguh LNGLNGPT. PT. BadakBadak LNGLNGPT. PT. ArunArun LNGLNGPT. Indonesia Power (PLN)PT. Indonesia Power (PLN)Etc.Etc.

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1PT

Section 1

outout

RSP

ALSIC

Section 2

1AUIC

1AUICSerial

network

Train A

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Typical Single Train ControlsTypical Single Train Controls(Suction Pressure Controls)(Suction Pressure Controls)

Antisurge Controls System

Performance Controls System

Compressor RefresherCompressor Refresher

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Compressor TypeCompressor Type

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Compressors

Positive DisplacementCompressor Dynamic Compressor

Reciprocating Compressor

Rotary Compressor

Membrane Compressor

Screw Compressor

Centrifugal

Axial

CCC FocusCCC Focus

Where do the different types of Where do the different types of compressor fit?compressor fit?

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Types of Compressor Types of Compressor -- Dynamic Dynamic Compressors Compressors

Axial Compressor Centrifugal Compressor

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Types of Compressor Types of Compressor -- Dynamic Dynamic Axial CompressorsAxial Compressors

Stator Blades

RotorBlades

Casing

Rotor Blades

StatorBlades

Casing

Shaft

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Rotor

Stator

Cross section of axial compressorCross section of axial compressor

Compressor outlet nozzle

Rotor blades

Labyrinth sealsGuide-vane actuator linkageStator Blades

Compressor inlet nozzle

Thrust bearingAdjustable guide vanes

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Barrel (Centrifugal)Barrel (Centrifugal) Bullgear (Centrifugal)Bullgear (Centrifugal)

Types of Compressor Types of Compressor –– DynamicDynamicCentrifugal CompressorsCentrifugal Compressors

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Compressor inlet nozzle

Thrust bearing

Journal bearingShaft and labyrinth seal

Impeller inlet labyrinth sealsDischarge volutes

Impellers

Drive coupling

Casing (horizontally split flange)

Compressor discharge nozzle

Horizontally Split Type (Centrifugal)Horizontally Split Type (Centrifugal)Horizontally Split Type (Centrifugal)

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Types of Compressor Types of Compressor -- Picture of Picture of Horizontally Split Type (Centrifugal)Horizontally Split Type (Centrifugal)

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Types of Compressor Types of Compressor -- Principal of Principal of Operation (Centrifugal)Operation (Centrifugal)

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Single-Section, Three-Stage Single-Case, Two-Section, Six-Stage

Types of Compressor Types of Compressor -- ClassificationsClassifications

What is the function of this cooler?

IntercoolingIntercooling reduces energy consumptionreduces energy consumptionbut results in having multiple compressor mapsbut results in having multiple compressor mapswhich need separate which need separate antisurgeantisurge protectionprotection

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Parallel Network

Two-Case, Two-Section, Six-Stage

Series Network

Types of Compressor Types of Compressor -- ClassificationsClassifications

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Why Compressor SurgeWhy Compressor Surge……and what happens and what happens

when they dowhen they do

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Surge PhenomenonSurge Phenomenon

• From A to B…….20 - 50 ms…………….. Drop into surge• From C to D…….20 - 120 ms…………… Jump out of surge• A-B-C-D-A……….0.3 - 3 seconds……… Surge cycle

Qs, vol

Pd

Machine shutdownno flow, no pressure

• Electro motor is started• Machine accelerates

to nominal speed• Compressor reaches

performance curveNote: Flow goes up faster because pressure is the integral of flow

• Pressure builds• Resistance goes up• Compressor “rides” the curve• Pd = Pv + Rlosses

Pd = Compressor discharge pressurePv = Vessel pressureRlosses = Resistance losses over pipe

Developing the surge cycle on the Developing the surge cycle on the compressor curvecompressor curve

Pd

Pv

Rlosses

B A

CD

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Rapid flow oscillations Rapid flow oscillations Thrust reversalsThrust reversals

Potential damagePotential damage

FLOW

PRESSURE

TEMPERATURE

TIME (sec.)

1 2 3

TIME (sec.)

1 2 3

TIME (sec.)

1 2 3

Major Process Parameters during Major Process Parameters during SurgeSurge

• Rapid pressure oscillations with process instability

• Rising temperatures inside compressor

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Some surge consequencesSome surge consequences

Unstable flow and pressureUnstable flow and pressureDamage in sequence with increasing Damage in sequence with increasing severity to seals, bearings, impellers, severity to seals, bearings, impellers, shaftshaftIncreased seal clearances and leakage Increased seal clearances and leakage Lower energy efficiencyLower energy efficiencyReduced compressor lifeReduced compressor life

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Factors leading to onset of Factors leading to onset of surgesurge

StartupStartupShutdownShutdownOperation at reduced throughputOperation at reduced throughputOperation at heavy throughput with:Operation at heavy throughput with:

-- TripsTrips-- Power lossPower loss-- Operator errorsOperator errors-- Process upsetsProcess upsets-- Load changesLoad changes-- Gas composition changesGas composition changes-- Cooler problemsCooler problems-- Filter or strainer problemsFilter or strainer problems-- Driver problemsDriver problems

Standard Antisurge Standard Antisurge Control Vs CCC Controls Control Vs CCC Controls

SystemSystem

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Flow

Pressure

minimum speed

maximum speedsurge limit

stonewall orchoke limit

power limit

process limit

stable zonestable zoneof operationof operation

adding control margins

Actual availableoperating zone

CCC Business in Constraint ControlCCC Business in Constraint Control

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Expanding the Operating EnvelopeExpanding the Operating Envelope

Operating Point

Limit

Operating Point

Setpoint

Base Ingredients:- Advanced algorithms- Rate of change feed forward signals- Fast hardware

Limit

Setpoint

General Purpose Control

CCC Control

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Standard Antisurge ControlStandard Antisurge Control

1UIC

CompressorCompressor

1FT

1PsT

ProcessSuction

1PdT

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AntisurgeController

Recycle Valve

Conventional Control Using Separate Conventional Control Using Separate Performance RecyclePerformance Recycle


ProcessSuction 1UIC

1FT 1

PsT1

PdT

1PIC

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ConventionalCapacity/PerformanceController

Additional Recycle Valve

Why Invest in Advanced Why Invest in Advanced Controls?Controls?

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How Will CCC How Will CCC ControlControl??

Antisurge Control?Antisurge Control?Capacity Control?Capacity Control?

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CCC Controls SystemCCC Controls System

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1UIC

VSDS

Compressor

1FT

1PsT

1TsT

ProcessSuction

1PdT

1TdT

1ST

1PIC

1HIC

Load

Serial network

AntisurgeController

PerformanceController

Control System ObjectiveControl System Objective

Control System Objectives:Control System Objectives:

The control system objective is to keep the The control system objective is to keep the process on its Primary Process Variable (PV) process on its Primary Process Variable (PV) setset--point, and to return it to setpoint, and to return it to set--point as quickly point as quickly as possible after a process disturbanceas possible after a process disturbance

The control system has to keep the process The control system has to keep the process on/return to seton/return to set--point while operating within point while operating within compressor operating envelope limits, including compressor operating envelope limits, including protection against surge and surge damageprotection against surge and surge damage

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Challenges of Compressor Challenges of Compressor Control SystemControl System

The ingredients of a successful compressor control systemThe ingredients of a successful compressor control systemare:are:

An algorithm that can accurately locate the operating point An algorithm that can accurately locate the operating point and its corresponding surge limitand its corresponding surge limitA controller execution speed that will allow a digital controlleA controller execution speed that will allow a digital controller r to emulate immediate analog controlto emulate immediate analog controlControl responses that allow different margins of safety for Control responses that allow different margins of safety for different operating conditionsdifferent operating conditionsAdvanced control strategies that can avoid the negative Advanced control strategies that can avoid the negative effects of loop interactioneffects of loop interactionA quick acting, correctly sized antisurge control valveA quick acting, correctly sized antisurge control valveThe elimination of unnecessary dead time or lag time within The elimination of unnecessary dead time or lag time within the systemthe systemValid load sharing strategiesValid load sharing strategies

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Standard Control VS CCC Standard Control VS CCC ControlsControls

StandardStandard CCCCCC

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1UIC

VSDSCompressor

1FT 1

PsT

1TsT

ProcessSuction

1PdT

1TdT

1ST 1

PIC

1HIC

Load

Serial network


ProcessSuction 1UIC

1FT 1PsT

1PdT

1PIC

Standard Control VS CCC Standard Control VS CCC ControlsControls

StandardStandard15% surge margin15% surge marginQuick opening valvesQuick opening valvesNo control of process No control of process variable via recyclevariable via recycleNo invariant coordinatesNo invariant coordinatesConcentrating on Concentrating on ‘‘ProtectionProtection’’

CCCCCCTypically 8% surge marginTypically 8% surge marginLinear valves with Linear valves with positioners for control positioners for control across 100% rangeacross 100% rangeControl of primary process Control of primary process variable by recycle when variable by recycle when speed limit is reachedspeed limit is reachedCan handle varying Can handle varying molecular weight gasesmolecular weight gasesConcentrating on Concentrating on ‘‘Control Control and Protectionand Protection’’

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CCC CCC ControlController protectionler protection

How CCC How CCC AntisurgeAntisurge Controller Controller protects compressor against protects compressor against surge?surge?

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1UIC

VSDS

Compressor

1FT

1PsT

1PdT

• The antisurge controller UIC-1 protects the compressor against surge by opening the recycle valve

DischargeSuction

Rc

qr2

Rprocess

Rprocess+valve

Antisurge Controller Operation Protection #1 Antisurge Controller Operation Protection #1 The Surge Control Line (SCL)The Surge Control Line (SCL)

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A

Rc

B When the operating point When the operating point crosses the SCL, PI crosses the SCL, PI control will open the control will open the recycle valverecycle valve

PI control will give PI control will give adequate protection for adequate protection for small disturbancessmall disturbances

SLL = Surge Limit LineSCL = Surge Control Line

qr2

Antisurge Controller Operation Protection #1 Antisurge Controller Operation Protection #1 The Surge Control Line (SCL)The Surge Control Line (SCL)

• PI control will give stable control during steady state recycle operation

• Slow disturbance exampleNext

A

Rc

B

• When the operating point moves quickly towards the SCL, the rate of change (dS/dT) can be used to dynamically increase the surge control margin.

• This allows the PID controller to react earlier.

• Smaller steady state surge control margins can be used w/o sacrificing reliability.

• Fast disturbance exampleQ2

Antisurge Controller Operation Protection #2 Antisurge Controller Operation Protection #2 Moving The Surge Control Line (SCL)Moving The Surge Control Line (SCL)

SLL = Surge Limit LineSCL = Surge Control Line

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Antisurge Controller Operation Protection #3 Antisurge Controller Operation Protection #3 The Recycle TripThe Recycle Trip®® LineLine ((RTLRTL))

Benefits:– 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

SLL = Surge Limit LineRTL = Recycle Trip Line

SCL = Surge Control Line

Output to Valve

Time

Open-loop Response

PI Control Response

PI Control Step Change

+

To antisurge valve

Total Response

Rc

Q2

OP

Next

After time delay CAfter time delay C22 controller checks if Operating Point is back to controller checks if Operating Point is back to safe side of safe side of Recycle TripRecycle Trip®® LineLine

-- If If YesYes: Exponential decay of : Exponential decay of Recycle TripRecycle Trip®® responseresponse..

Output to valve

Time

One step response

PI ControlRecycle Trip®

Total

100%

0%

C2

Multiple step responseOutput to valve

Time

PI Control

Recycle Trip®

Total

C2 C2 C2

What if one Recycle TripWhat if one Recycle Trip®® step step response is not enough?response is not enough?

- If No: Another step is added to the Recycle Trip®

response.

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Output to Recycle Valve

InputOutput to Turbine ValveSpeed InputsSpeed Inputs

Antisurge InputsAntisurge Inputs

Process Variable InputsProcess Variable Inputs

Serial Communication Link CCC-DCS

Flow

Pressure

Temperature

Gas Data

(Field Transmitter)

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Integrated control Decoupling of Integrated control Decoupling of Performance and Performance and AntisurgeAntisurge controlcontrol

∆Po

PIC-SP

Rc

Ps

SLL

SCL

AC

B

Integrated control Decoupling of Integrated control Decoupling of Performance and Performance and AntisurgeAntisurge controlcontrol

2. 2. The decoupling control starts to actThe decoupling control starts to actPerformance control send request Performance control send request to increase speedto increase speed

3. 3. The speed increasing combined with The speed increasing combined with antisurgeantisurge valve opening, then,valve opening, then,The trace of operating line as shownThe trace of operating line as shown

4. 4. The net control effect is more The net control effect is more stable operation even with large stable operation even with large process disturbanceprocess disturbance

5. 5. This decoupling control is can This decoupling control is can reduce the control safety margin, reduce the control safety margin, Therefore it can achieve energy Therefore it can achieve energy saving and safe operationsaving and safe operation

1. When operating at Point A, process 1. When operating at Point A, process encounters a large disturbance,encounters a large disturbance,operating point will move to Point Boperating point will move to Point B

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Antisurge Controller Operation Antisurge Controller Operation Protection #4 Protection #4 ““Safety OnSafety On””

How about if the protection not capable How about if the protection not capable against surge?against surge?

Compressor has real surgeCompressor has real surge

What will CCC controller do?What will CCC controller do?

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SCL = Surge Control Line

• If Operating Point crosses the Safety On® Line the compressor is in surge

SLL = Surge Limit LineRTL Line = Recycle Trip®

• The Safety On® response shifts the SCL and the RTL to the right

New SCL

New RTL

• Additional safety or surge margin is added

Additional surge margin

• PI control and Recycle Trip® will stabilize the machine on the new SCL

SOL = Safety On® Line

Pres

sure

axi

s

Flow axis

Antisurge Controller Operation Protection #5 Antisurge Controller Operation Protection #5 ““Safety OnSafety On””

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CCC CCC LOAD SHARING CONTROLS LOAD SHARING CONTROLS

SYSTEMSYSTEM

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Compressors are often operated in parallel and sometimes in seriCompressors are often operated in parallel and sometimes in serieses

The purposes of networks include:The purposes of networks include:RedundancyRedundancyFlexibilityFlexibilityIncremental capacity additionsIncremental capacity additions

Often each compressor is controlled, but the network is ignoredOften each compressor is controlled, but the network is ignored

Compressor manufacturers often focus on individual machinesCompressor manufacturers often focus on individual machines

A A ““network viewnetwork view”” of the application is essential to achieve good of the application is essential to achieve good surge protection and good performance control of the network.surge protection and good performance control of the network.

Compressor networksCompressor networks

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Control system objectives for compressors in parallel:Control system objectives for compressors in parallel:Maintain the primary performance variable (in this case Maintain the primary performance variable (in this case suction pressure), and then:suction pressure), and then:Optimally divide the load between the compressors in the Optimally divide the load between the compressors in the network, while:network, while:

•• Minimizing risk of surgeMinimizing risk of surge•• Minimizing energy consumptionMinimizing energy consumption•• Minimizing disturbance of starting and stopping Minimizing disturbance of starting and stopping

individual compressorsindividual compressors•• Operating within limitsOperating within limits

Load SharingLoad Sharing

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Load Sharing Control system types:Load Sharing Control system types:

1. Base and Swing Load Sharing system1. Base and Swing Load Sharing system2. Equal Flow Load Sharing system2. Equal Flow Load Sharing system3. CCC Equidistance Load Sharing controls system3. CCC Equidistance Load Sharing controls system

Load SharingLoad Sharing

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Process

PIC1

1UIC

VSDS

Compressor 1

2UIC

VSDS

Compressor 2

HIC1

Suction header

Swing machine

Base machine

Notes• All controllers act

independently• Transmitters are

not shown

Base and Swing Load SharingBase and Swing Load SharingFlow Diagram for Control ProcessFlow Diagram for Control Process

Next

Rc,1

qr,12

Rc,2

qr,22

Compressor 1 Compressor 2

PIC-SP

Swing machine Base machine

QC,2= QP,2QC,1QP,1

where:QP = Flow to processQC= Total compressor flowQC - QP = Recycle flow

QP,1

QP,1 + QP,2 = QP,1 + QP,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

Base and Swing Load Sharing Base and Swing Load Sharing Parallel Compressor ControlParallel Compressor Control

QP,2

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Process

PIC1

1UIC

Compressor 1

VSDS

Compressor 2

Suction header

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 FMD’s

1FIC

2FIC

2UIC

outout

out

RSPRSP

RSPRSP

RSPRSP

outout

RSPRSP

Equal Flow Load sharingEqual Flow Load sharingFlow Diagram for Control ProcessFlow Diagram for Control Process

VSDS

Next

Notes:• Requires additional capital investment in

FMD’s• Requires additional energy due to

permanent pressure loss across FMD’s• Poor pressure control due to positive

feedback in control system (see next)• Equal flow division is NOT recommended

Rc,1

qr,12

Rc,2

qr,22

PIC-SP

QP,1 QP,2QC,2

Equal flow Equal flowQP,1 = QP,2

Equal Flow Load sharingEqual Flow Load sharingParallel Compressor ControlParallel Compressor Control


where:QP = Flow to processQC= Total compressor flowQC - QP = Recycle flow

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Notes• All controllers are

coordinating control responses via a serial network

• Minimizes recycle under all operating conditions

Process

1UIC

VSDS

Compressor 1

VSDS

Compressor 2

Suction header

1LSIC

2UIC

out

RSP

Serial network

out

RSP

2LSIC

1MPIC

Serial network

Serial network

CCC Equidistance Load sharingCCC Equidistance Load sharingFlow Diagram for Control ProcessFlow Diagram for Control Process

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PIC-SP

0.10.2

0.3

DEV = 00.1

0.20.3

DEV1 DEV2

SCL = Surge Control LineRc,1

qr,12

Rc,2

qr,22


Dev1 = Dev2Q1 = Q2N1 = N2

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

CCC Equidistance Load sharingCCC Equidistance Load sharingParallel Compressor ControlParallel Compressor Control

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Loop Decoupling

FAMode

PI

Loop Decoupling

+

Analog Inputs

+

DEV

To antisurge valve To performance control element

PID

Loadbalancing

PV

PV

SP

Primaryresponse

DEV DEV

DEV

DEV from other loadsharing controllers

Primaryresponse

Average

SP

The load balancing responseThe load balancing response

Loadsharing Loadsharing ControllerController

Antisurge Antisurge ControllerController

Master Controller

RT

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CCC LOAD SHARINGCCC LOAD SHARINGControl System DrawingControl System Drawing

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MASTER CONTROLLER(Suction Header Controls)

LOAD SHARING CONTROLLER

ANTISURGE CONTROLLER

End SlidesEnd SlidesThank You very much for your Thank You very much for your kind attention and cooperationkind attention and cooperation

PT Putranata Adi Mandiri

Jl Kartini VIII No. 9

Jakarta 10750

Tel: (021) 6007850

Fax: (021) 6007846

Email: [email protected]

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