AIChE

Technical Paper
ChallengesAffectingProcessControlWhen
OperatingCentrifugalCompressors
Tony Andraos CountryManager,SaudiArabia
CompressorControlsCorporation

Challenges Affecting Process Control When Operating Centrifugal Compressors

Tony Andraos Country Manager, Saudi Arabia
Introduction

Pressure

The process objective of a centrifugal compression train control system is to keep the
primary process variable (PPV) (typically suction pressure in most processes) on set
point, and to return to set point as quickly as possible after a process disturbance. The
operating point must be keep within the safe train operating envelope (figure 1)
considering limits such as surge, speed, stonewall, pressure and power.

Speed Limit (Maximum)

Surge limit
Stable Operating Zone

Stonewall or
choke limit

Speed Limit
(Minimum)

Flow
Figure 1 Train Operating Envelope (critical speeds and useful speed range
omitted)
The standard control objectives are listed below with the control application/device in
which the control resides shown:

Personnel and Equipment safety (antisurge control and over-speed prevention

devices)
Prevention of surge within expected disturbances (antisurge control)
Recovery from surge resulting from larger than tuned for disturbances (surge
detection)
Control of the Primary Process Variable (PPV) within defined variation
(performance control)
Minimized flaring (flare control)
Load balancing of parallel or series compressor networks (load sharing control)

Operation within system limits (control functions incorporated within antisurge,

performance/load sharing controllers)
Control of driver (GT fuel control, steam turbine speed-extraction-induction
control)
Integration of control functions minimizing loop interaction (decoupling control
incorporated in other controllers)
Sequencing for start-up/stop (logic functions incorporated within other controllers)

Many factors affect the ability of the control system to operate optimally. These include
the design of the compressor recycle path and availability of field instruments (e.g. a flow
element). While it is easy to incorporate correct designs into new construction projects it
is sometimes very difficult to change piping or vessel location when retrofitting new
controls in existing plants, so it falls on the control system designer to provide the best
possible solution. Interesting challenges already addressed include some very difficult
situations like steam turbine driven compressors operating in parallel but without
compressor flow elements to map the operating point.
Urea plant CO2 compressors sometimes fall into this challenging category and this
interesting case is explained in some detail below.
Background
Large world scale urea plants typically employ an extraction/induction steam turbine
driving a two body, four section centrifugal compressor to compress CO2 from near
atmospheric pressure to more than 150 bar g. Older installations originally installed with
pneumatic compressor controls usually act on a single recycle valve (figure 2). These
compressor trains were invariable operated in manual control and only allow operation
above 95% load. No recycle cooler was required due to the JT effect of the gas
expansion across the recycle valve.
Speed
Increasing
Gear

Section

Section

Section

Section

Figure 2 Typical compressor arrangement (start-up vent/recycle lines omitted)

During a new construction project using this same format, but with a requirement for high
performance antisurge control, a system was designed with an antisurge controller on
the third section (the only section with a flow element) and with manual speed trim for
capacity control. When conducting a surge point verification test (a routine procedure for
new installations) the compressor experienced a 300 second multiple cycle surge event
(figures 3 & 4).

Flow
Rc
Rc

Flow

Figure 3 Surge Event, First Section

Figure 4 Surge Event, Fourth Section

It was observed that the output of the antisurge controller correctly called for full recycle
valve opening and that the valve action was correct. A question on valve sizing thus
remained. Clearly there was a need to investigate the event more fully and design a
corrective solution.
Aim
The aim of this paper is to outline the steps taken to uncover the root cause of the
problem and to design an effective control solution.

Methodology
The standard procedure for developing control algorithms or solutions is as follows:
1. See and understand the need
2. Model the conditions mathematically to arrive at a theoretical solution
3. Simulate the solution using a computer simulation
4. Prove the solution in the field
Computer Simulation
A high fidelity dynamic simulation was conducted using a model built using the
compressor makers section performance curves and the job piping isometrics and
vessel data sheets. The results were very informative. As would be expected with such
a high pressure ratio compressor requiring a speed increasing gear to raise the speed of
the second compressor body, the first section impellers was much larger than the fourth
section. This resulted in section (or stage) mismatch where the behavior of the
compressor sections interfered with one another (figure 5).

Figure 5 Section Mismatch (note operating point at surge flow limit for section
one while in choke conditions for section 4)
Trend plots data from the surge event confirmed this exact scenario; repeated surge in
section one compounded by choke conditions in section four. Simulation confirmed that

the situation would be contained when the recycle duty was handled by two valves; 4/3
and 2/1.
Valve Sizing
Various valve sizes were modeled in the computer simulation but it was found that no
performance improvement was possible by increasing the valve flow. In fact, the
conclusion was reached that a large process disturbance causing a collapse of flow
would result in a surge event regardless of valve sizing.
Solution
The best solution selected, and eventually proven, was to incorporate speed as a
component part of the antisurge protection. This required a variable speed governing
system for the extraction/induction steam turbine and a pressure controller to
automatically trim speed to maintain the PPV on set point (figure 6). The resulting
integrated system combined valve opening and speed adjustment (increase) when the
antisurge controller reached its surge control line set point. To provide a more precise
indication of operating point versus section surge limit/surge control line set point, the
antisurge controllers were moved to the first and fourth sections. An automatic start-up
was also possible by automating the fourth section vent valve and providing a close
signal from the fourth section antisurge controller. In all tested cases the 2/1, or 1/1,
start-up recycle line could remain closed during an automatic start.
It should be noted that the effective speed range for a CO2 compressor is quite limited,
so the automatic control of the PPV will be via speed and recycle.

Figure 6 Full Control Solution (steam turbine induction control omitted)

Interestingly enough, the single valve/single controller installations eventually proved

quite reliable when run at constant speed and with manual speed trim for process control.
Antisurge responses of opening the valve created some pressure disturbance, but in
those cases where adequate pipe volumes existing before and after the compressor, this
disturbance was within acceptable limits. Final protection was provided by a trip function
based on detection of multiple surge cycles. For installations with small inlet/discharge
volumes this single controller and manual speed trip arrangement proved unworkable.
Benefits
Documented compressor/process controllability improvements include elimination of
process disturbance related trips, greater plant turndown, operating at small recycle
levels not previously possible, automated start-up and lower energy consumption.
Unexpected Benefits
The correction of compressor/process controllability issues was always the primary aim
of the many retrofits completed. However, correction of this problem allowed access to,
and correction of, a steam balance problem where the steam turbine extraction pressure
could be controlled precisely and without live steam bypass. The energy saved in the
live steam alone almost always paid for the project retrofit cost within one year of
operation.
Conclusions
1. New installations should employ two recycle valves, 4/3 and 2/1.
2. Antisurge protection should be applied to the first and final sections.
3. Variable speed control is needed to contribute to antisurge protection.
*************
Acknowledgements:
Batson B.W. and Nicholson E.G. initial study
References:
Batson B.W.- Challenges of Controlling CO2 Compressors in Urea Plants
Mirsky S. - Control of CO2 Compressors in Urea Plants
Yuan Y. Z. - Retrofit the Control System of CO2 Compressor Train and Operating
Experience (Published in Chinese)
Zaghloul, M. M, - Developing Effective Control Strategies for CO2 Compressors in Urea
Plants