2013 Compressor Controls Corporation

Loadsharing for
Compressor Networks
 Compressor Networks

• The purposes of networks include:

– Redundancy
– Flexibility
– Incremental capacity additions
• Often each compressor is controlled, but
the network is ignored
• Compressor manufacturers often focus on
2013 Compressor Controls Corporation

individual machines
• A “network view” of the application is
essential to achieve good surge protection
and good performance control of the
network
 Equidistant Loadsharing
2011 Compressor Controls Corporation

• LSICs get their PV from their companion A/S controller

and their setpoint from the MPIC
• All controllers should coordinate their control responses
in real-time
 Equidistant Loadsharing

Rc,1 Compressor 1 Rc,2 Compressor 2

SCL = Surge Control Line DEV = 0
0.1
0.1
0.2
0.2
0.3
0.3
PIC-SP

Dev1 = Dev2
Q1 = Q2
2013 Compressor Controls Corporation

N1 = N2
2 2
qr,1 qr,2
DEV1 DEV2
• Machines operate at same Rc
Notes:
• The DEV is a dimensionless number representing the relative
distancesystem
• Maximum between the operating
turndown withoutpoint and or
recycle theblow-off
SCL
• Machines are kept at the same DEV which may correspond to
• Minimizes
different the risk of
speeds andsurge
flow since
rates all machines’ (recycle valves)
• absorb partwill
Recycle of only
the disturbance
start when all machines are on their SCL
• • Automatically
Since DEV isadapts to different
dimensionless, alltypes
sortsof
ofcompressors
machines can be
• CCC mixed: small,algorithm
patented big, centrifugals, turbine & motor drives
 Dynamic simulation:
Variable speed drive - parallel compressors

VSDS
RSP
Compressor 1

out
UIC Serial LSIC Serial
1 network 1 network

Load
2013 Compressor Controls Corporation

MPIC HIC
1 1

VSDS
RSP
Suction
Compressor 2 Process
out
UIC Serial LSIC
2 network 2
 MPIC
(P/F)

1
Process Pd
Process Ps PV
L/S data flow
Process Mass Flow PID
SP
DEV avg

OUT
LSIC 1 LSIC 2
(P/F) (P/F)
4 4
PV PV

SP
SP
5
2
OUT OUT
2013 Compressor Controls Corporation

3 To Speed 3
To Speed
Governor 1 Governor 2

UIC 1 UIC 2
(A/S) (A/S)

DEV DEV

6
OUT OUT

To A/S 1 To A/S 2
valve valve
 How does L/S work?
1. Master is reading/controlling the Process Variable.
2. Based on the deviation (error) between the process PV and the
process SP, the Master initiates a PID response to the P/F
controllers to increase/decrease speed.
3. The A/S controllers continuously calculate the DEV and send it
to the P/F controllers as their PV. Suppose DEV1=0.3 &
DEV2=0.2.
4. The P/F controllers send the DEV to the Master which calculates
the average deviation. (Avg DEV= 0.25 in our case).
5. The average deviation is sent back to the P/F controllers as a
new SP. The P/F controllers compare the new SP (new DEV)
2013 Compressor Controls Corporation

with their PV (old DEV) and adjust their DEV slowly. If the SP is
lower than PV, the P/F controller lowers the speed (at the speed
governor output) since it is running at a higher flow rate [here
we need to lower the DEV
move to the left
less speed]. In
our case, P/F1 (having SP=0.25 and PV=0.3) will decrease its
speed and P/F2 (having SP=0.25 and PV=0.2) will increase its
speed to run on higher DEV. This process is continuous.
• If disturbance happens and we have DEV < or = 0, Master will
help the A/S controllers by sending its PID output directly to
the A/S controllers to increase its output (whichever needs
help). So both PI from A/S and PID from Master help in
regulating the valve throughput.
• POC can be enabled in Master to improve performance.
 Parallel Load-sharing

- Load-balancing is tuned slower.

- Primary Response in LSIC is used when the DEV is +tive.
- Primary Response in A/S is used when the DEV is –tive only and we
need to recycle.
2013 Compressor Controls Corporation
 Equidistant Loadsharing
for multi-section compressors
VSDS RSP
Train A
Section 1 Section 2

out
UIC Serial UIC Serial LSIC Serial
1A network 2A network A network

Suction
MPIC
Header VSDS RSP 1
Train B
2013 Compressor Controls Corporation

Section 1 Section 2

out Process
UIC Serial UIC Serial LSIC
1B network 1B network B

• Select per train -- in the loadsharing controller (Master) - the section closest to the SCL (higher S
(lower DEV)). From UIC1A & UIC2A, minimum DEV is selected per train and sent back via LSIC-A to
Master. From UIC1B & UIC2B, minimum DEV is selected and sent back via LSIC-B to Master. Master
calculates new avg DEV for the network.
• By selecting the section closest to the SCL it is guaranteed that the other section on the same train
is not in recycle
 The Primary Response
• Master controller (MPIC) controls
the main Process Variable (PV) via
its PID control block
• The output of the MPIC PID goes to
the primary response block in the
loadsharing controller
MPIC
PV PID
1
• In the primary response block, the
controller checks if the machine is
close to the SCL:
– Yes: don’t reduce compressor
2013 Compressor Controls Corporation

throughput
– No: reduce compressor
throughput as necessary
• Apply loadsharing gain M0
• The primary loop gain of MPIC goes
directly to the performance control
element via the primary response Primary
block Response

To performance
control element
 The Primary Response
• In order to check if the machine is
close to the SCL, the LSIC primary
response block needs the A/S DEV
•
•
The DEV is reported by the UIC
When the machine is close to the
MPIC
SCL, MPIC output changes will be PV

•
redirected from the LSIC to the UIC
to help in opening the A/S valve
When DEV < or = 0, further
1 PID

reduction of machine throughput is

2013 Compressor Controls Corporation

handled through modulation of the

antisurge valve

Primary DEV Primary

Response Response

To antisurge
valve
 Loadsharing Response

• In order to maintain equal distance

from surge, each compressor needs
to be kept at the same antisurge DEV PV PID
• The antisurge controller reports its
current DEV to the load balancing
block in the loadsharing controller
• This reported DEV becomes the
2013 Compressor Controls Corporation

Process Variable (PV) for the load DEV

balancing PID loop in the LSIC
• The loadsharing controller also
reports this DEV to the MPIC
PV Load
Balancing

DEV
Primary
Response
 Loadsharing Response

• Other loadsharing controllers also

report their DEV to the master
controller to be averaged PV PID
• The MPIC sends the average
DEV to all LSICs as the set point DEV from Average
for all load balancing blocks other LSICs

• The load balancing block

2013 Compressor Controls Corporation

works to carefully balance the DEV

DEVs on all running
compressors
SP
• Its output is added to the total
output to the performance PV Load
control element Balancing

DEV
Primary
Response

To performance
control element +
 Pressure Override Control (POC)
• Performance control loop may be too slow
Benefits:
to react to a large disturbance
• The pressure excursion may be dangerously PID
• large
Fastandresponse
threatenduring fast/ machinery
a process upsets trip PV
PV
• • Pressure
Avoid process
Overridetrips due(POC)
Control to lack
canofbe PI
response
used to openintheperformance control
antisurge valve when a (One-Sided)
SP
elementslimit is exceeded
configured
• • When
Allowsthe closer
operating point drops
operation below the
to process
POC setpoint,
limits withoutnormal
takinga/srisks
control is resumed
• MPIC will ultimately stabilize the operating
2011 Compressor Controls Corporation

point on its primary process setpoint

Rc
Relief valve
setting

POC-SP
Antisurge
PIC-SP Response
2010

To antisurge
2
valve
qr
 Loadsharing Overview
(Simplified)

PV

POC PV
SP PID
PI
(One Sided)
POC SP

DEV from other

Average
loadsharing
controllers
Analog Inputs
2013 Compressor Controls Corporation

DEV
fA Mode

DEV DEV DEV

PV SP

PI RT Primary Load Primary

Response Balancing Response

+ +

Loop Loop
Decoupling Decoupling
LSIC
To antisurge valve
To performance
control element