Beruflich Dokumente
Kultur Dokumente
Compressor Control
Technical Product Guide
Single Stage
Inter-cooled
Refrigeration
COPYRIGHT
by Triconex Systems, Inc. La Marque, Texas, U.S.A.
All rights reserved. No part of this work covered by the copyright hereon may be reproduced or copied in any form or by any meansgraphic, electronic, or mechanicalwithout first receiving the written permission of Triconex Systems, Inc., La Marque, Texas, U.S.A.
NOTE: Triconex Systems, Inc. reserves the right to make improvements in the design, construction, and appearance of its products without prior notice.
Table of Contents
What is Surge? ....................................................................................... 7 Performance Curves ............................................................................. 7 Curve .................................................................................................. 7 Compressor Map ................................................................................... 8 A Universal Surge Curve .................................................................. 13 Determining HP/A02 .................................................................................................................................. 13 Determining (Q/A0)2 .................................................................................................................................. 14 Plotting the Surge Line ...................................................................... 14 Summary of Features ......................................................................... 21 Choice of Pressure Rise or Pressure Ratio Algorithms ............... 22 Safety Margin Recalibration ............................................................ 22 Setpoint Hover .................................................................................... 22 Dynamic Adaptive TuningTM ...................................................................................................... 23 Non-symmetrical Valve Response .................................................. 23 Purge and Start-up Logic................................................................... 24 Manual Control ................................................................................... 24 Proportional Function ........................................................................ 24 Valve Prep ............................................................................................ 25 Dump Output ...................................................................................... 25 Valve Linearization and Reversal ................................................... 25 Compensated Recycle Temperature Controller ........................... 25 Process Pressure Control ................................................................... 29
Compressor Surge
This document describes the implementation of a centrifugal compressor surge control in the TRISENTM digital governor or control system.
in work done per unit mass of the fluid. Foot pounds per pound (ft-lbf/ lb) and kilojoules per kilogram (kj/kg) are the common English and Metric units. For a given impeller design, diameter, and rotational speed, the amount of work energy expended is dependent on the volume flow at the suction. A0; that is, for a given compressor speed, there is only one valid set of gas properties (MW, Z and k) and suction temperature (Ts). If the gas composition and/or suction temperature is variable, multiple curves must be provided to show the performance of the stage. See the previous figure.
What is Surge?
Surge occurs in a turbo compressor when discharge head cannot be sustained at the available suction flow. Surge occurs at specific combinations of head and flow, as defined by the compressor manufacturer's performance curves. One or more of the following can result from surge: Unstable operation Partial or total flow reversal through the compressor Disrupted process Mechanical damage to the compressor
Curve
Compressor manufacturers use "" curves to define the performance of
The polytropic head developed for a given fluid (gas) and inlet conditions is proportional to the pressure coefficient "," as defined by equation (1).
1.4
1.2
2 3 1
100
1.0
Surge is usually accompanied by the following: Increase in discharge temperature Reduction in discharge pressure Increase in vibration Sharp rise in inlet temperature
.80
80
p
2 1 1 2 3 3
Polytropic Efficiency 60 p
40
.20
20
10
20
30
40
50
60
70
80
% Q / N
Performance Curves
A turbo compressor imparts energy to the gas by accelerating it through a rotating impeller to increase its velocity and pressure. This kinetic energy is then converted to a higher pressure in a diffuser. The amount of energy imparted to the gas is defined
Figure 1individual impeller stages. A typical "" curve is shown in Figure 1. "" indicates the polytropic head provided by the stage for a given volume flow at the suction. Each "" curve is specific for a given N/ 7
Impeller
Equation (1)
Hp =
where:
U2 g
Compressor Surge
Hp = Polytropic head = Pressure coefficient of the impeller for the specific gas U = Impeller peripheral velocity ft/sec g = Gravitational constant 32.17 ft/sec2
Compressor Map
While the "" curves are a tool used in the design stage, the final compressor characteristic is defined by a performance curve, or compressor map. This is a series of impeller "" curves combined as a multistage compressor. An example is shown in the next figure. NOTE: The Hp versus Q curve is good for one set of gas conditions (A0) only.
significant deviations from this ideal curve. As the speed increases, surge moves to later impeller stages, due to volume reduction by the initial stages, and consequent lower suction volume flow available to the later impeller inlets. The next figure is an example. Compressor performance maps are presented in various forms. Most provide a basic performance plot, as shown in Figure 3, but with additional curves, relating inlet temperature, molecular weight, pressure ratio, suction pressure, and driver horse-
In the Figure 1 example, the two sets of three curves indicate the performance of the impeller for three different gas conditions. The term A0 is used to define the sonic velocity of the gas at the suction conditions and is determined by equation (2).
80
Surge Line
Equation (2)
60 Hp Polytropic Head 40 (1000 Ft lbf/lb) 20 80% 0 0 500 1000 1500 2000 2500 Q - Inlet Flow (acfm) 105% 100% 90% Constant Speed Lines
A0 =
where:
1545 k Z s Ts g MW
A0 = Sonic velocity of the gas at the inlet conditions (ft/sec) k = Ratio of specific heats Cp/Cv Zs = Compressibility factor Ts = Inlet temperature R g = Gravitational Constant, 32.17 ft/sec2
The upper set of curves, in conjunction with equation (1), relate Hp to Q/ N (inlet flow (acfm)/speed (RPM)). The lower curves relate Q/N to polytropic efficiency hp. Curves 1 through 3 show performance for heavy, medium, and light gases, respectively. The left extreme of each line indicates the surge point.
Figure 2 Compressor Performance Map The Surge Line is not linear with respect to flow. In a low head, single impeller machine, compressing a light gas such as air, the surge line tends to follow the fan law. This law states the following: Capacity is proportional to rotating speed. Head is proportional to the inlet flow squared. Power required is proportional to the speed, cubed. Multi-impeller high head machines can have surge lines which have 8 power. Design gas conditions, such as compressibility factor (Z), and specific heat (k) are usually noted. If Ts and/or MW are variable, several surge curves may be plotted, showing surge limits for different gas compositions and suction conditions. From a surge control standpoint, the challenge is to keep the compressor out of surge without wasting energy on excessive recycling. This requires that the surge point be precisely computed from measurable, compres-
Compressor Surge
sor-operating conditions. This goal will be addressed in the construction of the Surge Line. First, we will describe how the TRISENTM system uses the recycle valve to avoid surge.
80
60 Hp Polytropic Head 40 (1000 Ft lbf/lb) Surge Line 105% Speed 100% Speed 90% Speed 20 80% Speed
Compressor Surge
NOTES ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________
10
Avoiding Surge
In the gas compressor section (Figure 4), surge can be avoided by recycling a controlled portion of the discharge flow back to the suction through a recycle valve. Recycling raises the suction pressure and lowers the discharge pressure, which increases flow and moves the operation away from surge. Raising speed also moves the compressor away from surge. This is a temporary solution because it also raises Pd and lowers Ps, which tends to drive the machine back towards surge. In the air compressor section (Figure 5), a blowoff valve is used to vent the compressor discharge to atmosphere. This does not affect the suction conditions, but it reduces discharge pressure and increases flow, which moves the operating point away from surge.
Suction
Recycle Valve
Suction
Discharge
11
Avoiding Surge
NOTES ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________
12
Ts =
MW=
Rc = =
where:
ity factor (Zs + Zd)/2 Suction temperature (degrees absolute) Molecular weight Compression ratio (Pd/Ps) Polytropic exponent
Determining HP/A02
Let us first examine the Head variable Hp/A02:
k 1 k p
Equation (3)
1545 Z a Ts ( R c 1) Hp = MW
where:
Equation (4)
A0 =
Surge Line
1545 k Z s Ts g MW
where:
Hp A0 2
90% 80% 105% 100%
N
%
A0 Q A0
2
A0 = Sonic velocity of the gas at the inlet conditions , ft/sec k = Ratio of specific heats Cp/Cv Zs = Compressibility factor Ts = Inlet temperature R g = Gravitational constant, 32.17 ft/sec2
Therefore: Equation (5)
Ts MW Ps
= = =
Za/Zs increases predictably with increasing head so it can be accommodated in the surge line. So by cancellation: Equation (6)
Hp R - 1 = c 2 k A0
h Z s Ts Q MW Ps = k Z s Ts 1545 A0
2
Because Q2 is proportional to h, the new curve no longer follows the fan law. A classic low head application will have a surge line that is closer to a straight line. At high heads, the surge often moves to a different impeller. Therefore, high head applications will still exhibit non-linearity. A typical surge curve may now look like Figure 7. Some applications can use a simpler variation of this surge computation technique. If both the head term (Pd/ Ps-1) and the capacity term (h/Ps) are multiplied by Ps, these terms reduce to Pd-Ps for the head and simply h for the capacity. However, there is a disadvantage of the Pd-Ps method, or Pressure Rise method. If the surge line is nonlinear and the suction pressure is variable, then errors will result when operating on a section of the curve that does not pass through the origin. If the surge line is linear or if the suction pressure is reasonably constant, this method is perfectly acceptable and can be used with confidence.
MW
Simplifying and canceling:
k 1 And substituting: = k p
Equation (7)
Q h = Ps k 1545 A0
A0
k1 k p c
- 1 k - 1 p
An analysis of equation (7) with actual compressor data shows that Hp/ A02 is minimally affected by minor variations in k and p, and is predominantly affected by Rc. Recall that Rc=Pd/Ps and the challenge has been met. The variables Pd and Ps are readily measured by conventional pressure transducers.
Because k appears in the denominator of both terms of Hp/A02, and Q2/A02, its effect is further minimized. If changes in k are ignored, the surge curve can be plotted as a function of Pd/Ps and h/ Ps. The relationship h/Ps is another way of saying h compensated for changes in Ps.
100
75
Pd/Ps
Determining (Q/A0)
50 90% 25
100%
% Speed 80%
Q2 =
where:
h Z s Ts MW Ps
Q h Zs
FT h SC
PT p I
P Recycle or Blowoff
Compressor
Suction
Discharge
PT FT Ps h SC I Pd
PT
Recycle or Blowoff
Figure 9 Pressure Ratio Method 15
16
Safety Margin Progressive Control Line Safe Area Constant Control Line
Surge Area
Pd Ps 5 0
25
0 0 20 40 60 80 100
h%
c
Figure 10 Typical Control Line
17
18
1 h Dp or Pd Ps
S urge Line hx
SU LIN
C ontrol Line
C ontroller S etpoint
hx
SU C LN AD M AR
C O N SP
9 H igh S elector
SU C O N
6 C ontroller S
P ID
hx 3 R ecalibrate M P roportional Term
PR O TM M AR G IN
hx 2 S urge D etect hx D um p (D O )
DUMP
V alve P rep
12
SU VLV VA PR EP
S tartup
VA
E nable (D I)
STU P
20
x4 = 92.6 y4 = 5.80
5 Pd Ps
2 1 0 20 40 h/Ps % 60 80 100
x4 = 92.6 y4 = 98.5
80 P
60
40
Setpoint Hover
In most applications, the compressor will not operate continuously, or for extended periods on the Surge Control Line. When operation is to the right of the control line (safe area), the setpoint to the Surge Controller is ramped (at a configurable rate) to within a configurable percent of the current h value. The following occurs after a small, quick movement toward surge, past the hover setpoint: Immediate opening of the recycle valve Hover setpoint is then ramped down (at the same rate) until the recycle valve closes. New operating point is established. If the setpoint reaches the Surge
rSUCLN
rSULIN
Controller Setpoint
rSUCSP
Pd/Ps
3
Hover Setting
2
kHOVER
kHOVRR
100
hx
Figure 14 Setpoint Hover 22
Each time a surge transition is detected, the safety margin is incremented (control line moved to
point. Normal gain is applied when the operating point is on the control line. As the operating point decreases to the left of the control line, a nonlinear increasing function is applied to the gain. As the operating point increases to the right of the control line, the gain will decrease to a minimum at the Setpoint Hover line. Dynamic Adaptive Integral - allows a minimum amount of integration when operating on the Surge Control Line. The Integral value increases nonlinearly as the operating point move away from the control line (either increasing flow or decreasing flow). This technique allows the surge controller to operate near its setpoint with primarily proportional action, yet when the operating point moves away from the normal control line, the restoring affect of the integral action increases.
G ain
N orm al
M in
h/P S
N orm al C ontrol Line
Surge Line
6
C ontroller Setpoint
Pd/Ps
3
H ov er Setting
2
1 0 20 40 60 80 100
h/P S
Figure 15 - Dynamic Adaptive Gain
Manual Control
Integral
M in
Two manual control options are available. The first option provides fullauthority manual control. It allows the valve to be closed, regardless of the action of the Surge Controller. This option is useful for testing and setup, but should not be configured for normal operation. If the system is left in manual operation, the Surge Controller will not be able to open the valve to prevent surge. The second option provides limitedauthority manual control. This option sets a minimum recycle valve limit, allowing the operator to open the recycle valve, but not close it if the controller needs to open it to avoid surge.
h/P S
N orm al C ontrol Line
S urge Line
C ontroller S etpoint
Pd/Ps
H ov er S etting
Proportional Function
The system has a proportional-only term, which forces the recycle valve to open, independent of normal P+I controller action. This occurs, due to a severe process upset, if the operating point moves to the left of the Surge Control Line, and the normal controller tuning provides insufficient response. This term begins to open the valve at a specified margin, to the left of the Surge Control Line, and fully opens the valve as the operating point reaches the Surge Line. In other words, the valve is opened proportional to the instantaneous operating margin, less the initiation value. The proportional term is applied through a signal selector, and the anti-windup action of the controller forces the controller output to track the proportional term.
20
40
60
80
100
h/P S
Figure 16 - Dynamic Adaptive Integral wait for the system to return to normal. is typically configured for one of the following: Always enabled Enabled at minimum governor Enabled by a remote contact or flag from the DCS Before the Surge Controller is enabled, the valve is held at the startup limit. When the Surge Controller is enabled, the start-up signal is ramped closed at a configurable rate
The TRISENTM Surge Controller provides for linearizing the output for an equal percentage trim recycle valve. This tends to produce a more linear overall system gain. Possible instability is avoided when the system operates at a different point than at which it was tuned. Most applications have a recycle valve with an air-fail open action (AFO), requiring reversal of the recycle valve output. The system is configurable for either direct, or reverse, output operation.
hx%
Figure 17 Proportional Function This feature will protect the machine, even if the Surge Controller is poorly tuned. feature requires a special I/P calibration for 6-20 mA input range. The 4-6 mA portion is used to under-pressure the valve closed. If the valve is air fail-open, this feature requires a special I/P calibration for 4-18 mA input current range. The 18-20 mA portion of the range is used to overpressure the valve closed.
Valve Prep
In some applications, the recycle valve is not equipped with a positioner. A positioner fully loads the valve diaphragm or cylinder on closed overtravel. This is undesirable because it takes too much time to bleed off the excess pressure to open the valve. The Valve Prep feature is designed to improve the speed of operation of these applications by the following: When operating away from the Surge Control Line, fully load or unload the diaphragm to positively close the valve. When operation moves within a specified distance of the Surge Control Line, set the loading to "poise" the valve to open. If the valve is air fail-closed, this
Dump Output
When a specified excursion to the left of the Surge Control Line occurs, a contact output can be configured to open a high-volume solenoid to quickly open the recycle valve. This feature is useful on large valves which have slower stroking times. As the system moves back from surge, the solenoid will close. This restores normal proportional control of the valve to the Surge Controller.
FT PT TT
PT TT
PT TT
PT TT
FT
FT
Recycle Valve
B
Tem
Pressure
P2
per atu re
Conventional Temperature Controller Setpoint (fixed)
P1
Enthalpy
Figure 19 P-h Diagram for Refrigerant
27
En
tro
py
28
achieved by adjusting the speed of the compressor and opening the recycle valve. Maximum capacity is reached when the turbine reaches its maximum operating speed and the recycle valve is fully closed. Minimum capacity is reached when the compressor is operating on the recycle line and the recycle valve is fully open. In effect, the Triconex Dynamic Process Control Algorithm is a special split-range controller with a variable breakpoint. The point at which the capacity control switches from controlling the speed to controlling the recycle valve opening is called the Dynamic Breakpoint. This point is dynamic because it is variant depending on the process flow and pressure demands. A conventional split range controller is shown in Figure 20. This type of controller does not take into account the slope of the surge control line. In effect, the split line must be based on the highest operating pressure ratio. The turbine minimum speed is based
100%
100%
100%
P 2 /P 1
Flow 2
Figure 21 - Process Decoupling using Dynamic Break Point 30
S urge Line
Pd Ps h PT PT FT Speed Controller S
P ID
M
D ecoupling
G ov ernor V alv e
P ID
M Surge Controller S
Process Controller
P ID
M Proportional Term
>
Startup
R ecycle V alv e
ST U P
32
Nomenclature
ACFM C Cp Cv FE G h hc Ha Hp k M MW N P Pb Pd Pf Ps Q
R Rc T Tb Td Tf Ts Z
Actual Cubic Feet Per Minute at flowing conditions Constant Specific heat of gas at constant pressure Specific heat of gas at constant volume Primary flow element, orifice, flow tube, etc. Gas specific gravity = MW/28.966 Differential head produced by flow element, usually H20 differential h corrected for suction pressure = h/Ps Head, Adiabatic, Foot-lbs/Pound Head, Polytropic, Foot-lbs/Pound Ratio of specific heats, Cp/Cv Mass flow rate, e.g., Lbs/Minute, Kg/Hr. Molecular Weight, Lbs/mole volume Rotative Speed, Revolutions Per Minute, RPM Pressure, Pounds per square inch absolute, psia Pressure at base conditions, usually 14.7 psia Pressure (absolute) compressor discharge Pressure (psia) at flowing conditions used to specify/calculate primary flow element Pressure (absolute) at compressor suction Gas volumetric flow rate at flowing conditions (e.g., ACFM, SCFM, m3/h, etc.) Gas Constant = 1545.3/MW Compression Ratio, Pd/Ps Temperature, R = F + 459.67 or K = C + 273.15 Temperature at Base Conditions, usually 60F Gas Temperature (R or K) at compressor discharge Temperature (R or K) at flowing conditions used to specify/calculate primary flow element Gas Temperature (R or K) at compressor suction Compressibility factor to correct for the deviation from the ideal gas flow. Density, lbs/Ft3
P MW 10.73 T Z
33
Nomenclature
SYMBOL VARIABLE
C CONSTANT DENSITY
10.73125 0.084784 8.3145 Lbs/Ft3 kg/M3 kg/M3
P PRESSURE
T TEMPERATURE
(k 1)
k
Polytropic
(k 1)
k p
where
p = Polytropic efficiency
34
35
36