SSPC K2700 Sequence of Operation

8/18/2019 SSPC K2700 Sequence of Operation

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SHELL MALAYSIA

SOUTH FURIOUS LEASE

Compressor Control System

Sequence of Operations

&Instruction Manual

Rev B

29 June 2011


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Shell MalaysiaCompressor Control System

Table of Contents Innovative Control Solutions Page ii

TABLE OF CONTENTS

1. GENERAL INFORMATION -------------------------------------------------- 1-1

Introduction ----------------------------------------------------------------------------------------------------------- 1-1

Compressor Control System Description & Overview -------------------------------------------------------- 1-1

2. OPERATOR GRAPHIC DISPLAYS ---------------------------------------- 2-1

Introduction ----------------------------------------------------------------------------------------------------------- 2-1

RSView ME Graphics Development Software ----------------------------------------------------------------- 2-1

Compressor HMI Screens ------------------------------------------------------------------------------------------ 2-2

Main Screen ---------------------------------------------------------------------------------------------- 2-2

Start Screen ---------------------------------------------------------------------------------------------- 2-3

Top Banner----------------------------------------------------------------------------------------------- 2-4

Trip Screens ---------------------------------------------------------------------------------------------- 2-5

Alarm Screen -------------------------------------------------------------------------------------------- 2-6

Engine Detail Screen ----------------------------------------------------------------------------------- 2-7

Compressor Detail Screen ----------------------------------------------------------------------------- 2-8

Recycle Control Screen -------------------------------------------------------------------------------- 2-9

3. PLC Logic 3-1

DCS Interface --------------------------------------------------------------------------------------------------------- 3-1

Start Sequence -------------------------------------------------------------------------------------------------------- 3-4

Sequence and Steps Table ----------------------------------------------------------------------------- 3-4

Unit Shutdown (Step 0) -------------------------------------------------------------------------------- 3-4

Permissives Not Met (Step 10) ------------------------------------------------------------------------ 3-4

Unit is Ready to Start (Step 20) ----------------------------------------------------------------------- 3-4

Drain/Purge Fuel Gas Line (Step 30) ----------------------------------------------------------------- 3-4

Purge Compressor (Step 40) --------------------------------------------------------------------------- 3-5

Purge Compressor xxx Sec Remaining (Step 50) --------------------------------------------------- 3-5

Open Bypass & Recycle Valve (Step 60) ------------------------------------------------------------ 3-5

Purge Recycle Line xxx Sec Remaining (Step 70) ------------------------------------------------- 3-5

Purge Complete (Step 80) ------------------------------------------------------------------------------ 3-5

Blowdown to Start Pressure (Step 90) ---------------------------------------------------------------- 3-5

Compressor / Engine Prelube (Step 100) ------------------------------------------------------------ 3-5

Engine Crank (Step 110) ------------------------------------------------------------------------------- 3-5

Engine Purge Mode (Step 120) ------------------------------------------------------------------------ 3-5 Engine Starting Mode (Step 130) --------------------------------------------------------------------- 3-5

Engine to Idle Speed Mode (Step 140) --------------------------------------------------------------- 3-5

Open Purge Valve (Step 150) ------------------------------------------------------------------------- 3-6

Open Suction Valve (Step 160) ----------------------------------------------------------------------- 3-6

Engine Warm-Up (Step 170) -------------------------------------------------------------------------- 3-6

Engine Oil Temp (Step 180) --------------------------------------------------------------------------- 3-6

Verification of Discharge Valve Opening (Step 190) ---------------------------------------------- 3-6

Ready to Load (Step 200) ------------------------------------------------------------------------------ 3-6


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Table of Contents Innovative Control Solutions Page iii

Load Control Enabled – Engine Speed (Step 210) -------------------------------------------------- 3-6

Close Bypass Valve (Step 220) ----------------------------------------------------------------------- 3-6

Compressor Loading (Step 230) ---------------------------------------------------------------------- 3-6

Load Control Enabled (Step 240) --------------------------------------------------------------------- 3-6

Compressor Unloading (Step 250) -------------------------------------------------------------------- 3-7

Open Bypass Valve (Step 260) ------------------------------------------------------------------------ 3-7

Engine Speed back to Idle (Step 270) ---------------------------------------------------------------- 3-7

Unit Normal Stop Cooldown (Step 280) ------------------------------------------------------------- 3-7

Post Lube (Step 290) ----------------------------------------------------------------------------------- 3-7

ESD (Step 500) ------------------------------------------------------------------------------------------ 3-7


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GENERAL INFORMATION Innovative Control Solutions Page 1-1

1. GENERAL INFORMATION

Introduction

The supplied Compressor Control System is intended to provide the interface for control andmonitoring of the Valerus supplied compression equipment at the South Furious Lease facility. Thismanual covers the following items:

Compressor Control System Description & Overview

Operator Interface Screens

Sequence of Operations

Compressor Control System Description & Overview

Each compressor control system is packaged in a pair of enclosures. One is a NEMA 4x stainlesssteel enclosure mounted on the local skid and contains a local PanelView, pushbuttons, lights andengine interface hardware and terminals. The second is a NEMA 3R steel enclosure to be fieldmounted in the site’s equipment room. It contains the actual PLC, a second PanelView.

The compressor control system is designed to accept one (1) incoming 120-240VAC 50/60Hz sourcefrom the UPS. Refer to drawings UPS-01 for AC power distribution connections.

The compressor control system utilizes Allen Bradley ControlLogix® PLC hardware and twoPanelView Plus 1000® Human Machine Interface HMI unit to facilitate control and monitoring of thesupplied compressor package. The Allen Bradley ControlLogix PLC hardware includes singleprocessor, Ethernet communications, local I/O chassis. The RedLion® Controller is supplied to allowfor communication using MODBUS® protocol to poll data registers within the PLC via ModbusIP andto gather data from the Waukesha ESM via RS485.


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OPERATOR GRAPHIC DISPLAYS Innovative Control Solutions Page 2-1

2. OPERATOR GRAPHIC DISPLAYS

Introduction

This section contains information about the operator control station, preparation for operation,description of control graphic operation, and illustrations that supplement and aid in understandingthe text. This information is intended to assist operations and maintenance personnel, and itdescribes both the manual functions an operator performs and the automatic functions generated bythe control system logic.

The compressor control system includes an Ethernet network and one PanelView Plus 1000graphical interface operating station. The PanelView Plus 1000 HMI is connected to the Ethernetnetwork via a switch that also provides internal network connectivity to the ControlLogix PLChardware.

RSView ME Graphics Development Software

Allen-Bradley’s RSView Studio software was utilized for development of the custom control andmonitoring graphics for the supplied control system. The software allows both static and dynamic

information to be displayed and/or controlled on the supplied Allen-Bradley PanelView Plus 1000touch-screen Human Machine Interface (HMI). The HMI continuously scans the PLC over theEthernet network to update displays, alarms, and logs archived data for use on trend screens.


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Compressor HMI Screens

Main Screen

The PanelView Plus 1000 HMI unit supplied with the compressor control panel includes a Main screenwhich is displayed when initially powered up. The Main screen which is shown above, includes buttonsthat allow navigation to other screens by touching them. The Main screen is accessible from everyscreen which always allows the operator to navigate to any screen within the HMI within two (2) touch

selections or less.

The Main screen also includes a login selector that will display additional screens when the controlsystem is placed in Maintenance or Configuration mode. A login ID and password are required in orderto place the control system into Maintenance mode and have access to the other screens.

There are 3 Levels of Users and Passwords:

1. Operator No Password

2. Tech Password Protected

3. Engineer Password Protected

The Current User indicates either Operator or Maintenance when Tech or Engineer is logged in.

A “ Forces Enabled” or “Simulator On” will appear in the upper left corner of the screen when one, orboth, of these conditions exist.

The “ICS” Logo will shut down the PanelView application and provide access to the basic PanelView

functions like time and date.

The Maintenance Section is not visible when the Login is Operator.


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Start Screen

The “Start” screen is accessed from the “ Main” screen by touching the “Start” screen button. The“Start” screen includes a blue banner located towards the top of the screen that indicates what state thatthe sequence is in or if there is a trip active that has not been reset the banner changes to read the FirstOut trip. Refer to the Sequence Chart included herein for further details and other sequence steps andthe Cause and Effect chart for trips.

The “Start” screen displays critical start-up process parameters. The status of the suction, blowdown,

discharge and recycle valves are each shown at the bottom of the screen. As previously mentioned, a button labeled “Main” is located at the bottom of the screen which providesnavigation back to the Main screen. A “Reset” touch button is also included at the bottom of the screenand performs the same function as the “Reset” pushbutton located on the front of the control panel door.The compressor “ Start” and “Stop” touch buttons are also located at the bottom of this screen alongwith the “Local” and “ Remote” mode indications these HMI buttons have corresponding hardwiredswitches mounted on the front of the control panel.

The “ SIM ON” indication is only visible when the control system is in “Simulation” mode. When thecontrol system is in “Simulation” mode all values, equipment status, and indications are being provided bysimulation logic located in the PLC processor. All field devices will default to a safe shutdown state andwill not move, or change while the control system is in “Simulation” mode. “Simulation” mode should onlybe enabled, or selected, when the compressor package is not running. This feature is provided fortraining and trouble-shooting purposes only.


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Top Banner

The top banner on several of the HMI screens shows the same information.

If any trip is active the banner shows the “First Out”. Keep in mind that there may be additional “Trips”

that will prevent the unit from resetting. Also the First Out doesn’t reset until ALL trips reset. So whatyou see in the red banner is what shut you down but not necessarily what is keeping the unit from

resetting. Navigating to the Trips screens are the only way to see all active trips. Anytime the banner is

red showing a first out touching the banner will change the screen directly to the Trips 1 page.

When the banner is Blue it is showing what step you are in of the sequencer. Refer to the Sequence and

Steps chart for additional information.

In several steps the compressor is waiting for something to happen such as a timer, temperature or RPM.

During these steps the banner will show what it is waiting for and/or the target it is trying to achieve.

One step is “Permissives Not Met” you cannot start the unit unless all the start permissives are made.

This includes No Trips, valves in auto, RPM at zero and so on. By touching the Blue banner only in this

step will take you to the Permissives’ screen and show you exactly what is keeping you from starting. Atother times the Permissives Screen is available from the Main Menu.


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Trip Screens

The “Trip” screens may be accessed from the “Main” screen by touching the “Trips” touch button. The“Trips 1” screen will appear upon touching the “Trips” touch button located on the “Main” menuscreen. The “ Trips 2” and “ Trips3” screens is accessed by depressing the “Next” touch button located

at the bottom of the “Trips 1” screen. The “Next” touch button located at the bottom right side allowsnavigation between the three “Trips” screens.

Every trip that is associated with the compressor package is shown on the three (3) trip screens with abox on the left side. The color “green” inside the box indicates that the condition is normal, the color“red” indicates a First Out Trip condition.

The “ Trip 1” screen shown above indicates that the Suction Scrubber Level 1st Stage High switch is in a

tripped condition. All trips are indicated on the “Trip” screens regardless of if the unit is running or not. Any trip that exists cannot be reset until the external device, or condition, has cleared first. All trips mustbe reset from the control panel or HMI screen after the condition has been corrected. In the exampleshown above, the water would have to either be drained from the scrubber to clear the high levelcondition, or the problem associated with the level sensing device corrected before the reset button willclear the trip condition.

Multiple “ALM” indications means there are, or were, multiple faults that occurred during the compressortrip. It is not unusual to have secondary alarms when a trip occurs.

Note: The “TRIP” indication is the most important indication on the screen. The “Trip” indication alsoserves primarily as a “ First Out” indication. Anytime the compressor package experiences a shutdownunintentionally due to a trip, the condition that initiated the first trip will be flagged with a “Trip” indicationas shown above. There will only be one “Trip” or “First out” indication.


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Start Screen 1 with an active trip condi tion

The banner on the “Start” screen will change to the color red and will also include the “First Out”trip as well.

Alarm Screen

The “Alarm” screen may be accessed from the “ Main” screen by touching the “Alarm” touch button.Refer to color code legend located in the bottom right corner of the screen. The Alarm screen alsoincludes touch buttons that provide alarm acknowledge and reset functionality.


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Engine Detail Screen

The “ Engine Detail” screen is accessed from the “Main” screen by touching the “ Engine Details” screen button. The “ Engine Detail” screen includes a banner located towards the top of the screen thatindicates Sequence Step or First Out.

The “ Engine Detail” screen includes status and indications of items that are critical to the safe operationof the supplied engine package.

As previously mentioned herein, a button labeled “ Main” is located at the bottom of the screen whichprovides navigation back to the “Main” screen. A “ Reset” touch button is also included at the bottom ofthe screen and performs the same function as the “ Reset” pushbutton located on the front of the controlpanel door.

The “Total Hours” is read from the Waukesha ESM system and cannot be reset by anybody. The“Ressetable Hours” is a function built in to the PLC and can be reset by Technician or Engineer levelpassword. A Reset Button becomes visible when the proper login is active.


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Compressor Detail Screen

The “ Compressor Details” screen is accessed from the “Main” screen by touching the “ Comp Details” screen button. The “ Compressor Details” screen includes a banner located towards the top of thescreen that indicates Sequence Step or First Out.

The “Compressor Details” screen includes the quantity of cylinders that are physically supplied with thepackage. The cylinders shown on the screen are intentionally laid out to match the physical location ifviewed from the top. This screen also includes the cylinders rod load, pressure and temperature

indications. Other parameters included suction and discharge pressures, compressor oil pressure &temperature indications, oil flow.

As previously mentioned herein, a button labeled “ Main” is located at the bottom of the screen whichprovides navigation back to the “Main” screen. A “ Reset” touch button is also included at the bottom ofthe screen and performs the same function as the “ Reset” pushbutton located on the front of the controlpanel door.


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Recycle Control Screen

The “Recycle Contro l” screen is accessed from the “Main” screen by touching Recycle Control Buttonor from the start screen by touching the “Recycle Valve”. This screen also includes a banner locatedtowards the top of the screen that indicates Sequence Step or First Out.

This screen includes three (3) PID control loops and one (1) Manual/Auto (M/A) face plate to facilitate“Automatic” and “ Manual” mode operation of the compressor control system. The Suction, Discharge,

and Pct Load Control PID loops are all placed in either the “Automatic” or “Manual” mode at the sametime from the M/A Station shown on the left side. These three (3) PID loops cannot be independentlyselected for Automatic or Manual mode operation since their control schemes are complex and internallycoordinated within the PLC logic.

The mode of each of the three (3) PID controllers is determined by the (M/A) control station that isdisplayed on the left side of screen. The M/A control station can be functionally operated along withproviding status indications as described below:

If the operator makes “MAN” selection, the “ MAN” button will change from gray to red. The M/A Stationon the left side of the screen will provide manual adjustment by adjusting the slider bar.

If the operator makes “ AUTO” selection, the “ AUTO” will change from gray to green and the three PIDcontrol loops will be controlled in “ AUTO” mode. The SP control function will only work in “ AUTO” mode

and is controlled through the touch areas marked “ SP ” decrease and “ SP ” increase buttons.

The “ SETPOINT” for each PID control loop can also be changed through the data entry touch area. Thiscan be achieved by touching the SP value area and typing/entering in the desired number on the pop-upnumeric keypad.

PV – “ PROCESS CONTROLLED VARIABLE” from the analog input module, scaled to engineeringunits, and displayed by a green bar graph and analog value.

SP – “ SETPOINT” analog value from the operator interface screen to the PLC, scaled to engineeringunits, and displayed by a cyan bar graph and analog value.

OUT – “CONTROLLED VARIABLE OUTPUT”, or “ CV” to the analog output module, scaled to 0 - 100PCT and displayed by a yellow bar graph and analog value.


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Trend Screens

Two Trend process screens are available, one for compressor temperature inputs and the other forcompressor pressure inputs. Each process trend screen is accessed from the main menu. Real time datais shown below trend in color code to the chart pen. Trend control buttons allow the operator to changethe trend viewing parameters. The Engine Trend (shown below) is also available for access from themain menu this screen provides face plate data for speed control along with the trend object.


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3. PLC LOGICThe PLC is an Allen Bradley ControlLogix PLC with a custom program to control and monitor the

compressor. The program is done with the software RSLogix 5000 Version 17.0. The program utilizes

several options and programming languages available from the RSLogix 5000 software including:

Ladder Logic programming Sequential Function Chart programming

Structured Text programming

User defined data types

Add-On instructions

Communication between the PLC, HMI and other equipment utilizes an Ethernet network with static IP

addresses in the 192.168.1.0 network.

DCS InterfaceAll DCS interface is done through the following tags. DCS_Analog and DCS_Digitals should only be

read by the DCS, it should never attempt to write to these registers. The DCS_Command andDCS_Setpoints are Read/Write. The DCS should monitor and “Track” these values and only write to

them to send commands. The DCS_Commands are Boolean commands where 0 is the normal state and a

Pulse of a 1 sends and initiates the command.

Tags:

DCS_Analog an array of 50 Real 32bit read only float valueso [0] Not Usedo [1] Engine RPMo [2] First Stage Suction Pressure in PSIGo [3] First Stage Discharge Pressure in PSIGo

[4] Second Stage Discharge Pressure in PSIGo [5] Third Stage Discharge Pressure in PSIGo [6] Not Usedo [7] First Stage Scrubber Level in Percento [8] Second Stage Scrubber Level in Percento [9] Third Stage Scrubber Level in Percento [10] Not Usedo [11] Not Usedo [12] Not Usedo [13] Air Receiver Pressure in PSIGo [14] Fuel Gas Flow in Percento [15] Compressor Cylinder 1 Temp in DegFo

[16] Compressor Cylinder 2 Temp in DegFo [17] Compressor Cylinder 3 Temp in DegFo [18] Compressor Cylinder 4 Temp in DegFo [19] Compressor Oil Temp in DegFo [20] Compressor Oil Pressure in DegFo [21] Not Usedo [22] Not Usedo [23] Engine Jacket Water Temp in DegFo [24] Aux Water Temp in DegF


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o [25] Engine Left Turbo Temp in DegFo [26] Engine Right Turbo Temp in DegFo [27] Engine Cylinder Left 1 Temp in DegFo [28] Engine Cylinder Left 2 Temp in DegFo [29] Engine Cylinder Left 3 Temp in DegFo [30] Engine Cylinder Left 4 Temp in DegF

o [31] Engine Cylinder Left 5 Temp in DegFo [32] Engine Cylinder Left 6 Temp in DegFo [33] Engine Cylinder Right 1 Temp in DegFo [34] Engine Cylinder Right 2 Temp in DegFo [35] Engine Cylinder Right 3 Temp in DegFo [36] Engine Cylinder Right 4 Temp in DegFo [37] Engine Cylinder Right 5 Temp in DegFo [38] Engine Cylinder Right 6 Temp in DegFo [39] Engine Oil Temp in DegFo [40] Engine Oil Pressure in PSIGo [41] Engine Load in Percento [42] Recycle Valve Position in Percent (0% = Closed)

o [43] Not Usedo [44] Not Usedo [45] Cooler Vibration in Milso [46] Compressor Vibration DE in Milso [47] Compressor Vibration NDE in Milso [48] Engine Vibration DE in Milso [49] Engine Vibration NDE in Milso [50] Not Used

DCS_Digitals an array of 51 (16 bit) read only integerso [0] First Out 0=”No First Out” 1-144 see “Trip Index” from C&Eo [1] Trips 1-16 as digital alarms Bit 0 is trip 1 and so ono [2] Trips 17-32 as digital alarms

o [3] Trips 33-48 as digital alarmso [4] Trips 49-64 as digital alarmso [5] Trips 65-80 as digital alarmso [6] Trips 81-96 as digital alarmso [7] Trips 97-112 as digital alarmso [8] Trips 113-128 as digital alarmso [9] Trips 129-144 as digital alarmso [10] Not Usedo [11] Alarms 1-16 as digital alarms see “Alarm Index’ from C&Eo [12] Alarms 17-32 as digital alarmso [13] Alarms 33-48 as digital alarmso [14] Alarms 49-64 as digital alarms

o [15] Alarms 65-80 as digital alarmso [16] Alarms 81-96 as digital alarmso [17] Alarms 97-112 as digital alarmso [18] Alarms 113-128 as digital alarmso [19] Not Usedo [20] Not Usedo [21] Purge Valve Status

Bit 0 = Closed Limit Switch Bit 1 = Opened Limit Switch


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Bit 2 = Faulto [22] Suction Valve Statuso [23] ByPass Valve Statuso [24] Blowdown Valve Statuso [25] Discharge Valve Statuso [26] Fuel Block Valve Status

o [27] Cooler Motor Status Bit 0 = Run Permit OK Bit 1 = Start Permit OK Bit 2 = Safety Interlock OK Bit 3 = Ready Bit 4 = Auto Bit 5 = Manual Bit 6 = Alarm Bit 7 = Proven Bit 8 = Start Fail Bit 9 = Stop Fail Bit 10 = Tripped

Bit 11 = Secondary Fault Bit 12 = Safety Fault Bit 13 = Run Permit Fault Bit 14 = Other Fault Bit 15 = Any Fault

o [28] – [49] Not Usedo [50] Boolean inputs

Bit 0 = Not Trips Active Bit 1 = Any Alarm Active Bit 2 = New Alarm Unacknowledged Bit 3 = Purge Valve in Auto Bit 4 = Suction Valve in Auto

Bit 5 = ByPass Valve in Auto Bit 6 = Blowdown Valve in Auto Bit 7 = Discharge Valve in Auto Bit 8 = Fuel Valve in Auto Bit 9 = Cooler Motor in Auto Bit 10 = Engine Speed in Auto Bit 11 = Recycle Valve in Auto

o DCS_Commands Single 16 bit Integer Read/Write from DCS Bit 0 = Remote Reset Bit 1 = Remote Stop Bit 2 = Remote Start Bit 3 = ReCycle Valve request Auto Mode Bit 4 = ReCycle Valve request Manual Mode Bit 5 = Speed Control request Auto Mode Bit 6 = Speed Control Request Manual Mode

o DCS_SetPoints array of 10 Real numbers 32 bit floating point Read/Write [0] = Load Control Operator Output Setpoint 0 – 100 Percent [1] = Speed Control Operator Output Setpoint 750 to 1200 RPM


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Start Sequence

The compressor package may be started by accessing the “Start” screen from the main menu locatedon the PanelView Plus 1000 HMI unit. The “Start” screen includes a banner that will display “Ready toStart” provided there are no trip conditions existing and Start Permits are all ok. If a trip condition exists itwill be displayed on the banner shown on the “Start” screen. If the “Ready to Start” indication is not

present proceed to the Trip screens to see what active faults are present. The trips associated with thecontrol system are outlined on the Trips screens previously shown herein. If a trip cannot be reset fromthe panel, the sensing device or abnormal condition must be corrected in order to proceed. Once all tripconditions are cleared, and a Reset has been initiated, the “ Ready to Start” will be visible on the Startscreen banner, and the package is ready to be started.

Note: Please refer to the “ Sequence Step Table” shown on the next page for a detailed list ofsequence steps and associated actions of the supplied compressor package.

Sequence and Steps Table

Refer to the attached table for the following steps:

Unit Shutdown (Step 0)

After a normal shutdown or reset from ESD this step closes blowdown valve and setup outputs for the next start.

Permissives Not Met (Step 10)

Sequence will hold here until the following conditions are met:

Purge Valve Closed and in Auto

Suction Valve Closed and in Auto

ByPass Valve Opened and in Auto

Blowdown Valve Closed and in Auto

Discharge Valve Closed and in Auto

Engine Speed less than 10 RPM

Recycle Valve Greater than 95%

Air Receiver Pressure Not Low

Cooler Motor Ready to start and in Auto

Ready to Start (Step 20)

If the Remote/Local selector switch is in the local position then compressor package may be started bypressing the “Start” touch button located on the start screen or pressing the panel mounted Start Pushbutton. If the Remote/Local switch is in the remote position then the start command must come from thedigital input signal “Remote Start” or the DCS Interface. After the start command is received then thecompressor package will either proceed to the Purge Sequence (Step 40) or advance to the Blowdownto Start Pressure (Step 90) mode. The Decision to purge is based on if any process gas pressure onthe compressor has dropped below 25 PSI. Also in while in this step waiting for a start if any of the start

permissives are lost the sequencer goes back to “Permissives Not Met”.

Drain/Purge Fuel Gas Line (Step 30)

The Sequencer is held in this step for 10 Seconds, during which the Fuel Block Valve is opened and FuelDrain Valve is also opened. After the 10 Seconds the drain valve is closed and sequencer is indexed tothe next step.


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Purge Compressor (Step 40)

“Purge Required” becomes active anytime any pressure in the unit goes below a “Purge Pressure” Set-Point typically 25 PSI. During this step the Purge Valve is opened, the Recycle Valve is closed, theBypass Valve is closed, and the Blowdown Valve is opened.

Purge Compressor xxx Sec Remaining (Step 50)Purge time is set from the HMI, typically 60 seconds. At the end of the purge timer the sequencer isindexed to the next step.

Open Bypass & Recycle Valve (Step 60)

Bypass and Recycle valves are opened. As soon as the Bypass valve come off of it’s closed limit switchand the Recyle valve is above 10% the sequence is index to the next step. We do not wait until the valveare full open.

Purge Recycle Line xxx Sec Remaining (Step 70)

After 10 Seconds (Typically) the sequencer is indexed to the next step.

Purge Complete (Step 80)

Purge valve will close. After the valve is closed, the sequencer indexes to the next step.

Blowdown to Start Pressure (Step 90)

With the suction and Purge valves closed and blowdown still open the blowdown valve is held open untilthe pressure in the unit is below “Start Pressure”, typically 200 PSI.

Compressor / Engine Prelube (Step 100)

The Engine is actually given it “Start” command at this step which starts the Engine Prelube cyclecontrolled by the Waukesha ESM. The Compressor Prelube pump will start with a 5 sec after the engine

prelube. Prelube time is set by the Waukesha Engine prelube time. After 55 seconds of Prelube or theengine start is engaged the both Compressor and Engine oil pressures are checked to verify they areabouve the LowLow Trip level. If they are not, a Prelube fail trip is activated. Sequencer is index to thenext step when engine starter is activated.

Engine Crank (Step 110)

Engine speed is monitored and the sequencer is index to the next step when speed is greater than 25RPM. If this speed is not achieved the Waukesha ESM will trip the unit for Crank Failure.

Engine Purge Mode (Step 120)

When the engine first begins cranking, the ignition is turned on but the engine fuel valve is left closed.

This is controlled by the Waukesha ESM

Engine Starting Mode (Step 130)

Once the Starter is engaged by the Waukesha ESM. This step will display crank time. Engine Provesaround 300 RPM by the Waukesha ESM.

Engine to Idle Speed Mode (Step 140)

After the engine proves running, and until engine speed will go to Idle (750 RPM)


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Open Purge Valve (Step 150)

The Purge valve is opened. Once proven open, the sequencer indexes to the next step.

Open Suction Valve (Step 160)

The suction valve is opened. Once proven open, the sequencer indexes to the next step.

Engine Warm-Up (Step 170)

The compressor is in “ Warm-up” mode for sixty (60) seconds as the typical setting. The “Warm-up” mode timer is adjustable and is accessible from the “ Timer Setting” screen. Even on “Hot” starts thisminimum warm-up period is active.

Engine Oil Temp (Step 180)

After engine warm-up timer completes, the engine oil temperature is verified to be at 110 DegF typicalsetting. The “ Oil Temperature Warm-up” setpoint is adjustable and the entry field is located on the

“ Misc. Setpoints ” display. In the event the temperature has not reached 110 DegF. After the oiltemperature is satisfied the sequence will advance. At this step the Engine speed can be put into manualand raised above the minimum idle speed. The higher engine speed can be used to assist the warm-upprocess.

Verification of Discharge Valve Opening (Step 190)

Open Discharge Valve. Once proven open, the sequencer indexes to the next step.

Ready to Load (Step 200)

As an option some units can be configured to not “AutoLoad”. If that option is activated the sequence willhold here until a manual load command is activated. This unit is configured with the “AutoLoad” Enabled

thus step is skipped.

Load Contro l Enabled – Engine Speed (Step 210)

The engine speed is accelerated from idle to a pre-determined “Minimum RPM Load” setpoint (currentlyset at 850 RPM). The “ Minimum RPM Load” setpoint entry field is adjustable and is located on the“ Misc. Setpoints ” screen. As the engine speed gets above 825 the sequence is indexed to the nextstep.

Close Bypass Valve (Step 220)

Byapss valve is closed.

Compressor Loading (Step 230)This step is not used in this compressor and is stepped through to load control enabled.

Load Cont rol Enabled (Step 240)

The PID control loops controlling the recycle control valve are released from tracking. The compressorwill operate in this step until a stop or shutdown.


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Compressor Unloading (Step 250)

The Recycle valve is placed back into output tracking and is opened to 100%. This function includes arate limiter so that the compressor unloads slowly. This is so other On-Line units can pick the load up.The current rate is 2.5% per Second. After output signal to recycle valve passes 95% the sequencer isindexed to the next step.

Open Bypass Valve (Step 260)

The Bypass valve is opened. Once proven open, the sequencer indexes to the next step.

Engine Speed back to Idle (Step 270)

Engine Speed will be switch to startup control and be put back to idle (750 RPM).

Unit Normal Stop Cooldown (Step 280)

The engine is allowed to run at idle speed, and a sixty (60) second cool down timer is initiated. The cooldown timer is adjustable and is accessible from the “ Timer Setting” screen. After the sixty (60) secondtimer has elapsed, the engine is stopped by the Waukesha ESM system. After the fuel and ignition have

been disabled the sequence will automatically advance to the “ Post Lube” (Step 290) mode.

Post Lube (Step 290)

The Waukesha ESM initiates an Engine Postlube after a normal shutdown. The compressor oil pumpswill be started 5 seconds after the engine. Both pumps will run for sixty (60) seconds. After Postlube thesequence is sent back to step 10. Also upon any shutdown other than ESD the sequencer immediately

jumps to step 290 bypassing unloading, and cooldown functions. The Post lube still continues as normal.

ESD (Step 500)

Any time a ESD Shutdown is detected the Sequencer Immediately jumps to Step 500. Thus bypass allUnloading, cooldown, and Postlube functions. Suction, Discharge and Fuel valves go close. Blowdownand Recycle valves go open. Cool down and post lube sequences are skipped.

SSPC K2700 Sequence of Operation

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Transcript of SSPC K2700 Sequence of Operation