Turbomachinery Control Solutions

Overview & Services

Statistics & Control, Inc., (S&C) turbomachinery control solutions are OEM neutral and operate on all leading third-party hardware and software control platforms compliant with IEC 61131.

Our turbomachinery control solutions have been implemented across the globe in numerous industry sectors, including power utility, onshore and offshore oil production, oil refining, gas transportation, and chemical plants.

S&C provides numerous turbomachinery control services, including but not limited to,

• Replacing black boxes and obsolete turbomachinery equipment and control systems

• Providing project management• Writing and customizing documentation• Providing field services and testing (factory

acceptance test—FAT, site acceptance test—SAT, commissioning, start-up, etc.)

Overview & Services

One of S&C’s strengths is retrofitting the actuation of existing steam control valves and old hydraulic control systems with Exlar actuators. This service/solution

• Provides complete retrofit kits• Includes speed gears, magnetic pick-ups, and

brackets• May be used for both electro-hydraulic and

electromechanical integrated control systems• Has several retrofit options

▫ Nonhazardous areas solution ▫ Hazardous areas solution up to the Class I,

Div 1 classification ▫ Simplex and patented redundant solutions

• Provides engineering & design, expertise, supervision for manufacturing & installation, and commissioning

The Capacity Control Solution controls and maintains a primary process variable with up to two limiting PIDs to provide more stable and reliable process control.

Primary process variables may include

• Power• Suction or discharge pressure• Flow rate

Limiting variables can be most any variable, including

• Motor current• Suction or discharge pressure• Flow

Capacity Control

Maintain your main station variables at appropriate set points and balance load among operating units with the Compressor Group Station Control Solution. This solution is available for units working in parallel, in series, or in series-parallel and includes motor-driven, reciprocating engine-driven, and turbine-driven compressors.

Hp

(ft.lb

/lb)

Qs (acfm)3000.0 4475.0 5950.0

1500

030

000

4500

0

7425.0

η (%

)66

.073

.380

.6

6636

7110

7584

8058

8532

9006

9954

9358

66367110

75848058

8532

90069480

9954

Compressor Group Station Control

The Gas Turbine Control Solution maintains the required turbine rotational speed and control fuel valves as well as guide vanes and nozzles (when present). This solution, which is available for new or retrofitted turbines, is typically integrated into the total train control system.

Pow

er (M

W)

Inlet Temperature (°F)-40.5 14 68.5

0.9

3.52

6.14

8.76

11.3

8

EGT (572.0)

EGT (662.0)

EGT (422.0)

EGT (842.0) EGT (922.0)EGT (1022.0)

E Flow (176)E Flow (220)

E Flow (265)

E Flow (309)

E Flow (353)

E Flow (375)

Fuel MW (51.0)

Fuel MW (68.0)

Fuel MW (85.0)

Fuel MW (102.0)

Fuel MW (119.0)

Fuel MW (136.0)Full Load Output

Gas Turbine Control

For stations with groups of turbomachinery units—whether in series, parallel, or a combination—and for groups of stations, the Master Control Solution is used to control and distribute load at the unit and station levels. This solution has two primary functions: load sharing and load balancing.

• Load sharing: Efficiently distributes load across units and stations and determines the best operating scenarios for both control levels

• Load balancing: Separate from load sharing; an optimization strategy that balances load across all units and stations based on specific balancing criteria

Master Control

The OptiRamp Critical Archive (ORCA) is an OEM-neutral critical archive that enables fast archiving (in milliseconds) for key data before and after a control event (a critical event). ORCA’s storage and parsing capacity allows this dynamic feature to store greater quantities of critical event data and to analyze what specific parameter caused the shutdown as well as how other parameters reacted to the change. ORCA is

• An embedded application that does not require an operating system, patches, etc.

• Easy to configure • Built into the low-level controller• Designed to provide valuable insight into high-

speed process conditions and events

OEM Controller

OptiRamp Critical Archive

The Power Management Control Solution for Active and Reactive Power provides multiple layers of control to balance active and reactive power among all operating units and transformers, provide precise control active and reactive power exchange with the power grid, and to conserve energy through load sharing.

Active Power/Frequency Control (P/F)

• Limits active power exchange with the grid• Ensures proportional load (MW) sharing among

generators• Controls frequency in islanded conditions

Reactive Power/Voltage Control (Q/V)

• Regulates bus bar voltage• Ensures proportional reactive power (MVAR)

sharing among generators and transformers• Limits reactive power exchange with the grid

Power Management Control for Active & Reactive Power

The Steam Turbine & Extraction Control Solution helps you operate your steam turbine closer to control limits to increase production and efficiency as well as minimize overspeed events. It is available for steam turbines with and without extraction.

This solution includes patented technology for Exlar actuators that provides redundancy to the steam turbine.

Steam Turbine & Extraction Control

Surge Prevention Control

The Surge Prevention Control Solution prevents compressor damage and process disturbances by controlling the gas flow through a compressor, maintaining energy efficiency and system capacity at the same time. When the application detects the compressor operating point is approaching surge conditions, the recycle control valve opens enough to recycle the gas, preventing the compressor from surge.

S&C’s solution is unique in that it uses enhanced action, which is always closed-loop control. When the operation point reaches the Enhanced Action Line, we

apply more aggressive PID control and only open the recycle valve as needed to prevent surge. This method provides a more stable process.

Rc (P

ress

ure

Ratio

)

Q (Volumetric Flow)

Det

ectio

n Zo

ne

Surge DistanceSPCA SP

Recycle ValveOpening Zone

Surg

e Li

neSu

rge

Con

trol

Lin

e

Surg

e D

etec

tor

Operating Point

Enh

ance

d Ac

tion

Lin

e

4401 Westown Parkway, Suite 124West Des Moines, IA 50266 USATelephone: 1.515.267.8700www.optiramp.com

OptiRamp® and the S&C logo are registered trademarks of Statistics & Control, Inc.Copyright © 2017 Statistics & Control, Inc. All rights reserved. Rev. 3 11/17

USA

Argentina

Angola

Bulgaria

Russia

Indonesia

Ukraine

Turkmenistan

Barbados

China

For more information about the S&C Turbomachinery Control and OptiRamp Solutions, contact one of our representatives. For a complete listing of our worldwide locations, visit our website at www.optiramp.com.