CCC Turbomachinery

Controls System
 Who is the CCC?
CCC is a Controls Company dedicated to
making the operation of Turbomachinery
Safe and Efficient

Safe = No Missed Commissioning

No Production Loss

Efficient = Minimum Power

The CCC Product is Control Solutions

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 In Operation 34 Years
• Offices Worldwide
• +/- 400 Employees
• 8300+ Installations
• 200 Major Retrofit Projects/Year
• World’s Largest GT Retrofitter

1974 2008
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 Series 3+ Products
¾ Multi-loop controllers for speed, extraction,
antisurge, & performance control
MTBF of Series 3 Plus controllers is 43.4 years,
¾ Serial communications for peer to peer
or 2.5 failures per million hours of operation
and host system communications
Series 5 Products

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Vanguard Duplex Chassis
MPU-750

Power Supplies

Extended Card

IOC-555
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 Series 5 Reliant Duplex

Same
Electronics
Assembly and
Terminations
as Reliant SN

Switching
Module
Status
Indicators

Connector for
Remote Manual
Switch Module Switchover
Pushbuttons

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 ®
Guardian Overspeed Trip System

• API-670
Compliant
• 2oo3 Voting
of Speed
Modules
• Redundant
Power
Supplies
• Hot-Swap
Speed
Modules
• Modbus
Comms

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 ®
Vantage Steam Turbine Governors

• Vantage GP
for API-611
General
Purpose
Turbines
• Vantage GD
for Generator
Drive
Turbines
• Local HMI for
Configuration
and
Maintenance
• Reliant in
an IP-54
Enclosure
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 Air Miser®TL Enclosure
• 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

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 Series 3++ Controllers

¾ Class 1, Div 2 / Class 1 Zone 2

¾ ATEX Group 2 Class 3
¾ Simplex or “hot backup” redundant
¾ All AO’s have built-in feedback loops to identify
hardware or wiring problems

¾ On-board temperature
monitoring
¾ On-board power supply
voltage monitoring
¾ Wired Ethernet version
¾ Completely backward
compatible with S3+
 Raising the Bar Advanced
Constraint Control
¾ Upstream
improved control strategies for load sharing, expanders,
integration of networks across platforms

¾ Midstream
improved control strategies for Boil Off Gas networks,
intense focus on all primary LNG services

¾ Downstream
broader approach to process control, rather than just
Turbomachinery control. Advanced control strategies for
Ethylene, FCCU and PTA Plants. (Next focus is Ammonia).

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CCC Installations - Indonesia
¾ PT. Pupuk Iskandar Muda
¾ PT. Pupuk Sriwidjaya
¾ PT. Pupuk Kujang
¾ PT. Pupuk Kalimantan Timur
¾ PT. DSM Kaltim Melamine Indonesia
¾ PT. Amoco Mitsui PTA
¾ PT. Polysindo Eka Perkasa
¾ PT. Chandra Asri
¾ Pertamina / Refinery (WGC Exor Project)
¾ ConocoPhillips Indonesia
¾ ExxonMobil Oil Indonesia
¾ Total Indonesie
¾ PT. Kangean Energi Indonesia
¾ BP Tangguh LNG
¾ PT. Badak LNG
¾ PT. Arun LNG
¾ PT. Indonesia Power (PLN)
¾ Etc.

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 Typical Single Train Controls
(Suction Pressure Controls)

RSP

Train A
Section 1 Section 2

out
LSIC UIC Serial UIC
A 1A network 1A

PT

1 Antisurge Controls System

Performance Controls
System Next
Compressor Refresher

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 Compressor Type
Compressors

Positive Displacement
Dynamic Compressor
Compressor

Reciprocating Compressor Centrifugal

Rotary Compressor Axial

Membrane Compressor

Screw Compressor
CCC Focus

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Where do the different types of
compressor fit?

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Types of Compressor - Dynamic
Compressors

Axial Compressor Centrifugal Compressor

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Types of Compressor - Dynamic
Axial Compressors
Rotor

Stator

Stator Blades
Rotor Blades Shaft

Casing

Rotor
Stator Blades
Blades
Casing

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 Cross section of axial compressor
Stator Blades Guide-vane actuator linkage Labyrinth seals

Rotor blades

Adjustable guide vanes

Thrust bearing

Compressor inlet nozzle Compressor outlet nozzle

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 Types of Compressor – Dynamic
Centrifugal Compressors

Barrel (Centrifugal) Bullgear (Centrifugal)

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 Horizontally Split Type (Centrifugal)
Discharge volutes Impeller inlet labyrinth seals

Impellers
Shaft and labyrinth seal
Drive coupling
Journal bearing

Casing
(horizontally split flange) Thrust bearing
Compressor discharge nozzle

Compressor inlet nozzle

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Types of Compressor - Picture of
Horizontally Split Type (Centrifugal)

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Types of Compressor - Principal of
Operation (Centrifugal)

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 Types of Compressor - Classifications

Single-Section, Three-Stage Single-Case, Two-Section, Six-Stage

What is the function of this cooler?

Intercooling reduces energy consumption

but results in having multiple compressor maps
which need separate antisurge protection
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Types of Compressor - Classifications

Two-Case, Two-Section, Six-Stage

Parallel Network

Series Network

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 Surge Phenomenon

Why Compressor Surge

…and what happens
when they do

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 Developing the surge cycle on the
compressor curve
Pd
• From A to B…….20 - 50 ms…………….. Drop into surge Pv
• From C to D…….20 - 120 ms…………… Jump out of surge Rlosses
• A-B-C-D-A……….0.3 - 3 seconds……… Surge cycle

Pd = Compressor discharge pressure

Pv = Vessel pressure
Pd Rlosses = Resistance losses over pipe
B A

• Pressure builds
D • Resistance goes up
C • Compressor “rides” the curve
• Pd = Pv + Rlosses
• Electro motor is started
• Machine accelerates
to nominal speed
• Compressor reaches
performance curve
Note: Flow goes up faster
because pressure is the
integral of flow
Machine shutdown
Qs, vol
no flow, no pressure
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 Major Process Parameters during
Surge
¾ Rapid flow oscillations
FLOW
¾ Thrust reversals
TIME (sec.)
¾ Potential damage
1 2 3

PRESSURE
• Rapid pressure
oscillations with
TIME (sec.)
process instability
1 2 3

TEMPERATURE
• Rising temperatures
inside compressor
TIME (sec.)

1 2 3

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 Some surge consequences

¾ Unstable flow and pressure

¾ Damage in sequence with increasing
severity to seals, bearings, impellers,
shaft
¾ Increased seal clearances and leakage
¾ Lower energy efficiency
¾ Reduced compressor life

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 Factors leading to onset of
surge
¾ Startup
¾ Shutdown
¾ Operation at reduced throughput
¾ Operation at heavy throughput with:
- Trips
- Power loss
- Operator errors
- Process upsets
- Load changes
- Gas composition changes
- Cooler problems
- Filter or strainer problems
- Driver problems
 Standard Antisurge
Control Vs CCC Controls
System

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 CCC Business in Constraint Control

process limit
Pressure adding control
margins
maximum speed
surge limit
power limit

stonewall or
choke limit

stable zone
Actual available
of operation
operating zone
minimum speed

Flow

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 CCC Business in Constraint Control

process limit
Pressure adding control
margins
maximum speed
surge limit
power limit

stonewall or
choke limit

stable zone
Actual available
of operation
operating zone
minimum speed

Flow

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 Expanding the Operating Envelope
Limit
General
Purpose
Control
Setpoint
Operating Point

CCC Limit
Control Setpoint
Operating Point

Base Ingredients:
- Advanced algorithms
- Rate of change feed forward signals
- Fast hardware
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 Standard Antisurge Control

Compressor
Antisurge
Controller

FT PsT PdT
1 1 1

UIC
Suction 1
Process

Recycle Valve

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 Conventional Control Using Separate
Performance Recycle

Conventional
Capacity/Performance
Compressor
Controller

F PsT PdT
T1 1 1

UI
Suction C1 Process
PIC
1

Additional Recycle Valve

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Why Invest in Advanced
Controls?

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How Will CCC Control?

¾ Antisurge Control?
¾ Capacity Control?

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 CCC Controls System

VSDS
Performance
Compressor Controller

Load
ST FT PsT TsT PdT TdT PIC HIC
1 1 1 1 1 1 1 1

Suction
UIC
1
Process

Serial
network

Antisurge
Controller
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 Control System Objective
Control System Objectives:

¾ The control system objective is to keep the

process on its Primary Process Variable (PV)
set-point, and to return it to set-point as quickly
as possible after a process disturbance

¾ The control system has to keep the process

on/return to set-point while operating within
compressor operating envelope limits, including
protection against surge and surge damage

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 Challenges of Compressor
Control System
The ingredients of a successful compressor control system
are:

z An algorithm that can accurately locate the operating point

and its corresponding surge limit
z A controller execution speed that will allow a digital controller
to emulate immediate analog control
z Control responses that allow different margins of safety for
different operating conditions
z Advanced control strategies that can avoid the negative
effects of loop interaction
z A quick acting, correctly sized antisurge control valve
z The elimination of unnecessary dead time or lag time within
the system
z Valid load sharing strategies

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 Standard Control VS CCC
Controls

¾ Standard ¾ CCC

Compressor
VSDS
Compressor
F P P
1 1 1
T s d
T T
U
Suction 1
I
Process Load
C P S F P T P T P H
1
I T1 T1 s1 s1 d1 d1 I1 I1
C T T T T C C
Suction U
I1
Process
C Serial
network

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 Standard Control VS CCC
Controls
¾ Standard
z 15% surge margin
z Quick opening valves
z No control of process
variable via recycle
z No invariant coordinates
z Concentrating on
‘Protection’
¾ CCC
z Typically 8% surge margin
z Linear valves with
positioners for control
across 100% range
z Control of primary process
variable by recycle when
speed limit is reached
z Can handle varying
molecular weight gases
z Concentrating on ‘Control
and Protection’
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 CCC Controller protection

How CCC Antisurge Controller

protects compressor against
surge?

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 Antisurge Controller Operation Protection #1
The Surge Control Line (SCL)

• The antisurge controller UIC-1 protects the compressor

against surge by opening the recycle valve

VSDS

Compressor Rc Rprocess

Rprocess+valve

FT PsT PdT
1 1 1

Suction Discharge
UIC
1

2
qr

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 Antisurge Controller Operation Protection #1
The Surge Control Line (SCL)
Rc SLL = Surge Limit Line
SCL = Surge Control Line

B
¾ When the operating point
A
crosses the SCL, PI
control will open the
recycle valve

¾ PI control will give

qr
2
adequate protection for
small disturbances

• PI control will give stable control during steady state

recycle operation
• Slow disturbance example
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Antisurge Controller Operation Protection #2
Moving The Surge Control Line (SCL)
• When the operating point
SLL = Surge Limit Line moves quickly towards the
SCL = Surge Control Line SCL, the rate of change
Rc
(dS/dT) can be used to
dynamically increase the surge
B control margin.
A • This allows the PID controller
to react earlier.

• Smaller steady state surge

control margins can be used
w/o sacrificing reliability.

• Fast disturbance example

2
Q

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Antisurge Controller Operation Protection #3
The Recycle Trip® Line (RTL)
Rc SLL = Surge Limit Line
RTL = Recycle Trip Line
SCL = Surge Control Line Benefits:
– Reliably breaks the
surge cycle
OP
– Energy savings due to
smaller surge margins
needed
– Compressor has more
turndown before
recycle or blow-off
– Surge can be
Output Q
2
prevented for virtually
to Valve any disturbance

Total Response PI Control Step Change

PI Control Response

Open-loop Response +
Time To antisurge valve

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 What if one Recycle Trip® step
response is not enough?
After time delay C2 controller checks if Operating Point is back to
safe side of Recycle Trip® Line
- If Yes: Exponential decay of Recycle Trip® response.
- If No: Another step is added to the Recycle Trip®
response. Output
to valve Multiple step response

Total

Output
to valve One step response
PI Control
100%

Recycle Trip®

Time
C2 C2 C2
Total
PI Control
Recycle Trip®
0%
Time
C2

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 Integrated control Decoupling of
Performance and Antisurge control

Output to
Input Speed Inputs Turbine Valve

Process Variable Inputs

Flow Output to
Pressure Antisurge Inputs Recycle Valve

Temperature

Gas Data

(Field Serial
Transmitter) Communication
Link CCC-DCS

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 Integrated control Decoupling of
Performance and Antisurge control
1. When operating at Point A, process
Rc encounters a large disturbance,
operating point will move to Point B
L

L
2. The decoupling control starts to act
SL

SC
B Performance control send request
to increase speed
C A
3. The speed increasing combined with
PIC-SP antisurge valve opening, then,
The trace of operating line as shown

4. The net control effect is more

stable operation even with large
process disturbance

5. This decoupling control is can

∆Po reduce the control safety margin,
Ps Therefore it can achieve energy
saving and safe operation

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 Antisurge Controller Operation
Protection #4 “Safety On”

How about if the protection not capable

against surge?

Compressor has real surge

What will CCC controller do?

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 Antisurge Controller Operation Protection #5
“Safety On”

SOL = Safety On® Line • If Operating Point crosses the Safety

SLL = Surge Limit Line
RTL Line = Recycle Trip® On® Line the compressor is in surge
SCL = Surge Control Line
• The Safety On® response shifts the
SCL and the RTL to the right
Pressure axis

• Additional safety or surge margin is

added

• PI control and Recycle Trip® will

New SCL stabilize the machine on the new SCL

New RTL

Additional surge margin Flow axis

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 CCC
LOAD SHARING CONTROLS
SYSTEM

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 Compressor networks
¾ Compressors are often operated in parallel and sometimes in series
¾ The purposes of networks include:
z Redundancy

z Flexibility

z Incremental capacity additions

¾ Often each compressor is controlled, but the network is ignored

¾ Compressor manufacturers often focus on individual machines
¾ A “network view” of the application is essential to achieve good
surge protection and good performance control of the network.

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 Load Sharing
Control system objectives for compressors in parallel:
z Maintain the primary performance variable (in this case
suction pressure), and then:
z Optimally divide the load between the compressors in the
network, while:
• Minimizing risk of surge
• Minimizing energy consumption
• Minimizing disturbance of starting and stopping
individual compressors
• Operating within limits

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 Load Sharing

Load Sharing Control system types:

1. Base and Swing Load Sharing system
2. Equal Flow Load Sharing system
3. CCC Equidistance Load Sharing controls system

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 Base and Swing Load Sharing
Flow Diagram for Control Process
VSDS
Swing
Compressor 1
machine
UIC
1

PIC
1

HIC
1
Suction
Process
header
VSDS

Compressor 2
Base Notes
machine • All controllers act
UIC
independently
2 • Transmitters are
not shown

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 Base and Swing Load Sharing
Parallel Compressor Control
Rc,1 Compressor 1 Rc,2 Compressor 2
Swing machine Base machine

PIC-SP

QP,1 + QP,2 = QP,1 + QP,2

2 2
qr,1 qr,2
QP,1 QC,1 QP,1 QP,2 QC,2= QP,2
Notes: where:
QP = Flow to process
• Base loading is inefficient QC= Total compressor flow
• Base loading increases the risk of surge QC - QP = Recycle flow
since compressor #1 will take the worst
of any disturbance
• Base loading requires frequent operator
intervention
• Base loading is NOT recommended
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 Equal Flow Load sharing
Flow Diagram for Control Process
RSP
VSDS

Compressor 1

out
UIC FIC RSP
1 1

out
PIC
1

Suction
header
Process
RSP
VSDS Notes
Compressor 2
• Performance controllers
act independent of
out P antisurge control
UIC FIC RS • Higher capital cost due to
2 2
extra Flow Measurement
Devices (FMD)
• Higher energy costs due
to permanent pressure
loss across FMD’s

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 Equal Flow Load sharing
Parallel Compressor Control
Rc,1 Compressor 1 Rc,2 Compressor 2

PIC-SP

Equal flow QP,1 = QP,2 Equal flow

2 2
qr,1 qr,2
QP,1 QP,2QC,2
Notes: where:
QP = Flow to process
• Requires additional capital investment in QC= Total compressor flow
FMD’s QC - QP = Recycle flow
• Requires additional energy due to
permanent pressure loss across FMD’s
• Poor pressure control due to positive
feedback in control system (see next)
• Equal flow division is NOT recommended
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 CCC Equidistance Load sharing
Flow Diagram for Control Process
VSDS
RSP

Compressor 1

out
UIC Serial LSIC Serial
1 network 1 network

MPIC
1
Suction
header Process
VSDS
RSP

Notes
Compressor 2
• All controllers are
UIC
out
Serial LSIC
coordinating
2 network 2 control responses
via a serial network
• Minimizes recycle
under all operating
conditions

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 CCC Equidistance Load sharing
Parallel Compressor Control
Rc,1 Compressor 1 Rc,2 Compressor 2
SCL = Surge Control Line DEV = 0
0.1
0.1
0.2
0.2
0.3
0.3
PIC-SP

Dev1 = Dev2
Q1 = Q2
N1 = N2
q2r,1 2
qr,2
DEV1 DEV2

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
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The load balancing response
PV
PID
SP

DEV from other

loadsharing
Average Master
Controller
controllers
Analog Inputs

DEV
FA
Mode
DEV DEV DEV

PV SP
Primary Load Primary
PI RT
response balancing response

+ +
Loop Loop
Antisurge Loadsharing
Controller Decoupling Decoupling Controller

To antisurge valve To performance

control element

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 CCC LOAD SHARING
Control System Drawing
MASTER CONTROLLER LOAD SHARING CONTROLLER
(Suction Header Controls)

ANTISURGE CONTROLLER

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 End Slides
Thank You very much for your
kind attention and cooperation

PT Putranata Adi Mandiri

Jl Kartini VIII No. 9
Jakarta 10750
Tel: (021) 6007850
Fax: (021) 6007846
Email: pamccc@cbn.net.id