Anti-Surge Presentation Mod LV

Load Compressor Anti-Surge Protection
Integrated Turbine-Compressor Control (ITCC)

Laurent Vallet – Mobile +213 61 41 36 84
Fax +213 21 60 10 81
laurent.vallet@ge.com
June 2006
GE Proprietary Information - Privileged & Confidential
30 Years of Integrated Turbine-Compressor Controls
Russian pipeline controls

Ready-to-ship 1970’s
2
14 June 2004
GE Proprietary Information – Privileged & Confidential
Overview
With constant compressor speed, as inlet flow to the compressor decreases, the
energy (head) produced by the compressor increases (curved lines)
Unstable flow conditions develop as flow through the compressor decreases to the
surge limit where the energy in the downstream process is greater than that produced
by the compressor
When flow reaches the
surge line, a sudden flow
Surge Control Line reversal occurs (a
compressor surge) and
discharge pressure
collapses.
Control systems use a
Surge Line surge control line to
establish a safety margin
to compensate for the
recycle loop period.
Process upsets CAUSE surge events resulting in compressor damage
3
14 June 2004
Predicting Surge Events
Surge Events Do Not Always Provide Advanced Warning
• Surge cannot always be anticipated by increased frequency or vibration
• Surge occurs rapidly, making detection and response difficult
SURGE EVENT - PERCENT of SURGE CONTROL LINE

150
140
130
120
110
100
90
80
70 3-Stage Refrigeration Compressor - SURGE detected at t=0.0

60
50
50 45 40 35 30 25 20 15 10 5 0 5
OPERATING VARIABLE 1st stage
OPERATING VARIABLE 2nd stage SECONDS
OPERATING VARIABLE 3rd stage
4
14 June 2004
Surge Control Application
Surge control is a unique and difficult control application:

Difficulty in accurately defining the compressor operating point from six
different field measurements
Difficulty in locating and defining the surge limit of the compressor
Compressor curve shape near surge line causes large flow changes for
small pressure changes
Interaction with other control parameters, such as levels, pressures and
temperatures
Sequencing and loading/unloading for multiple compressors operating in
parallel
Balance between machine protection and plant operation
5
14 June 2004
GE’s Surge Control Philosophy
Improve Reliability While Maximizing System Efficiency

Avoid process and compressor shutdowns
Avoid surge and compressor damage
Control process disturbances to minimize effect
Provide consistent and simple startup and shutdown
Smoothly transition valves to normal operating conditions.
Better steady-state process control
Better load balancing for parallel and series compressors
Reduce or eliminate recycle or blow-off
6
14 June 2004
Benefits of GE Integrated Control
Improves process efficiency and reduces power requirements
• Allows compressor to operate closer to the surge line, reducing
recycle requirements and saving costs
• Can optimize performance of entire system, not just individual
components
Significantly improves system reliability
• Reduces interactions between compressor and turbine controllers,
minimizing the risk of surge events (decoupling)
• Incorporates 5 separate control layers to react to any process
upsets
Minimizes operating and maintenance costs
• Faster and more interactive control virtually eliminates surge
events … extending compressor life and reducing maintenance
costs
• Reduced spare part requirements for control system
• Common, easy-to-use diagnostic and maintenance tools
7
14 June 2004
Savings
A 0.1% efficiency change would equate to reduced recycle and
saving re-processing of 0.1% of product. For an ethylene plant
producing 500,000 tons per year, tpy this would be a significant
savings as shown:
Compressor power consumed is:
0.65 kwatt/kg ethylene equates to 350,000 Kw/yr,
Pump horsepower consumed is:
0.18 kwatt/kg ethylene equates to 97,000 kw/yr,
Heat consumed is:
6,000 kcal/kg ethylene (assuming 20% heat addition)
equates to 700,000 kw/yr
Total Savings = $138,000 / year
8
14 June 2004
Mark VIe Controller Rack
Original surge control line
This is an example compressor map for 1st
New surge control line stage propylene refrigeration compressor in
a 800,000 tpy ethylene plant.
C3R First Stage
Head vs ACFM The new surge control set 10%
14
13
closer to the surge line will reduce
12 the recycle and save money. In
11
this case, 10% less flow translates
Isentropic Head (10^3 Ft)
10
9 to 312 Hp.
8
7 • For a Ps=19 PSIA, Ts= -35°F, Pd=38.6 PSIA,
6
5
the original control line conditions are: 45,165
4 ACFM, Head is 11,500; this requires 3365 Hp
• At the new surge control line, conditions
3
2
1 change to 41,276 ACFM, which requires only
0
0 1 2 3 4 5 6 7 3053 Hp
ACFM * 10^4
Savings = 312Hp / stage
$674 / day or $264,000 / year
Savings continue / stage.
9
14 June 2004
Integrated Turbine & Compressor Control
COMPRESSOR COMPRESSOR COMPRESSOR
TURBINE
SE 4KT-1 4KT-1 4KT-1
4KT-2 3RD STAGE
1ST STAGE 2ND STAGE
PT
3A/B
PT PT FT
SY
FT 4A/B 6 3A
FT PT 2
1A 2B
4C-4 4C-4
4C-4
Compressor Compressor
Control Control
Stage1 Stage2
SIC UIC UIC
Turbine Control
Integrated Turbine & Compressor

Control - SIC, UIC, PIC and Other
PIC Fault Tolerant Functions in ONE High Reliable Fault
2
Hardware Tolerant Digital Control System.
10
14 June 2004
Mark VIe Architecture
Plant Data Highway (TCP/IP, OPC, GSM, Modbus, PI Server, DNP 3.0)
Ethernet
Operator & System 1® Historian
Maintenance Condition OSI PI
Stations Monitoring
Unit Data Highway (EGD, NTP…)
Ethernet
Controller(s) Controller(s)
PTP IEEE1588 100MB Ethernet PTP IEEE1588 100MB Ethernet
Turbine Driven-Load Process Process

I/O I/O I/O I/O
Remote Remote
I/O I/O
Rotating Machinery Control Process Control
11
14 June 2004
Mark VIe Cabinets
Remote IO Cabinet
Controller Cabinet IO Cabinet
12
14 June 2004
GE Surge Control Enhancements
Software is custom configured for each application
System uses full “Polytropic head” algorithm for
standardization and better performance
Open loop BOOST response for added reliability
Patented Rate Controller calculates the rate of change of
the compressor operating point and positions recycle
valve to slow approach to surge
Maintains compressor protection in the event of a
transmitter failure
Automatic PID compensation delivers optimal tuning
under all operating conditions.
13
14 June 2004
Standard Anti-Surge Functions
• Signal Filtering
• Full Flow Calculations (no partial estimations)
• Signal Failure Protection
• Full TMR Capabilities
• Variable Gain Compensation
• I/O ON-Board Signal Conditioning
• 5 Surge Detection Routines
• Reduced Dead-Time (PRE-PACK)
• Signals in Engineering Units
• Automatic Start-Up Over-Rides
14
14 June 2004
Standard HMI Screens
ITCC Overview
Turbine Overview
Compressor Detail
Stage Detail
Start/Stop Sequence
Alarms/Trips/Sequence Of Events
Compressor Maps
real time operating point
15
14 June 2004
Available ITCC Services
Installation of Anti-Surge Software Module
- Connect & Pre-Configure Routines
- Create Standard MMI Screens & Alarms
Decoupling of the Speed and Process Control Functions
New P& I Drawings with standard ISA graphics
Review of Compressor Performance Maps
Verification of Flow Meter & Sensor Sizing, Location, and Spec.
Verification of Recycle Valve Size and Actuation
Field Mapping and Verification of Compressor Map
Complete range of services available for site-specific needs
16
14 June 2004
Control Options
• Load Sharing of Single and Multi-Stage Compressors

• Process Controller for:
- (PIC)Pressure Indicator Controller
- (TIC)Temperature Indicator Controller
- (LIC)Level Indicator Controller
- (FIC)Flow Indicator Controller
• Capacity Controller
• Inlet Throttle Valve Controller
• Machinery Protection and shutdowns
• Other Functions as required by Site Needs
17
14 June 2004
Danger Will Robinson!!!
EXTREME DANGER OF SLEEP IF YOU PROCEED!!
18
14 June 2004
Standard Anti-Surge Protection
Decoupling
Rate Controller
SCL PID Controller
BOOST with Pre_Pack
Surge Detection Responses
19
14 June 2004
Surge Control Basics
Determining the Operating Point (OP) & the Surge Limit Line (SLL)
Anti-surge control has the added difficulty of controlling to a

calculated variable. Anti-surge control measures five to six field
sensors and calculates the final control variable to control
against.
Q2
We use this term of to calculate the compressor operating
Hp
point.
A Surge Limit Point is determined by testing the compressor in the
field or from using the predicted curves supplied by the
manufacturer. This establishes the relationship of speed .vs.
surge limit line.
20
14 June 2004
Surge Control Basics – Controller Setpoint
 Q S.L.  MARGIN 2 Q2 HP S.L. S.C.L.


HP HP (S.C.L.)
O.P.
Q2
(O.P.)
HP N1 N2 N3
Q 2
 100 Control Variable
(S.C.L.)
HP Q Inlet Flow
When value = 100, operating point is on surge control line (SCL).

100 is the setpoint for the closed loop controller.
21
14 June 2004
Standard Anti-Surge Protection
HSS
% from Safety Line Boost
Prepack
Surge Detect Surge Recovery
Gain Compensation
SCL
% from SCL
Setpoint Adjust Rate
t
22
14 June 2004
Flow Rate Controller  Q2 

H 

 p
Rate control is governed by the derivative
t
A high derivative value indicates a process upset
The rate controller pre-acts to begin valve movement prior to the
operating point reaching the surge control line (SCL)
The rate limit (or setpoint) reduces as the operating point reaches
the SCL
The RATE CONTROLLER routine has separate tuning dynamics.
System stability is enhanced by PID tracking and PID hand-off.
By pre-opening the valve, the control eases into final operating
conditions.
23
14 June 2004
Flow Rate Controller
OPERATING VARIABLE - RATE PID EXAMPLE

170
• The Rate Controller regulates
160 the slope of the operating
150 variable
140 • The operating point gradually
130
transitions into closed loop
PID control
120
110 • The derivative setpoint (bold

100
blue line) and the operating
value (black line) curve into
90
10 0 10 20 30 40 50 60 70 80 90 the SCL
ANTI-SURGE OPERATING VARIABLE
Anti-Surge SECONDS
24
14 June 2004
Process Control Near Surge Conditions
Performance Curve Surge Line
Surge Control Line
Pc
P
N1 N2 N3
P
Q 1 Q2 o
As the operating point approaches the surge limit, the performance curve is flat,
resulting in a much greater change in compressor flow for the same change in
pressure ( Q 1). As the operating point approaches the SCL, there is little head
pressure change. The compressor will “slide” through this region easily.
Derivative and PID control is “difficult” near the SCL
25
14 June 2004
Rate & PID Control
The Rate Controller controls over the full compressor map
It continuously monitors compressor operations to regulate any
rapid movements towards the SCL
Different control routines are implemented to control the valve
Output to Valve
90
OUTPUT FROM INDIVIDUAL ROUTINES
80
70
Transitions
60
50
40
30
20
10
0
10 0 10 20 30 40 50 60 70 80 90
MANUAL OUTPUT
ANTI-SURGE PID OUTPUT SECONDS
RATE PID OUTPUT
26
14 June 2004
Rate Control Valve Position
• Although different controllers are activated, the actual signal being
sent to the valve is smooth and always under control.
• Transition from one control routine to the next routine is imperceptible
at the valve and to the process.
OUTPUT TO VALVE
90
80
70
60
50
40
30
20
10
0
10 0 10 20 30 40 50 60 70 80 90
VALVE OUTPUT
SECONDS
Rate control insures minimal process impacts from flow variations
27
14 June 2004
Flow Rate Controller
HSS
Prepack
Gain Compensation
SCL
% from SCL
t
28
14 June 2004
Surge Controller Tuning
Compressors require different tuning as process conditions
change the slope of the performance line is non-linear.
Controller (PID) is precisely tuned to provide stable control at
SCL
VARIABLE GAIN PIDs modulate their dynamics as compressor
dynamics change enabling tuning for all operating conditions
Input Signals
A To Closed Loop PID

PID - GAIN
B To Rate Controller
COMPENSATION
C To Override Controller PIDs
29
14 June 2004
Flow Signal Filtering
Flow signal noise masks true flow conditions to the controller
and must be eliminated as much as possible
• Raw signal must be adequately filtered for the Rate
Controller to accurately control the operating point
• Several filtering routines are included in software to best
match flow measurement devices used.
- The flow signal filtering technique that best fits the
application is enabled by the controller
• High speed rate group processing ensures good filtering
without compromising real flow values used in algorithms
Control on Actual Flow and Not the Signal Noise
30
14 June 2004
Flow Signal Filtering Rate of change is what is critical
and not actual signal value
FLOW SIGNAL FILTERING

P
The transmitter flow
15
signal, P, is shown
as the dotted line.
10
Solid line is the flow

0 signal after all GE
filters
5 Dashed line is the traditional
“Box-Car” style filter.
2 2.5 3 3.5 4 4.5 5 5.5 6
FLOW Raw Signal
Flow Filtered Sample & Average SECONDS
Flow Filtered ARMA
GE Flow Signal Filtering Delivers Best Performance
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14 June 2004
Special Responses
HSS
Prepack
Gain Compensation
SCL
% from SCL
t
32
14 June 2004
Background – Predicting Surge Limits
Surge Line defines limits of system operations without surge
conditions
Predicted Performance Map: Generated by the compressor
manufacturer after final wheel selection, provides most
conservative estimate of the surge line
Factory Performance Test Map: Generated by the compressor
manufacturer after factory performance test on equivalent gas,
provides a more accurate assessment of surge line
• May still be inaccurate due to actual gas conditions, piping, and
process constraints
Field Performance Test Map: Performed after the compressor is
installed in the process, is most accurate method of defining the
surge line
Compressor Life Impacts Actual Surge Limits
33
14 June 2004
Manufacturer’s Compressor Map
Surge Line (SL1)
Surge Control Line
Pc
SL2 N1 N2 N3
P
o
A compressor manufacturer usually guarantees performance up to the
surge line (SL 1). Usually, the compressor’s actual surge line is found
to the left of the manufacturer’s line. (SL 2) This line is typically
checked or confirmed during commissioning.
True Surge Limits Should Be Based on Field Operations
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14 June 2004
Surge Controller PIDs & Open Loop ACtions
• Surge Control Margin is distance between Surge Control Line
(SCL) and Surge Line (SL)
• Objective is to MINIMIZE the distance (margin) between SCL
and SL for minimum recycle flow while allowing margin for safe
operation
• Controller is tuned (P&I) to provide stable control on the SCL
during a steady state condition.
• Normal tuning values are not able to bring the compressor to
the SCL under all process upset conditions. Changes in flows
and pressures occur at different rates, and the surge controller
can not be tuned to handle every type of change.
Special Controller Responses Needed

for Unusual Process Upsets
35
2 March 2004
14
GEJune 2004 Information – Privileged & Confidential
Proprietary
Special Responses - BOOST
SL Added Response to PID output
Hp
SCL
1
2
N2 N3
N1
Q2 (ICFM)
• As operating point reaches the SCL (1), the controller opens the recycle or
blow-off
• If PID response is not large enough, compressor continues toward the SL,
reaching a 2nd setpoint in the controller
• At this point, the controller takes more drastic action by boosting the PID,
forcing the valve to open farther and avoiding surge conditions
Provides Immediate Action with Minimum Added Flow
36
2 March 2004
14
Proprietary
Open Loop Response - BOOST
BOOST: “Boosts” the PID output to
Output increase valve opening. The
BOOST function will take the PID to
a higher valve opening in a step
PI Control wise fashion. This provides the
O L immediate valve assistance when
PO in near surge conditions, yet has
EO
NP the stability of the typical closed
P+I Time loop PID Control.
110
BOOST RESPONSE
Valve - 20% Travel
105
Output
100
95
90
20 10 0 10 20 30 40 50 60 70 80
ANTI-SURGE PROCESS VARIABLE
Valve Position SECONDS
37
2 March 2004
14
Proprietary
Third Party Interfaces
Pre-Pack Function enhances BOOST and helps recover
from near surge condition sooner
• Temporary recovery routine active Time Delay
for a short duration Valve
Position
- Enables momentary over-stroke
Prepack
of recycle valve to overcome any Action
system lag time
• Easily customized for each Return to A-S PID
Control
compressor application Boost
• Reduces time required to recover Action by Rate & A-S PID controls
process control Time
Provides Additional Safety Factor and Faster Recovery
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14 June 2004
Pre-Pack Function Example
BOOST RESPONSE
106
Valve - 15% Travel
105
104
103
102
101
100
99
98
20 15 10 5 0 5 10 15 20 25 30 35 40 45 50
Valve Position SECONDS
106 BOOST RESPONSE w/ PRE-PACK

105
Valve - 15% Travel
104
103
102
101
100
99
98
20 15 10 5 0 5 10 15 20 25 30 35 40 45 50
Flow Filtered Sample & Average SECONDS
39
14 June 2004
14
Proprietary
Surge Detection and Recovery
HSS
Prepack
Gain Compensation
SCL
% from SCL
t
40
14 June 2004
Surge Detection
The controller must discriminate between noise & an actual
surge condition
Compressor Map during a SURGE
GE GCS employs several Hp
4
6 10
2 1
different routines to 3 7
6
ensure a surge event is 4
detected
5 10
4 5
• Flow derivative
• Speed derivative
4
4 10
Surge
Line
• Discharge Pressure
derivative 3 10
4
0 5000 1 10
4
2 10
4
2 10
4
• Absolute minimum flow SURGE DETECTION #1

ICMH
value Multi-Stage Compressor
41
14 June 2004
Surge Detection – Detectable Changes
P SURGE - FLOW SENSORS
140
120
100
80
60
40
20
Rapid Flow Changes
0
20
20 18 16 14 12 10 8 6 4 2 0 2 4
1st Inlet flow
2nd Inlet flow SECONDS
3rd Discharge flow
RPM SURGE 2 - SPEED

5700
5600
5500
5400
5300
5200
5100
Compressor Loading/Unloading
5000
4900
20 18 16 14 12 10 8 6 4 2 0 2 4
SPEED SECONDS
Flow and Speed are Readily Detectable and Related
42 14 June 2004
GE Proprietary
14 June 2004 Information – Privileged & Confidential
Surge Detection – Not Detectable Changes
KPa SURGE - PRESSURE SIGNALS
450
400
350
300
250
200
150
100
50
20 18 16 14 12 10 8 6 4 2 0 2 4
1st stage Inlet pressure
2nd stage Inlet pressure SECONDS
3rd stage Inlet pressure
Pressure sensors do not always detect radical swings and

hence can not always be used for guaranteed surge
detection.
In this multi-stage compressor application, surge detection
using pressure sensors was not enabled
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14 June 2004
High Speed Response
P FLOW SIGNAL DURING SUCCESSIVE SURGES
0 SURGE detected at Time = 0.0

9 8 7 6 5 4 3 2 1 0 1 2 3
FLOW
SECONDS
• It most cases, the first surge event in a cycle is the least damaging to the
compressor
- In the case above, the compressor didn’t experience a full flow reversal
• If the controller can detect the first surge and open the recycle valve quickly,
then the compressor may be saved from experiencing the full strength of
surge event … reducing compressor damage
High Speed Response Can Extend Operational Life

& Reduce Maintenance Costs
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14 June 2004
Surge Detection Response
Output to recycle valve goes to
100 %
pre-set position Surged M inimum Valve
Valve
Controller stores output value Position (SMP) after
Position surge detected =39%
at time surge was detected
5 % Safety
Fixed amount of opening 34 %
added to captured output at
time of surge to establish new
minimum valve position (SMP- 0%
Surge Minimum Position) Time
Surge Detected
PID control closes valve to control compressor but can not close valve below new
SMP value.
Once process recovers, operator resets SMP to zero to allow valve to go fully closed.
45
14 June 2004
GE Control Solutions Surge Control Technology Benefits
• Fast Accurate detection of approaching surge and avoiding the surge event
• Adaptive PID tuning depending upon operating area of map.
• Reduced Operational costs
- Horsepower savings, operate closer to surge control line
- Avoid Surge or limit the severity of a surge event
- Faster start-up times for complex plants
• Integrates the speed control and surge control in same controller
- Saves cost in hardware, training and inventoried spares
46
14 June 2004

Anti-Surge Presentation Mod LV

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Anti-Surge Presentation Mod LV

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Load Compressor Anti-Surge Protection

Integrated Turbine-Compressor Control (ITCC)

Russian pipeline controls

Process upsets CAUSE surge events resulting in compressor damage

SURGE EVENT - PERCENT of SURGE CONTROL LINE

70 3-Stage Refrigeration Compressor - SURGE detected at t=0.0

Surge control is a unique and difficult control application:

Improve Reliability While Maximizing System Efficiency

Total Savings = $138,000 / year

SIC UIC UIC

Integrated Turbine & Compressor

PTP IEEE1588 100MB Ethernet PTP IEEE1588 100MB Ethernet

Turbine Driven-Load Process Process

Rotating Machinery Control Process Control

• Load Sharing of Single and Multi-Stage Compressors

EXTREME DANGER OF SLEEP IF YOU PROCEED!!

SCL PID Controller

BOOST with Pre_Pack

Surge Detection Responses

Anti-surge control has the added difficulty of controlling to a

 Q S.L.  MARGIN 2 Q2 HP S.L. S.C.L.

When value = 100, operating point is on surge control line (SCL).

Surge Detect Surge Recovery

Setpoint Adjust Rate

OPERATING VARIABLE - RATE PID EXAMPLE

110 • The derivative setpoint (bold

Derivative and PID control is “difficult” near the SCL

Rate control insures minimal process impacts from flow variations

Surge Detect Surge Recovery

A To Closed Loop PID

C To Override Controller PIDs

FLOW SIGNAL FILTERING

Solid line is the flow

GE Flow Signal Filtering Delivers Best Performance

Surge Detect Surge Recovery

True Surge Limits Should Be Based on Field Operations

Special Controller Responses Needed

Provides Additional Safety Factor and Faster Recovery

106 BOOST RESPONSE w/ PRE-PACK

Surge Detect Surge Recovery

• Absolute minimum flow SURGE DETECTION #1

RPM SURGE 2 - SPEED

Flow and Speed are Readily Detectable and Related

Pressure sensors do not always detect radical swings and

0 SURGE detected at Time = 0.0

High Speed Response Can Extend Operational Life

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