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HydroCOMSaves energy, reduces capital costs & improves process control

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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

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HydroCOM saves energy

Typical application:

1,300kW compressor

80% average load

Energy costs €0.06 per kWh

Recycle valve is waste of money:

With HydroCOM:

€ 124,800 energy savings / year

Plus savings in CO2-emissions

Recycling is waste of energy:

Power loss: 1,300 x 0.2 = 260 kW

Losses: 2,080,000 kWh / year

100%80%

20%

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

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HydroCOM reduces compressor capital costs

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

.

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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

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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

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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

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With HydroCOM always at the forefront

HydroCOM on largest API compressor ever built

Power: 13.2 MW

Process: Hydro-treating

Stages: 3

Each stage

serves a differentprocess

Manufacturer: Thomassen

Model: C-85.6

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HydroCOM and compressor manufacturers

Worthington

Nuovo PignoneNuovo Pignone

Mitsui

Shenyang

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Applications – Refining & Exploration

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

Hydrogen desulphurisation

Hydrocracking

Hydrogen production

CCR platformer

Flare gas

LPG

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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

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Applications – Chemical & Technical Gases

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

Ethylene

Fertilizer

LDPE

Propylen

Air Separation

Syngas

Chlorine production

Melamin

Basic chemicals

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Applications – Natural Gas

ANR - EON - EPS - Exxon - Gaz de France - INA - Krio Odolanow - Marathon - MND - NAM -

NIOC - Northern - OMV - Pengrowth - Preussag - Questar - Perstorp - ROP - RAG - RWEStadtwerke Kiel - Tennessee Gas - Transwestern

Underground storage

Pipeline

Gas gathering

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Applications – Gas Turbine Plants

National Power - Fortum - RWE - Electrabel

Fuel boosters

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Working principle – Stepless control (1)

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Working principle – Stepless control (2)

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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.

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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.

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Working principle – Stepless control (5)

Energy savings

compared to recycle

valve control

Area enclosed by pV graph is

equivalent to the energy

consumed

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Working principle

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HydroCOM key-components

HydroCOM Actuator

Compressor Interface Unit (CIU)

Hydraulic Unit

Standardized components for high reliability and cost effectiveness on spares

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Components of HydroCOM - Actuator

HydroCOM AcutatorMicroprocessors 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 UnloaderThe 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.

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Components of HydroCOM - Actuator

Valve HousingOil inlet

Solenoid valve

High pressure piston

Oil outlet

Seal HousingVent

Leakage oil

Flare line

Optional: seal gas

Sealing elements

Temperature sensor

Electric Housing48VDC connection

HydroCOM field bus

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Components of HydroCOM – Actuator

HydroCOM Installation on 3 stage hydrogen compressor

Manufacturer: Neuman & Esser

User: BAYER, Germany

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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)

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Components of HydroCOM – Hydraulic unit

Tank 63/120l

Temperature

transmitter

Level switch

(fork type)

Ex-proof motor

Oil/air cooler

Duplex filter

Pressure

transmitter

Shown: Hydraulic unit with 120l tank

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HydroCOM system layout

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HydroCOM application range

Class I, Div.1, Gr. B, C, D, T4

AEx d,e IIB + H2 T4Ex-certification US (FM)

Class I, Div.1, Gr. A, B, C, DEx-certification Canada (CSA)

ExII 2G EEx de IIB + H2 T4Ex-certification ATEX, Japan

All, except O2 + acethylenGases

ring, plateSuction valve sealing element

yesNon-lube, corrosive gases

1200 rpmMax. compressor speed

120°CMax. suction temperature

160barMax. suction pressure

(0..) 10*…100%Control range

* Minimum continuous load depends on gas composition, pressures

and compressor design

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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.

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