CCC Turbomachinery Controls System

CCC
CCC
Turbomachinery
Turbomachinery
Controls System
Controls System
Who is the CCC? Who is the CCC?
Who is the CCC?
CCC is a
CCC is a
Controls Company
Controls Company
dedicated to
dedicated to
making the operation of Turbomachinery
making the operation of Turbomachinery
Safe
Safe
and
and
Efficient
Efficient
Safe = No Missed Commissioning
No Production Loss
Efficient = Minimum Power
The CCC Product is Control Solutions
Next
1974 2008
Offices Worldwide
+/- 400 Employees
8300+ Installations
200 Major Retrofit Projects/Year
Worlds Largest GT Retrofitter
In Operation 34 Years
In Operation 34 Years
Next
MTBF of Series 3 Plus controllers is 43.4 years,
or 2.5 failures per million hours of operation
Multi
Multi
-
-
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 communications
and host system communications
Series 3+ Products
Series 3+ Products
Series 5 Products
Series 5 Products
Next
Vanguard Duplex Chassis
Vanguard Duplex Chassis
Power Supplies
IOC-555
MPU-750
Extended Card
Next
Series 5 Reliant Duplex
Series 5 Reliant Duplex
Switching
Module
Connector for
Remote
Switch Module
Status
Indicators
Manual
Switchover
Pushbuttons
Same
Electronics
Assembly and
Terminations
as Reliant SN
Next
Guardian
Guardian

Overspeed Trip System
Overspeed Trip System
API-670
Compliant
2oo3 Voting
of Speed
Modules
Redundant
Power
Supplies
Hot-Swap
Speed
Modules
Modbus
Comms
Next
Vantage
Vantage

Steam Turbine Governors
Steam Turbine Governors
Vantage GP
for API-611
General
Purpose
Turbines
Vantage GD
for Generator
Drive
Turbines
Local HMI for
Configuration
and
Maintenance
Reliant in
an IP-54
Enclosure
Next
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 Miser
Air Miser
TL Enclosure
TL Enclosure
Next
Class 1, Div 2 / Class 1 Zone 2 Class 1, Div 2 / Class 1 Zone 2
ATEX Group 2 Class 3 ATEX Group 2 Class 3
Simplex or Simplex or hot backup hot backup redundant redundant
All AO All AO s have built s have built- -in feedback loops to identify in feedback loops to identify
hardware or wiring problems hardware or wiring problems
Series 3++ Controllers
Series 3++ Controllers
On On- -board temperature board temperature
monitoring monitoring
On On- -board power supply board power supply
voltage monitoring voltage monitoring
Wired Ethernet version Wired Ethernet version
Completely backward Completely backward
compatible with S3+ compatible with S3+
Raising the Bar Advanced
Raising the Bar Advanced
Constraint Control
Constraint Control

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

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

Downstream
Downstream
broader 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).
Next
CCC Installations
CCC Installations
-
-
Indonesia
Indonesia
PT. Pupuk PT. Pupuk Iskandar Iskandar Muda Muda
PT. Pupuk PT. Pupuk Sriwidjaya Sriwidjaya
PT. Pupuk PT. Pupuk Kujang Kujang
PT. Pupuk Kalimantan PT. Pupuk Kalimantan Timur Timur
PT. DSM PT. DSM Kaltim Kaltim Melamine Indonesia Melamine Indonesia
PT. Amoco Mitsui PTA PT. Amoco Mitsui PTA
PT. PT. Polysindo Polysindo Eka Eka Perkasa Perkasa
PT. Chandra PT. Chandra Asri Asri
Pertamina Pertamina / Refinery (WGC / Refinery (WGC Exor Exor Project) Project)
ConocoPhillips ConocoPhillips Indonesia Indonesia
ExxonMobil ExxonMobil Oil Indonesia Oil Indonesia
Total Total Indonesie Indonesie
PT. PT. Kangean Kangean Energi Energi Indonesia Indonesia
BP BP Tangguh Tangguh LNG LNG
PT. PT. Badak Badak LNG LNG
PT. PT. Arun Arun LNG LNG
PT. Indonesia Power (PLN) PT. Indonesia Power (PLN)
Etc. Etc.
Next
1
PT
Section 1
out out
RSP
A
LSIC
Section 2
1A
UIC
1A
UIC Serial
network
Train A
Next
Typical Single Train Controls
Typical Single Train Controls
(Suction Pressure Controls) (Suction Pressure Controls)
Antisurge Controls System
Performance Controls
System
Compressor Refresher
Compressor Refresher
Next
Compressor Type
Compressor Type
Next
Compressors
Positive Displacement
Compressor
Dynamic Compressor
Reciprocating Compressor
Rotary Compressor
Membrane Compressor
Screw Compressor
Centrifugal
Axial
CCC Focus CCC Focus
Where do the different types of
Where do the different types of
compressor fit?
compressor fit?
Next
Types of Compressor
Types of Compressor
-
-
Dynamic
Dynamic
Compressors
Compressors
Axial Compressor
Centrifugal Compressor
Next
Types of Compressor
Types of Compressor
-
-
Dynamic
Dynamic
Axial Compressors
Axial Compressors
Stator Blades
Rotor
Blades
Casing
Rotor Blades
Stator
Blades
Casing
Shaft
Next
Rotor
Stator
Cross section of axial compressor
Cross section of axial compressor
Compressor outlet nozzle
Rotor blades
Labyrinth seals
Guide-vane actuator linkage Stator Blades
Compressor inlet nozzle
Thrust bearing
Adjustable guide vanes
Next
Barrel (Centrifugal) Barrel (Centrifugal)
Bullgear (Centrifugal) Bullgear (Centrifugal)
Types of Compressor
Types of Compressor
Dynamic
Dynamic
Centrifugal Compressors
Centrifugal Compressors
Next
Compressor inlet nozzle
Thrust bearing
Journal bearing
Shaft and labyrinth seal
Impeller inlet labyrinth seals Discharge volutes
Impellers
Drive coupling
Casing
(horizontally split flange)
Compressor discharge nozzle
Horizontally Split Type (Centrifugal) Horizontally Split Type (Centrifugal)
Horizontally Split Type (Centrifugal)
Next
Types of Compressor
Types of Compressor
-
-
Picture of
Picture of
Next
Types of Compressor
Types of Compressor
-
-
Principal of
Principal of
Operation (Centrifugal)
Operation (Centrifugal)
Next
Single-Section, Three-Stage Single-Case, Two-Section, Six-Stage
Types of Compressor
Types of Compressor
-
-
Classifications
Classifications
What is the function of this cooler?
Intercooling Intercooling reduces energy consumption reduces energy consumption
but results in having multiple compressor maps but results in having multiple compressor maps
which need separate which need separate antisurge antisurge protection protection
Next
Parallel Network
Two-Case, Two-Section, Six-Stage
Series Network
Types of Compressor
Types of Compressor
-
-
Classifications
Classifications
Next
Why Compressor Surge
Why Compressor Surge
and what happens

and what happens
when they do
when they do
Next
Surge Phenomenon
Surge Phenomenon
From A to B.20 - 50 ms.. Drop into surge
From C to D.20 - 120 msJump out of surge
A-B-C-D-A.0.3 - 3 secondsSurge cycle
Q
s, vol
P
d
Machine shutdown
no flow, no pressure
Electro motor is started
Machine accelerates
to nominal speed
Compressor reaches
performance curve
Note: Flow goes up faster
because pressure is the
integral of flow
Pressure builds
Resistance goes up
Compressor rides the curve
P
d
= P
v
+ R
losses
P
d
= Compressor discharge pressure
P
v
= Vessel pressure
R
losses
= Resistance losses over pipe
Developing the surge cycle on the
Developing the surge cycle on the
compressor curve
compressor curve
P
d
P
v
R
losses
B A
C
D
Next
Rapid flow oscillations Rapid flow oscillations
Thrust reversals Thrust reversals
Potential damage Potential 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
Surge
Surge
Rapid pressure
oscillations with
process instability
Rising temperatures
inside compressor
Next
Some surge consequences
Some surge consequences
Unstable flow and pressure

Unstable flow and pressure
Damage in sequence with increasing

Damage in sequence with increasing
severity to seals, bearings, impellers,
severity to seals, bearings, impellers,
shaft
shaft
Increased seal clearances and leakage

Increased seal clearances and leakage
Lower energy efficiency

Lower energy efficiency
Reduced compressor life

Reduced compressor life
Next
Factors leading to onset of
Factors leading to onset of
surge
surge
Startup Startup
Shutdown Shutdown
Operation at reduced throughput Operation at reduced throughput
Operation at heavy throughput with: Operation at heavy throughput with:
- - Trips Trips
- - Power loss Power loss
- - Operator errors Operator errors
- - Process upsets Process upsets
- - Load changes Load changes
- - Gas composition changes Gas composition changes
- - Cooler problems Cooler problems
- - Filter or strainer problems Filter or strainer problems
- - Driver problems Driver problems
Standard Antisurge
Standard Antisurge
Control Vs CCC Controls
Control Vs CCC Controls
System
System
Next
Flow
Pressure
minimum speed
maximum speed
surge limit
stonewall or
choke limit
power limit
process limit
stable zone stable zone
of operation of operation
adding control
margins
Actual available
operating zone
CCC Business in Constraint Control
Next
Flow
Pressure
minimum speed
maximum speed
surge limit
stonewall or
choke limit
power limit
process limit
stable zone stable zone
of operation of operation
adding control
margins
Actual available
operating zone
Next
Expanding the Operating Envelope
Expanding 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
Next
Standard Antisurge Control
Standard Antisurge Control
1
UIC
Compressor Compressor
1
FT
1
P
s
T
Process Suction
1
P
d
T
Next
Antisurge
Controller
Recycle Valve
Conventional Control Using Separate
Conventional Control Using Separate
Performance Recycle
Performance Recycle
Process Suction
1
UI
C
1
F
T
1
P
s
T
1
P
d
T
1
PIC
Next
Conventional
Capacity/Performance
Controller
Additional Recycle Valve
Why Invest in Advanced
Why Invest in Advanced
Controls?
Controls?
Next
How Will CCC
How Will CCC
Control
Control
?
?
Antisurge Control?
Antisurge Control?
Capacity Control?
Capacity Control?
Next
CCC Controls System
CCC Controls System
Next
1
UIC
VSDS
Compressor
1
FT
1
P
s
T
1
T
s
T
Process
Suction
1
P
d
T
1
T
d
T
1
ST
1
PIC
1
HIC
Load
Serial
network
Antisurge
Controller
Performance
Controller
Control System Objective
Control 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)
set
set
-
-
point, and to return it to set
point, and to return it to set
-
-
point as quickly
point as quickly
as possible after a process disturbance
as possible after a process disturbance

The control system has to keep the process
The control system has to keep the process
on/return to set
on/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 damage
protection against surge and surge damage
Next
Challenges of Compressor
Challenges of Compressor
Control System
Control System
The ingredients of a successful compressor control system The ingredients of a successful compressor control system
are: are:
An algorithm that can accurately locate the operating point An algorithm that can accurately locate the operating point
and its corresponding surge limit and its corresponding surge limit
A controller execution speed that will allow a digital controlle A controller execution speed that will allow a digital controller r
to emulate immediate analog control to emulate immediate analog control
Control responses that allow different margins of safety for Control responses that allow different margins of safety for
different operating conditions different operating conditions
Advanced control strategies that can avoid the negative Advanced control strategies that can avoid the negative
effects of loop interaction effects of loop interaction
A quick acting, correctly sized antisurge control valve A quick acting, correctly sized antisurge control valve
The elimination of unnecessary dead time or lag time within The elimination of unnecessary dead time or lag time within
the system the system
Valid load sharing strategies Valid load sharing strategies
Next
Standard Control VS CCC
Controls
Controls
Standard
Standard

CCC
CCC
Next
1
U
I
C
VSDS
Compressor
1
F
T
1
P
s
T
1
T
s
T
Process
Suction
1
P
d
T
1
T
d
T
1
S
T
1
P
I
C
1
H
I
C
Load
Serial
network
Process Suction 1
U
I
C
1
F
T
1
P
s
T
1
P
d
T
1
P
I
C
Controls
Controls

Standard
Standard
15% surge margin 15% surge margin
Quick opening valves Quick opening valves
No control of process No control of process
variable via recycle variable via recycle
No invariant coordinates No invariant coordinates
Concentrating on Concentrating on
Protection Protection

CCC
CCC
Typically 8% surge margin Typically 8% surge margin
Linear valves with Linear valves with
positioners for control positioners for control
across 100% range across 100% range
Control of primary process Control of primary process
variable by recycle when variable by recycle when
speed limit is reached speed limit is reached
Can handle varying Can handle varying
molecular weight gases molecular weight gases
Concentrating on Concentrating on Control Control
and Protection and Protection
Next
CCC
CCC
Control
Control
ler protection
ler protection
How CCC
How CCC
Antisurge
Antisurge
Controller
Controller
protects compressor against
protects compressor against
surge?
surge?
Next
1
UIC
VSDS
Compressor
1
FT
1
P
s
T
1
P
d
T
The antisurge controller UIC-1 protects the compressor
against surge by opening the recycle valve
Discharge Suction
R
c
q
r
2
R
process
R
process+valve
Antisurge Controller Operation Protection #1
The Surge Control Line (SCL)
Next
A
R
c
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 valve recycle valve
PI control will give PI control will give
adequate protection for adequate protection for
small disturbances small disturbances
SLL = Surge Limit Line
SCL = Surge Control Line
q
r
2
PI control will give stable control during steady state
recycle operation
Slow disturbance example
Next
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 example
Q
2
Moving The Surge Control Line (SCL)
Moving The Surge Control Line (SCL)
Next
The Recycle Trip
The Recycle Trip

Line
Line
(
(
RTL
RTL
)
)
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
RTL = Recycle Trip Line
Output
to Valve
Time
Open-loop Response
PI Control Response
PI Control Step Change
+
To antisurge valve
Total Response
Rc
Q
2
OP
Next
After time delay C After time delay C
2 2
controller checks if Operating Point is back to controller checks if Operating Point is back to
safe side of safe side of Recycle Trip Recycle Trip

Line Line
- - If If Yes Yes: Exponential decay of : Exponential decay of Recycle Trip Recycle Trip

response response. .
Output
to valve
Time
One step response
PI Control
Recycle Trip
Total
100%
0%
C
2
Multiple step response
Output
to valve
Time
PI Control
Recycle Trip
Total
C
2
C
2
C
2
What if one Recycle Trip
What 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.
Next
Output to
Recycle Valve
Input
Output to
Turbine Valve
Speed Inputs Speed Inputs
Antisurge Inputs Antisurge Inputs
Process Variable Inputs Process Variable Inputs
Serial
Communication
Link CCC-DCS
Flow
Pressure
Temperature
Gas Data
(Field
Transmitter)
Next
Integrated control Decoupling of
Performance and
Performance and
Antisurge
Antisurge
control
control
P
o
PIC-SP
R
c
P
s
S
L
L
S
C
L
A
C
B
Performance and
Performance and
Antisurge
Antisurge
control
control
2. 2. The decoupling control starts to act The decoupling control starts to act
Performance control send request Performance control send request
to increase speed to increase speed
3. 3. The speed increasing combined with The speed increasing combined with
antisurge antisurge valve opening, then, valve opening, then,
The trace of operating line as shown The 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 disturbance process 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 operation saving 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 B operating point will move to Point B
Next
Antisurge Controller Operation
Antisurge Controller Operation
Protection #4
Protection #4
Safety On
Safety On
How about if the protection not capable

How about if the protection not capable
against surge?
against surge?
Compressor has real surge
Compressor has real surge
What will CCC controller do?
What will CCC controller do?
Next
If Operating Point crosses the Safety
On
Line the compressor is in surge

RTL 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
P
r
e
s
s
u
r
e

a
x
i
s
Flow axis
Safety On
Safety On
Next
CCC
CCC
LOAD SHARING CONTROLS
LOAD SHARING CONTROLS
SYSTEM
SYSTEM
Next
Compressors are often operated in parallel and sometimes in seri Compressors are often operated in parallel and sometimes in series es
The purposes of networks include: The purposes of networks include:
Redundancy Redundancy
Flexibility Flexibility
Incremental capacity additions Incremental capacity additions
Often each compressor is controlled, but the network is ignored Often each compressor is controlled, but the network is ignored
Compressor manufacturers often focus on individual machines Compressor manufacturers often focus on individual machines
A A network view network 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 networks
Compressor networks
Next
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 surge Minimizing risk of surge
Minimizing energy consumption Minimizing energy consumption
Minimizing disturbance of starting and stopping Minimizing disturbance of starting and stopping
individual compressors individual compressors
Operating within limits Operating within limits
Load Sharing
Load Sharing
Next
Load Sharing Control system types: Load Sharing Control system types:
1. Base and Swing Load Sharing system
1. Base and Swing Load Sharing system
2. Equal Flow Load Sharing system
2. Equal Flow Load Sharing system
3. CCC Equidistance Load Sharing controls system
3. CCC Equidistance Load Sharing controls system
Load Sharing
Load Sharing
Next
Process
PIC
1
1
UIC
VSDS
Compressor 1
2
UIC
VSDS
Compressor 2
HIC
1
Suction
header
Swing
machine
Base
machine
Notes
All controllers act
independently
Transmitters are
not shown
Base and Swing Load Sharing
Flow Diagram for Control Process
Next
R
c,1
q
r,1
2
R
c,2
q
r,2
2
Compressor 1 Compressor 2
PIC-SP
Swing machine Base machine
Q
C,2
= Q
P,2
Q
C,1
Q
P,1
where:
Q
P
= Flow to process
Q
C
= Total compressor flow
Q
C
- Q
P
= Recycle flow
Q
P,1
Q
P,1
+ Q
P,2
= Q
P,1
+ Q
P,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
Parallel Compressor Control
Q
P,2
Next
Process
PIC
1
1
UIC
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 FMDs
1
FIC
2
FIC
2
UIC
out out
out
RSP RSP
RSP RSP
R
S
P
R
S
P
out out
RSP RSP
Equal Flow Load sharing
VSDS
Next
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 (see next)
Equal flow division is NOT recommended
R
c,1
q
r,1
2
R
c,2
q
r,2
2
PIC-SP
Q
P,1
Q
P,2
Q
C,2
Equal flow Equal flow
Q
P,1
= Q
P,2
where:
Q
P
= Flow to process
Q
C
= Total compressor flow
Q
C
- Q
P
= Recycle flow
Next
Notes
All controllers are
coordinating
control responses
via a serial network
Minimizes recycle
under all operating
conditions
Process
1
UIC
VSDS
Compressor 1
VSDS
Compressor 2
Suction
header
1
LSIC
2
UIC
out
RSP
Serial
network
out
RSP
2
LSIC
1
MPIC
Serial
network
Serial
network
CCC Equidistance Load sharing
Next
PIC-SP
0.1
0.2
0.3
DEV = 0
0.1
0.2
0.3
DEV
1
DEV
2
R
c,1
q
r,1
2
R
c,2
q
r,2
2
Dev
1
= Dev
2
Q
1
= Q
2
N
1
= N
2
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
Next
Loop
Decoupling
FA
Mode
PI
Loop
Decoupling
+
Analog Inputs
+
DEV
To antisurge valve To performance
control element
PID
Load
balancing
PV
PV
SP
Primary
response
DEV DEV
D
E
V
DEV from other
loadsharing
controllers
Primary
response
Average
SP
The load balancing response
The load balancing response
Loadsharing Loadsharing
Controller Controller
Antisurge Antisurge
Controller Controller
Master
Controller
RT
Next
CCC LOAD SHARING
CCC LOAD SHARING
Control System Drawing
Control System Drawing
Next
MASTER CONTROLLER
(Suction Header Controls)
LOAD SHARING CONTROLLER
ANTISURGE CONTROLLER
End Slides
End Slides
Thank You very much for your
Thank You very much for your
kind attention and cooperation
kind attention and cooperation
PT Putranata Adi Mandiri
Jl Kartini VIII No. 9
Jakarta 10750
Tel: (021) 6007850
Fax: (021) 6007846
Email: pamccc@cbn.net.id

CCC Turbomachinery Controls System

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CCC

Serial communications for peer to peer

and what happens

Unstable flow and pressure

Damage in sequence with increasing

Increased seal clearances and leakage

Lower energy efficiency

Reduced compressor life

How about if the protection not capable

Line the compressor is in surge

response shifts the

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