The document provides information about a GE Oil & Gas training course on centrifugal compressor antisurge control. The 2-day course covers fundamentals of antisurge control systems and load sharing concepts. It is intended for control engineers and includes topics like compressor performance curves, abnormal operating conditions like surge, antisurge control and protection systems, antisurge screens, and load sharing overview. Prerequisites include completing a previous centrifugal compressor basics course.
The document provides information about a GE Oil & Gas training course on centrifugal compressor antisurge control. The 2-day course covers fundamentals of antisurge control systems and load sharing concepts. It is intended for control engineers and includes topics like compressor performance curves, abnormal operating conditions like surge, antisurge control and protection systems, antisurge screens, and load sharing overview. Prerequisites include completing a previous centrifugal compressor basics course.
The document provides information about a GE Oil & Gas training course on centrifugal compressor antisurge control. The 2-day course covers fundamentals of antisurge control systems and load sharing concepts. It is intended for control engineers and includes topics like compressor performance curves, abnormal operating conditions like surge, antisurge control and protection systems, antisurge screens, and load sharing overview. Prerequisites include completing a previous centrifugal compressor basics course.
The training course provides control Eng. with the fundamentals of compressor anti surge control system. Basics of Load Sharing concepts will be provided.
Prerequisite: Trainees must have already performed the Centrifugal Compressor Basic course.
Expected Audience: Control (ENG, Nouveaux & Anciens)
Course Content:
1. GE OIL & GAS CENTRIFUGAL COMPRESSORS Centrifugal compressor introduction
2. COMPRESSOR PERFORMANCE CURVES Introduction to Thermodynamic planes Performance and system resistance curves theory Operating Point and Conditions
4. ANTISURGE CONTROL AND PROTECTION Control system introduction Antisurge valve description Antisurge block diagram sequence description Antisurge control and protection philosophy Antisurge control and protection operation
GE Oil & Gas 5. ANTISURGE SCREENS - BASED ON SPEEDTRONIC MARK FAMILY Main screen field description Auto/manual operation Antisurge control status description
6. LOAD SHARING AND BALANCING OVERVIEW
7. QUESTION AND ANSWER
Course Duration: 2 Days GE Oil & Gas
Cen|r|/uga| Compressor An||surge TRAINING MANUAL
Customized for: SONATRACH (ALGERIA) GE Oil & Gas
GE Oil & Gas
This manual contains proprietary information of GE Oil & Gas Nuovo Pignone S.p.A. (GE Oil & Gas), and is furnished to its customers solely for customer training courses purposes.
This manual shall not be reproduced in whole or in part nor shall its contents be disclosed to any third party without the written approval of GE Oil & Gas. The instructions and information contained in the manual do not purport to cover all details or variations in equipment, or to provide for every possible contingency to be met during installation, operation, and maintenance.
Should further information be desired or should particular problems arise that are not covered sufficiently for the purchasers purpose, the matter should be referred to GE Oil & Gas.
GE Oil & Gas Cen|r|/uga| Compressor An||surge TRAINING MANUAL
SEZ .1 An||surge Presen|a||on
Customized for: SONATRACH (ALGERIA)
Centrifugal Compressor Antisurge GE Oil & Gas Oil & Gas Industry Applications 2 Antisurge Centrifugal Compressor- Introduction What is a compressor? Driven machine Rotating machine Its duty is to increase the gas pressure How it works? Increase the kinetic energy throgh rotating components and converts it into static pressure through the stator components, using the torque given by the driver Why do I need to compress a gas? Transport Create chemical reactions Gas storage Enhance oil production 3 Antisurge Centrifugal Compressor- Introduction Pipeline inspection device Offshore production platform Subsea equipment Oil/Gas field Re-injection plant Oil / gas processing plant LNG receiving plant LNG liquefaction plant Gas boosting station Oil boosting station Power generation plant Natural Gas storage plant Refinery / Petrochemical / fertilizer plant 4 Antisurge Centrifugal Compressor- Introduction According to the section arrangement of a centrifugal compressor, the internal components can be resumed in different sections. This section nomenclature is used to identify the different areas where the gas passes and this is also called GAS PATH. The gas flows through the compressor along the gas path. A compression stage consists of the impeller, which is the rotating part, and the diffuser, which is the stationary part. We can split a compressor gas path into different main sections: Suction stage Discharge stage Intermediate stage/s (multistage compressors) 5 Antisurge Centrifugal Compressor- Introduction 6 Antisurge Centrifugal Compressor- Introduction Shaft Inlet Volute Fin Casing Blade Impeller Suction Nozzle Suction Pipe The gas flow from the pipe arrives at the suction stage traveling in a radial direction and must be reoriented into an axial direction to enter the impeller. The purpose of the suction stage is to convey the gas into the first impeller with low load losses and with uniform pressure and velocity. Usually, the suction stage has a fin positioned at the opposite side of the suction flange, which splits the flow of the gas to avoid gas recycling in the inlet volute. 7 Antisurge Centrifugal Compressor- Introduction Gas inlet Gas inlet 8 Antisurge Centrifugal Compressor- Introduction The intermediate stages are the stages between the suction and the discharge; their number depends on how many impellers are installed on the shaft. Due to the fact that each compressor is fully customized, the geometry of the intermediate stages will change from compressor to compressor, according to operating specifications. Labirinth seals Diffuser Return channel Blades 9 Antisurge Centrifugal Compressor- Introduction P 4 ,C 4 P 1 ,C 1 P 2 ,C 2 P 3 ,C 3 ++ + +++ Increased velocity and pressure A compressor stage consists of the impeller, the diffuser and the return channel. The impeller rotates with the shaft, increasing both the velocity and the pressure of the gas. Regarding the pressure increase, we can say that it occurs within the impeller and the diffuser, and that the magnitude of this increase depends on the design of both of these. 10 Antisurge Centrifugal Compressor- Introduction 4 3 2 Impeller Inlet Blade Inlet Diffuser Inlet Diffuser Outlet Velocity Pressure Energy 1 2 3 4 1 As shown in this diagram: in the impeller both the velocity and pressure increase; in the diffuser the pressure increases and the velocity decreases due to the convergent design; and in the return channel there is no increase in pressure because the convergent design is chosen only to avoid load losses. The return channel is bladed in order to more effectively convey the gas toward the next impeller inlet, thus reducing load losses, but there is no further increase of pressure downstream the diffuser outlet. We can state that all the pressure increase realized within a compressor stage is made between the blade inlet and the diffuser outlet. 11 Antisurge Centrifugal Compressor- Introduction Last impeller Discharge volute The discharge section of the gas path is the connection between the inner parts of the compressor and the piping. The most important part is the Discharge volute. The discharge volute is installed after the last diffuser and convey the gas into the discharge piping. The volute has a variable section to impart low load losses to avoid decreasing the pressure. A fin is usually installed near the discharge flange to prevent gas recirculation within the volute 12 Antisurge Centrifugal Compressor- Introduction The performance curves are a graphical way to display the perfomance parameters, always related to Inlet flow. Each of the curves is related to a certain fixed speed. The parameters shown are: Polytropic Head Polytropic Efficiency Pressure Ratio Power Discharge Temperature Discharge Pressure 13 Antisurge Centrifugal Compressor- Introduction Maximum continuous speed (MCS) Minimum operating speed (MOS) D i s c h a r g e
p r e s s u r e
( b a r
a ) Inlet capacity 65% 80% 90% 98% 100% 105% Normal operating point 14 Antisurge Centrifugal Compressor- Introduction Surge Limit Line Choking Area 65% 80% 90% 98% 100% 105% Operating range 15 Antisurge Centrifugal Compressor- Introduction External system resistance curve Operating point 65% 80% 90% 98% 100% 105% The plot represents the envelope of all the possible operating conditions relevant to the given suction parameter. The actual operating point is unique and it is always the intersection between the compressor curve at the given speed and the plant resistance curve. 16 Antisurge Centrifugal Compressor- Introduction 65% 80% 90% 98% 100% 105% The plant resistance curve can change during operation 17 Antisurge Centrifugal Compressor- Introduction 65% 80% 90% 98% 100% 105% Operating stability Turndown Range 18 Antisurge Centrifugal Compressor- Introduction Surge Limit Line Choking Area 65% 80% 90% 98% 100% 105% Operating range Looking back at this performance curve diagram, the left and right limits for the perfomance map of a centrifugal compressor are called: Surge limit line and Choking area. To introduce the topic, choking is related to the maximum flow rate that the compressor can handle at a certain speed while surge is related to fluid dynamic instabilities that will occur if the flow rates decreases over a certain threshold at a certain speed. 19 Antisurge Centrifugal Compressor- Introduction Rapid decrease in performances and efficiency. The increase of gas speed inside the compressor can lead to high vibrations alarms. Choking rapresents the right limit of the perfomance curves. It is the maximum flow that the compressor can handle at that speed, given by the geometry of the impellers. Due to a change in system resistance, if the operating point reaches the choking limit, the flow remains constant but the discharge pressure will rapidly drop. 20 Antisurge Centrifugal Compressor- Introduction Choking is a physical limit of the compressor but it will mostly affect only the output. No detection or protection system is required to provide choking. What happens if the compressor chokes: The flow reaches M=1 at the inlet of the impeller (restricted section); Shock wave causes a dicontinuity of p and T. Maximum flow rate; Flow rate remains constant Discharge pressure will drop Gas velocity will increase Shock wave 21 Antisurge Centrifugal Compressor- Introduction What is it surge? "Axis-symmetric stall", more commonly known as "compressor surge" or "pressure surge", is a complete breakdown in compression resulting in a reversal of flow. This phenomenon occurs when the machine operates at a compression ratio close the maximum that the compressor can furnish at the speed at which it is running. Its due to the compressor's inability to continue working against the already-compressed gas behind it. What is it due to? The compressor either experiences conditions which exceed the limit of its pressure rise capabilities or is highly loaded such that it does not have the capacity to absorb a momentary disturbance, creating a rotational stall which can propagate in less than a second to include the entire compressor. What happens? During the normal operation: Increase of discharge pressure, downstream the compressor; decrease of suction pressure; increase of suction temperature. Due to high plant resistance, during Start up and Shutdown theres a high risk of surge phenomenons. Which are the main factors leading to Surge? 22 Antisurge Centrifugal Compressor- Introduction Surge is the left limit of performance curve, on the left of this line the compressor operates in unstable condition; Represents the maximum polytropic head of the curve; All surge points, defined for different speeds represent the Surge Limit Line SLL; 23 Antisurge Centrifugal Compressor- Introduction P 2 P 1 P 2 > P 1 Axial thrust 24 Antisurge Centrifugal Compressor- Introduction P 2 P 1 Axial thrust P 1 > P 2 25 Antisurge Centrifugal Compressor- Introduction Rapid flow oscillations Rapid pressure oscillations with process instability Rising temperatures inside the compressor Flow Pressure Temperature Time Time Time 26 Antisurge Centrifugal Compressor- Introduction Flow reverses in 20 to 50 milliseconds Surge cycles at a rate of 0.3 sec to 3 sec per cycle Compressor vibrates, shakes Temperature rise Whooshing noise or clanking noise Conventional instruments and human operators may fail to recognize surge 27 Antisurge Centrifugal Compressor- Introduction Unstable flow and pressure Damage increasing with severity to seals, bearings, impellers and shaft Increased seal clearances and leakage Lower efficiency Trips Reduced compressor life 28 Antisurge Centrifugal Compressor- Introduction The purpose of the antisurge control system is to keep the operating point, at each respective speed, from surpassing the surge limit line SLL. At the same time, the antisurge control system allows the compressor to maintain a safe working range. The opening of the antisurge valve causes an increase of compressor suction flow that will reduce the slope of the external system resistance curve, so the working point of the machine remains safely on the right of the critical surge flow. Surge Limit Line Choking Area 65% 80% 90% 98% 100% 105% Operating range External system resistance curve Operating point In order to maintain the compressor operation within a safe operating range, all the centrifugal compressors are equipped with an antisurge system. 29 Antisurge Centrifugal Compressor- Introduction The Antisurge Systemis composed by: Antisurge Valve Instrumentation: Flow indicator trasmitter Pressure indicator trasmitter Electronic controller Antisurge valve: Is a regulating valve, to avoid excessive recycles of flow that will reduce the output of the machine. Recycles flow from discharge to suction in order to reduce system resistance. Cv of this valve, according to the stroke, is first equiexponential, for smooth regulation, then linear, for protection. Is a Failure Open valve and is equipped with a solenoid valve for quick opening. Antisurge valve fully open (ZSL XXX) is a permissive to start. Instrumentation: The flow transmitter can be a rotameter, an annubar or, more commonly, a differential pressure transmitter across a calibrated orifice. In the last case we need also to measure the gas temperature to calculate the right density of the gas. 30 Antisurge Centrifugal Compressor- Introduction Antisurge valve: Is a regulating valve, to avoid excessive recycles of flow that will reduce the output of the machine. Recycles flow from discharge to suction in order to reduce system resistance. Cv of this valve, according to the stroke, is first equiexponential, for smooth regulation, then linear, for protection. Is a Fail to Open valve and is equipped with a solenoid valve for quick opening. Antisurge valve fully open (ZSL XXX) is a permissive to start. 31 Antisurge Centrifugal Compressor- Introduction The goal of this system is to maintain the operating point within a safe operating area. But we have to avoid to reach the SLL, surge limit line. For this reason, inside the controller, is stored another curve called SCL, surge control line, directly related to SLL. The relationship between SLL and SCL is the safety margin that we want to maintain, usually the points on SCL have 10% flow more than the points on the SLL at the same rotational speed. If the operating point remains on the right of the SCL, the antisurge valve will remain closed, otherwise it will start to open. During the Start-up the antisurge valve remains fully open until the compressor reaches the MOS, once reached that speed the valve turns in control, according to where the operating point is. As soon as the Shutdown sequence begins, antisurge valve becomes immediately fully open to prevent surge. 32 Antisurge Centrifugal Compressor- Introduction SL SPL SCL AS control curves The actual Surge Line is the place in which the machine surge, it can change its position because can change the thermodynamic parameters of the gas. All the other curves are calculated using a specific thermodynamic condition so they can not change. 33 Antisurge Centrifugal Compressor- Introduction AS control curves It is possible to have that after some change in the thermodynamic parameters, the surge line has moved while the surge protection line did not move (because set points must be inserted manually): SL SPL SCL 34 19/11/2013 Control system wiring and communication ways TURBINE GEAR BOX COMPRESSOR AUXILIARY MCC Mark VI F&G BN COMPRESSOR PLC HMI SIS UDH network MP EXT. POWER command feedback PDH 35 19/11/2013 Main parts Mark VI Hardware Panel introduction 1. VME rack r. Rack R s. Rack S t. Rack T 2. Protection Module 3. Terminal Boards 4. PDM 5. DACA1 (AC/DC) 6. Input filters 1 2 3 4 5 6 1r 1s 1t 2 Simplex 36 19/11/2013 Simplex-TMR connections I/O board I/O board I/O board FIELD I/O board I/O board I/O board Mark VI Hardware Panel introduction 37 19/11/2013 I/O board I/O board I/O board FIELD I/O board I/O board I/O board IONet (ethernet) Simplex-TMR connections Mark VI Hardware Panel introduction 38 19/11/2013 HMI Introduction The toolbox is a software for configuration of various control equipment. Therefore, each product package can consist of the toolbox, product files for the controller or drive, Trend Recorder, Data Historian, and product files for the System Database (SDB). To order the toolbox software and specific product support files. toolbox cimplicity The Cimplicity is a software for the definition and visualization of the HMI screens for real time control of power-plant, processes and equipment. In addiction, throught the Cimplicity software the operator can issue commands to the selected turbine or driven devices. 39 19/11/2013 feedbacks commands cimplicity Mark VI EGD TCI a l a r m toolbox HMI Introduction 40 19/11/2013 Graphic pages - load 41 19/11/2013 Graphic pages - load 42 19/11/2013 MKVI TT Antisurge signals FV-722 P T - 7 2 3 PT-723: Surge pressure transmitter P T - 7 2 1 PT-721: Discharge pressure transmitter F T - 7 2 1 FT-721: Surge diff-pressure transmitter TEMPERATURE TRANSMITTER T T - 7 1 5 TT-715: Surge temperature transmitter 43 19/11/2013 Antisurge signals Mark VI P o s i t i o n
H
: P o s i t i o n
L
C o m m a n d :
a 2 0 a s ON/OFF signal 44 19/11/2013 AS Sequence in MKVI Antisurge master enabling signal L4AS Antisurge master enabling signal L3: READY TO LOAD L94X: NO SHOUT DOWN L33CDMN: MIN. COMPRESSOR OPERATIVE SPEED L4: MASTER OPERATIVE SIGNAL L14LS: MINIMUM OPERATIVE SPEED 45 19/11/2013 AS Sequence in MKVI Start/Purge sequence L4AS = 0 A20as = 0% (AS valve completely opened) A20as = 100% (AS valve completely closed) to purge the compressor L1X = 1 (auxiliaries ON) And: No Water Wash No AS manual control No Compressor pressuruzed stopped Compressor purge a20as = 0% (AS valve completely opened) to purge the AS line AS purge acceleration Protection mode (a20as = 0% (closed) From L14LR = 1 (shaft revolution) to L3=1 (ready to load) Load L4AS = 1 (AS enabledl) a20as = 0-100% (AS valve in control) 46 19/11/2013 AS Sequence in MKVI Antisurge control Loop A PI controller regulates antisurge valve position in order to maintain the operative point on the control line (SCL). A20AS_MAR A20AS_PARM a20as 47 19/11/2013 AS Sequence in MKVI Antisurge control Loop A20AS_MAR A20AS_PARM a20as DEAD BAND: to PI error is added to avoid that measurement noise acts directly on PI output when operative point is near control line. The dead band is defined by 2 constant K20AS_DB_L and K20AS_DB_H. 48 19/11/2013 AS Sequence in MKVI Antisurge control Loop A20AS_MAR A20AS_PARM a20as RATE LIMITER: PI controller output rate is limited by the rate limiter function. Two ramps are defined: Opening rate is limited K20AS_ARATO (30%/s) Closing rate is limited by K20AS_ARATC (1.5%/s) 49 19/11/2013 AS Sequence in MKVI Antisurge specific funtions SLOW OPENING (L20AS_SO): It is activated in case of engine shoutdown. The valve, starting from tha actual position, is opened at a slow rate (K20AS_ARASO = 0.5%/s). All other comtrols remain active and, if required, the valve can be opened faster. When the function is deactivated, the valve is closed using the automatic closing rate (K20AS_ARRATC = 1.5%/s) until the normal activation controller action takes back the control. 50 19/11/2013 AS Sequence in MKVI Antisurge specific funtions TRANSIENT ABSORPTION (L20AS_TA): It is activated in case of rapid approaching to surge line. Detection: threshold K20AS_TA (S 1u -2 s -1 ) is reached and override by derivative parameter A20AS_PARAM. Action: the setpoint A20AS_MAR is increased by multiplying factor K20AS_TA_G (1.15). The original setpoint is than restored when the derivative parameter returns below the slow rate threshold K20AS_TA_R (S 1u -3 s -1 ). 51 19/11/2013 AS Sequence in MKVI Antisurge specific funtions SAFETY CORRECTION (L20AS_COR): It is activated if operating point approches surge line more than correction line (COR). Detection: AS parameter < K20AS_COR Action: set point is increased at fixed time (2.2s). Integral time is divided for 4 to uncrease integral action and, as consequence, speeding the valve opening. 52 19/11/2013 AS Sequence in MKVI Antisurge specific funtions SAFETY PROTECTION (L20AS_SPR): It is activated if operating point approches surge line more than protection line (SPR). Detection: AS parameter < K20AS_SPR Action: recycling valve fast opening ramp is initiated. Than safety protaction terminate when operating point parameter is above safety protection SPR line with hysteresis K20AS_SPRH. If the situation is not OK in 10s an alarm indicates a problem in the AS valve opening. Safety protection is also active during START/STOP sequence. 53 19/11/2013 AS Sequence in MKVI Antisurge specific funtions PROTECTIONS DISABLING When unit is operative (L4AS = 1), safety protection and correction can be disabled (normally to allow surge zone exploration) by the override command L43AS_O_CMD. In this case alarm L43AS_O_ALM is generated. DANGER !!! 54 19/11/2013 AS Sequence in MKVI Antisurge specific funtions MANUAL OPERATION (L43AS_CMD) Manual operation can be selected if at least one of the following condition is verified: Safety protection od safety correction not active Antisurge master enabing signal disabled (L4AS = 0) Protections disabled (L43AS_O_CMD) If MANUAL OPERATION is selected, recycling valve positio n is managed by five pushbuttons (with a ramp of 1%/s): 1. L5AS_C_CPB: AS valve close PB (fine tuning) 2. L5AS_O_CPB: AS valve ope PB (fine tuning) 3. L5AS_FC_CPB: AS valve close PB (latched till valve completely closed or L5AS_S_CPB is received) 4. L5AS_FO_CPB: AS valve open PB (latched till valve completely closed or L5AS_S_CPB is received) 5. L5AS_S_CPB: stop AS valve stroking 55 19/11/2013 Graphic pages - load 56 19/11/2013 Graphic pages - load 57 19/11/2013 Graphic pages - load 58 19/11/2013 Load sharing theory Regulation of the operating point of a compressor The operating point of a compressor can be changed (regulated) by means mainly two ways: Speed variation 65% 80% 90% 98% 100% 105% NPT = Pout and Qin NPT = Pout and Qin The operating point can be changed changing the shaft speed. 59 19/11/2013 Load sharing theory Regulation of the operating point of a compressor The operating point of a compressor can be changed (regulated) by means mainly two ways: Cooled bypass AS Closing = Pout and Qin AS Opening = Pout and Qin The operating point can be changed throught the managing of the antisurge valve. 65% 80% 90% 98% 100% 105% 60 19/11/2013 Load sharing theory Regulation of the operating points of 2 compressors in PARALLEL DRIVER 1 C1 DRIVER 2 C2 C o l l e c t o r Pout Qin1 Qin2 The goal is to share the load in equal parts on the two compressor trains, 50% on C1 and 50% on C2. Pout1 Pout2 Pout = Pout1 = Pout2 61 19/11/2013 Load sharing theory Regulation of the operating points of 2 compressors in PARALLEL 65% 80% 90% 98% 100% 105% 65% 80% 90% 98% 100% 105% Train 1 Train 2 If Driver1 increases its rpm, Pout1 increases. Pout = Pout1 =Pout2, so also Pout2 increases changing the resistance curve of the second compressor. For that reason the working point 2 goes closer the surge limit. When a train in a parallel configuration changes its speed, also the speed of the other train must be changed in the same way. 62 19/11/2013 Load sharing theory Regulation of the operating points of 2 compressors in SERIES DRIVER 1 C1 DRIVER 2 C2 C o l l e c t o r Pout Qin1 Qin2 Pout1 Pout2 The goal, in this configuration, is the managing of the requested Pout. An increasing of te Pout is implemented increasing the revolution speed. Pout = Pout1 + Pout2 63 19/11/2013 Load sharing theory Regulation of the operating points of 2 compressors in SERIES DRIVER 1 C1 DRIVER 2 C2 C o l l e c t o r Pout Qin1 Qin2 Pout1 Pout2 If the Pout needs to be increased, Driver2 can increase the speed. But, if only Driver2 increases the speed, this variation determines the lowering of the resistance curve of the Compressor1 that generates a decresing of Pou1; and finally the consequent new decreasing of Pout. When a train of a series changes its speed, also the speed of the other train must be changed in the same way. Pout = Pout1 + Pout2 64 19/11/2013 Load sharing theory Regulation of the operating points of 2 compressors. DRIVER C Qin Pout AS valve Fine regulation through the antisarge valve: Because the 2 compressors cannot be perfectly equal (for costruction tolerances, dirty...) even if they are revolving a the same speed, they will work a little bit differently one by the other. In consideration of that: speed regulation is not enoght . A fine regulation of the load sharing, both for series and parallel configurations, needs to be implemented by means of Cooled bypass method. 65 Antisurge Centrifugal Compressor- Introduction GE Oil & Gas Cen|r|/uga| Compressor An||surge TRAINING MANUAL
SEZ .2 Drawings
Customized for: SONATRACH (ALGERIA)
GE Oil & Gas BCL505/N assembly drawing SOS9929211 Performancecurves SOS9983763 Piping and instrument diagram SOM5081477 Instrument list SOM6609947 Control system functional description SOM6670429 Antisurge Valve SOS7248866 Antisurge valve data sheet RV 28465 Antisurge write-up SOS9983403 Performance curves SOS9983763 Drawings Index - BASIC TRAINING MANUAL Drawings Index