Softmap 30 D
Softmap 30 D
Softmap 30 D
Version 3.1
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1.0 Overview:
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SoftMap is a compressor analysis tool, and functions as an automated version
of the existing paper head vs flow compressor performance map provided by
Solar. As such, it includes all the benefits and limitations of a fixed head
vs flow map. While the Head vs Flow map provides maximum accuracy over
widely varying conditions, mach number effects caused by large changes in gas
consistency or suction pressure are not accounted for. Typically suction and
discharge pressures can be varied by a factor of 5, gas suction temperature
50 degF and gas SG by about 0.2 without introducing significant errors. If
the mach number for the checkpoint being calculated is more than 5% away from
that which would be calculated for the same head and flow point using the
original design conditions, an error will be flagged and the calculation
aborted.
5) Batch load compressor data. Data can be copied directly from a reservoir
analysis or other source to appropriate columns in the 'Data Log' sheet of
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the program along with the appropriate calculation code. All data records
which do not yet have a predicted RPM will have the all performance
parameters recalculated using the given performance calculation code when the
‘Record’ button on the map is pressed. Performance for up to 50 points at a
time can be calculated and plotted on the head vs flow chart in seconds.
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Home Sheet:
The home page functions as a navigation page only. From the ‘Home’ sheet the
user can go three different directions:
1: The ‘Solar Compressor Performance’ button sends the user to the ‘Solar
Compressor Performance sheet. From it one can calculate compressor
performance which is not specific to any particular compressor type or
staging. The sheet can be used to estimate the power and compressor
required for a particular compression duty.
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Solar Compressor Performance Sheet:
After the required data has been entered and the ‘Calculate’ button is
pressed the sheet will complete calculations for the checkpoint and display
the resulting checkpoint on the head vs flow map on the left of the page.
Multiple checkpoints can be saved and plotted.
By noting the maximum power required for a group of checkpoints one can
determine which engines will be appropriate for the duty. Likewise,
candidate compressors can be selected by observing which compressor
performance envelopes best cover the checkpoints. It needs to be emphasized
that the compressor envelopes shown refer to the performance for a given
compressor model, not what is possible using a single staging selection. The
compressor performance map for a given set of staging is much smaller. For
C160, C33, C505 and any other 1st or 2nd generation Solar compressors the
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max/min head and max/min flow ratios need to be less than 2:1. For the third
generation machines like the C40, C45, C65 the max/min ratio goes up to 3:1.
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Tandem Compressor Performance Sheet:
If the package that the ‘Softmap’ was created for has more than one
compressor on the skid the ‘Tandem Compressor Performance’ Sheet will be
available. If not, the ‘Tandem’ button on the ‘Home’ page will be replaced
by one directly linking the ‘LP compressor performance’ page. The tandem
program option can control two or more single body performance calculation
sheets to determine tandem performance. Two tandem calculation options are
available at this time:
2) Power Limited Flow. By pressing the ‘Calculate Tandem HP’ button the
power limited flow for the package can be calculated. This mode uses the
Target SQ Flow mode as a starting point. An SQ multiplier is then
estimated with the aim of consuming all of the power available. New SQ
values are estimated by multiplying the initial SQ values by the SQ
multiplier. This is done recursively until the power required equals
the power available.
When the tandem calculations are complete one can get details on any of the
individual compressor bodies by navigating to any of the individual
compressor performance sheets. This is done by pressing the appropriate
silver navigation button on the ‘Tandem Compressor Performance’ page.
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LP, IP, and HP Compressor Performance Pages:
The individual compressor performance sheets are the focus of the ‘Softmap’
program. The LP, IP, and HP compressor performance sheets are created from
the same template, only the source data is different. The Solar Compressor
performance sheet is extremely similar, except that no information comes from
or is compared to the map. Each sheet is made of six sections:
1) The compressor map on the upper left side of the page is a standard
Excel chart with the efficiency, surge, and speed line data plotted.
The data is based on checkpoints from Solar's GCASE compressor
performance program running at the design condition using the specific
compressor and staging shown in the ‘Map Info’ sheet. The speed lines
are black, the surge line pink, and the efficiency lines multi-colored.
Efficiency lines with the same value are the same color to enhance
readability. Typically the site name and compressor ID are shown in the
lower right hand corner of the chart. The chart can be refreshed and
the last point calculated and recorded in row 6 of the appropriate ‘Data
Log’ sheet by pressing the gold ‘Record Data’ button in the upper left
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corner of the chart. All of the existing data points are slid down a
row.
2) On the upper right side of the screen are the data history display
controls. The ‘Checkpoint #’ pull-down menu is used to select the key
historical checkpoint. This checkpoint is displayed on the map as a
purple triangle. It can sometimes hidden be behind the current
checkpoint that is red with a white cross. When the historical
checkpoints checkbox is selected up to the maximum number historical
checkpoints are plotted on the chart starting with the key historical
checkpoint. If the label checkbox is also selected each of the
checkpoint labels will be displayed as well. The labels work well if
only 1-5 checkpoints are displayed, but it gets hard to read with many
more. Finally, there is a ‘Max Checkpoints’ cell where the maximum
number of checkpoints plotted can be set(0-50).
4) Below gas analysis are the ‘Parameters Supplied’ pull-down and the
‘SCADA Input’ checkbox. The ‘Parameters Supplied’ checkbox allows the
user to select which parameters are used as inputs to calculate the
operating point. There are 11 different formulas plus an option to
import the key historic data point indicated in the Checkpoint# pull-
down menu. When the ‘SCADA Input’ checkpoint is selected, the input
data comes from the ‘SCADA Input’ sheet, not the ‘Compressor
Performance’ sheet. This feature can be used in two primary ways.
Since the sheet is originally made with the design point entered in the
SCADA Input sheet, it can be used has a handy reference to get the input
values back to known good values. Just select the SCADA checkbox and
press the gold ‘Calculate’ button. Alternately one can enter formulas
in the SCADA cells. The formulas can be used to link to a DDE server
providing live data. This makes it possible to evaluate the compressor
performance in real time.
5) The Excel cells in the lower right hand portion of the sheet are the
primary input and display cells. They are broken into three columns.
The first column is based input data or data directly calculated from
input data. It is called the ‘Actual’ column. The only exceptions to
that generalization are the formulas which use RPM as an input
parameter. The cells requiring an input value are highlighted in gold.
The second column is called the ‘Predicted’ column and uses the head and
flow from the first Actual Data to locate a point on the head vs flow
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map. Polynomial formulas are used to interpolate the predicted RPM,
efficiency, and position relative to the surge line. The predicted T2
is calculated using predicted efficiency and the actual pressures and
T1. Finally, there is the ‘Delta’ column. This column is used to
compare data between the actual and predicted columns as a percentage.
The ‘Poly’ checkbox in the lower right of this section is used to select
polytropic head and efficiency instead of the standard isentropic
method. When the polytropic box is checked the map is redrawn for
polytropic head and efficiency, the head and efficiency displayed
becomes polytropic, and the polynomials associated with the polytropic
map data are used as the basis for all map references.
The gold ‘Calculate’ button is in the lower right area of the page.
When the calculate button is pressed the input data is processed, the
data is logged in the ‘Datalog’ as the real-time checkpoint and the
real-time checkpoint, which is red with a white cross, is moved to the
new location on the head vs flow map. If there is an error in
calculation the operation is aborted and an error message is displayed.
Checkpoint Calculation
The ‘Actual’ column can currently be calculated using 11 different formulas.
RPM is only used to compare with the map prediction in calculation codes 2-8.
Since ‘Solar Compressor Performance’ page does not have RPM information it
only uses codes 1-8. The difference between each of the formulas is which
parameters are used for input and which for output. The formula should be
selected based on what parameters are known and believed to be most accurate.
The other values will be calculated. Parameters that are known, but not
required can be compared with the calculated values. The following formulas
can be used;
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Calculated Parameters Supplied Calc Code
Data From Log file Data from Log File 1
head, eff pwr P1, P2, T1, T2, SQ, RPM 2
head, eta, sq P1, P2, T1, T2, Pwr, RPM 3
head, p2 P1, T1, Pwr, SQ, RPM 4
head p1 P2, T1, Pwr, SQ, RPM 5
head, t2, eta P1, P2, T1, Pwr, SQ, RPM 6
head, t2, Pwr P1, P2, T1, SQ, RPM 7
head, t2, SQ P1, P2, T1, Pwr, RPM 8
head, p2, t2, Pwr P1, T1, SQ, RPM 9
head, p1,t2,Pwr P2, T1, SQ, RPM 10
head, ETA, SQ, Pwr P1, P2, T1, T2, RPM 11
The conditions that the chart was originally generated for are indicated in
the 'Map Info' page. It includes the compressor staging type, staging, seal
type, gas conditions, database information, and package information. It can
be viewed by pressing the silver ‘Map Info Pg’ button.
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While the map may be applicable to different packages and different
conditions, this information shows the basis of the map shown in the
‘Compressor Performance’ sheet.
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The ‘Data Log’ page is a spreadsheet used to record checkpoint data for it’s
related compressor performance sheet. Rows 6 and higher are used to record
data points. Row 5 is linked to the performance page’s input. Row 1
contains data from the last data point. All data displayed is in Solar
Units. If one wants to view the data in user units the data it needs to be
manually copied to a new spreadsheet and converted. The work area of the
‘User Units’ can be used to assist the process. To avoid changing the format
of the page use the ‘Paste Special’ / values only feature instead of the
standard ‘Paste’ feature in the ‘Edit’ menu of Excel.
A few of the rows and cells in the 'Data Log' sheet have special
functions. . The raw input data is copied to row #5.
. When a calculation is performed, the input data taken from row #5 and
the results pasted into row#2.
. When a data point is recorded the data in row#2 is copied to row #6, and
all data from the lower cells are bumped down.
. Cell #A2 saves the status of the plot "Historical' check box.
. Cell #A1 keeps track of the next checkpoint tag number to be used.
. Cell #A3 keeps track of which 'Chkpt#' is selected in the 'Compressor
Performance' sheet pull-down menu.
Two buttons are on the Data Log page. The left most button ‘Clear Data Log’
erases all of the data from row 6 and higher. The user should be very sure
this is what is desired before pressing the button. The right button is a
navigation button that brings the user back to the ‘Compressor Performance’
page.
Gas Analysis:
As stated earlier the gas properties for any of the compressor performance
sheets can be entered directly if one has the SG, k50, k300, PCP and PCT
values for the process gas. If not one can press the ‘Analysis’ button to
call up the ‘Analysis Method’ page. From this page the user can choose to
use obtain the gas properties based on SG (specific gravity) of the gas by
pressing the “SG Based Analysis’ button. Alternately one can press the
‘%Mole Based Analysis’ to use process gas constituents to determine the
process gas properties.
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SG Analysis:
The ‘SG Analysis’ page estimates the K50, k300, PCP and PCT given the SG. SG
values must be between .55 and 1.2. Type the SG of the process gas in the
appropriate cell and press <Enter> to have the values calculated. Once the
values look good press the ‘Copy Data to Performance Pg’ button. The
compressor performance sheet will be brought to the front and the gas
characteristic values will be pasted into the appropriate cells. If you want
to abort the process, press the ‘Escape’ button
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The following formulas are used to ESTIMATE the gas characteristics:
Mole Analysis:
The mole analysis assumes that the process gas is unsaturated and is based
upon the mole percentage of each of the constituents in the gas stream. If
the gas is saturated at the process pressures another program like GPASIM
will need to be used to determine what process gas is after the liquids are
removed.
PCPmix =
PCTmix /wt average(PCP/PCT)
PCPmix =
(1+1/3)*[wt average(PCT^1.25/PCP^0.5)/[(1 – 1/3)*wt average(PCP/PCT)]
Data from up to three separate gas streams can be used to determine the
process gas properties. If all is satisfactory, press the 'Copy Data to
Performance Pg’ button to paste the gas characteristics into the performance
sheet or press ‘Escape’ to abort the process.
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User Units Sheet:
Solar Units
Parameter Solar Units
Pressure psia
Temperature degF
Head Ft-Lb/Lbm
Actual/Velocity Flow ACFM
Mass Flow mmSCFD
If other units are used they are converted to Solar units before calculations
are made and converted back to the user units after the calculations are
finished. When units are changed the values in all the performance sheets,
and all the SCADA sheets are converted. In addition, all the performance
maps are converted to the new head and flow units, new scales are selected,
rescaled, and redrawn.
To change user units go to the Change Units sheet using the navigation
buttons, then use the pull down menus to select the desired units for
pressure, flow, head, mass flow, velocity flow, and temperature. To make the
changes effective, press the ‘Change Units’ button.
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If the units desired are not listed, custom units can be added to the default
list. The default list cannot be added to, modified or deleted. To add a
custom unit press the Add/Edit button. A pop-up menu will appear. Select
the unit type, and then fill out the name, factor and offset fields for the
new unit. When finished, press the Add/Edit button. To delete a custom set
of units first make sure that the current units are not the user units being
delete.
Definitions:
Factor = User Units/Solar Units
Offset = Solar Units when User Units = 0
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Example 1:
DegC
Factor = DegC/DegF = 0.55556
Offset = degF @0degC = -32
Example 2:
PSIG
Factor = PSIG/PSIA = 1.000
Offset = PSIA @0 PSIG = 15
Example 3:
TJ/day
Factor = TJ/day/mmSCFD = 1.17
Offset = mmSCFD @0 TJ/day = 0
The SCADA input sheet is an alternate location for data input. It is used by
the associated LP, IP or HP performance sheet when the SCADA checkbox is
selected. When the program is shipped the SCADA data is set to the original
design point.
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How To:
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2) Predict compressor performance
This operation is performed the same as 1), but the parameters supplied
will likely be different. P1, P2, T1 and SQ will likely be the input
parameters (formula #7). The point will be plotted on the head flow map and
can be recorded using the 'Record Data Pt' button.
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If multiple datapoints need to be run, one should consider loading the
Datalog sheet for the subject compressor manually as a batch.
. Enter some tag values in column 2 for reference.
. Enter the appropriate calculate codes in the 3rd column.
. Paste the required input parameters into the appropriate columns as well
in addition to the gas SG, k50, k300, PCP, and PCT.
When the 'Record Data Pt' button is pressed, all points selected will
attempt to be plotted. If the RPM predicted has been calculated, it is
assumed the record has been calculated. If not, and a calculation code has
been entered into column #3, the record will be processed. Selected points
begin at the 'Chkpt#' selected, and continues record-by-record down until
either the 'next record row' or the 'Records to display' is exceeded.
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3) Tandem Operation
A tandem program option is now available which can control two or more single
body performance calculation sheets to determine tandem performance. Two
tandem calculation options are available at this time:
1) Target SQ Flow. The target flow for both of the compressors must
supplied along with the suction pressure for the fist body, suction
temperature for all of the compressors, interstage pressure losses,
discharge temperature for the HP body, and RPM for all of the
compressors. Performance for each of the compressors is then calculated
using the RPM SQ and suction conditions to determine the discharge
pressures. The initial RPM for each of the compressors is changed by a
fixed ratio until the target discharge pressure is reached. Interstage
pressure drops are calculated using the dP pressure values entered in
the spreadsheet. If the suction pressure for one of the compressors is
fixed the interstage pressure loss calculation can be bypassed by
setting the dP to 999.
2) Power Limited Flow. This mode uses the Target SQ Flow mode to start
with, and then changes the target SQ of each body by the same factor
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until the power required equals the power available.
It is also possible to type in formulas to link the SCADA input cells to live
data using a DDE (DynamicDataExchang) link.
Appendix
Program Installation:
Softmap is typically provided on a CD-ROM disk with several files. Proper
installation is essential, as the ‘Softmap’ program will not work without
following the procedure.
2. **Install files**
Before starting make sure all of Excel workbooks are closed (hidden and
personal workbooks included.) Also make sure the Excel security is set
to Low or Medium. To do this, select the Tools item from the Excel menu
bar, and then pull down to the Macro item. (You may need to click on the
double down-arrow item to get the full Tools menu.) From the Macro menu
you can select the Security item and change it as necessary. Double
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click on the 'SoftMapInstaller*.xls' file and follow the installation
instructions. A 'Softmap' folder will be created on your C:\ drive and
the necessary files copied into it and the appropriate Windows registry
items set to make the program work.
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Curve Polynomials
When the soft-map is originally created several curve polynomial curve fit's
are made to speed calculations later. An isentropic and polytropic set of
curve fits is generated for each of the compressor bodies included in the
program.
Type Format
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