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Compressor Control Compressor Control

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Types of Compressor Types of Compressor
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100 MPa
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Positive Displacement
Compressors
1 MPa
10 MPa
(1,450 psia)
(14,500 psia)
D
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c
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P
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Data from CAGI

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Dynamic Compressors
1 m3/h
(0.6 CFM)
10 m3/h
(6 CFM)
100 m3/h
(60 CFM)
1000 m3/h
(600 CFM)
10,000 m3/h
(6,000 CFM)
100,000 m3/h
(60,000 CFM)
Flow (Approx Conversion)
(145 psia)
.1 MPa
(14,5 psia)
D
Compressor Performance Compressor Performance
Dynamic -
R
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Positive Displacement
- Variable Pressure,
C t t Fl
Dynamic
Variable Flow,
Constant
Pressure

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Q
Constant Flow
Constraint Control - Operating Envelope Constraint Control - Operating Envelope
Typical Performance Map
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Maximizing The Compressor Operating
Envelope Operating Limits
Maximizing The Compressor Operating
Envelope Operating Limits
Speed Limit (Maximum)
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Surge limit
p ( )
Stonewall or
choke limit
?
?

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Flow
Speed Limit
(Minimum)
Compressor Control Compressor Control
Compressors are the control element for the
process, so good control is needed for good
product quality
C i h t f
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Compression consumes huge amounts of
energy so good control normally translates to
energy and cost saving
Control objectives* include:
Safety of personnel, process and machinery
Precise control of the primary control variable for
process control (normally pressure)

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p ( y p )
Operation within limits
Operation in automatic mode with no, or minimal,
operator intervention
*All the above control objective points have both a price
tag, and a return on investment
Compression Systems Compression Systems
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Typical Motor Driven
Turbocompressor
Typical Motor Driven
Turbocompressor
Section 1 Section 2
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Section 1
out out
PIC
1A
UIC
1B
UIC
Serial
network 1A
Section 2

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Cost Points Product Quality by
Control of PPV
Cost Points Product Quality by
Control of PPV
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Section 1
out out
PIC
Section 2
1A
UIC
1A
UIC Serial
network
1A

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Control of Primary Process Variable via Performance, and helped by Recycle when required
Cost Points Tight Antisurge Control
with Minimized Recycle
Cost Points Tight Antisurge Control
with Minimized Recycle
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Section 1
out out
PIC
Section 2
1A
UIC
1A
UIC Serial
network
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Antisurge Control via Recycle , and helped by
Performance when required
Cost Points Cost Points
Flare Control aided by Recycle
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Section 1
out out
PIC
Section 2
1A
UIC
1A
UIC Serial
network
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Cost Points Cost Points
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Section 1
out out
PIC
Section 2
1A
UIC
1A
UIC Serial
network
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System Limits via recycle and/or speed
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Examples Examples

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Controllability Examples Controllability Examples
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P
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I ncrease Performance Example I ncrease Performance Example
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Shaft
power
q
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2

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A leading oil company realized a 2% production increase after
CCC antisurge control allowed operation closer to the
Surge Limit Line
Energy Saving Example Energy Saving Example
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The saving from this wet gas compressor installation:
First Section @ $ 174,008 per year + Second Section @ $ 167,049 per
year
Total = $ 341,057 per year
Energy Saving Example Air
Compressor Networks
Energy Saving Example Air
Compressor Networks
Advanced Control
Original Controls
Compressor Flow
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User Flow
Saudi Example Saudi Example
With the old DCS
antisurge system, the LP
compressor was
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p
running with 20 to 30%
recycle most of the time,
now with CCC system
installed and
commissioned the valve
fully closed

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LP: Normal Condition Winter: 1376 BHP, Normal Condition Summer: 1438 BHP.
Assuming recycling is 20% in summer and 30% in winter, then Power Loss in Recycling (using 0.746 factor) = 261.
Considering the following formula: 261 * 365 * 24 * 0.95 * 0.23 / 3.75 = USD 133,218 / Year is the Energy Loss Value.
D l i Al i h f D l i Al i h f
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Developing Algorithms for
Compressor Control - a Urea Plant
Case Study
Developing Algorithms for
Compressor Control - a Urea Plant
Case Study

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Developing Control Solutions? Developing Control Solutions?

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Developing Applications Functions Developing Applications Functions
Phase 1 see the need
Phase 2 mathematical study
Phase 3 computer simulation
Ph 4 fi ld t ti
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Phase 4 field testing

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Press
Different I nlet Conditions Means Different
Performance Maps
Different I nlet Conditions Means Different
Performance Maps
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Flow
Different I nlet Conditions Means Different
Performance Maps
Different I nlet Conditions Means Different
Performance Maps
Press
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Flow
The problem with commonly used (OEM provided)
coordinate systems of the compressor map is that these coordinates are
NOT invariant to suction conditions as shown
Algorithm I ssues Algorithm I ssues
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The surge limit thus becomes a surface rather
than a line
Algorithm I ssues Algorithm I ssues
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For control purposes we want the SLL to be presented by a single curve for
a fixed geometry compressor

Fundamental variables
The following variables are used to design and to characterize compressors
Through dimensional analysis (or similitude) we can derive two sets of invariant coordinates
Invariant coordinates
Advanced Control - Developing
I nvariant Coordinates
Advanced Control - Developing
I nvariant Coordinates
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characterizing compressor
operation
H
p
= f
0
(Q, , , , a, d, )
J = f
1
(Q, , , , a, d, )
where:
H P l t i h d
Dimensional analysis
or Similitude
Set 1
h
r
q
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N
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j
r
Re
Set 2
R
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q
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N
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j
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= Polytropic head
J = Power
Q = Volumetric flow rate
= Rotational speed
= Viscosity
= Density
a = Local acoustic velocity
d = Characteristic length
= Inlet guide vane angle
where:
h
r
= Reduced head
q
r
= Reduced flow
N
e
= Equivalent speed
= Guide vane angle
j
r
= Reduced power
Re = Reynolds number
R
c
= Pressure Ratio
NOT invariant coordinates
(H
p
, Q
s
)
Algorithm I ssues Algorithm I ssues
Invariant Coordinates
(h
r
, q
r
2
)
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where:
H
p
= Polytropic head
Q
s
= Volumetric suction flow
h
r
= Reduced head
q
r
2
= Reduced flow squared
NOT invariant coordinates
(R
c
, Q
s
)
Algorithm I ssues Algorithm I ssues
Invariant coordinates
(R
c
, q
r
2
)
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where:
R
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= Pressure ratio
Q
s
= Volumetric suction flow
q
r
2
= Reduced flow squared
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Urea Plant CO2 Compressors Urea Plant CO2 Compressors

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CO2 Compressors CO2 Compressors
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CO2 I nstallation Formats CO2 I nstallation Formats

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CO2 Compressor Configuration CO2 Compressor Configuration
Section 3 Section 4
Speed
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Section 1 Section 2
Section 3 Section 4
Speed
Increasing
Gear

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Adding Start- Up Vent Lines Adding Start- Up Vent Lines
Section 3 Section 4
Speed
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Section 3 Section 4
Speed
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Gear

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One Recycle Valve Case One Recycle Valve Case
Section 3 Section 4
Speed
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Section 1 Section 2
Section 3 Section 4
Speed
Increasing
Gear

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Two Recycle Valve Case Two Recycle Valve Case
Section 3 Section 4
Speed
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Section 1 Section 2
Section 3 Section 4
Speed
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Gear

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CCC Experience CCC Experience
1980s - retrofit of two valve installations in USA/Canada/Caribbean
No great difficulty found
1990s - new single valve installations in India
Flow element only on the third section
train in manual speed control
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questionable valve sizing
minimum budget allocated
use of a single antisurge controller monitoring the third section
the machine went into uncontrollable surge during surge testing
opening the valve had no effect
closing the valve seemed to take the machine out of surge

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One Recycle Valve Case One Recycle Valve Case
Section 3 Section 4
Speed
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Section 1 Section 2
Section 3 Section 4
Speed
Increasing
Gear
1
PT
2
PT
1
FT
1
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Uncontrollable Surge - One Antisurge
Controller Monitoring 3rd Section
Uncontrollable Surge - One Antisurge
Controller Monitoring 3rd Section
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Why? Why?
CCC developed a High Fidelity Dynamic Simulation of
the installation using actual installation data and
Compressor Makers Curves
stage mismatch was found - where the 1st section
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stage mismatch was found where the 1st section
could be in surge while the 4th in stonewall
the valve on its own is not sufficient to prevent surge
during large upsets - using a larger valve did nothing
to improve the situation

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What is the Solution? What is the Solution?
We found that using two valves, 4/3 and 2/1 would
eliminates the problem
For existing installations the only method available to
have effective antisurge control was to incorporate
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have effective antisurge control was to incorporate
performance control with variable speed, and employ
heavy decoupling
Note: if the machine is at full speed when a large
disturbance hits, then decoupling will not help

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Decoupling Decoupling

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I nteraction of Control Loops I nteraction of Control Loops
M t M t
Control Control
Antisurge Antisurge
Measurement Measurement
Control Control
Recycle Valve Recycle Valve
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Process Variable Process Variable
Measurement Measurement
Speed Speed
Compression Compression
System System
1
PIC
SG
Compressor
ST Driver

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2
UIC
Rc
Non- I ntegrated Performance and
Antisurge Loops
Non- I ntegrated Performance and
Antisurge Loops
We are operating at point A We are operating at point A
Large disturbance occurs Large disturbance occurs
The operating point rides the curve The operating point rides the curve
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A
PIC-SP
B
The operating point rides the curve The operating point rides the curve
to point B to point B
The Performance controller is taking The Performance controller is taking
the operating point down in valve position the operating point down in valve position
and thus down in flow and thus down in flow - - the tangent of the tangent of
that trajectory is thus (shown) that trajectory is thus (shown)
That means that the operating point That means that the operating point
must use a large control bias must use a large control bias
t id d th t bili t id d th t bili
C

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to avoid surge and then stabilize: to avoid surge and then stabilize:
Q
I ntegration of Control Loops I ntegration of Control Loops
SG
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PIC
2
UIC
Compressor
ST Driver
Peer-to-Peer
Serial Communication

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R
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I ntegration/ Decoupling of Antisurge
and Capacity Control
I ntegration/ Decoupling of Antisurge
and Capacity Control
We are operating at point A We are operating at point A
Large disturbance occurs Large disturbance occurs
The operating point rides the curve The operating point rides the curve
to point B to point B
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PIC-SP
A
C
B
This time we decouple the action This time we decouple the action
of the performance controller of the performance controller
The antisurge controller tells the The antisurge controller tells the
performance controller to speed up performance controller to speed up
the compressor (or open the the compressor (or open the
Guide vanes or suction throttle valve) Guide vanes or suction throttle valve)
The action of the performance The action of the performance
controller is increasing speed controller is increasing speed
(or opening guide vanes or inlet valve) (or opening guide vanes or inlet valve)

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( p g g ) ( p g g )
and increasing flow, and the resulting and increasing flow, and the resulting
Tangent is as follows (shown) Tangent is as follows (shown)
This results in a stabilization This results in a stabilization
action as shown action as shown
The result is an action requiring The result is an action requiring
only a small margin of safety only a small margin of safety
Next Problem Uncovered Next Problem Uncovered
Compressor HP Section LP Section
Mechanical Governor
with Ratio from Throttle Valve to Extraction Valve
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Extraction
Steam Header
Bypass valve
Adding Electronic Governor Adding Electronic Governor
Compressor
Steam turbine
SE
3x
HP Section LP Section
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Serial Serial
network network
OUT Extraction
Steam Header
Solving the Steam Bypass Problem
PIC
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Full Control Solution Full Control Solution
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From an article was published in a Chinese trade magazine,
" Automation In The Petrochemical Industry" , Vol.5, 1998. The
author is the Director of Instrumentation of Chishui Natural Gas
Chemical Corp. (CCC retrofitted the CO2 compressor trains in
Comment from Chinese Customer
After Retrofit
Comment from Chinese Customer
After Retrofit
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p ( p
June 96).
When the system load is reduced and the compressor must
recycle, the CCC system can reduce the recycle flow to 3000
Standard Cubic Meters per Hour (SCMH) compared with manual
open loop control before the retrofit.
There were many times the inlet flow of CO2 dropped below
14,000 SCMH due to a non-turbomachinery related process
reason, such as a problem at the CO2 removal section of
ammonia unit, where the CCC system respond quickly and thus

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ammonia unit, where the CCC system respond quickly and thus
avoided surge, and kept the compressor train on line. Before the
retrofit, the pneumatic system would definitely trip the machine
in such event, and in the worst case the machine would be
damaged due to surge.
Comment from Chinese Customer After
Retrofit
Comment from Chinese Customer After
Retrofit
With CCC TTC system, the direct energy saving was
calculated. It was 6.4 Million RMB (US$790,000) saving
per year at the same number of tons of urea produced
per year before the retrofit. All investment for the retrofit
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per year before the retrofit. All investment for the retrofit
including cost of equipment, freight cost, customs duty,
taxes, installation etc.,) was recovered less than 10
months.

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Data from the Equipment Superintendent of Daqing Petrochemical
Company:
They have been operating at full load for 18 months since the retrofit
The compressor train never trips in the event of the process sudden
changes that would have tripped the unit before
Comment from Chinese Customer
After Retrofit
Comment from Chinese Customer
After Retrofit
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changes that would have tripped the unit before
The start up of the turbine is simple and easy now, compared with
the old system
The improved speed/extraction control by the CCC TTC system has
reduced overall steam consumption due to the elimination of
supplemental steam expansion through the steam let-down valve
(constant let-down was necessary with the old PGPL governing
system as the extraction control was poor). On average, the steam
consumption is 5 metric tons per hour less than before. The result
of saving was 2 million RMB (US$246,000) per year (the plant buys

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of saving was 2 million RMB (US$246,000) per year (the plant buys
the steam from an outside CHP plant at 50 RMB per ton)
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Future Direction Future Direction

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Turbomachinery Controls Emulation Turbomachinery Controls Emulation
Dedicated PC
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Unique PC
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Compressor Performance Monitoring Compressor Performance Monitoring
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Q&A Q&A

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