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Turbomachinery Controls (TMC) Case Study Greenfield Industrial Compressor Projects
Nguyen Duy Dai (David)
Taiwan, June, 2016
Confidential Property of Schneider Electric
Taiwan Compressor Seminar
Contents
Page 2 Confidential Property of Schneider Electric |
1 SE Turbomachinery Project
Execution Capabilities
2 Case Study Greenfield ITCC XXX
Project
3 Case Study Greenfield ITCC XXX
Project
SE Turbomachinery Project Execution Capabilities
Page 3 Confidential Property of Schneider Electric |
Turbomachinery Control Application
Slide 4 Confidential Property of Schneider Electric
SE Turbomachinery Control Solutions
Slide 5 Confidential Property of Schneider Electric
Integrated Turbine
Generator Control (ITGC)
Compressor Controls
Turbine Controls
Mechanical Retrofits
Dynamic Simulation
Tricon/ Trident/ Tri-GP TMR
Tricon/ Trident/ Tri-GP TMR
Dynsim / Trisim
Integrated Turbine
Compressor Control (ITCC)
Generator Controls Tricon/ Trident/ Tri-GP TMR
High Speed Event Logger
Human Machine Interface
Trip Hydraulic Block
Overspeed Trip Electronics
TriLogger
Wonderware Intouch
Quadvoter
Trident (TMR)
Fault Tolerant Control System
Slide 6 Confidential Property of Schneider Electric
SIL Rating System
– SIL 3 Tricon, SIL 3 Trident and SIL 2 Tri-GP
Protect User’s Investment
– Providing solid migration path forward by
helping client remains continuously current
Availability Safety/
Availability Safety
Application Software
TriStation 1131
Slide 7 Confidential Property of Schneider Electric
CAD Like Program
– Function block based application
program visualize structure of
application program clear through for
more easy understanding
Market Proven Function
– All function block have proven from
market from world wide installation
Emulation & User build block
– Support emulation and verify
functionalities without hardware
Engineering and Design
Capabilities
Slide 8 Confidential Property of Schneider Electric
Engineering Analysis
– will help customer to improve existing
feature for more easy maintenance and
operation
Detail Engineering Design
– All detail engineering design go through
customer approval
Wide range design
– Mechanical design, Hydraulic design,
Instrumentation, sensor and power
measurement design
Dynamic Simulation Environment
Slide 9 Confidential Property of Schneider Electric
SimSci DynSim Modelling
– The simulation software is also one of
part of SE product.
– The Trisim enable bridging between
TS1131 software and Dynsim simulation
environment.
– Dynsim can be utilized as a plant model
of turbine generator model as per
project specific scope.
Enhance Wonderware Intouch
HMI - ArchestrA
Slide 10 Confidential Property of Schneider Electric
ArchestrA
– works based on SQL server.
– Technical high end graphics will impress
to operator for more clear identification
of operation status or operation.
– Servo calibration will support
maintenance team for more easier and
clear calibration environment with auto
sensor calibration sets.
– The real time operating trend and
historical trend will remained HMI PC for
review operation status.
SE Execution Plan for a TMC Project
Slide 11 Confidential Property of Schneider Electric
Risk Management
Conduct Risk Assessment meeting monthly.
Identify & Analyze Risk throughout the project phase.
Develop mitigation plans.
Review project critical path.
Develop fall back strategy and recovery plans.
Change Management
Conduct Change Review meeting whenever changes are
required.
Track and document all changes.
Assess the impact for each change.
Develop execution plan for each change.
KOM Established and
Structured Risk &
Change
Management
System
Site Survey/FEED
Design Specification
Detail Engineering /
Procurement
Staging & Testing
Installation, SAT &
Commissioning
SE (Singapore) Project Summary
Slide 12 Confidential Property of Schneider Electric
SE has delivered many Major TMC projects across the world
Experience with Major Oil & Gas Companies
- Exxon Mobil, CPC, Saudi Aramco, Sabic, Total, Shell, RasGas, Qatar
Gas, Petronas, SGC, PTT Chem, Petron, etc
Experience with Major EPC’s
- CTCI, Chiyoda, JGC, Toyo, MHI, GS, Daelim, Samsung, Huyndai, Technip, Fluor, Snam, Foster Wheeler, etc
Experience with Major OEM’s
- Mitsubishi, Elliott Ebara, Hitachi, Nouvo Pignone, etc
SE has delivered many TMC projects across the world
Experience with Major Oil & Gas Companies
- Exxon Mobil, CPC, Saudi Aramco, Sabic, Total, Shell, RasGas, Qatar
Gas, Petronas, SGC, PTT Chem, Petron, etc
Experience with Major EPC’s
- CTCI, Chiyoda, JGC, Toyo, MHI, GS, Daelim, Samsung, Huyndai, Technip, Fluor, Snam, Foster Wheeler, etc
Experience with Major OEM’s
- Mitsubishi, Elliott Ebara, Hitachi, Nouvo Pignone, etc
Project Reference List
Slide 13 Confidential Property of Schneider Electric
Project Name OEM / EPC End-User Location Year Execute
JUPC Ethylene Plant Project Elliott Ebara Turbomachinery Corporation(EETC)
Jubail United Petrochemical Company (JUPC) Al-Jubail Saudi, Arabia 2002 - 2003
ONGC Compressor Retrofit Project N.A Oil and Natural Gas Coporation Ltd India 2003
TOC Expansion Compressor Project Mitsubishi Heavy Industries, Ltd Thai Olefins Company Limited Rayong, Thailand 2003
SGC TS3420 Replacement Project N.A Samsung General Chemicals Co. Ltd Daesan, South Korea 2003
CPCL Governor Project N.A Chennai Petroleum Corporation Limited Chennai, India 2003
HPC No. 1 NCC TMC Revamped Project N.A Hyundai Petrochemical Co, Ltd Daesan, South korea 2003 - 2004
HPC No. 1 NCC TMC Revamped Project Elliott Ebara Turbomachinery Corporation(EETC)
PTT Public Company Limited Map Ta Phut, Thailand 2003 - 2004
Namhae Governor Project N.A Namhae Chemical Corporation South korea 2004
DSCL 35MW Mitsubishi Turbine Electronic Governor
N.A Shriram Fertilizer & Chemical Kota, India 2004
YNCC N.A Yeochun NCC Co., Ltd Yeosu, South Korea 2004
NPC TS410A Replacement Project N.A National Petrochemical Public Company Limited Rayong, Thailand 2005
FPCC Refinery HPC Project Elliott Ebara Turbomachinery Corporation(EETC)
Formosa Petrochemical Corporation Mai Liao, Taiwan 2004
Retrofit Kontrol Turbin Dan AVR Pltg Unit #2 PT Len Industri PT Indonesia Power Unit Bisnis Pembangitan Bali Bali, Indonesia 2005
MHI CNOOC Methanol Project Mitsubishi Heavy Industries, Ltd Lurgi / China Offshore Oil Company Hainan Province, P.R.China
2005
Hawiyah NGL Snamprogetti, Italy & JGC CORPORATION, JAPAN
Aramco Overseas Company Hawiyah, Saudi Arabia 2005
Qatar Gas II Development Project Mitsubishi Heavy Industries, Ltd Qatar Gas Liquefied Gas Company Ltd Qatar 2006
Project Reference List
Slide 14 Confidential Property of Schneider Electric
Project Name OEM / EPC End-User Location Year Execute
LGPC M2 Project Mitsubishi Heavy Industries, Ltd LG Petrochemical Co., Ltd Yeosu, South Korea 2005
Sinnopec - Maoming Ethylene Plant Project Mitsubishi Heavy Industries, Ltd Sinopec Maoming Petrochemical Company Ltd Maoming, Guandong, P.R. China
2005
NKCC DCS Revamp Project Yokogawa (Thailand) Ltd Nongkhae Cogeneration Company, Ltd Saraburi, Thailand 2006
SCC DCS Revamp Yokogawa (Thailand) Ltd Nongkhae cogeneration Co., Ltd. Saraburi, Thailand 2005
Pertamina Plaju Air Compressor Project PT Duta Instrument Alfa Sakti Pertamina Pt Ept Plaju Pertamina, Plaju Palembang
2005
Ar- Razi Plant-V Methanol Plant Project Mitsubishi Heavy Industries, Ltd Saudi Methanol Company (Ar-razi) Saudi, Arabia 2006
Tasnee Petrochemical Ethylene Plant Project Mitsubishi Heavy Industries, Ltd Linde Engineering / Tasnee Petrochemical Company Al Jubail, Saudi Arabia 2006 - 2007
SK Korea TMC Upgrade Project N.A. SK Corporation Ulsan, South Korea 2006-2007
Roma GE Gas Turbine Retrofit N.A. Origin Energy Power Limited Australia 2006
Sharq 3rd Expansion - Ethylene Plant Project Mitsubishi Heavy Industries, Ltd Eastern Petrochemical Company (Sharq) Jubail City, Saudi Arabia
2006 -2007
Yanbab CCS Ethylene Project Elliott Ebara Turbomachinery Corporation(EETC)
Yanbu National Petrochemicals Company Yansab, Saudi Arabia 2007
Yunnan Tianan ITCC System Hitachi Plant Technologies Ltd Yunnan Tianan Chemical Co. Ltd Kum Ming, P.R. China 2007
Qatar Gas III & IV Development Project Mitsubishi Heavy Industries, Ltd Qatar Gas Liquefied Gas Company Ltd Qatar 2007
Bali Gas Turbine Retrofit PT Dinar Semesta PT Indonesia Power UBP Bali Pesanggaran Bali, Indonesia 2006
NCC TMC Modification Project N.A. LG Chemical Ltd Daesan, South Korea 2006-2007
Haldia EBR Compressor Project Mitsubishi Heavy Industries, Ltd Haldia Petrochemicals Limited Haldia, India 2007
Project Reference List
Slide 15 Confidential Property of Schneider Electric
Project Name OEM / EPC End-User Location Year Execute
ExxonMobil Booster & Recycle Compressor Upgrade Project
ExxonMobil Asia Pacific Pte Ltd ExxonMobil Asia Pacific Pte Ltd Singapore 2007
LG Chem TMC Modification Invens Korea Samsung Total Co., Ltd South Korea 2006
KJO FDP-1 Project - Onshore/Offshore Honeywll Automation & Control Solutions
Kuwait Guif Oil Company (KGOC) and Aramco Guif Operation Company (AGOC)
Saudi, Arabia 2007 - 2008
Haldia Supermax Project N.A. Haldia Petrochemicals Limited Haldia, India 2007
PTTPE - 1000 KMTA Ethylene Plant Mitsubishi Heavy Industries, Ltd PTT Polyethylene Company Limited Rayong, Thailand 2007 - 2008
MOC Cracker Project Mitsubishi Heavy Industries, Ltd Map Ta Phut Olefins Co. Ltd Rayong, Thailand 2008
NCC Big-3 Compressor Control Sys (TMC) Revamp Project
N.A. Lotte Daesan Petrochemical Corp Daesan, South Korea 2007
DAC Hydrocracker Project Hitachi Plant Technologies Ltd Dragon Aromatics (Xiamen) Co. Ltd Xiamen, P.R. China 2008
EPG-PMS ITGC Upgrade Project N.A. KOSEP Bundang CHPP South Korea 2007
Saudi Kayan Olefins Project Kellogg Brown & Root Asia Pacific Pte Ltd
Saudi Kayan Petrochemical Complex Saudi, Arabia 2008
FCC RC-C4001 / C4401 Control System Replacement N.A. SK Energy Ulsan, South Korea 2008
Linde Ruwais-2 Project Mitsubishi Heavy Industries, Ltd Abu Dhabi Polymers Company Ltd Abu Dhabi, United Arab Emirates
2008 - 2009
NRP P-C2501 Control System Replacement Project N.A. SK Energy Ulsan, South Korea 2008
CGT & ERC Replacement Project Mitsubishi Heavy Industries, Ltd LG Petrochemical Co., Ltd Yeosu, South Korea 2008
Shenhua Baotou CTO Project Mitsubishi Heavy Industries, Ltd Shenhua Baotou Coal Chemicals Co. Ltd P.R. China 2008
Shenhua Ningxia Coal Based DME Project Mitsubishi Heavy Industries, Ltd Shenhua Ningxia Coal Industries Group Co. Ltd Ningxia, P.R. China 2008
Project Reference List
Slide 16 Confidential Property of Schneider Electric
Project Name OEM / EPC End-User Location Year Execute
STG-5 Diesel Generator Control PT Duta Instrument Alfa Sakti Petamina Pekan Baru, Indonesia 2009
Keramasan (AKE-Brent Project GT EM601B Project) PT Sulzer Hickham Indonesia PT Asta Keramasan Energi Indonesia 2008
Frame V Turbine Control Retrofit Project PT Sulzer Hickham Indonesia PT Lontar Papyrus Pulp & Paper Industry Sumatra, Indonesia 2008
Ma Aden Ammonia Project Samsung Engineering Co. Ltd Saudi Arabian Mining Company (Ma Aden) Ras Az Zawr City, Saudi Arabia
2008
JSC Shchekinoazot 1350 MTPD Methanol Project Mitsubishi Heavy Industries, Ltd Shchekinoazot Russia 2008
SK Energency #2PX-C5601/TZ-C5001 N.A. SK Energy Ulsan, South Korea 2008 - 2009
PTT Chem I-1 TS410A Upgrade Project N.A. PTT Chemical Public Company Limited Rayong, Thailand 2009
Braskem Green Plastic Project Hitachi Plant Technologies Ltd Braskem S.A Rio Grande Do Dul, Brazil
2009
AOFP Sonatrach Fertilizer TMC Project Mitsubishi Heavy Industries, Ltd Algeria Oman Fertiliser Project Algeria 2009
Sibur EP-300 Ethylene Plant Revamp Project Mitsubishi Heavy Industries, Ltd OJSC (Open Joint-Stock Company) Sibur Neftehum Russia 2009 - 2010
YNCC Compressor Control System Upgrade Project N.A. Yeochun NCC Co., Ltd Yeosu, South Korea 2009
Rithala - 108MW CCPP Project N.A. North Delhi Power Limited New Delhi, India 2009
Korea WP Pumped Storage Power Project Invensys Korea Korea Western Power Co., Ltd. Samrangjin, South Korea
2009 - 2010
Guararema Compression Station Project Mitsubishi Heavy Industries, Ltd Petrobras Brazil 2009 - 2010
200-C1 and 380-C1 Project N.A. PTT AR Rayong, Thailand 2009 - 2010
S Oil Electronic Governor Controller Upgrade Project
Invensys Korea S Oil Corporation Ulsan, South Korea 2010
Project Reference List
Slide 17 Confidential Property of Schneider Electric
Project Name OEM / EPC End-User Location Year Execute
Upgrade Steam Turbine Generator Control Project N.A. PTT Aromatics & Refining Public Company Ltd Rayong, Thailand 2010
EL-Tablazo 03 Cracker Project Mitsubishi Heavy Industries, Ltd Linde Engineering / Polinter El-Tablazo, Venezuela 2010
Jubail Export Refrinery Project Elliott Ebara Turbomachinery Corporation(EETC)
Saudi Aramco Total Refining and Petrochemical Company (SATORP)
Jubail City, Saudi Arabia
2010
SK Energy / No.1 RHDS DS-C1300 Control System Replacement Project
N.A. SK Energy Ulsan, South Korea 2010
TPC Maanshan EHC / ATSI/SGPFT (Unit #1) Project N.A. Taiwan Power Corporation Taiwan 2010
Technip Jubail Export Refinery Project Elliott Ebara Turbomachinery Corporation(EETC)
Saudi Aramco Total Refining and Petrochemical Company (SATORP)
Jubail City, Saudi Arabia
2010
Dual Feed Ethylene Cracker For Dahej Project Elliott Ebara Turbomachinery Corporation(EETC)
Oil and Natural Gas Corporation Limited (ONGC) India 2010
Linde Ruwais-3 Project Mitsubishi Heavy Industries, Ltd Abu Dhabi Polymers Company Ltd Abu Dhabi, United Arab Emirates
2010
Samco Acrylic Acid Complex Project Mitsubishi Heavy Industries, Ltd SAMCO Saudi, Arabia 2010
CPC No. 6 Naphtha Cracker Project Elliott Ebara Turbomachinery Corporation(EETC)
CPC Corporation Taiwan 2010
SCG (ROC) TS3410 Upgrade TS3000 Project. N.A. SCG Chemical Co. Ltd Rayong, Thailand 2010
RPLC Deep Conversion Project Mitsubishi Heavy Industries, Ltd Puerto La Cruz Refinery Venezuela 2010 - 2011
MATIX 2200 MTPD Ammonia Plant Project Mitsubishi Heavy Industries, Ltd MATIX Fertilizers & Chemicals Limited India 2010
NCC TMC Modification Project for LG Chemical / Daesan Plant
N.A LG Chem, Ltd. Daesan, South Korea 2010
SATORP CCS Project Invensys Saudi Aramco Total Refining and Petrochmical Company
Saudi Arabia 2010 - 2012
Feed Scope (GT Revamp) N.A. Pilipinas Shell Petroleum Corpn Philippines
Project Reference List
Slide 18 Confidential Property of Schneider Electric
Project Name OEM / EPC End-User Location Year Execute
Petronas (PFK) ITCC Project N.A. Petronas Chemicals Fertiliser Kedah Sdn Bhd Qatar 2011 - 2012
TCJV / PMP Project Mitsubishi Heavy Industries, Ltd Qatar Liquefied Gas Company Ltd. Qatar 2011 - 2012
Samsung-BP Chemical Anti-Surge Revamping Project
N.A. Samsung-BP Chemicals Co., Ltd Yeosu, South Korea 2011
HPCEM2 Project Mitsubishi Heavy Industries, Ltd Honam Petrochemical Corp. Yeosu, South Korea 2011 - 2012
NP UTC_REFAP NGC Project Hitachi Plant Technologies Ltd Petrobras S.A Brazil 2011 - 2012
No. 4/5 Compressor Governor Control TMC Project N.A. S Oil Corporation Ulsan, South Korea 2011
PTT Chem I-4 Plant 2 TMC Upgrading Project N.A. PTT Chemical Public Company Limited Rayong, Thailand 2011
Gas Turbine Control Systems Upgrading (ITGC) Project
N.A. Pilipinas Shell Petroleum Corpn Philippines 2012 - Ongoing
DSS-Tangerang-Retrofit Gas Turbin#1 Project PT Sulzer Turbo Services PT Dian Swastatika Sentosa Tbk. Indonesia 2012 - 2013
Toyo-K/Al-Bayroni Project Mitsubishi Heavy Industries, Ltd Al-Jubail Fertilizer Saudi Arabia 2012
Petron Battan Refinery Project Elliott Ebara Turbomachinery Corporation(EETC)
PETRON Corporation Philippines 2012
SK-H Project Elliott Ebara Turbomachinery Corporation(EETC)
SK Lubricant Korea South Korea 2012
PTT BV Project Elliott Ebara Turbomachinery Corporation(EETC)
PTT Chemical Public Company Limited Rayong, Thailand 2012
Laffan Refinery Diesel Hydrotreater (DHT) Project SAMSUNG ENGINEERING CO., LTD. Laffan Refinery Company Ras Laffan Industrial City, Qatar
2012 - 2013
SAFCO V – UREA Stand Alone Project Mitsubishi Heavy Industries, Ltd Saudi Arabian Fertilizer Company Saudi Arabia 2012 - 2013
Sabah Ammonia UREA (SAMUR) Project Mitsubishi Heavy Industries, Ltd Petronas Chemicals Fertiliser Sabah Sdn Bhd Sabah, Malaysia 2012 - 2013
Project Reference List
Slide 19 Confidential Property of Schneider Electric
Project Name OEM / EPC End-User Location Year Execute
Etileno XXI Project Braskem Idesa Sapi Project Mitsubishi Heavy Industries, Ltd Technip Italy S.P.A / Braskem Mexico 2012 - 2013
PTTGC BRANCH 3 CCS REVAMPING PROJECT - PTT Chemical Public Company Limited Rayong, Thailand 2012 - 2013
Unidade De Fertiliacntes Nigtogenados III Project Mitsubishi Heavy Industries, Ltd Petrobras S.A Brazil 2012 - 2013
Petron Battan Refinery C-7001 Project Elliott Ebara Turbomachinery Corporation(EETC)
PETRON Corporation Philippines 2012 - 2013
Ethydco Ethylene Project (EEP2) Mitsubishi Heavy Industries, Ltd The Egyptian Ethylene And (Ethydcderivatives Company O)
Egypt 2012 - 2013
CONTROL UPGRADE FOR MGT#2 AND MGT#3 N.A. PT Chervon Pacific Indonesia Sumatra, Indonesia 2013 LHDC RGC (K9602) Governor Control Upgrade Project
N.A. Exxonmobil Asia Pacific Pte Ltd Singapore 2013 - 2014
SKEC Ulsan Aromatics New PX Project Elliott Ebara Turbomachinery Corporation(EETC)
Ulsan Aromatics Co., Ltd. Ulsan, South Korea 2013
CILACAP REFINERY Elliott Ebara Turbomachinery Corporation(EETC)
Pertamina Indonesia Indonesia 2013
Lake Charles Chemicals Project (LCCP) Mitsubishi Heavy Industries, Ltd SASOL CHEMICALS USA, LLC / FLUOR ENTERPRISES, INC.
Lake Charles, Louisiana, USA
2013 - 2014
Long Chen Turbine Control Retrofit Project N.A. Long Chen Paper Co., Ltd Changhua, Taiwan 2013
Celanese Project Fairway Mitsubishi Heavy Industries, Ltd Celanese International Corporation Texas, USA 2013 - 2014
2014 NCC Expansion Project Mitsubishi Heavy Industries, Ltd LG Chem Ltd Yeosu, South Korea 2013 - 2014
Reliance ROG Cracker Project Elliott Ebara Turbomachinery Corporation(EETC)
Reliance Infrastructure Limited Jamnagar, India 2013 - Ongoing
Geodipa Retrofit Control System Project N.A. PT Geodipa Java, Indonesia 2013 - 2014
USGC Ethylene Project Mitsubishi Heavy Industries, Ltd Chevron Philips Chemical Company LP Baytown, Texas, USA 2013 - 2014
Project Reference List
Slide 20 Confidential Property of Schneider Electric
Project Name OEM / EPC End-User Location Year Execute
ExxonMobil NA Growth Olefins Recovery Baytown Project
Mitsubishi Heavy Industries, Ltd ExxonMobil Chemical Company Baytown, USA 2014 - 2015
Westlake Petro 1 Extended PDP Project Mitsubishi Heavy Industries, Ltd Westlake Chemical Corporation Sulphur, USA 2014 - 2015
CB&I/Ingleside (USA) Mitsubishi Heavy Industries, Ltd Ingleside Ethylene LLC Baytown, USA 2014 - 2015
Umm Wu'al Ammonia ITCC Project Samsung Engineering Co. Ltd Saudi Arabian Mining Company (Ma Aden) Ras Az Zawr City, Saudi Arabia
2014 - 2015
PTTCH I-1 Propylene Compressor TMC upgrading N.A. PTT Chemical Public Company Limited Rayong, Thailand 2014 - 2016
TG 2 & 4 Upgrade - RU II Dumai Mitsubishi Heavy Industries, Ltd Pertamina RU II Dumai, Indonesia 2014 - 2016
QGIT Petrobras Comerj Mitsubishi Heavy Industries, Ltd Petrobras Rio de Janeiro, Brazil 2014 - 2016
PTTGC I1 Elliott Compressor Controller N.A. PTT Chemical Public Company Limited Rayong, Thailand 2014 - 2016
YNCC1 TS3000 ITCC Modification N.A. Yeochun Ncc Co Ltd. Yeosu, South Korea 2014 - 2016
SKIC : STG#11 Trip Block Replacement N.A. Siam Kraft Industries Rayong, Thailand 2014 - 2016
HDC MX LLI Project Elliott Ebara Turbomachinery Corporation(EETC)
Hyundai Chemical Co., Ltd. Daesan, South Korea 2014 - 2016
Case Study – Greenfield Integrated Turbine Compressor Control (ITCC)
Page 21 Confidential Property of Schneider Electric |
Project Information
End User: XXX
Client : Mitsubishi Heavy Industries Compressor Corporation (MCO)
EPC : Linde
Project Configuration;
• One (1) Cracked Gas Compressor (CGC), 5 Stages
• One (1) Propylene Refrigeration Compressor (PRC), 4 Stages
• One (1) Ethylene Refrigeration Compressor (ERC), 6 Stages
Slide 22 Confidential Property of Schneider Electric
Scope Of Supply
Slide 23 Confidential Property of Schneider Electric
Integrated Turbine and Compressor Control (ITCC) System with. The system includes, but
not limited to the following items:
• Tricon PLC, Triplex CPU and I/O, Duplex Power Supply
• Rittal Cabinets, including components and wiring material, Hart Multiplexer, Signal
Isolators
• Bently Monitor
• Torquemeter
• Braun Overspeed Trip Device
• HMI, SOE and Engineering Workstation PCs
Scope Of Supply (Cont.)
Slide 24 Confidential Property of Schneider Electric
• Engineering Manufacturing and Management
Vendor shall provide an excellent project management service during project execution.
Engineering service includes but not limited design, hardware manufacture, cabinet
integration, system configuration, training, internal test, FAT, site service and commissioning
service
• Documentation
• Recommendation of Anti-Surge Instruments including calculate the necessity anti-surge
valve size (Cv value) as vendor’s control system to achieve successful operation
ITCC Function Requirement
Slide 25 Confidential Property of Schneider Electric
No Functions CGC PRC ERC Remarks
1 Alarm logic for Compressor and Turbine
2 Shutdown logic for Compressor and Turbine
3 Start-up Interlock logic for Compressor and Turbine
4 Start-up Sequence logic for Compressor and Turbine Semi-Auto start is applied
5 Auxiliary equipment interlocks logic for Compressor and Turbine
6 Anti-Surge Control
7 Compressor performance control 2 3 6
8 Turbine speed control (Governor) Implement in the DCS.
9 Turbine extraction pressure control 1 1
10 Temp. quench control
11 Condenser drum level control
12 Sealing steam press. Control Split Range Control
13 LO supply temperature control Split Range Control
14 Seal gas supply D/P control
15 Other single loop control
Project Organization Chart
Slide 26 Confidential Property of Schneider Electric
• Roles & Responsibilities
• Communication Protocol
• Response Time
Project Execution Phases
Slide 27 Confidential Property of Schneider Electric
Preliminary Design
Input
Initiation Phase Freeze Design Input
Kick Off Meeting Design Definition
Phase
Project Execution Plan HW Functional Design
Specification
Detail Engineering
Phase
Project Schedule System Architecture Cabinet detail drawing Test Phase- FAT
Project Quality Plan HMI Design
Specification
I/O assignment &
cross-wiring listing FAT Procedures
Shipment
(FOB Singapore)
Basis of Design
Document (BODD)
Cabinet integration (by
vendors) Internal Test
Pre-shipment
Inspection Test Phase- IFAT
Application logic
development HW & SW FAT
Shipping Doc &
Packing List
IFAT support at DCS
premises (out of
Scope)
Site Commissioning
Phase
Application HMI
development SAT Procedures
Procurement
Site commissioning
support ( Per Diem
Rate)
Project Execution Strategy
Slide 28 Confidential Property of Schneider Electric
• QUALITY
• The reference standards for the Quality System that will be adopted are:
– ISO 9001: 2008 Quality assurance requirement during design, development, fabrication, installation and assistance.
– ISO 9000: 2005 Quality Management Systems – Fundamentals and vocabulary
• SCHEDULE
• Specifications derived from the Design Definition phase shall be used extensively to minimize the engineering time,
improving efficiency and reducing the testing time
• Hardware & Software Freeze dates to be maintained as per Master Project Schedule to meet the committed Project
delivery dates
Project Execution Strategy
Slide 29 Confidential Property of Schneider Electric
● LOCATIONS AND COORDINATION
Project execution shall be carried out from Singapore
Invensys Engineering Excellence Centres engineers shall be mobilized to Singapore to support the project engineering and
FAT
Specific project engineers shall be mobilize for SAT and Site Commissioning.
● ENGINEERING CONSISTENCY
The detail engineering works of the project shall follow the Functional Design Specifications and Basis of Design
Document, developed with Mitshubishi and end-user during the Design Definition phase.
● PROGRESS COORDINATION – WITH CLIENT
Monthly Progress Report will be submitted to reflect the major milestone achieved during the reporting month and the
major task planned for the next month including the procurement status and deliverable document status.
● CHANGES
Control of changes is essential to meet the project schedule and cost.
Project Schedule – Major Milestones
Slide 30 Confidential Property of Schneider Electric
Milestone Date
PO awarded 31 Mar 2014
Project Kick Off meeting 22– 23 Apr 2014
Customer Design Input Issued 25 Apr 2014
Functional Design Specification Approval 17 Jun 2014
BODD Approval 22 Jul 2014
Hardware Design Freeze 24 Sep 2014
Software Design Freeze 24 Sep 2014
Design Freeze meeting (in customer office) 25 Sep 2014
Procurement Start and Complete 30 Jun – 31 Oct 2014
Cabinet Design Approved for material procurement & Construction 24 Sep 2014
Cabinet Integration Complete 12 Dec 2014
Software Application Complete 24 Nov 2014
Internal FAT 18 Dec 2014 – 16 Jan 2015
FAT 19 Jan – 6 Feb 2015
System Delivery (FOB Singapore) 27 Feb 2015
Project Network Architecture
Slide 31 Confidential Property of Schneider Electric
Project Deliverable Document List
Slide 32 Confidential Property of Schneider Electric
No Document Title
1 Vendor Engineering Document List
2 Quality Plan
3 Functional Design Specification (Hardware & Software)
4 Typical Loop Drawing
5 Network Architecture Drawing
6 HMI Design Specification
7 I/O Assignment Document
8 Cabinet Termination List
9 Cabinet Outline Drawing
10 System Cabinet Layout & Power Distribution Drawing
11 Marshalling Cabinet Layout & Power Distribution Drawing
12 Bently Cabinet Layout & Power Distribution Drawing
13 TS310SV Cabinet Layout & Power Distribution Drawing
Project Deliverable Document List
Slide 33 Confidential Property of Schneider Electric
No Document Title
14 Valve Sizing Document
15 Basis Of Design Document
16 Communication List
17 HMI Screens
18 Logic Printout
19 Factory Acceptance Test Procedure
20 Factory Acceptance Test Records
21 Site Acceptance Test Procedure
Compressor HMI Graphics
Slide 34 Confidential Property of Schneider Electric
Compressor HMI Graphics
Slide 35 Confidential Property of Schneider Electric
Compressor HMI Graphics
Slide 36 Confidential Property of Schneider Electric
Compressor HMI Graphics
Slide 37 Confidential Property of Schneider Electric
Compressor HMI Graphics
Slide 38 Confidential Property of Schneider Electric
Compressor HMI Graphics
Slide 39 Confidential Property of Schneider Electric
Completed Cabinets
Slide 40 Confidential Property of Schneider Electric
Completed Cabinets
Slide 41 Confidential Property of Schneider Electric
Completed Cabinets
Slide 42 Confidential Property of Schneider Electric
Packing and Shipment
Slide 43 Confidential Property of Schneider Electric
Case Study – Greenfield Integrated Motor Compressor
Control
Page 44 Confidential Property of Schneider Electric |
Project Information
End User: XXX
Customer : Elliot Ebara Turbo Machinery Corporation (EETC)
EPC : XXX
The Project Configuration
• One Net Gas Compressor
• One Recycle Gas Compressor
• One Recycle Compressor
Slide 45 Confidential Property of Schneider Electric
System Overview
Slide 46 Confidential Property of Schneider Electric
Project Challenges
As many other projects execution, after Kick Off Meeting, SE start designing base on the
project input documents, as usual, there are always have some technical queries on some
design input documents, however below are important issues that required to resolve at the
beginning of design phase
• There is a confusion on the interface requirement between DCS and ITCC’s HMI
• EPC bought the Anti-Surge Valve bigger than recommended Cv
• End-user and EPC in doubt with the control philosophy given by process licenser (UOP)
Slide 47 Confidential Property of Schneider Electric
Project Challenges
Base on the requirement there the operator can operate from ITCC’s HMI or DCS, however
the HMI/DCS selection philosophy is not so clear, this was resulted on unclear to design the
signal tracking between two systems (ITCC and DCS) and consequentially can impact on I/O
counts and detail design of control philosophy
With many years experience on integration between ITCC and DCS we studied customer
requirement and propose the new interface philosophy that can fulfil the customer
requirement with clear operation philosophy in both sides HMI and DCS, it also provide better
fallback strategies in the event of DCS/HMI communication failure
Slide 48 Confidential Property of Schneider Electric
Project Challenges
Slide 49 Confidential Property of Schneider Electric
The Anti-Surge Valve over sized could result on following issues:
• Make the anti-surge and performance control unstable
• Waste of energy due to over recycle
• Could drive compressor state to choke/stonewall condition and potentially damage
compressor
Usually to resolve this issue, the output demand to the ASV will be limited by pre-fixed value,
however this is not flexible for the operation when compressor operated in different
conditions, therefore after studied all of compressor designed operation conditions, the
Dynamic Limiter Control Solution was intruded and proposed to customer.
Project Challenges
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At the beginning EPC and End-user have some doubts on the control on control philosophy
from process licenser and additionally SE proposed changes on DCS/HMI operation interface
as well as the dynamic limiter control solution to resolve the anti-surge valve oversized. So
now the doubt from EPC and End-user getting bigger and the need of having some kind of
dynamic simulation to demonstrate all above control philosophies are good
Project Challenges
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The Trisation 1131 (the same software used for ITTC coding and programing) was used to
create the simulation model and also control logics, these both were tested by using the
Trisation Emulator and Wonderware HMI. Most of technical issues were clear and finalized
after using the simulation model to demonstrate the ITCC control features.
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FAT and Staging
Dynamic Simulation - High Fidelity Model
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The DynSim software was selected to do the high fidelity model for Recycle Gas Compressor
and Net Gas compressors to study and validate performance of the following steady state
cases:
• Emergency Trip of Compressor
• Normal Stop Of Compressor
• High Purity H2 Startup
• Startup of compressor from maximum possible suction pressure
The DynSim utilised the same HMI and the same control logic as the final product, so
dynamic changes were made possible which were passed into the final versions used during
commissioning.
The Simulation also an extremely useful Operator Training tool before, during and after the
commissioning phase
DynSim Modeling – Integrated Verification
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Recycle & Net Gas Comp. DynSim Modeling
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Recycle & Net Gas Comp. DynSim Modeling
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Recycle & Net Gas Comp. DynSim Modeling
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ESD Logic Simulated by DynSim
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Local Panel Interface Simulated by DynSim
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Net Gas Compressor Simulation Graphics
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Net Gas Compressor Simulation Graphics
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Net Gas Compressor Simulation Graphics
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Net Gas Compressor Simulation Graphics
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Net Gas Compressor Simulation Graphics
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Site Commissioning
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Site Commissioning
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Site Commissioning
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Other On Going Project at Staging
Other On Going Project at Staging
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Questions?
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