Series 3 Plus Antisurge Controller 103 Chapter 8 Output Variables This chapter tells how the valve position and actuator control signal are derived from the antisurge control response Analog Inputs Antisurge Control Response {intended Recycle Flow) Valve Flow Characterizer Remote Low =| Output Clamp Valve Dead Band Compensation —_—t ‘Output Clamps Tight Shut OFF —— I Figure 8-1 Output transformations T tied Valve Postion a | Output Reverse CouTreaaoat Output Tracking ‘Actuator Control Signal TMaOt (6.01)104 Chapter 8: Output Variables Figure 8-2 Intended Valve Position Valve Flow Characterization é g s 3 5 ° Control Response (Intended Flow) 1 Valve flow characterization ‘As shown in Figure 8-1, the intended valve position is calculated by applying Vaive Flow Characterization to the Antisurge Control Response (see page 82), which represents the intended recycle or blow-off fiow rate. If your control valve exhibits inherently non-linear flow, you can ren- der its actual flow linear with respact to the intended flow rate by selecting an appropriate Valve Flow Characterizer [MODE:A {C 8}, Figure 8.2 illustrates the relationship between the intended recycle flow and intended valve position for each pre-defined characterizer: {C8 High: for quick-opening valves {C8 Low: for equal-percentage valves {C 8 Off: for linear flow valves. For quick-opening valves, the flow is assumed to be proportional to the square root of the fractional valve opening. Thus, when {C 8 is HIGH, the control signal is obtained by squaring the intended flow rate calculated by the control algorithms. If the intended flow is 50 percept (1/2), for example, the valve position would be 25 percent [(1/2)° = 1/4}, For a signal-to-open valve with a 4 to 20 mA actuator, the output signal would be 8 mA, Conversely, the flow rate for an equal-percentage valve is assumed to be proportional to the square of the fractional valve opening, Thus, when {C8 is LOW, the contro! signal is obtained by taking the ‘square root of the intended flow rate. For example, if the intended flow is 25 percent (1/4), the valve position would be 50 percent (1/2). For a signal-to-open valve with a 4 to 20 mA actuator, the output sig- nal would be 12 mA. February 2001Series 3 Plus Antisurge Controller 105 Actuator Control Signal Figure 8-3 Valve Dead Band ‘Compensation The actuator contro! signal is the intended value {in percent of span) of the analog signal used to position the final control element. As shown in Figure 8-1, itis calculated by applying the following trans- formations to the Intended Valve Position: + Vaive Dead Band Compensation adapts the controller to valves with worn actuator linkages. *+ The Output Clamps limit the control signal's range. The Remote Low Output Clamp allows a companion device to increase the low clamp (and thus the minimum recycle rate) ‘+ The Tight Shut Off Response fully closes the control valve when itis at its low clamp position and the operating point is safely to the right of the surge contro! line. + Output Reverse adapts the controller to a signal to-close or sig- nal-to-open valve. . ‘+ Output Tracking keeps the control signal equal to a specified analog input whenever the D4 discrete input is asserted Signal + ours Time Valve dead band compensation Due to wear or design imperfections, the positioning of @ contro! valve might exhibit a dead band which must be overcome when the control action reverses direction. The Antisurge Controller can Counter this effect by adding or subtracting a Valve Dead-Band Bias [COND:A OUT 1} o the intended valve position. This bias is added when the control response is rising and sub- tracted when itis falling. Thus, a change in the control response's direction produces a step change in the control signal with a magni- tude equal to twice this bias (see Figure 8-3) Itis better to set this bias slightly too high (as opposed to too low), so that a. change in the direction of the control action will actually reverse the movement of the valve. A small antisurge Pl loop dead zone should then be configured to prevent such movements from Ss 1307 (60.1)106 Chapter 8: Output Variables Note: Output Clamps Note: Remote Low Output Clamp causing valve “chatter” when operating on the surge control line (see Dead Zone on page 83) Valve dead-band compensation can be disabled by assigning its bias a value of zero. This feature will not move the actuator control signal beyond either of its output clamps. ‘The range of the actuator control signal (ACS) is defined by the Recycle Low Clamp [COND:A OUT LOW] and Recycle High Clamp [COND:A OUT HIGH]. These clamps are implemented by raising or lowering the accumulated integral response (see General PI Algo- rithm on page 83) as needed to keep the ACS within the specified range. ‘These clamps are entered as the minimum and maximum intended valve positions, which correspond to the highest and lowest values that would be displayed on the front-panel OUT readout. Thats, the output will be constrained such that OUT never displays a number less than OUT LOW or higher than OUT HIGH. Any Valve Open relays will be triggered whenever the actuator con- trol signal is greater than the low output clamp. Because these clamps apply only when the controller is operating automatically, they do not restrict your ability to manually adjust the actuator control signal. When setting these clamps, keep in mind that they are applied atter flow characterization and valve dead band compensation but before the tight shut-off response and output reverse. ‘A 4 to 20 mA output is automatically generated with an offset zero, 30 you do not have to define that offset by setting the corresponding ‘output clamp. ‘The Antisurge Controller can be configured to use the output of another controller as its low output clamp when that signal is less than the low output clamp. This prevents the Antisurge Controller from reducing its output below that of the remote device, without risking integral windup or restricting its abiity to open the valve as needed to prevent surge. In contrast to Output Tracking, this feature holds the recycle valve open far enough to satisfy both controllers. To utilize this feature, connect the output of the remote device to any of the Antisurge Controller's otherwise unused analog inputs and set the Remote Low Output Clamp (MODE:A € 4] equal to that input’s channel number. Setting fE 4 to zero (Off) disables this feature February 2001Series 3 Plus Antisurge Controller 107 For example, if you connect the output of the remote device to CH7, fE 4 must be set to 7. The Antisurge Controller will use SV7 as its low output clamp when that signal is greater than the Recycle Low Clamp |COND:A OUT LOW, Itwill also flash its front-panel Tracking LED to indicate the low clamp is tracking the remote signal, even if the control signal is greater than that low clamp. Ifthe Output Reverse feature is set up for a signal-to-close valve, the complement of the designated signal is used as the remote low output clamp. The remote device must then be set up to decrease its output when a higher low clamp is desired. Note: The remote low clamp is ignored when the controller is operating in its Stop or Purge state. It does apply to manual operation, in which event raising the remote clamp can increase the displayed output (and open the valve) but lowering it will have no effect. ‘The remote low output clamp will be ignored if the specified signal variable is outside its transmitter testing limits. Tight Shut Off When the intended recycle flow rate is zero, the control valve should Response _ be fully seated and the recycle flow path completely blocked. Untor- tunately, this ideal can not always be achieved, particularly with worn valves, or those with teflon seats. The result can be a slight leakage that wastes energy and produces an annoying sound. Reducing the low output clamp (see page 108) to more fully seat the valve would produce a range of control signal variations that would have little effect on the actual flow rate. A better solution is to force the control signal to zero when the control response is below its low clamp and the possibility of surge is low. This result can be obtained by setting a non-zero Tight Shut-Off Line Distance [SPEC:A d 1], thus defining a non-zero tight shut-off mar- gin (see page 78). The controller will then force the actuator control ‘signal to zero (100 percent for a signal-to-close valve) when the intended valve position is at the low clamp and the operating point is to the right of the tight shut-off line. Once this feature is activated, the displayed output will remain at zero until operating conditions dictate that the control valve should be opened. At this point, the control signal jumps back to its low clamp before the controller's response to those conditions is added For example, any Recycle Trip response would begin from the low clamp, rather than from zero. To disable tight shut off, set its line distance to 99.9 percent. IM301 (6.0.7)108 Chapter 8: Output Vanables Output Reverse Output Tracking ‘The actuator control signal is adapted to the recycle or blow-off valve's direction (signal-to-close or signal-to-open) by setting the Recycle Valve Direction [MODE:A REV] parameter: * Direct action [REV Off] should be selected for a signal-to-open, fails-closed valve, The actuator control signal will then increase when additional flow is needed to prevent surge. + Reverse action [REV On] should be selected for a signal-to- lose, fails-open valve. The actuator contro! signal will then decrease when additional flow is needed to prevent surge. The Antisurge Controller can be set up as a signal selector for its final control element, so it can serve as a backup or alternate to another controller (for example, a DCS) This feature is set up by connecting the other controller's analog output to an unused Antisurge Controller analog input and setting the Output Tracking [MODE:A fE 5] parameter equal to that input's, channel number. For instance, if the output of the other device is, connected to CH7, set fE 5 equal to 7. If discrete input D4 is then asserted, the Antisurge Controller will set and keep its actuator contol signal equal to the designated input's signal variable (for example, SV7), the operating state will display as "Status TRACK”, and the Tracking LED wil flash. The controller will indicate whether it will return to automatic or manual operation when the D4 input is cleared, and you can change that selection by press- ing the AUTO/MAN key or forcing the Automatic coil. In either case, the transfer will be bumpless (there will be no discontinuity or rapid change in the output): + When returning from output tracking to Manual Operation (see page 31), the control signal remains constant. + When the controller returns to automatic operation, it sets the effective value of its DEViation to zero, then ramps it to the actual value (calculated from the analog inputs) at a rate set by the General Ramp Rate [PID:A G). Bumpless transfers to output tracking should be implemented in the ‘other controller. If the designated signal fails while output tracking is active, the con- troller will hold its output signal constant (see Default Output Fallback on page 70) This feature can be disabled by setting fE 5 to Off. February 2001Series 3 Plus Antisurge Controller 108 Chapter 9 Operating State Operating State Request Signals States and Transitions This chapter tells how to set up the Antisurge Controllers automatic sequencing, manual operation, and redundant control features. ‘As described in the Automatic Sequences section in Chapter 9 of IM302, loading and unloading of a compressor is sequenced mainly by its Performance Controller. Provided neither redundant contro! nor output tracking is active, an Antisurge Controller wil participate primarily by selecting an appropriate operating state in response to changes in its Operating State Request Signals: + When its compressor is stopped or idling, an Antisurge Control- ler operates in a Stop state that fully opens the recycle vaive. If the compressor is stopped, this minimizes any reverse flow or rotation that might occur ifthe discharge check vaive leaked. If it is idling, this minimizes the drive power and risk of surge. + If the compressor is then purged, the Antisurge Controller can select a Purge state that fully closes the recycle valve so purge gas can be forced through the compressor. + When the compressor is loaded, the Antisurge Controller selects its Fun state, which reduces the recycle rate as much as possible without risking surge. It will continue to modulate that valve as needed to prevent surge with a minimum of recycling as long as the compressor is running. * While the compressor is being unloaded, the Antisurge Control- ler will either ramp its recycle valve open (a normal shutdown) or open it as fast as possible (an emergency shutdown), The controller startup and shutdown features initiate and stop the continuous recalculation ofits output signals, thus providing transi- tions between its Run and Stop operating states. While these might bbe used to sequence a compressor startup or shutdown, they can alternately be set up to load and idle a running compressor. An Antisurge Controller can execute a shutdown and operate in its Stop state only if the Minimum Flow and Pressure [COND:A LVL 1] or Minimum Speed [COND:A LVL 2] has a non-zero value or the ‘Stop Requests (MODE:A 1B 1] are enabled + IfSV1 (usually a flow) or SV2 (usually the discharge pressure) {alls below the Minimum Flow and Pressure or the Rotational Speed (see page 53) falls below the Minimum Speed, the con- troller assumes the compressor is being unloaded and initiates ‘a normal shutdown. Setting either threshold to zero disables the corresponding tests, as does the failure of their analog inputs. TM301 (601)110 Chapter 9: States and Transitions Note: Startup Configuration Shutdown Configuration Stop State Valve Sharing Shutdowns, + Ifthe Stop Requests are enabled, a normal shutdown is initiated it discrete input Dé is asserted or a designated Stop/Purge ‘Companion [MODE:A 1B -] controller selects or initiates its stop state or shutdown sequence. + Ifthe Stop Requests are enabled, an emergency shutdown can be initiated by asserting this controller's D2 discrete input, but not that of any Stop/Purge Companion. If the Purge State [MODE:A {8 2] is enabled, itis selected whenever this controller is operating in its Shutdown state and its D3 discrete input or that of its Stop/Purge Companion is asserted, Prior to revision 756-001, specifying a Stop/Purge Companion dis- abled an Antisurge Controller's own D2, D3, and D6 discrete inputs. In most applications, an Antisurge Controller participates in a startup by simply switching to its Run state, which will then slowly close the valve as needed to prevent surge with a minimum of recycling. However, because temperature and pressure measurements will often lag the actual usually be inaccurate during major process tran- sitions, any Application Function {MODE:A {Aj that calculates the Polytropic Head Exponent (see page 52) will switch to the Default Sigma (COND:A CONST 4] when the compressor is unloaded. Dur- ing any subsequent startup, the Sigma Filter Constant [PID:A Tt 2] will effect a gradual transition to the calculated value. normal shutdown ramps the recycle valve to the position defined by the Recycle High Clamp [COND:A OUT HIGH] at the Stopping Ramp Rate [COND:A LVL 3}. If that ramp rate is set to zero (0.00), the control signal is immediately set to the high-clamp position, thus opening the valve as rapidly as possible. If the Safety On AutoReset [MODE:A 18 3] is enabled, initiating a shutdown will also reset the Surge Counters (see page 81) to zero. While operating in the Stop state, the controller holds the recycle valve fully open, as defined by the Recycle High Clamp (COND:A OUT HIGH]. In addition, manual control cannot be initiated while the. Stop state is selected unless Manual Override or Manual While ‘Stoppedis enabled (see Manual Override). In a valve-sharing application (see page 98), some compressors may be running while others are shut down. The primary Antisurge Controller wil then modulate the recycle valve as required to protect the compressors whose controllers are operating in the Run state (if its own compressor section is unloaded, it wll display its operating state as “Status OFF") February 200%Series 3 Plus Antisurge Controller 111 Any controller that continues to operate in the Rlun state after its ‘compressor is shut down will probably calculate a very negative DEViation, which would cause the primary controller to fully open its shared valve in a needless attempt to protect a stopped compres- sor. Thus, each valve-sharing controller must be set up to select its ‘Stop state when its compressor is not running, either by defining non-zero flow, pressure, or speed thresholds or by enabling and asserting a discrete shutdown request. Manual 7° protect against surge while operating in manual, the controller . will normally revert to automatic if the operating point moves to the Override {ett of the Recycle Trip control line. It will also revert to automatic if its operating state inputs dictate a transter out of the Run state. You can override these behaviors by enabling Manual Override [MODE:A MOR}. The controller will then remain in manual until the operator selects automatic operation, even ifthe compressor surges or is shut down . Off is the “safe” Manual Override setting. We advise you not to Caution: permanently enable that parameter, because it disables all surge protection while the recycle flow is being manually controlled. When manually operating the controller via its Modbus interface, you can determine whether or not Manual Override is enabled by reading the Manual Override coil or discrete, and can enable and disable this feature by setting and clearing that coil If Manual Override is disabled (as recommended), the controller cannot be manually operated while the Stop state is selected unless you have enabled Manual While Stopped {MODE:A {8 4]. If 1B 4 is ‘On and the operating point is to the left of the Recycle Trip line, you can select manual only if the Stop state is selected. TM301 (6.0.1)112 Chapter 9: States and Transitions Alternate Parameter Sets Note: Redundant Tracking Switching Conditions. ‘The Antisurge Controller supports up to three alternate sets of con- figuration and tuning parameters, as described in Chapter 3 of IM300/H. The Store Alternate Parameters [MODE LOCK 3 +] key sequence can be used to create them, while the Recall Alternate Parameters [MODE LOCK 3 +] procedure replaces the working set with one of the alternates, The Antisurge Controller also supports automatic switching between the first and second alternate sets. If Remote Parameter Switching [MODE:D LOCK 3] is enabled, clearing discrete input D7 will recall the first altemate parameter set and asserting that input will recall the second set. For example, if you had two compressors that could be operated either in series or in parallel, you could create a param- eter set for each application and use D7 to switch between them, Remote Parameter Switching must be enabled in both Parameter Sets 1 and 2 in order to alternate between them by asserting and clearing 07. ‘As described in the Redundant Controllers section in Chapter 8 of IM300/H, you can install one Antisurge Controller as an on-line “hot” backup to another. ‘The main controller and its backup must have Redundant Tracking [MODE:0 fE 1] enabled and have the same Controller ID Number [MODE:D COMM 0]. If they are also given the same Computer ID ‘Number |MODE:D COMM 0], Modbus While Tracking {MODE:D LOCK 0] must be disabled. For Antisurge Controllers, the Tracking discrete input is always D1 A tracking Antisurge Controller lights its Tracking LED, displays its operating state as “Status TRACK”, and monitors and duplicates the ‘outputs and auto/manual status of the active controller. ‘The redundant switching device is usually triggered by one of the main controller's Fault Relays (see page 45). That relay (usually CRI) is set up for normally-ciosed operation, so an automatic switch to the backup controller will occur it de-energizes. In addition, CR1 can be configured to indicate any one condition from Table 3-4, and either it or a hardware fault would then trigger a ‘switchover. It you want more than one of those conditions to initiate a control transfer, they can be assigned to additional relays wired in series with CRY February 2001