turbomachinery controls (plantpax)

Copyright © 2011 Rockwell Automation, Inc. All rights reserved.

Insert Photo HereTurbomachinery

Controls

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Turbomachinery Controls

1. Compressor Control

2. Turbine Control

3. HMI in TMC Applications

4. Applications

5. Hardware

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• Centrifugal and Axial Compressors

• Blowers and Fans• Integrally Geared Compressors

• Positive Displacement– Reciprocating– Screw Type– Vane and Lobe Type

Dynamic Require Surge Protection

Variable GeometryCan Not Surge

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Types of Compressors

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Reciprocating Compressors

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Reciprocating Compressor Details

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Screw Compressors

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Lobe and Vane Compressors

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Centrifugal Compressors

• Highest flow rates• Smallest Package• No reciprocating components, far

less vibration• There are no sliding components,

far less wear• Fewer metal to metal contact

surfaces, less wear• Less space required, smaller

foundation, lower pipe stress• Lower maintenance • Longer times between repairs

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Axial Compressors

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• Blades• Rotating Blades• Stationary Blades

• Inlet Guide Vanes• High Flow/ Low Head• Typically Air Service

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Compressor Surge

Surge occurs when the kinetic energy imparted into the gas by

the impeller is less than the potential energy in the discharge. When this occurs the flow of gas

will reverse direction.

What Happens During Surge

• Flow reduced and pressure ratio increase from point 1 to 3 along Speed Line

• Surge occurs at point 3

• Flow and pressure drop very quickly until flow reverses

• Flow reversal lowers Pressure Ratio and forward flow is re-

established• Cycle Repeats

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Compressor Control Objectives

• Prevent Compressor Surge– Surge prevention is multi-variable non-linear control, possibly limiting on other process

variables such as:• Suction pressure• Discharge pressure• Flow

• Control Compressor Capacity– Speed Control– Inlet Guide Vanes– Suction/Discharge Throttling

• Share load between compressor/driver to:– Minimize potential for surge (centrifugal only)– Optimize train efficiency– Minimize fuel consumption

• Automate start/stop functions for minimal disturbance to other units

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Surge Control Features

• Operating Point Tracking (OP Track)

• Automatic Control Line Adjustment• Dynamic Adaptive Tuning• Valve Slew Rate Control• Process Decoupling• Fallback Strategies• SurgeGard Incipient Surge Detection

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Software Tools

• Compressor Calculation Tools• Flow Measurement Tools• ActiveX HMI Tools• Data Collection and Event Capture

Tools• Data Analysis Tools

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Compressor Calculation Toolset

• Graphical Windows Application

• Simple easy to use• Lower engineering hours • Performs all Compressor

Calculations• Generates Control Maps

for all products

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Flow Calculation Toolset

• Graphical Windows Application

• Simple easy to use• Lower engineering hours • Performs all Flow

Calculations• Generates Data Sheets

for all flow devices

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ActiveX Compressor Map Object

• Works with any HMI that supports ActiveX Objects

• Simple easy to use• Automates graphical

display of compressor maps scaling

• Lower engineering hours• Consistent Displays

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Data and Event Capture

• Graphical Windows Application

• Simple easy to use• Up to 30 Minute Event

Capture• Typical 50 ms Sample

Interval• Network Support• Simple Data Export

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Data Analysis

• Graphical Windows Application

• Simple easy to use• Detailed Analysis • No Loss of Time

Resolution• Variable Time Playback• Time Calculation Between

Events

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Steam Turbine Control

Single Valve Steam TurbineSpeed (load) controlSpeed PIDRemote Setpoint

Two Valve Steam TurbineSpeed (load) controlSpeed PIDRemote SetpointExtraction controlExtraction map

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Single Valve Steam Turbine

• Very common in industry• Small single stage

turbines in low BHP up to 3500 BHP

• Hydraulic or electronic governor

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Two Valve Steam Turbine

• Uses higher pressure steam• Large load capability (MW

range)• Used For

– Energy recovery– Main plant steam– High HP generator/compressor

driver• Maintains pressure on one or

more plant steam headers• Used as part of a plant wide

energy plan

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Steam Turbine Control Objectives

• Provide power • Control process load• Protect the turbine and

the load– Over speed protection– Over load protection

• Provide extraction steam (2 valve turbine)

Turbine Startup Sequence

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PlantPAx Overview

Operator Interface

CIP Network (EtherNet/IP)

FT View HMI Data Server

Process ControlTurbo Machinery

Control

Condition Monitoring

Electrical Control & Safety

Intelligent Motor Control

Rotating Asset monitoring &

Protection

TMC Automation and control

Process Control

FT Historian

Maintenance Interface

Supervisor Interface

Compressor Control Application

. 3636

Compressor Control Application

3737

Compressor Control Application

. 3838

Electric Motor Application

. 4040

Steam Turbine Generator

. 4141

4242

. 4343

. 4444

(Confidential – For Internal Use Only) Copyright © 2011 Rockwell Automation, Inc. All rights reserved. 45

Steam Turbine Governor Applications

Typical Applications:– Pump/Fan Drives– Compressor Drives– Generator Drives

Process Plants that Generate Steam may have 100+ Steam Drives!

Typical Industries:– Refineries/Petrochemical– Fertilizer– Pulp and Paper– Steel Production– Power Generation

– auxiliary generators – waste heat recovery boilers– waste steam

– Steam driven refrigeration for buildings

Steam turbines are used in many of the same applications as electric motor/drive combinations when the customer has waste steam available

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The Competition - Steam Turbine

Built to purpose devices– Black box– No expansion capabilities– Limited features– Limited communications capabilities– Limited diagnostic capabilities (LED Status indicators)– Replace not repair

• Disconnect and reconnect all wiring• Requires retesting all field loops

– Separate handheld programming device required• May not be readily accessible• Additional cost item

– Limited operator interface capabilities (non tactile membrane buttons, confusing alphanumeric status indication codes)

Peak 150 & Vantage represent 90% of market opportunity(Confidential – For Internal Use Only) Copyright © 2012 Rockwell Automation, Inc. All rights reserved.

(Confidential – For Internal Use Only) Copyright © 2011 Rockwell Automation, Inc. All rights reserved. 47

Single Valve Steam Turbine Governor

Ready to Install - Pre-programmed Steam Turbine Control Solution

Greater Visibility– Full graphical interface vs. LED– Start-up sequence status at a glance

Easy to Install– Pre-programmed– Ready to install– Configurable through the HMI– Pre-configured operator interface– Proven TMC algorithms

Lower total cost of ownership– Standard CompactLogix™ hardware– Based on commercial off-the-shelf technology

(Confidential – For Internal Use Only) Copyright © 2011 Rockwell Automation, Inc. All rights reserved. 48

Greater Visibility

• Full graphical interface vs. LED• Start-up sequence status at a glance• Easy-to-use interlocks & permissives• Integrated overspeed testing

Start Sequence

Full color PanelView HMI simplifies operator interface

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Greater Visibility

• Detailed alarm management & diagnostics• Trending process assists in troubleshooting• Advanced troubleshooting and diagnostic information

allow more control and can help increase uptime– Manual or automatic start-up– Multiple critical speed avoidance ranges– Multiple idle (warm up) speeds

Full color PanelView HMI simplifies operator interface(Confidential – For Internal Use Only) Copyright © 2012 Rockwell Automation, Inc. All rights reserved.

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Easy to Install

• No programming necessary • Convenient NEMA enclosure,

terminations & power supplies • Proven TMC Control Algorithms• Multiple levels of passwords can

provide enhanced security

Pre-engineered assembly for easy installation(Confidential – For Internal Use Only) Copyright © 2012 Rockwell Automation, Inc. All rights reserved.

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Agenda

Copyright © 2012 Rockwell Automation, Inc. All rights reserved.

1. What Are Packaged Solutions

2. Single Valve Steam Turbine Governor

3. Single Stage Compressor Controller

4. Launch Tools

5. Roadmap

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Single Stage Compressor Control

Types of compressor:– Positive Displacement Compressors

– Reciprocating– Lube or screw

– Rotary– Axial– Centrifugal

Compressors are used in nearly every industry. Petrochemical, textiles, oil and gas production, even sewage treatment plants use compressors!

All rotary type compressors experience SURGE. Uncontrolled surge can damage the compressor

Rotary compressors are more efficient Provide much higher flow rates. Generally produce much less vibration Require less maintenance than positive

displacement machines

(Confidential – For Internal Use Only) Copyright © 2012 Rockwell Automation, Inc. All rights reserved.

Single Stage Compressor Controller and Recip Controller

• Greater Visibility– Full graphical interface– Start-up sequence status at a glance– Dynamic Compressor Performance Map

• Easy to Install– Pre-programmed– Ready to install– Configurable through the HMI– Pre-configured operator interface– Proven TMC control algorithms

• Lower total cost of ownership– Standard CompactLogix™ hardware– Based on commercial off-the-shelf

technology

Ready to Install – Pre-programmed Compressor Control Package(Confidential – For Internal Use Only) Copyright © 2011 Rockwell Automation, Inc. All rights reserved. 57

The Competition

• Limited Features – Surge control only– Proprietary hardware (“black box”)– Must add “Black Boxes” for added

features– Difficult to configure

• No HMI – LED display– Little operational information– No alarm management

• Limited Communications– Serial Modbus Slave only– Limited diagnostics

• Replace not repair• Restrictive Wiring Terminations

(Confidential – For Internal Use Only) Copyright © 2012 Rockwell Automation, Inc. All rights reserved.

Single Stage Compressor (SSC) Controller and Recip Controller

• Allen-Bradley® CompactLogix controller– Open architecture with a multitasking,

multiprocessing operating system– Ethernet and Serial Modbus

communications– Ready to use

– Various cabinet options– Power supplies standard– Wire terminations standard

• Full color PanelView™ Plus HMI– Simplifies and enhances operator

interface– Provides valuable insight and control

• Menu based configuration

(Confidential – For Internal Use Only) Copyright © 2011 Rockwell Automation, Inc. All rights reserved. 59

Commercial Off-the-Shelf Technology

Standard Features

• PanelView Plus Color Graphics • Alarm Management• Simple Navigation• System Status Monitoring• Multi-level Security• Trending• On screen Help• HMI Configuration

― modify― save― restore

A Feature Rich Compressor Controller(Confidential – For Internal Use Only) Copyright © 2011 Rockwell Automation, Inc. All rights reserved. 60

Dynamic Compressor Performance Map

Process Flow Diagram

Providing an Alternative for Compressor Control

Other built to purpose devices• Older Technology• Black box• No expansion capabilities• Limited features• Poor communications capabilities• Limited diagnostic capabilities• Replace not repair

Rockwell Automation Packaged Solution

• Pre-programmed, easy to configure • PanelView™ Color HMI operator interface• Dynamic compressor performance map• Surge and capacity control standard • Patented incipient surge detection • Commercial off-the-shelf technology• Easily integrated into a plant-wide network• Advanced troubleshooting & diagnostics

Yesterday Today

61(Confidential – For Internal Use Only) Copyright © 2012 Rockwell Automation, Inc. All rights reserved.

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Turbomachinery Control Products

• T6050 - SurgeGard • CompactLogix• ControlLogix• AADvance – Simplex, Redundant or TMR• Subsea AADvance • T6300 – Trusted TMR

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T6050 SurgeGard

• Analog device • Fast enough to see surge• Detects the onset of surge• Simple to install• Incorporated into Surge Control

Algorithms

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Incipient Surge Detection

Surge Event with Surge Guard Monitoring

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Surge Avoidance

Surge Avoidance with Surge Guard

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Gas Turbine Incipient Surge Detection

Copyright © 2011 Rockwell Automation, Inc. All rights reserved.

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