compressorsentinel - mcl control

CompressorSentinelTM

w w w . m c l c o n t r o l . c o m

Compressor Protection and Control System

2 0 0 4

w w w . m c l c o n t r o l . c o mCompressorSentinelTM


DescriptionMCL Control has developed a solution for the protection and controlof centrifugal and axial compressors either alone or in networks,combining specific needs of safety, high speed control strategies, andsequencing of each compression train with the global requirements ofmachines integration, production strategies, monitoring facilities,information supervision, and centralization. As a result, MCL Controlprovides a smart flexible solution at a very competitive cost thatdecreases when the same architecture is extended to the rest ofassociated production processes. For this reason, the global conceptof the CompressorSentinel offers answers that reach all the areasrelated with production (operation, maintenance, supervision,management, administration, etc.). Based on current ANSI/ISA andIEC safety standards requirements, CompressorSentinel complieswith the separation concept of having Safety and Control independentmodules as described below. Furthermore, the CompressorSentinelis based upon Compressor Controls Corporation’s (CCC) series 3 &5 platform for both control and sequencing, and upon IEC-61508compliant TÜV certified Programmable Electronic Systems (PES orSafety PLCs) for the process safety. The CompressorSentinelarchitecture can be adjusted for compliance with the required SafetyIntegrity Level (SIL) and availabi l i ty for your process.

Benefits

Package Benefits:

• Open architecture.

• Redundancy available

for Safety and Process

Control.

• TÜV and IEC

61508/61511 compliant

solution for Safety.

• High speed control

strategies.

• High Benefits/Costs

relationship.

Start up sequence:Implemented as a part of CCC’s series 5 controller or, in the case ofusing a CCC series 3+ for Process Control, on the latest version of themain PLCs or Hybrid Controllers manufacturers depending on customerbest interests. Its I/O modules can be installed in the same chassis withthe processor or under the concept of distributed I/O, located near theprocess in order to reduce installation costs but at the same time keepingsystem reliability and logic execution time. If the compressor driver isa gas turbine, MCL Control’s TurbineSentinel may be use to handlethe start up sequence.Process Control:Performed by a CCC’s series 3+ or series 5 controller. It includes flowand discharge or suction pressure control. In case of load sharing thealgorithm will be performed by the same controller. Decoupling with theAntisurge algorithm is included.

CCC’s antisurge controller


Benefits

Bently Nevada 3500 Series

Emergency Shutdown System Hima

Remote Operation/Monitoring:

“'Special emphasis wasmade in developing aninterface composedwith friendly displaysand commands, basedon the point of view ofthe operator, makinghim or her feel as partof the automationprocess.”'



Anti-Surge Control:Included and performed by digital controllers in exclusive operation for eachstage by a CCC Anti-Surge Controller. The controllers are configured toexecute the control and surge protection. Its functions are limited to handlethe recycling valves of each compressor stage in order to keep them awayfrom “the surge line”.Protection and Emergency Shutdown:Executed by an IEC-61508 compliant TÜV certified Programmable ElectronicSystems (PES or Safety PLCs) with full diagnostics technology. This PEScan be expanded in order to do gas and fire detection/extinction functions.This system offers fault tolerance flexibility complying with ANSI/ISA S 84latest release, allowing a safety/cost relationship in accordance with customerobligations.Vibration Monitoring System:Included and executed by a Vibration Monitoring System (Bently Nevadaor equivalent). Its integration to the supervisory system will be done viaModBus RTU through a secondary network or through the distributed I/Oarchitecture.Human Machine Interface:Special emphasis was made in developing an interface composed withfriendly displays and commands, based on the point of view of the operator,making him or her feel as part of the automation process and using thetools offered by the supervisory software, such as, security and accesslevel, alarms managing, graphics presentation, etc. This can be implementedin a local station close to the machine or in a PC in the control room. Thelocal station has same functionality as the control room station.The CompressorSentinel provides a series of standard displays alreadybuilt based on our experience with this kind of applications. Also, customdisplays can be configured based on client’s requirements and specialconditions existing in each application. The HMI is OPC compliant, allowingthe integration of other systems with the CompressorSentinel.Remote Operation/Monitoring:Available through portable wireless devices, such as, PDAs and laptops.Comprehensive solution:As a global solution for a group of plants conforming a gas compressioncomplex, the CompressorSentinel can be integrated with a distributedcontrol, providing concentration of information and operational data fromthe different subsystems that monitor and control the individual plants,besides handling the control loops related with the Complex generalproduction, advanced process control strategies, such as optimumcompressors load sharing, maximizing availability and benefits. This algorithmnot only takes into account the proximity to the surge line to decide whatcompressor to decrease velocity or recycle but its efficiency too. The distanceto the surge line will be taken into consideration only once a referenced lineis crossed.


BenefitsPerformance Calculations:Included without additional cost, avoiding any special engineering orannoying configurations.Flexibility:Easy adaptation to the specific requirements of any compressor.Investment:Higher Benefits/Costs relationship.Differed Production Costs:Reduced. These are totally proven solutions that guarantee the availabilityof a machine completely operational in the minimum time.Maintenance:Overall costs are decreased through a reduction of maintenance time,compared to solutions based on conventional PLCs for the Safety Module,in which it is necessary to manually diagnose the system very frequentlyand to program additional diagnostics to fulfill ISA S84, IEC 61508 & IEC61511 requirements, and tests demanded by current practices in orderto accomplish fail safe plant shutdowns.Documentation:All necessary technical documentation for the operation and maintenanceis included in English or Spanish. It includes the electronics, the controlstrategies and protection sequences. Optionally an Internet based updateservice is offered to incorporate new developments and the new hardwareand software versions. The P&IDs, PFDs, and wiring diagrams will beprovided through magnetic media in AutoCAD® files so that the clientcan modify them when considered convenient.Technical Support:Local and on-line via Internet.

Typical Screens for a Compressor

Architecture



The designed architecture uses the latest proven technology, following

the market trends in open networks like ControlNet, Ethernet/IP, OPC,

and Modbus. In accordance with current IEC and ISA safety standards,

each compressor has an independent safety system to implement the

required Safety Instrumented Function (SIFs) to achieve the Safety

Integrity Level (SIL). The safety PLC can be Diagnostics or TMR.

Depending on the safety requirements, safety logic can run on Hima,

Allen-Bradley, or several others safety controllers.

For control loops the CCC series 3+ or series 5 controllers are used. In

case of using a CCC series 3+ for control loops, a commercial single or

redundant PLC is used for the start-up/normal shutdown sequence.

The designed

architecture uses the

latest proven

technology, following

the market trends in

open networks based

on the Ethernet and

OPC platform.

w w w . m c l c o n t r o l . c o mCompressorSentinelTM


Architecture

Online Assistance

Plant ProcessControl System

Local OperatorStation

Inputs/Outputs:• Thermocouples• Transmitters• Reflux Valve Output (4-20 mA)

CONTROL FIELD NETWORK

Start Up Secuence(TurbineSentinel)

OPERATION / SUPERVISORY NETWORK

Remote Operator Stations

Process(Performance)

Controller

AntisurgeController

Safety Module(ESD/SIS)

Vibration

Compressor protection is usually done by dedicated specialized modules like

CCC Guardian for the Overspeed event.

Vibration monitoring can be done via Bently Nevada systems or via vibration

transmitters (like Metrix transmitters) directly to the PLC.

The HMI is based upon the Indusoft software, and it is easily integrated with

any other PLC or stand alone system via its OPC client interface and other

specific communication drivers. Many others HMI software can be used.


ExperienceMCL Control has been in the Automation business since 1989 becoming

a solution provider for the Oil and Gas industry and specializing in combustion

related processes as Steam Generation, Heating Processes,

Turbomachinery, and other safety areas as Emergency Shutdown Systems

and Fire and Gas Systems. Particular references will be provided upon

request.



FeaturesSafety Module TÜV approved. Input/Outoçput as required. Class I

Div II. Total diagnostics. Avoids the use ofexternal watchdog timers and additional diagnosticsroutines required in conventional PLCs. Emergencyshutdown.

Start-Up Sequence Compressor Controls Corporation Series 5 orimplemented on main commercial PLC or Hybrid. Ifthe compressor driver is a gas turbine, MCL Control’sTurbineSentinel is recommended.

Process Controller Compressor Controls Corporation Series 3+ or Series5.

Antisurge Controller Compressor Control Corporation Antisurge Controlleror implemented on the Sequence Controller undercustomers specifications.

Vibration Monitoring Bently Nevada or equivalent.Control Strategies All included. Performance and antisurge control.

Optimal load distribution algorithms.Human Machine Interface(HMI)

Human Machine Interface inLocal Panel

Optional. It includes the necessary schematics toperform the startup / shutdown of the machine. Basedon best industrial hardware and software in the market.All schematics included.

Cabinets with electronicdevices assembly

Included in accordance with NEMA standards andcustomer requirements.

Assembly Included.Documentation Engineering, Operations, and Maintenance Manual in

English or Spanish.Training According with client's needs.Technical support Local or On-line support after startup, according to

each maintenance contract.Communications ControlNet, FieldBus, Ethernet, OPC, Internet,

ModBus, HiBus, Data Highway, Highway Plus, Etc.Guarantee Hardware related to manufacturer conditions. MCL

Control’s Applications non obsolescence policy.Field Instrumentation Optional

Best industrial computers and industrial software in themarket. Many features available. All operations schematicsincluded. Designed in order to be psychologicallycompatible with operators, allowing them to carry out theirwork with a minimum of stress and mistakes.

Compressor Toolbox Configuration software running on portable computers inorder to configure control and safety strategies and tune upprocess units independently of Centralized HMI.

compressorsentinel - mcl control

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