Abstract: The stroking speed of an antisurge control valve is impeded by the combined damping effects of signal dead time and the inherent lag of ancillary pneumatic components within a primary control loop. Furthermore, as control valve actuator size increases, the negative influence of these two impediments (dead time and lag) is amplified. As a result, control valve response times are adversely affected; and the possibilities of surge-induced compressor damage and process upsets are heightened. For these reasons, this disclosure relates to a method for protecting turbocompressors from impending surge, and for preventing subsequent process upsets, by improving antisurge control. But more specifically, it describes a technique for decreasing damping effects by evacuating control valve actuators (diaphragm or piston) through restrictions having a lower resistance to compressible-fluid flow rather than through volume boosters--consequently, increasing a control valve's opening speed to that of an emergency shutdown.

Abstract: A turbocompressor's Surge Limit Line, displayed in coordinates of reduced flow rate (q.sub.r) and reduced head (h.sub.r), can be difficult to characterize if the slope of the line is small; that is, nearly horizontal. And it can be especially difficult to characterize if the surge line exhibits a local maximum or minimum, or both. This is often the case with axial compressors having adjustable inlet guide vanes, and for centrifugal compressors with variable inlet guide vanes and diffuser vanes. With their prime objective being the prevention of surge-induced compressor damage and process upsets, antisurge control algorithms should compensate for variations in suction conditions by calculating both the operating point and the Surge Limit Line, utilizing specific (invariant) coordinates derived by using the notations of similitude or dimensional analysis. The result is that the surge limit is invariant (stationary) to suction conditions.

Abstract: A method is provided for controlling fuel flow to the combustor of a gas generator turbine during sudden changes in load or during a surge cycle of the process turbocompressor. Surge control is initiated by analog input signals emanating from various devices located throughout the compressor-process system. The fuel control system includes input signals from the gas turbine driver. These signals are acted upon by the fuel control system which transmits a signal to a fuel valve actuator that controls the valve that meters fuel to the combustor. In addition to this sequence of control communication, however, is a rate-of-change in the amount of the fuel provided. The rate of the increase of the amount of fuel is determined by current operating functions of the fuel control system. However, because of the characteristics of general load rejection and recovery, and the abrupt nature of surge, the rate of change in the flow rate of fuel is extremely high.

Abstract: An improved method is provided for controlling fuel flow to the combustor of a gas generator turbine during sudden changes in load or during a surge cycle of the process turbocompressor. Surge control is initiated by analog input signals emanating from various devices located throughout the compressor-process system. The fuel control system includes input signals from the gas turbine driver. These signals are acted upon by the fuel control system which transmits a signal to a fuel valve actuator that controls the valve that meters fuel to the combustor. In addition to this sequence of control communication, however, is a rate-of-change in the amount of the fuel provided. The rate of the increase of the amount of fuel is determined by current operating functions of the fuel control system. However, because of the characteristics of general load rejection and recovery, and the abrupt nature of surge, the rate of change in the flow rate of fuel is extremely high.

Abstract: Balancing the load between compressors is not trivial. An approach is disclosed to balance loads for compression systems which have the characteristic that the surge parameters, S, change in the same direction with rotational speed during the balancing process. Load balancing control involves equalizing the pressure ratio, rotational speed, or power (or functions of these) when the compressors are operating far from surge. Then, as surge is approached, all compressors are controlled, such that they arrive at their surge control lines simultaneously.

Abstract: A method and apparatus are disclosed for preventing overspeed of a hot gas expander and its resultant load when the load (or a portion of it) is shed suddenly. In this situation, power applied by the expander to the shaft must be reduced, but normal feedback to the speed controller may be too slow to be effective. The load rejection may be sensed by a feedforward system before a significant speed increase is detected by the speed control loop. For this approach, the expander can be instrumented with either a flow measurement device, a downstream pressure, or a downstream temperature. Inlet pressure and inlet temperature are required. The method uses the characteristic map describing the expander (shaft power versus mass flow rate) along with a feedforward control action to anticipate the speed increase. By using dimensional analysis, the characteristic curves will collapse into single curves describing the parameters of reduced flow, reduced power, and pressure ratio.

Abstract: A method and apparatus are disclosed for protecting gas turbines (two- and three-shaft) from damage or destruction during dangerous transients. In this situation, fuel flow must be reduced, as needed, to keep the exhaust gas temperature below a maximum limit, thereby avoiding damage to blading in the turbine's first-stage. The dynamic action of the temperature downstream of the combustion chamber may be estimated and then used to correct the temperature measured by thermocouples. For this approach, the turbine is instrumented with an inlet pressure transmitter and an outlet temperature transmitter. The method dynamically estimates temperatures downstream of the combustion chamber and reduces the fuel flow rate if the estimated temperature approaches the temperature limit. Existing thermocouple measurements (EGT) are used as well as the pressure of air exiting the compressor (CDP) upstream of the combustion chamber.

Abstract: A method and apparatus are disclosed for controlling the rotational speed of gas and steam turbines, and hot gas expanders, with each of these drivers driving a rotational load by way of a shaft. To accomplish this control technique, it is necessary to easily and accurately calculate the amount of power which must be shed by the driver(s) to maintain a constant speed, i.e., neither accelerating nor decelerating. Action must be taken to reduce the power applied to the shaft by this amount. The method incorporates an open-loop approach and uses a time derivative to moderate the open-loop action accordingly.

Abstract: Compressors for processes, as used for refrigeration systems applied to ethylene production, are multiple stage machines; furthermore, sidestreams enter/exit between the stages. Since a flow measurement device is not available between stages, and the gas temperature entering most stages is unknown, it is difficult to calculate an accurate value for reduced flow for antisurge control purposes. A new method is described, whereby reduced flow alone is replaced by the product of the reduced flow and the equivalent speed. This allows accurate calculation of the distance of the operating point to the surge line since the inlet temperatures into the separate compression units (except the first) are not necessary. The invention described herein can be applied to multistage compression systems for a variety of processes.

Abstract: A method and apparatus are disclosed for protecting turbocompressors from unstable flow conditions (surge and stall). To accomplish this, it is necessary to easily and accurately calculate a compressor's operating point and its distance from the interface between the surge region and the stable region--this interface is referred to as the Surge Limit Interface. The proximity of the operating point to the Surge Limit Interface is calculated using measurements of properties throughout the compressor-process system. It is crucial that the calculation be invariant to suction conditions, especially gas composition. Disclosed are three coordinates, T.sub.r (reduced torque), P.sub.r (reduced power), and N.sub.e (equivalent speed). Each of these can be combined with other invariant parameters to construct coordinate systems in which to define the Surge Limit Interface and measure the distance of the operating point to that interface.

Abstract: A method and apparatus for maintaining a main process gas parameter such as suction pressure discharge pressure, discharge flow, etc. of a compressor station with multiple dynamic compressors, which enables a station controller controlling the main process gas parameter to increase or decrease the total station performance to restore the main process gas parameter to a required level, first by simultaneous change of performances of all individual compressors, for example, by decreasing their speeds, and then after operating points of all machines reach their respective surge control lines, by simultaneous opening of individual antisurge valves. In the proposed load-sharing scheme, one compressor is automatically selected as a leading machine. For parallel operation, the compressor which is selected as the leader is the one having the largest distance to its surge control line.

Abstract: A method of control and control apparatus for load sharing between multiple compressors working in parallel and/or in series which enables all of the load-sharing compressors to carry their optimum share of the load. This load-sharing scheme follows the safest load-sharing formula and also provides for substantial energy savings. It automatically divides the load whenever a strong decoupling between process control and compressors after the compressors' operating points cross their Surge Control lines.

Abstract: A control apparatus for antisurge protection of a dynamic compressor including a junction of a closed antisurge loop with a surge limit computing module and a two mode controller with a relay backup system with deviation alarms is characterized in operation in that during a slow disturbance, the two mode controller provides modulated antisurge protection by opening a relief valve, if the operating point of the compressor crosses the surge control line and during a dangerously fast disturbance, the relay backup system provides antisurge protection if a preestablished deviation of the operating point from the surge control line appears. A relay backup system opens the relief valve very quickly. When the relief valve is so opened, the process of the user of fluid from the compressor is compensated by increasing the performance of the compressor to maintain pressure or flow rate.

Abstract: Systems and methods are disclosed for the automatic control of one or more pumping and compressing machines and of the related fluid network. The purpose of such systems and methods is to maintain only the required pressure just after a source or just before a user so as to reduce the compressing or pumping energy required; to divide the load within a group of one or more compressing or pumping machines so as to compress the fluid with reduced use of energy and improved pressure control; to improve protection of the turbo compressors when used in parallel from dangerous levels of operation.

Abstract: A control system is disclosed for a noninteracting control and protection of a dynamic compressor having rotating vanes.The method consists of a junction of a few control circuits for controlling the performance of a dynamic compressor, for protecting compressor from approaching dangerous zones of operation, and for maintaining a required mass flow rate of a gas through the compressor.An automatic control system based on using the above method is distinguished by its simplicity, great transient and steady state precision and high reliability of surge protection.

Abstract: A method and apparatus for protecting a dynamic compressor from surge. The method includes a first step for providing a simultaneous control of a smaller relief means and a main control member of a dynamic compressor or the driver thereof for changing the performance of the compressor. This combined action provides for the protection from surge and at the same time insures the invariability of the main control parameters of pressure, mass flow rate to the user, or the speed of rotation. The second step provides for controlling a larger relief means and provides for antisurge protection in those cases when the first step is not sufficient to protect the compressor from surge. Apparatus is also provided for automatically implementing the method.

Abstract: A method is disclosed for a cascade control of a dynamic compressor to maintain a constant mass flow rate to a process. The method consists of a successive junction of control loops for controlling the speed of rotation, the pressure in the delivery, and the mass flow rate; the output signal of each outer loop being the input signal for the inner loop and each of the loops containing a compensating element to reduce the effects of large time constants of all previous loops.An automatic control system based on using the above method, distinguished by its great static and dynamic precision in maintaining a controlled parameter, and by the high reliability of protection of the compressor from surge, and protection from a dangerous increase of the speed of rotation and of a dangerous increase of the discharge pressure.

Abstract: A control system is disclosed for a cascade control of a dynamic compressor having a variable speed of rotation to maintain a constant pressure to a process. The method consists of a successive junction of control loops for controlling the speed of rotation, the flow rate of a compressor, the pressure in the delivery or in suction; the output signal of each outer loop being the input signal for the inner loop and each of the loops containing a compensating element to reduce the effects of large time constants of all inner loops.An automatic control system based on using the above method, distinguished by its great transient and steady state precision in maintaining a main controlled parameter, and by the high reliability of protection of the compressor from surge and from a dangerous increase of the speed of rotation.

Abstract: A method is disclosed for the improved operation of heating stoves for blast furnaces. This method is comprised of a combined use of an independent source of compressed air and potential and thermal energy of air remaining in the heating stoves at the end of a period of cooling. The purpose of this method is to reduce the time of filling of the ready to go on -- wind stoves by compressed air; to stabilize the operating conditions of the blast furnace; to save coke; to save the fuel spent on heating the stoves.