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Objectives
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
2009 General Assembly Yokohama, Japan
Introduction
Compressor Antisurge requires speed and reliability Can field-based control improve reliability and performance? How fast can we go with ith newer offerings?
2009 General Assembly Yokohama, Japan
What is Surge?
P Surge Line
B
105 % 100 % 95 %
Flow
2009 General Assembly Yokohama, Japan
Deep Surge!
P
C
Surge Line
B
Speed
100 %
Flow
2009 General Assembly Yokohama, Japan
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
What is Surge?
P Surge Line
B
Surge Area
105 % 100 % 95 %
Flow
2009 General Assembly Yokohama, Japan
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
2009 General Assembly Yokohama, Japan
Load changes, start/stop Gas Molecular Weight change Upstream p or downstream pressure p changes g Gas temperature changes
Surge control
P Surge Line
FTS TTS PTS
B'
Driver
A Speed
Compressor
FIC
TTD
105 %
100 % 95 %
Flow
2009 General Assembly Yokohama, Japan
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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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Controls total flow Allows operation close to low-flow BMS trip p point p Saves fuel costs and reduces CO2 emissions
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SGCR
FIC
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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 or less
2009 General Assembly Yokohama, Japan
Blow-off Valve
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1999 2009 Fieldbus Foundation
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
2009 General Assembly Yokohama, Japan 1999 2009 Fieldbus Foundation
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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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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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Blow-off Valve
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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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 hostsolved schemes Newer devices have increasingly fast and efficient function blocks
2009 General Assembly Yokohama, Japan 1999 2009 Fieldbus Foundation
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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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