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Breakout Session: Open
Architecture Controls &
Protections Solutions for Critical
Turbomachinery
2016 Siemens O&G Innovations Conference
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www.dresser-rand.com
• Dresser-Rand Control Systems
Overview
• Trends & technology
considerations
• Summary
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March 31 2016
Siemens O&G Innovations Conference
Dresser-Rand Control Systems – History & Footprint
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Global D-R Center of Excellence since 1959; Houston HQ
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Over 3000 systems delivered: >45 different OEMs
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Full O&G market segment footprint
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FEED support through aftermarket servicing
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Deep domain expertise: Leads > 250 yrs experience
Houston CE
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Full Turbomachinery Controls with OEM Pedigree
Drivers
Gas Turbines
Electric Motors
Driven
Steam Turbines
IC Engines
Centrifugal/Axial
Generators
Reciprocating
Blowers/Pumps
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Control & Protection Functionality Experience
Control/Protection Functionality
DRIVERS
Gas
Steam Motors &
IC
Turbines Turbines VFDs
Engines
Centrifugal/Axial
Compressors
DRIVEN
Recip
Compressors
Blowers
Generators & Pumps
E-power: excitation, AVR, PF, VAR
Synch/auto-synch
Steam extraction & admission control
Anti-surge control & detection
Fuel Control
Emissions compliance
Overspeed protection
Master/slave control
Load/sharing control
Fire & Gas monitoring & protection
Speed & performance control
SIS integration & SIL compliance
ESD/SIS shutdown
Auxiliary systems sequencing & protection
Normal train start/stop sequencing
HMI & remote train health monitoring
Complete spectrum of functionality built on deep domain application expertise
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Digital Platforms - PLCs & Purpose-built Controllers
Open Architecture PLCs
A/B ControlLogix
Triconex Tri-GP
Siemens S7-1500
GE RX3i
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Easier to integrate & design in redundancy
Lower project & operating costs
Operator mods & maintenance relatively easy
Purpose-built Controllers
Woodward MicroNet+
CCC Series 3++
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Fast, more difficult to integrate & maintain
Higher project & operating costs
More specialized operator training
Purpose-built controllers typically provide specialty control functionality
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Siemens O&G Innovations Conference
Embedded DCS Control Implementation Expertise
Honeywell Experion
ABB Symphony
Emerson Delta V
Siemens PCS7
Yokogawa Centum
DCS implementation of turbomachinery controls is a growing trend
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Comprehensive, Customer Preferred ,Train Solutions
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17 Turbo OEMs, >100 models
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7 Gas Turbine OEMs, 17 models
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14 Steam turbine OEMs
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7 Recip OEMs, 40 models
Broad spectrum of full train OEM experience
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TREND: PLC Speed & Power Advancements Driving
Increased Adoption vs. Purpose-built Platforms
Past – 20+ yrs ago
Control Application/Function
GT Fuel Control - w/Stall Detection
GT Fuel Control - No Stall Det
Compressor surge detection
Compressor Anti-surge control
Steam Turbine speed governor
Process & load sharing controls
Recip compressor capacity control
Sequencing logic - most machines
Safety Instrumented Functions
Loop Scan Range (m-sec)
Min
Max
5
10
10
25
20
25
25
50
50
100
100
200
100
200
100
200
100
200
Relative "Load" per loop (1-10)
Min
Max
6
7
5
6
2
3
4
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5
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5
7
3
4
2
4
2
4
Purpose-built Controllers
Woodward
CCC S3++
A/B CL
PLCs
S5
DCS
Triconex Experion 1st PCS7
DeltaV
Present Day
Control Application/Function
GT Fuel Control - w/Stall Detection
GT Fuel Control - No Stall Det
Compressor surge detection
Compressor Anti-surge control
Steam Turbine speed governor
Process & load sharing controls
Recip compressor capacity control
Sequencing logic - most machines
Safety Instrumented Functions
Loop Scan Range (m-sec)
Min
Max
5
10
10
25
20
25
25
50
50
100
100
200
100
200
100
200
100
200
Relative "Load" per loop (1-10)
Min
Max
6
7
5
6
2
3
4
5
5
7
5
7
3
4
2
4
2
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Purpose-built Controllers
Woodward
CCC S3++
A/B CL
PLCs
S7-1500
Triconex Experion
DCS
PCS7
DeltaV
PLC/DCS speed and power closing the gap on Purpose-built controllers
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Example: FPSO Motor/Gear/Compressor
Primary Requirements
• Fully integrated train control & protection (CO2 application, 2 trains per FPSO)
• Anti-surge control & detection – 2 stages
• Performance & load sharing control
• Virbration, displacement & temp monitoring & protection using B-N 3500
• Full train logic sequencing including all auxiliaries
• Dual-redundant (Duplex) platform, LCP in hazardous area
• Independent hard-wired relay backup ESD
• Hybrid Purpose-built and Open PLC solution with local & remote HMI
• MODBUS over Ethernet protocol for direct connection to DCS
• Integrated F&G monitoring system
• Minimize footprint & commissioning downtime
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Past – PLC & Purpose-Built Solution
DUAL REDUNDANT HOT-STANDBY PLC
ETHERNET
SWITCH
ETHERNET
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W
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PLC COMM PROTOCOL
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IO
IO
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C
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C
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C
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C
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C
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C
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RS-232 SERIAL OR MODBUS
OVER ETHERNET LINKS
PURPOSE-BUILT
PERFORMANCE & LOAD
SHARING CONTROL
(50-100 m-s)
LOCAL PLCBASED HMI
DUAL REDUNDANT
MODBUS OVER ETHERNET
TO
DCS
LCP
C
O
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MODBUS OVER
ETHERNET
REDUNDANT PURPOSEBUILT ANTI-SURGE
CONTROL STG 1 (~25 m-s)
REDUNDANT PURPOSEBUILT ANTI-SURGE
CONTROL STG 2 (~25 m-s)
PURPOSE-BUILT VIBRATION &
TEMP MONITORING SYSTEM
PWR CPU CONT RM ETH COM IO -
POWER SUPPLY
CENTRAL PROCESSING UNIT
PLC COMMUNICATION MODULE
REDUNDANCY MODULE
ETHERNET MODULE
SERIAL COPROCESSOR MODULE
I/O MODULE
PURPOSE-BUILT FIRE
AND GAS CONTROL
MODULE (100 m-s)
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Examples: Dual-redundant PLC & Purpose-built
FPSO CO2 Compressor Solution
FPSO Motor driven CO2 Compressor
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Triple-width LCP
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7 Purpose-built Controllers
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Dual-redundant PLC
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Purpose-built V&T System
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Panel-mounted HMI
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1.8x Cost of an alternative PLC
based system
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Present FPSO Solution – Simpler & Cost-effective
DUAL REDUNDANT HOT-STANDBY PLC
ETHERNET
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MODBUS OVER ETHERNET
PLC COMM PROTOCOL
P
W
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IO
IO
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IO
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SERIAL LINK OR MODBUS
OVER ETHERNET
C
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TO
DCS
MODBUS OVER
ETHERNET
PURPOSE-BUILT VIBRATION &
TEMP MONITORING SYSTEM
PWR CPU CONT RM ETH COM IO -
March 31 2016
LOCAL PLCBASED HMI
LCP
C
O
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PURPOSE-BUILT FIRE
AND GAS CONTROL
MODULE (100 m-s)
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ETHERNET
SWITCH
POWER SUPPLY
CENTRAL PROCESSING UNIT
PLC COMMUNICATION MODULE
REDUNDANCY MODULE
ETHERNET MODULE
SERIAL COPROCESSOR MODULE
I/O MODULE
Siemens O&G Innovations Conference
FPSO Example: PLC-based System is a Viable,
Simpler, Cost-effective Option
FPSO Motor driven CO2 Compressor
Demo Panel – same functionality
(exc. F&G system)
Current PLC technology yields significant: first cost, operating cost,
reliability, space, & maintainability benefits
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Siemens O&G Innovations Conference
TREND: DCS Implementation of Critical Control
Functions is Growing
Control Application/Function
GT Fuel Control - w/Stall Detection
GT Fuel Control - No Stall Det
Compressor surge detection
Compressor Anti-surge control
Steam Turbine speed governor
Process & load sharing controls
Recip compressor capacity control
Sequencing logic - most machines
Safety Instrumented Functions
•
•
•
Loop Scan Range (m-sec)
Min
Max
5
10
10
25
20
25
25
50
50
100
100
200
100
200
100
200
100
200
Relative "Load" per loop (1-10)
Min
Max
6
7
5
6
2
3
4
5
5
7
5
7
3
4
2
4
2
4
Experion
DCS
PCS7
DeltaV
DCS adoption is strongly influenced by customer redundancy philosophy
• Many customers prefer separate systems: “dissimilar redundancy”
• Different risk tolerance thresholds for critical systems
DCS platforms/networks becoming much faster vs. 20+ years ago
• Relative “Load” dependent
• Accepted alternative for 100-200 m-s functions
• Viable alternative for many 25-100 m-s functions
• Seamless integration with process control
Operator familiarity with DCS interfaces & maintainability is a big plus
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DCS Example: Steam Turbine/Compressor
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Functions distributed among dual-redundant Experion C-300 modules
Rear sub-panel contains ST speed, compressor suction throttling & anti-surge (@20 m-s)
Front sub-panel for logic sequencing & auxiliaries control (@50 m-s)
Duplex I/O & Firewall modules to protect from failure propagation or “intrusions”
Relative “load” on the low (4-5) end of the speed governing and anti-surge range
Rear sub-panel – 20-ms functions
Front sub-panel – 50-ms functions
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TRENDS: HMI, Remote Monitoring, & SIL Req’mts
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HMI: Licensed software whose mimic screens can be modified/accessed/displayed by the
DCS and/or on an OPC compatible device, are becoming more popular
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Remote Monitoring: Three schools of thought
• Home grown systems – most sophisticated operators, do most themselves
• Product based – software license, interpret the data & analytics internally
• Service based – channel the data to a third party for analysis & recommendations
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Safety/SIL
• Many closed-loop control functions (e.g. A/S) are not considered SIF
• Platforms integrated with SIS functions increasingly require SIL certification
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Summary
• Dresser-Rand Controls brings a unique value proposition to the market
• Deep domain machinery knowledge
• Controls platform breadth & customer flexibility
• End-to-end integration expertise
• Specific control & protection functions drive platform requirements
• Open architecture PLC/DCS technology has closed the performance
gap with traditional purpose-built controllers
• Customer solution options have expanded dramatically
• HMI, remote monitoring, & SIS technologies are influencing traditional
integrated control & protection system design
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THANK YOU!
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Contact page
John Rice
Director, Aftermarket Sales - Dresser Rand Controls
1202 W. Sam Houston Parkway
Houston, 77043, USA
Office:
Mobile:
+1 (713) 346-2119
+1 (713) 232-9394
E-mail: jrice1@dresser-rand.com
Tony Smolder
Sr. Controls PDM - Dresser Rand Controls
1202 W. Sam Houston Parkway
Houston, 77043, USA
Office:
Mobile:
+1 (713) 365-2694
+1 (281) 435-8784
E-mail: csmolder@dresser-rand.com
www.dresser-rand.com
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