CCS Compressor Control System

Description

Compressor control technology and solutions leverage generator set control technology and a highly reliable redundant system hardware/software platform. Employing internationally advanced compressor control algorithms, this fully automated solution ensures safe and efficient operation of the entire unit while freeing operators from manual tasks, achieving high efficiency and energy savings.

The compressor anti-surge control algorithm utilizes an independent coordinate system to automatically adapt and compensate for surge lines under varying compressor inlet conditions. This resolves surge line distortion caused by mismatches between design and actual operating conditions, establishing prerequisites for efficient unit operation. Simultaneously, dynamic decoupling algorithms between performance and anti-surge loops, along with multi-stage anti-surge loops, enable one-button compressor start/stop and fully automated load ramping operations. This control strategy seamlessly adapts to complex process production while maintaining safe unit operation. The multi-unit series-parallel control solution breaks through traditional single-unit control strategies. While considering individual unit control, it introduces a compressor cluster coordination controller to allocate load distribution among units. This ensures each unit operates at its optimal load state, significantly enhancing the efficiency of the compressor fleet and enabling fully automated cluster coordination management.

The T880 system is a turbine compressor integrated control system—CCS (Compressor Control System)—developed on the HiaGuard platform. Certified by TÜV Rheinland IndustrieService GmbH, it meets the SC3 system capability level and SIL3 safety integrity level defined in IEC 61508/IEC 61511.

The system fully incorporates a triple-redundant design philosophy to meet the real-time, high-reliability, and stability requirements of critical field equipment. It integrates dedicated compressor control software packages, including anti-surge control, performance control, and speed control.

Key Features of the T880 System

High Security:

● 2-out-of-3 architecture with diagnostics (2o03D) ensures system safety;

● Multiple data flow voting mechanisms;

● Triplication design achieves physical independence to prevent common-cause failures;

● High diagnostic coverage with comprehensive diagnostic functions;

● Built-in firewall functionality within communication modules.

High Availability:

● Supports degraded operation with 3-2-0 failover mode;

● Independent power supplies for system and field sides;

● 1+1 redundant power supply;

● Redundant configuration of communication and I/O modules with seamless switching;

● System availability up to 99.999%.

High Diagnostic Coverage:

● Fault diagnosis locatable to channel level;

● AI channels support over-limit, open-circuit, and short-circuit diagnostics;

● AO channels support open-circuit and readback diagnostics;

● DI channels support external cable grounding, open-wire, and short-circuit diagnostics;

● DO channels support field no-load, overload, and short-circuit diagnostics;

● PI channels support open-wire and under-limit diagnostics.

Robust SOE Functionality

● DI modules utilize hardware-based SOE functionality;

● DI modules cache up to 1000 SOE records;

● Control stations store up to 10000 SOE records;

● SOE resolution reaches 1ms.

Optimal System Integration

● Seamless integration with MACS systems;

● Supports integration with third-party DCS via Modbus interface.

Scalable System Architecture

● Single station supports up to 1 host cage + 6 expansion cages, providing 1,856 I/O points;

● Single domain supports up to 64 stations, with maximum support for 15 domains.

T880 System Architecture

(1) Hardware Architecture

The T880 system is a triple-modular redundant (TMR) and hardware fault-tolerant safety control technology-based system. It is suitable for real-time control of various complex and hazardous production processes, receiving field signals, executing logical operations, outputting control signals, and driving field actuators.

The T880 system comprises an Engineer Station and a Safety Control Station:

The Engineer Station's configuration software, Safe-AT, is a T3 tool certified to IEC 61508 SC3.

The control station comprises controller modules meeting IEC 61508 SIL 3 requirements, I/O modules with terminal boards, and network communication modules. The system rack structure includes a main rack and expansion/remote racks, interconnected via relays or fiber optics. Field instrument signals are connected to I/O modules through terminal boards and DB cables.

The system architecture is fully triplicated from input modules through controllers to output modules. Triplicated controllers utilize three independently configured controller modules operating synchronously. Triplicated I/O channels are configured on each I/O module; independent configuration of I/O modules alone meets IEC 61508 SIL3 requirements. For enhanced availability, I/O modules can be redundantly configured. The system controller and I/O modules incorporate multiple fault diagnosis measures implemented through both software and hardware, along with corresponding fault handling procedures, ensuring the system's safety integrity level. Independent 1+1 redundant power supplies, field power supplies, and redundant configurations for input/output modules and communication modules enhance the system's high availability.

(2) Network Architecture

The T880 system primarily consists of components such as the engineer station, operator station, history station, and control station, forming the system network and control network. The control network nodes comprise control stations and I/O modules. The T880 system supports 15 domains, each accommodating up to 64 control stations. A single station supports a maximum of 1,856 I/O points, while the host cage supports 224 I/O points.

System Hardware

The T880 system hardware primarily consists of the chassis, power supply module, controller, communication module, relay module, fiber optic module, input/output module, and other components.

T880 System Software:

(1) Configuration Software

Safe-AutoThink (Safe-AT) is proprietary configuration software developed specifically for industrial safety instrumented systems (SIS). It serves as the control logic configuration component within the T880 system. This software holds TUV Rheinland certification and fully complies with IEC 61508 requirements for SIL3 system T3 tools.

Safe-AT is a Windows-based programming tool serving as the development platform for interlock logic schemes. Primarily used for controller algorithm programming, it functions as the standard software package for hardware configuration and software programming. Installed on the engineer workstation, it operates under Windows XP/Windows 7/Windows 10. Its primary tasks include:

● Configuring project foundation information

● Hardware configuration

● Logic configuration

● Compilation and download

● Offline simulation

● Forced operation

● S0E viewing

● Controller operation monitoring, etc.

Safe-AT provides multiple programming languages compliant with IEC 61131-3 standards for implementing logic solutions.

● Ladder Diagram (LD)

● Function Block Diagram (FBD)

● Structured Text (ST)

(2) Monitoring Software

The system monitoring software is based on the HOLLiAS MACS V6 human-machine interface platform and runs on the operator station. MACS V6 is a human-machine interface monitoring software developed for the Microsoft Windows operating system, compatible with Windows XP/Windows 7/Windows 10 platforms. It acquires data from controllers via network communication and dynamically displays production data using the computer's powerful graphics capabilities. The Operator Station monitoring software serves as the most direct and critical human-machine interface, supporting external devices such as industrial keyboards and printers. Its primary functions include flowcharts, alarms, logs, reports, overviews, trends, control groups, parameter grouping, control adjustments, and system management.

MACSV6 offers powerful and diverse capabilities, including: data acquisition, control adjustment, alarms, trend charts, overview diagrams, simulated flowcharts, data overviews, log management, table management, event sequence recording, reports and data statistics, display management, human-machine dialogue, print management, system fault diagnosis and monitoring, system configuration, online parameter setting by operators, offline querying of archived data, control groups, and control loops.