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HydroCOM

High energy savings and excellent controllability

For efficient capacity control


Many capacity control systems waste energy, are slow and inaccurate.
HydroCOM, however, achieves best results and pays for itself within a short period of time.
It saves money due to excellent controllability and by significantly improving performance.

Some questions you should ask yourself


about your existing control system:

Economical aspects

Automation requirements

Does my control system waste energy like

Can my control system be fully integrated

a bypass valve?

into the DCS to allow remote control


unlike pockets and manual operation?

Process issues

Does it provide any kind of self-diagnosis

Does my control system react quickly

functions?

enough and does it precisely control all


required pressure levels, flow rates or

Environmental restrictions

other parameters unlike step control or

Does my system help to fulfil stringent

bypass valves?

environmental conditions unlike


control-flares?

Control range
Does my control system have any
limitations with respect to molecular
weight, suction pressure, temperature,
minimum load, etc. as with speed control,
pockets, step control etc.?

A wise investment
HydroCOM is the smartest, most efficient, stepless,
highly dynamic and fully automated control system.

What makes HydroCOM the perfect


answer to your compressor control
system problems?

Highest energy savings

Fully automated system

HydroCOM follows an intelligent concept:

HydroCOM interfaces to a DCS or

just the required amount of gas needed is

a loop controller.

being compressed.

Monitoring
Stepless control range

Monitor and protect your compressor with

HydroCOM uses hydraulic actuation to

RecipCOM, our machinery protection and

use the full control range. HydroCOM

online monitoring system. RecipCOM

is independent of process variations

is certified according to IEC 61508 /

such as suction pressure, molecular

61511, API 670 and ANSI / ISA-84.

weight changes, temperatures, and other


condtions.

Proven success
HydroCOM is used in a variety of

Highest control dynamics

applications. Basically every reciprocating

HydroCOM is very fast and precise due to

compressor installation can be equipped

the quick response of the solenoid valve

with HydroCOM.

inside the actuator:


within 3 crank-shaft revolutions
load changes from 10 to 100% are
possible.

Smart actuators are at the heart of HydroCOM

The basic principle of HydroCOM:


the compression stroke.
With HydroCOM the suction valve is kept
open by the unloader so a certain amount
of gas is pushed back into the suction
chamber. Then, at precisely defined point
of time, the unloader is released and the

PD

D r,50
D

Pressure

Normally gas is being compressed during

C r,50

suction valve closes. Therefore only the


gas remaining in the cylinder is being
compressed.

PS

Energy Savings at
50% partial load

B
Volume

nn
Electric housing

oil-section of the valve housing and the

Microprocessors inside the electric

gas-section of the compressor.

housings handle the fast and precise


actuator timing. When installing the
actuator only power supply and bus
cables have to be electrically connected.

oo
Valve housing
The valve housing is the hydraulic heart
of the HydroCOM actuator. Oil pressure

A temperature sensor measures


continuously the valve cover temperature
and makes this value available for
indication in the process control system.
This temperature is used to monitor the
condition of the suction valve.

(connection on top) is applied to the

qq
HydroCOM unloader

hydraulic piston to push the unloader

The motion of the HydroCOM unloader

down when needed. The solenoid valve

is controlled by the hydraulic pressure

(similar to those in common rail diesel

applied in the valve housing.

injection systems) is the fast switching


element giving the HydroCOM its high

rr
Suction valve

dynamics.

The HOERBIGER plate or ring type

pp
Seal housing
The seal housing fits directly to the
suction valve cover. It separates the

suction valve with non-metallic sealing


elements ensures long life time and best
efficiency.

HydroCOM integrates seamlessly

Modular system design


HydroCOMs modular design makes integration straight forward for both existing and
new compressor installations. Process control tasks are implemented in a DCS or a loop
controller. In a control panel the HydroCOM compressor interface unit (CIU) carries out
data exchange between the DCS and HydroCOM.

Field

Switchroom

TDC

1994

4-20 mA
binary signal
or Modbus

IA

BUS

CIU

OIL

Compressor Condition Report


Unit Name:
Location:

RTC21000 - C
FLL

Load Step:
Percent Load:

Model:
Unit Mfr:

TCV10
DRESSER RAND

Date:
4/28/1994 8:18:32 AM
Serial No.:

3
86.4 %

UNIT COSTS

HSS

Fuel Cost:
Brake Power from the load:
Cost of Each BHP:

1673.37
3654.50
0.46

$/day
bhp
$/bhp-day

ENGINE COSTS

Percent of Fuel Cost

Actual Fuel Consumption:


Predicted Fuel Consumption:
Deviation From Predicted:
Cost of Deviation:

8675.17
7434.80

BTU/BHP - hr
BTU/BHP
- hr
7434.80

1240.36
239.26
7282.35
87388.25

BTU/BHP - hr
$/day
$/month
$/year

14.3

COMPRESSOR COST OF LOSSES


Total Losses
Valve and Passage Losses:
Pulsation Losses:
Gas Recirculation Losses:

397.38
153.18
0.78

Total Compressor Cost:

Hydraulic Unit

DCS / PLC

bhp
bhp
mmscfd

Estimated Cost of Losses


172.86
66.63
5.97

$/day
$/day
$/day

245.46
7471.32
89655.86

$/day
$/month
$/year

484.72
14753.67
177044.11

$/day
$/month
$/year

TOTAL DEVIATION FROM PREDICTED

Percent of Fuel Cost


10.3
4.0
0.4

%
%
%

14.7

Percent of Fuel Cost


29.0 %

1995

1996

1997

1998

1994

1995

1996

1997

1998

HydroCOMs many success stories


Many users worldwide take advantage of the outstanding performance of HydroCOM.

Nearly 600 HydroCOM installations are


achieving significant advantages over
other systems.
HydroCOM installations are found in
many industrial applications including:
Chemical plants
Refineries
Gas transport and storages

Chemical

Gas turbine plant

Refining

Natural gas

Gas turbine plants


HydroCOMs leading edge technology,
optimal integration and excellent
maintenance features have proven to be
the ideal choice for customized process
control systems.
Not only does HOERBIGER lead the way
in compressor controls, it also provide
local support from the largest service
network in the world.

Refining

The benefits of HydroCOM at a glance

Maximum energy savings

Suction valve temperature

Stepless control for excellent

monitoring on-board.

controllability

Full integration into plant control

Broad control range for process

system

flexibility and easy start/shutdown


Fast and precise: ideal for stable

Fully automatic for easy operation


Easy and quick upgrade /

dynamic control

integration, fits on most


compressors

HydroCOM Specifications
Control Range

10 - 100% *

Max. suction pressure

160 bar / 2320 psi

Max. suction valve temperature

120 C / 220 F

Max. compressor speed

1200 rpm

Corrosive Environments?

yes

Non-lubricated service?

yes

Suction valve

non-metallic plate or ring

Max. number of actuators

48

Ex certifications

EU (ATEX), US (FM), Canada (CSA), Japan

* Control range depends on the application

www.hoerbiger.com

The HOERBIGER Group


HOERBIGER Compression Technology is a business unit of HOERBIGER Holding AG, Zug /
Switzerland. HOERBIGER is active throughout the world as a leading player in the fields of
compression technology, automation technology and drive technology. In 2008, its 6,300
employees achieved sales of around 1 billion Euro. The focal points of its business activities
include key components and services for compressors, engines and turbomachines, hydraulic
systems and piezo technology for vehicles and machine tools, as well as components and
systems for shift and clutch operations in vehicle drive trains of all kinds. Through innovations
in attractive technological niche markets, the HOERBIGER Group sets standards and delivers
cutting-edge solutions for the benefit of its customers.

No additional space required


High standardisation of parts /
systems for high reliability and
cost effectiveness on spares
Optional upgrade to online
monitoring including pV, rider ring
wear and vibration monitoring
Proven at nearly 600 installations