Taiwan Compressor Seminar Turbomachinery Controls · PDF fileTristation – Suction...

Turbomachinery Controls (TMC) Case Study Brownfield Industrial Compressor Projects (Malaysia Fertilizer + Korea Refinery)

Confidential Property of Schneider Electric

Taiwan Compressor Seminar

Confidential Property of Schneider Electric |

Contents

Case Study – Brownfield Integrated Turbine Compressor Controls (ITCC) upgrade at a Malaysian Fertilizer Plant

Case Study – Brownfield Compressor upgrade at a Korean Refinery

Case Study – Brownfield Integrated Turbine Compressor Controls (ITCC) upgrade at a Malaysian Fertilizer Plant


ITCC Project Case Study

Fertilizer plant configuration;

• Process Air Compressor

• Synthesis Gas Compressor

• Natural Gas Compressor

• Ammonia Compressor

• Carbon Dioxide(CO2) Refrigeration Compressor

Existing Control System;

• Woodward Turbine Control + CCC Anti-surge, Woodward changed to CCC

Slide 4 Confidential Property of Schneider Electric

ITCC – Integrated Turbine Compressor Control

SE’s ITCC is positioned strongly compared with conventional configurations and specs;

• TMR Hardware platform ensures high availability/reliability

• Minimized engineering and complexity thru integration

• Strength on both turbine control and compressor control solutions

• Customer specific control applications

• Market proven experience on Greenfield and Brownfield

• Regional project engineering and service support in Asia Pacific


Client Feedback

Engineering department feedback on current control system;

• “The existing platform is like black box, hard to approach and difficult to troubleshoot”

• “We have upgraded the existing turbine controls 5 years ago, but I’m still not happy with existing turbine control”

• “The past governors we have upgraded to governor controls with existing, but looks like this vendor is not really experienced in the turbine portion”

• “Once we decided to upgrade all turbine control and anti-surge control systems, the price from existing was higher than your ITCC configuration”


Existing System Configuration

Conventional configuration;

• Turbine control done with Woodward digital governor and compressor protection done with CCC surge protection

• Old Mitsubishi MHI unit installed with separate controllers. It is common nowadays that OEMs like MHI, EETC dictates the controls solution for ITCC packages

• Total 5 units of turbine-compressors, with most of the interfacing done by hardwiring between controllers


Existing System Configuration

Slide 8

Equip No. Description Governor Controller

Anti Surge Controller

KT/K-11-01 Natural Gas compressor (single stage) driven by back pressure steam turbine

CCC Series 5 Vanguard CCC Series 3+/DCS

KT/K-16-01 Syn gas compressor (3 stages) driven by condensing steam turbine with single extraction


KT/K-12-01 Process Air compressor (2 stages) driven by condensing steam turbine with steam Admission control


KT/K-19-01 Ammonia Refrigeration (3 stages) driven by back pressure steam turbine


KT/K-31-01 CO2 compressor (3 stages) driven by condensing single extraction steam turbine

CCC Series 5 Vanguard – Total Train Control


Existing Old System Configuration


New Installed System Configuration


Package ITCC offering

Invensys project not only was ITCC but also included;

• DynSim modeling package - Control checkout

• Wonderware InTouch HMI package

• Integrated simulation - Triconex/Wonderware/DynSim

• Integration with existing DCS

• Tight delivery timeframe required strong project management

• Structured team with correct technical capability

• Customer Peer review meetings

• Site installation and commissioning services


Decision Making Factors

System configuration was simplified and the customer convinced;

• Recent EPC Samsung Engineering project executed used as a reference

• Cost effective solution for customer (5 machines, 3 control platforms)

• Single engineering team to execute project of multiple scope offering

• ITCC package that integrated turbine-compressor controls

• Fertilizer Plant and typical design by licenser (Udhe, Germany)

• Triconex TMR reliability of the new control platform


Project Outcomes and Success

Before and after project a lot of qualification and verification activities;

• Communication with other experienced Triconex users with ITCC

• Customer-KOM with team

• Technical Peer Review meeting

• Project successfully delivered with End-user well satisfied


New Wonderware HMI – ITCC Overview


New Wonderware HMI – Startup & Modes


New Wonderware HMI – Surge Overview


New ITCC Application – Online Logic Status


DynSim Modeling – Integrated Verification


DynSim Modeling – K/KT-16-01 Syn Gas Model


DynSim Modeling – K-19-01 Surge Verification


Case Study – Brownfield Compressor upgrade at a Korean Refinery


Project Background For economical reasons, a customer in Korea decided to replace its oversized LP/HP steam turbo-compressor (4 stages) with a fixed speed motor and hydraulic turbo coupler driving only the existing LP 2 stages compressor (HP compressor has been removed)

At the same time, the existing Woodward 505 governor and CCC series 3 had to be upgraded and retrofitted to match the overall Hydraulic coupling start-up sequence and anti-surge application. This was implemented into a Tricon TMC.


Hydraulic Coupling



Solutions

This Schneider Electric project not only was the original governor and compressor control replacement by a Tricon TMC but also included;

• A Hydraulic Turbo coupling control together with our customized anti-surge control algorithm

• DynSim modeling package – (For Control checkout)

• Wonderware InTouch HMI package

• Integrated simulation – Triconex/Wonderware/DynSim

• Site installation and commissioning services including surge test to redefine the compressor surge line

Control Systems


Hydraulic Coupling Control

• The Voith Hydraulic coupling control included:

• Pre-Start conditions

• Main motor start and shutoff Sequence

• Auxiliary lube oil pump control. Lube oil pressure and bearing temperature monitoring

• Oil Tank heater control and level monitoring

• Shaft vibration monitoring

• Scoop tube speed control sequence

• Suction pressure control cascaded to scoop tube speed control


Tristation – Suction pressure control


Anti-Surge Control

• Together with the Hydraulic coupling control, we integrated in the same Tricon controller our standard compressor control solution to replace the redundant CCC (backup) Series 3 based on the existing P&ID, compressor data sheets and performance maps and flow elements


Wonderware HMI


Anti-Surge Control HMI Interface


Dynsim Model


Surge Test


Surge Test

Slide 33

The real surge experienced was recorded using Trilogger and happened when the margin reached -12% for a pressure ratio at 8.1365 and an operating point at 22.9%. This was repeated at 3 different pressure ratio conditions to plot the newly implemented surge line


Questions?


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