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CCC CCC TurbomachineryTurbomachineryControls SystemControls System
Who is the CCC?Who is the CCC?Who is the CCC?
CCC is a CCC is a Controls CompanyControls Company dedicated to dedicated to making the operation of Turbomachinery making the operation of Turbomachinery
SafeSafe and and EfficientEfficient
Safe = No Missed CommissioningNo Production Loss
Efficient = Minimum Power
The CCC Product is Control SolutionsNext
1974 2008
Offices Worldwide +/- 400 Employees 8300+ Installations 200 Major Retrofit Projects/Year Worlds Largest GT Retrofitter
In Operation 34 YearsIn Operation 34 Years
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MTBF of Series 3 Plus controllers is 43.4 years, or 2.5 failures per million hours of operation
MultiMulti--loop controllers for speed, extraction, loop controllers for speed, extraction, antisurge, & performance control antisurge, & performance control
Serial communications for peer to peer Serial communications for peer to peer and host system communicationsand host system communications
Series 3+ ProductsSeries 3+ Products
Series 5 ProductsSeries 5 Products
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Vanguard Duplex ChassisVanguard Duplex Chassis
Power Supplies
IOC-555
MPU-750
Extended Card
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Series 5 Reliant DuplexSeries 5 Reliant Duplex
Switching Module
Connector for Remote Switch Module
Status Indicators
Manual Switchover
Pushbuttons
Same Electronics Assembly and Terminations as Reliant SN
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GuardianGuardian Overspeed Trip SystemOverspeed Trip System
API-670 Compliant
2oo3 Voting of Speed Modules
Redundant Power Supplies
Hot-Swap Speed Modules
ModbusComms
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VantageVantage Steam Turbine GovernorsSteam Turbine Governors
Vantage GPfor API-611 General Purpose Turbines
Vantage GDfor Generator Drive Turbines
Local HMI for Configuration and Maintenance
Reliant inan IP-54 Enclosure
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NEMA 4 enclosure Touch Screen Color
Graphics Operator Interface Parameter monitoring Alarms (visual and audible) Events and data logging Real-time trending of process
data Control loop tuning and
maintenance screens Remote network and web data
access Optional Instrumentation
and Value Packages
Air MiserAir MiserTL EnclosureTL Enclosure
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Class 1, Div 2 / Class 1 Zone 2Class 1, Div 2 / Class 1 Zone 2 ATEX Group 2 Class 3ATEX Group 2 Class 3 Simplex or Simplex or hot backuphot backup redundantredundant All AOAll AOs have builts have built--in feedback loops to identify in feedback loops to identify
hardware or wiring problemshardware or wiring problems
Series 3++ ControllersSeries 3++ Controllers
OnOn--board temperature board temperature monitoringmonitoring
OnOn--board power supply board power supply voltage monitoringvoltage monitoring
Wired Ethernet versionWired Ethernet version Completely backward Completely backward
compatible with S3+compatible with S3+
Raising the Bar Advanced Raising the Bar Advanced Constraint ControlConstraint Control
UpstreamUpstreamimproved control strategies for load sharing, expanders, improved control strategies for load sharing, expanders, integration of networks across platformsintegration of networks across platforms
MidstreamMidstreamimproved control strategies for Boil Off Gas networks, improved control strategies for Boil Off Gas networks, intense focus on all primary LNG servicesintense focus on all primary LNG services
DownstreamDownstreambroader approach to process control, rather than just broader approach to process control, rather than just Turbomachinery control. Advanced control strategies for Turbomachinery control. Advanced control strategies for Ethylene, FCCU and PTA Plants. (Next focus is Ammonia). Ethylene, FCCU and PTA Plants. (Next focus is Ammonia).
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CCC Installations CCC Installations -- IndonesiaIndonesia
PT. Pupuk PT. Pupuk IskandarIskandar MudaMuda PT. Pupuk PT. Pupuk SriwidjayaSriwidjaya PT. Pupuk PT. Pupuk KujangKujang PT. Pupuk Kalimantan PT. Pupuk Kalimantan TimurTimur PT. DSM PT. DSM KaltimKaltim Melamine IndonesiaMelamine Indonesia PT. Amoco Mitsui PTAPT. Amoco Mitsui PTA PT. PT. PolysindoPolysindo EkaEka PerkasaPerkasa PT. Chandra PT. Chandra AsriAsri PertaminaPertamina / Refinery (WGC / Refinery (WGC ExorExor Project)Project) ConocoPhillipsConocoPhillips IndonesiaIndonesia ExxonMobilExxonMobil Oil IndonesiaOil Indonesia Total Total IndonesieIndonesie PT. PT. KangeanKangean EnergiEnergi IndonesiaIndonesia BP BP TangguhTangguh LNGLNG PT. PT. BadakBadak LNGLNG PT. PT. ArunArun LNGLNG PT. Indonesia Power (PLN)PT. Indonesia Power (PLN) Etc.Etc.
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1PT
Section 1
outout
RSP
ALSIC
Section 2
1AUIC
1AUICSerial
network
Train A
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Typical Single Train ControlsTypical Single Train Controls(Suction Pressure Controls)(Suction Pressure Controls)
Antisurge Controls System
Performance Controls System
Compressor RefresherCompressor Refresher
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Compressor TypeCompressor Type
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Compressors
Positive DisplacementCompressor Dynamic Compressor
Reciprocating Compressor
Rotary Compressor
Membrane Compressor
Screw Compressor
Centrifugal
Axial
CCC FocusCCC Focus
Where do the different types of Where do the different types of compressor fit?compressor fit?
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Types of Compressor Types of Compressor -- Dynamic Dynamic Compressors Compressors
Axial Compressor Centrifugal Compressor
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Types of Compressor Types of Compressor -- Dynamic Dynamic Axial CompressorsAxial Compressors
Stator Blades
RotorBlades
Casing
Rotor Blades
StatorBlades
Casing
Shaft
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Rotor
Stator
Cross section of axial compressorCross section of axial compressor
Compressor outlet nozzle
Rotor blades
Labyrinth sealsGuide-vane actuator linkageStator Blades
Compressor inlet nozzle
Thrust bearingAdjustable guide vanes
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Barrel (Centrifugal)Barrel (Centrifugal) Bullgear (Centrifugal)Bullgear (Centrifugal)
Types of Compressor Types of Compressor DynamicDynamicCentrifugal CompressorsCentrifugal Compressors
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Compressor inlet nozzle
Thrust bearing
Journal bearingShaft and labyrinth seal
Impeller inlet labyrinth sealsDischarge volutes
Impellers
Drive coupling
Casing (horizontally split flange)
Compressor discharge nozzle
Horizontally Split Type (Centrifugal)Horizontally Split Type (Centrifugal)Horizontally Split Type (Centrifugal)
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Types of Compressor Types of Compressor -- Picture of Picture of Horizontally Split Type (Centrifugal)Horizontally Split Type (Centrifugal)
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Types of Compressor Types of Compressor -- Principal of Principal of Operation (Centrifugal)Operation (Centrifugal)
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Single-Section, Three-Stage Single-Case, Two-Section, Six-Stage
Types of Compressor Types of Compressor -- ClassificationsClassifications
What is the function of this cooler?
IntercoolingIntercooling reduces energy consumptionreduces energy consumptionbut results in having multiple compressor mapsbut results in having multiple compressor mapswhich need separate which need separate antisurgeantisurge protectionprotection
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Parallel Network
Two-Case, Two-Section, Six-Stage
Series Network
Types of Compressor Types of Compressor -- ClassificationsClassifications
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Why Compressor SurgeWhy Compressor Surgeand what happens and what happens
when they dowhen they do
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Surge PhenomenonSurge Phenomenon
From A to B.20 - 50 ms.. Drop into surge From C to D.20 - 120 ms Jump out of surge A-B-C-D-A.0.3 - 3 seconds Surge cycle
Qs, vol
Pd
Machine shutdownno flow, no pressure
Electro motor is started Machine accelerates
to nominal speed Compressor reaches
performance curveNote: Flow goes up faster because pressure is the integral of flow
Pressure builds Resistance goes up Compressor rides the curve Pd = Pv + Rlosses
Pd = Compressor discharge pressurePv = Vessel pressureRlosses = Resistance losses over pipe
Developing the surge cycle on the Developing the surge cycle on the compressor curvecompressor curve
PdPv
Rlosses
B A
CD
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Rapid flow oscillations Rapid flow oscillations Thrust reversalsThrust reversals Potential damagePotential damage
FLOW
PRESSURE
TEMPERATURE
TIME (sec.)
1 2 3
TIME (sec.)
1 2 3
TIME (sec.)
1 2 3
Major Process Parameters during Major Process Parameters during SurgeSurge
Rapid pressure oscillations with process instability
Rising temperatures inside compressor
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Some surge consequencesSome surge consequences
Unstable flow and pressureUnstable flow and pressure Damage in sequence with increasing Damage in sequence with increasing
severity to seals, bearings, impellers, severity to seals, bearings, impellers, shaftshaft
Increased seal clearances and leakage Increased seal clearances and leakage Lower energy efficiencyLower energy efficiency Reduced compressor lifeReduced compressor life
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Factors leading to onset of Factors leading to onset of surgesurge
StartupStartup ShutdownShutdown Operation at reduced throughputOperation at reduced throughput Operation at heavy throughput with:Operation at heavy throughput with:
-- TripsTrips-- Power lossPower loss-- Operator errorsOperator errors-- Process upsetsProcess upsets-- Load changesLoad changes-- Gas composition changesGas composition changes-- Cooler problemsCooler problems-- Filter or strainer problemsFilter or strainer problems-- Driver problemsDriver problems
Standard Antisurge Standard Antisurge Control Vs CCC Controls Control Vs CCC Controls
SystemSystem
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Flow
Pressure
minimum speed
maximum speedsurge limit
stonewall orchoke limit
power limit
process limit
stable zonestable zoneof operationof operation
adding control margins
Actual availableoperating zone
CCC Business in Constraint ControlCCC Business in Constraint Control
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Flow
Pressure
minimum speed
maximum speedsurge limit
stonewall orchoke limit
power limit
process limit
stable zonestable zoneof operationof operation
adding control margins
Actual availableoperating zone
CCC Business in Constraint ControlCCC Business in Constraint Control
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Expanding the Operating EnvelopeExpanding the Operating Envelope
Operating Point
Limit
Operating Point
Setpoint
Base Ingredients:- Advanced algorithms- Rate of change feed forward signals- Fast hardware
Limit
Setpoint
General Purpose Control
CCC Control
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Standard Antisurge ControlStandard Antisurge Control
1UIC
CompressorCompressor
1FT
1PsT
ProcessSuction
1PdT
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AntisurgeController
Recycle Valve
Conventional Control Using Separate Conventional Control Using Separate Performance RecyclePerformance Recycle
CompressorCompressor
ProcessSuction 1UIC
1FT 1
PsT1
PdT
1PIC
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ConventionalCapacity/PerformanceController
Additional Recycle Valve
Why Invest in Advanced Why Invest in Advanced Controls?Controls?
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How Will CCC How Will CCC ControlControl??
Antisurge Control?Antisurge Control?Capacity Control?Capacity Control?
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CCC Controls SystemCCC Controls System
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1UIC
VSDS
Compressor
1FT
1PsT
1TsT
ProcessSuction
1PdT
1TdT
1ST
1PIC
1HIC
Load
Serial network
AntisurgeController
PerformanceController
Control System ObjectiveControl System Objective
Control System Objectives:Control System Objectives:
The control system objective is to keep the The control system objective is to keep the process on its Primary Process Variable (PV) process on its Primary Process Variable (PV) setset--point, and to return it to setpoint, and to return it to set--point as quickly point as quickly as possible after a process disturbanceas possible after a process disturbance
The control system has to keep the process The control system has to keep the process on/return to seton/return to set--point while operating within point while operating within compressor operating envelope limits, including compressor operating envelope limits, including protection against surge and surge damageprotection against surge and surge damage
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Challenges of Compressor Challenges of Compressor Control SystemControl System
The ingredients of a successful compressor control systemThe ingredients of a successful compressor control systemare:are:
zz An algorithm that can accurately locate the operating point An algorithm that can accurately locate the operating point and its corresponding surge limitand its corresponding surge limit
zz A controller execution speed that will allow a digital controlleA controller execution speed that will allow a digital controller r to emulate immediate analog controlto emulate immediate analog control
zz Control responses that allow different margins of safety for Control responses that allow different margins of safety for different operating conditionsdifferent operating conditions
zz Advanced control strategies that can avoid the negative Advanced control strategies that can avoid the negative effects of loop interactioneffects of loop interaction
zz A quick acting, correctly sized antisurge control valveA quick acting, correctly sized antisurge control valvezz The elimination of unnecessary dead time or lag time within The elimination of unnecessary dead time or lag time within
the systemthe systemzz Valid load sharing strategiesValid load sharing strategies
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Standard Control VS CCC Standard Control VS CCC ControlsControls
StandardStandard CCCCCC
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1UIC
VSDSCompressor
1FT 1
PsT
1TsT
ProcessSuction
1PdT
1TdT
1ST 1
PIC
1HIC
Load
Serial network
CompressorCompressor
ProcessSuction 1UIC
1FT 1PsT
1PdT
1PIC
Standard Control VS CCC Standard Control VS CCC ControlsControls
StandardStandardzz 15% surge margin15% surge marginzz Quick opening valvesQuick opening valveszz No control of process No control of process
variable via recyclevariable via recyclezz No invariant coordinatesNo invariant coordinateszz Concentrating on Concentrating on
ProtectionProtection
CCCCCCzz Typically 8% surge marginTypically 8% surge marginzz Linear valves with Linear valves with
positioners for control positioners for control across 100% rangeacross 100% range
zz Control of primary process Control of primary process variable by recycle when variable by recycle when speed limit is reachedspeed limit is reached
zz Can handle varying Can handle varying molecular weight gasesmolecular weight gases
zz Concentrating on Concentrating on Control Control and Protectionand Protection
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CCC CCC ControlController protectionler protection
How CCC How CCC AntisurgeAntisurge Controller Controller protects compressor against protects compressor against surge?surge?
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1UIC
VSDS
Compressor
1FT
1PsT
1PdT
The antisurge controller UIC-1 protects the compressor against surge by opening the recycle valve
DischargeSuction
Rc
qr2
Rprocess
Rprocess+valve
Antisurge Controller Operation Protection #1 Antisurge Controller Operation Protection #1 The Surge Control Line (SCL)The Surge Control Line (SCL)
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ARc
B When the operating point When the operating point crosses the SCL, PI crosses the SCL, PI control will open the control will open the recycle valverecycle valve
PI control will give PI control will give adequate protection for adequate protection for small disturbancessmall disturbances
SLL = Surge Limit LineSCL = Surge Control Line
qr2
Antisurge Controller Operation Protection #1 Antisurge Controller Operation Protection #1 The Surge Control Line (SCL)The Surge Control Line (SCL)
PI control will give stable control during steady state recycle operation
Slow disturbance exampleNext
ARc
B
When the operating point moves quickly towards the SCL, the rate of change (dS/dT) can be used to dynamically increase the surge control margin.
This allows the PID controller to react earlier.
Smaller steady state surge control margins can be used w/o sacrificing reliability.
Fast disturbance exampleQ2
Antisurge Controller Operation Protection #2 Antisurge Controller Operation Protection #2 Moving The Surge Control Line (SCL)Moving The Surge Control Line (SCL)
SLL = Surge Limit LineSCL = Surge Control Line
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Antisurge Controller Operation Protection #3 Antisurge Controller Operation Protection #3 The Recycle TripThe Recycle Trip LineLine ((RTLRTL))
Benefits: Reliably breaks the
surge cycle Energy savings due to
smaller surge margins needed
Compressor has more turndown before recycle or blow-off
Surge can be prevented for virtually any disturbance
SLL = Surge Limit LineRTL = Recycle Trip Line
SCL = Surge Control Line
Output to Valve
Time
Open-loop Response
PI Control Response
PI Control Step Change
+
To antisurge valve
Total Response
Rc
Q2
OP
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After time delay CAfter time delay C22 controller checks if Operating Point is back to controller checks if Operating Point is back to safe side of safe side of Recycle TripRecycle Trip LineLine
-- If If YesYes: Exponential decay of : Exponential decay of Recycle TripRecycle Trip responseresponse..
Output to valve
Time
One step response
PI ControlRecycle Trip
Total
100%
0%
C2
Multiple step responseOutput to valve
Time
PI Control
Recycle Trip
Total
C2 C2 C2
What if one Recycle TripWhat if one Recycle Trip step step response is not enough?response is not enough?
- If No: Another step is added to the Recycle Tripresponse.
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Output to Recycle Valve
InputOutput to Turbine ValveSpeed InputsSpeed Inputs
Antisurge InputsAntisurge Inputs
Process Variable InputsProcess Variable Inputs
Serial Communication Link CCC-DCS
Flow
Pressure
Temperature
Gas Data
(Field Transmitter)
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Integrated control Decoupling of Integrated control Decoupling of Performance and Performance and AntisurgeAntisurge controlcontrol
Po
PIC-SP
Rc
Ps
SLL
SCL
AC
B
Integrated control Decoupling of Integrated control Decoupling of Performance and Performance and AntisurgeAntisurge controlcontrol
2. 2. The decoupling control starts to actThe decoupling control starts to actPerformance control send request Performance control send request to increase speedto increase speed
3. 3. The speed increasing combined with The speed increasing combined with antisurgeantisurge valve opening, then,valve opening, then,The trace of operating line as shownThe trace of operating line as shown
4. 4. The net control effect is more The net control effect is more stable operation even with large stable operation even with large process disturbanceprocess disturbance
5. 5. This decoupling control is can This decoupling control is can reduce the control safety margin, reduce the control safety margin, Therefore it can achieve energy Therefore it can achieve energy saving and safe operationsaving and safe operation
1. When operating at Point A, process 1. When operating at Point A, process encounters a large disturbance,encounters a large disturbance,operating point will move to Point Boperating point will move to Point B
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Antisurge Controller Operation Antisurge Controller Operation Protection #4 Protection #4 Safety OnSafety On
How about if the protection not capable How about if the protection not capable against surge?against surge?
Compressor has real surgeCompressor has real surge
What will CCC controller do?What will CCC controller do?
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SCL = Surge Control Line
If Operating Point crosses the Safety On Line the compressor is in surge
SLL = Surge Limit LineRTL Line = Recycle Trip
The Safety On response shifts the SCL and the RTL to the right
New SCL
New RTL
Additional safety or surge margin is added
Additional surge margin
PI control and Recycle Trip will stabilize the machine on the new SCL
SOL = Safety On Line
P
r
e
s
s
u
r
e
a
x
i
s
Flow axis
Antisurge Controller Operation Protection #5 Antisurge Controller Operation Protection #5 Safety OnSafety On
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CCC CCC LOAD SHARING CONTROLS LOAD SHARING CONTROLS
SYSTEMSYSTEM
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Compressors are often operated in parallel and sometimes in seriCompressors are often operated in parallel and sometimes in serieses
The purposes of networks include:The purposes of networks include:zz RedundancyRedundancyzz FlexibilityFlexibilityzz Incremental capacity additionsIncremental capacity additions
Often each compressor is controlled, but the network is ignoredOften each compressor is controlled, but the network is ignored
Compressor manufacturers often focus on individual machinesCompressor manufacturers often focus on individual machines
A A network viewnetwork view of the application is essential to achieve good of the application is essential to achieve good surge protection and good performance control of the network.surge protection and good performance control of the network.
Compressor networksCompressor networks
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Control system objectives for compressors in parallel:Control system objectives for compressors in parallel:zz Maintain the primary performance variable (in this case Maintain the primary performance variable (in this case
suction pressure), and then:suction pressure), and then:zz Optimally divide the load between the compressors in the Optimally divide the load between the compressors in the
network, while:network, while: Minimizing risk of surgeMinimizing risk of surge Minimizing energy consumptionMinimizing energy consumption Minimizing disturbance of starting and stopping Minimizing disturbance of starting and stopping
individual compressorsindividual compressors Operating within limitsOperating within limits
Load SharingLoad Sharing
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Load Sharing Control system types:Load Sharing Control system types:
1. Base and Swing Load Sharing system1. Base and Swing Load Sharing system2. Equal Flow Load Sharing system2. Equal Flow Load Sharing system3. CCC Equidistance Load Sharing controls system3. CCC Equidistance Load Sharing controls system
Load SharingLoad Sharing
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Process
PIC1
1UIC
VSDS
Compressor 1
2UIC
VSDS
Compressor 2
HIC1
Suction header
Swing machine
Base machine
Notes All controllers act
independently Transmitters are
not shown
Base and Swing Load SharingBase and Swing Load SharingFlow Diagram for Control ProcessFlow Diagram for Control Process
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Rc,1
qr,12
Rc,2
qr,22
Compressor 1 Compressor 2
PIC-SP
Swing machine Base machine
QC,2= QP,2QC,1QP,1where:QP = Flow to processQC= Total compressor flowQC - QP = Recycle flow
QP,1
QP,1 + QP,2 = QP,1 + QP,2
Notes: Base loading is inefficient Base loading increases the risk of surge
since compressor #1 will take the worst of any disturbance
Base loading requires frequent operator intervention
Base loading is NOT recommended
Base and Swing Load Sharing Base and Swing Load Sharing Parallel Compressor ControlParallel Compressor Control
QP,2
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Process
PIC1
1UIC
Compressor 1
VSDS
Compressor 2
Suction header
Notes Performance controllers
act independent of antisurge control
Higher capital cost due to extra Flow Measurement Devices (FMD)
Higher energy costs due to permanent pressure loss across FMDs
1FIC
2FIC
2UIC
outout
out
RSPRSP
RSPRSP
RSP
RSP
outout
RSPRSP
Equal Flow Load sharingEqual Flow Load sharingFlow Diagram for Control ProcessFlow Diagram for Control Process
VSDS
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Notes: Requires additional capital investment in
FMDs Requires additional energy due to
permanent pressure loss across FMDs Poor pressure control due to positive
feedback in control system (see next) Equal flow division is NOT recommended
Rc,1
qr,12
Rc,2
qr,22
PIC-SP
QP,1 QP,2QC,2
Equal flow Equal flowQP,1 = QP,2
Equal Flow Load sharingEqual Flow Load sharingParallel Compressor ControlParallel Compressor Control
Compressor 1 Compressor 2
where:QP = Flow to processQC= Total compressor flowQC - QP = Recycle flow
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Notes All controllers are
coordinating control responses via a serial network
Minimizes recycle under all operating conditions
Process
1UIC
VSDS
Compressor 1
VSDS
Compressor 2
Suction header
1LSIC
2UIC
out
RSP
Serial network
out
RSP
2LSIC
1MPIC
Serial network
Serial network
CCC Equidistance Load sharingCCC Equidistance Load sharingFlow Diagram for Control ProcessFlow Diagram for Control Process
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PIC-SP
0.10.2
0.3
DEV = 00.1
0.20.3
DEV1 DEV2
SCL = Surge Control LineRc,1
qr,12
Rc,2
qr,22
Compressor 1 Compressor 2
Dev1 = Dev2Q1 = Q2N1 = N2
Notes: Maximum turndown (energy savings) without recycle or blow-off Minimizes the risk of surge since all machines absorb part of the
disturbance Automatically adapts to different size machines CCC patented algorithm
CCC Equidistance Load sharingCCC Equidistance Load sharingParallel Compressor ControlParallel Compressor Control
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Loop Decoupling
FAMode
PI
Loop Decoupling
+
Analog Inputs
+
DEV
To antisurge valve To performance control element
PID
Loadbalancing
PV
PV
SP
Primaryresponse
DEV DEV
D
E
V
DEV from other loadsharing controllers
Primaryresponse
Average
SP
The load balancing responseThe load balancing response
Loadsharing Loadsharing ControllerController
Antisurge Antisurge ControllerController
Master Controller
RT
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CCC LOAD SHARINGCCC LOAD SHARINGControl System DrawingControl System Drawing
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MASTER CONTROLLER(Suction Header Controls)
LOAD SHARING CONTROLLER
ANTISURGE CONTROLLER
End SlidesEnd SlidesThank You very much for your Thank You very much for your kind attention and cooperationkind attention and cooperation
PT Putranata Adi Mandiri
Jl Kartini VIII No. 9
Jakarta 10750
Tel: (021) 6007850
Fax: (021) 6007846
Email: [email protected]
