Turbomachinery Controls (TMC) Taiwan Compressor Seminar

Turbomachinery Controls (TMC) Case Study Greenfield Industrial Compressor Projects

Nguyen Duy Dai (David)

Taiwan, June, 2016

Confidential Property of Schneider Electric

Taiwan Compressor Seminar

Contents

Confidential Property of Schneider Electric |

1 SE Turbomachinery Project

Execution Capabilities

2 Case Study Greenfield ITCC XXX

Project

3 Case Study Greenfield ITCC XXX

Project

SE Turbomachinery Project Execution Capabilities


Turbomachinery Control Application

Slide 4 Confidential Property of Schneider Electric

SE Turbomachinery Control Solutions


Integrated Turbine

Generator Control (ITGC)

Compressor Controls

Turbine Controls

Mechanical Retrofits

Dynamic Simulation

Tricon/ Trident/ Tri-GP TMR

Tricon/ Trident/ Tri-GP TMR

Dynsim / Trisim

Integrated Turbine

Compressor Control (ITCC)

Generator Controls Tricon/ Trident/ Tri-GP TMR

High Speed Event Logger

Human Machine Interface

Trip Hydraulic Block

Overspeed Trip Electronics

TriLogger

Wonderware Intouch

Quadvoter

Trident (TMR)

Fault Tolerant Control System


SIL Rating System

– SIL 3 Tricon, SIL 3 Trident and SIL 2 Tri-GP

Protect User’s Investment

– Providing solid migration path forward by

helping client remains continuously current

Availability Safety/

Availability Safety

Application Software

TriStation 1131


CAD Like Program

– Function block based application

program visualize structure of

application program clear through for

more easy understanding

Market Proven Function

– All function block have proven from

market from world wide installation

Emulation & User build block

– Support emulation and verify

functionalities without hardware

Engineering and Design

Capabilities


Engineering Analysis

– will help customer to improve existing

feature for more easy maintenance and

operation

Detail Engineering Design

– All detail engineering design go through

customer approval

Wide range design

– Mechanical design, Hydraulic design,

Instrumentation, sensor and power

measurement design

Dynamic Simulation Environment


SimSci DynSim Modelling

– The simulation software is also one of

part of SE product.

– The Trisim enable bridging between

TS1131 software and Dynsim simulation

environment.

– Dynsim can be utilized as a plant model

of turbine generator model as per

project specific scope.

Enhance Wonderware Intouch

HMI - ArchestrA


ArchestrA

– works based on SQL server.

– Technical high end graphics will impress

to operator for more clear identification

of operation status or operation.

– Servo calibration will support

maintenance team for more easier and

clear calibration environment with auto

sensor calibration sets.

– The real time operating trend and

historical trend will remained HMI PC for

review operation status.

SE Execution Plan for a TMC Project


Risk Management

Conduct Risk Assessment meeting monthly.

Identify & Analyze Risk throughout the project phase.

Develop mitigation plans.

Review project critical path.

Develop fall back strategy and recovery plans.

Change Management

Conduct Change Review meeting whenever changes are

required.

Track and document all changes.

Assess the impact for each change.

Develop execution plan for each change.

KOM Established and

Structured Risk &

Change

Management

System

Site Survey/FEED

Design Specification

Detail Engineering /

Procurement

Staging & Testing

Installation, SAT &

Commissioning

SE (Singapore) Project Summary


SE has delivered many Major TMC projects across the world

Experience with Major Oil & Gas Companies

- Exxon Mobil, CPC, Saudi Aramco, Sabic, Total, Shell, RasGas, Qatar

Gas, Petronas, SGC, PTT Chem, Petron, etc

Experience with Major EPC’s

- CTCI, Chiyoda, JGC, Toyo, MHI, GS, Daelim, Samsung, Huyndai, Technip, Fluor, Snam, Foster Wheeler, etc

Experience with Major OEM’s

- Mitsubishi, Elliott Ebara, Hitachi, Nouvo Pignone, etc

SE has delivered many TMC projects across the world

Experience with Major Oil & Gas Companies

- Exxon Mobil, CPC, Saudi Aramco, Sabic, Total, Shell, RasGas, Qatar

Gas, Petronas, SGC, PTT Chem, Petron, etc

Experience with Major EPC’s

- CTCI, Chiyoda, JGC, Toyo, MHI, GS, Daelim, Samsung, Huyndai, Technip, Fluor, Snam, Foster Wheeler, etc

Experience with Major OEM’s

- Mitsubishi, Elliott Ebara, Hitachi, Nouvo Pignone, etc

Project Reference List


Project Name OEM / EPC End-User Location Year Execute

JUPC Ethylene Plant Project Elliott Ebara Turbomachinery Corporation(EETC)

Jubail United Petrochemical Company (JUPC) Al-Jubail Saudi, Arabia 2002 - 2003

ONGC Compressor Retrofit Project N.A Oil and Natural Gas Coporation Ltd India 2003

TOC Expansion Compressor Project Mitsubishi Heavy Industries, Ltd Thai Olefins Company Limited Rayong, Thailand 2003

SGC TS3420 Replacement Project N.A Samsung General Chemicals Co. Ltd Daesan, South Korea 2003

CPCL Governor Project N.A Chennai Petroleum Corporation Limited Chennai, India 2003

HPC No. 1 NCC TMC Revamped Project N.A Hyundai Petrochemical Co, Ltd Daesan, South korea 2003 - 2004

HPC No. 1 NCC TMC Revamped Project Elliott Ebara Turbomachinery Corporation(EETC)

PTT Public Company Limited Map Ta Phut, Thailand 2003 - 2004

Namhae Governor Project N.A Namhae Chemical Corporation South korea 2004

DSCL 35MW Mitsubishi Turbine Electronic Governor

N.A Shriram Fertilizer & Chemical Kota, India 2004

YNCC N.A Yeochun NCC Co., Ltd Yeosu, South Korea 2004

NPC TS410A Replacement Project N.A National Petrochemical Public Company Limited Rayong, Thailand 2005

FPCC Refinery HPC Project Elliott Ebara Turbomachinery Corporation(EETC)

Formosa Petrochemical Corporation Mai Liao, Taiwan 2004

Retrofit Kontrol Turbin Dan AVR Pltg Unit #2 PT Len Industri PT Indonesia Power Unit Bisnis Pembangitan Bali Bali, Indonesia 2005

MHI CNOOC Methanol Project Mitsubishi Heavy Industries, Ltd Lurgi / China Offshore Oil Company Hainan Province, P.R.China

2005

Hawiyah NGL Snamprogetti, Italy & JGC CORPORATION, JAPAN

Aramco Overseas Company Hawiyah, Saudi Arabia 2005

Qatar Gas II Development Project Mitsubishi Heavy Industries, Ltd Qatar Gas Liquefied Gas Company Ltd Qatar 2006




LGPC M2 Project Mitsubishi Heavy Industries, Ltd LG Petrochemical Co., Ltd Yeosu, South Korea 2005

Sinnopec - Maoming Ethylene Plant Project Mitsubishi Heavy Industries, Ltd Sinopec Maoming Petrochemical Company Ltd Maoming, Guandong, P.R. China

2005

NKCC DCS Revamp Project Yokogawa (Thailand) Ltd Nongkhae Cogeneration Company, Ltd Saraburi, Thailand 2006

SCC DCS Revamp Yokogawa (Thailand) Ltd Nongkhae cogeneration Co., Ltd. Saraburi, Thailand 2005

Pertamina Plaju Air Compressor Project PT Duta Instrument Alfa Sakti Pertamina Pt Ept Plaju Pertamina, Plaju Palembang

2005

Ar- Razi Plant-V Methanol Plant Project Mitsubishi Heavy Industries, Ltd Saudi Methanol Company (Ar-razi) Saudi, Arabia 2006

Tasnee Petrochemical Ethylene Plant Project Mitsubishi Heavy Industries, Ltd Linde Engineering / Tasnee Petrochemical Company Al Jubail, Saudi Arabia 2006 - 2007

SK Korea TMC Upgrade Project N.A. SK Corporation Ulsan, South Korea 2006-2007

Roma GE Gas Turbine Retrofit N.A. Origin Energy Power Limited Australia 2006

Sharq 3rd Expansion - Ethylene Plant Project Mitsubishi Heavy Industries, Ltd Eastern Petrochemical Company (Sharq) Jubail City, Saudi Arabia

2006 -2007

Yanbab CCS Ethylene Project Elliott Ebara Turbomachinery Corporation(EETC)

Yanbu National Petrochemicals Company Yansab, Saudi Arabia 2007

Yunnan Tianan ITCC System Hitachi Plant Technologies Ltd Yunnan Tianan Chemical Co. Ltd Kum Ming, P.R. China 2007

Qatar Gas III & IV Development Project Mitsubishi Heavy Industries, Ltd Qatar Gas Liquefied Gas Company Ltd Qatar 2007

Bali Gas Turbine Retrofit PT Dinar Semesta PT Indonesia Power UBP Bali Pesanggaran Bali, Indonesia 2006

NCC TMC Modification Project N.A. LG Chemical Ltd Daesan, South Korea 2006-2007

Haldia EBR Compressor Project Mitsubishi Heavy Industries, Ltd Haldia Petrochemicals Limited Haldia, India 2007




ExxonMobil Booster & Recycle Compressor Upgrade Project

ExxonMobil Asia Pacific Pte Ltd ExxonMobil Asia Pacific Pte Ltd Singapore 2007

LG Chem TMC Modification Invens Korea Samsung Total Co., Ltd South Korea 2006

KJO FDP-1 Project - Onshore/Offshore Honeywll Automation & Control Solutions

Kuwait Guif Oil Company (KGOC) and Aramco Guif Operation Company (AGOC)

Saudi, Arabia 2007 - 2008

Haldia Supermax Project N.A. Haldia Petrochemicals Limited Haldia, India 2007

PTTPE - 1000 KMTA Ethylene Plant Mitsubishi Heavy Industries, Ltd PTT Polyethylene Company Limited Rayong, Thailand 2007 - 2008

MOC Cracker Project Mitsubishi Heavy Industries, Ltd Map Ta Phut Olefins Co. Ltd Rayong, Thailand 2008

NCC Big-3 Compressor Control Sys (TMC) Revamp Project

N.A. Lotte Daesan Petrochemical Corp Daesan, South Korea 2007

DAC Hydrocracker Project Hitachi Plant Technologies Ltd Dragon Aromatics (Xiamen) Co. Ltd Xiamen, P.R. China 2008

EPG-PMS ITGC Upgrade Project N.A. KOSEP Bundang CHPP South Korea 2007

Saudi Kayan Olefins Project Kellogg Brown & Root Asia Pacific Pte Ltd

Saudi Kayan Petrochemical Complex Saudi, Arabia 2008

FCC RC-C4001 / C4401 Control System Replacement N.A. SK Energy Ulsan, South Korea 2008

Linde Ruwais-2 Project Mitsubishi Heavy Industries, Ltd Abu Dhabi Polymers Company Ltd Abu Dhabi, United Arab Emirates

2008 - 2009

NRP P-C2501 Control System Replacement Project N.A. SK Energy Ulsan, South Korea 2008

CGT & ERC Replacement Project Mitsubishi Heavy Industries, Ltd LG Petrochemical Co., Ltd Yeosu, South Korea 2008

Shenhua Baotou CTO Project Mitsubishi Heavy Industries, Ltd Shenhua Baotou Coal Chemicals Co. Ltd P.R. China 2008

Shenhua Ningxia Coal Based DME Project Mitsubishi Heavy Industries, Ltd Shenhua Ningxia Coal Industries Group Co. Ltd Ningxia, P.R. China 2008




STG-5 Diesel Generator Control PT Duta Instrument Alfa Sakti Petamina Pekan Baru, Indonesia 2009

Keramasan (AKE-Brent Project GT EM601B Project) PT Sulzer Hickham Indonesia PT Asta Keramasan Energi Indonesia 2008

Frame V Turbine Control Retrofit Project PT Sulzer Hickham Indonesia PT Lontar Papyrus Pulp & Paper Industry Sumatra, Indonesia 2008

Ma Aden Ammonia Project Samsung Engineering Co. Ltd Saudi Arabian Mining Company (Ma Aden) Ras Az Zawr City, Saudi Arabia

2008

JSC Shchekinoazot 1350 MTPD Methanol Project Mitsubishi Heavy Industries, Ltd Shchekinoazot Russia 2008

SK Energency #2PX-C5601/TZ-C5001 N.A. SK Energy Ulsan, South Korea 2008 - 2009

PTT Chem I-1 TS410A Upgrade Project N.A. PTT Chemical Public Company Limited Rayong, Thailand 2009

Braskem Green Plastic Project Hitachi Plant Technologies Ltd Braskem S.A Rio Grande Do Dul, Brazil

2009

AOFP Sonatrach Fertilizer TMC Project Mitsubishi Heavy Industries, Ltd Algeria Oman Fertiliser Project Algeria 2009

Sibur EP-300 Ethylene Plant Revamp Project Mitsubishi Heavy Industries, Ltd OJSC (Open Joint-Stock Company) Sibur Neftehum Russia 2009 - 2010

YNCC Compressor Control System Upgrade Project N.A. Yeochun NCC Co., Ltd Yeosu, South Korea 2009

Rithala - 108MW CCPP Project N.A. North Delhi Power Limited New Delhi, India 2009

Korea WP Pumped Storage Power Project Invensys Korea Korea Western Power Co., Ltd. Samrangjin, South Korea

2009 - 2010

Guararema Compression Station Project Mitsubishi Heavy Industries, Ltd Petrobras Brazil 2009 - 2010

200-C1 and 380-C1 Project N.A. PTT AR Rayong, Thailand 2009 - 2010

S Oil Electronic Governor Controller Upgrade Project

Invensys Korea S Oil Corporation Ulsan, South Korea 2010




Upgrade Steam Turbine Generator Control Project N.A. PTT Aromatics & Refining Public Company Ltd Rayong, Thailand 2010

EL-Tablazo 03 Cracker Project Mitsubishi Heavy Industries, Ltd Linde Engineering / Polinter El-Tablazo, Venezuela 2010

Jubail Export Refrinery Project Elliott Ebara Turbomachinery Corporation(EETC)

Saudi Aramco Total Refining and Petrochemical Company (SATORP)

Jubail City, Saudi Arabia

2010

SK Energy / No.1 RHDS DS-C1300 Control System Replacement Project

N.A. SK Energy Ulsan, South Korea 2010

TPC Maanshan EHC / ATSI/SGPFT (Unit #1) Project N.A. Taiwan Power Corporation Taiwan 2010

Technip Jubail Export Refinery Project Elliott Ebara Turbomachinery Corporation(EETC)

Saudi Aramco Total Refining and Petrochemical Company (SATORP)

Jubail City, Saudi Arabia

2010

Dual Feed Ethylene Cracker For Dahej Project Elliott Ebara Turbomachinery Corporation(EETC)

Oil and Natural Gas Corporation Limited (ONGC) India 2010

Linde Ruwais-3 Project Mitsubishi Heavy Industries, Ltd Abu Dhabi Polymers Company Ltd Abu Dhabi, United Arab Emirates

2010

Samco Acrylic Acid Complex Project Mitsubishi Heavy Industries, Ltd SAMCO Saudi, Arabia 2010

CPC No. 6 Naphtha Cracker Project Elliott Ebara Turbomachinery Corporation(EETC)

CPC Corporation Taiwan 2010

SCG (ROC) TS3410 Upgrade TS3000 Project. N.A. SCG Chemical Co. Ltd Rayong, Thailand 2010

RPLC Deep Conversion Project Mitsubishi Heavy Industries, Ltd Puerto La Cruz Refinery Venezuela 2010 - 2011

MATIX 2200 MTPD Ammonia Plant Project Mitsubishi Heavy Industries, Ltd MATIX Fertilizers & Chemicals Limited India 2010

NCC TMC Modification Project for LG Chemical / Daesan Plant

N.A LG Chem, Ltd. Daesan, South Korea 2010

SATORP CCS Project Invensys Saudi Aramco Total Refining and Petrochmical Company

Saudi Arabia 2010 - 2012

Feed Scope (GT Revamp) N.A. Pilipinas Shell Petroleum Corpn Philippines




Petronas (PFK) ITCC Project N.A. Petronas Chemicals Fertiliser Kedah Sdn Bhd Qatar 2011 - 2012

TCJV / PMP Project Mitsubishi Heavy Industries, Ltd Qatar Liquefied Gas Company Ltd. Qatar 2011 - 2012

Samsung-BP Chemical Anti-Surge Revamping Project

N.A. Samsung-BP Chemicals Co., Ltd Yeosu, South Korea 2011

HPCEM2 Project Mitsubishi Heavy Industries, Ltd Honam Petrochemical Corp. Yeosu, South Korea 2011 - 2012

NP UTC_REFAP NGC Project Hitachi Plant Technologies Ltd Petrobras S.A Brazil 2011 - 2012

No. 4/5 Compressor Governor Control TMC Project N.A. S Oil Corporation Ulsan, South Korea 2011

PTT Chem I-4 Plant 2 TMC Upgrading Project N.A. PTT Chemical Public Company Limited Rayong, Thailand 2011

Gas Turbine Control Systems Upgrading (ITGC) Project

N.A. Pilipinas Shell Petroleum Corpn Philippines 2012 - Ongoing

DSS-Tangerang-Retrofit Gas Turbin#1 Project PT Sulzer Turbo Services PT Dian Swastatika Sentosa Tbk. Indonesia 2012 - 2013

Toyo-K/Al-Bayroni Project Mitsubishi Heavy Industries, Ltd Al-Jubail Fertilizer Saudi Arabia 2012

Petron Battan Refinery Project Elliott Ebara Turbomachinery Corporation(EETC)

PETRON Corporation Philippines 2012

SK-H Project Elliott Ebara Turbomachinery Corporation(EETC)

SK Lubricant Korea South Korea 2012

PTT BV Project Elliott Ebara Turbomachinery Corporation(EETC)

PTT Chemical Public Company Limited Rayong, Thailand 2012

Laffan Refinery Diesel Hydrotreater (DHT) Project SAMSUNG ENGINEERING CO., LTD. Laffan Refinery Company Ras Laffan Industrial City, Qatar

2012 - 2013

SAFCO V – UREA Stand Alone Project Mitsubishi Heavy Industries, Ltd Saudi Arabian Fertilizer Company Saudi Arabia 2012 - 2013

Sabah Ammonia UREA (SAMUR) Project Mitsubishi Heavy Industries, Ltd Petronas Chemicals Fertiliser Sabah Sdn Bhd Sabah, Malaysia 2012 - 2013




Etileno XXI Project Braskem Idesa Sapi Project Mitsubishi Heavy Industries, Ltd Technip Italy S.P.A / Braskem Mexico 2012 - 2013

PTTGC BRANCH 3 CCS REVAMPING PROJECT - PTT Chemical Public Company Limited Rayong, Thailand 2012 - 2013

Unidade De Fertiliacntes Nigtogenados III Project Mitsubishi Heavy Industries, Ltd Petrobras S.A Brazil 2012 - 2013

Petron Battan Refinery C-7001 Project Elliott Ebara Turbomachinery Corporation(EETC)

PETRON Corporation Philippines 2012 - 2013

Ethydco Ethylene Project (EEP2) Mitsubishi Heavy Industries, Ltd The Egyptian Ethylene And (Ethydcderivatives Company O)

Egypt 2012 - 2013

CONTROL UPGRADE FOR MGT#2 AND MGT#3 N.A. PT Chervon Pacific Indonesia Sumatra, Indonesia 2013 LHDC RGC (K9602) Governor Control Upgrade Project

N.A. Exxonmobil Asia Pacific Pte Ltd Singapore 2013 - 2014

SKEC Ulsan Aromatics New PX Project Elliott Ebara Turbomachinery Corporation(EETC)

Ulsan Aromatics Co., Ltd. Ulsan, South Korea 2013

CILACAP REFINERY Elliott Ebara Turbomachinery Corporation(EETC)

Pertamina Indonesia Indonesia 2013

Lake Charles Chemicals Project (LCCP) Mitsubishi Heavy Industries, Ltd SASOL CHEMICALS USA, LLC / FLUOR ENTERPRISES, INC.

Lake Charles, Louisiana, USA

2013 - 2014

Long Chen Turbine Control Retrofit Project N.A. Long Chen Paper Co., Ltd Changhua, Taiwan 2013

Celanese Project Fairway Mitsubishi Heavy Industries, Ltd Celanese International Corporation Texas, USA 2013 - 2014

2014 NCC Expansion Project Mitsubishi Heavy Industries, Ltd LG Chem Ltd Yeosu, South Korea 2013 - 2014

Reliance ROG Cracker Project Elliott Ebara Turbomachinery Corporation(EETC)

Reliance Infrastructure Limited Jamnagar, India 2013 - Ongoing

Geodipa Retrofit Control System Project N.A. PT Geodipa Java, Indonesia 2013 - 2014

USGC Ethylene Project Mitsubishi Heavy Industries, Ltd Chevron Philips Chemical Company LP Baytown, Texas, USA 2013 - 2014




ExxonMobil NA Growth Olefins Recovery Baytown Project

Mitsubishi Heavy Industries, Ltd ExxonMobil Chemical Company Baytown, USA 2014 - 2015

Westlake Petro 1 Extended PDP Project Mitsubishi Heavy Industries, Ltd Westlake Chemical Corporation Sulphur, USA 2014 - 2015

CB&I/Ingleside (USA) Mitsubishi Heavy Industries, Ltd Ingleside Ethylene LLC Baytown, USA 2014 - 2015

Umm Wu'al Ammonia ITCC Project Samsung Engineering Co. Ltd Saudi Arabian Mining Company (Ma Aden) Ras Az Zawr City, Saudi Arabia

2014 - 2015

PTTCH I-1 Propylene Compressor TMC upgrading N.A. PTT Chemical Public Company Limited Rayong, Thailand 2014 - 2016

TG 2 & 4 Upgrade - RU II Dumai Mitsubishi Heavy Industries, Ltd Pertamina RU II Dumai, Indonesia 2014 - 2016

QGIT Petrobras Comerj Mitsubishi Heavy Industries, Ltd Petrobras Rio de Janeiro, Brazil 2014 - 2016

PTTGC I1 Elliott Compressor Controller N.A. PTT Chemical Public Company Limited Rayong, Thailand 2014 - 2016

YNCC1 TS3000 ITCC Modification N.A. Yeochun Ncc Co Ltd. Yeosu, South Korea 2014 - 2016

SKIC : STG#11 Trip Block Replacement N.A. Siam Kraft Industries Rayong, Thailand 2014 - 2016

HDC MX LLI Project Elliott Ebara Turbomachinery Corporation(EETC)

Hyundai Chemical Co., Ltd. Daesan, South Korea 2014 - 2016

Case Study – Greenfield Integrated Turbine Compressor Control (ITCC)


Project Information

End User: XXX

Client : Mitsubishi Heavy Industries Compressor Corporation (MCO)

EPC : Linde

Project Configuration;

• One (1) Cracked Gas Compressor (CGC), 5 Stages

• One (1) Propylene Refrigeration Compressor (PRC), 4 Stages

• One (1) Ethylene Refrigeration Compressor (ERC), 6 Stages


Scope Of Supply


Integrated Turbine and Compressor Control (ITCC) System with. The system includes, but

not limited to the following items:

• Tricon PLC, Triplex CPU and I/O, Duplex Power Supply

• Rittal Cabinets, including components and wiring material, Hart Multiplexer, Signal

Isolators

• Bently Monitor

• Torquemeter

• Braun Overspeed Trip Device

• HMI, SOE and Engineering Workstation PCs

Scope Of Supply (Cont.)


• Engineering Manufacturing and Management

Vendor shall provide an excellent project management service during project execution.

Engineering service includes but not limited design, hardware manufacture, cabinet

integration, system configuration, training, internal test, FAT, site service and commissioning

service

• Documentation

• Recommendation of Anti-Surge Instruments including calculate the necessity anti-surge

valve size (Cv value) as vendor’s control system to achieve successful operation

ITCC Function Requirement


No Functions CGC PRC ERC Remarks

1 Alarm logic for Compressor and Turbine

2 Shutdown logic for Compressor and Turbine

3 Start-up Interlock logic for Compressor and Turbine

4 Start-up Sequence logic for Compressor and Turbine Semi-Auto start is applied

5 Auxiliary equipment interlocks logic for Compressor and Turbine

6 Anti-Surge Control

7 Compressor performance control 2 3 6

8 Turbine speed control (Governor) Implement in the DCS.

9 Turbine extraction pressure control 1 1

10 Temp. quench control

11 Condenser drum level control

12 Sealing steam press. Control Split Range Control

13 LO supply temperature control Split Range Control

14 Seal gas supply D/P control

15 Other single loop control

Project Organization Chart


• Roles & Responsibilities

• Communication Protocol

• Response Time

Project Execution Phases


Preliminary Design

Input

Initiation Phase Freeze Design Input

Kick Off Meeting Design Definition

Phase

Project Execution Plan HW Functional Design

Specification

Detail Engineering

Phase

Project Schedule System Architecture Cabinet detail drawing Test Phase- FAT

Project Quality Plan HMI Design

Specification

I/O assignment &

cross-wiring listing FAT Procedures

Shipment

(FOB Singapore)

Basis of Design

Document (BODD)

Cabinet integration (by

vendors) Internal Test

Pre-shipment

Inspection Test Phase- IFAT

Application logic

development HW & SW FAT

Shipping Doc &

Packing List

IFAT support at DCS

premises (out of

Scope)

Site Commissioning

Phase

Application HMI

development SAT Procedures

Procurement

Site commissioning

support ( Per Diem

Rate)

Project Execution Strategy


• QUALITY

• The reference standards for the Quality System that will be adopted are:

– ISO 9001: 2008 Quality assurance requirement during design, development, fabrication, installation and assistance.

– ISO 9000: 2005 Quality Management Systems – Fundamentals and vocabulary

• SCHEDULE

• Specifications derived from the Design Definition phase shall be used extensively to minimize the engineering time,

improving efficiency and reducing the testing time

• Hardware & Software Freeze dates to be maintained as per Master Project Schedule to meet the committed Project

delivery dates

Project Execution Strategy


● LOCATIONS AND COORDINATION

Project execution shall be carried out from Singapore

Invensys Engineering Excellence Centres engineers shall be mobilized to Singapore to support the project engineering and

FAT

Specific project engineers shall be mobilize for SAT and Site Commissioning.

● ENGINEERING CONSISTENCY

The detail engineering works of the project shall follow the Functional Design Specifications and Basis of Design

Document, developed with Mitshubishi and end-user during the Design Definition phase.

● PROGRESS COORDINATION – WITH CLIENT

Monthly Progress Report will be submitted to reflect the major milestone achieved during the reporting month and the

major task planned for the next month including the procurement status and deliverable document status.

● CHANGES

Control of changes is essential to meet the project schedule and cost.

Project Schedule – Major Milestones


Milestone Date

PO awarded 31 Mar 2014

Project Kick Off meeting 22– 23 Apr 2014

Customer Design Input Issued 25 Apr 2014

Functional Design Specification Approval 17 Jun 2014

BODD Approval 22 Jul 2014

Hardware Design Freeze 24 Sep 2014

Software Design Freeze 24 Sep 2014

Design Freeze meeting (in customer office) 25 Sep 2014

Procurement Start and Complete 30 Jun – 31 Oct 2014

Cabinet Design Approved for material procurement & Construction 24 Sep 2014

Cabinet Integration Complete 12 Dec 2014

Software Application Complete 24 Nov 2014

Internal FAT 18 Dec 2014 – 16 Jan 2015

FAT 19 Jan – 6 Feb 2015

System Delivery (FOB Singapore) 27 Feb 2015

Project Network Architecture


Project Deliverable Document List


No Document Title

1 Vendor Engineering Document List

2 Quality Plan

3 Functional Design Specification (Hardware & Software)

4 Typical Loop Drawing

5 Network Architecture Drawing

6 HMI Design Specification

7 I/O Assignment Document

8 Cabinet Termination List

9 Cabinet Outline Drawing

10 System Cabinet Layout & Power Distribution Drawing

11 Marshalling Cabinet Layout & Power Distribution Drawing

12 Bently Cabinet Layout & Power Distribution Drawing

13 TS310SV Cabinet Layout & Power Distribution Drawing

Project Deliverable Document List


No Document Title

14 Valve Sizing Document

15 Basis Of Design Document

16 Communication List

17 HMI Screens

18 Logic Printout

19 Factory Acceptance Test Procedure

20 Factory Acceptance Test Records

21 Site Acceptance Test Procedure

Compressor HMI Graphics


Completed Cabinets


Packing and Shipment


Case Study – Greenfield Integrated Motor Compressor

Control


Project Information

End User: XXX

Customer : Elliot Ebara Turbo Machinery Corporation (EETC)

EPC : XXX

The Project Configuration

• One Net Gas Compressor

• One Recycle Gas Compressor

• One Recycle Compressor


System Overview


Project Challenges

As many other projects execution, after Kick Off Meeting, SE start designing base on the

project input documents, as usual, there are always have some technical queries on some

design input documents, however below are important issues that required to resolve at the

beginning of design phase

• There is a confusion on the interface requirement between DCS and ITCC’s HMI

• EPC bought the Anti-Surge Valve bigger than recommended Cv

• End-user and EPC in doubt with the control philosophy given by process licenser (UOP)


Project Challenges

Base on the requirement there the operator can operate from ITCC’s HMI or DCS, however

the HMI/DCS selection philosophy is not so clear, this was resulted on unclear to design the

signal tracking between two systems (ITCC and DCS) and consequentially can impact on I/O

counts and detail design of control philosophy

With many years experience on integration between ITCC and DCS we studied customer

requirement and propose the new interface philosophy that can fulfil the customer

requirement with clear operation philosophy in both sides HMI and DCS, it also provide better

fallback strategies in the event of DCS/HMI communication failure


Project Challenges


The Anti-Surge Valve over sized could result on following issues:

• Make the anti-surge and performance control unstable

• Waste of energy due to over recycle

• Could drive compressor state to choke/stonewall condition and potentially damage

compressor

Usually to resolve this issue, the output demand to the ASV will be limited by pre-fixed value,

however this is not flexible for the operation when compressor operated in different

conditions, therefore after studied all of compressor designed operation conditions, the

Dynamic Limiter Control Solution was intruded and proposed to customer.

Project Challenges


At the beginning EPC and End-user have some doubts on the control on control philosophy

from process licenser and additionally SE proposed changes on DCS/HMI operation interface

as well as the dynamic limiter control solution to resolve the anti-surge valve oversized. So

now the doubt from EPC and End-user getting bigger and the need of having some kind of

dynamic simulation to demonstrate all above control philosophies are good

Project Challenges


The Trisation 1131 (the same software used for ITTC coding and programing) was used to

create the simulation model and also control logics, these both were tested by using the

Trisation Emulator and Wonderware HMI. Most of technical issues were clear and finalized

after using the simulation model to demonstrate the ITCC control features.


FAT and Staging

Dynamic Simulation - High Fidelity Model


The DynSim software was selected to do the high fidelity model for Recycle Gas Compressor

and Net Gas compressors to study and validate performance of the following steady state

cases:

• Emergency Trip of Compressor

• Normal Stop Of Compressor

• High Purity H2 Startup

• Startup of compressor from maximum possible suction pressure

The DynSim utilised the same HMI and the same control logic as the final product, so

dynamic changes were made possible which were passed into the final versions used during

commissioning.

The Simulation also an extremely useful Operator Training tool before, during and after the

commissioning phase

DynSim Modeling – Integrated Verification



Recycle & Net Gas Comp. DynSim Modeling


ESD Logic Simulated by DynSim


Local Panel Interface Simulated by DynSim


Net Gas Compressor Simulation Graphics


Site Commissioning


Other On Going Project at Staging

Questions?


Turbomachinery Controls (TMC) Taiwan Compressor Seminar

Documents

Transcript of Turbomachinery Controls (TMC) Taiwan Compressor Seminar