Turbomachinery Control on the Honeywell Experion … · Turbomachinery Control on the Honeywell...

2012 Honeywell Users Group

Americas Symposium

Turbomachinery Control on the Honeywell Experion® PKS Platform

Boris Pusin Statistics & Control, Inc.

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

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

2012 Honeywell Users Group

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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

2012 Honeywell Users Group

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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

2012 Honeywell Users Group

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Surge Prevention

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Surge Prevention (Continued)

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Surge Prevention (Continued)

2012 Honeywell Users Group

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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

2012 Honeywell Users Group

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Steam Turbine Control

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Steam Turbine Control (Continued)

2012 Honeywell Users Group

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Steam Turbine Control (Continued)

2012 Honeywell Users Group

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Steam Turbine Control (Continued)

2012 Honeywell Users Group

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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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Capacity Control

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Capacity Control (Continued)

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Capacity Control (Continued)

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Master Control

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R3XX versus R4XX

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R3XX versus R4XX (Continued)

2012 Honeywell Users Group

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Visualizations

2012 Honeywell Users Group

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Projects

• KINEF Oil Refinery, Russia

• BP Cherry Point Oil Refinery, USA

• LINOS Oil Refinery, Ukraine

• Cherepovets “AZOT” Ammonia Plant, Russia

2012 Honeywell Users Group

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Project Statistics (Experion® PKS Platform)

• Commissioned units: 12

• Units yet to be commissioned this year: 11

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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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Oil Refinery (Continued)

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BP Cherry Point Refinery

• Surge control for fractionators compressors in catalytic cracking unit (C300)

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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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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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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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Ammonia Plant (Continued)

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Ammonia Plant (Continued)

2012 Honeywell Users Group

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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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Benefits (Continued)

• Applications using Honeywell’s Custom Algorithm Block (CAB) are more user friendly

• Reduce maintenance costs and training time

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Q &A

2012 Honeywell Users Group

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Statistics & Control, Inc.

www.stctrl.com

Thank you