CCC Surge Controller

Slide 1
January 27, 2015
Invensys proprietary & confidential
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are trade marks of Invensys plc
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CCC Anti-Surge Control

Sudheer Boppana
Invensys IOM
2009 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.
Invensys January 27, 2015
CCC SURGE CONTROLLER

Content of the Course
Foundation Course:
01.- Compressor Surge - Fundamentals
02.- CCC Anti-Surge Control
03.- CCC Operator interface
04.- Emulator OPC list
05.- OPC Engine Configuration for CCC S5 server
06.- CCC S5 configurator
Compressor Surge
:Basic Concepts
Compressor Surge: Basic Concepts

Centrifugal compressor is a dynamic displacement machine where
dynamic centrifugal force is applied to the gas transmitted by an
impeller, adding kinetic energy through acceleration of the gas.
This kinetic energy is retarded in a vaned or vaneless diffuser,
transforming most of that velocity energy into additional static
pressure.

For a given Discharge Pressure, a compressor has a certain minimum
volumetric flow rate below which the compressor becomes unstable.
Below this flow rate delivery of gas becomes irregular, due to
momentary reversals of flow through the compressor, with a
characteristic noise known as surge.
Each speed and pressure has its own surge point.
The locus of the surge points for different speeds and discharge
pressures is called the surge line.
Surge condition
N
Choke condition
(stone wall)
head
Volume Flow
Compressor Performance Curve

6

The typical duration of one SURGE CYCLE is 0.5 to 2.0 seconds.
SURGE
Pressure
Surge zone
Operating zone
B
C
D
D
Negative flow
OP
Surge Cycle
Positive flow

Major Consequences of surge
Process disturbances which may cause process trips and disruption
Damage to seals and bearings.
Lowering of compressor efficiency
Destruction of compressor rotor
Surge Protection
A combination of high discharge pressure and low flow(through the
compressor) can result in surge
Avoiding one or both of these situations prevents a compressor from going
into surge
Both the situations can be avoided by blow off or recycling a part of the
discharge gas back to the compressor suction when the operating point
nears surge.
CCC Anti-Surge
Control

CCC Compressor Control Corporation
CCC doesn't use flow rate in the calculation of various control variables,
instead it uses pressure drop across a flow element.
10

Proximity to Surge:
For simple systems,
For complex systems(multidimensional coordinates)
11

Flow compensation
The flow rate used in the calculation of Proximity to Surge should be
compensated to suction.
Various modes of compensation used in CCC control system
12

Surge Control Lines
Surge Limit Line(SLL): represents the actual surge line.

Surge Control Line(SCL): defines desired minimum distance between
operating point and SLL. The distance between SCL & SLL is determined by
safety margin (b).
Position of OP relative to SCL is given by S = Ss + b. f4(Z4)
Deviation: Current distance between OP and SCL , dev = 1 - S
13

CRso: Safety On incremental bias(b2) is added to the CRSO with each
additional surge event.
CRSO = b2,n = b2,n-1 + b2
Recycle Trip Line (RTL): It defines operating limit beyond which Recycle trip
response(step increments) is added to the PI response in order to open the
ASV faster.
The position of RTL will move to the right as a result of Safety On Response
(CRSO)
14

Anti-surge PI response:
S 1
2
CR p k p (e 'n e 'n 1 )
e
CRI
k p k r tc
2
Derivative Response:
CRD Tc (
(e 'n e 'n 1 )
dS s
db)
dt
Safety On Reset: This command will reset CRSO to 0 and reduce the surge
count to zero.
15
16
CCC Operator
interface
17
CCC Operator interface
18
19
20
Series5 Emulator
OPC list
21
Series5 Emulator OPC list

Emulator IP address
127.0.0.1
22
Emulator Instance
Emulator Instance Port
20547
20548
20549

Emulator Execution Control Variables
Emulator
Variable Description
Instance
23
Variable Name
OPC Variable Fully-Qualified ItemID
Data
Type
Access
Rights
Direction
Go to Stop State
@GV.Emulator.Command.Stop
127.0.0.1:20547.@GV.Emulator.Command.Stop
boolean
read/write input/output
Initialize to loaded IC
@GV.Emulator.Command.Reset
127.0.0.1:20547.@GV.Emulator.Command.Reset
boolean
Synchronize to PC clock @GV.Emulator.Command.Synchronize
127.0.0.1:20547.@GV.Emulator.Command.Synchronize
boolean
Execution Speed
@GV.Emulator.Command.RunOneStep. 127.0.0.1:20547.@GV.Emulator.Command.RunOneStep.
ExecutionSpeed
ExecutionSpeed
real
Step Time
StepTime
StepTime
real
Run One Step
RunOneStep
RunOneStep
boolean
One loop execution

complete
@GV.Emulator.Status.LoopCounter
127.0.0.1:20547.@GV.Emulator.Status.LoopCounter
integer
read
output
Emulator track state
@GV.Emulator.Status.EmulatorTrack
127.0.0.1:20547.@GV.Emulator.Status.EmulatorTrack
boolean
read
output
Internal Clock
(seconds)
@GV.Seconds
127.0.0.1:20547.@GV.Seconds
real
read
output
Internal Clock
(microseconds)
@GV.Microseconds
127.0.0.1:20547.@GV.Microseconds
real
read
output

Emulator Application Status Variables for Initialize
Emulator Controller
Instance
TAG
Variable Name
Data
Type
Access
Rights
Direction
Prog1.AS1_1.Status.Emulator.act_control_mo 127.0.0.1:20547.Prog1.AS1_1.Status.Emulator.act_control_mo
integer read/write input/output
de
de
UICA-660
UICA-660 Prog1.AS1_1.Status.Emulator.decouple_CV
127.0.0.1:20547.Prog1.AS1_1.Status.Emulator.decouple_CV
UICA-660 Prog1.AS1_1.Status.Emulator.state
127.0.0.1:20547.Prog1.AS1_1.Status.Emulator.state
UICA-660 Prog1.AS1_1.Status.Emulator.output
127.0.0.1:20547.Prog1.AS1_1.Status.Emulator.output
real
UICA-660 Prog1.AS1_1.Status.Emulator.b2_sum
127.0.0.1:20547.Prog1.AS1_1.Status.Emulator.b2_sum
real
UICA-660 Prog1.AS1_1.Status.Emulator.RT
127.0.0.1:20547.Prog1.AS1_1.Status.Emulator.RT
boolean read/write input/output
UICA-660 Prog1.AS1_1.Status.Emulator.RT_ignore_Kp
127.0.0.1:20547.Prog1.AS1_1.Status.Emulator.RT_ignore_Kp
UICA-660 Prog1.AS1_1.Status.Emulator.RT_decay_time 127.0.0.1:20547.Prog1.AS1_1.Status.Emulator.RT_decay_time
real
UICA-660 Prog1.AS1_1.Status.Emulator.RT_dead_time
127.0.0.1:20547.Prog1.AS1_1.Status.Emulator.RT_dead_time
real
UICA-660 Prog1.AS1_1.Status.Emulator.surge_count
127.0.0.1:20547.Prog1.AS1_1.Status.Emulator.surge_count
UICA-660 Prog1.AS1_1.Status.Emulator.start_time
127.0.0.1:20547.Prog1.AS1_1.Status.Emulator.start_time
real
UICA-660 Prog1.AS1_1.Status.Emulator.stop_time
127.0.0.1:20547.Prog1.AS1_1.Status.Emulator.stop_time
real
UICA-660 Prog1.AS1_1.Status.Emulator.limit1_active
127.0.0.1:20547.Prog1.AS1_1.Status.Emulator.limit1_active
UICA-660 Prog1.AS1_1.Status.Emulator.LimitCondition
127.0.0.1:20547.Prog1.AS1_1.Status.Emulator.LimitCondition boolean read/write input/output
24
real

Emulator Input/Output Variables
Emulator Controller Instrume Instrument
min max
Instance
TAG
nt TAG Description
LP Stg
FT-035/FTDischarge
0
036
diff. Pressure
LP Stg
PT-037/PTDischarge
-1
038
Pressure
LP Stg
TT-055 Discharge
0
Temperature
LP Stg
PT-036/PTSuction
-1
047
Pressure
LP Stg
TT-050 Suction
-50
Temperature
UICA-300
UICA-300
UICA-300
UICA-300
UICA-300
UICA300/UICA320/UICA340
ST-014
Compressor
Speed
UICA-300
Output
HIC-051 Override
(from DCS)
UICA-300
UICA-300
UICA300/UICA320/UICA340
UZ-361
ESD
UICA-300
UZ-304
LP Stg
Excessive
surge trip
25
unit
Variable Name
Data
Type
Access
Rights
Direction
50
mbar _In_1.ANI.dPo1.ext_Simulate_value
127.0.0.1:20549._In_1.ANI.dPo1.ext_Simulate_value
real
read/write
input
barg _In_1.ANI.Pd1.ext_Simulate_value
127.0.0.1:20549._In_1.ANI.Pd1.ext_Simulate_value
real
read/write
input
200
degC _In_1.ANI.Td1.ext_Simulate_value
127.0.0.1:20549._In_1.ANI.Td1.ext_Simulate_value
real
read/write
input
barg _In_1.ANI.Ps1.ext_Simulate_value
127.0.0.1:20549._In_1.ANI.Ps1.ext_Simulate_value
real
read/write
input
100
degC _In_1.ANI.Ts1.ext_Simulate_value
127.0.0.1:20549._In_1.ANI.Ts1.ext_Simulate_value
real
read/write
input
8900
RPM
_In_1.ANI.N.ext_Simulate_value
127.0.0.1:20549._In_1.ANI.N.ext_Simulate_value
real
read/write
input
100
_In_1.ANI.rlc1.ext_Simulate_value
127.0.0.1:20549._In_1.ANI.rlc1.ext_Simulate_value
real
read/write
input
Stage 1 Valve
position
feedback
100
_In_1.ANI.pos1.ext_Simulate_value
127.0.0.1:20549._In_1.ANI.pos1.ext_Simulate_value
real
read/write
input
Output to
UICA-301 valve 7914UICA-301
100
_Out_1.ANO.as1_out.Ano_field
127.0.0.1:20549._Out_1.ANO.as1_out.Ano_field
real
read
output
ESD
_In_1.DGI.esd.ext_Simulate_value
127.0.0.1:20549._In_1.DGI.esd.ext_Simulate_value
bool
read/write
input
EXC
_Out_1.DGO.as1_surge_trip.Dgo_field
127.0.0.1:20549._Out_1.DGO.as1_surge_trip.Dgo_field
bool
read
output
GI-301

Control Applications' Command and Status Variables
Emulator Controller Instrument
min max unit
Instance
TAG
Description
UICA-660
Safety On
Reset
Variable Name
Data
Type
Access
Rights
Direction
Prog1.AS1_1.Command.SO_reset
127.0.0.1:20547.Prog1.AS1_1.Command.SO_reset
boolean read/write
Antisurge
UICA-660 Fallback
Active
Prog1.AS1_1.Status.Operator.FALLBACK
127.0.0.1:20547.Prog1.AS1_1.Status.Operator.FALLBACK
boolean
read
output
Antisurge
UICA-660 Safety On
Condition
Prog1.AS1_1.Status.Operator.SO
127.0.0.1:20547.Prog1.AS1_1.Status.Operator.SO
boolean
read
output
Antisurge
UICA-660 Recycle Trip
Condition
Prog1.AS1_1.Status.Operator.RT
127.0.0.1:20547.Prog1.AS1_1.Status.Operator.RT
boolean
read
output
Antisurge
UICA-660 Active
Control Mode
Prog1.AS1_1.Status.Operator.act_control_ 127.0.0.1:20547.Prog1.AS1_1.Status.Operator.act_control_m
integer
mode
ode
read
output
UICA-660
UICA-660
26
17
Antisurge
Deviation
-1
Manual
Target to
Antisurge
Controller
100
none
none Prog1.AS1_1.Status.Operator.dev
Prog1.AS1_1.Command.man_target
input
127.0.0.1:20547.Prog1.AS1_1.Status.Operator.dev
real
read
output
127.0.0.1:20547.Prog1.AS1_1.Command.man_target
real
read/write
input
OPC Engine(Dynsim)
Configuration for CCC S5
server
27

CCC Surge Controller

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Slide 1

January 27, 2015

Invensys proprietary & confidential

Invensys and the Invensys logo

Learn & Share

CCC Anti-Surge Control

2009 Invensys. All Rights Reserved.

Invensys proprietary & confidential

Invensys January 27, 2015