ANTI-SURGE CONTROL SYSTEM
M.S.MANI , CES-INSTS. CES-INSTS .
CONTROL PHILOSOPHY In c a s e o f a P r o c e s s U n its t h e e m p h a s is is o n s a f e o p e r a tio n a n d p re c is e c o n tro l In c a s e o f R o ta r y M /C s th e e m p h a s is is o n s a f e o p e r a tio n a n d m o n ito r in g . 2
CONTROL PHILOSOPHY In c a s e o f a P r o c e s s U n its t h e e m p h a s is is o n s a f e o p e r a tio n a n d p re c is e c o n tro l In c a s e o f R o ta r y M /C s th e e m p h a s is is o n s a f e o p e r a tio n a n d m o n ito r in g . 2
Measurements : Health of a Rotary machine is best monitored by measuring and monitoring the following machine parameters :
ibration le!els of casing and / or shaft
"haft RPM
Relati!e location of the shaft with respect to a predetermined mar# $ e.g.%&ey phasor '
()ial shift of shaft
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Measurements
( CONTINUED):
•
Temperature of thrust bearing pads
•
Temperature of bearing housing
•
Temperature of lube oil return line
•
Oil/gas flow/pressure to seals
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Ma!"r #"ntr"$ s%stem
Auto start of stand by lube oil pump.
Lube Oil / Seal Oil back up system
Sequential start / stop (speed ramping of turbines to a!oid human error
"apacity control
Surge control system
"O#T$OL S%ST&'S LO") *+A,$A' UCP MCMS B-N 3300/3500 SERIES
ALLEN BRADLEY PLC-5/40
DCS CCC/TURBOLOG
FOXBORO I/A S E R IE S
! O O D ! A RD 505
BY ELECTRICAL
( A S A P P L I C A B L E )
ESD
MCC
PROTECH 03
TRICONEX TM R
LOCAL INDICATOR (M T L M A K E )
LOCAL CONTRO L PANEL ( IN F I E L D )
&
hat is Surge0 1
S2$,+#, +S A# 2#STAL& O3&$AT+#, "O#*+T+O# T4AT "A2S&S &$AT+" "O'3$&SSO$ 3&$5O$'A#"&
'
4&$& A#* 4&# S2$,& E)ERY A*IAL AN+ CENTRIUGAL O""2$S 1
COMPRESSOR ILL E*PERIENCE A +AMAGING PHENOMENON NON AS SURGE HEN THE LO THROUGH THE COMPRESSOR +ROPS /ELO A CERTAIN LE)EL
(
1% sure O##urs
Surge can be induced by low suction pressure, high discharge pressure and reduction of speed of the compressor
0
H"6 C"m7ress"r 8s a99e#te: :ue t" Sur8n
"ompressor damage results from repetiti!e or frequent surging
*uring Surge momentary flow re!ersal takesplace6 this leads to a !ery rapid pulsating flow backward and forward through the internals of compressor6 resulting in S&7&$& 7+$AT+O# and consequent damage 5
1at 1a77ens :ur8n Sure
5low re!erses in 89 to :9 milliseconds
Surge cycles at a rate of 9.; s to ; s per cycle
"ompressor !ibrates
Temperature rises
hooshing0 noise
Trips may occur
"on!entional instruments and human operators may fail to recognicess of the surge condition
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Ant8-sure C"ntr"$ s%stem -=#"nt:>
T1e #18e9 :ra6?a#@ "9 t18s a77r"a#1 8s t1e e998#8en#% 7ena$t%
T1e ener% t1at 6as use: t" #"m7ress t1e re#%#$e: 68$$ " t" 6aste
S", t1e #"ntr"$ s%stem s1"u$: ?e ta8$"re: t" "7en t1e sure #"ntr"$ a$e "n$% 61en an: as 9ar as ne#essar% t" st"7 sure 4
ASPECTS O SURGE CONTROL SYSTEM
C"m7ress"r $"6 7at1 1as 7r"?a?8$8t% "9 su::en 9$"6 re:u#t8"n
Is t1e C"m7ress"r 7r"8:e: 68t1 )ar8a?$e S7ee: +r8e
Is t1e C"m7ress"r 7r"8:e: 68t1 IG)
M"$e#u$ar e81t C1anes
Manu9a#turerBs Sure #ure an: teste: sure P"8nts
Sa9et% Mar8n
REUIREMENTS OR ANTI-SURGE CONTROL
API as@s 9"r 5D sa9et% :8stan#e ?et6een Sure $8ne an: #"ntr"$ $8ne, re9erre: t" sure 9$"6
T18s #"rres7"n:s t" 4 t" (D re9erre: t" 9u$$ rane 9$"6
T18s sa9et% :8stan#e nee: t" #"er - Ant8 sure #"ntr"$$er res7"nse t8me - L8m8te: str"@e s7ee: "9 /$"6-"99 a$e - Transm8tter a##ura#% an: :r89t -
Measur8n err"rs 61en t1e $"#at8"n "9 t1e sure $8ne 8s :eterm8ne:
-
C"m7ress"r 9"u$8n an: #1anes 8n as #"m7"s8t8"n &
SURGE +ETCTION METHO+S
+CS-M8n8mum $"6 #"ntr"$$er=On s78$$ ?a#@>
Me#1an8#a$ M8n8mum st"77er "n su#t8"n )a$e
O7erat8n P"8nt 7r"F8m8t% t" Sure #"ntr"$ L8ne
$"6 reersa$ :ete#t8"n - +899. Pr an: +899 Tem7.
Su::en +r"7 8n M"t"r #urrent
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C"m7ress"r Per9"rman#e Ma7
5or any operating cur!e the point of minimum flow and ma>imum pressure is known as the Surge limit point. The locus of all such points defines a cur!e known as surge line
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"urge control *iagram: +he diagram below shows the performance map of a compressor with the surge control lines . "&,+CH % -
2
3 P: -----Ps 4 3
,LO
. "UR/, 0IMI+ 0I1, -.P,R43RM(1C, CUR,"
2."UR/, C31+R30 0I1, 5.3P,R(+I1/ P3I1+
0
E99e#t "9 Gas #"m7"s8t8"n "n Sure 2 .8 .7 .5
M9.8
.2
M5.7
M2 new
6.8
M28
6.7 6.5 6.2 6 6
6.2
6.5
6.7
6.8
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Ant8sure C"ntr"$ S%stem Ant8 sure s%stem a#18ee t18s /% man87u$at8n t1e 7"s8t8"ns "9 Re#%#$e a$e =N"rma$$% 9"r Haar:"us Gas> /% us8n a /$"6 "99 a$e =N"rma$$% 9"r A8r "r N"n 1aar:"us a77$8#at8"ns> 8n "r:er t" ma8nta8n t1e "$umetr8# 9$"6 rate a?"e a sa9e, m8n8mum $ee$.
C"#$%&''"%
A()*'+%,& -./0&
4+
P+
++
++
P+
4+
4:
ANTI SURGE CONTROLLER
2
Sure C"ntr"$ Te#1n8;ues Ca$#u$ate
an: M"n8t"r t1e JO7erat8n P"8nt J "9 t1e C"m7ress"r. O7en t1e ent "r /$"6 "99 a$es 8n a #"ntr"$$e: 6a% . O7en t1e re#%#$e a$e= /et6een t1e :8s#1are an: su#t8"n "9 t1e #"m7ress"r> 8n a #"ntr"$$e: 6a%. In ar8a?$e s7ee: ma#18nes , re:u#e t1e s7ee:. 22
Sure C"ntr"$ )a$e
S2$,& "O#T$OL 7AL7& S+?+#, Surge control !al!es should be siimum speed and total recycle ;. Surge control line at normal operating pressure . The design capacity of the machine #ormally point @ is the go!erning case (i.e. lowest flow and lowest delta 3 and the !al!e usually pass flow the machine design capacity
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Sure #"ntr"$ )a$e=#"nt:..>
7AL7& "4A$A"T&$+ST+"S The installed characteristics of the surge control !al!e should be linear. This can be accomplished by either a linear trim characteristic control !al!e or line arising an equal percentage !al!e in the controller
S3&&* O5 $&S3O#S& The 7al!e is designed to Open fully0 from full close0 with in 8 seconds. This is accomplished by proper punematic accessories with 7al!e Actuator
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CONTROL SYSTEMS INSTALLE+ AT KG
CCC - COMPRESSOR CONTROLS CORPORATION - SERIES 3, SERIES 4
GHH- /ROSIG - TUR/OLOG
HARTMANN- /RAUN - PROTRONIC
2
S2$,& 3$OT&"T+O#/"A3A"+T% "O#T$OL 5O$ "$+T+"AL "O'3$&SSO$S +# BA'#A,A$
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HEAT PUMP COMPRESSOR
MIN ,LO- CONTROLLER IN +CS -ITH OPERATOR ENTERE+ SET POINT
MANUAL SPEE+ CONTROL THROUGH +CS
•
PLAT ,ORMERISOMAR GAS COMPRESSORS
MIN MECHANICAL STOP IN SUCTION )AL)ES
2&
TA+L ,AS "O'3$&SSO$ +E+ICATE+ CONTROL SYSTEM JTUR/OLOGJ ,ROM GHH /ASE+ ON COMPRESSOR PER,ORMANCE MAP
SURGE CONTROL /Y RECYCLE )AL)E MIN OPENING /Y OPERATOR SUCTION PRESSURE CONTROL /Y IG) IMPLEMENTE+ IN GHH
TRIP ON SURGE
2'
"O)&$ ,AS "O'3$&SSO$
*&*+"AT&* '2LT+ 7A$+AL& "O#T$OL C """ S&$&+S ;D "O#T$OLL&$ S2$,& "O#T$OL % $&"%"L& 7AL7& S&3A$AT&L% 5O$ 5+$ST A#* S&"O#* STA,& AS" 4AS 3$&SS2$& O7&$$+*& "O#T$OL(3O" 5O$ T4& 5+$ST STA,& *+S"4A$,& 3$&SS2$& A2TO "A3A"+T% "O#T$OL % S3&&* 7A$+AT+O# AS&* O# S2"T+O# 3$&SS2$&/"OL2'# O7&$4&A* 3$. *&"O23L+#, &T&&# 3&$5O$'A#"& A#* A#T+ S2$,& "O#T$OLL&$
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7,O 4T "O'3$&SSO$
*&*+"AT&* "O#T$OL S%ST&' ET2$OLO,E 5$O' ,44 AS&* O# "O'3$&SSO$ 3&$5O$'A#"& 'A3 S2$,& "O#T$OL % $&"%"L& 7AL7& TO 4AS#*L& *+55&$&#T 3$O"&SS "O#*+T+O#S ('OL T "4A#,& S&L&"T+O# S+T"4 +S 3$O7+*&* +# T4& 2"3. 'OL TC8.96.;6F.8 8G 7+S2AL+?AT+O# +S 3$O7+*&* +# T4& 3+. '+# O3&#+#, % O3&$ATO$ "A3A"+T% "O#T$OL +S % S3&&* "O#T$OL % O3&$ATO$. 20
3$T *&*+"AT&*
"O#T$OL S%ST&' 5$O' """ S&$+&S S%ST&' "O#T$OL S%ST&' +S *2AL $&*2#*A#T A#* 5A2LT TOL&$A#T 5ALL A") ST$AT&,% +S +'3L&'&#T&* 3$T "O#T$OLS A$& 7&$% "O'3L&H *2& TO '2LT+3L& +#T&$A"T+#, "O#T$OLS S2"4 AS &H3A#*&$ "O#T$OL *<A 3 "O#T$OL $H/$, ST&A' T2$+#& "O#T$OLS LO&$ "A3A"+T% "O#T$OL LOA* S4A$+#, "O#T$OL '/, "O#T$OL( L+'+T "O#$OL ,44
T2$OLO, "O#T$OL S%ST&' 5O$ STA$T 23 A#* 'A"4+#& 3$OT&"T+O# ,44 S3&"+AL S2$,& *&T&"TO$ AS&* O# *3 $&7&$SAL/ ITI $&7&$SAL( 5AST T/" A"$OSS S2"T+O# A#* *+S"4A$,& O5 T4& LO&$
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Turbine / "ompressor "ontrol System "oncept
3
Re9eren#es
Shell *ep @J&SCJ99 C "ompressor surge control systems
Shell *ep @J,SCJ99 C *esign requirements for compressor surge control systems
""" 3ublication for Accurately defining surge control line
,44CO$S+, C Turbolog operation manual
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