Performance Series 4 Controller The Series 4 Performance Controller is designed to provide precise and reliable capacity control of centrifugal and axial compressors. It can be easily configured for any of the following applications: PID ■ Controlling any single-input performance variable, such as a pressure or flow rate. ■ Calculating and controlling a mass flow rate that has been A/D compensated for temperature and pressure. ■ Manipulating the compressor’s proximity-to-surge in response to changes in the output of a master Performance Controller in a load-sharing network. The Performance Controller can also perform limiting control on critical pressures, temperatures, speeds, or other variables. This limiting improves process and compressor reliability by avoiding compressor trips caused by overload, overspeed, or high temperature. Separate PID calculations can be enabled for as many as two such limiting variables. The controller output is then manipulated to satisfy the most restrictive condition that exists at RAM any given time. As an Application Function Module in the Series 4 family of turbomachinery control products, the Performance Controller offers the added benefit of easy integration with other Application Function Modules. The Performance Controller’s loop-decoupling and load-sharing features make it the ideal companion to our innovative Series 4 Antisurge Controller. Integrated Performance and Antisurge Control Axial and centrifugal compressors require at least two control loops. One loop is used to manipulate the speed, inlet valve, or guide vanes to match compressor performance to process demand. A second loop is used to manipulate a recycle or blow- off valve to prevent surge. Close coordination is required to prevent loop interactions from creating oscillations of pressure and flow that can degrade both control precision and surge protection. Taking advantage of the Series 4 system’s high-speed communication capabilities, the Performance and Antisurge Controllers notify each other of their intended control actions. Each controller can then make appropriate adjustments to its
PB4104 (1.2) December 1996
PB4104 (1.2) December 1996
A own output so that it compliments, rather than impairs, the control
actions of its companion controller. This decoupling action provides more reliable surge protection The many features of the and improved performance control. Because the controllers do not operate at cross purposes, they can be tuned for faster Performance Controller include: response to achieve both high-speed and stable control. ■ Limiting control of any two Optimal Load Distribution in Multiple-Compressor Networks secondary process variables. Combining Series 4 Performance and Antisurge Controllers also enables you to use our patented load-sharing algorithm for ■ Automatic sequencing of multiple compressor applications. A load-sharing system consists of a cascade network with a master Performance compressor start-up and Controller, a secondary Performance Controller for each compressor, and a secondary Antisurge Controller for each shutdown. compressor case or section.
■ Input fault detection and fall- The master Performance Controller regulates the performance variable (for example, discharge pressure) indirectly, by digitally back strategies keep your communicating its output to the secondary Performance and Antisurge Controllers. They, in turn, directly manipulate the compressor on-line in the event control elements for each compressor. The Performance of transmitter failures. Controllers base their PID response on the compressor’s distance from surge, as calculated by the Antisurge Controllers, ■ Bumpless transfers between using the master controller’s output as a set point. This drives all the compressor operating points to a common distance from automatic and manual control surge. modes. This method optimizes overall process efficiency, avoiding unnecessary recycle or blow off. Load redistribution occurs ■ Complete integration of control automatically, even when compressors are being brought on- or off-line or when their efficiency changes (as when filters plug up). when used with other Series 4 Conventional load-sharing strategies employing base-loading, controllers. pressure-to-flow cascade, or biasing of a single controller’s output are far less effective — if they work at all. Such systems commonly experience load oscillations that degrade control precision. They also produce a less efficient load distribution in which the least-loaded compressors are more likely to surge. Total Train Control ® Systems The Series 4 Performance Controller is designed around the concept of a Total Train Control (TTC) system. A TTC system provides an integrated approach to control for an entire turbomachinery train or network of trains; it also provides fully- integrated system start-up and shutdown, decoupling of control loops, and load-sharing algorithms for multimachine networks. The advantages of such a system are repeatable start-ups, tighter control, prevention of trips due to adverse control loop interactions, and improved energy savings.
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