Turbomachinery Control on the Honeywell Experion PKS Platform Boris Pusin Statistics & Control, Inc.
Education: 2012 Honeywell Users Group Bio 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
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
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
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
Surge Prevention
Surge Prevention (Continued)
Surge Prevention (Continued)
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
Steam Turbine Control
Steam Turbine Control (Continued)
Steam Turbine Control (Continued)
Steam Turbine Control (Continued)
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
Capacity Control
Capacity Control (Continued)
Capacity Control (Continued)
Master Control
R3XX versus R4XX
R3XX versus R4XX (Continued)
Visualizations
Projects KINEF Oil Refinery, Russia BP Cherry Point Oil Refinery, USA LINOS Oil Refinery, Ukraine Cherepovets AZOT Ammonia Plant, Russia
Project Statistics (Experion PKS Platform) Commissioned units: 12 Units yet to be commissioned this year: 11
Surge control for 2012 Honeywell Users Group KINEF Oil Refinery 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 gearbox in hydrotreatment unit (C300) 2 instrumentation air compressors in new hydro cracking unit (C300) 1 process air compressor in hydro cracking unit (C300)
Oil Refinery (Continued)
BP Cherry Point Refinery Surge control for fractionators compressors in catalytic cracking unit (C300)
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
Results 2012 Honeywell Users Group Ammonia Plant (Continued) 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
Results Unit #402 2012 Honeywell Users Group Ammonia Plant (Continued) 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
Ammonia Plant (Continued)
Ammonia Plant (Continued)
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
Benefits (Continued) Applications using Honeywell s Custom Algorithm Block (CAB) are more user friendly Reduce maintenance costs and training time
Q &A
Statistics & Control, Inc. www.stctrl.com Thank you