Gas Turbine

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Challenges andOpportunities in

Turbomachinery Control

Challenges andOpportunities in

Turbomachinery Control

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AgendaAgenda

• Understanding the financial impact of turbomachinery control systems

• Turbo-compressor control

• Gas turbine control

• Specification writing

• CCC products and services

Salah Salem:Salah Salem:Salah Salem:Salah Salem:

Salah Salem:Salah Salem:

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Machinery

Process

Controls

CCC Turbomachinery

Controls

CCC Turbomachinery

Controls

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Lifecycle costsLifecycle costs

30-year life cycle costs for a 20,000 hp compressor

Costs in constant dollars

Source: “Experiences in Analysis and Monitoring Compressor Performance”Ben Duggan & Steve LockeE.I. du Pont, Old Hickory, Tennessee24th Turbomachinery Symposium

Maintenance Cost$4.5 Million

Initial Cost $1.5 Million

Energy Cost$180 Million

97% of total costs

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Lifecycle costsLifecycle costs

Source: “Experiences in Analysis and Monitoring Compressor Performance”Ben Duggan & Steve LockeE.I. du Pont, Old Hickory, Tennessee24th Turbomachinery Symposium

30-year costs per a 1,000 hp

What can we control?

0.0

5.0

10.0

15.0

Initial Cost Maintenance Energy Lost Production

$ Millions

?

Controllable

UncontrollableCosts in constant dollars

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Key Issues on Turbomachinery Controls

Key Issues on Turbomachinery Controls

• Energy consumed by turbomachinery is a major cost of operation in process plants and oil production operations

• Poor control is a major risk to the safe and reliable operation of turbomachinery

• The economic consequences of non-availability of turbomachinery is large

• Poor control can lead to false limitations on production

• Capable support services are critical to the successful application of turbomachinery controls

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Profit Enhancement Opportunities for CCC Customers

Profit Enhancement Opportunities for CCC Customers

• Maximize reliability of machinery and process:– Prevent unnecessary process trips and

downtime– Minimize process disturbances – Prevent surge, overspeed and associated

damage – Automate startup and shutdown

• Increase efficiency of machinery and process:– Operate at lowest possible energy levels– Minimize antisurge recycle or blow-off– Optimize loadsharing of multiple units– Operate close to limits, safely

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Control Retrofits are Economically Attractive

Control Retrofits are Economically Attractive

• Typical turbomachines last 30 years or more

• Control systems are technically obsolete in 10 years

• Old control systems may not be maintainable due to unavailability of Electronic component

• Newer control systems offer– Better performance– Better machinery protection– Better system availability

• Improved electronic components• Redundancy

• ROI (Return On Investment) can be attractive due to production increases and energy savings

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TurbinesGas

Turbines

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Challenges and opportunities in gas turbine control

Challenges and opportunities in gas turbine control

• Integration with controls of driven object (compressor, generator or pump)

The Control system of both the Gas Turbine as well as the compressor on the same seamless platform

Better control system in order to maintain or maximize machine and associated process reliability.

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ClassificationGas Turbines

Classification

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ClassificationsClassifications• Application

– Fixed speed - electrical power generation– Variable speed- mechanical drives, pumps, compressors

• Design– Industrial, heavy duty, robust long life– Aircraft derivative, lightweight, derated for stationary

applications

• Rotor– Single shaft (usually generator applications)– Dual shaft– Three shaft (aeroderivative types)

• Cycle– Simple cycle– Regenerative– Cogeneration, waste heat

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Heavy duty , One shaft Gas Turbine (FS7001)

Heavy duty , One shaft Gas Turbine (FS7001)

• One shaft gas turbine– Limited speed range– Heavy starting device

• Diesel• Steam turbine• E-motor

– High power class up to 110MW

FS5001W251

V63

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Heavy duty , One shaft Gas Turbine

Heavy duty , One shaft Gas Turbine

FS5001W251

V63

NHP NPT=

CDP

EGT (T4)B.V

Starter

Motor

IGV

EGT (T3)

T1

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SURGE EFFECT ON G.T. AIR COMPRESSOR

SURGE EFFECT ON G.T. AIR COMPRESSOR

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Combustion linersCombustion liners

GT Classification

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Exhaust Gas Temperature (EGT)Exhaust Gas Temperature (EGT)

T/C

Combustion Chambers

Flame Tubes

Thermo Couple Harness

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Two shaft aeroderivativesTwo shaft aeroderivatives

• Two shaft gas turbines– Variable speed range– Low power starting

device• Gas expander• E-motor• Hydraulic motor

LM2500AVONSaturn

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Two shaft aeroderivativesTwo shaft aeroderivatives

EGT (T4) EGT (T6)

CDP NPT

B.V

Starter

Motor

T1

NGGFuel Gas F.G.

Manifold

EGT (T3)

IGV

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Three shaft aeroderivativeThree shaft aeroderivative

• Three shaft gas turbine– Variable speed– Complex machines– VBV’s, VSV’s, IGV’s

RB211

LM1600LM5000GG4

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Three shaft aeroderivativeThree shaft aeroderivative

NPTT1

EGT (T6)

NLP

NHP

LP HP LPHP

EGT (T4)

T21 EGT (T3)

CDP

Starter

Motor

IGV

B.V

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Firing temperatureFiring temperature

Firing Temp Location

Firing temp.

Cost $

Fuel cost /kWh

Maintenance cost /kWh

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Inlet Guide Vanes and

Variable Stator Vanes

Restricts the volume flow

through the GT Compressor

Inlet Guide Vanes and

Variable Stator Vanes

Restricts the volume flow

through the GT Compressor

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IGV, VSV, VBV assemblyIGV, VSV, VBV assembly

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Variable Stator VanesVariable Stator Vanes

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LPSpeed

HPSpeed

T1

IGV, VBV and VSV controlIGV, VBV and VSV control

LP speed = Low Pressure Turbine speed

LPSpeed

HP speed = High Pressure Turbine speed

HPSpeed

T1 = Compressor Inlet Temperature for correction

T1

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Gas turbines with

second stage Nozzles

Control impacts

Gas turbines with

second stage Nozzles

Control impacts

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Two shaft industrial GT with 2nd stage nozzles

Two shaft industrial GT with 2nd stage nozzles

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2nd stage nozzle control2nd stage nozzle control

• Why Nozzles– Second stage Nozzles allow the HP turbine to run at its

optimal speed for better fuel efficiency. They remain at EGT limit

• Control implication– There is a strong interaction between NHP, FCV and Nozzle

control. This requires decoupling of controllers

• Start-up– Nozzles are open during start-up – Close at NHP idle speed

• Which GT’s has them– General Electric FS3002 and FS5002– Nuovo Pignone PGT5 and PGT10

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Two shaft industrial gas turbine Two shaft industrial gas turbine

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2nd stage nozzle assembly2nd stage nozzle assembly

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Efficiency Increases

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Regenerative gas turbine cycleRegenerative gas turbine cycle

•Efficiency improvementapprox. 30%

•Better fuel efficiency •approx. 25%

•Higher initial cost

•Higher maintenance cost

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CogenerationCogeneration

Tu

rbin

e

Gas turbine

Compressor SteamTurbine

Generator

•CogenerationGas turbineSteam turbineBoilerGenerator

•EfficiencyBetween 40% and 58%

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Gas turbine limits

of operation

Control limits

Gas turbine limits

of operation

Control limits

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PT speed

T ambient

90º

Gas turbine Performance mapsGas turbine Performance maps

Power

Slides at const Tamb

PT speed

T ambient

Power

PT speed

T ambient

This map is hard to visualize because of the 3D aspect.

90º

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Restrains and control limiting in the GT performance map

Restrains and control limiting in the GT performance map

PT speed

Power Power

T ambient

PhysicalMachine limits

PhysicalMachine limits

NPTunderspeed NPToverspeedCDPNGGEGT

Control Margins

Stable zoneof operation

Safe zone of operation

Safe zone of operation

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0

10

20

30

40

50

60

70

80

90

100

48:0

0.0

48:4

1.0

49:1

6.0

49:5

9.0

50:4

4.0

51:2

7.0

52:0

9.0

52:5

3.0

53:3

8.0

54:2

3.0

55:2

7.0

55:5

3.0

56:3

8.0

57:2

3.0

58:0

8.0

58:5

3.0

59:3

8.0

00:2

3.0

01:0

8.0

01:5

3.0

02:3

8.0

03:2

2.0

04:0

7.0

04:5

2.0

05:3

7.0

06:2

2.0

07:0

6.0

07:4

9.0

08:3

2.0

09:1

7.0

10:0

2.0

10:4

7.0

11:3

1.0

12:1

6.0

13:0

1.0

13:4

6.0

14:3

1.0

15:1

6.0

16:0

1.0

Time (Min)

% o

f fu

ll s

cale

Npt EGT Ngg FCV CDP

Start-up of RR Avon (real data)Start-up of RR Avon (real data)

GG IdleGG Idle

GG PurgeGG Purge

StartStart

IgnitionIgnition

GG controlGG control PT controlPT control

PT Warm upPT Warm up

Ngg

EGT

NPT

CDPFCV

NPT RatedNPT Rated

Min Gov.Min Gov.

Max Gov.Max Gov.

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Fuel systems

and valves

Fuel systems

and valves

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Fuel valveFuel valve

FUEL CONTROL VALVE

• Essential part in the control chain

• Specifications– High repeatability– High Accuracy– Robust– Short stroking time– Good fuel flow controllability during ignition and

normal operation

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Example: Simplified Fuel systemExample: Simplified Fuel system

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Standard Fuel System ExamplesStandard Fuel System Examples

P2

SpeedRatiovlv

FuelControl

vlv

GE Standard

FuelControl

vlv

Ignitionvlv

FCV with separate Ignition Valve

FuelControl

vlvIgnition

vlv

FCV with separate Ignition System

P

CCC 8402 Fuel Control

vlv

CCC solution 8402 FCV

44

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CCC 8420 Fuel Valve

The 8402 Fuel Control Valve

• A high quality, high performance fuel control valve • The 8402 is equipped with an electric stepper motor actuator

which can fully stroke the valve in only 250 milliseconds. • The valve has a 500:1 turn down ratio to provide precise fuel

delivery to the turbine from light off to maximum power. • The digital encoder for position measurement provides position

repeatability of 0.05 %.

45

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CCC Fuel Valve

Stepper MotorDigital Encoder

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Real valve installationReal valve installation

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Conventional and

Advanced Control Systems

Conventional and

Advanced Control Systems

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Conventional Control SystemConventional Control System

UIC

SIC

PIC

Gas generatorPower

TurbineProcess

Compressor

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Conventional Control ConseptConventional Control Consept

Completely independent controllers Controllers:

- Stand-alone PID Compressor performance control- Stand-alone PID Compressor anti-surge system - Stand-alone PID gas turbine fuel controller

Communication- None

Decoupling- None

Type of control- PID control

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Advanced Control SystemAdvanced Control System

UIC

SIC

PIC

Gas generatorPower

TurbineProcess

Compressor

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Advanced Control ConceptAdvanced Control Concept

Completely integrated concept

Controllers:- Integrated Compressor performance control

- Integrated Compressor anti-surge protection

- Integrated gas turbine fuel controller

Communication- High speed communication of statuses and values

Decoupling- Yes between all controllers

Type of control- Advanced control with patented algorithms

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Advanced Control ConceptAdvanced Control Concept

Simulation of

Control Systems

Simulation of

Control Systems

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Press.RatioPress.RatioPress.RatioPress.RatioPress.Ratio

PressureSet point

Flow

Press.Ratio

Flow

A

Power

OutputPower

NN maxN min

A

C

A

Diagram

Compressor Power MapCompressor Power Map GT. Performance MapGT. Performance Map

Compressor MapCompressor MapSpeed curve

EGT

Speed curve

Over Temp.Trip Area

Flame outTrip Area

SurgeLimitLine

ControlLine

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Press.RatioPress.RatioPress.RatioPress.Ratio

PressureSet point

Flow

Press.Ratio

Flow

A

Power

OutputPower

NN maxN min

A

C

A

Diagram

Point A = stable operating pointTHEN : Big Process Upset by a flow reduction

Point A = stable operating pointTHEN : Big Process Upset by a flow reduction

PressureSet point

EGT

Speed curve

Over Temp.Trip Area

Flame outTrip Area

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Press.RatioPress.RatioPress.Ratio

PressureSet point

Flow

Press.Ratio

Flow

AB

Power

OutputPower

NN maxN min

AB

C

A

B

Pressure increases , Flow reduction(this depends on the system volume)

At Point B , the Anti-Surge Recycle Control Valve starts to OPEN

At Point B , the Anti-Surge Recycle Control Valve starts to OPEN

PressureSet point

EGT

Speed curve

Over Temp.Trip Area

Flame outTrip Area

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Press.RatioPress.Ratio

PressureSet point

Flow

Press.Ratio

Flow

ABC

Power

OutputPower

NN maxN min

AB

CC

A

B

Approach to SURGE

C

PressureSet point

EGT

Speed curve

Over Temp.Trip Area

Flame outTrip Area

At Point C , the Operating point is on the SLLAt Point C , the Operating point is on the SLL

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Press.Ratio

PressureSet point

Flow

Press.Ratio

Flow

ABC

D

Power

OutputPower

NN maxN min

AB

C

D

D

A

B

SURGE

C

At point D , The compressor is surgingHigh risk of loss of flame

At point D , The compressor is surgingHigh risk of loss of flame

C

Flame outTrip Area

EGT

Speed curve

Over Temp.Trip Area

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PressureSet point

Flow

Press.Ratio

Flow

ABC

D

E

E

Power

OutputPower

NN maxN min

AB

C

DE D

A

B

Flow recovery

C

At point EHigh risk of an over temperature trip , or PT under speed trip

At point EHigh risk of an over temperature trip , or PT under speed trip

C

Over Temp.Trip Area

NPT under-speed

Area

PressureSet point

EGT

Speed curve

Over Temp.Trip Area

Flame outTrip Area

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PressureSet point

Flow

Press.Ratio

Flow

ABC

D

E

E

Power

OutputPower

NN maxN min

AB

C

DE D

A

B

Pressure recovery

CC

PressureSet point

EGT

Speed curve

Over Temp.Trip Area

Flame outTrip Area

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PressureSet point

F

Flow

Press.Ratio

Flow

ABC

D

E

E

Power

OutputPower

NN maxN min

AB

C

DE

FD

F

A

BC

Finally after a tour through the performance map, the process is at set point

Finally after a tour through the performance map, the process is at set point

AT SET POINT

C

PressureSet point

EGT

Speed curve

Over Temp.Trip Area

Flame outTrip Area

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What Can Be ImprovedWhat Can Be Improved

Avoidance of flame out- Fuel valve movement limiting during surge detection .

Limit the fuel valve rate of change limit for a specified time.

Avoidance of Over temperature trip- Derivative Exhaust temperature set point reduction.

As function of the rate of change of the EGT and CDP

Avoidance of Surge- Integrated control solution by using:

•Feed forward and De-coupling between all controllers•Patented control algorithms

–Derivative Close and open loop control –Pressure override control

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Simulation set-upSimulation set-up

• Tests:– Conventional PID control only– Conventional PID control and restricted FCV movement– Conventional PID control with Recycle Trip (open loop

response) and restricted FCV movement– Fully integrated control

• Settings:– Control settings were identical for all four tests

• Starting point:– Compressor with discharge valve fully open– Maximum discharge pressure– Recycle valve closed

• Test:– Step to close position of the process compressor discharge

valve

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Displayed test resultsDisplayed test results

Discharge pressure vs. flow

– Conventional PID control

– Conventional PID control with restricted FCV movement

– Conventional PID control integrated with R.T response and restricted FCV movement

– Total integrated solution

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Compressor Map Pd vs. Flow

Conventional Stand alonePID control

Conventional Stand alonePID control

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Conventional Stand alone PID control withRestricted FCV movement

Conventional Stand alone PID control withRestricted FCV movement

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Conventional Stand alone PID control with Restricted FCV movementand Recycle Trip™

Conventional Stand alone PID control with Restricted FCV movementand Recycle Trip™

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Fully integrated CCCTotal Train Control™ System

Fully integrated CCCTotal Train Control™ System

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Displayed test results

Comparison Charts of the four tests:-

- Compressor Discharge Pressure vs. Time scale

- Fuel Control Valve position (Power) vs. Time scale

- Exhaust Gas Temperature (EGT) vs. Time scale

- Power Turbine Speed vs. Time scale

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Compressor Discharge Pressure vs. Time

Compressor Discharge Pressure vs. Time

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Fuel Control Valve position (Power) vs. Time

Fuel Control Valve position (Power) vs. Time

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Exhaust Gas Temp vs. TimeExhaust Gas Temp vs. Time

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PT speed vs. TimePT speed vs. Time

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ConclusionsConclusions

• Gas turbine Fuel stroke limiting during a surge event:– Avoids a Gas turbine “loss of flame” trip– Reduces the magnitude of thermal and mechanical

stresses – Doesn’t affect the process response

• Exhaust temperature set point reduction– Prevents the gas turbine from an over temperature trip– Eliminates the need for unnecessary big control margins

on the Exhaust Gas Temperature limit

• Integrated solution– Avoids surge– Reduces the number of surge events, if they happen– Reduces the magnitude of process upsets– Reduces the magnitude of thermal and mechanical

stresses

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Minimizing GT Operating Margins

Minimizing GT Operating Margins

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Flexibility of CCC’s Fuel ControllerFlexibility of CCC’s Fuel Controller

NPT PID

EGT PID

CDP Limit CDP PID

Ngg PIDNgg Limit

Accel. Limit

Decel. Limit

Auto. Sequence

Ramp Control

EGT Limit

M

I

N

.

S

E

L

E

C

T

O

R

NPT S.P. M

A

X

.

S

E

L

E

C

T

O

R

FCV PID

T1

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EGT control algorithmEGT Limit

EGT Calc.Max

MedianAverage

EGT Calc.Max

MedianAverage

d

dt

d

dt

Kp * Td

Kp * Td -

+

EGT

Time

PID +

-

L

.

S

.

S

EGT SpreadEGT Spread

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OPEN LOOP RESPONSEF

uel

D

eman

dE

GT

Time

Time

Trip Limit

Open Loop S.P.

Closed Loop S.P.

Dead time

Close FCV

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EGT During Hot Start before and after Improved Control System

0 10 20 30 40 50 60 70 80 90

1200

1100

1000

900

800

700

600

500

400

300

200

100

0

sec

Deg F Original Control System

Improved Control System

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Maximum continuous running temperature

More power from your gas turbine!

CCC’s Unique EGT Control

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GG Speed (N1) Control AlgorithmGG Speed (N1) Control Algorithm

Ngg Limiting S.P.

d

dt

d

dt

Kp * Td

Kp * Td - +

PID +

-

L

.

S

.

SNgg

Ngg Control S.P. (Idle Speed)

Fuel Flow

Ngg

Decel Limit

Accel Limit Steady

State

H

.

S

.

S

Accel. Limit

Decel Limit

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NPT (N2) control algorithm

d

dt

d

dt

Kp * Td

Kp * Td - +

PID +

-

L

.

S

.

S

NPT

NPT HI Limiting S.P.

NPT LOW Limiting S.P.

NPT W.U. Speed S.P.

NPT Speed Load Control S.P.

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CDP control algorithm

L.S.S.

d

dt

d

dt

Kp * Td

Kp * Td

PID +

-

CDP

CDP Limiting S.P.

G.T. CompressorSurge Detected

Alarm / Shutdown

G.T. CompressorSurge Detected

Alarm / Shutdown

Fuel Flow

CDP

Decel Limit

Accel Limit Steady

State

H

.

S

.

S

Accel. Limit

Decel Limit

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Introduction to

Series 5

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Open Industry Standards in Series 5 Open Industry Standards in Series 5

Open hardware standards • cPCI bus standard• Power PC CPU• Open IO conditioning interfaceOpen software standards• OSE hardware real time OS from OSE systems• ProCon OS from KW software• Full-scale IEC-61131 programming environment • Win2000 compatible operator interfaceOpen network communication standards• 10 base-t Ethernet (TCP/IP)• Profibus DP• OPC• 16-bit Modbus RTU• Active-X Remote Access

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Series 5 Product FamiliesSeries 5 Product Families

VANGARD Control System

• Flexible Hardware Configuration• Available in Simplex and Duplex F.T. versions• Hot-swappable modules• Remote I/O capability• I/O scan and processes is within 2.5 msec.• Powerful CPU , combine high-speed control with sequencing• Advanced self-diagnostic features• Fast and reliable communication links, including both Ethernet and

serial communication

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Series 5 Product FamiliesSeries 5 Product Families

RELIANT Control System

• Rack/Panel Mount Packaging• Integrated Terminations• Serial Communications• 3 Fixed Hardware Configurations

• Simplex, non-conditioned I/O• Simplex, conditioned I/O• Duplex, non-conditioned I/O

• Cost Effective Solution for Smaller System• Simplex or Duplex• Continuous and small logic control

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Power SuppliesPower Supplies

LOCAL I/O CARD

IOC-555

LOCAL I/O CARD

IOC-555

MPU-750MPU-750

REMOTE I/O CARD

RCC-PBM

REMOTE I/O CARD

RCC-PBM

Series-5 Vanguard ChassisSeries-5 Vanguard Chassis

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Series-5 4-SLOT Vanguard ChassisSeries-5 4-SLOT Vanguard Chassis

MPU-750MPU-750

REMOTE I/O CARD

RCC-PBM

REMOTE I/O CARD

RCC-PBM

LOCAL I/O CARD

IOC-555

LOCAL I/O CARD

IOC-555

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• PowerPC Processor

• 233 MHz 32 bit uP• 3 Ethernet Channels

• 4 Serial Ports– 2 Intercontroller– 2 Application Dependent

• Flash Program Storage

• OSE Hardware RTOS

• KW ProCon 61131 OS

Series-5 System Processor BoardSeries-5 System Processor Board

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• 22 AI• 6 AO• 16 DI• 14 DO• 6 HI SPEED FI• Feedback on all Outputs• Fault Relay NO/NC

• 2.5 mS Sample Rate

• Precision Reference for Testing A/D Converter

Series-5 Local I/O ModuleSeries-5 Local I/O Module

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• Dual Power Inputs with Fuse Detection. • CCC and Standard Conditioning Modules.• CCC Modules Feature:

– Isolated Inputs/Outputs– Open Wire detection– Protection from wiring errors up to 240 VAC

Series-5 Simplex Local FTA’sSeries-5 Simplex Local FTA’s

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• Same Field I/O connections as Simplex FTA

• Same location and type of Conditioning Modules

• Two FTA Cables - one for each I/O card

Series-5 Duplex Local FTA’s Series-5 Duplex Local FTA’s

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System IntegrationSystem Integration

Train Tool W/S

Train Tool W/S

Series 5Series 5

OPC-Ethernet

Ethernet TCP/IP

• Serial Modbus to DCS or Host Computer

Mod

bus

Mod

bus

• Ethernet OCI to TrainTool

• OPC via TrainTool W/S

FieldField

DCSDCS

PP

P

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System ArchitectureSystem Architecture

Train Tool W/S

Train Tool W/S

Series 5Series 5

OPC-Ethernet

Ethernet TCP/IP

• Serial Modbus to DCS or Host Computer

Mod

bus

Mod

bus

• Ethernet OCI to TrainTool

• OPC via TrainTool W/S

FieldField

DCSDCS

RocketPort

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cPCI- bus B

cPCI- bus A

Ethernet

OPC-Ethernet

Series-5 Vanguard ArchitectureSeries-5 Vanguard Architecture

TO Series 5 , Series 4, or Series 3 Plus

Analogue FTA

Analogue FTA

22 AI6 AO

Analogue FTA

Analogue FTA

22 AI6 AO

Digital FTA

Digital FTA

14 DI16 DO6 FI

2 Fault Relay

Digital FTA

Digital FTA

14 DI16 DO6 FI

2 Fault Relay

DCSDCS

Train Tool W/S

Train Tool W/S

I/O CARD-B

I/O CARD-AM

odB

us

cPCI

optic to 2000m.

I/O Card

MPU

750

Serial Ports

Eth

erne

t Por

tsMPU

A

Serial Ports

Eth

erne

t Por

ts

For Eng.

cPCI

optic to 2000m.

I/O Card

MPU

750

Serial Ports

Eth

erne

t Por

tsMPU

B

Serial Ports

Eth

erne

t Por

ts

For Eng.

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OPC-Ethernet



Analogue FTA

Analogue FTA

Analogue FTA

Analogue FTA

Digital FTA

Digital FTA

Digital FTA

Digital FTA

cPCI- bus B

cPCI- bus A

DCSDCS

Train Tool W/S

Train Tool W/S

Ethernet

I/O CARD-B

I/O CARD-AM

odB

us

cPCI

optic to 2000m.

I/O Card

MPU

750

Serial Ports

Eth

erne

t Por

tsMPU

A

Serial Ports

Eth

erne

t Por

ts

For Eng.

cPCI

optic to 2000m.

I/O Card

MPU

750

Serial Ports

Eth

erne

t Por

tsMPU

B

Serial Ports

Eth

erne

t Por

ts

For Eng.

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OPC-Ethernet



Analogue FTA

Analogue FTA

Analogue FTA

Analogue FTA

Digital FTA

Digital FTA

Digital FTA

Digital FTA

cPCI- bus A

cPCI- bus B

DCSDCS

Train Tool W/S

Train Tool W/S

Ethernet

I/O CARD-B

I/O CARD-AM

odB

us

cPCI

optic to 2000m.

I/O Card

MPU

750

Serial Ports

Eth

erne

t Por

tsMPU

A

Serial Ports

Eth

erne

t Por

ts

For Eng.

cPCI

optic to 2000m.

I/O Card

MPU

750

Serial Ports

Eth

erne

t Por

tsMPU

B

Serial Ports

Eth

erne

t Por

ts

For Eng.

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OPC-Ethernet



Analogue FTA

Analogue FTA

Analogue FTA

Analogue FTA

Digital FTA

Digital FTA

Digital FTA

Digital FTA

DCSDCS

Train Tool W/S

Train Tool W/S

Ethernet

I/O CARD-B

I/O CARD-AM

odB

us

cPCI

optic to 2000m.

I/O Card

MPU

750

Serial Ports

Eth

erne

t Por

tsMPU

A

Serial Ports

Eth

erne

t Por

ts

For Eng.

cPCI

optic to 2000m.

I/O Card

MPU

750

Serial Ports

Eth

erne

t Por

tsMPU

B

Serial Ports

Eth

erne

t Por

ts

For Eng.

cPCI- bus A

cPCI- bus B

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OPC-Ethernet



Analogue FTA

Analogue FTA

Analogue FTA

Analogue FTA

Digital FTA

Digital FTA

Digital FTA

Digital FTA

DCSDCS

Train Tool W/S

Train Tool W/S

Ethernet

I/O CARD-B

I/O CARD-AM

odB

us

cPCI

optic to 2000m.

I/O Card

MPU

750

Serial Ports

Eth

erne

t Por

tsMPU

A

Serial Ports

Eth

erne

t Por

ts

For Eng.

cPCI

optic to 2000m.

I/O Card

MPU

750

Serial Ports

Eth

erne

t Por

tsMPU

B

Serial Ports

Eth

erne

t Por

ts

For Eng.

cPCI- bus BcPCI- bus A

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cPCI

optic to 2000m.

I/O Card

MPU

750

Serial Ports

Eth

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tsMPU

750

Serial Ports

Eth

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t Por

ts

cPCI

REMOTE AREA

DCSDCSTrain Tool

W/S

Train Tool W/S

OPC-Ethernet

Profi Bus I/O Card

ProfiBus Slave

ProfiBus Slave

ProfiBus Slave

ProfiBus Slave Up to 16 slaves

48-w

ire

Ope

n-L

ine

Inte

rnal

Bus

16 Ch. RFTA

16 Ch. RFTA

16 Ch. RFTA

16 Ch. RFTA

Up

to

32 c

h /

slav

e

For Eng.

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Power SuppliesPower Supplies

LOCAL I/O CARD

IOC-555

LOCAL I/O CARD

IOC-555

MPU-750MPU-750

REMOTE I/O CARD

RCC-PBM

REMOTE I/O CARD

RCC-PBM

Series-5 Vanguard ChassisSeries-5 Vanguard Chassis

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Series-5 4-SLOT Vanguard ChassisSeries-5 4-SLOT Vanguard Chassis

MPU-750MPU-750

REMOTE I/O CARD

RCC-PBM

REMOTE I/O CARD

RCC-PBM

LOCAL I/O CARD

IOC-555

LOCAL I/O CARD

IOC-555

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• PowerPC Processor

• 233 MHz 32 bit uP• 3 Ethernet Channels

• 4 Serial Ports– 2 Intercontroller– 2 Application Dependent

• Flash Program Storage

• OSE Hardware RTOS

• KW ProCon 61131 OS

Series-5 System Processor BoardSeries-5 System Processor Board

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• 22 AI• 6 AO• 16 DI• 14 DO• 6 HI SPEED FI• Feedback on all Outputs• Fault Relay NO/NC

• 2.5 mS Sample Rate

• Precision Reference for Testing A/D Converter

Series-5 Local I/O ModuleSeries-5 Local I/O Module

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• Dual Power Inputs with Fuse Detection. • CCC and Standard Conditioning Modules.• CCC Modules Feature:

– Isolated Inputs/Outputs– Open Wire detection– Protection from wiring errors up to 240 VAC

Series-5 Simplex Local FTA’sSeries-5 Simplex Local FTA’s

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• Same Field I/O connections as Simplex FTA

• Same location and type of Conditioning Modules

• Two FTA Cables - one for each I/O card

Series-5 Duplex Local FTA’s Series-5 Duplex Local FTA’s

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• Analog Inputs– 0.1 % accuracy – Failure Detection High and

Low– 15 bit resolution– Two reference channels

for converter verification– Voltage,Current,

millivolt,RTD, Thermocouple

• Analog Outputs– 0.1 % accuracy– Failure Detection -

including open wire– 12 bit resolution– 4 - 20 mA output

Series-5 Local AI & AO Conditioning ModuleSeries-5 Local AI & AO Conditioning Module

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• Digital Inputs– 110/220 V AC or DC– 24 V AC or DC– Isolated Modules– Status LED

• Digital Outputs– Mechanical Relay

• 250 VAC 5 Amps• 250 VA up to 200 Watts

– Solid State Relay• 260 VDC 1 Amp

– Status LED– Fused Output

Series-5 Local AI & AO Conditioning ModuleSeries-5 Local AI & AO Conditioning Module

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• Speed Inputs– 0.01% Accuracy– Active or Passive– 5 Hz to 40K Hz

Series-5 Local FI Conditioning ModuleSeries-5 Local FI Conditioning Module

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• Unique Fault-Tolerant Components– Fault-Tolerant FTA’s– Fault-Tolerant Chassis– Fault-Tolerant Software

• Components Common with Simplex System– CPU Card and I/O Cards– Power Supplies– FTA Cables– Conditioning Modules

Series-5 Fault-Tolerant ComponentsSeries-5 Fault-Tolerant Components

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• Distributed IO sub-system based on industrial protocol profibus DP (up to 12 Mb/s)

• Primarily for low-speed control loops

• Not for critical (shutdown) loops

• Up to 16 slaves per master

• Up to 32 channels per slave

• Operating ambient temperature:– -40 to 85 deg.C– (-40 to 65 deg.C for EM relays)

Series-5 Remote I/O Sub-SystemSeries-5 Remote I/O Sub-System

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Series-5 Remote I/O Sub-System NodeProfiBus Slave RFTA & Conditioning Modules

Series-5 Remote I/O Sub-System NodeProfiBus Slave RFTA & Conditioning Modules

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• Analog Inputs

– Dual-channel Modules

– Current, Voltage (V, mV), RTD (Platinum, Copper), TC K/J

– Accuracy - 0.15 %

– Open-Wire Detection

– Transmitter Failure Detection

– High-Voltage Isolation between Modules and between Field and System

– Field-side Over-voltage Protection up to 240 Vac across the Input

Series-5 REMOTE AI Conditioning ModuleSeries-5 REMOTE AI Conditioning Module

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• Analog Outputs


– Current 4-20 or 0-20 mA

– Accuracy - 0.15 %

– Open-Wire Detection


– Field-side Over-voltage Protection up to 240 Vac

Series-5 REMOTE AO Conditioning ModuleSeries-5 REMOTE AO Conditioning Module

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• Discrete Inputs


– 24 Vdc or 110/220 Vac

– Special Modules with embedded Open-Wire Detection


– LED Status Indication

Series-5 REMOTE DI Conditioning ModuleSeries-5 REMOTE DI Conditioning Module

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• Discrete Outputs


– Electro-mechanical Relaysup to 5A@24 Vdc or 110/220 Vac

– Embedded Open-Wire Detection

– Solid-state Relaysup to 1A@220Vdc


– LED Status Indication

– Fuse--protected Outputs

Series-5 REMOTE DO Conditioning ModuleSeries-5 REMOTE DO Conditioning Module

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• Optimized for smaller applications (single machines orsmall trains) with continuous control and small logic

• Three versions:• Reliant SN – Simplex with non-conditioned I/O• Reliant DN – Duplex with non-conditioned I/O• Reliant SC – Simplex with conditioned I/O

• Motorola Power PC 555 processor

• Same IEC 61131 applications softwareand tools as Series 5 Vanguard

• A single, common electronicsassembly for simplified maintenance

Series-5 RELIANTSeries-5 RELIANT

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Local Maintenance

Keypad

Local Maintenance

Keypad

Communication and Analog I/OTerminations

Communication and Analog I/OTerminations

Local Maintenance

Display

Local Maintenance

Display

Power, Frequency and Discrete I/O

Terminations

Power, Frequency and Discrete I/O

Terminations

Status IndicatorsStatus Indicators

Series-5 RELIANT SNSeries-5 RELIANT SN

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tion Switching

Module

Switching Module

Connector for Remote Switch

Module

Status Indicators

Status Indicators

Manual Switchover

Pushbuttons

Manual Switchover

Pushbuttons

Same Electronics

Assembly and Terminations as Reliant SN

Same Electronics

Assembly and Terminations as Reliant SN

Series-5 RELIANT DNSeries-5 RELIANT DN

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Analog InputConditioning Modules

Analog InputConditioning Modules

Communication Connectors

Communication Connectors

Discrete Output Conditioning Modules

Discrete Output Conditioning Modules

Discrete Input Conditioning Modules

Discrete Input Conditioning Modules

Series-5 RELIANT SCSeries-5 RELIANT SC

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MPU 555Main Processor

MPU 555Main Processor

I/O CardI/O Card

22 AI23 AO14 DO16 DI17 FI2 Fault Relay

22 AI23 AO14 DO16 DI17 FI2 Fault Relay

MEMORYMEMORY 6 Serial Port6 Serial Port

CONTROLDISPLAY

CONTROLDISPLAY

Series-5 RELIANT ArchitectureSeries-5 RELIANT Architecture

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Reliant Control System Analog I/OReliant Control System Analog I/O

• 22 Analog Inputs– 0.1 % Accuracy – High and Low Failure Detection– Field-Configurable for Voltage or Current

• 6 Analog Outputs– 0.1 % Accuracy– Failure Detection - Including Open Wire Integrity Monitor– 4 - 20 mA Output– Isolated

• 6 Frequency Inputs– 0.01 % Accuracy– Active or Passive– 5 Hz to 40K Hz

• 16 Discrete Inputs– 30 V AC or DC– Isolated

• 14 Discrete Outputs– Solid State Relay– 24 VDC– 1 - 2 Amp

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Reliant CommunicationsReliant Communications

5 Integrated RS-485 Serial Ports:-

Port 1: TrainLink Intercontroller Com.

Port 2: TrainTools Workstation

Port 3: Configurable as Series 3+ or Modbus

Port 4: Configurable as Series 4 or Modbus

Port 5: Configurable as TrainTools Workstation or Modbus

Train Tool W/S

Train Tool W/S

Series 5Series 5

OPC-Ethernet

Mod

bus

FieldField

DCSDCS

PP

P

Train Link

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• Vantage GP for API-611 General Purpose Turbines

• Vantage GD for Generator Drive Turbines

• Local HMI for Configuration and Maintenance

• Reliant inan IP-54 Enclosure

Vantage Steam Turbine GovernorsVantage Steam Turbine Governors

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• API-670 Compliant

• 2oo3 Voting of Speed Modules

• Redundant Power Supplies

• Hot-Swap Speed Modules

• Modbus Comms

Guardian Over-speed Trip SystemGuardian Over-speed Trip System

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Series 5 Temperature Specifications

• Vanguard– Operational Limits

• Level C1 (-0 to +55 °C)– Storage Limits

• Level C2 ( -40 to + 85 °C)• Reliant

– Operational Limits • 0 to +70 °C

– Storage Limits• -40 to + 85 °C

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• Vanguard:– Not rated for hazardous areas. – Temp. Operating Limit is up to 55 deg, C

• Reliant:– USA: Class 1, Division 2, Groups A-D, T3 (200 C)– Canadian: Class 1, Zone 2, Group IIC, T3 (200 C)– European (ATEX): Group II, Cat. 3, G, EEx, nACL, IIC, and T3– Temp. Operating Limit is up to 70 deg, C

• Vantage:– USA: Class 1, Division 2, Groups A-D, T3 (200 C)– Canadian: Class 1, Zone 2, Group IIC, T3 (200 C)– European (ATEX): Group II, Cat. 3, G, EEx, nACL, IIC, and T3

• Guardian:– USA: Class 1, Division 2, Groups A-D, T4A (200 C)– Canadian: Class 1, Zone 2, Group IIC, T4A (200 C)– European (ATEX): Group II, Cat. 3, G, EEx, nACL, IIC, and T4

Hazardous Area ClassificationsHazardous Area Classifications

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Offshore Platform ApplicationOffshore Platform Application

2 Parallel Trains

RR Avon Gas Turbine Driven Compressors

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Production IncreaseProduction Increase

• Customer had lowered EGT limit set point to eliminate tripping on EGT trip limit due to poor gas turbine control system

• Increase set point from 650 C to 660 C which is original OEM set point

• Results– 3.8% increase in Exhaust Gas Horsepower (EGHP)

– Translating this to the compressor map results in a 6000 Nm3/hr increase in flow at constant compression ratio

– 300 days/yr * 24 hrs/day * 6000 Nm3/hr = 43,200,000 Nm3/yr increased production

Equals $4,860,000/yr in increased production per machine!

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Offshore Platform ApplicationGulf of Mexico

4 Parallel Trains 250 MMSCFDDemag Delaval 3 section double-barrel compressors

LM 2500 Gas Turbines

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PROBLEMS PROBLEMS PROBLEMS!PROBLEMS PROBLEMS PROBLEMS!

• Domino Trip

• Recycle valve always open between 15-20 %

• EGT Limit always in operation

• At least 1 trip per month , some due to surge

• Speed Control always in Manual

• Excessive flaring

• Unstable suction pressure

• Unstable Discharge pressure

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ResultsResults

• Increased production by 7 million SCFD ($7.5 million/year)

• Elimination of trips caused by surging

• All control loops in auto eliminating operator intervention

• All recycle valves closed during normal operation

• Fast, reliable, smooth startups in automatic

• Stable suction pressure control at 4.5 psi

• Easy trouble shooting of control system problems with improved HMI

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System AvailabilitySystem Availability

• In the Past, Most Comparisons Have:– Focused on “The Box”, not on the Entire System.

– Used Oversimplified Models.

– Used a Safety System Mindset, Focusing Only on Dangerous Failures, and Not on the Total Failure Rate of Devices and the System.

– Ignored Controller Diagnostics, Common-Cause Failures, and Other Important Considerations.

• This Approach is Too Simplistic, and Leads to Invalid Conclusions.

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System BoundariesSystem Boundaries

• The Controller is Not the Whole System!

• Field Devices Have a Huge Impact on System Availability, and Must be Considered.

Controller

Sensors

Final Elements

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Summary of DataSummary of Data

• There is no significant system availability difference between topologies once field devices are included.

• Control system availability is greatly affected by issues related to field devices.

SYSTEM AVAILABILITY 2-1-0

DUPLEXMTBF (Years)

3-2-1-0 TRIPLEX

MTBF (Years)

3-2-0 TRIPLEX

MTBF (Years)

Controller Only Complete System Improved diagnostics (99%) Redundant Sensors (Duplex) Fallback Strategies High reliability outlet transducers Redundant Outlet transducers Automated Final Element Testing

117.9139 121.0418 109.4978 3.1484 3.1506 3.1419 3.2128 3.2131 3.2119 7.9197 7.9335 7.8014 5.3926 5.3989 5.3737 3.8324 3.8356 3.8228 3.2795 3.2818 3.2725 4.9329 4.9382 4.9171

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ConclusionsConclusions

• Availability analysis comparing controllers alone is not valid. The complete control system must be considered.

• Improving control system availability is best accomplished through increasing the effective availability of field devices.

• Hardware redundancy and software fallback strategies can both be very effective at increasing sensor availability.

• High-reliability output devices provide cost-effective availability increases.

• Automated partial-stroke valve testing isbeneficial if performed frequently.

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Increase compressor system reliability and availability with fall-back strategies


• 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

• The controller continuously monitors the validity of its inputs

• If an input problem is detected the controller ignores this input and automatically switches to a fall-back mode

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Fall-Back Benefits

– Avoids nuisance trips

– Alarms operator of latent failures

– Increases machine and process availability

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Process Safety Design - 1987Process Safety Design - 1987

• HSE Study of 34 Industrial Accidents

• Most Common Cause: Specification Errors

Design and Implementation

15%

Operation and Maintenance

15%

Installation andCommissioning

6%

Specification 44%

Changes After Commissioning

21%

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SpecificationsSpecifications

• Writing a good, tight specification is very important

• Don’t just focus on the hardware

• Don’t fall into the instrument upgrade trap

• Demand value and try to specify it

• Focus on– System performance– Algorithms– Proven experience on similar applications

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Acceptance Test RequirementsAcceptance Test Requirements

• Acceptance test requirements for new control systems– Antisurge Control

• In response to full closure of a substation suction or discharge block valve, the system must not allow any compressor to surge.

• In response to the simultaneous closure of both suction and discharge block valves, the system should not allow any compressor to surge more than once.

– Discharge Pressure Control• In steady state, deviation of the discharge pressure from its

set point shall not exceed 0.5 %.

– Load-Sharing Control• In response to bringing a compressor on-line or taking one

off-line, the control system shall reestablish steady-state operation with all units equally loaded (within 1%) in no more than 30 minutes.

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Acceptance Test RequirementsAcceptance Test Requirements

– Turbine Speed Control• In steady state, deviation of the turbine speed from its

set point shall not exceed 0.5%.

– Turbine Limiting Control• In response to a rise in the speed set point, the system

shall not allow an increase in speed after the exhaust-gas temperature has exceeded its limiting control threshold by 0.5% of the sensor span.

• In response to a rise in the speed set point, the system shall not allow an increase in speed after the air-compressor discharge pressure has exceeded its limiting control threshold by 0.1% of the sensor span.

• In response to a rise in the speed set point, the system shall not allow an increase in speed after the uncontrolled shaft speed has exceeded its limiting control threshold by 0.5% of span.

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Specialized, high speed, digital turbomachinery control equipment

Specialized, high speed, digital turbomachinery control equipment

• Purpose-built hardware provides optimum performance

• Allows implementation of specialized algorithms, many patented

• Provides redundancy level required for customer’s application

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

million hours of operation

Series 3 Plus PlatformSeries 3 Plus Platform

• Multi-loop controllers for speed, extraction, antisurge, & performance control

• Serial communications for peer to peer and host system communications

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• Series 4 features include:– Control multiple trains in one control system– I/O capacity tailored to each application– High speed communication links– Flexible fault

tolerance -simplex, duplex or triplex

– Highly configurable

Series 4 PlatformSeries 4 Platform

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• Design Screens

• Standard and Customized Screens

• On-Line Operation and Control

• Alarm and Event Management

• Critical Event Archiving Remote OnlookTM Diagnostics

Controller Overview

TrainView® Operator InterfaceTrainView® Operator Interface

Compressor Map Screen

Control System

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Guardian®

Overspeed Prevention SystemGuardian®

Overspeed Prevention System

• API 670 compliant

• CSA Certification– Class 1, Div 2, Groups A,B,C,D– Class 1, Zone 2, Exn IIC T4

• Enclosure IP-65 (NEMA 4)

• Alarms and history status

• Digital Tachometers for each Speed Module

• Flexible Mounting– 19” rack mount– Back mount

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Vantage®GPA Purpose-Built

Digital Governor for General-Purpose

Turbines

Specifically designed for condensing and back-pressure steam turbines driving synchronous generators.

Vantage®GD

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System Design & Consulting Services

System Design & Consulting Services

• Complete system design

• Right solution the first time

• Complete system documentation

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Field Engineering Services Field Engineering Services

• 94 Field engineers

• Expertise with processes, machinery and instrumentation

• Highly rated in customer satisfaction surveys

• Start-up services with on-going revenues

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CapabilitiesCapabilities

• Controlling over 7,000 turbomachines, including:– over 350 steam turbines– over 2,000 gas turbines

• 345 employees:– more than 200 engineers worldwide

• 19 PhDs • 60 Masters • 250 Bachelors• 47 full-time R&D personnel

• 13 Locations Worldwide

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Customers keep coming backCustomers keep coming back

80% of projects are from repeat

customers

Gas Turbine

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