Value Proposition

26 October 2009

Copyright 2009

Infinite Step Control

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Copyright 2009

Confidential & Proprietary

ISC-Infinite Step Control

Capacity Control Cost Savings

Engineering Overview

Unloader Hardware

Hydraulic Power Unit

Control System Details

Copyright 2009

Outline

Delayed suction valve closing

I-R pioneered ISC 50 years ago

Successful with integral gas engine through the

1970s but never actively pursued in process market

Copyright 2009

ISC Background

ISC Flow Turndown Chart

100

90
ISC turndown
Assuming 10% Base Clearance
and 10% Minmum Discharge
Volumetric Efficiency

80

70

50

40

30

20

10

0
1.00

1.50

2.00

2.50

3.00

3.50

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FLOW %

60

4.00

RATIO

Capacity Control
Background
Market Assessment
Need for capacity control

Recip compressors require devices to control (reduce) capacity to meet

process needs.

Recycle of unwanted gas wastes energy.

Capacity control devices reduce flow and save energy.

Todays market is again focused on energy savings (energy evaluations $300

- $1000 / hp / year)

Stepless systems offer greater flexibility in meeting process needs.

Copyright 2009

Capacity Control
Background
Typical Energy Costs
Electricity Cost $/Kwh
$/Hp/Year
Compressor
%
Power (HP) Recycle
10000
10%
5000
10%
1000
10%
500
10%
10000
15%
5000
15%
1000
15%
500
15%
10000
20%
5000
20%
1000
20%
500
20%

0.06
$
392
Savings Per
Year
$ 391,940
$ 195,970
$
39,194
$
19,597
$ 587,910
$ 293,955
$
58,791
$
29,395
$ 783,880
$ 391,940
$
78,388
$
39,194

0.1

0.15

$
653
Savings Per
Year
$
653,233
$
326,617
$
65,323
$
32,662
$
979,850
$
489,925
$
97,985
$
48,992
$ 1,306,466
$
653,233
$
130,647
$
65,323

$
980
Savings Per
Year
$
979,850
$
489,925
$
97,985
$
48,992
$ 1,469,775
$
734,887
$
146,977
$
73,489
$ 1,959,700
$
979,850
$
195,970
$
97,985

Copyright 2009

Capacity Control
Value & Payback Calculation

Problem:

7,000 HP Unit

50% Turndown average/year

$392hp/yr lost

Solution:

Infinite Step Control System- $463k (not including install)

Energy savings @ 3,500 HP turndown/yr- 1,372K

System payback <1 year

Improved process control, no recycle valve usage, reduced lube

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oil buildup
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ISC Benefits

Motor KW

Engineering Overview
Offered with every ISC

Not standard with HydroCOM

OEM Engineering Advantage

Machine records, drawings, tolerances, etc.

Torsional Analysis & Pulsation Analysis

Crucial for ensuring ISC and compressor compatibility

Proprietary ISC Simulation Software

Analyzes modified rod loads and valve dynamics
Simulates ISC Unloader motion and timing
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Engineering- Simulation of ISC system

Minimum Load

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Full Load

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ISC Unloader Hardware

One servovalve per

cylinder end sends
hydraulic pressure to
multiple actuators
No electronics at
individual valve locations
Actuator can be
separated from valve
cover without
interrupting compressor
operation
Individual fingers
operate valve elements
for even pressure

Hydraulic Pressure to
Unload

ISC
UNLOADER

Hydraulic Pressure
to Load

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 Copyright 2009

HydroCOM Actuator vs ISC Actuator

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ISC vs HydroCOM Actuator

Simple hydraulic circuit

No orifices in primary hydraulic circuit

No dynamic check valves

No directional spool valve

No electronics, no bus addresses, no

wiring!

Less seals and o-rings due to reduced

number of components
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ISC Servovalve by MOOG

Two servovalves per

cylinder send hydraulic
pressure to multiple
actuators
Torque motor translates
electrical signal to
hydraulic forces
Hydraulic oil moves
spool, not an electric coil
Used with intrinsically
safe barriers, Class 1
Div 1. Only uses
12VDC, 8mA

Gas Seals

Copyright 2009

Torque Motor

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Pressure compensated, variable

displacement pump

Energy efficient design- uses only

the pump capacity required

Fully instrumented for oil pressure,

oil temperature, and oil level

Duplex oil filters located on supply

and return

Easy maintanance on-the-fly

3 micron supply and return

filtration ensures proper oil
cleanliness

Differential pressure switch

signals when filter needs to be
changed

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Hydraulic Power Unit (HPU)

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ISC Control Panel

Fully-integrated, turnkey control

panel is standard with every ISC

Touch-screen HMI standard

Control panel includes all

hardware and software
necessary to operate the ISC
and the Hydraulic Power Unit
manually or remotely
No additional programming,
computers, or hardware needed!
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Standard Allen Bradley

hardware

PLC ladder-logic
software

Universal software
package, proprietary to
D-R is configurable for
all types of ISC
installations

Communicates with
most DCS
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ISC Controller Electronics

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ISC Controller
Electronic Controller - HMI Screens

All aspects of the hydraulic

system are instrumented
and monitored by the
controller software. Pump
start/stop, heating/cooling,
etc are fully controlled.
This is not the case with
HydroCOM
Controller monitors
condition of the pump, and
leakage of the system.
Shuts down if issue occurs.
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Benefits of ISC vs HydroCOM

OEM Engineering and design

Torsional, Pulsation, Full system simulation, comprehensive analysis

Robust Actuator Design

No orifices, throttling, bypass volumes, etc

No electronics

D-R Magnum Valve and Plunger

Multi-element technology valve and plunger reduces risk of catastrophic failures

Provides limpability

Centralized Servovalve design

Reduces system complexity

Increases safety- design is intrinsically safe, only requires 12V, 8mA

Premium Hydraulic Power Unit

Full instrumentation included- not just a sight glass on the side of oil tank!

Efficient variable-capacity pump design

Superior Controls Solution

Fully turnkey

User Interface included

Monitors/controls hydraulic system operation

Flexible controls- no custom programming

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ISC

HydroCOM

ISC controller is Allen-Bradley architecture w/

off the shelf components, industry standard,
available WW

Compressor Interface Unit (CIU) Proprietary

industrial controller, not industry standard

Hydraulic actuator separate MOOG servo

valve, service and parts available WW

Hydraulic actuator Integral solenoid and

hydraulic operator, proprietary parts limited
availability

2 servo valves required per cylinder

One hydraulic actuator required for each inlet

vlv

Electrical signal to each servo, 12V 8mA,

intrinsically safe

Electrical signal to each vlv cover, 48V not

intrinsically safe

Non lube due to a diaphragm seal

Not truly non lube,

Stand alone control panel, visual display (HMI)

included, PC not required.

Rack mounted CIU, no visual display, PC

required.

HPU Pressure compensated pump, variable

displacement, energy efficient

Hydraulic Power Unit (HPU) Constant

pressure gear pump, recycle pressure control
(not energy efficient)

HPU Level transmitter 4-20mA, provide real

time tank oil level & sight glass

HPU visual oil level indicator (sight glass)

Installation Turnkey, pre configured and

tested control panel

Installation labor intensive, site modifications

of controls required

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DR vs Hoerbiger

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Copyright 2009

info@dresser-rand.com