KRA PROJECT REPORT ON WGC CONTROLS AND OPERATION

U. SREENIVASU Date : 31st March 2001

1. INTRODUCTION
2. ANTISURGE CONTROL SYSTEM
3. WGC CONTROL SYSTEM
4. MODIFICATIONS
5. CONCLUSIONS
6. ANNEXURE
 INTERLOCKS
 FALL BACK
 STARTUP /SHUTDOWN SOP

A. INTRODUCTION :
The wet gas compressors (WGC) are manufactured by Mitsubishi Heavy
Industries , Ltd. The compressor system consists of two trains, each train is a two – stage
centrifugal compressors driven by steam turbine and with interstage coolers,. The two
trains are operating in parallel with antisurge control on each stage, loadsharing between
the two trains, and performance control for the compressor system .The antisurge controls
and the load sharing controls are by CCC. This project concentrates on understanding the
existing CCC logics in a better way and to incorporate new controls / logics for better
operational reliability.

B. ANTISURGE CONTROL SYSTEM :

SLL
SOL SCL

Operating
point

P, H, Pd NEW SCL AFTER SO

Tdo*dS/dt = 1
(fast)

Tdo*dS/dt = 0
(slowt)

b1 b2 Q, Q2
  Operating point (OP) ; The point on the compressor map that represents the current operating
location of the compressor.
 PI response ; The closed loop response of the antisurge controller.
 Recycle trip line (RTL) ; the line of the compressor map where the open loop RT response is
triggered.
 Recycle trip (RT); The distance between (RTL) and (SCL).
 Surge control line (SCL) ; The line on the compressor map where DEV has a zero value. If the
OP is left of the SCL then the recycle valve opens. If the OP is right of the SCL then the recycle
valve closes.
 Surge limit line (SLL) ; the line on the compressor map which represents the where surge
happens. If the OP is left of the SLL surge occurs.
 Safety on (SO) ; The distance between the SLL and the SOL.
 Safety on line (SOL);– The line on the compressor map where the controller recognizes surge and
the safety on response is triggered
 Anti surge PI response : A proportional – integral response of the antisurge controller to
manipulate the recycle valve based on the Deviation.
 Derivative response : A response of the antisurge controller where the (SCL) moves to meet the
operating point. How far the line moves is dependent on the speed of approach of the operating
point (Tdo*dS/dt) multiplied by the value (b3). This is done so the the recycle valve can open
sooner for a fast disturbance.
 Recycle trip response - an open loop response where the recycle valve is stepped open in
response to crossing the recycle trip line (RTL), causing the operating point (OP) to go back to
the surge control line (SCL)
 Safety on response : A response where the (SCL) and (RTL) are moved to a safer location (by the
amount b2). The operator should determine the cause of the safety on response and “RESET“ the
Safety on.
 Deviation (DEV) : The distance between the SCL and the OP. A positive value indicates the OP is
to the right of the SCL. A negative value indicates the OP is to the left of the SCL
 Width of safety margin (b) : The distance between the SCL and SLL based on the equation :
b = b1 + (b2 n) + (b3*T dO*dS/dt)
Where
b1 is initial safety margin – minimum distance between SCL and SLL
b2 is safety on bias – distance added to SCL each time surge is detected.
b3 – Derivative response – a response of the antisurge controller where the SCL moves to meet the
operating point.
 Falback : An alternate operational strategy to maintain the same level of surge protection in the
event of a required input failure.
 Limit : A response of the antisurge controller that can override the normal PI control based on a
secondary variable (Ps), (Pd) or (Rc).

C. WET GAS COMPRESSOR CONTROL SYSTEM

CONTROL SYSTEM PRIMARY OBJECTIVES;

 Antisurge control for each stage ; Train A. first stage , Train A second stage, Train B first stage
, and Train B second stage.
 Main column receiver pressure control

CONTROL SYSTEM SECONDARY OBJECTIVES ;

 Parallel loadsharing performance control which balances the loading of each compressor train
 Pressure override control with first stage antisurge control loop to elevate/restore main
column receiver pressure , if the column receiver pressure cannot be maintained by speed
modulation alone.
 Feedforward control loop decoupling between the loadsharing controllers and the antisurge
controllers.
 CONTROL SYSTEM FEATURES;
Duplex redundancy for the Master pressure controllers, load sharing controllers, and antisurge
controllers.
Redundent serial communications for operator interface through DCS
Turbine speed tracking, when the speed governor is not in the Remote set point mode.
Bumpless transfer between turbine speed tracking to normal control in the loadsharing controllers.

C.1 ANTISURGE CONTROLLER;

Each of the antisurge controllers uses five analog inputs to determine the location of the operating
point.
 Compressor suction flow
 Compressor suction pressure
 Compressor suction temperature
 Compressor discharge pressure
 Compressor discharge temperature

If the operating point of the compressor crosses a surge control line, the antisurge controller
will employ advanced closed loop and open loop surge control responses to modulate the recycle
valve. The surge surge control line is biased from the surge limit line in a dynamic manner that is
designed to provide adequate surge control with the minimum amount of necessary recycle.
In addition the antisurge controller will participate with its Master performance controller to
modulate the compressor’s throughput based on the latter’s load sharing response when the
compressor is recycling.
When process conditions dictate that both compressors of the same stage in each train operate
with continuous recycle , then the antisurge controllers will coordinate their control responses so
that the recycle rates of both compressors will be equalized. This feature can be disabled by
energizing the Disable recycle balancing discrete input.
Note :During commissioning , it was noticed that reverse rotation on the compressor
occurred during shutdown. Thus in order to prevent the above situation, a purge request is added
via hardwired discrete input to the first stage antisurge controllers whenever shutdown occurs.
During purge mode, the antisurge controller will keep its antisurge valve at fully closed position
during shutdown mode.

Controller operating states :

Shutdown state :
The controller assumes the SHUTDOWN operating state when the turbine speed goes
below a configured threshold ( 3100 RPM)
The SHUTDOWN operating state holds the recycle valve fully open, so that any high-
pressure gas leaking through check valve can flow around the compressor. This prevents surge
while the compressor is idling and protects against reverse flow when the compressor is stopped.
Starting state :
The STARTING state will be selected by the controller when the turbine speed goes
above a configured threshold (3100 RPM)
When in the STARTING state, the controller closes the recycle valve at configurable
start rate parameter, which is usually set to be faster than the normal PI control response. When the
recycle valve is closed (controller output reaches low clamp), or the deviation becomes lower than
deviation threshold the compressor automatically enters the RUN state.
RUN state ;
The antisurge controller modulates the recycle valve as needed to achieve its surge
control objectives.

C.2 MASTER PERFORMANCE CONTROLLER;

The master performance controller controls main column receiver pressure as its primary
process control variable. The controller receives one transmitter input that is proportional to main
column receiver pressure. The controller output is sent to the loadsharing performance controllers
 to be used as their set points. The load sharing controller in turn control the speed governor set
point. In addition, Master performance pressure controllers generate a load balancing set point
that will be used by the load balancing set point that will be used by the load sharing performance
controller of each of the two individual trains, to also modulate its set point to the speed governor,
so that the two parallel trains are operating at equal speed.
Another feature that is Pressure override control (P.O.C). when the turbine rotational
speed is lowered to the minimum governor speed to maintain the suction K.O. drum pressure, the
first stage antisurge controller can coordinate with master performance controller to open the first
section antisurge valve as necessary to elevate/restore the drum pressure. When the process
conditions restore, the antisurge valve is allowed to close first, before resuming speed modulation
for pressure control.

RUN state :
The RUN operating state maintains automatic control of train throughput using its PID
algorithm. The controller PID error and set point are initialized to values that provide bumpless
transfer into the RUN state.
When in the RUN state, the following control functions are performed
 Main column receiver pressure control
 Limiting control
 Load sharing
 Load balancing
 Automatic fall back

MANUAL state :
The MANUAL operating state allows the operator to directly control the output of the
controller, thereby allowing the operator to “manually” increase or decrease overall train
throughput via the load sharing controllers (not available from DCS). When toggled into the
MANUAL state , the MANUAL target parameter is initially set to the current controller output to
provide a bumpless transfer. The operator may then change the manual target parameter value by
asserting the UP or down discrete inputs. When in the Manual state, the controller’s set point
tracks the control variable to allow bumpless transfer back into the RUN state.

C.3 LOAD SHARING PERFORMANCE CONTROLLER;

Load sharing control consists of two load sharing performance controllers. These
controllers receive their set points from the master performance controller and operate in a
parallel load sharing configuration. The output of each load sharing controller modulates the
remote set point of the speed governor.
Parallel load sharing involves two different control responses. The first response, referred
to as primary capacity control, allows the master performance controller to regulate main column
receiver pressure by indirectly manipulating the compressor’s capacity and antisurge control
elements . This response throttles the compressor in response to change in the master controller’s
output , unless that would reduce throughput to the point that the compressor might surge. In that
case, compressor performance would be reduced by the antisurge controller’s loadsharing
response which opens the recycle valve.
The second response is known as load balancing. In parallel load balancing, each
antisurge controller reports its operating point, or distance from surge, to its companion load
sharing performance controller. The performance controllers then report these values to the master
performance controller, which averages them and sends the average valve back to each of the
performance load sharing controllers to use as set point. This process results in each compressor
operating equidistant from surge, which minimizes unnecessary recycle.

SHUTDOWN state ;
The controller assumes its shutdown state when the stopping sequence is ended. In the
shutdown state the output of the controller is held at the pre-configured stop output parameter
value, corresponding to the steam turbine’s minimum governor speed (3200 RPM)
 STARTING state :
The controller goes from its shutdown state into the starting state when the following
conditions are satisfied;
 The stop discrete is cleared
 The compressor speed is higher than the run threshold parameter value for a configured
number of seconds.
When in the starting state , the controller ramps up its output (increasing steam turbine speed from
its stop output value at a rate specified by the configurable start rate 1 parameter value. This ramp
up continues until the following conditions are satisfied;

D. MODIFICATIONS SUGGESTED :

D.1 CHANGE IN THE RAMP UP PHILOSOPHY DURING WGC STARTUP

Present startup :
At present while ramping up WGC during startup , the main column overhead receiver
pressure ( suction pressure ) drops suddenly as the compressor automatically ramps up to 3200
rpm As a result we are continuously flaring from the main column receiver ( during WGC ramp
up ) to maintain the suction pressure .
This has three distinct disadvantages
1. Wastage of money as a result of hydrocarbon flaring
2. Reactor – Regenerator pressure balance upset.
3. Sudden decrease in fuel gas export upsetting the other units

Recommendations :
 Provide a face plate in the DCS where the operator can key in the RPM up to which the
compressor should ramp up - From 1000 rpm to 3200 rpm . (Pl. note the automatic ramp up
crossing the critical speeds still holds good ).
 Reconfigure the “ Speed Increase “ / “Speed Decrease “ PB on the local control panel to
ramp up from 1000 rpm. Pl. note right now this facility is available only after 3200 rpm.

D.2 REDUCING HOT RAMP UP TIME :

At present hot startup and cold start up of WGC takes the same time (50 minutes for
reaching 3200 RPM). The hot start up time may be decreased to 15 minutes after confirmation
with MHI/CCC.

D.3 NEW LOGICS :

The following controls may be incorporated in consultation with CCC :
 Both antisurge valves should step open in case of FCC feed pull out . This will prevent the
compressor from going into surge due to drastic reduction in Main Column overhead pressure
after feed pull out.
 Compressor (1 st stage) low suction pressure override control. This will operate the antisurge
control valve to maintain the first stage suction pressure.
 Compressor (1 st stage) high discharge pressure limiting control : This will operate the
antisurge valve to reduce the discharge pressure. This is done to keep the balance line
pressure and hence the buffer gas delta P healthy at all times..
 Incorporate WGC trip in case pressure difference between buffer gas and balance line is less
than 0.05 kg/cm2 (check with MHI/John crane) for avoiding seal failure.

D.4 CHANGES IN OPERATING PHILOSOPHY:

 Turning gear to be operated in manual mode only for avoiding damage to the gear tooth in
case of maloperation
  Install hard wired bypass switch for bypassing the first stage common suction drum high
level trip .This will avoid unnecessary tripping of the compressors due to fluctuations in the
Level transmitters caused by pressure surges .
 Install software bypass switch for bypassing the steam XV close during steam turbine heat
up.
 Install digital feedback positioner for both antisurge valves .
 Fuel gas (down stream of amine absorber) as buffer gas in case of nitrogen failure. To be
checked with MHI/John crane.

D.5 RELIABILITY :
 Install a spare interstage cooler bundle with isolation valves to be used if there is any leak in
the existing bundles. This will prevent the unit from going down in case of exchanger tube
bundle leak.
 Feasibility study of laying a separate line from the available 12 kscg condensate header at
utilities to be carried out. At present we are dropping the pressure by a let down valve into a
tank and again pumping into the system using separate pumps .With this modification 414
P02A/B may not be required.
 Structure strengthning for avoiding the lines vibrations.

D.6 HSE :
 Install silencers on startup line vents for avoiding noise pollution.
 Extend the seal leak line outside the compressor house from safety point of view
 Extend the Nitrogen purge line outside the compressor house from safety point of view

E. CONCLUSION ;

 CCC logics pertaining to load sharing and anti surge controls have been thoroughly
discussed in this project for better understanding.
 The present start up procedure for WGC has been reviewed and the scope for improvement
pointed out
 Modification in the present start up procedure has been proposed for better operational control
and unit profitability
 New infra structural modifications have been proposed for better unit reliability