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Safety, Performance & Innovation in Oil&Gas Rotating Machines

(in lingua inglese)

Market Analysis Compressors and Pumps
About 2000 new compressor and 5000 new pumps installed every year for Oil, Gas & Petrolchemical market (from 2010 data)
- 30% of the market are motor & VSD driven
- New LNG plants & new pipelines (Asia, Brazil, Russia and North America)
- Compressing and pumping are expensive processes
- Main source of inefficiency:
- Old machinery
- Sub-optimal control schemes
- Bad tuning & maintenance

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Atti di convegni o presentazioni contenenti case history
mcT Petrolchimico 2012 intervento nella sessione plenaria

Pubblicato
da Alessio Rampini




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Estratto del testo
Alimentare Petrolchimico Milano, 29 novembre 2012! mcT 2012 - Tecnologie per il petrolchimico
Safety, Performance & Innovation in
Oil&Gas Rotating Machines ABB PA OGP A&ES & Politecnico di Milano DEI '' November 28th, 2012 Market Analysis
Compressors and Pumps
© ABB Group
December 3, 2012 | Slide 2 ' About 2000 new compressor and 5000 new
pumps installed every year for Oil, Gas &
Petrolchemical market (from 2010 data) ' 30% of the market are motor & VSD driven ' New LNG plants & new pipelines (Asia,
Brazil, Russia and North America) ' Compressing and pumping are expensive
processes ' Main source of inefficiency: ' Old machinery ' Sub-optimal control schemes ' Bad tuning & maintenance The Power of Integration
Process and Power Automation together
© ABB Group
December 3, 2012 | Slide 3 The Power of Integration
Process and Power Automation together
© ABB Group
December 3, 2012 | Slide 4 The Power of Integration
Process and Power Automation together
© ABB Group
December 3, 2012 | Slide 5 Traditional control solution for rotating equipments
A fragmented architecture
© ABB Group
December 3, 2012 | Slide 6 Lesson Learnt From Traditional Solution'.
© ABB Group
December 3, 2012 | Slide 7 Electrical Automation Safety &
Protections Process
Automation Machine
Control
© ABB Inc.
December 3, 2012 | Slide 8 DEIC
Drive & driven equipment integrated control system ' The integrated solution providing all the functionalities
required for the driving and driven rotating machine ' Features ' Complete libraries of control and protection funtions ' Supervision & monitoring on the assets ' Open & modular structure ' Easy integration with other ABB or third party systems ' Small footprint ' Reliable and safe hardware certified by T'V Rheinland ' Software designed according to IEC61131 standard
© ABB Group
December 3, 2012 | Slide 9 DEIC
Drive & driven equipment integrated control system ' The integrated solution providing all the functionalities
required for the driving and driven rotating machine ' Features ' Complete libraries of control and protection funtions ' Supervision & monitoring on the assets ' Open & modular structure ' Easy integration with other ABB or third party systems ' Small footprint ' Reliable and safe hardware certified by T'V Rheinland ' Software designed according to IEC61131 standard
© ABB Group
December 3, 2012 | Slide 10 DEIC
Drive & driven equipment integrated control system
© ABB Group
December 3, 2012 | Slide 11 Complete DCS solution,
granting best performance
and high safety level Compact version, fully
functional, no PC required Designed to respond to
highest and strictest safety
requirements, up to SIL3 level ENI Norge Goliat FPSO ' Reservoir: Oil & Gas ' Start production: late 2013 ' Production: more than 100 000 oil-drums per
day, 3.9 million cubic meter gas per day and
store 950 000 oil drums ' Client / Country: ENI Norge ' Duration: 2010 - 2014 ' Scope of Work: Feed, Electrification, Instrumentation, Control, Advanced Solution,
Telecommunication ' ENI Norge requirement: ' Minimize the number of interfaces for Electrical,
Instrumentation, Control and Telecommunication
systems ' Support during FEED ' Service Support
© ABB Group
December 3, 2012 | Slide 12 GOLIAT Automation Architecture
© ABB Group
December 3, 2012 | Slide 13 Electrical
Automation Safety &
Protections Process
Automation Machine
Control GOLIAT Automation Architecture
© ABB Group
December 3, 2012 | Slide 14 Electrical
Automation Safety &
Protections Process
Automation Machine
Control Not just Integration Main areas of innovation: ' Anti-Surge & Drive-assisted Anti-
Surge Control ' Advanced Load Sharing ' Performance Monitoring System The other areas of Innovation © ABB Group
Compressor instabilities
Surge © ABB Group
' Surge''s pressure and flow
oscillations cause high
compressor''s blades thermal
and mechanical stress ' The stress can be intense and
cause blades breaking ' Maximum efficiency stands very
close to surge limit Volumetric
flow [m3/h] Time [s] ' Gas compressors are unstable
in certain operating conditions ' Unstable operation can be
easily depicted in ' ''Surge' is the most dangerous
instability, related to low flow,
high discharge and/or low
suction pressures Compressor instabilities
Anti Surge Control © ABB Group
Pressure drop Flow drop Pressure Pitch Antisurge control Includes all ''standard' anti-surge control functionality: ' Control-line control ' Surge protection by ensuring 100% valve
signal before reaching the surge line ' Suction/discharge pressure control ' Gain-scheduling and valve linearization
functionality ' Fast control cycle time (10ms) Provides a fully open and integrated anti- surge control system: ' Reduces installation, commissioning,
training, and maintenance costs ' Providing the operators with the same look
and feel of the other control blocks
© ABB Group
December 3, 2012 | Slide 18 Anti surge control
The contribute of VSD © ABB Group
' Variable Speed Drives (VSD) as driver of
compressors and pumps is the new growing
trend ' This solution enhances availability and
energy efficiency of the system ' The only solution for subsea applications ' VSD have a response time of few
milliseconds to a step speed reference
change ' Gas turbines have a response time of several
seconds ' This rapidity can pave the way to new surge
protection schemes Anti surge control
The contribute of VSD © ABB Group
' Standard Anti-Surge Control suffers the
''slow' speed of the anti-surge valve ' Surge can take few fractions of seconds to
appear. ' VSD are significantly faster than the ASV and
can help the compressor to stay safe while
the ASV opens. ' Coordinated control between VSD and ASV
is a challenge in compressor protection
systems Advanced Load Sharing
What is Load Sharing Optimization © ABB Group
Same Head Optimized operating point Energy Saving Initial operating point Less efficient (Same Speed / Flow) (Different Speed / Flow) Case Study: Two Similar Compressors operating in parallel High Efficiency PT PT FT FT Advanced Load Sharing
What is Load Sharing Optimization © ABB Group
Control Identification
and learning
Optimization Advanced Load Sharing
A new approach © ABB Group
Currently the load balance between
parallel compressors is computed by: ' Same flow ' Same distance from surge Advanced load sharing is based on
optimization of machines performance
taking into account: ' Performance maps ' Compressors aging ' Field information The optimization parameters are adapted
as the system changes by using learning
algorithms. PT PT FT FT Field
Information Corrected References Advanced Load Sharing Process Control Desired
Pressures
and Flow DEIC Performance monitoring © ABB Group
Expected Performance Actual Performance ' The Performance Monitoring System
provides continuous monitoring of the
status of rotating equipment
(Compressors, Pumps, Turbines, ..) ' The actual status, measured from the field
and the expected status, defined by a
model of the rotating machine ' A vibration analyzer (Analyst) monitors the
status of the bearings and of the shaft
supported by ' This tool provides a powerful help for: ' Machine online status monitoring ' Predictive maintenance ' Fault diagnosis
© ABB Inc.
December 3, 2012 | Slide 25 Contact information
ABB Diego Pareschi ABB Italy OGP '' A&ES '' Advanced Solutions (+39) 02 2414 '' 3293 diego.pareschi@it.abb.com Politecnico di Milano Prof. Sergio Bittanti Politecnico di Milano Dipatimento di Elettronica ed Informazione (+39) 02 23399 '' 3543) bittanti@elet.polimi.it Alessandro Pesatori Politecnico di Milano Dipatimento di Elettronica ed Informazione (+39) 02 23399 '' 3609) pesatori@elet.polimi.it
© ABB Group
December 3, 2012 | Slide 26


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