Field-based Control for Compressor

Anti-Surge

John Rezabek
Process Control Specialist
ISP Lima LLC

2009 General Assembly

Yokohama, Japan
 Objectives

• Provide efficient and reliable surge

g
control to:
• Prevent
e e t su
surge
ge a
and
d co
consequent
seque t equ
equipment
p e t
damage
• Prevent p
process downtime
• Improve process stability
• Decrease blow off
• Reduce power consumption

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Yokohama, Japan
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© 1999 – 2009 Fieldbus Foundation
 Introduction
• Compressor Anti-
surge requires
speed and reliability
• Can field-based
control improve
reliability and
performance?
• How fast can we go
with
ith newer
offerings?

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Yokohama, Japan
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© 1999 – 2009 Fieldbus Foundation
 What is Surge?
ΔP
Surge Line Point where the flow
pattern collapses
B
Design Operating point

Speed

D
C
105 %

100 %

95 %

Flow

2009 General Assembly

Yokohama, Japan
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© 1999 – 2009 Fieldbus Foundation
 Deep Surge!
ΔP
Surge Line
Cycle lasts 300 ms to 3 ss,
C depending on speed,
B
compressor characteristics

E
Reverse flow finds
D Speed
blades resistance
100 %

Flow

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Yokohama, Japan
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© 1999 – 2009 Fieldbus Foundation
 Surge path

• If the throughput is reduced from A, the compressor

will follow the curve back to B.
• In B the flow collapses, going to zero at point C.
• With the head falling below the head capability of the
compressor, a new flow is produced (D).
• If the system
y load is the same,, the compressor
p will
go through A, B, C and back to D on and on.
• Each compressor speed has a point B, where the
flow collapses
• The collection of these points is called Surge Curve.

2009 General Assembly

Yokohama, Japan
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© 1999 – 2009 Fieldbus Foundation
 What is Surge?
ΔP
Surge Line Point where the flow
pattern collapses
B
Design Operating point

Surge
Area A

Speed

105 %

100 %

95 %

Flow

2009 General Assembly

Yokohama, Japan
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© 1999 – 2009 Fieldbus Foundation
 Consequences of Surge

• During surge, the flow variation produces prominent

axial oscillation.
• The frequency and displacement of this oscillation
depends on the compressor speed
speed, among other
factors.
• The oscillation can damage the bearings, impellers
and labyrinth seals, causing parts of the rotor and
stator to touch each other, resulting in serious
damage or destruction.
• Internal temperature can raise to dangerous levels.
• Compressor life is shortened
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Yokohama, Japan
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© 1999 – 2009 Fieldbus Foundation
 Factors leading to Surge

• Load changes, start/stop

• Gas Molecular Weight change
• Upstream
p or downstream pressure
p changes
g
• Gas temperature changes

2009 General Assembly

Yokohama, Japan
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© 1999 – 2009 Fieldbus Foundation
 Surge control
ΔP FTS TTS PTS
Surge Line

B'
FIC
Driver Compressor

A
Discharge
Speed TTD PTD Flow

105 %

Calculated 100 %
Setpoint Line
95 %

Flow

2009 General Assembly

Yokohama, Japan
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© 1999 – 2009 Fieldbus Foundation
 Process Blower – Simpler with milder
consequences
• Keeping the Blower out of the surge
region
i means a more stable
t bl flow
fl
• More stable flow allows running closer to
constraints
• Running closer to constraints means less
fuel CO2
fuel,

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Yokohama, Japan
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© 1999 – 2009 Fieldbus Foundation
Inside “peak
peak pressure”
pressure line,
line flow is unstable

Desired Operating
Point

Peak Pressure

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 Field-based control of blow-off valve
• Controls total flow
• Allows operation
close to low-flow
BMS tripp point
p
• Saves fuel costs
and reduces CO2
emissions

2009 General Assembly

Yokohama, Japan
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© 1999 – 2009 Fieldbus Foundation
 Surge Control Scheme

Discharge
Pressure SGCR SP

Blow-off FICC Blow-off

ff
Flow Σ (Total Flow) Valve

Flow to
Burner

Inlet
FIC
Louvers
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 Blower Anti-surge scheme
Flow to Burner

Total Flow
Setpoint

Total Flow
Controller
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© 1999 – 2009 Fieldbus Foundation
 Macrocycle Schedule

Discharge Pressure
Flow to Burner
Blow-off Flow
Calculate SP
Sum Flows
Burner Flow FIC

“Fast” PID / AO would reduce

Burner Flow Valve
required macrocycle to 325 ms
Total Flow FIC or less

Blow-off Valve
2009 General Assembly
Yokohama, Japan
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© 1999 – 2009 Fieldbus Foundation
 10,000 HP Turbine / Blower Anti
Anti-surge
surge
• Large critical
un spared
un-spared
asset
• Typically
yp y runs
at 5000 to 7000
RPM
• Expensive to
repair; lost
production
d ti
even more
expensive
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© 1999 – 2009 Fieldbus Foundation
 Discharge Flow / Pressure /
T
Temperature
t Measurement
M t

• Venturi Flow meter on

discharge
• Pressure and Temperature
p
Compensation
• Discharge and suction
converted to ACFM

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© 1999 – 2009 Fieldbus Foundation
 Control Scheme – FF for IO only

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© 1999 – 2009 Fieldbus Foundation
 Control Scheme – FF for IO only

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 Control Scheme – FF for IO only

CALC Block 2:
1) Calculates
CALC Block: Surge
Theoretical
1) Curve
Corrects SCFM
2)
2) Converts
C
Calculatescorrected
% Overd
SCFH
Surge to Suction
3) and
AddsDischarge
g
5 – 10%
ACFM
“Bump” when surge
3) is
Converts PSIG to
approached
PSIA

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Yokohama, Japan
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© 1999 – 2009 Fieldbus Foundation
 Control Scheme – FF for IO only

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 Macrocycle Schedule – no FF control

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 With Core Calculations in Field:
• Keep same “look and
feel” for operator
• “Percent over Surge”
calculation does not
fit nicely in standard
FF blocks
• CALC blocks will not
run in H1 card

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© 1999 – 2009 Fieldbus Foundation
 Converts Mass
With Core Calculations in Field: Flow to ACFM
at Suction
Conditions

New DP
cell does
Mass Flow
internally
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 With Core Calculations in Field:
Derives
Discharge ACFM
Asynchronously

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 With Core Calculations in Field: TRK_VAL
TRK VAL is a
constant 100%

HOST still ARTHM Sets “TRK

TRK_IN_D
IN D”
calculates surge calculates % over if Suction Flow <
2009 General Assembly

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Yokohama, Japan

© 1999 – 2009 Fieldbus Foundation

 Macrocycle Schedule – FF control

Discharge
Di h P
Pressure
Suction Temperature 1
Discharge Flow

Disch. Press. Push

ISEL’ doing
ISEL’s d i HHott B’up
B’
Disch. Temp. Push

Calc % Over Surge

Check if < 0%
Blow-off Valve 2009 General Assembly
Yokohama, Japan
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© 1999 – 2009 Fieldbus Foundation
 Business Results Achieved

• Data from CCC talks about 100K yearly

energy savings for a compressor about the
same size used in process air.
• Control in the field responds within the
macrocycle whereas in the DCS takes longer.
• Proven availability and fault tolerance with
physical layer diagnostics.

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© 1999 – 2009 Fieldbus Foundation
 Summary

• Anti-surge control is of great benefit, if not a

necessity
• Unless there is great economic benefit for
running close to surge, extraordinary cycle
times are not required
• Intelligent devices and field-based
deterministic control can be superior to host-
solved schemes
• Newer devices have increasingly fast and
efficient function blocks
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© 1999 – 2009 Fieldbus Foundation
 About the Presenter

• John Rezabek, Process Control Specialist,

ISP Lima LLC
• Began with Standard Oil and later BP,
working in refineries and chemical plants.
After 27+ years, still pulls into a process
plant and sits at DCS engineering console
nearly every day.

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© 1999 – 2009 Fieldbus Foundation