Hydro Com

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The

HydroCOM-System

Edition 2.01

General DescriptionHydroCOM 2.0

makes compressor controland monitoring

an easy job

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General Description 201 2 00-01-19

1 INTRODUCTION......................................................................................................3

2 ABBREVIATIONS....................................................................................................4

3 GENERAL FUNCTION.............................................................................................53.1 What is Hydro COM?.....................................................................................................................................5

3.2 Functional Descript ion HydroCOM .............................................................................................................6

3.3 The reverse f low regulation .........................................................................................................................7

3.4 Cont rol Strategy ...........................................................................................................................................9

3.5 Admissions .................................................................................................................................................103.5.1 Electromagnetic Compatability (EMC) ........... ............. ............ .............. ............ ............. .............. ..........103.5.2 Safety of low voltage devices.................................................................................................................103.5.3 Explosion protection ............. ........... .............. ............ ............ ............. ............ ............. .............. ............ 11

4 THE COMPONENTS OF THE HYDROCOM SYSTEM..........................................12

4.1 HydroCOM Actuators .................................................................................................................................124.1.1 Task.......................................................................................................................................................124.1.2 Design ...................................................................................................................................................12

4.2 Compressor Interface Un it CIU .................................................................................................................144.2.1 Duty .......................................................................................................................................................144.2.2 Design ...................................................................................................................................................14

4.3 External pow er supply ...............................................................................................................................144.3.1 Duty .......................................................................................................................................................144.3.2 Design ...................................................................................................................................................14

4.4 Isolation Ampl ifi er ......................................................................................................................................144.4.1 Duty .......................................................................................................................................................14

4.5 TDC-sensor .................................................................................................................................................154.5.1 Duty .......................................................................................................................................................15

4.6 Hydraulic Unit HU .......................................................................................................................................154.6.1 Duty .......................................................................................................................................................154.6.2 Design ...................................................................................................................................................15

4.7 Service Unit SU...........................................................................................................................................164.7.1 Duty: ......................................................................................................................................................16

4.8 The Compressor Condition Monitoring (CCM) Software Package.........................................................17

4.9 Measuring Module TIM...............................................................................................................................184.9.1 Duty: ......................................................................................................................................................184.9.2 Design ...................................................................................................................................................18

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1 IntroductionThe present version of the General Description Handbook shall describe inshort the function of the HydroCOM System. This manual is designed forgeneral information on the function of the system. Minor technical details ofthe delivered version may slightly deviate.

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2 Abbreviations

The following abbreviations will be used throughout this manual

Actuator unit for the actuation of the suction valvesCAoff switching point of the solenoid valve, at which the suction

valve opensCAon switching point of the solenoid valve, at which the suction

valve closes

CIU Compressor Interface UnitDCS Control System: either Distributed Control System,

programmable logical control or programmable loopcontroller

EPS External Power SupplyGIM General Interface ModuleHU Hydraulic UnitIA Isolation AmplifierIPS Internal Power SupplyIVD Intelligent Valve DriverPLC programmable logical controllerSU Service UnitTDC Top Dead CenterTIM Transmitter Interface Module

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3 General funct ion

3.1 What is HydroCOM?

The reliable, efficient, flexible compressor control system for optimal use of

resources.

HydroCOM is a hydraulically acutated computerised compressor controlsystem.

HydroCOM is a system for the stepless capacity control of reciprocatingcompressors in a range between 0 -100 %. It is based on components of theinjection technology for large Diesel engines, enhanced by state of the artdigital computing and control technology. Hydraulically actuated unloaderskeep the suction valves open during part of the compression cycle. Thuspart of the gas induced into the cylinder during the suction cycle is pushedback into the suction plenum. In this way the gas volume per working strokecan be controlled in the full range.

As the energy consumption of a compressor is essentially proportional to thequantity of gas compressed per compression cycle, this system realizes an

energy saving compressor control method.

The capacity control is driven either by a distributed control system or by aloop controller optionally supplied by HOERBIGER. Therefrom 4 .. 20mAsignals must be sent to the HydroCOM system (CIU).

Additional to this control function HydroCOM facilitates the monitoring of allvalve nest temperatures. They are transmitted via 4..20mA signals to thedistributed control system.

The new generation HydroCOM 2.0offers further the possibility when usingTIM measuring modules to install transmitters in the field and to transfer themeasured values via the HydroCOM bus to the control unit CIU. All themeasured values and status reports, as well as all control signals canoptionally also be transferred via MODBUS between the CIU and thedistributed control system.

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3.2 Funct ional Descr ipt ion HydroCOM

The drawing below shows the typical configuration of the HydroCOM-systemin a plant.

CIU

BUS

48 Vdc

Oil

FieldField DCS / PLCDCS / PLC

MaintenanceMaintenance

TDC

HU

TIM

IPS

15V

5V

HOERBIGER

SIM1

Valve #

Code #

Sc ro l l /

Res et

SIM 2

Valve #

Code #

Scroll /

Reset

SIM3

Valve #

Code #

Sc ro l l /

Res et

HOERBIGERHOERBIGERHOERBIGER HOERBIGER

HYD

ROCO

M

HOERBIGER

GIM

P owerTDC

EnableExt.Sim.

SensorE rror

P

hy

d

L

oS

U

M

O

D

B

U

S

SU

Control

Room

Control

Room

CCM

4..20 mA,binary contacts

Fig.1.: principle sketch HydroCOM system

HydroCOM actuators are installed on top of the suction valves of thecompressor. They perform the essential control activity, i.e. keeping thevalves open during part of the compression cycle. They are supplied with thenecessary energy via hydraulic lines from a hydraulic unit (HydroCOM-HU).

The actuators are driven via a data line and a power supply line by acompressor interface unit (HydroCOM-CIU). This CIU-unit serves as theinterface between the HydroCOM system and the overriding distributedcontrol system (DCS/PLC/loop controller). The compressor control task is

solved in the distributed control system.

The communcation between the DCS and the HydroCOM system isexchanged via 4..20mA analogue signals (compressor capacity, valve nesttemperatures) and via binary signals (warning, error, simulation,enable).HydroCOM 2.0 further offers the possibility to transfer the abovementioned analogue and digital signals between PLS and CIU viaMODBUS. In this case the communication goes via MODBUS-interface, nowiring between CIU and PLS is necessary.

A TDC-sensor informs the control unit CIU about the actual position of thepiston in the cylinder. The conversion to the exact opening and closing timeof the suction valves is done by the CIU. The capacity output of thecompressor thus becomes a simple analogue control variable for the plantoperator. By using digital control technology the HyroCOM system can reactwithin 2-3 turn of the crank shaft to changes of the required volume, thusminimizing dead times.

The compressor interface unit CIU can be connected to a service unit SU(IBM compatible PC) via an RS-232 interface. By means of the SU the CIU

can be configured using a Windowsbased program. Threshold values foralarms can be adapted to the actual operation parameters. In case ofmalfunction a detailed analysis of the CIU can be made via the SU.

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3.3 The reverse flow regulation

The capacity control method is based on the so called reverse flow regulationprinciple. A part of the gas which has been taken into the cylinder during thesuction cycle is conveyed back to the suction chamber during thecompression cycle.

2

Saved energy

at part load

Fig. 2.: The principle of reverse flow regulation

The above indicator diagram shows the function principle of the controlsystem. The cylinder pressure is a function of the actual position of thepiston inside the cylinder. In Pos.1 (bottom dead center, BDC) thecompression cycle starts. Without the HydroCOM system, under full loadoperation, the gas is compressed immediately after passing the BDC. Whenthe cylinder pressure reaches pos.2 the discharge valve starts opening. Thegas is pushed out of the cylinder. When the piston reaches pos.3 (top deadcenter, TDC) the re-expansion starts. The gas which is still in the cylinderdue to the cylinder clearance, re-expands. When the cylinder pressurereaches the suction pressure (pos.4) the suction valve opens and gas isinduced into the cylinder. The power necessary for the operation of thecompressor is proportional to the area enclosed by the indicator pressurecurve.

Check ValveCheck Valve

SolenoidValve

SolenoidValve

UnloaderUnloader

Suction ValveSuction Valve

M

HydraulicCylinder

HydraulicCylinder

Hydraulic UnitHydraulic Unit

Fig.3.: HydroCOM actuator - function

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By means of the HydroCOM system the suction valve of the compressorwhich is actuated by a fast-switching hydraulic solenoid, is kept open duringa part of the compression cycle by an unloader. Thus the indicator pressuredoes not follow the curve pos.1 to pos.2 ,but the line of pos.1 to pos.5. Therequired power input is therefore much lower than in the previouslydescribed case. The slight pressure increase (1-5) is due to pressure lossesin the valves. As the gas flows back from the cylinder chamber into thesuction line, the quantity of gas in the cylinder available for compression isreduced. At pos.5 a solenoid valve in the HydroCOM actuator is switched,thus the unloader which keeps the suction valve open is released and thesuction valve closes. The compression follows the line from pos.5 to pos.6.

One can see from the diagram that for this load case (approx. 50%) actuallyonly half the power input is required. Thus the principle of reverse flowregulation saves energy.

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3.4 Control Strategy

The compressor is either controlled by the distributed control system or byan external loop controller provided optionally by HOERBIGER.

One of the process variables (e.g. discharge pressure, suction pressure,flow volume..) is selected as control variable. The user defines a setpoint forthis variable. A PI controller is assigned to each stage of the compressor.The first stage is controlled according to the process variable. The output of

the first controller operates primarily the first stage. The interstage suctionpressures are selected as control variables for the higher stages. In order toavoid instabilities the controller output of the first stage is fed forward to thehigher stage loop controllers. The capacity delivered by each stage is variedby 4..20mA = appr. 0..100% controller signals which are sent to the CIU.The enclosed basic sketch shows this principle. A start-up function for thestart-up phase may be provided in the DCS configuration. It includes a start-up unloading function and a start-up ramp in order to obtain smooth loadingof the compressor after start-up.

Optionally HOERBIGER can either give assistance with the configuration ofthe DCS or HOERBIGER can deliver a programmed H&B loop controller.

Compressor

DCS

Hydraulic-Unit

Act uato rs

Y1: 4..20 mA=ca. 0..100%

Y2: 4..20 mA =ca. 0..100%Suction pressure 2nd stage

4...20 mA = 0-100 bar

Control Variable

TDC-Sensor

48 VDC

Setpoint

Feedforward

0%

100%

t

IPS

15V

5V

HOERBIGER

SIM1

Valve #

Code#

Scroll /Reset

SIM2

Valve #

Code #

Scroll /

Reset

SIM3

Valve #

Code #

Scrol l /

Reset


HYDROCOM

HOERBIGER

GIM

PowerTDC

EnableExt.Sim.

SensorError

PhydLo

SU

MODBUST1: 4..20 mA = -25..+125

T2: 4..20 mA = -25..+125

T3: 4..20 mA = -25..+125

T4: 4..20 mA = -25..+125

Wa: Warning

Er: Error

En: Enable

Sim: Simulation

Controller Output

CIU

PI-Controller

1st stage

Startup

ramp

PI-Controller

2nd stageSetpoint

Hy: Hydraulic Fault

HydroCOM Bus

Fig 4.: basic control scheme

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3.5 Admissions

The legal provisions of the different countries prescribe the observance ofregulations and directives concerning mainly safety matters. In the EEA andthe CENELEC countries (Belgium, Denmark, Germany, Finland, France,Greece, Great Britain, Ireland, Iceland, Italy, Luxemburg, The Netherlands,Norway, Austria, Portugal, Sweden, Switzerland and Spain ) theseregulations are standardized. Other countries have often quite differentregulations, sometimes the European ones may be applied.

Certain properties have to be certified by a homologation with an authorizedinstitution, while for others a producers declaration will do. In future the CE-sign will serve to attest compliance with all the directives in the EEA. At thetime being the CE-sign attests accordance with the machine safety directive,the EMC directive, and the low voltage device directive, whereas forexplosion protection there is a transient time until July 1st, 2003.

3.5.1 Electromagnetic Compatability (EMC)

Standards:EN 50081-1 electromagnetic compatibilityGeneric emission standard Part 1: residential environmentEN 50082-2 electromagnetic compatibility

Generic immunity standard Part 2: Industrial environmentand basic standards (e.g. EN 55011 and others)

The EMC-directive and their conversions into national law (e.g. Austrianelectrotechnical law with EMC regulation or German EMC law) define theconditions necessary to place electrical units on the market.

At one hand the functioning of the unit in an environment of electromagneticinterference must be guaranteed, on the other hand the unit must not causeharmful interference with its environment.With ISM-units (Industrial, Scientific, Medical) among which the HydroCOMsystem can be counted, no homologation is necessary, the compliance withthe applicable regulations has to be testified by a manufacturer's declarationand the CE-sign.

HOERBIGER had HydroCOM tested at a competent body and can therefore

issue the manufacturer's declaration.

3.5.2 Safety of low voltage devices

Standards: EN 61010-1 safety requirements for electricalequipment for measurement, control andlaboratory use, Part 1: General requirements

Those parts of HydroCOM which are supplied by mains voltage (essentiallythe CIU unit) are subject to the low voltage device directive. Examinationsare made and a technical documentation is kept available for authorities.

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3.5.3 Explosion protection

Standards: Electrical apparatus for potentiallyexplosive atmospheres

EN 50014 General requirementsEN 50018 Flame proof enclosures dEN 50019 Increased safety eadditional for the TIM module:EN 50020 intrinsic safety b

As most of the HydroCOM installations will be in potentially explosiveatmospheres, all units will be produced explosion proof.

Protection class EEx-d will be applied to the housing where the valveelectronics, the solenoid which drives the hydraulic valve and the sensorsare placed. EEx-e is applied to the terminal chamber and the construction ofthe solenoid.

With module TIM the housing containing the electronics is made inprotection class EEx-d, the terminal chamber for mains supply and bus inclass EEx-e, the terminal chamber for the transmitter lines in class EEx-ib.

The accordance with the European regulations is guaranteed by ahomologation with a testing laboratory as well as the required sample testsand it is certified by a mark of conformity on the unit.HOERBIGER have received FM Approval for the USA (The approval for themeasuring module TIM is still pending).In case further admissions become necessary the respective lead time andexpenditure have to be considered.

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4 The Components of the HydroCOM system

Compressor

DCS CIU

HU

Actu ators

Y1: 4...20 mA =appr. 0...100%

Y2: 4...20 mA =appr. 0...100%

T1: 4...20 mA = -25...+125

T2: 4...20 mA = -25...+125

T3: 4...20 mA = -25...+125

T4: 4...20 mA = -25...+125

Wa: Warning

Er: Error

En: Enable

Sim: Simulation

Suction pressure 1st stage

4...20 mA = 0-50 bar

Suction pressure 2nd stage4...20 mA = 0-100 bar

3*500VAC

Flare Gas

TDC-Sensor

230 VAC or

110 VAC

RS 232

SU

analogue signal lines

binary signal lines

48 VDC lines

VAC lines

hydraulic lines

flare lines

I

AEPSIA

IPS

15V

5V

HOERBIGER

SIM 1

Valve #

Code#

Scroll /

Reset

SIM2

Valve #

Code#

Scroll /

Res et

SIM3

Valve #

Code#

Sc ro l l /

Reset


HYDROCOM

HOERBIGER

GIM

Power

TDCEnable

Ext.Sim.

Sensor

Error

Phyd

Lo

S

U

MODB

US

Hy: Hydraulic Fault

MODBUS

Fig 5.: General view HydroCOM system

The above example shows (for a two-stage compressor) all the componentsand lines the HydroCOM system consists of. The following section willexplain the individual components in a general way.

These are

the HydroCOM Actuators Compressor Interface Unit

External Power Supply Isolation Amplifier TDC-sensor the HydroCOM HU (hydraulic unit) the HydroCOM SU (service unit) Measuring module TIM (optional, not shown)

4.1 HydroCOM Actuators

4.1.1 TaskThe HydroCOM actuators are those elements which act upon the valves viathe unloaders. The hydraulic pressure necessary for this purpose is supplied

by the hydraulic unit (HU). The actuators are controlled by the CompressorInterface Unit (CIU) and get their electrical power supplied by the EPS(External Power Supply).

4.1.2 DesignThe actuators consist of a valve housing, a seal housing and an electroniccontrol unit (IVD i. e. Intelligent Valve Driver).

In the valve housing there is a 3/2 way valve which is actuated by a solenoidand a retracting spring.. Depending on the position of the 3/2 way valve theactuator piston is either exposed to the pressure maintained by the

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hydraulic unit or to the atmospheric pressure (tank). A check valve is locatedupstream of this 3/2 way valve. During the phase of reverse flow through thesuction valve the fluid gets trapped. The pressure in the volume downstreamof the check valve and upstream of the pressure relief port of the switchingvalve may exceed the pressure of the hydraulic unit. Thus the systemrequires minimum auxiliary energy to drive the hydraulic unit.

In order to protect the moving parts of the unloading system as well as thevalve sealing elements against excessive impact stress a two stage throttleis installed in the actuator. It consists of a start bypass volume and anorifice. The bypass volume is filled during the first phase of the closingoperation ( 50% to 90% of the valve lift). Then when flowing through theorifice a high pressure is built up which dampens the valve plate motionconsiderably before it hits the seat.

The actuator piston acts on a push rod, which actuates the valve unloader.Sealing of this push rod is reached by a wiper element, sealing rings andguide bands which are installed in the sealing housing. This packing worksup to a pressure of 100 bars. Between the upper and lower guide there is aring chamber which has to be connected to flare.

A temperature sensor is located within this seal housing with the sensingpoint very close to the suction valve. Thus it is exposed directly to anypotential suction temperature changes caused by valve failure or extendedidling of the compressor.

Valve Housing

Oil in

Oil pressure sensor

Valve cartridge

Soft touch damper

Oil out

Piston cartridge

High pressure piston

Valve HousingOil in

Oil pressure sensor

Valve cartridge

Soft touch damper

Oil out

Piston cartridge

High pressure piston

Seal HousingLeakage out

Wiper ringsGuiding ringsSealing rings

Flare connectionTemperature sensor

Seal HousingLeakage out

Wiper ringsGuiding ringsSealing rings

Flare connectionTemperature sensor

Electric HousingConnection boxPrinted circuits incl.

Microcontroller andSafety barriers,Fuses, Bus Interface

Electric HousingConnection boxPrinted circuits incl.

Microcontroller andSafety barriers,Fuses, Bus Interface

Unloader RodUnloader Rod

Fig 6.: construction HydroCOM Actuator

In case hydraulic oil leaks into the seal housing it is led off by a leakage oilconnection into a collecting tank. The collecting volume for the leakage oil isconnected to atmosphere by two venting bores. Immediately below the

venting bores there are the leakage oil connections.

The valve electronics (IVD) are located in a flameproof housing (EEx-d).They control the solenoid, monitor the hydraulic pressure and measure thevalve nest temperature. Each actuator is equipped with a microprocessor forthe fulfillment of these tasks. This microprocessor solves drive, monitoring,and communication functions by means of a special program. The electricallines are connected to the CIU via a terminal chamber(EEx-e).

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4.2 Compressor Interface Unit CIU

4.2.1 DutyThe HydroCOM-CIU (Compressor Interface Unit) serves as an interfacebetween the HydroCOM-system and the distributed control system. Thecontroller output defined for each compressor stage is translated into the

opening and closing signals for the suction valves. The valve nesttemperatures, which are fed back by the actuators, are transferred to theDCS via the CIU. Further the transmission of enable-, warning-, error- , andsimulation signals is effected via the CIU. An IBM compatible PC (RS-232-Interface) can be connected to the CIU. Via this interface the CIU can beconfigured and checked. In order to open and close the suction valves withrespect to the crank-angle a TDC-sensor sends the TDC-pulses to the CIUwhich calculates the valve actuation timing.Data exchange to the DCS need not be effected via parallel wiring but canalternatively by carried out via MODBUS.

4.2.2 DesignThe Compressor Interface Unit consists of up to six Stage Interface Modules(SIM), the General Interface Module (GIM) and the Internal Power Supply(IPS). The modules are placed in a 19" sub-rack. Up to eight valves as wellas up to two Transmitter Interface Modules TIM can be controlled per SIM.

Head-end and crank end valves can be driven independently. There must beone data line to the compressor per SIM (For an exact specification of thedata line see the assembly and installation manual).

IPS

15V

5V

HOERBIGER

SIM 1

Valve #

Code #

Scroll /

Reset

SIM 2

Valve #

Code #

Scroll /

Reset

SIM 3

Valve #

Code #

Scroll /

Reset


HYDROCOM

HOERBIGER

GIM

Power

TDC

Enable

Ext.Sim.

Sensor

Error

PhydLo

SU MODBUS

Fig.7.: Front view HydroCOM-CIU

4.3 External power supply

4.3.1 DutyThe External Power Supply (EPS) serves for providing power to the IVDand the solenoids of the actuators. The solenoids require a supply voltage of48 VDC. A supply line has to be laid from the EPS to each valve (for exactspecification of the lines see the assembly and installation manual).

4.3.2 DesignDepending on the number of actuators three different models of EPS-unitsare available which differ in their power rating.

4.4 Isolation Ampli fier

4.4.1 DutyThe Isolation Amplifier interfaces the digital signal of the TDC sensor in thehazardous area (intrinsically safe circuit) to the safe area. A proximity switchacc. to NAMUR or DIN 19234 can be connected at the input. The output is

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connected to the CIU. Input, output and supply voltage are electricallyisolated from each other.

4.5 TDC-sensor

4.5.1 DutyThe TDC-sensor synchronizes the CIU with compressor speed. CIU andTDC-sensor are electrically separated by the isolation amplifier IA. The

TDC-Sensor is a cylindrical, inductive proximity switch according to DIN19234 (NAMUR).

4.6 Hydraulic Unit HU

4.6.1 DutyThe Hydraulic Unit serves to supply the actuators with oil in order to openthe suction valves. A pump pressurizes - depending on the suction pressureof the highest controlled compressor stage - oil from atmospheric pressureup to 150 bar. The oil is fed to the actuators via lines that can be shut-off.There are pulsation dampers close to inlet and outlet of the valves.The oil is led back unpressurized. Besides the oil supply lines a leakage oilline has to be connected to a separate collector tank. (The specification ofthe piping system can be found in the assembly and installation manual).

4.6.2 DesignThe following drawing shows the basic design of the hydraulic unit.

Hydraulic oil is pumped via a gear pump into the system. The oil isconnected to the circuits of each stage via redundant high-pressure-filterswith check valves (visual blocking indication).For each compressor stage one circuit is used. The maximum operatingpressure is maintained through a pressure control valve. Any overflowing oilis cooled down in a cooler and is sent via a return filter to the tank.

Depending on the customers demand the following options can beintegrated into the hydraulic unit:

signal for warning of tank oil level to DCS

signal for warning of tank oil temperature to DCS drip pan

oil heating (Stand by units during cold seasons)

If the customer wishes to purchase other options than these standardizedoptions we kindly advise to purchase the hydraulic unit by a local supplier.

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Fig .8.: principle design hydraulic unit

4.7 Service Unit SU

4.7.1 Duty:The service unit consists of an IBM-compatible PC (not supplied with theHydroCOM-system) and the respective service software based on MicrosoftWindows. It serves for configuration of the CIU and for analyzing the system.It is used for adapting the CIU to the special application. Limit values ofwarning and malfunction can be adapted. In case of damage, a detailederror analysis of the CIU can be established by means of the SU. Further itis possible to set the optimal switching time of unloader action in order toobtain a very soft opening of the suction valves.

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4.8 The Compressor Condit ion Monitoring (CCM) Software Package

The optional HydroCOM CCM (Compressor Condition Monitoring) softwarepackage can be used for online monitoring and smart alarm handling: e.g.deviation of theoretical and measured value.

Compared to conventional alarm handling much more sensitive alarm limits

can be set without insignificant alarms.

This CCM software runs on a PC which can be linked to the CIU using aRS232/485 data cable.

Fig.9: Alarm screens and trend diagram HydroCOM CCM

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4.9 Measuring Module TIM

4.9.1 Duty:The measuring module TIM serves to use the already existing data linebetween the field and the control room for additional measuring tasks.This especially concerns data relevant for machine diagnosis like dischargevalve temperatures, pressures, etc.Standard transmitters in 2-wire execution can be used (4 ... 20 mA). Theexplosion protection requirements have to be observed.

Terminal compartmentlike actuator

Flameproofhousing

Terminal compartmentfor transmitter circuits

Fig.10: Measuring Module TIM

4.9.2 DesignSimilar to the actuator the TIM is installed in the field. Therefor theelectronics are installed in a flameproof housing. The electrical connection issimilar to that of the actuator. Further there is a terminal compartment for 8intrinsically safe circuits. Power supply and safety barriers (EExib) for theintrinsically safe circuits are within the flameproof housing.

Windowsis a trademark of Microsoft Corporation

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