GE Energy OptiComp: Integrated Compressor Control Suite
Pushing the Boundaries When it comes to getting the most out of your process and plant assets, nothing matters more than turbomachinery control and protection. Given today s competitive realities, more and more users are driving their process compressors towards maximum efficiency. That means machines must be able to operate much closer to their surge limits allowing for wider process turndown. Is it possible to operate your process without surge and at the same time achieve high efficiency? The answer is a resounding yes with OptiComp* Integrated Compressor Control Suite by GE Energy. OptiComp is an integrated turbine and compressor control solution that delivers superior compressor surge control, process performance control, load sharing/balancing, auto sequencing and other auxiliary controls. OptiComp also integrates fully and seamlessly with GE Energy s Mark* VIeS Emergency Shutdown System, Bently Nevada* 3500 Vibration Monitoring System, and System 1* Machinery Condition Monitoring System. Drawing on 25+ years of accumulated domain knowledge in turbine and compressor controls, in gas processing and pipelines, GE offers a comprehensive and scalable solution with superior control software running on our fast and reliable Mark VI/MarkVIe control platforms. GE also provides the mechanical modifications, actuator/valve retrofits, and hydraulics and servo replacement. Further, GE can extend control and protective functions for equipment beyond the basic machine train, such as associated auxiliaries up to and including the entire compressor station. Supporting multiple OEM machines Our capability extends well beyond the fleet of GE machines. GE also supports a wide range of prime mover OEMs and virtually any OEM's compressor. OptiComp fully encompasses the machine s controls, protection, vibration, shutdown, and auxiliary systems such as seal oil and lube oil providing a single platform for controlling and monitoring every aspect of your compressor train. Integrated compressor controls: Upstream Gas gathering/processing plants Gas re-injection Midstream Pipeline booster compression NGL Processing LNG Downstream Chemical/Petrochemical plants Refineries Ethylene plants Fertilizer plants Prime Movers Industrial and aeroderivative gas turbines Steam turbines Electric motors (fixed or variable speed) Compressors & Blowers Centrifugal Axial Auxiliary Systems Lube oil Seal oil Dry Gas Seals Station Control and Sequencing 2
The Power of Integration A single platform for compressor and turbine control OptiComp integrates turbine controls and protection with compressor controls and protection, in a single unified platform for superior performance and a host of benefits that positively impact your Operations and Maintenance bottom line. The independent actions of separate turbine and compressor controllers can work against each other adversely impacting process stability and diminishing efficiency. By integrating these controls into a unified system, they work together seamlessly optimizing performance without sacrificing reliability. The result is enhanced compressor function, increased throughput productivity, and increased stability in your process or pipeline. Eight Ways to Enhance Your Operations with GE s OptiComp Integrated Compressor Control Suite Improved Process Control Increased process turndown minimizes recycle or blow-off. Design the HMI displays around your process GE s flexible Windows based Human Machine Interface (HMI) supports informed decision-making, intuitive operator control, and simple application building. Data is displayed in Imperial or Metric engineering units, including the displayed Compressor Map. Standard screens include a Detailed Stage screen for each compressor stage, a Compressor Train screen for each overall compressor, a Multi-unit Load Control and Sharing screen, and drop-ins on driver control screens to fully integrate the anti-surge controls and load controls. Other displays include: Unit Overviews Turbine detailed displays Compressor detailed displays Start/Stop Sequencing Dynamic Compressor Maps Alarms/Trips/Sequence Of Events Project-specific and customized screens are also supported. Improved Surge Control Greater immunity to sudden load disturbances and process gas inlet variations. Smoother Start-ups One vendor means smoother design engineering, and well coordinated site start-up just one cohesive team supporting a faster turnaround. Ease of Operation One common user interface for monitoring and control with data access from a single database, and one system for easier maintenance. Increased Reliability Fewer electronics, systems and interfaces increase the overall running reliability of the train. Smaller footprint Fewer control panels, fewer HMI Operator and Engineering workstations, and a single Historian. Lower capital investment Less hardware, less software, less spare parts, less time and money spent on training. Lower lifecycle costs Energy and production savings, reduced downtime, reduced mechanical wear and tear, fewer electronics to support. Application software can be displayed as interconnected function blocks or in ladder diagram format. Points can be dragged from one block to another and dropped to simplify editing. There are multiple block libraries to support generic blocks, such as comparators, and application-specific block libraries for applications such as gas turbines. Math blocks are available to execute a custom equation instead of stringing together many blocks. On-line help is provided for all standard blocks. 3
OptiComp: Optimum Control The trending tool can plot hundreds of signals where individual variables can be masked and unmasked as convenient for viewing. The dual cursors allow movement of the time axis and automatically calculate the minimum, maximum, difference, and average of variables between these two points in time. The tool also provides video type forward-reverse viewing of the recorded data. The Compressor Control Challenge As a compressor operating point approaches its surge limit, small changes in pressure result in large changes in flow, requiring quicker, more acute corrective action from the controller. The controller s embedded algorithms must be sophisticated enough to allow maximum compressor operating range, without compromising protection. This requires algorithms that can reliably measure distance from Surge as well as respond quickly and dynamically to changes in process conditions. GE Energy uses patented anti-surge technology that delivers both. It s in our algorithms Building on the power of integration, OptiComp provides a rich and powerful set of configurable control functions for effective surge control. This comprehensive and layered solution employs powerful, field proven and highly configurable algorithms to meet your process requirements. Effective anti-surge control starts with a primary control response that enables the compressor to safely operate closer to the surge line, increasing efficiency and reducing recycle. Adding a proactive response, the Rate Control function monitors how fast the Operating Point is changing to anticipate when the compressor approaches a surge condition, and acts to begin valve movement before the operating point reaches the surge control line. This helps ease the compressor into a stable and safe operating condition, and is particularly effective at countering rapid reductions in flow. The Boost and Safety Protection functions deliver a stronger protective response when the operating point moves significantly below the surge control line. And when a surge event does occur, latched protection from either Surge Minimum Margin or Surge Minimum Position helps prevent further surge events. Intelligent deadband helps to minimize process disturbances and protects the recycle valve from excessive wear. Deadband eliminates spurious recycle valve action when the operating point fluctuates rapidly around the surge control line. Intelligent deadband detects when conditions are stable and increases the deadband to further decrease valve action. The deadband is automatically lowered to provide greater sensitivity when the process changes. OptiComp gives you the flexibility to use any one of several criteria for surge detection: Minimum Flow, High Rate of Change of Flow, High Rate of Change of Speed, and Low Operating Point. External-signalbased detection for Thrust or other available Bently Nevada Vibration inputs are supported as well. Automatic gain compensation provides dynamic tuning under variable operating conditions. Decoupling isolates anti-surge control from external changes. Five general purpose inputs are available to provide transient feedforward adjustment of the anti-surge control based on conditions external to the anti-surge controller. 4
Additional features Proportional Gain increases the anti-surge control response at low compressor operating points to assist recovery across the Surge Control Line. Multi-Surge Trip and Fast-Acting Solenoid provide additional protection for multiple and sustained surges. Auxiliary Positioning of the recycle valve via up to three external inputs. Output Limiting reduces the risk of surge during process disturbances. Valve Characterization for non-linear recycle valves. Load control and load sharing Many industrial applications, including pipeline compressors, NGL and LNG applications, and various downstream applications use compressors operating in parallel or series. In these applications it is imperative for the compressor control system to not only maintain the target load parameter, but also support efficient sharing of process gas flow/load among the units. If the system cannot simultaneously perform these two vital functions, the process may suffer decreased efficiency, unnecessary recycle, and a degraded immunity to disturbances. This may also exacerbate problems during shut-down and start-up. Configurable Offset for recycle valves having a dead zone at zero stroke. Recycle Valve Overstroking to provide tight shut-off. Protections Override facilitates surge testing by disabling Boost, Safety Protection Response (SPR) and Operating- Point-Surge-Detection. Purge Switch closes the recycle valve to facilitate purging through the compressor during startup. Options Hot Recycle Line in processes that use a hot recycle path for fast and interim anti-surge response when the main recycle loop (sustained recycle) is very long. IGV Effect on the Operating Point when the compressor uses modulating Inlet Guide Vanes for capacity control. Quench Control for cooling recycle gas as applicable. Suction and Discharge Pressure Override Control assists the primary Pressure/Load/Capacity controls. Valve Position Feedback for alarming and valve tripping on anti-surge and hot recycle valves (if used). GE uses an integrated peer-to-peer Load Control and Load Sharing strategy. In the region close to the Surge Control Line the relative distance to the Surge Control Line is used as the load sharing variable; otherwise, control sharing transitions to a selected load parameter, typically Exhaust Gas Temperature (EGT), Gas Generator Speed, Steam Flow, or Motor Power. All Load Sharing controllers exchange their status and process variables via GE's proprietary high speed Unit Data Highway (UDH) network and each controller then calculates the applicable averages to generate its Load Control output. The comprehensive features of the Load Control/Load Sharing include fully shared or progressive loading, surge valve output biasing, override control, balancing among different-sized compressors, units adding and withdrawing, any reasonable load variable, gain compensation, and Local/Auto load sharing modes, among others. 5
Fast, Flexible and Fault-Tolerant Platform Every OptiComp solution we deliver is pre-tested and field-proven based on GE Energy s Mark VI/MarkVIe family of controllers. We can also custom-design a solution to meet your unique process and control system requirements. This flexibility extends to redundancy configurations. Simplex, Duplex and full TMR architectures are supported. These controllers perform fast execution/scan rates up to 10 msec to respond effectively to fast turbine fuel control and compressor anti-surge control loops. Both general purpose and turbine-specific I/O are supported. Turbine-specific I/O is used for direct interface to the unique sensors and actuators on turbines. This eliminates a substantial amount of interposing instrumentation. As a result, many potential single point failures are eliminated in the most critical area for improved reliability and reduced long-term maintenance. Controller and I/O features Self-diagnostics and early failure detection. All field inputs are filtered to remove noise and accurately control the operating point. Intelligent fallback strategies, including a backup, non-flowbased map and steady state protection against signal failures. Analog Output Failure Monitoring. 1 msec Sequence of Events (SOE). Ethernet is used at all levels including I/O networks, control networks with peer-to-peer communications between units, and plant network interfaces. Integrated train control solutions Operator and Maintenance Stations Plant Data Highway Train Historian Unit Data Highway Bently Nevada System 1* One Control with Distributed I/O for: Turbine and compressor sensors Monitoring, control and protection 10, 20, 40 ms frame rates Simplex, dual, triple redundant MKVIe Controller(s) MKVIeS Controller(s) TUV SIL Bently Nevada 3500 VMS TUV SIL IO Network 100 Mbps Ethernet IO Network 100 Mbps Ethernet Speed Vibration Servos Flame Auxiliaries Pressure/ Combustion/ Temperature DLE Sequencing Antisurge Process Control Safety Shutdown 6
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Experience Compressors are at the heart of your process. But it s not just the machinery that s at stake it s the processes they run, with production often worth millions of dollars per day. With so much at stake, you need a company with the multi-industry, multi-oem, multi-application experience to ensure the job is done right the first time. And, you need someone with the proven software, hardware reliability, and field support services to keep your machines and processes online 24/7/365 To learn more, ask us about our most recent success stories GE Energy 3800 North Wilson Avenue Loveland, CO 80538 USA + 1.970.461.5201 / 800.835.5182 www.ge-energy.com/controlsystems Select Global Office Locations Abu Dhabi, UAE +9712 6997147 Baton Rouge, LA, USA: +1.225.752.7576 Beijing, China: +86.10.65611166 Bracknell, United Kingdom: +44.01.344.460641 Burr Ridge, IL, USA: +1.630.920.8480 Campinas, Brazil: +55.19.2104.6900 Charlotte, NC, USA: +1.704.676.7750 Dhahran Airport, Saudi Arabia: +966.50.38.30303 Dubai, UAE +97.14.313.1816 Florence, Italy +39 055 423 8047 Gladesville, Australia: +61.298.44.6970 Houston, TX, USA: +1.713.640.1111 Johannesburg, South Africa: +27.11.653.8900 Maracaibo, Venezuela: +58.261.791.6159 Minden, NV, USA: +1.775.782.3611 Neu-Isenburg, Germany: +49.6102.73960 Poznan, Poland +48 22520 5325 Shanghai, China: +86.21.6453.04308 Singapore: +65.6863.3007 * Trademark of General Electric Company Windows is a registered trademark of Microsoft Corporation in the United States and other countries. 2008, General Electric Company. All rights reserved. GEA-15043 (03/08)