Hydrocom Specification Petronor NP HISA V1 - 0

HydroCOM 4.
0
for
PETRONOR
Bilbao
Version 1.0
Control Specification for Implementation in the DCS
2x Nuovo Pignone 4HF/2-1
HVW order 2152296
makes compressor control

and monitoring
an easy job
Contents
1 PREFACE .............................................................................................................1
1.1 Working principle of the HydroCOM-system............................................................................1
1.2 System configuration ..................................................................................................................1
1.3 Further documents......................................................................................................................1
2 ABBREVIATIONS .................................................................................................2
3 INTRODUCTION ...................................................................................................3
4 OPERATING CONDITIONS..................................................................................4
5 SCHEME OF THE PLANT ....................................................................................5
6 CONTROLLER LAYOUT ......................................................................................6
6.1 Control strategy ...........................................................................................................................6

6.1.1 Main control variable for make-up unit ...................................................................................6
6.1.2 Additional control variables for make-up unit .........................................................................6
6.1.3 Main control variable for recycle unit......................................................................................6
6.1.4 Basic control layout ................................................................................................................7
6.2 Tasks of control ...........................................................................................................................8
6.3 Signals between field and DCS..................................................................................................9
6.4 Block-diagrams and function of the control logic in the DCS ............................................. 10
6.4.1 Basics .................................................................................................................................. 10
6.4.2 Make-up 2nd stage ............................................................................................................... 10
6.4.3 Make-up 1st stage................................................................................................................ 13
6.4.4 Recycle stage ...................................................................................................................... 15
6.4.5 Enable Hydraulic Unit.......................................................................................................... 17
6.4.6 Enable HydroCOM CIU ....................................................................................................... 17
6.5 Description of functions blocks.............................................................................................. 18

6.5.1 PI-Controller (proportional gain Kc and integral time Ti)...................................................... 18
6.5.2 Split Range .......................................................................................................................... 19
6.5.3 Limitation ............................................................................................................................. 20
6.5.4 Scaling................................................................................................................................. 21
6.5.5 Start-ramp............................................................................................................................ 23
6.5.6 Stop-ramp............................................................................................................................ 24
6.5.7 Set point interstage pressure .............................................................................................. 25
7 SPECIAL OPERATING CONDITIONS ...............................................................26
7.1 Start Sequence.......................................................................................................................... 26
7.2 Stop of compressor.................................................................................................................. 27

7.3 Shutdown sequence of the HydroCOM system .................................................................... 28
7.3.1 CIU Error ............................................................................................................................. 29
7.3.2 Hydraulic oil pressure low-low............................................................................................. 29
7.3.3 Hydraulic oil temperature high-high .................................................................................... 29
7.3.4 Hydraulic oil level low .......................................................................................................... 29
7.4 HydroCOM system warning..................................................................................................... 30

7.4.1 CIU Warning ........................................................................................................................ 30
7.4.2 Hydraulic oil pressure low ................................................................................................... 30
7.4.3 Hydraulic oil temperature high ............................................................................................ 30
1 Preface
This Software Specification outlines the control concept for the
HydroCOM system installed on two Nuove Pignone Make-
up/Recycle compressors at Petronor plant Bilbao, Spain.
This document serves as basis for the software program

implemented in the DCS, supplied by Petronor.
1.1 Working principle of the HydroCOM-system

With the HydroCOM-system the capacity of a reciprocating
compressor can be regulated steplessly.
The gas volume compressed per piston stroke is adjusted by means

of the hydraulically actuated unloaders, which delay the closing of
the suction valve.
Part of the gas in the cylinder flows back into the suction chamber.
After closing the suction valves with electronic commands,
compression of the remaining gas in the cylinder is started.
Only the amount of gas which is used by the process is

compressed. Therefore HydroCOM saves energy.
1.2 System configuration

The whole control system consists of the
• Control program / Logic in the DCS
• HydroCOM CIU (Compressor Interface Unit) representing the
interface between controller and actuators
• HydroCOM actuators which control the closure of the suction
valves according to the control signal coming from the DCS
• Hydraulic Unit which supplies the actuators with oil pressure
• External power supply (EPS), supplying 48V to the actuators
• Top-Dead-Centre sensor, triggering one impulse per
compressor revolution for CIU internal calculations
1.3 Further documents

For detailed technical information on the HydroCOM system please
refer to the document: „The HydroCOM-System - Assembly and
Installation Instructions“
Control Specification Petronor NP HISA V1_0.doc 23.03.05 / LE
-1-
2 Abbreviations
Throughout this document the following abbreviations and terms are
used:
Actuator the device controlling the closure of a suction

valve
CIU Compressor Interface Unit
DCS Distributed Control System
Enable Binary signal, activates the load signals
(4..20mA), which are sent to the CIU
EPS External Power Supply (48VDC)
GIM General Interface Unit
HSS Hoerbiger Service Software
HU Hydraulic Unit
IA Isolation Amplifier
IPS Internal Power Supply
PT Pressure transmitter
SP Split point
TDC Top Dead Centre
W Controller setpoint
Y Controller output
X Process value
-2-
3 Introduction
The HydroCOM compressor control system is an integrated
compact solution which is capable to adjust gas flow (capacity) of a
compressor steplessly between 30% (depending on operating
condition and gas) to 100%.
Because of the integrated system solution, only a „simple“ 4..20mA

control signal per stage has to be provided to the CIU (compressor
interface unit). All other HydroCOM specific signal transformations to
operate the actuators are carried out by the CIU. Thus the
HydroCOM system is very easy to integrate into existing compressor
installations and allows efficient capacity control.
The control task itself, however, is not done inside the CIU.
Therefore, controllers have to be implemented in the DCS. This
document describes the layout of the control system and how the
controller output signals must be scaled and limited to allow highest
performance of HydroCOM system.
This controller layout is based on the technical meeting of 10th of

March 2005.
-3-
4 Operating conditions
Among others the following operating conditions as design condition
are defined:
Name Gas MOL-weight Suction pressure End pressure Suction temp. Minimum load
000 (Design) H2+CH4+ 2.7 / 5.7 13.6 / 65.5bara 66.2 / 91.3bara 38.0 / 65.0°C 30% / 30%
200 (Nitrogen) N2 28.0 / 28.0 7.8 / 17.2bara 17.8 / 25.1bara 33.0 / 40.0°C 100% / 100%
Remarks: first values are make-up unit / second values are recycle
-4-
5 Scheme of the Plant
Two compressors are made of three stages (four cylinders, one for
each stage make-up and two for stage recycle) to compress gas in
two separate units: The first two stages compress gas as make-up
unit. The third stage as recycle unit delivers gas of the discharge
make-up and recycle of the process.
The running compressor shall compress as design duty a hydrogen-

hydrocarbon-mixture from suction pressure 13.6bara up to a final
pressure of 91.3bara. Suction and discharge pressure can change
slightly during operation.
Both compressors, A and B, are equipped with a HydroCOM control

system on all suction valves. One compressor is running, one is a
stand-by unit. The compressors will operate in parallel mode just for
start-up and stop of one compressor.
The HydroCOM controls the compressors not during nitrogen duty.
Over each stage of the make-up unit of both compressors are

common bypass valves. The bypass valves are designed for full
capacity of the design and nitrogen duty.
The plant layout is shown in the figure below:
Spill back valve
PT
1st stage 2nd stage 3rd stage
MAKE UP A RECYCLE A
PT PT PT
PROCESS
FT
MAKE UP B RECYCLE B
PT
Spill back valve
Figure 1.: Scheme of Plant
Following section explains how to implement the controllers in the

DCS.
-5-
6 Controller Layout
6.1 Control strategy
The tow stages of the make-up unit maintain the pressure
downstream the process acc. to the demand of gas. The recycle
stage controls the total flow to the process.
6.1.1 Main control variable for make-up unit

The main control variable for the make-up unit of the compressor is
the pressure downstream the process. The 2nd stage of the make-up
unit maintains this value.
6.1.2 Additional control variables for make-up unit

At the same time, compression over these two stages is balanced
when certain interstage pressure level is maintained. Therefore the
interstage pressure of the make-up unit is controlled, too.
6.1.3 Main control variable for recycle unit

The main control variable for the third stage of the compressor is the
common flow in the process which will be adjusted manual.
-6-
6.1.4 Basic control layout
Basically the main control variable is the pressure downstream the
process. Thus a pressure transmitter senses this pressure and
transmits the value to the DCS.
Out of this pressure signal a control loop which is programmed in

the DCS calculates the load signal for the second stage of the make-
up unit.
To maintain balanced compression ratios of the compressor, the

interstage pressures must be controlled, thus a pressure transmitter
is installed in the suction line of the 2nd stage of the compressors.
The recycle stage controls the total flow to the process (combined
flow make-up and recycle gas of the process) according a manual
load signal.
Setting of
Split-point
A A or (M) M
W W
PIC PIC HIC 090
Split- Split-
Range Range
(Manual (Manual
Input) Input)
Spill back valve
PT
PROCESS
FT
MAKE UP B RECYCLE B
PT
Spill back valve
Figure 2.: Control layout of running compressor
-7-
6.2 Tasks of control
The concept is based on a complete integration of the control logic
in the DCS.
In general the DCS is used to:

• Starting of the compressors
• Loading of the compressors
• Adjust the load signal coming to the specific requirements of
the HydroCOM system
• Control of the compressors acc. to main controllers
• Control the interstage pressure
• Control the Hydraulic Unit
• Control compressor manually for Start and Stop
• Error Handling of the HydroCOM system
Over each stage of make-up unit of both compressors are common

spillback valves, which are designed for 100% of one compressor in
design and nitrogen duty.
In normal operation only HydroCOM controls the compressor load.

The bypass valves are closed and are active if the demand of gas is
less than the minimum load.
In case of HydroCOM failure on one compressor, the concerned

compressor delivers full load by deactivating the HydroCOM system.
The bypass valve will full-fill the control task.
-8-
Main motor
Main Motor running status
Compressor A / B
Motor Hydraulic unit Start
Motor Hydraulic unit Stop

Hydraulic Unit Hydraulic oil pressure
Compressor A/ B
Hydraulic oil temperature
Hydraulic oil level

DCS.
CIU Error
6.3 Signals between field and DCS
CIU Warning
GIM of CIU of
Control Specification Petronor NP HISA V1_0.doc

Compressor A/ B CIU Enable
-9-
DCS
TDC Signal from Flywheel
16x suction valve cover temperature
SIM 1 of CIU of
Load signal 1st stage
Compressor A/ B
Figure 3.: binary and analogue signals

SIM 2 of CIU of
Load signal 2nd stage
Compressor A/ B
SIM 3 of CIU of
Compressor A/ B Load signal 3rd stage
Binary Signal
Analogue Signal
between the Hoerbiger Compressor Interface Unit (CIU) and the
The following diagram shows the binary and analogue signals
23.03.05 / LE
6.4 Block-diagrams and function of the control logic in the DCS
6.4.1 Basics
One control loop in the DCS is used per compressor stage, in total
four. Common logic functions have to be integrated in the DCS too.
The detailed explanation of all functions is in the next section

“Description of function blocks”.
Used Delay timer are defined as follows:
In In
TDON TDOFF
Out Out
Time < delay time Time > delay time time
6.4.2 Make-up 2nd stage

The figure below shows the control loop in the DCS of the make-up
2nd stage.
Pressure
Automatic or (Manual)
0..100% Load Signal
PI-Controller
Make-up unit
Set point
Pressure
Figure 4.: Load signal make-up 2nd stage

The PI-controller creates a controller output signal out of the actual
pressure and its set point. The output is used to generate the load
signal of the 2nd stage make-up of both compressors.
The PI-controller has to be configured as follows: To increase the

pressure the controller has to increase the output.
The figure below shows how this load signal has to be processed:
- 10 -
x / 100%
Split point
Load Signal
Make-up unit A
Load Signal 0..100% 0..100% x..100%

Split range Limitation
Make-up unit
Load Signal
Make-up unit B
0..100% Load signal to

Spillback valve: Selector
Spillback valve
Manual load signal Auto/Manual
2nd stage
2nd stage
Spillback valve:
Automatic / Manual
Minimum load x = 30%
Figure 5.: Control loop make-up 2nd stage

The Split range divides the load signal between the HydroCOM and
the spillback valve of the 2nd stage make-up unit. An additional input
in this function is the split point, which defines the range of the
signals which are sent to the HydroCOM and the spillback valve. For
further details please refer to the section “Split-Range”.
The Limitation block prevents the compressor of overheating by

forwarding a minimum signal to HydroCOM. For further details
please refer to the section “Limitation”.
The Auto/Manual selector of the spillback valve gives the

operator the possibility to open and close the bypass individually
from the automatic capacity control. For plant start-up, nitrogen duty
and test-runs this function is needed.
As soon as the load signal is processed in the limitation block it has

to be divided for both compressors.
- 11 -
The figures below show how these two independent loadsignals
have to be processed:
Activate = 1
Activate Stop ramp
CIU Enable Enable = 1 MAX

Comp. A
Load Signal x..100%

Load Signal
Make-up unit A Selector Selector
Scaling 2nd stage compr. A
Start ramp Stop ramp
to CIU
Start ramp
MIN
Stop ramp
Figure 6.: Processing of load signal make-up 2nd stage A
Activate = 1
Activate Stop ramp

Compr. B
Load Signal x..100%

Load Signal
Make-up unit B Selector Selector
Scaling 2nd stage compr. B
to CIU
Start ramp
MIN
Stop ramp
Figure 7.: Processing of load signal make-up 2nd stage B

The Scaling block adapts the signal coming from the PI-controller to
the specific requirements of the HydroCOM-system. For further
details please refer to the section “Scaling”.
The Start-Ramp is used to achieve a smooth start-up of a

compressor. The load has to be ramped from 0% capacity (idle) to
the actual load signal within a certain time (typical between 1 to 5
minutes). If the other compressor is running the PI controller can
reduce the load of the already running compressor and bring both to
an equal load. For further details please refer to the section “Start-
Ramp”.
The Stop-Ramp is used to achieve a smooth stop of a compressor.

The load has to be ramped from the actual load signal down to 0%
capacity (idle) within a certain time (typical between 1 to 5 minutes).
If the other compressor is running, the PI controller can increase the
load to compensate the reduced load. To activate the stop ramp a
binary signal is used. As soon as the compressor is on idle, the
compressor has to be stopped within a certain time (typical 3
minutes). For further details please refer to the section “Stop-Ramp”.
- 12 -
6.4.3 Make-up 1st stage
The figures below show the control loop of the make-up 1st stage of
each compressor:
Suction
Pressure 2nd stage
Automatic
0..100% Load Signal
PI-Controller
Make-up 1st stage
Set point
Suction Pressure
2nd stage
Figure 8.: Control loop make-up 1st stage

The PI-controller creates a controller output signal out of the actual
interstage pressure (suction pressure of 2nd stage) and its set point.
The output is used to generate the load signal of the 1st stage make-
up of both compressors.
The PI-controller has to be configured as follows: To increase the

pressure the controller has to increase the output.
The figure below shows how this load signal has to be processed:
x / 100%
Split point
Load Signal
Make-up A
1st stage
Load Signal 0..100% 0..100% x..100%
Split range Limitation
Make-up 1st stage
Load Signal
Make-up B
1st stage
0..100% Load signal to

Spillback valve: Selector
Spillback valve
Manual load signal Auto/Manual
1st stage
1st stage
Spillback valve:
Automatic / Manual
Figure 9.: Control loop make-up 1st stage

The Split range divides the load signal between the HydroCOM and
the spillback valve of the 1st stage make-up unit. An additional input
in this function is the split point, which defines the range of the
signals which are sent to the HydroCOM and spillback valve. For
further details please refer to the section “Split-Range”.

forwarding a minimum signal to the HydroCOM. For further details
The Auto/Manual selector of the spillback valve gives the

operator the possibility to open and close the bypass individually
from the automatic capacity control. For plant start-up, nitrogen duty
and test-runs this function is needed.
- 13 -
As soon as the load signal is processed in the limitation block it has
to be divided for both compressors.
The figures below show how these two independent load signals
Activate = 1
Activate Stop ramp

Comp. A
Load Signal x..100%

Make-up A Load Signal
Selector Selector
1st stage Scaling 1st stage compr. A
to CIU
Start ramp
MIN
Stop ramp
Figure 10.: Processing of load signal make-up 1st stage A
Activate = 1
Activate Stop ramp

Compr. B
Load Signal x..100%

Make-up B Load Signal
Selector Selector
1st stage Scaling 1st stage compr. B
to CIU
Start ramp
MIN
Stop ramp
Figure 11.: Processing of load signal make-up 1st stage B

details please refer to the section “Scaling”.

Ramp”.

- 14 -
compressor has to be stopped within a certain time (typical 3
minutes). For further details please refer to the section “Stop-Ramp”.
The Scaling block adapts the signal to the specific requirements of

the HydroCOM-system. For further details please refer to the section
“Scaling”.
6.4.4 Recycle stage
The figure below shows the control loop in the DCS of the recycle
stage to control the total flow to the process:
Load Signal
Manual Recycle unit A
0..100% x..100%
PI-Controller Limitation
Load Signal
Recycle unit B
Figure 12.: Load signal Recycle stage

During standard operation this Controller is set to manual mode. So
the operator will set the output manually.
In a later stage the PI-controller can work in automatic mode. Then

the controller creates a controller output signal out of a process
value (e.g. actual flow) and its set point. This output is used to
generate the load signals of the recycle stage of both compressors.

forwarding a minimum signal to the HydroCOM. For further details
- 15 -
The figures below show how these two independent loadsignals
Activate = 1
Activate Stop ramp

Compressor A
Load Signal x..100%

Load Signal
Recycle unit A Selector Selector
Scaling 3rd stage compr. A
to CIU
Start ramp
MIN
Stop ramp
Figure 13.: Processing of load signal recycle stage A
Activate = 1
Activate Stop ramp

Compressor B
Load Signal x..100%

Load Signal
Recycle unit B Selector Selector
Scaling 3rd stage compr. B
to CIU
Start ramp
MIN
Stop ramp
Figure 14.: Processing of load signal recycle stage B

details please refer to the specific section.

ramp”.

compressor has to be stopped within 3 minutes. For further details
please refer to the section “Stop-ramp”.
- 16 -
6.4.5 Enable Hydraulic Unit
The figure below shows the block diagram to enable/disable the
Hydraulic Unit.
1= HU running
HU Start HU Motor
local / automatic 0= HU off running status
1=error
Emergency stop
From DCS
1=error 1= HU enabled
HydroCOM Motor HU
OR NOT OR
system error Enable
0= HU off
0= operation
Maintenance switch
1= maintenance
Figure 15.: Block diagram to enable and disable the HU in the DCS
The Hydraulic Unit is started locally at the compressor or

automatically. As long as the “HydroCOM system error” is not active,
the Hydraulic Unit can be operated. For details of this signal
generation refer to section “shutdown sequence”.
If the “HydroCOM system error” is active and the Hydraulic unit

should be started for maintenance or testing reasons the binary
signal “Maintenance” has to be activated.
6.4.6 Enable HydroCOM CIU

The figure below shows the block diagram to enable the HydroCOM
control.
HU motor 1=on TDOFF

running status 30sec
Main motor 1=on TDON 1=enable Enable

AND
running status 20sec to CIU
HydroCOM 1 = error TDON

NOT
system error 30sec
Figure 16.: Block diagram to enable HydroCOM system in Interface

controller
The signal “Enable”, which activates the HydroCOM system, is

generated automatically 20 seconds after compressor start. For
details of the start sequence refer to the section “start sequence”.
Once a failure occurs (so the HU is stopped) or the compressor is

stopped, the “Enable” is reset. A HydroCOM system error interlock a
setting of the Enable signal. When a HydroCOM system error occurs
the Enable is reset with 30 seconds delay.
- 17 -
6.5 Description of functions blocks
6.5.1 PI-Controller (proportional gain Kc and integral time Ti)
The PI controllers can be adjusted to the controlled system with their
controller parameters, the integral time (Ti) and the proportional gain
(kc).
Fine tuning of these parameters has to be done during start-up in

the field, however values in the range as stated in the following
(based on experience) may be used as start values for the
optimisation:
kC 0.8-3.5
Ti 10-90s
with the following definition of a PI-controller:
⎛ t ⎞
y (t ) = k c ⎜ e (t ) + ∫ e(τ ) dτ ⎟⎟
1
⎜ Ti
⎝ 0 ⎠
kC proportional gain
Ti integral time
e control error
y control signal
- 18 -
6.5.2 Split Range
The HydroCOM-system as well as the bypass valves are using the
same controller output signal. Therefore, the control signal is split up
into two signals: One for the HydroCOM actuators and one for the
spillback valve (bypass valve).
The logic for the Split-point is defined as follows:

1 = enable
CIU Enable
HydroCOM 1 = error
NOT AND
system error
100 %
Selector
input = 0
x / 100% Split point to
Selector Split range
x% function block
Selector
input = 1 Minimum load x = 30%
The characteristics of this split range function is shown below:
Split Range
Split Range Bypass valve/HydroCOM
100% Bypass valve/HydroCOM 100% 100% (in failure condition) 100%
(open) (open) HydroCOM
Control Signal bypass valve
Control Signal bypass valve
Control Signal HydroCOM
Control Signal HydroCOM

Byp
B
O
yp
oC
ass
as
dr
s
Output:
Output:
Output:
Output:
Hy
va
valv
l ve
e
0% 0% 0% 0%
(closed) 0% SP=30% 100% (closed) 0% SP=100%
Input: controller output signal Input: controller output signal
Typically the split range function is programmed as follows:
SP Split point = 30% or 100% (lower value = minimum load)

YInput PI Controller load signal 0….100% (100% = full-load)
YHydroCOM Control signal HydroCOM 0….100% (100% = full-load)
YBypass Control signal bypass valve 0….100% (0% = full-load)
If SP = 30% ( = minimum load)

If YInput ≤ SP then:
YHydroCOM = 0% (due to limitation later: minimum load)
YBypass = 100% - (YInput ⋅ 100% / SP)
Else:
YHydroCOM = (YInput – SP) ⋅ 100% / (100% - SP)
YBypass = 0%
Else:
YHydroCOM = 100%
YBypass = 100% - YInput
- 19 -
6.5.3 Limitation
This function prevents the system on overheating at part load. If the
HydroCOM is driven on low load for a longer time, then the suction
gas temperature increases due to valve losses which occur during
suction and reverse flow. Following diagrams show the suction gas
heating effect based on actual load conditions. To prevent damage
to suction valves and to the compressor, the load has to be limited.
Estimated suction and discharge temperature

as function of the compressor load
Duty: Design (000)
200°C
190°C Make-up 1st stage
180°C Make-up 2nd stage
170°C
Recycle
160°C
150°C
140°C
130°C
Temperature [°C]
120°C
110°C Discharge temperature
100°C
90°C
80°C
70°C
60°C Suction temperature
50°C
Minimum Load
40°C
30°C
20°C
10°C
0°C
0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100%
Capacity [%]
Figure 17.: Estimated suction and discharge temperatures

The characteristics of this limitation function is shown below:
Limitation
HydroCOM Make-up 1st and 2nd / Recycle
100%
signal HydroCOM
M
Limited control
O
C
ro
Output:
yd
H
x = 30%
Minimum load
0% 100%
Input: split range output
Figure 18.: HydroCOM Limitation
- 20 -
Typically the limitation function is programmed as follows:
YInput Split range output 0….100% (100% = full-load)

YHydroCOM Control signal HydroCOM 30…100% (100% = full-
load)
YHydroCOM = x + YInput ⋅ (100% -x ) / 100%
In this application (x = 30%)
YHydroCOM = 30% + YInput ⋅ 70/100
Remark: The input signal to the Limitation function will be rescaled

and as lowest value the minimum load is defined.
6.5.4 Scaling
A scaling block is required to scale the 0%...100% signal to a
4..20mA signal which is between a minimum (MIN) and a maximum
(MAX) current (as shown below).
This block allows higher controller dynamic by cutting off the lower
and upper dead band.
These dead bands are caused by the fact that the HydroCOM is an
universal system for all sizes of reciprocating compressors. To
compensate the different geometries the control signal to the CIU
has to be scaled. In between those two points the change rate of the
capacity is almost linear and needs not to be linearized.
The following diagrams show the relation between loadsignal(s)

from the controller (=compressor capacity) and actual control
signal(s) to the SIM(s) of the CIU.
Control signal versus capacity

Duty: Design (000)
100% 20,0mA
94% 19,0mA
88% Make-up 1st stage 18,0mA
81% Make-up 2nd stage 17,0mA
75% Recycle 16,0mA
69% 15,0mA
63% 14,0mA
control signal to CIU
control signal to CIU
56% 13,0mA
50% 12,0mA
44% 11,0mA
38% 10,0mA
31% 9,0mA
25% 8,0mA
Minimum Load
19% 7,0mA
13% 6,0mA
6% 5,0mA
0% 4,0mA
0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100%
compressor capacity (equals to controller signal)
Figure 19.: Control signals for the HydroCOM-system versus load/capacity
- 21 -
From above diagram following control current limits can be
determined:
Make-up 1st stage: Control signal

Maximum load limit 100% load 18.0mA MAX≅88%
(Minimum load limit at 30% load) 9.7mA MIN(30%)≅36
%
Minimum load limit at 0% load 6.5mA MIN≅16%
Make-up 2nd stage: Control signal

Maximum load limit (100% load) 18.0mA MAX≅88%
%
Recycle: Control signal

Maximum load limit 100% load 18.0mA MAX≅88%
%
Above limits have to be adjusted and optimized during

commissioning.
The control signal to the HydroCOM which are 4..20mA have to be

scaled to signals as shown above.
- 22 -
6.5.5 Start-ramp
In general a linear ramp function leads the make-up 1st , 2nd and
recycle stage of the compressors smoothly from 0% load to the
actual load signal, at least to minimum load from Limitation block. At
this point the ramp is quit and operation is passed over to the PI-
controller of the DCS.
The start-ramp is enabled with setting of the signal “HydroCOM

enable”. Typically 20 seconds after compressor start.
A typical ramp-rate is between 0,2..0,5%/sec, according to the

application.
CIU Enable
on
off
time
Typically 1 to 5 minutes
Load signal from

Control signal Limitation block
to scaling block Load signal to
Scaling block
100%
Start ramp
30%
0% Start-Ramp
stopped time
Figure 20.: Functionality of the start-ramp HydroCOM
The start-ramp forces the HydroCOM to delivery at least Minimum

load. So sooner or later the check valve after the compressor will
open and let the compressed gas through to the process. The rest of
the gas will be recycled by the spillback valve.
For details to start the compressor please refer to the section “Start
sequence”.
- 23 -
6.5.6 Stop-ramp
In general a linear ramp function leads the make-up 1st , 2nd and
recycle stage of the compressors smoothly from the actual load
signal to 0% load. At this point the ramp is quit and the operator has
to stop the compressor within a certain time (e.g. three minutes).
The stop-ramp is enabled with setting of the signal “Activate stop-

ramp”.
A typical ramp-rate is between 0,5..1%/sec, according to the

application.
Activate
Stopramp
on
off
time
Control signal Load signal to Load signal from

to scaling block Scaling block Limitation block
100%
Start-Ramp
Stop ramp
30% stopped
0%
time
Figure 21.: Functionality of the stop-ramp HydroCOM
For details to stop the compressor please refer to the section “Stop
sequence”.
- 24 -
6.5.7 Set point interstage pressure
The PI-controller compares the actual interstage pressure with a
defined set point. This set points can be calculated out of the actual
suction pressure make-up 1st stage and discharge pressure make-
up 2nd stage to reach equalized compression ranges over all two
stages.
The set point is calculated as follows:
Suction pressure 2nd stage:

1
⎛p ⎞ 2
p S 2 = k S 2 ⋅ p S 1 ⋅ ⎜⎜ D ⎟⎟
⎝ p S1 ⎠
ps2 suction pressure 2nd stage

ps1 suction pressure 1st stage
pd discharge pressure 2nd stage
ks2 coefficient of correction
note: use pressure for calculation in absolute values only !
The correction factors allow compensating of pressure drops in

drums, interstage coolers, etc. to optimise the set points.
Example:
ps1 ps2 pd
Cond. 000 (ITKK) 13.59 29.58 66.20
Ideal 13.59 29,96 66.20
Correction factor 0.99
All pressures in bara
For start-up use the following coefficient:
ks2 = 0,99
- 25 -
7 Special operating conditions
7.1 Start Sequence
Before starting the compressor main drive, the hydraulic unit must
be started manually or automatically (e.g. together with the oil-pump
of the compressor).
The sequence is defined as follows:
Compressor
drive
on
Compressor drive is started and the
signal “Main motor running status” is
off set in the DCS.
time
Main motor
running status
on
off
time
Motor speed
max
After short time, normal speed of the
0 compressor drive is reached.
CIU Enable time
on
After 20s the enable signal for the CIU
off is set by the DCS. The compressor is
time ready to feed gas.
Now the start-ramp function block

Control signal
Load signal from ramps the load of the HydroCOM
Limitation block Load signal to
to scaling block smoothly to the actual load, at least to
Scaling block
100% minimum load. Now the PI-controllers
control the compressor according to
the set points.
Start ramp
30%
If the load is less than the minimum
0% Start-Ramp load the gas in the make-up unit is
stopped time recycled by the spillback valve. The
gas in the recycle unit is recycled via
Figure 22.: Start sequence of the compressor with the process.
HydroCOM
- 26 -
7.2 Stop of compressor
To stop the compressor and do not harm the process by immediate
load steps (capacity reduction) the compressor has to brought to idle
operation. This will be done by a stop ramp. This sequence ends in
an unloaded compressor. As soon as the compressor is unloaded
the compressor has to be stopped within a certain time (e.g. the next
three minutes).
The sequence is defined as follows:
Activate
Stopramp
on
By setting the signal “Activate Stop-
off ramp” the stop-ramp function is
time initialized.
Control signal Load signal to Load signal from This functions will ramp the load down
to scaling block Scaling block Limitation block to idle operation.
100%
Within the next three minutes the

Start-Ramp
compressor has to be stopped.
Stop ramp
30% stopped
30 seconds later the Enable signal will
0%
be reset. For further details please
time
refer to the section “Enable CIU”.
Maximum 3 minutes
Compressor
drive
on
off
CIU Enable time
Time delay 30seconds
on
off
time
Figure 23.: Stop sequence of the compressor with

HydroCOM
Control Specification Petronor NP HISA V1_0.doc14.03.05 / PRC
- 27 -
7.3 Shutdown sequence of the HydroCOM system
The processing of this signal has to be done in the DCS.
Under some error conditions it is required to disable the HydroCOM

system. In these cases the control task can be no longer done by
HydroCOM. This section explains which errors result in such
operation changes. The “HydroCOM system error” gets active, the
HU will be disabled and stopped.
Consequently the compressor is then delivering 100% of load. The

control will be done by the bypass valve (see section “split range”)
At the same time the binary signal “HU motor running” will be reset.
Once the “HydroCOM system error occurred, the enable to the CIU
is reset as well (delayed for 30sec). For details refer to section
“Block diagrams to Enable HydroCOM”.
0=error
CIU Error NOT
HU Motor 1=running TDON

Running 30sec
1 = error HydroCOM
TDON
AND OR System
3sec
Error
Hydraulic Oil 1=low-low
Pressure Low-Low
Shut down
Hydraulic Oil 1=high-high

Temperature High-High
Shut down
Hydraulic Oil
0=low
Level Low NOT
Shut down
Figure 24.: Logic operation of the HydroCOM shutdown sequence
- 28 -
7.3.1 CIU Error
The integrated diagnostic function of the HydroCOM-system has
detected one or more electric or electronic errors. Concerned
suction valves have been unloaded automatically.
For a detailed error description please refer to the “CIU operating

instructions” manual.
7.3.2 Hydraulic oil pressure low-low

The integrated sensor for the hydraulic unit reads a hydraulic oil
pressure lower than 90bar. As a result HydroCOM actuators can no
longer unload the suction valves, thus the compressor delivers full
load. The hydraulic unit has to be switched off automatically. This is
an ATEX requirement.
Hydraulic Oil 1=Shutdown HU Hydraulic Oil

1=<80bar
Pressure Sensor Pressure
Low-Low Shut down HU
Figure 25.: Logic hydraulic pressure low-low
7.3.3 Hydraulic oil temperature high-high

The integrated sensor for the hydraulic unit reads a hydraulic oil
temperature higher than 80°C. The hydraulic unit has to be switched
off automatically. This is an ATEX requirement.
Hydraulic 1=Shutdown HU
1=>80°C Hydraulic Oil Temp.
Oil Temperature
Shut down HU
High-High
Figure 26.: Logic hydraulic oil temperature high-high
7.3.4 Hydraulic oil level low

A level switch is installed in each hydraulic unit to measure the
hydraulic oil level of the Hydraulic Unit. The hydraulic unit has to be
switched off automatically. This is an ATEX requirement.
Hydraulic Oil 0=low 1=Shut down HU Hydraulic Oil

Level Sensor NOT Level Low
Low Shut down HU
Figure 27.: Logic hydraulic oil level switch
- 29 -
7.4 HydroCOM system warning
The processing of this signal has to be done in the DCS.
If a non-critical system error occurs, so a failure is active which do

not harm the function of the HydroCOM system, in the DCS the
“HydroCOM system warning” gets active. This signal is for
information only. No automatic tasks have to be done. The
maintenance have to be informed.
Hydraulic 1=Warning
Oil Temperature
high
0=Warning 1=Warning HydroCOM

TDON
CIU Warning NOT OR System
3 sec
Warning
Hydraulic 1=Warning
Oil Pressure
low
Figure 28.: Logic operation of the HydroCOM warning
7.4.1 CIU Warning

The integrated diagnostic function of the HydroCOM-system has
found a temperature sensor failure. The control is still working,
however maintenance of the concerned HydroCOM part(s) is/are
necessary during next scheduled stop.
7.4.2 Hydraulic oil pressure low

The integrated sensor of the hydraulic unit for low hydraulic pressure
reads a oil pressure lower than 90bar. HydroCOM actuators can
unload the suction valves. The control is still working, however
maintenance of Hydraulic Unit is necessary.
Hydraulic Oil 1=Warning Hydraulic Oil

1=<90bar
Pressure Sensor Pressure
Low Alarm
Figure 29.: Logic of hydraulic pressure low
7.4.3 Hydraulic oil temperature high

A hydraulic unit (HU) temperature alarm is generated if the oil-
temperature exceeds a maximum of 70°C. If this alarm is activated,
control can continue, however maintenance shall be informed about
this event.
Hydraulic 1=Warning Hydraulic Oil

1=>70°C
Oil Temperature Temperature
High Alarm
Figure 30.: Logic hydraulic oil temperature high

Oil temperatures higher than 70°C result in too low oil viscosity. This
might harm the oil pump. It is recommended that maintenance has a
closer look to the HU, finding out the reason for high oil temperature
(e.g. not enough oil, etc.)
- 30 -

Hydrocom Specification Petronor NP HISA V1 - 0

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Hydrocom Specification Petronor NP HISA V1 - 0

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HydroCOM 4.

Control Specification for Implementation in the DCS

2x Nuovo Pignone 4HF/2-1

HVW order 2152296

makes compressor control

1.1 Working principle of the HydroCOM-system............................................................................1

1.2 System configuration ..................................................................................................................1

1.3 Further documents......................................................................................................................1

5 SCHEME OF THE PLANT ....................................................................................5

6 CONTROLLER LAYOUT ......................................................................................6

6.1 Control strategy ...........................................................................................................................6

6.2 Tasks of control ...........................................................................................................................8

6.3 Signals between field and DCS..................................................................................................9

6.5 Description of functions blocks.............................................................................................. 18

7 SPECIAL OPERATING CONDITIONS ...............................................................26

7.1 Start Sequence.......................................................................................................................... 26

7.2 Stop of compressor.................................................................................................................. 27

7.4 HydroCOM system warning..................................................................................................... 30

This document serves as basis for the software program

1.1 Working principle of the HydroCOM-system

The gas volume compressed per piston stroke is adjusted by means

Only the amount of gas which is used by the process is

1.2 System configuration

1.3 Further documents

Control Specification Petronor NP HISA V1_0.doc 23.03.05 / LE

Actuator the device controlling the closure of a suction

Control Specification Petronor NP HISA V1_0.doc 23.03.05 / LE

Because of the integrated system solution, only a „simple“ 4..20mA

This controller layout is based on the technical meeting of 10th of

Control Specification Petronor NP HISA V1_0.doc 23.03.05 / LE

Control Specification Petronor NP HISA V1_0.doc 23.03.05 / LE

The running compressor shall compress as design duty a hydrogen-

Both compressors, A and B, are equipped with a HydroCOM control

The HydroCOM controls the compressors not during nitrogen duty.

Over each stage of the make-up unit of both compressors are

The plant layout is shown in the figure below:

Spill back valve

1st stage 2nd stage 3rd stage

Figure 1.: Scheme of Plant

Following section explains how to implement the controllers in the

Control Specification Petronor NP HISA V1_0.doc 23.03.05 / LE

6.1.1 Main control variable for make-up unit

6.1.2 Additional control variables for make-up unit

6.1.3 Main control variable for recycle unit

Control Specification Petronor NP HISA V1_0.doc 23.03.05 / LE

Out of this pressure signal a control loop which is programmed in

To maintain balanced compression ratios of the compressor, the

Spill back valve

Spill back valve

Figure 2.: Control layout of running compressor

Control Specification Petronor NP HISA V1_0.doc 23.03.05 / LE

In general the DCS is used to:

Over each stage of make-up unit of both compressors are common

In normal operation only HydroCOM controls the compressor load.

In case of HydroCOM failure on one compressor, the concerned

Control Specification Petronor NP HISA V1_0.doc 23.03.05 / LE

Motor Hydraulic unit Start

Motor Hydraulic unit Stop

Hydraulic oil level

Control Specification Petronor NP HISA V1_0.doc

TDC Signal from Flywheel

16x suction valve cover temperature