Hoerbiger Hydrocom system

HydroCOM13th National Award for Excellence in Energy Management 2012: 22 - 23 August 2012, HICC, Hyderabad

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HOERBIGER India Pvt LtdHoerbiger India Pvt Limited was incorporated on 1993 and is fully owned subsidiary of Compression Technology a division of Hoerbiger Group. The Company have Regional Offices in Delhi, Vadodara, Chennai, Kolkata, Guwahati and Vishakapatnam.

PRODUCTS OF HOERBIGER INDIA

- Compressor valves for various gases / applications

- HydroCOM (Stepless Capacity Control System) & Continuous Compressor Monitoring

- Wear Components -Cylinder Rings, Piston & Piston Rod , etc

- Screw Compressor Components

- Reed Valve for semi-hermetic, hermetic and air brake applications.

- Compressor Components Services & Snap Shot Monitoring.

- Altronics Engine Controls, Ignition Systems, GTI Bi-fuel systems etc

HydroCOM Stepless Capacity Control System

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HydroCOM System - Features and benefits

Automatic capacity control system for reciprocating compressor

Fast and precise (much faster than a recycle valves)

Ideal for processes requiring stable dynamic control

Rapid response to changing demands (e.g. caused by problemswith up-/downstreams equipment or consumers)

High energy savings for quick amortisation

Only the required gas flow is compressed (no recycling)

Reduced tax for CO2 emissions


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HydroCOM Offers Outstanding Merits


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Working principle

During the compression stroke, an unloader holds the suction valve open to reduce the suction gas volume to the desired amount. HydroCOM releases the unloader at the desired capacity to close the suction valve so that only the gas remaining in the cylinder is compressed. This is also called

reverse flow principal as excess gas goes back to suction.


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Only required gas flow compressedEnergy consumption at 100% capacity with recycle valve control

Energy consumption at 50% capacity with HydroCOM

Area enclosed by pV graph is equivalent to the energy consumed


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High energy savings - ExampleTypical application:800kW compressor70% average loadEnergy costs INR 7.00 per kWh

100%70%

30%

Waste of energy:

With 30% recycle valve control :

800 x 0.3 = 240 KW Losses per year: 240 KWh * 8000 hrs

= 1,920,000 KW

Recycle Gas is waste of money:

1920000 KW * Rs. 7 = Rs 13,440,000per year

Energy saving using HydroCOM system is INR 13.4 million


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HydroCOM Key-components

HydroCOM Actuator

Compressor Interface Unit (CIU)

Hydraulic Unit


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Components of HydroCOM – Actuator


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Components of HydroCOM - Actuator

Actuator

Suction valve

Unloader


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Components of HydroCOM - CIU

Interface between PLC/DCS and actuatorsTransfers load signal from loop controller into opening/ closing commands for actuators.Hardwired I/Os and Modbus Interface for data exchange to PLC/DCSData 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 Components Installed on Compressor


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HydroCOM Application range

Control range (0..) 10*…100%

Max. suction pressure 160bar

Max. suction temperature 120°C

Max. compressor speed 1200 rpm

Non-lube, corrosive gases yes

Suction valve sealing element ring, plate

Gases All, except O2 + acethylen

Ex-certification ATEX, Japan ExII 2G EEx de IIB + H2 T4

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

Ex-certification US (FM) Class I, Div.1, Gr. B, C, D, T4AEx d,e IIB + H2 T4


HydroCOM Stepless Capacity Control System 16

Energy Savings in various Projects

Sr. Customer Plant Equipment Cost in INR Lacs

Fuel Savings MT/ Year

1 IOCL Gujarat HCU 324 20002 IOCL Mathura DHDT 262 10003 IOCL Guwahati HDT 85 5154 IOCL Barauni DHDT 225 2000


Energy Savings in various Projects

Sr. Customer Plant Equipment Cost in INR Lacs

Fuel Savings MT/ Year

1 IOCL Gujarat HCU 324 20002 IOCL Mathura DHDT 262 10003 IOCL Guwahati HDT 85 5154 IOCL Barauni DHDT 225 2000


HydroCOM Project ListSr. Customer Plant Compressor

Make Model Compressor Tag No

Motor Rating Qty Year of

Commissioning

1 Numaligardh Refinery Ltd,Numaligarh HCU Nuovo-Pignone 4HF/3 04-KA-003A (

MUG) 3.3 MW 1 May-06

2 Indian Oil Corp Ltd, Mathura OHCU Nuovo-Pignone 4HF/3 07-K-03C (MUG) 3.2 MW 1 Apr-07

3 IOCL Haldia DHDS NP 2HF/1 25-K-01A 2.8 MW 1 Mar-084 IOCL Haldia DHDS NP 2HF/1 25-K-01B 2.8 MW 1 July-08

5 Indian Oil Corp Ltd, Guwahati HTU Nuovo-Pignone 2HE/2 49-K-03B (MUG) 1.0 MW 1 Feb-09

6 BPCL Mahul, Mumbai HCU Kobe KR60/6 132-K-203B 4.2 MW 1 Apr-09

7 Chennai Petroleum Corp Ltd Chennai HCU Thomassen C45.5 207-MK-2C

(MUG) 4.2 MW 1 May-09

8 Indian Oil Corp Ltd, Mathura DHDT Mitsui C454 301-K-01A

(MUG) 4.2 MW 1 Jun-09

9 Indian Oil Corp Ltd, Barauni DHDT Thomassen C454 702-K-02B 5.2 MW 1 Jul-09

10 Indian Oil Corp Ltd, Barauni CRU BPCL 2HD/1 03-KA-02A 0.8 MW 1 Aug-09

11 Indian Oil Corporation Ltd, Gujarat, Vadodara HCU NP 3HF/3 06-KA-04A 2.8 MW 1 Nov-10

12Dresser-Rand India, Ahemdabad (IOCL, Gujarat Refinery)

VGO Dresser-Rand 14 HHE-VL 2093-KA-02 A/B 4.8 MW 2 Nov-10

13 BPCL CPCL Chennai DHDT BPCL 4HF/2 211-K1A/B 2.5 MW 2 Apr-11

14Bharat Petrolium Corporation, Kochi Refinery, Ambalmugal

DHDS NP 2HE/1 DDC-1B 1.5 MW 1 May-11

15 HPCL Vizag DHDT NP 2HE/1 60K-01-A/B 1.1 MW 2 Aug-12


HydroCOM Project ListSr. Customer Plant Compressor

Make Model Compressor

Tag No Motor

Rating Qty Year of Commissioning Remarks

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Thomassen Compression Systems ( Reliance Industries Ltd, Jamnagar)

JERP Thomassen C856 MC-RHZ-353-C01 A/B/C 13 MW 3 Jan-09

OE Fitted. Comm by

HVW

17 Neuman & Esser (BPCL Cochin Refinery) VGO N&E 3SVL500 VH-C-02 A/B 6.0 MW 2 Jan-11

OE Fitted. Comm by

HVW

18Neuman & Esser (HPCL

(HPCL Bhatinda Refinery)

- N&E 2SZL500 507-K-002A-B - 2 Jan-12OE Fitted. Comm by

HIPL

19Neuman & Esser (HPCL

(HPCL Bhatinda Refinery)

- N&E 2SZL500 509-K-002 A/B - 2 Mar-12OEM -

GreenfeildProject


HydroCOM - Key Features

Only the required gas flow is compressed (no recycling)

Automatic capacity control system for reciprocating compressor

Saves energy and improves controllability

Ideal for processes requiring stable dynamic control

Rapid response to changing demands

Around 900 Installations Worldwide.

In India, 48 Sold & 25 Running. Other will be commissioned in 2012-13


HydroCOM - Key Features

Reduced tax for CO2 emissions

Hoerbiger Hydrocom system

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