Taiwan Compressor Seminar Turbomachinery Controls · PDF fileGas Turbine AVR Compressor...

Turbomachinery Controls (TMC) Integrated Turbine Compressor Controls (ITCC)

Nguyen Duy Dai (David)

Taiwan, June, 2016

Confidential Property of Schneider Electric

Taiwan Compressor Seminar

Confidential Property of Schneider Electric |

Contents

Schneider Electric – Integrated Turbine Compressor Controls (ITCC)

• Triconex Turbomachinery Solution Overview

• Turbine Compressor Control & Protection Overview

• Why Integrated Turbine Compressor Control - ITCC

• Triconex ITCC System Solution Overview

• Triconex ITCC’s Features

• Triconex ITCC Engineering Environments

Triconex Turbomachinery Solution Overview


Turbomachinery Control Scope

Slide 4 Confidential Property of Schneider Electric

Generator Steam Turbine

Actuator with

LVDTs

Compressor

Motor

Gas Turbine

AVR

Compressor

Anti-Surge /

Performance

Mechanical

Retrofit and

Protection

Prime Movers Driven Equipment Auxiliaries

http://upload.wikimedia.org/wikipedia/commons/6/69/Generator-20071117.jpg

SE-Offering Segmentation


Turbine Compressor Control & Protection Overview


Compressor Controls

Main Controllers:

• Anti-Surge Control / Stonewall Control

• Compressor Performance Control

• Low Suction/High Discharge Pressure Override Controller

Auxiliary Controllers

• Seal Gas DP Controls (Seal Gas Press. Differential)

• Lube System

– Pumps/Heaters Control (JOP, AOP, EOP…)

– Oil Cooler Outlet Temperature Control


Compressor Protection

The compressor also need to be equipped with the emergency shutdown systems that

monitor the compressor conditions continuously and can quickly bring the compressor to

safety mode in the event of:

• Loss Compressor Seal Gas

• Loss Lube Oil Pressure

• High Vibration (Axial, Radial)

• High Temperature (Bearing, Loop Oil)


Steam Turbine Controls

Main Controllers:

• Governor Control (Speed Control)

• Extraction/Inlet/Admission Pressure/Flow Control

Auxiliary Controllers:

• Gland Sealing Control

• Howell Level Drum Control (required sometimes)

• Lube Oil Cooler Outlet Temperature Control


Turbine Controls

Auxiliary Interlocks:

• Pumps, Motors Start/Stop (for lube oil system, condensate system)

• Heater Start/Stop

• Turning Gear

• Trip SOVs Online Test

• Turbine Start Permissive


Turbine Protection

The turbine also need to be equipped with the emergency shutdown systems that to monitor

the turbine conditions continuously and can quickly bring the compressor to safety mode in

the event of:

• Over Speed

• Fail Safe

• MPUs Failure

• Low Lube Oil Press (Lube Oil, Control Oil)

• High Vibration (Axial, Radial)

• High Temperature (Bearing, Lube Oil, Extraction Steam)

• Low Inlet Steam Temp.

• Operator – Initiated Trip Slide 11 Confidential Property of Schneider Electric

Why Integrated Turbine Compressor Control - ITCC


Dis-Integrated Compressor Control

Historically, Turbomachinery Control has been managed separately from adjacent processes

and automation strategies. Equipment pieces from various suppliers utilize undisclosed

automation strategies so, in essence, they are unable to ‘speak’ to each other.

Conventional configuration;

• Anti-Surge Controllers provided by compressor control vendor

• Performance/Capacity Controller provided by compressor control vendor or by DCS

• Turbine/Compressor Auxiliary Controllers and Trip/Alarms Interlock provided by others

(DCS and PLC)

• Vibration Monitor System provided by packager


Dis-Integrated Compressor Control

Governor

Local Panel

Control

System

Surge

PLC Gateway

ESD

Vibration

Dis-advantages of Dis-Integrated Compressor Control

With the conventional configuration, it usually has more challenges and dis-

advantage as below;

• Not flexible to modify or expand scope due to many different vendors get involve

• Require more time and effort to putting all of above instruments/controller work together

• Integration testing will be challenges, and usually will be done at site which will lead to be

more surprises at last minus

• More training requires and difficult to be maintained overtime


Dis-advantages of Dis-Integrated Compressor Control


Governor

PT PT PT

FT

Failure of this transmitter

will cause the compressor

recycle valve to open

interrupting forward flow of

the gas, possible tripping

the process.

Failure of this transmitter

will cause the process

cascade to fail.

Integration Systems


Integration solves the hassle of managing multiple ‘black boxes’ by enabling

turbomachinery control elements to communicate with each other, and with

adjacent processes.

• Capabilty to perform more than one control task in a single system

Turbine Governor

Au

x /

In

terl

ock

s

DCS

EWS

ITCC-TMR

Integration Advantages


The benefits of integration are;

• Lower procurement costs

• Lower engineering costs

• Lower installation costs

• Flexible for modification, changes and add-on control scope

• Reduced space requirements

• Lower field instrumentation costs

Integration Advantages (Cont.)


• No controller-to-controller communication delays

• No interconnection of controllers required

• Elimination of controller conflicts

• Easy to coupling and coordination of turbine controls and compressor controls

• Single hardware system training

• Single system software training

• Simplified maintenance

Triconex ITCC Solution Overview


Triconex ITCC Oveview

Integration combines many functions such as machinery protection, prime mover (turbine,

main motors) start-up sequencing, load/speed control, compressor anti-surge control, and

auxiliary control/interlock (such as process control, alarming and tripping for lube oil, seal

gas, condensate, and gland sealing system, etc…) MMC interface INTO a single control

system.

To protect assets and enhance productivity, safety and lifecycle, SE-Triconex has designed

a comprehensive critical compressor control for turbine drive compressor machines. The

ITCC solutions can be tailored to suit a variety of compressor train configurations and

installations.


Triconex ITCC System Solution Overview


Triconex ITCC’s Features


Triconex ITCC Application Overview

Prime movers and compressor combination application


Steam Turbine

Compressor

Motor

Gas Turbine

Prime Movers

Triconex ITCC Application Overview


Trip / Interlock

Motor/Pumps Logic

Auxiliary Controls

Startup Sequence

Prime Mover Ctrl

Anti-Surge Ctrl

Stonewall Ctrl

Quench Temp. Ctrl

Limiter Ctrl

Performance Ctrl

Triconex ITCC - Compressor Controls

Compressor Controls;

• Anti-surge Control

• Stonewall/Choke Control

• Temperature/Quench Control (for refrigeration compressor application)

• Low Suction/High Discharge Pressure Override Control/Protection

• Performance/Capacity Control (Suction/Disch. Pressure or flow Control)

• Auxiliary Control (Seal Gas DP, Temp, Lube Oil…ect)

• Compressor Alarms/Trip Interlock logic

• Machinery Monitoring – Vibration, displacement, friction monitoring


Triconex ITCC - Prime Mover Controls


Steam Turbine Controls;

• Turbine Start-Up/Shutdown Sequence Control

• Governor/Speed Control

• Inlet/Extraction/Admission/Back Pressure Control

• Auxiliary Control (gland sealing control, hotwell level control…etc)

• Turbine Overspeed Protection (EOST/IOST)

• Turbine Alarms/Trip Interlock Logic

• Turning Gear/Pumps/Motors/Trip SOVs Test Interlock Logic




Gas Turbine Controls;

• Turbine Start-Up/Shutdown Sequence Control

• Governor/Speed Control

• Exhaust Temperature Control (Limiter)

• Dual Fuel Switching Control (If applicable)

• DeNox Control



Gas Turbine Controls;

• Auxiliary Control / Interlock

• Turbine OverSpeed Protection (EOST/IOST)

• Turbine Alarms/Trip Interlock Logic

• Turning Gear/Pumps/Motors/Fans, Louvers (Interlock Logic)

• Fire & Gas Protection




Main Motor Controls;

• Start/Shutdown Interlock Logic

• Speed Control (using VFD for Variable Speed Motor application)

• Over Current/Load Limiter Control

• Auxiliary Interlock Logic


Coordination Of Controls


Turbine Controls & Compressor Controls can be coordinated

• Speed Surge Decoupling

• Transmitter Voting / Sharing

• Feed Forward Control

Coordination between turbine speed (load) and Turbine Inlet/Extraction/Admission Header

Pressure Controls

• Speed (Load) / Inlet Pressure Control

• Speed (Load) / Admission Control

• Speed (Load) / Extraction Control

Triconex ITCC Controllers Coordination


DCP

ASC

20.0

45.0

12.0

AUT

PM

FM

Triconex ITCC - TMR Controller


Triconex TMR Platform Features;

• Proven Triple Modular Redundancy TMR PLC Platforms (Tricon-SIL3, Tri-dent-SIL3,

Tri-GP-SIL2)

• Sequence Of Event (SOE)

• Redundant TCP/IP Communication Configuration

• Modbus RS232/485 or TCP Communication

• Embedded OPC Server (optional)

• Detailed Diagnostics of Points of Each Module in System

What is Triconex TMR


Simplified Triconex TMR Architecture

Input Leg

A

Input Leg

B

Input Leg

C

Output Leg

A

Output Leg

B

Output Leg

C

Main

Processor

C

Main

Processor

B

I/O Bus

I/O Bus

I/O Bus

TriBus

TriBus

TriBus

Voter

Main

Processor

A

Input Termination

Output Termination

Auto Spare Auto Spare

Why Triconex TMR


Single Signal

?

Actual Field Condition ?

?

Time

High Alarm Set Point P

rocess V

ariable

Why Triconex TMR


Dual Signals

Time

?

Which Signal

is Correct ?

1oo2 Config = Shut down

High Alarm Set Point

Pro

cess V

ariable

Why Triconex TMR


TMR Signal

Time

High Alarm Set Point

2oo3 = Continue to operate

High Certainty this is

a bad signal

Pro

cess V

ariable

Why Triconex TMR


Dual versus TMR

No Faults on the Modules

Unlimited System Operation

TRICONEX

I/O in TMR Mode

DUAL

I/O in Dual

Mode

Why Triconex TMR


First Fault

TRICONEX

I/O in Dual Mode

DUAL SYSTEM

I/O in Simplex

Mode

A Simplex System has already shutdown !

Why Triconex TMR


Second Fault

TRICONEX

I/O in Dual

Mode

Second Point

marked as

Dual

Dual System shutdown !

DUAL

SYSTEM

Shutdown

Why Triconex TMR


Multiple Faults on Different Points

TRICONEX

Faulted

Points in

Dual Mode

Module is

still Dual

DUAL

SYSTEM

Shutdown

Why Triconex TMR


Second Fault on Faulted Point

TRICONEX

Point is

Marked as

Simplex

Module is

Simplex

DUAL

SYSTEM

Shutdown

Why Triconex TMR


Third Fault on Faulted Point

TRICONEX

Point is

Marked

as Zero

Shutdown

DUAL

SYSTEM

Shutdown

Triconex is TUV certified to Operate with 64 Faults on a Single Module !

Triconex TMR PLC Advantages


• On-line Module Repair/Replacement

Hot Swap I/O Modules

Hot Spares

• On-Line Program Changes

Application program can be modified & downloaded without interrupting turbine/compressor operation

• On-Line expansion

Modules

Chassis

• Diagnostics for each I/O point

• No Single Point Failure

• Proven Multi-Variable Control Algorithms

Availability Safety/

Availability Safety

A failed module can be replaced online

Catch problem before it become a threat to the process

Lifecycle Cost


Example of 30 years lifecycle costs for small process gas compressor and what we can control

0

5

10

15

Initial Cost Maintenance Energy Lost Production

Controllabe

Uncontrollabe

$ Millions

?

Source: “Experiences in Analysis and Monitoring Compressor Performance”

Ben Duggan & Steve Locke

E.I. du Pont, Old Hickory, Tennessee

Presented at the 24th Annual Turbomachinery Symposium

Triconex ITCC – Wonderware HMI


Wonderware is the market-leading industrial supervisory system, it utilize plots, visualization

techniques, and superior templates for real-time control and monitoring.

The HMI provides complete visualization of exactly what’s going on in the controlled and / or

monitored process at all times through high resolution color graphical and tabular displays.

Supervisory controls are issued using a combination of cursor positioning and keyboard

action.

• Friendly user-interface

• Provide high trending resolution, easy for process analysis and troubleshooting

• Easy to manage alarms and events

Typical Functions of ITCC System


Control Logics;

• Governor (Speed) Control

• Inlet/Extraction/Admission/Back Pressure Control

• Anti-Surge Control

• Compressor Performance/Capacity Control (Suction Press, Disch. Press. Disch. Flow)

• Limiter Control (High Discharge, Low Suction Press., High Current etc..)

• Quench Temperature Control

• Stonewall Control

• Auxiliary Control (Seal Gas Diff Press., Gland Sealing Press., Lube Oil Temp., Cond. Level, etc…)

Typical ITCC Functions of ITCC System


Sequence & Interlock Logics;

• Start-up Sequence

• Safety Shutdown Logic

• Alarm Logic

• Turning Gear Motor Start/Stop Logic

• Condensate Pumps Start/Stop Logic

• Lube Oil Pumps Start/Stop Logic

• Lube Oil Heaters Start/Stop Logic

• Startup Permissive Logic

Servo Control Solution

TRICON Bi-Polar Analog Output

•Features• Analog Output current: -60mA to +60mA

• Integrated Servo Control

• Coil feedback for continuous diagnostic

•Benefits• Integrated solution for Turbine Control

• Faster responsive control at millisecond speed

• Highest critical asset availability

AI TermAO Term

Mechanical

Interface

LVDT

Servo

CoilServo

CoilControl

Valve

Bi Polar

Current LVDT *

Interface

modules

AC Signal

Voltage

4-20mA

Triconex ITCC Servo Control Solution


SE-Triconex Offer ITCC Package Service


Full Implementation Service;

• Front-end Studies

• System Design

• Hardware Integration

• Software Integration

• Closed-loop system check-out and FAT

• System Integration Testing

• Installation and Commissioning Support

• Start-up assistance

• Long term maintenance and support

Triconex ITCC – Economics / Benefits


• Better integration capacities and longer lifecycle of the control system (30 years lifecycle commitment for Triconex)

• Improve the machinery protection

• Improve system reliability and availability

• Increase “insurance” against catastrophic failure

• Maximize process throughput

• Flexible to apply any sophisticated control strategy to suit for plant operation efficiency

SE-Triconex True Integration


SE-Triconex can provide the most complete and most effective system available for

controlling, monitoring, optimizing, evaluating, managing, troubleshooting, maintaining and

protecting turbomachinery assets.

Triconex ITCC Engineering Environments

Page 60 Confidential Property of Schneider Electric |

SE-Triconex TriStation 1131 Developer’s Workbench


TriSation 1131 Developer’s Work-bench is an integrated tool for developing, testing and

document safety and critical-process control application for Tricon controller. The

programing methodology, user interface and self-documentation capacities make the

system superior to traditional and competing engineering tools.

TriStation 1131 provides three editors which support IEC 61131-3 languages:

• Function Block Diagram (FBD)

• Ladder Diagram

• Structured Text

SE-Triconex TriStation 1131 Developer’s Workbench


TriStation allows you easy to:

• Create programs, function and function blocks

• Define the controller configuration

• Declare tagnames

• Test applications in an emulator

• On-Line download and monitor application

TriStation also provides:

• Password Security that defines users and their privileges with regard to editing,

library changes, state changes and other operations

Programing/Engineering Environment TS1131


System Configuration;



Easy to develop an application logic

TriStation 1131 Emulator


The Emulator Panel allows you to connect to an emulator, download the control program,

and test and debug the control program. The panel lists the programs, variables, and

tagnames in the control program. Testing can be done by dragging variables and tagnames

from the list to the monitor panel and changing the values as desired. You can specify

commands to run the control program without intervention, to run in single-step, or to halt

the execution.



Example of logic being emulated

Programing Development TS1131


Example of logic being emulated

SOE-Sequence Of Event


Triconex controllers and software include Sequence Of Events capability which provides the

potential to track/analysis events which lead to an unsafe process or system shutdown.

Enhance Diagnostic Management System


Easy for trouble shooting

Intouch Wonderware


Platform For Operational Success

Intouch Wonderware – HMI Development


Intouch Wonderware – Creating A Graphic Objects


Intouch Wonderware – Re-Usable Objects Library


New Wonderware HMI – ITCC Overview


New Wonderware HMI – Startup & Modes


New Wonderware HMI – Surge Overview


Wonderware HMI – Controller Faceplates


High Speed Trend - Trilogger


Trilogger Provides;

• Blazing performance – up to scan rate of Tricon

• Like having a thousand-line strip chart recorder

• The ultimate troubleshooting tool

Trilogger Packages Includes;

• Event Recorder

• Off-Line Playback Utility

• Remote Real-Time Data Monitoring



Trilogger Features

• Event Recoder– Collects data from Tricon, stores event data and acts as server for

Remote

• Playback – Runs on same or separate PC, plays back Event file and converts Event file

to Excel.

• Remote – Allows real-time viewing of data, remote access to data, manual triggering of

Event recorder



• High point capacity (up to 4000 points total)

Up to 2000 analog tags, physical I/O or calculated values

Up to 2000 discrete tags, physical I/O or internal flags

• Tricon driven time base

Multiple time synched Tricons will have synchronized event files

Remote connections will see the local Tricon time

• Multiple Event Triggers

Analog event triggers (high, low or both)

Discrete triggers on rising or falling edge

Every point can trigger an event

• Up to Thirty minutes of high speed data stored with adjustable trigger “fence”



Select tags to log Export from TS1131

Analog tags config

Digital tags config



2D view

3D view

Zoom

Buliding “Trend” from Excel file data

Any Questions?

Page 86 Confidential Property of Schneider Electric |

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