rockwell antisurge signal conditioning

Users Guide _____________________________________________________________________________________________________

T6050 SurgeGard

Incipient Surge-Conditioning Module

Issue 1

December 2004

ICS Triplex Turbo Machinery Control

2

Copyright Copyright 2004

By ICS Triplex

Houston, Texas, U.S.A.

All rights reserved. No part of this work covered by the copyright hereon may be reproduced or copied in any form or by any means--graphic, electronic, or mechanical--without first receiving the written permission of

ICS Triplex, Houston, Texas, U.S.A.

Printed in U.S.A.

ICS Triplex reserves the right to make improvements in the design, construction, and appearance of its products without prior notice.

T6050 Users Guide

PD-6050 Dec 04 3

Revision History Issue 1 12/15/04 First issue


4

Warnings! READ THIS ENTIRE MANUAL AND ALL RELATED PUBLICATIONS PERTAINING TO THE WORK TO BE PERFORMED BEFORE INSTALLING, OPERATING, OR SERVICING THIS EQUIPMENT.

Practice all plant and safety codes and standards. Failure to follow instructions can result in personal injury and/or property damage.

To prevent ignition of hazardous atmospheres, do not remove covers of Class I Division I (explosion-proof) units with power applied.

Qualified technicians should perform all servicing. Dangerous voltages may be present on the circuit boards.

Use extreme caution when working around power-input cables. These cables may have potentially lethal voltages on them.

Be very careful when working on the digital (or discrete) input/output field termination panels. The external devices being controlled can have high, potentially lethal voltages on them. Turn off the power to the external devices before disconnecting or connecting the cable or a wire between the digital (or discrete) input/output field termination panels and the field wiring.

Replace fuses only with specified parts for continued safe operation.

Equip the engine, turbine, or other type of prime mover with an over speed (over temperature or over pressure, where applicable) shutdown device that operates totally independently of the prime mover control device. This protects against run-away or damage to the engine, turbine, or other prime mover, or personal injury or loss of life, should the mechanical-hydraulic or electronic governor, actuator, fuel control, driving mechanism, linkage, or controlled device fail.

Make sure the charging device is turned off before disconnecting the battery from the system to prevent damage to a control system that uses an alternator or battery-charging device.

Prior to energizing the equipment, have qualified personnel verify all wiring and connections against vendor drawings. Incorrect wiring and/or connections can result in equipment damage.

Contact appropriate manufacturer for instructions on operation of engine, turbine, or driven unit. This manual does not contain this information.

If you have questions or need more information on installing and operating ICS Triplex equipment, contact ICS Triplex.

T6050 Users Guide

PD-6050 Dec 04 5

Disclaimer Because of the variety of uses for this equipment, the user of and those responsible for applying this equipment must satisfy themselves as to the acceptability of each application and the use of the equipment.

The illustrations in this manual are intended solely to illustrate the text of this manual. Because of the many variables and requirements associated with any particular installation, ICS Triplex cannot assume responsibility or liability for actual use based upon the illustrative uses and applications.

In no event will ICS Triplex be responsible or liable for indirect or consequential damages resulting from the use or application of this equipment.

ICS Triplex DISCLAIMS ANY IMPLIED WARRANTY OR FITNESS FOR A PARTICULAR PURPOSE.

No patent or copyright liability is assumed by ICS Triplex with respect to use of information, circuits, equipment, or software described in this text.

Reproduction of the content of this manual in whole or part, without written permission from ICS Triplex, is prohibited.

Warranty All ICS Triplex products are warranted to be free of defects in materials and workmanship for a period of one year from date of start-up of our equipment or 18 months from date of shipment, whichever comes first. In case of failure, ICS Triplex liability shall be limited to furnishing, but not installing, necessary repair parts; or at the option of ICS Triplex, to repairing the defective product at its manufacturing location, providing the equipment is returned at purchasers expense.

This warranty does not apply to equipment showing abuse or damage or to equipment which has been altered or repaired by others, except as authorized by ICS Triplex. Nor does it extend to products that have been subjected to a corrosive and/or abnormal atmosphere, or to product components (such as batteries, lamps, etc.) which have provided a normal service life.

ICS Triplex will determine if warranty applies when material is received at its manufacturing location. A purchase order and a Returned Material Authorization (RMA) must accompany all returned material to ICS Triplex Customer Care Department:

Regional Technical Services 4325 West Sam Houston Pkwy. North Suite 100 Houston, TX 77043-1219 USA Telephone: 713-353-2400

The purchase order number as well as the RMA number should be clearly marked on the outside of the shipping container. Regional Technical Services issues RMA numbers.

In no event will responsibility be assumed or implied for consequential damages arising from interrupted operation or any other causes.

This warranty is in lieu of all other warranties expressed or implied, and no one is authorized to assume any liability on behalf of ICS Triplex, or to impose any liability on behalf of ICS Triplex, or to impose any obligation on it in connection with the sale of any equipment other than as stated above.


6

Electrostatic Discharge Awareness Electrostatic discharge can damage or destroy electronic components, assemblies, or systems.

1. Keep the following materials away from components and work area: Styrofoam (polystyrene): cups, packing material cellophane: cigarette packages or candy wrappers vinyl: books or folders plastic: cups, bottles, ash trays

2. Avoid synthetic clothing. Instead wear cotton or cotton-blend materials. Keep components away from elastics, clothing, and hair.

3. Before handling electronic components, discharge static electricity buildup from your body by using a properly connected wrist strap.

4. Do not handle components in the field unless properly grounded via wrist strap. If you are not properly grounded: Do not pick up components. Do not touch the printed circuit board. Do not remove components from the chassis.

5. Transport all static-sensitive components only in static-shielding carriers or packages. Place static awareness labels on all components to prevent removal from static-shielding container during transit.

6. Handle all static-sensitive components at a static-safe work area including floor mat, wrist strap, air ionizer, ground cord, and conductive tablemat.

7. Wear a grounded wrist strap in the field whenever possible. Where wrist straps are impractical, wear grounded heel straps or special footwear on properly grounded dissipative flooring.

8. Do not subject components to sliding movements over any surface at any time.

Hardware & Installation

Guide _____________________________________________________________________________________________________

T6050 SurgeGard


Issue 1

December 2004

PD-6050 Dec 04 iii

Contents

ILLUSTRATIONS........................................................................................................................... IV

Chapter 1 - Introduction...........................................................................................1

ABOUT THIS MANUAL ..................................................................................................................1 USER EXPERIENCE PREREQUISITES ..........................................................................................2 REFERENCE DOCUMENTS............................................................................................................2

Chapter 2 - Product Overview .................................................................................3

Chapter 3 Hardware Descriptions........................................................................5

ENCLOSURE .....................................................................................................................................5 CIRCUIT BOARD..............................................................................................................................5 TERMINATIONS...............................................................................................................................5

Chapter 4 - Installation.............................................................................................7

SITE SELECTION CONSIDERATIONS ..........................................................................................7 ACCESS CONSIDERATIONS ..........................................................................................................7 UNPACKING AND INSPECTION ...................................................................................................8 MOUNTING.......................................................................................................................................8 WIRING..............................................................................................................................................9

General............................................................................................................................................9 Electrical Power Wiring ...............................................................................................................10

Chapter 5 - Specifications .....................................................................................13


PD-6050 Dec 04 iv

Illustrations Figure 1. T6050 General Appearance ................................................................................................. 3 Figure 2. Hardware Block Diagram .................................................................................................... 4 Figure 3. Mounting Dimensions.......................................................................................................... 8 Figure 4. T6050 Terminations............................................................................................................. 9 Figure 5. T6050 Simplified Schematic.............................................................................................. 10 Figure 6. Typical Field Wiring With A Current Transmitter Input .................................................. 11 Figure 7. Typical Field Wiring With A Voltage Transmitter Input . .11

T6050 Operations & Maintenance Guide Chapter 1 Introduction

Chapter 1 - Introduction This document applies to the T6050 SurgeGard which is an incipient surge-conditioning module designed to continuously monitor the frequency flow, pressure or current oscillations occurring before the compressor reaches the actual surge point(s). SurgeGard is patented and has been successfully used in many compressor control systems

About This Manual As its name implies, this manual is a guide to understanding and installing the T6050 hardware.

Since this document is relatively small, an index is not included. Instead, a detailed table of contents is provided. This manual contains the following chapters:

Chapter 1 - Introduction This chapter contains information about this document and related reference documents.

Chapter 2 - Product Overview This chapter presents an overview of the product as a whole.

Chapter 3 - Hardware Descriptions This chapter describes all of the hardware which comprises the T6050.

Chapter 4 - Installation This chapter explains how to install a T6050, including mounting and wiring.

Chapter 5 - Specifications This chapter provides general specification.

This document will be useful to anyone who is responsible for design, installation, and maintenance of a control system that contains a T6100, T6200 or T6300 Compressor Controller. Information presented here will enable knowledgeable persons to perform those tasks that are required for successful installation and maintenance of the T6050.


PD-6050 Dec 04 2

User Experience Prerequisites To effectively use the T6050, users should have some experience with the use of digital control systems, or have an instrumentation background. It is assumed that the personnel involved understand the basics of electronic control systems and good wiring practices. It is also assumed that personnel involved have access to the required tools.

Extremely advantageous, though not required, is experience with Windows-based software programs, compressor operation, and normal operations experience within a plant environment.

Reference Documents

T6050 Operations & Maintenance Guide

T6050 Hardware & Installation Guide Chapter 2 Product Overview

PD-6050 Dec 04 3

Chapter 2 - Product Overview The T6050 SurgeGard is an incipient surge-conditioning module designed to continuously monitor the frequency flow, pressure or current oscillations occurring before the compressor reaches the actual surge point(s). SurgeGard is patented and has been successfully used in many compressor control systems.

The T6050 continuous analog peak-detector circuit is more efficient (less than 1 ms) and reliable than the digital sampling (2-10 ms sample rate) for both incipient surge control and for surge spike detection. In both applications (analog or digital), high speed transmitters should be used when implementing incipient surge detection techniques.

The T6050 is loop powered and consists of a differential input band pass (1Hz to 10Hz) amplifier/filter, a low pass filter (10Hz), absolute-value, peak detector and a voltage-to-current converter; all enclosed in a termination type electronic component housing.

The T6050's small size and built-in termination assembly allow the module to be mounted virtually anywhere on 32 or 35mm width standard DIN/EN rail.

Figure 1. T6050 General Appearance


PD-6050 Dec 04 4

A block diagram of the hardware is shown in the figure below.

ANALOGINPUT

Currentor Voltage

DIFFER-ENTIAL

AMPLIFIERFILTER GAIN

ABSOLUTEVALUE

PEAKDETECTOR

VOLTAGETO

CURRENTCONVERTER

ANALOGOUTPUT

4-20mA

DC TO DCCONVERTER

LOOP POWER(22-32VDC)

4-20mATO ANTI-SURGECONTROLLER

CURRENTOR VOLTAGEFROM FLOW

TRANSMITTER

AC SIGAC SIGNAL

OUT

Figure 2. Hardware Block Diagram

T6050 Hardware & Installation Guide Chapter 3 Hardware Descriptions

PD-6050 Dec 04 5

Chapter 3 Hardware Descriptions

Enclosure The T6050 electronic component housing enclosure is designed to be mounted on both 32 and 35 mm width standard DIN/EN rail and is completely self-contained. The electronic component housing enclosure is manufactured of green KRILEN 6.6 Polyamide insulating material.

Circuit Board All circuitry, including dc-to-dc converter power supply, is contained on a single circuit board. All electrical parts are mounted on a rigid 1/16 thick fiberglass circuit board.

Terminations All wiring to and from the T6050 is connected to the integrated terminal blocks on the component housing enclosure. The terminal blocks have a KRILEN 6.6 polyamide insulating body, nickel-plated copper alloy connectors, and pressure screws. The pressure screws are captive and secured against self-loosening.


PD-6050 Dec 04 6

T6050 Hardware & Installation Guide Chapter 4 Installation

PD-6050 Dec 04 7

Chapter 4 - Installation

Site Selection Considerations The T6050 requires the following conditions during normal operation:

32 to 130F (0 to 55C)

5 to 96% relative humidity

Protection from direct contact with water, chemicals, and conductive dust

Limited exposure to sulfur compounds, acid other corrosive or reactive vapors or fumes, and conductive dust

Limited exposure to non-conductive dust and combustible dust and lint

Access Considerations There are very few restrictions on the mounting position of the T6050. The following should be taken into consideration:

All input/outputs are connected on the termination type electronic component housing. Adequate wireway space should be provided.

Outdoor installation is not recommended, but can be accomplished if the module is placed in an appropriate enclosure.


PD-6050 Dec 04 8

Unpacking and Inspection Upon receipt of the T6050, unpack it carefully and visually check for damage.

If anything is damaged, contact ICS Triplex for instructions for returning it to the factory. If everything appears to be in order, proceed with the instructions in the following paragraphs.

Mounting The following figure provides mounting dimensions for the T6050.

ics triplexT6050SurgeGard

56

75

T6050SurgeGard

X5 X304mA

3.15"(80)

0.79"(20)

3.15"(80)

0.79"(20)

2.76"(70) 2.98"

(75)

TOP VIEW

FRONT VIEW SIDE VIEW

Figure 3. Mounting Dimensions


PD-6050 Dec 04 9

Wiring

General

The following general guidelines apply to all wiring discussed in the following paragraphs.

Wire size range is 22-12 AWG stranded; recommended wire size range is 18-14 AWG.

All wiring should be multi-stranded annealed copper with insulation that meets the requirements of all applicable electrical codes; recommended shielded twisted pair cable for Analog Input and 4-20 mA Analog Output to reduce the possibility of noise pickup.

Keep all wire runs as short and direct as possible. Long wire runs are vulnerable to picking up stray electrical noise. Also, long wire runs are costly, but remote mounting may be necessary because of area classification, convenience, or other extreme field conditions.

Use care when running signal wiring near to or crossing conduit or wiring that supplies power to motors, solenoids, lighting, horns, bells, etc.

Avoid bringing T6050 wiring into junction boxes which contain other wiring.

AC power wiring should be run in a separate conduit from the T6050 I/O wiring.

CHECK ALL WIRING RUNS THAT ARE TO BE CONNECTED TO THE T6050.

All field device wiring to and from the T6050 is connected on the enclosure integrated terminal blocks at the sides of the unit. The T6050 terminations are shown in the figure below.

T6050SurgeGard

X5 X304mA

TOP VIEW

12

34

56

78

12345678

RESISTOR +RESISTOR -

LOOP PWR IN +4-20mA OUTAC SIG OUTAC COM OUT

IN +IN -

TERMINAL SIGNAL

Figure 4. T6050 Terminations


PD-6050 Dec 04 10

1

2

3

4

5

6

7

8

250Ohm

IN +

IN -

RESISTOR +

RESISTOR -

LOOPPWR IN +

4-20mAOUT

AC SIG OUT

AC COM OUT

*

* Remove jumperfor voltage input

Figure 5. T6050 Simplified Schematic

The additional guidelines below should be followed when wiring the T6050:

The stripped portion of the wires should be 5/16 (8 mm) long.

Wires should be inserted in the clamp type terminals until they touch the internal stops. The terminal screw should be tightened while holding the wire in place. Check for proper clamp pressure with a gentle tug on the wire.

Two-Wire Loop Power Wiring

The T6050 two-wire LOOP POWER IN + should be 22-32VDC.

The two-wire Loop Power current requirments are 45 mA surge maximum at power up, 2 mA + Analog Output Value (20 mA maximum) equals 22 mA maximum after power up.

The two-wire Loop Power power requirments are 1.44 watts surge maximum at power up, 0.7 watts maximum after power up.

Wiring Note 1: Due to the 45 mA current surge maximum at power up, the 22-32 VDC Loop Power In + at the T6050 SurgeGard Terminal 5 should be from a source that does not limit the current below 50 mA.


PD-6050 Dec 04 11

1

2

3

4

5

6

7

8

250Ohm

IN +

IN -

LOOP PWR IN +

4-20mAOUT

AC SIG OUT

AC COM OUT

T UC

CURRENTTRANSMITTER

JUMPER

(0/4-20mA)

(22-32VDC)(SEE WIRING

NOTE 1)

Figure 6. Typical Field Wiring with a Current Transmitter Input

1

2

3

4

5

6

7

8

250Ohm

IN +

IN -

LOOP PWR IN +

4-20mAOUT

AC SIG OUT

AC COM OUT

*


T UC

VOLTAGETRANSMITTER

(22-32VDC)(SEE WIRING

NOTE 1)

Figure 7. Typical Field Wiring with a Voltage Transmitter Input


PD-6050 Dec 04 12

T6050 Hardware & Installation Guide Chapter 5 Specifications

PD-6050 Dec 04 13

Chapter 5 - Specifications

Analog Input

Signal Types -10 - +10 V, 0-5 or 1-5 VDC; 0-20 or 4-20 mA (with jumper installed across terminals 3 and 4)

Input Frequency 0-20 Hz

Isolation +/- 15 VDC continuous

Common Mode Rejection 80 db min at 60 Hz peak input; +/- 10 VDC max

Maximum Input Voltage Range +/- 10 VDC operating, non-destructive

Transmitter Type 2- or 4-wire; transmitter excitation supplied from external source

Input Filtering differential input band pass (1Hz to 10Hz) amplifier/filter,

A low pass filter (10Hz), absolute-value, peak detector

Analog Output

Signal Type 4-20 mA two-wire loop powered

Load Resistance


PD-6050 Dec 04 14

Environmental

The T6050 controller meets the following environmental conditions without loss of accuracy.

Operating Temperatures: Ambient Relative Humidity Condition Ambient Temp Non-Condensing Normal Limits 0 - 50C 5 - 96 % Operative Limits 0 - 55C 5 - 96 % Transport Storage -40 - 70C 5 - 96 %

Vibration 5 60 Hz at 0.030 inch total excursion along X, Y, and Z axes

Chemical Corrosion Resistance Conformal coating is applied to board for protection against H2S, SO2, and traces of sand, salt, and dust.

Mounting 32 or 35 mm width standard DIN/EN rail

Dimensions

Height 2.98 (75 mm)

Width 3.15 (80 mm)

Depth 0.79 (20 mm)

Weight 0.15 lb (68 g)

Agency Approvals

US Patent

Operations &

Maintenance Guide _____________________________________________________________________________________________________

T6050 SurgeGard


Issue 1

December 2004

Contents

ILLUSTRATIONS........................................................................................................................... IV

Chapter 1 - Introduction...........................................................................................1

ABOUT THIS MANUAL ..................................................................................................................1 USER EXPERIENCE PREREQUISITES ..........................................................................................2 REFERENCE DOCUMENTS............................................................................................................2

Chapter 2 - Product Overview .................................................................................3

T6050 SURGEGARD BENEFITS .................................................................................................4 Increased energy savings ................................................................................................................4 Identifies and corrects for shifts in surge point/line .......................................................................4 Prevents Compressor Trips............................................................................................................4 Facilitates Actual Surge Point Line/ Testing..................................................................................4

HARDWARE FUNCTION ................................................................................................................4 Hardware Block Diagram ...............................................................................................................4 Typical Signal Conditioning...........................................................................................................5 Simplified Schematic......................................................................................................................5

TYPICAL T6050 FIELD WIRING WITH A CURRENT TRANSMITTER.....................................6 TYPICAL T6050 FIELD WIRING WITH A VOLTAGE TRANSMITTER ....................................6

Chapter 3 Applications .........................................................................................7

TECHNOLOGY PRINCIPLE ............................................................................................................7 APPLICATION CONSIDERATIONS ...............................................................................................7

Multi-Stage (body) Machine or machines with multiple discharge ports ......................................7 AI Activation Delay........................................................................................................................8 Flow Transmitter Mounting............................................................................................................8

TYPICAL T6050 SURGEGARD APPLICATIONS......................................................................8 Motor Driven Compressor Applications ........................................................................................8 Turbine Driven Compressor Applications......................................................................................8 Pipeline Compressor Applications .................................................................................................9 Motor Driven Centrifugal Blower Applications.............................................................................9 Turbine GG Applications ...............................................................................................................9 T6050 SurgeGard Stand-Alone Applications.............................................................................9

T6050 SURGEGARD FACTORY CALIBRATION PROCEDURE...........................................10 Equipment Required for Factory Calibration Procedure..............................................................10 Factory Calibration Procedure......................................................................................................10

Chapter 4 - Operations...........................................................................................11

T6050 SURGEGARD FIELD GAIN ADJUSTMENT PROCEDURE........................................11 ACTUAL SURGE LIMITS ..............................................................................................................11 SURGE TEST WAVE-FORM ANALYZER...................................................................................12 FIELD SURGE TESTING PROCEDURE.......................................................................................13

Chapter 5 - Maintenance........................................................................................15

T6050 SURGEGARD MAINTENANCE.....................................................................................15


PD-6050 Dec 04 iv

Illustrations Figure 1. T6050 General Appearance ................................................................................................. 3 Figure 2. Hardware Block Diagram .................................................................................................... 4 Figure 3. Typical Internal T6050 SurgeGard Signal Conditioning ................................................. 5 Figure 4. T6050 SurgeGard Simplified Schematic ......................................................................... 5 Figure 5. Typical T6050 Field Wiring With A Current Transmitter................................................. 11 Figure 6. Typical T6050 Field Wiring With A Voltage Transmitter.. 6 Figure 7. Typical Inlet ACFM vs Polytropic Head Ft-lb/lb Graph..12

T6050 Operations & Maintenance Guide Chapter 1 Introduction

Chapter 1 - Introduction This document applies to the T6050 SurgeGard which is an incipient surge-conditioning module designed to continuously monitor the frequency flow, pressure or current oscillations occurring before the compressor reaches the actual surge point(s).

About This Manual As its name implies, this manual is a guide to operating and maintaining the T6050 SurgeGard. Since this document is relatively small, an index is not included. Instead, a detailed table of contents is provided. This manual contains the following chapters:

Chapter 1 - Introduction This chapter contains information about this document and related reference documents.

Chapter 2 - Product Overview This chapter presents an overview of the product as a whole, including typical applications.

Chapter 3 - Applications This chapter describes the typical applications of the T6050 SurgeGard.

Chapter 4 - Operations This chapter explains the typical operations of the T6050 SurgeGard, including field gain adjustment procedure.

Chapter 5 - Maintenance This chapter provides general maintenance required.

This document will be useful to anyone who is responsible for design, installation, and maintenance of a control system that contains a T6100, T6200 or T6300 Compressor Controller. Information presented here will enable knowledgeable persons to perform those tasks that are required for successful installation and maintenance of the T6050.


PD-6050 Dec 04 2

User Experience Prerequisites To effectively use the T6050 SurgeGard, users should have some experience with the use of digital control systems, or have an instrumentation background. It is assumed that the personnel involved understand the basics of electronic control systems and good wiring practices. It is also assumed that personnel involved have access to the required tools.

Extremely advantageous, though not required, is experience with Windows-based software programs, compressor operation, and normal operations experience within a plant environment.

Reference Documents

T6050 Hardware & Installation Guide

T6050 Operations & Maintenance Guide Chapter 2 Product Overview

PD-6050 Dec 04 3

Chapter 2 - Product Overview The T6050 SurgeGard is an incipient surge-conditioning module designed to continuously monitor the frequency flow, pressure or current oscillations occurring before the compressor reaches the actual surge point(s). SurgeGard is patented and has been successfully used in many compressor control systems

The T6050 continuous analog peak-detector circuit is more efficient (less than 1 ms) and reliable than the digital sampling (2-10 ms sample rate) for both incipient surge control and for surge spike detection. In both applications (analog or digital), high speed transmitters should be used when implementing incipient surge detection techniques.

The T6050 is loop powered and consists of a differential input band pass (1Hz to 10Hz) amplifier/filter, a low pass filter (10Hz), absolute-value, peak detector and a voltage-to-current converter; all enclosed in a termination type electronic component housing.

The T6050's small size and built-in termination assembly allow the module to be mounted virtually anywhere on 32 or 35mm width standard DIN/EN rail.

Figure 3. T6050 General Appearance


PD-6050 Dec 04 4

T6050 SurgeGard Benefits Tune your application properly to obtain the T6050 SurgeGard benefits:

Increased Energy Savings The addition of incipient override control permits closer operation to the actual surge point/line, thus providing a wider operating window and saving energy by minimizing recycle/blowoff.

Identifies and Corrects for Shifts in Surge Point/Line Incipient surge detection continuously monitors the compressors operating point behavior in relation to symptoms of impending surge and allows for automatic correction of surge point/line shifts.

Prevents Compressor Trips Minimizes the impact of primary surge control and field instrument malfunction by providing incipient fall-back and override control. Thus, even in the event of key transmitter (such as flow) failures, the compressor will stay on-line, increasing plant availability.

Facilitates Actual Surge Point/Line Testing In addition to surge monitoring and override control, the incipient surge detection module facilitates testing of actual surge points, minimizing operation interference.

Hardware Function

Hardware Block Diagram

ANALOGINPUT

Currentor Voltage

DIFFER-ENTIAL

AMPLIFIERFILTER GAIN

ABSOLUTEVALUE

PEAKDETECTOR

VOLTAGETO

CURRENTCONVERTER

ANALOGOUTPUT

4-20mA

DC TO DCCONVERTER

LOOP POWER(22-32VDC)

4-20mATO ANTI-SURGECONTROLLER

CURRENTOR VOLTAGEFROM FLOW

TRANSMITTER

AC SIGAC SIGNAL

OUT

Figure 4. Hardware Block Diagram


PD-6050 Dec 04 5

Typical Signal Conditioning

Figure 3. Typical Internal T6050 SurgeGard Signal Conditioning

Simplified Schematic

1

2

3

4

5

6

7

8

250Ohm

IN +

IN -

RESISTOR +

RESISTOR -

LOOPPWR IN +

4-20mAOUT

AC SIG OUT

AC COM OUT

*



PD-6050 Dec 04 6

Figure 4. T6050 SurgeGard Simplified Schematic

Typical T6050 Field Wiring with a Current Transmitter

1

2

3

4

5

6

7

8

250Ohm

IN +

IN -

LOOP PWR IN +

4-20mAOUT

AC SIG OUT

AC COM OUT

T UC

CURRENTTRANSMITTER

JUMPER

(0/4-20mA)

(22-32VDC)

Figure 5. Typical T6050 Field Wiring with a Current Transmitter

Typical T6050 Field Wiring with a Voltage Transmitter


PD-6050 Dec 04 7

1

2

3

4

5

6

7

8

250Ohm

IN +

IN -

LOOP PWR IN +

4-20mAOUT

AC SIG OUT

AC COM OUT

*


T UC

VOLTAGETRANSMITTER

(22-32VDC)

Figure 6. Typical T6050 Field Wiring with a Voltage Transmitter

Chapter 3 - Applications

Technology Principle

When applying the incipient surge detection module T6050 SurgeGard it is important to understand the basic technology principle

Fluidic oscillations occur as a precursor to surge. This behavior is the result of momentary backflow at the inlet of the impeller (the re-circulation zone). Since the momentary backflow is more prevalent at the outer annulus (wall) of the re-circulation zone than at the central area, it is important that the fluidic oscillation detection conditioning is of fast response. The speed of response must be such that it does not obstruct the oscillation signature while allowing for low-pass filtering of the normal flow rate oscillations.

Fluidic oscillations can be measured as: I torsional load (motor-driven), Flow/Pressure at the inlet of the compressor or at the discharge (preferably direct at the back of the impeller casing) of the compressor. See applications below.

In consideration of the fluidic oscillations speed in the re-circulation zone, the analog circuitry of the T6050 SurgeGard is more efficient (continuous sampling rate) than the software version contained in the T6100 and T6200 (sampling rate of 2-5 ms) and is therefore recommended for most applications.


8

Application Considerations Control of turbomachinery presents numerous challenges and opportunities because the surrounding process or pipeline largely depends on the control systems availability, reliability and efficiency. Among the challenges are: effective surge control, automation of start-up, adaptable capacity control, optimum load sharing, turbine overspeed protection and operating close to the process limit to meet increasing production requirements and efficiency. Most compressor control systems currently on the market are not up to task. They rely on conventional calculated anti-surge techniques with limited fallback capabilities and inadequate control actions. Hence, there is risk on tripping a compressor due to surge or field instrument malfunction. Therefore very often these systems are configured with conservative safety margins that reduce the operating envelope of a compressor. This leads to lower yield, overall production decrease, loss of revenue and loss of operating profits. The T6050 SurgeGard with its capability to detect incipient surge (a pre-cursor to actual surge) offers a reliable solution to increase energy savings, identify and correct for shifts in surge points/line and to prevent compressor trips. This is achieved by the implementation of patented fluidic oscillation measurement which determines the actual surge points, therefore allowing closer operation to surge limits, providing a wider compressor operating window and compensating for certain field transmitter malfunctions (offering fallback features). The following is an application overview of the T6050 SurgeGard:

Multi-Stage (body) Machines or Machines with Multiple Discharge Ports It is necessary to use a differential pressure flow transmitter for each stage or port. Since the differential pressure signal sensitivity to the velocity pressure changes is critical for detection of fluidic backflow oscillations, it is important that the flow transmitter does not have a lag of greater than 100 milliseconds. For some applications a high speed transmitter with a very small sampling delay (ideally less than 7 milliseconds, Statham PD3000 or equal transmitter) is necessary.

AI Activation Delay The analog input (AI) from the SurgeGard (4-20 mA output of SurgeGard) is ignored/bypassed (for several minutes in applications for compressors with large volumes) in the anti-surge compressor controller configuration until the machine is on-line and starting to build a discharge head (already pre-configured in the T6100, T6200 and T6300).

Flow Transmitter Mounting If a flow transmitter is used as the incipient surge signal, the transmitter should be mounted directly above the flow element with no connecting tubing where liquid can condense and accumulate. Since many problems have been encountered on start-up, incipient surge protection and surge control, ICS TRIPLEX recommends this simple approach. Alternative installation methods can be used successfully, but a careful review of adherence to clean and short impulse lines is required.

T6050 Operations & Maintenance Guide Chapter 3 Applications

9

Typical T6050 SurgeGard Applications

Motor Driven Compressor Applications The incipient surge conditions (flow oscillations at the inlet of the impeller) are transformed to torsional load oscillations (electric motors are very sensitive to changing torque). Depending on the compressor-motor gear sensitivity, a good parameter for incipient surge detection is the motor power transducer (I or KW, without filtering). However, where multiple electric driven machines are powered from the same grid, it is necessary to apply a fall-back level (already pre-configured in T6100/6200/6300) to mask mutual noise from adjacent machines being started or stopped. Therefore, only Incipient-Surge-PID signals within the limits of the fallback levels are ramped forward to a safe signal selector, which is ored with the primary Anti-Surge-PID output to ease the compressor away from a region of instability. It is an optional configuration facility to increment the surge control line by a small percentage for each incipient surge occurrence. The offset may be cancelled automatically at the next shutdown of the compressor, or remain in the configuration until the next surge test.

Turbine Driven Compressor Applications The most suitable parameter for incipient surge detection on turbine-driven machines is normally a differential flow transmitter signal. Since the inlet flow or eye differential pressure signal sensitivity to the velocity pressure changes is critical for detection of fluidic backflow oscillations, it is important that the flow transmitter does not have a lag of greater than 100 milliseconds. For rapid process dynamics (small compressor, rapid upstream-downstream dynamics, etc), it must be a simple analog device with no filtering - less than 7 milliseconds delay (Statham PD3000 or equal transmitter, www.gultonstatham.com ). It should ideally be located in the suction manifold or compressor eye, downstream of any throttling device. A discharge flow or pressure transmitter is suitable for certain high pressure ratio applications. The incipient surge signature should be verified before enabling SurgeGard if a discharge pressure transmitter is used. For some applications, for example when the suction flow signal quality is questionable (excessive noise during normal operation), a combination of suction and discharge flow measurement may be applied. The primary anti-surge controller configuration must provide for high signal selection (already pre-configured in the T6100, T6200 & T6300).

Pipeline Compressor Applications The same incipient surge parameters apply as for motor or turbine driven applications described above. However, on the detection of surge spikes the signal selection criteria is different. Due to the traditionally low pressure ratio of pipeline compressors, together with high capacity, the most volatile surge spike parameter is the pressure transmitter at each compressors discharge. The anti-surge-PID and incipient surge PID should be fast tuned to the head/flow surge control line, while the surge spike detection and pressure PID should be fast tuned to the compressor discharge transmitter. This provides protection from mutual interaction between stations, whereby an unplanned trip of a downstream compressor causes a pressure spike to travel up the pipeline to cause a high-pressure shockwave. Typically, this wave causes high vibration trips, as it momentarily causes a rapid surge line transgression. The suction and discharge SurgeGards, in conjunction with the incipient and surge spike loops, alleviate this shock by identifying the pressure spike and easing open the recycle valves to a pre-set percentage for a given time (determined by testing) until the line has stabilized once more. The timing of the surge spike action depends on the distance between stations and is set per application.

Motor Driven Centrifugal Blower Applications


10

Same criteria as for motor driven compressors. The incipient surge conditions (flow oscillations at the inlet of the impeller) are transformed to torsional load oscillations (electric motors are very sensitive to changing torque). The parameter for incipient surge detection is the motor power transducer (I or KW, without filtering). However, where multiple electric motor driven blowers are powered from the same grid, it is necessary to apply a fall-back level to mask mutual noise from adjacent blowers (or other motor-driven equipment) being started or stopped.

Turbine GG Applications The most suitable parameter for incipient surge detection on turbine GG is normally the compressor discharge pressure transmitter signal. Since the pressure signal sensitivity to the velocity pressure changes is critical for detection of fluidic backflow oscillations, it is important that the pressure transmitter does not have a lag of greater than 2 milliseconds (Viatran model 548 or equal transmitter, www.viatran.com ). The transmitter should be located at the compressor discharge manifold.

T6050 SurgeGard Stand-Alone Applications

Same signal selection criteria as for motor driven compressors The T6050 SurgeGard is normally powered by any two-wire 4 - 20mA primary analog channel (24 Volt DC) as found in typical ICS Triplex or third-party DCS or PLC control system. The incipient surge detection/override function complements the primary anti-surge control algorithm. It will enhance the capabilities of most compressor control systems, especially those with fairly slow loop scan rates. The T6050 SurgeGard can identify and correct for shifts in the compressors surge point/line. It can also function as an independent backup to the primary anti-surge control system. However, it is essential that if applied independently and without compressor startup interlock (SurgeGard function bypass) that conservative SurgeGard Gain tuning is applied to compensate for fluidic oscillations during compressor startup (build up of discharge head).

T6050 SurgeGard Factory Calibration Procedure The T6050 SurgeGard output typically feeds into the Incipient Surge PID on the Anti-Surge controller. As mentioned above, the output of Incipient Surge PID is used in parallel (via a high selector function) with the Primary Anti-Surge PID control loop to control the recycle/blowoff valve. Based on the selected process signal, current (motor driven machines= I or KW) flow (h) pressure, etc. if such information is provided the T6050 SurgeGard is calibrated at the factory such that the output of the Incipient Surge PID signals an incipient surge only under the correct conditions. This calibration can be accomplished using the following procedure. Each T6050 SurgeGard is tested at the factory for complete 4-20mA output range and the two potentiometers on the T6050 are set to generate this complete range of output signal. The following paragraphs describe the steps to be executed to perform this same calibration procedure.

Equipment Required for Factory Calibration Procedure A T6050 SurgeGard, a waveform generator, an oscilloscope, a digital voltmeter, a 250-ohm precision 1 watt resistor, a 24 Volt DC power supply, test clips, and a separate 0 5 VDC power supply.

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Factory Calibration Procedure i) Connect the positive (+) terminal of the 24 VDC power supply to terminal 5 of the T6050 module. ii) Connect the 250-ohm precision resistor in series between terminal 6 of the T6050 module and the

negative (-) terminal of the 24 VDC power supply. iii) Connect the waveform generator across the input terminals 1 and 2 of the T6050. Be sure the Jumper

across the T6050 terminals 3 and 4 has been removed. iv) Turn on the 24 VDC power supply. v) Set the waveform generator output to 0 Hz sinusoidal waveform and amplitude of 0.5 Volts peak-to-

peak. Adjust the 4 mA (ZERO) potentiometer so that the output voltage from the T6050 across terminal 6 and the negative (-) terminal of the 24 VDC power supply is 1.0 VDC.

vi) Set the waveform generator output to 10 Hz sinusoidal waveform and amplitude of 0.50 Volts peak-to-peak. Adjust the X5 X30 (GAIN) potentiometer so that the output voltage from the T6050 across terminal 6 and the negative (-) terminal of the 24 VDC power supply is 5.0 VDC.

vii) Repeat steps v and vi until the 1.0 VDC and 5.0 VDC are reached respectfully. Now set the waveform generator output to 3 Hz and amplitude of 0.5 Volts peak-to-peak; the output voltage from the T6050 across terminal 6 and the negative (-) terminal of the 24 VDC power supply should be 4.4 VDC.

viii) Set the waveform generator output to 10 Hz and amplitude of 0.30 Volts peak-to-peak; the output from the T6050 across terminal 6 and the negative (-) terminal of the 24 VDC power supply should be 3.3 VDC.

ix) Remove the waveform generator from the input terminals 1 and 2 of the T6050. x) Connect the 0 - 5 VDC power supply across the input terminals 1 (+) and 2 (-) of the T6050. Set the

output of the 0 - 5 VDC power supply to any voltage between 1 and 5 VDC and turn on the power supply; adjust the output of the 0 5 VDC power supply between 1 and 5 VDC, the output voltage from the T6050 across terminal 6 and the negative (-) terminal of the 24 VDC power supply should stay at 1 VDC.

Notes:

The T6050 SurgeGard output voltage at terminals 5 and 6 has up to 100 mV ripples.

It is important to note that each T6050 SurgeGard gain needs to be adjusted for each individual machine (each stage, for multi-stage compressors) while in service. See Field Surge Testing following pages.


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Chapter 4 - Operations

T6050 SurgeGard Field Gain Adjustment Procedure For the T6050 SurgeGard field gain adjustment procedure, it is assumed that a current (motor I or KW) or a flow transmitter is used in the process. The transmitter is assumed to have a 4-to-20mA output (that oscillates during incipient surge) which feeds into the T6050 SurgeGard module input Terminals 1 and 2. ICS Triplex recommends adjusting the gain (X5 X30 potentiometer) of the T6050 to show full incipient surge (20 mA at the T6050 output Terminals 5 and 6) when the oscillations at the input Terminals 1 and 2 are 10% of the full range of the transmitter. Thus, for the example case, the output of the T6050 at Terminals 5 and 6 should be 20mA when the input signal indicates oscillation amplitudes of 5.6 mA. This translates to a voltage swing of 0.40 V peak-to-peak (10Hz) at the input Terminals 1 and 2 of the T6050 (across the internal 250-ohm resistor) corresponding to a 20mA output from the T6050 Terminals 5 and 6. Note that if it is desired to indicate a full scale incipient surge from 25% of the full range of the transmitter (instead of the 10% as used in the example above), the gain (X5 X30 potentiometer) should be adjusted so that the output of the T6050 at Terminals 5 and 6 should be 20mA when the input signal at Terminals 1 and 2 indicate oscillation amplitudes of 8.0 mA. This translates to a voltage swing of 1.00 V peak-to-peak (10Hz) at the input Terminals 1 and 2 of the T6050 (across the internal 250-ohm resistor) corresponding to a 20mA output from the T6050 Terminals 5 and 6.

Actual Surge Limits A request to test the compressors surge limits in order to determine the true surge control line is understandably unpopular because of the perceived risk of damage to the machine. However, the anti-surge control system minimizes this danger by allowing to quickly open the recycle/blow-off valve upon detection of incipient surge (flow reversal at the inlet of the compressor impeller, the re-circulation zone).

Field testing of surge points is important since the actual compressor surge limits usually differ significantly from the limits indicated by the compressor map. The surge line shown on a manufacturers compressor map results from an analysis of the compressor design and is not normally verified by testing with the actual gas. The map data is usually conservative. Also, piping arrangements on the compressor suction side can account for significant surge point discrepancies. Accommodating these inaccuracies often requires unnecessarily wide surge margins, which can result in excessive recycling or blow-off. Therefore, a strong economic incentive exists to establish

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and confirm the surge line by experimental field testing.

For the field tests of incipient surge and surge spike, the raw transmitter signal is monitored and recorded on a high-speed oscillographic recorder or T6050 SG-1:A2 wave-form analyzer. To calibrate the surge limit line, one or several surge tests have to be carried out. For variable speed compressors (turbine driven units) the surge test should, in addition to the 100 percent RPM, be taken at several speed settings in order to establish a reasonably complete surge line. The T6200 and T6300 controllers will automatically store the test points. The points are then linearly interpolated by a look-up table function to generate a precise surge control line.

Figure 7. Typical Inlet ACFM vs Polytropic Head Ft-lb/lb Graph

Surge Test Wave-form Analyzer To accurately verify the compressors incipient surge oscillation signature, it is recommended to use a waveform analyzer. There are several packages available. ICS Triplex offers the T6050 SG-1:A2 low cost wave-form analyzer starter kit, (model DI-194RS from DATAQ), which records data with 10-bits accuracy at rates of 240 samples/second. The module has four 10V analog inputs, two digital inputs for remote start/stop and remote event marker control and a convenient serial data port interface to your PC. The included software is Windows 95, 98, NT, ME, 2000, and XP compatible. Refer to www.dataq.com . The wave-form analyzer speed of 240 samples/sec is adequate for large process compressors. For rapid oscillation signature analysis applications (small compressors) it is recommended to use a high-speed waveform monitor.


14

Field Surge Testing Procedure

In a typical scenario for surge testing a compressor, it is necessary to override some of the protection features of an anti-surge controller (with the T6200 & T6300 controllers these override actions are automatically enabled; already pre-configured). This requires that the controller should be switched to manual mode, and the Surge Control Line (SCL) transgression feature be disabled. The compressor can now be throttled in order to emulate a potential process upset, or reduced capacity. Once instability is detected in the compressor instrumentation, the anti-surge loop (ASPID) can then be switched to automatic mode, in order to open the recycle valve rapidly before the machine actually reaches the Surge Limit Line. The Incipient Surge control loop can now be used to assist in detecting the on-set of surge. It is important that the Incipient Surge PID should also be placed in MANual with a self tracking feature, so that its Output will remain at 0%. The signal from the T6050 SurgeGard should now be observed on a trend display or a wave-form analyzer plot, so that the oscillations of the selected parameter, (motor current, flow, suction/discharge pressure for example) can be monitored. The T6050 SurgeGard will integrate these oscillations, to produce a process value (PV) proportional to the signal noise plus process noise as the compressor approaches surge. It is normally necessary to adjust the gain of the T6050, in order to have the right amount of sensitivity for each compressor installation. A T6050 that is set too sensitive will result in early opening of the recycle valve even though the compressor may be far away from surging. Once the optimum gain setting has been determined, the trend or wave-form analyzer plots can be used to repeat surge testing at different base conditions. Each test can be terminated at equal signal amplitude occurrences, without any necessity to risk actual surge damage by throttling the compressor too far. An accurate surge limit line can now be established safely and in a repeatable manner for all future surge tests. Once surge testing has been completed, the anti-surge controls can be restored to full operating conditions, the Incipient Surge PID Loop can be placed into automatic mode, with a test-proven set-point for future incipient surge override duty. It is also recommended that the Incipient Surge PID control block should feature a set-point balance and ramp (standard in the T6100, T6200 & T6300), so that the set-point will remain at the entered value, as found during the tests. The Incipient Surge PID Loop output must be ignored during start-up cycles (configured such that the Incipient Surge PID loop switches to AUTOmatic only after the start-up timer has expired; already pre-configured in the T6100, T6200 & T6300), due to the unstable conditions which may manifest themselves until the machine has stabilized and started to build some head pressure. For motor I or KW incipient surge parameters, it is also important to use a high signal fallback feature (FB function; already pre-configured in the T6100, T6200 & T6300), in order to mask out motor transducer noise from adjacent machines starting or stopping, when powered from the same electrical power grid.

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Actual Strip Chart of Surge Surge Avoidance with SurgeGard

Figure 8. Typical Surge Graph and Surge Avoidance Graph with T6050 SurgeGard


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T6050 SurgeGard Maintenance The T6050 SurgeGard has no consumable or replaceable components. Once the T6050 SurgeGard is in field service, it requires no maintenance and should function for years without failure or replacement under normal conditions. The only field service maintenance one might consider is the T6050 SurgeGard Gain Adjustment Procedure.

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