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new technology in reciprocating compressor.
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1
HydroCOMSaves energy, reduces capital costs & improves process control
HydroCOM 2
What is HydroCOM?
HydroCOM
is a stepless capacity control system for
reciprocating compressors in the oil & gas and chemical industry.
HydroCOM
� Saves energy
� Reduces capital costs of multi-stage
compressors
� Improves process control
2
HydroCOM 3
HydroCOM saves energy
Typical application:
1,300kW compressor
80% average load
Energy costs €0.06 per kWh
Recycle valve is waste of money:
With HydroCOM:
€ 124,800 energy savings / year
Plus savings in CO2-emissions
Recycling is waste of energy:
Power loss: 1,300 x 0.2 = 260 kW
Losses: 2,080,000 kWh / year
100%80%
20%
Only the gas flow required by your process is compressed (no recycling)
HydroCOM 4
HydroCOM reduces compressor capital costs
Capital costs of a multistage compressor with HydroCOM are lower than fora compressor with 50%, 75% and 100% step control.
� No energy savings can be achieved with 0%, 50% and 100% step control only.
� Therefore 50%, 75% and 100% load steps are required for efficient operation.
� At least two (2) cylinders
per stage are needed.
� Higher capital costs compared to
one (1) cylinder per stage with
HydroCOM
.
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HydroCOM 5
HydroCOM improves process control
Fast and precise (much faster than recycle valves)
� Ideal for processes requiring stable dynamic control
� Rapid response to changing demands (e.g., caused by problems
with up-/downstreams equipment or consumers)
Stepless for excellent controllability
� Bumpless capacity variation compared to
step control
� Start-up, switch over and shut down
without interfering with the process
� Ideal for process parameter
optimisation
� Multifunctional:
Used for load control and unloaded start/stop
HydroCOM 6
HydroCOM improves process control
Fully automatic
� Full integration into DCS/PLC possible
� Minimum intervention for operation required
(compared to manual control)
� Integrated suction valve temperatur monitoring
on-board
Large control range (0) 10*..100%
� Process flexibility
� Easy start and stop if only one common bypass is available for
several compressors
* Minimum continuous load depends on gas composition, pressures
and compressor design
4
HydroCOM 7
HydroCOM is experience
Experience
� 580 installations since 1996 in oil & gas, chemical and
power supply industry
Easy upgrade / integration
� Implementation within a short shut down period
� No modification of process gas piping required
� No civil works at the compressor necessary
HydroCOM 8
With HydroCOM always at the forefront
HydroCOM on largest API compressor ever built
Power: 13.2 MW
Process: Hydro-treating
Stages: 3
Each stage
serves a differentprocess
Manufacturer: Thomassen
Model: C-85.6
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HydroCOM 9
HydroCOM and compressor manufacturers
Worthington
Nuovo PignoneNuovo Pignone
Mitsui
Shenyang
HydroCOM 10
Applications – Refining & Exploration
Bayernoil - BP - BPCL - Caltex - CEPSA - Chemopetrol - Chennai - Chevron - China
Petrochemical - Concon - Conoco - Cosmo Sekiyu - Encana - ENI - ERG - EXXON - FPCC -Frontier - Grupa Lotos - Husky Oil - Idemitsu - INA - IOCL - Kinef Kirishi - Lukoil - Miro -
Mitsubishi - MOL - Natref - NZRC
Hydrogen desulphurisation
Hydrocracking
Hydrogen production
CCR platformer
Flare gas
LPG
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HydroCOM 11
Applications – Refining & Exploration
OMV - Pemex - PetroCanada - Petrochina - Petrobras - Petrom - Petronas - Petronor - PKN Orlen -
Preem - Reliance - Repsol - ROP - Samsung - Sasref - Saudi Aramco - Scanraff - Shell -Shin Nihon Sekiyu - Showa Yokkaichi Sekiyu - Singapore Ref. - Sinopec - Slovnaft - Star Alliance -
Suncor - Syncrude - Tamoil - TOTAL - Valero
HydroCOM 12
Applications – Chemical & Technical Gases
Air Liquide - Air Products - Akzo - AMI - Aventis - Azumures - BASELL - BASF - Bayer -
Borealis - BorsodChem - Clariant - Degussa - Domo - Dow - Enichem - Eval - Ineos - Infineum - Infraserv - Linde - Noretyl - OXEA - PCS Nitrogen - Puralube - Radici Chimica - Repsol -
Praxair - Sabic - Saudi Kayan - Tasnee - Total – Wacker - Yara
Ethylene
Fertilizer
LDPE
Propylen
Air Separation
Syngas
Chlorine production
Melamin
Basic chemicals
7
HydroCOM 13
Applications – Natural Gas
ANR - EON - EPS - Exxon - Gaz de France - INA - Krio Odolanow - Marathon - MND - NAM -
NIOC - Northern - OMV - Pengrowth - Preussag - Questar - Perstorp - ROP - RAG - RWEStadtwerke Kiel - Tennessee Gas - Transwestern
Underground storage
Pipeline
Gas gathering
HydroCOM 14
Applications – Gas Turbine Plants
National Power - Fortum - RWE - Electrabel
Fuel boosters
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HydroCOM 15
Working principle – Stepless control (1)
HydroCOM 16
Working principle – Stepless control (2)
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HydroCOM 17
Working principle – Stepless control (3)
A compressor suction valve
closes automatically at C
without HydroCOM.
HydroCOM actively controls
the timing when the suction
valve closes and keeps the
valve open from C – Cr at part
load. The gas volume in the
cylinder end is reduced and
the volume C – Cr is
discharged to the suction side.
HydroCOM 18
Working principle – Stepless control (4)
The line A-B-C-D-A shows the
complete cycle without
HydroCOM regulation.
Compression starts at C. The
compressor is running at full
load.
A-B-C-Cr-Dr is the cycle where
HydroCOM keeps the suction
valve open until Cr. Only the
gas volume B – Cr is
compressed to Dr. The
compressor is running
efficiently on part load.
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HydroCOM 19
Working principle – Stepless control (5)
Energy savings
compared to recycle
valve control
Area enclosed by pV graph is
equivalent to the energy
consumed
HydroCOM 20
Working principle
11
HydroCOM 21
HydroCOM key-components
HydroCOM Actuator
Compressor Interface Unit (CIU)
Hydraulic Unit
Standardized components for high reliability and cost effectiveness on spares
HydroCOM 22
Components of HydroCOM - Actuator
HydroCOM AcutatorMicroprocessors inside the actuator for
precise timing of the solenoid valve (similar
to common rail diesel injection systems).
The solenoid valve controls the oil pressure
acting on the hydraulic piston in the actuator.
Suction valve temp. monitoring on-board.
HydroCOM UnloaderThe motion of the unloader is controlled by
the hydraulic piston in the actuator.
Suction Valve
HOERBIGER ring or plate type suction valve
with non-metallic sealing elements ensures
long life time and
best efficiency.
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HydroCOM 23
Components of HydroCOM - Actuator
Valve HousingOil inlet
Solenoid valve
High pressure piston
Oil outlet
Seal HousingVent
Leakage oil
Flare line
Optional: seal gas
Sealing elements
Temperature sensor
Electric Housing48VDC connection
HydroCOM field bus
HydroCOM 24
Components of HydroCOM – Actuator
HydroCOM Installation on 3 stage hydrogen compressor
Manufacturer: Neuman & Esser
User: BAYER, Germany
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HydroCOM 25
Components of HydroCOM - CIU
� 19“ rack for installation in cabinet
room
� Interface between PLC/DCS and
actuators
� Transfers load signal from loop
controller (PLC/DCS) into
opening / closing commands for
actuators.
� Hardwired I/Os and Modbus
Interface for data exchange to
PLC/DCS
� Data display, service and
configuration with HydroCOM
Service Software (HSS)
HydroCOM 26
Components of HydroCOM – Hydraulic unit
Tank 63/120l
Temperature
transmitter
Level switch
(fork type)
Ex-proof motor
Oil/air cooler
Duplex filter
Pressure
transmitter
Shown: Hydraulic unit with 120l tank
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HydroCOM 27
HydroCOM system layout
HydroCOM 28
HydroCOM application range
Class I, Div.1, Gr. B, C, D, T4
AEx d,e IIB + H2 T4Ex-certification US (FM)
Class I, Div.1, Gr. A, B, C, DEx-certification Canada (CSA)
ExII 2G EEx de IIB + H2 T4Ex-certification ATEX, Japan
All, except O2 + acethylenGases
ring, plateSuction valve sealing element
yesNon-lube, corrosive gases
1200 rpmMax. compressor speed
120°CMax. suction temperature
160barMax. suction pressure
(0..) 10*…100%Control range
* Minimum continuous load depends on gas composition, pressures
and compressor design
15
HydroCOM 29
The benefits of HydroCOM
� Reduces the costs for energy and CO2- emissions.
� Reduces capital costs for multistage compressors.
� Stepless with large control range for excellent controllability of the process.
� Standardised components for highest reliability.
� Easy upgrade / integration for existing compressors.
� Proven at over 681 installations.
HydroCOM 30