ee ey het DEP Honeywai Series 3 plus Operator Training Manual January 1998 2 Horevvell BV AwisterdinaTable of Contents Chapter 1: INTRODUCTION COMPRESSORS 1 Reciprocating Compressors 2 Rotating Compressors 1.2. OPERATING MAP 1.24 Operating Point 1.22 The compressor Curve 1.23 Performance Limits 1.24 Axes 4.3 SURGE 1.3.1 Phenomenon 1.3.2 Protection Method Chapter 2: ANTISURGE CONTROL 24 SURGE LIMIT LINE 2.1.1 Axis Selection 2.1.2 Description of "Surge Limit Line” 21.3 Formulas for Hp and Qs 2.1.4 Swvalue"Ss” 2.2 SURGE CONTROL LINE 224 Safety Margin 222 S-value 22.3 Flow characteriser 23 "RECYCLE TRIP" ALGORITHM 2.4 MANUAL OVERRIDE 2.5 "SAFETY ON" ALGORITHM 251 Surge Detection using "Safety On Line" 2.5.2 Surge Detection using "Signature of Surce” 253 "Safety On" Response 254 “Derivative” Response 26 © SUMMARY (EXAMPLE) 2.7 FALLBACK STRATEGIES 2.8 AUTOMATIC START UP AND SHUT COWN 2.8.4 Start up sequence - Performance Controller 2.8.1.2 Shut down sequence - Performance Controller 2.8.1.3. Start uplShut down sequence - Antisurge Controller 29 PARALLEL OPERATION 29.1 Primary Control Response 292 Load Balancing Control Response. Appendix 1: CONTROLLER FRONT PANEL {oS ,Honeywe) Chapter 1:INTRODUCTION ee Im almost all Petrochemical processes, Compressors are used to transport ot compress gasses. Most processes depend on these compressors, so its important that they are operated ina reliable fashion. To accomplish this one needs to ‘Kaowr as much as possible of the state in which the machine is running, 50 measures can be taken to preveat shutdowns and keep the downtime of not only the compressor but the whole process to minimum, This reining Manual describes the man features ofthe C.C. (COMPRESSOR CONTROLS CORPORATION) Control System. In chapter 2 the Anise algorithms ae discussed. 1.1. COMPRESSORS In the field two basic types of compressors are used: Reciprocating and Rotating. 1.1.1. Reciprocating Compressors ‘The Reciprocating Compressors are Compressors of the Piston type. They work like a reversed combustion engine andare used in applications where avery high compression ratios required. 1.1.2 Rotating Compressors There are two distinct types of Rotating Compressors: the Axial and the Centrifugal Compressors, Axial ‘Compressors are used in applications that need high flow rates, Centrifugal Compressors are used in applications that ‘require a high compression ratio in combination with less high flow rates. Compressors that combine these two types are also seen, in those cases the first few stages of the Compressor are Axial (to create high flow rates) and the last few stages are Centrifugal (to build up more pressure), 1.2. OPERATING MAP From paragraph 1.1 you can extract that the two quantities flow and compression are very important when selecting ' compressor for a certain application. The range of operation depends on your process and should be covered by the selected compressor. While describing the operating range of a Compressor one often uses the so-called Operating ‘Map or Performance Map, Measured on the axes are pressure and flow (alterative axes are discussed in 1.2.4.) 1.2.1 Operating Point hen monitoring a Compressor ene can look at mechanical quantities like vibrations and displacements, or bearing nd gil temperatures, but one can also look at process quantities like gas low and pressures. The ftst will give you informaiton about mechanical year and/or problems, the later wil give you process/operating information. Using this information in the Operating Map will result in an up-to-date point of operation of the Compressor, the so-called Operating Saint. All process variations vil (aormally) result in movement of the Opersting Poin in the Operating Map.Siri ere eee aera 4.2.2 The Compressor Curve -. ( 'a Compressor operates witha fixed speed, the movement of the Operating Point in the Operating Map will be restricted t0 a single line. Ths line is called the Speed Curve or Performance Curve belonging to this specific speed. The movements will depend changes in process conditions. Pressure Ratio (Py/P.) or (P2/P4) saw” Operading Map ‘When operating a Variable Speed Compresst changing the speed, the Operating Point will move trom one Speet Freedoun in the Operating Map, or the Operating Map contains a number of Speed Curves. When od Curve (0 the other, creating one more degree of. Honeywsl 1.2.3. Performance Limits Of course the movement of the Operating Point in the Operating Map is restricted by a aumber of limits, The most obvious limits in the Operating Map are the following: process limit maximum speed power limit 7” __| stonewall or choke limit Actual available | operating zone Figure 2: Performance Limits minimum speed Qs, vot fall these limits are connected together a “ Actual available operating zor run in normal process conditions, willbe left, were the compressor may 1 Qs Volumetric fow fin] ia Suetion, 2: Qd Volumetric flow {m'/be in Di 5 Wo Mass low [kg/h] in Suction; Bor the yarves (pressure-axis) the following I: Bd Pressure {bar] in Discharge; 2: H#Pe Differential Pressure [bar] over the Compressor (##4Pc ~ Pd - Ps); 3: Re Compression Ratio (Re = Pd /Ps); 4: Hp Polytropic Head [ki/ka]; Phe Aves that selected by 20.0. ar0 acissod in pa4.3 SURGE 1.3.4 Phenomenon Surge is defined as *sefFoscilaions of pressure and low, often inching a flow reversal". A more thorough understanding ofthe Surge phenomenon can be attained by observing the movement of the Compressor Operating Point om its characteristic curve during Surge. > Compressor reaches surge point A + Compressor looses its ability to make pressure : + Suddenly P, drops and thus P,> P, + Plane goes to stall - Compressor surges P, = Compressor discharge pressu PL = Vessel pressure = Resistance lossas over pipe > Because P, > P, the flow reverses + Compressor operating point goes to point B Machine shutdown no flow, no pressure Figure & Surge Cycle 2 aL Consider a Compressor is started, thé machine accelerates to nominal speed. Ifthe load is reduced, the Operating Point wal “rides” the curve towafds A, the Surge Point. At this point the compressor will loose his ability to make pressure, Suddenly Pd drops aid thus Pv > Pd. The Operating Point to jump to point B, This means a flow reves Bhten observed during Surge. With negative Bow the Pd drops (from point B to C). At point C we find, that the fow {S insufficient to build up the pressure necessary to reach A, so the Operating Point jumps to D. Now the flow is in ‘excess ofthe foad and the Operating Point will move up the curve to reach A again, This completes one Surge Cycle The typical duration of one Surge Cycle is 0 Sto 20 seconds. Typed duration in movement from point Ato B wil take only 20 t0 50 ms. 1.3.2 Protection Method “The consequences of Surge are severe, Besides process disturbance andthe eventual process tips und disruption, surge can damage the Compressor, Damage to seals and bearings is common Internal clearances ars aliered, bea vatornal cooyle and thus lowering the Compressors offeiency Ongoing Surge can result in complete destruction of the cotor This ll asks fora good metho of protection. As discussed in 13.1. a combination of high diseharge pressure and low flow can result in Surge (Avoiding one or both ofthese situations prevents a Compressor from going into Surge) ‘A working solution can be found in a Recycle or Blow-off fine. Operating a valve, positioned inthis in, reduces the ‘ischarge pressure and increases the load thus preventing SurgeHoneywell Chapter 2: ANTISURGE CONTROL 2.1 SURGE LIMIT LINE To be able to proven « Compressor ftom experiencing Surge, one needs to know exacly where the "Surge Limit Line" is situated, This information needs to be downloaded in the Controller that controls the Recycle Valve. If this Contioller knows where to find the Surge Limit Line ad knows the location ofthe Operating Point with respect to that lin, then the Recycle Valve can be opened when necessary. 2.1.1 Axis Selection ‘The Surge Limit Line is determined by a (number of) surge test(s) during the commissioning phase ofa project. Information distilled from this testis programmed in the Antisurge Controller. When running the Compressor, the location ofthe Surge Limit Line should not change when the process conditions change. This means thatthe selection of the Axes of the Operating Map in which the Surge Limit Line is situated, i very significant. 39 3 for the y-axes discharge pressure is used, the Operating Point will not direct react to (only) suction pressure changes. This must mean thatthe Surge Limit Line is moving and that is just what we don not want. Ui Rc on the y-axes will result in a direct moving Operating Point when suction pressure changes. Ifnow the {temperature ofthe gas changes, the intemal energy of the gas changes. This again not directly resulting in a moving Operating Point, but a moving Surge Limit Line. It becomes clear that the selection of the Axes has to result ina. fixed Surge Limit Line and only Operating Point movement, during as many process changes as possible CCC. uses Polytropic Head (7) versus Suction Flow squared (7). H, is measured in [ki/kg], [m, [ft IbeTbm] te and O, is measured in (3), (tonnes/ay ee aMSeer a eae 2.4.2 Description of "Surge Limit Line” “Most limits in process are ofthe “one variable type. This means that you only need to know the value of one specifi transmicer, compare it with its maximum or minimum (limit) value, and contol an actuator accordingly. The Surge Limit Line is slighty different, First ofall the limit cannot be crossed without potential damage to Your Compressor, and secStaly the imi isnot the maximum or minimum vale of only one physical transite signal. In case of the Surge Limit, the limit is fine in the Operating Map, with FZ, on the vertical Axis and Q? onthe horizontal Axis. The challenge now is to find a way of describing the Surge Limit Line in such a way that we can see this imit as any other “one variable” type limit oe ‘SLL | " | H, jor ae 2 Pisce | } | | \ oe | = | Figure 3: Surge Limit Line = —— ” If the Surge Limit Lin is strait fine through the Grigin, this ine can be described by determining the angle (A) the line makes with the vertical axis. If the angle is known, the tangent of the angle is also known, fn other words, sou can describe the Surge Limit Line by determining the quotient of Q7 and &,, fora single point on dat fine (Fa ‘mila calculation is made fora the Operating Point, the distance to the Surge Limit can be determined. Taking a closer look at the formulas for £7, and Q, will lead to a surprising result.24.3 Formulas for Hp and Qs Polytropic Head: Volumetric Flow: _ lool t/T) = [7 toxl2./2) ani R=ATF 2.1.4 S-value "Ss" Foneywel oO Q) oy “ AAs shown the quotient (called "K-value”) of O? and H., determines the Surge Limit Line. In the field every Surge Limit Line ha different quotient or K-value, To create a universal way of contol, C.C.C. created a patented new variable, the S-value. In Series 3 and Series 3 plus Controllers this variable is defined as: A, Swvalue \Slaz =S,= Kx sue o lon es g Fi] where: eA © o “This S-value is proportional to the angular distance between the Operating Point and the Surge Limit Line, This S- value will atways be 1 fous) when the Operating Poim is on the Surge Limit Line! Including Fotmalas t.2, 3 and 4 in, gives us the following result:In CCC, documentation the following reduced formula is often used x Lan) ro) ret where: 9) and (10) Formulas 9 and 10 are called "Polytropic Head Reduced" and "Suction Flow Reduced’ "After manipulating the formulas for Polytropic Head (1) and Volumetric Suction Flow (2), it shows that you only ‘heed to know the values of five transmitters to be able to calculate the forrmula for the S-value (7). These five are: 1: Differential Pressure over a Flow Measuring Device HHP 2: Discharge Pressure Pa 3: Suction Pressure Ps 4 Discharge Temperature Td 5; Suction Temperature Ts ‘The characteriser fis a function of Hip, and will take care of the shape of the surge limit linex Honeywel 2.2 SURGE CONTROL LINE 2.241 Safety Margin . ‘The Surge Limit Line is an unstable limit, when the Operating Point crosses this limit the compressor will experience (Gf Teast) oie Surge Cycle. This might trip your machine or even lead to a total Process shutdown. The only way to prevent this from happening isto keep the Operating Point a reasonable distance away from the Surge Limit Line This means that the Recycle Valve as discussed in paragraph 1 3.2 needs to be opened when the Operating Point Teaches a pre-selected minimum distance to surge. This minimum distance is called the "Safety Margin" and can be visualised inthe Operating Map by drawing alin infront of the Surge Limit Line. | “Surge Contro” Zone Figure 6: Surge Control Line ‘The distance between the Surge Limit Line and the "Surge Control Line" (S.C.L.) is determined by the constant factor b, The Recycle Valve willbe closed as long as the Operating Point ison the right side ofthe Surge Como Line. When the Operating Point reaches or crosses the Surge Control Line, it enters the Surge Control Zone and the eayele Valve will be open2.2.2 S-value “The control action that opens the valve is of the Proportional Integral type (P!). Looking at the S-value of the Operating Point with respect to the Surge Control Line will change formula 8 to the next formula: +b, x f(AP) Gee De oe Notice that the $ in formula 12 has no subscript "s'. The difference between this S and the S from formula 8 is that it equals 1 (one) when the Operating ‘The control action that opens th 1, the Output of the Antisurge Controller will be: than 1, the Recycle Valve will be (PD) opened until Sis again equal to, or less 1e Recycle Valve uses Point is situated on the Surge Control Line rather than on the Surge Limit Line. the S-value as its Process Variable. As long as Sis smaller than ‘such that the Recycle valve will stay closed. When S grows bigger than 1. The operator interface of the “Antisurge Controller does not show this S-value. In stead of that it shows, the from $ derived value, DEViation. Deviation: par=r| (3) ‘Deviation is 0 (zero) when the Operating Point is situated on the Surge Control Line, positive on the right, and negative on the left side of the Surge Control Line.Honey, 22.3 Flow Characteriser Tn formula 12, the function f (AP, ) can be manipulated to create different shapes forthe Surge Control Line. Most commonis /(AF,) = 1, the Control Line will then be shaped like the one in figure 8. If f(AP,) = I/AP,, the ‘Surge Control Line will be parallel to the Surge Limit Line. In C.C.C. documentation this function is called SAP). 2.3 “RECYCLE TRIP" ALGORITHM . ‘The Speed Curves in the Operating Map are very flat inthe region of surge. The effect willbe that the flow wall oscillate more wien the Operating Point moves closer to surge. In other words, a small change in Polytropic Head will result in more change in Flow when the Operating Point moves closer to the Surye Limit Line. ‘The control action that opens the Recycle Valve when the Operating Point is moving to the left of the Surge Control Line, is ofthe Proportional Integral type. Ths is a Closed Loop control action and is typically slow. Increasing the speed of control (smaller Proportional Band and/or higher Reset Rate) will have a negative outcome on the stability of the system, Inthe C.C.C. Antisurge Controller an extra line is added between the Surge Limit Line and the Surge Control Line.“The extra line is called the "Recycle Trip Line” (RTL). When the Operating Point crosses this line, an Open Loop «sponte inated, Tis open loop control lgortmis aed to the PI control inerease he sped of spores oF a csntrol system. The objective is to prevent surge due to large or fast process disturbances. The distance between the Recycle Trip Line and the Surge Control Line is determined by the constant factor RT. “The Recycle Trip algorithm opens the Recycle Valve ina series of steps with a magnitude defined by formula 14 and ‘time interval C,. Stepping up the opening ofthe Recycle Valve continues as long asthe Operating Point stays on the left side ofthe Reoycle Trp Line and the movement isin the direction of the Surge Limit Line (pastive S/d), Eventually the Recycle Trip algorithm closes the Renjle vale exponentially with lag time f. ie sla OUTPUT Quick Opening ale! to om te ——> Figure 9: Reeycle Trip Algorithm Step magnitude, as mga exch tee sn sein nt th te eee racks eaten 0 "The magne of ach 9 i esa oot wanton om the sp acon athe open op sed ak tober se PL eoptse as :Honsywel 2.4 Manual OverRide ~ {In the Antisurge controller itis not possible for the operator to close the recycle valve in manual control in such a ‘way that the compressor will surge, The Manual OverRide (MOR) feature will prevent this in the controller. When ‘the Operating Point of the compressor moves to the let of the Recycle Trip Line, the Antisurge controller will switch {om manual into automatic control and initiate a Recycle Trip. The Operating Point will then move to the right ofthe Surge Control Line without bringing the compressor in surge. After this the Antisurge controller remains in automatic control until the operator switches back to manual contro. - 25 "SAFETY ON" ALGORITHM Surge could still occur if parameters are incorrectly set, or if process valve (Check Valve or Recycle Valve) response has deteriorated. In this event, an adaptive surge detection algorithm in the Antisurge Controller will detect the Surge Cycle and take measures to prevent this from happening again, Surge cam be deteced in two ways: using the "Safety On Line” (S.0.L.) or using the "Signature of Surge". 2.5.1 Surge Detection using "Safety On Lin tn paragraph 1.3.1 it shows that when a compressor experiences surge, the Operating Point will jump form the Surge Limit Line to the left side of the vertical axis (negative flow). In the Antisurge Controller this surge is normally detected with a detection line situated on the left side of the Surge Limit Line. This line is called "Safety On Line" (SOL) and initiates the "Safety On” Response. | | |ee eee 2.8.2 Surge Detection using "Signature of Surge" ad In some cases the flow measurement system damps the flow signal in such a way that peaks of the internal compressor flow will not be visible. This can happen when the orifice or venturi tube is located ata considerable distance from the compressor, orf the characteristics ofthe impulse lines to the transmitter are not optimal (to0 long, too small, filled with fuid etc.) This could lead to a situation thatthe controller does not notice the Operating Point roving to the left side of the Safety On Line, which in turn means thatthe controller does not detect surge, If this is the case, the controller can use an additional way of detecting surge. ‘Signature of Surge |At the moment of surge, the "Rate of Change" of the flow signal and the "Rate of Change" of the pressure signal will both be maximum (either negative or positive). The Safety On algorithm can monitor these signals and look for a Rate of Change grester than a pre-selected threshold, The following modes can be ised to initiate the "Safety On” Response: 1: Rapid Change in both Flow and Pressure signal, (MODE 1D 2; Rapid Change in ether Flow or Pressure signal (MODE 1D2-2) } Rapid Change in Flow signal only, (MODE 2: Rapid Change in Pressure signal only. (MODE #24)Honeyweil SO oe 2.5.3 "Safety On" Response ee ie Sty On Reon te ay on ofeach eo wil nt bth ‘number of surge cycles which do occur and the ikeifood of their recurrénce. The Safety On algorithm increases the Safety Margin (initially determined by the 6, factor) each time a surge is detected. The additional safety is determined by the b, factor. After the first surge cycle the Safety Margin is b, + by, after n surge cycles the Safety Margin has grown to b, +1 x b, SLL (Ty (scl) 7 RTL SCL & (2 Safety Margin= b, + n x b, Qo; — Figure 12: Safety On Response after one surge cycle Shwe In case of a Safety On Response an aitempt should be made to find out why this response was triggered and whether ‘of not the Amtisurge Controller needs to be reconfigured to provide a larger, permanent Safety Margin, Once the ‘determination has been made (and any needed reconfiguration has been completed), the RESET key can ke pressed to ‘extinguish the Safety On light and reset the actual Safety Margin to the initial Safety Margin 6,SSceeee ea see 2.5.4, “Derivative Response ‘The “Derivative” Response will be triggered when the Operating Point moves quickly towards the $.C.L. Due to this, feature the Safety Margin of the controller will be increased, with the result that the S.C-L. will move to the right. This increment of total b will be calculated as: b= bi +n%b2 +b3 * dsidt ‘Because the last factor depends on the speed of the Operating Point moving towards the S.C.L., the derivative response of the S.C_L. will always be different. ‘The advance of this derivative response a quicker opening of the recycle valve. ‘When the movement of the Operating Point stops, the magnitude of the derivative response will become zero and the S.CLL. will tum to the original position according to a pre-set ramprate at the S.CL. will catch up sooner with the Operating Point and results in SOL SLL RTL SCL SCL due to derivative response a RTL does not move during this action Figure 13: Safely On Response after operating point movement towards Surge Control LineHoneywsi: 2.6 SUMMARY (EXAMPLE) ‘This paragraph describes an example of an Operating Point moving through the Operating Map and initiating specific Antisurge Controller control actions. Figure 1: Example ‘When the Operating Point moves from point A to B, the Recycle Valve stays closed. At point B the valve is opened gradually on PI control. Crossing ofthe Recycle Trip Line (point C) will initiate the frst Recycle Trip step. the Operating Point sill moves towards the Surge Limit Line after C, seconds (point D), the second step is erated, The Valve gradually closes again when reaching point E.2.7 FALLBACK STRATEGIES ‘To prevent damage on the compressor, if one of the transmitters fails, a number of fallback strategies have been built into the Antisurge controller, Each of these can be individually enabled, according the customer requests, and each utilises one or more constants which are set in the controller. Some fallback strategies are commonly used, a short description is listed below; a y + All Antisurge controller applications require a flow-measurement fot the flow rate. If that input should fail, the only recourse is to open the antisurge valve far enough to prevent surge under the ‘worst possible process Conditions. ‘When it fails the controller switches from automatic to manual control, where the output will be set according the configured parameter in the controller. * When several pressure or temperature inputs fil, the controller will continue with automatic minimum flow control. The controller will protect against surge by maintaining the low signal value above some minimum level * fonly the discharge pressure fails, che controller will calculate the S-value with a default compression ratio, If fora certain application, the sigma is calculated by using T discharge and T suction and one ‘temperature input fails, the S-value will be calculated using the default sigma which is entered in the controller. + When the speed or guide vane angle signal fais, the controller wil calculate with a pre-configured input signal value. {tis also possible to activate fallback strategies forthe Performance controller. I°the analogue input fils for the control variable, the controller wil revert to manual control and allow the operator to manually adjust the output. By failure of one ofthe other analogue inputs, for example limiting loops, the controller wil substitute the pre- configured value forthe filed input's signal variable. For loadsharing applications the secondary controller will ‘svtch, on loss of Port 2 communication, to a stand alone controller.Honeywell. 2.8 AUTOMATIC START UP AND SHUT DOWN ‘With the C.C.C. controllers it is possible to automatically start up and shutdown the compressor. 5 lee Sos 2.8.1. Start up sequence - Performance Controller he 3\ Ge The start stats can come either from a digital contact or an analogue signal ‘The digital contact can come from a logic device which allows the compressor to come on line, the analogue signal usually comes fom the motor curfet or compressor speed transite. "e envonme] VET Belay tine onteter al emiteh to Renae ~ Performance Out>LVL4 —— Time Figure 15 Startup sequence Lapa pal ‘When the start signal is given to the Performance Controller, the output will stay constant for a certain time set by LVL 1 in seconds. Hereafter the controller starts increasing his output with a ramprate set by LVL 6. This ramp will continue until the Performance output signal is above the value set by LVL 4, the antisurge recycle valve is below the value of LVL 5 and the check valve is open. When these conditions are met, the controller will start normal PID control of the process variable 2.8.1.2 Shut down sequence - Performance Controller Centrotter| Output | Ramprate Ramprate ves 1 Time ‘Stop Signal (SV2 < LVL 2) The shut down sequence will bring the compressor offline. When the stop signa is given, the controler will decrease the output with the ramprate set by LVL 7. After the checkvalve is closed, the decreasing of the output wll continue with the ramprate set by LVL 6 until the output reaches LVL 3.2.8.2. Start up/Shut down sequence - Antisurge Controller In the start up or shut down sequence, the Antisurge controller can be configured in such a way that this controler vill receive the start or stop signal from the Performance controller. Inthe stop status the recycle valve is fully open ‘When it receives the start command signal, the recycle valve will ramp in close direction until the operating point will ‘come on the Surge Control Line. When the Antisurge controller will receive the stop signal, the antisurge valve will go fully open. ‘Also the Antisurge controller can receive a purge command which forces the recycle valve in the fully closed position. ra Parallel Operation {In some applications we can find compressors working in parallel. This means that in most cases they will have a common suction and discharge header. A typical example is illustrated below. Prosasa Figure 17 Example of parallel compressor train. 1 ‘As you can seein the above example CCC is using, wo Antisurge controllers and three performance controllers, Ta most parallel applications, the Master controller will control the discharge pressure, or flow, or suction pressure, {a this example the process variable is controlled by the speed Lets make a step by step overview to see what each controller will do inthis example“Honeywe! 2.9.4 Primary Control Response Figure 184 Schematic block diagram of control response. by ‘The Master controller will control the process variable and the output of the Master is sent as a “feed forward” signal to the Loadsharing and Antisurge controllers as showed in figure 18. Lets see what the antisurge and Loadsharing controller will do with this signa Figure 1838 Feed forward control response. The Loadsharing controler will check ifthe DEV >.0,{f this is true, the Loadsharing controllers output will change. or this reason the Loadsharing controller will monitor and display the DEV of the companion Antisurge controler The Antsurge controler wall check ifthe DEV is negative, If this is true, the Antisurge controllers output ‘will change. But the Antisurge controller will only open the recycle valve. The Master can of course not ask for closing the reeycle valve but only request for opening of the recycle valve. ileii=™. 2.9.2 Load Balancing Control Response. As you can se the main control objective is to satisfy the Master controller PV and SP. ‘But the Master controller will do also something else, it will monitor all the compani (DEV of the Antisurge controllers). These values will be averaged. | slg ‘The average value is sent back to the companion Loadsharing controllers as a SP. Loadsharing controllers PV DEV trom other nadsharing seat : et f ow ES | f aa 7 ar [icieeas ] Antaurae + Figure 18C Load balancing response [E the Loadsharing controller will receive a SP with alower value than the PV, the Loadsharing will reduce for ‘example the speed. Because if you reduce the speed, you will move the operating point closer to the SCL, which ‘means a lower DEV. {fon the other hand the SP is higher than the PV, the Loadsharing will increase for example the speed. Because if you jncrease the speed, you will move the operating point away fiom the SCL, which means a higher DEV, This is called the load balancing response. The balancing cesponse is normally a slow response and the Master conttol response is a fast response.Honeywe APPENDIX 4 Controller front panelee eerie eee ANTISURGE CONTROLLER FRONT PANEL Aails mr Sr ets ceuraesson ‘TRANFAIL: FALLBACK: COMERR: FAULT: AUTO/MAN: DOWN: Est SAFETY ON: DISPLAY SURGE COUNT: DISPLAY LIMIT: VENT, SCROWL: DEV: (1-S) Indicates how far compressor is deviating from minimum acceptable margin of safety fan Displays surge court (when DISPLAY _ ‘SURGE COUNT is pressed) oriindicates POC when pressure override control is active ALT: (Output signal to antisurge valve 0.100% Configurable ausiiary display Green light lt: controller in automatic. Flashing; Output is frozen due to transmitter failure Fellow light lit: controller in manual. Yellow light lit: step change in output to valve due to close approach to surge. SO: Red light lit surge of the compressor has been detected. LIMIT: Yellow light lit: zal limiting variable is at, or beyond, its threshold.“ Green light lit: controller in redundant tracking mode, Green light flashing: controller in output tracking mode. Red light lit: one of the analogue inputs is outside its alarm limits Yellow light lit: controller in one of its fallback modes. Red light lit: expected message fail to arrive on port or port? ‘Red light lit: controller has failed, should be replaced immediately Toggles between automatic and manual mode. Only in manual mode: changes output signal eroes surge count, sends ,C.L. to ital postion and safety margin to bL Displays surge count in ALT window. Displays limiting variable in DEV window and its limiting in ALT window (AUX tells which limit), Used to select AUX window display.2S isyne Antisurge Controtier AUX Displays Operating State Measured Variable Calculated Variable Menu Menu (Default Labels) Menu Status RUN APo #4H — Sigma= Hit Status STOP D Press HH Ro= HE Status PURGE S Press Het Ri a Status ESD Speed ### = Speed= #HHHE (This menu does not Scroll, D Temp #t# Flow = ##HHE the operating state is selected S Temp HH by an analogue or discrete input) Chan 7 He Chan 8 Ht * The display of any variable can be disabled * Acurrent variable is defined for each menu * Pressing the MENU key displays the current variable for the next menu * Pressing the SCROLL key displays the next variable in the current menuA eer 3 ‘TRANFAIL: FALLBACK: COMERR: FAULT: AUTO/MAN: UP-DOWN: REMOTE/LOCAL: DISPLAY LOOP x: MENU, SCROLL: PVs Displays scaled value of primary variable. SP: Displays scaled value of primary setpoint. OUT: Output signal to final control element 0- 100%. our AUX: Configurable auxiliary display pa i * : Green light lit: controller in automatic. Flashing; Output is frozen due to transmitter failure MANUAL: Tellow light lic: controller in manual REMOTE: Green light lit: Remote setpoint in use. LOCAL: Yellow light out: Local setpoint in use Change SP by UP-DOWN keys (during automatic control); ‘flashing : while in LOADSHARING fallback. LIMIT: Yellow light lit: limiting variable is at, or beyond, its threshold. kK Green light lit: contsoller in redundant tracking mode; Green light flashing: controller in output tracking mode, ‘Red light lit: one of the analogue inputs is outside its alarm limits Yellow light lit: controller in one ofits fallback modes, Red light lit: expected message fail to arrive on port] or port? Red light lit: controller has failed, should be replaced immediately Toggles between automatic and msnual mode In AUTO: changes local SP; in MAN: changes output Toggles between remote and local setpoints Displays limiting variable x in DEV window and its limiting SP in ALT window (AUX tells which limit) Used to select AUX window display.