17th Mediterranean Conference on Control & Automation

Makedonia Palace, Thessaloniki, Greece

June 24 - 26, 2009

A DCS Supervisory Control of a Centrifugal

Compessor for Oxygen Consumption Optimization
Silvia Maria Zanoli
Luca Barboni
D.I.I.G.A
affidabilità automazioni- I&C
Università Politecnica delle Marche
api raffineria di Ancona
Via Brecce Bianche, Ancona, Italy
Falconara , Ancona, Italy
s.zanoli@univpm.it
L.Barboni@apioil.com

Abstract—In this paper, a supervisory control system for syngas.

flue
gases steam
oxygen consumption optimization on a Syngas GT HRSG ST
Manufacturing Process Plant is proposed. A grey-box Heat Recovery Steam Turbine
Gas Turbine
Steam Generator
multivariable parametric identification of the oxygen fuel-oil
compressor system is first performed. Consequently, by
means of dynamic simulations the structure of an optimal electric electric
power power
control system has been determined, also reflecting the
implementation constraints linked with the use of a DCS. syngas
Finally, operating results of the system implemented on the ASG
fuel-gas Steam to
real process are shown which confirmed the expected results Auxiliary Steam
plants
obtained by simulations. Generator
diesel-oil
Keywords- Supervisory control, parametric identification, Figure 1. Schematic representation of a combined cycle power plant
relative gain array (RGA), antisurge control system, DCS.

I. INTRODUCTION This Unit is located in the Syngas Manufacturing

The IGCC plant (Integrated Gasification Combined
Cycle) located in the industrial area of api Refinery of
Ancona (ITALY) is devoted to the production of electric
power by using the heavy residues (TAR) coming from the
low pressure plants of the oil refinery. The combined cycle
plants, like the IGCC, enable for the thermal energy
recovery by re-using it for other industrial processes, such
as the steam production. In order to enhance the efficiency
level and the profitability of oil refineries as well as the
commitment to meet precise production standards, an
increasing level of system automation ([1], [2], [3], [4]) is
required. Furthermore, the existence of rigorous
environmental standards together with the need to operate
in high safety conditions contribute to the implementation
of automatic systems of rising complexity.
In the plant considered in the present study, depicted in
Fig. 1, the production of electric power (300 MW)
basically depends on the performances of a Gas Turbine
(GT), specifically planned for the combustion of a syngas,
and of a Steam Turbine (ST). The input steam is generated
through a Heat Recovery Steam Generator (HRSG) by
using the thermal energy contained in the GT flue gases.
Part of the steam generated by HRSG unit is sent to the
plants and, in order to face up additional steam requests,
the IGCC has also been provided with an Auxiliary Steam
Generator (ASG).
In order to minimise the pollution’s emissions, the Gas
Turbine, charge consists in a syngas generated by the
heavy residues cracking process, called gasification
(aprox. 60 t/h). The flow of high pressure oxygen (aprox
72 bar gauge) is sent to the gasification plant by a
centrifugal compressor, which is fed by low pressure
oxygen (aprox. 7.5 bar gauce) coming from an Air
Separation Unit (ASU).
Process Plant (SMPP) of the IGCC plant and it is designed
to produce a total of about 1800 tons per day of oxygen at
95% mol of purity, upon the project conditions.
Furthermore the ASU produces high pressure nitrogen for
syngas dilution to the Gas Turbine (GT), low pressure
nitrogen for utility uses, instrument air, and service air.
In this paper, a supervisory control system for the
oxygen consumption optimization is presented. The
proposed scheme aims at achieving economic advantages
especially preventing the continuous waste of oxygen
actually sent in the atmosphere in considerable quantities,
as well as limiting continuous wear of the vent valve.
Furthermore by replacing manual operations on valves by
automatic controllers the energy consumption is optimized.
II. ACTUAL PROCESS CONTROL SYSTEM
In the following, the processes central to the
functioning of the centrifugal compressor (Base Load
Oxygen Compressor, BLOC CM-8903) are described
together with its actual control system (see Fig. 2). The
gaseous oxygen coming out of the exchanger (E-8912) is
sent to the suction regulating valve PV-89607 of the
compressor through the pump P-8903A (acting on the
liquid phase). Under normal running conditions the suction
pressure control is automatically handled by the controller
PC-89250, which acts on the valve LV-89250, located on
the cryogenic pump P-8903A discharge (therefore
operating on liquid oxygen).
The suction valve of the compressor PV-89607 has
been designed to protect the compressor from over-
pressures, and the controller PC-89607 has a set-point
which is normally higher than the working discharge
pressure of the compressor.

978-1-4244-4685-8/09/$25.00 ©2009 IEEE 1196

 .
Figure 2. Actual control system for the BLOC centrifugal compressor
The BLOC recirculation system aims at controlling the
compressor load in case of low capacity operation so as to
avoid surge conditions [5]. The high-pass selector (in the
local panel of BLOC control) selects the highest signal
between the PC-89610 controller (in DCS) and the anti-
surge controller (UC-89610). The set point of the BLOC
discharge pressure (PC-89616) is normally equal to the
pressure required by the facilities (aprox. 72 bar gauge).
The implementation of the control is given, as from the
design, to the vent valve PV-89616.
The controller PDC-89316 for the differential pressure
of cryogenic pumps, and the controller FC-89650 (flow of
gaseous oxygen from the “main condenser” of the ASU),
are used during the start-up, with the centrifugal
compressor CM-8903 turned off) to gradually increase the
load of the ASU plant during the start-up operations.
The oxygen compressed by BLOC is sent to two
gasification reactors which regulate the flow fed through
the valves FV-80023 and FV-80123, according to a typical
lead-lag logic for the control of combustion ratios (Cross
Linked Ratios, CLR). The value of heavy oil flow being
processed is set by the operator according to the
percentage of maximum flow (33 t/h per each reactor)
through two manually operated stations (HC-80021, HC-
80121).
The control system of the discharge pressure CM-8903
through the vent PV_89616, even by guaranteeing good
performances as for the set point tracking terms and of the
decoupling action with the upstream plant, certainly
presents substantial economic disadvantages, such as the
continuous wear of the vent valve (subject to differential
pressures of 72 bar) and, primarily, the continuous waste
of oxygen sent to the atmosphere. Furthermore, the manual
control of the valve UV_89610 to adjust the machine at
every change of its working point does not satisfy the
economic target to limit the compressor energy
consumptions.
III. THE NEW CONTROL SYSTEM DESIGN SETTINGS AND
CONSTRAINTS
The new control logic has therefore to ensure a stable
control of the discharge pressure of the compressor CM-
8903. This should guarantee the possibility to keep the
vent PV_89616 closed (less wear of the valve and
1197
elimination of oxygen waste sent to the atmosphere)
together with the minimization of the recycle valve
UV_89610 opening (which will be kept as long as possible
closed, but used to assure the compressor working point at
a safe distance from its surge condition), with a consequent
energy saving.
In the realization of the controller special care should
be given to some process constraints. In particular, low
differential pressure on the cryogenic pump P-8903 should
be avoided in order to prevent emergency shut down
situations. In addition, as previously stated it should be
avoided to move the compressor working point in
proximity of its surge conditions. Finally, interaction
between the PCA_89250 and PC_89610A controllers
should be limited so as to minimise disturbances on the
line between the exchanger E-8912 and the compressor
suction.
A. Low differential pressure constraints analysis
The limit conditions for the pump P-8903 according to
the processed flow have been verified through a test. The
target was therefore to verify the maximum opening for the
valve LV_89250 and the maximum flow so as to enable
the reduction of the suction to pumps P-8903.
The valve LV_89250 has been opened by way of the
manual mode controller with consecutive 1–2% increases
until a maximum opening of 66.5% has been reached, in
order to detect the pressure increase of gaseous oxygen
according to the valve opening, under conditions of
constant flow (57.5 t/h).
Subsequently, under automatic pressure control (set-
point = 8.5 barg), the oxygen flow has been increased
beyond NOC flow of the plant (66.9 t/h). The differential
pressure on the pump has not gone through substantial
decreases (-0.2 bar) and the trip of P-8903 has not been
risked (differential pressure of trip = 4 bar).
The test results thus gave positive response about the
opportunity to use the valve LV_89250 as an actuator,
without running the risk of oxygen pump trip.
For safety reasons, within the monitoring control
diagram a logic of self-deactivation has been considered in
the event of low differential pressure on the pump together
with correlated visual and audio alarm for the operator.
B. Compressor surge
The set-point for the suction pressure of the
compressor CM-8903 is normally fixed so as to guarantee
the energy optimisation of the machine. The constraint
which determines the lower allowed suction pressure that
guaranties a correct machine performance is related to the
characteristic curves of the machine and to the antisurge
control system. In practice such a control system for the
protection of the compressor from surge starts to open the
recycle valve in order to guarantee the minimum
acceptable flow, as soon as the compression ratio
overcomes the given threshold. Such a threshold has been
chosen so as to have a minimum distance from the surge
under the most unfavourable temperature conditions.
C. Interaction and variables selection
The attempts experienced in the past, aiming at
controlling the discharge pressure PT_89607, had
alternatively involved the compressor suction valve
PV_89607 (16’ butterfly valve) and the recycle
UV_89610. Even though in the literature [5], [6], [7] the
compressor suction valve is typically used to control
discharge pressure, the results obtained through PV_89607
had never been satisfactory. Furthermore, since it was not
possible to achieve a suction oxygen storage on the line
from E-8912 to the CM-8903 suction, the line pressure
regulation had to be carried out through the LV_89250 (4’
globe) valve, acting on the liquid oxygen located upstream
the evaporator.
As often happens when different control loops are
within the same process, the question arises upon which
variable should be manipulated by each controller.
Therefore, as explained in the next section, proper
techniques [7], [8], [9] have been adopted in order to select
manipulated variable /controlled variable pairs which
guaranties a more efficient control action. Then, before
proceeding with the tests on the real system, different
control schemes have been simulated, by using from time
to time different pairings among the various actuators, i.e.
the manipulated variables, and the variables to be
controlled.
IV. MODELS IDENTIFICATION
A. “Grey-box” parametric models
By starting from simplified physical laws, which are
known except for a certain number of parameters, it has
been chosen to model the process by using a “grey-box”
parametric identification technique [10], [11]. That is, the
identification of the transfer functions has been carried out
without considering the physical system under
examination as a pure “black box”, but all the known
notions on the process physics under examination have
been utilised, limiting the identification procedure the
unknown parameters.
The obtained results have confirmed the initial choice
of a single pole and the dead time transfer functions, in
which the quoted parameters and the gain constituted the
unknown variables to estimate.
By starting from the prior knowledge of the system, it
has been decided to use the MISO output error models, in
order to focus the identification on the deterministic
transfer functions, by treating as white noise the part of
non-modelled dynamics that, in the present case, is
reasonably restricted [11], [12], [13].
1198
B. Valve PV_890607 modelling
The computed parametric identification previously
made was based on sampled process data which not
included the action of the valve PV_89607 the reason
being that historical functioning data were not available
for such an actuator (normally used only in the short start-
up transients, which is not the subject of this study). To
include this action effects, we built the mathematical
model of the valve based on the functioning equations of
such an actuator.
An interpolation of the valve characteristic curve,
function of the valve opening variable x, has been obtained
minimizing the square deviation between the points of the
characteristic curve and the following sigmoidal
approximation function:
K
 CˆV   
1  e    x  x0 

Considering the definition of the flow coefficient CV of
a valve the following equation can be written [6]:
 p  
 CV  Q   0    
 p  0 
in which Q is the fluid flow measured in [U.S. gal/min],
p0 and p are the reference and operative differential
pressure in [lb/in2] and 0 and  are the reference and
operative fluid density expressed in [lb/ft3]. From (1) and
(2) it is possible to write the equation of the mass flow
such as
q m  k  CV  x    P , T   p t/h 
  
where k is a coefficient which takes into consideration of
the measurement units and the constants introduced in the
previous formula.
As, for the considered application, in the typical
functioning range of the valve (0.016 bar) and for flow
ranging from 55t/h to 70t/h, the differential pressure is
rather constant, it was possible to draw a square function
between the upstream pressure of the PV_89607 and flow,
depending in a non linear way also by the valve opening.
 
Pupstream  f qm2 , x   
From (4), new transfer functions of PV_89607 on the
suction pressure and on the compressor discharge pressure
have been deduced, within the linear model previously
identified. As a matter of fact, by starting from the
knowledge of suction pressure variations and of the
compressor flow, the contribution of the valve PV_89607
on the discharge pressure was always assessable.
C. Variables selection
The problem of variables selection consists in solving
two important questions such as the choice of the
manipulable variable which has greater influence on the
variable to be controlled and the minimization of
interaction phenomena. The target is therefore to select
manipulated variable /controlled variable (MV/CV) pairs
which make the automatic control more efficient, by
considering the interactions of each manipulated variable
with each controlled variable. Very often techniques of this
kind are based on the knowledge of static gains matrix of
the process model. Nevertheless, also with a correct
selection of variables, it can be necessary to carry out a
subsequent calibration of control parameters and, if
necessary, to insert also decouplers within the control
system [7], [8], [14].
In the multivariable system being examined, in order to
find the best pairing between the control valves and the
pressure to be controlled (compressor suction and
discharge) the procedure known in literature as the
Relative Gain Array (RGA) has been adopted [7], [8], [9].
This procedure is based on the building of a matrix of the
relative gains Λ and its use to decide the pairings MV/CV.
Here below the obtained Λ matrixes are reported:
RGA1 LV-89250 LV-89610
Psuction 0.35 0.65
Pdischarge 0.65 0.35
RGA2 LV-89250 PV-89607
Psuction 0.2445 0.7555
Pdischarge 0.7555 0.2445
From the analysis of the results, it can be deduced that
the best pairing between MVs and CVs is the one that
associates the valve LV-89250 with the discharge pressure.
From the control viewpoint then, the suction pressure
could be manipulated both through the recycle valve UV-
89610 and through the PV-89607.
The conclusions reached with the RGA method are in
perfectly agreement with what is commonly known in
literature [7]: compressor flow and the compressor
discharge pressure control normally take place with the
valve having a higher differential pressure, that is to say
the valve LV-89250 (design Δp = 0.30 bar, line size 4’’),
whereas the suction pressure control takes place with the
valve having lower differential pressure, that is to say the
PV-89607 (design Δp = 0.02 bar, line size 16’’) or the
recycle valve UV_89610.
Furthermore, the dynamic simulations being carried
out and the later tests performed on the plant, as it will be
shown, have confirmed the conclusions drawn in this
paragraph.
D. Development of an “optimal” autotuning technique
Before implementing the control logic on DCS,
different control solutions have been simulated on the
realized model, by trying to quantify the diversity of
performances among the various possible MV/CV
pairings.
In order to assess the goodness of the designed control
structures, independently of the parametrization of the
control diagram (consisting in the gains and in the time
constants of feedback PID controllers, of feedforward
lead/lag controllers and of decouplers), an “optimal”
tuning technique has been developed.
The idea consists in finding the tuning parameters of
the entire control diagram minimizing a penalty function
similar to the one used for LQG optimal control. The
chosen functional J accounts for both the control error and
the control effort: i f


  
min J  min  e T i   Q  e i   u T i   R  u i  

 PV_89607, considering the disturbances introduced
if i i0
 
 min q1  eP2m i  q2  eP2a i  r1  uP2m i  r2  uP2a i
ii0
Every control logic has been trained over numerous
epochs by trying to minimize the above-described
1199
TABLE I. PERFORMACES OF MANUAL VS AUTOMATIC CONTROL FOR
THE COMPRESSOR DISCHARGE PRESSURE
functional through parameters manipulation of the various
feedback and feedforward controllers, with non-linear least
squares and non-linear simplex types algorithms, so to
avoid stopping on local minimums of the J functional
during the training phase (“suboptimal solutions”).
In order to make the training of control logic more
efficient, within the training epoch different simulated
disturbances following typical load variations of the
downstream process (load percentage of gasifiers) and set-
point variations of controllers have been introduced.
Obviously the goodness of the tuning of the control system
resulted to be connected with the predictive capacities of
the identified model, as well as by the quantity of
information contained in the training signals.
Here it is worth underlining that, although the problem
of local minimums was present and the lack of
information on all the possible cases of disturbances, the
method proved to be efficient from the operating
viewpoint and enabled to realize the “tuning” of logics
having also dozen of different parameters.
V. SIMULATION RESULTS
Once the goodness of the model was assessed by using
the classical cross-validation methods [10], [11],
simulations of the different control diagrams have been
carried out in order to assess the performances in terms of
control error and robustness, in face of the same
disturbances intentionally introduced on the system.
The final adopted scheme, shown in Fig. 4, entails the
following pairing between manipulated variables and
controlled ones.
LV_89250 ↔ PT_89607 (discharge)
PV_89607↔ PT_89607 (only protection for high
discharge pressures, as from original
design)
UV_89610 ↔ PT_89603 (suction)
In table 1 the control results obtained in simulation for
the compressor discharge pressure are reported,
compared with the ones obtained in practice by an expert
operator through manual control. The sampling period
used TS = 1s; the term IAE stands for the integral of
absolute values of the error in the period being examined.
Fig. 3 shows the simulated trends of the discharge
pressure and of the suction pressure (blue) as opposed to
the respective imposed set-points (green), and the
predicted positions for the valves LV_89250 and
through load variations of gasifiers.
It is worth pointing out that the introduced disturbances
correspond to real load variations occurred in a time
window of about 8 hours. The tuning parameters of

Figure 3. Simulation results
the diagram have been obtained with the autotuning
technique previously described.
The adopted control scheme (see Fig. 4) is
characterized by the compressor suction pressure set-point
manipulation through the combined action of two
contributions: a feedforward controller for the
compensation of disturbances introduced on the system by
set point load variations of the two downstream gasifiers
and a feedback controller of PID type (PC_89608) or the
compensation of any other disturbance derived both by
inaccuracies in the identified model dynamics, (used for
the calculation of the feedforward compensator) and by
any other unmeasured disturbance acting on the system.
The feedforward control is largely applied in the field
of chemical engineering, allowing substantial increases of
the control capacity, especially when facing, as in the case
under examination, with a non-linear process with a slow
dynamics [7], [8], but known through a parametric
identification.
The controller PC_89610 acts on the suction pressure
PT_89603, according to a (valve) position control scheme
[7], [8], applied in this case to the set-point of the suction
pressure (PCA_89250 controlling PT_89603).
A. Decoupler
Since both the recycle valve UV_89610 and the suction
pressure PT_89603 have an influence on the discharge
Figure 4. Proposed control system for the BLOC centrifugal compressor
1200
  .
Figure 5. SP (violet) and PV (yellow) of the discharge pressure “Pm”,
SP (violet) and PV (yellow) of the suction pressure “Pa”,
pressure to CM-8903, a partially decoupling [7] controller
has been introduced on the set-point of PCA_89250 in
order to decrease the interaction effects between the two
control loops.
Assuming the remote set-point (RSP) of PCA_89250 (u1)
and the position of the recycle UV_89250 (u2) as inputs,
and the PT_89603 (y2) and PT_89607 (y1) as outputs, the
process to be examined can be described by a 2x2 transfer
matrix P(s).
Since the adopted feedback control structure, in most
of the industrial processes, uses conventional SISO
controllers, the control matrix GC(s) results diagonal.
Indicating with GC1(s) and GC2(s) the two elements in
the diagonal, the modes of the closed loop system will be
related to the solution of the following characteristic
equation:
1  GC1 ( s )  P11 ( s )   1  GC 2 ( s )  P22 ( s )  
 
  GC1 ( s )  P12 ( s )    GC 2 ( s )  P21 ( s )   0
 It is clear that the closed-loop poles of the whole .
system tend to overlap with the ones of the two SISO
loops, if the second term of the algebraical sum tends to
cancel out. The choice carried out through the RGA
analysis [7], [8] tries to minimize the undesired
consequence of closed-loop poles displacement as an
effect of the “mixed” terms. In order to cancel out
completely this pairing term, it has nevertheless been
considered the insertion of a partial decoupler with the
purpose of cancelling out one of the undesired factors of
the product in “mixed” terms, simply calculated as a single
feedforward on the variable which manipulates the slowest
and most critical control variable, that is to say on the
remote set-point of PCA_89250.
The calculation of the controller parameters has
followed standard forward control techniques, and usual
considerations concerning the physical feasibility hold. In
the case under examination:
P12 s  
GDECOUPLER s    
 P11 s 
Figure 6. Comparison between the measured and the predicted
As it can be seen in Fig. 5, on a load increase of +0.5% variables trends
for each gasification train, the logic immediately increases 3. the use of the valve PV_89607 to control the
the RSP of PCA_89250 (Fig. 5b, green line). The
discharge pressure CM-8903 has also introduced
PCA_89250 controller starts opening the valve LV_89250
dangerous transients on the upstream system
and the suction pressure tends to increase. At the same
time the PC_89610A controller on the recycle detects the pressure, controlled by LV_89250. In particular,
suction pressure increase (its PV), and, as a consequence, if the system operates at higher pressures of the
it starts to close the UV_89610 valve (Fig. 5d), by upstream system, there would be the risk, during
transferring the action of the suction pressure on the the transients, of reaching the maximum
recycle valve. The latest trend represents the rate of allowable pressure threshold with the subsequent
performance of the compression ratio of CM-8903 during activation of the protection systems.
this transient. A limitation for the control effort amplitude 4. in order to optimise the downstream system and
of PC_89608 acting on SP of the suction pressure has been
to keep the recycle as close as possible, a revision
foreseen, in order to minimize the “controlled”
of process operating parameters would be needed
disturbances introduced on the suction pressure; such
variations are anyway replaced by a new position of the (in particular, it would be necessary to increase
compressor recycle at steady state conditions. the upstream pressure), with a consequent higher
energy dissipation from the upstream system.
What has been explained can be well interpreted by
referring to the typical curves of flow/pressure of the From the above-mentioned motivations, the use of the
compressor considering the working point shift caused valve PV_89607 has not been regarded economically
by suction pressure variations and the recycle valve profitable(which would introduce further pressure drops)
position, in order to compensate a disturbance inducing for the control of the discharge pressure.
minor pressure drops on the downstream circuit Analogous attempts have been carried out by using the
(decreasing of flow fed to the two gasifiers and consequent recycle valve of the compressor UV_89610 for the control
closing of the valves FV_80023 and FV_80123). of the discharge pressure PT_89607. Also in this case the
B. Discussion problems pointed out have been the energy non-
optimisation and the interaction with the controllers of the
The tests carried out by using the valve LV_89250 to upstream system.
control the suction pressure and the valve PV_89607 to
control the discharge pressure, have confirmed the
VI. OPERATIONAL RESULTS
theoretical aspects previously quoted; after all, the
following conclusions have been highlighted: After the simulation phase tests, the controller has been
implemented at the DCS. Figure 6 shows the system
1. with the normal operating pressures of the plant, performances with the new supervisory control relating to
the valve PV_89607 has not shown an acceptable a running period of about 12 hours outlighting a good
discharge pressure CM-8903 regulating capacity. match between the real trends (red line) with the simulated
2. To bring the valve to work to lower openings (in ones (blue), referred to the same process conditions. The
order to bring higher differential pressures on the trends in Fig. 6a represent the rate of performance of the
discharge pressure (blue for simulation data, red for
valve, and therefore a higher regulating capacity),
measured data) according to the load variations on the two
an automatic control on the compressor recycle gasification trains (see Fig. 6e). Fig. 6b represent the
would be needed (unforeseen in the original diagram of the suction pressure reaching the compressor:
logic) to avoid, in case of excessive closings of in green the set-point used as a manipulated variable for
PV_89607, the operation of the antisurge system. the control of the discharge pressure, in blue the simulation
and in red the measured values. The trend values of valves

1201
LV_89250 and UV_89610 are shown in the following
Fig.6c and 6d (green for simulation , red for measured
values), finally Fig. 6f represents the trend of the
compression ratio of the compressor.
Comparing the experimental results on the real system
with the prediction of the two controlled variables based
on the proposed model, it can be stated that a good
matching level has been achieved and that the controller is
expected to fulfill the assigned targets. Besides, from the
analysis of the results it can be stated that the opening of
the valve LV_89250 has been precisely predicted as well,
whereas there are problems in the estimation of the recycle
valve conditions. This is fundamentally linked to the fact
that the working point of the UV_89610 for the identified
model was far from the conditions of this validation. It
should be note d that the measured signal and the
simulated one roughly possess the same first derivative.
Prediction Real
IAE 6599 7080
< err [%] > 0.2214 0.2375
err max [%] 0.9969 1.3194
< err [bar] > 0.1594 0.1710
err max [bar] 0.7178 0.9500
samples 41400 41400
Although the disturbances inserted in the system
during the final test have been higher in both frequency
and intensity than in all the simulations tests, the control
system was always able to compensate by reaching at the
latest 0.95 bar of error during transients, with a load
variation of –5% for each gasifier. As a consequence of the
above load decreases and in relation to the behavior of
other supervisory controllers acting on the ASU, the load
to the other compressors is also reduced (in particular to
the BLOC centrifugal compressor), by allowing a “domino
effect” on the energy saving.
To safeguard the reliability of the productive process
various conditions of “bad quality” have been
contemplated on which occurrences the plant is
automatically and in a “bumpless” way switched back to
the originally designed strategy control. The planned
control system also contemplates different conditions of
“bad quality” to safeguard the reliability of the productive
process, and considering these conditions the plant can
automatically and in a “bumpless” way return under the
strategy of design control.
In particular, the present supervisory control system
stays active until: the pumps P-8903 run and are not at
maximum load; the discharge pressure PT_89607 is under
control (inhibition of supervisory control for high absolute
value of the derivative of the discharge pressure); the vent
valve PV_89616 in the compressor discharge is closed; the
butterfly valve PV_89607 is open at more than 85%; the
gasification reactors run; the compressor CM-8903 runs;
the compressor CM-8903 is not under surge conditions.
Whenever a single of these conditions is not satisfied, the
present supervisory control system is shutted down.
VII. CONCLUSIONS
If from the methodological point of view the
importance of the modelling and simulation approach in
the solution of complex control problems is reinstated,
from the operating point of view the new supervisory
control logic was able to ensures a stable control of the
discharge pressure to the compressor CM-8903, with
1202
consequent economic improvements deriving from the
following reasons:
a. possibility to keep the vent PV_89616 closed (less
wear of the valve and elimination of oxygen waste sent to
the atmosphere)
b. possibility to optimize recycle valve opening
UV_89610 (which will stay as long as possible closed, but
without bringing the compressor to the surge state), with a
consequent energy saving
c. possibility of a controlled operation at a lower
suction pressure, with a consequent energy saving
d. realization, together with the other supervisory
control systems of ASU, of an “avalanche effect” on the
energy optimization, since the oxygen consumption is
linked with the processed charge of the whole plant, which
in this case is exclusively linked to the consumptions
requested by the two gasifiers.
e. probable lower wear of the refractory and of the
feed injectors, thanks to a more stable pressure
f. its “robust” behaviour, both in terms of its
disturbances rejection capacity and in terms of “bad-
quality control”, it is useful for the DCS operator as with
other supervisory logics of the ASU.
Besides, the controller meets the required process
constraints avoiding the emergency shutdown of the
cryogenic pump due to a low differential pressure as well
as limiting the problems of interaction between the
PC_89250 and PC_89610A controllers therefore
minimizing disturbances on the line between the
exchanger unit and the suction compressor. The activation
of the antisurge logic is also avoided in practice, thus
adding more efficiency to the whole system.
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