2

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Challenges and
Opportunities in
Turbomachinery Control

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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:

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Machinery
Process
Controls
CCC
Turbomachinery
Controls

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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

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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

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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

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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

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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

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Gas
Turbines

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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.

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Gas Turbines
Classification

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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

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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

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Heavy duty , One shaft Gas
Turbine
FS5001
W251
V63
NHP NPT =
CDP
EGT (T4) B.V
Starter
Motor
IGV
EGT (T3)
T1

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SURGE EFFECT ON G.T. AIR
COMPRESSOR

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Combustion liners
GT Classification

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Exhaust Gas Temperature (EGT)
T/C
Combustion
Chambers
Flame Tubes
Thermo
Couple
Harness

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Two shaft aeroderivatives

Two shaft gas
turbines
Variable speed range
Low power starting
device
Gas expander
E-motor
Hydraulic motor
LM2500
AVON
Saturn

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Two shaft aeroderivatives
EGT (T4) EGT (T6)
CDP NPT
B.V
Starter
Motor
T1
NGG
Fuel Gas
F.G.
Manifold
EGT (T3)
IGV

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Three shaft aeroderivative

Three shaft gas turbine
Variable speed
Complex machines
VBVs, VSVs, IGVs
RB211
LM1600
LM5000
GG4

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Three shaft aeroderivative
NPT T1
EGT (T6)
NLP
NHP
LP HP LP HP
EGT (T4)
T21 EGT (T3)
CDP
Starter
Motor
IGV
B.V

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Firing temperature
Firing Temp
Location
Firing temp.
Cost $
Fuel
cost /kWh
Maintenance
cost /kWh

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Inlet Guide Vanes
and
Variable Stator
Vanes

Restricts the volume flow
through the GT Compressor

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IGV, VSV, VBV assembly

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Variable Stator Vanes

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Variable Stator Vanes

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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

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Gas turbines
with
second stage
Nozzles

Control impacts

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Two shaft industrial GT
with 2nd stage nozzles

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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 GTs has them
General Electric FS3002 and FS5002
Nuovo Pignone PGT5 and PGT10

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Two shaft industrial gas turbine

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2nd stage nozzle assembly

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Efficiency
Increases

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Regenerative gas turbine cycle
Efficiency improvement
approx. 30%

Better fuel efficiency
approx. 25%

Higher initial cost

Higher maintenance cost

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Cogeneration
T
u
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b
i
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e

Gas turbine
Compressor
Steam
Turbine
Generator
Cogeneration
Gas turbine
Steam turbine
Boiler
Generator

Efficiency
Between 40% and
58%

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Gas turbine
limits
of operation

Control limits

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PT speed
T ambient
90
Gas turbine Performance maps
Power
Slides at const T
amb

PT speed
T ambient
Power
PT speed
T ambient
This map is hard to visualize because of the 3D aspect.
90

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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

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0
10
20
30
40
50
60
70
80
90
100
4
8
:
0
0
.
0
4
8
:
4
1
.
0
4
9
:
1
6
.
0
4
9
:
5
9
.
0
5
0
:
4
4
.
0
5
1
:
2
7
.
0
5
2
:
0
9
.
0
5
2
:
5
3
.
0
5
3
:
3
8
.
0
5
4
:
2
3
.
0
5
5
:
2
7
.
0
5
5
:
5
3
.
0
5
6
:
3
8
.
0
5
7
:
2
3
.
0
5
8
:
0
8
.
0
5
8
:
5
3
.
0
5
9
:
3
8
.
0
0
0
:
2
3
.
0
0
1
:
0
8
.
0
0
1
:
5
3
.
0
0
2
:
3
8
.
0
0
3
:
2
2
.
0
0
4
:
0
7
.
0
0
4
:
5
2
.
0
0
5
:
3
7
.
0
0
6
:
2
2
.
0
0
7
:
0
6
.
0
0
7
:
4
9
.
0
0
8
:
3
2
.
0
0
9
:
1
7
.
0
1
0
:
0
2
.
0
1
0
:
4
7
.
0
1
1
:
3
1
.
0
1
2
:
1
6
.
0
1
3
:
0
1
.
0
1
3
:
4
6
.
0
1
4
:
3
1
.
0
1
5
:
1
6
.
0
1
6
:
0
1
.
0
Time (Min)
%

o
f

f
u
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l

s
c
a
l
e
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.

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Fuel
systems
and
valves

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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

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Example: Simplified Fuel system

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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

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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 %.

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45
CCC Fuel Valve
Stepper Motor Digital Encoder

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Real valve installation

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Conventional
and
Advanced
Control
Systems

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Conventional Control System
UIC
SIC
PIC
Gas generator
Power
Turbine
Process
Compressor

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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

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Advanced Control System
UIC
SIC
PIC
Gas generator
Power
Turbine
Process
Compressor

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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

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Advanced Control Concept
Simulation
of
Control
Systems

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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

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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

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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

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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

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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

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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

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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

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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 POI NT

C
Pressure
Set point
EGT
Speed
curve
Over Temp.
Trip Area
Flame out
Trip Area

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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

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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

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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

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Compressor Map Pd vs. Flow

Conventional Stand alone
PID control

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Compressor Map Pd vs. Flow

Conventional Stand alone PID control with
Restricted FCV movement

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Compressor Map Pd vs. Flow

Conventional Stand alone PID control with Restricted FCV movement
and Recycle Trip

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Compressor Map Pd vs. Flow

Fully integrated CCC
Total Train Control System

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Compressor Map Pd vs. Flow

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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

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Compressor
Discharge Pressure vs. Time

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Fuel Control Valve position
(Power) vs. Time

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Exhaust Gas Temp vs. Time

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PT speed vs. Time

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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
Doesnt 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

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Minimizing GT
Operating Margins

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Flexibility of CCCs 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

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EGT control algorithm
EGT Limit
EGT Calc.
Max
Median
Average

d
dt




Kp * Td



-
+


EGT
Time
PID
+
-
L
.
S
.
S
EGT Spread

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OPEN LOOP RESPONSE

F
u
e
l

D
e
m
a
n
d

E
G
T

Time
Time
Trip Limit
Open Loop S.P.
Closed Loop S.P.
Dead time
Close FCV

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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

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Maximum
continuous
running
temperature
More power
from your
gas turbine!
EGT Limit CCC
CCC SP Digital
Digital SP Analog
Analog SP
CCCs Unique EGT Control

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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

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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.

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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

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Introduction to
Series 5

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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

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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

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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

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Power Supplies
LOCAL I/O
CARD
IOC-555
MPU-750
REMOTE I/O
CARD
RCC-PBM
Series-5 Vanguard Chassis

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Series-5 4-SLOT Vanguard Chassis
MPU-750
REMOTE I/O
CARD
RCC-PBM
LOCAL I/O
CARD
IOC-555

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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

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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

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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 FTAs

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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 FTAs

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System Integration

Train Tool
W/S
Series 5
OPC-Ethernet
Ethernet TCP/IP
Serial Modbus to DCS
or Host Computer


M
o
d
b
u
s

M
o
d
b
u
s

Ethernet OCI to
TrainTool
OPC via TrainTool W/S


Field
DCS
P
P
P

2
0
0
5


C
o
m
p
r
e
s
s
o
r

C
o
n
t
r
o
l
s

C
o
r
p
o
r
a
t
i
o
n


System Architecture

Train Tool
W/S
Series 5
OPC-Ethernet
Ethernet TCP/IP
Serial Modbus to DCS
or Host Computer


M
o
d
b
u
s

M
o
d
b
u
s

Ethernet OCI to
TrainTool
OPC via TrainTool W/S


Field
DCS
RocketPort

2
0
0
5


C
o
m
p
r
e
s
s
o
r

C
o
n
t
r
o
l
s

C
o
r
p
o
r
a
t
i
o
n


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
M
o
d
B
u
s

cPCI
optic to 2000m.
I/O Card
MPU
750

Serial Ports
E
t
h
e
r
n
e
t

P
o
r
t
s

MPU
A

Serial Ports
E
t
h
e
r
n
e
t

P
o
r
t
s

For
Eng.
cPCI
optic to 2000m.
I/O Card
MPU
750

Serial Ports
E
t
h
e
r
n
e
t

P
o
r
t
s

MPU
B

Serial Ports
E
t
h
e
r
n
e
t

P
o
r
t
s

For
Eng.

2
0
0
5


C
o
m
p
r
e
s
s
o
r

C
o
n
t
r
o
l
s

C
o
r
p
o
r
a
t
i
o
n


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
M
o
d
B
u
s

cPCI
optic to 2000m.
I/O Card
MPU
750

Serial Ports
E
t
h
e
r
n
e
t

P
o
r
t
s

MPU
A

Serial Ports
E
t
h
e
r
n
e
t

P
o
r
t
s

For
Eng.
cPCI
optic to 2000m.
I/O Card
MPU
750

Serial Ports
E
t
h
e
r
n
e
t

P
o
r
t
s

MPU
B

Serial Ports
E
t
h
e
r
n
e
t

P
o
r
t
s

For
Eng.

2
0
0
5


C
o
m
p
r
e
s
s
o
r

C
o
n
t
r
o
l
s

C
o
r
p
o
r
a
t
i
o
n


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
M
o
d
B
u
s

cPCI
optic to 2000m.
I/O Card
MPU
750

Serial Ports
E
t
h
e
r
n
e
t

P
o
r
t
s

MPU
A

Serial Ports
E
t
h
e
r
n
e
t

P
o
r
t
s

For
Eng.
cPCI
optic to 2000m.
I/O Card
MPU
750

Serial Ports
E
t
h
e
r
n
e
t

P
o
r
t
s

MPU
B

Serial Ports
E
t
h
e
r
n
e
t

P
o
r
t
s

For
Eng.

2
0
0
5


C
o
m
p
r
e
s
s
o
r

C
o
n
t
r
o
l
s

C
o
r
p
o
r
a
t
i
o
n


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
M
o
d
B
u
s

cPCI
optic to 2000m.
I/O Card
MPU
750

Serial Ports
E
t
h
e
r
n
e
t

P
o
r
t
s

MPU
A

Serial Ports
E
t
h
e
r
n
e
t

P
o
r
t
s

For
Eng.
cPCI
optic to 2000m.
I/O Card
MPU
750

Serial Ports
E
t
h
e
r
n
e
t

P
o
r
t
s

MPU
B

Serial Ports
E
t
h
e
r
n
e
t

P
o
r
t
s

For
Eng.

2
0
0
5


C
o
m
p
r
e
s
s
o
r

C
o
n
t
r
o
l
s

C
o
r
p
o
r
a
t
i
o
n


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
M
o
d
B
u
s

cPCI
optic to 2000m.
I/O Card
MPU
750

Serial Ports
E
t
h
e
r
n
e
t

P
o
r
t
s

MPU
A

Serial Ports
E
t
h
e
r
n
e
t

P
o
r
t
s

For
Eng.
cPCI
optic to 2000m.
I/O Card
MPU
750

Serial Ports
E
t
h
e
r
n
e
t

P
o
r
t
s

MPU
B

Serial Ports
E
t
h
e
r
n
e
t

P
o
r
t
s

For
Eng.

2
0
0
5


C
o
m
p
r
e
s
s
o
r

C
o
n
t
r
o
l
s

C
o
r
p
o
r
a
t
i
o
n


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
M
o
d
B
u
s

cPCI
optic to 2000m.
I/O Card
MPU
750

Serial Ports
E
t
h
e
r
n
e
t

P
o
r
t
s

MPU
A

Serial Ports
E
t
h
e
r
n
e
t

P
o
r
t
s

For
Eng.
cPCI
optic to 2000m.
I/O Card
MPU
750

Serial Ports
E
t
h
e
r
n
e
t

P
o
r
t
s

MPU
B

Serial Ports
E
t
h
e
r
n
e
t

P
o
r
t
s

For
Eng.

2
0
0
5


C
o
m
p
r
e
s
s
o
r

C
o
n
t
r
o
l
s

C
o
r
p
o
r
a
t
i
o
n


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
M
o
d
B
u
s

cPCI
optic to 2000m.
I/O Card
MPU
750

Serial Ports
E
t
h
e
r
n
e
t

P
o
r
t
s

MPU
A

Serial Ports
E
t
h
e
r
n
e
t

P
o
r
t
s

For
Eng.
cPCI
optic to 2000m.
I/O Card
MPU
750

Serial Ports
E
t
h
e
r
n
e
t

P
o
r
t
s

MPU
B

Serial Ports
E
t
h
e
r
n
e
t

P
o
r
t
s

For
Eng.
cPCI- bus A
cPCI- bus B

2
0
0
5


C
o
m
p
r
e
s
s
o
r

C
o
n
t
r
o
l
s

C
o
r
p
o
r
a
t
i
o
n


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
M
o
d
B
u
s

cPCI
optic to 2000m.
I/O Card
MPU
750

Serial Ports
E
t
h
e
r
n
e
t

P
o
r
t
s

MPU
A

Serial Ports
E
t
h
e
r
n
e
t

P
o
r
t
s

For
Eng.
cPCI
optic to 2000m.
I/O Card
MPU
750

Serial Ports
E
t
h
e
r
n
e
t

P
o
r
t
s

MPU
B

Serial Ports
E
t
h
e
r
n
e
t

P
o
r
t
s

For
Eng.
cPCI- bus B
cPCI- bus A

2
0
0
5


C
o
m
p
r
e
s
s
o
r

C
o
n
t
r
o
l
s

C
o
r
p
o
r
a
t
i
o
n


Series-5 Vanguard Architecture
TO Series 5 , Series
4, or Series 3 Plus
cPCI
optic to 2000m.
I/O Card
MPU
750

Serial Ports
E
t
h
e
r
n
e
t

P
o
r
t
s

MPU
750

Serial Ports
E
t
h
e
r
n
e
t

P
o
r
t
s

cPCI
REMOTE
AREA
DCS
Train Tool
W/S
OPC-Ethernet
Profi Bus
I/O Card
ProfiBus
Slave
ProfiBus
Slave
Up to 16 slaves
4
8
-
w
i
r
e

O
p
e
n
-
L
i
n
e


I
n
t
e
r
n
a
l

B
u
s

16 Ch.
RFTA
16 Ch.
RFTA
U
p

t
o

3
2

c
h

/

s
l
a
v
e

For
Eng.

2
0
0
5


C
o
m
p
r
e
s
s
o
r

C
o
n
t
r
o
l
s

C
o
r
p
o
r
a
t
i
o
n


Power Supplies
LOCAL I/O
CARD
IOC-555
MPU-750
REMOTE I/O
CARD
RCC-PBM
Series-5 Vanguard Chassis

2
0
0
5


C
o
m
p
r
e
s
s
o
r

C
o
n
t
r
o
l
s

C
o
r
p
o
r
a
t
i
o
n


Series-5 4-SLOT Vanguard Chassis
MPU-750
REMOTE I/O
CARD
RCC-PBM
LOCAL I/O
CARD
IOC-555

2
0
0
5


C
o
m
p
r
e
s
s
o
r

C
o
n
t
r
o
l
s

C
o
r
p
o
r
a
t
i
o
n


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

2
0
0
5


C
o
m
p
r
e
s
s
o
r

C
o
n
t
r
o
l
s

C
o
r
p
o
r
a
t
i
o
n


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

2
0
0
5


C
o
m
p
r
e
s
s
o
r

C
o
n
t
r
o
l
s

C
o
r
p
o
r
a
t
i
o
n


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 FTAs

2
0
0
5


C
o
m
p
r
e
s
s
o
r

C
o
n
t
r
o
l
s

C
o
r
p
o
r
a
t
i
o
n


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 FTAs

2
0
0
5


C
o
m
p
r
e
s
s
o
r

C
o
n
t
r
o
l
s

C
o
r
p
o
r
a
t
i
o
n


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

2
0
0
5


C
o
m
p
r
e
s
s
o
r

C
o
n
t
r
o
l
s

C
o
r
p
o
r
a
t
i
o
n


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

2
0
0
5


C
o
m
p
r
e
s
s
o
r

C
o
n
t
r
o
l
s

C
o
r
p
o
r
a
t
i
o
n


Speed Inputs
0.01% Accuracy
Active or Passive
5 Hz to 40K Hz
Series-5 Local FI Conditioning Module

2
0
0
5


C
o
m
p
r
e
s
s
o
r

C
o
n
t
r
o
l
s

C
o
r
p
o
r
a
t
i
o
n


Unique Fault-Tolerant Components
Fault-Tolerant FTAs
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

2
0
0
5


C
o
m
p
r
e
s
s
o
r

C
o
n
t
r
o
l
s

C
o
r
p
o
r
a
t
i
o
n


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

2
0
0
5


C
o
m
p
r
e
s
s
o
r

C
o
n
t
r
o
l
s

C
o
r
p
o
r
a
t
i
o
n


Series-5 Remote I/O Sub-System Node
ProfiBus Slave RFTA & Conditioning Modules

2
0
0
5


C
o
m
p
r
e
s
s
o
r

C
o
n
t
r
o
l
s

C
o
r
p
o
r
a
t
i
o
n


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

2
0
0
5


C
o
m
p
r
e
s
s
o
r

C
o
n
t
r
o
l
s

C
o
r
p
o
r
a
t
i
o
n


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

2
0
0
5


C
o
m
p
r
e
s
s
o
r

C
o
n
t
r
o
l
s

C
o
r
p
o
r
a
t
i
o
n


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

2
0
0
5


C
o
m
p
r
e
s
s
o
r

C
o
n
t
r
o
l
s

C
o
r
p
o
r
a
t
i
o
n


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

2
0
0
5


C
o
m
p
r
e
s
s
o
r

C
o
n
t
r
o
l
s

C
o
r
p
o
r
a
t
i
o
n


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

2
0
0
5


C
o
m
p
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s
s
o
r

C
o
n
t
r
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l
s

C
o
r
p
o
r
a
t
i
o
n


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

2
0
0
5


C
o
m
p
r
e
s
s
o
r

C
o
n
t
r
o
l
s

C
o
r
p
o
r
a
t
i
o
n

Switching
Module
Connector for
Remote Switch
Module
Status
Indicators
Manual
Switchover
Pushbuttons
Same
Electronics
Assembly and
Terminations
as Reliant SN
Series-5 RELIANT DN

2
0
0
5


C
o
m
p
r
e
s
s
o
r

C
o
n
t
r
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l
s

C
o
r
p
o
r
a
t
i
o
n


Analog Input
Conditioning Modules
Communication
Connectors
Discrete Output
Conditioning Modules
Discrete Input
Conditioning Modules
Series-5 RELIANT SC

2
0
0
5


C
o
m
p
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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

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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

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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
M
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Field
DCS
P
P
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Train Link

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VANTAGE STEAM
TURBINE GOVERNOR

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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

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GUARDIAN OVER-SPEED
TRIP SYSTEM

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API-670 Compliant

2oo3 Voting of
Speed Modules

Redundant Power
Supplies

Hot-Swap Speed
Modules

Modbus Comms
Guardian Over-speed Trip System

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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

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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

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Offshore Platform Application
2 Parallel Trains

RR Avon Gas Turbine Driven Compressors

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3.8%
RR Avon

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3.8%
6,000 Nm
3

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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!

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Offshore Platform Application
Gulf of Mexico
4 Parallel Trains 250 MMSCFD
Demag Delaval 3 section double-barrel compressors
LM 2500 Gas Turbines

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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

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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

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SYSTEM AVAILABILITY

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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.

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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

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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
TRI PLEX
MTBF (Years)
3-2-0
TRI PLEX
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

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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.

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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

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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

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SPECIFICATIONS
ERRORS

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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%

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Specifications
Writing a good, tight specification is very
important

Dont just focus on the hardware

Dont fall into the instrument upgrade trap

Demand value and try to specify it

Focus on
System performance
Algorithms
Proven experience on similar applications

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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.

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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.

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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
customers application

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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

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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

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Vanguard

Reliant

Series 5 Systems

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Design Screens

Standard and Customized Screens

On-Line Operation and Control

Alarm and Event Management

Critical Event Archiving Remote Onlook
TM
Diagnostics
Controller Overview
TrainView

Operator Interface
Compressor Map Screen
Control System

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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

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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

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System Design &
Consulting Services
Complete system
design
Right solution the
first time
Complete system
documentation

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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

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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

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Customers keep coming back
80% of
projects are
from repeat
customers