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Station Controller and Cold Recycle Controller
The Station Controller designed and developed by CCS performs load-sharing or load-balancing of multiple compressor trains. It also controls single train performance and provides control for an optional cold recycle valve arrangement to protect turbo compressors with minimal intervention. The Station Controller is capable of controlling a station’s primary control parameter and/or individual train control parameter by using multiple PID algorithms.
The Station Controller provides fully-integrated, multi-loop, compressor load-balancing or performance control on a hardware independent platform. Our Station Controller application helps to effectively control the performance of turbo compressor(s) during start-up conditions as well as during (ab)normal operation with minimal operator intervention.
Customers have the option to predefine target controls for units working in parallel and/or series operation modes to optimize compressor efficiency and speed, or minimize station fuel gas consumption. CCS’s Station Controller delivers bumpless transfers between manual and automatic operating modes, and between main, alternative or limiting control loops. The Station controller’s input fault detection and fall back strategies protect compressors and keep all critical process equipment online.
CCS Station Control Advantages
• State-of-the-art surge prevention techniques utilize patented compressor pressure ratio control methods, even when flow is unavailable.
• Specifically designed for units differing in size and rapidly changing process conditions.
• Patented Efficiency Comparator for analysis of unit and/or plant operation.
Station Control Load-Balancing
Load-Balancing: When a unit is close to the surge line, while others operate in normal condition, the Station Controller directs control to the Surge Prevention Controller algorithm to unload the others and force more load to the unit close to surge. Next, the Load-Balancing smoothly equalizes the machines’ speeds, all while maintaining the main process parameter.
Optimizing algorithm: When your units operate in normal condition (e.g. far away from the surge line) the optimization algorithm takes over the control action and determines load-sharing between working units based on a predefined optimization target specified by the customer (e.g. compressor efficiency, fuel gas reduction or speed).