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SHELL MALAYSIA

SOUTH FURIOUS LEASE

Compressor Control System


Sequence of Operations
&
Instruction Manual
Rev B
29 June 2011

Shell Malaysia
Compressor Control System

TABLE OF CONTENTS
1. GENERAL INFORMATION -------------------------------------------------- 1-1
Introduction ----------------------------------------------------------------------------------------------------------- 1-1
Compressor Control System Description & Overview -------------------------------------------------------- 1-1

2. OPERATOR GRAPHIC DISPLAYS ---------------------------------------- 2-1


Introduction ----------------------------------------------------------------------------------------------------------- 2-1
RSView ME Graphics Development Software ----------------------------------------------------------------- 2-1
Compressor HMI Screens ------------------------------------------------------------------------------------------ 2-2
Main Screen---------------------------------------------------------------------------------------------- 2-2
Start Screen ---------------------------------------------------------------------------------------------- 2-3
Top Banner----------------------------------------------------------------------------------------------- 2-4
Trip Screens---------------------------------------------------------------------------------------------- 2-5
Alarm Screen -------------------------------------------------------------------------------------------- 2-6
Engine Detail Screen ----------------------------------------------------------------------------------- 2-7
Compressor Detail Screen ----------------------------------------------------------------------------- 2-8
Recycle Control Screen -------------------------------------------------------------------------------- 2-9

3. PLC Logic 3-1


DCS Interface --------------------------------------------------------------------------------------------------------- 3-1
Start Sequence -------------------------------------------------------------------------------------------------------- 3-4
Sequence and Steps Table ----------------------------------------------------------------------------- 3-4
Unit Shutdown (Step 0) -------------------------------------------------------------------------------- 3-4
Permissives Not Met (Step 10) ------------------------------------------------------------------------ 3-4
Unit is Ready to Start (Step 20) ----------------------------------------------------------------------- 3-4
Drain/Purge Fuel Gas Line (Step 30) ----------------------------------------------------------------- 3-4
Purge Compressor (Step 40) --------------------------------------------------------------------------- 3-5
Purge Compressor xxx Sec Remaining (Step 50) --------------------------------------------------- 3-5
Open Bypass & Recycle Valve (Step 60) ------------------------------------------------------------ 3-5
Purge Recycle Line xxx Sec Remaining (Step 70) ------------------------------------------------- 3-5
Purge Complete (Step 80) ------------------------------------------------------------------------------ 3-5
Blowdown to Start Pressure (Step 90) ---------------------------------------------------------------- 3-5
Compressor / Engine Prelube (Step 100) ------------------------------------------------------------ 3-5
Engine Crank (Step 110) ------------------------------------------------------------------------------- 3-5
Engine Purge Mode (Step 120) ------------------------------------------------------------------------ 3-5
Engine Starting Mode (Step 130) --------------------------------------------------------------------- 3-5
Engine to Idle Speed Mode (Step 140) --------------------------------------------------------------- 3-5
Open Purge Valve (Step 150) ------------------------------------------------------------------------- 3-6
Open Suction Valve (Step 160) ----------------------------------------------------------------------- 3-6
Engine Warm-Up (Step 170) -------------------------------------------------------------------------- 3-6
Engine Oil Temp (Step 180) --------------------------------------------------------------------------- 3-6
Verification of Discharge Valve Opening (Step 190) ---------------------------------------------- 3-6
Ready to Load (Step 200) ------------------------------------------------------------------------------ 3-6

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Compressor Control System
Load Control Enabled Engine Speed (Step 210)-------------------------------------------------- 3-6
Close Bypass Valve (Step 220) ----------------------------------------------------------------------- 3-6
Compressor Loading (Step 230) ---------------------------------------------------------------------- 3-6
Load Control Enabled (Step 240) --------------------------------------------------------------------- 3-6
Compressor Unloading (Step 250) -------------------------------------------------------------------- 3-7
Open Bypass Valve (Step 260) ------------------------------------------------------------------------ 3-7
Engine Speed back to Idle (Step 270) ---------------------------------------------------------------- 3-7
Unit Normal Stop Cooldown (Step 280) ------------------------------------------------------------- 3-7
Post Lube (Step 290) ----------------------------------------------------------------------------------- 3-7
ESD (Step 500) ------------------------------------------------------------------------------------------ 3-7

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Shell Malaysia
Compressor Control System

1. GENERAL INFORMATION
Introduction
The supplied Compressor Control System is intended to provide the interface for control and
monitoring of the Valerus supplied compression equipment at the South Furious Lease facility. This
manual covers the following items:

Compressor Control System Description & Overview


Operator Interface Screens
Sequence of Operations

Compressor Control System Description & Overview


Each compressor control system is packaged in a pair of enclosures. One is a NEMA 4x stainless
steel enclosure mounted on the local skid and contains a local PanelView, pushbuttons, lights and
engine interface hardware and terminals. The second is a NEMA 3R steel enclosure to be field
mounted in the sites equipment room. It contains the actual PLC, a second PanelView.
The compressor control system is designed to accept one (1) incoming 120-240VAC 50/60Hz source
from the UPS. Refer to drawings UPS-01 for AC power distribution connections.
The compressor control system utilizes Allen Bradley ControlLogix PLC hardware and two
PanelView Plus 1000 Human Machine Interface HMI unit to facilitate control and monitoring of the
supplied compressor package. The Allen Bradley ControlLogix PLC hardware includes single
processor, Ethernet communications, local I/O chassis. The RedLion Controller is supplied to allow
for communication using MODBUS protocol to poll data registers within the PLC via ModbusIP and
to gather data from the Waukesha ESM via RS485.

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Compressor Control System

2. OPERATOR GRAPHIC DISPLAYS


Introduction
This section contains information about the operator control station, preparation for operation,
description of control graphic operation, and illustrations that supplement and aid in understanding
the text. This information is intended to assist operations and maintenance personnel, and it
describes both the manual functions an operator performs and the automatic functions generated by
the control system logic.
The compressor control system includes an Ethernet network and one PanelView Plus 1000
graphical interface operating station. The PanelView Plus 1000 HMI is connected to the Ethernet
network via a switch that also provides internal network connectivity to the ControlLogix PLC
hardware.

RSView ME Graphics Development Software


Allen-Bradleys RSView Studio software was utilized for development of the custom control and
monitoring graphics for the supplied control system. The software allows both static and dynamic
information to be displayed and/or controlled on the supplied Allen-Bradley PanelView Plus 1000
touch-screen Human Machine Interface (HMI). The HMI continuously scans the PLC over the
Ethernet network to update displays, alarms, and logs archived data for use on trend screens.

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Compressor Control System
Compressor HMI Screens
Main Screen

The PanelView Plus 1000 HMI unit supplied with the compressor control panel includes a Main screen
which is displayed when initially powered up. The Main screen which is shown above, includes buttons
that allow navigation to other screens by touching them. The Main screen is accessible from every
screen which always allows the operator to navigate to any screen within the HMI within two (2) touch
selections or less.
The Main screen also includes a login selector that will display additional screens when the control
system is placed in Maintenance or Configuration mode. A login ID and password are required in order
to place the control system into Maintenance mode and have access to the other screens.
There are 3 Levels of Users and Passwords:
1. Operator
No Password
2. Tech
Password Protected
3. Engineer
Password Protected
The Current User indicates either Operator or Maintenance when Tech or Engineer is logged in.
A Forces Enabled or Simulator On will appear in the upper left corner of the screen when one, or
both, of these conditions exist.

The ICS Logo will shut down the PanelView application and provide access to the basic PanelView
functions like time and date.
The Maintenance Section is not visible when the Login is Operator.
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Compressor Control System
Start Screen

The Start screen is accessed from the Main screen by touching the Start screen button. The
Start screen includes a blue banner located towards the top of the screen that indicates what state that
the sequence is in or if there is a trip active that has not been reset the banner changes to read the First
Out trip. Refer to the Sequence Chart included herein for further details and other sequence steps and
the Cause and Effect chart for trips.
The Start screen displays critical start-up process parameters. The status of the suction, blowdown,
discharge and recycle valves are each shown at the bottom of the screen.
As previously mentioned, a button labeled Main is located at the bottom of the screen which provides
navigation back to the Main screen. A Reset touch button is also included at the bottom of the screen
and performs the same function as the Reset pushbutton located on the front of the control panel door.
The compressor Start and Stop touch buttons are also located at the bottom of this screen along
with the Local and Remote mode indications these HMI buttons have corresponding hardwired
switches mounted on the front of the control panel.
The SIM ON indication is only visible when the control system is in Simulation mode. When the
control system is in Simulation mode all values, equipment status, and indications are being provided by
simulation logic located in the PLC processor. All field devices will default to a safe shutdown state and
will not move, or change while the control system is in Simulation mode. Simulation mode should only
be enabled, or selected, when the compressor package is not running. This feature is provided for
training and trouble-shooting purposes only.

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Compressor Control System
Top Banner
The top banner on several of the HMI screens shows the same information.
If any trip is active the banner shows the First Out. Keep in mind that there may be additional Trips
that will prevent the unit from resetting. Also the First Out doesnt reset until ALL trips reset. So what
you see in the red banner is what shut you down but not necessarily what is keeping the unit from
resetting. Navigating to the Trips screens are the only way to see all active trips. Anytime the banner is
red showing a first out touching the banner will change the screen directly to the Trips 1 page.

When the banner is Blue it is showing what step you are in of the sequencer. Refer to the Sequence and
Steps chart for additional information.

In several steps the compressor is waiting for something to happen such as a timer, temperature or RPM.
During these steps the banner will show what it is waiting for and/or the target it is trying to achieve.

One step is Permissives Not Met you cannot start the unit unless all the start permissives are made.
This includes No Trips, valves in auto, RPM at zero and so on. By touching the Blue banner only in this
step will take you to the Permissives screen and show you exactly what is keeping you from starting. At
other times the Permissives Screen is available from the Main Menu.

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Compressor Control System

Trip Screens
The Trip screens may be accessed from the Main screen by touching the Trips touch button. The
Trips 1 screen will appear upon touching the Trips touch button located on the Main menu
screen. The Trips 2and Trips3 screens is accessed by depressing the Next touch button located
at the bottom of the Trips 1 screen. The Next touch button located at the bottom right side allows
navigation between the three Trips screens.
Every trip that is associated with the compressor package is shown on the three (3) trip screens with a
box on the left side. The color green inside the box indicates that the condition is normal, the color
red indicates a First Out Trip condition.

The Trip 1 screen shown above indicates that the Suction Scrubber Level 1st Stage High switch is in a
tripped condition. All trips are indicated on the Trip screens regardless of if the unit is running or not.
Any trip that exists cannot be reset until the external device, or condition, has cleared first. All trips must
be reset from the control panel or HMI screen after the condition has been corrected. In the example
shown above, the water would have to either be drained from the scrubber to clear the high level
condition, or the problem associated with the level sensing device corrected before the reset button will
clear the trip condition.
Multiple ALM indications means there are, or were, multiple faults that occurred during the compressor
trip. It is not unusual to have secondary alarms when a trip occurs.
Note: The TRIP indication is the most important indication on the screen. The Trip indication also
serves primarily as a First Out indication. Anytime the compressor package experiences a shutdown
unintentionally due to a trip, the condition that initiated the first trip will be flagged with a Trip indication
as shown above. There will only be one Trip or First out indication.

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Compressor Control System
Start Screen 1 with an active trip condition

The banner on the Start screen will change to the color red and will also include the First Out
trip as well.

Alarm Screen

The Alarm screen may be accessed from the Main screen by touching the Alarm touch button.
Refer to color code legend located in the bottom right corner of the screen. The Alarm screen also
includes touch buttons that provide alarm acknowledge and reset functionality.

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Compressor Control System
Engine Detail Screen

The Engine Detail screen is accessed from the Main screen by touching the Engine Details
screen button. The Engine Detail screen includes a banner located towards the top of the screen that
indicates Sequence Step or First Out.
The Engine Detail screen includes status and indications of items that are critical to the safe operation
of the supplied engine package.
As previously mentioned herein, a button labeled Main is located at the bottom of the screen which
provides navigation back to the Main screen. A Reset touch button is also included at the bottom of
the screen and performs the same function as the Reset pushbutton located on the front of the control
panel door.
The Total Hours is read from the Waukesha ESM system and cannot be reset by anybody. The
Ressetable Hours is a function built in to the PLC and can be reset by Technician or Engineer level
password. A Reset Button becomes visible when the proper login is active.

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Compressor Control System
Compressor Detail Screen

The Compressor Details screen is accessed from the Main screen by touching the Comp Details
screen button. The Compressor Details screen includes a banner located towards the top of the
screen that indicates Sequence Step or First Out.
The Compressor Details screen includes the quantity of cylinders that are physically supplied with the
package. The cylinders shown on the screen are intentionally laid out to match the physical location if
viewed from the top. This screen also includes the cylinders rod load, pressure and temperature
indications. Other parameters included suction and discharge pressures, compressor oil pressure &
temperature indications, oil flow.
As previously mentioned herein, a button labeled Main is located at the bottom of the screen which
provides navigation back to the Main screen. A Reset touch button is also included at the bottom of
the screen and performs the same function as the Reset pushbutton located on the front of the control
panel door.

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Compressor Control System
Recycle Control Screen

The Recycle Control screen is accessed from the Main screen by touching Recycle Control Button
or from the start screen by touching the Recycle Valve. This screen also includes a banner located
towards the top of the screen that indicates Sequence Step or First Out.
This screen includes three (3) PID control loops and one (1) Manual/Auto (M/A) face plate to facilitate
Automatic and Manual mode operation of the compressor control system. The Suction, Discharge,
and Pct Load Control PID loops are all placed in either the Automatic or Manual mode at the same
time from the M/A Station shown on the left side. These three (3) PID loops cannot be independently
selected for Automatic or Manual mode operation since their control schemes are complex and internally
coordinated within the PLC logic.
The mode of each of the three (3) PID controllers is determined by the (M/A) control station that is
displayed on the left side of screen. The M/A control station can be functionally operated along with
providing status indications as described below:
If the operator makes MAN selection, the MAN button will change from gray to red. The M/A Station
on the left side of the screen will provide manual adjustment by adjusting the slider bar.
If the operator makes AUTO selection, the AUTO will change from gray to green and the three PID
control loops will be controlled in AUTO mode. The SP control function will only work in AUTO mode
and is controlled through the touch areas marked SP decrease and SP increase buttons.
The SETPOINT for each PID control loop can also be changed through the data entry touch area. This
can be achieved by touching the SP value area and typing/entering in the desired number on the pop-up
numeric keypad.
PV PROCESS CONTROLLED VARIABLE from the analog input module, scaled to engineering
units, and displayed by a green bar graph and analog value.
SP SETPOINT analog value from the operator interface screen to the PLC, scaled to engineering
units, and displayed by a cyan bar graph and analog value.
OUT CONTROLLED VARIABLE OUTPUT, or CV to the analog output module, scaled to 0 - 100
PCT and displayed by a yellow bar graph and analog value.

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Compressor Control System
Trend Screens

Two Trend process screens are available, one for compressor temperature inputs and the other for
compressor pressure inputs. Each process trend screen is accessed from the main menu. Real time data
is shown below trend in color code to the chart pen. Trend control buttons allow the operator to change
the trend viewing parameters. The Engine Trend (shown below) is also available for access from the
main menu this screen provides face plate data for speed control along with the trend object.

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3. PLC LOGIC
The PLC is an Allen Bradley ControlLogix PLC with a custom program to control and monitor the
compressor. The program is done with the software RSLogix 5000 Version 17.0. The program utilizes
several options and programming languages available from the RSLogix 5000 software including:
Ladder Logic programming
Sequential Function Chart programming
Structured Text programming
User defined data types
Add-On instructions
Communication between the PLC, HMI and other equipment utilizes an Ethernet network with static IP
addresses in the 192.168.1.0 network.

DCS Interface
All DCS interface is done through the following tags. DCS_Analog and DCS_Digitals should only be
read by the DCS, it should never attempt to write to these registers. The DCS_Command and
DCS_Setpoints are Read/Write. The DCS should monitor and Track these values and only write to
them to send commands. The DCS_Commands are Boolean commands where 0 is the normal state and a
Pulse of a 1 sends and initiates the command.

Tags:

DCS_Analog
o [0]
o [1]
o [2]
o [3]
o [4]
o [5]
o [6]
o [7]
o [8]
o [9]
o [10]
o [11]
o [12]
o [13]
o [14]
o [15]
o [16]
o [17]
o [18]
o [19]
o [20]
o [21]
o [22]
o [23]
o [24]

an array of 50 Real 32bit read only float values


Not Used
Engine RPM
First Stage Suction Pressure in PSIG
First Stage Discharge Pressure in PSIG
Second Stage Discharge Pressure in PSIG
Third Stage Discharge Pressure in PSIG
Not Used
First Stage Scrubber Level in Percent
Second Stage Scrubber Level in Percent
Third Stage Scrubber Level in Percent
Not Used
Not Used
Not Used
Air Receiver Pressure in PSIG
Fuel Gas Flow in Percent
Compressor Cylinder 1 Temp in DegF
Compressor Cylinder 2 Temp in DegF
Compressor Cylinder 3 Temp in DegF
Compressor Cylinder 4 Temp in DegF
Compressor Oil Temp in DegF
Compressor Oil Pressure in DegF
Not Used
Not Used
Engine Jacket Water Temp in DegF
Aux Water Temp in DegF

o [25]
o [26]
o [27]
o [28]
o [29]
o [30]
o [31]
o [32]
o [33]
o [34]
o [35]
o [36]
o [37]
o [38]
o [39]
o [40]
o [41]
o [42]
o [43]
o [44]
o [45]
o [46]
o [47]
o [48]
o [49]
o [50]
DCS_Digitals
o [0]
o [1]
o [2]
o [3]
o [4]
o [5]
o [6]
o [7]
o [8]
o [9]
o [10]
o [11]
o [12]
o [13]
o [14]
o [15]
o [16]
o [17]
o [18]
o [19]
o [20]
o [21]

Engine Left Turbo Temp in DegF


Engine Right Turbo Temp in DegF
Engine Cylinder Left 1 Temp in DegF
Engine Cylinder Left 2 Temp in DegF
Engine Cylinder Left 3 Temp in DegF
Engine Cylinder Left 4 Temp in DegF
Engine Cylinder Left 5 Temp in DegF
Engine Cylinder Left 6 Temp in DegF
Engine Cylinder Right 1 Temp in DegF
Engine Cylinder Right 2 Temp in DegF
Engine Cylinder Right 3 Temp in DegF
Engine Cylinder Right 4 Temp in DegF
Engine Cylinder Right 5 Temp in DegF
Engine Cylinder Right 6 Temp in DegF
Engine Oil Temp in DegF
Engine Oil Pressure in PSIG
Engine Load in Percent
Recycle Valve Position in Percent (0% = Closed)
Not Used
Not Used
Cooler Vibration in Mils
Compressor Vibration DE in Mils
Compressor Vibration NDE in Mils
Engine Vibration DE in Mils
Engine Vibration NDE in Mils
Not Used
an array of 51 (16 bit) read only integers
First Out 0=No First Out 1-144 see Trip Index from C&E
Trips 1-16 as digital alarms Bit 0 is trip 1 and so on
Trips 17-32 as digital alarms
Trips 33-48 as digital alarms
Trips 49-64 as digital alarms
Trips 65-80 as digital alarms
Trips 81-96 as digital alarms
Trips 97-112 as digital alarms
Trips 113-128 as digital alarms
Trips 129-144 as digital alarms
Not Used
Alarms 1-16 as digital alarms see Alarm Index from C&E
Alarms 17-32 as digital alarms
Alarms 33-48 as digital alarms
Alarms 49-64 as digital alarms
Alarms 65-80 as digital alarms
Alarms 81-96 as digital alarms
Alarms 97-112 as digital alarms
Alarms 113-128 as digital alarms
Not Used
Not Used
Purge Valve Status
Bit 0 = Closed Limit Switch
Bit 1 = Opened Limit Switch

o
o
o
o
o
o

o
o

Bit 2 = Fault
[22]
Suction Valve Status
[23]
ByPass Valve Status
[24]
Blowdown Valve Status
[25]
Discharge Valve Status
[26]
Fuel Block Valve Status
[27]
Cooler Motor Status
Bit 0 = Run Permit OK
Bit 1 = Start Permit OK
Bit 2 = Safety Interlock OK
Bit 3 = Ready
Bit 4 = Auto
Bit 5 = Manual
Bit 6 = Alarm
Bit 7 = Proven
Bit 8 = Start Fail
Bit 9 = Stop Fail
Bit 10 = Tripped
Bit 11 = Secondary Fault
Bit 12 = Safety Fault
Bit 13 = Run Permit Fault
Bit 14 = Other Fault
Bit 15 = Any Fault
[28] [49] Not Used
[50] Boolean inputs
Bit 0 = Not Trips Active
Bit 1 = Any Alarm Active
Bit 2 = New Alarm Unacknowledged
Bit 3 = Purge Valve in Auto
Bit 4 = Suction Valve in Auto
Bit 5 = ByPass Valve in Auto
Bit 6 = Blowdown Valve in Auto
Bit 7 = Discharge Valve in Auto
Bit 8 = Fuel Valve in Auto
Bit 9 = Cooler Motor in Auto
Bit 10 = Engine Speed in Auto
Bit 11 = Recycle Valve in Auto
DCS_Commands Single 16 bit Integer Read/Write from DCS
Bit 0 = Remote Reset
Bit 1 = Remote Stop
Bit 2 = Remote Start
Bit 3 = ReCycle Valve request Auto Mode
Bit 4 = ReCycle Valve request Manual Mode
Bit 5 = Speed Control request Auto Mode
Bit 6 = Speed Control Request Manual Mode
DCS_SetPoints array of 10 Real numbers 32 bit floating point Read/Write
[0] = Load Control Operator Output Setpoint 0 100 Percent
[1] = Speed Control Operator Output Setpoint 750 to 1200 RPM

Start Sequence
The compressor package may be started by accessing the Start screen from the main menu located
on the PanelView Plus 1000 HMI unit. The Start screen includes a banner that will display Ready to
Start provided there are no trip conditions existing and Start Permits are all ok. If a trip condition exists it
will be displayed on the banner shown on the Start screen. If the Ready to Start indication is not
present proceed to the Trip screens to see what active faults are present. The trips associated with the
control system are outlined on the Trips screens previously shown herein. If a trip cannot be reset from
the panel, the sensing device or abnormal condition must be corrected in order to proceed. Once all trip
conditions are cleared, and a Reset has been initiated, the Ready to Start will be visible on the Start
screen banner, and the package is ready to be started.
Note: Please refer to the Sequence Step Table shown on the next page for a detailed list of
sequence steps and associated actions of the supplied compressor package.

Sequence and Steps Table


Refer to the attached table for the following steps:

Unit Shutdown (Step 0)


After a normal shutdown or reset from ESD this step closes blowdown valve and setup outputs for the next start.

Permissives Not Met (Step 10)


Sequence will hold here until the following conditions are met:
Purge Valve Closed and in Auto
Suction Valve Closed and in Auto
ByPass Valve Opened and in Auto
Blowdown Valve Closed and in Auto
Discharge Valve Closed and in Auto
Engine Speed less than 10 RPM
Recycle Valve Greater than 95%
Air Receiver Pressure Not Low
Cooler Motor Ready to start and in Auto

Ready to Start (Step 20)


If the Remote/Local selector switch is in the local position then compressor package may be started by
pressing the Start touch button located on the start screen or pressing the panel mounted Start Push
button. If the Remote/Local switch is in the remote position then the start command must come from the
digital input signal Remote Start or the DCS Interface. After the start command is received then the
compressor package will either proceed to the Purge Sequence (Step 40) or advance to the Blowdown
to Start Pressure (Step 90) mode. The Decision to purge is based on if any process gas pressure on
the compressor has dropped below 25 PSI. Also in while in this step waiting for a start if any of the start
permissives are lost the sequencer goes back to Permissives Not Met.

Drain/Purge Fuel Gas Line (Step 30)


The Sequencer is held in this step for 10 Seconds, during which the Fuel Block Valve is opened and Fuel
Drain Valve is also opened. After the 10 Seconds the drain valve is closed and sequencer is indexed to
the next step.

Purge Compressor (Step 40)


Purge Required becomes active anytime any pressure in the unit goes below a Purge Pressure SetPoint typically 25 PSI. During this step the Purge Valve is opened, the Recycle Valve is closed, the
Bypass Valve is closed, and the Blowdown Valve is opened.

Purge Compressor xxx Sec Remaining (Step 50)


Purge time is set from the HMI, typically 60 seconds. At the end of the purge timer the sequencer is
indexed to the next step.

Open Bypass & Recycle Valve (Step 60)


Bypass and Recycle valves are opened. As soon as the Bypass valve come off of its closed limit switch
and the Recyle valve is above 10% the sequence is index to the next step. We do not wait until the valve
are full open.

Purge Recycle Line xxx Sec Remaining (Step 70)


After 10 Seconds (Typically) the sequencer is indexed to the next step.

Purge Complete (Step 80)


Purge valve will close. After the valve is closed, the sequencer indexes to the next step.

Blowdown to Start Pressure (Step 90)


With the suction and Purge valves closed and blowdown still open the blowdown valve is held open until
the pressure in the unit is below Start Pressure, typically 200 PSI.

Compressor / Engine Prelube (Step 100)


The Engine is actually given it Start command at this step which starts the Engine Prelube cycle
controlled by the Waukesha ESM. The Compressor Prelube pump will start with a 5 sec after the engine
prelube. Prelube time is set by the Waukesha Engine prelube time. After 55 seconds of Prelube or the
engine start is engaged the both Compressor and Engine oil pressures are checked to verify they are
abouve the LowLow Trip level. If they are not, a Prelube fail trip is activated. Sequencer is index to the
next step when engine starter is activated.

Engine Crank (Step 110)


Engine speed is monitored and the sequencer is index to the next step when speed is greater than 25
RPM. If this speed is not achieved the Waukesha ESM will trip the unit for Crank Failure.

Engine Purge Mode (Step 120)


When the engine first begins cranking, the ignition is turned on but the engine fuel valve is left closed.
This is controlled by the Waukesha ESM

Engine Starting Mode (Step 130)


Once the Starter is engaged by the Waukesha ESM. This step will display crank time. Engine Proves
around 300 RPM by the Waukesha ESM.

Engine to Idle Speed Mode (Step 140)


After the engine proves running, and until engine speed will go to Idle (750 RPM)

Open Purge Valve (Step 150)


The Purge valve is opened. Once proven open, the sequencer indexes to the next step.

Open Suction Valve (Step 160)


The suction valve is opened. Once proven open, the sequencer indexes to the next step.

Engine Warm-Up (Step 170)


The compressor is in Warm-up mode for sixty (60) seconds as the typical setting. The Warm-up
mode timer is adjustable and is accessible from the Timer Setting screen. Even on Hot starts this
minimum warm-up period is active.

Engine Oil Temp (Step 180)


After engine warm-up timer completes, the engine oil temperature is verified to be at 110 DegF typical
setting. The Oil Temperature Warm-up setpoint is adjustable and the entry field is located on the
Misc. Setpoints display. In the event the temperature has not reached 110 DegF. After the oil
temperature is satisfied the sequence will advance. At this step the Engine speed can be put into manual
and raised above the minimum idle speed. The higher engine speed can be used to assist the warm-up
process.

Verification of Discharge Valve Opening (Step 190)


Open Discharge Valve. Once proven open, the sequencer indexes to the next step.

Ready to Load (Step 200)


As an option some units can be configured to not AutoLoad. If that option is activated the sequence will
hold here until a manual load command is activated. This unit is configured with the AutoLoad Enabled
thus step is skipped.

Load Control Enabled Engine Speed (Step 210)


The engine speed is accelerated from idle to a pre-determined Minimum RPM Load setpoint (currently
set at 850 RPM). The Minimum RPM Load setpoint entry field is adjustable and is located on the
Misc. Setpoints screen. As the engine speed gets above 825 the sequence is indexed to the next
step.

Close Bypass Valve (Step 220)


Byapss valve is closed.

Compressor Loading (Step 230)


This step is not used in this compressor and is stepped through to load control enabled.

Load Control Enabled (Step 240)


The PID control loops controlling the recycle control valve are released from tracking. The compressor
will operate in this step until a stop or shutdown.

Compressor Unloading (Step 250)


The Recycle valve is placed back into output tracking and is opened to 100%. This function includes a
rate limiter so that the compressor unloads slowly. This is so other On-Line units can pick the load up.
The current rate is 2.5% per Second. After output signal to recycle valve passes 95% the sequencer is
indexed to the next step.

Open Bypass Valve (Step 260)


The Bypass valve is opened. Once proven open, the sequencer indexes to the next step.

Engine Speed back to Idle (Step 270)


Engine Speed will be switch to startup control and be put back to idle (750 RPM).

Unit Normal Stop Cooldown (Step 280)


The engine is allowed to run at idle speed, and a sixty (60) second cool down timer is initiated. The cool
down timer is adjustable and is accessible from the Timer Setting screen. After the sixty (60) second
timer has elapsed, the engine is stopped by the Waukesha ESM system. After the fuel and ignition have
been disabled the sequence will automatically advance to the Post Lube (Step 290) mode.

Post Lube (Step 290)


The Waukesha ESM initiates an Engine Postlube after a normal shutdown. The compressor oil pumps
will be started 5 seconds after the engine. Both pumps will run for sixty (60) seconds. After Postlube the
sequence is sent back to step 10. Also upon any shutdown other than ESD the sequencer immediately
jumps to step 290 bypassing unloading, and cooldown functions. The Post lube still continues as normal.

ESD (Step 500)


Any time a ESD Shutdown is detected the Sequencer Immediately jumps to Step 500. Thus bypass all
Unloading, cooldown, and Postlube functions. Suction, Discharge and Fuel valves go close. Blowdown
and Recycle valves go open. Cool down and post lube sequences are skipped.

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