SISTEMAS DE CONTROLE

DE TURBOMÁQUINAS
a
3 Parte - Controle de Surge &
Capacidade
Desenvolvendo a curva do compressor

ΔP
R
P Rprocess,2
Rcdpc c Discharge
H Pressão
Relação
Head Diferencial
dePressure
pressão (P
Politropico (P
(Pd2d)-/PPs )s )or
or(P
(P 2 -1P
2 /P ) 1)
Rprocess,1

Rc2

Rc1

Curva do
compresor para
uma velocidade
específica N1

Q2 Q1 Q s, vol
normal
mass

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Desenvolvendo a curva do compressor

limite do processo
Rc
Adicionando
margem de
controle Máxima
Limite de velocidade
Surge
Limite de Potência

stonewall or
choke limit
Zona de operação estável
Zona de operação
disponível
minima
velocidade

Q s, vol

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 CONTROLE DE SURGE - Teoria do Surge

• Limites de Rotação: Definido

em função do nível de
esforços a que é submetido o
conjunto rotativo
Limite de Stonewall: É quando
o gás atinge um valor sônico
no interior do compressor,
normalmente na entrada do
impelidor
Limite de Surge: Ocorre
quando a vazão que o sistema
se mostra capaz de absorver é
inferior a um certo limite
 Estudando ciclo de surge na curva do compressor

P
• • DeCompressor
A até B 20 - 50atinge
ms o ponto de surge
mergulha no (A)
surge d
Pv
• Compressor não é capaz
• Compressor de aaumentar
inicia aumentaraa pressão
• Depressão
C até• D 20 - 120 ms “vai”
Compressor sai em
do surge
direção ao surge Rlosses
• Repentinamente
• A-B-C-D-A • 0.3Ponto P cai e P
A éd alcançado
- 3 seconds Ciclo
v > P
ded surge
• Avião•vaiCiclo
para deStall - Compressor
surge está completo surges

Pd Pd = Pressão descarga compressor

B A Pv = Pressão do vaso
Rlosses = Perda de pressão nas linhas
• Pressure builds• A Pressão do sistema diminui
D
• Resistance goes • upO compressor é novamente capaz de
C • Compressor “rides” superar Pv
the curve
• Pd = P v + R losses• Compressor “volta” para curva de
• Devido a P v > P d a vazão inverte • performance e vai
Motor elétrico para o ponto D
parte
• • Ponto
Devido
de ao fluxo reverso
operação a pressãovai
do compressor caipara • • O fluxo positivo
Máquina é restabelecido
acelera até velocidade
• B Pressão caindo => menor fluxo negativo nominal
• O ponto de operação vai para o ponto C • Compressor atinge a curva de
performance
• Nota: Vazão aumenta rápidamente porque
a pressão do vaso é zero

Máquina parada
Q s, vol
Sem vazão e
pressão
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 Principais parâmetros durante o surge

FLUX
O • Rápida oscilação do fluxo
• Reversão do esforço axial
• Dano potencial
1 2
3 TEMPO (s)

PRESSUR • Rápida oscilação da

E
pressão com instabilidade
do processo

1 2
3 TEMPO (s)

TEMPERATURA • Crescimento da
temperatura interna no
compressor

1 2
3 TEMPO(s
)
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CONTROLE DE SURGE - Teoria do Surge
 CONTROLE DE SURGE - Teoria do Surge
• LIMITE DE SURGE
associação do surge ao ponto máximo da curva de HEAD, sendo o ramo a
esquerda dito virtual devido a ser constituído de condições instáveis.
 CONTROLE DE SURGE - Teoria do Surge

DETERMINAÇÂO DO LIMITE DE SURGE

• O surge é um fenômeno relativo a um sistema de

compressão, sendo influenciado por uma serie de fatores
não só associados ao compressor como também aos
demais componentes envolvidos

• Há no entanto um certo interesse prático em fixar o limite

de operação estável independente das características do
sistema, que é um procedimento lógico, pois a influência
dos parâmetros alheios ao compressor se faz sentir muito
mais sobre a dinâmica do fenômeno do que sobre seu
ponto de deflagração.
 CONTROLE DE SURGE - Fundamentos do Controle

FUNDAMENTOS DE CONTROLE ANTI-SURGE

O fenômeno surge não é controlável, o que se faz na prática e evita-lo .

• Basicamente a idéia, no caso de uma condição de surge, é manter o

compressor funcionando no limite da estabilidade e recircular a vazão
excedente à demanda do sistema
CONTROLE DE SURGE - Fundamentos do
Controle
ESQUEMA DE CONTROLE DE SURGE
 Basic antisurge control system

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

opening the recycle valve
• Opening of the recycle valve lowers the resistance felt by the compressor
• This takes the compressor away from surge

Rprocess
Rc
Rprocess+valve
VS
DS
Compresso
r

F P sT P dT
T
1 1 1 2
q
Suctio Discharg
n e r
UIC • Surge parameter based on invariant
1
coordinates Rc and qr
– Flow measured in suction (ΔPo )
– Ps and P d transmitters used to
calculate R c

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 Antisurge controller operation
Protection #1: The Surge Control Line (SCL)

Rc SLL = Surge Limit • When the operating point

Line SCL = Surge Control crosses the SCL, PI control
Line
will open the recycle valve
B
• PI control will give adequate
A protection for small
disturbances

• PI control will give stable

control during steady state
recycle operation

• Slow disturbance example

2
q
r

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 Adaptive Gain
Enhancing the effectiveness of the PI controller

Rc • When the operating point

moves fast towards the SCL,
adaptive gain moves the SCL
B towards the operating point.
A • This allows the PI controller
to react earlier

• As a result a smaller steady

state surge control margin
can be achieved without
sacrificing reliability
2
q • Fast disturbance example
r

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 Antisurge controller operation
Protection #2: The Recycle Trip® Line (RTL)
SLL = Surge Limit
Line
• Total response
Disturbance
When
Operating
the
OP hits
operating
point
arrives
SCL
of
keeps
Moves
controller
the
themoving
point
PI
back
Operating
hits
is
tothe
the
the
RTL = Recycle Trip ® Line
Rc Pointside
controller
towards
Recycle
safe
sum of
(OP)
the
Trip
surge
of
opens
moves
PI
the
Line
control
and
RTL
valve
(RTL)
towards
hits
and
based
Recycle
the
Recycle
theon SCL
SCL = Surge Control
Line proportional
conclusion
Trip LineRT(RTL)
action
– The is:
and integral
function action
decays out the
– step
We areresponse
close to surge
–
– PI
Thecontroller integrates
PI controller to stabilize
is too slow to
• Benefits:
OP on SCL
catch the disturbance
– Get
– Energy
out savings due to smaller
of the dangerous zone
surge margin
• An open loop response is
– Compressor has more turndown
triggered
before recycle or blow-off
– Surge can be prevented for
virtually any disturbance

2
q
Output Recycle Trip®
r PI Control
to Valve Action

Total Response
PI Control
Response +
Recycle Trip ® Response
To antisurge
Tim valve
e
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 Recycle Trip® based on derivative of S s
Recycle Trip ® Benefits
Response calculation • Maximum protection
– No surge
d(S s) – No compressor damage
C = C 1T d
d • Minimum process disturbance
where: t – No process trips
• C = Actual step to the valve
• C1 = Constant - also defines maximum step
• Td = Scaling constant
• d(Ss)/dt = Rate of change of the operating
point

Output Medium Output Large

to valve to valve
100% disturbance disturbance

Total
PI
Total Control
PI
Control
Recycle Trip ® Recycle Trip ®
0
% Tim Tim
e e
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 What if one Recycle Trip® step response is not enough?

• After time delay C2 controller checks if Operating Point is back to

safe side of Recycle Trip ® Line (RTL)
– If Yes: Exponential decay of Recycle Trip ® response
– If No: Another step is added to the Recycle Trip ® response

Output One step Output Multiple step

to valve to valve
response response
100%
Total

PI
Total Control
PI
Control
Recycle Trip ®
0 Recycle Trip ®
% Tim Tim
e C2 C2 C2 e
C2
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 Antisurge controller operation
Protection #3: The Safety On ® Line (SOL)

SOL = Safety On ® Line •• PI

The
Additional
If Operating
control
Safetyand ®
safety
OnPoint
Recycle
response
or
crosses
surge
Trip ®
shifts
margin
thewill
Safety
theis
SLL = Surge Limit
stabilize
SCL® and the
added the machine
RTL to the
onright
the new SCL
Line = Recycle Trip ® Line
RTL On Line the compressor is in surge
SCL = Surge Control
Rc Line

Compressor can surge due to:

• Transmitter calibration shift
• Sticky antisurge valve or actuator
• Partially blocked antisurge valve or
recycle line
New SCL • Unusual large process upset
New RTL

2 Benefits of Safety On ® response:

Additional surge margin q
• Continuous surging is avoided
r
• Operators are alarmed about surge

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 Built in surge detector

• Surge signature is recorded during

Pressure and Flow Variations commissioning
During a Typical Surge Cycle
• Rates of change for flow and pressure
100
%
during surge are determined
• Thresholds are configured slightly more
conservative than the actual rates of
P change during surge
d
• Surge is detected when the actual rates of
0 change exceed the configured thresholds
% 1 TO 2
SECONDS
• The following methods can be used:
100
% • Rapid drops in flow and pressure
• Rapid drop in flow or pressure
• Rapid drop in flow only
ΔP
o
• Rapid drop in pressure only
• When surge is detected a Safety On ®
0 response is triggered
%
20 to 50 • A digital output can be triggered upon a
milli-
seconds
configurable number of surge cycles

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 Performance control by speed variation

SIC
Pd 1

Rprocess
Proces
A s
PIC - SP P
Nmax T1

NOP PIC
Nmin 1

• Required is
Changing
Pressure
Compressor power
speed
controlled
operates
is
generates
P1 in
bypoint
speed
a A
2 family
of
forrotation
given
of curves
Rprocess
Shaft q
power
r
Notes
• Most efficient (Power ≈ f(N)3)
P1 • Steam turbine, gas turbine or variable
speed electric motor
• Typically capital investment higher than
with other systems
2
q • No throttle losses
r
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Limiting P s or P d using the antisurge controller
VS
DS
Compresso
r

F P sT P dT
T
1 1 1

Suctio UIC Discharg

n 1 e

• The antisurge controller can be configured to limit:

• Maximum discharge pressure (Pd )
• Minimum suction pressure (P s)
• Both maximum P d and minimum Ps
• This does NOT conflict with antisurge protection

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 Interacting antisurge and performance loops
• Interaction starts at B
• Performance controller on
discharge pressure reduces
Rc
performance to bring
L

L
SL

SC pressure back to setpoint

• Unless prevented, PIC can
B drive compressor to surge

C A • Antisurge controller starts to

PIC-SP
operate at B
• Even if surge is avoided,
interaction degrades
pressure control accuracy
• Results of interaction
– Large pressure
ΔP deviations during
oPs disturbances
– Increased risk of surge
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 Interacting antisurge control loops
VS
DS
Section Section
1 2

UIC UIC PIC

1 2 1

Disturbanc
e

R R
Rc,1 Rc,2
R R

2 2
qr,1 qr,2

• • The
Antisurgeofcontroller
Opening recycle system
valve
UIC-1
onwill is oscillating
section
open •• Opening of controller
Disturbance
Antisurge recycle
comesvalvefrom on
UIC-2thesection
will open1
2 caused
the recycle
P s,2
valve
=P toSlowing
• d,1 to
protect
increase
section
down caused
the1 controller P d,1 would
discharge
the recycle
tuning =valve
sideP s,2 lead
to
to decrease
protect
to: section 2
• against
Result: surge • Increased risk of surge against surge
• Pd,2 increases
• Result:
•• P
Pd,1 decreases
d,1 increases
• Compressor damage• •• PP
Ps,2s,2 remains constant
decreases
d,2decreases
•• P
Ps,1 increases
s,1 remains constant
• Process trips • •• PR
Pd,2s,2 increases
increases
c,2remains constant
•• R
Rc,1 decreases • Bigger surge margins • •• Section
R 2 moves
decreases
Rc,2c,2increases towards surge
c,1 increases
•• Section
Section 1 1 moves
moves away • surge
Energy
from
towards surge waste •• Section22moves
Section movestowards
away from surge
surge
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Loop decoupling between multiple antisurge controllers
VS
DS
Section Section
1 2

UIC Serial UIC Serial PIC

1 networ 2 networ 1
k k

• All CCC controllers are connected on a serial network

• This allows them to coordinate their control actions
• When UIC-2 opens the recycle valve:
• Section 2 will be protected against surge
• Section 1 will be driven towards surge
• How much section 1 is driven towards surge depends on how much
the recycle valve on section 2 is opened
• The output of UIC-2 is send to UIC-1 to inform UIC-1 about the
disturbance that is arriving
• UIC-1 anticipates the disturbance by immediately opening its valve

Note: The same applies when the antisurge

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 Loop decoupling simplified block diagram
VS
DS
Benefits
Section
1
Section
2
• Each
UIC-1 controller
reports
Antisurge
UIC-2
Loop decoupling
is
• Avoids itshas
protecting
controller
PI
control PI
and and
its
block
value
values own
Recycle
section
UIC-2
Recycle
is decoupling
TripTrip
multiplies
system ofadded
opens
1
other ®
against
to values
gain
controllers
its
reported
output
oscillationsvalve
surge PIto
M
tousingnUIC-2
toPI
UIC-1
protect
and
UIC
1
Serial UIC
2
• allow
and
Same for
section
Recycle
antisurge
(performance
Recycletuning
2Trip ®
against
valve
Trip
decoupling
• Allows and
faster 1of
®
values relative
surge
antisurge)
takes
tuningwith loop
aregains
ofdecoupling
place
controladded between
gain
to output
system M2 to
networ
k different controllers
antisurge valve 1
• Reduced risk of surge
• Allows closer operation to surge limits
without taking risk

From other From other

Analog Inputs controllers Analog Inputs controllers

FA FA
Mode Mode
. . . .
PI n PI 2 PI 1 PI n
DEV Mn M2 DEV M1 Mn
1 2
P R + + P R + +
. . . .
I T RT n RT 2 I T RT 1 RT n
Mn M2 M1 Mn

+ + + +
Loop Loop
Antisurge Decoupling Antisurge Decoupling
Controller 1 Controller 2

To antisurge valve 1 To antisurge valve 2

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 Coordinates (H p, Qs) and (h r, q r2)

(Hp , Q s) (hr, qr2)

NOT invariant coordinates Invariant coordinates

where:
• Hp = Polytropic head
• Qs = Volumetric suction flow
• hr = Reduced head
• qr2 = Reduced flow squared
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 Coordinates (R c, Qs) and (R c, q r2)
(Rc, Q s) (Rc, qr2)
NOT invariant Invariant coordinates
coordinates

q r2

where:
• Rc = Pressure ratio
• Qs = Volumetric suction flow
• qr2 = Reduced flow squared
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 The surge parameter Ss

2
• The function f 1 returns the value of qr on the SLL for input h r

q2r,SLL
• As a result: Ss =
q2r,op h
Ss =
1
r
Ss > 1
OP
h
• Ss < 1 : stable operating zone r Ss < 1
• Ss = 1 : surge limit line (SLL)

• Ss > 1 : surge region 2

2 2
q
qr,SLL qr,op
r

OP = Operating Point

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 Introducing the distance between the operating
point and the Surge Control Line

• Step 1: Introduce parameter d = 1 - S s

• Step 2: Introduce parameter DEV = d - surge margin

• The parameter DEV is independent of the size of the compressor

and will be the same for each compressor in the plant

d =0
Ss = 1 Benefits:
h d <0 DEV = 0 • One standard surge parameter
r Ss > 1 in the plant
DEV < 0 • No operator confusion:
• DEV > 0 Good
Ss < 1
d >0 • DEV = 0 Recycle line
DEV > 0 • DEV < 0 Bad
2
Surge margin
q
r
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 Process Flow Diagram for base load control
*
VS
DS
Compressor Swing machine
1

UIC
1

PIC
1

HIC
1
Suction
Proces
header
s
VS
DS
Compressor Base machine
2 Notes
UIC • All controllers act independently
2
• Transmitters are not shown

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 Parallel compressor control by base loading
Compressor Compressor
*
Rc,1 1 Rc,2 2

Swing machine Base machine

PIC-
SP

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

2 2
qr,1 qr,2
QP,1 QC,1 QP,1 QP,2 QC,2= QP,2
Notes
• Load
Machines
Base
Swing load
machine
could
machine
operate
one
be is
or
re-divided
can
fully
more
atbe
same
loaded
running since
compressors
toReliminate
c and
withsuction
runs letand
recycle
and
recycle
without discharge
therecycle
other(s) absorb of boththe
• Base loading is inefficient
machines
load swingsare tied together
• Base loading increases the risk of surge since
compressor #1 will take the worst of any disturbance where:
• Base loading requires frequent operator intervention • QP = Flow to process
• QC = Total compressor flow
• Base loading is NOT recommended • QC - Q P = Recycle flow

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 Process Flow Diagram for equal flow division
RS
VS
P
DS
Compressor
1
ou
UIC t FIC RS
1 1 P

ou
t
PIC
1

Suction
Proces
header
RS s
VS Notes
P
DS
Compressor • Performance controllers act
2 independent of antisurge control
ou
UIC t FIC RS • Higher capital cost due to extra
2 2 P
Flow Measurement Devices (FMD)
• Higher energy costs due to
permanent pressure loss across
FMD’s

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 Parallel compressor control by equal flow division
Compressor Compressor
*
Rc,1 1 Rc,2 2

PIC-
SP

Equal flow QP,1 = QP,2 Equal flow

2 2
qr,1 qr,2
Q P,1 Q P,2Q C,2
Notes
• •Requires
Machine
Equal
Machines
Bias relay
flow
2are
operate
on
operates
division
remote
never
additional atmight
identical
with
capitalsame
setpoint since
recycle
work
Rc except
investmentwould suction
ifinwhile
both
by
only
FMD’s andif1discharge
machines
machine
coincidence
work are
curves
still-identical
different
hashave of both
turn
machines
down
resistance
same
• Requires are
duetied
steepness
additional together
to piping
energy duearrangments
to permanent pressure
loss across FMD’s where:
• Poor pressure control due to positive feedback in • QP = Flow to process
control system (see next) • QC = Total compressor flow
• QC - Q P = Recycle flow
• Equal flow division is NOT recommended
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 Process Flow Diagram for equidistant control for
parallel compressors
RS
VS
P
DS
Compressor
1
ou
UIC Serial t LSIC Serial
1 networ 1 networ
k k

MPIC
1

Suction
Proces
header
RS s
VS
P
DS Notes
Compressor
2 • All controllers are coordinating
ou control responses via a serial
UIC Serial t LSIC
2 networ 2 network
k • Minimizes recycle under all
operating conditions

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Parallel compressor control by equidistant operation
Compressor Compressor
Rc,1 1 Rc,2 2
SCL = Surge Control DEV =
Line . 0 .
1 .
1 .
2 . 2 .
3
3 PIC-
SP

Dev 1 = Dev2
Q1 ≠ Q2
N1 ≠ N2
2 2
qr,1 qr,2
DEV 1 DEV 2
Notes
• Since
The
Machines
DEV
DEV isare
operate
is
a dimensionless
kept at
at same
the same
R cnumber
all
since
relative
sorts
suction
representing
ofdistance
machines
and to
discharge
the
can
thedistance
be
Surge
mixed:
of Control
both
between
small,
Line
• Maximum turndown (energy savings) without recycle or blow-off
• machines
the
(SCL)
big,operating
axials,
Recycle are
willcentrifugals
point
tiedstart
only together
and the Surge Controlare
Line
• Minimizes the riskwhen all machines
of surge on their
since all machines SCL part of the
absorb
• Lines
This
The DEV
means
of equal
willinbepractice
disturbance DEV
the can
same the
befor
plotted
same
all machines
DEV
on the
for both
performance
but they
machines
willcurves
operateasatshown
different speeds and
• Automatically flow rates
adapts to different size machines
• CCC patented algorithm

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 The load balancing response
• This
In
Other
Theorder
fast
antisurge
loadsharing
master
average
loadsharing
to
master
balance
controller
DEV
controller
controller
controller
is
controllers
the
sent
calculates
machines
reports
out
controls
reports
toalso
all
the
the
they
this
report
the
actual Master Controller
• The load
primary
need
DEV
their
average
loadsharing
to
PV
DEV balancing
tothe
be
process
also
ofPV
kept
all
load
controllers
toto
reported
the
at
the block
balancing
variable
the
master
master
same
DEVis
toby a slow
become
block
controller
controller
PV’s
DEV
directly
in the SP P
controller
manipulating
loadsharing
for that will
all load balancing
controllerequalize
the finalblocks all DEV’s
control elements for V
PID
all parallel compressors
• This reported DEV becomes the Process S
• Its output(PV)
Variable is added
for thetoload
the total outputPID
balancing to P
the
loopperformance control element
DEV from other Averag
loadsharing controllers e

Analog Inputs

FA

DE
V
Mode
DE DE DE
V V V
P S
Primary Load Primary
P R V P
respons balancin respons
I T e g e

+ +
Loop Loop
Antisurge Decouplin Decouplin Loadsharing
g g Controller
Controlle
r
To antisurge valve To performance
control element
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The load balancing response

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