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Anti Surge Control System Basic Concepts

This document discusses anti-surge control systems for compressors. It covers topics like: - What surge is, how it develops and its causes - Basic concepts of anti-surge control systems like using a recycle valve to lower resistance and prevent surge - Challenging issues like algorithms, control responses, strategies, valve response times - Key terms like surge limit line, recycle trip line, safety on line - Performance control and issues that arise from non-integrated vs integrated systems of anti-surge and performance controllers - Techniques to minimize interactions and dead times - Criteria for selecting flow measurement devices and valve characteristics

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160 views

Anti Surge Control System Basic Concepts

This document discusses anti-surge control systems for compressors. It covers topics like: - What surge is, how it develops and its causes - Basic concepts of anti-surge control systems like using a recycle valve to lower resistance and prevent surge - Challenging issues like algorithms, control responses, strategies, valve response times - Key terms like surge limit line, recycle trip line, safety on line - Performance control and issues that arise from non-integrated vs integrated systems of anti-surge and performance controllers - Techniques to minimize interactions and dead times - Criteria for selecting flow measurement devices and valve characteristics

Uploaded by

pavijaya
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© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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ANTI SURGE CONTROL

SYSTEM

BASIC CONCEPTS
ISSUES FOR DISCUSSION
• Introduction to compressor control
• Surge Phenomenon, causes and remedy
• Basic ASC system
• Challenging Issues
– Algorithms
– Control responses
– Advance control strategies
– Quick response of control valve
– Elimination of dead time and lag time
• Surge limit line, Distance between SLL and operating point
• Performance control
• Non-integrated System
• Interacting Performance controller and ASC
• Integrated system
• Selection criteria for FMD and AS Valve
PERFORMANCE CURVE OF
COMPRESSOR
SURGE
• Surge : Very
fast process
• Order of
milliseconds
• Potential to
cause huge
damage and
losses
HOW SURGE DEVELOP ?
• Normal flow from higher pressure (P1) to
lower pressure(P2)
• In Compressor gas flows from low suction
pressure to high discharge pressure using
external power.
• If discharge valve is closed discharge pressure
(P2)increases. If P (P2 - P1 ) is more and
power is not sufficient, flow will be reverse.
SURGE PHENOMENON
• • Fig shows... how surge develops
using a model of an air compressor
pumping into a closed tank.
• Machine shutdown : no flow, no
pressure
• Machine start:
• High flow, less pressure (E)
• Start press. build up, decrease
flow( E to D to A)
• Reversal of flow at A and again
at C, causing flow & pressure
oscillations
CAUSES FOR SURGE

• Discharge valve is closed


• Suction flow decreases
• Power increases
• Change in gas composition
SURGE CONTROL METHODS

• Vent discharge pressure


– Wastage of power
– Loss of material
– Hazards
• Recycle from discharge to suction
– Wastage of power
ANTI-SURGE CONTROLLER

• KEY WORDS
– SURGE CONTROL LINE ( SCL )
– RECYCLE TRIP LINE ( RTL )
– SURGE LIMIT LINE ( SLL)
– SAFETY ON LINE ( SOL)
BASIC ANTI-SURGE CONTROL SYSTEM
• Anti surge controller
protect the compressor
against surge by opening
the recycle valve
• opening the recycle
valve lowers the
resistance felt by
compressor
• This takes compressor
away from surge
BASIC ANTI-SURGE CONTROL SYSTEM
CHALLENGING ISSUES
• An algorithm to accurately locate the operating point and its
corresponding surge limit
• A controller execution speed that will allow a digital
controller to eliminate immediate analog control
• Control response that allows different margins of safety for
different operating conditions
• Advance control strategies that can avoid the negative effect
of loop interaction
• A quick opening, correctly sized anti surge control valve
• The elimination of unnecessary dead time or lag time within
system
SURGE LIMIT LINE (SLL)
• Most limit in process are ‘one variable’ type, i.e.compare one
transmitter value with max/min set limit value and control
an actuator accordingly.
• SLL is slightly different :
– Limit can’t be crossed without potential damage to
compressor.
– Limit is not the max/min value of only one physical Tx
signal.
– It is a line in compressor map.
– Challenge: to describe SLL as a limit as any other ‘one
variable’ type limit.
DISTANCE BETWEEN SLL AND
OPERATING POINT
• Better we can measure the distance to surge, closer we
can operate to it without taking risk.
• THE CHALLENGE:
– SLL is not a fixed line but changes depending on
suction conditions: Ts,Ps,mw,Ks etc.
• CONCLUSION:
– ASC must provide ‘distance to surge’ calculation
that is invariant of any change in suction conditions.
– This will lead to safer control yet reducing the surge
control margin.
ALGORITHM ISSUES
• Typical compressor map includes : (Qs,Hp),
(Qs,Rc) or (Qs,Pd) coordinates, where:
• Qs = Suction flow(actual or std volumetric flow)
• Hp = Polytropic head
• Rc =Compressor ratio(Pd/Ps)
• Pd =Discharge pressure
• Ps =Suction pressure
• Ks =Exponent of isentropic compression
• These maps are defined for 1 specific set of inlet
parameters : Ps, Ts, MW, Ks
ALGORITHM ISSUES
• In commonly used
coordinate systems,
coordinates are
NOT invariant to
suction conditions.
• For control purpose
we want SLL to be
represented by a
single curve.
ALGORITHM ISSUES
ALGORITHM ISSUES
• NOT invariant • Invariant Coordinates
coordinates (Hp, Qs) (hr,qr2)
ALGORITHM ISSUES
• NOT invariant • Invariant Coordinates
coordinates (Hp, Qs) (hr,qr2)
PI RESPONSE TO SLOW
DISTURBANCES
• When the operating point
crosses the SCL, PI
control will open the
recycle valve.
• PI control will give
adequate protection for
small disturbances
• PI control will give stable
control during steady
state recycle operation
ADAPTIVE GAIN FOR FAST
DISTURBANCE
• When operating point moves fast towards
the SCL, adaptive gain moves the SCL
towards the operating point.
• This allows the PI controller to react
earlier.
• As a result smaller steady state surge
control margin can be achieved with out
sacrificing reliability
RECYCLE TRIP LINE
• RTL is between SLL and SCL.
• When operating point touches RTL, it is in danger
zone.
• PI controller is too slow to catch the disturbance.
• So, open loop response is triggered and valve is
opened with step response which is
programmable.
• If operating point is still above SCL repeated step
response is provided.
SAFETY ON LINE

• If operating point crosses


the safety on line the
compressor is in surge.
• The safety on response
shifts the SCL and RTL
to the right.
• Additional safety or surge
margin is added.
• PI and RT will stabilise
the machine on new SCL
COMPRESSOR PERFORMANCE
CONTROLLER
• ALSO CALLED :
– Through put control
– Capacity control
– Process control
• Matches the compressor through put to the load.
• Based on controlling…
– Discharge pressure by recycle throttling/discharge
throttling
– Suction pressure by suction throttling or speed
variation
ANTI-SURGE CONTROL
SYSTEM : NON-INTEGRATED
NON INTEGRATED ASC AND
PERFORMANCE CONTROLLER
• Operating point A rides to point B
on large disturbance.
• Performance controller is taking
the operating point down in speed
(To bring pressure back to SP) and
thus down in flow.
• Unless prevented, PIC can drive the
compressor to surge.
• Results: • ASC starts to operate at pt B.
– Large pressure deviation during • Even if surge is avoided, interaction
disturbances
degrades pressure control accuracy.
– Increased risk of surge
PERFORMANCE CONTROLLER
INTERACTS WITH ASC
• Both controllers manipulates the same variable
- the operating point of the compressor
• The controllers have different and some time
conflicting objectives.
• The control action of each controller affects the
other.
• This interaction starts at the surge control line-
near surge-and can cause surge.
HOW TO COPE WITH ASC AND
PERFORMANCE LOOP INTERACTION?

• De-tune the loops to minimize interaction. Result is


poor pressure control, large surge control margins
and poor surge protection
• Put one loop on manual so interaction is not possible.
Operators will usually put the ASC in manual.
Result : no surge protection and often partially open
anti surge valve.
• De-couple the interactions. Result: good
performance control accuracy, good surge protection
and no energy wasted on recycle or blow off.
MINIMIZING EFFECT OF DEAD TIME
• When capacity of the piping network between as
valve and compressor inlet is high, it works like a
filter with excessive time constant. There is very
considerable delay between AS valve opening and
increase in flow through compressor.
• This dangerous time delay can be corrected by
increasing the speed with AS valve opening. This is
done by ‘de-coupling’
• The dead time of the order of 3.5 seconds is improved
to 0.5 second by using ‘de-coupling’ technique.
INTEGRATION OF ASC AND
PERFORMANCE CONTROL
INTEGRATION/DECOUPLING OF ASC
AND PERFORMANCE CONTROL
• Operating point A rides to
point B on large
disturbance.
• At this time, performance
controller action is de-
coupled. ASC tells PC to
speed up the compressor.
• The resulting action is as
shown in Fig.
• Hence only small safety
margin is required.
FMD SELECTION CRITERIA
• Main criteria :
– Repeatability
– Sufficient signal to noise ratio
• Accuracy is NOT critical
• FMD delays must be very minimal
• Normally head flow meters based on principle of velocity measurement:
– Orifice plate
– Venturi
– Pitot tubes
• Recommended flow range: Max Comp flow.
• Recommended delta P : 250 mmwc or more.
AS VALVE STROKE SPEED AND
CHARACTERISTICS
• Adequate stroke speed is must for anti-surge protection
.Recommended stroke time:
– Size C to O O to C
– 1- 4 inch 1 sec < 3 sec
– 6-12 inch 2 sec < 5 sec
– >16 inch 3 sec < 10 sec
• Same closing time assures same loop gain in both directions.
• AS Valve characteristic:
– Selected to be open 80% to 90% for design conditions
– Can operate any where between 0 to 100 %
– To have equal loop gain over the whole operating range a linear
valve is required.
THANK YOU

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