CS03 PRECISION COMPRESSOR CONTROL SAVES ENERGY, ENDS SURGE
Advanced algorithms and high speed data readings enable compressor to operate near its highest efficiency without threat of damaging surge. "When the compressor surged, it felt like it wanted to get off its foundation and walk away, " said Robert Gaudet, Production Specialist at Dow Chemical Canada, Fort Saskatchewan, Alberta.  According to Gaudet, surge can be severe, with loud noises accompanying the collapse of pressure on the suction side and excessive vibration. Though Dow Canada's Elliott four-stage centrifugal compressor went into surge on several occasions with its pervious control system, it endured without apparent damage.  But surge is so frequent and potentially detrimental that operators controlled the compressor in a way that would prevent it - basically in the manual mode with a generous amount of recycle gas during periods of potential surge..."
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CS04 UPGRADING CONTROL SYSTEMS ON RUSSIA'S COMPRESSOR STATIONS
Gazprom and Compressor Controls Commission (CCC) 1000th Turbomachinery Control System for Massive Russian Pipeline.
In an on-going program that is amazing in its scope and almost unbelievable in its logistics, CCC commissioned its 1000th turbomachinery control system for Russia's Gazprom late in 1999. Since that time, Compressor Controls, Des Moines, Iowa, U.S.A., has commissioned additional control systems, moving the current total to well over 1000 since the project began in 1992. Gazprom operates one of the world's largest natural gas pipelines running from various production fields to users in Eastern and Western Europe.
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CS05 INTEGRATED TURBOMACHINERY CONTROL SYSTEMS FOR LNG PROCESSES
Compressor Controls Corporation (CCC) has developed and successfully implemented Integrated turbomachinery Control Systems (ITCS) for several world-scale plants located around the globe. ITCS is a multivariable control system that provides antisurge control; capacity/throughput control for compressors; and governor control for turbines. Accordingly, this article addresses: control-system design for various operational-modes; deficiencies inherent in conventional control systems; justification of integrated turbomachinery control; integration with a plant’s control system; and considerations for turbomachinery performance testing.
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CS06 GAS PROCESSING PLANTS: AUTOMATION OF COMPRESSORS
Gas processing plants are heavy users of compression equipment, and, thus, are in need of control systems. Although modern control systems are used to control the rest of the gas processing plant, the aim of this presentation is to underline the features that are essential for achieving good results from the rotating equipment. The following is a brief description of a role of compression/ expansion equipment in gas processing plants:
• Gas processing plants typically require compression of natural gas either upstream or downstream of a gas processing plant, or - sometimes - both. This compression requirement stems from the necessity to provide gas for the extraction facilities of a plant at the sufficient level of pressure. The processed ‘lean’ natural gas is then removed from the plant, typically via pipeline.
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CS07 INTEGRATED CONTROL SYSTEM FOR POWER RECOVERY TRAINS IN FCCU UNITS
An integrated Power Recovery Control System (PRCS) for a Power Recovery Train (PRT) provides automatic control during various operating modes: start-up, shutdown, full load, part load, and when either connected to or disconnected from an electrical grid. Additionally, PRCSs ensure high-speed adaptation to sudden mode-switches caused by component tripping or by loss of connection with electrical grids. PRTs are common to industrial processes, such as Fluidized Catalytic Cracking Units (FCCU) in refineries, nitric acid sections of ammonia fertilizer plants, and other process plants. The sole purpose of these trains is to recover energy from a process regenerator's flue gases and convert this kinetic/thermal energy into mechanical power; consequently reducing the consumption of traditional energy sources.
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CS08 BLAST FURNACE BLOWER OPTIMIZATION
This application note describes typical blast furnace blower applications found in the steel industry worldwide, it also provides examples of specialized control system solutions offered by Compressor Controls Corporation (CCC). In a fully integrated steel mill, reliable and efficient blast furnace operation is critical to the success and profit potential of the overall facility. Without an adequate and dependable supply of molten iron to the downstream steel-making processes, the delivery of product (to meet all important customer contracts) ranges from difficult to impossible. Blast furnaces require a steady flow of compressed air (wind) through the furnace bottom to feed the combustion process and to keep the molten iron (burden) elevated.
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CS09 PLATFORM FLEXIBILITY
Eric Mehl, Compressor Controls Corp.(CCC), USA, and Carlos Eli Chiarelli, Petrobras, Brazil, describe how the installation of CCC's Total Train Control System has given more flexibility to the operation of the P-18 platform. Specifically planned and designed for the Marlim Oil Field, Brazil, the Petrobras P-18 platform operates at 950 m of water. Initially, its compression system (comprising two three-stage, turbocompressor units) was developed for use with one compressor in continuous operation  and the other acting as a backup. Subsequently, the installation of controllers (antisurge, performance, and load sharing) by CCC afforded the two turbocompressors the operational flexibility of operating in parallel.
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CS12 INTEGRATED PROCESS AIR COMPRESSOR CONTROL SYSTEM OVERCOMES UNIQUE PROBLEM AT A PURE TEREPHTHALIC ACID (PTA) PLANT IN INDIA
Two process air compressors (steam and electrical power driven) having unequal capacity and operating in parallel provide the main air duty for the Pure Terephthalic Acid (PTA) plant, Patalganga unit at Reliance, India. During fouled rotor conditions, the compressor surged due to rapid grid frequency dips or at low frequency periods unloaded the motor driven compressor. With reductions in air supply to the reactor, the plant production was interrupted in a few cases. Projected annual savings, based on gain in PTA production under compressor-fouled conditions and the elimination of unscheduled shutdowns during low frequency periods of operation, were the main factors considered to justify the OEM control system replacement. After trying out various available options with the OEM supplied control system, The END USER decided to implement the Integrated Turbomachinery Control System (ITCS) solution. ITCS is a multivariable control system that provides anti-surge control, coordinated header pressure control, and parallel load sharing for energy efficient operation.
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CS13 A TOTAL INTEGRATED APPROACH
The Bayu-Undan platform is a unique world-scale offshore gas processing platform handling over 1.1 billion ft3/d of gas. The platform extracts over 115,000 bpd of combined condensate, propane & butane and produces over 950 MMSFCD of dry natural gas. The project was implemented in two phases. Phase 1, achieving production in early 2004, involved processing the wet gas to separate and store condensate, propane and butane; and re-injecting dry gas back into the reservoir. Phase 2, realizing production in early 2006, involved exporting the gas via pipeline to a LNG facility near Darwin, Australia.
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CS14 NEW COMPRESSOR CONTROL SYSTEM SAVES GAS PLANT ENERGY AND INCREASES PRODUCTION
In 2002, Saudi Aramco embarked on a program to replace controls for 16 compressors at the Ju'aymah Gas Plant (JGP). This article gives an overview of the project and addresses the improvements and benefits that resulted from this replacement. The JGP was commissioned in 1980 as part of the Saudi Arabian Master Gas System, which was initiated for recovering associated gases generated with crude oil production. Previously, the gases were flared. This program provided for collecting, compressing, fractionating and transporting natural gas liquids (NGL). The JGP is the largest NGL fractionation plant in the world, producing over 1 MM bpd of NGL products, including ethane vapor and C3+ liquids (primarily propane and butane) for both domestic and international markets.
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