Project (K.Grigoryev)
- 1. Renovation Complex Project on Gas Pipeline Asia-Europe All-round Automation, Electric systems, Fire Protection system control.
- 2. Gas Pipeline Asia-Europe Kassel München Saarbrücken Stuttgart Bayerngas Budget $52 million, Profit up to 30% Scope of work – 5 Compression Station, 20 Turbo Set+ centrifugal compression machine +package supported equipment +automatic, electric, fire protection systems, all-round automaton. Project Manager Konstantin Grigoryev
- 3. PROJECT MANAGEMENT, ENGINEERING WORK PACKAGE Site Survey Front End Engineering Design (FEED) , изучение проектов Организация монтажных и пуско-наладочных работ Math and algorithmization. Designing Software, Writing operating and instruction manual . Factory Acceptance Test (FAT), Site acceptance Test (SAT). Commissioning . Warranty and out-of-warranty support Operation staff training Control Instrumentation Training . Diagnostics Training Technical support and services Engineering, Procurement and Construction ( EPC ) Management
- 4. Basic feature of invention designed Control system is all functional subsystems combined in one hardwere-softwer complex. Science realized possibility to: To develop the integrated control system for all technological subsystem of Compressor Station ; To create integrated archiving database system for process equipment with high speed timing synchronization accounting cycle 50 ms. And possibility to keep the archive of events and trend log; To make configuration and service of the all subsystems on the one control engineering post; To simplify training process for service staff
- 6. hardware configuration Turbo Set Multiprocessor Control system . (TS MCS 5000-01) A utomatic system s designed for control one Turbo Set . Totally designed some modification TMCS for all type of Turbo Set used in GazProm. TMCS has free configurable architecture work cycles 1msec -10 sec, that gives the realize algorithms high speed process (ex. control of Turbo Set) and so background calculation tasks. Basic architecture has guaranteed : receiving till 200 digital input. receiving till 150 analog input output till 1 50 digital signal for actuators forming till 20 analog signal for servo drive communication interface MODBUS , PROFIBUS .
- 7. Compressor Station Multiprocessor Control system (CS MCS 5000-02 ) . System designed for automatic control technological process equipment of Compressor Station. System consist of peripheral knowledge-based information systems (PIS CS) : PIS CS – for control process equipment and functional control field equipment ; PIS GT – control gas treating ; PIS CSU – combustion, starting, impulse gas units ; PIS CU- air cooling gas units; Basic configuration of CS MCS 5000-2 provide : input 80 digital signals input 80 analog signals forming 40 command for actuating device forming 4 analog signals for servo drive communication via MODBUS , PROFIBUS . Hardware design has executed in versions : block-box with climatic for outside installation, instrument board for inside installation ,
- 8. Low Voltage Complete Plant (LVCP) LVCP provide full control switch on/off fan air cooling equipment air cooling , including soft start, vibration control cooling equipment . Provide commutation electro drives, current control of el. drives on start transient regime, regulation rotation speed , vibration protection, overload and insulation protection, thermo protection. LVCP designed on the basis of Simatic and element of Siemens's equipment . Communication on PROFIBUS .
- 9. CONTROL DESK ( CD ) . A utomation equipped working place , fulfills control for the all Technological Process of Compressor Station. On the desk installed : Work stations with function control all the technological equipment. Reserve Panel ( individual and extra control separate Turbo Set. Printers (archive hard copy, events, trends, shift reports)
- 10. SERVER PANEL ( SP ) Equipped; Visualization Server Сервер ( WinCC-server ) – resposible for communication between all users of automatic control system ( TS MCS 5000-01 , CS MCS 5000-2 , work station on Control Desk ) ОРС- server – supply communication with high level of Control System Server of archive data base Сервер (SDB ) – installed the Xeon of Intel .
- 11. SWITCHING SYSTEM (SS ) Serve for communication process of automatic system . Consist kit of communication network ( optical converter, network switch) Simplify assembling and service of automatic system.
- 12. Fire protection system Provide fire detection , control firefighting and gas detection on free-standing workshop ( Turbo Set, treatment impulse gas block etc. ) Basic configuration has certified and provide : input 120 and more tails ; input 36 digital signals from sensors ; input 8 analog signals ; input 8 intrinsically safe signals; output 60 signals to fire annunciator s; output 36 signals to actuators; output 36 signals to subsystem; human-computer interface fire protection system
- 13. Compressor Station’s All-round Automation Control Cystem
- 14. Hardware configuration ; Simatic S7- 4 00 Software SIMATIC WinCC RT v6.0 64K, SIMATIC S7, STEP 7 V5.2 SP1 TIP V ibration-measuring apparatus Relative displacement control equipment Rotor speed control equipment G as analysis system P ressure transducer Sitrans P Flow meter Thermocouple sensors C ontrol valve gas inlet tract E lectromagnetic valve s Gas ignition and control sytem UPS E mergency switch s D istribution device, Cable product Technical Competence and Solutions
- 15. SUPPORT EQUIPMENT Sensors control equipment for Actuators, Valve Drives
- 16. EQUIPMENT PACKAGE FOR REVAMPING REGULATION CONTROL SYSTEM AND LIMIT PROTECTION TURBO SET Трехходовой (распределительный) клапан на топливном и пусковом газе Клапан турбодетандера Запальный клапан Трехходовой (распределительный) клапан на топливном и пусковом газе Блок фильтров Стопорный клапан Регулирующий клапан Дроссельная шайба Два импульсных клапана управления ВВК (или два 2 золотника переключающих трехходовых с электромагнитным приводом для управления ВВК с гидравлическими сервомоторами) Датчик частоты вращения Золотник переключающий электромагнитный трехходовой подачи масла к расцепному устройству турбодетандера (или золотник переключающий электромагнитный четырехходовой управления расцепным устройством турбодетандера – для агрегатов оснащенных расцепным устройством без возвратной пружины) Реле давления Сигнализатор факелв Регулируемый дроссель Сигнализаторы предельных оборотов (СПОТ) Установочные изделия, конструкции и трубопроводы Расцепное устройство турбодетандера Блок управления клапанами
- 17. Sowtware products for Automation Control System of Turbo Set ( TS MCS 5000-01) Аadaptive thresholding Turbo Set, soft start and stop. Fuel Gas economy. Saving Fuel Gas. Fine stabilization of speed regulation 2 rpm. Preventive control Turbo Set’ drift specific parameters to risk zone . best setting turbo devices (gas treatment, valve binding, fuel gas binding etc.) Monitoring Turbo Set, regulation Fuel Gas Process
- 18. Sowtware products for Automation Control System of Turbo Set ( TS MCS) Optimization regim Compressor’s Map Regulation stalling characteristic resizing to 1% and monitoring surging line . Degreasing heating pipeline gas. Monitoring pressure blow’s characteristic for optimization Load Map . Control vibration spread for turbine set. Patented Software. Anti- stalling and surging regulation centrifugal blower and Compression Station