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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
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
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
2012 Honeywell Users Group
Americas Symposium
Surge Prevention
2012 Honeywell Users Group
Americas Symposium
Surge Prevention (Continued)
2012 Honeywell Users Group
Americas Symposium
Surge Prevention (Continued)
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
2012 Honeywell Users Group
Americas Symposium
Steam Turbine Control
2012 Honeywell Users Group
Americas Symposium
Steam Turbine Control (Continued)
2012 Honeywell Users Group
Americas Symposium
Steam Turbine Control (Continued)
2012 Honeywell Users Group
Americas Symposium
Steam Turbine Control (Continued)
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
2012 Honeywell Users Group
Americas Symposium
Capacity Control
2012 Honeywell Users Group
Americas Symposium
Capacity Control (Continued)
2012 Honeywell Users Group
Americas Symposium
Capacity Control (Continued)
2012 Honeywell Users Group
Americas Symposium
Master Control
2012 Honeywell Users Group
Americas Symposium
R3XX versus R4XX
2012 Honeywell Users Group
Americas Symposium
R3XX versus R4XX (Continued)
2012 Honeywell Users Group
Americas Symposium
Visualizations
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
2012 Honeywell Users Group
Americas Symposium
Project Statistics (Experion® PKS Platform)
• Commissioned units: 12
• Units yet to be commissioned this year: 11
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)
2012 Honeywell Users Group
Americas Symposium
Oil Refinery (Continued)
2012 Honeywell Users Group
Americas Symposium
BP Cherry Point Refinery
• Surge control for fractionators compressors in catalytic cracking unit (C300)
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
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
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
2012 Honeywell Users Group
Americas Symposium
Ammonia Plant (Continued)
2012 Honeywell Users Group
Americas Symposium
Ammonia Plant (Continued)
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
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
2012 Honeywell Users Group
Americas Symposium
Q &A
2012 Honeywell Users Group
Americas Symposium
Statistics & Control, Inc.
www.stctrl.com
Thank you