Breakout Session: Open Architecture Controls & Protections Solutions for Critical Turbomachinery 2016 Siemens O&G Innovations Conference Unrestricted www.dresser-rand.com • Dresser-Rand Control Systems Overview • Trends & technology considerations • Summary Unrestricted Page 2 March 31 2016 Siemens O&G Innovations Conference Dresser-Rand Control Systems – History & Footprint • Global D-R Center of Excellence since 1959; Houston HQ • Over 3000 systems delivered: >45 different OEMs • Full O&G market segment footprint • FEED support through aftermarket servicing • Deep domain expertise: Leads > 250 yrs experience Houston CE Unrestricted Page 3 March 31 2016 Siemens O&G Innovations Conference Full Turbomachinery Controls with OEM Pedigree Drivers Gas Turbines Electric Motors Driven Steam Turbines IC Engines Centrifugal/Axial Generators Reciprocating Blowers/Pumps Unrestricted Page 4 March 31 2016 Siemens O&G Innovations Conference 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 Unrestricted Page 5 March 31 2016 Siemens O&G Innovations Conference Digital Platforms - PLCs & Purpose-built Controllers Open Architecture PLCs A/B ControlLogix Triconex Tri-GP Siemens S7-1500 GE RX3i • • • Easier to integrate & design in redundancy Lower project & operating costs Operator mods & maintenance relatively easy Purpose-built Controllers Woodward MicroNet+ CCC Series 3++ • • • Fast, more difficult to integrate & maintain Higher project & operating costs More specialized operator training Purpose-built controllers typically provide specialty control functionality Unrestricted Page 6 March 31 2016 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 Unrestricted Page 7 March 31 2016 Siemens O&G Innovations Conference Comprehensive, Customer Preferred ,Train Solutions • 17 Turbo OEMs, >100 models • 7 Gas Turbine OEMs, 17 models • 14 Steam turbine OEMs • 7 Recip OEMs, 40 models Broad spectrum of full train OEM experience Unrestricted Page 8 March 31 2016 Siemens O&G Innovations Conference 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 5 5 7 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 4 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 Unrestricted Page 9 March 31 2016 Siemens O&G Innovations Conference 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 Unrestricted Page 10 March 31 2016 Siemens O&G Innovations Conference Past – PLC & Purpose-Built Solution DUAL REDUNDANT HOT-STANDBY PLC ETHERNET SWITCH ETHERNET P W R C P U C O N T R M E T H P W R C P U C O N T R M E T H PLC COMM PROTOCOL P W R C O N T IO IO IO IO IO IO IO IO IO IO C O M C O M C O M C O M C O M C O M 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 M 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) Unrestricted Page 11 March 31 2016 Siemens O&G Innovations Conference Examples: Dual-redundant PLC & Purpose-built FPSO CO2 Compressor Solution FPSO Motor driven CO2 Compressor • Triple-width LCP • 7 Purpose-built Controllers • Dual-redundant PLC • Purpose-built V&T System • Panel-mounted HMI • 1.8x Cost of an alternative PLC based system Unrestricted Page 12 March 31 2016 Siemens O&G Innovations Conference Present FPSO Solution – Simpler & Cost-effective DUAL REDUNDANT HOT-STANDBY PLC ETHERNET P W R C P U C O N T R M E T H P W R C P U C O N T R M E T H MODBUS OVER ETHERNET PLC COMM PROTOCOL P W R C O N T IO IO IO IO IO IO IO IO IO IO SERIAL LINK OR MODBUS OVER ETHERNET C O M C O M Page 13 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 M PURPOSE-BUILT FIRE AND GAS CONTROL MODULE (100 m-s) Unrestricted 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 Unrestricted Page 14 March 31 2016 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 Unrestricted Page 15 March 31 2016 Siemens O&G Innovations Conference DCS Example: Steam Turbine/Compressor • • • • • 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 Unrestricted Page 16 March 31 2016 Siemens O&G Innovations Conference TRENDS: HMI, Remote Monitoring, & SIL Req’mts • 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 • 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 • Safety/SIL • Many closed-loop control functions (e.g. A/S) are not considered SIF • Platforms integrated with SIS functions increasingly require SIL certification Unrestricted Page 17 March 31 2016 Siemens O&G Innovations Conference 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 Unrestricted Page 18 March 31 2016 Siemens O&G Innovations Conference THANK YOU! Unrestricted Page 19 March 31 2016 Siemens O&G Innovations Conference 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: [email protected] 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: [email protected] www.dresser-rand.com Unrestricted Page 20 March 31 2016 Siemens O&G Innovations Conference