Load sharing method and apparatus for controlling a main gas parameter of a compressor station with multiple dynamic compressors

A method of controlling a compressor station pumping gas from a process located upstream from said station to a process located downstream from said station;

• said compressor station consisting of a plurality of dynamic compressors working in series, each of which being operated by a unit final control means for changing the compressor performance;
• said compressor station being also equipped with a station control system adjusting the station performance to demands of both said upstream and downstream processes in order to maintain a main process gas parameter;
• said station control system consisting of a station control means controlling said station main process gas parameter;
• unit control means, one for each compressor, operating said unit final control means;
• and antisurge control means, one for each compressor, computing a relative distance between a compressor operating point and a respective surge limit, and preventing said distance from decreasing below some predetermined minimum level by opening an antisurge final control means, said method comprising:
• developing a corrective change of the output of said station control means to prevent a deviation of said main process gas parameter from its required level;
• computing for each individual compressor a normalized relative distance to a surge control line, said normalized distance being equal to zero at the moment when said relative distance of compressor operating point from the respective surge limit become equal to said predetermined minimum level;
• computing for each compressor a mass flow rate W.sub.c of gas flowing through the compressor and a mass flow rate W.sub.d being equal to W.sub.c less the mass flow rate of gas flowing through the antisurge final control means;
• selecting among said compressors working in series the lowest mass flow rate W.sub.m, among the W.sub.d for all compressors working in series, said mass flow rate representing the mass flow rate passing through all the compressors from said process located upstream from said compressor station to said process located downstream from said compressor station;
• computing for each compressor a deviation A of the mass flow rate W.sub.d computed for the specific compressor from said selected minimum mass flow rate W.sub.m which passes through all compressors;
• computing for each compressor a criterion R, said criterion R being equal to a product of one minus said normalized relative distance to the surge control line and a difference of said mass flow rate through the compressor W.sub.c minus said deviation .DELTA., said difference presenting an equivalent mass flow rate through said compressor;
• selecting among said criterion R for all compressors working in series the lowest criterion R;
• operating said unit final control means of the compressor with the lowest criterion R by a scaled corrective change of the output of said station control means to restore said main process gas parameter to the required level;
• developing a unit corrective signal for each individual compressor to equalize its criterion R with said selected lowest criterion R;
• operating said unit final control means for each individual compressor which criterion R is higher than said selected lowest criterion R by combination of the scaled changes of the output of said station control means and said unit corrective signal whereby said main process gas parameter is restored to the required level and criterion R is simultaneously equalized with the selected lowest criterion R.

A method of controlling a main process gas parameter of a compressor station comprising a plurality of dynamic compressors working in parallel or series:

• each dynamic compressor of said compressor station being operated by a unit final control means for adjusting the performance of the compressor to the demand of the process, each dynamic compressor of said compressor station also being supplied by an antisurge final control means for preventing surge;
• said compressor station having a control system including:
• a station control means for preventing a deviation of said main process gas parameter from its required set point;
• a unit control means for each compressor operating said unit final control means;
• and an antisurge control means for each compressor manipulating the position of said antisurge final control means, said method comprising:
• calculating for each individual compressor a relative distance to its surge limit line and a relative distance to its surge control line, said relative distance to said surge control line being equal to zero when said relative distance to the respective surge limit decreases to its minimum permissible level below which said antisurge control means starts to open said antisurge final control means;
• calculating for each individual compressor two functions from said relative distance to the respective surge control line;
• said first function being applied to said unit final control means and being equal to a constant M.sub.1 when said relative distance from said surge control line is higher than or equal to a predetermined level "r", and when said relative distance is lower than "r" but control of the main process gas parameter requires to increase the compressor performance;
• in all other cases said first function being equal to zero;
• said second function being applied to said antisurge final control means and being equal to:
• constant M.sub.2 when said relative distance to the respective surge control line is lower than said predetermined level "r" and the control of said main process gas parameter requires opening of said antisurge final control means;
• constant M.sub.3, said constant M.sub.3 being <0, when said relative distance to the respective surge control line is lower than said predetermined level "r" and the control of said main process gas parameter requires closing of said antisurge final control means;
• in all other cases, said second function being equal to zero;
• developing a corrective change of an output of said station control means to prevent a deviation of said main process gas parameter from its required level;
• multiplying for each compressor said corrective change of the output of said station control means by said first function of the relative distance to the respective surge control line and adding this value to the unit corrective signal of an output of said unit control means, said unit corrective signal equalizing said normalized relative distance to the compressor surge control line with the selected highest normalized distance, for compressors working in parallel, or equalizing respective criterion R values with the selected lowest value, for compressors working in series, and using the summation value as a set-point for a position of said unit final control means in order to control said main process gas parameter, said control being provided only when said relative distance to the respective surge control line is higher than or equal to said predetermined level "r," or when said relative distance is below "r" but said corrective change of the output of said system control means requires to increase the compressor performance;
• and
• multiplying for each compressor said corrective change of the output of said system control means by said second function of the relative distance to the respective surge control line, optionally adding this value to, or selecting the highest value in comparison with, the corrective change of an output of said antisurge control means preventing surge, and using the final value as a set-point for a position of said antisurge final control means to control said main process gas parameter when said distance to the respective surge control line is below said predetermined level "r."

An apparatus for controlling a compressor station pumping gas from a process located upstream from said station to a process located downstream from said station;

• said apparatus comprising:
• a compressor station consisting of a plurality of parallel working dynamic compressors, each of which being operated by a unit final control means changing the compressor performance and an antisurge final control means for protecting the compressor from surge;
• said compressor station being also equipped with a station control system adjusting the station performance in order to maintain a main process gas parameter;
• said station control system consisting of a station control means controlling said main process gas parameter;
• a separate antisurge control means for controlling surge in each respective compressor, each said separate antisurge control means for controlling surge in each respective compressor computing a relative distance between a compressor operating point and a respective surge limit and preventing said relative distance from decreasing below some predetermined minimum level by controlling the antisurge final control means;
• a separate unit control means for each respective compressor, said unit control means operating a unit final control element to maintain said relative distance equal to that of the compressor with the largest relative distance;
• said antisurge control means for each compressor including means for continuously measuring suction temperature, discharge temperature, suction pressure, discharge pressure, rotating speed, and differential pressure across a flow element in suction;
• continuously calculating a relative distance between the compressor operating point and respective surge control line;
• continuously transmitting said relative distance to the unit control means associated with the same compressor;
• continuously developing an antisurge corrective change based on said relative distance to the surge control line;
• adding the value of said antisurge corrective change to another corrective change value which is computed by multiplying a corrective change continuously received from a station control means, by a first function of said relative distance to the surge control line, said first function being continuously computed by said antisurge means;
• and continuously using a value which is optionally the greatest or the sum of the associated corrective changes as set-point of the position of said antisurge final control means to prevent said relative distance between the operating point and the surge limit from decreasing below a predetermined margin of safety;
• said unit control means, for each compressor, continuously receiving said relative distance from surge control line from said antisurge control means for same associated compressor;
• continuously computing a normalized relative distance by multiplying said relative distance by a scaling constant and transmitting said normalized relative distance to said station control means;
• continuously receiving from said station control means a highest normalized relative distance and computing a unit control means corrective action;
• adding said unit control means corrective action to another corrective change value which is computed by multiplying said corrective change continuously received from said station control means, by a second function of said relative distance to the surge control line received from said antisurge control means, said second function being continuously computed by said unit control means;
• and continuously using the summed value of the associated corrective changes as a set-point of the position of said unit final control means, manipulating the compressor performance to restore the station main process gas parameter to its required level and to equalize said normalized relative distance to the compressor surge control line with the highest normalized relative distance received from said system control means;
• said station control means for controlling the station main process gas parameter continuously measures the main process gas parameter;
• continuously computes the difference from a predetermined set-point limit for said main gas parameter, continuously computes a station control means corrective change;
• and continuously transmits said station control means corrective change to all unit control means and antisurge control means which comprise the station control system, for use by said unit control means and antisurge control means to restore the station main process gas parameter to its required set-point level;
• and
• said station control means continuously receives said normalized relative distances from unit control means for all compressors in the system;
• selects the highest normalized relative distance to respective surge control lines for all compressors which comprise the station, thereby selecting a leader and continuously transmits the highest normalized relative distance to all unit control means which are included in the station control system, to be used as a set-point for the unit control means in equalizing their respective normalized relative distance to their surge control lines with the highest normalized relative distance of the leader, in order to optionally share the flow load.

An apparatus for controlling a compressor station pumping gas from a process located upstream from said station to a process located downstream from said station;

• said apparatus comprising:
• a compressor station consisting of a plurality of dynamic compressors working in series, each of which being operated by a unit final control means changing the compressor performance and an antisurge final control means for protecting the compressor from surge;
• said compressor station being also equipped with a station control system adjusting the station performance in order to maintain a main process gas parameter;
• said station control system consisting of a station control means controlling said main process gas parameter;
• antisurge control means, one for each compressor, computing a relative distance between a compressor operating point and a respective surge limit and preventing said relative distance from decreasing below some predetermined minimum level by controlling the antisurge final control means;
• unit control means, one for each compressor, operating a unit final control element to maintain a criterion R, representing both said relative distance and the equivalent mass flow rate through the compressor, equal to that of the compressor with the smallest criterion R value;
• said antisurge control means for each compressor continuously measuring suction temperature, discharge temperature, suction pressure, discharge pressure, rotating speed, differential pressure across a flow element in suction and differential pressure across a flow element in discharge downstream of a tap off for the flow passing through antisurge final control means;
• continuously calculating the normalized discharge mass flow rate W.sub.d by multiplying said differential pressure across a flow element in discharge by said discharge pressure, dividing by said discharge temperature, taking the square root of the result and multiplying by a scaling constant;
• continuously transmitting said normalized discharge mass flow rate to said station control means, and continuously transmitting said discharge mass flow rate to said unit control means associated with said compressor;
• continuously calculating the normalized compressor mass flow rate W.sub.c by multiplying said differential pressure across a flow element in suction by said suction pressure, dividing by said suction temperature, taking the square root of the result, and multiplying by a scaling constant;
• and continuously transmitting said normalized compressor mass flow rate to said unit control means associated with said compressor;
• continuously calculating a relative distance between the compressor operating point and respective surge control line, continuously transmitting said relative distance to said unit control means associated with said compressor;
• continuously developing an antisurge corrective change based on said relative distance to the surge control line;
• continuously adding the value of said antisurge corrective change to another corrective change which is computed by multiplying a corrective change continuously received from a station control means, by a first function of said relative distance to the surge control line;
• said first function being continuously computed by said antisurge means;
• and continuously using a value which is optionally the greatest or the sum of the associated corrective changes as set-point of the position of said antisurge final control means to prevent said relative distance between the operating point and the surge limit from decreasing below a predetermined margin of safety;
• said unit control means, for each compressor, continuously receiving said relative distance from surge control line from said antisurge control means for same associated compressor;
• continuously computing a normalized relative distance by multiplying said relative distance by a scaling constant;
• continuously receiving a minimum normalized discharged mass flow rate W.sub.m computed by said station control means and continuously transmitted to all said unit control means in the station control system;
• continuously computing the mass flow rate deviation .DELTA. by subtracting said minimum normalized discharge mass flow rate W.sub.m from said normalized discharge mass flow rate W.sub.d for said compressor, continuously received from associated antisurge control means;
• continuously computing the equivalent mass flow rate W.sub.e by subtracting said mass flow rate deviation .DELTA. from said normalized compressor mass flow rate W.sub.c continuously received from associated antisurge control means;
• continuously computing criterion R for said compressor by multiplying one minus said normalized relative distance to the surge control line by said equivalent mass flow rate W.sub.e ;
• continuously transmitting said criterion R to said station control means;
• continuously receiving from said station control means a lowest criterion R value R.sub.m and computing a unit control means corrective action;
• adding said unit control means corrective action to another corrective change value which is computed by multiplying said corrective change continuously received from said station control means, by a second function of said relative distance to the surge control line received from said antisurge control means, said second function being continuously computed by said unit control means;
• and continuously using the summed value of the associated corrective changes as a set-point of the position of said unit final control means, manipulating the compressor performance to restore the station main process gas parameter to its required level and to equalize said criterion R with the lowest criterion R value R.sub.m received from said station control means;
• said station control means for controlling the station main process gas parameter continuously measures the main process gas parameter;
• continuously computes the difference from a predetermined set-point limit for said main process gas parameter, continuously computes a station control means corrective change;
• and continuously transmits said station control means corrective change to all unit control means and antisurge control means which comprise the station control system, for use by said unit control means and antisurge control means to restore the station main process gas parameter to its required set-point level;
• said station control means continuously receives said criterion R values for all compressors in the station;
• selects the lowest criterion R.sub.m value among all criterion R values received from all unit control means in the station control system, thereby selecting the leader;
• continuously transmits said lowest criterion R value, R.sub.m, to said unit control means for all compressors which comprise the station, to be used as a set-point for the unit control means in equalizing their respective criterion R values with the lowest criterion R value of the leader, in order to optionally share the compression load.

A method of controlling a compressor station pumping gas from a process located upstream from said station to a process located downstream from said station, said compressor station including a plurality of parallel working dynamic compressors;

• each of said compressors being operated by a unit final control means for changing the compressor performance;
• said compressor station being also equipped with a station control system for adjusting the station performance to demands of both said upstream and downstream processes in order to maintain a main process gas parameter, said station control system consisting of a station control means for controlling said main process gas parameter;
• unit control means, one for each compressor, for operating said unit final control means;
• and antisurge control means, one for each compressor, for computing a relative distance between a compressor operating point and a respective surge limit, and preventing said relative distance from decreasing below some predetermined minimum level by opening an antisurge final control means, said method comprising:
• developing a corrective change of the output of said station control means to prevent a deviation of said main process gas parameter from its required level;
• computing for each individual compressor a normalized relative distance to a surge control line, said normalized distance being equal to zero at the moment when said relative distance of compressor operating point from the respective surge limit becomes equal to said predetermined minimum level, selecting among said normalized relative distances to the respective surge control lines of parallel working compressors at least one of said normalized relative distances and creating a target relative distance, d.sub.m, which is a function of said selected one of said normalized distances;
• developing a unit corrective signal for each individual compressor to equalize its normalized relative distance to the respective surge control line with said target relative distance, d.sub.m ;
• and
• operating said unit final control means for each individual compressor, by combination of the scaled changes of the output of said station control means and said unit corrective signal whereby said process parameter is restored to the required level and said normalized relative distance to the compressor surge control line is equalized with the selected target relative distance, d.sub.m.

A method of controlling a compressor station pumping a gas from a process located upstream from said station to a process located downstream from said station;

• said compressor station consisting of a plurality of dynamic compressors working in series, each of which being operated by a unit final control means changing the compressor performance;
• said compressor station being also equipped with a station control system adjusting the station performance to demands of both said upstream and downstream processes in order to maintain a main process gas parameter;
• said station control system consisting of a station control means controlling said station main process gas parameter;
• unit control means, one for each compressor, operating said unit final control means;
• and antisurge control means, one for each compressor, computing a relative distance between a compressor operating point and a respective surge limit, and preventing said distance from decreasing below some predetermined minimum level by opening an antisurge final control means, said method comprising:
• developing a corrective change of the output of said station control means to prevent a deviation of said main process gas parameter from its required level;
• computing for each individual compressor a normalized relative distance to a surge control line, said normalized distance being equal to zero at the moment when said relative distance of compressor operating point from the respective surge limit becomes equal to said predetermined minimum level;
• computing for each compressor a mass flow rate W.sub.c of gas flowing through the compressor and a mass flow rate W.sub.d being equal to W.sub.c less the mass flow rate of gas flowing through the antisurge final control means;
• selecting among said compressors working in series the lowest mass flow rate W.sub.m, among the W.sub.d, for all compressors working in series, said mass flow rate representing the mass flow rate passing through all the compressors from said process located upstream from said compressor station to said process located downstream from said compressor station;
• computing for each compressor a deviation A of the mass flow rate W.sub.d computed for the specific compressor from said selected minimum mass flow rate W.sub.m which passes through all compressors;
• computing for each compressor a criterion R, said criterion R being equal to a product of one minus said normalized relative distance to the surge control line and a difference of said mass flow rate through the compressor W.sub.c minus said deviation .DELTA., said difference presenting an equivalent mass flow rate through said compressor;
• selecting among said criterion R for all compressors working in series at least one of said criterion R and calculating a target criterion R, R.sub.m, which is a function of said selected one of said criterion R;
• developing a unit corrective signal for each individual compressor to equalize its criterion R with said criterion R.sub.m ;
• and
• operating final unit control means for each individual compressor differently by combination of the scaled changes of the output of said station control means and said unit corrective signal whereby said main process gas parameter is restored to the required level and criterion R is simultaneously equalized with the criterion R.sub.m.

An apparatus for controlling a compressor station pumping gas from a process located upstream from said station to a process located downstream from said station;

• said apparatus comprising:
• a compressor station consisting of a plurality of parallel working dynamic compressors, each of which being operated by a unit final control means changing the compressor performance and an antisurge final control means for protecting the compressor from surge;
• said compressor station being also equipped with a station control system adjusting the station performance in order to maintain a main process gas parameter;
• said station control system consisting of a station control means controlling said main process gas parameter;
• a separate antisurge control means for controlling surge in each respective compressor, each said separate antisurge control means for controlling surge in each respective compressor computing a relative distance between a compressor operating point and a respective surge limit and preventing said relative distance from decreasing below some predetermined minimum level by controlling the antisurge final control means;
• a separate unit control means for each respective compressor, said unit control means operating a unit final control element to maintain said relative distance equal to that of the compressor with a target relative distance;
• said antisurge control means for each compressor including means for continuously measuring suction temperature, discharge temperature, suction pressure, discharge pressure, rotating speed, and differential pressure across a flow element in suction;
• continuously calculating a relative distance between the compressor operating point and respective surge control line;
• continuously transmitting said relative distance to the unit control means associated with the same compressor;
• continuously developing an antisurge corrective change based on said relative distance to the surge control line;
• adding the value of said antisurge corrective change to another corrective change value which is computed by multiplying a corrective change continuously received from a station control means, by a first function of said relative distance to the surge control line, said first function being continuously computed by said antisurge means;
• and continuously using a value which is optionally the greatest or the sum of the associated corrective changes as set-point of the position of said antisurge final control means to prevent said relative distance between the operating point and the surge limit from decreasing below a predetermined margin of safety;
• said unit control means, for each compressor, continuously receiving said relative distance from surge control line from said antisurge control means for same associated compressor;
• continuously computing a normalized relative distance by multiplying said relative distance by a scaling constant and transmitting said normalized relative distance to said station control means;
• continuously receiving from said station control means a target normalized relative distance and computing a unit control means corrective action;
• adding said unit control means corrective action to another corrective change value which is computed by multiplying said corrective change continuously received from said station control means, by a second function of said relative distance to the surge control line received from said antisurge control means, said second function being continuously computed by said unit control means;
• and continuously using the summed value of the associated corrective changes as a set-point of the position of said unit final control means, manipulating the compressor performance to restore the station main process gas parameter to its required level and to equalize said normalized relative distance to the compressor surge control line with the target normalized relative distance received from said system control means;
• said station control means for controlling the station main process gas parameter continuously measures the main process gas parameter;
• continuously computes the difference from a predetermined set-point limit for said main process gas parameter, continuously computes a station control means corrective change;
• and continuously transmits said station control means corrective change to all unit control means and antisurge control means which comprise the station control system, for use by said unit control means and antisurge control means to restore the station main process gas parameter to its required set-point level;
• and
• said station control means continuously receives said normalized relative distances from unit control means for said compressors in the system;
• selecting at least one of said normalized relative distances and creating a target relative distance which is a function of said selected one of said normalized distances and continuously transmits the target normalized relative distance to all unit control means which are included in the station control system, to be used as a set-point for the unit control means in equalizing their respective normalized relative distance to their surge control lines with the target normalized relative distance, in order to optionally share the flow load.

An apparatus for controlling a compressor station pumping gas from a process located upstream from a station to a process located downstream from said station;

• said apparatus comprising:
• a compressor station consisting of a plurality of dynamic compressors working in series, each of which being operated by a unit final control means changing the compressor performance and an antisurge final control means for protecting the compressor from surge;
• said compressor station being also equipped with a station control system adjusting the station performance in order to maintain a main process gas parameter;
• said station control system consisting of a station control means controlling said main process gas parameter;
• antisurge control means, one for each compressor, computing a relative distance between a compressor operating point and a respective surge limit and preventing said relative distance from decreasing below some predetermined minimum level by controlling the antisurge final control means;
• unit control means, one for each compressor, operating a unit final control element to maintain a criterion R equal to a target criterion R, R.sub.m ;
• said antisurge control means for each compressor continuously measuring suction temperature, discharge temperature, suction pressure, discharge pressure, rotating speed, differential pressure across a flow element in suction and differential pressure across a flow element in discharge downstream of a tap off for the flow passing through antisurge final control means;
• continuously calculating the normalized discharge mass flow rate W.sub.d by multiplying said differential pressure across a flow element in discharge by said discharge pressure, dividing by said discharge temperature, taking the square root of the result and multiplying by a scaling constant;
• continuously transmitting said normalized discharge mass flow rate to said station control means, and continuously transmitting said discharge mass flow rate to said unit control means associated with said compressor;
• continuously calculating the normalized compressor mass flow rate W.sub.c by multiplying said differential pressure across a flow element in suction by said suction pressure, dividing by said suction temperature, taking the square root of the result, and multiplying by a scaling constant;
• and continuously transmitting said normalized compressor mass flow rate to said unit control means associated with said compressor;
• continuously calculating a relative distance between the compressor operating point and respective surge control line, continuously transmitting said relative distance to said unit control means associated with said compressor;
• continuously developing an antisurge corrective change based on said relative distance to the surge control line;
• continuously adding the value of said antisurge corrective change to another corrective change which is computed by multiplying a corrective change continuously received from a station control means, by a first function of said relative distance to the surge control line;
• said first function being continuously computed by said antisurge means;
• and continuously using a value which is optionally the greatest or the sum of the associated corrective changes as set-point of the position of said antisurge final control means to prevent said relative distance between the operating point and the surge limit from decreasing below a predetermined margin of safety;
• said unit control means, for each compressor, continuously receiving said relative distance from surge control line from said antisurge control means for same associated compressor;
• continuously computing a normalized relative distance by multiplying said relative distance by a scaling constant;
• continuously receiving a minimum normalized discharged mass flow rate W.sub.m computed by said station control means and continuously transmitted to all said unit control means in the station control system;
• continuously computing the mass flow rate deviation .DELTA. by subtracting said minimum normalized discharge mass flow rate W.sub.m from said normalized discharge mass flow rate W.sub.d for said compressor, continuously received from associated antisurge control means;
• continuously computing the equivalent mass flow rate W.sub.c by subtracting said mass flow rate deviation .DELTA. from said normalized compressor mass flow rate W.sub.c continuously received from associated antisurge control means;
• continuously computing criterion R for said compressor by multiplying one minus said normalized relative distance to the surge control line by said equivalent mass flow rate W.sub.e ;
• continuously transmitting said criterion R to said station control means;
• continuously receiving from said station control means said target criterion R, R.sub.m, and computing a unit control means corrective action;
• adding said unit control means corrective action to another corrective change value which is computed by multiplying said corrective change continuously received from said station control means, by a second function of said relative distance to the surge control line received from said antisurge control means, said second function being continuously computed by said unit control means;
• and continuously using the summed value of the associated corrective changes as a set-point of the position of said unit final control means, manipulating the compressor performance to restore the station main process gas parameter to its required level and to equalize said criterion R with the target criterion R, R.sub.m, received from said station control means;
• said station control means for controlling the station main process gas parameter continuously measures the main process gas parameter;
• continuously computes the difference from a predetermined set-point limit for said gas parameter, continuously computes a station control means corrective change;
• and continuously transmits said station control means corrective change to all unit control means and antisurge control means which comprise the station control system, for use by said unit control means and antisurge control means to restore the station main process gas parameter to its required set-point level;
• said station control means continuously receives said criterion R values from said unit control means in the station control system;
• selects at least one of the criterion R among all criterion R received from said unit control means in the station control system and calculate a target criterion R, R.sub.m, which is a function of said selected one of said criterion R;
• continuously transmits said target criterion R, R.sub.m, to all of said unit control means in said station control system, to be used as a set-point for the unit control means in equalizing their respective criterion R with the target criterion R, R.sub.m, in order to optionally share the compression load.