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Woodward Vertex Product Manual

Digital control for performance and compressor control
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Released
Product Manual 35072V1
(Revision -, 4/2018)
Original Instructions
Vertex Digital Control
for Performance and Compressor Control
Volume 1
Installation, Operation, and Configuration Manual
Manual 35072 consists of 3 volumes (35072V1, 35072V2, & 35072V3).

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  • Page 1 Released Product Manual 35072V1 (Revision -, 4/2018) Original Instructions Vertex Digital Control for Performance and Compressor Control Volume 1 Installation, Operation, and Configuration Manual Manual 35072 consists of 3 volumes (35072V1, 35072V2, & 35072V3).
  • Page 2 Revisions— A bold, black line alongside the text identifies changes in this publication since the last revision. Woodward reserves the right to update any portion of this publication at any time. Information provided by Woodward is believed to be correct and reliable. However, no responsibility is assumed by Woodward unless otherwise expressly undertaken.

  • Page 3: Table Of Contents

    Part Number Options ..........................13   General Installation and Operating Notes and Warnings ................14   Controller Overview ............................. 15   Vertex Inputs and Outputs .......................... 22   Optional Distributed I/O ..........................27   Keypad and Display ............................ 28  ...
  • Page 4 Pressure Override PID Controls ....................... 205   9. C ....................208  HAPTER OMMUNICATIONS Modbus Communications .......................... 208   Port Adjustments ............................211   Vertex Control Modbus Addresses ......................211   10. P ............238  HAPTER RODUCT UPPORT AND ERVICE PTIONS Product Support Options ........................... 238  ...
  • Page 5 Released Manual 35072 Vertex Compressor Control Illustrations and Tables Figure 1-1. Vertex Compressor Control (With Display) ................13   Figure 1-2. Vertex Compressor Control (Without Display) ................. 14   Figure 1-1. Typical One Section Compressor Application ................16   Figure 1-2. Typical Two Section Compressor Application ................16  ...
  • Page 6   Figure 9-1. ASCII/RTU Representation of Three ..................209   Figure 9-2. Modbus Frame Definition ....................... 210 Table 1-1. Vertex (with display) Part Number Options ................13   Table 1-2. Vertex (without display) Part Number Options ................14   Table 1-1. Selectable functions for 4-20mA Analog Inputs ................. 22  ...
  • Page 7 Table 3-15. Specifications (Relay outputs) ....................54   Table 3-16. CPU Fault LED Flash Codes ....................55   Table 4-1. Factory set IP addresses for the Vertex CPU ................59   Table 4-2. Factory set account names and passwords for newer controls ..........59  ...

  • Page 8: Warnings And Notices

    To prevent damage to electronic components caused by improper handling, read and observe the precautions in Woodward manual 82715, Guide for Handling and Protection of Electronic Controls, Printed Circuit Boards, and Modules.
  • Page 9 Released Manual 35072 Vertex Compressor Control The products described in this publication may present risks that could lead to personal injury, loss of life, or property damage. Always wear the appropriate personal protective equipment (PPE) for the job at hand. Equipment that should be considered includes but is not...

  • Page 10: Electrostatic Discharge Awareness

    82715, Guide for Handling and Protection of Electronic Controls, Printed Circuit Boards, and Modules. An unsafe condition could occur with improper use of the software tools used with the Vertex control. Only trained personnel should have access to these tools. SOFTWARE...

  • Page 11: Regulatory Compliance

    Special Conditions for Safe Use The Vertex Compressor Control shall not be installed in areas exceeding Pollution Degree 2 as defined in IEC 60664-1 and Overvoltage Category II. The controls containing a LCD and Keypad must be mounted in a vertical position with air vents located at the top and bottom of the unit.
  • Page 12 Protective Earth Grounding of the Vertex Compressor Control connection to the PE terminal is required. Hazardous Locations The Low Voltage ATEX Vertex Compressor Control is suitable for use in Class I, Div 2, Gas, Groups A, B, C, and D & European Zone 2, Group IIC environments The risk of electrostatic discharge is reduced by permanent installation of the Vertex, proper connection of the equipotential ground lugs, and care when cleaning.
  • Page 13 Released Manual 35072 Vertex Compressor Control To reduce the risk of Electrical Shock the Protective Earth (PE) must be connected to the PE terminal on the enclosure. The conductor providing the connection must have a properly sized ring lug and wire Electric Shock gauge equal to or larger than 4mm²...

  • Page 14: Abbreviations

    Released Manual 35072 Vertex Compressor Control Ne pas utiliser les bornes d’essai du block d’alimentation ou des cartes de commande à moins de se trouver dans un emplacement non dangereux. Risque d'explosion Safety Symbols Direct Current Alternating Current Both Alternating and Direct Current...

  • Page 15: Chapter 1. General Information

    General Information Introduction This manual describes the Woodward Vertex Digital Compressor Control for use with one or two section compressors (axial and centrifugal). The option charts below shows the part numbers and the differences between the models. Volume 1 of this manual describes the control, provides installation instructions, defines hardware specifications, and explains the configuration (programming) and operating procedures.

  • Page 16: General Installation And Operating Notes And Warnings

    Vertex Compressor Control Table 1-2 lists models without an integrated display. These models are a bulkhead-mounted version of the Vertex. Configured without a display, the Vertex without a display is ideal for remote environments. Table 1-2. Vertex (without display) Part Number Options...

  • Page 17: Controller Overview

    11. Performance Limiter 2 PID 12. Load Sharing PID Depending on the configuration of the Vertex, these PIDs may be used or not used. Please refer to the Block diagrams listed later in this chapter to fully understand PID relationships.

  • Page 18: Figure 1-1. Typical One Section Compressor Application

    Released Manual 35072 Vertex Compressor Control Figure 1-1. Typical One Section Compressor Application Figure 1-2. Typical Two Section Compressor Application Woodward...

  • Page 19: Figure 1-3. Load Sharing Compressor Application

    Vertex control units can be connected together to equally share the load across multiple compressor trains. The Vertex can load share between two, three, four, or five compressor trains. The load sharing algorithm works with the performance controller outputs to maintain the common process variable (suction or discharge header pressure) and to balance the load between the compressors.

  • Page 20: Figure 1-4. Overview Of Asc Functionality Notes

    Released Manual 35072 Vertex Compressor Control Functional Block Diagrams An overview of the anti-surge and capacity control functions is shown in Figure 1-5. Use this diagram to match the ASC’s control features to the site-specific application. Many of the features of the ASC are configurable or optional.

  • Page 21: Figure 1-5. Overview Of Asc Functional Block Diagram

    Released Manual 35072 Vertex Compressor Control Figure 1-5. Overview of ASC Functional Block Diagram Woodward...

  • Page 22: Figure 1-6. Overview Of Performance Control Block Diagram

    Released Manual 35072 Vertex Compressor Control Figure 1-6. Overview of Performance Control Block Diagram Figure 1-7. Overview of Load Share Control Block Diagram Woodward...
  • Page 23 Configurable Load Sharing Auto Rejoin Operator Control Panel The Vertex is a field configurable compressor train control and operator control panel (OCP) integrated into one package. A comprehensive graphical operator control panel display and keypad is located on the Vertex’s front panel. This display can be used to configure the Vertex, make On-Line program adjustments, and operate the compressor/system.

  • Page 24: Vertex Inputs And Outputs

    Analog 4-20 mA Input Signals There are eight configurable analog inputs available on the Vertex hardware, each of which can be configured as one of the input functions in the table below. An additional eight analog input channels (up to 16) are available for each RTCnet AIO node configured.
  • Page 25 Released Manual 35072 Vertex Compressor Control Function Signal Name Description Remote demand for anti-surge valve HSS demand Stage 1 AS Valve HSS Demand selection. Delta-pressure from the compressor flow element Stage 2 Flow at suction or discharge Stage 2 Suction Pressure...
  • Page 26 Released Manual 35072 Vertex Compressor Control Train Quit Normal SD Req ASC1 External Excessive Surge Detected PFC Continue Sequence ASC1 Enable P1 Override Command PFC Halt Sequence ASC1 Disable P1 Override Command Spare 09 ASC1 Enable P2 Override Command Spare 10...
  • Page 27 Released Manual 35072 Vertex Compressor Control ASC1 Reset SMP External Alarm 2 ASC1 Increase Control Margin External Alarm 3 ASC1 Decrease Control Margin External Trip 2 ASC1 Reset Surge Counter External Trip 3 Control Outputs Actuator Outputs Two 4–20 mA or 20–160 mA configurable actuator outputs with linearization curves are available for use.
  • Page 28 Released Manual 35072 Vertex Compressor Control Conditional States Table 1-4. Selectable functions for Relay Output States ASC1 AS Valve Manual --- Not Used --- ASC1 AS Valve Full Manual Summary Shutdown ASC1 Surge Detected Trip Relay ASC1 Consecutive Surge Detected...

  • Page 29: Optional Distributed I/O

    These are available via the Configuration Menu (under RTCnet) and the user is free to select any or all of the nodes listed below. All distributed I/O channels have the same menu of functional choices as the lists above for the Vertex hardware I/O allow for the control I/O capacity to be expanded for specific application needs.

  • Page 30: Keypad And Display

    Manual 35072 Vertex Compressor Control Ethernet port 4 is dedicated for use between Vertex controls for Load Sharing functionality. Do not configure port 4 onto any network except for Vertex-to-Vertex communications. The control also communicates Servlink protocol (Woodward proprietary) via the Ethernet ports. Using Woodward’s Servlink to OPC Server tool any PC can use this connection to communicate to the control...
  • Page 31 These items do not require “Focus”, they are always available on that particular screen. The Vertex has a detailed Tutorial that is always accessible through the Service Menu. It provides ‘On-Screen’ help on topics such as Navigation, User Levels, Operating Modes, how to adjust parameters, and more.

  • Page 32: Watchdog Timer/Cpu Fault Control

    The IO Lock and CPU Health LED’s on the front left side of the display – are always in an identical state as the LED’s on the backside of the control. They are completely controlled by the Vertex control hardware and are not controlled by the GAP application.

  • Page 33: Chapter 2. Installation

    Shipping Carton Before unpacking the Vertex, refer to the inside front cover and page VI of this manual for WARNINGS and CAUTIONS. Be careful when unpacking the Control. Check for signs of damage such as bent or dented panels, scratches, and loose or broken parts.

  • Page 34: General Wiring Guidance

    Released Manual 35072 Vertex Compressor Control General Wiring Guidance Terminal block wiring must use multi-stranded wires to provide best results. Do not tin (solder) the wires that terminate at the node terminal blocks. The spring-loaded Cage Clamp or screw down terminal blocks is designed to flatten stranded wire, and if those strands are tinned together, the connection loses surface area and is degraded.
  • Page 35 (EMC) may require additional shielding precautions, such as wire run in metal conduit or double shielding. In general, the devices are designed with a sufficient level of EMC and immunity to EMI for the typical installation environment and added EMC precautions are not needed. Contact Woodward for more information In general, terminate shields to their landing point, on the IO node terminal block or cage clamp.

  • Page 36: Chapter 3. Hardware Specifications

    Hardware Specifications Vertex Description and Features The Vertex Compressor Control is a real-time, deterministic compressor controller that is available with or without an integrated HMI display. Enhanced communication options for Serial, Ethernet, and CAN are key features for improved networking and I/O expansion. To expand Controller I/O use into rugged environments use CAN and Woodward RTCnet nodes.

  • Page 37: Environmental Specifications

    Authorized Service Center if a replacement service is needed. Calibration and Functional verification Recommend calibration verification and functional operation every 24-36 months. This is especially important for spare units that need to be ready for immediate use. Contact a Woodward Authorized Service Center for assistance. Woodward...

  • Page 38: Electromagnetic Compatibility (Emc)

    Display LCD with backlight The Vertex display version uses a low power LED backlight display with a life expectancy of 60K hours to half brightness, at maximum operating temperature. If the display appears dim, use the “SCREEN SETTINGS”...

  • Page 39: Figure 3-2. Vertex Outline Drawing

    Released Manual 35072 Vertex Compressor Control Figure 3-2. Vertex Outline Drawing Woodward...
  • Page 40 Vertex Compressor Control Vertex (without display) Panel Mounting information:  There are 8x.268” diameter clearance holes for mounting the Vertex. The holes are for 8 x 10-32 bolts with a nut and washer to mount the unit.  Use screw length 1069-955 (.750 Long, 10-32) for panel thicknesses .100” or less. This assumes using a .25”...

  • Page 41: Figure 3-3. Vertex Outline Drawing

    Released Manual 35072 Vertex Compressor Control Figure 3-3. Vertex Outline Drawing Woodward...

  • Page 42: Input Power Specification

    Input Power Specification Table 3-2. Specifications (LV) LV Input Voltage range: 18-36 Vdc Input Power (max): < 77 W, 4.3 A max (Vertex) < 71 W, (Vertex) Output Voltage Holdup time: > 14 ms with 24 Vdc input voltage Isolation to other circuits: >...

  • Page 43: Visual Indicators (Led's) & Cpu Configuration

    Features  Interface standard: IEEE 802.3 (Ethernet)  Port Isolation: 1500 Vrms to PS, EARTH, and all other circuits  Control configuration using Woodward AppManager  Control monitoring, trending, and datalog collection  Control configuration of Ethernet IP addresses ...

  • Page 44: Table 3-5 Ethernet Ports #1-4 (10/100)

    Released Manual 35072 Vertex Compressor Control This module has been factory configured with fixed Ethernet IP addresses of  Ethernet #1 (ETH1) = 172.16.100.15, Subnet Mask = 255.255.0.0  Ethernet #2 (ETH2) = 192.168.128.20, Subnet Mask = 255.255.255.0  Ethernet #3 (ETH3) = 192.168.129.20, Subnet Mask = 255.255.255.0...

  • Page 45: Communications (Can)

    Vertex Compressor Control Communications (CAN) Four Isolated CAN ports are available for general communications as well as simplex distributed control. Compatible devices include Woodward RTCnet nodes products. Removable latching connector plugs are provided for field wiring. Network Termination: CAN networks must include a 120 Ω termination resistor at each end of the trunk line.

  • Page 46: Table 3-8. Belden Yr58684, Bulk Cable (Woodward Pn 2008-1512)

    Vertex hardware products. However, the shield must also be directly terminated to chassis (Earth) at one point in the network. In the case of Woodward equipment, the direct ground is meant to be located at the master device end, as it exits the master device’s enclosure.

  • Page 47: Communications (Rs-232/Rs-485)

    RS-485 networks require termination at both ends with approx. 90–120  impedance that matches the characteristic impedance of the cable used. Cable Note: Woodward cable 2008-1512 (3-wire) is a shielded, low capacitance 120-ohm cable that is designed for communications. This cable is also used for CAN communications.

  • Page 48: Communications (Service Ports)

    For debug use, a Woodward PN 5417-1344, USB to serial debug cable is required to attach this port to a PC. Trained Field Service personnel use this port only! Dura-Clik connector (male) Pin 1 –...

  • Page 49: Figure 3-4. Vertex Back Cover Label

    Released Manual 35072 Vertex Compressor Control Figure 3-4. Vertex Back Cover Label Woodward...

  • Page 50: Figure 3-5. Vertex Terminal Block Connectors

    Released Manual 35072 Vertex Compressor Control Terminal Block Connectors Figure 3-5. Vertex Terminal Block Connectors Woodward...

  • Page 51: Hardware - Speed Sensor Inputs

    Separate terminals provided for MPU and Proximity sensors  Isolated Prox Power (+24 Vdc) is provided with short-circuit protection  Woodward GAP block, diagnostics, and configuration support  GAP configurable update rates of 5 ms to 160 ms Table 3-10. Specifications (MPU/PROX)

  • Page 52: Hardware - Analog Inputs (4-20 Ma)

    Hardware - Analog Inputs (4-20 mA) AI Description and Features The Vertex Compressor Controller includes eight 4–20 mA input channels for I/O monitoring and control. Each channel is differential (self-powered) but can be software configured for Loop Power mode. An Isolated Loop Power (+24 Vdc) is provided for analog input transducers and includes short-circuit/over- voltage protection.

  • Page 53: Hardware - Analog Outputs (4-20 Ma)

    Group isolated from other circuits  Capable of driving higher impedance loads up to 600 ohms  Woodward GAP block, diagnostics, and configuration support  GAP configurable update rates of 5 ms to 160 ms Table 3-12. Specifications (AO) Number of channels...

  • Page 54: Hardware - Actuator Outputs

     Group isolated from other circuits  Capable of driving higher impedance loads  Woodward GAP block, diagnostics, and configuration support  GAP configurable update rates of 5 ms to 160 ms Table 3-13. Specifications (ACT) Number of channels 2 proportional drivers with source & return readbacks...

  • Page 55: Hardware - Discrete Inputs

    +24 V Contact Power with short-circuit and diode protection  Isolated power and discrete input group  Woodward GAP block, diagnostics, and configuration support  GAP configurable update rates of 5 ms to 160 ms  Time-stamping capability (1 ms) Table 3-16.

  • Page 56: Hardware - Relay Outputs

    Each Relay Output provides NO, COM, and NC contacts  Each Relay Output channel provides a coil voltage readback fault  Woodward GAP block, diagnostics, and configuration support  Contact isolation maintained at terminal blocks  ATEX approved version available using hermetically sealed relays ...

  • Page 57: Troubleshooting Fault Codes

    Verify cabling meets CAT-5 or better performance specs  Verify cables are shielded properly per Woodward spec (using inner foil and outer braid)  Verify each port is connected to the desired port & cable is labeled with correct port number ...
  • Page 58 CAN wiring checks  Verify the CAN wiring uses a high quality, 3-wire, shielded communication cable. For example, Woodward 2008-1512 (Belden YR58684) or equivalent low capacitance, shielded communications wire.  Verify CAN network length is < max length spec for the baud rate being used ...
  • Page 59 Released Manual 35072 Vertex Compressor Control  Verify each AI shield wire is terminated at the node properly.  Verify that all XDCR's channels use less than 250 mA of LPWR.  Functionally verify the wiring for each AI channel using a simulator source.
  • Page 60 Released Manual 35072 Vertex Compressor Control RTD, Input wiring checks  Verify each RTD (+,–) is not shorted to another input channel.  Verify each RTD (+) terminal is not shorted to PS (+), PS (–), EARTH.  Verify each RTD (–) terminal is not shorted to PS (+), PS (–), EARTH.

  • Page 61: Chapter 4. Manual Network Setup

    Released Manual 35072 Vertex Compressor Control Chapter 4. Manual Network Setup Factory Set IP Addresses for the Control Table 4-1. Factory set IP addresses for the Vertex CPU Port name IP address Subnet Mask Ethernet #1 172.16.100.15 255.255.0.0 Ethernet #2 192.168.128.20...

  • Page 62: Network Setup Instructions For The Control

    Released Manual 35072 Vertex Compressor Control Network setup instructions for the control Here is a simple flowchart, which shows the steps for configuring the control’s network settings to work on your network. The listing of factory set IP addresses are in Table 4-1 and detailed instructions for the steps in the flowchart are below: Figure 4-1.
  • Page 63 Released Manual 35072 Vertex Compressor Control Detailed network setup instructions for the control Execute the following steps (up to 8) to configure your control to work with your network. The control’s primary IP address must be compatible with your network, but cannot collide with an existing device’s address.

  • Page 64: Figure 4-2. Network Cable Connections

    3. Connect as shown in Figure 2-2 and power up the Woodward control. Figure 4-2. Network Cable Connections When you have the proper connection between the Woodward control’s Ethernet Port #1 and your PC, you will see the green “Link” LED remain on (solid) on your PC and on the control.

  • Page 65: Chapter 5. Distributed I/O Expansion

    Chapter 5. Distributed I/O Expansion The Vertex Compressor Control can be expanded to higher I/O counts by using the Woodward RTCnet distributed I/O nodes. GAP3.04 and Coder 6.0 or later software tools are required. Contact Woodward Marketing and Sales for compatibility with other Woodward products.

  • Page 66: Table 5-1. Useful Woodward Part Numbers At The Time Of Writing

    Released Manual 35072 Vertex Compressor Control Table 5-1. Useful Woodward Part Numbers at the Time of Writing CAN Cables (reference drawing 9097-2097) 5417-1127 Cable - CAN MicroNet drop, 7/8 inch male to M12 female (1 m) 5417-1142 Cable - CAN drop, 7/8 inch male to pigtail (1 m, mid gauge)

  • Page 67: Chapter 6. Control Description

    Type 4 Type 5 The Vertex control loops are independent of the type of compressor prime mover. Certain functions within the control are designed to work with specific prime mover types, such as the motor current limit protection in the Performance control.

  • Page 68: Anti-Surge Control

    Vertex Compressor Control Anti-Surge Control The ASC (Anti-Surge Control) is Woodward standard control software application function module designed for preventing surge in dynamic (axial and centrifugal) compressors and for providing additional control functions aimed at keeping compressor operation within safe limits and for maximizing compressor and process efficiency.

  • Page 69: Anti-Surge Control 2

    Released Manual 35072 Vertex Compressor Control Along with possible compressor damage, the process flow and pressure become very unstable doing surge contributing to upstream and downstream process upsets. Figure 6-2. Surge Cycle Figure 6-2 shows a typical surge cycle at a constant speed and constant suction density. The compressor, operating at point 1, has low discharge pressure and the output flow is at its maximum value.

  • Page 70: Figure 6-3. Stonewall

    Released Manual 35072 Vertex Compressor Control Compressor Choke (Stonewall) Compressor choke or stonewall is an undesired operating condition for centrifugal compressor. Choking of centrifugal compressor occurs when velocity of gas in the compressor reaches sonic velocity and further reduction of compressor discharge pressure can no longer increase flow through the compressor.

  • Page 71: Figure 6-4. Standard Compressor Map

    Released Manual 35072 Vertex Compressor Control Standard Compressor Performance Map The Standard Compressor Map is described by polytropic head, Hp, versus actual volumetric suction flow, Qa, and compressor speed, N, see Figure 6-4. Depending upon the compressor configuration and instrumentation, changes in molecular weight, temperature, and compressibility are compensated for accurate representation of the compressor operation.

  • Page 72: Figure 6-6. Process Control Diagram

    Released Manual 35072 Vertex Compressor Control C-100 Figure 6-6. Process Control Diagram Here it can be seen that the volumetric flow calculation is carried out using three measurements.  PT-105, compressor suction pressure  TT-105, compressor suction temperature  FT-105, differential pressure across the flow element The polytropic head calculation also requires three measurements.
  • Page 73 Released Manual 35072 Vertex Compressor Control The Surge Limit Line is programmed into the controller as a series of operating X-Y points (with a maximum of twelve). Compressor maps can be defined in different units. The ASC supports the following compressor map unit entries: ...

  • Page 74: Figure 6-9. Compressor Map S_Pv Regions

    Released Manual 35072 Vertex Compressor Control Figure 6-9. Compressor Map S_PV Regions A surge control margin is programmed by adding a correction factor percentage (%) to the flow values for the actual surge points, establishing a Surge Control Line. A typical surge control margin of 10% is attainable on most applications with proper anti-surge valve sizing, stroking speed, etc.

  • Page 75: Figure 6-9. Mode Select

    Released Manual 35072 Vertex Compressor Control Control Modes While on-line, the anti-surge controller is designed to operate in one of three control modes, Automatic, Manual with Backup, and Full Manual. These modes are provided to give the operator any level of control that is desired.

  • Page 76: Figure 6-10. Manual Setting Of Anti-Surge Valve

    Released Manual 35072 Vertex Compressor Control Figure 6-10. Manual Setting of Anti-Surge Valve Sequencing Functions During start-up and shutdown of the compressor, the compressor flow is fluctuating, and the process is unstable. This time between a start and stable automatic control is termed “off-line.” A separate routine is focused on detecting when automatic, or “on-line,”...

  • Page 77: Figure 6-11. On-Line Detection

    Released Manual 35072 Vertex Compressor Control Start Position If purge position is not set and no shutdown command received, a start command or “Zero Speed Level” triggered or “Zero Current level” triggered will ramp the anti-surge valve to the “Position During Startup” at “Valve Start Rate”.
  • Page 78 Released Manual 35072 Vertex Compressor Control Each on-line detection method may be enabled or disabled and setpoints configured in the Compressor Configuration section of the software. The Auxiliary Input (configurable discrete input or Modbus command), if enabled, must be a sustained input (toggle). This input is most often driven by a compressor safety system or sequencer.

  • Page 79: Figure 6-12. Anti-Surge Functions

    Released Manual 35072 Vertex Compressor Control Figure 6-12. Anti-Surge Functions Starting in the surge, or unstable operating region, there are three routines dedicated to preventing or responding to a surge. Surge Recovery and Surge Minimum Position (SMP) are the routines that react to a surge with a fixed (open loop) valve action.

  • Page 80: Figure 6-13. Surge Detection And Counter

    Released Manual 35072 Vertex Compressor Control Surge Detection The Surge Detection routines are configured to determine when a surge event has occurred, capture the surge signature, and maintain a surge counter. Refer to Section "What is Surge?" earlier in this chapter for further details of the actual surge event.

  • Page 81: Figure 6-14. Surge Recovery And Surge Minimum Position (Smp)

    (see the Loop Period section) and then begin decaying in a closing direction. Woodward Surge Recovery response is more effective in breaking surge cycles as it warrants additional opening of the anti-surge valve during surge event regardless on which method of detecting surge was used and what pattern the surge variable followed thereafter.

  • Page 82: Figure 6-15. Anti-Surge Valve Response To A Surge

    Released Manual 35072 Vertex Compressor Control Valve Position Loop Period 48 % Surge Recovery 39 % 34 % 32 % Surge BOOST Minimum Position 29 % Time Surge Detected Figure 6-15. Anti-Surge Valve Response to a Surge Consecutive Surge As an additional protection, it is possible to generate an alarm or a shutdown based on the number of detected surges within a configured time.

  • Page 83: Figure 6-16. Boost

    Released Manual 35072 Vertex Compressor Control Boost / Valve Step Opening The Boost, line is established between the Surge Limit Line and the Surge Control Line for a backup surge prevention in case the main PID loop and rate PID loop actions do not produce strong enough effect so to keep compressor operating to the right of surge control line.

  • Page 84: Figure 6-18. Anti-Surge Pid

    Released Manual 35072 Vertex Compressor Control The valve position demand will remain constant for a fixed amount of time (the loop period) waiting for the compressor operating point to return to the right of the Boost Line. If the operating point is in the safe region (above the Boost Line), the Boost action will begin to decrease and allow the anti-surge controllers to regain control.

  • Page 85: Figure 6-19. Rate Controller Pid

    Released Manual 35072 Vertex Compressor Control Rate Controller PID If the flow through the compressor reduces too rapidly, the Anti-Surge PID may not react fast enough to prevent a surge. The rate controller monitors the time derivative of S_PV and acts to open the anti-surge valve if this rate is too fast for the system to respond.

  • Page 86: Figure 6-20. Automatic Gain Compensation

    Released Manual 35072 Vertex Compressor Control The gain compensation routine scales the proportional gains of all PID loops (Anti-Surge, Rate Control, Suction Pressure Override, and Discharge Pressure Override) as well as Fast Speed Decoupling, discussed later in this chapter. Gain compensation is calculated differently depending upon the choice of Algorithm.

  • Page 87: Figure 6-21. Anti-Surge Decoupling

    Released Manual 35072 Vertex Compressor Control AGC is now configured at the current operating point. The gain factor will move above and below 1.0 as the compressor moves from this operating point. AGC may be configured before or after PID tuning, but in either case, PID loops should be tuned with AGC disabled.

  • Page 88: Figure 6-22. Effect Of Valve Layout On Adjacent Stage Decoupling Amounts

    Released Manual 35072 Vertex Compressor Control The second form of speed decoupling uses knowledge of the relationship between speed and flow to anticipate the necessary movement of the anti-surge valve. The change in speed is related to a change in flow, and the anti-surge valve moves to maintain the previous flow.
  • Page 89 Released Manual 35072 Vertex Compressor Control Process Control Routines The following routines can operate the anti-surge valve to control a process condition other than anti- surge control. Contained within the ASC software are suction and discharge pressure controllers. When the prime mover’s speed is varied to maintain suction or discharge pressure, two problems can occur.

  • Page 90: Figure 6-23. Pressure Override Control

    Released Manual 35072 Vertex Compressor Control Discharge Pressure Override The Discharge Pressure Override routine monitors the difference between the compressor discharge pressure and the discharge pressure setpoint. The override controller will open the valve to help reduce the discharge pressure. Obviously, the anti-surge valve cannot be used to increase discharge pressure, in which case the prime mover’s speed controller, or other control loop, acts alone.

  • Page 91: Figure 6-24. Auxiliary Control Variables

    Released Manual 35072 Vertex Compressor Control Auxiliary Control Up to two custom controllers may be added to the High Signal Select (HSS) bus within the ASC. One of these inputs is a configurable analog input that must be calibrated for 0–100% open on the anti-surge valve.

  • Page 92: Figure 6-25. Analog 4-20 Ma Input Signal Filtering And Failure Monitoring

    Released Manual 35072 Vertex Compressor Control Signal Filtering All of the signals that are input into the anti-surge controller may be filtered for noise. This aids in preventing false surge detections, prevents unnecessary response to noise, and stabilizes the control routines.

  • Page 93: Figure 6-26. Valve Position Freeze Routine

    Released Manual 35072 Vertex Compressor Control Valve Freeze Mode Under some operating conditions, the anti-surge valve may be continuously modulated at a partially open position. To eliminate unnecessary movements of the valve caused by process signal noise, the “Valve Freeze Mode” is used. When this mode is enabled, the valve will be held in position until a significant change in the process occurs.

  • Page 94: Figure 6-27. Valve Overstroke

    Released Manual 35072 Vertex Compressor Control Valve Position 105 % 100 % Time -5 % Figure 6-27. Valve Overstroke Valve Dither Many valve designs can develop memory if their positions remain constant for long periods. Other mechanical, electrical, or electro-mechanical devices in the anti-surge valve’s 4–20 mA loop, such as current to pneumatic transducers (I/Ps), can also suffer from this phenomenon.

  • Page 95: Figure 6-29. Valve Characterization

    However, valves with quick opening, equal-percentage, and modified equal percentage characteristic are also used in some applications. Woodward controls incorporates valve-linearizing function that converts control output to flow demand. An eleven-point linearization table is provided to characterize the demand output to the anti-surge valve’s flow characteristics.

  • Page 96: Figure 6-30. Boost Response With Pre-Pack

    Compressibility Calculation (Woodward Standard Operating Point Calculation Algorithm) Since Woodward Standard Algorithm uses calculated flow and polytropic head, such calculations require knowing gas compressibility factor Z. To input gas compressibility at suction (Z1), discharge (Z2), and flow meter (Zf) conditions: ...

  • Page 97: Figure 6-31. Gas Properties Calculations

    P_RT Figure 6-31. Gas Properties Calculations Specific Heat Ratio Calculation (Woodward Standard Algorithm) If the Standard Algorithm is selected, the specific heat ratio, or isentropic exponent, for the process gas must be known for polytropic head calculation. Default values for specific heat ratio and efficiency are configured into the control and used in the polytropic head calculation.

  • Page 98: Figure 6-32. Input Signal Configure And Failure Response

    Released Manual 35072 Vertex Compressor Control The speed-based stability monitoring described above is active only if a valid speed signal is available. If the unit is configured for Compressor-Only Mode, speed inputs are optional. The second action is taken if the system steady state condition changes or a second signal failure occurs while using the last good value for any input.

  • Page 99: Table 6-2. Temperature Fallback Strategy

    Released Manual 35072 Vertex Compressor Control The Last Good Value and Default Value routines will allow the compressor to run uninterrupted, thereby eliminating unnecessary recycling because of a transmitter failure. However, predicting the actual compressor operating point is somewhat compromised. Fail to Manual is the most conservative reaction, opening the anti-surge valve a configured amount beyond the current position to ultimately protect the machine when important process data is unavailable.

  • Page 100: Table 6-4. Suction Pressure Fallback Strategy

    Released Manual 35072 Vertex Compressor Control Table 6-4. Suction Pressure Fallback Strategy Last Values in Value if not stable Value on multiple failure or Good Ratio for Variable Stable P2 Fault Value Ratio Operation Indifferent Default P1 Default P1 Default P1...
  • Page 101 Released Manual 35072 Vertex Compressor Control Operating Point Calculations Standard Algorithm The Standard Algorithm operating point for a compressor is simply the volumetric inlet flow squared divided by the polytropic head, shown below. This equation can be expanded to show that it reduces to a form that only contains measurable quantities and constants.
  • Page 102 Released Manual 35072 Vertex Compressor Control The flow constant (K ) and Molecular Weight (MW) are input to the control during initial configuration. Flow element differential (h ), pressure (P ), and temperature (T ) are measured. As discussed previously, compressibility (Z ) is either configured as a constant or calculated on-line.

  • Page 103: Table 6-7. Typical Discharge Coefficients

    Released Manual 35072 Vertex Compressor Control These formulas for calculating flow constants assume SI engineering units of kPa, °C, kg/hr, m /hr, and mm. This matches the required inputs of the ASC. These constants will be different when compared to other flow measurements in different engineering units.
  • Page 104 Released Manual 35072 Vertex Compressor Control The calculated normal/standard volumetric or mass flow through the flow element can then be combined with any side-stream or adjacent stage flows resulting in the total flow through the compressor stage, Qs. However, actual volumetric suction flow is necessary to plot on the chosen compressor map, so the...
  • Page 105 Released Manual 35072 Vertex Compressor Control Where: k is the specific heat ratio, or isentropic exponent, of the gas p is the polytropic efficiency of the compressor T2 is the gas temperature at discharge conditions Z2 is the gas compressibility at discharge conditions After volumetric flow and polytropic head have been calculated, the controller can now combine these two values and calculate a single value representing the operating point of the compressor.
  • Page 106 When ASC2 is used, the Vertex IO can be expanded using RTCNet modules in order to accommodate the required IO counts. The same IO functions can be selected on an RTCNet Node as the Vertex control. Please see chapter 5 for details on RTCNet IO Expansion.

  • Page 107: Figure 6-33. Two Section Compressor With One Asv

    Released Manual 35072 Vertex Compressor Control Compressor Compressor Section 1 Section 2 Prime Mover Vertex Compressor Control No. 1 Suction Temp. No. 1 Suction Pressure No. 1 Suction Flow No. 1 Discharge Temp. No. 1 Discharge Pressure No. 2 Suction Temp.

  • Page 108: Commands

    Make this command through a contact input or Modbus/OPC. Train Normal Shutdown Request When this command is received, it indicates to the Vertex control that the unit is to be brought offline in a controlled fashion. The anti-surge controller(s) will begin ramping the valve(s) to the “Shutdown Position”...

  • Page 109: Performance Control

    Released Manual 35072 Vertex Compressor Control Performance Control The Performance Control (PFC) is commonly configured to drive suction/discharge throttle valves, Inlet Guide Vane position, or speed control setpoint. When configured, this control function is used to control compressor suction pressure, compressor discharge pressure, compressor flow, or any process variable related to compressor flow or load.
  • Page 110 Vertex Compressor Control Reset Position When the Vertex is tripped, the Sequence Ramp is forced to 0% demand. When all trips are cleared, the Sequence Ramp ramps to the “Reset Position” at the “Sequence Ramp Rate”. The “Reset Position” setting can be used in the case that the Performance demand output is driving a suction or discharge throttle valve to allow process gas to pressurize vessels and the compressor prior to starting the prime mover.

  • Page 111: Figure 6-36. Mode Select

    The shortest length of time a set point will move for an accepted raise or lower command is 40 milliseconds (120 milliseconds for a Modbus command). Optionally, program one of the Vertex’s analog inputs to position the Manual demand. This allows the Performance demand output to be positioned remotely by a process control or distributed plant control system.

  • Page 112: Figure 6-37. Performance Pid Overview

    Released Manual 35072 Vertex Compressor Control Performance PID The selection of the Process Variable to use for control is:  ASC 1 Suction Pressure  ASC 1 Discharge Pressure  ASC 2 Suction Pressure  ASC 2 Discharge Pressure ...
  • Page 113 Vertex Compressor Control Performance Set Point The Performance set point is adjustable with raise or lower commands through the Vertex front keypad, through remote contact inputs or through Modbus. In addition, the setpoint can be set directly by entering the new set point from the keypad or through Modbus communications. In addition, an analog input can be programmed to remotely position the Performance set point.
  • Page 114 Performance control is Inhibited, or Remote Performance Set Point is not programmed. The Remote Performance Set Point input may be enabled from the Vertex keypad, contact input, or Modbus/OPC communications. The last command given from any of these three sources dictates the state of the remote input.

  • Page 115: Figure 6-38. Limiter 1 Pid Overview

    Limiter 1 Set Point The Limiter 1 set point is adjustable with raise or lower commands through the Vertex front keypad, through remote contact inputs or through Modbus. In addition, the setpoint can be set directly by entering the new set point from the keypad or through Modbus communications.
  • Page 116 Remote Limiter 1 Set Point Optionally, one of the Vertex’s analog inputs can be programmed to position the Limiter 1 PID set point. This allows the Limiter 1 set point to be positioned remotely by a process control or distributed plant control system.

  • Page 117: Figure 6-39. Limiter 2 Pid Overview

    Manual 35072 Vertex Compressor Control The Remote Limiter 1 Set Point input may be enabled from the Vertex keypad, contact input, or Modbus/OPC communications. The last command given from any of these three sources dictates the state of the remote input. A contact input can be programmed to enable and disable the Remote Limiter 1 Set Point input/function.
  • Page 118 Limiter 2 Set Point The Limiter 2 set point is adjustable with raise or lower commands through the Vertex front keypad or through Modbus. In addition, the set point can be directly set by entering the new set point from the keypad or through Modbus communications.

  • Page 119: Load Sharing Control

    Vertex control units can be connected together to equally share the load across multiple compressor trains. The Vertex can load share between two, three, four, or five compressor trains. The Load Sharing (LS) algorithm works with the Performance controller output to maintain the common process variable (suction or discharge header pressure) and to balance the load between the compressors.

  • Page 120: Figure 6-41. Two Compressors Supplied By A Common Suction Header

    Released Manual 35072 Vertex Compressor Control Control Theory In many industrial processes, multiple controllers are given the task of controlling a common process variable. Consider the example of multiple compressors connected in parallel to a common suction header and a common discharge header, as shown in Figure 6-41.

  • Page 121: Figure 6-42. Load Share (Ls) Implementation

    In this example, a set of parallel trains (only the first train is shown) is controlling the common discharge header pressure. The shared parameter is the WSPV of the compressors. The Vertex control compares the WSPV of the first train with the WSPVs of the other trains. The difference between the first trains’...
  • Page 122 When a raise or lower Master Setpoint command is issued, the set point moves at the programmed “Setpoint Rate” setting. A specific set point may also be directly entered from the Vertex keypad or through Modbus/OPC communications. When this is performed, the set point will ramp at the “Setpoint Rate”...
  • Page 123 If the train is not the first to join the active load-sharing group, it will remain in the joining state for at least three seconds. After three seconds have elapsed, the Vertex will check the deviation between the train’s shared parameter and the shared parameter target.
  • Page 124 While the train is in the disabled state, the bias signal calculated from the shared parameter will be zero. The train can be transitioned to the disabled state at any time by a sending a Disable Load Sharing command. The LS enable and disable commands can be made from the Vertex front panel, contact inputs, or Modbus/OPC.
  • Page 125 Service Menu. By default, the Vertex does not perform ASV balancing across trains in the load sharing group and therefore the ASV deviation kickout is disabled by default.

  • Page 126: Figure 6-43. Load Share Communication Overview

    The load sharing communications are designed to be ‘plug-and-play’. There are only two steps for establishing communications between the units: 1) On the Configuration Menu > Load Sharing GUI screen, configure a unique Train ID for each Vertex in the load sharing group.

  • Page 127: Figure 6-44. Load Share Communication Status

    Vertex Compressor Control Figure 6-44. Load Share Communication Status When a communication link to one of the other Vertex units is failed, an alarm is annunciated. If train links are not healthy, verify the following: 1) Each Vertex in the load sharing group has a unique train ID.

  • Page 128: Chapter 7. Configuration Procedures

    Configuration Procedures Program Architecture The Vertex is easy to configure from the built-in graphical user interface (GUI). After the CPU self-test is completed and when powering up the control, the control displays the home screen and the CPU LED on the left side of the front panel should be green.

  • Page 129: Configuring The Vertex

    Configuration menu parameters. Configuring the Vertex Before the Vertex can operate any compressor train, configure the Vertex with a valid configuration. See Appendix A of this manual for a Vertex Configure Mode Worksheet. This chapter contains additional information related to completing this worksheet and configuring the specific application. Recommend this worksheet be completed and used to document your specific configuration.
  • Page 130 8. Use the navigation cross to navigate up/down/left/right and use ENTER to select a menu or item. The Vertex configure mode may be accessed if the unit is in a Shutdown state, no speed or flow is detected, and the correct user level is logged in (Configure or higher). For safety reasons the configuration may be monitored only and no changes will be accepted if the turbine is running.

  • Page 131: Figure 7-2. Configuration Menu - Configuration Mode (Edit)

    Released Manual 35072 Vertex Compressor Control Figure 7-2. Configuration Menu – Configuration Mode (Edit) Table 7-2. Configuration Modes and Descriptions Configuration Description Mode Train Configuration: Configure overall train layout, units used in the control, and train functionality Performance Configure Performance controller and sequencing...

  • Page 132: Table 7-3. Configure Menu Descriptions

    The configure menus are described in detail below and contain information detailing each question and/or Vertex configuration option. Each question/option shows the default (dflt) value and the adjustable range of that parameter (shown in parentheses). In addition, any additional configuration constraints appear in italics following the description.
  • Page 133 Released Manual 35072 Vertex Compressor Control Select the flow unit used to define the compressor Surge Limit Line points. dflt= N-m/kg Metric: Polytropic Head Unit Used [N-m/kg, kg-m/kg, kJ/kg] Imperial: [ft-lbf/lbm] The polytropic head unit used can only be selected with metric units. A fixed unit is applicable for imperial units.
  • Page 134 Released Manual 35072 Vertex Compressor Control Select the location of the temperature sensor(s) when used. Further selections can be made to use a default or calculated value of the temperature measurement instead of a measured value. A temperature sensor at the flow element is needed when using the standard algorithm.
  • Page 135 If the configuration is accepted, the status will change to "Configuration OK". The configuration must be valid in order to start the Vertex. Flow Element - (ASC Flow Element) - Calibration - (ASC Flow Meter Calibration) Flow dflt= 20000.0 (0.0, 1.0e+11)
  • Page 136 This field displays whether or not the generated flow coefficient has been configured and accepted. If the configuration is invalid, an error message will appear. If the configuration is accepted, the status will change to "Configuration OK". The configuration must be valid in order to start the Vertex. Send Calculated Value to Control...
  • Page 137 This field displays whether or not the surge/choke map has been configured and accepted. If the configuration is invalid, an error message will appear. If the configuration is accepted, the status will change to "All Data OK and Used". The configuration must be valid in order to start the Vertex. dflt= Display Only...
  • Page 138 This field displays whether or not the surge/choke map has been configured and accepted. If the configuration is invalid, an error message will appear. If the configuration is accepted, the status will change to "All Data OK and Used". The configuration must be valid in order to start the Vertex. Suction Temperature dflt= 0.0 (-500.0, 1000.0)
  • Page 139 This field displays whether or not the surge/choke map has been configured and accepted. If the configuration is invalid, an error message will appear. If the configuration is accepted, the status will change to "All Data OK and Used". The configuration must be valid in order to start the Vertex. X1 Value dflt= 1.01 (0.0, 1000000.0)
  • Page 140 Released Manual 35072 Vertex Compressor Control Enter a value to represent the x position of the 10th surge map point (rated condition). Y10 Value dflt= 1.2 (-1000000.0, 1000000.0) Enter a value to represent the y position of the 10th surge map point (rated condition).
  • Page 141 Released Manual 35072 Vertex Compressor Control Enter a value to represent the x position of the 4th choke point on the surge map (rated condition). Y4 Value dflt= 4.0 (-1000000.0, 1000000.0) Enter a value to represent the y position of the 4th choke point on the surge map (rated condition).
  • Page 142 Select a multiplier to manipulate the x axis value sent through modbus. AutoScale (On/Off) dflt= ON (ON/OFF) Select On to allow the Vertex to automatically scale the surge map. Select NO to manually configure the surge map display. ASC Antisurge Control...
  • Page 143 Released Manual 35072 Vertex Compressor Control dflt (Trigger)= NO (YES/NO) Use Minimum Discharge Pressure Level dflt (Level)= 0.0 (0.0, 25000.0) Check to enable the discharge pressure detection method for the online condition. Uncheck to not use this feature. Enter the required discharge pressure setpoint in the unit shown for the online condition.
  • Page 144 Released Manual 35072 Vertex Compressor Control NSD on Train NSD Request:Normal shutdown trigger from Train NSD command. NSD with Compressor 2 Offline: Normal shutdown trigger when ASC2 goes offline. Manual w/ Backup on NSD Complete dflt=YES (YES/NO) If YES is selected, the ASC will transfer to Manual with Backup Mode once the Normal Shutdown is complete.
  • Page 145 Released Manual 35072 Vertex Compressor Control dflt (Use)= NO (YES/NO) Minimum Flow Detection dflt (Trigger Setpoint)= 1.0 (0.01, 100000000.0) Check to enable the minimum flow surge detection routine. This routine, though included as a surge detection method, does not actually detect surge. It merely initiates the same open-loop Surge Recovery and Surge Minimum Position responses when the compressor operating point falls below the configured minimum flow set point.
  • Page 146 Released Manual 35072 Vertex Compressor Control dflt (Trigger Setpoint)= 150.0 (104.0, 200.0) Operating SP Limit To Detect Surge dflt (Captured Values)= Display Only Enter the limit for operating set point in percent to detect surge. When operating set point is less than the entered value, surge can be detected and counted, and anti-surge action can be activated.
  • Page 147 Released Manual 35072 Vertex Compressor Control dflt= Consec SRG RST used for Shift Reset [Consec SRG RST used for Shift Reset, Control Line Shift Reset SMP RST used for Shift Reset, Total SRG RST used for Shift Reset, Dedicated RST used for Shift Reset] When the surge counter is reset, the shifted amount will slowly ramp back to 0, returning the SCL to its original position.
  • Page 148 Released Manual 35072 Vertex Compressor Control The amount of time that the Maximum Number of Surges must be detected within in order to trigger the Shutdown on consecutive surges detected. Trip if Consecutive Surges SD Detected dflt= NO (YES/NO) Enable this option to issue a shutdown in case the set trip consecutive surge detection activates. This is defaulted to NO to not interfere with the Solo run during commissioning, however, it is recommended that this option is checked for normal operation.
  • Page 149 Released Manual 35072 Vertex Compressor Control Use Suction Temperature Last Good Value dflt= NO (YES/NO) When checked, the last good value failure response for the compressor suction temperature signal is enabled. If the signal fails, and compressor operation has been stable for approximately one minute, the stable suction temperature value will be retained for control, even though the input has failed.
  • Page 150 Released Manual 35072 Vertex Compressor Control The default pressure at flow element should always be set to the value at flow meter location regardless of a dedicated sensor being used. Default Temperature At Flow Element dflt= 1.0 (-273.0, 3000.0) If an alternate temperature signal is used for the flow measurement, enter a conservative default value to be used in the event that the alternate temperature signal fails.
  • Page 151 Released Manual 35072 Vertex Compressor Control Specify the delay time of anti-surge valve demand to add on the flow or pressure signal failure. Antisurge Control - PIDs - (ASC Normal Surge Controller Settings) Use Compensation on Normal PID dflt= NO (YES/NO) Check this checkbox to enable automatic gain compensation of the anti-surge PID’s proportional gain...
  • Page 152 Released Manual 35072 Vertex Compressor Control Select "Used with Actual P1" to enable suction pressure override control. This auxiliary controller will modulate the anti-surge valve when suction pressure falls below an established limiting setpoint. This control loop is usually used to help maintain suction pressure within the it process limits. One example of activating this control loop would be, in a situation when the motor or turbine speed reaches its minimum value and suction pressure continues to fall.
  • Page 153 Released Manual 35072 Vertex Compressor Control Decoupling may be necessary to provide action before an upset occurs. Upsets are anticipated from knowledge of the operating parameters and their relation to the operation of the anti-surge valve. dflt= No compressor decoupling used...
  • Page 154 Released Manual 35072 Vertex Compressor Control Decoupling 2 on Performance Demand, Decoupling 2 on External Signal 1] Decoupling signal source can be configured as: Decoupling on ASC Demand: The valve demand signal from the other ASC section. Decoupling on Performance Demand: The demand from the performance control...
  • Page 155 Released Manual 35072 Vertex Compressor Control Suction Pressure, ASC 2 Discharge Pressure, Dedicated Signal] Select which input the control should use. The input selected here should be configured as an analog input, which is used as the process value for this controller. If Dedicated Signal is used, then an analog input with "Process/Performance Input"...
  • Page 156 If YES, Manual Start is selected, and the Performance control will be placed in Manual mode as soon as the Vertex moves to the Start Completed state, and will hold the last demand set by the Sequence Ramp. If NO, Auto Start is selected, and the Performance control will be placed in Automatic mode as soon as the Vertex moves to the Start Completed state.
  • Page 157 Released Manual 35072 Vertex Compressor Control Limiter Control Limiter Control - (Performance Limiter 1) dflt= Not Used [Not Used, Motor Current/Power Input, ASC 1 Suction Limiter Configuration Pressure, ASC 1 Discharge Pressure, ASC 2 Suction Pressure, ASC 2 Discharge Pressure, Limiter Analog Input] Select which input the control should use.
  • Page 158 Released Manual 35072 Vertex Compressor Control Inverted? dflt= NO (YES/NO) Select YES if the Limiter control will be reverse acting. If NO is selected, the control will be forward acting. Set to YES if the valve needs to open when the input exceeds the set point. An example where the invert would be YES is for inlet pressure control.
  • Page 159 This is a user entered field. It allows entry of a unit label for this channel. Modbus Multiplier dflt= 1 [0.01, 0.1, 1, 10, 100] This is the multiplier that will be used for this parameter address on the Vertex slave Modbus communication link. Decimals Displayed dflt= 1 [0, 1, 2, 3] This is the number of decimals to be displayed on the Vertex screens for this parameter.
  • Page 160 Released Manual 35072 Vertex Compressor Control Select YES if the analog input channel function is not used by the Vertex control, but is used for Alarm/Trip monitoring in the Channel Events. Analog Inputs - Channel Events dflt= Display Only Analog Input 01 Signal Configured in Analog Inputs - AI_01 Displays the Function the channel is configured for.
  • Page 161 NO (YES/NO) Select YES to issue an alarm when an actuator fault is detected. If YES, the Vertex will issue an alarm if the analog channel has a fault. If NO, no fault alarm will be issued. A fault will be determined if the current drops below the failure level or if the difference between the current detected on the source and return wires of the circuit is greater than approximately 5%.
  • Page 162 Released Manual 35072 Vertex Compressor Control Drivers Driver Configuration Menu Demand dflt= Display Only Displays the current demand in percent. Readback dflt= Display Only Displays the current mA readback current sensed at the negative terminal. Min Range dflt= 0.0 (-1.0e+38, 1.0e+38) Set the value (in engineering units) that corresponds to 4 milliamps (mA) on the actuator output.
  • Page 163 Released Manual 35072 Vertex Compressor Control Use as Level Switch? dflt= NO (YES/NO) Select this to use this relay output as a level switch. Otherwise, the relay output will be a status indication. Relay Output Function Scroll through the menu by navigating the focus highlighter to the desired item, pressing ENTER, using the Adjust Up/Down Arrows, and then pressing the ENTER key again to select the option/function.
  • Page 164 RTCNet - (CAN Network - RTCNet I/O Nodes) Network Link Error dflt= Display Only The Vertex detects and error on the overall CAN network. Ensure that the each node has the correct, unique ID and that the baud rate is set to 500k. NMT Status...
  • Page 165 YES (YES/NO) Select YES for Deg F. Select NO for Deg C. Modbus Multiplier dflt= 1 [0.01, 0.1, 1, 10, 100] This is the multiplier that will be used for this parameter address on the Vertex slave Modbus communication link. Woodward...
  • Page 166 = 0.00392, the input should be 'American'. Decimals Displayed dflt= 1 [0, 1, 2, 3] This is the number of decimals to be displayed on the Vertex screens for this parameter. Ohm Value dflt= 100 Ohm [100 Ohm, 200 Ohm] This input determines what type of the RTD sensor is being used.
  • Page 167 Released Manual 35072 Vertex Compressor Control If hysteresis is negative, an alarm is triggered when the Input Signal becomes less than or equal to the Level Setpoint plus Hysteresis (absolute value) and the alarm condition is cleared when the input signal goes greater than the Level Setpoint.
  • Page 168 Use Modbus dflt= NO (YES/NO) Set to YES to use the Modbus communications feature of the Vertex. There are 3 identical Modbus ports available; 1 via the Serial port and 2 available via Ethernet. Select NO if Modbus communications will not be used.

  • Page 169: Exiting The Configure Mode

    IO Lock. If there are no errors in the configuration, the Vertex will be in the Shutdown state. At this point it may be ready to reset and run but, if this is the first time the Vertex has been configured with the unit’s actuator/linkage/valve, then it is recommended to run the valve stroking procedure in calibration...

  • Page 170: Table 7-4. Configuration Error Messages

    Wrong Product Model Detected Application. The maximum speed input is 35000 hertz. This is a limitation of the Vertex hardware/speed sensing circuitry. The frequency input of the speed sensor must be less than this value. The gear the speed sensor is mounted on may need to be changed to one with less Maximum Speed >...
  • Page 171 Released Manual 35072 Vertex Compressor Control Event Error Meaning Description The Remote Performance set point control function was configured but no Remote Performance set point Rmt PFC SP Configured, No Rmt AI analog input was configured. The Performance Limiter 1 function was programmed...
  • Page 172 Released Manual 35072 Vertex Compressor Control Event Error Meaning Description An authorized change to the compressor map, gas ASC1 Un-Auth New Setting properties, rated conditions, or flow metering device Detected settings has been made. Please confirm the settings. The compressor map configuration has been modified and must be reconfirmed in the Configuration Menu >...
  • Page 173 Released Manual 35072 Vertex Compressor Control Event Error Meaning Description The ASC1 control function was programmed but an ASC1 Configured but No P1 TX analog input for the suction pressure signal was not configured. The ASC2 control function was programmed but an...
  • Page 174 Released Manual 35072 Vertex Compressor Control Event Error Meaning Description See "Contact Input 02 Error". Error Contact Input 4 See "Contact Input 02 Error". Error Contact Input 5 See "Contact Input 02 Error". Error Contact Input 6 See "Contact Input 02 Error".
  • Page 175 Released Manual 35072 Vertex Compressor Control Event Error Meaning Description Error Relay Output 6 See "Relay 02 Error". Error Relay Output 7 See "Relay 02 Error". Error Relay Output 8 See "Relay 02 Error". Error RTC Node 5 Relay Output 1 See "Relay 02 Error".

  • Page 176: Calibration/Stroking Procedure

    Before calibrating or testing, the unit must be tripped and the feed gas supply removed. 1. The Vertex must be shutdown to enter Calibration Mode. 2. Go to the MODE screen by pressing the MODE key. 3. Enter Calibration Mode by pressing the ‘Calibration’ softkey. The following permissives must be met: a.
  • Page 177 Press the ‘Save Settings’ softkey to permanently save any minimum or maximum actuator settings into the Vertex. If variables are tuned or changed but not saved, then those changes will be lost if power is removed from the control or if the control receives a CPU reset.

  • Page 178: Chapter 8. Vertex Operation

    The Vertex is a field configurable compressor control and graphical user interface (GUI) integrated into one package. The Vertex control has been designed to run 2 separate, independent programs on the same platform. One controls the I/O and therefore controls compressor operation. The other program provides all the visual and command interaction with the user.

  • Page 179: Power-Up Screen

    Vertex Compressor Control Power-Up Screen Viewed from the front the Vertex – the following is the correct boot-up sequence of a Vertex unit loaded with the standard Vertex GAP and Qt GUI applications. Times are approximant. At Power-up Screen = BLANK /BLACK...

  • Page 180: Control Mode Architecture

    Outputs from the Vertex are disabled. This means that all Relays are de-energized and all Analog/Driver outputs are at zero current. Initially all Vertex’s must be placed in this mode to enter a valid configuration of the I/O and functions desired for the specific compressor application.

  • Page 181: User Login Levels

    Released Manual 35072 Vertex Compressor Control Figure 8-4. Control Mode Architecture User Login Levels Pressing the MODE key at any time will open the Login and Mode Screen Figure 8-5. Mode Screen Woodward...

  • Page 182: Navigation

    Woodward chose not to implement a touchscreen directly on this product. Using the RemoteView tool a user can take advantage of either a mouse device or a touchscreen on an external computer, but for navigation and selection directly on the Vertex display, buttons and an IN-Focus highlighter indication are used.

  • Page 183: Page Organization

    Configuration menus - The Configuration ‘HOME’ page contains navigation buttons to all features and options of the Vertex. When the unit is in Configure Mode (IOLOCK) the background of all pages will be a blue gradient as shown below, in addition to the status in the upper right.

  • Page 184: Figure 8-8. Configuration Menu - Operation Mode (View Only)

    Released Manual 35072 Vertex Compressor Control Figure 8-8. Configuration Menu – Operation Mode (View only) Figure 8-9. Configuration Menu – Configuration Mode (Edit) Refer to chapter 1 for more details about all of the keys – below are some general reminders about the...

  • Page 185: Figure 8-10. Overview Screen

    H/W action to open the Actuator circuits. For the Vertex, this button may be disabled in the configuration mode, but will always open the Actuator circuits when pressed. Analog outputs are not opened with a direct H/W action and may be preferred for compressor applications.

  • Page 186: Figure 8-11. Asc Control Popup

    Released Manual 35072 Vertex Compressor Control ASC Controller Popup Screen Figure 8-11. ASC Control Popup ASC Demands Screen Figure 8-12. ASC Demands Screen Woodward...

  • Page 187: Figure 8-13. Asc Demands Screen

    Manual 35072 Vertex Compressor Control The ASC Demand Valve Control screen will adapt to the configuration of the Vertex and show all configured options that can affect the final output demand to the ASV valve. During normal run operation, this screen provides the user with a clear picture of what control or ramp is controlling the valve demand output.

  • Page 188: Figure 8-14. Asc Compressor Map Screen

    Released Manual 35072 Vertex Compressor Control ASC Compressor Map Screen Figure 8-14. ASC Compressor Map Screen The ASC Compressor Map page can be accessed at any time from the runtime pages by pressing the “0” hotkey. It can also be navigated to from the Antisurge Control page. The screen is displays the Surge Limit Line, Boost Line, and Surge Control Line along with the current operating point (blue dot).

  • Page 189: Figure 8-15. Asc Control Dynamics Screen

    The ASC Control Dynamics allow the antisugre PID settings to be tune, along with a trend to plot the control and process response. This screen can be navigated to from the Antisurge Control screen or by pressing the ‘+/-‘ hotkey. The menu bar contains links to the other configured controllers in the Vertex. Woodward...

  • Page 190: Figure 8-16. Performance Control Screen

    Performance Control Screen Figure 8-16. Performance Control Screen The Performance Control screen will adapt to the configuration of the Vertex. During normal run operation, this screen provides the user with all details that are related to the Performance control loop.

  • Page 191: Figure 8-17. Performance Sequencing Screen

    Performance Sequencing Screen Figure 8-17. Performance Sequencing Screen The Performance Sequencing screen will adapt to the configuration of the Vertex and show all configured options that can affect the final output demand to the Performance valve. During startup, this screen provides the user with a clear picture the sequencing ramp controlling the valve demand output.

  • Page 192: Figure 8-18. Performance Valve Demand Screen

    Performance Valve Demand Screen Figure 8-18. Performance Valve Demand Screen The Performance Demand Valve Control screen will adapt to the configuration of the Vertex and show all configured options that can affect the final output demand to the Performance valve. During normal run operation, this screen provides the user with a clear picture of what control or ramp is controlling the valve demand output.

  • Page 193: Figure 8-19. Controllers Screen

    Controllers Screen Figure 8-19. Controllers Screen The Controllers screen will adapt to the configuration of the Vertex and show all configured options. During normal run operation, this screen provides the user with information similar to the Overview, but in a graphical gauge view. It provides larger values for distance viewing and control PID information which is useful for monitoring when the Vertex is near transition points between controllers or limiters.

  • Page 194: Figure 8-20. Analog Input Summary Screen

    Analog Input Summary Screen Figure 8-20. Analog Input Summary Screen The Analog Input Summary screen will display the status of all channels available on the Vertex hardware. The fault status, function, device tag, engineering value and units are shown for each channel as well as navigation buttons for each channel that take the user to a page showing all parameters available for that input.

  • Page 195: Figure 8-21. Contact Input Summary Screen

    Figure 8-21. Contact Input Summary Screen The Contact Input Summary screen will display the status of channels available on the Vertex hardware. The fault status, function, and device tags are shown for each channel as well as navigation buttons for each channel that take the user to a page showing all parameters available for that input.

  • Page 196: Figure 8-22. Analog Output Summary Screen

    Analog Output Summary Screen Figure 8-22. Analog Output Summary Screen The Analog Output Summary screen will display the status of all channels available on the Vertex hardware. The fault status, function, device tag, engineering value and units are shown for each channel as well as navigation buttons for each channel that take the user to a page showing all parameters available for that output.

  • Page 197: Figure 8-23. Relay Output Summary Screen

    Relay Output Summary Screen Figure 8-23. Relay Output Summary Screen The Relay Output Summary screen will display the status of all channels available on the Vertex hardware. The coil status, function, and device tag are shown for each channel as well as navigation buttons for each channel that take the user to a page showing all parameters available for that output.

  • Page 198: Stop Key

    Actuator Driver Summary Screen Figure 8-24. Actuator Driver Summary Screen The Actuator Driver Summary screen will display the status of the two channels available on the Vertex hardware. The fault status, function, current value (in mA), engineering value and units are shown for each channel as well as navigation buttons for each channel that take the user to a page showing all parameters available for that input.

  • Page 199: Figure 8-25. Alarm Screen

    Each individual alarm condition is available through the Modbus links to monitor the control status. A common alarm indication is also provided. Relay indications can be programmed to indicate a Vertex Common Alarm, in addition to the dedicated Alarm Relay output.
  • Page 200 Released Manual 35072 Vertex Compressor Control Event ID Description Meaning Analog Output Chan 3 readback failure detected (> 22 mA or AO_03 Readback Fault < 2 mA) Analog Output Chan 4 readback failure detected (> 22 mA or AO_04 Readback Fault <...
  • Page 201 Released Manual 35072 Vertex Compressor Control Event ID Description Meaning ASC#1: HSS#1 Fault External ASC HSS Analog Input failure (> 22 mA or < 2 mA) ASC#1: Primary Flow PV Flow dP Analog Input failure (> 22 mA or < 2 mA)
  • Page 202 Released Manual 35072 Vertex Compressor Control Event ID Description Meaning Primary Ctrl POS Performance Valve Feedback Analog Input Failure (> 22 mA Feedback Fault or < 2 mA) Performance PV Input Performance PV Analog Input Failure (> 22 mA or < 2 mA)
  • Page 203 Released Manual 35072 Vertex Compressor Control Event ID Description Meaning ASC#2: Surge On Motor Surge Detected: Motor Current Derivative Trigger Setpoint current Exceeded ASC#2: Choke Map Operating Point reached the Choke Line Reached ASC#2: Surges- AS valve Number of detected surges exceeds limit within a configured...
  • Page 204 Released Manual 35072 Vertex Compressor Control Event ID Description Meaning T4 Comms Failure Communication errors override active to Train 4 Override Active T5 Comms Failure Communication errors override active to Train 5 Override Active Kicked Out of Parallel Generic Load Sharing Kickout Alarm...

  • Page 205: Shutdown Summary

    Released Manual 35072 Vertex Compressor Control Event ID Description Meaning LS KO: Performance Load Sharing Kicked Out: Performance Mode in Manual Manual Enabled LS KO: ASC1 Offline Load Sharing Kicked Out: ASC1 has gone Offline LS KO: ASC2 Offline Load Sharing Kicked Out: ASC2 has gone Offline...

  • Page 206: Figure 8-26. Shutdown Summary Screen

    Vertex has a configuration error Unit in Calibration Mode Vertex is in Calibration Mode Power Up Trip Vertex lost power or the Configuration Mode was exited External Trip Input 2 External Trip #2 contact input was opened External Trip Input 3...

  • Page 207: Manual Dynamic Adjustments Of Anti-Surge, Performance, Limiter 1, Limiter 2, Load Sharing, And Pressure Override Pid Controls

    Each individual trip condition is available through the Modbus links to monitor the control status. A common trip indication is also provided. Relay indications can be programmed to indicate a Vertex Shutdown Condition (energizes for a shutdown condition) or a Trip Relay (de-energizes for a shutdown/trip), in addition to the dedicated Emergency Trip Relay output.

  • Page 208: Figure 8-27. Asc Dynamics Adjustment Screen

    They correspond to the P (proportional), I (integral), and D (derivative) terms, and are displayed by the Vertex as follows: P = Proportional gain (%)
  • Page 209 Vertex’s adjustable gains. If the accumulated mechanical gain (actuators, valves etc.) is very high, the Vertex’s gain must be very low to be added to the system gain required for system stability. Tuning Derivative The value of the Derivative Ratio (DR) term can range from 0.01 to 100.

  • Page 210: Chapter 9. Communications

    Our experience has been that not all serial interfaces on laptops or Desktop PCs work the same. Many USB-to-Serial converters work, but some do not. To use a Vertex Modbus port to monitor and/or operate, check the “Use Modbus” checkbox under the Configurations menu / Communications page. Monitor Only The three Modbus communication ports, are defaulted as read-only.

  • Page 211: Figure 9-1. Ascii/Rtu Representation Of Three

    Service Mode, if required. The Vertex control is programmed to function as a slave unit only. As a slave unit, the Vertex will only respond to a transaction request by a master device. The Vertex can directly communicate with a DCS or other Modbus supporting device on a single communications link, or through a multi-dropped network.

  • Page 212: Figure 9-2. Modbus Frame Definition

    Released Manual 35072 Vertex Compressor Control Figure 9-2. Modbus Frame Definition The Modbus function code tells the addressed slaves what function to perform. The following table lists the function codes supported by this control. Table 9-2. Modbus Function Codes Code...

  • Page 213: Port Adjustments

    Input coils are logical signals that are readable from, but not writable to, the Vertex control. An example of an Boolean read value would be a Vertex trip status indication. The input coil will have the value 1 if the statement in the description column is true and a 0 if false.

  • Page 214: Table 9-6. Boolean Write Addresses

    Analog Writes (Holding Registers) Holding registers are analog values that are writable to the Vertex control. These values can also be read from by a device performing error checking. An example of an analog write value would be a direct speed set point value as opposed to raise and lower commands.
  • Page 215 Released Manual 35072 Vertex Compressor Control Addr Description ASC#1: Disable P1 Override 0:0023 ASC#1: Enable P2 Override 0:0024 ASC#1: Disable P2 Override 0:0025 ASC#1: Purge Request 0:0026 ASC#1: Quit Purge Request 0:0027 ASC#1: Auxiliary Online 0:0028 ASC#1: Auxiliary Offline 0:0029...
  • Page 216 Released Manual 35072 Vertex Compressor Control Addr Description Limiter1 PID SP Lower 0:0066 Limiter1 PID Remote SP Enable 0:0067 Limiter1 PID Remote SP Disable 0:0068 PFC PID Setpoint GO 0:0069 PFC Limiter PID Setpoint GO 0:0070 PFC Sequence Ramp Position GO...

  • Page 217: Table 9-7. Boolean Read Addresses

    Released Manual 35072 Vertex Compressor Control Addr Description ASC#2: Start Position 0:0109 Enable Load Sharing 0:0110 Disable Load Sharing 0:0111 Request Setpoint Master Status 0:0112 Set T1 Comms Failure Override 0:0113 Reset T1 Comms Failure Override 0:0114 Set T2 Comms Failure Override...
  • Page 218 Released Manual 35072 Vertex Compressor Control Addr Description PFC Tracking 1:0024 Relay Output 1 State 1:0025 Relay Output 2 State 1:0026 Relay Output 3 State 1:0027 Relay Output 4 State 1:0028 Relay Output 5 State 1:0029 PFC PID Limited 1:0030...
  • Page 219 Released Manual 35072 Vertex Compressor Control Addr Description ASC#1: Off-Line - Start 1:0067 ASC#1: ASV Position Feddback Fault 1:0068 ASC#1: Off-Line - ESD 1:0069 ASC#1: On-Line 1:0070 ASC#1: On-Line - Ctrl SD 1:0071 ASC#1: On-Line - Online 1:0072 ASC#1: In Control - P2 Override...
  • Page 220 Released Manual 35072 Vertex Compressor Control Addr Description ASC#1: Suction Press Fault 1:0110 ASC#1: Disch Press Fault 1:0111 ASC#1: Suction Temp Fault 1:0112 ASC#1: Disch Temp Fault 1:0113 ASC#1: HSS#1 Fault 1:0114 ASC#1: Decoupling#1 Fault 1:0115 ASC#1: Decoupling#2 Fault 1:0116...
  • Page 221 Released Manual 35072 Vertex Compressor Control Addr Description PFC Limiter2 PID In Control 1:0153 PFC Limiter2 PID Enabled 1:0154 PFC Limiter2 PID Inhibited 1:0155 PFC Limiter2 PID Active 1:0156 PFC Limiter2 Remote SP Enabled 1:0157 PFC Limiter2 Remote SP Active...
  • Page 222 Released Manual 35072 Vertex Compressor Control Addr Description ASC#2: P2 Ovrd - P2 Ovrd Active 1:0196 ASC#2: Choke Ctrl in Automatic 1:0197 ASC#2: Choke Ctrl in Control 1:0198 ASC#2: Consecutive Surge Alarm Detected 1:0199 ASC#2: Surge on Flow Deriv 1:0200...
  • Page 223 Released Manual 35072 Vertex Compressor Control Addr Description Discrete Input 12 State 1:0239 Discrete Input 13 State 1:0240 Discrete Input 14 State 1:0241 Discrete Input 15 State 1:0242 Discrete Input 16 State 1:0243 Discrete Input 17 State 1:0244 Discrete Input 18 State...
  • Page 224 Released Manual 35072 Vertex Compressor Control Addr Description LN Node 5 DO 11 State 1:0282 LN Node 5 DO 12 State 1:0283 LN Node 5 DO 13 State 1:0284 LN Node 5 DO 14 State 1:0285 LN Node 5 DO 15 State...
  • Page 225 Released Manual 35072 Vertex Compressor Control Addr Description 1:0325 ALM_038: External alarm # 1 1:0326 ALM_039: External alarm # 2 1:0327 ALM_040: External alarm # 3 1:0328 ALM_041: Un-Authorized Start Attempted 1:0329 ALM_042: Spare 042 1:0330 ALM_043: Spare 043 1:0331...
  • Page 226 Released Manual 35072 Vertex Compressor Control Addr Description ALM_081: Performance PV Input Failed 1:0368 ALM_082: Remote Performance Setpoint Failed 1:0369 ALM_083: Remote Performance Demand Failed 1:0370 ALM_084: Performance Limiter PV Input Failed 1:0371 ALM_085: External Decoupling Signal Fault 1:0372 ALM_086: Motor Current/Power Signal Fault 1:0373 ALM_087: Perf Cntrl Reset Pos >...
  • Page 227 Released Manual 35072 Vertex Compressor Control Addr Description 1:0411 ALM_124: Vibration Input #4 Fault 1:0412 ALM_125: Signal Fault AI 1 1:0413 ALM_126: Signal Fault AI 2 1:0414 ALM_127: Signal Fault AI 3 1:0415 ALM_128: Signal Fault AI 4 1:0416 ALM_129: Signal Fault AI 5...
  • Page 228 Released Manual 35072 Vertex Compressor Control Addr Description SD031: Signal Fault AI 3 1:0454 SD032: Signal Fault AI 4 1:0455 SD033: Signal Fault AI 5 1:0456 SD034: Signal Fault AI 6 1:0457 SD035: Signal Fault AI 7 1:0458 SD036: Signal Fault AI 8...
  • Page 229 Released Manual 35072 Vertex Compressor Control Addr Description Load Sharing: Link 1 from T5 failed 1:0497 Load Sharing: Link 2 from T5 failed 1:0498 1:0532 ALM_137: Spare_137 1:0533 ALM_138: T1 Comms Failure Override Active 1:0534 ALM_139: T2 Comms Failure Override Active...

  • Page 230: Table 9-8. Analog Read Addresses

    Released Manual 35072 Vertex Compressor Control Addr Description 1:0573 ALM_178: LS KO: ASC Deviation 1:0574 ALM_179: LS KO: Parameter Deviation 1:0575 ALM_180: LS KO: ASC1 Surge 1:0576 ALM_181: LS KO: ASC2 Surge 1:0577 ALM_182: LS KO: ASC1 Full Manual Active...
  • Page 231 Released Manual 35072 Vertex Compressor Control Units Multiplier Addr Description Spare 3:0031 Spare 3:0032 Internal Board Temp 3:0033 24VDC 3:0034 Spare 3:0035 Spare 3:0036 Spare 3:0037 Spare 3:0038 ASC1 Readback (0-100%) 3:0039 FDBK AI Mult PFC Readback (0-100%) 3:0040 FDBK AI Mult...
  • Page 232 Released Manual 35072 Vertex Compressor Control Units Multiplier Addr Description LN Node 1 Analog Input 8 Val 3:0068 LN1 AI 08 Units LN1 AI 08 Mult LN Node 2 Analog Input 1 Val 3:0069 LN2 AI 01 Units LN2 AI 01 Mult...
  • Page 233 Released Manual 35072 Vertex Compressor Control Units Multiplier Addr Description ASC#1: Decoupling 1 Dmd (X100%) 3:0111 ASC#1: Decoupling 2 Dmd (X100%) 3:0112 ASC#1: Decoupling 3 Dmd (X100%) 3:0113 ASC#1: Speed Decp Dmd (X100%) 3:0114 ASC#1: Final Dcpl Demand (X100%) 3:0115...
  • Page 234 Released Manual 35072 Vertex Compressor Control Units Multiplier Addr Description ASC#1 Display Surge Map#1: Point X11 (EU) Configured Mult 3:0154 ASC#1 Display Surge Map#1: Point Y11 (EU) Configured Mult 3:0155 ASC#1 Display Surge Map#1: Point X12 (EU) Configured Mult 3:0156...
  • Page 235 Released Manual 35072 Vertex Compressor Control Units Multiplier Addr Description ASC#1 WSPV Numerator 3:0195 ASC#1 Polytropic Efficiency 3:0196 Spare 3:0197 Spare 3:0198 Spare 3:0199 Spare 3:0200 PFC Startup Position 3:0201 PFC Sequence Ramp 3:0202 PFC Remote Sequence Demand 3:0203 PFC Limiter PID Demand...
  • Page 236 Released Manual 35072 Vertex Compressor Control Units Multiplier Addr Description ASC#2: Ext HSS1 Demand (X100%) 3:0237 ASC#2: Ext HSS2 Demand (X100%) 3:0238 ASC#2: Decoupling 1 Dmd (X100%) 3:0239 ASC#2: Decoupling 2 Dmd (X100%) 3:0240 ASC#2: Decoupling 3 Dmd (X100%) 3:0241...
  • Page 237 Released Manual 35072 Vertex Compressor Control Units Multiplier Addr Description ASC#2 Display Surge Map#1: Point X10 (EU) Configured Mult 3:0280 ASC#2 Display Surge Map#1: Point Y10 (EU) Configured Mult 3:0281 ASC#2 Display Surge Map#1: Point X11 (EU) Configured Mult 3:0282...

  • Page 238: Table 9-9. Analog Write Addresses

    Released Manual 35072 Vertex Compressor Control Units Multiplier Addr Description ASC#2 Current/Power Derivative Surge Amp/sec Current AI Mult 3:0321 Detected(Amp/sec) ASC#2: WSPV Denominator 3:0322 ASC#2: WSPV Numerator 3:0323 ASC#2: Polytropic Efficiency 3:0324 Load Sharing: Voted PV 3:0325 Load Sharing: Master SP...
  • Page 239 Two different types of shutdown commands (emergency and controlled) can be issued through Modbus. The Emergency Shutdown command instantly takes the outputs to the safe positions. Optionally the Vertex can be configured to ignore this Emergency Shutdown command if it is desired to not allow the unit to be tripped through Modbus.

  • Page 240: Chapter 10. Product Support And Service Options

     An Authorized Independent Service Facility (AISF) provides authorized service that includes repairs, repair parts, and warranty service on Woodward's behalf. Service (not new unit sales) is an AISF's primary mission.  A Recognized Turbine Retrofitter (RTR) is an independent company that does both steam and gas turbine control retrofits and upgrades globally, and can provide the full line of Woodward systems and components for the retrofits and overhauls, long term service contracts, emergency repairs, etc.

  • Page 241: Returning Equipment For Repair

    All repair work carries the standard Woodward service warranty (Woodward Product and Service Warranty 5-01-1205) on replaced parts and labor.

  • Page 242: Replacement Parts

     The unit serial number, which is also on the nameplate Engineering Services Woodward offers various Engineering Services for our products. For these services, you can contact us by telephone, by email, or through the Woodward website.  Technical Support ...

  • Page 243: Technical Assistance

    Vertex Compressor Control Technical Assistance If you need to contact technical assistance, you will need to provide the following information. Please write it down here before contacting the Engine OEM, the Packager, a Woodward Business Partner, or the Woodward factory: General...

  • Page 244: Appendix A. Vertex Configuration Mode Worksheets

    Released Manual 35072 Vertex Compressor Control Appendix A. Vertex Configuration Mode Worksheets Control Part Number ______________________ Serial Number ______________________ Application ________________________________ Date ___________ For details on individual settings, refer to Chapter 7. Train Configuration Train Configuration - (Train Default Site Value...
  • Page 245 Released Manual 35072 Vertex Compressor Control Train Configuration - (Train Default Site Value Parameters) dflt= YES (YES/NO) External Trips in Trip Relay? dflt= NO (YES/NO) Reset Clears Trip Relay dflt= YES (YES/NO) Trip on Normal Shutdown Complete? dflt= YES (YES/NO)
  • Page 246 Released Manual 35072 Vertex Compressor Control dflt= 20000.0 (0.0, 1.0e+11) Flow dflt= 20.0 (0.0, 10000.0) Delta Pressure at Flow dflt= 20.0 (0.0, 100.0) Molecular Weight dflt= 20.0 (0.0, 1000000.0) Pressure at Flow Meter dflt= 20.0 (-600.0, 10000.0) Temperature at Flow Meter dflt= 1.0 (0.5, 1.2)
  • Page 247 Released Manual 35072 Vertex Compressor Control Compressor Mapping - (ASC Units Default ASC1 ASC2 and Multipliers) Value Value dflt= Display Only Status of Actual Map dflt= Display Only Actual Flow Unit Configured in Train Configuration dflt= X 1 Actual Flow Multiplier...
  • Page 248 Released Manual 35072 Vertex Compressor Control dflt= Display Only Power at Rated Calculated based on Rated Mapping Parameters Confirm Rated Conditions dflt= NO Compressor Mapping - (ASC Surge Default ASC1 ASC2 Map Configuration) Value Value dflt= Display Only Status of Actual Map dflt= 1.01 (0.0, 1000000.0)
  • Page 249 Released Manual 35072 Vertex Compressor Control dflt= 1.0 (0.0, 1000000.0) X2 Value dflt= 2.0 (-1000000.0, 1000000.0) Y2 Value dflt= 1.0 (0.0, 1000000.0) X3 Value dflt= 3.0 (-1000000.0, 1000000.0) Y3 Value dflt= 1.0 (0.0, 1000000.0) X4 Value dflt= 4.0 (-1000000.0, 1000000.0) Y4 Value dflt= 1.0 (0.0, 1000000.0)
  • Page 250 Released Manual 35072 Vertex Compressor Control dflt= 100.0 (0.0, 100.0) Position During Startup Antisurge Control - Sequencing - Default ASC1 ASC2 (ASC Sequencing Online Value Value Detection) dflt (Trigger)= NO (YES/NO) Use Minimum Speed Level dflt (Level)= 0.0 (0.0, 25000.0)
  • Page 251 Released Manual 35072 Vertex Compressor Control Antisurge Control - Surge Default ASC1 ASC2 Detection - (ASC Surge Detection Value Value Method Used) dflt (Use)= NO (YES/NO) dflt (Trigger Setpoint)= 80.0 (1.0, Flow Derivative Detection 300.0) dflt (Captured Values)= Display Only...
  • Page 252 Released Manual 35072 Vertex Compressor Control dflt= Consec SRG RST used for Shift Reset [Consec SRG RST used for Shift Reset, Control Line Shift Reset SMP RST used for Shift Reset, Total SRG RST used for Shift Reset, Dedicated RST used for Shift...
  • Page 253 Released Manual 35072 Vertex Compressor Control Antisurge Control - Signal Default ASC1 ASC2 Conditioning - (ASC Last Good Value Value Values) Use Suction Pressure Last Good dflt= NO (YES/NO) Value Use Discharge Pressure Last Good dflt= NO (YES/NO) Value Use Suction Temperature Last Good...
  • Page 254 Released Manual 35072 Vertex Compressor Control Antisurge Control - PIDs - (ASC Default ASC1 ASC2 Normal Surge Controller Settings) Value Value dflt= NO (YES/NO) Use Compensation on Normal PID dflt= 0.3 (0.0, 50.0) Proportional Gain dflt= 0.3 (0.0, 50.0) Integral Gain dflt= 100.0 (0.0, 100.0)
  • Page 255 Released Manual 35072 Vertex Compressor Control dflt= 0.3 (0.0, 50.0) Integral Gain dflt= 100.0 (0.0, 100.0) Speed Derivative Ratio dflt= () Initial Setpoint dflt= 0.1 (0.001, 10000.0) SP Rate of Change Antisurge Control - Decoupling - Default ASC1 ASC2 (ASC Decoupling - Main Settings)
  • Page 256 Released Manual 35072 Vertex Compressor Control Antisurge Control - Decoupling - (ASC Default ASC1 ASC2 Auxiliary Controls) Value Value dflt= NO (YES/NO) Use Auxiliary HSS1 dflt= 0.5 (0.0, 300.0) Signal Filter (HSS1) dflt= NO (YES/NO) Use Auxiliary HSS2 dflt= 0.5 (0.0, 300.0) Signal Filter (HSS2) dflt= -1.0 (-1.0, 101.0)
  • Page 257 Released Manual 35072 Vertex Compressor Control Performance Control - Default Site Value (Performance Configuration - Decoupling) dflt= Not Used [Not Used, External AI Signal, Decoupling Signal Selection ASV1 Demand, ASV2 Demand, HSS of ASV1 and ASV2] dflt= 0.0 (-10.0, 10.0) Gain dflt= 0.0 (0.0, 10.0)
  • Page 258 Released Manual 35072 Vertex Compressor Control Load Sharing Default Site Value Load Sharing - (Load Sharing) dflt= NO (YES/NO) Use Load Sharing? dflt= 2 (2,5) Number of Trains in Load Sharing dflt= 1 (1,5) Train ID dflt= WSPV [WSPV, Load Sharing Parameter...
  • Page 259 Released Manual 35072 Vertex Compressor Control Communications Communications - (Ethernet IP Configuration) Default Site Value dflt (Octet 1)= 172 (0, 255) dflt (Octet 2)= 16 (0, 255) ENET 1 Address dflt (Octet 3)= 100 (0, 255) dflt (Octet 4)= 15 (0, 255)
  • Page 260 Released Manual 35072 Vertex Compressor Control Analog Output Channels - Function Val@4 Val@20 Units Rdbk Actuator Output Channels - Function Range mA@0 mA@100 Dither Act Flt = SD Discrete Output Relays Level or Function Invert Level ON Level OFF State Logic RTCNet I/O Modes –...
  • Page 261 Released Manual 35072 Vertex Compressor Control Node 2 – 8 channels Analog Input 4-20mA & 2 channels Analog Output 4-20mA Function Val@4 Val@20 Units Modbus Mult. Disp Node 3 – 8 channels RTD Input (100 or 200 ohm) Function Mult Disp For each of the Analog Input Node channels above, events can be configured if desired.
  • Page 262 Released Manual 35072 Vertex Compressor Control NODE 3 Events Level 1 Level Setpoint Delay Alm1 Alm2 Trip 2 SP Hysteresis Woodward...
  • Page 263 Released Manual 35072 Vertex Compressor Control Node 4 – 16 channel Discrete Input (24Vdc) Function Invert Logic Node 5 – 16 channel Discrete Output (24Vdc) Level or Function Invert Level ON Level OFF State Logic When Actuator Outputs have been (In Service) Calibrated and Stroked, record values here.

  • Page 264: Revision History

    Released Manual 35072 Vertex Compressor Control Revision History New Manual Woodward...

  • Page 265: Declarations

    Released Manual 35072 Vertex Compressor Control Declarations Woodward...
  • Page 266 Released Manual 35072 Vertex Compressor Control Woodward...
  • Page 267 Email and Website—www.woodward.com Woodward has company-owned plants, subsidiaries, and branches, as well as authorized distributors and other authorized service and sales facilities throughout the world. Complete address / phone / fax / email information for all locations is available on our website.

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