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TM

Industrial Compressor Controls

• Standard

• Custom

CONTROLLING the power of ENERGY

Technical Seminars – 2012

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Woodward Compressor Controls

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Small Steam Turbine

Driven Compressors

(ITCC)

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Simple Compressor Control Options

505 CC-2 Controller • User configurable

• Turbine Controller

Single Valve Turbines

Single Extraction Turbines

• Compressor Controller

1 or 2 Loop

• Performance Control

included

Suction Pressure

Discharge Pressure

Operator

Control Station

(Optional)

Compressor Controller

Engineering Work Station

Plant DCS

Simple Compressor Train

5

24 Vdc

T&T Valve

Compressor Compressor

PT

PT

FT

PT

FT

Discharge Pressure No. 2

Side stream Pressure

Side stream Flow

Suction Pressure No. 1

Suction Flow No. 1

Recycle Valve No. 2

Recycle Valve No. 1

Turbine Speed

Actuator Demand Signal

ESD, Reset, Raise/Lower Speed, Open/Close Recycle Valves, 16 Configurable Inputs

10 Configurable Analog Inputs

Turbine/Comp Shutdown, Turbine/Comp Alarm, 10 Configurable Discrete Outputs

6 Configurable Analog Outputs

AI

AO

DO

Two RS232 Serial Modbus Ports

505CC-2 Application

505CC-2 Turbine & Compressor Control

A

6 6

EWS Screen – Turbine Configuration

7 7

EWS Screen – Compressor Config

8 8

OCP Screen - Overview

Configured for both turbine and compressor

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OCP Screen – Turbine Performance Map

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OCP Screen – Compressor Performance Map

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OCP Screen - Compressor Control

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OCP Screen - Compressor Control

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Small Motor Driven

Compressors

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Vertex-Pro Compressor Controls

Motor Drive Apps.

• MicroNet platform

Simplex or Redundant

• User Configurable

• Compressor Controller

Software

1 or 2 Loop Compressors

• Performance Control

included

• Compressor Load Sharing

• Optional - HMI Touch Panel

Touchscreen

(153 mm)

Vertex-Pro Compressor Controller

Configuration Tool

Plant DCS

Simple Compressor Train

VFD

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EWS Screen – Compressor Config

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EWS Screen – Compressor Config

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EWS Screen – Compressor Config

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OCP Screen – Turbine Performance Map

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OCP Screen – Turbine Performance Map

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Compressor Operation Screen

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Custom Compressor

Controllers

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Plant Control

Fault Tolerant

Controller

Compressor Island

VFD

Custom Compressor Controls

Compressor Controls

•Motor Drive

•Turbine drive

•Parallel & Series compressors

•Surge Anticipation Technology

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Custom MicroNet System Overview

T&T Valve

Compressor Compressor

PT

PT

FT

PT

FT

Discharge Pressure No. 2

Side stream Pressure

Side stream Flow

Suction Pressure No. 1

Suction Flow No. 1

Recycle Valve No. 2

Recycle Valve No. 1

PT

Inlet Pressure Signal

PT

Exhaust Pressure Signal

Turbine Speed

Actuator Demand Signal

Programmable Discrete Inputs

Programmable Analog Inputs

Programmable Discrete Outputs

Programmable Analog Outputs

AI

AO

DO

Ethernet, RS232, RS422, RS485 Ports

“Single, Dual or

Triplicated I/O As

Required To Meet

Availability Goals”

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PT

Compressor Compressor

PT

FT

PT

FT

PT

Compressor Compressor

PT

PT

FT

PT

FT

Compressor Train Controller

Compressor Train Control Functionality

Compressor Control Functionality • Anti-Surge protection for all loops • Start/Stop sequencing (valve positioning) • Suction/Discharge pressure control • Loop-to-Loop performance control • Loop-to-Loop decoupling action • Compressor load sharing

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CORE Software Modules

•Single Stage Industrial Compressor •Dual Stage Industrial Compressor •Dual Stage Industrial Compressor with Side Stream •Three Stage Industrial Compressor •Three Stage Industrial Compressor with Side Streams •Four Stage Industrial Compressor •Four Stage Industrial Compressor with Side Streams •Five Stage Industrial Compressor •Five Stage Industrial Compressor with Side Streams •Parallel compressors (3 max) •Series compressors (2 max) •API-611 Steam Turbine •API-612 Single Valve Steam Turbine •API-612 Single Extraction Steam Turbine •API-612 Double Extraction Steam Turbine

OEM Qualified / Field Proven Software Logic

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Global Experience

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Dushanzi Chooses Woodward

Dushanzi Chooses Woodward Woodward was selected as the control of choice for all three of Dushanzi’s new critical compressor trains (cracked gas, ethylene, and propylene) due to Woodward’s highly reliable control platforms, advanced compressor protection algorithms, and ability to control very difficult ITCC applications. The Woodward MicroNet TMR® control platform met all of Dushanzi’s, Linde’s, and Siemens’ stringent system control, protection, and plant interface requirements.

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Compressor Control

Overview

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Compressor Control Functions

• Surge Prevention

Anti-Surge Control (PID)

Rate Control (PID)

BOOST

• Surge Recovery

Surge Detection

Surge Recovery Routines

Surge Min Position

• Speed Bias Logic

Min Speed

Valve to Valve Decoupling

• Compressor-Based Process Limiting

• Aux Functions Sequence Positioning

Surge Control Line Biasing

Manual Control modes

Auto Gain Compensation

HSS Auxiliary Inputs

Surge Counter

Valve Freeze Logic

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Compressor Operating Point Calculation P

oly

tro

pic

He

ad

(H

P)

Volumetric Inlet Flow (QA)

Su

rge L

ine

Surg

e C

ontr

ol Lin

e

N1

N2

N3

Surge

Region

Standard Compressor

Performance Map

Operating

Point

BO

OS

T L

ine

X-axis (Flow) Represented by Actual Volumetric Flow Referenced to Suction Conditions

Y-axis (Head) Represented by Polytropic Head

Online Calculations Compensate for Varying Molecular Weights, Pressures, and Temperatures

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Surge

Limit

Pressure Limit

Speed Limit

Power Limit

Stonewall

% Flow

Pressure

Operating Envelope

Compressor System Limits

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Compressor Control Block Diagram

Anti-Surg

Accel

Suction

Discharge

To Recycle

Valve

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Compressor Control Block Diagram

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Compressor Operation Screen

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Compressor Control Basics

• Control Modes

Automatic

Full Surge Prevention & Surge Recovery Control

Manual with Backup

Operator Can Open Recycle Beyond the Value Set by the Automatic Demand

Cannot Close Beyond the Value Set by the Automatic Demand

Full Manual

Total Manual Control of Recycle Valve Position

Bypasses Automatic Controls (Surge Recovery can be Enabled)

Deactivates Decoupling Routines

• Starting, Shutdown & Purging Sequence Position Feature

Provides Fixed Position Control

• Support Functions On-Line Detection

Surge Detection

Captures Surge Signature via Derivatives of Pressure & Flow

Surge Counter

Number of Surge Cycles Since Last Reset

Freeze Mode

Stops Unnecessary Valve Movement During Steady State Operation

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Compressor Surge Prevention

• Closed Loop Actions (Modulated Output to Recycle Valve)

Anti-Surge PID The Main Anti-Surge Routine

Compares S_PV to 100

Dynamics Compensated With Operating Conditions

Rate PID Acts on Derivative of S_PV

Acts to Open Recycle Valve Earlier Than Anti-Surge PID

Useful For High Rates of Surge Onset

• Open Loop Actions (Opens Recycle Valve by Fixed Amount) BOOST

Opens Recycle Valve if Surge Control Line is Exceeded

Includes Pre-Pack to Adjust for Piping Lags

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Other Controller Functions

• Control capability

Parallel or Series Compressors

Load Sharing

Incipient Surge Detection

Performance Controller

Dynamic Compressor Surge Limit Line

Backup Strategies for Signal Failures

• Auxiliary Controls

Bearing Temperature Monitoring

Turbine Lube Oil

Compressor Gas Seals

Load Limiting (power limit and/or compressor choked flow)

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Compressor Surge Capture

Recursion Rate – 40 Milliseconds

Anti-Surge Valve Demand

Operating Point

Raw Flow Input – Flow Element dP

The control response returns the compressor operating point to a safe condition.

The primary closed-loop controls cannot prevent the operating point from reaching the Surge Limit Line—A surge occurs.

The compressor is unloaded.

Closed-loop controls begin to open the Anti-Surge Valve as the operating point moves below setpoint.

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Compressor Surge Capture

Recursion Rate – 160 milliseconds

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Process / Performance Control

• Typical performance or process control variables:

Compressor suction pressure

Compressor discharge pressure

Compressor flow

Another process dependent upon one of the above

PT

FY

ST

FY

FT

PT

TT

PIC SIC UIC

PT

TT

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NetSim Simulation Software

• Debug Software in the Office

• Import & Use OEM Models

• Reduce Commissioning Time

• Reduce Commissioning Risk

Actual Compressor Control

• Compressor

• Recycle Valve

• Package Aux

Compressor

Package

Emulation

• CPU Scan Rate

• I/O delays

• I/O Resolution

Control

Hardware

Emulation

Control

Software

Emulation

• Control Logic

• Start Sequencing

• Communications

SIMULATION PACKAGE ( MatrixX, Matlab, Simulink, ACSL )

Complete Package

Simulation

Motor

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Why Operators Choose Woodward?

• Reliable Hardware

Long MTBF periods

Field proven hardware and software

Global Support

• Advanced control algorithms developed

specifically for industrial compressors

• Smart-PID algorithms for bumpless mode transfers and load response anticipation

• Adaptive Speed and analog anti-aliasing filters

• Advanced load rejection and decoupling routines

to increased stability

• Simulation Tools (used for training & validation)

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Why Woodward?

• Faster scan rates:

5 – 10 milliseconds

• Faster compressor control point acceleration sensing

WGC = 100 microseconds

• Hardware reliability

DR or TMR offerings

• True System Determinism

Synchronized Software & I/O

• Better Service

MHI, Ebara, Conoco Phillips, Dresser Rand, BP, Chevron

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Why Woodward?

• Easier Software Changes

Changes can easily be made and tested at site

(KBR report)

Woodward NetSim Simulation package

• Better Control stability

Automatic PID dynamics selections makes starts easier

(BP report)

• Faster Flow signal filtering

Woodward uses 4 point filter – 20 milliseconds

• Better Service Tools

Woodward = 5 millisecond

• Safety Certified Products

MicroNetTMR, MicroNet-Plus, ProTech203

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TM

Industrial Turbomachinery Systems Improve Reliability Enhance Performance