HydroCOM

Saves energy, reduces capital costs & improves process control

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

HydroCOM

HydroCOM saves energy

Only the gas flow required by your process is compressed (no recycling)

Typical application: 1,300kW compressor 80% average load Energy costs 0.06 per kWh 100% 80%

Recycling is waste of energy: Power loss: 1,300 x 0.2 = 260 kW Losses: 2,080,000 kWh / year

Recycle valve is waste of money: With HydroCOM: 124,800 energy savings / year 20% Plus savings in CO2-emissions

HydroCOM

HydroCOM reduces compressor capital costs

Capital costs of a multistage compressor with HydroCOM are lower than for a 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

HydroCOM

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 5

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

HydroCOM

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

With HydroCOM always at the forefront

HydroCOM on largest API compressor ever built

Power: Process: Stages:

13.2 MW Hydro-treating 3 Each stage serves a different process

Manufacturer: Model:

Thomassen C-85.6

HydroCOM

HydroCOM and compressor manufacturers

Shenyang

Nuovo Pignone

Mitsui

Worthington

HydroCOM

Applications Refining & Exploration

Hydrogen desulphurisation Hydrocracking Hydrogen production CCR platformer Flare gas LPG

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

HydroCOM

10

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

11

Applications Chemical & Technical Gases

Ethylene Fertilizer LDPE Propylen Air Separation Syngas Chlorine production Melamin Basic chemicals
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

HydroCOM

12

Applications Natural Gas

Underground storage Pipeline Gas gathering

ANR - EON - EPS - Exxon - Gaz de France - INA - Krio Odolanow - Marathon - MND - NAM NIOC - Northern - OMV - Pengrowth - Preussag - Questar - Perstorp - ROP - RAG - RWE Stadtwerke Kiel - Tennessee Gas - Transwestern

HydroCOM

13

Applications Gas Turbine Plants

Fuel boosters

National Power - Fortum - RWE - Electrabel

HydroCOM

14

Working principle Stepless control (1)

HydroCOM

15

Working principle Stepless control (2)

HydroCOM

16

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

17

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.

HydroCOM

18

Working principle Stepless control (5)

Energy savings compared to recycle valve control Area enclosed by pV graph is equivalent to the energy consumed

HydroCOM

19

Working principle

HydroCOM

20

10

HydroCOM key-components

HydroCOM Actuator

Compressor Interface Unit (CIU)

Hydraulic Unit

Standardized components for high reliability and cost effectiveness on spares

HydroCOM

21

Components of HydroCOM - Actuator

HydroCOM Acutator Microprocessors 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 Unloader The 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.

HydroCOM

22

11

Components of HydroCOM - Actuator

Valve Housing
Oil inlet Solenoid valve High pressure piston Oil outlet

Seal Housing
Vent Leakage oil Flare line Optional: seal gas Sealing elements Temperature sensor

Electric Housing
48VDC connection HydroCOM field bus

HydroCOM

23

Components of HydroCOM Actuator

HydroCOM Installation on 3 stage hydrogen compressor Manufacturer: User: Neuman & Esser BAYER, Germany
HydroCOM 24

12

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

25

Components of HydroCOM Hydraulic unit

Pressure transmitter Oil/air cooler Ex-proof motor Temperature transmitter Level switch (fork type) Duplex filter

Tank 63/120l
Shown: Hydraulic unit with 120l tank

HydroCOM

26

13

HydroCOM system layout

HydroCOM

27

HydroCOM application range

Control range Max. suction pressure Max. suction temperature Max. compressor speed Non-lube, corrosive gases Suction valve sealing element Gases Ex-certification ATEX, Japan Ex-certification Canada (CSA) Ex-certification US (FM) (0..) 10*100% 160bar 120 C 1200 rpm yes ring, plate All, except O2 + acethylen ExII 2G EEx de IIB + H2 T4 Class I, Div.1, Gr. A, B, C, D Class I, Div.1, Gr. B, C, D, T4 AEx d,e IIB + H2 T4

* Minimum continuous load depends on gas composition, pressures and compressor design
HydroCOM 28

14

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

29

HydroCOM

30

15