LNGjournal October 2007 29

ENGINEERING FORUM
The emulator-calculated controller
outputs are sent back to the dynamic
model to control the position of the
recycle valves. With control parameters
downloaded from the plant CCC system,
the emulator would function the same
way as the field control system. The
emulator would also allow the tuning of
the parameters so that new control
strategies could be evaluated and new
tuning parameters could be tested.
A Visual Basic (VB) based script was
developed to externally control the
execution of the dynamic model, which
subsequently controls the execution steps
of the CCC emulator. Complete
synchronization between the dynamic
model and emulator was validated before
the integrated tool was put in use.
Simulation results
The integrated simulation tool was
validated against plant data collected
from a previous MCHE trip event, which
resulted in a trip of the MR compressor
train and surge of the compressors.
Dynamic data collected from the actual
event was used to validate the simulation
results.
According to the plant control logic, an
MCHE trip will initiate the following
operation sequences.
Close the axial compressor inlet guide
vane (IGV)
Stop heavy and light MR flows by
closing the MR flow control valves
Anti-surge control valves open when
compressor approaches SCL
With the opening of the anti-surge valves,
the MR compressors were expected to
remain on line in stable recycle operation.
However, in the actual event, the MR
compressors became unstable after the
MCHE trip, and eventually resulted in a
shutdown of the compressor train.
Plant data showing the closing of the
axial stage IGV, initiated by the MCHE
trip signal, and the compressor speed are
provided in Figure 5. Speed decay started
at approximately 49 seconds into the
event, indicating that a train trip was
initiated.
The dynamic model was first
initialized to plant conditions prior to the
event. Dynamic tasks were activated
based on plant control sequences. To
accurately emulate the real plant control
system, the simulation time step was set
to be the same as the scan frequency of
CCC controllers in the actual plant.
Figure 6 shows some of the
comparisons of dynamic simulation
results with plant data. Two of the plots
reproduced here are a) Compressor
discharge flow (shown as pressure
differential) and b) Suction and discharge
pressures.
Overall, the simulation was able
accurately to reproduce the plant event,
both in terms of the simulated
compressor conditions and control
responses from the emulator.
During the process, the dynamic
simulation model and CCC emulator
were validated separately and combined,
and deemed to be highly accurate and
reliable for the purpose of the study.
Control issues
Close examination of the MCHE trip
event as described in the previous section
suggested that, without other preventive
measures, the disturbance caused by an
MCHE trip could develop into a situation
that was beyond the controllability of the
CCC system.
Another finding was that the first
level PI control response apparently was
not tuned to serve such fast disturbances.
The anti-surge responses mainly relied
on the second level response by step-
increasing the output.
However, a sudden increase of flow to
one stage could itself magnify the
instability of the system as it could
deprive flow for the other stages.
The CCC system is designed to handle
a number of limitations over the
compressor operating window.
Given the complexity of the multi-
staged compressor system, plus the
extreme operating conditions imposed by
the plant operation, the CCC system
alone appeared to be ineffective in
handling certain scenarios.
Adding more safety margin to the
surge control line was not considered a
practical solution as it would
significantly affect the compressor
operation flexibility. Therefore, other
control improvements became necessary
to address these operating scenarios.
A trip of the PR compressors was
found to be more critical and could drive
the MR compressors into the unstable
region even faster. The controllability of
the MR system in the event of a PR trip
is studied in the first case study below.
The objective of this case study was to
improve the control strategies to ensure
continuous operation of the MR system
after a trip of the propane compressor
system.
The plant operation sequences in case
of a propane trip are similar to the
MCHE trip described earlier. However, in
the event of a loss of the PR system, the
reduction of MR flow to the MR
compressor train can occur in a faster
manner and thus would require more
prompt anti-surge control actions.
Recycle valves
The results indicate that the disturbance
caused by a propane trip could be more
severe as compared to an MCHE trip.
Although a series of step-increase control
responses were triggered, the MR
compressors moving rapidly into the
unstable region, and showed high
possibility of surge.
The simulation also took into account
the actuator performance in the field. The
recycle valves are shown to have a one-
second delay and a 3 percent dead band
before starting to open.
To prevent the foreseen surge event
from occurring, simulations were
performed to combine a feed forward
strategy with the CCC control algorithm.
The feed forward logic was applied to
ramp open the recycle valves at the
initiation of a propane trip. To avoid
upsetting the compressors, the
appropriate ramp target and ramp rate
of the recycle valves were tuned using the
simulation.
The pre-determined recycle valve
opening and ramp rate were insufficient to
keep the MR compressors in the stable
region. The second level control responses
from the CCC system were triggered before
the end of the feed forward ramp period.
The compressor system was unstable and
showed the tendency of surge.
With the final settings of the feed
forward parameters, the feed forward
logic was activated by the PR trip signal,
p23-30:LNG 3 12/10/2007 12:16 Page 7