Turbomachinery Control on the Honeywell Experion … · Turbomachinery Control on the Honeywell...
Transcript of Turbomachinery Control on the Honeywell Experion … · Turbomachinery Control on the Honeywell...
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2012 Honeywell Users Group
Americas Symposium
Turbomachinery Control on the Honeywell Experion® PKS Platform
Boris Pusin Statistics & Control, Inc.
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2012 Honeywell Users Group
Americas Symposium
Bio
• Education:
– BS and MS degrees in Engineering with emphasis on Steam and Gas Turbines from St. Petersburg State Technological University
• Experience:
– “LENGIPRONEFTECHIM,” state engineering company
– Compressor Controls Corporation
– Vice President at S&C
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2012 Honeywell Users Group
Americas Symposium
Company
• Statistics & Control, Inc. (S&C)
– Headquartered in West Des Moines, IA
– Full-service control engineering company with emphasis on turbomachinery control
– OptiRamp® software combines artificial intelligence with real-time simulation technology
– Many successful applications in oil & gas, power & utility, and other industries
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2012 Honeywell Users Group
Americas Symposium
Background: Relationship with Honeywell
• Many projects in Eastern Europe since 2008
• Signed master service agreement in 2011
• S&C provides turbomachinery control solutions on Honeywell’s Experion® PKS platform
• Solutions have used C200, C300, and C300-20 controllers
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2012 Honeywell Users Group
Americas Symposium
Surge Prevention Control Module
• Surge Prevention Control Application (SPCA)
– Controls gas flow through compressor
– Uses two levels of PID control to operate surge control valve
– Calibrated using manufacturer specifications and compressor maps or through field testing
– Uses S&C-specific faceplates and detail displays designed in native Honeywell format modified as necessary
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2012 Honeywell Users Group
Americas Symposium
Surge Prevention
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2012 Honeywell Users Group
Americas Symposium
Surge Prevention (Continued)
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2012 Honeywell Users Group
Americas Symposium
Surge Prevention (Continued)
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2012 Honeywell Users Group
Americas Symposium
Steam Turbine Control Module
• Steam Turbine Control Application (STCA)
– Starts, stops, controls, and protects steam turbines
– Uses PID loops to control valve position to maintain turbine speed set point
– Extraction turbines: maintains turbine speed/power and extraction pressure/flow
– Uses S&C-specific faceplates and detail displays designed in native Honeywell format modified as necessary
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2012 Honeywell Users Group
Americas Symposium
Steam Turbine Control
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2012 Honeywell Users Group
Americas Symposium
Steam Turbine Control (Continued)
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2012 Honeywell Users Group
Americas Symposium
Steam Turbine Control (Continued)
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2012 Honeywell Users Group
Americas Symposium
Steam Turbine Control (Continued)
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2012 Honeywell Users Group
Americas Symposium
Capacity Control Module
• Capacity Control Application (CPA)
– Controls primary variable with 2 limiting PIDs
– Primary variables: compressor suction or discharge pressure or flow through compressor
– Limiting variables: compressor motor current, suction or discharge pressure, or flow through compressor
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2012 Honeywell Users Group
Americas Symposium
Capacity Control
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2012 Honeywell Users Group
Americas Symposium
Capacity Control (Continued)
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2012 Honeywell Users Group
Americas Symposium
Capacity Control (Continued)
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2012 Honeywell Users Group
Americas Symposium
Master Control
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2012 Honeywell Users Group
Americas Symposium
R3XX versus R4XX
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2012 Honeywell Users Group
Americas Symposium
R3XX versus R4XX (Continued)
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2012 Honeywell Users Group
Americas Symposium
Visualizations
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2012 Honeywell Users Group
Americas Symposium
Projects
• KINEF Oil Refinery, Russia
• BP Cherry Point Oil Refinery, USA
• LINOS Oil Refinery, Ukraine
• Cherepovets “AZOT” Ammonia Plant, Russia
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2012 Honeywell Users Group
Americas Symposium
Project Statistics (Experion® PKS Platform)
• Commissioned units: 12
• Units yet to be commissioned this year: 11
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2012 Honeywell Users Group
Americas Symposium
KINEF Oil Refinery
• Surge control for
– 2 motor-driven wet gas compressors in gas fractionation unit (C300)
– 2 motor-driven hydrogen compressor in hydrotreatment unit (C300)
– 2 motor-driven compressors with variable speed gear-box in hydrotreatment unit (C300)
– 2 instrumentation air compressors in new hydro cracking unit (C300)
– 1 process air compressor in hydro cracking unit (C300)
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2012 Honeywell Users Group
Americas Symposium
Oil Refinery (Continued)
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2012 Honeywell Users Group
Americas Symposium
BP Cherry Point Refinery
• Surge control for fractionators compressors in catalytic cracking unit (C300)
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2012 Honeywell Users Group
Americas Symposium
Ammonia Plant
• Surge control & steam turbine and extraction control using C300-20 for
– Unit #401: synthesis gas compressor driven by Mitsubishi steam turbine with steam extraction
– Unit #402: air compressor driven by steam turbine
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2012 Honeywell Users Group
Americas Symposium
Ammonia Plant (Continued)
• Results
– One of first projects completed in Russia using C300-20 controllers
– Unit #401 • Extraction Steam Turbine Control Application
• Uses Honeywell’s Speed Protection Module (SPM)—converts frequency signal for application use
• Uses Servo Valve Position Module (SVPM)—drives Woodward governor coils
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2012 Honeywell Users Group
Americas Symposium
Ammonia Plant (Continued)
• Results
– Unit #402 • Electromechanical actuator
installed
• Uses Honeywell I/O Speed Protection Module (SPM) to convert frequency signal for application use
• Achieved turbine speed control accuracy of ±1 RPM
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2012 Honeywell Users Group
Americas Symposium
Ammonia Plant (Continued)
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2012 Honeywell Users Group
Americas Symposium
Ammonia Plant (Continued)
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2012 Honeywell Users Group
Americas Symposium
Benefits
• Now possible to have turbomachinery control solutions native to DCS
• Honeywell platform + S&C solutions = unified hardware/software platforms throughout enterprise
• Seamless integration into overall control system
• Maintain uniformity in faceplates and detail displays
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2012 Honeywell Users Group
Americas Symposium
Benefits (Continued)
• Applications using Honeywell’s Custom Algorithm Block (CAB) are more user friendly
• Reduce maintenance costs and training time
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2012 Honeywell Users Group
Americas Symposium
Q &A
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2012 Honeywell Users Group
Americas Symposium
Statistics & Control, Inc.
www.stctrl.com
Thank you