Sequence of Operations.pdf

8/11/2019 Sequence of Operations.pdf

http://slidepdf.com/reader/full/sequence-of-operationspdf 1/20

PETRO TECH

PERUANA

Compressor Control System

Sequence of Operations

&

Instruction Manual

Rev 0

29 Sep 2010



PETRO TECH PERUANACompressor Control System

Table of Contents Innovative Control Solutions Page ii

TABLE OF CONTENTS

1. GENERAL INFORMATION -------------------------------------------------- 1-1

Introduction ----------------------------------------------------------------------------------------------------------- 1-1

Compressor Control System Description & Overview -------------------------------------------------------- 1-1

2. OPERATOR GRAPHIC DISPLAYS ---------------------------------------- 2-1

Introduction ----------------------------------------------------------------------------------------------------------- 2-1

RSView ME Graphics Development Software ----------------------------------------------------------------- 2-1

Compressor HMI Screens ------------------------------------------------------------------------------------------ 2-1 Main Screen---------------------------------------------------------------------------------------------- 2-1

Start Screen ---------------------------------------------------------------------------------------------- 2-2 Trip Screens ---------------------------------------------------------------------------------------------- 2-3 Alarm Screen -------------------------------------------------------------------------------------------- 2-5 Engine Detail Screen ----------------------------------------------------------------------------------- 2-6 Compressor Detail Screen ----------------------------------------------------------------------------- 2-7 Recycle Control Screen -------------------------------------------------------------------------------- 2-8 Trend Screens -------------------------------------------------------------------------------------------- 2-9

3. PLC Logic ----------------------------------------------------------------------3-3-1

Start Sequence -------------------------------------------------------------------------------------------------------- 3-1 Sequence Step Table ------------------------------------------------------------------------------------ 3-2 Unit Shutdown (Step 0) -------------------------------------------------------------------------------- 3-3 Permissives Not Met (Step 10) ------------------------------------------------------------------------ 3-3 Unit is Ready to Start (Step 20) ----------------------------------------------------------------------- 3-3 Charge Headers (Step 30) ------------------------------------------------------------------------------ 3-3 Purge Compressor (Step 40) --------------------------------------------------------------------------- 3-3 Purge Compressor xxx Sec Remaining (Step 50) --------------------------------------------------- 3-3 Open Loading/Recycle Valve (Step 60) -------------------------------------------------------------- 3-3 Purge Recycle Line xxx Sec Remaining (Step 70) ------------------------------------------------- 3-3 Purge Complete (Step 80) ------------------------------------------------------------------------------ 3-3 Blowdown to Start Pressure (Step 90) ---------------------------------------------------------------- 3-3 Compressor-Engine Prelube (Step 100) -------------------------------------------------------------- 3-4 Engine Crank Mode (Step 110) ----------------------------------------------------------------------- 3-4 Engine Purge Mode (Step 120) ------------------------------------------------------------------------ 3-4

Engine Starting Mode (Step 130) --------------------------------------------------------------------- 3-4 Engine to Speed Mode (Step 140) -------------------------------------------------------------------- 3-4 Open Purge Valve (Step 150) ------------------------------------------------------------------------- 3-4 Open Suction Valve (Step 160) ----------------------------------------------------------------------- 3-4 Engine Warm-Up (Step 170) -------------------------------------------------------------------------- 3-4 Engine Oil Temp (Step 180) --------------------------------------------------------------------------- 3-4 Verification of Discharge Valve Opening (Step 190) ---------------------------------------------- 3-5 Ready to Load (Step 200) ------------------------------------------------------------------------------ 3-5 Load Control Enabled – Engine Speed (Step 210) -------------------------------------------------- 3-5




Table of Contents Innovative Control Solutions Page iii

Close Loading Valve (Step 220) ---------------------------------------------------------------------- 3-5 Compressor Loading (Step 230) ---------------------------------------------------------------------- 3-5 Load Control Enabled (Step 240) --------------------------------------------------------------------- 3-5

Normal Stop (Step 250) -------------------------------------------------------------------------------- 3-5 Open Loading Valve (Step 260) ---------------------------------------------------------------------- 3-5 Engine Speed back to Idle (Step 270) ---------------------------------------------------------------- 3-5 Unit Normal Stop Cooldown (Step 280) ------------------------------------------------------------- 3-5 Post Lube (Step 290) ----------------------------------------------------------------------------------- 3-6 ESD (Step 500) ------------------------------------------------------------------------------------------ 3-6

4. PRESSURE CONVERSIONS ------------------------------------------------- 4-6 PSIG to Bar Conversion -------------------------------------------------------------------------------- 4-6




GENERAL INFORMATION Innovative Control Solutions Page 1-1

1. GENERAL INFORMATION

Introduction

The supplied Compressor Control System is intended to provide the interface for control andmonitoring of the Valerus supplied compression equipment at the PETRO TECH PERUANAfacility. This manual covers the following items:

Compressor Control System Description & Overview

Operator Interface Screens


Compressor Control System Description & Overview

The compressor control system hardware is packaged in a NEMA 4x stainless steel enclosure.

The compressor control system is designed to accept one (1) incoming 120-240VAC 50/60Hzsource from the customer. Refer to drawings PWR-1 for AC power distribution and PWR-2 forDC power distribution connections.

The compressor control system utilizes Allen Bradley CompactLogix® PLC hardware and aPanelview Plus 1000® Human Machine Interface HMI unit to facilitate control and monitoring ofthe supplied compressor package. The Allen Bradley CompactLogix PLC hardware includessingle processor with built in Ethernet communications, local I/O chassis and Flex I/O Ethernetmodule. The Digi® Ethernet to RS232/RS485 converter is supplied to allow for communicationusing MODBUS® protocol to poll data registers within the PLC.




OPERATOR GRAPHIC DISPLAYS Innovative Control Solutions Page 2-1

2. OPERATOR GRAPHIC DISPLAYS

Introduction

This section contains information about the operator control station, preparation for operation,description of control graphic operation, and illustrations that supplement and aid inunderstanding the text. This information is intended to assist operations and maintenancepersonnel, and it describes both the manual functions an operator performs and the automaticfunctions generated by the control system logic.

The compressor control system includes an Ethernet network and one PanelView Plus 1000graphical interface operating station. The PanelView Plus 1000 HMI is connected to the Ethernetnetwork via a switch that also provides internal network connectivity to the Compact Logix PLChardware.

RSView ME Graphics Development Software

Allen-Bradley’s RSView Studio software was utilized for development of the custom control and

monitoring graphics for the supplied control system. The software allows both static and dynamicinformation to be displayed and/or controlled on the supplied Allen-Bradley PanelView Plus 1000touch-screen Human Machine Interface (HMI). The HMI continuously scans the PLC over theEthernet network to update displays, alarms, and logs archived data for use on trend screens.

Compressor HMI Screens

Main Screen

The PanelView Plus 1000 HMI unit supplied with the compressor control panel includes a Main screen which is displayed when initially powered up. The Main screen which is shown above,includes buttons that allow navigation to other screens by touching them. The Main screen isaccessible from every screen which always allows the operator to navigate to any screen withinthe HMI within two (2) touch selections or less.





The Main screen also includes a login selector that will display additional screens when thecontrol system is placed in Maintenance mode. A login ID and password are required in order toplace the control system into Maintenance mode and have access to the other screens.

A “ Forces Enabled” or “ Simulator On” will appear in the upper left corner of the screen whenone, or both, of these conditions exist.

Start Screen

The “Start” screen is accessed from the “Main” screen by touching the “Start” screen button.The “Start” screen includes a blue banner located towards the top of the screen that indicateswhat state that the sequence is in or if there is a trip active that has not been reset the bannerchanges to read the First Out trip. Refer to the Sequence Chart included herein for further detailsand other sequence steps and the Cause and Effect chart for trips.

The “Start” screen displays critical start-up process parameters. The status of the fuel, suction,blowdown, and recycle valves are each shown at the bottom of the screen.

As previously mentioned, a button labeled “Main” is located at the bottom of the screen whichprovides navigation back to the Main screen. A “Reset” touch button is also included at thebottom of the screen and performs the same function as the “Reset” pushbutton located on thefront of the control panel door. The compressor “ Start” and “Stop” touch buttons are also

located at the bottom of this screen along with the “Local” and “Remote” mode indicationsthese HMI buttons have corresponding hardwired switches mounted on the front of the controlpanel.

The “ SIM ON” indication is only visible when the control system is in “Simulation” mode. Whenthe control system is in “Simulation” mode all values, equipment status, and indications are beingprovided by simulation logic located in the PLC processor. All field devices will default to a safeshutdown state and will not move, or change while the control system is in “Simulation” mode.“Simulation” mode should only be enabled, or selected, when the compressor package is notrunning. This feature is provided for training and trouble-shooting purposes only.





Trip Screens

The “Trip” screens may be accessed from the “Main” screen by touching the “Trips” touchbutton. The “ Trips 1” screen will appear upon touching the “Trips” touch button located on the“Main” menu screen. The “ Trips 2” screen is accessed by depressing the “Next” touch buttonlocated at the bottom of the “Trips 1” screen. The “Next” touch button located at the bottom

right side allows navigation between the two “Trips” screens.Every trip that is associated with the compressor package is shown on the two (2) trip screenswith a box on the left side. The color “green” inside the box indicates that the condition isnormal, the color “red” indicates a First Out Trip condition.





Trip Screen 1 with an active trip conditi on.

The “ Trip 1” screen shown above indicates that the Suction Scrubber “A” Level High switch is ina tripped condition. All trips are indicated on the “Trip” screens regardless of if the unit is runningor not. Any trip that exists cannot be reset until the external device, or condition, has cleared first.

All trips must be reset from the control panel or HMI screen after the condition has beencorrected. In the example shown above, the water would have to either be drained from thescrubber to clear the high level condition, or the problem associated with the level sensing devicecorrected before the reset button will clear the trip condition.

Multiple “ALM” indications means there are, or were, multiple faults that occurred during thecompressor trip. It is not unusual to have secondary alarms when a trip occurs.

Note: The “TRIP” indication is the most important indication on the screen. The “Trip” indication also serves primarily as a “ First Out” indication. Anytime the compressor packageexperiences a shutdown unintentionally due to a trip, the condition that initiated the first trip will beflagged with a “Trip” indication as shown above. There will only be one “Trip” or “ First out” indication.





Start Screen 1 with an active trip condi tion

The banner on the “Start” screen will change to the color red and will also include the “First Out”trip as well.

Alarm Screen

The “Alarm” screen may be accessed from the “Main” screen by touching the “Alarm” touchbutton. Refer to color code legend located in the bottom right corner of the screen. The Alarmscreen also includes touch buttons that provide alarm acknowledge and reset functionality.





Engine Detail Screen

The “ Engine Detail” screen is accessed from the “Main” screen by touching the “EngineDetails” screen button. The “ Engine Detail” screen includes a banner located towards the topof the screen that indicates Sequence Step or First Out.

The “ Engine Detail” screen includes status and indications of items that are critical to the safeoperation of the supplied engine package.

As previously mentioned herein, a button labeled “Main” is located at the bottom of the screenwhich provides navigation back to the “Main” screen. A “ Reset” touch button is also included atthe bottom of the screen and performs the same function as the “ Reset” pushbutton located onthe front of the control panel door.





Compressor Detail Screen

The “ Compressor Details” screen is accessed from the “Main” screen by touching the “CompDetails” screen button. The “ Compressor Details” screen includes a banner located towardsthe top of the screen that indicates Sequence Step or First Out.

The “ Compressor Details” screen includes the quantity of cylinders that are physically suppliedwith the package. The cylinders shown on the screen are intentionally laid out to match thephysical location if viewed from the top. This screen also includes the cylinders rod load,pressure and temperature indications. Other parameters included suction and dischargepressures, compressor oil pressure & temperature indications, oil flow.

As previously mentioned herein, a button labeled “Main” is located at the bottom of the screenwhich provides navigation back to the “Main” screen. A “ Reset” touch button is also included atthe bottom of the screen and performs the same function as the “ Reset” pushbutton located onthe front of the control panel door.





Recycle Control Screen

The “Recycle Contro l” screen is accessed from the “Main” screen by touching Recycle ControlButton. This screen also includes a banner located towards the top of the screen that indicatesSequence Step or First Out.

This screen includes three (3) PID control loops and one (1) Manual/Auto (M/A) face plate tofacilitate “Automatic” and “ Manual” mode operation of the compressor control system. TheSuction, Discharge, and Pct Load Control PID loops are all placed in either the “Automatic” or“ Manual” mode at the same time from the M/A Station shown on the left side. These three (3)

PID loops cannot be independently selected for Automatic or Manual mode operation since theircontrol schemes are complex and internally coordinated within the PLC logic.

The mode of each of the three (3) PID controllers is determined by the (M/A) control station that isdisplayed on the left side of screen. The M/A control station can be functionally operated alongwith providing status indications as described below:

If the operator makes “ MAN” selection, the “MAN” button will change from gray to red. The M/AStation on the left side of the screen will provide manual adjustment by adjusting the slider bar.

If the operator makes “AUTO” selection, the “ AUTO” will change from gray to green and thethree PID control loops will be controlled in “ AUTO” mode. The SP control function will only work

in “ AUTO” mode and is controlled through the touch areas marked “ SP ” decrease and “ SP ” increase buttons.

The “ SETPOINT” for each PID control loop can also be changed through the data entry toucharea. This can be achieved by touching the SP value area and typing/entering in the desirednumber on the pop-up numeric keypad.

PV – “ PROCESS CONTROLLED VARIABLE” from the analog input module, scaled toengineering units, and displayed by a green bar graph and analog value.

SP – “SETPOINT” analog value from the operator interface screen to the PLC, scaled toengineering units, and displayed by a cyan bar graph and analog value.

OUT – “CONTROLLED VARIABLE OUTPUT” , or “ CV” to the analog output module, scaled to0 - 100 PCT and displayed by a yellow bar graph and analog value.





Trend Screens

Two Trend process screens are available, one for compressor temperature inputs and the otherfor compressor pressure inputs. Each process trend screen is accessed from the main menu.Real time data is shown below trend in color code to the chart pen. Trend control buttons allowthe operator to change the trend viewing parameters. The Engine Trend (shown below) is alsoavailable for access from the main menu this screen provides face plate data for speed controlalong with the trend object.




PLC Logic Innovative Control Solutions Page 3-1

3. PLC LOGIC

The PLC is an Allen Bradley CompactLogix PLC with a custom program to control and monitor the

compressor. The program is done with the software RSLogix 5000 Version 17.0. The program utilizes

several options and programming languages available from the RSLogix 5000 software including:• Ladder Logic programming

• Sequential Function Chart programming

• Structured Text programming

• User defined data types

• Add-On instructions

Communication between the PLC, HMI and other equipment utilizes an Ethernet network with static IP

addresses in the 192.168.1.0 network.

Start Sequence

The compressor package may be started by accessing the “Start” screen from the main menu

located on the PanelView Plus 1000 HMI unit. The “Start” screen includes a banner that willdisplay “ Unit is Ready to Start” provided there are no trip conditions existing. If a trip conditionexists it will be displayed on the banner shown on the “Start” screen. If the “Unit is Ready toStart” indication is not present proceed to the Trip screens to see what active faults are present.The trips associated with the control system are outlined on the Trips screens previously shownherein. If a trip cannot be reset from the panel, the sensing device or abnormal condition must becorrected in order to proceed. Once all trip conditions are cleared, and a Reset has beeninitiated, the “ Unit is Ready to Start” will be visible on the Start screen banner, and the packageis ready to be started.

Note: Please refer to the “ Sequence Step Table” shown on the next page for a detailed list ofsequence steps and associated actions of the supplied compressor package.





Sequence Step Table

Step Descri pti on S u c t i o n

B l o w d o w n

F u e l / S t a r t

F u e l V a l v e

S t a r t S O V

E n g i n e P r e l u b e

C o m p P r e l u b e

U n i t R e a d y

U n i t R u n n i n g

0 Unit Shutdown X

10 Permissives Not Met X

20 Unit Ready to Start X X

30 Charge Headers Delta P < xxx X X

40 Purge Compressor Starting X X

50 Purge Compressor xxx Sec Remain X X

60 Open Loading Valve X X

70 Purge Recylce Line xxx Remain X X X80 Purge Complete X X

90 Blowdown to Start Pressure < XXX X X

100 Compressor / Engine Prelube X X X X X

110 Engine Crank (RPM > XXX) X X X X

120 Engine Purge xxx Sec Remain X X X X

130 Engine Starting (RPM > XXX) X X X X X

140 Engine to Speed > XXX X X X X

150 Open Purge Valve X X X X

160 Open Suction Valve X X X X X

170 Engine Started Unit Running Warmup xxx Sec Remain X X X X X X

180 Engine Oil Temp = xxx X X X X X X

190 Verify Discharge Valve Open X X X X X X

200 Ready to Load XXX sec Before Shutdown X X X X X X210 Load Control Enabled, Eng Speed > xxx X X X X X X

220 Closing Loading Valve X X X X X X

230 Compressor Loading X X X X X X

240 Load Control Enabled X X X X X X

250 Compressor Unloading X X X X X X

260 Open Loading Valve X X X X X X

270 Engine Speed Back to Idle X X X X X X

280 Unit Normal Stop Cooldown xxx Sec Remain X X X X X X

290 Unit Stop Postlube X X X X

500 Unit ESD





Unit Shutdown (Step 0)

After a normal shutdown or reset from ESD this step closes blowdown valve and setup outputs for

the next start.

Permissives Not Met (Step 10)Sequence will hold here if there is a valve not in position or speed not at zero.

Unit is Ready to Start (Step 20)

If the Remote/Local selector switch is in the local position then compressor package maybe started by pressing the “Start” touch button located on the start screen or pressingthe panel mounted Start Push button. If the Remote/Local switch is in the remoteposition then the start command must come from the digital input signal “Remote Start”.

After the start command is received then the compressor package will either proceed tothe Purge Sequence (Step 40) or advance to the Blowdown to Start Pressure (Step90) mode.

Charge Headers (Step 30)

This unit does not have a purge and pressurization valve so this step is skipped.

Purge Compressor (Step 40)

“Purge Required” becomes active anytime any pressure in the unit goes below a “PurgePressure” Set-Point typically 50 to 100 PSI. If Purge required is active sequenceadvances to Step 50. If Purge is not required the entire purge section of the programgets skipped and step jumps directly to step 90.

Purge Compressor xxx Sec Remaining (Step 50)

Suction and Blowdown valves are opened and recycle valve is closed. Purge time is setfrom the HMI, typically 60 seconds.

Open Loading/Recycle Valve (Step 60)

Recycle valve is opened.

Purge Recycle Line xxx Sec Remaining (Step 70)

After Recycle valve output goes to 100% recycle lines are purged. Typically 10 seconds.Fuel valve opens.

Purge Complete (Step 80)

Close Suction valve.

Blowdown to Start Pressure (Step 90)

With the suction valve closed and blowdown still open the blowdown valve is held openuntil the pressure in the unit is below “Start Pressure”, typically 200 PSI.





Compressor-Engine Prelube (Step 100)

The Compressor and Engine prelube pumps start. This step is hold for prelube timeduration typically 60 seconds.

Engine Crank Mode (Step 110)Engine start signal opens the SOV to operate the engine starter. This step will advanceas Engine speed gets detected above 25 RPM. If 25 RPM is not achieved in 45 secondsthen shutdown will occur for over crank time.

Engine Purge Mode (Step 120)

Starter continues to crank the engine to purge the engine’s cylinders (cranking, Ignitionon, but no fuel) until the engine purge 2 second timer completes.

Engine Starting Mode (Step 130)

Engine Fuel valve opens. Upon completion of reaching 300 RPM’s the sequence willadvance to the “ Engine to Speed” mode (Step 140). If 300 RPM’s is not achievedwithin (120) seconds from the start of Prelube cycles a start failure will be activated.

Engine to Speed Mode (Step 140)

Wait until engine speed gets to Idle (750 RPM)

Open Purge Valve (Step 150)

No Purge and pressurization valve on this unit; this step is skipped.

Open Suction Valve (Step 160)

The suction valve is opened

Engine Warm-Up (Step 170)

The compressor is in “Warm-up” mode for sixty (60) seconds as the typical setting. The“Warm-up” mode timer is adjustable and is accessible from the “ Timer Setting” screen.

Engine Oil Temp (Step 180)

After engine warm-up timer completes, the engine oil temperature is verified to be at 60DegF typical setting. The “ Oil Temperature Warm-up” setpoint is adjustable and theentry field is located on the “ Misc. Setpoints” display. In the event the temperature hasnot reached 60 DegF. after sixty (60) seconds the step is held and does not advance until

the oil temperature is satisfied. After the oil temperature is satisfied the sequence willadvance.





Verification of Discharge Valve Opening (Step 190)

This compressor is not using a discharge valve thus this step is skipped.

Ready to Load (Step 200)

As an option some units can be configured to not “AutoLoad”. If that option is activatedthe sequence will hold here until a manual load command is activated. This unit is notconfigured with the “AutoLoad” Enabled thus step is skipped.

Load Contro l Enabled – Engine Speed (Step 210)

The engine speed is accelerated from idle to a pre-determined “Minimum RPM Load” setpoint (currently set at 775 RPM). The “ Minimum RPM Load” setpoint entry field isadjustable and is located on the “ Misc. Setpoints ” screen.

Close Loading Valve (Step 220)

Since these units have modulating Recycle valves this step is skipped and the sequencewill automatically advance to the “Compressor Loading” (Step 230) mode.

Compressor Loading (Step 230)

This step is not used in this compressor and is stepped through to load control enabled.

Load Cont rol Enabled (Step 240)

The PID control loops controlling the recycle control valve are released from tracking andplaced into the automatic mode. The compressor will operate in this step until a stop orshutdown.

Normal Stop (Step 250)

This step is not used for this compressor design and as such this step is skipped.

Open Loading Valve (Step 260) After output signal to recycle valve reaches 100% compressor is unloaded and movessequence step to 270.

Engine Speed back to Idle (Step 270)

Engine Speed output is put back to 0% or 750 RPM

Unit Normal Stop Cooldown (Step 280)

The engine is allowed to run at idle speed, and a sixty (60) second cool down timer isinitiated. The cool down timer is adjustable and is accessible from the “ Timer Setting” screen. After the sixty (60) second timer has elapsed, the engine is stopped by disablingthe fuel and ignition devices. After the fuel and ignition have been disabled the sequencewill automatically advance to the “ Post Lube” (Step 290) mode.





PETRO TECH

PERUANA

Compressor Control System


&

Instruction Manual

Rev 0

29 Sep 2010

Documents

Sequence of Operations.pdf