Turbomachinery Controls

ISA Will-DuPage

Presented by Hector Buchelly

May 2013

© 2010 Invensys. All Rights Reserved. The names, logos, and taglines identifying the products and services of Invensys are proprietary marks of Invensys or its subsidiaries. All third
party trademarks and service marks are the proprietary marks of their respective owners.
 Objectives

Turbomachinery Scope

Technical Solutions

Surge Control

Mechanical Retrofit

Slide 2
Rotating Equipment Scope
Prime Movers

Steam Turbine
Driven Equipment Auxiliaries
Generator
AVR

Actuator with
LVDTs
Gas Turbine

Compressor Compressor
Mechanical
Performance
Retrofit
and Motor
Protection Lube Oil
Seal Gas
MCC
Hydro-Turbine
TMC Proficiencies

Steam Turbines Gas Turbines Compressors

Integrated
Turbine/
Generators
Load Control
Solutions
TMC Offering Segmentation

Services

Nuclear TM Compressors

Utility/Power Mechanical
TM Retrofit
Steam Turbines

AEG-Kanis ABB
Dresser Turbodyne Dresser-Rand Pwr. A/S
Mitsubishi Hvy. Ind. Nuovo Pignone
ASEA STAL Allis-Chalmers Corp.
Dresser-Rand Elliott Company Shin Nippon
Siemens AG Bharat Heavy Ind. Ltd.
Steam Turbines

GEC Turbine Ltd. General Electric Co.

Murray Turbomachinery Westinghouse
Borsig Coppus Engineering
Garrett Turb. Eng. Co. Ingersoll Rand Co.
Terry Corporation Worthington
Carrier Corporation DeLaval
Kawasaki Heavy Ind.
Gas Turbines

• Allison: 501 • Rolls-Royce: RB211,

• Avon: 1533 Olympus
• BBC: Frame 11 • Ruston: TB3000,
• GE: Frame 3, Frame 5, TB4000, TB5000
Frame 7 • Solar: Centaur T48
• GE LM 2500 • Sulzer GT10
• Hispano-Suiza: 1202
• Westinghouse: W50,
• Pratt & Whitney: FT4, W101, W191, W251,
GG4, Twin Pac, Hi-Cap,
ST18 W352, W501
Process Application
Olefins Plants
• Furnace Gas
• Propylene Refrigeration
• Ethylene Refrigeration
Ammonia/Fertilizer
• Syn Gas
• Process Air
• Ammonia Refrigeration
• Feed Gas
• Carbon Dioxide
Nitric Acid—Process Air
Acrylic Acid—Process Air
Power Plants/Utilities
Process Application
Refinery Gas Separation
• FCCU Air Blower • Residual Gas
• Cat Gas • Propane Refrigeration
• Hydrogen Gas Pipeline
• Plant Air LNG
Compressor Test Stand
 Turbomachinery
Control Solutions

© 2010 Invensys. All Rights Reserved. The names, logos, and taglines identifying the products and services of Invensys are proprietary marks of Invensys or its subsidiaries. All third
party trademarks and service marks are the proprietary marks of their respective owners.

Slide 11 © Invensys 3-Aug-10 Invensys proprietary & confidential

Project Execution

1. Studies or Assesments
2. Hold Kickoff Meeting
3. Generate Project Basis of Design Document
4. Develop and Test Logic
5. Perform Factory Acceptance Test Procedure (FAT)
6. Ship Equipment
7. Develop Site Acceptance Test (SAT) and Surge
Testing
8. Perform SAT and Commissioning
Compressors

Governor Performance Surge

• Steam • Pressure • Single Valve

Turbines • Flow • Multi Valve
• Motors • Decoupling • Refrigeration
• Gas Turbines • Load Sharing
• Sequencing
Mechanical Retrofit

Single-Valve and Two-Valve Actuators

Speed Sensing

Systems: Overspeed, Trip, Multi-Valve

Hydraulic Pressure Units

TMC Solutions Interaction
Simulation Fast Trending

Control Program HMI

Critical Project Questions
• System
Will my compression system perform per the design?

• Control Strategy Development

What is the best way to control my system?

• Control Checkout and Tuning

Are the controls configured correctly and tuned well?

• Operator Training
Can I use my model to train my operators?
System
Verify the compressor system before the
FEED or commissioning:
• Compressor specifications
• Anti-surge valve size, characteristics,
stroke time

Check system performance at different

operating conditions:
• Compressor trips, driver failure, loss
of instrument air, etc.
• Valve opening time, changing
molecular weight, etc.
• Compressor start-up from cold or hot
standby
Establish Control Strategy

• Determine the best anti-

surge, performance control
approaches

• Test decoupling control

algorithms

• Establish start-up and shut-

down sequencing, start-up
guide vane position, T&T
valve position
Control Logic Checkout and Tuning

• Determine effectiveness of
controls

• Debug control logic on the

system rather than in the
field

• Establish initial controller

tuning

• Evaluate necessary
overrides for particular
upsets
TMC Process Modeling
Recycle valve Intercoolers Piping and Knock Out
critical flow drum volumes for
Performance accurate transients
Curves

Fluid feed
composition

Vapor-Liquid
Motor torque
Induction motor torque curve

2.5 Shaft rotating

Equilibrium
curves
2

inertia
“Flash”
1.5
Torque factor

1
Series1
0.5

0
0 0.2 0.4 0.6 0.8 1 1.2

-0.5

-1
speed - nornalized
TMC Dynamic Modeling Deliverables

Transmitter Outputs
1. Predictive Dynamic Process Model
Temperatures

Pressures
2. Validated Turbomachinery Controls
Flows

Limit Switches, etc.
3. Report with Lessons Learned and Key Recommendations

Dynamic
4. Operator Process
Training Model (optional)
System Turbomachinery Controls

Controller Outputs

Valve Positions

Speed

Trip Signals, etc.
The Non-Integrated Turbine
Control System
Non-Integrated Turbine Control System
Non-Integrated System
Different vendors are involved in and responsible for
control system components:

• Packager provides vibration monitor

• Compressor vendor or EPC contractor provides
surge and performance control
• EPC contractor provides interlocks
• Site performs integration testing
The Integrated Turbine
Control System
Integrated Control System
Integration Advantages
1. Reduces Space Requirements

2. Lowers Costs For:

• Procurement
• Engineering
• Installation
• Field Instrumentation

3. Eliminates Controller-Based:
• Communication Delays
• Interconnection
• Conflicts
Rotating
Equipment
Steam Turbines

Two Valve Three Valve

Single (single (double
Reheat
Valve extraction/ extraction/
admission) admission)
System Overview
Steam Turbine Sequencing
Fast Trending Sequence Capture
Compressor
Surge Control
Strategies
Minimum Flow Control

Pd
Ps

h
Ps
Maximum Pressure Control
Pd
Ps

h
Ps
Surge Control Basics

SIC
ST FT

PT
PIC TT
PT PT TT

UIC

FY

• Define operating point by measuring variables

• Compare with controller setpoint (surge
control line)
• Vary recycle (blow-off) to control compressor
on surge control line
Recycle Valve? What’s That?

SIC
ST FT

PT
PIC TT
PT PT TT

UIC

FY

Slide 37
Surge Control Basics
Opening the recycle valve helps the compressor avoid
surge by:

Re-circulating flow back

to the compressor inlet

Relieving resistance in
compressor discharge
network, allowing flow to
increase
The Surge Cycle
Pressure
3
2
4. Flow reverses as
4
discharge pressure drops

5 1 5. Drop in discharge
pressure re-establishes
forward flow (compressor
Flow
resumes full flow)
1. System resistance increases
discharge pressure required (operating Since resistance has not
point moves up the curve) changed, surge will
continue until the cycle is
2. Operating point nears the surge broken.
limit

3. Operating point goes into the surge

region

Slide 39
The Surge Cycle

The operating point can A complete surge cycle

move from stability into takes from 1/2 to 3
surge in fewer than 50 seconds, depending on
milliseconds. compressor size and
piping volume.

Slide 40
Why is Surge Bad?

It causes process upset because of flow reversals.

It damages seals.

It causes catastrophic failure of the compressor

when it is severe.

Slide 41
How Can Surge be Prevented?

• By accurately determining the operating point

• Through the surge controller’s anticipatory action

• By opening the recycle valve to decrease
pressure ratio and increase flow through
compressor

Slide 42
Control Features
Triconex Surge Control Features

• Surge Controller Setpoint Hover

• Automatic Adjustment of Safety Margin
• Independent Proportional Term
• Adaptive Tuning
• Fast Opening/Slow Closing of Recycle Valve
• Manual Recycle Valve Control Options

Slide 44
Traditional Surge Line
5 Surge
Line

Speed
Curves
4

Hp 3

1
0 20 40 60 80 10%
Flow 0

Slide
45
Compressor Performance

Hp

Q2 (ICFM)

• The compressor performance map can be redrawn as

the polytropic head vs. the inlet volume flow squared.

• The relationship between head and flow is not

changed by this modification.
 76
78
80
81

80
78
76
73
67
Polytropic
Head
Hp

0 10 20 30 40 50 60 70 80

100

80

Polytropic
Efficiency 60
h
p
40

20

0 10 20 30 40 50 60 70 80

Flow, Q
The Universal Surge Curve

P
( ) -1
P
2

h
P1
Universal Surge Line

Head Term

Pd
100% N
Ps 90% N
80% N

hs
Flow Term
Ps
The universal surge line is valid for all changes in
molecular weight and suction pressure.

Slide
49
Universal Surge Line
5 Surge
Line

Speed
Curves
4
Pd
__
Ps

1
0 20 40 60 80 10%
h
__ 0
Ps

Slide
50
Surge Margin
Safety Margin
Surge Control Features

• Universal Surge Line

• Automatic Adjustment of Safety Margin

• Independent Proportional Term
• Adaptive Tuning
• Fast Opening/Slow Closing of Recycle Valve
• Manual Recycle Valve Control Options

Slide 53
Setpoint Hover Feature
Surge Control Features

• Universal Surge Line

• Surge Controller Setpoint Hover

• Independent Proportional Term

• Adaptive Tuning
• Fast Opening/Slow Closing of Recycle Valve
• Manual Recycle Valve Control Options

Slide 55
Control Line Recalibration
Control Line
5 Surge Line Recalibrated
Control Line
Current
Operating
Point
4
Pd
__
Ps

1
0 20 40 60 80 100%
h
__
Ps

Slide
56
Surge Control Features

• Universal Surge Line

• Surge Controller Setpoint Hover
• Automatic Adjustment of Safety Margin

• Adaptive Tuning
• Fast Opening/Slow Closing of Recycle Valve
• Manual Recycle Valve Control Options

Slide 57
Surge Override
Surge
Override Control Line
Line
5 Surge
Line

0%
4
Pd Valve Output

Ps 100%

1
0 20 40 60 80 100%
h
Ps

Slide
58
Surge Control Features

• Universal Surge Line

• Surge Controller Setpoint Hover
• Automatic Adjustment of Safety Margin
• Independent Surge Override

• Fast Opening/Slow Closing of Recycle Valve

• Manual Recycle Valve Control Options

Slide 59
Adaptive Tuning
Surge Control Features

• Universal Surge Line

• Surge Controller Setpoint Hover
• Automatic Adjustment of Safety Margin
• Independent Surge Override
• Adaptive Tuning

• Manual Recycle Valve Control Options

Slide 61
Recycle Valve Opening/Closing

• Fast Opening

Quickly responds to surge condition, but does not

exceed response time of system

• Slow Closing

Allows turbine speed controller/process cascade

controller to smoothly adjust to new process
operating conditions

Slide 62
Surge Control Features

• Universal Surge Line

• Surge Controller Setpoint Hover
• Automatic Adjustment of Safety Margin
• Independent Surge Override
• Adaptive Tuning
• Fast Opening/Slow Closing of Recycle Valve

Slide 63
Manual Recycle Valve Control
Partial Authority
• Operator is allowed to open the recycle valve only when
his/her command is higher than the surge controller
demand
• Operator cannot close the recycle valve below the surge
controller demand

Full Authority
• Operator is allowed to close and open the recycle valve
with no surge protection
• Used to stroke test recycle valve prior to start-up
• Used in some fallback scenarios

Slide 64
Performance Control
Performance Control
The objective of a control loop is to operate a process:

• Within the operating zone

• In safe and stable manner with minimum human

interaction

• In a way that achieves operational design objectives with

optimum efficiency

Slide 66
Performance Control

How can we manipulate the capacity through the compressor to

influence the process?

Performance control can be accomplished in three ways:

1. By varying compressor speed via turbine or variable
frequency drive (VFD)
2. By using an inlet throttling valve for a constant speed
machine
3. By opening and closing the anti-surge valve (not very
efficient)

Slide 67
Decoupling Capacity
Control
Decoupling Capacity Control

The decoupling algorithm does the following:

• Absorbs fast load changes until compressor
speed/process valve can respond
• Prevents capacity control from driving compressor
into surge
• Decouples performance controller and surge
controller to prevent undesired interaction at low
rates

Slide 69
 Decoupling Capacity Control

Slide 70
 Surge Control and Capacity Control

Slide 71
 Surge Control

Slide 72
 Capacity/Decouple Control

Slide 73
Mechanical
Retrofit
Magnetic Pickups
Speed Gear

• Speed Gear
• Speed Probe
Mounting Bracket
• Speed Probes
Linear Variable Differential Transformer
Slide 78
78