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116805771-Gas-Turbine.ppt
- 2. © 2005 Compressor Controls Corporation Agenda • Understanding the financial impact of turbomachinery control systems • Turbo-compressor control • Gas turbine control • Specification writing • CCC products and services Salah Salem: Salah Salem: Salah Salem:
- 4. © 2005 Compressor Controls Corporation Lifecycle costs 30-year life cycle costs for a 20,000 hp compressor Costs in constant dollars Source: “Experiences in Analysis and Monitoring Compressor Performance” Ben Duggan & Steve Locke E.I. du Pont, Old Hickory, Tennessee 24th Turbomachinery Symposium Maintenance Cost $4.5 Million Initial Cost $1.5 Million Energy Cost $180 Million 97% of total costs
- 5. © 2005 Compressor Controls Corporation Lifecycle costs Source: “Experiences in Analysis and Monitoring Compressor Performance” Ben Duggan & Steve Locke E.I. du Pont, Old Hickory, Tennessee 24th Turbomachinery Symposium 30-year costs per a 1,000 hp What can we control? 0.0 5.0 10.0 15.0 Initial Cost Maintenance Energy Lost Production $ Millions ? Controllable Uncontrollable Costs in constant dollars
- 6. © 2005 Compressor Controls Corporation Key Issues on Turbomachinery Controls • Energy consumed by turbomachinery is a major cost of operation in process plants and oil production operations • Poor control is a major risk to the safe and reliable operation of turbomachinery • The economic consequences of non- availability of turbomachinery is large • Poor control can lead to false limitations on production • Capable support services are critical to the successful application of turbomachinery controls
- 7. © 2005 Compressor Controls Corporation Profit Enhancement Opportunities for CCC Customers • Maximize reliability of machinery and process: – Prevent unnecessary process trips and downtime – Minimize process disturbances – Prevent surge, overspeed and associated damage – Automate startup and shutdown • Increase efficiency of machinery and process: – Operate at lowest possible energy levels – Minimize antisurge recycle or blow-off – Optimize loadsharing of multiple units – Operate close to limits, safely
- 8. © 2005 Compressor Controls Corporation Control Retrofits are Economically Attractive • Typical turbomachines last 30 years or more • Control systems are technically obsolete in 10 years • Old control systems may not be maintainable due to unavailability of Electronic component • Newer control systems offer – Better performance – Better machinery protection – Better system availability • Improved electronic components • Redundancy • ROI (Return On Investment) can be attractive due to production increases and energy savings
- 10. © 2005 Compressor Controls Corporation Challenges and opportunities in gas turbine control • Integration with controls of driven object (compressor, generator or pump) The Control system of both the Gas Turbine as well as the compressor on the same seamless platform Better control system in order to maintain or maximize machine and associated process reliability.
- 12. © 2005 Compressor Controls Corporation Classifications • Application – Fixed speed - electrical power generation – Variable speed- mechanical drives, pumps, compressors • Design – Industrial, heavy duty, robust long life – Aircraft derivative, lightweight, derated for stationary applications • Rotor – Single shaft (usually generator applications) – Dual shaft – Three shaft (aeroderivative types) • Cycle – Simple cycle – Regenerative – Cogeneration, waste heat
- 13. © 2005 Compressor Controls Corporation Heavy duty , One shaft Gas Turbine (FS7001) • One shaft gas turbine – Limited speed range – Heavy starting device • Diesel • Steam turbine • E-motor – High power class up to 110MW FS5001 W251 V63
- 14. © 2005 Compressor Controls Corporation Heavy duty , One shaft Gas Turbine FS5001 W251 V63 NHP NPT = CDP EGT (T4) B.V Starter Motor IGV EGT (T3) T1
- 15. © 2005 Compressor Controls Corporation SURGE EFFECT ON G.T. AIR COMPRESSOR
- 17. © 2005 Compressor Controls Corporation Exhaust Gas Temperature (EGT) T/C Combustion Chambers Flame Tubes Thermo Couple Harness
- 18. © 2005 Compressor Controls Corporation Two shaft aeroderivatives • Two shaft gas turbines – Variable speed range – Low power starting device • Gas expander • E-motor • Hydraulic motor LM2500 AVON Saturn
- 19. © 2005 Compressor Controls Corporation Two shaft aeroderivatives EGT (T4) EGT (T6) CDP NPT B.V Starter Motor T1 NGG Fuel Gas F.G. Manifold EGT (T3) IGV
- 20. © 2005 Compressor Controls Corporation Three shaft aeroderivative • Three shaft gas turbine – Variable speed – Complex machines – VBV’s, VSV’s, IGV’s RB211 LM1600 LM5000 GG4
- 21. © 2005 Compressor Controls Corporation Three shaft aeroderivative NPT T1 EGT (T6) NLP NHP LP HP LP HP EGT (T4) T21 EGT (T3) CDP Starter Motor IGV B.V
- 22. © 2005 Compressor Controls Corporation Firing temperature Firing Temp Location Firing temp. Cost $ Fuel cost /kWh Maintenance cost /kWh
- 23. © 2005 Compressor Controls Corporation Inlet Guide Vanes and Variable Stator Vanes Restricts the volume flow through the GT Compressor
- 24. © 2005 Compressor Controls Corporation IGV, VSV, VBV assembly
- 27. © 2005 Compressor Controls Corporation LP Speed HP Speed T1 IGV, VBV and VSV control LP speed = Low Pressure Turbine speed LP Speed HP speed = High Pressure Turbine speed HP Speed T1 = Compressor Inlet Temperature for correction T1
- 29. © 2005 Compressor Controls Corporation Two shaft industrial GT with 2nd stage nozzles
- 30. © 2005 Compressor Controls Corporation 2nd stage nozzle control • Why Nozzles – Second stage Nozzles allow the HP turbine to run at its optimal speed for better fuel efficiency. They remain at EGT limit • Control implication – There is a strong interaction between NHP, FCV and Nozzle control. This requires decoupling of controllers • Start-up – Nozzles are open during start-up – Close at NHP idle speed • Which GT’s has them – General Electric FS3002 and FS5002 – Nuovo Pignone PGT5 and PGT10
- 31. © 2005 Compressor Controls Corporation Two shaft industrial gas turbine
- 34. © 2005 Compressor Controls Corporation Regenerative gas turbine cycle •Efficiency improvement approx. 30% •Better fuel efficiency •approx. 25% •Higher initial cost •Higher maintenance cost
- 35. © 2005 Compressor Controls Corporation Cogeneration Turbine Gas turbine Compressor Steam Turbine Generator •Cogeneration Gas turbine Steam turbine Boiler Generator •Efficiency Between 40% and 58%
- 37. © 2005 Compressor Controls Corporation PT speed T ambient 90º Gas turbine Performance maps Power Slides at const Tamb PT speed T ambient Power PT speed T ambient This map is hard to visualize because of the 3D aspect. 90º
- 38. © 2005 Compressor Controls Corporation Restrains and control limiting in the GT performance map PT speed Power Power T ambient Physical Machine limits Physical Machine limits NPTunderspeed NPToverspeed CDP NGG EGT Control Margins Stable zone of operation Safe zone of operation Safe zone of operation
- 39. © 2005 Compressor Controls Corporation 0 10 20 30 40 50 60 70 80 90 100 48:00.0 48:41.0 49:16.0 49:59.0 50:44.0 51:27.0 52:09.0 52:53.0 53:38.0 54:23.0 55:27.0 55:53.0 56:38.0 57:23.0 58:08.0 58:53.0 59:38.0 00:23.0 01:08.0 01:53.0 02:38.0 03:22.0 04:07.0 04:52.0 05:37.0 06:22.0 07:06.0 07:49.0 08:32.0 09:17.0 10:02.0 10:47.0 11:31.0 12:16.0 13:01.0 13:46.0 14:31.0 15:16.0 16:01.0 Time (Min) % of full scale Npt EGT Ngg FCV CDP Start-up of RR Avon (real data) GG Idle GG Purge Start Ignition GG control PT control PT Warm up Ngg EGT NPT CDP FCV NPT Rated Min Gov. Max Gov.
- 41. © 2005 Compressor Controls Corporation Fuel valve FUEL CONTROL VALVE • Essential part in the control chain • Specifications – High repeatability – High Accuracy – Robust – Short stroking time – Good fuel flow controllability during ignition and normal operation
- 43. © 2005 Compressor Controls Corporation Standard Fuel System Examples P2 Speed Ratio vlv Fuel Control vlv GE Standard Fuel Control vlv Ignition vlv FCV with separate Ignition Valve Fuel Control vlv Ignition vlv FCV with separate Ignition System P CCC 8402 Fuel Control vlv CCC solution 8402 FCV
- 44. © 2005 Compressor Controls Corporation 44 CCC 8420 Fuel Valve The 8402 Fuel Control Valve • A high quality, high performance fuel control valve • The 8402 is equipped with an electric stepper motor actuator which can fully stroke the valve in only 250 milliseconds. • The valve has a 500:1 turn down ratio to provide precise fuel delivery to the turbine from light off to maximum power. • The digital encoder for position measurement provides position repeatability of 0.05 %.
- 45. © 2005 Compressor Controls Corporation 45 CCC Fuel Valve Stepper Motor Digital Encoder
- 48. © 2005 Compressor Controls Corporation Conventional Control System UIC SIC PIC Gas generator Power Turbine Process Compressor
- 49. © 2005 Compressor Controls Corporation Conventional Control Consept Completely independent controllers Controllers: - Stand-alone PID Compressor performance control - Stand-alone PID Compressor anti-surge system - Stand-alone PID gas turbine fuel controller Communication - None Decoupling - None Type of control - PID control
- 50. © 2005 Compressor Controls Corporation Advanced Control System UIC SIC PIC Gas generator Power Turbine Process Compressor
- 51. © 2005 Compressor Controls Corporation Advanced Control Concept Completely integrated concept Controllers: - Integrated Compressor performance control - Integrated Compressor anti-surge protection - Integrated gas turbine fuel controller Communication - High speed communication of statuses and values Decoupling - Yes between all controllers Type of control - Advanced control with patented algorithms
- 53. © 2005 Compressor Controls Corporation Press. Ratio Press. Ratio Press. Ratio Press. Ratio Press. Ratio Pressure Set point Flow Press. Ratio Flow A Power Output Power N N max N min A C A Diagram Compressor Power Map GT. Performance Map Compressor Map Speed curve EGT Speed curve Over Temp. Trip Area Flame out Trip Area Surge Limit Line Control Line
- 54. © 2005 Compressor Controls Corporation Press. Ratio Press. Ratio Press. Ratio Press. Ratio Pressure Set point Flow Press. Ratio Flow A Power Output Power N N max N min A C A Diagram Point A = stable operating point THEN : Big Process Upset by a flow reduction Pressure Set point EGT Speed curve Over Temp. Trip Area Flame out Trip Area
- 55. © 2005 Compressor Controls Corporation Press. Ratio Press. Ratio Press. Ratio Pressure Set point Flow Press. Ratio Flow A B Power Output Power N N max N min A B C A B Pressure increases , Flow reduction (this depends on the system volume) At Point B , the Anti-Surge Recycle Control Valve starts to OPEN Pressure Set point EGT Speed curve Over Temp. Trip Area Flame out Trip Area
- 56. © 2005 Compressor Controls Corporation Press. Ratio Press. Ratio Pressure Set point Flow Press. Ratio Flow A B C Power Output Power N N max N min A B C C A B Approach to SURGE C Pressure Set point EGT Speed curve Over Temp. Trip Area Flame out Trip Area At Point C , the Operating point is on the SLL
- 57. © 2005 Compressor Controls Corporation Press. Ratio Pressure Set point Flow Press. Ratio Flow A B C D Power Output Power N N max N min A B C D D A B SURGE C At point D , The compressor is surging High risk of loss of flame C Flame out Trip Area EGT Speed curve Over Temp. Trip Area
- 58. © 2005 Compressor Controls Corporation Pressure Set point Flow Press. Ratio Flow A B C D E E Power Output Power N N max N min A B C D E D A B Flow recovery C At point E High risk of an over temperature trip , or PT under speed trip C Over Temp. Trip Area NPT under-speed Area Pressure Set point EGT Speed curve Over Temp. Trip Area Flame out Trip Area
- 59. © 2005 Compressor Controls Corporation Pressure Set point Flow Press. Ratio Flow A B C D E E Power Output Power N N max N min A B C D E D A B Pressure recovery C C Pressure Set point EGT Speed curve Over Temp. Trip Area Flame out Trip Area
- 60. © 2005 Compressor Controls Corporation Pressure Set point F Flow Press. Ratio Flow A B C D E E Power Output Power N N max N min A B C D E F D F A B C Finally after a tour through the performance map, the process is at set point AT SET POINT C Pressure Set point EGT Speed curve Over Temp. Trip Area Flame out Trip Area
- 61. © 2005 Compressor Controls Corporation What Can Be Improved Avoidance of flame out - Fuel valve movement limiting during surge detection . Limit the fuel valve rate of change limit for a specified time. Avoidance of Over temperature trip - Derivative Exhaust temperature set point reduction. As function of the rate of change of the EGT and CDP Avoidance of Surge - Integrated control solution by using: •Feed forward and De-coupling between all controllers •Patented control algorithms –Derivative Close and open loop control –Pressure override control
- 62. © 2005 Compressor Controls Corporation Simulation set-up • Tests: – Conventional PID control only – Conventional PID control and restricted FCV movement – Conventional PID control with Recycle Trip (open loop response) and restricted FCV movement – Fully integrated control • Settings: – Control settings were identical for all four tests • Starting point: – Compressor with discharge valve fully open – Maximum discharge pressure – Recycle valve closed • Test: – Step to close position of the process compressor discharge valve
- 63. © 2005 Compressor Controls Corporation Displayed test results Discharge pressure vs. flow – Conventional PID control – Conventional PID control with restricted FCV movement – Conventional PID control integrated with R.T response and restricted FCV movement – Total integrated solution
- 64. © 2005 Compressor Controls Corporation Compressor Map Pd vs. Flow Conventional Stand alone PID control
- 65. © 2005 Compressor Controls Corporation Compressor Map Pd vs. Flow Conventional Stand alone PID control with Restricted FCV movement
- 66. © 2005 Compressor Controls Corporation Compressor Map Pd vs. Flow Conventional Stand alone PID control with Restricted FCV movement and Recycle Trip™
- 67. © 2005 Compressor Controls Corporation Compressor Map Pd vs. Flow Fully integrated CCC Total Train Control™ System
- 69. © 2005 Compressor Controls Corporation Displayed test results Comparison Charts of the four tests:- - Compressor Discharge Pressure vs. Time scale - Fuel Control Valve position (Power) vs. Time scale - Exhaust Gas Temperature (EGT) vs. Time scale - Power Turbine Speed vs. Time scale
- 71. © 2005 Compressor Controls Corporation Fuel Control Valve position (Power) vs. Time
- 74. © 2005 Compressor Controls Corporation Conclusions • Gas turbine Fuel stroke limiting during a surge event: – Avoids a Gas turbine “loss of flame” trip – Reduces the magnitude of thermal and mechanical stresses – Doesn’t affect the process response • Exhaust temperature set point reduction – Prevents the gas turbine from an over temperature trip – Eliminates the need for unnecessary big control margins on the Exhaust Gas Temperature limit • Integrated solution – Avoids surge – Reduces the number of surge events, if they happen – Reduces the magnitude of process upsets – Reduces the magnitude of thermal and mechanical stresses
- 76. © 2005 Compressor Controls Corporation Flexibility of CCC’s Fuel Controller NPT PID EGT PID CDP Limit CDP PID Ngg PID Ngg Limit Accel. Limit Decel. Limit Auto. Sequence Ramp Control EGT Limit M I N . S E L E C T O R NPT S.P. M A X . S E L E C T O R FCV PID T1
- 77. © 2005 Compressor Controls Corporation EGT control algorithm EGT Limit EGT Calc. Max Median Average d dt Kp * Td - + EGT Time PID + - L . S . S EGT Spread
- 78. © 2005 Compressor Controls Corporation OPEN LOOP RESPONSE Fuel Demand EGT Time Time Trip Limit Open Loop S.P. Closed Loop S.P. Dead time Close FCV
- 79. © 2005 Compressor Controls Corporation EGT During Hot Start before and after Improved Control System 0 10 20 30 40 50 60 70 80 90 1200 1100 1000 900 800 700 600 500 400 300 200 100 0 sec Deg F Original Control System Improved Control System
- 80. © 2005 Compressor Controls Corporation Maximum continuous running temperature More power from your gas turbine! EGT Limit CCC CCC SP Digital Digital SP Analog Analog SP CCC’s Unique EGT Control
- 81. © 2005 Compressor Controls Corporation GG Speed (N1) Control Algorithm Ngg Limiting S.P. d dt Kp * Td - + PID + - L . S . S Ngg Ngg Control S.P. (Idle Speed) Fuel Flow Ngg Decel Limit Accel Limit Steady State H . S . S Accel. Limit Decel Limit
- 82. © 2005 Compressor Controls Corporation NPT (N2) control algorithm d dt Kp * Td - + PID + - L . S . S NPT NPT HI Limiting S.P. NPT LOW Limiting S.P. NPT W.U. Speed S.P. NPT Speed Load Control S.P.
- 83. © 2005 Compressor Controls Corporation CDP control algorithm L.S.S. d dt Kp * Td PID + - CDP CDP Limiting S.P. G.T. Compressor Surge Detected Alarm / Shutdown Fuel Flow CDP Decel Limit Accel Limit Steady State H . S . S Accel. Limit Decel Limit
- 85. © 2005 Compressor Controls Corporation Open Industry Standards in Series 5 Open hardware standards • cPCI bus standard • Power PC CPU • Open IO conditioning interface Open software standards • OSE hardware real time OS from OSE systems • ProCon OS from KW software • Full-scale IEC-61131 programming environment • Win2000 compatible operator interface Open network communication standards • 10 base-t Ethernet (TCP/IP) • Profibus DP • OPC • 16-bit Modbus RTU • Active-X Remote Access
- 86. © 2005 Compressor Controls Corporation Series 5 Product Families VANGARD Control System • Flexible Hardware Configuration • Available in Simplex and Duplex F.T. versions • Hot-swappable modules • Remote I/O capability • I/O scan and processes is within 2.5 msec. • Powerful CPU , combine high-speed control with sequencing • Advanced self-diagnostic features • Fast and reliable communication links, including both Ethernet and serial communication
- 87. © 2005 Compressor Controls Corporation Series 5 Product Families RELIANT Control System • Rack/Panel Mount Packaging • Integrated Terminations • Serial Communications • 3 Fixed Hardware Configurations • Simplex, non-conditioned I/O • Simplex, conditioned I/O • Duplex, non-conditioned I/O • Cost Effective Solution for Smaller System • Simplex or Duplex • Continuous and small logic control
- 88. © 2005 Compressor Controls Corporation Power Supplies LOCAL I/O CARD IOC-555 MPU-750 REMOTE I/O CARD RCC-PBM Series-5 Vanguard Chassis
- 89. © 2005 Compressor Controls Corporation Series-5 4-SLOT Vanguard Chassis MPU-750 REMOTE I/O CARD RCC-PBM LOCAL I/O CARD IOC-555
- 90. © 2005 Compressor Controls Corporation • PowerPC Processor • 233 MHz 32 bit uP • 3 Ethernet Channels • 4 Serial Ports – 2 Intercontroller – 2 Application Dependent • Flash Program Storage • OSE Hardware RTOS • KW ProCon 61131 OS Series-5 System Processor Board
- 91. © 2005 Compressor Controls Corporation • 22 AI • 6 AO • 16 DI • 14 DO • 6 HI SPEED FI • Feedback on all Outputs • Fault Relay NO/NC • 2.5 mS Sample Rate • Precision Reference for Testing A/D Converter Series-5 Local I/O Module
- 92. © 2005 Compressor Controls Corporation • Dual Power Inputs with Fuse Detection. • CCC and Standard Conditioning Modules. • CCC Modules Feature: – Isolated Inputs/Outputs – Open Wire detection – Protection from wiring errors up to 240 VAC Series-5 Simplex Local FTA’s
- 93. © 2005 Compressor Controls Corporation • Same Field I/O connections as Simplex FTA • Same location and type of Conditioning Modules • Two FTA Cables - one for each I/O card Series-5 Duplex Local FTA’s
- 94. © 2005 Compressor Controls Corporation System Integration Train Tool W/S Series 5 OPC-Ethernet Ethernet TCP/IP • Serial Modbus to DCS or Host Computer Modbus Modbus • Ethernet OCI to TrainTool • OPC via TrainTool W/S Field DCS PPP
- 95. © 2005 Compressor Controls Corporation System Architecture Train Tool W/S Series 5 OPC-Ethernet Ethernet TCP/IP • Serial Modbus to DCS or Host Computer Modbus Modbus • Ethernet OCI to TrainTool • OPC via TrainTool W/S Field DCS RocketPort
- 96. © 2005 Compressor Controls Corporation cPCI- bus B cPCI- bus A Ethernet OPC-Ethernet Series-5 Vanguard Architecture TO Series 5 , Series 4, or Series 3 Plus Analogue FTA 22 AI 6 AO Analogue FTA 22 AI 6 AO Digital FTA 14 DI 16 DO 6 FI 2 Fault Relay Digital FTA 14 DI 16 DO 6 FI 2 Fault Relay DCS Train Tool W/S I/O CARD-B I/O CARD-A ModBus cPCI optic to 2000m. I/O Card MPU 750 Serial Ports Ethernet Ports MPU A Serial Ports Ethernet Ports For Eng. cPCI optic to 2000m. I/O Card MPU 750 Serial Ports Ethernet Ports MPU B Serial Ports Ethernet Ports For Eng.
- 97. © 2005 Compressor Controls Corporation OPC-Ethernet Series-5 Vanguard Architecture TO Series 5 , Series 4, or Series 3 Plus Analogue FTA Analogue FTA Digital FTA Digital FTA cPCI- bus B cPCI- bus A DCS Train Tool W/S Ethernet I/O CARD-B I/O CARD-A ModBus cPCI optic to 2000m. I/O Card MPU 750 Serial Ports Ethernet Ports MPU A Serial Ports Ethernet Ports For Eng. cPCI optic to 2000m. I/O Card MPU 750 Serial Ports Ethernet Ports MPU B Serial Ports Ethernet Ports For Eng.
- 98. © 2005 Compressor Controls Corporation OPC-Ethernet Series-5 Vanguard Architecture TO Series 5 , Series 4, or Series 3 Plus Analogue FTA Analogue FTA Digital FTA Digital FTA cPCI- bus B cPCI- bus A DCS Train Tool W/S Ethernet I/O CARD-B I/O CARD-A ModBus cPCI optic to 2000m. I/O Card MPU 750 Serial Ports Ethernet Ports MPU A Serial Ports Ethernet Ports For Eng. cPCI optic to 2000m. I/O Card MPU 750 Serial Ports Ethernet Ports MPU B Serial Ports Ethernet Ports For Eng.
- 99. © 2005 Compressor Controls Corporation OPC-Ethernet Series-5 Vanguard Architecture TO Series 5 , Series 4, or Series 3 Plus Analogue FTA Analogue FTA Digital FTA Digital FTA cPCI- bus B cPCI- bus A DCS Train Tool W/S Ethernet I/O CARD-B I/O CARD-A ModBus cPCI optic to 2000m. I/O Card MPU 750 Serial Ports Ethernet Ports MPU A Serial Ports Ethernet Ports For Eng. cPCI optic to 2000m. I/O Card MPU 750 Serial Ports Ethernet Ports MPU B Serial Ports Ethernet Ports For Eng.
- 100. © 2005 Compressor Controls Corporation OPC-Ethernet Series-5 Vanguard Architecture TO Series 5 , Series 4, or Series 3 Plus Analogue FTA Analogue FTA Digital FTA Digital FTA cPCI- bus B cPCI- bus A DCS Train Tool W/S Ethernet I/O CARD-B I/O CARD-A ModBus cPCI optic to 2000m. I/O Card MPU 750 Serial Ports Ethernet Ports MPU A Serial Ports Ethernet Ports For Eng. cPCI optic to 2000m. I/O Card MPU 750 Serial Ports Ethernet Ports MPU B Serial Ports Ethernet Ports For Eng.
- 101. © 2005 Compressor Controls Corporation OPC-Ethernet Series-5 Vanguard Architecture TO Series 5 , Series 4, or Series 3 Plus Analogue FTA Analogue FTA Digital FTA Digital FTA cPCI- bus A cPCI- bus B DCS Train Tool W/S Ethernet I/O CARD-B I/O CARD-A ModBus cPCI optic to 2000m. I/O Card MPU 750 Serial Ports Ethernet Ports MPU A Serial Ports Ethernet Ports For Eng. cPCI optic to 2000m. I/O Card MPU 750 Serial Ports Ethernet Ports MPU B Serial Ports Ethernet Ports For Eng.
- 102. © 2005 Compressor Controls Corporation OPC-Ethernet Series-5 Vanguard Architecture TO Series 5 , Series 4, or Series 3 Plus Analogue FTA Analogue FTA Digital FTA Digital FTA DCS Train Tool W/S Ethernet I/O CARD-B I/O CARD-A ModBus cPCI optic to 2000m. I/O Card MPU 750 Serial Ports Ethernet Ports MPU A Serial Ports Ethernet Ports For Eng. cPCI optic to 2000m. I/O Card MPU 750 Serial Ports Ethernet Ports MPU B Serial Ports Ethernet Ports For Eng. cPCI- bus A cPCI- bus B
- 103. © 2005 Compressor Controls Corporation OPC-Ethernet Series-5 Vanguard Architecture TO Series 5 , Series 4, or Series 3 Plus Analogue FTA Analogue FTA Digital FTA Digital FTA DCS Train Tool W/S Ethernet I/O CARD-B I/O CARD-A ModBus cPCI optic to 2000m. I/O Card MPU 750 Serial Ports Ethernet Ports MPU A Serial Ports Ethernet Ports For Eng. cPCI optic to 2000m. I/O Card MPU 750 Serial Ports Ethernet Ports MPU B Serial Ports Ethernet Ports For Eng. cPCI- bus B cPCI- bus A
- 104. © 2005 Compressor Controls Corporation Series-5 Vanguard Architecture TO Series 5 , Series 4, or Series 3 Plus cPCI optic to 2000m. I/O Card MPU 750 Serial Ports Ethernet Ports MPU 750 Serial Ports Ethernet Ports cPCI REMOTE AREA DCS Train Tool W/S OPC-Ethernet Profi Bus I/O Card ProfiBus Slave ProfiBus Slave Up to 16 slaves 48-wire Open-Line Internal Bus 16 Ch. RFTA 16 Ch. RFTA Up to 32 ch / slave For Eng.
- 105. © 2005 Compressor Controls Corporation Power Supplies LOCAL I/O CARD IOC-555 MPU-750 REMOTE I/O CARD RCC-PBM Series-5 Vanguard Chassis
- 106. © 2005 Compressor Controls Corporation Series-5 4-SLOT Vanguard Chassis MPU-750 REMOTE I/O CARD RCC-PBM LOCAL I/O CARD IOC-555
- 107. © 2005 Compressor Controls Corporation • PowerPC Processor • 233 MHz 32 bit uP • 3 Ethernet Channels • 4 Serial Ports – 2 Intercontroller – 2 Application Dependent • Flash Program Storage • OSE Hardware RTOS • KW ProCon 61131 OS Series-5 System Processor Board
- 108. © 2005 Compressor Controls Corporation • 22 AI • 6 AO • 16 DI • 14 DO • 6 HI SPEED FI • Feedback on all Outputs • Fault Relay NO/NC • 2.5 mS Sample Rate • Precision Reference for Testing A/D Converter Series-5 Local I/O Module
- 109. © 2005 Compressor Controls Corporation • Dual Power Inputs with Fuse Detection. • CCC and Standard Conditioning Modules. • CCC Modules Feature: – Isolated Inputs/Outputs – Open Wire detection – Protection from wiring errors up to 240 VAC Series-5 Simplex Local FTA’s
- 110. © 2005 Compressor Controls Corporation • Same Field I/O connections as Simplex FTA • Same location and type of Conditioning Modules • Two FTA Cables - one for each I/O card Series-5 Duplex Local FTA’s
- 111. © 2005 Compressor Controls Corporation • Analog Inputs – 0.1 % accuracy – Failure Detection High and Low – 15 bit resolution – Two reference channels for converter verification – Voltage,Current, millivolt,RTD, Thermocouple • Analog Outputs – 0.1 % accuracy – Failure Detection - including open wire – 12 bit resolution – 4 - 20 mA output Series-5 Local AI & AO Conditioning Module
- 112. © 2005 Compressor Controls Corporation • Digital Inputs – 110/220 V AC or DC – 24 V AC or DC – Isolated Modules – Status LED • Digital Outputs – Mechanical Relay • 250 VAC 5 Amps • 250 VA up to 200 Watts – Solid State Relay • 260 VDC 1 Amp – Status LED – Fused Output Series-5 Local AI & AO Conditioning Module
- 113. © 2005 Compressor Controls Corporation • Speed Inputs – 0.01% Accuracy – Active or Passive – 5 Hz to 40K Hz Series-5 Local FI Conditioning Module
- 114. © 2005 Compressor Controls Corporation • Unique Fault-Tolerant Components – Fault-Tolerant FTA’s – Fault-Tolerant Chassis – Fault-Tolerant Software • Components Common with Simplex System – CPU Card and I/O Cards – Power Supplies – FTA Cables – Conditioning Modules Series-5 Fault-Tolerant Components
- 115. © 2005 Compressor Controls Corporation • Distributed IO sub-system based on industrial protocol profibus DP (up to 12 Mb/s) • Primarily for low-speed control loops • Not for critical (shutdown) loops • Up to 16 slaves per master • Up to 32 channels per slave • Operating ambient temperature: – -40 to 85 deg.C – (-40 to 65 deg.C for EM relays) Series-5 Remote I/O Sub-System
- 116. © 2005 Compressor Controls Corporation Series-5 Remote I/O Sub-System Node ProfiBus Slave RFTA & Conditioning Modules
- 117. © 2005 Compressor Controls Corporation • Analog Inputs – Dual-channel Modules – Current, Voltage (V, mV), RTD (Platinum, Copper), TC K/J – Accuracy - 0.15 % – Open-Wire Detection – Transmitter Failure Detection – High-Voltage Isolation between Modules and between Field and System – Field-side Over-voltage Protection up to 240 Vac across the Input Series-5 REMOTE AI Conditioning Module
- 118. © 2005 Compressor Controls Corporation • Analog Outputs – Dual-channel Modules – Current 4-20 or 0-20 mA – Accuracy - 0.15 % – Open-Wire Detection – High-Voltage Isolation between Modules and between Field and System – Field-side Over-voltage Protection up to 240 Vac Series-5 REMOTE AO Conditioning Module
- 119. © 2005 Compressor Controls Corporation • Discrete Inputs – Dual-channel Modules – 24 Vdc or 110/220 Vac – Special Modules with embedded Open-Wire Detection – High-Voltage Isolation between Modules and between Field and System – LED Status Indication Series-5 REMOTE DI Conditioning Module
- 120. © 2005 Compressor Controls Corporation • Discrete Outputs – Dual-channel Modules – Electro-mechanical Relays up to 5A@24 Vdc or 110/220 Vac – Embedded Open-Wire Detection – Solid-state Relays up to 1A@220Vdc – High-Voltage Isolation between Modules and between Field and System – LED Status Indication – Fuse--protected Outputs Series-5 REMOTE DO Conditioning Module
- 121. © 2005 Compressor Controls Corporation • Optimized for smaller applications (single machines or small trains) with continuous control and small logic • Three versions: • Reliant SN – Simplex with non-conditioned I/O • Reliant DN – Duplex with non-conditioned I/O • Reliant SC – Simplex with conditioned I/O • Motorola Power PC 555 processor • Same IEC 61131 applications software and tools as Series 5 Vanguard • A single, common electronics assembly for simplified maintenance Series-5 RELIANT
- 122. © 2005 Compressor Controls Corporation Local Maintenance Keypad Communication and Analog I/O Terminations Local Maintenance Display Power, Frequency and Discrete I/O Terminations Status Indicators Series-5 RELIANT SN
- 123. © 2005 Compressor Controls Corporation Switching Module Connector for Remote Switch Module Status Indicators Manual Switchover Pushbuttons Same Electronics Assembly and Terminations as Reliant SN Series-5 RELIANT DN
- 124. © 2005 Compressor Controls Corporation Analog Input Conditioning Modules Communication Connectors Discrete Output Conditioning Modules Discrete Input Conditioning Modules Series-5 RELIANT SC
- 125. © 2005 Compressor Controls Corporation MPU 555 Main Processor I/O Card 22 AI 6 AO 14 DO 16 DI 6 FI 2 Fault Relay MEMORY 6 Serial Port CONTROL DISPLAY Series-5 RELIANT Architecture
- 126. © 2005 Compressor Controls Corporation Reliant Control System Analog I/O • 22 Analog Inputs – 0.1 % Accuracy – High and Low Failure Detection – Field-Configurable for Voltage or Current • 6 Analog Outputs – 0.1 % Accuracy – Failure Detection - Including Open Wire Integrity Monitor – 4 - 20 mA Output – Isolated • 6 Frequency Inputs – 0.01 % Accuracy – Active or Passive – 5 Hz to 40K Hz • 16 Discrete Inputs – 30 V AC or DC – Isolated • 14 Discrete Outputs – Solid State Relay – 24 VDC – 1 - 2 Amp
- 127. © 2005 Compressor Controls Corporation Reliant Communications 5 Integrated RS-485 Serial Ports:- Port 1: TrainLink Intercontroller Com. Port 2: TrainTools Workstation Port 3: Configurable as Series 3+ or Modbus Port 4: Configurable as Series 4 or Modbus Port 5: Configurable as TrainTools Workstation or Modbus Train Tool W/S Series 5 OPC-Ethernet Modbus Field DCS PPP Train Link
- 129. © 2005 Compressor Controls Corporation • 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 Vantage Steam Turbine Governors
- 131. © 2005 Compressor Controls Corporation • API-670 Compliant • 2oo3 Voting of Speed Modules • Redundant Power Supplies • Hot-Swap Speed Modules • Modbus Comms Guardian Over-speed Trip System
- 132. © 2005 Compressor Controls Corporation Series 5 Temperature Specifications • Vanguard – Operational Limits • Level C1 (-0 to +55 °C) – Storage Limits • Level C2 ( -40 to + 85 °C) • Reliant – Operational Limits • 0 to +70 °C – Storage Limits • -40 to + 85 °C
- 133. © 2005 Compressor Controls Corporation • Vanguard: – Not rated for hazardous areas. – Temp. Operating Limit is up to 55 deg, C • Reliant: – USA: Class 1, Division 2, Groups A-D, T3 (200 C) – Canadian: Class 1, Zone 2, Group IIC, T3 (200 C) – European (ATEX): Group II, Cat. 3, G, EEx, nACL, IIC, and T3 – Temp. Operating Limit is up to 70 deg, C • Vantage: – USA: Class 1, Division 2, Groups A-D, T3 (200 C) – Canadian: Class 1, Zone 2, Group IIC, T3 (200 C) – European (ATEX): Group II, Cat. 3, G, EEx, nACL, IIC, and T3 • Guardian: – USA: Class 1, Division 2, Groups A-D, T4A (200 C) – Canadian: Class 1, Zone 2, Group IIC, T4A (200 C) – European (ATEX): Group II, Cat. 3, G, EEx, nACL, IIC, and T4 Hazardous Area Classifications
- 134. © 2005 Compressor Controls Corporation Offshore Platform Application 2 Parallel Trains RR Avon Gas Turbine Driven Compressors
- 137. © 2005 Compressor Controls Corporation Production Increase • Customer had lowered EGT limit set point to eliminate tripping on EGT trip limit due to poor gas turbine control system • Increase set point from 650 C to 660 C which is original OEM set point • Results – 3.8% increase in Exhaust Gas Horsepower (EGHP) – Translating this to the compressor map results in a 6000 Nm3/hr increase in flow at constant compression ratio – 300 days/yr * 24 hrs/day * 6000 Nm3/hr = 43,200,000 Nm3/yr increased production Equals $4,860,000/yr in increased production per machine!
- 138. © 2005 Compressor Controls Corporation Offshore Platform Application Gulf of Mexico 4 Parallel Trains 250 MMSCFD Demag Delaval 3 section double-barrel compressors LM 2500 Gas Turbines
- 139. © 2005 Compressor Controls Corporation PROBLEMS PROBLEMS PROBLEMS! • Domino Trip • Recycle valve always open between 15-20 % • EGT Limit always in operation • At least 1 trip per month , some due to surge • Speed Control always in Manual • Excessive flaring • Unstable suction pressure • Unstable Discharge pressure
- 140. © 2005 Compressor Controls Corporation Results • Increased production by 7 million SCFD ($7.5 million/year) • Elimination of trips caused by surging • All control loops in auto eliminating operator intervention • All recycle valves closed during normal operation • Fast, reliable, smooth startups in automatic • Stable suction pressure control at 4.5 psi • Easy trouble shooting of control system problems with improved HMI
- 142. © 2005 Compressor Controls Corporation System Availability • In the Past, Most Comparisons Have: – Focused on “The Box”, not on the Entire System. – Used Oversimplified Models. – Used a Safety System Mindset, Focusing Only on Dangerous Failures, and Not on the Total Failure Rate of Devices and the System. – Ignored Controller Diagnostics, Common-Cause Failures, and Other Important Considerations. • This Approach is Too Simplistic, and Leads to Invalid Conclusions.
- 143. © 2005 Compressor Controls Corporation System Boundaries • The Controller is Not the Whole System! • Field Devices Have a Huge Impact on System Availability, and Must be Considered. Controller Sensors Final Elements
- 144. © 2005 Compressor Controls Corporation Summary of Data • There is no significant system availability difference between topologies once field devices are included. • Control system availability is greatly affected by issues related to field devices. SYSTEM AVAILABILITY 2-1-0 DUPLEX MTBF (Years) 3-2-1-0 TRIPLEX MTBF (Years) 3-2-0 TRIPLEX MTBF (Years) Controller Only Complete System Improved diagnostics (99%) Redundant Sensors (Duplex) Fallback Strategies High reliability outlet transducers Redundant Outlet transducers Automated Final Element Testing 117.9139 121.0418 109.4978 3.1484 3.1506 3.1419 3.2128 3.2131 3.2119 7.9197 7.9335 7.8014 5.3926 5.3989 5.3737 3.8324 3.8356 3.8228 3.2795 3.2818 3.2725 4.9329 4.9382 4.9171
- 145. © 2005 Compressor Controls Corporation Conclusions • Availability analysis comparing controllers alone is not valid. The complete control system must be considered. • Improving control system availability is best accomplished through increasing the effective availability of field devices. • Hardware redundancy and software fallback strategies can both be very effective at increasing sensor availability. • High-reliability output devices provide cost-effective availability increases. • Automated partial-stroke valve testing is beneficial if performed frequently.
- 146. © 2005 Compressor Controls Corporation Increase compressor system reliability and availability with fall-back strategies • Over 75% of the problems are in the field and not in the controller • The CCC control system has fall-back strategies to handle these field problems • The controller continuously monitors the validity of its inputs • If an input problem is detected the controller ignores this input and automatically switches to a fall-back mode
- 147. © 2005 Compressor Controls Corporation Increase compressor system reliability and availability with fall-back strategies Fall-Back Benefits – Avoids nuisance trips – Alarms operator of latent failures – Increases machine and process availability
- 149. © 2005 Compressor Controls Corporation Process Safety Design - 1987 • HSE Study of 34 Industrial Accidents • Most Common Cause: Specification Errors Design and Implementation 15% Operation and Maintenance 15% Installation and Commissioning 6% Specification 44% Changes After Commissioning 21%
- 150. © 2005 Compressor Controls Corporation Specifications • Writing a good, tight specification is very important • Don’t just focus on the hardware • Don’t fall into the instrument upgrade trap • Demand value and try to specify it • Focus on – System performance – Algorithms – Proven experience on similar applications
- 151. © 2005 Compressor Controls Corporation Acceptance Test Requirements • Acceptance test requirements for new control systems – Antisurge Control • In response to full closure of a substation suction or discharge block valve, the system must not allow any compressor to surge. • In response to the simultaneous closure of both suction and discharge block valves, the system should not allow any compressor to surge more than once. – Discharge Pressure Control • In steady state, deviation of the discharge pressure from its set point shall not exceed 0.5 %. – Load-Sharing Control • In response to bringing a compressor on-line or taking one off-line, the control system shall reestablish steady-state operation with all units equally loaded (within 1%) in no more than 30 minutes.
- 152. © 2005 Compressor Controls Corporation Acceptance Test Requirements – Turbine Speed Control • In steady state, deviation of the turbine speed from its set point shall not exceed 0.5%. – Turbine Limiting Control • In response to a rise in the speed set point, the system shall not allow an increase in speed after the exhaust- gas temperature has exceeded its limiting control threshold by 0.5% of the sensor span. • In response to a rise in the speed set point, the system shall not allow an increase in speed after the air- compressor discharge pressure has exceeded its limiting control threshold by 0.1% of the sensor span. • In response to a rise in the speed set point, the system shall not allow an increase in speed after the uncontrolled shaft speed has exceeded its limiting control threshold by 0.5% of span.
- 153. © 2005 Compressor Controls Corporation Specialized, high speed, digital turbomachinery control equipment • Purpose-built hardware provides optimum performance • Allows implementation of specialized algorithms, many patented • Provides redundancy level required for customer’s application
- 154. © 2005 Compressor Controls Corporation MTBF of Series 3 Plus controllers is 43.4 years, or 2.5 failures per million hours of operation Series 3 Plus Platform • Multi-loop controllers for speed, extraction, antisurge, & performance control • Serial communications for peer to peer and host system communications
- 155. © 2005 Compressor Controls Corporation • Series 4 features include: – Control multiple trains in one control system – I/O capacity tailored to each application – High speed communication links – Flexible fault tolerance -simplex, duplex or triplex – Highly configurable Series 4 Platform
- 157. © 2005 Compressor Controls Corporation • Design Screens • Standard and Customized Screens • On-Line Operation and Control • Alarm and Event Management • Critical Event Archiving Remote OnlookTM Diagnostics Controller Overview TrainView® Operator Interface Compressor Map Screen Control System
- 158. © 2005 Compressor Controls Corporation Guardian® Overspeed Prevention System • API 670 compliant • CSA Certification – Class 1, Div 2, Groups A,B,C,D – Class 1, Zone 2, Exn IIC T4 • Enclosure IP-65 (NEMA 4) • Alarms and history status • Digital Tachometers for each Speed Module • Flexible Mounting – 19” rack mount – Back mount
- 159. © 2005 Compressor Controls Corporation Vantage® GP A Purpose-Built Digital Governor for General-Purpose Turbines Specifically designed for condensing and back- pressure steam turbines driving synchronous generators. Vantage® GD
- 160. © 2005 Compressor Controls Corporation System Design & Consulting Services • Complete system design • Right solution the first time • Complete system documentation
- 161. © 2005 Compressor Controls Corporation Field Engineering Services • 94 Field engineers • Expertise with processes, machinery and instrumentation • Highly rated in customer satisfaction surveys • Start-up services with on-going revenues
- 162. © 2005 Compressor Controls Corporation Capabilities • Controlling over 7,000 turbomachines, including: – over 350 steam turbines – over 2,000 gas turbines • 345 employees: – more than 200 engineers worldwide • 19 PhDs • 60 Masters • 250 Bachelors • 47 full-time R&D personnel • 13 Locations Worldwide
- 163. © 2005 Compressor Controls Corporation Customers keep coming back 80% of projects are from repeat customers