CCC Antisurge system at
K2503
A Training Presentation
By: IAS
What is Surge?
•Compressor surge is defined as a
sharp drop in discharge pressure and
flow rate, including a flow reversal.
•Compressor surge happens due to a
build-up of discharge pressure or a
flow rate reduction, which causes the
compressor to expend the built up
back pressure via a flow reversal.
•The flow reversal may cause severe •High Vibration
damage to the rotor & expensive
•Increase in Temperature between
process downtime. It is normally
stages
accompanied by:
The Solution
•As we can see, either an
increase in discharge
pressure
•Or reduction in flow will
cause surge.
•So the solution is to
measure these parameters
and increase flow on our
own when compressor gets
close to surge. This is done
through blow-off.
•A properly designed Antisurge System will have an adequately sized blow-
off or recycle valve, a fast response time and accurate positioning. The
result will be sufficient Surge protection without too much loss of efficiency.
CCC Antisurge system at
K2503
History
•1967 vintage refrig-compressor relocated from paqscagoula
had a long history of coupling failure. After coupling failure
in march of 1997, detailed study of existing design was
carried out.
•Deficiencies in existing valve stroking time, inadequate
execution response time of tdc3000 and the unnecessary
operation of machine at lower efficiency were major factors
in bringing the machine on ccc antisurge control.
•Hardware purchased in 1999 and project finally
implemented in the april of 2001.
Existing system architecture
LCN
NIM
PM
APM
Serial
Ps Ts Ft Td Pd Interface
Module
Port 3
A/O A/O (On APM)
Fault Fault Port 4
Tracking Tracking Trainview &
Primary RCS Backup Configurator
Port 1
Fy
Controller
Software
•The controller configurator software uses binary hex files
to download the controller software to series 3P
controllers. The BHF file is the actual program or code that
converts any controller into an antisurge controller, or
performance controller etc.
•Parameter sets are the table of values for all constants
¶meters that are part of the original code (downloaded
as a bhf). These parameters and constants include the tuning
parameters for the pid equation, designation of the analog &
discrete input channels and comm port settings. Parameter
sets exist as prj files.
Controller
Hardware Layout
E4 E2
LP Stage Antisurge
Control
HP Stage Antisurge
Control
E4 E2
Controller
Hardware Components
Controller Cards
•The CPU PCB assembly provides primary computational, serial
communication and discrete I/o capabilities.
•The analog PCB assembly provides all analog I/o circuit points.
•The power supply assembly converts the input power to the
voltages required by the controllers internal circuitry.
Controller Panels
•The front panel provides the controllers operator display and
input functions.
•The engineering panel provides the controller’s configuration and
tuning functions.
•The back panel provides wiring terminals for the controllers I/o
circuits.
Controller
Hardware
I/O Specifications
•Eight 4 to 20mA Analog inputs (CH1 to CH8)
•Two 4 to 20mA Analog outputs (Out1 and out2)
•Seven discrete 24Vdc inputs (D1 to D7).
•Five discrete 24Vdc relay outputs (CR1 to CR5).
Port Specifications
•Four Serial Ports (Port1 to Port4)
•Two serial ports (1 & 2) are used for communicating with
other CCC Controllers. Port3 is used for SI Communication
with external control system (e.g. TDC) and Port4 for
communication with host computers (I.e Trainview operator’s
station).
Controller
Hardware-Controller Cards
CPU PCB Assembly
•A Zilog Z80 CPU chip.
•A RAM chip for storing internal calculations.
•2 EPROM chips to store the control program
& parameters.
•2 I/O chips providing 4 serial ports, 8 DI’s
and comm between cpu and the and
engineering panel.
•A super-capacitor for powering the RAM
during power outages.
•8 electromechanical (DO) relays & their N/O
& N/C jumpers.
•Isolating power for the serial ports.
•Speaker for audible feedback.
Controller
Hardware-Controller Cards
Analog PCB Assembly
•The analog board has 8 analog
inputs that are referred to as ch1 to
ch8. All 8 of these inputs must be
configured as either current or
voltage inputs by placing the
configuration jumpers in either the C
or V positions.
•The two analog outputs (OUT1 &
OUT2) are factory configured as
either 20mA or 5Vdc by setting a
jumper on the inside of the back
panel.
Controller
Hardware
Front Panel
Assembly
The Antisurge controller’s
front panel features 4
alphanumeric readouts, 10
active led indicators and 8
control keys. It also includes
a beeper whose pitch maybe
altered from the front panel.
Controller
Hardware
Back Panel
Assembly
The Back Panel Assembly
comprises of 8 analog input
termination channels,2
analog outputs, 7 discrete
inputs, 5 discrete outputs
(CR1-CR5), one 24v output
terminal, and the
controller’s 5 comm ports.
The Back Panel also
features a 96~264 VAC and
21~32VDC power terminal.
Controller
Hardware
The Engineering panel is situated behind
Engineering
the front panel. Access to the
Panel
Engineering panel simply requires lifting
of the face plate.
Controller
Hardware
Engineering Panel •The Engineering panel allows you to
display or change parameter values &
Also executes process & controller
test procedures.
•The panel may be broken down into
three main sections:
•8 character alphanumeric readout.
•4 data group keys across the bottom.
•16 Data keys in the middle.
•The controller beeps and displays a
confirming message as each key is
pressed. If a key sequence is not
completed, the controller will beep &
clear the display after45 seconds of
keyboard inactivity.
Controller
Hardware
Engineering Panel Data keys
•The 4 Data group keys are used only
to initiate a new key sequence, at which
point, one of the 16 data keys is
pressed one or more times to select the
desired parameter to be viewed.
•The 2 gray data keys are used to end
key sequences, as under:
•Pressing CLEAR either aborts a
sequence without entering changes or
clears digits while entering a numeric
value.
•Pressing ENTER at the end of a
parameter entry sequence records
the new value.
Controller
Hardware
Engineering Panel Function
•The other 14 multi coloured Data keys are
divided into 4 sections each.one is gray,
each of the others is the same colour as a
data group key. The function of each such
key depends on when it is pressed in a key
sequence.if pressed immediately after a data
group key, the parameter in the matching
coloured area will be displayed. Otherwise,
it enters the value of the gray area.
Example
•Key sequence for Transmitter status
test: [Mode:D ANIN-] to do this,
press ‘mode’ till mode ‘D’ appears,
then press ‘ANIN’ then ‘-’. The
various anin’s maybe scrolled
through with the ‘.’ data key.
Controller
Engineering panel data keys
Useful modes & examples
•Very important mode as no parameter can be altered from
engineering panel without enabling it.
Controller
Engineering panel data keys
Useful modes & examples
Controller
Engineering panel data keys
Useful modes & examples
Controller
Engineering panel data keys
Useful modes & examples
Controller
Engineering panel data keys
Useful modes & examples
S3-Configurator
Purpose & Usage
•The Series 3 Plus Configurator is available as an engineering
tool to setup & tune controller parameters primarily during
the engineering stage of a project. In addition, this program
can be used to download controller software (as BHF files).
•Trainview software is the primary operator interface while S3
configurator is normally intended to be integrated for
maintenance and monitoring purposes.
•If the host computer running in the configurator software is
equipped with serial ports that conform to RS232, then an
RS422 to RS232 converter must be used as the controllers
operate on RS422. The recommended comm adapter is the AEG
OIC-422.
S3-Configurator
Communication Adapter
•If the host computer has a female d shell COM port, a one to
one cable with male connectors on each end will be required.
Only three pins on the connector will be used, Pin2 for Tx,
Pin 3 for Rx and Pin 7 for Ground. Remember, the adapter
must be connected to the controller’s PORT 4.
•The standard supply for the OIC-422 is a 110Vac powered
transformer.
S3-Configurator
Software Utilities
•Once a project directory is added from the settings menu, S3
Configurator opens with that directory in the project tree.
•The ‘SCAN FOR CONTROLLERS’ utility allows the user to
scan the host computers configured COM port for any serial
activity on that port. The controller is identified by the
computer ID number from 1 to 64.
•A particular parameter maybe searched in a parameter set and
its meaning searched from the relevant manual by simply
clicking on the parameter and pressing F1.
•The read and write parameter set utility allows access of and
changes to a parameter set inside the controller.
•The ‘Compare’ tab provides a useful means to check the
differences in two parameter sets. Any differences show up
highlighted in red.
•For converting one type of controller to another, a new bhf
must be loaded into the eprom. To do this though, the com
settings of the computer & controller should match.
MS3-Config
Comm Settings
MS3 Modbus Driver
•Ms3 is the software modbus
driver. The four buttons hold
restart, setup, log & Debug
options.
•The setup button helps to
configure the serial ports. Upto
ten channels are available for
assigning serial ports.
MS3-Config
Comm Settings
MS3 Modbus Driver •Editing a serial port leads to the
channel definitions. After
assigning a port, the baud rate,
parity and data & stop bits are
also set. These settings must
match those of the controller.
•The same settings must also be
updated in the computers com
port settings in the device
manager which is accessed from
the control panel of the pc.
Note
•If there is a mismatch in the settings of the controller and
Ms3 config, the engineering panel display in the controller
will instantly annunciate the error when a controller is
searched for. A mismatch in the Parity settings will be shown
by a ‘P’ and a difference in Baud rate settings as ‘F’ for
‘framing error’.
Software Procedures
READ PARAMETER SETS
•For reading a parameter set, a controller can simply
be selected from the “Search for controllers” tab by
clicking on it, after which ‘Ok’ should be pressed. The
tab has options for whether the parameter set being
read should overwrite an existing set or simply be
saved with a new name.
•Before a Parameter set is read, MODE LOCK 1 must be
set to OFF from the controller. This disables the
read/write inhibit parameter, as discussed earlier.
Software Procedures
WRITE PARAMETER SETS
•For writing a
parameter set, the
parameter set to be
written should be
opened and then
‘WRITE PARAMETER
SET’ selected from the
file menu. The rest of
the procedure is the
same, a controller
need simply be
selected from the
controller list. Rule
of MODE LOCK 1
applies here as well.
Software Procedures
Download BHF to Controller
•The following conditions must be met when
downloading a new BHF into a controller:
•Mode Lock 1 must be set to OFF.
•Must use port 4 on the series 3 plus controller.
•Must use 19200 Baud Rate & Odd Parity.
•Controller must be in Manual Mode.
Software Procedures
Download BHF to Controller
•For downloading, the
download option is
selected from the file
menu and a BHF is
selected from the LOAD
BHF File button on the
new window.
•The BHF for Antisurge
as provided by CCC is
numbered 756001. BHF’s
for other controllers
have also been provided
by CCC.
•The controller is
selected from the
controller list.
The redundant control
Selector
RCS
•The RCS provides redundancy of the
antisurge controllers on the
comressor. The front interface of the
redundant control selector indicates
which controller is presently active by
lighting its green MAIN or red BACKUP
led. This face plate also provides the
feature of manual switching & it is
possible to switch from the main to the
backup controller by pressing a
button.
•An important note is that the RCS will
not automatically return the control
of the process after the fault in the
main controller is fixed. This is to be
done manually. Also, control will not
be transferred to a failed controller.
The redundant control
Selector
•The RCS is
simply the
manual
RCS
changeover
switch and
face plate that
shows which
controller is Primary Backup
currently
running & Forced Indications
which is Changeover
tracking. The
actual
redundant
AO RCU AO
control is
achieved by the Fault Relays Fault Relays
RCU, which
sends the Tracking Tracking
final output to
the Fy.
Fy
The redundant control Unit
Controller Sequencing
•Woodward Governor controls the speed of the machine.
When the speed is below 5790 RPM, the antisurge
controllers display “status STOP”. Right now the antisurge
valves will be fully open.
•At this rpm of 5790, the controller changes its state from
“stop” to “run”.
•The controller gets this signal as a volt free discrete
output from the woodward governor at the given speed
through a programmable relay.
•The antisurge controller unloads the compressor by
ramping open the recycle valves when speed signal from
woodward governor decreases to 5785 RPM. Here the
controller goes into stop state.
•Under normal conditions, the primary controller’s discrete
input D1 is de-energized, rendering it in the active mode and
the redundant controller’s D1 is energized. The status
light on it’s front plate shows it to be in the tracking state.
The D1 signal comes from the RCU to both the controllers.
Power Distribution
•Redundant 110 Vac power supply for antisurge controllers.
•Primary controllers are on E4 110VAC ups, while backup
controllers are on E2 110VAC ups.
•Transmitter power is isolated, regulated, short circuit
protected 24VDC, 250mA maximum.
•RCS has a redundant 24Vdc power supply through PS1 and
PS2 (110VAC to 24VDC).
•Maximum power consumption including transmitter power is
35 watts.
FIC149P, FIC149R
DBAM
E4 FIC151P & FIC151R
110V
Controllers
TBAC
PS1 24V
FIC149 &
E2 TBDC 151 RCU’s
PS2
Q/A
