Fccu

Controlling turbomachinery
in the FCCU
Expander performance map
Calculating steps for inlet and bypass valves
Expander operation and control
Equation of motion
The CCC power swapping algorithm
Simplifications
Field results
Conclusion
Introduction FCCU process overview
Air blower control Expander control
Motor-generator control
Steam turbine control
Wet gas compressor control
Help Fwd Previous Acrobat Applications
Introduction to presentation
Power Recovery Train (PRT) in FCCU increases plant efficiency
Steam
turbine
Axial
Blower
Hot gas
Expander
Generator
Many PRTs dont operate at design capacity due to:
mechanical problems
control problems
To get optimum PRT control an integrated control system needs
to be implemented
Breaker opening is (one of) biggest disturbance on PRT

Hot gas
Expander
Advanced control will allow maximum power recovery without
sacrificing FCCU operational reliability
Menu Fwd Previous Rew Help
FCCU process overview
Hot gas
Expander
Orifice
Chamber
Regenerator
3rd stage
Separators
Reactor
Stripper
Flue gas
Cooler
Fractionator
Direct fired
Air heater
Generator
Breaker
SIC
UIC FIC
FIC
PIC DPIC
Section 2 Section 1 Turbine
UIC UIC
SIC
PIC
Axial
Blower
Steam
turbine
Expander control control schematic
Hot gas
Expander
Orifice
Chamber
3rd stage
Separators
Flue gas
Cooler
PIC DPIC
Regenerator
Reactor
Stripper
HSS
Limit control
Process
SIC
Mode selector
Breaker trip - loadshedding algorithm
Process
Orfice
Chamber
3rd stage
Separators
Flue gas
Cooler
PIC DPIC
Regenerator
Reactor
Stripper
Limit control
Mode selector
Hot gas
Expander
SIC
Generator
Breaker
JIC
HSS
Expander Control Loops
Control loops
Reactor/Regenerator differential pressure control
Regenerator pressure limiting
Speed control
Power control (for induction motor/generators)
Control elements
Inlet valve or inlet nozzle vanes
by-pass valves
Process Menu Fwd Previous Rew Help
Equation of motion
Process
Equation of motion:
I dN
dt
J J
2
2
=
+
When power is balanced rotational speed stays constant
Steam
turbine
Axial
Blower
Hot gas
Expander
Generator
Breaker
-13 MW -7 MW +3 MW +17 MW
When power is NOT balanced equation describes rotational
dynamics
Breaker trip - problem definition
Process
Generator breaker is opened due to problems on electrical side
Steam
turbine
Axial
Blower
Hot gas
Expander
Generator
Breaker
-13 MW -7 MW +3 MW +17 MW
Suddenly there is 7 MW excess power to accelerate PRT
Conventional systems rely on PID control to control speed
PID control is too slow to catch disturbance
PRT trips (in matter of seconds) on:
Overspeed
Other trip settings
Re-directing power is the challenge
Process
Hot gas
Expander
Generator
Breaker
-7 MW
Generator breaker opening causes load
drop of 7 MW
0 MW
Before breaker opening there was
power balance
17 MW is coming from regenerator
process
1
Note 1: We assume the bypass valve to be closed
+17 MW
17 MW was going into the expander
+17 MW
Control objectives after breaker
opening are:
Keep PRT speed constant
Keep differential pressure constant
After breaker opening 7 MW needs to
be shed through bypass valve to
achieve control objectives
+17 MW
+10 MW
+7 MW
This is achieved by simultaneous:
closing of the inlet valve
opening of the bypass valve
Close
Open
The CCC power swapping algorithm
The PRT control system handles the breaker
opening disturbance by:
Monitoring the breaker status
As soon as breaker opens switch to
expander speed control
2

Close inlet valve
Open bypass valve
Enable PID speed control on inlet valve
Re-direct differential pressure control to
bypass valve
In order to perform all functions the
following measurements are necessary:
p
0
, T
0
, p
1
, T
1
, p
2
, T
2

Position of inlet and bypass valves
Power measurement on motor/generator
Breaker status
Process
Hot gas
Expander
Generator
Breaker
Status
Close
Open
Note 2: We assume a synchronous generator
p
0
T
0
p
1
T
1
p
2
T
2
JT
How to calculate the steps on the inlet and bypass valve
The actions have been defined
Determining the magnitude of the steps requires:
Understanding the expander map
Understanding invariant coordinate systems
A whole bunch of calculations
Expander performance map
Typical expander map coordinates include:
Power versus Mass flow
Power versus Inlet pressure
The problem with these (OEM provided) maps is that they are NOT
invariant to inlet conditions
The parameters that typically vary in an expander system are:
Mass flow
Power
Inlet pressure
Inlet temperature
Angular speed
Usually expander characteristics are a weak function of angular
speed
Typical expander maps are not invariant
Most common (OEM provided) expander maps are not invariant to
inlet conditions
Changing from variant to invariant coordinates
Standard map of power versus mass flow is dependent on four
parameters:
Mass flow
Power
Inlet pressure
Inlet temperature
For control purposes the family of curves should reduce to a
single curve in a 2 dimensional space
Data will collapse into single curve using dimensionless
parameters
Dimensionless parameters are obtained through dimensional
analysis or similitude
Reducing the expander with dimensional analysis
Process
Power vs Mass flow
Not Invariant coordinates
Dimensional Analysis
Invariant coordinates
Reduced Power vs Reduced flow
Examples of invariant coordinate systems for expanders
Process
Reduced Power vs Reduced Flow Reduced Power vs Pressure ratio
j
J
p ZRT
r =
1 1
q
w ZRT
p
p
p
r
o
=

=
1
1
1
1
K
A ,
R
p
p
c =
1
2
Reduced power Reduced flow Pressure ratio
Calculating the steps on the inlet and bypass valve
Process
Calculate current
actual expander
power (J
bef
)
Step 1
J
aft

=
J
bef
- J
gen
Step 2
Calculate new
Inlet pressure (p
1
)
for expander
Step 3
Calculate step
on inlet valve
Step 6
Calculate c
v

inlet valve
for q
r,aft
Step 5
Calculate q
r,aft

for expander
Step 4
Calculate Ac
v

bypass valve
for q
r,aft
Step 7
Calculate step
on bypass valve
Step 8
Apply steps to
inlet valve and
bypass valve
Step 9
Step 1: calculate current actual expander power (J
bef
)
Step 1A: the reduced power is defined as:
9 steps
j
J
p ZRT
r bef
bef
, =
1 1
Step 1B: then actual power is:
J j p ZRT bef r bef bef bef = , , , 1 1
Step 1C: an invariant coordinate system is j
r
vs
R
c
, then:
J f R p ZRT bef c bef bef bef = 1 1 1 ( ) , , ,
Reduced Power vs
Pressure ratio
R
c
j
r
Step 1D: assuming Z and R constant for the
operating conditions of the expander, then:
J f
p
p
p T bef
bef
bef
bef bef =
|
\
|
.
| 2
1
2
1 1
,
,
, ,
Step 1E: actual power developed by expander
can be calculated using p
1
, p
2
and T
1
Step 2: J
aft
= J
bef
- J
gen
In order to calculate required power after breaker opening:
Calculate power of expander before breaker trip (step 1)
Subtract measured power on generator before breaker trip
9 steps Menu Fwd Previous Rew Help
Step 3: calculate new inlet pressure (p
1
) for expander
9 steps
Step 3A: we know that:
j f R r c = 1( )
Step 3B: after breaker trip we need:
J j p ZRT aft r aft aft aft = , , , 1 1
Step 3C: using 3A and 3B and assuming Z and R
constant:
J f
p
p
p T aft
aft
after =
|
\
|
.
| 2
1
2
1 1
,
,
Step 3D: this can be rewritten as:
p
J
f
p
p
T
aft
aft
aft
1
2
1
2
1
,
,
=
|
\
|
.
|
Step 3E: assume p
2
and T
1
stay constant when inlet valve closes
Step 3F: p
1
can be calculated by iteration
Step 4: calculate q
r,aft
for expander
9 steps
Step 4A: reduced power j
r
vs reduced flow q
r
is an invariant
coordinate system:
q f j r r , ( ) exp = 3
Step 4B: use two invariant coordinate systems to determine q
r,exp
:
j f R r c = 1( )
and
Reduced Power vs Reduced Flow
j
r
q
r
Reduced Power vs Pressure ratio
R
c
j
r
Step 5: Calculate c
v
inlet valve for q
r,aft
(1)
9 steps
Step 5A: we need to calculate the c
v
corresponding to the new q
r,aft
Step 5B: flow equation for valves from ISA standards:
w N F c p Y
x MW
T Z
p v =

8 0
0
Step 5C: multiply both sides by the term :
T Z
MW
0
w
T Z
MW
N F c p Y x p v

=
0
8 0
Step 5D: this can also be written as:
w
T Z
MW
p
N F c Y
p
p
p v

=
0
0
8
0
A
Step 5: Calculate c
v
inlet valve for q
r,aft
(2)
9 steps
Step 5E: the factor

, therefore:
( )
Y
x
F x
f R
k T
v =

= 1
3
4
w
T Z
MW
p
N F c f R
p
p
p v v

=
0
0
8 4
0
( )
A
Step 5F: the factor

, therefore:
( )
Ap
p
p p
p
p
p
f Rv
0
0 1
0
1
0
5 1 =

= =
w
T Z
MW
p
N F c f R f R p v v v

=
0
0
8 4 5 ( ) ( )
Step 5: Calculate c
v
inlet valve for q
r,aft
(3)
9 steps
Step 5G: the function f
4
and f
5
and the constants N
8
and F
p
can be
combined into a new function, thus:
( )
w
T Z
MW
p
f R c v v

=
0
0
6
Step 5H: we defined , thus:
q
w
T Z
MW
p
r inlet , ~

0
0
q f
p
p
c r inlet v , =
|
\
|
.
| 7
0
1
Step 5: Calculate c
v
inlet valve for q
r,aft
(4)
9 steps
Step 5I: q
r,inlet
can also be calculated by pressure compensation on
q
r,exp
, assuming T
0
=T
1
and Z
0
=Z
1
:
q q
p
p
r inlet r , , exp =
|
\
|
.
|
1
0
Step 5J: combining step 5H and step 5I, we get:
c
q
f
p
p
p
p
v inlet aft
r aft
aft
aft
, ,
, exp,
,
,
=
|
\
|
.
|

|
\
|
.
|
7
0
1
1
0
Step 6: Calculate step on inlet valve
9 steps
Step 6A: determine actual position of valve from position transmitter
Current valve
position
Step 6B: lookup actual c
v,inlet,aft
from valve characteristic
c
v,inlet,aft
Step 6C: determine new valve position after breaker trip
New valve
position
Step 6D: step is current valve position minus new valve position
0
10
20
30
40
50
60
70
80
90
100
1
0
2
0
3
0
4
0
5
0
6
0
7
0
8
0
9
0
1
0
0
% maximum opening
%

m
a
x
i
m
u
m

C
v
Step 7: Calculate Ac
v
bypass valve for q
r,aft
9 steps
To keep p
0
constant total mass flow needs to stay constant:
w
total
= w
inlet
+ w
bypass
Inlet and bypass valve have same inlet conditions, then:
q
r,total
= q
r,inlet
+ q
r,bypass
The q
r,bypass
needs to be increased by the drop in q
r,inlet
We now calculate:
Ac
q
p
p
q
p
p
f
p
p
v bypass
r bef
bef
r aft
aft
,
, exp,
,
, exp,
,
=

|
\
|
.
|
|
\
|
.
|
(
|
\
|
.
|
1
0
1
0
8
0
2
Step 8: Calculate step on bypass valve
9 steps
Step 8A: determine actual position of valve from position transmitter
Current valve
position
Step 8B: lookup actual current c
v
from valve characteristic
Current c
v
Step 8C: Add Ac
v,calc
to C
v,current
Ac
v,calc
Step 8D: From new c
v,aft
determine new valve position
New c
v,aft
New valve
position
0
10
20
30
40
50
60
70
80
90
100
1
0
2
0
3
0
4
0
5
0
6
0
7
0
8
0
9
0
1
0
0
% maximum opening
%

m
a
x
i
m
u
m

C
v
Step 9: Apply steps to inlet valve and bypass valve
9 steps
Step 9A: calculate actual steps to inlet valve and bypass valve:
A A Output Output C inlet act inlet calc , , = 1
A A Output Output C bypass act bypass calc , , = 2
Step 9B: apply calculate steps to inlet and bypass valves
Simplifications
When not all data is available simplification can yield good results
Characterize power as function of valve position
Power
Valve position
Linear relationship between Apower and Avalve
AJ
Avalve
Limitations of the simplifications
Limitations:
Relationships are very non-linear
Simplifications are only valid in limited operating range
Errors increase with deviation from design conditions
Nevertheless:
It is better to do something than to do nothing!
Field results
Control system tuning was tested using dynamic simulation
Actual control system was interfaced with simulation
Full generator load rejection resulted in 200 RPM speed excursion
Steam
turbine
Axial
Blower
Hot gas
Expander
Generator
Breaker
18 MW 11 MW 10 MW 24 MW
Test was repeated in the field under full load conditions on FCCU
Generator load rejection resulted in only 30 RPM speed excursion
Conclusion on power swapping algorithm
The power swapping algorithm significantly increases
controllability of PRT during breaker opening
PRT can then be operated at higher recovery rates without
sacrificing FCCU operation reliability
Simplification of algorithm can still yield good result but accuracy
diminishes
Due to economic effect pay-back period on new control system
can be extremely short
Air blower control
Axial blower
Direct fired
Air heater
FT TT PT
FIC FT
TT
PT
TT
PT
ZT
UIC
Process
Air blower provides air to regenerator
FIC controls mass-flow via stator vanes or IGVs
UIC protects compressor from surge
FIC and UIC are de-coupled to avoid oscillations
during low load conditions
Motor-generator control
Power limiting in motoring mode
Power limiting in generating mode
Auto-synchronization for isochronous generator
During startup
After breaker trip
Steam turbine control
Steam turbine
HSS
1
SE
B
SE
C
SE
A
SIC
1
FT
2
FIC
2
TIC
3
TT
3
SIC provides speed control during startup
Speed control disabled in grid operation
FIC limits steam flow to minimum required
level
TIC limits exhaust temperature to maximum
level
Bumpless transfer between all functions
Wet gas compressor control
Section 1
FT
TT
PT
TT
PT
Section 2
FT
TT
PT
TT
PT
UIC
1
UIC
2
PT
1
PIC
1
SIC
1
SE
1
Wet gas compressor maintains pressure in overhead accumulator
Output of pressure controller PIC-1 is setpoint for ST speed
controller SIC-1
UIC-1 and UIC-2 protect compressor sections from surge
All controllers are decoupled to avoid oscillations during different
load conditions
Some typical wet gas compressor configurations
Section 1 Section 2
Section 1 Section 2
Some typical wet gas compressor configurations (contd)
Section 1 Section 2
Section 1 Section 2

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Controlling turbomachinery

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